A technical hiccup in the Bauna floating production storage and offloading (FPSO) vessel deployed in the Santos Basin offshore Brazil has cost exploration and production company, Karoon Energy, about 10 days of production shut in, resulting in 4% lower yeild in the fourth quarter of 2024, when compared to the previous quarter.
This was triggered by the failure of two of the 16 FPSO mooring anchor chains, which is currently being addressed by Karoon and the FPSO operator, Altera & Ocyan (A&O), as the team tries to figure out the root cause behind the failure and identify ways to mitigate the risks of recurrence. Karoon is considering acquiring the FPSO for a smoother monitoring of the vessel, and is in talks with A&O to gauge the feasability of the plan.
"Longer term, given the significance of the FPSO to our operations, we see measurable operational and economic advantages in having direct control over the vessel. The company is in negotiations to acquire the FPSO from the current owner and operator, A&O, subject to finalising terms. Further details will be provided if and when a binding agreement is reached," said Julian Fowles, the Chief Executive Officer and Managing Director of Karoon.
Boosting FPSO efficiency
Achieving around 95% FPSO efficiency has also been a roadblock for Karoon as it remained low by atleast a 10% for 2024. To boost performance reliability, Karoon will soon be initiating a flotel-supported maintenance campaign on the vessel following the acquisition of relevant regulatory approvals. This floating hotel moored by the FPSO has been contracted to accommodate extra
manpower for a planned maintenance programme to methodically eliminate maintenance backlog so that equipment redundancy on the FPSO can be attained. The entire campaign might span across a period of two months, requiring the FPSO to remain non operational for at least 30 days. The company is expecting the Bauna FPSO to attain monthly efficiency of 88-92% (excluding shutdowns) in this year.
"While the Bauna Project production is starting to benefit from the work completed to clear the most production-critical maintenance issues, FPSO efficiency in CY24 was 84.5%, well below our long term expectations of 90-95%. A key focus in 2025 will be to increase FPSO efficiency towards that goal. The first step, a flotel-supported campaign to substantially reduce the maintenance backlog and improve equipment redundancy, is expected to commence shortly, once remaining regulatory approvals are received," said Fowles.
Karoon has also secured a vessel to conduct well intervention activities in SPS-88 in Bauna within the first half of the year so that it can be brought back onstream before mid-year. Fowles believes this to be a crucial step, alongside the flotel-supported maintenance campaign, in 'the reinstatement of production from SPS-88, which we expect back online at rates of 2,000 – 2,500 bopd before mid-year, is expected to help mitigate natural decline in 2025'.
A lightweight well intervention vessel will be deployed to replace the faulty gas lift valve in the SPS-88 completion string. The relevant approvals and necessary support vessels have been put in place for the intervention activities to begin.
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