reliable subsea oil& gas transportation paper - presentation slides 6 november 2015

www.seafloconsultancy.co.uk

Reliable Subsea Oil & Gas Transportation Systems 6th November 2015 – WMTC, Rhode Island, USA. Charles A. Reith and Kaj B. Lagstrom


Long Subsea Tie-Backs to FLNG and the Safe Export and Transportation of LNG to Strategic Global Gas Sales Hubs.


Operator’s Perspective on Applying API-RP-17N

Underpinning subsea system operability, integrity into a

Production Assurance Program with high reliability/

availability over life of field on long offset subsea tie-back

to shore in a remote location overall tie-back 140km.


Key Expectations and Status - API-RP-17N and ISO 20815

•  Improving reliability performance into SPS equipment, rather than working on the reliance upon redundancy, maintainability to achieve availability, particularly in deep water.

•  Seeking to mitigate any deferred production scenario’s. This may end up in developing a cost optimal IMR Inspection maintenance and repair strategy over the life of field.

•  ISO 20815 defines 12 Common Key Performance objective requirements over the life of field operations.

Modelled data


Risk-EX Effects of Optimizing Risk Profiles and NPV, with MFOP in Early Field Life


‘ RISKEX ’ This figure illustrates how different RISKEX™ components affect different parts of the project lifecycle, such as CAPEX, OPEX, production and revenue changes, time of 1st Oil or Gas and production profile shape elements.

How to Achieve Improved Availability Uptime, Reduce your OPEX and Asset Risk Profile

www.seafloconsultancy.co.uk 7 - COMOPS Meeting 8th Dec, 11

Long Offset Subsea – Tie Back 140 Km to shore with over 230 Km export pipelines

www.seafloconsultancy.co.uk Flow Assurance – OPS 2011

TORMORE MANIFOLD

LAGGAN MANIFOLD

2 x 18” PRODUCTION PIPELINES – 140 km

SEVEN SEAS – 2012

MEG LINE AND SERVICE LINE UMBILICAL

Dual 18” Flowlines, 8” Meg Injection, 3” Service Line and Umbilical


One of Worlds Longest Umbilical Installations- with a Critical Weather Window over the initial 125km


Heavy Lift Vessel – Installation of Subsea Template/Manifolds July 2012 - 900 Tonnes Weight

www.seafloconsultancy.co.uk 11 09/11/2015

SPS- (API-RP-17N *MFOP criteria) Operating Performance, Acceptance Standards •  Performance / Operability

Standards & Acceptance Criteria were set within the Production Assurance Programme-PAP


ROV–ROT Intervention Tooling Accessibility Checks via Simulator


Subsea Compression Required in Life of Field Operations

Modular Design Interface Built Into Template/Manifolds, Close to Well Slots

www.seafloconsultancy.co.uk 14 PAP Programme

09/11/2015

Production Assurance Programme (PAP) - Moving Forward

•  Incentive mechanism to primary contracting entities to deliver high reliability, operability and asset integrity.

•  Improve the maintenance free operating period (MFOP) from FMECA and RAM analysis outputs.

•  Develop IMR Vessel Strategy and reduce operational- Intervention life cycle risks.

www.seafloconsultancy.co.uk 15 PAP Programme 09/11/2015

PAP-Strategy Framework - Lifecycle Levels

Por?olio Management-‐Level 1 Strategic Asset the

Business case – value adding contribuEon. Programme Management Level 2-‐ The planning

level of PAP into asset-‐operaEons. Level 3 & 4 ImplementaLon & ExecuLon modes of developing the Subsea Performance Standards-‐Integrity criteria +IMR Strategy Plan–Reliability

Assurance Documents-‐Procedures + Manuals, etc.


