INGENIOUS. The alternative in energy services LAUNCH ISSUE. Maximising the life of subsea assets. The corrosion challenge

Transcription

1 INGENIOUS The alternative in energy services LAUNCH ISSUE Maximising the life of subsea assets The corrosion challenge Proserv helps industry ACT during hard times

2 Maximising the life of subsea assets Proserv s problem solving solutions engineering approach provides operators with significant cost-savings. The corrosion challenge Proserv has developed an innovative suite of technologies for corrosion inspection, prevention and monitoring. Proserv helps industry ACT during hard times In a low oil price marketplace, how can subsea operators continue to prosper and maximise field life? David Lamont CEO Welcome We are very pleased to launch the first issue of our new-look magazine, ingenious Accurate and reliable subsea positioning in challenging environments By Sam Hanton, Vice President Subsea Services Pioneering the way in well abandonment solutions Proserv s technology solution can deliver up to 25% efficiency savings. An ingeniously simple smart solution for remote environments Manufactured by our engineering team in the Middle East, Proserv has developed a solution for real time monitoring in remote locations. At a time when the market is focused on making continual savings, we at Proserv are delighted to share some of the ways in which we are using our ingeniously simple solutions approach to solve our clients challenges, more efficiently and effectively than ever before. In line with our company ethos, we are becoming well known as one of the leading challenger brands in the oilfield services sector. It isn t necessarily about being smaller; it s about being bold enough to be different. In a traditionally conservative industry such as oil and gas, Proserv is challenging the industry to think smarter and break away from the norm. What worked before is not sustainable in today s current operating environment, so changing our approach as an industry is essential to our long term survival. There are some great examples throughout the magazine of our brand spirit in action and how we have delivered ingeniously simple solutions with our clients. From the adoption of an exciting new approach to optimise subsea production on page 12, to a step change solution for well abandonment on page 18, the articles in this magazine provide a small snapshot of how we can help deliver a more sustainable future for our clients, the Proserv way.

3 02 03 Maximising the life of subsea assets. Below are just two examples where we have supported operators with their engineering challenges, helping to prevent the loss of production and optimise the lifespan and performance of their assets. Operator challenge Proserv s problem-solving solutions engineering approach provides operators with significant cost-savings. In line with our challenger brand mentality, we continue to actively promote and encourage new ways of working in order to provide outstanding results for our clients. Early engagement is, and will always be, essential for Proserv. It allows us to get to the heart of the problem, quickly, and come up with a unique solution that will deliver the project more efficiently in line with specific client requirements. We believe our clients don t have to settle for the same old approaches and methodologies time and time again. In this current climate especially, being presented with a safe, more reliable and more economical solution, for the long-term, is a truly compelling proposition. Background In the early 1990s, a global oil major purchased a subsea controls system that included pipeline subsea safety isolation valves (SSIV). A field ready spare was also purchased and stored, to provide contingency. As the units in place were more than 20 years old, the decision was taken to re-fat the spare SSIV to check its serviceability. The unit was stripped down and the incumbent controls supplier was contacted to establish whether they could support the main valve on the SSIV, with a view to ordering parts or replace the valve if required. The client s controls supplier was unable to support this valve, or offer a replacement for the obsolete parts. Solution The proposal provided by the client s controls supplier was to sell a new electrohydraulic SSIV which would not have been compatible with the installed system. The client would have had to replace a 400m umbilical and upgrade the existing controls system to operate the new electro-hydraulic SSIV. As a rapid-response engineering solutions provider, Proserv was contacted to determine whether there was a solution to work around the controls supplier s negative response of having to replace the entire SSIV and controls system. The solution offered by Proserv saved the client from spending many millions to replace the existing subsea system and the cost of lost production. Furthermore, Proserv was able to offer a future-proof component obsolescence management plan. The SSIV was transported down to our subsea control centre of excellence in Great Yarmouth, UK, for testing on a base plate. The filter and filter block were removed and dismantled, and the existing filter element removed and discarded, along with the filter block seals. The unit was then re-assembled with new seals and a new filter element. The solution offered by Proserv saved the client from spending many millions The same was then done with the Directional Control Valve (DCV), which went on to achieve a shutdown time of 20.6 seconds, which was acceptable to the client. A full FAT was carried out by the Proserv team in Great Yarmouth, which was witnessed and accepted by the client s representatives. The Proserv value Potential project savings in excess of 10-12m Maximises the life of subsea assets through proactive obsolescence management Mitigates the risk of loss production Cost-effective and quick execution of an engineering solution

