2009 IChem EHazards XXIPaper 127
2009 IChem EHazards XXIPaper 127
2009 IChem EHazards XXIPaper 127
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Gerhard Ersdal
University of Stavanger (UiS)
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Abstract
The Energy Institute (EI) has supported and co-ordinated an oil and gas industry
project to investigate potential measures for the ageing effects on Safety Critical
Elements (SCEs) as defined by the offshore safety regulations Prevention of Fire
and Explosion, and Emergency Response, (PFEER), and Design and Construction
etc. (DCR). This investigation has led to a measurement method of business
processes that can provide Leading Indicators and also a novel modification of the
Failure Modes, Effects and Criticality Analysis linked with ageing processes.
This assessment process is being supplemented by research supported by the
Norwegian Petroleum Safety Authority (PSA) which is looking at embedding
ageing assessments into the assurance processes leading to checks on the
performance of hazard barriers (as required by Norwegian safety regulations).
The paper will describe what these 2 projects have found and how between them
they have developed a synergy resulting in a range of assessment approaches,
produced Key Performance Indicators for ageing and have set a number of
principles for defining possible life extension.
Overview
Figure 1 encapsulates an overview of the ageing trends of equipment.
Where equipment has a safety critical function, at all times during the
installation’s lifecycle (in both the UK and Norwegian sectors) minimum
acceptability criteria must be set, below which the PSs of an SCE must not fall.
The Performance Indicators (PIs) concern the measurement of how well the
effects of ageing are being managed; when processes are being managed well,
Performance Standards will be maintained in the face of ageing.
Conclusions
In the work carried out for both sponsors, there has been much interest in
looking at Leading Performance Indicators. The authors have reported in previous
Hazards papers on the success of Maturity Modelling and it is our view that
Maturity Modelling again provides the most suitable candidate for Leading
Performance Indicators. Indeed, one of the follow-on activities from managing the
effects of ageing SCEs is by suitable maintenance and this formed the subject of
a paper by the authors at Hazards XX [Hart 2008]
In this project, a number of activities have been identified that can be used to
manage the effects of ageing on SCEs and structures (whether SCEs or not). For
each of these activities it is possible to identify Performance Indicators to
determine how well these activities are being carried out. The activities
undertaken by senior management have been combined into a maturity model
and represent a method of defining effective leading Performance Indicators to
supplement more convention measures of performance.
The consideration of the use of barrier theory has been used to assist the steps
required to develop life extension strategies and additional management
processes have been identified which enhance both management of the effects of
ageing and life extension.
References
Energy Institute, 2007(i): Capability maturity model for maintenance
management, Energy Institute Report, ISBN 978-0-85293-487-6.
Energy Institute, 2007(ii), Guidelines for the management of safety critical
elements, ISBN 978-0-85293-462-3
Galbraith, D., Sharp, J. V., 2007, Document id: POS-DK07-136 (for PSA)
Hart, K., Sharp, J.V., Wintle, J., Galbraith, D., Terry, E., 2008, Leading indicators
for the management of maintenance programmes; a Joint Industry Programme,
Hazards XX, IChemE
Health & Safety Executive, 1995, The Offshore Installations (Prevention of Fire
and Explosion, and Emergency Response) Regulations, Statutory Instrument
No. 743
Health & Safety Executive, 2005, The Offshore Installations (Safety Case)
Regulations, Statutory Instrument 2005 No. 3117
Health & Safety Executive, 2006, Developing process safety indicators: A step-
by-step guide for chemical and major hazard industries, HSG 254, ISBN
0717661806
Health & Safety Executive, 2007, Key Programme 3: Asset Integrity Programme,
http://www.hse.gov.uk/offshore/kp3.pdf
Sharp, J. V., Ersdal, G., Galbraith, D., 2008, Development of Key Performance
Indicators for Offshore Structural Integrity, 27th International Conference on
Offshore Mechanics and Arctic Engineering, OMAE
Wintle, J., Sharp, J. V., 2008, Requirements for Life Extension of Ageing Offshore
Production Installations, TWI Report 17554/1/08 (for PSA)
Wintle, J., Hart, K., Sharp, J.V., Galbraith, D., Terry, E., 2009, A Capability
Maturity Model for Maintenance Management Offshore; An Energy Institute Joint
Industry Project, Safe and Reliable Life Extension of Topside Equipment Offshore,
IMechE
Figure 1: Overview of ageing trends
Brief
General
Description of
Ageing Further Descriptive Notes
Ageing
Descriptors
Mechanisms
Specification Failure to adapt This ageing aspect concerns the specification and choice of equipment type based upon an
superseded (by to change equipment technology which is deemed to be no longer valid, i.e. no longer functional,
technology – discredited or obsolete.
