8. ketil hox

Ketil Hox Teekay Petrojarl

FPSO Start-up in the North Sea – Overcoming Challenges with Practical Strategies

Content of presentation

• Regulatory challenges • Challenges in start-up and preparation thereof • Harsh weather – Influence on hook-up? • Interface management • Framework for effective start-up

• Operational experience

• Lessons learned

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Which rules shall we follow?

Regulatory challenges

Regulatory pyramid

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PSA

Normative rules (e.g. DNV, SOLAS,

NORSOK etc.)

Field specific Requirements

International Engineering Standards

(ISO, API etc)

PSA (Ptil in Norway)

Main priorities for 2015 • SAFE LATE LIFE

• THE FAR NORTH

• MANAGEMENT RESPONSIBILITY

• BARRIERS

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PSA: WEAKENING WIL NOT BE ACCEPTED

The PSA expects the industry to deal with its economic challenges without affecting safety, says director general Anne Myhrvold: «On the contrary, cost cuts and efficiency enhancement processes must help to strengthen safe operation.»

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AoC and Safety Case?

• Norway requires Acknowledgment of Compliance

• UK requires Safety Case

• May they be combined?

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What characterizes a FPSO?

• Moveable and reusable • Independent of water depth • Large oil storage • May carry large topside weight • Movement of vessel must be catered for

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Combined AoC and Safety Case?

Yes, To be able to fulfill the possibility of more that one location, we have to. Remember: We do not know the next location.

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Safety in design and operation

Regulatory challenges

NORSOK standards

• The NORSOK standards are developed by the

Norwegian petroleum industry to ensure adequate safety, value adding and cost effectiveness for petroleum industry developments and operations. Furthermore, NORSOK standards are as far as possible intended to replace oil company specifications and serve as references in the authorities regulations.

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Safety philosophy

• Inherently safe 1. Passive protection above 2. Active protection

• Avoid accidents

1. Reduce probability of accidents to happen above 2. Limit the consequence

Make the easier way also the safer way

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Safe and functional design

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Preparation for start-up

Challenges in start-up

Start-up – Main objective

• Ensure a safe start-up and

• flawless continued operation

Remember: Start-up is only valuable when it is the beginning of operation

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Basis for successful operation

• Operation and operation support involved in design

• Design as one single and integrated unit

• Build and plan for easy operation and maintenance

• Design philosophies established early and obeyed in execution

• Clear tagging and numbering system

Remember: The FPSO is built once and used for a long time

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Prerequisite for successful operation

• Ready for start-up certificate is preceded by: – Mechanical completion

– Commissioning

– Hand-over to Operation

Remember: You cannot start any system unless it is MC and commissioned.

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Shutdown vs start-up

• The shut down systems shall be designed and built to achieve the following:

– Avoid potential hazards to escalate to accidents

– Reduce the potential extent of an accident

– Protect equipment

• Successful start-up relies on a correct shutdown system

• A perfect shutdown system reacts when, and only when, there is a real hazard

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Safety philosophy

• The paramount objective is to avoid injuries to personnel and reduce damage to equipment.

• The philosophy for the shut down system includes:

– All incidents will be handled at the lowest possible level

– Cascading effects shall be avoided

– There will be a common shutdown system for the FPSO

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• The shutdown system shall be logically divided into three main levels of shutdown:

– Abandon ship shutdown (AS)

– Emergency shutdown (ESD)

– Process shutdown (PSD)

• Basic system philosophy is that a signal on a certain level shall never initiate shutdowns or actions on higher levels, but shall always include shutdowns on lower levels

Safety philosophy

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Safety by simplicity

• The governing design principle shall be safety by simplicity.

• When there are alternative equipment or design solutions available, the most easy to operate, service and maintained shall be selected.

Make the easier way also the safer way

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• Layout for easy interface: – Large modules commissioned at construction site – Central pipe rack to ease interface – Instrument and power cabling terminated at single location for easy hook up

• Layout for safe operation : – Easy maintenance access – Safe material handling, i.e. avoid lifting – Utilize layout to ensure clean water

• There is no conflict between safe and maintainable layout

Layout for safe and easy maintenance (and interface)

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Safety in design and operation

Harsh weather – Influence on hook-up?

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Weather

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Harsh weather on Petrojarl I

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Harsh weather challenge

Hook-up and all offshore operations have weather limitations: Typical limitation: Hs 2-3 m Normal in the summer, not that normal in the winters

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Harsh weather challenge

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When are the most costly mistakes done?

Interface and integration

Interface and integration challenges

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• Interface is easy - • It is just about

communication

• Because it is about communication -

• It is difficult

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• Where two work scopes meet and data needs to be supplied from one interface party to the other

• Interface data will exist in several forms

• A mixture of ”hard” and ”soft” interfaces exist on FPSO projects

– ”Hard” interfaces: Where there is a physical connection – ”Soft” interfaces: Where data is of more general nature or design philosophy /

basis related.

What is an interface

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• Where are surprises most likely to appear?

• Within vendor packages or between vendor packages?

– Between, i.e. at interfaces

Interface and integration challenges

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• Main objective of interface management is to:

– Avoid surprises

• Surprises are prevented by:

– Knowledge and control

– What you know, will not surprise you

• Inspect, never expect

Interface Management – Risk Mitigation

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Layout to ensure safe material handling

Operational experiences

Initial design phase

• Thorough studies of:

– Layout – Material handling – Process flow

• Do these factors cooperate or compete?

– Layout and Material handling cooperate – Process flow may compete (and loose)

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Limit lifting

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• Move horizontally when possible

• Lift if necessary

Construction and modification challenges

• Ensure realization of design intentions in construction • Avoid hidden pitfalls by interface control • Maintain focus during operation and modifications

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• Subhead of the slide Deck

Obstructions

Pitfalls

• Subhead of the slide Deck

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What is the punch list status?

Preparation for start-up

Punch list during commissioning

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Ready for start-up premises

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When are the most costly mistakes done?

Lessons learned

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• Subhead of the slide Deck

Narrow transport route

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Forklifts do not climb stairs

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• Prepare design from start based on: – Design philosophies – Include lessons learnt, experience and operational specifications

• Defend the design principles during detailed engineering and construction

• The most costly mistakes are done early and corrected late

Summary

The first obstacle is most detrimental

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Questions?

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Thank you ketil.hox@teekay.com

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