Ageing and life extension

Transcription

1 Ageing and life extension April 7th workshop

2 Background NPD recommended NORSOK AGn to start developing guidelines for life extension (2000). NPD initiated a PhD study on ageing and life extension of offshore facilities (2002) NPD proposed to establish working groups in ISO TC67 (2002). Ageing rigs initiative from HSE and NPD (2004) PSA gave ageing and life extension main priority (2005) PSA requested an overview from operators of facilities and their status with respect to design life and need for life extension (2006). PSA requested an initiative from OLF towards developing procedures for life extensions (2006)

3 Facilities on the Norwegian continental shelf Number Installation year /04/2010 3

4 Strategy Improve handling of applications for life extensions. - To be submitted 1 year before end of design life period as stated in the PDO (Plan for development and operation). Improve regulation and standards for life extensions. Increase the knowledge and competency about ageing and aspects of ageing that may reduce safety. - R&D projects, evaluation of industry activity, overview of other industries handling of ageing and life extension. Increase the awareness related to ageing and life extension challenges in our industry. Establish database on facilities with installation date, design life, and life extensions.

5 Main priorities of the PSA R&D to better understand aspects of ageing that may reduce safety of facilities. - SINTEF, Cranfield University / Ocean Structures, Aalborg University, etc In cooperation with the operators association (OLF) develop standards and guidelines for life extension. Developing a data base with information on installation date, design life and other issues concerning life extension for facilities in Norwegian petroleum activities. Development of internal procedures and check-lists for consideration of life extension applications. Participating in and organising workshops, conferences, meeting etc. to inform about issues related to ageing and life extension. Collaborating with relevant authorities (NMD, HSE, MMS, SodM, etc.)

6 Main Document OLF guideline No. 122 Published in June 2008 Sub- Documents Permanente structures Offshore Structures Published May 2008 Drilling and Well Systems Check List Published in May 2008 Drilling systems and Well integrity, including conductors, BOP and down hole equipment Export and intra field Pipelines and risers. Transport Systems Process Systems Emergency Shutdown, Evacuation, Barriers, Fire and Gas Detection and other safety systems. Living Quarters, Escape Ways, Material and Chemicals Handling, Control Rooms, Man machine interfaces. Technical Safety Systems,,Working Environment and Risk management Underwater installations Consent Applications for Life Extension of Facilities are submitted to the Petroleum Safety Authority (PSA) Norway and Norwegian Petroleum Directorate (NPD).

7 Life extension applications Åsgard C (2005) until 2018 Ula (2005) until 2028 Ekofisk 2/4-B (2005) until 2015 Statfjord A (2007) until 2028 Valhall QP, PCP & DP (2007), QP until 2010, PCP and DP till 2015 Hod (2008) until 2015 Norpipe oil (2008) until 2028 Gyda (2009) until 2030 Veslefrikk A & B (2009) until 2020 Ekofisk (2009), - 2/4-H and 2/4-Q until 1 Sept 2013, - 2/4-C until 1 Sept 2013 (2028), - 2/4-FTP until 31 Dec 2015, - 2/4-BS01, 2/4-W and 2/4-SF until 31. Dec 2012, - 2/4-A until 31 Dec 2016, - 8 pipeline between 2/4-C and 2/4-B until 2028, - 12 pipeline for water injection from 2/4-K to 2/4-W until 31 Dec 2012 (2028) Norpipe gas and B11 (2009) until

8 Major challenges Decisions are not made when application is submitted. - Plans to study health and safety issues on the facility are described, rather than concluding on what the operator will do with respect to health and safety in the life extension period. - Applications are being submitted before it has been decided whether a life extension will be funded by the production license. - Several solutions to identified health and safety issues are still being put on the table when applications are being submitted. Lack of standards for application and comparison

9 Main priorities of the PSA R&D to better understand aspects of ageing that may reduce safety of facilities. - SINTEF, Cranfield University / Ocean Structures, Aalborg University, etc In cooperation with the operators association (OLF) develop standards and guidelines for life extension. Developing a data base with information on installation date, design life and other issues concerning life extension for facilities in Norwegian petroleum activities. Development of internal procedures and check-lists for consideration of life extension applications. Participating in and organising workshops, conferences, meeting etc. to inform about issues related to ageing and life extension. Collaborating with relevant authorities (NMD, HSE, MMS, SodM, etc.)

