Report from Axess AS February Magazine

Transcription

1 Report from Axess AS February 2013 Magazine safe lifting operations

2 Leder General Manager, Børge Gjeldvik A LIFTING OPERATION IS NOT SIMPLY A LIFTING OPERATION client oriented and solution focused organization Since starting up in the late nineties the company has developed rapidly from the initial inspections of offshore installations based on access technique. This is a vital part of our operations even today, but Axess has grown to cover a much wider field. The development has been gradual and we have competent employees who have contributed to making Axess what it is today. More than 240 skilled staff are employed by the company which is a leading player when it comes to inspection, integrity management, design and construction in the offshore and energy industry. The working environment is characterised by sporty, outdoor people used to looking after themselves and the people around them. This is also evident in the company culture and in the way the company reasons. One of our most important areas of priority is advanced lifting operations. We have developed a unique skill in this field and we can take on the most complex lifting operations. It is not just about a lifting operation. Detailed planning is necessary to find the best way to do the job. The job must then be carried out in a safe and efficient manner and finally we must submit documentation for the job done. This must all be done in a way that meets the requirements of the authorities, the clients and, last but not least, our own requirements regarding safety and efficiency. We are our strictest critic and must always stay ahead of the rules and regulations in force. We know that more and more players consider hiring Axess for advanced lifting operations. This shows that we are on the right track and that our clients are satisfied with us and the processes we run. In this edition of AxMag we will concentrate on our competency in connection with cranes and lifting operations, as well as inspection and integrity management. Wishing you a good reading! Regards, Børge Gjeldvik General Manager Inspection & Integrity Management Maintenance management Structure Integrity management Inspection planning/rbi Lifting and Drilling Equipment Certification DROPS In-service Inspection Electro Inspection Engineering & Construction Crane maintenance and modification Design/analysis of complex structures Advanced lifting and skidding operations with RAT Delivery of tailor made cranes and tools AXESS Inspection services Inspection/QC NDT services Pipeline Products, Technology & Innovation Custom ultrasonic tools Innovation projects Product development 2 AxMag - October 2012 A report from Axess AS 3

3 safe lifting in demanding ENVIRONMENTS Safe lifting operations is a focus area in the offshore industry. A strict regulatory framework governs the planning and implementation of lifting operations. Each lifting operation is unique and the combination of formal qualifications and extensive experience is the base of success to achieve a safe and efficient execution. This field has received increased attention over the last few years due to a number of serious incidents. The number of incidents involving falling objects is one of the things the clients note and the consequences of such incidents are significant. Axess therefore carries out thorough planning and method studies to eliminate risk. We also hold short seminars on Norsok R-002 and R-003 for our clients to increase the knowledge of the regulatory framework. This keeps both the clients and us on our toes. According to Norsok R-003 all lifting operations must be planned in advance. In the planning phase the focus is on finding the best method to implement a safe and efficient lifting operation. When a method has been selected, the planning work continues by implementing relevant regulatory requirements, facility specific requirements and procedures as well as our own procedures for safe lifting operations. When the actual lifting operation starts we concentrate on staff continuity in order to transfer the quality of the planning phase to the implementation phase. The use of skilled personnel with the right formal and practical background throughout the lifting operation, from planning to implementation and follow-up, contributes greatly to our success, says Magnus Gabrielsen, focal point for safe lifting operations in Axess. from start to finish A lifting operation involves more than just lifting. A lifting operation includes all administrative and operational activities before, during and after a load has been shifted. Staff continuity is an important factor in succeeding with a safe lifting operation. Through our framework agreement with Statoil as specialists in complex and not complex lifting equipment we have on several occasions experienced that the planning of a lifting operation has not been adequate in connection with installation of equipment. The focus of the manufacturers is often on optimum functioning of the equipment on installation and the client does not always have enough knowledge of the regulatory framework for lifting operations. This has resulted in manufacturers supplying equipment not prepared for lifting, thus making installations considerably more expensive and time-consuming for the client. We aim to be involved at an early stage in this kind of project to be able to contribute to an optimum installation with regard to safety and efficiency. This will also be more relevant when Norsok R-002 now imposes stricter requirements for design and certification of lifting equipment. Axess takes responsibility for the entire project, from feasibility studies to complete installation. In order to take this kind of responsibility the company is completely dependent on having the person with the right competency and relevant experience in the right place. To us it is important that the people we choose to execute the different stages of the job are experienced in offshore work, that they know what the job involves and have a first hand knowledge and understanding of the regulatory framework currently in force. This is one of the fields in which we excel, says Gabrielsen. specialist operations There are a number of regulatory requirements regarding both the equipment and the methods used in offshore lifting operations. On the way from shore base to installation an object will come under several regulations for lifting. Lifting operations are often associated with downtime or the use of equipment at high day rates. Economic interests always push for a time-efficient lifting operation, ie. to achieve a safe lifting operation which is also time-efficient, and this puts stiff demands on skill and planning. Axess is a specialist business with its own specialist department. The regulatory framework often lays down requirements regarding the hiring of a specialist business in connection with lifting equipment and lifting operations, for instance when a temporary suspension point for loads weighing more than two metric tons is used. In each project relevant regulatory and documentation requirements are defined by a team of engineers who plan the lifting operation together with the people from the specialist department. flexibility and efficiency The offshore industry has safety at the top of their list of priority. And right behind we find another priority: efficiency. Two lifting operations are never alike. The projects vary and there are a number of rig specific requirements and common for them all is the requirement that a lifting operation must be carried out in a safe and efficient manner. There are rig specific requirements for every single project and we constantly look for methods adapted to the specific project in question. It is about having an understanding of the regulatory framework that enables us to optimise the lifting with regard to safety and efficiency. If for instance we exaggerate the lifting capacity, the efficiency will be affected. We must calculate for both efficiency and safety and find the right method, Gabrielsen explains. 4 AxMag - October 2012 A report from Axess AS 5

