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Imagination at work.
Rod Tester – GE Oil & Gas February 5th, 2014
Legacy Field Technology Backfit to Extend Field Life & Uptime
Agenda
Introduction
Supportability Overview Ways to keep you producing.....
Brownfield Upgrade Model What we said.....
Case Studies What we did.....
Experiences to Date What we learned…..
Future Opportunities Where we can go.....
Summary
© 2014 General Electric Company – All rights reserved
The Brownfield Opportunity
Extending field life with sustainable technology
Primary
Recovery
Secondary
Recovery
Tertiary
Recovery
© 2014 General Electric Company – All rights reserved
Tackling GE’s Installed Base
The need for solutions that adapt to changing field situations over time
Pre 2000 fields
230 SCMs still producing 750+ SCM’s into the 2020’s
Post 2000 fields
© 2014 General Electric Company – All rights reserved
25 fields 48 fields
GE’s Supportability Strategy
Strategies appropriate to operational needs
5 10 15 20
Cost of
ownership
per annum
Years in service
Capital cost
of Brownfield
Upgrade
Continuous support with
Obsolescence Management and
Critical Spares provisioning
Support costs post
Brownfield Upgrade
© 2014 General Electric Company – All rights reserved
System
Operational
SCM – MCS – SPCU – HPU - WOCS
Sensors – DCVs – Computers – PLCs – SEM – SMU – LSCM – EPCM
Subassemblies of 1st Line Spares
Printed Circuit Boards – Filters – PLC modules – Power Supplies
Subassemblies of 2nd Line items
Complete Bill of Materials
Individual Electronic Components
Production sustainability
1st Line (major)
2nd Line (minor)
3rd Line (components)
Obsolescence Monitor
Managing Obsolescence From The Foundation
GE’s Obsolescence Management Programme
2010 2011
Electronic Component Tool Reqts
GE Workflow process
External Service Offering
Development of Obsolescence Management Plan
Roll Out & Customer Take Up
Establish Customer
Needs
3rd Party Items Non Electronics Parts
Software
3rd Party Audit (2013) “….. the most complete evidence based approach seen within the Operators supply base to date”
2012 2013
Fully compliant with IEC 62402
© 2014 General Electric Company – All rights reserved
Upgrading Brownfields – Systems Solutions
Controls Upgrade Subsea
Controls Refurb Subsea
Full Controls System
1
2
3 Existing MCS
Existing MCS
New SEM
Upgraded Legacy SCM
New MCS
New SEM
ModPod SCM
New SEM
ModPod SCM
Legacy SCM
Existing MCS
Emulation Required © 2014 General Electric Company – All rights reserved
Electronics & Technology Evolution
PC
1981 1987 1992 2001 2009 2012
VAX
PC/PLC Hybrid
SEM4
SEM2
SEM1
Su
bse
a E
lec
tro
nic
s
To
psi
de
Ele
ctr
on
ics
SemStar5
PLC
PDP 11
TI99
SEM2K/2K+
SEM3
Obsol. Mgmt.
© 2014 General Electric Company – All rights reserved
SemStar5 – Next Generation SEM
• Fully ISO 13628-6 compliant SEM
• Ethernet TCP/IP based architecture
• SIIS & IWIS fully compatible
• Support for future topologies & architectures
• Backwards compatibility for legacy SEM products
• Built-in strategy for obsolescence management
Smart Instrumentation
Process & Downhole
SmartCenter
Child
SCM
Parent
SCM
Grand
Child
SCM
Grand
Child
SCM
Child
SCM
Grand
Child
SCM
Child
SCM
Grand
Child
SCM
Child
SCM
Parent
SCM
Grand
Child
SCM
Grand
Child
SCM
Child
SCM
Grand
Child
SCM
Child
SCM
Grand
Child
SCM
Backfit Solutions
© 2014 General Electric Company – All rights reserved
Implementing the Brownfield Model
SemStar5 ModPod New Sensors Remote Links
Installation scheduling
FEED Upgrade Options-
Electronics unit level
Control pod level
System Level
Upgrade
Requirement
Identified –
FEED study triggered
Technology insertion tool box
Today’s qualified technology solves
yesterdays challenges
Optimisation by the “how to apply” route rather than “what to
apply “
Cost benefit analyses
All options
Pro’s & con’s matrices
SCM adaptors
Dual band comms
Comms routers
Installation solutions
Optimum
solution
decision
© 2014 General Electric Company – All rights reserved
Backfit Emulation Strategy
Ensuring legacy support on maturing products
Field Specific Configuration
SEM3
Emulator
SEM2k
Emulator
SEM4 Emulator
DEVELOPMENT PRODUCT
SEM2k Translator
SEM3 Translator
Profibus Translator
Legacy Sensor
Interface
Data Accumulator
Se
mS
tar5
Ba
seli
ne
(T
VC
M)
Field Specific Configuration
Field Specific Configuration
© 2014 General Electric Company – All rights reserved
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
Current status
• 27 pods deployed and working • Multi vendor upgrade success • Improved bandwidth (~1Mb/s) • All interfaces proven
Design outcome • Single pod solution achieved • Multiple adaptor plates • SemStar5R solves DHPT’s issue • Additional functionality delivered • Enhanced comms – subsea router • Open architecture
1st Major Brownfield Upgrade
© 2014 General Electric Company – All rights reserved
Statoil Snorre B Project
Current status • 3 pods deployed and working • Next 14 SCM upgrade kits in progress • Profibus emulation success
• Improved supportability
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
© 2014 General Electric Company – All rights reserved
Statoil Troll B Upgrade Project
Current status
• Concept / FEED studies complete • Main contract underway • 2015 installation campaign for
first half manifold of SCMs
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
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
Current status • First 6 pods ready for deployment • Revised MCS design in progress • System integration &
commissioning in planning stage
Key operator challenges • Old system yet to be brought on line • Increased functional / safety reqts • New standards in force • MCS obsolescence
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
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
Qualified products + Validated techniques = Effective bespoke solutions
Project SemStar5
Refurb Pod
ModPod Adaptor Plate
Sensor Upgrade
Dual Band
Comms
New MCS New Topside I/F (SMU)
SemStar5R
Comms Router (Fibre)
Smart Center
Link
Install. Strategy
Challenge
TVCM
Balder
Snorre B
Troll
Corrib
Alpha
Beta
Gamma
© 2014 General Electric Company – All rights reserved
Solutions that adapt to changing field situations over time
The Brownfield Opportunity – Non GE Oil & Gas Fields
Pre 2000
Post 2000 2395
1097
© 2014 General Electric Company – All rights reserved
Installation type Fields SCM’s
GE’s Legacy Fields 25 230
GE’s ModPod Fields 48 750+
Non GE Fields 350 3500+
Supportability Roadmap for Legacy Fields
Long Term Supportability
Requirement
Sustainability
Study
Specific Risk Reduction Studies
Spares Stocking & Unit Upgrades
Obsolescence
Management
Brownfield Upgrade Study
Field Upgrade
Project
Asset Management -
Spares Stocking & Unit Upgrades
Continuous Product
Improvement FRACAS
© 2014 General Electric Company – All rights reserved