Quality Assurance Framework to Enable Additive Manufacturing Based Digital Warehousing for Oil and Gas Industry

2021 ◽  
Author(s):  
Sastry Yagnanna Kandukuri ◽  
Ole-Bjørn Ellingsen Moe
Keyword(s):  
Quality Assurance ◽  
Additive Manufacturing ◽  
Inventory Management ◽  
Value Chain ◽  
Oil And Gas ◽  
New Technology ◽  
Oil And Gas Industry ◽  
Spare Parts ◽  
Lead Times ◽  
On Demand

Abstract Additive manufacturing (AM) makes it possible to produce parts on demand, close to operations, with significantly reduced lead times compared to conventional manufacturing. However, without standardization or guidelines, additively manufactured parts could raise the risk of unexpected or premature failures due to inherent variation of mechanical and metallurgical properties associated with this new technology. This is especially true when the reduced lead time is the desired advantage, where speed may be prioritized over quality. A standardised framework is proposed to free up value locked in physical warehouse inventory and reduce inventory management cost through digital warehousing in a safe and cost-efficient way. Through a joint industry project, with participating companies throughout the entire AM value chain, we propose an assurance framework that answers questions such as: can the digital drawing be available when needed? Can the parts be made ‘first time’ right when needed? Can it be made with the same quality at another location next time? Which party is responsible for the different stages? What requirements should be in place for the companies who wish to manufacture on demand? The digital warehouse assurance framework discussed in this work demonstrates that digital warehousing powered by AM could potentially shorten lead times for sourcing parts and reduce the need for costly storage, maintenance and coordination of spare parts that are rarely used. We also discuss the different variants of digital warehousing we may see, and the roles and responsibilities various digital warehouse stakeholders have for facilitating unambiguous communication. AM is already disrupting supply chains in many other industries, but it is in its infancy in the oil & gas, offshore and maritime sectors as they ponder challenges with intellectual property (IP) and usage rights for original equipment manufacturers (OEM) designs, standardization of technology interfaces and the lack of knowledge and trust of the technology. The digital warehouse quality assurance framework proposed and discussed in this work is unique and has potential to not only accelerate adoption of AM in oil & gas and offshore sectors, but also contribute to a significant reduction of emissions, including greenhouse gases.

Additive Manufacturing in the Oil and Gas Industry Overview

2020 ◽  
Author(s):  
Carlo De Bernardi
Keyword(s):  
Additive Manufacturing ◽  
Inventory Management ◽  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Lessons Learned ◽  
Current Status ◽  
Gas Industry ◽  
Standardization Process ◽  
Process Feedback ◽  
Different Levels

Abstract The API 20S Standard is designed to play a crucial role in leveraging Additive Manufacturing (AM) to foster innovation in the oil and gas industry. The paper, in association with the standard, will facilitate the understanding of how AM will enable equipment design improvements, faster prototyping, and better inventory management. By way of discussing the progress, challenges, and lessons learned from the standardization process, the paper aims to encourage a safer, broader, and faster adoption of AM technologies in the mainstream oil and gas applications. The paper will summarize the streamlining process, feedback from the API 20S task group, and current status of the standardization efforts. Additionally, upcoming challenges and the potential for the oil and gas industry industries to contribute to the standard will be summarized. The paper will also showcase a novel tiered approach (Additive Manufacturing Specification Levels) to allow the users of the document to match different levels of criticality.

Modeling and analysis of the on-demand spare parts supply using additive manufacturing

2019 ◽  
Vol 25 (3) ◽  
pp. 473-487 ◽  
Author(s):  
Yuan Zhang ◽  
Stefan Jedeck ◽  
Li Yang ◽  
Lihui Bai
Keyword(s):  
Supply Chain ◽  
Additive Manufacturing ◽  
Spare Parts ◽  
Production Optimization ◽  
Arrival Process ◽  
Powder Bed Fusion ◽  
Content Type ◽  
Modeling And Analysis ◽  
Powder Bed ◽  
On Demand

PurposeDespite the widespread expectation that additive manufacturing (AM) will become a disruptive technology to transform the spare parts supply chain, very limited research has been devoted to the quantitative modeling and analysis on how AM could fulfill the on-demand spare parts supply. On the other hand, the choice of using AM as a spare parts supply strategy over traditional inventory is a rising decision faced by manufacturers and requires quantitative analysis for their AM-or-stock decisions. The purpose of this paper is to develop a quantitative performance model for a generic powder bed fusion AM system in a spare parts supply chain, thus providing insights into this less-explored area in the literature.Design/methodology/approachIn this study, analysis based on a discrete event simulation was carried out for the use of AM in replacement of traditional warehouse inventory for an on-demand spare parts supply system. Generic powder bed fusion AM system was used in the model, and the same modeling approach could be applied to other types of AM processes. Using this model, the impact of both spare parts demand characteristics (e.g. part size attributes, demand rates) and the AM operations characteristics (e.g. machine size and postpone strategy) on the performance of using AM to supply spare parts was studied.FindingsThe simulation results show that in many cases the AM operation is not as cost competitive compared to the traditional warehouse-based spare parts supply operation, and that the spare parts size characteristics could significantly affect the overall performance of the AM operations. For some scenarios of the arrival process of spare parts demand, the use of the batched AM production could potentially result in significant delay in parts delivery, which necessitates further investigations of production optimization strategies.Originality/valueThe findings demonstrate that the proposed simulation tool can not only provide insights on the performance characteristics of using AM in the spare parts supply chain, especially in comparison to the traditional warehousing system, but also can be used toward decision making for both the AM manufacturers and the spare parts service providers.

