Design Optimisation

Chevron Gorgon Stage 3 Project

Chevron’s Gorgon Stage 3 (GS3) development will connect the Geryon and Eurytion fields to Gorgon’s existing subsea infrastructure back to Barrow Island. The development involves the three manifolds, 35-kilometre production flowline, MEG pipeline and umbilical to deliver fluid from the six wells. SEA Global was engaged by Chevron to perform Concept and Pre-FEED engineering to identify the optimal development strategy. Using SEA’s advanced automation tools the concepts were assessed and optimized at a system level and to a far greater detail than traditionally possible, enabling smooth and effective transition into FEED.

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The project entails connecting fields at water depths of 1200-1350m using a 35 km long, 24-inch pipeline of CRA and Carbon Steel. SEA Global completed Concept and Pre-FEED engineering, applying automated scientific programming and advanced optimization systems.

The work included evaluating comprehensive field architectures, performing detailed transient and steady-state thermohydraulic flow assurance modeling for sizing, and designing subsea components like trees, spools, and manifolds across varying contracting strategies. The scope further covered routing, thickness design, cathodic protection assessments, on-bottom stability/roughness tasks, Top of Line and Bottom of Line corrosion modeling, 3D global buckling/walking models, and an Engineering Critical Assessment (ECA) to prevent onerous installation welding constraints.

Water Depth
1200-1350m

Drill Centre
6 trees, dual manifolds, subsea to subsea pigging, future expansion

Pipeline Length
35 km

Pipeline Diameter
24-inch CRA and Carbon Steel

Design Pressure
28.4 MPa

Scope of Work

Concept Development & Strategy

Created, optimised and compared a wide range of development options to identify best concept for GS3, including field architecture and detailed engineering to demonstrate performance and identify key contract strategies.

Integrated Production Modelling, Flow Assurance & Line Sizing

Integrated production modelling was performed to identify the best performing development scenarios using detailed steady state and transient thermohydraulic modelling. This enabled system performance to be optimised and to define mechanical design inputs.

Subsea architecture

The subsea architecture (including power, controls, trees, spools and manifolds) was designed and optimised across a range of vendor contracting strategies and for a specific vendor and installation contractor capabilities.

Mechanical Design

Application of automated scientific programming techniques across all mechanical design tasks for multiple combinations of well count, line size and development scenarios. Scope included routing, wall thickness, coatings, cathodic protection, on-bottom stability and on-bottom roughness.

Material Selection

Detailed Top of Line (TOL) and Bottom of Line (BOL) corrosion modelling based on Integrated Production Modelling (IPM) forecasting across a range of reservoir outcomes identified significant reductions in CAPEX through materials selection and coating configuration, and as input to system architecture.

Buckling, Walking & ECA

3D whole system global buckling and walking models were used to determine the buckle initiation strategy and understand axial walking, suitable strategy to manage global buckling. An engineering critical assessment (ECA) was also performed to demonstrate fracture would not impose onerous welding constraints for installation contractors.

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