API-RP-17N - Production Assurance Programme - Reliability / Availability

Design

Detail Design Manufacture

Install

Operate Failure -Mitigations

errors

defects

Errors Defects

Prev

ent

Prev

ent

Prev

ent

Prev

ent

Reliability led Design + FMECA and RAM Analysis + PAP Installation risk mitigation planning

Data collection Data analysis Feedback Feedback Feedback Feedback

Quality& Reliability led Manufacture Qualification testing

Pre-commissioning – Ops (Risk) assessment-procedure checks

IMR Strategy - PLAN + Risk based inspection Monitoring

www.seafloconsultancy.co.uk Laggan Tormore Project 09/11/2015

Production Assurance Programme – PAP Where we are today !

• API-‐RP-‐17N is sEll relaEvely new by applicaEon across the industry, not all operators have a General SpecificaEon (GS) or defined requirements in terms of how to develop reliability /availability across SPS contract’s.

• Most operators align to API-‐RP-‐17N and seek subsea producEon systems availability to 96 % -‐ greater than > via safe operaEng pracEces, with high reliability management.


Bath Tub Curve, Subsea Goal

B

reak

dow

n ra

te

System Life cycle

Early Life failures Random failures

Wear out Failures

Remove expensive Early

Life Failures

Remove expensive Early

Life Failures

Design out all Foreseeable early life and through life failures Design out all Foreseeable early life and through life failures

Past

Subsea Goal

Decommission before

wear out

Decommission before

wear out

Remove or Minimise foreseeable through life

failures

Remove or Minimise foreseeable through life

failures

Anticipated Field Life


Condition Performance Monitoring Across Subsea Production Systems

•  Dual Redundant Channel Modules

•  Monitoring abnormal trends, in pressures, temperatures, sensor readings, reporting and alerting to Control Room Operators

•  Back to operations support teams in office Desk-Top


Condition Performance Monitoring

•  Identify abnormal trends, diagnose, advise and alert. Data Collector, Event Logs, Historian data base.

•  Stable asset integrity across the life cycle via effective risk management tools.

Asset Integrity Management Services


“LIFE OF FIELD” – SUBSEA INSPECTION, INTERVENTION, MAINTENANCE AND REPAIR (IMR) VESSEL CONTRACTING AGREEMENT

Asset Integrity Management Services

Early Contractual Engagement for Subsea (IMR ) Vessel


Regionally Shared Vessel; (IMR) specification, tool pool of ROV Intervention Tooling, common interfaces, ISO 13628-8- ST 001,+ Critical Spares

IMR Vessel Strategy 09/11/2015


Why –Subsea Integrity Management is Important

23 Laggan -Tormore 09/11/2015

“Aims to ensure the integrity of an asset within a set of specified operational limitations throughout the lifecycle ”

Ref- DNV-OS codes of practice

Verify, to be in compliance with original design specifications


AUV’s –AIV’s –ROV’s Subsea Inspection Capabilities, seabed mapping and Vessel Inspections


AIV’s & Pipeline Scanning Tools support Subsea Integrity Management Inspection Regimes


Subsea Wells to Floating Production Systems


Integrated Dynamic Analysis of Floating Production Vessels and Subsea Infrastructure, Riser Systems


Vessel Hull characteristics, Dis-connectable Turrets, Sea State Conditions, +40 Years Basis Of Design


Some FLNG Vessel Design Considerations for High Subsea Uptime

•  Limitation of excessive FLNG vessel motions impacting operability and any steel catenary riser designs.

•  Mooring system line failure or inability to cope with future surface

facility and riser upgrades.

•  Inability of the riser to vessel interface design to accommodate any future expansion requirements.

•  Riser System Inspection or Failure Prevention. •  Subsea Power Supply or Chemical Injection System availability.

•  Offloading System Availability.

•  Storage and Ballast System Failure (inability to offload hydrocarbons due to resulting global hull strength constraints).