4 04 05 Operator challenge Shell required the remote removal of an existing 8 flexible riser from a North Sea FPSO and, due to HSE and cost considerations, divers were not an option. In addition, it was stipulated the FPSO infrastructure housing the flexible riser could not be damaged to ensure that immediate re-use was possible. P roserv was asked to take over existing tooling designs and execute an intensive 16 week schedule, which included the procurement, assembly and testing of three tool designs. The main tool was a cutting manipulator, required to remotely sever 40 x M33 studs in order to release the bend restrictor from the lower i-tube in a controlled, non-destructive, fully remote manner. Existing Proserv tooling was used to sever the flexiriser from the end fitting. As the project progressed, further challenges arose both on and offshore, which Proserv added to their scope of work. Following a successful FAT of each of the tooling components, a full system integration test (SIT) was conducted prior to the offshore execution. This SIT used full size test pieces and was held at Proserv s Birchmoss facility, one of our subsea centres of excellence. A collaborative approach to QHSE resulted in good communication and full transparency throughout The Proserv value Right from the start this was a fast-track, tight timeline project. Despite everything that came up the team at Proserv delivered every time with no accidents. Full project management through the whole project lifecycle Dedicated engineering and technical specialists to allow real-time solutions whether on or offshore Direct contact with Shell helped streamline decisions and responses, allowing delivery within the original schedule In-house engineering and procurement enabled the challenges that became apparent to be addressed by Proserv rather than over reliance on multiple vendors Without your team s determination and commitment, the riser removal scope of the Anasuria riser replacement project would not have been a success. It has been a pleasure to work with the Proserv team.

5 06 07 The corrosion challenge. Preventing corrosion is vital in every step in the production of oil and gas. From pipelines to production platforms, from drilling through to abandonment, corrosion is an adversary worthy of all the high technology and research we can throw at it. T he total annual cost of corrosion in the oil and gas production industry is estimated to be $1.372 billion, broken down into $589 million in surface pipeline and facility costs, $463 million annually in downhole tubing expenses, and another $320 million in capital expenditures related to corrosion. Corrosion costs the oil and gas industry tens of billions of dollars in lost income and treatment costs every year. The need to change A growing proportion of our global subsea infrastructure and platforms are reaching the end of their intended design life some have already exceeded design life. Combine this with the challenges we currently face as an industry and you realise there is a need to look and behave differently from what we are used to. We need to collaborate to deliver more for less. We need to work together earlier. faces every asset manager. In parallel, there is a drive to delay action and reduce costs. Solutions that can improve knowledge on the true integrity of assets are enablers for getting the timing right for the right action. This is critical if, as an industry, we are to remain competitive and meet the challenge of reducing costs. Asset integrity can only be achieved effectively if we have the right data and information to make informed decisions. Too often we take action based on poor data because we re scared of what might happen; this is the harsh reality that A new approach Once we understand what action needs to be taken, we need to challenge ourselves to understand what the appropriate, fit for purpose and cost effective solutions are from the outset. Too

