Wood Group Mustang Magazine Spring 2012

7/27/2019 Wood Group Mustang Magazine Spring 2012

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Spring 201

People Oriented...Project Driven

Inside This Issue... FPSO Topsides Design - Best Practices

Project Profile - Shell Perdido Project

Employing Best Practices in Offshore Automation

Visit us at OTC Booth 450


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For a totally integrated solution to your energy project,

contact Dynamic Industries, Inc. at:

Corporate Ofce600 Jefferson St., Suite 1400

Lafayette, LA 70501

Ph: 337.237.1898

Fax: 337.769.9615

Houston Ofce10777 Westheimer Rd., Suite 1175

Houston, TX 77042

Ph: 713.781.5510

Fax: 713.715.6678

The diverse capabilities of its sister companies in Dynamic Energy Services

International, LLC (DYNESI), formerly the Moreno Group, allow DII to offer

additional services including material supply, equipment rental, construction

labor and emergency response, environmental and technical services.

Dynamic Industries, Inc. (DII) provides expansive and integrated full-service fabrication, construction and maintenanceservices to a broad range of worldwide markets, including upstream (onshore/offshore) and downstream oil and gas,

industrial, mining and chemicals.

From structural steel fabrication of offshore jackets, drilling and production decks to process plant modules, DII is a prove

leader in heavy and light fabrication capabilities. We have the ability to transport nished projects by water, rail and truck

from our facilities located around the world.

Complementing our core fabrication capabilities, DII provides a comprehensive array of essential eld services. From

installation and connection of the fabricated units, through commissioning and ongoing facility maintenance, both

domestically and worldwide, DII is the logical choice.

www.dynamicind.com

Total Integrated Solutions

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Spring2012

PeopleOriente

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InsideThisIssu

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FPSOTopside

sDesign-BestP

ractices

ProjectProfile

-ShellPerdido

Project

EmployingBe

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VisitusatO

TCBooth45

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Alliance Engineering has executed pre-FEED, FEED, and

Detailed Design or 18 world-class FPSOs/FSOs (oating

production, storage and ooading) projects, including

the rst FPSO approved or use in the U. S. Gul o

Mexico. The cover photo is the Jubilee Field FPSO,

operating ofshore Ghana. Alliance provided the

Detailed Design or the topsides on this 1.6 million

bbl storage capacity vessel.

ABOUT THE COVER:

HOUSTON

16001 Park Ten Place

Houston, Texas 77084

(713) 215-8000 (713) 215-8506 Fax

www.mustangeng.com

ALABAMA

One Metroplex Drive, Suite 100

Birmingham, Alabama 35209

(205) 970-4977 (205) 970-4928 Fax

CALIFORNIA

2830 Howe Road, Suite A

Martinez, Caliornia 94553

(925) 231-4151 (925) 229-8220 Fax

DELAWARE

4550 New Linden Hill Road, Suite 400

Wilmington, Delaware 19808

(302) 993-2600 (302) 993-2699 Fax

GEORGIA

12600 Deereld Parkway, Suite 315Alpharetta, Georgia 30004

(770) 945-0200 (770) 945-0932 Fax

SOUTH CAROLINA

30 Patewood Drive, Suite 200

Greenville, South Carolina 29615

(864) 288-3009 (864) 404-2388 Fax

ABU DHABI

15th oor, Dhar Tower,

Najdah Street at Electra Street

Abu Dhabi, UAE

+971 (0)2 650-4449 +971 (0)2 650-8006 Fax

ANGOLA

Wood Group Kianda Lda.Rua Rainha Ginga, No. 87, 11th andar

Edicio Endiama-De Beers

Luanda, Angola

+244 222 444 876

KUALA LUMPUR

The ICON, Jalan Tun Razak,

W-07-01, Level 7, West Wing,

50400 Kuala Lumpur, Malaysia

603 230 22800

LONDON

St Andrews House, West Street

Woking, Surrey, GU21 6EB, U.K.

44 (0) 1483 717700

MUMBAI

Tower C, Rolta Technology Park

Street No.22, MIDC

Marol, Andhere (East)

Mumbai, India 400 093

91 22 6672 8500 91 22 6672 8600 Fax

SAUDI ARABIA

Mustang Al-Hejailan DAR PI

Al-Butain Tower (Across rom Mercure Hotel)

Prince Turki Bin Abdul Aziz Street

Corniche Eastern Province

Al Khobar 31952, Saudi Arabia

966 3 869 7100 966 3 869 7200 Fax

Table of ContentsLocations .......................................................................................3

Employing Best Practices In Offshore Automation .......6

Solutions Outside of the Box ...............................................11

Total Project Delivery.............................................................. 14

Two Leaders are Now The Leader in ................................ 16Topsides Design

Unequalled Topsides Experience .......................................17

Getting You What You Need, ..............................................18

When and Where You Need It.

Experience is in Mustangs DNA ........................................ 20

Advertiser Index....................................................................... 26

Project Profile: Lightweight Topsides Design............... 27

Produces Efficient, Lower Cost Facilities for Perdido

You Cant Go Wrong ...............................................................29

Need to Enhance Your Oil & Gas Recovery?...................32

FPSO Topsides Design-Best Practices ...............................34

Working in the Shale? .............................................................39

Using Experience to Integrate Total EPCM Delivery ...40

We are Carrying on The Scouting Tradition ...................43

LNG - Experience The Difference ......................................44

Add the Best Professionals to Your Team ...................... 46

When You Need Them

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2010

2011

2009

2008

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TitanLightest topsides built on a floating structure

Jack St. MaloFirst ultra-deepwater development in theLower Tertiary Trend

Worlds first re-deployable floating facility

- -

PerdidoWorlds deepest SPAR production platform

a aLargest topsides built in the Netherlands

ShenziWorlds largest MOSES TLP;Worlds largest oil capacity single lift topsides

-

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Automation projects for offshore production

facilities are becoming more challenging.