4 Illustration: Crane analysis safe upgrading of cranes The challenge with upgrading of cranes is to be in control and be absolutely sure the safety systems can be trusted and that they are designed in accordance with the current regulatory framework.our force is that we have been working with cranes and crane regulations for more than 20 years. Without being inflexible, we contribute with solutions which improve the safety on oil installations. a strong crane environment The Axess crane environment possesses peak competence in regulatory comprehension in connection with crane modifications. We use this competence to assist our clients in the different stages of the job, without flexibility and creativity having to suffer. This is one area where we must know the legislation to the letter and at the same time have the ability to find the best solution for each individual project. Our advantage over our competitors is that we can assist the client in all the stages of a modification project, says Stian Blø, focal point in Axess. undertakes the most complicated jobs Since the start in 1998, the company has gradually developed its expertise on cranes and lifting for the offshore industry. The company, which from the start has been a specialist company, is today considered an expert on cranes and lifting, able to undertake complicated modification processes and lifting operations offshore. We can assist with studies as background material for decisions on what it is possible to do with the existing cranes. We can for instance act as consultants to a third party and offer advice on crane procurement and specifications as well as assist the client with crane replacement and upgrading, whether it be small Davit cranes and overhead cranes or large offshore cranes. We enjoy a challenge and are more than happy to take on the most complicated jobs, says Blø. Over the last few years Axess has carried out several large modification jobs on deck cranes on drilling rigs such as Transocean Arctic and Transocean Winner as well as major upgrading of both steering system and capacity of BOP cranes. Our framework agreements with Statoil and several rig companies enable us to continue to progress so that we are able to stay ahead when it comes to future regulations. Terje Aamodt. Over the last five years Axess has been involved in projects to replace and upgrade deck cranes on more than 15 North Sea installations. Our involvement spans from feasibility study to fully installed and certified crane. Our force lies in the use of Norsok R-003 during installation, NMD 854/En in design and Norsok S-002 in HES. FACTS AXESS LOAD RECORDER THE WAY TO AN ETERNAL AND SAFE LIFE? Unfortunately, we cannot meet the wish for an eternal life for a crane. We can however contribute to a safe implementation of jobs and a longer service life for cranes. The load analyser, Axess Load Recorder, was fully developed in 2012 and is in high demand. At the present time, there isn't an equivalent system on the market. What sets this system apart from the others is the "black box" function which logs data continuously. Information may be extracted in the event of an incident during the lifting operation. The data appear directly on a screen enabling the client's expert to deal with the problem right away. longer service life One of the great advantages of the system is the service life monitoring which goes right down to component level. At the same time, we have complete control of all the lifting operations carried out during the service life of the crane and we also have control of load distribution and machinery. The system includes a maintenance calendar based on running hours as well as a regular maintenance calendar. All this enables the client to do a thorough assessment of the maintenance requirements at all times and thus prolong the service life of the crane. Question: - What is the total strain on the lifting equipment over a period of time? - Has the crane been exposed to overloading? - Is it possible to go back and learn anything about the incident? Reply: Axess Load Recorder answers these questions. It provides you with an online tool offering a complete list of service life analyses of the structure and machinery of the lifting equipment, available online at any time. Key parameters are stress cycles, running hours, S.W.P. calculations, spectrum factors, log showing past overloading and load distribution. Axess Load Recorder full online overview. 6 AxMag - October 2012 A report from Axess AS 7

