How to avoid Major Accidents, Contractors in the Oil and ... · Hazard Identification (HAZID)...

How to avoid Major Accidents,

Contractors in the Oil and Gas Industry.

Project Director Jan-Tore Elverhaug

November 2012

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EPC focus

2

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Kværner Work scopes:

•All scope is related to new plants and units/modules for the oil and gas

industry, prior to installation for operations.

•Work is performed according to clients specifications.

•Scope can consist of:

•Feasibility and concept studies

•System definition and detailed engineering

•Procurement

•Construction and assembly

•Commissioning. (normally assistance to clients)

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ED&S September 2008 Slide 4

How we work

Kvaerners Project Execution Model (K PEM) is based on best practice from

many of the industry’s most challenging projects

K PEM ensures efficient project execution and risk management, for

deliveries on time, on budget and with the agreed quality

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via Slide Master “View”/”Master”/”Slide Master” 06.11.2012

© Kvaerner 2011 5

1A 1B 1C 1D 2A 2B 2C 3A 3B 3C 3D 4A 4B 4C 5A 5B 5C 5D 6A 6B 6C

Op

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Detailing &

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System

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1A 1B 1C 1D 2A 2B 2C 3A 3B 3C 3D 4A 4B 4C 5A 5B 5C 5D

Milestone

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6A 6B 6C

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Focus area related to Major accidents Risk identification and Risk reduction Experience and knowledge transfer

Involvement from all participants in the project

Focus on highest risk and most efficient risk reduction activities

– Design, Product and Technology development

– Planning and execution of activities.

– Choose the correct subcontractors / suppliers

Gate review to identify status on activities prior to proceed.

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Concept selection

Which alternative is the preferred?

Considering potential for major accidents, natural environment, working environment?

Concept definition

The basis for an inherently safe design is made: segregation of the facility info safe and hazardous areas, location of LQ/evacuation means, escape route design, process design, ventilation solution, type of power generation etc.

Concept risk analysis assesses the major accident risk potential

Risk reducing measures (ALARP process) will be assessed continuous

Activities reated to

Major accident prevention

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System Definition

Hazard Identification (HAZID) Systematic review to reveal potential

hazards related systems/areas

HAZOP – Hazard and Operability study Systematic review of each sub part of

process systems to evaluate hazards and operability

Quantitative risk analysis (QRA)

ALARP (As low as reasonable practicable) process

SIL (safety integrity level) and reliability analysis

Human factors analysis

Establish/develop safety philosophies and strategies

Establish/develop performance standards for safety critical barriers

Design of safety barriers

BAT (Best available technology) process

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6-

Nov-

12

Slide 9

Major hazard management - FPSO Example

Compr. gas turbines (ign. source)

Main power

generation

Potential ignition

source (turbine air

intake)

Wind direction

Turret (fire/ explosion potential)

LQ

Process area (fire/ explosion

potential)

Before

After

Utility area serves

as a barrier

between

turret/process

areas and LQ

Potential ignition

sources located

upwind process area

Electric compressors

(reduces ignition

probability)

Wind direction

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10

Project Management

•Fabrication drawings and work

preparation for prefabrication

completed (prefab. job cards) .

Project Execution

•Production of fabrication

drawings

•Preparation of jobcards/work

packages

•Material take off finalised and

bulk material top up orders

placed

•Completion requirement

incorporated in fabrication

documentation

•Issue Isometrics IFC

•Materials on site for use

Project Management

•Implementation of

subcontractors HSE & QA

programs reviewed

Project Execution

•Engineering databases

complete

•All fabrication Bulk Material

delivered

•Shop engineering detailing and

work preparation for fabrication

•Pipe spools, Steel sections and

Concrete sections

prefabricated.

•Deep/major foundations &

trenches completed.

•Construction site temporary

facilities completed

•Hook-up/Commissioning

Subcontracts awarded

Project Management

•HSE program for construction

updated to include Assembly/

Erection phase

•Management Plan documents,

schedules and budgets updated

for next phase (HSE, Scope,

Time, Cost, Quality, People and

Team, Communication, Risk

and Procurement &

Subcontracting)

•Project Management Plan

updated (for next phase)

•Milestone Review held

Project Execution

•Layout and 3D Model as built

mark up of part

assemblies/modules

•All Bulk Material available to

support the Assembly / Erection

sequence

•Part assemblies and

modules/package units

fabricated and mechanically

complete

•Commissioning commenced on

selected systems

Project Management

•HSE program for construction

and completion defined

•Milestones and Detailed

Construction Schedule verified.

•Team Alignment program

continued

•Updated Project Mgmt Plan

implemented

Project Execution

•HSE risk assessment complete

•Close out HAZOP action items

•Final vendor information from

all PO’s incorporated in System

and Area Engineering

•Layout / 3D model

documentation issued for

construction

•Relevant System Engineering

documentation issued for

construction

•Material take off finalised and

bulk material top up orders

placed

•2nd priority FC Subcontracts

awarded

•Hook-up/Commissioning

Subcontracts inquired

•Issue P& IDs IFC (QL4)

Complete 3D model / Layout

design

Prepare and check fabrication

drawings, material, job cards/work

Orders

Complete prefabrication work

Receive and check equipment

Shipment of preassembly/test

mounting

Module fabrication

Module transportation to assembly

site

Commissioning according to

Completion method.

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11

Project Management

•HSE requirements for Assembly & MC

stages established & implemented

•Work permit system established

•Cost, schedule & risk program updated

•Team Alignment program continued


implemented

Project Execution

•Temporary Services & Power

Distribution in place and Site roads

complete up to sub-base.

•Major equipment, Pre- assemblies &

modules transported to site and final

positioned.

•On site fabrication and erection of

major vessels and process equipment.

