OTC 16561

Subsea gas compression - A future option

Bernt Bjerkreim, Norsk Hydro ASA

Copyright 2004, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in
Houston, Texas, U.S.A., 3–6 May 2004.

This paper was selected for presentation by an OTC Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Offshore Technology Conference and are subject to
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Abstract
Ormen Lange is a long step-out gas field developed with gas
processing facilities 120 km from the production wells. The
development strategy is to deplete the reservoir. In order to
maintain the production platau as long as possible and recover
the anticipated gas and condensate resources, future compres-
sion is required for Ormen Lange.
This paper describes the base case future compression al-
ternative, the floating production platform.
The paper also describes subsea gas compression as an al-
ternative to the floating production platform and how the
qualification strategy is outlined in order to ensure a qualified
subsea gas compression system at the time of concept selec-
tion for future gas compression.
Introduction
Ormen Lange is a gas field located 100 km off the northwest
coast of Norway on the Norwegian continental shelf, in water
depth varying between 850 and 1,100 meters.
The reservoir covers an area 40 km long, eight to 10 km
wide and 3,000 meters below the surface. Recoverable re-
serves are estimated to approximately 397 billion Sm3 dry gas
and 28.5 million m3 condensate.
Ormen Lange is under development and production will
start October 1, 2007.
.
Fig. 1. Ormen Lange development
Summary
The main drive mechanism for the Ormen Lange reservoir is
pressure depletion. The estimated recoverable reserves are
based on the use of future compression facilities for pressure
boosting upstream from the onshore plant, as the reservoir
pressure declines.
The Ormen Lange subsea units and layout will be designed
to accommodate the flexibility to evaluate and decide the type
of offshore compression unit(s) at a later stage. The options
considered are:
• Subsea compression.
• Topside compression on a platform.
The final decision on an offshore compression concept can
be postponed for a number of years after subsea production
start-up of the Ormen Lange field. An evaluation of the matur-
ity of the required technology and risk assessment for the two
alternatives will be performed when required, as determined
by production experience. This, in combination with pressure
boosting onshore, upstream of the processing plant, will define
the best timing of further compression facilities offshore. In-
stallation of offshore compression in 2016, as indicated by this
report, is therefore to be considered as an example only. On-
shore compression is considered as proven technology and is
therefore not described further in this report.
Topside compression, represented by a semi submersible,
is chosen as the base case for offshore compression.
2 OTC 16561
It should be noted that the subsea control of the gas pro-
duction, MEG supply, etc., will still be from the on shore ter-
minal CCR, even if an offshore compression platform is in-
stalled.
A qualification program for the subsea compression con-
cept is proposed executed until a decision for implementation
is taken. In this report, the cost for this qualification program
is included as part of the base case cost estimate. The decision
for possible implementation will be taken after sufficient pro-
duction experience has been obtained.
Installation and commissioning, related to the semi sub-
mersible, riser towers, tie-in of production jumpers, etc., will
have no minimum impact on the continued gas production
from the subsea production units
Design premise
This section covers platform based compression, subsea com-
pression and onshore precompression.
The facility design basis describes the purpose of the fu-
ture compression facility as follows:
“The main drive mechanism is pressure depletion. The es-
timated recoverable reserves are based on use of future com-
pression facilities for pressure boosting upstream of the on-
shore plant, as the reservoir pressure declines.
The production can be described by the following produc-
tion phases:
• Early production
o Production prior to installation of future compression
facilities.
o Installation of future compression facilities.
o A flowing wellhead pressure of typically 140 bara is
required to meet an onshore arrival pressure of 75 bara
and a sales gas export rate of ~60 MSm3/sd, and this
determines the time for installation of the future com-
pression facilities.
• Production after installation of future compression facili-
ties:
o Onshore plant arrival pressure is maintained at 75 bara,
and the sales gas export rate is maintained at
~60 MSm3/sd.
• Tail production:
o The future compression facilities can no longer provide
pressure boosting to meet an onshore arrival pressure
of 75 bara and a sales gas export rate of ~60 MSm3/sd,
this corresponds to a flowing wellhead pressure of
typically 100 bara.
o The production flow gradually decreases.
o Flowing wellhead pressures continue to decrease to a
pressure of typically 60 bara, which is the minimum
pressure accommodated for.
o Onshore plant arrival pressure is typically maintained
at 75 bara (as an alternative, the onshore plant arrival
pressure may also be further reduced).
The design premise requirements are reflected as follows:
• The Ormen Lange facilities will include flexibility for in-
stallation of future compression facilities, being one or a
combination of the following:
o Offshore compression platform.
o Subsea compression.
o Onshore booster compression upstream gas processing.
Bypass of the compression facilities will be possible.”
Onshore pre-compression
Site arrangement shall allow for installation of future onshore
compression facilities for pressure boosting upstream of gas
processing, to provide the possibility to accommodate poten-
tially low onshore plant arrival pressures (i.e. considerably
less than 75 bara).
The required site area arrangements include reservation of
space for two gas booster compressor trains (one per 30” pipe-
line/slug catcher arrangement), located downstream the slug
catchers.
Offshore compression
The offshore compression will be designed to:
• Receive wellstream from each of the four template headers
on the two initial templates (A and B), and to receive well-
stream from the two future templates (C and D).
• Distribute compressed wellstream to each of the two 30”
pipelines, with the possibility to also distribute the com-
pressed wellstream to the third optional 30” pipeline.
Offshore compression platform. The offshore compression
platform will include the following (as basis for PDO):
• Two compressor trains only.
• Local (offshore) power generation.
A flowing wellhead pressure of typically 100 bara corre-
sponds to a platform top riser pressure of typically 90 bara at a
sales gas export rate of ~60 MSm3/sd.
A minimum flowing wellhead pressure during tail produc-
tion of typically 60 bara corresponds to a minimum platform
