Case Study:Field Proven Innovations for Impact Protection and Life Extension

Health, Safety and Environmental aspects

of Gas offshore Terminals

Singapore28-29 September 2010

F. LEGERSTEE

Project Manager

Offshore Rules Development

[email protected]

2Health, Safety and environmental aspects of Gas offshore Terminals – FPSO Congress - Singapore 28-29 September 2010

► Introduction

► Identification of main hazards

� Comparison with classic FPSO

► Tools and methodology

� Risk analysis

� Regulations

► A few word on Regulation, statutory requirements and norms

► Conclusions

AGENDA

Introduction


BV active involvement in the LNG Industry

Rawgasentry

CondensateLPG/Ethane

LNG LNG

Salesgas

Onshore Gastreatment

LiquefactionStorage

Regasification

Sea transport

BV services are provided throughout the LNG Chain


Main Idea

Identification of main Hazards


FLNG main Hazards

►Health

� Hazardous products from the production or the process

� Cryogenic

►Safety:

� Fire

� Explosion

� Cryogenic

►Environment

� Release of gas (methane, propane, etc…)

� Release of liquid (condensate)


Hazard Events

Loss of containment

ImpactRupture of tanks, pressure vessel,

piping, valves, etc…

Leak during offloading


Hazard Identification

Loss of containment

Cryogenic Release Gas Release



Loss of containment


Steel rupture RPT explosionEvaporating

to gas

Potential Escalation



Loss of containment


Dispersion(depending of gas

density)

Fire

(with ignition source)

Explosion

(with ignition source)

Potential Escalation


Feedback from LNG industry

► 40 years of LNG transportation by sea

� With regular trading routes

� Worldwide involvement

• Europe – Africa

• Asia Pacific

►No major accident

►A few LNG incident, mainly in the the 1st years (1970’s)

� Most of incidents happened at harbour, during loading / offloading

� At sea most of the incident lead to gas dispersion, without fire or explosion. But sometimes with high damage on steel structure due to cryogenic temperature


Rapid Phase Transfer

► In case of

� LNG leakage to sea

� LNG leakage in water in a process system (vaporizer)

►Quick vaporisation of LNG to gas, leading to physical explosion

►Air and underwater blast

RPT spillage of 9m3 of LNG at Sea (1984)

(Courtesy of GdfSuez)

►Phenomena studied in the past by gas companies but still difficult to model

►Concern for offloading system


LNG dispersion

► LNG is a liquid: driven by gravity

► LNG will vaporise immediately and “slowly” (except for RPT)

►Vaporised gas will ignite only if quantity of methane and oxygen are matching

� Too rich in methane: no ignition

� Too poor in methane: no explosion

►Vaporised gas is lighter than air, and will go downwind

►Dispersion analysis to be done to define

� Safety area at sea level

� Safety area at helicopter level

Environmental Aspect


Installations phase

► Selection of the location

� Close to shore:

• in someone backyard

• Shallow water is where most of marine life are

• High impact in case of accident

� Far from shore

• Expensive subsea systems

• LNG transfer offshore

• Evacuation in offshore condition

► Installation activities

� Disturbance of sea bed, water turbidity

• Long term consequences on marine organism

� Emission from installation boats (to air and to sea)

• Short term local consequences on marine life

� Traffic disruptions (Commercial of leisure boat)

• Short term local consequences on human activites


Operations phase

►Sea pollution

� Oil leakage (from process and machinery)

� Heavy metal from coating

� Sewage water

� Hull disposal to sea

• Temperature of cooling water (or warming water in case of vaporizer)

• Produced water

• Ballast water from export LNG carriers

Long term consequence to the environment:

Disease/disappearance of some species

Development of new species


Operations phase

►Air pollution

� Combustion engines

• Oil fired for boilers, diesel engines, etc..

