OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs

Rob Potthurst, Lloyd’s Register

Oil and Gas Services

Presentation on

Tanker Conversions
to FPSOs
Rob Potthurst
Offshore Floating Units
Oil and Gas
Oil and Gas Services

Overview
� Market summary
� LR Experience
� Key issues
� Rules and Regulations
� Hull strength and fatigue
� Some lessons learnt (hopefully)

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

FPSO / FSO
Market

Ship-type Floating
Oil and Gas Services

Production Units
Newbuild Conversion
(30%) (70%)

Total 70+ units worldwide

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Future Floating Offshore

Oil and Gas Services

Installation Projects
FSO
TLP Semi
(8%)
(11%) (3%)
FPSO
SPAR
(60%)
(18%)

Analysis of asset types identified under the

most likely development solution
Oil and Gas Services

F(P)SO Capabilities
Typical Requirements
� Storage 200,000 - 2,000,000 barrels
� Production 30,000 - 300,000 bopd
� Vessel 100,000 - 350,000 tonnes
� Water depth 70 - 1500 metres
� Topsides 2000 - 33000 tonnes
� Risers 1 - > 30
� Wave height benign - > 30 metres
� Air temp -20oC - > 30oC

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

LR Experience
Oil and Gas Services

LR Experience

� FPSO and FSO Units ~ 40

� Steel Fixed Platforms ~ 800
� Buoys ~ 15
� Pipelines ~ 70
� Jack-ups ~ 50
� Semi-submersibles ~ 75
� Concrete Structures ~ 30

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Floating Production Installations

Oil and Gas Services

- LR Worldwide Experience
West of
Shetlands North
1 Sea
19

Canada
3
Mediterranea Vietna
n m
4 Philippine
2
s
Australia 2
Brazi 5
l
3 New
Zealand
1

Recent Conversion Experience

Oil and Gas Services

� Amerada Hess Triton

� Amerada Hess Fife
� Amerada Hess Bluewater Durward/Dauntless
Durward/Dauntless
� Bluewater Bleo Holm
� Expro Efiat Abana
� MAS Curlew
� Petechim Vietsovpetro Dragon
� Petrobras Roncador
� Petrobras Barracuda (ex PP.Moraes)
PP.Moraes)
� Reading & Bates Seallion
� Shell Todd Maui B
� SLP/Maersk
SLP/Maersk Conoco MacCulloch
� Shell soreena

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Example of Conversion

Conoco MacCulloch
North Sea Producer - Teesside
Oil and Gas Services

Example of Conversion

Whakaaropai”
FPSO ““Whakaaropai”
for Shell Todd Maui B Field

Oil Storage Capacity approx. 760,000bbls

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Conversions
Key Issues
Oil and Gas Services

Overall requirements

� Shallow/Deepwater
� Turret/Spread mooring
arrangements
� Permanent / Disconnectable
moorings
� Small/Large displacement hulls
� Benign/Harsh environments
� Project management required

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

What makes an FPSO different

from a trading tanker?
� Operations and safety requirements
� Layout and arrangement
� Specified service/location
� Rules and regulations
� Design/construction/commissioning
� In-situ inspection/maintenance
Oil and Gas Services

Key Choice Drivers

� Project and client requirements
� time to first oil
� location/environment
� function
� life cycle costs
� Statutory and National Authority requirements
� Ship Yard schedule
� availability / capability / price
� location
� Availability of suitable tonnage
� capacity
� condition, age
� upgrading scope
� New build: 2 to 3 years; Conversion: 1 to 2 years

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Hull Selection Issues (conversion)
� Vessel age, condition and service history
� hull global strength
� remaining corrosion margins
� remaining fatigue life
� structural steelwork replacement
� Mooring structure
� internal or external modifications
� structural reinforcement
� Topside integration
� structural reinforcement
� Upgrades
� equipment / systems
� coatings / corrosion control
� machinery
� accommodation

Conversion - Major Works

Oil and Gas Services

Existing Hull
� Removals/modifications
� hull steelwork, coatings etc.
� propulsion and other machinery
� rudder/steering gear
� accommodation, deckhouses and helideck
� piping systems
� Upgrades
� marine and topsides control system integration
� fire protection systems and their integration
� power generation systems and their integration
� cargo tank venting arrangement
� ballast and cargo oil pumps and valves
� inert gas system
� utility systems (eg
(eg water, steam, heating)

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Conversion - Major Works

Oil and Gas Services

Hull Additions
� turret or spread mooring system, equipment, etc
� riser porches or fluid transfer system and piping
� provision of thrusters
� installation of process deck supports
� process systems PAUs,
PAUs, flare and piping
� blast walls
� life saving equipment
� fire and gas equipment and systems
� evacuation measures
� bulwark and breakwater
� lifting equipment
� loading instrument (computer)
� offloading system

Mooring Arrangements
Oil and Gas Services

Internal
Bow Turret
Mooring Mooring

Spread
Mooring

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Turret Mooring Systems
Internal External

Riser Turret Mooring

Large Internal Turret Small Internal Turret
(D)

Buoyant Turret Submerged Turret External Turret Mooring

Mooring (D) Production (D)

General arrangement
Oil and Gas Services

Living quarters Flare Tower

Oil Gas
Sep. Comp. Turret
Metering
P.G.

