Espirito Santo FPSO: Turret & Installation ...
Espirito Santo FPSO
Turret & Installation Challenges SNAME/MTS Joint Meeting
Texas A&M University March 26, 2010
Chris Wibner
Upstream Major Projects Shell International Exploration & Production, Inc.
Espirito Santo FPSO Contractor owned and operated FPSO (evolution of GFPSO project) Shell is operator (50%) with partners Petrobras (35%) & ONGC (15%) FPSO Contractor - BDFT (SBM & MISC JV) Major subcontractors: • Keppel Shipyard (hull conversion, turret fabrication, topsides integration)
• Dynamac (topsides fabrication) • BT Engineering (topsides fabrication)
1780 m water depth at FPSO location Internal turret with 21 riser/umbilical slots First turret moored FPSO to accept Steel Lazy Wave Risers
Espirito Santo - Topsides Details 100 kbopd oil processing capacity (low API) 50 mmscfpd gas compression 150 kbpd total liquids processing capacity
130 kbwpd produced water treating capacity 75 kbwpd water injection w/ sulfate reduction for Phase II 150 kbwpd additional water injection deck space
Topsides weight ~ 8,500 tons Unique challenges: Heavy oil processing (16 API), services for subsea artificial lift systems (i.e.15 MW available AL power, VFDs, Hot oil circulation with gas spike capability)
Vessel As Arrived in Singapore (’06)
Espirito Santo - Turret Challenges • Lazy Wave Steel Risers & Umbilicals – Vertical load 2,200 tonnes
• Multiple Heavy lifts for integration into vessel • Large swivel stack – 12 units ~ 150 tonnes
• High Voltage • Centralized riser/umbilical pull-in winch
• Separate riser & umbilical decks • Riser spool piece connection inside lower turret
Turret Cross Section
Lower Turret Layout Difference
Umbilical deck
Max SL
Max SL
Riser deck
Typical flexible riser
SLWR
Collar deck
Construction Challenges
Built by decks and stacked Inclined I-tubes, complex alignment and fit up Umbilical I-tubes required a reverse bend to mitigate clashing Complex lay-out of I-tubes, generates more engineering studies Dimensional control
Site integration testing
Integration Photos - Turret Gantry
Manifold
Bogie Support Structure Collar Structure
Lower Turret
LOWER MOONPOOL INSTALLATION
Upper Moonpool Integration
Upper Moonpool Integration after 2nd DD
BC-10 FPSO TURRET (LOWER TURRET)
Lower Turret Integration
BC-10 FPSO TURRET (Bogie Support Structure)
BC-10 FPSO TURRET (UPPER TURRET)
BC-10 FPSO TURRET (TURRET MANIFOLD)
Riser / Umbilical Interface
Risers clamp castings (12)
Umbilical bellmouths (3)
Umbilical Future (6) Mooring Connectors (9)
Swivel Stack 154 tonnes 24 m Height Unit 12 – Electro Optical
Unit 11 – Hot Oiling Service Swivel Unit 10 – Utility LP & HP Unit 9 – Gas Export / Injection Units 7 & 8 – HV Electrical Unit 6 – Water Injection Unit 5 – Gas Production Unit 4 – Firewater Units 1,2,&3 – Oil Production
Pull-in Winch
• New concept • Design developed in house by SBM • Winch platform provides 3 Motions 2 axis of rotations 1 sliding
BC-10 FPSO Pull-in Winch
Chain Wire
Riser Wire
SLWR & Umbilical Pull-in Installation team ready for another pull-in within 6 to 8 hours
Conclusions Steel Risers are feasible from a turret moored FPSO Interface between the turret & steel risers proved feasible Winch platform design provided full satisfaction
Comprehensive dimensional control management is a necessity Site integration testing is extremely important Installation time comparable to flexible riser
QUESTIONS ?
Turret & Installation Challenges SNAME/MTS Joint Meeting
Texas A&M University March 26, 2010
Chris Wibner
Upstream Major Projects Shell International Exploration & Production, Inc.
Espirito Santo FPSO Contractor owned and operated FPSO (evolution of GFPSO project) Shell is operator (50%) with partners Petrobras (35%) & ONGC (15%) FPSO Contractor - BDFT (SBM & MISC JV) Major subcontractors: • Keppel Shipyard (hull conversion, turret fabrication, topsides integration)
• Dynamac (topsides fabrication) • BT Engineering (topsides fabrication)
1780 m water depth at FPSO location Internal turret with 21 riser/umbilical slots First turret moored FPSO to accept Steel Lazy Wave Risers
Espirito Santo - Topsides Details 100 kbopd oil processing capacity (low API) 50 mmscfpd gas compression 150 kbpd total liquids processing capacity
130 kbwpd produced water treating capacity 75 kbwpd water injection w/ sulfate reduction for Phase II 150 kbwpd additional water injection deck space
Topsides weight ~ 8,500 tons Unique challenges: Heavy oil processing (16 API), services for subsea artificial lift systems (i.e.15 MW available AL power, VFDs, Hot oil circulation with gas spike capability)
Vessel As Arrived in Singapore (’06)
Espirito Santo - Turret Challenges • Lazy Wave Steel Risers & Umbilicals – Vertical load 2,200 tonnes
• Multiple Heavy lifts for integration into vessel • Large swivel stack – 12 units ~ 150 tonnes
• High Voltage • Centralized riser/umbilical pull-in winch
• Separate riser & umbilical decks • Riser spool piece connection inside lower turret
Turret Cross Section
Lower Turret Layout Difference
Umbilical deck
Max SL
Max SL
Riser deck
Typical flexible riser
SLWR
Collar deck
Construction Challenges
Built by decks and stacked Inclined I-tubes, complex alignment and fit up Umbilical I-tubes required a reverse bend to mitigate clashing Complex lay-out of I-tubes, generates more engineering studies Dimensional control
Site integration testing
Integration Photos - Turret Gantry
Manifold
Bogie Support Structure Collar Structure
Lower Turret
LOWER MOONPOOL INSTALLATION
Upper Moonpool Integration
Upper Moonpool Integration after 2nd DD
BC-10 FPSO TURRET (LOWER TURRET)
Lower Turret Integration
BC-10 FPSO TURRET (Bogie Support Structure)
BC-10 FPSO TURRET (UPPER TURRET)
BC-10 FPSO TURRET (TURRET MANIFOLD)
Riser / Umbilical Interface
Risers clamp castings (12)
Umbilical bellmouths (3)
Umbilical Future (6) Mooring Connectors (9)
Swivel Stack 154 tonnes 24 m Height Unit 12 – Electro Optical
Unit 11 – Hot Oiling Service Swivel Unit 10 – Utility LP & HP Unit 9 – Gas Export / Injection Units 7 & 8 – HV Electrical Unit 6 – Water Injection Unit 5 – Gas Production Unit 4 – Firewater Units 1,2,&3 – Oil Production
Pull-in Winch
• New concept • Design developed in house by SBM • Winch platform provides 3 Motions 2 axis of rotations 1 sliding
BC-10 FPSO Pull-in Winch
Chain Wire
Riser Wire
SLWR & Umbilical Pull-in Installation team ready for another pull-in within 6 to 8 hours
Conclusions Steel Risers are feasible from a turret moored FPSO Interface between the turret & steel risers proved feasible Winch platform design provided full satisfaction
Comprehensive dimensional control management is a necessity Site integration testing is extremely important Installation time comparable to flexible riser
QUESTIONS ?
