Presentation of PROD class notation

Classification

A 3rd party independent verification activity including:

– Design approval

– Fabrication surveys

– Functional testing

– Periodical surveys during operation

DET NORSKE VERITAS

Topsides classification

Classification is split into mandatory and voluntary parts:

Mandatory notation Voluntary notation

Production and Storage Unit

PROD

Overall topsides issues Topsides issues limited to the process plant

The split is by systems and equipment – not area.Process deck level is not a class notation split line

PROD Verification or Classification?

• Verification:– can only suggest improvement, cannot give requirements.

• Classification: – gives requirements and recommendations to the project

– challenges the project participants for fulfilment of agreed requirements

– aims for picking up issues fallen between chairs when:• No technical discipline thinks they have got the responsibility

• The contract does not specify sufficiently safety details

• Interface problems

• Hazard not identified at all

• Quality assurance arrangement overlooks details in where initiating event is hidden.

DNV-OS-E201

O F F S H O R E S T A N D A R D

Hydrocarbon Production Plant

October 2000

Contents:o Design Principleso Production and Utility Systemso Relief and De-pressurising Systemso Risers and Crude Export Systemso Electrical, Instrumentation and Control Systemso Pipingo Equipmento Structureso Materials and Corrosion Protectiono Manufacture, Workmanship and Testingo Certification and Classification

The Voluntary DNV PROD Standard

DNV refers to international standards

• DNV PROD standard refers to 76 international standards, e.g.:– 41 API references

– 7 ISO references

• DNV principles applied for PROD:– Increased use of internationally recognised standards as

basis for class

– More liberal practice for accepting alternative standards to the ones listed as basis for class, e.g.:

• Accepting Pressurised Equipment Directive of European Union (CE-mark)

DNV Criteria for Accepting a Standard

• Widely used in many parts of the world• Widely recognised as representing good practice• Regularly maintained up to date • Developed by a committee representing the principal

industry technical stakeholders (e.g. owners, operators, regulators, designers, manufacturers, certification bodies, academics)

• Reviewed by DNV and found to represent an acceptable minimum level of safety

Interfaces between class notations

O F F S H O R E S T A N D A R D

Hydrocarbon Production Plant

October 2000

O F F S H O R E S T A N D A R D

Safety Principles and Arrangements

October 2000

O F F S H O R E S T A N D A R D

Fire Protection

October 2000

O F F S H O R E S T A N D A R D

Electrical Installations

October 2000

O F F S H O R E S T A N D A R D

Instrumentation

October 2000

O F F S H O R E S T A N D A R D

InstrumenMetallic Materialstation

October 2000

O F F S H O R E S T A N D A R D

Structural Design

October 2000

Standard for Voluntary class Standards for Mandatory class

O F F S H O R E S T A N D A R D

Marine and Machinery Systems

and EquipmentOctober 2000

PROD counts in barrier establishmentW. Haddon: Accidents occur when objects are affected by harmful energy in the absence of

effective barriers between the energy source and the object

Danger

Several measures might be needed to obtain required safety level.

Process contribution to risk picture

Foredeling av FAR-TALL på Ulykkesområde for en FPSO

Risers 1 %

Process49 %

Marine Accidents32 %

Collisions18 %

Risk picture expressed by FAR- value for a (small) FPSO shows significant contribution from process plant

PROD is an ALARP activity

PROD class in projects

• Multi-discipline skilled personnel in each review– Knowledge of regulations and standards– Used to search for substandard– Looks beyond discipline borders– Experienced with different company philosophies– Experienced with different contractor/vendors– VQSC (Veritas Quality Scheme for Class) approved.

• DNV staff of technical specialists available for assistance• Cost-effective activity

– Experience based selection and limitation of documentation– Well-defined survey involvement– To the point review and survey– Flexibility with ‘equivalent solutions’.

One 3rd party reviewer for entire FPSO simplifies.– No interfaces between 3rd parties to manage.

– Substantial double work is avoided

– All 3rd party reviewed technical documents and comments are collected in one database, available world wide during project lifetime

– One team approaching both design contractors and vendors

PROD class in projects

PROD class and vendors

• Vendors normally to be responsible for obtaining certification

• Product certificate turns to be a ‘driving force’

• Certification coordinator in PROD class team

• DNV offices near to vendor involved in survey, subject to sufficient VQSC approvals

• Opportunity to include PROD certification in project mechanical completion activity.

• Periodical surveys– Annual– Renewal (each 5 year)

• Other surveys – Damages– Repair– Alterations– Conversions

• PROD assumes that a QA system exists– PROD survey means continuous check of In-service

Inspection and maintenance program of the FPSO

PROD class during production life

• Modification– Arrangement for assessment of design, fabrication,

installation and testing as per newbuilding approach

– Access to files from newbuilding project

• Class specialists available for assistance / troubleshooting on board.

PROD class during production life

PROD (N)Area  Reference 

Production plants, general  NPD Facilities Regulations (2001-09-03) with Guidelines 

Process systems  NORSOK P-001NORSOK P-100 

Process safety systems  ISO 10418API RP 14 C 

Piping Systems   NORSOK L-001 NORSOK L-002  

Mechanical equipment  DNV-OS-D101 

Technical Safety  NORSOK S-001 

Subsea installations  NORSOK U-001 NORSOK U-002 ISO 13628 

Electrical Installations  DNV-OS-D201 

Instrumentation and Control Systems  DNV-OS-D202