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FPSO FALCON

TECHNICAL DESCRIPTION REPORT

FPSO Falcon

FPSO Falcon Technical Description Rev C1 8/7/2009 Page 1

TABLE OF CONTENTS

1. INTRODUCTION..............................................................................................................................4 2. FPSO GENERAL DESCRIPTION ...................................................................................................5 3. FPSO BASIS OF DESIGN...............................................................................................................8

3.1. Design Conditions ................................................................................................................8 3.1.1. Location and Environmental Data for the FPSO Design......................................8 3.1.2. Operational limits .................................................................................................8

3.2. Classification, Rules, Standards, Codes and Certificates ....................................................8 3.2.1. Classification........................................................................................................8 3.2.2. Class and Regulatory Body Rules .......................................................................9 3.2.3. Country of Registration ........................................................................................9

3.3. TOPSIDES FACILITY.........................................................................................................10 3.3.1. Volume Improvement Project (VIP) Changes ....................................................10 3.3.2. Topsides Processing Facilities...........................................................................10 3.3.3. Power Generation Capacity ...............................................................................11 3.3.4. Oil Processing System.......................................................................................11 3.3.5. Gas Processing Systems...................................................................................13 3.3.6. Water Injection System ......................................................................................14 3.3.7. Utility Systems ...................................................................................................15

3.4. VESSEL..............................................................................................................................16 3.4.1. Hull .....................................................................................................................17 3.4.2. Accommodation .................................................................................................17 3.4.3. Upper Deck Structures.......................................................................................17 3.4.4. Lifting, Handling and Warehousing ....................................................................17 3.4.5. Corrosion Protection ..........................................................................................17 3.4.6. Refrigeration ......................................................................................................18 3.4.7. HVAC Systems ..................................................................................................18 3.4.8. Propulsion System .............................................................................................18 3.4.9. Power Generation System .................................................................................18 3.4.10. Ballast System ...................................................................................................18 3.4.11. Sewage System .................................................................................................18 3.4.12. Steam and Condensate System ........................................................................18 3.4.13. Fuel Systems .....................................................................................................18 3.4.14. Lubricating Oil System .......................................................................................19 3.4.15. Compressed Air Systems...................................................................................19 3.4.16. Valve Hydraulic System .....................................................................................19 3.4.17. Fresh Water System ..........................................................................................19 3.4.18. Sea Water Systems ...........................................................................................19 3.4.19. Bilge System ......................................................................................................19 3.4.20. Slop System.......................................................................................................19 3.4.21. Off Spec Oil Tank...............................................................................................19 3.4.22. Inert gas System ................................................................................................20 3.4.23. Fire Fighting, CO2 and Foam Systems ..............................................................20 3.4.24. Safety and Life Saving Equipment .....................................................................20 3.4.25. Tank Gauging System .......................................................................................20 3.4.26. Cargo and Crude Oil Washing System ..............................................................20 3.4.27. Offloading Of Stabilized Crude. .........................................................................20 3.4.28. Tandem Mooring And Offloading Systems. .......................................................20

3.5. TURRET AND MOORING SYSTEMS................................................................................21 FPSO Falcon Technical Description Rev C1 8/7/2009 Page 2


3.5.1. Mooring System .................................................................................................23 3.5.2. Riser System......................................................................................................23 3.5.3. Swivel Stack.......................................................................................................24

APPENDICES............................................................................................................................................25 I. FPSO Equipment Capacity Summary ................................................................................25 II. Topsides.............................................................................................................................25 III. Vessel Particulars...............................................................................................................25 IV. Turret and Tandem Mooring Data ......................................................................................25 V. FPSO FALCON History ......................................................................................................25


1. INTRODUCTION

This Technical Description has been developed as a general narrative of the FPSO Falcon incorporating the FPSOs design and project history for the purposes of vessel redeployment in suitable future projects.

The FPSO Falcon has been designed and built as a generic FPSO suited for deep water conditions, up to 2100 meters. The generic concept means that it has been designed to cope with a wide range of field properties, Metocean conditions, and water depths, for relocation between fields during its lifetime. The unit has been deployed on the Yoho field offshore Nigeria, for ExxonMobil. In addition to being suitable for West African Metocean conditions, studies have been performed to determine its suitability for use in other geographic regions such as Brazil.


