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1 F e b r u a r y 2006
IHI Marine United Inc. has developed, designed and constructed the world’s first LPG-FPSO, with the largest
storage capacity as a marine storage facility, by applying IHI’s excellent technology, design capability and highly
qualified construction skills. To meet the unique requirements of the LPG-FPSO, e.g. long operability at a site far
from dry docks, reduced vessel motions, cargo transfer between floaters, easiness of maintenance, high safety,
etc., IHI has applied serveral unique technologies such as the IHI-SPB tank system. Continuous operation of the
LPG-FPSO to commercialize the associated petroleum gas field will contribute toward reduction of CO2 emissions
to moderate climate change. The outline of the LPG-FPSO is described.
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Vo l . 39 N o . 1 F e b r u a r y 2006
field. Recently, however, from the viewpoints of equipment, piping, and apparatuses, we studied safety
environmental issue, CO 2 reduction, and effective systems called HAZID (Hazard Identification) and
utilization of energy resources, attention has been paid to HAZOP (Hazard and Operability) together with the
the movement of commercializing the associated gasses as owners. We took various measures including pipe
liquefied gas and transporting it to consumption areas. To arrangement with less accumulated damage, which will
this end, gas separating equipment, reliquefaction and allow emergency venting to discharge LPG. And we
refrigerating units and storage tank facilities are required. provided heat-resistance for pressure vessels, and installed
Various systems are available for this purpose, such as blast-reducing panels on refrigeration/reliquefaction
a system utilizing offshore platforms with land tanks and a rooms and designed strong accommodation structure
system in which all facilities are installed on land only. assuming an explosion at the plant part.
Among them, the LPG-FPSO having storage tanks in the 3.5 Challenge toward larger type
hull structure and plant and reliquefaction/refrigerating This LPG-FPSO has the largest cargo capacity of
units on the deck allows maximum cost reduction. We any existing LPG ships in the world (maximum
expect that its concept will increase in the future. about 85 000 m 3). We paid detailed attention in the
Especially, this LPG-FPSO system can be utilized in design analysis and construction.
marginal sea areas such as deep sea areas far away from
the land.
4. Specifications of LPG-FPSO
4. 1 Outline
3. Required specifications and applicable The principal particulars are shown below and the general
technologies arrangement is shown in Fig. 2.
The main specifications and applicable technologies Length overall (Loa) 262.65 m
required for realizing this LPG-FPSO are as follows. Length between perpendicular (Lbp)
3.1 High reliability to realize continuous operation 230.00 m
without docking for 20 years Breadth (Mould) 49.00 m
We adopted cargo tanks of the IHI-SPB system to assure Depth (Mould) 29.30 m
the reliability over the life of the LPG-FPSO and also Design draft (Mould) 13.20 m
adopted materials and paints superior in durability for Scantling draft (Mould) 13.20 m
various units of equipment. As to the structural strength Cargo storage capacity (-50 deg. C)
including hull, tanks, and plant parts, we confirmed 135 000 m3
adequate strength by conducting analyses based on the sea Cargo production capacity 5 940 m3/d
conditions of the North Atlantic Ocean, which is severer Cargo offloading capacity 5 400 m3/h
than those of the sea area of installation. Deadweight Approx. 93 000 t
3.2 Technologies to avoid plant shutdown International gross tonnage 111 246
In addition to the high specifications and high redundancy International net tonnage 33 374
of the plant itself, we were requested to prevent the plant The cargo tank consists of 6 tanks having a capacity of
performance from deteriorating even in large waves that 135 000 m3 in total at -50 deg. C, and all the tanks can be
are experienced once in 10 years. For this reason, we loaded with both propane and butane. The fore end
pursued a type of hull shape to minimize hull motion portion of the hull is provided with single point mooring
based on motion analysis and water tank testing. As a (turret) and accommodations for 60 persons. On the deck,
result, we developed the optimum type of hull shape with from the fore portion of the hull, propane refrigeration unit
the rolling angle within 5 degrees. To reduce the hull room, propane/butane separating plant (depropanizer), and
motion even in a combination of winds and waves butane refrigeration unit/reliquefaction unit room are
expected, we installed a 3 000 kW-class thruster for arranged. At the stern, the LPG discharging process vent
maintaining the LPG FPSO direction. The generators and tower is installed.