6 08 09 Friction welding has become an essential part of many asset owners integrity management programmes. often we default back to convention by purchasing hardware before planning the installation. Is there another option, an ingeniously simple option? Proserv has developed an innovative suite of technologies to improve data quality on subsea corrosion monitoring, simplifying the decision making process and reducing risk. Proserv s data can prove that, despite visual and ROV probe inspection, the asset is protected and will reach the required design life. Should action in the form of anode retrofit be required, Proserv s leading approach is to develop the installation methodology first and cathodic protection design second. Adopting this approach with unique technologies, such as friction welding with ROVs, is creating a step-change in the industry as Proserv continues to partner with clients to develop the right solution. The solution With Proserv s NASCoM Acoustic Monitoring and Control technology, data relating to the corrosion and protection status of assets can be recovered without having ROVs or divers in the water. Not only does this enable data to be recovered at a much greater frequency than before but the cost of doing so is significantly reduced. Through Proserv s NASCoM technology, the data is also better quality as the monitors are at fixed permanent locations meaning that errors are less prevalent and trending over time is significantly more accurate. Proserv s friction welding technology provides the ability to retrofit galvanic anodes with ROVs to platforms, FPSOs, pipelines and subsea structures. This innovative technical solution offers asset owners a new alternative to impressed current cathodic protection (ICCP) systems and clamps fitted by divers. The same solution is also used to attach acoustic corrosion monitors that not only enable the condition of the asset to be known, they also provide data on the performance of the retrofitted anode system. The technology has a strong proven track record and has become an essential part of many asset owners corrosion and integrity management programmes. What are the benefits of friction welding? Significantly reduced installation costs A fully ROV installed galvanic anode retrofit solution Ability to retrofit discrete sacrificial anodes to in service FPSO hulls Extremely low resistance and robust connection Extremely low profile termination reducing snag risk No stray currents that could damage electrical equipment and control systems Minimal detrimental effect to the structural integrity of the parent material What other applications is friction welding used for? Anode attachment in oil storage tanks Brownfield topside structural upgrades and repairs Subsea remediation securing of caissons and fastening of cofferdams Greenfield modifications new topside modules on FPSOs and platforms Attachment of nipples hot tapping and salvage Pin hole leak repairs friction plug welding

7 10 11 Case study: remote anode replacement Client: Global oil major Location: Gulf of Mexico Project background Over 200 anodes on the hull of a floating production platform had suffered fatigue related failure. The platform was in production so recovery back to a dry dock was not an option. A replacement method for the anodes to the hull while in service and producing was required. Furthermore, the attachment method solution had to be diverless and provide better weld quality than wet welding. Solution Proserv s friction welding technology was used to replace like for like anodes, using an ROV. This was a challenge considering the anodes were 400lb in weight. Extensive testing was carried out in advance to qualify the performance of the friction weld including fatigue, tensile and electrical continuity tests. The installation was completed using the ROV that was permanently on board the FPS and was done in conjunction with other planned ROV operations. This reduced installation costs significantly, improved operational efficiency and improved safety. Scope Proserv s hydraulic friction welding system was integrated to a customised ROV tooling package for this work scope. The ROV prepared each location and positioned the anode against the hull. Each 400lb anode required two tripartite friction welds for secure attachment. Continuity was achieved by welding a stud to the existing doubler plates, through a machined hole in the new anode strap. The final weld was qualified to the client s specification with programmed weld parameters. Once offshore, the friction welding system consistently executed the same weld parameters where data for all production welds are provided to the client for their records. The Proserv value This unique method was an industry first - previously the alternative would have been wet welding with divers or ICCP system. Significant installation cost savings as launched by ROV off the platform - no vessel required Low risk to personnel through use of ROVs Uninterrupted production This unique method was an industry first as it was ROV deployed

8 12 13 Proserv helps industry ACT during hard times. In a low oil price marketplace, how can subsea operators continue to prosper and maximise field life? With Proserv, there s a simple answer. Core to the Proserv offering is the practice of working around the problem to find out the best solution rather than trying to address the issue with a single restrictive product offering approach A new approach A high reliability of hydrocarbon production and a consistent revenue return on investment are fundamentals for any operator and yet many companies are failing to achieve this for a variety of reasons. With more than 80 per cent of world energy use still reliant on fossil fuel, the maintenance and optimisation of oftenaging brownfield subsea fields is critical. The industry has a moral as well as an economic obligation to maximise total production from these difficult reserves. At Proserv, we have identified that almost half of all client engagement looking for alternative solutions is because of dissatisfaction with the reliability of their current subsea production control systems. Others are seeking to add new wells or instrumentation to an existing asset, or simply looking to extend field life. The challenges and opportunities that the industry faces with brownfield subsea developments are varied, but all too often the industry s initial response to them is not. The frequent reaction to a problem is to call for a complete system change - to remove the old and replace with new - when sometimes a more flexible approach may be appropriate.