5 REPLACED ÅSGARD'S HEART FROM MOUNTAIN TO PLATFORM Look at these two pictures. What do they have in common? At first sight, nothing. However, if you do a more thorough thought exercise you will find a number of similarities between these two very different elements, and most of them are about risk understanding. The Axess environment is characterised by sporty, outdoor people used to looking after themselves and the people around them. This is also evident in the company culture and in the way the company reasons in business matters. The methodology is the same. If you are going skiing in the mountains, you start making assessments the moment you get up in the morning. Through the window you see if the weather is good, you check the temperature and the online weather service to see if the weather will last through the day. Your rucksack has already been packed containing probe pole, avalanche transceiver, spade and helmet. Once on the way, you assess the slopes ahead and maybe you also check the profile of the snow and do a snow stability test. What you are doing is to assess the risk and take steps to eliminate the risk. You simply plan for a safe trip for yourself and your companions. Project planning is about understanding how to do the job, have the right equipment, no more or no less than what you need. And you must make sure you haven't forgotten anything. It would be critical not to have a spade if your companion is hit by an avalanche. You must have the ability to predict what may happen. If so, you have what is needed to take the right decisions and measures. We must always identify the critical stages and reduce the risk. This applies to ski trips as well as work on offshore platforms. The safest regulatory framework of our industry is our own, but since we are such a small company one person may influence how the rest of the company performs, says Trond Stokke, senior engineer in Axess. Skipicture: Søndre Venjetind, Romsdal. grapher: Øyvind Høgset. In 2011, Axess was involved in a complicated job replacing the swivel of the Statoil-owned vessel Åsgard A. Axess was subcontractor of Agility Group (former Grenland Group) and contributed with its competence in the choice of method and the actual implementation. The swivel was approx. 15 metres high and weighed more than 150 metric tons. The swivel is often called the heart of an FPSO (floating production) vessel, it is the device linking the vessel to the underwater installation on the sea bed. Everything - from produced oil, gas export, water injection, hydraulics, methanol, low-voltage and high-voltage - passes through the swivel making it a relatively complex device. The said project was carried out in 2011 during a two months shutdown on Åsgard A and the planning and implementation were very demanding. good planning, speedy implementation Efficiency and good planning are essential to avoid costly downtime. We had an extended responsibility for the planning and implementation of all offshore lifting and rig operations. The purpose of replacing the swivel during the shutdown in 2011 was to ensure that the vessel would have a service life corresponding to the current plans for the future. It has been a demanding project with a great many interfaces and complex technical solutions and we in Statoil are very pleased with both the result and the implementation, says Geir Mæland, head of engineering in Statoil. And he continues; It has been a challenging project as regards HES. Many and heavy lifts in a narrow area on a vessel in continuous motion required meticulous advance preparations and good risk management along the way. The focus on HES has been strong and according to feedback from the shutdown team and platform management, the key to a safe and successful operation was to assign a large number of dedicated and proficient resources to the job. One criterion for success was the good cooperation between project and operation. Our suppliers on board have also worked well together and shown great flexibility. Illustration Replacing a swivel. (Agility Group) 8 AxMag - October 2012 A report from Axess AS 9

