Professional Documents
Culture Documents
FPSO Operational Problems
FPSO Operational Problems
• 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
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
Moorings/DP
9%
(7)
Vessel SW/COW/Vent
Offloading System 10%
22% (8)
(17)
5
Number of Incidents
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
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
Survey Tool
Turret
(30 issues/problems reported)
Layout
(19 issues/problems reported)
• 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
Industry Challenges
• Hull & Marine (Major)
– Accommodation – need to increase accommodation levels for short
periods
• Caisson Systems (Major)
– Evaluation needed of practicality of using inboard mounted caissons to
deliver seawater direct
• Mechanical Handling
– Develop best practices for range of handling systems
• Hull Shape
– Learn for past experiences wrt bow shape
• Painting
– Need to develop painting technology and methods compatible with project
demands
• Thrusters
– Develop methods for removal and repair of thrusters
Industry Challenges
• Turret swivels/tie-backs
– Low cost method needed to upgrade swivel capacity and to pull in new
risers with minimum downtime
• Design Input from Operations
– Support operators providing input to design
• Operations and Support
– In Situ Repairs and Modifications Critical
– Need to revise all aspects of marine standards to account for minimum
maintenance and in-field repairs
• Process
– Need for work and an industry specification for moving separation
equipment
• Role of Vendors/OEM (Major)
– Need to secure post supply technical support and minimum performance
levels from suppliers
• Codes and Classification, Approvals and Safety Verification (Major)
– Need to tighten FPSO class specifications
The International Association of Oil & Gas Producers encompasses the world’s leading
private and state-owned oil & gas companies, their national and regional associations, and
major upstream contractors and suppliers.
Vision
• To work on behalf of all the world’s upstream companies to promote responsible and
profitable operations.
Mission
• To represent the interests of the upstream industry to international regulatory and
legislative bodies.
• To achieve continuous improvement in safety, health and environmental performance
and in the engineering and operation of upstream ventures.
• To promote awareness of Corporate Social Responsibility issues within the industry
and among stakeholders.
Objectives
• To improve understanding of the upstream oil and gas industry, its achievements
and challenges and its views on pertinent issues.
• To encourage international regulators and other parties to take account of the
industry’s views in developing proposals that are effective and workable.
• To become a more visible, accessible and effective source of information about the
global industry - both externally and within member organisations.
• To develop and disseminate best practices in safety, health and environmental
performance and the engineering and operation of upstream ventures.
• To improve the collection, analysis and dissemination of safety, health and
environmental performance data.
• To provide a forum for sharing experience and debating emerging issues.
• To enhance the industry’s ability to influence by increasing the size and diversity of
the membership.
• To liaise with other industry associations to ensure consistent and effective
approaches to common issues.
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