4/19/2013

Tanker Based FPSOs

Ashish Budhiraja – SBM OFFSHORE

May 3rd, 2013 – University of Texas, Austin

1
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Introduction

• Hull & Mooring Group Manager - SBM Offshore in Houston

• MS Degree in Structural / Civil Engineering
• Registered Professional Engineer (PE) in Texas
• More than 20 years experience in shipbuilding & offshore engineering
industry

2
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

1
 4/19/2013

FPSO
(Floating Production Storage & Offloading)

Mooring
System
Topsides

Vessel

Espadarte FPSO – Petrobras - Brazil

3
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

FPSO – Cross-Section

PIPE RACK
PROCESS MODULES

PROCESS DECK

MAIN DECK

CARGO OIL

BALLAST
(AVAILABLE)

4
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

2
 4/19/2013

What is the purpose of the FPSO ?

Receive crude oil from sea bed reservoir,
Transform crude oil into stabilized crude (for sea transport),
Separate/ treat water, gas, impurities from crude oil,
Store stabilized crude oil.
Export into shuttle tankers stabilized crude.

5
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

How versatile is FPSO ?

• FPSO has been proven to be a versatile system for all regions and
conditions.
• Over 120 FPSOs in every other regions of the world from West Africa to
Northern Atlantic Margin;
• Water depths from 20 meters (Chang Qing Hao) in South China Sea;
Offshore Brazil Tupi FPSOs are being designed for over 2,000m water
depths.
• Vessel sizes from 50,000 bbl to 2,000,000 bbl storage;
• Production rates from 10,000 bbl/d to 250,000 bbl/d;
• Maximum number of risers up to 80.

6
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

3
 4/19/2013

What makes FPSO popular ?

• FPSO has storage capacity and can operate independently in areas

without pipeline networks.

• FPSO utilizes the tanker hull form that can be newly constructed in one of
the many experienced shipyards or converted from a large existing
supply of tanker fleet. This results in cost advantage.

• FPSO provides ample deck space for topsides processing equipment

and crude storage capacity.

• FPSO is mobile and can be re-located to other fields.

7
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Why do Clients want to lease an FPSO?

• To benefit from a unit for field duration shorter than expected life of the unit.
• To minimize expenditure (pay only for what is needed during the time needed).
• To reduce overall CAPEX and shift part of it to OPEX.
• To shift residual value risk to the contractor.
• To avoid financing.
• To minimize tax exposure
• Etc…

8
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

4
 4/19/2013

FPSO Relocation – Drivers

• Fields are getting depleted
• Contract term ends
• Residual value
• Flexibility in adaptation
• Cost effective – Lower Capex
• Minimized schedule risk

9
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

FPSO Relocation (contd.)

•

FPSO VI ESPADARTE FPSO FPSO Ciadade de Anchieta

10
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

5
 4/19/2013

What are the choices for Vessel ?

• New Build / Purpose Built

• Intercept: Vessel already under construction and now to be adapted for

FPSO

• Conversion: Generally a Trading Tanker to converted to FPSO

11
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

FPSO – BUILDING BLOCKS

•HULL
•TOPSIDES
•MOORING

12
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

6
 4/19/2013

What do we consider during Hull selection ?

• KEY PROJECT CRITERIA

–Design life  age
–Storage capacity  size
–Tank arrangement – is double hull required ?
–Environmental design criteria (severe or benign)

13
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Hull Selection considerations – contd.

