Beruflich Dokumente
Kultur Dokumente
Houston, TX
Presentations
Session I
Panel of Invited Speakers
June 7, 2000
1
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Table of Contents
Speaker page
James Regg, U.S. Minerals Management Service 3
LCDR Russell Proctor, U.S. Coast Guard 13
Paul Finnigan, Dept. of Minerals & Energy, W. Australia 25
Deborah M. Mattos, Petrobras, Brazil 53
Stephen Ovens, Occupational Safety & Health Service,
New Zealand 64
Daniel Salas, PEMEX, Mexico 81
Oyvind Tuntland, Norwegian Petroleum Directorate, Norway 105
Peter Mills, Health & Safety Executive, United Kingdom 111
2
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
James Regg
United States
Minerals Management Service
3
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Regulating an FPSO-based
Development in the U.S. GOM
Jim Regg
Regg,, MMS
4
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Likely Configuration
Analyzed in EIS
5
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Comparative Risk
Assessment
§ Relative risk of FPSO compared to existing
deepwater GOM production facilities
§ OTRC, EQE, DeepStar
DeepStar,, MMS, USCG
§ Project Update
§ Phase I: System definitions completed
§ Phase II: Events and Outcomes completed
§ Phase III: Consequence and Frequency
§ Refinements and Mitigation Alternatives
§ Project Completion by January 2001
6
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Existing Reviews
§ Development Operations
Coordination Document
§ Development intentions
§ Public input; environmental
§ Conservation Review
§ Other existing plans,
permits, submittals
§ Deepwater Operations Plan
7
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
DWOP Strategy
§ DWOP
§ Conceptual, Preliminary, Final Parts
§ Guideline - Industry/MMS effort
§ Early dialogue; focus on “total system”
§ Sand face to transportation
§ MMS approval prior to major $$ commitments
§ Alternative compliance and departures
§ Avoid unnecessary regulatory rewrites
§ Best Available and Safest Technology
DWOP Timing
Discovery Conceptual
Conceptual System Selected Part
30 days
Final
First Production + 90 days
Part
60 days
8
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Subpart B Enhancements
§ Subpart B - Plan
submittal requirements
§ Incorporate DWOP
§ Curtailment of
operations planning
§ Hazards analysis
§ Conservation review
§ full development
§ premature abandonment
Photo courtesy of Bluewater Offshore
9
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Subpart I Enhancements
§ Platforms and Structures - design,
fabrication, installation, use, inspection, and
maintenance
§ Application process; verification program;
certified verification agents; fixed platforms only
§ Technical modification
§ Reference existing industry standards
§ Eliminate prescriptive details
§ Rewrite
§ All types of Floating Production Systems
Industry Standards
§ API RP 2FPS - Planning, Design, and
Construction of Floating Production
Systems
§ API RP 2RD - Design of Marine Risers for
Floating Production Systems and TLP’s
§ API RP 2SK - Design and Analysis of
Stationkeeping Systems
§ API RP 14J - Hazard Analysis for Offshore
Production Facilities
§ Others?
§ Offloading guidelines
10
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
§ Memorandum of Understanding
§ Effective 12/16/98
§ Implementation
§ Identifying standards and regulations
§ Determine where changes or enhancements
needed to table of responsibilities
§ Clear jurisdictions; component level
§ Active and ongoing dialogue with USCG
11
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Thank You!
12
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
13
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
OTRC: June 7-
7-8, 2000
14
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
15
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
16
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
17
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
18
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
19
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
20
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
21
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Lightering Activities
FPSOs will engage in lightering activities
• Lightering operations are governed by the regulations in
33 CFR 156.200
• Tankerman/Persons-In-Charge are required for all lightering
operations
• Work-Rest periods apply
• Designated Lightering Zones may be established by the
District Commander
- The District Commander sets operating restrictions
- Gulf of Mexico operating regulations found in 33 CFR
156.330
Shuttle tankers or tank barges must be U.S. flagged if they are
delivering the produced crude oil to facilities on U.S. shores.
22
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
MMS/CG Memorandum of
Understanding (MOU)
§ MOU Purpose:
Purpose: clarify agency
responsibilities
§ New MOU signed December 16, 1998
§ Replaces old CG/MMS MOU from 1989
§ Developed with considerable industry input
§ Clarifies agency responsibilities…especially for
floating OCS units including FPSOs
23
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
CONCLUSION
24
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Paul Finnigan
Australia
Department of Minerals & Energy
Western Australia
25
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO’s - Australian
experiences
Paul Finnigan
e mail - p.
p.finnigan
finnigan@
@dme
dme..wa
wa..gov
gov.au
.au
Workshop objectives
26
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Workshop focus
§ Permanent vs disconnectable
§ Conversion vs new build vessels
§ Oil storage and offloading
§ Manning and evacuation
§ Vessel motion and stability
§ Gas handling / transport
27
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
28
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO overview
§ As at Oct 98, some 47 FPSO’s in use
worldwide, plus 24 under construction
(Bluewater figures)
§ 23 in use in UK / Norway, 7 in Australia
§ Relatively few owned by oil companies,
(Cossack Pioneer, Griffin Venture, (Aus),
Schiehallion, Anasuria, (UK), Petrobras,
(Brazil))
§ Main players - PGS, Bluewater, Modec
BP ‘Schiehallion’
29
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Australian FPSO’s
§ BHPP ‘Griffin Venture’ - newbuild, (94)
§ Woodside ‘Cossack Pioneer’ - conversion, (97)
§ BHPP ‘Buffalo Venture’ - conversion, (99)
§ Woodside ‘Northern Endeavour’ - newbuild, (99)
§ BHPP ‘Skua Venture’, (now removed), (91) **
§ Newfield ‘Challis Venture’ (ex BHPP), (89)
§ Newfield ‘Jabiru Venture’ (ex BHPP), (86)
§ Phillips Elang-Kakatua ‘Modec Venture 1’ **
FPSO advantages
§ Large deck area, and potential topsides
weight
§ ‘Inherent safety’ via separation, by distance,
of process, from accommodation.
§ Deep water capability
§ Economics of leasing
§ Re-useable - ‘low’ decommissioning costs
30
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Permanent vs disconnectable
§ Australia has a mix of FPSO’s, dependent
upon environmental conditions at location.
§ BHPP ‘Griffin Venture’ and Woodside
‘Cossack Pioneer’ both have disconnectable
turrets, to allow to move to shelter in face of
impending cyclones.
§ BHPP ‘Buffalo Venture’ and Woodside
‘Northern Endeavour’ permanently stationed
in field.
