Converted tankers into FPSO:

Life extensions structural challenges

Damien THIERY
Offshore Project Engineer
Bureau Veritas HO Paris
damien.thiery@bureauveritas.com

Introduction: converted tankers into FPSO

In 2014: Conversions represent approximately 70% of the F(P)SO units
Forecast of F(P)SO orders over the next period (2014-2018):

Conversion 55%
New built 25%
Redeployment 20 %
2 phases should be taken into account:

Tanker Service
FP(S)O Service
Life extension: when the asset exceeds its design life
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Contents

1. Hull structure challenges

2. Structural analysis
Strength assessment
Fatigue assessment

3. Integrity management System

4. Conclusion

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Hull structural challenges

Previous history: as trading services and during the transit

RAO Roll

RAO Pitch

RAO Roll
RAO Pitch

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Hull structural challenges: Tanker service

What are the main hull degradation processes of a tanker ?

Corrosion

Fatigue cracks / fatigue accumulated damage

What is the current hull condition ?

Is the operating history (log book) fully known ?

Are previous inspection / repair reports available ?

Which is the outcome from the condition assessment survey (corrosion) ?

How site environmental conditions compare with tanker class notation ?

MCE Deepwater Development 2014 - Madrid

Hull structural challenges: FPSO Service

How to ensure the hull is eligible to be converted ?

Which are the results of feasibility study and in terms of strength and fatigue ?

Design conversion verification by structural assessment: forecast future

condition and expected end of life.

What are the necessary repairs to face the FPSO service life ?

IMR strategy to be defined in order to ensure the operational continuity

Is there an Asset Integrity Management System planed ?

MCE Deepwater Development 2014 - Madrid

Structural Analysis

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Structural Analysis
Input for the structural analyses :

Key structure drawings

Capacity plan

Trim & stability booklet

Weight distribution

Tanker speed and trading routes history

Towing/transit speed and route

Repair history, detected failures, damages, particular findings:

cracks, indents, impacts, pitting,
Corrosion as is condition or reassessed scantlings
FPSO operational
sequence

Loading

conditions,

Loading/Unloading

Site metocean conditions

Hydrodynamics & heading analysis results

Mooring analysis results (mooring loads at hull interface)

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Structural Analysis: Strength analysis

Strength analysis

Design waves applied on the model to maximize load

parameters.
Yielding verification
Buckling verification

FINDINGS

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Structural Analysis: Fatigue analysis

Fatigue analysis

Operational loading condition + transit condition

Assessment of typical locations (determined by experience & fatigue scan)
Analysis of previously detected cracks on board
Assessment of repair solutions

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Structural Analysis: Particular areas

Crane Pedestals

Turret-Hull Interface

Hopper knuckle

Topsides stools
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Structural Analysis
Outputs of structural analysis
Remaining life assessment
Inspection plan definition based on hot spot maps
Determination of repair/modification solution
To avoid further cracking
To insure sufficient corrosion margin
To avoid integrity issues resulting in production down time
To avoid hot work or dry dock

Area 1

Area 2

Area 3

Area 4

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Integrity management System

Operator & Partners
ensuring that FPSO inspection plan is carried out and updated with documents
(modifications, inspection findings, corrective actions )

Classification Society

Project Team
Inspection Plan

Site inspectors

Contractor

Marine operation Production

department

department

Safety

Maintenance

department

department

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Conclusion
CONVERSION
Tanker service

FPSO service

Trading routes

Sites conditions

Damages and repairs

Expected service life

Surveys

Structural analysis

Structural analysis

Inspection & Maintenance

Corrosion and structural integrity are the main challenges

Finite Elements Analyses and Asset Integrity System

provide answers regarding :

The status of the hull structure = condition assessment
If the unit is suitable for intended = life extension
How to anticipate / minimize / avoid offshore structural work before
going offshore
Follow-up in service (Class surveys, operator inspections)
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