DEEP WATER

FIELD DEVELOPMENT
 INDEX

SAIPEM TODAY 4

SAIPEM ENGINEERING & CONSTRUCTION 6

SAIPEM DEEP WATER OIL & GAS FIELD 8

DEVELOPMENT

SAIPEM: A COMPLETE CONTRACTOR 12

FOR THE MOST CHALLENGING DEEP WATER
UMBILICALS, RISERS AND FLOWLINES PROJECTS

SAIPEM’S HIGH TECH PRODUCTS AND 28

ADVANCED PROPRIETARY SOLUTIONS

NEW CONCEPTS UNDER DEVELOPMENT: 40

RISER SYSTEMS

NEW CONCEPTS UNDER DEVELOPMENT: 42

SUBSEA PROCESSING

PROJECT REFERENCES 46
­3
SAIPEM
TODAY
SAIPEM TODAY IS A WORLD LEADER IN THE GLOBAL SUPPLY
OF ENGINEERING, PROCUREMENT, PROJECT MANAGEMENT,
CONSTRUCTION AND DRILLING SERVICES WITH DISTINCTIVE
CAPABILITIES IN THE DESIGN AND EXECUTION OF LARGE-SCALE
OFFSHORE AND ONSHORE PROJECTS.

Saipem has a strong bias towards oil

and gas frontiers, namely activities
in harsh and remote areas, in deep
waters as well as in extremely cold and
hot environments, applying significant
technological competences in many
diverse fields such as gas monetization
and heavy oil exploitation.

Saipem is organized in two Business

Units: Engineering & Construction
and Drilling.

­4
­5
SAIPEM
ENGINEERING & CONSTRUCTION
FOLLOWING AN AGGRESSIVE GROWTH STRATEGY, WHICH INCLUDED
IN THE LAST DECADE THE ACQUISITION OF MANY CONSTRUCTION,
TECHNOLOGY AND ENGINEERING COMPANIES, MOST PROMINENTLY
OF SNAMPROGETTI, BOUYGUES OFFSHORE, SOFRESID AND MOSS
MARITIME, SAIPEM HAS BECOME ONE OF THE WORLD LARGEST
AND MOST COMPLETE ENGINEERING AND CONSTRUCTION COMPANIES
IN THE GLOBAL OIL AND GAS MARKETS, ONSHORE AND OFFSHORE.

­6
Ever since its initial steps in the fifties and numerous project execution installation; also revamps, upgradings,
as the construction division of Snam, centres around the globe, and with maintenance, decommissionings,
the pipeline company of the Eni Group yearly revenues exceeding 10 billion €/y; reclamations and decontaminations.
in Italy, Saipem has pursued all held together by outstanding project
a systematic growth strategy, based management skills. Saipem today operates in virtually every
on the development of internal assets, world market, often in remote locations
expertise and skilled resources, as well Through the involvement of our global with harsh environmental conditions
as on the acquisition of other players EP(I)C hubs in Milan, Rome and Fano and challenging logistics, leveraging
with their own asset bases, such as (Italy), Paris (France) and Chennai on its proven experience across the
Micoperi in late eighties, and many (India), which operate in connection most significant product lines in the
others. with a growing number of medium size oil and gas production onshore,
and smaller regional engineering offshore, in deep water; gas and oil
In the last decade, Saipem has and project execution centres transportation via offshore and onshore
continued its growth by acquiring employing altogether over 7,000 pipeline systems; midstream, refining,
Bouygues Offshore and Sofresid in engineers, Saipem balances high chemicals, power generation from fossil
France, Moss Maritime in Norway, IDPE project execution quality with a as well as from renewable sources;
in India and Snamprogetti in Italy, competitive cost and - most importantly environmental industries, maritime
and by carrying out a multibillion - with a major emphasis on local works and infrastructure.
investment program into the expansion know-how and content.
of its offshore construction and drilling This new series, therefore, outlines
fleets. Since the year 2000, Saipem’s This well-integrated multicenter Saipem’s integrated references
market capitalization has grown more approach provides a consistent design in engineering and construction
than sixfold and its revenues tenfold.(*) and robust execution philosophy markets offshore and onshore,
on all our projects worldwide. according to individual business
The organizational integration of Top priority is provided throughout and technology lines.
this considerable asset base, namely to all HSEQ aspects.
the network of engineering centres,
fabrication and support yards in several Saipem therefore offers a complete
continents as well as the offshore range of project definition
construction fleet, has been completed and execution services, offshore
gradually over the years - most recently and onshore, particularly for
with the creation of a unified Business the complex “mega-projects” required
Unit Engineering & Construction, by the market today: from feasibility
an entity with over 30,000 employees and conceptual studies to complex
(excluding corporate and BU Drilling integrated solutions combining design,
staff) from over 100 nationalities, engineering, procurement, field
with over 60 permanent establishments construction, fabrication and offshore

(*) Until Dec. 31, 2010

­7
SAIPEM DEEP WATER OIL & GAS
FIELD DEVELOPMENT
SINCE ITS EARLY DAYS, SAIPEM HAS HAD A STRONG BIAS TOWARDS
FRONTIER PROJECTS, SUCH AS THE EXPLOITATION OF THE SUBSEA
OIL & GAS FIELDS, WHICH HAVE BEEN DISCOVERED IN DEEPER
AND DEEPER WATERS. TO MATCH THE CHALLENGES OF ULTRA
DEEP WATERS AND NEW GEOGRAPHICAL AREAS, OVER THE YEARS
SAIPEM HAS DEVELOPED OUTSTANDING ENGINEERING AND PROJECT
MANAGEMENT SKILLS, SPECIFIC PROPRIETARY TECHNOLOGIES AND
A TOP CLASS DEDICATED CONSTRUCTION FLEET, BECOMING ONE
OF THE MAJOR PLAYERS IN THE DEEP WATER FIELD DEVELOPMENT
ARENA.

