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APCPCWM_4828539:WP_0000045WP_0000045

Lessons Learned from FPSO

Design Engineering in DSME

14 Nov. 2007 Gyeongju FPSO Forum

J.G. Kang and J.H. Heo
Structure R&D Team
Daewoo Shipbuilding & Marine Engineering

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CONTENTS
DSME Offshore Experiences
FPSO Challenges
Structural Engineering Activities
Lessons Learned from Activities
Keyword for Engineering Success

The House of Wisdom & Innovation

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DSME
OFFSHORE EXPERIENCES
Russia
Marathon Molikpaq
Process Unit
Canada
Tera Nova FPSO
ExxonMobil Sable P/F

Norway / Denmark

India
ONGC SHG & SHW
Reliance Jamnagar Refinery
Essar Oil Refinery

Statoil Asgard B Semi

Statoil Siri Storage Tank

China
Phillips Xigiang
P/F & FPSO
Gulf of Mexico
Shell Brutus TLP
BP Thunder Horse Semi PDQ
BP Atlantis Semi PQ

Angola
Chevron South Nemba & Lomba P/F
Chevron Kungulo Water Injection P/F
Chevron North Nemba P/F
Chevron Sanha Condensate P/Fs
Chevron Benguela Belize CPT
ExxonMobil Kizomba A & B TLP
Total Dalia FPSO
Nigeria
Chevron Agbami FPSO
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FPSO CHALLENGES
FPSO is ...

Floating Production, Storage and Offloading unit

Offshore facility to be strongly and steadily positioned in place for her all
life (more than 20yrs)
Numerous interfaces among hull, topsides and sub-sea facilities
Hull structure to perfectly serve huge oil plants under any environments
Numerous potential

risks during operation

Offshore Mega-projects
World Class construction yard is required

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FPSO CHALLENGES
Key Points in Engineering

IIF (Incident

Injury Free) of FPSO operators

Various disciplines to be organically managed

High value engineering works to be organized

Reliable communications among Class, Company and Other
interface parties are required

Long-lead equipment to be distinctively managed

Weights of topside modules to be fully shared in all disciplines
Information from vendor, interface parties to be supplied on time

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FPSO CHALLENGES
Difficulties in Engineering

Unclear definition of Ship & Offshore area

Offshore rule? Or Ship rule?
Rigorous requirement by Company

Various loading conditions required

Direct loading analyses like DLA, SFA & ALS required by CPY
Atypical format of site

environment data

Numerous (endless ?) design

changes

Highly dependence on Company

Classes still updating

Offshore rules

Lots of interface parties & schedule delay of critical information

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AGBAMI FPSO
Oil storage capacity : 2.2

Mbbls

Spread mooring 4 x 3 lines

Non propulsion
Light ship weight : 70000 ton (hull + LQ), 33000 ton (topsides)
LOA / Breadth / Depth : 320 m / 58.4 m / 32 m
Owner & Class : Chevron & ABS
Flag : Nigeria
Onsite location : Off-west
Service life : 20

of Nigeria

years

Operating water depth : 1500 m

EPC (hull + topside) project by DSME

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AGBAMI FPSO
AGBAMI Field ...

Water depth 1500 m

Oil-in-place estimate : 1.7 Bill bbls
Discovered in late 1998
Located at offshore Nigeria

Nigeria

BONGA
Currently Booming to
Develop New Oil Fields
AGBAMI

AKPO

USAN
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STRUCTURAL
ENGINEERING ACTIVITIES
Direct
Direct Loading
Loading
Analysis
Analysis

Initial
Initial Design
Design
SafeHull
Phase
A&B

Collision
DOI
Blast
Accidental
Accidental Load
Load
Assessment
Assessment

Dynamic
Loading
Analysis

Fatigue
Fatigue Analysis
Analysis
Spectral
Fatigue
Analysis
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STRUCTURAL
ENGINEERING ACTIVITIES
Initial Design ...
ABS
ABS
SEAS
SEAS

Wave
Wave
Condition
Condition

ABS
ABS
SafeHull
SafeHull

Phase
Phase A
A

Phase
Phase B
B

Initial
Initial Scantling
Scantling
Simplified
Simplified Fatigue
Fatigue
FEA
FEA based
based
Strength
Strength &
&
Fatigue
Fatigue

Key Plan
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STRUCTURAL
ENGINEERING ACTIVITIES
Lessons Learned from
Initial Design...

Setting schedule

on time is vital not to impact other post-activities

Clarifications of Company specification to be finalized as early as

possible

Key plan and Trim & Stability Booklet to meet the schedule
Scantling with sufficient contingency
Need to understand hydrodynamic characteristics on barge
Hull

shaped

Need to understand interface loading patterns (yet, there are seldom

specific information from interface parties)
Program related to be capable of handling

owners requirement

(e.g. site metocean wave data)

Ref. : metocean = meteorology + oceanography
The House of Wisdom & Innovation
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STRUCTURAL
ENGINEERING ACTIVITIES
Requirement for DLA ...