equipment Note, that this may include;
Obsolescence
obsolescence)
o The cessation of suitable spares for the equipment
Improvements o Growing evidence of systematic breakdowns & reliability failures
in technology
and standards o Shortcomings identified under particular operating phases/conditions
(exacerbated by
loss of people, Example impacts might be;
experience and o Deluge valve internals no longer available (especially elastomeric throated valves)
expertise)
o Cracking of TEMPSC hoist points arising from partial launch tests
o Poisoning of gas detectors due to the offshore operating environment (where they
prove excessively sensitive to fumes/particles from regular maintenance)
Specification Improvements This ageing aspect concerns the specification and choice of equipment type based upon an
superseded (by in technology analysis method or technology which is deemed to be no longer valid.
technology – and standards Note, this may include;
incident/
consequence o Fire and explosion calculation methods
Loss of people,
analysis) o The durations of resistance of material to jet fire impingement
experience and
expertise o The calculated extent of gas dispersion
Specification Failure to adapt This ageing aspect concerns the potential changes to Major Accident Hazards which may
superseded (by to change render the Performance Standards of SCEs inadequate. Most carefully, it should be applied to
events) the accumulation of “creeping” changes whereby minor modifications to the process creates a
potentially major change.
Improvements
in technology Example impacts might be;
and standards o Increased fire loads potentially causing breach of key systems
o H2S break-through into producing wells but with no H 2S detection systems or NACE
rated pipe work
o Mothballed equipment containing residue hydrocarbons
External Physical This ageing aspect concerns the more traditionally acknowledged understanding of ageing
degradation deterioration whereby external conditions in the environment or action resulting from operations and
maintenance cause a degradation of the exterior of equipment.
A key issue with this form of ageing is that it is generally time-dependent rather than use-
dependent and will be easily identifiable without disassembly or performance testing, indeed,
the performance may be unaffected, certainly in the early stages of ageing.
Example impacts might be;
o Rust or other oxidation build-up on external surfaces
o Chipping and marking from maintenance work on adjacent equipment
o Accumulated damage from scaffolding
o Paint spray in sensitive areas, e.g. switch units or junction boxes from periodic
repainting
Internal Physical This ageing aspect concerns another more traditionally acknowledged understanding of ageing
degradation deterioration whereby the continued functioning of the equipment causes wear-out of internal materials and
components.
A key issue with this form of ageing is that it is use-dependent ands that the physical
degradation due to wear may not be easily identifiable without disassembly or performance
testing.
Example impacts might be;
o Valve stem seal leakage
o Flange degradation and seepage
o Bearing wear on rotating machinery
o Internal erosion on pipe walls and fittings (e.g. on bends or restrictions, orifice
plates, intrusive measuring devices)
Figure 2: Illustration of application of management processes
Process P1:-Development of a corporate strategy/policy for the management of ageing SCEs within the organisation as a whole.
a. Define top level strategic 1. Develop company objectives with respect 1. Company mission 1. Number of queries from regulators and 1. Company safety alerts
goals for management to ageing installations (and SCEs) statement referring to employees regarding company position on
2. Audit reports
of ageing SCEs for managing ageing asset status
2. Monitor industry trends and review
generic hazards installations 3. QA feedback
feedback from interested parties 2. Increasing number of deficiencies in ageing
(stakeholders) 2. Company annual returns SCEs reported from assets 4. Stakeholder queries &
responses
3. Establish a programme to compare 3. Company publicity
company objectives against competitors to literature
define ‘best in class’
4. Corporate Safety plan
referring to managing
ageing installations
Process P2:-Planning of the management of ageing SCEs based on the agreed strategy and policy and the defining of suitable performance indicators.
