Design Philosophy and Criteria Vol 2
Design Philosophy and Criteria Vol 2
Design Philosophy and Criteria Vol 2
The following are the key objectives/philosophies of the project to ensure that the value of the asset is maximized, consistent with the wider business objectives of Husky Oil and Petro-Canada: life-cycle considerations will be taken into account during decision-making; integrity of the Project (in terms of safety of personnel, environment and property, and business interruption) is crucial. The project will employ risk management and value engineering principles. Refer to Volume 5, Preliminary Safety Plan and Concept Safety Analysis; equipment will be selected on the basis of proven history; availability targets will be developed for each system; safety is of prime concern and the Project will endeavour to provide a safe, healthy, and comfortable working environment through the design and operation of the facilities for all personnel. Formal safety assessments and the reporting of safety performance will be undertaken throughout the duration of the project pursuant to the Safety Plan; the environment will be protected in compliance with all pertinent laws and regulations, the Operator's Environmental Policy and the site-specific Environmental Management System (see Comprehensive Study Part One EIS). The Project will be required to demonstrate that objectives are being met through regular performance review and supplemented by periodic auditing; and as deemed practical, the design will ensure that construction, testing, integration and precommissioning are performed at the quayside with offshore activities limited to FPSO tie-in and final commissioning.
This design philosophy will be implemented through the technical project management approach described in Section 10.1.1. 8.2 Regulations, Codes And Standards
A Newfoundland Offshore Certificate of Fitness will be obtained for White Rose production and drilling facilities. The installations will conform to the requirements of current Canadian federal and provincial regulations, including but not limited to: Newfoundland Offshore Certificate of Fitness Regulations; Newfoundland Offshore Petroleum Production and Conservation Regulations; Newfoundland Offshore Petroleum Installation Regulations ; Petroleum Occupational Health & Safety Regulations Newfoundland; Newfoundland Offshore Petroleum Drilling Regulations ; Newfoundland Offshore Area Petroleum Diving Regulations ;
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Canada Shipping Act ; Canada-Newfoundland Offshore Petroleum Board Offshore Waste Treatment Guidelines; Newfoundland Offshore Area Guidelines for Drilling Equipment : and any and all other applicable laws.
Engineering and design practices will be common across the Project and all designs will conform to Canadian Standards, or approved equivalent International Standards, and relevant Codes and Standards listed in the above documents. Generally accepted international standards, such as American National Standards Institute (ANSI)/American Society of Mechanical Engineers (ASME) specifications and American Petroleum Insititue (API) recommended practices, will be applied as appropriate. The most recent edition of applicable codes will be used. The production vessel, mooring, propulsion and marine systems will require classification by a certifying authority yet to be selected, but which will be chosen from amongst: American Bureau of Shipping; Bureau Veritas; Det Norske Veritas (DNV); or Lloyd's Register of Shipping.
The vessel will be Canadian-flagged. 8.2.1 Codes and Standards for the Floating Production, Storage and Offloading Facility/Mobile Offshore Drilling Units
The design of the FPSO will be based upon relevant codes and standards of internationally recognized agencies such as the following: API; ASME; Canadian Standards Association; International Standards Association; International Electrotechnical Commission; International Maritime Organization (IMO); NACE; National Fire Protection Association; and Transport Canada.
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A list of some of the potentially relevant codes and standards applicable to the FPSO and/or MODU is provided in Appendix 8.A. 8.2.2 Codes and Standards for Subsea Facilities
The design of the subsea facilities will be based upon relevant codes and standards of internationally recognized agencies such as the following: API; Canadian Standards Association; and DNV.
A list of some of the potentially relevant codes and standards applicable to the subsea facilities is provided in Appendix 8.A. 8.2.3 Codes and Standards for Shuttle Tankers
The design of the shuttle tankers will be based upon current relevant codes and standards of internationally recognized agencies such as the following: American Bureau of Shipping; Transport Canada; Institute of Electrical and Electronic Engineers; or IMO.
A list of some of the potentially relevant codes and standards applicable to shuttle tankers is provided in Appendix 8.A. 8.3 Environmental Criteria
Refer to the EIS (Comprehensive Study Part One) for an in-depth examination of the White Rose environment. The Grand Banks region has a harsh environment much like the northern North Sea. Intense storms occur frequently in winter with winds generally from the northwesterly and westerly directions. Restricted visibility due to fog is common, especially in the spring and summer months, when warm air masses overlie the cold ocean surface. The information presented in this section presents the best data currently available.
