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4.1 Introduction
This chapter describes the proposed development in sufficient detail to allow an understanding of all stages and components, and to assist in determining the associated environmental impacts. Throughout this chapter, various references are made to specific equipment, practices, and technical terms used through the industry. Many of these have been included in the Glossary at the end of the document, to provide the reader with more detail. The following description of project details describes the proposed development as well as is currently possible. Some details are firm, while for others further information is required and decisions on these are yet to be made. In the case of the latter, a range may be provided to cover possible options. Where a range of alternatives is proposed, the assessment of environmental impact (presented in Chapter 6) has included consideration of the full range of alternatives. For the purposes of the approval process, BHP Billiton has nominated two areas; the Pyrenees Development Area and the Notional Development Area (refer to Figure 4.1). The surface components associated with the proposed development of the Pyrenees hydrocarbon reservoirs including the FPSO, riser turret and mooring will be located within the Pyrenees Development Area. The Notional Development Area encompasses the Pyrenees Development Area and several locations that are considered to be prospective for hydrocarbon deposits. Should future activities result in the discovery of economically viable oil fields within the Notional Development Area, or other known fields within the Notional Development Area
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be appraised as economically viable, then production wells and potentially water and gas re-injection wells, will be drilled into the fields and these will be linked back to the Pyrenees production facility by installed flowlines. Environmental management of the proposed development will be implemented through a Health, Safety, Environment and Community Management System (HSEC-MS). The HSEC-MS is described in Chapter 8, and includes a discussion of the environmental principles on which the proposed development will be managed.
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PROJECT DETAILS
With the exception of drilling and well construction activities, and some offshore activity associated with installation, hook-up and commissioning, virtually all components of the proposed development will be fabricated and assembled away from the proposed development location. Typically only IHUC activities are required at site prior to commencement of production. The production process is expected to have the design capacity to treat up to 15,100m3/day crude oil, which will be directed to the FPSO tanks for storage. Crude oil will be exported from the FPSO onto trading tankers approximately once every 5 to 10 days initially, becoming less frequent as production declines over the life of the proposed development. Waste management from the proposed development will give priority to the prevention and minimisation of waste materials. Under normal operating conditions produced water will be re-injected into a proven reservoir. It is estimated that this can be achieved more than 90% of the time. If the re-injection system is unavailable, produced water will be discharged to the ocean at oil-in-water concentrations below the limits that are required by law (24 hour average less than 30mg/L, maximum less than 50mg/L). To ensure compliance with regulations the oil-in-water concentration will be measured constantly by an electronic meter whenever produced water is discharged overboard. Surplus gas will not be routinely flared, although flaring may be necessary during commissioning, initial production, production restarts, maintenance, process upsets and equipment down-time. The FPSO will have a safety flare system, which is a normal design feature
of offshore oil and gas facilities. Re-injection of surplus gas for disposal will be into a suitable geological formation. Greenhouse gas emissions from the proposed development will be mainly associated with combustion of fuel gas used to provide power generation for the facilities. The highest rate of release of greenhouse gases is likely to be during the commissioning period, before gas reinjection systems are fully operational. Following this, the emissions profile is expected to be relatively flat, with emissions in the order of 162,000 t/year CO2eq over the life of the proposed development. The decision not to flare surplus gas will result in an approximately 30% saving of potential greenhouse gas emissions compared to a base case that includes flaring of surplus gas. Decommissioning will be carried out at the end of the field life, in accordance with prevailing legislation and industry best practicable technology and practices at that time. The aim will be to decommission production facilities, abandon operating areas, and leave sites as near as practicable to their original condition. The proposed use of an FPSO that can be easily removed will help meet this aim.
Phase 2 consists of drilling of additional production wells and linking other fields within the Notional Development Area back through subsea manifolds and flowlines to the Pyrenees production facility (a process referred to as tie-back).
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The Pyrenees Development could start operating in 2008, with a field life of approximately 20 to 25 years. Future tie-back opportunities (that is subsea connections of new fields within the Notional Development Area to the FPSO using flowlines) that may potentially occur would extend production life of the facilities beyond this time. An indicative high-level schedule for the proposed development is shown in Figure 4.3.
and water-based drilling fluids will be discharged to ocean. NWBMs will be recovered and returned to shore for reconditioning and reuse or disposal. Drilling activities for the Phase One Pyrenees Development are likely to take around 12 to 18 months to complete. Should tie-back opportunities eventuate it is anticipated that production drilling associated with a Phase Two tie-back would take a similar length of time.
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PROJECT DETAILS
as the base fluid NWBM. NWBMs can have a number of different base fluid types, each with varying characteristics. Examples include, synthetic-based (SBMs), or ester-based (EBM) drilling mud systems. Synthetic-based muds are likely to be used for lower-hole sections due to their improved performance relative to WBMs. Drilling muds have a number of significant functions during the drilling process, including: Exerting pressure in the well to prevent uncontrolled flow of formation fluids, mechanical instability and cave-ins Forming a relatively impermeable filter to prevent mud loss Chemically inhibiting well-bore instability and dispersion of drilled cuttings Removing drill cuttings from the drill bit and transport them to surface for separation Suspending drilled cuttings and weighting material during extended periods without circulation Transmitting hydraulic power to the drill bit and down-hole tools Cooling and lubricating the drill string Inhibiting corrosion of the drill string and well-bore tubulars.
