Shtokman Development AG Offshore Floating Production Unit (FPU): Valves Technical meeting with Russian valve manufacturers Moscow 24th June 2010
Summary Offshore Project Description FPU presentation Valves main characteristics General design requirements 2
Shtokman Field Mourmansk : 650 km 280 km 650 km 3
340 water depth reservoir 2 000 m below mud line Reserves estimated to 3 700 GSm3 Covers an area of 1 400 km2 2 subsea templates per drill center 3 Drill centers - 20 wells 16 flow-lines & 14 flexible risers Floating Platform: Ice resistant & disconnectable floater Design capacity: 71.2 MSM 3 /d Winterization Subsea trunkline to shore 2 x 36 x 550 km Dry 2 phase transport Drilling rigs Logistics (vessels & helicopters) Ice and Iceberg Management 4
FPU Main Characteristics presentation Ice resistant & turret disconectable floater Self propulsion (3 aft / 2 bow thrusters) Gas treatment Design capacity: 71.2 MSm 3 /d 3 separation & dehydration trains in parallel (3x33%) 2 condensate treatment trains (2x100%) Compression: 85 MW compression duty 160 barg discharge Gas and Condensate metering before biphasic export Power Generation Normal 3 dual fuel TGs - 3 x 40MWe (n+1) Essential 4 diesel generator 4 x 10MWe (n) Emergency 1 EDG approx 2MWe Cold start 1 Cold start generator approx 120kW Fully winterized FPU FPU POB capacity (300 / 350 for maintenance period in summer) 5
FPU Process presentation To Users (HP and LP) INLET SEPARATION INFIELD RISERS Production manifold (3 x 33%) Fuel gas system (1 x 100%) Gas Compression (4 x 33 %) Inlet Separator (3 x 33%) EXPORT Gas Metering To 36" trunkline 1 Gas Metering To 36" trunkline 2 TEG Regen. Package Swi vel Gas dehydration train (3 x 33%) GAS PROCESS CONDENSATE TRAIN (2 x 100%) MP Compression (2x 75 %) De-sanding MEG pretreatment, reclamation and regeneration To Produced water treatment Overboard 6
Shtokman FPU Main technological challenges Topsides Winterization) Daily production (70MSm3/d) EER Technological Development Ice-resistant hull design for sea ice and iceberg First FPU development of its kind paving the way for future Arctic development Disconnectable through MRB/Turret/swivel 7
FPU CLASSIFICATION Dual CLASS Russian Maritime Register of Shipping / BV Class notation as follows: I HULL MACH Offshore Service Barge Production Unrestricted navigation - Shtokman Field AUTO POSA IG VeriSTAR-HULL HEL ARC DYNAPOS ALM LSA COLD STI COMF 8
FPU Layout Design Principles (1/2) Topsides arrangement is optimized considering Shtokman challenges including: Safety and Environmental requirements Cold weather, harsh sea and remote location conditions Huge gas inventory onboard 50 years life time requiring stringent IMR Layout is strictly organized in order to keep the hull as a safe space Segregate risks from topsides process to hull Great care on hull penetrations for interfaces between hull and topsides Achieve adequate safe haven in hull Marine systems are able to run independently from process topsides (i.e. as a ship) And. FPU Hull space has been used to locate some utilities equipment/systems FPU Hull deck has been used in order to optimize layout and limit winterization impacts. 9
FPU Layout Design Principles (2/2) LQ & Utilities functions Process functions Flare stack & KO drums Safer Low Pressure and Liquid High Pressure Gas TR No gas Below main deck Storage of Water etc & utilities equipment Storage of MEG, Diesel, slop etc & utilities equipment Safer (& warmer) 10
FPU Living Quarter Design Principles The Temporary refuge is a key element of EER Strategy and FPU Safety Concept. The TR is a protected and independent cocoon inside the LQ designed for: Direct connection with the Safety Escape tunnel Withstanding all major accidental hazards Increasing the survival period on the FPU Getting most of the Evacuation Equipment (Primary/Secondary) immediately adjacent to the Living Quarters Allowing personnel to stay onboard during/after an accident until the last moment (i.e. no capsizing of Hull) Allowing personnel to wait safely for best moment to evacuate. TR is located at aft to benefit from the Ice-Free Channel created by the FPU. With the TR, the FPU Hull is, at first, our Life Buoy 11
Valves main characteristics Categories Topsides approx Qty Hull approx Qty Size Rating Actuated On/Off Valves 750 145 2 to 42 150# to 2500# Manual On/Off Valves Automatic and Manual control valves 3000 360 2 to 42 1 to 24 300# to 2500# Relief valves 365 75 2 to XX 300# to 2500# All valves will be supplied by main contractor or packages vendors from approved vendor list Main ON/OFF valves types used: Ball valves for practically all process applications Gate valves for utilities Butterfly valves for utilities Special Butterfly Valves (2 or 3 off sets) for process applications 90 150# to 2500# 12
Valves main characteristics Main valves materials used: Low Temperature Carbon Steel (LTCS) Stainless Steel (SS) Duplex, Super Duplex LTCS + Inconel 625 WO on all wetted areas For critical functions: M/M seating, double sealing barriers (dynamic & static), fire safe, antistatic, interchangeability; Due to tight layout onboard Mono-block Double Block & Bleed (DBB) valves are considered, mostly in Turret; To address long design life of the plant (50 Years) following features observed: High level of integrity, reliability and availability; Enhanced design and robust materials selection; Proof sealing systems; Enhanced FAT; 13
Mono-block DB&B Valves typical design 14
Valves main characteristics Typical application for monobloc DBB inside Turret area (QCDC System) 15
Valves main characteristics: side entry, forged body, flange ends 16
Valves main characteristics: full welded body 17
Valves main characteristics; side entry, forged body, hub ends 18
Ball valve with DP seat design 19
Main general requirements All valves to be design, fabrication and testing in full compliance with applicable SDAG bases of design specifications (GS-EP-PVV-112 & 142, GS-EP-INS-101 & 137 and other project specifications); For Marine applications, Dual class requirements (BV & RS) shall be applied; Interchangeability; Applicable Codes & Standards: ASME B 31.3, ASME B16.34, API 6D, API 598, API 6FA/607 BS 6755xx 20
THANK YOU 21