Quality Management system to Enhance Offshore & Subsea ESP Run life and Reliability Reda Elmahbes Baker Hughes / Mohamed Elmhabbes Saipem Libya

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1 Quality Management system to Enhance Offshore & Subsea ESP Run life and Reliability Reda Elmahbes Baker Hughes / Mohamed Elmhabbes Saipem Libya ABSTRACT Offshore and subsea wells present multiple challenges for conventional Electrical Submersible Pumping System ESP. As conventional ESPs have much shorter run lives compared to the filed life and the intervention cost for Subsea and offshore application are very expensive, demanding ESP system with longer run life is a necessity to economically produce from those types of wells. This paper discusses how Quality Assurance QA and Quality Control QC systems to enhance ESP system run life. Moreover, this paper illustrates Quality Management System as a business strategy designed to add value to customers and satisfying all their requirements. In any integrated ESP subsea or offshore system, overall reliability is a function of reliability of each equipment; therefore, assuring reliability and quality for each component in the equipment is crucial to extend overall run life for the system and reduce well intervention cost. All manufacturing process supported with the QA&QC requirements such as Documentation, Monitoring, Measurement, Audit, Equipment Traceability, Dimensional Conformance, Witness Test, Vibration Test, and Factory Acceptance are to improve ESP system reliability and significantly increase system run life. This paper describes the benefit of the QA & QC systems to boost ESP system run life and enhance reliability in subsea and offshore application, where the intervention cost is significantly expensive. Reduce well intervention helps the customer to lower operational expenditure OPEX and down time related to ESP failures due to quality issues. Also, decrease optional of any health, safety, and environment HSE incident related to rig work over operation. The proposed solution helped the operator to improve overall ESP system run life and reliability. It also helped the customer to reduce OPEX, well down time, and potential HSE risk related to well intervention and work overs. INTRODUCTION Saipem is a major player off Mediterranean Sea with interests in every major oil & gas exploration and production operations. With high cost of intervention especially for offshore operation, the need of longer production system runlife is essential to economically produce and operate the offshore wells. In today s environment, where reduced budgets, enhance safety, and aggressive schedules are becoming customary, a higher emphasis on procedural and equipment quality and reliability is imperative to ensure that the end product will meet the performance standards that are required and expected. Subsequently Baker Hughes Oil & Gas services Artificial Lift system division developed an innovative approach to implementing QA & QC for all Saipem offshore ESP operation in general and for the

2 emergency booster pump specifically. Figure 1 shows typical booster pump configuration which Saipem currently using. Fig 1 Saipem ESP Booster& Subsea System The Saipem subsea system project was managed by Baker Hughes quality department team based in Claremore, Oklahoma. The quality department helped to implement and execute the quality plan to manufacture, assemble, test, and deliver the ESP system. By treating the each component of the ESP as a system, planning and execution of quality assurance actions can reduce the level of risk associated with motor, pump, seal, cable, and downhole gauge failures. The implementation of Baker Hughes QA & QC enhanced the overall performance of ESP system and extends the system runlife. Saipem project requirement The following table shows Saipem reference codes and standards requirements: Table 1 Saipem Reference Codes & Standards Code & Standards Reference Part 4: Subsea Wellhead and tree ISO Design and operation of subsea production systems equipment Part 6: Subsea Production control ISO Design and operation of subsea production systems systems ISO Design and operation of subsea production systems Part 8: Remotely operated vehicle DNV 158 Rules for Planning and Execution of Marine Operations Part 2 Chapter 5: Lifting API RP 2A WSD Recommended Practice for planning, designing and construction of fixed offshore platforms Working stress design ISO Pipeline Transportation System Subsea Pipeline Valves DNV OS D201 Electrical installations DNV STANDARD FOR CERTIFICATION Lifting appliances API RP 11S3 Recommended Practice for Electrical Submersible Pump Installations API RP 11S4 Recommended Practice for Sizing and Selection of Electric Submersible Pump Installations API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries

3 Quality requirement for subcontractors In general, Contractor has Quality requirements for the subcontractors which are all described in specific project procedure; this procedure defines the minimum Quality Requirements to be fulfilled by SUBCONTRACTOR in order to ensure implementation of the Project Quality Management System defined for the subsea system project, the procedure describes : Subcontractor responsibilities Activity description: Quality assurance activities Quality control activities Control of fabrication process Identification and traceability Storage and handling of material equipment Control of monitoring and measuring devices Inspection notification Inspection statues Reports Report of inspections (certificates) Applicable QCR/ITP for project QCP Project Quality Management System (QMS) Structure The QMS which was implemented for Saipem subsea system project consists of four main levels as shown in the figure 2. Fig 2 QMS Levels Level 1 includes quality policy statement, framework, objectives, and quality manual and could be summarized as follow:

