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April 1 2009

Safety Concept of DSME LNG FPSO: A shipbuilders perspective

Sung Hoon Sean Kim, Ph. D. Daewoo Shipbuilding & Marine Engineering

Future Products & Business Development Institute

2009. 4.1

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Recent/On-going projects

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2009. 4.1

TOC DSME HSE Engineering Risk on Offshore LNG Plants

Comparison with those on Oil FPSOs

DSME LNG FPSO

Features Layout Process Safety Devices

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HSE Engineering in DSME

Drilling rig & drillships FPSOs FSRU & LNG RV Cruiseship Reliability

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2009. 4.1

LNG RV
Reviewed by LRNA & ABS
FERA
Regas facilities besides trunk deck of No. 1 tank Jet fire
Fire rated walls to protect tanks

SUS Plating & Deluge at the pump bottom

CFD Explosion analysis

Leak in the STL Effect of Relief panel Ventilation condition

FRA, reproduced by DSME using Neptune

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LNG FSRU
A research project FRA using Neptune Emergency relief design
Vent Flare

Toxic gas dispersion

Collision Risk Assessment

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2009. 4.1

Risk on Offshore LNG Plant, Myths & Facts

Myth
Explosion comparable to hydrogen bomb
Collision or vulnerability to terrorist attack?

Fact
Embrittlement of steel structure exposed to cryogenic spill Dangerous process

Spill on water
Rapid phase transition (RPT) blast? Vapor cloud traveling toward a center of population?

High pressure, flammable and/or cryogenic fluid Flammable refrigerant maybe Safety by distance shall be compromised

Total collapse of containment tank?

A pool fire within the full tank impounding area? Tank top fire?
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2009. 4.1

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Inherent Safety LR Guidance

Adequate separation / segregation of hydrocarbon inventories Reducing the level of confinement in a hazardous area Minimising the size of hydrocarbon inventories available for escalation Suitable location or protection of essential systems and equipment Use of passive systems, i.e. fire and/or blast walls and PFP, including protection against spills Use of active protection systems, i.e. fire fighting, ESD, PSD.

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2009. 4.1

Approach to Assess the Risk

Independent studies
Leak frequency Dispersion
Flammable gas evaporated from LNG release
Offsite hazard impact irrelevant on an offshore plant

LQ impairment due to exhaust or flammable gas, smoke, etc

Fire
Jet/Pool fire & the frequency of escalation Passive fire specification

CFD Explosion
Congested semi-closed modules Ductility level blast specification

Drop object Collision

Side-by-side offloading and/or tandem offloading

QRA

Not only related with the process failure but with non-hydrocarbon accidents
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Oil FPSOs by DSME

AGBAMI

Pazflor
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2009. 4.1

Comparison of Risks on Oil FPSO & FLNG(1/2)

Oil FPSO Composition - Hydrocarbons mainly heavier than C3, C8, C10 and a little C1 - Larger heat radiation - High pressure gas at compressor module - Large liquid inventory along the process - Spill containment over the deck -Heavy hydrocarbons with smoke - Little evaporation when released - Process gas heavier than air - Smoke from the pool fire shall be considered FLNG - Mainly C1

Jet fire

- High pressure gas inventory would have more risk of jet fire - Liquid inventory rather limited - Liquid spill to be driven overboard - To be evaporated with energy from ambient air -Dense vapor just release from LNG process would slump over the deck - Less confined and congested topside to have better ventilation - Little smoke - Readily dispersed and having less reactivity

Pool fire

Dispersion

VCE

- Large explosion reactivity

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Comparison of Risks on Oil FPSO & FLNG(2/2)

Cryogenic hazard - Welded stainless piping & equipment with the minimum number of flange connections - Deluge to prevent brittle fracture - Vapor cloud control - Hot wet flaring - Cold dry flaring - Cold vent Side-by-side & tandem offloading -Mainly risers through internal turret containing mainly gas - Enclosed space to be mechanically ventilated Ex. 1, Large scale FLNG, 460x75 lifting 50,000 ton topside ~ 1.45 ton/m2 Ex. 2, DSME LNG FPSO(Mid size), 330x65 lifting 20,000 ~ 0.93 ton/m2
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Flare & vent - Hot wet flaring - Cold dry flaring - Cold vent Offloading Well fluid reception Tandem offloading - Two phase feed liquid - Mainly exposed riser inlets at one side of the vessel containing mainly liquid Ex. Agbami, 320x59 lifting 35,000 ton topside ~ 1.85 ton/m2

