CASE STUDY ON THE IMPLEMENTATION OF A PIMS SYSTEM FOR AN OFFSHORE ASSET FROM ENGINEERING TO SOFTWARE

Transcription

1 CASE STUDY ON THE IMPLEMENTATION OF A PIMS SYSTEM FOR AN OFFSHORE ASSET FROM ENGINEERING TO SOFTWARE By: Jane Dawsn- Principal Integrity Engineering Cnsultant PII Pipeline Slutins (PII) a GE Oil & Gas and Al Shaheen jint venture Abstract The QP ffshre pipeline netwrk is getting mature and several pipelines in peratin have reached r exceeded their design life. In rder t cater fr the present and future prductin levels frm the abve fields, QP cnducted an initial risk assessment study t rank the criticality f the ffshre pipeline netwrk. The study identified thse pipelines mst critical t QP s peratins. The mst critical ffshre pipelines (51 ff) were then subjected t a detailed Pipeline Integrity Review. This paper describes the scpe and the main findings f this prject. PII wrked tgether with the client's team ver a 14 mnth cntract perid t establish a cmprehensive understanding f the integrity f such an ageing asset and t supprt QP with the required integrity management tls t maintain the pipelines ging frward. Cmprehensive pipeline integrity management system (PIMS) sftware was implemented that was integrated with QP s existing pipeline GIS and was aligned with current industry best practice t effectively manage and mitigate the principal pipeline hazards and risks Intrductin Maydan Mahzam (MM) and Bul Hanine (BH) are the tw majr ffshre il fields perated by Qatar Petrleum (QP). The QP ffshre pipeline netwrk cmprises f apprximately 160 flwlines and exprt pipelines. The flwlines transprt well fluid prduced at the wellheads t ffshre platfrm prcessing facilities. The exprt pipelines transprt the crude il, water and assciated natural gas prduced frm the well fluid at the prcess platfrms fr varius purpses nshre. The QP ffshre pipeline netwrk is getting mature and several pipelines in peratin have reached r exceeded their design life. In rder t cater fr the present and future prductin levels frm the abve fields, QP cnducted an initial risk assessment study t rank the criticality f the ffshre pipeline netwrk. The study identified thse pipelines mst critical t QP s peratins. These mst critical pipelines (51 ff) were then subjected t an Engineering Cnsultancy Study t perfrm a Pipeline Integrity Review (PIR) f the 51 pipelines in light f the extended future peratin. The pipeline integrity review was cnducted fr QP by PII. This paper describes the scpe f the PIR study cnducted and the main findings f the prject. Prject Objective In cmmissining the PIR study QP s requirements were t safely extend the perating life f the selected pipelines, t assess the level f risk assciated with this life extensin and t identify the adequate measures needed t bring peratinal risks in line with standard industry practice/level. The verall bjective f the study was therefre as fllws: Evaluate the cnditin f the 51 selected ffshre pipelines Establish their fitness-fr-purpse and need fr any remedial wrk Determine the level f risk assciated with cntinuing perating life Identify the remedial measures and csts required t bring peratin risks in line with standard industry practice levels Prduce individual pipeline study reprts (integrity management plans) Establish a GIS based Pipeline Management System (PIMS) Prvide PIMS dcument philsphy (Crprate Philsphy and Cdes f Practice)

2 T meet these bjectives the PIR study invlved the fllwing phases: Phase 1: Data gathering, review, and data integratin, Phase 2: Engineering evaluatin f Fitness Fr Purpse (FFP), Phase 3: Prbabilistic Assessment f Pipeline Failure (PAPF) and cnsequence assessment, Phase 4: The preparatin f scpe f wrk fr Frnt End Engineering Design (FEED) based n the cnclusins and recmmendatins f the Pipeline Integrity Review (PIR) Study, and Phase 5: The develpment f QP GIS based crprate Pipeline Integrity Management System (PIMS), crprate philsphies and cdes f practice dcuments addressing in particular, abandnment and decmmissining f pipelines, leak detectin and methdlgy fr ensuring integrity f pipelines/repair f pipelines including additinal measures t assess integrity f unpiggable pipelines. Subject Pipelines Figure 1 prvides an verview f QP s pipeline netwrk. The 51 pipelines cvered under the prject scpe are generally lcated within r cnnecting frm/t ne f the fllwing ffshre lcatins described belw: Nrth Field Alpha (NFA) - PS4, Maydan Mahzam Field (MM) PS-2 Prductin Statin (PS2), Halul Terminal and Exprt facilities, Bul Hanine Field (BH) PS-3 Prductin Statin (PS3), and Idd Elshargi Nrth Dme (PS1) The pipelines cnvey a variety f prducts with varying pressures and prduct specificatins. Fur (4) f the pipelines included in the prject were nshre transprtatin lines. Figure 1 Overview f the QP Pipeline Netwrk

