FPSOs in the Gulf of Mexico
Carlos Mastrangelo
Kirk Barwick
Lincoln Fernandes
Erich Theisinger
Petrobras America Inc.
Summary
FPSO Introduction
– History
– Operational experience
Phased development concept
Cascade & Chinook EPS concept
– Overview
– Disconnectable FPSO
– Production Capacity
– Offloading System
– Mooring System
Conclusion
FPSO Introduction
Typical FPSO layout
Helideck
Accommodation
Utilities
Flare
Cranes Offloading
Process Plant
The World’s First FPSO – 1977
1st
Generation
Delta FPSO– 20,000 bopd
Sources: Douglas-Westwood Ltd. 2002. The World Deepwater Report 2003–2007.
London: Douglas-Westwood. 254 pp.
Smulders, L.H. and P.J. Klein. 1978. Castellon seabed wells flow to
process and storage tanker. Oil and Gas Journal 76(2):55–56/61–62.
FPSOs in Campos Basin Since 1979
Tower-Yoke
Calm-Yoke
PP Moraes at Garopa
60,000 bopd
2nd Generation
PP Moraes at Albacora
60,000 bopd
FPSO Evolvement
Petrobras-37
Petrobras-43
3rd Generation
Complex units
Secondary recovery 4th Generation
Oil, gas and water treatment
More than 30 risers connected Complex units
More than 50 risers connected
Petrobras’ FPSOs and FSOs
Petrobras-32
Petrobras-33
Petrobras-31
Petrobras’ FPSOs and FSOs
Petrobras-34
Petrobras-37
Petrobras-35 Petrobras-47
Petrobras’ Chartered FPSOs
FPSO-II
w/ SBM
Seillean
w/ Transocean
Espadarte
Chartered bases - w/SBM
Mooring Options
Petrobras’ Chartered FPSOs
The Seillean
Roncador & Jubarte Fields
Since 1998
Water depth up to 2,000 m
Displacement 79,600 tons
Processing capacity 20,000 bpd
Storage capacity 306,000 bbl
Examples of Disconnectable
Mooring Systems
Year Type Location
1986 Riser Turret Mooring Jabiru, Australia
1989 Riser Turret Mooring Challis, Australia
1991 Riser Turret Mooring Skua, Australia
1993 Riser Turret Mooring Griffin, Australia
1993 Internal Turret Lufeng, China
1994 Internal Turret Xijiang, China
1995 Riser Turret Mooring Cossack, Australia
1997 Internal Turret Lufeng, China
1998 Riser Turret Mooring Elang/Kakatua, Australia
2000 Internal Turret Terra Nova, Canada
2002 Internal Turret White Rose, Canada
2003 Internal Turret Woollybutt, Australia
2005 Internal Turret Mutineer/Exeter, Australia
2006 Riser Turret Mooring Enfield, Australia
2006 Internal Turret Stybarrow, Australia
Floating Production Units x Operator
Petrobras 31
Shell 12
ExxonMobil 12 World Fleet
Statoil 11 Total: 172 Units
bp
BP 9 FPSO (105)
FPSO (105)
ConocoPhillips 8 SS (38)
SEMI SUBMERSIBLE (38)
Kerr-McGee 7 SPAR (14)
SPAR (14)
CNOOC 7 TENSIONTLP
LEG(15)
PLATFORM (15)
Chevron 6
Eni 6
Other 63
0 10 20 30 40 50 60 70
Source: © 2006 Quest Offshore Resources Floating Production Database
Petrobras’ FPSO and FSO Fleet
FPSO and FSO(*) Vessels
Petrobras Chartered
P-31 P-38* Seillean
P-32 P-43 Espadarte
Operation
P-33 P-47 Brasil
P-34 P-48 Marlin Sul
P-35 P-50 Golfinho 1 Year 2006 FPSO FSO* Total
P-37 Rio de Janeiro Operation 16 1 17
Construction 6 1 7
Golfinho 2
Construction
Total 22 2 24
P-53 Cidade de Macae*
P-54 Opportunity 1 January 2007
Opportunity 2
Siri
Phased Development
Concept
Petrobras Phased Development Concept
The use of an Early Production Unit is to provide
enough reservoir and production data to identify a
more suitable definitive system.
Common practice by Petrobras in Brazil
Tertiary play area of GOM is unknown, with unproven
reservoirs
Early production period can improve facility design (safety,
size, design life, maximize oil recoverable)
Phasing provides flexibility
– Goal is to optimize safety, hydrocarbon recovery, and facility
infrastructure
Cascade & Chinook
EPS Concept
Overview
Subsea Layout
FSHR Configuration
FPSO Characteristics
Ship shaped self propelled vessel
Storage Capacity ~ 500,000 bbls.
