This document provides an overview of FPSO (floating production storage and offloading) vessel design and systems. It discusses the key components of an FPSO including the hull, mooring systems, fluid transfer systems, topside process facilities, marine systems for cargo handling and offloading, and support utilities. The document focuses on turret mooring systems as the predominant mooring type used on FPSOs and how they enable weathervaning and fluid transfer between subsea infrastructure and the topside processing facilities.
Speaker: Dr Jinzhu Xia, Head Consultant, Marine, Granherne, Australia
Date: Tuesday, 6 March 2012
Hosted by: WA Oil & Gas Facilities Group a co-venture between Engineers Australia and the Society of Petroleum Engineers (SPE)
Fpso – general overview of conversion & topside process description -abstractAnoop Rajendran Nair
Abstract of the technical presentation on FPSO conversions and modularised topside process taken at MASTECH 2011 at Sharjah as part of Gulf Maritime Expo 2011.
Speaker: Dr Jinzhu Xia, Head Consultant, Marine, Granherne, Australia
Date: Tuesday, 6 March 2012
Hosted by: WA Oil & Gas Facilities Group a co-venture between Engineers Australia and the Society of Petroleum Engineers (SPE)
Fpso – general overview of conversion & topside process description -abstractAnoop Rajendran Nair
Abstract of the technical presentation on FPSO conversions and modularised topside process taken at MASTECH 2011 at Sharjah as part of Gulf Maritime Expo 2011.
This course is intended for officers and key ratings that have not
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prescribed by Regulation V/1, paragraph 1.2 of the International
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general operational sequence and liquefied gas tanker terminology.
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This course is intended for officers and key ratings that have not
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complement. It covers mandatory minimum training requirements
prescribed by Regulation V/1, paragraph 1.2 of the International
Convention on Standards of Training, Certification and Watchkeeping for
Seafarers, STCW-95 and it includes basic safety and pollution-prevention
precautions and procedures, layouts of different types of liquefied gas
tankers, types of cargo, their hazards and their handling equipment,
general operational sequence and liquefied gas tanker terminology.
Introduction to offshore oil and gas surface facilities, including drilling rig types, topside and substructures, jacket, compliant tower, jack up, gravity based structure, fpso, fso, semi submersible, tlp, spar, wellhead platform, processing platform, pipeline, and surface facilities selection
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A cargo hatch or deck hatch or hatchway is type of door used on ships and boats to cover the opening to the cargo hold or other lower part of the ship. To make the cargo hold waterproof, most cargo holds have cargo hatch. Hatch covers of ships are designed to be efficient and cost-effective, as an initial investment and during service, and at the same time should suit the demands of the various types of cargo vessels. With the many changing trends of cargo transportation, it would be expected that the design and structure of cargo holds would change to meet the needs of modern shipping. This is clearly evident with container tonnage and the vehicle decks of the Roll-on, Roll-off (Ro-Ro) vessels. However, the changes in the carriage of general cargoes have been comparatively small. This is possible because most merchandise will suit the more popular container or similar unit load movement.
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Book Formatting: Quality Control Checks for DesignersConfidence Ago
This presentation was made to help designers who work in publishing houses or format books for printing ensure quality.
Quality control is vital to every industry. This is why every department in a company need create a method they use in ensuring quality. This, perhaps, will not only improve the quality of products and bring errors to the barest minimum, but take it to a near perfect finish.
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3. 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
5. 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
7. 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
8. 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
9. 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
10. 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
11. 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
12. 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)
13. 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
14. 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
15. 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
16. 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
27. 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
28. 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
31. 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
35. Process Plant Layout
• Layout based on
-Safety
-Operability
• Most hazardous process areas
-Furthest from accommodation (TSR)
• Critical Level control
-Close to midships
37. 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
39. FPSO Building Blocks
• Main systems for FPSO are:
- Hull type
- Oil storage
- Moorings
- Fluid transfer
- Topsides process plant
- Offtake and export
- Accommodation
40. 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
45. 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
52. 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
53. 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
55. 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
56. 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
57. 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
60. 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
63. 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
65. Turret Design
• Three types of turret mooring systems
- External
- Internal
- Submerged
• Each type can be sub-divided into:
- Disconnect type
- Permanent connect type
83. 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
87. 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
88. Oil /Gas Separation
• First stage HP separation
• Second stage MP separation
• Third stage LP separation
• Electrostatic coalescing
• Well test separation
89. Oil / Gas Separator with Wave Motion
Internals
91. 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
93. Support Utilities
• Fuel gas
• Flare & drainage
• Compressed air system
• Heating medium system
• Cooling medium system
• MP steam
• Seawater system
• Chemical injection
system
• Power generation
95. 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
96. Safety Assessment
• Need to consider
» Layout of equipment
» Consequences of fire / explosion
» Safety venting
» Design of the fire system
» Containment & drainage of process fluids
97. Alternative Technologies
• Multi-phase flow metering
• Subsea water separation
• Subsea raw water injection
• Multi-phase booster pumping
• Subsea power distribution
113. Marine Systems
• Choice of Ship
• Tank Arrangements
• Loading/Offloading
System
• Cargo Pumps
• Ballast System
• Stops System
• Inert Gas System
• Vessel/Topsides
Interface
114. 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
115. 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
125. 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
126. 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
127. 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