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.uk7
- COMOPS Meeting 8th Dec, 11
Long Offset Subsea –
Tie Back 140 Km to shore with over
230 Km export pipelines

www.seafloconsultancy.co.ukFlow 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

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

PAP 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.

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
Prevent
Prevent
Prevent
Prevent
Reliability led Design + FMECA and RAM Analysis
+ PAP Installation risk mitigation planning
Data collection
Data analysis
FeedbackFeedbackFeedbackFeedback
Quality& Reliability
led Manufacture
Qualification testing
Pre-commissioning – Ops (Risk)
assessment-procedure checks
IMR Strategy -
PLAN + Risk
based inspection
Monitoring

www.seafloconsultancy.co.ukLaggan 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
Breakdownrate
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 failuresDesign 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)
Amplitude(deg./m)
Bilge radius = 2.50m
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)
Amplitude(deg./m)

•  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
Ageing Assets &

Field Life Extension Philosophy Age

Ageing Assets &

LE Screening ProcessAgeing 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 ?

Reliable Subsea Oil& Gas Transportation Paper - Presentation Slides 6 November 2015

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