59
Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth, Australia Prof. Kevin Mullen The FLNG Forum 2013 Delivering knowledge on the latest technologies, concepts and challenges for the FLNG revolution Take a deep breath, as we plunge below the water line to look as the subsea systems which supply our Floating LNG production. Why do we need to consider the subsea part? Well the subsea part is not just “business as usual”. In fact, just as Floating LNG is a game changer, so the subsea part has to be re- engineered too: • Firstly, to take advantage of the new opportunities that come from having the LNG plant right next to the gas reservoirs, instead of hundreds of kilometres away, • And secondly, to avoid the pitfalls that can come with this new technology. 1 20/10/2018 Subsea Developments for FLNG Production

Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

  • Upload
    others

  • View
    6

  • Download
    3

Embed Size (px)

Citation preview

Page 1: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Subsea Developments for FLNG Production3-4 December 2013 | Fraser Suites, Perth, Australia Prof. Kevin Mullen

The FLNG Forum 2013 Delivering knowledge on the latest technologies, concepts and challenges for the FLNG revolution

Take a deep breath, as we plunge below the water line to look as the subsea systems

which supply our Floating LNG production.

Why do we need to consider the subsea part? Well the subsea part is not just

“business as usual”.

In fact, just as Floating LNG is a game changer, so the subsea part has to be re-

engineered too:

• Firstly, to take advantage of the new opportunities that come from having the LNG

plant right next to the gas reservoirs, instead of hundreds of kilometres away,

• And secondly, to avoid the pitfalls that can come with this new technology.

1

20/10/2018Subsea Developments for FLNG Production

Page 2: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Agenda

� Subsea Developments for FLNG Production

� Smaller, Smarter, More Dangerous

• Turning constraints of FLNG to advantage

• Impact of FLNG on subsea field layout

• New subsea technologies for FLNG

• Risks to FLNG from subsea developments

� Case study

The context in which I’m speaking is the Browse LNG type developments, with

massive offshore infrastructure, long distance subsea pipelines, and onshore LNG

plants, being developed instead with Floating LNG.

I believe that these Floating LNG developments can be described as “Smaller,

Smarter, More Dangerous“, and I’m going to outline a framework of what I mean by

those words, and then give a case study to put some flesh on the bones.

2

20/10/2018Subsea Developments for FLNG Production

Page 3: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Smaller, Smarter, More Dangerous

� Australian LNG projects, capital costs and unit costs

• FLNG is small – single train

• Typical fields will require several FLNG

• Prelude: 3.6 – 5 MTPA LNG

Source: BREE

pa

To see how FLNG compares with typical LNG developments, you need to understand

that FLNG is small.

Prelude is only 3.6 MTPA. Typical fields would require 2 or 3 FLNG vessels. Woodside

say they will need 3 for Browse.

Mind you, Exxon Mobil are talking about a 7 MTPA facility for Scarborough, though I

think that’s a bit ambitious.

The Shell Prelude vessel is designed for 3.6 MTPA of LNG, but also produces 1.3

MTPA of condensate and 0.4 MTPA of LPG.

For a field with no liquids, the processing equipment on a Prelude-sized vessel could

handle 5 MTPA of LNG.

At this point, you may be beginning to see some cracks in the concept of the one-

size-fits-all FLNG approach.

Reservoirs are different sizes, and contain different amounts of gas and liquids. It’s

unlikely that you can just move an FLNG from one field to another, the processing

equipment on board would have to be changed.

3

20/10/2018Subsea Developments for FLNG Production

Page 4: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Smaller, Smarter, More Dangerous

� Having FLNG close to wells is an enabler

• Allows pipeline heating

• Reduces dependence on chemicals

� Shorter distance to wells

• No need for compression or boosting

• Less failure-prone equipment on the seabed

• Slugs and liquid hold-up in flowlines is less of a problem

With remote subsea gas fields, you can’t use some of the new technologies that are

available.

For example, big fields like Gorgon and Snohvit use MEG injection to prevent hydrate

formation. Conventional developments like these can’t use heated flowlines because

the distance is too great and the power losses would be excessive.

With a FLNG vessel close to the wells, you can have electrically heated flowlines,

which avoids the problems of handling the chemical MEG.

Another benefit of shorter distances is that new technologies such as subsea

compression and pumping and separation are not needed, which means there is less

equipment on the seabed which can fail. And that too is smart.

