Trends in causes of offshore releases by severity classification

The Hydrocarbon Release Database (HCRD) contains data on loss of containment events in the UK sector of the North Sea. The data shows a decrease in the annual number of releases. A study was carried out to determine whether statistically significant trends are apparent when categorizing releases by severity and specific cause. It was investigated whether the relative contribution of some causes as compared to all releases, had changed over time.The main conclusion is that over the analysed period (1993–2014), the relative contribution of “Procedures” as a cause for release has decreased with statistical significance. “Design” improvements seem to lead to a reduction in releases too. Finally, “Equipment” was improving at the slowest rate, if at all, until 2005. Since then, it appears to improve as well. These findings are robust, at least for the total set of data, and the releases of Significant severity. For releases of Major severity, the number of incidents is too small to justify any conclusion on trends.The conclusions suggest that over the analysed period improvements in offshore safety have been mainly driven by improvements in management, covering elements like procedures, competence and compliance.     

Risk assessment in the offshore industry

This paper describes the implementation and use of risk assessment in the offshore industry in relation to safety aspects — safety to people's life and health, as well as environment and property. Although risk assessments may be based on both qualitative and quantitative methods, the main focus here will be on quantitative risk assessments (QRA). The development of offshore QRA has been lead by a mutual influence and interaction between the regulatory authorities for the UK and Norwegian sectors of the North Sea as well as the oil companies operating here. The experience from this area has been the main basis during the writing of this paper.     

Root causes of hydrocarbon leaks on offshore petroleum installations

Hydrocarbon leaks on offshore installations may result in severe consequences to personnel, to the environment and to assets. In order to prevent such leaks, it is crucial to understand their root causes. The objective of this paper is to study the circumstances of hydrocarbon leaks on the Norwegian continental shelf (NCS). In the study, all reported hydrocarbon leaks from process inventories on all offshore installations on the NCS, with an initial leak rate higher than 0.1 kg/s in the period 2008–2014, have been considered. This includes 78 hydrocarbon leaks, of which about 60% have occurred during manual intervention on normally pressurized systems. The dominating activity when leaks occur is preventive maintenance. A significant fraction of the leaks occur during the preparation for maintenance; such a preparation is typically carried out during the night shift. About half of the leaks are associated with wellhead area and manifolds, separation and compression systems. A substantial fraction of the leaks can be associated with verification faults, dominated by the failure to comply with procedural requirements that are needed to carry out independent verification.     

20 Years on lessons learned from Piper Alpha. The evolution of concurrent and inherently safe design

It has now been well over 20 years since the North Sea Piper Alpha disaster in 1988. There have been many lessons learned; some documented others just etched in memory. The event chronicled many significant changes in the offshore industry. The emanating point for most sweeping changes has been the Cullen Report and the UK North Sea industry. This paper reviews some of the critical lessons and identifies many ‘secondary’ finer points that constitute important learnings. The paper looks at major changes instigated by step changes in safety criticality. It is argued that the ‘second tier’ modes of failure such as corrosion, materials degradation, environmental cracking, erosion, plant ergonomics, etc. need to be better examined. These mechanisms are dangerous threats to the integrity of deep subsea assets, and it is noted that such root causes of failure as witnessed or predicted have yet to be fully appraised. The authors’ use wide experiences and case histories to highlight such concerns, offering rational fit-for-purpose solutions. The industry disconnections between, urgency to build, knowledge transfer, and management of change, are refocused. Powerful advances in risk-based mechanical, process, materials, and corrosion engineering are emphasized and the use of key performance indicators (KPIs) are reasoned for best life-cycle integrity. To keep up with the pace of growth in the deepwater sector, methods of concurrent and inherently safe design have evolved in a world where the practicalities and costs of modification, repair and retrofit are extremely difficult. Hence getting it right at the outset is paramount. Thus the drive for purposeful investment, at design is more justifiable, than the traditional practice of postponing costs (and problems) to operations. In this way the ominous ‘gray’ zone between the two cost centers is better bridged for reasons of safety and commercial advantage.     