During the last years, the deep water Saipem date back to the late eighties,
offshore production has represented when the Saipem 7000 installed subsea
one of the most dynamic sectors of the structures in 525 m water depths in
entire E&P sector. The overall offshore the Gulf of Mexico for Conoco on the
activity has been increasing both in Green Canyon project.
shallow and deep waters, but the rise
in deep waters has been much more After several North Sea installation
rapid. projects carried out in 300 m water
depth by the same vessel in the
The average depth of subsea wells nineties, including Saga Petroleum’s
installation has fast increased from Snorre TLP template/ moorings and
around 200 m in the early nineties to Norsk Hydro’s Troll Field subsea
nearly 1,000 m today, while the record structures, as well as after the
installation water depth has risen from installation of risers, umbilicals and
around 500 m of the nineties to nearly subsea structures carried out by the
3,000 m of today. Maxita Multipurpose DP Vessel on Eni’s
Aquila Field in 830 m water depth in
The activity in deeper waters, harsher the Adriatic Sea, a major milestone was
environments and more remote represented by the Diana Hoover Spar
locations has been a key industry trend and Flowlines project in the Gulf of
over the last decade, thanks to large Mexico awarded to Saipem by Exxon in
deep water fields in US GOM, Brazil 1997.
and West Africa (especially Angola and
Nigeria) – the focus of enormous new That project included the installation of
project developments by NOCs, IOCs the spar caisson vessel and topsides (all
and independents alike, all increasingly together weighing more than 50,000 t)
seeking opportunities in new frontiers as well as flowlines and steel catenary
for oil & gas development at greater risers in 1,480 m water depth. The
water depth. heavy lift and laying activities were
both performed by the Saipem 7000, Saipem delivered the URF EPIC
The first deep water operations of which had been newly converted to of the Usan Project for Total (Nigeria)
­8
a combination derrick and pipelaying 1,450 m water depth, the project saw appearance in the subsea market,
vessel by the addition of the world’s the debut of the FDS Multipurpose while the subsea field operators started
largest J-lay tower for deep water DP Crane & J-lay Vessel, conceived challenging the contractors with the
operations. and designed for deep water field request for EPIC lump sum contracts
development projects to cover all assigned after design competitions
A new age of deep water field duties: the installation of seabottom among a restricted number of
development projects was inaugurated structures/ components and the laying contractors. This new market segment
in 1997 with Saipem’s acquisition - of umbilicals, risers and flowlines, as grew strongly, particularly in the South
through its Saibos subsidiary - of the well as the first ever 16” oil offloading Atlantic region, both in West Africa and
Girassol Field Umbilicals, Risers and steel lines installed mid-water. in Brazil.
Flowlines installation contract from The acronym URF (Umbilicals, Risers
Elf Exploration Angola. Located in a and Flowlines) started making its

­9
A major example of this new approach an entire integrated deep water field Steel Catenary Risers (SCR)
was represented by the Kizomba A development project within a single • Usan URF project for Elf Petroleum
Tie-back System project awarded to EPIC contract. Nigeria in 2008, based again on
Saipem by Esso Exploration Angola in SHRs, which saw the debut of
2001. The complex, integrated project Kizomba A was then followed by many the FDS2, featuring the first pre-
included engineering, procurement, other outstanding projects based on installable, de-coupled 24” Oil
construction and installation of Saipem’s original technologies and Offloading System and the first large
umbilicals, risers and flowlines in a installed by the Saipem FDS and/or the diameter piles (5 m OD) ever driven in
1,200 m water depth, besides the Saipem FDS2 Multipurpose DP Crane deep water (700 m)
largest (20”) steel Oil Offloading Lines and J-lay Vessels, often supported by • P55 project in 2010 for Petrobras in
(OOL) ever installed mid water, later the S3000 for umbilical laying and Brazil, using again SCRs.
overcome by the 24” OOL of the Usan heavy subsea construction work,
project. The selected riser concept was such as for example the following The above projects, as well as many
the original Single Hybrid Risers (SHR) breakthrough projects: others in the South Atlantic, were
design by Saipem, here applied for the carried out by Saipem’s engineering
first time. • Kizomba B, negotiated by the client and project execution center in Paris,
with Saipem in 2002, featuring the with significant local content provided
Saipem built its reputation and first Pipe-in-Pipe Single Hybrid Riser, especially in Nigeria and in Angola.
continuously increased its strength in installed in 970 m water depth As at the same time other geographical
the marketplace by combining original • Rosa Field tie-back SURF project in areas were introducing similar
riser and flowline designs, suitable 2003 for Total Angola, including developments, in order to better serve
for the most diversified scenarios and the installation of the heaviest ever these newer markets, Saipem exported
often patented by Saipem (including Bundle Hybrid Offset Riser (BHOR) its experience to other execution
pipe-in-pipe solutions for demanding tower (4,175 t in 1,200 m water centers, such as for example to Fano in
thermal insulation requirements), with depth) and the world longest and Italy. The West Delta Deep Marine EPCI
powerful installation vessels capable heaviest rigid spool (110 m x 40 t) project (phase IV) in 2006, the Sequoia
of providing reliability, safety and cost • Akpo URF project in 2005 for Total Joint Development project in 2008 and
effectiveness. In this way, Saipem was Upstream Nigeria Ltd including the the West Delta Deep Marine project
in the position to design and execute installation of the deepest (1,400 m) (phase VIIIb) in 2011, all major tie back
­10
projects for Burullus Gas Company packages, all in 1,400 m water depth. primarily dedicated to subsea and
in the Egyptian Mediterranean Sea, floaters structures.
in depths ranging between shallow With the Guara-Lula NE and the
waters and 1,100 m, were carried out P55 SCR/flowlines projects under With this unique experience, broad
in this way. execution in Brazil, recently joined offering of different concepts and a
by the acquisition of the Saphinoá top class fleet of dedicated installation
One of the most recent acquisitions of and Cernambi Sul project, Saipem and pipe laying vessels, Saipem is
Saipem in this market segment - also is actually deepening its presence in now in the front line to tackle the
thanks to the outstanding capabilities the Pre-salt area, one of the most challenge of the ultra deep water
of the new field development ship promising regions of the world for projects in the traditional provinces of
FDS2 - is the Liwan Subsea Tie-back the whole E&P sector. the South Atlantic and Gulf of Mexico,
EPCI project for Husky Oil, which and it is ready to provide full project
is opening the Chinese market by Here, Saipem is applying its innovative execution capabilities in all major
developing this first deep water field riser concepts in a highly challenging provinces worldwide, including the
in the South China Sea. The scope of environment, where its operations new deep water areas, such as East
work includes 12” and 22” flowlines, are supported by the enhanced India, Indonesia, South China Sea and
an 80 km long umbilical and the engineering organization in Rio de Western Australia.
deployment of 400 t of manifold Janeiro and by the new Guarujá yard,

­11
SAIPEM: A COMPLETE
CONTRACTOR FOR THE MOST
CHALLENGING DEEP WATER
UMBILICALS, RISERS AND
FLOWLINES PROJECTS
FULL RESPONSIBILITY FOR THE ENGINEERING,
PROCUREMENT, CONSTRUCTION AND INSTALLATION
OF UMBILICALS, RISERS AND FLOWLINES SYSTEMS.

