Process Leak For Offshore Installations Frequency Assessment Model - PLOFAM
Process Leak For Offshore Installations Frequency Assessment Model - PLOFAM
Report for:
Equinor ASA
Draft A 15.11.2018 This draft version is an update of the report Ingar Fossan and Are
105586/R1 released 18.03.2016, ref /1/ Opstad Sæbø
Final 06.12.2018 Comments from Equinor, Safetec and DNV GL, Ingar Fossan and Are
and Lilleaker Consulting AS are implemented Opstad Sæbø
Preface
Extensive work has been carried out during the recent years regarding models for estimating leak
frequencies and ignition probabilities for offshore facilities at the Norwegian continental shelf (NCS). This
has resulted in the PLOFAM (Process leak for offshore installations frequency assessment model) and
MISOF (Modelling of Ignition Sources on Offshore oil and gas Facilities) 2018 models.
The developed models seek to give a realistic and unbiased prediction of hydrocarbon process leaks and
ignitions for an average facility on the NCS for the coming years. Users of the models and their results
should however be aware of the following aspects:
• PLOFAM (2) is tuned to give the same number of leaks >0.1 kg/s as observed in historical data for
NCS in the period 2006 – 2017, and predicts significantly fewer leaks than previous models
• The MISOF (2) model will for most modules give higher ignition probabilities than previous models. It
builds on few ignited events, and the statistical uncertainty is therefore relatively high. The
contribution from external ignition may be essential in such regard
For some analysed offshore modules, the combined use of these models may result in no dimensioning
loads (ref. PSA’s Facility regulation §11). Each risk owner needs to decide how these aspects shall be
considered in their risk management.
Executive summary
Hydrocarbon process leaks are a major contributor to offshore risk. The last decade the industry has used
a model denoted “Offshore QRA - Standardised Hydrocarbon Leak Frequencies” (SHLFM) to estimate leak
frequencies for these incidents. This model originates from the JIP project “Standardised Hydrocarbon
Leak Frequencies”, which was first reported in final version in 2005. Based on experience from use of the
model, Equinor has appreciated the need for a thorough revision of the methodology, and initiated a
project where the purpose has been to create an updated leak frequency model that can be accepted as
an industry standard for the Norwegian Continental Shelf by consultancy companies and operators.
To achieve this, Equinor contracted Lloyd’s Register Consulting (LRC), DNV GL, Safetec and Lilleaker
Consulting AS to work together. In addition to the four consultancy companies, the operators
ConocoPhillips and Lundin were invited to the project. LRC has been the lead contractor while the others
have contributed as advisors through workshops, document review and discussions in meetings. The
project has been run in two phases during the periods March – December 2015 and June – December
2018. Personnel participating in workshops (in one or both phases) are listed in Table 1.1. Also other
subject matter experts have been involved in video conferences and discussions.
PLOFAM is designed to be a tool for estimation of future leak frequencies for use in QRAs. Overall the
model is built on a combination of the explanatory variable that shows the strongest correlations with
experienced number of leaks, and rational explanations and causalities reflecting known failure modes.
The number of equipment (for each equipment type) is concluded to be the best single explanatory
variable to build the model on. However, as only one explanatory variable is chosen for the model, there
are many factors influencing the leak frequency that are not captured by the model, which will give rise to
stochastic effects. The historical leak frequency per installation at the NCS can vary significantly from the
NCS average and from the model prediction, as a result of the stochastic effects, and also if the conditions
at a particular installation deviates from the normal conditions at installations on NCS.
The leak frequency model covers process leaks occurring during all operation phases, and topside leaks
from the well system occurring during normal production. The leak scenarios may have a leak point
associated with well, process system (including fuel gas system) or utility systems. The leak frequency for
process leaks estimated by the model accounts for leaks occurring both in the process system and utility
system fed from the process system. The model does however not give separate leak frequencies for
process releases through utility systems and through process system. Three main leak scenarios are
defined for the leak frequency model. That is Process leak, Producing well leak and Gas lift well leak.
Furthermore, the model distinguishes between leak scenarios where the total released amount of
hydrocarbons is ≤10 kg, and >10 kg. These leaks are classified as Marginal leaks and Significant leaks,
respectively. Only the Significant leak scenario is relevant for detailed modelling of consequences and
dimensioning accidental loads in a formal QRA. The Marginal leak scenario is only relevant with regard to
immediate exposure of personnel in the close vicinity to scene of the leak to accidental loads or for small
poorly ventilated enclosures.
