LR FPSO Design

8/13/2019 LR FPSO Design

1/34

OGP Marine Risks Workshop Proceedings

OGP

. Tanker Conversions to FPSOsRob Potthurst, Lloyds Register

OilandG

asServices

OilandG

asServices

OilandG

asServices

Presentation onPresentation on

Tanker ConversionsTanker Conversions

toto FPSOsFPSOs

RobRob PotthurstPotthurst

Offshore Floating UnitsOffshore Floating Units

Oil and GasOil and Gas

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

OverviewOverview

Market summaryMarket summary

LR ExperienceLR Experience

Key issuesKey issues

Rules and RegulationsRules and Regulations

Hull strength and fatigueHull strength and fatigue

Some lessons learnt (hopefully)Some lessons learnt (hopefully)


2/34

International Association of Oil & Gas Producers

OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

FPSO / FSO

Market

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Total 70+ units worldwideTotal 70+ units worldwide

NewbuildNewbuild

(30%)(30%)

ConversionConversion

(70%)(70%)

ShipShip--type Floatingtype Floating

Production UnitsProduction Units

Tanker Conversions to FPSOs - Rob Potthurst, Lloyds Register ()


3/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Future Floating OffshoreFuture Floating Offshore

Installation ProjectsInstallation Projects

Analysis of asset types identified under theAnalysis of asset types identified under themost likely development solutionmost likely development solution

TLPTLP

(11%)(11%)

FSOFSO

(8%)(8%) SemiSemi

(3%)(3%)

SPARSPAR

(18%)(18%)

FPSOFPSO

(60%)(60%)

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

F(P)SO CapabilitiesF(P)SO Capabilities

Typical RequirementsTypical Requirements

Storage 200,000 - 2,000,000 barrels

Production 30,000 - 300,000 bopd

Vessel 100,000 - 350,000 tonnes

Water depth 70 - 1500 metres

Topsides 2000 - 33000 tonnes

Risers 1 - > 30

Wave height benign - > 30 metres

Air temp -20oC - > 30oC



4/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

LR Experience

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices LR ExperienceLR Experience

FPSO and FSO Units

Steel Fixed Platforms ~ 800

Buoys Pipelines

Jack-ups

Semi-submersibles

Concrete Structures

~ 40

~ 15

~ 70

~ 50

~ 75

~ 30



5/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Floating Production Installations

- LR Worldwide Experience

BraziBrazill33

CanadaCanada33

NorthNorthSeaSea1919

MediterraneaMediterraneann44

VietnaVietnamm22

AustraliaAustralia55

PhilippinePhilippiness22

NewNewZealandZealand

11

West ofWest ofShetlandsShetlands

11

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Recent Conversion ExperienceRecent Conversion Experience

Amerada Hess TritonAmerada Hess Triton

Amerada Hess FifeAmerada Hess Fife

Amerada HessAmerada Hess BluewaterBluewater DurwardDurward/Dauntless/Dauntless

BluewaterBluewater BleoBleo HolmHolm

ExproExpro EfiatEfiat AbanaAbana

MAS CurlewMAS Curlew

PetechimPetechim VietsovpetroVietsovpetro DragonDragon

PetrobrasPetrobras RoncadorRoncador

PetrobrasPetrobras Barracuda (exBarracuda (ex PP.MoraesPP.Moraes))

Reading & BatesReading & Bates SeallionSeallion

Shell Todd Maui BShell Todd Maui B

SLP/SLP/MaerskMaersk ConocoConoco MacCullochMacCulloch

ShellShell soreenasoreena



6/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Example of ConversionExample of Conversion

ConocoConoco MacCullochMacCulloch

North Sea ProducerNorth Sea Producer -- TeessideTeesside

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Example of ConversionExample of Conversion

FPSO Whakaaropaifor Shell Todd Maui B Field

FPSO FPSO WhakaaropaiWhakaaropaifor Shell Todd Maui B Fieldfor Shell Todd Maui B Field

