FPSO

Ship Shape Production Systems

   2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

n

FSO - Floating Floating Storage Storage Offlo Offloading ading

n

FPSO - Floating Production Storage & Offloading Offloading

n

FPDSO FPDSO - Floating Production Production Drilling Drilling Storage Storage & Offloading

n

New Build

n

Tanker Conversion

n

Own

n

Lease

Growth in the World’s FPSO Fleet 80 FPSO Fleet in

70

Service at Year End

60 50 40 30 20 10

   7    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

0 1985 1987 1989 1991 1993 1995 1997 1999 2001

Drive Dr ivers rs - FPSO FPSO Sele Selecti ction on Major Factors Favor FPSO Selection n

Oil Production

n n

Wet Tree Development Lack of Pipeline/ Infrastructure

n

Requirement of Early Production System

n

Client Looking for Leased Solution Greater Water Depth

n

Factors Favor Other System

   4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

n

Local Regulations in Some Countries

n n

Gas Production Harsh Environment

n

Cost

Conver Conversio sion n vs Ne New w Bui Build ld Conversion Conversion – Hull Availabili Availability ty Driven Driven By: Topside Definition (Weight) Changes to Hull and Ship Systems are Detrimental Age/Life Age/Life Extension Extension – Structural Structural Work Work Maintenance Purpose Built: Delivery Time Driven by Ship Yard Slot Availability Flexibility Only During Basic Engineering

   1    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Conversion of New-Builds: Complete Hull at Shipyard, No Carry-over Work Don’t Integrate Ship Systems with Topside Systems Minimise Ship System Changes

FPSO Problem Areas & Lessons Learned UNDERESTIMATES: Immaturity (Norms, Cost Factors) SCOPE DEFINITION (Customer/Contractor) (Customer/Contractor) Fit For Purpose Expectation Process Design Incomplete Control of Changes Layout Layout Incomplete Incomplete - Maintenance/O Maintenance/Operatio perations ns INTERFACE WITH MARINE SYSTEMS: What is Topside / What is Ship

   2    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

OPERATOR INTERFACE: Topside Process Differs from Ship System SCHEDULE - OVER OPTIMISTIC EXPECTATIONS EXPECTATIONS Topside Hull Integration

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    3    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

INTERFACE CONTROL Ship / Hull / Topsides Engineering / Fabrication Management of Change

Fabrication & Integration Construction Method – Topside Package 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    4    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

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

   5    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

SAFETY HAZOPs System isolation philosophies Escape and evacuation

Success Factors n

Comprehensive Role by Topsides Engineer: n

Utilization of experienced personnel and  lessons learned 

n

Process design for the  entire

n

Perform detailed design for topsides  integration and commissioning 

   6    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

n

Value Engineering 

complex 

Success Factors Construction: n

Construction management supported by Engineering staff through completion of fabrication and commissioning

   7    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

n

Constructabilit Constructability y reviews early and across all interface interfaces s

n

Participants exchange execution procedures

n

Minimize and simplify participant interfaces

Critical Issues To First Oil

   8    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

n

Concept Selection

n

Critical Path Determination

n

Shipyard Slot Reservation

n

Process Facilities Definition

n

Realistic Schedule Expectation

Drivers for Contracting • Earl Early y Part Partne nerr Sele Select ctio ion n • Con Contra tracto ctors rs Selec Selected ted for for “Best “Best-i -in-Cl n-Class ass”” • Agre Agreed ed Execu Executi tion on St Stra rate tegy gy • Agre Agreed ed Di Divi visi sion on of Work Work

   9    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Success Factors Project Controls • Estimating  • Scheduling  • Cost Management  • Interface Management     0    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Bonga Project

   4    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Dry Tree Unit with a FPSO

   5    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Conventional FPSO Processes

Crude Oil Oil Separation Separation Crude

GasDehydration Dehydration Gas

   6    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

WaterInjection Injection Water

AssociatedGas GasCompression Compression Associated

OilyWater Water Clean-up Clean-up Oily

Process Support Support Utilities Utilities Process

FPSO Components COMPONENT BREAKDOWN

   0    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

FPSO Topside Module Layout

   1    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Trading Tanker Conversion to a FPSO

   4    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Motion Analysis at FPSO  Akpo size FPSO - Extreme Regular Regular waves waves : H = 6.6 m, T = 11.4 s, Offshore Offshore Nigeria

   7    5    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Note : Animation speed is 5 times actual for clarity ! 