31
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Environmental conditions
§ North West Shelf - Cyclone season Nov -
April
§ 100 year design storm (Hmax) approx 20 m,
(60 ft), 10 - 15 sec period. Current 2 m/s,
winds upto 60 m/s (1 minute data).
§ Comparison -UK N Sea, (Hmax) approx 32
m, (96 ft)
§ Water depths - 80 m (240 ft) at Cossack,
130 m (390 ft) at Griffin
32
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Environmental conditions
(cont’d)
33
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Newbuild vs Conversion,
(cont’d)
§ Newbuild allows better integration of
design process with the goal setting
philosophy of Safety Case style
legislation. (eg ‘H’ class bulkheads
rather than A60).
§ Age of vessel (for conversion) - ‘quality’
of hull, tanks etc may be an issue.
Extended period on station without
drydocking.
34
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
35
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Laminaria turret
36
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
37
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
38
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
39
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
40
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Shell ‘Anasuria’
Texaco ‘Captain’
41
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
42
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
43
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO incidents
§ Gas turbine rotor disintegrated, leading to
large scale fire in FPSO engine room. No
fatalities, but field shut in for 4 months, whilst
refit / repairs undertaken. FPSO taken to
shipyard.
§ Omissions in hazard identification process.
§ Some protective systems failed to operate -
inadequate design and procurement of
equipment.
44
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Other issues
§ Fitment of VOC (volatile organic
compound) gas / vapour return systems
to FPSO and shuttle tanker,
(environmental issue). (BP Schiehallion)
§ ‘Green water’ on decks, (damage to
process equipment, (eg Chevron ‘Alba’
FSU) or hull, (BP ‘Petrojarl Foinaven’)
§ Integrity of swivel seals, (loss of
containment)
§ Type of mooring - drag chain vs turret.
45
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Texaco ‘Captain’
46
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
47
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Maersk ‘Curlew’
48
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
49
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
UK FPSO’s
50
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
UK FPSO’s (cont’d)
§ Bluewater ‘Uisge Gorm’ on Amerada Fife
§ PGS ‘Petrojarl Foinaven’ (West of
Shetlands)
§ PGS ‘Petrojarl 1’ (1986)
§ Reading & Bates, (ex BP) ‘Seillian’ SWOPS
§ Maersk Curlew
§ Maersk ‘North Sea Producer’ on Conoco Mc
Cullough
§ Kerr McGee ‘Gryphon A’
UK FPSO’s (cont’d)
§ Texaco ‘Captain’
51
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
52
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Deborah M. Mattos
Brazil
Petrobras
53
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
ABSTRACT
Petrobras has presently six FPSOs operating in Campos Basin and the forecast is to complete fourteen
units until 2003, including recently installed FSOs and other units in conversion, installation or contract
phase. Some aspects of the design, conversion and operational ex perience are discussed in this paper.
The Brazilian ruling scenario in terms of petroleum, environment and maritime political and technical aspects
is briefly mentioned. Environmental impact studies, safety requirements, risk assessment and studies
developed in this area are highlighted, including: gas dispersion in open areas, fire propagation and passive
protection, explosion and fire prevention in cargo tanks, and risk of collision. Some technical aspects as “as
new” x “all new” conversion philosophy and plate replacement are examples of typical subjects to be faced
during conversion phase. Vessel motion and offloading represent important feedback from the operation, to
the designers of new FPSOs. Finally, technological needs are shown, concerning mooring and risers
systems and development of new concepts such as FPDSO.
INTRODUCTION
The experience acquired by Petrobras in Floating Production Storage and Offloading Systems (FPSOs)
becomes evident when it is noticed that six units with this conc ept are already in operation in Campos Basin.
Adding three FSOs in operation and five more units under construction, installation or contract stage, the
figures grow to fourteen systems in the beginning of 2003.
Although some initiatives in the use of FPSO/FSO concept in Braz il started in 1979 and several mooring
systems, such as spread mooring, tower-yoke, calm system and calm-yoke were adopted (1), the decision of
their intensive use began in 1994. At that time Petrobras decided to convert the P.P. Moraes FPSO,
renamed P-34, into an Early Production System (EPS) for Barracuda and Caratinga Field, installing a new
process plant and a turret system to moor the unit in 840 m of water depth. First oil of P-34 came in mid-
1997, through 11 production wells.
54
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
The increasing production in the Campos Basin, assured by the oil from Albacora and Marlim Fields, lead to
a re-evaluation of the Basin export system, since the existing pipelines were already at maximum capacity.
The appointed solution was the use of FPSOs, converted from available Very Large Crude Carriers (VLCCs)
of Petrobras ’ fleet. These vessels, being of the single hull type, were restricted on some international sea-
lanes. In spite of the average service age of 22 years, they were always maintained up to the standards
required by the Classification Society.
In this scenario began almost at the same time, the conversion of four former tankers, namely Vidal de
Negreiros (P-31), Cairu (P-32), Henrique Dias (P-33) and Jose Bonifacio (P-35). A few months later, another
unit (P-37) was contracted, but this time, the main contractor supplied the tanker (also a VLCC). Two FSOs,
P-47 and P-38, were added to the initial conversion list, incorporating turret mooring systems. A small tanker
(28,000 dwt), named Avare, was the first unit in Campos Basin installed through a Differentiated Compliance
Anchoring System (DICAS), a spread mooring system.
The experience with leased FPSOs started with Early Production Systems: FPSO II installed in Marlim Sul
through a calm-yoke mooring system and Seillean, a full Dynamic Positioned (DP) vessel, for Roncador.
Former FPSO VI, renamed Espadarte FPSO, is the only example of a leased Permanent System. Table I
shows some data about the mentioned FPSOs /FSOs, not including FSOs moored to monobuoys.
All FPSOs used as Permanent Systems have a large number of risers connected (up to 47), implying in
large diameter internal turrets. They also have large process plants installed and present a large number of
swivel paths. A 20 years design life was specified.
Experience gained from operating ship shape production units has been useful for improving technical
specifications and determining the life expectancy design for future conversions, and keeps us confident that
safe operational procedures are the main way to prevent oil spills.
55
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
The first official step in the history of petroleum in Brazil was the creation of the National Petroleum Council
(CNP) in 1938, to assess the requests for research and mining of oil reservoirs, which was enforced by law
to be performed by Brazilians.
