FPSO

Ship Shape Production Systems
n FSO - Floating Storage Offloading

n FPSO - Floating Production Storage & Offloading
n FPDSO - Floating Production Drilling Storage & Offloading
n New Build
n Tanker Conversion
n Own
© ABB Lummus Global Inc. - 2
n Lease
Sec12_FPSO_All.ppt
Growth in the World’s FPSO Fleet
80
FPSO Fleet in 70
Service at Year
End 60
50
40
30
20
10
0
1985 1987 1989 1991 1993 1995 1997 1999 2001
Sec12_FPSO_All.ppt
Drivers - FPSO Selection
Major Factors Favor FPSO Selection
n Oil Production
n Wet Tree Development
n Lack of Pipeline/ Infrastructure
n Requirement of Early Production System
n Client Looking for Leased Solution
n Greater Water Depth
Factors Favor Other System

n Local Regulations in Some Countries
n Gas Production
n Harsh Environment
n Cost
Sec12_FPSO_All.ppt
Conversion vs New Build
Conversion – Hull Availability Driven By:

Topside Definition (Weight)
Changes to Hull and Ship Systems are Detrimental
Age/Life Extension – Structural Work
Maintenance
Purpose Built:
Delivery Time Driven by Ship Yard Slot Availability
Flexibility Only During Basic Engineering
Conversion of New-Builds:
Complete Hull at Shipyard, No Carry-over Work

Don’t Integrate Ship Systems with Topside Systems
Minimise Ship System Changes
Sec12_FPSO_All.ppt
FPSO Problem Areas & Lessons Learned
UNDERESTIMATES:
Immaturity (Norms, Cost Factors)
SCOPE DEFINITION (Customer/Contractor)

Fit For Purpose Expectation
Process Design Incomplete
Control of Changes
Layout Incomplete - Maintenance/Operations
INTERFACE WITH MARINE SYSTEMS:

What is Topside / What is Ship
OPERATOR INTERFACE:
Topside Process Differs from Ship System
SCHEDULE - OVER OPTIMISTIC EXPECTATIONS

Topside
Hull
Integration
Sec12_FPSO_All.ppt
TOPSIDES - ENGINEERING/PROCUREMENT
DESIGN/ENGINEERING
Invest in Basic Engineering
Establish / Define Basis }Process/Controls
}Safety
}Layout
Review Construction / Integration Method
Rigorous Weight Monitoring
PROCUREMENT
Early Commitment Major Equipment
Avoid Delivery of Equipment to Site with Punch List
INTERFACE CONTROL
Ship / Hull / Topsides
Engineering / Fabrication
Management of Change
Sec12_FPSO_All.ppt
Fabrication & Integration
Construction Method – Topside Package Sizing
Complete Fabrication at Fab Yard
Execute Pre Commissioning at topsides Fab Yard
Simplify hook-up
Fix interfaces with Marine Systems
Maximise inshore Pre Commissioning at Integration Facility

Sec12_FPSO_All.ppt
Operational Input into the Design
OPERATIONAL
Process start up and operating philosophies
Offshore vessel inspection philosophies
MAINTAINABILITY
Maintenance philosophies
Accessibility
Transport and mechanical handling
Spare philosophy
SAFETY
HAZOPs
System isolation philosophies
Escape and evacuation
Sec12_FPSO_All.ppt
Success Factors
n Comprehensive Role by Topsides Engineer:
n Utilization of experienced personnel and
lessons learned
n Process design for the entire complex

n Perform detailed design for topsides
integration and commissioning
n Value Engineering
Sec12_FPSO_All.ppt
Success Factors
Construction:
n Construction management supported by Engineering staff
through completion of fabrication and commissioning
n Constructability reviews early and across all interfaces
n Participants exchange execution procedures
n Minimize and simplify participant interfaces

Sec12_FPSO_All.ppt
Critical Issues To First Oil
n Concept Selection
n Critical Path Determination
n Shipyard Slot Reservation
n Process Facilities Definition
n Realistic Schedule Expectation
Sec12_FPSO_All.ppt
Drivers for Contracting
• Early Partner Selection

• Contractors Selected for “Best-in-Class”
• Agreed Execution Strategy
• Agreed Division of Work
Sec12_FPSO_All.ppt
Success Factors
Project Controls
• Estimating
• Scheduling
• Cost Management
• Interface Management
Sec12_FPSO_All.ppt
Bonga Project
Sec12_FPSO_All.ppt
Dry Tree Unit with a FPSO
Sec12_FPSO_All.ppt
Conventional FPSO Processes
CrudeOil
OilSeparation
Separation AssociatedGas
Associated GasCompression
Compression
Crude
Gas Dehydration
Gas Dehydration OilyWater
Oily WaterClean-up
Clean-up
WaterInjection
Water Injection ProcessSupport
Process SupportUtilities
Utilities
Sec12_FPSO_All.ppt
FPSO Components
COMPONENT BREAKDOWN
Sec12_FPSO_All.ppt
FPSO Topside Module Layout
Sec12_FPSO_All.ppt
Trading Tanker Conversion to a FPSO
Sec12_FPSO_All.ppt
Motion Analysis at FPSO
Akpo size FPSO - Extreme Regular waves : H = 6.6 m, T = 11.4 s, Offshore Nigeria
Note : Animation speed is 5 times actual for clarity !

