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FPSO Hazard Issues
FPSO Hazard Issues
FPSO
FPSO (Floating Production, Storage and Offloading) is an oil
& gas plant built on a ship-like structure
Process facilities or topsides on deck; Oil storage tanks in hull
Built to 2 differing standards or philosophy - Process and
Marine
FPSOs stay in location for field life, 7-20 years. Process standards
based on repairs, inspections and maintenance carried out in situ
Marine standards and codes assume periodic visits to port and
occasional dry-docking with plenty of maintenance time in ports
And the twins never meet!
Topsides at one level, built in modules around a central
pipeway
Half Deck to Full Deck Modules 800-2,500t; stick build 150t, 1990s;
Pallet build 500-800t, 2000s
FPSO’s Movements & Shipping Terms
FPSO undergo axial, rotational & static motions affecting equipment & structural design.
Turret mooring minimizes Surge, Sway and Yaw TLP mooring allows Surge and Sway
Direction Axial Rotational Static
X, Longitudinal Surge Roll (3-4°) List (1°)
Y, Transverse Sway Pitch (2-3°) Trim (1°)
Z, Vertical Heave Yaw
Transient Rotational Motions
Roll- Side to side rotation, about the fore-aft axis
Transient Lateral Motions Pitch- Rotation about beam/ transverse axis, fore and aft ends rise & fall
Surge: Fore and aft Yaw- Rotation about vertical axis, fore and aft ends to swing from side to side
Sway: From side to side Stable Tilt
Heave: Up and down Listing- Lasting, stable tilt, lean or heel, along longitudinal axis, due to
Heave
P or
t Si List
y de
Swa Sta
Y rb o Trim
Pitch ard
Roll Hog – Ballast; wave crest amidships
X
Bow, Fore
Su r Sag – Full load; trough amidships
ge
Motion Impact on humans
FPSO is always in motion – in calmer or moderate
or severe sea conditions. May induce sea sickness
No acclimatization period on landing on FPSO
and onshore after spell of duty
Difficult to maintain balance while moving
around. In moderate and severe weather,
attention is more focused on self-protection and
avoiding injury
Sea sickness and motion impact may impair
decision making
Recommend: Human Response Analysis to
ensure that risks arising out of motion sickness
are clearly identified and the effects managed
Motion impact on Equipment
Separation, Liquid levels, Weight & Center-of-gravity
Vessels: Even after shut down, vessels, tanks and columns
may contain liquid. Internals should withstand likely loads
from sloshing liquid inventory
Forces while transiting to site & after mooring at site
Structural members suffer deflections, stresses and fatigue
Hogging and sagging of deck plates during transit and at site
Equipment support, tie-down and liquids impact acceleration loads
Equipment spec should identify site specific motions and
accelerations
Equipment should be sized to meet motion impact – high values for
non-operational and moderate values for operational cases
Wind tunnel and model tank tests recommended to verify analytical
modeling
Motion Impact-Liquid levels
Separators & Columns
Liquid remix, foam on motion. Use Inlet devices/perforated baffles
Internals fail due to liquid acceleration load, sloshing, fatigue of internals.
Provide good support
Poor separation. Locate in center along ship length
Sloshing uncovers liquid outlet, leads to gas blowby. Specify high LALL
Uncovered vapor outlet leads to liquid carry-over. Use outlet devices
Storage Tanks: Sloshing leads to damaged coating and accelerated
corrosion of floor and wall plates
Packed columns and stripper towers:
Packing, trays and demisters may move. Potential loss or degradation in
function. Design support rings, foundations and holding down bolting to suit
Poor liquid distribution. Use high pressure drop distributor and high liquid
circulation rate. Used packing instead of trays
GDU Reboiler: High pressure drop distributor for rich glycol; higher level
to submerge heating coils
Motion Impact-Liquid levels
Level control & trip:
Liquid levels may not be same at opposite ends of long vessels. Alarms and
trips should consider this to avoid spurious action
Floats affected by acceleration. Use DP switches
Have time delay or averaging to smooth trip readings
Provide additional nozzles on top with stilling wells
Line slope: Pitch and roll + list and trim affects free draining of liquids
Drain system:
Static slope due to FPSO trim affects gravity flow / self-draining. May lead to
backflow and overflow
Provide check valves in liquid outlets. Provide baffles in tank. Check seal loop
levels
Flare header liquid hold-up may reduce blow down capacity and increase
back pressure on PSV/BDV/RV. Provide drip legs in flare header to remove
collected liquid to eliminate liquid accumulation
Motion Impact-Liquid levels
Rotating equipment, (centrifugal and reciprocating pumps
and compressors along with their drivers, turbines, diesel
engines and cranes)
Lube oil, seal oil and hydraulic oil reservoirs should be able to handle
excessive sloshing of liquids, without damaging internal baffles or loss
of pump suction
Bedplates and holding down bolts should be designed accordingly
Compressor:
Compressor KOD could get flooded momentarily, by liquid hold-up in
pipes that causes slugs and poor performance
Liquid carried over to compressor:
cokes on blades. Results in unbalanced loads and shaft/ bearing failure
Gas seal failures
Cracked pistons due to liquid carry-over
Repeated bundle change-outs
Install larger scrubbers than normal
FPSO Trim Impact
Trim
Your every action in a day, considering its impact on you, your family,
your colleagues and friends, will make it a way of life!