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Ageing and life extension

April 7th workshop

PTIL/PSA

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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Number

Facilities on the Norwegian


continental shelf
14

12

10

Installation year

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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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Main Document

OLF guideline
No. 122
Published in June 2008
Sub- Documents

Permanente structures

Offshore
Structures
Published May 2008

Export and intra field


Pipelines and risers.

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.

Drilling and Well


Systems
Check List

Drilling systems and Well


integrity, including
conductors, BOP and down
hole equipment

Published in May 2008

Transport
Systems

Process
Systems

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).

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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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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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

Ageing relevant for this


SSC?
*

Guiding documents and


principles:
-Present regulation
-Risk reduction
-ALARP
-BAT
-Continuous improvement

Future use:
-Planned changes and
modifications to facility
-Planned changes in
operation of the facility
-Changes in risk due to
modifications

Maintenance according
to existing plans and
methods.

Criticality evaluation:
-Main safety functions?
-Barrier?
-Inspectable?
Assess integriy:
-Analyse and assess
safety in life extension
-Evaluate mitigations

Documentation of
technical and operational
integrity.

Make Decisions:
-Mitigating measures
-Operational restrictions
-Future maintenance

Plan for implementation of


measures and
modifications.

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

Maintenance plan and


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Is it possible to inspect and


mitigate?
Knowledge?

Good

Some

Poor

Replace

Some
Measures?

No

PTIL/PSA

AGEING MANAGEMENT

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

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Structure of Contents
Ageing and life extension management
General
part

Obsolescence and
organisational issues

Analyses of material degradation

Specific
part

Wells

Pipelines
Risers
Subsea production
systems

Topside
process
equipment

Safety
systems

Material handling and


cranes

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.
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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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PTIL/PSA

Myth 1: Why life extension its just


continuing normal operation.

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Myth 2: Life extension is just


maintenance.
AGEING MANAGEMENT

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

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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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