Winter 2002
Featuring:
Knowledge Sharing Canyon Express Project IT Investments Communication Buoy
Flow Assurance BP Charity INTEC Teaches HMC S-Lay Study
Note From The President Delft: The Place To Be Employee of the Quarter Ferguson Joins INTEC
Knowledge Sharing: The Wind in INTEC's Sails
INTEC Focuses on Knowledge Sharing, Creation
Free and open sharing of knowledge is a cornerstone of INTEC's continued success. INTEC thrives on developing and delivering creative and innovative technical solutions for its clients, as well as applying what we already know in new situations to efficiently manage and engineer projects.

INTEC's four founding partners (Willem Timmermans, Jim Gillespie, Bert Schultz, and David McKeehan) constantly shared and increased their complementary knowledge of offshore industry technology, practices, and clients. Working closely, they carefully catalogued each major document they produced with key words (today's metadata) so it could be easily retrieved. Bert Schultz and David McKeehan talked at lunch almost every day and ran three miles together twice a week. "Knowledge sharing was almost visceral in those days," McKeehan says. "We'd have arguments and challenges in the middle of the woods - and some of them really improved our speed."

The company's growth from four people in one office to more than 550 people in 10 offices (plus numerous additional locations) around the globe has provided a lot more knowledge to share, and made sharing more complex than going for a run or shouting around the corner. Both formal and informal processes are in place and under development to ensure knowledge sharing and growth continue as the company's size increases.

INTEC's knowledge sharing and growth processes include exploiting resources such as AskINTEC to find and share knowledge for our clients' benefit. They also support a culture that rewards knowledge sharing and work processes that sustain knowledge creation and documentation.

Sharing knowledge is accomplished within the context of another cornerstone of INTEC's success: exhibiting the highest levels of honesty and ethical standards in all that we do. INTEC maintains the confidentiality of client information and controls access to confidential or sensitive information from multiple clients. INTEC project and document control procedures address these issues in specific circumstances and codify the values of integrity and ethical practice that underly all INTEC actions.

INTEC realizes that different knowledge items have different values (and the values can change over time). To address this issue, we've developed and are in the process of implementing INTEC's Knowledge Hierarchy so different levels of authority and trust can be assigned to different items.

As projects increasingly are executed by people in multiple locations around the world, global knowledge sharing has transitioned from optional to essential for basic project work. To meet project requirements, INTEC has invested considerably in beefing up its IT infrastructure for efficient global retrieval - providing the basis for secure, reliable, cost-effective access to INTEC electronic resources in any location from any location.

Canyon Express Project: Production Update

Since "first gas" in September of last year, the Canyon Express field operators (TotalFinaElf E&P USA, BP and Marathon), supported by the INTEC project team have been busy completing the hook-up and commissioning of remaining wells, and starting production from these. Activities included the installation and testing of well jumpers, connection of controls and chemical injection functions to each tree, and commissioning of the platform systems supporting subsea production.

Well jumper installation was carried out by Sonsub from the vessel 'Midnight Hunter' under the guidance of INTEC's Howard Jones and Todd Riley, and included well jumper connection to Marathon Oil's well MC348-1, the world's deepest production well (7,209 ft).

TTotalFinaElf powered up and commissioned the subsea electrical and hydraulic systems, and methanol flushing for each well with the assistance and expertise of INTEC's Paul Martyniak and Monteiro Neto. Close coordination was required between platform personnel and installation/ROV vessel personnel to ensure safe operations and efficient movement of vessels.

Once prepared, each of the 9 wells was started up in accordance with the development's Operating Guidelines and the Operator's desired starting sequence.

Onshore, support activities from the INTEC project team in Houston, led by John Stearns, kept commissioning and start-ups on track.

Various problems were encountered during the well commissioning and start-ups. However, INTEC assisted TotalFinaElf with tackling the issues and modifying operating procedures where required and all wells were finally brought on line. Gas production rates have reached in excess of 450MMSCFD.

After the start-up of all wells, the INTEC team continues to support TotalFinaElf, with flow assurance and subsea expertise. After start-up of the wells, INTEC's Ravi Gudimetla provided TotalFinaElf with detailed information on the best ways to ramp up production from the new wells, calculate methanol requirements, and manage liquids from subsea. The INTEC team also prepared a comprehensive set of Intervention Work Packs (IWPs) to enable the operators to rapidly and effectively mobilize ROV support vessels and carry out subsea interventions.

