asset integrity - step change in safety · asset integrity toolkit original target of 50%...

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Asset Integrity

“We must have effective asset integrity management.”

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Step Change in Safety launched

Safety Culture expectations

Look this Way – safety observations system guidelines

Leading Performance Indicators guidelines

Support team established

The UK is the safest place to work in the worldwide oil and gas industry by 2010

www.stepchangeinsafety.net

SADIE launched

Changing Minds guidelines

Best Practice guide to Handling Tubulars

Safety Leadership training syllabus

Understanding SI971 Safety Reps guidance

ESR Network

OIM Network

Fatality Report

Focal Point Network

Vantage POB piloted

Temple Model created

Deliver a 50% improvement in industry safety performance over the next 3 years

ECI launched

Asset Integrity Toolkit

Original target of 50% improvement in industry safety performance was achieved

Design and Handling of Chemical Tanks guidance

Design and Handling of Cargo Baskets guidance

Green Hat policy

Making the UK is the safest place to work in the worldwide oil and gas industry

Step Change fully funded via membership

Hydrocarbon Release Reduction Toolkit

Strategic Plan 2010 – 2015 established

Support team directly employed

Minimum Industry Safety Training launched

SPAN Network

Workplace Health workbook

Human Factors, First Steps guidance

Green Hat policy revised

Leadership Expectations guidance

Coaching for Safety guidelines

Safety for Wireline Operations guidance

Health and Safety Management Systems Interfacing guidance

Health and Safety Management Systems Interfacing guidance revised

Understanding SI971 Safety Reps guidance updated

“Skeleton Sid”

“Silence is Consent”

“Consequences” & “Martins Story”

Leading Performance Indicators updated

Loading Lifeboats during Drills guidance

Green Armband policy

Lifting and Mechanical Handling guidance

Mechanical Joint Integrity guidance

Control of Work, Performing Authority standard

Lifting standards updated

Assurance & Verification Suite

Step Change in Safety, what you need to Know

Boots on for Safety launched

Personal Responsibility for Safety launched

Task Risk Assessment guidance updated

Best Practice guide to Manriding “Its Your Choice”

Team Leader directly employed

OIM Guidance For Offshore Rota and Rest Periods

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Hydrocarbon Release Reduction

SI971 Reps on SCLT

50% HCR Reduction Target established

Workforce Engagement Toolkit

2


SAFE

TY M

OM

ENT 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

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SAFE

TY M

OM

ENT 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

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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

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0

50

100

150

200

250

300

126p

167

187

Total HCRs

Target = 94


Work Group

Steering Group

Asset Integrity Steering Group

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)

Focused on preventing HCRs

Steering Group

Work Groups

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• 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


Hydrocarbon Reduction Release Plan • Clear performance criteria

• Plan owner

• KPIs ownership

• Quarterly reporting period

• Monitor trends – not a green light frenzy

• Simple, visible dashboard visible to all offshore crew

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On or ahead of plan

< 1%

zero overdue

zero overdue

zero overdue

< 4 weeks overdue

zero overdue

On or ahead of plan

zero overdue

< 80%

zero overdue

on plan

zero overdue

zero overdue

All KPI's satisfactory

Low

Completion of Small Bore Tubing remedials

Q1

Status

Completion of Flexible Hose Remedials

Q1 StatusKey Work AreaHCR

AREA

Delivery against Pressure System Inspection Plan

% Inspection results below acceptable limits

Replacement of Defined Life Repairs

API 510 Pressure Vessel Inspections

Le

ad

ing

In

dic

ato

rs -

Ma

inta

inin

g A

sse

t In

teg

rity

Corrective Work Orders from Weeps & Seeps complete

CAT 3 & 4 Pipework FM Anomaly WO closure

Joint Management failures

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

Completion of Flexible Hose Inspections

Corrosion Inhibition

Small Bore Tubing baseline inspection completed


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


• 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

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• 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

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• 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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asset integrity - step change in safety · asset integrity toolkit original target of 50%...

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