shell

Shell Exploration & Production

File

Titl

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opyr

ight

: She

ll Ex

plor

atio

n &

Pro

duct

ion

Ltd.

UKOOA Offshore Maintenance Management Workshop

Performance Standards Assurance in Shell UK Offshore Installations

Thurs 27th May 2004

Colin LeightonProject Lead


Summary

A simple and transparent process to provide daily indication of the status of safety critical elements.

The performance standard assurance process is being implemented on Shell North Sea platforms. It uses the standard maintenance management functionality in SAP PM to capture the results of tests of safety critical element suitability, and track equipment defects that have the potential to impair the required functions.

It also enables real time status reports of compliance with performance standards.

2


MAH

Identification

Performance Standards

SAP PM

Incorporate PS acceptance criteria into SAP PM routines.

Installation Team Monitor results, manage risk

Report results

On shore. Review trends and take corrective action

Revisions to Performance Standards

Equipment Performance Assurance – Linking Installation Risk and Integrity Management with risk mapping and Safety Case.

HSE/Safety Case

Assessment of Major

HazardsShort Term

Long Term

Integrity Management, Incorporating Performance Standards Assurance

Revisions to Hardware Design

Identification of Major Hazards

HAZID/HAZOP

3


Basis of the process

1.Simple Performance Standards to document:

•The functionality required of safety critical equipment to meet the installation hazard analysis

•The performance to be measured and acceptance criteria required to demonstrate ongoing functionality.

• Simple equipment checks rather than design checks e.g. is it working rather than lumens output.

•Risk mitigation measures required when functionality is impaired.

2.

Maintenance and Inspection Routines in SAP PM which include:

•Electronic reference to the corresponding performance standard.

•Format to capture the Pass or Fail status of safety critical equipment as measured against the performance standard acceptance criteria.

4


Risk Management

Area of reduced safety, (Increased risk) some barriers are not functional.When in this area PSAP lists remedial measures that need to be put in place to return to Green area

Safe OperatingEnvelope

Direction ofIncreasing Risk

•The Performance Standards maintains installation in the Green Zone. (Acceptable risk) •Not meeting Performance Standard results in increased risk thus moving the installation out of the Green Zone.•Risk Mitigation Measures brings the Platform back into the Green Zone 5


Benefits of the approach

There are a number of benefits from the approach, these include:

•Awareness and knowledge

–Awareness and understanding by operations and maintenance personnel of performance standards and the functions required of safety critical equipment is increased

–Involvement of operations and maintenance personnel in the assessment of suitability achieves greater engagement with platform risk management.

•Safety Critical Element status visibility:

–Safety Critical Element suitability is indicated directly from SAP PM reports.

–The integrity status of the installation is more widely available.

✓

✓

✓

✓6


Performance Standard structure

Risk Mitigation Text:Measurable Acceptance Criteria Text:

PS-E002

Risk Mitigation Text:Measurable Acceptance Criteria Text:

PS-E001 (Unique Ref)

Function: Text (Functional requirement of SCE)

Safety Critical Element Title

Goal: Text (High level goal consistent with hazards assessment.)

Maintenance, Inspection and Test results (Pass or Fail) are reported against the performance standard reference number.

The unique reference number in the performance standard is created in SAP PM asset register.

The Pass/Fail performance standard acceptance criteria is repeated in the SAP PM Maintenance work order.

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Performance Standard example – Fire and Gas Detection

Risk Mitigation Text:Heat DetectionPS-F001-05

Risk Mitigation Text:Alarm TestPS-F001-05

Risk Mitigation Text:Flame DetectionPS-F001-03

Risk Mitigation Text:H2S DetectionPS-F001-04

Risk Mitigation Text:Smoke DetectionPS-F001-02

Risk Mitigation Text:Aspirated Gas DetectionPS-F001-05

Risk Mitigation Text:Flammable Gas DetectionPS-F001-01

Function: Text (Functional requirement of SCE)

Safety Critical Element – Fire & Gas Detection

Goal: Text (High level goal consistent with hazards assessment.)

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Performance Standard Fire & Gas Test Results

0

20

40

60

80

100

120

140

Flam. G

as D

etSm

oke D

etFla

me Det

H2S D

etAlar

msHea

t Det

Aspira

ted G

as D

etOil M

ist Det

TR In

let -

Smok

e

Gas In

Serv

Wate

rTR

Inlet

- Fla

meTR

Inlet

- Gas

CO Det

TR In

let -

H2S

Test Type

Num

ber

of te

sts

PASSFAILFAF

Illustrative Data

9


Performance Standard Fire & Gas Test Results

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Flam. G

as D

etSm

oke D

etFla

me Det

H2S D

etAlar

msHea

t Det

Aspira

ted G

as D

etOil M

ist Det

TR In

let -

Smok

e

Gas In

Serv

Wate

rTR

Inlet

- Fla

meTR

Inlet

- Gas

CO Det

TR In

let -

H2S

Test Type

Num

ber

of T

ests

PASSFAILFAF

10


0

100

200

300

400

500

600

700

800

A B C D E F G H I J K L M N P

Installation

Num

ber

of T

ests

PASSFAILFAF

Performance Standard Test Results – All InstallationsInstallations

Data can be taken directly

from SAP PM in this format

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Performance Standard Test Results – All Installations

0%

20%

40%

60%

80%

100%

A B C D E F G H I J K L M N P

Installation

Num

ber

of T

ests

PASSFAILFAF

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Conclusions

•Process

–Visibility of the performance standard related work has increased.

–Test history of Safety Critical Elements has much greater visibility.

–SCE status has clarity

The implementation of the Performance Standard Assurance Process is as much about people as it is about processes, the observations so far are:

•People

–There are many more discussions around performance standards and safety critical equipment

–Conformance to the new process is gradual, however, non conformance is also very visible so feedback can be rapid and direct.

–This is a change in approach and some teams align quicker than others, but the simplicity caters for simple communications.

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