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[ africa americas asia europe oceania ] S t r u c t u r e S o f t h e f u t u r e f r o m the start of next year, an innovative floating Production storage and offloading Vessel will supply wärtsilä Power to the PaPa terra oilfield. Brazil is no stranger to unique designs that require Vision, courage and determination. the P-63 fits this Prodigious mould. T e x T: V e s a e s k o l a p h oto s : V e s a e s k o l a a n d V e l h o t 3.12 Twentyfour7. 17
[Right] The P-63 will be connected to Papa Terra s light oil production wells The P-63 is currently being built in china and will soon start on its voyage to the coast of Brazil. Wärtsilä is supplying the Floating Production Storage and Offloading vessel with three main power modules, under a contract with the Brazilian industrial group QUIP. It is a unique vessel in many regards. First of all, it is the first FPSO vessel to utilize gas engines to produce more than 100 MWe of power. It is also vast in size. With a length of 346.3 metres it stretches beyond the normal field of vision. The other strategic measures are draught 22.9 metres, beam 57.3 metres, and gross tonnage 153,517. In a Chinese shipyard everything is big but the P-63 is still an impressive sight. Wärtsilä s contract includes commissioning, start-up and operational supervision. The vessel will be located 110 kilometres off the Brazilian coast. The engineer as conductor Juha Nurmi is a Site Manager at the P-63 construction dock. The three Wärtsilä power modules include two 18-cylinder 50DF tri-fuel engines, alternators and other ancillary equipment. Nurmi will look after the P-63 until it sails to Brazil. Its main innovation is the technology that gives its engines their unique tri-fuel capability, he explains. They will be able to run either on gas, on processed crude oil directly from the oilfield or on marine diesel. The modules have a self-supporting structure and they consist of two totally separated engine rooms. It is a typical Engineering, Procurement and Construction (EPC) project for Wärtsilä. But of course the new technology means challenges for Nurmi. Wärtsilä has full responsibility for delivering the tested modules to the customer s FPSO platform. This includes a comprehensive high-end power management system from Wärtsilä Norway. The modules are due to be operating in the offshore field from the first half of next year. The project was divided into several phases. First you plan and then you plan some more. Then you need some serious engineering, construction and commissioning work before you run the first full load tests. At times Nurmi feels like the conductor of a huge orchestra. Seamless integration between the different work phases is essential. Our time frame was set by the main project schedule of the platform. It may not sound too complicated, but it is a major challenge to link the construction schedule of the power modules to the construction of the whole FPSO. And everything is done here in China at the same shipyard. new life for a supertanker The P-63 is being created by converting a supertanker, the Nisa, built in 1983. When the conversion is complete, the FPSO vessel will have the capacity to produce 140,000 barrels of oil per day and compress 1,000,000 m3 of gas per day. Its minimum storage capacity will be 1,000,000 barrels. The conversion is a huge undertaking, involving the installation of 16 topside facilities weighing 14,000 metric tons. There will be three oil processing units, a gas compression unit, the three Wärtsilä power generation units, two manifold modules, a flare unit, utilities facilities and two water treatment and injection units. There are several teams in different locations handling the different work phases of the power modules project. This keeps Nurmi busy. Managing all the teams has been the real challenge of this project. In offshore technologies we face the challenges typical of a marine environment, like hull movements and corrosion. Ambient temperatures and load variations have to be considered too. All these issues need to be taken into account during the engineering. Of course on top of them are all the normal requirements of safety, quality and so on. Now that the final test runs are almost complete, Nurmi can t wait to see how the P-63 will work on the field. This is such a significant technology shift. Everybody working in the offshore market is eagerly anticipating the final outcome. Me too...... 18 Twentyfour7. 3.12
