Contents. 1 Overview of Ship-Shaped Offshore Installations Front-End Engineering Preface Acknowledgments How to Use This Book.

Size: px

Start display at page:

Download "Contents. 1 Overview of Ship-Shaped Offshore Installations Front-End Engineering Preface Acknowledgments How to Use This Book."

Joy Moore
6 years ago
Views:

1 Table of Preface Acknowledgments How to Use This Book page xv xix xxi 1 Overview of Ship-Shaped Offshore Installations Historical Overview of Offshore Structure Developments Early History History from World War II to the Early 1970s History after the Early 1970s Process of Offshore Oil and Gas Developments System Concepts for Deep- and Ultradeep-Water Field Developments Semisubmersibles Spars Tension Leg Platforms Ship-Shaped Offshore Units A Brief History of the FPSO Installations Trading Tankers versus Ship-Shaped Offshore Units New Build versus Tanker Conversion Layout and General Arrangement of FPSOs Deck Area and General Arrangement Layout Relationships between Principal Dimensions Double-Hull Arrangements Tank Design and Arrangements Longitudinal Strength Characteristics of FPSO Hulls Drawings of a Hypothetical FPSO Aims and Scope of This Book 28 References 29 2 Front-End Engineering Introduction Initial Planning and Contracting Strategies Engineering and Design Principal Aspects Driving Project and Vessel Costs 34 v

2 Table of vi 2.5 Selection of Storage, Production, and Offloading Capabilities Site-Specific Metocean Data Process Facility Design Parameters Limit-State Design Requirements Risk-Assessment Requirements Project Management Post-Bid Schedule and Management Building Material Issues: Yield Stress Building Material Issues: Fracture Toughness Hull Structural Scantling Issues Action-Effect Analysis Issues Fatigue Design Issues Hydrodynamic Impact-Pressure Action Issues: Sloshing, Slamming, and Green Water Vessel Motion and Station-Keeping Issues Topsides Design Issues Mooring System Design Issues Export System Design Issues Corrosion Issues Accommodation Design Issues Construction Issues Equipment Testing Issues Towing Issues Field Installation and Commissioning Issues Inspection and Maintenance Issues Regulations and Classing Issues 52 References 53 3 Design Principles, Criteria, and Regulations Introduction Structural Design Principles Working Stress Design Limit-State Design Critical Buckling Strength Design Comparison among the Three Design Methods Limit-State Criteria for Structural Design and Strength Assessment Probabilistic Format versus Partial Safety Factor Format Probabilistic Format Partial Safety Factor Format Considerations Related to Safety Factors Unified Design Requirements for Trading Tanker Hull Structures Design Principles for Stability Design Principles for Towing and Station-Keeping Design Principles for Vessel Motions Design Principles for Safety, Health, and the Environment Design Principles for Safety Design Principles for Health Design Principles for the Environment 77

3 Table of vii 3.10 Regulations, International Standards, and Recommended Practices 78 References 80 4 Environmental Phenomena and Application to Design Introduction Environmental Data Waves UKOOA FPSO Design Guidance Notes for UKCS Service American Petroleum Institute Recommended Practices Det Norske Veritas Classification Notes Winds Water Depths and Tidal Levels Currents Air and Sea Temperatures Snow and Icing Marine Growth Tank Sloshing Fundamentals Practices for Sloshing Assessment Measures for Sloshing Risk Mitigation Bow Slamming Fundamentals Practices for Bow-Slamming Assessment Measures for Bow-Slamming Risk Mitigation Green Water Fundamentals Practices for Green-Water Assessment Measures for Green-Water Risk Mitigation Considerations Related to the Return Period Wave Energy Spectra Expressions The Generalized Pierson Moskowitz Spectrum The JONSWAP Spectrum Directional Wave Spectra Design Basis Environmental Conditions 107 References Serviceability Limit-State Design Introduction Design Principles and Criteria Practices for Actions and Action-Effects Analysis Elastic Deflection Limits: Under Quasistatic Actions Support Members Plates between Support Members Elastic Buckling Limits Elastic Plate Buckling Elastic Stiffener Web Buckling Elastic Tripping of Stiffener Elastic Stiffener Flange Buckling 128