4

20/10/2018Subsea Developments for FLNG Production

Page 5: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Smaller, Smarter, More Dangerous

� FLNG puts all processing equipment in close proximity

• FLNG vessel exposed to inventory of risers and flowlines

• Prone to escalation

• Inherently dangerous, not inherently safe

� An as-yet unproven technology

• Potentially subject to cost blowouts

• More dangerous to your bottom line

� FLNG systems will suffer more downtime than onshore LNG

• No linepack in long pipelines

• More dependent on high availability subsea systems

• More risk to your bottom line

More dangerous? Well, putting explosive or inflammable things close together is a

recipe for disaster. We saw this in the pipeline rupture and fire at Varanus Island,

where the narrow pipeline corridor resulted in one ruptured pipeline setting off

another and then another.

FLNG vessels are big – very big – and they use air gaps between modules. But putting

all that equipment close together increases the risk of escalation. Also, hooking the

FLNG up to the subsea system increases the risk.

We’ve also go the issue of technical risk. The previous Shell Australia head Ann

Pickard described FLNG as the potential "saviour" of Australia's LNG industry. She

said that FLNG technology represents a way for Australia’s LNG industry to become

more cost-competitive in the face of potentially cheaper LNG exports out of the

United States and Canada.

She said “The Australian LNG industry has a major problem in general. Floating is the

most cost competitive new entrant to LNG in Australia. We do see it as probably the

potential saviour of the Australian LNG industry over the next decade or so.”

Woodside seem to have bought into that, too. But is that naïve, for an unproven

technology?

Another area of concern is the availability of FLNG systems.

Conventional systems have the benefit of long pipelines which act as a buffer and

allow LNG production to continue when the subsea system is down.

FLNG systems don’t have this buffer. If the subsea system trips, you have to shut

down LNG production. Recycling the gas around the process may buy you a bit of

time, but eventually you have to shut down. You are totally reliant on a high

availability subsea system.

5

20/10/2018Subsea Developments for FLNG Production

Page 6: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Constraints of FLNG

� Smaller size of FLNG

• Too small for the big WA fields

• Browse needs 3!

� FLNG entirely offshore

• Needs crew offshore (Prelude needs 110 man crew)

• Needs crew change/personnel transfer

Explain about constraints.

Tell the wolf story.

6

20/10/2018Subsea Developments for FLNG Production

Page 7: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Constraints of FLNG

� Smaller size of FLNG

• Too small for the big WA fields

• Browse needs 3!

� FLNG entirely offshore

• Needs crew offshore (Prelude needs 110 man crew)

• Needs crew change/personnel transfer

Explain about constraints.

Tell the wolf story…

Two fur trappers, Jacques and Pierre, were up in the great white north in a quest for

wolf pelts, which were bringing in good money back in those days. One night they

were awakened by the sound of snarling and growling. They looked out of their tent

and discovered that they were surrounded by a vicious pack of wolves. Their hunting

gear was out of reach, and so they were basically defenceless. Jacques turned to

Pierre and said, “Those wolves look mean and hungry, and there are about fifteen of

them and only two of us. I guess you know what that means.” And Pierre answered,

“Yeah, we’re rich!”Courtesy Rev. Stephen H. Wilkins, Georgetown Presbyterian Church, http:/www.gtpres.org/130407.pdf

7

20/10/2018Subsea Developments for FLNG Production

Page 8: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� Smaller size of FLNG

• Allows phased development of larger fields

• Reduces financial exposure and initial CAPEX

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Avoids onshore protest activity (e.g. James Price Point)

• Still some risk from offshore activism

� FLNG entirely offshore

• Less risk of environmental approval delays or native title issues

� FLNG entirely offshore

• No requirement for WA Domgas

These apparent constraints actually confer some very significant benefits.

• The smaller size of FLNG means there is reduced financial exposure and the CAPEX

is lower.

• Being entirely offshore means that protests and direct action are less likely.

• The approvals process may be simpler.

• And it may avoid a requirement for Domgas in Western Australia.

8

20/10/2018Subsea Developments for FLNG Production

Page 9: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� Smaller size of FLNG

• Allows phased development of larger fields

• Reduces financial exposure and initial CAPEX

Let’s look at how the smaller size of FLNG allows us to have phased developments.

9

20/10/2018Subsea Developments for FLNG Production

Page 10: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� Smaller size of FLNG

• Allows phased development of larger fields (3 FLNG for Browse)

• Reduces financial exposure and initial CAPEX

Chart: UWA Subsea Technology 2013 Team 1

Cashflow for FLNG vs onshore LNG

For example, a Browse sized field with 3 FLNGs would not have them all coming

online at the same time. They would be built and installed in phases, so the initial

outlay is only for a single FLNG, not three.