2. FPSO GENERAL DESCRIPTION

The following is a general description of the topsides, vessel and turret of the FPSO Falcon. Further information with PFDs, GAs, and Equipment details is provided in Appendices section. Topsides The FPSO Topsides Modules have been fabricated in Singapore and UAE, and were installed and interconnected to form the complete oil, gas, and water processing facilities, in Singapore. There are a total of 17 Modules each weighing between 75 and 710 tonnes. The topsides was originally designed and constructed as a 3 stage separation system plus electrostatic treater, with a capacity of 90,000 bpd (later debottlenecked to 120,000 bpd). The Topsides were modified in 2004 as a part of a Volume Improvement Project (VIP) to increase the maximum oil production rate to 168,500 bopd. This upgrade involved converting the existing separation train into 2 x 50% trains, each having 2 stages (High Pressure and Low Pressure) of 3 phase separation, with a common electrostatic coalescer. The crude oil can be desalted in the Low Pressure separators if required. Treated oil from the electrostatic coalescer and/or final stage of separation flows to the cargo tanks for storage until it can be offloaded to a shuttle tanker. The Falcon is currently still configured in the high capacity 2 stage VIP mode, but can easily be converted back to the original 3 stage mode if required. The following sections describe the current VIP mode. Produced water from the separation equipment is processed to remove dissolved gas after which it flows to the FPSO slop water tanks for settling. The water is monitored for oil in water content prior to discharging overboard or further processing by hydrocyclones. Separated gas from the High Pressure Separator is compressed to high pressure to allow it to be re-injected. This avoids the need for flaring and in some cases may allow the reservoir pressure to be sustained. Some of the gas is used as fuel on the FPSO, both in the vessels boilers and to fuel the dual fuel gas turbines which drive the power generators, water injection pumps and main gas compressors. Approximate fuel gas consumption of the unit is 11 -15 MMscfd. The Main Gas Compression consists of 2 x 50% gas compressor trains each complete with associated suction, interstage and discharge coolers and scrubbers. Gas from the Low Pressure Separator is compressed by 1 x 100% electric driven dry, screw compressor to a pressure where it can join the produced gas from the High Pressure Separator at the inlet to the Main Gas Compression. Gas is dehydrated in a Tri Ethylene Glycol (TEG) Dehydration System, located between the 2nd and 3rd stages of the Main Gas Compression. After dehydration the gas is routed to gas injection risers via the gas injection swivel in the turret. The utilities needed for operation of the FPSO, including electrical power, cooling medium and heating medium, are provided on the Topsides. The electrical power is provided by two dual fuel gas turbine driven generators, and distributed to users by switchgear located in the Local Equipment Room, also located on the Topsides. The heating and cooling medium systems are both closed loop system containing tempered, fresh water. The heating medium is heated by steam from the vessels boilers, and the cooling medium cooled using seawater.


Seawater for the cooling of the cooling medium system, and for supply to the gas turbine driven water injection pumps is provided by submerged lift pumps located in caissons in a water ballast wing tank. The seawater is filtered and deaerated in the water treatment system to meet the quality requirements for injection into the reservoir. Other ancillary systems for operation, such as testing laboratory, pigging pumps, and chemical injection are also provided on the topsides. Vessel Export quality crude oil, received from the Topsides is stored in the Vessels cargo tanks until arrival of an offloading tanker, which will transport the oil to its chosen destination. There are 13 crude oil tanks with a total capacity of 2.1 million barrels of oil. The vessel also has two slop tanks for final cleanup of produced water and slops, and three water ballast tanks. Crude oil will be transferred to an offloading tanker, which will approach the FPSO and be moored by a hawser to the stern. A floating hose will be connected to the offloading tanker to allow the contents of the FPSO cargo tanks to be transferred to the offloading tanker, an operation that will take around 24 hours, typically a 1 MM bbls parcel size. The accommodation can house up to 100 persons, mainly in 1 and 2 bed cabins. As well as cabins the accommodation includes a large galley and mess, and three separate TV lounges and a gymnasium. The accommodation block also provides the normal working spaces, including the Central Control Room, Radio Room and offices. A hospital and sick room are located in the accommodation, and lifeboats for 200 people or double the maximum Persons on Board (POB). Extensive fire fighting and life saving appliances are located throughout the vessel to assist a trained crew to deal with all types of emergencies that could occur. Turret The FPSO Falcon has an external turret suitable for permanently mooring the unit on location. The turret chain table has slots for 15 risers and umbilicals, and is configured for 9 mooring lines in a 3 x 3 arrangement. A roller bearing system within the turret allows the central fixed part to remain geostationary, while the hull is allowed to freely weathervane around the turret in response to prevailing wind, wave, and current forces. Fluids, electrical power, and control/data signals are transferred between the turret and the topsides via SBM proprietary designed and supplied swivels.

Yoho Field Production Data

During her time on the Yoho field the FPSO Falcon achieved the following production data / year:

Pre-VIP

Production period (months) 28

Average Oil Production 116,637 bbls

Average Oil Production Uptime 99.11%

Average Gas Compressed and Treated 82.31 MMscfd


Safety Record (Lost Time Accidents) 0

Post-VIP (June 2005)