Tight schedules, new standards and technologies,

a high degree of system integration and

customization and complex execution

environments are all common. Integrating Best Practices into a

project is a proven approach for improving project outcomes. This

is especially true for the Front End Engineering Design (FEED)

phase of the project, a period when relatively low cost activities

can create significant and positive results. Suggested FEED best

practice examples are presented and their importance discussed.

Standards andRegulatory RequirementsEarly in the project the applicable regulations and standards (Client

and industry) are reviewed and confirmed. When designing a facility

in a new operating region, the environmental conditions, local design

practices and regulatory requirements may differ from the Client

standards and practices. Both should be reviewed and revised

as needed to align with project requirements. Differences and

discrepancies between documents should be reconciled, and a

conflict-free set of project standards developed.

Automation Design Basis (ADB)& System Block DiagramsThe Automation Design Basis (ADB) and System Block Diagrams

are cornerstone documents that guide the development of all

subsequent deliverables. Troubled automation projects that later

experience frequent changes and significant design errors often

begin with a missing, inconsistent or inadequate design basis. The

ADB begins with a full listing of the regulatory requirements and

the reconciled Client and industry standards. Process Automation

System (PAS) subsystems and major components, interfaces to

3rd party systems, basic architecture and key technologies are

described. Basic requirements include control console design,

monitoring and control functions, alarm management requirements,operator display types and the operating philosophy for controlling

complex package equipment, e.g., compressors, from a Central

Control Room (CCR). Basic hardware, power and electrical design

requirements are defined. System wide topics such as PAS

availability, reliability, performance, maintainability and sparing

requirements are also defined. Lessons learned are assessed and

documented in a dedicated section to highlight their importance.

Design studies are completed and the outcomes integrated into

the document.

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The PAS Block Diagrams should provide an accurate overview of

the PAS architecture, major subsystems and equipment locations.

Control consoles, engineering workstations, and PAS interfaces

to packaged equipment, electrical systems, Fire and Gas Systems

(FGS), the facility IT network and to a remote control location are

shown. Block Diagrams should also be provided for CCTV, power

management, instrument asset management and machine condition

monitoring systems to clarify major equipment components,

architecture, location and scope of supply boundaries. The ADB

and System Block Diagrams should provide a well thought out

and consistent design concept that is fully aligned with the Basis

of Design (BOD) and the Automation Philosophy documents.

Remote Operations Design BasisA Remote Operations Design Basis (RODB) is an important tool

for defining project requirements for monitoring and controlling

an offshore facility from a remote location. This document should

define the functional capabilities required at each location and thesupporting infrastructure needed to support each

capability. Supporting infrastructure may include

alternate power systems, modified building

HVAC systems, additional fuel and chemical

storage, and telecommunications systems that

provide the necessary network security, bandwidth

and reliability. Additional regulatory restrictions

apply when operating in US waters. (1)

Electrical Design

CoordinationWorking with electrical engineering, typical

electrical schematics are developed that show the

PAS hardwired, serial and network interfaces to

common Motor Control Center (MCC) and

Variable Frequency Drive (VFD) types. Authoring

a mutually agreed VFD interface specification can

be helpful. Electrical one-line drawings should

include the major electrical support equipment

identified in the ADB and RODB.

Process & InstrumentDiagrams (P&IDs)P&IDs identify most of the PAS I/O information

needed to size the PAS system. Because of their

high I/O contribution, P&ID typicals should be

developed for common control valve, MCC and

VFD types that indicate PAS interface details

and tagging conventions. PAS-connected fire and

gas detectors, manual ESD stations and typical

connections to packaged equipment, e.g., trip and

trouble alarm status, are also considered when

developing the PAS I/O counts. Presentation standards for alarms,

complex controls, safety system functions and PAS interfaces to

3rd party and packaged systems are also agreed.

Instrument Index and TaggingA comprehensive guide covering instrument tagging, naming,

character restrictions on tags and descriptors (inherent to some PAS)

and standard abbreviations should be developed. For computer

aided design tools like Intergraphs SmartPlant Instrumentation

(SPI), a project standard implementation guide, supporting standards,

and SPI wiring module templates tailored to the selected PAS are

essential. Custom SPI fields used to auto-configure PAS I/O

should be identified and implemented. The tagging guide and the

SPI documents are issued to Vendors and contractors with a

contractual obligation to follow these documents. Both contribute

to achieving tagging and wiring consistencies across the facility.

The SPI standards insure the databases from different contractors

can be merged into a single facility database at project completion.

TASK NAME

Initial activities

Standards & regulations review

Automation design basis

System block diagrams

Remote operations design basis

Interdisciplinary coordination

Analysis and assessments

Specifications & guidelines

Ancillary system block diagrams

Execution plans & contract documents

Estimate basis & cost estimate

Conceptual schedule for a nine-month FEED for an offshore automation project.

ID

1

2

3

4

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11

JAN FEB MAR APR MAY JUN JUL AUG SEPT

The Safety Requirements Specification (SRS) required by IEC 61511 andANSI/ISA 84.00 is a special case because of its increased complexity and affecton other disciplines and organizations.


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Space and WeightPAS space requirements can affect the topsides layout and the

building and machinery space dimensions. Resistance to change in

these areas often begins early. This information should be provided

near the FEED midpoint for a project that has a major space and

weight problem. The information needed to estimate

cabinet counts and power consumption include thePAS equipment make and model, estimated I/O counts,

equipment locations and spare I/O requirements.

