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339
2 JONATHAN S. COLTON AND YEE WENO LOW SPE 5010t
340
SPE 50101 A STRATEGIC APPROACH TO DESK3NINGFPSO VESSEL PCWVERGENERATING SYSTEMS 3
systems specification generation. Such a design approach . .. . .. .. . ... ... . . . . .. ... . .. . .. ... ....(1)
framework has five major advantages. Fwst, all of these P, (t) = $ P, (t)
Sal
modules can be developed concurrently as separate models
and tested individually prior to being incorporated into the PT( t ) = ~so pow~ Pdik? as ti~ion of time
structure. This maximizes the effectiveness and eficiency of P,(t) = Individual systems power profiles as tbnction of time.
the whole design process. Resources are made to solve the
“ P“ (t)
major tecbno-economic issues of the project in a top-down and PI(t) = Utilities power profile= ~— . .. .. . ... (2)
overall perspective. *=1 s
Second, the modules’ development allows the level of
Here PI(t) is expressed as a laplacian fimction and PI( t ) is firs
analytical and mathematical complexity to be refined in stages
through the timeline continuum and this allows the design = 1 and P. ( t ) are individual utilities power units.
process itself to change with time and become adaptive to
handling fiture power generation design problems while Pz(t)= ~H(t–2n)– H(t–2n–1) . .. .. . . . ...(3)
maintaining an overall coherent structure. Third, the power n=o
generation systems, when designed, should have access to
Here P2 ( t ) is expressed in a heaviside fimction and Pz( t ) is fors
iniiormation and rules from both land-based and offshore-
= 2 and n being the number of periods per time period. Examples
based industries. Power’generation systems could be designed
Of ,%%SOf dflkrerlt SySttXllSpOWm load reqtientS w
to sets of requirements pertaining to these two industries and illustrated in F@ires 5 to 8. LXe cycle costs encompassing capital
their solutions can be compared. These comparisons will give
costs, opemting and probabilistic loss of production costs are
designers a feel for the trends in design between the two
modeled into the life cycle cost (LCC) module Q. The time value
industries and this will help them to judge the power
of money and investment decisions are considered in this module.
generation systems technology developments in the fiture.
Equations (4) to (7) show the cost model for net present value of
Fourt~ the design process rdlows present designem to
capital costs, operational costsand lost of production costs.
continue merging existing power generation systems with new
systems in a formal manner not based solely on criteria
Z.(t) =:zfl(t) ...................................... (4)
matching and evaluation. The existing power generation /9=1
systems information is entered into the knowledge database
and becomes one of the choices in the selection of future where ~ t ) = Total life cycle costs of the power generating
systems. The existing systems reliability condition also can be systems and +1( t ) = Total life cycle capital costs or
set up in the reliability module and this allows the conceptual
design team to assess the overall impact of maintainkg the old
zD=l(t) =Rt(t)~Ei (t) . .. ... ... .. . . .. .. . . .. . .. ..... (5)
system and to be able to assess alternative design ideas. The i=1
f~h advantage is that the design process allows major design
issues not encountered presently to be added as new modules here FQ(t) is the annual recove~ factor (can be geometric,
to facilitate solving fbture power generation systems design linear or constant); p = 1,... no. of equipment components and
problems. In other words, the design process framework is systems, Ei(t) = the equipment components and systems cost
made robust to facilitate internal changes to be made within its and is a fl.mction of time. Ei(t) are not necessary hardware
structure to enhance its context as well as allowing it to equipment components cost alone. NORSOK [8] capital cost
broadening its capability. components are composed of the following: Design and
Administratio~ Equipment and Material, Fabrication
Example discussion. Installation Commissioning, Insurance spares, and
Figures 1, 2, and 3 illustrate schematically the overall Reinvestment cost. The operating costs is represented by
problem statement formulation for the design of power equation (6) as follows:
generation systems. In our design process, the power
generation system configured is required to fi.dfill simulated