As per ABSs DLA guidance

Global FE analysis with one(1) longi. sized mesh to be checked
Local FE analysis with 1/10 longi. sized mesh to be checked from
zooming process of Global FE results
Yield & buckling check to be in accordance with ABS ship rule & FPI
Loading condition to be evaluated;
- URS (Unrestricted Service) Condition with 20 yrs RP based on North Atlantic
- Onsite condition with 100 yrs RP
- Repair loading condition with 1 yr RP at Onsite wave data
- DOC loading condition with 1 yr RP at Onsite wave data
- Hull damage loading condition with 1 yr RP at Onsite wave data & heeling

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STRUCTURAL
ENGINEERING ACTIVITIES
Lessons Learned from
Dynamic Loading Analysis

Loading pattern to be set as early as possible

Need to verify hydrodynamic characteristics on time from seakeeping
analysis

Design basis to be finalized as soon as possible

Various studies for coping with comments of Class & Company to be
prepared beforehand

Communications with Class / Company are of essence

Key plan and T/S booklet to be issued on time
Never forget URS (Unrestricted Service Condition)
Class to specify hull area & offshore area
Interface loads to be properly input on time
Need to fully understand requirements of Company
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STRUCTURAL
ENGINEERING ACTIVITIES
Requirement for SFA ...

Spectral fatigue analysis

As per ABSs SFA guidance (e.g. t x t mesh size, extrapolation & etc.)
Onsite condition
- Full : 33%
Normal
Normal fatigue
fatigue assessment
assessment
- Ballast : 33%
- Intermediate : 33%
- Transit : 1%
Seagoing condition (URS)
Owners
Owners additional
additional requirement
requirement
- Full : 45%
assuming
assuming navigating
navigating vessel
vessel
- Ballast : 40%
at
at North
North Atlantic
Atlantic
- Harbor : 15%

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STRUCTURAL
ENGINEERING ACTIVITIES
Environment for SFA ...
Swell governing sea-state
Two(2) peaked spectra of swell
(main + secondary)
Three(3) peaked spectral feature
recorded
Swell : unidirectional
Local wind : omnidirectional

North
Atlantic
Ocean

Swells

Storm
South Atlantic Ocean
Wind-driven
Wave

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STRUCTURAL
ENGINEERING ACTIVITIES
Spectral Fatigue
Analysis ...
Local
Local wave
wave (high
(high frequency)
frequency)

Swell
Swell (low
(low frequency)
frequency)

Scatter Diagram

FPSO Motion

Scatter Diagram

FPSO Motion

Wave Spectrum

Stress RAO

Wave Spectrum

Stress RAO

Spectral
Spectral
combine
combine

Stress Response
Spectrum

Stress Response
Spectrum

S C = S S2 + SW2

C =

1
SC

S S2 S2 + SW2 W2

Stochastic Analysis
(Short term or Long term)
Total Damage (DCom)
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STRUCTURAL
ENGINEERING ACTIVITIES
Lessons Learned from
Spectral Fatigue Analysis

Unreasonable to apply URS condition in Fatigue

Need to understand interfaces & their loads

Design basis to be finalized as early as possible through 3-party meeting

Need to clarify analysis conditions (onsite and/or seagoing)
Make decision of screening method and FE model extent
Seakeeping analysis tool to be decided at early stage and hydrodynamic
characteristics to be confirmed each other

Communication through RFI and feedback is of essence

Need to clarify applicability of metocean data from CPY
Need to set up LCF procedure
Damage calculation options like S-N curve, thickness correction and etc. to
be determined at the early stage
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STRUCTURAL
ENGINEERING ACTIVITIES
Accidental Loading
Analysis (Study) ...
Fire

TY
E
AF

S
L
A

Ship
Collision

Explosion

R
U
T
C
U
R
T

Drop
Object

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STRUCTURAL
ENGINEERING ACTIVITIES
Assessment Process for ALS
SPEC. REVIEW

COMPANY

FEED DEVIATION

CONTRACTOR

CONTRACT

CONSULTING

EVENT SCENARIO

Risk
Risk Assessment
Assessment

DESIGN ACC. LOAD

DAL
DAL
(Design
Accidental
(Design Accidental Load)
Load)

INITIAL DESIGN
QRA

Analytical
Analytical Cal.
Cal.

Nonlinear
Nonlinear FEA
FEA

DESIGN ASSESSMENT
SCANTLING CONFIRM

Design
Design Verify
Verify

Design
Design Modify
Modify

Design
Design Set
Set Up
Up
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STRUCTURAL
ENGINEERING ACTIVITIES
Lessons Learned from
Accidental Loading Studies

Need to set up relevant assessment

method at early stage

Need to understand QRA basis (e.g. scenarios, frequency, etc)

Need to receive QRA report on time from consulting party
Need to understand operation
Need to check PFP

process of FPSO operators

area as early as possible

Need to define vulnerable

areas

Communications with Class / Company and consulting party

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KEYWORD
for Engineering Success

Sschedule
SSpeci-

fication

SSafety

User
U
Customize

CE
S
SU
CC
ES
SS
UC
S
EEnvir-

onment

CConservativity

CComm-

unication

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BON VOYAGE, AGBAMI!!

!
u
o
Y
!
t
o
i
t
e
s
d
k
a
n
a
m
h
e
T
l
W
l
A

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