Following the transition from the main project to an operations support role, the new work scope required of INTEC includes continued flow assurance and subsea intervention support, and now also includes the generation of an Inspection, Maintenance and Repair (IMR) system for the subsea system.

IT Investments Support Efficient Global Capture and Retrieval

INTEC's information technology (IT) infrastructure has one important goal:

Share INTEC knowledge worldwide to meet project and client requirements

This means INTEC will have the:

  • Right information (from anywhere), at the
  • Right time (24x7), in the
  • Right place (to anywhere), for the
  • Right person (remote or local), at the
  • Right cost, both
  • Securely and reliably
To serve its clients well, INTEC must address many IT issues generally associated with much larger companies - security, multiple and global locations, remote locations, changing project membership, large graphics files, rapidly changing technology coupled with increasing price-performance in telecommunications and processing speed - but without the extensive IT budget and staff of larger companies. INTEC maintains an IT infrastructure that is both cost-effective and responsive to ever-changing project requirements.

At least one INTEC office is open at any time of the work week. Sharing IT knowledge and resources across INTEC locations allows for 24x7 global operations, a feature usually available only in much larger companies. INTEC's global approach to IT also allows global monitoring of and support for IT performance in all locations.

Central to INTEC's global IT infrastructure is an internet-based Virtual Private Network (VPN) that securely and effectively connects INTEC offices and personnel worldwide as though all resources and people were in one location. This feature enables knowledge sharing and truly global project execution.

The VPN also provides secure access and virus protection from two vendors at three levels: firewall, server, and workstation. INTEC does not allow e-mails with executables, thereby substantially reducing the risk of damaging worm-style viruses. These safeguards allow INTEC to operate securely, while facilitating knowledge sharing.

Project team members and other colleagues working in different INTEC offices can connect via NetMeeting to take advantage of simple videoconferencing, whiteboarding, and application sharing. International teleconferences and meetings can be scheduled via Exchange and Outlook. Traveling users can log into a networked computer in any office and have immediate access to their home office resources.

What's next? Plans include further exploiting the VPN technology for online conferencing, better data storage management, additional global redundancy, faster backup and recovery capability, more efficient use of bandwidth - all leading to better, faster, lower-cost projects for INTEC clients.

Communication Buoy Replaces Control Umbilical
INTEC's Perth office recently completed a conceptual study for the application of a disc shaped buoy, termed 'Disc Control Buoy' for a 2-4 well subsea gas development offshore Victoria, southeastern Australia. The buoy, located in 130 m water depth, is subjected to severe sea states and is proposed as an alternative to a 65 km control and chemical injection umbilical from shore. The Disc Control Buoy is similar to a conventional SPM although its structural arrangement, including bilge keels, is configured to minimize roll/pitch motions.

The buoy control system allows remote control of the field from the onshore processing facilities 65 km from the mainland. The subsea development is linked to the Disc Control Buoy which houses the power generation, electronics, fluids, pumps, hydraulic power, control system and communications packages. The normally unmanned facility provides full field control via the communications link from the onshore plant. The buoy equipment is of proven design and virtually everything on this facility can be interrogated or controlled remotely. To achieve the field availability of 97%, proven reliable components are combined with sufficient redundancy or backups to avoid total system failure.

The Buoy layout and orientation were driven largely by the following factors:

  • The need to segregate the equipment into a minimum of three areas:
    • Subsea controls, general controls and communications
    • Power generation with diesel generators and batteries–this area is relatively noisy due to the diesel generators and has a battery room requiring particular ventilation
    • Chemical injection–this area is subject to potential chemical spills and must be segregated from other areas
  • Nine external compartments 1.5 m wide to accommodate ship impact at the waterline
  • Motion reduction measures, namely a 'step' above the external compartments to entrain water and bilge keels to increase drag at the edges of the buoy
The resulting buoy layout is a three section circular unit as indicated.

An accelerated project schedule identified that the Disc Control Buoy can be executed in about a 54-week period. Detailed design of the buoy, including detailed specifications for procurement, is expected to take about 28 weeks with fabrication and outfitting estimated at 40 weeks (with about a 12 week overlap between design and fabrication).