Production period (months) 8

Average Oil Production 145,135 bbls

Average Oil Production Uptime 99.90%

Average Gas Compressed and Treated 87.08 MMscfd

Safety Record (Lost Time Accidents) 0


3. FPSO BASIS OF DESIGN

The main particulars of the FPSO FALCON VESSEL are specified in the section below: HULL MAIN PARTICULARS Name: FPSO Falcon (ex T/T Esso Kawasaki, Amazon Falcon) Year built: 1975, Kawasaki HI, Japan Year Converted: 2001 2002 Keppel Shipyard, Singapore Class: American Bureau of Shipping Port of registration: Nassau, Bahamas Hull type: Single sided, single bottom Accommodation: 100 persons in single and double berth cabins Tank heating: 1st & 2nd Stage Slop Tanks DIMENSIONS Length Overall: 362.76 m Length between Perpendiculars: 325.00 m Molded Breadth: 56.00 m Molded Depth (at CL): 29.80 m Design Full Load Draft (mld): 22.30 m (summer) Deadweight: 298,753.00 mt Lightship Weight: 52,857.00 mt Full Load Displacement: 351,650.00 mt STORAGE CAPACITY Cargo capacity: 2,100,000 bbls Ballast capacity: 360,000 bbls

3.1. Design Conditions

3.1.1. Location and Environmental Data for the FPSO Design

The FPSO Falcon was designed for West-Africa Metocean conditions (Nigeria to Angola) and deployed at the Yoho field, offshore Nigeria, for ExxonMobil. Refer to the Appendix for information on mooring design criteria.

3.1.2. Operational limits

The FPSO is designed to survive a storm when sailing in transit to site, up to the extreme oceanographic conditions at the voyage, defined as the 10 year return interval storm for the voyage around the Cape of Good Hope.

The FPSO is designed to remain connected to the mooring system and complete systems of risers, up to the extreme oceanographic conditions at site, defined as the 100 year return interval storm in West Africa.

The FPSO is designed to continue to offload the export parcel to a tandem moored VLCC, up to the extreme oceanographic conditions at site, defined as the 1 year return interval storm at site.

3.2. Classification, Rules, Standards, Codes and Certificates

3.2.1. Classification

The FPSO is designed and constructed under special survey of the American Bureau of Shipping, to obtain the following Class Notation:


A1 - Floating Production Storage and Offloading System

Classification was obtained for uninterrupted service of the system, without the need for dry-docking for 10 years, with on-site Class surveys only for Classification status maintenance.

3.2.2. Class and Regulatory Body Rules

The conversion was executed in compliance with the following Class and International Regulatory Bodies rules, regulations and guides:

Guide for Building and Classing Floating Production Storage Systems, 1996, American Bureau of Shipping.

Offshore Facilities Guide, Third edition October 1998, American Bureau of Shipping.

International Convention for the Safety of Life at Sea Consolidated Edition, 1997, IMO

International Convention of the Prevention of Pollution from Ships (MARPOL) 1974/1978, Consolidated Edition, IMO, 1997.

International Load Line Convention, 1966, Protocol 1988 amendments. Convention on the International Regulations To Prevent Collisions At Sea (COLREG) 1972, as changed by the following resolutions: A-464 (XII) Amendments To The International Regulation To Prevent Collisions At Sea, 1972

Convention on the International Maritime Satellite organization (INMARSAT)

Radio Rules of the International Telecommunication Union, Geneva 1979.

International convention of Tonnage Measurements of Ships, 1969.

Civil Aviation Authority (CAA) Cap 437, A guide to criteria, recommended minimum standards and best practice for offshore helicopter landing areas.

IMO resolutions A649 (16)

Relevant OCIMF guidelines.

3.2.3. Country of Registration

The vessel is currently registered in the Bahamas.


3.3. TOPSIDES FACILITY

3.3.1. Volume Improvement Project (VIP) Changes

In order to achieve an increase in the oil production rate from 120 kbopd to 165 kbopd from the production trains with minimum number of modifications, the following process train changes were made under the FPSO Falcon VIP in 2004:

The single train process system was modified to provide 2 x 50% process trains.

Modification was achieved by changes to the piping systems on Modules 1 - HP/IP Separation, Module 2 - LP Separation, Module 6 - Gas Dehydration, and Module 19 - Methanol Storage and reconfiguration of the swivel.

Modification also involved a number of changes to the DCS control system to protect and control the new arrangement, operating pressures and chemical injection systems.

These VIP changes were designed to be reversible, and hence the vessel can easily be brought back to the original pre-VIP capacity and specifications if required.

3.3.2. Topsides Processing Facilities

Process trains: 2 Oil production rate: 165,800 bopd (original design pre-VIP 120,000 bopd) Design total liquids handling: 165,800 blpd Gas compression: 118 MMscfd Produced water: 50,000 bwpd Water injection: 90,000 bwpd Gas injection/Gas Lift: 95 MMscfd


Fuel Gas: 21 MMscfd

3.3.3. Power Generation Capacity

Topsides: 2 x Dual fuel gas turbine generators 6245 kVA each Vessel: 2 x Steam turbine alternators 2750 kVA each Essential: 1 x Diesel generator set 1250 kVA Emergency: 1 x Diesel generator set 600 kVA

3.3.4. Oil Processing System

The crude processing system consists of two separate processing trains. The main processing train comprises of the original HP Separator, LP Separator and Electrostatic Treater with interstage heating. The secondary processing train comprises of the original Test Separator (converted into a two-stage gas-liquid separator) and the IP Separator.

