Docstoc

Technology Consulting Brochure - DOC

Document Sample
Technology Consulting Brochure - DOC Powered By Docstoc
					                                                                                    The JIP is currently delivering:
                                                                                    1) Analysis of historical BOPE reliability in the Gulf of Mexico from 1
                                                                                    January 2004 through 31 December 2006;
                                                                                    2) Evaluation of the theoretical reliability ramifications of longer testing
  2009 NATIONAL TECHNICAL CONFERENCE & EXHIBITION,                                  frequencies;
                NEW ORLEANS, LOUISIANA                                              3) Recommended optimal testing frequency;
                                                                                    4) Evaluation of applicable, new BOP equipment testing technologies; and
AADE 2009NTCE-03-01                                                                 6) Recommendation of best practices testing practices and relationship, if any,
NUMERICAL METHODS FOR ANALYSIS OF SUBSEA                                            between testing practices and frequency.
EQUIPMENT - YOUR BOPE BY THE NUMBER                                                 Work scope was separated into BOPE for subsea and surface applications,
                                                                                    with schedule priority being given to subsea. As of this paper’s date, the
AUTHOR(S) & AFFILIATIONS:                                                           subsea final report is under review by the steering committee for submission
                                                                                    to the MMS.
DON SHAFER, CTO, ATHENS GROUP
                                                                                    Data Requirements for the Study
Revised Abstract: The Minerals Management Service (MMS) recently                    One of the key requirements of this study; after the subsea BOPE expertise
funded a three-year Joint Industry Project (JIP) to determine the historical        of the subject matter experts, was obtaining the correct data needed for study.
reliability (failure rates and resultant NPT) of function and pressure testing of   This included data acquisition, verifying its provenance, managing the
subsea BOPE systems, including severity relative to safety and well integrity.      collected data, defining the analysis and executing the statistical processes.
The JIP conducted the surveys with leading operators and drilling contractors       The following tasks were performed:
in the Gulf of Mexico. This presentation will discuss the data collection           1)         Categorized well description data from MMS
method for conducting this JIP.
                                                                                    2)         Reviewed data and determine required sample sizes for statistically
The Offshore Operations Committee (OOC), International Association of                          valid 95% confidence level of results for four categories of wells
Drilling Contractors (IADC) and Petroleum Equipment Suppliers                                  based on the rigs (age, equipment, and configuration) used to drill
Association (PESA) identified the need for a new JIP to investigate the                        them:
reliability of BOP Equipment. It has been several years since any analysis has
                                                                                    a.         Subsea BOPE systems
been conducted; most importantly, there have been no analysis conducted on
the latest generation rigs.                                                         b.         Multiplex control systems
With an understanding of downtime causes, BOPE and control systems                  c.         Piloted hydraulic systems
reliability can be increased, therefore decreasing downtime and saving rig          d.         Grouped by similar configurations of annulars and rams.
owners and operators millions of dollars annually while maintaining excellent
safety environmental performance.                                                   e.         Grouped by contractor owned or rental
The Problem: BOPE Variable Reliability                                              4)         Developed databases, one each for surface and Subsea, for data to
                                                                                               be extracted. Informed participants and requested feedback so as
• Operating costs have tripled                                                                 to maximize efficiency and minimize delays due to re-examination
• Many stack configurations exceed minimum requirements with more                              of data. Databases will include but not be limited to the following
redundancy                                                                                     data:
• Blind Shear Rams Implemented (surface) are not testable                           a.         Well name and number (confidential)
The Solution:                                                                       b.         Water depth
• Execute an industry funded JIP                                                    i.         0-2k-ft
• Utilize expert third party consulting companies.                                  ii.        2-4k-ft
The Development Committee awarded the JIP management to WEST                        iii.       4-6k-ft
Engineering Services. WEST will enlist the help of The Athens Group,                iv.        >6k-ft
whose expertise in statistical analysis complements WEST’s BOP leadership.
