Asset life extension

These vessels are among the most technically complex vessels in the world, and Maersk FPSO is a supplier to some of world’s leading energy companies. Maersk FPSO recently commissioned ABB Consulting to undertake three separate projects in relation to ageing and life extension.

The first project was for the Curlew Field, which is developed via subsea facilities feeding into an FPSO owned by Maersk FPSO. The field partners are Shell (50%) and Esso (50%), with Shell as the operator. As part of an internal Curlew Status Review project, ABB were asked to undertake a study to identify the major issues and areas of capital expenditure required in order to extend the life of the FPSO through to 2019. The study was focused on the topsides pressure systems, rotating equipment and fire protection safety systems. The study involved an initial workshop with key operations and maintenance personnel to identify the scope of the study and understand existing life limiting issues.


Maersk Curlew FPSO.


This was followed by a structured review of the original design data for the systems as well as the operational history, inspection reports and maintenance records. This allowed the multidiscipline ABB team to identify the life limiting issues, quantify the risk in terms of health, safety, environment, reputation and production as well as develop pragmatic recommendations to eliminate the issues or reduce the risks.

The cost for individual recommendations was then estimated, together with proposed implementation dates. This facilitated the development of an expenditure profile for the asset through to the revised cessation of production date.

The second project was also for the Curlew Field and involved undertaking an audit of the integrity management systems associated with ageing and life extension ahead of a forthcoming Key Programme 4 (KP4) audit by the Health & Safety Executive. This audit involved on site structured discussions with the main operations staff and main engineering disciplines together with a review of sample documentation across the five principal elements of the KP4 audit programme.

The third project was for the North Sea Producer FPSO which is currently located on the MacCulloch Field and is operated by ConocoPhillips. This project involved the design and facilitation of a one day workshop to identify potential ‘gaps’ in the integrity management systems associated with ageing and life extension ahead of a forthcoming KP4 audit by the Health & Safety Executive. The output from this workshop was then used to develop an ‘improvement roadmap’.

All three projects were completed in a short time frame to the overall satisfaction of the client.

“ABB’s Asset Integrity Management team carried out an Asset Life Strategy Review and a KP4 gap analysis audit for our unit Maersk Curlew. Both studies were carried out on time and to the approved budget and we were satisfied with the reports produced as the final outcome of the studies.”

Niels Poulsen, Mechanical Engineer, Maersk FPSOs.