3 Phase 1: Data gathering, review, and data integratin As part f Phase 1 f the prject a site visit was cnducted in rder t btain an verview f QP s pipeline system, its peratinal and integrity strategies and t start the lng prcess f cllecting the data required fr the PIR study and the PIMS. The data cllectin required a jint effrt between QP and PII with QP perfrming mst f the data surce identificatin and gathering and PII cnverting the infrmatin int usable data. Overall mre than 5 GB f data was gathered, checked and laded int the GIS database as part f the prject, including: Alignment sheets fr 51 pipelines (ttal f 965 km) Centerlines fr each f the pipelines were set up in the GIS Cnditin mnitring data fr each f the pipelines. The main techniques fr inspecting the cnditin f pipelines were by means f ROV's, Aut UT surveys/crrsin cupns and Cathdic Prtectin. In-line inspectin (ILI) using intelligent pigging was perfrmed n nly a few pipelines. The cnditin mnitring data imprted int the GIS database included: 107 ROV reprts 85 external UT reprts 9 ILI reprts The prduct cmpsitin, prductin rate data and crrsin cntrl infrmatin was cllected fr each f the pipelines Additinal data elements fr mre than 90 attributes (fr use in the risk and FFP assessments) were entered fr multiple line segments (~40,000 individual entries) Early n in the data gathering and review prcess a Data Gap Analysis Reprt was prduced. The gap analysis reprt identified the parameters essential fr cnducting the required scpe f wrk, reviewed the surce dcuments, analysed the types and quality f data cllected, identified any gaps in the data fr the 51 pipelines and recmmended the further curse f actins t be undertaken in relatin t the data gathering phase f the prject. It was agreed that where infrmatin regarding specific data elements culd nt be prvided in the freseeable future (did nt exist), QP and PII wuld agree n apprpriate and cnservative default values fr the data elements. The last task within Phase 1 was t prduce a Study Basis f Design reprt. The purpse f this dcument being t clearly set ut the fllwing: Statement f the Study scpe f wrk, referencing methdlgy and deliverables Basic Data t be used in the Study including assumptins Listing f sftware t be used in the Study Listing f industry cdes and standards t be used in the Study. The bjective f the Study Basis f Design reprt was fr QP and PII t agree at an early stage in the prject these items thus reducing the risk f misunderstandings in the prject scpe, methdlgies applied etc later n in the prject that may lead t prject delays. Phase 2: Engineering Evaluatin f Fitness Fr Purpse (FFP) The Engineering Evaluatin f the FFP phase invlved perfrming a cnditin assessment n each f the 51 pipelines. This assessment invlved the fllwing steps: 1. A review f the histrical and current IRM activities and recrds (ILI, Caliper, autmated- UT (Aut-UT), crrsin and ROV inspectins). Feature and significant event summaries were prvided fr each pipeline based n the available mst recent survey data and accunting fr any remedial and interventin wrk cnducted since the last survey. 2. An FFP evaluatin f the mst recently knwn cnditin f the pipeline utilising industry best practice. This required the determinatin f the current and histrical peratinal parameters assciated with each pipeline, the assessment f the severity f any reprted pipeline anmalies (crrsin, dents, weld anmalies, mill faults), the determinatin f the maximum allwed (critical) span length and assessment f any reprted spans r ther stability anmalies, identificatin and recmmendatin f the necessary actins that

4 shuld be taken t ensure the current and n-ging FFP f the pipeline based n its mst recently knwn cnditin. 3. An external Crrsin Review t assess f the effectiveness f the pipeline crrsin prtectin system including a review f the external survey data relating t the Cathdic Prtectin system and an assessment f sacrificial ande depletin invlving the determinatin f the remaining life fr each ande and the estimated time t replacement. 4. An Internal Crrsin Review t review the n-ging risk frm internal crrsin in the 51 pipelines including an in-depth peratinal analysis f the transprted prducts, perating cnditins (temperature, pressure, flw-rate), inhibitin, prduced water, slids, bacterial cntaminatin, leak histry in rder t evaluate the internal crrsin threat t each f the pipelines and t estimate crrsin deteriratin rates. 5. An estimate f the csts assciated with the prpsed rectificatin/remediatin activities recmmended. Phase 3: Prbabilistic Assessment f Pipeline Failure (PAPF) and Cnsequence Assessment The Prbabilistic Assessment f Pipeline Failure and Cnsequence Assessment n each f the 51 pipelines invlved the fllwing steps: 1. The develpment f the prbabilistic assessment mdels fr each applicable threat t the safe peratin f the subject pipelines and the evaluatin f the prbability f pipeline failure by threat and by pipeline segment. 2. The identificatin f prbabilistic industry benchmark levels and cmparisn against the results fr the QP pipelines. 3. Evaluatin f the cnsequences assciated with a failure (i.e., a lss f cntainment event causing either a leak r rupture release). 4. The cmbinatin f the prbability f failure results and the cnsequence f failure results t give the verall risk f failure fr each pipeline and each pipeline segment. 5. A summary f the recmmended remedial activities per pipeline priritised accrding t the level f risk and demnstratin f the benefits in terms f reductin in risk after the remediatin activities are perfrmed. The threats applicable t the 51 pipelines in the study were cncluded t be: Internal Crrsin External Crrsin Mechanical Damage Sur Cracking Weather and Outside Frce and Incrrect Operatins The prbability f failure (per year) was estimated by threat and by pipeline segment where the pipelines were segmented as fllws: Start riser Safety zne 1 Main Subsea sectin Safety zne 2 r Shre Apprach End Riser r Onshre sectin Nte the nshre sectins where apprpriate were further segmented t accunt fr changes in the envirnment, the land use and ppulatin density etc.