Roll Raos at beam seas

0.00E+00

5.00E-01

1.00E+00

1.50E+00

2.00E+00

2.50E+00

3.00E+00

3.50E+00

4.00E+00

4.50E+00

5.00E+00

0.00 5.00 10.00 15.00 20.00 25.00 30.00

Period (sec)

Ampl

itude

(deg

./m)

Bilge radius = 2.50mBilge radius = 1.80mBilge radius = 1.50mBilge radius = 0.80m

The Effect of Bilge Radius Reduction Analysis on Floating Production System Motions Analysis Output from new build floater Roll Raos at beam seas

0.00E+00

5.00E-01

1.00E+00

1.50E+00

2.00E+00

2.50E+00

3.00E+00

3.50E+00

4.00E+00

4.50E+00

5.00E+00

0.00 5.00 10.00 15.00 20.00 25.00 30.00

Period (sec)

Ampli

tude (

deg./

m)

Bilge radius = 2.50mBilge radius = 1.80mBilge radius = 1.50mBilge radius = 0.80m


•  Currently little experience regarding failure types and operational issues experienced with LNG Offloading systems at sea. Potentially insufficient data available for a meaningful system RAM analysis.

•  Recent design concepts are based on tandem offloading in conjunction

with a conventional mooring hawser system and a cryogenic offloading hoses often supplied in 12m sections for easy IMR. Offloading hose design life is still being debated, hence consideration should be given to redundancy in the system.

•  Currently this concept appears to be the most CAPEX and OPEX efficient. •  A safety benefit of the tandem offloading system based on a mooring

hawser and offloading hoses is the increased distance between the FLNG facility and the LNG carrier (70 – 100m) reducing collision risks and domino effects.

•  A dedicated DP LNG shuttle tanker (carrier) would potentially allow for

offloading concepts based on offloading from a mid-ships manifold.

FLNG Facility - LNG Offloading System - Designs and Availability Issues


LNG Offloading System Mooring Howser and Cryogenic Hoses-in Tandem offloading System


Subsea Wells to FLNG, LNG Offloading Evolving Technology, Needs to Deliver Safe, Robust and Reliable Design Solutions

• 


Monetizing Stranded Gas Fields: Shell Prelude Significant Offshore FLNG Facility

600,000 Tonnes x 488 m Long. Bigger than the Empire State building and is a Floating Production Facility.


FLNG Barge with Moored FSRU-LNG Carrier Offloading LNG Carrier Offloading Facility, Multi (3) Body Model Dynamic Analysis, Complex Mooring Arrangements, Operability / Availability Uptime


LNG Carriers have a reliable performance and excellent safety transportation track record over many years.

LNG Carrier Safety and Reliability


LNG Carrier Development


Ageing Assets & Life Extension Regimes

Project Example: •  Implications on Agreed Operating Life expectations, Asset

Integrity, CAPEX and OPEX budgets, sparing philosophy, and agreed minimum operating spare parts lists.

•  Implications on pertinent Regulatory or Code changes. •  Class Rules and Maintenance of Floating Production facility

in Class.

•  Safety Case and defined Safety Critical Elements (SCE), 3rd Party (IRC) and or Client Self Verification Requirements.

•  Re-commissioning, Decommissioning Budget Costs. •  Implications for facilities IMR Strategy.


Life Extension – Process

•  Criticality system reviews, component risk based assessments were carried out in 2 Phases- 1. Preliminary & 2. Detailed reviews, analysis and re- design calculations performed where applicable

Evaluation Define Components

Assess BOD , consider Failure Consequences

Define Probability of Failure

Business Environment Safety CriEcal Elements

Likelihood Time Element Current Status Anomalies

Review and conduct risk based assessments, document

miEgaEons

Define InspecEon Type & Frequency changes in IRM where appropriate.

Available Methods Applicability + Industry best pracEces.

Follow agreed methodology –flow diagram Phase 1, 2.

