OTC 15314 A Solution For FPSO Module Integration

P.A.Thomas, S. Malek, N. Tcherniguin, and V. Bestel, TECHNIP-COFLEXIP

Copyright 2003, Offshore Technology Conference This paper was prepared for presentation at the 2003 Offshore Technology Conference held in Houston, Texas, U.S.A., 58 May 2003. This paper was selected for presentation by an OTC Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Offshore Technology Conference or officers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented.

Abstract Technip-Coflexip has developed a new installation concept called the Jack-Deck (Patent Pending Patent N FR 01.16835 registered on 24/12/2001) which enables installation of FPSO Topsides on to a FPSO Hull Deck in one or two Integrated Modules with weights of up to 19800T each (See Figure 1). This installation method facilitates extensive precommissioning and commissioning of the Integrated Modules at their Construction Yard. It considerably reduces the onshore hook-up and integration work required on top of the FPSO Hull Deck. Consequently the overall FPSO Construction Schedule and Cost are significantly reduced. This paper describes the Jack-Deck installation method and discusses the consequences on Topsides layout and structural design. It also highlights the main benefits of the system.

Introduction With the discovery of new Oil & Gas fields located in deep waters and the recent development of subsea completions and flexible risers, FPSOs have become more and more commercially attractive. They enable development of fields with little infrastructure for oil export and offer not only a low installation cost, but also a low decommissioning cost at the end of field life. They offer the advantage of being readily redeployed on other fields. All these points have expanded the FPSO market and encouraged Oil & Gas Companies to invest in this type of production system. Many FPSOs have already been successfully installed in West Africa and other parts of the world. Several others are under construction, and many proposals for future FPSO Development Projects are in preparation with early installation objectives. The traditional method for constructing an FPSO is to build the hull in a Shipyard and the Topsides in a separate Construction Yard. The topsides are split into several modules, typically 8 to 14 with weights ranging from 1000T up to 3000T. The modules and / or the hull are then transported to the integration yard where the modules are lifted and installed in place on top of the FPSO Hull Deck.

Fig 1: Jack Deck installation concept

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Due to the large number of modules, the lifting and installation phase can extent for several weeks and the integration, pre-commissioning and commissioning work may have to be interrupted to allow the installation of the modules as they arrive at the integration site. This traditional method has been imposed on FPSO Contractors by the high elevation of the FPSO hull deck above the quay, which can reach up to 30m, and by the relatively small lifting capacities of most of the Construction Yards, which are generally limited to 3000T. Selecting yards with higher lifting capabilities would reduce competition and further increase the fabrication and integration costs. In any case, the lifting capabilities of these particular yards are still limited to around 7000T, which is low in comparison with the Jack Deck 's installation capacity. This traditional method has several drawbacks that lead to a time consuming and high fabrication and integration cost. Some of the major disadvantages are listed below: Increased management, co-ordination and interfaces for the fabrication, procurement and transportation of the numerous modules Incomplete pre-commissioning of modules before their installation on top of the FPSO Hull Deck leading to difficulties with Equipment Vendors Major integration, pre-commissioning and commissioning work on top of the FPSO hull deck (located at about 30m above the quay) Increased numbers of Simultaneous Operations (SIMOPS) due to the fact that the integration and pre-com /com work is being carried out at the same time. Requirement for additional safety constraints and precautions due to SIMOPS. Early delivery of the FPSO hull is required to allow enough time for the integration, pre-com /com work to be carried out. FPSO rotation to enable the installation of modules, during which time no integration work can be carried out. One Technical Room is required per module for precommissioning purposes. This large number of technical rooms increases operating constraints during commissioning activities and FPSO operation.

Figure 1 shows the overall installation concept with the Integrated Module having been jacked-up by the 8 Jack Legs which are bearing on foundation mats on the seabed. In order to save installation time, the Jack Legs are preinstalled on the Integrated Module at the Construction Yard before its transportation to the Integration site. At the Integration Site, the transportation barge is moored into position. The module is jacked-up after sea fastening has been removed and the transportation barge is towed away from underneath the module and then the FPSO Hull is towed in between the legs and under the module. Once the FPSO is in position, the module is lowered until it fully rests onto its supports. The FPSO Hull is equipped with conical guides that allow accurate settling of the Integrated Module. (See Figures 2 to 4).

