Asset Integrity For Floaters

Transcription

1 eni Ss.p.aA. upstream & technical services Master in Petroleum Engineering and Operations Asset Integrity For Floaters Author: Oladejo Oluwasegun San Donato Milanese October 2014

2 Master in Petr.Engineering & Operations Stage Subject Asset Integrity For Floating Production Units Author Oladejo Ganiyu Oluwasegun Company Tutors Maurizio Lanzo Domenico D Acierno University Tutor Prof. Francesca Verga Division eni S.p.A. Upstream & Technical Services Dept. Floaters/Logis services 2 San Donato Milanese October 2014

3 List of Content Stage Subject Asset Integrity For Floating Production Units Project Scope Introduction to FPSO The Floating fleet under direct operatorship Applicable rules and standards for FPSO management Asset Integrity Introduction Asset Integrity management for FPSO Conclusions services 3

4 Project Scope Introduction to the floating production units with a special focus on floating production storage offloading (FPSO). Preliminary Study of applicable rules and standards to manage the integrity of an FPSO Synthetic research to develop an asset integrity system for FPSO services 4

5 List of Content Stage Subject Asset Integrity For Floating Production Units Project Scope Introduction to FPSO The Floating fleet under direct operatorship Applicable rules and standards for FPSO management Asset integrity Introduction Asset Integrity Management for FPSO Conclusions services 5

6 Introduction To FPSO A floating production, storage and offloading (FPSO) unit is a floating vessel used by the offshore oil and gas industry for the production, processing of hydrocarbons and for storage of oil. An FPSO vessel is designed to receive hydrocarbons produced by itself or from nearby platforms or subsea template, process them, and store oil until it can be offloaded onto a tanker or, less frequently, transported through a pipeline. services 6

7 Introduction to FPSO: Drivers The FPSO concept allows oil companies to produce oil in more remote areas and in deeper water than would have been economically possible with other technology, like fixed piled structures. The ability to refurbish or upgrade the FPSO to tie-in additional fields or use in other projects; and The mobility of the FPSO and relative ease of decommissioning. The FPSO is used to recover petroleum discovered and developed by a company (or more commonly a joint venture) under an exploration permit and production license. services 7

8 List of Content Stage Subject Asset Integrity For Floating Production Units Project Scope Introduction to FPSO The Floating fleet under direct operatorship Applicable rules and standards for FPSO management Asset integrity Introduction Asset Integrity Management for FPSO Conclusions services 8

9 Floating units in Eni Business services 9

10 The Floating Fleet Under direct operatorship: FIRENZE FPSO Firenze FPSO was built by saipem in the year 1989 in jugoslavia, it was converted from a trading Tanker vessel to FPSO in 2011 in Dubai. The FPSO was bought from saipem in she is presently in operation in the Aquila field in offshore Brindisi, Southern Adriatic Sea. Italy. It has a production capacity of 12,000 barrels per day. Design flowrates: Oil production Liquids (Oil + water) Gas production Gas lift Water production Starage capacity: 12,000 BPD 18,000 BPD 205,000 Sm3/d 300,000 Sm3/d 1,500 Sm3/d 700,000 bbl Vessel: - Aframax type - Double Hull DWT m Length - 42,48 m Breadth - 20,70 m Depth - Accommodation for 56 people services 10

11 List of Content Stage Subject Asset Integrity For Floating Production Units Project Scope Introduction to FPSO The Floating fleet under direct operatorship Applicable rules and standards for FPSO management Asset integrity Introduction Asset Integrity Management for FPSO Conclusions services 11

12 Applicable rules and Standards for FPSO Management International rules and regulations (IMO convention, ISM/ISPS, MARPOL, SOLAS) Coastal State Regulations Flagging Classification of Society services 12

13 Asset Integrity Introduction Stage Subject Asset Integrity For Floating Production Units Project Scope Introduction to FPSO The Floating Fleet Under Direct Operatorship Applicable rules and standards for FPSO management Asset integrity Introduction Asset Integrity Management for FPSO Conclusions services 13