scholarly journals Evaluating the Readiness Level of Additively Manufactured Digital Spare Parts: An Industrial Perspective

2018 ◽  
Vol 8 (10) ◽  
pp. 1837 ◽  
Author(s):  
Niklas Kretzschmar ◽  
Sergei Chekurov ◽  
Mika Salmi ◽  
Jukka Tuomi
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Industry ◽  
Spare Part ◽  
Spare Parts ◽  
Survey Study ◽  
Lead Times ◽  
Supply Networks ◽  
Readiness Level ◽  
End Use ◽  
Technological Limitations

Additive manufacturing of digital spare parts offers promising new possibilities for companies to drastically shorten lead times and to omit storage costs. However, the concept of digital spare parts has not yet gained much footing in the manufacturing industry. This study aims to identify grounds for its selective rejection. Conducted from a corporate perspective, outlining a holistic supply chain network structure to visualize different digital spare part distribution scenarios, this survey study evaluates technical and economic additive manufacturing capabilities. Results are analyzed and discussed further by applying the Mann-Whitney test to examine the influence of the company size and the presence of 3D-printed end-use components within supply networks on gathered data. Machines’ limited build chamber volumes and the necessity of post-processing are considered as the main technical challenges of current additive manufacturing processes. Furthermore, it can be concluded that company sizes have a significant effect on perceived technological limitations. Overall, the results lead to the conclusion that the readiness level of the digital spare parts concept demands for further development.

scholarly journals An empirical study of oil and gas value chain agility in the UAE

2018 ◽  
Vol 25 (9) ◽  
pp. 3541-3569 ◽  
Author(s):  
Ala Shqairat ◽  
Balan Sundarakani
Keyword(s):  
Supply Chain ◽  
United Arab Emirates ◽  
Value Chain ◽  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Value Chains ◽  
Study Region ◽  
Content Type ◽  
Moderate Effect ◽  
The Impact

Purpose The purpose of this paper is to investigate the agility of oil and gas value chains in the United Arab Emirates (UAE) and to understand the impact of implementing supply disruption (SD) strategies, outsourcing strategies (OS) and management strategies (MS) on oil and gas value chain agility (VCA). The results can support the oil and gas industry across the UAE to build resilience in the value chain. Design/methodology/approach The research design consists of a comprehensive literature review, followed by questionnaire-based survey responses of 106 participants and comprehensive statistical analysis, thus validate the developed theoretical framework and contribute to both practical and methodological approaches. Findings The findings indicate that oil and gas value chain in the UAE has moderate a significant degree of SD, when OS in place that are synchronized with the overall MS. Among the hypotheses developed, two were accepted thus warranting both SD strategies (r=+0.432) and MS (r= +0.457) found to have a positive moderate effect on VCA. The third hypothesis was rejected by revealing OS (r=+0.387) found to have a positive moderate relationship with VCA. Therefore, implementation of all three strategies has a positive moderate effect on the agility of the value chain and, therefore, supports to sustain competitive position. Research limitations/implications Some of the limitations of this research include the geographic coverage of the study region and other methodological limitation. Practical implications The research provides guidance for oil and gas supply chain managers to better understand the critical factors that impact and determine VCA. The paper also describes relevant strategies that should be taken into consideration by these managers in order to build their agile value chains. Social implications The research contributes to the social dimensions of supply chain sustainability of how resilient is the oil and gas value chain during uncertain conditions, so that it can respond to uncertain changes in order to contribute to corporate social responsibility. Originality/value This research is the first of its kind in the UAE region to assess the link between dimensions of agile value chain, OS, SD strategies and MS primarily from the Emirates of Abu Dhabi and Dubai.

scholarly journals Additive Manufacturing and Maritime Spare Parts: Benefits and Obstacles for the End-Users

2021 ◽  
Vol 9 (8) ◽  
pp. 895
Author(s):  
Evanthia Kostidi ◽  
Nikitas Nikitakos ◽  
Iosif Progoulakis
Keyword(s):  
Additive Manufacturing ◽  
New Technology ◽  
Spare Part ◽  
Spare Parts ◽  
Successful Implementation ◽  
Maritime Industry ◽  
End User ◽  
Space Reduction ◽  
Questionnaire Method ◽  
Industrial Context

3D printing or additive manufacturing (AM) (in the industrial context) is an innovative, as opposed to subtractive, technology, bringing new opportunities and benefits to the spare part supply chain (SPSC). The aim of this work is to capture the views of the stakeholders at the end of the chain, extruding factors that will benefit the end-user and the factors that are likely to be an obstacle, by employing the questionnaire method. Company objectives regarding spares (cost reductions, improvement of services, space reduction) have been prioritized differently by the stakeholders. The most important barriers according to the participants are the quality assurance of the spare parts made by the new technology followed by the know-how and skills of staff. Other views such as suitable parts are suggested. The practical value of this work, in addition to assessing the readiness of the industry, is that it provides guidance for the successful implementation of AM in the maritime industry.

