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Espirito Santo FPSO

Turret & Installation ChallengesSNAME/MTS Joint Meeting Texas A&M University March 26, 2010

Chris Wibner

Upstream Major Projects

Shell International Exploration & Production, Inc.

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Contractor owned and operated FPSO (evolution of GFPSO project)

Shell is operator (50%) with partners Petrobras (35%) & ONGC (15%)

FPSO Contractor - BDFT (SBM & MISC JV)

Major subcontractors:

Keppel Shipyard (hull conversion, turret fabrication, topsides integration)

Dynamac (topsides fabrication)

BT Engineering (topsides fabrication)

1780 m water depth at FPSO locationInternal turret with 21 riser/umbilical slots

First turret moored FPSO to accept Steel Lazy Wave Risers

Espirito Santo FPSO

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100 kbopd oil processing capacity (low API)

50 mmscfpd gas compression

150 kbpd total liquids processing capacity

130 kbwpd produced water treating capacity75 kbwpd water injection w/ sulfate reduction for Phase II

150 kbwpd additional water injection deck space

Topsides weight ~ 8,500 tons

Espirito Santo - Topsides Details

Unique challenges: Heavy oil processing 16 API), services for subsea

artificial lift systems i.e.15 MW available AL power, VFDs, Hot oil

circulation with gas spike capability)

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Vessel As Arrived in Singapore (06)

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Lazy Wave Steel Risers & Umbilicals Vertical load 2,200 tonnes

Multiple Heavy lifts for integration into vessel

Large swivel stack 12 units ~ 150 tonnes

High Voltage

Centralized riser/umbilical pull-in winch

Separate riser & umbilical decks

Riser spool piece connection inside lower turret

Espirito Santo - Turret Challenges

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Turret Cross Section

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Umbilical deckCollar deck

SLWR

Typical flexible riser

Max SLMax SL

Lower Turret Layout Difference

Riser deck

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Construction Challenges

Built by decks and stacked

Inclined I-tubes, complex alignment and fit up

Umbilical I-tubes required a reverse bend to mitigate clashing

Complex lay-out of I-tubes, generates more engineering studies

Dimensional control

Site integration testing

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Integration Photos - Turret

Gantry Manifold

Bogie Support Structure

Lower TurretCollar Structure

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LOWER MOONPOOL INSTALLATION

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Upper

Moonpool Integration

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Upper

Moonpool Integrationafter 2nd DD

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BC-10 FPSO TURRET(LOWER TURRET)

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Lower Turret ntegration

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BC-10 FPSO TURRET(Bogie Support Structure)

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BC-10 FPSO TURRET(UPPER TURRET)

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BC-10 FPSO TURRET(TURRET MANIFOLD)

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Riser / Umbilical Interface

Risers clamp castings (12)

Umbilical bellmouths (3)

Umbilical Future (6)

Mooring Connectors (9)

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154 tonnes 24 m Height

Unit 12 Electro Optical

Unit 11 Hot Oiling Service Swivel

Unit 10 Utility LP & HP

Unit 9 Gas Export / Injection

Units 7 & 8 HV Electrical

Unit 6

Water Injection Unit 5 Gas Production

Unit 4 Firewater

Units 1,2,&3 Oil Production

Swivel Stack

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Pull-in Winch

New concept

Design developed in house by SBM Winch platform provides 3 Motions

2 axis of rotations

1 sliding

BC 10 FPSO P ll i Wi h

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BC-10 FPSO Pull-in Winch

RiserWire

ChainWire

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SLWR & Umbilical Pull-in

Installation team

ready for another

pull-in within 6 to 8

hours

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Conclusions

Steel Risers are feasible from a turret moored FPSO

Interface between the turret & steel risers proved feasible

Winch platform design provided full satisfaction

Comprehensive dimensional control management is a necessity

Site integration testing is extremely important

Installation time comparable to flexible riser

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QUESTIONS ?