14 What is Asset Intergrity? An asset has integrity when it is operated and maintained so that the combination of the likelihood of failure and the consequence of failure makes the risk to people, to the environment, and to the company as low as reasonable practical. services 14

15 List of Content Stage Subject Asset Integrity For Floating Production Units Project Scope Introduction to FPSO The Floating fleet under direct operatorship Applicable rules and standards for FPSO management Asset integrity Introduction Asset Integrity Management for FPSO Conclusions services 15

16 Asset Integrity Management(AIM) for FPSO The Primary concern of the FPSO asset integrity management is to maintain the asset in a fit-for-service condition while extending its remaining life in the most reliable, safe, and cost-effective manner. In addition to regulatory and company requirements services 16

17 Asset Integrity Management(AIM) for FPSO Out of the typical asset integrity issues for conventional production plant (topside), the distinctive features of floating production unit can be grouped under the headings: Hull structural integrity Hull watertight integrity Station keeping Turret/swivel Marine systems services 17

18 AIM for FPSO-Hull Structural Integrity services 18

19 AIM for FPSO-Hull Structural Integrity The bow-tie diagram below outlines what is considered the typical/minimum prevention and mitigation barriers that are expected to be in place along with additional recommended barriers required to understand the integrity of the installation and to manage the ageing of the hull structure services 19

20 AIM for FPSO-Hull Structural Integrity Strength Fatigue And Damage: Elements Ageing Mechanism Controls Life Extension Actions Life of field Assesment: I. Strength and stability Analysis II. Fatigue Analysis Ship type hull structure Increased Field Life Change in Loading/ Offloading pattern Corrosion Cyclic loading Cumulative impact of Peak loads Modifications.- - Increased structural loads - Collision damage - Corrosion Structural Inspections to Verify performance against analysis results. Structural inspections Structural anomalcy management. Loading/ offloading procedure Structural re-evaluation using up to date methods. Fatigue analysis based on historical load, heading and metocean data. Verification of analysis against inspection findings. Robust integrity management strategy. Increased Inspection frequency and scope. Re-analysis to improve understanding of loads. Understand how to carry out repairs - Vibration services 20

21 Corrosion Protection: AIM for FPSO-Hull Structural Integrity Elements Ageing Mechanism Controls Life Extension Actions Impact damage Anti fouling inspection Corrosion threat assessment. Marine growth assessment. Anode renewal. External Hull Anode depletion Structural behaviour ICCP testing. Evaluate ICCP system Performance using inspection findings and review Coating disbondment operating procedures Anode Surveys Traffic and impact damage, Coating Inspection, Corrosion threat assessment, Erosion. Anode surveys, Anode renewal, Coating disbondment, Tank Washing, Review Coating suitability for current Change of tank,service/ Demucking. service, maximum water levels, Operating philosophy, Increased in service Coating repair and renewal procedures. temperature, Internal Hull Scale/sludge build up. Topsides structures including:- Flare tower, cranes, process modules, turret, towing and mooring arrangements, offloading system, accommodation. Coating disbondment Coating inspection Corrosion threat assessment, Review existing coating specifications and performance to establish inspection/repair/replacement philosophy services 21

22 AIM for FPSO-Hull Watertight Integrity services 22

23 AIM for FPSO-Hull Watertight Integrity Elements Ageing Mechanism Controls Life Extension Actions Coating, Procedures to inspect and Sea chests and stub pieces Corrosion Inspection maintain(filling of blanks etc) Obsolescence assessment, Valves Corrosion Inspection Modifications, Erosion.. Testing Valve replacement Testing, Obsolescence assessment, Hydraulics and control systems Corrosion, Physical damage Inspection Corrosion assessment, Spares. Remote valve Operations Corrosion Inspection Obsolescence assessment, Corrosion assessment, Spares. services 23

