Terra Nova FPSO: Certification and Technical Integrity Challenges
Authors: Maguire M.J. , Ewida A.A. , Leonard C.M. 
Published: October 2008

The Terra Nova FPSO will be the first floating production installation to operate in the unique and harsh environment of the Grand Banks. In order to avoid the threat of icebergs the FPSO will be able to quickly disconnect from its mooring and to proceed under its own power. The FPSO is therefore required to be certified as both an offshore installation and as a ship. The paper focuses on initiatives implemented to ensure fitness for purpose of the installation within a complex regulatory climate while reducing commercial risk related to the broad geographic and technical spread of development activities. The paper also provides an overview of the Terra Nova development and discusses prominent technical challenges encountered.

Introduction

The changing nature of today's international oil industry is clearly reflected by the increasing use of floating production systems worldwide. See Table 1 for recent installations classed/certified by Lloyd's Register.

Floating Production, Storage and Offloading Installations (FPSOs) present a number of advantages for operators:Hull structures can be straightforward to build, based on conventional shipbuilding technology (with exception of mooring system/turret integration, discussed in more detail below);Expensive offshore work can be kept to a minimum as most of the construction, hook-up and commissioning can be completed onshore;FPSOs are able to handle heavy payloads and equipment may be added incrementally to fit production and reservoir changes;They provide storage and offloading facilities;They are easy to decommission and can be used again in other fields.

FPSOs are integrated production systems that are made up from diverse types of components to enable them to produce, store and export crude oil. Performance standards must therefore be able to account for a large number of variables as illustrated in Figure 1 below and which include:Structures/conversionsMooring systemsProcess plantSafety systemsStabilityInspection/maintenance on site

The increase in FPSO developments has brought new challenges. A fundamental difficulty with FPSOs has been in achieving accurate technical integration of their various components. Major components of FPSOs and their integrated subsea facilities can be, and often are, manufactured in diverse locations around the world in order to meet contract completion schedules. For example, the Terra Nova FPSO hull was built in South Korea, the process modules in Newfoundland and Europe, the mooring system components in Abu Dhabi, subsea facilities in Europe and North America with the final integration and installation occurring in Newfoundland. Similarly, the design of different elements can take place in a multitude of geographical locations. Careful interface management is key to ensuring technical integration can be achieved during the design phase, in order to prevent costly rework during construction. In addition to the above noted challenges, Terra Nova is the first FPSO designed and built for continuous service in the extreme, ice-prone environment of the Grand Banks of Newfoundland, and area known as Iceberg Alley (see fig. 2). Unique design solutions have been necessary to mitigate the threats posed by this harsh environment.