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OTC 18544

Dalia Development - The FPSO Story and Package Challenges! "o#illerat$ ! %egna#lt$ Total &'P (ngola) *! +ero#,$ Technip D"P.

Copyright /00$ O22shore Technology Con2erence

This paper 3as prepared 2or presentation at the /00 O22shore Technology Con2erence held ino#ston$ Te,as$ !S!(!$ 60 (pril-6 "ay /00!

This paper 3as selected 2or presentation 7y an OTC Program Committee 2ollo3ing revie3 o2in2ormation contained in an a7stract s#7mitted 7y the a#thors.! Contents o2 the paper$ aspresented$ have not 7een revie3ed 7y the O22shore Technology Con2erence and are s#7ect tocorrection 7y the a#thors.! The material$ as presented$ does not necessarily re2lect anyposition o2 the O22shore Technology Con2erence$ its o22icers$ or mem7ers! Papers presented atOTC are s#7ect to p#7lication revie3 7y Sponsor Society Committees o2 the O22shoreTechnology Con2erence! &lectronic reprod#ction$ distri7#tion$ or storage o2 any part o2 thispaper 2or commercial p#rposes 3itho#t the 3ritten consent o2 the O22shore TechnologyCon2erence is prohi7ited! Permission to reprod#ce in print is restricted to an a7stract o2 notmore than 600 3ords) ill#strations may not 7e copied! The a7stract m#st contain conspic#o#sackno3ledgment o2 3here and 7y 3hom the paper 3as presented! 9rite +i7rarian$ OTC$ P!O!:o, 86686;$ %ichardson$ T< 5086-686;$ !S!(!$ 2a, 01-=/-=5/-=465!

Abstract

This paper will review the hull design together with topsidesprocess modules and functions.

It will also focus on the schedule challenges duringconstruction in Korea, the steel crisis and the yards workloads.

The global supply chain and management of the contractorsand main subcontractors will also be addressed.

Designed and built by Dalia Mar rofundo !DM", a

consortium of Technip # $aipem # $tolt in the T$$ %ointventure together with $amsung &eavy Industries !$&I" and

Daewoo $hipbuilding ' Marine (ngineering !D$M(" inKorea, the )$* is + metres long and - metres wide

capable of millions barrels oil storage at an averageproduction capacity of /, barrels per day. It has a 0totalli1uid2 handling capacity of /3, barrels per day and a gascompressing capacity of 4 million sm+per day. A special

seawater treatment for sulphate removal module isincorporated. $&I undertook the task of building the 33,

tonnes double skinned hull and 0about half2 of the topsidemodules. D$M( completed the remaining modules and

undertook the installation and integration of all the topsidesmodules before sail away. T$$ had the responsibility foronshore pre and final commissioning.The )$* is moored with a 5 point chain spread linked to 56

metre high, 5- tonnes suction anchors and attached to the

vessel by 5 mm diameter, sheated cables 5,4 metres long,with 5 metre chain segments at either end. 7eight controlwas very effective maintaining the weight within the original

targets.

Dalia )ield *verview)or more details refer to Dalia paper *T8 543+4.

9efer to )igure 5 for the general field layout with the )$* andits mooring lines, above the subsea production facilities.

)igure 5 : Dalia Development ;ayout

8

before storage.roduced water is treated and re:in%ected into the reservoir for

pressure maintenance. $eawater is treated to complement thetotal in%ection capacity of /3, barrels of water per day.

roduced gas is used as fuel and the balance is re:in%ected inthe reservoir until e?port to the future Angola ;@< plant.Three / M7

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electrical, hydraulic and &CA8 e1uipment as well as office

space are located. In all, there are 5+6 rooms with the lowerlevels comprising of technical workshops, offices and

changing facilities. *ne full level is dedicated to the kitchenand a restaurant. There are also rela?ation areas including amain lounge, library, television rooms, cinema and a gym.)our personnel, who manage everything on the vessel from

the subsea production facilities, the topside processing and

other marine activities and utilities, also in the same block,man the control room. The helideck !for $uper uma

helicopters" and telecommunication tower are installed on the topdeck. The accommodation block is also the ultimate

refuge, being gas tight and built to resist hydrocarbon fires or

even e?plosions. In case of evacuation the personnel will

board the four self propelled, free fall, survival craft, with acapacity of / seats. Two davit launched lifeboats are located at

the bow, with a capacity of 6 seats and two more marine

evacuation systems are also available.Detailed design began for the )$* work package when the

pro%ect was given the green light end April +. The firststeel was cut at the $&I shipyard in Banuary / and

construction began immediately after for the /3 blocksforming the hull. The main hull e1uipment, such as the

electrical power generators, cargo oil pumps, ballast pumps,hydraulic power units and firewater pumps were installed

before the hull was launched in August, a ma%or milestoneachieved only eight months after first steel was cut. The hull

then floated along the 1uay whilst the main accommodationblock was installed together with some structural supports !toreceive the process modules" and the central piping rack. *ncompletion, the hull was towed to the D$M( yard on the other

side of the Ko%e Island, where the topside modules wereinstalled. The modules have been fabricated at both $&I and

