fpso overall design
DESCRIPTION
--TRANSCRIPT
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FLOATING OFFSHORESTRUCTURES
Ship-shaped:Floating Production, Storage andOffloading Systems
OE4652 Floating Structures
Ir. H. Boonstra
Offshore Engineering
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CONTENT
• Types
• Design drivers• Sizes
• Shapes
• General Arrangement• Systems
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WORLD FLEET FPSO
August 2005 data (Offshore Magazine)
• 99 operating units
• About 50/50 leased/operator owned
• 15 under construction or repair/modification• 1 LPG FPSOs
• 27 units being bid
142 altogether
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FPSO DISTRIBUTION JULY 2005
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FAMILY
• Regular Tankers
• SPM Terminals
• FSU (floating storage unit)
• FSO (floating storage & offloading unit)
• FPSO• FSRU (regasification)
• LNG-FPSO (liquefied natural gas)
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FPSO - why
• Recoverable asset
• Marginal fields (North Sea)
• Political stability (Nigeria)
• Re-use is feasible
• Lack of infrastructure (storage)
• Deep water
• Improve First Oil Date
• Parallel engineering
• Drill while you build
Anasuria
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FPSO – Layout
FALCON
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255 000 dwt
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GIRASSOL
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DESIGN DRIVERS
• Reservoir characteristics
• Field life/service life
• Site conditions
• Subsea development lay-out
• Regulatory standards & operator requirements
• Well intervention needs
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RESERVOIR CHARACTERISTICS
• Plateau production capability
• Pressure, temperature, viscosity
• Wax, asphaltenes
• CO2 and H2S content →materials, coatings
• Water cut → bpd throughput > bopd
• Gas content (GOR) → compression, gas swivel
• Water or gas injection
• Gas lift
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PRODUCTION PROFILE
Usually
peaking
up front
Water cut
influence
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SITE CONDITIONS
• Sea surface : wind, waves, currents →
spread mooring or weather-vaning• Waves : motions, accelerations →
workability; extreme motions, stresses; fatigue
•
Current profile for risers → vortex shedding• Water depth : risers, mooring system
• Sea bed soil conditions for anchors
• Air temperature → gas turbines
possibility of ice
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SUBSEA LAY-OUT
• Direct tie-backs versus manifolding
• Turret diameter and number of risers
• Limited passes through swivel
• Swivel complexity
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STANDARDS AND CODES
• Classification Society (Lloyds, ABS, DNV, etc.)
• Coastal State
• Flag State
• International Conventions : IMO, SOLAS, MARPOL
• Detailed standards : API, ASME, ISO, ILO, etc
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VESSEL SIZE DETERMINATION
• Field production rate (bopd)
• Oil specific gravity (ton/m3, degrees API)
• Shuttle tanker schedule, days between offloading
• Sea state persistence data
• Complexity, size & weight of process plant
• Gas disposal : use, export, re-inject
• Availability of ships (for conversion)
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SHUTTLE SCHEDULE
• Regular or irregular
• Effect of weather on mooring up / disconnecting
• Mechanical breakdowns
Result : FPSO storage capacity =
bopd x shuttle interval plus a 10 - 15% reserve
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CRITERIA FOR TRANSFER source : UKOOA
500-800 m Visibility
35-40 knots35-40 knotsWind speed
15 sec15 secMax wave period
9.5 m8 mMax wave height
5.5-6.0 m4.5 mSign wave height
DisconnectConnect
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PERSISTENCE DATAexample : Gulf of Thailand
All year persistence of significant wave height
Threshold Lar er than threshold Smaller than threshold
m Duration Duration
Mean (hr) Max(hr) % of time Mean (hr) Max(hr) % of time
0.5 91 1091 69.5 49 1541 30.5
1 45 348 21.8 138 2861 78.21.5 27 185 5.7 357 6758 94.3
2 22 127 1.4 1093 7751 98.6
2.5 17 102 0.4 3009 8758 99.6
3 18 63 0.2 4373 8782 99.8
3.5 14 43 0.1 6254 8782 99.94 11 11 0 7965 8782 100
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DESIGN STEPS
• Determine total storage tank capacity
• Max. filling of tanks typically 98%
• Determine dwt capacity requirement
• Add estimated weight of the process plant
• From comparable ships, estimate main dimensions andlightweight or steelweight
• Allow for project specifics (e.g. turret)
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MAIN DIMENSIONS
• Largely determined by deadweight capacity
• Sometimes restriction of draught
• In North Sea and similar : risk of green water on deck / slamming on bow : ship shape with high freeboard atbow
• In benign areas : barge shape (cheaper to build)
L = length between pp B = width, beam
T = draft D = depth
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TANKER DWT-VOLUME RATIOTank Capaci t ies, 1923 ship s
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
0 100,000 200,000 300,000 400,000 500,000 600,000
DW T
T a n k v o l u m
e ,
t h o u s a n d b a r r e l s
Abt 7.5 bbls/ton
s.g.~ 0.84 ton/m3
