FPSO Design & Technology Course

Introduction

This three day course will focus on the key technical questions that an FPSO team need to address as part of the overall design project. The course has been exclusively designed to equip participants with the key tools needed to find answers to these questions and to make the appropriate decisions to advance future projects. The course will cover the full spectrum of issues relating to FPSO design projects which will allow

technical personnel to obtain a better understanding of challenges and risk areas associated with this.

Outline

Day 1

Floating Production Market o Floating production market: presentation by geographical areas: North Sea, West

Africa, North America, Brazil, Asia Pacific (including Australia), Arctic etc. o Characteristics of main areas: location, environment, water depth, others o Major floating production developments in each area (field names, floaters). o Typical field layouts and field development requirements

Floater Design and Technology

o Presentation of the different types of floaters: Mono-hull, Semi-submersible, Deep

draught Semi-submersible, Spar, TLP, FDPSO, others. o Functional requirements o Field characteristics o Production characteristics o Operation Characteristics o Topsides o Storage / export facilities

o Constructability (and construction materials) o Scheme maturity o Flexibility o Cost drivers o Decommissioning and re-use

Field Architecture with Floating Production Units and Subsea Systems

o Factors driving the Field lay-out; Reservoir & Fluids, Subsea Wells trajectories, SPS &

SURF Building blocks & lay-out, Choice of Floater, Mooring lay-out, choice of Risers systems, Export system & requirements for subsea Work-Over operations.

o Detailed System Design Analysis and Flow Assurance main issues, constrains & mitigations.

o Analysis of specific Fields Lay-outs in Shallow waters and Deep waters with Semi-subs

FPV & FPSO/FLNG.

Topsides Design – Introduction to Process Systems o Introduction to reservoir fluids: oil, condensate, gas

Reservoir data, API density Emulsion, foam, hydrates, naphtenates, wax, sulphates

Presentation of the main functions of topsides processing: o Oil separation o Gas treatment and compression

o Water injection o Produced water o Flare

o Other process systems o Utility systems o Completed by identification of specific process requirements for a floater:

Vessel motion, weather considerations, lay-out

Case Study 1: Process systems operations on BP Angola FPSO Greater Plutonio o Review of the training CD every BP operator must learn before going offshore, to

operate the FPSO facilities and the Subsea Production facilities. (From Reservoir to oil and mgas export systems with Full Processing operations & controls).

Day 2

Topsides Design – Introduction to other Disciplines

o Presentation of the important disciplines (besides process) regarding topsides design: o Safety: health, safety and environment (fire and gas detection, active and passive

protection, escape, evacuation, rescue, emergency systems, etc) o Piping and layout: equipment piping, pipe racks, routing, spools, pipe supports o Structures: module design, pancakes, space frames, supports

o Electrical: power generation (main generators, essential and emergency generators, electrical distribution)

o Instrumentation: integrated control and safety system (ICSS) etc o Telecommunications o Handling: cranes, monorails, lay-down, access o Corrosion protection o Accommodation

Design Requirements, Codes and Standards

o Identification of the main requirements, rules and standards, which govern the design o Country-enforced rules and regulations o Classification Societies rules and regulations

o Project specific documents

o Operating Oil & Gas Companies general specifications o International Codes and Standards – References.

Hull Design

o Presentation of the main Design issues o New Hull or second hand tanker conversion o Main hull features

o Main hull systems o Detail design general requirements o Detail design requirements for ship areas o Detail design requirements for offshore areas

Mooring Design

o Types of mooring : spread mooring, turret mooring

o Mooring system design(loads, layout, analysis) o Mooring system components(winches & fairleads, chains, wire ropes, etc) o Mooring system installation o Developments for deep water o Maintenance, inspection and replacement of mooring lines

Turret Mooring and Swivels o Turret mooring: types of systems o Weathervaning and mooring forces o Turret position on FPSO o Turret size o Turret bearing system o Mooring lines connection and handling

o Risers connection and handling o Fluid control and power transfer system (swivel technology, drag chain system, etc.)

o Other aspects (safety, fabrication, installation and testing, operation, patents)

Day 3

Case Study 2: Chevron Alba FSO; First SBM internal turret in the North Sea o A detailed review of the turret system, mooring lines design and installation, Chain

table & Flexible

o Risers connections, main deck turret piping & valves, pigging system, fluid swivel and back-up, leak

o Detection system, interfaces with cargo piping & Oil export + Diesel export to ANP, Integrity monitoring and Surge systems.

Riser Design for Floaters

o Different types of riser systems: Dynamic flexible risers, SCRs, Hybrid tower systems with multiple or single risers & other current solutions. History & track records

o Design requirements o Characteristics (structural design, dimensions, fluid types, etc.)

o Key functional requirements and drivers (including dynamic loads) o Analysis methodologies, model testing & dynamic stimulation demonstration of a

design example

Oil Export Options and Offshore Offloading

o Different types of Offloading tankers o Direct Offloading systems : Side by side, Tandem offloading o Remote offloading systems: CALM buoy, UKOLS, STL, SAL & SALM, etc. o Safety requirements during offloading o Cargo offloading metering systems

o Shuttle tanker operations and safety track record

Case Study 3: The Total Angola FPSO DALIA Story, operating in deep water Block 17-1400m

o A review of this very large, spread moored FPSO, designed for heavy oil production.

Largest Subsea Production system operating 71 subsea wells. o Update on current operations.

FPSO Design Development

o Development phases: conceptual, FEED, detail design o Conceptual design : Objectives and deliverables o Pre-project design or FEED : Objectives and deliverables, FEED activities

o Detail design : Objectives and deliverables, Detail design activities o Critical subjects are addressed : o Schedule and man-hours o Interfaces o Risk management: technical audits, technical reviews, HAZOPs, etc. o Weight Control

Learning Objectives

Upon Completion of this programme; the participants will be able to:-

Understand the floating production market by geography and their design types & characteristics;

Examine the key design and technology considerations for FPSO construction today; Identify the critical design requirements, codes and standards which govern FPSO design; Review the main functions of topside process systems, its typical production capabilities

and related disciplines; Understand key design considerations for Hull, Mooring, Swivels & Fluid Transfers Systems

and Risers; Learn Oil export and offshore offloading requirements and systems; and

Gain an overview of FPSO design development projects and the key factors for success.