asset integrity ndc_iadc seminar 20 apr 09
TRANSCRIPT
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Understanding Asset Integrity
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Asset Integrity
Ability of an asset to perform its required
function to its design capabilityeffectively and efficiently whilstsafeguarding life and the environment.
Defining Asset Integrity
Asset
All physical facilities required for theoperation.
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Asset Integrity Management
Means of ensuring that :People,
Systems,
Processes andResources
which deliver the integrity, are in place, inuse & fit for purpose over the wholelifecycle of the asset.
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Is Asset Integrity Necessary?
Are Asset Monitoring systems satisfactory? Is Key Staff Competent?
Is Maintenance of assets good?
Is Design adequate for the application?
Have you exceeded design life of asset?
Have Changes been adequately controlled?
Are Emergency procedures defined?
Is the Integrity process independently audited/verified?
The list could go on.
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Cantileverlevel
Standard turn table drive Top drive
Typical Retrofit: Topdrives
Will the derrick withstand thetorsion loads?
Like legs, has derrick beenanalyzed for inertial forces frommost severe transit motion?
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How Often Do You Check?
Worn rack teeth change the contact ratio and therebythe design assumption
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Does Operating Staff Know?
When brake discs need tobe checked?
When the springs been
renewal?
How much is the brake
holding torque?
How much lining wear is
permitted before changing
discs?
How much is the allowed
airgap?
Are these details part of
the maintenance
procedures?
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How Assets were Lost
Weve seen these before.
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26 Years Previously
Faults found indesignand construction
Ineffective regulationsand quality oversight
Loss of watertight
integrity
Water entered into theballast control room
Lack ofsurvival gearandtraining
Crewdid notunderstandhow tooperatethe ballastsystemOCEAN RANGER 1982: 84 persons died;
loss unknown
Courtesy DNV
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20 Years Back Lack of communication between
shifts Three parallel gas trains
One closed down
Safety valve removed
Next shift, started closedtrain again
Consequences escalated Platform not designed forexplosions
Surrounding platformsproduction increased
Assumed living quarters asafe place Several did not try to
evacuatePIPER ALPHA- July 1988: 167fatalities, loss $ 1270 million Courtesy HSE UK
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17 Years Before
First structurewithout independent3rd party verification
Water pressureexceeded thecapacity of thestructure - cellsimploded, thestructure sprang leakand sank
Total loss of about
$700 million
Sleipner A - August 23,1991: 0 fatality, loss $365 million
Courtesy HSE UK
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7 Years Back
Pumps for repairwithout taking any
other alternativepreventive actionOpening ballast tankfor inspection withoutfollowing proceduresDelay in activation ofthe drainage pump
Deficient proceduresand training to deal withemergency situationsPetrobras 36 March 2001: 11 fatalities,
loss $ 515 million
Courtesy HSE UK
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Recently 3 Years ago
Crane on platform non-operational, causedupwind approach
Boat collided with gasriser
Riser protectionineffective
No deluge protection
Vessel operating withdeficiencies
Only two of eightlifeboats launchedBHN Platform 2005: 22 fatalities,
loss $195 million
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Then two years ago. in 2007
Rig oscillated in roughweather
Cantilever struck
production valve tree
Sub surface safety
valves unable to closecompletely
Structural or jacking
failure suspected
Two months to kill well
Large oil spillInvestigations not yet
made publicUsumacinta 2007: 21 fatalities,losses undeclared
Courtesy HSE UK
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Evolution of Change
26 Yrs
20 Yrs17 Yrs
7 Yrs
3 Yrs 2 Yrs Are wesafetoday?
MODU CODE REVISED
SAFETY CASE REGIME
INDEPENDENT DESIGN VERIFICATION
BALLASTCONTROL
ALARP PRINCIPLE
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Unfortunately.
April 2008: Helicopter crashes into Black Seadrilling rig, 19 dead
Sept 2008: Helicopter crashes while takingoff from Offshore rig in Dubai, 4 dead
Oct 2008: Delay of SCR maintenanceprogram on jack up rig causes fire, losses$200,000
Apr 2008: Sudden crane boom crash injuresone
Apr 09: Another helicopter crashes in offshore
platform operations, 8 dead
Feb 08: Crane boom crash on offshore rig, 1dead, 1 injured
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Clearly.
Asset Integrity is a pressing need Previous attempts have had limited success
Gaps are plenty
Industry cannot afford to Learn from Own
ExperienceWe need to be Wiser without being Sadder
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Why Now?
World Jack up fleet is not getting youngerWeather changes are threatening existing
operating zones
Insurance demands are making it less lucrative
to operate in some areas These rigs are now migrating to safer benign
areas
The overall average regional rig age is thus likely
to increase This does not have to be a problem except.
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The Challenges
Maintenance programs have been sporadic andtotally non-uniform
Spares for obsolete equipment is a challenge
Knowledge pool is being fast depleted
Regulatory controls are not the same
The migration/influx is changing the way things
are done
We need to have procedures in place to deal withthe change
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Are We Alone?