Oil Storage Capacity approx. 760,000bbls



7/34


OGP

OilandGasServices

OilandGasServices

OilandGasServices

Conversions

Key Issues

OilandGas

Services

OilandGasServices

OilandGas

Services

Overall requirementsOverall requirements

Shallow/DeepwaterShallow/Deepwater

Turret/Spread mooringTurret/Spread mooring

arrangementsarrangements Permanent /Permanent / DisconnectableDisconnectable

mooringsmoorings

Small/Large displacement hullsSmall/Large displacement hulls

Benign/Harsh environmentsBenign/Harsh environments

Project management requiredProject management required



8/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

What makes an FPSO differentWhat makes an FPSO different

from a trading tanker?from a trading tanker?

Operations and safety requirementsOperations and safety requirements

Layout and arrangementLayout and arrangement

Specified service/locationSpecified service/location Rules and regulationsRules and regulations

Design/construction/commissioningDesign/construction/commissioning

InIn--situ inspection/maintenancesitu inspection/maintenance

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Key Choice DriversKey Choice Drivers

Project and client requirementsProject and client requirements

time to first oiltime to first oil

location/environmentlocation/environment

functionfunction

life cycle costslife cycle costs

Statutory and National Authority requirementsStatutory and National Authority requirements Ship Yard scheduleShip Yard schedule

availability / capability / priceavailability / capability / price

locationlocation Availability of suitable tonnageAvailability of suitable tonnage

capacitycapacity

condition, agecondition, age

upgrading scopeupgrading scope

New build: 2 to 3 years; Conversion: 1 to 2 yearsNew build: 2 to 3 years; Conversion: 1 to 2 years



9/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Hull Selection Issues (conversion)Hull Selection Issues (conversion)

Vessel age, condition and service historyVessel age, condition and service history hull global strengthhull global strength remaining corrosion marginsremaining corrosion margins remaining fatigue liferemaining fatigue life structural steelwork replacementstructural steelwork replacement

Mooring structureMooring structure internal or external modificationsinternal or external modifications structural reinforcementstructural reinforcement

Topside integrationTopside integration structural reinforcementstructural reinforcement

UpgradesUpgrades equipment / systemsequipment / systems coatings / corrosion controlcoatings / corrosion control machinerymachinery accommodationaccommodation

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices ConversionConversion -- Major WorksMajor Works

Existing HullExisting Hull

Removals/modificationsRemovals/modifications hull steelwork, coatings etc.hull steelwork, coatings etc. propulsion and other machinerypropulsion and other machinery rudder/steering gearrudder/steering gear accommodation, deckhouses andaccommodation, deckhouses and helideckhelideck piping systemspiping systems

UpgradesUpgrades marine and topsides control system integrationmarine and topsides control system integration fire protection systems and their integrationfire protection systems and their integration power generation systems and their integrationpower generation systems and their integration cargo tank venting arrangementcargo tank venting arrangement ballast and cargo oil pumps and valvesballast and cargo oil pumps and valves inert gas systeminert gas system utility systems (utility systems (egegwater, steam, heating)water, steam, heating)



10/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices ConversionConversion -- Major WorksMajor Works

Hull AdditionsHull Additions

turret or spread mooring system, equipment, etcturret or spread mooring system, equipment, etc

riser porches or fluid transfer system and pipingriser porches or fluid transfer system and piping

provision of thrustersprovision of thrusters

installation of process deck supportsinstallation of process deck supports

process systemsprocess systems PAUsPAUs, flare and piping, flare and piping

blast wallsblast walls life saving equipmentlife saving equipment

fire and gas equipment and systemsfire and gas equipment and systems

evacuation measuresevacuation measures

bulwark and breakwaterbulwark and breakwater

lifting equipmentlifting equipment

loading instrument (computer)loading instrument (computer)

offloading systemoffloading system

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Mooring ArrangementsMooring Arrangements

BowBow

MooringMooring

InternalInternalTurretTurret

MooringMooring

SpreadSpread

MooringMooring



11/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Turret Mooring SystemsTurret Mooring Systems

Large Internal TurretLarge Internal Turret Small Internal TurretSmall Internal Turret Riser Turret MooringRiser Turret Mooring

(D)(D)

External Turret MooringExternal Turret MooringSubmerged TurretSubmerged Turret

Production (D)Production (D)Buoyant TurretBuoyant Turret

Mooring (D)Mooring (D)

InternalInternal ExternalExternal

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices General arrangementGeneral arrangement

Living quarters at the sternLiving quarters at the stern

Living quartersLiving quarters

OilOilSep.Sep.

