Replicant's FPSO (Pre-Salt)

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FEED of Topside for 8 Pre-Salt FPSO’s



The Lula and Guará are the first oil discoveries in the vast Brazilian Pre-Salt cluster, located in the Santos Basin in Blocks BM-S-9 and BM-S-11. The operator, Petrobras, holds the majority interest. BG Group, Repsol Sinopec Brasil and Galp are partners.

The joint accumulation of Tupi and Guará exceeds an estimated recoverable volume of 8 billion barrels of oil equivalent with a specific gravity of around 30º API.

As part of field development, operator and partners are contemplating the use of 8 new-built FPSOs (Floating Production, Storage and Offloading units).

DORIS Engenharia Ltda is responsible for the FEED of the 8 FPSO topsides and technical assistance for all modules EPCI and integration to FPSO hulls.

SERVICES PROVIDED BY DORIS:

• FEED of Replicant Topside for 8 FPSOs of BM-S-9 and BM-S-11.

• Technical evaluation and follow-up of critical long-lead items.

• Local content assessments for EPCI of modules.

• Interface management.

• Technical assistance during bidding process of all strategic items and packages.

• Technical assistance to Client during execution, up to commissioning, in engineering office and on construction yard.

MAIN CHARACTERISTICS:

• Oil Processing Capacity: 150,000 bbl/d

• Produced Water treatment capacity: 120,000 bbl/d

• Gas Flow and Treatment Capacity: 6,000,000 Sm3/d

• Maximum pressure of natural gas injection: 550 bara

• Maximum pressure of CO2 injection: 450 bara

• Gas Lift Pressure: 245 bara

• Risers porch: 63 risers

• Power Generation (Turbo generators): 4x 25 MW

• Number of topside modules: 17

• Topside dry weight: 17,000 ton

• Project duration: 8 years

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8 May
2014
The Brazil national oil company (NOC) Petroleo Brasileiro SA (Petrobras) is preparing the second call for tender for the integration of the floating, production, storage and offloading (FPSO) vessels P-72 and P-73 with a new design resulting from the relocation of these replica FPSOs within the Santos Basin offshore Rio de Janeiro.

Originally, the P-72 and P-73 FPSOs were the two last replica units of the FPSOs series of eight vessels identified from P-66 to P-73.

According to Brazilian regulation on the local content, all these FPSOs were due to be designed, built and integrated in Brazilian shipyards.

But the accumulations of projects as complex and as large as these FPSOs in the local shipyards, sometime not even existing when awarded, generated huge bottlenecks and caused major delays in Petrobras production plans.

For this series of eight FPSOs, Petrobras selected Estaleiro Rio Grande (ERG) shipyard for the construction of the hulls.

Petrobras_P-72-Tupi-Northeast_P-73-Iara-Surround_MapThen Petrobras sanctioned the integration of the topsides for the first six FPSOs of this series from P-66 to P-71:

– P-66 Lula South to Keppels Fels

– P-67 Lula North to Mendes Junior – OSX

– P-68 Lula Far South to Jurong Shipyard

– P-69 Lula West to Keppels Fels

– P-70 Iara Horst to Mendes Junior – OSX

– P-71 Iara North West to Jurong Shipyard

Then the allocation of the P-72 and P-73 were left pending in the meantime to see how first FPSOs construction should move on.

In order to compensate the delay taken by these last two FPSOs P-72 and P-73, Petrobras received the approval from Brazil Government to charter two substitutes FPSOs.

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In 2013, Petrobras organized a call for tender to charter these two FPSOs under the name of:

– Cidade de Marica

– Cidade de Saquarema

This charter contract was finally awarded to the tandem SBM Offshore and Quieroz Galvao Oil & Gas (QGOG).

With this charter contract the Cidade de Marica and the Cidade de Saquarema FPSO will be able to start operations on December 2015 and February 2016 at the Lula Alto field and Lula Central field respectively.

In the meantime Petrobras decided to relocate:

– P-72 to Tupi North East

– P-73 to Iara Surround

Because of this relocation, the process of the FPSOs had to be redesigned in order to match with the higher content of hydrogen sulfide of the new blocks .

