Finding Petroleum FPSO Conference Integrity and Safety associated with Floating Operations Martin L Shaw MBA C Eng C Mar Eng FI Mar EST AFNI Managing Director Marine Operations and Assurance Management Ltd
Outline Context What the FPSO hull needs to do Requirements drive design decisions New build Conversion Case Studies Operation and Export Assurance
Why use an FPSO? No pipeline infrastructure Deep water Environmental issues- disconnectable? Small field Re-usable? Early first oil Courtesy BP PLC
PROTECTION Integrity vs. Economics-The Balance PRODUCTION (PERFORMANCE) After James Reason Managing the Risks of Organisational Accidents
What the hull needs to do Primary Requirements Keep the water out Keep the oil in Stay upright Carry the weight Stay where you put it
What the hull needs to do Secondary Requirements Production and export optimisation Economics Early oil Cost Maintainability Accessibility Safety Comfort
Requirements drive design Field Production Reserves Environment Wind and waves Current Tropical Storms Legislation Safety Case Accommodation Double Hull FPSO Design Size DH/DS/SH Process plant size Connectable/disconnectable Accommodation for d/aft Mooring system Offtake system Weathervaning/spread mooring Dumb/powered Off take Conventional/shuttle System/ spot Distance from market Offshore Loading Discount Critical Decision Newbuild or conversion
New Builds Benefits New, clean hull with no history Can be designed for the purpose deck support for double deckers double sided simplifying structure and improving stability accommodation can be larger/located forward if required Risks Costs can get high Specialised yards Build yard process flow Unique designs have unique risks Optimisation Hull design Hull strength Size
Conversions Benefits Reduced build time(?) Ship shaped and engined for disconnectable Cheaper(?) History Risks Design risk at FEED while hull choice being made Suitable Hulls Single hull or double hull few double sided Lighter scantlings and high tensile steel problems Limits on deck load Tank and deck repair work can be expensive Accommodation Size Position
Case Study One location two solutions Powered FPSO, limited storage, originally with dp1 tankers Weathervaning (limited heading control) FPSO, 1 million bbl storage with dp2 tanker Courtesy Teekay Courtesy BP PLC
Case study-legislation issues Courtesy BP PLC
Integrity of the offtake system Storage Capacity Production Weather Offshore Loading Discount Weather issues Weathervaning or STL DP shuttle Dedicated vessels More control over system Transhipment Port Additional Port Costs Brings extra storage to system Final export on trade tankers on terminal loading Shuttle FPSO Market Trade port delays can shut down production Needs multiple vessels Offshore loading discount Conventional Trade Tankers Wells Benign Conditions Could be spread moorings and buoy May Require Tugs Unpredictability/Laydays Offshore loading discount Interface Issues
Simpler Assurance Is the design right for the field and the environment? Change Management Assurance Risk Design Standards Construction Standards Learning Competency Operating Procedures Contractor selection Offtake vetting Yes Is the unit being built to the design intent? Yes moams.net No Is the unit being operated to the design intent?
Conclusions Number and scale of FPSO Developments increasing Good FPSO design, construction and operation is a blend of offshore and marine disciplines Field requirements and environment drive design choices which drive integrity System integrity important Assurance and change management during design, build and operations provides integrity And finally...
Without the F your PSO is sunk Questions?