Section
1 General
1.1 Application
1.1.1 The requirements of this Chapter apply to the process plant facility on
board production and storage units as defined in Pt 3, Ch 3 Production and Storage Units. The process plant facility includes the equipment and
supporting structure and systems used for oil and gas production including inlet
facilities, separation, treating and processing systems and equipment and systems
used in support of production operations, where permitted by the national Flag
Administration. The requirements of this Chapter are considered to be supplementary
to the requirements in other relevant Parts of the Rules.
1.1.2 The Rules cover the design strength and safety aspects of the process
plant facility installed on board production and storage units, and the aim to
minimise the risk to personnel on board and facilities.
1.1.3 The operational aspects, performance and reliability of the process
plant facility are not covered by class except when they have an effect on the
overall safety of the production unit, the personnel on board or the
environment.
1.1.4 The Rules are framed on the understanding that a unit with an installed
process plant facility will not be operated in environmental conditions more severe
than those for the design basis and class approval.
1.1.5 It is the responsibility of the Owners/Operators to ensure that the
process plant facility is properly maintained and operated by qualified personnel
and that the test and operational procedures are clearly defined and complied
with.
1.1.6 The limiting design criteria on which approval is based are to be stated
in the unit’s Operations Manual.
1.2 Class notations
1.2.2 Production units with an installed process plant facility which comply
with the requirements of this Chapter, or recognised Codes and Standards and its
complementary requirements previously agreed with LR (see
Pt 3, Ch 8, 1.5 Recognised Codes and Standards), will be
eligible for the assignment of the special features class notation PPF.
1.2.3 When a production unit is to be verified in accordance with the
Regulations of a Coastal State Authority, an additional descriptive note may be
assigned in accordance with Pt 1, Ch 2 Classification Regulations.
1.3 Scope
1.3.1 The following additional topics applicable to the special features class
notation are covered by this Chapter:
- Major equipment and structures of the process plant facility,
such as, but not limited to:
- Oil or gas production, processing
and treating system, including flowlines from the riser termination
flanges at the turret or agreed interface, manifolds, production
swivels, separators, heaters and coolers, processing columns, piping
systems, relief and blowdown systems and produced water treatment
systems.
- Production plant safety
systems.
- Production plant utility systems
when they have an effect on the overall safety of the production
unit and the personnel on board.
- Riser compensating and tensioning
system.
- Relief and flare system.
- Well control system.
1.3.3 Marine piping systems, hull machinery piping systems, bulk storage and offloading of
process plant products such as oil and gas condensates and crude oil and bulk
storage, loading and offloading of chemicals required for the operation of the
process plant are to comply with the Rules and Regulations for the Classification of Ships, July 2022 and applicable IMO International Conventions
and Codes such as SOLAS and the IBC Code; these systems are to be considered classed
(CL).
1.3.4 Boundaries on the production and utilities systems of the process plant
facility which are covered by this part of the Rules (see Pt 3, Ch 8, 1.3 Scope 1.3.3) and those covered by
the Rules and Regulations for the Classification of Ships, July 2022 are
to be defined and agreed with LR at the earliest stages of the project through the
mark-up of Process and Utilities Flow Diagrams (PFDs and UFDs) and, subsequently
confirmed at a mature stage of the project, through the mark-up of the Piping and
Instrumentation Diagrams (P&IDs). Those diagrams are to show the interfaces
between the process plant systems covered under these Rules and the classed systems
as referenced in Pt 3, Ch 8, 1.3 Scope 1.3.3.
1.4 Plant design characteristics
1.4.2 Attention is to be given to the relevant Statutory Regulations of the
National Administration in the country of registration and the area of operation, as
applicable.
1.4.3 The process plant facility as detailed in Pt 3, Ch 8, 1.3 Scope and any supporting structures above
the deck are to be designed for all operating and transit conditions in accordance
with recognised and agreed Codes or Standards, suitably modified to take into
account the unit’s motions and marine environmental aspects. Except for the
emergency condition, as detailed in Pt 3, Ch 8, 1.4 Plant design characteristics 1.4.4, the total stress in any component of the plant is
not to exceed the applicable Code value at the temperature concerned, unless
expressly agreed otherwise by LR, whether the plant is operative or non-operative,
when subjected to any possible combination of the following loads, as applicable:
- Static and dynamic loads due to wave-induced motions of the
unit.
