fpsos - iumi · how fpso's are built / converted fpso's are usually ‘ship-shaped’ and...

FPSOs

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Spencer Clark

Msc, B.Eng(Hons), C.Eng, C.MarEng,MRINA, MIMarEST

Deputy Chief Executive Officer

www.concordiaconsultancy.com

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FPSOs

1. Introduction2. Types of FPSO3. Mooring FPSOs4. Risks Associated With FPSOs5. Environmental Factors6. Repair Challenges7. Technical & Engineering Observations8. Future of FPSOs

FPSOs

1. Introduction2. Types of FPSO3. Mooring FPSOs4. Risks Associated With FPSOs5. Environmental Factors6. Repair Challenges7. Technical & Engineering Observations8. Future of FPSOs

FPSOs

1. Introduction2. Types of FPSO3. Mooring FPSOs4. Risks Associated With FPSOs5. Environmental Factors6. Repair Challenges7. Technical & Engineering Observations8. Future of FPSOs

FPSOs

1. Introduction2. Types of FPSO3. Mooring FPSOs4. Risks Associated With FPSOs5. Environmental Factors6. Repair Challenges7. Technical & Engineering Observations8. Future of FPSOs

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Good Morning !

Please raise your right hand if you think San Diegois a suitable choice of venue for an IUMI conference?

Good Morning !

Please raise your right hand if you think San Diegois a suitable choice of venue for an IUMI conference?

Good Morning !

Please raise your right hand if you think San Diegois a suitable choice of venue for an IUMI conference?

Good Morning !

Please raise your right hand if you think San Diegois a suitable choice of venue for an IUMI conference?

TM

Keep your hand up if:

You have heard of FPSOs before?

Keep your hand up if:

You have heard of FPSOs before?

Keep your hand up if:

You have heard of FPSOs before?

Keep your hand up if:

You have heard of FPSOs before?

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Keep your hand up if:

You know what FPSO stands for?

Keep your hand up if:

You know what FPSO stands for?

Keep your hand up if:

You know what FPSO stands for?

Keep your hand up if:

You know what FPSO stands for?

TM

Keep your hand up if:

You have ever been involved with FPSO claims before?

Keep your hand up if:

You have ever been involved with FPSO claims before?

Keep your hand up if:

You have ever been involved with FPSO claims before?

Keep your hand up if:

You have ever been involved with FPSO claims before?

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1. INTRODUCTION1. INTRODUCTION1. INTRODUCTION1. INTRODUCTION

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What is an FPSO...?What is an FPSO...?

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What Does an FPSO Do?What Does an FPSO Do?

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FPSO Subsea ArrangementsFPSO Subsea Arrangements

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Why use an FPSO?Why use an FPSO?

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Marginal Field ExplorationMarginal Field Exploration

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FPSO AdvantagesFPSO Advantages

Marginal field exploitation

Ability to disconnect

Operate in remote locations

Flexibility to move to a new field

Oil storage capability

Good safety record to date

Can be leased = lower up front costs

Cost amortised over several fields

Marginal field exploitation

Ability to disconnect

Operate in remote locations

Flexibility to move to a new field

Oil storage capability

Good safety record to date

Can be leased = lower up front costs

Cost amortised over several fields

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Types of Processing UnitsTypes of Processing Units

They look the same but – the risks are different

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2. Types of FPSO2. Types of FPSO2. Types of FPSO2. Types of FPSO

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Early FPSOsEarly FPSOsThe first oil FPSO was the Shell Castellon, built in Spain in 1977

2

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FPSO “Armada Perkasa”

05/09/12

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FPSO “Crystal Ocean”

05/09/12

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FPSO “Pioneer”

05/09/12 22

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FPSO “Girassol”

05/09/12 222

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FPSO “Alisa Craig”

05/09/12

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FPSO “Kizomba”

05/09/12 22

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FSO “Khalij-E-Fars”

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FPSO “Skarv”

05/09/12

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“Shell Prelude” FLNG

05/09/12

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3. Mooring FPSOs3. Mooring FPSOs3. Mooring FPSOs3. Mooring FPSOs

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Spread MooringSpread Mooring

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FPSO Mooring SystemsFPSO Mooring Systems

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FPSO Mooring SystemsFPSO Mooring Systems

Single Point Mooring (SPM) Systems

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FPSO Mooring SystemsFPSO Mooring SystemsTugs

Dynamic Positioning

Main engine propulsion

Bow / Stern Thrusters

Hold back moorings

Tugs

Dynamic Positioning

Main engine propulsion

Bow / Stern Thrusters

Hold back moorings

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FPSO Mooring SystemsFPSO Mooring Systems

