OTC-25865-MS

The Buoy Supporting Risers (BSR) System: Engineering a Solution for

Ultra-Deep Water Subsea Developments in Harsh Environments
Ivan Cruz, Gustavo Hepner, Daniel Karunakaran, Claudia Claro, Frederico Nicoletti, Emmanuel Fontaine,
and Majid Hesar, Subsea 7; Marcus Tadeu R. de Paula, and Leandro C. Trovoado, Petrobras

Copyright 2015, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 4 –7 May 2015.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
The Sapinhoá and Lula North-East fields were developed through pilot systems composed of satellite
wells connected to spread moored FPSOs. Each of these developments needed to connect up to 45 lines
coming from the wells to a single balcony at FPSO portside, not including gas export riser and its ESDV
umbilical. It was expected variable levels of CO2 and H2S, posing the challenge to find a suitable solution
that endure the 27 years life of the fields in 2140m water depth in the harsher Santos Basin. To cope with
these challenges, Petrobras and partners (BG E&P Brazil and Repsol Sinopec Brazil, in Sapinhoá field,
BG E&P Brazil and Petrogral Brazil, in Lula Field) decided to pursue a decoupled risers’ system solution
and launch a “design competition process” which ended up selecting the Buoy Supporting Risers (BSR)
concept solution developed by Subsea 7. This paper describes the BSR System and the needed careful
physical and numerical modelling and massive analysis of a largely complex new system, backed up by
prototype tank testing, all of them tackled to capture the in-place behaviour to generate the design input
envelopes for all system components.

Introduction
Evaluation of the Santos Basin province produced fluids indicated that levels of CO2 and H2S were
significantly high enough to pose serious challenges for flexibles lines to withstand the endurance life of
the fields, predicted to last for 27 years, specially under dynamic condition aggravated by the 2140m water
depth and the harsher environment. All these factors combined led operator and partners to decide to
develop the fields with decoupled risers systems made with rigid pipes provided with adequate corrosion
resistant alloy (CRA). Decoupling the risers from the platform (FPSO- Floating Production Storage and
Offloading) directly induced dynamic loading would grant enhanced fatigue endurance for the rigid risers
with the additional benefit of reducing the payload on the platform, a one-sided balcony spread mooring
FPSO, coming from 45 lines hanging from 2140m water depth. For these specific cases, a saving of some
five thousand metric tons on payload was achieved. Another benefit of this system, although not
experienced in the project due to execution scheduling constrains, see reference (Camozzato, G. et al.,
2015), is the potential pre-installation of the risers’ system, allowing for a quick production ramp up.
2 OTC-25865-MS

The concept is to have the risers coming from the wells’ end to an intermediate structure, protected
from the surface environmental loading, and then continue to the FPSO through low-tension and
“damped” double catenary flexible jumpers. For the SCRs, a seabed transition to flexibles flowlines is
made through PLETs/VCMs (pipeline end termination/vertical connection modules) for the connection
with the wells’ Christmas trees. The system comprises of two tether moored buoys submerged at 250m
below surface, capable to accommodate 22 or 23 lines each. A single buoy displaces close to 10,000
(metric) tons of water, providing a nominal net up thrust of 32,500kN (3,250 metric tonnes) after all lines
have being connected. The system net tension is set to cope with both FPSO and buoy offsets responding
to the environment loads as well as conveyed fluids density variation. The buoy shaped as a closed
pontoon with uneven volumes to balance the asymmetric payloads from the risers coming from the deep
seabed end from those from the flexible jumpers continuing through the buoy to the FPSO, see Figure 1.
The BSR Buoy dimensions are 52m wide by 40m long by 10m height.

Figure 1—System overall configuration

The tethered mooring lines are connected on both the Buoy and the foundation ends through gimbaling
devices that allow the built up of conical angles to accommodate all sorts of loading: platform offsets,
forces coming from risers or jumpers and the direct action from the environment (currents), therefore, the
system resembles a tension-leg platform (TLP) where the inverted pendulum-like movements don’t affect
the Buoy even-keel condition. The lateral offset envelope mostly results from the balance between the
restoring horizontal forces projected from the inclined tethers tension, which is a direct function of the
available net up thrust, the catenaries horizontal pull and the external action from current and platform
pull-push force coming from its own excursion transmitted to the Buoy through the jumpers. It is worth
noting that a single rigid riser offers a drag area of some 500m2 which rivals with the Buoy’s biggest
vertical panel area at the risers’ pontoon face, therefore, the risers’ drag area dominate by far the system
response to the current loading alongside the water column.
It is clear from the above that the choice of the net up thrust provided by the Buoy for any possible
payload is the key parameter to ensure the system overall functionality: if too small it would loosely move
OTC-25865-MS 3

around with potential issue of clashing with platform mooring lines or building up excessive angles at
risers’ top ends or tethers and excessive sagging movements on jumpers; if too high, the size and strength
of all structural components, including mooring, foundations and Buoy hull, would impact the system
cost. A parametric costing constrained-optimization study was performed during FEED phase which
demonstrated that the deeper the Buoy and the closer to the FPSO, the most cost effective the system
would turn, allowing for setting the minimum net up thrust that still provided a sound design to fulfill
operator requirements and system needed functionality. Operator’s requirement to keep the buoy at diving
access depth, limited it to be around 250m. With this input and with a nominal offset of 400m from the
FPSO, the net up thrust of 32,500kN has proven to be the cost effective nominal value to provide the
adequate excursions and coupling with FPSO, free of interferences and with reasonable angular and loads
variations for the system key elements, including failure cases such as accidental tanks’ flooding or a
complete loss of a tethered mooring line. Also, it would need to accommodate the conveyed fluids
possible density variation passively, meaning with no ballasting intervention. With all these aspects
considered, the pay load variation in the Buoy could amount to around 7,000kN, resulting in the system
need to accommodate and function properly within a net tension variation within the range of 28,000kN
to 35,000kN, approximately.
Some operator requirements were key for the design of the system overall:
● The system shall withstand the simultaneous accidental flooding of (any) two tanks keeping Buoy
attitude within acceptable envelope for its own stability and integrity of the other components,
especially risers in general and SCRs’ flexjoints in particular; and tethers’ connections angles;
● Moreover, even on such accidental case, it was required to have a positive net tension at each tether
bottom connection to foundations;
● The system shall withstand a sudden and complete loss of any tether mooring line, including the
dynamic transient pulse generated, still keeping an attitude within admissible envelope for other
elements. In case of such event, a ballast intervention on appropriate tanks could bring the Buoy
closer to an even keel condition allowing for the failed mooring line retrofitting.