power scenarios in the most economical manner for the vessel
$& ~u(t)~j(t)
zp=~(t)=~ i=l
............................(6)
or plant. The power input scenarios module @ (please refer to
Figures 1,2, and 3) contains the power growth power demand ~Eg=Operating factors associated with each particular
variations, and the number of power profiles that are to be equipment p = 1,... no. of equipment and m = 1,... no. of
used in the numerical solution. Power demand scenarios are operating factors per equipment. NORSOK [8] operational
simulated as a time-based function both periodically and cost wmponents are composed of the following Man-hour,
throughout the operating lifetime of the systems to provide a spares and consumable, logistics, energy consumption,
feel to the designer on the types and changes to systems that insurance COS4and onshore support cost. The costs incurred in
will meet the project operating scenarios. Typical profiles for 10SSof production is represented by equation (7):
an oil field production (also called production profiles) can be
modeled as shown in equations (1) to (3). ZP=3(t) = Q ~pDL .................................. (7)
341
4 JONATHAN S. COLTON AND YEE WENG LOW SPE 50101
where Clav= Average no. of critical failures per year, stru@re fi.mction that is monotonically increasing (iiproving
p=Probability of production reduction due to ftiiures, with modifications). The procedure involves first computing the
D=Duration of production reductio~ and L=quantity of reliabMy of each of the equipment reliabdity, the basic power
production loss per time unit. Investment opportunity costs system diabilii and then the complete power genemtion system
and construction time effects are modeled as part of the reliabii. The availability, mdainab~ and spares allocation
economic problem statement. Figure 9 illustrates the effects of is solved as part of the overall design problem Wtement. Both the
the cat components and their behavior with time. The time availrdility and maintainability
“ numbers are used in the life cycle
effkct of the project schedule on construction cost is taken into cost iimction- Figure 13 ikstrates a configuration of a simple
consideration in the development of the model for the various system with redundancy consideration. The reliability fimction is
major cost values. Figure 10 illustrates the construction expressed in its general form as equation (12>
schedule for the construction of a typical FPSO vessel power
generation system. The financing opportunity cost penalty
involved with long construction time is illustrated in Figure
al(xJ= @(x,, x2,..., xn)=f
[
R @)&fi (k)
1=1 i=! 1
11. The increase in financing cost reflects loan financing for . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..(12)
the project. Figure 12 illustrates a particular twenty years, n and H me basic reliability structure timctions. A power
three-shift per day workmode scenario in the maintenance and system with redundancy is illustrated by Figure 13. Another
operation of the power plant systems. The figure reflects a system reliabWy as depicted in F@re 14 is modeled w
constant power output right from the beginning of plant
operation and non-negative power start-up operating cost. It RX =Rs1(O+Rs2(9+Rs3(0 ......... .................. (13)
includes maintenance and operating spares costs.
Environmental COZ cost is incorporated as a fi.mction of the The engineeringmodule @of Figure 4 contains the aIgebraic and
numerical modeliig between the attributes and associadve rules
continuous power output for the plant systems taking the
defining the relationships between the attributes and the state of
information from the environmental and safety modules @
the systems. Weig@ volumetric spaces, maximum and minimum
and @. Quantitative regulative rules such as C02 taxes and
power ratings as required by NORSOK and Class&cation
safety requirements governing criticality and redundancy of
Societies are modeled. This module also models the behavior and
systems as required by industry regulatory bodies [8] are
connectivity grammar to allow placement and layout to be
modeled in modules @l and @. Here, rules governing
optimized. The knowledge database (KDB) contains all the
mechanical equipment selectio% environmental care, and
objects and systems itiormation that form the system
technical safety requirements are formulated into engineering
configurations. In this knowledge database, the extensional
parameters and associative roles to allow numerical modeling.