Drilling mud is mixed, stored and maintained in surface tanks (or pits) on the MODU. The mud is pumped by way of HP pumps down the well and out through the drill bit (which has holes in it), returning to the surface via the annulus between drill pipe and the bore hole or casing. In a closed circulation system, that is after the riser has been set allowing muds to be carried back up to the MODU, the mud returns to the surface equipment where it is processed using a range of solids-removal equipment. This equipment removes a large proportion of drilled cuttings from the mud and recovers as much drilling mud from the cuttings as practicable. Presently, the well designs for Pyrenees are too immature to select specific drilling mud systems. However, it is possible to define a range of options. Table 4.1 summarises the range of drilling muds that could be used for each particular hole section. The mud volumes are estimates only and will vary depending on the fluid selections made. Where the circulation system is open, the drilling mud (seawater and seawater based mud sweeps) is discharged directly to the seabed. Where a closed system is used and the drilling mud is recirculated, drilling mud from one section can be recovered for use in subsequent sections. At the end of a well, the entire WBM volume is discharged to the ocean. If NWBMs are used they are recovered and sent ashore for treatment and re-use or disposal. If NWBM is used a small amount of drilling mud associated is retained on the drilled cuttings, typically in the order of 10% of mud per cuttings by weight, and is washed to sea with the cuttings. A number of additives may be used in very small amounts for bacterial control, corrosion inhibition, or to provide special mud properties as necessary for particular geological formations.
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Table 4.1: Summary of drilling mud and volumes of mud and cuttings discharged for two cases: a) all water based muds, b) water-based and synthetic based muds
445
1000
WBM
292
594
292
594
4964
10098
311
1350
WBM
69
380
20
301
977
6144
216
2881
WBM
147
551
14
273
1967
8255
Total
585
1609
403
1252
9217
25925
445
1000
WBM
292
594
292
594
4964
10098
311
1350
SBM
69
56
20
12
977
776
216
2881
SBM
147
121
14
12
1967
1621
Total
585
855
403
702
9217
13923
Figure 4.4: Schematic Illustration of Cuttings and Drilling Muds Treatment and Discharge During Drilling
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PROJECT DETAILS
The optimal well design, based on the depth and geological constraints of the proposed development, is not compatible with current re-injection systems. Re-injection for the proposed development would require extensive research and design to develop a new re-injection wellhead system that could cope with the well design and water depths of the proposed development. This is not be commercially feasible, and introducing unproven technology would increase the risk associated with the proposed development.
For ship-to-shore disposal, cuttings are transferred via augers or vacuum tubing to skips on the rig. An alternative may include the use of bulk storage bins with transfer using flexible hoses. The skips are back-loaded to supply vessels and transported to shore for processing. Onshore processing may include various techniques, including incineration, thermal desorption, solvent extraction, ultrasonic or steam.
Each option entails its own environmental effects as well as practical, technical and cost constraints. The base case disposal option is discharge to sea. In Australia, drill cuttings from SBM are routinely discharged to ocean. For cuttings re-injection, the cuttings are transferred from the solids control equipment to a slurrification and re-injection unit. The cuttings are ground to less than 300mm in size, usually with seawater and sometimes mixed with a simple, water-based viscosifier to prevent solids settling. A high-pressure pump is then used to displace and inject the slurry into a suitable sub-surface formation. Injection can be continuous or intermittent depending on the volume for disposal and the achievable rate. This option was not found to be feasible due to a number of technical and commercial constraints, including: There is no suitable geological formation to re-inject the cuttings into. The Mandu formation, which would be targeted for cuttings re-injection is extremely unconsolidated, and would allow vertical fractures at relatively low injection pressures. As there is no cap rock above this formation, re-injection could result in vertical fractures running right up to the surface, which would release cuttings onto the seabed.
Following completion of these activities, the FPSO hull will be mobilised to the site and connected to the mooring. Several additional activities remain to be completed before start-up, including: Installation of flowline risers Installation of umbilical risers Installation of riser for the gas export line Proof-loading of moorings Subsea well completions.
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The spatial relationships between system components and construction equipment selection will influence the timing and sequence of these activities. The layout represented in Figure 4.5 represents a base case for discussing installation, commissioning, operation and decommissioning for this evaluation of environmental impacts and risks. The FPSO is centred at least 1,500m from the nearest subsea well cluster and each well cluster is located for optimal distance from the reservoir that it services. In several instances, there are at least two feasible alternative approaches for installation of components of the FPSO system use of a designated vessel for all installation tasks, or use of multiple or specialized vessels to complete installation. Use of a specific construction vessel for installation of several components would present some advantages, but would require that activities, which might be performed in parallel, be done in sequence. Vessel availability, cost, and a number of other considerations will also influence the final selection of construction equipment. The following combinations are considered to be representative of the base-case scenario: Mooring anchors and lines - anchor handling vessels (one or two vessels) Flowlines and gas and water re-injection line dynamically positioned pipelaying vessel Umbilicals dynamically positioned cable/umbilical vessel Installation of manifolds, hook-up FPSO, installation of risers and hook-up of gas and water re-injection lines dynamically positioned construction vessel.