DESIGN OF THE BEST FIELD ARCHITECTURE FOR THE

CLIENTS’ NEEDS AND FOR MAXIMIZING THE PROJECT
RETURN.

DEVELOPMENT OF ADVANCED PROPRIETARY SYSTEMS

BASED ON INNOVATIVE PRODUCTS AND SOLUTIONS.

UTILIZATION OF UNIQUE VESSELS, TAILOR-MADE FOR HIGH
TECH SOLUTIONS.

FABRICATION AND INSTALLATION OF SUBSEA

DEEP WATER ENGINEERED EQUIPMENT TO COMPLETE
THE RANGE OF SERVICES OFFERED TO CLIENTS.

Saipem’s proprietary technologies

cover the design, supply and
execution of even the most complex
subsea systems
­12
­13
UNIQUE ASSETS:
TOP QUALITY ENGINEERING TO ACHIEVE
THE BEST FIELD ARCHITECTURE
INTEGRATING NEW TECHNOLOGIES & ALTERNATIVE FIELD
ARCHITECTURES TO OPTIMIZE FLOW PERFORMANCE AND
ENHANCE RECOVERY.

CARRIED OUT IN THE COMPETENCE CENTERS IN PARIS

AND FANO (ITALY), AS WELL AS IN NEW ENGINEERING
CENTERS, SUCH AS RIO DE JANEIRO AND LUANDA.

An example of a complex field architecture

­14
­15
QUALIFICATION
OF INNOVATIVE CONCEPTS,
SOLUTIONS AND MATERIALS

­16
 The qualification of new concepts, Quality is the key driver for
such as the risers systems BIRD, SIR® continuous developments of
(*), together with new solutions high specification materials, from
and materials, strongly contributes metallurgically bonded clad pipes
to enhance the value added to the to alternative novel exotic material
project solutions, in order to deal with new
pipelines requirements including
Novel technical solutions have been high pressure, high temperature,
qualified by Saipem for the subsea heavy wall thickness, high steel
developments in Brazil, in order to grade, high fatigue criteria and
meet specific service requirements highly corrosive environment
with an increased focus on the
long term structural integrity of the
most critical elements of the field
architecture

(*) See Chapter “New Concepts and Systems under development: risers systems”

P55 Project - Brazil

The utilization of cladded pipes in
the critical sections of the risers
has required the development and
qualification of suitable welding and
NDT procedures and equipment to
ensure the necessary high quality level
of both onshore and offshore welding.
­17
UNIQUE ASSETS:
ADVANCED VESSELS FOR ADVANCED
EXECUTION CHALLENGES
ALIGNMENT OF ORIGINAL TECHNICAL SOLUTIONS WITH
DEDICATED, FIT FOR PURPOSE INSTALLATION VESSELS.

HIGH TENSION CAPABILITIES FOR LAYING VESSELS

ALLOWING THE ADOPTION OF LARGE THICKNESS PIPES AND
PIPE-IN-PIPE (PIP) SYSTEMS.

The multipurpose advanced vessels in subsea works and providing general FDS
FDS2 and FDS are equipped to J-lay support to the projects’ activities, • Capability of J-laying in ultra-deep
subsea pipelines in up to 2,000 m expand the services offered by Saipem waters pipes with diameter
of water depth, while the S3000 to Inspection, Maintenance and Repair up to 22”
is specialized in laying flex flowlines (IMR) and survey. • Lifting capacity up to 600 t
and umbilicals and in lifting heavy • Dynamic positioning DP3.
subsea structures. URF MAIN VESSELS DEDICATED
TO INSTALLATION S3000
The entire fleet covers the full range • Laying of flexible pipelines and
of typical subsea works, spanning FDS2 umbilicals
from rigid pipelines, risers, umbilicals • The newest vessel, in operation • Installing mooring systems and
and flexibles installation to flying leads/ from 2011 subsea structures
jumpers positioning, from structures • Evolution of its sister ship • Lifting capacity up to 2,200 t.
and manifolds to subsea process units Saipem FDS
and mooring installations. • Capability of J-laying in ultra-deep
waters pipes with diameter
Smaller construction vessels, ROVs up to 36”
and diving support vessels, in addition • Lifting capacity up to 1,000 t
to strengthening the global presence • Dynamic positioning DP3.
­18
 FDS2

FDS

S3000

NORMAND CUTTER
Construction and ROV Support vessel
­19
UNIQUE ASSETS:
UNDERWATER INTERVENTION
EQUIPMENT
REMOTELY CONTROLLED SUBMERSIBLE VEHICLES (ROV) DEDICATED TO A RANGE
OF SUBSEA CONSTRUCTION AND INTERVENTION TASKS, INCLUDING INSPECTION,
MAINTENANCE AND REPAIR (IMR) OPERATIONS. SAIPEM ROVS CARRY A VARIETY OF
SPECIALIZED TOOLING PACKAGES DESIGNED TO INTERVENE ON SUBSEA EQUIPMENT,
SUCH AS SUBSEA MANIFOLDS.

