Health and Safety Executive

Health and Safety Executive

HSE Perspective on UK Pipeline

and Riser Integrity Management

Douglas Souden

Principal Pipelines Inspector

Health & Safety Executive

Aberdeen

Seminar – 19 October 2011, Stavanger: A System

Approach to Pipeline & Riser Safety and Integrity

HSE Information relating to Pipeline safety and integrity can be found on the HSE web site: http://www.hse.gov.uk/pipelines/index.htm

Scope of Presentation

• Introduction and Background

• UK Regulation, Integrity Management

Standards and Good Practice

• KP4: Aging and Life Extension

• Lessons Learned – San Bruno

• Leadership and SPI’s

• Summary of key points

Source: HSE

HSE Offshore Strategy http://www.hse.gov.uk/offshore/priorities.htm

• Leadership and SPI’s

• Safety Culture / Workforce Involvement

• Asset Integrity (KP4 – 3 year programme)

Current Strategy Priorities:

OSD Mission Statement: “Our mission is to assure safe management and

control of major accident hazard risks and prevent catastrophic incidents in the

offshore Oil and gas industry”

Source: Step Change HSE Offshore Pipeline Delivery Guide:

• Encourage a proactive pipeline lifecycle Integrity Management approach

• Deliver and share targeted and consistent intervention plans

• Share lessons learned from incidents and investigations

• Promote improved development and sharing of Industry good practice

UK Offshore Hydrocarbon Releases

Source: Step Change

Data Source: DECC (2009)

Pipelines Safety Regulations 1996

• Regulation 13 - Maintenance absolute legal duty to maintain in an efficient state, in efficient

working order and in good repair throughout the pipeline life cycle

secure safe operation

prevent loss of containment

• Regulation 23 – Major accident prevention document identify hazards and pipeline integrity threats

formally record and document results

implement adequate safety management system

revise or replace as often as appropriate

• Regulation 20 to 22 – Notification to HSE concerns significant changes affecting level of risk

notify at completion of concept design

Captures new MAHP’s or changes to operating regime

Source: HSE Source: HSE

Integrity Management: Standards

and Industry Good Practice

• Provide a specific IM System framework and guidance in

support of main design codes

• Initial USA - Onshore focused on critical risk areas

– API 1160 (2001) and ASME B31.8S (2004)

• More recent European issued guidance - aligned to subsea

pipeline systems:

– DNV RP-F116 (2009 – under review)

– Engineering Institute Guidance (2009)

– UK Oil & Gas Flexibles IM Guidance (2010)

• New standards emerging for Life Extension:

– NORSOK Standard Y-002 (2010)

– Draft ISO Recommended Practice

Source: Energy Institute

Integrity Management System

Source: DNV RP 116

Aging Overview

Evidence of degradation and damage

OR

Insufficient knowledge / information to know the extent of possible deterioration

________________________________

Need to consider effects of:

accumulating or accelerating damage

modifications

obsolescence

changes of process & / or well conditions

advances in knowledge and technology

organisational issues / loss of corporate knowledge

Source: HSE RR509

The 4 Stages of Equipment Life

Source: HSE

Degradation and Re-assessment

• Accumulation of damage and

defects important

• Effective monitoring & review of

degradation vital to support

ongoing integrity

• Internal corrosion detrimental if

not predicted or controlled

• Approach must be consistent

with lifecycle and reflect internal

inspection capability; or

• Other type of periodic validation

of corrosion modelling via direct

measurement required

Time or Deterioration Rate

Deterioration

Model Worst Case

MAWT

Actual can only

be established

by

measurements

Monitoring Degradation

Periodic Validation and Assessment

Source: HSE RR509

Source: HSE

Pipeline Life Extension

• Need to justify operation beyond

original design life conditions

• Engineering investigation required

(backward & forward look) to verify

continued fitness for future service

• Pipeline design codes call for a

formalised process and record

• Industry Guidance provides

framework for assessment; eg

NORSOK Y-002 (Dec 2010)

• Understanding the degradation

processes, good records and

effective management of aging are

crucial to successful life extension

Source: HSE

Source: HSE RR509

KP4 – Aging and Life Extension

• Planned 3 Year Inspection programme to 2013

with supporting activities and outputs:

– Development of guidance and good practice

– Appropriate research

– Development of an Industry Network

– Stakeholder Engagement

– Feedback to Industry

• Aim is to ensure that the risks to asset integrity

associated with Aging and life extension are

being controlled effectively

KP4 Inspection approach

Programme in 3 phases: • Phase 1 – initial onshore then

offshore verification;

• Phase 2 – KP4 elements linked to future offshore inspection;

• Phase 3 – Programme close out and feedback

Multi-Discipline Team Approach:

• Organisational factors; Structural integrity; Materials, Maritime integrity; Process plant integrity; Fire & blast; Mechanical integrity; Electrical & control systems integrity; Wells and Pipelines

