2. INNOVATIVE IDEAS FOR LIGHT MODULES FOR FPSO & FLNG
1.) INTRODUCTION ……HERE BACKGROUND OF SELF AND PAST
EXPERIENCE WITH MODULES SHALL BE SHARED
2) FPSO & FLNG ……CURRENT STATUS
3) FUTURE PROSPECTS FOR FPSO & FLNG……..PERSPECTIVE
PLANNING & GROWTH PROSPECTS
4) CHALLENGES IN DEVELOPING FLNG PROJECTS
5) INNOVATIVE IDEAS & APPROACH
6) EXPECTED TRENDS IN FLNG / FPSO
7) A POSSIBLE WAY FORWARD
8) CONCLUSION
5. THE ONE STOP SHOP
THE ONE STOP SHOP
1 DESIGN/ 5 ONSITE
ENGINEERING COMMISSIONING
2 PIPE & FITTING 4 INTEGRATED
MANUFACTURING COATING
3 FABRICATION / SPOOLING
6. 2. FPSO & FLNG CURRENT STATUS……
CURRENTLY @ 100+ FPSO’S UNDER OPERATION
’
ONE FLNG PLANT UNDER EPC AND COUPLE OF THEM UNDER FEED / CONCEPT STAGE
MAINLY ONSHORE TECHNOLOGY & PLANT DESIGN CONCEPT APPLIED TO SHIP. ENGINEERING WISE
POSSIBLE TO IMPROVE WITH INVOLVEMENT OF ESTABLISHED ENGG COMPANY HAVING BOTH
POSSIBLE TO IMPROVE WITH INVOLVEMENT OF ESTABLISHED ENGG COMPANY HAVING BOTH
OFFSHORE & ONSHORE EXPERIENCE
NEED TO INVOLVE MODULE SUPPLIERS HAVING ENGINEERING BACKGROUND TO ENSURE TROUBLE
FREE MODULE TIE UP & OPERATION ON THE SHIP
FREE MODULE TIE UP & OPERATION ON THE SHIP
CURRENTLY THE FLNG CONCEPT OF FULL LAND BASED PLANT BEING FIXED ON FLOATING HAS SOME
CHALLENGES TO ADDRESS ISSUE RELATED TO SLOSHING MOVEMENT, INTER SHIP TRANSFER,
OPERATION OF PLANT DURING ROUGH WEATHER CONDITION ETC
OPERATION OF PLANT DURING ROUGH WEATHER CONDITION ETC
Worldwide need for clean burning fuel
• Shortage of large fields near shore leads to high project cost.
• The cost escalation has led to floating LNG production on a vessel (FLNG)
b) A way to develop stranded gas fields, isolated, remote from land and other Infrastructure
c) Alternative to flaring and re-injection
d) Alternative to land-based Greenfield LNG-plants
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e) Market uncertainty
• Improved technology in LNG storage & transfer (sloshing and motion effects)
• FPSOs are conventional, over 100 in operation
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• Hundreds of offshore gas fields over 0.5 trillion cubic feet, suitable for 1 – 2 MTPA
FLNG.
10. 4. CHALLENGES IN DEVELOPING FLNG PROJECTS
There are a number of issues that need to be carefully examined when considering
a floating LNG facility
a floating LNG facility
• Location & sea condition
• Survival in storm conditions
• Ensuring smooth facility operation in motion & rough sea
E i h f ili i i i & h
• Suitable sites having available large quantity of Gas which can be trapped subsea
• Availability of skilled manpower to build & operate, material and equipments /
package modules suitable for operation in marine environment, suppliers,
Certifying agency…..