Saipem owns an extensive state-of-the

art fleet of of about 60 highly
sophisticated ROVs:

Including the heavy duty

“Innovator” ROV series, fit to
operate in ultra-deep waters up
to 3,000 m

Developed and manufactured

in-house with characteristics
customized for specific project needs

Supported by a large, specialized

fleet of vessels

Operating in harsh and challenging

environments with the most
innovative tools provided by
Saipem design and manufacturing
capabilities.
­20
The highly versatile and powerful “Innovator” ROV’s, owned and operated by Saipem, are entirely designed and built in-house
­21
UNIQUE ASSETS:
ENHANCED LOCAL FABRICATION
AND CONSTRUCTION CAPABILITIES
WITH HIGH TECHNICAL SPECIFICATIONS

­22
Local design, fabrication and A new yard under construction Excellent quality of local
integration in host countries of high in Guarujá (Brazil), conceived to subcontractors, such as Petrojet
tech components in fully owned support deep water Pre-salt projects in Maadia yard (Egypt), thanks to
yards of Soyo (Angola) and strategic cooperations agreements
Rumuolumeni-Port Harcourt developed by Saipem
(Nigeria)

Fabrication of subsea products

and equipment, such as Pipeline
End Manifolds (PLEM), subsea
manifolds, in-line structures, well-to
manifold jumpers, flowline spools
and riser base jumpers, as essential
complements of URF EPIC projects,
allowing maximum extent of local
content.

­23
 ANGOLA
PETROMAR SOYO YARD
Rosa project
FABRICATION OF THE MANIFOLD FOUNDATIONS, SUPPORT STRUCTURES, PRODUCTION
AND WATER INJECTION FLOWLINES AND PIPE-IN-PIPES; FINAL ASSEMBLY AND TESTING
OF THE MANIFOLDS, FABRICATION AND ASSEMBLY OF BHOR RISER TOWER

Kizomba A and B projects

FLOWLINES COMPONENTS INCLUDING PLETS AND JUMPERS, IN ADDITION TO FINAL
ASSEMBLY OF THE BHOR BUOYANCY TANKS

Rosa project - PIP Quad joints fabrication Rosa project - BHOR Risers Tower

Kizomba A project Kizomba B project – Gravity base foundations

­24
 NIGERIA
RUMUOLUMENI-PORT HARCOURT YARD
Usan project
FABRICATION OF MAIN COMPONENTS OF THE OFFSHORE URF PROJECT

Rumuolumeni-Port Harcourt yard aereal view

­25
 BRAZIL
GUARUJÁ YARD (UNDER CONSTRUCTION)
DEDICATED TO SUBSEA STRUCTURES AND RISERS, IN ADDITION TO FLOATERS,
TO COMPLY WITH THE EXTREMELY AMBITIOUS HIGH-TECH LOCAL CONTENT
REQUIREMENTS FOR PRE-SALT PROJECTS

Area of 35 hectares in Guarujá, within the industrial hub of Santos, the largest port and industrial area in
Brazil: excellent pool of resources and services

Strategically located, approx. 350 km from the Santos Basin and 650 km from the Campos Basin, ideal to
support development of new ultra-deep water fields.

Guarujá yard - Brazil

­26
 EGYPT
PETROJET’S MAADIA YARD
WDDM Phase IV and Phase VIII projects
FABRICATION OF SUBSEA STRUCTURES AND SYSTEM INTEGRATION TESTS

WDDM Projects - Subsea facilities at fabrication yard

­27
SAIPEM’S HIGH TECH PRODUCTS
AND ADVANCED PROPRIETARY
SOLUTIONS

­28
­29
HIGH PERFORMANCE IN-FIELD
FLOWLINES FOR DEEP
AND ULTRA-DEEP WATERS
HIGH SPEC MATERIALS (LINEPIPE, COATINGS), HIGH TECH SOLUTIONS
(PIPE IN PIPE), WELDING AND NON-DESTRUCTIVE TESTING EQUIPMENT
FOR THE STRINGENT THERMAL AND DURABILITY REQUIREMENTS OF
DEEP AND ULTRA DEEP WATERS.

Development and qualification of

tailored welding procedures, Non-
Destructive Testing (NDT) procedures
and equipment for carbon steel and
exotic materials

­30
INCONEL FIELD JOINT

FUSION BONDED JOINT

INFLATABLE CLAMP CERAMIC FIBER BELT ELECTRICAL WIRE

SYSTEM (ICS)

WATER INJECTION ANNULUS FOR PROPER FUSION BONDED JOINT HDPE LINER
PIPELINE CS WELDING (FBJ)

Inconel Field joint and Fusion Bonded Joint are innovative solutions for flowlines
protected from corrosion by an internal plastic liner, allowing time-and cost-efficient
offshore installation with both J-lay and S-lay methods

­31
 Upset & Machined End Pipes
are an innovative technology
developed and tested with Vallourec
& Mannesman Tubes, Germany:
enhanced pipe geometry to improve
weld fatigue life and remove need
for buckle arrestors.

High performance thermal insulation

materials and solutions including a low
cost gel (here shown during filling test)
for water depth down to 3,000 m, easy
to fabricate in large quantities also in
local yards and adaptable to any shape.
This gel, under qualification, can be
easily modified to serve also as a low
cost buoyancy material.

­32
Forged Ends PIP is an innovative performance and minimization of the
technology for PIP flowlines and offshore installation time and costs.
risers, allowing an increased fatigue

Single offshore butt weld

Circumferential
metal-metal contact surface

Field joint wet insulation Pressure balanced cavity

Outer pipe

Inner pipe

Dry insulation Onshore butt welds (prefabrication)

­33
ULTRA DEEP WATER RISERS
FROM STEEL CATENARY RISERS TO SINGLE,
PIPE-IN-PIPE OR BUNDLED HYBRID RISERS, FOR:

Difficult environments

Compact field layouts

Phased and modular developments

High thermal performances

The Steel Catenary Risers (SCR) were

successfully designed and installed
by Saipem in Walker Ridge (USA),
P55 (Brazil), Akpo (Nigeria) and Diana
Hoover (USA) projects.

­34
The Pipe-in-Pipe configuration of the SHR (PIP- SHR)
allows a double service use in the same riser (e.g.
production fluid in the inner pipe and gas lift in the
annulus). Designed and installed by Saipem for the
very first time on the Kizomba B Project, it has been
recently adopted for the Usan Project.

