The Design and Classification of Floating Regasification Units Focus on Novel Aspects
Transcript of The Design and Classification of Floating Regasification Units Focus on Novel Aspects
XXII COPINAVAL Buenos Aires, 30 September 2011
THE DESIGN AND CLASSIFICATION OF FLOATING REGASIFICATION UNITS FOCUS ON NOVEL ASPECTSDino Ettore Cervetto Head of RINA Technical Services
traditional scheme of gas import by the seaEXTRACTION SITE
GAS LIQUEFACTION
LOADING ON BOARD SHIPS (LNG CARRIERS)
traditional scheme of gas import by the seaLNG CARRIERS
ONSHORE/SHELTERED WATER TERMINALS
REGASSIFICATION PLANTS
NATIONAL NETWORK
LNG ships discharging at offshore terminalsPotentially lower costs when compared to some onshore alternatives. Reduced construction and delivery risks. Reduced safety, security, and navigational risks. Increased terminal availability. More flexible location selection. Simplified decommissioning. Possibility of re-using of existing oil terminals
LNG ships discharging at onshore terminals
LNG ships discharging at offshore terminals
LNG ships discharging at offshore terminalsLNG CARRIER WITH REGASSIFICATION MODULE OFFSHORE BUOY OR TERMINAL
NATIONAL NETWORK
FSRU located offshoreLNG SHUTTLE CARRIER OFFSHORE FLOATING STORAGE TERMINAL WITH REGASSIFICATION MODULE (FSRU) NATIONAL NETWORK
Floating Storage and Regasification Units
LNG carrier ships converted: Permanently moored units Purposely new built ships: Sailing vessels Disconnectable SPM Permanently moored units
regasification sitesBrazil-1Regasification 2.5 bcm/yr
Brazil-25.1 bcm/yr
Livorno OLT5.1 bcm/yr
Dubai4.0bcm/yr
Rovigo
Neptune
Triton5.0 bcm/yr
Port Dolphin
Storage
129,000m3
138,000m3
137,000m3
125,000m3
147,000m3
147,000m3
147,000m3
Location
Existing Pier
New Pier
Offshore
New Pier
GBS Offshore
Offshore
Offshore
Offshore No Transfer LNGRV used
LNG Transfer
Over jetty / loading arms on jetty
Over Jetty / Loading arms on FSRU
Side by Side Side by Side / Side by Side / / Loading Loading arms Loading arms arms on on FSRU on GBS FSRU Riser to subsea p/l HP Arms on Jetty
No Transfer LNGRV used
Side by Side / Loading arms on FSRU
Gas Transfer
HP Arms on Jetty
HP Arms on Jetty
Pipeline
HP Pipe via STL
HP Pipe via STL
HP Pipe via STL
Vaporization
Closed Loop
Closed/Open Loop
Open Loop
Open Loop
Mooring System
Conventional
Conventional
Turret Mooring
Conventional
GBS Fixed
STL Mooring
STL Mooring
STL Mooring
Flexibility
LNGC
LNGC
-
LNGC
-
LNGC
LNGC
LNGC
offshore regasification
Energy Bridge Exmar/Excelerate Neptune LNG GdF HoeghConventional loading On board regasification Send out via STL or conventional manifold Enhancement: Ship to Ship Transfer with hoses (in sheltered waters or moderate sea environment)
offshore regasification
fixed floating terminal
Brazil FSRU Projects Petrobras/Golar Dubai FSRU - ShellPermanently moored to jetty LNG loading via conventional loading arm Send out via manifold No direct ship to ship transfer
fixed floating terminal
FSRU located offshore
Technical Challenges Authority Engineering
XXII COPINAVAL Buenos Aires, 30 September 2011
FSRU TECHNICAL CHALLENGES NOVEL TECHNOLIGIES
FSRU design challenges
Location & sea condition Type of vessel & containment Mooring of the facility Access for export / import vessels (tugs & pilotage) Method of transfer of cargo Novel Technology use What if the LNG supply vessel must leave part full?
