DESIGN AND TECHNOLOGY

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

 O FFSHO RE & M A RIN E C O N SULTIN G L TD .

Copyright © 2013 BB Offshore & Marine Consulting Ltd.

All rights reserved.

No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including
photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the author,
except in the case of brief quotations embodied in critical reviews and certain other noncommercial uses permitted by
copyright law.

E-MAIL: INFO@BBOMC.COM
HTTP://WWW.BBOMC.COM

BB Offshore & Marine Consulting Ltd.

 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

BB Offshore & Marine Consulting Ltd.

 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)

BB Offshore & Marine Consulting Ltd.

 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

BB Offshore & Marine Consulting Ltd.

 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

BB Offshore & Marine Consulting Ltd.

 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

BB Offshore & Marine Consulting Ltd.

 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

BB Offshore & Marine Consulting Ltd.

 ABOUT THE AUTHOR

Bruno Ban Msc 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, offshore 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, fixed and subsea), such as FPSOs, DP
(Dynamic Positioning) vessels, petrochemical plants, pipe layers and subsea interfaces.

Bruno worked for major offshore 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 industry’s behavior, technical requirements, developments and progress. This book
is the product of the author’s vast experience and is an invaluable resource for understanding the
technical value and complexity of FPSOs and such installations.

BB Offshore & Marine Consulting Ltd. 291

 BB O shore & Marine Consul ng Ltd.
HTTP :// WWW . BBOMC . COM
INFO @ BBOMC . COM

P h o n e + 31 10 451 30 8 8
P h o n e + 8 6 1 5 9 89 8 7 78 6 4

A publication of BB Offshore & Marine Consulting Ltd.