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1/27/22, 10:46 PM Guide to floating production systems - everything you need to know | EMA

Home About Us Floating Production Reports Advisory Services Blog/News Contact

A Guide to Floating Production Systems

Are you confused about the many


variations of Floating Production Systems?
Here is everything you need to know about the 8 types of systems currently in
operation worldwide.

Chapter 1: Chapter 2: Chapter 3: Chapter 4:Hi there! Our newest quarterly


Chapter 5:
report is out now and we expect
Background on Floating Production Tension Leg Spars
pace of new awards to increase.
System Production Semis Platforms
Variations Storage and
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Chapter 6: Chapter 7: Chapter 8: Chapter 9: Chapter 10:


Floating Floating Floating Mobile Offshore Final Selection
Liquefied Storage and Storage and Production Units
Natural Gas Regasification Offloading
Units Units Vessels

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Hi there! Our newest quarterly


report is out now and we expect
pace of new awards to increase.

1 Background on System Variations


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Floating Production systems (FPSs) emerged in the 1970s as an option to produce hydrocarbons that were discovered further offshore
in water depths that exceeded viability of fixed platform installation. Today FPS units are available in numerous shapes and size each
with their own unique characteristics, strengths and weaknesses. Each production unit an operator selects is typically designed for a
specific offshore field though some units have been repurposed through upgrade and/or modification.

Initial production from FPSs began in 1975 from Argyll in the North Sea followed by production in 1977 from Castellon in the Spanish
Mediterranean. During the next few decades FPSs were primarily installed in the Gulf of Mexico and the North Sea. Thereafter,
exploration and discoveries in other hydrocarbon basins worldwide saw increased FPS installation activity off Brazil, West Africa and
Southeast Asia.

An operator’s decision to develop a field with an FPS requires assessment of numerous factors with oil pricing being one of the most
influential and deciding. The FPS selection decision must include review of field geology and environmental characteristics including
hydrocarbon specification, reservoir requirements (water/gas/chemical injection), well/subsea configuration, water depth, ocean
current and weather. Additional decision factors include expected life of field, onboard hydrocarbon storage and/or processing
requirements, potential tiebacks, budget, distance to shore and proximity to any existing nearby infrastructure, on and offshore.

Since 1975, offshore field development solutions and FPS designs have become increasingly more complex. Additional improved
hydrocarbon extraction, zonal isolation, increased pumping power for injection, larger mud motors, enhanced seismic, rotary
steerable systems, deeper large bore wells, horizontal drilling, and lateral drilling have all contributed to the expansion of the FPS
armada and flotilla. Consider the relative simplicity of available car options in the late 70s in comparison to the available options on a
new vehicle today – even standard vehicle safety features have improved exponentially.

2 Floating Production Storage &


Offloading Units
Floating Production Storage and Offloading Units (FPSO) are
considered the most flexible of all FPS types and certainly the most
prevalent. FPSOs produce and store hydrocarbons offshore in
varying water depths. These units receive the complete wellstream,
separate the oil, water and gas, store the oil and offload the
stabilized crude oil to export tankers.

As of December 2019, 174 FPSOs were in operation, with 25


available and 25 on order.

The first FPSO, Shell’s Castellon was installed in 384 ft (117 m) of


water. Over the years installed water depths have increased. The
current water depth record for FPSO installation is held by SBM’s
Turritella FPSO which currently services Shell’s Stones development
in the U.S. Gulf of Mexico in 9,500 ft (2,900 m) of water.

As water depths have increased for FPSO installation so too have


production and storage capacities. Newer FPSOs have processing
Hi there! Our newest quarterly
capability exceeding 250,000 boe/d, up from 30,000 boe/d. Current
report is out now and we expect
maximum storage capacity is at 2.3 million barrels, a considerable
pace of new awards to increase.
increase from 11,000 barrels early on.

Capital costs for FPSOs range from $200 million to beyond $3


billion.

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FPSOs have three key components, the hull, topside and mooring
system. FPSO designs vary by vessel and are tailored to a field’s
characteristics. As an example, the Turritella FPSO features a large
disconnectable buoy allowing the FPSO to escape inclement
weather, specifically hurricanes.