Once the first FLNG is installed and commissioned, it starts generating revenue, so a

second and then a third can be brought into service.

The benefit of the phased development is that the financial exposure is far less than

for conventional developments, where the entire system has to be built before any

LNG can be produced.

10

20/10/2018Subsea Developments for FLNG Production

Page 11: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� Smaller size of FLNG

• Allows phased development of larger fields (3 FLNG for Browse)

• Reduces financial exposure and initial CAPEX

• Going from MEGA-Project to Mini-MEGA-Project

$50-60 billion exposure $13 billion exposure

In effect, we are going from MEGA-Projects to Mini-MEGA-Projects.

For brevity, I shall refer to the Mini-MEGA-Projects as Mini-Me.

11

20/10/2018Subsea Developments for FLNG Production

Page 12: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� Smaller size of FLNG

• Allows phased development of larger fields (3 FLNG for Browse)

• Reduces financial exposure and initial CAPEX

• Going from MEGA-Project to Mini-MEGA-Project

$50-60 billion exposure $13 billion exposure

Now, although I’m showing Dr Evil and his naughty little clone here, neither type of

project is actually evil.

But that is not the perception of 4% of the public.

12

20/10/2018Subsea Developments for FLNG Production

Page 13: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Opposition to gas developments

Courtesy West Australian, 29 Jul 2013

In fact, 4% of the public strongly oppose gas developments, indeed they are

ideologically opposed to fossil fuel use and climate change through human activity.

This survey by the Australian Petroleum Production & Exploration Association shows

that part of the community opposes the type of developments that we are

discussing, with a small part in strong opposition.

A large part of the community hold the middle ground on these issues.

It’s important for oil and gas companies to manage those who strongly oppose them,

and also seek the favour of those holding the middle ground.

Besides exploration licences and production licences, companies need a “social

licence” to operate.

13

20/10/2018Subsea Developments for FLNG Production

Page 14: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Still some risk from offshore activism

• Avoids onshore protest activity (e.g. James Price Point)

• Avoids protracted delays (e.g. Corrib)

So taking the activities offshore can reduce the opportunities for protest and

consequent delays.

We saw protest at James Price Point, and there have been extended delays at Shell

Corrib in Ireland.

14

20/10/2018Subsea Developments for FLNG Production

Page 15: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Shell Corrib timeline

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Avoids onshore protest activity (e.g. James Price Point)

• Still some risk from offshore activism

• “Shell has learned, through listening, that you need to go beyond compliance to win the trust of your neighbours”

First gas on Corrib should have been in 2007

15

20/10/2018Subsea Developments for FLNG Production

Page 16: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Shell Corrib timeline

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Avoids onshore protest activity (e.g. James Price Point)

• Still some risk from offshore activism

• “Shell has learned, through listening, that you need to go beyond compliance to win the trust of your neighbours”

However, there were protests from locals who felt that Shell was not listening to

their concerns about an onshore pipeline running past their houses. Jailing them

turned the protestors into heroes, and there was a groundswell of support and

resistance from the community and the international environmental lobby.

16

20/10/2018Subsea Developments for FLNG Production

Page 17: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Shell Corrib timeline

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Avoids onshore protest activity (e.g. James Price Point)

• Still some risk from offshore activism

• “Shell has learned, through listening, that you need to go beyond compliance to win the trust of your neighbours”

An independent safety review failed to impress as the community had lost

confidence in the proponents.

17

20/10/2018Subsea Developments for FLNG Production

Page 18: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Shell Corrib timeline

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Avoids onshore protest activity (e.g. James Price Point)

• Still some risk from offshore activism

• “Shell has learned, through listening, that you need to go beyond compliance to win the trust of your neighbours”

Legal challenges and appeals about the environmental approvals caused further

delays, with the onshore pipeline being re-routed.

18

20/10/2018Subsea Developments for FLNG Production

Page 19: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� FLNG entirely offshore

• Reduces exposure to environmental direct action

• Still some risk from offshore activism

• Avoids onshore protest activity (e.g. James Price Point)

• Avoids protracted delays (e.g. Corrib)

� Shell Corrib

• Mediation failed – “the parties are unable to resolve the differences between them”

• “Shell has learned, through listening, that you need to go beyond compliance to win the trust of your neighbours”

Despite attempts at mediation, the landowners and Shell were unable to come to

agreement.

It’s important to recognise that the 4% who strongly oppose gas developments will

not be persuaded by anything we say or do to change their mind. They have to be

managed in a way that offsides them and makes them seem unreasonable or cranks,

because that will distance them from the undecided majority and make them more

in favour of our gas developments.

