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

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF
February 2, 2005

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Different types of Floating Units

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF
February 2, 2005

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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

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF
February 2, 2005

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FPSO
FPSO = Floating Production Storage & Offloading

FPSO Girassol, Angola, Total

Asgard A, Norvway, Statoil

Bertrand LANQUETIN - DGEP/TDO/LSO/SSF
February 2, 2005

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FSO FSO = Floating Storage & Offloading FSO Pathumabaha.DGEP/TDO/LSO/SSF February 2. 2005 8 . PTTEP ex-FSO15 Domy. Congo. 2005 7 FG(P)SO FG(P)SO = Floating Gas (Production) Storage & Offloading N'Kossa NKP et N'Kossa 2. Total Bertrand LANQUETIN . Nigeria.DGEP/TDO/LSO/SSF February 2. Gulf of Thailand. Total (decommissioned) Bertrand LANQUETIN .

Norway. 2005 10 .SemiSemi-Submersibles Asgard B.DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2. Total Bertrand LANQUETIN . 2005 9 TLP TLP = Tension Legs Platform TLP Magnolia. Conoco TLP Matterhorn. Statoil Bertrand LANQUETIN . USA. USA.

typhoons. production system. ChevronTexacco Bertrand LANQUETIN . currents • Construction and installation cost Bertrand LANQUETIN . 2005 11 Choice of the Floating Units Governing parameters: •Water depth • Development requirements Storage capacity. USA. Field life duration.DGEP/TDO/LSO/SSF February 2. 2005 12 . waves .Spars Genesis spar.DGEP/TDO/LSO/SSF February 2. production rate • Metocean conditions Extreme return conditions.

DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2. 2005 14 . 2005 13 Forecast for 20032003-2007 • FPSO • FSO • Semi-submersibles • TLP • Spars : : : : : 50 units 34 units 15 units 13 units 11 units Bertrand LANQUETIN .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 x 78 FPSO x 34 Semi-Sub x 6 Spars x 13 TLP Bertrand LANQUETIN .

Nigeria (Shell) Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. conventions : API ISO ISGOTT OCIMF. Spain (Shell) N'KOSSA NKP 1996 : Concrete barge for gas production. Congo (Total) FLNG Barge project . Angola (Total) CASTELLON DELTA 1977 : First FPSO.DGEP/TDO/LSO/SSF February 2. … • Class rules (if classed) Bertrand LANQUETIN . norms. 2005 15 International and National rules • International rules (IMO) : SOLAS and ISPS (*) MARPOL (*) MODU ILLC ISM • National rules : flag if any government regulations • Standards. 2005 16 .History of FPSO DALIA Future FPSO.

2005 18 . however: • General specifications can be given to engineerings. age • Exploitation. marine operations Organisation purposely set-up: • Marine experts • Transverse multi-disciplinary structure “Groupe Supports Flottants” Bertrand LANQUETIN . … They cover: • Design.DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2. integrity. 2005 17 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 • • Bertrand LANQUETIN . contractors.Company Referential (Total E&P) Referential is mandatory worldwide: HIERARCHY OF COMPANY RULES & SPECIFICATIONS • Internal to Company. yards.

Hull and structure Bertrand LANQUETIN . Total.DGEP/TDO/LSO/SSF February 2. Total. 2005 20 .DGEP/TDO/LSO/SSF February 2. 2005 19 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. Nigéria FPSO Girassol. Angola Bertrand LANQUETIN .

2005 Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. 2005 21 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 m² 193 315 m² > 300 000 m 22 • Weight • Production • Type • Mooring lines CONSTRUCTION ANCHORING TOPSIDES • External coating : • Tank coating : • Cables : February 2. Norway Bertrand LANQUETIN . Statoil.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.DGEP/TDO/LSO/SSF .

DGEP/TDO/LSO/SSF February 2.Girassol example Bertrand LANQUETIN . 2005 23 Girassol Bertrand LANQUETIN . 2005 24 .DGEP/TDO/LSO/SSF February 2.

... Example of corrosion in a ballast tank Bertrand LANQUETIN . walls and bulkheads. … Consequences ? Cracks due to weakening of the structure. Causes ? Shipyards more used to ship design. welds.… 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 Bertrand LANQUETIN . 2005 26 .DGEP/TDO/LSO/SSF February 2. 2005 25 Problems usually encounted: encounted: fatigue of structures Where ? Stiffeners. ... steel wastage. Difficult and expensive to repair at sea. in a F(P)SO efforts and behaviour is different.DGEP/TDO/LSO/SSF February 2. bulkheads. reinforcements. bad quality or damaged coating. weakening of the structure. ballasts et side shell compartments Causes ? Corrosive atmosphere.Problems usually encounted: encounted: corrosion Where ? Mainly in tanks.… Metocean conditions at the anchoring location Frequency of loading & discharging Consequences ? Fatigue cracks.