Providing preliminary CCR and instrument rack room

layouts insures the proposed equipment fits correctly,

provides the necessary egress spacing and supports an

Operations and Human Factors review of the control

room. PAS power consumption, used to size back-up

battery systems, is needed to estimate battery weight

and room size. Large, deck-mounted PAS panels

are placed in the topsides 3-D layout model early to

account for their space and weight affect.

ConstructibilityMinimizing PAS cables that cross module construction splits

can reduce the offshore installation time and cost. By thoughtful

selection of where PAS equipment is located, the cross-module

interconnects are limited to f iber optic and network cables. A

modular design enables the PAS to be commissioned in sections

as construction progresses. UPS power-up is often delayed in

fabrication yards. The quality of yard and temporary offshore

power is often poor and can cause PAS damage and early aging.

Providing critical PAS equipment with a secondary power feed

from a distribution panel sourced from the emergency bus and

isolation transformers may be a prudent design. This design may

also apply if the equipment is required to operate when the primary

generators are offline or not available; the secondary source power

is supplied from a temporary or Hurricane generator.

Specifications, Guidelinesand Functional SafetyDeveloping technical specifications and guidelines is a significant

FEED activity. The intended audience and use of each document

should be assessed, and the content and level of detail thoughtfully

determined. Completed documents must fully align with the ADB

and Block Diagrams. All applicable standards and regulations

listed in the ADB are referenced. PAS interfaces to external systems,

e.g., instrument asset management and machine condition monitor-

ing systems, should be clearly and explicitly defined. The Safety

Requirements Specification (SRS) required by IEC 61511 and

ANSI/ISA 84.00.01 is a special case because of its increased

complexity and affect on other disciplines and organizations.

Given the wide variance among contractors, the SRS content and

detail should be agreed before work commences. (2) Preliminary

SIL calculations on common Safety Instrumented Function (SIF)

configuration types are recommended to assure that FEED designs

can meet SIL targets.

Package EquipmentA decision should be made early in FEED on which equipment

packages are provided with embedded Packaged Equipment

Control Systems (PECS). If a PECS is specified, the PAS interface

design may include a few hardwired signals supplied for critical

alarms, control and safety functions, and a serial or network

connection to manage the increased data exchange required to

support remote monitoring and control. The remote capability

tends to drive the complexity of the PAS interface design. A software

specification should be provided that defines the facility-standard

handshake protocol to detect interface failure and verify that net-

work exchanged control commands are received and implemented.

It also specifies the requirements for data exchange bit packing,

use of floating and integer type points and scaling, local/remote

control transfer switching and data needed to mimic the PECS

HMI displays within the PAS. PECS design and equipment selection

can be affected if the package contains SIF components. Early

identification of SIF requirements can prevent costly and late

design changes. Industry and Client network security standards

can place additional restrictions on the permitted PECS equipment

and design and must be clearly defined. (3) Critical packages may

require redundant power feeds and on-skid power supplies. PECS

interfaces to external instrument asset management, predicative

machine monitoring and fire alarm systems are common. Package

equipment vendors may have limited experience in some or all of

these areas. Successful implementation requires clear and explicit

requirements in procurement documents and specifications.

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Design Coordination with OtherDisciplines and OrganizationsAchieving early design and schedule alignment with other

disciplines and contractors can have a signif icant and positive

impact on the FEED and EPC-phase work quality and productivity.

When reviewing documents created by others it is often beneficial

to insert technical clarifications and references to automation

documents. This insures that others have a shared and commonunderstanding of a PAS interface requirement. The Instrument

Design Basis should address valve partial stroke testing and safety

transmitters if they are requirements in the SRS. A common FGS

Cause and Effect Chart that summarizes the type of f ire and gas

detectors used in the facility, where they connect, and which

system initiates executive actions provides an invaluable

coordination tool when issued to the topsides, hull and building

contractors and package equipment vendors. The topsides, hull,

marine, subsea, and telecommunications design basis documents

should reference the pertinent automation documents when there

is a significant technical interface to PAS or an ancillary system,

e.g., CCTV or asset management.

EPC Phase Execution Planand Contract CoordinationThe automation contracting and execution plan for the detailed

EPC phase must be developed in time to support the cost estimate.

The plan should be adjusted to reflect the contracting strategy

employed. Critical path scheduling should identify the long lead

and early need activities and equipment that may be needed before

the EPC phase is sanctioned. When proposal requests for other

contractors are being developed, an interface Roles and

Responsibility matrix and a clear delineation of scope are both

essential. Employing a MAC contracting strategy changes the

division of responsibilities between contractors. This must be

included and detailed in their RFPs.

An aggressive PAS schedule can result if the project intends to

float the hull early or requires early delivery of a high fidelity

Operator Training Simulator (OTS). The OTS is often integrated

with the PAS software to enhance operator training and to support

design and verification studies. Other disciplines and organizations

are affected if they provide information required to progress the

early PAS design. The added cost and change in execution plans

should be reflected in their proposals and contracts. The OTS

vendors proposal and execution plan should identify how

they address the compressed schedule and staged and

incremental deliveries of engineering information and PAS

software. (4)

Cost EstimateThe scope of the Class 3 cost estimate and the methods

used to develop the estimate is defined and agreed.

Providing an Estimate Basis document can be a useful

approach. This document, issued early for Client review,

lists the estimate assumptions and provides a narrative on

how equipment and services costs are acquired or

developed. The estimate process often has many sequential

tasks of varying length and takes several months to

complete. The workshould be detailed and scheduled early

to insure a timely completion.

References:1. Bureau of Ocean Energy Management, Regulation and Enforcement, Supervisory Control and Data Acquisition Systems (NTL No.

