Campo ROB BOY

Lloyd’s Register: IQPC 11th Annual FPSO Congress 2010
Classification and
Regulatory Standards used
in Novel Design Concepts
for Deepwater
Developments
Alastair Jones
OUTLINE
• 20 minute presentation
• 10 minutes for questions and answers
• Content:
• Introduction
• New Build versus Conversion
• Rules and Regulations (Overview)
• LR Managed Verification Scheme (Overview)
• Technology and New Developments
• Summary
World’s First’s in Floating 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
INTRODUCTION
TYPICAL FPSO PARAMETERS

• New-build or Conversion
• Storage 200,000 - 2,000,000
barrels
• Production 30,000 - 250,000 bopd
• Vessel 100,000 - 350,000
tonnes
• Water depth 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
WHAT MAKES AN FPSO DIFFERENT FROM A

TRADING TANKER?
• Operations and safety requirements

• Layout and arrangement
• Specified service / location
• Different Classification Rules
• National / Local Authority Rules and Regulations
• Complexity of design, construction & commissioning
• In-situ inspection / maintenance
Typical FPSO
Development
-Multiple Interfaces
Client
Hull Shipyard
Engineering Contractor Mooring System Supplier
Class Topsides Fabricator
Topsides Integration Yard

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

MOORING ARRANGEMENTS
Internal turret
mooring
Bow
mooring
Spread
mooring
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
Turret & Swivel

System
Swivel Stack
Access Structure Swivel stack
Turret upper
slewing bearing
Turret cylinder Lower bearing
Moonpool Chain stopper

Mooring
Risers lines
DEVELOPMENT ALTERNATIVES :
NEWBUILD vs CONVERSION
KEY CHOICE DRIVERS 1 OF 2
• Project and client requirements
• Schedule / time to first oil (new build: 2 to 3 years;

conversion: 1 to 2 years)
• Location / environment
• Topsides function / size (Oil / Gas / LPG / LNG?)
• Field life, CAPEX and OPEX
• Early production or full field?
KEY CHOICE DRIVERS 2 of 2
• Ship yard schedule

• Availability / capability / price
• Location
• Availability of suitable tonnage

• Capacity and suitability
• Condition and age
• Statutory and National Authority requirements

NEW BUILD HULL - ADVANTAGES
• Compliance with latest regulations

• Design for required service and life
• Integrated design
• High standard of detailing
• Service experience fed back
• Inclusion of margins
NEW BUILD HULL - DISADVANTAGES

• Higher initial costs (CAPEX)
• Longer schedule
NEW BUILD – SHELL gFLNG

NEW BUILD TOTAL AKPO FPSO

NEW BUILD – NGANHURRA FPSO

Permanent Means of Access (PMA)

• SOLAS requirements for newbuild vessels
• All internal tanks

• Eliminate need for staging, rafting or rope
access
• Access for close up examination
• Utilise tanks structural members, or provide
dedicated arrangements
• Standards for ladders, handrails, etc
• Portable equipment may be used for some
SOLAS
Permanent
Means of Access
(PMA)
NEW BUILD - SNEPCO BONGA FPSO

Example Transit case (Bonga)

NEW BUILD – SHELL EA FPSO

NEW BUILD LPG & CONDENSATE FSO LIBERDADE

NEW BUILD - TERRA NOVA FPSO

NEW BUILD - FPSO ‘NORTHERN

ENDEAVOUR’
TOPSIDE SUPPORT STRUCTURE

• Gravity loadings
• Hull motions
• Hull girder stresses
• Hull girder deflections
NEW BUILD – ‘SEILLEAN’ DP FPSO (ex BP