attributes tiormation of objects and systems that makeup the
Three examples of such regulatory rules are given as follows:
final power generation systems are known. These information are
SO,N) < 0.2%(weight) ... .. . ... . .. ... ... .. . .. . ... ...(8) used as data by the ovemll design process. Such an approach is
able to utilize the prior engineering tiorrnation and knowledge
S02 is the sulphur dioxide discharge for each particular accumulated by an orgauizadon. In our approack the data are
equipment. presently stored in Microsofi EXCEL”” spreadsheet format. The
D 1~~~)< D I,W=, —-’~+ S@O=J=S@OEJ information is convertible into MICROSOFT ACCESS’’”
database form Figures 15 and 16 illustrate some of the systems
properties and attdmtes. The design process fia.mework uses
.... . ..... .. .. . . .. .. . . .. . .. .. .. (9) MICROSOFT VISUAL BASIC’” algorithm with its OLE object
Equation 9 shows a preferential rule as in equipment selection f-es to provide a plattiormfor all the design process activities
given the discharge of nitrogen oxides discharge of equipment 1 to take place and to i%cilitate inter- connectivity between the
and 2, the lower discharge value equipment is preferred. module. Figures 17 to 20 ilhstrate the interfhce written in Visurd
Basic where constant interfacing of iniiormation between
z C02 (tax) =0.12US$/m3 forgas engines .. . .. . . .. .. .... (10)
designers and computer is allowed. Analytical and mathematical
and models in the modules were developed by using both EXCEL
fimction fmtures and VIswd Basic mathematical programming
z C02(tax) = 0.12US$ I litre for diesel engines ....(11) language. The design process approach is first to allow the
analytical model be used for the optimal selection of systems
Equations (10) and (11) show the costs of operating either gas based on an object fimction statement. Then the results horn this
turtines or diesel engines as a tax operating cost. Such rules are analytical modulewill be passed to the second anrdytical module.
incorporated in the design. Reliti~lity module @ modeled the The second analytical model allows the optimal placement and
overall reliability of the whole power generation systems. The layout of the systems based on the behavior grammar
mathematical reliability model for the whole power generation
system is built from the two (simple series and parallel) reliability
structure models into a coherent reliability structure model. A 2The extensionalattributesdefine the object or class of objects
coherent structure is defined here as a mathematical reliabili~ in the real world. Example a car extensional attributes are ail its
aggregates,e.g., steeringwheel,seats and etc.
342
SPE 50101 A STRATEGIC APPROACH TO DESIGNING FPSO VESSEL POWER GENERATING SYSTEMS 5
connectivity between objects and systems [29]. The results of this Floating Production Storage and Offloading System. in 26th
module are fd to the interthce computer in graphical f- that Annual Offshore Technology Conference. 1994. Hou.stq
will show choices and decisions made by the designers. Figure 20 Texas. USA.: SPE, OTC 7443.
illustrates the output based on a particular set of economic 7. Corrigu M.M., Iboy, W. van. and Hong, Z. T. Luihua 11-
1 Development - MAXIMO Systematic Maintenance
scenario inputs. The selected equipment and all the relevant
System. in 1996 Offshore Technlogy Conference. 1996.
iniiortnatioq such as the seleded model of the systm its wei~ Houston: OTC 8190.
power outpu$ machinery space parameters and the vafious cost 8. httphww.nts.no, NORSOK STANDARDS, 1997.
components are displayed for the designer to make Iin-ther design 9. Assayag, S., Prallow E., and %rtori, F. Improvements in
decisions. Overall, this design process approach allows the Design of Converted FPSOS Regarding 20 Years Operation
conceptualdesign team to visualiie the placement and layout of without Docking. in 1997 Offshore Technology Conference.
the power generation systems with respect to the dfikrent 1997. Houston, Texas, USA: SPE, OTC 8389.
simulated power scenarios based on the latest numerical 10. Davi~ C. Development of a Gas Field Of&hore
modeling. This approach therefore bridges the gap between form Thailand Using an FPSO. in 1997 Offshore Technology
Conference. 1997. Houstoq Texas. USA.: SPE, OTC 8377.
visualization of the systems that are designed to satisfjIthe 11. Milhnaker, A., Y% L., and Adhun, J. The Challenges of
simulated operating scenarios. Basically, the design process Lufcng 22-1 Development. in 1997 OEkhore Technology
generates specifications based on forecasting of operating Conference. 1997. Housto~ Texas. USA.: SPE, OTC 8466.
scenarios rather than having designers having to work from 12. Brennaq T.J., Palmer, K. L., Kopp, R J., KIUplli~ A. J.,
technical specifications. Future work will test the models which Stagliano, V., and Burtraw, D., A Shock to the System
are incorporated in this design method. Resbucturing American’s Electricity Industry. 1st @ ed.