• Gas fired for boilers, gas turbines

� Venting

• Methane is stronger greenhouse gas than CO2

Long term consequence to the environment

But CH4 emits less CO2and heavy particles than other hydrocarbon fuel


Operations Phase

►Management of other field products

� For LNG FPSO, critical production by-products may have to be managed:

• Heavier hydrocarbons

• Mercury

• H2S

• Naturally Occurring Radioactive Materials

• Etc…

►Management of process products

� Methanol, glycol, etc…

In case of leakage, consequences may impair locally environment and health


Operations phase

► Traffic disruption

� Asset Safety Area

� Continuous movement of boat (tug, supply, workboat, etc…)

� Shuttle LNG carriers operations (huge vessels)

� Subsea systems: Fishing and anchoring limitations

► Impairment of visual environment

During operation impacts on public resentment

During operation on commercial traffic


Decommissioning

►Similar effect to installations:

� Disturbance of sea bed, water turbidity

• Long term consequences on marine organism

� Emission from installation boats (to air and to sea)

• Short term local consequences on marine life

� Traffic disruptions (Commercial of leisure boat)

• Short term local consequences on human activites

►Dismantling of the hull and process

� Toxic materials

Regulation, statutory requirements and norms


Rules that are applicable :

- Coastal State Regulations

- Flag State Regulations

- Class Rules

- IMO (International Maritime Organisation) Conventions

Applicable Rules


Coastal State Regulations

� FPSO-LNG must comply with coastal state regulations in the territorial seas it is operating (from the boundary of a State’s internal waters to twelve miles from its baselines)

� The Coastal State also possess some rights in the EEZ (Exclusive Economic Zone) which consists of a 200 mile-broad strip between the Coast and the High Seas

� Coastal States may require FPSO-LNG to be flagged and classed.

Applicable Rules


Flag State Regulations

� Ships and Mobile Offshore Units trading internationally are to comply with safety regulations of the Maritime Authority in the country whose Flag the unit is flying (the Flag State)

� Flag States adopt and implement the safety regulations given in conventions issued by IMO

� An owner has normally the choice to select the flag

� Production/storage units do not need to carry a flag (except when required by Coastal State) but are free to move in international waters when carrying a flag

Applicable Rules


Relations between Coastal State, Flag and Class

� Flag State requires classification

� Delegation of authority from Flag State to Class is a common practice

� For operation in territorial waters there are additional local regulations

� Delegation of authority from Coastal State to Class is rare

Applicable Rules


International Maritime Organisation (IMO)

� United Nations body for maritime affairs

� From its earliest days, the IMO’s most important objectives have been the improvement of maritime safety and the prevention of marine pollution

� It is responsible for developing new regulations and procedures for the shipping industry, or revising existing ones.

� Most of these will subsequently be incorporated in national legislation.

� At present the IMO consists of 162 Member States, often referred to as Flag States

IMO


The main IMO documents that could be applicable to LNG-FPSOs are:

- SOLAS 1974

- IGC Code

- MARPOL 73/78

- MODU Code

- Load Line Convention 66

- COLREG 1972

- Tonnage 1969

The degree to which an IMO regulation is enforced depends on the Flag State : it is important to check Flag Authority’s position early in a project

IMO


SOLAS (International Convention for the Safety of Life at Sea)

The main objective of the SOLAS Convention is to specify minimum standards for the construction, equipment and operation of ships, compatible with their safety. Flag States ratifying the Convention are responsible for ensuring that ships under their flag comply with its requirements, and a number of certificates are prescribed in the Convention as proof that this has been done.

SOLAS scope includes the construction, the safety equipment, the life saving appliances and the radio communications

IMO


COLREG (Convention on the International regulations for preventing of collision at sea)

The Convention defines the arrangement regarding steering and sailing rules, lights and shapes, sounds and light signals to be provided onboard the unit in order to prevent collision.

Technical requirements concerning lights and shapes and their positioning, sound signalling appliances and international distress signals are included in the Convention.

IMO


MARPOL (International Convention for the Prevention of Pollutionfrom Ships)

The MARPOL Convention covers most if not all the technical aspects of pollution from ships, and applies to ships of all types.

The Convention has six annexes which contain regulations for the prevention of various forms of pollution.

IMO


LOAD LINES 66

Early naval architects and shipbuilders recognized long ago that, by limiting the draft to which a ship may be loaded, they could make a significant contribution to the safety of that ship. Such a limit or “freeboard” relates to the stability and the structural strength of the hull, the reserve buoyancy, and amount of water reaching the weather deck; hence to the degree of water tightness required to stop it entering the hull. These are the main objectives of the LOAD LINES Convention.

All assigned load lines must be marked amidships on each side of the ship, together with the deck line as follows:

IMO


IGC CODE (International Code for the construction and equipment of ships carrying liquefied gas in bulks)

The Code covers the following areas: ship survival capability & location of cargo tanks, ship arrangements, cargo containment, piping systems, materials of construction, cargo pressure / temperature control, cargo tank vent systems, environmental control, electrical installations, fire protection & fire extinction, mech. ventilation in cargo area, instrumentation (gauging, gas detection), personnel protection, filling limits for cargo tank, use of cargo as fuel, operating requirements.