SWOPS)
CONVERSION - VESSEL SELECTION ISSUES

• Vessel age, condition and service history
• hull global strength
• remaining corrosion margins
• remaining fatigue life
• structural steelwork replacement
• Mooring structure
• internal or external modifications
• structural reinforcement
• Topside integration
• structural reinforcement
• Possibility of upgrades to equipment, systems, machinery &

accommodation
CONVERSION – HELIX PRODUCER 1 FPU

CONVERSION – NINGALOO VISION FPSO

© PROSAFE PRODUCTION 2010
CONVERSION – CASPIAN SEA FSO

CONVERSION – NGUJIMA-YIN FPSO

CONVERSION – FSU SOORENA
Conoco MacCulloch
North Sea Producer -
Teesside
RULES AND REGULATIONS

(OVERVIEW)
DEFINITIONS
• 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
GOVERNING REGULATIONS
• Classification Rules
• Local and / or National Authority
• Some authorities require identification of Safety Critical Elements (ie.
Hull)
• SCEs then require verification by third party against Performance
Standard
• Class rules provide appropriate Performance Standard
• Flag state
• International conventions for ships
• SOLAS, MARPOL, LOADLINE, TONNAGE
• Disconnectable FPSOs effectively become ships – flag becomes relevant
SCOPE OF LR FPSO RULES

• LR Rules cover the following aspects :
• hull and marine systems
• mooring systems
• risers (optional)
• process plant (optional)
• drilling plant (optional)
• LR Rules governing FPSOs have been updated in April 2008

• FOIFL Rules refer to Ship Rules – Oil Tankers
• New LR ShipRight –FOI Procedure
• Both revised Rules and the new procedure can be
downloaded free
• Register to downlaod your copy of the Rules from
www.rules.lr.org
LR RULES AND REGULATIONS FOR A

FLOATING OFFSHORE INSTALLATION AT A
FIXED LOCATION Rules
Rules
Rules
and
and
and
RulesRegulations
RulesRegulations
and
Regulations
and
Regulations
Regulations
Rules and
Regulations
Part
Part
Part
Part 4444Rules and
Regulations
Part45
Part 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
LR MANAGED VERIFICATION SCHEME

(OVERVIEW)
LR Project Manager
Manages all Project Class & Verification activities

• Develop Project Quality Plan including Detailed Work
Instructions
• Report Progress & cost control for the project
• Directly interface with project, alliance partners,
approved contractors
• Identify requirements for Classification/ Verification
• Liaise with LR Technical Centres & Survey Offices to
co-ordinate LR services
LR Project 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…….

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
Typical
Project
Validation
Work
Instruction
(VWI)
Service Implementation
Design Appraisal
Procurement
Main Site Survey of Fabrication
Main Site Survey of Testing and Commissioning
Installation Survey
Hook-up and Commissioning Survey
Service Implementation –
Design Appraisal
Work Instructions and VWIs passed to LR design appraisal specialists.
Review of ‘Main Contractor’ & Equipment Supplier’s key design
documents (Independent Analysis only performed when judged to 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.
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.
Service Implementation -
Main Fabrication Site Survey
Instructions passed to the surveyors in the form of Work Instructions and
VWIs.
Attend Pre-inspection meeting to review and mark up Main Contractor
Quality Plans and Procedures.
Survey on a sampling basis, monitoring the activities of the site QA/QC
team, against approved plans.
Attend selected tests.
♦ Hydrotests, Loop Tests, Commissioning, Cause & Effect, etc.
Review supporting documentation for free issue materials, equipment
and Main Contractors certification records.
Agree punchlist of outstanding items.
Typical
Anomaly
Report
Service Implementation –
Survey at Onshore and Offshore Project locations
Instructions passed to the surveyors in the form of Work
Instructions and VWIs.
Attend initial meeting offshore to review and mark up Main
Contractor Quality Plans and Procedures.
Survey attendance on a block visit basis, monitoring the activities
of the offshore QA/QC team. Emphasis: key stages such as
substructure installation.
Witness selected tests.
♦ Hydrotests, HUC Tests, Commissioning, Cause & Effect, etc.
Review Offshore Contractors certification records.
Agree punchlist of outstanding items and monitor to closeout.
Recommend issue of final deliverables.
Typical
Design
Appraisal
CRS
Typical Class Notation
• ? OI 100 AT Floating Oil Production and Oil Storage Installation

for service at the ????Field, Offshore ???? LI, OIWS, ShipRight –
FOI (SDA, FDA,CM)
? OMC, IGS, UMS, LA
With descriptive notes
ShipRight COW, IGS(LR), Spread Moored, Helicopter Deck
Technology & New Developments