a. Interpret the strategy 1. Issue asset/project specific strategy 1. Project/asset HSE plan 1. Project queries from stakeholders due to 1. MoM
for a particular documents before start of project or absence of strategy statements
2. Project/asset HSE 2. Safety queries
installation and its SCEs. acquisition of asset
management system
3. HSE project inspections &
3. Safety case queries
4. Modules within documents
describing approach to
ageing SCEs
Process P3:-Implementing of schemes to gather performance and test data for performance indicators on the condition/management of ageing SCEs.
a. Undertake activities to 1. Testing regime and schedule established 1. Maintenance records 1. Decreasing level of performance of ageing 1. Maintenance records
measure data for PIs, eg early in the project/asset life and clearly systems and components in functional tests
2. Production reports 2. Production reports
tests on SCE with communicated
2. Increasing SCE unreliability or unavailability
respect to PSs, analysis 3. Production forecasts
2. Testing team with responsible competent due to ageing
of effectiveness of SCE
individuals appointed early in the 4. SCE compliance checks
control systems. 3. Increasing failure rates for ageing SCEs
project/asset life and clearly communicated
5. ICP WSE reports
3. Increasing percentage of functional tests
completed to schedule
Sub-process Potential PIs Typical deliverables or Potential PIs Typical deliverables or
Descriptions Leading outputs Lagging outputs
Process P3:-Implementing of schemes to gather performance and test data for performance indicators on the condition/management of ageing SCEs.
b. Undertake activities to 1. Testing regime and schedule established 1. Maintenance records 1. Decreasing level of performance of ageing 1. Maintenance records
measure data for PIs, eg early in the project/asset life and clearly systems and components in functional tests
2. Production reports 2. Production reports
tests on SCE with communicated
2. Increasing SCE unreliability or unavailability
respect to PSs, analysis 3. Production forecasts
2. Testing team with responsible competent due to ageing
of effectiveness of SCE
individuals appointed early in the 4. SCE compliance checks
control systems. 3. Increasing failure rates for ageing SCEs
project/asset life and clearly communicated
5. ICP WSE reports
3. Increasing percentage of functional tests
completed to schedule
Process P5:- Setting out and implement an appropriate remediation schemes to ensure SCEs meet the required Performance Standards
a. Set out and implement 1. Programme upgrades based on increasing 1. Maintenance plan 1. Maintenance and upgrade programmes 1. Maintenance records
an appropriate risk levels and requirements to maintain falling behind schedule
2. HSE plan 2. HSE plan
remediation scheme to risk control established early in the
2. No improvement in performance of ageing
ensure SCEs meet the project/asset life and clearly communicated 3. Maintenance records
SCEs noted after maintenance and upgrade
required PSs
2. Performance Standard monitoring programmes have been set in place
programme established early in the
3. Implementation of defined life repair
project/asset life and clearly communicated
Including; scheme falling behind schedule
3. Establish a scheme for identifying ‘defined
Carrying out of ‘defined
life repairs’ early in the project/asset life
life repairs’
and clearly communicated
Process P6:-Verifying and Assuring that the ageing SCEs are performing both as isolated systems or in concert with other SCEs
a. Verify and/or Assure and 1. Establish early on a comprehensive scope 1. Safety plan 1. Monitor the number of disagreements 1. MoM
verify that the ageing of work in conjunction with the ICP with between the duty holder and appointed ICP
2. Safety management 2. Safety records
SCEs are performing, specific consideration of ageing SCEs as
system 2. Increasing numbers of failures/near misses
both as isolated systems components and whole systems 3. LTI reports
& incidents attributed to ageing (using Root
or in concert with other 3. Safety case
Cause Analyses) 4. RIDDOR reporting
SCEs 4. WSE
5. Board management
reports
Table 3: Examples of leading and lagging indicators for 2 typical SCEs
Life
Main process Sub-processes Ageing
extension
6. Integrity
reporting,
assurance
evaluation
and
of
6.1 Assurance of integrity
effectiveness of SIM 6.2 Evaluation of effectiveness of
inspection programme
6.3 Management reporting