Crondall Energy

Duncan Peace
Introduction to FPSO Design and Technology

1

Crondall Energy Consultants Ltd
28, City Business Centre, Hyde Street, Winchester, SO23 7TA Tel +44 (0)1962 842233
www.crondall-energy.com




IBC FPSO Training Course
Perth ~ November 2005

Introduction to FPSO Design and
Technology
Duncan Peace Crondall Energy


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

2
Agenda
1. General Introduction
Definitions
Strengths and weaknesses
Regional aspects
Market situation

2. Building blocks
Key components
Hull selection and design
Interface with topsides
Station keeping
Interface with sub-sea

3. Key technologies
Turrets and swivels
Different turret types
What is going on inside a swivel?
New developments

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

3
Part 1
General Introduction


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

4
Definitions
FPU -Floating production unit a general expression for all floating production units, but
sometimes also used to describe units without storage such as semi-submersible units

FPSS floating production semi-submersible

FSU or FSO Floating storage unit OR floating storage and offloading unit

FPSO floating production storage and offloading units

MOPU general term for mobile offshore production units, but may include jack-up units as
well as floating units


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

5
FPSS and TLP
Marco Polo
Images courtesy of Modec/Sofec
Semi submersible production facility.
Tension leg production facility.

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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FPSOs and FSUs
Floating storage facility
Floating production storage &
offloading facility
Images courtesy of Modec/Sofec

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

7
FPSO Strengths and weaknesses
Strengths

Economics low hull and conversion cost can
provide best development solution

Mobility Easy to move from construction site to
field easy to relocate from field to field

Insensitive to water depth concept is relatively
insensitive to water depth - can operate from
~30m 3,000 metres

Large deck area and load capacity mono-hull
configuration provides large deck payload
capacity and is relatively insensitive to additional
payload

Storage capacity allows export of product by
shuttle tanker not pipeline dependent

Weaknesses

Additional marine equipment and crew (relates
partly to storage) makes operating costs
relatively higher

Lack of drilling capability Turret moored
solutions with drilling not yet operating
although concepts exist

Turret systems can act as a constraint on riser
numbers and sizes

Need to use sub-sea trees and flexible risers
(relatively expensive)

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

8
Regional issues
North Sea
Challenging met ocean environment drives technology innovation
Heavily regulated
Mature infrastructure
Units tend to have smaller storage than in benign areas

W. Africa
Benign met ocean environment benign regulatory environment
Significant distance to market drives higher storage capacity
Stranded gas is a challenge little infrastructure

Brazil
Moderate environment moderately regulated
Pioneering deepwater technology
Established infrastructure

SE Asia/Australasia
Cost & schedule driven
Benign environment; some regional climatic factors cyclones & typhoons

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

9
Market position of FPSOs
Current worldwide fleet of
FPSOs numbers are
estimated at around 110+
units working or idle units as
at the end of 2004, plus
around 30+ under
development.

Forecasts show a further
100+ planned for the next 5
years which may or may
not be realised. However,
20+ units per year will be a
challenge for the industry

History and forecast both
suggests that of these
prospects; around 2/3rds will
be FPSOs;
GLOBAL FORECAST 2004-2008
14
9
19
20
10
36
22
1
13
102
TLP's
SPARS
FPS's
FPSO's SOUTH EAST
ASIA
FPSO's AUSTRALASIA
FPSO's AFRICA
FPSO's AMERICA
FPSO's MIDDLE EAST
FPSO's EUROPE
Source: Infield Systems Ltd., Offshore Magazine (May 2004)

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Market Forecast @ November 2005
Under Construction or with firm plans
23 FPSOs
7 FPSSs
3 SPARs
3 TLPs

Probable or possible developments
78 FPSOs
5 FPSSs
2 SPARs
7 TLPs

Source: OGPOD Database/CEC Analysis
The FPSO remains the numerically dominant technology for floater developments
Numbers will continue to challenge industry supply of resources

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Why are FPSOs so important?
FPSOs have become the technology of choice for new developments in deepwater;

Outside the GOM they are the dominant technology;

Significant growth forecast global fleet expected to almost double over the next 5+ years;




THE FPSO HAS GONE FROM A PERIPHERAL TECHNOLOGY IN BENIGN AREAS TO
THE MAIN SOLUTION FOR MODERATE/DEEP OFFSHORE DEVELOPMENTS
WORLDWIDE
CHALLENGE FOR THE INDUSTRY IS HOW TO MEET THE SCALE OF THE FORECAST
INVESTMENTS.