9 14 15 Proserv Augmented Control Technologies (ACT) Is an approach that involves allowing additional control technologies to be deployed to augment an existing control system and open up a range of opportunities that were previously not available for the client. When faced with a challenge around equipment reliability, obsolescence or a subsea field upgrade, Operators are typically presented with a solution by the Original Equipment Manufacturer (OEM) to replace their systems, which is a very expensive exercise and it can also affect production. Proserv is currently challenging the market to think differently here. Think smart and break out from the norm Core to the Proserv offering is the practice of working round the problem to find the best solution rather than trying to address the issue with a single restrictive product offering approach. Rather than discard all the old technology and equipment, not all of which necessarily needs changing, a more cost-effective solution is to work with the current system, selectively removing and replacing the components where change is required, and improving performance overall. Alan Peek, VP Subsea Controls and Communications at Proserv, said: In these austere times, it is fundamental to change the way we act and respond to a challenge. Operators have to ask themselves how long they can afford to do nothing, which is why we re encouraging them to think co-exist rather than replacement. Just as there s never been a greater need for industry collaboration, we must think smarter about technology and how we can use what already exists in different ways together. Alan Peek, VP Subsea Controls and Communications Case study: Subsea control module (SCM) retrofit Client: Ithaca Location: North Sea Project background Proserv provided a retrofit for a remote unmanned platform in the North Sea, which included two subsea production wells linked to its host platform. The subsea control system was over 20 years old, unsupported from the OEM and had suffered from poor system availability, unscheduled shutdowns and limited remote support. Solution In order to solve the issues, a study was undertaken to consider the implications of a subsea electronic module (SEM) replacement within each SCM, including the use of existing inductive couplers which are inherent in the system. Each SCM was disassembled, pre tested, retrofitted and FAT tested with new Proserv electronics. The surface control system was also replaced with a new master control station to replace the OEM system and provide communications to the retrofit SCMs. solution with the incumbent SCMs and thus an upgrade path to improve availability and support. The Proserv value Substantially less expensive than a replacement Significantly greater technical performance and reliability Enabled production from an otherwise unproductive field Higher reliability and availability Optimised uptime State of the art electronics and connectivity Remote connectivity Scope We must think smarter about technology and how we can use what already exists in different ways together The work involved using the existing SCM hydraulic and mechanical hardware but replacing the SEM for a more reliable and fully supported unit. This provided a replacement

10 16 17 Accurate and reliable subsea positioning in challenging environments. Operating in a low oil price marketplace is presenting many exciting new opportunities for Proserv as we continue to help companies become more efficient and fitter for the future. by Sam Hanton Vice President Subsea Services M ore than ever, in the current climate efficiency is the holy grail for every project and company. This usually refers to the need not to waste time, effort or, ultimately, money. Proserv s NASNet, a deepwater acoustic positioning system is focussed on providing a long term, low maintenance multi-user solution to subsea positioning over the life of a field. The system has built up a significant track record around the world, most recently on a project in 1300m water depth in offshore northern Norway. Our client chose NASNet for its time and cost saving capabilities. For this project, it was planned to deliver significant vessel time savings in the installation and recovery of the acoustic array, an expectation realised during deployment as the client experienced a six day reduction in their schedule compared to conventional systems. The benefit of the long term capability of the acoustic stations was highlighted when, due to vessel schedule changes, the project extended into a second year. Despite regular use by multiple vessels over several months, followed by a six month winter standby period, there was no requirement to spend time changing out batteries. Even with seven vessels from two contractors using the acoustic array there are still opportunities to further increase efficiencies. For example, the array was installed after the start of drilling activities and various seabed surveys, but had the system been in place earlier further time savings could have been provided. Likewise for longer term IRM and additional installation or drilling activities, a longer term deployed system offers both flexibility and consistency. The project will continue through the summer of Commenting on the benefits gained from using the NASNet system, the client said: We strongly believe it was the right choice for the project s context: deepwater, remote location, harsh weather conditions with short operational weather windows. During the project NASNet has been used both as a standalone positioning system, making use of its new differential mode to optimise and also in combination with closelycoupled Inertial Navigation Systems (INS) to optimise positioning quality. With this capability the system can be used in a Sparse LBL mode using NASNet Mini Stations to reduce the number of units for, typically, more localised coverage areas. In order to gain the maximum benefits for projects there needs to be early consideration and engagement of positioning strategy, with a big picture view of the project in its entirety, rather than allowing separate units and users to dictate a piecemeal approach. Collaboration between operators, contractors and positioning suppliers means a common system, NASNet, can be used to the benefit of all. Proserv s NASNet, a deepwater acoustic positioning system is focussed on providing a long term, low maintenance multiuser solution over the life of a field.

