Technology Deployment in Deepwater Projects – The Bonga Example

Abstract

Abstract This paper presents some of the technologies that were deployed by the Deepwater Projects & Engineering (DWP) team in the Bonga field to enhance production, reduce deferment and maintain asset integrity. This paper is one of a series of Bonga themed papers for OTC 2024. Noteworthy amongst the deployed technologies are: A Smart Isolation Plug (smart plug) which was deployed during the first-of-its kind replacement of the gas export (GE) riser flex joint (FJ) in the Gulf of Guinea to reduce production deferment and flaring while mitigating the risk of loss of containment during continuous production. The smart plug eliminated the need to depressurize the 100 km GE pipeline (an ~6-8 days activity), which would have resulted in ~30 MMscf/d gas flaring for ~4 days and significantly reduced the GHG (Greenhouse Gases) emission impact of the FJ on Bonga. This also eliminated the requirement to repressurize upon project completion which would have required an additional 1-2 days. Thus, the Smart Plug provided ~16 days saving to the project execution schedule. The laser scanning which is built on imaging technology and enabled faster project delivery through Asset visualization, ensuring faster and increased accuracy in Engineering and Fabrication through dimensional control and for corrosion management. Other immediate benefits included quick turnaround of As-built updates, reduction of GHG emissions and safety exposure from offshore flights/travels through the Bonga i-site Asset Visualization Portal. The Structural Digital Twin (SDT) which is capable of on-demand assessment of the Hull and the Topsides structures of the Bonga FPSO (Floating Production Storage and Offloading). It provides leading performance indicators, ascertains the current health of our facilities including the Safety Critical Structures, enables proactive maintenance planning and evaluation for future conditions related to tie back and life extension. It also enables an organized way of reporting FPSO performance that improvises the approval process with Class society. ROV installable Anodes is vendor technology that was available for subsea structures. It was considered for mooring, internalized for use on the Bonga FPSO mooring chains and has helped to slow down the uniform corrosion rate. Implementation of this technology as barrier against material loss provides an in-situ remedy for brownfield application thereby enhancing assurance related to asset integrity to mitigate the loss of station keeping. This paper provides an overview of the successful deployment of some technologies by the DWP team on the Bonga field's journey to the production of one billion barrels of oil. Industry professionals can leverage information in this paper to successfully execute projects on their own journey to achieve more production/less deferment while maintaining asset integrity.