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 FPSOThe 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 ENGINEERINGThe 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.

INSTRUMENTATIONThe 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 PROTECTION1. 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

•

19

Subsea Control Building

Corrosion Inhibitor pumps skidMethanol pumps skids

HPU/HCU frame

Onshore fabrication pictures

April 21, 202320

Loadout & Offshore Installation pictures

Subsea Control Building load out(one half) 2 halfs of Subsea Control Building offshore

Methanol pumps skids on Bonga Corrosion Inhibitor pumps skids on Bonga

21

Scaffolding for habitat on BongaLifting of HPU/HCU frame

Installation of HPU/HCU frame Welding in habitat on Bonga

Offshore Installation pictures

April 21, 202322

Offshore Installation pictures

Subsea Control Building Inside Subsea Control Building

HPU installed on Bonga TUPA installed and hooked up