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HSE AGEING & LIFE

EXTENSION INSPECTION
PROGRAMME
Alex Stacey
Offshore Division
Health & Safety Executive

PRESENTATION OUTLINE
Ageing on the UKCS
Background information
Importance to HSE / Industry / Stakeholders
Regulations

HSE / OSD activities on Ageing

Related interventions
Guidance
S&T
Pilot Study on Ageing Installations
Scope
Inspection findings

Ageing & Life Extension Inspection programme


Programme scope

UKCS Installations (DECC)


300

250

250
200

200

146 installations
108 installations
>20 years old
>25 years old

150

150
100

100
50

50
0

1968
1968
1970
1970
1972
1972
1974
1974
1976
1976
1978
1978
1980
1980
1982
1982
1984
1984
1986
1986
1988
1988
1990
1990
1992
1992
1994
1994
1996
1996
1998
1998
2000
2000
2002
2002
2004
2004
2006
2006
2008
2008

No of UKCS installations in production


No of UKCS installations in production

300

Year of first oil/gas

Year of first oil/gas

Small steel jacket


Small steel jacket
Large steel jacket
Large steel jacket
Jackup
Jackup
Concrete GBS
Concrete GBS
Semi-sub
Semi-sub
FPSO
FPSO
TLP
TLP

RENEWED FOCUS ON AGEING


AND LIFE EXTENSION

Cash Flow

Traditional models of dwindling reserves & increasing


O&M costs predict end of life
revenue

Cost (ops &


maintenance)

time
Probability of end
of life

Enhanced recovery methods and the good market drive


life extension
Is asset being managed adequately?

19
78
19
79
19
80
19
81
19
82
19
83
19
84
19
85
19
86
19
87
19
88
19
89
19
90
19
91
19
92
19
93
19
94
19
95
19
96
19
97
19
98
19
99
20
00
20
01
20
02
20
03
20
04
20
05
20
06
20
07

Annual oil production (Million cu.m)

AGEING PRODUCTION

Year

2007 Supply - Reliance on Older


Fields
16%
Morecambe S

Oil

Buzzard

14%

Proportion of production from field

Dry gas
Associated gas

Britannia

12%

10%
Rough
8%

6%

Elgin

Foinaven

Forties
Brent

4%

Beryl

Leman Per.
Leman Shell
West Sole

Ninian
Claymore
Magnus
Viking
Beryl
Brent

2%

0%
0

10

15

20

25

Age of installation

30

35

40

45

LOSS OF INTEGRITY
Ageing: Potential for accumulating and / or accelerating
damage and subsequent loss of integrity
Need to focus on asset integrity management (AIM) of
ageing (organisational issues, inspection, technology)
Need:
good data on current condition
understanding of degradation processes &
response
use of best technology / latest assessment methods
(e.g. system strength) to determine safety margins
development of new techniques (e.g. online
monitoring)
implementation strategy

Bathtub Curve

Wear-out
phase

Early life
failures

Steady failure rate

Time

EXAMPLES OF DETERIORATION

Elect/Inst cables & tray

Door on TR HVAC room

Main truss below lifeboat

Cellar deck grating support steel work

EXAMPLES OF DETERIORATION

Blast wall connections

KP3: ASSET INTEGRITY KEY


PROGRAMME
KP3 Aim
To ensure that duty holders manage effectively the risk of
any failure of structure, plant, equipment or systems, which
could either cause or contribute to, or prevent or limit the
effect of, a major accident and / or cause fatalities.

KP3 Focus
The integrity management of safety critical elements
(SCEs), which provide the barriers to major accident
hazards
Concentrated on the current condition of key assets, not
the management of future integrity / ageing issues

KP3 BACKGROUND
Weaknesses in the implementation of the
independent verification process

Emphasis on costs (resulting in reduced manning


and multi-tasking) affecting potential safety
performance
Backlog of maintenance work
Significant incidents due to maintenance or integrity
failures

AGEING SCENARIOS
Time-dependent mechanisms
Fatigue (welded connections, piles, supports)
Corrosion
Creep (non-metallic components)

Damage or deterioration over time


Accidental damage (ship impact, dropped objects cumulative
effects)
Environmental overload
Geological & geotechnical (subsidence, scour, pile failure)

External changes with time

New technologies / understanding


More stringent standards
Failure to adapt to change
Obsolescence
Loss of knowledge base

UK REGULATORY PROVISIONS
FOR AGEING

SCR (2005): 5-yearly safety case thorough review and revision

Safety case revision if proposed to extend use beyond design life


(Explicit reference to life extension clarifies the need for specific consideration)

