Bp Subsea Reliability Implementation Manual

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Reliability Implementation Manual

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Implementing Subsea Reliability Improvement in Projects

“IT MUST WORK” Issue Date: November 2006 Downloaded Date: 05/17/2007 05:49:52 The latest update of this document is located in the BP ETP and Projects Library

Foreword

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To be prepared by Andy Ingels at the request of Dave Brookes due in November 2006

Foreword Reliability Implementation Manual

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Executive Summary The BP Subsea Reliability Strategy, presented in The BP Subsea Reliability Strategy, A guide for BP Leaders [1], aims to improve reliability performance of equipment, increase first year operability, and reduce early life failures within subsea systems worldwide. This document develops the strategy principles first introduced in the original publication, in April 2003, of this guide for BP Leaders and identifies how these can be adopted into BP subsea projects. GP 78-03, Guidance on Practice for Achieving Reliability in Subsea Projects [2], requires the use of this manual to identify the required Reliability Tasks necessary to meet the requirements of the strategy. GP 7804, Guidance on Practice for Reliability Techniques for Subsea Projects [3], similarly requires the appendices to this manual to implement the required Reliability Tasks in projects. This manual is included in the ETP library for use with GP 78-03 and GP 78-04. The use of GP 78-06, Guidance on Practice for Subsea Prototype Qualification Procedure [4], and GP 78-26, Guidance on Practice for Subsea Reliability and Maintenance Data Collection [5] is required by GP 78-03, GP 78-04 and this manual.

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Define reliability and maintainability goals and requirements for the system under development, and link to the BP CVP and other relevant BP processes Plan Reliability Tasks by CVP stage to meet the reliability and maintainability goals and requirements Design the system to meet the reliability and maintainability goals and requirements (where possible) Provide assurance that the requirements have been met and assurance of the extent to which the goals have been met Capture and feedback reliability data into BP lessons learned databases and those of suppliers as appropriate.

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Ten specific Reliability Tasks have been developed to enable subsea projects to implement the Reliability Strategy by achieving the following objectives:

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The aim is that GP 78-03 and GP 78-04 together with this manual, GP 78-06 and GP 78-26 will provide a consistent approach to achieving reliability across all BP subsea projects and will convey a clear and consistent message of the requirements through the procurement cycle. The key tasks for reliability achievement are grouped by CVP stage with flowcharts and tables defining how and when different activities should be completed. For each CVP stage a Reliability Task table provides guidance on specific activities and associated timing. However, they do not prescribe exactly how the work will be carried out or by whom. This is deliberate. Every project is different. Teams should make judgements on how to implement the strategy according to the resources and skills available. A set of comprehensive appendices support the task tables with more detailed guidance. The technical risk categorisation task (R1) assesses the level of technical risk within the subsea project. This enables the user to determine the importance of each of the Reliability Tasks, identify the reliability effort required for the project and implement the requirements of GP 78-03, GP 78-04 and this manual accordingly.

Executive Summary Reliability Implementation Manual

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Contents 1

EXECUTIVE SUMMARY

2

CONTENTS

3

1.

INTRODUCTION

4

2.

EVOLUTION OF THE RELIABILITY STRATEGY TO DATE

6

3.

RELIABILITY ACTIVITY REQUIREMENTS BY CVP STAGE

8

4.

HOW TO USE THIS MANUAL - WORKED EXAMPLE

12

5.

THE ROLE AND RELATIONSHIP OF QM TO RELIABILITY

17

6.

VERIFICATION AND VALIDATION OF RELIABILITY TASKS

18

7.

APPRAISE STAGE RELIABILITY TASKS

19

8.

SELECT STAGE RELIABILITY TASKS

23

9.

DEFINE STAGE RELIABILITY TASKS

10.

EXECUTE STAGE RELIABILITY TASKS

11.

OPERATE STAGE RELIABILITY TASKS

12.

GLOSSARY

13.

LINK TO RELIABILITY STANDARDS

14.

REFERENCES

15.

BP CONTACTS AND CHAMPIONS

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FOREWORD

29

50 54 56 57 58

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36

Technical Risk Categorisation

Appendix R2

Defining R&M Requirements

Appendix R3

Reliability Planning

Appendix R4

Reliability Assurance

Appendix R5

Reliability Value Analysis

Appendix R6

Reliability Analysis and Modelling

Appendix R7

Design & Manufacture for Reliability

Appendix R8

Contractor & Supplier Selection & Contracting

Appendix R9

Reliability Data Collection and Lessons Capture

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Appendix R1

Appendix R10 Reliability Qualification Activities

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1.

Introduction

The purpose of The Reliability Implementation Manual is to offer guidance on how the BP Subsea Reliability Strategy should be implemented within subsea projects. The majority of subsea projects undertaken by BP involve development or enhancement of equipment and systems. This Reliability Strategy aims to improve reliability performance of equipment, increase first year operability, and reduce early life failures within our subsea systems worldwide, and can be summarised by the following graph.

Design Designout outall all Foreseeable Foreseeableearly earlylife lifeand andthrough throughlife lifefailures failures Wear out Failures

Remove RemoveororMinimize Minimize foreseeable foreseeablethrough throughlife life failures failures

Decommission Decommission before before wear wearout out

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Remove Remove expensive expensiveearly early life lifefailures failures

Random Failures

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Failure rate

Early Life Failures

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Reliability Strategy Goal

Operating time

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Historical performance

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This document develops the principles contained in The BP Subsea Reliability Strategy, A guide for BP Leaders [1] (The Strategy Guide) and identifies how these can be adopted into subsea projects. It provides the necessary supporting guidance required by GP 78-03, Guidance on Practice for Achieving Reliability in Subsea Projects [2], and GP 78-04, Guidance on Practice for Reliability Techniques for Subsea Projects [3], to implement the BP Subsea Reliability Strategy within BP subsea projects.

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New technology development projects and field development projects using novel equipment / new technologies will inevitably involve a significant level of design and qualification testing and this manual interfaces with the qualification requirements of GP 7806, Guidance on Practice for Subsea Prototype Qualification Procedure [4]. The practices in this manual, though designed for field development projects, may therefore also provide useful guidance to achieve improvement in technology reliability for new technology developments projects. This manual is relevant for all subsea system equipment likely to be included in the subsea procurement specification. The following diagram describes a typical subsea system. Design analysis techniques for different types of equipment will mean that the interpretation and application of the guidelines outlined in this manual may be slightly different for different types of subsea equipment. It is also important to note that the approach that has been developed is not limited in application to subsea, and has the potential to be applied across projects in all disciplines. Importantly for the reliability of subsea projects to continue to meet BP requirements and continue to improve with time, collection of performance data is essential. GP 78-26 [5] defines the requirements for data collection as recommended by this manual. In addition to this manual’s alignment to CVP, it is also closely linked to and supports the objectives of other BP processes such as Front End Loading (FEL) and Value Improvement Processes (VIP), referenced amongst others, in the Major Projects common process (MPcp). Introduction Reliability Implementation Manual

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PRODUCTION FACILITY Master Control Station Power/ Comms Unit

Hydraulic Power Unit Chemicals Choke/sep metering

SUPPORT VESSEL

DRILL RIG

Intervention Surface Support

Surface tree (upper safety block)

• Controls • Umbilical • Lift • Heave comp. • ROV

Workover control system • HPU • Master contr. unit • Umbilical reels • Surface tree shut down panels • ESD panels • Local control point

Surface tree adaptor joint Riser tension joint

Pipelines or umbilical hangoff/term.

Tool carrier(s)

W.O. riser joints

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Umbilical

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Stress joint

Misc. tools for sea line pull in/connections, running of contr. module, pig launcher, protection structure, etc.

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Risers

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SEA LEVEL

Import riser base or tie-in spool

Export riser base or tie-in spool

Emerg. D’.connect Pk Lower riser pack Tree protection struc.

Tools for running of tubing hanger, tree cap, etc.

Tree cap Control module

Tree

Choke Tubing hanger

Manifold / distribution module

Prod. Guide base

Foundation structure (could be common for trees and manifold)

Downhole sensors/valves Packer Reservoir

Diagrammatic Representation of a Typical Subsea System

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2.

Evolution of the Reliability Strategy to Date

The BP Subsea Reliability Strategy, first introduced in 2003, is based on closely interlinked processes identified as key to achieving competence in reliability management. The identified processes fall into three main categories that have the underlying themes of Identification, Implementation and Investment. These processes, described in The Strategy Guide [1], are key practices that companies should have in place as part of their everyday business management and without these processes in place, companies will be unable to demonstrate their ability to achieve the level of reliability expected of their products by BP. Emanating from these processes are the 10 specific Reliability Tasks (R1 to R10), initially defined in the original version of this manual, which was published in February 2005 as The Reliability Handbook, to be implemented within a project to achieve the required level of reliability.

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The BP Subsea Reliability Strategy A Guide for BP Leaders

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In 2006, implementation of these tasks became a mandatory requirement for BP subsea projects through the issue of GP 78-03 [2] and GP 78-04 [3]. At the same time this manual was renamed, produced electronically and updated both to align with these two GPs and to provide supporting essential guidance for projects. In addition, The Strategy Guide [1], has been updated to make readers aware of the GPs, to show the linkage between the 10 Reliability Tasks and the key processes, and to align the definition of the key processes with those described in API RP 17N “Recommended Practice Subsea Production System Reliability & Technical Risk Management” [6] which has been drafted since The Strategy Guide [1] was first published. The hierarchy of these BP documents and other relevant GPs is shown in the following diagram.

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GP 78-03 Achieving Reliability in Subsea Projects

Reliability Implementation Manual

GP 78-06 Qualification of Technology for Subsea Projects

GP 78-26 Subsea Reliability & Maintenance Data Collection

GP 78-04 Reliability Techniques for Subsea Projects

GP 78-05 Testing of Subsea Equipment: FAT, EFAT and SIT

Reliability Implementation Manual Appendices

GP 78-30 Integrated Subsea System Testing/ Commissioning/ Start-up

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The Strategy Guide is intended for BP leaders although it is expected that all BP engineers will read this manual. GP 78-03 is aimed at more senior members of the BU and project team whilst the other documents are intended for engineers involved in implementing reliability activities. The typical readership within BP of the documents is shown below. Contractors and suppliers will, at different levels in their organisation, also need to follow a similar level of readership in order to tender and undertake their contractual requirements

Gatekeeper, EA, TA Project Manager Reliability Lead Project Engineers

9 9 9 9 9

9 9 9 9 9

Reliability Implementation Manual

9 9 9 9

GP 78-04

9 9 9

Reliability Implementation Manual Appendices

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Document that should be read to understand what is required by BP Document that is best read to gain further understanding and detail

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GP 78-03

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Senior Management

Strategy Guide

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3.

Reliability Activity Requirements by CVP Stage

This manual ties in directly to the BP Capital Value Process (CVP) and provides guidelines on how to improve reliability throughout the life of a subsea system. This encompasses engineering, procurement, installation, commissioning and operation. As such this document is intended to help project engineers focus on reliability goals and requirements, forecast and allocate resources and set direction for reliability activities. The BP Capital Value Process is used both for project assurance and to successfully steer and manage a project from field appraisal through the FEED and detailed design stages and into operation. Each CVP stage is divided by a ‘Gate’, which requires the submission of a ‘Decision Support Package’ (DSP) for approval by the project ‘Gatekeepers’ before moving to the next stage of the project. Develop the Project Right

Choose the Right Project

*SELECT

Gate

*DEFINE

DSP

Gate

*EXECUTE

DSP

Gate

DSP

*OPERATE

Gate DSP

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Gate

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*APPRAISE

Deliver the Project Right

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The output from the reliability activities form part of the reliability assurance documentation, collated as the RAD, which shall be available to support the DSP at each CVP stage gate.

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Roles and Responsibilities The Reliability Strategy has implications for contractors (engineering services) and suppliers (hardware) working for BP.

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The main reliability responsibility of contractors and suppliers is to develop processes to deliver systems that meet BP requirements. They shall be able to carry out reliability and availability modelling, manage reliability data, modify design and test for reliability and to be able to provide reliability assurance to projects.

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It is the responsibility of the BP project team integrated with its selected engineering contractors to determine reliability goals and requirements and make decisions that encompass reliability assessment. The managing team shall carry out reliability value analysis, investigate high level system reliability, plan and budget for reliability, give direction to the contractors and suppliers, carry out review activities including validation and verification of Reliability Tasks, and assess and manage technical risks. All subsea project managers, shall be responsible for communicating the reliability expectations to their teams and suppliers, and shall be accountable for delivery of reliability performance. A Reliability Lead, reporting to the project manager, shall be appointed for each subsea project and shall be • Accountable for ensuring that the R&M requirements are achieved and championing the Reliability Strategy; • Responsible for maintaining the overall project Reliability Plan, schedule and assurance documentation; • Employing specialist reliability resources as required; • Prioritising the application of reliability techniques to obtain maximum benefit; • Overall leadership of BP contractors, suppliers and sub-suppliers to achieve effective reliability implementation and alignment with goals and requirements. Package managers shall be accountable for delivery of subsea equipment to address the R&M goals and meet the R&M requirements for the package and responsible for maintaining the package Reliability Plan, schedule and assurance documentation. Reliability Tasks This manual contains guidance on how and when Reliability Tasks shall be carried out to generate the maximum benefit to the project. The Reliability Tasks are designed to influence the way reliability is managed during design and manufacture in the subsea Activities by CVP Reliability Implementation Manual

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industry. They shall influence the way systems are selected, with increased emphasis placed on a supplier’s reliability management capability. This approach demands greater assurance from suppliers that the required level of reliability will be achieved. Projects shall plan for their reliability activities from the outset and high-level R&M goals and requirements, described in the RAD, should be included within the Basis of Design (BOD) to demonstrate satisfying the Statement of Requirements (SOR). Each project shall have documented systems in place to meet the expectations, including justification, where necessary, why certain tasks are not applicable to that project. The Reliability Task tables that follow in Sections 7 to 11, for each CVP stage, aim to provide guidance on specific activities and associated timing. However, they do not prescribe exactly how the work will be carried out or by whom. This is deliberate. Every project is different. Teams should make judgements on how to implement the initiative according to the resources and skills available. In some cases (such as for long lead items), it may be necessary to accelerate the reliability process to keep up with the design process i.e. do certain CVP stage Reliability Tasks before the official start of that CVP stage.