Sec12_FPSO_All.ppt
Export Options: Traditional Offloading from an FPSO
1) Side by Side H
2) Tandem Standard Tanker

H
Tug
Spread or Turret Moored
3) CALM Standard Tanker
Tug
Spread Moored
Sec12_FPSO_All.ppt
Offloading with a D.P. Tanker
Approaching an FPSO
with a Dynamically
Positioned tanker:
Shown here in North

Sea, may be
attractive for more
remote & deeper
waters, e.g. GoM.
Sec12_FPSO_All.ppt
Use of an air gun

for to carry a
messenger line
to the D.P.
tanker
Sec12_FPSO_All.ppt
Transfer hose
visible is at left on
FPSO stern.
Mooring hawser (for

safety backup) at
a dedicated bow
loading station on
a D.P. tanker
Sec12_FPSO_All.ppt
No tugs
No hose/hawser
handling vessel
Able to hookup in
rough weather.
Waves up to 5.5m
Brazil & GOM

deepwater?
Sec12_FPSO_All.ppt
Deep Water Offloading System
Function
n Oil transfer from production vessel to tanker
Objectives
n Reduce loads on FPSO from offloading system
n Efficient loading, i.e. low pressure loss
n High reliability at low maintenance and inspection
requirements
n Competitive price
Sec12_FPSO_All.ppt
Motion Analysis at Offloading Side
Bluewater CALM buoy. Extreme Regular Wave: H = 6.6 m, T =11.4 s, Offshore Nigeria
Sec12_FPSO_All.ppt
Station Keeping Methods
n Catenary moored
n Taut wire moored
n Turret - Internal vs. External
n Tendons
n Dynamically positioned (DP)
n Suction or driven pile

n Chain wire chain
n Chain polyester chain
Sec09_MooringandAnchor_All.ppt
Mooring System
n Temporary Mooring
n Drilling Rig/ Vessels
n Permanent Mooring
n Single Point / Turret Mooring
n Spread Mooring ( SPAR/ SCF/ FPSO/ Barge)
n Taut Mooring
n Foot Print is Small
n Anchors are closely spaced and has higher vertical load
n Catenary Mooring
n Foot Prints are Larger
n Anchors are spread out and installed primarily for

horizontal load
Spread Mooring
n Chain Only
n Huge load on vessel
n Preferably shallow water
n Chain Wire Chain
n Used traditionally
n System weight becomes a challenge in deepwater
n Chain Polyester Chain
n Reduces system weight in deepwater and ultra deepwater
n May increase installation cost
Deepwater Characteristics Related To Mooring
n Vessel Offset determines mooring selection
n Length/elasticity of lines is significant for optimization
n Taut systems are most often advantageous solutions
n Permanent and large vertical loads on anchors

n Soft or very soft soils
Mooring Components
n Anchors
n Mooring Lines and Tethers
n Connecting Components and Details
n Installation Aids
Spread Mooring
n Design Code
n API RP 2SK - Regular Mooring
n API RP 2SM- Synthetic Mooring
n DNV
Mooring Layout
W. Africa Mooring System Layout
Figure 6-2 BONGA FPSO MOORING CATENARY PLOT

CATENARY MOORING SYSTEM
Base Case Configuration @ pretension = 136 tons
1050
1,496 m fairlead to anchor
horizontal distance
900
46 meters long
92mm K4 chain
Height above Seabed (m)
750
600
1340 meters long
86mm w ire rope
450
457meters long
90mm K4 chain
300
150
0
-1500 -1250 -1000 -750 -500 -250 0 250
X from Fairlead (m)
Mooring Line Assembly/ Make Up
Comparison of Anchors for Taut Moorings
BUCKET ANCHOR HICAP ANCHOR HIVEL ANCHOR

W = 100% W = 55% W = 25%
Equal Capacity and Soil Conditions
Anchor Pile Installation
Suction Anchors
Subsea Connector
HiCap Anchor ® - Installation
1. MATING 2 LOWERING AND POSITIONING
3. EMBEDMENT BY SUCTION 4 RETRIEVAL OF INSTALLATION LID

Anchor - Installation
1 Lowering to Seabed 2. Weight Penetration
3. Embedment by Suction 4. Retrieval of Installation Lid