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FPSO DWT-VOLUME RATIO
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STORAGE-PRODUCTION RATIO
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RESERVES-PRODUCTION
MMboe
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TANKER LENGTHLength of Tankers, 1923 ships
0,00
50,00
100,00
150,00
200,00
250,00
300,00
350,00
400,00
450,00
500,00
0 100.000 200.000 300.000 400.000 500.000 600.000
DWT
L e n
g t h b e t w e e n P P ,
215+ 0.00037 dwt
for 100-300 kdwt
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TANKER BEAMBeam of tankers, 1923 ships
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
0 100,000 200,000 300,000 400,000 500,000 600,000
Deadweight tonnage
M o u l d e d b e a m
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OIL TANKER LIGHTWEIGHT
0
0,05
0,1
0,15
0,2
0 100000 200000 300000 400000
Deadw eight Capaci ty (at full draught)
lwt/dwt
lwt/LBD
Linear (lwt/LBD)
Linear (lwt/dwt)
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DESIGN APPROACH
• Determine the required storage capacity
• Start with an “educated” guess of dimensions• Determine scantlings, based on Rules or first principles
• Check the required storage volume, weight capacity
•
Include reasonable volume for water ballast• Change dimensions and start again
The lwt/dwt statistics of tankers enable a bypass of the
cumbersome determination of scantlings
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FPSO DIMENSIONS
Always check :
• displacement = ρgCBLBT + skin, appendices• displacement = lightweight (incl. process plant) + deadweight +
suspended items (risers, anchor lines)
• deadweight = cargo weight + fuel + fluids in systems + crew +
miscellaneous• T max = D - freeboard
• Minimum freeboard determined by ship rules, for large tankersabt. 6 m
• Positive GM (GM = MB + BK – GK)
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SHAPES AND TYPES
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TYPES
• New-built or conversion
• Ship-shape or barge-shape
• Oil, LPG, LNG
• Spread moored or weather-vaning
• Internal or external turret
• Midship, bow, stern position
• Tandem or side-by-side offloading
• Gas re-injection or sales (pipeline)
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FPSO SHAPE Ship Shape•
In North Sea and similar•Green water on deck
•Risk of slamming at bow
•High freeboard at bow
•Or :because of conversion
Barge shape•Benign areas
•Cheaper to build
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CONVERSION VERSUS NEW
BUILDING
• Available time from decision to first oil
• Cost aspects
• Lifetime (fatigue considerations)
• Availability of appropriate conversion tanker
• size
• age
• history of use
• New built may be ship-shape or barge-shape
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DESIGN OF ARRANGEMENT
• Spread mooring or SPM
• SPM midship, internal in bow, external to bow
• Side or tandem offloading
• Flare tower or ground flare; position
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DESIGN OF ARRANGEMENT
• Accommodation (living quarters, LQ) : position upwind
or downwind of the process plant• Separation between LQ and flare
• Heliport unrestricted access
• Process plant subdivision• Thruster (at stern)
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MOORING
Soft Yoke (Nigeria)
Internal Turret (UK)
Spread Moored (Nigeria, risers attachedto side)
DP (China, temporarily)
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OFFLOADINGTandem
• Usually within 24 hours• Sea-state limits for mooring
up and for remaining
moored• Shuttle tanker may be
purpose built or a tanker of convenience
Side by sideSPM
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FPSO BRASIL
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255 000 dwt
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BLEO HOLM
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GIRASSOL
LNG FSRU NEW BUILT
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LNG FSRU – NEW BUILT
• SBM design
LNG FSRU CONVERSION
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LNG FSRU – CONVERSION
• SBM design
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PROCESS PLANT
PROCESS PLANT
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PROCESS PLANT
• At elevation above tank deck
• Subdivided in functional Pre-Assembled Units (PAUs), “pancakes”
• Multitude of interconnections
•Small to large
• 2 000 – 30 000 tonnes
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DEMOLITION OF EXISTING
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DEMOLITION OF EXISTING
DECK STRUCTURES
ELEVATED DECK
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ELEVATED DECK
• Typically 2.5 m above (closed) main deck
• Minimizes impact of green water
• Provides natural ventilation
• Separates (explosions in) topsides from cargo tanks
• For Northern North Sea:
Green water : elevation above still water to be taken 18-
22 m at bow, 10-12 m midship and stern
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(FPSO) PROCESS PLANT
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(FPSO) PROCESS PLANT• Separation Oil, Gas, Water
• Stabilized crude oil storage
• Gas handling – compressors, dehydration
• Water cleaning & disposal• Cooling and heating
• Flare
• Injection : gas, water, chemicals
• Gas lift
• Utilities
FIELD SPECIFIC !!
