FPSO Hystory Old&New

INTEGRITY MANAGEMENT OF FLOATING PRODUCTION UNITS
PIANC SEMINAR ON LIFE CYCLE APPROACH IN PORT INFRASTRUCTURE BRUSSELS FEBRUARY 2, 2005 Bertrand LANQUETIN - DGEP/TDO/LSO/SSF
February 2, 2005
Total in brief
Total Group : 4th petroleum group in the world 122 000 employees, present in 120 countries
Exploration & Production of the Total Group: 30% Onshore 70% Offshore
Bertrand LANQUETIN - DGEP/TDO/LSO/SSF
February 2, 2005 2
Content of the presentation
The Floating Units Worldwide Hull and Structure of F(P)SO Anchoring of F(P)SO Offloading of the production Floating Units Integrity Management

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Different types of Floating Units

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Acronyms
FSU : Floating Storage Unit FPU : Floating Production Unit FPSU : Floating Production & Storage Unit FSO : Floating Storage & Offloading FPSO : Floating Production Storage & Offloading FDPSO : Floating Drilling Production Storage & Offloading FSG : Floating Storage of Gas FGSO : Floating Gas Storage Offloading FPSG : Floating Production Storage of Gas

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FPSO
FPSO = Floating Production Storage & Offloading
FPSO Girassol, Angola, Total
Asgard A, Norvway, Statoil

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FSO
FSO = Floating Storage & Offloading
FSO Pathumabaha, Gulf of Thailand, PTTEP
ex-FSO15 Domy, Nigeria, Total (decommissioned)

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FG(P)SO
FG(P)SO = Floating Gas (Production) Storage & Offloading
N'Kossa NKP et N'Kossa 2, Congo, Total

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SemiSemi-Submersibles
Asgard B, Norway, Statoil

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TLP
TLP = Tension Legs Platform
TLP Magnolia, USA, Conoco
TLP Matterhorn, USA, Total

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Spars
Genesis spar, USA, ChevronTexacco

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Choice of the Floating Units
Governing parameters:
Water depth Development requirements

Storage capacity, production system, Field life duration, production rate
Metocean conditions
Extreme return conditions, typhoons, waves , currents
Construction and installation cost

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The Floating Production Units in 2003
12 2 6 13 1 2 11 6 1 2 19 8 1 7 4 3 7 1 1 2 1 1 2 2 1 3 1 11
78 FPSO
34 Semi-Sub
6 Spars
13 TLP

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Forecast for 20032003-2007

FPSO FSO Semi-submersibles TLP Spars
: : : : : 50 units 34 units 15 units 13 units 11 units

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History of FPSO
DALIA Future FPSO, Angola (Total)
CASTELLON DELTA 1977 : First FPSO, Spain (Shell)
N'KOSSA NKP 1996 : Concrete barge for gas production, Congo (Total)
FLNG Barge project , Nigeria (Shell)

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International and National rules
International rules (IMO) :

SOLAS and ISPS (*) MARPOL (*) MODU ILLC ISM
National rules :
flag if any government regulations
Standards, norms, conventions :

API ISO ISGOTT OCIMF,
Class rules
(if classed)
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Company Referential (Total E&P)

Referential is mandatory worldwide: HIERARCHY OF COMPANY RULES & SPECIFICATIONS
Internal to Company, however: General specifications can be given to

engineerings, contractors, yards, They cover:
Design, age Exploitation, integrity, marine

operations Organisation purposely set-up:
Marine experts Transverse multi-disciplinary

structure Groupe Supports Flottants
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Classification Societies
4 classification societies have rules for offshore :
American Bureau of Shipping (ABS) Rules & Guides for Offshore Installations Bureau Veritas (BV) Rules for the classification of Offshore Units Guidances Notes Rule Notes Det Norske Veritas (DNV) Offshore Codes : Rules for classification Recommended practice Offshore standards Classification notes Lloyd's Register of Shipping Classification of offshore installation at a fixed position

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Hull and structure

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Hull design (new built) built)

Double Side Full Width Cargo Tanks
SBT SBT
Double Side Centerline Bulkhead

SBT
Oil Tank
Oil Tank
Oil Tank
SBT
FSO Unity, Total, Nigria
FPSO Girassol, Total, Angola

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Hull design (new built) built)