Significant cost savings, compared to the umbilical, are obtained during installation of the Disc Control Buoy due to the simple installation methods, analogous to that of a SBM (or CALM buoy).

The buoy consists of the following:

  • Three access towers at 120 degrees, one of which also supports the vents and mast for the telecommunications, navigation aids and weather monitoring equipment
  • Acommunication mast on the northeast tower which has a clear communication path to the onshore facilities to the northwest
  • Ajib on each tower that a chain block can be attached to for lifting equipment when necessary. It is assumed that equipment will be lifted on and off by a support vessel crane
  • An access ladder from the sea at each tower with fenders to protect personnel climbing the ladder
  • The buoy structure consisting of an outer circular shell and an inner ring 1.5 m inside the outer shell which is sectioned into small compartments. This compartmentalized outer section provides strength and protection in case of collision by a vessel
  • Entry to the buoy main compartments via the tower with a water tight bulkhead door providing access to the inner main compartments
The study proved the feasibility of this solution, including:
  • Establishing the overall buoy size and general arrangement
  • Establishing the motions of the buoy in conditions when personnel are expected to board and work in the buoy and during extreme storms
  • Confirming that telecommunications between the buoy and the onshore gas plant has 97% availability
  • Ensuring that the buoy will survive a 50 year return cyclonic storm
  • Establishing the buoy capital cost (CAPEX) and the annual operating costs (OPEX)
Brandon Hughes, INTEC's Study Manager for the work reported that the study has demonstrated that the Disc Control Buoy is a practical and cost effective solution for the development and is considered technically robust.
Flow Assurance & Operability In Deepwater Systems Course

On November 19 & 20, 2002 in Aberdeen, Scotland, Steven Cochran, INTEC's Houston Flow Assurance Group Leader, gave an industry course entitled "Flow Assurance and Operability in Deepwater Systems". Eighteen participants attended the course from operators, equipment manufacturers, engineering and consulting firms, and construction companies. This course covered many areas related to flow assurance and was intended for those who are familiar with subsea design considerations but lacking a solid understanding of flow assurance. The course addressed the issues in a qualitative manner, with relevant and current case studies included.

Flow assurance and operability are central to the design and operation of oil and gas production and transport facilities, particularly so for deepwater production systems. Flow assurance encompasses primary design requirements such as line diameter and insulation requirements as well as the prediction and control of solids, such as hydrates and waxes. Flow assurance must address how the whole production system behaves during various operating modes (startup, steady state, shutdown, rate change, and others) throughout the field life and during the development of operating strategies consistent with the system design.

BP Charity Check

As BP were preparing to wind down their subsea construction activity in the West of Shetlands area of the UK they sent a request to INTEC's London based hardware business unit for an urgent gasket design. After INTEC delivered the typical excellent result in record time, the following letter was received:


John,
Please pass on our thanks and appreciation to all parties involved in the supply of the restriction orifice gaskets. To deliver within 15 days is a fantastic achievement, considering that raw materials had to be sourced, and that a gasket design had to be developed from scratch then manufactured and tested. To add to this, there was a bank holiday weekend mid-way through the delivery period.

In recognition of this outstanding performance we are making an award of £500, to be donated to a charity of your choice. Thanks again for your efforts.

Regards,
Sandy Meldrum
BP Northern Business Unit Subsea Team.


The photograph shows the check being handed over by the INTEC (UK) Managing Director, Peter Roberts to Mr John Archer, Volunteer Development Manager for Tearfund (www.tearfund.org). Mr. Archer mentioned some of the more 'engineering' based aspects of Tearfund's activities such as water and public health. He said that more than 1.1 billion people in the Third World lack access to safe water and Tearfund would commit the donation to drilling programs that assist communities in Ethiopia to improve their own water supply. Being able to help such a worthwhile cause is a bonus to the satisfaction of a job well done.

INTEC Teaches About Subsea Technology in Perth

The University of Western Australia has a mission to be a focal point for high quality oil and gas education, training, and research and development. INTEC in Perth is helping it to achieve this objective.

