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Article history: Technological advances in exploration and production mean that production platforms in Chinese Bohai
Received 1 July 2014 Bay have many developments that are now operating beyond their original design life. As equipment
Received in revised form ages, there are increasing challenges to maintain its integrity. Issues related to LE management of
10 November 2014
offshore facilities in government regulations, industrial associations and international oil companies
Accepted 2 December 2014
Available online 3 December 2014
were investigated. The results showed that emphasizing the requirements of labor union and industrial
associations was a great feature in Norway, which was practical in Chinese Bohai Bay. Therefore, with the
combination of the LE management system in Norway with the current situation in Chinese Bohai Bay, LE
Keywords:
Offshore platform
management model which integrates RBI, RCM, FMECA, and SIL risk assessment methods together was
Life extension designed in order to improve understanding and ensure that LE issues were addressed across all aspects
Ageing of asset management during the entire LE period. Finally, an example of three production offshore
Topsides process system platforms on a gas field in the Bohai Bay was used to go through the LE management process and address
Risk assessment the issues in each phase. The suggestions for improving LE management and technologies were given.
© 2014 Elsevier Ltd. All rights reserved.
1. Introduction
failure with time (Kancev and Cepin, 2011; Kancev et al., 2011; Gran
et al., 2012).
Offshore ageing platforms in China are mainly distributed in the This paper is aimed at investigating a kind of LE management for
Bohai Bay and South China Sea. The first offshore platform, offshore production platforms to demonstrate that there is suffi-
ChengBei, which is still in production, reached its original design cient technical, operational and organizational integrity to continue
life in 2005. In the South China Sea, the WeiZhou10-3 platform safe operation beyond the LE period.
came into LE stage at first in 2008. This paper first explains the LE background in the Bohai Bay and
The age profile for fixed platforms in the Bohai Bay is shown in the principles of establishing an LE management system. The next
Fig. 1. This indicates that almost 40, approximately 43.8% of the total section describes the development of LE management in the North
population, will be beyond their original design life by 2021. It is Sea. The third section designs an LE management model for top-
evident that this proportion is steadily increasing with time, sides process systems. Section four illustrates and discusses an
particularly as the rates of decommissioning and new installations application case of LE management model. Conclusions are re-
are relatively low. ported in section five.
The successful implementation of an LE management plan for
offshore installations depends on the understanding of the degra-
dation process, the availability of an appropriate level of data on the 2. LE management development in the North Sea
actual condition of the equipment, reliable assessment methods
and an implementation strategy to deal with the increasing risk of Many offshore installations in the North Sea are now reaching or
have exceeded their original anticipated design life of typically
around 25 years in Fig. 2. LE is a necessary phase in the life cycle of
many offshore installations on both the UKCS and NCS.
* Corresponding author. Over 127 platforms, 50% of the total population of fixed plat-
E-mail address: liuyangyangag@gmail.com (Y. Liu). forms on the UKCS, exceeded the original design life in 2003 (Stacey
http://dx.doi.org/10.1016/j.jlp.2014.12.002
0950-4230/© 2014 Elsevier Ltd. All rights reserved.
358 H. Liu et al. / Journal of Loss Prevention in the Process Industries 35 (2015) 357e365
3. LE management model
Design & installation Operation Life extension period Failures and challenges analysis involves applying RBI technique
1 Material(s), protection, 14 Information about 21 Information about
to static mechanical equipment, RCM technique to rotating and
insulation maintenance and planned maintenance machinery equipment, and SIL technology to instrumented pro-
2 Process definition and modification and modification tection systems. As for the obsolescence and organizational chal-
design criteria 15 Process/operation 22 Process/operation lenges, gap analysis was used to identify challenges.
3 Equipment parameters parameters
specifications 16 Info. from condi- 23 Changes in classification
4 Design codes and tion monitoring due to change in oper- 3.3.1. Introduction of risk assessment methods
standards 17 Info. from inspec- ation parameter
RBI analysis is primarily intended to be used for the planning of
5 Design drawings tion/testing 24 Length of life extension
6 Design life calculations 18 Info. from similar period in-service inspection for offshore topsides static mechanical pres-
7 Operation and process operation sure systems when failures by loss of containment of the pressure
info. 19 New standards and envelope (DNV, 2010) are considered.
8 Installation load recommended
RCM is closely related to, and takes its form from FMECA. It is an
9 Installation accidents practice
10 As-installed/built 20 New tools/design
approach which places emphasis on analyzing the system func-
documentation methods/experi- tions, function failures, and prevention of these failures. RCM
11 Technical and engi- ence since design techniques can be used to create a cost-effective maintenance
neering queries and blueprint to identify risk criteria, the symptoms of system func-
variations
tions, and address the main causes of systems failure and equip-
12 Close-out and certifi-
cation packs ment failure.