Most activities that are carried out below the water surface will rely on electrically powered remotely operated vehicles (ROVs) to provide visual perspective and to perform certain limited work functions. Prior to the beginning of installation work at the site, a long baseline acoustic-positioning array will be established on the seafloor. This array provides accurate navigational control for positioning objects on the seafloor and is used for both drilling and construction activities.
Current proposal is for the surplus natural gas to be re-injected to the Macedon gas reservoir, however it is possible that facilities relating to the gas re-injection system (flowlines, injection well and associated systems) could be located outside the Pyrenees Development Area, but still within the Notional Development Area, or directed to a gas export line.
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PROJECT DETAILS
it would be deeply embedded in the seafloor following installation. Piled anchors typically comprise a small number of long, slender pipes (piles), grouped together for each mooring line. Each pile would be inserted into a drilled hole and cemented in place. The tops of the piles for each group would be connected to a small frame structure to which the mooring line is attached. Such structures would be expected to protrude 2 to 3m above the seabed. Alternative anchor type options that may be considered include: Gravity: A single gravity anchor installed for each anchor line (i.e. it does not move because of its large weight). Such an anchor would be a steel-framed structure (such as a large box) that is filled with heavy material (usually iron ore), and may protrude approximately 6m above the seabed following installation. Suction anchors: A suction anchor is a single short and squat round steel pile with a closed top. After embedding the bottom of the pile in the seafloor, the water that is trapped in the pile is pumped out. This forces the pile further into the seafloor. The pile would be expected to protrude some 1 to 2m above the seabed following installation.
BHP Billiton have extensive experience in the operation of FPSOs on the North West Shelf and northern Australia. FPSO design will be based on the environmental conditions specified in Section 5.4. The options currently being assessed for procuring the FPSO hull include: A new-build FPSO Converting a tanker (either new or existing) into an FPSO Converting an existing FPSO to suit the specific field requirements.
Before being considered for service as an FPSO, any existing vessels will be subject to thorough pre-purchase inspections to ensure that the condition of the vessel is understood, and that the scope of any refurbishment work required to ensure the vessel is suitable for its intended service is clear. The vessels original construction, age, and service and maintenance history will also be considered during the selection process. Strength and fatigue assessments will be conducted to ensure that the hull has the required strength and service life. These assessments will consider the particular environment that the FPSO will see in service, the use of in-water survey (in lieu of dry-docking), and will provide the basis for the in-service inspection programme. The final size of the FPSO has not been determined at this stage and storage could vary between 110,000 and 175,000m3. The FPSO will have its own propulsion system and will be disconnectable, allowing the vessel to leave the area prior to extreme weather events or for large-scale maintenance works. The vessel will be double-hulled which means the bottom and sides of the ship will have two layers.
4.4.4 Anchoring
The FPSO will be held on location by turret mooring and anchor systems, which also allow the vessel to weathervane to align with prevailing environmental conditions. The mooring lines and flexible risers are attached to a mooring buoy, which connects to the FPSO turret system. From 6 to 16 mooring lines may be used in various configurations. The lines may be a combination of chain, and/or wire, synthetic rope and elements. The anchors are expected to be drag embedment anchors or piles. Drag embedment anchors are similar to those used by large ships, but would be considerably larger. The anchor would be installed such that
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4.4.6 Flowline and gas and water re-injection lines and installation
Production will flow from each subsea well through a short flowline (sometimes referred to as a jumper) to a nearby manifold. From the manifold the production will pass through flowline end modules (FEMs). From the FEMs, flowlines (i.e. one pair for each manifold) run along the seafloor and are connected individually to flexible (lazy S or lazy wave) production risers, which are suspended from the FPSO turret, passing through riser guide tubes within the turret cylinder, and connected at the riser termination deck on the turret. Installation of the flowlines will be performed by a dynamically positioned lay vessel and will likely begin by lowering the FEM, with the flowline connected, setting the FEM on the seafloor within 15 to 30m of the subsea manifold and laying in the direction of the FPSO location. The end of the flowline will be terminated, lowered, and temporarily abandoned on the seafloor in the vicinity of the planned location of the lower end of the production riser, which will be connected to the flowline and installed after the FPSO mooring is in place. The lay vessel will likely be resupplied (with material, fuel etc.) either by supply vessel or cargo barges towed by tugs. At this stage it is not known whether stabilisation (i.e. covering to prevent movement) of the flowlines will be required. If it is required, stabilisation at the depths that occur over the proposed Pyrenees Development Area is usually achieved by placing concrete mats over the flowlines. Following installation of a flowline, international codes and authorities require that a hydrostatic pressure test is performed in order to prove the strength and leak-tightness of the system. This test is normally a part of the pre-commissioning activities. The hydrostatic test (hydrotesting) is performed by pressurising the flowline with water to the required pressure level, usually in the order of 25% above maximum operating pressure. At its completion, the hydrotest water will be discharged to sea from the flowline end-manifold on the seafloor, or recovered through the production process and discharged to sea at the surface. In addition to seawater or freshwater, the hydrotest water may contain a dye to aid in the detection of any leaks, a biocide, and an oxygen scavenger to prevent corrosion of the flowline. Disturbance of seafloor sediments by both FEMs and flowlines will be limited to narrow areal corridors and shallow sediment depths. The routes selected avoid any sensitive features and problematic seafloor topography. The gas re-injection line in this base-case scenario is assumed to run from a FEM at the bottom end of the export riser from the FPSO south to a location for re-injection within the Notional Development Area. The water re-injection line runs to the north and then east to injection points at all three fields.