P.G.P.G.

GasGasComp.Comp.

MeteringMetering

Flare TowerFlare Tower

TurretTurret

Living quartersLiving quarters

P.G.P.G.

OilOilSep.Sep.

GasGasComp.Comp.

MeteringMetering

Flare TowerFlare Tower

TurretTurret

Living quarters at the bowLiving quarters at the bow



12/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

FPSO

Rules and Regulations

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Governing RegulationsGoverning Regulations

Local National AuthorityLocal National Authority

Class Rules for FPSO InstallationsClass Rules for FPSO Installations

Flag StateFlag State

International ConventionsInternational Conventions

SOLAS, MARPOL, LOADLINE,SOLAS, MARPOL, LOADLINE,TONNAGETONNAGE



13/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices National RegulationsNational Regulations

U.K.U.K. HSE safety case and verificationHSE safety case and verification

Canada(NS)Canada(NS) CNOPB, TC(flag) ,RQF, classCNOPB, TC(flag) ,RQF, class

BrazilBrazil (BNW), class, flag(BNW), class, flag

NigeriaNigeria Marine Notice, class, flag(N)Marine Notice, class, flag(N) Gulf of MexicoGulf of Mexico FollowsFollows

__________________________________________________________

International ConventionsInternational Conventions

SOLAS, MARPOL, LOADLINE,SOLAS, MARPOL, LOADLINE,TONNAGETONNAGE

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

DefinitionsDefinitions

ClassClass

Rules Based / Risk BasedRules Based / Risk Based

CertificationCertification

To Regulations and CodesTo Regulations and Codes VerificationVerification

To Performance CriteriaTo Performance Criteria

ClassClass\\CertificationCertification\\VerificationVerification

often combinedoften combined



14/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Rules for a Floating OffshoreRules for a Floating Offshore

Installation at Fixed LocationInstallation at Fixed Location

Rules and

Regulations

Part 4

Rules and

Regulations

Part 4

Rules and

Regulations

Part 4

Rules and

Regulations

Part 4

Rules and

Regulations

Part 5

Rules and

Regulations

Part 4

Rules and

Regulations

Part 3Rules and

Regulations

Part 2

Rules and

Regulations

Part 1ARules andRegulations

Part 1

Parts 2 to 9

Technical Regulations

Parts 2 to 9Parts 2 to 9

Technical RegulationsTechnical Regulations

Part 1APart 1A

Risk Based ApproachRisk Based Approach

Part 1Part 1

RegulationsRegulations

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Scope of LR FPSO RulesScope of LR FPSO Rules

LR Rules cover the followingLR Rules cover the following

aspects :aspects :

Hull and Marine SystemsHull and Marine Systems

Mooring SystemsMooring Systems

Risers (optional)Risers (optional)

Process plant (optional)Process plant (optional)

Drilling plant (optional)Drilling plant (optional)



15/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

LR ClassificationLR Classification

AlternativesAlternatives

Prescriptive RulesPrescriptive Rules -- business as usualbusiness as usual

Flexibility of Risk Based optionsFlexibility of Risk Based options

Risk Based SolutionsRisk Based Solutions

Applicable to Design of both hull andApplicable to Design of both hull andtopsides, although generally hulltopsides, although generally hulladopts prescriptive approachadopts prescriptive approach

Applicable to Periodic InspectionApplicable to Periodic Inspection(draft LR guidance available)(draft LR guidance available)

