capability presentation living with obsolescence and reliability...impact of failure likely to be...

Capability Presentation

AOG 2015 Subsea Conference, 11th – 13th March

2015 - Perth Conference & Exhibition Centre,

Western Australia

Subsea Controls, Sensors & Monitoring

K.Glanville

Design & Development Manager

Living with obsolescence

and reliability

Agenda

• Challenges and opportunities

• Limitations and Ailments of ‘older

systems’

• Upgrade of a North Sea Asset

• Conclusion

2

Challenges and

opportunities

3

Australian liquids Production

Australia’s production of oil, condensate and LPG has been in decline since it

peaked in 2000

4

© 2015 Proserv. All Rights Reserved.

UKCS Production

Since the initial licensing issued in 1964 approximately 42 billion barrels of oil

equivalent [boe] have been produced within the UKCS; upwards of 12 to 24

billion boe could be produced;

5

Production in the UKCS has fallen 38% between 2010 and 2013 with 72% of

this attributed to a drop in production efficiency;

Source: UKCS Maximizing Recovery Review: Final Report published by Sir Ian Wood 24th February 2014


% o

f cu

mm

ula

tive

oil

pro

du

ctio

n

1975 to 2014

UKCS offshore oil production 1975 to 2014, source DECC Nov2014

UKCS Production .. Cont’d

© 2015 Proserv. All Rights Reserved. 6

Recently recommendations within the final

report ‘UKCS Maximising Recovery Review’

related to improvements to production facilities

to address a decline in production efficiency

and maximize the remaining resources which

included: -

• Extending the life for the existing

infrastructure and facilities;

• Implementation of technologies to

realize production improvements;

Source: UKCS Maximizing Recovery Review: Final Report

published by Sir Ian Wood 24th February 2014

Limitations and

ailments of ‘Older

systems’

7

Obsolescence: -


8

Unscheduled shutdowns; inability to

support field life extensions or

introduction of new technology

Limited supply chain influence;

IT/automotive industry typically higher

volumes with shorter life cycle

Impact of failure likely to be exasperated

by redesign, requalification and

ultimately reliability and cost

Obsolescence: the loss or impending loss of original manufacturers products or raw

materials

Obsolescence: - Reactive / Proactive management

Proactive approach whilst mitigating

risk can result in high cost for LTB’s;

should be part of technology

roadmap


9

Reactive management –

responding to manufacturer’s PCN

alerts; impact of legislation on

availability e.g RoHs

Proactive management – Design to

provide obsolescence resilience;

Life Time Buy of key components

Reactive approach for subsea

can be risky and expensive and

potentially effect reliability of

product

Reliability: -

10

Reliability: ability of equipment, system to consistently perform its intended function

on demand without degradation or failure.

A working system or component will eventually fail ..


Extending, sustaining and optimising ageing assets often limited by current

technology

11

Power / Communication system

limitations often a barrier to

implementing production /

instrumentation or surveillance

technology

Performance and Functionality: -

Product support / knowledge

impacted by developments in

response to product and

industry requirements


Assessing condition and performance opportunities

Extending the life, facilities or existing functionality of the subsea system may

include any or all of the following: -


12

Power capacity and quality; support for

additional loads and potential impact on

communications system upgrades

Communications performance;

Environmental, Umbilical and existing

communication equipment often define

limitations to system upgrade

Subsea Standardisation


13

Subsea integration; system upgrades

should address connectivity,

performance and standardisation

Topside interfaces

SUBSEA

TOPSIDE

Se

ns

or

va

lue

s Co

ntro

l

SensorCANOpen (SIIS)

SensorModbus/RTU

SensorIWIS

CiA309: CAN on IP

Modbus/TCP on IP

Modbus/

TCP

All protocols

carried by IP

SCM

Data acquistion

server

SensorOther

SensorSensor

SensorSensor

MDIS

CUSTOM

PROTOCOL

SUPPORT

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=UA7H8Pf7Ds9vyM&tbnid=RC-vWlE9AlC5GM:&ved=0CAUQjRw&url=http://www.odi.com/products/Ethernet/Ethernet.asp&ei=8NBvUpTtEKyr0gW27YCICQ&bvm=bv.55123115,d.ZGU&psig=AFQjCNGwEUn1bedocIMUYQQUluUEF6XplA&ust=1383146059899847

Upgrade of a North

Sea asset

14

Upgrade field overview

The Toni field is 100% operated by CNR and has been in operation since

the Early 1990’s has produced approximately 60 mboe; source DECC Nov

2014.