­35
The Single Hybrid Risers (SHR) in developments where the conditions are Projects, it is now being utilized also
its Single or Pipe-in-Pipe versions, not suitable for SCR. Previously applied for the Gas Export of the Saphinoá
decouples the riser from the vessel by Saipem on the Kizomba A, Kizomba Norte and Cernambi Sul Pre-salt fields
dynamic motions and allows B, Usan and Kizomba Satellites EPC3 in Brazil.

FPSO

Air Can
Top Jumper Gooseneck

Steel Pipe

Rotolatch
Suction Pile

­36
The Bundle Hybrid Offset Riser (BHOR) water depth ensuring an extremely and 2 Water Injection risers, it’s one of
was firstly engineered, fabricated and compact field layout and very high the biggest Riser Towers ever designed
installed in 2006 on the Rosa field thermal performances. Housing in the and installed.
(Block 17 offshore Angola) in 1,460 m same bundle 4 Production, 4 Gas Lift

FPSO

Buoyancy Tank

Top Assembly
Flexible Jumpers
Top Bulkhead

Bundle Main Section

Bottom Assembly
Production
and Riser Base
Bulkheads

The Steel Lazy Wave Riser (SLWR)

concept, finally selected for the
development of the Saphinoá Norte
field (Brazil), relies on a buoyant section
in the riser to provide flexibility and
enhanced fatigue life, particularly in the
touchdown area.
­37
SINGLE POINT MOORING (SPM)
AND OIL OFFLOADING LINES
SYSTEMS (OOL)
TO ALLOW THE SAFE TRANSFER OF PRODUCED FLUIDS
FROM THE FPSO TO THE EXPORT SHUTTLE TANKER.

Saipem has developed and further improved this product

during the years, establishing several industry records with
the installation of:

The first 16” mid-water OOL in 2000

The world’s largest (20”) mid-water OOL in 2003

The first pre-installable de-coupled 24” OOL in 2011

(Decoupled Hybrid Offloading System, DHOS).

The first DHOS was developed and installed by Saipem in

2011 for USAN Project.

FPSO BUOY

Top Assembly (SPM Side)

Flexible Hose & Buoyancy Tank

Top Assembly (FPSO Side)

& Buoyancy Tank

Jumper Hang Off Jumper Hang Off

(FPSO Side) (SPM Side)

Tendon

OOL

FPSO mooring BUOY mooring

­38
The installation midwater of the 20” Oil Offloading Lines of
the Kizomba A project was a world record. The same concept
is adopted for Akpo, Kizomba B and Girassol projects.

FPSO BUOY

BUOYANCY
ELEMENTS

FPSO mooring BUOY mooring

­39
NEW CONCEPTS UNDER
DEVELOPMENT: RISER SYSTEMS
THROUGH ITS MULTIDISCIPLINARY COMPETENCES, KNOW-HOW
AND PROPRIETARY TECHNOLOGIES, SAIPEM IS DEVELOPING NEW
RISER SOLUTIONS TO ADDRESS DEEPER WATERS AND MORE
DIFFICULT ENVIRONMENTAL CONDITIONS, FOR THE MOST
CHALLENGING APPLICATIONS.

The BIRD Riser Tower Concept,

patented by Saipem, offers a very
compact field layout, a long service life
(low fatigue), optimized fabrication and
installation arrangement contributing
to a cost effective solution.

­40
 FPSO

Buoyant Flexible
Jumper

Heavy Flexible
Jumper

Buoyant
Rigid Part

The Single Independent Riser (SIR®) evolution of the top tensioned riser environmental conditions and
Concept excluding the need of a (SHR), further improving the dynamic ensuring a long service life and an easy
buoyancy tank, constitutes the natural behavior of the risers under extreme maintainability.
­41
NEW CONCEPTS
UNDER DEVELOPMENT:
SUBSEA PROCESSING
FOCUSING ON DEEP WATER AND HIGH PRESSURE APPLICATIONS.

GAS/LIQUID SEPARATION

The Vertical Multi-Pipe Separator

is a robust technology based on
several parallel pipes with reduced A Joint Industry Program is on-going
wall thickness for easier fabrication with Total, Petrobras and Eni, including
compared to a conventional gravity the definition and qualification of
separator. Manifolds and pump the whole subsea station as well as
modules are retrievable. additional flow performance tests.

Qualification completed

­42
SUBSEA LIQUID/LIQUID
SEPARATION AND PRODUCED
WATER TREATMENT

SpoolSep for bulk water gravity

separation with long residence time for
better efficiency. Several pipes, working
in parallel, are installed independently
as standard spools: modular design
allows easy maintenance and
intervention.

Qualification tests under way for water separation and sand management.

Subsea water debottlenecking station

including bulk water separation with
a spoolsep followed by water deoiling
and desanding modules.

­43
SPRINGS: SUBSEA SEAWATER
TREATMENT FOR OIL FIELD WATER
INJECTION

Collaboration program since 2007

between Total, Saipem, Veolia
and Westgarth, SPRINGS improves
the economics of marginal fields
by suppressing the water injection
network and minimizing modifications
on the existing platform.

Designed for 3,000 m water depth,

the SPRINGS 20,000 bwpd standard
unit corresponds to the capacity
of 1 or 2 water injection wells with a
water specification of less than 40 ppm
residual sulfates.

­44
Qualification ON-GOING

­45
DEEP WATER FIELD DEVELOPMENT
PROJECT REFERENCES

­46
­47
PETROBRAS
Saphinoá NORTE AND CERNAMBI SUL COLLECTION AND EXPORT SYSTEMS
(BRAZIL)
Scope of work: Design, construction and installation of SLWR
(Steel Lazy Wave Riser) for the collection system at the Saphinoá
Norte field and Single Hybrid Riser (SHR) for the gas export systems
at the Saphinoá Norte and Cernambi Sul fields, in water depths of
about 2,200 m
Highlights:
14 km of 18” gasline
5,5 km of 20” gasline
4 PLETS
Contract: EPIC
Vessels employed: FDS2
Contract award: October 2012
Under Execution

Utilization of the Guarujá yard for the fabrication of part

of the risers system equipment.

