Salamander Energy Ltd – Kambuna EPF, Sumatra Indonesia

Project Overview
Expro PTI undertook early in 2009, the complete turnkey supply of an onshore EPF facility, located at Pakalan Brandan, North Sumatra Indonesia. The facility was designed as a complete “stand alone” onshore oil and gas processing facility including Oil and gas Separation, Gas Compression, Gas Dehydration and metering, Condensate stabilization and pumped export via a 20km pipeline, power utilities, firewater system.

The design production rates for the plant are 40 Mmscf/d and 4000 BCPD respectively.

The project was mobilized within 16 weeks from our Batam Yard facility, and was installed, ready for production within 20 weeks overall from Contract award.

Expro PTI ongoing services include the complete operational manning for the facility, design and logistic support, utilities, maintenance etc.

All elements of the project were completed wholly by Expro PTI staff, other than pressure vessel fabricators for vessel refurbishment work. No other major contractors were employed on the project.

NuCoastal (Thailand) Ltd – Songkhla “A” and Songkhla “B” MOPU developments

Project Overview
Expro PTI undertook earlier this year, the complete turnkey supply, including the supply of the Jack-up Rig ‘Soraya’ for an offshore MOPU development on the Songkhla A oilfield located in the southern end of the Gulf of Thailand.

The initial project requirements were for a very rapid mobilization of the MOPU with installed process facilities within a six week period. The equipment was mobilized out of our Batam facility and installed on the MOPU within 4 weeks. The MOPU was then dry towed to location. The initial design requirements were for 15,000 BOPD and approximately 3mmscf/d associated gas. Associated gas is flared and stabilized crude being pumped to an adjacent moored FSO Tanker. Production commenced from the MOPU 8 weeks after instructions were received to mobilize the MOPU. Expro PTI provided full operations crew for the MOPU and production operations.

The first phase of the Songkhla A project did not include water treatment equipment as only small quantities of produced water were anticipated which were planned to be stripped out at the FSO tanker.

Expro PTI has since received a major contract scope expansion which includes for an offshore replacement of the current facilities with a 30,000 BOPD process package including water treatment for well injection, gas treatment for fuel gas usage, Test Separator package and other system enhancements including upgrades and changes to the MOPU facilities. This has come with a contract extension and the concept to use the Songkhla A MOPU as a Central Processing Platform (CPP) for the entire field development.

In addition to the work on Songkhla A, Expro PTI has completed mobilization and installation of a second 20,000 BOPD process package which has been installed on a second MOPU (Workships Seafox 6).

Expro PTI has worked closely with the candidate MOPU supplier and the Classification Society to address all Class issues associated with integration of the process facilities on the Vessel. Expro PTI provided installation and hook-up supervision of the process facilities onto the MOPU whilst in a Singapore conversion Shipyard.

This facility includes oil, gas and water separation, flaring, fuel gas treatment, oil, water and gas metering and two phase pumping of well fluids back to the Songkhla A MOPU.

Expro PTI ongoing services will include the complete production facilities operational manning for the facility, design and manpower logistic support, maintenance.

NN252 MOPU Topsides – PTTEP, Nang Nuan Field, Thailand

In October 2004, PTT Exploration & Production (PTTEP) awarded an LOM contract to a consortium including Expro, to supply, install and operate a marine production spread in the Gulf of Thailand.Together with Aus Siam Marine Co and AEE Thailand Inc, Expro was contracted to build, own and operate a jack-up production unit to cater for marginal field production comprising extended well testing and cyclic production of the Nang Nuan field. Operating in water depths of about 35m, the field is located some 30 km offshore eastern Thailand.

Technical management of the rig conversation phase was provided by Expro. Our main role in the consortium was to supply, manage and operate the surface production topsides facilities installed onboard the jack-up NN252. The equipment was deployed from Expro’s operations base in Batam, Indonesia, to the rig in December 2004 and the jack-up was commissioned at site in April 2005. First oil was in summer 2005.

Bourbon Opale FPSO Topsides – Pemex, Mexico

In December 2003, Expro was selected by Bourbon Offshore to supply the topsides process facility for their FPSO, the Bourbon Opale. The vessel, being provided for a Pemex contract in the Gulf of Mexico, was designed to produce the well fluids on Pemex’s well testing and well clean-up operations on multiple fields.   The process equipment was manufactured in Great Yarmouth, UK and then transported to the Aker Langsten yard in Norway. The topsides process facility was then installed at the shipyard location.

For this fast-track project, the schedule required the process topsides to be engineered and fabricated by 20 April 2004 with an anticipated sail out date in early May 2004 – a total period of less than 24 calendar weeks from the contract award.

