Summer 2001
Featuring:
Shell Bonga Project Proyecto Tigre in Argentina Petrobras Guanabara Bay Loading Line Note from the President Asian Gas Grid
3D Bottom Roughness Farewell From Bert Schultz Employee of the Quarter Deepwater Pipeline Conference Private Sector Initiatives
INTEC Regatta 2001 OTC 2001 OMAE 2001 Deeptech Seminar Clean Energy Round Table
Shell Bonga Project
Shell Nigeria Exploration and Production Company Ltd (SNEPCO) has recently entered into a number of major Engineer, Procure, Install, and Commission (EPIC) contracts for the much anticipated development of their deepwater BONGA Field Development. The contract for provision of the gas export pipeline, flowlines and risers was awarded to Stolt Offshore Services SA, who had been working with INTEC and others for many months to secure this prestigious project.

Project Overview
The BONGA Field is located southwest of Warri, about 90 km offshore Nigeria in approximately 1,100 m water depth. The current development includes a permanently spread moored FPSO, to which ten 10-inch and 12-inch diameter production flowlines will transport multi-phase hydrocarbons from subsea wells via eight steel catenary risers (SCRs). Treated seawater will be injected into the reservoir using three 12-inch diameter water injection flowlines to a number of subsea injection wells. Produced oil will be transported from the FPSO to shuttle tankers via a Single Point Mooring (SPM) System. Processed gas will be exported to the Offshore Gas Gathering System (OGGS) RP1 Platform located in shallow water using a 16-inch diameter gas export pipeline, approximately 92 km in length.

Scope of Services
In March 2001, INTEC commenced the detailed engineering design on behalf of Stolt Offshore Services S.A. as part of a combined engineering team. INTEC’s primary responsibilities include: layout of the infield flowlines, export pipeline route selection, flow assurance of the gas export pipeline and water injection flowlines, detailed mechanical design of the gas export pipeline, water injection flowlines, and all activities required for the detailed design and qualification of the SCRs. INTEC is also responsible for input into Stolt Offshore’s procurement packages including the preparation of material specifications, requisitions and performance of technical bid evaluations.

Field Layout
A significant element of the early work on the project has been the development of the field layout. Bonga FieldThe local topography is dominated by a large channel that traverses the development area, and in the northern area, mud volcanoes rise approximately 100 m above the seafloor. Evidence exists for the widespread occurrence of shallow gas and there are numerous large depressions and deep pock-marks, gas chimneys and carbonate concretions. Studies performed by the Norwegian Geotechnical Institute (NGI) and SNEPCO indicated many areas where geo-hazards excluded or restricted drilling activities and the placement of subsea facilities. In addition to geo-hazards, the field layout must also consider other facilities within the development, e.g. well locations, umbilicals, man-ifolds, FPSO and SPM moorings, and significant interfaces with SNEPCO and other development contractors is ongoing. Another important consideration is the tension induced by the SCRs, which have been shown to influence pipeline and flowline spanning, axial stability of the flowlines and stability of the flowline curves.

Steel Catenary Risers
One of the most challenging aspects of the project is undoubtedly the detailed design of the SCRs. This is the first time that SCRs will be installed on an FPSO, and the SCRs will be the first for West Africa. The SCRs encompasses eight (6 x 10-inch and 2 x 12 inch) production flowline SCRs, two 12-inch water injection SCRs and one 16-inch gas export SCR.

The SCRs will be connected to the BONGA FPSO by flexible joints that are to be designed to fit a one-size receptacle. All SCRs have the same departure angle of 15 degrees. The SCR detailed design will include static analysis, extreme and survival dynamic analysis, vortex induced vibration (VIV) fatigue analysis and random wave seastates fatigue analysis. Interference and clashing analysis between two adjacent SCRs, and between an SCR and a gas lift riser or an umbilical will also be investigated. Fracture mechanic assessments, and design and coordination of the fatigue test pro-grams for the SCR welds are also part of INTEC’s scope of work.