­48
BURULLUS GAS COMPANY
WDDM PHASE VIIIB DEVELOPMENT PROJECT
(EGYPT)
Scope of work: Expansion of the existing West Delta Deep Marine
(WDDM) infrastructure with further seven wells in water depths
ranging from 400 m to 1,100 m
Highlights:
38 km of 10” rigid pipelines
43 km of umbilicals
Fabrication of subsea structures - 1 manifold, 13 PLETs, 19 jumpers
Contract: EPIC
Vessels employed: FDS - Normand Cutter
Contract award: May 2011
Under Execution

Execution model replicating the concept already adopted successfully

in previous projects:

Project Management located in the Project Execution Center of

Fano during the detailed engineering phase and then partially
relocated to Egypt during the local fabrication phase

Engineering team result of a combination of resources and skills

from the Subsea Field Development Groups located in Fano and
Paris.

­49
HUSKY OIL CHINA LTD
LIWAN 3-1 GAS FIELD DEVELOPMENT
(CHINA)
Scope of work: Subsea flowlines system, umbilical system, subsea
structures in a water depth reaching about 1,400 m
Highlights:
2 main 22” gas export lines, 79 km long each, from 200 m to 1,400
m water depth
4 infield production flowlines for a total length of 13 km, from a
water depth of 1,330 m to 1,440 m
1 infield production flowline 23 km long in an additional field
2 umbilical sections for a total of 79 km
Contract: EPIC
Vessels employed: FDS – FDS2
Contract award: April 2011
Under Execution

First deep water project in South China Sea

Heavy subsea construction tasks executed by the new vessel FDS2

to deploy approx. 400 t of manifold packages in 1,400 m water
depth

Numerous climatic challenges, from typhoons to high sea

currents.

­50
PETROBRAS
GUARA - LULA NE PIPELINES
(BRAZIL)
Scope of work: Rigid gas export pipelines, PLEMs, PLETs, jumpers at
water depths up to 2,130 m
Highlights:
54 km, 18” pipeline connecting the FPSO Guara to FPSO Cidade de
Angra dos Reis
22 km, 18” pipeline connecting the FPSO Lula NE to FPSO Cidade de
Angra dos Reis
Contract: EPIC
Vessels employed: FDS2 - Normand Cutter
Contract award: April 2011
Under Execution

Novel technical solutions focusing on structural long term integrity

of the most critical elements of the field architecture, like the riser
systems

Utilization of exotic materials to prevent corrosion.

­51
ENBRIDGE OFFSHORE FACILITIES LLC
WALKER RIDGE - BIG FOOT OIL EXPORT LATERAL PIPELINE
(USA)
Scope of work: Oil export pipeline from Big Foot field development
in Walker Ridge to a subsea tie-in in Amberjack Tahiti - Green
Canyon; SCR, PLET in max water depth of 2,130 m
Highlights:
20” export line approx. 60 km long
1 SCR approx. 3 km long
Contract: T&I
Vessels employed: Castorone
Contract award: March 2011
Under execution

First application worldwide of the new giant pipelayer Castorone.

­52
PETROBRAS
P55 STEEL CATENARY RISERS AND FLOWLINES
(BRAZIL)
Scope of work: Subsea system inclusive of subsea inter-connections
(spools), SCRs and flowlines in water depths ranging from 1,500 to
1,900 m
Highlights:
16 SCRs - Each SCR is associated to a corresponding flowline section
for a total of 50 km of risers and 25 km of flowlines
Contract: EPIC
Vessels employed: FDS2
Contract award: July 2010
Under execution

Development and qualification of suitable welding and NDT

procedures and equipment to ensure the necessary high quality
of both onshore and offshore welding.

­53
TOTAL UPSTREAM NIGERIA
EGINA FLOWLINES, RISERS, OFFLOADING SYSTEMS AND OFFSHORE WORKS
(NIGERIA)
Scope of work: EPCI of the Umbilical, Riser, Flowline project scope
and of the FPSO mooring system within the Egina field, located in
the Nigerian block OML 130 at a water depth of maximum 1,750 m.
Highlights:
Five 23-29 km x 12”-14” Production and Water Injection flowlines
20 km x 14” Gas Export pipeline
8 Single Hybrid Risers (4 Pipe-in-Pipe) with related riser integrity
monitoring system
2 unbounded 2 km x 20.5” w-shaped flexible oil offloading lines
16 FPSO suction piles anchors and 9 OLT buoy suction piles
3 umbilical arches systems with riser integrity monitoring systems
49 subsea structures, spools, jumpers
Contract: EPIC
Vessels employed: Saipem FDS 2, Saipem 3000
Contract award: April 2013
Under execution

One of the most important field developments currently on-going

in the Gulf of Guinea.

­54
ESSO EXPLORATION ANGOLA
KIZOMBA SATELLITES EPC3 TIEBACKS PHASE 2
(ANGOLA)
Scope of work: Tieback of 3 new drill centres to the existing
Kizomba B and C FPSOs in Angolan Block 15, in 1,350 m of
maximum water depth.
Highlights:
37 km of production pipe-in-pipe flowlines
21 km of water injection flowlines
PLETS, FLETS, suction piles, jumpers
43 km of umbilicals
Contract: EPIC
Vessels employed: Saipem FDS, Saipem 3000
Contract award: December 2012
Under execution

A further development of the Kizomba project series.

­55
BURULLUS GAS COMPANY
WDDM PHASE IXA DEVELOPMENT PROJECT
(EGYPT)
Scope of work: In 850 m of maximum water depth, the project
includes rigid flowlines, flexible flowlines, umbilicals, power and
communication cables, manifold, jumpers, PLETS, tie-in spool bases,
goose-necks, flying leads and other subsea structures.
Highlights:
57 km x 10”-12” rigid flowlines
2 km x 8”-14” flexible flowlines
80 km of umbilicals, 56 km of power and communication cables
1 manifold, 15 PLETS, 90 flying leads
Contract: EPIC
Vessels employed: Saipem FDS
Contract award: March 2013
Under execution

A further development of the West Delta Deep Marine

project series.

MEDITERRANEAN SEA

WEST DELTA
DEEP MARINE

Alexandria
Cairo

EGYPT
­56
CHEVRON
WALKER RIDGE - JACK & ST. MALO EXPORT PIPELINE
(USA)
Scope of work: In the Gulf of Mexico ultra-deep water plays at
2,140 m w.d., oil export pipeline from the Jack & St. Malo fields
located about 500 km south of New Orleans.
Highlights:
24” export line approx. 230 km long
20” SCR approx. 4 km long
2 ILS
Contract: T&I
Vessels employed: Castorone
Contract award: November 2010
Under execution

Castorone’s debut in the Gulf of Mexico.

