Ali Anaturk

OML118
An Overview of the Lessons Learned from

FPSO Operations Industrywide for Future
Standard and Novel FPSO Concepts
Ali Anaturk,
B.Sc., M.Sc., M.B.A., C.E./UK, P.E./USA, Fellow IMechE
Penguins FPSO Lead, Principal Project Eng.
FPSO EUROPE CONGRESS, Feb 2015
Copyright of International Exploration and Production Company Ali Anaturk Feb 2015 1
OUTLINE
1. Summary
2. History
3. FPSO Categories
4. Lessons Learned
5. Life Extension
6. Industry needs : Standards, Regulations
7. Closing
1.0
SUMMARY
SUMMARY
Floating Production Systems with Oil Storage capacity (FPSO, FPS) are
operating successfully over 3 decades (164 in operation by Jan/2015).
Owner operated & custom build tendency in large volumes, Lease tendency
in lower volumes. Tendency towards deeper water
Most FPSOs are designed using ship rules and class requirements. Many are
approaching their design life with uncertainty on rules and standards for life
extensions.
Class rules require dry docking every 5 years while the Floating Systems are
expected to remain in the field much longer. Ad-hoc rules introduced in-lieu of
this requirement.
Relying on fully class rules using ship technology may give false sense of
security.
Noble storage concepts (non ship shaped) provides opportunities and basis
for discussion for applicability of ship rules.
2.0
HISTORY
FPSO Trends : Water Depth (Ref: IMA/EMA)
Significant tendency
towards deeper waters
Few FPSO s
approaching design life
Relatively young
FPSO Trends : Storage volume (Ref: IMA)
Large volume usually custom made

and owner operated
Strong lease market at

low volumes
Worldwide Non-disconnectable FPSOs (Ref : IMA)
• There are no non-disconnectable FPSOs worldwide older than 20 years. Conkouati is the only
one which reached to 20 yrs on location without dry docking. Mostly less than 15 yrs old.
Zafiro Trinity Spr/Nig BONGA

Producer/Eq. Hull repaired with SPS
Guniea
Exxon life extension
Conkouati/Congo is expected
Site repairs with
SPS
Anasuria/NS
,
Schiehallion/NS
Gryphon A/NS replaced after 15
Snapped anchors, years
off field in 2011
Disconnectable FPSOs are taken to dry dock every 5 years and therefore can be operated longer then non-
disconnectable vessels. They are usually leased/contractor operated and used for smaller production fields.
Non-disconnectable FPSOs are usually custom made. West Africa FPSO’s tend to be large spread moored vessels.
SOME OF SHELL OPERATED FPSO VESSELS
ANASURIA CURLEW
BONGA SEA EAGLE
3.0
FPSO CATEGORIES
FPSO CATEGORIES
Custom build and owner operated (North Sea, West Africa, Brazil)
Converted and Leased FPSO
New concepts with Storage (circular, semi, spar)
Offloading (tandem, CALM buoy, disconnectable)
Station keeping (spread, turret, DP)
Risers (Flexible, Steel Catenary)
Mooring (synthetic & chain, wire & chain, suction or driven piles)
Blanketing (hydrocarbon, inert)
4.0
LESSONS LEARNED
HULL KNOWN ISSUES
In lieu of Dry Dock Inspection Requirement every 5 years, most operators

agree with class societies to perform in situ inspections every 2 to 5 years
Internal Tank inspection : Significant impact to production
Corrosion protection (missing anodes, failed ICCS systems)
Coating failure especially around appurtenances riser supports
Fatigue cracks (especially older tanker with high strength steel)
Green and white water on deck (barriers being added on several FPSOs)
Main deck corrosion (requires heavy maintenance)
Marine growth (external, caissons and water ballast tanks)
Leaks through sea chests (firewater systems etc)
Uncontrolled weight increase
CLASS requirements usually covers hull
HULL FATIGUE
Uncertainties in fatigue life calculation is large
In situ repairs of internal tank cracks feasible but not clear how reliable
Ship shaped FPSOs are more vulnerable to fatigue than fixed platforms or
TLPs
HULL CORROSION PROTECTION
Industry’s confidence on coating has not increased significantly. There is no reference
point in industry which shows survival of coating beyond the design life.
Anodes protection is limited to its protection zone. There are many blind spots.
ICCP systems are good, if they work. Requires maintenance
If internal coating fails, aggressive repair program may be effective.
If the external coating starts failing and anodes are not able to protect the entire
underwater surface of structure, then there may be large areas of hull corroding
relatively fast.
There is very limited industry experience to repair hull external plating under the
water and none in such large scales
HULL FLOODING RISK
While hull is double skin, machinery areas are single skin prone to rupture
and flooding
Sea Chests prone to sea water leaks
Recommend to isolate areas but also instrument against flood risk
Avoid sea chests in the machinery space areas
To FW ring main
Check valve
Strainer
3 way cooler
Cooling water dump