DynamicPositioning(DP)

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RisersRisers

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RisersRisers

Emergency Disconnect Damage Risks

Maximum Bend Radius

Uncontrolled Disconnections

Pollution Risk

Emergency Disconnect Damage Risks

Maximum Bend Radius

Uncontrolled Disconnections

Pollution Risk

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Deep Water Riser TechnologyDeep Water Riser Technology

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Deep Water Riser TechnologyDeep Water Riser Technology

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Deep Water Riser TechnologyDeep Water Riser Technology

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4. Risks Associated With FPSOs4. Risks Associated With FPSOs4. Risks Associated With FPSOs4. Risks Associated With FPSOs

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RisksRisks

Impossible to remove risk

Important to identify risks and manage / mitigate

Humans involved

No blame culture should be adopted

Near misses should be reported and recorded

Impossible to remove risk

Important to identify risks and manage / mitigate

Humans involved

No blame culture should be adopted

Near misses should be reported and recorded

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RisksRisks

Hull structural damages, hull envelopeCOT & WBT, plating and stiffnessCorrosion, fatigue, contract incidentsPower generation and compressor systemsPaint coating systems (external & internal)RisersTurret system including swivels and chain tableMooring system damagesSubsea equipmentOffloading EquipmentOperational Errors

Hull structural damages, hull envelopeCOT & WBT, plating and stiffnessCorrosion, fatigue, contract incidentsPower generation and compressor systemsPaint coating systems (external & internal)RisersTurret system including swivels and chain tableMooring system damagesSubsea equipmentOffloading EquipmentOperational Errors

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Operational ErrorsOperational Errors

Captain and station keeping

Offloading hose entanglement

Shuttle tanker contact damage

Crew language barriers

Captain and station keeping

Offloading hose entanglement

Shuttle tanker contact damage

Crew language barriers

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5. Environmental Factors5. Environmental Factors5. Environmental Factors5. Environmental Factors

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Environmental FactorsEnvironmental Factors

http://blog.skytruth.org/

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6. Repair Challenges6. Repair Challenges6. Repair Challenges6. Repair Challenges

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Offshore RepairsOffshore Repairs

Offshore intervention $,$$$,$$$ !!!

Heavy Lifting Equipment Offshore is costly

In service repairs vs production outage

Offshore Repairs increases headcount on FPSO

Accommodation problems - Beds!

Temporary Flotels

Offshore intervention $,$$$,$$$ !!!

Heavy Lifting Equipment Offshore is costly

In service repairs vs production outage

Offshore Repairs increases headcount on FPSO

Accommodation problems - Beds!

Temporary Flotels

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7. Technical & EngineeringObservations

7. Technical & EngineeringObservations

7. Technical & EngineeringObservations

7. Technical & EngineeringObservations

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Demand for deeper water depths to access oil andgas reserves

'Easy' oil has gone

Development of deepwater riser systems

With increasing depth comes increasingEngineering challenges

Demand for deeper water depths to access oil andgas reserves

'Easy' oil has gone

Development of deepwater riser systems

With increasing depth comes increasingEngineering challenges

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Technical and Engineering ObservationsTechnical and Engineering Observations

Conversions

New Buildings

Routine Inspection & ROV access

Classification Societies

Conversions

New Buildings

Routine Inspection & ROV access

Classification Societies

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How FPSO's are Built / ConvertedHow FPSO's are Built / Converted

FPSO's are usually ‘ship-shaped’ and resemble amodified oil tanker

Purpose built or converted from an existing hull

Modifications to increase the strength or fatigueresistance in particular areas

Hull bending - hogging and sagging

FPSO's are usually ‘ship-shaped’ and resemble amodified oil tanker

Purpose built or converted from an existing hull

Modifications to increase the strength or fatigueresistance in particular areas

Hull bending - hogging and sagging

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Naval ArchitectureNaval Architecture

Buoyancy = Hogging of Hull

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FPSO NewbuildingsFPSO Newbuildings

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FPSO NewbuildingsFPSO Newbuildings

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FPSO Oil Tanker ConversionsFPSO Oil Tanker Conversions

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FPSO Oil Tanker ConversionsFPSO Oil Tanker Conversions

Tanker Conversion

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FPSO ConversionsFPSO Conversions

