MAGAZINE Report from Axess AS Total Rig Integrity Management www.axess.no
AXESS MAGAZINE 3 : Contents World-Class Integrity Solutions for intro: Integrity solutions as tools for productivity and safety...4 Global partner...5 DRILLING Contractors ENERGY FPSO Contractors MMO SURF Axess total rig inspection management...6 Keep it safe, keep it going... 6 Benefits of Axess TRIM... 8 a problem solver...9 Material handling the axess way...10 3D-Animations as a tool for improved safety and increased margins...12 Contributing to a safer petroleum industry...13 Axess organization...14
4 AXESS MAGAZINE AXESS MAGAZINE 5 Integrity solutions as tools for productivity and safety Global partner Over 50 percent of the oil and gas installations in the Norwegian sector have turned 20 years. This makes maintenance work an important tool in securing productivity and safe working conditions in the future. To achieve maximum uptime and zero harm, the operators depend on competent and reliable partners who know their needs and their installations. Axess has developed from being a skilled supplier to the oil and gas industry to become a global partner. We deliver world-class integrity solutions to the global oil and gas industry. Axess deliver custom made world class integrity solutions. In close cooperation with our clients we are developing plans and implementing measures that will make the installation live longer, be more productive and even more important; safer. In our company we are using the three C s as leading stars for how we are working and how we are to be perceived by our customers; Competence, Continuity and Capacity. SURF SOLUTIONS FOR SURF COMPANIES Inspection and quality control services Advanced non destructive testing services Inspection engineering Vendor surveillance Børge Gjeldvik Competence During 2012, Axess has been an important partner on 150 offshore installations worldwide. We have followed our customers abroad and have established the company in Singapore, Houston and Rio de Janeiro. The high competence we have gained from many years in the Norwegian market is well received by the international offshore and energy market. We have developed to become an international player and we can proudly state that we deliver world class integrity solutions. MMO SOLUTIONS FOR MMO COMPANIES Safe lifting operations DROPS & derrick inspections Crane Maintenance modification and replacement Continuity In 2012 Axess had an absence rate due to sickness of two percent. This shows that our employees enjoy their jobs and are working in a safe manner. Our low absence rate and that few quits working in Axess makes us able to deliver continuity to our customers. We have several times experienced that our own employees know the rig s better than the customers themselves. We think it is important that our employees know the customer and the installations well. That makes us a competent and predictable long term partner. FPSO Contractors SOLUTIONS FOR FPSO CONTRACTORS Safe lifting operations Material handling DROPS & derrick inspections Crane Maintenance modification and replacement Risk based inspection Safety on Electrical systems - NR10 Safety on boilers and pressure vessels - NR13 Capacity Axess is growing fast. In 1999 we were two hard working employees based in Molde. Today we have 270 highly skilled colleagues mostly engineers. Our growth has always followed the demand in the market. Axess is an attractive company and we are doing well in the competition to attract the best engineer heads. However, we are working hard every day to develop our employees and provide them with challenges that make them stand out as the best at their work. To us capacity and competence are interdependent. We deliver competence. ENERGY SOLUTIONS FOR ENERGY COMPANIES Safe lifting operations Material handling DROPS & derrick inspections Crane Maintenance modification and replacement Risk based inspection Safety on Electrical systems - NR10 Safety on boilers and pressure vessels - NR13 By involving our Integrity Management services already in the planning of an installation, errors are eliminated and we ensure that we find the best solutions before the asset is put in to operation. Our customers should know that we deliver complete TRIM (Total Rig Integrity Management) packages for the offshore and energy industry. In this issue of Axess Magazine you can read about our TRIM solutions and how they are adding value to our customers. Drilling Contractors SOLUTIONS FOR DRILLING CONTRACTORS Safe lifting operations Material handling DROPS & derrick inspections Crane Maintenance modification and replacement Risk based inspection for drilling rigs Lifting and drilling equipment certification Safety on Electrical systems - NR10 Safety on boilers and pressure vessels - NR13