Project Team
The INTEC project team has quickly grown to include 20 full and part time personnel led by Andrew Brady (Project Manager), and assisted by Steve Lee (Engineering Manger). The pipeline/flowline team includes Terence Tan, Angus Reid, David Raby, Thomas Avery and Jennifer Bell. The SCR design team is led by Basim Mehka and includes Uwa Eigbe, with John Shanks as Technical Advisor. Nick Sinnet provides flow assurance support, David Kim is responsible for structures, QHSE issues are the responsibility of Steve Grieves and Peter Grumley, and the Project Designer is Timothy Palombo. The Project Services team is led by Jim Lentz, and includes Lynda Farley and Rachell Allen. Other INTEC personnel provide specialist input in support of materials, subsea and safety issues.

INTEC maintains a close working relationship with Stolt Offshore through their permanent in-house representative, Mike Fitzpatrick.

The current phase of INTEC’s involvement in the project is planned for completion in June 2002, although potential involvement in procurement and construction support may extend INTEC’s involvement into 2003.

Proyecto Tigre in Argentina - EPC Contract Management by INTEC

The INTEC office in Argentina is working on the Proyecto Tigre Project, one of the largest ongoing onshore engineering projects in the Argentinian oil and gas industry.

The project consists of a 168 km long 22-inch diameter crude oil pipeline from Brandsen to Campana, in the Province of Buenos Aires. The facilities at Brandsen comprise three 20,000 m3 storage tanks and a 660 to 850 m3/h pumping station, with all associated buildings and ancillary systems. The crude oil has a design viscosity of 250 centistokes at 20 ºC. When the project is completed (by the middle of 2002), the system will transport oil through an existing terminal and pipeline to the new facilities, onward to the ESSO Refinery in Campana.

The client, (Oiltanking EBYTEM), has been working on the project for five years. INTEC’s participation, which started three years ago, includes the following: Design Basis, Pipeline Route Survey and Route Selection, Special Pipeline Crossings Evaluation, Pipeline Alignment Sheets, Pipeline, Storage Tanks and Pumping Facilities FEED, Pipeline Diameter Optimization Studies, Tender Document Development, Assistance During Bidding Process, and the Environmental Impact Assessment.

The new pipeline system will partially eliminate transportation by small tankers along the Paraná River, reducing environmental risks. Leak detection systems and 24-hour SCADA monitoring will also ensure a more efficient operation of the new system.

Safety and environmental studies were performed by INTEC to comply with provincial and national regulations. In addition, permission had to be obtained from all landowners, public services and official authorities with jurisdiction for the areas affected by the pipeline right-of-way. This process required a year to complete, visiting every single property along the way, and getting in touch with every owner.

INTEC is subsequently assisting Oiltanking with the EPC Contract Management. INTEC responsibilities include: Engineering Revision, Construction Inspection, Procurement Supervision, Fabrication Inspection, Tests Control, FAT, Commissioning and Start Up Supervision.

PETROBRAS Guanabara Bay Loading Line

INTEC Engineering is currently completing the detailed design for a new hot oil pipeline project to an existing tanker loading facility in Guanabara Bay, Rio de Janeiro, Brazil. The 15-km long, 18-inch diameter pipeline for PETROBRAS will utilize an unusual pipe configuration to address the potential for upheaval buckling in varied offshore/overland geotechnical conditions. The very soft soil conditions in a large tidal flat area were of special interest when performing the design calculations to DnV OS-F101 fatigue criteria over a planned 40-year service life.

Bryan Hartman (INTEC Onshore Facilities Business Unit Manager) and Jose Alberto Costa dos Santos (PETROBRAS Project Manager) reviewed the tie-in plans to existing refinery piping facilities at the beginning of the new PE-3 Pipeline. The planned route then proceeds across two sections of Guanabara Bay and two islands before dividing and extending to two fixed offshore tanker berths.

The second island crossed by the proposed alignment, Ilha d’Agua (Water Island in Portuguese) includes a tank farm used in the terminal operations. Loading LineTRANSPETRO will operate the pipeline from the control room on this island. Glenn Lanan (INTEC Senior Project Manager, on left) and Alex Mayants (INTEC Project Manager) are seen examining the rocky shoreline site for one of the three shore crossings on Ilha D’Agua.