24 AIM for FPSO-Station Keeping services 24

25 AIM for FPSO-Station Keeping services 25

26 AIM for FPSO-Station Keeping Elements Ageing Mechanism Controls Life Extension Actions Spread moored systems including: mooring attachment points and riser Increased mooring loads due to modifications, Changes in metocean Inspection/NDT Revise Mooring analysis conections data. Heading control and mooring Assistance Wear obsolescence Inspection/NDT, Maintenance, Head monitoring Revise operating methods and controls, Revise system Performance, Reliability and spare availability. services 26

27 AIM for FPSO-Turrets And Swivels services 27

28 AIM for FPSO-Turrets And Swivels services 28

29 AIM for FPSO-Turrets And Swivels Turret: Elements Ageing Mechanism Controls Life Extension Actions Systems including:- Increased bearing Inspection/NDT, Verify heading analysis Mooring attachment loads due to wear, Lubrication, assumptions with historic arrangements, bearings, drive Increased friction, Swivel torque records(weather vanning units Increased loads to monitoring, only), additional windage Grease analysis, Review bearing/elastomer arising from Bolt torque suitability for anticipated service modifications. checks, life loads. Elastomer Develop off the shelf work inspections, packages for repair. Bearing inspections-wear down, Head monitoring. services 29

30 AIM for FPSO-Turrets And Swivels Swivel: Elements Ageing Mechanism Controls Life Extension Actions Systems including:- Increased bearing Inspection/NDT, Verify heading analysis Mooring attachment arrangements, bearings, drive loads due to wear, Increased friction, Increased loads to Lubrication, Swivel torque monitoring, assumptions with historic records(weather vanning units only), additional windage Grease analysis, Review bearing/elastomer arising from Bolt torque suitability for anticipated service modifications. checks, life loads. Elastomer Develop off the shelf work inspections, packages for repair. Bearing inspections-wear down, Head monitoring. services 30

31 AIM for FPSO-Marine Systems services 31

32 AIM for FPSO-Marine Systems Cargo Systems: Elements Ageing Mechanism Controls Life Extension Actions Cargo pumps Cargo pipework, couplings and valve Control systems (hydraulics,actuators,instruments) Slop tank pipework and valves Cargo washing systems and guns Wear, Erosion, Obsolescence. Obsolescence, Corrosion/Erosion, Seal/Seat failure, Cyclic stresses, Pipe support failure Obsolescence, Corrosion, Mechanical damage, Hydraulic contamination. Obsolescence, Corrosion/Erosion, Seal/Seat failure, Cyclic stresses, Pipe support failure Vibration, Leakage, corrosion Offloading systems including hose reel) Wear, Corrosion, Mechanical damage, Elastomer degradation Condition Monitoring, Regular maintenance. Inspection. Function testing, Visual inspection, Hydraulic oil sampling/testing. Inspection. inspection inspection, hawser load history and sensor calibration, corrosion protection. Obsolescence assessment. Fatigue assessment, Corrosion assessment. Review of performance, and reliability and redundancy of system. Review spare availability Corrosion assessment Review spares availability Obsolescence assessment, Fatigue assessment. services 32

33 Inert Gas: AIM for FPSO-Marine Systems Elements Ageing Mechanism Controls Life Extension Actions Wear, Condition Monitoring, Cargo pumps Erosion, Regular maintenance. Obsolescence assessment. Obsolescence. Obsolescence, Cargo pipework, couplings and valve Corrosion/Erosion, Seal/Seat failure, Inspection. Fatigue assessment, Corrosion assessment. Cyclic stresses, Pipe support failure Obsolescence, Function testing, Control systems (hydraulics,actuators,instruments) Corrosion, Mechanical damage, Hydraulic contamination. Visual inspection, Hydraulic oil sampling/testing. Review of performance, and reliability and redundancy of system. Review spare availability Obsolescence, Slop tank pipework and valves Corrosion/Erosion, Seal/Seat failure, Inspection. Corrosion assessment Cyclic stresses, Pipe support failure Vibration, Review spares availability Cargo washing systems and guns Leakage, corrosion inspection Offloading systems including hose reel) Wear, inspection, Obsolescence assessment, Corrosion, hawser load history and sensor Fatigue assessment. Mechanical damage, calibration, Elastomer degradation corrosion protection. Heating coil Vibration, Leakage, Mechanical damage, corrosion Inspection, Leak testing, Heat testing, Contamination checks, Corrosion assessment, Spares. Boiler water treatments. services 33