6 AXESS MAGAZINE AXESS MAGAZINE 7 T R I M Total Rig Integrity Management Keep it going, keep it safe Phase 1: Plan Phase 2: Do Phase 3: Check Phase 4: Act Safety and productivity are the main goals for the oil and gas industry. Aging installations need continuous maintenance to secure maximum production and zero harm. Axess Total Rig Integrity Management (TRIM) system is designed to meet each rig s needs and keep them going in a safe manner. ExtendeD lifetime 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. Continuous inspections and maintenance helps to keep the production running smoothly and to extend the rig s lifetime. cost effective Axess role is to close all findings or deviations for measurements and inspections. As our engineers do the whole process, from inspections to shutting down findings, so we don t have to send out personnel several times, and therefore is cost effective. from start to finish The management has the responsibility to safeguard the operations and control the risk. However, the different operators are also involved in risk management to avoid damage and unforeseen costs. Our experience tells us that integrity management must be established already in the development phase of an installation and every stage, from start to finish. perfectly prepared One focus area of integrity management is the importance of making the right decisions early in the construction and manufacturing phases. The reason is that you should build an installation that is perfectly prepared for the next phase - the operation phase. This is how we do it In the following pages we ll describe how Axess is working with the TRIM system towards our customers. All deliveries are designed to meet the unique challenges of our customers, but we are describing the main scope of our system from the planning of a rig to the operation phase. This is how we do it. Whether it s for new builds or existing installations, the working methods are the same. We start with planning. Together with our customers, we will sit down and go through the installation s maintenance systems and establish work packages that meet the needs of the individual customer, in accordance with applicable regulations. We end up with a detailed longterm work plan that focuses on not just finding errors, but also closing them. In this phase we are establishing the baseline condition of the installation. The Axess TRIM method ensures continuous improvement and is providing predictable costs as a result of stable rig performance. At the same time, this working method reduces the number of mobilizations and contributes to a safer working environment. We are establishing the terms and acceptance criteria for the job to be done. The needs of the different rigs will vary. Therefore the planning phase is extremely important. By investing in well planned long term integrity programs, the risk of unforeseen incidents and costs are significantly reduced. The selection of an integrity program is based on an evaluation of which methodology is best suited with regards to safety, cost effectiveness, effects on production and equipment redundancy. This is the data collection or modification phase. According to the work plan, we perform inspections or do modifications as a result of earlier findings. The goal is to define the rig s technical condition and close findings from earlier inspections. A large number of the existing installations have been operating for many years. To keep the level of productivity and safety at an acceptable level, it is important to know the rig s condition, at all times. A long term integrity management program is essential to be able to act proactively. For the operators to keep maximum uptime and demonstrate an acceptable level of safety, they have to be in control of the state of the installation at all times. Axess is not only finding issues, but also closing them. The findings and modifications work done in this stage of the process is summarized in reports and documentation; this forms the basis for the next phase the evaluation phase. By involving our integrity manage ment competence as a partner, we are responsible for the whole process. We know the total scope and the customers save costs, as the number of mobilizations are reduced. One of the core values in A xess is to strive for continuous improvement. By performing thorough evaluations of our surveys, we get an excellent basis for improvements. At this stage we are suggesting changes or adjustments to the integrity management program or make changes in the implementation methods. We are also evaluating towards applicable regulations and make necessary changes in evaluation criteria s. In this phase we are looking at how our personnel are performing and if the correct competence is used in the projects. We are continuously monitoring customer satisfaction and we are working hard to keep it high. All improvements identified in phase 3 needs to be adjusted. The continuous focus on high performance and putting the right people on the right jobs are important to us. We are working hard to improve the next year s data collection and ensuring that we are inspecting the correct spots. All knowledge from the previous phases is used when we plan the next job with the client. Our goal is to be a hassle-free partner, who takes care of our customer s unique needs, and contributes with our knowledge and competence to ensure maximum uptime and zero harm. These four steps make our services and solutions run smoothly with our client s needs as spearhead.
