Oil & Gas Consultancy Smart Solutions. Field Development Gas Processing LNG Gas-to-Liquids

Transcription

1 Oil & Gas Consultancy Smart Solutions Field Development Gas Processing LNG Gas-to-Liquids

2 Whether it s getting the right project... or getting the project right ideas success ONSHORE & OFFSHORE OIL & GAS FIELD DEVELOPMENT PIPELINES OIL & GAS PROCESSING PLANTS LNG GAS-TO-LIQUIDS 1

3 Our oil and gas team can help you with both of these challenges. We are a little unusual. Where else can you find a flexible, responsive team of consultants who have had real project execution experience - a team that can actually deliver their concepts and design in the field and see the successful start-up of facilities they have designed? The Oil and Gas Division, headquartered in Reading, UK, unites Foster Wheeler s oil and gas experts located around the world into a single group focused on meeting the needs of the onshore/offshore upstream oil and gas, gas processing, LNG and gas-to-liquids (GTL) markets. Our talented team of oil and gas experts works with clients from the very earliest feasibility and concept design stages of a potential project. They are highly experienced professionals who have the ideas and imagination to work with you to arrive at the optimal development solution for your oil and gas asset, and then deliver your revenue stream, as planned. 2

4 A unique service Our team Our oil and gas experts provide the insight and creativity to help screen, shape and develop cost-effective solutions for our clients oil and gas projects, from wellhead to product delivery. We have a reputation for delivering high quality conceptual designs, feasibility studies and front-end designs which lay the foundations for a successful project. Flexible, independent, responsive Our people can think like consultants. They are flexible, focused and committed to working closely with our clients to develop the optimum solution. But because we are also a renowned, experienced EPC and project management contractor, our solutions are also practical, constructable and based on real costs and local knowledge. Our global offices are close to our clients decision centers, allowing us to deliver our expertise locally. This mix of specialized technical expertise, backed by Foster Wheeler s impressive project execution capability, provides our clients with a unique service to the industry. 3

5 Working together Our large team of experts come from all different areas of the oil and gas industry, with some key specialists having extensive experience as owners, consultants and contractors. They are able to understand your business drivers and objectives and clearly see issues from your perspective. 4

6 Understanding our clients With buy-back contracts and production sharing agreements becoming more commonplace, success in oil and gas field development depends on issues such as combining optimized technical solutions with local capability, local content, logistics and land acquisition. We have a broad understanding of cost dimensions of drilling, completion of installed facilities and production operations. Our services are flexible, robust and auditable and solutions can be developed in parallel with reservoir appraisal and simulation. We can fast-track projects to expedite revenue thereby reducing clients costs. We can work independently or as an integrated client team. Additionally, by interactive working with reservoir and drilling engineers, we can help provide the optimum field development solutions. Expertise and experience Our breadth of experience is of particular benefit when considering integrated upstream and downstream projects. The integration of the energy, offsites and utility systems is key to providing economic solutions, particularly for LNG and GTL projects. Our clients projects are sometimes situated in very challenging locations or environments with little or no infrastructure or perhaps urban, industrial or military areas. We can offer considerable experience with such projects as well as addressing problems in places that are environmentally sensitive, for example, wetlands, areas subject to periodic flooding, deserts, coastal marshes and offshore. Market & economic analysis Strategic planning Feasibility master planning Conceptual design services Oil & gas field development expertise Project consultancy services Pipeline services: - routing studies - dynamic analysis - stability analysis Prospect evaluation Due diligence audits Environmental studies Hazard identification and assessment Power and utility integration 5

7 Right project, right outcome Rapid evaluation of scenarios Value improvement practices - applied early Real in-house estimating data State-of-the-art process synthesis tools Robust estimate... no surprises We offer a proven concept design screening process. This process provides optimized process schemes with accurate, risk-assessed capex and opex estimates - the right foundation for project development. This integrated process enables our clients to accelerate the development of their assets on a sound technical and economic basis, using a reliable cost-benefit analysis. We provide a field development scheme which is robust to changes, with fewer unknowns and a significantly reduced chance of surprises later in the project lifecycle. This process is inherently transparent, as all project stakeholders are fully involved in the design and estimating process. It is also highly compatible with our clients gate review processes. Critical factors for successful field development concept selection include: a robust scenario evaluation methodology rigorous management of technical risk to identify potential show stoppers accurate cost estimation the application of value improvement practices to optimize capex and opex and improve overall project economics. Our screening process provides a fast and effective means of evaluating multiple concept options using process simulation, conceptual plot plans and equipment sizing. We use sized equipment lists, together with benchmarked in-house cost databases and assessments of fixed and variable operating costs to screen options quickly. Because we are also an experienced EPC contractor our cost data is based on real projects and our solutions are practical. 6

