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PRACTICAL
ENGINEERING
MANAGEMENT OF
OFFSHORE OIL AND
GAS PLATFORMS
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or any information storage and
retrieval system, without permission in writing from the publisher. Details on how to seek
permission, further information about the Publisher’s permissions policies and our arrangements
with organizations such as the Copyright Clearance Center and the Copyright Licensing
Agency, can be found at our website: www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copyright by
the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research
and experience broaden our understanding, changes in research methods, professional practices,
or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in
evaluating and using any information, methods, compounds, or experiments described herein.
In using such information or methods they should be mindful of their own safety and the
safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors,
assume any liability for any injury and/or damage to persons or property as a matter of
products liability, negligence or otherwise, or from any use or operation of any methods,
products, instructions, or ideas contained in the material herein.
Human civilization relies for its survival on energy sources. Up to now with
the explosion of technological developments in using renewable energies
like wind, water, solar, and other sources like atomic energy, the main
energy source worldwide has been the hydrocarbons in oil and gas reser-
voirs. These are found both onshore and offshore in specific parts of the
world.
This book concentrates on the engineering management role for design
of oil and gas offshore platforms. The book’s title shows it is related to
the oil and gas sector (Part 1). It is known that other than wind turbine
platforms in northern Europe, like in Denmark, and a few surveillance
platforms [1] all other platforms are fabricated for oil and gas production.
Part 2 of this book is applicable to all engineering sectors.
I started my career as a structural engineer and gradually shifted to
offshore structures and covered all steps one by one up to the level of
engineering manager. I worked during university years and have experi-
enced all positions including drafter, surveyor, workshop technician, esti-
mator, junior/senior/lead engineer, and finally engineering manager. This
book is the outcome of more than 30 years of experience in different
projects.
Since offshore platform design is a multidisciplinary task, I have faced
many questions related to other disciplines. Maybe some of these questions
were clear to even a junior engineer in those disciplines. But for me,
coming from another discipline, the concepts needed further study.
I strongly believe that no engineering manager can succeed just by
concentrating on general items and project schedule issues. He shall actively
participate in technical discussions. It doesn’t mean that the engineering
manager shall interfere with the lead engineer’s role, but he needs to have
an idea of what the discussion is about and what solutions have been found
for similar problems in other projects. In addition, he shall specifically
understand the consequences of each decision on other disciplines. In an
exaggerated sense, he shall know whether the undergoing discussion is
about a single valve or a large vessel or a complicated package that may
impact other disciplines’ design and activities. This will enable him to
differentiate between minor and major issues and foresee consequences of a
decision on other disciplines and total design.
xiii
xiv Preface
Every effort is made to ensure that the information given in this book is
accurate and conforms to international standards. In spite of this, readers are
recommended to refer to the latest edition of all standards. Any human
activity may have some errors. This book is also not an exception.
It is understood that a detailed discussion of all disciplines and systems is
beyond the scope of this book. In fact, if I borrow a sentence from one of
my university teachers, this book may provide “1 cm depth of an
ocean-wide knowledge.” The extent of required information is very
widespread but the degree of information given in this book is very pre-
liminary and suffices only to give a list. Once more it is important to
emphasize that the engineering manager need not and shall not undertake/
interfere with the responsibility of lead engineers. But when two lead
engineers are talking, then the engineering manager has to distinguish
whether they are talking about the fiction movie shown last night on the
TV or a system that is required for the function of the intended platform,
which may impact the environment, safety of the operators on the plat-
form, and comfort of the people living inland.
The second part of this book is broad enough for all consultants.
Chapter “Balancing Between Client and Task Force Engineers” describes
how the engineering team shall be selected and how their working envi-
ronment, salaries, etc. defined. A competent engineer is not a commodity
that can be easily procured off the shelf of the first store on the street. In
addition, the smartest engineers working on “separate islands” without links
to one another may not be able to design a platform. A team of engineers
working together, identifying other disciplines’ requirements and clients’
interests is needed to produce the desired result.
Chapter “Balancing Between Client and Task Force Engineers” also
explains how this team shall work as individual disciplines and together as
an integrated engineering team. Performing a sophisticated analysis may be
easier than matching two interface lines. Changing/impacting the design of
other disciplines due to decisions made in another discipline is inevitable.
The important point is that critical interface information shall be transferred
accurately and on time to avoid heavy rework and, more importantly,
before the point of no return.
Chapter “Handling Design Documentation” describes how project
documents shall be handled. This covers both engineering documents
produced by the team and those generated by vendors. The procedure to
control smooth flow of documents is described.
Preface xvii
Having said all of the above, this book is not intended to be a manual. It
only describes my experience in offshore oil and gas projects.
It is important to note that information given in this book is gathered
from a number of different projects. I am not sure, but it seems Albert
Einstein has said: “That which remains in the brain after studying every-
thing and forgetting everything is knowledge.”
A major portion of the information is gathered from available literature.
Since the information was gathered over the course of several years, in some
cases I may have forgotten the references. If in any case proper references
are not given, I sincerely apologize. A large part of the information is also
selected from project documents. No engineering activity starts from dis-
covery of fire. Each project builds on go-by documents available from
previous projects.
My colleagues and friends have had an important share in teaching me
the unknowns. With some of them I have worked more than 15 years in
the same organization. My work experience with the Iran Marine Industrial
Company (SADRA) is one of the best parts of my life. All of my colleagues
in the SADRA structural group are now working in high-level positions in
reputable companies around the globe. If I start to list their names, I would
have to give a very long list of engineers in other departments as well and
still might forget some names. In addition to colleagues, I have enjoyed
working with very highly qualified managers. These managers and engi-
neers have finished many projects and have overcome countless unknowns.
Therefore, I prefer to thank all of them and wish them happiness and
success in any part of the world in which they are now and any job or role
that they have or will have.
After SADRA I spent long years with Snake Lay Technology Engi-
neering (SLTE). Some of the sketches in this book refer to SLTE projects.
It was my privilege to work with several highly qualified managers and
engineers at this company.
I will be more than glad to receive any criticisms, comments, technical
advice and further explanations from valued readers. The role of the en-
gineering manager is not a rigid concept. It deals with technical facts and
human relations. In some cases in both of these areas two multiplied by two
may not always be equal to four.
Challenges in each project are an indispensable part of the process.
Each project has its own challenges. In some you work only to receive
salary. In some projects you actually enjoy working! Challenging technical
aspects, knowledgeable clients and colleagues, cooperating teams, sense of
Preface xix
xxi
xxii Abbreviations
DS Data Sheet
DVC Design Verification Certificate
EIA Environmental Impact Assessment
EOR Enhanced Oil Recovery
EPCIC Engineering, Procurement, Construction, Installation
and Commissioning
ESD Emergency Shut Down
ESDV Emergency Shut Down Valve
ESP Electrically Submerged Pump
FAT Factory Acceptance Test
FDB Final Data Book
FEED Front End Engineering Design
FGS Fire and Gas System
FWKO Free Water Knock Out
GOR Gas Oil Ratio
GPG Good Performance Guarantee
GPM Gallon Per Minute
GRP Glass Fiber Reinforced Plastic
GTG Gas Turbine Generator
HAT Highest Astronomical Tide
HAZID Hazard Identification
HAZOP Hazard and Operability
HC Hydrocarbon
HMB Heat and Material Balance
HMI Human Machine Interface
HOD Head Of Department
HP High Pressure
HPHT High Pressure High Temperature
HPU Hydraulic Power Unit
HRS Hollow Rectangular Section
HVAC Heat, Ventilation and Air Conditioning
ICSS Integrated Control and Safety System
IDC Inter Disciplinary Check
IDLH Immediately Dangerous to Life and Health
IEC International Electrotechnical Commission
IFA Issued For Approval
IFC Issued For Comment
IP Ingress Protection
IR Infra Red
IS Intrinsically Safe
Abbreviations xxiii
Introduction to Offshore
Platforms
Offshore platforms have been fabricated for a variety of purposes. Army
support units, surveillance activities, navigational purposes, etc. are all kinds
of offshore platform usage. The study by Dawson [1] provides several ex-
amples of usage other than oil and gas sector. Many studies [5e14] have
introduced different types of offshore platforms with an emphasis on
structural behavior and configuration.
This book concentrates only on offshore platforms that are fabricated for
drilling, transferring crude oil and gas to the surface, production enhancing,
preliminary processing and transferring to onshore facilities, or exporting. In
addition it concentrates on fixed-type jacket platforms. The studies by Patel
[6] and Wilson [7] have given sketches showing platform type versus water
depth. Above w400 m depth the fixed jacket platform becomes uneco-
nomical. In ultra-deep waters, using this concept is not feasible.
Other types of platforms like guyed towers, tension legs, semi-
submersibles, floating structures, etc. are out of this book discussion. Several
issues have to be pointed out:
• The structural behavior of fixed jacket platforms is different compared
with others. This applies to all aspects like analysis, approval, construc-
tion, transportation, and installation. Discussions in chapter “Disciplines
Involved in Offshore Platforms Design,” Section 2.10 are related to
fixed jacket platforms.
• In deep waters, due to higher cost of the supporting structure, it is not
economical to dedicate each platform to a specific task, like accommo-
dating operators, production, processing, etc. For these platforms nor-
mally all functions are performed on the same unit.
• Process design, power generation/distribution, control systems, piping,
and installed equipment more or less follow the same concepts as
explained in this book.
• Document handling and procedures applicable to engineering office are
also the same.
In 1947 the first steel offshore platform was installed and drilled far away
from shoreline. Companies continuously progressed to deeper water. The
first offshore platform was installed in 6-m water depth. About 30 years
later, in 1978 jackets were installed up to a depth of 311 m [6]. Cognac
Platform has been fabricated in 386-m (1265-ft) water depth [7]. Beyond
such depth using conventional jacket-supported platforms may not be
economical. Other offshore platform types such as guyed tower and tension
leg platforms were developed.
Fixed jacket structures were fabricated in different designs like monop-
ods, tripods, four-, six-, or eight-legged jackets, lifted jackets, launched
jackets, gravity-based structures, etc. to suit design requirements.
In deep waters fixed jackets may not be economical. Instead, floating
structures like semisubmersibles and drill ships have been used.
Figure 1.1 Offshore oil complex with living quarter (LQ), production platform (PP),
wellhead platform (WHP), and flare.
Figure 1.2 Offshore oil complex with living quarter (LQ), compression/production
platform, and flare.
Introduction to Offshore Platforms 7
2. This topside has six legs. Hatched parts below legs and topside are tem-
porary fabrication supports. Loadout skid beams are placed near LQ.
This photo was taken before weighting. Temporary supports will be
installed directly below offshore transportation elastomers.
3. At top deck some sunshades are installed to protect equipment from
direct sunlight. Air coolers are installed at this elevation. Wind velocity
increases with elevation. One of the formulas describing wind velocity
variation versus elevation is the power 1/8 law. It means that the ratio of
wind velocity at elevation Z to velocity at elevation þ10.0 m above sea
level is equal to (Z/10)0.125. On this platform air coolers were located at
31.0-m elevation, which has 15% increased velocity. On the top deck
there are also fewer obstacles to hinder wind movement. Besides natural
flow, fan speed induces maximum air change.
4. Helipad is visible at the corner with its safety nets in cantilevered position.
Below helipad satellite connection antenna is installed. Pedestal crane is
installed opposite to helideck to avoid obstacle in helicopter approach.
Introduction to Offshore Platforms 11
5. Two stair towers are constructed at opposite ends of the platform. This
ensures that if one side is blocked for any reason the other approach is
available for escape. Access to the boat landing is from the pedestal crane
side adjacent to the column connected to the stair tower.
6. Overhang area covered with acoustic protection walls contains two sur-
vival crafts. Each one has 70-persons capacity. They are installed at the
same level with offices and working area. Cabins are at higher
elevations.
7. Joint strengthening is not visible on the sketch but is similar to the pro-
duction platform in Fig. 1.4. This LQ was installed by floatover oper-
ation. This can be understood from large free span between two side
legs and braces supporting long span beams at approximately quarter
span points. This large span allows floatover barge entrance between
legs.
8. Installation guides for connecting bridge to PP are shown at side. Bridge
support is installed below deck to enable bridge walkway at the same
elevation with deck. This allows trolley passage to PP.
9. Generators’ exhausts are at bridge walkway level. Since prevailing
wind is in LQ to PP direction, operators walking at this bridge may
face hot air. This subject may be considered as a flaw in this design.
It cannot be installed in the opposite direction because wind will
blow hot gases to cabins. The two perpendicular directions also have
the boat landing and lifeboats. Considering complex layout installing
at this point is okay. However, hot gas release point could have
been elevated.
b. Production platform: This platform normally takes in crude oil and
gas from satellite wellhead platforms for processing to enable eco-
nomic transmission to onshore facilities or to offshore export point.
Normally processing crude oil and gas offshore is limited to a de-
gree to enable it being safely and with minimal costs transferred
onshore or exported. Providing process facilities on offshore plat-
forms is very expensive. However, if minimal processing is not per-
formed, then pipeline shall be fabricated from special alloy material,
which is very expensive and normally is only used in short distances
or as platform piping. Chemical injection to prevent corrosion or
hydrate inhibition is another means to enable safe transmission to
onshore.
Fig. 1.4 shows a six-legged oil production platform that is bridge
connected to LQ in Fig. 1.3. Numbers on the figure refer to explanations
12 Practical Engineering Management of Offshore Oil and Gas Platforms
that follow. In the original photo a wellhead platform was visible at the end
that is removed in the sketch.
1. Water being discharged to sea is visible at side. Treated water separated
from crude shall be directed to open drain caisson and not to sea. Part of
service water used for pressurizing fire water ring via jockey pump may
be directly discharged to sea. It may be better to change water discharge
location away from boat landing. Splashes may reach personnel board-
ing or leaving via supply boat.
2. At the opposite side, external risers with their structural guard are
visible. For safety reasons internal risers are more preferred. If a riser is
added after platform installation, external configuration shall be used.
For this platform, topside installation method (floatover) has dictated
external riser.
3. Heavy stiffened joints at quarter span points in first elevation plus brace
connection at the same location shows that during transportation these
points have been used as temporary supporting points. These stiffened
joints plus a long, unobstructed span between jacket legs and the fact
that drain deck is not constructed shows this platform is installed by
floatover method. To avoid clash with installation barge, external risers
have been constructed. Below support joint shear keys as guide to elas-
tomer pads are visible.
4. Attached to each leg, barge bumper can be seen.
5. Portable tanks containing different chemicals are stored at edge of first
elevation.
6. Bridge support is installed below second elevation. This enables direct
cargo transfer using trolley from platform via bridge to the next plat-
form. If they didn’t need to move transport trolley over the bridge,
then support could have been fabricated at the same elevation with plat-
form level and two or three steps could be used to access bridge.
7. Bridge installation padeye with supporting rings is also visible at one
side. Similar padeyes at opposite side and next to support at nearby plat-
form are also installed.
8. Pedestal crane and its boom rest are visible at top elevation. It has full
access over boat landing.
c. Service platform: In some offshore complexes specific functions
may be located in a separate platform. Normally these are utility
functions like power generation, gas compression, water/gas injec-
tion pumps, etc.
Introduction to Offshore Platforms 13
Niemand leide uit deze verhandeling, uit deze naamlijsten af, dat ik
het mijne heb willen toebrengen tot het jammerlijke in onbruik stellen
onzer edele en schoone Oud-Friesche mans- en vrouwennamen. O!
zulk streven, den Stand-Fries onwaardig, is verre van mij! Juist het
tegenovergestelde heb ik beoogd. En wat mijzelven persoonlijk
aangaat, mij dunken de Friesche namen ook in hunne
hedendaagsche verbasterde vormen, schooner, althans den waren
Fries, der echte Friezinne passender, in allen gevalle eigenaardiger
en volkseigener, als de oude, oorspronkelijke vormen. Ik voor mij
hoor eenen Fries liever G r e u l t en F r j e a r k noemen als
G e r h o l d en F r e d e r i k , eene Friezinne liever H a r m k e en
R o m k j e als H e r m a n n a en R o m b r e c h t a , al zijn dan ook de
eerstgenoemde namen slechts verbasterde en verkorte vormen van
de laatsten. Maar niet iedereen denkt aldus. En zoo hoop ik dan met
dit opstel te bereiken dat deze of gene Fries, die zijnen kinderen niet
met de oude Friesche namen zijner eigene ouders en verwanten
noemen wil, omdat die namen hem niet meer behagen in hunne
hedendaagsche vormen, dan daarvoor in de plaats geen vreemde,
onfriesche, vaak ongermaansche namen neme, noch ook die oude
namen op dwaze en gansch onredelijke wijze verbastere en
verderve, maar dat [235]die man die namen in hunne oude,
oorspronkelijke, volle, schoone en zinrijke vormen, volgens
bovenstaande handleiding, herstelle.
Men versta mij wel. Ik wil niet ontkennen dat er een timmerman
geweest kan zijn, die zich zelven eerst den naam L a t s m a of
B o r e n g a of H a m m e r s m a toeëigende, of een bleeker die zich
O s i n g a , een bakker die zich B o l l e m a noemde. Maar zelf
bedacht, zelf gevormd heeft die timmerman, die bleeker, die bakker
die namen niet. Die namen bestonden reeds, waren reeds eeuwen
lang door Friesche maagschappen gedragen geworden; door
maagschappen, die volstrekt niet eenen timmerman, noch eenen
slachter of bakker tot stamvader hadden. Die namen waren, althans
ten deele, toenmaals nog het eigendom van oude, veelal adellijke of
eigenerfde, nog bestaande geslachten. Of anders, zoo die namen
werkelijk reeds uitgestorven waren met de geslachten, waaraan ze
van ouds her hadden toebehoord, dan bestonden nog wel de staten
en de saten van die geslachten, die hunne oorspronkelijke, aloude
woonsteden, hunne stamzetels waren geweest (bij voorbeeld
O s i n g a - s t a t e , L a t s m a - s a t e ); en zoo waren die
geslachtsnamen den volke nog bekend en mondsgemeen.
Natuurlijk gaat het niet aan, zoude het veel te veel van de beperkte
ruimte in dit boek innemen, wilde ik den waren oorsprong van al
deze geslachtsnamen hier nader ontvouwen en [241]aantoonen. De
opmerkzame vindt dien oorsprong, vindt dien oorspronkelijken
samenhang dezer geslachtsnamen met oude Friesche
mansvóórnamen, vindt menigmaal ook het bewijs hunner aloudheid
in mijne Friesche Naamlijst (Leeuwarden, Meyer en Schaafsma,
1898). Toch wil ik mij zelven het genoegen gunnen (en, zoo ik hoop,
daar mede den lezer niet ongevallig zijn), een paar dezer namen te
ontleden. Nemen wij L a t s m a en H a m m e r s m a ; die door
Professor Wassenbergh als timmermansnamen worden
voorgesteld.
Deze vijf namen kunnen nog met een zeer groot aantal anderen,
soortgelijken, aangevuld worden, allen nog heden ten dage bij de
Friezen voorkomende. Zie hier eenigen daarvan: Z a a g s m a , voor
eenen timmerman; B r e e u w s m a voor eenen schuitmaker;
D r a a i s m a voor eenen pottebakker (naar het pottebakkerswiel,
dat de man dagelijks draait); K o e s t r a of S c h a a p s t r a voor
eenen veehouder; G r a s m a voor eenen greidboer; P l o e g s m a
voor eenen bouwboer; G r a a n s m a , K o o r n s t r a , Z a a d s m a
voor eenen graankoopman; P r a a m s m a voor eenen schipper;
S c h r ij f s m a voor eenen klerk; S l o t s m a voor eenen slotemaker;
P r u i k s m a voor eenen pruikmaker; P r u i m s m a voor eenen
vruchtenventer; Te r p s m a voor den man wiens huis op of nabij
eene terp staat; en vele tientallen dergelijken meer. Immers toen de
lieden, die eenen geslachtsnaam wilden of moesten aannemen,
eenmaal op dit dwaalspoor gekomen waren, was er schier geen
einde aan het bedenken van dit soort fantasie-namen.
Het woord vleinaam (of vleivorm van eenen naam) is door mij
bedacht geworden, en eerst in gebruik genomen, in navolging van
het Hoogduitsche woord Kosename (Koseform eines Namens),
waarmede de Duitschers hetzelfde begrip aanduiden. Ook
Kosename is een kunstmatig gevormd woord, door eenen geleerde
bedacht, en niet door de spraakmakende gemeente; het is niet in
den levenden volksmond ontstaan. Waar Duitschers en
Nederlanders dus tot eenen kunstmatigen vorm hunne toevlucht
nemen moeten, om zeker begrip aan te duiden, daar kan de nooit
volprezene Friesche taal, die zoo overrijk is in kernachtige, de zaken
duidelijk en op volksaardige wijze omschrijvende woorden, maar
vrijelijk putten uit haren woordenschat. De Friezen toch gebruiken,
om hetzelfde begrip aan te duiden, dat Duitschers en Nederlanders
met Kosename en vleinaam weêrgeven, het woord poppenamme;
afgeleid van poppe, schootkindje. Dit woord poppenamme is zooveel
te kernachtiger, duidelijker en beter, drukt zooveel te juister uit wat
men ermede wil te kennen geven, als poppe juist niet een
schootkindje in het algemeen en in alle voorkomende gevallen
beteekent, maar bepaaldelijk het woord is waarmede teedere
moeders, in moederlijke troetelliefde, hare kleine kinderen
liefkoozenderwijze noemen. [248]
Een vleinaam dan is die vorm van den eenen of anderen vóórnaam,
zooals die door kinderen, welke nog niet goed spreken kunnen,
worden verbasterd, en zooals die dan door moeders, welke hare
schootkinders liefkoozen en vertroetelen, in ’t gebruik worden
overgenomen en behouden. Menig klein meiske van tweejarigen
leeftijd kan haren naam A e l t s j e (in Nederlandsche spelling
A a l t j e ) nog niet duidelijk uitspreken, maar noemt zich-zelve
A e y e (in Nederlandsche spelling A a y e ). De moeder, in deze
kinderlijke uitspraak behagen vindende, noemt haar kind, door
moederlijke teederheid gedreven, ook A e y e (A a y e ). De vader
volgt haar hierin wel na, en de oudere kinderen, met de overige
huisgenooten en de nabestaanden, eveneens. Weldra wordt het
kind, ook al wordt het grooter en grooter, en al kan het al lang ten
duidelijksten A e l t s j e (A a l t j e ) zeggen, in den huiselijken kring,
en ook daar buiten, nooit anders genoemd dan A e y e (A a y e ). En
als het kind volwassen geworden is, ook dan nog blijft (in menig
geval—niet als vaste regel, altijd en overal) die vleivorm van haren
eigenlijken naam haar eigen en bij, en uitsluitend in gebruik; en op ’t
laatst weet schier niemand anders, of de maagd, de vrouw, heet
werkelijk A e y e (A a y e ), haar heele leven lang.