• Required deck space

• Stability
• Global strength / scantlings (thicknesses)
• Fatigue and design life
• Freeboard in fully loaded condition (green water prevention or protection)
• Minimum draft in ballast condition (wave slamming)

14
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

7
 4/19/2013

Typical Principal Characteristics of VLCC Tanker

• Length Overall (LOA) = 330m

• Breadth = 58m

• Depth = 30m

• Design Draft = 21m

• Storage Capacity = 2 Million bbls

• Deadweight = 300,000 Tonnes

• Block Coefficient = .82

15
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Typical Tank Arrangement of 1970’s (Single Skin

Tanker)
 Cargo Tanks
 Ballast Tanks
 Slop Tanks

16
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

8
 4/19/2013

Typical Tank Arrangement of Double Hull Tanker

(Suezmax)
RRECEPTION BALLAST
CARGO OIL
& SLOPS (AVAILABLE)

BALLAST AVAILABLE IN
INNER BOTTOMS AND
IN WINGS

17
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Comparison of Conversion vs. New Build

• Schedule: Conversions are implemented faster.

• Cost: Conversions are less expensive.

• Fatigue life: Can be a major issue for Conversion -

trading vessel might have exhausted its fatigue
life during operations.

• Metocean: Conversion suitable for milder environments

(West Africa, Brazil) and New Builds
generally better suited for severe environments.

• Design specs: More difficult to apply oil company specifications

for Conversions as compared to New Build.

18
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

9
 4/19/2013

Vessel Selection Criteria for Conversions

• Technical Criteria:

 Storage Capacity
 Tank Arrangement
 Hull Steel / Equipment Condition
 Amount of Asbestos in older tankers
 Trading History
 Steel Grade
 Build Quality
 Owner(s)
 Machinery – Engine room, Propulsion System

19
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

What type of Steel is used for Hull ?

• Mild Steel only

• High Tensile Steel only (HT32, HT36, HT40)

• High Tensile Steel on Deck and Bottom and rest Mild Steel

• Use of High Tensile Steel may result in Fatigue (failure under cyclic
loading), Buckling and Coating problems.

20
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

10
 4/19/2013

Hull Design Criteria & Tools

• Hull design is performed using Class Society Rules (ABS, DnV, BV & Lloyds)

• The application of Class Society Rules is facilitated through the use of Software:
ABS SafeHull, DnV Nauticus, BV Veristar and Lloyds Ship Right

• The rules investigate Yielding, Buckling and Fatigue modes of failure

21
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Which design conditions are considered for FPSO

Hull ?
• Design for Transport to the site (typically with 10-yr return wave).
• In-place 100-year Design Environmental Condition with varying Drafts
(Full, Intermediate & Ballast).
• Accidental Conditions – Compartment Damage / Impact with Supply
Boats / Blast / Dropped Objects.
• Design for Maintenance and Repair Conditions (typically with 1-yr return
wave).
• Simultaneous Loading/Offloading conditions.
• Effects of Mooring and Riser Loads on the Design of Hull / Mooring
Interface Structures.

22
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

11
 4/19/2013

What is Hogging and Sagging of the Hull ?

23
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Which Hull Loadings are considered ?

• Still Water Bending Moments and Shear Forces (Hogging and Sagging).
• Wave Induced Bending Moments and Shear Forces (Hogging and
Sagging).
• External Sea Water Pressures.
• Internal Tank Pressures.
• Inertial loads due to accelerations.
• Loads due to slamming (as applicable).
• Green Water Loads.

24
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

12
 4/19/2013

Hull Loadings (contd.)

• Supply Boat impact Loads.

• Sloshing loads – high dynamic pressures due to partially filled tanks.
• Loads due to loading/unloading.
• Mooring / Riser Loads in way of Turret support structure.
• Topsides Loads in way of Module support structure.

25
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

What is the main aim of Hull Structural Integrity ?

• Hull Structural failures necessitating major repairs (dry-docking) should

not occur during the service of an FPSO.

26
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

13
 4/19/2013

What are the Life Extension / Hull Structural Integrity &

Maintenance considerations for a conversion ?

• Hull fatigue/strength has been partially consumed as a result of its past service as
a trading tanker.

• Hull strength may have been reduce due to corrosion.

• Need to re-assess the Hull for new tank loadings (if applicable) and site-specific
environment for operation at site (for which it was not originally designed for).

