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Isope I 07 054 PDF
Isope I 07 054 PDF
Sixteenth (2007)
(2007)
International
International
Offshore
Offshore
andand
Polar
Polar
Engineering
Engineering
Conference
Conference
Lisbon, Portugal, July 1-6, 2007
Copyright 2007 by The International Society of Offshore and Polar Engineers(ISOPE)
ISBN 978-1-880653-68-5; ISBN 1-880653-68-0(Set); ISSN 1098-6189 (Set)
The Comparison of Various SCR configurations for Bow Turret Moored FPSO in West Africa
Mason Wu, Kevin Huang
Acergy, North America and Mexico
Houston, TX, USA,
installation of the SCR riser (Tenet, 2006), pull-in system (Judd, 2005)
and FPSO (Xavier, 2006) are also shown in the literature. We have also
carried out the conceptual evaluations for several SCR related
configurations for Bow Turret Moored FPSO, which has gained more
popularity in the latest deepwater field development in West Africa
(Wyllie, 2006). Bow Turret Moored FPSO has a number of advantages,
including high schedule flexibility, and possible parallel component
construction resulting in lower total construction cost. One of its
disadvantages is that the heave motion at the turret is relatively higher
than that of the conventional FPSOs. This excessive heave motion
could cause large quantity of high stress cycles within the riser. One
possible solution is to use SCRs with high quality welds at certain
critical locations to provide satisfactory fatigue performance.
Consequently, this option would impose challenges on the welding
procedures and quality control of the welds. Another potential design
issue for SCR is the high compression load at the touchdown point for
thermally insulated risers. A proven concept to solve both of the fatigue
and compression problems is to use the full Lazy wave type of SCRs,
with large quantity of buoyancy modules attached to the riser to decouple the FPSO motions from the riser TDP. However, this solution is
also quite expensive due to the cost of buoyancy modules as well as the
cost to install them. Thus, a mini-lazy wave type of SCR configuration
is proposed as a candidate of more cost-effective solution. At the same
time, a weighted SCR by clamping heavy collars near the TDP to
mitigate the FPSO motions has also been studied. Comparing to the
buoyancy modules, the clamp weights cost less in hardware and
installation as well. To cover a wider range of FPSO applications, the
riser assessment is carried out on both AFRAMAX and VLCC classes.
ABSTRACT
This paper presents a high-level study of three different Steel Catenary
Riser (SCR) configurations and the associated strength and fatigue
requirements for Bow Turret Moored Floating Production Storage and
Offloading (FPSO) system in West Africa environment. The three SCR
configurations that have been studied are: simple SCR, weighted SCR
and Mini-Lazy Wave (MLW) SCR. This study is intended to provide
the performance comparisons among these riser configurations,
particularly the dynamic response characteristics at the touch down
point (TDP). The study results reveal that the MLW SCR has the best
performance for both fatigue and strength, followed by the weighted
SCR and then the simple SCR. For the strength assessment, MLW SCR
provides satisfactory von Mises stresses, and completely eliminates the
riser compression at the TDP, where high compressions for the Simple
SCR and moderate compression for the weighted SCR are observed.
For the fatigue assessment, comparing to the simple SCR, the MLW
SCR significantly improves the fatigue performance at the TDP, while
the weighted SCR provides marginally better fatigue performance as
well. It is concluded that the MLW is a promising configuration for
bow turret moored FPSO applications in West Africa environment, and
deserves further assessment.
INTRODUCTION
For the Deep Water riser applications, SCRs (Quintin et al. 2007),
Hybrid Riser Towers (HRTs), and flexible risers are the most popularly
used concepts. Flexible risers are generally motion tolerant, but costly
and limited in size and pressure rating. Therefore, there is always an
interest to extend the application scope for SCRs, and/or the variation
version of SCRs. Some general comparisons between SCRs and HRTs
have been performed by Alliot et al. (2005), Wu et al. (2006), and
Blevins et al. (2007).