3 Production Semis
Production Semis were initially converted from existing drilling rigs,
with the first conversion taking place in 1975 for use on the
Hamilton Brothers Argyll and Duncan fields in the North Sea. As of
December 2019, 39 Production Semis are in operation. The units
are well suited for use on complex deepwater fields involving a
large number of wells over a dispersed area.

Production Semisubmersibles are non-ship shaped units capable


of production and drilling. Typically Production Semis have two
horizontal hulls connected to four cylindrical or rectangular column
pontoons that rise above the water to support the topside. The
pontoons are partially filled with seawater to stabilize the platform.
Production semis are extremely stable and have wide deck spaces
topside to support processing.

However, Production Semis do not have onboard production


storage capability and must be connected to a pipeline or a
Floating Storage and Offloading (FSO) unit. Additionally, as
Production Semis are installed in deeper waters, the increased
mooring line weight decreases the unit’s deckload storage capacity.

Production Semis currently operate in water depths between 262 ft


and 7,874 ft (80 m and 2,400 m). The deepest Production Semi is
currently the Independence, operated by Atwater Valley Producers
in the U.S. Gulf of Mexico located in 8,005 ft (2,440 m) of water.
Production Semis currently process between 20,000 b/d of oil
(Innovator in the U.S. Gulf of Mexico) and 270,000 b/d of oil (Troll B
in the Norwegian North Sea). Production semis typically have gas
processing capacity exceeding 1,600 mmcf/d.

Production semis may be conversions or purpose-built newbuilds.


Conversion costs range between $140 million and $800 million,
and newbuild costs begin around $500 million and exceed $2.7
billion.
Hi there! Our newest quarterly
report is out now and we expect
pace of new awards to increase.

3 Production Semis
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Production Semis were initially converted from existing drilling rigs,


with the first conversion taking place in 1975 for use on the
Hamilton Brothers Argyll and Duncan fields in the North Sea. As of
December 2019, 39 Production Semis are in operation. The units
are well suited for use on complex deepwater fields involving a
large number of wells over a dispersed area.

Production Semisubmersibles are non-ship shaped units capable


of production and drilling. Typically Production Semis have two
horizontal hulls connected to four cylindrical or rectangular column
pontoons that rise above the water to support the topside. The
pontoons are partially filled with seawater to stabilize the platform.
Production semis are extremely stable and have wide deck spaces
topside to support processing.

However, Production Semis do not have onboard production


storage capability and must be connected to a pipeline or a
Floating Storage and Offloading (FSO) unit. Additionally, as
Production Semis are installed in deeper waters, the increased
mooring line weight decreases the unit’s deckload storage capacity.

Production Semis currently operate in water depths between 262 ft


and 7,874 ft (80 m and 2,400 m). The deepest Production Semi is
currently the Independence, operated by Atwater Valley Producers
in the U.S. Gulf of Mexico located in 8,005 ft (2,440 m) of water.
Production Semis currently process between 20,000 b/d of oil
(Innovator in the U.S. Gulf of Mexico) and 270,000 b/d of oil (Troll B
in the Norwegian North Sea). Production semis typically have gas
processing capacity exceeding 1,600 mmcf/d.

Production semis may be conversions or purpose-built newbuilds.


Conversion costs range between $140 million and $800 million,
and newbuild costs begin around $500 million and exceed $2.7
billion.

4 Tension Leg Platforms


Tension Leg Platforms (TLPs) are the third most popular Floating
Production System and as of December 2019, 28 currently are in
operation. About two-thirds of these units are installed in the Gulf
of Mexico, with others located off Africa, Brazil, in the North Sea
and offshore Southeast Asia.
Hi there! Our newest quarterly
Key components of a TLP include the hull, topside and moorings.
report is out now and we expect
TLPs are production systems that are attached to the seabed by
pace of new awards to increase.
tendons, typically numbering between 6 and 16. The tendons allow
the buoyant hull to have limited vertical movement while allowing
for horizontal movement. Due to tendon tension TLPs have very
limited surface motion that provides a stable platform for drilling
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1stare
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hydrate/high wax crude where well maintenance must be


considered. However, one drawback to using a TLP is that as
tendon weight increases (deep water installations) payload capacity
decreases.