- Loads resulting from hull flexural effects at the plant support
points, as appropriate.
- Direct wind loads.
- Normal gravity and functional loads.
- Thermal loads, as appropriate.
- Ice and snow loads, as appropriate.
1.4.4 In general, the process plant facility and its equipment as detailed in
Pt 3, Ch 8, 1.3 Scope and any supporting
structures above the deck are to be designed for an emergency static condition with
the unit inclined to the following angle:
- Column-stabilised and tension-leg units:
25° in
any direction.
- Surface type units:
22,5° heel, port and
starboard, and trimmed to an angle of 10° beyond the maximum normal
operating trim.
- Self-elevating units:
17° in any direction in
transit conditions only.
These angles may be modified by LR in particular cases as considered
necessary. In no case is the inclined angle for the emergency static condition to be
taken less than the maximum calculated angle in the worst damage condition in
accordance with the appropriate damage stability criteria.
1.4.5 In the emergency condition defined in Pt 3, Ch 8, 1.4 Plant design characteristics 1.4.4, the plant is to be assumed to have maximum
operating weights, temperatures and pressures unless agreed otherwise with LR.
Systems or equipment that could be shut down and depressurised in advance of this
event may not need to be designed to satisfy this requirement. For such systems or
equipment, a risk assessment (see ISO 31010: Risk management, Risk assessment
techniques) is to be presented to LR in which the credible events that can lead to
the damage condition are identified, followed by those systems or equipment that
could be shut down and if required depressurised, demonstrating that neither the
integrity of the process plant nor the safety of the personnel on board is impaired.
When applicable, the plant is also to be subjected to ice and snow loads. Wind loads
need not be considered to be acting during this emergency condition. The total
stress in any component of the plant or support structure above the deck is not to
exceed the minimum yield stress of the material.
1.5 Recognised Codes and Standards
1.5.1 Process plant facilities designed and constructed to international Codes
and Standards other than the Rule requirements will be considered for
classification, subject to the alternative standards being agreed by LR to give an
equivalent level of safety to the Rule requirements. It is essential that in such
cases LR is informed of the Owner’s proposals at an early stage in order that a
basis for acceptance of the standards is agreed with LR. See
Pt 12 Recognised Codes and Standards for the Classification of Offshore Units for applicable international Codes and Standards
considered by LR as an equivalent level of safety to Rule requirements.
1.5.2 In general, the requirements in this Chapter are based on internationally
recognised Codes and Standards for the process plant facility as defined in Pt 12 Recognised Codes and Standards for the Classification of Offshore Units . Other Codes and National Standards may be used
after special consideration and prior agreement with LR. When considered necessary,
additional Rule requirements are also stated in this Chapter.
1.5.3 Where necessary, the requirements of those agreed Codes and Standards are
to be suitably modified and/or adapted to take into account all marine environmental
aspects.
1.5.4 The agreed Codes and Standards may be used for design, construction and
installation but where considered applicable by LR, compliance with the additional
requirements stated in the Rules is required. Where there is any conflict the Rules
will take precedence over the Codes or Standards.
1.5.5 The mixing of Codes or Standards for each equipment item or system is to
be avoided. Deviation from the Code or Standard or the intentional mixing of them
must be specially noted in the documentation and approved by LR.
1.6 Equipment categories
1.6.1 The approval and certification of process plant equipment in accordance
with this Chapter are to be based on equipment categories previously agreed with
LR.
1.6.2 Production and process plant equipment including its associated pipes,
valves, instrumentation, electrical installations and skids is to be divided into
equipment Categories 1A, 1B and II, depending on the complexity
of manufacture and its importance with regard to the safety of personnel and the
installation and the possible effect on the environment.
1.6.3 The following equipment categories are used in the Rules:
1A Equipment of primary importance to safety, for which
design appraisal and survey during fabrication are considered essential. Equipment
in this category is of complicated design/manufacture and is not normally mass
produced.
