mooring integrity & fuma why is it needed? how is it …€¦ · mooring integrity • moorings...
TRANSCRIPT
AOEC 14
Mooring Integrity & FUMA
Why is it needed?
How is it achieved?
Sept 2014
Mooring Integrity
• Moorings are Safety Critical Components, inherently protecting the vulnerable subsea architecture (risers, umbilicals, flowlines etc), together with hydrocarbon production and adjacent assets
• Mooring Failure is regarded as a Class 1 Hazard, the highest rating by the UK Health & Safety Executive
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Mooring Systems Typical Field Infrastructure
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Mooring Systems Typical Field Infrastructure
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Mooring Systems FPSO Expanding market
Source EMA 6/14 & Infield 6/13
• 264 FPS at 6/14, 60%
are FPSOs
• Compound annual growth of 18% to 2017, increasing in size, value & complexity
• 95% increase in 10 years to 2017
• Drivers - monetise gas at remote locations & focus on deep water
• Dominated by Africa, Latin America & Australasia
Mooring Systems FPSO Expanding market
Prelude FLNG:
• 488m by 74m hull
• 600,000 tonne weight
• Kizomba A FPSO is 285m by 63m
• 90m high turret
• 250m water depth
• Cat 5 cyclones (>156 mph)
• 24 legs, 15.1 & 11.6 miles of chain & wire
Source: The Engineer 09 & ship technology.com
• 7-8 additional Asia-Pacific FLNG projects proposed
Source: Upstream 5/11
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Mooring Systems FPSO Expanding market
Prelude LNG Terminal Kanowit LNG Terminal Abadi Bonaparte Scarborough
Operator Shell Exmar Petronas Excelerate Inpex Masela GDF
Suez/Santos ExxonMobil
Status (as of Feb ‘14)
Under construction
Under construction
Under construction
FEED completed
FEED in progress
FEED in progress
pre-FEED completed
Location 200 km W of
Australia Caribbean coast
of Colombia 180 km N of
Bintulu, Malaysia Lavaca Bay, Texas
coast 350 km E of East
Timor 170 km N of
Australia 220 km NW of
Western Australia
Water Depth 250 m Unknown 80 m Unknown 350-1000 m 85-100 m 900-970 m
L x B 488 x 75 m 144 x 32 m 365 x 60 m 338 x 62 m ~500 x 80 m ~400 x 70 m 495 x 75 m
Environment (Typhoon)
Hs: 11.0 m - Hs: 13.6 m - Hs: 5.5 m Hs: 11.0 m Hs: 13.0 m
Expected First Production
2017 2015 2015 2018 2019 2019 2020-21
Mooring Systems Hardware
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Mooring make up:
• Chain, mostly studless, up to 6.5 inch
• Wire – unsheathed or sheathed spiral or 6 strand
• Polyester rope – unsheathed or sheathed
• Connecting shackles
• Buoyancy support modules (buoys)
• Anchors or piles
Mooring Systems Hardware
Spread mooring Single point mooring - external turret Source: API RP 2SK
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Mooring Systems Vulnerability – inherent design
• Limited redundancy in mooring system, chain as strong as its weakest link
• Difficult to inspect & maintain, degradation & retirement issues
• Rapid incident escalation (eg cascading failure) in hostile environments
• Consequences lead to major loss including damage to subsea & seabed architecture and adjacent infrastructure
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Mooring Systems Vulnerability - Codes
Issues:
• Various codes on mooring design, less on installation, operation, inspection & retirement
• Differences in technical standards between Societies
• Regional differences within Societies – how good is the surveyor?
