OPERA Lunchtime Briefing. Mooring Integrity Offshore O&G. January 2012 Alastair Trower President

Transcription

1 OPERA Lunchtime Briefing Mooring Integrity Offshore O&G January 2012 Alastair Trower President

2 Today s agenda Brief Company Introduction Mooring System - Failure History Consequences of failure Industry response Rules, guidance and regulation Operator s Philosophy a review of experience Inspection capabilities technology overview Suggested Inspection Methodology a future plan? Conclusions/Questions

3 Welaptega Marine - What do we do? Offshore, Underwater Inspection Regular Inspection of underwater systems Ensures profitable operation while reducing environmental and human risk

4 What do we do? Emergency response (OSM!) Immediate, high value intelligence What shape? Remove/repair/rebuild?

5 Global Impact Full Operating Base Sales Base Project Area Expected 2012/13

6 Mooring System Failure History Maersk Oils Alpha Gryphon FPSO February 2 nd Force 8 gale Catastrophic mooring failure

7 18,000 Barrels per day 18 months production Cost of Recovery $800M Lost Opportunity? 40% drop in share price

8 Cascade Chinook 2,496m water depth 5 FSHR riser towers BOEM Go 19/3/2011 Failure 23/3/2011 Single chain link First Oil delay

9 Recent Failure History Banff FPU Apollo Spirit FSU Northern Producer Dalia FPSO - Captain FPSO Chain run out Nan Hai Sheng Li 7 lines/3 Risers Balder Fairlead notching 70% of UK Fleet 3 have had multiple incidents 4 have had multi-line failures Mean time to failure = 7.6 years Systems designed for 25+ years with safety factor Nan Hai Fa Xian 4 Lines

10 Consequences of failure Production loss $1.1m/day/10k BOEPD Operational Cost of situation recovery and affect on ongoing Opex Insurance Premiums Human Risk Environmental risk Shareholder value and confidence

11 Regulatory Background UK - HSE Norway - PSA GoM - BOEMRE Australia - NOPSA West Africa SE Asia IRF Meets every 2 years

12 Classification Societies Unified Requirements under IACS Each society has their own broad based rule set Relatively non-prescriptive Open to interpretation Don t take into account recent trends Judgement made at the local surveyor level

13 Operator s Philosophy Majors Generally take M.I. seriously Business Unit structure makes a global approach difficult Localised approach based on regime in place Independents Linear relationship! Contract Fleet MI does not fit into business plan Class is seen as the absolute maximum rather than the minimum

14 Degradation Mechanisms

15 Technologies Qualitative 3 Dimensional Video General Visual Inspection of all components Quantitative Rope Measurement 360 video record of rope surface and OD measurements Chain Measurement Link length and double diameter dimensional checking Geometric Reality 3 Dimensional Modelling to assess condition of damaged components

16 Real-time HD 3D Video Real-time HD 3 Dimensional Video Cameras rated to 4000m Topside viewing suite Provides high quality, distortion free permanent visual record Identify: Pitting Growth Loss of material Corrosion Cracking

17 Optical Caliper Controls to ROV 4 x Video Cameras Acetyl Framework

18 Dimensions measured

19 Chain Baseline Repeatable measurement process (In-air/In-water) Rapid data (1-2 seconds per link) Identifies potential weakness in manufacturing process Allows data build up over time Chain 1 Chain 2 Chain 3 Chain 5 Chain

20 Rope Measuring System (RMS) Continuous automated cleaning, inspection and measurement of Wire and Fibre mooring rope Fibre identification of surface damage & internal broken strands Wire identification of surface damage & internal corrosion Regular compliance Inspection Post-Installation Baseline Post-installation damage inspection

21 RMS Inspection What RMS measures Four video cameras Continuous automatic diameter measurement Continuous 360 degree footage archive Identifies changes in diameter at <0.5mm resolution

22 Geometric Reality 3D Modelling Dual high resolution digital stills cameras Synchronous triggering Variable LED Lighting

