FPSO

Understanding FPSO-1:
Do you know what the following means:

1) BOPD: Barrels of Oil Per day the FPSO can handle and process
2) MMSCFD:Million standard cubic feet per day of gas the FPSO can process
3) BWPD: Barrels of Water Per Day the FPSO produces as part of separation
4) BOE: Barrel of oil equivalent, a way to convert Oil & Gas produced to an
equivalent Oil quantity. This depends on the calorific values of gas. Generally
5600 to 6000 cubic feet of gas is considered equivalent to 1 barrel of oil
5) GOR: Gas Oil Ratio. The ratio if Gas to Oil in crude.
Understanding FPSO-2:
A) You know the value addition to a tanker hull when converted to an FPSO is in the
range of 10 to 20 times.
B) A VLCC(US$ 120mn)when converted to an FPSO can value between approx US$ 1.20 Bn
to US$ 2.3 Bn and depends of the "NAME PLATE CAPACITY" of FPSO...
Like the specification of an automobile ie 3.40x1.7x1.5m /1800 kg/ 2000 cc/ 200
bhp/ 190 N.m. torque/ 180 kmph Max speed , FPSO also have a specification called
the "Name Plate Capacity".
Sample Name Plate Details of FPSO below (sample):
1) HULL:
L x B x D x T: 249x50x27x18m
2) STORAGE:
100,000 cu.m.
3) POB (Person On Board):
120
3b) HELIDECK:
Sikorsky S61N
4) HULL TYPE:
SH or DH (Single or Double Hull) Newbuild / Conversion
3b) LIFE:
20 Years
5) MOORING:
External turret/ Internal Turret/ Spread Moored
6) PROCESSING:
Oil: 60,000 BOPD
Gas Handling 70 mmscfd
Gas Injection 70 mmscfd
PW capacity: 125,000 bwpd
(produced water)
WI capacity: 125,000 bwpd
(water Injection)
Topside Dry: 13,500 t
Topside Ope: 16,600 t
6) TOPSIDES:
Typical modules in FPSOs include
Riser balcony, Oil Processing, Gas Processing, Gas Compression/ reinjection,Flare
KOD Module, Flare tower, Chemical Processing/ Injection, Utility Module, Water
Injection, Fuel Gas/ Flas gas, Power Generation (geenrally 2 nos), E House Module,
Laydown Modules (2 Nos)
7) SPECIAL MODULES
CO2 Modules, CO2 Compression(when gas with high CO2 content) , Sulphur processing
modules ( Crude with high Sulphur content)
Understanding FPSO-3
FPSO projects are known widely for CAPEX overshoot, due to several reasons. Study
shows that if the CAPEX overshoot is <= 25% of planned CAPEX; the project is
considered well planned and executed.
A well planned and executed "engineering" can significantly reduce the CAPEX
overshoot.
An experienced team from the following 16 to 17 disciplines are mandatory for an