• Standards only periodically updated (behind the curve, e.g. new failure modes)
• Societies recognise that existing rules do not ensure FPSO mooring integrity
Source: Oil & Gas UK Report OP023 (2008)
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Mooring Systems Vulnerability - Codes
• Class Rules evolving from seafaring background
• Existing developments: Class - Ageing, many legacy systems in place (eg SPMs & offloading tankers). Equipment replacement considered as repairs, obsolete Class codes utilized
• Tanker conversions to FPSOs, change in duty
• New developments – Speedier, smaller operators, remote & unpredictable environments, deeper water, more subsea infrastructure, increased asset values
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Main Factors Influencing Long-Term Mooring Integrity including inspection and maintenance, mooring jewellery
Source: HSE 2006 study
•Also inspection and maintenance, mooring jewellery
Mooring Systems Vulnerability – mooring legs
Terminations:
• Hawse tubes - highest tension with
additional bending, twisting stresses & link contact wear
• Touchdown - heavy contact with sea floor containing rock of comparable hardness to steel -> severe localized wear
• Touchdown - accelerated corrosion (aerobic), chain moves above & below mudline, parent metal exposure
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Mooring Systems Vulnerability – fatigue
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Mooring Systems Vulnerability – fatigue
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Mooring Systems Vulnerability – fatigue
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Mooring Systems Vulnerability – corrosion
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•Corrosion comes in many forms…
• Design codes generally allow for <0.8 mm/year
•SRB Corrosion - In warm, shallow waters, often near river estuaries
• FPSOs with touchdown zone dynamics (eg draft change due to offloading)
• Corrosion rates at up to 2-4 mm/year
(Welaptega, 2014)
Mooring Systems Vulnerability - Ageing Assets
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Failure trends? – recent incidents
• Early life failures, design, manufacture, & installation
• Reduction in mid-life
• Increasing end of life failures; dominated by operational causes
(OTC 24181)
Mooring Systems Losses
Cascade Chinook - Loss 3/11
• 6.25” chain
• Faulty weld repair causes fracture in single chain link
• 440T buoyancy tank supporting hybrid riser released
• Chain vulnerable to hydrogen induced stress cracking – post heat treatment
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Mooring Systems Losses
Recovered Subsea Arches
Gryphon - Loss 2/11
• winds > 55 knots, ~12m waves, 10 leg mooring, 18 year old chain
• Leading leg fails below design load
• DP loses heading, FPSO turns beam on
• 21 degree roll, 3 more legs lost
• 180m movement damaging subsea kit (Maersk, 9/11)
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Mooring Systems Losses
Mooring Loss Statistics:
• 1 in 50 chance of a single line failure per floating asset per year. This equates to a 1 in 2 chance of line failure over a 25 (say) year design life.
• 1 in 350 chance of a multiple line failure (and/or infrastructure damage) per asset per year. 1 order of magnitude worse than industry (DNV) guidelines
• Permanently moored assets only. Based on known losses. (2001-11, 23 documented failures inc. 8 system failures, 4 with riser failure).
• Moving forward, these numbers are an underestimate. They do not recognise that all assets have continuously ageing mooring infrastructure.
• Mitigation, to reduce the chance of failure, is essential.
Source: Mooring Integrity Forum, Monaco, 2014, OTC 24025
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Floating Unit Mooring Assessment (FUMA)
• FUMA is an endorsement (not a warranty) for underwriters use.
• Insurers have relied on Class & Operators to ensure adequacy of design & Mooring System integrity.
• JRC mandated Engineering Sub-committee to investigate need for a formal process for Mooring System Assessment.
• Reflects other JRC Assessment Processes, discretionary/voluntary, flexible.
Mooring Systems FUMA
Floating Unit Mooring Assessment (FUMA)
• An underwriting tool, value-adding for assureds.
• Structured consistently with other JRC survey documents eg CAR MWS & Well Plan review (Guidance Notes, Endorsement, Codes of Practice, Workscopes).
• Consideration given to International Standards, Design & Operation Codes, Integrity Management Systems, Industry Best Practice.
• Interaction with industry/operators and Oil & Gas Mooring Integrity Workgroup.
Mooring Systems FUMA
Floating Unit Mooring Assessment (FUMA)
• Promote dialogue between Underwriters and Assureds, without dictating.
• Report becomes ‘Material Information’ & supports INFORMED underwriting decision making.
• Assist Underwriters in better understanding the Assureds operational practices, integrity management and experience.
• Enhance risk reduction for both Assureds and Insurers.
Mooring Systems FUMA
• Intended for Moored Floating Units OTHER THAN MODUs.
• Initial Screening Process (ISP) may indicate FUMA is not required (Generic considerations: Age, Design, Type, Class, Operating Standards)
• It’s a tiered process, light touch (Level 1) to full physical (Level 4).
• Entry can be at any level, but with all preceding levels performed (assessing physical condition is important but understanding Assured’s core philosophy is critical).
Mooring Systems FUMA – getting started
Mooring Systems Risk Screening
• Moored Risk Screening for FPSOs, FSOs, Spars, TLPs, SPMs & drilling units
• Used across a Portfolio of Moored Risks (or Operators) to assist Underwriters with risk mitigation
• Major incident likelihood (frequency) established by Naval Architects based on mooring complexity, age, design code, water depth, operational aspects, extreme environment vulnerability, inspection & monitoring etc
• Risk Consequence considers insured exposure, field infrastructure - subsea architecture, adjacent platforms
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•High: Intolerable Risks; mitigation is essential
•Intermediate: Unacceptable, reduce to ALARP
•Low: Acceptable: Consider ALARP
• Level 1: Remote Desktop & Correspondence
Review of design limits, operational procedures & history against relevant IACS standards and industry’s best practice.
