FLNG from front-end studies up to smooth execution. Dominique GADELLE Vice President Upstream / LNG Technip France Paris, March 11 th, 2015
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1 FLNG from front-end studies up to smooth execution Dominique GADELLE Vice President Upstream / LNG Technip France Paris, March 11 th,
2 Table of contents I. The (F)LNG Industry II. Why go offshore? III. The challenges Engineering Procurement Project management IV. Ongoing open sea FLNG projects V. Conclusion 2
3 3 I. The (F)LNG Industry
4 Quadrillion of Btu Billions of cubic feet per day 800 Natural Gas: A good combination of compromises Worldwide use of primary energy World energy consumption 500 Gas demand % % Gas share in worldwide energy demand % 27% 23% Gas demand will witness a surge in demand by 2030 Industry and power generation are the main gas markets 4 Sources: EIA, BP Energy Outlook 2030, January 2013
5 Natural gas demand continues its steady growth 5 Gas demand to grow 1.9% p.a Industry and power generation remain the main gas markets although transportation sector is growing fast Sources: BP Energy Outlook 2035, January 2014
6 Billion cm/y (BCM) Long term natural gas and LNG trade NG consumption BCM (1990 to 2012, 2.8%/y) NG international trade BCM (1990 to 2012, +5.6%/y) LNG trade BCM (1990 to %/y) '00 '02 '04 '06 '08 '10 '12 Source : Cedigaz/BP 6
7 LNG industry key figures end million tons of LNG traded 41% supplied from the Middle East Qatar: 77 MTPA, 1/3 of the global market 75% of global LNG demand came from Asia End liquefaction trains in operation in 17 countries Total production capacity: 286 MTPA (utilization 83%) 7 Sources: GII GNL 2013
8 8
9 Mismatch between gas reserves and demand 2% 17% 32% 17% 5% 27% 40% 13% 15% 4% 5% 4% 8% 3% 5% 3% % of proved gas reserves by region, including unconventional gas from CEDIGAZ 2012 edition % of gas consumption by region from 2013 BP energy outlook 2030 Major gas trade movements LNG 1 Major gas trade movements pipeline 1 1 Simplified trade movements 9
10 LNG: 60% of international gas trade growth Cost LNG Pipeline cost: function of distance LNG cost: concentrated at the terminals, low marginal cost per kilometer Sources: Cedigaz Transportation distance 10
11 II. Why go offshore? 11
12 Why FLNG? Increasing gas demand in Asia Economics Cost optimization in areas with high construction costs Deeper and further offshore reserves Pipeline too complicated or too long No immediate delivery infrastructure nor local market Stand-alone gas fields opportunities Associated gas disposal opportunities Sustainable development Insufficient reserves for dedicated onshore LNG plant Technical difficulties for deeper and further offshore reserves Difficulty in landing gas onshore Enable oil fields development Monetize associated gas rather than re-injection or flaring Environment Potential redeployment Floating LNG offers the best CAPEX for large lean gas fields or stranded gas fields 12
13 FLNG is a game changer for the LNG industry Upstream FLNG: Upstream + offshore treatment, liquefaction & offloading on transport Pipelines Onshore treatment & liquefaction Transport Regasification Distribution The LNG supply chain 13
14 III. The challenges Engineering Procurement Project management 14
15 From onshore to offshore Onshore LNG FLNG Volume and weight optimization is the key to move offshore. It is a challenge for Space & organization Motion management Weight control & center of gravity management Safety 15
16 Onshore liquefaction plant capacity Qatargas LNG Trains 7.8 Hanas LNG plant QatarGas LNG trains 4 & MTPA micro mini mid large maximum largest ever construit built 16
17 MTPA Historical trend of (F)LNG plants Comparison onshore LNG & FLNG plants capacity Capacity range of FLNG projects under study or execution Qatar mega Trains Yemen Yamal Prelude 2 1 Petronas FLNG Onshore LNG plant Offshore LNG plant
18 Layout comparison: onshore LNG plant vs FLNG Yemen LNG: production 6.7 MTPA LNG 47 Ha 7 Ha/MTPA GNL Prelude FLNG: production 3.6 MTPA LNG 488 x 74 = 3.61 Ha 1 Ha/MTPA GNL 18
19 An FLNG is built on industrial experience Natural gas liquefaction Subsea field development Large FPSOs and innovation in open sea LNG transfer 19
