R E Q U I R E D R E A D I N G F O R T H E G L O B A L O I L & G A S I N D U S T R Y S I N C E 1 9 7 5

PLUS: STEVE HATTON ON WHY COMPOSI TES ARE READY FOR THE ULTRA-DEEP RI SER CHALLENGE
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OFFSHORE ENGINEER
Accusations fly in
Macondo fallout
Claw out for US Gulf
decommissioning
The shape of
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How best practices
optimize topsides design
Adhering to best practice in areas such as process optimization and piping, electrical and structural design will help to deliver
safe and operable FPSO topsides that minimize capital and operating expenditures. Alliance Engineerings
Norb Roobaert, Juan Campo, Howard Newman and Alan Phillips outline their approach to topsides design optimization.
Offloading approach area
Buoy
Helicopter approach area
Helicopter approach area
Flare
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Mooring lines
Accommodations
and helipad
Supply boat approach area
Anchors
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Vessel orientation best practices.
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among accommodations and all process
and utility modules regardless of the
perceived risk or classification. Laydown
areas, if not used to store hydrocarbons/
chemicals for long periods of time, are the
only exception.
Equipment within each module should
be arranged with heaviest items closest
to the hull centerline and on the lower
levels to reduce the effect on the FPSOs
center of gravity. Towers and tall vessels
should also be located in modules as
near as possible to the hull centerline to
reduce the affect of sea state conditions
on equipment performance and support
structure.
Roll onboard an FPSO has the most
variation from horizontal due to sea
state conditions. The shaft of rotating
equipment should be orientated parallel
to the longitudinal axis of the FPSO hull.
This mitigates the effect of the ships roll,
reducing impact on rotating equipment
performance and increasing reliability
and uptime.
Structural
Modular systems simplify overall
shipyard construction and
reduce integration cost and
schedule. Modules can be
independently fabricated,
tested and delivered
to the shipyard as
complete packages
ready for integration,
commissioning and
start-up. >page 47
The layout of the FPSO topsides
is driven by the method of mooring,
sea state factors, and placement of
the modularized process and utility
systems, with allowance for operability,
maintenance and, above all, safety.
Vessel topsides orientation should
be determined early as it effects the
configuration of all topsides elements.
The FPSO discussed in this example
is a spread moored vessel. Other vessel
mooring types will have different
requirements for topsides orientation.
In this case the flare is placed downwind
of the prevailing wind direction
and as far away as possible from the
accommodations. Helicopter approaches
should be at quartering angle in the
direction of predominant wind and above
the accommodations. The approach angle
must take into account obstructions from
the flare, vertical equipment above the
module structure, the destabilizing effects
of exhaust gases from turbine-powered
equipment and visual aids for helicopter
touchdown.
Metocean data and dropped-object risk
factors were considered in determining
supply boat approach to allow for
primary and optional offloading
scenarios. An offloading
buoy is the primary means of
delivering cargo and the supply
boat approach should always be
up-current so the boat will drift
away from the FPSO if it loses
power. Laydown areas should be
adjacent to the supply boat access to
allow for ease of loading and offloading
supplies and equipment. Riser locations
should be on the opposite side from the
supply boat access to reduce risk from
dropped objects during transfers between
vessels.
The FPSO layout best practice utilizes
an arrangement of process and utility
modules alongside a central pipe rack.
The pipe racks must be of a similar length
to their adjacent modules.
The most hazardous modules, based on
process system, should be placed farthest
from the accommodations to maximize
safe distances. Lowest risk modules,
such as the utility modules, are placed
closest to the accommodations. A 20m
gap, or a safe zone, should be maintained
S
uccessful topsides design requires
effective decision making in five
areas: process optimization, and
module, piping, electrical and structural
designs. Key to success is experienced
engineers and designers who understand
best practices for the structural interface
between hull and topsides modules and
for optimized equipment location, safety,
maintenance and operability.
FPSO topsides projects developed
by utilizing best practices benefit from
the application of systematic detail
design based on experience and proven
results. The result is improved quality
and consistency. Cost and schedule are
reduced through efficient engineering
and design that minimizes equipment and
simplifies fabrication, installation and
commissioning.
Process optimization
Optimizing the process before beginning
detail design is a critical component of
best practice and delivers measureable
benefits to operators.
An FPSO was designed to accommodate
oil production of 100,000b/d, associated
gas production of 250mmcf/d, produced
water of 100,000b/d, and water injection
of 275,000b/d at 5000psig surface
pressure. The process optimization
goals were to meet HSE requirements,
export maximum oil quantities, reduce
capital expenditures, minimize deck
space and operating weight, minimize
process complexity, maximize reliability,
minimize operating cost and maximize
net present value.
The process optimization resulted
in the utilization of an oil stabilization
process that maximized oil recovery and
operated at higher pressures to minimize
compression. The resulting facility
consisted of 10 modules and reduced
topsides weight by 7000 tons compared to
conventional stage separation, providing
an approximate savings of $300 million.
Layout
Best practices help define the location of
living quarters, safe access/egress, flare,
hazardous and non-hazardous process
systems, ship loading and unloading
activities, and supply vessel and
helicopter operations.
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Vessel orientation best practices.
FPSO
layout best
practices.
The topsides of the Thai Binh-VN FPSO,
operated by Vietnams Cuu Long Joint
Operating Company, were designed using
best practices.