Sea chest
Diesel engine
Booster pump
MOORING and RISERS
Moorings are generally classed and subject to class inspections, issues
 Line breakage
 Fatigue due to tension and/or out of bending
 Scouring of some anchor leg
 Corrosion (suction piles) and high consumption of anodes
 Difficulties in underwater inspections (if pull-in winch not available)
Risers
 Flexibles : External damage, rupture, burst, fatigue, water hammer
 Steel Catenary risers : Flex joint leaks (10-15 yrs lifetime), VIV
OFFLOADING SYSTEMS
Options
 Offloading buoys
 Tandem offloading
Probably most vulnerable part of the FPSO system due to frequent use
Past incidents
 Tanker collision : Examples loss of control, close proximity during
hose pickup
 Offloading system failures
 Premature failure of offloading hoses
TOPSIDES KNOWN ISSUES
Most of topsides problems from other types of vessels such as corrosion
Rotating : Cavitation, Seal Failures, Inlet pressure decline, Early Rebundling
Static Equipment: Corrosion, Pipe movements, burst, vibrations, blockage
Changes from design: More gas or water, Unexpected chemicals (Naphtanetes,
Oxygen, H2S), environment (wind, current and wave), more tiebacks
Obsolescence: Lack of spares, significant to control systems
Overboard water quality
CLASS Usually do not cover topsides
RELIABILITY OF FPSO SYSTEMS
Most FPSO operates above 90 % availability

Unavailability is usually due to planned and unplanned shutdowns
Production losses are mostly due to maintenance, shutdowns but also
due to equipment failures and trips
UNPLANNED SHUTDOWNS
CAUSES OF PRODUCTION LOSSES
5.0
LIFE EXTENSION
BACKGROUND ON AGEING (HSE UK)
“Ageing equipment is equipment for which there is evidence or likelihood of

significant deterioration and damage taking place since new, or for which
there is insufficient information and knowledge available to know the
extent to which this possibility exists. The significance of deterioration and
damage relates to the potential effect on the equipment’s functionality,
availability, reliability and safety.“
LIFE EXTENSION METHODOLOGY
Identify safety critical systems and associated issues
Establish if these systems are being operated within design criteria
Establish if vessel in-situ operations are safe, economic (availability,
maintenance ) and decide between life extension or decommissioning
Develop mitigation plans for the issues, design reassessment, in-situ repairs,
replacement, increased maintenance and inspection, additional spares,
replacement of obsolete equipment
LIFE EXTENSION GUIDELINES
Life Extension of a facility strongly depends on
 Maintenance, inspection, sparing, replacement, obsolescence, availability
and reliability, economic operation, recertification, class acceptance…
 It is essential relevant data collected continuously including metocean, vessel
motions, maintenance records, equipment history, production fluid change
history, changes in design basis, operating history, …
 Early Life extension planning (no point to start 1-3 yrs before design life ends
 Evaluation of critical items with respect to remaining lifes
Colour Description Action
System has an integrity issue resulting in an imminent risk of Immediate Action is
loss of production or failure of the safeguarding system, and Required – Act Now
therefore requires immediate remedial action by Asset
Manager.
System has an integrity issue- operating outside applicable Remedial action is
design codes and standards- and requires remedial action required within one Year
within one year by the Asset Manager. and < 3 years
System does not have immediate risk of loss of production Remedial action is
or failure but the integrity cannot be assured for the design required within one Year
life of the asset and requires action by Maintenance and >3 years
/Operations Focal Points.
System is being actively managed in accordance with System life > Design life
practices defined in the Operations and Maintenance
Manuals, Asset Integrity Management Manuals or equivalent.
TYPICAL RISKS (No specific project or vessel)
6.0
INDUSTRY NEEDS FOR STANDARDIZATION AND
RULES
REGULATIONS & STANDARDS
Aspiration no harm to people and environment

Gap in regulations for FPSO design and operations worldwide
Need for an industry wide standard for FPSO design new build and
conversion
Align FPSO standards with offshore industry standards similar to TLPs,
Semis and SPARs
 For example ship rules require dry docking every 5 years, this needs
to be reviewed and appropriate new rules to be developed
Need alignment between FLAG & CLASS and OFFSHORE
requirements
7.0
CLOSING
SUMMARY
FPSOs made many fields feasible in particular in areas where there is little
or no infrastructure.
Many FPSOs are approaching to end of their design life and operators are
facing challenges to extend the life in-situ without dry docking or replace
the vessel with a period of shutdown (6 months – 2 yrs)
For vessels with potential life extension more inspection and maintenance,
focused organization, more resources, are recommended. Dependence on
class alone may give a false sense of safety.
New standards and regulations are needed for both leased and custom
build FPSOs.

Ali Anaturk

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Ali Anaturk

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OML118

An Overview of the Lessons Learned from

FPSO EUROPE CONGRESS, Feb 2015

Large volume usually custom made

Strong lease market at

Zafiro Trinity Spr/Nig BONGA

BONGA SEA EAGLE

In lieu of Dry Dock Inspection Requirement every 5 years, most operators

Cooling water dump

Most FPSO operates above 90 % availability

“Ageing equipment is equipment for which there is evidence or likelihood of

Aspiration no harm to people and environment

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