IMO


MODU (Code for the Construction and Equipment of Mobile Offshore Drilling Units)

IMO MODU Code specifies safety technical requirements applicable to offshore drilling units in addition to SOLAS general requirements.

This Code has been developed to provide an international standard for mobile offshore drilling units of new construction which will facilitate the international movement and operation of these units and ensure a level of safety for such units, and for personnel on board, equivalent to that required by SOLAS 1974 and the ICLL 1966, for conventional ships engaged on international voyages.

IMO


►Societies set up by marine insurers

► To meet the need of marine insurers : rating of the ships to covered by hull insurance

► First class societies

� Lloyd’s Register (1760)

� Bureau Veritas (1828)

� American Bureau of Shipping (1862)

� Det Norske Veritas (1864)

Class Societies Origin


FLAG STATE

CLASS SOCIETYPORT STATE

HULL INSURERCHARTERER

SHIPOWNER

Actors of the marine safety


►Classification is the appraisal on the level of compliance of a vessels to the rules set up by the class society

► This appraisal is represented by class notations entered on the certificate and periodically transcribed in the society’s register

Definition of class


► The Rules published by the society give the requirements for the assignment and maintenance of classification for seagoing ships

► Aim = to protect a ship as a piece of property

► Various types of rules

� Steel ships

� Offshore units

� Inland navigation vessels

� Submarine craft

� Yachts

� High speed craft

� Navy ships

The classification Rules


Field of the classification Rules

COVERED BY CLASS

► Materials

► Structural strength

► Main & auxiliary machinery

► Electrical installations

► Cargo installations

► Fire protection

► Stability

NOT COVERED BY CLASS

► Mode of propulsion

► Power of propulsion unit

► Manning

► Comfort on board

► Requirements for ‘user friendliness’

► Requirements for maintenance friendliness


THE CLASSIFICATION PROCESS

►Approval of drawings

► Inspection of materials

►Survey of the hull and the control equipment

► Issuance of class certificates

►Once in service, periodical, occasional and class renewal surveys


THE DESIGN CHECKING PROCESS

►At the preliminary stage, subdivisions and preliminary stability booklet may be checked

►Second, scantlings are checked for local elements and the primary structure

► The final phase consists of an analysis of structural details, machinery diagrams and outfit falling within the scope of classification


NEW CONSTRUCTION

Ship-owner

Equipmentmanufacturer

Class Certification Office

Class Plan Approval OfficeClass

Surveillance at yard Office

Shipyard

Manufacturer

LPO centerShipyard

CLASS RULES


►During their live, ships are submitted to regular surveys for the maintenance of class in accordance with IACS Unified Requirements

►Within a cycle of 5 years there are :

� Annual survey

� Intermediate survey

� Renewal survey

► In addition occasional surveys

►Enhanced Survey Programme for bulk carriers and tankers

CLASSIFICATION INTERVENTION : SHIPS IN SERVICE


WHAT IS CLASS1

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DEFINITION OF CLASSSelectiveSelective surveyssurveys

““Risk Based InspectionRisk Based Inspection”” withwith FocusFocus on on ””Critical AreasCritical Areas””

Qualification of surveyorsQualification of surveyors


On the 11th September 1968: the International Association of Classification was created

The IACS is composed of 10 members:

- American Bureau of Shipping (ABS)

- Bureau Veritas (BV)

- China Classification Society (CCS)

- Det Norske Veritas (DNV)

- Germanisher Lloyd (GL)

- Korean Register of Shipping (KRS)

- Lloyd’s Register (LR)

- Nippon Kaiji Kyokai (NK)

- Registro Italiano Navale (RINA)

- Russian Maritime Register of Shipping (MRS)

IACS


► 130 Flag States have delegated their statutory activities to recognised organisations including class

►Main delegations : IMO conventions

� Technical inspections of vessels

� Issuance of certificates

►Delegation for ISM Code regulations

� Assessment of the Safety Management System (SMS) of the shipping company by audits and reports

