Kvalifisering av ny teknologi

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1 Kvalifisering av ny teknologi Siemens AS Siemens Oil & Gas solutions - Offshore All rights reserved.

2 De tre viktigste tingene subsea: Pålitelighet Pålitelighet Pålitelighet

3 Hvorfor kvalifisering? Ved introduksjon av ny teknologi Usikkerhet omkring teknologiens pålitelighet/tilgjengelighet Ingen tidligere erfaring å bygge på Kanskje ingen relevante standarder å støtte seg til Ved introduksjon av eksisterende teknologi i nye omgivelser (for eksempel dypere vann) Usikkerhet omkring teknologiens anvendelighet og pålitelighet i de nye omgivelsene Begrensede tidligere erfaringer å bygge på Behov for å bekrefte at utstyret kan benyttes til det gitte formålet Page Copyright Oil & Gas All rights reserved 2011

4 Forholdet til kunden/sluttbruker Alt utstyr skal forventningsvis selges til/benyttes av en kunde/sluttbruker Ny teknologi/ny anvendelse usikkerhet om egnethet og pålitelighet Behov for tillit hos kundene/sluttbrukerne Dialog og samspill med kunden/sluttbrukeren gjennom kvalifiseringsprosessen er viktig! Bringe inn erfaringer kunden/sluttbrukeren har fra liknende teknologi eller anvendelser Bygge den nødvendige tilliten til teknologien Få aksept for at teknologien faktisk er kvalifisert! Page Copyright Oil & Gas All rights reserved 2011

5 Hva skal vi forstå med kvalifisering? In this document technology development is defined as the activities needed for bringing new technology up to a certain level of maturity. Technology qualification is defined as the additional activities required for implementation of this technology. Qualification (definition) Qualification is a confirmation by examination and provision of evidence that the new technology meets the specified requirements for the intended use. Hence, qualification is a documented set of activities to prove that the technology is fit for purpose. Page Qualification The process of demonstrating that an item has reached a particular level of technology readiness, whether that involves using existing technology in a new environment or new technology. Qualification is the process of providing the evidence that a technology will function within specific operational limits with a specified level of confidence. Copyright Oil & Gas All rights reserved 2011

6 Stikkord for kvalifisering In this document technology development is defined as the activities needed for bringing new technology up to a certain level of maturity. Technology qualification is defined as the additional activities required for implementation of this technology. Qualification (definition) Qualification is a confirmation by examination and provision of evidence that the new technology meets the specified requirements for the intended use. Hence, qualification is a documented set of activities to prove that the technology is fit for purpose. Qualification The process of demonstrating that an item has reached a particular level of technology readiness, whether that involves using existing technology in a new environment or new technology. Qualification is the process of providing the evidence that a technology will function within specific operational limits with a specified level of confidence. Level of maturity Fit for purpose Activities Process Page Copyright Oil & Gas All rights reserved 2011

7 Aktuelle standarder/prosedyrer for kvalifisering DNV RP-A203 API 17Q Egne prosedyrer/prosesser hos operatørselskapene Page API 17N Copyright Oil & Gas All rights reserved 2011

8 Kvalifiseringsprosessen Legg merke til at dette er en iterativ prosess med tilbakekoblinger til design hvis det identifiseres svakheter og/eller høy risiko. Qualification Basis Technology Assessment Refine Concept High risk identified Failure Mode and Risk Identification Deploy yes Conceptual weakness identified Teqnology Qualified? Performance Assessment Qualification Execution Develop Qualification Plan Abort no Page Copyright Oil & Gas All rights reserved 2011

9 Qualification Basis The Qualification Basis is mainly based on a product requirement specification (PRS) containing: System description Functional requirements System-wide requirements Functional architecture Interface requirements Reliability requirements Codes and Standards HSE requirements Other factors that are important for the Qualification Basis: Operating philosophy Maintenance strategy Page Copyright Oil & Gas All rights reserved 2011

