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1. INTRODUCTIONPractical training was conducted by L&T for First year M.Tech (UoP) from 16th to 31st May, 2014. The training was organised in two phases. The first phase was in L&T, Valdel office, where the organization structure and the project work flow were detailed. The roles of different disciplines in overall engineering process were highlighted. The second phase was held at Modular Fabrication unit at Kattupalli, on 30th and 31st, where the role of yard and the various interfaces involved between engineering, clients, vendors, etc were explained. A visit to the ship building facility of followed. In this report, the details of the training sessions have been compiled.

2. COMPANY PROFILE L&T-Valdel Engineering Private LimitedL&T-Valdel Engineering Private Limited {LTV} was formed in the year 2004 as a Joint Venture between Larsen & Toubro Limited {L&T) and Valdel Corporation Private Limited, pioneers in providing Engineering Services for Oil & Gas Industry. The entity formally known as John Brown Technologies was established in the year 1991 at Bangalore.LTV focusses on providing Complete Engineering Solutions for Upstream Oil & Gas Sector and offers Design Engineering Services covering Conceptualization/ Feasibility Studies, Debottlenecking Studies, FEED, Pre-bid Engineering, pre-engineering Survey, Detailed Engineering, Procurement Engineering, As-builting services and Project Management services for Oil & Gas Projects Globally. LTV also provides 3-D modeling services in both PDS and PDMS environment,LTV provides its services for the following Offshore installations/Structures: Wellhead (Fixed Leg) Platforms Process Platforms Revamp/Modification of Platforms Pipelines (both trunk and spur lines), Sub-sea and Cross CountryLTV has delivered engineering services for 38 process/wellhead platforms, revamp of 195 process/wellhead platforms, 128 pipeline segments (11 under execution).LTV is committed to implementing and maintaining a quality Management System, which is certified to the international standard BS EN ISO 9001:2000 and IS/ISO 9001:2000, LTV is also certified for y Information Security Management System Standard ISO/IEC 27001:2005. LTV has been providing its services to Indian domestic E&P operators like ONGC, Cairn Energy, Niko Resources etc., Indian/International EPC Contractors like L&T, HHI, SHI, Clough Oil & Gas, etc.LTV is executing a contract for detailed engineering services for an Onshore Field Development Project in Rajasthan, India with Mustang Engineering, Houston and also with Iv Oil & Gas, Netherlands for compressor module engineering in ONGC and for case-specific jobs in the North Sea.

3. SCHEDULE of training16th May to 29th May 2014Training at L&T Valdel,Chennai

30th May to 31st May 2014Training at MFFKattupalli

PART I: L&T, Valdel ChennaiDateDisciplineTraining ParticularsTiming

16th MayStructuralOverview of LTVs Offshore Structural Discipline10.30 am to 1.30 pm

Interactive session3.30 pm to 5.30 pm

17th MayStructuralOverview of Geo tech10.30 am to 12.30 pm

Interactive session3.30 pm to 5.30 pm

19th MayStructuralEngineering , Drafting10.30 am to 12.30 pm

Interactive session3.30 pm to 5.30 pm

20th MayStructuralEngineering , Drafting10.30 am to 12.30 pm

Interactive session3.30 pm to 5.30 pm

21st MaySafety & QualityDepartmental Presentation10.30 am to 12.30 pm

Quality orientation

3.30 pm to 5.30 pm

22nd MayMechanicalDepartmental Presentation10.30 am to 12.30 pm

Inter departmental checking requirements3.30 pm to 5.30 pm

23rd MayPipingLecture on piping & interdisciplinary coordination10.30 am to 12.30 pm

Interaction with leads to understand a typical well head Layout3.30 pm to 4.30 pm

Basic of Stress & Materials engineering4.30 pm to 5 pm

Interactive session5 pm to 5.30 pm

26th MayProcessDepartmental Presentation10.30 am to 12.30 pm

Interactive session3.30 pm to 5.30 pm

27th MayInstrumentationInstrumentation & Control system including structural interfaces10.30 am to 12.30 pm

Interactive session3.30 pm to 5.30 pm

28th MayElectricalElectrical Power system & Equipments including structural interfaces10.30 am to 12.30 pm