Traditionall Offloadin Offloading g from an an FPSO Export Options: Traditiona 1) Side by Side

H

Standard Tanker

2) Tandem H

Tug

Spread or Turret Moored    7    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Standard Tanker

3) CALM H

Tug

Spread Moored

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.    8    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Offloading with a D.P. Tanker Use of an air gun for to carry a messenger line to the D.P. tanker

   9    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Offloading with a D.P. Tanker 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    0    5    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Offloading with a D.P. Tanker No tugs No hose/hawser handling vessel Able to hookup in rough weather. Waves up to 5.5m

   1    5    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Brazil & GOM deepwater?

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

   4    5    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

n

High reliability at low maintenance and inspection requirements Competitive price

Motion Analysis at Offloading Side Bluewater Bluewater CALM buoy. Extreme Extreme Regular Wave: H = 6.6 m, T =11.4 s, Offshore Offshore Nigeria Nigeria

   8    5    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Station Keeping Methods

   3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

n

Caten Catenar ary y moor moored ed

n

Taut wire moored

n

Turret Turret - Internal Internal vs. Exter External nal

n

Tendons

n

Dynamically positioned (DP)

n

Suction or driven pile

n

Chain wire chain

n

Chain polyester chain

Mooring System n

Temporary Mooring n

n

Drilling Rig/ Vessels

Permanent Mooring n

Single Point / Turret Mooring

n

Spread Mooring ( SPAR/ SCF/ FPSO/ Barge) n

n    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Taut Mooring n

Foot Print is Small

n

Anchors are closely spaced and has h as higher vertical load

Cate Catena nary ry Moori Mooring ng n n

Foot Prints are Larger  Anchors are spread out and installed primarily for  horizontal load

Spread Mooring n

n

n

   5    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Chain Only n

Huge load on vessel

n

Preferably shallow shallow water 

Chain Wire Chain n

Used traditionall tr aditionally y

n

System weight becomes a challenge in deepwater 

Chain Polyester Chain n

Reduces system weight in deepwater and ultra deepwater 

n

May increase installation cost

Deepwater Characteristics Related To Mooring

   6    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

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 or very soft soils

Mooring Components

   7    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

n

Anchors

n

Mooring Lines and Tethers

n

Connecting Components and Details

n

Installation Aids

Spread Mooring n

   8    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Design Code n

API RP RP 2SK 2SK - Regula Regularr Moori Mooring ng

n

API RP 2SM2SM- Synthe Synthetic tic Moo Moorin ring g

n

DNV

Mooring Layout

   0    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

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

   )   m    (    d   e    b   a   e    S   e   v   o    b   a    t    h   g    i   e    H    1    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

900

46 meters long 92mm K4 chain

750 600 1340 meters long 86mm 86mm w ire rope

450 457meters long 90mm K4 chain

300 150 0

-1500

-1250

-1000

-750

-500

X from Fairlead (m)

-250

0

250

Mooring Line Assembly/ Make Up

   2    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Comparison of Anchors for Taut Moorings

   3    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

BUCKET ANCHOR

HICAP ANCHOR

HIVEL ANC ANC HOR

 W = 100%

 W = 55%

 W = 25%

Equal Capacity Capacity and an d Soil Conditions Conditions

Anchor Pile Installation

   5    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Suction Anchors

   6    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Subs Subsea ea Conn Connec ecto tor  r 