Appraise

Select

Define

Execute

Execute

Engineering & Procurement

Construction & Handover

D1

E1

C1

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Reliability Task Name / Reliability Implementation Manual Appendix ref #.

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The following table lists the Reliability Tasks (R1 to R10) and is a synopsis of the Reliability Tasks required per CVP stage. Blank entries in the table indicate that a specific Reliability Task is not required in the respective CVP stage. The labels A, S, D, etc are given to distinguish between the different CVP stages as explained in Section 4 following. i.e. A = Appraise, S= Select, etc.

Operate

Technical Risk Categorisation

A1

S1

R2

Defining R&M Goals and Requirements

A2

S2

D2

E2

C2

R3

Reliability Planning

A3

S3

D3

E3

C3

O3

R4

Reliability Assurance

A4

S4

D4

E4

C4

O4

R5

Reliability Value Analysis

S5

D5

R6

Reliability Analysis & Modelling

S6

D6

E6

R7

Design and Manufacture for Reliability

D7

E7

R8

Contractor and Supplier Selection and Contracting

R9

Reliability Data Collection and Lessons Capture

R10

Reliability Qualification Activities

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R1

A8

S8

A10

S10

O5 O6

D8

D10

E10

C9

O9

C10

O10

Core Reliability Task required for all subsea projects Reliability Task required for all subsea projects but detail and resources will vary significantly with technical risk Reliability Task required for projects intending to use technology that requires significant qualification Reliability Task required for replacement of installed hardware

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Input Tasks Six Input Tasks, listed in the table below, have been defined to ensure that the necessary data is made available, by the project team and to the project, to undertake the Reliability Tasks listed the table above. The table below also lists the Input Tasks in terms of when they are required by CVP stage (using the same CVP coding as for the Reliability Tasks i.e. A = Appraise, etc).

Input Tasks Required for Reliability Tasks

Synopsis

Requirement by CVP stage A S D

Project Risk Review

I.3

Quality Management

I.4

Safety Management

I.5

Reliability Data

I.6

Qualification Status

9 99 9 9 9

9 99 9 9

9 99 9 9 9

99 9 9 9

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Lessons I.1 Learned Review

The MPcp requires the capture and review of lessons learned at every CVP stage. The lessons learned usually cover the whole life of the project from strategic thinking and decision making, through project execution and the delivery of benefits. The TAs, supported by the project team shall be responsible for ensuring that past lessons impacting on reliability performance are considered at every CVP stage. Clear actions shall to be identified to ensure the lessons are implemented on the project. These shall then input to the reliability activities. An assessment of project risks is required by the BP Risk Management Guidelines for Major Projects at each CVP stage. These activities should explicitly address risks that impact product reliability with clear actions to ensure the risks are mitigated through the project and are addressed in the Project Risk Response plans. These shall then input to the reliability activities. Reliability effort will not bring value to a project unless it is carried out to the appropriate level. A project, which adopts reliability, and then is forced to cut resources will likewise not realise the benefits of the effort. Integrity Management is a mandatory process in BP. The Project Quality Management System (QMS) aims to ensure that the specified levels of integrity, quality and reliability required to meet BP business goals are attained, demonstrated and delivered in operation. Strong Quality Management implementation is therefore fundamental to meet and achieve reliability requirements. The R&M goals and requirements and Reliability Plan shall reflect the requirements of QM, both in design and manufacture, and Reliability Tasks identified to address quality improvement requirements. Also, data derived from QM activities, needed as evidence of qualification and/or reliability assurance, shall be sought. There is a strong interface between safety management and reliability management. Both disciplines consider the avoidance of failure and their consequences. The objective of reliability management is to avoid failures that may generate any adverse consequence including loss of functionality, production downtime, a need for intervention or safety incidents. The consequences of functional failure (loss of operability) of a safety critical system are higher than for non-safety equipment. It is essential therefore that the higher risks are accounted for in the reliability analysis to determine any required reliability improvements for the equipment. If a Safety Critical Element requires a very high level of reliability then this shall be reflected in the technical risk categorisation and associated Reliability Tasks at each CVP stage. RM data from historical projects and other operating facilities is required to support the assessment of reliability, availability & production efficiency. i.e. data feed into reliability analysis. Historical RM data should be used to identify the achieved reliability in similar conditions and failure modes that have been experienced and to help determine the R&M goals and requirements for the project. The BP reliability databases, held by operators, should be interrogated and collected at appropriate times in the design to provide inputs to reliability analysis and assurance. For each system, subsystem and component, as appropriate, the expected service conditions shall be considered in order that historical data available is shown to be relevant. This input task relies on earlier projects collecting RM data as required by GP 78-26, “Guidance on Practice for Subsea Reliability and Maintenance Data Collection”. The BP MPcp requires a Technology Plan to be identified and updated through the project at each CVP stage. The increased risks associated with use of new technology or existing technology in a new environment should be recognised by the project team early on and actions taken to identify acceptable reliability performance requirements together with the means for demonstrating that acceptable reliability performance may be expected in service. The high cost of discovering unqualified hardware at subsystem, component or constituent part level late in a project means that this is an essential task. This input task identifies the Technology Readiness Level of equipment and is based on GP 78-06, “Guidance on Practice for Qualification of Technology for Subsea projects”

E C O

99 9 9 9

9 99 9 9 9

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Reliability Activity Definition Levels As the project moves through its lifecycle, more is known about the detail of the design and hence the plan to manage the reliability of the design. To reflect this, the scope for reliability activity is considered at a definition level appropriate to the CVP project stages, namely: Activity Level

Definition

A

Appraise Stage

Project level

Involves the impact of subsea infrastructure on the total project performance

S

Select Stage

System level

Involves the entire subsea system as a combination of Well System, Control System, Manifold System, Connection System, etc.

D

Define Stage

Package level

Involves individual subsystems, e.g. Well System (as a combination of Wellhead, Tree, Tubing Hanger), Production Controls (as a combination of SCM, HPU. MCS, etc.)

E

Execute Stage Engineering and Procurement Phase

Component level

Involves individual components within each sub-system such as: Gate Valve, Tree Cap, Connector, SCM, Sensor, etc., manufacturing processes

C

Execute Stage Construction and Handover Phase

Installation and operation level

Involves equipment, tasks, procedures and interfaces particularly in relation to installation hardware.

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CVP Stage

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4.

How to Use this Manual - Worked Example

In order to implement the Reliability Strategy, Sections 7 to 11 of this manual provide the information needed by the Project Reliability Lead and package managers to build the required Reliability Plan for the project. The sections are structured in terms of specific reliability engineering and technical risk management tasks, grouped by CVP stage. A Reliability Plan template in the form of a spreadsheet is provided via this link: T3 Define Reliability Plan Template. The structure of the Reliability Plan is detailed in Appendix R3. The Appendices to this manual provide the necessary detailed guidance and provide links to templates for engineers performing the tasks. For each CVP stage, a summary flowchart shows the relevant Reliability Tasks which are colour coded blue. The flow chart boxes are labelled A for Appraise, S for Select, D for Define, etc. and numbered according to the Reliability Task numbering and associated appendices to this manual.

Update Reliability Plan for Select and Define S3

Update Qualification Plan for Options S10

High Level Option RAM Modelling S6

Option Reliability Value Analysis S5

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Appraise Select Define Execute engineering and procurement phase Execute construction and handover phase Operate.

Upgrade Option R&M Goals and Requirements S2

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A– S– D– E– C– O–

Option Technical Risk Categorisation S1

Contractor Reliability Capability and Scope for Define S8

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Reliability Assurance to assist Option Selection S4

Define Gate

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There are some Reliability Tasks that need to be performed in parallel (i.e. S1-S2, S3-S10, etc.).

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The flowchart for Select, taken from Page 23, is shown for example.

• • • • • •

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Additional tasks normally undertaken to satisfy CVP, or other BP processes, are also required as inputs to the Reliability Tasks and have the code, I. They are: Lessons Learned (I.1), Project Risk Management (I.2), Quality Management (I.3), Safety Management (I.4), Reliability Data Management (I.5) Qualification Status (I.6)

These are colour coded red and are shown alongside the CVP flowchart in a table which indicates which Reliability Tasks they input to. The Select input tasks, taken from Page 23, are shown here.

Input Tasks

Required by

I.1 Lessons Learned

S1, S2, S8

I.2 Project Risk Review

S1, S2

I.3 Quality Management

S3, S4, S8, S10

I.4 Safety Management

S1

I.5 Reliability Data

S2, S6

I.6 Qualification Status

S1, S10

The flowcharts and referenced task input provide information concerning the order in which the tasks should be performed. For each CVP stage, the first Reliability Task is Technical Risk Categorisation (see Appendix R1). The output of this task is a technical risk category (A, B, C or D) for the project, an option, a package or component.

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For each CVP stage, the flow charts are followed by a set of CVP Reliability Task tables to be used to build the Reliability Plan. These look up tables provide details of the requirements for each Reliability Task shown in the flowchart and describe: • • • • •

the Task Goal the Task Description the Task Input the Task Output the Task Resources

The task description tables also contain columns for each of the four technical risk categories (A, B, C & D) which show (i) the importance of the task, (ii) the need for the task and the type of reliability activity (quantitative/qualitative) and (iii) the predicted effort required for that task appropriate to each technical risk category. Colour coding schemes are used in the tables to relate the category of the project/package/component to the recommended level of reliability activity. The Select stage Reliability Task S3, taken from page 26, is shown as a worked example: Technical Risk Category A B C D

Update Reliability Plan for Select and Define Task Goal

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S3

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CVP Task Descriptions

Define at a more detailed level, the type of activity required to demonstrate reliability in the project.

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Description

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Input

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Output Resources

The Importance of the task is shown in the Goal section and is scored in terms of: H High

M Medium

L Low.

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The importance designation given for each technical risk category has been predetermined and shall be followed as described. Technical Risk Category A B C D

CVP Task Descriptions

S3

Update Reliability Plan for Select and Define Task Goal

Define at a more detailed level, the type of activity required to demonstrate reliability in the project.

H

H M L

Importance

Description

Input

Output Resources

Hence, it can be seen, for example, that Task S3 is of medium importance for a technical risk category C project option.

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The task description is broken into a number of action steps and references the relevant appendix, in this case R3, and a hyperlink to the appendix. By linking to Appendix R3 additional detail necessary to compile a reliability plan is provided to assist. Technical Risk Ref Category A B C D

CVP Task Descriptions

Update Reliability Plan for Select and Define Task Goal Description

Define at a more detailed level, the type of activity required to demonstrate reliability in the project. For each option, review the preliminary Reliability Plan defined at Appraise. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements set based on the technical risk categorisation and the CVP Reliability Task tables. Identify additional Reliability Tasks required for option technology qualification and by QM. Update and identify a practical Reliability Plan for the Select and Define stages including: • The reliability activities required (e.g. FMECA, FTA, RBD, Quantitative reliability analysis at system and sub-system level). • When they will be required within the Select & Define project schedule. • The resources required to facilitate these activities, including the definition of the Reliability Team Identify a high level vision for reliability activities in the Execute stage of the project.

H

H M L

Importance

R3

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S3

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Input

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Output Resources

Technical Risk Ref Category A B C D

Update Reliability Plan for Select and Define Task Goal Description

Input

Output Resources

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S3

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CVP Task Descriptions

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The required input for a Reliability Task (earlier Reliability Tasks and Input Tasks) is shown with the associated task reference (S1, S2, I.3, etc). The required output from the task is also shown. i.e. in this case, an updated Reliability Plan.

Define at a more detailed level, the type of activity required to demonstrate reliability in the project. For each option, review the preliminary Reliability Plan defined at Appraise. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements set based on the technical risk categorisation and the CVP Reliability Task tables. Identify additional Reliability Tasks required for option technology qualification and by QM. Update and identify a practical Reliability Plan for the Select and Define stages including: • The reliability activities required (e.g. FMECA, FTA, RBD, Quantitative reliability analysis at system and sub-system level). • When they will be required within the Select & Define project schedule. • The resources required to facilitate these activities, including the definition of the Reliability Team Identify a high level vision for reliability activities in the Execute stage of the project. Option technical risk categorisation Option R&M goals and requirements Quality Management Qualification Plan Appraise stage Reliability Plan An updated Reliability Plan

H

H M L

Importance

R3

S1 S2 I.3 S10 A3

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Further colour coding shows the level of detail required for each activity within the task for each project/package/component technical risk category. This shows whether a particular activity needs to be carried out and how. This relates directly to the indicated effort as quantitative activities inherently require more effort than qualitative activities. The different quantitative and qualitative approaches and requirements are explained in each of the Appendices.

CVP Task Descriptions Quantitative

S3

Qualitative

Unnecessary

Technical Risk Ref Category A B C D Appendix

Update Reliability Plan for Select and Define Task Goal

H

H M L

Importance

R3

S1 S2 I.3 S10 A3

ro l

Output Resources

le

d

Input

Co

py

Description

Define at a more detailed level, the type of activity required to demonstrate reliability in the project. For each option, review the preliminary Reliability Plan defined at Appraise. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements set based on the technical risk categorisation and the CVP Reliability Task tables. Identify additional Reliability Tasks required for option technology qualification and by QM. Update and identify a practical Reliability Plan for the Select and Define stages including: • The reliability activities required (e.g. FMECA, FTA, RBD, Quantitative reliability analysis at system and sub-system level). • When they will be required within the Select & Define project schedule. • The resources required to facilitate these activities, including the definition of the Reliability Team Identify a high level vision for reliability activities in the Execute stage of the project. Option technical risk categorisation Option R&M goals and requirements Quality Management Qualification Plan Appraise stage Reliability Plan An updated Reliability Plan

nt

Quantitative tasks involve considering characteristics by numerical properties representing amount, size, probability, etc.

co

Qualitative tasks involve considering characteristics by descriptive, non-numerical or semi-numerical properties.

Un

Note: If a project is required to carry out a reliability activity in a quantitative manner, it is also required to carry out any relevant qualitative aspects of the activity.