15

Requirement was to initially evaluate the two manifold production and

injection system and propose an upgrade that would enable new production

/ injection wells with improved availability and performance;


Topside system evaluation / upgrade

Determine upgrade potential re performance and interface capacity for power

and communications; existing power system suitable to support current

system, communication performance and functionality was an area for

improvement; future additional power/communication support incorporated

16

Powe r

TxD

RxD

RS23

2LA

N

Powe r

C

V

SUBSEA POWER

OC COf fO

1 On

Nemo 96 HD + IME

U I P· Q · S E· T

R+ = 100 K MP:A1 = 180 K A2 = 120 K

ALARM1 2

TESTRESE T

kWA- IS OMETE R®IR DH1065

BEND ER

RS232

50 to 600 kHzUp to 1,3Mbps

2.5MM TSP

Typ. 900/2200 Hz

Existing fsk Modem

16MM cores

Typ. 250Vac 60 Hz

Existing EPU

Ethernet/RS485 MCS/DCS link

Proserv TPCU

Evaluate DCS link integration strategies to select optimum solution; upgrade

ultimately coincided with DCS improvements and hence solution of direct

Proserv TPCU implemented, bypassing existing system;


Subsea system evaluation / upgrade

Existing separate communication & power; low frequency/data-rates,

existing power distribution suitable for proposed extension;

17

OCC/DIPLEXER

MAINSPOWER240V/50Hz

OCC/DIPLEXER

Attenuator 6dB insertion Loss

Existing Modem/simulator equip

Existing Modem/simulator equip

0-99dB

16mm2 PARALLEL POWER CONDUCTORS

2.5mm2 SCREENED SIGNAL TWISTED PAIR

Cable reel length = 500m

DC Load

Evaluation of potential strategies using spare umbilical dynamic riser

section; owing to physical construction of cable optimum solution

determined to implement communications on power conductors;

In-built diagnostics tool within Proserv OCC used in conjunction with

physical measurement tools to evaluate / optimise configuration /

performance


Subsea System Architecture

OCH


18

Existing EPU / communication

system

XT with Dual SEM

Subsea Control

Module

Channel A

Channel B

EDU ~6km

Umbilical

TPCU

SEM A

SEM B

SEM B

SEM A

Future

production /

Instrumentation

/ data systems

Channel B only – shown for

Clarity

Project summary

OCH [housing FO

interrogators


19

TPCU The existing production system had field / life

extension opportunities but also

obsolescence and reliability challenges

• Following extensive testing and evaluation using current

Proserv technology a coexist solution was proposed

which would provide a ~40kbps co-exist transparent

channel.

• Remote diagnostics, performance monitoring in

addition to resolving obsolescence and reliability

issues;

• The solution physically integrated into existing system

architecture without existing equipment modification

other than jumper reconfiguration;

• Additionally, equipment could readily be re-deployed /

reused to provide standard interfaces for data or

controls equipment

Conclusion

20

Conclusion

The UKCS has upwards of 12 to 24 billion boe that could be

produced; Production in the UKCS has fallen 38% between 2010

and 2013 with 72% of this attributed to a drop in production

efficiency; Source: UKCS Maximizing Recovery Review: Final Report published by Sir Ian Wood 24th February 2014


21

Proserv field proven technology was used to facilitate the upgrade of an

existing UKCS control system asset to support innovative improved

performance, functionality and reliability

Living with Obsolescence and reliability while

providing ‘enhanced recovery opportunities’

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