maintenance and operation of hipps

8/11/2019 Maintenance and Operation of HIPPS

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Monitoring the Reliability PerformanceHigh Integrity Pressure Protection Sys

Baris Arslan

Senior Safety ConsultantOilconx Risk Solutions (ORS)

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This presentation is about

How to maintain HIPPS?

How to demonstrate the reliability of HIPPS in operation?

Human Reliability & HIPPS Maintenance

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The beginning of wisdom is to call things with their

right names

HIPPS protects downstream equipment against

overpressure coming from upstream.

Instrument based systems for secondary

protectionor HIPPS?

Why is HIPPS so special?

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HIPPS or not


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Procedures for analyzing maintenance

performancefor: Systematic faults & recurring faults

Assessing demand rates (if higher than design

basis or not)

Diagnosis / repair / revalidation

Ensuring that functional safety is maintained

during operation and maintenance Availability of skills and resources for

maintenance

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Chronological documentation

maintenance Results of tests

Documentation of the time

Documentation of modificat

High safety integrity systems

severe consequencesnot s

maintenance procedures

IEC:61508 2010ensuring functiona

during operational phase


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OLF 070 gives detailed guidance about

SIS (indirectly HIPPS) maintenancefocusing on: SIS Maintenance Scope

Use of vendor documents

Functional testing requirements

Integral / partial tests

Maintenance reporting Compensating measures upon overrides

and failures

Reporting of demands / anomalies

P-001contains Requirements about testing frequency

Valve leakage testing frequency

System regularity aspect

Reference is made to IEC standards

API 521, Annex E.5 gives som

about HIPPS testing. Highligh Considering site resources w

testing frequency

Potential for introducing faul

shutdowns due to human er

API 17OSubsea HIPPS The proof test intervals are t

in the maintenance procedu

Experience data to include f

based on the number of perf

SIF together with how many

in a failure

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OLF/NORSOK views on HIPPS maint


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PM Procedure for each HIPPS

Linked to design basis documents (such as SRS)

Maintained database for information such as demands, failures etc.

Well-designed infrastructure to accomodate information flow (maintenance reports

damage codes, automatic notifications etc.)

Well established procedures to analyse failure data

Verification and validation activities (see assurance on next slide)

Competent (and available) personnel to make decisions in due time

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Key requirements for HIPPS mainte

appear to be


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System responsible is notified

Origin of data is controlled (document traceable)

Equipment type (manufacturer, year etc. checked)

Operating conditions are verified

Failure code and long text is checked (i.e. in compliance

with corporate guideline/EN 14224)

Offshore personnel is consulted for data validation

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Test period

Acceptance criteri

Pass/fail statemen

Revisions on desig

Competence requi

Verification of fun

component basis

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Two Stage Offshore Failure Data Val

for HIPPS


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90% confidence interval hasbeen applied for OREDA

based studies

70% confidence interval forIEC-based appraoch

Only useful lifetime has beenincluded due to

Offshore site-acceptance test Onshore factory acceptance

test

Assumption: Sub-componentsare replaced before the wear-out period (e.g. lifetimereplacements)

Useful lifetime and confidence inte


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Field data is vital for the credibility of

Periodic Reliability Monitoring

Standardized data format is necessary toadress failure cause and failureconsequence

Data needs to be collected for all HIPPScomponents, e.g. input devices, controlunits and final elements

Why is it difficult to collect data? It requires:

Resources (positive & negativereporting)

Competence and motivation

Sophisticated ERP systems

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In case of HIPPS failures (offshore

training package


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Different strategies based on HIPPS

classification (see Slide 4) For 1st generation HIPPS, focus on dangerous

undetected failures and

For 3rd generation HIPPS, classification of both

safe and dangeorus failures

Failure database is updated based on failure

classifications

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Classification of failure codes for dif

generations HIPPS


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PERIODIC CHECKS

Keep it simple

Use existing reliability model (if any) for aparticular HIPPS

(clear benefits if the model is not softwaredependent, e.g. excel based or similar)

Apply simple but recognized methods toevaluate the effect of failure inter-arrival times,distributions, sampling etc.

Determine a final failure rate to update themodel

Is the HIPPS performance acceptable?

Where is the acceptance criteria?

ACCEPTANCE CRITERIA

Again, different acceptance criteriaclassifications (Slide 4)

Some examples:

Fully risk-based approach

Risk-based approach with minim

requirements API-based judgments (equal to concept)

Remember: Two-stage assuto verify acceptance criteria

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Periodic Verifications
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Classical human error producing conditions apply widely to full-automatic HIPPS operation

and maintenance

Based on our experience, typically observed human errors on HIPPS relate to red markeditems in the North Sea:

Poor feedback (reporting)

Physical capabilities exceeded

No independent check after testing

Unclear allocation of function and responsibility

An incentive to use more dangerous methods

A poor or hostile working environment Task pacing caused by intervention of others

Operator inexperienced

Little or no independent checking or testing of output

High level emonotional stress

Disruption of normal work sleep cycles

Unfamilarity with the situation which occurs (infrequent or new situation)

A need to unlearn a technique and apply one which requires application of another philosophy

HIPPSHuman Error Producing Con


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Human reliability is a huge concern for

HIPPS operation and maintenance

Numerous incidents have been observedat different companies where HIPPSvalves and/or transmitters have beendisabled

Generally speaking, limited focus on

quantification of human reliability formaintenance of HIPPS in the oil and gasbusiness

Limited failure reporting regarding humanfailures during maintenance

Human reliability must be c

an integral part of overall HIPPS

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Human reliability & HIPPS mainten


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Failure of HIPPS may lead to major accidents with catastrophic consequences

Maintenance & Operationlongest lifecyclewe need reliable HIPPS all the way thru

A customized approach is needed for different types of HIPPS, Operating Company and

HIPPS maintenanceif done as advised by IECis a complex job requiring strict collabinteraction at all levels. It requires highly competent, motivated people and enhanced datools

Collection and analysis of data are very important. Credibility of simply everything is dont collect correct field data from offshore oil platforms

Human failures remain as a big concern. Human reliability must be adressed as a part oreliaibility

No quick-fix for HIPPS maintenance

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Conclusion


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Baris Arslan

Senior Safety Consultant

[email protected]

+46 735391827

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For more information, please contact
mailto:[email protected]:[email protected]:[email protected]:[email protected]

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