Floating Production, Storage and Offloading (FPSO) vessels are in demand. They are cost-efficient, movable and can operate in all conditions. Aker Kvaerner’s Maritime Tentech is ready with an FPSO design for the emerging market in the Gulf of Mexico.
The continuing search for oil is taking the offshore industry farther out and deeper down. The increasing depths, inhospitable working environments and focus on cutting costs push the technological envelope for almost every new project. The FPSO is the perfect tool for the job. Its mobile since it has the hull of a ship, far-reaching because of its flexible mooring and riser systems, and cost-efficient in production.
High standards
Maritime Tentech is a long-time user of DNV Softwares FPSO design tools. The company, which is the FPSO product responsible within the Aker Kvaerner Technology division, specialises in structural design of vessel and turret, hydrodynamic analysis, naval architecture, marine operations, installation and offshore modifications, and more.
Says manager Børre Knudsen, Half of the purpose-built FPSOs in the North Sea are of Maritime Tentech design. Currently we have seven FPSOs in production in the U.K. and Norway. FPSO operators in these waters have high demands for quality due to the tough weather conditions, and our North Sea FPSO design is of the highest standard in the business. It may cost more, but it saves the operators money throughout production.
Maritime Tentech has used DNV Softwares FPSO package for code checking, advanced strength assessments, hydrodynamic analysis and mooring simulations. Says Knudsen, DNV Softwares tools are of invaluable help in our work, and they have played an especially important role in the development of our new FPSO design for the Gulf of Mexico.
Emerging market
The Gulf of Mexico was only recently opened up for oil production using FPSOs. Maritime Tentech has used the experience garnered from work on its state-of-the-art North Sea FPSO design to make a cutting-edge design specifically for this emerging market.
Knudsen explains: The work has taken 18 months and considerable investment. As part of the process we approached ten U.S. oil companies and asked them what they were looking for in a design for the Gulf of Mexico. This input, coupled with our experience from the North Sea and the authorities regulations, has given us enough information to create a generic design for the Gulf.
For example, the U.S. operators requested that the vessel could be abandoned in case of hurricanes, which means it must handle well in response to waves and wind. The design therefore specifies no thrusters for heading control and an internal turret that is moved forward to improve weathervaning capabilities.
Production friendly
A partner in this design process has been giant Korean shipbuilder Hyundai. Says Bård Leite, a Maritime Tentech designer, Together with Hyundai we have simplified the design as much as possible, focusing on the most cost-efficient solutions. The design is production friendly. It ensures a vessel with good seakeeping, flexible solutions for top weights and ample storage capacity. It can readily be adapted to customer specifications.
The design was concept-approved by DNV early this year, and Knudsen already has several parties interested. The U.S. Coast Guard, however, is waiting for the first test case, as the industry bides its time.
New challenges in the Gulf
There are several problems connected with production in the Gulf, explains Knudsen, The ocean floor is very undulating and quite deep, reaching depths of 3,000 metres. The area experiences extreme seasonal winds and a strong loop current. In addition the authorities do not allow gas flaring nor re-injection into the ground, which leaves few options.
He is certain, however, that all of these problems can be overcome through planning and by using the right technology, such as a well-designed FPSO.
Lifecycle approach to FPSO operation
Earlier this year DNV Software initiated co-operation with Industrial & Financial Systems Norway (IFS). The two partners combine maritime know-how and market-leading technology to develop a unique IT solution for proactive asset management for FPSO operations. The software solution combines DNV Softwares tools for structural re-assessment and planned maintenance, with IFSs business applications for planned maintenance, logistics and equipment purchase.
Says Øystein Goksøyr, Head of DNV Software Business Development, The solution covers all phases in the life cycle of a floating oil production vessel. The knowledge gained from the design and construction of the vessel is stored in a database that provides powerful decision support and knowledge management for FPSO operators. This will offer them a higher level of maintenance that will minimise downtime in oil production without compromising safety onboard.
This development will help progress FPSO design even faster.