Recommended Practice on Subsea Production System Reliability, Technical Risk, and Integrity Management

API RECOMMENDED PRACTICE 17N SECOND EDITION, JUNE 2017

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Copyright © 2017 American Petroleum Institute

Foreword

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Contents

Page

1. Scope 1

2. Normative References 1

3. Terms, Definitions, Acronyms, and Abbreviations 2

   1. Terms and Definitions 2

   2. Acronyms and Abbreviations 7

4. Document Outline and Application 10

   1. General 10

   2. Document Road Map 10

   3. Project and Operation Applicability 11

   4. Equipment Applicability 12

   5. Life Cycle Stages 13

   6. Company Documentation 13

5. Overview of Reliability, Technical Risk, and Integrity Management 14

   1. General 14

   2. Underlying Philosophy 14

   3. Assessment and Management of Risk 15

   4. Define Step of DPIEF Cycle 17

   5. Plan Step of DPIEF Cycle 21

   6. Implement Step of the DPIEF Cycle 21

   7. Evaluate Step of the DPIEF Cycle 22

   8. Feedback Step of the DPIEF Cycle 22

   9. KPs for RIM 24

6. Recommended Practice for Each Life Cycle Stage 26

   1. General 26

   2. Configuration Management (CM) 27

   3. Application of the DPIEF Assurance Cycle 27

   4. Timing of the DPIEF Loop in the Asset Life Cycle 29

   5. Design Stages 29

   6. Manufacture, Assembly, Testing, Installation, and Commissioning (MATIC) 29

   7. Operations 30

   8. Field Upgrades and Field Extensions 32

   9. Life Extensions 32

   10. Decommissioning 33

Annex A (informative) Technical Risk Categorization (TRC) 35

Annex B (informative) Detailed Description of Reliability and Integrity KPs 40

Annex C (informative) Risk-based Scope of Work for Reliability, Integrity,

and Technical Risk Management 107

Annex D (informative) Integrity Management Data Collection 136

Annex E (informative) New Technology Qualification 143

Annex F (informative) Application of Test Statistics 160

Bibliography 167

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Contents

Figures

Page

1. API 17N Road Map 11

2. How API 17N Applies to a Company’s Reliability, Technical Risk, and Integrity Management Documentation 13

3. DPIEF Reliability and Integrity Assurance Cycle 15

4. Assessment and Management of Risk 16

5. KPs for RIM 24

6. Summary of the Life Cycle 26

7. Application of DPIEF Cycle to the Subsea System Life Cycle 28

8. The Relative Time in the Asset Life Cycle That Each Stage of the DPIEF Loop Should Be Applied 30

9. Double DPIEF Loop in Operations 31

1. Procedure for Allocation of RIM Goals and Requirements 45

2. Reliability and Integrity Activity Effort 51

3. Design for Reliability and Integrity Process 54

4. Relationship Between Operator’s DfRI and Supplier’s DfRI Processes 55

5. Outline TQP 86

6. Data Collection and Usage Strategy 90

7. Example Output from an RCMM Audit 99

C.1 Typical Relationship Between the Operator and Supplier with Respect to Activities 115