The separators are designed for the following produced water carry-over (percentage of total liquid flow):

Main Train (Train #1)

HP separator 10 vol% LP separator 1 vol%

Secondary Train (Train #2)

Test separator 100 vol% IP separator 2 vol%

The combined oil system is capable of handling 165,800 bpd of incoming well fluids. The main processing train will handle 85,100 bpd of incoming well fluids and 75 MMscfd incoming gas. The secondary process train is designed to handle 80,700 bpd of incoming well fluids and 65 MMscfd incoming gas.

Offspec Crude

For current VIP configuration, for crude that does not meet specification, a dedicated off-spec tank can be used for production which can be recycled over the oil separation train by means of the stripping pump.

During this recycling, maximum production rate would be decreased; i.e. sum of off-spec crude and incoming crude should not exceed the rates mentioned in the section above.

Operating Conditions

The oil processing system was designed for the following operating conditions in the Separators:

Main Train (Train #1)

HP Separator

Design operating pressure 19 bar(g) Operating temperature 37 C Slug capacity 250 bbls


LP Separator

Design operating pressure 1 bar(g) Operating temperature 80 C

Electrostatic Treater


Secondary Train (Train #2)

Test Separator

Design operating pressure 19 bar(g) Operating temperature 48 C Slug capacity 50 bbls

IP Separator


Crude Oil Properties

The FPSO Falcon is designed for API Gravity 25-40.

Crude Oil Shipping Specification

The oil processing system is designed to achieve the following product specifications at offloading:

Reid vapor pressure 10 psia Basic Sediment & Water (ASTM D4377/4007) 0.5 vol% Salt content (ASTM D3230) 35 ptb (lb/kstb)

The most stringent specification of BS&W or salt content was governing.

In order to meet these specifications at maximum production rates some treatment in the cargo tanks (e.g. water stripping, vapor boil-off) could be required before offloading.

Produced Water Disposal Specification

The maximum allowable oil-in-water content for the produced water will be monitored by the oil-in-water content meter and can be adjusted to meet the oil-in-water content specifications.

The maximum allowable disposal temperature of produced water was 50C.

Slugging

During start-up (i.e. low production capacity) and normal operation, hydrodynamic slugging could occur. In this case, slugging is handled by:


chokes in the turret, an ample slug volume in the receiving separators (250 bbls in HP separator and 50 bbls in

Test Separator) and a sufficient margin between operational pressure and design pressure of the inlet system

(HIPPS setting)

3.3.5. Gas Processing Systems

Total Gas Production Rates

The processing system is capable of handling 188 MMscfd. This is comprised of 168 MMscfd of produced associated gas and 20 MMscfd of returned lift gas. The gas compression system is capable of compressing 95 MMscfd for lift gas and gas injection purposes, and 21 MMscfd for fuel gas.

The difference between the gas compression capacity and the process capacity can be flared continuously in the HP & LP flare systems.

The Flash Gas Compression (FGC) System is designed to handle 8 MMscfd for the first stage of compression.

Gas Lift System

The gas lift system is designed for the following peak capacity:

Max. installed lift gas capacity 20 MMscfd Normal operating pressure (@ max. 60C) 172 bar(g)

Gas Injection

The gas from the gas compression system or lift gas, not used as fuel gas, can be re-injected into the reservoir.

The gas injection system was designed for the following peak capacity:

Max. installed gas injection capacity 95 MMscfd Min. operating pressure @ 60C at injection riser 310 bar(g)

Gas Dehydration System

A TEG Gas Dehydration System is installed to prevent hydrate formation. In this system gas is dehydrated to a water content of 1.5 lbs H20/MMscf (i.e. dewpoint < -10C @ 310 bar(g))

A methanol injection system is installed to prevent hydrate formation during start-up/ shutdown and during short term upsets in the Gas Dehydration System.

HP Fuel Gas System

The key design parameters for the HP fuel gas system (for gas turbines) are as follows:

Capacity 21 MMscfd (total fuel gas) Operating pressure HP fuel gas 30.0 bar(g)


The HP fuel gas is superheated to 20C above the hydrocarbon dew point at the operating pressure. The HP fuel gas off-take is downstream of the gas compression 2nd stage, downstream of the TEG dehydration system.

If the compression system is shut down, dual fuel HP fuel gas consumers shall switch over automatically to MGO.

LP Fuel Gas System

The key design parameters for the LP fuel gas system (for the vessel boiler) are as follows:

Capacity 7 MMscfd (included in HP total) Operating pressure 6 bar(g)

The LP fuel gas is superheated to 10C above the hydrocarbon and water dew points at the operating pressure. LP fuel gas will be taken from the HP fuel gas system. When no compression is available, e.g. for start-up, LP fuel gas is taken (via the HP fuel gas scrubber) directly from the HP separator to allow gas firing of the dual fuel boiler.

LP fuel gas piping is traced/insulated to maintain superheat and avoid downstream condensation.

3.3.6. Water Injection System

Injection Capacity

The water injection system is designed for a maximum de-oxygenated seawater injection capacity of 90,000 bpd. Minimum capacity is 10,000 bpd.

