Update on SURF IM Joint Industry Project Patrick OBrien Patrick O - - PowerPoint PPT Presentation

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Update on SURF IM Joint Industry Project

2012 SPIM Conference, 7th December 2012, London Patrick O’Brien Patrick O Brien, Group Director Strategic Business & Marketing, Wood Group Kenny

Experience that Delivers

Introduction

Key Presentation Points:

• SURF IM Participation & Workscope
• Picture Tour of what is being done

g

• How SURF IM JIP is evolving for the future

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Experience that Delivers

SURF IM Joint Industry Project y j

• Participation:

– BG, BHP Billiton, BP, Chevron, Hess, Maersk Oil, Petrobras, Petronas, Shell, Suncor Total Woodside Suncor, Total, Woodside

• Scope:

– Review of SURF System Design & Operation (An integrated approach) – Review of SURF System Design & Operation (An integrated approach) – Comprehensive Catalogue of Failures & Failure Mechanisms – Identify and catalogue existing inspection and monitoring technology Evaluate Inspection & Monitoring Technology Gaps and identify emerging – Evaluate Inspection & Monitoring Technology Gaps and identify emerging appropriate technologies for SURF inspection & monitoring – Prepare a Best-Practice Guidance Note for SURF Integrity Management

• Schedule

– Commenced: January 2011 – Complete: Mid 2013

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Experience that Delivers

– Complete: Mid 2013

SURF Integrity Management Guideline g y g

Public Dom ain Review Relevant I ndustry Standards Operator Experiences

Best Practice SURF IM

Operators’ Best Practices Expertise in

Is sharing possible?

Mapping Failure Modes onto an

W ood Group Kenny Experience Expertise in I ntegrity Managem ent & Technology

Modes onto an Inspection & Monitoring Strategy

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Experience that Delivers

SURF IM Work Scope (Graphically) ( y)

I ndustry Experience

Design and Operational Requirements

• Operational Experience
• Design Experience
• Failure Modes/ Mechanisms

Failure Mechanisms

SURF I M JI P Scope of W ork

I ndustry I ntegrity Managem ent

Holistic Integrity Management Methodology Inspection and

p

g Approach

Inspection Monitoring

Methodology Requirements p Monitoring Requirements

Assessm ent of I nspection/

Monitoring Sampling Testing & Analysis

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Experience that Delivers

I nspection/ Condition Monitoring Methods

Potential New Insp. and Monitoring Technologies

Assessment of Probability of Occurrence (as input to Risk) Occurrence (as input to Risk)

Probability

U P P

• 



y Index, P

] [ A DU TSO P P

• 

  

T h l St O t Technology Step-Out: Uncertainty concerning new technology applications Anomaly: Uncertainty due to anomaly or defect from construction, installation or operation. Design Uncertainty : Uncertainty from

• Inputs: design basis
• Response: analytical

p techniques or tools

What we don’t know we don’t know What we know we don’t know What we know we know

Increase in P due to uncertainty

Po TSO DU we know 1 2 3 4 5

uncertainty Possible reduction in P due to IM measures reducing uncertainty

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Experience that Delivers

reducing uncertainty

SURF IM Evolution

• Physical and VC Meetings

Physical and VC Meetings

• 3-Day Physical Meetings

– Perth March 2011 – Houston November 2011 – Aberdeen and Oslo May 2012 – London October 2012 P i M 2013 – Paris May 2013

• Meetings take time (1.5 days) to share knowledge on subsea component failures

and subsea operations experience and subsea operations experience – Engage local operator offices as we move around

• SURF IM Scope Extension

– Subsea Processing – SURF IM Business Case – Sharing Experience on Application of New Inspection & Monitoring Techniques

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Experience that Delivers

Techniques

Develop / Review IM Performance Standards/ Processes

Corporate Requirements & Standard Risk Matrix Regulatory Requirements Integrity Basis Preparation

Output

Assemble / Review System Data System Subdivision & Grouping Design Data F b/I t ll I ti d / Previous IM Work (e.g. Risk analysis, IM Plans) Failure Mode Database HAZID Hazard & Risk Analysis Reporting / Documentation Risk Analysis Fab/Install, Inspection and / or Operational Data Risk Assessment All risks acceptable? Implement Barriers / Mitigation Measures Reliability Assessment No Yes Failure Database Develop Integrity Management Plan Inspection Monitoring Analysis and Testing Operational Procedures Preventative Maintenance Anomaly Limits / KPIs Anomaly Limits / KPIs Anomaly Limits / KPIs Anomaly Limits / KPIs Anomaly Limits / KPIs Database of Available IM Measures Integrity Management Plan S St t Implement Integrity Management Plan Periodic Review & Fitness Assessment Risk Assessment and / or IM Plan Revision Inspection and / or Operational Data Spares Strategy Schedule Plan executed?