8 Malcolm Harrison Divisional Director Oil & Gas Division Malcolm has in-depth oil and gas experience, including significant experience in the design and operation of cryogenic process plant gained working for an international oil company in the North Sea. Stephen Ward Oil & Gas Manager Stephen s strong technical and commercial awareness of the oil and gas industry incorporates more than 25 years managing offshore and onshore oil and gas projects for oil companies, contractors and consultants. Patrick Sahm Process Consultant Patrick has more than 25 years in process engineering. His experience includes gas processing NGL, condensate recovery from natural and associated gas, and depressurization studies. Sam Hwong Offshore Consultant Sam s 30 years oil and gas experience includes deepwater, platforms and LNG terminals. His expertise lies in plant layout, and structural and geotechnical engineering for heavy seismic, severe wave and mud sliding conditions. Bipin Patel Gas-to-Liquids Consultant Bipin s major strengths lie in the NGL process industry, heavy oil upgrading, and GTL technology. He has 25 years indepth experience in these industries including strategic planning, business development, project management and operations management. A wealth of experience and a can-do attitude Ken Bond Pipelines Consultant Ken has over 35 years experience in the oil and gas industry. His particular strengths are in upstream production, transportation facilities and technical and economic studies for oil and gas developments. Jean-Louis Marquis Process Consultant Jean-Louis 30-year process experience includes NGL recovery, onshore reception and gas treatment plants, and revamping existing plants to increase NGL yield. 7

9 Dr CC Yang LNG Technology Manager CC Yang s 30 years experience in the industry includes 15 years in developing concepts and designs for LNG liquefaction plants and receiving terminals for highly-complex onshore and offshore projects. Thomas David Process Consultant With more than 20 years experience, both in a contracting and production technical support capacity, Tom s particular expertise includes gas processing and transmission, NGL and condensate fractionation, LNG recovery and offshore facilities. Chris Noble Process Consultant Chris has an impressive track record spanning 30 years with particular expertise in conceptual and front end engineering, field development, planning, commissioning and plant operation for offshore platforms, terminals, gas liquefaction plants and storage systems. Peter Brook LNG/Gas-to- Liquids Manager Peter has extensive expertise in the field of synthesis gas technology, gas treating, NGL extraction, LNG, synfuels and syngas (hydrogen, oxo-syngas and methanol). His management experience ranges from conceptual studies to commissioning activities. Jeremy Cooke Gas-to-Liquids Consultant Jeremy has significant experience in the management of gas-to-liquids projects. His expertise lies in conceptual design, development of technology for licensors and economic evaluation. Tariq Shukri LNG Consultant Tariq has over 20 years experience in managing the design of gas processing and LNG plants, together with 12 years operating LNG plants. His expertise lies in conceptual design, technical and economic evaluation, delivering FEEDs and commissioning. Michael Barclay LNG Consultant Michael has managed process engineering for a large number of gas liquefaction and gas processing projects. He has written numerous papers and received patents and awards for his research into many aspects of LNG and gas processing plant design and operation. Right people, right expertise 8

10 Smart thinking By harnessing our imagination and experience, we help solve difficult problems for our clients. 9

11 Innovative solutions Some examples: Offshore Gas Condensate Field Development During the FEED, a conceptual study was undertaken to improve the understanding of the duty envelope of the slug catcher and establish a suitable configuration and operating strategy. This field in the Middle East is intended to export wellstream fluid to a single onshore slug catcher through multiple parallel multiphase trunklines. A novel solution was developed to handle large volumes of aqueous phase delivered after protracted trunkline operation in a stratified flow regime. Oilfield Conceptual Design During a study for one of the largest major new oilfields in the Middle East, we were able rapidly to develop new schemes for each building block of the development. Using our concept design screening process, we provided cost estimates to meet the client s demanding schedule. The final robust and cost-effective conceptual design ultimately became the basis for a buy-back contract with the state oil company. Gas Pipeline The conceptual study carefully evaluated the line sizing and operating condition options to avoid unwanted phase changes and resulting operational instability. The facility is intended to receive ethane feedstock by pipeline with an ambient temperature almost exactly at the critical temperature of the feedstock gas. Methanol Recovery for Shell s Malampaya Onshore Gas Plant A value engineering exercise was undertaken on the project prior to detailed engineering to identify areas for project cost savings. It was established that removing the methanol within the amine unit rather than by washing upstream provided a significant cost saving. Other cost-saving ideas implemented included simplifying the utility systems for the heat and power supply, optimizing the design, equipment selection, procurement processes, contracting and construction methods. The project was completed under budget, with first gas ahead of schedule. 10

