Power FPSO New MEG System Concept Select & PreFEED

Objective

Energean sought to implement a new Mono Ethylene Glycol (MEG) system on the Energean Power FPSO to support the long-term production plateau by integrating the Olympus field. The project aimed to de-risk future production, optimise hydrate management and ensure operational reliability through an efficient MEG regeneration and reclamation unit (MRU). (image courtesy of Energean plc)

Project Scope

The project involved a Concept and PreFEED study performed by io consulting to define the optimal MEG system, ensuring seamless integration with the FPSO’s existing infrastructure. Key aspects included:

1. Concept Selection: Evaluating MEG treatment solutions to meet hydrate mitigation requirements.
2. Technical Definition: Designing the MRU and supporting utilities to operate within FPSO space, weight, and utility constraints.
3. Integration Planning: Identifying modifications needed across topsides and hull systems.
4. Vendor Engagement: Assessing proposals from multiple MRU suppliers to ensure technical feasibility and cost efficiency.
5. Execution Planning: Developing an installation and commissioning strategy aligned with FPSO operations.

Findings & Recommendations

Findings

• MEG System Selection:
  • A full-stream reclamation approach was chosen, maximising salt removal efficiency and system reliability.
  • The chosen MRU design balances footprint constraints with processing capacity (3,200 bwpd of formation water).
• Infrastructure & Layout Constraints:
  • Module M04 was allocated for the MRU, with supporting systems distributed across topsides and hull.
  • Space constraints required a multi-level module configuration and efficient mechanical handling solutions.
• Process & Utility Upgrades:
  • New inlet heaters (2 x 50%) were installed to manage cold Olympus production and prevent hydrate formation.
  • Three gas-fired heaters (50% capacity each) were required to supplement the existing heating medium system.
  • FPSO stability and weight distribution were assessed, ensuring safe operations post-integration.
• Environmental & Safety Considerations:
  • GHG emissions were minimised by optimising heater selection and leveraging waste heat recovery.
  • Fuel gas was chosen for MEG storage tank blanketing, reducing emissions and aligning with FPSO-wide practices.
• Execution Strategy & Cost Optimisation:
  • The project was divided into two work packages:
    • MRU Supplier Package (modular process unit).
    • FPSO Integration Package (piping, electrical, structural modifications).
  • CAPEX was reduced through competitive vendor pricing and benchmarking against similar offshore brownfield MEG projects.

Recommendations

1. Finalise FEED Definition:
   • Validate MRU vendor selection through detailed engineering.
   • Ensure process design accounts for future production uncertainties.
2. Structural & Layout Adjustments:
   • Confirm feasibility of the multi-level module configuration during FEED.
   • Optimise equipment placement for mechanical handling and maintenance access.
3. Process & Utility Optimisation:
   • Conduct final validation of heating and cooling duty requirements.
   • Ensure integration of new fired heaters and inlet heaters without disrupting FPSO operations.
4. Environmental & Safety Compliance:
   • Conduct detailed emissions analysis to further optimise fired heater performance.
   • Implement monitoring systems for MEG tank blanketing and waste heat recovery efficiency.
5. Execution & Cost Control Measures:
   • Maintain two-package execution strategy to streamline procurement and installation.
   • Further refine CAPEX estimates using vendor feedback and FEED-level costing.