2009-G24)

2. Tom Shephard and David Hansen, IEC 61511 Implementation The Execution Challenge (Control Magazine, May 2010)

3. Andrew Ginter and Walt Sikora, Cybersecurity for Chemical Engineers (Chemical EngineeringJune 2011)

4. Tom Shephard, How to Develop a Project Execution Plan (Control Engineering Magazine, December 2009)

This article is excerpted from an article appearing in Offshore Magazine, November 2011, authored by Mustangs automation project

manager Tom Shephard, CAP, PMP. For further information, please contact him at [email protected].


10/48

10

Bringing energy and the environment into harmony.

The Americas: (Intl +1) 713-354-6100/EMEA: (Intl +33) 2-35-25-5225

Asia-Pacifc: (Int l +60) 3-2093-6633/ [email protected]

RELIABILITY ISSUES NEVER SLEEP.

WE MAKE SURE YOU CAN.

CompressorsTurbo & Recip / Steam Turbines / Gas Turbines / Control Systems / Expanders

At Dresser-Rand, we know any unscheduled interruption of a clients downstream

operation is simply unacceptable. Thats why we make engineering reliability a primary

focus. From one of the worlds largest hydrogen compressors (pictured at right) to our

single-stage steam turbines, Dresser-Rand downstream solutions are easy to maintain.

But for us, its not just about selling superior products, its about providing peace of

mind as well. So, when you do need help, rest assured were there for you.


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Solutions Outside of the BoxTHE COMPLETE PACKAGE

People Oriented... Project Driven

www.mustangeng.com1


12/48

www.awc-best.com

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Double Block and Bleed Valves

Tube Fittings andInstrument Valves

Process Instrumentation Gauges & Bi-MetaThermometers

Rupture DiscsProcess Filtration

Automation

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Engineering.

Fabrication.

Technical Design.

Backed by more than a centurys worth of experience, DXP provides a single source for

engineering, technical design and fabrication of pump packages. From pump selection to

installation and all processes in between, DXPs engineering staff provides the in-depth

technical expertise that has earned us our reputation as a world-class pump company.

DXP Enterprises, Inc. - 11947 FM 529 - Houston, TX 77041 - 713-937-2800

www.d xp e .co m

SpitzerIndustries,Inc.CorporateOffice11250TannerRd

Houston,TX77041Tel:713.466.1518

Fax:713.482.2780

www.spitzerind.com

rizonIndustries,Inc.

7007F362Brookshire,Texas77423Tel:281.375.7700

Fax:281.375.7979

www.orizonindustries.com

SpitzerIndustries,Inc./

MurNsOell,Inc.,ea-./a0r1ca2o341-151o3

13863IndustrialRoadHouston,TX77015

P..Box96097

Houston,TX77213Tel:7132304200

Fax:7132304250

Waterfront Facility at Greens Bayou

Property: 32 Acres

Under Roof: 188,000 sq. ft. Fabrication Shop: (4) Four bays 100 x 400 ea.

Lifting Capacity: (8) Eight 50T Bridge Cranes

Hook Height: 95 ft. under hook

Water Access: (2) Two barge slips

Water Depth at Slip: 12-15 ft.

Spitzer is a custom fabricator and packager of equipment

and systems specializing in: Subsea Structures

Engineered Process and Production Skid Packages

ASME VIII, Div. 1 and Div. 2 Pressure Vessels[U, U2 & R Stamps]

Specialty Structural Weldments

Spitzer has the in-house capabilities to provide: Project Management

Engineering Design / Drafting

Quality Control

Procurement

Contact us at: [email protected]

1


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In today's challenging economic climate, creative thinking, accurate cost estimates and a

commitment to technical excellence are crucial to the success of capital projects. Mustanghas a superior reputation for providing owners with total project delivery, from feasibilityanalysis and front-end engineering to facility startup.

Whether a project is grassroots, revamp, expansion or modernization, Mustang has theexperience and capability to successfully execute your project to achieve the desired results.

Contact Mustang today!

Total Project Delivery

With a Reputation for Excellence

[email protected]

www.mustangeng.com

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Getting rough?

www.lewa-inc.c

You can trust that LEWA will be there with you 24 hours a

day, 365 days a year with its network of well-experienced

engineers, worldwide service and repair facilities.

Packaged systems for chemical

& methanol injection

Closed Drain Pump Packages

LNG and gas treatment (gas odourization)

Full engineering support from FEED

to start-up phase

International project management

Worldwide service

LEWA, Inc.

132 Hopping Brook Road

Holliston, MA 01746, USA

Phone +1 508 429 - 7403

[email protected]

Gulf Coast Sales & Service Center

3433 N. Sam Houston Parkway West, Suite 400

Houston, TX 77086, USA

Phone +1 713 577 - 5392

[email protected]


16/48

Providing the technical expertise for a successful project...

any concept, any size, any water depth.

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UnequalledTopsidesExperience

Visit Wood Group Mustang

at OTC Booth 4505

2003

2002

2001

2007

2006

2005

2004

2010

2011

2009

2008

Horn Mountain

Worlds deepest dry tree production platform

MICA PompanoWorlds longest deepwater oil tieback pipeline

Northstar

First offshore production facility in Arctic

ZafiroFirst FPSO off Equatorial Guinea

Thunder HorseLargest semi-submersible in the world

TitanLightest topsides built on a f loating structur

Jack St. MaloFirst ultra-deepwater development in theLower Tertiary Trend

OPTIEXWorlds first re-deployable floating facility

Marco PoloWorlds deepest TLP (at installation)

MagnoliaWorlds deepest TLP

Benguela-Belize and Tombua-LandanaFirst Compliant Piled Towers outside theGulf of Mexico

PerdidoWorlds deepest SPAR production platform

ValhallLargest topsides built in the Netherlands

ShenziWorlds largest MOSES TLP;Worlds largest oil capacity single lift topsides

Independence HubWorlds deepest semi-submersibleWorlds deepest production platform

DianaSet world records for depth, heavy lift,horizontal drilling and control system design

The integration of Mustang and Alliance

Engineering under the Wood Group Mustang

brand has taken two leaders in topsides

engineering and design and created THE LEADER.The two companies have provided the industry

with a broad rsum of industry records for First,

Deepest, Largest, and Lightest on deepwater

projects around the globe.