� Living quarters at the stern

Flare Tower
Oil Gas Living quarters
Turret
Sep. Comp.
Metering
P.G.

� Living quarters at the bow

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

FPSO
Rules and Regulations

Governing Regulations
Oil and Gas Services

� Local National Authority

� Class Rules for FPSO Installations
� Flag State
International Conventions
SOLAS, MARPOL, LOADLINE,
TONNAGE

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

National Regulations
Oil and Gas Services

� U.K. – HSE safety case and verification

� Canada(NS) – CNOPB, TC(flag) ,RQF, class
� Brazil – (BNW), class, flag
� Nigeria – Marine Notice, class, flag(N)
� Gulf of Mexico – Follows…
_____________________________
International Conventions
SOLAS, MARPOL, LOADLINE,
TONNAGE…
Oil and Gas Services

Definitions
� Class
� Rules Based / Risk Based
� Certification
� To Regulations and Codes
� Verification
� To Performance Criteria
� Class\Certification\Verification
often combined

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Rules for a Floating Offshore

Oil and Gas Services

Installation at Fixed Location

Rules
Rules andand
RulesRegulations
and
RulesRegulations
and
Rules Regulations
and
Regulations
Regulations
Rules and

Part
4444
Part
Regulations

Part
Part
Part
Rules and

45
Regulations

Part Rules and

Part 3 Regulations

Parts 2 to 9
Rules and

Part 2 Regulations

Technical Regulations
Part 1A
Rules and
Regulations

Part 1 ��
����
Part 1A
�� Risk Based Approach

Part 1
Regulations
Oil and Gas Services

Scope of LR FPSO Rules

� LR Rules cover the following
aspects :
� Hull and Marine Systems
� Mooring Systems
� Risers (optional)
� Process plant (optional)
� Drilling plant (optional)

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

LR Classification

� Alternatives
� Prescriptive Rules - business as usual
� Flexibility of Risk Based options

� Risk Based Solutions

� Applicable to Design of both hull and
topsides, although generally hull
adopts prescriptive approach
� Applicable to Periodic Inspection
(draft LR guidance available)

AA6c

LR Guidance Notes
Oil and Gas Services

Supporting the Rules

� An Overview of Regulatory Issues

� Conversion of Tankers for Floating
Production Service
� Ship Type Hull Structural Appraisal and
supplement Additional Structural Aspects

� Positional Mooring Systems and supplement Fibre

Ropes for Offshore Moorings
� Periodic Inspection
� Design Appraisal of Semi-Submersible Units

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Conversions
Hull strength and fatigue

Hull Design Considerations

Oil and Gas Services

� hull strength, arrangement and materials

� 100-year site specific criteria
� local connection details and fatigue life (min 20 years)
� range of loading conditions
� vessel motions and accelerations
� mooring system and hull integration
� process support structure
� slamming and green seas
� sloshing
� helideck, cranes and cargo offloading system
� accommodation
� corrosion control
� construction tolerances and fabrication quality
� philosophy for in-service periodic survey
� interfaces

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Model Testing - support

� To support design calculations

� Riser & mooring design
� Loading, excursions, separation
� FPSO/shuttle tanker interaction
� Hull motions, slamming, green
seas
Oil and Gas Services

Ship Rules - basic hull strength

� Parametric equations for :

� Wave bending moment/shear force
� inertia
� Hull modulus
� FEA requirement
(strength/fatigue)
� Local strength
� WW service (limitation options)
� Equivalence through IACS

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

FPSO Hull - Global Strength
� Minimum class rule standard
� Site specific environmental criteria
� Effect of mooring system
(+weathervaning
(+weathervaning)
� Process facilities
� Long term service (at site)
� Range of loading conditions
(including inspection and accidental cases)
� Slamming/green seas

FF2-
FF2-1g
Oil and Gas Services

Global Hull Design – wave BM & SF

� Still water loading conditions often more severe
for FPSOs
� Class Rules permit review of Rule versus Site
specific wave bending moments and shear forces
� Will depend upon site environmental criteria
� Harsh environment wave BM and SF are close to and
may exceed Ship Rule requirements
� Benign environment are less than Ship Rules but not to
be taken less than 70% of unrestricted service Ship Rule
requirements in general
� Multisite operation may require assessment
� Owners requirements, eg corrosion margins
� Towing and temporary conditions to be
considered