8 AXESS MAGAZINE AXESS MAGAZINE 9 Benefits of Axess Total Rig Integrity Management system: A problem solver Reduce downtime, higher efficiency Safety improvement Building total inspection programs Vitalizing the improvement loop with client Fixed price for fixed scope Taking overall care of inspection in drilling and marine area Give continuous improvement Predictable cost Reduced number of mobilizations/year Focus on helping closing findings; not only finding them Terms Maintenance Strategies Maintenance Program Planning maintenance ACtivities and work packages Execution of maintenance Typical deliveries for pressurized systems: Integrity management handbook Integrity management program Annual integrity reports Typical deliveries for drilling and lifting equipment: Baseline survey Integrity management program Annual integrity reports Axess works closely with Dolphin Drilling AS at all their Norwegian rigs; Borgland, Bideford and Broad Ford. Our experience with Axess is that they not only point out problems as a result of the inspections, they also come with well-founded and useful suggestions for improvements that makes us able to address the challenges, and help us close them, says Steinar Johnsen, Technical Superintendent for Bideford Dolphin. Dolphin Drilling AS uses Axess TRIM concept that involves setting up a good set of plans for the implementation of DROPS inspections, RBI (Risk Based Inspections), expert controls, drilling control and closure of findings. The companies are working together to find the best solutions to ensure maximum uptime and no injuries. For us to make the right decisions, we depend on a sound basis. We experience Axess as thorough and effective. Continuity is also important for us. Axess is a young company with many young people, but our experience is that they have solid professional expertise. The Axess people on our rigs have extensive experience and know us and the rigs very well. It is important that the same people are on the same jobs over time, says Johnsen, who points out that this can be a challenge for a company that is growing quickly, as experienced employees often end up behind a desk in administrative roles. Closure of findings Axess is committed to being accessible and flexible; flexible in terms of adapting the solutions to the various needs of a given time, and available in terms of being there when the customers needs is actually there. We are very satisfied with the follow-up we get from Axess. The feedbacks from the rigs are good. The combination of being there on short notice, providing expertise, equipment and technology with high standard, makes us very satisfied with the job done, says Johnsen who has over 30 years experience in the maritime industry. Axess takes responsibility for the entire process. They ll not only find errors and potential hazards and pass the ball back. They also close findings. A summary of the findings on DROPS inspections at three Norwegian Dolphin Drilling rigs over the last three years, show that the systematic work gives results. Only on Bideford the number of findings has gone steadily down from 65 in July 2009 to 4 open findings after inspection in January 2013. The tendency is the same on the other rigs. Statistics show that we limit risk and increase the uptime of equipment through continuous improvement. When we take responsibility for the entire improvement process from planning, inspections and reporting for improvement, documentation and maintenance program, we become a full partner in our projects. This gives our clients the continuity, safety, quality and not least lower cost, as we cut the number of mobilizations offshore, says Department Manager Knut Stefanussen in Axess. Axess has first-hand knowledge of rules and regulations, and is an important contributor in the whole value chain. Axess is setting premises, knows the rules and authorities, makes long term inspection plans, annual programs, and closes findings.