� Periodical verifications

Delegation to class

Examples of development followed by Bureau Veritas


EN 1474 for offshore LNG

►Development of European norm regarding LNG transfer

� 3 parts to qualify the LNG transfer systems

• 1) Rigid arms at quay

• 2) Flexible hoses at quay

• 3) Additional requirements for offshore use

►Norm used by some of the major LNG transfer system

� FMC for rigid arms

� Technip for aerial flexible hose

� SBM for floating flexible hose

►BV Rules for offshore gas terminal (NR 542) is making reference to this norm


CONVENAV - CONception et cycle de Vie Environnemental des NAVires

► 01/2008 – 09/2010 ANR funded (Pôle MerBretagne label)

� Partners: DCNS (leader), BUREAU VERITAS,

ENSAM, IFREMER, SITA

� Goals:

• Develop a method for assessing the

environmental impacts of a ship

• Develop an eco-design tool for ships

• Develop a ship environmental performance

monitoring tool

� Status:

• Data collection and structuring achieved

• Preliminary LCA of a frigate completed

• Definition of specific eco-indicators in progress

• Eco-design tool specification in progress

� Coming next:

• Complete eco-design and monitoring tools

specifications.

• Development and tests of these tools Dismantling

WasteMaterials

DismantlingTechniques

Analysis ofproblems inDismantling

Material End ofLife Analysis

Improvement ofDismantlingTechniques

New ShipDesign

How to improvethese Techniques?

How to avoid theseproblems?

Environment

Economy

Safety


Definition of bestdisposal or

recycling routes

Improvement ofMaterials End ofLife scenario

Environment

Economy

Safety

DismantlingWasteMaterials

DismantlingTechniques

Analysis ofproblems inDismantling

Material End ofLife Analysis

Improvement ofDismantlingTechniques

New ShipDesign

How to improvethese Techniques?


Environment

Economy

Safety


Definition of bestdisposal or

recycling routes

Improvement ofMaterials End ofLife scenario

Environment

Economy

Safety

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► 2006-2009 ANR founded (PRECODD)

� Partners : CEDRE, INERIS, BV, MeteoFrance, IRSN, Gaz de France, BEA mer, Marine Nationale, TOTAL

� Goals

• Define accident scenarios for early decision making of French coast guards in

their first approach

• Provide experimental data

• Provide quick simulation tools

� Status

• BV achieved scenario definition

• Small scale experiments in laboratory

(Ineris)

• Large scale experiments in Brest harbour

� Coming next

• Simulation of toxic/flammable cloud

dispersion

• Quick intervention sheet

CEDRE pictures

GALERNE - Evaporating GAs/Liquids and Risk for life and Environment

Some details of BV Rule Note 542 for Offshore Gas Units

Tospides and Transfer systems


NI 542 - Principles

� Semi-probabilistic approach; generally, PSF based criteria

� Net scantlings approach

� Environmental loads with a return period of 100 years

� Mandatory sloshing study : direct calculation or model tests

� Prescriptive criteria for hull girder strength and local scantlings

� FEM 3D models are mandatory for hull and independent tanks assessment


NI 542 - Principles

►Approach similar to FPSO Rules; unit’s areas are defined as :

� “offshore area”

� “ship area”

►Structural members of offshore areas are categorized as :

� Special category

� First category

� Secondary category


NI542 - Principles

Hydrodynamic analysis

Steel grade selection

Design loadsLoad parameters

Hull girder strength

Sloshing assessment

Temperature in the design condition

Fatigue assessment

-Spectral fatigue-Deterministic

Hull scantlings

-Plating-Ordinary stiffeners

3D FEM model

- Primary supporting members

Other structures

-Offshore areas-Local structural improvements

Cargo containment-Independent tanks (A, B, C)-Membrane tanks-Integral tanks-Supports and keys


NI542 - Cargo containment system

Membrane tanks►Scantlings of inner hull are to comply with the hull requirements

►Specific allowable stresses or hull deflections indicated by theDesigner are to be taken into account

IMO Type AIndependent tanks

►Internal pressures to be calculated as for the hull structure, using the hydrodynamic analysis and direct calculation for sloshing

►Specific requirements for scantlings of plates and ordinary stiffeners covering:

� Minimal gross thickness

� Subject to lateral pressure

� Testing condition

►3D finite element model assessment is mandatory for the primary supporting members



IMO Type BIndependent tanks

► Internal pressures to be calculated as for the hull structure, using the hydrodynamic analysis and direct calculation for sloshing

►Scantlings of plating and ordinary stiffeners subjected to lateral pressure

►Buckling assessment (plating and stiffeners)

