Mastering Floating Production, Storage and Offloading System

Introduction

This 5-day intensive training course will cover the general technology and design factors influencing the installation, operation, construction, and survival of FPSOs that any FPSO project teams need to address when overseeing an FPSO project. Participants will learn to equip themselves with a detailed understanding of feed to Detailed design of FPSO covering major FPSO technical configurations, layouts, process systems, to the latest and future field development in floating production systems.

In addition to various safeties, health and environment issues pertaining to FPSO to be covered, participants will also get to draft and implement Structural Integrity Management system and learn about current hot topics such as recent developments in FPSO applications and long term Asset Integrity Management of FPSO to maximize FPSO operation and production.

Various FPSO and other floating production system case studies will be covered throughout the course to illustrate various design concepts and FPSO configurations while having a complete view of FPSO field developments.

Objectives

• Understand the current trend of floating production systems and their design & technology
• Enhance your knowledge on key design and technology factors governing FPSO design choices
• Determine the key design requirements based on the most recent International Standards outlining detailed FPSO design
• Analyze  and REVIEW the functions and applications of various process systems, layouts and other major configurations onboard an FPSO
• Master key parameters in designing the Hull, Mooring, Turret, Swivels, and Risers
• Apply an effective approach to designing FPSO against fatigue and wave slamming occurrences
• Learning about the transition of from design to the specification of a system for through-life Structural
• Integrity Management (SIM) and its requirements world-wide and in SE Asia
• Incorporate good Asset Integrity Management practices from the FPSO industry

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

• FPSO Project Engineers/Managers  
• Offshore Installation Managers
• Subsea & Topside Engineers           
• Naval Architects
• Facilities Engineers                          
• Process Engineers
• Production Engineers
• Marine Engineers
• Development Engineers
• Operation Engineers/Managers
• Design Engineers
• Structural Integrity Engineers/Managers
• Plus anyone who is involved in or working with FPSO projects who require knowledge on the design, technology and management of FPSO.

Course Outline

Day 1: Review of Floating Production Facilities

• Brief history and introduction to oil and gas production using floating production facilities
• Description and coverage of the entire course
• Overview of floating offshore production facilities
• Oil & gas production – critical driving factors
• Field development requirements and options leading to the selection of a floater

Main floater configurations: barge, semi-submersibles TLPs, SPARS, and FPSOs

• Normal phases in a field development using a floater
• Front End Engineering Design (FEED)
•  Design for new-build hull or inspection
• Design for conversion
• Mooring arrangements
• Interface with producing wells
•  Common fabrication and assembly options
•  Provision for in-field inspection, maintenance, and repair
• Installation, operation, and removal
• Typical strengths and weaknesses of different floating options
•  Special circumstances in favor of a ship-shaped FPSO
•  FPSO operations in shallow water and deep water
•  Effect of numbers of wells, high gas content
• The severity of the weather, whether in regular seasonal hurricanes or only in rare typhoon  Met ocean data, design codes and major load components for FPS
• Introduction to met ocean data (ISO 19901-1 for use in ISO 19904-1)
•  Important issues for FP installation, survival, operation and supply
•  their description and representation in design code requirements
• CLASS EXERCISE - Identifying typical ranges of parameters for different areas of the South China Sea and other major world oil provinces
• Applicable design codes, standards, and rules leading to the functional requirement
• Issues influencing the choice of floating production systems - pipelines, storage and offloading
• Main quasi-static loading and bending issues critical to FPSO design

Day 2: FEED Design and Marine Effects on FPSO Projects

• FEED design - choices and options associated with FPSOs
• Examples of typical field developments employing FPSOs
• FPSO configurations – global responses and marine
• Weight and space management – ballast, crude, fuel, and storage
•  Hydrostatics and stability requirements
• Still-water bending
• Interpretation of typical met ocean report data – as used for design
• Winds, waves, currents, tides, etc – variation with height, averaging period, direction, extreme values, elegance data, etc
• Characteristics of short-term descriptions of wind and waves, currents, typhoons, tides, storm surges, squalls, and loop-currents.
•  How they are described and represented numerically in codes
•  Effects of motions on ship layout
•  Introduction to the use of probability distributions and extreme values