4 Table of viii 5.6 Permanent Set Deflection Limits: Under Impact-Pressure Actions Plates between Support Members Longitudinally Stiffened Panels between Transverse Frames Cross-Stiffened Plate Structures Illustrative Examples Intact Vessel Stability Vessel Station-Keeping Vessel Weathervaning and Heading Control Vessel Motion Exceedance Vibration and Noise Mooring Line Vortex-Induced Resonance Oscillation Corrosion Wastage 145 References Ultimate Limit-State Design Introduction Design Principles and Criteria Actions and Action-Effects Analysis Structural Component Configuration Ultimate Strength of Plates Fundamentals Closed-Form Expressions Analytical Methods Semianalytical Methods Nonlinear Finite-Element Methods Illustrative Examples Ultimate Strength of Stiffened Plate Structures Fundamentals Closed-Form Expressions Analytical Methods Semianalytical Methods Nonlinear Finite-Element Methods Illustrative Examples Ultimate Strength of Vessel Hulls Fundamentals Closed-Form Expressions Progressive Hull Collapse Analysis: Idealized Structural Unit Method Background of Idealized Structural Unit Method ISUM Structural Modeling ISUM Plate Element 188 (1) Nodal Forces and Nodal Displacements 189 (2) Strain versus Displacement Relationship 189 (3) Stress versus Strain Relationship 191 (4) Tangent Stiffness Equation 192 (5) Displacement (Shape) Function 193 (6) Failure State Considerations 194 (7) Post-Ultimate Strength Behavior 195 (8) Benchmark Study of the Plate Element 195

5 Table of ix ISUM Beam-Column Element 195 (1) Nodal Forces and Nodal Displacements 197 (2) Strain versus Displacement Relationship 197 (3) Stress versus Strain Relationship 197 (4) Displacement (Shape) Function 198 (5) Tangent Stiffness Equation 198 (6) Failure State Considerations 199 (7) Post-Ultimate Strength Behavior 199 (8) Benchmark Study of the Beam-Column Element Illustrative Examples 201 (1) Test Hull Models under Vertical Bending 201 (2) An FPSO Hull under Vertical Bending 204 (3) A Shuttle Tanker Hull under Combined Vertical and Horizontal Bending 208 References Fatigue Limit-State Design Introduction Design Principles and Criteria Cyclic Stress Ranges S N Curves Fatigue Damage Accumulation Practices for Spectral-Analysis-Based FLS Design Seakeeping Analysis Stress Range Transfer Functions Global Structural Analysis Local Structural Analysis and Hot Spot Stress Calculations Definition of Hot Spot Stress Finite-Element Analysis Modeling Selection of S N Curves Fatigue Damage Calculations High-Cycle Fatigue versus Low-Cycle Fatigue Time-Variant Fatigue Crack Propagation Models 250 References Accidental Limit-State Design Introduction Design Principles and Criteria Damaged Vessel Stability: Accidental Flooding Collisions Fundamentals Practices for Collision Assessment Nonlinear Finite-Element Modeling Techniques Dynamic Material Properties Illustrative Examples Dropped Objects Fundamentals Ultimate Strength Characteristics of Dented Plates Under Axial Compressive Loads Under Edge Shear Loads 287

6 Table of x Closed-Form Expressions for Ultimate Strength of Dented Plates Under Axial Compressive Loads Under Edge Shear Loads Fire Fundamentals Practices for Fire Assessment Gas Explosion Fundamentals Practices for Gas Explosion Action Analysis Prescriptive Methods Probabilistic Methods Practices for Gas Explosion Consequence Analysis Illustrative Examples Progressive Collapse of Heeled Hulls with Accidental Flooding Considerations for ALS Applications to Ship-Shaped Offshore Units 313 References Topsides, Mooring, and Export Facilities Design Introduction Topsides Facilities Oil and Water Separation Facilities Gas Compression Facilities Water Injection Facilities Cargo Handling Systems Utility and Support Systems Safeguard Systems Structural Design and Fabrication Considerations for Topsides and Their Interfaces with the Hull Types of Topsides Supports Multipoint Support Columns Sliding/Flexible Support Stools Transverse Girder Supports Types of Topsides Flooring Types of Topsides Fabrication Built-In Grillage Deck Preassembled Units Structural Analysis of Topsides Modules and Interfaces Interface Management and Other Lessons Learned Mooring Facilities Types of Moorings Spread Moorings Single-Point Moorings 338 (1) Fixed Tower 338 (2) CALM 338 (3) SALM 340 (4) ALP 340 (5) SPAR 342 (6) SAL 342 (7) Turret Mooring 342