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

100 Year Hs / Tp Contours
20
20

18

West of Shetland
16

14

Hs1

Hs
2�i

Hs2
2�i 12

Hs3

Northern North Sea

2�i

10

6 Central North Sea

4

Tp
4
2 6 10 14 18 22 26 30
2 TP1 � TP2 � TP3 30
2�i 2�i 2�i

Some typical criteria

Oil and Gas Services

Hs Tp
Nigeria 3.1 7.6
Offshore Iran 5.9 10.2
Australia 7.2 11.1
U.K. Central 13.0 15.2
West of Shetland 17.1 16.0
Nova Scotia 16.0 14/18

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Accidental Loads
Oil and Gas Services

� Collision due to supply boat /

shuttle tanker / iceberg
� Dropped object
� Explosion / blast
� Ultimate strength criteria
Oil and Gas Services

Steel Grades
� Class rules for ships
� New requirements for low
temperature operation
� Structural categories
� Thickness
� Location

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Hull Strength/Fatigue FEA
� Cargo / ballast tank area
� Hopper knuckle connection
� Mooring structure and hull integration
� Riser porches and supporting structure
� Topsides support structure and hull integration
� Flare tower support structure
� Access tower support structure
� Offloading station support structure
� Main crane pedestals and support structure
� Helideck structure
� Additional locations depending on vessel
function and owners requirements

Fatigue Life
Oil and Gas Services

Factors of Safety
Inspectable/ Fatigue Life Factor
Repairable Consequence of Failure
Non-substantial Substantial
Yes, dry 1 2
(see note 1)
Yes, wet 2 4
(see note 2)
No 3 10
Substantial consequences of failure are defined as loss of life,
uncontrolled outflow of hazardous products, collision or
sinking and should include for progressive failure scenarios.
Note 1 : includes external components which can be dry inspected / repaired.
repaired.
Note 2 : includes external components below the minimum operating draft
which can only be inspected in water , but dry repairs could be carried out.

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Typical Critical Areas

Oil and Gas Services

Process Supports

Stress Concentration
Misalignment
Welding
Oil and Gas Services

FPSO Fatigue Enhancement

Details (conversion)
Examples of modification to hull longitudinal connection details

Transverse frame

Additional lug Additional

bracket
Transverse frame

Longitudinal Addition
Longitudinal/Transverse frame
connection al
Shell plate bracket

Transverse frame
Longitudinal
Additional
bracket Shell plate
Exten
Within cargo and ballast
Item
Longitudinal t
Additional Lugstanks
Bottom and side shell (up to
limit of wetted area)
Shell plate Additional Bkts Bilge area and side shell
(up to limit of wetted
area)

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Green Seas
Oil and Gas Services

� Rule
requirements
typ.
typ.
8 - 14m � Model testing
� Pressures
� Breakwater
� Drainage

Bottom Slamming
Oil and Gas Services

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Sloshing in Cargo Oil Tanks

Oil and Gas Services

� Tank Size
� Hull form
� Environment
� Natural Periods
� LR FLUIDS

Typical Hull Protection System

Oil and Gas Services

Coating

High
performance
NB : Impressed
Water coating
current system
Max. W.L. ballast
Cargo oil not allowed in
tanks
Coating HPC
+
Min. W.L.
SA

HPC

High performance coating +

cathodic protection system

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Fabrication Tolerances and Welding

� tolerances should be in accordance with

good shipbuilding practice, and agreed with
LR
� special attention given to fatigue sensitive
areas
� enhanced NDE levels will be necessary for
identified fatigue sensitive areas
� assumptions used in analytical fatigue
assessments to be consistent with
construction

NDE Testing of Welds - general

Oil and Gas Services

� Intersection of butts and seams & section welds

� Butt welds in plating
� Seam welds in plating
� Bilge keel butts
� Structural items fabricated with full/part penetration
welding (hopper knuckles, sheerstrake, hatchway coamings)
� Penetrations & attachments to hull (sea inlets, piping, anode
supports)
� Moonpool integration structure
� Topside support structure connections to hull structure
� Additional requirements for low temperature operations

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

FPSO some
In-service feedback

FF1-
FF1-3c
Oil and Gas Services

Some Design Life Issues

� Holistic approach for project / good

communications
� Design for required service
� Compatibility of hull structural, systems and
topsides interfaces
� Production equipment for required service
� Marine equipment robustness, particularly
cargo/ballast and control/electrical systems
� OIWS requirements and corrosion protection
� Access arrangements
� Provision of spare parts

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Design- Frequent areas of concern