The water treatment facilities upstream of the water injection pumps are designed to produce 105,000 bpd of water, which is including 9000 bwpd to feed the fresh water generator for crude oil washing and approximately 6000 bwpd for firewater system flushing.

Injection Water Specification

The water injection system is designed to achieve the following injection water specification:

Sea water supply conditions to the Water Injection system:

Design pressure SW supply 15.0 bar(g) Normal supply pressure 2.5 bar(g) Solid content < 3 ppmv

Injection water specifications / conditions:

Injection pressure @ pump discharge min. 303 bar(g) Design pressure @ Turret 345 bar(g) Treated seawater quality:

Removal of all solids > 100 microns Dissolved oxygen < 10 ppb O2 Seawater can be treated with periodic shock doses of biocide to kill bacteria.


3.3.7. Utility Systems

Flare System

The FPSO is equipped with two independent flare systems, i.e. a HP and an LP flare for the disposal streams. Under the VIP increased production conditions continuous flaring was expected: 50 MMscfd via the HP Flare and 19 MMscfd via the LP Flare.

The HP flare system was originally designed for a peak flaring capacity of approximately 137 MMscfd, i.e. design associated gas production plus returning lift gas and allowance for simultaneous compression system blowdown, and a continuous flaring capacity of 93 MMscfd. Post VIP rates are 164 MMscfd peak flaring. The flare system was adequately designed to handle the increase in flow. Shielding was installed to limit the impact of radiation from the flare. The flare design capacity is adequate to allow depressurization of both production flowlines in 1 hour. Gas injection flowline depressurisation for hydrate prevention was not required.

The original LP flare system is designed for a peak flaring capacity of approximately 93 MMscfd, based on the emergency case for gas blow-by from the HP Separator to the Produced Water Flash Vessel, and 7 MMscfd continuous production flaring. Post VIP rates are 19 MMscfd continuous flaring via the LP flare and 93 MMscfd peak flaring.

Power Generation System

The topsides power generation systems uses prime-mover dual fuel type (gas and liquid) turbine generator sets.

Under normal conditions the power generation system, with one set in stand-by mode, shall be able to supply all unit consumers, and start the largest electrical motor.

Topsides installed power generation will feed all Topsides FPSO consumers. Vessel consumers will be fed by vessel power generation facilities, comprising of 2 x steam turbine alternators.

One diesel-driven emergency power generator and one diesel driven essential power generator is installed in the vessel.

Chemical Injection System

The system consists of storage and supply facilities for the following three subsystems:

1. Chemicals for Subsea 2. Chemicals for Topsides Process 3. Chemicals for Water Injection

Chemicals include typically methanol, demulsifier, scale inhibitor, corrosion inhibitor, oxygen scavenger, biocides.

For subsea, the following storage facilities are provided as a minimum:

Methanol 1677 bbls Corrosion inhibitor 109 bbls Scale inhibitor 25 bbls

Utility Stations


Utility stations are provided for modules that require to be serviced with e.g. service air, MGO and fresh water. The different locations of these facilities are to be determined based on the requirements of the modules.

A utility line (fed from the existing vessel fire & general service pumps) is installed along the deck to supply seawater for general purposes as e.g. deck washing.

During start-up the seawater lift pumps for topsides will not be operational. A dedicated start-up cooling water pump is provided to enable cooling of the power turbines in this case.

Laboratory

The laboratory is equipped with standardized ASTM test equipment.

Metering

Throughout the facilities, various streams can be monitored by metering as follows:

Crude to cargo tanks +/- 10% Lift gas +/- 10% Injection gas +/- 10% Produced water +/- 10% Injection water +/- 10% Flare gas +/- 10% Fuel gas +/- 10% Crude to shuttle tankers fiscal Oil, water & gas from HP separator +/- 10%

3.4. VESSEL


3.4.1. Hull

A comprehensive survey of the hull steel structure was carried out during the FPSO FALCONs original conversion to identify steel renewals necessary to meet the required 15 year service life and Class requirements. No high tensile steel was used in the vessels original or conversion designs.

Major modifications made to the hull itself during her conversion included the removal of her bulbous bow and the addition of an external turret.

3.4.2. Accommodation

The current accommodation block accommodates a total of 100 Persons On Board (POB), i.e. a normal POB of up to 85 with additional capacity for a further 15 temporary personnel. A combination of one and two man cabins make up the 100 person capacity.

3.4.3. Upper Deck Structures

Additional deck structures added during the vessels conversion include a helicopter deck designed to accommodate the Sikorsky S-61N and S-92A helicopter types, a stern offloading platform, a process deck support structure, a flare boom, two inert gas vent masts, a deck crane pedestal and a stern tandem mooring arrangement.

