Special Report – Offshore Accommodation and Engineering Modules by The Magazine Production Company

Special Report

Offshore Accommodation and Engineering Modules The Ferguson Group Offshore Accommodation and Workshop Modules Building Blocks for Offshore Enterprise Modular Technologies Converge Many Roles for Modules Environment and Safety Challenges

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Published by Global Business Media

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Flexibility and Quality Maintaining Standards The Ferguson Range Accommodation Modules Workspace Modules NORSOK Workspace Modules

Building Blocks for Offshore Enterprise

Publisher Kevin Bell

Modules All Around Us Oil and Gas Remote Workers Still Need Creature Comforts Multi-Tasking Building Technology Matching the Structure to the Job

Business Development Director Marie-Anne Brooks

Modular Technologies Converge

Editor John Hancock Senior Project Manager Steve Banks Advertising Executives Michael McCarthy Abigail Coombes

Convergence Breeds Convenience Adapting Standards for a New Purpose Boxes Become Buildings Flexibility Meets Changing Needs

Many Roles for Modules

For further information visit: www.globalbusinessmedia.org

Permanent, Temporary or Additional Not Only Living Quarters The Renewable Sector

Material in advertisements and promotional features may be considered to represent the views of the advertisers and promoters. The views and opinions expressed in this publication do not necessarily express the views of the Publishers or the Editor. While every care has been taken in the preparation of this publication, neither the Publishers nor the Editor are responsible for such opinions and views or for any inaccuracies in the articles.

Francis Slade, Staff Writer

Production Manager Paul Davies

The opinions and views expressed in the editorial content in this publication are those of the authors alone and do not necessarily represent the views of any organisation with which they may be associated.

John Hancock, Editor

Peter Dunwell, Correspondent

Environment and Safety Challenges

John Hancock, Editor

International Challenge and Risk A Growing Sector Safety on the Platform Making the Rules

References 15

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SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Foreword T

he USA expects to be energy independent

sleeping quarters) and decent workspaces will be

by 2035, much of which will derive from the

critical to ensuring that the best people are attracted

exploitation of ever more difficult-to-reach oil and

to and stay in the industry. Modular buildings will

gas reserves. For the foreseeable future, oil and

contribute heavily to that because they can ensure

gas will continue to sit atop of the energy providers’

continuity of standards when temporary or additional

tables, maintaining their importance to the global

buildings are required and can upgrade to the latest

economy as ever more reserves are identified and

standards as they arise.

exploited. This will mean taking exploration and

We look at that flexibility and at the way in which

production into ever more difficult and inhospitable

convergence of modular structure engineering with

offshore environments which might, in turn, mean

strengthened standards for ISO type containers

that the weeks and months of working shifts in the

used in the offshore sector has enabled modular

offshore sector today will become many months

building to tap into an international set of standards

or more in the sector of tomorrow.

and an established global transport infrastructure.

This Special Report opens with an article that

And, of course, it isn’t only accommodation for which

looks at Ferguson Group, one of the world’s leading

modular buildings are required. Offshore platforms

suppliers of containers, accommodation and

are all about engineering with equipment needing to

workspace modules to the offshore energy industry.

be housed and functions needing spaces in which

Key to its success is its emphasis on research and

they can be performed. Last, but far from least, we

development using its highly skilled workforce, which

look at safety issues, which are so important to the

includes not only manufacturing staff but designers

good management of an offshore structure, and how

and associated personnel. The articles goes on to

good quality modular buildings can be part of the

describe the Ferguson range of products.

safety culture.

If workers are to work in such inhospitable places for ever longer periods, it will be more than simply money that will maintain their morale and ensure their motivation. High quality accommodation (not simply

John Hancock Editor

John Hancock has been a journalist for nearly 25 years. He has written and edited articles and papers on a range of defence, engineering and technology topics as well as for key events in those sectors. Subjects have included aero-engineering, testing, aviation IT, materials engineering, weapons research, supply chain, logistics and naval engineering..

