procurement risk management - subsea uk risk management for... · procurement risk management of...
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Procurement Risk Managementof
Flexible Pipes and Umbilicals
Presented by
Hanh Ha
Kuala Lumpur Convention Centre
9th June 2010
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Content
• Who are BPP-TECH?
• SURF Procurement – What is it about.
• How and where do we control quality?
• Why do we need to control quality?
• Lessons-learnt and how we deal with it...
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Company Overview
BPP-TECH provides specialist engineering, research and product development services to the offshore hydrocarbon and marine industries.
• Company formed in 1981
• Offices in London, Houston and Aberdeen
• Staffed by experienced, highly qualified engineers
• Operating worldwide
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Company Overview
• Analysis & review of subsea architecture:flexible pipes, risers, umbilicals, power cables, flowlines and moorings
• product development & joint industry projects (JIP)
• procurement support, production advice & client representation
• concept and feasibility studies for floating offshore systems
• offshore monitoring and instrumentation
• insured risk and failure analysis
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SURF Procurement
• SURF – Subsea Umbilical, Risers & Flowlines
• The reliability of the subsea production system from the mudline to the sea surface is critical to production in terms of control and flow assurance
• Subsea system components are often safety critical
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SURF Procurement
• There is a history of defects and incorrect designs leading to significant losses
• The majority of field failures relate to manufacturing defects passing through inadequate QA/QC systems
• Ready acceptance of manufacturer’s non-conformance reports in the face of schedule and cost pressures
• FAT - Factory acceptance testing does not ensure long term reliability
• Use of inappropriate procedures and equipment encountered during installation
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Quality Control
• How and where do we control quality?
• Specification
• Design & analysis
• Material procurement
• Manufacturing
• Packing and loading
• Mobilisation & offshore installation
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Design and Analysis
• Prediction of strength, internal strains and service lives
• Global hydro-elastic structural response calculations
• Local nonlinear structural analysis
• Analysis of designed and as-built structures
Finite element meshDeepwater optical fibre cable
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Analysis of Flawed Design
Finite element analysis of the deepwater optical fibre cable
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Qualification Testing
Laborious but often necessary qualification testing– Rotational and Reel Loading Tests
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Qualification Testing
Failure of separators in a deepwater umbilicaldue to crush loads from bending on a reel
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Raw Material Supply
Rejected tensile armouring wires from the sub-suppliers
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Raw Material Supply
Wire defects found on “Approved” wire stockfrom the sub-suppliers
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Umbilical Failure
In-service umbilical thermoplastic hydraulic hose rupture
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Umbilical Failure
Kidney-shaped hose cross-section at failure location
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Umbilical Failure
Damage during production – inadequate setup quality control
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Flexible Pipe Manufacture
Extrusion problem due to inadequate QA/QC procedures
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Flexible Pipe Manufacture
Resulting extrusion defect– irregular sheath thickness
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Remedial Procedure
Permanent change in underlying tape securing procedure
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Inner Surface
Outer Surface
~ 5mm
Crack notch in pressure sheath
Manufacturing Feature
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Close-up of notch
Manufacturing Feature
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In-Service Crack
In-service crack propagation from manufacturing feature
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End Fitting Failure
End fitting dissection to determine root cause of failure
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End Fitting Failure
Incorrect dimensional control on critical components
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Creep under pressure into un-supported sheath location
End Fitting Failure
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Packing & Loadout
Inadequate packing procedure at factory leading to a near-miss offshore
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Mobilisation Issues
Improper weld during sea-fastening operation during mobilisation
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Mobilisation Issues
Inadequate loadout planning – Last-minute welding of deck covers to main deck on the transport vessel during mobilisation!
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Mobilisation Issues
Inadequate mobilisation planning that could have led to over-bending of riser during loadout
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Mobilisation Issues
Requiring “on-the-ground” intervention to rectify problem
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Mobilisation Issues
Panoramic view of “on-the-ground” solution to over-bending problem
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Mobilisation
Detailed planning required for mobilisation of SURF components
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Installation Issues
All set and ready to go...
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Installation Issues
Inappropriate installation planning leading to “on-the-ground”
improvisation to make things work!
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Installation Issues
Pipe alignment issues – Mid-line connection the brute force way...
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Installation Issues
Notice the vessel main crane on the starboard side?
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Installation Issues
... or use the laws of physics to make life simpler!
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Offshore Failures
Inadequate installation planning leading to...
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Offshore Failures
Buckled pipe Kinked cable
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Offshore Failures
Some failure modes are totally unforeseen!
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Lessons-Learnt
• What do we do with all the lessons-learnt?
• Feed lessons-learnt back into new SURF programmes
• Apply lessons-learnt into other forms of procurement processes
New Project
Lessons-LearntFailures/Near-misses Better Procedures
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Lessons-Learnt
• Make use of lessons-learnt to enhance the development of new technologies...
• Cryogenic transfer hoses for the LNG market
• High capacity dynamic power cables for very long and
deepwater offshore applications
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New Technologies
10-year development programme for the Lloyds Type-Approved Dynamic Cryogenic Offshore Transfer Hose
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New Technologies
High capacity dynamic power cable development programme currently undergoing strenuous testing for qualification
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Questions?
Thank You
For
Your Attention!