IPF – Exxon Neftegas, Chayvo Field, Sakhalin Island

In March 2004, Expro was selected by Exxon Neftegas Limited (ENL) to supply, build, install, commission and operate a 50,000 bbl/day, 150 MMscfd Interim Production Facility (IPF) for the Chayvo Field in far eastern Russia. The IPF was provided on a lease, operate and maintain basis.

The contract was based on a 14-month period of operation and would run until completion of the permanent Onshore Production Facility (OPF) on Sakhalin I, due in September 2006.

Expro’s track record in delivering such projects on schedule was the key in this award. Even so, the project was particularly challenging due to the combination of remote location and harsh environmental conditions at site. This required detailed logistics management involving shipment by road, rail and sea. Project management, engineering and procurement for the project were co-ordinated out of Expro’s Houston office. This was convenient for ENL’s project team and cold weather equipment vendors in the USA and Canada.

Certification, licensing and permitting for the production facility were critical for this project, and were a joint effort between Expro, ENL and the Russian certification authorities.

The IPF was mechanically complete and first oil delivered by the end of July 2005.

Operation and maintenance was carried out by Expro using locally recruited personnel and expatriate supervisors. All personnel were trained and certified according to Russian regulatory requirements.
Expro subsequently received a letter of commendation from ENL in recognition of the excellent job performed on this project.

Swamp Queen FPF/EPF – Chevron, Dibi Field, Nigeria

In 2005, Chevron selected Expro to supply a fast-track, fit-for-purpose Early Production Facility (EPF) for its Dibi concession in Nigeria. The EPF is mounted on the Swamp Queen barge, operating in block OML 49, northwest of Chevron’s Escravos terminal in Nigeria. Processing capacity is 60,000 bbl/day.

The project was executed on a staged basis, starting with a FEED study to develop the EPF requirements. This resulted in a contract award for supply of the EPF, including conversion of the barge into a full Floating Production Facility (FPF), with design, procurement & fabrication of the equipment modules, installation on the barge, commissioning at site, and operation & maintenance for two years. Associated offsite activities were also carried out including design, procurement & fabrication work for pipework and pipe supports, installation of this equipment, commissioning, and sand pad dredging and installation.

The FPF is a complete self-contained unit with 36-man accommodation module and helideck. Processed crude is exported via flowlines to the Escravos terminal, with the gas utilised as fuel or being flared. Produced water is disposed of by re-injection.

First oil was achieved in mid-2007.

Rowan Gorilla VII MOPU Topsides – Tuscan Energy, Ardmore Field, UK

The project was awarded in September 2002 to supply the topsides process facility for redevelopment of the Ardmore field, UKCS, on a lease, operate and maintain basis. The contract was based on a two-year period of operation. The topside facility was placed on the Rowan Gorilla VII jack-up as a mobile offshore production and drilling unit.

Completed in early June 2003, the facility was shipped to McNulty Offshore’s yard for installation on the Rowan jack-up before the rig departed for the field.

First oil was achieved ahead of schedule on 27 September 2003, with well fluid production rates of up to 22,000 bbls/d. Expro’s process facility then stabilised and conditioned this produced crude on the jack-up MOPU. By using two mooring buoys Tuscan was able to maintain production throughout the shuttling operations. Tuscan Energy’s CEO recognised Expro’s and the other contractors’ efforts on the project by saying: “We’ve given them a lot of responsibility, access to (financial) upside in the project and, to a man, they have performed.”

“Achieving production again from this field is a tremendous boost for the North Sea and is an indication of what is still possible in this area through innovative thinking and utilisation of the latest available technologies.”

ESP 1 MOPU EPF – Shell, Soroosh Field, Iran

Shell Exploration BV was selected by the National Iranian Oil Company (NIOC) to develop the Soroosh and Nowrooz oil fields, lying in around 30-40 m water depth, located 120 km offshore Iran.In June 2000, Expro Swire Production Limited was contracted to supply and operate an early production facility which was required ahead of permanent facilities on the field. Scope included the supply, installation and operation of a Mobile Offshore Production Unit (MOPU) alongside the field’s new production jacket at Soroosh. The facility was required for a period of 20 months before installation of the permanent field infrastructure, and had the capacity to produce up to a maximum of 100,000 bbl/day.The ex-Mansal ‘Muna’ MOPU was acquired,renamed ‘ESP 1’ and mobilised to Dubai for conversion. The vessel was recertified and machinery zero houred. Modifications included a water injection facility capable of 50,000 bbl/day, as well as process upgrades to handle the Soroosh well fluids. This work was complete in under 32 weeks.

Flexibility in Expro’s approach meant a number of important design and engineering changes could be made without affecting the schedule. Additional workscope included addition of a 500 tonne power generation module, complete with eight 1MW Aggreko diesel generators and 11 kV high voltage switchgear, to meet the requirements of a revised ESP design. A temporary wellhead deck was also procured, fabricated and installed at location to allow the wellheads to be supported from the ESP 1 until installation of the permanent deck four months later.

