In this blog post, we will look at the structure and functions of FPSOs, which have emerged as a new solution for marine resource development, and their advantages over fixed platforms.
If someone asked me about the future of the shipbuilding and marine industry, as a shipbuilding engineer, I would answer “marine resources.” Given the current situation of depletion of resources on land and the need for alternative resources, human activities will inevitably turn to the unexplored ocean. With the advancement of technology, we are now entering an era where we can explore and extract various resources from the ocean. Power generation using marine energy, deep-sea mineral resource extraction, and marine biological resource research all fall under the category of marine resources. This multifaceted approach makes the future of the shipbuilding and marine industry even brighter.
Looking at the current state of Korea’s shipbuilding industry in light of these universal demands, we can be even more confident in our answer. Currently, Korea’s shipbuilding industry is losing market share to the rapidly growing Chinese shipbuilding industry. Korea’s shipbuilding industry market share ranked first until the mid-2000s, but it has since been pushed out of the top spot by China in the race to win low-cost orders. This situation has presented new challenges for the shipbuilding industry in Korea, and as a result, it has focused on developing high value-added shipbuilding technology. The shipbuilding industry in Korea, sensing a sense of crisis, recognized the need for new high value-added shipbuilding technology. In response, Korean shipyards are gradually turning their attention to the development of marine resources.
The facilities used to develop marine resources are generally referred to as “offshore plants.” In a broad sense, marine energy facilities, observation facilities, and marine facilities are also classified as offshore plants, but in the shipbuilding and marine industry, structures related to marine resource development are commonly referred to as offshore plants. The main function of offshore plants is to drill for marine resources. In the past, offshore drilling was carried out at fixed plants, where drilling and refining were performed before the oil was sent to onshore storage facilities. This method required large plants to perform both drilling and refining, and long pipelines had to be connected to onshore facilities. Because they were fixed, it was difficult to install them in waters deeper than 200 meters, and the plants had to be dismantled when the oil wells were depleted. FPSOs were developed to solve these problems.
FPSOs (Floating Production Storage and Offloading) are floating plants that handle all aspects of crude oil production, refining, storage, and offloading. In other words, it handles all processes except drilling. After a drillship (drilling facility) completes drilling, the FPSO pulls crude oil from the wells. The FPSO refines the oil to obtain only the oil we want. Since the plant is only responsible for drilling, the use of FPSO can dramatically reduce the size of the plant. In addition, since FPSO performs all functions except drilling, the process is simplified. Furthermore, FPSO can replace onshore storage facilities and long pipelines, thereby improving the stability and profitability of crude oil drilling. Furthermore, FPSOs are structures suitable for small-scale oil well development. Fixed platforms must be dismantled when oil wells are depleted, which is a costly and complicated process, but FPSOs do not need to be dismantled after drilling is complete and can simply be moved. In addition, FPSOs have large decks, which makes it easy to secure space and design them compared to other plants. In particular, old ships with low utility value can be converted into FPSOs, and many FPSOs have actually been designed by converting existing ships.
The main function of FPSOs is to extract pure oil from crude oil. So, what kind of process system is used in this process? Let’s take a look at the systems used in each step. First, the mixture extracted from the oil well through a vertical pipe is sent to a heater for primary heating. The reason for applying heat is to reduce viscosity, which improves flow and increases efficiency during fluid classification. The fluid then enters a production separator, where it is separated into oil, gas, and water through fluid dynamics. During this process, the oil undergoes a compound removal process and is stored in tanks. The stored oil is then unloaded into shuttle tankers and transported to supply destinations. After undergoing a gas removal process, the gas is sent to a generator or a flare tower system (a facility that collects and burns residual excess gas generated during the process) to remove liquid components. Water is filtered through a water treatment system, and some of it is used to regulate the pressure of the oil well.
In order for the FPSO, which carries out these processes internally, to function as a floating plant, it must be fixed in place without being swayed by any external forces. There are two main components that enable the FPSO to remain fixed in place during operation. The first is the turret equipment. The turret uses a swivel to keep the FPSO fixed even when the ship is swayed by external forces such as waves and wind, so that the crude oil production line is not affected. The turret also acts as a passageway for cables called umbilicals to supply power and signals to the subsea wells. Another piece of equipment is the mooring system. The basic mooring devices are the spread mooring method, which involves anchoring mooring lines to the seabed and connecting them to the hull, and the turret mooring method, which incorporates mooring functions into the turret equipment. The appropriate mooring method is selected according to the surrounding environment, such as wind, tides, and terrain. In stable environments, the spread mooring method is mainly used, while in relatively unstable environments, the turret mooring method is mainly used. In more extreme environments, such as the polar regions, a disconnectable internal turret mooring method is used. This system is designed to prevent damage or destruction of FPSOs caused by external forces (waves, icebergs, etc.) that exceed design conditions in the harsh environment of the polar regions. In the event of an emergency, this system can disconnect from the hull and reconnect.
The shipbuilding industry in Korea is making various efforts to secure unrivaled technological capabilities in the offshore plant market. For example, research is actively underway to develop eco-friendly offshore plants. The industry is moving toward protecting the marine environment and pursuing sustainable development. The introduction of such eco-friendly technologies will play an important role in enhancing competitiveness in the international community.
Currently, the Korea shipbuilding industry has solidified its position with FPSOs as its main ship type and has achieved remarkable results in the FPSO field. One of the representative examples of Korea’s FPSO technology is the self-propelled FPSO. Generally, FPSOs do not have engines and are moved using tugboats. However, in polar regions, there is a risk of damage to the hull from ice and ice floes, so FPSOs must be able to move on their own. For this reason, the need for self-propulsion arose, and in February 2004, Samsung Heavy Industries built the world’s first self-propelled FPSO, the Ngangara. In addition, in 2010, Hyundai Heavy Industries received an order for a super-large cylindrical FPSO and obtained new certification. Compared to existing FPSOs, cylindrical FPSOs are more resistant to harsh marine environments such as wind, currents, and waves, enabling efficient operation in polar regions. In the same year, Daewoo Shipbuilding & Marine Engineering also received an order for a large offshore drilling facility, distinguishing itself in the drilling field. These achievements are examples of the innovative technology and challenging spirit of the shipbuilding industry in Korea. Based on these successes, the industry will continue to achieve even greater results in the future.
In addition to technology, human resource development and education also play an important role in the development of the shipbuilding and offshore industry. The future development of marine resources and the sustainable growth of the shipbuilding and offshore industry require talented individuals with specialized knowledge. To this end, various universities and research institutes are conducting a wide range of programs and research related to marine engineering. Young talents are being provided with opportunities to contribute to the development of the marine industry through such education and research.
