Belanak Field Development

5/13/2019 Belanak field development combines platforms, FPSO, FSO, subsea links - Offshore
Belanak field development combines

platforms, FPSO, FSO, subsea links
11/01/2003
Innovative technology key to eld economics
Eldon R. Ball
Managing Editor
Development of the ConocoPhillips Belanak eld offshore Indone-sia will combine a range of
production structures, including two drilling platforms, an FPSO, a oating storage and
of oading (FSO) vessel, and a variety of subsea connections. The eld, con-sidered non-
commercial on its discovery more than 20 years ago, owes its success to advances in
technology and the cooperation of multinational oil companies and construction contractors.
ConocoPhillips, as operator, contracted with Halliburton af liates PT Brown & Root

Indonesia Ltd. (PTBRI) and Dresser Kellogg Energy Services (DKES) to design, engineer,
procure, construct, and install the FPSO, moorings, and exible risers.
Initial hull design and engineering were performed in Leatherhead, UK, while topsides design
and project procurement were conducted from Singapore. Dalian New Ship Heavy Industry
Co. Ltd. (DNS) shipyard in Dalian, China, completed the hull, marine electrical module, and
living quarters in August. PT McDermott Indonesia Ltd. (PTMI) is building the topsides at its
Batam, Indonesia, shipyard and will install them on the completed hull. Migas, PT Indospec,
and the American Bureau of Shipping are certifying the facilities. The project is managed
from Singapore.
The Belanak oil and gas eld is located in the Indonesian sector of the Natuna Sea northwest
of Kalimantan. It lies in 300 ft of water in the eastern portion of ConocoPhillips' block B
concession area, and it contains mainly wet gas. When the Belanak eld was discovered, its
remote location and limits of the available technology made development economically
impractical.
https://www.offshore-mag.com/articles/print/volume-63/issue-11/technology/belanak-field-development-combines-platforms-fpso-fso-subsea-links.… 1/9
In January 1999, the Indonesian state oil and gas company, on behalf of the Republic of
Indonesia, signed a gas sales agreement with SembCorp Gas (SembGas) of Singapore for the
delivery of 2.5 tcf of gas over 22 years, with rst deliveries beginning in 2001. The gas is
supplied from three production sharing contracts (PSCs) in the West Natuna Sea, including
the South Natuna Sea Block B PSC (operated by ConocoPhillips Indonesia Inc. Ltd.), the
Kakap PSC (operated by ConocoPhillips Kakap Ltd.), and the block A PSC (operated by
Premier Oil Natuna Sea BV).
Belanak has access to two pipeline systems – the West Natuna Transportation System, which
goes to Singapore, and a second line that goes to the Duyong eld and connects into the
Malaysian system to Kertah.
Click here to enlarge image
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These gas reserves are connected to the Singapore gas market via the ConocoPhillips-
operated West Natuna Transportation System, a 656-km, 28-in. pipeline and gathering grid in
the West Natuna Sea.
To meet the supply obligations under the SembGas and Petronas sales agreements and to
develop and produce extensive oil reserves, ConocoPhillips and its South Natuna Sea block B
partners, in partnership with Inpex Natuna Ltd. and Texaco South Natuna Sea Inc., began
developing several South Natuna Sea elds. The cornerstone of this effort is the Belanak eld
project.
Field development
Development of Belanak started in October 2000, and sales to Malaysia began on schedule in
August 2002, with the gas coming from dry gas elds in the western area of block B. Block B
partners include ConocoPhillips Indonesia Inc. Ltd. (operator with 40% share), Inpex Natuna
Ltd. (35%), and Texaco South Natuna Sea Inc. (25%).
The Belanak structure consists of two elds: Belanak and Southwest Belanak. The elds
cover an area 16 km long and 4 km wide. Seven exploration wells have been drilled to date,
showing ve main reservoirs:
Arang – a series of dry gas sands at 6,000 ft depth

Gabus Massive – a thin oil rim overlain by a large gas cap at 8,000 ft depth
Gabus Zone 3 – a series of oil sands overlain by a large gas cap at 8,500 ft depth
Lower Gabus – a thick oil sand overlying a water contact at 9,000 ft depth
SB90 – a series of thin gas condensate rich sands at 9,200 ft.
ConocoPhillips plans to develop the eld by drilling 34 production wells from two wellhead
platforms. The Gabus Massive reservoir will be developed with long horizontal wells, while
the other reservoirs will be developed using conventional deviated wells. The Gabus Massive
completion designs require downhole sand control (sand exclusion liners). The wells in the
other reservoirs simply require oriented perforating. The dry gas reserves in the Arang
reservoir will be developed later.
Belanak has proved hydrocarbon reserves equivalent to 142 MMboe. Gas reserves are
estimated at 398 MMcf and oil reserves at 33 MMbbl. Production is scheduled to start in
November 2004. Gas will be transported to Malaysia via a 96-km, 18-in. pipeline from block
B to the Duyong complex offshore Malaysia for further transport by Petronas to mainland
Malaysia.
The development facilities will include:
Two xed wellhead platforms and an oil of oading buoy