Interactive session3.30 pm to 5.30 pm

29th MayProject & PlanningDepartmental Presentation10.30 am to 12.30 pm

Interactive session10.30 am to 12.30 pm

PART II: MFF, KattupalliDateDisciplineTraining ParticularsTiming

30th MayHSEHSE induction & functional overview10.30 am to 11.00 pm

Project Management & MarketingOverall presentation MFFK11.00 am to 11.30 pm

ProcurementFunctional Overview11.30 am to 12.00 pm

Production PlanningDepartment Presentation & Functional Areas12.00 am to 12.45 pm

Plant & MachineryDepartment Presentation & MFFK & shipbuilding visit01.45 am to 04.45 pm

31st MayDesign & EngineeringDepartmental Presentation10.30 am to 11.30 pm

ProductionFunctional Overview11.30 am to 12.00 pm

WeldingDepartmental Presentation12.00 am to 01.00 pm

QualityQA/QC, QMS, NDT02.00 am to 03.00 pm

Surface coating and corrosion preventionFunctional Overview03.00 am to 04.30 pm

4. TRAINING AT LTV CHENNAI 4.1 Overview of LTVS Offshore DisciplineThe first part of the training was conducted at L&T, Valdel office. The training started with an overview of oil & gas industry and the processes involved in a typical EPC project. The engineering phase was explained in detail with examples from past projects. The various departments involved in engineering, their role and interfaces were then briefed by the respective departments during the course of the training.Structural Engineering Department of LTV mainly involves the designing of Jackets and topsides and also modules for FPSO units. Green field as well as brown field projects have been undertaken for both Indian and international clients. The engineering phase can be subdivided asi. Front End Engineering Design (FEED)FEED involves concept creation based on the data available after survey and exploratory drilling. The type of structure is decided based environmental conditions, soil characteristics, remoteness of location and reservoir size. The accuracy with which the FEED is carried out varies for different projects. The drawings and data generated at the end of this stage is used as the input for Pre-bid engineering.

ii. Pre-bid EngineeringAt the end of FEED, the tender is floated by the client to invite contractors to bid for the project. This phase is known as pre-bid engineering. Preliminary analysis are carried out by contractors and approximate Material Take Off(MTO) is generated. After applying appropriate contingencies, this is used to estimate the project cost and bid for the project.iii. Detailed EngineeringOnce the project is allotted, the detailed engineering phase begins. This involves designing the structures after carrying out all relevant global and local analysis. Accurate design and MTO is generated based on which procurement and fabrication may be carried out. Good for Fabrication drawing are generated at the end of this stage. The time spent for detailed engineering depends on the accuracy with which FEED is done. More accurate the FEED, lesser the time required in detailed engineering.

Analysis:Various analysis are carried out during the course of the engineering for structural design. They arei. Design of Jacket

ii. Design of topside

iii. Design of foundation Pile sizing & optimization Pile drivability On-bottom stability Mudmat design Pile stick-up Pile self-penetration (run down) Conductor drivabilityFor critical joints, Finite Element Analysis is carried out, if required.For the design of bridges, analysis is carried out to account for the amount of deflection that would occur due to self-weight. Based on this, they are fabricated with pre-camber to compensate for the deflection due to self-weight.For some cases, special analysis are carried out. For example, Time history analysis: This is used for seismic analysis of the structure. This used to ensure that the primary structure and critical systems remains intact under Rare Intense Earthquake. Soil Liquefaction analysis: This is used to ensure no pull out or rupture occurs in the primary structure. Pushover analysis: This analysis is used to ascertain the reserve strength available in the structure to withstand extreme environmental conditions. The analysis is carried out till collapse. Transportation Fatigue analysis: In this analysis, spectral fatigue analysis is carried out to find out the fatigue damage caused due to transportation. This is important if the transportation period is very long.As a part of the training, analysis of structures using SACS software was explained. The various load combinations used, supports to be simulated, member releases, hydrodynamic parameters to be applied, etc. were briefed. In-place, load out, lift, transportation, floatation and upending analysis were explained using previously modelled structures.

