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PROJECT DESCRIPTION
4.1
OVERVIEW
4.1.1
What is LNG?
49
4.2
PROJECT OVERVIEW
4.2.1
The Project
50
Figure 4.2
FLNG Facility
LNG Carrier
Anchors
4
Flowliness
Wellheads
Figure 4.3
4.2.2
Project Justication
Project Objectives
The project objectives are to extract, treat and sell the
discovered gas resources in the Prelude eld to meet growing
51
Production Capacity
The FLNG facility will have a design capacity of 3.6 million
tonnes per annum (mtpa) of LNG, 0.4 mtpa of LPG and
1.3 mtpa of condensate.
Project Lifespan
The project is aiming to commence Front-End Engineering
and Design (FEED) in the second half of 2009 and to take
a Final Investment Decision (FID) to commit to the project
in early 2011. From FID it will take about ve years before
the FLNG facility has been built and towed to site ready for
start-up. During this period the subsea wells will be drilled
and the subsea infrastructure installed ready to supply gas to
the FLNG facility on its arrival. Current planning indicates
that the development drilling program is expected to take
approximately two years.
The FLNG facility will be designed to operate for up to 25
years between dry docks and the hull will be designed for
a 50 year life. It is intended that the facility will remain on
station over the Prelude eld for 25 years.
An indicative timeline for the project development is
provided in Table 4.1.
4.3
ANALYSIS OF ALTERNATIVES
4.3.1
52
Table 4.1
Project Phase
Target Date
Development drilling
2013
Subsea construction
2014
2015
Commissioning
2015
First gas
2016
Decommissioning
2040
Do Nothing Alternative
4.4
DESIGN CONSIDERATIONS
4.4.1
53
54
Sequestration Targets
Two possible subsurface structures have been evaluated as
potential sinks to enable long-term, secure geo-sequestration
of the reservoir CO2.
a. Sequestration into the Swan Formation
This would inject reservoir CO2 back into the Swan
formation, which contains the Prelude eld, at 4000 m
depth, some distance away from the crest of the Prelude
eld where the gas producer wells will be located. The CO2
would be compressed to 250 bar, dehydrated (inter-stage)
and then pass through the swivel in the turret on the FLNG
facility, back down a exible riser to the sea oor and then
to a single injection well.
Technical areas requiring further work are:
this would be the rst project to reinject CO2 back
into a producing gas reservoir at the start of eld life.
The extent and rate of CO2 recirculation within the gas
reservoir is uncertain and may impact on CO2 content
in the feedgas in the later life of the Prelude eld;
in the early years, re-start of the CO2 compressors
after a trip could prove dicult due to high reservoir
backpressure; and
the CO2 reinjection could have a pressure maintenance
and a positive sweep eect in the reservoir, providing an
enhanced oil recovery benet.
55
10
56
The ALARP philosophy aims to reduce negative impacts or risks to be as low as reasonably practicable.
4.4.4
Unplanned Events
4.5
COMPARISON TO OTHER
PROJECTS
57
Figure 4.4
58
4.6
PRELUDE DEVELOPMENT
DESCRIPTION
4.6.1
Introduction
Production Wells
Existing LNG Developments
Existing LNG developments oshore northern Australia are:
the North West Shelf Venture (NWSV) project, located
in the Carnarvon basin approximately 1,000 km
southwest from the Prelude FLNG Project and feeding
the NWSV LNG Plant on the Burrup Peninsula;
Pluto LNG project (under construction), located
approximately 1,100 km SW of the Prelude FLNG
Project; and
Bayu Undan oshore development, located
approximately 600 km northeast of the Prelude FLNG
Project and feeding the Darwin LNG Plant.
11
PFW is water that has accumulated naturally within the same rock strata as the hydrocarbons and that ows to the surface with the gas and hydrocarbon liquids from the
production wells. It comprises a mixture of condensed water and saline formation water.
59
Figure 4.5
Subsea Infrastructure
Flexible
risers
Anchors
Umbilicals
Riser base
manifold
Flowlines
Production
manifold
Wellheads
See Chapter 6 for further details on drill cuttings disposal.