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

AA6cAA6c

LR Guidance NotesLR Guidance Notes

Supporting the RulesSupporting the Rules

An Overview of Regulatory Issues

Conversion of Tankers for Floating

Production Service Ship Type Hull Structural Appraisal and

supplement Additional Structural Aspects

Positional Mooring Systems and supplement FibreRopes for Offshore Moorings

Periodic Inspection

Design Appraisal of Semi-Submersible Units



16/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Conversions

Hull strength and fatigue

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Hull Design ConsiderationsHull Design Considerations

hull strength, arrangement and materials 100-year site specific criteria local connection details and fatigue life (min 20 years) range of loading conditions vessel motions and accelerations mooring system and hull integration process support structure slamming and green seas sloshing helideck, cranes and cargo offloading system accommodation corrosion control construction tolerances and fabrication quality philosophy for in-service periodic survey interfaces



17/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Model TestingModel Testing -- supportsupport

To support design calculationsTo support design calculations

Riser & mooring designRiser & mooring design

Loading, excursions, separationLoading, excursions, separation

FPSO/shuttle tanker interactionFPSO/shuttle tanker interaction

Hull motions, slamming, greenHull motions, slamming, greenseasseas

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Ship RulesShip Rules -- basic hull strengthbasic hull strength

Parametric equations for :Parametric equations for :

Wave bending moment/shear forceWave bending moment/shear force

inertiainertia

Hull modulusHull modulus

FEA requirementFEA requirement(strength/fatigue)(strength/fatigue)

Local strengthLocal strength

WW service (limitation options)WW service (limitation options)

Equivalence through IACSEquivalence through IACS



18/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices FPSO HullFPSO Hull -- Global StrengthGlobal Strength

Minimum class rule standardMinimum class rule standard

Site specific environmental criteriaSite specific environmental criteria

Effect of mooring systemEffect of mooring system(+(+weathervaningweathervaning))

Process facilitiesProcess facilities Long term service (at site)Long term service (at site)

Range of loading conditionsRange of loading conditions

(including inspection and accidental cases)(including inspection and accidental cases)

Slamming/green seasSlamming/green seas

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

FF2FF2--1g1g

Global Hull DesignGlobal Hull Design wave BM & SFwave BM & SF

Still water loading conditions often more severefor FPSOs

Class Rules permit review of Rule versus Sitespecific wave bending moments and shear forces

Will depend upon site environmental criteria Harsh environment wave BM and SF are close to and

may exceed Ship Rule requirements Benign environment are less than Ship Rules but not to

be taken less than 70% of unrestricted service Ship Rulerequirements in general

Multisite operation may require assessment Owners requirements, eg corrosion margins Towing and temporary conditions to be

considered



19/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

100 Year Hs /100 Year Hs / TpTp ContoursContours

2 6 10 14 18 22 26 304

6

8

10

12

14

16

18

2020

4

Hs12 i

Hs22 i

Hs32 i

302 TP12 i

TP22 i

TP32 i

West of ShetlandWest of Shetland

Northern North SeaNorthern North Sea

Central North SeaCentral North Sea

Hs

Tp

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Some typical criteriaSome typical criteria

HsHs TpTp

NigeriaNigeria 3.13.1 7.67.6

Offshore IranOffshore Iran 5.95.9 10.210.2

AustraliaAustralia 7.27.2 11.111.1U.K. CentralU.K. Central 13.013.0 15.215.2

West of ShetlandWest of Shetland 17.117.1 16.016.0

Nova ScotiaNova Scotia 16.016.0 14/1814/18



20/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Accidental LoadsAccidental Loads

Collision due to supply boat /Collision due to supply boat /shuttle tanker / icebergshuttle tanker / iceberg

Dropped objectDropped object

Explosion / blastExplosion / blast

Ultimate strength criteriaUltimate strength criteria

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Steel GradesSteel Grades

Class rules for shipsClass rules for ships

New requirements for lowNew requirements for low

temperature operationtemperature operation

Structural categoriesStructural categories ThicknessThickness

LocationLocation



21/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Hull Strength/Fatigue FEAHull Strength/Fatigue FEA