ARX modeling approach to leak detection and diagnosis

This work presents a time series strategy for detection, location and quantification of leaks in large pipeline systems. The technology has two active components, which operate sequentially: the Detector and the Localizer. The Detector continuously screens real-time data, searching for any anomalies such as leaks, which are detected (or not) depending on their size and position. The Detector is based on auto-regressive multi-input/multi-output (MIMO) ARX predictors with one input filter. Subsequent to successful leak detection, the Localizer is launched to diagnose the leak via estimation of its parameters – diameter and location – using recorded data on a Search Time Window that includes information in the neighborhood of the instant of detection. The Localizer is also an ARX predictor, but with two input processors, the first is a filter for dynamic plant inputs and the second filter processes “parameter signals” of active leaks. The Localizer is developed beforehand via model identification with plant data under the action of known, artificially simulated, leaks. It is, therefore, able to recognize an active pattern of leak parameters, by maximizing the adherence of its predictions to data in the Search Time Window. The proposed detection and location methods were successfully tested in simulated leak scenarios for an industrial naphtha pipeline.     

Safety climate and hydrocarbon leaks: An empirical contribution to the leading-lagging indicator discussion

Hydrocarbon (HC) leaks are important initiating events for major accidents in the oil and gas industry. This study explores the extent to which a safety climate indicator from a survey on working conditions undertaken in an oil and gas company (n = 2188) can be used as a leading and/or lagging indicator in relation to HC leaks on 28 offshore installations. It was found that more negative safety climate scores were associated with increasing numbers of HC leaks over a 12-month period following the survey. The safety climate indicator explained more of the variance in HC leaks than technical indicators. HC leaks in the 12-month period preceding the survey did also correlate significantly with the safety climate indicator. More HC leaks during this period were associated with worse scores on the safety climate indicator. Thus, the results support that the safety climate measure could serve as leading and lagging indicator for HC leaks. The results and their possible implications are discussed.     

Risk indicators for major hazards on offshore installations

Major hazards risk indicators are proposed for offshore installations, based on what has been used by the Petroleum Safety Authority Norway for the Risk Level approach in the Norwegian offshore petroleum industry. Since 2002 also leading indicators are used, in the sense that indicators for barrier performance are included together with the lagging indicators. There are individual indicators for a number of barrier functions, including fire and gas detection, a number of safety valves, active fire protection and mustering of personnel. The performance of the leading indicators during several years of data collection as well as lessons learned from the project are discussed. This is followed by a review of how indicators may be used by individual companies, and how the lessons may be utilised by individual companies to develop risk indicators for individual installations as well as company wide indicators.     

Two leaks detection in viscoelastic pipeline systems by means of transient

This paper presents a technique for detecting and locating leaks in a single viscoelastic pipe, by means of transient analysis. The system studied is a reservoir-pipe-valve structure. The viscoelastic behavior of the pipe wall material is modeled by a generalized KelvinVoigt model. To determine the leak location, the mathematical formulation has been solved by the method of characteristics. The approach by the method of characteristics is often chosen because it is based on the concept of acoustic wave propagation which is the main mechanism of all transient events considered. The presence of the two leaks in a pipe partially reflects pressure waves initiated by the sudden closure of a downstream shut-off valve. These waves affect the shape and the amplitude of the time-history-pressure. The computed results describe the influence of the presence of two leaks on pressure time-history and the effect of leaks locations and sizes on the pressure signal behavior. The effect of the pipe wall viscoelasticity on the two leaks detection and sizing is also discussed. The leaks discharges are determined by resolving two independent equations derived from literatures and based on transient analysis. The friction and leaks depths effects on two leaks locations and sizing are involved.     

