Asset Integrity. We must have effective asset integrity management.

Transcription

1 Asset Integrity We must have effective asset integrity management. follow us Mon a ktwitter i n g t h@stepchangeinfo e U K t h e s a f e s t p l a c e t o w o r k i n t h e w o r l d w i d e o i l a n d g a s i n d u s t r y.

2 Step Change in Safety launched Deliver a 50% improvement in industry safety performance over the next 3 years Support team established The UK is the safest place to work in the worldwide oil and gas industry by SADIE launched Vantage POB piloted ECI launched Temple Model created Original target of 50% improvement in industry safety performance was achieved Boots on for Safety launched Making the UK is the safest place to work in the worldwide oil and gas industry Step Change fully funded via membership Strategic Plan established Support team directly employed Minimum Industry Safety Training launched 50% HCR Reduction Target established Team Leader directly employed SI971 Reps on SCLT OIM Network Green Hat policy ESR Network Changing Minds guidelines Best Practice guide to Handling Tubulars Safety Leadership training syllabus Safety Culture expectations Look this Way safety observations system guidelines Health and Safety Management Systems Interfacing guidance SPAN Network OIM Guidance For Offshore Rota and Rest Periods Leading Performance Indicators guidelines Focal Point Network Green Armband policy Fatality Report Best Practice guide to Manriding Understanding SI971 Safety Reps guidance Silence is Consent Loading Lifeboats during Drills guidance Leading Performance Indicators updated Its Your Choice Health and Safety Management Systems Interfacing guidance revised Personal Responsibility for Safety launched Lifting and Mechanical Handling guidance Design and Handling of Cargo Baskets guidance Task Risk Assessment guidance updated Design and Handling of Chemical Tanks guidance Skeleton Sid Understanding SI971 Safety Reps guidance updated Asset Integrity Toolkit Leadership Expectations guidance Coaching for Safety guidelines Green Hat policy revised Safety for Wireline Operations guidance Step Change in Safety, what you need to Know Workplace Health workbook Hydrocarbon Release Reduction Toolkit Hydrocarbon Release Reduction Consequences & Martins Story Human Factors, First Steps guidance Control of Work, Performing Authority standard Lifting standards updated Mechanical Joint Integrity guidance Assurance & Verification Suite Workforce Engagement Toolkit 2

3 SAFETY MOMENT Incident Background Whilst well testing the fire and gas system detected gas in the module at 10% and 20% of LEL On checking a smell of gas was detected, plant was shutdown and blow-down Further investigation revealed a 1/4" diameter hole on the oil outlet pipe-work of the test separator Priority inspection work-scope of oil process lines was developed and inspection carried out 100% inspection No integrity anomalies identified 3

4 SAFETY MOMENT Lessons Learned Identify periods of stagnant operation on vulnerable systems and implement strategy to ensure corrosion mitigation is employed eg. - Chemical management or process pipe-work flushed and purged if system inactive for extended periods of time Operational dead legs should be identified and managed Integrity personnel should be consulted on ORAs if they affect the way pressure systems equipment is operated Ensure RBI inspections, inspection coverage recommendations, and recommended inspection techniques are appropriate where dead leg conditions exist, and highly localised corrosion mechanisms are possible Review material selection for known problem areas Do NOT assume that past historical corrosion rates may be the same as current 4

5 50% reduction in all *reportable hydrocarbon releases by the 2012/2013 reporting year compared with a 2009/2010 baseline (1 Apr 2012 to 31 Mar 2013) * Reportable hydrocarbon releases are releases of gas, crude oil and refined products (e.g. diesel and lube oils) with the potential to cause harm 5

6 300 Total HCRs p 100 Target =

7 Steering Group Asset Integrity Steering Group Work Group Work Groups Verification Ian Wright (DNV) Technical Authorities Bruce Lawson (Total) Eric Henderson (Petrofac) Hydrocarbon Release Prevention Ian Buchan (Talisman) Jim MacRae (Nexen) FPF / FPSOs John Fleming (Maersk FPSO) Steering Group Focused on preventing HCRs 7

8 HCR Prevention workgroup Good practice HCR Plan guidance: draft complete, wells and specific FPSO elements to be included Joined-up thinking: developing engagement brand with Art Department focused on embedding, quality support materials and value adding Secondee: HCR database work with HSE, root cause and OIR 12 8

9 Leading Indicators - Maintaining Asset Integrity Hydrocarbon Reduction Release Plan HCR AREA Key Work Area Delivery against Pressure System Inspection Plan % Inspection results below acceptable limits Q1 Status On or ahead of plan < 1% Q1 Status Clear performance criteria Plan owner API 510 Pressure Vessel Inspections Completion of Flexible Hose Inspections Completion of Flexible Hose Remedials KPIs ownership Quarterly reporting period Small Bore Tubing baseline inspection completed Completion of Small Bore Tubing remedials Replacement of Defined Life Repairs < 4 weeks overdue On or ahead of plan Monitor trends not a green light frenzy Simple, visible dashboard visible to all offshore crew Inspection of Defined Life Repairs Completion of Valve Integrity Surveys Completion of Valve Survey CAT 4 remedial scope Level 3 audit of weeps & seeps routines complete Corrective Work Orders from Weeps & Seeps complete < 80% on plan CAT 3 & 4 Pipework FM Anomaly WO closure Corrosion Inhibition All KPI's satisfactory Joint Management failures Low 9

10 Engagement Packs Impact of HCR release Safe isolation & plant reinstatement (incl GOC) Small bore tubing & flexible hoses Bolted joint / flange and valve management Pipework (corrosion management, fabric maintenance, temporary repairs) Reporting, investigation & lessons learned 10

11 FPSO workgroup Completed additional analysis, FPSOs contribute more HCRs when compared to manned fixed installations Potential addition to HCR / AI toolkit focused on analysis assumptions Inclusions in good practice HCR plans 11

12 Assurance and Verification workgroup Tier 1 - workforce leaflet complete, in print 2000 copies, share fair and heliport drop Tier 2 - final document complete, in print Tier 3 - technical authoring complete, design 60% complete, target availability end June electronic only 12

13 Technical Authorities Assess and document the implementation of TAs in Duty Holder organisations via an industry questionnaire Definition of the key roles to be delivered by TAs in Operating Companies as a single organisational model is neither practical nor deliverable Instead, individual Operating companies should agree the roles in their respective organisations and ensure that the TA function can be delivered more uniformly 13

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