Risk Minimization by the Use of Failure Mode Analysis in the Qualification of New Technology—Recent Project Experience in Completions and Sand Control

Abstract

Abstract This paper reports on a Reliability Assessment Program for sand control completion technology. The Failure Modes Effects and Criticalities Analysis (FMECA) method was used to provide a systematic reliability assessment, identifying and ranking critical issues and potential improvements focused on those criticalities. The FMECA process is an integral piece of the qualification program for the operator's new technology developments. The FMECA analysis was utilized by the operator to provide assurance in the technical and functional capability of the new technology systems. A detailed systematic approach provided opportunities to identify potential risks and mitigate them prior to operations. The process helped identify potential issues, otherwise possibly not considered. The importance of this process is critical given the current trend of more complex completion designs in increasingly adverse conditions. The increasing capital completion cost for subsea, high pressure, high temperature (HPHT), deeper, and more complex systems necessitates a high level of assurance and long-term sand control integrity. The main objectives of the FMECA projects were - ➢to produce a reliability assessment of the system;➢to identify the critical aspects that need engineering resources focused on them;➢to identify key actions to address those critical aspects and reduce the risks. The systematic approach for FMECA entailed 4 key steps - Compiling the baseline system documentation set;Establishing suitable ranking criteria for Severity, Probability of Occurrence and Detectability;Identifying and exploring the failure modes;Finally, analyzing the FMECA results to highlight critical failure modes, and producing a key actions list, addressing all of those critical failure modes. The detailed analysis provided graphical views of the data to highlight points of concern and focus on key issues to mitigate during the technology implementation. The failure modes exhibited a wide range of RPN (Risk Priority Number) values, allowing those of most concern to be easily identified. We identified more than 30 failure modes of concern for each project (out of more than 130 failure modes detailed in total). They were highlighted in the FMECA sheets, and extracted as a Key Actions list for implementation by the project team. The value was realized from the rigor in the design and qualification process, identified QA/QC measures, implementation efficiency, and risk mitigation for future application. The identified failure modes produced a list of issues that could potentially jeopardize a well, production, reserves, or millions of dollars of expenses if not mitigated. Each identification of a potential failure mode, along with the risk mitigation actions, contributed to an increased chance of success. The quality of the results depended on the amount of challenge and creative input offered in the workshops. Diligence to the process and communication of actions are key to the success of a failure mode analysis for new technology.