CFD-based assessment and visualization of the failure consequences of LPG tankers

This paper presents a simulation analysis of the explosions following an LPG leak and visualizes the consequences of the accident to reduce the consequences of the LPG leak explosion. Firstly, this paper proposes a CFD numerical simulation-based method for visualizing the consequences of LPG tanker failure. The method combines satellite maps and CFD numerical simulation data to visualize the consequences of LPG leaks and explosions, taking into account the influence of obstacles on the danger range of leaks and explosions; Secondly, this paper applies the method to a liquefied petroleum gas accident that occurred in the Wenling section of the Shenhai Expressway and performs CFD numerical simulation on the accident process and visualizes the consequences of the accident. Therefore, this method can provide a theoretical reference for the prior prevention of LPG accidents and the analysis of the consequences of accidents, as well as certain practical guidance instructive.     

极端海况下海洋石油结构的风险评估

根据中国海上石油工业缺乏独立的风险评价体系的现状 ,笔者对极端海况进行了环境荷载的联合概率分析 ,利用随机模拟技术 ,求解结构的失效概率 ,提出结构失效分析的新方法 ,并利用DNV提供的历史数据 ,对结构失效的后果做了适当分析。以埕北 12 C井组平台作为实例 ,对平台甲板高程 (AirGap)失效分析进行了实例计算。结果表明 ,使用多维联合极值分布理论及相应的求解方法 ,是离岸工程结构物风险评估的重要手段。     

On the analysis of hydrocarbon leaks in the Norwegian offshore industry

There have been several major offshore accidents in different offshore regions since 2005. In Norway there have been several very serious near-misses during the last ten years, several of which involving serious hydrocarbon leaks with catastrophic fire and explosion potential. All these severe occurrences demonstrate the importance of learning from major accident precursors in order to appraise the risk potential involved in critical offshore operations. This paper is based on analysis of about 175 hydrocarbon leaks in the period 2001–2010. Regulatory requirements in Norway are aimed at preventing as far as possible such occurrences during night time, but the analysis shows that this has been far from successful. The industry has for many years claimed that the maintenance personnel are the main group of employees involved in causing these leaks. This study has shown that leaks during the execution of maintenance and modification are less than half of the leaks, and that failures during the preparation for carrying out maintenance tasks are more frequent. Such preparations have often been conducted during night shift. The analysis gives a strong incentive to change this practice.     

Barrier management in the offshore oil and gas industry

Accident investigations indicate that inadequate barrier management has been a main cause of many accidents in the process industry. In 2013, the Norwegian Petroleum Safety Authority issued a barrier management framework for the offshore oil and gas industry. The framework describes principles related to barrier management and may be a valuable guide for the entire process industry. However, the offshore industry faces several challenges when implementing the framework. This paper discusses these challenges and clarifies the central concepts and steps of barrier management. A key message is the need for clarity and integration in a systematic approach to risk and barrier management.     

Leak location of pipelines based on transient model and PSO-SVM

An improved and integrated approach of support vector machine and particle swarm optimization theory (PSO-SVM) is first used to detect the leak location of pipelines and overcome the problem of multiple leaks. The calibration and predictive ability of improved PSO-SVM is investigated and compared with that of other common method, back-propagation neural network (BPNN). Two conditions are evaluated. One with a leak involves a set of 20 samples, while another with two leaks has 127 samples. Both internal and external validations are performed to validate the performance of the resulting models. The results show that, for the two conditions, the values calculated by improved PSO-SVM are in good agreement with those simulated by transient model, and the performances of improved PSO-SVM models are superior to those of BPNN. This paper provides a new and effective method to inspect the multiple leak locations, and also reveals that improved PSO-SVM can be used as a powerful tool for studying the leak of pipeline.     

海上生产设施远程监控和管理系统的建设探讨

针对海洋石油行业面临的海上作业设施如何安全有效监控及管理的问题,从实际的安全生产管理需求出发,结合通信网络链路及传输特点,采用先进的远程监控技术和海洋石油应急管理理念,设计开发了海上生产设施远程监控和管理系统平台,并论述了总体框架、软硬件结构及发展趋势。系统已经作为保障安全生产的重要手段应用于海上作业平台及船舶运输,提高了安全生产管理水平,并取得了很好的效果。     

Development and application of equipment maintenance and safety integrity management system