► 3D FEM model assessment is mandatory for primary supporting members (PSM)

►Yielding criteria for PSM:

► Tanks primarily constructed of bodies of revolution (ex MOSS)

► Tanks primarily constructed of plane surfaces (ex SPB)

►Buckling criteria for PSM

►Fatigue analysis is to be performed for areas specified by Designer and agreed by BV; the analysis is to comply with the requirements for hull structure

►Crack propagation analysis : reference to Steel Ships Rules for gas carriers, using the loads in offshore environment defined in NI 542



IMO Type CIndependent tanks

►Internal pressures to be calculated as for the hull structure, using the hydrodynamic analysis and direct calculation for sloshing

►Scantlings of pressure vessels class 1

►Assessment of stiffening rings in way of tank supports; the loads used for this check are those defined in NI 542

Stiffening rings in way of tank supports



Tank supports

►Supports of independent tanks are to be assessed through FEM calculations

►The following types of supports are covered:

� Antirolling supports

� Antipiching supports

� Anticollision supports

� Antiflotation supports

►Checking criteria are in accordance with IGC Code (BV interpretation)

Other items covered by NI 542

►Extent of secondary barrier

► Insulation

► Insulation materials

►Material of construction for tanks – reference to IGC Code

►Construction and testing


NR542 – Topside systems

►Requirements for the design approval of :

• Process systems – class notation “PROC”

• Liquefaction plant – class notation “gas liquefaction”

• Revaporization plant – class notation “RV”

• Transfer systems – class notation “liquefied gas offloading”

►Qualification of unproven technology

►Principles and typical recommendations relating to topside layout



Unproven technology

►New technology or existing technology in new environment

►The qualification is requested before design approval in order to identify criticality levels

►Risk based methodology proposed in the guidance note NI 525

FAnnual

FrequencyDefinition

1 < 10-4

Extremely improbable: not expected in the system life

2 10-4

- 10-3

Improbable: not anticipated in the system life

3 10-3

- 10-2

Extremely remote: should not happen in the system life

4 10-2

- 10-1

Remote: expected few times in the system life

5 > 10-1

Reasonably probable: expected several times in the system life

S Factor

54321

NC1

LC2

MC3

HC4

SC5

F-

Fa

cto

rSA Severity Definition

1 Negligible No damage to personnel, safety functions fully available

2 Minor Light injuries to personnel and/or local damage to safety functions

3 Severe Serious injuries to personnel and/or large local damages to safety functions

4 Critical Fatalities amongst personnel locally, impairment of safety functions

5 Catastrophic A large number of fatalities amongst personnel also outside the event area, total impairment of safety functions



Design requirementsConstruction surveyTesting

►Common body of requirements in BV Offshore Rules (Part C) :

• Pressure vessels

• Heat exchangers

• Piping systems

• Gas turbines

• Electrical installations

►Additional requirements from IGC Code for equipments and components in direct contact with liquefied gas or vapours

►Additional requirements for process systems (PROC) in BV NR459

►Other recognized codes and standards for items not covered above:

• EN 1473

• NFPA 59A

• NFPA 59



Formal safety assessment process (FSA)

Topside layout

Risk analysis

►Safety assessment based on FSA techniques

►Structural fire integrity

►Fire fighting equipments

►Emergency control stations

►Life saving appliances

►Methodology based on:

• API RP 14J

• EN ISO 17776



Topside layout

►Requirements coherent with API RP 14J, EN ISO 13702, NORSOK S-001, IGC Code

►Safety principles, grouping of equipments, partition into fire zones

►System arrangement, explosion mitigation

►Requirements for accommodations, temporary refuge and means of escape


NR542 – Transfer systems

► New additional notation : liquefied gas offloading

� Covers the classification of transfer systems for liquefied gas

► The notation covers transfer arms in :

� Side-by side configuration

� Tandem configuration


NR 542 – Transfer systems

► Principles :

� Overall requirements coherent with EN 1474 (1 to 3)

� Structural requirements coherent with BV Offshore Rules and NR526 (Lifting Appliances)

► Items covered :

� Materials (with respect to IGC Code)

� Clearance study, envelope

� Dimensions of product lines

� Design loads and structural safety

� Safety systems and features

� Type approvals

� Manufacturing and testing



Design principles

►Risk assessment

►Clearance study, balancing

►Materials

►Product line dimensions

Design Loads

►Relative motions and accelerations assessed by model test or direct calculations

