Download - Fpso Design and Technology
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
11
Crondall Energy Consultants Ltd28, City Business Centre, Hyde Street, Winchester, SO23 7TA Tel +44 (0)1962 842233
www.crondall-energy.com
IBC FPSO Training CourseIBC FPSO Training Course
Perth ~ November 2005Perth ~ November 2005
Introduction to FPSO Design and Introduction to FPSO Design and TechnologyTechnology
Duncan Peace Duncan Peace –– Crondall Energy Crondall Energy
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
22
Agenda
1. General Introduction Definitions Strengths and weaknesses Regional aspects Market situation
2. Building blocks Key components Hull selection and design Interface with topsides Station keeping Interface with sub-sea
3. Key technologies Turrets and swivels Different turret types What is going on inside a swivel? New developments
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
33
Part 1
General Introduction
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
44
Definitions
FPU -Floating production unit – a general expression for all floating production units, but sometimes also used to describe units without storage such as semi-submersible units
FPSS – floating production semi-submersible
FSU or FSO – Floating storage unit OR floating storage and offloading unit
FPSO – floating production storage and offloading units
MOPU – general term for mobile offshore production units, but may include jack-up units as well as floating units
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
55
FPSS and TLP
Marco Polo
Images courtesy of Modec/Sofec
Semi submersible production Semi submersible production facility.facility.
Tension leg production Tension leg production facility.facility.
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
66
FPSOs and FSUs
Floating storage facilityFloating storage facility
Floating production storage Floating production storage & offloading facility& offloading facility
Images courtesy of Modec/Sofec
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
77
FPSO – Strengths and weaknesses
Strengths
Economics – low hull and conversion cost can provide best development solution
Mobility – Easy to move from construction site to field – easy to relocate from field to field
Insensitive to water depth – concept is relatively insensitive to water depth - can operate from ~30m – 3,000 metres
Large deck area and load capacity – mono-hull configuration provides large deck payload capacity and is relatively insensitive to additional payload
Storage capacity – allows export of product by shuttle tanker – not pipeline dependent
Weaknesses
Additional marine equipment and crew (relates partly to storage) makes operating costs relatively higher
Lack of drilling capability – Turret moored solutions with drilling not yet operating – although concepts exist
Turret systems can act as a constraint on riser numbers and sizes
Need to use sub-sea trees and flexible risers (relatively expensive)
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
88
Regional issues
North Sea Challenging met ocean environment – drives technology innovation Heavily regulated Mature infrastructure Units tend to have smaller storage than in benign areas
W. Africa Benign met ocean environment – benign regulatory environment Significant distance to market – drives higher storage capacity Stranded gas is a challenge – little infrastructure
Brazil Moderate environment – moderately regulated Pioneering deepwater technology Established infrastructure
SE Asia/Australasia Cost & schedule driven Benign environment; some regional climatic factors – cyclones & typhoons
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
99
Market position of FPSOs
Current worldwide fleet of FPSOs numbers are estimated at around 110+ units working or idle units as at the end of 2004, plus around 30+ under development.
Forecasts show a further 100+ planned for the next 5 years – which may or may not be realised. However, 20+ units per year will be a challenge for the industry
History and forecast both suggests that of these prospects; around 2/3rds will be FPSOs;
GLOBAL FORECAST 2004-2008
14
9
1920
10
36
22
1
13
102
TLP's
SPARS
FPS's
FPSO's SOUTH EASTASIA
FPSO's AUSTRALASIA
FPSO's AFRICA
FPSO's AMERICA
FPSO's MIDDLE EAST
FPSO's EUROPE
Source: Infield Systems Ltd., Offshore Magazine (May 2004)
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1010
Market Forecast @ November 2005
Under Construction or with firm plans 23 FPSOs 7 FPSSs 3 SPARs 3 TLPs
Probable or possible developments 78 FPSOs 5 FPSSs 2 SPARs 7 TLPs
Source: OGPOD Database/CEC Analysis
The FPSO remains the numerically dominant technology for floater developments
Numbers will continue to challenge industry supply of resources
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1111
Why are FPSOs so important?