• Standardised approach: Use of templates

• Some initial teething and calibration issues

Source: HSE Source: HSE

KP4 – Progress

• KP4 Policy and Strategy documents on line

• Campaign of industry/stakeholderawareness

• Continued development of HSE web page

• Inspection templates shared with Industry

• Encouraged development of an Industry Network

– Managed by Oil & Gas UK via Step Change web site

– Over 90 members

– Plans for UK Industry Guidance

• Initiated update of HSE guidance on Thorough Reviews OIS 4/2009

• Phase 1 completed for first 3 duty holders

Lessons Learned - Recent Example of

Pipeline Integrity Failures

• On 9 Sept 2010 a rupture occurred on

a 30” gas pipeline in California at San

Bruno operating at approx. 400psig

• Eight people were killed and many

more injured and 38 homes destroyed

• Evidence of Integrity Management

system failures

• Video

Source: NTSB

US NTSB Report on San Bruno:

Safety Management Failings

• No clear management focus on major hazards and pipeline system safety.

• Haphazard approach to record keeping and management/data analysis.

• 'Threat identification' not sufficient.

• Evidence of delays to critical pipeline repairs.

• Insufficient resources available for pipeline integrity assessments.

• Resource bottlenecks meant some important work not done.

Sourc

e: N

TS

B

Leadership and Performance

Indicators

• Safety Leadership Process Safety Leadership Principals

– Expectation that organisations with major hazard risks have adopted the eight principles of major hazard leadership developed by the Process Safety Leadership Group (PSLG).

– HSE will inspect using Leadership Assessment Tool (LAT)

• Safety Performance Indicators (SPI’s)

– Expectation that operator’s will have developed an effective suite of SPIs

– Leading and Lagging indicators should be identified

– Expect that a Gap Analysis will have been carried out against HSG254

– Most operators using a Traffic Light System approach

Summary of Key Points

• Pipeline Integrity Management remains a key priority focus for HSE, both offshore and onshore:

– Related pipeline ageing and life extension issues will be inspected as part of the KP4 Programme

• HSE expect duty holders to have robust/effective integrity management systems throughout the pipeline lifecycle:

– Systems should reflect good practice and must be subject to regular monitoring, audit and review

– Strong leadership, effective use of SPI’s and sharing of lessons learned and good practice are important factors

• Effective management of Aging is a vital component to successful Life Extension projects

• Formal review of Pipeline Life Extension expected in line with good practice and emerging Standards

References

• HSE Web Site Offshore Oil ad Gas Pages: Aging and Life Extension of Offshore Installations http://www.hse.gov.uk/offshore/Aging

• OIS 4/2009, Guidance on Management of Aging and Thorough Reviews of Aging Installations, Offshore Information Sheet No. 4/2009, Health and Safety Executive, http://www.hse.gov.uk/offshore/infosheets/is4-2009.pdf

• DNV-RP-F116: Integrity Management of Submarine Pipelines October 2009

• Energy Institute S813 Guideline on the Integrity Management of Subsea Facilities

• Process Safety Leadership Group (PSLG) – Principles of Process Safety Leadership http://www.hse.gov.uk/comah/buncefield/pslgprinciples.pdf

• HSE Delivery Guide on Major Accident Hazard Process Safety Indicators http://www.hse.gov.uk/comah/guidance/process-safety-performance-indicators.pdf

• HSE Research Report RR509 - Plant Aging: Management of equipment containing hazardous fluids or pressure 2006 http://www.hse.gov.uk/research/rrhtm/rr509.htm

• US NTSB Investigation Report into the San Bruno Natural Gas Transmission Pipeline explosion September 9, 2010 http://www.ntsb.gov/doclib/reports/2011/PAR1101.pdf

• Step Change and Oil & Gas UK Aging and Life Extension Network http://www.stepchangeinsafety.net/about/workgroups/Ageingandlifeextensionofoffshoreinstallations.cfm

• OP010 - State of the Art Report on Flexible Pipe Integrity and Guidance Note on Monitoring Methods and Integrity Assurance for Unbonded Flexible Pipes (2010) http://www.oilandgasuk.co.uk/publications/viewpub.cfm?frmPubID=152

• SINTEF Report (Clients PSA, Norway): Aging and life extension for offshore facilities in general and for specific systems

• NORSOK standard, Life Extension for Transportation Systems, Rev 1, Dec 2010 http://www.standard.no/en/Sectors/Petroleum/NORSOK-Standard-Categories/Y-Pipelines/Y-0021/

• ISO/NP TS 12747, Draft ISO Recommended Practice: Petroleum & Natural Gas Industries - Pipeline Transportation systems - Pipeline Life Extension, International Standards Organisation, 2008, Geneva, Switzerland.

Any Questions?

Source: HSE

Source: HSE

Source: HSE

Source: HSE

Source: HSE