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The estimated Effort required for each task is shown in the Resources section and is scored in terms of approximate man-hours to complete the task. It should be noted that every project is different and this resource ranking is intended to give a general indication, not a prescriptive maximum. The resource / effort ranking is defined as; VH H M L VL

Very High > 200 man hours High < 200 man hours Medium < 100 man hours Low < 50 man hours Very Low < 10 man hours

So, in the example below, a technical risk category A or B design option is estimated to require up to 50 man hours to construct the Reliability Plan during Select, whereas a technical risk category C or D design option is estimated to require less than 10 hours.

CVP Task Descriptions Quantitative

Unnecessary

Update Reliability Plan for Select and Define Task Goal

H

H M L

Importance

R3

nt

S1 S2 I.3 S10 A3

co

Output Resources

Un

Input

ro l

le

d

Co

Description

Define at a more detailed level, the type of activity required to demonstrate reliability in the project. For each option, review the preliminary Reliability Plan defined at Appraise. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements set based on the technical risk categorisation and the CVP Reliability Task tables. Identify additional Reliability Tasks required for option technology qualification and by QM. Update and identify a practical Reliability Plan for the Select and Define stages including: • The reliability activities required (e.g. FMECA, FTA, RBD, Quantitative reliability analysis at system and sub-system level). • When they will be required within the Select & Define project schedule. • The resources required to facilitate these activities, including the definition of the Reliability Team Identify a high level vision for reliability activities in the Execute stage of the project. Option technical risk categorisation Option R&M goals and requirements Quality Management Qualification Plan Appraise stage Reliability Plan An updated Reliability Plan The plan should be defined by the project Reliability Lead together with a reliability specialist in negotiation with the project manager.

py

S3

Qualitative

Technical Risk Ref Category A B C D Appendix

L

L VL VL

Effort

As the project moves through CVP, the project Reliability Lead and package managers shall use the relevant CVP Reliability Task table as a guide to help build and update the project Reliability Plan. The tables facilitate the use of the technical risk category for an item (project, option, package, component, process) to determine the need for and the importance of a task, understand what is required from the task and to estimate the level of resources needed for that task.

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5.

The Role and Relationship of QM to Reliability

Strong Quality Management (QM) implementation is fundamental to meet and achieve R&M goals and requirements. It is vitally important, therefore, that BP, contractors and suppliers implement appropriate QM processes and controls in all subsea projects from concept design through manufacture, assembly and construction, following BP Engineering and Quality Management Guidelines. These guidelines are entered in the ETP library as a 50 series ETP. The design of a system or package will define the optimum reliability that shall be achieved for that equipment based on manufacturing and operational risks. Design decisions can both increase and decrease the inherent reliability of the equipment and shall take into account the controls required to maintain reliability during manufacture, assembly and construction. For example, material specifications may be changed to reduce cost at the design stage; however the associated difficulty of managing the lower cost material during manufacture may result in lower reliability and extra overall cost. Manufacturing, assembly and fabrication processes can only maintain or reduce the reliability theoretically inherent in the design. Therefore: The QM Process shall ensure that reliability goals and requirements are set in the Design phase and are managed throughout manufacturing and installation to ensure reliability meets or exceeds actual expectations in operation;

•

The QM effort and resources shall be allocated to ensure that equipment reliability is not compromised by poor quality assurance and control processes during manufacture, assembly, test, handling, storage and installation.

Co

py

•

d

Integration of Integrity Management, Quality Management and Reliability Management

nt

ro l

le

Integrity Management is a mandatory process in BP. The Project Quality Management System (QMS) aims to ensure that the specified levels of integrity, quality and reliability requirements to meet BP business goals are attained, demonstrated and delivered into operations. Likewise, the implementation of the BP Reliability Strategy is a mandatory process of the subsea function (see GP 78-03 and GP 78-04). It is not the intention of this manual to describe the QMS that would normally be required within a subsea project. The reliability team shall undertake its responsibilities in close collaboration with the QM function, incorporating their requirements within the project QMS.

co

In BP subsea projects the QMS shall incorporate R&M goals and requirements and practices. This typically addresses the following: In forming the Reliability Team, attention to its structure and linkage to the QM function shall be addressed.

•

Formation of the Reliability Team within in the project team, including as a minimum a Reliability Lead, to report directly to the Discipline Project Manager, with a functional link to the EA.

•

Integrate the activities defined by the Subsea Reliability Strategy into the QMS.

•

Define the Field Availability requirements and incorporate the Reliability Plan into the QMS to identify the reliability tasks to be implemented in the design, manufacturing, fabrication, transportation, preservation, construction and installation activities, and any quality verification stage improvement processes to be applied.

•

Provide verification and validation activities and data as evidence of qualification and/or reliability assurance, to be reviewed and approved by the reliability management team.

•

Roles, responsibilities and accountabilities of the QM and Reliability Teams and the necessary interfaces.

•

Quality Management resources shall be involved in and agree the completion and verification of Reliability Plans and Reliability Assurance Documents.

Un

•

Integration of Reliability into Contractor and Supplier QMS It is important for BP to recognise and for contractors and suppliers to understand that industry standard QMS do not normally address equipment reliability and that good reliability practices should be integrated within their existing QMS. It is envisaged therefore that contractors and suppliers shall be assessed on their historical performance and how their approach to reliability is integrated into their design and manufacturing QM systems. Further details on required reliability capabilities can be found in Appendix R8 “Contractor and Supplier Selection and Contracting”

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6.

Verification and Validation of Reliability Tasks

It is essential to ensure that the Reliability Tasks are carried out correctly and effectively and that reliability decisions are based on appropriate data and assumptions. Throughout the project lifecycle it is necessary to invoke internal processes for the verification and validation of the reliability activities carried out in the project. Verification and validation of Reliability Tasks is a very important activity within the BP Reliability Strategy. BP or a BP appointed third party shall review the Reliability Tasks to verify that the tasks are being performed correctly and that valid data, models, assumptions, etc are being used. Depending on the task, the reviews should be performed by two or more of the following: A BP engineer from the current project team familiar with the reliability activity A BP engineer from outside the project team familiar with the reliability activity Peer review team Independent external verification and validation authority with expertise and experience in subsea reliability A member of the BP Project QM team

py

• • • • •

Co

Greater confidence can be gained from the verification and validation process, when carried out by a reviewer independent to the original task. Verification and validation should be carried out at a number of levels as described below: Validation

le

d

Validation is the process which substantiates whether a physical entity, a model, data, a test or assumption within their domain of applicability, possesses a satisfactory range of accuracy consistent with the intended application. i.e. “Are we using the right data or model?”, “Is it the correct test?”

ro l

Data: Ensure that all data and assumptions are validated against historical data and experience to ensure that decisions are being based on correct assumptions.

nt

Models: Validate all models used to ensure the results predicted correlate with the results seen in reality.

Un

Verification

co

Tests: Validate all planned testing to ensure that the correct test is being performed. For example, a test designed to demonstrate functionality does not necessarily demonstrate reliability.

Verification is the process which determines the extent to which a procedure, task, physical product or model conforms to its specification. i.e. “Are we performing the task correctly?”, “Does the valve hold pressure?” Data: Verify all data, design assumptions and reliability models used for reliability analyses to be obtained from valid sources and databases. Processes: Ensure that all required processes and activities, deemed as necessary by the application of this manual, have been completed appropriately. Capability: Benchmark the capability of the organisation to perform against the key BP reliability processes. This information should be shared within BP. Peer Reviews As part of the verification and validation process, Peer Reviews organised as normal practice to satisfy CVP should review the Reliability Plan, the status of the required reliability activities and assure that the reliability risks associated with the project are properly identified and being correctly mitigated. The Peer Review team should therefore include personnel familiar with reliability techniques and their application.

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Appraise

7.

Select

Define

Execute

Operate

Appraise Stage Reliability Tasks

Goal

Determine project feasibility and alignment with business strategy

Activities

Understand project drivers; identify viable opportunities to pursue, with an emphasis on business goals and the probability of success.

Reliability Input

Define project technical risk category by consideration of major project challenges and technical risks together with the need for improved reliability and novel technology. Consider the role of reliability within the project and its decisions, and consider how this should be managed and developed.

Identify High Level R&M Goals & Requirements A2

py

High Level Technical Risk Categorisation A1

Qualification Plan for Technology Stretch A10

le

d

Co

Create Reliability Plan for Appraise & Select A3

nt

ro l

Contractor Reliability Capability for Select A8

Un

co

Initiate Reliability Assurance (RAD) A4

Input Tasks

Required by

I.1 Lessons Learned

A1, A2, A8

I.2 Project Risk Review

A1, A2

I.3 Quality Management

A3, A4, A8, A10

I.6 Qualification Status

A1, A10

Select Gate

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Appraise

Select

Define

Execute

Appraise Task Descriptions Quantitative

Ι.1

A Lessons search and a Project Knowledge Management Plan are required by the BP MPcp at the start of the Appraise stage. The lessons learned at this stage should cover the whole life of the project from strategic thinking and decision making, through project execution and the delivery of benefits.

Project Risk Review Description

An assessment of project risks is required by the BP Risk Management Guidelines for Major Projects at the start of the Appraise stage. By being rigorous in the risk review in the early stages of a project it is possible to demonstrate the existence of these risk areas to the Asset management and develop appropriate risk response plans including contingency allowances to the estimate and programme. Specific areas where risks to reliability achievement should be addressed are the application of new or unproven technology or the application of existing technology in new or extended environments.

Quality Management

py

Ι.3

Unnecessary

Technical Ref Risk Category A B C D Appendix

Project Lessons Learned Description

Ι.2

Qualitative

Operate

Ι.6

Co

The R&M goals and requirements and Reliability Plan shall reflect the requirements of QM, both in design and manufacture, and Reliability Tasks identified to address quality improvement requirements.

Qualification Status

The BP MPcp requires a Technology Plan to be identified at the Appraise stage with sources of funding identified to ensure appropriate use and viable development of any necessary innovative technologies. A high level review of technology needed in the project together with its current qualification status (TRL) is required at the start of the Appraise stage. This activity should address both the field environment and the need for improved reliability through implementation of new technology.

High Level Technical Risk Categorisation

H

H

H

H

Importance

R1

co

Description

Identify the overall level of technical risk involved in the project by deciding into which technical risk category the project is classed. Identify other projects in the region or similar environments with appropriate characteristics, to learn from experiences • Project environment • Development complexity • Reservoir conditions • Greenfield vs. Brownfield Consider the major project challenges and technical risks. Identify requirements for reliability improvement. Using the technical risk categorisation table, select a project risk category. Later in Appraise, confirm the project technical risk category is in accordance with the qualification status of the required technology identified in terms of its TRL. Lessons learned from previous projects Project risks High level R&M goals and requirements Qualification status of technology A statement of overall project technical risk category with justification. The decision-maker should seek the advice of technical experts.

nt

Task Goal

Un

A1

ro l

le

d

Description

Input

Output Resources

Ι.1 Ι.2 A2 Ι.6 VL VL VL VL

Effort

Appraise Reliability Implementation Manual

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Appraise

Select

Define

Execute

Appraise Task Descriptions Quantitative

Identify High Level Reliability and Maintainability Goals and Requirements Identify high-level R&M goals and requirements for the project as a whole.

Description

Consider the potential impact of identified technical risks on project value. Explore the acceptability of the major technical risks. Weigh up the balance between maintainability strategy and reliability strategy and identify strategy focus to be finalised in Select stage. From the above specify the following R&M goals and requirements: • Organisational requirements • Overall production availability requirements/goals • MFOP goals (if appropriate) • Reliability goals for new technology Key business objectives Lessons learned from previous projects Project technical risk categorisation Project risk management • A statement of the project R&M goals and requirements should be included in the BOD to demonstrate satisfying the SOR. • Specification of Project R&M goals and requirements including those for tender and procurement documents The evaluation should be carried out by the Appraise team supported by a reliability specialist.

Resources

Co

Output

Create Reliability Plan for Appraise and Select

L

Importance

R2

Ι.1 A1 Ι.2

VL VL VL VL

H M L

L

Effort

Importance

R3

Output Resources

A1 I.3 A2 A10

Un

Input

co

nt

ro l

Description

Indicate at a high level, the type of activity required to demonstrate reliability in the project. Ascertain from the R&M goals and requirements the general level of effort considered beneficial to achieve any reliability improvement required. Identify Reliability Tasks required as part of the qualification process for high technical risk category projects. Outline a practical Reliability Plan for the Select stage (based on the CVP Reliability Task tables), including: • The reliability activities required. • When they are required within the Select project schedule. • The reliability leadership and organisation for Select stage. • The resources required to facilitate these activities. Identify a high level vision for reliability activities in later stages of the project Project technical risk categorisation Quality Management High level R&M goals and requirements Qualification requirements A preliminary Reliability Plan The plan should be outlined by the Reliability Lead in negotiation with the project manager. It should be included with the risk and uncertainty assessments of the high level CVP Plan.

d

Task Goal

H M L

py

Task Goal

Input

A3

Unnecessary

Technical Ref Risk Category A B C D Appendix

le

A2

Qualitative

Operate

VL VL VL VL

Effort

A10 Qualification Plan for Technology Stretch Task Goal Description Input

Output Resources

Indicate at a high level, the activity required to demonstrate qualification in the project. Initiate the qualification process for unqualified technology utilising a qualification matrix and identify the level of activity required in later CVP stages. Technology qualification status (TRL) Reliability Plan Quality Management A preliminary qualification matrix and Qualification Plan The qualification plan should be outlined in conjunction with the Reliability Lead and relevant suppliers and specialists.