4 The Quality Policy Statement and Framework establishes the overall intentions, direction and executive management s affirmation of Baker Hughes quality commitment to comply with requirements and continually improve the effectiveness of the quality management system. Quality Objectives are established annually to further the overall goal of satisfying the project requirement. The objectives, progress towards meeting the objectives and the role all employees play in meeting objectives are communicated to employees throughout the organization. The Quality Manual establishes the scope and requirements of the Quality Management System, establishes justifications for exclusions to the International Standard/Specification and provides an explanation of the interaction of the processes in the system. The Quality Policy Statement, Framework and Manual are inherently linked and reviewed concurrently to ensure they form a consistent and coherent system. Level 2 include documents which specified methods to carry out an activity or process. The documentation define the responsibilities, authorities and what activities for implementing the quality system in accordance with the requirements of the developed quality manual for the project. Each Level 2 document should reference applicable Level 3 document, Level 4 forms, and resulting records. Level 3 documents detail the acvies on how to accomplish specific tasks necessary to ensure the effective planning, operation and control of an activity or process. Some Level 3 documents may reference forms that, once completed, may become quality records. Some forms may be considered Level 3 documents, if the requirements of the form are inherently obvious Level 4 includes forms, records and reference documents which could be summarized as follow: Forms. Provide for an organized recording of information/data gathered when performing specific tasks related to the quality management system. Work instructions will reference those forms that apply. Records. Provide evidence that processes and specifications have been performed according to specified requirements. Reference Documents. Copies of these documents required to design and manufacture products and operate the quality system are maintained, including externally controlled documents. Project Quality Assurance (QA) Quality assurance is being achieved in the Saipem offshore and subsea project through the implementation of documented QMS. This system provides the organizational structure, procedures, processes and resources to be utilized by Baker Hughes to manage Saipem Project. Systematic implementation, monitoring and follow up of the QMS provides assurance of the QA & QC requirements such as Documentation, Monitoring, Measurement, Audit, Equipment Traceability, Dimensional Conformance, Witness Test, Vibration Test, and Factory Acceptance.

5 Project Quality Plans The strategy provides Saipem with the framework to help them develop the quality plans, quality control, and project quality plan (PQP) for the project in uniform and consistent manner. These plans set out the project quality objectives, identify (QA & QC) activities and processes necessary to achieve quality objective to enhance the runlife of the system and to focus the attention on the prevention of nonconformities. The project Quality Plan defines the Project Quality management system that will be applied by Baker Hughes for the execution of the Project The Saipem subsea system project. In particular it specify all the Quality requirements to be applied during all the stages of the project, the project procedures issued to support the project work process and the QA & QC activities, to be conducted to achieve the Quality objectives of the project. The PQP shall enable the project management to assess the Quality objectives and to focus the attention on the prevention of nonconformities Project Quality Implementation Baker Hughes quality management team is responsible for ensuring that quality plans and associated processes and procedures are effectively implemented and verified. The quality management team is also responsible for assuring the quality related policies and strategies are clearly understood by employees. Understanding the quality process is crucial to the implementation plan to meet the target runlife of the ESP system. The following is the summary of the quality process and implementation plan for Saipem subsea system project. Equipment Inspection and Testing Plan for Saipem subsea system Project Multiple analysis were evaluated to ensure that all necessary equipment inspection and testing is performance before equipment delivery. List of checks, inspections, and testing are displayed in the table below. Table 2 Testing & Inspection Plan ITEM BASIC DESCRIPTION OF CHECKS AND TESTS Baker Hughes 1. AFTER CONTRACT AWARD (before manufacturing) ACTION CODE Saipem 1.1 SUPPLIER's and Sub Vendors Inspection and Test Plan (ITP) 1.2 Pre-inspection meeting 1.3 Sub Vendors List 1.4 Copy of main sub orders and checking description 1.5 Inspection schedule (revised on monthly basis )

6 Manufacturing and Inspection Procedures (before start of manufacturing) Manufacturing procedures (traceability, cutting, beveling, rolling, heat treatment, painting, repairing etc ) Welding procedures with qualification approval, repair and welders qualification 2.3 NDT procedures and NDT operator qualification 2.4 Testing procedure (pneumatic, hydro-test, visual & dimensional, etc) 2.5 Painting & pickling/passivation procedure 2.6 Dossier to be prepared by SUPPLIER for local regulation (CS) 3. DURING FABRICATION (for any relevant part or auxiliary) 3.1 Checking of instrument calibration (transmitters, orifice plate, actuated valve) 3.2 Raw material certificates checking INCLUDING welding consumables and baseplates, auxiliaries equipment, 3.3 Welding Witness Heat treatment ( checking of thermocouples, diagram review) NDT tests : - Pump housing, Pumps pipe caisson Casing/casing welding/shaft/impeller/gas, recycling oil & chemical lines piping - welding Welding/ impellers/journal bearing Witness/ 3.6 Hardness test 3.7 Review of SUPPLIER Data Book when fabrication progress is at 50% 3.8 Electrical and instrumentation cable testing (continuity, isolation) 3.9 Electrical equipment insulation resistance and continuity test 3.10 Valves tests (Valves stroking and functional testing of installed instruments and control valves) 4. HYDROSTATIC TEST 4.1 Internal and external visit before hydro-test (ID and thickness) N/A

