0020 introduction to fpso design
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FPSO DESIGN- AN INTRODUCTION
Kamal K. Ravi
Engineering Projects& System Manager PTSC M&C
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Introduction to Floating Production Systems
Chapter 1
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Floating Production Systems
• Classified as:
Semi-submersible and tension leg platforms
- Little or no storage capacity
Spars
- Limited storage capacities
FPSO – primarily mono-hull vessel
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Typical View of an FPSO
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Water Depth and Sea States • Water depths
Shallow
-Less than 50m
Moderate
-Down to 300m
Deep
-Down to 1500m
Ultra Deep
-Beyond 1500m
• Sea states
Benign
-Hs 0 to 4.0m
Medium
-Hs 4.0 to 9.0m
Severe
-Hs 9.0 to 14.0m+
Hs=significant wave
height
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FPS Application Chart
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History of the FPSO
• 1977 First FPSO- Castellon Field
Offshore Spain
Mooring –SALM
Water dept 117m
• During 1980s
Moderate depths
Benign waters
Cost effective solution
- For marginal fields
Proven safety record
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History of the FPSO
• During 1990s
- Deeper waters
- Rougher seas
- Black oil reservoirs
• Early 21st Century
-Ultra deep waters
-Large numbers of risers
-Very high throughputs
-Storage – VLCC Class
-Newly built vessels
-Handle gas liquids
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The Pros and Cons
• Advantages
- Utilises existing ships
- Faster development
- Reduced upfront costs
- Early cash flow
- Re-usable
- Higher residual value
- Lower abandonment costs
• Disadvantages
- No drilling
- Subsea wells only
- Rushed design can lead to mistake
- Weather dependency
- Production
- Offtake
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What is an FPSO?
• F = Floating – it looks like a ship – but is it?
• P = Production - Produces and processes a reservoir fluid
• S = Storage – Vessel’s cargo tanks store product crude
• O = offtake – Crude is offloaded to shuttle tanker
• That is the Simple Look
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Mooring the FPSO
• An FPSO is essentially a ship permanently moored on the open ocean
• Stresses imposed on the hull need to be minimised
• Ship has to survive for life of project
• Weathervaning is a natural effect which minimises stressess
• Allows ship to align itself with the wind, wave and current
• Turret mooring allows weathervaning
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Cargo Handling on FPSO
• An FPSO is a crude oil tanker
• Two issues are critically important
Loading and offloading the cargo
- Creates stresses on hull- have to be minimised
-Achieved by load monitoring and ballast system
Storing the product crude safely
- Cargo tank atmosphere potentially explosive
- Tanks must remain “inerted” at all times
- Achieved by use of inert gas system (IGS)
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Production and Processing on FPSO
• Two issues important Sustaining and optimising reservoir productivity - Sustaining reservoir pressure - Optimising reservoir flow - Assurance of flow from reservoir to processign centre Safe, efficient and effective processing - Maximising liquids recovery - Disposal of gas safety and economically - Treatment and disposal of produced water - Efficient use of chemicals to aid both production and
processing
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FPSO Design Issues
• Main Technical Questions
Selection of the mooring system
- Predominantly turret mooring, but spread mooring and yoke mooring also used
Location of the accommodation block
- Conventionally at aft end of ship
- New build vessels may have forward accommodation
Process plant layout, based on safety and operability
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Turret Mooring System
• Mooring turret is unique FPSO feature
• Serves three purposes:
Anchors vessel at geo-stationary position
Allows vessel to weathervane
Provides conduit for fluid transfer
- Subsea reservoir infrastructure to
topside processing plant
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Turret Designs
Turret designs based on location
- Either external to the hull of the vessel
- Or internally fitted inside the hull
Choice based on:
- Geographical location
* Sea states, strom systems, ice, etc
- Water depth
- Number of fluid transfer risers
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External Turret Design
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Spread Mooring
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Buoy Yoke Mooring
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Jacket Soft Yoke Mooring
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Jacket Soft Yoke Mooring
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Internal Turret Design (Tentech)
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Detail of Internal Turret
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Large Internal Turret
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Disconnectable External Turret
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Disconnectable Internal Turret
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Location of Accommodation
• Largely influenced by position of turret
• Research shows that turret should be on further aft than 19% of length of vessel
• Achieves optimal operational efficiency
- Maximises weathervaning
- Minimises “pitching” effect
• May exlude choice in placement of accommodation
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Accommodation in Aft Location
• Normal solution for ship conversions
• Allows for optimal positioning of turret
• Stern abandonment is safest option
• Crew downwind of fire / smoke / flame
Additional engineering may be needed
- To protect “safe refuge’
- To allow for helicopter operations
- To minimise flare radiation effects
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Tantawan Explorer Aft Accommodation
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FPSO Firenze – Italy Aft Accommodation
