Rod Tester - Subsea UK

Legacy Field Technology Backfit
to Extend Field Life & Uptime
Rod Tester – GE Oil & Gas
February 5th, 2014
Imagination at work.
Agenda
Introduction
Supportability Overview
Brownfield Upgrade Model
Case Studies
Experiences to Date
Future Opportunities
Summary
Ways to keep you producing.....
What we said.....
What we did.....
What we learned…..
Where we can go.....
© 2014 General Electric Company – All rights reserved
Introduction
Imagination at work.
The Brownfield Opportunity
Primary
Recovery
Secondary
Recovery
Tertiary
Recovery
Extending field life with sustainable technology
© 2014 General Electric Company – All rights reserved
Tackling GE’s Installed Base
Pre 2000 fields
Post 2000 fields
230 SCMs still producing
750+ SCM’s into the 2020’s
25 fields
48 fields
The need for solutions that adapt to changing field situations over time
© 2014 General Electric Company – All rights reserved
Supportability Overview
Ways to keep you producing.....
Imagination at work.
GE’s Supportability Strategy
Continuous support with
Obsolescence Management and
Critical Spares provisioning
Cost of
ownership
per annum
Capital cost
of Brownfield
Upgrade
5
10
Support costs post
Brownfield Upgrade
15
20
Years in service
Strategies appropriate to operational needs
© 2014 General Electric Company – All rights reserved
Managing Obsolescence From The Foundation
Production
System sustainability
Operational
SCM – MCS – SPCU –
HPU - WOCS
1st Line (major)
Sensors – DCVs – Computers –
PLCs – SEM – SMU – LSCM – EPCM
2nd Line (minor)
Subassemblies of 1st Line Spares
Printed Circuit Boards – Filters – PLC modules
– Power Supplies
3rd Line (components)
Subassemblies of 2nd Line items
Complete Bill of Materials
Individual Electronic Components
Obsolescence
Monitor
GE’s Obsolescence Management Programme
Electronic
Component
Tool Reqts
2010
Establish
Customer
Needs
External
Service
Offering
3rd Party Audit (2013)
“….. the most complete evidence
based approach seen within the
Operators supply base to date”
Roll Out & Customer Take Up
2011
2012
GE
Workflow
process
Development of Obsolescence
Management Plan
2013
3rd Party Items
Non Electronics Parts
Software
Fully compliant with
IEC 62402
© 2014 General Electric Company – All rights reserved
Upgrading Brownfields – Systems Solutions
Full Controls System
1
New
SEM
New
MCS
ModPod SCM
Existing
MCS
2
Legacy
SCM
Controls Upgrade
Subsea
New
SEM
Existing
MCS
ModPod SCM
3
Controls Refurb
Subsea
New
SEM
Existing
MCS
Upgraded
Legacy SCM
Emulation Required
© 2014 General Electric Company – All rights reserved
Subsea Electronics
Topside Electronics
Electronics & Technology Evolution
TI99
PDP 11
VAX
PC
PLC
PC/PLC Hybrid
Obsol. Mgmt.
SEM1
SEM2
SEM3
SEM2K/2K+
SEM4
SemStar5
1981
1987
1992
2001
2009
2012
© 2014 General Electric Company – All rights reserved
SemStar5 – Next Generation SEM
SmartCenter
Backfit Solutions
• Fully ISO 13628-6 compliant SEM
• Ethernet TCP/IP based architecture
Smart Instrumentation
Process & Downhole
• SIIS & IWIS fully compatible
Child
SCM
Parent
SCM
• Support for future topologies & architectures
Grand
Child
SCM
Child
SCM
Grand
Child
SCM
• Backwards compatibility for legacy SEM products
• Built-in strategy for obsolescence management
Grand
Child
SCM
Child
SCM
Grand
Child
SCM
© 2014 General Electric Company – All rights reserved
Brownfield Upgrade Model
What we said
Imagination at work.
Implementing the Brownfield Model
Technology insertion tool box
SemStar5
Upgrade
Requirement
Identified –
FEED study
triggered
Installation
scheduling
ModPod
New Sensors
Remote Links
FEED Upgrade OptionsElectronics unit level
Control pod level
System Level
SCM
adaptors
Dual band
comms
Today’s qualified
technology solves
yesterdays challenges
Cost benefit
analyses
All options
Pro’s & con’s
matrices
Comms
routers
Optimum
solution
decision
Optimisation by the
“how to apply” route
rather than “what to
apply “
Installation solutions
© 2014 General Electric Company – All rights reserved
Backfit Emulation Strategy
SemStar5 Baseline (TVCM)
DEVELOPMENT
Data
Accumulator
PRODUCT
SEM3 Translator
SEM3
Emulator
Field Specific
Configuration
SEM2k Translator
SEM2k
Emulator
Field Specific
Configuration
SEM4
Emulator
Field Specific
Configuration
Profibus Translator
Legacy Sensor
Interface
Ensuring legacy support on maturing products
© 2014 General Electric Company – All rights reserved
Case Studies
What we did
Imagination at work.