In the past decade alone, Wood Group Mustang

has designed more than 500,000 metric tonnes of

topsides worldwide, resulting in the production of

over 1.5 million BPD oil. In addition, Wood Group

Mustang has been responsible for the only

Compliant-Piled Tower structures installed outsideof the Gulf of Mexico.

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Getting You What You Need,When and Where You Need It.

Mustangs Procurement professionals have the global expertise to obtain and deliver the right materials and equipment

wherever needed, within budget and on schedule. Our vast experience, supported by PACESETTER, Mustangs

proprietary web-based project delivery system, providing access 24/7 to cutting-edge material control and tracking for

your project, enables us to provide you with up-to-date equipment, materials and subcontract information. We offer the

complete package of procurement and subcontracting services, or just the portion you need, for your project no matter

the size, no matter the location. Our mission is to be your first choice in Procurement Services around the world.

Upstream Downstream Pipeline Automation Process & Industrial

Global Sourcing Strategies Vendor Inspection Coordination

Procurement/Subcontract Execution Planning Home Office Materials Management

Transportation & Logistics Studies Load-out/Transportation Coordination

Procurement & Subcontracting Procedures Job Site/Field Material ControlVendor/Subcontractor Qualifications & Surveys Purchase Order/Subcontract Administration

Requests for Proposal/Bid Evaluations Supplier Invoice Administration & Control

Office & In-Shop Expediting

For further information, please contact [email protected] / 1+713-215-8696.

www.mustangeng.com

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As your complete premium steel resource, Edgen Murray ensures your steel supply requirements and schedules are

met with exacting precisiondelivered on time from the best possible sources. We work with world-class mills and

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edgenmurray.com 30+ Locations Worldwide

Plate / Structural / Pipe / Fittings / Valves

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Experience is in Mustangs DNA.To say that Mustang has automation and control experience is an understatement. Most of its management team

has worked in the industry for more than 30 years. They are supported by specialists, managers and engineers

averaging close to 20 years of systems expertise and industry project knowledge. Mustang offers vendor

independence, alliances with the most recognized technology producers and global experience in:

Main Automation Contracting Human Machine Interface

Systems Integration Alarm Management

Project Management Network Security

Functional Safety Manufacturing Execution Systems

Advanced Process Control Environmental Data ManagementAbnormal Condition Management

Look to Mustang. We have built-in experience to get projects done right.

Automation and Control


[email protected]

www.mustangeng.com

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ServingTheTexaSgulfCoaST

Houston Corpus CHristi Freeport Beaumont

pHone: (713) 856-9206 Fax: (713) 856-9299

www.oliverequip.Com

speCialty equipment sales

Leistritz began the manuacture o screw pumps more

than 80 years ago, and the rst product was a unique

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the screw amily has expanded to 3-rotor, 5-rotor, and 2-rotor

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o the Chemical Processing, Marine, Oil and Gas, Rening, Power

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Milton Roy is the worlds largest manuacturer o controlled volume

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AGI Industries.................................................................................41

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Beta International............................................................................41

Bran+Luebbe..................................................................................23

Cameron.............................................................................back cover

Chart Energy....................................................................................22

Cruver, Robbins & Fu, LLP............................................................44

Deep South Crane & Rigging..........................................................26

Dresser Rand...................................................................................10Dynamic Industries, Inc..........................................inside front cover

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Edgen Murray..................................................................................19

Emerson..........................................................................................5

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Freeport Welding & Fabricating, Inc...............................................10

GBA-Corona, Inc............................................................................45

GEA Rainey Corporation.................................................................45

General Welding Works, Inc..........................................................28

Gulf Coast Alloy Welding..............................................................44

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LEWA, Inc......................................................................................15

Mammoet........................................................................................31

New Industries.................................................................................30

Oil States Industries, Inc.................................................................28

Oliver Equipment Company............................................................21

Performance Contractors, Inc.........................................................42

Powell Industries...............................................................................4SoTec..............................................................................................41

Spitzer.............................................................................................13

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Alliance Engineering, a part of Wood Group Mustang, has expertisein successfully developing topsides for major offshore fields in avariety of project types, including floating production, storage andoffloading (FPSO) units; deepwater floating platforms; and fixedstructures. Alliance has built an established and well-earnedreputation for designing and implementing lightweight, single-lift

deepwater topsides. Alliance is associated with numerous worldrecords and industry firsts, including the deepest tension-legplatform (TLP), deepest spar, deepest semi-submersible platform,deepest dry tree unit, first dry tree mini-TLP, and first mini TLP.

This reputation and its successful design of BPs fast-track HornMountain topsides production facility were reasons why Shellchose Alliance to provide front-end engineering and design anddetailed design of the topsides for its Perdido platform, the worldsdeepest drilling and production spar facility. Alliance also providedconceptual design services, fabrication and installation support,and commissioning support for the unique topsides.