Recent years have seen the first uses of steel catenary risers (Legras,
2006, Nolop et al. 2007) with spread moored FPSOs for deepwater
field developments in West Africa. The lessons learnt from the
788
DESIGN BASIS
Table 3. Design Wave Parameters
The studied riser system for the turret-moored FPSO consists of three
10 insulated production lines, one 10 water injection line, one 8 gas
injection line, and one 4 gas lift line. The riser parameters are listed in
Table 1. The design pressure is 5,500psi (37.9Mpa) for production riser
and 4,500psi (31Mpa) for injection and gas lift riser.
Table 1. General Riser Data
Riser Type
Production
Water Injection
Gas Injection
Gas Lift
Number
OD in (mm)
3
1
1
1
10.75 (273.1)
10.75 (273.1)
8.75 (222.25)
4.56 (115.82)
Parameter
Swell Hs (m)
Swell Tp (s)
Associated Sea Hs (m)
Associated Sea Tp (s)
In (mm)
In (mm)
deg
Ksi (MPa)
In (mm)
%
In (mm)
In (mm)
lb/ft 3 (kg/m3)
In
lb/ft 3 (kg/m3)
3
8.75 (222.25)
10.75 (273.1)
9 or 15
API 5L X65
65 (448)
1 (25.4)
12.5
0.12 (3)
GSPP
3.5 (88.9)
45 (720)
FBE/TSE
0.12 (3)
85 (1360)
ft
lb/ft (kg/m)
lb/ft (kg/m)
lb/ft (kg/m)
FBE
656.2 (200)
48 (71.4)
156 (232)
183 (272)
lb/ft (kg/m)
lb/ft (kg/m)
43 (64)
70 (104)
kip-ft 2 (kg-m2)
71,628 (3017)
Kip (Te)
840,650 (381)
Axial Stiffness
1000-yr
4.5
13.5
1
6
15.5
1
6
16
1.5
6
Production Riser
Number of Risers
Minimum Nominal ID
Pipe OD
Riser Top Angle
Material
Material Yield Stress
Nominal wall thickness
Wall thickness tolerance
Internal corrosion
Insulation Type
Insulation Thickness
Insulation Density
External Coating Type
External Coating Thickness
External Coating Density
100-yr
Return Period
1-yr
The FPSO will be located in offshore West Africa, where swell waves
are typical and dominant. Table 3 summarizes the swell dominated
design wave parameters. The data of Current and Wind used are for
typical West Africa conditions. They are not listed here since they are
deemed not as critical as design wave (swell).
789
SCR CONFIGURATIONS
The nominal top departure angles were chosen as 15 degrees for simple
and weighted SCR concepts, and 9 degrees for mini-lazy-wave concept.
It was assumed that helical strakes cover the top 200m section of SCR
to suppress the possible vortex-induced vibration (VIV). The SCR is
assumed to be formed by insulated steel pipes jointed by girth weld.
Other key parameters are listed in Table 4.
Strakes
The studied SCR concepts have similar top interface with FPSO turret
and bottom interface with pipeline or subsea equipment. The main
difference is the arrangement near the seafloor region. The weighted
SCR concept has a section of pipe with dead weight collars attached,
while the mini-lazy wave concept has a section of pipe with buoyancy
modules attached. Both concepts are intended to modify the dynamic
characteristics near the SCR TDP for better strength and fatigue
performance.
Table 4. SCR Key Parameters for Different Concepts
Parameter
Unit
Simple
Weighted
Mini-Lazy
Wave
Water Depth
Nominal Top Tension
Bottom Eff. Tension
Departure Angle
Suspended Length
Horiz Span to TDP
Straked Length
m
kN
kN
deg
m
m
m
1515
2177
559
15
1996
1088
200
1515
2463
634
15
1924
977
200
1515
1780
280
9
2190
1280
200
Buoyancy Module
OD:2.5m
L:2.5m
Qty:11
Weight Clamp
Wt:2.9ton
Qty:16
Weight Clamps
Buoys
790
The studies were carried out on both vessels for more general
conclusions. Each vessel different load conditions, i.e. ballast and 50%
loaded, and full loaded, were checked and compared.