The model itself consists of mathematical equations for the frequency hole size distribution per standard
equipment type per equipment dimension. Thus, the model is equipment size dependent. A significant
effort has been made to build a model where both the total leak frequency and the frequency for
ruptures are equipment size dependent, unique for every standard equipment type, and as good as
possible reflects the most common failure modes. The model includes the following new equipment types
not included in SHLFM; compact flanges, steel piping, flexible piping, gas lift well, producing well and a
model for leaks from hoses used in temporary operations.
The strategy has been to build a model that gives a best estimate for future leak frequencies, i.e. to create
an unbiased model without built in conservatism. It is observed a significant decreasing trend in historical
leak frequency with time for installations on the NCS in the period after year 2000 (actually since 1992).
The number of historical leaks in the period 2006-2017 is used as target for the total leak frequency while
leak data from the period 2001 – 2017 is used as target for the relative leak rate distribution. Targeting
this frequency level would imply that the model will estimate about 30% lower leak frequency than the
average leak frequency in the period 2001 – 2017, but also 30% higher leak frequency than seen for any
years after 2011, i.e. the chosen target level for the model account for uncertainty in the data material
and shifts in underlying causal factors (e.g. emerging unknown degradation mechanisms due to age or
changing operational conditions) affecting the future trend in leaks occurring on installations on the NCS.
In total the combination of the targeted total leak frequency and the fraction of large leaks will decide the
targeted leak frequency for large leaks, and is regarded reasonable and as a best estimate, slightly
approached from the conservative side. Note also that conservatism is embedded in the guideline for use
of PLOFAM in QRAs.
The stochastic uncertainty has been quantified and is larger for large leak rates than for small leak rates.
This is important to consider when evaluating the accuracy of a QRA model based on PLOFAM. For leak
rates above about 30 kg/s, the relative stochastic uncertainty constitutes a factor in the range 1.5 to 2.5.
i.e. based on the historical data it can be argued that the target value used for parametrization of the
model can be both a factor 1.5 – 2.5 higher and lower than the target values used in PLOFAM (PLOFAM
targets the most likely value). As a consequence it is shown that if two leaks >100 kg/s where one of
them is larger than 300kg/s occur tomorrow, the model will still be valid.
(1) Reproduce the total number of leaks at NCS in the period 2006 – 2017
(2) Reproduce the total cumulative leak rate frequency distribution (i.e. the leak rate distribution) seen in
historical data from NCS in the period 2001 – 2017, which is the defined target for the model,
when applied to all installations on NCS.
(3) Reproduce the observed contribution to leaks originating from the different equipment types. The
model does also reproduce the observed frequency distribution of leaks with respect to initial leak
rate for the most dominating equipment types at NCS (i.e. valves, flanges, instruments and steel
pipes).
The model is mainly validated towards available data of leaks that has occurred at installations on the
Norwegian Continental Shelf (NCS), but also data from the United Kingdom Continental Shelf (UKCS) has
been utilized where the data material for NCS is scarce. A main overall conclusion is that the underlying
hole size frequency distribution for equipment at installations located on the NCS is similar to the
distribution for equipment located on UK installations. The differences may be explained by uncertainty
related to the datasets (both the leaks and the population data, and the way equipment is counted and
leaks are assigned to equipment types). Furthermore, also the total frequency and time trend in the leak
frequency at UKCS is similar to the total leak frequency and time trend seen on NCS. The model is
therefore regarded as valid for both sectors.