An FPSO vessel
An LPG-FSO vessel.
The facilities will be linked by subsea pipelines, pipeline end manifolds (PLEMs), risers, and
power cables. The facilities will be tied into the existing block B gas pipeline infrastructure,
which in turn will be connected to the pipelines of the West Natuna Transportation System
The two 24-slot wellhead platforms, with associated pipelines and an oil-of oading buoy, will
support depletion of the two Belanak elds. The platforms are fully automated, remotely
operated, normally unmanned facilities that are monitored by personnel located on the
FPSO.
The top deck of each platform is sized to support a full platform-based drilling rig capable of
drilling to 25,000 ft, with support equipment including three mud systems and
accommodation for about 110 workers during the drilling phase. Drilling from the platforms
will begin in October using a Nabors self-erecting platform rig.
The facilities will be linked by subsea pipelines, pipeline end manifolds, risers, and power
cables, and tied into the existing block B gas pipeline infrastructure.
The Belanak structure consists of two elds and ve main reservoirs. ConocoPhillips plans to
drill 34 wells from two wellhead platforms.
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FPSO complexity
The Belanak FPSO is intended as the central oil and gas processing hub for the block B
eastern area. The FPSO is one of the most complex vessels of its type in existence and is the
world's rst FPSO-based LPG plant. It has the capacity to handle production from other
nearby elds, such as Kerisi, Hui, and Belut, which are all in different stages of development.
Hydrocarbons will be produced from wells drilled on wellhead platforms A and B. Crude oil
will be processed on the FPSO and exported via the loading buoy. Gas will be transported
through the export line, while LPG will be of oaded from the nearby FSO.
The Belanak facilities will be capable of:
Producing and processing oil, dry gas, and LPG

Intermediate storage and exportation of stabilized crude oil
Exporting pipeline-speci cation dry gas
Intermediate segregated storage and export of LPG products (propane and butane).
Process and export capacities are:
100,000 b/d of oil

28,000 b/d of recovered LPG, including condensate
420 MMcf/d of sales gas
Gas injection capacity of 200 MMcf/d
The LPG-FSO will be turret-moored 2.2 km southeast of the FPSO. The mooring will enable
the vessel to weathervane freely. LPG will be received from the FPSO through two rigid
export pipelines, connecting the PLEM at the FPSO with a PLEM beneath the LPG-FSO. Two
exible risers will connect the PLEM to the swivel turret mounted on the bow of the LPG-
FSO.
The LPG-FSO vessel will be able to store 78,000 cu m of LPG. The LPG, in refrigerated or
pressurized form, will of oad to trading LPG carriers. During of oading, the tankers will be
moored alongside the LPG-FSO.
Contract negotiations for the LPG-FSO are in progress. The vessel may be either a
conversion or a new-build.
Technological challenges
The size and complexity of the topsides and the inherent dif culties of installing an LPG plant
on a oating structure challenged both the topsides and marine designers. The Belanak FPSO
is the most complex ConocoPhillips has installed offshore, and the safety, environmental, and
process engineering considerations for the unit are considered to be at the leading edge of
the offshore industry's knowledge and experience.
The FPSO will have a topsides operating weight of nearly 31,000 tons, with the following
design features:
Processing capacity of 100,000 b/d of oil or total uids, with up to 50,000 b/d of
produced water
Storage of 1 MMbbl of oil and condensate
Of oading capacity of 25,000 bbl/hr of oil or condensate to a shuttle tanker via the
of oading buoy
Low-pressure gas compression of 360 MMcf/d through two 11,000-hp electrically
driven compressors
Treatment of 377 MMcf/d of sour gas to remove hydrogen sul de
Dehydration of 522 MMcf/d of gas

Export of 24,000 b/d of propane and butane
Export of up to 420 MMcf/d of sales-quality gas through two Rolls Royce RB211-driven
export compressors
Re-injection of 200 MMcf/d of gas through a 14,000-hp electrically driven compressor
Generation of 50 MW of continuous electrical power using ve Rolls Royce Avon-
driven generator sets
30-year design life, with no requirement for interim dry-docking.
Marine considerations
Unique challenges faced the marine design and engineering teams, including:
The 30-year service life