As in the case of the subsea flowlines, disturbance of sediments by the deepwater portion of the gas and water re-injection lines will be limited to narrow corridors. The routes selected avoid any sensitive features and problematic seafloor topography.
4.4.8 Flowlines
Flowlines will carry crude oil, reservoir water and natural gas from the wells to the FPSO via risers, which are flexible pipes, or a combination of rigid and flexible pipes, from the seabed to the FPSO. They also transfer water and gas from the FPSO to selected wells for injection. Flowlines may be either flexible pipe or rigid steel pipe and will link each well manifold to the FPSO. Flowlines are expected to be laid directly onto the seabed by either: Tow spread: where a length of flowline is completely built onshore, towed to location and lowered into position Specialised pipe-laying vessel: a ship that is equipped to allow pipelines to be built offshore (or onshore in the case of a reel laying vessel) and laid in place.
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PROJECT DETAILS
Safety Flare
The majority of systems on the FPSO will arrive on-site already commissioned or at least pre-commissioned. For example, the power systems will be commissioned on diesel in the integration yard prior to sailing to the field. However, there are some systems that cannot be fully commissioned until reservoir fluids first flow onto the FPSO. These may include: Production separation systems Gas compression systems Gas re-injection systems Fuel gas systems Flare systems Water injection systems Crude storage and offloading systems.
operating conditions are established. Commissioning is expected to occur over a period of approximately three months. The FPSO will be supported in the field by at least one and possibly two supply vessels during the commissioning period. At the peak of these activities, there may be in the order of 70 personnel on the FPSO.
Commissioning involves the progression of equipment and systems from mechanically complete (pre-commissioned) to a state of demonstrated readiness to operate safely. This is achieved on a system-by-system basis by: Pre-operation integrity and functional checks (readiness to operate) Controlled first introduction of process medium, flow and energy Subsequent checks to demonstrate correct operation, start-ups and shut-down.
This will allow gas, water and crude oil systems to become functional as an integrated process for the first time. The commissioning period is where these systems are being tested and adjusted to bring them to normal operating performance. While commissioning is taking place, discharges and emissions may be higher before steady-state
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of equipment, and secondly as a result of minor modifications made after start-up. The total capacity of the oil storage tanks depends on the FPSO selected, with potential storage volumes for the FPSO varying between 110,000 and 175,000m3. At peak design production levels, the FPSO will receive between 13,000 and 15,100m3 of oil and 1.7 million m3 of gas per day from the 13 producing wells. The system will also be capable of handling a maximum of 17,500m3 of produced water per day. Production will flow through the swivel and into a process train with two-stage separation. Each processing stage separates oil, gas, and water at successively lower pressures. The oil may pass through temporary separation tankage before being delivered to onboard storage tanks in the hull of the FPSO. Gas will be further processed to reduce its moisture content before being either used in the onboard power generation or recompressed to be used for artificial lift (gas lift) and the surplus gas re-injected via the gas re-injection line. Diversion of any of the gas production stream to the flare system will only occur in the event of equipment failure, or the need to relieve system pressure (refer to Section 4.6.6). Produced water extracted from the production flow will be re-injected under normal operating conditions (refer to Section 4.6.4). Monitoring and control of subsea wells will be performed from the FPSO, except when control is turned over to a MODU during workovers and recompletion activities. Continuous FPSO activities involving the subsea wells may include hydrate suppression, corrosion inhibition and flow improving (demulsifier) chemicals. These chemicals are pumped through the umbilical to the manifold and are injected into the production stream at or near the wellhead. The characteristics of reservoir production streams vary widely, but formation sediments, and other substances will be produced with the well fluids to the surface production facilities. The material which is removed from surface production facilities will be processed on board in order to separate the various components. Hydrocarbons will be incorporated into the production or gas reinjection streams, water will be cleaned up and re-injected, and other materials will be shipped back to shore for disposal. Drilling and downhole workover operations that may be required after installation will be performed by a MODU. The MODU will be moored or dynamically positioned over the subsea trees, as is typical of other subsea development schemes, and, other than initiating shutting and restart of the wells, will not involve any activities on the FPSO itself.
Figure 4.7: Predicted Crude Oil and Water Production Profiles For Pyrenees Development (Without Tie-backs)
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PROJECT DETAILS
Under normal operating conditions, produced water will be re-injected into the Pyrenees oil field. It is estimated that this can be achieved more than 90% of the time. If the re-injection system is unavailable, such as during commissioning, re-injection equipment downtime and process upsets, produced water will be discharged to the ocean at oilin-water concentrations below the limits required by law (P(SL)A and Petroleum (SL)(MoE) Regulations: 24-hour average less than 30mg/L, maximum less than 50mg/L. When produced water is discharged overboard, oil-in-water concentrations will be measured continuously using an electronic meter, to ensure compliance with regulations. If produced water from the oil and water separators exceeds the specification for maximum allowable oil-in-water concentration for re-injection, or if the re-injection system is unavailable, produced water may initially be routed to slops tanks located within the FPSO hull where it would be subject to further separation. The recovered oil from the slops tanks would be transferred via skimming pumps to oil storage and the cleaned water transferred to the water re-injection system or discharged to sea. In the case of this water being discharged overboard, it will be monitored for oil-in-water content.
