MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

Table of Contents

2 MODULE DESIGN SPECIFICATIONS 1

2.1 EXAMPLE STRUCTURAL DESIGN SPECIFICATION FOR MODULES 2

2.1.1 GENERAL 2
2.1.2 SYSTEM OF UNITS 2
2.2 DESIGN CRITERIA 3
2.2.1 STRUCTURAL STEEL CLASSIFICATION 3
2.2.2 MATERIAL PROPERTIES 4
2.2.3 MATERIAL THICKNESS REQUIREMENTS 5
2.2.4 MATERIAL SPECIFICATION 6
2.2.5 CORROSION PROTECTION 7
2.2.6 FIRE PROTECTION 7
2.3 LOAD CONDITIONS 8
2.3.1 GENERAL 8
2.3.2 DEAD AND IMPOSED LOADS 8
2.3.3 ENVIRONMENTAL LOADS 10
2.3.4 SEA TRANSPORTATION LOADS 12
2.3.5 LOAD OUT AND INSTALLATION 14
2.3.6 LOAD COMBINATIONS 18
2.4 DESIGN AND ANALYSIS 21
2.4.1 GENERAL 21
2.4.2 WEIGHT CONTROL 21
2.4.3 SERVICE LIFE 21
2.4.4 ANALYSIS PROCEDURES 21
2.4.5 COMPUTER PROGRAMS 22
2.4.6 ALLOWABLE STRESSES 22
2.4.7 ALLOWABLE DEFLECTIONS 22
2.5 STRUCTURAL DESIGN DETAILS 23
2.5.1 WELDING SPECIFICATIONS 23
2.5.2 BOLT SPECIFICATIONS 23
2.5.3 PAINTING / COATING SPECIFICATIONS 23
2.5.4 GRATING SPECIFICATIONS 24
2.5.5 WALKWAYS, STAIRS AND LADDER SPECIFICATIONS 24
2.6 REFERENCE DOCUMENTATION 25
2.6.1 GOVERNING DESIGN CODES & REGULATIONS 25

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2 Module Design Specifications

There is no single UK or any national design code that covers the design of modules. The Oil and Gas
Industry is organised so that projects are funded and managed by major oil operators such as BP; Shell;
Exxon Mobile; Chevron Texaco etc. These companies normally contract the engineering work for the
major projects onto service companies and consultants such as Production Services Network (PSN);
Wood Group Engineering (North Sea) Ltd (WGE) and Atkins.

Most large module design projects write a Basis of Design document, normally called the ‘module design
specification’, which contains all the reference and code material necessary to carry out the structural
engineering work. The specification normally contains the following:

• Platform Location and description

• Module description
• Design Codes
• Grade of steel to be used
• Applied loadings
• Weight control requirements
• Dimensional control
• Deflection limits
• Allowable stresses

The module design specification will provide the guidelines required by the project team to successfully
design, fabricate and install the modules.

An example of a module design specification is shown in this section.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.1 Example Structural Design Specification for Modules

2.1.1 General

This Structural Design Specification forms the technical basis for the structural design of a topsides
module. The module design parameters and the relevant statutory requirements, guidance notes,
procedures, codes and standards are defined. The design conditions considered in this specification are
those relevant to the construction, sea transportation, lifting, installation and in place position of the
module. Accidental scenarios such as fire, explosion and dropped objects are not considered.

Structures covered by this specification include:

• Truss chords, columns and bracing;

• Deck beams, stringers, plating and gratings;
• Access walkways, stairs and ladders;
• Equipment supports;
• Lifting points;
• Installation aids;
• Seafastening;
• Corrosion protection.

2.1.2 System of Units

All analysis, design calculations, drawing dimensioning and detailing shall be carried out using the
Systeme International d’Unites (SI Units).

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.2 Design Criteria

2.2.1 Structural Steel Classification

Structural steel shall be categorised according to the application and the consequence of failure, as
follows:

2.2.1.1 Primary Structural Steel

Primary structural steel is used in members essential to the overall integrity of the structure, and for
other structural members of importance to the operational safety of the structure. Primary structural
steel shall include the following:

• Main Truss Framing (including Chords.)

• Primary Support Beams.
• Main Equipment Supporting Members
• Lift Trunnions and Padeyes.
• Crane Pedestals

Primary steel materials (predominantly Grades S355) shall comply with BS EN 10225: 2001 – Spec. for
Weldable Structural Steels for Fixed Offshore Structures and shall be fabricated in accordance with
EEMUA 158.

