SBM - FPSO Sepetiba

SBM Offshore announced on 11.12.2019, that it has firmed up contracts with Brazil’s Petróleo Brasileiro S.A. (Petrobras) for the 22.5-years lease and operation of a floating production, storage and offloading unit (FPSO) to be deployed at the Mero field in the Santos Basin offshore Brazil.

FPSO Sepetiba, formerly known as Mero 2, will be built under SBM’s Fast4Ward program, which incorporates a newbuild, multipurpose hull combined with several standardized topsides modules, and is expected to be delivered in 2022, SBM said.

The FPSO will link to 16 wells and will have the capacity to process up to 180,000 barrels of oil per day (bpd), with water injection capacity of 250,000 barrels per day, associated gas treatment capacity of 12 million standard cubic meters per day and a minimum storage capacity of 1.4 million barrels of crude oil. It will be spread moored in approximately 2,000 meters water depth. Production startup is planned for 2022.

The Libra block, where the Mero field is located, is under Production Sharing Agreement to a Consortium comprised of Petrobras, as the operator, with 40%, Shell with 20%, Total with 20%, CNODC with 10% and CNOOC Limited with 10% interest. The consortium also has the participation of the state-owned company Pré-Sal Petróleo SA (PPSA) as manager of the Production Sharing Contract.

The project partners announced final investment decision (FID) for the second phase of the Mero development in June. SBM announced a binding letter of intent (LOI) for the project at that time.

Following the launch of FPSO Sepetiba, it is expected that another two FPSOs of the same capacity will be added, subject to partner approvals, according to Petrobras. The Brazilian state-controlled oil company said in June that all four units will be deployed in the northwestern part of the Libra block (Mero field), as the central and southeast panels are under exploration until 2020

Process Safety Management

JOB SAFETY ANALYSIS (JSA) & CAE

Computer Aided Engineering (CAE) was first used for building FPSO P-63 by Petrobras. In the video, the lady explains in Portuguese, which if the reader is not familiar with, a translation in a nutshell is in the sub-script.

The Offshore Industry has started implementing or already implemented use of CAE in JSA processes. It is a very powerful tool. 

Risk Categories
                     
                     > with VOC risk
                     > with Electrical Risk
                     > with Environmental Risk
                     > with Gas (H2S, CH4, O2) Risk
                     > with Heat Exposure Risk
                     > with Flooding Risk
                     > with Personal Injury Risk
                     > with Fall from Height Risk

Within the CAE, the Equipments and Zones are already parametrized with their Risks involved

Risk Mitigation

Intrinsic
                     > Zone Isolation
                     > Valve Isolation
                     > Electrical Isolation
                     > Gas Freeing
                     > Video Monitoring
                     > Remote Sensing Monitoring
                     > Emergency Shut Down available

Equipments

                     > Appropriate Safety Harness
                     > Working Aloft Equipments: Fall Arrest Blocks, Snap Hooks, Fire Resistant Ropes, Wire Rope Anchor Strops etc
                     > Anchor Points (CAE already has them in design for every Zone)
                     > Anchor System for Working at Heights when no Anchor Point available by design.
                     > Position & Restrain Lanyards with Snap Hooks
                     > Working Height Saddles/ Chairs
                     > Portable/ Handheld/ Helmet attached Ex proof Light
                     > Tripod for Emergency Rescue
                     > Emergency Rescue Kit for Heights
                     > Emergency Rescue Kit for Enclosed Spaces
                     > BA Sets on location
                     > Portable Gas Detectors (H2S, CH4, O2, HC LL etc - Type declared by CAE)
                     > Portable Extinguisher (Type declared by CAE)
                     > Standby Fire Hose under pressure on Location

Support Personnel
                      
                     > Watchman at Entrance
                     > Handy Man on Deck for Working Aloft
                     > Accompanying Person
                     > Rescue Team with BA set
                     > Rescue Team for Working Aloft
                     > Stand by Fire Team with Pressurized Hoses
PPE

                     > Appropriate Overall
                     > Appropriate Helmet, Gloves and Boots
                     > Appropriate Eye & Ear Protection.

The CAE, has all these Risk Mitigation data already fed and matched per Risk per Zone/Equipment. The system knows how the Zones/Equipments connect to each other, and what Isolations required.

Job Categories

Routine

Inspection
Job - with Hot Work
Job - without Hot Work
Cargo Transfer
Bunker Transfer
Water Transfer
Goods & Provision Transfer
Lifting Gear use
Mooring Operations
Navigation Watch
Engine Room Watch
Cargo Control Room Watch
Production Control Watch
Safety Drills (except Lifeboat Launching)

Within CAE, the Routine Activities per Zone/Equipment gets compared with the Risks involved and the Mitigation Measures are displayed.

Non - Routine (in Operation)

Structural construction/Repair - with Hot work
Structural construction/Repair - without Hot work
Equipment Replacement/Repair/Installation - with Hot work
Equipment Replacement/Repair/Installation - without Hot work
Critical Inspection - UTM, Pipeline X-Ray etc
Life Boat Launching Drill

Obs: Less liberty i.e some jobs can not be done e.g. Hot Work on deck of an FPSO

Special (with Planned Shut Down PSD)

Structural construction/Repair - with Hot work
Structural construction/Repair - without Hot work
Equipment Replacement/Repair/Installation - with Hot work
Equipment Replacement/Repair/Installation - without Hot work
Critical Inspection - UTM, Pipeline X-Ray etc
Life Boat Launching Drill

Obs: More Liberty. Most Topsides jobs can be done.

The CAE gets fed with all the Job Category Information and the system alerts automatically the Risks involved in the Zone or Equipment, where the job is to be carried out, and the subsequent Mitigation Measures.

The Process Safety Management (PSM) is the Interface on board to interact with CAE model and mediate Job Safety. It integrates the Permit To Work (PTW) with the JSA by CAE. The PSM also gets feedback from the Remote Sensing systems e.g. Fire and Gas Detectors, and alerts or restricts Jobs according to deficiencies detected.

The PSM can also override Ownership of a PTW, and allocate different Ownership, when it detects greater risk to one job being from another job in adjacent zone (vertical or horizontal) or connected equipment and can also merge both as a single job.

The PSM takes out the possibility of Human Error by its power of Bird´s Eye 3D 360 degree view of the Job Layout, including risks which are abstract by nature. For its proper functioning the Remote Sensing and Critical equipments should be working properly. Hence these equipments require great degree of Redundancy.