Petrobras – Petroleo Brasileiro S. A. - was created in 1953 to run the oil business in Brazil, according to the
law which instituted the state monopoly for research and mining, refining and transportation of petroleum
and its byproducts. In 1963, the monopoly was extended to include imports and exports of petroleum and its
byproducts. However, since November 1995, as a result of a Constitutional Amendment, Brazil has now
permitted the presence of other companies which can compete with Petrobras in all branches of the oil
industry.
With the purpose of regulating, contracting and controlling economical activities linked to the petroleum
industry, for the benefit of the country, in August 1997 the Nat ional Petroleum Agency (ANP) was created,
being subordinate to the Ministry of Mines and Energy. ANP is in the organization process to fully assume
its attributions.
The responsibility for the protection and improvement of the env ironmental quality is attributed to several
organizations, among which it is worth mentioning: the Ministry of Environment, Hydric Resources and
Legal Amazon – MMA – (Central Body); the Environment National Council – CONAMA – (consulting and
deliberating organ) and the Brazilian Institute for Environment and Renewable Natural Resources – IBAMA
– (executing organ).
The warranty of the environmental equilibrium is the main target of the IBAMA, which was created in 1989
to attend public and private action that could interfere in the environmental resources quality, aiming at the
ecologically sustainable economical development.
One of the instruments to control potentially polluting and/or natural resources demanding activities is the
requirement of an Environmental License. In the case of offshore installations, this license is issued by
IBAMA, following regulation by CONAMA.
For the issuing of the Operation License for FPSOs, IBAMA has been demanding Environmental Impact
Studies, which considers the impacts of continuous activity, and some studies related to Risk Assessment
techniques, in order to identify and evaluate the consequences of accidental scenarios. It is foreseen a
trend of governmental organizations to formalize requirements, and even though to create federal laws .
Maritime Politics and Regulations
The Rules of the Maritime Authority for traffic and permanence of vessels in Brazilian Waters are the
attribution of the DPC (Harbor and Coast Directory), an organization of the Brazilian Navy.
The Brazilian administration follows the International Maritime Organization (IMO) requirements stated in
the Convention for the Safety of Life at Sea (SOLAS) and in the Code for the Construction and Equipment
of Mobile Offshore Drilling Units (MODU Code) and in the amendme nts to the International Convention for
the Prevention of Pollution from Ships (MARPOL Convention).
Only formally recognized Classification Societies by DPC are qualified to perform audits, inspections,
surveys and to issue certificates related to conventions and regulations in the name of the Brazilian
Government .
Classification Society Rules
Petrobras owned FPSOs are classified by American Bureau of Shipping (ABS), Lloyd’s Register of
Shipping (LRS) and Bureau Veritas (BV). Guides and Rules for FPSOs are normally directed to new
building units, and conversion cases receive an individual treat ment.
In order to guarantee a suitable performance of the FPSO during its life span, special requirements were
established by Petrobras for structural verification, taking into account peculiar conversion aspects, such
as previous fatigue damage as an oil tanker, thickness corrosion rates, Brazilian environmental and new
cargo loading conditions (2).
56
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
DESIGN EXPERIENCE
FPSOs owned by Petrobras have been converted from oil tankers adopting the lump sum type contract. In
the integrated bidding process, the Main Contractor, that means the Conversion Yard, associated with a
Detailed Engineering Design Company, has been the responsible for all items supply. Petrobras technicians,
with the aim of achieving a good operational performance, have generated a large amount of technical
specifications called Basic Design.
The mentioned documentation was based on previous experience with other concepts of production units
and has being improved during the last five years as the result of conversion and operational experience with
FPSOs. The relevant technical requirements have been addressed in other opportunities (3), including a
more detailed discussion on structural (2) and turret (4) requirements, and here only safety and risk
assessment aspects will be mentioned.
Safety Philosophy
The safety philosophy for offshore installations has been consolidated in a document that comprehends the
following points:
•· Life-saving appliances and equipment;
•· Active and passive fire protection systems;
•· Safety requirements for electrical, drainage, ventilation and air conditioning systems;
Gas detection is an essential step in all safety procedures, allowing starting safety measures like flow
interruption, elimination of ignition sources and personal evacuation.
Using a methodology based on computational simulation of the airflow around and inside the open areas of
the process plant, an optimized gas detection system can be reac hed (5). This methodology has been used
by Petrobras since 1995. Until now, several offshore units, including FPSOs have been analyzed and the
studies were approved by Classification Societies.
In order to rationalize the criteria for structural passive prot ection design against fire accidents, in 1988
Petrobras created a work group which opted for the development of specific procedures aiming to analyze
the severity and consequences of fire accidents (6).
57
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
These procedures allow quantitative analysis by computational simulation of the various steps present in a
fire accident, considering: leakage process, flame development, heating of structure and nearest
equipment, propagation risk, and changes in the structural strength and behavior as a function of thermal
and mechanical loads.
The first successful results of the application of these procedures in the conversion of semi-submersible
platforms, like increase in installation safety and reduction in the initially designed passive protection, and
also in evaluation of old passive protection elements replacement in existing fixed platforms, encouraged
further applications.
Considering FPSOs , besides the process plant fire risks similar to a semi-submersible platform, a significant
inventory is added from cargo tanks. Safety devices as inert gas system and water cannons to comply with
SOLAS requirements were provided, but Petrobras technicians have been still concerned and intensive
studies have been performed.
To avoid that fires at process plant could ignite fire in cargo tanks, two basic philosophies can be applied:
using grated floors at process plant deck (avoiding gas accumulation between the deck and the tank top) or
using plated floors (avoiding that a fire at the process plant deck reaches and propagates to cargo tanks).
Through computational simulation, the choice was for adopting plated floor, surrounding possible fire focus,
avoiding the strong heating of the cargo tanks. Other important point found is the necessity of keeping the
integrity of pipe racks, since normally this is the route of control cables, deluge lines and large hydrocarbon
piping.
In order to define preventive actions against explosion and fire in cargo tanks, a work group was created
at Petrobras in December 1998. The task included: bibliographic research, data gathering, preliminary
hazard analysis, reliability analysis of the inertization system of a FPSO already installed, computer
simulation of the effects of a fire in the process plant, etc. As a result of this study, several
recommendations were addressed, which are going to be issued as operational directives and
procedures.
Recommendations of the International Safety Guide for Oil Tankers & Terminals (ISGOTT), a publication
by the Oil Companies International Marine Forum (OCIMF) are usually followed, mainly in hot work
execution, in Petrobras ’ FPSOs as reference for operational procedures.