top riser pressure of typically 50 bara.
Subsea compression. The subsea gas compression station(s)
will include power distribution equipment. The power distri-
bution equipment will be designed to:
• Receive required amount of power from the main trans-
former.
• Distribute the electrical power to all users.
• Individually regulate the speed of all electrical motors.
The required power will be delivered at Ormen Lange with
a main power cable. The power system will be designed to:
• Deliver required electrical power and transform down the
power from the transmission voltage and down to a distri-
bution voltage level.
• Supply all control functions.
• Enable power connection to the power distribution equip-
ment.
• Enable control connection to the gas compressor station(s).
Technical description onshore pre-compression
No specific study has been performed for the onshore com-
pression system. Space has been reserved in a suitable location
at the plant, and conventional VSD driven gas compressors are
assumed to be installed at the appropriate time. The compres-
sors would take feed gas off the slug-catchers and no pre-
cooling would be required. The existing feed gas heaters could
be converted to serve as compressor aftercoolers.
OTC 16561
Leadtime for design, purchase and installation of such a
system will be 36 months minimum and no qualification is
required.
The cost for such a solution will depend on the size of the
compression installed. This will be decided at the appropriate
time based on production experience and market considera-
tions. No cost has therefore been assigned to this option.
Installing onshore precompression does not influence the
selection of technology for offshore compression, but it delays
the time when such facilities will be required.
Technical description offshore compression
platform
The offshore compression platform has the following design
data:
Capacity: Gas export of 60 MSm3/d to shore.
Inlet pressure*: 140 bara initially, decreasing to
70 bara with time.
Export pressure*: 140 bara (fixed) at riser-top.
Inlet temperature: Starting at 30 oC, decreasing with
time.
Export temperature: 50 oC
Slug capacity: 50 m3 instantaneously.
Living quarter 80 persons.
*Inlet and outlet pressure will depend on the final riser configuration and the
location of the platform.
The future compression platform is required when the
wellhead pressure decreases so that a rate of 60 MSm3/sd to
the onshore facilities can not be maintained without boosting.
The topside design is based on minimum processing of the
fluid. The process involves separation of the gas and liquid
phases, with compression of the gas and boosting of the liquid.
The gas and liquids are mixed and transported to shore in the
same multiphase pipelines used prior to platform installation
for further processing onshore.
Bypass of the compression platform is designed for. The
production rate onshore is then limited to the hydraulic capac-
ity of the pipelines at the relevant wellhead pressure, decreas-
ing with time.
For the minimum processing platform, the focus has been
to keep the process as simple as possible. A two-train configu-
ration has been chosen due to limitation in equipment sizes.
The challenge with this configuration is to have high energy
efficiency throughout the lifetime of the installation. Rebun-
deling of the compressors is planned. The current driver cho-
sen for each of the compressors is an LM2500+ tubine. Pow-
erwise, the LM2500+ is too big for the initial phase and on the
short side for the later phase. Future investigations will look at
the possibility for making a compressor selection that by
means of later rebundling, would make up two 100% units in
the initial phase and two 50% units in the later phase with the
higher pressure ratio. BAT evaluations will be performed in
basic design with regard to overall energy efficiency.
The 24 hours-a-day control and monitoring of the platform
will be done from the onshore CCR. The platform CCR will
normally be manned during daytime by an operator, while
there are field operators around on the platform continuously
accessible by wireless communication.
The main power supply configuration is 2x100%, two gas
turbine driven generators with LM1600 gas turbines.
3
Emergency power is supplied by 2x100% diesel driven
generators.
Hull. The semisubmersible is a four-column structure with a
quadrangular pontoon supporting the deck structure. The term
"lower hull" is used to identify the hull up to the top of the
columns, while the term "upper hull" means the deck structure
between the top of the columns up to and including the main
deck.
The pontoon gives flexibility with respect to riser connec-
tion/hang-off, in addition to advantageous strength characteris-
tics for temporary conditions (transport/mating). The cross
sections of the pontoons are rectangular to ease fabrication and
to improve motion characteristics through high natural damp-
ing. The pontoon height selection is based on experience from
similar constructions mostly related to strength requirements.
To ensure robustness with respect to longitudinal center of
gravity the pontoons are made asymmetrical.
The length between columns is both NS and EW c/c
66.56 meters. The column dimension is 17.92x17.92 meters
with a bilge radius of 5.76 meters.
Topside. The main load-carrying element of the upper hull is
a rectangular box structure with the perimeter aligned with the
outer edges/center bulkheads of the columns in transverse and
longitudinal direction.
The living quarter are a separate module supported at main
deck level.
Layout. The prevailing wind direction is from southwest. The
living quartera (LQ) are located at the west side of the deck,
with the heli-deck positioned above in the SW corner.
The location of the flare is in the opposite corner from the
helideck. (NE).
The overall dimensions of the deck are as follows:
93.5 meters long x 66.56 meters wide. That includes the LQ
and riser balcony. The total area taken up by the process is
approximately 2,900 m² on both main- and cellar- deck levels.
This includes area taken up by walkways, future area and
spare area. The upper process deck (main deck) is 8 meters
above the cellar deck.
The CCR and CER are located on the mezzanine deck
level, directly underneath the LQ.
Workshop and central stores are located close to the living
quarters on the main deck level. There are direct walkways
and escape routes to the lifeboats from the workshops.
Good access is provided for forklift truck access to work-
shop and central stores.
A fire/blast wall segregates the process area from the util-
ity area.
A main transport and walkway is located on both deck ele-
vations. For vertical transport, a lift is located near the work-
shop and main stores.
One pedestal crane is located on the south side. The duty
for the pedestal crane is common laydown, and laydown for
the living quarter. The crane can also be used to assist with
installation of future equipment in spare areas.
For vertical transport of goods down to the hull, there is
one lift in both the NW and SE shafts.
4 OTC 16561

