LR FPSO Basic Principle Training

FPSO Hull Structure, Design and Maintenance The Basic Principles
Alastair Jones Business Manager Oil & Gas Services Lloyds Register Asia
Alastair Jones FPSO Hull Structure, Design and Maintenance
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OUTLINE
75 minute presentation 15 minutes for questions and answers Notes expand on issues covered by presentation Content: Introduction New Build versus Conversion Rules and Regulations (Overview) Hull strength issues Hull fatigue design In-service survey Lessons learnt and In-service Incidents
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INTRODUCTION
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WHAT MAKES AN FPSO DIFFERENT FROM A TRADING TANKER?

Operations and safety requirements Layout and arrangement Specified service / location Different Classification Rules National / Local Authority Rules and Regulations Complexity of design, construction & commissioning In-situ inspection / maintenance
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TYPICAL FPSO PARAMETERS

New-build or Conversion Storage Production Vessel Water depth Topsides Risers Wave height Air temp Turret or Spread mooring arrangements Permanent / Disconnectable Turret 200,000 - 2,000,000 barrels 30,000 - 250,000 bopd 100,000 - 350,000 tonnes 30 - 2000 metres 2000 - 33000 tonnes 1 - > 30 benign - > 30 metres -20C - > 30C
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SOME TYPICAL ENVIRONMENTAL CRITERIA

Hs Nigeria 4.0 Tp 7.6
Offshore Iran
Australia Brazil U.K. Central
5.9
6.0/7.0 7.0 13.0
10.2
11.1 15.4 15.2
Gulf of Mexico
Nova Scotia West of Shetland
12.0 / 13.0
16.0 17.1
14 / 15
14 / 18 16.0
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Typical General Arrangements

Living quarters Oil Sep. Utilities Prod Water/Inj. Gas Comp. Flare Tower Turret
Living quarters at the stern

Living quarters
Flare Tower Turret Prod Water/Inj. Utilities Gas Comp. Oil Sep.
Utilities
Alastair Jones
Living quarters at the bow

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FPSO Hull Structure, Design and Maintenance
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MOORING ARRANGEMENTS
Internal turret mooring
Bow mooring
Spread mooring
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TURRET MOORING SYSTEMS Internal External
Large Internal Turret
Small Internal Turret
Riser Turret Mooring (D)
Buoyant Turret Mooring (D)

Submerged Turret Production (D)

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External Turret Mooring
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Turret & Swivel System
Swivel Stack Access Structure Turret upper slewing bearing
Swivel stack
Turret cylinder
Lower bearing
Moonpool
Chain stopper Mooring lines

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Risers
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They dont have to be ship shaped !
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DEVELOPMENT ALTERNATIVES :
NEWBUILD vs CONVERSION
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KEY CHOICE DRIVERS 1 OF 2

Project and client requirements Schedule / time to first oil (new build: 2 to 3 years; conversion: 1 to 2 years) Location / environment Topsides function / size (Oil / Gas / LPG / LNG?) Field life, CAPEX and OPEX Early production or full field?
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KEY CHOICE DRIVERS 2 of 2

Ship yard schedule Availability / capability / price Location Availability of suitable tonnage Capacity and suitability Condition and age Statutory and National Authority requirements
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NEW BUILD HULL - ADVANTAGES

Compliance with latest regulations Design for required service and life Integrated design High standard of detailing Service experience fed back Inclusion of margins
NEW BUILD HULL - DISADVANTAGES

Higher initial costs (CAPEX) Longer schedule
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NEW BUILD GRIFFIN VENTURE FPSO
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NEW BUILD - TERRA NOVA FPSO
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NEW BUILD SHELL EA FPSO
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NEW BUILD - SNEPCO BONGA FPSO
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CONVERSION - VESSEL SELECTION ISSUES

