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Classification and Regulatory Standards used in Novel Design Concepts for Deepwater Developments
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Transcript of 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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
INTRODUCTION
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical FPSO Development
-Multiple Interfaces
Hull Shipyard
Mooring System Supplier
Topsides Fabricator
Topsides Integration Yard
Class
Engineering Contractor
Client
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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..
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
MOORING ARRANGEMENTS
Bowmooring
Internal turretmooring
Spreadmooring
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
DEVELOPMENT ALTERNATIVES :
NEWBUILD vs
CONVERSION
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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?
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD –
SHELL gFLNG
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD TOTAL AKPO FPSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD –
NGANHURRA FPSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
SOLAS Permanent Means of Access (PMA)
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD -
SNEPCO BONGA FPSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Example Transit case (Bonga)
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD –
SHELL EA FPSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD LPG & CONDENSATE FSO LIBERDADE
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD -
TERRA NOVA FPSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD -
FPSO ‘NORTHERN ENDEAVOUR’
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
TOPSIDE SUPPORT STRUCTURE•
Gravity loadings
•
Hull motions
•
Hull girder stresses
•
Hull girder deflections
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD –
‘SEILLEAN’
DP FPSO (ex BP SWOPS)
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION –
HELIX PRODUCER 1 FPU
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION –
NINGALOO VISION FPSO ©
PROSAFE PRODUCTION 2010
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION –
CASPIAN SEA FSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION –
NGUJIMA-YIN FPSO
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION –
FSU SOORENA
Conoco
MacCulloch
North Sea Producer -
Teesside
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
RULES AND REGULATIONS (OVERVIEW)
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
LR RULES AND REGULATIONS FOR A FLOATING OFFSHORE INSTALLATION AT A FIXED LOCATION Rules and
Regulations
Part 4
Rules and Regulations
Part 4
Rules and Regulations
Part 4
Rules and Regulations
Part 4
Rules and Regulations
Part 5
Rules and Regulations
ABCD
Part 4Rules and Regulations
ABCD
Part 3Rules and Regulations
Part 2
Part 1A
Risk Based Approach
Part 1
Regulations
Rules and Regulations
Part 1A
Parts 2 to 9
Technical RegulationsRules and Regulations
Part 1
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
LR MANAGED VERIFICATION SCHEME (OVERVIEW)
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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…….
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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 )
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical Project Validation Work Instruction (VWI)
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Service Implementation
Design Appraisal
Procurement
Main Site Survey of Fabrication
Main Site Survey of Testing and Commissioning
Installation Survey
Hook-up and Commissioning Survey
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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.
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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.
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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.
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical Anomaly Report
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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.
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical Design
Appraisal CRS
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Technology & New Developments
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
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
Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
For more information,
please contact:
Lloyd’s Register Asia
Energy Upstream Business
T: +65 6278 9444
F: +65 6273 1662