2.2.1.2 Secondary Structural Steel

Secondary structural steel is used in members whose contribution to the integrity of the structure as a
whole is not significant. Secondary structural steel shall include the following:

• Floor Stringers and Stiffeners.

• Floor Plate.
• Pipe Racks/Supports.

Secondary steel materials (Grades S355) shall comply with BS EN 10225: 2001 – Spec. for Weldable
Structural Steels for Fixed Offshore Structures and shall be fabricated in accordance with EEMUA 197.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.2.1.3 Tertiary Structural Steel

Tertiary structural steel has no significant influence on the integrity of the structure. Tertiary structural
steel shall include the following:

• Stairs and Walkways.

• Access Platforms.
• Cable/Instrumentation Supports.
• Floor Grating.

Tertiary steel (predominantly Grades S275) shall comply with BS EN 10025: 1993 – Specification for Hot
Rolled Products of Non-alloy Structural Steels and their Technical Delivery Conditions and BS EN
10210:1997 – Spec.- Hot-Finished Structural Hollow Sections.

2.2.2 Material Properties

The permissible design yield strength of steels of various thicknesses shall be as tabulated below :-

Steel Grade Thickness Range Minimum Yield Stress (N/mm^2)

(mm) Plates Sections
S275 t ≤ 16 275 275
16 < t ≤ 40 265 265
40 < t ≤ 63 255 -
63 < t ≤ 80 245 -
80 < t ≤ 100 235 -
S355 t ≤ 16 355 355
16 < t ≤ 25 355 345
25 < t ≤ 40 345 345
40 < t ≤ 63 335 335
63 < t ≤ 100 325 -
100 < t ≤ 150 320 -
S460 t ≤ 16 460 460
16 < t ≤ 25 440 440
25 < t ≤ 40 420 440
40 < t ≤ 63 415 430
63 < t ≤ 80 405 -
80 < t ≤ 100 400 -

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

Other steel design properties for use in design shall be as follows:

Young’s Modulus (E) 205000 Mpa

Shear Modulus (G) 80000 Mpa
Poisson’s Ratio (ν) 0.3
Density (ρ) 7850 kG/m3

Coefficient of thermal expansion 11.7 x 10-6/oC

Units: Mpa = N/mm2

2.2.3 Material thickness Requirements

The minimum material thickness of structural steelwork shall be as follows:

Minimum Thickness,
Item Area/Location
[mm]

Floor Deck Plate General Deck Area 6

Floor Deck Plate Laydown 10
Deck Plate Helideck 10
Wall plating Cladding 4
Webs 6
Primary Members
Flanges 10

Webs 6
Secondary Members
Flanges 8

Primary Tubulars - 6
Grating General Deck Area 25

Handrails (post & top rail) External 4mm

Reduced thicknesses may be adopted for pre-fabricated items which are inherently corrosion resistant
(e.g. stainless steel wall cladding).

Coating of steelwork shall be in accordance with the Specification for Protective Coating

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.2.4 Material Specification

The following table provides information on specifying materials for use in a topsides module:
Steel Grades
Category Plates Sections Welded Seamless Application
Hollow Hollow
Sections Sections
Primary Members essential to the overall integrity of the
S355G11+N/M

S355G13+N/Q

S355G14+N/Q
S355G7+N/M
S355G9+N/M

structure and of importance to the operational safety,

e.g.:
- module legs;
- main truss chords and bracing;
- main deck beams and cantilevers;
- crane pedestal and support;
- blast/fire walls.

Special As Primary subject to in-service through-thickness

N/A
S355G12+N/M

S355G15+N/Q
S355G10+NM
S355G8+N/M

stress or fatigue loading or highly constrained welding

Primary
during fabrication, e.g. at lift points.

Secondary Members not essential to the overall integrity of the

S355G2+N

S355G1+N

S355G1+N

S355G1+N

structure, e.g.:
- deck plates and stringers;
- main equipment supports;
- walkways, stairs and access platforms;
- monorails/mechanical handling aids;
- wall framing and cladding.

Tertiary Members not essential to the overall integrity of the

S275J2G3

N/A
S275J2G3+N

S275J2H

structure, temporary items e.g.:

- handrailing;
- minor equipment supports;
- misc. brackets and stiffeners;
- cap/seal plates.