3.4.4. Lifting, Handling and Warehousing

To facilitate lifting and handling on topsides, a pipe rack mounted travelling crane and an upper deck pedestal type crane were installed. The travelling crane is installed on the vessels centerline, and handles lifts within the topsides areas and for the entire length of the topsides. The pedestal crane is installed amidships on the starboard side, and handles lifts from the upper deck and topsides overboard, including the transfer of personnel. Also available is one (1) electro-hydraulic provisions store crane installed at the portside of the accommodation structure to handle goods and equipment on-board the FPSO and occasionally to/from supply boats in case of fairly smooth sea conditions.

The crane load capacities (SWL) are as follows:

Store crane: 5 tonnes Deck crane: 10 tonnes at 35 m outreach 15 tonnes at 23 m outreach Pipe rack travelling crane: 3 tonnes at 30 m outreach

10 tonnes at 25 m outreach A designated supply boat handling area (complete with Yokohama fenders) where attending services vessels come alongside is located on the starboard side next to the deck pedestal crane. Lifts that cannot be made by the two cranes on topsides are made using I-beams and A-frames that have been installed throughout the topsides in strategic locations.

3.4.5. Corrosion Protection

Protection of the hull from corrosion is provided through the application of coatings, the installation of sacrificial anodes, and the utilization of an impressed current system. All sacrificial anodes are of the diver replaceable type.


3.4.6. Refrigeration

The original cold rooms and provisions refrigeration system was expanded and replaced during FPSO conversion work to accommodate the larger crew size of 100 POB men.

3.4.7. HVAC Systems

Additional HVAC capacity was added to the vessel during the FPSO conversion work. This work included the expansion of the accommodation block HVAC, as well as the refurbishment and renewal of ventilation for all machinery spaces.

3.4.8. Propulsion System

The original steam propulsion system is still intact and operable, and can be used for transit during mobilization to site. The steering system and all associated controls are also still functional.

3.4.9. Power Generation System

The original steam driven T/A sets are still in place and operational during transit and on site after the FPSO is installed. As a back up, an Essential generator was installed along with an Emergency generator. Once installed, power required onboard the FPSO will be generated by the topsides power plant for topsides consumers, and by the Engine Room generating sets for vessel consumers. Capacities for the vessel installed generators are as follows:-

Two (2) steam turbine driven alternator (T/A) sets of 2,200 kW, One (1) essential diesel driven generator set of 900 kW, One (1) diesel driven emergency generator set of 480 kW.

3.4.10. Ballast System

The existing seawater segregated ballast system is comprised of a steam turbine driven Ballast Pump, ballast stripping eductors, piping and valves. The current configuration of tanks is two wing tanks (No 3 P&S) amidships, the Fore Peak and Aft Peak tanks.

3.4.11. Sewage System

The existing sewage treatment plant is designed to accommodate a maximum complement of 100 Persons On Board (POB), i.e. a normal POB of 85 with additional capacity for a further 15 temporary personnel. This system, along with the accommodations was expanded during the original FPSO conversion work. As part of the waste management systems, an incinerator and garbage compactor was also installed.

3.4.12. Steam and Condensate System

The existing two (2) boilers located in the Engine Room were overhauled and converted to firing on either liquid or gas fuel. These units are still intact, and are used to provide steam to all steam consumers on topsides and within the hull. During a transit voyage to site, steam from these boilers is used to drive the vessels main propulsion and steam alternator turbines.

Low pressure steam is also available through the existing steam plant, and is available for such systems as tank heating, topsides heating, fresh water generation etc.

3.4.13. Fuel Systems

The existing fuel systems onboard the FPSO include an HFO, MGO, Fuel Gas, and helicopter refueling system. These systems are all designed to service the vessel, topsides and helicopter refueling operations.


HFO handling and supply is dedicated to boiler operations in the Engine Room. MGO handling and transfer is provided for Engine Room and topsides consumers. Fuel gas handling and distribution is provided for Engine Room and topsides consumers, for the firing of boilers and gas turbines. Helicopter refueling equipment is dedicated to the refueling requirements of visiting helicopters.

3.4.14. Lubricating Oil System

The original lubricating oil system in the Engine Room that stores, purifies and distributes lubricating oil was modified and retained, and is still operational.

3.4.15. Compressed Air Systems

The original compressed air system was replaced during the FPSOs conversion. The current service air system is comprised of 4 x 50% oil free compressor sets and 4 x 50% adsorption air dryer and filter sets. This system services all service air consumers.

Instrument air is supplied by 2 x 100% retro-fitted oil free air compressor sets and 4 x 50% adsorption air dryer and filter sets. This system services all instrument air consumers.

3.4.16. Valve Hydraulic System

All submerged cargo and ballast valves (in-tank valves), together with all valves that are operated during routine cargo operations are hydraulically actuated. A retrofitted HPU and control system provides power to operate the system. Cargo tank valve isolation is double block.

3.4.17. Fresh Water System

Additional Fresh Water generating capacity was added to the vessel during the FPSO conversion work. This work included the installation of a third water maker and associated transfer and distribution equipment to accommodate the expansion of the POB to 100 persons.

3.4.18. Sea Water Systems

The original seawater service system was expanded to supply new equipment installed in the Engine Room during the FPSO conversion work, and is designed to support all vessel and FPSO operations. A Marine Growth Protection System (MGPS) is also installed.