Corrosion inhibitors may be used on a continuous basis or selectively (e.g. during pigging operations) to establish and maintain an inhibiting film. Typical treatment dosages range between 5 and 100ppm. Corrosion inhibitors are predominantly water-soluble and under normal circumstances would be re-injected with the produced water stream.
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in chemical makeup from one crude composition to the next and are commonly associated with the formation of emulsions. Asphaltenes can be controlled mechanically through pigging or through chemical injection of asphaltene dispersants (also termed inhibitors). A typical liquid dispersant consists of a polymer in a hydrocarbon solvent. Pyrenees crude oil has low asphaltene content and it is unlikely that asphaltene dispersants will be required. However, should they be needed asphaltene dispersants are typically used on a continuous basis to prevent build up in flowlines and to prevent asphaltene pad formation in production equipment; they may also act to protect producing formations from damage due to asphaltene plugging. Treatment dosages typically range from 20 to 500ppm and are determined based on the characteristics of the crude oil, the type of system being used and the application method. Applications entail injection of dispersants down the wellbore. Dispersants remain in the production stream (i.e. are not recovered during processing).
4.6.4.6 Biocides
Biocides are used to prevent or control the growth of sulphur-reducing bacteria (the by-products of sulphur-reducing bacteria are hydrogen sulphide, which is both corrosive and toxic in high concentrations, and iron sulphide, which can interfere with oil separation) consequently they are highly toxic. To improve performance and avoid the potential for development of biocide-resistant bacteria, biocides are generally applied in short batches of a relatively high concentration rather than as a continuous dosage. The biocides that are used on the North West Shelf typically have either aldehydes or amine salts as the active ingredients. Both of these types of biocide are soluble in water and under normal circumstances would therefore be re-injected with the produced water stream.
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PROJECT DETAILS
It is possible that a very small stream of low grade LP gas might be flared continuously for the first 18 months. Consideration was given to capturing and compressing this gas for re-injection, however the energy expended in compression would exceed, and negate, any greenhouse gas benefits associated with re-injection. Gas re-injection systems are expected to comprise coolers and vessels for recovering liquid hydrocarbons from the gas, dehydration systems and high-pressure compressors for delivery of the gas. The FPSO will have an emergency flare system in line with normal design of offshore oil and gas facilities. It is possible that technical advances may create other gas disposal options in the future life of the proposed development. The potential export of natural gas for sale into the domestic gas market is being considered in the longer term. Should this occur, the gas export pipeline would be subject to a separate environmental impact assessment process.
required during commissioning, initial production, process restarts, maintenance, and equipment downtime. During normal operations there will be some flaring of LP natural gas during the first year of operations and a small pilot flare will be run continuously throughout life of operations as a means of ignition for the emergency flare. Surplus gas will not be flared under normal operating conditions.
4.6.7.3 Flare
An emergency depressuring (flare) system, also referred to as a safety flare system, will be provided in line with normal design of offshore oil and gas facilities. The safety flare is designed to provide a safe means of rapidly disposing pressurised gas from process equipment in the event of emergency or process upset. The flare system is also
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and extinguishers. The most appropriate system for each area will be selected based on detailed risk assessments. Ozone-depleting substances will not be used for these systems. Safety equipment including fire pumps, emergency lighting and communications equipment, are generally designed to be completely independent and with appropriate levels of redundancy. Independent fuel or energy sources, such as diesel fuel may be used.
4.6.7.7 Accommodation
Accommodation facilities will be provided for personnel required for commissioning (estimated 60 to 80 people in addition to the operational crew) and production and maintenance during normal operations (estimated 30 to 40 people), with capacity available for additional personnel during campaign maintenance (estimated 10 to 20 people). Typical living room, quarters and galley facilities are shown on Figure 4.9.
Periodically, the FPSO will require stocks of materials to be replenished. One mechanism that is used for the transfer of bulk materials (such as diesel fuel and process chemicals) is to transfer them via hose from a supply boat. This transfer operation is commonly known as bunkering. Equipment and procedures for bunkering are yet to be specified, and will be selected to avoid or reduce the potential for a spill. For example, unique couplings are likely to be used on the various bunkering lines to avoid cross contamination. Dry-break couplings are likely to be used to reduce the potential for liquid loss when hoses
39
PROJECT DETAILS
are decoupled, and procedures will be implemented that define seastate conditions under which bunkering is permitted. An alternative method for transfer of smaller volumes (up to about 5m3) is in tote containers or drums. Tote containers have dry-break couplings on the valve assembly, which is recessed to prevent accidental impacts that may cause a release of contents.
Dampier. To ensure that safe operations are maintained while the trading tanker is loading, the pilot stays on board the vessel as Loading Master and shore representative. When secure, prior to loading, a full safety inspection is conducted. Once loading, repeat inspections are undertaken on a regular basis. If any safety violations occur, the pilot is fully empowered to suspend loading operations and remove the vessel from the FPSO. When ready for offloading, the trading tanker will be met two to four km away from the FPSO by an offloading support vessel (OSV). The purpose of the OSV will be to assist the trading tanker as it approaches the FPSO, and connect mooring lines, hawser and offloading hose. The hawser is passed between the FPSO and trading tanker and secured, and the offloading hose connected. During cargo transfer operations, a towline from the stern of the OSV to the stern of the trading tanker will connect the vessels. The purpose of this configuration is to ensure the trading tanker and FPSO remain the required distance apart and in the required alignment. Trading tankers typically have an oil storage capacity in the order of 100,000m3. A full offloading operation is expected to last 36 to 48 hours, while the actual transfer of oil may take 24 to 36 hours. When the cargo has been transferred, the trading tanker is disconnected and sails away. A range of procedures are implemented with respect to pilotage and offloading operations. A Terminal Handbook will be developed for the FPSO and this will list all the offloading operations requirements which will need to be met.