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E V E R Y O N E I N O F F S H O R E I S M O N I T O R I N G T H E P - 6 3 A N D I T S G R E A T T E C H N O L O G Y S H I F T 3.12 Twentyfour7. 21
Challenge of the harvest Papa Terra crude oil field, located in the Campos Basin, was discovered in 2003. The field lies at a water depth of 1190 metres. Petrobras operates the field with a 62.5 percent interest; the rest is held by Chevron. At first the field was not very attractive commercially, and the final investment decision of 5.2 billion dollars wasn t made until January 2010. Drilling operations will start next year. The field is estimated to contain 0.7-1.0 billion barrels of oil equivalent. About 380 million barrels of oil is expected to be recovered from the field. The current barrel price of about 80 dollars makes the field worth some 30 billion dollars. Altogether there will be 29 wells operating in the area. The heavy oil production wells will be connected to a tension leg wellhead platform (TLWP) P-61. The light oil production wells will be connected to the P-63. The effect of the fields on the Brazilian economy will be enormous. The country is already a modern industrial power and the new reserves will strengthen it even more. Papa Terra will roughly double Brazil s oil and natural gas reserves. Its GDP is already in the world s top ten, and the new discoveries will push it higher, but there is a catch. To recover some of the new resources will require innovation and new thinking. To fully reap the harvest, new technologies are needed. First the new oil and gas reserves must be drilled, then they have to be produced, stored and transported. Fortunately Wärtsilä had the answers to some of those demands. Deep water production Some of the new fields hidden below the seabed of the Atlantic Ocean lie very deep indeed, in a geological formation known as the pre-salt layer. Drilling at a depth of more than 2000 metres is no easy task. With the input of the new fields, the expected daily production from the pre-salt layer is expected to rise above one million barrels of oil by 2020. To do so will require new drilling rigs, new FPSOs and support vessels, new refineries and LNG terminals, pipelines and compression facilities. The challenge of drilling is only half of the task. Logistic networks also need to be upgraded and expanded to match the task ahead. Stig Bøtker is Sales Director of the offshore division at the Wärtsilä. Based in Norway he already has knowledge of deep water production. The P-63 is a new departure, a way of creating power offshore on an FPSO. The power requirement was a challenge and the market has been very interested in our solution. Bøtker is very proud of the Wärtsilä innovation. The solution is environmentally friendly, has a fuel efficiency second to none and will be able to burn not only well gas but crude oil too. It is therefore especially well-suited for field development with limited gas reserves. Stig Bøtker points out how Wärtsilä, with its long traditions in the maritime and power sectors, is ideally placed for the challenges. We can take the whole lifecycle responsibility for projects like this from concept development to turnkey contract to service and maintenance. Wärtsilä has a worldwide.. organization able to support the whole. project. 22 Twentyfour7. 3.12
Baywatch Brazil: a lifeguard scans the beach. 3.12 Twentyfour7. 23
[Below and right] Life in Rio revolves around the shore: its beaches, its harbours and the offshore industry. 24 Twentyfour7. 3.12