Review / Propose Revision of Neglected Procedures

Regulatory / Compliance Review (If Required) Fitness Statement & Recommended Changes Regulatory / Compliance No Yes

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Experience that Delivers

Fit for Purpose? Develop & Execute Repair / Remediation Plan g y p Reports (If Required) No Yes Yes

Integrity Through Field Life g y g

Risk Management and Integrity Management S trategy

Feasibility Feasibility Concept Concept FEED FEED Detail Detail Operate Operate De- De-

Design Design

Feasibility Feasibility Selection Selection FEED FEED Design Design Operate Operate Commission Commission Installation Installation Manufacture Testing (FAT, SIT) Storage/Preservation Pre-Commission Commission

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Experience that Delivers

Failure Modes Categorisation g

• Accidental Damage
• Fatigue

Failure Drivers

• Corrosion/Erosion
• Electrical;
• Flow Assurance/ Flow Restriction
• Temperature

P

• Pressure

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Experience that Delivers

Mapping Failure Modes to IM Strategy g gy

M f il d b id tifi ti f i ti b li d Map failure modes by identification of existing baseline and emerging technology:

Failure No. Equipment Failure Consequence Integrity Management Measures Equipment Sub- Failure Failure Initiator Mechanism Failure Record of O CS CE CC Monitoring Inspection Testing and Procedures Maintenance F Equipment component Driver Mode Initiator Mechanism Result Occurrence CS CE CC Monitoring Inspection Analysis Procedures Maintenance Subsea Piping - Jumpers, Flowlines and Spools SP 001 Subsea Piping

• 1. Jumpers
• 2. Flowlines
• 3. Spools

ental Damage External damage collapse

• r rupture
• 1. Dropped objects due to 3rd party
• 2. Anchors and mooring vessels
• 3. Dragged line
• 4. ROV impact
• 5. Natural disaster (iceberg

Deformation

• r over stress

due to localized

• carbon containment

Happened to

• perator(s)

NA M H

• 1. Pressure

1.GVI

• 1. Metal loss

defect assessment

• 1. Deck lifting and

handling

• 2. Vessel exclusion

zone

• 3. Dropped object

Accide

• r rupture

interaction, storm, etc)

• 6. Trawl board/fishing activity

impact Loss of Hydro reporting

• 4. ROV handling

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Experience that Delivers

Technology Review Process gy

Failure Modes Assessm ent ( Task 1 .0 ) Baseline I nspection & Monitoring Measures Baseline Technology Catalogue Public Dom ain I dentification

• f Em erging

T h l i TRL Assessm ent Review Technologies Operator Experiences How is I ntegrity Assessed? Technology Gaps

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Experience that Delivers

Baseline Inspection & Monitoring Technology Technology

Compilation of Baseline Technology

• Identification of technologies available to support baseline

Inspection & Monitoring Measures Inspection & Monitoring Measures

• Completion of catalogue with technologies available to be

deployed for assessment of specific defect or deterioration.

• Classification based on Failure Drivers

– Facilitate mapping of technologies to failure mode assessment assessment – Systematic approach to ensure comprehensive review f – Presentation using a Flowchart format

• Compilation of technology datasheets

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Experience that Delivers

Baseline Technology Mapping

Electrical Power / Communications Electrical Power / Communications

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Experience that Delivers

Baseline Technology Mapping

Erosion / Internal Corrosion Erosion / Internal Corrosion

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Experience that Delivers

Technology Datasheets Compilation gy

Technology Datasheet Catalogue Technology Datasheet – Catalogue

Method 1.3 Intelligent NDT Inspection Pigging

Magnetic Flux Leakage

Control Systems

Magnetic Flux Leakage

PURPOSE 1 Applicable S t To utilize magnetic fields to detect flaws and cracks in steel sections. MFL are currently used extensively in intellignet pigs as a NDT inspection technique Subsea Piping Subsea Structures (main piping) Umbilicals Xmas Tree DDD : Defect, Detection and Degradation Monitoring 2 Strategic Level Systems DDD : Defect, Detection and Degradation Monitoring ELR : Exposure, Load and Response Monitoring SLM : Safety Limit Monitoring GLC : General Layout and Configuration Monitoring Global Integrity / Condition. 3 Scope of C diti 2 Strategic Level Local Integrity / Condition. Exposure / Environment. External. Internal. In-line Condition Assessment 4 Level of Intrusion

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Experience that Delivers

In-line.