Concept of BSR System

Buoyancy Supporting Riser system consists of a Buoy which functions as a submerged TLP that acts as
an intermediate platform where the steel catenary risers are connected on one side and the flexible jumpers
on the other side which links to the floating production unit. The Buoy is connected to the sea bottom by
8 tethers, two on each corner of the Buoy. See schematics in Figure 2. The net up thrust provided by the
Buoy carries the SCR loads and four-corner tethers in combination with the up thrust gives the stability
of the whole system to withstand the SCR pull, current forces on risers and the lateral movement due to
vessel offset. The up thrust and tether system keeps the Buoy even keel for various lateral movements with
marginal set down from the “inverted” pendulum action.
4 OTC-25865-MS

Figure 2—BSR System and Configuration

The top angles of risers and jumpers have been defined to optimize risers’ length, payload at the BSR
Buoy and minimize the risk of interference between risers and mooring line of the system. Angles of each
type of lines can be seen in Figure 2.
System Overall Field Layout
The subsea layout is prepared considering the proposed development of the field in two phases, see Figure
3. The subsea layouts as far as the pipeline end terminations (PLET) radius take into account the routes
of the future and spare flowline bundles. The definition about the type of risers at each BSR slot followed
the sequence of riser type defined for the FPSO balcony. The balcony is a structure on the port side of
the FPSO, hence facing east on these fields’ layouts, which contains the connections of the flexible and
umbilical jumpers.

Figure 3—Subsea Field Layout (Sapinhoá) with BSR excursion envelope plotted
OTC-25865-MS 5

The FPSO mooring system is used to ensure the right positioning of the system foundations. The
interference between mooring lines and BSR system at suspended section and at the seabed has been
studied in detail in order to provide sufficient space to avoid interference between adjacent BSRs and the
FPSO mooring lines.
The cost of the project is directly associated to the length of risers, jumpers, tethers and BSR size.
Considering that, the separation of BSR from FPSO, BSR depth and size has been optimized to reduce
the payload and balance the length of tethers, jumpers and risers. The global performance analysis have
been carried out and confirmed that the best cost solution also gives the best performance of the BSR
system.
BSR Buoy and Tethers functional description
The BSR Buoy itself has 48 compartments to adjust the ballast/buoyancy during lowering and hook-up
to the foundations as also as during lines installation, and therefore define the trim/heel of the Buoy. See
Buoy compartments as shown in Figure 4. The ballast is needed for balancing the moment of the loads
to get the Buoy with suitable floating condition. The up thrust of Buoy is a definition of the system and
preferably should be set close to 32,500kN for any scenario since its installation, in order to maintain the
system stiffness. When lines are added to the Buoy, the up thrust is reduced exactly by the same load of
lines added. To recalibrate the system stiffness, ballast is removed from the tanks when risers are installed
to the Buoy. It is desirable that ballast removed from tanks be as closer as possible to the referred riser
slot. It keeps the BSR even keel and keeps the loads on tethers properly distributed.

Figure 4 —BSR Buoy Ballast Compartment

The system has been designed for variation of fluid densities considering the data provided by Operator
and Partners. The BSR Net Up thrust variation found is about 2% for each range of density for operational
phase I and 4% for phase full. For instance, in phase full it represents ⫹4% of load on the tethers when
risers have lighter fluids density inside and ⫺8% for shutdown density fluid (highest).
The scantling of the BSR Buoy had two design drivers during design phase. The BSR Buoys have been
divided in 48 tanks in order to make easier the BSR Buoy lowering during its installation, the BSR Buoy
inclination control, tethers load control per corner, as well as minimizing the BSR Buoy vertical
displacement in case of two adjacent tanks failure. Based on that, the tanks near each corner of riser
pontoon were subdivided in smaller tanks reducing the BSR Buoy vertical displacement and inclination
for accidental flooded compartment.
6 OTC-25865-MS

A total eight (8) tethers are provided for BSR Buoy station keeping. Two tethers on each corner gives
redundancy for the system, however, this needs proper tether adjustment to get even tension in mean
position. Most part of the load supported by the Buoy comes from the risers, and then the most part of
total ballast are inside of those tanks.
Risers and Jumpers Description
The PLETs are located at a radial distance of 3,000m from the FPSO geometric centre, equally spaced
along the arc between the innermost mooring lines in the east, called the PLET arc, or PLET Radius. Steel
catenary risers connect the PLET to the Buoy. For each riser type, there is an associated jumper. The
flexible jumpers are installed between the balcony of the FPSO and the inboard pontoon of the BSR Buoy.
The nominal separation between the centre of the FPSO balcony and the centre of the BSR Buoy inboard
pontoon is 386m for all BSR systems.
Global Performance Analysis
Two different scenarios have been evaluated in the global performance analysis to design the BSR system
to withstand the most severe environmental load throughout whole life of field. The first phase, Phase I,
is defined as the first stage of development of the field, when the BSR System starts to operate, and the
second comprises all risers and jumpers installed. Combining both phases with all current profiles, loading
scenarios (intact extreme and accidental cases) and different fluid densities expected through the life of
field, it results a total of 3.600 load cases per Buoy or 14.400 static load cases for the 4 Buoys from both
fields.
All component of the BSR system had to be modelled in finite element software. The BSR buoy was
the component that had the highest attention in proper modelling wherein Subsea 7, 2H Offshore, Intecsea
and Orcina were involved.
Appurtenances Modeling
All accessories above the BSR Buoy (i.e. chutes, gutters, tether hang-off, riser hang-off, SCR flex joints,
top riser, monitoring equipment, jumpers section on the moonpool and etc.) have been considered as
outfitting. All equipment weight have been summed and considered as a single mass above the BSR Buoy.
BSR Buoy Modeling
The BSR Buoy modelling strategy adopted a number of “Layers” of 6D buoys to represent the pontoons
of the hull, the effect of ballast, drag and appurtenances, see Figure 5.

