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Life Extension of Aging
Petroleum Production
Facilities Offshore

Per Otto Selnes, M.Sc.
Manager Operations
Norwegian Oil Industry Association
www.olf.no


Contributor:
Gerhard Ersdal, Ph.D.
Principal Engineer
Norwegian Petroleum Safety Authority
Introduction
•   A large part of the Norwegian gas and oil production facilities
    have reached their initial design life, but the respective
    fields are still producing substantial levels of hydrocarbons.

•   In order to ensure technical and operational integrity of
    these ageing facilities the Norwegian oil industry Association
    (OLF) has initiated a project to establish the necessary
    standards and guidelines for assessing and ensuring safe
    life extensions.
Background
Technical and operational integrity of
offshore facilities on the Norwegian
Continental Shelf (NCS) is important
for:
• the safety, health and welfare of
  offshore employees and their families
• not harming the environment
• making sure that the owners get no
  interruption of their revenues, nor do
  the government and the citizens of
  the country
Complex issue
Age vs status on application for consent
• Number of installations on the NCS excl. pipelines:     103

• Number of consents expiring by end 2015:                44

• Number of new consents given (Incl. 1 expiring 2015):   26

• Number of applications being prepared / handled:        7

• Number of applications due?                             1

• Number of installations shut down:                      2

• Removed/disposed of, additional to the 103              5

• Disposals approved                                      7
Norwegian pipelines
 First installations (year)                         1971

 Total number of items in database :                920

 Cumulated length of large pipelines (km):          6 100

 Large variations in length, size and design life

 Lengths:                     23 km - 1 200 km

 Diameter (inches):           1’’ – 44’’

 Design lifetime (years) :    5 - 50
Scope of work
Work divided in two:
• Firstly to develop and issue recommended
  guidelines, outlining a proposal for the
  preparation of the application of a new
  consent;

• Then to develop tools necessary to assess
  continued safe operation.
  Split in the following areas:
    • Risk management
    • Working environment
    • Structural integrity
    • Technical safety systems
    • Drilling & well systems
    • Top side process & utility systems
    • Transport systems (pipelines etc.)
    • Sub sea systems
Consent Applications for
Lifetime Extension of Facilities
Scope of the OLF guideline for assessments and preparation of applications

                                                                        OLF guideline
                                   Main Document
                                                                          No. 122
                                                                     Published in June 2008


                                                                           Sub- Documents


                                                                                            Drilling and Well        Drilling systems and Well
                           Permanente structures              Offshore                                               integrity, including
                                                             Structures                          Systems             conductors, BOP and down
                                                                                               Check List            hole equipment
                                                          Published May 2008
                                                                                         Published in May 2008


                                                            Transport                         Process
                           Export and intra field
                           Pipelines and risers.            Systems                           Systems


      Emergency Shutdown, Evacuation,                  Technical Safety                     Underwater
      Barriers, Fire and Gas Detection and other           Systems,
      safety systems.                                                                       installations
      Living Quarters, Escape Ways, Material               ,Working
      and Chemicals Handling , Control Rooms,
      Man machine interfaces.                          Environment and
                                                       Risk management

                                              Consent Applications for Life Extension of Facilities are submitted to the Petroleum
                                              Safety Authority (PSA) Norway and Norwegian Petroleum Directorate (NPD).
Deliveries
Guideline for the assessment and documentation
of service life extension of facilities
Three chapters
• Outlines a proposal for the preparation of the application
  of renewed consent required prior to use of a facility
  exceeding the current consent period
• The guideline identifies how the operators can assess and
  document safe operation of facilities for an extended
  period
• Facilitate the preparation the Application for Consent for
  Life Extension

Start early
• It is recommended to start the evaluation and application
  process at least two years prior to the expiry of the current
  consent period
Technical Safety Systems and
Working Environment
Risk Management
• Gives detailed comments and
  recommendations for the assessment of
  facilities concerning the areas outlined
    – recommends Quantitative Risk Analysis
      (QRA) and necessary sensitivity studies
      to be updated addressing the scenario
      and operating conditions envisaged
      during the life extension period

   – Evaluations of factors that may be
     expected to change over time should be
     included in the sensitivity evaluations.
Technical Integrity
• Normally it is possible to safely operate an installation
  beyond its calculated fatigue life by using the inspection
  results available

• For structural details that can not be inspected,
  recommendations are given in the standard.