Note: Grade S460 steel shall only be used where a substantial weight saving can be demonstrated to
offset the higher material cost.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.2.5 Corrosion Protection

Structural steelwork shall be prepared and painted in accordance with the Specification for Protective
Coating of the appropriate operator.

All closed sections shall be fully seal welded to avoid internal corrosion.

Where applicable, steel deck gratings, stairtreads and handrails shall be hot dip galvanised to BS EN ISO
1461: 1999.

Suitable isolation shall be provided at interfaces between mild steel and aluminium or stainless steel to
prevent bi-metallic corrosion.

2.2.6 Fire Protection

The extent of passive fire protection (PFP) required is dependent on area classifications and the results
of the Fire Risk Assessment (FRA). Specific requirements will be confirmed by technical safety during
the detail design of a module structure.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.3 Load Conditions

2.3.1 General

This section describes the various loads to be used in design of a topsides module, including dead loads,
imposed loads, environmental, transportation and installation loads.

Accidental loadings such as fire, dropped objects, blast etc will not be considered in this specification.
Such loads must be evaluated on a case by case basis and are dependant on many factors within the
structure. If such loads are present an evaluation of them will be undertaken and the results
incorporated in the design criteria.

2.3.2 Dead and Imposed Loads

2.3.2.1 Dead Loads

Dead loads shall be defined as those loads which are essentially static and constant in magnitude and
will include, where applicable, the following:

• Self-weight of structure
• Dry weight of equipment
• Dry weight of bulk materials, eg. pipes, cables, etc.
• Weight of protective coatings ie. fire proofing

2.3.2.2 Imposed Loads

Imposed loads will be defined as those loads, which arise from the operational use of the platform.
These loads are variable in magnitude and position and will include, where applicable, the following:

• Operating loads from equipment, machinery and vessels

• Operating loads from bulk material including weights of consumables and stores
• Contents of piping
• Drilling loads
• Personnel loads
• Dynamic loads from equipment and machinery

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

The intensity of imposed loads for various areas and design cases are given in the table below:

Area Deck Plate Main Deck Girders

& Stringers and Main Truss
Framing
Laydown & Storage U= 25 kN/m2
U= 15 kN/m2
Areas C= 40 kN

U = 5 kN/m2
Process Areas U = 5 kN/m2
C = 3 kN
Access Platforms, U = 5 kN/m2
U = 5 kN/m2
Walkways & Stairs C = 3 kN

Local Equipment/ U=7.5 kN/m2

U=7.5 kN/m2
Switchgear Room C= 10 kN

Notes:
U = Uniformly distributed load.
C = Concentrated load on an area 0.3m x 0.3m.
For grated deck areas, U = 5 kN/m2, C = 5 kN on an area 0.3m x 0.3m

For design of handrails, the following horizontal loads shall be applied to the top rail dependent on the
use and location.

Load
Location/Use of Handrail
[kN/m]

Access Platforms 0.50

External Areas And Escape Routes 0.74

Heavy duty laydown areas 1.5

2.3.2.3 Thermal Loads

Thermal loads for specific structures and equipment shall be considered on an individual basis and shall
include the following where appropriate:
• Thermal loads from temperature effects of fluid in piping, equipment and wellheads
• Heat radiation from exhaust and ignited events

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

• Flare radiation on adjacent structures

2.3.3 Environmental Loads

Environmental loads on the structures arise from direct exposure of the topsides to wind, ice and snow
conditions and indirect loading from the action of wind, waves and current on the substructure.
Environmental loads shall be determined using the environmental data supplied with the platform
function specification or safety case. The following information is based on experience of such data:

2.3.3.1 Air and Sea Temperatures

Maximum Minimum
Ambient air temperature 25.°C -6.°C
Surface seawater temperature 21.2°C 0°C
Seabed seawater temperature 7°C 6°C

2.3.3.2 Ice and Snow

Snow loading
Snow shall be assumed to have a density of 500kg/m3 and will accumulate on all horizontal and
windward facing surfaces as follows:

Horizontal surfaces 250mm

Windward facing surfaces 40mm

Ice loading
Ice shall be assumed to have a density of 900kg/m3 and will accumulate on upward and windward
facing surfaces as follows:

3 to 15m - 100mm thick

Height Above Mean
15 to 100m - 100mm – 50mm linearly decreasing
Sea Level (MSL):
+ 100m - 50mm