Figure 5—BSR Buoy modeling – Layer Full model used in the Analysis – All Layers
OTC-25865-MS 7

The Layer 1 is used to model the structure of BSR pontoons, which accounts for the mass, added mass,
moment of inertia and volume properties. Eight 6D buoys are used to model four pontoons were located
at the geometric centre of each pontoon;
The Layer 2 used to model the ballast inside the compartments of each pontoon. It accounts for the
mass and moment of inertia properties. Four 6D buoys located at the centre of each pontoon were used;
The Layer 3 used to model the appurtenances. It accounts for the mass, volume and moment of inertia
is modelled by one 6D buoy located at the centre of mass of appurtenances;
The Layer 4 used to model the drag in horizontal and vertical planes of each section of the structure.
It accounts for the mass, volume and moment of inertia. Five 6D buoys located at the geometric centre
of the BSR Buoy and at the geometric centre of each pontoon were used;
The Layer 5 used for result extraction purpose. One 6D buoy located at the BSR Buoy reference
system.
Key Parameters
The BSR System comprises some key elements that have been intensely analysed by the global
performance analysis.
Some important parameters are: BSR Unit maximum near, far and transverse offsets; BSR Unit
maximum and minimum set down; Flexible jumper angles at FPSO sides; Flexible jumper Minimum
Bending Radius (MBR); Flexible jumper maximum depth; Flexible jumper tensions at BSR and FPSO
sides; Flexible jumper minimum tension along length; SCR maximum Flexjoint angles; SCR maximum
loads - top tensions and touchdown zone (TDZ) bending moments; SCR minimum and maximum TDP
tension; SCR Minimum Bending Radius (MBR) at TDZ; Tether nominal and maximum angles at the top
and base; Tether nominal, maximum and minimum tensions at the top and base.
Based on the environmental load data (waves and current) and FPSO response amplitude operators
(RAO), the global BSR system response applies some load for each one of the parameters listed in the
previous paragraph. Therefore, they have been thoroughly analyzed throughout static and dynamic
analyses.
Static Analysis
The focus of static analyses was to determine the static response of all the BSR System under current
loading and critical design parameters for all operational phases during a range of operational (1yr current
and waves), extreme and accidental conditions as well as the fluid densities. From the 14.400 static load
cases, results of each key parameter are extracted and the worst static response under current loading is
selected.
The medium FPSO draft has been assumed for the static global analysis since it did not affect
significantly the global static response of the BSR System. The dynamic analysis is performed for all
FPSO drafts.
Due to FPSO offset and current load acting on system, the BSR Buoy moves horizontally, following
the current profile direction. The Buoy moves from the nominal position, on phase full and intact case,
a horizontal longitudinal displacement varying from about ⫹70m toward SCRs TDP (Near position) up
to about -100m toward FPSO (far position). The BSR displaces in the horizontal transversal direction
more than -130m toward South direction (Northern Buoys) and about -110m (Southern Buoys) whilst all
Buoys displace toward north around ⫹90m. The maximum absolute horizontal displacement expected
among the four Buoys is approximately 140m.
In case of an accident of a mooring happens, the Buoy may experience no more than 1m of additional
displacement.
The global interference analysis has been conducted for a number of sub-systems of the BSR System
and field layout. Global interference assessment covered the following checks:
8 OTC-25865-MS

● BSR Systems against each other in the same field;

● BSR System against Mooring Lines of the FPSO;
● Tethers against Flexible Jumpers;
● BSR Hull against SCR’s.
For all global interference cases assessed, interference between equipment was not an issue, even for
FPSO accidental mooring and tether accidental cases.
The main static loads found for the main key parameters are listed below:
● Risers: The maximum riser built angle found was 7,2deg whilst the maximum effective top tension
was 2207kN.
● Jumpers: The maximum flexible jumper built in angle at the FPSO connection was 15deg for
Water injection production line, 17deg for service line and 22.5deg for electrical hydraulic
umbilical. The maximum effective top tension at FPSO side was 946kN for gas injection (GI) line
and 525kN at the BSR side.
● Tethers: The maximum effective top tension found at the spiral strand wire was 7,500kN (53% x
MBL) for accidental case while the maximum flexjoint built in angle was 11deg.
● Bottom chain: This section will not see compression during whole life of field. The minimum
effective tension found was 193kN. The maximum built angle at bottom connector was
6.4deg.foreseen was the bottom section of the tether,
● The load case which presents the maximum top connector effective tension, 7,800kN, occurs for
the failure of a tether. The maximum effective tension for the same tether in the intact extreme
condition is 4,830kN. Therefore, the contribution of the accident (tether failure) on the total
loading is around 38% (2,960kN), whilst the environmental conditions (operational and extreme
parcels), contributes to only 7% (523kN). The other 55% (4,300kN) of the total tension are due to
nominal (or functional) loads.
● Foundations: The maximum resultant force that tethers transfer to the foundations is 8970kN.
● BSR: The maximum BSR Buoy tilt angle found was 8.2deg.

Dynamic Analysis
From each main result presented in the Static analysis section, but not limited to, the load cases are
identified and selected to run dynamic analysis.
A waves’ screening approach adopted uses irregular JONSWAP waves’ spectra combining with the
extensive knowledge of the BSR dynamic behaviour from the system design. For each Critical Design
Parameter a total of up to 5 wave directions of varying significant wave height (Hs) and peak periods (Tp),
in both combinations of 10year wave – 100year current and 100year wave – 10year current have been
considered.
Results from static analysis clearly define the extreme loading conditions in terms of current loading
and direction which produce the worst static loading response for each given Critical Design Parameter.
The methodology defined that the wave associated with this current direction must be one of the 5 waves
analysed.
The waves’ directions for the 100yr extreme storm cases are shown in Figure 6. Note that the selection
of waves for the wave screening analysis encompasses both the highest waves, (South, South-southwest
and Southwest), as well as the Beam Portside wave, which is known to excite severe response of the BSR
Buoy. Furthermore, the nominal wave direction associated to the critical load case identified from the
static analysis was also considered.
OTC-25865-MS 9

Figure 6 —Wave direction run for Global analyses

Using this method it was possible to determine the critical dynamic environmental loading scenario for
each key design parameter of the BSR System. The analyses were conducted based on 30 minute irregular
wave simulations using a range of wave periods. From these short analyses, estimates of the peak dynamic
response from 3hrs extreme storm are calculated using the standard deviation (STD), assuming a Rayleigh
distribution. This is conducted for each wave period and direction until the calculated critical period and
wave direction is identified. Afterward, sensitivity analysis was conducted to define the critical FPSO
draft using the most critical HS/Tp already known. Once the critical draft is known, a sensitivity of HS/Tp
with ⫾0.5s is done, using the same methodology of wave screening in order to identify the critical wave
period and FPSO draft.
Dynamic 3h analysis have been conducted based on the wave screening conclusions for each BSR
System key component, for all the four BSR units from both the Sapinhoá and Lula-NE fields. The
simulations consider 10,800s extreme storm durations with JONSWAP waves.

