FPSO Book Preview

DESIGN AND TECHNOLOGY

Bruno Ban Msc. O.M.E.E.

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CONTENT

FPSO MARKET . . . . Page 1 20 FPSO Introduction Why an FPSO? What Makes FPSOs So Important? FPSO Market Presented by Geographical Regions Characteristics of the Geographical Areas Typical North Sea Weather Conditions (illustrated) Typical Field Layouts Global Annual Crude Oil Production by Region Global Annual Gas Production by Region Active and Planned Vessels (FPSOs) Deployment of FPSOs Supply and Demand Balance (challenges) Market Changes Specialist FPSO Contractor Market New Built versus Conversion Market Approach (New FPSO by Region) FPSO Outlook Positive

FPSO DESIGN AND TECHNOLOGY . . . . . . Page 21 - 96 Type of Floaters (general) FPSO Project Phase Factors Influencing FPSO Specification Key FPSO Components Functional Specification

Design Elements Design Concept Design Principles Project Execution HSE Principles Operating Principles Commissioning Principles Field and Reservoir Data Design Life Ship Classification Design and Construction Verification General Arrangement (Drawing) Applicable Safety Critical Elements Ship Motion, Acceleration and Deflections Shuttle Tanker Offloading Limits (Example) Process Data for FPSO Utility Systems (Example) Mechanical Handling


Start-up and Shutdown Philosophy FPSO Interfaces Vessel Description

FPSO Particulars Vessel Layout Ship Systems Utility System

Shipbuilding and Offshore Approach Understanding Ship Building and Offshore Approach Hull Design

Main Particulars General Arrangement and Tank Layout Still Water Loads Minimum Freeboard Weight Control Stability

FPSO Hull Design Process Adopting Design Process Design Spiral FPSO Simplified Hull Design Procedure Design Optimization Topside Interface Loads related to Motion and Deformation Rule Based Loads Design Impact Mooring and Topside Interface Materials Hull Loads Topside Interface Loads Stress Buckling and Fatigue

Hull and Topsides Structural Interfaces Hull Structure Design Construction Considerations Interface Drawing Deformation Effects Deformation Categories Interfaces Support Girder Design Relative Displacement Between PAUs

VESSEL - TANKER Page 97 - 110 Tanker Type Size and Price Comparison Vessel Selection Vessel Inspection Scheme Vessel Repair and Life Extension Requirements Prior to Conversion into FPSO Hull Condition Assessment Tanker General Arrangement (Drawing)


MOORING DESIGN AND ARRANGEMENTS (STATION KEEPING) Page 111 - 164 Type of Mooring Systems

Spread Mooring System Turret Mooring System

Interfaces Load Transfer for a Turret Mooring System Turret Bearing Systems and Arrangements Effecting Turret Lessons Learned

Internal Turret Mooring System and Disconnectable Internal Passive Turret Internal Active Turret

External Turret Mooring System and Disconnectable CALM (Catenary Anchor Leg Mooring) SALM (Single Leg Anchor Mooring) Historic Developments from CALM and SALM Systems DP (Dynamic Positioning) Tower Mooring

Turret or Spread Mooring Design Mooring System Selection Scheme Turret Installation Challenges Permanent versus Disconnectable FPSO FPSO Turret - Swivel System

Swivel and Fluid Transfer System (FTS) Types of Fluid Transfer Systems Swivel Design Philosophy Swivel Specification Swivel Manufacturers

Riser and Subsea Riser Interface Coupled Risers Un-Coupled Risers Riser Turret Vessel Interfaces Sub-Sea Interface Mooring Line Configuration at the Vessel Interface Challenges

OFFLOADING (EXPORT) . . . Page 165 - 180 General Offloading Offloading Risks Cargo Control System Green Line Cargo Tanks Cargo Pumps and Export Line Cargo Valves and Controls Cargo Offloading Bow and Stern Equipment Emergency Shutdown and Release