Table 1.1 – Personnel participating in one or more workshops in both project phases. Also other persons
have been involved in video conferences, project meetings and discussions
Name Company Role
Phase 1 (2015)
Eli Bech Equinor Equinor project manager
Unni Nord Samdal Equinor Technical point of contact
Espen Fyhn Nilsen Equinor Technical point of contact
Marie Saltkjel ConocoPhillips Participant
Espen Skilhagen Lundin Participant
Robert Schumacher Lundin Participant
Are Opstad Sæbø Lloyds's Register Consulting Project manager/participant
Ingar Fossan Lloyds's Register Consulting Technical responsible
Erik Odgaard Lloyds's Register Consulting Quality assurer
Jan Pappas Lloyds's Register Consulting Participant
Jens Garstad DNV GL Participant
Andreas Falck DNV GL Participant
Jo Wiklund Lilleaker Consulting AS Participant
Jens Morten Nilsen Lilleaker Consulting AS Participant
Jon Andreas Rismyhr Safetec Participant
Geir Drage Berentsen Safetec Participant
Morten Skjong Safetec Participant
Ole Magnus Nyheim Safetec Participant
Abbreviation Description
ACH Air change per hour
ASCV Annulus safety check valve
ASV Annulus safety valve
DHSV Downhole safety valve
ESD Emergency shut down
HCRD Hydrocarbon release database
HSE Health and safety executive
LRC Lloyd’s Register Consulting
Modelling of Ignition Sources on Offshore oil and gas
MISOF
Facilities
NCS Norwegian continental shelf
Process Leak for Offshore installations Frequency
PLOFAM
Assessment Model
P&ID Piping and instrumentation diagram/drawing
Ptil Petroleumstilsynet (Petroleum safety authority)
PWV Production wing valve
QRA Quantitative risk analysis
Risikonivå i norsk petroleumsvirksomhet (Risk level in
RNNP
Norwegian petroleum industry)
SHLFM Standardised hydrocarbon leak frequencies model
TN Technical note
UKCS United kingdom continental shelf
1 Introduction .....................................................................................................................................1
1.1 Report structure ....................................................................................................................1
1.2 Objective ...............................................................................................................................2
2 Philosophy for model development and expectations to the model ..................................................2
3 Leak scenarios covered by the model ...............................................................................................2
4 Model summary and application of the model .................................................................................6
4.1 Mathematical formulation .....................................................................................................6
4.2 Equipment types covered by the model .................................................................................8
4.3 Application of the model .......................................................................................................9
4.4 Example of application of the model ...................................................................................10
5 Data basis ......................................................................................................................................11
5.1 NCS data .............................................................................................................................11
5.2 UKCS data ...........................................................................................................................12
6 Model parameterisation and validation ..........................................................................................13
6.1 Parametrization methodology..............................................................................................13
6.2 Overall validation .................................................................................................................15
7 PLOFAM parameters ......................................................................................................................20
8 Comparison of PLOFAM and SHLFM ..............................................................................................21
9 Robustness of PLOFAM ..................................................................................................................23
10 Summary and concluding remarks .................................................................................................26
11 References .....................................................................................................................................28
Table 3.1 - Leak scenarios covered by the model. They occur in well system, process system or utility
system (process leaks fed through utility systems). Scenarios that are not listed in this table are not
covered by the model
Leak point in well system Leak point in process Leak point in utility system
system
1. Producing well/Injection 4. Leak point in 5. Leak point in flare system (low
well: Topside well release process system pressure or high pressure flare
where the inventory bet- between PWV and system)
ween DHSV and PWV is topside riser ESDV/- 6. Excessive releases through flare
released during normal storage ESDV. The tips and atmospheric vents that
production. fuel system is exceed the design specification
2. Gas lift well: Topside well regarded as part of and pose a fire and explosion
release where the inven- the process system. hazard to equipment, structures
tory between the ASV or personnel. Such leaks are de-
and the barrier towards noted vent leaks.
the process system is 7. Leak point in utility systems that
released. In cases where is fed by hydrocarbons stemm-
no ASV is present, the ing from process system.
entire inventory in the gas Systems covered by the model
lift annulus to the ASCV are:
may be released. Assu-
a. Open drain system
ming that the check valve
ASCV is functioning, b. Closed drain system
otherwise there is no c. Chemical injection systems.
barrier towards the reser- d. Produced water
voir.
3. Release of hydrocarbon
fluid from annuli that are
not used for gas lift.
Three main leak scenarios for modelling in QRAs are defined in PLOFAM. That is Process leak,
Producing well leak and Gas lift well leak.