Coffee, samba and power The P-63 reinforces Wärtsilä s presence in Brazil, which has already been very strong, thanks to Power Plants. Jorge Alcaide is Regional Director of Wärtsilä Power Plants in Brazil. We are already responsible for the construction of 25 plants here, with a total output of more than two gigawatts. Wärtsilä has power plant operations and maintenance services in almost every Brazilian state. The installed base is currently 2.5 GW, of which more than 1.8 GW are under O&M agreements. We recently delivered Suape II, a project with a capacity of 380 MW. It was the biggest plant Wärtsilä had ever built. Together with new business opportunities it will add almost 600 MW to our total capacity in Brazil by 2013. This brings total output to more than three gigawatts, but Jorge is sure that more will come. The perspective for the future is even better. Natural gas has a lot of potential. The Flexicycle solution is a major driving force for us in the upcoming energy auctions. wärtsilä in brazil: 1987 LIceNSING agreement SIGNeD WITh IShIBRaS ShIPyaRD TO MaNuFacTuRe WäRTSILä VaSa 22 engines IN BRazIL 1990 WäRTSILä DIeSeL DO BRaSIL IS FOuNDeD 1991 WäRTSILä BRazIL GeTS ITS FIRST ShIP POWeR ORDeR WheN IT SuPPLIeS GeNeRaTING SeTS TO The BRazILIaN NaVy 1996 FIRST WäRTSILä POWeR PLaNT SOLD IN BRazIL 1997 WäRTSILä SeLLS ITS FIRST OPeRaTIONS & MaINTeNaNce agreement IN BRazIL 1998 BRaNch OFFIce OPeNeD IN MaNauS 2000 FIRST WäRTSILä WORkShOP IN RIO De JaNeIRO 2004 SecOND WORkShOP OPeNeD, NOW IN MaNauS 2008 a WäRTSILä LaND & Sea academy IS established IN MaNauS 2009 WäRTSILä ReacheS 1 GW OF INSTaLLeD capacity IN BRazIL under O&M agreements 2012 INSTaLLeD BaSe ReacheS 2.5 GW 3.12 Twentyfour7. 25
On Land and sea Wärtsilä has operated successfully in Brazil since 1990 and now employs more than 600 people there. Its headquarters and one workshop are located in Rio de Janeiro. We need no further invitation to visit this magnificent city. Rio de Janeiro is just a few hundred kilometres from the Papa Terra oilfield. If I had a free hand to landscape any place in the world into the perfect environment for a city, I couldn t do better than what Rio de Janeiro already is. Spread over and between lush green hills, wrapped around a magnificent clear blue-watered bay, this breath-taking city hides its real size. It is hard to imagine that a city of nine million people could look so cosy. Maybe it is the Brazilian way of life, to enjoy life as long as you can, that makes the visitor s heart beat faster? Or perhaps it is legendary beaches like Copacabana and Ipanema that make your heart ache? Luiz Antonio Maggioni is a Business Development Manager working for Wärtsilä in Brazil. Wärtsilä Brazil sees great opportunities in contributing to the growth and development of the Brazilian economy and also in the oil and gas sector. Offerings by all our business segments Ship Power, Power Plants, and Services are an excellent match for current and future demand. Maggioni has been busy in all sectors. Wärtsilä Ship Power focuses on marine solutions: ship design, power generation, propulsion solutions, automation and offshore installations. Our installed base in Brazil consists of engines in more than 200 ships and rigs, with a total generating capacity exceeding 1 GW. The P-63 is of course a perfect complement to our portfolio. The role of Wärtsilä Services is to support our customers throughout the lifecycle of their installations by optimizing system performance, efficiency and operation, and also by optimising maintenance, says Maggioni. Land-based power plants are very popular as well. At the end of 2010, Wärtsilä Services entered into Operations and Maintenance Agreements with Borborena Energética S.A. for the UTE Cambina Grande Power Plant (164 MW) in Paraiba, with Maracanaú Geradora de Energia S.A for the UTE Maracanaú Power Plant (168 MW) in Ceará and also with Linhares Geração S.A. for the UTE Linhares Power Plant (204 MW). Life is a beach We take a final stroll around Rio. Beginning at the Museum of Contemporary Art atop a cliff in Niterói (see the article on Brazilian visionary Oscar Niemeyer later in this publication), we end up back at the beaches. Life in Rio centres on the shoreline. The city is bordered by its beaches and its harbours. Oil has a strong presence too. There are several oil platforms in the surrounding waters and the port is incredibly busy. It s a reassuring sight. In the current global economic situation, it s good to see a brighter future ahead. 26 Twentyfour7. 3.12
R I O S S A U C E R - S H A P E D A R T M U S E U M C O N T E M P L A T E S T H E N E X T G E N E R A T I O N O F V I S I O N A R Y S T R U C T U R E S, B U I L T F O R B R A Z I L S O F F S H O R E I N D U S T R Y. 3.12 Twentyfour7. 27