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.
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 FPSO
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
Espirito Santo - Topsides Details
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)
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
Espirito Santo - Turret Challenges
Turret Cross Section
Umbilical deck
Collar deck
SLWR
Typical flexible riser
Max SL Max SL
Lower Turret Layout Difference
Riser 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
Lower Turret
Collar Structure
LOWER MOONPOOL INSTALLATION
Upper Moonpool Integration
Upper Moonpool Integration
after 2
nd
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)
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
Swivel Stack
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
Riser
Wire
Chain
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 ?