J Shaped Double Hull 2 Longitudinal Bulkheads in Cargo Oil Tank Oil Tank Oil Tank J Shaped Double Hull CL Bulkhead Oil Tank Oil Tank
SBT
SBT
SBT
SBT
Norne FPSO, Statoil, Norway

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Girassol example (water depth 1 400 m) TOTAL E&P Angola

HULL Length Breadth Depth Displacement Deadweight Tanks : : : : : : : : : : 300 m 60 m 31 m 51 280 t 343 000 t 12 (6 x 2) 20 000 t 200 000 bopd Spread 12 (4 x 3) 67 430 m 193 315 m > 300 000 m
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Weight Production Type Mooring lines

CONSTRUCTION ANCHORING
TOPSIDES
External coating : Tank coating : Cables :

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Girassol example

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Girassol

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Problems usually encounted: encounted: corrosion

Where ? Mainly in tanks, ballasts et side shell compartments Causes ? Corrosive atmosphere, bad quality or damaged coating, Consequences ? Cracks due to weakening of the structure, steel wastage, ... Difficult and expensive to repair at sea.
Example of corrosion in a ballast tank

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Problems usually encounted: encounted: fatigue of structures

Where ? Stiffeners, reinforcements, welds, bulkheads,... Causes ? Shipyards more used to ship design, in a F(P)SO efforts and behaviour is different, Metocean conditions at the anchoring location Frequency of loading & discharging Consequences ? Fatigue cracks, weakening of the structure, walls and bulkheads, Difficult and costly repairs at sea Class certificate renewal (if classed) can be a problem in case of heavy damage
Example of crack at a bulkhead level

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Problems usually encounted: encounted: chock & collisions
Where ? Side shell Causes ? Support vessels moored alongside or container handling Consequences ? Deformations, cracks, weakening of the side shell structure, corrosion, ...
FSO XV Domy, removed from service in Spring 2003

February 2, 2005
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Problems usually encounted: encounted: Green Waters

Where ? Bow, turret, topside structures, deck equipment Causes ? Difficult to model the greenwater and difficult to design the bow shape accordingly Consequences ? Damages, equipment loss
Protection du touret de Schiehallion, UK
Source : analysis of green water suceptibility of FPSO/FSU on the UKCS (Bomel Ltd - 2001)
FPSO Asgard A et her protection panels (white)

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Mooring / Anchoring

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External turret
Weathervanning of the F(P)SO facing prevailing metocean

conditions
Rather expensive system, uneasy maintenance The turret can be disconnectable to escape typhoon (ex. China sea)
February 2, 2005 30
Internal turret
Protection of the turret and
risers/umbilicals against the climatic conditions
Expensive system, uneasy maintenance Number of risers limited (say 20 to 40)
Example of use: North Sea

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Fixed Mooring : spread mooring
Simple system , less

expensive
Mono-directional Allows an important number

of risers connected to the side of the F(P)SO
Example of use: W. coast

Africa
February 2, 2005 32
SEPLA anchor
Allows vertical tension component on the anchor

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Classical anchor
Only horizontal traction is permitted on the anchor

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Suction anchor

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Mooring line : chain
Unexpensive because widely

used
Corrosion and fatigue leading to

safety coefficients above 10
Low resistance in torsion Heavy linear weight, not

compatible with deep water locations

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Mooring line : cables

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Mooring line : composite

Light material suitable
for deep water locations
Subject to wear in
case of friction

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Mooring line configuration: taut, taut, catenary (or semisemi-taut) taut)
Catenary :
Taut lines :
unexpensive Important offsets of the

floating unit
February 2, 2005
reduced offsets of the floating

unit
Requires anchors accepting

vertical tensions
39
Problems usually encounted: encounted: anchorings

Where ? Chains, cables, synthetic lines, connectors Causes ? Design in fatigue not always mastered, lines and components (connectors, ) difficult to inspect Consequences ? Difficult to repair in deep water locations; in case of breakout, the offset is greater and may be critical (risers)
FPSO Girassol with offloading buoy

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Production offloading

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Offloading on buoys

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Tandem offloading
Risks during manoeuvre of the export tanker near the F(P)SO Situation more difficult to handle in case of spread mooring Tugs of sufficient number and capacity required to control the
relative behaviour of the export tanker and the F(P)SO
February 2, 2005 43
SideSide-byby-side offloading
Risks during manuvre of

the export tankerwhile berthing alongside the FSO (not recommended for FPSO)
Duration of the manoeuvres

February 2, 2005
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Needs for an Integrity Management of Floating Units

Continuous follow-up of the structure and moorings Inspection, repair & maintenance programme / RBI Initial assessment followed by periodic reassessments Assistance in case of problem and remedial solutions Analysis in case of emergency Storage of data, access to databank through a network system, reporting
Accidents : got the best reaction
Inspection & Maintenance : what, where, how?