Oil and Gas Services

� Marine/offshore regulations and practices

� Topsides structure supports (alignment, motions)
� Hull vibration
� Crane specification and integration with hull
� Corrosion - general
� Access and escape routes compatibility
� Hazardous area and classification interfaces
� Piping systems (compatibility/flexibility)
� Topside equipment / motions / helicopter operations
� Marine / Topside system integration
� Use of GRP / FRP, pipework etc
� Wave impact and green sea loading
� Rudder and steering gear
� Laydown areas
� Effect of exhaust (heli-operations)

Design Issues - Interfaces

Oil and Gas Services

� Interface Management is a critical influence on

project success
� LR Project Manager provides interface between
design and class/certification processes
� Technical interfaces to be developed include:
� Escape and access routing
� Hazardous area definition
� Venting arrangements (clear of hazardous areas and for inspection
inspection
activities)
� Power generation and supply systems, normal and backup
� Bunding/prevention
Bunding/prevention of spillage to main deck
� Control System and alarm circuits
� Crude oil pumping and piping system between vessel, process and
offloading systems, including materials
� Fire Water, Cooling and Injection Water
� Heating system, Compressed air supply
� Topsides structure alignment at integration with deck
� Deck crane integration with hull structure
� Mooring system integration with hull structure

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Structural Inspection
� Carried out on location
� Provides detection / monitoring
capacity
� Annual, intermediate & major
surveys
� Major survey (5 years or continuous)
� IWS in lieu of dry docking
� Internal survey
� cleaning & gas freeing
� access arrangements/safety
� lighting/ventilation
� loading conditions

FPSO Incident History Examples

Oil and Gas Services

� Hull Structure � Topsides

� Shuttle tanker collision
� Bow Wave Impact Damage
� Tank Overpressurisation
� Seawater caisson
preferential Corrosion
� Integration of surface and
subsea corrosion protection
� Rudder/steering gear
� Marine Equipment
� Corrosion in cooling and
heating systems due to poor
fluid chemistry control
� Material problems on
seawater systems
� Vibration induced failures
� Inadequate application of
PFP
� Gas Turbine problems
� Produced Water
Corrosion
� Damage due to wave
impact (green water)
� Cargo Venting System
failure
� Pipework and Production
Train Leakage
� Riser / turret connections

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

FPSO Incident History

Oil and Gas Services

Statistics (Reported)
Vessel Nature of Incident No. of
System Incidents
Hull Structure failure in heavy weather 1
Other structural failure 3
Collision 6
Topsides Structural failure in heavy weather 3
Process equipment failure 2
Fire 0
Machinery Engine Room fire 2
Engine Room power failure 1
Main engine failure 1
Rudder / steering gear failure 3
Other Hydrocarbon release 2
Explosions 0
Loss of anchor(s) 1
Ref : 22 vessels, approx 10 years of records
See also Quantified Frequency of shuttle tanker collision during offtake operations,
operations, IMCA
Oil and Gas Services

Vibration Damage – flare stack

Vortex vibrations @ Beaufort 4 - 5

View A

View B
Proposed
reinforcements - two
lateral braces.

Brace on Port Side -

cracked over 180o at
connection to forward
chord.
View A Turret Deckhouse

View B

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International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Mooring System Installation
� Problems Experienced
� Handling equipment failures
� Wire ropes
�Poor tension control
�Loops formed
�Bird caging
� Chains
�Lack of straightness
�Installed with twist
�Tangles & breakage
Oil and Gas Services

Results from a Structural Survey

Example of Defect
Area Locations
shown on Side Shell

Cargo/ballast tanks Defect

B B B B B B B

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 OGP Marine Risks Workshop Proceedings

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Oil and Gas Services

Typical Damage
Side shell longitudinal connection
Web frame

Crack
Face bar

Shell Web frame

plating stiffener

Shell
longitudinal

Crack Broken welding

Oil and Gas Services

Examples of Internal Welded

Repairs
Side shell Stiffener with
soft toe
Fracture New Bulkhead
Side shell locations stiffener
Bulkhead longitudinal
stiffener section
Transverse bulkhead
Stiffener
Transverse Additional
bulkhead radius bracket

Side
longitudin
al
Side longitudinal Backing bracket

Side shell Pillar

stiffener

Additional lug

©  OGP 

International Association of Oil & Gas Producers

Tanker Conversions to FPSOs - Rob Potthurst, Lloyd’s Register ()

Internal Repair - Non-Welded

Oil and Gas Services

Bolted plates
Hole drilled at crack
termination
Stiffener
ck
Frame Cra gth
len

Facing
Longitudinal
plate

Crack Transverse
web frame

External girder Section of hull

Local weld Grinding
reinforcement
Oil and Gas Services

End of LR
Presentation

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