One of UWA's goals is to meet the current and future requirements of the Australian oil and gas industry for professional engineers by providing university courses tailored to industry needs. INTEC engineers are assisting UWAby bringing their expertise and professional experience to the subsea technology module, which forms part of the prestigious Master of Oil and Gas Engineering course. This module receives backing from across the industry, but INTEC provides four of the eleven lecturers, with the encouragement and support of general manager Steve Hindmarsh.

The new INTEC lecturers, assembled presentations and delivered them for the first time in 2002: Martyn Witton (subsea connections and tie-ins), Stuart McKay (installation and fabrication), and Laurence Upston (manifolds). Kevin Mullen has lectured at UWA since 1998, and delivers an introduction, focusing on subsea control systems and umbilicals. He also assists in coordinating the course, as well as preparing and assessing the student assignments.

The module covers all aspects of subsea technology, including current hardware and installation techniques, as well as new developments. For the assignment, the students are formed into teams and given a subsea oil or gas field to develop. This tests the students' understanding of the subject, and teaches them skill sets enabling them to work together more effectively. An award is made to the winning team at a presentation night.

The effort made by all the lecturers is personally rewarding and builds self-confidence, acting as a showcase for their own areas of expertise. The substantial INTEC presence has also greatly enhanced the standing of INTEC with the UWA Centre of Oil and Gas Engineering, and with the offshore industry in Australia.

UWA and the Centre of Oil and Gas Engineering attract engineering students from across the world. Further details at www.oil-gas.uwa.edu.au.

HMC S-Lay Conversion Study

Heerema Marine Contractors (HMC) and INTEC are collaborating to extend the capabilities of the fleet to a new generation of versatile Semi-Submersible Construction Vessels (SSCV) capable of both heavy-lift and pipeline installation.

Conceptual and market studies were completed in December 2002 to lay the groundwork for development of a modular S-lay system, suitable for mounting on the portside of either the SSCV Hermod or the SSCV Thialf. The modular pipelay system will not compromise the existing lift capabilities of the vessel, but complement it by adding the capability to install infield and intra-field pipelines.

The vessel's S-lay capabilities are suitable for pipeline sizes between 6-inch and 20-inch for water depths ranging from 20-200 m. With a base case design of 5 work stations which are extendable to 7 stations, the vessel has the flexibility to handle standard pipe, insulated lines, weight coated pipe and pipe-in-pipe. The initial target market for one of the vessels with the S-lay system is the projects in the Atlantic Basin, which require a combination of heavy lift and pipelay capabilities, utilizing a large SSCV as a stable work platform.

A Note from the President
This note is written on the road in Australia, a country which is energy independent because of vast quantities of coal, oil and gas, A Note from the Presidentand a lot of sunshine, while mountainous Tasmania also has hydropower. Nevertheless the country has an energy policy that promotes energy conservation and environmental responsibility. Although there are a lot of unpaved roads across the very thinly populated interior, one sees few off-road vehicles, or SUV's as they are called in the US.

This situation is in contrast to the US where the opposite appears to be happening. A lack of a sensible policy that emphasizes judicious use and conservation of energy has resulted in faster growing energy demand while the country's own resources are declining. The reliance on imports cannot be reversed, and the suggestion that the US could ever become energy independent again is unrealistic as long as fossil fuels are the main source. The problem is that these imports are coming more and more from regions that are not known for their political stability or social equality. The US is not alone in this situation as most of Western Europe and some Asian countries are even more reliant on imports, but there these challenges are partly met by a serious conservation culture.

Automobiles consume a large part of the energy used in the US, and there has been a successful effort at improving the energy efficiency of cars over the years, with one notable exception, the above-mentioned SUV. Since for some strange reason these are classed as light trucks, and are thus exempt from fuel efficiency rules, there has been a boom in the sale of these vehicles with their ever bigger engines, negating much of the energy conservation effort. American historian Barbara Tuchman once wrote a book on famous historical follies, which she defined as disastrous actions by those in power while the information about the circumstances and likely effects of such actions were obvious. I believe

this applies to the US handling of the energy situation, which makes the country more dependent on foreign regimes that are unstable or unappetizing, or both.

