HULL STRUCTURAL ASSESSMENT AND REFURBISHMENT FOR CONVERSION FPSOS. T. de Beer N. van Nood. IHC Gusto Engineering B.V.
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1 HULL STRUCTURAL ASSESSMENT AND REFURBISHMENT FOR CONVERSION FPSOS T. de Beer N. van Nood IHC Gusto Engineering B.V.
2 PARTIES INVOLVED operator engineering team site team class yard Information flow between the parties needs to be defined on forehand (content, time schedule)
3 CONVERSION PROCESS review of the vessel history inspection check of hull scantlings and fatigue check of global hull structure and global hull loads preparation of steel renewal report execution and verification of structural repairs and modifications implementation of corrosion protection scheme delivery of 3D hull database implementation of condition monitoring program for the FPSO
4 REVIEW OF VESSEL HISTORY existing vessel drawings survey records gauging reports pre-purchase inspections examine for evidence on details prone to fatigue repeating structural failure widespread fatigue failure grounding or collision repairs large scale inserts corrosion wastage regions of wastage being partly renewed
5 INSPECTION An FPSO is not a tanker! year 5 year to next field life dry docking all tanks visual inspection all tanks thickness gauged pit mapping of full tank bottom
6 EXAMPLE PITMAP
7 PLATE RENEWAL CRITERIA Renewal thickness at conversion as-built thickness min. allow. thickness renewal thickness as-built thickness / re-assessed thickness subtract rule allowable wastage thickness at substantial corrosion (75% of allowable wastage) add future corrosion renewal thickness at conversion Future corrosion: lifetime times yearly corrosion rate Corrosion rates comparable to tankers, except deck head
8 THICKNESS MEASUREMENT (cont d) FIRST TRANSVERSE SECTION AT FRAME NUMBER: 92 SECOND TRANSVERSE SECTION AT FRAME NUMBER: 86 THIRD T STRAKE NO. ORG. NO. ORG. NO. GAUGED DIMINUTION P DIMINUTION S GAUGED DIMINUTION P DIMINUTION S POSITION OR THK. OR THK. OR LETTER mm PORT STBD mm % mm % LETTER mm PORT STBD mm % mm % LETTER 1st below sheer nd rd th th th th th th th th th th th th R 16.2 R th R 16.3 R th R 17.4 R th S 17.7 R th # # 0.0 #DIV/0! 0.0 ##### ## # 0.0 ##### 0.0 ##### 20th # # 0.0 #DIV/0! 0.0 ##### ## # 0.0 ##### 0.0 ##### 21st # # 0.0 #DIV/0! 0.0 ##### ## # 0.0 ##### 0.0 #####
9 TYPICAL CALCULATIONS steel renewal thickness at conversion allowable still water bending moments and shear forces fatigue check of longitudinal structure overall strength check using 3D FE analysis topsides integration detailed fatigue check for selected locations
10 CALCULATIONS (cont d) renewal thickness and structural modifications to site team before inspections (when possible) results for longitudinal structure (2D calculations) can be available early on in project results from 3D FE analysis available in a later stage
11 CALCULATION DETAILS re-assessed thickness (FPSO site specific) may be used due to concept of renewal thickness, no need for use of gauged data in calculations discrepancies may exist between rule nominal design corrosion values and rule allowable corrosion margins (same as for new buildings)
12 CALCULATION DETAILS (cont d) fatigue calculations highly sensitive to trading history allowable sum of trading damage and FPSO damage: 1.0 trading damage 0.8 allowable FPSO damage 0.2 trading damage 0.88 (+10 %) allowable FPSO damage 0.12 (-40 %) fatigue problems solved by local modifications
13 CALCULATION DETAILS (cont d) buckling: deck webs (topsides loads) longitudinal bulkheads (overall hull shear forces)
14 STEEL RENEWAL REPORT inspections and calculations result in steel renewal report as main document contains sketches and tables of renewals, supplemented by drawings of modifications steel renewal report is regularly updated based on latest calculation results
15 CONDITION MONITORING For FPSO inspection program is developed based on 2 1 / 2 year inspection cycle, plus visual inspection each time tank is entered All inspection data entered in 3D hull database
16 3D HULL DATABASE
17 CONDITION MONITORING For FPSO inspection program is developed based on 2 1 / 2 year inspection cycle, plus visual inspection each time tank is entered All inspection data entered in 3D hull database Hull database contains all relevant information at the time of delivery from the conversion yard plus FPSO inspection and repair data
18 CONCLUSION Factors contributing to a successful conversion apprehend that FPSO is not the same as tanker integrate the work of all parties involved start conversion engineering at the earliest opportunity conversion work is just the start for a lifelong hull condition monitoring program After proper conversion the structural integrity of the converted hull does not have to be inferior to that of a new built hull
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