1. Outline TQP 144

2. Decision Logic for Selection of Qualification Process 146

3. Sample Product Qualification Sheet 153

Tables

1. Operator Business Requirements and Reliability/Integrity Implications 24

2. Project and Asset Life Cycle Focus and Considerations 27

1. TRC for Equipment 37

2. TRC for Procedures 38

3. Example Level of Effort Expected for Different TRC Risk Levels Throughout the Asset Life Cycle 39

1. Types of Reliability and Integrity Assurance Evidence 62

2. Suggested Constituent Parts of an RIAD 64

3. FMECA Summary 67

4. FTA Summary 68

5. RBD Summary 69

6. ETA 70

7. Physics of Failure Summary 71

8. Importance Analysis Summary 72

9. Qualitative Common Cause Failure Analysis Summary 73

10. Quantitative Common Cause Failure Analysis Summary 74

11. RAM Analysis Summary 75

12. RCA Summary 76

13. HAZOP Study Summary 77

14. HAZID Summary 78

15. Barrier/Bowtie Analysis 79

16. Data Sources 92

17. Overview of RCMM Levels 98

18. Typical Instruments for Organizational Learning 105

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Contents

Page

1. Dependence of Qualification Path on TRL 146

2. Example Contents of Technology Qualification Assurance Document 152

3. TRL Ladder Stages 154

4. Qualification of Existing Technology—Extensions and Modifications 159

1. Example of Sorted Failure Data 160

2. Example Ti Values 161

3. Chi-squared Distribution Table 164

Introduction

Reliability and integrity can have major environmental, safety, and financial impacts for all organizations involved in designing, manufacturing, installing, and operating subsea equipment. The complexity of technical and organizational challenges in subsea projects and operations requires continual attention to detail to achieve high reliability and integrity performance.

Equipment reliability is important both to system integrity and to production. For example, poor seal reliability in a flow line connector may result in loss of containment with the potential for environmental damage. Valves that fail to close on command may prevent isolation and compromise safety. Valves that fail to open on command may compromise production.

Budget and schedule constraints can lead to limited information and time for making decisions. This can introduce varying levels of uncertainty that have the potential to affect equipment reliability, integrity, and associated operational risks. In particular, any potential failures that lead to loss of containment or loss of production should be thoroughly investigated and actions taken to manage the risks that such events generate.

This recommended practice (RP) provides a structured approach that organizations can adopt to manage technical uncertainty throughout the life cycle of a subsea system. This may range from the management of general project risk through to the identification and mitigation of potential equipment failure modes, affecting integrity or production.

Most organizations will find much that is familiar and recognized as good practice. Some sections of the annexes may only be of interest to the reliability and integrity specialist. The basic approach, however, is simple and consistent and when applied correctly has the potential to greatly reduce the financial, safety, and reputational risks, arising from potential failures, throughout the life cycle of subsea systems.

Although this RP is focused on subsea production equipment, the guidance is generic and may be easily adapted to address the design of subsea hardware used for drilling operations including the subsea blowout preventer and lower marine riser package.

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Recommended Practice on Subsea Production System Reliability, Technical Risk, and Integrity Management

1. Scope

   
   

   This recommended practice (RP) aims to provide operators, contractors and suppliers with guidance on the management and application of reliability and integrity management (RIM) engineering techniques in subsea projects and operations within their scope of work and supply. It is applicable to:

   
   

   • standard and nonstandard equipment (within the scope of API 17A);

     
     

   • new field developments, further development of existing fields and field upgrades;

     
     

   • all life cycle phases from feasibility through design, manufacture, and operation to decommissioning.

   
   

   NOTE API 18LCM [1] gives additional guidance on general requirements for life cycle management of equipment.

   
   

   This RP is not intended to replace individual company processes, procedures, document nomenclature, or numbering; it is a guide. For example, this RP does not prescribe the use of any specific equipment or process. It does not recommend any actions, beyond good engineering practice. However, this RP may be used to enhance existing processes, if deemed appropriate.

   
   

2. Normative References

The following normative documents contain provisions that, through reference in this text, constitute provisions of this standard. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. For undated references, the latest edition of the normative document applies.

API Recommended Practice 17A, Design and Operation of Subsea Production Systems—General Requirements and Recommendations

API Recommended Practice 17Q, Technology Qualification for Subsea Equipment, Second Edition

NOTE API 17Q, Second Edition is planned for publication in 2017. Annexes E and F are included in this document to provide interim guidance and will be removed once API 17Q, Second Edition is published. For all references in the text to API 17Q, the reader should refer to these annexes until API 17Q is published.

API Recommended Practice 75, Recommended Practice for Development of a Safety and Environmental Management Program for Offshore Operations and Facilities

API Recommended Practice 580, Risk-Based Inspection

BS 1 IEC 2 62198:2001, Project risk management—Application guidelines

DNV-RP-A203 3, Technology Qualification, July 2013

IEC 61508, Functional safety of electrical/electronic/programmable electronic safety-related systems

1 British Standards Institution, Chiswick High Road, London, W4 4AL, United Kingdom, www.bsi-global.com.

2 International Electrotechnical Commission, 3, rue de Varembé, P.O. Box 131, CH-1211 Geneva 20, Switzerland, www.iec.ch.

3 DNV GL, Veritasveien 1, 1363 Hovik, Norway, www.dnvgl.com.

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