Aker Kværner Engineering & Technology

Technology & Front End

Report

TECHNICAL DOCUMENTATION FRONT SHEET

Type of Report : Pages :1 of 9

For Information Volume:

Classification:
None

BLOCK – “F” GAS PLATFORM

- US GOM FIT FOR PURPOSE FACILITY

Issued for Information A Aug 10 DRL DJ / GW DRL

Reason for issue Rev. Issue Date Made Chk'd Proj.

by by Appr.
PO No.: H1076050 Doc No.:1076050-AKI-Z-RA-1001 Responsible Party: AKI - FE
Aker Kværner Engineering & Technology
Technology & Front End
Report
Title: Doc. No.: Rev.: Date: Page:
CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 2 of 9

INDEX

1. INTRODUCTION .......................................................................................................3

2. FACILITY DESCRIPTION ........................................................................................4

2.1. Well Bay ......................................................................................................................4
2.2. Production System .......................................................................................................4
2.3. Gas Dehydration System .............................................................................................4
2.4. Produced Water Treatment ..........................................................................................4
2.5. Relief System...............................................................................................................5
2.6. Power Generation ........................................................................................................5
2.7. Instrument Air System.................................................................................................5
2.8. Fuel Gas System ..........................................................................................................5
2.9. Diesel Fuel System ......................................................................................................5
2.10. Compression ................................................................................................................5
2.11. Material Handling........................................................................................................6
2.12. Safety Systems............................................................................................................6
2.13. Buildings - Power Distribution & Control Room........................................................6
2.14. Living Quarters & HD .................................................................................................6
2.15. Other Utilities ..............................................................................................................6

3. PROPOSED STUDY DELIVERABLES....................................................................7

4. AKER KVAERNER EXPERIENCE ..........................................................................9

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1. INTRODUCTION
This file note presents a description of typical Gulf of Mexico practices for low cost “fit for purpose”
gas platform production facilities.
Gulf of Mexico “shallow water” operations (up to ~300 ft) utilize Jack – Up MODU drilling or skidded
API MASE (Minimum Area Self Erecting) Drill Rigs.
With the Block “F” Field located in 120M (390 ft) – this file note focuses on use of Skidded API
Rigs.
A typical API Rig Platform for gas production is illustrated below with provision of 13 – 18,000 sq. ft
main deck area provided to accommodate the rig with operating weights of up to 6,000 ST.
Typical overall topside dry weight is ~ 2200 to 2750 Tons including ~1000 tons of production
equipment and utilities – excluding the leased drill rig and associated leased rig power plant and
temporary sleeper cabins. The installed Cost of this platform would typically be $125M to
$145M – excluding any local taxes or duties.

These types of Gas Platforms have the following functionality:

• Dry Tree Wellbay with typically up to 15 slots and manifolds designed for well shut – in
pressure with test log.
• Production rates of up to 150 Mmscfd – free flowing initially. Compression – space for future
addition of gas engine reciprocating unit (s)
• VRU – provision of a small VRU unit to recover flash gas
• Condensate coalescing and Produced Water treatment with IGF unit to 15 ppm
• Often no gas dehydration if sweet gas – though space for electric dehydration if higher CO2
• Main deck space and payload for a API skidded Rig and associated engine skid and
sleepers
• Topsides structure consists of a two – level deck and sub – cellar located on a 4 or 6 batter
- leg jacket and skirt piles.

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CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 4 of 9

2. FACILITY DESCRIPTION
This section describes typical GOM practices for the respective facility system designs.

2.1. WELL BAY

Wellbays for these types of gas developments are typically 6 to 15 slots on 7’6” or 8’ spacing –
dependent on well completion size and rating. Trees are rated up to 10,000 psi as required to
exceed maximum shut – in pressure. Provision of local well control panel and HPU unit for tree
valves and main gas export departure SDV valve.
Hydrates – most shallow water GOM well systems do not have methanol injection upstream of
choke as sea temperature is favourable and pressures typically less than 4000 psi. For higher shut
– in pressures it is prudent to have methanol injection above the downhole SSCV and upstream of
the choke for initial start – up if well shut in at sea temperature.

2.2. PRODUCTION SYSTEM

Single horizontal production separator with inlet even flow device, vane pack demister and vortex
breaker. Design pressure to suit ANSI 600 flange rating at 1460 psig. Three – phase separation of
water and condensate. Parallel test separator. Condensate routed through a coalescer operating at
sales gas pressure and routed into the gas export line. Sales gas Metering skid provided and gas
export pig launcher, SDV and corrosion inhibition for the export pipeline.

