Subsea, Umbilicals, Risers and Flowlines (SURF): Performance Management of Large Contracts in an Overheated Market; Risk Management and Learnings

Abstract

Abstract Greater Plutonio is BP's biggest subsea project worldwide and consists of 5 separate fields in 1500m of water, over an areal extent of 4,880km2, 150khm offshore Angola in Block 18. One of the many challenges of the development concept was to deliver the complex Subsea production system, Umbilicals, Risers and Flowlines (SURF) which will connect the 43 subsea wells to the spread moored 2 million barrel storage, new build FPSO with production capacity totaling 240,000 barrels per day, in an integrated manner over a fast track schedule to allow a safe, efficient and phased start up, with rapid production ramp up. The challenge was heightened by a commitment to deliver the highest level of local Angolan content ever achieved to date. This paper will address the challenges in project managing SURF projects of this size and highlight some of the unique aspects and challenges of this development, particularly given its Angolan content and market conditions by applying risk management principles and applying learning from previous deepwater projects in WAF, GoM and West of Shetland It is supplemented by companion papers covering specific areas of the development from sand face to facilities (OTC - 19673, 19674, 19675, 19676 and 19669). The key points and challenges to note about the SURF system are:43 wells with flexibility and expandability in the subsea architecture for up to 88 wellsSingle compliant riser tower with condition monitoring system, fabricated and assembled in AngolaHighly dynamic seabed flowlines subject to high lateral buckling forces and end expansions107km dynamic and static production control, chemical injection and data acquisition umbilicals150km production insulated flowlines, water injection plastic lined, gas injection and service flowlinesSimultaneous subsea construction, commissioning, start up, production and offtake operationsProvision for a future subsea gas export offtake The project was led by a core BP Project Leadership Team supported with directly hired contract staff co-located to major contractors' offices to work in integrated teams, through FEED, system engineering, detailed design, procurement, manufacture, fabrication, installation, commissioning, start up and production. Throughout the project functional departments provided expert technical support and integrity assurance with formal reviews and specialist advice. BP partnered with their key contractors to identify key project drivers, issues and challenges, and then mapped out a plan to systematically improve safety performance, especially in Angolan fabrication yards and for offshore simultaneous marine construction and commissioning operations. This partnering approach increased ownership and ensured that improvements were embedded in the contractor's systems and procedures, as well as enabling the contractors to take advantage of the significant safety resources/experience available within BP.