IMPLEMENTATION OF A GLOBAL RBI STANDARD – EXPERIENCES AND CHALLENGES Maintech-konferansen 2016

Trondheim 30.03.2016

Roar Bye, Teekay Offshore Production

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• Teekay Offshore Production

• Background

• The Ambition

• The Contract (SoW/contract strategy/organization)

• Experiences

• Piranema Spirit – a case

• Looking forward & Key Success Factors

Topics

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Teekay Offshore Production TOP

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Our Fleet

Solid Customers Portfolio TEEKAY

OFFSHORE AT A GLANCE $

30+ Years of Experience

2000+ Employees

60+ Offshore Vessels

7 Offices Europe, Canada, Brazil, Philippines

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11 FPSO units

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Petrojarl Knarr (BG Norge)

Petrojarl Varg (Talisman)

Petrojarl I* (QGEP)

Piranema Spirit (Petrobras)

Petrojarl Foinaven (BP)

Voyageur Spirit (E.ON)

Hummingbird Spirit (Centrica Energy)

Petrojarl Banff (CNR) Petrojarl

Cidade de Itajai (Petrobras)

Petrojarl Cidade de Rio das Ostras (Petrobras)

Libra** (Petrobras)

(*upgrade ongoing) (**under conversion)

• Largest independent operator of FPSOs in the North Sea

• 30+ years of experience • Growing presence in Brazil • Potential to competitively

pursue FPSO projects anywhere in the world

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Background

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Teekay Petrojarl 2011 – RBI Contractors

Petrojarl Foinaven (BP)

Petrojarl Banff (CNR)

Petrojarl Cidade de Itajai (Petrobras)

Petrojarl Knarr (BG Norge)

Petrojarl Varg (Talisman)

Petrojarl I (StatoilHydro)

Sevan Voyageur (E.ON Ruhrgas)

Petrojarl Cidade de Rio das Ostras (Petrobras)

Sevan Piranema (Petrobras)

Sevan Hummingbird (Centrica Energy)

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Asset Integrity Management in TOP

• Corrosion Management Corrosion management shall be addressed in all design phases and follow the sequence:

• Material selection • Surface protection • Internal surface protection • Chemical treatment • Monitoring (instrumentation,

laboratory sampling, observations)

• Inspections (RBI)

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The Ambition

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• Establish a global TKPJ standard for Risk Based Inspections and handling of anomalies.

• Establish and implement best practice of integrity management of topside process plant (pipes and drums)

• Reduce risk of loss of containment and possible major accidents (ALARP)

• Establish a web based arena that encourages experience transfer across units and full transparency of integrity status

• Establish a partnership with a global RBI services’ supplier that has the same level of ambition wrt. operational excellence

• Establish a long long-term integrity focus in accordance with authorities’ expectations for long term integrity management of ageing units

The Ambition

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The Ambition

Oceaneering approach to Global RBI Contract

• Comprehensive and consistent service across the fleet and all

locations

• Increased reliability and predictability in performance, risk and

safety

• Access to global support and capability

• Cross fleet knowledge and experience transfer

• Enhanced vessel lifetime planning

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The Contract (SoW/strategy/ organisation)

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The contract SoW and strategy Scope of Work Compensation Contract startup Lump sum Familiarisation, RBI analysis (initial and detailed), start-up and handover

One-off payment

Onshore work Lump sum RBI analysis (annual update) Annual payment

Inspection planning Reporting Support to TKPJ Operation (meetings etc.)

Long term integrity management Offshore Work Reimbursable Inspection By the hour

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The contract organisation (R&Rs) • Contract Owner

• TOP contract Holder • OAI Contract Holder

• Quality, standardisation, working principles, alignment • TOP Technical Authority Integrity Engineering • OAI Senior Corrosion Engineer/ OAI Senior Inspection Engineer

• Single point of contact - FPSO level • TOP Maintenance Superintendent • OAI Asset Responsible

• Inspection execution • Fixed rotation • Campaigns

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Our Experiences

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• Documentation gathering and hand-over • availability, traceability, quality, lack of, inconsistence in

data/documentation • No complete RBI or inspection history from incumbent contractors

were handed over for any of the FPSOs

• Underestimation of complexity and workload of simultaneous operation support and establishment of RBI system • Access to docs, data extraction, QA/QC

Experiences

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• Steep learning curve for TOP: • Integrity management capacity and competency (corporate and

asset level) • Governing documents revised during start-up

o RBI procedure o Anomaly management o Document management

Experiences, cont.

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• Rules and legislations differ from North Sea to Brazil • E.g. NR-13

• Inspection regime is different between NCS and UKCS: • Offshore Inspection Engineer • NDT Technician • UK QA formal processes (Senior endorsement)

• Contract interpretations – underestimated by both TOP and Oceaneering

Experiences, cont.

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Piranema Spirit – a case

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Piranema case – preferential weld corrosion

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• Welds inspected: ~ 1250 inspections • Mainly phased array • Radiography

• Repairs: • Total: 256 welds

o 54 spools - 22 lines o Pressure vessels

Piranema case – Weld repair project

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Looking forward & Key Success Factors

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• Review of: • Governing documents • RBI analyses • Inspection Program/Plans

• Establish Global TOP RBI Forum • Key personnel onshore and offshore • Contract understanding • Governing documents’ awareness

• Global RBI Workshop • Key personnel in Oceaneering and TOP

Improvement areas - TOP

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Facsimile from DN 14.03.2016

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RBI Web page – ‘one stop shop’

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Barrier dashboard

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Safety Case

MAH’s

Safety Critical Elements Register

Verification Scheme/ Performance Standards

Asset

Assurance Activities

Teekay Offshore Management Process

Barrier Strategy

Monitoring

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Key success factors

• Quality – ‘we never compromise on integrity’

• Transparency – ‘close the loop’

• Communication and alignment – ‘common understanding of the issues’

• Efficiency – ‘remember the R in RBI’

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