9f2b157c1b63452586ca8d2287ed5149 (1)
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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 ?
top related