• Level 2a/2b: Attended Technical Review
(2a: Attendance Onshore, 2b: Attendance Onshore & Offshore)
Attendance by Mooring Assessors of onshore facilities and, if required, of offshore location.
• Level 3: Physical Inspection
Physical inspection of moorings and third-party engineering as required.
• Level 4: Detailed Physical Inspection
Physical inspection of moorings to higher specification and third-party engineering as required.
Mooring Systems FUMA – assessment levels
• Can be at any point in moored unit lifecycle (pre or post installation – benchmarking, mid-life, if life extension planned).
• Uses competent Mooring Assessors; any party on which Insurers & Assureds mutually agree.
• Assessors may include Insurer’s internal engineering capability, and/or 3rd party (eg MWS with specialist mooring skills/experience, other specialist engineer).
• Workscope is applied. Assessor delivers findings to both Assured & Insurers.
Mooring Systems FUMA – when, how, who?
Mooring Systems FUMA - reporting
Mooring Systems FUMA - reporting
FUMA Level 4 Mooring Assessment - Tasks :
• Pre-engineering to tailor inspection campaign
• Offshore inspection campaign
‒ 2D/3D high def. focused visual inspections
‒ Chain/wire/fibre measurement tools, 3D modelling
• Review & report on risks associated with:
‒ Historic mooring failures and blackouts
‒ Operator Performance Standards
‒ Original design analysis and assumed extreme environment
‒ Operational philosophies and procedures
‒ Inspection findings
Mooring Systems FUMA 4 – typical tasks
FUMA Level 4 Mooring Assessment – Tasks:
• Review and report on risks associated with:
‒ Reported operations & offloading against original design inputs
‒ Mooring fatigue life re-assessment
‒ Subsea architecture complexity & vulnerability
‒ Collision risks & consequences – floating, water column & seabed
‒ Identify & report on ‘gaps’ in operations, maintenance and inspection procedures
‒ Recommendations for future inspection campaigns and wider mooring integrity management
Mooring Systems FUMA 4 – typical tasks
Mooring Systems FUMA & Integrity Management
Ideally a Mooring Integrity Management System exists:
• Part of Operator Safety Management System
• Developed, owned & administered by Operator
• Recognition that Moorings are Safety Critical
• Key components:
– System Description. Design, Manufacturing & Deployment
– System Performance Standards (specific, measurable, agreed, realistic & timed)
– Normal & Damaged Operational Procedures
– Component Risk Review (ALARP)
– Monitoring & Inspection driven by Risk Review
– Feedback into Performance Standards
– Suitable Tracking Systems to close out anomalies Source: Oil & Gas UK Report OP023 (2008)
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‒ Most likely failure modes ‒ Identification of critical components ‒ Mooring Extreme & Fatigue Analyses ‒ Max. Operational & Survival Conditions
•Pictures: BPP-TECH, 2012
• Analysis of vessel loading conditions and hydrodynamics (Orcaflex)
Mooring Systems
Tools used - FUMA4
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‒ FEA (Abaqus) for chain components ‒ In-house analysis models for damaged
wire ropes
•Pictures: BPP-TECH, 2013
• Analysis of structural integrity of critical components based on Welaptega inspection results and FEA
Mooring Systems
Tools used - FUMA4
Key high risk items identified in previous studies:
• Failure to establish meaningful root causes of historic failures
• Failure to implement recommendations made in internal accident investigations
• Absence of line-tension verification systems
• Lack of coherent emergency plans for mooring failures
• Mooring inspections not conducted deeper than 30m (air diving limit)
• Severe chain degradation known to operator – No action taken to manage reduced capacity
Mooring Systems FUMA – Identified Risks
Key recommendations made in previous studies:
• Root cause analyses to be completed by competent persons
• Engineering studies to account for ‘real-world’ condition of system
• Line-tension verification system to be installed as priority
• Mooring line failures to be simulated in drills and findings integrated in emergency procedures
• Comprehensive mooring inspection programme to be implemented
• Take ownership of mooring integrity management – don’t rely on Class Societies to do this for you
Mooring Systems FUMA – Recommendations
Development of effective mooring management strategies leading to:
• Safer mooring systems, less prone to failure
• Better “early warning” of mooring component degradation
• Rapid identification of failures through improved monitoring
• More efficient response of on-board and shore-based staff to mooring failure
• Minimisation of mooring failure consequences
• Reductions in number and size of insurance claims, improved insurance terms
• Lower downtime and improved productivity
• Improved industry reputation
Mooring Systems FUMA – Benefits
Lessons Learnt
• We NEED to know what we really have down there…
• How is it performing currently, how vulnerable is it
• How much longer is it going to be fit-for-service.
We don’t know what we don’t know
and we won’t know until…
We make a conscious effort to go and find out!
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