Hazardous Installations Directorate Offshore Division KEY PROGRAMME 3

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Hazardous Installations DirectorateOffshore
DivisionKEY PROGRAMME 3

• INSTALLATION INTEGRITY
• Roger Fronks
• Principal Inspector/Project Manager

Step Change OIM Network - 20 May 2004
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KP3 Installation Integrity

• Topic and key programmes 2004/2005
• 3 Topic Programmes
• Musculo-skeletal disorders and improving
  occupational health risks
• Reduction in FPSO collision risks
• Incorporating health and safety in design
  
• 3 Key Programmes
• KP1 managing offshore process integrity
• KP2 risk management in the workplace and
• KP3 .. Installation Integrity.

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KP3 Installation Integrity

• A pilot programme of offshore inspections focused
  on maintenance management and backlogs to inform
  the main programme. This was undertaken between
  October last year and March this year and is
  complete.
• A 3 year inspection programme focussed on key
  integrity issues to commence second quarter 2004.
• Joint supporting projects with external
  stakeholders such as UKOOA
• The sharing of our programme findings with all
  stakeholders as promptly as possible
  

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Stan Cutts Specialist InspectorProcess
Integrity

• What are HSE Offshore Divisions current concerns
  about offshore major hazards and what are we
  doing about them ?

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KP3 Installation Integrity

• Working to common template
• Examination of records
• Check suitability of performance stds
• Interrogate backlog/overdue list
• Includes reactive work
• Standards of DH and contractors
• Includes physical testing of SCEs

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What do we mean by Integrity ?

• Integrity refers to the risk of failure
• of structure, plant, equipment or systems,
• which could either cause or contribute to
• a major accident and/or cause fatalities.
• It also includes structure, plant, equipment
• or systems that prevent or mitigate the
• effect of a major accident and/or fatalities.

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Integrity
Another way of putting it. Does it do
what it says on the tin ?
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Why Now ?

• Ageing Installations
• Industrys Commercially-Driven Changes
• Reduced Manning
• Reduced Maintenance/Inspection
• Deficiencies identified in KP1
• Specific Incidents e.g. Brent B

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KP3 Priority Areas

• Integrity of piping repairs
• Risk assessments and Hazops
• Awareness of personnel
• Valve failures
• Hydrocarbon containment
• ESDV issues

• Maintenance quality and backlog
• Lack of resources
• Competence
• Mitigation systems
• Corrosion
• (Ship collision)

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How ?

• Maintenance Policy/Strategy
• Enactment
• Predictive Analysis
• Number/Frequency of Breakdowns
• Performance Standards
• Backlog Justification
• Deferrals Process
• Traceability of SCE definition

• ICP Interface
• Verification System
• Replacement Parts
• Repair Techniques
• Role of TAs
• Supervision
• Competence
• Capacity for Human Error
• System Testing

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Weaknesses Observed on some installations

• Backlog
• Corrosion
• Maintenance Management System
• Beach Support
• Planning
• Supervision
• Performance Standards
• Physical Evidence
• SCE Performance

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Conclusions from KP3 Pilot

• Based on 11 inspections, sufficient evidence has
  been gathered to justify the following
  challenges
• Is the maintenance function adequately resourced
  ?
• Is the planning of SC maintenance efficient ?
• Is the quality of maintenance acceptable ?
• Is the performance of SCEs reliable ?
• Are inspection and audit standards optimal ?
• Is supervisory and engineering support solid ?
• HSE influence can help to remedy deficiencies in
  these important areas

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KP3 Inspection Programme

• A number of fully developed KP3 inspections will
  be undertaken between now and 31 March 2005.
• Each inspection will be undertaken using a
  template developed from the KP3/2 pilot and the
  Belfry Workshop.
• A multi-disciplinary team comprised of at least
  one IMT inspector and two topic specialists will
  carry out each inspection.
• Each inspection will take at least two weeks, to
  include an offshore inspection of at least 3 days
  duration plus pre and post onshore components and
  report preparation. 

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Installation Integrity Relevant Law

• HSWA S2 general duty
• DCR R8 maintenance of integrity
• PUWER R4 suitability of work equipment
• R5 maintenance
• SCR R2 definition of SCE/verification
• PFEER R5 assessment
• R9 prevention fire/explosion
• R19 - suitability and condition of
  plant
• COSHH R9 maintenance, examination of control
  
  
• measures
• LOLER R9 thorough examination of lifting plant

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We consider it very important.

• That we explain to you what we are doing and why
• That KP3 is a joint and co-operative venture with
  the duty holders
• That the workforce are fully on board, and fully
  informed