Diego Lamacchia (INTEC Project Engineer) has been stationed in Rio de Janeiro as a Project Technical Coordinator through the detailed design work which coincide with Carnival and peak tourist season. When asked, Diego characterizes the project, people and location as “Otimo!” (great in Portuguese). Even now, with the onset of winter in the Southern Hemisphere, Diego still finds time during the weekends to go to some of the beautiful beaches in and around Rio. The next phase of INTEC’s project work includes construction contracting support, and continued support through procurement, permitting and field construction work.

A Note from the President
We place a lot of emphasis these days on efficient storage and retrieval of information so we can do our work better and faster, and at INTEC we continue to work on our support systems, infrastructure and knowledge management for this purpose. A Note from the PresidentThis effort will improve our ability to get and use the right information at the time it is needed. At the same time, as engineers and technical people, we must not lose touch with the physical world in which we are doing our projects by believing that systems and computer programs is all that is needed to get the best result. I was reminded of the fact that engineering has been (and still is) an art during a recent long walk in the French countryside.

The map of the Auvergne region identified a bridge across the river Viaur as a landmark. I assumed this would be one of the bridges designed by Gustave Eiffel, the French engineer who left us the Eiffel tower. It turned out that the design of this one had been the subject of a design competition and that a gentleman named Paul Bodin beat out Eiffel and was awarded the contract. The design was made around 1888, and the bridge was completed in 1902. It spans the Viaur valley most gracefully, but it was the design concept that impressed me, as it consisted of two independent balanced space frames resting on hinged supports. They form arches by a hinged connection making the whole system statically determinate!

The space frames are built up out of trusses made of riveted steel shapes (the literature claims that over a million rivets were placed by hand). BridgeContrary to the Eiffel tower which is made of cast iron, this was one of the first applications of steel and allowed the designer to achieve the longest span in a steel arch type bridge in France: 220 m.

The most amazing thing is actually that this design was accomplished without the use of modern analytical techniques, let alone computers. It required the engineer to develop an intuitive feel for how the forces and stresses would flow, and how to apportion the material, based on experience and working with scale models. It is evident that engineering in those days was an art, and one has to admire those early pioneers. However, even today it is important that we not lose this feel for the physical reality of our design solutions. While we must use analytical techniques and computer programs for greater precision and to accelerate the progress of work, we should still look at the result with a critical eye and make sure that it is not only mathematically correct, but also feels right. Let’s keep in mind that engineering remains an art, and strive for solutions that have the elegance of Paul Bodin’s Viaur bridge.

W. J. Timmermans
President

Asian Gas Grid
A Pipeline From Southeast to Northeast Asia

INTEC Engineering has been working with the PEG, the Partnership for Equitable Growth, a non-profit organization set up by the APEC Business Advisory Council, to develop a clean energy strategy for APEC economies, particularly those in Asia. One of the projects undertaken by PEG is to harness the vast amount of gas reserves in the Southeast Asian region (Indonesia, Malaysia, Thailand and Vietnam), and transport the gas via a large diameter pipeline to China, where it is anticipated that a shift to the use of natural gas is necessary as part of China’s clean energy policy.

Currently, the project plans to obtain gas from Natuna Alpha D, where gas reserves in place are estimated to be approximately 222 trillion cubic feet (tcf). Asian Gas Grid MapAllowing for removal of carbon dioxide, it is estimated that the reservoir contains approximately 46 tcf of sales quality gas. This volume can satisfy two requirements; the supply security into the TRANS ASEAN GAS network, a system of inter and intra pipelines planned to ensure gas supplies to ASEAN countries, and a supply of approximately 2,000 million standard cubic feet per day (mmscfd) to China for at least 25 years.

Studies by INTEC have shown that a pipeline from Natuna Alpha D to the JDA (Joint Development Authority of Malaysia and Thailand) and then to the Nam Con Son area, Danang (Vietnam), Hong Kong, Fuzhou and Shanghai (China) is feasible. It is estimated that a 48-inch diameter pipeline approximately 5,000 km long with several compression facilities along the route will transport 500 mmscfd of sales quality gas to Fuzhou, China and another 1,500 mmscfd to Shanghai, China. The logistics of the pipeline system will be immense, and will create significant opportunities for economic advancement in the region. For example, the project will require 4 million tonnes of steel, 420,000 pipe joints to be coated with anti-corrosion and concrete weight coating and approximately 40,000 joints with sacrificial anodes. A fleet of construction vessels will be required for approximately 4 years to install the pipelines and offshore compression facilities.