Subsea Flowlines
12
60
Pigging refers to the practice of using pipeline inspection gauges or pigs to perform various operations on a pipeline, such as cleaning and inspection, without stopping the
ow of the product in the pipeline.
Figure 4.6
FLNG facility
Flexible Risers
Eight 12 inch exible risers will convey the gas from the riser
base manifolds on the seabed to the underside of the FLNG
turret. The exible risers will be designed to accommodate
the motions of the FLNG facility on the ocean surface.
4.6.3
FLNG facility
The FLNG facility will process the gas from the production
wells into LNG, LPG and condensate. These products
will be stored and subsequently ooaded to purpose built
marine tankers for delivery to market. The processing,
storage and ooading equipment (termed the topsides
facilities) will be mounted on a hull, about 480 m long and
75 m wide. The FLNG facility will weigh 600,000 tonnes
deadweight when fully ballasted.
The FLNG facility will be a double hull design (both sides
and bottom), so that the contents, including the LNG,
LPG and condensate storage, are contained within an
internal hull completely encased by an outer hull, providing
additional containment and protection.
Figure 4.6 provides an indicative illustration of the proposed
FLNG facility.The FLNG facility will be permanently moored
to the seabed and will be able to weathervane (rotate around
the mooring turret according to wind and current directions)
to minimise the inuence of weather and sea conditions. The
FLNG facility will have 3x5 MW azimuth thrusters, used to
maintain a xed heading during tanker berthing.
The FLNG facility will provide:
a stable platform for the topsides gas treating
liquefaction plant;
storage and facilities to export LNG, LPG
condensate;
accommodation for operations, maintenance
support personnel;
ancillary facilities including all workshops, oces
and
and
Anchor System
The FLNG facility will be held in position by four groups
of six anchor chains, arranged at the four quadrants around
the FLNG turret. The chains are secured by suction piles
which will penetrate deep into the seabed. The piles will
typically be 10 m in diameter and 20 m to 30 m in length,
with each weighing between 140 and 180 tonnes.
and
and
61
Table 4.2
Key Process
Unit
Production facilities
Gas reception
Gas/liquid separation
4.7
FLNG PROCESSES
4.7.1
Introduction
Once the feed gas has reached the FLNG facility, processing
will commence on the FLNG topsides. When processing at
100% design capacity, the volume of feed gas equates to 680
million standard cubic feet per day (scfd) which produces 3.6
mtpa of LNG, 0.4 mtpa of LPG and 1.3 mtpa of condensate.
The feed gas is delivered from the turret and the condensate
fraction is stabilised and drawn o to storage. Any
Production Formation Water (PFW) that may be associated
with the hydrocarbons is separated o for treatment prior
to discharge to sea. The gas is then metered and treated
to remove acid gases such as carbon dioxide and hydrogen
sulphide (termed sweetening the gas), impurities and
water. The dry, sweet gas is then cooled by refrigerant
streams to separate out the heavier hydrocarbons, which
are fractionated and recovered as condensate and LPG. The
refrigerant process continues, reducing the temperature of
the dry sweet gas until it liquees. The resulting LNG is
then routed for storage in insulated tanks at atmospheric
pressure, prior to being ooaded to a tanker.
An overview of the process is provided in Figure 4.7 and in
greater detail in the following sections.
4.7.2
62
Power/Steam
Generation
Waste Water
Treatment
Pressure Relief
Chemical Injection
Drainage
Storage
Figure 4.7
4
AGRU to prevent freezing and subsequent blockages in the
liquefaction unit.
The gas stream ows up the absorber columns against a
counter current ow of an aqueous amine solution (activated
Monodiethylamine (aMDEA)), removing the CO2 by
chemical reaction to less than 50 ppm in the treated gas
stream. The amine solution is drawn from the bottom of
the absorber, rich in acid gas components, and the pressure
reduced and ashed at an intermediate pressure to release
the entrained and dissolved hydrocarbons. The ash gas is
routed to the fuel gas system. The ashed solvent is then
heated to allow the chemical reaction to reverse and release
the acid gas in the regeneration column. The amine solution
is then cooled and recycled to the absorber as lean solution
ready to absorb more acid gas, while the acid gas is vented
to atmosphere via the are stack to ensure its safe disposal.