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Accommodation in in Forward Location
• Most applicable for new build FPSOs
• Turret is aft of accommodation
• Crew upwind of fire / smoke / flame
• Forward abandonment may be difficult in rough weather
• Motion effects may make living conditions uncomfortable for crew
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Accommodation – Forward FPSO Norne
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Accommodation – Forward FPSO Asgard A
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Number of FPSOs Built
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Process Plant Layout
• Layout based on
-Safety
-Operability
• Most hazardous process areas
-Furthest from accommodation (TSR)
• Critical Level control
-Close to midships
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Distribution of FPSOs Worldwide (2008)
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Recent FPSO Developments (2000-2010)
• West Africa - Serpentina, Mystras, Sanha, Kizomba,AKPO - USAN • Brazil - Espadarte, Brasil • Australasia - Northern Endeavour, Venture 11 • South East Asia - Su Tu Den • Canada - Terra Nova
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FPSO Systems
Chapter 2
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FPSO Building Blocks
• Main systems for FPSO are:
- Hull type
- Oil storage
- Moorings
- Fluid transfer
- Topsides process plant
- Offtake and export
- Accommodation
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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
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Tanker Conversion
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Conversion Installing Topsides Modules
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New Built Hull
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Northern Endeavour New-Build
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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
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The External Turret System
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Simple External Turret
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Large External Turret
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Disconnectable External Turret
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Internal Turret System
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Internal Turret
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Fluid Transfer System
• Function of system: - To connect subsea risers to topsides process plant • Fact - Risers are stationary pipes - Topsides plant is on weathervaning ship • Problem - How to connect the two • Answer - Fluid swivel
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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
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Radial Swivel Joint
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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
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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
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Offtake and Export
• Crude oil export from an FPSO
- Connection to a pipeline
- Direct ship transfer
- Using a surface hose either floating or reeled
- Transfer through a loading buoy
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Direct Ship to Ship Offtake
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CALM Loading Buoy
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Accommodation • Two possible locations - Bow or Stern • Accommodation block contains temporary safe
refuge (TSR) • Layout of topsides plant must be based on: - Survivability of TSR
Greatest risks remote Gas or smoke ingression via HVAC prevented Fire and blast-proofing may need to be upgraded
- Unhindered personnel access to TSR from any point on deck
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Cost Estimate Conceptual Design- Large FPSO
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Turret and Mooring Systems Design
Chapter 3
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Turret Mooring System
• Mooring turret is unique FPSO feature
• Serves three purposes:
- Anchors vessel at geo-stationary position
- Allows vessel to weathervane
- Provides conduit for fluid transfer
Subsea reservoir infrastructure to topside processing plant
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Turret Overview
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Turret Design
• Three types of turret mooring systems
- External
- Internal
- Submerged
• Each type can be sub-divided into:
- Disconnect type
- Permanent connect type
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Disconnectable External Turret
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External Turret Permanent Mooring
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External Turret – Permanent Moored
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Internal Permanently Moored Turret
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Internally Permanently Moored Turret
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Maersk Curlew FPSO Turret - 1996
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Maersk Curlew FPSO
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FPSO Anasuria Turret Manifold Decks
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Large Diameter Internal Turrets
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Small Diameter Turrets
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Internal (Submerged) Disconnect Turret
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Submerged Turret
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Spread Moorings
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Bow Anchoring for Spread Mooring
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Jacket or Tower Mooring
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Tower Mooring
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Ship’s Motion
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Vessel Motion across the Sea Surface
• Based on the period » Short period motion due to waves
– 6 to 20 second typically