Reducing Weight at Every OpportunityThe topsides design techniques were key enablers to permit Shellto advance the Perdido project. Designing the deck for single-liftinstallation avoided redundant steel weight and resulted inimproved deck space utilization, lower installation cost, morecomplete pre-commissioning, and faster offshore hook-up andcommissioning. The lightweight topsides reduced hull displacement

Lightweight topsides designproduces efficient, lowercost facilities for Perdido

P R O J E C T P R O F I L E

and mooring loads, provided a faster overall project schedule, andimproved overall project economics.

In partnership with Shell, Alliance demonstrated ingenuity andflexibility by engineering a fit-for-purpose topsides design. In thedesign process, Alliance investigated and implemented many solu-

tions to reduce lift and operating weights. The design, equipmentlayout and human factors engineering relied heavily on sophisti-cated 3D modeling techniques and input from experiencedoperations personnel. Alliance challenged equipment suppliers toreduce the size and weight of their equipment. Combined withShells innovative solutions to reduce the riser load on the spar, thisapproach resulted in significant weight reduction and a significantsavings in time and cost. The facility accommodates productionfrom five subsea direct vertical access separation caissons.

Sophisticated Instrumentation and ControlAlliance worked very closely with the main automation contractorto design and implement a world class facility control system for

Perdido. Every facet of the facilitys processes, including topsides,hull, and subsea, can be managed from Perdidos central controlroom. The process control portion of Perdidos facility controlsystem is based on Yokogawas Centum CS 3000 distributedcontrol system (DCS). For safety shutdown and emergencysupport, Yokogawas ProSafe RS for safety integrated systems wasused. The ProSafe RS is a TV SIL-3 rated safety system. TheCentum CS 3000 DCS and ProSafe RS safety system communicateseamlessly, allowing safe integration of the controls and shutdownsystems for the facility.

Project SuccessThe topsides, after completion of fabrication at the Kiewit yard in

Ingleside, Texas, was transported to the field and was installedonto the Perdido spar in March 2009. At 9,350 short tons, this liftis the heaviest ever made in the Gulf of Mexico. The Perdidotopsides was designed with a lift weight that matched the liftingcapacity of Heeremas Thialf installation vessel. Perdido reachedfirst oil during the first quarter of 2010. At a water depth of 7,817feet in the Alaminos Canyon offshore Texas, it is the worldsdeepest drilling and production spar and represents anotherinnovative and successful project for Alliance.

This project profile first appeared in Pennwell PublishingCompanys Perdido supplement.

2OTCs 2012 Dstgshd Achvmt Award


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Successful topsides design requires effective decision

making in five areas: process optimization, and module,

piping, electrical and structural designs. Key to success is

experienced engineers and designers who understand best practices

for the structural interface between hull and topsides modules

and for optimized equipment location, safety, maintenance and

operability.

FPSO topsides projects developed by utilizing best practices

benefit from the application of systematic detail design based on

experience and proven results. The result is improved quality and

consistency. Cost and schedule are reduced through efficient

engineering and design that minimizes equipment and simplifies

fabrication, installation and commissioning.

Process optimizationOptimizing the process before beginning detail design is a critical

component of best practice and delivers measureable benefits to

operators.

An FPSO was designed to accommodate oil production of 100,000

bpd, associated gas production of 250 mmscfd, produced water of

100,000 bpd, and water injection of 275,000 bpd at 5,000 psig surface

pressure. The process optimization goals were to meet HSE

requirements, export maximum oil quantities, reduce capital

expenditures, minimize deck space and operating weight, minimize

process complexity, maximize reliability,

minimize operating cost and maximize net

present value.

The process optimization resulted in the

utilization of an oil stabilization process that

maximized oil recovery and operated at

higher pressures to minimize compression.

The resulting facility consisted of 10 modules

and reduced topsides weight by 7,000 short

tons compared to conventional stage

separation, providing an approximate savings

of $300 million.

LayoutBest practices help define the location ofliving quarters, safe access/egress, flare,

hazardous and non-hazardous process

systems, ship loading and unloading

activities, and supply vessel and helicopter

operations.

The layout of the FPSO topsides is driven by the method of

mooring, sea state factors, and placement of the modularized

process and utility systems, with allowance for operability,

maintenance and, above all, safety. Vessel topsides orientation

should be determined early as it affects the configuration of all

topsides elements.

The FPSO discussed in this example is a spread moored vessel.

Other vessel mooring types will have different requirements for

topsides orientation. In this case the flare is placed downwind of

the prevailing wind direction and as far away as possible from the

accommodations. Helicopter approaches should be at quartering

angle in the direction of predominant wind and above the

accommodations. The approach angle must take into account

obstructions from the flare, vertical equipment above the module

structure, the destabilizing affects of exhaust gasses from turbine-

powered equipment and visual aids for helicopter touchdown.

Metocean data and dropped-object risk factors were considered

in determining supply boat approach to allow for primary and

optional offloading scenarios. An offloading buoy is the primary

means of delivering cargo and the supply boat approach should

always be up-current so the boat will drift away from the FPSO if i

loses power. Laydown areas should be adjacent to the supply boat

access to allow for ease of loading and offloading supplies and

equipment. Riser locations should be on the opposite side from the

supply boat access to reduce risk from dropped objects during

transfers between vessels.

The FPSO layout best practice utilizes an arrangement of process

and utility modules alongside a central pipe rack. The pipe racks

must be of a similar length to their adjacent modules.

Figure 1 illustrates vessel orientation best practices.

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The most hazardous modules, based on process system, should

be placed farthest from the accommodations to maximize safe

distances. Lowest risk modules, such as the utility modules, are

placed closest to the accommodations. A twenty meter gap, or a

safe zone, should be maintained among accommodations and all

process and utility modules regardless of the perceived risk or

classification. Laydown areas, if not used to store hydrocarbons/

chemicals for long periods of time, are the only exception.