Utilization of S-lay installation method in ultra-deep waters.

­57
SHELL NIGERIA E&P
BONGA NORTHWEST – OPL 212
(NIGERIA)
Scope of work: Development of 12 subsea wells of Bonga
Northwest, tied back into the Bonga main infrastructure, in water
depths between 900 m and 1,200 m
Highlights:
4 production flowlines Pipe-in-Pipe for a total of 13 km
4 umbilicals for a total of 15 km
4 production manifolds
Contract: EPIC
Vessels employed: FDS - S3000
Contract award: Sept. 2009
Under execution

First deep water project awarded by Shell to Saipem in Nigeria

First tie-in into the Bonga Main Infrastructure

Entire Project Execution carried out in Nigeria.

­58
ESSO EXPLORATION ANGOLA
KIZOMBA SATELLITES PROJECT EPC3 TIEBACK
(ANGOLA)
Scope of work: Tieback of 4 new drill centers to the existing
Kizomba A and B installations (Block 15) in water depths ranging
from 1,000 m to 1,350 m
Highlights:
5 PiP 16”-10” production pipelines for a total of 49 km
4 water injection pipelines for a total of 38 km
2 PiP SHRs connected to Kizomba A FPSO and Kizomba B FPSO
18 FLETs and PLETs
Contract: EPIC of risers and flowlines; T&I of umbilicals, optical
cables, manifolds
Vessels employed: FDS - FDS2 - S3000
Execution: 2009-2012

Further development of the Kizomba A/B and Marimba Projects

Construction activities in Ambriz, Soyo (Petromar) and Italy

(Intermare Sarda)

About 110 quad joints produced in Soyo for a total lenght of

pipelines of approx. 52 km.

Republic
of the Congo

Democratic
Republic
of the Congo

Soyo
KIZOMBA
FIELD COMPLEX

SOUTH
ATLANTIC
OCEAN
Angola

­59
TOTAL E&P ANGOLA
BLOCK 17 GAS EXPORT PIPELINE PROJECT – PHASE 1
(ANGOLA)
Scope of work: Gas Export Pipeline system to transport associated
gas from Block 17 Dalia and Girassol loop (1,200 m water depth) to
an injection platform in Block 2 (40 m water depth), PLEMs, Tie-ins
Highlights:
24” pipeline 43 km long
16” pipeline section 67 km long
Contract: EPIC
Vessels employed: FDS, S3000, Normand Cutter
Execution: 2008-2012

First high-pressure gas exporting system built entirely in deep

waters and connected to another subsea system already in
production (Gas Gathering Project).

­60
ELF PETROLEUM NIGERIA
USAN
(NIGERIA)
Scope of work: URF system in a project consisting of subsea wells
tied back to a moored FPSO in water depth ranging from 730 m
to 800 m
Highlights:
More than 60 km of production and water/gas injection flowlines
7 SHRs, including PiP-SHRs
72 km of main umbilicals
Oil Loading Terminal - SPM Buoy and 2 Offloading lines
16 2 km long FPSO anchor lines
Contract: EPIC
Vessels employed: FDS - FDS2 - S3000 - Bourbon Pearl
Contract award: March 2008
2008-2012

Record achieved: First Pre-installable De-coupled 24” Oil

Offloading System

First contract for the new FDS2 field development ship.

­61
ENI E&P
FIRENZE FPSO
(ITALY)
Scope of work: installation of the mooring system of the Firenze
FPSO, of flexible flexible risers and umbilical system in the Aquila field
at water depths of 815 m
Highlights:
Installation of both the FPSO and the SURF system
Contract: Supply and Installation
Vessels employed: Normand Cutter
Execution: 2009-2011

Subsea tie-in campaign and FPSO hook-up operations under

difficult weather conditions.

­62
PETROBRAS
URUGUA-MEXILHAO GAS PIPELINE
(BRAZIL)
Scope of work: Transportation of gas from FPSO Cidade de Santos
in Urugua Field, in approx. 1,300 m water depth, to the Mexilhao
Platform, in approx. 170 m water depth
Highlights:
Gas pipeline 175 km long, 18”
PLEM, PLET, tie-in spools
Contract: Engineering, installation and pre-commissioning of the
18” gas pipeline; EPIC of tie-in spools; supply of materials
Vessels employed: FDS, Normand Cutter
Execution: 2008-2010

Important step for the Saipem presence in Brazil.

­63
BURULLUS GAS COMPANY
SEQUOIA JOINT DEVELOPMENT PROJECT
(EGYPT)
Scope of work: Subsea equipment, umbilicals, flowlines, jumpers
and spool pieces in water depth ranging from 70 to 570 m
Highlights:
5 flowlines 10” totalling 29 km
5 infield umbilicals totalling 29 km
1 main pipeline 24 km long, 22” - South Manifold to Rashid
1 main umbilical 24 km long
Contract: EPIC
Vessels employed: FDS - Bourbon Pearl - Normand Cutter
Execution: 2008-2009

Very tight project schedule

Many offshore operations to be performed simultaneously,

because of the schedule constraint

New facilities to be installed in a very congested area.

­64
TOTAL UPSTREAM NIGERIA LTD
AKPO
(NIGERIA)
Scope of work: URF, mooring system, oil export system and gas
export pipeline in max water depth of 1,350 m
Highlights:
16” gas export line 150 km long
10 infield lines for a total of about 35 km - as part of 4 production
loops
4 water injection flowlines for a total length of 30 km
14 SCRs connected to FPSO
37 FLETs
31 spools
Offloading Buoy with its mooring system
2 export OOLs 2.7 km long each
Contract: EPIC
Vessels employed: FDS - S3000 - Bourbon Trieste - S355
Execution: 2005-2009

Record achieved: Designed and installed the deepest (1,400m)

Steel Catenary Riser (SCR) connected to a FPSO in West Africa.