Figure 3.1 - Illustration and summary of the leak scenarios to be modelled in a QRA based on
PLOFAM, together with the leak scenarios Full pressure leaks (Limited leaks and Full leaks) and
Zero pressure leaks defined in the SHLFM Ref. /4/
1
The frequency for production wells and injection wells are considered to be identical. The leak scenario is
denoted production well only
The parameters in the equations above are described in Table 4.1. Note that except for the
parameters 𝑑𝑑 and 𝐷𝐷, all parameters are in general unique for every equipment type, even though
this is not reflected in the mathematical formulation above. A list of unique parameter values for
𝐹𝐹ℎ𝑖𝑖𝑖𝑖𝑖𝑖 , 𝐴𝐴0 , 𝑀𝑀0 , 𝐴𝐴𝐷𝐷 , 𝑀𝑀𝐷𝐷 , 𝐵𝐵𝐷𝐷 and 𝛼𝛼 necessary to estimate leak frequencies for every equipment type
included in the model are given in Table 7.1. 𝐹𝐹ℎ𝑖𝑖𝑖𝑖𝑖𝑖 is the historical leak frequency (given in leaks
per year per piece of equipment), for the relevant equipment. The other parameters are
dimensionless model parameters. The subscript “0” is used to indicate the total leak frequency
for an equipment and hence the “starting point” on the y-axis. The subscript D is used to
indicate the frequency for getting a hole diameter equal to the equipment diameter 𝐷𝐷. Both 𝐹𝐹0
and 𝐹𝐹𝐷𝐷 are in general dependent on the equipment diameter 𝐷𝐷, which is indicated in the
parenthesis:
𝐹𝐹1 is useful both when implementing the model and when describing the rationale for the model
(see TN-5 Appendix A).
For a further detailed description of the rationale for the model, derivation of the expression for
the slope parameter and illustrations, it is referred to TN-5 Appendix A. The appendix also
compares the model with the previous leak frequency model used in the industry, denoted
SHLFM, Ref. /4/, and explains the difference.
Table 4.1 - Summary of all parameters used for each equipment type in the model. Except for the
parameters 𝑑𝑑 and 𝐷𝐷, all parameters are in general unique for every equipment type. Note that not
all parameters are included in the above equations. Some are introduced later in the report.
Parameter Description
𝐹𝐹(𝑑𝑑, 𝐷𝐷) Hole size frequency distribution (see TN-1) [year-1 equipment-1].
𝐹𝐹𝐷𝐷 The total full bore hole frequency [year-1 equipment-1]. The subscript D is
used to indicate the frequency for getting a hole equal to the equipment
diameter 𝐷𝐷.
𝐹𝐹𝐷𝐷 = 𝐹𝐹(𝑑𝑑 = 𝐷𝐷, 𝐷𝐷).
𝑚𝑚 Slope parameter
𝐹𝐹ℎ𝑖𝑖𝑖𝑖𝑖𝑖 The average leak frequency (independent of equipment diameter) for the
-1 -1
relevant equipment type [year equipment ]
Equipment Fhist,sign
A0 M0 AD MD BD α
type
Standard
1 0 18 -1.45 0.005 0.5 2.50E-05
flange
Table 4.4 – Calculated total leak frequency 𝐹𝐹0 (𝐷𝐷 = 101.6), rupture frequency 𝐹𝐹𝐷𝐷 (𝐷𝐷 = 101.6),
𝐹𝐹1 (𝐷𝐷 = 101.6) = 𝛼𝛼 ∙ 𝐹𝐹𝐷𝐷 (𝐷𝐷 = 101.6) and slope parameter 𝑚𝑚(𝐷𝐷 = 101.6) for the 4” standard flange.
Equipment
𝐹𝐹0 𝐹𝐹𝐷𝐷 𝐹𝐹1 𝑚𝑚
type
Standard
2.50E-05 6.79E-07 3.39E-07 -0.93
flange
Table 4.6 - Leak rate intervals, corresponding hole size intervals and leak frequency
5 Data basis
The model has been developed, parameterised and validated towards data gathered from two
sources of data:
• NCS data: 254 incidents recorded at all installations located on the NCS in the period
01.01.2001 – 31.12.2017
• UKCS data: 4561 incidents at installations on the UKCS recorded in HCR database in the
period Q3 1992 - Q1 2015
The NCS and UKCS databases are described in detail in TN-2 and TN-3, respectively. A short
review is given in Chapter 5.1 and 5.2.
Equipment Description
type
Steel pipe The quality of the population data in HCRD for steel pipes is judged to be
poor. Hence, the model is parameterized based on a subset of the NCS
population dataset where equipment counts of length steel pipe are
available. However, available data in HCRD have been used to model the
effect of equipment size on the hole size distribution for steel piping
Compact No data is available from UKCS and only limited data available from
flanges installations on NCS. A separate assessment is performed to set the model
parameters
Air-cooled heat No units registered at NCS. UKCS data applied to set parameters.
exchanger
Flexible piping No population data available at NCS. UKCS data applied to set parameters.