4.6.7.10 Drains
The drainage and disposal systems include closed drains, open drains, bilge and oil recovery systems and slops tanks. Deck drainage consists mainly of washdown water and occasional rainwater. While no wastes will be routinely discharged via deck washdown, the washdown or rainwater run-off will generally be directed overboard, and may contain small quantities of oil, grease and detergents. Areas on the FPSO which are more likely to have small oil leaks will be directed to a sump (or similar collection system) which is in turn directly connected to an oily water separation system, such as the slops tanks. Overflow systems are also provided which may discharge directly to sea in the event of high rainfall intensities. Oil is removed from the upper part of the slops tanks by skimming pumps and the water is directed to the water injection facilities or discharged into the ocean. This discharge water stream will be monitored for oil-inwater content. The closed drains system collects and disposes of volatile hydrocarbon liquid drained directly from process equipment for maintenance or operational reasons. Collected hydrocarbon liquids are normally pumped back to the process, but depending on contaminants, may have to be collected and sent back to shore for recycling, treatment, or disposal. The bilge and oil recovery system generally collects waste liquids from the engine room and other machinery spaces. Liquids are processed prior to discharge or stored until disposed to a suitable reception facility.
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BHP Billiton uses a comprehensive shipping database to assess ships. The principal database contains records of over 6,000 vessels and utilises a large range of tools to assess ships including: Casualty record Class history Flag history Operational performance Owner audits Port state inspections Ship operator assessment SIRE inspections Structural analysis Terminal feedback.
The OCIMF also maintains a database to which major oil companies contribute inspection reports. The use of both these databases ensures that the most current inspection information is available to assist in the assessment process.
4.6.9.2 Helicopters
A helideck and associated equipment will be provided to meet standard offshore facility requirements for the transfer of personnel and supplies. Helicopter fuel storage on the FPSO is not envisaged.
41
PROJECT DETAILS
Both work-over wells and drilling of additional wells would use similar processes and facilities as described for development drilling.
The most direct threat of a tsunami that may affect the Pyrenees Development Area is the Sunda Trench plate subduction zone bordering southern Indonesia. Travel time for a tsunami from the Sunda Trench to the proposed development area is of the order of two hours. As such, an effective early warning system is not feasible. However, given the negligible impact of a tsunami on the proposed development, an early warning system is considered unnecessary.
Preparation activities including: Tasks required to keep the facility in a state of readiness in case a cyclone develops, e.g. ensuring adequate fuel is onboard Tasks required based on distance of a cyclone from the facility (e.g. storage or tie down of certain items) Critical tasks including down-manning if necessary, checking of propulsion and steering equipment, shutdown of production and disconnection Cyclone monitoring.
Communications including: OSVs The trading tanker(s) which are in the field or may be approaching MODUs which might be in the field Helicopter operator Fixed wing aircraft operator Reconnection activities.
4.7 Decommissioning
Decommissioning will be carried out at the end of the project, in accordance with prevailing legislation and industry best practicable technology and practices at that time. The aim is to decommission production facilities and abandon operating areas to leave them as near as practicable to their original condition. The proposed use of an FPSO that can be easily removed helps meet this aim. The sequence of decommissioning includes: Shutting down of production processes Flushing of risers, flowlines and subsea facilities Plugging and abandonment of wells Disconnection of the FPSO and movement from the location.
The capability of the facilities to withstand extreme weather events is assessed by BHP Billiton engineering studies to meet regulatory requirements including P(SL)A requirements, and verified separately by an independent agency, such as Lloyds of London or the American Bureau of Shipping. The likely wave height and period of a tsunami in the Pyrenees Development Area falls within the range of extreme weather conditions that are included in the design criteria for the development (Section 5.2.1.4). The proposed development will be designed to meet 100-year non-cyclonic storm surface currents of greater than 1m/sec; consequently, tsunamis are not an engineering risk in deep water.
It is expected that decommissioning will include removal of most structures above the surface of the seabed, including flowlines, manifolds and moorings for the FPSO. The time of decommissioning is unknown. A detailed decommissioning plan will be prepared and submitted to the relevant authorities prior to commencement of decommissioning activities.
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4.7.1 Wells
Decommissioning of wells will be planned to achieve the following objectives: To isolate formation fluids from each other To isolate formation fluids from the surface To leave the seabed clear of obstructions.
Wells will be decommissioned in accordance with all regulatory requirements in place at the time of decommissioning and with consideration of the best environmental outcomes. It is intended to leave any remaining drilled cuttings in place. Decommissioning and suspension of wells is currently regulated via Section 107 of the P(SL)A, and P(SL)A Schedule. The DITR, as well as APPEA1, have developed guidelines for the decommissioning of offshore petroleum facilities.