►Dead load

►Cargo load

►Design pressure

►Ice accumulation

►Wind loads

►Thermal loads

►Standard stowed and operating conditions: combination of loads

Structural safety

►Criteria for yielding, buckling, fatigue

►Assessment of supporting structure and pedestal

►Assessment of product line

►Assessment of swivels

►QCDC body



► Risk assessment study to be submitted for information

► The study has the following objectives:

� Failure modes identification

� Evaluation of the design, based on operational procedures

� Definition of limiting conditions for offloading operations

� Identification of safety critical elements – selection based on

consequence of failure

� Record of accidental loading conditions related to safety critical

elements



► Limiting conditions for offloading operations to be specified by the Owner, in agreement with the risk assessment report

► Minimum parameters :

� Maximum allowable wave height

� Limiting metocean conditions (wind, current, ice and snow)

� Limiting air temperatures

� Configurations of gas carrier (ex: manifold position)

� Limiting draughts of the unit

� Envelopes of the transfer system



► Clearance study is to include :

� Fabrication and erection tolerances

� Maximal deflections of the transfer system during operations

► Checkpoints are chosen case-by-case, based on general arrangement



► Design temperatures based on direct calculation, taking into account :

� Specified cargo temperature

� Local environmental conditions – air temperature ranges

► Steel grades of supporting structure in compliance with BV Offshore Rules, as for special category elements

► Materials for piping and elements in contact with cargoes in compliance with IGC Code, Ch 6



► Assessment of combined motion of unit and gas carrier

► Parameters of interest:

� Relative motions between checkpoints

� Absolute accelerations at checkpoints

► Checkpoints :

� On riser or pedestal of transfer arm

� At gas carrier manifold



► Design wind velocity to be taken at 10 m above sea level, as a 3seconds gust speed :

� For stowed conditions – 100 years wind velocity and not less than

51.5 m/s

� For operating conditions – wind velocity at the probability level of

limiting conditions

► Wind force :



► Structural criteria are defined for the following loading conditions

� Stowed position

� Operating conditions

� Maintenance conditions

� Hydrostatic test

� Emergency release conditions

� Accidental conditions

Bureau Veritas Services for Offshore Gas Terminals

Introduction


Bureau Veritas Services for FLNG

► Classification, Certification, 3rd party verifications

� Concept or basic approval

� Review of the project at each progress phases with regards to the local

law, international codes and standards

► New technologies evaluation and qualification

� Evaluate the new technologies with regards to their functional requirements

� Quantify their associated risk

� Define qualification needs and qualification program

► Technical assistance

� Marine

� Pipes and offshore structure

� Process


SELECTED OFFSHORE LNG TERMINALS

BV involved in several on-going OFFSHORE LNG projects as follows:

► Australia: Prelude for SHELLGeneric LNG FPSO for GDFSUEZ

► Africa: FLSO project for SHELL

► Europe: OLT (Livorno) for SAIPEM and E-ON

Triton for GDF

► South America: Brazil: Tupi for PETROBRAS

Small scale terminals for various with contractors for utility companies

► China: Projects of offshore LNG terminals in cooperation with MARIC (Small and large scale LNG FPSO, large scale FSRU)

► South-East Asia 1 LNG FPSO project with Saipem


Classification, certification and 3rd part verification


Concept Appraisal

►Concept appraisal principles, a close follow-up of designer work:

� Basic concept approval

� Design approval

� Final approval

►Concept approval provides at each project stage a confirmation of the feasibility considering both the current state of the art and applicable Rules


Concept Appraisal

► Basic concept approval

� Mainly refers to qualitative studies

� Confirmation that project outlines are in line with current state of the art and applicable rules

� States the applicable laws, rules and code

► Design approval

� Refers to the first quantitative studies

� States that the design is in accordance with the rules and criteria considered

� List the calculations and tests that will be required for the final concept approval

► Final concept approval

� All calculations and tests required have been done, reviewed and approved

� Fabrication process and limitations are mentioned

� States the concept limitations


New technologies review and risk analysis


Risk analysis

RecommendationsFMECA Worksheet Report n° XXX

Operational Mode : Date :

N° Item description Failure Description Failure Effect Risk Reducing Rating Actions /