Geotechnical:The soil parameters required for the design of piles and mudmat are provided by the client. Two extreme are provided, namely the under-rated capacity and over-rated drivability. GRLWEAP is used for the design of piles. The thickness near the seabed is generally kept higher to allow for scouring. Even in the case of under-driving, this increased thickness should be maintained. Check for over-driving is generally not done.The Soil Resistance during Driving (SRD) is an important factor to be considered while deciding the installation of piles. The thickness of the pile at the end is kept slightly higher to reduce the internal skin friction. There are different types of pile driving. Continuous SRD of 50% Restart - a sequence of 12 blows followed by a gap. SRD of 70-80% Full setup - stoppage due to unexpected causes, up to 24 hours or more during which the soil is allowed to regain its original characteristics. SRD of 100%The pile capacity can be verified at site from the no. of blows required for the driving.The other type of analysis carried out is on-bottom stability. This checks the stability of the jacket from upending till pipe driving. Check for over turning, sliding, bearing capacity are done. Structural analysis of the mudmat is also done. The flooding sequence for the upending is also ascertained.

Softwares:Some of the major softwares used in the structural department are SACS : Design of structures including pre-service and in-service analysis USFOS : Time series seismic analysis AutoCAD : 2D & 3D drafting BOCAD : 3D modelling and extraction of fabrication drawings PDS and PDMS : 3D modelling

Inter-departmental interaction:Structural department has to interact with other departments for various inputs. They are briefly summarized in the following interaction matrix.

INTERACTION MATRIX

DEPARTMENTINPUTOUTPUT

Piping Equipment Layout Piping weight data Piping special supports Topside framing details Piping support details

Pipelines Riser loads Riser/ I & J tube locations Jacket face member details PLEM structural details

Mechanical Equipment data Material handling input Topside framing details Equipment support Monorails/ davit

HSE Safety Layout Safety equipment Fire & blast scenarios

Electrical & Instrumentation Anodes & Jackets E&I equipment Bulk weight Surface area calculation for cathodic protection

Survey agencies/ Client Soil report Oceanic data Details of existing facilities Installation philosophy Barge data Structural drawings Design reports MTO RFQ/ TBE WCR

a. Safety & QualitySafety is paramount in the design, fabrication and installation of offshore structures. Safety to personnel is of highest importance, followed by safety to environment and structure. During the design of the structure and equipment, all relevant codes and standards are followed to maintain quality, which in turn ensures safety. At the start of a project HAZID (Hazard Identification) workshops are carried out. All the possible locations which can cause failure of structure or systems are identified and hazard mitigation measures are analysed. The equipment layout is finalized based on this study.

As the engineering progresses, HAZOP (Hazard and Operability Analysis) are carried out periodically to ensure that all safety & quality regulations are followed and all hazardous area are isolated appropriately. Further, regular Quality audits are conducted to ensure that all issued drawings are engineered following the required codes and standards. All drawing are sent to other disciplines for Inter Department Check (IDC), to ensure there are no misalignment of facilities.

There are different audits that are carried out. These are used to obtain quality certification for the company. These certifications are important for a company to bid for projects and to carry out the engineering and installation. The different qualification audits that are carried out are QMS Quality Management System audits EMS - Environmental Management System audits OSHAS - Occupational Health and Safety Management System audits ISMS Information Security Management System

b. MechanicalThe mechanical department is involved and the design and procurement of equipment packages for the platform. The department is subdivided into 2 parts Static: The design of static equipments are dealt with here. The only loading considered are the self-weight and the product loads in the equipment. Examples of static equipment are pressure vessel, heat exchangers, tanks and pig launcher receiver. Rotary:The design of rotary equipments are dealt with here. The loading consists of both static and dynamic components. Apart from self-weight and the product loads, the dynamic loads due to the rotating components like motors are also considered. Examples are pumps, turbines, compressor and diesel engines.The work of the mechanical department at LTV mainly involves coordinating with the vendor for the equipment packages. Based on the process requirements and the equipment layout, equipment packages are identified and external vendors are chosen. The design specifications are submitted by the vendor, which is then verified to ensure all codes and standards are followed, client requirements are met with and that no clashes with other facilities exists. The other important task is the material handling study. During operation, equipments may have to be removed for maintenance or some parts may require replacement. This study ensures that sufficient space, safe path and laydown areas are available for this operation. Trolleys or padeyes have to be provided for this. The main interfaces with structural department are Input for WCR (Weight Control Report) Input for Equipment support (location, CoG and loading) Material Handling loads

c. PipingPipes are hollow circular section which carries fluid from one point to another. Pipes with all the fittings like elbow, tee, etc are called piping and a network of piping is known as piping system. The department of piping engineering deals with the design of the piping system for the offshore platform.