Technology Datasheets Compilation gy

T h l D t h t ( td ) Technology Datasheet (contd.)

External. Internal. In-line. Fully on line system No downtime required but operational conditions must 4 Level of Intrusion 5 Downtime Fully on-line system. No downtime required but operational conditions must be adjusted to release and receive pigging tools and to carry out actual inspection run. Production shutdown required. Production shutdown and system opening required. Installed during construction; no further interference. 5 Downtime Requirement Installed during construction and requires shutdown for inspection. Continuous. Periodic. Condition based. 7 Access Pigging requires release trap, reception trap and assurance of wide ID 6 Frequency of Use Requirements (i) Capable of detecting cracks wider than 0.1mm and longer than between 25 to

• 50mm. Pipe diameter range from 8 to 30inches

(ii) Poor internal pipeline cleaning prior to inspection run, presence of small ID valves or other components compared with pipeline ID, presence of tight bends tees or 90° elbows and out of roundness or ovality of pipe due to valves/components and wide bends on pipeline system. 8 Limitations bends, tees or 90 elbows and out of roundness or ovality of pipe due to shocks or blows, falling objects, etc. (iii) Battery life on inspection tool must be sufficient for each stage of inspection run. 9 Identifiable Failure Modes

Allow to detect pipeline wall condition and ascertain the following types of corrosive attack: Pitting, top of line corrosion, bottom of line corrosion, erosion-corrosion, flow related corrosion CO corrosion H S corrosion and stress corrosion cracking

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Experience that Delivers

corrosion, CO2 corrosion, H2S corrosion and stress corrosion cracking.

Technology Datasheets Compilations gy

T h l D t h t ( td ) Technology Datasheet (contd.)

Description of Method The following equipment is relevant to intelligent pigging inspection: MFL inspection: An electromagnetic testing technique; for this case the pigging tool is equipped with very powerful rare earth magnets and these in contact with the pipe wall create a magnetic field, which is stable and uniform if there are no indications. H if th i di ti t ( ll thi i ) th ti fi ld 11 E i t 10

• Polyurethane cups pipeline cleaning pig.
• Steel brushes/scrapers pipeline cleaning pig.
• Chemicals/inhibitors flushing pig.
• Dummy calibration pig.

The following equipment is relevant to intelligent pigging inspection: 11 Equipment

• Fully instrumented (UT or MFL + recorder + battery pack) inspection pig.

12 Preparation Requirements To carry out intelligent pigging inspections delivery or release traps and reception traps must be available topside. Traps are ancillary items of pipeline equipment, with associated pipework and valves for introducing a pig into a pipeline or removing a pig from a pipeline. Usually for engineering design purposes, traps are considered p p y g g g p p , p "pipeline accessories" and thus trap barrels are designed according to ANSI B31.4 (Liquid pipelines) or ANSI B31.8 (Gas pipelines); quick opening trap end closures are designed according to ASME VIII, Div. 1. At traps locations lifting capabilities (permanent or temporary) are required to handle the heavy and long intelligent inspection pigs. Depending on the length of the pipeline several traps may be necessary, otherwise the pig's battery-pack charge may not last the complete run. In addition, careful coordination with Operations must be forthcoming to assure the appropriate pipeline flow conditions for optimum pig velocity. 13 Time Requirements Pigging operations: Depend on length of pipeline being inspected and number of pigging traps in system.

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Experience that Delivers

(i) Scan rates of Pigs typically 0.2 to 4m/s.

Emerging Technologies g g g

SURF IM Objectives

• Industry survey of emerging technology

Industry survey of emerging technology

• Identification of IM technology gaps and on-going technology development

to address these gaps to address these gaps

• Sources include public domain, operator experience, vendor contacts
• Technologies are identified along with vendors, type of application and

methodology gy

• For emerging technologies, the objective is to assign a Technology

Readiness Level assessment based on API 17N

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Experience that Delivers

Readiness Level assessment based on API 17N

Emerging Technologies g g g

Year C t l S b X Areas of Application Technology Company TRL reached TRL Control Systems Flowline Jumper Subsea Structures Umbilicals Xmas Trees Intelligent Pigging - EMAT Rosen GE 5 2008

• Intelligent Pigging -

R 2 2012 Intelligent Pigging Eddy Current Rosen 2 2012

• Ultrasonic Phased

Array Sensor GE Sensorlink ClampOn 5 2010

• WT

Measurement Magnetostrictive Sensor Guided Wave Technology SWRI GUL TWI TNO 5 2012