Plant congestion

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DSME LNG FPSO

330m x 65m, topside weight about 20,000 ton Production 2 MTA through 2 trains Process deck 6m above the hull deck Living Quarter located upwind Flare tower slanted Gas turbines located above the process deck Extended anchoring platform
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DSME LNG FPSO

Barge type hull Two rows of storage tanks -Little risk from sloshing -Strong support for topside structures Storage of 200K LNG/20K LPG Condensate to be consumed as fuel Internal turret system with weathervaning capability 2x5MW Azimuth thrusters

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2009. 4.1

DSMEs Two-Row Tank/Design Evolution

Low sloshing load
Small tank width leads to less internal flow Avoid resonance with ship motion No concerns on CCS against sloshing load

Strong support for offshore topside module

Strong longi. bulkhead supports heavy topside Free from additional support for topside Small deck deflection

138K LNGC

2-row FLNG

Experimental setup
Impact Pressure Time History
1 Row Tank 2 Row Tank

Economical solution
Cost-effective and optimum solution comparing other Independent CCS

Model test

Pressure

1-row
P ressu re

2-row

1080

1082

1084

1086

1088

1090 Time [sec]

1092

1094

1096

1098

1100

Centerline bhd. for 2-Row arrangement

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DSME LNG FPSO

Conceptual development
A competitive medium-scale model for offshore non-associated gas well (less acid & lean)
Liquefaction process
SMR technology of B&V, a renowned liquefaction technology Client-preferring technology applicable Gas turbine driven compressors to require smaller electric load

DSME design to Float, Storage, & Offloading

A barge with internal turret system and facilities for side-by-side offloading Gas treatment & utility modules design Cargo handling system Two-row arrangement of GTT NO. 96 CCS

Safety consideration
Conceptual layout review in the current stage
Major FLNG safety issues being considered

Detailed safety study planned

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2009. 4.1

Layout Living quarter

Separated from the process area Protected by the Fire/Blast wall
No jet fire grade Ductility level blast design

To protect the lifeboat station STL Compartment to be separated from the LQ via the lay-down area
Blast attenuation Safety against the jet fire & dispersion

Grated process deck to be extended to the LQ for easy material handling & working path
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Layout Internal turret

Harsh sea condition to prefer the internal turret system
HP feed gas to be contained only within the turret

Location
To be located as close to the bow
For good weathervaning capability

Not to be close to LQ
Blast relief Flammable gas Machinery space in the hull to separate

Structural integrity
Longitudinal deformation Swivel movement Blast loading Mechanical ventilation No passive fire fighting on equipment & structure inside the structure

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2009. 4.1

Layout Gap for enhanced ventilation

Process deck
Plated within process modules
To prevent the release from the topside to slump down to the hull deck

6m above the hull deck Grated between modules to release flammable gas and explosion

Small safety gaps between modules to enhance ventilation

Effect be analysed through CFD analysis

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Fire risk
Jet fire
Safety gap to prevent an escalation from the jet fire
7 or 10 minutes of direct exposure

Pool fire
For in-site layout, BS EN 1473
15 kW/m2 on the unprotected metal outer surface of an adjacent LNG tank Design spill

Dimensioning jet fire shall be identified of the frequency of 1.0E4/yr. Deluge, ineffective to mitigate the jet fire Heat up analysis
Lowesmith (2007) Gas jet fire 0.1
Length Total heat flux 5 180 0.25 0.08

For an FLNG,
Cargo tank protected within the hull Design spill from equipment would be limited

1.0
15 250 0.4 0.095

10
40 300 0.55 0.095

>30
65 350 0.7 0.095 21 2009. 4.1

f hc

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Layout Escape route

The primary on the hull deck
An alternative & material handling way on the process deck

The secondary crossway between modules Full redundancy allowing impairment of one route
Port & Starboard The secondary muster area (SMA) aft

Protection of SMA against fire, explosion and heat from the flare

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Layout Clearance btn the hull & the process decks Spaces for CCS maintenance
Maintenance through liquid & gas dome Retractable main cargo pumps Favorable ventilation condition on the hull deck

Release at the hull deck

Hull deck piping of an LNG FPSO will be coarser than that of an Oil FPSO. Welded & insulated piping design of an LNG FPSO will be less susceptible to leakage.