Ice and snow shall be considered to occur simultaneously. For structures which are not wind-sensitive,
the general imposed loads are considered to include snow and ice. For structures that are wind sensitive
snow and ice accretion must be considered.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.3.3.3 Wind loads

Wind loads arise from the action of wind on the exposed surfaces of the topsides and appurtenances.
The conversion of basic wind speed to design wind speed at a given height shall be in accordance with
the formula presented below. The subsequent conversion to dynamic pressure and the derivation of
force and pressure coefficients shall be in accordance with CP3: Chapter V: Part 2 or BS6399: Part 2 –
Wind loading for buildings.

Extreme Storm Wind

The extreme storm wind speed is defined as the 100-year return storm. On wind sensitive structures
the 100-year storm shall only be applied to the un-iced structure. The 10-year storm shall be used in
combination with snow and ice accretion.

If applicable, the dynamic effects of wind gusting and vortex shedding shall be assessed for slender
members, which may be susceptible to vibration.

The following omni-directional extreme storm wind speeds at 10.0m above mean sea level (MSL) shall
be used for the design of the topsides module:

Wind - Design Storm (100 years)

1 min Mean Gust 3 sec Gust
43.4m/s 51.8m/s

Variation of wind speeds with elevation shall be taken as:

Vh = V10.(h/10)exp
where: Vh = wind speed at height, h above MSL (m/sec)
V10 = wind speed at 10.0m above MSL (m/sec)
exp = 0.08 for the 3 second gust
0.08 for the 5 second gust
0.09 for the 15 second gust
0.11 for the 1 minute mean
0.14 for the 1 hour mean
h = height above mean sea level (m)

The appropriate wind speed averaging time will be selected in accordance with British Standard CP3
Chapter V: Loading, Part 2: Wind Loads.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

Operating Wind
The omni-directional operating wind shall be taken as having a mean hourly speed of 29.6m/sec at
10.0m above MSL.

2.3.4 Sea Transportation Loads

2.3.4.1 General

The loading to be included for transportation analysis shall include:

• Structure self-weight
• Equipment and bulks dry weight
• Transportation inertia loads

The analysis shall be based on the following assumptions:

• The barge shall be assumed to roll and pitch about its longitudinal and transverse axes of
symmetry, respectively in the water surface plane
• The module shall be located at an extreme position on the barge

Localised seafastening of equipment inside the module shall be designed in consultation with the
associated vendors. The seafastening shall be distinctively painted and have cut lines clearly indicated.

Stresses in sea fastening and grillage shall not exceed allowable stresses as defined by API or AISC ASD
in accordance with the utilised steel grade and material thickness.

Stresses in the module structure during transportation shall not exceed the allowable stresses as defined
by API or AISC ASD increased by a factor of one third.

2.3.4.2 Barge Motions

The dead weight and centre of gravity positions of all equipment of significant weight shall be
considered in the design analysis to obtain the correct generated inertial loads. Until the actual tow
route and schedule is known, the inertia loads will be generated using standard industry criteria, see
table below. These figures are based on a barge of dimensions 90m x 27m x 7m (400feet x 100feet)
and are applicable to a summer tow in the North Sea. A static analysis should be carried out on the
design using these figures to determine member and joint forces under transportation.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

Roll amplitude 20º

Roll period 10 sec

Pitch amplitude 12.5º

Pitch period 10 sec

Heave acceleration 0.2 x g

20º

Fh Barge
Roll Zi

F
Fv

Two separate combinations of motions shall be considered:

• Roll + Heave;
o Typical values for Fh & Fv under these combined loads can be calculated using:
ƒ Fh = 0.8 x g and Fv = 1.2 x g
• Pitch + Heave.
o Typical values for Fh & Fv under these combined loads can be calculated using:
ƒ Fh = 0.4 x g and Fv = 1.4 x g

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2.3.5 Load out and Installation

2.3.5.1 General

An outline installation methodology, not-to-exceed lift weights, minimum clearances, appropriate

dynamic amplification factors and installation guide philosophy should be established as early as possible
in the design. Two main points for consideration are load out and offshore installation.

2.3.5.2 Load out

The loads used for the module load-out analysis shall include:
• Structure self-weight;
• Equipment and bulk dead weights;
• Rigging installation aids and equipment;
• Temporary structures and equipment;
• Deformation Loads due to out of level supports.

