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Q U A R T E R L Y J O U R N

2006
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Q1
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BLIND FAITH CHALLENGES TECHNOLOGY LIMITS by Ron Ledbetter


Chevron has embarked on what has devel- Detail Design work. The resulting concept The extreme operating condi-
oped into a ground-breaking project in the is a subsea development of three initial pro- tions caused INTEC to perform
Gulf of Mexico. In February of 2004, duction wells tied back to a new-build extensive analysis on the effects
INTEC was asked to help prepare feasibil- semisubmersible. The building block of HP/HT (High Pressure/High
ity studies for a prospect in Mississippi approach using clustered subsea wells and Temperature) relative to the flow-
Canyon Block 696 called Blind Faith. No a nearby gathering manifold allows easy lines, risers and PLETs as part of
single condition made this prospect a fron- future expansion. In fact, Chevron/Kerr- the FEED and initial Detail Design
tier development. The Blind Faith field is in McGee plan two additional infield wells in work. Because of these operating
approximately 7,000 feet of water. This is the near future. The development plan has conditions, the Blind Faith team
certainly deepwater but not record setting. the initial system designed to accommodate worked closely with the Chevron
Shut-in wellhead pressures are in the five production wells. However, the facility Tahiti team to investigate the capabil-
12,500 psi range; again high pressure, but design also includes the ability to act as a ities of the industry subsea equipment
not frontier levels. Wellhead temperatures hub for other fields in the future. suppliers. The results of this study fig-
are expected to be in the area of 280˚ F, ured heavily in the evaluation of tech-
which, as an oil system, could be as high as The subsea system includes 15,000 psi nical bids and consideration of follow-
300˚ F with JT heating. Once again, this is rated trees, a four-slot, dual-header gather- up qualification testing.
high but not earth shattering. However, the ing manifold and two insulated 7-inch pro-
combination of deepwater, high pressure, duction flowlines with SCRs. The host The Blind Faith project is currently in
and high temperature has put industry tech- facility is located 4.5 miles away in Block the initial stages of Detail Design.
nology at its limits. To make things even 650. The system is pressure rated for the Contracts have been awarded for the
more interesting, Chevron and partner maximum possible shut-in pressure of design and supply of subsea equipment,
Kerr-McGee had fundamental differences 12,500 psi. Flow assurance studies resulted a subsea umbilical, and flowline line-
in offshore field development philopso- in an operating philosophy balancing pipe. Installation contracts are planned
phies that led to some adjustments while chemical injection and thermal retention. for award in the first quarter of 2006.
underway. The Control/Chemical Injection System is The subsea installation campaign is
designed to deliver chemicals to both the planned to start in the third quarter of
To develop Blind Faith in a more fast-track tree and manifolds for hydrate manage- 2007. First oil is planned for early
fashion, Chevron adapted their CPDEP ment, corrosion control and scale / asphal- 2008. INTEC will continue to work as
process and adopted a more Kerr-McGee tene treatments. Wet thermal insulation for part of Chevron's integrated project
like approach to field development. To trees, jumpers, manifold, flowlines and ris- management team through start-up.
address the technical issues for this chal- ers make up the thermal retention strategy.
lenging project, Chevron has
put together a team of experi-
enced subsea experts, which
includes INTEC subsea and
pipeline engineering staff. A
subsea project office was set
up in INTEC's Houston
offices during the early phas-
es of work and continues to be
the hub of subsea work,
although much of the current
design work is being done at
various contractor facilities.

