13. FPSO Operational Problems Don Smith, OGP

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1 OGP Marine Risks Workshop Proceedings 13. FPSO Operational Problems Don Smith, OGP FPSO Operational Problems Don Smith OGP Analysis of Accident Statistics for Floating Monohull and Fixed Installations UK HSE Study Analysis of offshore accident statistics from (6 years period): No fatalities 21 accidents involving hospitalisation 85 3-day off work 317 dangerous occurrences 221

2 International Association of Oil & Gas Producers FPSO Operational Problems - Don Smith, OGP (2) Dangerous Occurrences for Floating Production Systems * Fire/Explosion 8% Substance 3% Collapse 1% Positioning/Dropped Object/Adverse Weather 12% Collision 2% Hydrocarbon Releases 48% (37% total population) Potential Collision 3% Stability 0% Evacuation 1% Pipeline 4% Wells 0% Diving 1% Biological 0% Electrical 4% Lifting Machinery 8% Pressure 5% * Provisional Total Number of Dangerous Occurrences 317 FPSO Dangerous Occurrence Categories Riser/Turret/Swivel Vessel SW/COW/Vent Offloading System Moorings/DP Collision/Stability Motion Related Incident 222

3 OGP Marine Risks Workshop Proceedings FPSO Operational Problems - Don Smith, OGP (3) Distribution of FPSO Dangerous Occurrences Motion Related Incident 15% (12) Collision/Stability 11% (9) Moorings/DP 9% (7) Offloading System 22% (17) Riser/Turret/Swivel 33% (26) Vessel SW/COW/Vent 10% (8) Wave Related Incidents ( ) Number of Incidents Year 17 Greenwater, 2 Wave Slam 0.28 incidents per vessel year 223

4 International Association of Oil & Gas Producers FPSO Operational Problems - Don Smith, OGP (4) Comparison of Accident Rates (per installation type) Accident Rate (per installation) /97 97/98 98/99 99/00 00/01 01/02 Year FPSO All Comparison of Accident Rates (per 100,000 Workers) Accident Rate (per , Workers) /97 97/98 98/99 99/00 00/01 01/02 Year All FPSO 224

5 OGP Marine Risks Workshop Proceedings FPSO Operational Problems - Don Smith, OGP (5) A summary Report on FPSO Lessons Learned, gathered from 4 Norwegian FPSOs May 2002 Prepared for the Norwegian Oil Industry Association (OLF) Study Aims and Methodology Aim: to collect lessons learned from experiences of operators of Norwegian FPSOs Information collected from 4 installations: Jotun A (ExxonMobil) Varg (Norsk Hydro) Asgard and Norne (Statoil) 225

6 International Association of Oil & Gas Producers FPSO Operational Problems - Don Smith, OGP (6) Survey Tool Seven Main Areas: Hull and Marine Turret Layout Project Management Operations and Support Codes/Classification Manning and Safety Hull and Marine (172 issues/problems reported) Green Water (Critical) 3 out of 4 FPSOs affected by greenwater loads Hull Strength (Critical) 3 out of 4 FPSOs suffered crack between tanks Accommodation (Critical) Insufficient beds leading to repair/maintenance/upgrade delays Ballast & Cargo Pipework (Major) Construction Standards for cargo and ballast pipework proven indequate, leading to weld failures, leaks and corrosion Corrosion & Coatings (Major) Need for good inspection programme Cranes (Major) Solid booms not optimum (more suited to port side application) 226

7 OGP Marine Risks Workshop Proceedings FPSO Operational Problems - Don Smith, OGP (7) Hull and Marine Helicopters (Major) Siting and size of helidecks (need to involve helicopter operators in future designs) Hull Capacity (Major) Limited shuttle tanker capacity driving need for increased FPSO storage capacity Inert Gas System (Major) Use of hydrocarbon blanketing to replace inert gas Moorings (Major) Improved understanding of permanently stopped mooring designs (as opposed to use of individual anchor winches) Motions Assumptions (Major) Better prediction of roll limits and its impact on topside fatigue design Power Generation Choice of appropriate main power generation (to maximise efficiency) Turret (30 issues/problems reported) Turret Location (Critical) Benefits of free swivelling turrent Turret Design (Critical) Problems with 2 of 3 turret bearings Need to make all components easily serviceable and replaceable Risers (Major) Range of problems experienced Good riser design and operation essential Swivels (Major) Concerns over long term reliability Drag Chains (Major) Range of problems leading to high maintenance and operational problems Swivels may be the better option in many cases 227