7 4.2 Test parameters check (including water analysis) N/A 4.3 Hydrostatic tests for pumps package including at least (but not limited to) : - Fabricated pump housing, - Pressure casing for subsea control system, - Piping (Gas line, Pump Recycling system line, - Chemical line and oil line), - Body of valves for control and safety valves 4.4 Mfr s nameplate stamping and certificate record 4.5 Pneumatic tightness test Witness 4.6 Helium test (when applicable) Witness Pneumatic test for control valves (seal-plug seal / Actuator shell & diaphragms seal) Pneumatic test for safety valves (disk-nozzle seal, bellows seal) Witness Witness 4.9 Cleaning & drying Witness 5. Balancing Test 5.1 Balancing test of rotor components Witness 5.2 Overspeed test of rotor components Witness Dye penetrant check and dimensional check after overspeed Individual balancing of rotor components & dynamic balancing test of rotor Witness Witness 5.5 Overspeed test of rotor Witness 5.6 Clearances check Witness Functional and Performance Test Inspection before test (Accessibility, insulation check, fire protection check, material physical integrity, cleanliness, supporting, equipment levelling..., quantity, tests and measurement, etc.) Performance test for Pump as per API610 for each operating condition Variable Speed Drive System (VSD) Test: - Transformer Routine test & Type Test (the last only for one unit in case of several VSD) Converter Routine test & Type Test (the last only for one unit) - Combined Test: including HV motor, converter and feeding Transformer 6.6 Complete unit test full load / full speed including job Variable Speed Drive System (VSD) Test

8 6.7 Torsional vibration measurement shall be specified if SUPPLIER recommends it. 6.8 ise and vibration measurement N 6.9 Inspection after test and dismantling, check of cleanliness 6.10 Visual and dimensional check 6.11 mechanical running test of spare pump if any N/A 6.12 mechanical running test of spare pump rotor and electric motor N/A 7. AUXILIARIES TEST 7.1 Functional check of local control panels Witness 7.2 Functional check of local control panels Witness 7.3 Control system UCP FAT during the complete witnessed unit test (full load string test) Witness 7.4 Vibration monitoring module tests and certificates Witness 7.5 Calibration certificates review of instrumentation Witness 7.6 Explosion proof certificates review for electrical, instrumentation parts, Mechanical protection 7.7 Instrument tubing to be leak tested. Witness N/A 8. FINAL INSPECTION BEFORE SHIPMENT 8.1 Visual inspection & cleanliness 8.2 Flange protection, pipe checking 8.3 Marking, tagging & nameplate checking 8.4 Dimensions & quantity checking 8.5 Painting checking (visual, thickness, color, sample, certificates ) Witness 8.6 Certificates review 8.7 Weight, dimensions, center of gravity, lifting points

9 8.8 Earthing connection check, electrical continuity check 8.9 Visual inspection of Spare parts for commissioning & start-up, 6 months & 2 years operation, and Capital spare parts: visual and quantity, identification check 8.10 Visual inspection of special tools, storage special tools 8.11 Visual inspection of spare pump rotor, spare electric motor, spare pump seal system or spare pump if any 8.12 Inspection release note issue 8.13 SUPPLIER data book review (100%) 9. PACKING INSPECTION And / Or EXPEDITING Review of packing list and shipping documents Witness Packing checking (as per applicable documents) Witness Preservation for shipment checking Witness Transportation and Handling procedure and transport drawings review 10. FINAL DOCUMENTATION REVIEW Final dossier for local regulation SUPPLIER data book (copies and CD-Rom) Equipment Identification and Traceability for Saipem Project For this project Baker Hughes establishes and maintains procedures for identifying product by suitable means from receipt of raw material and purchased items and during all stages of production, delivery and installation. Components are identified per the requirements specified on engineering drawings. Identification may be by stamping, etching, bagging, I.D. plate or tagging, depending on the material and geometry of the part being identified. Written specifications document the information to be identified on components. Written procedures maintain the documented traceability of components and assemblies. Traceability to the batch number is maintained for polymers and elastomers. The documents used in providing traceability include: Material test reports (chemistry, mechanical properties, etc.), n destructive reports, Shipping reports Certification reports as required.