10 Technology Maturity Assessment Divide technology into manageable elements Assess the technologies with respect to novelty Identify the main challenges and uncertainties related to the new technology Application area Technology Proven Limited New or unproven field history Known Limited knowledge New to Industry ) No new technical uncertainties 2) New technical uncertainties 3) New technical challenges 4) Demanding new technical challenges Class 1 elements is subject to a regular sound engineering process, with adequate quality assurance and quality control. Class 2 to Class 4 elements shall be qualified according to the work process described in the TQ recommended practice, to be Fit for purpose as applicable standards might not exist. Page Copyright Oil & Gas All rights reserved 2011

11 Technology Readiness Level (TRL) TRL Development Stage Completed Definition of Development Stage Concept 0 Unproven Idea Basic research, scientific/engineering principles observed and reported. No analysis completed Proof of concept Prototype Field Qualified 1 Analytically Proven Concept Concept and basic functionality proven by analysis. Not all technical requirements need to be met. 2 Physically Proven Concept Concept and novel features of design validated by physical model and functional tests in laboratory environment 3 Prototype Tested A prototype is built and put through (generic) functional and performance tests in laboratory testing environment 4 Environment Tested Designed and built as production unit or full scale prototype and put through qualification program in simulated environment (e.g., hyperbaric chamber to simulate pressure) or actual intended environment (e.g., subsea environment) but not installed or operating. 5 System Integration Tested 6 System Installed 7 Proven Technology Designed and built as production unit or full scale prototype and integrated into intended operating system with full interface and functional test but not usually in intended field environment. Full interface and functional test program performed in intended or closely simulated environment and operated for less than 3 years Production unit integrated into intended operating system, installed, and operating in same environment and operating conditions for more than 3 yr with acceptable reliability, demonstrating low risk of early life failures in field. TRL (according to API RP17N) can be used as an extended Technology Assessment and as a tool to determine progress in the qualification process The technology qualification process usually goes up to TRL 5 The TRL can be used to classify technology supplied by vendors Page Copyright Oil & Gas All rights reserved 2011

12 Failure Mode and Risk Identification FMECI Purpose: 1. Input for qualification plan, high risk failures and focus areas for qualification 2. Give a critical review of the design, detect weaknesses and identify key elements in design Page Copyright Oil & Gas All rights reserved 2011

13 Failure Mode and Risk Identification FMECI FMECI workshops, should involve a panel of experts covering the necessary fields of competences and experiences Gather data in a FMECI worksheet (Failure Mode and Effects Criticality Identification worksheet) (Guidance in IEC 60812) Copyright Oil & Gas All rights reserved 2011 Page

14 Failure Mode and Risk Identification Do a Risk Ranking of the failures identified (as part of the FMECI) Depending on the complexity of the project, an FTA (Fault Tree Analysis) or RBD (Reliability Block Diagram) can be performed to increase failure coverage Loss of control of an SCM G001 Loss of Subsea network G003 After the Failure Mode and Risk Identification there might be required changes or improvements to be made on the design, they should be implemented at this stage Qualification as iterative process Loss of Subsea control link A A.4 Loss of Subsea control link B U002 Same as loss of link A Page Copyright Oil & Gas All rights reserved 2011

15 Risk Ranking Example Failure Mode and Risk Identification Probability 1 Not expected to occur during system s lifetime 2 Expected to occur once in system s lifetime 3 Expected to occur more than once in system s lifetime 4 Expected to occur more than once in five year 5 Expected to occur more than once in one year Consequence Equipment Health and Safety Environment 1 Insignificant Insignificant Insignificant 2 Reduced main function Minor, a few lost workdays Minor 3 Partly loss of main function Major, long term absence Moderate 4 Loss of main function Single fatality, permanent disability Considerable 5 Major equipment damage Multiple fatality Severe Page Copyright Oil & Gas All rights reserved 2011