INTEC has assisted Chevron


in developing a design con-
cept, which has evolved from
the early feasibility studies
through Front End
Engineering to the current
A Note from the CEO
Farewell
NEW BEGINNINGS by Bruce Crager
As I sit down to write my last
Quarterly Journal article, I remember
my dread at having to write my first I would like to thank Pieter Heerema as well
one. Writing, as you all have wit- as the other Directors of INTEC Engineering
nessed by now, is not one of my for the opportunity to join the Company and
strengths. However, I have grown to lead INTEC into the future. I would also like
enjoy the opportunity to communi- to thank Johnny Reed and the current team of
cate with a wide audience on topics of interest to me and, hope- INTEC managers and employees for their ded-
fully, to our industry community in general. I have particularly ication and hard work over the last several
enjoyed the responses I have received, especially those that pro- years. Together they have helped INTEC con-
vided a different point of view. I must say that the tinue as the premier offshore engineering firm
discipline of writing down your ideas really tests how well you in locations around the world. Having both
understand and can support your own positions. That in itself has collaborated with and competed against
been a learning experience for me. INTEC in the past, I have a healthy respect for
its people and accomplishments. It is a real
As this will be my last written communication with the INTEC privilege for me to join this team.
staff, I want to express my gratitude for the warmth with which I
was received from the moment I began. I experienced that wel- In my first column of the Quarterly Journal, I would like to comment on our
come not only at headquarters but in all our offices around the industry and on what I believe INTEC's response should be. First, the offshore
globe. Everybody was prepared for a change and responded with oil and gas segment is in an exciting and positive phase. We continue to have
open minds and willing hands. We made some difficult choices, new projects, achieve new technical breakthroughs for greater water depth and
asked folks to work extremely hard and are now beginning to longer distances, and are achieving record revenues and profits in almost all
reap the benefits of these extra efforts. I can truly say that it has segments of our industry. However, this boom cycle requires more trained per-
been the most rewarding experience of my career. The profes- sonnel than ever before and our personnel resources are becoming extremely
sionalism and the pride of the individuals here at INTEC made thin. INTEC recognizes this concern and we are actively recruiting for posi-
the difficult possible. The mutual respect that "INTECers" have tions throughout the Company. INTEC is an exciting place to work and we are
for each other and for our clients is one of the hallmarks of life at successfully attracting and retaining the best talent.
INTEC, and I have not even mentioned our reputation for techni-
cal excellence and innovation. That is, after all, what INTEC's Second, in addition to the boom cycle, which generates significant work, our
clients pay for. INTEC has that inimitable process that makes it industry is continuing to set new technical records. INTEC will continue to be
one of the best. I referred to it in an earlier article as our produc- on the forefront of innovative technology. I have been asked by a number of
tive "do loop." That is, we attract creative people because we people what the initials I-N-T-E-C stand for. While I do not know how the
execute challenging projects and we execute challenging projects original 4 founders came up with this name, I would like to suggest that being
because we attract creative people. Don't ever give that up! It leaders in Innovative Technology would certainly be applicable to INTEC. We
will carry INTEC forward in whatever future direction you will continue to make investments in technologies and knowledge manage-
choose. ment to ensure INTEC is the place to go for finding state-of-the-art solutions.

It's now time to say my last good-byes and turn the CEO office Third, our customers are continuing to look for new and better ways to do busi-
over to Bruce Crager. Many of you already know Bruce and what ness. We at INTEC are committed to finding ways to support our customers’
a great fit he is for INTEC. Please extend to him that same wel- needs and to be creative in both our technical and business processes. This
come I experienced. Although I am leaving INTEC, I will still be includes not only finding creative technical solutions but also looking for com-
in the Heerema family and will look forward to working with mercial models that support both operators and service companies.
INTEC in my new role at HMC.
I am excited about joining INTEC Engineering and look forward to leading
All the Best, this excellent organization as we continue to grow and serve the industry. My
door is always open; please let us know how we can support your projects.

2
2006 Q1

ONGC G1 AND GS15 INTEGRATED FIELD DEVELOPMENT


(G1DP) PROJECT by Jim Chase
Project Description Project Status
INTEC Engineering was appointed by approximately 400m at the most remote well. Onshore construction is currently underway.
Clough Engineering Limited (CEL) to be the The wells will produce both oil and gas, with The site has been cleared and foundations for
3rd Party Consultant for ONGC for all tech- G1-11 well being primarily a gas producer. major equipment items such as compressors
nical matters under the contract for the Well G1-9 will have a dual zone completion to have been cast.
Integrated Development of the G1 and GS15 allow change over from oil to gas production.
fields G1DP project. This will be accomplished by means of a Offshore construction started in December
hydraulically controlled down hole sliding 2005 and is scheduled to finish by the end of
CEL (an Australian based Engineering sleeve valve to access oil and gas bearing for- April 2006. Offshore construction activities
Contractor) is the main engineering contractor mations at different levels in the wellbore. A in the Bay of Bengal are constrained by the
for the G1DP project that includes the integrat- multiplex electro-hydraulic control system will monsoon season which is characterized by
ed development of the G1 field, further devel- control the operation of the G1 field from the cyclonic storms.
opment of the existing GS15 field and new onshore control room via a 30km main umbili-
onshore processing facilities. cal and a system of infield umbilicals to
distribute the control functions to the
manifold and individual wells.