Cargo / ballast tank areaCargo / ballast tank area

Hopper knuckle connectionHopper knuckle connection

Mooring structure and hull integrationMooring structure and hull integration

Riser porches and supporting structureRiser porches and supporting structure

Topsides support structure and hull integrationTopsides support structure and hull integration

Flare tower support structureFlare tower support structure Access tower support structureAccess tower support structure

Offloading station support structureOffloading station support structure

Main crane pedestals and support structureMain crane pedestals and support structure

HelideckHelideck structurestructure

Additional locations depending on vesselAdditional locations depending on vessel

function and owners requirementsfunction and owners requirements

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Fatigue LifeFatigue Life

Factors of SafetyFactors of Safety

Substantial consequences of failure are defined as loss of life,uncontrolled outflow of hazardous products, collision orsinking and should include for progressive failure scenarios.

Note 1Note 1 : includes external components which can be dry inspected / repa: includes external components which can be dry inspected / repaired.ired.

Note 2Note 2 : includes external components below the minimum operating draft: includes external components below the minimum operating draftwhich can only be inspected in water , but dry repairs could bewhich can only be inspected in water , but dry repairs could be carried out.carried out.

Inspectable/

Repairable

Fatigue Life Factor

Consequence of Failure

Non-substantial Substantial

Yes, dry(see note 1)

1 2

Yes, wet(see note 2)

2 4

No 3 10



22/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Typical Critical AreasTypical Critical Areas

Process SupportsProcess Supports

Stress ConcentrationStress Concentration

MisalignmentMisalignment

WeldingWelding

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

FPSO Fatigue EnhancementFPSO Fatigue Enhancement

Details (conversion)Details (conversion)

Examples of modification to hull longitudinal connection detailsExamples of modification to hull longitudinal connection details

Additional lugAdditional lug

Longitudinal/Transverse frameLongitudinal/Transverse frameconnectionconnection

AdditionalAdditional

bracketbracket

LongitudinalLongitudinal

Transverse frameTransverse frame

Shell plateShell plate

AdditionAdditionalalbracketbracket







AdditionalAdditionalbracketbracket

Within cargo and ballastWithin cargo and ballast

tankstanks

ItemItem

ExtenExten

ttBottom and side shell (up toBottom and side shell (up tolimit of wetted area)limit of wetted area)

Bilge areaBilge area andand side shellside shell(up to limitof wetted(up to limitof wetted

Additional LugsAdditional Lugs

AdditionalAdditional BktsBkts

area)area)



23/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Green SeasGreen Seas

RuleRulerequirementsrequirements

Model testinModel testin PressuresPressures

BreakwaterBreakwater

DrainageDrainage

typtyp..

88--14m14m

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Bottom SlammingBottom Slamming



24/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Sloshing in Cargo Oil TanksSloshing in Cargo Oil Tanks

Tank SizeTank Size

Hull formHull form

EnvironmentEnvironment

Natural PeriodsNatural Periods

LR FLUIDSLR FLUIDS

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Typical Hull Protection SystemTypical Hull Protection System

HighHighperformanceperformance

coatingcoating

High performance coating +High performance coating +cathodiccathodic protection systemprotection system

WaterWaterballastballast

Max. W.L.Max. W.L.

Min. W.L.Min. W.L.

HPCHPC

++

SASA

HPCHPC

CoatingCoating

NB : ImpressedNB : Impressedcurrent systemcurrent system

not allowed innot allowed inCargo oilCargo oiltankstanks

CoatingCoating



25/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Fabrication Tolerances and WeldingFabrication Tolerances and Welding

tolerances should be in accordance withgood shipbuilding practice, and agreed withLR

special attention given to fatigue sensitiveareas

enhanced NDE levels will be necessary foridentified fatigue sensitive areas

assumptions used in analytical fatigueassessments to be consistent withconstruction

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices NDE Testing of WeldsNDE Testing of Welds -- generalgeneral

Intersection of butts and seams & section weldsIntersection of butts and seams & section welds

