Procurement Risk Management of Flexible Pipes and Umbilicals. Presented by Hanh Ha Kuala Lumpur Convention Centre 9 th June 2010

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2 Procurement Risk Management of Flexible Pipes and Umbilicals Presented by Hanh Ha Kuala Lumpur Convention Centre 9 th June 2010

3 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...

4 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

5 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

6 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

7 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

8 Quality Control How and where do we control quality? Specification Design & analysis Material procurement Manufacturing Packing and loading Mobilisation & offshore installation

9 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 Deepwater optical fibre cable Finite element mesh

10 Analysis of Flawed Design Finite element analysis of the deepwater optical fibre cable

11 Qualification Testing Laborious but often necessary qualification testing Rotational and Reel Loading Tests

12 Qualification Testing Failure of separators in a deepwater umbilical due to crush loads from bending on a reel

13 Raw Material Supply Rejected tensile armouring wires from the sub-suppliers

14 Raw Material Supply Wire defects found on Approved wire stock from the sub-suppliers

15 Umbilical Failure In-service umbilical thermoplastic hydraulic hose rupture

16 Kidney-shaped hose cross-section at failure location Umbilical Failure

17 Umbilical Failure Damage during production inadequate setup quality control

18 Flexible Pipe Manufacture Extrusion problem due to inadequate QA/QC procedures

19 Flexible Pipe Manufacture Resulting extrusion defect irregular sheath thickness

20 Remedial Procedure Permanent change in underlying tape securing procedure

21 Manufacturing Feature Outer Surface ~ 5mm Inner Surface Crack notch in pressure sheath

22 Close-up of notch Manufacturing Feature

23 In-Service Crack In-service crack propagation from manufacturing feature

24 End Fitting Failure End fitting dissection to determine root cause of failure

25 End Fitting Failure Incorrect dimensional control on critical components

26 End Fitting Failure Creep under pressure into un-supported sheath location

27 Packing & Loadout Inadequate packing procedure at factory leading to a near-miss offshore

28 Mobilisation Issues Improper weld during sea-fastening operation during mobilisation

29 Mobilisation Issues Inadequate loadout planning Last-minute welding of deck covers to main deck on the transport vessel during mobilisation!

30 Mobilisation Issues Inadequate mobilisation planning that could have led to over-bending of riser during loadout

31 Mobilisation Issues Requiring on-the-ground intervention to rectify problem

32 Mobilisation Issues Panoramic view of on-the-ground solution to over-bending problem

33 Mobilisation Detailed planning required for mobilisation of SURF components

34 All set and ready to go... Installation Issues

35 Installation Issues Inappropriate installation planning leading to on-the-ground improvisation to make things work!

36 Installation Issues Pipe alignment issues Mid-line connection the brute force way...

37 Installation Issues Notice the vessel main crane on the starboard side?

38 ... or use the laws of physics to make life simpler! Installation Issues

39 Inadequate installation planning leading to... Offshore Failures

40 Offshore Failures Buckled pipe Kinked cable

41 Some failure modes are totally unforeseen! Offshore Failures

42 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-Learnt Failures/Near-misses Better Procedures

43 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

44 New Technologies 10-year development programme for the Lloyds Type-Approved Dynamic Cryogenic Offshore Transfer Hose

45 New Technologies High capacity dynamic power cable development programme currently undergoing strenuous testing for qualification

46 Questions? Thank You For Your Attention!