FPSO

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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

n Lease

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Growth in the World’s FPSO Fleet

0

10

20

30

40

50

60

70

80

1985 1987 1989 1991 1993 1995 1997 1999 2001

FPSO Fleet inService at YearEnd

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Drivers - FPSO SelectionMajor Factors Favor FPSO Selectionn Oil Productionn Wet Tree Developmentn Lack of Pipeline/ Infrastructure n Requirement of Early Production Systemn Client Looking for Leased Solutionn Greater Water Depth

Factors Favor Other Systemn Local Regulations in Some Countriesn Gas Productionn Harsh Environmentn Cost

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Conversion – Hull Availability Driven By:Topside Definition (Weight)Changes to Hull and Ship Systems are DetrimentalAge/Life Extension – Structural WorkMaintenance

Purpose Built:Delivery Time Driven by Ship Yard Slot AvailabilityFlexibility Only During Basic Engineering

Conversion of New-Builds:Complete Hull at Shipyard, No Carry-over WorkDon’t Integrate Ship Systems with Topside Systems

Minimise Ship System Changes

Conversion vs New Build

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UNDERESTIMATES:Immaturity (Norms, Cost Factors)

SCOPE DEFINITION (Customer/Contractor)Fit For Purpose ExpectationProcess Design IncompleteControl of ChangesLayout Incomplete - Maintenance/Operations

INTERFACE WITH MARINE SYSTEMS:What is Topside / What is Ship

OPERATOR INTERFACE:Topside Process Differs from Ship System

SCHEDULE - OVER OPTIMISTIC EXPECTATIONSTopsideHullIntegration

FPSO Problem Areas & Lessons LearnedFPSO Problem Areas & Lessons Learned

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DESIGN/ENGINEERINGInvest in Basic EngineeringEstablish / Define Basis }Process/Controls

}Safety}Layout

Review Construction / Integration MethodRigorous Weight Monitoring

TOPSIDES TOPSIDES -- ENGINEERING/PROCUREMENTENGINEERING/PROCUREMENT

PROCUREMENTEarly Commitment Major EquipmentAvoid Delivery of Equipment to Site with Punch List

INTERFACE CONTROLShip / Hull / TopsidesEngineering / FabricationManagement of Change

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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

Fabrication & Integration Fabrication & Integration

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Operational Input into the DesignOperational Input into the Design

OPERATIONALProcess start up and operating philosophies

Offshore vessel inspection philosophies

MAINTAINABILITYMaintenance philosophiesAccessibilityTransport and mechanical handlingSpare philosophy

SAFETYHAZOPsSystem isolation philosophiesEscape and evacuation

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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

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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

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Critical Issues To First OilCritical Issues To First Oil

n Concept Selection

n Critical Path Determination

n Shipyard Slot Reservation

n Process Facilities Definition

n Realistic Schedule Expectation

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Drivers for ContractingDrivers for Contracting

• Early Partner Selection

• Contractors Selected for “Best-in-Class”

• Agreed Execution Strategy

• Agreed Division of Work

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Project Controls

• Estimating• Scheduling• Cost Management• Interface Management

Success FactorsSuccess Factors

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Bonga Project

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Dry Tree Unit with a FPSO

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Crude Oil SeparationCrude Oil Separation

Gas DehydrationGas Dehydration

Associated Gas CompressionAssociated Gas Compression

Oily Water Clean-upOily Water Clean-up

Water InjectionWater Injection Process Support UtilitiesProcess Support Utilities

Conventional FPSO Processes

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COMPONENT BREAKDOWNCOMPONENT BREAKDOWN

FPSO Components

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FPSO Topside Module LayoutFPSO Topside Module Layout

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Trading Tanker Conversion to a FPSOTrading Tanker Conversion to a FPSO

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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 !

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Export Options: Traditional Offloading from an FPSO

H

H

H

3) CALM

2) Tandem

1) Side by Side

Spread or Turret Moored

Standard Tanker

Standard Tanker

Spread Moored

Tug

Tug

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Offloading with a D.P. Tanker

Approaching an FPSO Approaching an FPSO with a Dynamically with a Dynamically Positioned tanker:Positioned tanker:

Shown here in North Shown here in North Sea, Sea, may be attractive for more remote & deeper waters, e.g. GoM.

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Use of an air gun Use of an air gun for to carry a for to carry a messenger line messenger line to the D.P. to the D.P. tankertanker

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Transfer hose Transfer hose visible is at left on visible is at left on FPSO stern.FPSO stern.

Mooring hawser (for Mooring hawser (for safety backup) at safety backup) at a dedicated bow a dedicated bow loading station on loading station on a D.P. tankera D.P. tanker

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No tugs

No hose/hawserhandling vessel

Able to hookup in rough weather.

Waves up to 5.5m

Brazil & GOM deepwater?