2.3.5.3 Offshore Lifting Loads

The loads associated with offshore lifting shall include:

• Structure self weight
• Equipment and bulks dead weight
• Temporary structures and equipment
• Rigging installation aids

2.3.5.4 Lift Forces

Lift Weights
During the conceptual design phase, the equipment, piping and bulk loads applied in the various
structural analyses shall have a contingency factors of 1.2 added to account for probable weight
increases.

In addition, the self weight of the deck, made up of primary, secondary and tertiary steel framing
shall be increase by 5% to account for mill tolerance, welds, stiffeners and paint.

The contingency factors will reduce over the life of the project, reflecting a progressive reduction in
allowances as design and construction proceeds, and more accurate vendor data is available.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

The Gross Lift Weights and Hook Weights (including rigging) of the module shall be obtained from a
design weight report prior to loadout.

Dynamic Amplification factors

A Dynamic Amplification Factor (DAF) shall be applied to the Lift Weights as follows to give a Design Lift
Load:

Lift Weight DAF

>2500 tonnes 1.10
1000 to 2500 tonnes 1.15
100 to 1000 tonnes 1.20
<100 tonnes 1.30

Note that these DAF’s are applicable to offshore lifts by a single vessel.

In addition to the above, the following factors are to be used in conjunction with the DAF:-
• Wt. Allowance = 1.2 (As mentioned previously)
• Centre of Gravity (CoG) Shift = 1.05 (CoG misalignment)
• Consequence Factor = An additional Factor of Safety (FOS) applied to critical members
according to the consequence arising from their failure. The following consequence factors shall
be applied:
1.35 to lift point (applies to padeyes)
1.15 to main load path members
1.0 to all other members

Skew Lift
To account for sling mismatch, lift point fabrication tolerances etc., skew loads shall be applied to the
lifted structures. For a single hook four point lift, the Design Lift Load, DLL, (excluding slings) shall be
distributed over the lifting points in such a way that 75% of the load is carried by any two diagonally
opposite points and 25% by the remaining two. Where loose spreader bars or a lifting frame are used
the distribution shall be 60% - 40%.

Centre of gravity Envelope

A lift analysis shall be carried out using a centre of gravity position envelope appropriate to the status of
the weight information.

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2.3.5.5 Rigging Design

Sling Angles
The nominal angles between the lift sling and a horizontal plane shall be considered to be in the range
of 55o to 70o.

Sling & Shackle forces

The sling and shackle forces will be calculated on the distribution of the hook load based on a skew lift
and increased in proportion to the sling vectored geometry.

2.3.5.6 Lift points

Padeyes
Lift point joint details shall avoid through-thickness tensile stresses if at all possible. Due to possible
misalignment of the padeyes and possible longitudinal tilt during lift, an additional force of 5% of the
sling force shall be taken into account, acting transversely to the padeye at the centre of the pin hole.
Combined (equivalent) stresses in the padeyes shall be calculated using the Von Mises equation:

fc = √(fx2 + fy2 - fx.fy + 3fs2) where fx and fy are the direct stresses in the x and y directions (due to
axial and bending loads) and fs is the algebraic sum of the shear stresses. The maximum allowable
stress for the combined loads should not exceed the following:

fc ≤ 0.75x Fy

The following guidelines should also be considered when designing a padeye:

• The design of the padeye and its connection to the module should be based upon shear
connection details whenever possible.
• Whenever possible, the type of shackles to be used should be determined prior to
commencement of padeye design.
• The padeyes should have no more than one cheek plate on each side of the main plate.

Padears / Trunnions
The design of padears / trunnions shall comply with the following criteria:
• Due to possible misalignment of the padears and possible longitudinal tilt during lift, an
additional force of 5% of the sling force shall be taken into account, acting transversely to the
padear at the centre of the trunnion. Half the additional force will be absorbed by each sling
keeper plate.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

• The trunnions shall be designed to transfer the full sling load including torsion and secondary
effects. The diameter of the trunnion should be at least three times the required sling diameter.
• To prevent movement of the slings a sling retainer device shall be designed and attached to the
keeper plate.
• All sharp edges likely to damage the sling during handling and transportation shall be removed
and radiused.