Shell said this about Corrib, but I don’t think they actually learned it.

In fact, at the start of the week, Shell's Australian chairman Andrew Smith put

Premier Colin Barnett on notice over his opposition to floating LNG, saying WA risked

losing the chance of playing host to the fledgling multibillion-dollar global industry.

I don’t sense much listening there, just the arrogance that got them into trouble on

Corrib.

19

20/10/2018Subsea Developments for FLNG Production

Page 20: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Is the tolerance of green activism changing?

� Paul Watson of Sea Shepherd has faced legal action from the United States, Canada, Norway, Costa Rica, and Japan

• After skipping bail following an arrest in Germany in 2012, Interpol issued red notices requesting his arrest.

� The activist who caused a $314 million temporary plunge in Whitehaven Coal's share price could face 10 years in jail

• Jonathan Moylan issued a fake ANZ press release claiming ANZ had pulled a $1.2 billion loan because of environmental concerns

� Greenpeace vessel Arctic Sunrise arrested by Russia

• Piracy charges for boarding the Gazprom drill rig Prirazlomnaya have been downgraded to hooliganism

� Senator Eric Abetz says

• "With the Greens it is always a case of the ends justifying the means.’’

20

20/10/2018Subsea Developments for FLNG Production

Page 21: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Turning constraints of FLNG to advantage

� FLNG entirely offshore

• Potentially no requirement for WA Domgas

• Western Australia’s domestic gas reservation policy, instated in 1977, was updated in 2006 and requires LNG Producers to make available domestic gas equivalent to 15% of LNG production from each LNG export project

• Sales revenue of export gas and domestic gas (15% of total gas production) are approximately $12/MMBTU and $8/GJ

Pie Chart: based on data from UWA Subsea Technology 2013 Team 3

74%

8%18%

Revenue Component

Export Gas

DomGas

Condensate

Domgas comprises 15% of LNG production but only gets 8% revenue due to the

lower sales price of Domgas.

Another interesting thing from the piechart is that condensate and LPG can generate

a large revenue stream in addition to LNG sales.

21

20/10/2018Subsea Developments for FLNG Production

Page 22: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

New subsea technologies for FLNG

� Heating of flowlines for hydrate prevention

• Direct electric heating or trace heating or heated water pipes

• Eliminate need for MEG

• Eliminate need for MEG reclamation on FLNG vessel

� Why?

• Shell Prelude has 800 m3/day MEG regeneration system to provide buffer storage, collection and regeneration of MEG

• MEG facilities including MEG storage tanks,MEG desalination package, MEG regeneration package, MEG injector and MEG booster pumps

Image: Cameron

MEG module for offshore Brazil applicationRich MEG flow 120 m3/day

300 tonne module

x6

22

20/10/2018Subsea Developments for FLNG Production

Page 23: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

New subsea technologies for FLNG

� Direct Electrical Heating (DEH)• AC current to pipe

• Field Proven: Single phase required

• High voltage and power required (100-150 W/m)

� Electrical Heat Tracing (EHT)• Heating cables between pipe and insulation

• Pipe in Pipe (PIP)

• AC three phase power

• Low voltage, low power (4-30 W/m)

• Higher safety, less dielectric ageing

• Qualified wire traces and subsea connectors

• Allows redundancy

� Integrated Production Bundle (IPB)• Hot water tubes between pipe and insulation

• Use spare heat from compression / power generation

• Use for risers Images: Technip

Heated Flexible

Flowline

Electrically Trace Heated Pipe-in-Pipe

Image: Total

DEH

AC current to pipe - return through pipe or external cable

Field Proven: NaKika (Shell, GOM) – 5 cases in Norway (Statoil)

23

20/10/2018Subsea Developments for FLNG Production

Page 24: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

New subsea technologies for FLNG

� Electrical Heat Tracing (EHT)

• Low voltage, low power (4-30 W/m)

• Redundant trace heating cables

• Fibre optic for thermal monitoring

Image: Technip

The power required is relatively small, and the highest demand is during pipeline

warm-up, when the wells are not producing, and the platform power is not needed

for processing and liquefaction.

When maintaining the temperature, the power demand is less.