D$M( shipyards. $&I supply included the crude oil

separation, power generation and oil offloading e?portmodules, whilst D$M( supplied amongst others, the waterin%ection and gas compression together with the flare, pipe

racks and manifolds. All the topside modules were installedbetween mid May and mid Bune 3. The ne?t phase saw theintegration of the piping connections and cabling betweenmodules. )$* Dalia receiving not less than 3, pipe

spools, 5,+ km of cables and appro? -, m of paint.*nshore commissioning was the final work performed on the

)$* prior to sail away from D$M( in March -.At the peak of the construction activities, nearly three and a

half thousand personnel were working together at both $&Iand D$M( yards. )rom Banuary / until sail away, nearly4,, person:hours were spent within a creditable &$(

performance.)$* Dalia left Korea +/ months after contract award andwithin days of the original schedule date and arrived in the field

on the nd of $eptember -.

&ull Design and 8onstruction by $&I !)igures to 3"

The hull is of a double skinned design, with side ballast tanks

over the full length of the cargo tanks, two fore and two aft peak

ballast tanks. The main characteristics and capacities areE ; ?F ? DE + metres ? - metres ? ++. metres

Design draughtE /.+ metres

OTC 18544

DisplacementE /5-, tonnes

&ull light shipE 3/,+4 tonnes

Topside operating weightE +6,/ tonnes Mooring

loadsE ,+/ tonnes

9iser loadsE /,/3 tonnes

*il *ffloading ;inesE +- tonnes

5 8argo tanks with a total capacity of ,, barrels

slop tanks, 5 ballast tanks, 3 diesel oil tanks, methanoltanks, / fresh water tanks and bilge tanks.

The main tanks are e1ually distributed portside and starboarcofferdams installed between the methanol and cargo tan

between the machinery space and the cargo tanks. 8protection of the hull is performed by sacrificial anodes in thAll ballast tanks are painted and the hull e?terior is protecteimpressed current system.

An aerial view of the Korean yards is shown in )igure +

together with hull construction views in )igures / and 3.

Fire P#mps

ydra#lic Po3er nits / &ssential ' 1 &mergency enerators 1448 k9 /1/0

/ sets o2 5,00>3 6 "9) 11k? 50h@ m6Ah

4 Free2all

li2e 7oats

Fire P#mps / Davit la#nched li2e 7oats1448 k9 /1/0

m6Ah

4 "ethanol P#mps/ :allast P#mps

1/ Cargo Oil P#mps / Slop P#mps B / Skimming P#mps

)igure : )$* &ull : Main (1uipment ' ;ocation

)igure +a : $&I Gard

)igure +b : D$M( Gard

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P6/$ P41 ' P4/ "od#le erection stat#s Dec! /004

)igure 4a : Topsides : $&I 8onstruction

P6/$ P41 ' P4/ "od#le erection stat#s Fe7! /005

)igure 4b : Topsides : $&I 8onstruction

P6/$ P41 ' P4/ "od#le erection stat#s "arch /005

)igure 4c : Topsides : $&I 8onstruction

as Compression Train ( :P5/ mod#le complete

)igure : Topsides : D$M( 8onstruction

OTC 18544

)igure 5a : Topsides : &ull Deck before Module Installation

)igure 5b : Topsides &eating Medium Module : Installation

)igure 55a : Topsides 8ompletion

)igure 55b : Topsides 8ompletion

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OTC 18544

Innovative rocess to Manage Dalia &eavy *il

8rude separation and treatment

)luids from each production header are routed to twoidentical trains, which consist of a first stage separator, a

dehydrator, a second stage separator and a desalter. (ach train isdesigned to produce 33= of the average production capacity of/, barrels per day.