4.7.4
Gas Dehydration
Mercury Removal
Once the gas has passed through the gas treating units,
63
Liquefaction
4.7.9
MEG System
4.7.8
64
Drainage
There will be two drainage systems on the FLNG facility, an
open deck system and an internal deck system.
a) Open Decks
Drainage from these open areas will predominantly comprise
washdown water, sea spray run-o and rainwater.
For safety reasons, the open deck areas where the LNG or
LPG process equipment is located will be grated so that
spilled material quickly falls through the deck and away
from the process equipment. To avoid embrittlement of the
structure by cryogenic liquids, other open deck areas will
have a 500 mm camber to freely drain LNG or LPG spills
overboard as quickly as possible.
65
66
Additional Utilities
Additional utilities (instrument air, nitrogen, seawater
desalination, domestic waste water treatment) will be
4.8
4.8.1
Development Drilling
Well drilling for the Prelude FLNG Project will use two
types of muds, both water based mud (WBM) and synthetic
based mud (SBM). The SBM will be used on the deeper
and more challenging well sections. WBMs are usually
discharged to sea at the end of their useful life or at the end
of the drilling program, whereas SBMs are recovered and
returned onshore for recycling or disposal.
Overview
Hole Size
Mud Type
Main Components
Detailed SBM formulation is still to be determined but potential base oils include
Alpha Olephin blends (eg. MI Novatec) or rened alkanes with carbon chains of
C10-C20 (eg Shell Saraline 185V)
67
Cleanup involves owing well uids and brine to the rig storage
tanks and diverting reservoir gas to burners. Well cleanup will
typically involve owing the well at up to 150 million scfd and
burning the produced uid for one to two days to ensure all
drilling liquids are removed from the well. During clean-up,
the wells owing performance will be assessed. It is likely that
all eight well clean-ups will be undertaken one after the other
at the end of the drilling program.
4.8.2
Emissions to Air
Installation of Upstream Facilities
Gaseous emissions arising during proposed development
drilling will largely be combustion related, from operation
of equipment and machinery and well clean-up. These
include atmospheric emissions of sulphur dioxide (SOx),
nitrogen oxides (NOx), CO2 and particulates in smoke.
The quantities of gaseous emissions are relatively small and
will, under normal circumstances, be quickly dissipated
into the surrounding atmosphere.
Liquid Waste
Liquid wastes from the drilling program are expected to
include:
Grey water and sewage in the order of 10 m3 per day,
which will be treated by the on-board treatment system.
Minor kitchen waste, shower and laundry wastes that
will be capable of passing through a 25 mm diameter
screen prior to discharge.
WBM, which is discharged to sea in bulk at the end of the
drilling program as per standard oil industry practice.
Minor volumes of SBM (approximately 36 m3 per well)
all discharges of cuttings contaminated with SBM
mud will be measured using standard Australian oileld
procedures and should contain less than 6.9% residual
SBM by weight. There will be no dumping of bulk SBM.
Minor volumes of hazardous waste such as used oil,
chemicals, solvents, acids/ caustics, paint and drilling
uid additives. These will be stored on board the rig,
pending transport onshore for disposal at suitably
licensed facilities.
Emissions to Air
The only air emissions generated during the subsea
installation will be from vessel engines and diesel generators
operating on an incidental basis eg power generation,
cranes, re water pump etc.
Solid Waste
Liquid Waste
Solid wastes from the drilling program are expected to
include:
Minor volumes of non-hazardous wastes including
68
Solid Waste
Solid wastes from the subsea installation and hook up
activities are expected to include:
minor volumes of non-hazardous wastes including
paper, rope, various packaging timber, metal and
plastic, which will be periodically transferred onshore
for recycling or disposal; and
minor volumes of hazardous waste including aerosol
cans, batteries and oil lters.
Table 4.4
Summary
A summary of key activities and their potential
environmental implications is provided in Table 4.4.