• Piles securing the installation to the sea bed are an
  example of such structural elements

• Specific requirements to design fatigue factors for
  calculation of fatigue damage from driving are given,
  based on driving records
Structural Integrity for Existing
Offshore Load-Bearing Structures
New Norsok Standard
• NORSOK N-006 standard gives requirements
  for assessment of the structural integrity of
  offshore structures in-service and for life
  extension

• NORSOK N-006 is applicable to all types of
  offshore structures used in the petroleum
  activities, including bottom founded structures
  as well as floating structures.
Drilling & Well Systems
Checklist has been established
• General considerations and requirements:
   – Brief status on drilling facilities & wells

   – Main degradation mechanisms and corresponding
     control measures relating to “Safety Critical
     Equipment”
   – Well integrity situation and potential changes in the
     related risk-picture
   – Potential well stimulation, intervention & work over
     methods/ limits
   – Future activity level and modification plans
   – Future capabilities required to monitor, access,
     operate, maintain and abandon drilling- and well
     facilitiesCondition of utility systems to support future
     D&W activities
   – Future capabilities to serve for potential “tie-ins” and
     specific measures for enhanced petroleum recovery
     in the area
Top Side Process and Utility Systems
A list of systems that should be
addressed during assessing life
extension of top side’s process and
utility systems has been established
• Containing “common factors” to be
   considered when evaluating the
   integrity of process and utility
   systems.
    – Have conditions changed from when
      the system was designed?
    – Will future operations still be within
      the capabilities of the system?
    – Could specific studies be required
      (list typical studies for individual
      systems)
Transport and sub sea systems
Norsok standards
Transport Systems (Pipelines Etc.)
• The transport system in this context is facilitating transport through
  pipelines, risers and loading hoses intra-field, inter-field and as trunk
  pipelines to shore and onshore.

Sub Sea Systems
• Subsea systems are increasingly used on
  the Norwegian Continental Shelf and
  this standard is prepared
  to support the process of assuring
  technical integrity of the sub sea
  system and its elements beyond
  the original approved
  service life.
Conclusion
The guidelines, standards and
checklists developed through
this project will provide
valuable assistance to
offshore facility owners and
authorities when assessing
the condition of aging
facilities, and if they can be
safely operated for a new
consent period.

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Life extension of aging petroleum production facilities offshore