Three dedicated seawater lift pumps in caissons were installed during the FPSO conversion work, and are provided for the sea water supply to the topsides process cooling medium systems and other consumers.

3.4.19. Bilge System

The existing Bilge system was retrofitted with a new Oily Water Separator as part of the FPSO conversion work.

3.4.20. Slop System

There are two Slop tanks in the FPSOs cargo block. The tanks are arranged and piped as a 1st and 2nd stage separation system. The two Slop tanks are designated as Produced Water / Slop Tanks, both of which are provided with heating coils sized to maintain the Slop tank contents at a fixed temperature to facilitate the oil separation process and cargo tank washing operations.

3.4.21. Off Spec Oil Tank

A single Off Spec Oil tank is provided, and is located at No. 1 Center in the cargo block.


3.4.22. Inert gas System

The existing Inert Gas (IG) generating system downstream of the two Main Boiler uptakes is a flue gas extraction system. IG piping on the Upper Deck to the cargo block is through two independent mains. One is an IG/Vent main, and the second is a Purge/Vent main. The two dedicated headers have branches connected to each individual cargo and slop tank.

3.4.23. Fire Fighting, CO2 and Foam Systems

During the FPSO conversion work new and expanded fire protection systems were installed throughout the FPSO. Currently there is a fire water system, an Upper Deck AFFF foam system, a dedicated helicopter fire water and foam system, and several fixed CO2 fire suppression systems for various compartments and machinery spaces. Loose portable fire fighting equipment is distributed throughout the FPSO in designated fire fighting stations.

3.4.24. Safety and Life Saving Equipment

There are three (3) existing Totally Enclosed Motor Propelled Survival Crafts (TEMPSC) currently installed on the FPSO. Two are rated for 50 men, and a third is sized for 100 men. One of the 50 man units is designated as a Life/Rescue Boat. A total of 10 liferafts are installed on the FPSO, eight aft by the accommodations, and two forward near the focsle.

Safety equipment is stored and located throughout the FPSO at each of the safety stations and safety lockers.

3.4.25. Tank Gauging System

The installed tank gauging system is of the radar type tank level gauging system, and is installed for all cargo, slop, ballast tanks as well as draft gauging. The tank level monitoring and draft measuring systems are connected to a tank gauging work station in the Central Control Room for monitoring the FPSO loading conditions in all operating conditions.

3.4.26. Cargo and Crude Oil Washing System

The existing cargo piping system in the cargo tanks, slop tanks and pump room is connected to four (4) steam driven centrifugal cargo pumps, two (2) steam reciprocating stripping pumps and two (2) stripping eductors. This is all ships original equipment. In tank piping consists of three bottom mains as well as valving and piping to facilitate all routine FPSO cargo operations.

Crude Oil Washing (COW) machines are installed in all cargo, slop and Off specs tanks.

3.4.27. Offloading Of Stabilized Crude.

Offloading of stabilized crude to Shuttle tankers will be through a fiscal metering skid and offloading station located on the port aft quarter of the FPSO. A discharge line is piped from the fwd Upper Deck from the metering skid to the aft station where the hard piping is connected to a floating hose. This system is designed to provide a nominal offloading rate of 1 million barrels in a 24 hour period.

3.4.28. Tandem Mooring And Offloading Systems.

An offloading porch on the FPSOs port aft quarter, and a deck mounted mooring hawser QRH (Quick Release Hook) make up the FPSOs Tandem Offloading System. This system is designed to moor export tankers of up to 350,000 mt dwt during offloading operations. Provision for monitoring of the mooring hawser loads can be done locally or remotely in the CCR.


3.5. TURRET AND MOORING SYSTEMS

The FPSO Falcon had an external turret integrated into her bow during her conversion into an FPSO. The turret structure has five (5) decks including the chain table.


Turret Structure General Arrangement

The five main decks in the turret are the Gantry Deck, the Upper Deck, the Lower Deck, the Turntable deck, and the Chaintable. In addition to these five main decks, there are several other small access platforms throughout the turret structure.

The Gantry Deck supports the lifting gantry that surrounds the swivel stack, drives the rotating parts of the swivels, and provides a laydown area for swivel and other maintenance operations. The Upper Deck contains manifold piping, valves as well as pig launchers and receivers. The Lower Deck supports the rigid piping from riser terminations, flow control and Emergency Shutdown valves (ESDs). All equipment associated with riser and anchor leg pull-in is also mounted on this deck. The Turntable Deck provides access from the rotating part of the turret to the stationary part, and is where the turrets main bearing is located. It is also through this deck that all loads are transferred from the turret to the vessel via the rigid arm. The Chaintable Deck contains all of the equipment and structure required to moor the FPSO and to terminate and hang subsea umbilicals and risers.


3.5.1. Mooring System

The mooring system for the turret is a 3 x 3 anchor leg arrangement. Lifting of anchor legs for hook-up and the tensioning of the mooring system is achieved through a permanently mounted winch in the fixed part of the turret.