February 2, 2005 45
The main components of the Integrity Management Programme IMPLEMENTATION OF THE "ASSET INTEGRITY MANAGEMENT"
(4 COMPLEMENTARY TASKS):
MODELS / TOOLS (*)
IRM CYCLE (AND RBI)
"RE-ASSESSMENT"
REACTIONS EMERGENCY SITUATIONS

= interaction
(*) INCORPORATES THE TREATMENT OF THE INFORMATION AND REPORTING

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MODELS AND DATABASE HULL FINITE ELEMENTS MODEL (FEM) MOORING MODEL (WHERE NECESSARY GLOBAL MODEL FOR
COUPLED ANALYSIS) RISK BASED INSPECTION MODEL (RBI) DATA MANAGEMENT MODEL
WEB BASED SYSTEM FOR EASY EXCHANGE / ACCESS /

UPDATING OF THE INFORMATION AND EXPERIENCE POOLING

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FEM model : SESAM (example ) (example)
Model of various structures
Assembly of structural models
SESAM
Structural analysis Fatigue calculation
Visualisation of the results

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FEM model: model: VeriSTAR (example) example)
Hull model
VeriSTAR Hull
FEM calculations
Fine mesh for critical details and fatigue calculation

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Mooring calculation softwares : ArianeAriane-3D and Hydrostar (example) example)
Modelling of the units & hydrodynamic calculations
ArianeAriane-3D Hydrostar
Displacements & Efforts in the mooring lines calculations
Modelling of the environment & recording of the metocean data

February 2, 2005
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Mooring calculation softwares : DeepC (example) example)
Modelling of the mooring
Importation of the hull models and hydrodynamic results from namiques de Sesam
DeepC
Recording of the metocean data Visualisation of the results

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EXAMPLE OF SEMANTIC AND 33-D MODEL (FOR EASY NAVIGATION THROUGH THE DATABASE)
3-D model

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ASSET DATA FOLLOWFOLLOW-UP: EXAMPLE OF DATA RELATED TO CLASS / REGULATION FOLLOWFOLLOW-UP
Flagging system (colours) when inspection is overdue

February 2, 2005 53
IRM CYCLE AND RBI NOTHING WILL REPLACE THE INSPECTION PROGRAMME THE "INSPECTION MANAGEMENT AND DECISION TOOL" HELPS
THE INSPECTOR (PREPARATION AND RECORDING) AND THE SUPERINTENDENT (MANAGEMENT OF INSPECTIONS, EVALUATION OF FINDINGS AND MAINTENANCE DECISION) THE "RBI TOOL (RISK BASED INSPECTION): INCORPORATES THE NOTION OF ACCEPTABLE RISK (FATIGUE LEVELS, RISK OF COLLAPSE, DEGRADATION OF THE ANTI-CORROSION COATING, AND COST) DETERMINES / ADJUST THE INSPECTION INTERVALS DEVELOPS AND STRUCTURES THE INSPECTION PLAN (EQUIPMENT RANKING BY CRITICALITY)

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INSPECTION MANAGEMENT AND DECISION SUPPORT TOOL (EXAMPLE)

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ACTIVITIES UNDERTAKEN IN A RBI APPROACH
Inspection data evaluation Analysis of results
Inspection Philosophy Inspection Systematics Acceptance criteria
RBI
Consequence of Failure Safety, Environment, Economy Probability of Failure Materials/Environment and Strength Risk evaluation per component
Inspection and testing Execution & Reporting
Inspection Management
Inspection Plan Inspection details, planning, logistics
Inspection Programme Method, Timing, Coverage, Location

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PERIODICAL ASSESSMENT FOLLOWS THE FIRST ASSESSMENT. IS DONE YEARLY. ALLOWS A