2.3. GAS DEHYDRATION SYSTEM

If required by Contract or high CO2 – then Operators select a standard glycol dehydration unit (no
gas stripping to achieve say 6 lb/Mmscf); with either direct fired or electric elements. Typically 200
kw unit (10 gpm glycol) for a 100 Mmscfd capacity and 100 deg F inlet gas. Provision of inlet filter
scrubber (Peco type).

2.4. PRODUCED WATER TREATMENT

Produce water is routed from the Production Separator to the Water Skimmer and skimmed
condensate is pumped back to the separator using Texsteam H.P. gas - driven plunger pumps.

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CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 5 of 9

The produced water is then treated in an IGF unit (multi - compartment with induced draft agitators)
– with oil skimmed off to the closed drain sump and produced water routed to the open drain tank
and overboard below 15 ppm.

2.5. RELIEF SYSTEM

Vent systems are often deployed for gas platforms with a 316L HP vent header and HP flare drum
for cold blowdown with a fluidic molecular seal on the vent tip boom and CO2 snuffing system. The
HP scrubber pumps are air driven diaphragm type to route the liquids to the closed drain tank.

2.6. POWER GENERATION

The size of the Power Generation system is indicative of the complexity of the facility. GOM gas
platforms have minimal facilities, wide us of gas – driven pumps and minimal buildings with
enclosed HVAC demands. Typical power units are simple gas engine “enginators” sized 2 x 100%
at 300 to 500 kw each plus a diesel emergency unit sized at 200 kw. With gas dehydration – if
electric regeneration is used – then the power units will need to be 3 x 50 percent configuration.
Power and complexity savings are achieved as follows –
• Use of HP gas Texsteam driven pumps (plunger) and Wilden diaphragm types.
• No RO Unit – use ship bunkering of potable water
• Drill rig supplies own temporary pump in platform casing and powered by Rig.
• No fuel gas superheating required for gas engines versus use of turbines
• Closed drain Sump Pumps use air driven pumps to route to PW Skimmer Oil bucket and
then thru the HP Gas driven Texsteam Pumps to the production separator.
• No SW Lift Pumps – use a small SW lift Pump or Jockey Pump for wash down services
only. No cooling, no potable water service, no platform supply to the drill rig water
• No hypochlorite unit.

2.7. INSTRUMENT AIR SYSTEM

Typically 2 x 200 scfm units with filters, driers and receiver.

2.8. FUEL GAS SYSTEM

Simple scrubber receiver operating at sales gas pressure with letdown through filter separators.
Dry gas – so no hydrate and no superheat required for gas engines.

2.9. DIESEL FUEL SYSTEM

With a much reduced power generation demand – the crane pedestal often provides a 7 day
supply 980 – 100 bbl) for the emergency gen set with the main generators running off “buy – back”
gas in the event of platform shutdown. Simple transfer boost pumps provided and filters to supply
the EG, Crane and Survival Craft.

2.10. COMPRESSION
Some installations have a gas driven VRU – self contained with belt driven radiator.

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CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 6 of 9

2.11. MATERIAL HANDLING

Typically 35 / 5 ton 100 ft boom crane and 460 HP diesel engine. Electric and manual hoists and
monorails provided as required on the decks.

2.12. SAFETY SYSTEMS

Two x 100 percent diesel firewater pumps per NFPA. 2 x 50 man POB TEMPSC. F & G Systems
per API RP 14C, 14J and USCG.

2.13. BUILDINGS - POWER DISTRIBUTION & CONTROL ROOM

This is provided in a single MCC Building normally located on the upper Main Deck next to the LQ.
Workshop and Warehouse Buildings are located on the Production Deck.

2.14. LIVING QUARTERS & HD

Normally the permanent LQ is only sized for the longterm operation – typically 12 to 15 beds. The
drilling rig supplies its own temporary sleeper units (pressurized and fire proof).