24

20/10/2018Subsea Developments for FLNG Production

Page 25: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

New subsea technologies for FLNG

Courtesy: Total

Power requirements for Islay EHT

Power required

per metre

Overall power

required

Maintain temperature above

HAT (ca 20°C)4 to 8 W/m Ca. 50 kW

Heat up pipeline from 4

to 20°C in 24 hours15 to 20 W/m Ca. 120 kW

Heat up pipeline from 4

to 20°C in 30 hours with

15% of hydrates30 W/m Ca. 180 kW Power

20 W/m

8 W/m

4ºC

20ºC

Temperature

Heat up

Maintain

� Electrical Heat Tracing (EHT)

• Low voltage, low power (4-30 W/m)

• Redundant trace heating cables

• Fibre optic for thermal monitoring

The power required is relatively small, and the highest demand is during pipeline

warm-up, when the wells are not producing, and the platform power is not needed

for processing and liquefaction.

When maintaining the temperature, the power demand is less.

25

20/10/2018Subsea Developments for FLNG Production

Page 26: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

New subsea technologies for FLNG

� Reeled installation

• Faster than S-lay or J-lay

• Fabrication is performed onshore

• Controlled environment, off the critical path

• Weld repairs are performed onshore

Image: Technip

Courtesy: Chuck Horn/SUT

S-lay

Reeling onto installation vessel

The Electrical Heat Traced Pipe in Pipe used on the Islay project was installed by reel

lay, which offers faster installation than methods such as S-lay and J-lay where pipes

are welded together on the pipelay vessel.

A completer reel length is fabricated onshore in controlled conditions, and reeled

onto the installation vessel, taken out to the field, and unreeled onto the seabed. Lay

rates of up to 16 kilometres per day can be achieved with reel lay.

The Electrical Heat Traced Pipe in Pipe is qualified for sizes up to 12” which makes it

ideally suited for FLNG developments. These don’t have the 40” export pipelines

need by the Gorgon and Ichthys type projects.

So we can use spare power or waste heat, and use reel installation. It gets rid of the

MEG recycling equipment and frees up space on the vessel. It’s like the planets

coming into alignment, everything is right for this new technology

26

20/10/2018Subsea Developments for FLNG Production

Page 27: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Risks to FLNG from subsea developments

� Risk is higher with FLNG than FPSOs

• Risk = Likelihood x Consequence

• Likelihood is higher with gas than with oil developments

• Consequence of loss of FLNG = $13 billion Shell Prelude

• Consequence of loss of FPSO = $1.5 billion UIBC 2012 data

� Shell statement in Prelude EIS

• After comprehensive studies, model testing and in-depth reviews, Shell’s FLNG design safety is considered equal to the latest FPSO or integrated off shore facility.

27

20/10/2018Subsea Developments for FLNG Production

Page 28: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Risks to FLNG from subsea developments

� Ignominious

• Marked by shame or disgrace

Image: Woodside

The Real Estate for Browse LNG at James Price Point

28

20/10/2018Subsea Developments for FLNG Production

Page 29: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Risks to FLNG from subsea developments

� Ignominious

• Marked by shame or disgrace

Image: Woodside

The Real Estate for Prelude

29

20/10/2018Subsea Developments for FLNG Production

Page 30: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Risks to FLNG from subsea developments

� Ignominious

• Marked by shame or disgrace

Image: Woodside

The Real Estate for 3 x FLNG

30

20/10/2018Subsea Developments for FLNG Production

Page 31: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study

Courtesy: UWA Subsea Technology 2013 Team 1

31

20/10/2018Subsea Developments for FLNG Production

Page 32: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: Geoscience Australia

Major gas fields: development status, as of March 2012

32

20/10/2018Subsea Developments for FLNG Production

Page 33: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Reservoir Gas CondensateCO2

Content

Torosa 8.5 Tcf 159 MMbbl 8% CO2

Brecknock 4.0 Tcf 144 MMbbl 8% CO2

Calliance 3.0 Tcf 114 MMbbl 12% CO2

Remoteness of Browse Basin from Existing Infrastructure

Challenging Access

Courtesy: UWA Subsea Technology 2013 Team 1

33

20/10/2018Subsea Developments for FLNG Production

Page 34: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: Scott Reef Rugbjerg_2009

Perspective view of Scott Reef from the west.

The coral atoll Scott Reef is located in 500 m water depth on the edge of the

continental shelf.

Note the deep channel with steep sides between the two reefs.

34

20/10/2018Subsea Developments for FLNG Production

Page 35: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

35

20/10/2018Subsea Developments for FLNG Production

Page 36: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

36

20/10/2018Subsea Developments for FLNG Production

Page 37: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

� Subsea systems with LNG facilities on Scott Reef

Image: LNG Conceptual Design Strategies

This concept is unlikely to get environmental approval.

