White Rose FPSO

White Rose FPSO

A Successful Harsh Environment FPSO
A Successful Harsh Environment FPSO
Phil Clark, SNAME Calgary November 19
th
2008
- 2 -
The White Rose Project
The White Rose Project
- 3 -
White Rose at First Oil
- 4 -
Grand Banks Harsh Environment
- 5 -
FPSO Design
FPSO Design
- 6 -
FPSO design challenges
FPSO design challenges
The ability to quickly and reliably disconnect the risers and
vessel moorings and leave the location under self propulsion if
threatened by an unmanageable iceberg
The need for high structural integrity at low temperatures
reinforcement for sea ice and ice impacts
Remain on location for minimum 15 years
Extensive green water protection
Extensive winterization for cold climate operations
Enhanced radar for Iceberg detection
- 7 -
Project Management - St. Johns Newfoundland - Husky
Hull - Korea - Samsung
Turret - Middle East Abu Dhabi - SBM/Imodco
Topsides - Newfoundland and Atlantic Canada - AMKC
Operations - Newfoundland - Husky
Topsides to Hull
Interface
Interface Turret to
Topsides
Structural Interface Deck - Hull
Interface
Turret
to Hull
SBM
AMKC
Samsung
FPSO Execution Strategy
- 8 -
Base Vessel Design
Base Vessel Design
- 9 -
Changes to the Hull Design
- 10 -
Vessel Specifications
- 11 -
Vessel Specifications
- 12 -
Vessel Specifications
- 13 -
Model Testing and Analysis
White Rose Turret and Mooring System
White Rose Turret and Mooring System
Turret Gantry
Structure
Centerline of Rotation
of FPSO
Risers
(Generic)
Mooring
Lines
- 15 -
160 m
142 mm D
R35 Studless
Chain
142 mm D
R35
Studless
Chain
160 m
142 mm D
R35
Studless
Chain
15m
800 m
128 mm D
Spiral Strand
Wire
120 m
152 mm D
R35 Studless
Chain
40m
Clump Wts 1.9 te / m
128 mm D
Spiral
Strand
Wire
85m
3 x 3 Pattern
FPSO
Anchoring
Radius:
1310 m
Typical Anchor Leg Pile
Buoy
60m
Mooring line composition
- 16 -
Gantry Structure
TER
Main Bearing
Elastomeric Support
Connecting Chain
Main Connector
Inflatable Seals
Bottom Bearing
Chain Hawse
Travelling Hoist
Swivel Stack
Access
Piping Deck
Chain Puller
Access in Turret
Fluid Connector
Riser Buoy
Riser
Dis-connectable Turret Design
- 17 -
Turret Components
Turret Components
Gantry
Piping deck
Top bearing
Turret chamber
Bottom Bearing Ring
Swivel Stack
Elastomeric
supports
Buoy Receptacle
- 18 -
Dis
Dis
-
-
connectable Buoy
connectable Buoy
and Connectors
and Connectors
Structural
Connector Hub
QC / DC Chamber
Buoy Structure
Chain Hawse
- 19 -
Buoy Connector in Turret
Buoy Connector in Turret
Structure
Structure
- 20 -
Topside Design
- 21 -
FPSO Construction
FPSO Construction
- 22 -
March
2002
Aug 16
2005
April 2004
Q4 2005 -
Q1 2006
Q2 2003
November
2002
August
2002
Project Sanction
Turret Fabrication
Commences
Hull Fabrication
Commences
Development
Drilling
Commences
First Oil
FPSO Arrival
Marystown
Sailaway
August
2002
Topsides Fabrication
Commences
Overall Schedule
- 23 -
Turret: Machining the Lower Bearing
- 24 -
Trial Fit of Buoy to Turret
- 25 -
Buoy Connector and Riser Valves
Buoy Connector and Riser Valves
- 26 -
Turret components ready for shipping
Turret components ready for shipping
- 27 -
Buoy showing QC/DC riser valves
Buoy showing QC/DC riser valves
- 28 -
Samsung Keel Laying
Samsung Keel Laying
- 29 -
Samsung Float Up and Repositioning
- 30 -
Samsung Block Assembly
- 31 -
Moonpool Structure & Integration into Hull
- 32 -
Moonpool Structure & Integration into Hull
- 33 -
Main Deck, Fire main & typical deck stools
- 34 -
Hull: Just Out of drydock
- 35 -
Turret Installation
Turret Installation
- 36 -
Arrival in Newfoundland
Arrival in Newfoundland
- 37 -
SeaRose FPSO arrival Marystown
SeaRose FPSO arrival Marystown
- 38 -
Approaching the piers
Approaching the piers
- 39 -
Marystown Cow Head Fabrication Facility
Marystown Cow Head Fabrication Facility
- 40 -
Lampson Transi-lift Crane
- 41 -
Lampson Transi
Lampson Transi
-
-
lift counterweight
lift counterweight
- 42 -
M45 Utility module lift
M45 Utility module lift
- 43 -
Landing M45 Module
Landing M45 Module
- 44 -
Winter 2004/Summer 2005
- 45 -
Preparation for Sailaway
Preparation for Sailaway
- 46 -
Sailaway August 16
Sailaway August 16
th th
2005
2005
- 47 -
White Rose Dedicated Shuttle Tankers
White Rose Dedicated Shuttle Tankers
- 48 -
Factors Contributing to Success
Factors Contributing to Success
Carry out comprehensive FEED to enable detailed functional
specifications to be written.
Incorporate a formal lessons learnedprocess from the experience of
other FPSO programs.
At sea service and maintenance of structure and equipment has to be
comprehensively considered during detailed design operations input
is essential.
Shipbuilders build ships, EPC contractors build O&G equipment. Dont
mix the two cultures in one contract.
Have logical and minimal contractual and technical interfaces and
manage them intensely.
Use IT technologies extensively better to over-communicate.
Establish a strong, but efficient management of change process.
Establish an independent expert project review committee with periodic
reviews of the project.
FPSO service is very severe material and equipment selection for
durability and reliability is paramount.
- 49 -
Jasmine Knutsen: Connection trials
- 50 -
Heather Knutsen: First Cargo
- 51 -
Operations Performance
Performance and reliability to Date:
Exceeded initial expectations
Total of 792 lost time incident (LTI) free days for production
operation (as of December 31 2007)
95% facility uptime
2006 production just over 32 MMBbls
2007 production was 43 MM Bbls with average annual daily rate
of 117,000bbls/day
Development drilling of 18 well base field completed in 2007
Government and regulator approval to operate facility to a
maximum of 140 thousand bbls/day or 50MMbbls/year.