The Design and Classification of Fsru PDF

XXII COPINAVAL Buenos Aires, 30 September 2011
THE DESIGN AND CLASSIFICATION OF

FLOATING REGASIFICATION UNITS
FOCUS ON NOVEL ASPECTS
Dino Ettore Cervetto
Head of RINA Technical Services
traditional scheme of gas import by the sea

EXTRACTION SITE
GAS LIQUEFACTION
LOADING ON BOARD
SHIPS (LNG CARRIERS)
traditional scheme of gas import by the sea

LNG CARRIERS
ONSHORE/SHELTERED WATER
TERMINALS
REGASSIFICATION
PLANTS
NATIONAL NETWORK
LNG ships discharging at offshore terminals

Potentially 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 CARRIER WITH
REGASSIFICATION
MODULE
OFFSHORE
BUOY OR
TERMINAL
NATIONAL
NETWORK
FSRU located offshore

LNG 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 sites
Brazil-1
Brazil-2
Livorno
OLT
Dubai
Regasification
2.5 bcm/yr
5.1 bcm/yr
5.1 bcm/yr
4.0bcm/yr
Storage
129,000m3
138,000m3
137,000m3
125,000m3
Location
Existing Pier
New Pier
Offshore
New Pier
LNG Transfer
Over jetty /
loading arms
on jetty
Over Jetty /
Loading arms
on FSRU
Gas Transfer
HP Arms on
Jetty
HP Arms on
Jetty
Riser to
subsea p/l
HP Arms on
Jetty
Vaporization
Closed Loop
Closed/Open
Loop
Open Loop
Open Loop
Mooring
System
Conventional
Conventional
Turret
Mooring
Flexibility
LNGC
LNGC
Rovigo
Neptune
Triton
Port
Dolphin
5.0 bcm/yr
GBS Offshore
Side by Side
Side by Side / Side by Side /
/ Loading
Loading arms Loading arms
arms on
on FSRU
on GBS
FSRU
147,000m3
147,000m3
147,000m3
Offshore
Offshore
Offshore
Side by Side /
Loading arms
on FSRU
No Transfer
LNGRV used
No Transfer
LNGRV used
Pipeline
HP Pipe via
STL
HP Pipe via
STL
HP Pipe via
STL
Conventional
GBS Fixed
STL Mooring
STL Mooring
STL Mooring
LNGC
LNGC
LNGC
LNGC
offshore regasification
Energy Bridge Exmar/Excelerate

Neptune LNG GdF Hoegh
Conventional 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 - Shell
Permanently 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
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 challenges

Corrosion 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 UNITS

Transfer 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 LNG
Loading 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 mooring
Ships motions model testing & verification
Verify mooring system in offshore conditions
Operating limits
Operations (mooring/unmooring)
Reliability
Availability of ships
Failure modes
regasification process
The 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
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 Class
Rules - Technology Qualification Process
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
RINA REFERENCES
our last projects

Adriatic 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. Livorno

Type
FSRU, Floating
Storage
Regasification Unit
Capacity
3,75 bcmy
Status
In reconversion
Services 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 Recanati

Type
Offshore FSRU
Capacity
5 bcmy
Status
Authorisation phase
Services provided:
Classification of the unit
Risk assessment
Technology qualification
The first offshore FSRU with internal turret
RINA TOOLS TO ADDRESS NOVEL

TECHNOLOGIES
TECHNOLOGY 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

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

Define Qualification Basis with stakeholders
System 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 assessment
Manageable elements
Degree of novelty
Classification of equipment according

to the degree of novelty
1) No new technical uncertainties
2) New technical uncertainties
3) New technical challenges
4) Demanding new technical challenges
Experience with Loading Arms

Well 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
Loading arms: novelty challenges

Relative unit-ship motions

LNG release
Clash between loading arms
LNG spill during emergency release
Pressure surge
Structural issues
Integration with onboard systems
Qualification of flexible hose material

Novelty 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
Qualification of hose with ERC and QC/DC valves

ageing)
LNG release
Pressure surge
Drop of hose
Operational practice and interfaces
Swinging motions
Relative unit-ship motions
Amplitude drop during emergency release
Release during purging/pressure test
Integration with onboard system
Qualification of hose with ERC and QC/DC valves and

mast structures or pipe deck skid
ageing)
LNG release
Pressure surge
Drop of hose
Swinging motions
Relative unit-ship motions (allowable working envelope)
Mast structures or pipe deck skid
Qualification of the hose overall transfer system


Materials (compatibility with LNG, at sea, deformation and stresses, ageing)

LNG release
Pressure surge
Drop of hose
Swinging motions
Relative unit-ship motions (allowable working envelope)
Mast structures or pipe deck skid
Reliability / availability requirements
Hose interference
Qualification methods
Risk 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

Risk 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
RINA Guide on Risk Analyses
Overall consistency of safety

requirements in International and
National Regulations
Extensive application of risk assessment

techniques (HAZID, FMECA, consequence
models etc.)

Data collection and deliverables
Analysis of measurements and tests
to verify the engineering analysis
Functionality assessment
Deliverables
Technology Assessment
Qualification Plan
Qualification Report
Approval
Final Certificate after

satisfactory completion of final
tests on board
engineering analyses: LNG transfer system

Marinization 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 LNGC
Target performance:
- 20 years design life
- Transfer allowed within a limiting
environmental condition
- maximization of the availability of the
transfer
Motion
envelope
(loading arms)
Motion
envelope
(flexible hoses)
Motion
envelope
(flexible hoses)

Envelope Quick
Comparison
Range Based on our experience based

on 137,000m3 ship moored to FSRU
(similar size)
Vertical: Vessel motion +/- 2m
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 Arrangements
Ships motions (model testing
& verification)
Verify mooring system
Operating limits
Operations (mooring/unmooring)
Reliability
Availability of ship
Failure modes
engineering analyses: fluid vaporizers

Identification 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)
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 Class
Rules - Technology Qualification Process
Rules & Standards

Floating
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 systems

2008: 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 rules
NEW 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 rules
Six different parts:
PART A
Classification and Surveys
PART B
Hull and Stability
PART C
Machinery, Systems and Fire Protection
PART D
Materials and Welding
PART E
Service Notations
PART F
Additional Class Notations
RINA rules
Application:
FSO
Storage and off-loading of liquid hydrocarbons
FPSO
Production, storage and off-loading of liquid hydrocarbons
FSRU
Off-loading, Storage and/or regasification of liquefied

natural gases
MODU
Mobile Offshore Drilling Units
FLNG
Floating LNG (Liquefaction units)

C X [Hull] X [Mach] [FSO] [FPSO] [FSRU] [MODU] [FLNG]
Operating area notation Additional Class Notations
RINA rules and guides

Guide 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
Working with you . to meet your needs.
Thanks for your kind attention

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XXII COPINAVAL Buenos Aires, 30 September 2011