The large topsides loads (31,000 tons) that impacted stability
The need for stringent motions restrictions, to ensure that the LPG pro-cessing
facilities onboard could operate ef ciently.
The hull has been designed and built as a double side, single bottom con guration with no
self-propulsion. It includes 14 oil/condensate cargo tanks providing 1 MMbbl of storage, 18
ballast tanks (14 wing tanks and four fore and aft peak tanks), and two slop tanks.
The FPSO contains 14 cargo pumps: one located in each tank delivering 1,000 cu m/hr, with
three booster shipping pumps (2,000 cu m/hr) located on deck. Four pumps handle ballast
through at 1,400 cu m/hr into a 14-in. ring main at tank bottoms.
Mooring and motions

Weather conditions in the Natuna Sea favor a spread-moored system of anchoring, with no
turret required. The FPSO will be moored with aft facing the prevailing northeasterly winds,
and it will be anchored by 14 mooring lines requiring over 11,000 m of 127-mm-thick steel
chain anchored into the seabed by 14 suction piles.
This system has been shown to have a fatigue life of over 300 years and is designed to
withstand a 100-year storm without exceeding the exible riser watch circle.
Two riser porches are located forward and amidships on the starboard side. These will
support nine exible risers – two production, two oil of oading, two LPG export, two
wellhead platform gas injection, and one gas export riser. Three 13.8-kv subsea power cables
exit the FPSO from the riser porches.
The mooring system is designed to ensure that the motion of the operating vessel is
adequately stable for reliable LPG production. The allowable movement at the top of the LPG
fractionation columns, some of which are over 60 m high, is +/- 2° from vertical (roll or pitch,
including static tilt). The current design demonstrates less than 1.75° more than 99% of the
time.
The hull was designed and built to last 30 years without the need for dry-docking.
Belanak FPSO marked major milestone for China yard

The contract to build the hull, marine electrical equipment module, and the 120-person living
quarters with Dalian New Ship Heavy Industry Co. Ltd. (DNS) of Dalian, China, marked the
rst time that ConocoPhillips and Kellogg Brown & Root (KBR) had built an FPSO hull in
China. Likewise, DNS had not previously built an FPSO of such size and to such exacting
speci cations.
DNS was established in August 2000 when it was separated from the original Dalian
Shipyard within which it had operated for 40 years. The Chinese government, through the
China State Shipbuilding Corp., has invested heavily in DNS, which now has a capacity of
200,000 dwt per year. DNS has delivered over 60 vessels, including semisubmersible rigs,
jackups, and two previous FPSOs. This track record plus an order book for 14 newbuilds,
including ve 300,000-dwt very large crude carriers, helped show that DNS could meet the
demands for competitive price, quality, and the exacting delivery schedule expected by the
Belanak FPSO project team based in Singapore.
ConocoPhillips and Dresser Kellogg Energy Services (DKES) say they worked as a team with
DNS throughout the construction period. Communication between DNS and the DKES site
team in Dalian, as well as the design teams in Leatherhead, UK, and Singapore was seen as a
challenge. To help facilitate communication, the project leadership integrated teams with
Mandarin-speaking members in key positions. To DKES and ConocoPhillips, the success of
the teamwork was demonstrated in the delivery of the completed hull, marine electrical
module, and living quarters in 18 months from rst cutting of steel on March 15, 2002, and
24 months from the beginning of design.
The ship was built using modern shipbuilding block assembly. The aft section, representing
about 40% of the hull, was built on a slipway and then launched into the sea to be towed to
the 375-m x 80-m drydock. In drydock, the fore section blocks were assembled and the whole
hull joined together.
In parallel to the hull assembly, the 4,700-ton marine electrical module was constructed on
the quayside along with the 1,220-ton, 120-person living quarters. Both modules were lifted
onto the hull in drydock in March. The hull was launched from drydock on March 26 and was
docked along the quayside for nal tting-out and commissioning of the marine systems.
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5/13/2019 Belanak field development combines platforms, FPSO, FSO, subsea links - Offshore

Belanak field development combines

Innovative technology key to eld economics

ConocoPhillips, as operator, contracted with Halliburton af liates PT Brown & Root

Arang – a series of dry gas sands at 6,000 ft depth

The development facilities will include:

Two xed wellhead platforms and an oil of oading buoy

The Belanak facilities will be capable of:

Producing and processing oil, dry gas, and LPG

Process and export capacities are:

100,000 b/d of oil

Dehydration of 522 MMcf/d of gas

The 30-year service life

Mooring and motions

Click here to enlarge image

Belanak FPSO marked major milestone for China yard

About Us | Site Map | Privacy Policy | Terms and Conditions

© 2019 Endeavor Business Media, LLC. All rights reserved.

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