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 ships discharging at offshore terminals

LNG ships discharging at offshore 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
Regasification 2.5 bcm/yr

Brazil-2
5.1 bcm/yr

Livorno OLT
5.1 bcm/yr

Dubai
4.0bcm/yr

Rovigo

Neptune

Triton
5.0 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 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

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 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 Technology Qualification

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 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 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

XXII COPINAVAL Buenos Aires, 30 September 2011

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

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 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 qualification certification

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

technology qualification certification

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

technology qualification certification

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

technology qualification certification

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

technology qualification certification

Qualification of hose with ERC and QC/DC valves

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 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 skid
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 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 system

Novelty 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 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

technology qualification certification

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 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 deliverables

Analysis 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 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

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 system

Envelope 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 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)

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 & 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 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 rules
Application: FSO FPSO FSRU MODU FLNG
Storage 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 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

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