6 ADVANCED THRUSTER REPLACEMENT ON NORNE The Statoil-owned vessel Norne has produced and stored enormous quantities of oil since it was put into operation in the late nineties. The FPSO (floating production, storage and offloading) vessel operating on the Norne field off the Helgeland coast of Norway has since 2000 made use of Axess' expert competence in planning and lifting operations in connection with replacement of thrusters. The method used before us becoming business partners was time-consuming and not very automated. It is commonly known that the word inefficiency is not very highly valued in the petroleum industry. We developed specialised lifting equipment for the lowering and raising of thrusters which takes place from the inside of the Norne vessel. Our solutions contribute to a safe, secure and considerably less timeconsuming execution. HES is given top priority in this kind of operation. With good planning and extensive experience in safe lifting operations we ensure safe and good solutions in cooperation with our clients, says Jostein Tverdal, head of engineering installation in Axess. Besides working with Statoil we also work with Deep Ocean which contributes with crane and ROV vessels (remote-controlled underwater vessel). Axess is responsible for the stages taking place onboard the Norne vessel in connection with thruster replacement: from planning and HES measures to mechanical dismantling and installation plus installation of lifting equipment and implementation of the lifting operation. The vessel s narrow working space is a challenge and the deck capacity is small compared to the amount of suspension points. The most critical point of the operation is when the thruster lands on the deck of the crane vessel: that is when the Norne vessel and the lifting vessel are linked. We must at all times take possible flaring, underwater risers and significant wave height into consideration. All this necessitates good planning and established routines, says Tverdal. Statoil. FACTS FPSO vessel An FPSO (floating production, storage and offloading) vessel is a floating vessel used in the offshore oil and gas industry for treating hydrocarbons and for oil storage. An FPSO vessel is designed to receive hydrocarbons produced on nearby platforms or frames, treat them and store oil until it can be transferred to a tanker or transported through a pipeline. FPSO vessels are preferred in not developed offshore regions as they are easy to install and do not require a local pipeline to export the oil. An FPSO vessel can be a converted oil tanker or a purpose built vessel. 10 AxMag - October 2012 A report from Axess AS 11

7 Terje Aamodt. OUTSTANDING MATERIAL HANDLING SYSTEM Loads for monorails, pulleys and lifting eyes Rigging equipment and loose lifting equipment Material handling through shafts and hatches Standardisation of lifting equipment limiting the amount of types of equipment Based on experience we also see that a lot of installed equipment lacks methods and lifting points for service and replacement. We therefore recommend that material handling is assessed on a continuous basis in the design and construction phases, thus saving large amounts of money for our clients on modifications and new installations as well as improving the working environment on board. offshore cranes There are strict requirements regarding the placement of an offshore crane. It is important to choose the right place for the crane and by this we mean that the position of the crane operator must be optimal for him to have an overview of the areas to be serviced by the crane. The planning must also facilitate material handling with a minimum of lifting operations as well as sufficient space for safe temporary storage. Lifting in blind zones is a very poor solution. It is therefore important to optimise the crane and the lifting paths for the most normal lifting operations. The material handling on an offshore installation should be characterised by systematic efficiency and extreme focus on safety. This will give reduced downtime, if any, and consequently increase the economic margins. This requires a well-oiled logistics system and good planning. Not everybody is able to deliver this. We have developed a unique method for development and presentation of the company s material handling plans. This applies to methods for information gathering on board, information processing on shore and delivery to clients. Our customers can access the material handling plans directly in our online material handling database. The Petroleum Safety Authority Norway demands that all mobile installations on the Norwegian continental shelf must have a material handling plan. The requirements are specified in Norsok R-002 which together with other Norsok standards provides guidelines for the content of a material handling plan. There are many considerations to take into account in the planning of material handling on board. Especially the need for storage space will vary, dependent on the operational phase of the installation. For example, different operations will have different need for storage space. new installations It is about facilitating work spaces and lifting devices with a view to maintaining a safe, secure and efficient material handling. This applies to the outside as well as the inside of the device. For new installations Norsok R-002 requires documentation of offshore crane studies and general material handling. As for the general section, Axess can assist with following: Evaluation of simultaneous crane operations on deck - this may also be verified and substantiated by a 3D design tool Protection requirements in case of falling objects Goods handling to/from helideck Terje Aamodt This is what Axess supplies Material handling plan in compliance with Norsok R-002, requiring among other things: Description of all material handling equipment. Description of standardised dimensions, foundations and suspension points of the lifting equipment. Requirements regarding certification and marking of foundations and suspension points of the lifting equipment. Description of the most important methods of material handling in connection with internal transportation on the installation. Description of function, size and location of storage space. Description of any element to be handled weighing more than 25 kilos, including identification number, location, weight, dimension, expected maintenance/replacement intervals, type of lifting equipment, lifting/ handling procedures, transportation route, etc. 7 Requirements regarding transportation routes/roads including the width and height of the different areas. 8 Description of goods handling to/from the helideck. 9 Description of the handling of loading hoses including replacement of hoses. 10 Description of areas requiring special protection of equipment. 11 Material handling drawings based on drawings of equipment placement or 3D plans including pipes and valves including: The entire amount of equipment to be handled, including lifting ears, monorails, access roads, etc. A table showing identification numbers of the equipment to be handled including corresponding identification numbers of the lifting equipment to be used Loading capacity for areas and transportation routes/roads 12 AxMag - October 2012 A report from Axess AS 13

