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OPERA Lunchtime Briefing
Mooring Integrity – Offshore O&G
January 2012
Alastair Trower
President
a.trower@welaptega.com
(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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Welaptega Marine - What do we do?
Offshore, Underwater Inspection
Regular Inspection of underwater systems
Ensures profitable operation while reducing environmental and human risk
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
What do we do?
Emergency response (OSM!)
Immediate, high value intelligence
What shape?
Remove/repair/rebuild?
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Global Impact
Full Operating Base Sales Base Project Area Expected 2012/13
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Mooring System Failure History
Maersk Oils – Alpha Gryphon FPSO
February 2nd2011 2011
Force 8 gale
Catastrophic mooring failure
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
18,000 Barrels per day
18 months production
Cost of Recovery
$800M
Lost Opportunity?
40% drop in share price
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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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
UK - HSE
Norway - PSA
GoM - BOEMRE
Australia - NOPSA
West Africa
SE Asia
IRF – Meets every 2 years
Regulatory Background
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Degradation Mechanisms
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Optical Caliper
4 x Video Cameras
Controls to
ROV
Acetyl Framework
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Dimensions measured
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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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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) Copyright – Welaptega Marine Limited – All rights reserved 2012
Geometric Reality – 3D Modelling
Dual high resolution
digital stills cameras
Synchronous triggering
Variable LED Lighting
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Geometric – 3D Modelling
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Geometric – 3D Modelling
Corroded Chain Link
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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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
Chain Anomalies
Meshed Point Cloud
Mesh with Photo
Overlay
Chain Anomalies
MisalignmentNarrowing
Cosmetic
Flat Spot
Chain Anomalies
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Installation damage
GoM Spar
WROV Lift wire nicked
sheathing
10 days before first oil!
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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?
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
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
(c) Copyright – Welaptega Marine Limited – All rights reserved 2012
www.welaptega.com
Alastair Trower
President
Welaptega Marine Limited
T. +1 (902) 422 8303
a.trower@welaptega.com
Contact Details
To download the Oil and Gas UK Mooring Integrity Guidelines:
www.welaptega.com
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