The hydrocarbon is pumped up from the reservoir via the conductor and is sent for preliminary processing on the platform. For the transportation of the product, piping systems are essential. The extracted hydrocarbon is sent through a phase separator, after which each phase is tested for the hydrocarbon content. It has to then be transferred to a process platform or onshore facility. Preliminary processing is done before this to avoid overloading the pipeline and to remove corrosive substances.

The pressure in the wellhead has to be maintained to ensure controlled and uninterrupted flow. A Christmas tree is a set of valves provided for this. It controls the flow from the well to the equipments in the platform. An emergency shut off valve is provided on the wellhead near the seabed. This gets closed in case of a fire or blast on the topside.

Based on the flow rate, the pipe size, material and the thickness are decided by Process department. These are given as input are given in the form of Piping Material specification (PMS) and Valve Material Specification (VMS). The pipe routing is given in the P&ID (Piping and Instrumentation Diagram). The piping department analyses the routing to check for clashes. Stress analysis is also carried out to check for thickness and coating, if any. For high temperature fluids, expansion loops or bellows are provided in the piping system to reduce thermal stresses.

The main input from the piping department is the equipment layout. The structural and piping department works hand in hand to finalize the topside framing plan and resolve clashes. The equipment layout is decided function, loading, maintenance and access. The equipments are located based on flow, safety and maintenance. They should also be accessible during the platform installation.

Also, piping requires supports at regular interval. The support location and loading details are provided to the structural department.

d. ProcessThe engineering starts from the process department. Process flow diagram (PFD) and Piping & Instrumentation Diagram (P&ID) are the process department outputs, which are the input for all the other departments.

Oil is found in pores of soils, from which it is extracted by sinking well casings. There are three types of casings, production casing, intermediate casing and protective casing. In case there isnt sufficient pressure for the extraction, submersible pumps can be sunk in the reservoir or pressurized fluid can be pumped in through the intermediate casing.

Once the well is drilled, sand or cement is pasted on the reservoir. This ensures that the sand is filtered out and only oil is extracted. This is known as well completion. There are different types of well Vertical well Horizontal well Multilateral well Directional drilling / Slant wellThe hydrocarbon is passed through the test separator. The gas which is separated out may be flared off. But to maintain pressure in the system, it is usually re-injected. In case the gas is being flared off, the moisture is removed by dehydration to conserve fuel.

Some of the softwares used are HYSYS Simulate reservoir fluid characteristics HTRI Heat exchanger design PIPENET Fire water hydraulics SPPID PFD & P&ID preparation PHAST HSE study (flare radiation analysis)e. InstrumentationInstrumentation is the science of measurement and control of process variables. The major variables that are measured in the offshore platform are pressure, temperature, level, flow rate. Sensors, transducers, transmitters, indicators, displays, recorders, data loggers, etc. are used for this purpose.

There are two types of instrumentation available. The pneumatic type, which gives the output in terms of pressure (psi) and the electronic type, which gives an output in amperes. Controllers are installed for the measurement of the process variables and use the output to control valves, motors, etc. There are different types of controllers installed. Programmable Logic Controller (PLC) Scan time interval is in milliseconds. Used in emergency shutdown systems. Distributed Control System (DCS) Scan time is higher (2-3 seconds) Supervisory Control and Data Acquisition system (SCADA) Used in unmanned wellhead platforms.For setting up automated shut off systems, the controllers are set with a limit value. When the sensor output exceeds the value, the controller automatically shuts off valve.

Some of the important instrumentation systems are: PIG (Piping Inspection Gauge): It is used for inspection and maintenance of pipelines. At regular intervals, the PIG is launched into the line and it travels through the system and comes out through the receiver, after the inspection. F&G detection (Fire and Gas Detection): There are different limits which are set to ensure that there is no fire or blast occurs in the platform. Lower Explosive Limit (LEL), Upper Explosive Limit (UEL), Lower Flammable Limit (LFL) and Upper Flammable Limit (UFL). Well Head Control Panel (WHCP): This is the system which controls are the Christmas panel.