CENPES, the engineering branch of Petrobras, performed the second front end engineering and design (FEED) of the P-72 and P-73 FPSOs.

After this redesign, the P-72 and P-73 FPSOs should keep their original template capacity of 150,000 barrels per day (b/d).

Petrobras is planning to call for tender the integration of the P-72 and P-73 FPSOs topsides on the third quarter 2014 in targeting the first production at Tupi North East and Iara Surround in 2014.

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Petrobras’ P-70 FPSO is one of the last in a series of FPSOs ordered in 2010. At the time, oil prices were high, and the industry was booming. Originally, Petrobras ordered eight FPSO units beginning with P-66, all of which were to be completely built in Brazil. Due to construction delays, Petrobras cancelled the last three units (P-71, P-72 and P-73), and later re-contracted to take delivery of P-71.

Each of the six FPSO units (P-66 through P-71) is designed to process 150,000 b/d of oil and 6 MMcm/d of gas, while storing 1.6 million bbls of oil.

According to Petrobras’ First Quarter Production and Sales Report published in April, the P-71 FPSO, the last of these serial units, arrived in Espirito Santo, in southeastern Brazil, to undergo integration with other modules at the Jurong Aracruz Shipyard. Completion is scheduled for 2022.

It has taken Petrobras 10 (plus) years to complete this lot of identical units, the majority of which ended up being built in China. By comparison, leased units from Modec and SBM with similar specifications (Cidade de Ilhabela, Cd Marica, Cd Saquarema, Cd Mangaratiba MV24, Cd Itaguai MV26, Cd Campos dos Goytacazes MV29), were all converted in China in approximately three years.

Despite FPSO project delays and missteps, Petrobras is faring well during these uncertain times. “The negative effects of the global recession caused by the public health crisis did not substantially impact production and sales performance in 1Q20,” wrote Petrobras in the first quarter report.

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Sembcorp Marine’s Subsidiary Jurong Do Brasil Secures a Contract Worth US$674 Million for Modules Construction and Integration of FPSOs P-68 AND P-71

Singapore, August 29, 2012: Sembcorp Marine’s subsidiary Jurong do Brasil Prestacao de Services Ltda (JDB) has secured a contract worth US$674 million for the construction of a total of 8 modules and module integration works for 2 Floating Production Storage and Offloading vessels (FPSO) P-68 and P-71 from Tupi B.V., a consortium owned by majority shareholder Petrobras Netherlands B.V., together with BG Overseas Holdings Ltd and Galp Energia E&P B.V.

As part of the agreement, Tupi B.V. has a similar contract option to construct 4 modules and modules integration for a FPSO to be exercised within 18 months of the contract signing.

Under the contract, the FPSOs P-68 and P-71 will have identical work scopes, comprising the fabrication of 4 modules for each FPSO and module integration works. Scheduled for completion in 60 months, the P-68 and P-71 will be deployed in the Tupi field offshore Brazil. Each FPSO will have a production capacity of 150,000 barrels of oil per day (bopd).

The fabrication of the modules and the integration of the FPSOs will be carried out in Sembcorp Marine’s wholly-owned Brazilian subsidiary Estaleiro Jurong Aracruz.

Mr Martin Cheah, President of Jurong do Brasil and Country Head in charge of Latin America said “We are pleased to be awarded this contract and to support Petrobras and its partners to grow their FPSO fleet in Brazil. Jurong Shipyard, the parent company of Jurong do Brasil, is a key player in the Brazilian Oil and Gas market and has to-date delivered 12 FPSO/FSO/FPU projects to Petrobras. Jurong is proud to be recognised by Petrobras as their key partner and to be entrusted the fabrication and integration of these high-specification FPSOs which will operate in the highly challenging deep pre-salt fields, even though our shipyard Estaleiro Jurong Aracruz is still in its early phase of construction.”

The above contract is not expected to have any material impact on the consolidated net tangible assets and earnings per share of Sembcorp Marine for the year ending December 31, 2012.