The union of these two entities ensures that the JIP will have the industry's       c.         Well depth
leading engineering and consulting experts maximizing the expectation of            d.         Test pressure data
practical, usable recommendations. The purpose of JIP was to determine
                                                                                    i.         2-5 ksi
optimal testing frequency and preferred test methodology in order to
improve operating efficiency while maintaining reliability and integrity of         ii.        5-7.5 ksi
BOPE (Blowout Prevention Equipment). With increased BOP testing                     iii.       7.5-10 ksi
frequency and improved BOP pressure testing methods, the estimated
savings is $193 million/yr.                                                         iv.        >10ksi
Based on:                                                                           e.         Test temperature data
• 36 DW MODU’s in GOM at end of 2007                                                f.         Stump testing protocol
- $376 k/day Average Rig Rate and                                                   g.         H2S data
~$651 k.day Average Spread Rate                                                     h.         Operator (confidential)
• 13 Additional High Capacity Units by 2009                                         i.         Drilling contractor (confidential)
- $436 k/day Average Rig Rate and                                                   j.         Rig name (confidential)
~ $711 k/day Average Spread Rate                                                    k.         BOP stack location for this report is all subsea
                                                                                    l.         Equipment configuration


Page 1 of 4, 488b8a85-3ccb-4891-af59-215350d0e7eb.doc
m.         Status of operations at time of testing                                 This is the categorization of the final data sets used in the study. The steps
n.         Reason for test                                                         executed to get these in shape for statistical analysis follow. Basic summary
                                                                                   numbers of the study’s data sets show thee operational time and testing time
i.         Regulatory time requirements                                            within the final data set for the basic summary number are as follows:
ii.        After setting casing with the casing running tool                       Total Operations Time (hh:mm:ss)             882811:42:00
iii.       Other                                                                   Total Testing Time (hh:mm:ss)                32448:01:00
o.         If drilling interrupted for a dedicated BOP test, what were             Testing % of Ops       3.68%
           implications?
i.         Time of testing
ii.        Testing methods
                                                                                                   Total Number of MMS Subsea Wells                                 239
iii.       Testing procedures
p.         Number of days since well spud
                                                                                                      Total Number of Wells Recorded                                233
q.         Days since last major overhaul or prior significant maintenance                           Total Number of Wells Remaining                                  6
r.         NPT by equipment type                                                                    Total Number of Well Test Records                             4244
i.         Successful tests by equipment type                                                              Average Well Tests per Well                               21
ii.        Failed tests by equipment type                                                                   Total Number of Well Tests                           89189
s.         NPT by control system type                                                               Average Component Tests per Well                                383
5)         Successful tests by control system type                                                            Tests Remaining to 100%                             2297
6)         Failed tests by control system type
                                                                                                             Current Confidence Factor                          97.49%
a.         New technology, if any, utilized on tests (see Section 2 Testing
           Methodology below)
b.         MMS waiver applied for and/or granted                                   This table shows the distribution of well records and component tests by
                                                                                   Lease Operator:
7)         Finalized implementation and staffing plan and resultant schedule
                                                                                         Lease Operator                 Well Records         Component Tests
           and communicated same to participants.                                   LO_01                         366                      7508
8)         Developed reporting and feedback protocol for status                     LO_02                         63                       1512
                                                                                    LO_03                         469                      10477
           communication.                                                           LO_04                         303                      6499
Previous to this study, there was no consistent method employed to gather,          LO_06                         69                       1449
                                                                                    LO_07                         18                       378
verify and analyze GOM BOPE incident, testing or performance data. There            LO_08                         522                      11519
was not one method for acquiring data. We found data with the MMS,                  LO_09                         731                      16159
operators, operating partners and individual drilling contractors to secure data    LO_10                         41                       697
                                                                                    LO_11                         88                       1506
within the time frame of interest. This data was delivered in many forms -
                                                                                    LO_12                         24                       456
from day reports to databases. The following process ensured repeatability in       LO_13                         236                      4511
the data collection:                                                                LO_14                         27                       511
                                                                                    LO_15                         49                       931
1.         Work with the committee and MMS, to identify all sources of data         LO_16                         144                      2736
                                                                                    LO_17                         106                      1985
2.         Request that data be sent with a recommended format for delivery         LO_18                         64                       1324
           to West                                                                  LO_19                         366                      7862
                                                                                    LO_20                         29                       628
3.         Log all data requests and data received with respect to data source,     LO_21                         91                       1997
           format and quality                                                       LO_22                         36                       789
                                                                                    LO_23                         272                      5211
4.         If data is not received within a reasonable time, a second request       LO_24                         48                       894
           plus telephone follow-up will begin
                                                                                         Figure 1:        Lease Operator Data Distributions
5.         Status of the data collection with names of contacts will be
           documented.