16 Develop Qualification Plan Qualification shall focus on the areas of high technological uncertainties, and shall demonstrate that the design meets the requirements and that all failure modes are addressed Qualification can be done by: Documented experiences Numerical analysis Testing Procedural precautions The selected qualification method shall: Address the identified failure modes of concern Reduce uncertainties and risks Document sufficient margin to failure Qualification method and acceptance criteria shall be well defined Page Copyright Oil & Gas All rights reserved 2011

17 Procedural precaution?? Page Copyright Oil & Gas All rights reserved 2011

18 Develop Qualification Plan The Qualification Plan is a document that describes all relevant qualification activities that will be undertaken the master plan! The qualification plan contains: Overview of all qualification activities - the Qualification Matrix Qualification methods Acceptance criteria Time plan Cost estimate The input to the qualification plan is The system requirements The identified failure modes TRL can be used to track the progress of the qualification Page Copyright Oil & Gas All rights reserved 2011

19 The Qualification Matrix Overview of qualification activities connecting component ID, failure mode ID and activity ID. Activity ID Failure mode ID Compone nt ID Component n.m-y n.m-x n.m Component name Hy Fun Age An Others Qual. Method Qualification description Test site Title and reference to test procedure Where to test Customer witnessing Mark if wanted Test report reference Reference to test report(s) Outcome of qual. Activity Deploy/ Abort/ Redesign Page Copyright Oil & Gas All rights reserved 2011

20 Test procedures Complex systems will require qualification in several steps Tests will be necessary for multiple components and subsystems until a final prototype can be built and tested. Detailed descriptions with acceptance criteria for each test cannot be included in the qualification plan it will be far to extensive! Each test described in detail in a test procedure Test object Test description Test equipment Acceptance criteria HSSE requirements Relevant references Page Copyright Oil & Gas All rights reserved 2011

21 Qualification Execution Analysis and testing is performed according to the qualification plan and test procedures Tests performed by vendors shall be witnessed as necessary Test setup, execution and results shall be sufficiently documented so the test can be remade under the same conditions if necessary test procedures Results of tests are reported in separate test reports Results of ananlyses are reported in dedicated analysis reports Page Copyright Oil & Gas All rights reserved 2011

22 Performance Assessment The Performance Assessment shall verify that all acceptance criteria are met A reliability analysis shall be made based on the data from the Failure Mode and Risk Identification, updated with the data obtained from the Qualification Execution An updated FMECI, FTA, RBD or another reliability method should be used to demonstrate that performance and reliability targets are met and that all failure modes are addressed Page Copyright Oil & Gas All rights reserved 2011

23 Kvalifiseringsprosessen Qualification Basis Technology Assessment Refine Concept High risk identified Failure Mode and Risk Identification Deploy yes Conceptual weakness identified Teqnology Qualified? Performance Assessment Qualification Execution Develop Qualification Plan Abort no Page Copyright Oil & Gas All rights reserved 2011

24 Utfordringer i kvalifisering Forholdet til standarder/normer! Standarder som tilsynelatende er gjeldende, men som ikke dekker den nye teknologien eller den nye anvendelsen. Fullstendig mangel på standarder. Page Copyright Oil & Gas All rights reserved 2011

25 Utfordringer i kvalifisering Når er vi i mål? Når kan vi si at en teknologi er kvalifisert? Ulike syn hos kunde/sluttbruker og leverandør Behov for godt samarbeid Fare for overspesifisering behov for standarder Page Copyright Oil & Gas All rights reserved 2011

26 Misforståelser kan være en mulig feilårsak Page Copyright Oil & Gas All rights reserved 2011

27 Siemens Subsea Power Grid - Enabling Subsea Processing further Takk for oppmerksomheten! - og takk til mine gode kolleger John Dawes og Andreas Karvonen for verdifull input Copyright Oil & Gas All rights reserved 2011 Page

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