Statoil TVCM Project
Key operator challenges
• Field life to 2030/40
• Reduce obsolescence exposure
• Multiple SCM / DHPT configurations
• Different pod vendors
• Improved instrumentation
• Upgrade without recovering trees
• Uncertainty over existing installed
equipment status
© 2014 General Electric Company – All rights reserved
Statoil TVCM Project
Design outcome
• Single pod solution achieved
• Multiple adaptor plates
• SemStar5R solves DHPT’s issue
• Additional functionality delivered
• Enhanced comms – subsea router
• Open architecture
Current status
•
27 pods deployed and working
•
Multi vendor upgrade success
•
Improved bandwidth (~1Mb/s)
•
All interfaces proven
1st Major Brownfield Upgrade
© 2014 General Electric Company – All rights reserved
Statoil Snorre B Project
Key operator challenges
• Obsolescence
• Support of 27 wells to 2040
• Unique original SEM4 modules
• Upgrade without recovering trees
• No topside changes (3rd party system)
• Old system documentation
Design outcome
• Risk balanced upgrade
• Full SemStar5 emulation of SEM4
• Old SCM’s retained
• Attrition replacement programme
• Ethernet port added to SCM
• Future functional expansion enabled
Current status
•
3 pods deployed and working
•
Next 14 SCM upgrade kits in progress
•
Profibus emulation success
•
Improved supportability
© 2014 General Electric Company – All rights reserved
Statoil Troll B Upgrade Project
Key operator challenges
• Electronics obsolescence
• Field life extension to 2030+
• SEMs and SMUs supportability
• Upgrade during well re-completion
programme
• No functional changes now
• Low risk change out philosophy
Current status
•
Concept / FEED studies complete
•
Main contract underway
•
2015 installation campaign for
first half manifold of SCMs
Design outcome
• Interchangeable SEM3 / SemStar5
pods
• Upgraded SMUs with evolution path
to GE’s new Backfit SMU
• Old SCMs retained
• Re-use existing tooling
• Future functional expansion
available with SemStar5
© 2014 General Electric Company – All rights reserved
Shell Corrib Project
Key operator challenges
• Old system yet to be brought on line
• Increased functional / safety reqts
• New standards in force
• MCS obsolescence
Current status
•
First 6 pods ready for deployment
•
Revised MCS design in progress
•
System integration &
commissioning in planning stage
Design outcome
• SEM upgrade to meet ISO 13628-6
• DCV upgrade – latest shutdown reqts
• Latest SCM design enhancements
incorporated
• All deployed SCMs to be replaced with
new or upgraded units
• Assess options for MCS upgrade
© 2014 General Electric Company – All rights reserved
Solving other Brownfield Challenges
Issue
GE’s Solution
Non standard pod funnel
Early risk reduction engineering:
Adapted current running tool design
New field owner with new ideas
Smart well functions easily
accommodated post FEED
No Pod headroom for adaptor plates
ModPod qualified components into old
Pod shell
Limited topside space / changes =
installation challenges
Extensive installation options explored
Topside space issue resolved
Topside redundancy architecture
parallel changeout philosophy
New dual band SMU conceived
Competitor system changeout
Early risk reduction engineering:
Adaptor plate fit up test
On / off shore comms validation tests
Parallel system architecture review & risk
assessment
© 2014 General Electric Company – All rights reserved
Experiences to Date
What we learned
Imagination at work.
Obsolescence – There Is No Silver Bullet Solution
• 1st Line & 2nd Line Spares are not enough
• Obsolescence Management Is a Life Cycle Process
• Planning a Robust Management Process Is Key
• Mitigate & Buffer Surprises With Stock Provisioning
© 2014 General Electric Company – All rights reserved
Brownfield Execution Key Success Factors
• Map and re-map during FEED
• Field surveys…critical to know what’s really there
• Engagement with offshore teams
• Engagement with legacy engineers
• “Team” partnership with the Customer
• SCM Mounting Base Adaptors
• Expertise … having the right people on the team
• Consistency in personnel from FEED to delivery
© 2014 General Electric Company – All rights reserved
Brownfield Execution Lessons Learned
•
•
•
•
•
•
•
•
•
Existing Equipment – subsea surprises
Early specification GAP analysis.
Ensure one team approach
Proactive risk management
Repeat’ part number is a myth
Poor status of the existing (legacy) documentation
Start planning the installation phase during FEED
Corporate “buy in“ using sponsors group meetings
You can never have enough testing
Brownfield upgrades are demanding and complex … but are achievable
© 2014 General Electric Company – All rights reserved
GE model approach validated
Project
SemStar
5
Refurb
Pod
ModPod
Adaptor
Plate
Sensor
Upgrade
Dual
Band
Comms
New MCS
New
Topside
I/F (SMU)
SemStar
5R
Comms
Router
(Fibre)
Smart
Center
Link
Install.
Strategy
Challenge
TVCM
Balder
Snorre B
Troll
Corrib
Alpha
Beta
Gamma
Qualified products + Validated techniques
= Effective bespoke solutions
© 2014 General Electric Company – All rights reserved
Future Opportunities
Where we can go
Imagination at work.
The Brownfield Opportunity – Non GE Oil & Gas
Fields
Installation type
Fields SCM’s
Pre 2000
1097
Post 2000
2395
GE’s Legacy Fields
25
230
GE’s ModPod Fields
48
750+
Non GE Fields
350
3500+
Solutions that adapt to changing field situations over time
© 2014 General Electric Company – All rights reserved
Summary
Imagination at work.
Supportability Roadmap for Legacy Fields
Specific Risk Reduction
Studies
Long Term
Supportability
Requirement
Sustainability
Study
Spares Stocking
& Unit Upgrades
Obsolescence
Management
Asset
Management Spares Stocking
& Unit Upgrades
Brownfield
Upgrade Study
Field Upgrade
Project
FRACAS
Continuous Product
Improvement
© 2014 General Electric Company – All rights reserved
Questions?
Imagination at work.