12 Creativity in action Meeting C2 & C3 Content Foster Wheeler has developed a viable solution (patent pending) to the issue of existing LNG baseload plants producing LNG with C2 and C3 content unsuitable to service the USA market. Our design reduces C2 and C3 from the send out gas, at the LNG receiving terminal sites. By using low temperature LNG as a cooling medium for the column overhead, economic separation is achieved. This requires no gas compression because LNG is used as a refrigerant in a direct-contact condenser, which condenses enriched C1 vapor to produce a lean LNG for liquid pumping. LNG Vaporizer Heat Integration & Emissions Elimination By using waste heat from a nearby power plant, we developed an innovative solution (patent pending) to reduce emissions from the LNG vaporizers, and improve the overall LNG receiving terminal and plant facility thermal efficiency. Our design eliminated fuel requirements and presented significant environmental advantages over traditional open rack and submerged combustion type vaporizers. Integrated Gas Plant GTL Barge, West Africa We realized potential additional revenue stream of $20m/yr for a capex of less than $25m by optimizing the balance of utilities and offsites. These specific improvements (patent granted) were made to the tail gas management system by identifying low capital cost which increased the net liquid production by nearly 10%. Sasol GTL We have been working with Sasol on its GTL process since 1995 and we are its single point licensor. We have helped Sasol enhance plant performance, drive costs down and have carried out pre-feasibility, feasibility studies and FEEDs. We engineered the ORYX GTL project in Qatar, the first of the new generation of GTL plants, and are working as part of the project management team during the EPC phase. Fuel and Tail Gas Management For unreacted syngas, light hydrocarbons and CO 2, we have assessed their use as a stable heating resource and developed solutions for hydrocarbon and hydrogen recovery, recycling hydrogen and CO 2, and using CO 2 for syngas ratio adjustment. 12

13 Delivering results 13

14 Delivering success Dolphin Offshore Project, Qatar FEED for two offshore production platforms, two subsea multiphase pipelines and an onshore gas processing plant. Aramco Overseas Company Haradh Gas Program, Saudi Arabia FEED contract and PMC engineers in the contractor s offices for a new gas plant, upstream gas gathering manifold and transmission line system, downstream gas and condensate line network, residential housing for 1,000 men and new high voltage (380 & 230kV) power supply. Completed six months early, 25% below budget with $140m client revenue gain due to early completion. PTT Gas Separation Plant, Thailand Feasibility study, FEED, EPC selection and PMC services for a new gas plant, including ethane, propane, LPG and CO 2 removal. Sasol Temane Field Development, Mozambique FEED and EPC management in a challenging location for grassroots gas field development including gas processing, 11 wellsites, flowlines and inter-field trunklines. TNK-BP Oil Products Facility, Russia Concept selection study to evaluate options for capacity and operations criteria, cost estimating and outline design for import and export facility, including a marine facility, tankage and rail unloading terminal. LNG Conceptual Study, West Africa Evaluating the technical, economic and commercial feasibility of constructing a world-scale LNG plant in West Africa, including offshore gas transport pipelines, gas processing, liquefaction, storage and infrastructure. GASCO OGD-III & AGD-II, Abu Dhabi Project management consultant, managing and technically evaluating the FEED bidders, making FEED award recommendations and subsequently managing FEED execution. The development included a gas gathering and injection pipeline and manifold system, two new trains of gas, expansion of the NGL fractionation plant, and additional condensate storage and handling at the refinery. We are now PMC for the EPC phase of OGD-III. Oman LNG, Qalhat, Oman Detailed engineering and EPC for two-train grassroots LNG liquefaction plant with tankage, marine terminal and all utilities. Subsequent award of EPC contract for additional train for Qalhat LNG. 14

15 Turning vision into reality Did you know? We have over a century of experience and a proven track record in worldclass project execution We have actively participated in the offshore/onshore upstream oil and gas industry since the 1930s We have successfully engineered some of the world s largest oil and gas field and gas processing developments In the past 3 years we have engineered and managed projects with a total capacity in excess of 8 billion scfd of gas We have engineered one of the world s longest high-pressure sour gas pipelines, 500 kms by 56" diameter and one of the longest sub-sea multiphase pipelines, 105 kms by 32" diameter, both in the Middle East 15

16 We have the right people with a can-do attitude and the commitment to deliver. oilandgas@fwc.com Main Engineering Centers USA 585 Dairy Ashford, Houston, Texas T F UK Shinfield Park, Reading, Berkshire, RG2 9FW, UK T +44 (0) F +44 (0) Italy Via Sebastiano Caboto 1, Corsico, Milan, Italy T F France 92 Quai de Bercy, Paris Cedex 12, France T F Spain Edificio Foster Wheeler, Calle Gabriel Garcia Marquez, 2, Las Rozas, Madrid, Spain T F Turkey Kozyatagi-Sari Kanarya Sokak 22, Yolbulan Plaza, B-Block, 34742, Istanbul, Turkey T F Singapore 991E Alexandra Road, Block 7 #01-25, Singapore T F Thailand 217 Moo 12, Sukhapiban 8 Road, Tungsukhla, Sriracha, Cholburi 20230, Thailand T /6, /3 F /444 South Africa (Location) 2nd Road, Halfway House, Midrand, 1685, South Africa (Correspondence) PO Box 76, Halfway House, Midrand, 1685, South Africa T F