BSR Buoy dynamic behavior

Whilst the BSRs are located 250m below the mean water level and are unaffected directly by waves on
the ocean surface, dynamic loads are applied to the BRS System as a result of wave loading on the FPSO
through the flexible jumpers. As illustrated in Figure 7, the riser balcony at the FPSO moves vertically due
to heave/roll of the vessel under wave loading and, consequently, the catenary shape of the jumper
changes with each movement. This results in a corresponding change in the vertical load that the jumpers
apply on the inboard side of the BSR Buoy. Whilst this variation in load is small if compared to the
nominal jumper load, when it is applied at a period close to that of the BSR System natural frequency in
heave or pitch, then resonant response of the BSR Buoy will occur.
10 OTC-25865-MS

Figure 7—How Dynamic Loads are applied to the BSR

Vertical displacement of the FPSO connection of the flexible jumpers due to vessel motion alters the
catenary shape of the jumpers and, consequently, the jumper tension on the inboard side of the BSR varies
dynamically and excites the BSR System.
The dynamic variation of vertical jumper load on the BSR Buoy causes the BSR Buoy to pitch and/or
heave, but dynamic surge, sway, roll and yaw of the BSR Buoy is small. The main BSR Buoy motions
are pitch and/or heave, and the dynamics of the BSR Buoy can be understood largely by 3 parameters,
these being: BSR Tilt (Pitch ⫹ Roll); Inboard tether tension range; and the Outboard tether tension range.
The main 3h dynamic results among all 4 BSR Buoys are listed in Table 1:

Table 1—Dynamic analysis results for key design parameters

Parameter Dynamic Value

Riser Maximum Riser Top Effective Tension - kN 2,227 (GIS)

Maximum Riser Top Built-in Angle – deg 11.1
Tether Maximum Spiral Strand Cable Top Effective Tension – kN - Extreme 5,149 (36.7% ⫻ MBL)
Maximum Spiral Strand Cable Top Effective Tension – kN - Accidental 8,562 (61.2% ⫻ MBL)
Maximum Tether Top Flexjoint Built-in Angle – deg 12.2
Minimum Spiral Strand Cable Bottom Effective Tension – kN 85.8
Maximum Tether Bottom Flexjoint Built-in Angle – deg 6.3
BSR Buoy BSR Unit Tilt Angle – deg 10.4
Maximum BSR Vertical Displacement at the Corner – m(1) 8.6
Minimum BSR Vertical Displacement at the Corner – m(1) ⫺7.3

(1)Positive vertical displacement is BSR moving upwards.

Most of the load cases that resulted as being the most critical dynamic response, were derived from
beam-portside (BP) or southwest (SW) / south-southwest (SSW) waves.
Chain Fatigue Assessment
The fatigue contribution on the chain links comes from the tension to tension (T-T) fatigue and the out
of plane bending (OPB) fatigue. However, the bending moment distribution through the chain links is
such that the maximum OPB occurs at the first free link closest to the Buoy, or the chain stopper (dogs).
The fatigue life due to Buoy motion is thus expected to be the minimum at this particular link chosen for
study and the fatigue at the blocked link was therefore disregarded. In order to obtain the interlink stiffness
and SCFs of this critical link, a detailed analysis of the interlink connection was performed using Abaqus.
The moment at the first free link as a function of the built in angle (for OPB contribution) was obtained
from the Global analysis performed with DeepLinesTM. With all the results of the reconstituted stress in
the first link due to T-T and OPB for over 2150 loading cases in hands, the stresses time series were
OTC-25865-MS 11

generated and the rainflow counting method considered in order totalizing the corresponding fatigue
damage. According to OPB joint industry project (JIP) methodology, the fatigue curves are to be extracted
from the recommended practice DNV RP C 203. The stress range against number of cycles (S-N) curve
B1 for free corrosion in sea water was then considered. OPB JIP has highlighted the possibility of using
a less conservative curve for the OPB phenomenon by having a double slope curve reducing the damage
for small amplitude stress cycles, which has been not considered at the project time, in order to stay on
the safe side. The minimum fatigue life obtained for the first free link was 315 years, thus above the
required 270 years (27 year field life with a safety factor of 10). The fatigue life in the free section of the
chain was therefore considered acceptable.

Figure 8 —Chain fatigue hotspots

It is worth noting that the careful selection of gimbaling device type was key for fatigue endurance
related to the dominating OPB fraction contribution. The adopted flex-element type has no breakup force
that a friction bearing type one would have, for instance (see description below).
It is also worth noting that the small bottom chain section, although experimenting higher T-T stress
ranges, has expected higher fatigue endurance life due to the negligible OPB presence.
BSR System main elements description
In the following subsections we provide a walkthrough the BSR system itself key components. The SCRs
are presented in (Gouveia, J. at al. 2015).
BSR Buoy hull description and design
The Buoys are typical hull structures designed and built in accordance with regular applicable codes and
provided with internal compartments to allow proper ballast distribution and consequent attitude adjust-
ments for all the loading conditions to which these structures are submitted along their life time. The great
variety of loading conditions, such as towing, lowering, different in-place riser configurations, differential
pressures, sagging and hogging conditions as well as the locally applied loading from tethers and lines on
specific parts of the hull, drove the design of the BSR hulls. The Buoys overall dimensions are 52m at the
SCR pontoon extension, by 40m at the side pontoons extension which connect the SCR pontoon to the
jumper pontoon. The side pontoons have heights which vary from 10m at SCR side against 5m at the
jumper side, see Figure 9. Typical hull strengthening made of web frames equally spaced at about 5m and
bulkheads, which are the tanks boundaries, stiffened by steel angle profiles spaced roughly 450mm each
was adopted. Compartmentalisation was thoroughly considered with respect to failure modes, installation
and operability. The distribution of compartments was carefully determined to allow the correct up thrust
distribution in order to balance the pay-loads where they occur, thus preventing global bending stresses.
12 OTC-25865-MS

