legacy field technology backfit to extend field life & uptime

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


Introduction

The Brownfield Opportunity

Extending field life with sustainable technology

Primary

Recovery

Secondary

Recovery

Tertiary

Recovery


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


25 fields 48 fields


Supportability Overview Ways to keep you producing.....

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


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


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.


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



Brownfield Upgrade Model What we said

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


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)





Case Studies What we did

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


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


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


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


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


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



Experiences to Date What we learned

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


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


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


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



Future Opportunities Where we can go

Solutions that adapt to changing field situations over time

The Brownfield Opportunity – Non GE Oil & Gas Fields

Pre 2000

Post 2000 2395

1097


Installation type Fields SCM’s

GE’s Legacy Fields 25 230

GE’s ModPod Fields 48 750+

Non GE Fields 350 3500+


Summary

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



Questions?

legacy field technology backfit to extend field life & uptime

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