20 Subsea design and installation is part of an FLNG project Services Architecture Products Deep water installation & construction Flexible pipe Flexible / rigid pipelaying Rigid pipelines Inspection, repair & maintenance Umbilicals 20
21 FLNG the main challenges LNG tank sloshing over 25 years without dry docking Offloading LNG between two vessels in the open sea Importing large quantities of HP feed gas through a swivel Equipment and piping loads due to motion Maintenance Marine environment (salt, humidity ) Marinization of gas processing facilities Compact designs Designing for motion Feed gas - sulphur free; high methane content preferred Safety - escalation, cryogenic spill management Local content Synergy with domestic gas schemes (except for LPG) Logistics / accommodation Insurance - storms, piracy Expansion capacity Engineering Procurement Project management Marine/ mechanical Process/ Safety Non technical 21 Other more critical challenges can only be discovered at detailed design & fabrication stages
22 Topsides weight, in tonnes Large FPSO experience is useful for FLNG FPSOs installed, by topsides weight, 1977 to 2013 Engineering Procurement Project management Largest size and weight FPSOs FLNGs topsides weight forecasts Girassol FPSO, Total Dalia FPSO, Total Akpo FPSO, Total Akpo FPSO, Nigeria, 320 x 60m P-58 & P-62 FPSOs, Petrobras Sources: Infield Systems Database
23 FLNGs use FPSOs construction strategy Modularization expertise Akpo FPSO Engineering Procurement Project management 23
24 but there are still differences to take into account Engineering Procurement Project management Piping & Layout Equipment size Large-bore Heavy walls Special grade piping unknown in the shipbuilding / offshore industry Constructability Detailed design to be adapted for pancake / flip-over construction method Access to the deck during integration Turret Mooring System integration Long distance to walk for the workers 24
25 From wells to LNG, a complex process Engineering Procurement Project management 20 C, 50 bars Methane rich gas Field facilities Pipeline Pipeline Reception reception Sulphur Acid gas removal Sulphur recovery CO2 purification and reinjection Not present offshore Can be foreseen LNG Train Fuel gas (8-12% of feedstock) LNG storage loading N2 rejection LNG -162 C, 1 bar Dehydration Mercury removal NGL recovery Methane Liquefaction MEG / Water Ethane, Propane, Butane, Pentane Refrigeration loop Fractionation Refrigerant LPG storage Condensate stabilisation Condensate storage Utility production for the plant Power plant Cooling water Fire fighting systems Nitrogen generation Flare Water treatment 25
26 Optimized scheme selection methodology Engineering Procurement Project management What are the key parameters or technologies? LNG rate Cooling media Liquefaction technology Refrigerant drivers Efficiency of liquefaction Power demand FLNG autoconsumption CO2 content LPG extraction Heating media Fuel gas demand 26 26
27 Leading liquefaction processes Engineering Procurement Project management Expander process - Nitrogen based cycles Pros Safety (Inert gas refrigerant) Less sensitive to motion (all gas) No HC refrigerant storage Cons Very low efficiency of liquefaction Large number of equipment High deck area per unit of capacity Proven in air separation industry Used for re-liquefaction of boil-off gas onboard QMax & QFlex LNG carriers References in liquefaction Courtesy of Air Products Train capacity circa 1 MTPA 27
28 Leading liquefaction processes Engineering Procurement Project management Pros DMR : Dual Mixed Refrigerant High efficiency of liquefaction Small layout area of the precooling exchanger (vs C3-MR) Balance of power between the two refrigeration cycles Simplification for compactness Cons Amount of liquid HC (safety) Refrigerant make-up and storage required (safety) Sensitive to motion Industrial references Courtesy of Air Products Train capacity 2.5 MTPA+ 28
29 FLNG capacity limit = Hull size Engineering Procurement Project management Akpo FPSO : 320 m Prelude FLNG : 488 m 4 FIFA soccer fields, 105mx65m Prelude FLNG 29