T.P. Breman. 1996, Washington Resources for the Future.
138.
13. P* G., and Beitz, W., Engineering Design. 2nd@ cd. K
The present work is an on-going part of a research contribution Wallace. 1996: Springer-Verlag. 544.
towards the design of huge scale engineering artitkts. The 14. Fraatz, J.P., Koster, T. E., Y% L., Haire, W. M., and
research goal is to develop insight into designing effective and Shimamur~ Y. Luihua 11-1 Development - Design and
Fabrication Considerations for the FPSO Nanhai Sheng Li.
efficient design process fiwnework that can be used cotiortably
in 1996 Ot%hore Technology Conference. 1996. Houstow
by the industries. The design process approach discussed here is Texas. USA.: SPE, OTC 8188.
for the design process approach to offsho~based power 15. Voorsh O.v. Operational Experience of FPSO Uisege Germ.
generation systems design. Economic and engineering issues are in 1996 OtTshore TecbnoIogy Conf%reace. 1996. Houstonj
both used to guide the pms tkunevvork and forming problem Texas. USA.: SPE, OTC 8071.
structure. The process framework supports individual modules 16. Seoles, L., Qniley, N. and Sozonoff, S.S. Tanker-Based
and main analytical modelers. Modeling of the design process Floating ProductioIx Start-up and Operational Experience
framework and problem structure is explained and discussed. with FPSO II over the First Eighteen Months. in 15th
Offshore Technology Conference. 1983. Houstom Texas.
USA.: SPE, OTC 4545.
ACKNOWLEDGMENTS 17. Voors~ O.v,, BaaQ J. de., LoenhouL van., and Kreke~ M.
The authors gratefidly acknowledge Kvaerner ASA (Norway) Conversion of Existing Tanker to North Sea FPSO Use. in
and Kvaerner 011 and Gas (Norway) for sponsoring the on 27th Annual Ofi%hore Technology Conference. 1995.
going research in marine systems design which this paper is a Housto~ Texas. USA.: SPE, OTC 7724.
part. 18. Jaquith, P.E., et al., A Parametric Approach to Machinery
Unitization in Shipbuilding. Journal of Ship Prodnctiow
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6 JONATHAN S. COLTON AND YEE WENG LOW SPE 50101
Synthesis of Utility Systems by Simulated Annealing. Table 1: Economic and Technical Requirements for FPSO
Computers Chemical Engineering, 1995. 19(4): p. 481-488. Svstems.
25. McDonrd& J.R, The Forecasting of Growth of Demand for
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Wang, and McDona14 J. R, Editor. 1994, McGraw-Hill. p.
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1-88. Requirements
26. Wang, X., Power System Probabilistic production
Simulatio% in Modern Power System Planning X Wan% Short Project Time Frame:
and McDonal& J. R, Editor. 1994, McGraw-Hill. p. 166- Constructinganew FPSO takes 18 to [30~ [6], [31]
246. 24 months
27, Rasanen, M., Ruusune~ J., and Hammalaine~ R P., Conversion of an existing vessel [9], [10], [14], [11], [32],
Object-Orricnted Modeling Software for Electric Load takes 12to16months - r151
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Systems Systems
35. Barsness,E.J., and MilIer,R T. PrehminaryDesignof a 10
MWE OTEC Power Plant and 50 MWE OTEC Power Power Growth Prediction I I (+)3
Modules.in 1M AnnualOffsshoreTechnologyConference. Power Demand Variation within I 1
1979.Huston,Texas.USA.: SPE, OTC 3587. one period (+)
36. Robcrton, R Hydro Electric Energy Solution for the Troll Number of Power Profiles (+)
Platform and Onshore Plant. in 1997 Of&here Technology Number of Operating Modes (+)
Conference.1997.Housto~ Texas.USA.: SPE,OTC 8415.
