Industry momentum in recent years has been towards the implementation of risk-based integrity management (IM) programs for entire subsea systems (where subsea systems emcompass all hardware from the sand face downhole, to the top of the riser, inclusive of system interfaces, as defined in API RP 17N). This is evident from industry initiatives such as the Subsea Systems Integrity Management JIP (SURF IM JIP) and proposed revisions to industry codes of practice such as ISO 13628/12 "Dynamic Risers for Floating Production Installations" and API RP 17N "Subsea Production System Reliability and Technical Risk Management". This paper presents a holistic approach to the development of risk-based integrity management programs, consistent with current industry best practice and JIPs that have advanced technology in these areas. The methodology balances the risk-based approach to maintaining asset integrity of the system as a whole with the reliability-based approach often adopted to define the preventative maintenance and sparing strategies for subcomponents of the subsea system. A risk-based approach to integrity management is typically focused on identifying the IM measures required to manage the risk of catastrophic system failures with adverse safety, environmental, operational or reputational consequences. Reliability methods, in contrast, are typically focused on mitigation or preventative maintenance to avoid the unplanned failure of an asset's subcomponents (e.g. mechanical or electrical subsystems), the failure of which typically would not on their own lead to full system failure. A holistic IM program identifies the inspection, monitoring, analysis, procedural and preventative maintenance measures advocated to manage the integrity of the subsea system in its' entirety, balancing risk-based integrity management with reliability-centered maintenance. The authors will demonstrate the implementation of this methodology for greenfield and brownfield projects (from the conceptual stage through to decommissioning). Emphasis is placed on how the integrity needs of a system mature over its lifetime to ensure a continuous, practical IM program.
Regulatory changes in recent years have shown more stringent drilling riser inspection and maintenance criteria with the objective of minimizing Health, Safety and Environmental (HSE) risks, as evident with the December 2009 draft MMS NTL on integrity issues surrounding dedicated drilling risers used on floating production facilities. Additionally, the catastrophic Macondo incident has brought to the forefront the risks associated with traditional offshore drilling, which lends an added emphasis to clear assessment and management of HSE risks for all drilling and production risers. This paper presents the methodology proposed for the risk-based comparison of different production and drilling riser system configurations. The methodology is recommended for the concept selection phase of any new drilling riser development to enable a side-by-side comparison of the critical risks within each system. This risk approach facilitates the identification of required mitigation measures to reduce risks to As Low As Reasonably Practical (ALARP). In addition an Integrity Management Strategy is proposed and recommended mitigation measures are compiled in different categories: design, inspection and operating measures. An action tracking database then assigns the implementation of mitigation measures to appropriate development phases (including the operations phase) to allow traceability and ensure risks remain ALARP. The authors will demonstrate the implementation of this methodology for three drilling riser configurations: a monobore drilling riser (base case), a drilling riser with an insert casing riser system, and a monobore drilling riser with a Subsea Isolation Device (SID) system. The case study will consider a deepwater, normally pressured Gulf of Mexico field, taking into account the following scenarios: running the drilling riser; running of drill string and casing; drilling, before and in the hydrocarbon payzone; simultaneous operations (SIMOPs); and other vessel-related activities. Following typical practices for deepwater developments in the Gulf of Mexico, a surface blowout preventer (SBOP) is assumed to be employed for managing well control. The insert riser system and the SID system will be considered by comparison to the monobore system to facilitate the presentation of each option. The most critical risks associated with all three drilling riser systems will be determined in a clear and transparent manner, along with the measures that are required to mitigate these risks to ALARP.
An improved approach is presented for the cost efficient, reliable development and implementation of a holistic Integrity Management (IM) plan for risers systems. Examples based on project experience are provided, illustrating how this process can be applied to Green and Brownfields alike. Flexible Pipe, Top Tension Risers (TTR) and Steel Catenary Riser (SCR) major hazards will be evaluated for a new development tie-in to existing facility, as major material compatibility threats may arise. Consideration regarding available mitigation measures will be discussed. This process will also identify synergies in the planning and scheduling of integrity management activities that can help achieve significant cost benefits through optimized mobilizations with other offshore interventions. The intent is to retain focus on practical retention of technical integrity throughout the riser lifecycle, while emphasizing that integrity management is a dynamic process that takes advantage of best practices from both analysis and operations personnel. Similarly, good interface between design and operations teams can ensure better co-operation between the CAPEX and OPEX cost centers. This then ensures design personnel have the data required to better optimize immediate life cycle ‘fitness for purpose’ as well as future reassessment capabilities of the system.
Integrity management (IM) is an ongoing lifecycle process for ensuring safe operation and fitness for service of offshore oil and gas production systems, including riser and flowlines. Riser and flowlines offer a means of transporting fluids between subsea wells and the host platform. A key component of the riser system is above water riser hull pipes. With their proximity to topside equipment and the people on the platform, these pipes are considered safety critical, and are therefore, subject to rigorous and frequent inspections followed by an engineering assessment of the findings. A thorough knowledge of the past and current conditions of these pipes is required to manage the risk to their integrity. Traditionally, these inspections are carried out by rope access technicians. Such activities are often limited by accessibility, weather, and/or Personnel on Board (POB) availability and involve risks to inspector's safety. This paper discusses the motivation and business driver for developing and implementing new robotic inspection technologies for above water riser inspection. The technology management process of robotic inspection tools is outlined. Comparison is made between traditional and new inspection technologies based on BP Gulf of Mexico (GoM) robotic inspection campaigns. Examples are presented to demonstrate the reduction of safety risks and improvement of inspection execution and effectiveness. The paper also discusses the potential areas of future development, which include methods for pipe wall thickness measurement and data analytics, such as automated recognition approach to characterize and quantify features in the images.
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