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)
0
50
100
150
200
250
300
1 9 6 8
1 9 7 0
1 9 7 2
1 9 7 4
1 9 7 6
1 9 7 8
1 9 8 0
1 9 8 2
1 9 8 4
1 9 8 6
1 9 8 8
1 9 9 0
1 9 9 2
1 9 9 4
1 9 9 6
1 9 9 8
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
1 9 8 7
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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AGEING & LE INSPECTION
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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AGEING & LE INSPECTION
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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