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Glas Dowr CSU load-out
STRUCTURAL WEIGHT PROCESS FACILITIES
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STRUCTURAL WEIGHT PROCESS FACILITIES
• Depends on flat versus 3D Pre-Assembled Units (PAU)
• Typically 30-40 % of total PAU weight• Self bearing structure for
• Load out
• Installation by heavy lift• Decoupling from ship’s hogging/sagging
ASSEMBLY
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ASSEMBLY
• "Pancake approach" saves time (ideally)
• .....but adds weight• Planning and logistics are essential
• Don't wait, expedite
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LIFTING PROVISIONS
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LIFTING PROVISIONS
TYPICAL COMPLETED TOPSIDES
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TYPICAL COMPLETED TOPSIDES
OIL PROCESSING MODULES
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OIL PROCESSING MODULES
Oil Separation LP
Oil Separation HP
GAS COMPRESSION MODULES
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Gas Process
Flare Stack
HP/LP Flare Knockout
Gas Compression
Gas Treatment
WATER INJECTION MODULES
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Water Treatment
Water Injection
STEAM / POWER
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Power Generation
Steam Generation
/
GENERATION
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FPSO SYSTEMS
Safety
Cargo Handling
Miscellaneous
Operation
Support Systems
SAFETY
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Fire and Gas
Emergency shut downDeluge
Safe Haven / Temporary Refuge
Emergency lighting Access and escape
Life boats, life rafts, helicopter
Seabed safety valve
FIRE FIGHTING
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• Pressurized fire mains throughout ship
•
Deluge system in specific areas• Sprinkler system in accommodation
• CO2 or other system in ship engine room
• Foam system on helideck
• Main fire pumps + jockey pump• Diesel driven emergency fire pump
• Fire & Gas detection system, monitored in CCR
ACCESS & ESCAPE
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• Main access by helicopter
• Heliport includes safety induction room• Escape by helicopter or boat
• conventional closed life boats
•free fall boats
• Life rafts as required by IMO
• Fast Rescue Craft
OPERATION
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Central Control Room
Power generation
Power distribution
Uninterruptable Power Supply
Remote cargo valve control
Material handling / laydown
Fresh/potable water
Tank monitoring
CARGO HANDLING
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Crude distribution
Tank monitoringFiscal metering
Offloading
Inert gas & tank ventilationBallast
Corrosion protection
CARGO
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• Central pumproom or deepwell/submersible pumps
• Single or multiple segregations
• Tank level gauges
• Settling tank(s)
• Slop tank(s)
• Cargo control system
• Remote control of valves
• Sloshing and free surface effects
CRUDE STORAGE TANKS
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• Storage tanks for 5-10-20 days peak production
• Storage for off-spec production• Max size per tank 30,000 m³ (MARPOL)
• Slop tank(s)
•
Segregated ballast tanks• Double hull principle : not (yet) required for FPSO
• Volatile Organic Compounds (VOC) control in crudetanks
INERT GAS
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• Purpose : preventing explosive conditions
• IG generator or stack exhaust gas• VOC’s depend on crude composition
• Crude flammability grade A-E depends on vapor
pressure (RVP measured at 31.8° C) and flash point• Lighter crude usually is more flammable
BALLAST
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• Purpose : draft and trim control
• Always segregated ballast tanks• Mainly wing tanks + peak tanks
• Corrosion protection
•
Inspection
OFFLOADING
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• Tandem shuttle mooring
• hawser• offloading hose
• quick release provisions
•
shuttle collision risk • Side by side shuttle mooring (unusual)
• Separate SPM berth (spread moored FPSO)
•
Fiscal metering system
GLAS DOWR
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Reel for theoffloading hose
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GLAS DOWR
Offloading hose reel
GLAS DOWR
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Bunker hose and hawser reels
TANDEM OFFLOADING TO
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MIDSHIP
SUPPORT SYSTEMS
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Pig launcher & receiver
Material handlingCrude oil washing
Anchor line tensioning
Cooling & heatingDrain systems
UTILITIES
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• Neither ship nor process
•Power plant for compressors, process etc
• Disposed water treatment
MATERIAL HANDLING
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• Deck crane(s)
•Lay down area(s)
• Trolleys, deck equipment
• Swivel module handling system
MISCELLANEOUS
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Accommodation
Communications and Public Address System
Shipboard power distributionHVAC
Seawater
Fresh water
Grey water, sewage treatment, incinerator
Fuel, lubrication oil
Thruster
ACCOMMODATION
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• Position of living quarters upwind or downwind of
process area• Safe Haven /Temporary Safe Refuge
• Central Control Room
• Client cabin(s) and office
• Temporary accommodation of larger maintenancecrews
HVAC (heating, ventilation, air-conditioning)
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• Forced ventilation in living quarters and hull
•
Natural ventilation of process plant• HVAC designed for worldwide conditions
• Flaps in air ducts close on fire alarm
FUEL & LUB OIL
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• Concentrated in ship’s engine room
•
Diesel pipeline to gas turbines in utilities• Supply by supply boat or shuttle tanker
FRESH WATER
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• Fresh water makers on waste heat or board net
•
Sewage treatment unit• Engine cooling may be on closed fresh water circuit
THRUSTER(S)
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• Requirement with midship turret
•
Sometimes with bow turret• Automatic thrust control, heading feedback