1B Equipment of primary importance to safety for which
design appraisal and witnessing the product quality are considered essential.
Equipment in this category may or may not be mass produced but not included either
in category 1A or II.
II Equipment related to safety which is normally mass
produced and manufactured to recognised Codes and Standards and it has proven
reliability in service but excludes equipment in category 1A and
1B.
1.6.5 A guide to equipment and categories is given in Pt 3, Ch 21 Guidelines on Scope of Survey Certification of Safety Critical Equipment. A full list of equipment
categories for each process plant facility is to be agreed with LR before its design
and manufacture. Minor equipment components and systems or equipment that, through
the use of a risk assessment and/or in agreement with LR are demonstrated as not
impairing the safety of the production unit, need not be categorised. For process
plant equipment not listed in the above-referenced Chapter, designers and
manufacturers should contact the LR Technical Support Office for further guidance on
design and survey requirements that will be applicable to that particular equipment.
1.7 Equipment certification
1.7.1 Equipment is to be certified in accordance with the following
requirements:
- Category 1A
- Design verification and issue of a Design Appraisal
Document (DAD) as applicable to the equipment in question, any
exception to this Rule requirement requires prior agreement with
LR.
- Pre-inspection meeting at the suppliers with agreement
and marking of quality plan and inspection schedule.
- Survey during fabrication.
- Review of fabrication documentation
(Manufacturer Record Book).
- Final inspection with monitoring of
function/pressure/load tests.
- Issue of a certificate of conformity.
- Category 1B
- Design verification and issue of a DAD as applicable to
the equipment in question, to be defined on a case-by-case basis at
the equipment categorisation stage (see
Pt 3, Ch 8, 1.6 Equipment categories 1.6.5).
- Final inspection with monitoring of
function/pressure/load tests.
- Review of fabrication documentation
(Manufacturer Record Book).
- Issue of a certificate of conformity.
-
Category II
- Supplier’s/manufacturer’s works’ certificate giving
equipment data, limitations with regard to the use of the equipment
and the supplier’s/manufacturer’s declaration that the equipment is
designed and fabricated in accordance with the project recognised
Standards or Codes and any specific project requirements.
1.7.2 All equipment recognised as being of importance for the safety of
personnel and the production and process plant facility is to be documented by a
Manufacturer Record Book.
1.8 Fabrication records
1.8.1 Fabrication records are to be made available for Categories 1A and
1B equipment for inspection and acceptance by LR Surveyors. These records
should include the following:
- Manufacturer’s statement of compliance.
- Reference to design specification and plans.
- Traceability of materials and materials certificates
(see
Pt 3, Ch 8, 4.4 Materials for further
details).
- Welding procedure tests and welders’ qualifications.
- Heat treatment records.
- Records/details of non-destructive examinations.
- Load, pressure and functional test reports.
1.9 Installation of plant equipment
1.9.1 The installation of equipment on board the unit is to be controlled by LR
in accordance with the following principles:
- All Category 1A and 1B equipment delivered to the
unit is to be accompanied by a certificate of design appraisal (DAD) as
applicable to the equipment in question, an equipment certificate of
conformity and all other necessary documentation.
- All Category II equipment delivered to the unit is to be
accompanied by equipment data and a works’ certificate.
- Control and follow-up of non-conformities/deviations/conditions
or limitations specified in design certificates and certificate of
conformity.
- Ongoing survey and final inspection of the installed production
and process plant.
- Monitoring of functional tests after installation on board in
accordance with an approved test programme.
- Issue of a plant installation report.
1.10 Maintenance and repair
1.10.1 It is the Owner’s/Operator’s responsibility to ensure that installed
production and process plant is maintained in a safe and efficient working condition
in accordance with the manufacturer’s specification.
1.10.2 When it is necessary to repair or replace installed production and
process plant, any repaired or spare part is to be subject to the equivalent
certification as the original.
1.11 Plans and data submissions
1.11.1 Plans, calculations and data are to be submitted as required by the
relevant Parts of the Rules together with the additional plans and information
listed in this Chapter. Plans are to be submitted in electronic format, although
hard copies will also be accepted.
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