INTEC’s Scope of Work


INTEC's scope of work includes the review
and approval of the engineering designs and
INTEC was earlier contracted by ONGC to The GS15 field is an existing field in water documentation produced by CEL, subcontrac-
complete the Front-End Engineering Design depth of 8m to 10m that has been developed tors and equipment vendors. The scope also
(FEED), prepare the bid package, attend pre- with monopod platforms. The development includes construction supervision during off-
bid conferences and assist with the Bid plan calls for the modification of one existing shore installation.
Evaluation. The main engineering contract was platform to accept an additional well and for a
eventually awarded to CEL in January 2005. new monopod platform with two new wells. A The project has been managed from the INTEC
The contract between ONGC and CEL new 8-inch pipeline will link the existing plat- KL office but has utilized INTEC resources
required CEL to appoint a 3rd party consultant form and the new platform and then tie in to globally with engineers from KL, Houston,
from a list approved by ONGC. INTEC was one of the new 10-inch lines from the G1 London and Perth offices participating and in
then contracted by CEL to fulfill the role of 3rd development at a subsea wye spool. The wye some cases traveling to CEL's subcontractor
party consultant to ONGC. connection will allow pipeline pigs launched and vendor design centers in India and
from the platforms to pass into the 10-inch line Singapore.
The G1DP project is located in the Bay of to be received onshore.
Bengal off the east coast of India. The G1 field Engineers from INTEC offices mobilized to
is a subsea development consisting of 5 satel- The onshore facilities include: pig India at the end of December 2005 as ONGC
lite wells tied back to a subsea manifold with launcher/receivers for the 10-inch pipelines, representatives during the installation activities
flexible flowlines. The well streams are co- separation facilities, oil storage, gas compres- from facilities, waste water treatment, control
mingled at the subsea manifold, from whence sion facilities, waste water treatment, control systems, chemical injection, power generation,
they flow to the onshore terminal via two 10- systems, chemical injection, power generation, electrical equipment, buildings and civil works.
inch carbon steel pipelines. These also allow electrical equipment, buildings and civil works.
round trip pigging from the shore. Water depth
at G1 is just over 200m at the manifold to
3
INTEC DELIVERS EIU FEED PROJECT IN
Project Overview
The following is a summary of the
INTEC has been awarded the FEED for the activities:
Etim, Inim and Utue Safety Health and
Environmental (EIU-SHE) upgrades for Mobil · Install new dedicated living quar-
Producing Nigeria. This project will be exe- ters platforms and flare platforms
cuted in Lagos in the offices of NETCO, our with bridge connect to the pro-
JV partner for this project. Although INTEC duction platforms.
has been involved with many Nigerian pro-
jects before, this is our first FEED project that · Install new living quarters build-
is wholly executed in Nigeria in compliance ings, production offices, telecom-
with the government's directive that all munications rooms, work shops,
FEED's will be executed in country. warehouses, evacuation facilities,
and helipads on the new living
The FEED project will be executed over an 11 quarters platforms.
month period. The detailed design for this pro-
ject will be executed under the EPCM frame-
work that is currently in the bid process. The
· Remove existing living quarters
FEED work is being performed by a joint team buildings and production offices
of INTEC and NETCO personnel. INTEC has from the existing production plat-
mobilized a number of lead discipline engi- forms.
neers and an engineering manager to Lagos as
part of the INTEC/NETCO integrated project · De-bottleneck existing process
team. plants at Etim and Inim produc-
tion platforms to increase produc-
The Etim, Inim, Utue (EIU) Safety Health and tion capacity.
Environmental (SHE) Upgrade Project facili-
ties belong to Mobil Producing Nigeria · Install new elevated flares and
Unlimited (MPNU), including the production integrate with existing process
platforms, new living quarters platforms, new plants.
flare platforms, process units and utilities.

· Upgrade the existing safety systems and


integrate with the new living quarters and
flare platform safety systems.

· Install additional safety equipment to com-


ply with MPN specifications and API
RP14C.
The main objectives of the EIU SHE Upgrade · Remove existing U-tube flares, structure,
Project are to bring the facilities into compli- and underwater flare lines. · Install new escape capsules on existing
ance with the Company's current safety, health production platform and new living quarters
and environmental standards by installing new · Provide new utility systems on new living platforms and remove existing escape
living quarters and flare platforms to reduce quarters platforms. capsules.
risk to personnel, increase equipment integrity
and reliability for long term operation, and de- · Replace some existing utility systems on · Install new Switchgear/MCC/UPS building.
bottleneck existing plants of the Etim and Inim production platform with new facilities on
production platforms to increase production. new living quarters platforms.