The overall hull shape reveals mainly the requirement to allow for the best conformance of the flexibles
radius laying on top of the decks, whereas the details and connections were kept the simplest whenever
possible, thus minimising fabrication timeframe and costs by the rectangular pontoon type structure with
flat plate construction and minimal rolled corners. Also, as the major payload contribution comes from the
risers which go all the way down to the seabed, one of the pontoons, called SCR pontoon, is bigger than
the opposite side pontoon, called the jumper pontoon. The compartmentalization encompasses ballasting
tanks, kept open and equalized in pressure with the external seawater during lowering operations to reach
250m depth, and installation tanks which have their internal pressure controlled during the Buoy lowering
in order to keep the differential pressure conditions within the design envelope for each lowering step
planned. While the ballast tanks are totally deballasted prior to Buoy set up for Life of Field (LoF) phases,
the installation tanks which have the role to help during the lowering operations are unfilled during this
phase, have also the function to provide the residual up thrust needed on the system in order to cope with
the jumpers and risers vertical loads during the variable risers configurations that may be assumed by the
system during LoF. In order to cope with all the uncertainties and inherent risks from the lowering phase,
a differential pressure design limit of 376kPa or up to 500kPa in case an unexpected accidental case takes
place was defined for the installation tanks, while a lower value (200kPa and 266kPa for accidental cases)
was assumed for the ballast tanks. During LoF, the offset of the inverted pendulum system imposes a
vertical movement which corresponds to a variation of less than 100kPa which for the ballasting
compartments were covered by the above design differential pressure of ⫹/⫺ 200kPa. Due to the small
level of stress and the low number of cycles imposed to the hull by these offset and all other system
movements, this differential pressure fluctuation during LoF did not cause significant fatigue damage to
the structure.

Figure 9 —BSR Buoy Hull

BSR Buoy Ballast System

The BSR is designed to ensure that the BSR attitude and angles, yaw, trim and list are within the required
limits considering that no active ballasting is required during normal operation of the system encompass-
ing all internal fluid density variation on the risers. Ballast operations are only planned during installation
and when a considerable number of risers are changed on the Buoy, thus significantly affecting the
corresponding payload. The Buoy is featured with a ballast system for interventions on the compartments
during installation and operational activities. As more risers are installed more of the operational
compartments are dewatered. This feature was also essential for the Buoy installation and attitude fine
OTC-25865-MS 13

adjustment. The 52m SCR pontoon allows proper lines support distribution along this dimension, while
the 40m on the perpendicular direction provides room for proper ballast and consequent attitude
adjustment, by the corresponding rigthening arm between pontoons.
BSR Buoy Tether Porches
The Buoy is provided with two tether connection/hang-off porches on each corner. Each tether is
connected to the BSR Buoy hull through a dedicated porch integrated to the BSR hull primary bulkheads
structure. As such, the tether porches were an important drive on the overall Buoy fabrication schedule.
These receptacles, similarly to usual risers’ receptacles, are featured with extended baskets/funnels
planned to accommodate vertical relative motions expected during the installation process. Likewise, for
the LoF period, additional features such as structural articulation by means of flexible joints components
in order to align the tethers load direction were provided, as described on the next paragraphs.
BSR Buoy Flexible Lines balcony & SCR hang offs
The Buoy is provided with hang offs for the flexibles and rigid lines porches at the SCR pontoon side
shell. Like the tether porches, the SCR ones are provided with flexible joints articulation to accommodate
the system motions, as well as the usual funnels device to accommodate installation vertical movements.
In order to allow proper diverless connection through the Angular Connection Module (ACM) and with
the flexible portion of the lines, the SCR porches were positioned at the upper part of the SCR pontoon
side shell, as indicated on Figure 10. On the other hand, the flexible porches were positioned at a lower
level, thus allowing for proper flexible lines curvature and conformity to the deck chutes provided for this
purpose. The required horizontal distance for installation, proper access during maintenance as well as
minimum length of the SCR pontoon extension, were provided.

Figure 10 —Tether and risers hang offs

BSR Buoy Monitoring System

As the BSR attitude, the tether tension values and risers built in angles are critical parameters for the BSR
system safekeeping, a permanent monitoring system was put in place with the purpose to check the system
integrity on a daily basis, as one of the conclusions from a risk analysis performed. The system is formed
by a set of equipment installed on the Buoys top deck, a communication umbilical which connects the
Buoys to the FPSOs and another set of equipment on top of the FPSOs. The system is routinely managed
by the FPSOs, however, to account for any equipment fails, it allows data to be retrieved directly from
the Buoys by the use of Remotely Operated Vehicles (ROVs). Some of the parameters measured are the
14 OTC-25865-MS

FPSO absolute surface position, short period motions and attitude, BSR absolute positions, BSR short
period motions and attitude, BSR up thrust by tether tension measures, SCR top dynamic and static
inclinations and accelerations, Flexible jumpers dynamic and inclinations at FPSO end, sea water
temperature, sound speed and depth at the BSR as well as visual inspection by cameras.

Figure 11—BSR Monitoring System: subsea and platform elements

BSR mooring Description and Design

There are 8 mooring tethers connected to each Buoy, two per corner. The tether composition comprises
a working Chain Tail at the top end of the tether to allow incremental tether length and tension adjustment,
a Sheathed Spiral Strand wire (SSW) rope section just beneath the chain with torque balanced construction
to improve fatigue performance, and a Bottom Chain Tail at the bottom region of the tether to simplify
installation operation by protecting the SSW from being compressed in case of an potential contact with
the seabed. Interconnecting the above components there are Y- and H-links which allow proper assembly
of the complete length of tether.
OTC-25865-MS 15