10 Electronic or hardcopy documentation necessary to provide traceability is maintained as a part of the quality records system, which provides for retention, maintenance, disposition, retrieval, and protection against loss or damage. In addition, Multiple analysis were evaluated to ensure that all necessary equipment inspection and testing is performance before equipment delivery. List of equipment identification and traceable sub components is showing in the following tables. Motor Traceable Components: Table 3 Motor Traceable Components Component Head Base Shaft Stator Housing Lower Tandem Motor Adapter Lower Tandem Reservoir Housing Magnet Wire Stator Adapter Flange Fasteners Elastomers Carbide Sleeves, Bushings & Inserts Seal Traceable Components: Table 4 Seal Traceable Components Component Head Base Shaft Housing Coupling Guides Mechanical Seal Expansion Element Flange Fasteners Elastomers Carbide Sleeves & Bushings

11 Pump Traceable Components: Table 5 Pump Traceable Components Component Head Base Shaft Housing Coupling Intake Discharge Impellers Diffusers (includes bottom diffusers) Top Bearing Bearings Flange Fasteners Elastomers Carbide Sleeves & Bushings Intake Traceable Components: Table 6 Intake Traceable Components Component Body Shaft Coupling Flange Fasteners Carbide Sleeves & Bushings Motor Lead Extension Traceable Components: Table 7 Motor Lead Extension Traceable Components Component Polyimide Film Armor Insulation Lead Barrier Tube Pothead Housing Elastomer

12 Variable Speed Drive Traceable Components: Project Audit Program Table 8 Variable Speed Drive Traceable Components Component Printed Circuit Boards Enclosure To endure continuing process compliance and identify improvement opportunities, qualified competent auditors review the processes defined in the relevant documentation procedures. A schedule of audit of the Saipem project is approved by management and amended during the project to ensure that the systems of control are continually reviewed for effectiveness. This ensures that reliable products and services that will meet and exceed project requirements, including compliance with industry standards, relevant statutory legislation and regulations. Project Quality Management Value Added Effective quality management is a key component of the ESP runlife enhancement for the Saipem subsea system project. Implementing such a system helped Saipem to achieve the runlife target for the ESP system and maximize their Key Performance Indicators (KPI). Also, the quality management process helped Saipem to reduce OPEX, well down time, and potential HSE risk related to well intervention and work overs. The following table summarizes the runlife improvement for ESP system which is installed in the Saipem project with implanting improved quality management and ESP system with standard quality system. Table 7 Runlife Improvement implementing new QMS Implementation of Saipem Project Quality Management system Implementation of Standard Quality Management Average ESP runlife 5 Years 2.5 years As shown in Table 2, the runlife and system reliably is doubled with the implementation of the enhanced QMS. Implementing the QMS helped Baker Hughes to identify any equipment ESP equipment, components, and sub component malfunction which contribute to avoid failures and improve system reliability. Applying the QMS helped Saipem to achieve the target runlife for ESP system and economically produce using the ESP technology. Enhancing the runlife of the ESP system save millions of dollars for Saipem where the average cost for well intervention is 0.5 million dollar per day. The estimate average cost saving per intervention is around 2.5 million. The following table shows a comparison of average workover cost in 10 years applying different quality management.

13 Table 8 Workover Cost Comparison between Standard & Saipem Project Quality Management Average Workover Cost in 10 Years Workover Cost for ESP implementing Standard Quality Management Workover Cost for ESP implementing Saipem Project Quality Management 10 Million USD 5 Millions USD Conclusion Quality Assurance and Quality Control is an important and valuable segments of any offshore and subsea operation. For effectiveness, it needs to be consistent in plan and personnel, from conceptual design, through manufacturing, equipment traceability, testing and installation. Projects especially the ones with high OPEX cost should maintain quality assurance and quality control effort in conjunction with the engineering effort to ensure that QMS is actually realized. Even though the cost of applying enhanced QMS is high compare standard QMS, the cost of equipment failure is significantly higher. The results shows that implementing the right QMS plan can tremendously reduce the OPEX and economically produce form those types of wells. References 1. Dinkins, W., Lana, D, ELmahbes, R.: ENI Saipem Temp Subsea Booster, Baker Hughes Project Neely, B., Gipson, F., Clegg, J., Wilson, P., Capps, B.: Selection of Artificial Lift Method, 2000 SPE Annual Technical Conference and Exhibition. 3. Dr. Robert C. Byrd, PE, Donald J. Miller, Steven M. Wiese: Cost Estimation for Offshore Oil & Gas Facility and Decommissioning, 2014 AACE International.