•Main Structures & Bridges Complete

Project Management

•Implementation of HSE requirements

verified

Project Execution

•Major equipment, Pre- assemblies &

modules assembly installed.

•Install Balance of Plant Equipment and

interconnecting piping systems.

•Minor structures, E & I installation and

Main insulation complete.

•Final Labelling & Identification started.

•Operation & Maintenance Manuals

available.

Project Management

•HSE program for system completion

phase established

•Management Plans, schedules and

budgets updated for next phase (HSE,

Scope, Time, Cost, Quality, People and

Team, Communication, Risk and

Procurement & Subcontracting)

•Project Management Plan updated (for

next phase)

•Phase close-out Milestone Review

Project Execution

•Relevant as built mark-up complete

•Construction work mechanical complete

& quality records available.

•Categorised Punch lists for all systems.

•All systems ready for commissioning

and commenced in accordance with

system completion schedule

•Final Insulation, Labelling &

Identification complete.

Transport and final install the

modules and all components and

pre-assemblies into a complete

Topside, in accordance with the

installation method.

The work is performed at the

assembly yard / onshore plant.

The Topside is MC completed,

ready for commissioning.

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12

Project Management

•HSE requirements implemented

•Relevant documentation

(LCI/DFI/DFO) updated with As-

built and commissioning

information

•Team Alignment program

continued


implemented

Project Execution

•Perform and finalise all

commissioning activities.

•Preparations for start-up

•Temporary items removed.

•Relevant documents updated with

“as commissioned” information

•Punch List cleared for start-up

Project Management

•HSE requirements implemented

Project Execution

•Preparation for sail away

•Perform tow out

•Complete installation of

substructure / moorings / tethers

•Complete installation of the

production facility

•Document offshore

installation/hook-up work MC

complete

•Offshore commissioning

Project Management

•Total HSE program implemented

•Service assistance agreement

established

•Operational responsibilities (if any)

formalised

•Delivery protocol executed-project

contract object handed over

•Mobilise and maintain resources

for Contract Close Out Phase

Project Execution

•All project work completed to

enable issue of delivery protocol

•Punch lists at delivery time

established including identification

of carry over work including POs

and subcontracts

•Method and schedule to close

punch lists (COW) agreed with

Client

Project Management

•Establish agreements on

execution of post start-up

performance and HSE measure-

ments and rectifications

•Management Plan documents as-

built, with lessons learned

•All As-built and LCI documentation

handed over

•Key experience figures

summarised and transferred to

BU/BS

•Issue of Delivery Protocols and

commercial closing of POs and

subcontracts

•Final Account established

•Final revenue/net margin report

issued

•Relevant documentation, BGs /

PCGs and systems handed over to

warranty organisation

•Completion Certificate established.

•Project Close-out report issued

Project Execution

•Punch list / COW including PO

and subcontractor scope

completed

•Complete and release hand-over

documentation

•Subcontractor and third party

invoices closed out

•Completion of Sub-contracts and

POs Final Accounts and

Completion Certificates

•POs assigned to Client if

requested

•Experience/lessons learned

reports issued

Perform onshore commissioning

of the systems in a safe manner,

in accordance with pre-defined

commissioning plans and

procedures.

Transport, Install and hook-up

the Topside and perform

necessary offshore

commissioning.

Perform the hand-over to

operation and close-out the

Project.

© Kvaerner 2012

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or


ED&S September 2008 Slide 13

How we work

Kvaerners Project Execution Model (K PEM) is based on best practice from

many of the industry’s most challenging projects

K PEM ensures efficient project execution and risk management, for

deliveries on time, on budget and with the agreed quality

© Kvaerner 2012

Edit date:


or


6-

Nov-

12

Slide 14

Activities/systems to verify a safe design

PEM – Project Execution Model

Quality Management system

IDC - All relevant documents/drawings shall be reviewed by relevant

disciplines

Design verifications (internal)

Design reviews (internal)

HAZOP

Risk analysis including HAZID

Other verifications (e.g. SIL)

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Copyright and disclaimer

Copyright

Copyright of all published material including photographs, drawings and images in this document remains vested in Kvaerner and third party contributors as appropriate.

Accordingly, neither the whole nor any part of this document shall be reproduced in any form nor used in any manner without express prior permission and applicable

acknowledgements. No trademark, copyright or other notice shall be altered or removed from any reproduction.

Disclaimer

This Presentation includes and is based, inter alia, on forward-looking information and statements that are subject to risks and uncertainties that could cause actual results

to differ. These statements and this Presentation are based on current expectations, estimates and projections about global economic conditions, the economic conditions

of the regions and industries that are major markets for Kværner ASA and Kværner ASA’s (including subsidiaries and affiliates) lines of business. These expectations,

estimates and projections are generally identifiable by statements containing words such as “expects”, “believes”, “estimates” or similar expressions. Important factors that

could cause actual results to differ materially from those expectations include, among others, economic and market conditions in the geographic areas and industries that

are or will be major markets for Kvaerner’s businesses, oil prices, market acceptance of new products and services, changes in governmental regulations, interest rates,

fluctuations in currency exchange rates and such other factors as may be discussed from time to time in the Presentation. Although Kværner ASA believes that its

expectations and the Presentation are based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual results

will be as set out in the Presentation. Kværner ASA is making no representation or warranty, expressed or implied, as to the accuracy, reliability or completeness of the

Presentation, and neither Kværner ASA nor any of its directors, officers or employees will have any liability to you or any other persons resulting from your use.

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How to avoid Major Accidents, Contractors in the Oil and ... · Hazard Identification (HAZID)...

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Transcript of How to avoid Major Accidents, Contractors in the Oil and ... · Hazard Identification (HAZID)...