TSE101

Technical Safety Engineering Foundation

5.2.2 Site Layout (Additional Offshore

Specifics)

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GSNL-HPTS

Copyright of Shell Projects & Technology RESTRICTED September

Month 2010
2011 1
LAYOUT DESIGN OFFSHORE – THINGS TO CONSIDER

The main drivers for the development of an offshore facility layout are
costs, lost production, safety, and weight.
The primary objective of layout development, as well as for layout
optimization, is to ensure that the facility will be developed in such a
way that all categories of risks (including HSE, technical, political,
economic – cost & schedule, operational) in the facility are reduced to
as low as reasonably practicable (ALARP) during all phases of its life,
from construction to decommissioning.
Hazard management, inherent safety principles and good practices
are key contributors to achieve this objective.
The application of Quantitative Risk Assessment (QRA) and the
concept of Risk Tolerability Criteria in comparing alternative layout
designs is considered valuable as part of the decision-making
process. In addition to that it will help in demonstrating that the risk
criteria have been achieved, and that the risks are indeed ALARP.

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LAYOUT DESIGN OFFSHORE

There are a number of important differences between an onshore and

offshore plant.
Water depth is an important consideration which will drive the overall
layout configuration:
 In shallow waters the facilities could easily be split-up in a number
of small support structures (jackets) each carrying individual
functions like wells, oil processing, process support and
accommodation,
 In deeper water the costs of jackets or floating platforms would drive
the concept to design for compact integrated facilities installed on a
platform.

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LAYOUT DESIGN OFFSHORE

From left to right:

1, 2) conventional fixed platforms; 3) compliant tower; 4, 5) vertically
moored tension leg and mini-tension leg platform; 6) Spar ; 7,8)
Semi-submersibles ; 9) Floating production, storage, and offloading
facility; 10) sub-sea completion and tie-back to host facility.

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MAIN TYPES OF FLOATING PLATFORMS – TLP

Tension-Leg Platforms (TLP)

TLPs are floating platforms
tethered to the seabed in a
manner that eliminates most
vertical movement of the
structure. The "conventional"
TLP is a 4-column design which
looks similar to a
semisubmersible.
TLP facilities can be installed at
a shore base, facilities are
typically weight constrained
due to limited amount of
buoyancy, limited water depth
(< 4000ft or so).

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MAIN TYPES OF FLOATING PLATFORMS – SPAR

Spar
 The classic spar is a deep-draft,
caisson-type, floating structure with a
fully compartmented upper section
that is buoyant and with 2 lower
sections that are flooded. The lowest
compartments in the upper buoyant
section are configured for variable
seawater ballast to maintain draft and
trim under varying topside loading
conditions. The typical applicable
water depth range is considered to be
from 1,500 ft. to 10,000 ft.
 Smallest footprint (so largest fire and
explosion risks), requires an offshore
lift of the facilities, facilities are
typically weight constrained due to
limited amount of buoyancy.
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MAIN TYPES OF FLOATING PLATFORMS – SEMI-SUB

Semi-sub:
 Semi-sub facilities can be installed at a shore base, typically large
footprint (though not as big as an FPSO).

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MAIN TYPES OF FLOATING PLATFORMS – FPSO

Floating Production, Storage and Offloading (FPSO):

 Eliminates the need for an oil pipeline (though requires oil carrier to
approach the facility for transfer of oil), highest amount spacing due
to being the largest footprint.

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LAYOUT DESIGN OFFSHORE

With respect to infrastructure, offshore installations (which are in the

form of fixed or floating installations) are located in remote areas. As
such the ability to support the installation logistically (by offloading
consumables by supply boats as well as transporting people by
helicopter) will be one of the important considerations.
The layout of the installation should take into account the number and
position of offshore pedestal cranes, storage area on the upper deck
as well as laydown areas at various locations on each of the other
decks.

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CONSTRUCTION

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LAYOUT DESIGN OFFSHORE

During the initial layout development phases the construction

requirements should be considered.
For example in an offshore construction yard crane lift and reach
should be addressed early to ensure that equipment can still be lifted
of the platform decks.
During construction of an offshore plant a designated construction
area may be required for storage, fabrication, construction and
commissioning facilities adjacent to the plant site

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INSTALLATION

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LAYOUT DESIGN OFFSHORE

A main constraint is be the ability to install equipment on the offshore

facility.
While onshore this would be achieved by road or waterways,
installing large and heavy equipment offshore requires large offshore
cranes (refer to the picture on the left-hand side of the previous slide )
or other methods, like float-over operations (see picture on the right-
hand side), to position the facilities on the supporting substructure.
Alternatively, the facilities could be installed at a shore base and the
entire facility floated to the site (however this is dependent on the type
of floating structure).