RAPID AND RELIABLE RE-ANALYSIS IN ORDER TO: EVALUATE THE EFFECTS OF MODIFICATIONS / CHANGES (IN OPERATIONS, DESIGN) PREPARE THE BASIS OF THE INSPECTION PLAN REEVALUATION EVALUATE THE CONSEQUENCES OF THE INSPECTION FINDINGS ("FRACTURE MECHANICS", ) COMPARE THE RESULTS OBTAINED FROM THE MONITORING WITH THE ANALYTICAL RESULTS (MODELS) EVALUATE THE EFFECTS / CONSEQUENCES OF THE FLOATING UNIT AGEING AND DEGADATION AND THE IMPACT, ESTABLISH THE CUMULATED FATIGUE (BASED ON REAL HISTORICAL DATA) DOCUMENT THE LONGEVITY STUDIES
February 2, 2005 57
TYPICAL EXAMPLE OF A GLOBAL MODEL AND OF SUBSUBMODELS USED FOR A STOCHASTIC ANALYSIS
Global model
Sub-models

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EMERGENCY RESPONSE SERVICE (ERS) ASSISTANCE SERVICE 24 HR/DAY IN ORDER TO PERFORM ALL
NECESSARY CALCULATIONS AND ESTABLISH RECOMMENDATIONS RELATED TO: STABILITY / RESISTANCE OF THE FLOATING UNIT AFTER HULL OR MOORING DAMAGE STABILITY / HULL RESISTANCE IN TRANSITORY STAGES LIKE LIGHTENING, BALLASTING, CARGO TRANSFER EXTREME CONDITIONS SURVIVAL IN DAMAGE STATE, WEATHER AND OPERATIONAL RESTRICTIONS,

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THIRD PARTY ASSISTANCE COMPANY = SOFTWARES, EMERGENCY RESPONSE SERVICE, ADVISOR (NEUTRALITY)
Company Head Office Third party assistance company
Design / Softwares IRM / RBI Re-Assessment Emergency Response
Operated
Company Subsidaries
General Manager Asset Manager Marine Superintendent
Maintenance
Inspection
Contractor
Leasing
Class

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Some of the proposed integrity management systems reviewed
Bureau Veritas :
AIMS
Veristar Offshore (Assessment of life-cycle hull conditions) /
(Asset Integrity Management System for the database and web based system) Life - Cycle Asset Integrity Management / FLCM (Field Life
DNV Software :
Cycle Management System for the database and web based system)
Lloyd's Register : V.Ships : EM&I :
Integrity Assessment of Floating Structures Through Life Condition Monitoring System (TLCM) Asset Integrity Management System (AIMS)

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END

February 2, 2005
62

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INTEGRITY MANAGEMENT OF FLOATING PRODUCTION UNITS

Content of the presentation

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Different types of Floating Units

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

FPSO Girassol, Angola, Total

Asgard A, Norvway, Statoil

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

FSO Pathumabaha, Gulf of Thailand, PTTEP

ex-FSO15 Domy, Nigeria, Total (decommissioned)

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

N'Kossa NKP et N'Kossa 2, Congo, Total

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Asgard B, Norway, Statoil

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

TLP Magnolia, USA, Conoco

TLP Matterhorn, USA, Total

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Genesis spar, USA, ChevronTexacco

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Choice of the Floating Units

Water depth Development requirements

Construction and installation cost

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

The Floating Production Units in 2003

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Forecast for 20032003-2007

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

DALIA Future FPSO, Angola (Total)

CASTELLON DELTA 1977 : First FPSO, Spain (Shell)

FLNG Barge project , Nigeria (Shell)

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

International and National rules

International rules (IMO) :

Standards, norms, conventions :

Company Referential (Total E&P)

Internal to Company, however: General specifications can be given to

Design, age Exploitation, integrity, marine

Marine experts Transverse multi-disciplinary

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Hull and structure

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Hull design (new built) built)

Double Side Centerline Bulkhead

FSO Unity, Total, Nigria

FPSO Girassol, Total, Angola

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Hull design (new built) built)

Norne FPSO, Statoil, Norway

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Girassol example (water depth 1 400 m) TOTAL E&P Angola

Weight Production Type Mooring lines

External coating : Tank coating : Cables :

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Problems usually encounted: encounted: corrosion

Example of corrosion in a ballast tank

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Problems usually encounted: encounted: fatigue of structures

Example of crack at a bulkhead level

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF

Problems usually encounted: encounted: chock & collisions

FPSO Hystory Old&New

FPSO Hystory Old&New