FSRU design challengesCorrosion Protection System and Inspection Access Structure following site specific loads Additional loads: Flare tower, Mooring system, Risers, Topsides, Lifting Appliances, Helideck No drydock, repairs limited over design life Dynamic loading-unloading sequences Transit condition Flag and local requirements
FSRU novel technologies
OFFSHORE STORAGE MOORED UNITSTransfer of LNG in open sea Semi-rigid transfer arms (Loading arms) Full flexible hoses
Ship-to-ship mooring in open sea Regasification process on board in an open sea environment
transfer of LNG
transfer of LNGLoading arms: well proven for transfer between ship and shore for LNG, but never used in open sea conditions between two moving objects Flexible hoses: no evidence of previous experiences The following aspects are to be investigated Operating envelope Reliability (maintenance) Operations connection/disconnection Availability Failure modes Technology Qualification
ship-to-ship mooringShips motions model testing & verification Verify mooring system in offshore conditions Operating limits Operations (mooring/unmooring) Reliability Availability of ships Failure modes Technology Qualification
regasification processThe following ship motions-related issues are to be investigated: Fatigue Additional stress on supports/saddles Impact on heat transfer area due to liquid motions inside the shell Technology Qualification
certification issues Ship arrangement Class Rules (new RINA Rules for the Classification of Offshore Installations) and International regulations, National Laws and Standards Process Marinization of on-shore existing technologies Technology Qualification Process Unit-to-ship mooring and LNG transfer Rules - Technology Qualification Process Class
RINA experience
Experience gained from the application of a rational approach:Class Rules and International Regulations safety criteria Risk assessment Technology qualification as a systematic approach to the qualification of novel technologies, to ensure that they are fit for their intended service
XXII COPINAVAL Buenos Aires, 30 September 2011
RINA REFERENCES
our last projectsAdriatic LNG, offshore regasification GBS, Rovigo OLT offshore FSRU, Livorno Nuove Energie, onshore regasification plant, Porto Empedocle EET, offshore regasification plant, Morocco ENI, offshore ORSA project, Adriatic Sea API Nva Energia, offshore FSRU, Ancona Ionio Gas, onshore regasificatino plant, Priolo Terminal Alpi Adriatico, offshore regasification GBS, Monfalcone Medgas, onshore regasification plant, Gioia Tauro Triton, offshore FSRU, Porto Recanati Enel, offshore storage and transhipment unit, Porto Tolle Fiamma 2000, LPG offshore terminal, Ardea Humpuss, Pomalaa, Mandiodo and Halmahera FSRU projects, Indonesia Blue Mgmt, CNG technology development project, Italy
ADRIATIC LNG, Rovigo
Type offshore GBS Capacity 8 bcmy Status In service
Services provided: Support during authorization phase Certification of structural design and marine operations Notified body for PED CE marking Direzione Lavori according to Law 1086/71 Preparation of inspection strategy and procedures according to RBI techniques Loading master Security Assessment, PFSP preparation, training to personnel
The first regasification terminal Offshore Gravity Based
OLT FSRU TOSCANA. LivornoType FSRU, Floating Storage Regasification Unit Capacity 3,75 bcmy Status In reconversionServices provided: Authority engineering Owner engineering FSRU unit classification Technology qualification Specialist studies (ship handling, seakeeping, mooring, fatigue, ) RISP (Port Integrated Safety Report) preparation Support for definition of O&M and SSVV
The first offshore FSRU
TRITON, Porto RecanatiType Offshore FSRU Capacity 5 bcmy Status Authorisation phaseServices provided: Classification of the unit Risk assessment Technology qualification
The first offshore FSRU with internal turret
XXII COPINAVAL Buenos Aires, 30 September 2011
RINA TOOLS TO ADDRESS NOVEL TECHNOLOGIESTECHNOLOGY QUALIFICATION RULES AND STANDARDS
technology qualification certification Why do we need Technology Qualification?The main reason is to satisfy banks/insurances. In the current credit crisis the new complex technology or new uses of existing complex technology is seen as high risk Secondly permitting (Safety) The technology qualification by independent 3rd party reduces this risk