corrosion. cracks. turret..Problems usually encounted: encounted: chock & collisions Where ? Side shell Causes ? Support vessels moored alongside or container handling Consequences ? Deformations.2001) FPSO Asgard A et her protection panels (white) Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2.. weakening of the side shell structure. removed from service in Spring 2003 Bertrand LANQUETIN . topside structures. FSO XV Domy. UK Source : analysis of green water suceptibility of FPSO/FSU on the UKCS (Bomel Ltd .DGEP/TDO/LSO/SSF February 2. . 2005 27 Problems usually encounted: encounted:« Green Waters » Where ? Bow. 2005 28 . equipment loss Protection du touret de Schiehallion. deck equipment Causes ? Difficult to model the greenwater and difficult to design the bow shape accordingly Consequences ? Damages.

DGEP/TDO/LSO/SSF February 2. 2005 30 . uneasy maintenance • The turret can be disconnectable to escape typhoon (ex.DGEP/TDO/LSO/SSF February 2. 2005 29 External turret • Weathervanning of the F(P)SO « facing » prevailing metocean conditions • Rather expensive system.Mooring / Anchoring Bertrand LANQUETIN . China sea) Bertrand LANQUETIN .

2005 31 Fixed Mooring : spread mooring • Simple system . uneasy maintenance • Number of risers limited (say 20 to 40) • Example of use: North Sea Bertrand LANQUETIN .Internal turret • Protection of the turret and risers/umbilicals against the climatic conditions • Expensive system.DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2. 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 Bertrand LANQUETIN . 2005 32 .

2005 33 Classical anchor Only horizontal traction is permitted on the anchor Bertrand LANQUETIN . 2005 34 .SEPLA anchor Allows vertical tension component on the anchor Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2.

2005 35 Mooring line : chain • Unexpensive because widely used • Corrosion and fatigue leading to safety coefficients above 10 • Low resistance in torsion • Heavy linear weight.DGEP/TDO/LSO/SSF February 2. not compatible with deep water locations Bertrand LANQUETIN . 2005 36 .DGEP/TDO/LSO/SSF February 2.Suction anchor Bertrand LANQUETIN .

2005 37 Mooring line : composite • Light material suitable for deep water locations • Subject to wear in case of friction Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2.Mooring line : cables Bertrand LANQUETIN . 2005 38 .

connectors Causes ? Design in fatigue not always mastered.DGEP/TDO/LSO/SSF February 2. …) difficult to inspect Consequences ? Difficult to repair in deep water locations. 2005 40 . taut. in case of breakout. cables.DGEP/TDO/LSO/SSF February 2. synthetic lines. the offset is greater and may be critical (risers) FPSO Girassol with offloading buoy Bertrand LANQUETIN .Mooring line configuration: taut. 2005 • reduced offsets of the floating unit • Requires anchors accepting vertical tensions 39 Problems usually encounted: encounted: anchorings Where ? Chains. catenary (or semisemi-taut) taut) Catenary : Taut lines : • unexpensive • Important offsets of the floating unit Bertrand LANQUETIN . lines and components (connectors.

Production offloading Bertrand LANQUETIN . 2005 41 Offloading on buoys Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. 2005 42 .DGEP/TDO/LSO/SSF February 2.

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 Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. 2005 43 SideSide-byby-side offloading • Risks during manœuvre of the export tankerwhile berthing alongside the FSO (not recommended for FPSO) • Duration of the manoeuvres Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. 2005 44 .

how? Bertrand LANQUETIN . access to databank through a network system. 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. where. 2005 46 .DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2. reporting Accidents : got the best reaction Inspection & Maintenance : what.Needs for an Integrity Management of Floating Units • • • • • • Continuous follow-up of the structure and moorings Inspection. 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 Bertrand LANQUETIN .

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 Bertrand LANQUETIN . 2005 47 FEM model : SESAM (example ) (example) Model of various structures Assembly of structural models SESAM Structural analysis Fatigue calculation Visualisation of the results Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. 2005 48 .DGEP/TDO/LSO/SSF February 2.

2005 49 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 Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2. 2005 50 .DGEP/TDO/LSO/SSF February 2.FEM model: model: VeriSTAR (example) example) Hull model VeriSTAR Hull FEM calculations Fine mesh for critical details and fatigue calculation Bertrand LANQUETIN .

DGEP/TDO/LSO/SSF February 2.DGEP/TDO/LSO/SSF February 2.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 Bertrand LANQUETIN . 2005 52 . 2005 51 EXAMPLE OF SEMANTIC AND 33-D MODEL (FOR EASY NAVIGATION THROUGH THE DATABASE) 3-D model Bertrand LANQUETIN .