Equipment within each module should be arranged with heaviest

items closest to the hull centerline and on the lower levels to reduce

the effect on the FPSOs center of gravity. Towers and tall vessels

should also be located in modules as near as possible to the hull

centerline to reduce the affect of sea state conditions on equipment

performance and support

structure.

Roll onboard an FPSO has

the most variation from

horizontal due to sea state

conditions. The shaft of

rotating equipment should be

orientated parallel to the

longitudinal axis of the FPSO

hull. This mitigates the effect

of the ships roll, reducing

impact on rotating equipment

performance and increasing

reliability and uptime.

StructuralModular systems simplify overall shipyard construction and reduce

integration cost and schedule. Modules can be independently

fabricated, tested and delivered to the shipyard as complete

packages ready for integration, commissioning and start-up.

Generally accepted spacing between modules is one meter clearance;

this can be reduced to six hundred millimeters between module/rack.

Modules should be designed with a three meter gap from edge of

hull to outermost edge of module, excluding stairs, to allow

overhead access to the ships main deck and to provide a perimeteregress zone.

FPSO modules are designed along a standard general ratio of the

ships length divided by 10. This means for modular sections the

length between outer module supports is a maximum of one tenth

of the length of the hull being used.

Arranging the pipe rack along the longitudinal centerline allows

process and utility equipment to be arranged on either side. This

allows for later introduction of equipment, packages or modules

with minimum risk to previously installed topsides components.

The floor of the pipe rack should be at the same elevation as the

lower deck level common to all modules to provide primary

maintenance access.

FPSO module sizes are also restricted by the fabricators lift capacity.

Module support designs allow for the behavior of the hull and

topsides. Increased hull modules and complex flexibility issues

require the link between the topsides and hull to be broken.

Modules designed to be on a sliding stool system are able to move

and reduce stress to the hull. Although two or three longitudinal

frames usually are utilized, typically only one stool support per

module longitudinal frame is pinned to the hull; the other stools are

sliders. The pin stool allows for free rotation but restricts

translation in up to three directions. The sliding stools prevent

movement only in the vertical downward direction, although some

are designed to limit

translation in the hull

transverse direction as

well. This minimizes

the effects of hull

hogging and sagging

on both the module

and the hull while

keeping the module

secured to the hull.

All structural

interfaces with the

topsides modules or

riser porches are

designed to be

directly over a hull

bulkhead or frame.

The design of FPSO modules includes many load cases resulting in

braced structures and less access to equipment. Sea state conditions

greatly affect the design of FPSO topsides. Structures must allow

for lateral bracing at every change in pipe rack direction regardless

of its size. All long, straight-run pipe racks need to be tied back tomodule columns and have racking bracing in multiple locations

along their length.

The in-place analyses of the modules include operating and

extreme environmental conditions. The modules are also designed

to be transported from the shipyard to the production site and lifted

from the fabrication yard or transportation barge to the ship.

Spectral fatigue analyses incorporating both the in-place and transit

conditions are performed.

Figure 2 illustrates FPSO layout

best practices.

Figure 3 illustrates the pin stool

best practice.

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A free zone is established between

hull, marine and topsides systems.

All systems should be excluded from

this zone unless recognized to be

part of the integration or hook-up.

A minimum of a three-meter air

gap is used between the hull deck

centerline and the underside of the

modules. This gap is kept as small

as possible to maintain the lowest

possible center of gravity on the

FPSO hull. Top of module support

stool is the battery limit between

the topsides and marine structures.

PipingKey to success for piping design

is controlling interconnect piping

between module/pipe rack and

module/hull. Dedicated areas should

be defined as having the least amount of differential movement.

Interconnect piping on modules with sliding supports should be

located in the module corner closest to the pinned-end support. The

piping should be designed to have a fixed point in the module

before crossing to the pipe rack or module-to-hull gaps to reduce

dynamic stresses in equipment nozzles. Sufficient horizontal and

vertical offset should be present to obtain greater pipe flexibility.

Piping should not cross the module-to-module gaps but should be

routed via the pipe rack to reduce vessel-induced stress.

ElectricalFPSO electrical systems should be designed to utilize more than

one electrical building. Having a main electrical building aft and an

auxiliary electrical building forward reduces the need to route a

large number of trays throughout the vessel from one location.

The addition of an auxiliary electrical building distributes the

cable tray runs more evenly over the pipe rack, allowing for more

efficient use of space, smaller electrical buildings and lower

module weights. Power generators, main transformers, main

electrical building and large motors such as water injection pumps

must be located in close proximity to reduce the amount of

medium- and high-voltage cabling. These loads should also be as

close as practical to the main generation station to reduce voltage

drop due to cable resistance/reactance. Medium- and low-voltage

switchgear and medium-voltage motor control center should be

routed longitudinally due to height-to-depth ratio. Low-voltage

motor control centers should be routed laterally, again because of

the height-to-depth ratio.

Conclusion

Best practices for FPSO topsides design begins with optimizingthe process, followed by equipment selection and layout according

to established guidelines for safety and operability. The piping,

structural and electrical designs all should follow established best

practices guidelines. Following these best practices will increase

the safety and operability of the topsides design while reducing costs.Figure 4 illustrates piping interface best practices

This article was authored by Alliance Engineerings Norb Roobaert, PE; Juan Campo, PE; Howard Newman; and Alan Phillips, PE. It originally

appeared in the January 2012 issue ofOffshore Engineer. For additional information, go to www.alliance-engineering.com.

