The Problem of Design Errors on FPSOs

Rod Rainey WS Atkins Marine Structures London

It is generally agreed that design errors are one of the major risks on FPSOs. See attached press report of a Norwegian survey which concluded A majority of the problems experienced on FPSOs derived from design issues. The fundamental problem is that floating structures are much more difficult to design than fixed ones. The traditional trial-and-error approach of the marine industry, although it is excellent in the long term, is vulnerable with new floating concepts like FPSOs. The design errors include: Hull design errors. Main hull girder or transverse frames too weak for harsh environment. Local strength inadequate for wave impact or green water . Subsea design errors. Moorings undersized. Mooring terminations prone to fatigue. Problems with untried riser suppliers. Riser end terminations (bend restrictors) too weak. Topside design errors. Steelwork, pipework and pressure vessels not properly designed for fatigue loads from ship motions . Steelwork and pipework not properly designed to accommodate hull flexing. Marine system design errors. Ballasting system s insufficiently robust, or too difficult to operate in an emergency. Installation design errors. Numerous, because installation procedures are hard to practice beforehand. Design errors are hard to predict in advance, by definition. What can be done, however, is to predict their likelihood, from experience, based on the particular circumstances of the FPSO. It s also possible to say in advance what the i consequences of various design errors are. We have found that this work is best accomplished in a formal HAZID-type session, which we call a DELAC (Design Error Likelihood and Consequence) session. The Table overleaf is a table of the type produced by a DELAC session. Further Tables would address particular items in more detail, and be specific to the FPSO in question.

19 th November 2002

Design Error Liklihood and Consequence (DELAC) Analysis of FPSOs, in general Hull Error Likelihood High with untried hull designs in harsh environments High with all new designs, or old designs in new environments Consequence Expensive dry-docking needed, but no other risk Fairly easy to fix, but risk of dangerous riser damage

Moorings

Risers

High with all new designs or new Danger of hydrocarbon spill and equipment suppliers major accident Low unless special flow features (e.g. condensate slugs) Low unless layout is very cramped

Topsides (process)

Topsides (structure)

Should in theory be low, but Expensive repairs needed. many mistakes have been made Some risk to pipework. Evidently high, due to problems being underestimated High unless design is very standard Severe risk of total loss of FPSO Mainly economic risk, because no hydrocarbons

Marine systems

Installation

19th November 2002