Original –Design

Document



Field Life Extension Philosophy Age



LE Screening Process Ageing Assets and Life Extension Regimes for Subsea to Floaters


The Reliability Philosophy

‘Leave no

stone unturned’ Make every possible effort to check and verify all equipment design, operaEng envelope condiEons, funcEonaliEes, interfaces and performance criteria are in

acceptable state before installaEon deployment subsea.


Lessons Learned

•  Create a project environment, encouraging CAPEX and OPEX optimized risk control process for the design, operation, IMR and, if applicable, life extension of the complete field facilities.

•  For a field development, both subsea and surface facilities system reliability

and availability requirements and associated design, operating and IMR solutions from wellhead to point of export should be developed in an integrated manner to allow for an overall optimization of CAPEX, OPEX and Life Time Costs.

•  FMEA and RAM Analysis and incorporation of analysis results into the facilities

designs should be an ongoing process through all project design phases.

•  Project Management to allow for in project budgets and Level 3 schedules for reliability, redundancy, robustness, expansion, IMR, sparing and life extension during early design phases and in the basis of design, technical specifications and contract scope of work documents.

•  A strong management focus on CAPEX reductions may result in significantly increased life time costs, safety and environmental risks.


Lessons Learned

•  Create the right working environment across project execution teams, with a realistic focus on both CAPEX to OPEX and Asset Integrity, Life of Field implications.

•  Supply Chain Capacity, availability of certain materials globally.

•  People understanding, appreciating

The importance of FMECA & RAM

analysis outputs

•  Engineering Design house experience in the use and application of API-RP-17N in Pre-Feed or FEED was mixed not a consistent understanding of how to apply it. Thereafter, once in Execute mode difficult to implement.

•  Data to support MFOP criteria not well defined

•  FLNG systems is still new technology

Life of Field Operability, Asset

Integrity with high Reliability/

Availability

Reduce Design Complexity

Remove poor

Designs Before

Installation

SPS EPC and EPCI-SURF Contracting Strategies


Equipment Standardisation

Conclusions: •  Clear guidance on techniques •  API 17’s, NORSOK U001,

DNVGL-RP0002 •  Experience gap,

focus on detail •  Reliability Engineering is key •  Create the right working

environment with right culture

•  It is a Cyclic Industry, Low oil prices

•  Simplification •  It’s a Risky Business

-Effective Project Management Execution Delivery teams is required

Cost Reductions will come from

more standardisation

Reduce Complexity

Remove Defects Before

Installation

Results in Reduced Risk


The Reliability Philosophy Conclusions: •  Encourage the use of standard

equipment design solutions. •  More proactive approach to

obsolescence issues. •  DNV-RP-0401 been in place

since 1985 Ref: Safety & Reliability. Criteria for Statement of Compliance

•  Latest RP’s, NORSOK U-001 •  Updates in SINTEF-OREDA Data •  SURFIM JIP Forum, PSA Norway •  Adherence will underpin safety,

operability and consistent criteria •  FLNG systems are still

new technology •  Industry Collaboration,

Share Lessons Learnt

Fault Tolerant Configurations

Reduce Complexity

Remove Defects Before

Installation

Residual Risk


The Principles of the Reliability Capability Maturity Model

D Definition of Reliability Goals & Requirement

P Organising and planning for Reliability

I

Design and manufacture for Reliability

Risk and Reliability Analysis and Modeling

Verification and Validation

Project Risk Management

Reliability Qualification

Performance Tracking & Data Management

Supply Chain Management

Management of Change

F Reliability Assurance

Organisational Learning

5 Reliability OPTIMISED using adaptive processes.

4 Reliability MANAGED and influences design. Improvements made in response to failures.

3 Reliability DEFINED and measured but there is limited feedback for improvement.

2 REPEATABLE performance but standard procedures do not address reliability/improvement.

1 Reliability uncontrolled and procedures AD-HOC.


How to Achieve Improved Availability or Uptime

I Drive a Mercedes for Reliable Performance!


Questions Please ?