Brasoil, Brazil awarded the contract of converting a Very Large Crude Carrier (VLCC) Henrique Dias / Jose Bonifacio into a Floating Production Storage and Offloading System (FPSO) (P-33 / P-35) to Hyundai Heavy Industries Co. Ltd. (HHI), Korea.  This FPSO is now operating in the Marlim Field, Campos Basin, Offshore Brazil. The water depth in this area is around 780 / 855 Mts.
HHI retained our company for the Design and Detail Engineering services for the Topside Production Systems, Utilities, Vessel Conversion and Turret Mooring System.
Our company engineers were sent to USA, China and Korea to survey the ship and collect relevant data. The basic engineering and detail engineering work was completed in our office in New Delhi. Onsite support was provided to HHI during the fabrication, pre-commissioning and commissioning stages.
The FPSO came on stream in May 1999.

The details of the P-33 FPSO are as follows:
Size of Ship          :330 M (length) x 54.5M (breadth) x 27.8 M (depth)
Dead Weight (t)    : 279,749
Water Depth         : 780M (2558.4 Ft.)
Capacity –  Oil      : Production – 50,000 Bopd
                              Offloading – 150,000 Bopd
                             (100,000 from P-26)
               - Gas    : 1.5 MM Nm3 / day
Water Injection     : 440m3 / hr

The details of the P-35 FPSO are:
Size of Ship             : 337 (Length) x 54.5 (Breadth) x 28.00 (Depth)
Dead Weight (t)       : 270,358
Water Depth            : 855M (2804.4 Ft.)
Capacity –    Oil       : Production – 100,000 Bopd
                               Offloading – 150,000 Bopd
                               (50,000 from P-29)
                - Gas      : 3 MM Nm3 / day
Water Injection        : 800 m3 / hr

Our Company was retained as Engineering Contractors for the BUFFALO Venture FPSO by M/s Schlumberger Wireline & Testing Services Inc, Singapore.

Buffalo is located in the north Timor Sea, Australia and was discovered in October 1996. The Buffalo oil is light crude oil with a low gas oil ratio.  The gas flashed from crude oil is relatively rich in CO2 and has traces of H2S. BHP Petroleum PTY, Australia awarded the FPSO, Riser, Rigid Flow line and offshore  installation contract to MODEC INC of Japan who appointed M/s Schlumberger as the  Project Manager.

We carried out Basic Design & Detailed Engineering, Engineering for Procurement and related services for Process facilities comprising of three skids viz. Process Module, Gas Compression / Dehydration Module and Flare Knockout Drum Module.

The facilities related to Oil & Gas on FPSO are designed to handle following throughputs:

S.No.  Description                    Base Case       Upgraded Case
1.       Oil Rate                        40,000 BPD       60,000 BPD
2.       Liquid Rate                    50,000 BPD      75,000 BPD
3.       Water Rate                    30,000 BPD      45,000 BPD
4.       Gas Lift Rate                  8 MMSCFD      12 MMSCFD
5.       Flash Gas Compressor    2.2 MMSCFD     2.2 MMSCFD

Elf Exploration Angola, awarded a contract to MPG (Mar Profundo Girassol), for the delivery of complete Floating Production Storage and Offloading unit (FPSO) to be installed in the Girassol field.  MPG sub-contracted the construction of the FPSO to Hyundai Heavy Industries (HHI), Korea.

Girassol is located about 210km NNW of Luanda, Angola and is one of the deepest water projects yet undertaken in offshore West Africa.

HHI contracted our company for Detailed Engineering & related services for Topside facilities for the FPSO. In addition to this, we provided support in Procurement services and Field Engineering during the modification and fabrication stages in Ulsan, Korea and France.

