Corrosion risk assessment and safety management for offshore processing facilities.

1. INTRODUCTION ........................................................................................................... 1 2. BACKGROUND TO RISKS ASSOCIATED WITH OFFSHORE PROCESSING FACILITIES ................................................................................................. 2 2.1 CORROSION AND SAFETY RISKS....................................................................................... 2 2.2 LEGISLATION........................................................................................................................ 3 2.3 HYDROCARBON RELEASES................................................................................................ 4 2.4 MANAGEMENT OF INSTALLATION SAFETY ....................................................................... 8 2.5 MANAGEMENT OF OILFIELD CORROSION ........................................................................ 9 2.5.1 Background ................................................................................................................ 9 2.5.2 Integration of Safety and Corrosion Management ....................................................11 2.5.3 Risk Control Systems (RCS) .................................................................................... 14 2.5.4 Assessment of Corrosion Risks ............................................................................... 15 2.5.5 Managing the Corrosion ........................................................................................... 18 2.5.6 Summary Overview of Objectives ............................................................................ 21 2.6 CONCLUSION ...................................................................................................................... 22 3. REVIEW OF CURRENT SITUATION........................................................................... 24 3.1 DISCUSSIONS WITH INDUSTRY SPECIALISTS................................................................ 24 3.2 DOCUMENT REQUIREMENTS ........................................................................................... 27 4. DRAFT GUIDELINES FOR CORROSION MANAGEMENT AND RISK ASSESSMENT FOR OFFSHORE PROCESSING FACILITIES.......................................... 29 4.1 INTRODUCTION................................................................................................................... 29 4.1.1 Purpose .................................................................................................................... 29 4.1.2 Content ..................................................................................................................... 29 4.1.3 Inclusions.................................................................................................................. 30 4.2 LEGISLATION...................................................................................................................... 32 4.2.1 General..................................................................................................................... 32 4.2.2 The Safety Case....................................................................................................... 32 4.2.3 Design and Construction .......................................................................................... 33 4.2.4 Inherent Safety ......................................................................................................... 33 4.3 ORGANISATIONAL ARRANGEMENTS ............................................................................... 33 4.3.1 Duty Holder Arrangements. ...................................................................................... 33 4.3.2 Risk Control Systems (RCS) .................................................................................... 34 4.3.3 Steps for Basic Safety Management ........................................................................ 35 5 DISCUSSION AND CONCLUSIONS........................................................................... 38 5.1 PHASE 2 PROJECT ............................................................................................................. 38 5.2 CORROSION AND CORROSION CONTROL MANAGEMENT IN THE OIL & GAS PRODUCTION INDUSTRY................................................................................................... 39 5.3 CORROSION RISK ASSESSMENT – INDUSTRIAL CASE STUDIES ................................ 39 v 5.4 BASIC HEALTH & SAFETY MANAGEMENT AND VERIFICATION FOR OFFSHORE PROCESSING ...................................................................................................................... 39 6. RECOMMENDATIONS................................................................................................ 40 APPENDIX A CORROSION AND CORROSION CONTROL MANAGEMENT IN THE OIL & GAS PRODUCTION INDUSTRY ........................................................... 41 BACKGROUND ............................................................................................................................ 41 INTRODUCTION .......................................................................................................................... 41 A1 CORROSION PROCESSES................................................................................................. 42 A1.1 “Sweet” Corrosion .................................................................................................... 42 A1.2 “Sour” Corrosion ....................................................................................................... 43 A3 EXTERNAL CORROSION .................................................................................................... 44 A4 CORROSION CONTROL OPTIONS .................................................................................... 45 A5 DEVELOPMENT OF A CORROSION CONTROL PROGRAMME....................................... 46 A6 IMPLICATIONS FOR MAINTENANCE ................................................................................. 48 A7 CORROSION MANAGEMENT ............................................................................................. 48 APPENDIX B INDUSTRY CORROSION SPECIALISTS.................................................. 50 APPENDIX C REFERENCE DOCUMENTATION............................................................. 51 APPENDIX D – BACKGROUND ON CORROSION MANAGEMENT ................................ 52