Both emergency generators and firewater-pump generators
are located on the cellar deck.
Process description. Due to equipment limitations (vessel
sizes and compressor drivers), the main process is divided in
two parallel trains. Each train is provided with a supply header
connected to dedicated risers. The supply headers for the two
trains are not connected. A subsea manifold system makes it
possible to route the different wells to both supply headers,
depending on the characteristics of the wells. The two pipe-
lines to shore may also be operated at different pressures. The
process system is designed for full shut-in pressure. HIPPS
solutions are regarded feasible and will be considered in the
basic engineering for this concept.
Each gas train consists of a two-phase Inlet Separator, two
parallel suction coolers, a suction scrubber, a gas compressor
potential templates and deliver the compressed gas to all three
potential pipelines to shore.
The physical interfaces between the initial Ormen Lange
development and the subsea compression alternative will be
the same as for the platform compression alternative.
Subsea compression system layout. The two subsea gas
compression stations will be positioned adjacent to the well
templates. The discharge from the compression stations will
be connected to a modified pigging loop located at the end of
the two multiphase pipelines transporting the gas to the land-
based gas processing facilities.
Subsea
compression
2x16" 2x16"
D C

and two parallel after coolers. Each liquid train consists of a 20" 20"

condensate booster pump and a condensate export pump. The 2x16" 2x16"

two trains have a common set of spare pumps. 30"

30"

Technical description subsea compression 2x18" 2x18"

A B

Summary. Subsea gas compression is estimated to have a sig- 20" 20"

4x20"
nificantly lower investment cost than the platform compres-
sion alternative, with the same core functionality of compress- 25 MW Gas

ing gas for transportation purposes to shore for further proc- Compressor
Template
Main Transformer

essing and export. module

A subsea compression system is not qualified. If such a

system is qualified at the time of concept selection for off- Fig. 2. Ormen Lange development including future subsea com-
pression.
shore gas compression, the advantages of applying subsea gas
compression can be summarized as follows:
Qualification strategy. Subsea gas compression consists of
• Lower investment cost.
the following two main parts:
• Sequential development of offshore gas compression in-
• Subsea gas compression station.
stallation and thereby staggered investment cost profile.
• Long step-out power supply.
• Possibly reduced operational cost.
Technical Selection of Selection of
In order to ensure fully qualified subsea compression qualification one contractor Feed studies one contractor
for piloting For Ormen Lange
equipment and create general confidence in such equipment and
Competitive
and
Basic design competitive
by the decision makers, two years of pilot testing the subsea tendering
tendering
compression system has been proposed.
Qualifying subsea gas compression might also yield poten- System studies EPC of pilot EPC of subsea
tial new and more cost-effective design for the offshore plat- And testing compression