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SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

The Ferguson Group Offshore Accommodation and Workshop Modules Ferguson Group

The Ferguson Group had its beginnings in Aberdeenshire, Scotland, over 35 years ago and today has grown to one of the world’s leading suppliers of containers, accommodation and workspace modules and accommodation service vessels to the offshore energy industry, with many onshore applications too. The main bases are located in Scotland, Norway, Australia, Singapore and Dubai providing high quality containers and accommodation solutions to the offshore sector. All our containers and modules are manufactured to DNV 2.7-1 / EN12079 standards. The offshore accommodation and workspace modules are designed and manufactured by the Ferguson Group’s in-house manufacturing base in Scotland and are built to the latest specifications. In-house manufacturing facilities means that the Group is able to control and guarantee the quality of the end product, costs and delivery schedules. The accommodation modules and workspace modules are A60 fire rated, manufactured to DNV 2.7-1 / EN 12079 and for Norwegian markets NORSOK standards are also available. The modules are designed with weight in mind, the largest of its accommodation modules 10.3m fully serviced unit weighing 15,000kg. All of the accommodation and workspace modules have the benefit of a smaller footprint for tight deck spaces. The modules can be stacked up to four high, with linkable/adaptable walkways to form accommodation complexes, and are designed in such a way as to offer end users with flexible interiors for accommodation and workspace modules. A variety of Zone 1, Zone 2 and safe area modules are available. The designed link corridor system used in a complex, offers maximum flexibility, with easy linking to form integrated accommodation areas and multi module complexes.

which means that clients can customise the inside of the Group’s standard modules for their project’s specific requirements. The company has a fit-out team who can adjust internal layouts specified by the client. Quality Standards – the Ferguson Group is committed to high standards of safety and quality across the international business with HSEQ systems that rigorously monitor and control standards very carefully. Our products are certified to ISO 9001 and ISO 14001 for our environmental management systems and OHSAS 18001 for occupational health and safety. Within the offshore energy industry, the FPAL, Achilles and other performance assessment ratings are very important. Ferguson Group products enjoy excellent performance feedback and are the industry benchmark in a number of categories.

Maintaining Standards Research and Development is key at the Ferguson Group and whilst the accommodation and workspace modules are built to the highest standards, there is a policy of research and development to ensure that units remain the highest quality available. Design, construction methods, safety standards, materials, equipment, technology and interiors are under constant review with staff, clients and suppliers. Skilled Workforce – central to the success of every organisation is its workforce and at Ferguson Group we have award-winning apprentices and highly skilled crafts people working at our manufacturing base in Inverurie, Scotland. As well as in-house manufacturing, there is a team of designers, fabrication, fit-out, electrical engineering, HVAC engineering, procurement and process management all on-site.

Flexibility and Quality

The Ferguson Range

Ferguson Group’s accommodation and workspace modules have the ability to offer clients the flexibility of ‘customised standardisation’

The range of Ferguson modules includes: •A ccommodation modules to sleep 1, 2, 3, 4, 8 people, along with accommodation complex www.offshoretechnologyreports.com | 3

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Ferguson Group’s

accommodation module exceed most permanent living quarter (PLQ) standards. In addition to the offshore accommodation modules, Ferguson Group provides a range of offshore ancillary and workspace modules. The ancillary modules can be supplied to supplement the accommodation modules for larger POB (persons on board) complexes. Based on the standard module range, these ancillary services allow delivery of fully self-contained, standalone complexes. The workspace modules are stackable and can be interlinked in any configuration to suit the footprint available.

accommodation and workspace modules have the ability to offer clients the

Modules

flexibility of ‘customised standardisation’ which mess module

means that clients can customise the inside of the Group’s standard modules for their project’s specific requirements.

units including galleys, mess rooms, locker rooms, gymnasiums, recreation rooms, medic suites and laundry rooms. • Workspace modules in 10.3m, 7.6m, 6m, 4.8m, 4.5m and 4m lengths with configurations including offices, laboratories, coffee shops/tea shacks, LWD/MWD/test cabins etc. The design incorporates full compliance with DNV lifting sling specification, blast rating with structural strength for stacking up to four high and overall safety, added flexibility of footprint requirement as overhang is possible. Safety is paramount and each module has a Programmable Logic Controller (PLC) fire and gas detection system fitted as standard. This incorporates an easy access control panel and direct integration with the installation’s own central controls. Comfort is important for crew and the modules are fitted as standard with an advanced, integrated split air conditioning system making the modules suitable for the widest range of global environments. This advanced air-conditioning system can be separately controlled in each cabin area for individual comfort. Every accommodation cabin has en-suite facilities with under floor heating for faster drying, increasing safety and comfort for personnel. The comfortable living quarter facilities exceed HSE guidelines for space and include high quality mattresses, secure lockers, comfortable seating and excellent sound insulation for 24 hour sleeping ability. Each module is designed with quality in mind – the internal design includes high quality fittings and contemporary colour schemes which mean that temporary living quarter (TLQ) standards in an