Vessel age, condition and service history hull global strength remaining corrosion margins remaining fatigue life structural steelwork replacement Mooring structure internal or external modifications structural reinforcement Topside integration structural reinforcement Possibility of upgrades to equipment, systems, machinery & accommodation
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CONVERSION MAJOR WORKS SUMMARY

FLARE TOWER FLUID TRANSFER SYSTEM ACCOMMODATION, LSA, EERA UPGRADE AND BLASTWALLS HELIDECK
CCR
TURRET AND MOORING STRUCTURE
TOPSIDES AND SUPPORT SRUCTURE
BREAKWATER
CRANES AND LAYDOWN AREAS OFFLOADING SYSTEM
CARGO & MARINE SYSTEMS

BULWARK
ENGINE AND STEERING GEAR
EXTERNAL COATINGS HULL STRUCTURAL UPGRADES
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EXAMPLE OF CONVERSION
Conoco MacCulloch North Sea Producer - Teesside
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EXAMPLE OF CONVERSION
Conoco MacCulloch North Sea Producer - Teesside
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RULES AND REGULATIONS (OVERVIEW)
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DEFINITIONS
Class to Class Society Rules LR Rules for a Floating Offshore Installation at a Fixed Location (FOIFL Rules) LR Rules for Ships Certification to Regulations and Codes Verification to Performance Standards
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GOVERNING REGULATIONS
Classification Rules Local and / or National Authority Some authorities require identification of Safety Critical elements (ie. hull) SCEs then require verification by third party against Performance Standard
Class rules provide appropriate Performance Standard

Flag state International conventions for ships SOLAS, MARPOL, LOADLINE, TONNAGE Disconnectable FPSOs effectively become ships flag becomes relevant
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SCOPE OF LR FPSO RULES

LR Rules cover the following aspects : hull and marine systems mooring systems risers (optional) process plant (optional) drilling plant (optional) Rules governing FPSOs are currently being updated: FOIFL Rules refer to Ship Rules Oil Tankers As of April 2006 new tanker rules for double sided vessels Developed jointly by ABS, DNV and Lloyds Register See www.jtprules.com
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LR GUIDANCE NOTES SUPPORTING THE RULES

An Overview of Regulatory Issues Conversion of Tankers for Floating Production Service Ship Type Hull Structural Appraisal and supplement Additional Structural Aspects Positional Mooring Systems and supplement Fibre Ropes for Offshore Moorings Periodic Inspection Design Appraisal of Semi-Submersible Units
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HULL STRENGTH ISSUES
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HULL GIRDER - WAVE BENDING

D eep D r a ft LR Ru le
Bending M om ent
Lig h t D r a ft
50
100
150
200
250
D i s tan ce fro m A ft Pe rp e n d i cu l ar (m )
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HULL GIRDER - BENDING MOMENT CAPACITY

800000 Hull Capacity
600000
400000
SWBM Allowable
200000
-200000
-400000
SWBM Allowable
-600000 Hull Capacity -800000
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HULL GIRDER - WAVE SHEAR
100 Year Deep Draft
Shear Force
LR Ru le
Light Draft
50
100
150
200
250
D istance from Aft Perpendicular (m)
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GLOBAL HULL DESIGN WAVE BM & SF

Still water loading conditions often more severe for FPSO Wave loading depends upon site environmental criteria: harsh environment wave BM and SF are close to and may exceed Ship Rule requirements benign environment wave BM and SF are less than Ship Rules (but not to be taken less than 70% of unrestricted service Ship Rule requirement) Multisite operation may require assessment Towing, inspection and temporary conditions to be considered FOIFL Rules require assessment of site specific wave loading (100 year return values) Ship rules employ simple parametric equations for wave loading (20 year return values) Longitudinal SF and BM determine (mostly) longitudinal material
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Example Transit case (Bonga)
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HULL STRENGTH / FATIGUE FE MODELS

Cargo / ballast tank area Mooring structure and hull integration (turret and/or chainstoppers) Riser porches and supporting structure Topsides support structure and hull integration Flare tower support structure Offloading station support structure Main crane pedestals and support structure Helideck structure Additional locations depending on vessel function and owners requirements See also section on Fatigue
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CARGO TANK MODEL

