Integrity; know your weak spots

Inspection management, integrity & corrosion prevention

2

Agenda

1. Approach2. findings 2008 &20093. Integrity4. Fort Eben Emael5. Seek for weak spots and threads 6. Improvement7. Inspection results8. Recommendations9. New threads10. AOB

Staatstoezicht op de MijnenMinisterie van Economische Zaken

3

Approach• Joined inspections with HSE UK for external corrosion project.• Step Change In Safety asset integrity toolkit as guideline.• 9 Dutyholders and 20 visits.• Incident analyses.• Database SodM gas leakages, general leakages and spills.• PDCA cycle central in project.


4

Findings in 2008 & 2009?

Positive; Dutyholders are improving on integrty. Organizations are adjusted to new insights ( based on the ‘Baker Panel report’). Information from inspections, audits and maintenance reports is frequently linked and analyzed holistic to get a total view on integrity

Still all duty holders have incidents.Analyzing gas leaks and spills points to good management on systems and disciplines but a failing integral management system.

17% instrumentation failures 50% technical failures16% hoses / couplings / flanges 34% during operat./maint. activities10% overflowing diesel / skimmer tanks


5

Integral auditing on integrity

Only few duty holders have a structured audit system on the technical integrity to know the status of the complete offshore installation. Audits are made on systems like pressurized equipment, maintenance system and organisation (ISO 901).


good

Verry good

improvement needed failing system

maintenance

pressurized-

equipment

organisation

6

What is integrity?ASSET INTEGRITY OF A FACILITY IS ACHIEVED WHEN THE RISK OF FAILURE ENDANGERING THE SAFETY OF PERSONNEL, THE ASSET VALUE OR THE ENVIRONMENT IS AS LOW AS REASONABLE PRACTICABLE.

ASSET INTEGRITY is a continuous process of knowledge and experience applied throughout the lifecycle to manage the risk of failures and events in design, construction, and during operation of facilities to ensure optimal production without compromising safety, health and environmental requirements

What is the integrity core idea?


7

Intermezzo

Know your weak spots!


8

Fort Eben EmaelBelgium 1939. Eben Emael is a giant fortress. 17 bunkers from various types. Total fire power: 2100 kg. a minute. An impressive piece of Belgium defense. Inside this fortress, 60meter under the top, underground barracks for 1.200 soldiers. Military experts from various countries agreed that this fortress was one of the strongest in Europe. To concur this fortress was impossible!


9

The fall.

Guess how much time the Germans needed to get control on the fortress?

Answer: 15 minutes and a 71 crew!


10

New threats; Para's, gliders and the hollow charge


11

The fortress strength was its weakness! To convinced of their own strength.Design based on WO I.No studies or analyzes on new threads.Operational, no plan B.Artillerists not trained on man to man battle.Low moral.

The bottom line was that the fortress failed on organization, technology and human skills

The fortress was NOT sound!

DesignIntegrity

TechnicalIntegrity

(maintenance / inspection)

OperationalIntegrity

AssetIntegrity


12

Know your weak spots!

Integrity is not about your strength but about to know your weak spots!


13

Seek for weak spots and threads

Active investigation to weak spots in

technology and organization.

HAZOP's, audits, etc.

Involve your workforce in

integrity. Create ownership!

Use independent verification and

reports.

Weak spots are no threads if you


14

Gaslekkages totaal Nogepa gas leak data base

2003 2004 2005 2006 2007 2008

0

10

20

30

40

50

60

70

80

90

aan

tal

Overige lekkages totaal uit MIS (exclusief gaslekkages)

2003 2004 2005 2006 2007 2008

0

10

20

30

40

50

60

70

80

90

100

aa

nta

l

Improvement possible


15

Inspection results

Positive:

• Audits • A lot focus on maintenance and inspection.• External corrosion a lot better than in the UK.• TCVT certification scheme for offshore cranes improves safety.


16

Recommendations

Secure technical integrity.

Use reports and independent verification to improve.

Involve your workforce in integrity. Create ownership to improve.


17

New threads

Aging workforce. Ownership and experience can get lost. Life time extension installations. Is everything covered?Credit crisis, cut cost.Organization, information management.New design philosophies.Verification by NoBo' s???????????????????


18

Questions / AOB

Real strength is to know your weak spots.

Be open minded and seek for threads.

A planned audit system is one way to improve integrity.


Integrity; know your weak spots

Documents

Transcript of Integrity; know your weak spots