Function Comp Mode Cause Local End Measures F S D C Remarks

HAZID/FMECA

FunctionalAnalysisFunctionalAnalysis Main

FunctionsFlux Out

Flux In

Constraint

Functions

Components

Qualification

InspectionMaintenance

Design


Example of application

► Marine systems

� Hull

� Containment system

� Mooring system

� Anchoring system

► Process

� Inlet Facilities

� Acid Gas Removal

� CO2 Disposal

� Gas Dehydration

� Mercury Removal

� NGL Recovery

� NGL Fractionation

� Liquefaction

� End Flash Gas system

� Utilities

► Interface

� Offloading facilities

� Turret system

� Risers


Example of methodology: Technology Qualification

► Technology assessment:

� Evaluate the novelty of each technology used in the project

• New ; Extrapolated from proven ; few references ; proven

• Used in similar conditions or different conditions

► FMECA (Failure Mode, Effects, and Criticality Analysis) workshop:

� Gather technology experts

� Quantify the risks of each new technology

� Determine the main need for qualifications

► Qualification plan requirements

� From novelty ranking and FMECA, list the critical qualification actions

� Based on this document the Engineer can build the qualification plan

► Fitness for purpose evaluation

� As a conclusion of the above work, the fitness for purpose of each technology is evaluated.

► Reference document:

� BV NI 525 Risk Based Qualification of Unproven Technology


Example of methodology: Project Preparation

►Benchmarking of technologies:

� Pros and Cons of each technology

� Building a benchmarking method

►Help to prepare a FEED dossier

� Applicable Rules and regulations

� Required certificates

� Main studies and qualifications that will necessitate a special attention


Technical Assistance


Additional services: risk and safety studies (at FEED stage)

► Marine

� Hydrodynamic analysis

� Mooring and anchoring

� Structural analysis

► Process

� Review of design of equipments

� Certification

� Risk analysis

► Riser, flexible hoses and structure

� Review of design

� Certification

� Risk analysis

► Risk and safety studies

� Computational Fire Simulation

� Computational Simulation of Gas Leakage and Dispersion

� Design of Deluge Systems

� Noise and Vibration Analyses

� Design of Public Address and General Alarm Systems

� Static and Dynamic Structural Analyses

� Preliminary Hazard Analysis

� Hazard and Operability Analysis - HAZOP

� Collision Assessment

� Dropped Object Analysis

� Quantitative Risk Analysis

� Other studies


Marine



►Hydrodynamic analysis is mandatory for gas terminals

►Hull girder loads, unit motions and accelerations are to be determined for 100 years return period

Environment data►Provisions of Offshore Rules

►Scatter diagram

Loading conditions►Specific loading conditions for offshore permanent units

►Sensitivity analysis and heading study may be requested

Unit response

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2

Wave freq. [rad/s]

Pit

ch

RA

O

[dg

/m] RAO

Design values for structural analysis

Design values for structural analysis

0° = 360°

90°

180°X

Y

240°

120°

270°

210°330°

300°

30°

60°

150°

Oc

cu

rren

ce

Significant Wave Height (m)

Peri

od T

m (s)

Scatter Diagram



►Heading analysis

� Waves, wind and current effects

� Action from anchoring, mooring of other vessel, riser…

►Sea keeping motion analysis:

� 3D diffraction radiation theory

� Model tests

� Effect of partially filled tanks

LNG CarrierLNG CarrierLNG CarrierLNG Carrier


Sloshing, Membrane tanks

∆∆∆∆t

PI

t

SEA KEEPING

MOTIONS

MODEL TESTS CFD SIMULATIONS

EK,VI,PQS

DROP TESTS

PM

PI, PQS, ∆∆∆∆tPI, ∆∆∆∆t Calibration

MembraneQualification

Hull Scantlings

BV Rule VerificationDynamic Structural Analysis

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2

Wave freq. [rad/s]

Pit

ch

RA

O

[dg

/m] RAO

V

PI

)

Scatter Diagram


Relative motions

► Tandem Offloading

� Fish tailing effect

� Minimum distance between unti and shuttle

► Side-by-side Multi-body interaction

� Linear Energy Dissipation

� Expression of velocity potential

� Integration equation extended to a part of the free surface


Alongside Mooring

► The mooring between the vessels must be considered:

� Wires

� Tails

� Quick release hooks

� Fenders


Mooring - Anchoring

► Time domain simulations of mooring and anchoring

� Extreme

� Fatigue

►Heading analysis


Structural Analysis

►Complete ship analysis


Structural Analysis

► 3 holds analysis

X

Y

Z


Structural Analysis

►Details analysis

� Hull details

� Topsides / hull interface

� Turret

� Interface with containment system


StructuralMesh

HydrodynamicCalculation

Coarse MeshCalculation

Fine MeshCalculation

SpectralCalculation

On site fatigue analysis


Fatigue Analysis


Process & Structure


►Structure certification

� Structural Design Review

• Jacket

• Topsides structure

� Construction survey locally

Offshore Structures Certification


Structural and lifting facilities :

► Topsides Flares► Burner boom► Cranes (NR526)► Spreader bars► Topside modules► Subsea Modules (PLEM, PLET)

Reference Codes : API, Eurocode, FEM, Client specifications, Classification Societies Rules

Classification/certification of structural equipment


Offshore

Onshore

Classification/Certification of process equipment

Pressure and mechanical equipment :

► Pressure Vessels► Boilers► Heat Exchangers► Pumps and Compressors► Piping and fitting► Subsea systems► Pressure Safety valves► Atmospheric tanks

Reference Codes : Class Rules, ASME VIII, PD 5500, CODAP, TEMA, API Standards, EN 13445 & 13480, ASME B31.3, CODETI, Client specifications….


Classification/Certification of safety equipment

► ESD System, Instrumentation ► Fire and gas detection system► Fire fighting equipment (deluge, fixed fire-

extinguishing system…)► Life saving appliances► Passive fire protection of shelters/topside

modules► Ventilation system (H.V.A.C.)

Reference Codes : Class Rules, API Standards, NFPA, SOLAS, MODU Code, Client specifications, National Regulations….


Inspection and Expediting of Equipment :

► Pressure vessels, heat exchangers, piping and fittings atmospheric tanks, pumps and compressors.

► Fire-fighting equipments, life-saving appliances.

► Structural items, cranes and lifting equipment.

► Quality control of materials, welding & heat treatment and Non-destructive testing services.

► Assistance in assessment, approval & surveillance of performance of contractor’s staff.

► Worldwide shop inspection and expediting at vendors and expediting of the purchase orders..

Shop inspections & expediting, pre-shipment inspection…


Risk-Based Inspection

A B C D E12

43

5

Inspection plan to be validated

ApprovedInspection plan


Riser, Flexible hoses


► Assessment and verification of design on SURF projects (IRC) :� rigid pipelines systems : single pipe or pipe-in-pipe, onshore and offshore� flexible risers and flowlines : bonded and non-bonded type

� umbilicals, fiber optic cables� ancillary items : bend stiffeners, buoyancy modules, bend restrictors� independent calculations capabilities

► Type approval certification of flexible pipe / umbilical / ancillary items manufacturers (TAC)� assessment of material dossiers, material compatibility� evaluation of design rules and design tools

► Coordination of second and third party inspections (COC) during� qualification testing (small & full scale tests and dissections) in laboratories / institutes � fabrication at manufacturer’s plant

� offshore and onshore installations and pre-commissioning activities

► Evaluation of new solutions (Concept Approval) � cryogenic rigid and flexible pipes

� reinforced thermoplastic pipes (plastic + aramid tapes)

► Appraisal of :� material selection report, cathodic protection & corrosion studies

� fitness-for-service studies, flow assurance studies

► Risk Analyses, FMECA, HAZID, for pipeline systems

Pipelines, Risers & Umbilicals : Our services


Inspection Tools for Asset Integrity Management


VeriSTAR AIMS on-service follow-up

Inspection

&

Maintenance Program

RESULTS

CORRECTIVE

MAINTENANCE

SURVEYS

BORN AS DESIGNED LIVING AS IS

Unexpected

Modifications

Improvements

VeriSTAR AIMS application

UNIT

DELIVERY

Inspection

&

Maintenance Program

RESULTS

CORRECTIVE

MAINTENANCE

SURVEYS RESULTS

CORRECTIVE

MAINTENANCE

SURVEYS

BORN AS DESIGNED LIVING AS IS

Unexpected

Modifications

Improvements

VeriSTAR AIMS application

UNIT

DELIVERY


Hull Life Cycle

drawings

HLC model

Offshore operating unit

Build HLC model

Make Thickness measurements

Hull monitoring

Update dwg


Move Forward with Confidence

Thank You for

Your Attention

Case Study:Field Proven Innovations for Impact Protection and Life Extension

Technology

Transcript of Case Study:Field Proven Innovations for Impact Protection and Life Extension