6.         The ONLY way to ensure that the data is not biased is to collect it     Figure 1: Lease Operator Data Distributions
           from numerous sources, using many paths with a repeatable
           process. The data will be verified through our collection process
           and the quality of the source identified based on past performance
           in providing information to the MMS and industry bodies.
           Athens Group provided quality assurance and quality control for
           the statistical analyses developed. Athens Group audited the
           collection process executed by West from the time data was ready
           for loading. No data was used without a 100% identification of its
           source and quality. The software and techniques used for the
           analyses was documented and transparent to the JIP technical
           committee. There were NO proprietary algorithms or applications
           used to manipulate the data. All statistical analyses were done
           using generally accepted industry practices and tools such as Excel
           and MatLab.
Data Categorization
This table shows the distribution of well records and component tests by Rig:
                                                                                     Data Preparation Steps
Rig          Well          Component
Name         Records       Tests                                                     Step_01 – Acquire all the raw data from West which consisted of 24 files
RIG_01
RIG_02
             200
             109
                           4400
                           2071
                                                                                     containing 9.64 Megabytes of data.
RIG_03       250           5250
RIG_04       74            1554                                                      Step_02 – Process the raw data into component data sets consisting of 3 files
RIG_05       191           4584                                                      in 35.6 Megabytes of the following formats:
RIG_06       202           4444
RIG_07
RIG_08
             153
             267
                           3366
                           5103
                                                                                     1.          Summary - The key information for the summary sheet.
RIG_09       85            1954
RIG_10       82            1476                                                      2.         AllWestInput - all of the data sets contained in each of the spread-
RIG_11       221           4862                                                                 sheets in Step_01 are combined in this worksheet. The Each sheet
RIG_12       190           4409
RIG_13       23            391                                                                  for each Lease Operator is copied and pasted into this worksheet.
RIG_14       204           4284                                                                 The first three columns containing the data entry verification data
RIG_15       24            431
RIG_16       172           3956                                                                 are deleted. The heading rows are copied intact and checked for
RIG_17
RIG_18
             100
             38
                           2200
                           760
                                                                                                each sheet to ensure than the format in each Lease Operator's
RIG_19       67            1474                                                                 workbook is consistent. This sheet is then copied to the next sheet
RIG_20
RIG_21
             183
             28
                           4209
                           616
                                                                                                as its starting point.
RIG_22       144           2736
RIG_23       136           2312                                                      3.          PrepInput01 - the data from the previous worksheet was sorted
RIG_24       138           2346                                                                 headings. Next the data was sorted by Lease Operator to identify
RIG_25       190           3679
RIG_26       124           2578                                                                 and delete any blank rows from the original sheets. This is also the
RIG_27       123           2706                                                                 point at which Total Lease Operator Input Records and Total
RIG_28       46            1012
RIG_29       75            1641                                                                 Unique Wells by API # are calculated. There were a total of 4299
RIG_29
RIG_30
             75
             55
                           1641
                           1100
                                                                                                Lease Operator records entered covering 279 unique API number
RIG_31       113           2373                                                                 well instances. The Unique API numbers were determined by the
RIG_32
RIG_33
             15
             185
                           330
                           3885
                                                                                                Excel Advanced Filter function in the Data Menu with unique
RIG_34       9             117                                                                  values checked. This was the first pass numbers. As the process
RIG_35
RIG_36
             12
             16
                           228
                           352
                                                                                                continued, more well data was acquired to get to the +95%
Figure 1:    Rig Data Distribution                                                              reliability.