34 AIM for FPSO-Marine Systems Internal lining/coating damage. Corroded inlets/drains sticking valves/floats Inspection and testing, Cleaning de-mister pads, Maintenance, Maintain coatings/linings, Check for water carry over, Dismantle level regulators/float valves Corrosion assessment. Spares Corrosion(internal/External) Inspection/NDT Draining residual Water Corrosion assessment Loss of seal Loss of seal, Sticking valves, Corrosion. Inspection, Maintenance Regular maintenance, Cleaning, Testing, Monitoring of breakers liquid levels, density and anti-freeze properties. Obsolescence assessment, Corrosion assessment, Spares. Obsolescence assessment, Corrosion assessment, Spares. Obsolescence, Loss of accuracy Regular maintenance and testing, Calibration of sensors Obsolescence assessment, Corrosion assessment, Spares. services 34

35 Ballast Systems: AIM for FPSO-Marine Systems Elements Ageing Mechanism Controls Life Extension Actions Loss of seal, Vibration testing, Ballast pumps Reduced efficiency, Wear, Overhauling, Inspection, Obsolescence assessment, Corrosion assessment, Corroded supports Monitoring pressure. Spares. Corrosion, Ballast system pipework in tanks Cracking, Pipe Support failure. Inspection. Corrosion assessment. Loss of seal. Inspection, Obsolescence assessment, Valves Maintenance. Corrosion assessment, Spares. Ballast system in machinery spaces corrosion Inspection. Corrosion assessment Vibration, Review spares availability Cargo washing systems and guns Leakage, corrosion inspection Control systems(including hydraulics, actuators & instruments) Obsolescence, Corrosion, Mechanical damage, Hydraulic contamination Function testing, Visual inspection, Hydraulic oil sampling/testing Review performance, Reliability and redundancy of system, Review spares availability services 35

36 AIM for FPSO-Marine Systems Control Systems: Elements Ageing Mechanism Controls Life Extension Actions Valve control Obsolescence modification Inspection, Maintenance System review, Obsolescence assessment Tank monitoring, flood detection and bilge system Loading control software services 36

37 AIM for FPSO-Marine Systems Marine Utilities: Elements Ageing Mechanism Controls Life Extension Actions Valve control Obsolescence modification Inspection, Maintenance System review, Obsolescence assessment Tank monitoring, flood detection and bilge system Loading control software services 37

38 List of Content Stage Subject Asset Integrity for Floating Production Units Project Scope Introduction to FPSO The Floating fleet under direct operatorship Applicable rules and standards for FPSO management Asset integrity Introduction Asset Integrity Management for FPSO Conclusions services 38

39 Conclusions The Effective Management of FPSO Asset Integrity Requires That Competent People With Sound Understanding of the Issues Take Effective Actions To Enable The Asset Continue to Function Safely For its Required Service Life. The Key is On the Build of Design, People, Understanding The Systems and Maintenance Strategy/Actions, While Clearly Defining: Design for Asset Integrity Maintenance plan, inspection and Strategy/Approach Actions Corrosion inspection and maintenance plan Continuous Machinery Inspection/maintenance Development and Application of International Standards, Best Practices and Company Guidelines services 39

40 Acknowledgements I would thank Eni s.p.a. upstream and technical services Management for permission to present this work and related results and Management of Floaters/FIROP/LOGIS colleagues for the technical support and needed assistance. services 40 San Donato Milanese October 2014