Ageing and Life extension for structures. David Galbraith Ocean Structures / Sigma Offshore

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1 Ageing and Life extension for structures David Galbraith Ocean Structures / Sigma Offshore 1 PSA Seminar 19 November 2008

2 What is different for structures Additional ageing mechanisms and other changing factors Structural failure is unacceptable Design failure probabilities < 1x10-4 Tendency for personnel to have blind faith in the structure Some design loadings are unknown E.g. Wave heights based on statistics and extrapolation Can have step changes in loadings (wave impact on deck) Inspection and maintenance of substructures Extremely expensive underwater inaccessible use of divers Few opportunities for inspection Fewer for remedial work (cannot be replaced) Many reasons for assessment Including extended life 2

3 Ageing and life extension for structures Types of structure Fixed steel platforms and foundations Fixed concrete platforms and foundations Floating platforms and moorings Topsides primary structure Topsides secondary structure Different levels of criticality Different methods of maintenance Different costs of inspection and maintenance

4 Structural ageing and degradation mechanisms Fatigue Corrosion and concrete degradation mechanisms Geological and Geotechnical Hazards Accidental Damage Extreme Weather Modifications and Change of Use Marine Growth Gross Errors due to Human and Organizational Factors 4

5 Fatigue Many cracks exist in offshore structures Early designs of fixed steel structure had weak fatigue detailing Short fatigue lives Poor weld execution Current design and assessment has fatigue factors up to 10 Critical and uninspectable components Early designs used a factor of 2 throughout Cracking can lead to: Floating structures loss of buoyancy and/or stability Fixed steel structures loss of strength & loss of redundancy 5 Fatigue also affects concrete, but not an issue for operating platforms

6 Fatigue life factors PSA Seminar 19 November

7 Corrosion Protection provided by: painting and coatings topsides Corrosion under passive fire proofing can be a particular problem Anodes and painting substructure Many steel structures are unpainted below splash zone Wrap plates some special areas e.g. Some splash zones Corrosion allowance particularly splash zone Inspection, maintenance & repair Repainting topsides steelwork Inspection of cathodic protection potentials Replacement / addition of anodes Piles are a difficult area critical area, unispectable, not directly protected Topsides condition Often poor maintenance history EI publication on assessment of corrosion 7

8 Geological and Geotechnical Hazards Installation foundation hazards Pile pull-out in tension Pile punch-through in compression Degradation of pile capacity due to cyclic loading Geological hazards Differential settlement Seabed scour Subsidence and slope instability Scour and subsidence can lead to wave impact on deck 8

9 Accidental Damage Ship Collision Supply boat (frequent) vessel masses now ~ 5000T Other service vessel (occasional) Passing vessel (rare) Dropped objects Range of objects and associated damage Radios & scaffold poles to Mobile cranes, tubulars, containers Particular concerns Major impact damage Impact on risers Enhanced corrosion rates Accumulated damage 9

10 Extreme Weather Most NS platforms design for 100 year return storm Elastic response effectively undamaged The 100-year storm as understood at the time Deck height at 100 year storm + 1.5m (from 5 in GoM) Current criteria includes withstanding 10,000-year return storm Structure still has to stand no safety factors But some platforms have suffered subsidence Various R&D projects have tried to compare predicted versus measured forces due to storms Effects of climate change? Life extension Main issue is wave in deck Early designs with no subsidence often not an issue 10

11 Modifications and Change of Use Many changes made during life of platform Weight management tools should be used Weight audit can be necessary depending on historical weight control For life extension future uses of the platform should be considered Norwegian regulations: Life extension and change in use are separate applications 11

12 Marine Growth Marine growth can add weight and environmental loading Can be very significant in warmer climates Inspection and cleaning techniques Hard (e.g. Mussels) and soft (e.g. Seaweeds) marine growths have differing significance Generally not a significant issue in Central and Northern North Sea Not particularly significant for life extension 12

13 Gross Errors due to Human and Organizational Factors Underdesigned structural elements Damaged elements at the installation stage Poor quality inspections and missed damage Gross errors can accumulate during the life of an installation 13

14 Structural Integrity Management Ongoing process throughout platform life Cyclic process Techniques and methods well understood and documented 14

15 Structural assessment Guidance given in ISO particularly for fixed steel structures World wide applicability Also NORSOK N-006 All platform types mainly NS applicability Also API-RP2 SIM All platform types (but mainly fixed steel) mainly GOM applicability Various assessment initiators Based on current design methodology Allows refinement of techniques 15

16 Assessment indicators A. Changes from design or assessment basis, including 1. Change of platform exposure level 2. Weight or C of G changes, 3. more onerous environmental conditions and/or criteria, 4. more onerous component or foundation resistance data and/or criteria, 5. excessive scour or subsidence, etc. 6. inadequate deck height, B. Damage or deterioration of a primary structural component: C. Exceedance of design service life, if either the fatigue life is less than required extended service life, or degradation of the structure due to corrosion is present, or is likely to occur BUT IS A REQUIREMENT UNDER NORWEGIAN REGULATIONS 16

17 Potential show stoppers High fatigue utilization factor Excessive storm utilization Insufficient knowledge High fatigue utilization and limited inspectability Cumulative effect of damage excessive (including accidental damage) Widespread fatigue damage Damage tolerance requirements Not meeting acceptance criteria 17

18 Learning from decommissioned structures Grouted piles Repairs to joints and members Materials and welding Ring stiffened joints Flooded members Closure welds Cast Joints Verification of underwater inspection capability Protocol for recovery of components available from Ptil 18

19 Fixed steel platforms and foundations Fatigue damage Corrosion damage Accumulation of damage from all sources Uninspectable components (e.g. Piles, internally stiffened joints) Wave in deck 19

20 Fixed concrete platforms and foundations Anode usage (e.g. Unintentional electrical continuity) Wave in deck Prestressing tendonds condition Undetected corrosion 20

21 Floating platforms and moorings Increasing wave heights Fatigue damage Effects on buoyancy and stability Ballast control systems 21

22 Topsides structure Poor historical maintenance Painting backlog Degradation of PFP Wave in deck Walkways / grating & handrails 22

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