» Longer period due to wind and waves – Can be several minutes
– This is weathervaning
• Mooring forces increase with motion » In other words in rougher the seas the greater are
the mooring forces – More or stronger anchors
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Mooring Chain Table
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FPSO Mooring Spreads
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Process Facilities
Chapter 4
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Processing Facilities on a Typical FPSO
• Functional requirements
» Oil /gas separation
» Gas compression and treatment
» Produced water treatment and disposal
» Water injection
» Gas export / re-injection
» Support utilities
» Chemical injection and distribution
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Oil /Gas Separation
• First stage HP separation
• Second stage MP separation
• Third stage LP separation
• Electrostatic coalescing
• Well test separation
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Oil / Gas Separator with Wave Motion Internals
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Overall Topsides Module Layout
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Gas Compression & Treatment
• The three compression stages and associated compressors are:
» Flash gas compression K-201
» MP gas compression K-202
» HP gas compression K-203
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Water Injection
• Seawater supply
• Vacuum de-aeration
• Chemical injection
• Injection water delivery
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Support Utilities
• Fuel gas
• Flare & drainage
• Compressed air system
• Heating medium system
• Cooling medium system
• MP steam
• Seawater system
• Chemical injection system
• Power generation
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Utilities Integration Diagram
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Chemical Injection System
• Consists of three sub-systems
» Topsides
– For oil / gas & injection water processing & protection
» Hydrate inhibition
– For production & gas processing
» Subsea
– For wellhead & flowline protection
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Safety Assessment
• Need to consider
» Layout of equipment
» Consequences of fire / explosion
» Safety venting
» Design of the fire system
» Containment & drainage of process fluids
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Alternative Technologies
• Multi-phase flow metering
• Subsea water separation
• Subsea raw water injection
• Multi-phase booster pumping
• Subsea power distribution
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An SBM Vessel
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Power Generation Module
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Utilities (CM+HM) Module
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Water Injection Pumps
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Water Injection Module
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Chemical Injection & Water Injection
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Oil / Gas Separation Module
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Methanol Storage & Injection
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Glycol Regeneration
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Flare K.O Drums
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End of a Hard Day’s Work
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Mess Hall
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Gourmet Kitchen
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Her Own Power
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Marine Systems
Chapter 5
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Marine Systems
• Choice of Ship
• Tank Arrangements
• Loading/Offloading System
• Cargo Pumps
• Ballast System
• Stops System
• Inert Gas System
• Vessel/Topsides Interface
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Choice of Ship
• Factors affecting the choice of ship are:
» Cost of conversion vs new build
» Field life and redeployment
» Need for additional strengthening
» Cargo tank conditions
• Capacity of cargo storage and offloading
• Condition of machinery
• Propulsion type
• Free area for topsides plant
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Vessel Sizes
• Tanker sizes used for FPSO conversion
» VLCC (very large crude carrier)
– 200,000 to 319,000 dwt
» Suezmax
• 120,000 to 200,000 dwt
» Aframax
• 75,000 to 120,000 dwt
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FPSO Tank Arrangements
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Cargo Offloading Systems
• Floating Hose
• Reeled Hose
• CALM Buoy
• Submerged Hose
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Floating Hose Arrangement
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FPSO Stern Offloading
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Stern Offloading Hose Reel
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Reeled Hose Arrangement
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CALM Buoy
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Submerged Hose System
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Submerged Cargo Pumps
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Tank Cleaning
• Crude Oil Washing – COW
» Removes wax and sediment build-up
» Carried out during offloading operations
» Uses warmed crude oil
» Following oil washing
– Water washing used prior to tank inspection
– Water washing can generate static charges
– Always done under inert gas blanket
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Tank Vapour Recovery
• Today’s environment focus is on:
» Emissions!!
• Cargo tank operations – no exception
• Tank vapour recovery is modern trend
» Don’t vent tank vapour – re-use it!!
• Problem – its “inert” nature
• Answer – don’t use “inert” gas
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Tank Blanketing
• Latest development is tank blanketing
» Use a gas that will:
– Exclude air, but be re-usable
» Hydrocarbon gas fills that need
• During loading tank gases
» Recovered for use as fuel
• During offloading separator gas
» Flows into tanks to exclude air