Anchor Project: Best Practices and Lessons from Detailed Design Through Fabrication of the Anchor FPU

Abstract

Abstract The Anchor semi-submersible floating production unit (FPU) is a Chevron operated Gulf of Mexico (GOM) deepwater facility with a nameplate capacity of 75,000 bopd and 28 mmscfd and future expansion capability. This paper provides an overview of the FPU from detailed design through fabrication including design philosophy, equipment selection, pre-investment, and construction methodology as well as insights into Anchor’s contracting and execution strategy. Principles such as minimum functional objective (MFO), conditions precedent (CP), and on-ground max are discussed, as are some of the key decisions that enabled successful delivery of the Anchor FPU such as early contractor engagement and implementation of a rigorous weight management program. Final investment decision (FID) for the Anchor project was reached in 4Q2019 and soon after in early 2020, the world began to experience impacts from the COVID-19 global pandemic. Actions taken by the Anchor project team to address the many challenges of executing a major capital project (MCP) during a global pandemic and market downturn will also be shared. Anchor followed a general contracting strategy similar to past projects executed by Chevron in the GOM. While this approach requires a larger Owner’s team to manage multiple contracts and interfaces, it also provides greater visibility and earlier recognition of potential execution challenges thereby enabling the project team to react faster with direct input to mitigate or address issues as soon as they are identified. A large number of contracts were executed to deliver the FPU including separate topsides engineering, hull engineering, topsides fabrication and integration, hull fabrication, and systems completion contracts. The Anchor hull was fabricated in South Korea and transported via a heavy transport vessel to the Anchor topsides fabrication site in the US Gulf Coast where the topsides was integrated to the hull. Construction was completed in May 2023 and the Anchor FPU was wet towed from the fabrication yard to its final location in the GOM for installation and execution of the offshore hookup & commissioning (HUC) campaign. For clarity, the following terms are used throughout this paper. High Pressure High Temperature (HPHT) refers to equipment rated to pressures greater than 15,000 psi and/or temperatures equal to or greater than 350°F. Anchor is a high pressure project under the HPHT category. 20K refers to the Anchor project’s technology development and qualification program.