Figure 12—BSR Mooring

BSR mooring Top connector

Inside the tether hang off porch the mooring hang-off device (Top Connector) was planned to meet some
essential functions, such as articulation, adjustment in length and tension, locking mechanism and
interchangeability. Articulation was provided by means of flexible joints which allow tethers to be in line
with the tension loading originated from the Buoys vertical net up thrust and lateral off set movements.
The top connectors are able to interface with a temporary device called tether tensioner and thus have their
tension and length adjusted both, during installation or operational phases. Each top connector has a
locking mechanism through which the chain can be gripped with a resolution of one link. In addition,
flexjoint was designed in a way to absorb the maximum angular requirements during the LoF, including
accidental loading conditions.
BSR mooring Chain
The chain at the top of tether allows incremental tether length and tension adjustment. The stud-less R4
grade chain was considered optimal for installation and subsequent tether change-out requirements during
LoF. Because the chain management structure is electrically connected to the Buoy hull, additional
cathodic protection (CP) accounting for this mass of steel as provided on the hull, whereas the chain was
conservatively considered unprotected by the CP and thus, provided with additional corrosion thickness.
16 OTC-25865-MS

BSR SSW (Spiral Strand Wire)

The SSW wire rope construction comprises a number of final hot dip galvanized high strength steel wires
that are spun together over a sealed center. The ultimate method of corrosion protection is achieved by
the application of a polyethylene sheath (11mm) which gave a design life in excess of the required 30
years. The closed socket is electrically isolated from the connecting assembly (H-links at top and Bottom
socket) by an electrical isolation coating (Orkot ®) fitted to the sockets rings, yet with adequate resistance
characteristics to cope with the tether tension. To prevent the sheathed spiral strand being subjected to
localized bending stress at the socket during handling for installation, a bend stiffener was provided. Also
given the results of the tether fatigue assessment made, no VIV strakes to be installed on the tethers were
considered. For details on the BSR mooring and top connectors please refer (Cruz, I. et al. 2015).
BSR Bottom Connector
On the bottom end of each tether, a Bottom Connector device was provided to allow perfect assembly
between tethers and foundations. Likewise the upper top connectors, some essential features were planned
for the bottom connectors, such as articulation and interchangeability. The bottom connector concept was
based on an inverted hang off male part mated to an inverted hang off female porch which is integrated
to the top of the foundation structure. This has been a well proven method for hanging off flexible and
SCRs from floaters, and has worked well during connection of the tethers to the foundations. The
articulation was provided by means of a flexible joint incorporated to the male part. This form of
articulation was proven to be the most robust and effective to provide the required complacence needed
by the system. Other additional features included a sealed compartment to the flexible joint with the aim
to avoid undesirable debris damage to the elastomer. Likewise on the top connector, the flexjoint bearing
element was designed to absorb the maximum angular displacements while in operation, including
accidental loading conditions.

BSR Foundation Description and Design

This section describes the Buoy anchoring principle and the foundation elements design aspects.
Anchoring principle
The Buoy operating depth is at around minus two hundred fifty meters below the sea level. From this
elevation, each corner of the rectangular Buoy supports two mooring lines that are themselves connected
at the bottom to a suction pile anchor. In total each Buoy is thus anchored by height mooring lines (4⫻2)
and four suction anchor piles on the seabed (⫺2140m being the maximum bottom elevation). The bottom
connector is the latest structural piece part of the mooring arrangement transferring Buoy up-thrust to the
anchor pile. Each bottom connector is locked in one of the pile twin top receptacles. The anchor piles have
a diameter of 8 meters and a skirt of 18 meters. Overall pile size reaches 23 meters accounting for the top
anchoring structure made of a reinforced plate, counter weight supports and a central core pipe sustaining
the connector receptacles. A total of 16 piles and 64 counter weights are part of the Sapinhoá Lula NE
project and field layout in order to anchor the four BSR systems. All 16 piles and 64 counterweights have
the same respective design.
Track record
This suction pile anchor principle combined with the action of counterweight has been extensively used
on SURF projects where a riser tower systems such as a single hybrid riser (SHR) or hybrid riser tower
(HRT) needed a foundation to counteract an upthrust and side way loads induced by an upper buoyancy
tank and the environmental action on the flexible umbilical lines connected to an FPSO and the upper riser
structure. Projects where the Riser systems have been anchored by this method showed the robustness and
the reliability of such an anchor system. On the Sapinhoá Lula NE foundation anchors, the novelty comes
with the connection of the mooring lines to twin receptacles connected to a core pipe.
OTC-25865-MS 17

Suction anchor dead weight versus external loads

Based on the BSR Buoy to suction pile connection principle described above, the Buoy upthrust load is
transferred downward to the seabed anchors. Each top pile receptacle is a key part of the load path and
transfers loads to the top core pipe that is itself welded to the top of the suction pile as shown in Figure
13a. Upward tension in each connector is thus transferred to the top of suction pile. The top of pile is
reinforced by inner structural girders below the mud-line. Four peripheral receptacles support the
counterweights. The later are steel canisters having a filling capacity of 25 cubic meters. They are made
of thick welded rolled plates and fitted with a top pad-eye for the subsea deployment. Their inner void is
filled with steel shot and grit solidified with a clever special mix of cement, stones and additives. This
provides a very fit for purpose high density dead weight that is lowered to the seabed by the installation
vessel. Each counterweight then rests permanently on top pile peripheral supports. The counterweight
dead load is transmitted to the top pile reinforced structure by means of cantilever guider plates.

Figure 13—Buoy anchor arrangement as on the seabed. Global of FEA suction pile. Local FEA with connector.

Each of the four counterweights applies a downward load of around 1150 KN which is also combined
with the suction pile submerged dead weight of around 1700 KN. Total amount of deadweight averages
a value of 6300 KN. Geotechnical soil resistance exposed in the next sections and the above listed
deadweights counteracts the upward and sideway mooring line loads and overmatch the required reaction
resistance to the Buoy upthrust. The top connector receptacles sustain the upward pre-tension and some
lateral loads induced by the mooring lines sway that can be 5 deg in dynamic operating conditions and
10 deg in extreme case. The connector items are fitted with a steel reinforced elastomer allowing the
rotation angle and still transfer the upward load to the pile receptacle contact surface. The defined
pre-tension of the spiral strand wires and chains limits the lateral displacement of the Buoy that is induced
by environmental loads such as direct current load on the Buoy and wave drag forces on the flexible lines
that are heading on the FPSO. Vertical upward dynamic loads (100-year environmental conditions)
applied on anchor pile are in the order of 8600 KN (for 7500 KN static).
Suction pile architecture and structural design
The top pile architecture has been guided by the mooring line arrangement and spacing constraints. The
upper part design that is used to connect the mooring line bottom connector was guided by the functional
requirement to have a spacing of five meters between the two adjacent mooring lines. The upper mooring
line spacing on the Buoy being of five meter as well and this ensures a perfect static verticality of the
mooring lines. Bottom connectors are connected subsea and the operation needs to be reversible as well.
This has led to a side entry design where the bottom connector is first guided by a fork-like guiding device
and then inserted underneath the bearing thick plate of the receptacle as shown in Figure 13a. This design
18 OTC-25865-MS