13 Design records Adequate SIL levels could be established for the different
required for final instrumented protection systems, and right lever of layers of pro-
decommissioning
tection would be identified. This was carried out in accordance with
planning
Industry Practice IEC61508/511. Alternative codes could also be
agreed. Then the SIL validation was followed up (Grossel, 2005; 3.4. LE management planning and implementing
Langeron et al., 2008).
The purpose of a maintenance program in Fig. 6 is to control all
risks associated with degradation of equipment. The program shall
include activities and maintenance intervals per equipment.
3.3.2. Obsolescence and organizational challenges Input to the process was the system breakdown structure and
With respect to obsolescence, it is necessary to identify chal- functional classification of the process system in question. Then, an
lenges related to requirements and regulations, new and advanced RCM/RBI/SIL analysis was carried out. Identification of relevant
technology (IAEA, 2009), outdated technology (Hollins, 2009; HSE, failure modes and estimation of failure probability should primarily
2012), spare parts, new operational conditions and anticipated be based on operational experience of the actual equipment, and
needs during the LE period, overall layout and space challenges on alternatively on generic failure data from similar operations. Again,
the facility (Hokstad et al., 2010). the task involved authority/company requirements.
Another main question is whether sufficient human resources For equipment classified with low consequence of failure, a
are available to operate during the LE period. Possible organiza- planned corrective maintenance strategy may be selected (run to
tional challenges during the LE period are related to human re- failure). However, a minimum set of activities to prolong lifetime
sources (No 2008; HSE, 2012). A disciplined approach to matters is may also be considered.
needed so that the loss of an individual from organization does not Finally, all the maintenance tasks should be packed and sched-
disproportionately impair operational capability (UK, 2012). uled, considering production plans of the plant, resources re-
Considering management structure of the duty holder in Fig. 7 quirements, and schedule should be turned around to derive to the
composed of platform senior leader, technical director, supervisor final maintenance plan.
(Conchie et al., 2013), and site personnel (O'Dea and Flin, 2001)
including maintenance personnel and operation personnel, main-
taining a trained and competent work force with an awareness of 3.5. Measuring effectiveness of LE management model
equipment is an important issue for LE (Mearns and Flin, 1995;
Qingfeng et al., 2011). A gap analysis was conducted by providing Applying indicators to evaluate safety integrity is important for
a check list for identifying obsolescence and organizational risk follow-up and decision making during operation of ageing facilities.
factors (Mearns and Flin, 1995; Vinnem et al., 2012), including de- An indicator of ageing is a sign or evidence that some damage has
viation from new requirements, new needs, new technology, lack of already occurred or is about to occur, and can be thought of as
spare parts, lack of space and lack of competence. symptoms of ageing damage. Duty holder had KPIs in place to aid
the LE risk assessment or operational performance against defined Propose actions to extend the service life beyond the design life
leading and lagging indicators (Vinnem et al., 2006; Vinnem, 2010). assumed to be 20 years
These arrangements included KPIs designed to monitor and mea- For the static mechanical equipment, assess failure risks
sure the effectiveness of LE management. (probability of failure, consequences of failure)
Some of the Various Types of Indicators are inspection/moni- Recommend an RBI strategy to keep failure risks below
toring results. The occurrence of specific failures/failure modes, acceptable levels
number of various undesired events, and reduced performance of For the machinery rotating equipment, assess reliability and
process of quality of product are observed, status with respect to failure modes
obsolescence, status with respect to organization and human re- Recommend an RCM strategy to maintain current levels of
sources (Hokstad et al., 2010). reliability
For instrumented protection systems, assess the probability of
4. Application case accident scenarios, and specify SIL related to each SIF loop.
Select some typical SIF loops to do the SIL verification. Recom-
In this study, the LE management model was developed on three mend an SIS strategy to maintain the specified SIL.
offshore production platforms on a gas field in the Bohai Bay, which Recommend work processes of the management system to
was aimed at developing improved practices to ensure the safe ensure asset integrity is managed and demonstrated for the
operation of topsides process system of the ageing production extended life of the systems
platform, and identify shortcomings in duty holder's approaches.
The platforms were commissioned in 1992, and the age of the
facilities reached 21. On the basis of a typical design life of 20 years, 4.2. (Step 0) system breakdown
it can be assumed that the facilities are now operating beyond their
original design life. System breakdown can be used both on system level and on
component level, see Table 2.
4.1. Study objective
4.3. (Step 1) collect background information
This LE pilot study has been commissioned by duty holder with
the following objectives for static mechanical equipment, ma- Most critical information can be collected from operation
chinery rotating equipment and instrumented protection systems: manual, maintenance manual and enterprise software system
(Table 3).
Determine the condition and current life expectancy of the The collection and systematization of information at different
systems stages is indicated in Table 1. For each system or component, the
Table 2
Equipment or components chosen for further analysis.
Table 3 Table 4
Source of input information. Degradation status of static mechanical equipment.
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