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Part 2
Building Blocks


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Key components and design features
Hull and hull (marine) systems

Station keeping and fluid transfer
facilities

Topsides process equipment

Internal interfaces

Interface with sub-sea equipment & wells

Interface with offloading arrangements

In this presentation we will deal with
the first two ~and leave the remainder
to subsequent presentations
Image IHC Caland Annual Report
Image Courtesy of Bluewater

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hulls and Hull Systems

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hull selection New build or conversion
New Build

More flexibility in selecting key design criteria
Schedule (design and build longer duration than conversion)
High costs
Often selected in robust met-ocean environments
May become more prevalent as numbers of suitable conversion candidates decrease OR hull prices
increase
My be preferred if conversion scope would be extensive because
No suitable conversion candidates
Remedial work for structure &/or marine systems extensive or high risk
Major compliance issues

Conversion
Dominates the global supply of FPSOs
Quicker and cheaper solution
Key decisions will be around scope of conversion/upgrade/replacement

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

16
Hull selection -New build and conversion challenges
New build challenges
Schedule impact
Yard availability
Competition
Design choices


Conversion challenges
Conversion candidate vessel (age - double v single hull)
Scope definition
Structural integrity
Utilities & hull systems integrity
Interfaces & integration of systems
Technical standards & compliance
Material selection and corrosion protection
Contractor skills, experience & capacity
Scope growth


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hull design - Design Features
Key Issues
Deadweight
Cargo (storage) capacity
Equipment (payload) capacity

Hull structure - Global and local strength

Main vessel lay-out - Deck space - Location of accommodation (NB)

Location of turret % LBP

Need to be considered

Hull form, fineness and sea-keeping considerations (NB)

Bow shape, free board (forecastle & ship side) (NB)

Green water protection
NB = Issues where scope
for choice exists with new-
builds

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hull structure

Tank arrangements - Double sides v full double hull

Arrangement of tank spaces (NB)

Longitudinal bulkheads (NB)

Integration with topsides and other interface structures

Layout of other hull spaces for utilities etc. (NB)





NB = Issues where scope
for choice exists with new-
builds

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hull structure - cargo tank arrangements
Double side single
bottom
Double side double
bottom
Three cargo tank
arrangement

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hull layout-aft accommodation
Utilities Blast wall Fwd
Accommodation Helideck Process Turret

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Hull layout -fwd accommodation
Turret Process Helideck Utilities
Accommodation
Blast wall
Fwd

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

22
Hull design - Hull systems and utilities
Layout of major features (NB)
Accommodation & TR
Main marine systems & utilities
Cargo & ballast & Pump room
Main Power, emergency power,
Fire pumps.
HVAC,
IG
Other spaces and services required for auxiliary equipment and shared systems
Vessel upper deck piping arrangements (pipe rack integration)

Integration of hull marine and topsides systems
Power/fuel
Control and safety systems
Emergency power


NB = Issues where scope
for choice exists with new-
builds

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

23
Interface with Topsides equipment and systems
Design and layout of topsides will be covered later by Simon Lowe of Maersk Contractors

Interface issues will be covered by Gary Doyle of Crondall Energy Consultants

However, there are a number of key issues that need to be considered by the hull design
process

Structural integration of topsides support stools & module support structure into hull structure layout

Consideration of required maximum topsides weight and CoG

Layout and space considerations in the area of the vessel upper deck

Extent of integration of hull and topsides systems

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

24
Station keeping

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

25
Station keeping - Key design Issues
Station keeping options are:

Mooring with a turret mooring system allows weathervaning to prevailing met-ocean conditions
Spread mooring fixed or mostly fixed orientation (some partially compliant systems)
Dynamic positioning (rare only two units currently operating in this mode)
Permanent or disconnectable

Key decision inputs will be the prevailing met-ocean conditions:

Severity of conditions
Nature of severe events cyclones etc.
Directionality of conditions (dominant direction)
Extent to which prevailing conditions are co-linear (sea wave and swell OR sea wave and
wind/current)
Economics (capital cost versus operating uptime)


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

26
Turret or Spread Mooring?
Weather conditions, directionality & persistence

Riser requirements (number, size and configuration)

Permanent v disconnectable

Offloading some spread moored systems now have separate offloading facilities

Other factors
Process performance and uptime
Hull fatigue





Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

27
Turret Moored - the Alvheim FPSO
Images courtesy of APL

Vessel is based on the
Statoil/Navion multi
purpose shuttle tanker
(MST) concept
85,300 Dwt tanker
Double hull
dp3 class
120,000 bbl/day oil
production
125,000 mmscf gas
handling

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

28
Spread mooring the Sendje Berge
Images courtesy of Bergesen

Vessel is based on a
VLCC

2 million bbls storage

60,000 bpd production

Spread mooring

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

29
DP Position Keeping FPSO Munin
The Bluewater owned
and operated Munin has
operated in both turret
moored mode (this
image) at the Lufeng field
in China and the Xijiang
field also in China

Vessel is based on the
Statoil/Navion multi
purpose shuttle tanker
(MST) concept
95,500 Dwt
Double hull
dp2 class
60,000 bbl/day
production
Images courtesy of Bluewater

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

30
Interface with sub-sea equipment
Turret and swivel provide the main interface between the FPSO and the sub-sea system


Swivel systems allow the transfer of:

Production fluids from the sub-sea equipment to the vessel
Export fluids from the vessel to the sub-sea infrastructure
Well/sub-sea management/control fluids e.g. methanol
Electrical signals for control and monitoring
Electrical power for driving sub-sea/down hole equipment e.g. ESPs

Turret provides connection to mooring lines and mechanical support for the risers and
umbilicals


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

31
Interface with sub-sea equipment
Images courtesy of Bluewater Images courtesy of Modec Inc.

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

32
Sub-sea interface
Images courtesy of APL

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Part 3
Key Technologies


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

34
Key Technologies
Development of turret and swivel systems which allow n x 360 degrees rotation have been
the key technologies which have allowed FPSOs to be used in all met-ocean environments

Turret allows vessel to weathervane that is, to take up a position which aligns it with the
dominant forces of wave, wind and current.

Weathervaning has the effect of minimising environmental loads on the station keeping
system, and minimises the most sensitive vessel motions generally for a mono-hull roll.

This has the effect of minimising disturbance to process equipment and personnel and
maximising the facility uptime.

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

35
Different Turret Types
Internal turrets

External turrets (forward of bow - normally)

Permanent or disconnectable

Yoke moored

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

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Internal Turrets
Images courtesy of APL

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

37
Internal Turrets
Images courtesy of APL

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

38
Internal Turrets
Images courtesy of Bluewater
Turntable Access Structure
(alternative: Deckhouse)
Swivel Stack
Turntable
Turret
Casing / Moonpool
Spider
(bottom ship)
(upper deck)

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

39
Internal Turrets
Images courtesy of Bluewater
Casing/Moonpool
Mooring Legs
Spider
Lower Radial Bearing
Turret (with riser pipes)
Main Roller Bearing

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

40
Turntable- Typical Lay-out
Includes for example:

Subsea Control Skids
Pipe headers
Control valves
Pig receivers
Pig launchers
Installation Winch

Images courtesy of Bluewater

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

41
External turrets - Baobab Ivoirien FPSO
Images courtesy of Modec/Sofec
970 m water depth
8-leg polyester
mooring
357,000 dwt tanker
conversion
2.0 million bbls storage

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

42
External turrets- FPSO Fluminense Brazil
Images courtesy of Modec/Sofec
800 m water depth
357,000 dwt tanker conversion
1.2 million bbls storage

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

43
External turrets - Cuulong MV9 FPSO
Images courtesy of Modec/Sofec

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

44
Yoke Mooring
CNOOC Bohai Bay QHD32-6 FPSO (China)
Kome Kribi FSO
w/ Tower Yoke Mooring System
Images courtesy of Modec/Sofec
66 ft water depth
New-build vessel
1.0 million bbls storage


Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

45
Disconnectable systems
SBMs External and Internal solutions
External or Riser Turret Mooring Internal turret with disconnectable buoy

Images courtesy of SBM

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

46
The Riser Turret Mooring (RTM)
Cossack Pioneer

Location NW Shelf
Australia

Vessel size: 152,000 Dwt

Topsides
115,000 bopd

Images courtesy of SBM

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

47
Disconnectable internal turret system
APLs STP system
Images courtesy of APL

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

48
Disconnectable systems Terra Nova
Images courtesy of Modec/Sofec
Turret Access
Structure

Upper Turret



Lower Turret



Spider Buoy
Fluid Swivel

Manifold System

Upper Bearing





Connector System


QC/DC Connectors


Lower Bearing

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

49
Swivel systems

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

50
Swivel systems
Swivel systems allow the transfer of:

Production fluids from the sub-sea equipment to the vessel
Export fluids from the vessel to the sub-sea infrastructure
Well/sub-sea management/control fluids e.g. methanol
Electrical signals for control and monitoring
Electrical power for driving sub-sea/down hole equipment e.g. ESPs

Swivel systems allow n x 360 degrees rotation

Swivel manufacturers are pushing back the boundaries of pressure and temperature to limit
of around:
~400+ barg
~120c



Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

51
What is going on inside a swivel?
Images courtesy of Bluewater

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

52
What is going on inside a swivel?
Images courtesy of Framo

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

54
Leadon FPSO stack
Images courtesy of Framo
Leadon power slip ring to be
installed later when required
(4 x 1 MW)
Fluid paths
Utilities

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

56
Swivel stack modules
Images courtesy of Bluewater

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

57
P37 Swivel stack
Images courtesy of Bluewater

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

58
New developments the Sevan SSP
Concept

Scaleable oil storage capacity (0.3-2
MMbbl)
High deck load capacity
No requirement for weathervaning,
avoiding complicated/ costly turret swivel
system
Standard riser connections, umbilical and
power cable terminations
Accommodates large number of risers
Low investment for future risers
Images courtesy of Sevan Marine

Crondall Energy
Duncan Peace
Introduction to FPSO Design and Technology

59
New developments the Sevan SSP
Piranema SSP300
construction
at Yantai Raffels
Picture Sep 23, 2005
Images courtesy of Sevan Marine