4
2006 Q1

NIGERIA WITH PARTNER NETCO by Uri Nooteboom and Vance Williams


The Etim, Inim and Utue production platforms The Etim Facilities
were installed in 1972 and although these plat- Etim facilities consist of
forms are well past their original design life four wellhead platforms
they continue to operate to this date. MPNU and a production plat-
has decided to give a new lease of life to these form, located in 105 feet
platforms by upgrading them to comply with of water.
the Company's current safety, health and envi-
ronmental standards. The Inim Facilities
Inim facilities consist
The EIU SHE Upgrade Project work scope of two wellhead platforms
consists of both Greenfield and Brownfield and a production platform.
work at each of the three platforms.
The Utue Facilities
The Etim, Inim, and Utue production plat- Utue facility is a three
forms (PP's) are located offshore Nigeria in platform complex.
OML-67 & OML-70 lease blocks approxi-
mately 40 to 50 km south of Que Iboe INTEC in Nigeria
Terminal (QIT). The platforms were installed
in 1972 in water depths ranging from approxi- It is a privilege to collaborate with NETCO The challenge is a rewarding one, indeed. The
mately 85 to 120 feet. Each PP receives well on this important FEED project. EIU project represents the first in a growing
stream (FWS) production from two or more commitment to building INTEC's Nigerian
capability. INTEC Consulting and
Engineering Services Nigeria Ltd was created
to develop our own local expertise. Our first
employees are in Lagos working on projects
for Shell, also in collaboration with NETCO.

Our team in Lagos is seen here at their "first annual" Christmas dinner. Our team members
are Vance Williams, Mark Wieland, Ron Rayford, Frans Blaas, Lorrey Muellenberg,
Ali Zada and Mike Hamlin. Not pictured is new team member Mark Mueller.

wellhead platforms (WHP's) and has topsides Vance Williams leads our eight person INTEC
facilities including two phase separation, oil team. Included in our responsibility is training
pumping, power generation, utilities and living and sharing technology. Vance brings experi-
quarters. Oil and water are pumped to QIT via ence from previous Lagos based projects that
pipeline. There are no gas compression facili- contributes to understanding the requirements
ties; all gas is flared. and the comparatively new challenges of
delivering a world class FEED solely in
Nigeria. Vance Williams visiting a
church school in Lagos
5
CRUDE OIL RECEIPT FACILITIES PROJECT by Julia Yusoff
Kochi Refineries Limited (KRL) is a sub-
sidiary of Bharat Petroleum Corporation
Limited, an undertaking of the government of
India. KRL has proposed to set up crude oil
import facilities consisting of an offshore
Single Point Mooring (SPM) System in the
Arabian Sea off Cochin, a Shore Tank Farm
(STF) at the Cochin shore and an offshore /
onshore pipeline system connecting the SPM
to KRL through the STF.

The STF, including the shore tank farm, is


proposed to be set up at Puthuvypeen at the
sea shore at Cochin, about 24km away from
KRL. The SPM is proposed to be located at
about 19.425km west from Puthuvypeen in
the Arabian Sea.

The tanker terminal and pipeline facilities SPM and Pipeline System
will basically consist of a Single Point
Mooring (SPM) and a 48-inch nominal out- INTEC Scope of Service Project Status
side diameter submarine pipeline to handle
offloading of tankers up to VLCC of 300,000 KRL has appointed INTEC Engineering as INTEC has almost completed detailed engi-
DWT including a double banking and lighter- the Project Management Consultant for the neering of the project and is now in the
age option. subsea part of the project. The project is process of floating RFQs for various activi-
planned to be commissioned in the second ties. RFQs for line pipe, SPM system, hoses,
In addition, there are two (2) 30-inch nominal quarter of 2007. anti-corrosion coating and concrete coating,
outside diameter backwater pipeline sections and third party authority (TPA) have already
linking the onshore pipeline. The sections are INTEC scope of services includes: been floated. A line pipe manufacturer has
approximately 0.6km and 3.0km long. The · Project Management Consultant for the been selected and the P.O. has been placed.
prevailing depth along the backwater sections offshore and backwater section Discussions are ongoing with the two select-
is in the range of 1m to 2m. · Detailed Engineering ed vendors for the SPM system. The offshore
installation contract is expected to be awarded
· Procurement Support in April 2007.
· Construction Management
· Pre-Commissioning
· Commissioning Services

6
2006 Q1

Employee of the Quarter


Mauricio daCosta
Mauricio has more than 25 years in the He has been a key player in the process to
offshore industry. His background in subsea develop the subsea design for Chevron
systems engineering covers the full scope of Frade, and his role will be even more signif-
subsea completion equipment hardware. He icant as the project moves forward into the
holds a BSME from the Catholic University execution phase in the 2nd quarter of 2006.
of Petropolis, Rio de Janeiro, Brazil.
Mauricio was born in Rio de Janeiro, Brazil
Mauricio joined INTEC in the Houston and has international experience having
office in March 2004 and has been responsi- worked in France, Zaire and Angola. He
ble for supporting multiple projects as lived in Houston from 1990 to 2000 then
Subsea Team Lead. He also provides techni- moved to Rio for a project assignment. He
cal support to INTEC Brazil in developing returned to Houston in 2003.
expertise in subsea equipment hardware.
Mauricio spends his free time windsurfing
or playing tennis.