7 Table of xi Mooring System Selection for an FPSO in Deep Water Design Considerations for Mooring Systems Export Facilities Methods of Export Types of Shuttle Tanker Export Design Considerations for Export Systems 352 References Corrosion Assessment and Management Introduction Marine Corrosion Mechanisms Fundamentals Types of Corrosion General Corrosion Pitting Corrosion Grooving Weld Metal Corrosion Factors Affecting Corrosion Mathematical Models for Corrosion Wastage Prediction Overall Behavior of Corrosion Mechanical Models Corrosion Depth Formulations Data Collection of Corrosion Measurements Characteristics of Observed Corrosion Wastage Annualized Corrosion Rates Phenomenological Models Options for Corrosion Management Corrosion Margin Addition Coating Surface Preparation Types of Coating Selection Criteria of Coating Material Methodologies for Coating-Life Prediction Cathodic Protection Ballast Water Deoxygenation Chemical Inhibitors 395 References Inspection and Maintenance Introduction Types of Age-Related Deterioration Methods for Damage Examination Corrosion Wastage Examination Fatigue and Other Crack Examination Mechanical Damage Examination Probability of Detection and Sizing Recommended Practices for Trading Tankers Condition Assessment Scheme Enhanced Survey Programme 409

8 Table of xii Emergency Response Services Ship Inspection Report Programme Risk-Based Inspection RBI Team Setup Component Grouping and Baselining Risk-Based Prioritization Inspection Plan Development Inspection Strategy Scope of Inspection Frequency of Inspection Inspection Execution Analysis of Inspection Results RBI Program Updating Risk-Based Maintenance Time-Variant Failure Mechanisms Planned Maintenance Condition Monitoring Combination of Planned Maintenance and Condition Monitoring Failure Finding Recommended Practices for Ship-Shaped Offshore Units Inspection Practices Maintenance Practices Effect of Corrosion Wastage on Plate Ultimate Strength Effect of Fatigue Cracking on Plate Ultimate Strength Effect of Time-Variant Age-Related Deterioration on FPSO Hull Ultimate Strength Reliability: An Academic Example Scenario for Sea States and Operational Conditions Scenario for Time-Variant Corrosion Wastage Scenario for Time-Variant Fatigue Cracking Time-Variant Ultimate Hull Strength Reliability Assessment Considerations for Repair Strategies 439 References Tanker Conversion and Decommissioning Introduction Tanker Conversion Selection of Suitable Tankers Condition Assessment of Aged Tanker Hull Structures Inspection and Maintenance Renewal Scantlings for Tanker Conversion Repair of Defects, Dents, Pitting, Grooving, and Cracks Residual Strength Assessment Reusability of Existing Machinery and Equipment Addition of New Components Appraisals of Conversion Yard 456

9 Table of xiii 12.3 Decommissioning Regulatory Framework Technical Feasibility Issues Safety and Health Issues Environmental Issues Cost Issues Decommissioning Practices for Ship-Shaped Offshore Installations 460 References Risk Assessment and Management Introduction Process for Formal Safety Assessment System Definition Hazard Identification Risk Assessment Risk-Management Options Cost Benefit Analysis Decision-Making Recommendations Qualitative Risk Assessment Quantitative Risk Assessment Frequency Analysis Consequence Analysis Risk Representation Risk Management during Design Selection of Materials Layout for Hazard Impact Minimization Limit-State Design Passive Safeguards for Fire and Explosion Accelerated Degradation Protection Risk Management during Operation Collisions Dropped Objects Active Safeguards for Fire and Explosion Inspection and Maintenance 485 References 486 Appendix 1. Terms and Definitions Appendix 2. Scale Definitions of Winds, Waves, and Swells A2.1 Beaufort Wind Scale 503 A2.2 Wave Scale 503 A2.3 Swell Scale 504 Appendix 3. Probability of Sea States at Various Ocean Regions A3.1 Identification of Ocean Areas Using Marsden Squares 505 A3.2 Probability of Sea States in the North Atlantic 506 A3.3 Annual Sea States in the North Atlantic 507 A3.4 Annual Sea States in the North Pacific 508

10 Table of xiv A3.5 Characteristics of 100-Year Return Period Storms at Various Ocean Regions 509 A3.6 Extremes of Environmental Phenomena at Various Ocean Regions 510 Appendix 4. Scaling Laws for Physical Model Testing A4.1 Hydrodynamics Model Tests 511 A4.1.1 Froude Scaling Law 511 A4.1.2 Reynolds Scaling Law 511 A4.1.3 Vortex-Shedding Effects 512 A4.1.4 Surface Tension Effects 512 A4.1.5 Compressibility Effects 513 A4.2 Structural Mechanics Model Tests 513 Appendix 5. Wind-Tunnel Test Requirements Appendix 6. List of Selected Industry Standards Index 531

Fatigue strength of knuckle joints - a key parameter in ship design D. Beghin Marine Division, Bureau Veritas, Paris, France

Fatigue strength of knuckle joints - a key parameter in ship design D. Beghin Marine Division, Bureau Veritas, Paris, France Abstract Structural integrity of knuckle joints in inner hull for double hull