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The following modules are designed to complement the accommodation units: Mess modules configured to provide flexible or fixed seating to accommodate up to 28 personnel per 10.3m module. Optional self-service facilities are available. Galley module supplied with full marine specification stainless steel catering equipment, including bain-marie / serving equipment, hot plates, ovens, dishwashers, dry stores, cold/freezer stores, , sinks and fire suppressant system. Freezer/chiller/dry store units can also be provided. Recreational modules equipped with soft seating, TVs, lounge storage, furniture, and internet points. Gymnasium 10.3m modules equipped with various cardio-vascular gym equipment, sauna, wet unit, shower facilities, lockers and bench seating/changing facilities. The medic suite comprises a medic room complete with medic couch, sink, fridge, lockable storage cabinet and medic office facilities – desk, cupboards and filing cabinets. The suite also contains a recovery room with two beds and wet unit facility. Laundry fit-out comprises commercial washers and driers, linen storage, preparation area and laundry baskets. Locker/toilet/wash modules fitted out with full or half height lockers, bench seating, hand washing facilities and toilet facilities. Office modules can be configured from single person executive to multi-person operation (up to 12). Fit-outs comprise desks, operators’ chairs, filing cabinets, storage space, with power/telephone/ IT cabling pre-installed. Laboratories can be customised to fit stainless steel worktops, sinks, chemical storage cupboards, fume cabinets, storage cupboards etc. LWD/MWD/Test cabins configured as required including adjustable height worktop, operators’ chairs, document storage, wall cupboards, multiple cable transits and data racks. Coffee Shop/Tea Shack complete with bench seating, tea/coffee making points, hot water boilers and sink/cupboards (can be smoking or non smoking).

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Module Dimensions

Accommodation Modules

Accommodation Module – Product Summary • 2 sets of bunk beds • Lockers including hanging and shelving space • En-suite shower rooms with under floor heating • Shower with integral hot water system •D esk & workspace, including pin board and chair •A ir-conditioning unit with individual thermostatic control • PLC based fire and gas detection unit • Category II lighting, low brightness • High quality fixtures and fittings cabin • Attractive relaxing decor and soft furnishings • Quick and easy hook-up to onboard services • Designed for easy stacking •M anufactured in-house to ISO 9001, ISO 14001 and OHSAS 18001 standards •O ptional fire escape hatches replace windows if required Workspace Modules

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SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Comfort is important for crew and the modules are fitted as standard

Workspace Module – Product Summary • A60 fire rated module •F lexible internal layouts to suit customer’s requirements •A ir-conditioning unit with individual thermostat control • PLC based fire and gas detection unit • Category II lighting, low brightness • High quality fixtures and fittings • Quick and easy hook-up to onboard services • Designed for easy stacking •M anufactured in-house to ISO 9001, ISO 14001 and OHSAS 18001 standards

with an advanced, 6m and 4.8m NORSOK Workspace Modules

integrated split air conditioning system making the modules suitable for the widest range of global environments.

NORSOK Workspace Modules Product Summary • NORSOK compliant, A60 fire rated module •D NV 2.7-1 / DNV 2.7-2 / BS EN 12079 certification •C lassified for Zone 2 Hazardous area (ATEX Ex II 3G, EEx v3 IIB T3) in accordance with BS EN 50381:2004 • CE marked • ISO corner castings fitted top and bottom for easy stacking and interlocking • Recessed pad eyes for ease of stacking • PLC based fire and gas detection unit •Z oned air conditioning (optional) compliant with noise level requirements • A60 window and protection frame • Height adjustable work surfaces •F lexible internal layouts to suit working environment standards • Plug & play hook up For further information visit www.ferguson-group.com

lab module

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SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Building Blocks for Offshore Enterprise John Hancock, Editor