Offloading – tandem to shuttle vessel
Mooring System – disconnectable internal turret – 3x3 mooring legs
Connected – 100-year winter storm + 100-year loop current
Disconnected – for named storms & hurricanes
Casing FPSO
Disconnectable
Buoy Anchor Mooring line
Riser
HYBRID
RISER
Cascade & Chinook
EPS Concept
Disconnectable FPSO
DISCONNECTABLE
MOORING & RISER SYSTEM
Buoy connected Close isolation valves Disconnect Buoy
FPSO in production Ready for disconnect Winch down and release
at equilibrium
DISCONNECTABLE
MOORING & RISER SYSTEM
FPSO evacuated FPSO Returns FPSO reconnected
Buoy in submerged Pull in Buoy Restart production
condition
Cascade & Chinook
EPS Concept
Topsides
Topsides Capacity
Crude Oil
– Stabilized, produced water and gas is separated, crude oil is stored
in the cargo tanks and fiscal metered prior to being offloaded to a
shuttle vessel
Produced water
– Treated, then discharged to sea according to NPDES requirements
Gas
– Compressed, dehydrated, and used for fuel gas, with the balance
exported via a gas pipeline.
Fluids Maximum
Oil Flow 80,000 bpd
Produced Water Flow 16,000 bpd
Gas Flow 16MMscfpd
FPSO Inherent Particularity
Vessel Motion
On a ship-shape FPSO all equipment are subjected to higher motions
than other typical floating production units
It is important to understand the subtleties of the motions and
implications on the topsides design
– Orientation of rotating equipment – alignment of centrifugal /
reciprocating pumps and compressors
– Position of process vessels along the ship
– Sloshing effects
– Selection of equipment less sensitive to motion
– Exposure to green water possible with some designs
– Fatigue issues in the topside supporting structure due to the
transmission of hull-bending stress into the topside modules
– Level control systems on long horizontal vessels
Cascade & Chinook
EPS Concept
Offloading
Typical Tandem Offloading
Offloading Characteristics
• Shuttle Vessel (SV) with a maximum of 500,000 bbls storage capacity
• FPSO with Stern Discharge System (SDS)
• SV with Bow Loading System (BLS)
• Distance between FPSO and
SV – 150 m
• Offloading operations with tug
assistance
• Retrievable hose and mooring
hawser
• Telemetry System between
vessels
• FPSO with hawser tension
monitoring system
• FPSO and SV with emergency shutdown capability including ‘no-leak’
valve closures and a quick disconnect system
Typical FPSO Offloading System
Typical SV Bow Loading System
HYDRAULIC ROLLER
CHAIN STOPPER FAIR LEAD
BLS COUPLER
VALVE
Cascade & Chinook
EPS Concept
Mooring Design
Mooring Design Basis
FPSO connected: 100-year non-hurricane event (winter storm)
Buoy/moorings/risers (disconnected): 100-year hurricane & 100-year
loop current
Complete disconnection duration: 24 hours or less (includes all
preparatory works from production discontinuation to buoy release)
Buoy release criteria: ≤1 hour & ≤Hs = 4.5m (final disconnection step)
Reconnection criteria: ≤12 hours & ≤Hs = 2.5m (complete
mooring/riser reconnection with topsides ready to receive produced
fluids)
Petrobras FPSO Guidelines &
Standard Requirements
Compliance with Petrobras
Corporate Guidelines
R&D and technical support
Considering the unique
characteristics of GOM
FPSO Compliance Requirements
U.S. Minerals Management Service (MMS)
U.S. Coast Guard
U.S. Environmental Protection Agency (EPA)
Classification Society Rules and Guidelines
Flag State Regulations
International Maritime Organization (IMO)
– SOLAS
– MARPOL
– All IMO safety management system requirements
National and International Guidelines
– OCIMF
– API RP-2SK
– ISGOTT
Summary
We consider the FPSOs a proven and reliable
technology.
The industry’s experience will be utilized for the
FPSO concept in the GOM.
It will comply with all U.S. regulations and
Petrobras FPSO guidelines.
The EPS will allow for an optimum field
exploitation.
The disconnectable concept mitigates the risk
associated with hurricanes.
Contact Information
Carlos Mastrangelo
Petrobras America Inc.
2101 City West Blvd. Building 3, Third Floor
Houston TX 77042
Phone: 713 808 3090
E-mail: mastrangelo@petrobras-usa.com