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electrical buildings and lower module
weights.
Power generators, main transformers,
main electrical building and large motors
such as water injection pumps must be
located in close proximity to reduce the
amount of medium- and high-voltage
cabling. These loads should also be as
close as practical to the main generation
station to reduce voltage drop due to cable
resistance/reactance.
Medium- and low-voltage switchgear
and medium-voltage motor control center
should be routed longitudinally due to
height-to-depth ratio.
Low-voltage motor control centers
should be routed laterally, again because
of the height-to-depth ratio.
Conclusion
Best practices for FPSO topsides design
begins with optimizing the process,
followed by equipment selection and
layout according to established guidelines
for safety and operability. The piping,
structural and electrical designs all
should follow established best practices
guidelines.
Following these best practices will
increase the safety and operability of the
topsides design while reducing costs.
Norb Roobaert, PE, chairman of Alliance
Engineering, has 40 years of engineering and
project management experience in the oil & gas
industry. Roobaert holds degrees in chemical
engineering and chemistry from the
University of Michigan.
Juan Campo, PE, manages Alliance
Engineerings structural department and has
more than 40 years of experience in the oil &
gas business. Campo is licensed in 13 states,
has been granted three US patents and holds
degrees in civil engineering from Louisiana State University
and Tulane University.
Howard Newman manages the piping
department at Alliance Engineering. He has over
32 years of experience in the oil & gas industry
and is pursuing a chemical engineering degree
at the University of Houston.
Alan Phillips, PE, a senior electrical engineer
at Alliance Engineering, has worked on 13
FPSO topsides electrical designs and holds
a degree in electrical engineering technology
from the University of Houston.
modules or riser porches are designed to
be directly over a hull bulkhead or frame.
The design of FPSO modules includes
many load cases resulting in braced
structures and less access to equipment.
Sea state conditions greatly affect the
design of FPSO topsides. Structures must
allow for lateral bracing at every change
in pipe rack direction regardless of its
size. All long, straight-run pipe racks
need to be tied back to module columns
and have racking bracing in multiple
locations along their length.
The in-place analyses of the modules
include operating and extreme
environmental conditions. The modules
are also designed to be transported
from the shipyard to the production site
and lifted from the fabrication yard or
transportation barge to the ship. Spectral
fatigue analyses incorporating both
the in-place and transit conditions are
performed.
A free zone is established between hull,
marine and topsides systems. All systems
should be excluded from this zone unless
recognized to be part of the integration or
hook-up. A minimum 3m air gap is used
between the hull deck centerline and the
underside of the modules. This gap is
kept as small as possible to maintain the
lowest possible center of gravity on the
FPSO hull. Top of module support stool is
the battery limit between the topsides and
marine structures.
Piping
Key to success for piping design is
controlling interconnect piping between
module/pipe rack and module/hull.
Dedicated areas should be defined as
having the least amount of differential
movement. Interconnect piping on
modules with sliding supports should be
located in the module corner closest to the
pinned-end support. The piping should
be designed to have a fixed point in the
module before crossing to the pipe rack
or module-to-hull gaps to reduce dynamic
stresses in equipment nozzles. Sufficient
horizontal and vertical offset should be
present to obtain greater pipe flexibility.
Piping should not cross the module-to-
module gaps but should be routed via the
pipe rack to reduce vessel-induced stress.
Electrical
FPSO electrical systems should be
designed to utilize more than one
electrical building. Having a main
electrical building aft and an auxiliary
electrical building forward reduces the
need to route a large number of trays
throughout the vessel from one location.
The addition of an auxiliary electrical
building distributes the cable tray runs
more evenly over the pipe rack, allowing
for more efficient use of space, smaller
Generally accepted spacing between
modules is 1m clearance; this can be
reduced to 600mm between module/rack.
Modules should be designed with a three-
meter gap from edge of hull to outermost
edge of module, excluding stairs, to allow
overhead access to the ships main deck
and to provide a perimeter egress zone.
FPSO modules are designed along a
standard general ratio of the ships length
divided by 10. This means for modular
sections the length between outer module
supports is a maximum of one tenth of the
length of the hull being used.
Arranging the pipe rack along the
longitudinal centerline allows process
and utility equipment to be arranged
on either side. This allows for later
introduction of equipment, packages
or modules with minimum risk to
previously installed topsides components.
The floor of the pipe rack should be at
the same elevation as the lower deck
level common to all modules to provide
primary maintenance access.
FPSO module sizes are also restricted
by the fabricators lift capacity.
Module support designs allow for
the behavior of the hull and topsides.
Increased hull modulus and complex
flexibility issues require the link between
the topsides and hull to be broken.
Modules designed to be on a sliding stool
system are able to move and reduce
stress to the hull. Although two or three
longitudinal frames usually are utilized,
typically only one stool support per
module longitudinal frame is pinned
to the hull; the other stools are sliders.
The pin stool allows for free rotation
but restricts translation in up to three
directions. The sliding stools prevent
movement only in the vertical downward
direction, although some are designed to
limit translation in the hull transverse
direction as well. This minimizes the
effects of hull hogging and sagging on
both the module and the hull while
keeping the module secured to the hull.
All structural interfaces with the topsides
Pin stool best practice.
Piping interface best practices.
OE
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