07 HSE Ageing & Life Extension Inspection Programme_Stacey_HSE

8/9/2019 07 HSE Ageing & Life Extension Inspection Programme_Stacey_HSE

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HSE AGEING & LIFEEXTENSION INSPECTION

PROGRAMME

Alex Stacey

Offshore DivisionHealth & Safety Executive


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PRESENTATION OUTLINE

● Ageing on the UKCS

Background information

Importance to HSE / Industry / Stakeholders

Regulations

● HSE / OSD activities on Ageing

Related interventions

Guidance

S&T

Pilot Study on Ageing Installations• Scope• Inspection findings

● Ageing & Life Extension Inspection programme

Programme scope


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UKCS Installations (DECC)

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50

100

150

200

250

300

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1 9 9 4

1 9 9 6

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2 0 0 0

2 0 0 2

2 0 0 4

2 0 0 6

2 0 0 8

Year of first oil/gas

N o o f

U K C S i n s t a l l a t i o n s i n p r o d u c t i o n

Small steel jacket

Large steel jacket

Jackup

Concrete GBS

Semi-sub

FPSO

TLP

108 installations

>25 years old

146 installations

>20 years old


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RENEWED FOCUS ON AGEING

AND LIFE EXTENSION

● Traditional models of dwindling reserves & increasing

O&M costs predict end of life

● Enhanced recovery methods and the good market drive

life extension

● Is asset being managed adequately?

C a s

h F l o w

time

Probability of endof life

revenue

Cost (ops &

maintenance)


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AGEING PRODUCTION

0

1

2

3

4

5

6

7

8

1 9 7 8

1 9 7 9

1 9 8 0

1 9 8 1

1 9 8 2

1 9 8 3

1 9 8 4

1 9 8 5

1 9 8 6

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1 9 8 8

1 9 8 9

1 9 9 0

1 9 9 1

1 9 9 2

1 9 9 3

1 9 9 4

1 9 9 5

1 9 9 6

1 9 9 7

1 9 9 8

1 9 9 9

2 0 0 0

2 0 0 1

2 0 0 2

2 0 0 3

2 0 0 4

2 0 0 5

2 0 0 6

2 0 0 7

Year

A n n u a l o i l p r o d u c t i o n ( M i l l i o n c u . m

)


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2007 Supply - Reliance on Older

Fields

0%

2%

4%

6%

8%

10%

12%

14%

16%

0 5 10 15 20 25 30 35 40 45

Age of installation

P r o p o r t i o n o f p r o d u c t i o n f r o m f

i e l d

Oil

Dry gas

Associated gas

Buzzard

FortiesElgin

Foinaven

Britannia

Morecambe S

Rough

Leman Per.Leman Shell

West SoleViking

Beryl

Brent

Beryl

Brent

MagnusNinian

Claymore


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LOSS OF INTEGRITY

● Ageing: Potential for accumulating and / or acceleratingdamage and subsequent loss of integrity

● Need to focus on asset integrity management (AIM) ofageing (organisational issues, inspection, technology)

● Need:

good data on current condition

understanding of degradation processes &response

use of best technology / latest assessment methods(e.g. system strength) to determine safety margins

development of new techniques (e.g. onlinemonitoring)

implementation strategy


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EXAMPLES OF DETERIORATION

Door on TR HVAC room Cellar deck grating support steel work

Elect/Inst cables & tray Main truss below lifeboat


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EXAMPLES OF DETERIORATION

Blast wall connections


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KP3: ASSET INTEGRITY KEY

PROGRAMME

● KP3 Aim

‘To ensure that duty holders manage effectively the risk ofany failure of structure, plant, equipment or systems, whichcould either cause or contribute to, or prevent or limit the

effect of, a major accident and / or cause fatalities.’

