Classification and Regulatory Standards used in Novel Design Concepts for Deepwater Developments

Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010

Classification and Regulatory Standards used in Novel Design Concepts for Deepwater Developments

Alastair Jones


OUTLINE

•

20 minute presentation

•

10 minutes for questions and answers

•

Content:

•

Introduction

•

New Build versus Conversion

•

Rules and Regulations (Overview)

•

LR Managed Verification Scheme (Overview)

•

Technology and New Developments

•

Summary


World’s First’s in Floating Systems1977

World’s 1st FPSO ‘Castellon’

for Shell (Spain)

1984

World’s 1st TLP ‘Hutton’

for Conoco

(UK)

1986

World’s 1st Disconnectable

FPSO ‘Jabiru

Venture’

for GAR

(Australia)

1989

World’s 1st Dynamically positioned FPSO ‘Seillean’

for BP (UK)

1996

1st Purpose Designed FPSO for the North Sea – ‘Captain’

for

Texaco (UK)

1998

1st Purpose Designed FPSO for West of Shetland – ‘Schiehallion’

for BP (UK)

1999

1st set of ‘Risk Based’

Rules for Floating Offshore Units

2001

1st FPSO for North American waters ‘Terra Nova’

for Petro-

Canada

2009 1st

Ship Shaped, Disconnectable, DP FPU ‘Helix Producer 1’ (GOM)

NOW

1st

Deepwater Semi FPS ‘Gumusut’

in Malaysian Waters for Shell & 1st

FLNG Unit for Australian Waters, Shell Prelude


INTRODUCTION


TYPICAL FPSO PARAMETERS•

New-build or Conversion

•

Storage

200,000 -

2,000,000 barrels

•

Production

30,000 -

250,000 bopd

•

Vessel

100,000 -

350,000 tonnes

•

Water depth

30 -

2000 metres

•

Topsides

2000 -

33000 tonnes

•

Risers

1 -

> 30

•

Wave height

benign -> 30 metres

•

Air temp

-20°C -

> 30°C•

Turret or Spread mooring arrangements

•

Permanent / Disconnectable Turret


WHAT MAKES AN FPSO DIFFERENT FROM A TRADING TANKER?

•

Operations and safety requirements

•

Layout and arrangement

•

Specified service / location

•

Different Classification Rules

•

National / Local Authority Rules and Regulations

•

Complexity of design, construction & commissioning

•

In-situ inspection / maintenance


Typical FPSO Development

-Multiple Interfaces

Hull Shipyard

Mooring System Supplier

Topsides Fabricator

Topsides Integration Yard

Class

Engineering Contractor

Client


Typical General Arrangements

Living quarters at the sternLiving quarters at the stern

Living quartersLiving quartersOil Oil Sep.Sep.

Prod Water/Prod Water/InjInj..

Gas Gas Comp.Comp.

UtilitiesUtilities

Flare TowerFlare Tower

TurretTurret

Living quartersLiving quarters

Oil Sep.Oil Sep.Gas Gas Comp.Comp.

UtilitiesUtilities

Flare TowerFlare Tower

TurretTurret

Living quarters at the bowLiving quarters at the bowUtilitiesUtilities

Prod Water/Prod Water/InjInj..


MOORING ARRANGEMENTS

Bowmooring

Internal turretmooring

Spreadmooring


TURRET MOORING SYSTEMS

Large Internal Turret Small Internal TurretRiser Turret Mooring (D)

Submerged Turret Production (D)

Buoyant Turret Mooring (D)

Internal External

External Turret Mooring


Turret & Swivel System

Turret upper Turret upper slewing bearingslewing bearing

Swivel stack

Chain stopper

RisersMooring

lines

Moonpool

Turret cylinder Lower bearing

Swivel Stack Swivel Stack Access StructureAccess Structure


DEVELOPMENT ALTERNATIVES :

NEWBUILD vs

CONVERSION


KEY CHOICE DRIVERS 1 OF 2

•

Project and client requirements

•

Schedule / time to first oil (new build: 2 to 3 years; conversion: 1 to 2 years)

•

Location / environment

•

Topsides function / size (Oil / Gas / LPG / LNG?)

•

Field life, CAPEX and OPEX

•

Early production or full field?


