225931722 Fpso Design and Technology

Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology

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Crondall Energy Consultants Ltd28, City Business Centre, Hyde Street, Winchester, SO23 7TA Tel +44 (0)1962 842233

www.crondall-energy.com

IBC FPSO Training CourseIBC FPSO Training Course

Perth ~ November 2005Perth ~ November 2005

Introduction to FPSO Design and Introduction to FPSO Design and TechnologyTechnology

Duncan Peace Duncan Peace –– Crondall Energy Crondall Energy


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Agenda

1. General Introduction Definitions Strengths and weaknesses Regional aspects Market situation

2. Building blocks Key components Hull selection and design Interface with topsides Station keeping Interface with sub-sea

3. Key technologies Turrets and swivels Different turret types What is going on inside a swivel? New developments


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Part 1

General Introduction


44

Definitions

FPU -Floating production unit – a general expression for all floating production units, but sometimes also used to describe units without storage such as semi-submersible units

FPSS – floating production semi-submersible

FSU or FSO – Floating storage unit OR floating storage and offloading unit

FPSO – floating production storage and offloading units

MOPU – general term for mobile offshore production units, but may include jack-up units as well as floating units


55

FPSS and TLP

Marco Polo

Images courtesy of Modec/Sofec

Semi submersible production Semi submersible production facility.facility.

Tension leg production Tension leg production facility.facility.


66

FPSOs and FSUs

Floating storage facilityFloating storage facility

Floating production storage Floating production storage & offloading facility& offloading facility



77

FPSO – Strengths and weaknesses

Strengths

Economics – low hull and conversion cost can provide best development solution

Mobility – Easy to move from construction site to field – easy to relocate from field to field

Insensitive to water depth – concept is relatively insensitive to water depth - can operate from ~30m – 3,000 metres

Large deck area and load capacity – mono-hull configuration provides large deck payload capacity and is relatively insensitive to additional payload

Storage capacity – allows export of product by shuttle tanker – not pipeline dependent

Weaknesses

Additional marine equipment and crew (relates partly to storage) makes operating costs relatively higher

Lack of drilling capability – Turret moored solutions with drilling not yet operating – although concepts exist

Turret systems can act as a constraint on riser numbers and sizes

Need to use sub-sea trees and flexible risers (relatively expensive)


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Regional issues

North Sea Challenging met ocean environment – drives technology innovation Heavily regulated Mature infrastructure Units tend to have smaller storage than in benign areas

W. Africa Benign met ocean environment – benign regulatory environment Significant distance to market – drives higher storage capacity Stranded gas is a challenge – little infrastructure

Brazil Moderate environment – moderately regulated Pioneering deepwater technology Established infrastructure

SE Asia/Australasia Cost & schedule driven Benign environment; some regional climatic factors – cyclones & typhoons


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Market position of FPSOs

Current worldwide fleet of FPSOs numbers are estimated at around 110+ units working or idle units as at the end of 2004, plus around 30+ under development.

Forecasts show a further 100+ planned for the next 5 years – which may or may not be realised. However, 20+ units per year will be a challenge for the industry

History and forecast both suggests that of these prospects; around 2/3rds will be FPSOs;

GLOBAL FORECAST 2004-2008

14

9

1920

10

36

22

1

13

102

TLP's

SPARS

FPS's

FPSO's SOUTH EASTASIA

FPSO's AUSTRALASIA

FPSO's AFRICA

FPSO's AMERICA

FPSO's MIDDLE EAST

FPSO's EUROPE

Source: Infield Systems Ltd., Offshore Magazine (May 2004)


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Market Forecast @ November 2005

Under Construction or with firm plans 23 FPSOs 7 FPSSs 3 SPARs 3 TLPs

Probable or possible developments 78 FPSOs 5 FPSSs 2 SPARs 7 TLPs

Source: OGPOD Database/CEC Analysis

The FPSO remains the numerically dominant technology for floater developments

Numbers will continue to challenge industry supply of resources


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Why are FPSOs so important?

FPSOs have become the technology of choice for new developments in deepwater;

Outside the GOM they are the dominant technology;

Significant growth forecast – global fleet expected to almost double over the next 5+ years;

THE FPSO HAS GONE FROM A PERIPHERAL TECHNOLOGY IN BENIGN AREAS – TO THE MAIN SOLUTION FOR MODERATE/DEEP OFFSHORE DEVELOPMENTS

WORLDWIDE

CHALLENGE FOR THE INDUSTRY IS HOW TO MEET THE SCALE OF THE FORECAST INVESTMENTS.