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2009. 4.1

Layout Topside Pipe Rack

Running above the main material handling way
Safe from material handling over the process deck The material handling way as a ventilation alley & an alternative escape route Ladders between longitudinal modules

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Explosion Risk
Release Dispersion Ignition Explosion
Release frequency & inventory to depend on detail design Dispersion depend on
Ventilation condition : Layout, confinement, congestion, buoyancy,

Ignition source shall be rated Explosion strength

Light hydrocarbon would have small explosion efficiency Controlled by layout

Design Overpressure once in 10,000 years Materials

NG Cold natural gas Propane Refrigerant
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Layout Mixed Refrigerant & Storage

Mixed refrigerant
Another source of flammable gas leak
C1, C2, C3, C5 & N2

Separate storage for C2, C3, & C5

Normally No Flow from the refrigerant storage to suction drum Located at a well ventilated area Away from LQ & SMA Considering re-arrange vessels longitudinally

Hazard to be considered
Heat from the flare Drop accident from crane operation

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Layout Offloading platform

Side-by-side offloading of LNG only! Protection
SUS plated under the grated manifold deck Water deluges QCDC & ESD

Consequence of release
RPT on contact with the water within the gap would exert no risk Explosion on the FLNG with little impact on the LNGC
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2009. 4.1

Layout Flare tower

Tower slanted aft
With no condensate to be offloaded, no risk on tandem-offloading vessels

Flaring scenario (draft)

No flaring in normal condition
Normal BOG will be consumed as fuel for G/T

Operation/Emergency flaring
Start-up Process shutdown

Separate vents for topside & cargo

Topside equipment maintenance Tank purging Tank pressure relief

Tip design & tower height will be determined Heat shield on SMA Heat on the MR storage tank
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Typical Liquefaction Process

Cryogenic Refrigeration System
CO2, Sulfur Refrigerant

Flash Gas

BOG/FG Compression

Fuel

Acid Gas Removal

Dehydration

Liquefaction

End Flash

Feed Stock

Inlet Separation

C5+

Fractionation

C1+C2

LNG Product

Produced Water Treatment

H20 C5+

C3+C4

BOG

LPG Storage Tank

H20

LNG Storage Tank

Condensate Storage Tank

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2009. 4.1

SMR Black &Veatch, PRICO

Benefits of SMR
Competitive efficiency Small equipment count Compact heat exchanger adopting aluminum plate fin

FLNG, August, 2007

A small number of drivers Limited inventory of refrigerant Simple operation

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Gas Treatment

AGRU
Little CO2 content in the feed gas from non-associated gas well

Dehydrator
2x100%

Fractionation
Adjust LNG HHV & Stabilize condensate Located around the midship to minimize the motion

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Utility Gas Turbine

Gas turbine
For MR compressor
Located at the upper deck above the MR process Two trains configuration Well separated from LQ

For electric power generation

Right behind of the LQ at the port side Safe equipment requiring no hazard area classification

Turbine blade rotor failure as a potential risk

Rather a common practice on offshore plant

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Safety Device Cryogenic spill

Piping of cryogenic flow over the deck minimized
Around the cold box and the short direct run-down LNG piping to cargo tank

Protection
Shield for HP flanges Drip trays for LP flanges Local SUS plating may be considered

Management
Deluge under the offloading station Spill overboard Evaporation by natural ventilation Closed drain system to return large spill Air blower away from the vessel

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Safety Device Fire fighting

Passive fire protection - Fire rating
Design fire scenario Jet fire rating
Large inventory hydrocarbon vessels including MR storage Primary structure such as module stools, columns, base of the flare tower SMA aft

Hydrocarbon fire rating

Fire wall behind the LQ

Active Fire Fighting

Water deluge on area & equipment Dry powder system Foam monitor

Details to be considered after FERA

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Conclusion DSME, prepared for HSE issues on an LNG FPSO! DSME LNG FPSO
Optimum design & layout will be developed to obtain inherent safety Process risk as well those from SMR will be controlled
A compact process technology would enable a safer design FERA will be used to manage the process risk!

Non-process risk will be controlled HSE will be an independent discipline during whole process of development
Systematic risk assessment Structural design to withstand design accidental loads
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2009. 4.1

Thank you!
DSME
Future Products & Business Research Institute

Sung Hoon Sean Kim T. +82-2-2129-0864 E. vivlavie@dsme.co.kr

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