FLOATING ,PRODUCTION, STORAGE &
OFFLOADING SYSTEM - FPSO
.
THE FPSO
Objectives of the Presentation.
1. To showcase PETAN members capabilities in handling various FPSO
Topside packages and systems.
2. Emphasise PETAN members experiences with FPSO Topsides and past
and current involvements.
3. To highlight various contract opportunities that could be awarded for
execution by PETAN members .
4. To highlight areas where Local Content Targets can be achieved and
required local capacity developments or initiatives can be achieved.
THE FPSO
The FPSO is broadly made up of the hull and top-side. The hull stores the
processed crude and the top-side does the processing.
The Hull is built by the EPCIC contractors while the various Topside
packages are designed, manufactured, built, integrated , installed and
commissioned by various OEM representatives , sub-contractors and
integrators like PETAN members all over the world.
OEM equipment , OEM components , various OEMs sub-assemblies are
either installed as it is , assembled to build various packages and panels or
integrated to produce the desired processes , electrical, mechanical ,
telecommunications or safety management systems.
These are key areas where PETAN members have capabilities and roles to
play.
THE TOPSIDE OF AN FPSO
The top-side have mechanical and electrical sub divisions.
All equipment on-board the FPSO are initially defined by the
individual disciplines:
- by process (for process type equipment: separators, other
- pressure vessels, filters, columns, pumps, compressors, etc.),
- by electrical engineering (for electrical equipment: main
- generators, essential & emergency generators, etc.),
- by mechanical engineering (for mechanical equipment:
- cranes, lifting appliances, monorails, etc.)
- by safety ( for safety related equipment: fire water pumps,
- deluge systems, etc.)
FPSO TOPSIDE
FPSO MODULES
•.
TOPSIDES: INTRODUTION TO OTHER
DISCIPLINES (OPPORTUNITIES)
LIFE CYCLE OF FPSO TOPSIDE
For all the various areas mentioned above , the following are both
opportunities and requirements to build capacity on an FPSO:
-
Design and engineering opportunities
Fabrication and Installation
Hook-up and Integration
Commissioning
PIS/Major maintenance and/turnkey retrofit
Engineered equipment supply service
OEM equipment supply, installation, commissioning and PIS
MECHANICAL ENGINEERING
For the Mechanical engineering scope , the following opportunities
or equipment are usually grouped into several packages for the
purpose of obtaining quotations or awarding subcontracts from the
OEM, OEM representatives, independent system integrators or
EPCM companies.
Typical packages for a large FPSO project are as follows:
Main turbo-generators
Compressors (Low pressure: LP1, LP2…)
Compressors (Medium pressure: MP1,
MP2…)
Compressors (High pressure: HP1, HP2…)
Gas Dehydration (Glycol regeneration)
Crude oil offloading pumps
Water injection pumps
MECHANICAL ENGINEERING
-
Crude oil offloading pumps
Water injection pumps
HVAC equipment
Flare and HC blanket gas recovery
Sea water coarse and fine filtration
Produced water hydrocarbons
Injection water dehydration unit
Inert gas generation unit
Waste heat recovery unit
HP/LP fuel gas skid
Pedestal cranes
Wash water unit
Sea water lift pumps
MECHANICAL ENGINEERING
-
Hot water circulation pimps
Cooling water pumps
Air compressor & dryer packages
Fire water pump
Chemical injection
Sea water chlorination
HP/LP flare tips + ignition panel
Subsea methanol injection pumps
Nitrogen generation
Sea water/cooling water exchangers
Foam skid
Pressure vessels (carbon steel)
Pressure vessels (carbon steel + SS 316Lcladding)
Shell & tube heat exchangers
Pumps (API 60 – Centrifugal
Pumps (others)
ELECTRICAL ENGINEERING
Generation and distribution Philosophy
It is generally based on the use of three sets of generators:
Main turbine generators: this provides power to the complete FPSO in
normal operating conditions.
Essential diesel generators: Supplies hull and living quarters in the event
of a shutdown or failure of the main turbine.