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• Whether we really need such huge FLNG terminals or whether a smaller version
can be more productive and economical
• Access for export / import vessels (tugs & pilotage)
• Type of plant, liquefaction / regasification
• Type of plant liquefaction / regasification
• Type of vessel & containment
• Mooring of the facility
• Method of transfer of cargo
M th d f t f f
• Deck congestion
12. BENEFITS OF MODULARIZATION
FASTER TO BUILT, QUICKER CASH FLOW FRM PRODUCT DELIVERY, EARLY PROD
SAFER
COST EFFECTIVE (CONST COST SAVING, LESS TESTING ON SITE / SHIP)
BETTER QUALITY DUE TO CONTROLLED WORKING CONDITION
MINIMIZE IMPACT & FIELD WORK AT FINAL PRODUCTION SITE
MINIMIZE IMPACT & FIELD WORK AT FINAL PRODUCTION SITE
MINIMIZE LAYDOWN SPACE
MINIMIZE IN‐AIR WORK
STRUCTURAL / FOUNDATION REQUIREMENT SIMPLIFIED
REDUCE DELAYS DUE TO ADVERSE WEATHER
FEWER FITTING ERRORS
FEWER FITTING ERRORS
PROCUREMENT SIMPLIFIED
MATERIAL & EQUIPMENT ARE EXPENSIVE & DIFFICULT TO OBTAIN ON TIME
SHORTEN SCHEDULES FURTHER BY CONCURRENT PROCESSES SUCH AS
FABRICATION, PERMITTING & LOGISTICAL ARRANGEMENTS
UNIQUE MODEL OF COMPANY CAPABLE OF LSTK ENGG, FABRICATION,
UNIQUE MODEL OF COMPANY CAPABLE OF LSTK ENGG FABRICATION
PROCUREMENT & CONSTRUCTION SERVICES FOR MODULAR PROJECT
GLOBAL NETWORK OF ENGG PROCUREMENT CONSTRUCTION RESOURCES
ENSURING FASTER DELIVERY
13. PITFALLS OF MODULARIZATION
Bad Management
Incomplete planning
Incomplete planning
Material delivery not synchronized with the module assembly
Location of module yard
Construction begins too soon
Construction begins too soon
Decisions during construction are made based on construction completion date not on
the basis of the potential incurred cost by incomplete or un‐installed components
Case study:
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•Typical issue like for one module the EHT (Electric Heat Tracing) had not been designed and
they were proceeding with the installation of the Insulation.
•The modules were going to be finished and shipped in this state. Someone had made the
decision that shipping the modules without the EHT but installing the insulation was the
best thing to do.
•This decision was a typical example of how the modularization concept can turn from a
major cost reduction initiative to a disaster.
major cost reduction initiative to a disaster
•The insulation and cladding will have to be removed and probably wasted because the size
will most likely be larger than installed at the yard
•The EHT cables will have to be field installed
The EHT cables will have to be field installed
•The power points and connections and will have to be field installed
•Field costs will be exponentially more as compared to the cost of those at the module yard
Commissioning and start‐up will be delayed.
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• The project will see a major cost overrun.
14. INNOVATIVE & CORRECT APPROACH FOR MODULARIZATION
Modularization concept must start at feed stage
Create a strong integrated Management team for the Detailed design
Plan the procurement of materials in the order of assembly
Pl h f i l i h d f bl
The detailed design must be initiated using the module or modules as the
basis and the components and equipment must be designed to fit the module
not the module designed to suit the equipment
Constructability must be done at the planning stage, e.g. the fabricators and
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module assembly team should be involved at the detailed design stage. g
Long lead items must be identified and purchased well in advance
Module assembly must be done using the 80/20 rule meaning that the
assembly does not begin unless 80% of the module materials have been
assembly does not begin unless 80% of the module materials have been
received and the other 20% have been purchased and are in the process of
being delivered.
The module assembly yard should be adjacent to the water to avoid
The module assembly yard should be adjacent to the water to avoid
shipping constraints in terms of size and weight.
15. INNOVATIVE COST SAVING METHOD FOR MODULARIZATION
Standardize the sizes of structural components
Meaning that do not over engineer if a common size works,
Meaning that do not over engineer if a common size works
even if it is a heaver section than is required the bulk purchase of
a common size will result in cost saving g
Bulk purchase electrical cable and wire early
If there are multiple modules that will be assembled together
If there are multiple modules that will be assembled together
on the vessel, perform all hydrostatic testing in the module yard
and use the “In‐Process” inspection system for the joints
between the modules.