58
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Risk of Collision
Petrobras is one of the participants in the JIP “Risk and Reliability of a FPSO in Deepwater Gulf of
Mexico”. Regarding the collision scenarios identified in the JIP (7), that is, passing vessel collisions,
visiting supply vessels and offloading shuttle tankers, some comments can be made regarding Campos
Basin reality.
The area of oil exploitation in Campos Basin is not permitted to commercial shipping routes, so the
“passing vessel collision scenario” is not so relevant.
During offloading operations, the boundary conditions help for decreasing collision risk in the “offloading
shuttle tanker scenario”:
“Visiting supply vessels scenario” although identified in the JIP as not so relevant, because of the
unexpected significant oil spill, represent the main concern of Petrobras technicians. The use of fenders,
supply boats with bow thrusters capabilities, and increase in its bollard pull capacity are some examples of
mitigating measures that have been adopted.
Its worth mentioning that weather conditions in Brazil are mild, mainly related to significant wave heights
(7.8 m for 100-years return period and 5.7 m for 1-year) and the absence of hurricanes.
CONVERSION EXPERIENCE
The conversion work in the shipyards has brought some unexpected problems that were evaluated and
some modification had to be done in relation to the original specifications. Although contract strategy
affects the conversion final result, and, consequently, the performance of the FPSOs on site, this subject
will not be addressed here. Technical experience resulted from tasks developed in different parts of the
world, like China/Korea, Singapore, Spain and Brazil is briefly shown in sequence.
The “as new” philosophy considers that there is no need to substitute all the existing equipment of the
tanker, as pumps and piping, by new ones. However, this equipment should be repaired to become like
new. This criterion was adopted in the first converted units.
It was soon noticed that this concept was too abstract, and lead to a lot of discussion between the
operator and the shipyard (1). In addition, many equipment that seemed suitable from the out side proved
to be in bad condition when disassembled and had to be replaced. It has caused a problem to the
shipyard that suffered from some delays in its procurement process. Finally, some equipment were very
old and it would be very difficult to get spare parts during the 20 years lifetime of the FPSO.
59
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Therefore, after P-35, it was decided to change the conversion philosophy to “all new” what meant that
all equipment and piping should be necessarily changed. Only the hull of the tanker would be kept.
As already mentioned, first FPSOs were converted tankers from Petrobras ’ own fleet. Later, as there
were no more VLCCs available, it was required to the conversion contractor to supply the ship to be
converted. It was quickly noticed, that in the second phase the tankers were in much worse situation
than in the previous, as can be confirmed by Table II that shows the amount of steel replaced in each
FPSO. The case of P-35 is an exception, where the large amount of steel renewal may be explained by
the fact that the ship was an ore-oil.
It must be highlighted that our specification requires that all plates shall not reach substantial corrosion
range during the unit operating life of 20 years without dry-docking. Therefore, it is requested an
additional corrosion margin, based on Petrobras ’ experience.
OPERATIONAL EXPERIENCE
Vessel motion
The environmental condition in the Campos Basin is multi-directional. Sometimes, occurrences of wind and
current misaligned with long period wave (swell) induces a beam sea condition and consequently high roll
motion response.
Another reason of high vessel motion is due to Cargo Loading and Offloading Procedure. Several tanks with
certain oil amount cause the FPSO to have a very low KG (vertical position of center of gravity) when the ship
finishes the offloading. The low KG results in a high metacentric height, causing the natural period of the ship
to be very low (around 13 s), in that situation.
The two facts above (multi-directional environmental and low KG), when taken together, caus es the FPSO to
have resonant roll motions. In P-31, for instance, there were four shutdowns in one year caused by excessive
motions (angles greater than 12 degrees).
For the design of new FPSOs, a more realistic cargo loading and offloading plan will be considered. In
addition, the enlargement of the bilge keel, that in a VLCC usually has only 45 cm and covers only 40% of the
vessel length, will be specified. A model test investigation, performed in the Institute for Technological
Research of the State of Sao Paulo - IPT – Brazil, indicated that the enlargement and extension of the
existing bilge keels can reduce vessel motions to a compatible level for a proper process plant design with no
downtime expected.
60
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
For the existing units, however, the only possible solution is to define some limits on the cargo loading and
offloading plan in order to try to reduce or to avoid having the ship in a resonant situation.
One of our units has an automation of the sequence cargo loading, according to a pre-defined loading plan.
This system comprises two main software. The first one is to proceed a pre-defined cargo sequence that will
minimize the roll motion, bending moment and shear forces along the vessel. The second one is a safety
program that guarantees normal operation and double-checks the process sequence. An alarm and a trip
interrupt any abnormal operation. At anytime, authorized operation staff can interrupt the cargo sequence and
operate manually. This system is being used in one of our FPSO with very good results for almost three years
and is being considered ready to be used in other FPSOs.
Offloading
Offloading operations through shuttle tankers are a vital issue for Campos Basin production. The experience
acquired with 280 tandem moorings and more than 111 million bbls offloaded until December of 1999 provide
confidence in the feasibility and reliability of this operation. It is expected to offtake 60% of all Brazilian oil
production through FPSOs and FSOs by the year 2004(1).
With the aim of increasing the lifetime of the offloading hose and allow its easy inspection, it has been required
a retrieval system. The choice of all main contractors has been for a chute system, where the hose is stored in
a long cradle, alongside of the deck. The chute system provides a better stern layout, in comparison to the
alternative hydraulic reel system, because of the large diameter (20”) and length (250 m) of the hose, besides
being less expensive.
Unfortunately, some problems had been experienced with this chut e system in the beginning of their
utilization. The chute used to provoke wear of hose and it was difficult to handle the hose in the cradle and to
make the connection of the hose end to the rigid pipeline at the stern of the FPSO. In this situation, the
offloading operations used an alternative offloading system (8 inches floating hose). This alternative was
specified in the design phase to give more flexibility in the case of start-up of the main system or its
unavailability due to maintenance or repair. As the alternative hose has a smaller diameter, this results in
longer offloading periods and, consequently, greater operational costs. Chute suppliers have been doing
adjustments, in order to make this system operational.
The use of offloading arrangement with floating hoses permanently on the water and the connection on the
shuttle at the bow are now under economical evaluation, since that design is considered reliable with no
significant downtime. Ten calm buoys with floating hoses operating in Campos Basin help to relay in this
option.
With the exception of FPSO Seillean, all other offloading operations are done by shuttle tankers moored by a
tensioned hawser to the FPSO, permanently assisted by at least one tug-boat. The hawser (150 m length) is
retrieved onboard by winches at the stern. The hawser winch with vertical axis drum, proved to be very
cumbersome and is not accepted anymore. Horizontal axis drum is now being required.
TECHNOLOGICAL NEEDS
The use of FPSOs in offshore Brazil is a reality. Nevertheless, some challenges have to be faced and
overcome, mainly due to the displacement to deeper waters. PROCAP 3000 – Technological Innovation
Program in Ultradeep Water Exploitation Systems, a new step now in progress of a capacitating program that
has began in 1986, has a comprehensive portfolio, in which many projects are direct or have application to
FPSOs. These projects are linked to general programs, and those that have interest for FPSO concept are
presented in sequence.
The objective of this program is to develop and make available new technologies for subsea pipelines,
control umbilicals and diverless connections, considering all phases from design to installation. Flexible risers
with diameters limited to 10 inches have already been developed for application in semi-submersible
platforms up to 1,500 m of water depth. As FPSOs have higher motion amplitudes compared to semi-
submersibles, a check has to be done, focusing on the feasibility for its use in FPSOs.
61
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
A Steel Catenary Riser (SCR) of 10 inches diameter for gas exportation was installed successfully by
Petrobras on P-18, a semi-submersible platform, and a monitoring program conducted by Petrobras R&D
Center is in progress since 1998. Two more SCRs, one for oil and other for gas export, both of 10 inches in
diameter, were installed in February/March 2000 in P-36, a semi-submersible platform moored in 1360 m of
water depth. The extension of this concept to FPSO is not obvious, due to its higher static offset and more
severe dynamic conditions, mainly heave motion. As a consequence, careful analyses are being performed.
Tethered Buoy Riser and Self Standing Riser are concepts that Petrobras is also interested in. The first one
would make feasible the use of SCR for FPSOs .
In the case that some Technical and Economical Feasibility Study , for a new field development, indicate that a
Well Head Dry Completion Platform near a FPSO is the best solution, there will be the necessity of developing
a Midwater Transfer Line. At this moment, critical issues like fatigue life at both end connections, vortex
induced vibration, movements caused by multiphase flow, anchoring devices and interaction between flowline
and anchorline have to be investigated.
The objective of this program is to develop technology to moor drilling, production and offloading systems in
water depths up to 3,000 m. Besides in-house work, there is also collaboration of Universities, Research
Institutes and Private Companies.
Three alternative solutions are considered: spread catenary, taut-leg and differentiated compliance (DICAS)
mooring system. For each system, four main aspects are being inv estigated: materials, design procedure and
criteria, installation and maintenance. Results already obtained show that it is economically feasible to moor
drilling and production units in water depths up to 3,000 m (8).
Taut-leg mooring systems are already in utilization in semi-submersible platforms since October 1997. For
FPSOs a more compliant configuration is adopted, due to the big draft range achieved during operation. FPSO
II has been moored in Marlim Sul Field at 1,215 m of water depth through a taut -leg mooring system, using a
vertical loaded anchor (VLA) as anchoring device, since November 1999.
Regarding polyester ropes, some improvements are still possible, such as efficient non-linear modeling
tools, development of a protection against the ingress of soil and development of more efficient and easier to
handle terminations. Short samples of fiber rope are installed in selected mooring lines, which are removed
regularly to assess retained strength.
As fixed points, several alternatives have been tested, such as suction piles, drilled and grouted piles and
vertical loaded anchors (VLA). Improvements are possible, mainly in installation procedures aiming time
saving with consequent cost reduction.
Torpedo Pile is the name of a free-fall anchoring system, a new concept developed and patented by
Petrobras , consisting of a tubular structure with a conical end tip, filled with high density ballast. It has
already been used for pipeline anchoring, allowing big savings due to the decrease in flexible line length. In
mooring systems application, it will reduce anchoring and installation costs and improve shot precision.
Tests are being performed, focusing certification as fixed point for mooring systems.
As an alternative for FPSO turret, a spread mooring system known as DICAS (Differentiated Compliance
Anchoring System) has been developed and are in use in small ves sels. The principle of operation is a
substantially higher compliance on the stern lines, giving partial weather vane capability. The installation of
two FPSOs based on converted VLCCs using DICAS, planned for Barracuda and Caratinga Fields, will
bring more operational experience.
An additional project develops an expert system to support mooring installations. This system will
consolidate 20 years of experience in offshore operations and provide real time support to future
installations.
The possibility of congregating drilling and/or completion, production and storage facilities in only one vessel
is a tempting solution in terms of cost savings. Nevertheless, several aspects have to be investigated for the
adoption of a FPDSO.
62
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Petrobras is conducting some studies with FPDSO and following researches of other Companies, in order to
select the best options for Brazilian scenarios including dry or wet completion, with the aim of directing some
future Technical and Economical Feasibility Studies.
CONCLUSION
Although the experience acquired by Petrobras in the use of FPSOs cannot be denied, there are still many
challenges to be surpassed. In the technological field, looking for applications in ultra deep waters, risers
systems are the more demanding attention subject. Regarding design and operation, the focus on safety has
to be always kept and the risk possibility has to be always reduced. A systematic utilization of risk assessment
techniques, directed to life, environment and installations is expected.
The concern with safety, health and environment in some way can be measured by the great amount of
certificates according to ISO14001, BS8800 and ISM Code achieved by the operating plants of the Company.
Very recently, in May 22, 2000, auditors from Bureau Veritas Quality International (BVQI) recommended the
Campos Basin’s E&P to be certified, after concluding that all requirements ex pressed in the Safety
Environment and Health Management System were fulfilled. This means that the platforms, ships, laboratories,
offices and all other areas and activities shall comply with requirements of ISO14001, BS8800 and ISM Code.
Next goal is to have 100 % of operational units certified according to ISO 14000 and BS 8800 until the end of
2002.
It’s worth mentioning that the Basic Engineering Design developed by R&D Center has been certified by DNV
according to ISO 9001 since December, 1999.
However, to fulfill legal and ruling requirements is not enough, Petrobras is aiming to be in the forefront of
technology and management. The Company is going to invest US$ 1 billion in the next four years for the
implementation of the Excellency Program in Environmental Manage ment and Operational Safety so as to
ensure operational safety of its installations, minimize environ mental risks and contribute toward sustainable
development. It is a demonstration that Petrobras is giving environmental management the same importance
that it gives to its productivity.
ACKNOWLDGEMENTS
The authors would like to thank Petrobras for the permission to publish this paper. They also wish to express
their gratitude to the colleagues for the help and advice during compiling of this paper, notably Marcia S.
Araujo, Denise Faertes , Marina B. Fachetti, Arney M. Silva and Carlos Cyranka.
REFERENCES
63
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Stephen A. Ovens
New Zealand
Occupational Safety & Health Service
64
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
JUNE 2000
65
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
MAUI FIELD
66
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
MAUI-B PLATFORM
FPSO - WHAKAAROPAI
67
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
DESCRIPTION
FPSO - WHAKAAROPAI
MOORING TURRETT
68
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
MOORING DESIGN LIMITS
FPSO - WHAKAAROPAI
VIEW OF MOORING SYSTEM
69
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
OPERATIONAL HISTORY
FPSO - WHAKAAROPAI
ENVIRONMENTAL PROTECTION
§ No spills during operation to date
§ MARPOL compliant voluntarily
§ Strict environmental conditions imposed
§ Outside 12 mile limit - Maritime Safety
Authority (MSA) enforcement
§ HSE Safety Case
§ Dry break on loading hose
§ Automatic shutdown on offloading at pre-
pre -
set conditions
70
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
DECK VIEW FORWARD
FPSO -WHAKAAROPAI
OFFLOADING OPERATIONS
71
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
NZ LEGISLATIVE FRAMEWORK
PETROLEUM REGULATIONS
OFFSHORE INSTALLATIONS
72
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
REGULATORY COMPLIANCE
§ Safety Case review by Regulator
§ no approval or acceptance
§ Regulator inspections and audits
§ Operator audits - SMS
§ Parent Company audits - extensive
§ Classification body rules - kept in
Class
§ Certificate of Fitness - 5 year term
with annual inspections.
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ JURISDICTION ISSUES
§ MANNING ISSUES
§ CONVERSION ISSUES
§ MOTION AND FATIGUE ISSUES
§ EVACUATION ISSUES
§ EQUIPMENT ISSUES
73
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ JURISDICTION
§ arrived under own power - MSA jurisdiction
§ once all anchors set - Chief Petroleum
Inspector
§ lot of discussion and concern from MSA -
particularly for a potential breakaway
§ established a tripartite Protocol document
between MSA, Operator and Chief Petroleum
Inspector
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ MANNING
§ was a very controversial issue
§ extensive debate with MSA, maritime unions,
operator and regulators
§ agreed that once tethered was no longer a ship
§ 13 crew - work 12 hour shifts - 2 weeks
on/2weeks off
§ multi
multi--skilled (with marine and process
experience)
§ planned maintenance staff on when required
§ reduction in risk and opex
74
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
MANNING STRUCTURE
FPSO
SUPERINTENDANT
(OIM)
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ CONVERSION
§ marine systems vs process systems
§ diesel shutoff valves
§ old piping (deck and internal)
§ remove redundant piping in refit - not later
§ smoke resistant doors
§ ensure doors seal against smoke ingress in
accommodation area
§ extended life
§ operational life to exceed original design life -
reassessment required
§ pump room location
75
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ Asbestos
§ widespread
throughout vessel
§ remove or manage
§ regular monitoring
§ encapsulate in PVC
§ identify and label
§ strict procedures and
work permit for cutting
into piping and walls
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ Tank Integrity
§ hydrocarbons detected in ballast tank
§ quality assurance essential in all tank
inspections during conversion
§ also in application of coatings in ballast tanks
§ ensure Company involvement in Project early
§ repairs during operations result in lost
production and long, costly repairs
§ empty, clean tanks and identify areas
§ cut out corrosion areas - weld patches
76
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
TANK CORROSION
FPSO - WHAKAAROPAI
TANK CORROSION
77
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ EVACUATION
§ no dedicated Standby Vessel
§ supply vessel in field approx. 50% of time
§ no Fast Rescue Craft (seas too rough)
§ escape by helicopter or lifeboats
§ with weather vane potential for smoke
impairment of a lifeboat station
§ smoke hoods and survival suits provided
§ manage risks to ALARP through Safety Case
78
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ EQUIPMENT
§ gas export pipeline
§ plastic lined
§ some cracking of lining suspected
§ export gas temperature too high -
hydrolysing lining
§ installed additional gas cooler to reduce
temperature to 53 degrees
§ monitor pipeline annulus for gas leakage
FPSO - WHAKAAROPAI
OPERATIONAL ISSUES
§ Rudder
§ superfluous now but
used on voyage from
Singapore
§ prefer to remove
§ high maintenance of
steering mechanism
§ tried unsuccessfully to
lock rudder (broke
pins)
§ maintain
79
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO -WHAKAAROPAI
OPERATIONAL ISSUES
§ Crane operations
§ limited due to pitch
and high roll
conditions
§ high pedestal
increases pitch
and roll - limits use
§ height to clear
process
§ process area - no
lift zone
FPSO - WHAKAAROPAI
SUMMARY
80
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Daniel Salas
Mexico
PEMEX
81
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Sistema Flotante de
Almacenamiento
y Descarga (FSO)
82
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Antecedentes
83
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
84
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
85
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Estadísticas mundiales
de torretas internas y
externas
Fuente :
Asociación Marítima Internacional
Consideraciones de
Diseño
86
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
45
No. de buque tanques
40
35
30
25
20
15
10
0
1970 1972 1974 1976 1978 1980 1982 1984 1986 1988
EXP. EXP.
PLATAFORMA
1 2
DE
PRODUCCION
(SEPARACION Y BOMBEO)
TRANSPORTE
OLEODUCTO ALMACENAMIENTO
CONTROL DE CALIDAD
Y MEDICION
Concepto FSO
Proyecto Cantarell
87
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Torreta Interna
Torreta
Externa
88
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
1993 Conoco North Sea HEIDRUN 16 515 928 OIL Dynamic Riser
1993 Conoco North Sea HEIDRUN 16 515 928 OIL Dynamic Riser
1993 Conoco North Sea HEIDRUN 16 515 928 OIL Dynamic Riser
89
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
20 m a 1,000 m
Perfil de corriente: D V D V
90
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
91
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
92
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Estructura soporte
de la torreta
93
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Pre-fabricación
de la
Torreta
Reemplazo de
placa del fondo
del casco
94
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Túneles de los
propulsores transversales
Propulsores
transversales
95
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Instalación de la
Torreta
Instalación de los
sistemas de medición
Medidores de desplazamiento
positivo
Un probador comùn
96
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Brazos marinos de
descarga al costado
97
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
F
C B
FSO “Ta`kuntah”
CONJUNTO
98
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
200 Millas
Mar territorial Mexicano
Desactivación
sistema de
propulsión
FSO 1
Remolque al sitio
99
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
1. - U N A B A R R E R A C O N T E N E D O R A D E P E T R Ó L E O D E 2 5 0 M T S . D E L O N G . , P A R A H A S T A 7 2 , 0 0 0
BLS.
2. - B O M B A A U T O M Á T I C A D E I N D U C C I Ó N P R I M A R I A D E 3 0 0 0 R P M .
3. - U N A P R E S A D E D E C A N T A C I O N .
4. - B R A Z O S D E 2 0 P I E S C / U P A R A D I S P E R S A R P E T R Ó L E O .
5. - D I S P E R S A N T E S B I O D E G R A D A B L E S .
100
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
101
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Datos de Operación
Descarga simultánea
102
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Operación Portuaria
VOLUMEN BUQUE
AÑO TRB
EXPORTADO TANQUES
1998
12'330,450 21 1'305,998
AGO-DIC
1999
39'488,078 73 3'532,325
ENE-DIC
2000
17'812,336 41 2'329,175
ENE-ABR
FSO “TA’KUNTAH”
Tiene capacidad para realizar operaciones de descarga con mar de 15-17 pies
Ta’kuntah (352,000 DWT) es el tercer FSO más grande del mundo qu e se ha construido, después del
instalado en Yemen (408,000 DWT) y el instalado en Colombia (400 ,000 DWT)
Es el segundo FSO más grande del mundo en servicio, después de la salida de operación del FSO de
Colombia en 1996
Cuenta con la más avanzada tecnología del mundo en la industria de los FSO’s
Cuenta con los más grandes sistemas de medición en el mundo instalados en un FSO (120,000 BPH)
103
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
104
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Oyvind Tuntland
Norway
Norwegian Petroleum Directorate
105
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSOs
Oyvind Tuntland
Director of Technical and Working Environment department
Norwegian Petroleum Directorate
e-mail: Oyvind.Tuntland@ npd.no
I will first say a few word about the petroleum recourses offshore Norway, the climate as well as the
Norwegian petroleum legislation. Then I will move on to the application of FPSOs on the Norwegian
Continental Shelf. At the end I will share some experience we have had with our FPSOs .
I expect to use the time I have been given, so if you have any questions please wait until the end of my
presentation.
In the early nineties the oil exploration on the Norwegian Continental Shelf moved into deeper waters further
away from existing infrastructure like pipeline systems. This fact together with cost competitiveness called
for floating production and storage concepts. A natural choice was the FPSO with its flexibility with respect
to water depth and advantageous storage capacity.
Petroleum resources
The Norwegian petroleum production in 1999 totalled 1 062 millio n barrels of oil, 45,5 billion Sm3 gas and 10
billion tonnes NGL/condensate. Average daily oil production was 2.91 million barrels, which ranks Norway
as number seven among the world’s leading oil producers and as number three among the world’s leading
net crude exporters. The estimated value of the Norwegian petroleum export in 1999 was equivalent to $19
billion.
Cumulative output since petroleum production began in 1971 comes to 2.7 billion Sm3 oil equivalents, which
represent approximately 21 per cent of the total expected recoverable resources. Discovered petroleum
resources are 9.6 billion Sm3 oil equivalents, while in addition comes undiscovered petroleum resources
estimated to 3.7 billion Sm3 oil equivalents. This sums up the total petroleum resources on the Norwegian
continental shelf to roughly 13.2 billion Sm3 oil equivalents.
106
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Norway ’s gas export totalled 45.5 billion Sm3 in 1999, which represented approximately 2 per cent of the
world’s consumption. Norway ranks among the world’s top 10 gas exporters, and Norwegian deliveries
account for 10 per cent of the gas consumption in Western Europe.
At the end of 1999 46 fields are in production on the Norwegian Continental Shelf. In association with these
fields are 106 installations, divided into 5 floating production, storage and offloading ships (FPSO), 6 floating
production semisubmersibles (FPU) of which one is made of concrete, 3 floating storage and offloading ships
(FSO), 2 tension leg platforms (TLP) of which one is made of concrete, 1 production jack-up, 75 jackets and
12 concrete gravity based installations. In addition there are 108 subsea installations. 8 – 12 drilling rigs and
vessels are engaged on an annual basis. 9300 kilometres of pipeline have been installed to transport crude
oil, condensate and gas to onshore facilities in Norway, Great Britain, Germany, Belgium and France.
During 1999, 28 exploration wells (18 wildcats and 10 appraisals) were completed or temporary abandoned.
The forecast predicts a decline in oil production during the nex t decade. To minimize this effect, we have in
the recent years aimed at encouraging discovery of petroleum res ources. The effort has been concentrated
on finding resources near existing infrastructure and on testing new exploration models. Substantial
undiscovered resources are thought to remain on the Norwegian Continental Shelf.
The North Sea is the most explored part of the Norwegian Continental Shelf. The geological understanding is
good for most of the area. Even small discoveries may have a good profitability if these facilities are used in a
rational way. The North Sea will probably be a core region for future exploration, which could also be
extended to less known parts of the area. Great interest is focused on exploring new areas of the shelf. Some
of this acreage, the Møre and Vøring Basins in the Norwegian Sea involves water depths down to 1500
metres. During 1999, a dry exploration well was drilled on ‘Gjallarryggen’ in 1352 metres water depth, which
represents a new record on the Norwegian Continental Shelf. But some major parts of the shelf have not
been opened for exploration drilling yet, such as Skagerak , Lofoten, Vesterålen and the waters surrounding
Spitsbergen and Jan Mayen as well as in the Barents Sea etc.
Pertaining to the regulations we will issue a guideline listing standards which we recommend. These
recommendations will mainly be based on the NORSOK-standards. The NORSOK-standards are industrial
standards developed by the petroleum industry in Norway, in a similar way as the API -standards have been
developed in USA. But we will also give options to use other rec ognized rules, codes or standards. The
functional requirements in the regulations are fulfilled by following the listed standards.
107
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
The Norwegian regulatory requirements to manning of the maritime functions onboard FPSOs are based on
the Norwegian Maritime Directorate’s requirements for personnel onboard mobile offshore units. This means
that control room operators taking care of maritime functions and operations are to have a similar knowledge
within the relevant maritime areas as is required for control room operators onboard Norwegian registered
mobile offshore units. Personnel with higher maritime competence is also required onboard.