But it has the singular benefit of being the most cost-effective way of developing

these reserves.

37

20/10/2018Subsea Developments for FLNG Production

Page 38: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

$150 million study for Browse LNG DTUs

38

20/10/2018Subsea Developments for FLNG Production

Page 39: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Paul Howes of the Australian Workers' Union described the decision by Woodside to

shelve the LNG project at James Price Point as “the great Australian rip-off”.

Rita Augustine of the Jabirr Jabirr tribe was in tears as she spoke of feeling let down

and deeply saddened that benefits from the project appeared lost to her people. She

said “These people who were protesting were selfish towards our people, even the

protesters that came from overseas. It had nothing to do with them. It is not their

country.”

39

20/10/2018Subsea Developments for FLNG Production

Page 40: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

UWA Subsea Technology 2013 teams

40

20/10/2018Subsea Developments for FLNG Production

Page 41: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Team 1 Team 2 Team 3 Team 4

Project

Analogues

Shell Prelude Chevron Gorgon (+ Apache

East Spar Control Buoy)

Wandoo B Inpex Ichthys

Topsides FLNG LNG trains at JPP LNG

Precinct

Concrete Gravity Structure

with slug catcher in 45 metre

WD, LNG trains at JPP LNG

Precinct

Infield Central

Processing Facility with

compression, LNG

trains at JPP

Export Pipeline N/A 40" CS 310 km pipeline 26" CS x 115 km, 24" CS

240 km export pipeline

36" CS x 325 km export

pipeline

CAPEX Initial CAPEX 13.4 billion,

total $45 bn

$47.3 bn 22 billion (questionable

benchmark ing )

36 billion

LNG trains 4.2, 4.3, 4.7 MTPA 3 off 4 MTPA 3 off 4.3 MTPA 2 off 3.65 MTPA

Nominal flowrate 717+740+800 MMSCFD 2200 MMSCFD 1748 MMSCFD 1500 MMSCFD

Field life 39 years 19 years 25 years 36 years

Control of field Closed loop MUX-EH Closed loop MUX-EH, via

control buoy

MUX-EH (fibre optic), from

CGS

MUX-EH from CPF

NPV 35 billion,

10% discount rate

18 billion 12 billion 15 billion

Payback 6.5 years after production 6 years after production 6 years after production 8 years after production

First LNG 2024 2017 2018 2017

Well count 53 wells total 26 wells total 46 wells total 19 wells total

Drilling Phases 6 (9+10+12+13+5+3 wells) 13 (19+1+1+1+1+1+2+5+

1+1+1+1+1 wells)

5 (13+8+8+10+7 wells) 7 (6+1+1+1+1+1+1+2+

1+1+1 wells)

Trees 7" horizontal 7" vertical monobore trees 7" enhanced horizontal trees 7" horizontal

Completions 7" completions 9 5/8" and 7" completions 9 5/8" and 7" completions 9 5/8" completions

CO2 Reinject into reservoir Reinject into reservoir, 18"

CS 280 km pipeline

The central processing facility Samsung Heavy Industries will build for Ichthys will

cost $2.26 billion.

The pipeline for 889 kilometers gas transmission costs $1 billion

The onshore LNG plant near Darwin including two LNG trains with a capacity of 4.2

million tons per year each costs $15 billion .

The Ichthys subsea facilities cost $2 billion.

41

20/10/2018Subsea Developments for FLNG Production

Page 42: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

Challenging Reservoir

42

20/10/2018Subsea Developments for FLNG Production

Page 43: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

Challenging Environment

43

20/10/2018Subsea Developments for FLNG Production

Page 44: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

Subsea-to-Shore tieback Tieback to Offshore Processing Facility

and to LNG Plant Onshore

Floating LNG

Option A

Option C

Option B

We came up with 3 development concepts: The first option is Subsea-to-shore

directly tie-back to onshore terminal. This option provides flexibility while

minimising CAPEX by eliminating the need of offshore processing facilities. One of

the major issues of this solution is flow assurance issue. These issues would be

controlled from the shore terminal which is the main challenges to the concept.

Option B is using Offshore processing facility concept similar to the first concept, but

instead of having control and say MEG distribution from shore, this will be supplied

from the platform. Any solution which involved chemical treatment is easier to be

implemented using a topside. In addition, condensate processing could be done on

this facility & transferred to FPSO. Whilst the processed gas from this processing

facilities could be exported to either the James Price Point, Karratha or possibly tie in

to Inpex Ichthys pipeline. We also considered the use of fixed platform for processing

located at the shallow water.