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There are sea ice incursions and icebergs in the Grand Banks area. Superstructure icing can occur between December and March because of the temperature, wind and wave conditions. The seabed is composed of dense sands, cobbles and boulders overlying alternating silty clay and fine sand beds to a depth of 40 m. 8.3.1 Data
This section provides details of environmental data that are planned to be used in the design of the White Rose facilities. The final figures used for design will be reviewed with C-NOPB and Transport Canada and the certifying authority. The physical environment (wind, waves, currents) of the Jeanne d'Arc Basin is described in Tables 8.3-1 and 8.3-2. Table 8.3-1 Extremes at White Rose Location - All Months and Years Combined
Wave (m) Return Period (years) 1 10 25 50 100 Significant wave height 10.5 12.7 13.5 14.1 14.7 Maximum wave height 19.7 23.8 25.2 26.3 27.4 Associated spectral peak period 13.5 14.9 15.4 15.8 16.1 1-h mean 23.6 27.7 28.8 29.7 30.5 10-min mean 25.0 29.4 30.5 31.5 32.3 Wind (m/s) 1-min mean 28.8 33.8 35.1 36.2 37.2 15-s mean 31.2 36.6 38.0 39.2 40.3 3-s mean 33.7 39.6 41.2 42.5 43.6
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Table 8.3-2
Well Site
Near Surface
White Rose N-30 White Rose A-17 White Rose L-08 White Rose E-09 White Rose J-49 White Rose L-61 White Rose N-22 Trave E-87 Trave E-87 Aug Oct, 1999 Jun Aug, 1999 Mar Jun, 1999 May July, 1988 Aug Nov, 1985 Dec Feb, 1985 Jul Oct, 1984 Nov Jan, 1984 Feb Mar, 1984 Aug Oct, 1999 Mar Jun, 1999 Jul Aug, 1988 May - July, 1988 Jan Feb 1988 Sept Oct, 1987 Aug Nov, 1985 Jul Nov, 1984 Feb Mar, 1983 Nov Jan, 1983 Mar Jun, 1999 Jul Aug, 1988 May- Jul, 1988 Jan Feb, 1988 Aug Nov, 1985 Nov Jan, 1983 Feb Mar, 1983 Southeast Northeast Northwest Southeast South Northeast Southwest South Southeast Northeast South Southeast Southeast Southeast Southwest Southeast Southeast South Southeast Southeast Southeast Southwest Southeast Southeast Southeast Southeast
Mid-Depth
White Rose N-30 White Rose L-08 White Rose A-90 White Rose E-09 White Rose E-09 Whites Rose E-09 White Rose J-49 White Rose N-22 Trave E-87 Trave E-87 Near Bottom White Rose L-08 White Rose A-90 White Rose E-09 White Rose E-09 White Rose J-49 Trave E-87 Trave E-87
The design ambient conditions, and icing and iceberg data for the White Rose location are summarized in Tables 8.3-3 and 8.3-4, respectively. The seawater characteristics in the White Rose area are presented in Table 8.3-5. White Rose is located at the extreme southern perimeter of a marginal ice zone. In the ice season (February to July), the area is subject to variable sea ice cover consisting of multi-year pack ice drifting south from the Labrador Sea, together with generally smaller first-year floes formed locally. Icebergs originating from glaciers in Greenland and Ellesmere Island drift south through the White Rose area with the Labrador Current. Icebergs classified as large (up to 4,500,000 t) have been observed in the area.
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Table 8.3-3
Air Temperature ( C) Water Temperature (Surface) ( C) Water Temperature (20 m depth) ( C) Water Temperature (50 m depth) ( C) Flying Visibility <1 km / Ceiling < 100 m
Table 8.3-4
Theoretical Superstructure Icing Accumulation on 5 cm Cylinder Glaze and Rime Icing (mm) Spray Icing (mm) Icebergs Sightings One Degree Grid Mass (t) Speed (km/h) Sea Ice Occurrence Within 25 km Source: Husky Oil Basis for Design
Table 8.3-5
Seawater Properties
Chemical Component Density at 15.4 C Na K Ca Mg Cl HCO3 SO4 Quantity 1,024 kg/m 9,772 mg/L 351 mg/L 438 mg/L 1,167 mg/L 17,498 mg/L 128 mg/L 1,922 mg/L
Iceberg scours up to 1.5 m deep have been measured on the seafloor in the White Rose area. In order to avoid contact with scouring icebergs, subsea wellheads and templates must be placed in an open glory hole, with the top of the equipment a minimum of from 2 to 3 m below the mudline. The FPSO will disconnect from its mooring on the approach of an unmanageable iceberg of mass greater than 100,000 t. The hull and moorings will be designed to withstand impact with icebergs up to this weight.