Fig 2: Integrated Module Barge Arrival at Integration Site

To overcome these disadvantages, Technip-Coflexip has conceived a new installation concept called the Jack Deck that allows the installation of the FPSO Topsides on the FPSO hull deck in one or two Integrated Modules with weights up to 19,800T each. The Integrated Module(s) can be completed and fully pre-commissioned at the construction site prior to its transportation to the integration site. New installation method The proposed method consists of fabricating the FPSO topsides in only 1 or 2 large Integrated Modules, loading them out onto a transportation barge using the traditional skidding method, and transporting them to the integration site where these modules are jacked-up and installed on the FPSO Hull Deck using the Jack Legs.

Fig 3: Jacking-up of Integrated Module and Removal of Transportation Barge

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Fig 4: Entrance of the FPSO Hull below the elevated Module and Installation of the Module onto FPSO Hull Guidance of the FPSO hull in between the Jack Legs is achieved by placing guides either directly constructed within the mud-mat structure or directly fixed on to the edge of the Integration Site quay. As an additional safety precaution, the installation operation is carried out in sheltered waters and the Jack Legs are designed to resist impacts from the FPSO Hull. The Jack Legs are then removed from the Integrated Module by means of a lifting crane. A 450T capacity crane is sufficient to handle the Jack Legs and their foundations. Alternatively, a smaller crane with a capacity of 250T can perform this task by removing each Jack-Leg in 2 pieces. First the Leg together with its foundation, and then the Jack Frame. (See section Jack Legs detailed description below). In the case of two Integrated Modules, the Jack Legs are placed on the second Module, which will be in a stand-by position next to the FPSO, and the same operation is repeated. After installation, the integration and commissioning work can immediately start. Jack Legs Detailed Description Each Jack Leg has a Jack Frame that enables the Leg, which is simply supported on a foundation mat, to slide vertically. The relative vertical movement between the Leg and the Jack Frame is achieved by a rack and pinion system identical to those used on the Elgin and Harding TPG 500 self elevating jack-up platforms. The Jack Frame design has been developed to be easily connectable to, and disconnectable from, the Integrated Module structure. The connection detail fully accommodates the imposed moments and forces. Figure 5 shows a typical Jack Frame structure. Fig 6: Jack Cases inside the Jack Frame Fig 5: Jack Frame Structure Each Jack Frame is designed to accommodate one or two Jack Cases (of 4 pinions each) depending on the lifting capacity required. The Jack Case pinions are powered by means of Hydraulic Power Units (HPUs) that are located on top of the Jack Frame. Figure 6 below shows the Jack Cases inside the Jack Frame.

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The Leg is designed to resist the module dead weight and environmental loads together with P-delta effects that may result from gaps and Leg deformation under wind loads. The bottom of the Leg is provided with a foundation mat that avoids penetration into the seabed during the jacking phase. Figures 7 and 8 show these elements.

Jacking Capacities Each Jack Leg has a maximum Nominal Lifting Capacity of 2400T and an Ultimate Lifting Capacity of 2640T. Technical and economical considerations have led to the conclusion that the best compromise between the reduction in integration work and the investment cost of the Jack Legs is to limit the number of Jack Legs to eight. With this number, FPSO Topsides of up to 19800T can be installed in one single Integrated Module. For Topsides in excess of this weight, the Topsides would be split into 2 Integrated Modules. Integrated Module(s) Layout As previously noted, a FPSO Topsides layout is traditionally split into several independent modules (typically 8 to 14). Some of them are single deck modules, whilst others are double decked modules. Due to the Jack-Deck installation method, the modules are grouped together to form one or two double-decked Integrated Module(s) having a width equal to or slightly larger than the width of the FPSO Hull. This grouping has the advantage of providing additional space for lay-down areas or for future topside expansion. This additional space can also be used to increase the safety distance between the Process Systems and the Living Quarters. From a structural perspective, the Topside structure is provided with transverse framing at the edge to which the Jack Frames are temporarily connected for the installation operation. The minimum number of transverse frames required within the Topside structure is half the number of Jack Legs required for the installation. When the Topsides weight is in excess of 19800T and two Integrated Modules are required, the Topsides split is made to reduce the connection work at the Integration Site. Generally one Process module and one Utility module are considered since less onerous integration and precommissioning work is required between these systems. The Jack Deck installation concept enables a reduction in the number of technical rooms since only one is required per Integrated Module. This considerably facilitates the pre-commissioning, commissioning and operational activities. Figure 9 below shows a typical FPSO Topsides layout with two Integrated Modules specifically developed for installation with the Jack Leg system. The segregation between the Integrated Modules and the living quarters at the aft, and the flare at the bow, are noted as a significant safety advantage.