H M

Importance

R10 Ι.6 A3 I.3 VL VL

Effort

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Appraise

Select

Define

Execute

Appraise Task Descriptions Quantitative

A8

Qualitative

Unnecessary

Operate

Technical Ref Risk Category A B C D Appendix

Contractor Reliability Capability for Select Account for reliability engineering capability in the tendering process. Investigate engineering contractor commitment to reliability engineering (both long term and short term) that results in an improvement in reliability performance and consider use of incentives. Include project R&M goals and requirements and required Reliability Tasks in tender and procurement documents and prepare contractor reliability capability evaluation criteria. When reviewing tenders, evaluate engineering contractor’s capability to design for reliability together with their ability to perform specific Reliability Tasks. This shall take into account organisational systems and processes they have in place to support reliability improvement. Examine tenders for specific reliability engineering activities. The award of contracts may consider all or some of the following: • Change Management Procedures • Implementation of Lessons Learned Systems • Reliability Data Management • Reliability Analysis and Modelling • Design for Reliability • Reliability Assurance • Reliability Value Analysis Lessons learned from previous projects Quality Management Project technical risk categorisation High level R&M goals and requirements Reliability Plan Assessment of engineering contractor reliability capability and a preliminary execution schedule including reliability activities, targets and incentives The contractor reliability capability should be evaluated by a reliability specialist in conjunction with the project Reliability Lead

H

H M L

Importance

R8

Ι.1 I.3 A1 A2 A3

Initiate Reliability Assurance

Initiate the development of a Reliability Assurance Document (RAD). Define Reliability Assurance Document format for the project. Within the RAD: • Describe the project technical risk category providing background information and evidence to support the category selected. • Describe high level R&M goals and requirements of the contender options. • Record the outline of the preliminary Reliability Plan and Qualification Plan for each contender option. • Summarise engineering contractor reliability capability from tenders. Project technical risk categorisation Quality Management High level R&M goals and requirements Reliability Plan Qualification Plan Contractor reliability capability assessment A Reliability Assurance Document (Appraise) to be included with the Decision Support Package (DSP) presented for the Select Gate. The RAD should be prepared by the Reliability Lead with support from a reliability specialist as appropriate.

L VL VL

H M M L

Effort

Importance

R4

co

Task Goal Description

L

Un

A4

ro l

Resources

nt

Output

le

d

Input

Co

py

Task Goal Description

Input

Output Resources

A1 I.3 A2 A3 A10 A8

VL VL VL VL

Effort

Appraise Reliability Implementation Manual

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Appraise

Define

Execute

Operate

Select Stage Reliability Tasks Goal

Select preferred project option(s)

Activities

Select, develop and compare project option(s) and appropriate technologies by focusing on the uncertainties, technical risks and other associated economic factors.

Reliability Input

Define R&M goals and requirements to achieve business goals. Option evaluation should consider reliability assessment and technical risk categorisation of each option. Consider how technical risk/uncertainty shall be managed. Apply lessons learned.

Upgrade Option R&M Goals and Requirements S2

Update Reliability Plan for Select and Define S3

Update Qualification Plan for Options S10

py

Option Technical Risk Categorisation S1

Co

8.

Select

Option Reliability Value Analysis S5

le

d

High Level Option RAM Modelling S6

Required by

I.2 Project Risk Review

Un

Input Tasks

co

nt

ro l

Contractor Reliability Capability and Scope for Define S8

I.3 Quality Management

S3, S4, S8, S10

I.4 Safety Management

S1

I.5 Reliability Data

S2, S6

I.6 Qualification Status

S1, S10

I.1 Lessons Learned

Reliability Assurance to assist Option Selection S4

S1, S2, S8

S1, S2

Define Gate

Select Reliability Implementation Manual

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Appraise

Select

Define

Execute

Select Task Descriptions Quantitative

Project Lessons Learned Description

Project Risk Review Description

Quality Management

Safety Management

Co

le

Reliability Data

A review of relevant reliability data is required during the Select stage to provide approximate figures for the potential reliability that may be achieved by the different design concepts under consideration. This data inputs to the reliability activities.

ro l

Description

Ι.6

If safety critical hardware forms an integral part of an option or the project, this shall be identified and reflected in the technical risk categorisation and associated Reliability Tasks. It is important that safety critical hardware achieve a high level of reliability and availability performance by undergoing reliability analysis for functionality and operability.

d

Description

Ι.5

In defining the R&M goals and requirements and building a Reliability Plan, the requirements of the QM system shall be identified such that the Reliability Tasks, both in design and manufacture, address any identified quality improvement requirements.

py

Description

Ι.4

An assessment of project risks is required by the BP MPcp at the start of the Select stage before the Project Risk Management Plan can be drafted. It is essential that the risk to the achievement of reliability is specifically considered in the project and that the team have the space and vision to remain long sighted in their aims and objectives.

Qualification Status Description

nt

Ι.3

An assessment of similar projects and any applicable lessons is required by the BP MPcp to ensure relevant lessons have been identified and applied to the project at the start of the Select stage. The BP MPcp also requires that project lessons from Appraise and Select are captured at the end of the Select stage.

The BP MPcp requires the Technology Plan to be updated in Select to ensure progress on development and implementation of all unproven essential (enabling) and value enhancing technologies such that risks are acceptable and mitigation plans identified. A high level review of technology needed for each option together with its current qualification status (TRL) is required at the start of the Select stage. This activity should address both the field environment and the need for improved reliability through implementation of new technology and/or layout.

co

Ι.2

Unnecessary

Technical Risk Ref Category A B C D Appendix

Un

Ι.1

Qualitative

Operate

Select Reliability Implementation Manual

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Appraise

Select

Define

Execute

Select Task Descriptions Quantitative

Unnecessary

Technical Risk Ref Category A B C D Appendix

Option Technical Risk Categorisation Task Goal Description

H

H

H

H

Resources

d

VL VL VL VL

Ι.1 A1 Ι.2 S2 I.4 Ι.6 Effort

Define R&M goals and requirements for specified options. Review environmental and operability conditions that affect the reliability or maintainability of each system option under investigation Consider the potential impact of identified option risks on option value. Explore the acceptability of the major option risks. Identify balance between maintainability strategy and reliability strategy for each option Update organisational requirements for each option Define R&M goals and acceptance criteria for each option: • Overall production availability requirements/goals for the major subsea packages • MFOP goals, if appropriate • Reliability goals for new technology Following reliability and value analysis (S5 & S6) and accounting for CAPEX/OPEX implications, update the R&M goals and requirements accordingly if appropriate. Key business objectives Lessons learned from previous projects Reliability data Option technical risk categorisation Reliability Plan at end of Appraise Project risk management Appraise stage R&M goals and requirements • A statement of the option R&M goals and requirements should be included in the BOD to demonstrate satisfying the SOR. • Specification of option R&M goals and requirements including those for tender and procurement documents The evaluation should be carried out by the Select team supported by a reliability specialist.

H

H M L

Importance

R2

co

nt

Task Goal Description

ro l

Update Option Reliability and Maintainability Goals and Requirements

Un

S2

le

Output

Importance

R1

Co

Input

Determine the technical risk category of each development option. This technical risk categorisation task focuses on development options. It is important to consider the novelty of the options and level of experience with the technology. Identify other projects with similar development technologies and consider in terms of appropriate characteristics and experience including: • Project environment • Reservoir conditions • Development complexity • Brownfield issues Consider the major project challenges and technical risks by option including any requirement for reliability stretch. Identify requirements for reliability improvement. Identify requirements for safety critical hardware. Using the technical risk categorisation table, select a technical risk category for each option under consideration. Later in Select, confirm the option category is in accordance with the qualification status of the technology required for the option identified in terms of its TRL. Lessons learned from previous projects & engineer/supplier liaison Appraise stage project technical risk categorisation Project risks High level option R&M goals and requirements Requirements for safety critical hardware Qualification status of required technology for each option A statement of technical risk category, with justification, for each development option under consideration. The decision-maker should seek the advice of technical experts.

py

S1

Qualitative

Operate

Input

Output

Resources

Ι.1 I.5 S1 A3 Ι.2 A2

L

L VL VL

Effort

Select Reliability Implementation Manual

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Appraise

Select

Define

Execute

Select Task Descriptions Quantitative

S3

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

Update Reliability Plan for Select and Define Task Goal Description

H

H M L

Co

S10 Update Qualification Plan for Options

L VL VL

Effort

H

H

Importance

R10 Ι.6 I.3 A10 S3 L

L

Effort

Un

Output Resources

co

nt

Input

Indicate at a high level, the activity required to demonstrate qualification for each option. Update the qualification matrix for unqualified technology and identify the level of activity required in later CVP stages for each option, in particular those items requiring significant qualification to minimise project schedule inputs. Technology qualification status (TRL) Quality Management Appraise Qualification Plan Option Reliability Plan Qualification matrix and Qualification Plan for each option The Qualification Plan should be outlined in conjunction with the Reliability Lead and relevant suppliers and specialists.

le

Description

L

ro l

Task Goal

S1 S2 I.3 S10 A3

d

Output Resources

Importance

R3

py

Input

Define at a more detailed level, the type of activity required to demonstrate reliability in the project. For each option, review the preliminary Reliability Plan defined at Appraise. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements set based on the technical risk categorisation and the CVP Reliability Task tables. Identify additional Reliability Tasks required for option technology qualification and by QM. Update and identify a practical Reliability Plan for the Select and Define stages including: • The reliability activities required (e.g. FMECA, FTA, RBD, Quantitative reliability analysis at system and sub-system level). • When they will be required within the Select & Define project schedule. • The resources required to facilitate these activities, including the definition of the Reliability Team Identify a high level vision for reliability activities in the Execute stage of the project. Option technical risk categorisation Option R&M goals and requirements Quality Management Qualification Plan Appraise stage Reliability Plan An updated Reliability Plan The plan should be defined by the Reliability Lead with support from a reliability specialist where necessary in negotiation with the project manager.

Select Reliability Implementation Manual

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Appraise

Select

Define

Execute

Select Task Descriptions Quantitative

High Level Option RAM Modelling

Output

Resources

L

Importance

R6

S1 S2 S5 I.5

M

L

L

VL

H

H M

L

Effort

ro l

Determine the commercial value of investing in specific reliability improvement for the various options under consideration to deliver high level R&M goals and requirements. Define value acceptance criteria e.g. maximise value Determine the reliability improvement required for each option from the R&M goals and requirements and by comparison with the RAM analysis results. Investigate the impact of reliability improvement on the overall value of the project and /or investigate the impact of value improving options on the overall reliability of the project. Evaluate the investment/effort trade-off with the reliability/value achieved. If the investment required is greater than can be economically achieved/justified the R&M goals and requirements may have to change. Project/option technical risk categorisation R&M goals and requirements RAM analysis model and results Summary to include an estimate of the level of investment/effort required to improve value/achieve reliability targets for each option The reliability value analysis should be defined by a reliability specialist with input from the project manager.

Importance

R5

co

nt

Description

le

Option Reliability Value Analysis Task Goal

H M M

py

Input

Co

Description

Assess the probability of system failure modes and their impact on availability for each option Identify system failure modes that will cause production outages through a preliminary FMECA. Keeping analysis at a package level, assess the probability of system failure modes. Feed this information into a high level RAM model Use the RAM model to assess the acceptability of the system configuration and the relative importance of the various system elements (packages). Perform Common Cause Failure Analysis to identify packages vulnerable to common cause failures. (Quantitatively where data permits). Interface with value analysis to identify potential for reliability improvement Project/option technical risk categorisation R&M goals and requirements Reliability Value Analysis Reliability Data • FMECA and CCFA reports and associated mitigation action list. • Report RAM analysis results as evidence of reliability achievement at this stage of analysis in the Reliability Assurance Document. • For technical risk category D, the output from previous project work should be sufficient. The RAM analysis should be carried out by the reliability specialist with direct review/input from the project team. A reliability specialist should support engineers performing FMECA/CCFA activities.

d

Task Goal

S5

Unnecessary

Technical Risk Ref Category A B C D Appendix

Input

Output Resources

Un

S6

Qualitative

Operate

S1 S2 S6

L

L

VL VL

Effort

Select Reliability Implementation Manual

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Appraise

Select

Define

Execute

Select Task Descriptions Quantitative

S8

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

Contractor Reliability Capability and Scope for Define Task Goal

H

H M L

Importance

R8

Ι.1 I.3 S1 S2 S3 S10 S6 S5

L

L VL VL

Effort

H

H M L

Importance

Reliability Assurance to Assist Option Selection Task Goal Description

Input

Output Resources

Update the Reliability Assurance Document (RAD) to provide assurance and evidence that the best value option has been selected. Review RAD format for the project. Within the RAD: • Describe the technical risk category for each option providing background information and evidence to support the category selected • Describe option R&M goals and requirements • Present results of the high level systems reliability modelling of each option and any value analysis for reliability improvement • Present the updated version of the Reliability Plan and Qualification Plan including relevant estimates of effort and resource • Summarise how QM reliability requirements shall be addressed • Summarise contractor reliability capability from tenders Project technical risk categorisation Reliability requirements Reliability Plan Qualification Plan Quality Management High level systems reliability modelling Reliability value analysis Contractor reliability capability assessment Appraise stage RAD A Reliability Assurance Document (Select) to be included with the DSP presented for the Define Gate The RAD should be prepared by the Reliability Lead with support from a reliability specialist as appropriate.

Un

S4

nt

Resources

co

Output

ro l

le

d

Input

Co

py

Description

Account for reliability engineering capability in the tendering process, achieve long-term improvement in reliability performance Investigate contractor commitment to reliability engineering (both long term and short term) that results in an improvement in reliability performance and consider use of incentives. Include project R&M goals and requirements and required Reliability Tasks in tender and procurement documents and prepare contractor reliability capability evaluation criteria. When reviewing tenders, evaluate contractor’s capability to design/manufacture for reliability together with their ability to perform specific Reliability Tasks. This shall take into account organisational systems and processes they have in place to support reliability improvement Examine tenders for specific reliability engineering activities. The award of contracts may consider all or some of the following: • Change Management procedures • Implementation of Lessons Learned Systems • Reliability Data Management • Reliability Analysis and Modelling • Design for Reliability • Reliability Assurance • Reliability Value Analysis Lessons learned from previous projects Quality Management Project technical risk categorisation R&M goals and requirements Reliability Plan Qualification Plan High level systems reliability modelling Reliability value analysis Assessment of contractor reliability capability and their preliminary schedule including required reliability activities, targets and incentives for Define. The contractor reliability capability should be evaluated by a reliability specialist in conjunction with the project Reliability Lead

R4

S1 S2 S3 S10 I.3 S6 S5 S8 A4

L

L VL VL

Effort

Select Reliability Implementation Manual

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Appraise

9.

Select

Define

Execute

Operate

Define Stage Reliability Tasks Goal

Finalise project scope, cost and schedule and obtain project funding

Activities

Develop and define the selected option(s) and provide the appropriate level of detailed planning and design to determine the scope of the project and to develop more detailed cost and schedule estimates.