The waste management process to be adopted by the proposed development will give priority to the prevention and minimisation of hazardous waste materials and will focus on reducing the quantities of waste requiring disposal, such as through pre-qualification, tendering and contracting processes. The objectives of the waste management process are to: Identify opportunities to prevent and/or reduce waste generation from the proposed development through design and operation standards Identify opportunities to re-use, recycle or reprocess wastes generated during all phases of the proposed development To reduce the amount and toxicity of wastes requiring disposal Identify and eliminate hazards to human health and the environment (to as low as reasonably practicable) Utilise certified waste transporters and disposal facilities for ultimate waste disposal if other options are not practicable Document waste management information, including inventory, disposal, waste characteristics and procedures.
A comprehensive Waste Management Plan will be developed and integrated into the design phase of facilities and processes. The proposed development will comply with the requirements of the NEPM National Pollutant Inventory (NPI) and any relevant requirements of the National Environmental Protection (Movements of Controlled Waste) Measure.
4.8 Wastes
A variety of wastes will be generated in association with drilling, installation, commissioning, production and decommissioning activities. Key waste categories have been identified and include: Non-hazardous solid wastes Hazardous solid wastes Produced water discharge Greenhouse gas emissions.
These categories and the waste management principles to be applied for the proposed development are discussed below. A summary of expected waste types and quantities is provided at the end of this chapter (Section 4.8.6).
http://www.appea.com.au/Publications/docs/WellDecommGuide.pdf
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PROJECT DETAILS
Estimates of quantities of hazardous wastes generated over the life of the proposed development are provided in Section 4.8.6. It is also possible that scales potentially containing naturally occurring radioactive materials (NORMs) may accumulate and will require periodic disposal.
The Kyoto Protocol listed greenhouse gases that apply to the proposed development include carbon dioxide (CO2), methane (CH4) and nitrous oxide (N2O). There will be no emissions of perfluorocarbons, hydrofluorocarbons or sulphurhexafluoride from the proposed development. The potential environmental effects of other atmospheric emissions, such as nitrogen oxides (NOx), sulphur oxides (SOx), volatile organic compounds (VOCs), cargo tank vents and fugitive emissions, have also been assessed.
Table 4.2: Global Warming Potential of Different Gases Relative to CO2 Gas Carbon dioxide (CO2) Methane (CH4) Nitrous oxide (N2O) Perfluorocarbons Hydrofluorocarbons Sulphurhexafluoride
Source: IPCC, 1995
No hydrogen sulphide (H2S) has been detected in the Pyrenees reservoir fluids, thus no H2S emissions are predicted to result from the use of stationary combustion sources. Reservoir performance will be continuously monitored through the production systems and well testing to identify issues such as increase in concentration of H2S. Fuel gas will be available and is the preferred fuel for normal operation, with backup provided by diesel.
Table 4.3: Predicted Greenhouse Gas (Tonnes per year) Emissions for Year 1 Operation Power Generation Process Heating Flare Emissions Tank Venting Fugitive Emissions TOTAL (Tonnes) CO2 92,077 24,865 16,414 <0.1 <0.1 150,422 CO 90.2 7.2 54.7 <0.1 <0.1 147 NOx 7.4 2.0 0.5 <0.1 <0.1 12 CH4 14.1 0.6 220 154.1 1.3 270 CO2eq 95,018 25,539 22,107 3,774 31.2 161,169 % 64.9 17.4 15.1 2.6 <0.1 100
*GWP applied: CO2: 1, CO: 0, NOx: 0, N2O: 296, SOx: 0, CH4: 23, VOC: 0
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The following sources of greenhouse gas emissions from the Pyrenees Development have been identified during operations: Power generation of electricity from dual fuel turbines (or their equivalent direct drive machines if selected) Flaring of hydrocarbon gas required to maintain safe operating conditions for the operational and emergency flares Emissions associated with inert gas generation (i.e. tank venting during crude loading) Fugitive emissions resulting from minor leaks in pipe connections and equipment.
Power Generation
The majority of greenhouse gas emissions are from combustion of gas for the powering of equipment. Table 4.4 presents a breakdown of the predicted emissions from equipment sources. Power requirements have been minimised where possible in the Pyrenees Development by utilising the following design features: Direct crude inter-stage heating requirements have been minimised by using heat recovery from product oil and produced water streams The use of cross exchangers to recover process heat significantly reduces the process heating duty and therefore the pumping and duty/electrical load for the heating medium circulation system Where possible the layout will facilitate free flow of liquids from the LP Separator and electrostatic coalescer via the process cross exchanger to the produced water treatment system. This will avoid the electrical power requirements that would otherwise be associated with pumping water and crude from the electrostatic coalescer to the produced water treatment system and crude export system respectively Water carryover with the oil from the HP separator will be minimised and separation of water at HP will be maximised. Removal of water in the HP separator will enable the water to free flow to the water treatment system and will reduce interstage heating requirements The electrical energy for the entire facility shall be supplied from central dual fuelled (fuel gas/MDO) turbine driven power generators. In the event of central generation total failure, power for essential services shall be supplied from an emergency diesel generator(s) and critical services from UPS systems. 45
Atmospheric emissions are quantified based on the Tier 3 Approach, developed according to the E&P Forum (1994) methods for estimating the principle inventory sources of atmospheric emissions including combustion equipment, tank/storage vents, flare and fugitive emissions (Figure 4.12). The results of this analysis are expressed in terms of CO2eq to compare the emissions from various greenhouse gas emissions based on their GWP. A prediction of the annualised account of main energy types, their consumptions and associated greenhouse gas emissions are shown in Table 4.3. Assuming total recoverable reserves of 19,875,00t (125 million barrels) of crude oil and an operational lifespan of 20 to 25 years the average annual greenhouse gas efficiency is calculated to be 0.16 to 0.20t CO2eq per tonne of product.