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With respect to marine growth, allowance will be made in the design for occurrence of this on the vessel hull, mooring lines and risers. It will be based on the following information in Table 8.3-6. Table 8.3-6 Marine Growth Thickness
Marine Growth Thickness (mm) To be determined. 50 150 100 50
Elevation Above Mean Sea Level Above + 2.5m +2.5m to - 1.5m -1.5m to - 7.5m -7.5m to - 14.5m Below - 14.5m
8.3.2
Operational Limits
The FPSO design targets will be established for the following operational capabilities: continuous production; station-keeping; operation in sea ice; and normal planned disconnection.
Following vendor selection and receipt of equipment/system documentation, the operating manuals will be written to define the limits for operation imposed by equipment and environmental considerations. These will deal with such factors as: maximum deck loads (for stability of the FPSO); environmental conditions for helicopter operation; tanker mooring and loading; and other production activities.
Limiting environmental conditions will be specified as guidelines in the operating manuals. 8.3.3 Physical Environmental Loadings
The effect of physical environmental loadings (wind, waves, current, ice) on the facility will be analyzed using established recognized methods, and will be based upon relevant codes and standards, technical literature, research reports and society rules. Model testing will also be carried out. Consideration will be given to load combinations and simultaneous occurrences of environmental conditions.
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The design will take into account the physical environmental data presented in Tables 8.3-1 to 8.3-6 inclusive. 8.3.4 Production System Response
Applicable analytical methods and model tests will be used to assess the motion characteristics and station-keeping ability of the FPSO in various states of draft. Recognized methods will be used to carry out structural and fatigue analyses. Stability analyses will also be carried out on the facility for both an intact and a damaged state. The production response will also be evaluated with respect to the resulting motion characteristics and station-keeping of the FPSO. 8.4 Functional Criteria
The White Rose Field will be developed using subsea completions tied back to a mono-hull type FPSO unit, moored in approximately 125 m of water, with the crude oil transported to market by shuttle tankers. Accommodation, production separation, water injection, gas lift, gas re-injection, and crude export facilities will be provided on the FPSO. The White Rose Field is expected to produce a medium-weight crude at approximately 30 API, with a relatively high pour point and wax content. The wellstream fluid will be stabilized to produce an onspecification crude for export through an offloading hose to a shuttle tanker. Produced gas will be used as fuel and for gas lift, with excess gas being injected into the Avalon formation. Produced water will be treated to comply with offshore waste treatment guidelines, prior to discharge overboard. The subsea facilities will include up to 25 wells. There will be up to 10 to 14 producers, with the rest being water injectors for waterflood operations or gas injectors for gas conservation. The wells will be distributed between up to four drill centres. The current base case optimum design for the South Avalon Pool calls for eight production wells, five water injection wells and two gas injectors spread within three glory holes. Production and injection fluids will be manifolded at the seabed and transported via flowlines and flexible risers to the FPSO. Up to 10 wells will be drilled prior to First Oil and will include at least one gas injector and sufficient water injectors to meet initial water injection requirements. The majority of the wells are planned to be horizontal wells. Subsea wellheads will be located in glory holes to protect them from iceberg scour. Equipment within the glory hole will be designed such that the top is a minimum of 2 to 3 m below the mudline.
