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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