Modular units put structure where conditions are less than permanent, hospitable or predictable

locker room module – interior

Modules All Around Us Modular structures are a common sight today. Whether it’s as part of a construction or engineering project, as additional space in a school or for an office, providing a science establishment in the polar regions or bringing the facilities and convenience of a building into a war zone, modular structures quickly create useful structures by bringing together a number of pre-assembled units into a whole building. In the case of one example of modular building, the brand name ‘Portacabin’ has entered the English language as a generic term for a temporary building, albeit that some remain in place for decades. But, while the ubiquitous site office modules are usually situated in relatively easily accessible by road and hospitable places, there are plenty of occasions when a ‘temporary’ structure is called for where the site can neither be described as accessible by road nor hospitable. Given the range of unit sizes and fittings available today, that might mean pretty much any sort of facility in more or less any accessible environment; something which very much typifies the needs of the oil and gas industry in general and the

offshore exploration and extraction sector of that business in particular.

Oil and Gas The oil and gas offshore sector uses a number of different types of exploration and production platforms (the more correct term than ‘oil rig’) but they share some things in common, including… they’re huge, they’re costly to build and operate, they are potentially very hazardous places and they are not easily accessible for daily commuting to work. So ‘shifts’ tend to be of weeks or even months rather than hours duration and that means that the workforce has to housed and provided with all the staples of life and some leisure. Offshore production platforms are loaded with engineering and technological wonders but, for all the technology, they also need people. That often means more than a hundred workers of all types on one platform at any one time; far from home, often far from the shore. While they can be self-sufficient for the most basic needs with on-board desalination plants to ensure supplies of fresh water and generators to supply electrical power1, most other supplies have to be brought to the platform. www.offshoretechnologyreports.com | 7

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

The applications for modular buildings in the offshore environment are as broad as in onshore situations, including, in addition to accommodation modules, welfare modules, catering and leisure modules, places for worship, communications rooms, control rooms, ROV (remotely operated vehicle) control cabins, engineering and workshop cabins.

“To help cope with these issues, petroleum companies frequently put a great deal of effort into providing comfortable living conditions for offshore workers. In many cases, quarters are on par with those found on major cruise ships – featuring private rooms, satellite TV and even gym, sauna and recreation facilities. The food on board also tends to be above average – and available 24 hours a day. After all, work on an oil rig continues day and night, with employees working rotating schedules of daytime and nighttime shifts. Helicopters and ships bring in most of the necessary materials for day-to-day life on an oil rig, often through choppy weather conditions.”2 says ‘How Stuff Works’. And it is true that most requirements can be delivered; but, once on board a platform, all of those functions, facilities and supplies have to be housed and delivered in an environment that, at least, allows workers not on shift to enjoy some creature comforts and those on shift to work in the most hospitable conditions practicable for their job: which is where modular units come in.

Remote Workers Still Need Creature Comforts Chris Lo, writing in December 2010 for ‘Offshore Technology’3 well summarised the conditions that prevail in offshore oil and gas environments and one of the means by which some of the challenges of the environment are met: “It is well known that offshore workers in the oil and gas sector have one of the most demanding and intensive working schedules in the world. On offshore oil platforms, shifts can stretch to weeks or even months, with workers having to contend with dangerous weather conditions and equipment as well as being hundreds of miles from their families for extended periods. As the technical possibilities of what can be achieved on a platform expand, oil and gas operators are looking for a new level of quality when it comes to maintaining the safety and morale of their employees. “Whether it is for long-term drilling operations or quick engineering works, the offshore oil and gas industry is supported by flexible accommodation units to make sure that workers are provided for during their long work shifts at sea, usually with crate-like accommodation modules. While this might not sound like the height of luxury, things have moved on significantly in the last decade, with standards steadily rising and the range of available offshore facilities expanding.” As an example of what can be incorporated into an offshore accommodation module, Oil Rig Job International4 describes modern modular accommodation as, “… the eating and sleeping quarters for employees; it also includes offices and a meeting room. Each accommodation

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module contains a TSR or Temporary Safe Refuge that are (sic) used in emergency situations.”

Multi-Tasking Building Technology Indeed, the applications for modular buildings in the offshore environment are as broad as in onshore situations, including, in addition to accommodation modules, welfare modules, catering and leisure modules, places for worship, communications rooms, control rooms, ROV (remotely operated vehicle) control cabins, engineering and workshop cabins and many more besides. A lot of this flexibility is derived from the fact that modules are pre-assembled in high quality factory conditions, incorporating the required fixtures and fittings for their intended purpose with the highest specification of health and safety materials, assemblies and standards built-in from the outset. This is important for any use but especially so for use in a potentially hazardous environment far from any external emergency services. Modular construction also offers other benefits. Flexibility is a much sought after attribute in any system and the more so for a system that has to serve a sector in which there is need for long term production units but with growth and reduction in size as economics and markets dictate and for temporary structures to complete one stage of a process. To meet these variations, there are three categories of living quarters used on offshore facilities: permanent living quarters (PLQs), temporary living quarters (TLQs) and additional living quarters (ALQs).