is symmetrical with regard to pile mid vertical plane. The top of pile core pipe harbors the twin receptacles
and guiding devices to help the installation of the bottom connector as described above.
While the structural arrangement of the top part is aimed at resisting the up-thrust load, the top plate
and skirt is designed for suction pile installation or retrieval (overpressure and underpressure). The
numerical structural calculations have been performed based on dynamic and extreme tension loads of the
BSR mooring lines. Local and global FEA models have been done as per Figure 13b, to cover all the
design cases from transoceanic transportation, offshore lifting, seabed installation and in-place analyses.
Local model involved contact elements and connector modelling to accurately verify the strength of the
connection Figure 13c. Fatigue induced by the Buoy motions and riser/flexible loads have been also
integrated in the foundation structural analysis.
A comprehensive cathodic protection system prevents corrosion for the operating field life duration of
27 years. Pile is fitted with cathodic protection aluminum anodes to protect the anchor pile arrangement.
Further upward a special bushing insulates the pile from the mooring lines components. The suction piles
as it is generally the case are not painted on the inner and outer surfaces non- exposed to sea water (buried
parts) to ensure a better soil interaction as explained thereafter.

BSR Foundations - Geotechnical Design

From an anchoring point of view there are certain similarities between the BSR and TLPs. TLPs being
floaters experience a large variable component of tension in their tethers superimposed on a steady state
component. This is due to the large variations in the draft of the hull in waves and swells. On the other
hand, BSR is a submerged element, free from buoyancy variations and hence experiences significantly
milder dynamic loading than a surface moored floating unit, such as a TLP. The foundation concept
selected for the BSRs is similar to that of the Norwegian TLPs in the North Sea (e.g. Snorre and Heidrun).
These use massive multicellular concrete foundation units that are installed by suction and incorporate
provision for placement of a large quantity of iron ore on top as ballast. These foundation anchors are
sized such that during calm weather the steady state tension in the tethers is balanced by the dead weight
of foundation unit itself plus ballast. During the storms however, the additional variable load component
mobilizes the additional geotechnical resistance of foundation anchor. In this way, the net loading on soil
over long periods of calm is eliminated and hence neither consolidation due to dead weight, nor gradual
pulling out of soil occurs.
This concept of minimizing the variable load component has several major advantages. For the risers
it reduces the fatigue damage, and from a geotechnical point of view effectively eliminates the large
fluctuations of loads on foundation anchors, and hence the large cyclic stresses on foundation soils which
is well known to reduce their shear strength. The foundation anchors of the BSR were designed in a
similar way to the TLPs mentioned, except that advantage was taken of the long-term drained capacity of
soil to reduce the demand on a large quantity of dead weight to be transported, lowered and placed at such
great depths.
The final solution provided was the steel suction anchor described above with optimum dimensions of
8m diameter and 18m skirt penetration. This size, considering other structural components necessary to
transfer the double tether loads at the top, weighs about 180t in air, which was the safe limit stipulated
for the designated installation vessel. Additional ballast was provided in the form of four counterweight
units mounted on housings on top of the anchor, as described in the previous section.
The pull-out capacity of the suction anchor/counterweight system was checked for the normal
operating calm weather conditions and at maximum design event. The former is governed by the pull-out
capacity afforded by drained soil strength properties, whereas the latter more rapid loading event is
governed by the pull-out capacity of soil under undrained conditions. An LRFD design approach was
adopted utilizing the partial load and resistance factors recommended in Reference (DNV, 2011). A 3D
geotechnical finite element model was used to analyze the soil-structure behavior of the system and
OTC-25865-MS 19

developed the geotechnical load-displacement response curves, see Figure 14. The model incorporated
large-sliding frictional contact on both faces of the skirt. The linearly increasing interface shear resistance
with depth was calibrated to the local undrained shear strength of the clay, duly reduced by the appropriate
␣-factor. Many features such as the possibility of leakage of suction and vent valves at the top was
explored using this model. Full details of geotechnical design will be revealed in a subsequent dedicated
OTC Paper.

Figure 14 —3D rendered illustration of the in-place BSR buoy.

Flexible pipes and Umbilicals as part of the BSR System

The BSR system used flexible pipes and umbilicals to acquire the following functionalities:
Flexible Pipes:
● Dynamic jumpers (located between the BSR end the FPSO) connecting the SCRs to the FPSO,
providing production flow to the FPSO and water and gas injection to the wells,
● Static Jumpers (located between the PLETs and the X-mas trees) connecting the wells to the SCRs,
● Service lines (passing through the BSR buoy) providing services to the wells; Umbilicals:
● Controls umbilicals (passing through the BSR buoy), providing direct control to the wells,
● BSR monitoring umbilical (dedicated to the BSR system monitoring), providing readings of
various properties acquire at the BSR buoy level to the FPSO;
With exception of the BSR monitoring umbilical all other flexible pipes and umbilicals were not part
of the project’s scope of work. However, intense interfacing with client and suppliers were required during
design phase due to their interfaces to the BSR system dynamic behavior and also regarding their future
installation.
Figure 14, shows the 3D rendered model of the BSR buoy, with details to the Dynamic Jumpers,
Service lines and Control umbilicals.
Flexibles Interfaces General Aspects
As indicated in figure 14, it is possible to identify all the considerations taken into the design of the BSR
buoy top surface developed to allow fast and safety installation and also to accommodate all the flexible
pipes and umbilicals during their entire operational life.
The route for them started in the balcony for SCRs, umbilicals and service lines, properly arranged at
the riser’s pontoon side in order to have all these lines arriving at the top surface of the buoy in a perfect
20 OTC-25865-MS

curvature and also to allow the installation of additional future lines with no disturbance of the existent
ones.
In the sequence, gutters were built and positioned to accommodate the double catenary of the flexible
products over the buoy through its moonpol respecting their MBRs and also providing the proper required
slack to allow the installation of the compliant clamp at the jumper’s pontoons (see figure 15).