3


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CRUVER, ROBBINS

& FU, L.L.P.A T T O R N E Y S A T L A W

(713) 621-6800

Leaders in the Preparation and negotiation of

domestic and international EPCcontracts

Prosecution, prevention andmanagement of E&C claims

Purchase and sale of E&C businesses

Compliance with the Foreign CorruptPractices Act

Counselors to the engineeringand construction industries

www.cruverlaw.com

Gulf Coast Alloy Welding, Inc. (GCAW), an established fabricator of ASME Code pressure vessels, tray towers andcolumns, has been serving the oil & gas and petrochemical industries since 1981. We have been providing equipmenfor capital projects both direct to major petrochemical plants and various engineering and construction firms.

Certified to ASME Section VIII Div. 1 & 2 ASME Section 1 ASME Code Stamps: U, U2, R and S Custom Fabrication Clad Vessels (all materials) Weld Overlay nozzles, pipe and vessels Turn Key Modular Equipment Skid Packages Equipment through 19 in diameter and 300 in length Heavy wall fabrication through 8 thick Special Linings Sandblasting and painting in house

GCAWs strength lies in our ability to handle all RFQs promptly and accurately. Our engineering and design servicesutilize the most current design programs with capabilities to electronically transfer engineering documents world wideFor a brochure and/or additional information, please call us at 1-281-821-0543 or email us at [email protected].

G u L f C O A S T A L L O y W e L D i n G

4403TheissRoadP.O.Box1327

Humble,Tx77338Phone:(281)821-0543Fax:(281)821-0545

A Quality Pressure Vessel and Service Fabrication Companywww.GCAW.com

Experience The DifferenceMustang has experience with executing LNG projects

regasification or liquefaction, onshore or offshore, grassroots

or brownfield. We have:

LNG Experience Concept Studies, FEED, EPCM for

liquefaction and regasification with NGL recovery

Modular Experience Proven scalable modular designs

for offshore and onshore process modules

Topsides Experience Extensive topside designs forfloating production facilities and FLNG

Operating Experience Operating and maintenance

specialists to take projects beyond startup

Technology Experience Project design experience with

third party liquefaction and regasification technologies

Needing a partner for your next LNG regas or liquefactionproject? Look to Mustang. Experienced. Global. Ready.

E-mail: [email protected]

Houston London Luanda Mumbai

Abu Dhabi Saudi Arabia Kuala Lumpur

www.mustangeng.com


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GBA-Corona, Inc. H ou s ton L ondon M iL a n

GBA-Corona, Inc.

Houston, TX 77036

Tel: 713-773-9933

Fax: 713-773-9940

GBA Ltd.

Slough, UK

Tel: +44-1753-575710

Fax: +44-1753-575750

GBA srl

Monza, Italy

Tel: +39-039-492718

Fax: +39-039-2794257

GBA-Corona specializes in all of your flaring needs. From simple

pipe flare applications to the most complex staged systems, GBA has

the expertise and equipment to fit the process conditions.

GBA flare systems are specifically designed with both performance

and longevity in mind without losing sight of cost. This combina-

tion is essential for all applications and should be demanded by all

operators and engineers.

For a complete listing of all of our equipment and service,

please visit our web site at www.gba-corona.com or contact us at

[email protected]

Flares for the FutureFlares for the Future

GEA Heat Exchangers=GEA Rainey Corporation

ROMO=t=`~=o~I=`~~I=l~~=TQMNR=qK=EVNUF=OSSJPMSMI=~]~~KI=~]~~K=K~~K, www.gea-heatexchangers.geagroup.com

Air Cooled Heat Exchangers for the Process and Power Industries

GEA Rainey Corporation, located outside Tulsa, Oklahoma, designs, fabricates andservices air cooled heat exchangers for the chemical, petrochemical, refinery, gasprocessing, gas transmission and power generation industries.

GEA Rainey Corporation is organized within GEAs Heat Exchanger Segment, theheat exchanger market world leader,and benefits from the latest engineering andmanufacturing technologies as well as the strong financial stability of a globallydiversified organization. The result is an unmatched level ofknowledge andcapability for your local and global projects. Utilizing access to our globalmanufacturing facilities provides additional flexibility forregional material andcode compliance as well as local delivery.

Please contact us today for all your air cooled heat exchanger needs.


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Mustangs Professional Services Group can provide you with experienced on-site engineering andsupport services personnel when you need them. We have engineers, designers, managers,

administrators, project controls, field service and other positions available to solve your fluctuating

staffing demands. Just call us, and we will fill your requirements with the right people. Take

advantage of these benefits:

Staffing flexibility Turnaround specialists

Reduced recruiting costs Worldwide coverage

Immediate productivity Phase-out after project completion

Mustang-provided benefits package No termination costs

Contact Lanny Ottosen to learn more about how Mustang can put professionals to work for you.

713/350-7233

[email protected]

www.mustangeng.com

Add the Best Professionals to

Your Team When You Need Them.

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Joined upthinking

A plant is made up o a million decisions, big and small.Its a complex fow o people, resources, designs andschedules. Success requires collaboration, and a completeunderstanding o strategic activities and events.

With AVEVA inormation integrity, all project data can be exploited

and shared at every stage o the assets lie, joining up the details

to show the big picture. The result is accurate and efcient projectperormance and asset operations that are always under control,

reducing risk, time and cost.

With a global sales and service network in more than 40 countries,

AVEVA is a leader in engineering design and inormation management

solutions or the process plant industry.

Choosing AVEVA will be one o the best decisions you ever make.

www.aveva.com4


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Return Address

Mustang Engineering

6001 Park Ten Place

Houston, TX 77084

PRSRTSTDU.S.Postage

PAIDChampaign,Permit100

Documents

Wood Group Mustang Magazine Spring 2012