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

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

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)

World’s 1st TLP ‘Hutton’

for Conoco

World’s 1st Disconnectable

FPSO ‘Jabiru

Venture’

for GAR

(Australia)

World’s 1st Dynamically positioned FPSO ‘Seillean’

for BP (UK)

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

Texaco (UK)

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

for BP (UK)

1st set of ‘Risk Based’

Rules for Floating Offshore Units

1st FPSO for North American waters ‘Terra Nova’

for Petro-

Canada

2009 1st

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

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

2000 metres

Topsides

2000 -

33000 tonnes

Risers

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

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

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

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

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

Regulations

Part 4

Rules and Regulations

Part 4

Part 5

Part 4Rules and Regulations

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:

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

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: energyasia@lr.org

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