The project will now move into feasibility and FEED stages, with a gas delivery date targeted before the end of this decade. This schedule provides for sufficient time to develop the Natuna Alpha D reservoir, and also to manage the logistics of installing a 5,000 km large diameter gas transmission pipeline system.

INTEC is very proud to be associated with the PEG to develop this prestigious international project. Dr. Shafiq Abdullah, CEO of PEG, and Lim Man Onn, the Project Coordinator are the driving forces behind this project. Steve Lee led the INTEC team until his transfer to the INTEC Houston office. The baton has now been passed to Dr. Shahreen Madros, INTEC KL Director, David McKeehan, INTEC Senior Vice President, and Indu Mahendran, INTEC KL General Manager, are key proponents of this project, and attended the Asian Gas Grid Round Table held recently in Kuala Lumpur.

New INTEC Capability: 3D Bottom Roughness

INTEC has developed new pipeline routing software capabilities to remain on the leading edge of pipeline technology. Richard Snepvangers, INTEC Delft Project Engineer, has completed the first 3D bottom roughness analyses for the Norsk Hydro Ormen Lange Field Development using a model developed in ANSYS. The model was successfully completed with the support of Dr. Janardhanan’s, INTEC Senior Engineer, previous work at INTEC Houston on similar software initiated for the BP Mardi Gras Project.

INTEC is completing routing and layability studies with Heerema Marine Contractors for the Ormen Lange Field Development. Dual 30-inch gas production pipelines will be routed across the toe of the ancient Storegga Landslide. The seismically triggered slide occurred approximately 7,000 to 8,000 years ago, and is well known for the resulting tsunami that washed over Scotland and other North Sea coasts.

The Client, Norsk Hydro, has large concerns over pipeline spanning and the feasibility of required mitigation techniques as early conceptual studies identified 400 meter long spans with separations of up to 20 meters. The terrain encountered in the Ormen Lange Project will continue to challenge INTEC’s routing expertise and experience developed during the Malampaya (offshore Philippines) and Blue Stream (Black Sea) Pipeline Projects. The Storegga Area is considered the worst pipeline route terrain encountered to date, and therefore the ultimate challenge.

ANSYS Model
3D View
The ability to perform bottom roughness analysis in 3 dimensions (instead of the conventional 2D analysis of OFFPIPE) means that we are able to model the interaction of spans, global buckling (upheaval and lateral), and variable seabed terrain. The ANSYS model provides the ability to track the load history of the pipe from installation, hydrotesting and operation. This allows the plastic strain history to be “remembered” from one load step to the next, resulting in an enhanced estimate of critical spans. The pipeline position, both vertically and horizontally is tracked throughout the loading history, providing a powerful tool for assessment of the stability of curves and pipeline sections on side slopes.
A Fond Farewell From Bert Schultz

Bert Schultz After 30 exciting and challenging years in the offshore oil and gas industry, I will be leaving INTEC at the end of June to pursue opportunities in community outreach ministries. I want to express my sincere appreciation and gratitude to all those persons and companies who provided opportunities for me to participate in many very rewarding offshore projects located throughout the world.

I thank Texaco for my initiation into the offshore industry during my first years after graduating from the University of Nebraska. Going offshore for the first time was quite an experience for a ‘farm boy from Nebraska’. I was thrilled to be part of the design, fabrication and installation team for the first platform installed offshore Texas after the first federal offshore Texas lease sale in 1967/1968, followed by several years in the Texaco Central Offshore Engineering Group located in New Orleans, an exciting historic port city.

I thank Fluor for the opportunity to be part of the design, fabrication and installation team for the world’s first offshore LPG facility located offshore Indonesia. The project included the world’s first LPG FSO system, my beginning in offshore terminal projects and the first of many international assignments. I also want to thank Fluor for the opportunity to be the Engineering and Construction Manager for the Louisiana Offshore Oil Port (LOOP) Project, the first deepwater terminal in the United States.