Reliability Input

Perform technical risk categorisation for packages. Finalise reliability assessment of the project; create a clear reliability strategy to define in detail the reliability activities and resources required for the project. These requirements shall be defined within project specifications.

Update Qualification Plan for all Packages D10

d

Update Reliability Plan for Define and Execute D3

Co

Update System Architecture to Meet R&M Goals & Requirements D7

Allocate Package R&M Goals and Requirements D2

py

Package Technical Risk Categorisation D1

le

Package RAM Modelling

co

nt

ro l

D6

Package Reliability Value Analysis D5

Required by

I.1 Lessons Learned

D1, D2, D8

I.2 Project Risk Review

D1, D2

I.3 Quality Management

D2, D3, D4, D8, D10

I.4 Safety Management

D1

I.5 Reliability Data

D2, D6, D8

I.6 Qualification Status

D1, D10

Un

Input Tasks

Contractor / Supplier Reliability Capability & Requirements for Execute D8 Update Reliability Assurance D4

Execute Gate

Define Reliability Implementation Manual

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Appraise

Select

Define

Execute

Define Task Descriptions Quantitative

Ι.1

The BP MPcp requires the Project Knowledge Management Plan to be updated for the Define stage activities accounting for the relevant networks and systems for knowledge sharing that have been identified. A regular two-way transfer of knowledge between the project and the company is essential to ensure lessons are identified, captured and transferred to the relevant parties as the project progresses.

Project Risk Review Description

Ι.3

Unnecessary

Technical Risk Ref Category A B C D Appendix

Project Lessons Learned Description

Ι.2

Qualitative

Operate

The BP MPcp requires the Project Risk Management Plan to be confirmed at the start of Define with the assessment of project risks being demonstrated to be at an acceptable level. The risk register is required to be updated to represent the current status of risks, opportunities and response plans with quantification on expected values wherever possible.

Quality Management The R&M goals and requirements and Reliability Plan specified in Define shall reflect the requirements of QM, from design through to manufacture, and Reliability Tasks identified shall address any necessary quality improvement needs. Also, data derived from QM activities, required as evidence of qualification and/or reliability assurance, shall be required.

Ι.4

Co

py

Description

Safety Management

If safety critical hardware forms an integral part of a package or the project, this shall be identified and reflected in the technical risk categorisation and associated Reliability Tasks. The safety analysis may be used as a starting point for the reliability analysis but the project shall recognise the different context of the two analyses and ensure that functionality critical failure modes are also identified, evaluated and managed.

Ι.5

ro l

le

d

Description

Reliability Data

For each system, subsystem and component, as appropriate, the expected service conditions shall be considered in order that historical data available is shown to be relevant. A review of relevant reliability data is therefore required during the Define stage to provide approximate figures for the potential reliability that may be achieved by the designs under consideration. This data then inputs to the reliability activities.

Qualification Status Description

Un

Ι.6

co

nt

Description

The BP MPcp requires the Technology Plan to be updated in Define to ensure that progress on development and implementation of all unproven essential (enabling) and value enhancing technologies are completed by the appropriate time in Execute. A review of technology needed for each package together with its current qualification status (TRL) is required at the start of the Define stage.

Define Reliability Implementation Manual

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Appraise

Select

Define

Execute

Define Task Descriptions Quantitative

D1

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

Package Technical Risk Categorisation Task Goal Description

H

H

H

H

Ι.1 S1 I.2 D2 I.4 Ι.6

Co

L

L

L

L

H

H M L

Effort

Allocate Package Reliability and Maintainability Goals and Requirements Importance

R2

co

nt

Description

Update System R&M goals and requirements for the selected Option and allocate requirements to equipment packages. Review environmental and operability conditions that affect the reliability or maintainability of each package, also address manufacture, ease of construction, quality and ease of installation. Consider the potential impact of identified package risks on system value. Explore the acceptability of the package technical risks. Identify balance between maintainability strategy and reliability strategy for each package and ensure the design specifications reflect these strategies. Specify organisational requirements for each package Define R&M goals and acceptance criteria for each package: • Package reliability goals/stretch • Package maintainability goals • Package MFOP goals (as appropriate) Following package reliability and value analysis and architecture improvements (D5, D6 and D7), update the R&M goals and requirements accordingly. Key business objectives Lessons learned from previous projects Reliability data Project/package technical risk categorisation Project risk management QM requirements Reliability Plan at end of Select Select stage R&M goals and requirements • Statement of the package R&M goals and requirements to be included in RAD. • Specification of package R&M goals and requirements to be included in tender and procurement documents The evaluation should be carried out by the Define team supported by a reliability specialist.

ro l

Task Goal

Un

D2

d

Resources

le

Output

Importance

R1

py

Input

Determine the technical risk category of the major engineering packages This technical risk categorisation task focuses on the major engineering packages, for example risers or trees. Although full detail will not be known about the packages, issues such as water depth or reservoir conditions quickly indicate the higher technical risk technologies. As the project team increases, engineers responsible for the major packages will join the team. They shall consider the technical risk category of their particular package. In particular it is necessary to consider • Novelty - it is often the minor changes that cause the major problems • Interfaces between packages, equipment and companies • Requirements for reliability improvement • Safety critical hardware Using the technical risk categorisation table, select a technical risk category for each package under consideration. Where possible, this should be finalised with suppliers before Execute. Later in Defne, confirm the package technical risk category is in accordance with the package technology qualification status identified in terms of its TRL. Lessons learned from previous projects & engineer/supplier liaison Select stage project technical risk categorisation Project and package risks Package R&M goals and requirements Requirements for safety critical hardware Qualification status of required technology for each package A statement of technical risk category, with justification, for each major engineering package. The technical risk categorisation should be defined by BP package engineers with the support of the reliability specialist.

Input

Output

Resources

Ι.1 I.5 D1 Ι.2 I.3 S3 S2

L

L VL VL

Effort

Define Reliability Implementation Manual

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Appraise

Select

Define

Execute

Define Task Descriptions Quantitative

Unnecessary

Technical Risk Ref Category A B C D Appendix

Update Reliability Plan for Define and Execute

Output Resources

H M L

Importance

py

R3

D1 D2 I.3 S3 D10

Co

Input

H

d

Description

Define at a more detailed level, the activities required to demonstrate reliability in the project. Review the updated Reliability Plan defined at Select. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements, the qualification requirements and QM requirements. Update and identify a practical Reliability Plan for Define and Execute stages based on the CVP Reliability Task tables and the technical risk categorisation results, including which reliability activities are required, when they are required and what resources are required to facilitate these activities (they should allow for including installation commissioning and operations expertise, as appropriate). These activities should include (but not be limited to) the following: • FMECA (both for reliability and qualification) • TRAP (Levels 1 & 2) • FTA/RBD at system and sub-system level (both for reliability and qualification as appropriate) and RAM Model • Development of a reliability testing programme (in conjunction with the qualification testing programme) to demonstrate reliability. Reliability analysis during the Define stage facilitates the decision regarding what to test and how to test. The overall project schedule may require early procurement of some long lead items, in which case relevant reliability activities should be planned for early. Project/package technical risk categorisation Project/package R&M goals and requirements Quality Management Select stage Reliability Plan Qualification Plan An updated Reliability Plan The plan should be defined by the project Reliability Lead together with a reliability specialist in negotiation with the project manager.

le

Task Goal

ro l

D3

Qualitative

Operate

M

M

L VL

H

H M L

Effort

D10 Identify Qualification Plan for all Packages

Output Resources

nt

Importance

R10 Ι.6 I.3 S10 D3

co

Input

Specify the activities required to demonstrate qualification for each package. Update the qualification matrix for all equipment and identify the qualification testing and associated acceptance criteria required in Define and Execute for each package. Technology qualification status (TRL) Quality Management Select Qualification Plan Package Reliability Plan Qualification matrix and Qualification Plan for each package The Qualification Plan should be outlined in conjunction with the Reliability Lead and relevant suppliers and specialists.

Un

Task Goal Description

L

L VL VL

Effort

Define Reliability Implementation Manual

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Appraise

Select

Define

Execute

Define Task Descriptions Quantitative

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

D6 Package RAM Modelling Description

Input

H M L

L

Importance

R6

D1 D2 D5 S6 I.5

L

L VL

Effort

Determine the commercial value of investing in specific reliability improvement for the package design to deliver the necessary R&M goals and requirements. Define value acceptance criteria e.g. maximise value. Determine the reliability improvement required for each package from the R&M goals and requirements. Investigate the impact of reliability improvement on the overall value of the project and/or the impact of value enhancements on the overall reliability of the project. Evaluate the investment/effort required to achieve the reliability improvement. If the investment required is greater than can be economically achieved the R&M goals and requirements may have to change. Project/package technical risk categorisation R&M goals and requirements RAM analysis model and results System reliability value analysis at Select Summary to include an estimate of the level of investment/effort required to improve value/achieve reliability targets for each package The value analysis should be defined by a reliability specialist with input from the project manager.

H M M L

Importance

R5

Input

Output Resources

Un

co

nt

Description

ro l

D5 Package Reliability Value Analysis Task Goal

M

le

Resources

d

Co

Output

Assess the probability of package failure modes & their impact on system availability Identify package failure modes that will cause production outages through a FMECA. Considering the failure logic within each package, using RBDs or FTA assess the probability of package failure modes. Refine the Select RAM analysis model in more detail for each package Assess the importance of the various components to the package failure modes Perform Common Cause Failure Analysis to identify package components vulnerable to common cause failures. Interface with value analysis to optimise reliability improvement and/or support decision making on the cost effectiveness and reliability impact of design improvements Project technical risk categorisation R&M goals and requirements Reliability value analysis High level Select stage system reliability analysis Reliability data • FMECA, RBD, FTA, CCFA reports and associated mitigation action list. • Report RAM analysis results as evidence of reliability achievement at this stage of analysis in the Reliability Assurance Document. • For technical risk category D, the output from previous project work should be sufficient. The RAM analysis should be carried out by a reliability specialist with direct review/input from the project team. A reliability specialist should support engineers performing FMECA/RBD/FTA/CCFA activities.

py

Task Goal

D1 D2 D6 S5

L

L VL VL

Effort

Define Reliability Implementation Manual

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Appraise

Select

Define

Execute

Define Task Descriptions Quantitative

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

D7 Update System Architecture to Meet R&M goals and requirements

Input

Output

L

Importance

R7

D1 D2 D6 D5

M

L VL VL

Effort

H

H M L

Importance

R8

co

nt

Description

Account for reliability engineering capability in the tendering process, achieve long-term improvement in reliability performance Investigate contractor/supplier commitment to reliability engineering (both long term and short term) that results in an improvement in reliability performance and consider use of incentives. Include project R&M goals and requirements and required Reliability Tasks in tender and procurement documents and prepare contractor/supplier reliability capability evaluation criteria. When reviewing tenders, evaluate contractor’s/supplier’s capability to design/manufacture for reliability together with their ability to perform specific Reliability Tasks. This takes into account organisational systems and processes they have in place to support reliability improvement. Examine tenders for specific reliability engineering activities, the award of contracts may consider all or some of the following: • Change Management procedures • Implementation of Lessons Learned Systems • Reliability Data Management • Reliability Analysis and Modelling • Design/Manufacture for Reliability • Reliability and Qualification Testing • Reliability Assurance • Reliability Value Analysis Lessons learned from previous projects Quality Management Reliability data Project/package technical risk categorisation R&M goals and requirements Reliability Plan Qualification Plan Package reliability modelling Reliability value analysis Assessment of contractor/supplier reliability capability and a preliminary execution schedule including reliability activities, targets and incentives The contractor/supplier reliability capability should be evaluated by a reliability specialist in conjunction with the project Reliability Lead.

ro l

Task Goal

le

Contractor/Supplier Reliability Capability and Requirements for Execute

Un

D8

d

Resources

H M L

py

Description

Review and improve system design to meet overall system R&M goals and requirements. Determine the reliability improvement required for the system as a whole and for each package from the analyses in D5 and D6. For each reliability improvement required, determine whether the improvement is best achieved through: • changing the configuration; • improving component reliability; • introducing redundancy. As part of the Value Improvement Process during design, it is necessary to consider reliability improvement opportunities. It is also necessary to evaluate the impact on reliability of other value improving and cost reducing opportunities. A critical aspect of design for reliability, as well as identifying the need for change, is the identification of the impact of change on reliability. Follow up from a change order should include a re-assessment of technical risk, reliability and availability. Project technical risk categorisation R&M goals and requirements Systems reliability analysis Reliability value analysis Summary report describing recommendations for design improvement to achieve reliability improvement to meet the R&M goals and requirements The system design should be assessed for reliability improvement and impacts of change by the Define team supported by a reliability specialist.

Co

Task Goal

Input

Output Resources

Ι.1 I.3 I.5 D1 D2 D3 D10 D6 D5

L

L VL VL

Effort

Define Reliability Implementation Manual

34

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Appraise

Select

Define

Execute

Define Task Descriptions Quantitative

Unnecessary

Technical Risk Ref Category A B C D Appendix

Update Reliability Assurance Task Goal Description

H

H M L

Co

d

le

ro l

L

L VL VL

Effort

nt

Resources

D1 D2 D3 D10 I.3 D6 D5 D7 D8 S4

co

Output

Importance

R4

py

Input

Update the Reliability Assurance Document (RAD) to provide assurance and evidence that the system and package design is achieving required reliability. Review Reliability Assurance Document format for the project. Within the RAD: • Describe the project technical risk category for each major package providing background information and evidence to support the category selected. • Describe the project/package R&M goals and requirements also included in the Basis of Design and package specification documents • Present results of the systems reliability modelling of the selected option • Present the updated version of the Reliability Plan and Qualification Plan including relevant estimates of effort and resource. • Summarise how QM reliability requirements will be addressed • Describe any changes made to system design/architecture that impact reliability • Present summary of contractor/supplier reliability capability from tenders Project technical risk categorisation R&M goals and requirements Reliability Plan Qualification Plan Quality Management Systems reliability analysis Reliability value analysis Updated system/package design Contractor/supplier reliability capability assessment Select stage RAD A Reliability Assurance Document (Define) to be included along with the Decision Support Package (DSP) presented for the Execute Gate. The RAD should be prepared by the Reliability Lead and package engineers with support from a reliability specialist as appropriate.