The first TLP, Hutton, was installed in 1984 for Conoco for
operation in the North Sea. Worldwide water depths for installed
units are between 656 ft and 5,200 ft (200 m and 1,585 m).

TLPs can be used for production or as wellhead platforms.


Wellhead TLPs have no processing capabilities and are attached to
an accompanying production facility. Production TLPs currently
have processing capability from 25,000 b/d to 360,000 b/d.

TLP costs range from $500 million to over $1 billion depending on


water depth, location and topside facilities.

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5 Spars
Spars are similar to TLPs in that both are platform structures that
float vertically in the water, allowing production or drilling facilities
to be installed. As with other floating production systems,
components of a Spar include the hull, topside and mooring
system.

Spars are most commonly used in the US


Hi there! OurGulf of Mexico,
newest quarterlydue to
their suitability for ultra-deepwater installation and access to the
report is out now and we expect
GOM pipeline network.
pace of new awards to increase.

As of December 2019, 21 spars currently are in operation.


Neptune, the first production Spar, was delivered in 1996 at a cost
of $300 million
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Outlook in 1,936 ft (590
2022-2026, hostedm) of by
water. The most
Offshore
recent Spar, Aasta
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are complete, will be installed by Equinor in 4,265 ft (1,300 m) of


water in the Norwegian Sea. Perdido was installed by Shell in 8,005
ft (2,440 m) of water and currently is the deepest Spar installation.

Initially, Spars were designed with a full length cylinder exceeding


656 ft (200 m), three of these classic designs were built and
installed: Neptune, Genesis, and Diana. Newer spars, called truss
spars, no longer have a full length cylinder, but rather an upper
hard tank and a lower truss structure.

Spars are extremely stable, making them suitable for drilling as


well as production. Though no current installed units offer storage,
Aasta Hansteen (topsides currently under construction) will have
onboard storage capacity of 160,000 bbls.

Additional Spar strengths include minimum vertical movement,


drilling capability, dry tree accommodation, and relative
insensitivity to ultra-deepwater installation. However, Spars are
expensive and require a horizontal tow for installation at
destination. In addition, a heavy lift vessel or floatover crane vessel
for hull/topside mating is necessary. Other drawbacks include
minimal to zero storage and the Spar’s stacked deck design limits
future flexibility.

5 Spars
Spars are similar to TLPs in that both are platform structures that
float vertically in the water, allowing production or drilling facilities
to be installed. As with other floating production systems,
components of a Spar include the hull, topside and mooring
system.

Spars are most commonly used in the US Gulf of Mexico, due to


their suitability for ultra-deepwater installation and access to the
GOM pipeline network.

As of December 2019, 21 spars currently are in operation.


Neptune, the first production Spar, was delivered in 1996 at a cost
of $300 million and installed in 1,936 ft (590 m) of water. The most
recent Spar, Aasta Hansteen, cost $2.6 billion, and when topsides
are complete, will be installed by Equinor in 4,265 ft (1,300 m) of
water in the Norwegian Sea. Perdido was installed by Shell in 8,005
ft (2,440 m) of water and currently is the deepest Spar installation.
Hi there! Our newest quarterly
report is out now and we expect
Initially, Spars were designed with a full length cylinder exceeding
656 ft (200 m), three of these classic designs were built and pace of new awards to increase.

installed: Neptune, Genesis, and Diana. Newer spars, called truss


spars, no longer have a full length cylinder, but rather an upper
hard tank and a lower truss structure.
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Spars are extremely stable, making them suitable for drilling as


well as production. Though no current installed units offer storage,
Aasta Hansteen (topsides currently under construction) will have
onboard storage capacity of 160,000 bbls.

