System Sustainability & Obsolescence Management
The foundation for optimised life of field partnership
SUT – Controls Down Under19th October 2016
Safety Moment The Morning after….
Most of us enjoy a few glasses of wine to accompany our
evening meal, especially during industry events where we
often meet up with old colleages and friends.
However, we mustn’t forget that it takes time for alcohol to
work its way out of our systems.
As a rough guide, drivers should allow at least one hour to
absorb alcohol, plus at least one hour for each unit
consumed.
Just three 250ml glasses of wine and you can’t drive for 13
hours!
Being banned from driving would change your life in so
many ways…
The only way you know you’ll be safe to drive is if your
blood alcohol is at 0.
GE Proprietary and Confidential Information© 2016 General Electric Company – For Internal Use Only
Current Production Efficiency Challenges of Aging Infrastructure
Sustainability Cycle
Technology Insertion
5Yr
s
Sustain Operations ???
Enhance Operations ???
£’s
Materials Available
Repairs Supported
10Yrs 25Yr
s
20Yr
s
15Yr
s
Materials enter EOL
Technical Challenges
Review before order
FEED STUDY
£’s£’s £’s £’s
LOF Agreement
Yearly HLFS
Quarterly Updates
Asset Life ???
FEED STUDY
Next Gen SEM Next Gen Pod New Sensors Next GEN MCS
Multi-generational Product Plans
FEED STUDY
Budget
Cycle
FEED Study provides Solutions
Obsolescence removed
Asset Sustained
Cycle Repeats!!!
Product Life Cycle & Obsolescence Management
Brownfield
Enhancing
SEM3 to
SemStar5
Emulation
Back-Fit SMU
SEM2K to
SemStar5
Emulation
Next Gem MCS
Sustaining
Upgrades
Spares
DCV Upgrades
M.C.S. Review
SEM
Obsolescence
Obsolescence
Reporting
Maintaining Installed Base
System Sustainability
Product Life Cycle & Obsolescence Management
6
March 2010
GORGON
SARAWAKBONGA
ABO
KIZOMBA
SATs & PHASE II
MONDO
SAXI BATUQUE
TOMBUA LANDANA
LOBITO TOMBOCO
LIANZI
GNASHLI
SNOHVIT
BUZZARD
SKARV
FARRAGON
RHUM
CORRIB
BURRULLUS
BONNACCIA
15/06
Obsolescence Services – Engagement Map
DEEP PANUKE
POMPANO
ARNOLD
ASPEN
TROIKA
XXXX – Signifies Obsolescence Reporting
XXXX – Signifies LOF Contract
Joint Operator
Specification
3428A
Obsolescence
Management
Guide
IEC 62402Process Expectation
Controls Upgrade
Subsea
Controls Refurb
Subsea
Full Controls System
1
2
3
Upgrading Brownfields – Systems Solutions
Esso Norge
‘Balder’
Stone Energy
‘Pompano’
Statoil ‘Troll B’
Statoil ‘Snorre BLegacy SCM
Old SEM
Existing
MCS Statoil ‘TVCM’
8
Case study: SmartCenter delivers savings for Canadian Natural Gas CompanySmartCenter delivers considerable value and savings for a
Canadian natural gas company:
• Remotely located platform
• logistics for field service engineers complex and
considerable.
• SmartCenter deployed during the commissioning phase of
the project to enable maximum impact and savings.
• Majority of engineering support conducted remotely through
SmartCenter by expert engineers in the subsea controls
Centre of Excellence, Bristol UK.
Value Driver #1 – Remote ad-hoc fault diagnosis
• Commissioning and fault diagnosis conducted remotely by onshore
experts for the commissioning period of 6 months.
• Removed the need and cost of a full-time offshore commissioning
support engineer.
• Conducted over 2 man weeks of fault finding which saved at least 4
mobilisation charges.
Value Driver #2 – Remote software updates
• Delivered 3 remote software updates to the system during
commissioning.
• Removed the need for 3 x 1 week offshore trips and associated
mobilisation costs.
Value Driver #3 – Remote implementation of Modbus links
• Implemented a Modbus transparent link to DHPT cards and enabled
the periodic gathering of data remotely.
• Removed the need for a 1 week offshore trip and associated
mobilisation costs to install the link.