  • 1. Life Extension of Aging Petroleum Production Facilities Offshore Per Otto Selnes, M.Sc. Manager Operations Norwegian Oil Industry Association www.olf.no Contributor: Gerhard Ersdal, Ph.D. Principal Engineer Norwegian Petroleum Safety Authority
  • 2. Introduction • A large part of the Norwegian gas and oil production facilities have reached their initial design life, but the respective fields are still producing substantial levels of hydrocarbons. • In order to ensure technical and operational integrity of these ageing facilities the Norwegian oil industry Association (OLF) has initiated a project to establish the necessary standards and guidelines for assessing and ensuring safe life extensions.
  • 3. Background Technical and operational integrity of offshore facilities on the Norwegian Continental Shelf (NCS) is important for: • the safety, health and welfare of offshore employees and their families • not harming the environment • making sure that the owners get no interruption of their revenues, nor do the government and the citizens of the country
  • 5. Age vs status on application for consent • Number of installations on the NCS excl. pipelines: 103 • Number of consents expiring by end 2015: 44 • Number of new consents given (Incl. 1 expiring 2015): 26 • Number of applications being prepared / handled: 7 • Number of applications due? 1 • Number of installations shut down: 2 • Removed/disposed of, additional to the 103 5 • Disposals approved 7
  • 6. Norwegian pipelines First installations (year) 1971 Total number of items in database : 920 Cumulated length of large pipelines (km): 6 100 Large variations in length, size and design life Lengths: 23 km - 1 200 km Diameter (inches): 1’’ – 44’’ Design lifetime (years) : 5 - 50
  • 7. Scope of work Work divided in two: • Firstly to develop and issue recommended guidelines, outlining a proposal for the preparation of the application of a new consent; • Then to develop tools necessary to assess continued safe operation. Split in the following areas: • Risk management • Working environment • Structural integrity • Technical safety systems • Drilling & well systems • Top side process & utility systems • Transport systems (pipelines etc.) • Sub sea systems
  • 8. Consent Applications for Lifetime Extension of Facilities Scope of the OLF guideline for assessments and preparation of applications OLF guideline Main Document No. 122 Published in June 2008 Sub- Documents Drilling and Well Drilling systems and Well Permanente structures Offshore integrity, including Structures Systems conductors, BOP and down Check List hole equipment Published May 2008 Published in May 2008 Transport Process Export and intra field Pipelines and risers. Systems Systems Emergency Shutdown, Evacuation, Technical Safety Underwater Barriers, Fire and Gas Detection and other Systems, safety systems. installations Living Quarters, Escape Ways, Material ,Working and Chemicals Handling , Control Rooms, Man machine interfaces. Environment and Risk management Consent Applications for Life Extension of Facilities are submitted to the Petroleum Safety Authority (PSA) Norway and Norwegian Petroleum Directorate (NPD).
  • 10. Guideline for the assessment and documentation of service life extension of facilities Three chapters • Outlines a proposal for the preparation of the application of renewed consent required prior to use of a facility exceeding the current consent period • The guideline identifies how the operators can assess and document safe operation of facilities for an extended period • Facilitate the preparation the Application for Consent for Life Extension Start early • It is recommended to start the evaluation and application process at least two years prior to the expiry of the current consent period
  • 11. Technical Safety Systems and Working Environment Risk Management • Gives detailed comments and recommendations for the assessment of facilities concerning the areas outlined – recommends Quantitative Risk Analysis (QRA) and necessary sensitivity studies to be updated addressing the scenario and operating conditions envisaged during the life extension period – Evaluations of factors that may be expected to change over time should be included in the sensitivity evaluations.
  • 12. Technical Integrity • Normally it is possible to safely operate an installation beyond its calculated fatigue life by using the inspection results available • For structural details that can not be inspected, recommendations are given in the standard. • Piles securing the installation to the sea bed are an example of such structural elements • Specific requirements to design fatigue factors for calculation of fatigue damage from driving are given, based on driving records
  • 13. Structural Integrity for Existing Offshore Load-Bearing Structures New Norsok Standard • NORSOK N-006 standard gives requirements for assessment of the structural integrity of offshore structures in-service and for life extension • NORSOK N-006 is applicable to all types of offshore structures used in the petroleum activities, including bottom founded structures as well as floating structures.
  • 14. Drilling & Well Systems Checklist has been established • General considerations and requirements: – Brief status on drilling facilities & wells – Main degradation mechanisms and corresponding control measures relating to “Safety Critical Equipment” – Well integrity situation and potential changes in the related risk-picture – Potential well stimulation, intervention & work over methods/ limits – Future activity level and modification plans – Future capabilities required to monitor, access, operate, maintain and abandon drilling- and well facilitiesCondition of utility systems to support future D&W activities – Future capabilities to serve for potential “tie-ins” and specific measures for enhanced petroleum recovery in the area
  • 15. Top Side Process and Utility Systems A list of systems that should be addressed during assessing life extension of top side’s process and utility systems has been established • Containing “common factors” to be considered when evaluating the integrity of process and utility systems. – Have conditions changed from when the system was designed? – Will future operations still be within the capabilities of the system? – Could specific studies be required (list typical studies for individual systems)
  • 16. Transport and sub sea systems Norsok standards Transport Systems (Pipelines Etc.) • The transport system in this context is facilitating transport through pipelines, risers and loading hoses intra-field, inter-field and as trunk pipelines to shore and onshore. Sub Sea Systems • Subsea systems are increasingly used on the Norwegian Continental Shelf and this standard is prepared to support the process of assuring technical integrity of the sub sea system and its elements beyond the original approved service life.
  • 17. Conclusion The guidelines, standards and checklists developed through this project will provide valuable assistance to offshore facility owners and authorities when assessing the condition of aging facilities, and if they can be safely operated for a new consent period.