Subsea Facilities - Technology Developments, …

1 Petroleumstilsynet Report No.: 2014-0113, Rev. 03 Document No.: 18IM1UH-4 Date: Subsea Facilities - Technology Developments, Incidents and Future Trends Unrestricted distribution (internal and external) Keywords: Subsea Facilities STATE OF THE ART TRENDS INCIDENTS Unrestricted distribution within DNV GL Limited distribution within DNV GL after 3 years No distribution (confidential) Secret Reference to part of this report which may lead to misinterpretation is not permissible.

2 Rev. No. Date Reason for Issue Prepared by Verified by Approved by A Draft issue GUNDE/KLOEN/PEWAL BLEI / CMAR BJORS 01 First issue GUNDE/KLOEN/PEWAL BLEI / CMAR BJORS 02 Second issue GUNDE/KLOEN/PEWAL BLEI / CMAR BJORS 03 Final issue GUNDE/KLOEN/PEWAL BLEI / CMAR BJORS DNV GL Report No. 2014-0113, Rev. 03 Page i Table of contents 1 EXECUTIVE SUMMARY .. 1 2 INTRODUCTION .. 2 Scope of work 3 3 Technology HISTORICAL TRENDS .. 4 General Subsea solutions 4 Subsea architecture, Regional differences 5 Wellhead system 6 Trees 7 Connection systems 9 Control and Instrumentation 10 Workover Systems 11 Subsea process and boosting 12 Umbilical 14 Template and manifold 15 4 OVERVIEW AND OUTLOOK NCS AND GLOBALLY.

3 17 Equipment databases 17 Summary of results from equipment databases 18 5 INCIDENTS .. 23 incident and accident databases 23 Information extracted from incident databases 25 6 INTEGRITY MANAGEMENT .. 30 System integrity 30 Subsea Integrity Management (SIM) 30 Life Cycle Information (LCI) 30 Barriers 30 Threats 31 Safety philosophy 32 Integrity management system (IMS) 33 Guidelines and standards for establishing a SIM system 35 Main challenges related to Integrity Management in operation 37 7 DEGRADATION MECHANISMS AND FAILURE MODES .. 39 Description of Failure modes 39 Degradation mechanism 39 8 CURRENT KNOWLEDGE AND FUTURE RISK.

4 46 Material degradation 46 Future Subsea Facilities 47 Standardised building block Subsea development 48 Existing Subsea Facilities and life extension 49 9 MONITORING, INSPECTION AND TESTING METHODOLOGY .. 51 Monitoring methods 52 Inspection methods 53 DNV GL Report No. 2014-0113, Rev. 03 Page ii Testing methods 56 10 FUTURE TRENDS, DEVELOPMENTS AND CHALLENGES .. 58 Future trends 58 Standardisation 60 Developments 61 11 RECOMMENDATIONS FOR IMPROVEMENT OF KNOWLEDGE SHARING .. 62 12 REFERENCES .. 63 Appendix A Threats to Subsea Facilities and Umbilicals Appendix B Abbreviations DNV GL Report No.

5 2014-0113, Rev. 03 Page 1 1 EXECUTIVE SUMMARY In the development of offshore oil and gas fields, more and more of the fields are utilising Subsea technologies. An increasing number of Subsea wells and trees in operation both at the Norwegian Continental Shelf (NCS) as well as in other regions for offshore activities can be seen. This leads to an increase in the volume for maintenance of Subsea Facilities and wells in the years to come. In addition, the effect of an ageing population of systems in operation will also require maintenance and/or replacement.

6 Today a number of fields are also being assessed for life extension, which also contributes to increased number of systems in operation as the average years in service increases. An increased risk level can also be visualised with more challenges ahead. This is because the industry prepares for going deeper, colder, more remote and with more demanding production fluids. In today s society there are also ongoing discussions whether to move or not to move into more environmentally sensitive areas. Complexity is now also taking step changes with the realisation of Subsea processing and compression.

7 Finally, systems are getting more complex, harder to test and to predict prospective failure modes. These factors mentioned above may lead to an overall higher risk level than the industry has handled before. In addition the no acceptance for incidents has become stricter, both seen from the authorities and the society s point of view. The increased risk level has to be mitigated by focusing on planning, engineering, fabrication and realisation of projects. For these reasons mentioned above the Petroleum Safety Authority has taken the initiative to commission this report from DNV GL to bring focus and clarity into these issues.

8 This document describes current technologies, experiences, incidents and future Technology trends. It can be seen as a contribution to increase the awareness to personnel or organisations working in or entering into this industry. The document has consulted several databases. Some databases are operated and maintained by authorities and others are operated by private entities. These databases have been consulted for different purposes; To provide facts for reported Technology choices sorted on geographical areas To trend incidents which have led to spill of hydrocarbons to the environment The focus for this report has been incidents resulting in loss of containment.

9 Incidents that have led to loss of production time or ability to produce have not been reported. This is mainly due to the lack of such information. It is in general a challenge to extract information that can be used for trending or establishing root cause for an incident from these open sources. It is recommended and considered of outmost usefulness and importance, with respect to HSE and Technology development , that the industry take further responsibility for knowledge sharing and provide more transparency through international databases where useful information can be retrieved.

10 For future trends and technologies documents compiled by industry joint efforts have been used rather than marketing materials and company plans. The document also contains a comprehensive list of degradation mechanisms, which forms a sound background for designers, operators and personnel involved in integrity management processes. DNV GL Report No. 2014-0113, Rev. 03 Page 2 2 INTRODUCTION The development of Subsea Technology has been based on a step by step development over the years adding more and more functionalities to the various systems.