I want to thank Bob Brown for the opportunity to work at RJBA and Associates and help form an Offshore Terminals and Floating Production Systems Group. While at RJBA, I met Willem Timmermans, Jim Gillespie and David McKeehan. After 4 years together at RJBA, we became partners in the formation of INTEC Engineering, my most challenging and rewarding opportunity. After a 21-year association with these three extraordinary individuals, I cannot thank them enough for their unwavering friendship, support and exemplary professionalism.

To all my friends at INTEC, I thank each of you for the time we have spent on numerous projects, for the memories of milestone projects in Taiwan, offshore Western Canada and the Gulf of Mexico. To all my friends in Malaysia, thank you for your support and efforts in helping me establish the INTEC office in Kuala Lumpur. Most of all, I want to thank my wife Karen, who has been at my side through all the ups and downs of the international offshore oil and gas industry, an industry whose challenging projects, world renown companies and exceptional staffs I will fondly remember all the days of my life. Thank you, one and all!

Richard Snepvangers - Employee of the Quarter

Richard Snepvangers Originally an employee of Petergaz working on the BlueStream project, Richard Snepvangers joined INTEC Delft during the course of the project in 1998.

The way Richard deals with formulas or FEA packages and imagines the objects being stressed can often be very enjoyable to the onlooker. He has been the main man behind the programming from the Heerema J-lay collar design tool to the piling analysis tool, not to mention the work he did on the Blue Stream Pipeline behavior in response to various strange flows and soil movements along the continental slopes. What makes us particularly proud is his recent contribution to the Ormen Lange Project. The route area is believed to be the most rugged terrains that pipelines have ever seen. Richard masterminded the ANSYS algorithm plus associated pre-processing bits and pieces succeeding in adding a fully operational 3-D bottom analysis model to the INTEC toolbox. This model works in full 3-D, capable of handling sharp horizontal snaking and vertical seabed sloping. This work has greatly enhanced our capability in bottom roughness analysis, as well as buckling puzzles. Fellow engineers perceive Richard as a world class stress engineer.

When Richard is not stressing about stress analysis, he is taking time for his friends. He is often found jetting around the world in search of the ultimate cultural experience; Easter in Egypt, summer on board a survey vessel surfing the Middle East. At the same time he remains a real Dutch soul and bought a house along a picturesque canal of the historic center of Delft.

Deepwater Pipeline and Riser Technology Conference

INTEC Engineering participated in the 2001 Deepwater Pipeline and Riser Technology Conference held in Houston from March 20 to 29, 2001. Dr. Andrew Palmer, our Corporate Technology Manager, was a principal lecturer for the Marine Pipeline Course, covering topics in design, construction risk and safety, etc.

INTEC engineers Andre Nogueira and Glenn Lanan presented a paper titled “Applications of a Rational Model for Collapse of Deepwater Pipeline,” and Jonathan Jury presented a paper titled “Host Vessel Motion Impacts on SCR Stability.” Aconference also included a Flow Assurance and Operability (FAO) course hosted by INTEC specialists Dr. Steven Cochran and Geir Saether.

PSI (Private Sector Initiatives)
Volunteer Home Repair Program

Every fall and spring, INTEC participates in the Volunteer Home Repair Program organized by Private Sector Initiatives (PSI). PSI HomeSavers is a non-profit organization founded in 1982 by Houston corporate and community leaders to encourage private sector efforts focused on housing revitalization for elderly or disabled homeowners.

Since 1999, INTEC volunteers have been involved with the program, having repaired a total of four homes to date. HouseVolunteers bring ladders, paint brushes, scrapers, and a smile on their face. For the two Saturdays spent working on each home, volunteers get a chance to hone their carpentry and painting skills, while helping others in our community. The volunteers become acquainted with the homeowner, and experience the joy in the homeowner’s face when the project is done.