From 2004 to 2007:
29 organisations worked on thesubject and issued a Toolkit tohelp organisations establish AssetIntegrity.
This was done but reports indicatethe gaps still persist.
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Protective Barriers Layers of protection separate the
initial hazard from the final undesiredoutcome.
No layer is 100% effective, there areholes
When the holes line up, the undesiredevent will occur
Overview Integrity Management Model
Element Model Various key topics need to be
considered when assuring integrity. These represent the principal
aspects which need to be controlledby the Integrity Management System
Can be considered as the layers ofprotection in the Barrier model.
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Why all the Elements?
Is it not sufficient to just look at the Hardware? Is it not enough to maintain the asset?
Is this an overkill?
Has the Industry seen different?
Unfortunately .Yes
OCEAN RANGER
PIPER ALPHA
PETROBRAS 36
BHN PLATFORM
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Assessing Organisation Risks
Establish the Standards
Identify Organisation Risks
Analyse the Risks
Evaluate the Risks
Put a Management system in place for the Risks
Monitor & Review the Process
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Establishing the Barriers
http://www.clker.com/clipart-16533.html -
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Asset Lifecycle Integrity
Design suitability Allocate funds for integrity in design
Ensure compliance with codes at constructionstage
Ensure availability of design criteria
Develop operating & maintenance strategy basedon design
Control asset modifications
Monitor changing operating climate
If acquiring, assets acquire carefully, addressingunknowns
If retiring/scrapping assets do so carefully
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Human Element
Ensure Equipment Serviceability
Document and Publish Work Procedures
Analyze workload for Key staff
Establish Work Authorization Processes
Above all .inculcate Integrity Behavior
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Competency
Standards
Earmark staff with critical responsibilities Identify required competencies per Job Determine level of proficiency
Training
Establish relevant training standards Verify competency levels
Monitoring
Establish and apply promotion criteria
Prepare and apply RACI charts to keystaff Refresh the competency periodically,
especially emergency response
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Monitoring & Review
Establish Asset Integrity KPIs
Verify performance standards ofbarriers
Audit performance of AssetIntegrity
Incident Investigations
Benchmark performance againststandards (Internal/ External)
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Lastly
The world financial position will result in possiblecutbacks
More is being demanded from existing units
Owners are upgrading assets, sometimes without
adequate controls and checks
Platforms are seeing much higher loads than they
were originally designed for
Additional well slots often with lower level of
protection are being added
Existing controls have failed previously
If ever Asset Integrity was a priority it is TODAY
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THANK YOU
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Establishing AIMS
Systems & Processes Identify & Introduce Standards, CoPs, RPs
Establish Integrity Documentation ( Identification,Verification, Approval & Controls, etc)
Establish Competency Assurance Systems Establish system to Identify & Register all
Integrity Critical Eqpt & Systems
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Establising AIMS Contd
Establish Performance standards for all IntegrityCritical Equipments & Systems
Revisit Project processes & introduce Integrityreview processes
Establish Quality Assurance systems for Supplychains
Establish Project Handover documentationrequirements
Establish Integrity Inspection, Testing,Monitoring, Maintenance Planning & Scheduling
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Engineering & Design
Ensure that proper engineering & design data isavailable for all assets
Confirm that the assets are being operated withindesign limits
Modify if required the operation to match designcapability
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Inspection & Certification
Ensure that clear inspection procedures andfrequency is established
Ensure that certification bodies are competent
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Competency & Training
Identify staff that have responsibilities for assetintegrity
Attach documented competency requirements forthe tasks
Evaluate staff for gaps in competency Train staff to address the gaps
Re-evaluate staff for training effectiveness
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Management of Change
Confirm that MOC addresses all aspects ofCompany business
Establish a corporate level ownership for MOC
Using the HSE Observation program revisit
previous MOCs and remove anomalies
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Audit & Quality
Establish an audit program to confirmeffectiveness of Asset Integrity Systems
Appoint suitable auditors with skills for integrityaudits
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Asset Integrity Growth
Lowest level, learner,ad hoc,defined by absence of qualities
in higher levels.
Can repeat what it has done before, but notnecessarily define what it does do.
Can saywhatit does andhowit goes about it.
Can control what it does. It lays downrequirements and ensures these are metthroughfeedback.
Is Best Practice. Capable oflearning and adapting itself. It notonly uses experience to correctany problems, but also to changethe nature of the way it operates.
Defined
Managed
Optimized
Repeatable
Initial
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Enter Asset Integrity
1. System & Processes
2. Maintenance
3 . Engineering & Design
4. Audit & Quality
5. Inspection & Certification
6.Competency & Training
7. Operation
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Is Rig Upgrades the Answer?
Maybe. but Structural Fatigue Study must be based on degraded
condition
Apply environmental loads based on operating history
Be careful with localised stiffening of structures
Prepare revised inspection plans based on design
review
Update rig documentation manuals and drawings
Re-train key staff for change