FLNG reduces the number of elements in the supply chain: no offshore

platform/FPSO, pipeline to onshore plant or onshore infrastructure required. Whilst

it potentially saved the infrastructure cost; the risk and technology associated with

this solution would be incorporated in cost calculation.

Option A Standard industrial solution is by MEG injection to prevent hydrate plugging

in the flowline.

Option C This is a novel concept that currently being built by Shell for Prelude

Project.

44

20/10/2018Subsea Developments for FLNG Production

Page 45: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

TOROSA – South

Phase 4

TOROSA – North

Phase 3

BRECKNOCK

Phase 2

CALLIANCE

Phase 1

FLNG 1

10Prod+2 CO2 Injection

TOTAL 12 wells

FLNG 2

13Prod+2 CO2 Injection

TOTAL 15 wells

FLNG 3

11Prod+2 CO2 Injection

TOTAL 13 wells

FLNG 1

11Prod+2 CO2 Injection

TOTAL 13 wells

Explain about reservoir boundary, planned location of sweet spots

Phased development

It should be noted that Torosa South is the most difficult reservoir to develop. By this

sequential the development, we could do more studies on the best technology to

develop Torosa South.

45

20/10/2018Subsea Developments for FLNG Production

Page 46: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

NPVa = $31.78B, IRR = 6.87%

NPVb =$27.46B, IRR = 5.78%

NPVc=$35.03b, IRR = 10.53%

Arrow shows the Start of Production

Cash flow

46

20/10/2018Subsea Developments for FLNG Production

Page 47: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

0

500

1000

1500

2000

2500

3000

0 5 10 15 20 25 30 35 40

Pro

du

cti

on

ra

te M

MS

CF

/D

Production Year

Production Rate vs Time

Production capacity

Operation rate

47

20/10/2018Subsea Developments for FLNG Production

Page 48: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Manifold: C01

Phase 0 (4ea)Slot - S01,S02,S03,S04

Future expansion wells:S05,S06

Manifold: C02

• Phase 0 (3ea)Slot - S01,S02,S03

SDU

UMBILICALS

PLET

X-TREE

JUMPER

UMBILICALS

FIELD LAYOUT: CALLIANCE

Water depth: 500 m

Water depth: 380 m

• Phase 1 (2ea)Slot - S04, S05

• Phase 2 (1ea)Slot - S06

Injection Wells

Phase 0 (2ea injection wells daisy-chain)

RISER BASE + SSIV

UTA

PLET

INJECTION PIPELINE

FLOWLINE

PRODUCTION X-TREE

SPARE SLOTSDU

INJECTION X-TREE

PRODUCTION PIPELINE

MANIFOLD

N

At first glance, it’s similar to Prelude.

But there are some significant differences.

The single umbilical on Prelude is recognised as a single point of failure, so dual

umbilicals are used to each drill centre.

There are two CO2 injection wells for disposal of CO2. On Prelude, the 7% CO2 is

simply vented to atmosphere.

20/10/2018

48

Subsea Developments for FLNG Production

Page 49: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

`

Manifold: B01

• Phase 1 (6ea)Slot - S01,S02,S03,S04,S05,S06

Manifold: B03

• Phase 3 (3ea)Slot - S01,S02,S03

Water depth: 680 m

Water depth: 500 m

Manifold: B02

• Phase 2 (3ea)Slot - S01,S02,S03

FIELD LAYOUT: BRECKNOCK

• Phase 4 (1ea)Slot - S04

Injection Wells

• Phase 1 (2ea CO2

Injection wells)

INJECTION PIPELINE

FLOWLINE

UMBILICALS

SPARE SLOT

PRODUCTION PIPELINE

MANIFOLD

RISER BASE + SSIV

UTA

PLET

PRODUCTION X-TREE

SDU

INJECTION X-TREE

N

20/10/2018

49

Subsea Developments for FLNG Production

Page 50: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Water depth: 290 m

Manifold: T03

Phase 4 (2ea)Slot - S01,S02

Manifold: T02

Phase 3 (2ea)Slot - S01,S02

FIELD LAYOUT: TOROSA – NORTH

Manifold: T01

Phase 2 (6ea)Slot - S01,S02,S03,S04,S05,S06

Phase 5 (1ea)Slot – S03

(Inset) Manifold T01

Injection Wells

Phase 2(2ea CO2 injection wells)

INJECTION PIPELINE

FLOWLINE

UMBILICALS

SPARE SLOT

PRODUCTION PIPELINE

MANIFOLD

RISER BASE + SSIV

UTA

PLET

PRODUCTION X-TREE

SDU

INJECTION X-TREE

N

20/10/2018

50

Subsea Developments for FLNG Production

Page 51: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Ave. inclination 10 degrees

Manifold: T04

Phase 3 (6ea)Slot - S01,S02,S03,S04,S05,S06

Manifold: T05

Phase 4 (2ea)Slot - S01,S02

Manifold: T06

Phase 5 (3ea)Slot - S01,S02,S03

Water depth: 1000 m

Water depth: 500 m

Injection Wells

Phase 3 (2ea CO2 injection wells daisy-chain)

INJECTION PIPELINE

FLOWLINE

UMBILICALS

SPARE SLOT

PRODUCTION PIPELINE

MANIFOLD

RISER BASE + SSIV

UTA

PLET

PRODUCTION X-TREE

SDU

INJECTION X-TREE

FIELD LAYOUT: TOROSA – SOUTH Ave. inclination 5.7 degrees

Water depth: 2000 m

Water depth: 1500 m

N

Torosa South

Uses the FLNG vessel from the depleted Calliance field.

Drilling and production from inside the reef will not be permitted, so all drilling takes

place from outside the reef, and outside the reservoir, using deviated drilling to

reach in from the wellheads to the reservoir itself. This will need directional drilling

with a reach of 6 or 7 kilometres, which is on the edge of current technology, but

should be easier in 15 years time.

20/10/2018

51

Subsea Developments for FLNG Production

Page 52: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

52

20/10/2018Subsea Developments for FLNG Production

Page 53: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 2

Carbon Sequestration

53

20/10/2018Subsea Developments for FLNG Production

Page 54: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Case Study – Browse LNG Development

Courtesy: UWA Subsea Technology 2013 Team 1

Project Economics Key Figures

CAPEX - $46.16B Total Project Cost

FLNG -$42.92B

Subsea -$3.24B

OPEX - $440M per FLNG vessel annually

including fuel, staff, transport assistance

NPV10 $35.03B

IRR 10.53%

Parliamentary Enquiry CALDWELL/METCALFE/ BP - FLNG proposal will likely result in

an internal rate of return of somewhere between 12.5 per cent to 13 per cent and

that the onshore project would likely have returned somewhere around 11.5 per

cent

54

20/10/2018Subsea Developments for FLNG Production

Page 55: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Closing Remarks

� The Shell Prelude development

• Single umbilical – single point of failure

• 9% CO2 vented up flare stack – 2.3 MTPA

Image: Shell Environment Plan Prelude Drilling

SSIVs at riser base, 4 12” flexible risers

55

20/10/2018Subsea Developments for FLNG Production

Page 56: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

FLNG – Another South Sea Bubble?

� The South Sea Bubble

• 1718-1721

• The first stock market crash

The South Sea Bubble was the first stock market crash, and it peaked and crashed in

1720.

56

20/10/2018Subsea Developments for FLNG Production

Page 57: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

FLNG – Another South Sea Bubble?

� The South Sea Bubble

• 1718-1721

• The first stock market crash

Sir Isaac Newton, celebrated here on the British pound note, was an early investor.

Fortunately, he got out early, making a small fortune.

57

20/10/2018Subsea Developments for FLNG Production

Page 58: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

FLNG – Another South Sea Bubble?

� The South Sea Bubble

• 1718-1721

• The first stock market crash

However, when he saw that the stock price was still going up, he reinvested heavily

just before the market collapsed.

And he lost a large fortune.

He’s reputed to have said “I can calculate the motion of heavenly bodies, but not the

madness of people.”

I think the FLNG market is overheated for two reasons:

Firstly, the South Sea Bubble effect. Everyone its trying to get on the bandwagon.

Eventually the market will stabilise with a “horses for courses” approach to

conventional developments and FLNG.

Secondly, FLNG is being used as a lease retention strategy. In Australia, companies

can’t just sit on reserves and not develop them. If they don’t bring them to

production, they need to explore the lease by seismic or drilling, or carry out

development studies. I think that some FLNG studies are being carried out just to

hold onto the lease, until the company is ready to develop the field.

58

20/10/2018Subsea Developments for FLNG Production

Page 59: Subsea Developments for FLNG Productionsubseaproduction.systems/assets/files/Subsea Developments...Subsea Developments for FLNG Production 3-4 December 2013 | Fraser Suites, Perth,

Subsea Developments for FLNG Production

� Smaller, Smarter, More Dangerous

[email protected]

59

20/10/2018Subsea Developments for FLNG Production