A control room is provided on the platform to monitor all the control systems. It has an operator station to monitor all the systems, an engineering station to override any system if required, Remote terminal Unit (RTU) for controllers on other platforms, Master Terminal Unit (MTU) where all RTU signals are monitored. It also controls the CCTV, paging, intercom and radio signals within the platform.

The instrumentation inputs to structural department are WCR (Weight Control Report)Trimmer beam support locationsAccess PlatformsFalse ceiling/ Roofing requirements

f. ElectricalThe major electrical systems in the offshore platform are power generation unit and Cathodic Protection System.The fuel for power generation can be from one of the following sources.Fuel gas from process Used in process platformExternal dieselSolar Most economical. But requires a large spaceWind Usually used as backup for solarBattery Used as backup

There are different voltage levels for different generator or turbine systems.Some of the major electrical equipments areGeneratorsTransformersSwitchgearsHybrid charge controller and regulatorLighting and small power systemsCathodic Protection SystemNavigational AidsCables, cable trays

The interfaces with structural department areWCR (Weight Control Report)Cable tray location and loading

AutoCAD, ETAP are some softwares used in the electrical department.

g. Projects & PlanningProjects department co-ordinates between the engineering unit, fabrication yard and the client. The hydrocarbon project happens in three stages. Upstream consists of the drilling and production of the hydrocarbon. In the mid and downstream stage, the extracted oil is transported, stored and sent for gas processing. The final stage is the downstream stage where it goes to refineries and then for distribution and marketing.There are 4 phases in the upstream stage. They are Phase I : Exploration and field development Phase II : Concept selection, FEED and floating the tender Phase III : Bidding, awarding the project, EPC and handover Phase IV : Production, modification, requalification and decommissioningThe document control register is maintained by the projects and planning department. As the engineering progresses, the project department monitors that the drawings and reports are released as per schedule and that the MTO does not exceed the estimated level. Any deviations have to be accounted for and an alternate plan has to be created.

5. MODULAR FABRICATION FACILITY - KATTUPALLIThe Kattupalli project can be divided into four major components such as modular fabrication facility, ship-lift, production shops and commercial port.

The 400,000 sq m yard has a modular fabrication facility with a heavy load out jetty and an initial dredged channel of 6m below chart datum. L&Ts export oriented Modular fabrication Facility offers offshore platform and floating cum storage units and similar projects/systems for oil & gas sector as per the intended operation of the approved SEZ. L&T has a controlling interest in its joint venture ship building limited (LTSB) with Tamilnadu Industrial Development Corporation Ltd (TIDCO). MFF yard at Kattupalli is in Tamilnadu on Indias east coast near Chennai.The L&T Kattupalli yard is in developing stage and the advantage of this yard is that at the jetty water depth is 12 m therefore the jetty can be used for load out of large or heavy structures. This yard is mainly built for Jacket construction.Yard Area: 400,000 sq mWaterfront: 450m (Approx)Load out Capacity for Deck/Module: up to 24,000 MTLoad out capacity for Jacket: 15,000 MT

SHIP-LIFT:A unique feature of the shipyard is an in-house designed Ship-Lift with lifting capacity of 18,000 tones and a transfer mechanism, which enables shipbuilding and ship repairs of several vessels simultaneously.It consists of two 200 meter long outfitting jettys supported with two piled platforms, one cross transfer area, two defense repair berths, one wash down berth, and two commercial repair berths. This facility will be used for launching of newly built ships as well as for lifting of marine vessels for repair works. The self-weight of ship lifting platform is about 8200 tons and is facilitated with 64 winches of 590ton capacity each for lifting the platform along with the vessels. There are 64 motors, one used for each winch, even if one motor fails then the lifting process is to be stopped and the motor should be repaired or replaced. For this purpose 6 motors are kept in standby mode.

6. CONCLUSIONThe sessions at L&T, Valdel and the Fabrication yard were successfully completed. The trained helped us gain an overall knowledge of the engineering and the fabrication phases of an offshore project. It helped in understanding the direction of work flow, various interactions involved between department, yard and client, the inputs required and outputs generated, etc. It also gave us an overall idea about the type of work that is carried out at the different centers, which will be helpful in choosing our preferred location at the end of the M.Tech course.