10 Evaluation of facility History: -Original design and fab -Actural degradation and trends -Incidents -Inspecion results -Changes to facility As-is condition: -Evaluate condition -Collect information (design, fabrication, installation & operation) -Identify deviations and gaps from regulations -New knowledge Future challanges: -Ageing-related failure modes and ageing of barriers -Changes to environment -Spare parts -Competence Future use: -Planned changes and modifications to facility -Planned changes in operation of the facility -Changes in risk due to modifications Ageing relevant for this SSC? * Maintenance according to existing plans and methods. Guiding documents and principles: -Present regulation -Risk reduction -ALARP -BAT -Continuous improvement Assess integriy: -Analyse and assess safety in life extension -Evaluate mitigations Criticality evaluation: -Main safety functions? -Barrier? -Inspectable? Make Decisions: -Mitigating measures -Operational restrictions -Future maintenance Maintenance that account for ageing, system effects of ageing, and the increasing likelihood of failures due to ageing. Documentation of technical and operational integrity. Plan for implementation of measures and modifications. Maintenance plan and system of KPI s and acceptance levels. 12/04/

11 Is it possible to inspect and mitigate? Knowledge? Good Some Poor Replace Measures? Some No

12 AGEING MANAGEMENT A. Material degradation B. Obsolescence C. Organisational issues - Material properties - Operation conditions - Environmental conditions - Maintenance practices - Equipment out of date - New needs - New technology - New requirements - Reorganisation - Ageing of personnel - Transfer of knowledge 12/04/

13 Structure of Contents Ageing and life extension management General part Analyses of material degradation Obsolescence and organisational issues Specific part Wells Pipelines Risers Subsea production systems Topside process equipment Safety systems Material handling and cranes Challenges and Lacks of knowlege 13

14 Knowledge gaps (SINTEF report) Understanding and assessing degradation mechanisms and modelling of degradation mechanisms for various materials and equipment. Developing and applying reliable methods for subsea inspection and monitoring. Understanding and increasing awareness of common cause failures of equipment due to ageing. Assessing the effects of and utilising methods for monitoring of facility loads. Understanding ageing of electronic equipment and cabling. Optimising test interval for safety systems with respect to material degradation due to ageing. Understanding the results of testing, inspection and monitoring of process equipment with respect to degradation mechanisms. Understanding the consequences of combining old and new equipment. Assessing the effects of subsidence on relevant SSC, such as structure, helideck and free fall lifeboats. 14

15 Recommended further research and development (SINTEF report) Analyses of degradation mechanisms of critical systems, comprising: - Modelling of main degradation mechanisms, also considering the combined effect of various degradation mechanisms, common cause failures and effect of operational conditions. - Development of systems for data collection and use of field experience with degradation failures. Developing a general guideline for design of the life extension processes encompassing the entire facility. Improving maintenance management systems for ageing and life extension so that all three ageing aspects are being processed in parallel, in order to - evaluate and improve the operator s maintenance systems prior to and during life extension. - Improve awareness and overall knowledge of the SSC on the facility, e.g. combinations of old and new equipment, availability of spare parts, common cause failures, new types of operation and new technology. 15

16 Further work in the PSA Evaluate needs for updating rules and regulations. Collaborate with operators and operators association to update regulation and standards. Further development of the SISU data base Further studies related to working environment on ageing facilities International standardisation and further collaboration with authorities in the UK, US, etc. Continuation of presenting and interchanging findings and results in relevant forums

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18 Myth 1: Why life extension it s just continuing normal operation. 12/04/

19 Myth 2: Life extension is just maintenance. AGEING MANAGEMENT A. Material degradation B. Obsolescence C. Organisational issues - Material properties - Operation conditions - Environmental conditions - Maintenance practices - Equipment out of date - New needs - New technology - New requirements - Reorganisation - Ageing of personnel - Transfer of knowledge 12/04/

20 Myth 3: If the facility is safe today, it is also safe tomorrow 12/04/

21 Myth 4: Life extension is not a safety issue, it is just a cost issue. Partly true, but misleading It will cost to keep the safety to the expected level (mitigations, repair, improvements, maintenance). Safety is the primary factor! 12/04/

22 Myth 5: There is no statistics that indicate that ageing is a problem. There is a lot of evidence that ageing is a problem, including: - Crack history on ageing ships and rigs - Subsidence - Accidental damages - Corrosion - Etc. 12/04/