● KP3 Focus

The integrity management of safety critical elements

(SCEs), which provide the barriers to major accidenthazards

Concentrated on the current condition of key assets, notthe management of future integrity / ageing issues


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KP3 BACKGROUND

● Weaknesses in the implementation of theindependent verification process

● Emphasis on costs (resulting in reduced manningand multi-tasking) affecting potential safetyperformance

● Backlog of maintenance work

● Significant incidents due to maintenance or integrityfailures


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AGEING SCENARIOS

● Time-dependent mechanisms

Fatigue (welded connections, piles, supports)

Corrosion

Creep (non-metallic components)

● Damage or deterioration over time

Accidental damage (ship impact, dropped objects – cumulativeeffects)

Environmental overload

Geological & geotechnical (subsidence, scour, pile failure)

● External changes with time New technologies / understanding

More stringent standards

Failure to adapt to change

Obsolescence

Loss of knowledge base


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UK REGULATORY PROVISIONS

FOR AGEING

● SCR (2005): 5-yearly safety case ‘thorough review’ and revision

● Safety case revision if proposed to extend use beyond design life

(Explicit reference to ‘life extension’ clarifies the need for specific consideration)

● DCR (1996):

Periodic maintenance / remedial work Performance standards

Independent verification by ICP

● PFEER (1995): inherent safety by design, preventive, detection, control and mitigation measures

● PUWER (1998): control of hazards due to equipment failure; requirement for appropriateinspection and maintenance procedures to be in place

● PSR (1996): life cycle requirements to maintain pipeline ‘in an efficient state, in efficient working order and in good repair ’;

identify hazards, evaluation of risks (including susceptibility to damage)

● HSWA (1974) / MHSWA (2003)

● Use of modern codes & standards, good practice (e.g. HSG65):

- Policy, Organisation, Planning, Maintenance, Audit, Review


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Safety Management System (OGP)


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OSD ACTIVITIES ON AGEING

● Technical policy and strategy on ageing (structural integrity)

● Thorough Reviews & Safety Cases

● Inspection

SIMIP

Pilot study on ageing installations (2009)

Development of full inspection programme on Ageing & Life Extension: 2010 - 2013

● S&T Technology projects, e.g.:

• SI: SIM, overview of ageing on UKCS, life extension, new technology, review of worldwidepractices, structural monitoring, mobile installations issues, fatigue, residual stresses,materials

• Corrosion Standards and guidance, incl. HSE Information Sheet 4/2009 on Thorough Review guidance

● Stakeholder engagement Dissemination (e.g. OMAE, PSA, IMechE, IChemE) Ongoing collaboration with PSA, Norway Ageing Network (2010 / 11)


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STAKEHOLDER ENGAGEMENT:

HSE / PSA COLLABORATION

● Regular HSE / PSA meetings (AS / Gerhard Ersdal, Rolf Hinderaker,Erik Hørnlund)

● PSA seminar ‘Ageing Installations & Life Extension’, 25 May 2007

● PSA seminar ‘Ageing Installations & Life Extension’, November2007

● OMAE conference, HSE / PSA Workshop on Ageing, June 2008

● HSE / PSA Ageing meeting, February 2010

Structural integrity, corrosion, F&B, process integrity, mechanicalintegrity, electrical & control systems, pipelines

● PSA Seminar on Ageing & Producing Life Extension, 7-8 April 2010


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OSD ACTIVITIES ON AGEING

● Technical policy and strategy on ageing (structural integrity)

● Thorough Reviews & Safety Cases

● Inspection

SIMIP

Pilot study on ageing installations (2009)

Development of full inspection programme on Ageing & Life Extension: 2010 - 2013

● S&T Technology projects, e.g.:

• SI: SIM, overview of ageing on UKCS, life extension, new technology, review of worldwidepractices, structural monitoring, mobile installations issues, fatigue, residual stresses,materials

• Corrosion Standards and guidance, incl. HSE Information Sheet 4/2009 on Thorough Review guidance

● Stakeholder engagement Dissemination (e.g. OMAE, PSA, IMechE, IChemE) Ongoing collaboration with PSA, Norway Ageing Network (2010 / 11)


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HSE GUIDANCE ON THOROUGH

REVIEWS - OIS 4/2009

● Thorough review of the safety case

Thorough review summary

Asset life extension

● Management of ageing Fire and explosion risk assessment

• Risk assessment • Options for addressing ageing

Structural integrity

• Structural integrity management • Life extension

Performance indicators

Organisational issues

● Issues with ageing


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AGEING SI S&T: 2008 - 2011

● Framework for the Structural Integrity Management of Fixed Installations

● Framework for the Structural Integrity Management of Mobile Installations ____________________________________________________________________

