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OPERA Lunchtime Briefing

Mooring Integrity – Offshore O&G

January 2012

Alastair Trower

President

[email protected]

(c) Copyright – Welaptega Marine Limited – All rights reserved 2012

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


Welaptega Marine - What do we do?

Offshore, Underwater Inspection

Regular Inspection of underwater systems

Ensures profitable operation while reducing environmental and human risk


What do we do?

Emergency response (OSM!)

Immediate, high value intelligence

What shape?

Remove/repair/rebuild?


Global Impact

Full Operating Base Sales Base Project Area Expected 2012/13


Mooring System Failure History

Maersk Oils – Alpha Gryphon FPSO

February 2nd2011 2011

Force 8 gale

Catastrophic mooring failure


18,000 Barrels per day

18 months production

Cost of Recovery

$800M

Lost Opportunity?

40% drop in share price


2,496m water depth

5 FSHR riser towers

BOEM ‘Go’ 19/3/2011

Failure 23/3/2011

Single chain link

First Oil delay

Cascade Chinook


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

Nan Hai Fa Xian – 4 Lines

Recent Failure History

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


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

Consequences of failure


UK - HSE

Norway - PSA

GoM - BOEMRE

Australia - NOPSA

West Africa

SE Asia

IRF – Meets every 2 years

Regulatory Background


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

Classification Societies


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

Operator’s Philosophy


Degradation Mechanisms

C:/Users/atrower/Desktop/Presentations/welaptega_interactive_app_v2/welaptega_interactive_app_v2/welaptega.exe


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


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


Optical Caliper

4 x Video Cameras

Controls to

ROV

Acetyl Framework


Dimensions measured


Chain Baseline

182

184

186

188

190

192

194

196

-6 0 6 12 18 24 36 48

Chain 1

Chain 2

Chain 3

Chain 5

Chain 5

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


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


RMS Inspection

Four video cameras

Continuous automatic diameter measurement

Continuous 360 degree footage

archive

Identifies changes in diameter at <0.5mm resolution

What RMS measures

C:/Users/atrower/Desktop/Videos/RMS/Sheathing damage.mp4


Geometric Reality – 3D Modelling

Dual high resolution

digital stills cameras

Synchronous triggering

Variable LED Lighting

../Videos/3DM/ROV Using 3D Modelling on a subsea BOP.avi


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


Geometric – 3D Modelling

Corroded Chain Link


Mooring Components – Camera Positions

Mooring Components – Point Cloud

Point Cloud with marker magnet

Cross-Section 8 Area = 7828 mm2

(Nominal Cross-Section Area of 108mm Chain=9159mm2)Cross-Section Locations

Mooring Components - Analysis

Answer the question


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

../Photo Mosaic/Cascade Chinook/Buoyancy Can-oct23 update.jpg


Chain Anomalies

Meshed Point Cloud

Mesh with Photo

Overlay

Chain Anomalies

MisalignmentNarrowing

Cosmetic

Flat Spot

Chain Anomalies


Installation damage

GoM Spar

WROV Lift wire nicked

sheathing

10 days before first oil!


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


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


Regular Inspection – Installed Fleet

During Service Life

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


Regular Inspection - Annual InspectionGeneral 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


Estimated / Ball Park CostsDesign Phase

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. $300-450K per annum


Estimated / Ball Park CostsFive year 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?


ComplicationsDeeper Water

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


ConclusionsMooring Systems are here to stay

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


ConclusionsInevitable degradation

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


www.welaptega.com

Alastair Trower

President

Welaptega Marine Limited

T. +1 (902) 422 8303

[email protected]

Contact Details

To download the Oil and Gas UK Mooring Integrity Guidelines:

http://www.welaptega.com/

www.welaptega.com

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