Figure 15—Detail of a particular step of the jumper’s installation procedure where it is possible to identify the role played by the BSR
buoy gutters at the moonpol for the proper settlement of the jumpers and their compliant clamp on its holding berth.

And finally, with the difference in height and the front curvature of the jumper’s pontoons, the BSR
buoy will provide alone the proper displacement control surface for them to start their suspended double
catenary up to the FPSO allowing that all dynamic displacements and movements will occur in a
prescribed controlled way.

Flexible Pipes – Dynamic Jumpers

The specification for the dynamic jumpers interface was generated providing inputs to client regarding
their expected weight over length ratio and expected dynamic behavior (top tension and accelerations).
This specification was used by client and suppliers to design, engineer and fabricate the flexibles. Further,
the design loop was closed inserting the flexible pipe properties into the BSR system model adjusting the
BSR system behavior (mainly via the BSR buoy ballast diagrams, tethers top tension) properly.
First end of the dynamic jumpers were connected to the SCRs via ACM at the riser pontoon (see figure
16), a compliant clamp was installed at a specific length of the jumper such as it lay over the jumpers
pontoon (see figure 17) which supports all the dynamic loads from their double catenary as a subsea end.
At their surface termination, the jumper is supported via a traditional hang-off clamp on I-tube config-
uration (see figure 18).
OTC-25865-MS 21

Figure 16 —Jumper connections (with ACM) at the riser’s pontoon (Design and Subsea view).

Figure 17—Compliant clamp at the Jumper’s pontoon (Design and Subsea view).

Figure 18 —Schematic of the Flexible Jumper’s at the FPSO end.

Additionally of that a special care was taken to the abrasion wear between dynamic jumpers and to the
dynamic section of the service lines and control umbilicals at the jumper’s pontoon, by assembling PU
abrasion protection at the lines just outside of the compliant clamp berth and also by painting the surface
of the BSR jumper’s pontoon with a wear resistant coating system.
Flexible Pipes – Static Jumpers
The static jumpers were complete out of the project scope of work. Neither specification nor any other
document was generated to them. Basically they were connected to the risers PLET at the subsea end, via
regular VCMs.
22 OTC-25865-MS

Flexible Pipes – Service Lines

The specification for the service line interface was generated providing inputs to client regarding their
expected weight/length ratio and expected dynamic behavior (top tension and accelerations), as it was
produced for the dynamic jumpers.
The main difference is the fact that these lines are routed through the BSR system, on top of the BSR
buoy which provides mid-water support and de-coupling load to the FPSO as a traditional mid water arch.
In this sense, the connection at the jumpers pontoon is the same as explained before for the dynamic
jumpers (see figure 17), as is the same at the topside end in the FPSO (see figure 18).
However at the riser’s pontoon the connection between the 2 service line segments is provided via a
direct connection between 2 end-fittings (see figure 19), kept in a quasi-vertical position via a conical
support designed and developed specially for the BSR buoy. Also, to allow the later installation, a special
bend stiffener prolonger was used into the conical support (see figure 20).

Figure 19 —Line diagram of the flexible service line used at the BSR system.

Figure 20 —Bend stiffener prolonger designed for the flexible pipes and umbilicals coupling and support at the BSR buoy riser’s
pontoom

Control Umbilicals
The specification for the control umbilicals interface was generated providing inputs to client regarding
their expected weight/length ratio and expected dynamic behavior (top tension and accelerations), as it
was produced for the service lines once these umbilicals are also routed through the BSR system, on top
of the BSR buoy which provides mid-water support and de-coupling load to the FPSO as a traditional mid
water arch.
In this sense, the connection at the jumpers pontoon is the same as explained before for the dynamic
jumpers (see figure 17), as is the same at the topside end in the FPSO (see figure 18).
OTC-25865-MS 23

However at the riser’s pontoon the umbilical structure was designed as a single length (no splices to
the umbilical components - see figure 21) and kept in a quasi-vertical position via a conical support
designed and developed specially for the BSR buoy. Also, to allow the later installation, a special remote
armor-pot encapsulated by the bend stiffener prolonger was used into the conical support (see figure 21).

Figure 21—Line diagram of the control umbilicals used at the BSR system.

BSR Monitoring Umbilicals

The procurement specification for the monitoring umbilicals interface was generated as part of the project
scope of work. As different of all other lines the monitoring umbilical did not cross the space between
riser’s and jumper’s pontoons as all the other lines on top of the BSR buoy, but it uses BSR side pontoon
(see figure 22) as connection and support interface.

Figure 22—Diagram of the monitoring umbilical at the BSR system, assembled on top of the side pontoon of the BSR buoy.

This solution made viable the installation of the UTA over the BSR buoy at the perfect spot (for the
sake of the monitoring system) and also provides excellent support to the umbilical.
The connection at the topside end in the FPSO follows the same principle defined for all other jumpers
(see figure 18).

Acknowledgements
To INTECSEA for the engineering services on the BSR buoy hydrodynamics, naval architecture, global
performance analysis, structural and fabrication design and mooring design and fatigue assessment.
To 2H Offshore Engineering for engineering services on the global fields’ layout, global performance
analysis and riser design.
To Principia Offshore for the engineering services on chains’ out of plane bending (OPB) and total
fatigue assessment.
24 OTC-25865-MS

To MARIN for the engineering services and reduced scale tank tests performed.
The authors would like to thank Subsea 7, Petrobras, BG E&P Brasil, Repsol Sinopec Brasil and
Petrogal for permission to publish this paper. However its content only reflects the opinion of the authors
and does not imply endorsement by the Company.

References
Camozzato, G. et alet al. 2015. Execution challenges for a first of its kind project in Santos Basin
Brazil. Paper OTC-25843-MS presented at the Offshore Technology Conference, Houston, 04-07
May.
Cruz, I. et alet al. 2015. The new technology enablers developed and deployed on a live project. Paper
OTC-25832-MS presented at the Offshore Technology Conference, Houston, 04-07 May.
DNV, Offshore Standard OS-C101, Design of Offshore Steel Structures, General (LRFD Method),
April 2011
Gouveia, J. et alat al. 2015. Steel Catenary Risers (SCRs): from Design to Installation of the First
Reeled CRA Lined Pipes. Part I - Risers Design. Paper OTC-25839-MS presented at the Offshore
Technology, Houston, 04-07 May.