KEY CHOICE DRIVERS 2 of 2

•

Ship yard schedule

•

Availability / capability / price

•

Location

•

Availability of suitable tonnage

•

Capacity and suitability

•

Condition and age

•

Statutory and National Authority requirements


NEW BUILD HULL -

ADVANTAGES

•

Compliance with latest regulations

•

Design for required service and life

•

Integrated design

•

High standard of detailing

•

Service experience fed back

•

Inclusion of margins

NEW BUILD HULL -

DISADVANTAGES

•

Higher initial costs (CAPEX)

•

Longer schedule


NEW BUILD –

SHELL gFLNG



NEW BUILD TOTAL AKPO FPSO


NEW BUILD –

NGANHURRA FPSO


Permanent Means of Access (PMA)

•

SOLAS requirements for newbuild vessels

•

All internal tanks

•

Eliminate need for staging, rafting or rope access

•

Access for close up examination

•

Utilise tanks structural members, or provide dedicated arrangements

•

Standards for ladders, handrails, etc

•

Portable equipment may be used for some


SOLAS Permanent Means of Access (PMA)


NEW BUILD -

SNEPCO BONGA FPSO


Example Transit case (Bonga)


NEW BUILD –

SHELL EA FPSO


NEW BUILD LPG & CONDENSATE FSO LIBERDADE


NEW BUILD -

TERRA NOVA FPSO


NEW BUILD -

FPSO ‘NORTHERN ENDEAVOUR’


TOPSIDE SUPPORT STRUCTURE•

Gravity loadings

•

Hull motions

•

Hull girder stresses

•

Hull girder deflections


NEW BUILD –

‘SEILLEAN’

DP FPSO (ex BP SWOPS)


CONVERSION -

VESSEL SELECTION ISSUES

•

Vessel age, condition and service history

•

hull global strength

•

remaining corrosion margins

•

remaining fatigue life

•

structural steelwork replacement

•

Mooring structure

•

internal or external modifications

•

structural reinforcement

•

Topside integration

•

structural reinforcement

•

Possibility of upgrades to equipment, systems, machinery &

accommodation


CONVERSION –

HELIX PRODUCER 1 FPU


CONVERSION –

NINGALOO VISION FPSO ©

PROSAFE PRODUCTION 2010


CONVERSION –

CASPIAN SEA FSO


CONVERSION –

NGUJIMA-YIN FPSO


CONVERSION –

FSU SOORENA

Conoco

MacCulloch

North Sea Producer -

Teesside


RULES AND REGULATIONS (OVERVIEW)


DEFINITIONS

•

Class

•

to Class Society Rules

•

LR Rules for a Floating Offshore Installation at a Fixed Location (FOIFL Rules)

•

LR Rules for Ships

•

Certification

•

to Regulations and Codes

•

Verification

•

to Performance Standards


GOVERNING REGULATIONS•

Classification Rules

•

Local and / or National Authority

•

Some authorities require identification of Safety Critical Elements (ie. Hull)

•

SCEs then require verification by third party against Performance Standard

•

Class rules provide appropriate Performance Standard

•

Flag state

•

International conventions for ships

•

SOLAS, MARPOL, LOADLINE, TONNAGE

•

Disconnectable FPSOs effectively become ships –

flag becomes relevant


SCOPE OF LR FPSO RULES•

LR Rules cover the following aspects :

•

hull and marine systems

•

mooring systems

•

risers (optional)

•

process plant (optional)

•

drilling plant (optional)

•

LR Rules governing FPSOs have been updated in April 2008

•

FOIFL Rules refer to Ship Rules –

Oil Tankers

•

New LR ShipRight

–FOI Procedure

•

Both revised Rules and the new procedure can be downloaded free

•

Register to downlaod

your copy of the Rules from www.rules.lr.org

http://www.rules.lr.org/


LR RULES AND REGULATIONS FOR A FLOATING OFFSHORE INSTALLATION AT A FIXED LOCATION Rules and

Regulations

Part 4

Rules and Regulations

Part 4


Part 4


Part 4


Part 5


ABCD

Part 4Rules and Regulations

ABCD

Part 3Rules and Regulations

Part 2

Part 1A

Risk Based Approach

Part 1

Regulations


Part 1A

Parts 2 to 9

Technical RegulationsRules and Regulations

Part 1


LR MANAGED VERIFICATION SCHEME (OVERVIEW)


LR Project Manager

Manages all Project Class & Verification activities

•

Develop Project Quality Plan including Detailed Work Instructions

•

Report Progress & cost control for the project

•

Directly interface with project, alliance partners, approved contractors

•

Identify requirements for Classification/ Verification

•

Liaise with LR Technical Centres & Survey Offices to co-ordinate LR services


LR Project DeliverablesDeliver the Validation to Client’s Specification

and Classification

to Equivalent Rule

requirements via an integrated scheme:

Comment on list of SCEs and Performance Standards.Agreement on the scope of Validation.Design Appraisal Comment Response Sheets.Validation Activity/Anomaly Reports.Validation Work Instructions (VWIs)Statements of Validation for design appraisal, construction, installation and commissioning of all of the facilities.Classification certificate for the offshore facility.

Delivered as shown in the next slide…….