● Review of Classification Society Rules for Floating Installations on the UKCS

● Evaluation of Worldwide Practices on the Structural Integrity Management and

Regulation of Ageing Installations● Overview of the UK's Ageing Offshore Infrastructure

● Techniques and Technologies for Ageing Jacket Integrity ____________________________________________________________________

● Review and Appraisal of Current Structural Integrity Monitoring Technologies forOffshore Applications

● Review and Assessment of Material Property Requirements for Mobile Installations

● Further Study of Fatigue Damage to Girth Welds From Low Stresses in theLoading Spectrum (JIP)

● Investigation of Residual Stresses in Welded Joints (JIP)


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AGEING & LE INSPECTION

PROGRAMME

● Pilot study on ageing installations: 2009

3 duty holders

Generic management, Structural integrity, Fire & explosion,Corrosion, Pressure systems integrity

Set of standard questions for each topic area – ‘templates’

● Ageing & LE Inspection Programme: 2010 - 2013

Review of findings from pilot study

Development of full programme for 2010 – 2013


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PILOT STUDY

Inspection Overview

Serious deficiencies

requiring immediate

attentionMatters raised

formally linked to

ongoing work or

change

No matters needing

formal raising withthe DH

No consideration of

or management of

ageing

Awareness of

ageing. Some

evidence of ageing

being managed.

AIM system takes

full account of

ageing

Duty

Holder Platform

Structural

Integrity

Fire &

ExplosionCorrosion

Pressure

Systems

Integrity

DH1 P1

DH2 P2

DH3 P3


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PILOT STUDY

Key Findings

● Findings to date suggest lack of full recognition of the significanceof ageing processes in connection with life extension beyond theoriginal design life

● Ageing not considered explicitly

● Varied approach between DHs and topics – asset maintenancenot always a high priority

● Influence of commercial pressures on AIM

● Reliance on contractors and ICP● All 3 DHs aware of OIS 4/2009 (HSE website)

● All 3 DHs receptive to an industry forum on ageing issues


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PROGRAMME 2010 - 2013

Aims:

● to inspect DHs’ safety management systems with

respect to the arrangements for the thorough review of safety cases

the management of the risks to asset integrity associated withageing and life extension

● to identify shortcomings in duty holders’ approaches● to develop improved practices to ensure the safe

operation of all offshore installations on the UKCS


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PROGRAMME 2010 - 2013

● Full programme: 2010 – 2013

● Launch: 19 May 2010, Aberdeen

● Supported by policy and strategy documents

● Ageing fixed and mobile installations

● Inspection of DH AIM systems - special focus on key installations

● Onshore and offshore inspections

● Topic areas: structural integrity, process plant integrity, pressure

systems integrity, materials (including corrosion), mechanicalintegrity, maritime integrity, electrical & control systems integrity,wells, pipelines, organisational issues


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INSPECTION PROGRAMME -

Supporting Activities

● Stakeholder engagement

Press releases

Dissemination (workshops, seminars, conferences, journals, etc.)

Liaison with key industry bodies (e.g. OIAC, Step ChangeIn Safety, Oil & Gas UK, IADC, BROA)

Ageing webpage

● S&T on A&LE aspects of AIM

● Review & updating / development of standards and

guidance, incl. OIS 4/2009 on Thorough Review

Guidance

INSPECTION PROGRAMME


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INSPECTION PROGRAMME –

Key Outputs

● Final report

● Guidance on Ageing, Life Extension & the Thorough Review

process

● Industry network for the exchange information and

experience on ageing and life extension issues

● Development of best practice on ageing

● Improved asset integrity management


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PRESENTATION OUTLINE

● Ageing on the UKCS

Background information

Importance to HSE / Industry / Stakeholders

Regulations

● HSE / OSD activities on Ageing

Related interventions

Guidance

S&T

Pilot Study on Ageing Installations• Scope

• Inspection findings

● Ageing & Life Extension Inspection programme

Programme scope


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07 HSE Ageing & Life Extension Inspection Programme_Stacey_HSE

Documents

Transcript of 07 HSE Ageing & Life Extension Inspection Programme_Stacey_HSE