Floating vessels with dry tree production equipment are large capital expenditure projects with multiple interfaces often spanning several entities, including the Operator, Engineering Procurement and Integration Contractor (EPIC), Rig Builder, Production and Drilling Top-Tensioned Riser (TTR) supplier, Subsea Wellhead supplier, and Surface Wellhead/Tree supplier. Design and Interface Management play a significant role in the success of a project of this magnitude. The Shell Malikai Single Combo Casing Top Tensioned Riser (SCCTTR) was successfully deployed and commissioned on the first TLP in Malaysia. The Malikai SCCTTR is an industry first and an example of innovative design configuration coupled with rigorous project execution to deliver a system that is an enabling technology for current industry market conditions. The SCCTTR is a single riser used first for drilling and then remains in place for the full field life. This provides significant cost savings, both in hardware and operational time for large field developments, but introduces technical challenges to meet the requirements of both traditional drilling and production/water injection risers. This paper presents key design challenges to meet the requirements for ‘multi-purpose’ configuration and identifies how they were addressed to accomplish the project goal of flawless delivery. Project management was a key factor in achieving this goal. Shell chose a one-stop solution for delivery of the subsea wellhead and SCCTTR which provided advantages in management of interfaces and overall delivery. While this minimized interfaces, it still required a significant effort to coordinate components from multiple continents to deliver a single system. In addition to project management, the system required innovative design, as illustrated by the tensioner system, which introduced new features such as deflection absorbing bearing pads to limit the impact of the SCCTTR on the TLP hull design. Even with the additional features, the new tensioner system was designed, manufactured, and qualified within the project schedule. The Malikai SCCTTR stands as a testament to what can be accomplished when innovative design approach is coupled with robust project management and collaborative efforts between operator and equipment suppliers.
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