Butt welds in platingButt welds in plating

Seam welds in platingSeam welds in plating

Bilge keel buttsBilge keel butts

Structural items fabricated with full/part penetrationStructural items fabricated with full/part penetration

weldingwelding (hopper knuckles,(hopper knuckles, sheerstrake, hatchway coamings)

Penetrations & attachments to hullPenetrations & attachments to hull (sea inlets, piping, anode(sea inlets, piping, anodesupports)supports)

MoonpoolMoonpool integration structureintegration structure

Topside support structure connections to hull structureTopside support structure connections to hull structure

Additional requirements for low temperature operationsAdditional requirements for low temperature operations



26/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

FPSO some

In-service feedback

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

FF1FF1--3c3c

Some Design Life IssuesSome Design Life Issues

Holistic approach for project / goodcommunications

Design for required service Compatibility of hull structural, systems and

topsides interfaces Production equipment for required service Marine equipment robustness, particularly

cargo/ballast and control/electrical systems OIWS requirements and corrosion protection Access arrangements Provision of spare parts



27/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices DesignDesign-- Frequent areas of concernFrequent areas of concern

Marine/offshore regulations and practices

Topsides structure supports (alignment, motions)

Hull vibration

Crane specification and integration with hull

Corrosion - general

Access and escape routes compatibility

Hazardous area and classification interfaces

Piping systems (compatibility/flexibility)

Topside equipment / motions / helicopter operations Marine / Topside system integration

Use of GRP / FRP, pipework etc

Wave impact and green sea loading

Rudder and steering gear

Laydown areas

Effect of exhaust (heli-operations)

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices Design IssuesDesign Issues -- InterfacesInterfaces

Interface Management is a critical influence onInterface Management is a critical influence onproject successproject success

LR Project Manager provides interface betweenLR Project Manager provides interface betweendesign and class/certification processesdesign and class/certification processes

Technical interfaces to be developed include:Technical interfaces to be developed include: Escape and access routingEscape and access routing

Hazardous area definitionHazardous area definition Venting arrangements (clear of hazardous areas and for inspectioVenting arrangements (clear of hazardous areas and for inspectionn

activities)activities)

Power generation and supply systems, normal and backupPower generation and supply systems, normal and backup

BundingBunding/prevention of spillage to main deck/prevention of spillage to main deck

Control System and alarm circuitsControl System and alarm circuits

Crude oil pumping and piping system between vessel, process andCrude oil pumping and piping system between vessel, process andoffloading systems, including materialsoffloading systems, including materials

Fire Water, Cooling and Injection WaterFire Water, Cooling and Injection Water

Heating system, Compressed air supplyHeating system, Compressed air supply

Topsides structure alignment at integration with deckTopsides structure alignment at integration with deck

Deck crane integration with hull structureDeck crane integration with hull structure

Mooring system integration with hull structureMooring system integration with hull structure



28/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Structural InspectionStructural Inspection

Carried out on locationCarried out on location

Provides detection / monitoringProvides detection / monitoringcapacitycapacity

Annual, intermediate & majorAnnual, intermediate & majorsurveyssurveys

Major survey (5 years or continuous)Major survey (5 years or continuous)

IWS in lieu of dry dockingIWS in lieu of dry docking

Internal surveyInternal survey cleaning & gas freeingcleaning & gas freeing

access arrangements/safetyaccess arrangements/safety

lighting/ventilationlighting/ventilation

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices FPSO Incident History ExamplesFPSO Incident History Examples

Hull Structure

Shuttle tanker collision

Bow Wave Impact Damage

Tank Overpressurisation

Seawater caissonpreferential Corrosion

Integration of surface andsubsea corrosion protection

Rudder/steering gear

Marine Equipment

Corrosion in cooling andheating systems due to poorfluid chemistry control

Material problems onseawater systems

TopsidesTopsides

Vibration induced failuresVibration induced failures

Inadequate application ofInadequate application ofPFPPFP

Gas Turbine problemsGas Turbine problems

Produced WaterProduced WaterCorrosionCorrosion

Damage due to waveDamage due to waveimpact (green water)impact (green water)