11 18 19 Pioneering the way in well abandonment solutions. Proserv s well severance technology solution can deliver up to 25% efficiency savings From rig-less surface well cutting solutions in the Gulf of Mexico through to deep-water subsea well severance and recovery challenges in the North Sea, Proserv has been supporting clients with their decommissioning projects for over 20 years. With over 130 well cuts completed by the Proserv team within the last five years, the evolution of our engineering capabilities and services in this field has developed rapidly in line with our reputation and our fast company growth.

12 20 21 Going above and beyond In addition to our superior technology offering, Proserv has a strong services mentality and a real can-do attitude, ensuring projects are delivered successfully and on-time whilst keeping costs low and within budget. An example of this was a fast-track project contracted to Proserv, which required the speedy mobilisation of equipment and personnel to deliver a subsea severance work scope in challenging well conditions. Our evolution Proserv s offering has evolved significantly from being able to provide water-abrasive cutting tools and services for cutting pipe (single string) to being able to sever and recover multi-string casing from vessels, rigs or platforms in subsea or surface wells. Our waterabrasive technology has developed from decades of engineering, product design, testing and field experience and, when combined with our strong entrepreneurial spirit and service-driven attitude, this has allowed us to continuously improve, push technology boundaries and provide an outstanding service to clients. One such innovation has been in the development of water abrasive cutting methods which has led to the creation of our Multi- String Cutting (MSC) tool for severing multiple casings. Furthermore, this tool has the ability to lock, seal and de-water wells at depths up to 300m, making it an efficient cutting solution for challenging deeper water campaigns. When combined with Proserv s Well Head Retrieval (WHR) tool, wells can be severed and recovered in a single trip to provide clients with a responsive and efficient decommissioning method. This is just one in a series of technical enhancements that will allow Proserv to provide a truly versatile, highly efficient and highly reliable subsea abrasive cutting solution to meet any well severance challenge. This tool has the ability to lock, seal and de-water well at depths up to 300m Client: Exploration and production company Location: North Sea Project background To carry out a fast-track well abandonment project on three subsea wells over several days. Proserv and a competitor were approached to come up with a complete solution over an eight week period. One of the subsea wells was very problematic and both clients had little confidence in the water abrasive cutting solutions available in the market at that time to successfully complete a well severance and recovery operation. Solution Based on our global expertise and track record, Proserv was able to quickly demonstrate our technical competencies and, specifically, how this project could be completed by our team within such a tight time frame. Once award of the contract was received, full equipment mobilisation and testing was carried out to meet the eight week delivery deadline. We offered the client a contingency solution utilising our extensive experience in subsea excavation and diamond wire cutting for the problematic well as we had anticipated that we would have to sever this well externally without the use of the MSC tool. The provision of the MSC tool and contingency solution gave the client confidence that we could complete the workscope in any eventuality. Using the expertise from our global MSC teams in the US and the UK, Proserv was able to complete a successful severance operation on the problematic well without reverting to our contingency plan. This further reinforced the capability and effectiveness of our MSC tooling solution to the client. Conclusion A very successful project outcome led to Proserv securing more work for the severance of additional wells. Having experienced rival tooling solutions in operation, the client praised Proserv s MSC tool for its superior cutting capability and speed.

