FPSO Deck Mating Using Ballast Adjustable Pontoons
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Solution Overview
Problem
The construction of Floating Production Storage and Offloading (FPSO) units is hindered by the time-consuming and costly process of loading, assembling, and integrating multiple modules, which is constrained by crane capacity and requires unanticipated repairs on refurbished vessels.
Innovation Solution
A method and system involving the assembly and integration of modules onshore or in a floating barge, using ballast adjustable pontoons to support and transfer pre-integrated module assemblies onto an FPSO vessel, reducing the need for on-board integration and enabling timely delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If modules are loaded one-by-one using cranes onto the FPSO deck, then the load capacity of cranes is respected, but the time and cost to finalize the FPSO project increases
Solution Approach 1:
The system segments the loading process by using multiple pontoons that can be independently ballasted and positioned. Each pontoon can carry modules and transfer them to the FPSO deck simultaneously, dividing the single-crane sequential loading into multiple parallel loading operations, thereby reducing overall project completion time while respecting individual crane load capacities.
Solution Approach 2:
Modules are pre-assembled and pre-integrated on the pontoons before being transferred to the FPSO deck. This preliminary assembly and integration work is performed while the pontoons are still in the water, allowing modules to be ready for immediate installation upon deck transfer, significantly reducing the time required for on-deck assembly and integration activities.
2Ease of manufacture
If multiple modules are assembled and integrated on the FPSO deck, then the FPSO becomes operational, but the process is time-consuming and costly
Solution Approach 1:
The system performs assembly and integration of modules in advance while they are positioned on the pontoons in the water. Pre-integration areas are provided on the pontoons where modules can be assembled and tested before being transferred to the FPSO deck, eliminating the need for time-consuming on-deck assembly operations and reducing overall project timeline.
Solution Approach 2:
The pontoons serve as an intermediary platform between module fabrication and FPSO deck installation. This intermediate platform provides a stable environment for module assembly and integration, allowing work to be performed in a controlled setting before final installation, thereby reducing the time and cost of on-deck operations.
3Reliability
If refurbished FPSO hulls undergo unanticipated repairs and reinforcements, then structural integrity is ensured, but the loading, assembly, integration, and commissioning process is further constrained and delayed
Solution Approach 1:
The system performs all module assembly and integration activities in advance while modules are on the pontoons, before the FPSO hull requires any repairs or reinforcements. This timing ensures that the critical path for module installation is not affected by hull maintenance activities, allowing parallel execution of hull repairs and module preparation without delaying overall project completion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time and cost associated with loading and integrating modules by pre-assembling and pre-integrating modules before installation, allowing for faster completion of FPSO projects.
Implementation Method 1
supporting the module assembly with one or more ballast adjustable pontoons
Data Source
AI summary
A method for constructing an FPSO comprises (a) assembling and integrating a plurality of modules to form a module assembly for installation on the FPSO. In addition, the method comprises (b) supporting the module assembly with one or more ballast adjustable pontoons. Further, the method comprises (c) positioning the module assembly over a deck of a vessel after (a) and (b). Still further the method comprises (d) de-ballasting the vessel and/or ballasting the one or more pontoons to load the module assembly onto the deck of the vessel after (c).