Risk Minimization by the Use of Failure Mode Analysis in the Qualification of NewTechnology-Recent Project Experience in Completions and Sand Control

摘要

This paper reports on a Reliability Assessment Program forrnsand control completion technology. The Failure ModesrnEffects and Criticalities Analysis (FMECA) method was usedrnto provide a systematic reliability assessment, identifying andrnranking critical issues and potential improvements focused onrnthose criticalities. The FMECA process is an integral piece ofrnthe qualification program for the operator's new technologyrndevelopments.rnThe FMECA analysis was utilized by the operator to providernassurance in the technical and functional capability of the newrntechnology systems. A detailed systematic approach providedrnopportunities to identify potential risks and mitigate themrnprior to operations. The process helped identify potentialrnissues, otherwise possibly not considered.rnThe importance of this process is critical given the currentrntrend of more complex completion designs in increasinglyrnadverse conditions. The increasing capital completion cost forrnsubsea, high pressure, high temperature (HPHT), deeper, andrnmore complex systems necessitates a high level of assurancernand long-term sand control integrity.rnThe main objectives of the FMECA projects were –rn€ to produce a reliability assessment of the system;rn€ to identify the critical aspects that need engineeringrnresources focused on them;rn€ to identify key actions to address those criticalrnaspects and reduce the risks.rnThe systematic approach for FMECA entailed 4 key steps -rn1. Compiling the baseline system documentation set;rn2. Establishing suitable ranking criteria for Severity,rnProbability of Occurrence and Detectability;rn3. Identifying and exploring the failure modes;rn4. Finally, analyzing the FMECA results to highlightrncritical failure modes, and producing a key actionsrnlist, addressing all of those critical failure modes. The detailed analysis provided graphical views of the data tornhighlight points of concern and focus on key issues to mitigaternduring the technology implementation. The failure modesrnexhibited a wide range of RPN (Risk Priority Number) values,rnallowing those of most concern to be easily identified.rnWe identified more than 30 failure modes of concern for eachrnproject (out of more than 130 failure modes detailed in total).rnThey were highlighted in the FMECA sheets, and extracted asrna Key Actions list for implementation by the project team.rnThe value was realized from the rigor in the design andrnqualification process, identified QA/QC measures,rnimplementation efficiency, and risk mitigation for futurernapplication. The identified failure modes produced a list ofrnissues that could potentially jeopardize a well, production,rnreserves, or millions of dollars of expenses if not mitigated.rnEach identification of a potential failure mode, along with thernrisk mitigation actions, contributed to an increased chance ofrnsuccess.rnThe quality of the results depended on the amount ofrnchallenge and creative input offered in the workshops.rnDiligence to the process and communication of actions are keyrnto the success of a failure mode analysis for new technology.