As a result, Expro’s fast-track, marine-based, turnkey ESP 1 production MOPU allowed Shell to achieve production earlier than would otherwise have been possible. Uptimes in excess of 98% were maintained throughout the life of the project, whilst the crew also achieved two years operations without a Lost Time Injury.

Kodeco Energy Ltd. – Poleng Field MOPU, Offshore Indonesia

Expro PTI provided a 30,000 BOPD Oil Production Facility, which was installed on the jack-up platform,’Taurus’. We were contracted on a ‘life-of-field’ basis. The facilities were contracted for a period of 12 years.

This project was undertaken on a turnkey basis, and we were responsible for conceptual design,equipment preparation, equipment installation, commissioning and start-up.

Process Design – 30,000 BOPD, 3,000 BWPD, 10 MMSCFD Gas.

Thai Shell – Nang Nuan Offshore Early Production System

In association with Swire Pacific Offshore, Expro PTI were contracted for the turnkey supply of a Floating Production Unit (FPU), including all operations (marine, process and wellhead) and including maintenance of the field facilities and shuttle tanker management for cyclic production from the Thai Shell Nang Nuan Offshore field.

The project which was commissioned in 1993 completed in August 1997.

Ampolex Australia – Wandoo ‘A’ Development

A comprehensive 16,000 BPD Early Production Process System installed onto the Ampolex jackup rig ‘Hakuryu VII’ in Dampier, Western Australia, in late 1993. This system was later modified to process up to 28,000 BFPD. The facilities were initially installed to complete a 120 day EWT phase followed by EPF perations if proved commercial.Production Testers Australia managed all third party contractors involved in the design of the completely new process facilities, built under strict quality control to the Clients fully detailed specification requirements.This system was based on 3 stage separation train and included, separators, electrostatic coalescer, steam generation plant, plate heat exchanger and shell and tube exchangers in a complex and efficient heating system for the problematic 19 deg API crude.

Maersk Oil Qatar – Al Shaheen MOPU, Qatar

Project Overview
In conjunction with our joint venture partners,Swire Pacific Offshore, Swire Production Testers (SPT) was awarded a contract by Maersk Oil Qatar AS. The contract was for the provision of a jack-up production unit (MOPU) installed at the Al Shaheen C location, Block 5 offshore Qatar.

The facility used the refurbished ex drilling unit Cliffs Drilling No.10 which was chartered to SPT by Cliffs Drilling Inc. The facilities provided had a design throughput capacity of 60,000 bopd\100MMscfd gas. The MOPU operated with an uptime in excess of 99.5%.

On behalf of SPT, we designed the facility at our Perth office, and undertook the entire project management phase including procurement, facility construction and installation, hook-up, commissioning and operation.The complete facility was hooked up and commissioned June 1997 only seven months after the contract award was issued by Maersk.

SPT leased and operated the facility for Maersk on a turnkey basis. Expro PTI had a subcontract with SPT for the provision of all production personnel to the project.

We were responsible for senior level management of the contract and all production operations under the contract.

Swamp Queen EPF – Shell, Tunu/Ogbotobo Fields, Nigeria

The Swamp Queen was first commissioned for Shell Petroleum Development Company (SPDC) in 1995 when an ex-Santa Fe drilling barge was converted by Expro into a 20,000 bbl/day floating production facility for the Tunu Field.

Two years later SPDC commissioned an upgrade to the facility to produce 50,000 bbl/day. The new topsides equipment was installed on the Swamp Queen with contract award to first oil within 17 weeks, including accomplishing the retrofit in a record 14-day shut down period.

The facility was originally stationed on the Tunu field, but was re-deployed (by Expro) to the Ogbotobo Field in 1997. After five years of production for SPDC in the Niger Delta, the Swamp Queen FPF was shut down in 2001 and cold stacked in Port Harcourt until being decommissioned in 2002. The 50,000 bbl/day topsides were removed and returned to Europe ready to be utilised on another production facility.

EPF – Agip, Zinnia Field, Tunisia

In 1995 Agip awarded a contract to Expro for the supply of an Early Production Facility (EPF) as part of the Zinnia project, onshore Tunisia.

The EPF was required to treat well fluids from up to two wells, separating and processing the fluids to meet the required export specifications for gas, exported by pipeline, and crude oil, exported by road tanker.

The EPF was provided on a full turnkey basis to the client, including design, engineering, installation of the equipment, commissioning, start-up and operation by Expro personnel. At the end of the lease, operate and maintenance (LOM) contract, Agip exercised their option to purchase the facility.