­65
BURULLUS GAS COMPANY
WEST DELTA DEEP MARINE PHASE IV EPIC PROJECT
(EGYPT)
Scope of work: Subsea facilities and control system for 8 additional
wells to the existing Scarab/Saffron and Simian development fields
in water depth from 400 m to 1,000 m.
Highlights:
7 coated flowlines with PLETs for a total length of 61 km
8 infield umbilicals for a total length of 68 km
2 manifolds
25 jumpers
Contract: EPIC
Vessels employed: FDS - Grampian Surveyor - Normand Cutter
Execution: 2006-2008

Very tight project schedule

Many offshore operations to be performed simultaneously

because of the schedule constraint

New facilities to be installed in a very congested area

First deep water EPIC project executed in Egypt with an initial task
force in Fano integrating the Group’s capabilities.

­66
TOTAL E&P ANGOLA
BLOCK 17 GAS GATHERING PROJECT
(ANGOLA)
Scope of work: Gasline and umbilicals to collect gas from Blocks 17
and 18 in water depths ranging from 1,150 to 1,370 m
Highlights:
Flowline 12”, 9 km long
Umbilical about 3 km long
2 FLETs
4 Spools
Contract: EPIC
Vessels employed: FDS
Execution: 2007

Republic
of the Congo

Democratic
Republic
of the Congo

Soyo
GIRASSOL
DALIA

SOUTH
ATLANTIC
OCEAN
Angola

­67
ESSO EXPLORATION ANGOLA
MARIMBA NORTH EPC3 TIE-BACK-SYSTEM
(ANGOLA)
Scope of work: Subsea tieback system of Marimba North field
(Block 15) to the FPSO/TLP Kizomba A systems, including: flowline,
water injection pipeline, gas injection pipeline, subsea umbilical, in
water depth of 1,300 m
Highlights:
10/16” pipe-in-pipe production lines, two 10” injection lines
with their respective jumpers for a total lenght of about 30 km
6 FLETs
Contract: EPIC
Vessels employed: FDS - S3000
Execution: 2005 - 2007

Intermediate structures for the gas injection systems, FLETs and

jumpers fabricated in Petromar yard (Soyo).

­68
TOTAL E&P ANGOLA
ROSA SURF DEVELOPMENT
(ANGOLA)
Scope of work: URF contract for a tie-back to Girassol in water
depth of 1,400 m
Highlights:
Production lines for 55 km
Water injection lines for 40 km
1 BHOR
Production umbilicals from FPSO to manifold for a total of 60 km
Approx. 23,000 tons of linepipes
Vessels employed: FDS - S3000
Contract: EPIC
Execution: 2003 - 2007

Record achieved: Heaviest Bundle Hybrid Offset Riser tower ever

installed (4,175 t), at a 1,200 m water depth

Record achieved: World longest and heaviest rigid spool:

80/110 m - 30/40 t.

­69
ESSO EXPLORATION ANGOLA (BLOCK 15) LTD
KIZOMBA B TIE-BACK SYSTEM
(ANGOLA)
Scope of work: URF, Oil Offloading system, FPSO mooring, control
lines and manifolds in water depth up to 1,200 m
Highlights:
5 SHRs, including PiP-SHRs
25 km of Pipe-in-Pipe flowlines
SPM Buoy
2 OOLs diam 20”
Contract: EPIC
Vessels employed: FDS
Execution: 2002 - 2005

Record achieved: First Pipe-in-Pipe Single Hybrid Risers (PIP - SHR),

weighing 400 t, designed and installed in 970 m.

­70
ESSO EXPLORATION ANGOLA (BLOCK 15) LTD
KIZOMBA A TIE-BACK SYSTEM
(ANGOLA)
Scope of work: URF, Oil Offloading System, FPSO mooring, control
lines and manifolds in max water depth of 1,200 m
Highlights:
6 SHRs
6 flowlines totalling 17 km
SPM Buoy
2 OOLs diam 20”
Contract: EPIC
Vessels employed: FDS
Execution: 2001 - 2004

Record achieved: First Single Hybrid Riser (SHR) designed and

installed

Record achieved: World largest Oil Offloading Lines (20-inch)

installed midwater.

­71
ELF EXPLORATION INC.
CANYON EXPRESS
(USA)
Scope of work: Flowlines and jumpers in water depths
from 100 to 2,210 m
Highlights:
2 flowlines for a total length of 176 km
Contract: Detailed Engineering (Partial), Procurement (Partial),
Transportation, Installation, Pre-Commissioning
Vessels employed: FDS
Execution: 2000 - 2002

Record achieved: Deepest sealine laid in the Gulf of Mexico

at 2,210 m water depth.

­72
ELF EXPLORATION ANGOLA
GIRASSOL
(ANGOLA)
Scope of work: Export lines, jumpers, umbilicals in water depth
of about 1,450 m
Highlights:
5 production umbilicals for a total of 29 km
Contract: T&I
Vessels employed: FDS
Execution: 1998 - 2001

Record achieved: First 16-inch steel Oil Offloading Lines (OOL’s)

installed mid-water

First job for the new FDS vessel, a ship specialized in new field
developments.

­73
EXXON COMPANY USA
DIANA HOOVER SPAR (DDCV) & FLOWLINES
(USA)
Scope of work: Spar, pipelines and SCR installation in water depth
of approx. 1,480 m
Highlights:
12 suction piles and mooring lines.
Connection of DDCV to mooring system.
Two 10” flowlines 15 km long.
One 6” flowline 15 km long
Five SCRs with diameters of 6”-10”-18”.
Contract: EPIC
Vessels employed: Saipem 7000
Execution: 1997 - 2000

Highest standards of safety achieved

DDCV Hull weighting 34,000 t

Installation of 2 Topsides modules for a total of about 16,000 t.

­74
AGIP
FIRENZE FPSO
(ITALY)
Scope of work: Installation and hook-up of risers, umbilicals, subsea
structures and tie-ins in max. water dephts of about 830 m for the
Firenze FPSO in the Aquila field
Highlights:
ROV services
Contract: T&I
Vessels employed: Maxita
Execution: 1997 - 1998

Firenze FPSO: 138,000 DWT vessel, moored by an 8-legged

catenary system.

­75
NOTES

­76