Cargo Oil Metering Unit Metering Application Cargo Sampling Unit and Line Flushing Tanker Mooring Equipment (Hawser and QR [ quick release]) Communication Telemetry

FPSO TOPSIDE DESIGN & REQUIREMENTS . . . Page 181 - 238 Overview Availability Material Selection Structural Design

Structural Configuration of Topsides Design Considerations Topsides Design Structural Design Topsides Support Configuration Topsides Layout

Topsides Process System Concept Selection Preparing the Basic Design of the Separation System Gas/Liquid Separation Crude Processing Gas Handling Systems Gas Processing Requirements Gas Compression Recycle Compression Export Compression Dehydration Produced Water Treatment Water Injection

Power and Heating Power System Power Requirements Vessel (existing system) Heating Requirements Fuel Gas Requirements Environmental Requirements Operational Issues Heating System

Utility Systems Utility Systems Available within the Vessel (for Topsides)

Firewater Seawater and Electro Chlorination Steam Open Drains Compressed Air System Diesel Supply Potable Water


Aviation Fuel Overboard Discharges (seawater and produced water after treatment)

Utility Systems Integrated within the Topsides Fuel Gas Heating System/WHR Closed Cooling Water System Seawater Filtration and Treatment Chemical Injection System Flare Nitrogen Closed Drains Freshwater for Crude Desalination Process Cooling Water

Utility System Available within the Vessel and Integrated within the Topsides HVAC

Centralized System and Control Philosophy De-centralized Centralized and Distributed Recommendation

Control and Safety System PCS Process Control System PSD Process Shutdown System F&G Fire and Gas System ESD Emergency Shutdown System Subsea Control System Production Hydraulic Power System

Other Design Requirements Electrical Design Instrumentation Design Telecommunication Mechanical Design Piping Design Heat Tracing and Insulation Corrosion Monitoring (Topsides equipment and piping)

Topsides Installation Challenges Successful Topside Design Corrosion Protection

Hull FPSO Cathodic Protection Design Challenges


CONSTRUCTION/COMPLETION, PRE-COMMISSIONING AND COMMISSIONING . . . Page 239 - 256

General Commissioning Guiding Principals Commissioning Phases Timeframe MC Mechanical Completion Pre-Commissioning Commissioning Completions Flowchart Completions Certificate Flow Post Commissioning Summary of Completion Activities and Milestones

RULES AND REGULATIONS, CODES AND STANDARDS . . . Page 257 - 274 General Classification and Regulations Statutory Regulations (Coastal State Requirements) Flag State Requirements Flagging National and International Rules and Regulations, Codes and Standards List of Selected Industry Standards

LESSONS LEARNED . . . . . . Page 275 - 280 Key Factors Commercial Safe Execution

TERMS AND ABBREVIATIONS . . Page 281 - 286

SOURCES OF INFORMATION . . . . . . Page 287 - 289


B r u n o B a n M s c O . M . M . E

Bruno Ban is an Electrical Engineer (MSc) and Maritime Transport Engineer (BSc) who has over 35 years of experience in the maritime, oshore oil & gas industry. His wealth of knowledge and experience, ranging from service engineering, trouble shooting and operations to commissioning, construction and project management, has contributed to many successful projects worldwide. Past projects include a wide range of installations (mobile, xed and subsea), such as FPSOs, DP (Dynamic Positioning) vessels, petrochemical plants, pipe layers and subsea interfaces. Bruno worked for major oshore O&G companies until 2000, when he set up his own company BBOMC Ltd., continuing to provide technical and management support, training, and consulting to the industry. In recent years Bruno has committed himself to the Floating Production Industry, studying and analyzing the industrys behavior, technical requirements, developments and progress. This book is the product of the authors vast experience and is an invaluable resource for understanding the technical value and complexity of FPSOs and such installations.

ABOUT THE AUTHOR

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