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OVERALL FIELD LAYOUT – PLATFORM ORIENTATION

One of the most important considerations applicable to offshore

layout development is the orientation of the platforms

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PLATFORM ORIENTATION

In developing the overall field layout, obtaining accurate data about

the prevailing wind and wave directions within the area is very
important.
As such, every effort should be made to obtain the data for the actual
geographical area
In the real case example shown on the previous slide, the prevailing
wind as well as the prevailing wave direction is for 75 % of the time
coming from the true north direction.
The example addresses a number of layout issues which all will be
influenced in one way or another by prevailing wind and wave
directions.
One of the issues is related to the approach and orientation of the
jack-up drilling rig required to drill the wells in the wellhead
platforms.
A jack-up is a drilling platform which can be elevated itself out of the
water by means of a jacking system and skid the drilling function over
the well slots in the wellhead platform. Determining the optimum
orientation of the jack-up will be based on a number of
considerations.
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OVERALL FIELD LAYOUT – PLATFORM ORIENTATION

For reasons of unobstructed approach and good mooring, good

helicopter approach and offtake, good supply boat access and
offloading, the jack-up should preferably be orientated at the plant
west side of the wellhead platform. Also this position is good in the
event of fire of oil wells in the well bay area as there will be limited
potential that smoke to reach the safe part of the jack-up.

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OVERALL FIELD LAYOUT – INSTALLATIONS OF TOPSIDES

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OVERALL FIELD LAYOUT – INSTALLATIONS OF TOPSIDES

In terms of topsides facilities the concept was based on an integrated

topsides for process platform 1 a and installed following the float-over
concept.
For the topsides for process platform 2 a modular concept was
proposed which would be installed on the jacket support frame by
means of a barge crane.
One of the main considerations to decide for a float-over or barge
crane lift is the weight of the topsides
Nowadays installing large and heavy platform topsides by float-over
has become standard practice. The main concern with float-over
operations would be that during the float over operation the heading
of the barge which supports the topsides should be in line with the
dominant wave conditions. This means the jackets will have to be
constructed in a line perpendicular to the prevailing wave direction.

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OVERALL FIELD LAYOUT – OPTIMUM TOPSIDES
CONFIGURATION

Guidance on the
selection and design
of blast wall is
provided in DEP
37.01.10.11

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OVERALL FIELD LAYOUT – OPTIMUM TOPSIDES
CONFIGURATION

Although from a float-over operation, the transportation barge has

been in the right heading for installing the topsides, the proposed
layout of the topsides as above is not preferred in view of the previous
slide.

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OVERALL FIELD LAYOUT – OPTIMUM TOPSIDES
CONFIGURATION

Due to the orientation of the process vessels, there will be hardly any
effect from natural ventilation going through the topsides decks as the
decks are significantly blocked by the large diameter separator vessels
(reduced air flow).
A much better configuration would be to rotate the topsides 90
degrees such that natural ventilation will lead to optimum air flow (see
next slide).

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OVERALL FIELD LAYOUT – OPTIMUM TOPSIDES
CONFIGURATION

So, in developing the overall field layout configuration the designer

should address 2 considerations e.g. the preferred heading of the
installation barge for carrying out the topsides float-over and the
proper orientation of the topsides to allow for maximum natural
ventilation.
To achieve the 2 objectives the design contractor had to modify the
topsides as well as the leg configuration of the jacket of process
platform 1.
At the same time the design contractor recognized the benefits or the
float-over concept and proposed also a float-over installation for the
topsides of process platform 2

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OVERALL FIELD LAYOUT – OPTIMUM TOPSIDES
CONFIGURATION

Subsequently, as part of fire mitigation assessments, the large deck

areas raised the requirement to split in smaller fire areas and resulted
in reduced fire water demand.

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OFFSHORE LIVING QUARTERS: KEY POINTS

Acts as control center for facility, communications center, hotel and

feeding area for employees, muster area in case of emergencies
Helidecks are typically placed on the living quarters
With regards to layout, needs to be placed in safest area possible,
e.g. upwind and far away as possible from hydrocarbons or toxics
Typically designed to Class requirements (e.g. ABS Habitability
standards) and Shell internal standards for health requirements
Designed to withstand credible explosion and fires so that personnel
can muster and escape via lifeboats (e.g. installation of fire and
explosion walls if required)
HVAC system designed to shut during an event so as to not have
smoke ingress into the living quarters

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SUMMARY
Site selection considerations: distance to urban area, access to/from
site, utilities, construction, environmental impacts, codes and
regulations, communications, etc.
The master plan is the overall spatial arrangement of the individual
process plants, utility plants and general facilities within the site
boundary. Numerous considerations to take into account, including
topography, climatology, possible extensions, possibilities for raw
materials, regulatory restrictions, etc.
 Safety distances to reduce risk by maximizing distance between people,
equipment, and hazards, reduce the severity of a hazard or an incident
after it has occurred, help to reduce the likelihood of a minor incident
developing into a major event
 Additional guidance for special operations such as LNG/LPG
 Additional considerations for Offshore applications

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SUMMARY
Offshore specifics:
 The main drivers: costs, lost production, safety, and weight
 Quantitative Risk Assessment (QRA) valuable for comparing alternative
layout designs
 Important considerations:
 Water depth
 Prevailing wind and wave directions
 Orientation of the platforms (for installation by topsides float-over and maximum natural
ventilation during normal operation)
 Living quarters to be placed in safest area possible, e.g. upwind and far away as possible
from hydrocarbons or toxics

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