• Need to ensure future structural integrity of the Hull is maintained by

replacing/adding steel, putting Cathodic Protections system and performing
comprehensive periodic on-station Surveys.

27
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Hull Life Extension Activities

FPSO DESIGN BASIS SURVEY

NEW DESIGN
HULL CONDITION
CONDITION/LOADS

HULL STRENGTH
ANALYSIS

FATIGUE STEEL
TRADING HISTORY
ANALYSIS
RENEWAL
PLAN
CORROSION
PROTECTION PLAN

28
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

14
 4/19/2013

Hull Structural Analysis

• Determination of steel renewal thickness at conversion.

• Determination of allowable Stillwater Bending Moment and Shear forces.
• Performing Fatigue check for the longitudinal\transverse structure.
• Perform strength/fatigue checks using 3-D/2D FE analysis for assessing
both global and local effects.

• Failures modes investigated:

• Yielding
• Buckling
• Fatigue

29
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Hull Strength Assessment Procedure

• Evaluate the longitudinal strength of Hull using Class Society Rules based on
beam theory. Class Software such as ABS – Safehull, DnV Nauticus, Lloyds
Ship Right or BV Veristar can be utilized.

• For transverse strength and validation of longitudinal strength, develop and

analyze global 3-D FEM (coarse mesh) of the Hull. Class Software can be
utilized.

• For local strength, develop and analyze local 2-D/3-D fine mesh models of a
typical webframe and horizontal stringer. The local models will incorporate loads
and boundary conditions form the 3-D global model.

• Hull-to-Topsides interface shall be investigated by developing local FEM models

and will take into account local and global loads.

• Post-process global and local models for Yielding, Buckling and Fatigue.
30
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

15
 4/19/2013

3-D 3-Hold FEA Model of Hull

31
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Local FEA – Strength and Fatigue

Hotspots

32
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

16
 4/19/2013

Global FE Hull Modeling with Moonpool

33
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Integrated Hull & Turret Finite Element Model

34
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

17
 4/19/2013

Longitudinal Strength
• Cargo Loading Conditions
Longitudinal Strength At Sea Condition
<---Aft (Meters) Fwd--->
0.0a 50.0f 100.0f 150.0f 200.0f 250.0f 300.0f 350.0f
100.0
Weight x 100.0
Buoy. x 100.0
Shear x 200.0
B.M. x 8000.0
BMSH x 8000.0
BMSS x 8000.0 50.0
SFSP x 200.0
SFSN x 200.0

0.0

-50.0

-100.0

35
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Global Wave Loads

• Global Wave Loads

Maximum Wave Maximum Wave

Shear Force Bending Moment
Gulf of Mexico 91% 76%
Northern Atlantic 100% 100%
Offshore Brazil 53% 48%
West of Africa 25% 24% 36
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

18
 4/19/2013

Fatigue Life

• Remaining fatigue life for Conversion accounts for its past service history
including its Trading History as Tanker.

• Typical fatigue locations / connections analyzed for fatigue include:

• Longitudinal connections at Webframes and Transverse bulkheads
• Bracket toes of typical Web frames
• Bracket toes of typical Horizontal Girders
• Hull Penetrations

37
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Corrosion Protection

• Corrosion protection is most critical for maintaining the Hull structural

integrity

• Ballast tanks, slop tanks – Coating and anodes

• Cargo tanks – Coating and anodes on bottom / Deck

• Void Spaces – Coating, de-humidifiers

• External shell – Anti-fouling coating, impressed current system

38
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

19
 4/19/2013

Hull Inspections & Surveys

• Detailed Initial Survey at onset of Conversion to determine the scope of

refurbishment. It involves:
• Extensive close-up visual inspection of structure (cracking, wastage).
• UT Thickness measurements to determine the Steel thicknesses.
• Detailed measurements and mapping of all areas showing pitting.
• In-Service / On-site Surveys: It involves:
• Comprehensive scheduled inspections program for Cargo Tanks and Ballast
Tanks.
• Hull Condition monitoring facilitated by database capturing the vessel history,
repairs, gaugings, recommendation for future repairs and future inspections.

