1. Improving Safety – Reducing Hydrocarbon Releases Pipework Vibration / Fatigue Awareness Stuart McGregorJeremie Neillo Senior Project EngineerBusiness Development Manager Date: 30 th June 2010 Department: Plant Integrity

2. Page 1 Purpose Background Hydrocarbon releases are a major risk offshore Accounts for 33% of all dangerous occurrences reported to HSE A significant proportion are caused by vibration fatigue This is avoidable Purpose To give you an understanding of: What vibration fatigue is Why you should consider it What you can do about it

3. Page 2 Introduction Doosan Babcock Energy Have over 110 years experience in the energy sector Have a long history for designing, supplying and constructing efficient coal fired power plant Are a leading engineering services provider for the power and energy sector, including offshore Worked with the offshore industry to develop the AVIFF (avoidance of vibration fatigue failure) Guidelines, which are regarded as the benchmark for managing pipework vibration fatigue Have significant experience of identifying and resolving vibration issues offshore - reducing HC releases

4. Page 3 Agenda What role does vibration play in pipework failure What are the benefits of good vibration awareness What is the solution Worker involvement, what role do you play The future – how do we keep moving forward

5. Page 4 What is vibration… Vibration Small movements rapidly to and fro Oscillations

6. Page 5 What is fatigue… Fatigue Progressive and localized structural damage that occurs when a material is subjected to cyclic loading Can lead to failure

7. Page 6 Is Piping Vibration really an issue… What type of vibration failures can occur Is this a real threat to us

8. Page 7 Small Bore Connections (SBC’s) SBC are at significant risk from vibration fatigue Potential for failure at the welded connection to main line Greatest risk on thin walled pipework What does high risk look like

9. Page 8 Small Bore Connections

10. Page 9 Small Bore Connections – With Support Brackets

11. Page 10 Failure at welds in main lines Designed to recognised piping code by Competent Engineers 6” Flare Pipework Failed in service due to Turbulent Excitation Pipework was observed to be vibrating (at Low Frequency) but no action was taken When may this be a particular risk

12. Page 11 Fretting Pipework vibration can result in Fretting Fretting can occur when there is relative motion between 2 surfaces Potential for loss of containment What fretting risks should we look out for

13. Page 12 Benefits of Vibration Awareness – Safety & Environmental Significant progress made by industry: From early 2000’s to today, HC releases in the North Sea caused by vibration fatigue have nearly halved Some operators have made very significant progress, some have made minimal progress Major KPI by HSE & Insurance industry

14. Page 13 Benefits of Vibration Awareness – Case Study – North Sea Platform Before - 2004 10 off HC releases in 2004 5 off were vibration related At least 2 vibration release resulted in controlled shut down 1 off was a 10 day shut down for major weld repairs Minimal proactive management of vibration fatigue Potential for major accident to occur Status - 2004 Major unknown and unmanaged risks Significant impact upon safety and productivity Atleast 10 days lost production (£40-60M) After - 2005 Full vibration review of platform Modifications to reduce rectify identified risks Ongoing maintenance & healthcare plan in place Total cost including modification approx £1M 10 off vibration failures since 2005 No controlled shut downs Status 2010 Risks known and being proactively managed Minimal impact upon safety and productivity Risks ALARP – As Low As Reasonably Practicable

15. Page 14 Solutions – The Engineers Role Follow AVIFF guidance to minimise risks –Initial surveys (office and site based) –Resolve concerns –Ongoing monitoring (annual / following major change) Consider Vibration –At design stage –Prior to changes / updates Process change New plant equipment Pipework changes (Carbon steel to Super-Duplex)

16. Page 15 Solutions – What Role Can you Play… Would would you do if…..

17. Page 16 Solutions – What Role Can you Play… Keep your eyes and ears open Pipework vibrating Leaks / drips Noise, especially tonal Changes from yesterday / last trip Don’t assume someone else has reported the concern You can be the eyes and ears of the safety / Asset integrity team

18. Page 17 Look Out For Clamps – Maintenance & Inspection Example of critical clamp not been re-instated correctly after intervention work on line

19. Page 18 Solutions – What Role Can you Play… Look out for….. Small Bore Connections vibrating Pipework vibrating Fretting risks Small leaks / drips Noise Changes since yesterday / last visit Clamps / brackets refitted correctly

20. Page 19 The Future – How Do We Keep Moving Forward Be Proactive Follow and apply AVIFF guidelines Implement regular health checks for vibration fatigue Consider vibration before major changes Consider vibration at design stage Keep your eyes and ears open Report concerns

21. Page 20 Questions Stuart McGregor Senior Project Engineer Tel: 01224 224 316 Email: smcgregor@doosanbabcock.com Jeremie Neillo Business Development Manager Tel: 01224 224 315 Email: jneillo@doosanbabcock.com