MÆRSK INSPIRER COMBINES DRILLING AND PRODUCTION
IN THE VOLVE FIELD
Inspirer by name: inspiring by nature
- the combination of drilling and production on one rig is very rare. MÆRSK INSPIRER is the world’s largest and most advanced jack-up drilling rig but now it has its own integrated high-end process facility which makes it unique. It provides the capability of moving into smaller fields, in places with very tough conditions, where fixed installations could never give sufficient return on investment. It is proving itself to be a highly successful solution for both operator and contractor.
From inspiration to reality in just seven years
The project began on 23 October 2001 with an invitation from Statoil, the Operator, for Maersk FPSOs and Maersk Drilling to combine forces to investigate a small field called Volve, about 220 km off the coast of Stavanger, in the Norwegian Central North Sea. Exploiting a marginal field like this is unusual but rising oil prices and pressure from authorities to exploit existing resources makes the project attractive.
Even though it is apparently a small and difficult field, the Maersk FPSOs and Maersk Drilling commercial and technical staffs are undaunted. Here is a challenge. They are inspired. They soon determine that a cost-effective and exciting solution is possible.
They decide on a concept that is similar to the jack-up solution used for Statoil in the Yme field but the difference would be a much larger, more complex approach. The topside facilities are now module-based, which effectively reduces rig conversion time. Built in South Korea, MÆRSK INSPIRER is one of the new XL rigs and is chosen because it offers greater water depth capability. It has a higher variable deck load compared to a conventional jack-up and more than double the deck space.
Throughout 2004 the project is designed, presented, negotiated and finally accepted. On 7 December a Letter of Intent is signed between Statoil and Maersk for a combined drilling and production unit, keeping the name, MÆRSK INSPIRER. It is the largest rig project ever undertaken by Maersk. Vetco Aibel of Haugesund in Norway is subcontracted to provide topside facilities and rig modifications. The power module, well-head and process modules are to be built in Thailand. Integration between rig and the modules is to be carried out at the Aibel Shipyards in Haugesund, Norway.
The project in outline:
The greatest challenge is to accommodate the topside facility on the deck of MÆRSK INSPIRER and to combine both drilling and production in one integrated unit. Major modifications are needed to include production, well head, flare facilities, and other minor rig interface modifications.
The project consists of the following phases:
- Design and engineering
- Fabrication of topside facilities
- Modification of MÆRSK INSPIRER
- Installation, hook-up and commissioning of the process modules
- Drilling and offshore hook-up
- Combined drilling and production
MÆRSK INSPIRER is to simultaneously drill and produce the Volve field. Once drilling is complete the unit is to produce until the field is abandoned. The contract also includes the possibility of work-over and drilling services on an ongoing basis, on request from Statoil.
- Hydrocarbons are to be processed on the rig itself
- Gas is to be transported by pipeline to the Sleipner East template
- Oil is to be transferred by pipeline to an FSO vessel, moored about two kilometres from MÆRSK INSPIRER
It is to drill eight wells which are expected to yield between 55 and 75 million barrels a year. The job should have a minimum duration of three years, but could extend to a maximum of ten.
The capacities of the MÆRSK INSPIRER after its conversion into a drilling and production unit:
| Oil production: |
9,000 m3/day |
| Gas production: |
1,500,000 m3/day |
| Produced water: |
10,400 m3/day |
| Power generation: |
24 megawatts |
The project progresses
On 31 March 2005 Maersk Drilling and Maersk FPSO’s largest ever contract is signed by CEO, Claus V. Hemmingsen and Statoil’s Morten Ruth, Senior VP, Technology and Projects for drilling and production on the same rig. ‘I am very proud to be signing one of our largest contracts to date,’ said Hemmingsen. ‘I look forward to continuing the excellent relations we have built up with Statoil. This project will build on, and further cement, the strong relationship Maersk has with Statoil,’ the CEO said, after the signing ceremony.
Project Manager Frederik Smidth and his project team now proceed, with the famous ‘constant care’, with the objective of meeting the drilling and production deadlines agreed in the contract.
By now the truly international dimensions of the project are emerging. Maersk is based in Denmark. The rig was built in South Korea, Aibel of Norway carried out design of the topside facilities at their Oslo offices and in Singapore; modules were built at Map Tha Put in Thailand and transported to Haugesund shipyards back in Norway for modification and integration with the rig itself. And with numerous sub-suppliers from all over the world MÆRSK INSPIRER lives up to its name in the global marketplace.
Ensuring safety onboard
- MÆRSK INSPIRER has a core crew of 58-62, although there will be around 100 people onboard during normal operation to take care of both production and drilling.
- The storage ship Navion Saga has an offload capacity of more than 100,000 m3 making it capable of storing about 12 days’ worth of top production.
- All communication takes place on broadband via Sleipner or cable.
- The rig has its own standby vessel and an agreement with a UK-based SAR helicopter should such assistance be necessary.
- The rig is equipped with remote-control radar for shipping traffic, operated and monitored from the Sandsli emergency preparedness centre.
- Onshore support consists of four frontline people with a technical support backup of 12 people.
On 9 May 2007 MÆRSK INSPIRER leaves the Aibel shipyard in Haugesund, Norway. It has spent the last six months being modified to include a combined process and utility module capable of generating 24MW, and of exporting 60,000 barrels/d of oil and 1,500,000 Sm3/d of gas. A well-head module has also been attached to the aft of the rig, which can carry 15 wells. The topside facility has been positioned to the right of the derrick so that they both share central position on the rig
Later that month MÆRSK INSPIRER is towed to the VOLVE field in the Norwegian North Sea and drilling starts immediately. 2,600,000 man hours have been spent on the project at the various sites.
On stream and full steam ahead
Just seven months later oil production commences on the enormous rig. It is now February 2008, a lucky Leap Year, so on the auspicious 29th, the Volve field is officially opened by Per Wulff, Managing Director of Maersk Drilling Norway and Tore Torvund, Executive VP of Exploration & Production at StatoilHydro. ‘This business concept got off to a good start and has already shows a regularity of almost 100% which bodes well for the future,’ said Tore Torvund, ‘Good cooperation is the key to success and StatoilHydro is delighted with the progress shown so far.’
Less than a month later, on 16 March 2008, the first offload from the storage ship Navion Saga took place.
Since then MÆRSK INSPIRER is exceeding all expectations in the Volve field. The rig has a daily production of up to 30,000 barrels, more than 650,000 Sm3/d of gas has been transferred, and 7,900 m3 of water has been pumped into the reservoir. The next oil producing well is ready where the prognosis is a maximum topside capacity of close to 60,000 barrels a day.
MÆRSK INSPIRER is proving itself worthy of its name. Despite extremely harsh weather and marine conditions, small, formerly inaccessible fields are within reach. The project has proven the power of good co-operation at every stage. It is truly ‘inspiring’ with its global perspectives, flexibility, and ability to extend ever further and deeper in extreme conditions, to the benefit of all.