The Topsides Process Module being lifted onto the FPSO Vessel in Singapore

Customer’s problem

Rubicon Offshore International expressed a need for a 44,000 barrels per day, single lift process module to install on their FPSO vessel for one of their offshore production operations.

Expro’s solution

Expro designed, engineered and supplied the complete process module from their Batam Base in Indonesia, with detailed engineering support from the Houston office. This project required all new-build equipment items to complete the required process facilities scope.

Results

The equipment was manufactured using several fabricators in Batam with final assembly at a quayside location for rolling onto a barge and shipping across to Singapore for installation on the FPSO. A separate drains/flare knock-out vessel was also provided for installation below the main deck module. The single lift module weighs 400 tonnes and comprises an oil processing system with two stages of separation and produced water treatment. The system is fully packaged with a PLC control and safety shutdown system and designed to handle up to 24,000 bbl/day of oil, 20,000 bb/day of water and 5 MMscfd of associated gas.

Technologies used

The process system includes two stages of separation with feed and interstage heating and product cooling to stabilise the oil before metering and storage in the vessel’s tanks. Separated water is treated by a hydrocyclone unit with direct feed from the first stage separator and final polishing through a degasser vessel before transfer to a water injection package.