Decommissioned oil tanker

Availability of suitable second hand ‘donor’ tanker hulls

Avoid in-service fatigue damage

Poor weld quality

Decommissioned oil tanker

Availability of suitable second hand ‘donor’ tanker hulls

Avoid in-service fatigue damage

Poor weld quality

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FPSO ConversionsFPSO Conversions

Structural loadings encountered by FPSO's

Conversions should improve the local detail design toenhance fatigue performance

Require structural fatigue enhancements

Structural loadings encountered by FPSO's

Conversions should improve the local detail design toenhance fatigue performance

Require structural fatigue enhancements

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FPSO ConversionsFPSO Conversions

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Cargo Oil Tank (COT) DamageCargo Oil Tank (COT) Damage

Damages in way of primary structural members

Cracks at the intersection of the bottom longitudinal stiffeners withtransverse web frames in way of the connecting brackets

Damage in way of brackets, e.g. transverse bulkhead lower brackets

Local weld defects - crack initiators

Defects monitored, evaluated and repaired

Repairs require a high level of NDT and strict welding control

Damages in way of primary structural members

Cracks at the intersection of the bottom longitudinal stiffeners withtransverse web frames in way of the connecting brackets

Damage in way of brackets, e.g. transverse bulkhead lower brackets

Local weld defects - crack initiators

Defects monitored, evaluated and repaired

Repairs require a high level of NDT and strict welding control

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Water Ballast Tank (WBT) DamageWater Ballast Tank (WBT) Damage

Fatigue cracks detected after 2-3 years of operation as an FPSO

No evidence of failure noted in 13 years as a trading tanker

WBT cracks arrested by drilling & grinding

Damages assessed and repaired on location whilst maintainingproduction

Hot work required adjacent tank emptying and cleaning

Oil and water levels in adjacent tanks relevant

Tanks then monitored monthly

Fatigue cracks detected after 2-3 years of operation as an FPSO

No evidence of failure noted in 13 years as a trading tanker

WBT cracks arrested by drilling & grinding

Damages assessed and repaired on location whilst maintainingproduction

Hot work required adjacent tank emptying and cleaning

Oil and water levels in adjacent tanks relevant

Tanks then monitored monthly

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Power Generation / Compressor SystemsPower Generation / Compressor Systems

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Paint Coating SystemsPaint Coating Systems

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Turret System Including Swivels and Chain TableTurret System Including Swivels and Chain Table

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Mooring System ChallengesMooring System Challenges

Anchor chain failure

Clump weight detachment

Thrash zone areas

Chain table problems

Catienary mooring spring effect

No Go Zones (“NGZ”) on sea bed

Disconnect / Reconnect (emergency and routine)

Anchor chain failure

Clump weight detachment

Thrash zone areas

Chain table problems

Catienary mooring spring effect

No Go Zones (“NGZ”) on sea bed

Disconnect / Reconnect (emergency and routine)

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8. Future of FPSOs8. Future of FPSOs8. Future of FPSOs8. Future of FPSOs

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Future of FPSOsFuture of FPSOs

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10 Reasons Why FPSOs are the Future of Oil & Gas10 Reasons Why FPSOs are the Future of Oil & Gas

1. Shorter time to field = Faster revenue generation2. Reduced investment = less overheads3. FPSOs do not have to be custom built4. FPSOs can evade harsh weather5. FPSOs can move from field to field6. Abandonment costs are less than for fixed platforms7. FPSOs can be used in shallow and deep waters8. Asset integrity costs reduced with FPSOs9. FPSOs reduce costly and expansive underwater infrastructure10.FPSOs are more environmentally friendly than platforms

1. Shorter time to field = Faster revenue generation2. Reduced investment = less overheads3. FPSOs do not have to be custom built4. FPSOs can evade harsh weather5. FPSOs can move from field to field6. Abandonment costs are less than for fixed platforms7. FPSOs can be used in shallow and deep waters8. Asset integrity costs reduced with FPSOs9. FPSOs reduce costly and expansive underwater infrastructure10.FPSOs are more environmentally friendly than platforms

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It is easy to forget thatthe devil is in the

detail

It is easy to forget thatthe devil is in the

detail

If Classdidn't see itwhy should

I?

If Classdidn't see itwhy should

I?

And Finally…….And Finally…….

It is easy to forget thatthe devil is in the

detail

It is easy to forget thatthe devil is in the

detail

If Classdidn't see itwhy should

I?

If Classdidn't see itwhy should

I?

TM

Spencer Clark

Msc, B.Eng(Hons), C.Eng, C.MarEng,MRINA, MIMarEST

Deputy Chief Executive Officer

www.concordiaconsultancy.com