2.3.5.7 Placement Forces

Consideration is to be given to the provision of bumpers and guides during the placement of individual
modules. Any installation guides and bumpers shall be designed to withstand the local impact forces,
which may be imposed during installation, as well as providing a suitable lead-in for the lifted packages.

Impact forces are dependent on the proposed installation method. Preliminary design of primary guides
shall be based on the following values expressed as a percentage of the static hook load:

Guide Post Guide Post “Cow Horn” Cow Horn” Stabbing Cone
(sloping) (vertical) (Bumper) (Guide)
Horizontal (Fh) 10% 10% 10% 5% 10%
Vertical (Fv) 10% 1% 1% 10% 10%
Lateral (Fi) 5% 5% 10% 5% 0%

Fi
Incoming
Incoming
Bumper

Fv Module
Module
Guide
Bumper
Guide
Fh Fi

Topsides
ELEVATION PLAN

In general the design condition for each of the above on both bumper and guide will be Fh + Fv + Fi

The forces on secondary guides shall be considered as 50% of the above values.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

In the event of an accidental overload, the guides and bumpers shall be designed to yield before
damage occurs to the primary structure of either the new packages or existing topsides.

2.3.5.8 Placement Tolerances

Positional tolerances for primary and secondary installation guide systems shall be agreed with the
specified design contractor with due regard to subsequent offshore hook-up operations.

2.3.5.9 Topside supports

Forces acting on the existing structure at the support locations during placement of the module shall be
calculated by distributing the module design weight proportional to the distance to the Centre of gravity.
Any two diagonally opposite supports shall be designed to withstand 100% of the design weight,
increased by the appropriate D.A.F The exception to this is a hook-on module where the load is only
taken by hooks in two locations. In this arrangement the D.A.F is increased to 2.0 and the existing
structure should be checked locally for the increased set down loads.

2.3.6 Load Combinations

The topsides structure shall be designed to withstand the maximum stresses resulting from the
combinations of loads expected during its life. These will include:

Load Combination Constituent Load Cases

1. i) Maximum in-place environmental loads
ii) Maximum in-place dead & functional loads
2. i) Maximum in-place environmental loads
ii) Minimum in-place dead & functional loads
3. i) Normal in-place environmental loads
ii) Maximum in-place dead & functional loads
4. i) Maximum in-place dead & functional loads (hydrotest)
5. i) Load-out forces
ii) Transportation wind loads
iii) Associated dead & functional loads
6. i) Transportation forces (roll + heave)
ii) Transportation wind loads
iii) Associated dead & functional loads
7. i) Transportation forces (pitch + heave)
ii) Transportation wind loads

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

iii) Associated dead & functional loads

8. i) Lift loads (distribution type A*)
ii) Associated functional loads
9. i) Lift loads (distribution type B*)
ii) Associated dead & functional loads
* indicates maximum sling force distribution across diagonal lift points. Additional load combinations
shall be assessed where there is evidence that they may be critical to the design.

2.3.6.1 Inplace Load Combinations

Load Combination Identifier

Notes:
1) For wind sensitive structures only
2) For input to jacket analysis

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.3.6.2 Load-Out, Transportation & Installation Load Combinations

Load Combination Identifier

Notes:
1) indicates maximum sling force distribution across diagonal lift points.
2) includes seafastening of equipment, temporary bracing etc.
3) includes slings, shackles, spreader beam etc.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.4 Design and Analysis

2.4.1 General

The topsides module shall be designed to withstand the loads specified for the fabrication, load-out,
transportation, installation, in-place and accidental conditions. Allowable (or working) stress design
methods shall be applied to primary and secondary structures in accordance with API RP2A - WSD and
AISC – ASD 9th edition.

2.4.2 Weight Control

The total structural weight and centre of gravity for each item shall be determined from material take-
offs with allowances appropriate to the design status. Weight and centre of gravity data shall be
incorporated within vendor drawings.

2.4.3 Service Life

Module structural components shall be designed for a minimum service life of 20 years. Fatigue sensitive
components shall have a 40-year design life. For individual items of equipment where the service life is
less than that of the facility as a whole, the fatigue life of supporting structural components shall be at
least twice the service life.

2.4.4 Analysis Procedures

2.4.4.1 Static Analysis

Static analysis of the module shall be carried out in accordance with recognised engineering practice and
shall be based on accepted material characteristics data. The analysis shall cover all stages of
fabrication, load-out, transportation, installation, hook-up and in-service life for the most unfavourable
conditions foreseen within the criteria stated in this Specification.