Atmospheric No data available at NCS nor UKCS. Recommended to use process vessel
vessel model presuming that the vessel is slightly over-pressurized.
Figure 6.2 – Overall significant leaks: complementary cumulative relative leak rate distribution for
all installations operating at NCS in the period 2006-2017
Figure 6.4 – Overall significant leaks: observed number of leaks vs. predicted number of leaks for
all installations operating at NCS in the period 2006-2017. Datapoints below the grey line indicate
underprediction. Datapoints above the grey line indicate overprediction
Table 7.1 – PLOFAM model parameters. 𝐹𝐹ℎ𝑖𝑖𝑖𝑖𝑖𝑖 is given both for Significant and Marginal leaks.
Equipment type 𝐴𝐴0 𝑀𝑀0 𝐴𝐴𝐷𝐷 𝑀𝑀𝐷𝐷 𝐵𝐵𝐷𝐷 𝛼𝛼 𝐹𝐹ℎ𝑖𝑖𝑖𝑖𝑖𝑖,Significant 𝐹𝐹ℎ𝑖𝑖𝑖𝑖𝑖𝑖,Marginal
Air-cooled heat exchanger* 1 0 0 0 3.0E-02 0 5.0E-04 0
Atmospheric vessel* 1 0 0 0 1.0E-01 0 5.0E-04 0
Centrifugal compressor 1 0 0 0 6.0E-03 0 1.3E-03 0
Centrifugal pump 1 0 0 0 3.0E-05 0 3.0E-03 0
Compact flange 1 0 0 0 1.0E-03 0.90 3.0E-06 0
Filter 1 0 0 0 8.0E-04 0 2.3E-03 0
Flexible pipe* 1 0 0 0 4.0E-01 0.75 1.4E-04 0
Gas lift well 1 0 0 0 2.5E-02 0 1.0E-04 1.0E-04
Hose 1 0 0 0 4.0E-01 0.75 6.0E-05 1.5E-05
Instrument 1 0 0 0 1.5E-01 0 1.3E-04 0
Pig trap 1 0 0 0 2.0E-02 0 1.7E-03 0
Plate heat exchanger 1 0 0 0 1.0E-03 0 3.5E-04 0
Process vessel 1 0 0 0 6.0E-04 0 5.0E-04 0
Producing well 1 0 0 0 2.0E-02 0 2.0E-05 1.3E-04
Reciprocating compressor 1 0 0 0 1.0E-02 0 5.0E-03 -
Reciprocating pump 1 0 0 0 3.0E-05 0 3.0E-03 -
Shell and tube heat exchanger 1 0 0 0 7.5E-03 0 3.3E-04 -
Standard flange 1 0 18.0 -1.45 5.0E-03 0.50 2.5E-05 5.0E-06
Steel pipe 4.20 -0.3 17.6 -1.75 1.0E-03 0.90 1.4E-05 2.0E-06
Valve 1.11 -0.1 16.0 -1.70 1.0E-03 0.50 2.15E-04 3.5E-05
Figure 8.2 – Comparison of SHLFM and PLOFAM. The bars display the ratio per leak category for
the total of gas and liquid leaks. For the SHLFM, only Full pressure leaks, i.e. Full leaks and Limited
leaks are included. In PLOFAM, only significant leaks are included
Figure 9.2 – Relative leak rate distributions for the periods 2001 – 2017 (target for model), 2006 –
2017, 2007 – 2017, and 2001 – 2017 including two leaks >100 kg/s where one leak is larger than
300kg/s potentially occurring tomorrow
/1/ Lloyd’s Register Consulting, “Process leak for offshore installations frequency assessment
model – PLOFAM”, report no: 105586/R1, Rev: Final B, Date: 18.03.2016
/2/ Lloyd’s Register Consulting, “Modelling of ignition sources on offshore oil and gas facilities
- MISOF”, Date: November 2018, Report No: 107566/R2, Rev: Final
/3/ Lloyd’s Register Consulting, “Blowout and well release frequencies based on SINTEF
offshore blowout database 2017”, 20 April 2018, Report No: 19101001-8/2018/R3 Rev:
Final
/4/ DNV, Offshore QRA – Standardised Hydrocarbon Leak Frequencies, report number 2009-
1768, rev. 1, 16.01.2009.