other utilities were provided with sufficient redundancy. The flag is Bahamas and the classification is ABS
3.3 Easy maintenance on the ocean (American Bureau of Shipping).
With the floating facility, many units of equipment are 4.2 Plant & cargo part
arranged on a limited area. To facilitate maintenance on The propane/butane mixture of room temperature/high
the ocean, we fully investigated the arrangement elements pressure (18 deg. C, 22 bar) is introduced into this LPG-
such as securing carry-out routes and repair areas of FPSO through undersea pipelines and risers and separated
various units of equipment. As a result, we installed 5 into propane and butane by the depropanizer. Figure 3
deck cranes and realized smooth maintenance shows the process flow.
performance through optimum arrangement. Within the plant, the mixture is adjusted to 6.2 bar, 18
3.4 Securing safety deg. C by the LPG surge vessel, and the sulfur content is
As to the plant part, cargo part, machinery part and related removed by the H2S scrubber, and then it is heated to 30
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Fig. 2 General arrangement
deg. C and separated into propane and butane of 17 bar, capacity of 100% of necessary capacity × 2 units for
100 deg. C by the fractionating column. The separated propane, 100% × 1 unit for propane/butane, and 100% × 1
propane and butane are cooled to -40 deg. C and -10 deg. unit for butane. As the refrigerant, propane is used. The
C, respectively, in the refrigeration unit room and stored depropanizer was made by NIKKI K.K. (JGC) in Japan
as liquefied gas (LPG) in the cargo tanks. The and the refrigeration/reliquefaction equipment by HGS
refrigeration units for propane and butane have the (Hamworthy Gas Systems AS) in Norway.
capacity of 50% of necessary capacity × 3 units and 100% The LPG in the tanks is offloaded into LPG carriers
× 2 units, respectively. assigned from time to time by a maximum of 10 cargo
The LPG in the tanks is vaporized due to heat ingress pumps. The pressurized butane can also be offloaded at a
from outside, but liquefied by the reliquefaction units and rate of 550 m3/h.
returned into the tanks. The reliquefaction units have a
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operation over a long period of time like this LPG-FPSO. No.6 Hold
With this LPG-FPSO, the depropanizer plant,
Fig. 5 Structural model of plant part and hull part for FEM analysis
refrigeration unit room and reliquefaction unit room are
installed about 8 m or more above the deck. Since they are
very large structures, it is not proper to design them an analysis program developed by IHIMU to design for
separately from the hull. So, the structural analysis of securing safe operation. (4) In preparation for future
these large structures was made integral with the hull deck increase in transporting volume, the hull aft portion is
portion. Figure 5 shows the entire analysis model. provided with tandem type mooring equipment and cargo
Especially for the depropanizer plant installed on the hull handling equipment to cope with LPG carriers of a
that has motion in waves, unlike land plants, IHIMU maximum 125 000 m3 class.
conducted detailed strength checking, including fatigue The piping design was made optimum using the three-
strength. dimensional CAD system “Ajisai” that has been
4.4 Hull part developed independently by IHIMU, as in the case of the
When LPG is offloaded, an LPG carrier (maximum hull design. Figure 6 shows the typical three-dimensional
85 000 m3) is moored alongside the LPG-FPSO, and the piping arrangement on the deck.
fenders, winches and quick release hooks necessary for The 60-person accommodations with luxurious interiors
the mooring are installed on the deck. When the assure comfortable living even for a long stay. The safety
specifications of this equipment were decided, we is strengthened by adopting walls, windows and doors of
estimated the relative motion of this LPG-FPSO and LPG H-class structural fire protection (H-60). In designing the
carriers based on sea conditions for LPG offloading using helicopter deck installed at the top of the accommodation
space, tunnel tests were conducted by Research &
Deck Anti-rolling chock Deck girder
Development Division (Yokohama) of Ishikawajima-
Harima Heavy Industries Co., Ltd. (hereinafter called IHI)
to investigate the effects of the gust and exhaust gas from
Anti-flotation chock
Water ballast tank
Horizontal girder
Insulation
Access space
L
C
Support
Fig. 4 Cross section of IHI-SPB tank Fig. 6 Three dimensional piping arrangement on deck
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Vo l . 39 N o . 1 F e b r u a r y 2006
CS3000 CS3000
node node FIRE DETECTOR
…
FPSO Control Center ( FCC )
Prosaef Prosaef
PC PC
…
…
FOR
Optical Fiber Cable
PLC for #1 propane Reliq. compressor PLC for #1 propane Ref. Compressor
R1 cont. C1 control
FOR
…
R4 PLC for #4 butane Reliq. compressor C3 PLC for #3 propane Ref. Compressor
cont. control PLC f or # 1
boiler c o nt.
FOR
Prosafe
CPU/
Prosafe
CPU/
… Prosafe
Prosafe Prosafe …
node node CPU/
node CP U/ remote
node node
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Vo l . 39 N o . 1 F e b r u a r y 2006
REFERENCES
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