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The subsea system will be designed to minimize any environmental consequences from equipment failure or damage. As far as is practical, the location and layout of subsea equipment will provide ease of access for inspection, testing, repair, replacement or removal. In the event of a forecast possible ice scour, the vulnerable subsea facilities will be shut in and flushed to minimize any possible spills. Flowlines may be trenched to reduce the risk from scouring icebergs. This would provide enhanced on-bottom stability as well as improved thermodynamic characteristics. These systems are discussed in Chapter 9. Emergency shutdown valves will be provided. These will ensure the safety of personnel and minimize environmental effects in the event of accidental damage to the production facilities. 8.4.1 Design Flow Rates and Capacities
8.4.1.1 Floating Production, Storage and Offloading Facility Design Parameters The preliminary design flow rates and capabilities for the FPSO are shown in Table 8.4-1. The design throughput of up to 18,000 m/d is based on the technical and economic evaluations carried out to date. An ongoing optimization program will be in place over the life of the field, to capture potential incremental capacity up to 20,000 to 22,000 m/d through debottlenecking, increased well performance or the tying in of additional reserves from the North Avalon and West Avalon Pools and other potential secondary pools. Table 8.4-1 Preliminary Design Requirements for the White Rose FPSO
Capacity 12,000 to 18,000 m/d 15,000 to 30,000 m/d 30,000 to 35,000 m/d 3 to 7 106 m/d 3 to 7 106 m/d 1 to 3 106 m/d 40,000 m/d 110 to 135 10m
System Oil Production Rate Water Production Rate Total Fluids Production Rate Gas Production Rate Gas Injection Rate Field Gas Lift Rate Water Injection Rate Oil Storage
8.4.1.2 Well Design Parameters Horizontal production wells will be used, with pressure maintenance provided by horizontal or highly deviated water injection wells throughout the reservoir. Excess produced gas will most likely be injected into North Avalon or West Avalon Pools. The well design parameters of production wells, water injection wells and gas injection wells are shown in Table 8.4-2.
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Table 8.4-2
Maximum Oil Production Rate Maximum Liquid Production Rate Maximum Water Cut Percent Minimum Bottom Hole Pressure Nominal Wellhead Flowing Pressure Flowing Wellhead Temperature Shut-in Wellhead Pressure Shut-in Wellhead Temperature Maximum Gas Lift Pressure Maximum Gas Lift Rate per Well Maximum Water Injection Rate Maximum Wellhead Injection Pressure Wellhead Injection Temperature Shut-in Wellhead Pressure Shut-in Wellhead Temperature Maximum Gas Injection Rate Maximum Wellhead Injection Pressure Wellhead Injection Temperature Shut-in Wellhead Pressure Shut-in Wellhead Temperature
8.4.2
Design Life
The White Rose facilities will be designed for a service life of 20 years. Elements of the facilities may be designed for a service life of less than 20 years, provided this results in a reduction in life cycle costs and can be demonstrated to satisfy project risk management criteria. Target fatigue lives for the turret and vessel will follow Lloyds rules or equivalent, while topside and subsea equipment will be in accordance with needs as specified in this section and the requirements of API, Lloyds and Canadian Standards Association guidelines and practices or equivalents. The design of the White Rose facilities will have the flexibility to handle subsurface uncertainty in the most cost-effective manner, without jeopardizing life of field operations, while also catering for future expansion requirements.
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Materials will be selected in accordance with the requirements for their service, environment, temperature and compatibility with interface materials. 8.4.3 Well Fluids and Product Specification
8.4.3.1 Produced Oil Characteristics Typical Avalon oil characteristics are discussed in Section 4.2 and are provided in Table 8.4-3. Table 8.4-3 Typical Avalon Oil Characteristics
Characteristic Component N2 CO2 H2 S Methane Ethane Propane i-Butane n-Butane i-Pentane n-Pentane Hexane+ Total Pour Point Wax appearance temperature Wax Content 0.54 (mol %) 1.04 (mol %) 0.00 (mol %) 48.83 (mol %) 4.20 (mol %) 2.88 (mol %) 0.52 (mol %) 2.13 (mol %) 0.88 (mol %) 1.11 (mol %) 37.87 (mol %) 100.00 (mol %) < 12 C 45 C 8.0% by weight Value
CO2 is present in the well stream fluids in the range of 1 to 2 mol % and will create some corrosion concerns when water is produced. Suitable materials to resist CO2 corrosion will therefore be specified. Although no significant sulphur compounds have been detected in the well stream fluids, experience suggests that the introduction of seawater injection tends to produce small levels of H2 S in the reservoir. Suitable materials will be specified to meet NACE requirements for sour service as appropriate. 8.4.3.2 Export Crude Characteristics Well fluids will be processed to produced stabilized crude oil with the characteristics and specifications shown in Table 8.4-4.