Table 5 General Vessel Data for AFRAMAX
Vessel
AFRAMAX
Load Condition
LOADED BALLAST
Displacement
98850
43370
Length OA (m)
230
Length BP (m)
222
Breadth
32.2
Depth
22
Draught at midship
15.7
7.4
Unit
Te
m
m
m
m
m
10.09
15210
175.62
338
325
56
26.7
14.1
15550
174.73
20.5
16280
173.04
5.83
-0.79
-4.46
345.85
345.85
345.85
16.61
12.6
6.2
791
Generate Weighted
Hs vs Tp Curve
Wave Scatter
Diagram
OrcaFlex Simulation
Runs
Fatigue Damage
Clearance
Retrieve Stress
Ranges
Calculate Stress
RAOs
119
118
We also used the Rain Flow Counting technique to calculate the SCR
fatigue for selected cases, and compared the results to the spectral wave
fatigue approach, and good agreements have been observed.
far
117
cross
Clearance (m)
116
near
115
114
113
112
111
110
The buoyancy modules for mini-lazy wave concept causes hog bend
and sag bend on the pipes. It is undesirable to have clashing between
the sag bend section and seabed. Therefore, the clearance is checked to
confirm the design. Figure 3 shows the definitions of the clearance. In
our nominal mini-lazy wave configuration, the sag bend is
approximately 100m above the seabed. We checked the clearance from
two aspects:
109
108
0%
1%
2%
3%
4%
5%
STRENGTH RESULTS
The maximum von Mises stresses are checked along the risers and the
governing locations are identified. The stress utilization ratios are
compared in Table 7. Figure 5 shows the maximum von Mises
distribution along the riser for all the three concepts for extreme design
case. It shows that:
1.
The risers experience relatively high stress in the whole
section due to the high design pressure.
2.
The simple SCR has a very narrow stress spike at the TDP,
which is the most critical location. As expected, in both
weighted and MLW concepts, the stress level at the TDP has
been significantly reduced.
3.
For the MLW configuration, the von Mises at the hog bend
section could be higher than the rest of the pipe section. This
stress is obviously related to the buoyancy module
arrangement. In other words, this will be a design task that
requires careful considerations.
792
300
Max Op
1.26
0.58
0.67
1.2
0.75
0.74
Extreme
Survival
1.08
0.86
0.62
0.5
0.71
0.58
1.02
0.73
0.65
0.48
0.72
0.63
290
250
SCR
weighted
200
MLW
150
100
50
0
TDP
270
10
20
30
40
50
60
time (sec)
von Mises (MPa)
250
230
210
FATIGUE RESULTS
190
Table 8 and 9 show the relative fatigue life comparisons between the
studied concepts for VLCC and AFRAMAX FPSO respectively. The
worst fatigue damage at the TDP region was reported. The results have
been normalized by the simple SCR fatigue life for DNV-E curve for
simplicity.The fatigue life ratio for simple SCR is selected as 1 for
DNV-E curve, while all other data are the relative ratios to the simple
SCR with DNV-E curve. It shows the MLW is able to improve the riser
fatigue life at the TDP by 5~6 times, while weighted SCR improves by
2 times. Both FPSOs have similar trend. VLCC provides slightly better
performance due to its larger displacement and lower motions.
170
150
0
500
1000
1500
2000
2500
290
270
250
TDP
230
210
190
170
150
0
200
400
600
800
1000
1200
1400
1600
1800
2000
290
270
250
TDP
Buoy Section
230
210
190
In summary, best fatigue performance was obtained with the mini lazy
wave configuration with a fatigue life that was approximately three
times the weighted riser and six times the simple SCR. In all cases, the
worst damage was obtained in the touchdown zone. As indicated in the
following table the calculated minimum fatigue life of the mini lazy
wave and weighted risers are significantly improved from the Simple
Catenary Riser. AFRAMAX has lower fatigue lives than those of
VLCC. It is possibly due to smaller vessel yielding more vessel
motions: heave and pitch induced heaves.
170
150
0
500
1000
1500
2000
2500
793
VLCC
DNV-B DNV-D DNV-E
17.82
56.00
198.64
1.45
3.27
8.00
1
2.27
5.55
AFRAMAX
DNV-E
0.38
0.71
1.91
CONCLUSIONS
Table 9 Fatigue Life Comparison Summary - AFRAMAX
Description
AFRAMAX
VLCC
DNV-B
DNV-D DNV-E
In this paper conceptual level analysis has been carried out to compare
three different SCR configurations. The clearance between the
buoyancy module section and the seabed has been checked and is not
likely a design concern for MLW SCR. The study results reveal that the
MLW SCR has the best performance for both fatigue and strength,
followed by the weighted SCR and then the simple SCR. For the
strength assessment, MLW SCR provides satisfactory von Mises
stresses, and completely eliminates riser compression at the riser TDP.