Loadings:
Hull girder SF & BM External pressure Cargo loads Topside loads
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MOORING TURRET INTEGRATION
Loadings: Mooring system and risers Hull girder SF & BM Internal / external pressure
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TOPSIDE SUPPORT STRUCTURE

Gravity loadings Hull motions Hull girder stresses Hull girder deflections
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BOTTOM SLAMMING
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BOW AREA IMPACT

Effects forward bottom structure Factors affecting slam pressure: bluffness of bow pitch response / wave length wave steepness wave height breaking waves loading condition (draft)
Model testing advisable Rules contain requirements relating to draft, pressure, extent and scantlings
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GREEN SEAS BOW AND MAIN DECK
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GREEN SEAS MAIN DECK

Tanker heading off the waves due to Wind Current Wave crest travels along ships weather side Energy is concentrated Wave height increases Water is shipped on the main deck in midship section Impact on structures and equipment
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GREEN SEAS
Factors affecting green seas: pitch response / wave length wave steepness wave height breaking waves loading condition (draft) bow shape Rules for ships incorporate allowances within design heads for superstructures, deckhouses, bulwarks and decks. Model testing advisable
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SLOSHING IN CARGO OIL TANKS
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SLOSHING IN CARGO OIL TANKS

Sloshing is the dynamic magnification of pressures within cargo/ballast tanks Partial fillings the norm for FPSOs (NOT so for trading oil tankers) Influencing Factors: Tank size Hull form Environment / Weathervaning Natural periods of both vessel and fluid Tank fill levels
Sloshing analysis required (e.g. LR FLUIDS) Analysis may result in an increase in scantlings at tank tops Restrictions may be placed on fill levels in certain tanks
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ACCIDENTAL LOADS
Collision due to supply boat / shuttle tanker / iceberg Dropped object Explosion / blast Ultimate strength criteria (10000 year wave?)
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HULL FATIGUE DESIGN
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FATIGUE the problem

The effect on metal of repeated cycles of stress. There is no obvious warning, a crack forms without appreciable deformation of structure making it difficult to detect the presence of growing cracks. Fractures usually start from small nicks or scratches or fillets which cause a localised concentration of stress. Failure can be influenced by a number of factors including size, shape and design of the component, condition of the surface or operating environment. Fatigue life of structural details need to be assessed for FPSO
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FATIGUE LIFE ASSESSMENT

Identification of critical areas Detailed finite element analysis to assess Stress Concentration Factors Site specific analysis of dynamic loads Previous service history to be assessed (for conversions) Selection of S/N curves Other relevant issues: Cathodic protection / coatings Fabrication, tolerances, welding Inspection / Inspectability Repair / structural detail improvement Fracture mechanics assessment
Note: fatigue is highly sensitive to loading (stress range3)

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EXAMPLE FEM MESH ARRANGEMENT TO DETERMINE SCFS
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FATIGUE LIFE - FACTORS OF SAFETY

Inspectable / Repairable Fatigue Life Factor Consequence of Failure
Non - substantial Yes, dry (see note 1) Yes, wet (see note 2) No 1 2 3
Substantial 2 4 10
Substantial consequences of failure are defined as loss of life, uncontrolled outflow of hazardous products, collision or sinking and should include for progressive failure scenarios.
Note 1 : Includes external components which can be dry inspected / repaired. Note 2 : Includes external components below the minimum operating draft which can only be inspected in water, but dry repairs could be carried out.
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TYPICAL CRITICAL AREAS

Process supports
Stress concentration Misalignment Welding
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FABRICATION TOLERANCES AND WELDING

Tolerances should be in accordance with good shipbuilding practice, and agreed with Class Society Special attention given to fatigue sensitive areas Enhanced NDE levels will be necessary for identified fatigue sensitive areas Assumptions used in analytical fatigue assessments to be consistent with construction
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FPSO FATIGUE ENHANCEMENT DETAILS CONVERSION