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Part 2

Building Blocks


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Key components and design features

Hull and hull (marine) systems

Station keeping and fluid transfer facilities

Topsides process equipment

Internal interfaces

Interface with sub-sea equipment & wells

Interface with offloading arrangements

In this presentation we will deal with the first two ~ and leave the remainder to subsequent presentations

Image IHC Caland Annual Report

Image Courtesy of Bluewater


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Hulls and Hull Systems


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Hull selection – New build or conversion

New Build

More flexibility in selecting key design criteria Schedule (design and build longer duration than conversion) High costs Often selected in robust met-ocean environments May become more prevalent as numbers of suitable conversion candidates decrease OR hull prices

increase My be preferred if conversion scope would be extensive because

• No suitable conversion candidates• Remedial work for structure &/or marine systems extensive or high risk• Major compliance issues

Conversion Dominates the global supply of FPSOs Quicker and cheaper solution Key decisions will be around scope of conversion/upgrade/replacement


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Hull selection -New build and conversion challenges

New build challenges Schedule impact Yard availability Competition Design choices

Conversion challenges Conversion candidate vessel (age - double v single hull) Scope definition

• Structural integrity• Utilities & hull systems integrity• Interfaces & integration of systems• Technical standards & compliance • Material selection and corrosion protection

Contractor skills, experience & capacity Scope growth


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Hull design - Design Features

Key Issues

Deadweight Cargo (storage) capacity Equipment (payload) capacity

Hull structure - Global and local strength

Main vessel lay-out - Deck space - Location of accommodation (NB)

Location of turret % LBP

Need to be considered

Hull form, fineness and sea-keeping considerations (NB)

Bow shape, free board (forecastle & ship side) (NB)

Green water protection

NB = Issues where scope NB = Issues where scope for choice exists with for choice exists with

new-buildsnew-builds


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Hull structure

Tank arrangements - Double sides v full double hull

Arrangement of tank spaces (NB)

Longitudinal bulkheads (NB)

Integration with topsides and other interface structures

Layout of other hull spaces for utilities etc. (NB)




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Hull structure - cargo tank arrangements

Double side Double side –– single bottomsingle bottom

Double side Double side –– double double bottombottom

Three cargo tank Three cargo tank arrangementarrangement


2020

Hull layout-aft accommodation

UtilitiesUtilitiesBlast wallBlast wall FwdFwd

AccommodationAccommodationHelideckHelideck ProcessProcess TurretTurret


2121

Hull layout -fwd accommodation

TurretTurretProcessProcess HelideckHelideckUtilitiesUtilities

AccommodationAccommodation

Blast wallBlast wall

FwdFwd


2222

Hull design - Hull systems and utilities

Layout of major features (NB) Accommodation & TR Main marine systems & utilities

• Cargo & ballast & Pump room

• Main Power, emergency power,

• Fire pumps.

• HVAC,

• IG Other spaces and services required for auxiliary equipment and shared systems Vessel upper deck piping arrangements (pipe rack integration)

Integration of hull marine and topsides systems Power/fuel Control and safety systems Emergency power




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Interface with Topsides equipment and systems

Design and layout of topsides will be covered later by Simon Lowe of Maersk Contractors

Interface issues will be covered by Gary Doyle of Crondall Energy Consultants

However, there are a number of key issues that need to be considered by the hull design process

Structural integration of topsides support stools & module support structure into hull structure layout

Consideration of required maximum topsides weight and CoG

Layout and space considerations in the area of the vessel upper deck

Extent of integration of hull and topsides systems


2424

Station keeping


2525

Station keeping - Key design Issues

Station keeping options are:

Mooring with a turret mooring system – allows weathervaning to prevailing met-ocean conditions Spread mooring – fixed – or mostly fixed orientation (some partially compliant systems) Dynamic positioning (rare – only two units currently operating in this mode) Permanent or disconnectable

Key decision inputs will be the prevailing met-ocean conditions:

Severity of conditions Nature of severe events – cyclones etc. Directionality of conditions (dominant direction) Extent to which prevailing conditions are co-linear (sea wave and swell OR sea wave and

wind/current) Economics (capital cost versus operating uptime)


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Turret or Spread Mooring?

Weather conditions, directionality & persistence

Riser requirements (number, size and configuration)

Permanent v disconnectable

Offloading some spread moored systems now have separate offloading facilities

Other factors Process performance and uptime Hull fatigue


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Turret Moored - the Alvheim FPSO

Images courtesy of APL

Vessel is based on the Statoil/Navion multi purpose shuttle tanker (MST) concept 85,300 Dwt tanker Double hull dp3 class 120,000 bbl/day oil

production 125,000 mmscf gas

handling


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Spread mooring –the Sendje Berge

Images courtesy of Bergesen

Vessel is based on a VLCC

2 million bbls storage

60,000 bpd production

Spread mooring


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DP Position Keeping – FPSO Munin

The Bluewater owned and operated Munin has operated in both turret moored mode (this image) at the Lufeng field in China and the Xijiang field also in China

Vessel is based on the Statoil/Navion multi purpose shuttle tanker (MST) concept 95,500 Dwt Double hull dp2 class 60,000 bbl/day

production

Images courtesy of Bluewater


3030

Interface with sub-sea equipment

Turret and swivel provide the main interface between the FPSO and the sub-sea system

Swivel systems allow the transfer of:

Production fluids from the sub-sea equipment to the vessel Export fluids from the vessel to the sub-sea infrastructure Well/sub-sea management/control fluids e.g. methanol Electrical signals for control and monitoring Electrical power for driving sub-sea/down hole equipment e.g. ESPs

Turret provides connection to mooring lines and mechanical support for the risers and umbilicals


3131

Interface with sub-sea equipment

Images courtesy of BluewaterImages courtesy of Modec Inc.