Matching the Structure to the Job Because of the standards to which most ‘bare’ production platforms have been built, modular units can be put in place, stacked (usually up to four high) and/or linked to form whatever whole structure is required and ‘plugged in’ to the platform’s own services infrastructure. They can, as easily, be reconfigured, extended or reduced to match accommodation and engineering areas to changing requirements and, of course, they can be moved to another location with relative ease. So, far from the basic accommodation units of past decades, the modular structure not only delivers fixed structure comfort, equipment and safety in temporary or inhospitable environments but it also enables businesses to tailor accommodation and engineering structures to current needs and to build whatever type of complex they want; or, rather, that their business priorities demand. These really are the building blocks of enterprise for a challenging environment.

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Modular Technologies Converge Francis Slade, Staff Writer

A simple name for logical technologies that have come together to change the ways we trade, work and live.

Convergence Breeds Convenience Modular buildings are nothing new but the idea has progressed enormously since the advent of the ISO standard shipping container that revolutionised world trade and spawned a whole raft of alternative applications, including adding value to the modular building concept through convergence, a process familiar to technology enthusiasts. Probably the commonest example of convergence is the mobile phone which can take and send photographs and movies, store and play music, receive and send emails or short messages and even make and receive telephone calls. A number of technologies have converged to make this possible and that’s how it is with the convergence of engineering solutions used in the international standard intermodal container5 and modular buildings.

Adapting Standards for a New Purpose The first shipping container was invented and patented in 1956 by Malcolm McLean, owner of the fifth largest trucking company in the United States. He’d bought his first truck in 1934 when cargo was loaded and unloaded to and from various sized crates, a slow process and by no means standardised. McLean set out to develop a standardised way of handling cargo between trucks, ships and warehouses. From that came the iconic ISO container that is credited with revolutionising world trade. The ISO standard container that he developed, along with the transportation infrastructure and fixing system that now accompany it6 has also lent its dimensions and standardisation to the modular building unit, significantly enhancing the ease and cost of transporting units to where they are needed. By dint of the standard fixing bases for containers, several modes of transport (particularly road, rail and sea) can be used to move compatible units around the world without the need to unload and reload cargoes at every entrepôt. The container is simply moved from

the locking mechanism on one load bed to the identical locking system on another. This same facility not only enables modular building units to be more easily moved from site to site but also provides the basis for securing the unit to the structure on which it is to be sited. Also, a compatible system with that used to securely stack containers can be used to stack modular building units. “Standardized accommodation modules with intelligent design allow for a wide spectrum of setup solutions from a single room to a whole village. Based on the footprint of a 20ft ISO-standard container, the module format ensures an economical transportation by road, rail and sea – just like any freight container.“7 However, modular buildings use better locking mechanisms than freight containers and are not stacked so high.

Boxes Become Buildings There is nothing new in containers that no longer meet the structural standards required for their prime transport purpose being adapted for other purposes, including accommodation and work space. There is even a practice called shipping container architecture which has created a building system using steel intermodal shipping containers as structural elements because of their inherent strength, wide availability and relatively low cost. “They are designed to carry heavy loads and to be stacked in high columns. They are also designed to resist harsh environments – such as on ocean-going vessels... Due to their high strength, containers are useful for secure storage.”8 Of course, while a number of architects, such as Adam Kalkin, have built original homes using discarded shipping containers, freight boxes are not made for accommodation and so cannot provide ideal conditions. But while some people were modifying containers for other uses, others were modifying container engineering to match the challenges of offshore operations; “The ‘offshore’ container differs in some important respects from its sea transport (‘ISO’) counterpart. www.offshoretechnologyreports.com | 9

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Standardized accommodation modules with intelligent design allow for a wide spectrum of setup solutions from a single room to a whole village. Based on the footprint of a 20ft ISOstandard container, the module format ensures an economical transportation by road, rail and sea – just like any freight container.