5 Phase 4: The preparatin f scpe f wrk fr Frnt End Engineering Design (FEED) based n the cnclusins and recmmendatins f the Pipeline Integrity Review (PIR) Study The purpse f this phase in the prject was t draw up the necessary dcumentatin and detailed scpes f services fr the required FEED and rectificatin wrks as recmmended in the Phase 2 and Phase 3 tasks. The scpe f services described in this dcument included: Detailed engineering f rectificatin wrks; Freespan Rectificatins; Pipeline Stabilisatin Rectificatins; Pipeline Crssing Rectificatins; Sacrificial Ande Retrfits; Anmaly repairs; Replacement f a damaged pipeline sectin. The dcument was structured as a stand-alne scpe f services suitable fr QP s use in any future invitatin t tender (ITT). Phase 5: The develpment f QP GIS based crprate Pipeline Integrity Management System (PIMS), crprate philsphies and cdes f practice dcuments addressing in particular, abandnment and decmmissining f pipelines, leak detectin and methdlgy fr ensuring integrity f pipelines/repair f pipelines including additinal measures t assess integrity f unpiggable pipelines. Managing pipeline integrity requires a cmprehensive system in place t supprt it. As a minimum, that system must address prcess, peple, and activities t manage the pipeline. In this Phase f the prject PII prvided a sftware slutin (referred t as the PIMS sftware hereafter) that ties the three elements (prcess, peple, and activities) tgether in a seamless and integrated system. The PIMS sftware takes the user step by step thrugh the pipeline integrity management cycle (Figure 2). This Phase f the prject invlved the fllwing steps: 1) The supply f PII s PIMS sftware including upgrading / mdificatin f the existing QP ArcSDE Gedatabase structure t an industry standard APDM data mdel. The fllwing applicatins frm PII s suite f standard sftware prducts were delivered: - PipeView Facility fr ArcGIS (PVAG) - PipeView Access - PipeView Integrity (PVi) Risk assessment mdule Data alignment mdule Feature assessment mdule 2) Data migratin frm the existing QP ArcSDE Gedatabase and cnversin f data identified frm ther surces t the APDM gedatabase. 3) Implementatin f the PIMS sftware in QP s ffices, n-site acceptance testing and training f QP s persnnel in the use f the sftware. 4) Develpment f QP crprate plicies, philsphy, cdes f practice & prcedures t address the fllwing in accrdance with Internatinal Cdes and standards and best Industry Practice: Abandnment / decmmissining f pipelines Leak detectin, accepted leak rates/frequencies, crrsin mnitring Pipeline integrity methdlgies, pipeline repair, integrity f unpiggable lines

6 Figure 2 Pipeline Integrity Management Cycle Prject Findings and Cnclusins Over a 14 mnth cntract perid, PII wrked tgether with QP s team t establish a cmprehensive understanding f the integrity f such an ageing asset and t implement the required integrity management tls and technlgy transfer t facilitate the safe peratin and maintaining the pipelines ging frward. Overall the PIR study f the 51 pipelines invlved the evaluatin f the severity f mre than: 600,000 ILI anmalies 4,600 pipeline spans 500 crssings 100 stabilizatins 600 andes The prject delivered mre than: 350 written reprts 250 risk prfiles (befre and after remediatin) 51 integrity management plans As a result f the PIR study ver 800 remediatin activities were identified (and cst estimated) in rder t safeguard the immediate n-ging integrity f the 51 subject pipelines, including: Rectificatin f critical freespans, pipeline crssings and ineffective stabilisatins Ande retrfits / replacement ROV surveys ILI surveys Aut UT surveys The prject was successfully cmpleted with QP s bjectives being met: The cnditin and fitness-fr-purpse f the 51 subject pipelines was established The level f risk assciated with current and the n-ging peratin was determined The remediatin activities and csts required t bring peratin risks in line with standard industry practice levels were identified

7 Pipeline study reprts and pipeline integrity management plans were prduced fr all 51 pipelines PIMS GIS based sftware was implemented and data frm QP s existing Gedatabase was migrated and ther relevant data surces cnverted A PIMS philsphy and guidance dcument describing industry current practices and highlighting industry best practices. Finally, it is wrth nting that althugh QP had many up t date prcesses and systems in place fr managing the integrity f their pipeline netwrk, the PIR study was able t fill in the prcess and technlgy gaps in supprt f QP s gal f being a best practice Pipeline Integrity Management Operatr in the gulf regin and glbally in the pipeline industry.