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Structural Integrity Management for Aging Offshore Infrastructures
2016 US-China Oil and Gas Industry Forum
2 an employee-owned company
Structural Integrity Management for Aging Offshore Infrastructures
• Types of infrastructure considered Fixed platforms Floating production systems
– Semi – FPSO – TLP – SPAR
Subsea Equipment Pipelines (both rigid and flexible) Flowlines (both rigid and flexible)
3 an employee-owned company
API Floating Systems Standards
• API RP 2FPS, Planning, Design, and Constructing Floating Production Systems • API 2A-WSD, Planning, Designing and Constructing Fixed Offshore Platforms-Working
Stress Design • API Spec 2C, Specification for Offshore Cranes • API RP 2D, Recommended Practice for Operation and Maintenance of Offshore Cranes • API Bull 2INT-MET, Interim Guidance on Hurricane Conditions in the Gulf of Mexico • API RP 2MOP, Marine Operations • API RP 2RD, Recommended Practice for Design of Risers for Floating Production
Systems (FPSs) and Tension-Leg Platforms (TLPs) • API 2SIM, Structural Integrity Management of Fixed Offshore Structures • API RP 2SK, Design and Analysis of Station Keeping Systems for Floating Structures • API RP 2T, Recommended Practice for Planning, Design and Constructing Tension Leg
Platforms • API Bull 2U, Stability Design of Cylindrical Shells • API Bull 2V, Design of Flat Plate Structures • API RP 14J, Recommended Practice for Design and Hazards Analysis for Offshore
Production Facilities • API RP 75, Recommended Practice for Development of a Safety and Environmental
Management Program for Offshore Operations and Facilities • AISC 360-05, Specification for Structural Steel Buildings • AWS D1.1, Structural Welding Code - Steel
4 an employee-owned company
Organizational Elements of API RP 75 • Safety and Environmental Information • Hazards Analysis • Management of Change • Operating Procedures • Safe Work Practices • Training • Pre-Startup Review • Emergency Response and Review • Investigation of Incidents • Audit of Safety and Environmental Management Program
Elements • Records and Documentation
5 an employee-owned company
API RP 75 • Recommended Practice for Development of a
Safety and Environmental Management • Program for Offshore Operations and • Facilities • Contains 12 building blocks or “elements”
1 Equipment-based
11 Organizational
• Not labeled as IM, but content is similar to major oil company IM programs
6 an employee-owned company
Primary Damage Mechanisms
• Age
• Construction flaws
• Corrosion
• Fatigue
• Storms
• Lack of maintenance and upkeep
7 an employee-owned company
Structural Integrity - Examples
8 an employee-owned company
Hurricane Damage
9 an employee-owned company
Why is Integrity Management (IM) important?
• Emotional and economical cost to families from the loss of loved ones.
• Impact to the environment
• Impact to a company’s reputation
• Financial impact
• Loss of production
10 an employee-owned company
IM Cycle
Plan Implement
Measure
Document
ImproveIM Cycle
Plan Implement
Measure
Document
ImproveIM Cycle
Develop Plans (Risk-based, if applicable) and Procedures:
Monitoring
Inspection
Testing
Maintenance
Implement Plans
Measure Results – KPIs
Document Results
Identify Improvements/Changes
Periodic “Health Check” Assessments
“Sur
veill
ance
”
11 an employee-owned company
Components of FSIM • Overall weight management
and stability considerations
• Deck and Deck structure
Strength and fatigue
• Station keeping Systems – mooring lines, tendons, foundations/anchors, hull-mounted equipment
• Riser Systems – riser pipe, buoyancy, tensioners, porches
• Global performance – analytical versus measured
• Marine or Performance Monitoring
• Marine Systems – ballast, bilge, seawater
12 an employee-owned company
Full Life Cycle Approach
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate
Project Life Cycle
Functions
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Moorings/Foundations
Moorings/Foundations
RisersRisers
SubseaEquipment
SubseaEquipment
WellsWells
Drilling Drilling
Topsides EquipmentTopsides Equipment
DeckStructure
DeckStructure
HullStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate Decommission& Remove
Decommission& Remove
Commission/Test
Commission/Test
Fabricate/ManufactureFabricate/Manufacture
Design Design Install/Assemble
Install/Assemble
OperateOperate
Project Life Cycle
Functions
13 an employee-owned company
• Requires strong management direction and support
• Includes involvement from: Design to Decommissioning and Removal
Deficiencies or defects may occur at any stage of a project
Not just an “Operations” issue
Full Life Cycle Approach
14 an employee-owned company
Full Life Cycle Approach
• System Definition Functional requirements System Architecture
• Risk Assessment System or Component FMECA or FTA
• Design • Verification and Validation • Manufacture • Installation • Operations and Maintenance
15 an employee-owned company
Full Life Cycle Approach (Risk)
Hazard
Incident or Accident
Hazard
Incident or Accident
Decommission & Remove
Commission/ Test
Fabricate/ Manufacture
Design Install/ Assemble
Operate
Project Life Cycle
Swiss Cheese Failure Model
Barriers against failure
16 an employee-owned company
Full Life Cycle Approach – Examples of Unintended Failures (Risk)
• Design Barrier: Industry-accepted design codes are presumed to
provide adequate safety.
Unintended Weakness: Codes are applied outside of their originally intended scope.
• Fabricate/Manufacture Barrier: High quality material specifications are provided for
the project.
Unintended Weakness: Counterfeit material is used because of poor Quality Assurance processes.
17 an employee-owned company
Sleipner – North Sea - 1991
• Concrete gravity based structure • As it was deballasted onto the seafloor, rumbling noises
heard, followed by the sound of seawater pouring into the unit
• Began sinking and the buoyancy chambers imploded
Courtesy: Statoil
18 an employee-owned company
Sleipner Root Cause
• Inaccurate finite element approximation during calculations in the design of the structure.
• Stresses on the ballast chambers were under estimated by 47% and some concrete walls were designed too thin.
19 an employee-owned company
Ocean Ranger
February 15, 1982 The world’s largest semi-submersible capsized and sank on the Grand Banks with the loss of 84 crew members.
20 an employee-owned company
Ocean Ranger Canadian Royal Commission Findings
• Crews were not trained in emergency response.
• Safety equipment was inadequate.
• There were design and construction flaws, particularly in the ballast control room.
• Detailed instructions and personnel trained in the use of the ballast control panel were not available
21 an employee-owned company
Alexander Kielland – North Sea 1980
• The flotel lost one of its five legs in severe gale force winds, but not an extreme storm.
• The accident started with one of the bracings failing due to fatigue, thereby causing a succession of failures of all bracings attached to this leg.
• 123 Fatalities
22 an employee-owned company
This was traced to a small 6mm fillet weld which joined a non-load-bearing flange plate to this D-6 bracing.
This flange plate held a sonar device used during drilling operations.
Alexander Kielland – North Sea 1980
23 an employee-owned company
P-36 - Brazil
24 an employee-owned company
North Sea and Gulf of Mexico Major Incidents
25 an employee-owned company
Full Life Cycle Approach
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate
Project Life Cycle
Functions
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate
Moorings/Foundations
Risers
SubseaEquipment
Wells
Drilling
Topsides Equipment
DeckStructure
HullStructure
Moorings/Foundations
Moorings/Foundations
RisersRisers
SubseaEquipment
SubseaEquipment
WellsWells
Drilling Drilling
Topsides EquipmentTopsides Equipment
DeckStructure
DeckStructure
HullStructure
HullStructure
Decommission& Remove
Commission/Test
Fabricate/Manufacture
Design Install/Assemble
Operate Decommission& Remove
Decommission& Remove
Commission/Test
Commission/Test
Fabricate/ManufactureFabricate/Manufacture
Design Design Install/Assemble
Install/Assemble
OperateOperate
Project Life Cycle
Functions
26 an employee-owned company
Thank You!