8 International Association of Oil & Gas Producers FPSO Operational Problems - Don Smith, OGP (8) Layout (19 issues/problems reported) Layout (Critical) Layout of equipment a critical issue: Main generators too close to accommodation Poor mechanical handling solutions Exhaust and flare radiation problems Module overcrowding Poorly located vents Access and escape route problems Poor workshop and stores location Need to involve all stakeholder in planning layout Project Management (29 issues/problems reported) Capex Overruns and Schedule Delays (Critical) On only 1 of 4 were Capex overruns avoided (even then the build quality was poorer than expected and opportunities for low cost improvements missed) Benefits of working with contractor to maintain quality and provide assistance to improve efficiency Construction Management (Major) Failure of design contractors and shipyard to interpret functional requirements Failure to manage builders and suppliers More upfront work needed on selection of equipment and specification of quality Project Input from other Groups Need to learn from experience of past builds 228

9 OGP Marine Risks Workshop Proceedings FPSO Operational Problems - Don Smith, OGP (9) Operations and Support (74 issues/problems reported) Compression (Critical) 2 of 4 FPSOs had serious compression problems (gas seal failures, repeated bundle change-outs and cracked pistons) Need to consider benefits of larger scrubbers to provide a safety factor against unknowns Compression (Major) Vibration from reciprocating compressors can be a problem Care needed in procurement of compressor Need to review noise and vibration levels Uptime Performance (Critical) Lack of fully objective data to access uptime performance Shuttle tanker/offloading (Major) Need to learn from good operational practices Manning and Safety (7 issues/problems reported) Safety General (Critical) No evidence FPSOs are less safe than other installations Evidence suggests need for active attention to safety Crew (Major) Need to carry multi-skilled mariners within base crew 229

10 International Association of Oil & Gas Producers FPSO Operational Problems - Don Smith, OGP (10) Industry Challenges Hull & Marine (Major) Accommodation need to increase accommodation levels for short periods Caisson Systems (Major) Evaluation needed of practicality of using inboard mounted caissons to deliver seawater direct Mechanical Handling Develop best practices for range of handling systems Hull Shape Learn for past experiences wrt bow shape Painting Need to develop painting technology and methods compatible with project demands Thrusters Develop methods for removal and repair of thrusters Industry Challenges Turret swivels/tie-backs Low cost method needed to upgrade swivel capacity and to pull in new risers with minimum downtime Design Input from Operations Support operators providing input to design Operations and Support In Situ Repairs and Modifications Critical Need to revise all aspects of marine standards to account for minimum maintenance and in-field repairs Process Need for work and an industry specification for moving separation equipment Role of Vendors/OEM (Major) Need to secure post supply technical support and minimum performance levels from suppliers Codes and Classification, Approvals and Safety Verification (Major) Need to tighten FPSO class specifications 230

11 What is OGP? The International Association of Oil & Gas Producers encompasses the world s leading private and state-owned oil & gas companies, their national and regional associations, and major upstream contractors and suppliers. Vision To work on behalf of all the world s upstream companies to promote responsible and profitable operations. Mission To represent the interests of the upstream industry to international regulatory and legislative bodies. To achieve continuous improvement in safety, health and environmental performance and in the engineering and operation of upstream ventures. To promote awareness of Corporate Social Responsibility issues within the industry and among stakeholders. Objectives To improve understanding of the upstream oil and gas industry, its achievements and challenges and its views on pertinent issues. To encourage international regulators and other parties to take account of the industry s views in developing proposals that are effective and workable. To become a more visible, accessible and effective source of information about the global industry - both externally and within member organisations. To develop and disseminate best practices in safety, health and environmental performance and the engineering and operation of upstream ventures. To improve the collection, analysis and dissemination of safety, health and environmental performance data. To provide a forum for sharing experience and debating emerging issues. To enhance the industry s ability to influence by increasing the size and diversity of the membership. To liaise with other industry associations to ensure consistent and effective approaches to common issues.

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