FPSOs have become the technology of choice for new developments in deepwater;
Outside the GOM they are the dominant technology;
Significant growth forecast – global fleet expected to almost double over the next 5+ years;
THE FPSO HAS GONE FROM A PERIPHERAL TECHNOLOGY IN BENIGN AREAS – TO THE MAIN SOLUTION FOR MODERATE/DEEP OFFSHORE DEVELOPMENTS
WORLDWIDE
CHALLENGE FOR THE INDUSTRY IS HOW TO MEET THE SCALE OF THE FORECAST INVESTMENTS.
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1212
Part 2
Building Blocks
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1313
Key components and design features
Hull and hull (marine) systems
Station keeping and fluid transfer facilities
Topsides process equipment
Internal interfaces
Interface with sub-sea equipment & wells
Interface with offloading arrangements
In this presentation we will deal with the first two ~ and leave the remainder to subsequent presentations
Image IHC Caland Annual Report
Image Courtesy of Bluewater
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1414
Hulls and Hull Systems
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1515
Hull selection – New build or conversion
New Build
More flexibility in selecting key design criteria Schedule (design and build longer duration than conversion) High costs Often selected in robust met-ocean environments May become more prevalent as numbers of suitable conversion candidates decrease OR hull prices
increase My be preferred if conversion scope would be extensive because
• No suitable conversion candidates• Remedial work for structure &/or marine systems extensive or high risk• Major compliance issues
Conversion Dominates the global supply of FPSOs Quicker and cheaper solution Key decisions will be around scope of conversion/upgrade/replacement
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1616
Hull selection -New build and conversion challenges
New build challenges Schedule impact Yard availability Competition Design choices
Conversion challenges Conversion candidate vessel (age - double v single hull) Scope definition
• Structural integrity• Utilities & hull systems integrity• Interfaces & integration of systems• Technical standards & compliance • Material selection and corrosion protection
Contractor skills, experience & capacity Scope growth
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1717
Hull design - Design Features
Key Issues
Deadweight Cargo (storage) capacity Equipment (payload) capacity
Hull structure - Global and local strength
Main vessel lay-out - Deck space - Location of accommodation (NB)
Location of turret % LBP
Need to be considered
Hull form, fineness and sea-keeping considerations (NB)
Bow shape, free board (forecastle & ship side) (NB)
Green water protection
NB = Issues where scope NB = Issues where scope for choice exists with for choice exists with
new-buildsnew-builds
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1818
Hull structure
Tank arrangements - Double sides v full double hull
Arrangement of tank spaces (NB)
Longitudinal bulkheads (NB)
Integration with topsides and other interface structures
Layout of other hull spaces for utilities etc. (NB)
NB = Issues where scope NB = Issues where scope for choice exists with for choice exists with
new-buildsnew-builds
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
1919
Hull structure - cargo tank arrangements
Double side Double side –– single bottomsingle bottom
Double side Double side –– double double bottombottom
Three cargo tank Three cargo tank arrangementarrangement
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2020
Hull layout-aft accommodation
UtilitiesUtilitiesBlast wallBlast wall FwdFwd
AccommodationAccommodationHelideckHelideck ProcessProcess TurretTurret
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2121
Hull layout -fwd accommodation
TurretTurretProcessProcess HelideckHelideckUtilitiesUtilities
AccommodationAccommodation
Blast wallBlast wall
FwdFwd
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2222
Hull design - Hull systems and utilities
Layout of major features (NB) Accommodation & TR Main marine systems & utilities
• Cargo & ballast & Pump room
• Main Power, emergency power,
• Fire pumps.
• HVAC,
• IG Other spaces and services required for auxiliary equipment and shared systems Vessel upper deck piping arrangements (pipe rack integration)
Integration of hull marine and topsides systems Power/fuel Control and safety systems Emergency power
NB = Issues where scope NB = Issues where scope for choice exists with for choice exists with
new-buildsnew-builds
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2323
Interface with Topsides equipment and systems
Design and layout of topsides will be covered later by Simon Lowe of Maersk Contractors
Interface issues will be covered by Gary Doyle of Crondall Energy Consultants
However, there are a number of key issues that need to be considered by the hull design process
Structural integration of topsides support stools & module support structure into hull structure layout
Consideration of required maximum topsides weight and CoG
Layout and space considerations in the area of the vessel upper deck
Extent of integration of hull and topsides systems
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2424
Station keeping
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2525
Station keeping - Key design Issues
Station keeping options are:
Mooring with a turret mooring system – allows weathervaning to prevailing met-ocean conditions Spread mooring – fixed – or mostly fixed orientation (some partially compliant systems) Dynamic positioning (rare – only two units currently operating in this mode) Permanent or disconnectable
Key decision inputs will be the prevailing met-ocean conditions:
Severity of conditions Nature of severe events – cyclones etc. Directionality of conditions (dominant direction) Extent to which prevailing conditions are co-linear (sea wave and swell OR sea wave and
wind/current) Economics (capital cost versus operating uptime)
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2626
Turret or Spread Mooring?
Weather conditions, directionality & persistence
Riser requirements (number, size and configuration)
Permanent v disconnectable
Offloading some spread moored systems now have separate offloading facilities
Other factors Process performance and uptime Hull fatigue
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2727
Turret Moored - the Alvheim FPSO
Images courtesy of APL
Vessel is based on the Statoil/Navion multi purpose shuttle tanker (MST) concept 85,300 Dwt tanker Double hull dp3 class 120,000 bbl/day oil
production 125,000 mmscf gas
handling
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2828
Spread mooring –the Sendje Berge
Images courtesy of Bergesen
Vessel is based on a VLCC
2 million bbls storage
60,000 bpd production
Spread mooring
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
2929
DP Position Keeping – FPSO Munin
The Bluewater owned and operated Munin has operated in both turret moored mode (this image) at the Lufeng field in China and the Xijiang field also in China
Vessel is based on the Statoil/Navion multi purpose shuttle tanker (MST) concept 95,500 Dwt Double hull dp2 class 60,000 bbl/day
production
Images courtesy of Bluewater
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3030
Interface with sub-sea equipment
Turret and swivel provide the main interface between the FPSO and the sub-sea system
Swivel systems allow the transfer of:
Production fluids from the sub-sea equipment to the vessel Export fluids from the vessel to the sub-sea infrastructure Well/sub-sea management/control fluids e.g. methanol Electrical signals for control and monitoring Electrical power for driving sub-sea/down hole equipment e.g. ESPs
Turret provides connection to mooring lines and mechanical support for the risers and umbilicals
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3131
Interface with sub-sea equipment
Images courtesy of BluewaterImages courtesy of Modec Inc.
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3232
Sub-sea interface
Images courtesy of APL
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3333
Part 3
Key Technologies
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3434
Key Technologies
Development of turret and swivel systems which allow n x 360 degrees rotation have been the key technologies which have allowed FPSOs to be used in all met-ocean environments
Turret allows vessel to weathervane – that is, to take up a position which aligns it with the dominant forces of wave, wind and current.
Weathervaning has the effect of minimising environmental loads on the station keeping system, and minimises the most sensitive vessel motions – generally for a mono-hull – roll.
This has the effect of minimising disturbance to process equipment and personnel and maximising the facility uptime.
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3535
Different Turret Types
Internal turrets
External turrets (forward of bow - normally)
Permanent or disconnectable
Yoke moored
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3636
Internal Turrets
Images courtesy of APL
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3737
Internal Turrets
Images courtesy of APL
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3838
Internal Turrets
Images courtesy of Bluewater
Turntable Access StructureTurntable Access Structure
(alternative: Deckhouse)(alternative: Deckhouse)
Swivel StackSwivel Stack
TurntableTurntable
TurretTurret
Casing / MoonpoolCasing / Moonpool
SpiderSpider
(bottom ship)(bottom ship)
(upper deck)(upper deck)
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
3939
Internal Turrets
Images courtesy of Bluewater
Casing/MoonpoolCasing/Moonpool
Mooring LegsMooring Legs
SpiderSpider
Lower Radial BearingLower Radial Bearing
Turret (with riser pipes)Turret (with riser pipes)
Main Roller BearingMain Roller Bearing
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4040
Turntable- Typical Lay-out
Includes for example:
Subsea Control Skids
Pipe headers
Control valves
Pig receivers
Pig launchers
Installation Winch
Images courtesy of Bluewater
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4141
External turrets - Baobab Ivoirien FPSO
Images courtesy of Modec/Sofec
970 m water depth
8-leg polyester
mooring
357,000 dwt tanker
conversion
2.0 million bbls storage
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4242
External turrets- FPSO Fluminense Brazil
Images courtesy of Modec/Sofec
800 m water depth
357,000 dwt tanker conversion
1.2 million bbls storage
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4343
External turrets - Cuulong MV9 FPSO
Images courtesy of Modec/Sofec
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4444
Yoke MooringCNOOC Bohai Bay QHD32-6 FPSO (China)
Kome Kribi FSOw/ Tower Yoke Mooring System
Images courtesy of Modec/Sofec
66 ft water depth
New-build vessel
1.0 million bbls storage
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4545
Disconnectable systemsSBM’s External and Internal solutions
External or Riser Turret Mooring Internal turret with disconnectable buoy
Images courtesy of SBM
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4646
The Riser Turret Mooring (RTM)
Cossack Pioneer
Location NW Shelf Australia
Vessel size: 152,000 Dwt
Topsides 115,000 bopd
Images courtesy of SBM
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4747
Disconnectable internal turret systemAPL’s STP system
Images courtesy of APL
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4848
Disconnectable systems –Terra Nova
Images courtesy of Modec/Sofec
Turret AccessStructure
Upper Turret
Lower Turret
Spider Buoy
Fluid Swivel
Manifold System
Upper Bearing
Connector System
QC/DC Connectors
Lower Bearing
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
4949
Swivel systems
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5050
Swivel systems
Swivel systems allow the transfer of:
Production fluids from the sub-sea equipment to the vessel Export fluids from the vessel to the sub-sea infrastructure Well/sub-sea management/control fluids e.g. methanol Electrical signals for control and monitoring Electrical power for driving sub-sea/down hole equipment e.g. ESPs
Swivel systems allow n x 360 degrees rotation
Swivel manufacturers are pushing back the boundaries of pressure and temperature to limit of around: ~400+ barg ~120c
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5151
What is going on inside a swivel?
Rotor StatorRotor Stator
Images courtesy of Bluewater
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5252
What is going on inside a swivel?
Images courtesy of Framo
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5454
Leadon FPSO stack
Images courtesy of Framo
Leadon power slip ring to Leadon power slip ring to be installed later when be installed later when
required (4 x 1 MW)required (4 x 1 MW)
Fluid pathsFluid paths
UtilitiesUtilities
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5656
Swivel stack modules
Images courtesy of Bluewater
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5757
P37 Swivel stack
Images courtesy of Bluewater
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5858
New developments – the Sevan SSP
Concept
Scaleable oil storage capacity (0.3-2 MMbbl)
High deck load capacity No requirement for weathervaning,
avoiding complicated/ costly turret swivel system
Standard riser connections, umbilical and power cable terminations
Accommodates large number of risers Low investment for future risers
Images courtesy of Sevan Marine
Crondall EnergyCrondall EnergyDuncan PeaceIntroduction to FPSO Design and Technology
5959
New developments – the Sevan SSP
Piranema SSP300constructionat Yantai Raffels Picture Sep 23, 2005
Images courtesy of Sevan Marine