While high TDP compressions for the Simple SCR and moderate TDP
compression for the weighted SCR are observed. For the fatigue
assessment, comparing to the simple SCR, the MLW SCR significantly
improves the fatigue performance at the TDP, and the weighted SCR
provides marginally better fatigue performance as well. This is
attributed to the weighted SCR configuration not being able to
adequately de-couple the vessel heave motions between the riser top
end and the touchdown zone. Limiting vessel heave by moving the
riser hang off point closer to the vessel midship will improve the
performance of the free hanging configurations. However, there is
certain limitation to how much we can move riser hang-off/turret point
toward the midship for the weathervane requirement of turret moored
FPSO.
DNV-E
Simple
21.23
2.17
2.63
Weighted
MLW
39.42
107.64
4.03
11.01
1.86
5.07
3.20
2.91
45
40
SCR
35
Weighted
MLW
30
25
20
15
10
5
0
0
10
15
20
25
1.E+04
1.E+03
SCR
MLW
1.E+02
ACKNOWLEDGEMENTS
Weighted
TDP (MLW)
TDP (Weighted)
1.E+01
The authors are indebted to Acergy for supporting this paper, especially
the assistance from Jean-Francois Saint-Marcoux and Jean-Luc Legras ,
the guidance from Ian Frazer, and Cynthia/Donnas preparation of the
manuscript.
TDP (SCR)
1.E+00
0
500
1000
1500
2000
2500
REFERENCES
SCR
Weighted
Damage (1/yr)
0.03
MLW
Alliot V., Legras J., Perinet, D., (2004), A Comparison Between Steel
Catenary Risers and Hybrid Riser Towers for Deep Water Field
Developments, DOT 2004, New Orleans, LA.
American Petroleum Institute, (1999), Design of risers for Floating
Production Systems (FPSs) and Tension-Leg Platforms (TLPs),
Recommended Practice 2RD, First Edition, January 1999.
Blevins, RD, Wu, M., (2007), "Investigation of Interference between
Upstream and Downstream Cylinders in a Current", Offshore
Technology Conference, paper 18529, Houston, Texas.
Det Norske Veritas, (1984), Fatigue Strength Analysis for Mobile
Offshore Units, Classification Note 30.2, August 1984.
Judd, S., Okonkwo U., Penel, G., (2005), Re-usable and multipurpose
pull-in system, OWA 2005, Abuja, Nigeria.
Legras, Jean-Luc, (2006), Riser Design for Offshore Nigeria
challenges and solutions, OWA 2006, 14-16, Abuja, Nigeria.
0.02
0.01
0
2
11
13
15
17
19
21
23
794
Nolop, N., Elholm, E., Wang, H., Hoyt, D., Kan, W., (2007),
Montbarbon, S., Quintin, H., Steel Catenary Risers and Offloading
System for the Erha Field Development, OTC 2007, Houston, TX
Quintin H., Legras J., Huang, K., Wu, M., (2007), Steel Catenary
Riser Challenges and Solutions for Deep Water Applications, to be
published OTC2007 Paper 19118, Houston, Texas.
Tenet, C., Duquesnes, V., (2006), Steel Catenary Riser Installation on
FPSO, DOT 2006, Houston, TX
Xavier, B., Dubreuil, G., Johns, J., (2006), Lessons Learnt from the
Installation of Deep Water FPSOs, DOT 2006, Houston, 2006.
Wu, M., Saint-Marcoux, J-F, Jacob, P., Birch, V., (2006), The
Dynamics of Flexible jumpers connecting a Turret Moored FPSO to
a Hybrid Riser Tower. DOT 2007, Houston, TX
Wyllie, M., W., J., Joynson, J., (2006), Recent Trends in FPSO Design
and Project Execution Applied to Leased Vessels, OTC 18061,
Houston, Texas.
795