Livelink Data Management

D E S IG N R E V IE W

P ro g re s s R e p o rts L lo yd ’s R e g is te rP ro jec t M a n a g e r

D e s ig n R ev ie wC o -o rd in a to r

E P IC - 1C o -o rd in a to r

(C lie n t / C o n trac to rR e p rese n ta tive )

C o m p a n y(P ro jec t / E n g ine e rin g M a na g e r)

L iv e L in kS e rv e r

M o n ito rM on ito rO ve rv ie w

LR V IS 1 3 5

E P IC - 2C o -o rd in a to r

(C lie n t / C o n trac to rR e p rese n ta tive )

N o tif ic a tio n

C o m m e n tR e sp o n s e S h e e t

(C R S )

C o m m e n tR e s p o n s e S h e e t

(C R S )

D o c s /D ra w in g s

C o m m e n tR e s p o n s e S h e e t

(C R S )

D o c s /D ra w in g s

P ro d u c e “T a s ks ”T o S p e c ia lis ts

R e fe r S p ec ia lis t to th eL iv eL in k D o cu m e n ts

R o u te re p lies to an d fro ma n d trac k v ia D o cu m e n t

T rac k in g S y s tem

P ro d u c e F u ll A u d it T ra il toC o m p le tio n o f a ll D o c s an d

D ra w in g s

*

* O u tlo o k T as k sP ro v id e trac k in gP ro v id e d ia ryP ro v id e re p o rt in fo rm a tio nP ro v id e a le rts to ove rru n (la te re sp on se )


Typical Project Validation Work Instruction (VWI)


Service Implementation

Design Appraisal

Procurement

Main Site Survey of Fabrication

Main Site Survey of Testing and Commissioning

Installation Survey

Hook-up and Commissioning Survey


Service Implementation – Design Appraisal

Work Instructions and VWIs passed to LR design appraisal specialists.

Review of ‘Main Contractor’ & Equipment Supplier’s key design documents (Independent Analysis only performed when judged to berequired).

♦

Design analyses and primary drawings, Sample review of schematic diagrams such as P&IDs, SLDs, Cause & Effects.

Comments detailed in Comment Response Sheets (CRS).

Monitor and report status to closeout of LR CRSs.

Advise site surveyors of status and any special instructions for survey so that they can verify the facilities as-built.


Service Implementation - Procurement Survey

Main Contractor Procurement registers and Contract PO Quality Verification Matrix reviewed by LR to identify orders involving SCEs

LR to review ITPs for orders with SCEs for adequacy of inspection involvement (including Classification requirements).

Identify orders where LR involvement required at source.

Any required LR design appraisal arranged with Project lead engineers.

Potential involvement for LR surveyable orders is attendance at PIM, final testing and Document review. Cognisance taken of:

♦

2nd

party inspection activities.

♦

Code survey for pressure vessels and lifting appliances included

in this work where applicable.

Selected LR MDR review at main sites.


Service Implementation - Main Fabrication Site Survey

Instructions passed to the surveyors in the form of Work Instructions and VWIs.

Attend Pre-inspection meeting to review and mark up Main Contractor Quality Plans and Procedures.

Survey on a sampling basis, monitoring the activities of the site QA/QC team, against approved plans.

Attend selected tests.

♦

Hydrotests, Loop Tests, Commissioning, Cause & Effect, etc.

Review supporting documentation for free issue materials, equipment and Main Contractors certification records.

Agree punchlist of outstanding items.


Typical Anomaly Report


Service Implementation – Survey at Onshore and Offshore Project locations

Instructions passed to the surveyors in the form of Work Instructions and VWIs.

Attend initial meeting offshore to review and mark up Main Contractor Quality Plans and Procedures.

Survey attendance on a block visit basis, monitoring the activities of the offshore QA/QC team. Emphasis: key stages such as substructure installation.

Witness selected tests.

♦

Hydrotests, HUC Tests, Commissioning, Cause & Effect, etc.

Review Offshore Contractors certification records.

Agree punchlist of outstanding items and monitor to closeout.

Recommend issue of final deliverables.


Typical Design

Appraisal CRS


Typical Class Notation

• OI 100 AT Floating Oil Production and Oil Storage Installation for service at the ????Field, Offshore ???? LI, OIWS, ShipRight –FOI (SDA, FDA,CM)

OMC, IGS, UMS, LAWith descriptive notesShipRight COW, IGS(LR), Spread Moored, Helicopter Deck


Technology & New Developments


TECHNOLOGY & NEW DEVELOPMENTS

•

Revised FOIFL Rules launched May 08

•

New Software ShipRight for FOI’s

under

development

•

Existing Guidance on FLNG being updated in line with revised Rules


Summary

•

Most FPSO projects are different, beware of “generic”!

•

Engage Class Society / Verifier and Regulator early

•

Consider alternatives (e.g. newbuilding/conversion/unit type) carefully and evaluate options

•

Define the interfaces and make sure they are being managed

•

Ensure that operational experience is embedded into the design

•

Adopt and implement a single managed verification scheme.

•

Appoint single points of contact in each key stakeholder organisation

who is responsible for regulatory compliance


For more information,

please contact:

Lloyd’s Register Asia

Energy Upstream Business

T: +65 6278 9444

F: +65 6273 1662

E: [email protected]

Date post:	20-May-2015
Category:	Technology
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