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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

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Motion Analysis at Offloading Side

Bluewater CALM buoy. Extreme Regular Wave: H = 6.6 m, T =11.4 s, Offshore Nigeria

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Station Keeping Methods

� Catenary moored� Taut wire moored� Turret - Internal vs. External� Tendons� Dynamically positioned (DP)

� Suction or driven pile� Chain wire chain� Chain polyester chain

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Mooring System

� Temporary Mooring

� Drilling Rig/ Vessels� Permanent Mooring

� Single Point / Turret Mooring � Spread Mooring ( SPAR/ SCF/ FPSO/ Barge)

� Taut Mooring � Foot Print is Small� Anchors are closely spaced and has higher vertical load

� Catenary Mooring � Foot Prints are Larger� Anchors are spread out and installed primarily for

horizontal load

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Spread Mooring

� Chain Only� Huge load on vessel� Preferably shallow water

� Chain Wire Chain� Used traditionally� System weight becomes a challenge in deepwater

� Chain Polyester Chain� Reduces system weight in deepwater and ultra deepwater� May increase installation cost

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Deepwater Characteristics Related To Mooring

� Vessel Offset determines mooring selection

� Length/elasticity of lines is significant for optimization

� Taut systems are most often advantageous solutions

� Permanent and large vertical loads on anchors

� Soft or very soft soils

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Mooring Components

� Anchors

� Mooring Lines and Tethers

� Connecting Components and Details

� Installation Aids

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Spread Mooring

� Design Code� API RP 2SK - Regular Mooring� API RP 2SM- Synthetic Mooring� DNV

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Mooring Layout

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W. Africa Mooring System Layout

Figure 6-2 BONGA FPSO MOORING CATENARY PLOTBase Case Configuration @ pretension = 136 tons

0

150

300

450

600

750

900

1050

-1500 -1250 -1000 -750 -500 -250 0 250

X from Fairlead (m)

Hei

ght a

bove

Sea

bed

(m)

1340 meters long86mm w ire rope

457meters long90mm K4 chain

1,496 m fairlead to anchor horizontal distance

46 meters long92mm K4 chain

CATENARY MOORING SYSTEM

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Mooring Line Assembly/ Make Up

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Comparison of Anchors for Taut Moorings

BUCKET ANCHORW = 100%

HICAP ANCHORW = 55%

HIVEL ANCHORW = 25%

Equal Capacity and Soil Conditions

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Anchor Pile Installation

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Suction Anchors

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Subsea Connector

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HiCap Anchor ® - Installation1. MATING 2 LOWERING AND POSITIONING

3. EMBEDMENT BY SUCTION 4 RETRIEVAL OF INSTALLATION LID

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Anchor - Installation1 Lowering to Seabed 2. Weight Penetration

3. Embedment by Suction 4. Retrieval of Installation Lid

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Pile Installation

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TLP Anchors

Decisive factors selecting the optimum type� Soil conditions (strength, layering)� Acceptable/Required transfer of loads into the seabed

(dynamic loads - ‘suction’, permanent loads weight and shear or weight only)

� Total logistics thus installation methodMain types� Soft clay (e.g. GoM, West Africa)� Layered, ‘difficult’ soil profile

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TLP Anchor Soft Clay (e.g. GoM, West Africa)

Steel Plate10 mm

LWA Concrete200 mm

Composition ofthe Cylindrical Shell

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TLP Anchor for Layered Seabed (e.g. N. Sea)

Soft

Stiff/hard

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Anchor - Installation Method

40 m120 ft

100 m300 ft

Tension 250 t

Thrust 35 tThrust 35 t

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Mooring Lines

Types considered in optimization of the mooring systems

� Steel Wire Ropes (sheathed)� Polyester Ropes� Stiff Fiber Ropes (Aramid, Kevlar, …)

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Asgard ‘A’ FPSO

ASGARD A

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External Turret

West Africa New Build FPSO Shape

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11 path swivel serves: • Oil•Gas •Water

Plus• hydraulic• chemical injection• signal/optical

Petrobras 37Petrobras 37 FPSOFPSO

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Petrobras 37Petrobras 37 FPSOFPSO

Turntable and Swivel installed on top of turret to serve43 risers

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Tendons

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Deepwater Tendon Options� Pressurized Tendons

� Technology Exists� Design and Safety Concerns

� Staggered Wall Tendons

� Step Diameter Tendons

� Composite Tendons� Requires New Technology (Under Development)� Extensive Test Program

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TLP Tendons - Stresses Due Water Pressure

p (z)outer p (z)out er p (z)outer

p (z)inne r

CONVENTIONAL DESIGN ABB DESIGNAlt. A Alt. B

Price 100% Price 70%

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Tendon Systems

� Top Tendon Connector� Bottom Tendon Connector� Tendon Pipe Connector� Tendon Weight vs Depth� Deepwater Tendon Options

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Pivot Latch Top Tendon Connector

� Auto Length Adjustment� Ratcheting Design� Pre- or Co-Installed� Threaded or Grooved Load

Segment� Synchronized & Centralized� No Rotation Required� Remote Hydraulic Operation &

Installation W/Manual Override

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Tendon Porch

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TG-5 Bottom Tendon Connector

� No Rotation to Install� Few Moving Parts� Simple Stab/Release� Integral Centralizer� Resets on Removal

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Tendon Pipe Connector

� Optimized Profile to Balance Load Transfer

� Improved Fatigue Design� Easy Installation

� Stab to Preset� Pressure to Release

� No Rotation Required

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J Lay Tower for Tendon Installation

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J Lay Tower for Tendon Installation

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Saibos J Lay

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ROV to Monitor Pile Installation

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TLP Tendons - Tow Method

Leading tug

Tendon

Towline

Trailingtow gear

Clump weight

Trail ing tug

Leading towinggear

Arranged as a fail-to-safe system

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Upending of Tendon by Lowering

Towline

Lead tug

Leadingtow gear

Clump weight

Auxiliary towlineTrailingtug

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Installation - Dragging to Target and Pull-in

Lead tug

Tendon

Anchor

Towline

Trailing tug

Tuggerl ine

Pull-inline

Towline

Upendedtendon

Tow gearAnchor Clump

weight

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Installation Vessel

FPSO

Documents

oiln n n n n abb lummus

lease n n abb lummus

fpso abb lummus global

n n entire complex

punch list abb lummus

n construction management

n value engineering

system n local regulations