• Data gathered remotely every week for 5 weeks, which would have
otherwise required an offshore mobilisation each week.
~$200k saved
~$120k saved
~$70k saved
~$390k saved over a 6 month period
Production & System
Performance
Leak Detection & Condition Monitoring
VFM
Hydrate Formation
Wax Formation
Chemical Injection
Optimization
Fluid Consumption
Actuator performance
Choke performance
SmartCenterTM
24/7 Support
& Smart Apps
Brownfield Asset Integrity
Enhanced System PerformanceHydraulic Fluid Loss Advisor
Choke Health Modelling
Umbilical Electrical Integrity
Subsea Processing
Condition Monitoring
Sensor Health
Valve Actuator
Performance
Corrosion/Erosion Monitoring
System Sustainability Management
Production System
Health Monitoring
Acoustic
Leak Detection
Condition Monitoring
GE Proprietary and Confidential Information
© 2016 General Electric Company – For Internal Use Only
Analytics ambition
f (x, y, z ….)
Data stream
Data streamData stream
Data stream
Outputs
Analysis
- Value trend- Rolling Average 1
- Rolling Average 2
- Rolling Average 3
- Value Limits (+ve & -ve)
- Rate of Change of Trend- Plot of rate of change
Diagnosis
- Hydraulic Fluid Usage
- Actuator Profiling
- Choke Performance
Monitor
- Flowline Integrity
- Electrical Integrity
- Sensor (P/T) Integrity
- Data Communication Int’ty
Prognosis
- Virtual Flow Metering
- Hydrate Formation Analysis
- Wax Formation Analysis
- Chemical Injection Optn
Analysis = what’s happening
Diagnosis = why this is happening
Prognosis = if this continues to
happen then the outcome is
……….
GE Proprietary and Confidential Information© 2016 General Electric Company – For Internal Use Only
Hosting a Subsea Digital Service –the ‘Predix’ Platform
Why Predix?
- Common Historian
- Data exchange between Apps
- Open Source Host
Enablers – Benefits – Outcomes
Enablers
Data-driven asset
performance and Failure
mode management
Life of Field Monitoring
Subsea-focussed analytics
for flow and assets
Subsea System operations
scenario planning toolkits
Informed, risk-based strategies for
maintenance planning & spares holding
Improve MTTR/MTBR
Reduce Vessel Costs & utilisation
Support Fast, accurate decisions
Optimise spares holding
Enhance field and system knowledge
Benefits
Flow rates
Avoid Unplanned Downtime
Optimise:
Consumables
Outcomes
Field maintenance costs
Maintenance
Action
Solution Delivery
Eliminate Sub-Sea Hydraulic fluid loss, by using supplied
System Data to support targeted intervention
Operator contacted
GE to report they had
excessive hydraulic
fluid loss Sub-Sea,
but no idea where it
was occurring.
Operator shared
operational data.
G.E. remotely
analysed SCM logs
and isolated failure
using flow meter
data.
Operator
recovered
effected SCM.
Excessive
hydraulic fluid
loss eliminated
Increasing volumes of Hydraulic control fluid being lost
Sub-Sea, but no understanding where loss was occurring
Customer Challenge
Intervention and
Operational Support
IOC – North SeaAutomotive
Chemicals
Food &
Beverage
Heavy Industry
Oil & Gas
Power
Generation
Other
Asset Performance
Management
Automation
Brilliant
Manufacturing
Cyber Security
Predix
NA
Europe
MENAT
APAC
China
NAM
SMARTCENTER: A remote connection allowing domain
expert access to off-shore systems, allowing faster
analysis / solution deployment
Collaboration with client on scale and history
of problem 1
3
2Remote System analysis takes place with zero
production impact
System Data identified failure event. Targeted
Intervention with minimal recovery scope.
HPU Pump Cycle
Environmental impacts avoided.
$0.75M of OPEX Costs avoided per year.
Reduction in HPU cycle & Valve events. Early
life failures avoided
ResultsWas
Deteriorated
After Intervention
14GE Title or job number
10/11/2016
Commercial Opportunities Overview
The move to continuous & consistent monitoring i.e. Data Stream
promotes the introduction of innovative commercial arrangements.
Typically these involve :-
• Cash flow optimization
• Production performance
• Equipment availability and performance
• GE operational performance