One would think that energy conservation would be counter to the interest of the oil industry, and that in this business we should be pleased with increased demand. After all, that's what keeps creating new development projects for INTEC to take on. As I said, even with conservation energy use would grow, and alternatives to fossil fuels will take much time to develop, even if there were a serious effort to that effect. In other words, the need for new deepwater developments and INTEC's expertise therein will continue for many years. What the energy industry values more than increases in demand or prices is price stability. Threats to the political and economic status quo in the Middle East, West Africa and Latin America disturb this stability, and will result in sudden variations in supply and thereby price fluctuations. While the oil industry has always been cyclical, that is not the desired state. Government policies that support energy conservation and increase supply options will help stability; unbridled growth and inefficient energy use, combined with political moves that upset the balance will cause instability.

We better get ready to roll with the next series of punches; the future isn't what it used to be. Meanwhile, I suggest you start a new trend and consider a hybrid electrical car instead of an SUV for your next vehicle.

By the way, while visiting our new Perth office Steve Hindmarsh invited me to participate in the ultimate energy efficient activity: sailing a race. As the accompanying photograph demonstrates, this pleasure can be combined with business!

W. J. Timmermans
President

Delft: The Place To Be...
In April 1996 INTEC Engineering B.V. was established - the third INTEC office after Houston and Kuala Lumpur. Why Delft? Well, there are many reasons, but here are just a few.

Delft has the oldest, largest and most comprehensive technical university in The Netherlands (founded in 1862) and well known worldwide. With over 13,000 students and 2,100 scientists (including 200 professors), it is an establishment of both national importance and significant international standing. The University has been providing technical education for nearly 160 years. Renowned for its high standard of education and research, the University collaborates with other educational establishments and research institutes, both in The Netherlands and overseas. It also enjoys partnerships with governments, branched organizations, numerous consultancies, the engineering industry, and companies from both small and medium business sectors.

Delft has a wide-spread reputation as "The Knowledge City". Every day, people all over the world make use of inventions made in Delft. Some of the many examples include the ANWB (comparable to AAA) emergency telephones along the motorway. The ice-skating suit used to achieve record times on the ice is also an idea born in Delft. The design on the Dutch side of the Euro was also conceived in Delft. Delft takes knowledge seriously and applies it practically in the fields of water and soil, architecture and design, environmental technology, information technology and innovative transport systems.

Specifically to INTEC Delft office, the most noticeable contribution from the university is a majority of our engineering staff. Most of us have been closely tied to the university, either as students, or as faculty members. We permanently maintain one or two MSc thesis students on our team, who naturally link us with the Offshore Technology Group of the university and form a reliable stream of INTEC new blood. Another university facility within a stone's throw from our office that we make frequent use of is the library, which also functions as the national technical archive.

There are at least 21 famous historic buildings in the city of Delft. These include the 15th century "Prinsenhof" (or "Princes Court", the site of the murder of William of Orange in 1584), the Town Hall, also from the 15th century and the Old Church, the official burial place of the royal family since the death of William of Orange. For a virtual tour of the most prominent historical buildings of Delft, you can visit the following web site: www.monument.delft.nl.

On top of all that, Delft offers a variety of museums that can often be found in monumental buildings. You'll find a wide variety of museum collections. For example, in the Army Museum you will see how Holland was defended in earlier times. In the Tools Museum are many examples of the types of tools were used in former days and in the 'Prinsenhof", the residence of the late William of Orange, you will experience history on the exact spot where 'The Father of our Fatherland' was murdered by Balthazar Gerards. As you can see, there are plenty of interesting places to visit during your stay in Delft. They all are easily accessible by foot from the center of town.

And last but not least, in Delft you are within 15 minutes by car to the centers of Rotterdam (and Rotterdam Airport) and The Hague and 30 minutes to the center of Amsterdam (and Amsterdam Airport).

Also, as INTEC EAME (Delft and London) are to cover quite a large operational area, Delft provides an excellent exit base for the European main land, Middle East and Russia. During its six years of existence, the Delft office has been involved in a variety of interesting projects in many locations, from Sakhalin to Madeira and from Norway to Nigeria. Of these projects, BlueStream (two 24-inch pipelines across the Black Sea at 2,150 m water depth) has been the most challenging one.

Finally, when you want to take a break and contemplate all the impressions, the best way to do that is in a typical Dutch pub. There are plenty...

