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FPSO Operational Problems: Don Smith OGP
FPSO Operational Problems: Don Smith OGP
• UK HSE Study
• Analysis of offshore accident statistics from 1996 – 2002 (6
years period):
– No fatalities
– 21 accidents involving hospitalisation
– 85 3-day off work
– 317 dangerous occurrences
Dangerous Occurrences for Floating
Production Systems 1996-2002*
Fire/Explosion Substance Collapse Positioning/Dropped
8% 3% 1% Object/Adverse
Weather
12%
Collision
2%
Lifting Machinery
8%
Pipeline
4% Diving Biological Electrical Pressure
Wells
0% 4% 5%
0% 1%
• Riser/Turret/Swivel
• Vessel SW/COW/Vent
• Offloading System
• Moorings/DP
• Collision/Stability
• Motion Related Incident
Distribution of FPSO Dangerous Occurrences
Moorings/DP
9%
(7)
Vessel SW/COW/Vent
Offloading System 10%
22% (8)
(17)
Wave Related Incidents (1995 – 2000)
5
Number of Incidents 4
0
1995 1996 1997 1998 1999 2000
Year
50
45
40
Accident 35
Rate 30
25
(per FPSO
20
installation) 15 All
10
5
0
96/97 97/98 98/99 99/00 00/01 01/02
Year
Comparison of Accident Rates
(per 100,000 Workers)
7000
6000
5000
Accident
Rate (per 4000
100,000 3000 All
Workers) FPSO
2000
1000
0
96/97 97/98 98/99 99/00 00/01 01/02
Year
A summary Report on FPSO Lessons Learned,
gathered from 4 Norwegian FPSOs – May 2002
• Layout (Critical)
– Layout of equipment a critical issue:
• Main generators too close to accommodation
• Poor mechanical handling solutions
• Exhaust and flare radiation problems
• Module overcrowding
• Poorly located vents
• Access and escape route problems
• Poor workshop and stores location
– Need to involve all stakeholder in planning layout
Project Management
(29 issues/problems reported)
• Compression (Critical)
– 2 of 4 FPSOs had serious compression problems (gas seal failures, repeated
bundle change-outs and cracked pistons)
– Need to consider benefits of larger scrubbers to provide a safety factor
against unknowns
• Compression (Major)
– Vibration from reciprocating compressors can be a problem
– Care needed in procurement of compressor
– Need to review noise and vibration levels
• Uptime Performance (Critical)
– Lack of fully objective data to access uptime performance
• Shuttle tanker/offloading (Major)
– Need to learn from good operational practices
Manning and Safety
(7 issues/problems reported)