Un

D4

Qualitative

Operate

Define Reliability Implementation Manual

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Appraise

Select

Define

Execute

Operate

10. Execute Stage Reliability Tasks Execute Engineering and Procurement Phase

Goal

Finalise detailed design and procure equipment with approved cost and schedule.

Activities

Manage detailed engineering and procurement to ensure that the project achieves its cost, schedule and operability goals.

Reliability Input

The Reliability Plan shall be fully implemented through detailed design and procurement to ensure that all necessary reliability activities are carried out and that all equipment and systems are designed, procured and verified against R&M requirements.

Update Package R&M Goals and Requirements E2

Co

py

Component Technical Risk Categorisation E1

Design and Procure to meet R&M Goals and Requirements E7

Update Qualification Plan for all Packages E10

ro l

le

d

Update Reliability Plan for Execute E3

Un

co

nt

Detailed Reliability Analysis E6

Input Tasks

Required by

I.1 Lessons Learned

E1, E2, E6, E7, E10

I.2 Project Risk Review

E1, E2

I.3 Quality Management

E2, E3, E4, E7, E10

I.4 Safety Management

E1

I.5 Reliability Data

E2, E6, E10

I.6 Qualification Status

E1, E10

Manufacture Packages to meet R&M Goals and Requirements E7 Reliability & Qualification Testing E10 Update Reliability Assurance E4 Construction Gate

Execute Reliability Implementation Manual

36

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Appraise

Select

Define

Execute

Execute Engineering & Procurement Task Descriptions Quantitative

Ι.1

The BP MPcp requires the Project Knowledge Management Plan to be updated for the Execute stage activities accounting for the relevant networks and systems for knowledge sharing that have been identified including peer assists and after action reviews as appropriate. A regular two-way transfer of knowledge between the project and the company is essential to ensure lessons are identified, captured and transferred to the relevant parties as the project progresses.

Project Risk Review Description

Ι.3

Unnecessary

Technical Risk Ref Category A B C D Appendix

Project Lessons Learned Description

Ι.2

Qualitative

Operate

The BP MPcp requires the Execute risk targets to be confirmed within the Define boundaries or variances explained, such that the overall assessment of project risks can be demonstrated to be at an acceptable level. A formal cross-discipline process is in place to track performance, manage risks and communicate these and lessons learned openly across the project.

Quality Management The R&M goals and requirements and Reliability Plan for Execute shall reflect the requirements of QM, from design into manufacture, and Reliability Tasks shall address quality improvement needs. The QM activities at Execute have the potential of having the biggest impact on whether the design reliability can be achieved or not. Also, data derived from QM activities, required as evidence of qualification and/or reliability assurance, is required.

Ι.4

Co

py

Description

Safety Management

The use of safety critical hardware in a package or the project shall be confirmed at the start of Execute. The necessary high level of reliability and availability performance shall be assured by undergoing reliability analysis and implemented through design and manufacture for functionality and operability.

Qualification Status Description

nt

Ι.6

For each system, subsystem and component, as appropriate, the expected service conditions shall be considered in order that historical data available is shown to be relevant. A review of relevant reliability data is required during the Execute stage to provide approximate figures for the potential reliability that may be achieved by the selected design.

co

Description

ro l

Reliability Data

The BP MPcp requires that all technology options as defined in the Technology Plan are resolved by Execute and the results are supported by an implementation plan inclusive of technical, financial and schedule risk mitigation plans. A review of the current qualification status (TRL) of each component of each package is required at the start of the Execute stage. This activity should address any changes such as operating environment, technology, architecture, manufacturing process, materials, etc. since previous projects.

Un

Ι.5

le

d

Description

Execute Reliability Implementation Manual

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Appraise

Select

Define

Execute

Execute Engineering & Procurement Task Descriptions Quantitative

E1

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

Component Technical Risk Categorisation Task Goal Description

H

H

H

H

Ι.1 D1 I.2 E2 I.4 Ι.6

Co

M

M

M

M

H

H M L

Effort

Input

Output Resources

Importance

R2

nt

Description

Review/update package R&M goals and requirements in response to supplier’s R&M activities and design improvements. Review and update package R&M goals and requirements once package components are specified in more detail. Consider the potential impact of identified package design and manufacturing risks on overall system availability and value. Consider the potential impact of identified construction and installation risks on overall system availability and value. Key business objectives Lessons learned from previous projects Reliability data Package/component technical risk categorisation Project risk management Quality Management Define stage R&M goals and requirements Reliability Plan at end of Define Updated statement of the package R&M goals and requirements to be included in updated RAD. The evaluation should be carried out by the Execute team, including suppliers and installation contractors, supported by a reliability specialist.

co

Task Goal

ro l

Update Package Reliability and Maintainability Goals and Requirements

Un

E2

le

Resources

d

Output

Importance

R1

py

Input

Determine technical risk category of the engineering package major components This technical risk categorisation task focuses on the major components of the engineering packages, for example valves, materials, seals, sensors, control pods, etc. The purpose is to quickly indicate the higher technical risk components and packages. BP and contractor engineers responsible for the major packages shall consider and take ownership of the reliability technical risk category of the components of their particular package. It shall consider • Novelty - it is often the minor changes that cause the major problems • Interfaces between packages, equipment and companies including key installation equipment • Requirements for reliability improvement • Safety critical hardware Using the technical risk categorisation table, select a technical risk category for each component under consideration. Confirm the component category is in accordance with its technology qualification status identified in terms of its TRL. Lessons learned from previous projects Define stage project technical risk categorisation Project and package risks Package R&M goals and requirements Requirements for safety critical hardware Qualification status of each major component in the system A statement of technical risk category, with justification, for each major component. The technical risk categorisation should be agreed between BP and the contractor package engineers with the support of the reliability specialist and other relevant technical experts.

Ι.1 I.5 E1 Ι.2 I.3 D2 D3

M

L

L VL

Effort

Execute Reliability Implementation Manual

38

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Appraise

Select

Define

Execute

Execute Engineering & Procurement Task Descriptions Quantitative

Unnecessary

Technical Risk Ref Category A B C D Appendix

Update Reliability Plan for Execute Description

Input

Output Resources

Define at a more detailed level, the activities required to demonstrate reliability during the Execute stage. Review the Reliability Plan produced at Define. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements, the qualification requirements and QM requirements. Update the detailed Reliability Plan for the Execute stage including which reliability activities are required, when they are required and what resources are required to facilitate these activities. These activities should include (but not be limited to) the following: • FMECA (for reliability and qualification) • TRAP (Levels 1 & 2) • FTA/RBD at system and sub-system level (for reliability and qualification as appropriate) and updating of the RAM Model • Development and implementation of testing programme to demonstrate reliability Project technical risk categorisation R&M goals and requirements Quality Management Define stage Reliability Plan Qualification Plan An updated Reliability Plan. The plan should be defined by the project Reliability Lead together with a reliability specialist in negotiation with the project manager and the BP and contractor package engineers.

Importance

R3

E1 E2 I.3 D3 E10

H

M

L VL

H

H M L

le

Update the activities required to demonstrate qualification for each package. Update the qualification matrix for all equipment and identify the qualification testing and associated acceptance criteria required during Execute for each package. Technology qualification status (TRL) Quality Management Define Qualification Plan Package Reliability Plan Qualification matrix and Qualification Plan for each package The Qualification Plan should be developed in conjunction with the Reliability Lead and relevant suppliers and specialists.

Effort

Importance

ro l

R10 Ι.6 I.3 D10 E3

nt

co

Output Resources

H M L

H

M

L VL

Effort

Un

Input

d

E10 Update Qualification Plan for all Packages Task Goal Description

H

py

Task Goal

Co

E3

Qualitative

Operate

Execute Reliability Implementation Manual

39

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Appraise

Select

Define

Execute

Execute Engineering & Procurement Task Descriptions Quantitative

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

E6 Detailed Reliability Analysis

Resources

Importance

py

R6

d

Co

E1 I.1 E2 D6 D5 I.5

le

ro l

Output

nt

Input

M L

M

L

Effort

co

Description

Identify and assess the probability of package failure modes and define H H clear mitigation strategies Identify and evaluate package and component failure modes that will cause production outages through a FMECA. Considering the failure logic within each package, assess the probability of package failure modes using RBDs or FTA. This should also address interface and installation failure modes and should recognise the impact or failure through the system. Assess the importance of the various components to the failure modes Perform CCFA to identify items vulnerable to common cause failures. Define Specific, Measurable, Achievable, Realistic and Time-Bound (SMART) Mitigation actions. Investigate the design of the system and packages and identify any further technical risks to be managed through the TRAP Level 1 process Towards the end of detailed design, investigate the design of critical packages and components and identify any further technical risks to be managed through the TRAP Level 2 process. Update Define stage RAM analysis to represent full equipment scope and system architecture using verified data relevant to supplied equipment. Project technical risk categorisation Lessons Learned R&M goals and requirements RAM analysis from Define stage Reliability value analysis from Define stage Reliability data Report results of each activity as evidence of required mitigations to ensure reliability achievement. Once actions are closed out they should be reported in the Reliability Assurance Document. For technical risk category D, the output from previous project work should be sufficient. RAM analysis should be carried out by a reliability specialist with direct review/input from the project team. Other reliability analysis should be carried VH H out by all relevant members of the project team (BP, contractors and suppliers) with support from a reliability specialist.

Un

Task Goal

Execute Reliability Implementation Manual

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Define

Execute

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Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

E7 Design and Procure to Meet R&M goals and requirements Importance

R7

R10

le

d

Co

py

E1 E2 E3 E10 E6 I.1

M

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L VL

Effort

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Resources

H M L

nt

Output

H

co

Input

Design and procure packages which meet the R&M goals and requirements During Execute it is essential to ensure that the design meets the R&M goals and requirements and that reliability is considered as integral to the design process. Manufacturing and assembly implications should be considered in design decisions so that the design’s reliability potential is not compromised by these processes. Last minute design changes and associated manufacturing errors can result in early life failures. Any relevant mitigations identified as required in the reliability analysis (FMECA, TRAP, etc) should be implemented as required during Execute. Change Control: BP, contractors and suppliers shall ensure they have robust change control procedures in place to ensure that any changes to the design are fully understood and correctly implemented and qualified if they are necessary. These shall be flagged to the project team and appropriate MoC and Risk Review processes should be initiated. Design Quality Control: The contractor/supplier shall possess a design document control process which meets BP’s quality acceptance criteria. Review or Initiate Reliability and Qualification Tests: In some cases additional tests may be initiated where they are deemed necessary. Project technical risk categorisation R&M goals and requirements Reliability Plan for Execute Qualification Plan for Execute Detailed reliability analysis Lessons learned from previous projects List of closed out reliability mitigations and corrective actions implemented during design to be included in the Reliability Assurance Document. The package design should be managed for reliability achievement by the package manager with verification carried out by the Reliability Lead with support from a reliability specialist.

Un

Task Goal Description

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Qualitative

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Operate

Technical Risk Ref Category A B C D Appendix

E7 Manufacture Packages to Meet R&M goals and requirements Manufacture packages which meet the R&M goals and requirements During Execute it is essential to ensure that the design’s reliability potential is not compromised by the manufacturing and assembly process. Manufacturing defects in components often result in early life failures. It is important therefore to ensure that no defects occur during manufacture or in subsequent assembly. Any relevant mitigations identified as required in the reliability analysis (FMECA, TRAP, etc) should be implemented as required during manufacture. Change Control: BP, contractors and suppliers companies shall ensure they have robust change control procedures in place to ensure that any changes in the manufacturing process are avoided if possible or are fully understood and correctly implemented and qualified if they are necessary. These shall to be flagged to the project team and appropriate MoC and Risk Review processes should be initiated. Manufacture Quality Control: The supplier shall possess a manufacturing process which meets BP’s product quality acceptance criteria. Any weak or defective components shall be identified and removed. Where appropriate (e.g. for volume production items) sampling tests to be included to detect defect rates. Review or Initiate Reliability and Qualification Tests: The plan for Reliability and Qualification tests shall be reviewed and in some cases additional tests may be initiated where they are deemed necessary. Link to FRACAS (Failure Reporting And Corrective Action System) Information on the defects and loss of quality shall be recorded in the suppliers FRACAS system. Project technical risk categorisation R&M goals and requirements Reliability Plan for Execute Qualification Plan for Execute Detailed reliability analysis Lessons learned from previous projects Quality Management List of closed out reliability mitigations and corrective actions implemented during manufacture and assembly to be included in the Reliability Assurance Document. The package manufacture should be managed for reliability achievement by the package manager with verification carried out by the Reliability Lead with support from a reliability specialist.

H

H M L

Importance

R7

R10 E1 E2 E3 E10 E6 I.1 I.3

nt

M

M

L VL

Effort

co

Resources

Un

Output

ro l

le

d

Input

Co

py

Task Goal Description

Execute Reliability Implementation Manual

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Define

Execute

Execute Engineering & Procurement Task Descriptions Quantitative

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

E10 Reliability and Qualification Testing Task Goal Description

M L

I.1 I.3 I.5 E1 E2 E3 E10 E6

Co

d

Update Reliability Assurance

nt

Description

Update the Reliability Assurance Document (RAD) to provide assurance and evidence that the system and package design has been designed, manufactured and tested to achieve required reliability. Review RAD format for the project. Within the RAD: • Describe the technical risk categories for each package and major component providing background information and evidence to support the category selected. • Describe the project/package R&M goals and requirements also included in the Basis of Design and package specification documents • Present results of the reliability analyses carried out in Execute and demonstrate mitigation actions being completed and closed out. • Present the updated version of the Reliability Plan and Qualification Plan including necessary reliability and qualification testing • Summarise how QM reliability requirements have been addressed • Describe any changes made to system design/architecture that impact reliability • Present summary results of the reliability/qualification testing carried out Project/package/component technical risk categorisation R&M goals and requirements Reliability Plan Qualification Plan Quality Management Reliability analysis results Updated design. Evidence of implementation of manufacturing/assembly mitigation actions Reliability and qualification testing results Reliability Assurance Document (Define) A Reliability Assurance Document (Execute) The RAD should be compiled by the Reliability Lead and package engineers with input from suppliers and support from a reliability specialist as appropriate. Ownership of the RAD should be transferred to the installation team at handover of equipment from suppliers.