Pile Installation
TLP Anchors
Decisive factors selecting the optimum type

n Soil conditions (strength, layering)
n Acceptable/Required transfer of loads into the seabed
(dynamic loads - ‘suction’, permanent loads weight and
shear or weight only)
n Total logistics thus installation method
Main types
n Soft clay (e.g. GoM, West Africa)
n Layered, ‘difficult’ soil profile
TLP Anchor Soft Clay (e.g. GoM, West Africa)
Composition of
the Cylindrical Shell
LWA Concrete
200 mm
Steel Plate
10 mm
TLP Anchor for Layered Seabed (e.g. N. Sea)
Soft
Stiff/hard
Anchor - Installation Method
40 m
120 ft
Thrust 35 t Thrust 35 t
Tension 250 t
100 m
300 ft
Mooring Lines
Types considered in optimization of the mooring

systems
n Steel Wire Ropes (sheathed)
n Polyester Ropes
n Stiff Fiber Ropes (Aramid, Kevlar, …)
Asgard ‘A’ FPSO
ASGARD A
Sec12_FPSO_All.ppt
West Africa New Build FPSO Shape
External Turret
Sec12_FPSO_All.ppt
Petrobras 37 FPSO
11 path swivel
serves:
• Oil
•Gas
•Water
Plus
• hydraulic
• chemical injection
• signal/optical
Sec12_FPSO_All.ppt
Petrobras 37 FPSO
Turntable and Swivel

installed on top of
turret to serve
43 risers
Sec12_FPSO_All.ppt
Tendons
Deepwater Tendon Options
n Pressurized Tendons
n Technology Exists
n Design and Safety Concerns
n Staggered Wall Tendons
n Step Diameter Tendons
Composite Tendons
n
n Requires New Technology (Under Development)
n Extensive Test Program
TLP Tendons - Stresses Due Water Pressure
CONVENTIONAL DESIGN ABB DESIGN

Alt. A Alt. B
pinne r(z)
pout er(z)
pout er(z) pout er(z)
Price 100% Price 70%
Tendon Systems
n Top Tendon Connector

n Bottom Tendon Connector
n Tendon Pipe Connector
n Tendon Weight vs Depth
n Deepwater Tendon Options
Pivot Latch Top Tendon Connector
n Auto Length Adjustment

n Ratcheting Design
n Pre- or Co-Installed
n Threaded or Grooved Load
Segment
n Synchronized & Centralized
n No Rotation Required
n Remote Hydraulic Operation &
Installation W/Manual Override
Tendon Porch
TG-5 Bottom Tendon Connector
n No Rotation to Install
n Few Moving Parts
n Simple Stab/Release
n Integral Centralizer
n Resets on Removal
Tendon Pipe Connector
n Optimized Profile to
Balance Load Transfer
n Improved Fatigue Design
n Easy Installation
n Stab to Preset
n Pressure to Release
n No Rotation Required
J Lay Tower for Tendon Installation
J Lay Tower for Tendon Installation
Saibos J Lay
ROV to Monitor Pile Installation
TLP Tendons - Tow Method
Trail ing tug

Leading tug
Towline
Leading towing Tendon

gear Trailing
Clump weight
tow gear
Arranged as a fail-to-safe system
Upending of Tendon by Lowering
Trailing
Lead tug Auxiliary towline tug
Leading
tow gear
Towline
Clump weight
Installation - Dragging to Target and Pull-in
Le ad tug Tr ailing tug
Towline
Tendon
Tugge r
l ine
Upended
tendon
Towline
Pull-in
line
Anchor Clump Anchor
Tow gear weight
Installation Vessel

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Titluri conexe

Ship Shape Production Systems

n FSO - Floating Storage Offloading

Factors Favor Other System

Conversion – Hull Availability Driven By:

Complete Hull at Shipyard, No Carry-over Work

SCOPE DEFINITION (Customer/Contractor)

INTERFACE WITH MARINE SYSTEMS:

SCHEDULE - OVER OPTIMISTIC EXPECTATIONS

Construction Method – Topside Package Sizing

Complete Fabrication at Fab Yard

Execute Pre Commissioning at topsides Fab Yard

Fix interfaces with Marine Systems

Maximise inshore Pre Commissioning at Integration Facility

n Process design for the entire complex

n Constructability reviews early and across all interfaces

n Participants exchange execution procedures

n Minimize and simplify participant interfaces

• Early Partner Selection

Note : Animation speed is 5 times actual for clarity !

2) Tandem Standard Tanker

3) CALM Standard Tanker

Shown here in North

Use of an air gun

Mooring hawser (for

Brazil & GOM

n Suction or driven pile

n Anchors are spread out and installed primarily for

n Vessel Offset determines mooring selection

n Length/elasticity of lines is significant for optimization

n Taut systems are most often advantageous solutions

n Permanent and large vertical loads on anchors

n Soft or very soft soils

n Mooring Lines and Tethers

n Connecting Components and Details

Figure 6-2 BONGA FPSO MOORING CATENARY PLOT

BUCKET ANCHOR HICAP ANCHOR HIVEL ANCHOR

Equal Capacity and Soil Conditions

3. EMBEDMENT BY SUCTION 4 RETRIEVAL OF INSTALLATION LID

3. Embedment by Suction 4. Retrieval of Installation Lid

Decisive factors selecting the optimum type

n Layered, ‘difficult’ soil profile

Types considered in optimization of the mooring

Turntable and Swivel

n Staggered Wall Tendons

n Step Diameter Tendons

CONVENTIONAL DESIGN ABB DESIGN

Price 100% Price 70%

n Top Tendon Connector

n Auto Length Adjustment

Trail ing tug

Leading towing Tendon

Arranged as a fail-to-safe system

Le ad tug Tr ailing tug

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