The document outlines the classification and regulatory standards for Floating Production Storage and Offloading (FPSO) units as discussed at the Lloyd's Register and IQPC 11th Annual FPSO Congress in 2010. It covers key topics such as new build versus conversion options, design parameters, and rules governing FPSO installations, while emphasizing the importance of engaging with class societies early in the project. The presentation also highlights recent technological advancements and stresses the need for a managed verification scheme to ensure compliance and operational efficiency.

1. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Classification and
Regulatory Standards used
in Novel Design Concepts
for Deepwater
Developments
Alastair Jones

2. 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

3. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
World’s First’s in Floating Systems
1977 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

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

5. 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

6. 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

7. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical FPSO
Development
-Multiple Interfaces
Client
Hull Shipyard
Engineering 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 2010
MOORING ARRANGEMENTS
Internal turret
mooring
Bow
mooring
Spread
mooring

10. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
TURRET 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 2010
Turret & Swivel
System
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 2010
DEVELOPMENT ALTERNATIVES :
NEWBUILD vs CONVERSION

13. 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?

14. 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

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 2010
NEW 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 2010
NEW BUILD – NGANHURRA FPSO

20. 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

21. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
SOLAS
Permanent
Means of Access
(PMA)

22. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD - SNEPCO BONGA FPSO

23. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Example Transit case (Bonga)

24. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW 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 2010
NEW BUILD - TERRA NOVA FPSO

27. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD - FPSO ‘NORTHERN
ENDEAVOUR’

28. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
TOPSIDE SUPPORT STRUCTURE
• Gravity loadings
• Hull motions
• Hull girder stresses
• Hull girder deflections

29. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
NEW BUILD – ‘SEILLEAN’ DP FPSO (ex BP
SWOPS)

30. 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

31. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION – HELIX PRODUCER 1 FPU

32. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION – NINGALOO VISION FPSO
© PROSAFE PRODUCTION 2010

33. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION – CASPIAN SEA FSO

34. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION – NGUJIMA-YIN FPSO

35. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
CONVERSION – FSU SOORENA
Conoco MacCulloch
North Sea Producer -
Teesside

36. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
RULES AND REGULATIONS
(OVERVIEW)

37. 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

38. 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

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 2010
LR RULES AND REGULATIONS FOR A
FLOATING OFFSHORE INSTALLATION AT A
FIXED 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 2010
LR MANAGED VERIFICATION SCHEME
(OVERVIEW)

42. 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

43. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
LR Project Deliverables
Deliver 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 2010
Livelink 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 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

48. 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 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 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.

50. 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.

51. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical
Anomaly
Report

52. 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.

53. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Typical
Design
Appraisal
CRS

54. 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, LA
With descriptive notes
ShipRight COW, IGS(LR), Spread Moored, Helicopter Deck

55. Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Technology & New Developments

56. 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

57. 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

58. 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
E: energyasia@lr.org