H

H M L

Effort

Importance

R4

co

Task Goal

M VL

Un

E4

le

Resources

ro l

Output

Importance

R10

py

Input

Perform the required equipment tests to improve confidence in the ability of the H H equipment to function satisfactorily in service Reliability/qualification tests planned and defined during Define & Execute shall be implemented as the manufacturing and assembly proceeds. The majority of qualification is testing performed in Execute but long lead items may need testing in Define. Based on the qualification requirements identified through the use of qualification matrices during Define and further requirements identified during FMECA / TRAP processes, perform traditional qualification tests and, where appropriate, Accelerated Life tests and stress-screening tests. Investigate failed or defective parts and submit to the Failure Reporting System. Results of successful tests shall be assessed and submitted as a contribution to the Reliability Assurance Document. Use the results from FAT and SIT to further demonstrate appropriate qualification. Lessons learned from previous projects Quality Management Reliability data Project/package technical risk categorisation R&M goals and requirements Reliability Plan for Execute Qualification Plan for Execute Detailed reliability analysis Reports of qualification tests carried out and any particular findings from the tests that shall be addressed. These should be referenced in the Reliability Assurance Document. The qualification programme should be managed for reliability achievement by the package manager with verification carried out by the Reliability Lead with VH H support from a reliability specialist.

Input

Output Resources

E1 E2 E3 E10 I.3 E6 E7 E10 D4

H

M

L VL

Effort

Execute Reliability Implementation Manual

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Define

Execute

Operate

Execute Construction and Handover Phase Goal

Produce an operating asset consistent with scope, cost, schedule and operability requirements.

Activities

Manage construction and handover to ensure that the project achieves its cost, schedule and operability goals.

Reliability Input

Define, evaluate and implement tests and procedures as required by the Reliability Plan. Prepare the Reliability Assurance Document for handover to demonstrate that all reliability activities have been carried out and that all equipment and systems and procedures are verified against R&M requirements.

Procedure Technical Risk Categorisation

Update R&M and Construction Task Goals & Requirements C2

Update Qualification Plan C10

le

d

Update Reliability Plan including Testing & Procedure Validation C3

Co

py

C1

Un

co

nt

ro l

Hardware & Procedure Testing C10

Input Tasks

Required by

I.1 Lessons Learned

C1, C2, C10

I.2 Project Risk Review

C1, C2

I.3 Quality Management

C2, C3, C4, C10

I.4 Safety Management

C1

I.5 Reliability Data

C2, C10

I.6 Qualification Status

C1, C10

Complete Reliability Assurance for Start-up C4 Reliability Data and Lessons Capture C9

Operate Gate

Execute Reliability Implementation Manual

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Define

Execute

Execute Construction & Handover Task Descriptions Quantitative

Project Lessons Learned Description

Ι.2

The BP MPcp requires the Project Knowledge Management Plan to be updated for the Execute stage and prepared for the transition to Operate, with the impact within the project of lessons learned, recorded. Plans for managing information and transferring it for use in Operations shall be in place. A process of Lessons Capture is required as part of this before the end of Execute. A continuation of knowledge sharing processes through Execute such as peer assists and after action reviews should be maintained as appropriate. .A review of lessons learned relating to construction and handover activities are part of this.

Project Risk Review Description

Ι.3

Unnecessary

Technical Risk Ref Category A B C D Appendix

The BP MPcp requires the Execute risk targets to be confirmed such that the overall assessment of project risks can be demonstrated to be at an acceptable level. An assessment of project risks relating to construction and handover activities is particularly important during this phase of Execute.

Quality Management

The QM activities at Execute have the potential of having the biggest impact on whether the design reliability can be achieved or not. The Reliability Tasks therefore shall address the QM requirements. This is particularly important during assembly, construction and in testing. Also, data derived from QM activities, required as evidence of qualification and/or reliability assurance, shall be sought.

Co

Description

py

Ι.1

Qualitative

Operate

Description

Ι.6

le

ro l

Reliability Data

nt

Ι.5

The consequences of functional failure (loss of operability) of a safety critical system are higher than for non-safety equipment. It is essential that the higher risks associated with safety critical equipment are accounted for in the reliability tasks at this stage of Execute, particularly in terms of assembly and construction for functionality and operability and in terms of specification for reliability and acceptance testing.

A review of reliability data associated with historical failures arising from installation and commissioning activities is required during the Execute stage to inform the reliability activities.

Qualification Status Description

co

Description

d

Safety Management

Un

Ι.4

The BP MPcp requires that the design intent is rigorously controlled through procurement and construction, with the application of new technology tested and operational implications reflected in commissioning and start-up plans. The current qualification status (TRL) of each component of each package together with details of any remaining qualification testing is required at hand over from the manufacturer to the installation team.

Execute Reliability Implementation Manual

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Define

Execute

Execute Construction & Handover Task Descriptions Quantitative

C1

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

Procedure Technical Risk Categorisation Task Goal Description

Update R&M and Construction Task Goals and Requirements H

H M L

Importance

R2

co

nt

Description

Review/update R&M and construction Reliability Task requirements in response to qualification, construction and installation activities Review and update R&M goals and requirements as qualification, construction, installation and testing progresses. Consider the potential impact of identified construction risks on overall system availability and value. Assess the potential consequences of failure during a procedure both in relation to hardware damage and delayed start-up Determine the acceptability of the risks for each procedure. From the detailed RAM analysis, confirm the maintainability strategy and the consequential spares and vessel availability necessary to achieve overall project availability goals/requirements. Key business objectives Lessons learned from previous projects Reliability data Detailed RAM analysis Project technical risk categorisation Project risk management Quality Management requirements Reliability Plan at handover of equipment from suppliers Execute stage R & M goals and requirements An updated statement of the R&M goals and requirements to be included in updated RAD The evaluation should be carried out by the Construction and Handover Execute team supported by a reliability specialist.

ro l

Task Goal

Input

Output Resources

Un

C2

le

d

Output Resources

Co

py

Input

Determine the technical risk category of the procedures to be used for H H H H Importance construction, installation and testing. This technical risk categorisation task focuses on the procedures to be used R1 during construction, installation and testing. The purpose is to quickly indicate the higher technical risk procedures where there is potential for the procedures to affect the reliability of equipment to be installed e.g. through increased stresses, minor surface damage, incorrect connections, etc The technical risk category of the procedures shall consider • Novelty in equipment used for installation or in procedures - it is often the minor changes that cause the major problems • Interfaces between packages, equipment and companies including installation equipment. • Workforce experience • Safety critical hardware • Qualification status of packages and equipment Using the technical risk categorisation table, select a technical risk category for each procedure under consideration. Lessons learned from previous projects Ι.1 Technical risk categorisation of project specific novel installation equipment D1 Project and package risks I.2 Package R&M goals and requirements E2 Requirements for safety critical hardware I.4 Qualification status of each major component in the system I.6 A statement of technical risk category, with justification, for each procedure. The technical risk categorisation should be agreed between BP and the contractor with the support of the reliability specialist and other relevant technical experts VL VL VL VL Effort including engineers responsible for installation, testing, etc.

I.1 I.5 E6 R1 I.2 I.3 E3 E2

M

L VL VL

Effort

Execute Reliability Implementation Manual

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Define

Execute

Execute Construction & Handover Task Descriptions Quantitative

Unnecessary

Technical Risk Ref Category A B C D Appendix

Update Reliability Plan including Testing and Procedure Validation

Output Resources

Importance

R3

C1 C2 I.3 E3 C10

L

L VL VL

Effort

H

H M L

Importance

nt

R10 Ι.6 I.3 E10 C3

co

Output Resources

Update the activities required to demonstrate qualification for each package Update the qualification matrix for all equipment and identify the remaining qualification testing and associated acceptance criteria that are required before installation and handover to operations. Technology qualification status (TRL) Quality Management Execute Qualification Plan Reliability Plan Qualification matrix and Qualification Plan for each package The Qualification Plan should be developed in conjunction with the Reliability Lead and relevant suppliers and specialists.

Un

Input

ro l

C10 Update Qualification Plan Task Goal Description

H M L

py

Input

H

Co

Description

Define at a more detailed level, the activities required to demonstrate reliability during this phase of the Execute stage. Review the Reliability Plan. Make an updated assessment of the level of effort considered necessary to achieve the R&M goals and requirements, the qualification requirements and QM requirements. Update the detailed Reliability Plan for this part of the Execute stage including which reliability activities are be required, when they are be required and what resources are required to facilitate these activities. These activities should include (but not be limited to) the following: • Process FMECA • Procedure Operation Risk Analysis • FTA, ETA as required by FMECA and Operation Risk Analysis • Procedure Testing/Simulation • Confirmation and implementation of reliability testing programme to demonstrate reliability • The definition and responsibilities of the Reliability Team shall reflect the transferred responsibility following delivery of the equipment to the construction and installation teams. Project technical risk categorisation R&M goals and requirements Quality Management Execute stage Reliability Plan Qualification Plan An updated Reliability Plan The plan should be defined by the project Reliability Lead together with a reliability specialist in negotiation with the project manager and the BP and contractor package engineers.

d

Task Goal

le

C3

Qualitative

Operate

L

L VL VL

Effort

Execute Reliability Implementation Manual

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Define

Execute

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Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

C10 Hardware and Procedure Testing Task Goal

Description

M

L

I.1 I.3 I.5 C1 C2 C3 C10 E6

Complete Reliability Assurance for Start-up

H

H M L

Importance

R4

co

nt

Description

Complete the Reliability Assurance Document (RAD) to provide assurance and evidence that the system and packages have been built and tested to achieve required reliability. Review Reliability Assurance Document for the project. Within the RAD: • Describe the technical risk categories for each procedure providing background information and evidence to support the category selected. • Update the R&M goals and requirements for construction activities and testing procedures • Present results of the procedure testing carried out including demonstration of mitigation actions being completed and closed out • Present the updated version of the Reliability Plan and Qualification Plan including the necessary reliability and qualification testing • Summarise how QM reliability requirements have been addressed • Describe any changes made to procedures that impact reliability • Present summary results of the testing carried out Project and procedure technical risk categorisation R&M goals and requirements Reliability Plan Quality Management Qualification Plan Procedure, reliability and qualification testing results Execute Design and Manufacture Phase RAD • Completed Reliability Assurance Document for Project • The RAD should be included along with the Decision Support Package (DSP) presented for the Operate Gate. The RAD should be compiled by the contractor Execute team / Reliability Lead with support from a reliability specialist as appropriate.

ro l

Task Goal

Effort

Un

C4

M VL

le

d

Resources

Co

Output

Importance

R10

py

Input

Ensure that procedures used during assembly, installation and testing does not impact on reliability of installed hardware. H H Perform the required equipment tests to improve confidence in the ability of the equipment to function satisfactorily in service Procedures to be used for assembly, installation, commissioning and start-up should be tested or simulated prior to implementation to ensure that the procedures do not affect the reliability of the installed hardware. Incorrect procedures often result in unexpected early life failures of hardware or delays in start-up. The reliability and qualification tests planned and defined during Define and Execute stages shall be implemented as assembly, installation and commissioning proceed. Use the results from acceptance testing, SIT, post-installation tests, commissioning and other testing to further demonstrate appropriate qualification. Lessons learned from previous projects Quality Management Reliability data Procedure technical risk categorisation R&M goals and requirements Reliability Plan for Execute Qualification Plan for Execute Detailed reliability analysis Reports of tests carried out and any particular findings from the tests that require addressing. These should be referenced in the Reliability Assurance Document. The qualification programme should be managed for reliability achievement by the contractor Execute project team with verification carried out by the VH H Reliability Lead with support from the reliability specialist as appropriate.

Input

Output

Resources

C1 C2 C3 I.3 C10 C10 E4

H

M

L VL

Effort

Execute Reliability Implementation Manual

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Define

Execute

Execute Construction & Handover Task Descriptions Quantitative

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

C9 Reliability Data and Lessons Capture

R9

H

M VL

Effort

d

Co

py

H

le

Resources

Importance

ro l

Output

H M L

nt

Input

H

co

Description

To demonstrate performance to regulatory authorities and to provide data for future analysis and design. Record reliability failures and good practices during the project stage up to the point of package or system handover to operations. All data shall be collected to meet the requirements of GP 78-26. Key lessons shall also be retrieved and fed back into future projects via BP Project Lessons Learned processes defined within the BP MPcp Knowledge Management Process and recorded in the ETP shared learning library. Corrective actions shall also be recorded and shall be based on a failure analysis conducted, where appropriate, with the equipment suppliers to understand the technical and root causes of failure. Information concerning: • Failures, • Near misses, • Good practices Reliability Data Lessons learned Data should be collected by the contractor Execute team and fed to BP corporate reliability data management function.

Un

Task Goal

Execute Reliability Implementation Manual

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Execute

Operate

11. Operate Stage Reliability Tasks Goal

Evaluate asset to ensure performance to specifications and maximum return to shareholders.

Activities

Support and evaluate the project end result over a one-year initial operating period and through the life of the field.

Reliability Input

Monitoring of technical performance, compare with assumptions and feedback results and lessons learned. Investigate options for reliability improvements when replacing items at scheduled maintenance or through failure. Treat major modifications as new projects and follow reliability principles and practices.

py

Operate Reliability Plan O3

d

Reliability Value Analysis of Design Improvements O5

le

Reliability Analysis of Design Improvements O6

nt

ro l

Qualification of Design Improvements O10

Co

Collection, Analysis & Validation of Reliability Data O9

Minor Upgrades & Modifications

Un

co

Update Reliability Assurance O4

Input Tasks

Required by

I.1 Lessons Learned

O3, O6, O9

I.3 Quality Management

O3, O4, O9, O10

I.4 Safety Management

O3

I.5 Reliability Data

O6, O9

I.6 Qualification Status

O10

Operate Reliability Implementation Manual

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Define

Execute

Operate Task Descriptions Quantitative

Project Lessons Learned Description

Quality Management Description

Safety Management Description

Ι.5

The QM activities at Operate still have the potential of having significant impact on whether the design reliability can be achieved or not. Also, data derived from QM activities, required as evidence of qualification and/or reliability assurance, shall be sought. A review of the Reliability Tasks needed to meet the QM requirements is required, particularly in relation to operations and data collection.

py

Ι.4

The BP MPcp requires the Project Knowledge Management Plan to be finalised for the transition to Operate, with the impact within the project of lessons learned recorded. Plans for managing information and transferring it for use in Operations shall be implemented. A process of Lessons Capture is required as part of this handover process. A process shall also be set-up to inform future projects and development work on the longer-term application of novel technology incorporated within the project as well as a retrospect review of key lessons.