13 22 23 Conventional versus unconventional? In line with our ingenious simplicity philosophy and challenger brand mentality, Proserv is a champion of new methods that improve operation time and provide greater efficiencies for clients. Compared to the conventional method of using knives for severing wells, Proserv s multi-string cutting solution can sever multi-string casings in one trip. If the well is not cemented to the seabed, the use of mechanical knives can be particularly challenging due to this instrusive method. In a marketplace where cost, project efficiencies and vessel time are all huge driving factors in determining a project s viability and success, clients need to have confidence in the severance solution they have chosen. Proserv s multi-string cutting solution is reliable and predictable no matter what the well circumstances, and in certain situations the Proserv solution excels over rivals and the traditional alternative. Using the Proserv method, we can sever all casings and recover the wellhead in one single trip and in a fraction of the time (in a 300m well, with the annuli sealed, typical cutting time is approximately four to six hours). Explosives are another option for many organisations, however because of tighter HSE and environmental rules and regulations and the time it takes to seek permission in line with strict HSE guidelines, using explosives is often viewed as the very last resort. This method also has varying levels of success with no real control over the severance of the well. The following is an example of Proserv using its multi-string cutting solution over more traditional methods. We were looking for new technology and methods to improve and simplify P&A operations. Proserv s MSC tool provided the ideal solution for our needs, providing superior cutting capability and speed. - Global Subsea Contractor Client: Leading global independent operator Location: North Sea Project background The client has embarked on a programme of work to decommission a field in the North Sea. Proserv was engaged to supply a solution for the internal cutting and recovery of wells during March A semi-submersible drilling rig was contracted by the client to complete the work and Proserv deployed its Multi-String Cutting (MSC) equipment spread to complete the operation. Solution Proserv s MSC tool uses abrasive water jetting technology and was selected as the solution to conduct internal well severance. This method was chosen over traditional methods as it offered significant time savings and the adaptability to sever strings made up of differing IDs, cemented or un-cemented. Tooling to recover the severed wellheads was also mobilised allowing single trip severance and recovery. The cutting time for a three string well ranged between four and six hours with the eighth well campaign completed over the course of nine operational days. Conclusion This is the first rig-based well severance and recovery project completed by Proserv in the North Sea. The operation was completed ahead of schedule with well severance times exceeding client expectations. A strong collaborative effort between Proserv, the client and rig teams resulted in an efficient and successful campaign. The Proserv value Reliable cut of cemented or non-cemented casing strings Contactless cutting technology reduces risk of stuck in hole Single trip severance and recovery Adaptable tooling that can deal with various casing IDs Reduced vibration in drill string

14 24 25 An ingeniously simple smart solution for remote environments During these difficult times improving operational efficiency is key in adapting to changing conditions. Clients expect to have access to the same services wherever they are: on land, on board a supply vessel, rig or even an oil platform. At Proserv, we are continually breaking new ground with our R&D to help clients find new, more efficient and cost-effective ways to operate. One such example involved a client in the Middle East that had 800 onshore solar powered wells with basic hydraulic controls with no communication back to their control centre. Due to the amount, location and geographical spread of these panels they were only able to visit each well every four to eight weeks. Varying well pressures were tripping the panel and closing the well safety valves, losing up to 1000 BOE/D without any notification in some instances. The Proserv Smart Box Proserv developed the Smart Box, which was manufactured by our engineering teams in the Middle East as a realtime monitoring solution for evaluating onshore and offshore wells in remote sites. Unplanned shutdowns can cost operators up to 1% of total annual production and with the Smart Box, shutdowns are detected instantly avoiding prolonged production losses and lowering operating costs. The Smart Box is an intelligent device with an inbuilt GSM modem that collects information from production equipment at the well site then transmits alerts to personnel via GSM straight to a mobile device. This ingeniously simple technology solution can be embedded within any of our systems and customised to a client s exact specification for increased operational efficiency. This is a perfect example of how Proserv can use its extensive engineering capabilities to quickly develop a technical solution to solve a very particular client challenge and create significant cost savings. Sam Norris, General Manager for our operations in the Middle East & Africa, said: This is a great example of our engineering teams doing what they do best, which is actively seeking new ways in which we can improve the performance and reliability of our clients operations. For this particular example alone, it is believed we made considerable cost savings, which demonstrates the added-value Proserv can provide regardless of the environment or circumstances.

15 Our talent is our future. The challenging marketplace has shown how important a knowledgeable, flexible and well trained workforce is to the success of Proserv. Through the Proserv Academy, we are transforming the lives of our people by creating an aspirational learning and performance culture where our people can continually develop, thrive and reach their fullest potential. #makeithappen