Emergency diesel generator: Supplies the safety related systems and
maintain minimum life support services for personnel on-board in the
event of a total shutdown or failure of main turbine and essential
generators.
ELECTRICAL ENGINEERING
The opportunities and capabilities -Electrical systems
1.Main power generation and distribution ( Mains Switchboards)
2.Essential power generation and distributions (essential, non essential
switch boards)
3.Emergency diesel generator and distribution boards.
4.Uninterruptible power supply (UPS)
5.Power distribution control system (PDCS) with following functions:
Control of the power distribution system, load shedding, start inhibit of
loads according to generators spinning reserves, automatic transfer
sequence, event recording and parameter trending, display of alarms,
interface to the ICSS.
INSTRUMENTATION
The integrated control and safety systems (ICSS) is the core for control and
safety. It provides monitoring, control and safety for the process, utility,
marine and subsea facilities. It consist of the following elements:
•
PCS(Process Control System): control of all the non-safety related
monitoring,
•
PSS(Process Safety System): first layer of safety protection in
response to process parameters that have exceeded their normal limits
(SIL2),
•
ESD(Emergency Shutdown System): second layer of safety
protection (SIL3)
•
USS(Ultimate Safety System): third and final layer of protection
using diverse technologies (SIL3),
•
HMI(Human Machine Interface) to provide all equipment operations
interfaces
INSTRUMENTATION
•
FGS(Fire and Gas System): to provide Hull and Topsides Fire and
Gas detection and alarms and executive actions,
•
PDS(Process Data Server): to implement data recording and
reporting,
•
Training Simulator: to provide dynamic process simulation for
operator training,
•
Administration / Maintenance: management access level to
operational status
•
P3 type package interfaces.
The P3 type packages are supplied with their own Unit Control Panel
(UCP) and local operator interface. They are supervised and controlled by
the ICSS on a higher level via the PCS< F&G PSS and /or ESD
subsystems, They comprise of :
•
Turbo-Generators
TELECOMMUNICATION
Telecommunication systems opportunities are for:
1.
Communication on the FPSO,
2.
Communication around the FPSO,
3.
Long distance communication to/from the FPSO.
Communication on the FPSO:
PABX
UHF Operations Trunked Radio System
Public Address and General Alarm Systems (PA/GA)
CCTV System
Entertainment System
Environmental & Meteorological System
TELECOMMUNICATION
Communication around the FPSO,
VHF Marine Radio stations
Marine Surveillance Radar systems with AIS
Aeronautical NDB’s and NAVAIDS
Point to Multi-point Radio links to/from FPSO facilitating
communications with ships, drilling rigs and other vessels
operating in the FPSO
Long distance communication to/from the FPSO.
Subsea fibre optic cable
Satellite communications
CORROSION PROTECTION
1. Topside Protection – corrosion protection to separators, surge tanks, etc
2. HULL Protection
•Coatings
• Ocean-going ship is required to be dry-docked at intervals not exceeding 5
years
• A FPSO may be moored offshore for 15 years or more
•Impressed Current Cathodic Protection: Control electrode location, Stray current
interference, Anode design
•Sacrificial Anodes (Recommended strategy: Sacrificial anodes if life on station is
greater than 10 years)
3. TANKS Protection
•For cargo and slop tanks, sea water, void & produced water storage tanks
•For topsides tanks
4. MOORING Systems
•Fairleads , Chain connectors , chains , wire ropes , etc.
5. RISERS
Onshore fabrication pictures
•
Subsea Control Building
Methanol pumps skids
HPU/HCU frame
19 skid
Corrosion Inhibitor pumps
Loadout & Offshore Installation pictures
Subsea Control Building load out(one half)
Methanol
April
13, 2015
pumps skids on Bonga
2 halfs of Subsea Control Building offshore
20
Corrosion Inhibitor pumps skids on Bonga
Offshore Installation pictures
Lifting of HPU/HCU frame
Installation of HPU/HCU frame
Scaffolding for habitat on Bonga
Welding in habitat on Bonga
21
Offshore Installation pictures
Subsea Control Building
HPU installed on Bonga
April 13, 2015
Inside Subsea Control Building
22
TUPA installed and hooked up