FPSO Systems

Chapter 2

ESD Simulation Training Technical Training Courses 1

 FPSO Building Blocks

Main systems for FPSO are:

» Hull type
» Oil storage
» Moorings
» Fluid transfer
» Topsides process plant
» Offtake and export
» Accommodation
ESD Simulation Training Technical Training Courses 2
 Hull Types

Classic hull type for FPSO:

» Mono-hull, crude carrier classification
» Segregated ballast
– Mono-hull meaning single steel shell
– Double-hull not standard requirement
Exceptions – GoM, NWS Australia

Hull can be either:

» Existing carrier – suitable for conversion
» Newly built specifically for FPSO service
ESD Simulation Training Technical Training Courses 3
 Tanker Conversion

Courtesy of SBM

ESD Simulation Training Technical Training Courses 4

ESD Simulation Training Technical Training Courses 5
 Conversion
Installing Topsides Modules

Courtesy of SBM

ESD Simulation Training Technical Training Courses 6

 New Build Hull
Courtesy of SBM

ESD Simulation Training Technical Training Courses 7

 NORTHERN ENDEAVOUR
New-Build

Courtesy of SBM

ESD Simulation Training Technical Training Courses 8

 Moorings

The moorings for an FPSO can be:

» Spread moorings
– Benign conditions
– Any water depth
» Jacket or tower moorings
– Moderate conditions
– Shallow waters
» Turret moorings
– Any conditions and water depth
ESD Simulation Training Technical Training Courses 9
 The External Turret System
Swivel Stack

Weathervaning
Bearing

Turret

Automatic
Chain Stoppers
Chaintable

Flexible
Risers

ESD Simulation Training Technical Training Courses 10

 Simple External Turret

Courtesy of SBM

ESD Simulation Training Technical Training Courses 11

 Large External Turret

Courtesy of SBM

ESD Simulation Training Technical Training Courses 12

 Disconnectable External Turret

Courtesy of SBM

ESD Simulation Training Technical Training Courses 13

 Internal Turret System

Deckhouse

Product swivel

Turntable

Axial bearing

Product piping

Turret
Turret casing

Radial bearing

Spider
Chain stopper
Flexible riser
Anchor chain

ESD Simulation Training Technical Training Courses 14

 Internal Turret

Courtesy of SBM

ESD Simulation Training Technical Training Courses 15

 Fluid Transfer System

Function of system: Problem!!

» To connect subsea » How to connect the
risers to topsides two
process plant Answer
Fact » Fluid swivel
» Risers are stationary
pipes
» Topsides plant is on
weathervaning ship

ESD Simulation Training Technical Training Courses 16

 Fluid Swivels

Predominant fluid transfer system is the

fluid swivel
Commonly referred to as the radial swivel
joint
The term toroidal swivel is used to
describe shape of fluid pathway

ESD Simulation Training Technical Training Courses 17

 Radial Swivel Joint

Courtesy of Brown Brothers

ESD Simulation Training Technical Training Courses 18

 Moorings and Fluid Transfer

Fluid swivels only required for:

» Turret moorings
» Jacket moorings
Spread moored FPSOs:
» Do not rotate around mooring point
» Do not require swivel joints

ESD Simulation Training Technical Training Courses 19

 Topsides Process Plant

Processing which occurs on an FPSO:

» Three-phase separation of the well fluids
» Gas recompression
» Gas treatment
» Produced water treatment
» Injection water treatment
Standard black oil processing
» Practiced worldwide
ESD Simulation Training Technical Training Courses 20
ESD Simulation Training Technical Training Courses 21
 Offtake and Export

Crude oil export from an FPSO

» Connection to a pipeline
» Direct ship to ship transfer
– Using a surface hose either floating or reeled
» Transfer through a loading buoy

ESD Simulation Training Technical Training Courses 22

 Direct Ship to Ship Offtake

Courtesy of Bluewater

ESD Simulation Training Technical Training Courses 23

 CALM Loading Buoy

Courtesy of Bluewater

ESD Simulation Training Technical Training Courses 24

 Accommodation

Two possible » Survivability of TSR

locations – Greatest risks remote
– Gas or smoke
» Bow or Stern ingression via HVAC
Accommodation prevented
– Fire and blast-proofing
block contains may need to be
temporary safe upgraded
refuge (TSR) » Unhindered
Layout of topsides personnel access to
TSR from any point
plant must be based
on deck
on:
ESD Simulation Training Technical Training Courses 25
ESD Simulation Training Technical Training Courses 26
ESD Simulation Training Technical Training Courses 27
 Field Development Comparisons using FPSOs
US$Millions
250 800
Reserves & Production Rates Subsea & FPSO Costs
Reserves 700 Subsea Cost
Thruput FPSO Cost
200
600 Av. cost new build
Av. cost conversion
500
150

400

100
300

200
50

100

0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Av Well b/d Reserves

No Development Operator Year Capex FPSO Subsea No Wells Build/Con
Mbls/day MMbls
Typically: 1 Tazerka Shell 1982 352 286 66 6 5 16 Con
- Wells 5-20 2 Jabiru BHP 1985 151 120 31 3 10 15 Con
- Producing 5-20 Kb/d 3 Chalis BHP 1989 172 142 30 5 10 60 Build
- New Build $M245 4 Skua BHP 1992 157 127 30 3 9 25 Con
- Conversion $M180 5 Griffin BHP 1993 450 242 231 11 8 130 Build
6 Cossack WOP 1993 252 147 147 4 20 60 Con
7 Wan/Coss WOP 1995 428 173 195 6 20 250 Con
8 WOP/study WOP 1995 642 292 350 9 8 197 Con
9 Teal Shell Expro 1996 695 340 355 12 7 100 Build
10 WOS BP 1996 748 245 503 19 8 180 Build
11 Gryphon K/McG 1994 383 255 127 12 7 94 Con
12 Maui Oil STOS 1996 115 76 39 8 4 30 Con
13 Liuhua Amoco 1996 590 145 330 20 3 75 Con
14 Angola/study Shell 1994 759 199 460 5 5 186 Build

28
Cost Estimate Conceptual Design – Large FPSO
4%
Location - West Africa Onshore
Greenfield site
2mmbls storage & 175Kbls/day
All up cost $1556million of which
FPSO $490 32 %
Wells

22 %
Facilities

9% 29 %
Host Subsea
4%
Export

Installation Project
Scope Total Design Materials Fabrication
& hook-up management
Wells 38 off 492 11 188 282 11
Subsea as per above 452 16 211 105 105 16
Host 2 mmbls new VLLC 143 12 65 44 10 12
Facilities 175 kbl/d 347 29 206 64 19 29
Export 60 km P/L 62 5 13 13 26 5
Onshore Base 60 5 13 13 24 5
Total 1556 78 696 239 466 78

29