                                                                                     4.         PrepInput02 - First all the MMS data columns are deleted up to
                                                                                                the Lease Operator column. Next a unique id - Key01 - for each
Figure 1: Rig Data Distribution
                                                                                                test record - NOT incident - is created using the API and Test
    Rig Contractor               Well Records               Component Tests
RC_01                        2107                        42540                                  Date fields. The formula is
RC_02                        46                          1012                                   =TRUNC(VALUE(LEFT(C2,11)+D2)*1000,0) where the first
RC_03                        146                         3358
RC_03                        1                           23                                     11 characters of the API filed are converted to a numeric value
RC_04
RC_05
                             40
                             43
                                                         783
                                                         946
                                                                                                and then that is added to the numeric value of the Test Start Yr
RC_05                        43                          946                                    field. That sum is truncated to zero numbers to the right of the
RC_06                        744                         15843
RC_07                        1092                        24109                                  decimal. The API field has to be limited to the first 11 because
       Figure 1:          Rig Contractor Data Distributions                                     there are multiple entries separated by commas in this field. Next
             Test press                   Well Records          Component Tests                 the test time was calculated for each record by subtracting the start
5-7.5 Ksi                              681                   14351
2-5 Ksi                                831                   17215                              time from the end time. This became another check on the data
7.5-10 Ksi
≥ Ksi
                                       663
                                       48
                                                             14134
                                                             1012
                                                                                                entry where dates were inconsistent with reality. NOTE: In order
       Figure 2:          Test Pressure Data Distributions
                                                                                                to check for duplicate lease operator test records, this formula was
Wellbore Fluid                         Well Records          Component Tests                    put into conditional cell format for the calculated Key ID column:
Synthetic-Based Mud
Water Based Mud
                                       1599
                                       95
                                                             33822
                                                             1863
                                                                                                =COUNTIF($A:$A,A2)>1 . Setting the cell formatting to red
20% Saturated Salt                     37                    805                                identified the duplicate records.
Seawater                               332                   6905
Other                                  148                   3065
Spud Mud - Dkd                         4                     80
       Figure 3:          Wellbore Fluid Data Distributions
                                                                                     5.         Worksheet reorganized in order to facilitate the normalization of
            Test Fluid                    Well Records           Component Tests                the data into specific equipment test sets.
Synthetic-Based Mud                    1592                  33667
Water Based Mud                        104                   2043                    Step_03 – This step generated the anonymized data set to be used for the
20% Saturated Salt
Seawater
                                       38
                                       331
                                                             827
                                                             6886
                                                                                     statistical analysis. 1 file of 20.3 Megabytes was generated containing these
Other                                  147                   3046                    work sheets:
Spud Mud - Dkd                         5                     102
       Figure 4:          Test Fluid Data Distributions                              0.         Summary
             Test Type                    Well Records          Component Tests
Function                               1930                  40524                   1.         Anonymizer
Wellbore and Function                  2292                  48193
Wellbore                               2                     46                      2.         PrepInput03
       Figure 5:          Test Type Data Distributions
             BOP Class                    Well Records          Component Tests      3.         FixedTimeDurations
VI                                     2646                  53383
VIII                                   336                   7918                    4.         WellTestRecord
VII                                    1249                  27638
       Figure 6:          BOP Class Data Distributions                               5.         WellTestSpecs
     Control Systems Type
Piloted
                                        Well Records
                                     1828                   1828
                                                                   Component Tests
                                                                                     6.         ControlSystemTests
Mux                                  2416                   2416
       Figure 7:          Control Systems Data Distributions
                                                                                     7.         RamBlockTests
                                                                                     8.         AnnularTests
Figure 2: Rig Contractor Data Distributions                                          9.         ValveTests
10.        LMRPtests                                                                mean downtime (MDT). Because the uptime is equivalent to the failure time,
11.        WellHeadConnectorTests                                                   it is also known as the mean time to failure (MTTF). The downtime can
                                                                                    consist of repair time and other delays. If there are no delays, then downtime
12.        AllFailures                                                              is equivalent to the repair time. In this case, the mean downtime (MDT) is
Step_04 – After anonymization, 1 file of 33.0 Megabytes was generated               equivalent to the mean time to repair (MTTR). MTTR is also known as mean
containing the analyzed failure cluster data.                                       corrective time. Under the steady-state condition, the following well-known
                                                                                    relationships exist:
0.         Summary
                                                                                    MCT = MUT + MDT
1.         PrepInput03
                                                                                    When there are no delays in repair:
2.         FailureClusterAPI
                                                                                    MTBF = MTTF + MTTR
3.         FailureClusterRig
                                                                                    Availability = MTTF/MTBF = MTTF/(MTTF + MTTR)
Step_05 – The cluster data from Step 4 was exported as separate .csv files and
used as input to MatLab’s statistical workbench.                                    As discussed earlier, MTTF is a function of system age. The expected time to
                                                                                    the first system failure is called the mean time to first failure (MTTFF).