The main features of this FPSO are as follows :
    Hull Data                               :Length – 300 m
                                                 Breath – 60 m
                                                 Depth – 30.5 m
    Water Depth                          :1400 m
    Wells                                    :23 Production
                                                :14 Water Injection
                                                :3 Gas Injection
    Max. Liquid Flow Rate (Field)    :300,000 bpd
    Max. Oil Production Flow Rate   :200,000 bpd
    Gas Injection Capacity             :8000,000 sm3/d @ 285 bar
    Water Injection Capacity          :400,000 bwpd @ 150 bar
    FPSO Oil Storage Capacity        :2,000,000 bbl
    Offloading Capacity                 :8000 m3/h (Tandem Offloading)
                                                 6000 m3/h (Loading Buoy)
    Living Quarters Capacity          :140 persons

FPSO ERHA PROJECT

Exxon Mobil, Nigeria awarded the contract for the delivery of complete Floating Production Storage and Offloading unit (FPSO) to be installed in the Nigeria Offshore field (ERHA) to Saipem Paris.  This FPSO is to be located approx 140 Km in Nigeria Offshore Block OPL 209 in 1200M water depths.

Saipem retained our company for the Design and early activities & Detail Engineering services for the 11 Topside modules (including power generation, water injection, separation) involving all disciplines viz Mechanical, piping, structural, electrical, instrumentation.

About 30 engineers from our company were sent to Paris from all disciplines to assist Saipem during the define phase to review & verification of bid document, preparing queries register, finalizing design basis memorandum, procurement engineering etc. Our engineers were involved in process simulations, piping studies, data sheets, PFD’s/ P&ID’s, equipment layout, Stress analysis, PDMS modeling, structural analysis etc to bring to AFD status. Later the detailed engineering work was completed in the our design office in New Delhi. On site support was provided to Saipem during the fabrication, pre-commissioning and commissioning stages.

The details of the ERHA FPSO are:
Size of Ship         : 285M (Length) x 63M (breadth) x 28M (Depth)
Water Depth        : 1200M
Total Liquid Rate   : 245,000 B/d
Oil Rate               : 210,000 B/d Average
                           230,000 B/d Early Years
Gas Handling Rate : 15.3 Msm3/d (540 Mscf/d) 379 barg/5500 psig
Produced Water    : 90,000 B/d
Seawater Injection: 150,000 B/d 280 barg
Fuel Gas Rate       : 1.13 Msm3/d (40 Mscf/d)
Gas Lift Rate        : 1.13 Msm3/d (40 Mscf/d)
Living Quarters     : Capacity for 100 persons                                                             

Modec International LLC retained our company as the Engineering consultant for the Topside Engineering & Design services for Floating Production Storage and Offloading System (FPSO) for Petrobas & operation of the FPSO at Espadarte Sul field RJS 409 in the Campos Basin offshore Brazil.

Saipem s.p.a engaged STEP from the Pre-bid / FEED stages to work on the complete topsides facilities as its engineering partner for the Gimboa Floating Production Storage and Offloading System (FPSO), Block 4/05 for Sonangol P & P in Angola. The FPSO is a conversion of the VLCC Magdalaine to be owned & operated by Saipem.

STEP as Topside engineering agency in its various projects was involved right from the development of the concept and FEED as a part of the integrated team of the EPC Contractor / Customer.  A team of lead engineers were deputed to Milan for 3 months for assisting & preparing FEED activities along with the back office support being extended from the STEP home office during this phase. Later the team brought the complete package back home to have effective transfer for detailed engineering. 

STEP is involved in the complete Process Design verification & updation, Data sheet and RFQs, Detail Engineering services for the COMPLETE Topside facilities involving all disciplines, vendor engineering expediting, HAZOP & procurement engineering support & bid evaluation, operational and maintenance manuals and field engineering support services as would be required related to yard queries etc. The engineering time schedule is 10 months.

The topsides facilities consists of 17 Modules & the total weight is approx 11,671 MT. Facilities include Gas compression, Oil Separation & Processing train, Produced water treatment, Power generation (Steam turbines) & associated heating media, Gas dehydration & Gas lift and or export system, Flare, Fuel Gas, Fired heater, Seawater lift, Chemical injection, Sulphate injection (where required), flowline circulation, cooling media, instrument and utility air & open and closed drain systems related to all disciplines, crude metering / export, pigging, central pipe rack & cranes.