The Frade field is situated 370 km from the coast of Rio de Janeiro in the northern Campos Basin, Brazil. The heavy oil and gas field is located at a water depth of 1,128 meters. The field is operating 11 production and four water injection wells. Oil is produced through the Frade FPSO, which is moored by an internal turret and located at a water depth of 1,080m. The oil is stored and transported onshore by crude oil tankers.
FPSO Frade can accommodate 33 risers and has an oil production capacity of 100,000 barrels of oil per day (bopd). The vessel’s gas compression capacity is 106 MMcf/d, and its water injection capacity is 150,000 bwpd. It has a storage capacity of 1,550,000 barrels and weighs 273,576 DWT.
Challenge
As part of a requirement from the Brazilian National Petroleum Agency (ANP), the operator had to install two new skids over existing modules in the middle of the Frade FPSO. The project involved multiple hot work applications, including welding and grinding, for the installation of these new structures on top of the existing ones.
Planning
The project plan was to deliver the installation in three phases. The first phase of the project involved installing a longitudinal reinforcement beam, ensuring the modules had the necessary strength to withstand the additional load from the new skids. The second and third phases were the installation of the skids.
*image for illustration only
Solution
The work scope required the delivery of two habitats, which were then rebuilt onboard 27 times. This ensured maximum efficiency all around and safe enclosure of the hazardous work as needed for the completion of the hot work.
During phases two and three, the SAFEHOUSE habitats had to be built as quickly as possible, with the skid suspended by the crane, to enable a weld point to hold it in place after the crane’s release. The remaining welding work could then be completed. The SAFEHOUSE habitats were operated simultaneously, embracing the legs of the new skids. The gas sensing modules were located on the main deck.
Outcome and benefits
The project was completed as planned with our technicians onboard a total of 43 days. As a result, we delivered 640 safe man-hours, with all hot work completed safely, allowing production to continue as usual and eliminating the need for a shutdown.