Maximize the work in the module yard and minimize the work
performed in the field or on the ship.
24. CONTROL ROOM & SWITCHGEAR MODULES IN FLOATING ENVIRONMENT ARE
QUITE STANDARDIZED AND USED IN PAST FOR POWER BARGE CASE STUDY FPP
BARGE.….CASE
25. 6. EXPECTED TRENDS IN MODULARIZATION - PRINCIPLES DRIVING THE MODULE
DESIGN…….
DESIGN
• Safety
• Process functions rationale
– Central interconnecting pipe rack to feed process modules
– Follow logic of flows to minimize piping lengths
– Minimize motions of key equipment
Minimize motions of key equipment
• Modularization philosophy
– Well‐defined hull / topsides interfaces
– Mechanical completion by function – easier testing & pre‐commissioning
– Size / weight of modules selected to enable lifting by conventional means
• Addressed technological difficulties
Addressed technological difficulties
– Process selection / on board floater
– Machinery selection
– Layout / plot plan
/ plot plan
• Good understanding of technical quantities / cost of facilities
• Facility remains « on par » in terms of project magnitude with currently delivered large
oil FPSOs
• Important commercial potential for medium scale gas accumulations
26. GAS TURBINES GUIDELINES
The Gas Turbine selected has to be referenced as:
• Off shore application (FPSO)
• Power generation (Electrical motor)
• Mechanical driver (High “power density” and efficiency for big compressors)
power density
• Aero-derivative (high efficiency)
• Machine proven reliability
27. LIQUEFACTION TECHNOLOGY SELECTION CRITERIA……
• TECHNOLOGICAL SELECTION STRATEGY
– Selection of a simple and robust liquefaction process, adapted to medium capacity
l f l d b l f d d d
and marine environment with high inherent safety
– Avoid the use of large HydroCarbon (HC) liquid inventory (such as: refrigerants
used in onshore LNG plants)
– Minimization of two‐phase flows
– Minimization of distillation towers
– No by‐products (as LPG) to avoid logistics constraints
– Use of proven equipment in identical or similar technologies (gas turbines, heat
exchangers…)
exchangers )
– For utilities and common facilities (sea water cooling, flare …), stay within
capacities already in place in large FPSOs. (200,000 BOPD)
LNG FPSO
OFFSHORE
LNG
FSRUs
28. ACID GAS REMOVAL PACKAGE …….
• RECOMMENDED INTERNALS IN MOVING ENVIRONMENT : STRUCTURED PACKING
– Trays and random packing are not recommended because of liquid channeling and
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efficiency drops
– Structured packing is less affected by tilt and motion thanks to an higher
hydraulic resistance to sideways flow
• MOTION IMPACT ON STRUCTURED PACKING PERFORMANCES
– A permanent tilt has an effect on liquid flow repartition.
p q p
– Periodic oscillations have a natural mixing effect, less damaging on
performances than permanent tilt
29. CRITICAL ISSUES FOR MODULE /EQUIPMENT LOCATIONS……
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– The column should be located as close as possible from the centre of gravity of
the ship to limit liquid maldistribution
– Intermediate remixing distributors reduce the consequence of the liquid flow
distortion. This leads to an increase of the column length.
– Specific distributors, enable to mitigate motion on distribution – experienced
vendors to be considered to avoid problems
31. Typical LNG Offloading
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– LNG Carrier offloading every three days
– Berthing offloading & departure: 18 hours
Berthing, offloading & departure: 18 hours
– Rate: 10,000 to 14,000 cubic meters/hour
NGL Pipeline
NGL Pipeline
Gas Conditioning
Plant
LNG
Gas Pipelines
G Pi li
L N G
Surface Storage
Vaporization