30 Example of Floating LNG layout Engineering Procurement Project management Source: 2009 Technip R&D Study 30
31 Marinization of process equipment Engineering Procurement Project management Installation of motion sensitive equipment close to center of gravity to limit accelerations Critical gas / liquid separators and columns designs are validated through CFD studies performed to ensure even velocity profiles and flow distribution in compact equipment and to study sloshing effect on liquid inventories Marinization studies for critical equipment (cryogenic heat exchangers, columns ) supported by licensors and vendors studies 31
32 LNG Storage Engineering Procurement Project management Key parameters or technologies to be considered LNG storage capacity governed by size of shuttle LNG carriers Sloshing behavior Previous experience Inspection / maintenance over 30 year operations without dry-docking Competitiveness: schedule, cost, shipyards competition 2 technologies available Membrane SPB tanks NO96 Invar Aluminium: fabrication by IHI; integration by shipyard Mark III stainless steel Stainless steel: fabrication & integration by shipyard Dominate the LNGC market Space efficient 32
33 LNG offloading Engineering Procurement Project management 2 technologies for LNG offloading Side by Side Tandem Strength Minor modification of carrier High transfer flow rate Weakness Sensitive to perpendicular waves (beam sea) Tug assistance + thrusters Safety issue (escalation) Strength High availability Safety distance No tug assistance if DP Weakness Major modification of carrier Limited flow rate 33
34 Safety Engineering Procurement Project management What are the key parameters or technologies to be evaluated? F-LNG layout Hazard segregation and protection principles Environmental emissions control Availability study of the facility What will be the basis for making the decision? HazId, HazOp reviews and HSE studies will allow to identify hazard, risk and environmental impacts and facility availability will help to make the decision Safety is ensured with blast walls and gaps between modules 34
35 Equipment specifications & partnerships with suppliers Engineering Procurement Project management Equipment with new specifications & requirements Adjustment to the marine environment (sloshing ) Larger, heavier & more complex Impact on constructability Acceleration and related loads due to vessel movements The support of industry leading suppliers is one of the keys to the success of our projects Some equipment is specifically designed for FLNG facilities New higher quality standards to minimize work offshore Larger / heavier equipment impact on logistics 35
36 Production risers Umbilicals Turret & mooring Management of the interfaces during detailed design Engineering Procurement Project management Equipment suppliers Topsides Hull (including LNG storage) Interfaces between topsides and hull are critical: Main deck layout is a mix of piping & equipment Some topsides equipment are located in the hull Blast & spill protection of the substructure Subsea control systems All interfaces are managed and controlled by the topsides designer 36
37 A combination of skills Engineering Procurement Project management Onshore Offshore Subsea The FLNG Technology is based on Onshore, Offshore & Subsea expertise. Ideally the three segments shall be available in the same operating center 37
38 A multi-center execution plan Engineering Procurement Project management Example: Prelude FLNG Goeje, South Korea Hull engineering Construction Module integration up to mechanical completion Procurement of steel and other selected bulk Construction management Onshore commissioning Paris, France Shell & TSC project directorates IT / methods Project controls Procurement of tagged items and equipment Topsides engineering Substructure interface management Construction coordination Monaco TMS design Dubai, UAE TMS construction Offshore Tow, hook-up & commissioning Chennai, India Support on topsides engineering Kuala Lumpur, Malaysia Support on topsides engineering Perth, Australia Subsea engineering & installation Support for regulatory requirements Offshore hook-up & commissioning support 38