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Table 8.4-4
Item Stabilized crude specific gravity range @ 15C Stabilized crude API gravity RVP, Vapour pressure at 50C (kPa) BS&W (% vol. Basis) Kinematic Viscosity at 40C (cst) Sulphur (weight %) * Data based on E-09, L-08 and A-17 Crude Assays
8.4.3.3 Produced Water Characteristics Significant water production is not expected during the early life of the field. Any water produced initially will be primarily formation water. Formation water characterization is discussed in Section 3.2; a typical expected composition is shown in Table 8.4-5. Table 8.4-5 Typical Formation Water Composition
Ion Na K Ca Mg Ba Sr Fe B Mn Cl Br I HCO3 SO4 Concentration (mg/L) 15,860 250 757 102 3.01 122 2.63 56.4 0.25 25,550 53 58.2 1,068 390
All produced water will be treated and disposed of directly overboard and will meet the requirements of the 1996 Offshore Waste Treatment Guidelines (NEB, C-NOPB and C-NSOPB 1996). Carbonate scaling is expected to occur in the producing wells as a result of the presence of carbon dioxide/bicarbonate ions in the reservoir fluids. Barium/strontium sulphate scaling may also be a problem in the producers after water breakthrough as a result of formation water/injection water incompatibility. Additional work is planned to better define the design basis for scaling.
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8.4.3.4 Sand Production South Avalon development is expected to exhibit sand-free production prior to water breakthrough, but following water breakthrough, experience shows that these types of formations may exhibit tendency to produce sand. Studies are ongoing to assess the formation sand production tendency. Consideration will be given to the installation of sand detection upstream of test and first stage separators. Consideration will also be given to building in flexibility for all production and test piping to have sand detection installed any time during the field life. In addition, the design of the facilities will address the provision for on-line removal of excess sand. The subsea production system design will also take into consideration the results of the studies on potential sand production. 8.4.3.5 Other Well Design Considerations The likelihood of asphaltine deposition at either flowing or shut-in conditions is still being addressed. If this proves likely, remedial measures will be designed. The same also applies to the possible formation of hydrates during both flowing and shut-in conditions. 8.4.3.6 Chemical Injection Requirements The following chemicals may be required for production operations: methanol; corrosion inhibitor; demulsifier; wax inhibitor; scale inhibitor; oxygen scavenger; antifoam; biocide; asphaltine inhibitors; hypochlorite; polyelectrolyte; and hydrogen sulphide scavengers.
A final decision on the need for these chemicals will be part of the detailed design together with the quantity required. Adjustments based on actual production performance will be made. An offshore
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chemical management system similar to that used for other Grand Banks operations will be in place to govern the safe use of chemicals offshore. 8.5 Geotechnical Criteria
Side scan sonar images of the White Rose area indicate that the surficial geology is a thin veneer of fine to medium grained sand over a coarser substrate, consisting of sand and gravel. Occasional occurrences of gently-sloped gravel mounds in the area may correspond with old iceberg scour berms. This information, together with other geotechnical information gathered for the White Rose oilfield, is summarized in Table 8.5-1. Table 8.5-1 Stratigraphy of Substrate in White Rose Area
Lithology Sand (fine to medium sand, relatively hard packed) Sand and gravel (and cobbles) Thickness 0 to 3 m Remarks Sub-littoral deposits formed seaward of the late Wisconsian shoreline. Occurs in water depths greater than 100 m. This unit is composed of two facies: a normally consolidated facies deposited in basinal areas and over much of the Grand Banks, it is often interbedded or underlying the Downing Silt, and an overconsolidated facies which occurs over large areas of the Grand Banks, often underlying the normal consolidated facies. It is in unconformable contact with the underlying Banquereau Formation. The unconformity is related to subaerial and glacial erosion. Seaward dipping beds are dominantly shales and mudstones.
2 to 10 m
10 to 700 m
Additional data on the soil types and characteristics are based upon a series of glory holes that were completed in the Grand Banks area for the Terra Nova development. This information is summarized in Tables 8.5-2 to 8.5-4. From the current state of geotechnical and geological knowledge of the Grand Banks, based on site-specific surveys done for the White Rose drilling program as well as published data, it is reasonable to infer that geotechnical conditions at the White Rose site will be similar to those at the Terra Nova and Hibernia site.