Examples of modification to hull longitudinal connection details
Additional lug Additional bracket Shell plate Longitudinal Shell plate
Extent Item Additional Lugs Within cargo and ballast tanks Bottom and side shell (up to limit of wetted area) Bilge area and side shell (up to limit of wetted area)
Transverse frame Additional bracket Longitudinal
Transverse frame
Longitudinal / Transverse frame connection Transverse frame Additional bracket Longitudinal
Additional Bkts
Shell plate
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FPSO IN-SERVICE SURVEY
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IN SERVICE SURVEY PROGRAM

Source : developed by the owner / operator against list of surveyable items Survey plan to be approved by Class
To address : Class requirements Regulatory requirements Overall hull structure configuration & critical areas
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STRUCTURAL INSPECTION
Carried out on location Provides detection / monitoring capacity Annual, intermediate & major surveys Major survey (5 years or continuous) IWS in lieu of dry docking Internal survey considerations: cleaning & gas freeing access arrangements/safety Lighting / ventilation loading conditions for strength
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IN WATER SURVEYS
Requirements for OIWS notation Cathodic protection and high resistance paint Underwater marking Tank inspection conditions included in hull girder analysis Venting/isolation arrangements for tank entry Arrangements considered for survey/changeout of thrusters, sea chests, rudder bearing etc.
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Permanent Means of Access (PMA)
SOLAS requirements for newbuild vessels
All internal tanks
Eliminate need for staging, rafting or rope access

Access for close up examination Utilise tanks structural members, or provide dedicated arrangements Standards for ladders, handrails, etc
Portable equipment may be used for some
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SOLAS Permanent Means of Access (PMA)
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SOME LESSONS LEARNT and IN-SERVICE INCIDENTS
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GENERAL LIFE OF FIELD ISSUES

Holistic approach for good integrated solution Offshore instead of Ship maintenance philosophy Design for accidental loads, including wave impact Compatibility of hull structural, systems and topsides interface design Fatigue Design (& life to date for conversions) Production equipment for extreme weather conditions Marine equipment robustness, particularly cargo/ballast systems OIWS requirements and corrosion protection Access (operability / maintainability / inspectability) In-service survey effect on downtime Provision of spare parts
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FPSO INCIDENT HISTORY Examples of problems

Hull Structure Localised fatigue failure bow wave impact damage shuttle tanker collision tank overpressurisation seawater caisson preferential corrosion integration of surface and subsea corrosion protection
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FPSO INCIDENT HISTORY - STATISTICS (REPORTED)

Vessel system Hull Nature of incident Structure failure in heavy weather Other structural failure Collision Structural failure in heavy weather Process equipment failure Fire Engine room fire Engine room power failure Main engine failure Rudder / steering gear failure Hydrocarbon release Explosions Loss of anchor (s) No. of incidents 1 3 6 3 2 0 2 1 1 3 2 0 1
Topsides
Machinery
Other
Ref : 22 vessels, approx 10 years of records
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FATIGUE FAILURES
Area Shown Example of defect locations on side shell Cargo / ballast tanks Defect
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TYPICAL DAMAGE
Side shell longitudinal connection Web frame
Crack
Face bar
Shell plating Web frame stiffener
Shell longitudinal
Crack
Broken welding
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EXAMPLES OF INTERNAL WELDED REPAIRS

Side shell Fracture locations Bulkhead stiffener Stiffener Transverse bulkhead Backing bracket Side shell Side longitudinal Side shell New longitudinal section Stiffener with soft toe Bulkhead stiffener Transverse bulkhead
Additional radius bracket

Side longitudinal Pillar stiffener
Additional lug
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SCHIEHALLION FPSO BOW WAVE IMPACT DAMAGE

Similar incidents Varg Norne Alba
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FPSO RULE AMENDMENTS FOR FORE END STRUCTURES