39
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Cargo and Ballast System

• OPERATIONAL CONSIDERATIONS

–SIMULTANEOUS LOADING (≈ 100 000 bpd continuous) AND OFFLOADING

(≈ 900 000 bpd periodic)

–MAINTAIN HULL BENDING & SHEAR STRESS within allowable

(predetermined) limits by continuous cargo & ballast load distribution
management

–TANK ENTRY DURING PRODUCTION for annual inspection or repair

requires ability to maintain a pattern of tanks empty

40
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

20
 4/19/2013

Tandem Offloading

41
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

FPSO – BUILDING BLOCKS

• HULL

•TOPSIDES
• MOORING

42
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

21
 4/19/2013

Topsides Layout Principles

• Use of “Pre-engineered” modular arrangements.
• Safety by separation. Adequate space between topsides modules to
reduce risk of escalation in case of accident.
• Maximum separation distance between HP hydrocarbons and
accommodation.
• Accommodation aft & turret at bow.
• Low risk utility modules as buffer in between.
• Topsides facilities on raised platforms.

43
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Topsides Arrangement

PIPE RACK

WATER TREATMENT FLARE TOWER

& RE-INJECTION

QUARTERS
&
CONTROL POWER GENERATION OIL PROCESS GAS PROCESS P/S TURRET &
OIL OIL MANIFOLDS
OFFLOADING METERING

44
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

22
 4/19/2013

Hull to Topsides Interface Requirements

• Supporting the topsides modules on the hull by transferring the loads safely into
the hull.
• Minimizing the effect of hull deformations on the topsides.
• Providing space for all deck piping and hull equipment.
• Providing space for safe (tank) access and mechanical handling operations on
hull deck.
• Allowing for sufficient natural ventilation of the upper deck to prevent build-up of
explosive gaseous mixtures.
• Creating a fire division / barrier between the topsides and hull upper-deck.
• Creating a division in the hazardous area classification for electrical equipment
selection.

45
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Which Loading Conditions are Topsides designed for ?

• Lifting Condition: Modules are lifted from the quayside or transport barge onto
the FPSO.

• Transit Condition: Transit from the Yard to the site of operation 10-yr storm.

• Design Environmental Condition (DEC): 100-yr storm condition on site.

• Design Operating Condition (DOC): 1-yr storm condition on site.

46
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

23
 4/19/2013

Topsides Module Lift and Integration

47
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Material Handling

Piperack Trolley

Traveling Crane

48
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

24
 4/19/2013

Which loads are typically included in the Topsides design ?

• Permanent Loads: Weights of the equipment & structure

• Live loads: Liquids, Personnel
• Deformation loads: At the interface of Topsides & Hull to account for Hogging
& Sagging deformations
• Inertial loads: Due to vessel motions & accelerations
• Green Water Loads: Loads on module due to overtopping of water on main
deck.
• Wind Loads
• Accidental loads: Due to Blast, Fire & Dropped Objects

49
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

INTERFACE – HULL TO TOPSIDES

• Typical Hull/Topsides
Interfaces include:

–Multi-column supports

–Cruciform support stool

50
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

25
 4/19/2013

Multi-column Support Concept

Advantages:

• Equipment load is distributed over a large no. of columns. The reinforcements s

to the existing hull structure minimized.
• The module yard can fabricate the module without columns as columns are pre-
installed on the vessel.

Disadvantages:
• Deck access is impaired due to large no. of columns.
• Due to multiple contacts along the length of the module, the deck curvature is
partially transferred to pancake beams of the module.
• Several welded connections have to be made during the module installation.

51
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Cruciform Support Concept

Advantages:
• Due to high load bearing capacity relatively low no. of stools are required. This
allows for the flexibility in routing of pipes and layout of modules.
• Provides for large open space beneath the module. This leads to easier
satisfaction of safety, access and ventilation requirements.

