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Structural Integrity Management

Structural Integrity Management (SIM) aims to ensure facilities are sufficiently safe through condition assessment and continuous improvement of inspection and repair programs. Key aspects of SIM include validating structural analyses and fabrication quality, detecting issues through inspection, and implementing compensating measures. SIM takes an integrity engineering approach that considers the actual condition, rather than just inspection management. Challenges to SIM include overreliance on theoretical predictions rather than actual conditions, insufficient ownership of condition data and assessments, and ensuring proper competencies in inspection, closing of findings, and life cycle documentation. Validation studies show refined SIM approaches better predict fatigue crack growth.

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161 views12 pages

Structural Integrity Management

Structural Integrity Management (SIM) aims to ensure facilities are sufficiently safe through condition assessment and continuous improvement of inspection and repair programs. Key aspects of SIM include validating structural analyses and fabrication quality, detecting issues through inspection, and implementing compensating measures. SIM takes an integrity engineering approach that considers the actual condition, rather than just inspection management. Challenges to SIM include overreliance on theoretical predictions rather than actual conditions, insufficient ownership of condition data and assessments, and ensuring proper competencies in inspection, closing of findings, and life cycle documentation. Validation studies show refined SIM approaches better predict fatigue crack growth.

Uploaded by

onnly1964
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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SIM – STRUCTURAL INTEGRITY MANAGEMENT

Structural Integrity - Introduction


Orginator: Ole Tom Vårdal ole.tom.vardal@axess.no
Presentation: Espen Kalland espen.kalland@axess.no
The key question!

• How can we be sure that the facilities are sufficiently safe?

• We need to be sure that no accidents occur.

Can we trust;
a) the structural analyses ?
b) the fabrication quality ?
c) the technical documentation?
d) the inspection process ?

Detect -> Compensating measures


Integrity Management
vs.
Inspection Management

Integrity Eng. Inspection

Condition Perform
Assessment – inspection –
The process of The process
What to be done
of How to do

Integrity Engineering and Inspection


working together on-site, on-shore and off-shore.

Page 7
Operational part of SIM
• Supervice inspection
• Adjust program
• Define and secure proper repair and modification
• Deliveries:
a) Inspection reports
b) Insp.eng- reports
c) Integrity reports
d) Design of modification
e) M&R reports (Modification & Repair )

Operational Data  Condition Data  Reduced uncertainties


Validation Studies – The Benefit of
Refinements
• Studies for Philips Petroleum, bp, TFE, PSA-N and HSE-UK in the period 1995-1999,
• 3 published reports by HSE-UK and more than 10 papers
• Detailed assessment of more than 500 fatigue cracks

Main Conclusion
• Traditional follow-up regime
– 20-40% of the detected cracks are in accordance with the initial fatigue analyses
– Crack growth does mainly occur at details given poor fabrication quality
– All units given comparable amount of inspections
• Refined Follow up and RBI (level 3 and partially level 2)
– The calculations are based on As-Is description
– 70-80% of the fatigue crack growth are according the calculated crack growth
potential
– The scope of inspection varies from 30 to 200% of a traditional follow up scope
Competance at Site
Unit 1 - As-Is description and improved follow-up regime for
inspection, repair, modifications and weld improvement

• Upon 10 years operation


– 73 fatigue cracks of 1 at weld improved area i.e. hot spot given ultra high
fatigue loads

Unit 2 - Traditional site team for inspection, repair and


modification
• Upon 5-years operation
– 180 fatigue cracks at 143 different locations
– All cracks at hot spot given high fatigue loads
– Main reason: Poor workmanship for weld improvement and local
modification
Benefits of level 3
• Avoid non required re-inspections
• Details are improved before failure occur, hit rate: 25% versus 80%
• Avoid or reduce On-shore inspection
• Avoid or reduce the need for re-construction
• Prepared for life time extension and utilization of capacity beyond the design
requirements
• Competence at site secure effective closing of findings
– detect – recommend – get approval - implement

The cost of failure vs. the cost required to avoid failure


• AIMS developed in cooperation with the rig owners that have experienced
the cost of failure
Main Challenges - 1:

• The old “How to do culture” i.e.


To Maintain the given design ≠ Integrity Management

• Insufficient ownership for the Condition Data and Condition


Assessment i.e.
– Gross errors related to look ahead of present findings
– Gross errors in the Condition Data and basis for
Condition Assessment
– Follow the procedure without sufficient ownership of
Integrity element

Continuous Improvement of Follow-up Scheme

Page 15
Main Challenges - 2:

• The theoretical approach and neglection of As-Is i.e.


Theoretical predictions ≠ The reality

• The inspection and repair history is the Key Book i.e.


– Identify shortcomings and application area for the
theoretical predictions
– Identify inspection program for validation
– Based on observation obtain reasonable conclusion of
the safety for structural integrity

Page 16
Main Challenges - 3
Activity and Competence
• Inspection
• Report inspection results and apply acceptance criteria
• How to close (design) and secure closing (construction) of
findings?
• The Life Cycle Documentation; a) Structural analyses
results and design data, b) Inspection, operation and
construction data
• Condition assessment and program for inspection and
improvements
• Reporting to PSA, Client and Owners
THANKS

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