Kevin Mullen - Employee of the Quarter

Kevin and a group of colleagues in Perth made the move to INTEC in June 2002. He had been working with Saipem on the umbilical system for the BHP Billiton Minerva Field in the Bass Strait. The outcome of his analysis was an umbilical with acceptable valve response times. The onshore sections are presently being installed, with the subsea sections to follow.

Since coming to Australia five years ago, he still finds that every day is like being on holiday. Blue skies and shrieking parrots can't help but lift your spirits. Cycling to the office in the mornings is refreshing, but going home in the afternoon heat calls for a plunge in the pool to cool off. Cycling home one night, he had to dodge a family of kangaroos. He enjoys the company of his three teenagers, who have adapted to Australia well. His ambition is to be a better husband, and to live up to the INTEC values of honesty and integrity at home as well as at work.

INTEC sponsored Kevin for permanent residency in Australia, and he is now selling his home in England to settle down in the ideal climate of Perth. Kevin's wife Audrey is in England at the moment, where she went to court and got bailiffs to remove squatting tenants from the family home. She then cleaned it up (filling two skips with rubbish), and found a buyer for it. She's amazing! What do they say about virtuous wives? Worth far above rubies? It's her birthday just after she gets back to Perth...

Ferguson Joins INTEC

Graham Ferguson joined INTEC's Houston office on January 6 as business unit manager, Marine Installation Management. A Scotsman from Glasgow with a mechanical engineering background, Graham has over 20 years of experience in the offshore oil and gas exploration and production industries as an accomplished subsea engineer and project manager. He has spent the majority of his career with BP in the UK and Houston, and has detailed experience of all stages of offshore projects having invested his time with engineering consultants, drilling contractors and an equipment supplier.

As an employee of BP, Graham helped develop standardization in subsea equipment and led many industry initiatives to define systematic and consistent specifications for analysis and operation of wellheads, trees, risers and control systems. Beginning in 1995, Graham helped take the innovative ETAP development in the North Sea from conceptual evaluation to first oil. This development had many new technologies and novel commercial arrangements. Graham was also responsible for the subsea engineering efforts, which included subsea metering, multiphase pumping and subsea-deployed pigs. More recently, Graham was heavily involved in the conceptual development strategies, technology planning and execution of BP's deepwater GoM fields. Graham has led many teams in Houston, including his last position at BP as the facilities project manager of the spar-based Mad Dog development in the Gulf of Mexico deepwater developments business unit.

Now firmly based in Houston with his wife and three children, Graham joins INTEC Houston under Chris Tam, Vice President Operations, as the manager accountable for establishing the company's growth into capital project management. The Marine Installation Management business unit will extend INTEC's engineering scope of services into the execution phase of offshore projects, including procurement and construction. The new BU will build on INTEC's project execution experiences of West Delta Deep, Canyon Express, Horn Mountain, and Mardi Gras.

INTEC Engineering, Inc.
Intercontinental Building
15600 JFK Boulevard, 9th Floor
Houston, TX 77032, USA
tel: (281) 987-0800
Primary Fax: (281) 987-3838
Admin Fax: (281) 987-2002
e-mail: info@intec-hou.com
INTEC Engineering (SEA) SDN. BHD.
Suite 12.2, 12th Floor
Menara Aik Hua
Changkat Raja Chulan
50200 Kuala Lumpur, Malaysia
Tel: +60 (3) 202-2488
Fax: +60 (3) 202-3488
e-mail: info@intec-mal.com.my
INTEC Engineering B.V.
Poortweg 14
2612 PA Delft, The Netherlands
P.O. Box 3178
2601 DD Delft, The Netherlands
tel: +31 (15) 256-5675
FAX: +31 (015) 256-0194
email: info@intec-delft.com
INTEC Engineering S.R.L.
Lavalle #465
Planta Baja
1047, Buenos Aires
Argentina
tel: +54 (1) 14 327-4120
FAX: +54 (1) 14 327-4121
email: info@intec-hou.com
INTEC-egis
Adelaide House
200, Adelaide Terrace
Perth, Western Australia 6000
tel: + 61 (8) 9220 9374
FAX: + 61 (8) 9325 9897
email: info@intec-hou.com