Disadvantages:
• The small no. of supports requires a strong module deck and under deck
stiffening may be required. That is why this is not a popular option for projects
involving conversions of existing tankers.
• The fabrication of stool itself is more complicated as compared to the columns
of multi-column support concept.

52
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

26
 4/19/2013

ACCOMMODATION
Accommodation generally located aft. Accommodation extension /
upgrade required to handle increased Person on Board (POB)
requirements.

Extensions, Additional Cabins, Offices, Conference rooms

53
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Completed Topsides

54
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

27
 4/19/2013

FPSO – BUILDING BLOCKS

• HULL
• TOPSIDES
•MOORING

55
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Mooring System - Options

• Concept Type:
– Fixed Spread Mooring
– Weathervaning
• Tower Soft-Yoke
• External Turret
• Internal Turret (Roller bearing & Bogie bearing)
• Disconnectable (Riser Turret, RTM & Buoy Turret, BTM)
• Mooring System Type
– Catenary or Taut Leg
• Mooring Leg Components:
–Chain
–Steel Wire
–Polyester

56
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

28
 4/19/2013

Spread Mooring

Chains

Chains

• Fixed heading, no weathervaning

• Suitable for mild and uni-directional environments
• Tandem offloading difficult, often requires offloading buoy & pipeline or multiple
support vessels

57
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Soft Yoke Mooring

Suitable for Shallow water
depth (<25m) where catenary
solution does not work.
Yoke

Suspended weight that

gets lifted during
excursion and provide a
restoring force

58
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

29
 4/19/2013

Turret Mooring
Swivel stack

Mooring legs

Flexible risers

59
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Turret Systems – Main Types

60
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

30
 4/19/2013

Raised External Turret

61
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Raised External Turret

Advantage: Disadvantage:
• Increases “apparent” waterdepth • Increases mooring dynamics
• Does not use deck space • Extension structure

EQUILIBRIUM
Apparent water
POSITION
depth between
Overrun stoppers & seabed

Increase of
WD in
comparison Waterdepth
to internal
turret Possible Chafing
between keel & mooring
leg in overrun condition

62
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

31
 4/19/2013

Design Drivers – Waterdepth

Avoid slamming on structure

Air Gap to avoid

slamming effect

Crest of the max. survival wave

height and minimum freeboard

63
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Internal Turrets

INTERNAL TURRET
Up to 75 risers in
deepwater, example shown
for 45 risers in 1400 m
64
water depth
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

32
 4/19/2013

Internal Turret
Internal Turret – Main Components

 Fixed part (earth bound)

- Mooring lines & chain connectors
- Risers
- Turret fixed structure
- Fixed part of fluid transfer system

 Interface b/w fixed & rotating parts

- Bearing
- Swivel

 Rotating part (vessel fixed)

- Gantry structure

65
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Internal vs. External Turret Selection Criteria

• Design Environmental Conditions
- External turret: Mild to medium design environments (e.g. West Africa, some cases in
Brazil)
- Internal turret: Harsher environment (e.g. North sea, Brazil)
- Disconnectable systems: harsh weather & regulatory req’t (e.g. GoM), Iceberg

• Riser Count – Turret diameter

- External turret: Typically 20 risers or less
- Internal turret: Typically 30 to 40 risers – can be designed up to 100 risers

• Water depth – riser and mooring loads

66
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

33
 4/19/2013

Disconnectable Turrets

External Turret Internal Turret

Riser Turret Mooring Buoy Turret Mooring
(RTM) (BTM) 67
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Internal DisconnectableTurret
 White Rose BTM System:
 Offshore Newfoundland
 Design environmental conditions:
 Wave (Hs) 15.5 m (Tp: 12-
16 sec)
 Wind (1-hr) 35.2 m/sec
 Current 1.32 m/sec
 12 risers / 121 m WD
 Possibility for rapid disconnection

68
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

34
 4/19/2013

Bearing System Selection

Considerations:
• Mooring Loads – Vertical & radial forces and moments
• Number of risers will determine the bearing diameter
• Cost

Types:
• Roller Bearing
• Bogie Bearing (Axial Bogies & Radial Wheels)

69
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com
Ashish Budhiraja 3rd May 2013

Roller Bearing

Radial
Rollers

70
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com
Ashish Budhiraja 3rd May 2013

35
 4/19/2013

Roller Bearing (contd.)