efficient engineering of an FPSO..It is the team work of these diciplines that
makes it happen...
1) Process
2) Instrumentation
3) Electrical
4) Mechanical (static/ rotary)
5) Piping
6) Layout/ Handling
7) Safety/ Loss prevention engg
8) Architecture
9) HVAC
10) Materials
11) Structures
12) Technical Management
13) Naval
14) Mooring
15) Marine
16) Planning
17) Document Control DCC
Excluding Construction related engineering
What is the significance of BOE in FPSOs?
a) BOE or barrel of oil equivalent is the total energy generation capacity of an
FPSO
b) The BOE has an almost direct relation to the FPSO CAPEX, but depends also on
addiitional facilities due to Chemical composition of crude (ie high sulphur
content, high CO2 content, high salt content, waxy low API crude etc)
c) BOE hence has a direct relation also to the OPEX of FPSO due to reasons in b
above
d) BOE has also a relation to the total topside weight in an FPSO and hence the
FPSO size.
e) BOE hence is also related to the ROI or return of investment and profitability
of the FPSO project.
One of the most critical activity of the FPSO engineering is the Weight and COG
reporting, especially of the topsides which forms the major component after the
hull, mooring, risers, dechouse/ super structure, outfittings etc. Hence a very
frequent Weight and COG monitoring is very critical (recommended monthly) to ensure
that the weight and COG doesnt exceed the allowable weight and COG of the
floater.This is based on Stability/ Damage stability of the hull in line with
SOLAS/ Class requirements.. An error in such calculation can result in:
(1) Reduced storage capacity of the FPSO thereby affecting name plate capacity &
earning potential of the vessel
(2) Non issuance of "requested Class Notation" by Class society
(3) Total rejection of facility by Owner (possible) due to non compliance with Name
plate capacity..
Understanding FPSO 6:
The most exciting and challenging part about FPSO topside design is the more than
14 primary analysis for each module and carried out to qualify the FPSO topside
structure, unlike any other offshore / onshore structure.
Total modules in a large FPSO range from 15 to 20 modules for a VLCC FPSO with
about 200,000 bopd & approx 250 mmscfd capacity.
Each module is then modeled in 3D modeling tool and generates over 150 to 200
drawings per topside module. A total of about 3000 structural drawings for FPSO
topside in a large FPSO is itself an amazing feat.
These include PRIMARY STRUCTURE ANALYSIS

> Operating DOC
> Extreme DEC
> Damage DDC
> Transit DTC
> Blast Analysis (SLB/ DLB)
> Jet fire analysis
> Lifting and Padeye analysis
> Loadout analysis
> Laodout Grillage analysis
> Tranportation/ seafastening analysis
> Primary connection fatigue (simplified)
> Primary connection fatigue (spectral)
> Dropped object analysis (laydown etc)
> Radiation strength analysis (flare tower)
SECONDARY STRUCTURE ANALYSIS

> Secondary design(equipment support/ pipe support/ davit foundations/ lifting
beams/ trolley ways etc)
> Monorail and handling padeye design
The team work of the highly skilled and motivated engineers and Tekla modellers for
topside structural design and modelling is so amazing that I don't think any other
structural design feat includes so many detailed analysis..
Hats off to the Successful team behind such exhaustive work worth commenting..
ynamic Analysis of an Offshore Wind Turbine:-
The range of wind speed at which a wind turbine is designed to operate is from
about 2 m/s to 4 m/s to about 18 m/s to 20 m/s.Beyond which the turbine is on
brakes.
(1) An rpm of 15 to 30 rpm (0.25 Hz to 0.50 Hz)is acieved with the above wind speed
(for a typical 2.5 to 3.0 MW wind turbine).
(2)The alternator inside generates power has an rpm of 1800 to 2000 rpm (30 Hz to
34 Hz) by a bull gear system.
(3) The design challenge of the wind turbine structure is to design the global
structure of wind turbine (including blades) & the blades alone (each) falling out
of the frequency range of 0.25 Hz (min) to 34 Hz (max); where the mass
participation is = 80%...
(4) In addition the floater type wind turbine is subject to motions of roll; pitch
heave; surge; sway and yaw..The period of these motions also need to be studied to
ensure these fall outside the natural period of the global structure of wind
turbine (including blades) & the blades alone (each) by min +/- 20%
Recommend the natural frequency of the main structure (including blades) & the
blade alone (each) to be away from above exciting frequency range by +/- 20%
The above is considering a sample 2.5 to 3.0 MW turbine. This could be slightly
different for other turbinea of higher power including the latest 12 MW offshore
wind turbine.(biggest offshore wind turbine)
An engineering challenge really worth thinking..

FPSO

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Understanding FPSO-1:

Do you know what the following means:

Sample Name Plate Details of FPSO below (sample):

An experienced team from the following 16 to 17 disciplines are mandatory for an

These include PRIMARY STRUCTURE ANALYSIS

SECONDARY STRUCTURE ANALYSIS

ynamic Analysis of an Offshore Wind Turbine:-

An engineering challenge really worth thinking..

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