FPSO Interface Engineering:

Maximising Project Success

FPSO Congress 2009

29th / 30th September 2009
Noel Denton
process – DPS Group Engineering Manager
system integrators
 Introduction

1. Who are DPS?

2. What’s important about

interface engineering

3. Project Interfaces

4. Summary
 CORE CAPABILITIES

Conceptual, FEED and Detailed

Design
Process System Design, Supply &
Support
Process Package / Module Supply
Troubleshooting and Onsite
Engineering Services
Manpower Services
In-House Research & Development
Portfolio of Patented Technologies

Return to
DPS Home
Page
 Heating/Cooling Medium
Module Yard Supervision
FPSO EXPERIENCE

CSU / Produced Water

Riser Balcony / Turret

Interface Engineering

ESD / DCS System

Module Supply EPC

Power Generation
Gas Compression
Gas Dehydration
Flare Knock Out

Water Injection
Detailed Design
Basic Design
Chim Sao 80,000 bpd
2008 50 mmscfd
Dua

45,000 bpd
2008 Oyo 60 mmscfd

Cascade & 80,000 bpd Direct

2008 16 mmscfd
Chinook
Responsibility

45,000 bpd
2008 Ruby 29 mmscfd Interface

East 30,000 bpd

2007 35 mmscfd
Fortune

25,000 bpd
2005 Generic 50 mmscfd

Bunga 30,000 bpd

2004 40 mmscfd
Kertas
 Importance of
process system integrators
Engineering
Project CAPEX
Project Manhours
 Impact of Change

Progress
 FPSO Interface Engineering

Responsibilities/Objectives

1. Manage Subcontractors

2. Align Engineering
between subcontractors

3. Incorporate Pre-
Comm./Commissioning
Requirements

4. Minimise change
 FPSO Interfaces

1. Client / Contractor

2. Riser & Mooring / FPSO

3. Hull / Topsides

4. Module / Module

5. Module / Utility
 1. CLIENT /
process system integrators
CONTRACTOR
 How is the contract defined?

A BALANCED APPROACH IS REQUIRED

prescriptive v functional

Basis of Design
& Functional Specification
 Prescriptive Approach

Prescriptive:

Up front FEED completed ($)

Client must know what they want
Data must be available to complete FEED
Longer project cycle time
Level playing field for bidding process
How does it apply to conversions?
 Prescriptive Approach
Tendering Stage

Conceptual Detailed
FEED
Design Design
Handover Handover

Basis of Design P&IDs Detailed design drawings

PFDs Equipment list Equipment specifications
Material balance Data sheets MTOs
Preliminary equipment list Layout studies Fabrication vendor docs
Preliminary layout Plot plan Purchase orders
Preliminary planning Line list
Project description Instrument schedule
Draft P&IDs Material Specifications
Draft line list Control system spec
Load list
Main equipment specs
Basic MTOs
Updated project
description
 Functional Approach

Functional:
Gives contractor freedom
More up front engineering to be done by
contractor, before contract award ($)
Design not optimised at bid stage as
insufficient time to evaluate
Good design from one contractor
passed to others and technical
advantage lost
Client must accept Contractors
engineering standards and practices
 Functional Approach
Typical stage at which
FPSO Tender is issued

Conceptual Detailed
FEED
Design Design
 Design Competition

Benefits of Design Competition:

Paid aspect promotes focus

Allows client and contractors to develop
common designs
Allows project team to develop
relationship
Project Focus
Best of Both Worlds
 Successful Approach

Team Work – Who wins if one

party fails?

Communication
Ability to make decisions
Common Goal
Project Focus
Understand the requirements
More specs doesn’t mean more
understanding
TECHNICAL INTERFACES
 Typical Project Structure

Oil
Regulators
Company

FPSO
Contractor

Turret and Gas Other Marine

Mooring Compression Topsides Conversion
2. RISER AND
process system integrators
MOORING / FPSO
 Riser & Mooring / FPSO
Mooring
• Safely maintain unit on
station
• Minimise excursions for
risers / protect from
riser over bend
• Weather-vaning or fixed
• Internal / external
turret
• Soil conditions are a
strong influence on
selection
http://tss.trelleborg.com/com/www/media/pictures/industries/
marine/FPSO_sept05.jpg
 Riser Interfaces
Risers
• Flow Assurance
• TOR Conditions => Heating / Cooling Requirements
• TOR Conditions => Compression Requirements
• Waxing => Pigging / Insulation Requirements
• Slugging => Topsides Design Impacts
• Buoyancy
• PLEM Loads
• Water Depth
• Riser Design Impacts
• Shallow water is not necessarily easier
3. HULL/TOPSIDES
process system integrators
 Hull / Topsides
Stability Analysis

Topsides Weights

Topsides Sizes

Bilge Keels Required?

Fatigue Analysis

Topside Support Layout

Greenwater Analysis

Impact on topside layout

Module Support Structure

Flare Tower
Module Support Structure
Module Support Structure
Module Support Structure
Module Support Structure
Module Support Structure
4. MODULE/MODULE
process system integrators
Multiple Modules – Multiple Systems
Multiple Modules – Multiple Systems

Module 3D Software used

FPSO Autodesk Inventor
CSU Module Intergraph PDS
Flare Module Intergraph PDS
Pipe Rack Aveva PDMS
M60 A&B Gas Compression CADWorx
M61 TEG Module Bentley Autoplant
Interface Complexity
 Module / Module

• Multiple Sources of Supply

• Multiple Engineering Systems

• Cascade Effect of Change

• Consistency of Approach

• Piping isn’t the only Interface

• Ensure the overall segregation makes sense

 5. MODULE/UTILITY
process system integrators
 Utility / Topsides
Fire Water System

Ensure all the loads are captured early

Examine PFP early

Cooling Water System

Clearly define supply and return

conditions

Heating Medium

Power Generation

Drain Systems
 Module / Utility

Fuel Gas System

• How will you start-up?

• What is being used for purge?

• What quality is required?

Instrument Air
• Beware of purged motors and panels

• Can marine and topsides be combined?

• Is air being used for any pumps?

 Module / Utility

Flare System
• Early definition of flare and blowdown
loads

• Capture all loads – they may not all be

on the modules!

• Flare tower height impacts

• Radiation shielding

Control and Shutdown Systems

• Confirm I/O early

• Use configurable I/O if possible

• Where is the CCR?

• Class Compliance
 Regulator, IVB, Classification…..

National IVB
Regulator

Project

Client Classification
Body
 SUMMARY
process system integrators
 Summary

• Start project with clearly defined basis

• Complexity Requires Clarity

• Robust Management of Change Procedures

• Open and Empowered Teams - COMMUNICATION

• Understand Requirements

Successful interface management

can maximise the success of your
project!
 Noel Denton
Group Engineering Manager
DPS (Bristol) Ltd

ndenton@dps-global.com
www.dps-global.com

THANK-YOU: Any Questions?

process system integrators