4.8.3
Commissioning
Activity
Key Details
Potential impacts on
EPBC Act Matters
Development Drilling
Installation of Subsea
Facilities
FLNG Hook Up
Vessel Activities
(including towing
FLNG facility to site)
69
Emissions to Air
Emissions during the commissioning phase will occur
through the incidental use of diesel driven power generators
and air and sea transportation. The sources are principally
diesel engines and work vessels, which will be diused
sources producing relatively minor emissions. Emissions
Table 4.5
70
Liquid Waste
Liquid wastes from the commissioning activities are
expected to include:
grey water and sewage in the order of 30 m3 per day,
which will be treated by the on-board treatment system;
kitchen waste, shower and laundry wastes that will pass
through a 25 mm diameter screen prior to discharge;
minor volumes of hazardous waste such as used oil,
chemicals, solvents, acids/caustics and paint, which will
be transferred onshore for disposal at an appropriately
licensed facility;
hydrotest seawater and inhibitor (about 1,500 m3); and
buer (diesel) and MEG from umbilical line ushing,
which will be recycled on board.
Solid Waste
Solid wastes arising during commissioning are expected to
include:
minor volumes of non-hazardous wastes including
paper, rope, various packaging timber, metal and
plastic which will be periodically transferred onshore
for recycling or disposal; and
minor volumes of hazardous waste including aerosol cans,
batteries, used oils and oil lters, which will be periodically
transferred onshore for recycling or disposal.
Summary
A summary of key activities and their potential
environmental implications is provided in Table 4.5.
Activity
Key Details
Logistical support
(including environmental incidents
during testing and
commissioning)
Hydrotesting and
dewatering of
owlines and FLNG
facility pipework
Atmospheric emissions
Physical presence of vessels and helicopters
Ballast water, bilge water and drainage
water
Noise and light emissions
Hydrotest water discharge
Potential impacts on
EPBC Act Matters
Noise and light impacts on
listed species
Vessel interactions with listed
species
Discharge impacts on
Commonwealth Marine
Environment
4.8.4
Export of Hydrocarbons
During loading, a LNG or LPG carrier would moor
alongside the FLNG facility or a condensate tankers would
moor in tandem astern of the FLNG facility, with the
FLNG facility using its thrusters as necessary to maintain
position. Two 80 tonne bollard pull tugs will assist with the
docking process for LNG and LPG carriers while only one
tug is required when docking condensate tankers. Note that
only one tanker of any description will be loaded at a time.
a) Venting
A general no venting principle with respect to the disposal
of hydrocarbon streams from process units and other
equipment will be applied during the operation of the
FLNG facility. Some venting, however, may be necessary
in special cases where routing to the are is prohibited for
safety or other technical reasons.
b) Flaring
A no aring principle for disposal of hydrocarbon streams,
which applies to normal plant operations, will be applied
to the project. Any aring that is required will follow the
recommendations of API 521, Pressure Relieving and
Depressurising Standard, which outlines that the are shall
be luminous and bright and show smokeless combustion
at all operating gas ow rates. During start-up and shutdown, controlled aring will be necessary to ensure safe
operating procedure.
c) CO2
Each storage tank on the FLNG facility will have its own
dedicated loading pumps. Boil o gas generated during
LNG or LPG loading operations will not be ared but will
be routed back to the low pressure fuel gas system via the
vapour return lines.
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CO2
(000s tpa)
966
Combustion CO2
1260
58
Flare CO2
Total CO2 Emissions
2284
f)
VOCs
Liquid Waste
d) NOx
NOx emissions will be produced from boiler and aring
operations. Calculation of the NOx emissions from the
boilers was based on maximum allowable NOx discharge
limit of 240 mg/Nm3 for this equipment (Table 4.7). There
are also a number of diesel drivers that will run on an
incidental basis for emergency power generation, re water
pump etc. The emissions are an order of magnitude smaller
than the boilers and aring contributions and have not
been included in this assessment.
Table 4.7
tpa
Boilers
2144
Flare
134
Total
2278
e) Sulphur emissions
The hydrogen sulphide (H2S) in the feed gas is almost
completely removed in the AGRU and vented (see Table
4.8). As a result, very little H2S will end up in the fuel gas
to the boilers to be converted into SOx (estimated less than
1 tonne per annum). The remaining H2S will be distributed
over the products and not emitted.
