Levetidsforlengelse g Konvertering av tankskip t il til FPSO
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1 Levetidsforlengelse Konvertering av tankskip til FPSO
2 This is Inocean Established in 1996, Oslo. Conversions and new-builds for Offshore applications Naval Architecture with special focus on; hydrodynamics & stability structure design & engineering marine systems mooring & riser systems marine operation
3 Engineering track record 22 FPSO/FSO conversions First FPSO to Mexico (GoM). First FPSO to US (GoM). Offshore West Africa, Indian Ocean and Brazil. Newbuild drillship Dalian Developer. Key Naval Arch/Engineer for semi-modus, EikR Erik Raude and dleiv Eiik Eiriksson. PMC team for FSU newbuild Korea/China
4 Inocean FPSO Conversion Projects BW Nisa -> P-63 FPSO (Papa Terra) 180, bopd and (1 MSm3/d gas) 2,000,000 bbls storage capacituy Production start: 2013
5 Inocean FPSO Conversion Projects Knock Allan FPSO Canadian Natural Resources, Gabon, West Africa bopd oil capacity bbls storage Spread mooring Aker Smart 1 FPSO Reliance Industries Ltd. India bbls storage Turret mooring Knock Adoon FPSO Addax Petroleum, Nigeria, West of Africa bopd oil capacity bbls storage Spread mooring DeepProducer FPSO DP FPSOcean bbls storage DP unit Knock Nevis FSO Maersk, Qatar bbls storage Spread mooring
6 Basis for FPSO conversion is an existing tanker
7 FPSO after conversion
8 The Conversion candidate -Typical conversion candidate is a tanker built between 1980 and Tankers are typically y designed for 20 years World Wide operation with intermediate docking every 5th year -FPSO design may require years continued service life, without docking!! -Total lifetime may be up to years
9 Main aspects for LTE of tankers The lifetime extension program concerns the following items: 1. Auxiliary machinery and equipment Exposed to wear Can be repaired and replaced during operation Consequence of failure is minor or serious => Increased system redundancy and maintenance programs 2. Piping system inside hull in cargo area Exposed to corrosion No access for repair or replacement during operation Consequence of failure is serious => Replacement and application of non metallic materials, GRE etc. 3. Hull structure in cargo area Exposed to corrosion and fatigue cracking No access for repair or replacement during operation Consequence of failure may be catastrophic!! => Lifetime extension program for hull structure
10 LTE methodolgy 1. Review project specific data for the FPSO 2. Select candidate vessel 3. Establish current condition of the vessel 4. Model new operational environment 5. Reassess structure based on vessel condition and project specific loads 6. Establish yard scope for steel replacement and modifications to structure
11 Vessel selection - two main issues: Vessel in poorer condition than anticipated Structural layout is not suited for FPSO operation
12 Structural analysis for LTE 1.Corrosion Ultimate limit state (ULS) analysis, using extreme loads 2.Cracks Fatigue limit state analysis (FLS)
13 Characteristics of tanker structures Size...
14 Structure inside wing tank Sidelongitudinal and web frame connection Crosstie
15 Acces for inspection of single hull tankers Inspection of certain areas may be a challenge, particularly side shell connections Perform extensive UTM, crack mapping and inspections prior to arrival at yard
16 Transverse bulkhead connection Sidelongitudinal Bulkhead
17 Example of typical fatigue crack Stress concentration? Crack in stringer deck
18 Stress induced corrosion Crack in bottom longitudinal
19 Edge corrosion in ballast tanks
20 Characteristics of tanker structures...and complexity A typical tanker contains connections which may be exposed to fatigue cracks
21 Criticality of typical fatigue damages on tankers
22 Simplifed fatigue analysis vs. FEM analysis FEM analysis: Fractures in web plate and topstiffener connection. Simplified: Fractures in side longitudinal and sideshell connection
23 Full stochastic analysis sequence for hull Quantify loads from historic trade Assess Damage history Establish analysis model based on actual damages Identify stress concentrations Predict field specific fatigue life for FPSO Class approval of hull for extended service life
24 Trade history and load simulation Quantify loads from historic trade Trading tanker Tanker to FPSO FPSO 3457, , , ,0 60 3, ,0 75 1, , Wave statistics along the trading route are collected from metocean databases FPSO design basis, provides the metocan data, to use for prediction of FLS loading for the FPSO
25 Identification of cracks and probable causes Quantify loads from historic trade Assess Damage history Inspection and class reports reveals frequent fractures in these connections at full load and ballast waterline For newbuilding, this information is not available, thus a screening must be carried out. Either from simplified calculations or review of stress plots on FE model
26 FE-model for fatigue analysis Quantify loads from historic trade Assess Damage history Global FEM model Establish analysis models based on actual damages Fine mesh model, to analyze critical details
27 FE analysis with actual loads of critical areas Quantify loads from historic trade Assess Damage history Establish analysis model, based on actual damages ages Identify stress concentrations HS SLn-1 HS SLn-2
28 Compare analysis results with damage history Quantify loads from historic trade Assess Damage history Establish analysis model, based on actual damages Identify stress concentrations Predict field specific fatigue life for FPSO Fatigue Life Side Longitudinal SL32 at Frame Site Alaska Tanker Kakinada FPSO Lifetime [ Years ] Condition Partly Usage Factor 26 Ballast 1.01 Fulload Ballast Fulload Total Usage Factor Fatigue Life
29 Results Quantify loads from historic trade Assess Damage history Establish analysis model, based on actual damages Identify stress concentrations Predict field specific fatigue life for FPSO Fatigue analysis results Class acceptance of vessel life time extension Modification of details Repair scope Input to inspection program
30 Ultimate Limit State loading Establish FPSO Loading conditions Calculate maximum stillwater forces Calculate site specific waveloads Calculate strucural response: (buckling check, shear analysis) Minimum thickness list which is input to steel renewal scope Bending stress from global hull deformation Plate and stiffener buckling governs the minimum thickneses in deck and bottom plating
31 Still water limit curve for FPSO operation 6000 Envelope limit curves Design Limit curve main class Limitcurve FPSO MS (MNm) Buckling capacity check of deck and bottom pos from AP
32 Reassessed minimum thickness list Increased life time due to increased allowable reduction in scantlings Renewal criteria lowered from 18.00mm to 15.6mm
33 Establish and communicate the repair scope Results from minimum thickness calculations and fatigue assessment will provide the input to the repair scope Large amount of information to be communicated with conversion yard, e.g 5000 to soft brackets to be installed at the right location
34 Steel renewal when afloat High cost for dry-docking steel renewal tends to be performed when afloat Large possibility for built-in stresses in longitudinal structure Potential cracking and buckling problems during operation
35 Basis for Lifetime Extension PROPER DESIGN BRIEF Well defined operational philosophy Valid Metocean data UPDATED KNOWLEDGE ON THE CURRENT CONDITION Description of the structural t details Repair and damage history EXPERIENCE AND KNOWLEDGE ON TANKER VESSELS ADVANCED ANALYTICAL TOOLS CAPACITY TO ANALYZE LARGE FE MODELS
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