technology qualification certification TQ certificate includes: RINA Guide on TQ Processes Safety Fitness for service Functionality Verification of compliance with Client-defined targets Verification of interfaces between the new technology and the existing systems
technology qualification certification Define Qualification Basis with stakeholdersSystem description System types, capacities and interfaces Environmental data of operation, Functional requirements, RAMS, Codes and standards
Inherent uncertainties Materials, Dynamic responses, loads, Installation, tests,
technology qualification certification
Technology assessmentManageable elements Degree of novelty
Classification of equipment according to the degree of novelty1) No new technical uncertainties 2) New technical uncertainties 3) New technical challenges 4) Demanding new technical challenges
technology qualification certification
Experience with Loading ArmsWell proven for transfer between ship and shore for LNG Never used in open water between two moving objects The following to be investigated Operating envelope Reliability (maintenance) Operations connection/disconnection Availability Failure modes
Design out problems
technology qualification certification
Loading arms: novelty challengesRelative unit-ship motions LNG release Clash between loading arms LNG spill during emergency release Pressure surge Structural issues Integration with onboard systems
technology qualification certification
Qualification of flexible hose materialNovelty challenges (to be refined on the basis of the actual hose design)Materials (compatibility with LNG, at sea conditions, deformation and stresses, ageing) LNG release Pressure surge Drop of hose
technology qualification certification
Qualification of hose with ERC and QC/DC valvesNovelty challenges (to be refined on the basis of the actual hose design)Materials (compatibility with LNG, at sea conditions, deformation and stresses, ageing) LNG release Pressure surge Drop of hose Operational practice and interfaces Swinging motions Relative unit-ship motions Amplitude drop during emergency release LNG spill during emergency release Release during purging/pressure test Integration with onboard system
technology qualification certification
Qualification of hose with ERC and QC/DC valves and mast structures or pipe deck skidNovelty challenges (to be refined on the basis of the actual hose design)Materials (compatibility with LNG, at sea conditions, deformation and stresses, ageing) LNG release Pressure surge Drop of hose Operational practice and interfaces Swinging motions Relative unit-ship motions (allowable working envelope) Amplitude drop during emergency release LNG spill during emergency release Release during purging/pressure test Integration with onboard system Mast structures or pipe deck skid
technology qualification certification
Qualification of the hose overall transfer systemNovelty challenges (to be refined on the basis of the actual hose design)Materials (compatibility with LNG, at sea, deformation and stresses, ageing) LNG release Pressure surge Drop of hose Operational practice and interfaces Swinging motions Relative unit-ship motions (allowable working envelope) Amplitude drop during emergency release LNG spill during emergency release Release during purging/pressure test Integration with onboard system Mast structures or pipe deck skid Reliability / availability requirements Hose interference
technology qualification certification
Qualification methodsRisk assessment, HAZID, FMECA (failure causes, functional elements, interfacing) Engineering analyses (to reduce the risks limiting the uncertainties) Tests on materials and hoses Maintenance policy in order to fulfil the availability targets, through cost benefit analysis
technology qualification certificationRisk assessment is based on the estimation of probability and consequences of events, such as: Fire Hazardous gas dispersions Hazardous liquid spills Propagation effects Suggest mitigation measures ALARP Overall consistency of safety requirements in International and National Regulations
RINA Guide on Risk Analyses
Extensive application of risk assessment techniques (HAZID, FMECA, consequence models etc.)