Table 4.8
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H2S
tpa
171
Table 4.9
VOC / BTEX
Flare
unconverted
HC (tpsd)
ETHANE
0.2
0.4
PROPANE
0.0
0.1
IBUTANE
0.0
0.0
BUTANE
0.0
0.0
BENZENE
1.1
TOLUENE
3.1
XYLE NE
Total
Condensate
storage tanks
(tpsd)
Fugitive
emissions
(+10 %) (tpsd)
Total
(tpsd)
Total
(tpa)
0.1
0.7
221
0.0
0.1
37
30
0.3
0.3
101
1.1
369
3.1
1039
4.4
0.5
0.4
0.1
5.4
1,799
Note: An allowance has been included for emissions from condensate tanks when vapours are unable to be routed to the fuel gas system due to maintenance or shutdown.
Solid Waste
Solid wastes arising during normal operations are expected
to include:
non-hazardous general wastes such as paper, rope,
various packaging timber and metal;
non-hazardous materials from the production process
such as sands and grit from pigging; and
hazardous waste including used or spoilt water treatment
chemicals, used mercury absorbent, used molsieve,
process sludges, batteries, used lube oils and oil lters.
Solid wastes will be returned to shore for processing.
The waste management strategy during operations and
maintenance is designed to optimise segregation of waste
in the oshore location and to minimise contamination of
recovered waste destined for recycling or disposal.
Maintenance
Over the course of their lives the production wells may
require maintenance work which will be carried out by a
MODU working over the well. This will involve similar
processes and facilities as described for the development
drilling process above but without the use of drill muds
Plant layout has been designed to allow safe, easy and fast
removal, transport and reinstatement of all components
that might require removal for maintenance work.
The planned maintenance strategy shall be developed to
ensure:
the maintenance activities (with resultant higher
movements of personnel and equipment) are planned
to reduce HSE risks to ALARP; and
maximum availability and integrity of the FLNG
facility whilst optimising costs and manning.
Biological accumulation on the FLNG facility hull is
unlikely due to application of anti-fouling. In the event that
it does occur, any build-up will be removed by mechanical
cleaning by divers or Remotely Operated Vehicles (ROV).
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4.8.5
Workforce
In total, about 320 personnel will be employed in the
operation of the FLNG facility. During normal operations,
approximately 220 personnel will work onboard the FLNG
facility, working as two 110 man crews on a rotational
roster (eg three weeks on, three weeks o), employed to
carry out operations, maintenance and/or provide support
functions. The remaining 100 personnel will comprise day
sta located ashore at the Maintenance Workshop and
in Perth and will be employed to provide technical and
administrative support.
Summary
A summary of the main anticipated operational and
maintenance activities and their potential environmental
implications is provided in Table 4.10.
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4.8.6
Table 4.10
Activity
Key Details
Logistical support
FLNG facility
operations
Atmospheric emissions
Physical presence of vessels and helicopters
Ballast water, bilge water and drainage
water
Noise and light emissions
Estimated discharge volume of Subsea
control uid is 23 m3 per year
Export shipping
Maintenance activities
Noise emissions
Light emissions
Atmospheric emissions
Table 4.11
Potential impacts on
EPBC Act Matters
Noise and light impacts on
listed species
Vessel interactions with listed
species
Discharge impacts on
Commonwealth Marine
Environment
Noise and light impacts on
listed species
Discharge impacts on
Commonwealth Marine
Environment
4
Discharge impacts on
Commonwealth Marine
Environment
Spill impacts on
Commonwealth Marine
Environment and listed species
Noise and light impacts on
listed species
Vessel interactions with listed
species
Noise and light impacts on
listed species
Activity
Key Details
Flushing of subsea
owlines
Capping of wells
Physical presence
Air emissions
Noise and light emissions
Potential impacts on
EPBC Act Matters
Discharge impacts on
Commonwealth Marine
Environment
Physical disturbance impacts
on Commonwealth Marine
Environment
Vessel interactions with listed
species
Noise and light impacts on
listed species
75