39 IV. Ongoing open sea FLNG projects 39
40 Two open sea FLNG under construction Shell FLNG LNG capacity: 3.6 MTPA Prelude FLNG in Australia under construction Steel cutting of the hull in October 2012 Steel cutting of the topsides in January 2013 Hull launching in November 2013 Petronas FLNG LNG capacity: 1.2 MTPA Offshore Malaysia Execution started in June 2012 Steel cutting of the hull in June 2013 Hull launching in April
41 Shell Floating Liquefied Natural Gas contracts Technip leader in a consortium with Samsung Master Agreement The design, construction and installation of multiple FLNG facilities over 15 years Generic FLNG FEED Prelude FLNG FEED Offshore Western Australia Prelude FLNG EPCI Contract under which the FLNG would be built when the project would receive the final investment decision Prelude FLNG NTP Prelude FLNG subsea Agreement to strengthen FLNG collaboration
42 Shell Prelude FLNG First FLNG project ever sanctioned First of two FLNG projects for Technip First FLNG under the TP / SHI Frame Agreement with Shell Largest floating structure ever built Largest multi-centers offshore project ever (Paris, KL, Perth, Chennai) 200 km from the nearest point on the mainland m water depth Length: 488 m, width: 74 m Weight: Steel: tonnes Displacement (tanks full): tonnes Comparison Eiffel tower iron structure = tonnes Prelude Steel: 36 Eiffel towers Displacement (tanks full): 82 Eiffel towers Annual production 3.6 MTPA LNG capacity 1.3 MTPA condensate 0.4 MTPA LPG Total liquid production: boe /day 42
43 Prelude EPCIC construction Prelude FLNG is being built in SHI s shipyard in Geoje, South Korea One of the largest dry docks in the world A yard equipped with a t capacity floating crane The first steel cutting of the hull started in October 2012 The first steel cutting of the topsides started in January
44 Petronas FLNG 1 Partnership: Daewoo Shipbuilding & Marine Engineering Second FLNG project worldwide, also located in Asia-Pacific A challenging project Location: Malaysia Production: 1.2 MTPA of LNG Petronas FLNG 1: a mid-scale project but a fast-track schedule 44
45 FLNG projects in progress 3 open-sea projects at construction phase FLNG project Country F.I.D. Distance from shore (km) Water depth (m) Meteo Operator Capacity MTPA Prelude FLNG Australia 05 / Benign (Cyclones) Shell 3.6 Petronas FLNG1 Malaysia 06 / Benign Petronas 1.2 Petronas FLNG2 Malaysia 01 / Benign Murphy nearshore projects at construction phase FLNG project Country F.I.D. Distance from shore (km) Operator Capacity MTPA 45 Exmar FLNG barges 1 & 2 Colombia 01 / 2012 Quay side Exmar 0.5
46 FLNG possible areas of development Arctic Circle Remote fields Canada & Alaska Nearshore Offshore East coast High cost of onshore construction Eastern Mediterranea High cost of construction Sensitive political environment Brazil Pre-Salt Associated Gas Difficult access to land Remote fields and deep water Africa Better security offshore Remote fields and deep water Asia / Pacific Many small fields Presence of subsea trenches Australia Remote fields Sensitivity to construction on the coastline High cost of onshore construction 46
47 LNG and FLNG investment drivers LNG FLNG High demand for LNG worldwide Marketing flexibility versus pipelines Technology readily available under license with well developed service industry Good returns through long term sales agreements Access to resources for IOCs Ideal for reserves located far offshore in deep water Economically attractive in areas with high onshore construction costs Potential for reduction of overall field development time Development of small fields with relocation Monetize offshore associated gas versus reinjection or flaring 47
48 V. Conclusion Floating LNG is reaching maturity Numerous challenges are met in the design, engineering and construction phases of an FLNG facility Several IOCs & NOCs have expressed interest for this technology and many areas worldwide offer a good environment for FLNG developments As of March 2015: 3 open-sea FLNG FIDs among which 2 executed by Technip 48
49 and coming soon 49
50 Thank you 50
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