Additional Spar strengths include minimum vertical movement,


drilling capability, dry tree accommodation, and relative
insensitivity to ultra-deepwater installation. However, Spars are
expensive and require a horizontal tow for installation at
destination. In addition, a heavy lift vessel or floatover crane vessel
for hull/topside mating is necessary. Other drawbacks include
minimal to zero storage and the Spar’s stacked deck design limits
future flexibility.

6 Floating Liquefied Natural Gas Units


Floating Liquefied Natural Gas Units (FLNGs) are the newest type of
floating production system. As of December 2019, four units
currently are in operation with four on order. FLNGs are floating
gas-liquefaction plants mounted on ship-shape or barge hulls with
internal storage. The units are designed to be positioned on or
near a subsea natural-gas resource or moored in a location where
gas can be received from an onshore source.

The FLNG hull is used to store LNG and other liquids. Topsides may
be configured for liquefaction-only or configured for both
liquefaction and processing. Field characteristics and location
predominately determine which topside configuration is installed
on the unit. Current FLNG designs are either turret or jetty moored
systems.

FLNGs can be grouped into four sub-types: Mega, Mid-size, Export


Liquefaction Terminal, and Liquefaction Barge. Installed in
Australia’s Browse Basin, Shell’s Mega Prelude FLNG has processing
capacity of 3.5 mtpa of gas, 35,000 b/d of LPG/condensate and
storage capacity of 220,000 m3 LNG and 1.3 million bbls of
LPG/condensate.

Current water depths for FLNGs range between 262 ft and 7,418 ft
(80 m and 2,261 m).

The units are complex and costly, especially with the addition of
processing capability. Storage capacity, mooring and design impact
Hi there! Our newest quarterly
cost. Current liquefaction only units range in cost from $300 million
report is out now and we expect
to $1.8 billion and processing and liquefaction units cost between
$1.8 billion and $7 billion. pace of new awards to increase.

FLNG strengths include avoiding the need for pipelines and


onshore facilities. The units may be built as serial units in a
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following field depletion. Drawbacks include incorporation of


technology not yet proven in offshore service and the associated
unknowns. In addition, the separation process in LNG production is
sensitive to vessel motion. Without onshore facilities, potential
opposition from local government may exist too, as no onshore
jobs would be created.

7 Floating Storage and Regasification


Units
Floating Storage and Regasification Units (FSRUs) enable natural-
gas delivery to consumers in locations physically or commercially
inaccessible by pipeline. FSRUs function similarly to land-based
LNG regasification plants. They receive, store and regasify LNG that
is transported in LNG carriers. Delivered LNG is stored in the FSRU
until required – then transformed to gas via a heat transfer plant
mounted on the hull.

As of December 2019, 25 units are in operation with four available,


14 units are on order.

FSRUs can be purpose built as a regasification facility or an LNG


carrier may be converted for use as a regasification unit. Some
FSRUs are former LNG Regasification Vessels (LNG Regas). LNG
Regas units predate FSRUs and function as LNG carriers with
gasification capabilities. Some of these units have been converted
to FSRU service.

Topsides primarily contain power generation and regasification


equipment. LNG is stored in the vessel hull and FSRUs may be
moored offshore or positioned alongside a jetty. Current FSRUs
have been moored in water depths between 66 ft and 367 ft (20 m
and 112 m).

FSRUs have processing capability of between 240 mmcf/d and


1,000 mmcf/d of gas with LNG storage between 126,000 cubic
meters and 263,000 cubic meters. Newbuild cost ranges from
$200-$300 million. Converted units are typically cheaper.

FSRUs can limit environmental opposition that would apply to a


land-based LNG regas plant. Units may be used as a peak seasonal
receiving/regas facility and as an LNG carrier in off-peak season.
With mobility, the units may also be relocated on completion of a
Hi there! Our newest quarterly
contract.
report is out now and we expect
pace of new awards to increase.
The FSRU’s primary drawback is generally having less storage and
regasification capacity compared to land-based terminals.