RISK OF COLLAPSE. 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.DGEP/TDO/LSO/SSF February 2.ASSET DATA FOLLOWFOLLOW-UP: EXAMPLE OF DATA RELATED TO CLASS / REGULATION FOLLOWFOLLOW-UP Flagging system (colours) when inspection is overdue Bertrand LANQUETIN . EVALUATION OF FINDINGS AND MAINTENANCE DECISION) • THE "RBI“ TOOL (RISK BASED INSPECTION): ƒ INCORPORATES THE NOTION OF “ACCEPTABLE RISK” (FATIGUE LEVELS. DEGRADATION OF THE ANTI-CORROSION COATING. 2005 54 . AND COST) ƒ DETERMINES / ADJUST THE INSPECTION INTERVALS ƒ DEVELOPS AND STRUCTURES THE INSPECTION PLAN (EQUIPMENT RANKING BY CRITICALITY) Bertrand LANQUETIN .DGEP/TDO/LSO/SSF February 2.

Economy Probability of Failure Materials/Environment and Strength Risk evaluation per component Inspection and testing Execution & Reporting Inspection Management Inspection Plan Inspection details.DGEP/TDO/LSO/SSF February 2. logistics Inspection Programme Method. Location Bertrand LANQUETIN . 2005 56 . 2005 55 ACTIVITIES UNDERTAKEN IN A RBI APPROACH Inspection data evaluation Analysis of results Inspection Philosophy Inspection Systematics Acceptance criteria RBI Consequence of Failure Safety. Timing. Coverage. planning.INSPECTION MANAGEMENT AND DECISION SUPPORT TOOL (EXAMPLE) Bertrand LANQUETIN . Environment.DGEP/TDO/LSO/SSF February 2.

DESIGN) ƒ PREPARE THE BASIS OF THE INSPECTION PLAN REEVALUATION ƒ EVALUATE THE CONSEQUENCES OF THE INSPECTION FINDINGS ("FRACTURE MECHANICS". ALLOWS A RAPID AND RELIABLE RE-ANALYSIS IN ORDER TO: ƒ EVALUATE THE EFFECTS OF MODIFICATIONS / CHANGES (IN OPERATIONS. 2005 58 .PERIODICAL ASSESSMENT • FOLLOWS THE FIRST ASSESSMENT.DGEP/TDO/LSO/SSF February 2. ESTABLISH THE CUMULATED FATIGUE (BASED ON REAL HISTORICAL DATA) ƒ DOCUMENT THE LONGEVITY STUDIES Bertrand LANQUETIN . 2005 57 TYPICAL EXAMPLE OF A GLOBAL MODEL AND OF SUBSUBMODELS USED FOR A STOCHASTIC ANALYSIS Global model Sub-models Bertrand LANQUETIN . IS DONE YEARLY.DGEP/TDO/LSO/SSF February 2. …) ƒ COMPARE THE RESULTS OBTAINED FROM THE MONITORING WITH THE ANALYTICAL RESULTS (MODELS) ƒ EVALUATE THE EFFECTS / CONSEQUENCES OF THE FLOATING UNIT AGEING AND DEGADATION AND THE IMPACT.

WEATHER AND OPERATIONAL RESTRICTIONS. EMERGENCY RESPONSE SERVICE.DGEP/TDO/LSO/SSF February 2. 2005 59 THIRD PARTY ASSISTANCE COMPANY = SOFTWARES. 2005 60 .DGEP/TDO/LSO/SSF February 2. BALLASTING.EMERGENCY RESPONSE SERVICE (ERS) • ASSISTANCE SERVICE 24 HR/DAY IN ORDER TO PERFORM ALL NECESSARY CALCULATIONS AND ESTABLISH RECOMMENDATIONS RELATED TO: ƒ STABILITY / RESISTANCE OF THE FLOATING UNIT AFTER HULL OR MOORING DAMAGE ƒ STABILITY / HULL RESISTANCE IN TRANSITORY STAGES LIKE LIGHTENING. 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 Bertrand LANQUETIN . … Bertrand LANQUETIN . CARGO TRANSFER ƒ EXTREME CONDITIONS SURVIVAL IN DAMAGE STATE.

DGEP/TDO/LSO/SSF February 2.Cycle Asset Integrity Management / FLCM (Field Life • DNV Software : Cycle Management System for the database and web based system) • Lloyd's Register : • V.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 .Ships : • EM&I : Integrity Assessment of Floating Structures Through Life Condition Monitoring System (TLCM) Asset Integrity Management System (AIMS) Bertrand LANQUETIN . 2005 62 .DGEP/TDO/LSO/SSF February 2. 2005 61 END Bertrand LANQUETIN .

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