The first stage separator is a three:phase separatoroperating at 5 bars. Due to high emulsion forming tendency of

the crude, the phase inversion process achieves oil andwater separation, by re:circulating the produced water at the inlet

of the separator. In addition there is a heater in the

recycle line to maintain the separator inlet at 3>8. nder

pressure control, the flash gas from the separator is routed to the& gas manifold. The water from the separator is routed to the

water treatment system. The water is removed under

pressure because of the potential of naphthenate deposition. The

retention time is 3 minutes for oil and water.The water#oil emulsion from the first stage separator is

pumped to the crude#crude e?changer, which e?changes heat

with the hot crude to storage. The crude is then heated furtherto ->8 in the heating medium e?changer and routed to thedehydrator which achieves an outlet F$'7 of .3=. The

produced water is routed back to the inlet of the first stageseparator.

The crude is then flashed at 5.- bars in the second stagetwo phase separator with gas routed under pressure to thesuction of the ; compressor. The retention time is +minutesfor oil only.

The crude is pumped to the desalter. 7ash water is addedupstream of the desalter inlet at >8. The produced water and

wash water is pumped back to downstream of the crude heater.The oil is first cooled down in the crude#crude e?changer

and the crude rundown cooler to 3>8. The crude then mi?eswith the crude from the second separation train prior toentering the cargo tanks below deck.

$and Betting*nline sand %etting is provided to the first stage and test

separator and the dehydrator. The second stage separator and the

desalter are provided with offline sand %etting.

$lug &andling

The slug management is primarily based on riser gas lift

and chokes in the production manifold on top of the risers.

The first stage separator is designed to handle 3 mJ ofhydrodynamic slugs, based on coincident slugging from the two

flowlines in a production loop.rovision is made for deck mounted slug:catchers, as a

contingency plan, in case of higher than e?pectedhydrodynamics slugs.

Topside roduction Manifolds

The topside production manifolds interface the subsea IFrisers !eight risers serving the four loops" with the two

production headers and with the test header. They alsointegrate pigging facilities with permanent provision forspherical pigs and temporary provisions for intelligent pigs. Themanifolds can also be used to direct dead crude from a

cargo tank into any production loop to prevent hydrate

formation in case of shut down.

Integrated 8ontrol and $afety $ystem

The simplified Integrated 8ontrol and $afety !I8$$" schematic and its principal functions are show in )igure 5.

9orkstation

CSS :#s

Fo,7oro :rocess 8ontrol $ystem

Controller :rocess $hutdown $ystem:&ull 8ontrol $ystem

:$ubsea 8ontrol nit

:&ydraulic ower nit

:Marine functions including

storage, ballasting, offloading

:!not D8$"

Direct AO

Tricone, 5=; SSS

%emote Controller 1;88 FS

mod#les

Sa2ety :#s

;604 total direct topsides AO

DA;IA I#*

Traditional direct AO 15;0 total hard AO incl package

18=/ serial AO package///; PCS 100000 ra3 s#7sea data o2 3hich1=4 PSS 15000 s#7sea data sent to CSS

-Package inter2ace #sing ;6 serial links 150 displays 0G 2or s#7sea.-Fast OPC ethernet links 7et3een CSS and s#7sea

)igure 5 : Dalia I8$$ fully distributed across - Technical 9ooms

Mechanical 8ompletion and Gard 8ommissioningThe final stages of mechanical completion and commissioningincluded connecting all the piping, terminating the electrical

cables and performing the final tests, notably all the hydroteststo confirm all the pressure containments. After clearing all the

ma%or items on the various punch lists, the efforts wereconcentrated on the commissioning phase. Additional

personnel were mobilised to cover several taskssimultaneously, re1uiring some night work for leak testing 'hydrotests, to ensure the sail away delivery dead line. Theminor commissioning activities remaining were completed

during the voyage.

7eight 8ontrol to Meet *riginal Targets !)igure 5+"Management of the topside weight was specified in the lumcontract awarded to DM.

enalties covering special events and weight control were

agreed by DM, based on issuing a first weight report twomonths after contract award. This report was based on Total

specification with estimated dry and gross weight and centre

of gravity position together with stability curves according to

I8;; based selected hull and selected hull contractor. The

I8;; stability curve was not to e?ceed conditions based onE

@et and gross values issued from weight reports, checked

and accepted by Total, inclusive of all weights identifiedfor itemised and bulk items, live loads, futures andoperating fluids.

A mutually agreed allowance for centre of gravity positionand weight based on the weight report result. (?ceeding

these values carried a DM agreed penalty clause.

Fetween contract award and Buly 3 control of thevarious modules was closely monitored with 5+ revisions

of the weight report.

ltimately, with the close control and cooperation betweenall parties, weight control was effectively managed, asshown below.

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)igure 5+ : Total *peration 7eight !tonnes"

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