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    Turret & Installation Challenges: Espirito Santo FPSO

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    Uthanmalliah Nagarajan
    This document summarizes the challenges of the Espirito Santo FPSO turret and installation. The FPSO is contractor owned and operated by Shell, Petrobras, and ONGC in 1780 meters of water off Brazil. It has a 21 slot internal turret to accommodate steel lazy wave risers, a first for a turret moored FPSO. Unique challenges included processing heavy low API oil and interfacing subsea artificial lift systems. Integration of the large turret with multiple heavy lifts and a 150 tonne swivel stack presented construction challenges. Dimensional control and site integration testing were necessary due to the complex layout and engineering required for the internal inclined tubes.

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    Turret & Installation Challenges: Espirito Santo FPSO

    Uploaded by

    Uthanmalliah Nagarajan
    61 views26 pages
    This document summarizes the challenges of the Espirito Santo FPSO turret and installation. The FPSO is contractor owned and operated by Shell, Petrobras, and ONGC in 1780 meters of water off Brazil. It has a 21 slot internal turret to accommodate steel lazy wave risers, a first for a turret moored FPSO. Unique challenges included processing heavy low API oil and interfacing subsea artificial lift systems. Integration of the large turret with multiple heavy lifts and a 150 tonne swivel stack presented construction challenges. Dimensional control and site integration testing were necessary due to the complex layout and engineering required for the internal inclined tubes.

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    This document summarizes the challenges of the Espirito Santo FPSO turret and installation. The FPSO is contractor owned and operated by Shell, Petrobras, and ONGC in 1780 meters of water off Brazil. It has a 21 slot internal turret to accommodate steel lazy wave risers, a first for a turret moored FPSO. Unique challenges included processing heavy low API oil and interfacing subsea artificial lift systems. Integration of the large turret with multiple heavy lifts and a 150 tonne swivel stack presented construction challenges. Dimensional control and site integration testing were necessary due to the complex layout and engineering required for the internal inclined tubes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    61 views26 pages

    Turret & Installation Challenges: Espirito Santo FPSO

    Uploaded by

    Uthanmalliah Nagarajan
    This document summarizes the challenges of the Espirito Santo FPSO turret and installation. The FPSO is contractor owned and operated by Shell, Petrobras, and ONGC in 1780 meters of water off Brazil. It has a 21 slot internal turret to accommodate steel lazy wave risers, a first for a turret moored FPSO. Unique challenges included processing heavy low API oil and interfacing subsea artificial lift systems. Integration of the large turret with multiple heavy lifts and a 150 tonne swivel stack presented construction challenges. Dimensional control and site integration testing were necessary due to the complex layout and engineering required for the internal inclined tubes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    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 ?

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