TECHNOLOGY & NEW DEVELOPMENTS
• Revised FOIFL Rules launched May 08

• New Software ShipRight for FOI’s under
development
• Existing Guidance on FLNG being updated in line
with revised Rules
Summary
• Most FPSO projects are different, beware of “generic”!

• Engage Class Society / Verifier and Regulator early
• Consider alternatives (e.g. newbuilding/conversion/unit type)
carefully and evaluate options
• Define the interfaces and make sure they are being managed
• Ensure that operational experience is embedded into the design
• Adopt and implement a single managed verification scheme.
• Appoint single points of contact in each key stakeholder
organisation who is responsible for regulatory compliance
For more information,

please contact:
Lloyd’s Register Asia

Energy Upstream Business
T: +65 6278 9444

F: +65 6273 1662
E: energyasia@lr.org

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

World’s First’s in Floating Systems

TYPICAL FPSO PARAMETERS

WHAT MAKES AN FPSO DIFFERENT FROM A

• Operations and safety requirements

Engineering Contractor Mooring System Supplier

Class Topsides Fabricator

Topsides Integration Yard

Typical General Arrangements

Utilities Prod Water/Inj

 Living quarters at the stern

 Living quarters at the bow

TURRET MOORING SYSTEMS

Buoyant Turret External Turret

Turret & Swivel

Turret cylinder Lower bearing

Moonpool Chain stopper

KEY CHOICE DRIVERS 1 OF 2

• Project and client requirements

• Schedule / time to first oil (new build: 2 to 3 years;

KEY CHOICE DRIVERS 2 of 2

• Ship yard schedule

• Availability of suitable tonnage

• Statutory and National Authority requirements

NEW BUILD HULL - ADVANTAGES

• Compliance with latest regulations

NEW BUILD HULL - DISADVANTAGES

NEW BUILD – SHELL gFLNG

NEW BUILD TOTAL AKPO FPSO

NEW BUILD – NGANHURRA FPSO

Permanent Means of Access (PMA)

• All internal tanks

NEW BUILD - SNEPCO BONGA FPSO

Example Transit case (Bonga)

NEW BUILD – SHELL EA FPSO

NEW BUILD LPG & CONDENSATE FSO LIBERDADE

NEW BUILD - TERRA NOVA FPSO

NEW BUILD - FPSO ‘NORTHERN

TOPSIDE SUPPORT STRUCTURE

NEW BUILD – ‘SEILLEAN’ DP FPSO (ex BP

CONVERSION - VESSEL SELECTION ISSUES

• Possibility of upgrades to equipment, systems, machinery &

CONVERSION – HELIX PRODUCER 1 FPU

CONVERSION – NINGALOO VISION FPSO

CONVERSION – CASPIAN SEA FSO

CONVERSION – NGUJIMA-YIN FPSO

CONVERSION – FSU SOORENA

RULES AND REGULATIONS

SCOPE OF LR FPSO RULES

• LR Rules governing FPSOs have been updated in April 2008

LR RULES AND REGULATIONS FOR A

LR MANAGED VERIFICATION SCHEME

Manages all Project Class & Verification activities

 Comment on list of SCEs and Performance Standards.

Delivered as shown in the next slide…….

Livelink Data Management

Typical Class Notation

• ? OI 100 AT Floating Oil Production and Oil Storage Installation

Technology & New Developments

TECHNOLOGY & NEW DEVELOPMENTS

• Revised FOIFL Rules launched May 08

• Most FPSO projects are different, beware of “generic”!

For more information,

Lloyd’s Register Asia

Living quarters at the stern

Living quarters at the bow

Comment on list of SCEs and Performance Standards.