Classification and Regulatory Standards used in Novel Design Concepts for Deepwater Developments
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Alastair Jones, Energy Upstream Sector Manager, ...

Alastair Jones, Energy Upstream Sector Manager,
Lloyd’s Register Asia shares with us the classification and regulatory standards
to novel design concepts for deepwater
developments.

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

  • 1. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Classification andRegulatory Standards usedin Novel Design Conceptsfor DeepwaterDevelopmentsAlastair Jones
  • 2. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010OUTLINE• 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
  • 3. 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 Units2001 1st FPSO for North American waters ‘Terra Nova’ for Petro- Canada2009 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
  • 4. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010INTRODUCTION
  • 5. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010TYPICAL 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
  • 6. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010WHAT MAKES AN FPSO DIFFERENT FROM ATRADING 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
  • 7. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 Typical FPSO Development -Multiple Interfaces Client Hull ShipyardEngineering Contractor Mooring System Supplier Class Topsides Fabricator Topsides Integration Yard
  • 8. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 Typical General Arrangements Living quarters Flare Tower Oil Gas Sep. Comp. Turret Utilities Prod Water/Inj. Water/Inj. Living quarters at the stern Flare Tower Turret Living quarters Prod Water/Inj. Water/Inj. Utilities Gas Oil Sep. Comp. Utilities Living quarters at the bow
  • 9. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010MOORING ARRANGEMENTS Internal turret mooring Bow mooring Spread mooring
  • 10. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010TURRET MOORING SYSTEMS Internal External Riser Turret Large Internal Turret Small Internal Turret Mooring (D) Buoyant Turret External Turret Mooring (D) Submerged Turret Production (D) Mooring
  • 11. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Turret & SwivelSystem Swivel Stack Access Structure Swivel stack Turret upper slewing bearing Turret cylinder Lower bearing Moonpool Chain stopper Mooring Risers lines
  • 12. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010DEVELOPMENT ALTERNATIVES :NEWBUILD vs CONVERSION
  • 13. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010KEY 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?
  • 14. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010KEY 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
  • 15. 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
  • 16. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD – SHELL gFLNG
  • 17. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
  • 18. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 NEW BUILD TOTAL AKPO FPSO
  • 19. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD – NGANHURRA FPSO
  • 20. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Permanent 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
  • 21. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010SOLASPermanentMeans of Access(PMA)
  • 22. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD - SNEPCO BONGA FPSO
  • 23. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Example Transit case (Bonga)
  • 24. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD – SHELL EA FPSO
  • 25. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 NEW BUILD LPG & CONDENSATE FSO LIBERDADE
  • 26. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD - TERRA NOVA FPSO
  • 27. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD - FPSO ‘NORTHERNENDEAVOUR’
  • 28. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010TOPSIDE SUPPORT STRUCTURE• Gravity loadings• Hull motions• Hull girder stresses• Hull girder deflections
  • 29. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010NEW BUILD – ‘SEILLEAN’ DP FPSO (ex BPSWOPS)
  • 30. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010CONVERSION - 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
  • 31. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010CONVERSION – HELIX PRODUCER 1 FPU
  • 32. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010CONVERSION – NINGALOO VISION FPSO © PROSAFE PRODUCTION 2010
  • 33. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010CONVERSION – CASPIAN SEA FSO
  • 34. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010CONVERSION – NGUJIMA-YIN FPSO
  • 35. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010CONVERSION – FSU SOORENA Conoco MacCulloch North Sea Producer - Teesside
  • 36. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010RULES AND REGULATIONS(OVERVIEW)
  • 37. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010DEFINITIONS• 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
  • 38. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010GOVERNING 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
  • 39. 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
  • 40. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010LR RULES AND REGULATIONS FOR AFLOATING OFFSHORE INSTALLATION AT AFIXED LOCATION Rules and Rules and Rules and Regulations RulesRegulations and Regulations Rules and Regulations Regulations Rules and Regulations Part54444 Part Part Part Rules and Regulations Part Part 4 Rules and Part 3 Regulations Rules and Regulations Parts 2 to 9 Rules and Technical Regulations Part 2 Regulations Part 1A Part 1 Part 1A ABCD Risk Based Approach ABCD Part 1 Regulations
  • 41. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010LR MANAGED VERIFICATION SCHEME(OVERVIEW)
  • 42. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010LR Project ManagerManages 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
  • 43. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010LR 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…….
  • 44. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
  • 45. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Livelink Data Management D E S IG N R E V IE W Com pany L lo y d ’s R e g is te r P r o g r e s s R e p o r ts (P ro je c t / E n g in e e rin g M a n a g e r) P r o je c t M a n a g e r Mo r n it o n ito O ve r Mo r v ie w D o c s /D ra w in g s N o tific a tio n E P IC - 1 C o -o r d in a to r D e s ig n R e v ie w (C lie n t / C o n tra c to r C o -o r d in a to r R e p re s e n ta tiv e ) C om m ent C om m ent R esponse S heet R esponse S heet (C R S ) L iv e L in k (C R S ) S e rv e r P ro d u ce “T asks” * T o S p e c ia lis ts D o c s /D ra w in g s E P IC - 2 C o -o r d in a to r (C lie n t / C o n tra c to r R e fe r S p e c ia lis t to th e R e p re s e n ta tiv e ) L iv e L in k D o c u m e n ts C om m ent R esponse S heet (C R S ) R o u te re p lie s to a n d fr o m a n d tr a c k v ia D o c u m e n t * O u tlo o k T a s k s T r a c k in g S y s te m P ro v id e tra c k in g P ro v id e d ia ry P ro v id e re p o rt in fo rm a tio n P ro d u c e F u ll A u d it T r a il to C o m p le tio n o f a ll D o c s a n d P ro v id e a le rts to o v e rru n (la te re s p o n s e ) D r a w in g s L R V IS 1 3 5
  • 46. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 Typical Project Validation Work Instruction (VWI)
  • 47. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Service Implementation Design Appraisal Procurement Main Site Survey of Fabrication Main Site Survey of Testing and Commissioning Installation Survey Hook-up and Commissioning Survey
  • 48. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Service 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 be required). ♦ 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.
  • 49. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Service Implementation -Procurement SurveyMain Contractor Procurement registers and Contract PO QualityVerification Matrix reviewed by LR to identify orders involving SCEsLR to review ITPs for orders with SCEs for adequacy of inspectioninvolvement (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, finaltesting 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.
  • 50. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Service 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.
  • 51. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 Typical Anomaly Report
  • 52. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Service 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.
  • 53. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010 Typical Design Appraisal CRS
  • 54. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Typical 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, LA With descriptive notes ShipRight COW, IGS(LR), Spread Moored, Helicopter Deck
  • 55. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Technology & New Developments
  • 56. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010TECHNOLOGY & 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
  • 57. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010Summary• 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
  • 58. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010For more information,please contact:Lloyd’s Register AsiaEnergy Upstream BusinessT: +65 6278 9444F: +65 6273 1662E: energyasia@lr.org