technology qualification certification Data collection and deliverablesAnalysis of measurements and tests to verify the engineering analysis Functionality assessment Deliverables Technology Assessment Qualification Plan Qualification Report Approval
technology qualification certification
Final Certificate after satisfactory completion of final tests on board
engineering analyses: LNG transfer systemMarinization of Liquefied Gases loading arms fitted on the FSRU:Identification of critical aspects due to the novel offshore application:Side-by-side mooring (clash studies) Emergency release disconnection (testing of timing and liquid release) Fatigue (material testing, calculations) Automation and alarms (FMEA and field tests) Interface with safety systems (ESD) of the FSRU topside and LNGCTarget performance: - 20 years design life - Transfer allowed within a limiting environmental condition - maximization of the availability of the transfer
engineering analyses: LNG transfer system
Motion envelope (loading arms)
engineering analyses: LNG transfer system
Motion envelope (flexible hoses)
engineering analyses: LNG transfer system
Motion envelope (flexible hoses)
engineering analyses: LNG transfer systemEnvelope Quick Comparison Vertical: Vessel motion +/- 2m Range Based on our experience based on 137,000m3 ship moored to FSRU (similar size) Dynamic: +/-: 2m Static (between two decks) +/-1.3m Total: +/-3.3m Transverse pre alarm: 3.25m Static Tolerance Fender: +/- 0.25 Dynamic Displacement:+/- 2.0m Total: +/- 2.25m Longitudinal pre alarm: 3.25m Mooring tolerances: +/- 1.0m Dynamic tolerances: +/- 3.25m Total: +/- 4.25m
engineering analyses: side by side mooring
Mooring ArrangementsShips motions (model testing & verification) Verify mooring system Operating limits Operations (mooring/unmooring) Reliability Availability of ship Failure modes
engineering analyses: fluid vaporizersIdentification of major risks:Fatigue of structural internal details and interface with the hull : inertial loads due to wave motions in operation / survival / transit conditions thermal stresses
Sloshing issue with regards to internal baffles arrangement and minimum filling level 3D CFD direct assessment Target performance: - 20 years design life - Process continuity (no limitations due to the environmental conditions)
XXII COPINAVAL Buenos Aires, 30 September 2011
RULES AND STANDARDS
certification issues Ship arrangement Class Rules (new RINA Rules for the Classification of Offshore Installations) and International regulations, National Laws and Standards Process Marinization of on-shore existing technologies Technology Qualification Process Unit-to-ship mooring and LNG transfer Rules - Technology Qualification Process Class
Rules & StandardsFloating Units fall between traditional marine and onshore regulations The scope of each may vary depending upon location One solution will not fit all Experience will help to ease this process Class & Regulatory Bodies need to be consulted at a very early stage
International regulations
Typically:SOLAS MARPOL IGC STCW (depending on location)
As none of these rules have been written with offshore gas in mind, they need to be carefully studied to determine what is applicable based upon the specific project
Regional regulations
European Union (EU) Directives Pressure Equipment Directive (PED) Marine Equipment Directive (MED)
EN1474-1 for LNG loading arms EN1474-2 for LNG flexible hoses EN1474-3 for offshore LNG transfer systems
standard for transfer systems2008: adoption of: EN1474-2:2008 qualification standard for LNG flexible hoses EN1474-3:2008 qualification standard for offshore LNG transfer systems
This standard is incorporated in the RINA Rules For Offshore Units and already applied for the FSRU project (loading arms)
RINA rulesNEW RINA RULES FOR THE CLASSIFICATION OF FLOATING OFFSHORE UNITS AT FIXED LOCATIONS AND MOBILE OFFSHORE DRILLING UNITS entered into force in March 2010
appropriate for the new projects, to entail the use of advanced technologies based on RINA experience gained in classification of floating units, especially of FSRU TOSCANA include the existing Rules for the classification of mobile offshore drilling units, duly modified eliminate the necessity to refer to other Rules
RINA rulesSix different parts:PART A PART B PART C PART D PART E PART F Classification and Surveys Hull and Stability Machinery, Systems and Fire Protection Materials and Welding Service Notations Additional Class Notations
RINA rulesApplication: FSO FPSO FSRU MODU FLNGStorage and off-loading of liquid hydrocarbons Production, storage and off-loading of liquid hydrocarbons Off-loading, Storage and/or regasification of liquefied natural gases Mobile Offshore Drilling Units Floating LNG (Liquefaction units) C X [Hull] X [Mach] [FSO] [FPSO] [FSRU] [MODU] [FLNG] Operating area notation Additional Class Notations
RINA rules and guidesGuide for Risk Analyses Guide for Technology Qualification Processes RINA Guide on Software Acceptance in Marine Applications RINA Guide for the Design and Operation of Liquefied Natural Gas (LNG) Carriers RINA Guide for structural design of oil tankers
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