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7 Floating Storage and Regasification


Units
Floating Storage and Regasification Units (FSRUs) enable natural-
gas delivery to consumers in locations physically or commercially
inaccessible by pipeline. FSRUs function similarly to land-based
LNG regasification plants. They receive, store and regasify LNG that
is transported in LNG carriers. Delivered LNG is stored in the FSRU
until required – then transformed to gas via a heat transfer plant
mounted on the hull.

As of December 2019, 25 units are in operation with four available,


14 units are on order.

FSRUs can be purpose built as a regasification facility or an LNG


carrier may be converted for use as a regasification unit. Some
FSRUs are former LNG Regasification Vessels (LNG Regas). LNG
Regas units predate FSRUs and function as LNG carriers with
gasification capabilities. Some of these units have been converted
to FSRU service.

Topsides primarily contain power generation and regasification


equipment. LNG is stored in the vessel hull and FSRUs may be
moored offshore or positioned alongside a jetty. Current FSRUs
have been moored in water depths between 66 ft and 367 ft (20 m
and 112 m).

FSRUs have processing capability of between 240 mmcf/d and


1,000 mmcf/d of gas with LNG storage between 126,000 cubic
meters and 263,000 cubic meters. Newbuild cost ranges from
$200-$300 million. Converted units are typically cheaper.

FSRUs can limit environmental opposition that would apply to a


land-based LNG regas plant. Units may be used as a peak seasonal
receiving/regas facility and as an LNG carrier in off-peak season.
With mobility, the units may also be relocated on completion of a
contract.

The FSRU’s primary drawback is generally having less storage and


regasification capacity compared to land-based terminals.

8 Floating Storage and Offloading Hi there! Our newest quarterly

Vessels report is out now and we expect


pace of new awards to increase.

Floating Storage and Offloading vessels (FSOs) are primarily used in


conjunction
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Floating
and production floaters (Semis, TLPs and Spars) to provide
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offshore field storage of oil and gas condensate.

As of December 2019, 102 FSO units are in operation.

In some cases, FSOs are used as offshore storage/export facilities


for onshore production fields and as
storage/blending/transshipment terminals for crude oil or refined
products.

Most FSOs store oil, although a few store LPG or LNG. Oil storage
capacity on FSOs range from 60,000 barrels to 3 million barrels.
LPG FSOs store between 54,000 m3 and 83,000 m3 of liquefied
petroleum gas. LNG FSOs store around 130,000 m3 of liquefied
natural gas.

Most FSOs in operation are single-hull tankers modified for


storage/offloading use. The majority of FSOs operate in Southeast
Asia.

FSOs have many mooring options based on location and have been
installed in water depths between 49 ft and 3,871 ft (15 m and
1,180 m).

Converted FSOs cost between $30 million and $200 million while
newbuild FSOs cost between $100 and $300 million. Currently, 102
units are in operation.

Strengths include large storage capacity and multiple mooring


options. Conversions to FSO are considered relatively simple and
when storage is no longer required, the units may be relocated or
converted to FPSOs. One of the only drawbacks is FSOs do not
have processing capacity.

9 Mobile Offshore Production Units


Mobile Offshore Production Units (MOPUs) are essentially jack-up
rigs with production facilities. MOPUs are installed in shallow
waters (less than 100 m) and are connected to a Floating Storage
and Offloading vessel (FSO) or pipeline. MOPUs can be used for
drilling and/or production. As of December 2019, five units are
available currently with five on order.

The first MOPU was installed in the Ekofisk Field in the Norwegian
Hi there! Our newest quarterly
North Sea in 1971. The units are mainly used in the Mediterranean,
report is out now and we expect
South Asia and Southeast Asia, although a few MOPUs have been
designed for harsh environments pace of new
like the awards
North Sea to
andincrease.
Canada.

MOPUs may be converted from existing jackups or purpose built.


Converted units cost from $50 million to $180 million while
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and $300 million.

MOPU topsides are usually a single layer due to deckload weight


limitations and primarily contain connection to risers, processing
and/or drilling equipment and accommodation. MOPUs have no
storage and no external mooring systems.