37. Smiti D.W., and Mawby, M. J. Use of Safety System Life Cycle Cost
PerformanceStandardsto Optimize Platfbrm Maintenance. Sd%tyReguktiOIIS
in 1997 OffkhoreTechnologyConference. 1997. Hous@ Environment Issues (+)
Texas.USA.: SPE,OTC 8363. -!3 Environment and
Condidons (+)
operational support (+)
Reliability I I
Weight and Size Issues (+) i
Equipment Opemtmg “ Life Issues I I (+)
TransportaMity (+)
344
SPE 50101 A STRATEGIC APPROACH TO DESIGNING FPSO VESSEL POWER GENERATING SYSTEMS 7
I
Figure 3: A diagrammatic guide to a electrical power
t
T 1 generation problem requirements.
II
,-------- !
Air In
:
,?
Generator #1 + ! Geaerator #2
)
la Transformer
c
Condense
)
T Power Out
jh-g’Y524Jq~
............................. Modules
;
I
.........------
------
I
...........------
..........----
...... --, /
Analytical
Modeler I
Q Concept
Design
Team
o Ss(-)kw
systems.
345
8 JONATHAN S. COLTON AND YEE WENG LOW SPE 50101
m- -*— Pmfl&
$fmar Fwr Ph.me$ ProfVe lhrae Phases Pfofik
; ‘%? W2w p view
Vwi$si
millingS@8m Puwfi F@.p.irement iv V&a
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Vtwis,d CW-LmdqI FC+W Requirements
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. . ...... - .- . . . ......—.
--------------..-,--+ ... . .......—... . ...
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,-.dcsigrter--- . - ,. . .... . . .. . . ..+. ... . .. ..”....--. .—.. ...... ... .. .. .. ...;
i
.—.—
346
SPE 50101 A STRATEGIC APPROACH TO DESIGNING FPSO VESSEL PCRNERGENERATING SYSTEMS 9
Figure 7: Simulation of an oil field profile by approximation design guide for designer.
I&J-l
1
1.027
+Capilal EquipmentCosts
J5EEEE7 +
-
InstallationC.3+MS
Commissioning COS*
347
10 JONATHAN S. COLTON AND YEE WENG LOW SPE 50101
—
m—~- lmq~~
r3.,4--- .-..--...-.—.. -—..-.--.. =..-..- .. .. —.——— ——=.
3
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Figure 11: Construction time effect on investment costs. F@re 12: Operational and long term cash flow
model.
b,
A
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o s,
o
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s
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.,,
Figure 13: Reliability model for a system S1with redundancy. Figure 14: A gas turbiie and diesel power generating system.
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348
SPE 50101 A STRATEGIC APPROACH TO DESIGNING FPSO VESSEL POVVERGENERATING SYSTEMS 11
Figure 16: Data of some gas and steam turbine combination electric power generating systems.
Figure 17: Conceptual design guidelines for the design of FPSO vessel power generating systems.
.... .. . . .,,. . .. ... ... . .. . ., ,.
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12 JONATHAN S. COLTON AND YEE WENG LCJfd SPE 50101
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\- ug R-* p{iJ&&wn ‘. P&uw?OPmfikw&d km”; ;
/ @ 1. 13-&uFCIWPhases P&e
; r 2. “* ThCeo I=%@s P@!?
;:
~, ~ 3. P&J&3*,,~*w& F’r&& ;i~ uS$’#&@l ~ ““ :
: fl ~.Ch&gned SMOG& %%”. i!
‘...... .... ,.. ,.-. . . . ..”.:: .. .. . . . ;.- . ,. ...”.. . . .... ... . .. ..+ . .- J
‘~ ## R~s&@ @8 fi~ ~z ~~ “,,,: ““- .:-nb* ~ “~
Figure 20: Data output (or BOM of system) for power generation system design process.
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