Recreation module – Interior

The latter is designed and certified according to international standards to ensure compatibility with dock handling equipment worldwide and to be stacked on freighters. The offshore container, on the other hand, is intended to be rough handled on supply ship decks and to withstand dynamic loading associated with being snatched by installation cranes.”9 That from Woodside Safety and Training’s ‘Offshore Safety Rep Training’ programme. The convergence of these engineering developments (modular building, containers for buildings and engineering for harsh environments) has added great value to the provision of modular buildings for the offshore industry. Safety is a critical consideration not only in the construction of modular buildings but also in their handling – each module is still a large item to be handled. Builders of modular accommodation and workplace units based on ISO container standards have heavily adapted the boxes for a different use but the dimensions and fixings still enable them to enjoy the benefits of a modular system with a ready-made global transport infrastructure already in place. That said, the many container size portable units intended for offshore use such as portable offices, temporary control modules and

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accommodation modules are not containers, although they are usually certified to offshore container standards for compatibility and safety purposes.

Flexibility Meets Changing Needs The convergence of standardisation and modular design means that accommodation and workspace structures can be custom built for each platform according to its specific function. “Accommodation Modules can be utilised as either stand-alone units (depending on customers’ individual requirements) or can be linked and stacked together to form multipurpose, multi-level accommodation complexes. Linking kits are supplied with each module (the seals are waterproof and provide a watertight barrier) and the modules are designed to link together quickly and thus minimise valuable hook up time.”10 The standards are even used to build utility units for holding supplies of fresh water or for containing waste water. The modular constructions used today are the happy progeny of two brilliantly simple and effective technologies that, together, have revolutionised much of the physical side of trade, commerce and enterprise.

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Many Roles for Modules Peter Dunwell, Correspondent

Accommodation extends a long way beyond sleeping quarters and modular systems can cater for all those requirements

The purposes to which modular structures are applied on offshore oil and gas platforms might be broken down into two areas: buildings to house what has to be done and buildings that make it possible for workers to be there. They are of equal importance. This paper breaks the two down into accommodation and engineering. But even within these subsectors, there are quite wide variations in how accommodation and workspace structures are made and used. Like everything else with offshore installations, the governing reality is that the whole facility has to operate away from any fixed, shore-based infrastructure. That means that it has to provide an environment to closely match what workers onshore would find as to facilities and safety standards, even on a changing or a temporary basis. Offshore platforms usually employ one or more of three types of accommodation or living quarters. gym module – Interior

Permanent, Temporary or Additional Permanent living quarters (PLQs) might well be part of the structure of the platform built during the platform’s initial construction or at a subsequent refit and, as such, are pretty much fixed and inflexible. But there are two other categories of living quarters. Temporary living quarters (TLQs) are usually installed to cater for an additional work force brought onto the platform to complete a specific and finite task such as the hook-up and commissioning phase or, perhaps, a major maintenance or improvement job conducted on station and while the platform continues with its usual work. Once the job is finished, the units can be removed and moved to the next job. Additional living quarters (ALQs) are installed when a larger workforce is going to be required as the result of a long term increase in a platform’s work. Although their installation might leave them on the platform for an indefinite period – possibly the remainder of the platform’s operating life – unless the whole thing is returned to shore for a proper (and very expensive) refit, ALQs are likely to be of modular construction to allow them to be transported to and installed using the existing infrastructure.

Whichever of the above three accommodation types is installed, workers today expect high standards of facilities so that, in addition to work and living space, modules will need to be installed for kitchen and dining spaces, laundry, gym, bathroom facilities, entertainment systems, place for worship and healthcare centre. On platforms served by a helicopter service, there will need to be a heli-lounge for arrivals and departures processing.

