Hilal redevelopment project

The existing Hilal platform is located in the Shoab Ali field in the Gulf of Suez. The platform was constructed and installed in 1984. However, 10 years later, the platform was severely damaged by ship impact and fire. Figure 1.1 shows the facility immediately post the ship impact.

Hilal Platform after Ship Impact and Fire
Figure 1.1 Hilal Platform after Ship Impact and Fire

Further to the impact, the topsides were replaced and production resumed. However, the repair work to the jacket proved to be inadequate, and the three conductors contributed to poor structural rigidity, which resulted in excessive conductor/platform relative deflections and consequent rupture of the oil export flow line in 2004.

A further repair to the substructure was made and production resumed, but due to ever growing concerns over environmental protection and safety of operators, a decision was made to cease production and shut down the wells in 2007. Figure 1.2 shows the current condition of the platform.

Hilal Platform current condition
Figure1.2 Hilal Platform current condition

Temporary rigging were installed in 2008 as an attempt to stabilize conductor guide frames and 24” conductors. After recent negotiations on concession agreement extension, GUPCO had intentions to bring oil production back from the field. The Torsina Board agreed on September 26th to progress the “New Platform” option into FEED Engineering.
The production is expected to reach 3-5 Mbbl/d of crude oil. The cost of the new platform is estimated around $234 million.

The project’s main contractors are: ENPPI (FEED & Detailed Engineering), Petrojet (Procurement & Fabrication) and PMS (Offshore work). The project is scheduled to be completed in the third quarter of 2013.
New Build Option
New jacket will be installed at a distance of approximately 200m from the existing one, which would allow the existing platform to be safely removed.

Advantages of New Build options:
– New Jacket installation involves less offshore activities.
– Conventional piling.
– No requirement for diving.
New topsides will be designed in accordance with relevant standards and regulations
PIPELINES: Existing 12 and/or 18” pipelines will be re-instated. No failures of lines have been recorded. The integrity of the lines will be assured through inspection. Besides, a 12” or 18” tie-in spool will be installed. The pipeline will then be leak tested. Moreover, the existing 8” L spool will be replaced by another one, same size with integral tee.
Drilling: new seven wells will be drilled according to plan.

Project’s Status
1. Engineering
ENPPI is progressing PFDs, process simulation and revising the process piping design as per the recent design change on the flange ratings. Also, the company commenced engineering activities for line designation table, material selection guide and telecoms philosophy. Currently, ENPPI Structural Team is progressing in place analyses design report and jacket preliminary steel drawings.

2. Contracts
Hilal Pipelines Inspection Tender commercial evaluation is complete. Principal Bid Committee memorandum is under approval for award.
The Project Team is working on drafting the Petrojet Structural Materials Provision and Fabrication Contract; expected to be issued to PSCM before the end of October. The team has also issued a memorandum to PSCM asking an International Offshore Installation Tender to be initiated. PSCM is working on the tendering strategy.

3. Procurement
Petrojet issued tender for the provision of structural bulk materials. Technical evaluation of the quotations is in progress. On the other side, ENPPI is progressing technical evaluation of these quotations: Chemical Injection System, Safe Guard System, Pig Launcher and Receiver, Electrical Solar System Power Supply. Besides, ENPPI issued tender for these items, is collecting quotations from the market: Navigational Aids, Gaskets, Hot Bends, Multiphase Flowmeter, Pressure Regulating Valves.

4. Other Issues
A site visit was held to review the existing condition of the Ras El Ush Control Room.
At the end of 2010 and early 2011, the following has been done:
Securing & Stabilizing of existing PF to avoid its Collapse
All the current producing wells is Plugged & Abandoned.

By Osama El-Sayed
Projects General Manager for investments and JVs, EGPC


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