2.4.4.2 Dynamic Analysis

The structural analysis shall consider increases in local stresses and displacements caused by the
structure’s dynamic response to environmental, rotating equipment or accidental loading. The effects of
dynamic response shall be combined with the stresses and displacements due to the static loads
resulting from the various load combinations.

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The scope of the analysis required will depend on the nature and geometry of specific structures and
their sensitivity to dynamic loading. Where appropriate, the effects of fatigue shall be considered and
fatigue lives evaluated.

2.4.5 Computer Programs

The module shall be analysed using a three dimensional linear elastic computer analysis incorporating
both frame and plate/shell elements where required. Post-processing facilities should include code
checking of frame members to a recognised national code.

2.4.6 Allowable Stresses

For primary and secondary structural items analysed using allowable (or working) stress design
methods, AISC/API basic allowable stresses shall be used.

For load combinations incorporating extreme storm environmental conditions, the basic allowable
stresses may be increased by one third subject to the provisions of AISC/API. This increase shall also
be applied for the transportation load case (if necessary).

2.4.7 Allowable Deflections

Deflections shall be calculated based on dead, operating and live loads. Recommended maximum
deflections for specific structural elements are as follows:
Deck Plates (locally) - twice the plate thickness
Deck Stringers, Main Deck Beams, - span/300
Truss Chords - span/360
Cantilevers - span/180

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2.5 Structural Design Details

2.5.1 Welding Specifications

Joint details shall be configured with due consideration given to the extent and accessibility of welds as
well as future maintenance and inspection requirements. Highly restrained welds resulting in through
thickness stresses shall be avoided where possible. Joint details shall be designed to prevent water
ingress and retention.

Liaison with the Fabrication Contractor at an early stage in the structural design is desirable.

Tube to tube joints shall be checked for punching shear in accordance with API RP2A

The following welding specifications shall be used for the fabrication and construction of all structures.

• Welding terms and symbols are in accordance with BS EN 22553:1995

• All welding shall be carried out to approved procedures.
• Extent and type of inspections and acceptance levels shall be in accordance with EEMUA
197:1999 for secondary structures and EEMUA 158 for all primary structures

2.5.2 Bolt Specifications

Suitable methods for prevention of moisture ingress to any joint that is bolted shall be adopted.

The following bolting specifications will be used for the construction of all structures.
• All bolts to be in accordance with B.S EN ISO 898-1:1999 and nuts to be grade 8 in accordance
with BS EN 20898-2:1994. Washers are in accordance with BS EN ISO 887:2000. All bolts, nuts,
locking nuts and washers to be hot dipped galvanised to BS EN ISO 1461:1999.
• All bolts / set screws to be grade 8.8 (in accordance with the above spec) and be supplied C/W
nut, locknut and washer U.N.O.

2.5.3 Painting / Coating Specifications

The following painting / coating specifications will be used for all new steelwork and the repair of any
damaged steelwork.

• Platform / oil company specific coating specification will apply to all paint systems.
• Handrail panels, gratings and ladders to be hot dipped galvanised to BS EN ISO 1461:1999.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

• Offshore areas where fireproofing or paint has been damaged are to be restored to the original
standard. Passive fire protection should be in accordance with specific product specifications.

The following national standards will also apply to all steelwork coating and preparation:

• BS 4232 : 1967, Specification for surface finish of blast-cleaned steel for painting
• BS 5493: 1977, Code of practice for protective coating of iron and steel structures against
corrosion.
• BS 7079:1990, Preparation of steel substrates before application of paints and related products
• Norsok M-501 Surface preparation and protective coating (Rev. 5, June 2004)

2.5.4 Grating Specifications

The following grating specifications will be used for the installation and the repair of any damaged
gratings.
• Gratings to match existing; supplied and fixed in accordance with BS4592:1987. Panels to be
fixed to support steelwork using a minimum of 4 No. Hilti studs and fixing discs. (Alternative
grating fixings by means of 4 No. saddle type clips per panel will be noted on relevant project
drawings).

2.5.5 Walkways, Stairs and Ladder Specifications

Walkways, handrails, stairs and ladders shall be designed in accordance with industry standards. For
primary escape routes the minimum width of walkway and stair routes shall be 1.2m. The layout at a
change of direction shall enable a stretcher to be easily manoeuvred in a horizontal plane. The plan
dimensions of a stretcher and bearers can be taken as 2.5m long by 0.75m wide. Clear head height on
all walkways will be at least 2.1m.

