02 Ageing and Life Extension_Ersdal_Ptil

PTIL/PSA

Ageing and life extension

April 7th workshop

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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).

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Facilities on the Norwegian continental shelf

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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.

PTIL/PSA

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.)

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PTIL/PSA

Offshore Structures

Published May 2008

Transport Systems

Underwater installations

Drilling and Well Systems

Check List Published in May 2008

OLF guidelineNo. 122

Published in June 2008

Permanente structures

Export and intra field Pipelines and risers.

Drilling systems and Well integrity, including conductors, BOP and down hole equipment

Technical Safety Systems, ,Working Environment and Risk management

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.

Process Systems

Consent Applications for Life Extension of Facilities are submitted to the Petroleum Safety Authority (PSA) Norway and Norwegian Petroleum Directorate (NPD).

Main Document

Sub- Documents

PTIL/PSA

Life extension applications

sgard 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, - 8pipeline 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 2028

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PTIL/PSA

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.

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PTIL/PSA

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.)

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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 that account for ageing, system effects of ageing, and the increasing likelihood of failures due to ageing.

Criticality evaluation:-Main safety functions? -Barrier?-Inspectable?

Documentation of technical and operational integrity.

Maintenance plan and system of KPIs and acceptance levels.

Assess integriy: Make Decisions:-Analyse and assess -Mitigating measuressafety in life extension -Operational restrictions-Evaluate mitigations -Future maintenance

Plan for implementation of measures and modifications.

Guiding documents and principles:-Present regulation-Risk reduction -ALARP-BAT-Continuous improvement

Maintenance according to existing plans and methods.

PTIL/PSA

Is it possible to inspect and mitigate?

Knowledge?

Good Some Poor

Measures?

Replace

Some

No

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A. Material degradation

- Material properties- Operation conditions- Environmental conditions- Maintenance practices

B. Obsolescence

- Equipment out of date- New needs- New technology- New requirements

C. Organisational issues

- Reorganisation- Ageing of personnel- Transfer of knowledge

AGEING MANAGEMENT

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Structure of Contents

Ageing and life extension management

Analyses of material degradation Obsolescence and organisational issues

Material handling and cranesWells

PipelinesRisers

Subsea production systems

Topside process

equipment

Safety systems

Specific part

General part

Challenges and Lacks of knowlege

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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.

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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 operators 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.

PTIL/PSA

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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Myth 1: Why life extension its just continuing normal operation.

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Myth 2: Life extension is just maintenance.

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A. Material degradation

- Material properties- Operation conditions- Environmental conditions- Maintenance practices

B. Obsolescence

- Equipment out of date- New needs- New technology- New requirements

C. Organisational issues

- Reorganisation- Ageing of personnel- Transfer of knowledge

AGEING MANAGEMENT

PTIL/PSA

Myth 3: If the facility is safe today, it is also safe tomorrow

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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!

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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.

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Ageing and life extensionBackgroundFacilities on the Norwegian continental shelfStrategyMain priorities of the PSASlide Number 6Life extension applicationsMajor challengesMain priorities of the PSASlide Number 10Is it possible to inspect and mitigate? Slide Number 12Structure of ContentsKnowledge gaps (SINTEF report)Recommended further research and development (SINTEF report)Further work in the PSASlide Number 17Myth 1: Why life extension its just continuing normal operation.Myth 2: Life extension is just maintenance.Myth 3: If the facility is safe today, it is also safe tomorrowMyth 4: Life extension is not a safety issue, it is just a cost issue.Myth 5: There is no statistics that indicate that ageing is a problem.