2.15. OTHER UTILITIES

Potable water by bunkering – though ROs are low cost but add to the power load. Sewage units
are typically macerator type. Wash down pump and storage tank. Open Drain Sump Tank and air
pumps.
TYPICAL STRUCTURE – WITH AND WITHOUT DRILLING RIG

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Aker Kværner Engineering & Technology
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Title: Doc. No.: Rev.: Date: Page:
CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 7 of 9

3. PROPOSED STUDY DELIVERABLES

1. FACILITY BASIS ..................................................................................................... 4

2. FACILITY DESCRIPTION ....................................................................................... 7

2.1. MANIFOLD SYSTEMS............................................................................................ 7
2.2. PRODUCTION SEPARATION ................................................................................ 7
2.3. CONDENSATE TREATING..................................................................................... 8
2.4. VRU COMPRESSION SYSTEM ............................................................................ 8
2.5. VENT SYSTEM ....................................................................................................... 9
2.6. GAS DEHYDRATION & GAS SALES...................................................................... 9
2.7. BOOST GAS COMPRESSION (IF APPLICABLE)................................................... 9
2.8. PRODUCED WATER .............................................................................................. 9
2.9. UTILITY WATER SYSTEM ................................................................................... 10
2.10. POWER GENERATION ........................................................................................ 10
2.11. FIRE WATER & SAFETY SYSTEMS .................................................................... 11
2.12. MATERIAL HANDLING ......................................................................................... 11
2.13. LIVING QUARTERS.............................................................................................. 11
2.14. CHEMICAL INJECTION ........................................................................................ 11

3. DECK LAYOUT & SAFETY CONSIDERATIONS .................................................. 12

3.1. SAFETY IN DESIGN ASPECTS........................................................................... 12
3.1.1. SAFETY GOALS ................................................................................................... 12
3.1.2. Layout and Orientation .......................................................................................... 12
3.1.3. Isolation, Shutdown and Blowdown ....................................................................... 13
3.1.4. Bunding and Drainage........................................................................................... 14
3.1.5. Hazardous Area Classification............................................................................... 14
3.1.6. Ventilation ............................................................................................................. 15
3.1.7. Explosion Mitigation and Protection....................................................................... 15
3.1.8. Passive Fire Protection.......................................................................................... 16
3.1.9. Active Fire Protection ............................................................................................ 16
3.1.10. Fire Detection........................................................................................................ 18
3.1.11. Combustible Gas Detectors................................................................................... 19
3.1.12. Egress Routes....................................................................................................... 19
3.1.13. Temporary Refuge ................................................................................................ 20
3.1.14. Evacuation / Escape Systems ............................................................................... 21
3.2. Layout Configuration Issues .................................................................................. 22
3.3. Structural Engineering ........................................................................................... 22
3.3.1. Structural Design Premise..................................................................................... 22
3.3.2. Concept Topsides & Jacket framing ...................................................................... 22
3.3.3. Concept Pile Foundation Design ........................................................................... 22
3.3.4. Installation Methodology........................................................................................ 22
3.3.5. Topsides, Jacket & Piling Bulk MTOs .................................................................... 22

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CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 8 of 9

4. EXECUTION PLAN ............................................................................................... 23

4.1. Background ........................................................................................................... 23
4.2. Execution Method.................................................................................................. 23
4.2.1. Engineering ........................................................................................................... 24
4.2.2. Procurement.......................................................................................................... 24
4.2.3. Fabrication & Installation ....................................................................................... 25

5. CAPEX COST ESTIMATE .................................................................................... 26

6. APPENDICES ....................................................................................................... 26
6.1. LAYOUT................................................................................................................ 32
6.2. PROCESS FLOW SCHEMATICS ......................................................................... 32
6.3. PROCESS STREAM SUMMARIES....................................................................... 32
6.4. EQUIPMENT LIST, COSTS & LLI’s....................................................................... 32
6.5. ELECTRICAL LOAD LIST ..................................................................................... 32
6.6. OTHER DATA ....................................................................................................... 32

Study Cost of $150,000 and a Duration of 10 - 12 Weeks from ARO.

10099-Z-1000 CPC Block - F - Aker Kvaerner Rev A Aug 15.doc

Aker Kværner Engineering & Technology
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CPC Block “F” Gas Platform 1076050-Z-RA-1001 A Aug 10 07 9 of 9

4. AKER KVAERNER EXPERIENCE

Aker Kvaerner Houston through it’s acquisition in the late 90’s of Enercon have appreciable
experience of fixed structure platforms in GOM and International.
In addition – the Aker Kvaerner Kuala Lumpur Office has many fixed platform projects in Malaysia
and South China Sea area.
An example below is for a Aker Kvaerner platform handling 600 Mmscfd (8 times larger than
Block “F”) – yet has a topsides weight of only 4000 MT.

10099-Z-1000 CPC Block - F - Aker Kvaerner Rev A Aug 15.doc