Fig 7: Jack Frame with the leg

Fig 8: Leg foundation

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The second method consists of building the Integrated Module in one single piece formed of at least 3 longitudinal rows and transversal rows as required for jacking. The central row and the inner transversal frames are doubled. Then, once the module is installed, the short beams between the doubled rows and frames are cut and removed to leave each module independent from one another. The third method of construction is similar to the second one except that the internal rows and frames are not doubled. The splitting of the Integrated Module in several small ones is obtained by providing specific connection details that allow, after the Integrated Module has been installed, horizontal sliding between the upper beams and vertical frames as appropriate. Whatever the construction concept is, the main transversal frames have to be designed to resist the lifting loads. The corresponding structural weight increase is largely compensated by the layout optimisation described above. Schedule Improvement and Cost Saving Due to the construction of the FPSO topsides in only one, or two Integrated Modules, split between process and utilities and the reduction in the number of technical rooms, it becomes possible to carry out extensive pre-commissioning and commissioning work of the topsides at the construction yard. This improves efficiency since the work is done at a low elevation instead of on top of the FPSO Hull Deck. The overall FPSO construction schedule can be shortened by at least 3 months compared with a standard construction scheme. Additionally, since more Topside pre-commissioning work can be done at the Construction Yard, this enables a later delivery of the FPSO hull compared with the traditional method. Conclusion The Jack Deck installation method presents a large number of advantages that reduce the overall fabrication and integration schedule and cost of an FPSO Development Project. These advantages can be summarised as follows: The Jack Deck installation method provides full flexibility for the Topside Contractors to choose their preferred construction method according to their construction capabilities. The concept considerably reduces the integration, precommissioning and onshore commissioning work on top of the FPSO Hull Deck. The reduction in integration time allows a later delivery of FPSO Hull compared with a traditional construction method, thus providing more flexibility in the overall schedule. The method also considerably reduces the number of load-out and transportation operations It facilitates the overall management for transportation activities and the integration work.

Fig 9: FPSO typical Topside Configuration for Jack Leg installation Other aspects influence the final configuration and the number of Integrated Module(s) to be installed. The main factors are the weight and location of the centre of gravity of the modules, the water depth at Fabrication and Integration Sites, Load-out Operations and Transportation Limitations, as well as Soil Capacity at the Integration Site. Integrated Module(s) Structural Concept and Construction Generally, one of the main concerns for the FPSO Topside structural design is the deformations induced by the Hull Hogging and Sagging under wave loads and under the filling/emptying of crude oil tanks. Considering the relatively low stiffness of the Topside structure compared with the Hull structure, the Hull deformations are in fact imposed deformations for the Topsides structure. As a consequence, the resulting fatigue stresses cannot be solved by stiffening the Topside structure. The simplest way to avoid such problems is to dissociate the Hull deformation from the Topsides structure. This dissociation is obtained if modules are supported on 4 points only. Supporting the Integrated Modules on four points leads to major local reinforcement in the Hull Structure, which is very expensive to achieve since the Hull is generally designed and built using standard ship building practice. Therefore the structural concept of the Integrated Module is for it to be readily split into several smaller structurally- individual modules after installation, each one of them being supported on 4 points only, and provided with neoprene pads. The supporting points are then directly located in line with the transversal frames. Several different construction methods can be used to provide sufficient flexibility for each potential Construction Yard to choose from, according to their construction capabilities and preferences. The first method consists of building the Integrated Module in several small modules that can be assembled together with connecting devices that provide the necessary resistance of the transversal frames during installation. Following installation, the connecting devices are removed and all the modules become structurally independent again.

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It increases flexibility in the selection of fabrication and integration sites since it eliminates the requirement for heavy lift capabilities. The Jack Legs are re-usable The method also enables the full decommissioning of the FPSO Topsides using a reversed operation The installation concept reduces the number of Technical Rooms and thereby reduces cost and simplifies FPSO operations and pre-commissioning, commissioning activities

Acknowledgement The authors would like to thank the management of TECHNIP-COFLEXIP OFFSHORE BRANCH for granting them permission to publish this paper. The authors express their special appreciation to their colleagues for their support and advice.