Processing, utility and production facilities – topsides

• CLASS EXERCISE - Impact considerations of various factors on FPSO design: e.g. speculate on effects of Tsunami
• FPSO configurations – processing, utility and production facilities
• Field development factors and their effects on choice of floater or FPSO
•  Oil and Gas production characteristics - their effects on equipment and layout
• Oil, gas and produced water handling requirements
• Flaring or otherwise
• Power generation and utility equipment
• Accommodation requirements and location
• Factors affecting equipment, piping, and electrical layout
• Considerations for instrumentation and telecoms
• Structural support for fabrication and operation
• VOC emission, recovery and treatment
• Effects of motions on equipment specs, layout, and operations
•  Examples of typical layouts of FPSO process and utility equipment

 Day 3: Design of risers, turrets, moorings, offloading including response dynamics

• FPSO configurations – global responses and marine (continued)
• Effects of wave, wind and current directionality and spread seas
• Weather warning or spread mooring
• The turret - why a turret?
• Turret options – permanent or detachable
•  Turret locations - effects on response and equipment layout
• Mooring design with or without thruster assistance
• Modeling of hydrodynamic loading, vessel motions, and structural responses
• Response amplitude operators
• Motion responses in short term sea states
• Extremes motion responses
• Combining quasi-static and dynamic loads
• A brief discussion of non-linear and second-order effects

CLASS EXERCISE - Review of example from the previous day and examples of the above as applied to some typical FPSOs for participants to tackle

• Design issues affecting moorings, flexible risers, umbilical and offloading
•  Oil export & offloading systems and effects of met ocean data and voyage on operation planning

Structural Design using ISO 19904-1

• FPSO structural design
• Hull design requirements and specifications
• Limit states design: ULS, SLS, ALS, FLS
• Hull bending and its influence on topsides supporting structures
• Structural design – beam bending
• Cross-section design
• CLASS EXERCISE - Identify a list of items and functions that differentiate an FPSO from a trading tanker
• New-build FPSO converted new-build tanker and converted old tanker
   Pros and cons
• Availability and cost
• Safety in design
• HSE, planning for escape, evacuation, and rescue
• Fire and gas detection alarms
• Design for fire and blast

Day 4: Design for green water, slam, and fatigue

• Green water, slamming and wave slam loading
• Freeboard exceedance
• Different types of slamming
• Sea states that dominate green water loading and wave slam
• Findings of Safe Flow JIP
• A recent review of the experience of slam damage for UK HSE
• Designing for fatigue
• Detailing methods specified by ISO 19904-1 and American Bureau of Shipping(ABS)
•  Review of the spectral assessment approach
•  Effects of crude/ballast loading
• Effects of environment loads, the loading/unloading cycle and operating practice
• Met ocean input requirements
• Contributions of vessel responses and load combinations
• Appropriate global hydrodynamic and structural models
• Detailed models of fatigue stresses in components and structural details
• Miners rule
• S-N data
• Processing data for each short-term storm
• Processing data for long-term effects
• How safety factors are incorporated in fatigue design
• Identification of predominant vessel loading conditions and sea states
• Experience gathered about important details affected by fatigue

SIM systems, Asset Integrity Management, and future FPSO developments

• Structural integrity management systems: ISO 19904-1 and world-wide experience
• The design interface
• Internal inspection: access and safety
• References to recent experience
• Establishing a SIM system
• An operator’s view
• Appropriate inspection methods
• FPSO structural performance JIP and findings
• Study of best practice
•  Norwegian experience
• Risk-based inspection (RBI) and UK HSE Laboratory findings
• Relevance to ISO requirement and how it may evolve
• Speculation about future field developments using FPSOs
• Recent developments and potential design challenges
• Asset Integrity Management issues
• Latest developments in FLNG

Day 5: Practical cases