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Abstract
To date, nine deepwater export systems have been installed by
Oil Companies, or are under construction. The first deepwater
export system, on the GIRASSOL field (Angola), was
installed in 2001. Since then, a further three systems are now
in place, one on the BONGA field (Nigeria) and two on the
KIZOMBA field (Angola). A further five are under design or
construction (ERHA, DALIA, GREATER PLUTONIO,
AGBAMI and AKPO).
All these export systems are based on the concept of a large
surface buoy, shaped, in most cases, like a flat cylinder. These
buoys are anchored to the sea bed by an array of semi-taut
composite anchor lines and support several generally two mid-water export lines.
Although these systems show clear differences in anchor line
arrangement and composition, and also in export line diameter
and configuration, they indicate that the design of deep water
export systems has reached maturity.
In its first part, the paper gives a general outline description of
the nine export systems mentioned above. It explains what the
key design drivers are and describes the design process,
addressing successively the following issues:
a. derivation of mooring force and definition of the
anchoring system;
b. buoyancy requirements and hydrostatic stability;
c. coupled motion response in waves;
d. fatigue in anchor lines and export lines.
In the second part, the paper highlights the major limitations
of the present systems. It describes the various concepts
recently developed in the Industry and discusses their relative
merits and drawbacks.
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400 m
z
y
For the export lines, two main options have been adopted by
the Industry: steel pipes and un-bonded flexible pipes. Steel
export lines seem to be the most popular. They are used on all
systems except BONGA, which is designed to accommodate
three rough bore flexible lines and DALIA, which will receive
two lines of similar construction.
The parameters which drive the selection of the line diameter
are obviously the required throughput and the acceptable
pressure losses in the lines.
Irrespective of the line construction and of its diameter, the
configurations adopted vary from the simple suspended U
catenary shape (ERHA, GREATER PLUTONIO, AGBAMI)
to the so-called Lazy W configuration (GIRASSOL,
BONGA, DALIA, KIZOMBA A and B), with buoyancy
elements distributed in a symmetrical pattern along the middle
section of the lines. One must also mention the asymmetrical
Lazy W adopted on AKPO. For this configuration, the
buoyancy element section is moved toward the FPSO side (see
Ref. [7], [8] and [9]).
The export line configurations must accommodate the relative
offsets of the FPSO on one end and of the surface buoy on the
other end. This can represent a severe design constraint for the
FPSO and terminal anchoring systems when un-bonded
flexible lines are used. Steel lines appear to be much more
tolerant on FPSO and buoy excursions, but their fatigue design
is more critical. To achieve the specified design lives,
limitations of the diameter and increase of the wall thickness
associated with special treatments of the welded joints are
generally required, at least on the buoy side.
The export lines impose on the rest of the system the
following design constraints:
a. a static horizontal pull, which has to be compensated
by the anchor legs opposed to the export lines;
b. a static vertical pull, which drives, to a significant
extent, the buoyancy requirement of the surface buoy;
c. limited wave induced first order motions at their
extremities. This is generally not an issue at the
FPSO end, but it is definitively a serious one at the
buoy end.
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x
y
165
217.5
Hawser pull
Swell direction
-50
-30
50
30
b.
In the first scenario, the tension is 54% larger than the tension
in the second, for the same measured hawser tension. To
properly estimate the level of tension in the anchor legs, it
becomes necessary to low-pass filter the mooring force signal
and to estimate its quasi-static and dynamic components
separately.
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The above description has not yet addressed the issue of the
fatigue design of the anchor legs and of the export lines. This
is in fact, the key one. Fatigue is essentially driven by the buoy
first order motions. By definition, a buoy tends to follow the
waves, even when it is connected to heavy export lines and
taut anchor legs.
Fatigue can be critical for the anchor legs, and especially the
top chain segments which are subject to combined tensiontension and out-of-plane bending (OPB) fatigue. It is however
rather simple to overcome potential fatigue problems in the
chains. A larger diameter and a longer connecting arm are the
traditional answers to this issue.