form alternative.
• Location for the subsea compression piloting could be at
Nyhamna (dedicated test facilities) or as part of a satellite
development tied back to existing infrastructure, where in-
creased calculated risk for such a development is accepted
and accounted for. Both pilot options will be explored, but
the dedicated test facility at Nyhamna remains the base
case option until otherwise decided.
Design premise. In order to ease the comparison between
platform compression and subsea compression, the subsea
compression alternative will have the same basic functionality
as the platform compression alternative.
The subsea compression alternative will be arranged such
that compression power can be utilized for the two first tem-
plates and two pipelines are installed. The arrangement will
additionally have the capability to compress gas from all four
Information
flow between
contracts handled
by Company
Fig. 3. Ormen Lange subsea gas compression qualification
stragegy.
For each of the two parts, qualification activities will be
conducted with selected vendors in order to mature identified
critical components. All results from the qualification activi-
ties will be supplied to potential main contractors through sys-
tem studies. At the completion of this two year qualification
phase, all prequalified main contractors will compete during
competitive tendering for the subsea gas compression pilot.
At completion of the subsea gas compression pilot (esti-
mated to take three years) and the subsequent two years test-
OTC 16561 5

ing period, the subsea gas compression system is regarded as

fully qualified. Long step-out power supply
Main Transformer compensation
Selected generic system for pilot set-up (draft)
After completion of the subsea gas compression pilot, Penetrator
FEED and competitive tendering might well be conducted for
delivery of subsea gas compression system at Ormen Lange.
Combined power&control cable

Subsea gas compression generic pilot set-up. In order to

ensure competitive tendering and include all components,
which might be required for a future subsea gas compression
system at Ormen Lange, a generic pilot set-up has been devel-
oped. All main contractors competing for the subsea gas com-
pression system pilot must ahere to this generic pilot set-up. Termination
The generic set-up offers:
• Flexibility with regard to:
o Future technical content. Date: 2004-01-19 • Page: 8 • Hydro Oil & Energy

o Market competitiveness.
• Putting the focus on a gas compression system rather than
compressor technology.
• Allowing all vendors to deliver their products and tech-
nologies.
• Requiring vendors to demonstrate if some functionalities
can be omitted.
• Final optimization of the gas compressor system may be
postponed until after qualification rather than as a prereq-
uisite for the technical qualification and piloting activities.
Fig. 5. Possible generic set-up for long step-out power supply.
Subsea compressor piloting at Nyhamna. A pilot test facil-
ity at Nyhamna is used as a base case for the cost estimate of a
fully qualified subsea compression system. The test facilities
will be able to conduct representative wet gas compression,
representing Ormen Lange conditions. In addition, the test
facilities should be made such that the subsea gas compression
system pilot can be utilized as an additional gas export com-
pressor and/or on-shore precompression.

Wet gas handling

Test Com. for VSD and swith gear

Anti surge valve Connectors and penetrators test mode. LV Power

Control and utilities

Compressor**
CB and VSD

Anti surge cooler

Input cooler
Separator*
Control Inflow based
liquid added
system dewpointed

Choke pressure
dump gas and
Sand trap in slug

Closed loop for

during

CB and VSD Pump

*Slug handling,
liquid separation,
fines handling
and
Date: 2004-01-19 gas
• Page: scrubbing
5 • Hydro Oil & Energy ** Liquid tolerant or not
Figure 6.: Nyhamna test facility set-up.
Fig. 4. Subsea gas compression generic pilot set-up.

Long step-out power supply generic set-up. As for the sub- Functional requirements. The Nyhamna plant will have
sea gas compression generic pilot arrangement, a generic set- the following general requirements in order to support its test
up is in the process of being established for the long step-out facilities:
power supply. • Capacity to control and operate the test facility and equip-
ment being tested from the central control room.
• 132 kV, 20 MVA power supply to the test facility.
• 690 V power supply to the test facility.
• 440/230 V power supply to the test facilities.
• Gas supply for wet gas testing:
o 15 MSm3/d gas supply to the test facilities, with capa-
bilities for choking and adding representative liquid
and solids to the gas.
• Gas supply for durational testing:
o 5 MSm3/d gas supply to the test facilities.
• Capability to pump the liquid from the test facility to the
process system.
6 OTC 16561

• Capability to pump seawater to and from the test pit.

The following are the preliminary specific requirements
for a Nyhamna test facility:
• General test area of 25x50 meters (including the indoor
area).
• Local HPU and chemical injection room (3x4 meters).
• Indoor test pit 20x30 meters, 12 meters deep.
• Indoor lay-down area of 20x10 meters.
• Pump system to empty and re-fill the test pit.
• Overhead crane (100 tonnes), capable of:
o Reaching the indoor lay-down area.
o Reaching the test pit.