10 AXESS MAGAZINE AXESS MAGAZINE 11 Material handling the Axess way Assist in all phases Material handling can for the lifespan of an installation be roughly divided in the following main phases: Axess contributes in all phases of material handling processes on offshore rigs, and carries out thorough design reviews of the rig s material handling design documentation. By involving Axess in the early phase of the rig design we identify unpractical and unsuitable solutions which later could have a negative effect on the material handling and rig s logistics. Design Construction Operation Decommissioning Axess is assisting clients in all phases from design to decommissioning. Axess knowledge is that each phase follows the other and that the most cost effective method is to follow up and correct the material handling in all stages. As a result of the large amount of information needed to comply with the Petroleum Safety Authority Norway (PSA) requirements, Axess has developed a method for information gathering and presentation of the material handling. Online material handling database Good material handling plans not only help to meet stringent regulatory requirements for the offshore industry. Well-oiled material handling systems are essential to reduce downtime and increase the economic margins. Axess unique method for developing and presentation of customer s material handling plans is an important tool in this matter. We call it the Axess way. Traditionally, material handling plans have been delivered as a fixed document. In order to fulfill the requirements given in Norsok R-002, Axess has developed an online material handling database for client use. This database does not only give the client easy access to the existing plans, but also gives the users a method for feedback and comments directly in the database. As a result, the users can easily get an overview on eventually identified changes, challenges and comment in the plan. The Axess material handling systems helps customers: Secure reliable operations Improve Health, safety and environment standards Avoid downtime Ensure compliance with national laws and regulations Improve economic margins Avoid damage on structure Increase technical integrity Early involvement gives added value The online database is a valuable tool to prevent incidents and maximize uptime and efficiency and to secure continuous improvements. The Axess model makes material handling a more complete development and maintenance tool instead of just reporting inspection findings. According to the Petroleum Safety Authority Norway (PSA) all mobile installations on the Norwegian continental shelf must have a material handling plan and an overall philosophy on this field. The NORSOK standards provide guidelines for what these plans must include. These sets of regulations are all about facilitating work spaces and lifting devices that put efficiency and security first. Axess recommends that material handling is included as an important part of the design and construction phases. Our experience is that those customers who involve us in an early phase, for example in the planning of a new installation, get added value. This contributes to safe handling of material and economical profit - as a result of minimum downtime and good planning in early phase. Apart from saving large amounts of money for our clients on modifications and new installation this will contribute to a better working environment on board, says Litlere.
12 AXESS MAGAZINE AXESS MAGAZINE 13 Axess a part of the audit team for the new NORSOK R-003: Contributing to a safer petroleum industry Axess has a central role in the development of the NORSOK standard for offshore lifting operations. Senior Engineer at Axess, Magnus Gabrielsen, is a member of the audit team for NORSOK R-003 which updates the standard that sets standards and guidelines for the safe use of lifting equipment on the Norwegian continental shelf. Dutch treat The standard is intended to establish, maintain and develop an acceptable level of safety for personnel, property and the environment in the planning and execution of lifting operations. Audits are conducted when needed, which is usually every five to ten years. The audits make sure that new experiences, new technologies and best practices, based on input from users, are taken into account. This ensures continuous improvement. 3D-Animations as a tool for improved safety and increased margins Axess must take all the experience and expertise to use when a 35 meter long tube for produced water (Caisson) is to be installed on Statoil-owned Brage. What takes the lifting operation from difficult to spectacular is that the pipe is partially installed subsea. To do this Axess use 3D animations as a planning tool and as a strict implementation plan. Animated schedule The use of animations in the offshore industry is nothing new. What is special about this lifting operation is how the animation is used. Each step in the lifting process is accurately illustrated in a 3D animation which the project uses as a strict plan for implementation. We have never used animations in this way before. We have used it as illustrations and in the planning, but never used it in such a practical way before. Proper use of animation allows us to eliminate errors and not