Espirito Santo FPSOTurret & Installation Challenges

SNAME/MTS Joint Meeting Texas A&M University March 26, 2010

Chris Wibner

Upstream Major Projects

Shell International Exploration & Production, Inc.

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 location

Internal turret with 21 riser/umbilical slots

First turret moored FPSO to accept Steel Lazy Wave Risers

Espirito Santo FPSO

100 kbopd oil processing capacity (low API)

50 mmscfpd gas compression

150 kbpd total liquids processing capacity

130 kbwpd produced water treating capacity

75 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)

Vessel As Arrived in Singapore (’06)

• 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

Turret Cross Section

Umbilical deckCollar deck

SLWR

Typical flexible riser

Max SLMax SL

Lower Turret Layout Difference

Riser deck

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

Integration Photos - Turret

Gantry Manifold

Bogie Support Structure

Lower TurretCollar Structure

LOWER MOONPOOL INSTALLATION

Upper Moonpool Integration

Upper Moonpool Integrationafter 2nd DD

BC-10 FPSO TURRET(LOWER TURRET)

Lower Turret Integration

BC-10 FPSO TURRET(Bogie Support Structure)

BC-10 FPSO TURRET(UPPER TURRET)

BC-10 FPSO TURRET(TURRET MANIFOLD)

Riser / Umbilical Interface

Risers clamp castings (12)

Umbilical bellmouths (3)

Umbilical Future (6)

Mooring Connectors (9)

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

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 Pull-in Winch

RiserWire

Chain Wire

SLWR & Umbilical Pull-in

Installation team

ready for another

pull-in within 6 to 8

hours

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

QUESTIONS ?