Equipment management in process industry in China essentially belongs to the traditional breakdown maintenance pattern, and the basic inspection/maintenance decision-making is weak. Equipment inspection/maintenance tasks are mainly based on the empirical or qualitative method, and it lacks identification and classification of critical equipment, so that maintenance resources can’t be reasonably allocated. Reliability, availability and safety of equipment are difficult to control and guarantee due to the existing maintenance deficiencies, maintenance surplus, potential danger and possible accidents. In order to ensure stable production and reduce operation cost, equipment maintenance and safety integrity management system (MSI) is established in this paper, which integrates ERP, MES, RBI, RCM, SIL and PMIS together. MSI can provide dynamic risk rank data, predictive maintenance data and RAM decision-making data, through which the personnel at all levels can grasp the risk state of equipment timely and accurately and optimize maintenance schedules to support the decision-making. The result of an engineering case shows that the system can improve reliability, availability, and safety, lower failure frequency, decrease failure consequences and make full use of maintenance resources, thus achieving the reasonable and positive result.     

Management of life extension for topsides process system of offshore platforms in Chinese Bohai Bay

Technological advances in exploration and production mean that production platforms in Chinese Bohai Bay have many developments that are now operating beyond their original design life. As equipment ages, there are increasing challenges to maintain its integrity. Issues related to LE management of offshore facilities in government regulations, industrial associations and international oil companies were investigated. The results showed that emphasizing the requirements of labor union and industrial associations was a great feature in Norway, which was practical in Chinese Bohai Bay. Therefore, with the combination of the LE management system in Norway with the current situation in Chinese Bohai Bay, LE management model which integrates RBI, RCM, FMECA, and SIL risk assessment methods together was designed in order to improve understanding and ensure that LE issues were addressed across all aspects of asset management during the entire LE period. Finally, an example of three production offshore platforms on a gas field in the Bohai Bay was used to go through the LE management process and address the issues in each phase. The suggestions for improving LE management and technologies were given.     

含硫气井井筒完整性风险评价研究

针对含硫气井开发过程中井筒完整性失效风险,建立了含硫气井风险评价模型。采用Bow-tie模型将井筒完整性的失效形式分为水力屏障失效、实体屏障失效和操作管理屏障失效3个方面,确定了含硫气井井筒完整性失效的28个风险因素;基于层次分析法定量确定了各风险因素的权重,通过风险矩阵法评估了风险因素发生的可能性与严重程度,实现了对井筒完整性风险等级的划分。将以上方法对某含硫气井进行了应用,确定了该井的风险等级及主要风险因素。研究结果表明:建立的风险评价模型能够对含硫气井井筒完整性进行评价,确定风险等级。该方法的应用有助于降低含硫气井的事故风险,可为含硫气井完整性现场管理提供参考。     

Microwave-assisted preparation of two-dimensional amphiphilic nanoplate herding surfactants for offshore oil spill treatment

Oil spills are the uncontrolled release of liquid hydrocarbon by ruptured pipelines and tanker hulls, or blowouts and leaks from offshore storage facilities and drilling rigs, either by faulty human behaviors or inevitable natural aging processes. Spills cause disastrous environmental and economic consequences, with the effects of marine habitat damage for lasting decades, necessitating a critical need for efficient oil spill mitigation and leakage treatment. In this study, we develop a two-dimensional (2D) amphiphilic nanoplate as the herding surfactant for retracting spilled oil offshore on the seawater surface with various temperature and saline concentrations. Applying 2D nanoplate herding surfactant causes areas of thin oil slick floating on water to largely shrink and form a thick bulk layer. This transformation lays the foundation for the next-step oil treatment and recovery. Microwave-assisted synthesis method was used to fabricate the surface-modified zirconium phosphate (ZrP) nanoplates as the oil herder, which has an amphiphilic characteristic, containing both hydrophilic and hydrophobic properties. The 2D nanoplate surfactants decrease the air-water surface tension to facilitate the oil herding process efficiently. Using this herding procedure, we propose a biocompatible, high herding efficiency and cost-effective 2D herding surfactant fabrication method and offer a new direction for oil treatment in the offshore process safety field.