Cargo Venting SystemCargo Venting Systemfailurefailure

Pipework and ProductionPipework and ProductionTrain LeakageTrain Leakage

Riser / turret connectionsRiser / turret connections



29/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices FPSO Incident HistoryFPSO Incident History

Statistics (Reported)Statistics (Reported)

Ref : 22 vessels, approx 10 years of recordsRef : 22 vessels, approx 10 years of records

See alsoSee also Quantified Frequency of shuttle tanker collision during offtakeQuantified Frequency of shuttle tanker collision during offtake operationsoperations, IMCA, IMCA

VesselSystem

Nature of Incident No. ofIncidents

Hull Structure failure in heavy weather 1Other structural failure 3Collision 6

Topsides Structural failure in heavy weather 3

Process equipment failure 2Fire 0

Machinery Engine Room fire 2Engine Room power failure 1Main engine failure 1Rudder / steering gear failure 3

Other Hydrocarbon release 2Explosions 0Loss of anchor(s) 1

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Vibration DamageVibration Damage flare stackflare stackVortex vibrations @ Beaufort 4Vortex vibrations @ Beaufort 4 -- 55

View A

View B

View A

View B

Turret Deckhouse

Brace on Port Side -cracked over 180o atconnection to forwardchord.

Proposedreinforcements - twolateral braces.



30/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Mooring System InstallationMooring System Installation

Problems Experienced

Handling equipment failures

Wire ropes

Poor tension control

Loops formed

Bird caging

Chains

Lack of straightness

Installed with twist

Tangles & breakage

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Results from a Structural SurveyResults from a Structural Survey

Example of DefectExample of Defect

AreaAreashownshown

Cargo/ballast tanksCargo/ballast tanks DefectDefect

B B B B

LocationsLocations

on Side Shellon Side Shell

B B B



31/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices

Typical DamageTypical Damage

Side shell longitudinal connectionSide shell longitudinal connection

CrackCrack

CrackCrack

ShellShelllongitudinallongitudinal

ShellShellplatingplating

Face barFace bar

Web frameWeb framestiffenerstiffener

Broken weldingBroken welding

Web frameWeb frame

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

Examples of Internal WeldedExamples of Internal Welded

RepairsRepairs

Side shellSide shellBulkheadBulkheadstiffenerstiffener

Side longitudinalSide longitudinal

FractureFracturelocationslocations

TransverseTransversebulkheadbulkhead

StiffenerStiffener

Side shellSide shell PillarPillarstiffenerstiffener

Additional lugAdditional lug

Backing bracketBacking bracket

Side shellSide shell

SideSidelongitudinlongitudin

alal

NewNewlongitudinallongitudinal

sectionsection

BulkheadBulkheadstiffenerstiffener

Transverse bulkheadTransverse bulkhead

AdditionalAdditionalradius bracketradius bracket

Stiffener withStiffener withsoft toesoft toe



32/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices Internal RepairInternal Repair -- NonNon--WeldedWelded

Hole drilled at crackHole drilled at crackterminationtermination

Bolted platesBolted plates

StiffenerStiffener

FrameFrame

LongitudinalLongitudinalFacingFacingplateplate

Crack

Crack

length

length

TransverseTransverseweb frameweb frame

CrackCrack

Local weld GrindingLocal weld GrindingSection of hullSection of hullExternal girderExternal girder

reinforcementreinforcement

OilandGa

sServices

OilandGa

sServices

OilandGa

sServices

End of LREnd of LR

PresentationPresentation



33/34


OGP

OilandG

asServices

OilandG

asServices

OilandG

asServices LR Contact DetailsLR Contact Details

Bob Boon

Business Development, Oil & Gas, LondonTel : 020 7423 2248

Fax : 020 7423 2066

e-mail : [email protected]

Rob Potthurst

Offshore Floating Units, LondonTel : 020 7423 2314

Fax : 020 7423 2066

e-mail : [email protected]



34/34


LR FPSO Design

Documents

Transcript of LR FPSO Design