8 INTEGRITY MANAGEMENT AS A tool FOR PRODUCTIVITY AND SAFETY Model - Continuous improvement Resources Maintenance programme Planning Result More than 50 per cent of the oil and gas installations in the Norwegian sector have turned 20 years. This has consequences for the maintenance of installations. In order to maintain maximum production and zero damage it is necessary to be in control of the technical state of the installation at all times. It is the management s responsibility to safeguard the operations and control the risk, but the different operators are also involved in risk management to avoid damage and unforeseen costs. This means that we depend on skilled and knowledgeable engineers with risk management ingrained. The majority of those working in Axess are fond of outdoor activities, they are used to assess risks and find good solutions when on trips. Whether it is a summit trip, a mountain hike or on an oil installation the attitude to safety and precision is ingrained. Our skilled and knowledgeable engineers in overalls shut down any findings or deviations from measurements and inspections. Consequently, we don't have to send out personnel several times to finish a job and it is therefore cost effective. Integrity management must be established already in the development phase of an installation and every stage, from start to finish, must be taken into account. One focus area of integrity management is the importance of making the right decisions early on in the construction and manufacturing phases. The reason being that you should be able to build an installation using the best possible solutions before the next phase - the operation phase. The focus area in the operation phase will be to monitor and make status reports identifying the need for inspection, repairs/replacements and modifications. In connection with establishing technical integrity Axess can assist with the following: Certification of lifting and drilling equipment Material handling plans Inspection of falling objects (DROPS) Crane engineering services Electrotechnical inspection Inspection of systems under pressure Structure maintenance Maintenance management Axess has wide experience from more than 50 drilling units (jack-up/semi-sib, drill ship) and FPSO vessels. continuous improvement Axess contributes to continuous improvement by using experienced engineers in the field, people with extensive theoretical and analytical knowledge who are good at assessing and who submit suggestions for improvement. The model on the next page shows how we work on processes for continuous improvement. Organisation Material Documentation Resource requirement Aim and requirements Improvement measures ACTIVE MANAGEMENT AND VERIFICATION Cause analyses TIME-SAVING ANALYSING METHODS IMPROVE SAFETY Execution Deviation reporting Technical condition Risk level Regularity Cost Model Maintenance improvement wheel Illustration Power Allocation for normal load. If you are to lead, you must be in control Axess prepares technical status reports If you are to prepare status reports, you must be familiar with the requirements Axess identifies the requirements and acceptance criteria If you are to assess the status, you must have measurements Axess prepares inspection programmes (RBI) and maintenance programmes (RCM) If you are to obtain information of reasonable quality, you must use the right quality in measuring Axess prepares inspection and maintenance procedures When an engineer sits down to design a new product for the offshore industry, a number of vital questions must be clarified as early as possible. What is the service life of the product when in daily use? How heavy can the load be before something breaks down? The list with questions like these can be rather long and it is therefore essential to use a good tool which gives you the answers. Axess uses state-of-the-art computer programmes which model a structure and can simulate the physical reality in a precise way. The company s engineers have the skill to interpret the results in relation to the regulatory framework used on the Norwegian continental shelf, says Lars Walle, project manager of design in Axess. The tools are used to simulate reality to find the ideal method tailored to the situation and problem to be solved. Calculation by hand is in many cases insufficient to ensure safety. An advanced computer programme makes it possible to simulate the structure more precisely, thus providing a better and clearer answer as regards the state of the installation. This is definitely an advantage in more complex structures as it is time-saving and it provides clearer answers. 14 AxMag - October 2012 A report from Axess AS 15

9 Molde - Headquarters Postboks 2197 Oscar Hanssens veg Molde Tel. (duty): Kristiansund Omagata Kristiansund Tel. (duty): Bergen Trollhaugmyra Straume Tel. (duty): Orkanger Grønøra 7300 Orkanger Tel. (duty): kristian.nelvik@axess.no Trondheim Nedre Ila Trondheim Tel. (duty): Houston Axess North America Inc Katy Freeway, Suite Houston, TX Tel.: +1 (281) christian.nerland@axess.no Rio de Janeiro Axess do Brasil Ltda Rua Professor Álvaro Rodrigez º andar, Botafogo CEP Rio de Janeiro RJ Tel.: +55 (21) mail@axess.com.br Singapore Axess Offshore Pte Ltd 159 Telok Ayer Sreet Singapore Tel.: