Transcript Document

FPSO’s : NO TWO ALIKE
FPSO
PAST ISSUES AND
TYPICAL CLAIMS
Houston Marine Insurance Seminar - September 2012
Ted Miller, Charles Taylor Adjusting – Houston
EJM 21 Aug 1022
Review and Discussion Points
1. The early days (80’s): FPSO’s local conversions from existing tanker hulls
2. The condition of some early FPSO Tanker hulls and hull prospects
3. US GOM Fleet
4. Manufacturing issues
5. Mooring line issues
6. Umbilical Issues
7. Flexible Riser issues
8. Hull Issues
9. Topside process system issues
10. Loss of station keeping - major event
11. Repair and remediation costs
12. Wrap up
Zafiro Producer Early FPSO Conversion in Galveston and Portugal
Major ballast tank, bottom and steelwork repairs.
Operated Offshore Equatorial Guinea 1996
Jamestown – FPSO Early Production System - Kewit South Texas
Minimal hull repairs, built 1957 41,500 dwt.– heavy scantlings.
Early Production Vessel
Condition of tanker hulls for conversion
Condition of Tanker as FPSO conversion candidate is Critical
Extract :Australian Transport Safety Bureau Findings
The Kirki carried all necessary statutory safety certificates. Safety surveys had been carried out
within the schedules required by the relevant international safety conventions. The scheduling of
the Kirki's special five-year survey at 22 years, rather than at 20 years, was consistent with the
ship's survey program and within the rules covering the frequency of special surveys.
The defects in the life-saving appliances, fire-fighting equipment, cargo equipment and the
condition of engine room equipment were so numerous and of such a nature that the Inspector
cannot accept that they all developed over a short period of time.
The patching with canvas and the camouflaging of No7 tank lids was a deliberate attempt to
mislead any person undertaking a load line survey. It is not possible to determine when the lids
were patched, and it might not have been done with the knowledge of the owners or those on
board the Kirki on 21 July 1991.
Significant defects should have been observed during surveys by Classification Society;
inspections by the Oil Major Vetting and the Vessel managers and operators; and inspections by
the Port State Maritime Safety Authority.
The Classification Society was responsible for the issue of statutory certificates on behalf of the
Hellenic Republic of Greece. The procedures adopted by the Society during structural surveys
failed to identify the areas of localised corrosion. The condition of ballast tanks 13 and 14 together
with the number and nature of deficiencies in safety equipment, indicates that a number of surveys
over a period of time, including surveys that were conducted under international safety
conventions, were not performed effectively.
U S GULF OF MEXICO FLEET
U. S. GULF OF MEXICO
FPSO FLEET
Single FPSO Unit
Multiple moored FPU’s
US Gulf of Mexico HELIX PRODUCER 1
Ship Shaped Floating Production Unit FPU
Disconnectable Transfer System - DTS
Converted Ferry – Croatia in 2008
Topsides installed Corpus Christi Texas 2009
Operating Water depth 2,100ft
Deployed at Green Canyon 237 Phoenix Field (Ex Typhoon)
US Gulf of Mexico
BW Pioneer
First FPSO – Disconnectable
Converted in China and Singapore in 2010
Originally Double Hull 1992 Tanker
Operating Water depth 8,200 – Ultra Deepwater)
Deployed at Walker Ridge 249 Cascade and Chinook Fields
World Record Polyester Mooring Depth
12 (11+1 spare) lengths x 2.5km long x 800 tonne MBL Polyester Tethers. This is a
new world record for continuous lengths of polyester mooring tether.
MANUFACTURING ISSUES
• Modern analytical tools – get design /
specifications right
• Reliant on manufacturers to produce to
spec. and codes
• Operators however rely on QA-QC of
manufacturers and suppliers
• Onsite inspections by operator essential
• Reliance on 3rd party Inspectors
• Small issues – catastrophic events
MOORING LINE ISSUES
Many different designs, layouts and materials
More incidents likely as FPSO systems age
•
•
•
•
Chain lines – Steel
Wire Rope lines – Steel
Synthetic fiber rope lines – Polyester
Shackles, Links and Jewelry - Steel
• Relatively few manufacturers of large
diameter mooring components worldwide.
Steel Mooring chains and equipment
A chain system is only as good as its weakest link
Catastrophic Failures in Mooring Systems Possibly
Put Floating Structures at Risk
In early 2011, a single point mooring system for a deepwater Gulf of Mexico (GOM) project
failed at the chain. Based on the investigation of this event and a review of historical events,
BOEMRE is revising and re-issuing Safety Alert #259.
The investigation determined that a 6 ¾inch diameter, 862-pound chain link in the
tether chain had fractured and separated
near its butt weld. Analysis of the fracture
indicated that the chain link had a weld
repair and the fracture initiated in the
middle of the weld. Three links of the 24link tether chain were found to have weld
repairs.
Mooring Line Failure - 2
Brittle fracture caused by
reversible temper
embrittlement (RTE) during
shackle heat treatment
Tear in steel wire line sheathing
g
FPSO Sheathed steel wire rope Mooring Line
Installation vessel
deployment line
damaged HDPE
coating on mooring
line, exposing wire
• Can the cathodic protection reserve
cope over life cycle - No Cost
• Can local repair be carried out –
Minimal cost
• Must the rope to be replaced. –
• Very expensive repair.
Strand Ends being Prepared for Splicing
Strand Ends being Prepared for Splicing
Polyester Mooring Ropes
9 “Diameter Polyester outer sheath
Main Strands 8 triple 1-1/2 “ 4RH Lay and 4LH Lay
Main Strands 8 triple 1-1/2 “ 4RH Lay and 4LH Lay
Strand ends being prepared for splicing Eye to Link
Other mooring line Issues
Chain to Rope Transition Link misassembly which caused damage to
one link and line:
Are the other 9 links and lines “damaged” if their links wrongly assembled?
Deepwater and Ultra DW - Lead Time for replacement components
Very limited manufactures, propriety information, installation spread availability,
unique designs, new engineering for repair procedures, timing and logistics
Umbilical Issues
Damage due to design detail and unexpected delay
Flexible Risers and flowlines.
Flexible Manufacture
Carcass formation
Flexible in carousel
>
<
Sheath extrusion (twice)
Insulating & taping
<
> Pressure armouring >
Axial armouring
Flexible Risers and flowlines.
Pressure Armor Pitch Handling or operational errors can cause unlock and Failure
• .
Leak
•
Leak Detection – Line or end fitting
Pressure Armour Pitch - Errors cause unlock & failure
39
RISER CORROSSION
Hull Issues
• External Hull Sacrificial - Anode Loss
in Transit
• Paint peeling on side shell – Damage or
Warranty
• Ship Hull Bilge keel damage Cause
under investigation
• Sterntube seals leaking – Damage or
maintenance issue
Topside Industrial Process Systems
• Gas Turbine Gas generator blade - Accelerated Corrosion
• Flare Tower insulation loss – manufacturing defect
• Blade keeper parting FPSO off India – OEM Facility in
USA
• Multiple Gas Turbines to OEM in Houston
• Compressor module FPSO North Sea - although built and
installed as module repairs required entire compression unit
to be removed – Massive increase in repair cost
Gas Turbine – Gas generator blade damage
•
Hot corrosion caused by combination of sodium & sulphur
•
Sulphur from high sulphur diesel
•
Sodium from seawater – air intakes ingest spray.
•
Question on other units :
•
Aggressive deposits form before blade material corrodes
•
Is contamination damage &/or is dismantling, cleaning, rebuilding &
retesting covered
??
Fire on gas compression module
Entire unit has to be removed for repairs
• Loss of Station keeping
• FPSO with central turret / drag chain system
• FPSO thruster operation is required to maintain heading
• Multiple risers umbilicals / flowlines
• Failure of heading / station keeping & mooring systems
• Brief electrical power failure
• Excursion beyond dynamic riser & umbilical operating limits
First FPSO Full Field Development
‘Gryphon’ North Sea 1993
Loss of Station keeping - Major Event
• Extensive damage to risers, subsea facilities and turret
• Extended repair period due to specialist equipment
• FPSO has to be removed to drydock for repairs
• Field restoration expensive
• Very large LOPI Claim - well in excess of the Physical Damage
Costs - Construction Examples
•
•
•
•
•
•
•
•
Flexible Riser Failure
Mooring Line Failures
Turret Weld Failures
Bilge Keel Cracks
Thruster Seal Failure
Fire Main Leaks
Turbine Corrosion
Anode Failures
9,000,000 - 25,000,000
17,000,000 - 52,000,000
12,000,000
20,000,000
12,000,000
6,000,000
5,000,000
10,000,000
Costs - Operating Examples
• Loss of Submerged Mooring Buoy
LOPI
• Loss of Station Keeping
LOPI
• Fire in Gas Compression Module
LOPI
• Failure of Quick Disconnect Turret
LOPI
2,000,000
100,000,000
300,000,000
500,000,000
20,000,000
150,000,000
25,000,000
250,000,000
WRAP UP