This last spring, INTEC volunteers worked on Thelma Wade’s home on the Northeast side of Houston. The two weekends were a big success, and Thelma will definitely enjoy her newly painted home and her front porch swing. Individuals who contributed their time and energy included David Brady, Kim Clarke, Jason Falls (Team Leader), Steve Huffer, Michelle Lang, Maureen Martin, Phil Martin, Steve McDaniel, Risa Parker, Umberto Ricciardo, Bert Schultz, Karen Schultz and Jason Taylor.

INTEC Regatta 2001

INTEC Engineering held its second Regatta in Galveston Bay on April 28, 2001. INTEC Regatta 2001 featured eight boats of various classes and more than 50 employees and guests. The fleet was a mixture of privately owned and chartered vessels in the 27 ft. to 33 ft. length range. INTEC personnel skippered all but two boats, and all boats were crewed by INTEC employees and their guests. The INTEC Delft office was represented by its General Manager, Martin Bruins, as one of the skippers.

House The day of the regatta broke crystal clear with light winds of 3 to 5 knots. Not the best sailing conditions, but good conditions nonetheless. However, just after the starting horn, the wind came up to 12 to 15 knots for the entire race. With favorable wind, there was lots of racing and good fun. Several boats fought back and forth for position throughout the race.

Following the regatta, INTEC hosted a “Shrimp Boil” for all employees at a nearby marina. The atmosphere was great, the sunset was beautiful, and the food was excellent.

If measured by fun and smiles, the INTEC Regatta 2001 was a great success. We had more boats and more crews than the last Regatta in 1999. We had participation from other offices with Delft taking home one of the trophies. There was plenty of food and good company.

OTC 2001

The 33rd annual Offshore Technology Conference, running April 30 to May 3, 2000 in Houston, was well attended this year, with a total of registered attendees in excess of 47,500.

OTC 2001 In addition to our exhibition booth, three papers were presented by INTEC engineers. Glenn Lanan, John Ennis of BP Exploration, Patrick Egger of Houston Contracting and Kenneth Yockey of Alaska Interstate Construction, participated in the conference by presenting a paper titled “Northstar Offshore Arctic Pipeline Design and Construction,” OTC 13133. “Canyon Express Field Performance Simulation,” OTC 13131, was coauthored by Ravi Gudimetla and Bryan Wallace of Marathon Oil Company. Geir Saether, Ravi Gudimetla and Bryan Wallace presented a paper titled “Canyon Express Slugging and Liquids Handling,” OTC 13073.

The highlight of this event for INTEC was the presentation of the Special Meritorious Award For Engineering Innovation at our booth on April 30, 2000 by Hart’s C&P Magazine to INTEC’s BP Northstar Project Team, represented by Glenn Lanan.

OMAE 2001

The 20th International Conference on Offshore Mechanics and Arctic Engineering was held in Rio de Janeiro, Brazil from 3 June to 8 June, 2001. INTEC presented two papers at the Conference Offshore Technology Symposium. The first paper, “New Frontiers in the Design of Steel Catenary Risers for Floating Production Systems,” was presented by Basim Mekha. The second paper “The Modern Field Development Approach,” was presented by Antonio Critsinelis and has been accepted for publication in the Journal of Offshore Mechanics and Arctic Engineering.
Deeptech Seminar

In April 2001, INTEC presented a paper titled “The Role of Flow Assurance in Deepwater Field Developments” at the Deepwater Production Technologies Seminar held in New Delhi, India. The seminar focused on new deepwater blocks being released by the Indian Government, and was attended by over 350 delegates.
Clean Energy Round Table Summit

INTEC Engineering was invited to participate in a round table summit on Clean Energy Initiatives chaired by the Prime Minister of Malaysia, YAB Dato Seri Dr. Mahathir Mohamed. Also attending the summit were the President and CEO of Petronas and the Chairmen of Shell Malaysia, and other prominent members from the oil and gas industry from all the APEC countries. INTEC KL (Kuala Lumpur) General Manager, Indu Mahendran presented a paper titled “Asian Gas Grid Infrastructure Delivery System, Techno-Commercial Issues.” David McKeehan, INTEC Senior Vice President, and Dr. Shahreen Madros, INTEC KL Director, also participated at the table summit.
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