• MFL & UT

Pipeway 5 2011

• & U

pe ay 5 Digital Radiography VJ Technologies Applus RTD 5 2010

• Electric Field Mapping

Sensors Roxar Fox tek 7(1) 2007

• Sensors

Fox-tek Electrical Resistance Probes – Spool Teledyne Cormon 6(2) 2008(2)

• Halfwave

DNV 5 2012

• Gamma Ray

Tracerco 7/5(3) 2008

• 19

Experience that Delivers

Transmission Survey Tracerco 7/5( ) 2008

Emerging Technologies g g g

Year Areas of Application Technology Company TRL Year reached TRL Control Systems Flowline Jumper Subsea Structures Umbilicals Xmas Trees Reson Aquadyne SeaBat Leak Detection Sonar SeaBat acoustics Sonardyne Wavefront Blueview Technologies 5 2012

• Technologies

Weatherford (Come Monday) Bio Sensor Biota Guard

• Fiber Optic

Measurement Schlumberger 5 2012

• Measurement

g Physical Damage AUV Lockheed Martin UTEC Kongsberg C&C Cybernetix 7(4) 2005

• Physical Damage

(CVI) Cybernetix Teledyne Gavia AUV Seebyte ECA 7(4) 2005

• Blockage

Pulsed Pressure Paradigm 6(5)

• 20

Experience that Delivers

Blockage Pulsed Pressure Paradigm 6(5)

Gaps & Recommendations

Gap analysis to identify areas that require additional development and provide a Gap analysis to identify areas that require additional development and provide a road map to bridge the gaps between current status of technology and the desired performance specification.

Gap Recommendations Uncertainties of internal corrosion and internal corrosion/erosion models. A study to baseline various corrosion models against volunteer member corrosion monitoring/ inspection results.

NB: Draft Only

Follow results from multiple corrosion/ erosion model JIP, such as University of Tulsa JIP, Ohio JIP, TOPCORP JIP and Deepstar findings from Alternative to ILI. Standardized method/ process for chemical selection and performance verification Develop a method /process to validate chemical effectiveness performance and dose optimization Corrosion Management verification. effectiveness performance, and dose optimization. Best practice on the design of flood water treatment:  Chemical package design.  Injection practices.  Performance verification / monitoring through life of the flood. Standard practices for the design of flood water

• treatment. JIP member organizations will all have

internal practices that could be drawn together for mandatory minimum requirements and best practice g g y q p recommendations. Uncertainties with corrosion susceptibility of 316 clad steel when exposed to seawater (e.g.: if 316 clad when exposed to water begins to pit, does the pitting Guidelines for the corrosion resistance of 316L to seawater / clad pipe based on depth/ temperature/ location.

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Experience that Delivers

cease if the seawater is removed and production conditions imposed).

Gaps & Recommendations

Gap Recommendations

Sand Management Sand detection technology unreliable Yes/No in some instruments. Review the detectability limits of current sensors (especially acoustic), and methods of quantifying sand

NB: Draft Only

Review Recommend Practice for sensor location. Remote instrumentation Issue of power source/retrievable for battery replacement or alternative power source Develop/investigate wireless acoustic instrumentation in subsea service. Either constantly transmitting ones (some systems use the pipeline as a “cable”), or passive systems that are interrogated by ROV on a periodic basis (physical dock

• r ireless transmission)

Condition Monitoring

• r wireless transmission).

Online strain gauges A review of state-of-the-art and development of guideline of best practice and how long term reliability can be achieved. Tools to predict degradation on control systems Review industry best practice and propose guideline. Leak Detection Time lag on detection of oil leaks. More efficient detection/ diagnostic techniques and remediation for oil leaks (Identification, localization, quantification and classification, as per Ref. 8) e.g. system should have the ability to detect x liters of oil coming from x drill Leak Detection g y y g center. Blockage Ability to quantify % of lines that are plugged, location, length and characterization A review of best practice and propose guideline. Technologies available should also be assessed to benchmark results.