MOPUs are a cost effective solution for production of marginal


fields. Jackup to MOPU conversion costs are typically lower than
other options and the units may be redeployed and re-leased.
Drawbacks to MOPU selection/usage include limited water depth
and production capacity. Lack of onboard storage requires the
addition of either a FSO or pipeline to the production solution,
further limiting flexibility.

9 Mobile Offshore Production Units


Mobile Offshore Production Units (MOPUs) are essentially jack-up
rigs with production facilities. MOPUs are installed in shallow
waters (less than 100 m) and are connected to a Floating Storage
and Offloading vessel (FSO) or pipeline. MOPUs can be used for
drilling and/or production. As of December 2019, five units are
available currently with five on order.

The first MOPU was installed in the Ekofisk Field in the Norwegian
North Sea in 1971. The units are mainly used in the Mediterranean,
South Asia and Southeast Asia, although a few MOPUs have been
designed for harsh environments like the North Sea and Canada.

MOPUs may be converted from existing jackups or purpose built.


Converted units cost from $50 million to $180 million while
newbuilds for harsh environments may cost between $200 million
and $300 million.

MOPU topsides are usually a single layer due to deckload weight


limitations and primarily contain connection to risers, processing
and/or drilling equipment and accommodation. MOPUs have no
storage and no external mooring systems.

MOPUs are a cost effective solution for production of marginal


fields. Jackup to MOPU conversion costs are typically lower than
other options and the units may be redeployed and re-leased.
Drawbacks to MOPU selection/usage include limited water depth
Hi there! Our newest quarterly
and production capacity. Lack of onboard storage requires the
report is out now and we expect
addition of either a FSO or pipeline to the production solution,
pace of new awards to increase.
further limiting flexibility.

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10 Final Selection
Prior to selection of a FPS, the field operator and its partners
evaluate various options for economic development of the field.
Based on field characteristics, oil price, water depth, weather,
location, and other variables mentioned above commercial and
strategic decisions are prepared. Then, technical assessments and
commercial estimates are made and reviewed in an iterative
process until an optimum field development solution is selected.
Once the FPS design is chosen, the specifications are developed
and bidding documents are prepared. Following pre-qualification
of all potential bidders, the operator submits a tender with
requests for bids to the pre-qualified bidders.

This phase of FPS selection and bid tendering process often takes
as long, or longer, than the actual FPS construction. Contract award
is often based on lowest price, assuming the bidder’s proposal
fulfills all the technical, commercial, and contractual requirements.

Eight FPS designs types have been conceptualized and built in 50


years and these offerings provide operators with field -specific
solutions to efficiently and effectively produce their discoveries.
FPSOs remain the uncontested crowd favorite, the newer designed
FLNG units have potential to eliminate onshore infrastructure and
FSRUs expand hydrocarbon production to remote markets.

Likely additional FPS designs will be conceptualized and built


during the next 50 years as field characteristics and drilling
techniques and technologies continue to evolve. For now though,
operators must methodically choose between an FPSO, Production
Semi, TLP, Spar, FLNG, FSRU, FSO and MOPU.

Did you know EMA offers accurate and dependable


market intelligence for the Floating Production
Sector?

 Download a Free Sample Hi there! Our newest quarterly


Report Now report is out now and we expect
pace of new awards to increase.

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1/27/22, 10:46 PM Guide to floating production systems - everything you need to know | EMA

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Energy Maritime Associates, Releases
Complete FPS Report
237 Pandan Loop #08-04, Series- 2022
Singapore, 128424 $7,600.00 $5,800.00
Press Release:
Energy
FPS Quarterly Report - Maritime 0
2022 Associates
Go to our Contact Form
$3,800.00
Releases July
FPS Outlook Report 2022- 2021 Floating
2026 Production
$3,800.00 Report
 August 11,
2021

Press Release:
Energy
0
Maritime
Associates
Releases Q2
2021 Floating
Production
Report
 April 21, 2021

© Energy Maritime Associates Pte Ltd


Hi there! Our newest quarterly


report is out now and we expect
pace of new awards to increase.

10am EST, Feb 1st | Upcoming Webinar: Floating Production Outlook 2022-2026, hosted by Offshore
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