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Table 8.5-2
Layered Clay and Sand with Cobbles/ Boulders Clay with Cobbles No data below 1.6 m.
2.3 to 8.0 m fine grained sand with clay matrix, numerous stones (good initial strength) 8.0 to 9.0 m stiff grey/green clay
4 to 5.5 m sand, gravel and cobbles/boulder; Friction Angle = 44 Cohesion = 0 kPa 5.5 to 9.5 m layered clay and sand with cobbles/boulders; Friction Angle = 42, Cohesion = up to 28 kPa 9.5 to 16.5 m clay with cobbles and boulders high to low plasticity
Table 8.5-3
Soil Type
Sand, Sand and Gravel Hardpan Sand and Clay (Layers) Clay
Grain Density 2.66 g/cc Ave. cone resistance 1.94 MPa Ave. cone resistance 1.99 MPa
PI: 12-45% PL: 20-40% LL: 32-85% PI: 32-60% PL: 23-40% LL: 55-90%
1.72 1.96
27 - 50
35 - 40
50 - 215
* = derived from direct shear test ** = derived from point load test PL = Plastic Limit: minimum water contact limit at which soil exhibits plastic behaviour (no crumbling), less water and soil passes to a liquid state. PI = Plasticity Index: difference between liquid limit and plastic limit, the water contact range within which the soil exhibits plastic properties. LL = Liquid Limit: maximum water content limit at which soil exhibits plastic behaviour (does not flow), more water and soil passes to a liquid state. Relative Density = the density of a granular material in comparison to the same soil in its densest possible state, which is RD = 100% and a soil in its loosest possible state RD = 0%. Bulk Density = ratio total mass to total volume. Data Reference: Subsea Well Iceberg Protection Study, C-CORE, December 1999.
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Table 8.5-4
Cu = 1000 kPa =37o , c= 36 kPa (single test) Sand, Gravel and Cobbles = 44O , c= 0 kPa Layered Clay, Sand & Cobbles = 42O , c = 0 kPa = 37o , c= 28 kPa, Cu = 150 kPa clay, av. =40o , c= 0 kPa Clay with Cobbles/Boulders = 36o , c= 38 kPa, Cu = 134 kPa It should be noted that drained cohesion values are uncertain. = friction angle. c = cohesion. Cu = undrained shear strength. CIU test = consolidated isotropic undrained triaxial compression strength. Data Reference: Subsea Well Iceberg Protection Study, C-CORE, December 1999.
21%
Past interpretations of biota present in seabed photographs have suggested that the seabed is relatively stable, with relatively little sedimentary transport within the region. This is supported by recent mapping exercises within the region. These clearly display anchor marks from old drilling programs, preserved in sand after 15 to 20 years. The White Rose area is in an area of relatively low seismic activity. The Charlie-Gibbs Fracture Zone Dover Fault, the Newfoundland Transform Fault and the eastern edge of the continental shelf, bound the area. Past seismic events are not well documented for the offshore, particularly for earthquakes with magnitudes less than 5. The Laurentian Channel located along the Newfoundland Fracture Zone is the most seismically active portion of the Newfoundland Continental Shelf. Most of the earthquakes occur in the Laurentian Slope Seismic Zone, and are thought to be associated with the Glooscap Fault part of the Newfoundland Fracture Zone. In 1929, a magnitude 7.2 earthquake occurred, with after-shocks as high as magnitude 6. A re-examination of the data was unable to determine if the slump that generated the 1929 tsunami was the result of an earthquake of approximately magnitude 6 or the result of a mini-slump that coalesced into a major slump. In 1951, 1954 and 1957, earthquakes with magnitudes ranging around 6 occurred in the same area. The White Rose field is located over 650 km northeast of the Grand Banks 1929 earthquake epicentre.
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The area is located on a stable cratonic block and, in common with the Hibernia and Terra Nova sites, is within the seismicity Zone 1. This is based on a scale of 0 to 5. Zone 0 is represented by the Aseismic Gulf of Mexico, while areas of severe seismic activity, such as the Gulf of Alaska are Zone 5. Seabed equipment and anchor piling will be designed accordingly. For water level and current speeds associated with tsunamis generated by offshore earthquakes, see Section 8.3.1 above.
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