Fatigue problems in the export lines are somewhat more
difficult and more expensive to resolve. These difficulties may
impose a reduction in the diameter of the export lines, at the
expense of the pressure losses, or to increase the wall
thickness of the pipe, which has a direct cost impact. The
quality of the welded joints needs also to be carefully
controlled, should the export line designer want to benefit
from more favorable design fatigue curves.
Buoy motions in waves must not be considered as a design
parameter. Buoy motions are the result of the dynamic
response of the coupled system. However, it is possible to
play, within a limited range, with the characteristics of the
buoy and of the anchoring system to improve these motions.
Some general guidance can be given:
a. a softer pattern (anchoring and export lines) will
generally offer more favorable motions for fatiguedriven components, owing to its effect on surge
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b.
c.
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a.
b.
c.
Field layout
Distance FPSO - Terminal
Flow rate
Pressure @ FPSO outlet
Stabilized crude oil properties
Water depth
Export tanker size
Operational conditions
Hydrostatic stability
requirements (intact hull /
flooded hull)
Flexjoints / bend-stiffeners
angular limitations
Service life
Yes
Yes
Chains
OK?
No
Export
lines OK?
No
One can see a large range of export line pulls, from 60 tonnes
up to 280 tonnes. The impact on the anchor leg patterns and
the levels of anchor leg pre-tension is obvious.
As noted previously, the quasi-static mooring forces are
spread in a much narrower range, from 180 tonnes to 255
tonnes. This difference just reflects the difference between the
intensity of the 1-year squall offshore Angola (1min. wind at
10 m = 19.8 m/s) and the 10-year squall offshore Nigeria
(1min. wind at 10 m = 29.7 m/s).
Most of the buoys have been given a diameter of 23 m and a
height of 8 m. These dimensions have been sufficient to
accommodate the most demanding export line configuration
met so far. In one case, the height of the 23 m diameter buoy
had to be increased to 10 m. This is explained not only by the
large vertical pull applied by the anchor legs and the export
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d.
e.
f.
Submerged
Buoy
FPSO
2 OOLs
2 Tendons
1 Catenary
Anchor Leg
DDCALM
10
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the moored vessel. The turntable provides the support for the
pipe support platform and the boarding platform.
Buoy alone
Surge RAO
Surge RAO
1.50
3.50
1.25
3.00
Amplitude m/m
Amplitude m/m
1.00
0.75
0.50
0.25
0.00
0.25
2.50
2.00
1.50
1.00
0.50
0.50
0.75
Frequency rd/s
1.00
0.00
0.25
1.25
Heave RAO
1.50
1.25
1.25
1.00
0.75
0.50
0.25
0.00
0.25
0.75
Frequency rd/s
1.00
1.25
1.00
1.25
Heave RAO
1.50
Amplitude m/m
Amplitude m/m
0.50
1.00
0.75
0.50
0.25
0.50
0.75
Frequency rd/s
1.00
DDCALM
1.25
0.00
0.25
0.50
0.75
Frequency rd/s
Conventional buoy
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11
Conclusion
ALS
CALM
CAPEX
DAF
DDCALM
FPSO
OPB
OPEX
SALM
TSALM
ULS
VELPA
VLA
References
12
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Notes: the figures given in the table refer to the buoy at rest
position, with the export lines full of crude oil at its nominal
density.
Mean
Water depth (m)
1200
Maximum
Minimum
1370
940
Operational
conditions
10-year
squall
1-year
squall
VLCC
25
20
Steel
2*22
Lazy W
Steel
2*16
Lazy W
Export lines
flexibles
3*18.7 -ID
6840
7500
6000
Export line
horizontal pull (t)
190
280
60
370
500
200
220
255
180
700
850
540
Pre-tension in most
loaded leg (t)
140
166
87
Maximum excursion
(intact m)
93
135
47
Maximum excursion
(one-leg-broken - m)
108
145
58
1060
1350
750
23
19
10
7.0
3.9
5.8