• Available Options

- Single piece 3 race roller bearing

 Used in smaller diameter turrets (<8m diameter) – forging & transportation limitations
 Usually delivered as a complete stand alone assembly
 Simplest options for smaller number of risers and low design loads

- Segmented 3 race roller bearing

 Used in larger diameter turrets (between 8m & 14m diameter)
 More complex
 Main difficulty is ensuring alignment between different segments
 Also segmented systems are very sensitive to hull flexural motions

71
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Roller Bearing + Lower Friction Bearing System

Main roller bearing

• Located around main deck level

• Supported by ring box on flexible
pads
Upper
spherical
Lower friction bearing support
Main
• Located around keel level bearing

This system is typically used for large

internal turret systems:

• High Horizontal Load capacity Lower

• Bearing isolated from moments lateral
bearing
72

© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com

Ashish Budhiraja 3rd May 2013

36
 4/19/2013

Bogie Bearing (with Radial wheels)

73
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Bogie Bearing

Axial Bogies

Radial Wheels

74
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

37
 4/19/2013

Bogie Bearing Advantages

• Bogie wheel bearing has no maximum ID to limit number of risers (75 – 100 risers
possible).
• Bogie wheel bearing easier to integrate into vessel due to no lower bearing
support assembly below water line.
• No limiting ID enables riser connection deck to be located above vessel main
deck, resulting in safer design.
• Bogie wheel bearing easier to repair in the field.
• Scalable design.
• Proven design.

75
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Bogie Bearing System Machining

• Machining of rail support structure by means of portable machine
• Optimal alignment between race tracks for axial & radial wheels and
support structure

Turret

Turret support
structure
76
Turret & Bogie Bearing System
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com
Ashish Budhiraja 3rd May 2013

38
 4/19/2013

Swivel Stack

77
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Turret Hydrodynamic Load Analysis – Typical Load Cases

78
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com
Ashish Budhiraja 3rd May 2013

39
 4/19/2013

Turret DL Analysis – Cases Selected for Snapshots

Mooring Line & riser snapshot loads are typically provided for (together
with turret accelerations):

• Max total moment on bogies

• Max total radial load on wheels

• Max total vertical load on axial bogies

• Max compression force on axial bogies

Minimum compression force on axial bogies (negative value indicates a
potential uplift problem)

79
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Moonpool in the Hull for Internal Turret Integration

Hull
Hull

Keel

80
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com
Main
Ashish Budhiraja 3rd May 2013

deck

40
 4/19/2013

Turret Component Fabrication

Manifold Gantry
Decks
Turret Cylinder

81

© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com

Ashish Budhiraja 3rd May 2013

Bogie System Integration

Install turret support structure Install Bogies

Lift and lower turret into moonpool Set turret collar onto bogie wheels

82
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

41
 4/19/2013

Chain Table for Very Large Turret

83
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

Lowering of Turret Cylinder

84
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com
Ashish Budhiraja 3rd May 2013

42
 4/19/2013

Lifting & Integration of Manifold Decks

85

© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com

Ashish Budhiraja 3rd May 2013

Gantry Lift & Integration

86

© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com

Ashish Budhiraja 3rd May 2013

43
 4/19/2013

FPSO ready for Field Installation

87
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

THANK YOU!

88
© SBM Offshore 2012. All rights reserved. www.sbmoffshore.com Ashish Budhiraja 3rd May 2013

44