Not Only Living Quarters Over and above that, systems need to incorporate a communication unit linked up to pre-installed wiring for telephone, PA and IT use and decent air-conditioning systems which, in some environments, will be combined with positive pressure ventilation systems as well as, in the kind of application we are covering here, a secure fire extinguishing system to protect the modular structure in addition to any platform based sprinkler or alarm system. Similarly, workspaces can vary from workshops to equipment housing to laboratories, again with a range of ancillary services required. And there will need to be www.offshoretechnologyreports.com | 11

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

One solution has been the building of offshore accommodation vessels which can house the workforce alongside the engineering vessels on which they’ll be working for the duration of the installation.

galley module – interior

storage facilities; offshore installations should be capable of being operated independently of any support for up to 14 days in the event of weather halting supply. Furthermore, because the dimensions of a platform or vessel on which the modular structure is to be installed might not fit perfectly the standard sizes, there will need to be a range of variations in length to allow a structure to be tailored for the space available. Equipment housing is one area where modular units get back close to the shipping containers whose dimensions and standards they have borrowed. For instance, compressed air and steam generators, if left in the open, could have the potential to generate the kind of spark that would be dangerous for oil and gas installations. Therefore, with this type of equipment, health and safety agencies such as the UK Health and Safety Executive (HSE) recommend packaging the equipment in a self-contained unit. “Using a packaged unit has a number of advantages; it simplifies foundation work, reduces installation time and provides a properly engineered and adequately guarded assembly of components in a compact space. However, the user is still responsible for siting the system so that incoming air is as dry and free from contaminants as site conditions allow. Both the air entering the [equipment housing] and the delivered air must be as dry, clean and cool as possible.”11

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The Renewable Sector One offshore energy related activity for which there are no platforms on which to install accommodation and engineering units (modular or otherwise) is the renewables sector, installing huge wind generators in the ocean far from land. Currently, a significant cost for the sector is the transportation of workers from shore out to the installation site and back at the start and end of each shift. This can add as much as four or five hours to a shift making the work less attractive and making the workforce less able to adopt flexible working practices. One solution has been the building of offshore accommodation vessels which can house the workforce alongside the engineering vessels on which they’ll be working for the duration of the installation. Offshore installations have often been described as cities on the sea, which is not a bad description, given their size and the levels of activity that they sustain. But because of the range of those activities and the complexity of what is needed to keep them going, modular accommodation has had to evolve ever more sophisticated solutions to meet the needs of an offshore industry that is constantly pushing technology and engineering limits as well as exploiting ever more challenging areas of the ocean.

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Environment and Safety Challenges John Hancock, Editor

Modular buildings have to meet the challenges of offshore and the regulations and standards that govern the sector

ews footage of the Piper Alpha oil production platform burning following the world’s worst offshore disaster in 1988 (167 people were killed) brought home the incredible dangers that accompany offshore oil and gas production. As Robert Lamb writing in ‘How Stuff Works’ put it; “Once the exploratory drilling phase is over and geologists have determined that a petroleum reservoir is worth the massive expense, oil companies prepare to establish an offshore production platform. These rigs are designed to last decades, often far from land and in some of the most hostile waters on Earth.”12 Risk is an ever present part of the business.

International Challenge and Risk There are offshore oil and gas fields around the world, in all climatic conditions and offshore oil and gas production is more challenging than landbased installations due to the remote and harsher environment. But, over and above the element of risk, offshore manned facilities also present logistics and human resources challenges. An offshore oil platform is a small community in itself with cafeteria, sleeping quarters, management, and other support functions. Supplies and even waste are transported by ship, which requires careful planning of both the supply chain and of the accommodation on the platform.13 Three major challenges face modular building manufacturers; establishing a working and support presence in each of the areas where oil and gas fields are located, provision of all the facilities required for an isolated community and the need to build safety into everything. On top of the climatic challenges, offshore platforms (colloquially known as rigs) are large constructions with many opportunities for systems and fittings to fail. Flowtech Energy describes the complexity of an offshore platform as a, “structure that comprises of a number of multifarious parts, each with its own specific function and purpose. It is a unit made of smaller units like drill machinery, the control and power system, and all sorts of instrumentation required for efficient

accommodation module – interior

oil extraction. Offshore Oil Field Drilling Systems [need] wide-ranging, integrated power along with proper instrumentation and control, and a communication system as the working conditions in an oil field are highly demanding. Rigs are required, on a compulsory level to maintain a static level of safety and also ensure measures to protect the ecological milieu.”14

A Growing Sector Although oil wells have been established underwater since at least the nineteenth century, “The first commercial offshore oil rig began drilling in 1947 off the coast of Louisiana in the Gulf of Mexico in just 14 feet of water. Permanent platforms were the first offshore oil rigs to drill successfully in deep waters, followed by the drill ships and semi-submersible offshore oil rigs that became widespread in the 1960s. These could reach to a depth of 1,000 feet. Since then, offshore oil rigs have stayed much the same in basic design, but their capabilities have evolved www.offshoretechnologyreports.com | 13

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

Because of the need to maintain safety which can be much more easily managed within a set of globally recognised standards, canteen

the offshore sector has been subject to a number of standard setting and regulatory agencies.

greatly and the amount of offshore oil rigs in use worldwide has skyrocketed.”15 With that and improving expectations of working conditions and accommodation quality, the demand for quality accommodation and workplace structures has also grown.