   7    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

HiCap Anchor  ® - Installation 1. MATING

3. EMBEDMENT BY SUCTION

   8    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

2 LOWERIN G AND POSITIONING

4 RETRIEVAL OF INSTALLATION LID

Anchor - Installation

   9    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

1 Lowerin g to Sea bed

2. We ight Pen etratio n

3 . Embed ment by Suc tio n

4. Ret rieval o f Installation Lid

Pile Installation

   0    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

TLP Anchors Decisive factors selecting the optimum type n

Soil conditions (strength, layering)

n

Acceptable/Required transfer of loads into the seabed (dynamic (dynamic loads loads - ‘suction’, ‘suction’, permanent permanent loads loads weight weight and shear or weight only)

n

Total logistics thus installation method

Main types    1    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

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 Cylindri Cy lindrical ca l Shell Shell LWA Concrete 200 mm

   2    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Steel Plate 10 mm

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

Soft

Stiff/hard    3    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Anchor Anchor - Instal Installat lation ion Metho Method d 40 m 120 ft

Thrust 35 t

Thrust 3 5 t

Tension 250 t

100 100 m 300 300 ft

   4    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Mooring Lines Types considered in optimization of the mooring systems

   5    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

n

Steel Wire Ropes (sheathed)

n

Polyester Ropes

n

Stiff Fiber Ropes (Aramid, Kevlar, …)

Asgard ‘A’ FPSO

   9    1    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

ASGARD A

West Africa New Build FPSO Shape External Turret

   0    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

 Petrobras 37  FPSO

11 path swivel serves: • Oil •Gas •Water

   1    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Plus • hydr hydrau auli licc • chemic chemical al inje injecti ction on • sign signal al/o /opt ptic ical al

 Petrobras 37 FPSO

Turntable and Swivel installed on top of  turret to serve 43 risers

   2    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A    ©

Tendons

   7    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Deepwater Tendon Options n

   8    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Pressurized Tendons n

Technology Exists

n

Design and Safety Concerns

n

Staggered Wall Tendons

n

Step Diameter Tendons

n

Composite Tendons n

Requires New Technology (Under Development)

n

Extensive Test Program

TLP Tend Tendons ons - Stress Stresses es Due Due Water Water Press Pressure ure CONVENTIONAL DESIGN

ABB DE DESIGN   Alt. A

Alt. B

pinne inne r( z)

pouter( z)

   9    2    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Price 1 00%

pout er( z)

Pric e 70%

pouter( z)

Tendon Systems

   0    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

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 

   1    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

n

Auto Length Adjustment

n

Ratcheting Design

n

PrePre- or Co-In Co-Insta stalle lled d

n

Threaded or Grooved Load Segment

n

Synchronized & Centralized

n

No Rotation Required

n

Remote Hydraulic Operation & Installation W/Manual Override

Tendon Porch

   2    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

TG-5 Bottom Tendon Connector 

   3    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

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

   4    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

n

Stab to Preset

n

Pressure to Release

No Rotation Required

J Lay Tower for Tendon Installation

   5    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

J Lay Tower for Tendon Installation

   6    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Saibos J Lay

   7    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

ROV to Monitor Pile Installation

   9    3    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

TLP TLP Ten Tendo dons ns - Tow Tow Met Metho hod d

Trail ing tu tu g

Leading tug Towline Leading towing gear

   0    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

Tendon Clump Clump weigh weigh t

Trailing tow gear

Arranged as a fail-to-safe system

Upending of Tendon by Lowering Lead tug

Leading tow gear Towline

Clump weight

   1    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

 Auxiliary towline

Trailing tug

Installatio Installation n - Dragging Dragging to Target Target and and Pull-in Pull-in

Lead tug

Tr ailin il ing g tug

Towline Tendon Tugger line

Upended tendon Towline

   2    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A

 Anchor

Tow gear

Clump  weight

Pull-in line

 Anchor

Installation Vessel

   3    4    .   c   n    I    l   a    b   o    l    G   s   u   m   m   u    L    B    B    A