Mireille FRANCO DEV/TEC/STR FPSO LIFE EXTENSION TOTAL APPROACH
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1 Mireille FRANCO DEV/TEC/STR FPSO LIFE EXTENSION TOTAL APPROACH
2 FPSO LIFE EXTENSION: OUTLINE INTRODUCTION TOTAL WOLDWIDE FPSO FLEET LIFE EXTENSION CONCLUSIONS 2
3 INTRODUCTION
4 INTRODUCTION Life extension Support and its systems Production Export systems This presentation will focus in FPSO HULL 4
5 INTRODUCTION Life extension relies on: IMMR plan Integrity Management System Life Extension - Integrity Management System involved from Design to Decommisioning - Design based in proved standards and good quality construction Design & Construction Condition Assessment (Analysis & Inspection) - Condition assessment : analysis and regular inspection - IMMR plan in place 5
6 TOTAL FLEET
7 FLOATING UNITS AROUND THE WORLD World fleet: 150 FPSOs (not considering the unconventional as SEVAN) IN OPERATION YEAR 2010s YEAR 2000s YEAR 1990s YEAR 1980s 60% Approx. are converted hulls
8 FLOATING UNITS: TOTAL S FLEET FLOATING UNITS: NKP (concrete FPU, 1996) Farwah (FPSO, 2003) NKS II (FGSO, 1996) Dalia (FPSO, 2006) Girassol (FPSO, 2001) Akpo (FPSO, 2009) Unity (FSO, 2002) Serepca 1 ( ) Alima (FPU, 2008) replaced by Kingsway Pazflor (FPSO, 2011) Usan (FPSO, 2012) CLOV (FPSO, 2014) PAZFLOR FPSO AKPO FPSO MOST OF THEM SITUATED IN THE GULF OF GUINEA, MILD ENVIRONMENTAL CONDITIONS NKP FPU SOME NEW UNITS COMING SOON: EGINA (FPSO, 2017) MOHO NORD (FPU+TLP, 2016) DALIA FPSO GIRASSOL FPSO 8
9 LIFE EXTENSION
10 LIFE EXTENSION DESIGN LEVEL ACCEPTABLE Acceptable loss of performance PERFORMANCE The EXTENSION OF LIFE keys are: LIFE EXTENSION Unacceptable loss of performance 1. To know the acceptable level of performance for the FPSO 2. To know about the condition of the FPSO 3. To know about how the FPSO is aging. Design life 10 TIME
11 LIFE EXTENSION Drivers for Life Extension are mostly commercial and taken in a case by case basis. Some particularities: Specifications highly dependent on past life of the unit International Reference Standards not specific for FPSO extension of life Project to be executed with ongoing operations Relevance of the time varying factors: Previous repairs survival Coating degradation / integrity Fatigue Others: Metocean reassessment New technologies New standards / Rules 11
12 LIFE EXTENSION MAIN OBJECTIVE: KEEP INTEGRITY OF THE UNIT Extension of life is also an IN SERVICE philosophy - Keeping integrity and fitness today for avoiding big scopes in the future 12
13 LIFE EXTENSION MAIN OBJECTIVE: KEEP INTEGRITY OF THE UNIT Extension of life is also an IN SERVICE philosophy Annual Review Meeting of FU Condition GSF, 3 rd Party Assist. Cy, Subsidiary Inspection Plan Subsidiary Models Update & re- Analysis 3 rd -p. Comp. (control by GSF) Inspection Plan Update Subsidiary Inspection Reporting and Updating of the database Subsidiary Inspection Plan Execution Subsidiary 13
14 LIFE EXTENSION MAIN OBJECTIVE: KEEP INTEGRITY OF THE UNIT Extension of life is also an IN SERVICE philosophy FATIGUE MONITORING 14
15 ENGINEERING
16 ENGINEERING 1. PAST 1. Good data (Design, Installation, Operation) 2. PRESENT 1. Assessment «As it is»: understanding the degradation processes and the response of the unit 2. Rules and standards in force 3. New tools 3. FUTURE 1. Requirements for future operation 2. IMMR plan 16
17 ENGINEERING 1. HISTORY : docs review 1. Inspection reports: class and owner 2. Maintenance records 3. Repairs records 4. Design dossier: site conditions, corrosion allowances, Class rules 5. Operational conditions 6. Definition of Inspection plan for structure and critical equipment 2. INSPECTION 1. Hot spot driven inspection 2. Critical equipment 3. Close visual inspections of hull (cleaning): coating status/corrosion 4. Equipment inspections/surveys 5. UTM measurements 6. Underwater inspections 7. Mooring-if intended to be kept 17
18 ENGINEERING Be aware of initial INCERTAINTIES which may be carried over future life AND ALSO of new project uncertainties: - Unavailable drawings, reports, feedback - Loads: metocean, operation loads - New failures types to be considered: pitting? Vibrations? - Quality of original construction: coating application? - Computerized models simplifications 18
19 ENGINEERING 3. Preliminary Analysis/ studies 1. Gap between old Codes and Rules/Codes in force: IMPACT 2. Site conditions gap with previous metocean-impact 3. New Production conditions if any- topsides/equipment 4. 2D evaluation of actual scantlings 5. Corrosion forecast-evaluation 6. Rough Estimation of steel renewal 7. Equipment to be kept/refurbished/replace: spares availability 8. Preservation 9. 2D fatigue screening 10. 3D fatigue- deterministic? 11. Mooring 4. Analysis/studies 1. Full 3D FEM strength and fatigue analysis 2. Steel renewal: thickness diminution and pitting 3. Steel repairs/ steel modifications 4. Equipment compatibilities 5. Class requirements 6. Mooring 19
20 ENGINEERING TOTAL General Specifications / Company Standards From design to decommissioning Enhanced Ship Technology for Offshore Industry needs: - additional corrosion margins - adapted fatigue safety factors - fabrication and construction enhanced focusing in critical areas - Yielding, Buckling and Fatigue addressed through latest finite elements calculations methodologies - Permanent means of access - IMMR plan and conditions included in design. - Mooring design as critical system Continious improvent & room for new Knowledge and technology, FEED BACK from Industry and new methods. -: 20
21 WORKS EXECUTION & LESSONS LEARNT
22 LIFE EXTENSION DRY DOCK Engineering results: scope Important Steel bottom to be renewed Important equipment to be installed/un-installed Shipyard // offshore units opportunities ON SITE Engineering results: scope No Steel bottom to be renewed No topsides modification Pure extension of life (no relocation) Schedule and economics 22
23 CONCLUSIONS
24 FIRST CONCLUSIONS: The number of Life Extesion projects is expected to increase with the aging of the existing units Aging and life extension is to be faced from day one: By designing for a long and healthy life By having in place a commited ASSET INTEGRITY MANAGEMENT TO BE ENCOURAGED -PRIORITY TO INSPECTIONS FOR ESTIMATION OF SCOPE OF WORK -ANALYSIS COVERING BOTH PREVIOUS OPERATIONAL LIFES AND FUTURE CONDITIONS -PRIORITY TO GOOD CLEANING FOR CLOSE VISUAL INSPECTIONS -REPAIRS/RENEWAL: FORECAST OF FUTURE DEGRADATIONS -DO NOT UNDERESTIMATE THE DIFFICULTIES OF EXECUTION IN CONFINED SPACES -USE QUALIFIED AND RELIABLE VENDORS 24
25 ANY QUESTION?? THANK YOU!! 25
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