3232

Sub-sea interface



3333

Part 3

Key Technologies


3434

Key Technologies

Development of turret and swivel systems which allow n x 360 degrees rotation have been the key technologies which have allowed FPSOs to be used in all met-ocean environments

Turret allows vessel to weathervane – that is, to take up a position which aligns it with the dominant forces of wave, wind and current.

Weathervaning has the effect of minimising environmental loads on the station keeping system, and minimises the most sensitive vessel motions – generally for a mono-hull – roll.

This has the effect of minimising disturbance to process equipment and personnel and maximising the facility uptime.


3535

Different Turret Types

Internal turrets

External turrets (forward of bow - normally)

Permanent or disconnectable

Yoke moored


3636

Internal Turrets



3737

Internal Turrets



3838

Internal Turrets


Turntable Access StructureTurntable Access Structure

(alternative: Deckhouse)(alternative: Deckhouse)

Swivel StackSwivel Stack

TurntableTurntable

TurretTurret

Casing / MoonpoolCasing / Moonpool

SpiderSpider

(bottom ship)(bottom ship)

(upper deck)(upper deck)


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Internal Turrets


Casing/MoonpoolCasing/Moonpool

Mooring LegsMooring Legs

SpiderSpider

Lower Radial BearingLower Radial Bearing

Turret (with riser pipes)Turret (with riser pipes)

Main Roller BearingMain Roller Bearing


4040

Turntable- Typical Lay-out

Includes for example:

Subsea Control Skids

Pipe headers

Control valves

Pig receivers

Pig launchers

Installation Winch



4141

External turrets - Baobab Ivoirien FPSO


970 m water depth

8-leg polyester

mooring

357,000 dwt tanker

conversion

2.0 million bbls storage


4242

External turrets- FPSO Fluminense Brazil


800 m water depth

357,000 dwt tanker conversion



4343

External turrets - Cuulong MV9 FPSO



4444

Yoke MooringCNOOC Bohai Bay QHD32-6 FPSO (China)

Kome Kribi FSOw/ Tower Yoke Mooring System


66 ft water depth

New-build vessel



4545

Disconnectable systemsSBM’s External and Internal solutions

External or Riser Turret Mooring Internal turret with disconnectable buoy

Images courtesy of SBM


4646

The Riser Turret Mooring (RTM)

Cossack Pioneer

Location NW Shelf Australia

Vessel size: 152,000 Dwt

Topsides 115,000 bopd

Images courtesy of SBM


4747

Disconnectable internal turret systemAPL’s STP system



4848

Disconnectable systems –Terra Nova


Turret AccessStructure

Upper Turret

Lower Turret

Spider Buoy

Fluid Swivel

Manifold System

Upper Bearing

Connector System

QC/DC Connectors

Lower Bearing


4949

Swivel systems


5050

Swivel systems

Swivel systems allow the transfer of:

Production fluids from the sub-sea equipment to the vessel Export fluids from the vessel to the sub-sea infrastructure Well/sub-sea management/control fluids e.g. methanol Electrical signals for control and monitoring Electrical power for driving sub-sea/down hole equipment e.g. ESPs

Swivel systems allow n x 360 degrees rotation

Swivel manufacturers are pushing back the boundaries of pressure and temperature to limit of around: ~400+ barg ~120c


5151

What is going on inside a swivel?

Rotor StatorRotor Stator



5252

What is going on inside a swivel?

Images courtesy of Framo


5454

Leadon FPSO stack

Images courtesy of Framo

Leadon power slip ring to Leadon power slip ring to be installed later when be installed later when

required (4 x 1 MW)required (4 x 1 MW)

Fluid pathsFluid paths

UtilitiesUtilities


5656

Swivel stack modules



5757

P37 Swivel stack



5858

New developments – the Sevan SSP

Concept

Scaleable oil storage capacity (0.3-2 MMbbl)

High deck load capacity No requirement for weathervaning,

avoiding complicated/ costly turret swivel system

Standard riser connections, umbilical and power cable terminations

Accommodates large number of risers Low investment for future risers

Images courtesy of Sevan Marine


5959

New developments – the Sevan SSP

Piranema SSP300constructionat Yantai Raffels Picture Sep 23, 2005

Images courtesy of Sevan Marine

Documents

225931722 Fpso Design and Technology