It is essential that the higher risks associated with safety critical equipment are accounted for in the Operate Reliability Tasks to optimise functionality and operability and to manage any required reliability improvements for the equipment. A review of the Operate Reliability Tasks needed as part of Safety Management requirements is therefore required.

Co

Ι.3

Unnecessary

Technical Risk Ref Category A B C D Appendix

Reliability Data

A review of relevant reliability data is required during the Operate stage to provide approximate figures for the potential reliability that may be achieved by the installed design. This data shall be used as a comparator with actual achieved reliability. Data may also be required to assess the benefits of replacing hardware with improved components.

Qualification Status

nt

The BP MPcp requires that plans are put in place to monitor and assess the performance of the plant and component systems through operations against the Basis of Design. This shall involve feedback with appropriate technology groups and other projects. In addition, during the Operate stage equipment may need to be replaced, either through scheduled maintenance or because of unexpected failure. In the interim, alternative equipment may become qualified for application in the project and its qualification status (TRL) shall be updated and made available to the project.

co

Description

Un

Ι.6

ro l

le

Description

d

Ι.1

Qualitative

Operate

Operate Reliability Implementation Manual

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Define

Execute

Operate Task Descriptions Quantitative

Technical Risk Ref Category A B C D Appendix

Operate Reliability Plan

Output Resources

Collection, Analysis & Validation of Reliability Data Task Goal

H

M L

To validate predicted reliability against experience, to demonstrate performance to regulatory authorities and to provide data for future analysis and design. All data shall be collected to meet the requirements of GP 78-26. Set up systems and procedures to ensure data is collected and collated from all relevant activities such as: • testing (qualification, FAT, SIT) • commissioning • operation • monitoring • inspection • intervention and repair This data shall include service conditions, durations, and intervention requirements specific to project designs. Particular note should be made of non-conformances and failures which should be investigated and reported thoroughly. Data shall be collated according to BP (OREDA) standard guidelines into a reliability database and analysed to provide validation against predicted performance. Key lessons shall also be retrieved and fed back into future projects via BP Project Lessons Learned processes and recorded in the ETP shared learning library. Reliability data and key lessons shall also be fed back to suppliers to inform them on the performance of their product and hence allow them to understand the need for reliability improvement Detailed reliability analysis Project lessons learned Quality Management Reliability data Submissions to BP/OREDA and lessons learned databases Data should be collected by operations group and fed to BP corporate reliability data management function.

Importance

R3

C4 I.1 I.3 I.4

M

L

L

VL

H

H M L

Effort

Importance

R9

Un

co

nt

ro l

Description

H

py

Input

Co

Description

Plan the R&M activities required during Operate for continued reliability assurance and feedback Ascertain from the R&M goals and requirements the general level of effort considered beneficial to achieve the required reliability and production availability. Ascertain QM and safety management requirements. Outline a practical plan for reliability for the Operate stage including: • The reliability activities required • When they are required within the Operate project schedule • The reliability leadership and organisation for Operate stage • What resources are required to facilitate these activities Outline procedures for data collection both for feedback to future projects and to provide evidence for regulatory authorities in line with GP 78-26 Outline procedures for investigating and reporting failures Outline procedures for replacing equipment with identical or improved components following failure or at scheduled replacement including the reliability analysis/assessment that is required to support the decision Project RAD Lessons learned from previous projects and operations Quality Management Safety management Reliability Plan for Operate The plan should be outlined by the project Reliability Lead together with a reliability specialist in negotiation with the project manager.

d

Task Goal

O9

Unnecessary

le

O3

Qualitative

Operate

Input

Output Resources

E6 I.1 I.3 I.5 H

H

M VL

Effort

Operate Reliability Implementation Manual

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Define

Execute

Operate Task Descriptions Quantitative

Qualitative

Unnecessary

Operate

Technical Risk Ref Category A B C D Appendix

O10 Qualification of Design Improvements Task Goal Description Input Output Resources

Description

Input

To ascertain the options for and the benefits of replacing hardware (either at scheduled replacement or following failure) with components having improved reliability. Confirm if predicted reliability of component has been achieved during life of project.

Importance

I.3 I.6 L

L VL VL

Effort

H

H M L

Importance

Co

Reliability data Risk assessment for hardware replacement Detailed reliability analysis should be performed by a Reliability Specialist

Output Resources

E6 I.1 I.5

L

L VL VL

Effort

H

H M L

Importance

ro l

Input

Project value analysis model Value analysis justification for hardware replacement Project RVA should be performed by a reliability specialist with input from the project manager

nt

Description

To ascertain the value of replacing hardware (either at scheduled replacement or following failure) with components having improved reliability. Update previous detailed RAM Analysis and Reliability Value Analysis to determine value and benefits of improved hardware. Project RAM model

co

Task Goal

le

Reliability Value Analysis of Design Improvement

R1

d

Output Resources

R6

Undertake root cause analysis for significant or repeated failures Perform a technical risk categorisation exercise and risk analysis (e.g. FMECA) for all replacement hardware Project RAM model Lessons learned during this and other projects

R5 E6 E5 L

L VL VL

Effort

H

H M L

Importance

Update Reliability Assurance Task Goal

Description

Input

Output Resources

Update the Reliability Assurance Document (RAD) to provide assurance and evidence that the system continues to achieve the required reliability and production availability. Demonstrate that replacement hardware has been designed, manufactured and tested to achieve required reliability. Confirm predicted hardware availability with actual performance Provide evidence that QM R&M goals and requirements continue to be met Provide details of failures and their causes Update technical risk category for replacement hardware Update reliability analysis, qualification and all testing as appropriate Updated Reliability Plan for Operate Project RAD Reliability Plan for Operate Quality Management Summary of results from data collection Qualification test results for replacement hardware Updated reliability analysis Reliability value analysis results for replacement hardware Updated RAD Reliability Lead

Un

O4

H M L

Reliability Analysis of Design Improvement Task Goal

O5

H

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O6

To ascertain the options for replacing hardware (either at scheduled replacement or following failure) with components having improved reliability. Check qualification of technology development since start-up to ascertain if improved technology is available for use. Quality Management Qualification Status Identification of improved technology available for use Reliability specialist and Reliability Lead

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12. Glossary This glossary has been formed to provide explanation of acronyms used in the manual and its appendices.

BP Terms

Holistic Early Uncertainty Assessment

BOD

Basis of Design

CVP

Capital Value Process

DSP

Decision Support Package

EA

Engineering Authority

FEL

Front End Loading

GO

Great Operator

HSSE

Health, Safety, Security, and Environment

MPcp

Major Projects common process

PHSER

Project, Health, Safety and Environmental Review

RAD

Reliability Assurance Document

RM

Reliability and Maintenance

SCE

Safety Critical Equipment

SMART

Specific, Measurable, Achievable, Realistic and Time-Bound

SOR

Statement of Requirements

TA

Technical Authority

TRAP

Technical Risk Assurance Process

VIP

Value Improvement Process

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ALERT

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Industry Terms ALT

Accelerated Life Testing

CAPEX

Capital Expenditure required for all stages of the project (including identified operating spares on hand over)

CCFA

Common Cause Failure Analysis

CMMIS

Computerised Maintenance Management & Information Systems

EFAT

Extended Factory Acceptance Test

ESS

Environmental Stress Screening

ETA

Event Tree Analysis

Failure Mode

Description of the manner in which failure has occurred or may occur

FAT

Factory Acceptance Test

FEED

Front End Engineering Design

FMECA

Failure Modes and Effects Criticality Analysis

FRACAS

Failure Reporting And Corrective Action System

FTA

Fault Tree Analysis

HALT

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Highly Accelerated Stress Screening

Hazard Rate

The fraction of failures of items in service per unit time

HAZID

Hazard identification

HAZOP

Hazard and Operability

HIPPS

High Integrity Pressure Protection System

HPU

Hydraulic Power Unit

IMR

Inspection, Maintenance and Repair

ISO

International Standards Organisation

JIP

Joint Industry Project

LCC

Life Cycle Costing

MCS

Master Control System

MFFOP

Minimum Failure Free Operating Period

MFOP

Maintenance Free Operating Period

MoC

Management of Change

MTBF

Mean Time Between Failure

MTTF

Mean Time To Failure, (average value of the times to failure)

NPV

Net Present Value

OPEX

Operating Expenditure over the operational life of a development

OREDA

Offshore Reliability Database

QM

Quality Management

QMS

Quality Management System

R&M

Reliability and Maintainability

RAM

Reliability, Availability and Maintainability

RBD

Reliability Block Diagram

RCA

Root Cause Analysis

RCMM

Reliability Capability Maturity Model

RVA

Reliability Value Analysis

SCC

Stress Corrosion Cracking

SCM

Subsea Control Module

SIT

System Integration Test

SST

Step Stress Testing

TRL

Technology Readiness Level

WELL MASTER

Reliability Database of Well-completion Equipment Technical Effectiveness

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13. Link to Reliability Standards There are a number of national and international standards and guidelines that support and direct the implementation of reliability activities within projects. This manual is not designed to replace these, but to support and link into them. The following table shows how the 10 Reliability Tasks required by this manual relate to some of these standards. Any work carried out in accordance with these standards for these tasks should be considered to also satisfy the requirements of this manual. However, working with contractors and suppliers in the application of this manual in accordance with GP 78-03 and GP 78-04 may introduce variances between the requirements of the standards and the GPs. In such an instance BP shall determine the practice to be followed with due regard to local regulatory requirements.

R4 R5 R6 R7 R8 R9 R10

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Reliability Assurance Reliability Value Analysis Reliability Analysis and Modelling Design and Manufacture for Reliability Contractor and Supplier Selection and Contracting Reliability Data Collection Reliability Qualification Activities

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9

9

9

9

9

9

9

9

9

9

9 9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

9

ISO 13628 [19]

ISO 15663 [18]

ISO 20815 [17]

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9

9 9

9 9

9 9

API RP 17 – N [6]

IEC 61508/61511 [16]

IEC-60605-3 [15]

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OLF GL 70 [13]

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9

Reliability Planning

ISO 9000-4/IEC-60300 [14]

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OREDA standard ISO 14224 [12]

ISO/TS 29001:2003 [11]

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ISO 9001:2000 [10]

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Technical Risk Categorisation Defining R&M goals and requirements

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DNV-RP-A203 [9]

Mapping of Key Tasks to International Reliability Standards

AS/NZS 4360:1999, [8]

Norsok standard Z-016 [7]

The list of codes and standards given below is offered for high level guidance and may not be all inclusive. It is important to ensure that more detailed equipment and procedure specific codes and standards are identified and complied with as may be necessary.

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9

9

Link to Standards Reliability Implementation Manual

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14. References BP Subsea Reliability Strategy, A guide for BP Leaders’ published in April 2003

[2]

BP GP 78-03, Guidance on Practice for Achieving Reliability in Subsea Projects, July 2006

[3]

BP GP 78-04, Guidance on Practice for Reliability Techniques for Subsea Projects, July 2006

[4]

BP GP 78-06, Guidance on Practice for Subsea Prototype Qualification Procedure, July 2006

[5]

BP GP 78-26, Guidance on Practice for Subsea Reliability & Maintenance Data Collection

[6]

API RP 17N “Recommended Practice “Subsea Production System Reliability & Technical Risk Management”

[7]

Norsok standard Z-016: "Regularity management and reliability technology", Rev. 1, Dec. 1998.

[8]

Standards Australia and Standards New Zealand AS/NZS 4360:1999, "Risk Management".

[9]

DNV-RP-A203 "Qualification procedures for new technology", September 2001.

[10]

ISO 9001:2000, “Quality Management Systems”

[11]

ISO/TS 29001:2003: Petroleum, petrochemical and natural gas industries -- Sector-specific quality management systems -- Requirements for product and service supply organizations

[12]

ISO 14224 Petroleum and gas industries - Collection and exchange of reliability and maintenance data for equipment.

[13]

Norwegian Oil Industry Association Guideline OLF GL 70, "Guidelines for the application of IEC 61508 and IEC 61511 in the petroleum activities on the continental shelf", Feb. 2001.

[14]

ISO 9000-4/IEC-60300 Dependability Management, 2003.

[15]

IEC-60605-3 Equipment reliability testing, 1986.

[16]

IEC 61508/61511 Functional safety of electrical/electronic/programmable electronic safety related systems, part 1-7.

[17]

ISO/DIS 20815 Petroleum, petrochemical and natural gas industries – Production assurance and reliability management, 2005

[18]

ISO 15663 Petroleum and natural gas industries – Life cycle costing

[19]

ISO 13628 Petroleum and natural gas industries – Design and operation of subsea production systems

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[1]

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15. BP Contacts and Champions The following list of names is not offered as a comprehensive list. There have been many other helpful contributors, simply too many to name, so apologies are offered for exclusions.

Aberdeen

Sunbury [email protected]

Andy Bennett

[email protected]

Keith Williams

[email protected]

David Brookes

[email protected]

Steve Burchell

[email protected]

Craig Duell

[email protected]

Alan Edwards

[email protected]

Kevin Muller

[email protected]

Andy Sworn

[email protected]

Paul Tooms

[email protected]

Geoff Vine

[email protected]

Houston

Bill Broman

[email protected]

Mike Byrd

[email protected]

Barbara Fagan

[email protected]

Ray Fleming

[email protected]

Gary Harrison

[email protected]

Cathal Kelly

[email protected]

Christopher Lindsey-Curran

[email protected]

Mark Siegmund

[email protected]

Trevor Smith

[email protected]

Mark Worsley

External Consultants

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[email protected]

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Norway Eiliv Janssen

[email protected]

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[email protected]

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Tom Ames

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Zander Bruce

[email protected]

Caroline Roberts-Haritonov

[email protected]

Neil Robertson

[email protected]

John Strutt

[email protected]

Karl Woods

[email protected]

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Liz Garry

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