Basis - Ship Rule requirements using min. service speed 12 - 15 knots Site specific assessments required where expected to be more severe Model test measurements of impact pressures recommended Integrated structural design approach to be adopted using direct calculation methods (LR Rules for permissible stress requirements)
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For more information, please contact: Lloyds Register Asia Oil and Gas Services
T: +65 6273 3424 F: +65 6273 1662 E: alastair.jones@lr.org
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FPSO Hull Structure, Design and Maintenance The Basic Principles

Alastair Jones FPSO Hull Structure, Design and Maintenance

Alastair Jones FPSO Hull Structure, Design and Maintenance

Alastair Jones FPSO Hull Structure, Design and Maintenance

WHAT MAKES AN FPSO DIFFERENT FROM A TRADING TANKER?

Alastair Jones FPSO Hull Structure, Design and Maintenance

TYPICAL FPSO PARAMETERS

Alastair Jones FPSO Hull Structure, Design and Maintenance

SOME TYPICAL ENVIRONMENTAL CRITERIA

Alastair Jones FPSO Hull Structure, Design and Maintenance

Typical General Arrangements

Living quarters at the stern

Living quarters at the bow

FPSO Hull Structure, Design and Maintenance

Internal turret mooring

Alastair Jones FPSO Hull Structure, Design and Maintenance

TURRET MOORING SYSTEMS Internal External

Large Internal Turret

Small Internal Turret

Riser Turret Mooring (D)

Buoyant Turret Mooring (D)

Submerged Turret Production (D)

External Turret Mooring

Turret & Swivel System

Swivel Stack Access Structure Turret upper slewing bearing

Chain stopper Mooring lines

They dont have to be ship shaped !

Alastair Jones FPSO Hull Structure, Design and Maintenance

Alastair Jones FPSO Hull Structure, Design and Maintenance

Alastair Jones FPSO Hull Structure, Design and Maintenance

KEY CHOICE DRIVERS 1 OF 2

Alastair Jones FPSO Hull Structure, Design and Maintenance

KEY CHOICE DRIVERS 2 of 2

Alastair Jones FPSO Hull Structure, Design and Maintenance

NEW BUILD HULL - ADVANTAGES

NEW BUILD HULL - DISADVANTAGES

Alastair Jones FPSO Hull Structure, Design and Maintenance

NEW BUILD GRIFFIN VENTURE FPSO

Alastair Jones FPSO Hull Structure, Design and Maintenance

Alastair Jones FPSO Hull Structure, Design and Maintenance

NEW BUILD - TERRA NOVA FPSO

Alastair Jones FPSO Hull Structure, Design and Maintenance

NEW BUILD SHELL EA FPSO

Alastair Jones FPSO Hull Structure, Design and Maintenance

NEW BUILD - SNEPCO BONGA FPSO

Alastair Jones FPSO Hull Structure, Design and Maintenance

CONVERSION - VESSEL SELECTION ISSUES

CONVERSION MAJOR WORKS SUMMARY

TURRET AND MOORING STRUCTURE

TOPSIDES AND SUPPORT SRUCTURE

CRANES AND LAYDOWN AREAS OFFLOADING SYSTEM

CARGO & MARINE SYSTEMS

ENGINE AND STEERING GEAR

EXTERNAL COATINGS HULL STRUCTURAL UPGRADES

Alastair Jones FPSO Hull Structure, Design and Maintenance

Conoco MacCulloch North Sea Producer - Teesside

Alastair Jones FPSO Hull Structure, Design and Maintenance

Conoco MacCulloch North Sea Producer - Teesside

Alastair Jones FPSO Hull Structure, Design and Maintenance

RULES AND REGULATIONS (OVERVIEW)

Alastair Jones FPSO Hull Structure, Design and Maintenance

Alastair Jones FPSO Hull Structure, Design and Maintenance

Class rules provide appropriate Performance Standard

Alastair Jones FPSO Hull Structure, Design and Maintenance