DCR (1996):
Periodic maintenance / remedial work
Performance standards
Independent verification by ICP

PFEER (1995): inherent safety by design, preventive, detection, control and mitigation measures

PUWER (1998): control of hazards due to equipment failure; requirement for appropriate
inspection and maintenance procedures to be in place

PSR (1996): life cycle requirements to


maintain pipeline in an efficient state, in efficient working order and in good repair;
identify hazards, evaluation of risks (including susceptibility to damage)

HSWA (1974) / MHSWA (2003)

Use of modern codes & standards, good practice (e.g. HSG65):


- Policy, Organisation, Planning, Maintenance, Audit, Review

Safety Management System (OGP)

OSD ACTIVITIES ON AGEING


Technical policy and strategy on ageing (structural integrity)
Thorough Reviews & Safety Cases
Inspection

SIMIP
Pilot study on ageing installations (2009)
Development of full inspection programme on Ageing & Life Extension: 2010 - 2013

S&T

Technology projects, e.g.:


SI: SIM, overview of ageing on UKCS, life extension, new technology, review of worldwide
practices, structural monitoring, mobile installations issues, fatigue, residual stresses,
materials
Corrosion
Standards and guidance, incl. HSE Information Sheet 4/2009 on Thorough Review guidance

Stakeholder engagement

Dissemination (e.g. OMAE, PSA, IMechE, IChemE)


Ongoing collaboration with PSA, Norway
Ageing Network (2010 / 11)

STAKEHOLDER ENGAGEMENT:
HSE / PSA COLLABORATION
Regular HSE / PSA meetings (AS / Gerhard Ersdal, Rolf Hinderaker,
Erik Hrnlund)
PSA seminar Ageing Installations & Life Extension, 25 May 2007
PSA seminar Ageing Installations & Life Extension, November
2007
OMAE conference, HSE / PSA Workshop on Ageing, June 2008
HSE / PSA Ageing meeting, February 2010
Structural integrity, corrosion, F&B, process integrity, mechanical
integrity, electrical & control systems, pipelines
PSA Seminar on Ageing & Producing Life Extension, 7-8 April 2010

OSD ACTIVITIES ON AGEING


Technical policy and strategy on ageing (structural integrity)
Thorough Reviews & Safety Cases
Inspection

SIMIP
Pilot study on ageing installations (2009)
Development of full inspection programme on Ageing & Life Extension: 2010 - 2013

S&T

Technology projects, e.g.:


SI: SIM, overview of ageing on UKCS, life extension, new technology, review of worldwide
practices, structural monitoring, mobile installations issues, fatigue, residual stresses,
materials
Corrosion
Standards and guidance, incl. HSE Information Sheet 4/2009 on Thorough Review guidance

Stakeholder engagement

Dissemination (e.g. OMAE, PSA, IMechE, IChemE)


Ongoing collaboration with PSA, Norway
Ageing Network (2010 / 11)

HSE GUIDANCE ON THOROUGH


REVIEWS - OIS 4/2009
Thorough review of the safety case
Thorough review summary
Asset life extension

Management of ageing
Fire and explosion risk assessment
Risk assessment
Options for addressing ageing

Structural integrity

Structural integrity management


Life extension

Performance indicators
Organisational issues

Issues with ageing

AGEING SI S&T: 2008 - 2011

Framework for the Structural Integrity Management of Fixed Installations

Framework for the Structural Integrity Management of Mobile Installations


____________________________________________________________________

Review of Classification Society Rules for Floating Installations on the UKCS

Evaluation of Worldwide Practices on the Structural Integrity Management and


Regulation of Ageing Installations

Overview of the UK's Ageing Offshore Infrastructure

Techniques and Technologies for Ageing Jacket Integrity


____________________________________________________________________

Review and Appraisal of Current Structural Integrity Monitoring Technologies for


Offshore Applications

Review and Assessment of Material Property Requirements for Mobile Installations

Further Study of Fatigue Damage to Girth Welds From Low Stresses in the
Loading Spectrum (JIP)

Investigation of Residual Stresses in Welded Joints (JIP)

OSD ACTIVITIES ON AGEING


Technical policy and strategy on ageing (structural integrity)
Thorough Reviews & Safety Cases
Inspection

SIMIP
Pilot study on ageing installations (2009)
Development of full inspection programme on Ageing & Life Extension: 2010 - 2013

S&T

Technology projects, e.g.:


SI: SIM, overview of ageing on UKCS, life extension, new technology, review of worldwide
practices, structural monitoring, mobile installations issues, fatigue, residual stresses,
materials
Corrosion
Standards and guidance, incl. HSE Information Sheet 4/2009 on Thorough Review guidance

Stakeholder engagement

Dissemination (e.g. OMAE, PSA, IMechE, IChemE)


Ongoing collaboration with PSA, Norway
Ageing Network (2010 / 11)

AGEING & LE INSPECTION


PROGRAMME
Pilot study on ageing installations: 2009

3 duty holders
Generic management, Structural integrity, Fire & explosion,
Corrosion, Pressure systems integrity
Set of standard questions for each topic area templates
Ageing & LE Inspection Programme: 2010 - 2013
Review of findings from pilot study
Development of full programme for 2010 2013

PILOT STUDY
Inspection Overview
Duty
Holder

Platform

DH1

P1

DH2

P2

DH3

P3

Structural
Integrity

Fire &
Explosion

Corrosion

Pressure
Systems
Integrity

No consideration of
or management of
Serious deficiencies
ageing
requiring immediate
attention
Awareness of
Matters
raised
ageing. Some
formally
to
evidencelinked
of ageing
ongoing
work or
being managed.
change
AIM system takes
No
full matters
accountneeding
of
formal
raising
with
ageing
the DH

PILOT STUDY
Key Findings
Findings to date suggest lack of full recognition of the significance
of ageing processes in connection with life extension beyond the
original design life
Ageing not considered explicitly
Varied approach between DHs and topics asset maintenance
not always a high priority
Influence of commercial pressures on AIM
Reliance on contractors and ICP

All 3 DHs aware of OIS 4/2009 (HSE website)


All 3 DHs receptive to an industry forum on ageing issues

AGEING & LE INSPECTION


PROGRAMME 2010 - 2013
Aims:
to inspect DHs safety management systems with
respect to
the arrangements for the thorough review of safety cases
the management of the risks to asset integrity associated with
ageing and life extension

to identify shortcomings in duty holders approaches


to develop improved practices to ensure the safe
operation of all offshore installations on the UKCS

AGEING & LE INSPECTION


PROGRAMME 2010 - 2013
Full programme: 2010 2013

Launch: 19 May 2010, Aberdeen


Supported by policy and strategy documents
Ageing fixed and mobile installations

Inspection of DH AIM systems - special focus on key installations


Onshore and offshore inspections
Topic areas: structural integrity, process plant integrity, pressure
systems integrity, materials (including corrosion), mechanical
integrity, maritime integrity, electrical & control systems integrity,
wells, pipelines, organisational issues

INSPECTION PROGRAMME Details


Fixed platforms

Semi-submersibles
& FPSOs

Jack-ups

Onshore

Offshore

Onshore Offshore Onshore Offshore

Year 1

Year 2

Year 3

Duty holder prioritisation:


- asset / platform age
- manning
- known issues (PAITs / TRs)

INSPECTION PROGRAMME Supporting Activities


Stakeholder engagement
Press releases
Dissemination (workshops, seminars, conferences,
journals, etc.)
Liaison with key industry bodies (e.g. OIAC, Step Change
In Safety, Oil & Gas UK, IADC, BROA)
Ageing webpage

S&T on A&LE aspects of AIM


Review & updating / development of standards and
guidance, incl. OIS 4/2009 on Thorough Review
Guidance

INSPECTION PROGRAMME
Key Outputs
Final report
Guidance on Ageing, Life Extension & the Thorough Review
process
Industry network for the exchange information and
experience on ageing and life extension issues
Development of best practice on ageing
Improved asset integrity management

PRESENTATION OUTLINE
Ageing on the UKCS
Background information
Importance to HSE / Industry / Stakeholders
Regulations

HSE / OSD activities on Ageing

Related interventions
Guidance
S&T
Pilot Study on Ageing Installations
Scope
Inspection findings

Ageing & Life Extension Inspection programme


Programme scope

CONCLUSIONS
Consideration of ageing issues is a key element of asset /
installation integrity management
Operating beyond the intended design life brings
technological, managerial and economic challenges
Findings to date suggest lack of full recognition of the
significance of ageing processes in connection with life
extension beyond the original design life
HSE needs to work with the UK industry and towards a unified
approach to the integrity management of ageing offshore
infrastructure across all installation types
Way forward: Ageing & LE Inspection Programme
Ageing offshore installations are set to be a key HSE priority
for the foreseeable future

www.hse.gov.uk