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MSC OIL AND GAS STRUCTURAL ENGINEERING – EG5069 CONCEPTUAL DESIGN OF TOP-SIDE MODULES

2.6 Reference Documentation

2.6.1 Governing Design Codes & Regulations

The structural engineering design will be carried out in accordance with the following design codes and
references were applicable:-
[1] American Petroleum Institute, “Recommended Practice for Planning, Designing and Constructing
Fixed Offshore Platforms – Working Stress Design”,
API RP2A - WSD, 20th Edition, July 1993
[2] American Petroleum Institute, “Recommended Practice for Planning, Designing and Constructing
Fixed Offshore Platforms - Load and Resistance Factor Design”,
API RP2A - LRFD, 1st Edition, July 1993
[3] American Institute of Steel Construction, “Manual of Steel Construction - Allowable Stress
Design”, AISC - ASD, 9th Edition, 1989
[4] American Welding Society, “Structural Welding Code – Steel”, ANSI/AWS D1.1-88
[5] Department of Energy, “Offshore Installations: Guidance on Design, Construction and
Certification”, Fourth Edition, 1990
[6] SI 1996 No 913, Offshore Installation and Wells, Design and Construction Regulations
[7] EEMUA Publication no.158 – Engineering Equipment and Materials Users Association –
Construction Specifications for Fixed Offshore Structures in the North Sea
[8] EEMUA Publication no. 197 - Engineering Equipment and Materials Users Association –
Construction Specifications for Secondary Steel on Fixed Offshore Structures in the North Sea
[9] British Standards Institution, BS EN 10225: 2001 - Specification for Weldable Structural Steels
for Fixed Offshore Structures
[10] British Standards Institution, BS EN 10025: 1993 - Specification for Hot Rolled Products of Non-
alloy Structural Steels and their Technical Delivery Conditions
[11] British Standards Institution, CP3: “Code of Basic Data for the Design of Buildings”, Chapter V:
Loading, Part 2: Wind Loads
[12] British Standards Institution, BS6399: Part 1: 1984, “Design Loading For Buildings: Code of
Practice for Dead and Imposed Loads”
[13] British Standards Institution, BS4: Part 1: 1993, “Structural Steel Sections: Hot-rolled Sections”

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[14] British Standards Institution, BS EN 10210:1997, “Specification for Hot-Finished Structural

Hollow Sections”
[15] British Standards Institution, BS EN 10056-1: 1999, “Specification for Structural Steel Equal and
Unequal Angles”
[16] British Standards Institution, BS EN 22553: 1995, “Welded, Brazed and Soldered Joints –
Symbolic Representation on Drawings”
[17] British Standards Institution, BS2853: 1957, “The Design and Testing of Steel Overhead Runway
Beams”
[18] British Standards Institution, BS2573: Part 1, “Rules for the Design of Cranes. Specification for
Classification, Stress Calculations and Design Criteria for Structures”
[19] British Standards Institution, BS 476: “Fire Tests on Building Materials and Structures”.
[20] British Standards Institution, BS EN ISO 1461:1999 “Hot Dip Galvanised Coatings on Fabricated
Iron and Steel Articles”
[21] Offshore Installations Prevention of Fire and Explosion and Emergency Response (PFEER)
Regulations, SI 743/ 1995
[22] The Steel Construction Institute, Document No.150, 1992, "Interim Guidance Notes for the
Design and Protection of Topside Structures Against Explosion and Fire"
[23] London Offshore Consultants Limited, “Guidelines for Marine Operations”, OPL, 1997
[24] Noble Denton “Guidelines for Loadouts” Report No 0013/NDI, April 2002
[25] Noble Denton “Guidelines for Marine Transportations” Report No 0014/NDI, April 2002
[26] Noble Denton “Guidelines for Lifting Operations By Floating Crane Vessels” Report No 0027/NDI,
October 2002
[27] Lloyds Register of Shipping, “Code for Lifting Appliances in a Marine Environment” (CLAME),
1987
[28] Health and Safety Executive, Guidance Note PM20, “Cable Laid Slings and Grommets”, August
1986

The list is not exhaustive and does not include any oil operator specific specifications that some of the
larger oil companies may wish the contractor to use.

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