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FPSOs
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TM
Spencer Clark
Msc, B.Eng(Hons), C.Eng, C.MarEng,MRINA, MIMarEST
Deputy Chief Executive Officer
www.concordiaconsultancy.com
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TM
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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TM
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?
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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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TM
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?
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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?
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Spencer Clark
Msc, B.Eng(Hons), C.Eng, C.MarEng,MRINA, MIMarEST
Deputy Chief Executive Officer
www.concordiaconsultancy.com