SUBSEA AWARENESS IN PERTH by Kevin Mullen

In October 2005, the The course was actually oversubscribed, but the numbers attend-
Australasian branch of the ing had to be kept down because of space limitations at the differ-
Society of Underwater ent offices and sites where the course was delivered.
Technology ran a Subsea
Awareness Course in One of the delegates said the high point of the course was "having
Perth, Western Australia. presenters from different companies - it kept the course dynamic
It followed the format and gave a broad overview of subsea technology and industry."
which has proved success- Most of the presenters were locally based, but some traveled from
ful in other SUT centres the UK specifically for the course. Another delegate concluded
such as Aberdeen, Houston "Nice coordination of a lot of speakers and different backgrounds.
and London. Very smooth for first time Down Under."

A session on the final after- And what did the SUT think? Well, after they had reviewed the
noon was presented by Feedback Forms over the weekend, we received profuse thanks,
Kevin Mullen of INTEC and an invitation to repeat the course twice next year!
Engineering Perth and
addressed "The Subsea
Challenge." It focused on High Temperature and Pressure design
issues, Assets in the Abyss, and Challenges of Long Distance
Tiebacks. It also took a look at the impact of computing and data NEWSFLASH
management on oil industry activities (the e-Field). Kevin compiled
his presentation with the assistance of material from Vince Vetter INTEC is pleased to announce the
and Tom Choate in Houston. continuation of the Congo River Crossing
The five-day course was attended by 18 delegates from local and
Project into Pre-FEED Completion Phase.
international oil companies, from consultancies, service companies,
and equipment providers, and from regulatory authorities.

7
Q 1 2 0 0 6

INTEC Participates in Subsea Tie-Back Forum


INTEC participated in the As exploration and production activities
fifth annual Subsea Tie- move into deeper water farther off the conti-
Back Forum held at the nental shelf, subsea tie-backs are the
Moody Gardens Hotel in development solution of choice. INTEC has
Galveston on March 1-3. been a leader in this field, providing subsea
This highly successful event is tie-back related engineering around the world
organized by PennWell and including such firsts as the world’s longest
was attended by more than the deepest subsea production facilities, the
1300 engineers and managers deepest pipeline, and the first multi-phase
involved in deepwater oil and subsea meter.
gas field developments.
Participation has grown tremen- INTEC's Bruce Crager and Steve Cochran
dously since 360 engineers and serve on the forum advisory board. INTEC
managers attended the first will also participate in the next Subsea Tie-
Forum held in 2001. Back Forum, scheduled to be held February
27 to March 1, 2007, at Moody Gardens
Hotel in Galveston.

INTEC Conference Highlights at OTC


May 1-4, 2006 Booth 2317
Event:
Tuesday, May 2 Media Conference
11:00 am Topic: Offshore Arctic Development

Technical Papers:
Monday, May 1 Advances in Riser and Umbilical Technology
2:00 pm 18202 Dynamic Analysis of Pipe-in-Pipe Steel Catenary Risers with Direct
Modeling of Structure Interaction C. Masson, J. Fang, D. Jordon, P. Hayes

Tuesday, May 2 Deepwater HP/HT, HIPPS, and Thermal Performance


9:30 am 18169 Commissioning and Startup of the Caesar and Cleopatra
Mardi Gras J. Wiseman, S. Saner, BP.

Wednesday, May 3 Deepwater Steel Catenary Risers


2:00 pm 18180 Wave-Loading Fatigue Performance of Steel Catenary Risers
(SRCs) in Ultra Deepwater Applications J. Fang, S. Jesudasen, J. Xu

2:00 pm 17912 Safety Factors for Ultra Deepwater SCR Handover Operations
S. Jesudasen, P. Olden, K. Dyson, J. Hoose

2:00 pm 18312 Subsea Construction, Repair, Commissioning and Operation


Free-Span Remediation Studies for the K2 Pipe-in-Pipe
Flowlines C. Routh, E. Eigbe, M. Fletcher, M. Hensley, D. Ling

Australia · Brazil · Malaysia · Mexico · The Netherlands


United Kingdom· United States

www.intecengineering.com

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