Step_06 - Generate1 file of .348 Megabytes containing the final report              MTTFF is important for systems where online repairs are tolerable but not
versions for the subsea analysis.                                                   offline repairs. The use of MTTF for both MTTFF and steady-state MUT is
                                                                                    another source of confusion. It should be noted that for a single-component
A Note on MTTF versus MTBF                                                          system, with perfect repair, MTTFF is equivalent to MUT. Therefore,
                                                                                    regardless of what MTTF refers to, its value is the same for single-
According to some sources, MTBF is applicable only when failure times               component systems. In the majority of systems, MDT or MTTR is negligible.
follow exponential distributions. According to other sources, MTBF is               In such cases, MTBF ≈ MTTF. Therefore, in most practical cases, MTTF =
applicable only for repairable systems. I've also heard that MTBF is nothing        MTBF
more than MTTF. What do MTTF and MTBF really mean? Are there
differences between these terms?
MTBF (mean time between failures) is the expected time between two                  http://www.mms.gov/
successive failures of a system. Therefore, MTBF is a key reliability metric for    For a copy of the Original JIP Prospectus please refer to:
systems that can be repaired or restored. MTTF (mean time to failure) is the
                                                                                     http://www.westengineer.com/Jip%20Trifoldr3.pdf
expected time to failure of a system. Non-repairable systems can fail only
once. Therefore, for a non-repairable system, MTTF is equivalent to the              http://office.microsoft.com/en-
mean of its failure time distribution. Repairable systems can fail several times.     us/excel/HA011366161033.aspx?pid=CL100570551033).
In general, it takes more time for the first failure to occur than it does for
subsequent failures to occur. Therefore, MTTF for a repairable system can           http://www.mathworks.com/products/statistics/
represent one of two things: (1) the mean time to first failure (MTTFF) or (2)
the mean uptime (MUT) within a failure-repair cycle in a long run.
While MTBF is one of the most widely used metrics in reliability engineering,
it is also one that causes a great deal of confusion. By going through the
theoretical definitions and alternative uses for MTBF, the reasons for this
confusion become apparent.
In most reliability engineering literature, and particularly in theoretical
literature such as research papers, MTBF represents the mean time between
failures. It is applicable when several system failures are expected. This is
possible only when the system is restored after a failure. The restoration can
be performed by repair or replacement of some of its failed components.
Such systems are known as maintainable systems or repairable systems.
After restoration, the system may not be as good as new. This is because the
repair of the failed components may be imperfect, warm components may
still be present in the system, or all failed components may not have been
restored. Once a restored system is returned to operation, it can fail again
after some time. The failure of the system leads to downtime. Therefore,
between two consecutive failures, the time can be divided into uptime and
downtime. The time between failures is referred to as a failure-repair cycle
time. In most cases, this time stochastically decreases with the age of the
system. This means that although there are some random variations in time,
on average, there is a decreasing trend. Therefore, strictly speaking, the
MTBF of the system is a function of system age.
If all system failures can be restored, then in a long run, the estimate of the
cycle time becomes constant with respect to the system age. This is known as
the steady-state condition. Theoretically, this condition exists as time tends to
infinity. However, for reliable systems where downtime is small in
comparison to uptime, the steady-state condition can be realized in a short
time. Therefore, in practice, the MTBF is calculated by assuming that the
system has reached the steady-state condition. Because the MTBF is the
expected value of the failure-repair cycle time, it is sometimes referred to as
the mean cycle time (MCT).
The values for uptimes and downtimes can also change with system age and
reach their asymptotic values. The expected values of the uptime and down-
time in the steady-state condition are known as the mean uptime (MUT) and

				
DOCUMENT INFO
Shared By:
Categories:
Tags:
Stats:
views:24
posted:8/16/2011
language:English
pages:4
Description: Technology Consulting Brochure document sample