Why FPSOs
FPSOs can operate in wide ranges of water depths compare to fixed ins tallations. In Norway we have FPSOs
working in water depths from 126 metres to 338 metres. An other advantage of FPSOs is the storage capacity.
FPSOs do not need to be connected to already existing infrastructure such as pipelines, as they have their own
storage facilities and offloading facilities. As a third advantage; FPSOs can be built and equipped word wide
and towed to location. This means that FPSOs can more or less be built where price and quality are best at the
time of contract award.
Of course also the rapid development in subsea and well technology areas as well as the flexible riser
technology, have worked in the direction of FPSOs.
Today Norway has five – 5 – FPSOs in operation. As storage units, Norway have three – 3 - FSUs and one
more FSU is due to come this year.
The Norne FPSO entered into operation in November 1997, followed by Varg 1998 and Jotun, Balder and
Åsgard in 1999.
The FPSOs on the Norwegian Continental Shelf are all turret moored. All of them are weathervaning, which
means that the turret is locater in the forward half of the ship, and waves and wind will keep the FPSO with its
bow towards the weather. To help it to stay on a steady controlled course, the FPSOs are equipped with
thruster assistance systems.
Normally the master on the FPSO finds the best heading with respect to waves and wind. I.e the heading
giving the smallest movements and the best working conditions for the processing of the crude oil. Often
waves and wind come from different directions. Due to required natural ventilation in the processes area, it
is normal to keep the wind in a slight angle to the bow and the waves more on the side of the bow. Because
of the good motion characteristics of the FPSO, shut down of the production due to motion of the process
with respect to equipment is not regarded as a problem.
Offshore loading
In Norway offshore loading started from articulated columns at t he Statfjord field in 1979. The shuttle tanker
was moored to the column with hawser, but also had some thrusters assistance. The crude oil was
transferred to the shuttle tanker with a loading hose.
More or less the same technology is used for tandem loading from FPSOs or FSUs.
The shuttle tanker is moored to the aft end of the FPSO and in addition the tanker have a dynamic
positioning (DP) system.
Typical distance between the two ships in operation is 75 – 80 meters. Of course the hawser and the loading
hose are some metres longer.
Fore use in an emergency, the shuttle tankers are equipped with an emergency release, so the captain on
the shuttle tanker can disconnect from the FPSO and leave without oil spill.
Offshore loading gives the freedom to the owner of the field to deliver the oil where ever he wish. This can
be a good solution for a licence with more than one owner. The different owners may then use their own
refineries.
Only a few days in the winter season the weather is so severe that offshore loading is not possible. But
because of the storage capacity the production has to be reduced or stopped only a few times for waiting on
weather.
108
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
FPSO’s experience
I will now briefly mention some challenges experienced related to FPSOs.
•Physical protection like raised forecastle, wave breaking walls or local reinforcement of equipment and
structures,
•operational restrictions like reduced draft, change in static trim and restrictions with respect to personnel in
green water zones.
Green water is regarded by NPD as a safety risk for the following reasons:
Statements from the operators of the production vessels also indicate that green water may lead to shut
down of production as often as on an annual basis.
Last week, during the ISOPE conference in Seattle, a paper summing up our incidents, experience and views
on green sea was presented.
c) Flexible risers
One of the major challenges with regards to the flexible rises on a FPSO is how to perform a proper
inspection and condition evaluation.
The Norwegian regulations require annual inspection of all pipeline systems by the most suitable method
available at any time. The inspection of flexible risers on FPSO’s is made very complicated by the turret, the
risers guide tube and the end fittings. In addition flexible risers have a complicated composition with different
layers and materials making methods for inspections a challenge. There are at present no proven methods
for inspection, but a few methods are close to be accepted.
d) DP/collision
An FPSO was hit by a shuttle tanker this year. Damages to the FPSO were limited to local dents at the aft
end and the flare tower. The collision was caused by a combination of three factors onboard the shuttle
tanker; a small error in the DP logic and/or erroneous operation of the DP system together with lack of
awareness.
e) Coating
Shortly after arrival at the field in the North Sea, extensive c racking of topside coating was revealed on an
FPSO. Cracking, as much as 60 per cent in extent, was observed on piping, structures and auxiliary
equipment in three modules.
The phenomenon has been discovered at several installations, bot h off- and onshore, coated with similar
coating and thereby representing a major challenge in respect of maintenance. The main reason for the
cracking has not been identified yet.
109
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
f) Fatigue
A joint industry research project regarding fatigue capacity int ernally in FPSO hulls is being headed by The
Norske Veritas in Norway. Since FPSOs in general are supposed to remain offshore without interruption as
compared to ordinary ships which can be docked every 5 th year, it is important to prevent occurrence of
fatigue cracks in the internal details of FPSO hulls. The projec t started in 1998, and the objective is to
calculate fatigue lives for various connections and verify the c alculations by tests. Thus unfortunate shapes
of connections can be avoided.
And as the next speaker is from the Health and Safety Executive in UK, there is to say that we have a close
cooperation with HSE.
110
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Peter J. Mills
United Kingdom
Health and Safety Executive
111
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
“SUCCESSFUL REGULATORY
PRACTICES AND
EXPERIENCES”
Peter J Mills
HSE Offshore
Division’s Mission Statement
112
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Successful Regulatory
Practices and Experiences
Case specific
§ Safety Case Assessment
§ Inspection
§ Investigation of Accidents and
Incidents
§ Enforcement
113
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
§ Representational Influence
§ Codes and standards (API, ISO)
§ Industry Associations (UKOOA, MCA,
NPD)
§ Stake holders
§ Papers and open reports
§ Research
114
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
UK FPSOs 204
61ºN
Schiehallion
Petrojarl Foinaven
Gryphon
13 15 16
Petrojarl 1
Captain North Sea Producer
Bleo Holm Alba
21 22
Glas Dowr
Anasuria
Triton Banff
Curlew
Berge Hugin
29 30
Uisge Gorm
39
110
Liverpool Bay
50ºN
C08380R\01\067U 0º 4ºE
Anasuria
Liverpool Bay
Alba FSU
Gryphon A
Triton
Bleo Holm
Glas Dowr
Berge Hugin
Curlew
Captain
Uisge Gorm
Petrojarl Foinaven
Petrojarl 1
Ramform Banff
115
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
Major
(12)
Major = Hospitalisation accidents
O3D
O3D = Over 3 days off work
(66)
DO = Dangerous occurrences
DO
(182)
116
FPSO Workshop Proceedings: Presentations June 7, 2000 - Session I: Invited Speakers
Houston, TX
UK FPSO Experience
117