23 Geometric 3D Modelling 3 Dimensional Modelling from 2D Stills Geometrically accurate models Exportable into many formats Uses: Post Incident Problem Identification and Diagnosis Repair design Structural Integrity Analysis

24 Geometric 3D Modelling

25 Geometric 3D Modelling

26 Corroded Chain Link

27 Mooring Components Camera Positions

28 Mooring Components Point Cloud Point Cloud with marker magnet

29 Mooring Components - Analysis Cross-Section 8 Area = 7828 mm 2 Cross-Section Locations (Nominal Cross-Section Area of 108mm Chain=9159mm 2 )

30 Answer the question

31 Post-Incident Case Studies 3 Dimensional Modelling from 2D Stills Geometrically accurate models Exportable into many formats Uses: Post Incident Problem Identification and Diagnosis Repair design Structural Integrity Analysis

32 Chain Anomalies

33 Chain Anomalies Mesh with Photo Overlay Meshed Point Cloud

34 Chain Anomalies Misalignment Narrowing Cosmetic Flat Spot

35 Installation damage GoM Spar WROV Lift wire nicked sheathing 10 days before first oil!

36 3D Modelling deployed Photographs taken to construct geometrically accurate model of damage Dimensional metrics reported Regulator agreed to line swap out deferred until after first oil $20-30 Million saving for the client

37 Inspection Methodology New Developments Prior to Installation Design verification MIRR where, what to inspect for Build-in inspection plan (and budget) at project phase to feed in to Operations phase Dry Baseline to validate as delivered components Upon Installation Post-Installation inspection and wet baseline Identify and quantify Installation damage and follow through Change of ownership/insurer Due diligence Data validation/verification

38 During Service Life Regular Inspection Installed Fleet Annual Program Mobilise relevant technology based on design and past findings Source / Design technology based on experience and new requirements Feed intelligence into dynamic fatigue model Five Yearly Requirements Regulatory life cycle inspection 5 yearly or annual Driven by class requirements Driven by regulation Prescriptive nature requires specific measurements

39 Regular Inspection - Annual Inspection General Visual Inspection using HD 3D Video Focus on areas of known issues previous inspection history and hot spots Anomaly register for later reporting/follow-up/escalation Cleaning Target areas of chain and wire measurement areas Quantitative Chain Measurement in groups Rope Measurement selected lines Anomalies Capture 3D Modelling data (2D Stills) of noted anomalies Post process required anomalies into models

40 Design Phase Estimated / Ball Park Costs Engineering Support Inspection planning and budgeting Day rate engineering on as needed basis Manufacturing Verification C. $200k Post-Installation Baseline C. $300k Annual Program C. $ K per annum

41 Five year costs Estimated / Ball Park Costs Continuous Mooring Integrity Program = C. $2-3m Single line failure $5-7m Multi-line failure Recovery Cost = c. $5-700m LOP = $5-700m Comparison with and/or Impact on premiums?

42 Deeper Water Complications Increased costs of operation Greater technical risk eg. Cascade Chinook Higher technology complication Storm Frequency 10% Increase in wind speed 7% increase in wave height

43 Mooring Systems are here to stay Conclusions Increasing complication with depth and new materials Failures occur in all systems and in non-designed manner Increase in intelligence is mandatory due to inevitability of long term failure Fire and Forget Engineering doesn t work Designers need to get more involved in Lifecycle Management Cost and risk exposure is increasing Changing climate Deeper water Fleet is aging

44 Inevitable degradation Conclusions The fleet is aging Planned maintenance backlogs are worsening Demographics are playing a strong role Majors under increasing scrutiny to: protect investment standardise approach Insurance industry has an opportunity to derive more from: Due diligence Compliance related inspection

45 Contact Details Alastair Trower President Welaptega Marine Limited T. +1 (902) To download the Oil and Gas UK Mooring Integrity Guidelines:

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