3.5.2. Riser System

A total of 15 slots for risers and subsea umbilicals are provided within the FPSOs chain table. Lifting of risers and umbilicals, as with anchor legs, is achieved through a permanently mounted winch located in the fixed part of the turret.

Arrangement of Slots in Chaintable

Riser pigging equipment is located on the Turret Upper Deck, and consists of the following equipment:

Pig launcher/receiver for HP production Pig launcher/receiver for LP production Pigging pump (located on topsides)

The pigging system is designed for round-trip pigging with dead crude through either flowline. During pigging, the HP production manifold is used for backflow of dead crude from the pigging pump to the pig launcher in the turret.

The maximum launching pressure for pigs is 99 bar(g) (1440 psig).

Provision is also made to supply the pigging pumps with MGO for initial flowline dewatering prior to first well start-up.


3.5.3. Swivel Stack

The swivel stack inside the FPSOs turret has six (6) fluid/gas swivels, a utility swivel, and an electrical power/signal swivel. Looking from the lowest swivel upwards, the swivel stack is comprised of:-

12 inch double entry/exit HP Production swivel

12 inch double entry/exit LP Production swivel

10 inch single entry/exit Water Injection swivel

6 inch single entry/exit Pigging swivel

LP Utility swivel

Electric / signal swivel

HP Utility swivel

6 inch Gas Injection / Lift swivel

A seal arrangement and leak recovery system between each of the fluid/gas swivel elements prevents leakage to atmosphere, and provides leak detection.

A HIPPS (High Integrity Pressure Protection System) is also part of the design, and it protects the process system against overpressure in the incoming risers within the turret.


APPENDICES

Additional data on the FPSO is contained in the following appendices:

I. FPSO Equipment Capacity Summary

Table of Capacities (Topsides, Vessel, Turret)

II. Topsides

Gas Processing PFD 1 & 2 (post VIP configuration)

Oil Processing PFD (post VIP configuration)

Topsides General Arrangements

Key One Line Diagrams

III. Vessel Particulars

FPSO General Arrangement

FPSO Capacity Plan

Cargo System PFD

IV. Turret and Tandem Mooring Data

Turret Elevation

Turret Piping Production PFD (post VIP)

Turret PDMS

V. FPSO FALCON History

An overview of the FPSO FALCONS history is as listed below:-

1975 T/T ESSO KAWASAKI original construction, Kawasaki HI, Japan

2001 2002 FPSO FALCON conversion, Keppel Shipyard, Singapore

2002 Installed on Yoho Field, Nigeria operating as an FPSO

2005 VIP modifications made to FPSO topsides on Site Nigeria

2006 Demobilized and put into layup alongside in Singapore

The FPSO FALCON is currently still in her layup berth in Singapore, and is under continuous surveillance and periodic inspection and maintenance.

1. INTRODUCTION 2. FPSO GENERAL DESCRIPTION 3. FPSO BASIS OF DESIGN 3.1. Design Conditions 3.1.1. Location and Environmental Data for the FPSO Design 3.1.2. Operational limits

3.2. Classification, Rules, Standards, Codes and Certificates 3.2.1. Classification 3.2.2. Class and Regulatory Body Rules 3.2.3. Country of Registration

3.3. TOPSIDES FACILITY 3.3.1. Volume Improvement Project (VIP) Changes 3.3.2. Topsides Processing Facilities 3.3.3. Power Generation Capacity 3.3.4. Oil Processing System 3.3.5. Gas Processing Systems 3.3.6. Water Injection System 3.3.7. Utility Systems

3.4. VESSEL 3.4.1. Hull 3.4.2. Accommodation 3.4.3. Upper Deck Structures 3.4.4. Lifting, Handling and Warehousing 3.4.5. Corrosion Protection 3.4.6. Refrigeration 3.4.7. HVAC Systems 3.4.8. Propulsion System 3.4.9. Power Generation System 3.4.10. Ballast System 3.4.11. Sewage System 3.4.12. Steam and Condensate System 3.4.13. Fuel Systems 3.4.14. Lubricating Oil System 3.4.15. Compressed Air Systems 3.4.16. Valve Hydraulic System 3.4.17. Fresh Water System 3.4.18. Sea Water Systems 3.4.19. Bilge System 3.4.20. Slop System 3.4.21. Off Spec Oil Tank 3.4.22. Inert gas System 3.4.23. Fire Fighting, CO2 and Foam Systems 3.4.24. Safety and Life Saving Equipment 3.4.25. Tank Gauging System 3.4.26. Cargo and Crude Oil Washing System 3.4.27. Offloading Of Stabilized Crude. 3.4.28. Tandem Mooring And Offloading Systems.

3.5. TURRET AND MOORING SYSTEMS 3.5.1. Mooring System 3.5.2. Riser System 3.5.3. Swivel Stack

APPENDICES I. FPSO Equipment Capacity Summary II. Topsides III. Vessel Particulars IV. Turret and Tandem Mooring Data V. FPSO FALCON History

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