least to facilitate excellent communication to all parts of a project. A good animation may show rig management how an operation is done, and at the same time show a technician how a screw is to be fixed. In the Brage project we have put so many resources in this animation that we are using it as a process description we adhere slavishly, where errors and risks are removed in the early phase, says Stokke. Precision work With a ROV (remotely operated subsea vehicle) as eyes, the caisson is carried in place and installed 15 meters below water. The temporary clamp that takes care of wave forces is also installed subsea. The operation requires a lot of equipment and many planning hours. Axess has put a lot of resources in a detailed and thorough animation that is used during the operation. Igor Voljevica is a project engineer who works with design in Axess. He is passionate about his work and has put a lot of effort into the animation of the Brage-operation. My task was to modulate the necessary components to visualize the different lifting operations, and to make a video about the way of doing this. The goal was to discover possible hazards and to create something that is easy to communicate to all involved parties in the project. The project involves a lot of complicated lifts that are not easy to describe in other ways, says Voljevica. Magnus Gabrielsen These companies participate in the audit group to NORSOK R-003 Talisman Maersk Statoil Axess AS BP Shell COPNO NORSOK PSA Aker Solutions COSL Drilling Dolphin Drilling Seadrill NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety, value adding and cost of development and operations in the petroleum industry. The standards that are developed meet the Authority requirements, rules and regulations related to the industry. It s the industry itself that is responsible for the development of standards. One can look at it as a kind of cost-sharing in which none of the players involved get paid for their efforts, but they get firsthand knowledge of what is happening within their field. Meanwhile, the participants learn from each other s core competencies. Everyone in the group is here because they have something to contribute with, says Gabrielsen. The Committee consists of approximately 15 members who are mainly drawn from the major oil companies as well as smaller players who are committed and want to influence developments in the industry. We took the initiative and expressed a strong desire to contribute to a safer and more efficient industry. NORSOK standards are mainly of a technical nature and are aimed at technical personnel. What is special with NORSOK R-003 is that it is very operational and describes how the lifting equipment in the petroleum industry is to be used in a safe manner. I am glad that Axess will have an impact on how this will be achieved, says Gabrielsen. Lack of compliance According to Gabrielsen, the biggest challenge of this field is lack of compliance with the standard. In most cases when a lifting-related issue occurs, it can be related to the lack of planning and human error. NORSOK R-003 requires that all lifting operations should be planned. The whole industry has an important job to encourage compliance with the standard, says Gabrielsen also suggests that participation in the audit team also adds a dimension to Axess customers, he says and continues: NORSOK R-003 describes both how the lifting equipment is to be used safely, and the role of our Enterprise of Competence department. There is much uncertainty about the requirements for lifting in the industry. By participating in the audit group, we get in-depth knowledge of the requirements and the meaning behind them. This means we can guarantee the customer that we supply according to requirements and best practices, at all times, says Gabrielsen.
14 AXESS MAGAZINE client oriented and solution focused organization Maintenance management Structure Integrity management Inspection planning/rbi Lifting and Drilling Equipment Certification DROPS In-service Inspection Electro Inspection Crane maintenance and modification Design/analysis of complex structures Advanced lifting and skidding operations with RAT Delivery of tailor made cranes and tools Inspection/QC NDT services Pipeline Special Periodic Survey Custom ultrasonic tools Innovation projects Product development Inspection & Integrity Management Engineering & Construction Inspection services Products, Technology & Innovation AXESS
Molde Kristiansund Trondheim Bergen Orkanger Houston Singapore Rio de Janeiro World-Class Integrity Solutions Head office MOLDE Postboks 2197 Oscar Hanssens vei 5 6415 Molde Tel. (duty): +47 982 43 600 Bergen Trollhaugmyra 15 5353 Straume Tel. (duty): +47 982 43 600 Trondheim Nedre Ila 39 7018 Trondheim Tel. (duty): +47 982 43 600 Orkanger Grønøra 7300 Orkanger Tel. (duty): +47 41 78 06 30 Houston Axess North America Inc 15915 Katy Freeway, Suite 501 77094 Houston, TX Tel.: +1 (281) 994-0380 Rio de Janeiro Axess do Brasil Ltda Rua Professor Álvaro Rodrigez 352-13º andar, Botafogo CEP 22280-040 Rio de Janeiro RJ Tel.: +55 (21) 3239-4850 E-mail: mail@axess.com.br Kristiansund Omagata 114 6517 Kristiansund Tel. (duty): +47 982 43 600 Singapore Axess Offshore Pte Ltd 159 Telok Ayer Sreet 068614 Singapore Tel.: +65 8202 2666 www.axess.no