Sevan Marine ASA Floating LNG FPSO -how to put the gas into exportable parcels. Carnegie ASA Shippingklubben, Oslo January 28, 2008

Transcription

1 Sevan Marine ASA Floating LNG FPSO -how to put the gas into exportable parcels Carnegie ASA Shippingklubben, Oslo January 28,

2 ORGANISATION Sevan Marine ASA 100% 100% 100% 100% Sevan Production AS Sevan Marine do Brasil Ltda Sevan Pte Ltd Singapore Sevan Drilling 100% 80% Sevan Production Services Pte Ltd Kanfa AS 100% Sevan TBN Pte Ltd. Kanfa TEC Kanfa Aragon Mator 100% Sevan TBN Pte Ltd. 2

3 Business model focuses on core competences BOO Build Own and Operate Design Engineering Construction Ownership Operation FOCUS Proprietary technology In-house expertise Hull Topside (Kanfa) Long-term construction capacity secured with key yards In-house expertise in project management and execution Ownership in all units Partnerships on a case by case basis Operation responsibility Combines internal and external resources Lease contracts no reservoir exposure RATIONALE The core competencies and competitive advantages are within the technology Inhouse marine and process expertise provides optimization and flexibility Construction capacity is a critical success factor Extensive construction program in the years ahead requires key competence in execution Full control of own technology Higher returns over a longer period Full control through own operation management Increased flexibility 3

4 -a process design and engineering company providing process equipment, modules, systems and consultancy services Separation and gas modules Sevan Piranema Separation module Sevan Hummingbird 4

5 -specialists in separation, gas handling, water treatment and process performance optimization Process performance Offshore troubleshooting, optimization and testing Modifications Process simulation Design optimization Design evaluation Concept studies 3. party verification Property testing Seminars 5

6 -Design, engineering of and delivery thermal energy systems Thermal Energy Equipment and Systems: Waste Heat Recovery Units (WHRU) for heating medium production Water/glycol mixtures Thermal oils Heat Recovery Steam Generators (HRSG) Saturated Steam for Heating Purposes Superheated Steam for Steam Turbine Operation HRSG auxiliary Systems Make-up Water System incl. Integrated Fresh Water Maker System Chemical Dosing System Blow Down System Feed Water/Deaerator System Steam And Water Monitoring System Online system Manual Sampling System HRSG/Steam Cycle Control Logic Steam Cycle Balance of Plant Analysis Retrofit/Modification Projects 6

7 -with focus on gas applications: FPSO gas systems, gas compression, offshore LNG, process packages gas compression unit 7

8 Internal Turret External Turret Disconnectable Turret No turret, no swivel Storage High deck load capacity Excellent motions TLP Semi Spar 8

9 Sevan - Insignificant bending stresses Eliminating typical fatigue loads and deflections for traditional floaters FPSO Semi Sevan 9

10 Design features HIGH COST EFFICIENCY COMPARED TO SHIP-SHAPED AND SEMIS SHIP-SHAPED SEMI SEVAN Deflection of hull Interaction forces between hull and drilling modules Fatigue exposure of structural members Turret area reduces structural integrity of the hull and is exposed to mooring forces Numberless structural details in aft and bow area Full penetrated welds and extensive NDT in critical areas Long cable and pipe runs Transverse forces and torsion forces in deck structure, pontoons, columns and bracings Equipment integrated in structural elements in deck box, columns and pontoons Local details exposed for high stresses and fatigue High tensile steel to reduce weight Full penetrated welds and special welding procedures Air gap and slamming Insignificant deflection in deck structure All modules supported by the hull structure, limited integration Repeatable details and structure elements Normal steel and welding procedures Mostly fillet welds Modularized topside Short cable and pipe runs 10

11 Construction Efficient hull construction with high repeatability around circle Standard panel and block fabrication All structural members are of standard dimensions and quality Short construction time Storage Displacement Diameter Deck Area (bbl) (mt) (m) (m2) Hull Deck Sevan Sevan Sevan Sevan

12 Sevan Platforms, Main Benefits Concept Scaleable storage capacity High deck load capacity/ stability reserves No requirement for weathervaning Avoiding complicated/costly turret swivel system Standard riser connections, umbilical and power cable terminations Accommodates large number of risers Low investment for future risers Operations Less maintenance and risk of downtime (No maintenance intensive turret or swivel) High operability due to low heave and roll/pitch motions Safe and efficient offloading 12

13 Sevan unit tested in 10,000 year cyclone conditions, Hs=20m - without need to disconnect 15

14 FPSO Sevan Hummingbird motions in adverse weather conditions confirmed Significant wave heights up to 9-9,5 meter, typical max. wave heights up to meter Mean wind above knots, gusting close to 80 knots Motions recorded and concluded to be in accordance with or better than model test and analysis Normal operation and commsisioning activities continued uninterrupted during the storm No green sea on deck observed 16

15 THE FIRST UNIT IS ON FULL CONTRACT RATE TO PETROBRAS S.A. FPSO SEVAN PIRANEMA Petrobras statement in press release dated October 11 th 2007: ( ) The new platform has unprecedented technical characteristics: the round hull, unlike the traditional floating systems, is more versatile and stable, rendering it safer for the operations. ( ) 17

16 Sevan Piranema - Offloading to shuttle tanker 18

17 The Sevan Platforms - a versatile technology - FPSO Floating Production Storage Offloading GTW Gas To Wire (Offshore powerplant) MODU Mobile Offshore Drilling Unit MSV Multipurpose Support Vessel FDPSO Floating Drilling Production Storage Offloading LNG/LPG FAU Floating Accomodation Unit 19

18 Floating LNG FPSO where pipelines not viable Associated gas By-product of offshore oil production Short term enhancing oil production Long term detrimental to oil production, increased gas/oil ratio Smaller reserves but rich in NGL/condensate Stranded gas Isolated pockets remote from land and other field infrastructure Deep water Significant reserves 20

19 Gas Properties

20 Sevan gas treatment concepts Power generation from produced gas Sevan platform as mobile power plant site FSRU LNG receiving terminal with regas and/or power generation Storage for CNG Platform and storage for GTL Offshore LNG production, storage and offloading 22

21 Sevan GTW 540MW Powerplant Main Characteristics Power production from locally produced gas Transmission lines to platform cluster and/or shore Combined cycle (gas/ steam turbines) The Sevan GTW consists of 8 Siemens SGT800 Gas Turbine generator sets Heat Recovery Steam Generators (HRSG) 4 Steam Turbine generator sets Plant power capacity is 540 MWe net At full utilization this represents 4,73 TWh/year Plant efficiency is 54% (Air/ Seawater temp 15/7 degc) Estimated gas consumption is 2 MM SM 3 /day CO2 handling feasible (ref study with SINTEF) Net power capacity after CO2 removal is 450MW Net efficiency after CO2 removal is 45% CO2 injection into subsea reservior (facilitates IOR initiatives) 23

22 FLNG associated gas Oil Processing Facility Gas Pretreatment & Gas Liquefaction Facility SEVAN LNG FLOATER Oil FPSO Risers Mooring Chains Single Gas Riser PLEM Production Line 25

23 FLNG stranded gas Gas Pretreatment & Gas Liquefaction Facility SEVAN LNG FLOATER Risers Mooring Chains Production Line PLEM 26

24 FLNG stranded gas, stand alone platform 27

25 Floating LNG production more complex than conventional floating production Gas and liquid reception (10-13MSm3/d) Gas purification Liquefaction LNG and NGL/condensate storage LNG and NGL/condensate transfer system LNG process power requirement (50-60 MW/MMTPA) Cryogenic processing equipment and piping Congested processing configuration due to limited area and space Specialized Cryogenic containment system partially filled mode Offloading to LNG carriers SOLVENT REGENEN. SOLVENT REGENEN. LPG & C5+ SEPARATION C5+ LPG FEED GAS BULK CO 2 REMOVAL + CO2 1.5% - 3% CO2 SECONDARY CO 2 REMOVAL 50 ppm CO2 28 WATER REMOVAL Hg REMOVAL LIQUEFACTION LNG

26 Sizing of offshore LNG production facilities Production rate in the range of 5-8 MMTPA: Large storage capacity Processing footprint and weights well out of scale for a floating unit Mixed refrigerant or mixed fluid cascade processes Production rate above 3-5 MMTPA: Storage of to m3 of LNG and up to m3 of NGL and condensate Mixed refrigerant or mixed fluid cascade processes Production rate up to 3MMTPA: Storage capacity of to m3 LNG and up to m3 of NGL and condendate Reduction of specific power to produce LNG by maximizing the NGL recovery. Proven nitrogen cycle for liquefation 29

27 High capacity plants, 3-8 MPTA (and above) Cascade LNG process utilizes essentially pure refrigerant components. High efficiency, but high operation, start up and operation costs. Refrigerant employed are propane, ethylene and methane. Mixed pre-cooled mixed refrigerant LNG process provides efficient process utilizing multi-component mixture of hydrocarbons comprising of propane, ethane and methane in one cycle. A separate propane cycle is utilized to pre-cool the natural gas and the mixed refrigerant stream to appr. -35 degr F. High inventory of hydrocarbons in the process 30

28 Nitrogen cycle for floating LNG FPSO, main advantages Reduction of hydrocarbon inventory in the process Proven technology More compact design Heat exchangers more robust for offshore operation The refrigerant remains in gaseous state No need to fraction the NGL as refrigerants The NGL could be exported as condensate mixture Reasonable efficiency versus investment 31

29 Nitrogen comp. Tr. 1 Piping Tr. 1 Nitrogen comp. Tr. 2 Dehydration Piping Tr. 2 Liquefaction Tr. 2 Amine module Liquefaction Tr. 1 Water treatment Separation Stabilisation/ BOG 32 Fuel gas

30 Fuel gas Water treatment Water treatment Liquefaction Trains Stabilisation/BOG Stabilisation/BOG Separation Amine module Amine module Dehydration Dehydration Nitrogen comp. Trains Nitrogen comp. Trains 33

31 General layout Layout example MDO Various pumps Machinery MDO Machinery Various electrical FW Pumps Pumps Various machinery Unspecified e.g. accomodation Electrical FW Unspecified Large spaces in hull 34

32 16 Ballast tanks Double sides and double bottom Cargo compartment 35

33 LNG, NGL and condensate storage 36

34 Self supported cryogenic tank LNG tank Tank stoppers Tank shell with stifferners and frames Double hull ballast tanks Void space with gas detection Tank shell Insulation Secondary barrier Load bearing cryogenic insulation 37

35 Sevan cryogenic tank arrangement features Large volume, low weight and small surface area Insignificant effect on stability and motions High structural integrity with respect to: Stress level Fatigue Crack propagation Reduced heat transfer and BOR due to small LNG tank surface area Low structural weight of tank reducing energy in cool-down phase No filling restriction due sloshing Standard fabrication and welding procedures 39

36 Shuttle tanker operation Standard operational procedures Reduced or no Fish Tailing, Large Swell and Freak Wave effects compared to a FPSO Collision risk with the Sevan unit is consequently reduced during loading operation. DP Shuttle Tankers No stand-by vessels required Connection in Sea states up Hs=4.5m Disconnection in Sea states above Hs=6m Conventional Tankers Stand-by vessel required to hook up the hose. Connection in Sea states up Hs=3m Stern thrust of tons to be applied during the operation Disconnection in Sea states above Hs=4,5-5m 40

37 Offloading systems Side-by-side loading in sea states up Hs 2.5m Tandem loading in sea states up Hs= m Side-by-side in sea states up Hs= m Designed by: StatoilHydro Framo Engineering Aker Kværner Pusnes MIB Italiana SpA 41

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39 The Sevan FLNG FPSO features Now swivel and turret arrangement Low hull weight and high displacement Large deck area and high deckload carrying capacity Stability and high stability reserves Favourable motions reducing pressure loads from sloshing and interaction forces between hull and the contaiment system Dimensions and support of absorbers and regeneration coloumns reduced Less interaction forces between the FPSO and LNG carrier during offloading Large storage capacity for LNG, NGL and condensate Standard offloading to LNG carriers 43

40 Floating LNG FPSO - a source of energy at competitive price 44

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42 FLNG Technology and concepts by Kanfa Aragon AS

43 Why FLNG? Annually a tremendous amount of oil-associated gas is flared or vented due to the distance from the fields to the markets Annual gas flaring exceeding 150 Billion m3 pr year More than 350 million tonnes CO2 emissions per year West Africa, South America and Asia topping oil-associated gas flaring statistics Political trends and increased energy demand will change the existing flaring philosophy Stranded and oil-associated gas liquefied to LNG clearly can represent a new energy supply source

44 Floating LNG (FLNG) Can receive gas from new or existing oil FPSO (separate hull) Converted ship, new hull or barge For small stranded gas fields For associated gas fields Mid-size, mtpa LNG LNG storage & offloading Feed up to 14 Mill Sm 3 /day 1 4 LNG trains

45 Generic or tailor made FLNG Oil Processing Facility Gas Pretreatment & Gas Liquefaction Facility Oil FPSO LNG FPSO (FLNG) Mooring Chains Risers Gas Riser PLEM Production Line

46 Generic or tailor made FLNG Oil Transfer to Shuttle Tanker Side-by-side LNG Transfer to LNG Shuttle Side-by-side Oil FPSO LNG FPSO (FLNG)

47 Generic or tailor made FLNG Oil Processing Facility Gas Pretreatment & Gas Liquefaction Facility SEVAN LNG FLOATER Oil FPSO Risers Mooring Chains Single Gas Riser PLEM Production Line

48 Oil and LNG FPSO For oil fields with associated gas One hull for oil and LNG Converted ship, new hull or barge Gas pre-treatment & liquefaction Oil separation and water treatment Oil storage & offloading LNG storage & offloading

49 LNG process overview PRIMARY PROCESSES ACID GAS (CO 2, H 2 S) FEED GAS SOLVENT REGENERATION DEHYDRATION REGENERATION NGL REMOVAL NITROGEN REFRIGERATION LNG CO2 REMOVAL DEHYDRATION & HG REMOVAL LIQUEFACTION SECONDARY PROCESSES WATER CONDENSATE, LPG BOG HANDLING FUEL SYSTEM WATER TREATMENT CONDENSATE STABILISATION LPG FRACTIONATION POWER GENERATION TYPICAL UTILITY SYSTEMS PROCESS DRAIN HP FLARE COOLING MEDIUM HEATING MEDIUM NITROGEN MAKE-UP NITROGEN MAKE-UP AMINE DRAIN LP & COLD FLARE ELECTRICAL SYSTEM CONTROL SYSTEM SAFETY SYSTEM

50 Aragon liquefaction technologies Based on the classic Brayton/Claude Cycle PRETREATED FEED GAS LNG HEAT EXCHANGER CYCLE COMPRESSOR BOOSTER COMPRESSOR TURBO EXPANDER

51 Aragon liquefaction technologies SPECIFIC TROPICAL CONDITIONS (kwh/kg LNG) SINGLE EXPANDER N2 CYCLE ~ 0.8 kwh / kg DOUBLE EXPANDER N2 CYCLE kwh / kg ARAGON OPTIMISED EXPANDER CYCLE* kwh / kg PRECOOLED DOUBLE EXPANDER N2 CYCLE ~ 0.45 kwh / kg SUITABLE FOR SMALL / MEDIUM SCALE FLNG SUITABLE FOR SMALL / MEDIUM SCALE FLNG SUITABLE FOR MEDIUM SCALE FLNG FOR SOME APPLICATIONS HIGHLY COMPLEX SUITABLE FOR LARGE SCALE LNG PLANTS ONLY SINGLE MIXED REFRIGERANT ~0.40 kwh / kg CASCADE, PRECOOLED MRC, DUAL / CASCADE MRC < kwh / kg PLANT COMPLEXITY (QUALITATIVE) * PATENT PENDING TECHNOLOGY

52 Expander Cycles for LNG liquefaction Gas Expander Cycles are superior to Mixed Refrigerant Cycles when it comes to simplicity Simple to start, operate and shut down Simple refrigerant generation Robust for changing feed gas composition Robust for the offshore environment - no liquid phase refrigerant Non-flammable refrigerant = high inherent safety level Can be built compact and light

53 Optimised Dual N2 Expander Cycle Kanfa Aragon has developed new liquefaction technology (patent filed) Combines state of the art optimisation of the well-proven Dual Nitrogen Expander Cycle with the new concept for Optimised Offshore Liquefaction Optimised product yields Maximised LNG production Minimal or no condensate bi-production if preferred Integrated LPG / NGL recovery if preferred Very high efficiency Integrated and optimised power generation LNG specifications adjusted acc. to Client requirements

54 2 MTPA design example NITROGEN COOLING PRE-TREATMENT MODULE LIQUIFACTION MODULE GAS TURBINES

55 Liquefaction capacities PARALLEL LNG TRAINS LNG PRODUCT FEED GAS 1 LNG TRAIN UP TO 0.9 MTPA 2 LNG TRAINS UP TO 1.8 MTPA 3 LNG TRAINS UP TO 2.7 MTPA UP TO 125 MMSCFD UP TO 3.5 MSm 3 /d UP TO 250 MMSCFD UP TO 7 MSm 3 /d UP TO 375 MMSCFD UP TO 10.5 MSm 3 /d SINGLE PRE-TREATMENT TRAIN FOR ALL SIZES

56 1 MTPA design example PRE-TREATMENT MODULE LIQUIFACTION MODULE COMPRESSOR MODULE

57 Project execution CLIENT Concept (FEED) Process Design Detail Engineering Fabrication (Shop) Engineering Fabrication & MC CLIENT Overall EPC responsibility and single point of contact Multidiscipline competence Focus on Client requirements and needs from day one

58 FPSO market technologies and solutions DEHYDRATION DEW POINTING NGL RECOVERY HP COMPRESSION GAS PIPELINE GAS LIFT GAS INJECTION ACID GAS REMOVAL (CO2 / H2S) LPG RECOVERY LPG FRACTIONATION OFFSHORE LNG LNG EXPORT BOOST./RECOVERY COMPRESSION STABILISATION LPG EXPORT OIL / GAS / WATER SEPARATION SYSTEM OIL TREATMENT VAPOUR CONTROL OIL PIPELINE OIL STORAGE WELL STREAM & MANIFOLD SYSTEM SAND CLEANING WATER TREATMENT SEAWATER TREAT. & INJECTION FLARE SYSTEMS AIR N2 COOLING W. SYSTEM. ARAGON FUEL GAS COMPR. FRESHWATER STEAM/HEAT SYSTEM KANFA FUEL GAS TREATM. CHEMICALS / INJECT. WASTE HEAT RECOV. KANFA-TEC

59 Kanfa References 5 FPSO topsides delivered according to EPC contracts 2 FPSO topsides will be delivered this year