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Experience that Delivers

Gaps & Recommendations

Gap Recommendations

NB: Draft Only

Gap Recommendations Alternative to ILI:  Technology limited to coating.  Removal of insulation.  Accuracy for defect sizing. Develop a ROV deployable system with the following specification:  Good accuracy – the ability to provide WT data in ½-inch (12.7mm) resolution pixels within 0.2 mm;  Depth capable – the ability to go down to 11,000+ feet (3400m) of

NB: Draft Only

y g  Marinization of tools.  Issues with 360 deg access, for buried pipe.  Source/Energy to subsea application.  Pipe-in-pipe. p p y g ( ) water;  WT capable – the ability to inspect pipe walls up to 50 mm thick;  Speed capable – the ability to inspect at typical ROV speeds of several knots.  Ability to detect through typical subsea pipeline and field joint coatings Inspections  Ability to detect through typical subsea pipeline and field joint coatings, 3LPP, FBE, TSA, Shrink sleeves etc. WT Inspection ILI Develop a ILI tool with the following specification:  Small size – the ability to enter 6-inch lines and navigate through pipe bends; G d b tt lif th bilit t i t 40 il i t 2 5 MPH (16  Good battery life – the ability to inspect a 40 mile pipe at 2.5 MPH (16 hours);  Good accuracy – the ability to provide 360º WT data in ½-inch (12.7mm) resolution pixels within 0.2 mm;  Depth capable – the ability to go down to 11,000+ feet of water;  WT capable – the ability to inspect pipe walls up to 50 mm. Cost effective inspection campaigns. Further develop AUV technology to perform close visual inspection. Reliability of corrosion monitoring spools. Develop guideline on how to improve long term reliability of subsea corrosion monitoring spools. Better and reliable fatigue crack inspection tools ILI Further development of technology tools and algorithms to analyze results

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Experience that Delivers

Better and reliable fatigue crack inspection tools ILI type. Further development of technology, tools and algorithms to analyze results.

Internal SURF IM Discussions

Typical Discussion Topics: Real-time continuous monitoring system (corrosion) Real time continuous monitoring system (corrosion)

• Ultrasonic Phased Array Sensor

– Vendors for this technology: GE (Rightrax), Sensorlink (Ultramonit) and ClampOn (Corrosion Erosion Monitoring).

• Electrical field mapping technique:

– Vendors for this technology: Roxar (CorrOcean) – Field Signature Method (FSM) and Fox-tek – Pin-Point Electrical Field Mapping (FSM) and Fox tek Pin Point Electrical Field Mapping

• Magnetostrictive Sensor Guided Wave Technology:

V d f thi t h l SWRI GUL TWI d TNO

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Experience that Delivers

– Vendors for this technology: SWRI, GUL, TWI and TNO.

Supplier Presentations to SURF IM

GE Oil d G

• Lockheed Martin

– AUV Inspection Technology

• Clamp-on
• GE Oil and Gas

– Umbilical & Flexible Riser Monitoring

• Cameron

– Acoustic Sand Detection

• Weatherford

– Leak Detection and others

• Cameron

– Remote Subsea Infrasture Condition Monitoring

• AGR
• Applus RTD

– Various metal inspection technology – Wall Thickness & Weld Inspection

• Aker Solutions & Bornemann

– Subsea Pumping Technology

• Viper Subsea

– V-SLIM Insulation Resistance Monitoring

• Framo

– Condition Monitoring of Subsea Pumps

• Eagle Burgmann
• Smart Fibres Ltd

– Optical Sensing Technology for Subsea Condition Monitoring

• Eagle Burgmann

– Subsea Sealing Technology for Pumps

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Experience that Delivers

AUV Technology for Inspection gy

S L kh d M ti W b it Source: Lockheed Martin Website

Graphic: Surveying a Pipeline L kh d M ti ’ M li AUV Lockheed Martin’s Marlin AUV

• 3D High resolution optical and acoustic sensor package

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Experience that Delivers

g p p g

Condition Monitoring Subsea Pumps

Smart Fibres Ltd Smart Fibres Ltd. R t b i i t t d ith Fib B

Source: Smart Fibres Ltd.

• Rotor bearings instrumented with Fibre Bragg

Grating (FBG) strain sensors

• Alerts changes in twin-screw loads and geometry
• Shown to be able to detect early damage within twin-

screw shaft

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Experience that Delivers

screw shaft

Future of SURF IM

Where do we go from here?

• SURF IM will deliver it’s scope by mid 2013
• Phase 2 now in planning

– SURF IM Forum – Specific Study Scopes Specific Study Scopes – Other operators coming on board

• Effective engagement with supply chain and technology developers of

Effective engagement with supply chain and technology developers of inspection and condition monitoring technology

• Lever for ongoing technology development

Lever for ongoing technology development – Spawn off JIPs on collaborative technology qualification / trialing for a range of specific inspection and monitoring techniques to close the technology gaps

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Experience that Delivers

gy g p

Thank you A ti ? Any questions?

Experience that Delivers