PROJECT DETAILS
The main consumers of power on the process topsides are the HP gas compressors and the water injection pumps (included in major topsides pumps). For the hull systems the major users of power are the thrusters and cargo off-loading pumps. Exhaust gases from the power generation turbines contain predominantly carbon dioxide with small amounts of nitrogen oxides, carbon monoxide and unburned hydrocarbon. The use of low NOx burners may not be feasible for dual fuel requirements. This issue will be resolved during further design activities.
Emergency flaring disposes 1t of natural gas per day, assuming two trips/failures each year. Flare emissions associated with normal operations and emergency flaring are estimated to contribute approximately 15% of the total CO2eq emissions. The emission generated during flaring will contain water vapour, carbon dioxide, carbon monoxide, nitrogen oxides, nitrous oxides and unburned hydrocarbons.
Fugitive Emissions
Fugitive emissions are estimated to contribute 31 tonnes CO2eq/year during annual production.
Process Heating
Heat is principally required on the topsides for process heating to aid oil/water separation and to achieve crude specifications. It is also used on an intermittent basis for heating the cargo tanks wash water, heating the slops tank. A closed loop, pressurised water heating medium system will be used. Alternatively LP stream from the FPSO marine systems may be used depending on final configuration.
Flare Emissions
A flare system will be provided to ensure safe disposal and discharge of gases and liquids resulting from relief, blowdown and vent streams from the topsides and turret area. During normal operation, some noncontinuous and non-routine activities will lead to flaring and venting of gas. The flare system is designed to handle peak emergency rates as well as flaring continuously at facility peak design gas rates. Flaring of associated gas from the FPSO will be minimised, although a small continuous source is required to maintain an ignited flare pilot. During normal operations, the proposed development will not flare surplus gas (other than LP flare in first year and continuous flare purge over the life of the project). Where possible, all produced gas not consumed for power generation or for maintaining the flare pilot will be compressed and re-injected (or exported). The operational flare requires a continuous flow of LP, small flow streams, such as gas dehydration TEG regeneration off-gas, and is disposed as part of the continuous flare pilot. HP compressor maintenance and the compressor gas seal leaks are also included in the emissions estimate for continuous flaring.
Table 4.4: Equipment Greenhouse Gas Emissions Equipment HP Compressor Train 1 HP Compressor Train 2 Major Topsides Pumps Other Topsides Systems Hullside Equipment1 Subsea Equipment TOTAL (Tonnes) 91,507 89.8
(1) This is hullside power usage during on station production only.
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The IG system will be in compliance with Classification Society requirements to provide safe atmospheric discharge of the tank gases to compensate for the loading/unloading of crude oil, normal tank breathing due to temperature fluctuations and the emergency relief of over/under pressure.
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PROJECT DETAILS
Table 4.5: Summary of Expected Waste Types and Quantities Installation and Commissioning Pyrenees fields only 60 100 20 100 5 0.3 10 420500 Nil Nil 1,700 Nil 150 15 4,000 600 20 20,000 Tie-back fields 100 150 30 120 5 0.3 10 420500 Nil Nil 5,000 Nil 150 50 12,000 1,800 50 70,000 Drilling Pyrenees fields -only 10 per well 40 per well 10 per well 5 per well 5 0.3 10 420500 275-450 300-400 Nil Nil 150 Nil 400 50 1 210,000 Tie-back fields 10 per well 40 per well 10 per well 5 per well 5 0.3 10 420500 275-450 300-400 Nil Nil 150 Nil 1,200 150 3 620,000 Production Pyrenees fields only 30 per year 60 per year 10 per year 50 per year 5 0.3 10 50,000 100,000 275-450 300-400 Nil 1,760 60 30 per year 8,000 600 60,000 162,000 per year Tie-back fields 50 per year 80 per year 15 per year 60 per year 5 0.3 10 50,000 100,000 275-450 300-400 Nil 1,760 60 100 per year 24,000 1,600 180,000 162,000 per year Decommissioning Pyrenees fields only 500 30 30 30 5 0.3 10 420500 Nil Nil Nil Nil 150 15 200 30 10 20,000 Tie-back fields 1,500 50 50 50 5 0.3 10 420500 Nil Nil Nil Nil 150 50 600 100 20 70,000
Waste Type(unit)
Recyclable inert (t) Non-recyclable Inert (t) Recyclable hazardous (t) Non-recyclable hazardous (t) Sewage (m /day) Food scraps (m3/day) Greywater (m3/day) Cooling water (m3/day) Drilling muds (m3/well) Drill cuttings (m /well) Hydrotest water (m ) Produced water (m3 /year)* Desalination brine (m3/day) Subsea control fluids (m3) NOx (t) SOx (t) VOC (t) Greenhouse gases (t CO2eq)
3 3 3
*Based on peak water production rates and discharge to sea for 10% of time
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