Safety on the Platform ‘Rig Safety’ is a practice in its own right, even extending to explosion-proof accommodation. And, because some areas are more dangerous than others, an internationally recognised zoning standard BS EN 60079/10 has been devised for installations where combustible gases, vapours or mists are likely to be present, especially applicable to oil and gas installations.16 •Z one 0 Where an explosive atmosphere is usually present. •Z one 1 Where an explosive atmosphere is likely to occur occasionally. •Z one 2 Where an explosive atmosphere is not likely to occur or will persist for a short period only. Accommodation and workplace modules must be accredited to be safe in the zone where they are sited. There is also a fire resistance rating system in which A60 and H120 standards indicate acceptable levels of fire retarding in structures and infrastructure items such as wiring.

Making the Rules Because of the need to maintain safety which can be much more easily managed within a set of globally recognised standards, the offshore sector has been subject to a number of standard setting and regulatory agencies, including… •D NV (Stiftelsen Det Norske Veritas) together with Lloyd’s Register and American Bureau of 14 | www.offshoretechnologyreports.com

Shipping, the three major companies in the classification society business. •T he UK Health and Safety Executive (HSE) issues guidance to all parts of industry and commerce but there is a specific notice that is relevant to offshore accommodation, Notice 62. • I SO standards (ISO 9001: 2000) govern the production processes when modular units are manufactured to ensure quality and delivery timing. •O ther standards for manufacturing offshore accommodation include the SOLAS (International Convention for the Safety of Life at Sea) standards on fire rating. Offshore accommodation modules are usually designed to DNV 2.7-1/EN 12079 specifications set for offshore containers. As Woodside Safely and Training explains17: “the offshore container has to be ‘tougher’ [than the freight shipping container] and, in this respect, DNV 2.7-1 applies to strength and integrity in all three phases of transport: shoreside (by fork lift truck), by supply vessel, and lifting by crane onto and off offshore installations. The need is for sufficient strength to withstand the forces encountered in offshore operations and not suffer complete failure even if subject to extreme loads.” In an article of this length, we can do little more than indicate that standards exist. If you need to deal with them, then the strong advice is to contact the relevant authorities for the latest and fullest information which might run to hundreds of pages. But, everything that goes onto an offshore platform has to meet the highest standards, especially accommodation structures and modular systems.

SPECIAL REPORT: OFFSHORE ACCOMMODATION AND ENGINEERING MODULES

References: 1

Wikipedia http://en.wikipedia.org/wiki/Oil_platform

How Stuff Works http://science.howstuffworks.com/environmental/energy/offshore-drilling8.htm

Offshore Technology http://www.offshore-technology.com/features/feature105568/

Oil Rig Job International http://www.oil-rig-job.com/equipment.html

Wikipedia http://en.wikipedia.org/wiki/Freight_container

eHow http://www.ehow.com/list_7652255_iso-container-specifications.html

Offshore Technology http://www.offshore-technology.com/contractors/accommodation/diogenes-modules/

Wikipedia http://en.wikipedia.org/wiki/Shipping_container_architecture

Offshore Safety Rep Training http://www.woodsidesafety.co.uk/containers.html

MML Marine http://mmlmarine.com/accommodation_modules

HSE http://www.hse.gov.uk/pubns/priced/hsg39.pdf

How Offshore Drilling Works http://science.howstuffworks.com/environmental/energy/offshore-drilling6.htm

Wikipedia http://en.wikipedia.org/wiki/Offshore_drilling

Flowtech Energy http://www.flowtechenergy.com/Oilfield-Services/offshore-oil-field-drilling-rigs/

eHow http://www.ehow.com/about_4597210_offshore-oil-rigs.html

Hazardous area zones http://www.hse.gov.uk/fireandexplosion/zoning.pdf

Offshore Safety Rep Training http://www.woodsidesafety.co.uk/containers.html

www.offshoretechnologyreports.com | 15

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