Unlocking the Potential: Understanding the Psychological Factors That Influence Technology Adoption in the Upstream Oil and Gas Industry

SPE Journal ◽  
2019 ◽  
Vol 25 (01) ◽  
pp. 515-528
Author(s):  
Ruby Roberts ◽  
Rhona Flin
Keyword(s):  
Technology Adoption ◽  
Psychological Factors ◽  
Oil And Gas ◽  
New Technologies ◽  
New Technology ◽  
Oil And Gas Industry ◽  
Research Area ◽  
Organizational Level ◽  
Innovative Technology ◽  
Future Research

Summary To maximize the opportunities for the adoption of newly developed products, there is a need to better understand how psychological factors have an impact on the acceptance and deployment of innovative technology in industry. While there is extensive general literature on the psychological factors that influence consumer behavior and the use of new technologies, there seemed to be very limited understanding of this topic, specifically relating to the upstream energy sector. A literature review was conducted to (1) identify what, if any, research has been conducted in relation to the psychological factors influencing technology adoption and deployment in the oil and gas (O&G) industry and (2) identify what interventions have been developed to support technology adoption in O&G. A literature search was undertaken, and given the limited research anticipated, minimum selection criteria were applied on the basis of Cochrane quality control (Higgins and Green 2011). In the 17 articles that met the search criteria, there was limited discussion of the psychological factors that have an impact on O&G technology adoption. The articles were subject to Braun and Clarke (2006) thematic analysis, producing a list of psychological factors that influence technology adoption in O&G. Only five psychological factors were identified: personality (e.g., exploration traits and risk aversion), attitude (e.g., trust and not-invented-here syndrome), social (e.g., social norms), cognition (e.g., risk perception), and psychological factors at an organizational level (leadership and organizational culture). In addition, our review identified a small number of interventions that were developed and deployed to support technology adoption in O&G. Given the early stages of this research area, combined with the relevance for technology innovation in upstream O&G, our review adds to the literature by identifying an initial framework of the key psychological factors. This essential set of factors can be used to direct future research, as well as to support effective interventions aimed at supporting the introduction of new technology.

Wet Compression: Performance Test of a 3D Impeller and Validation of Predictive Model

2016 ◽  
Author(s):  
Veronica Ferrara ◽  
Lars E. Bakken ◽  
Stefano Falomi ◽  
Giuseppe Sassanelli ◽  
Matteo Bertoneri ◽  
...  
Keyword(s):  
Performance Test ◽  
Oil And Gas ◽  
Dynamic Pressure ◽  
New Technology ◽  
Mechanical Damage ◽  
Oil And Gas Industry ◽  
Gas Industry ◽  
Compression Performance ◽  
Laboratory Setup ◽  
Wet Compression

In the last few years wet compression has received special attention from the oil and gas industry. Here, the development and implementation of new subsea solutions are important focus areas to increase production and recovery from existing fields. This new technology will contribute to exploitation of small and remote fields and access in very deep water. In this regard liquid tolerance represents a viable option to reduce the cost of a subsea compression station bringing considerable simplification to the subsea process itself. However, the industry may experience some drawbacks: the various levels of liquid presence may create operational risk for traditional compressors; the liquid may cause mechanical damage because of erosion and corrosion of the internal units and the compressor performance might be affected too. The experimental investigation conducted in the study considers dry and wet conditions in a laboratory setup to understand how the presence of liquid influences the stage performance. The test campaign has been carried out at the Norwegian University of Science and Technology, NTNU, in Trondheim, to assess the performance and operating range of a tridimensional impeller when processing a mixture of gas and liquid phases. Experimental results allowed validating the OEM internal prediction code for compressors’ performance in wet conditions. Finally, the effect of liquid on machine operability has been assessed through a left-limit investigation by means of dynamic pressure probes readings in order to evaluate the stall/surge behaviour for different values of liquid mass fraction.

Harnessing the value of data in asset management for production assurance and to lower operating costs

2013 ◽  
Vol 53 (2) ◽  
pp. 491
Author(s):  
Paul Agar
Keyword(s):  
Asset Management ◽  
Net Present Value ◽  
Oil And Gas ◽  
New Technology ◽  
Critical Role ◽  
Oil And Gas Industry ◽  
Life Cycles ◽  
Critical Element ◽  
Management Decisions ◽  
Asset Data

With rising costs, a tight labour market, and prolonged global economic uncertainty, it is unsurprising that investment decisions are being re-evaluated across Australia's resources and energy industry. Amid this tough market environment, effective asset management has never been more important. Asset management was first adopted by Australia's oil and gas industry in the early 90s and is now well entrenched. There is widespread acknowledgement that it breaks down project complexity and plays a critical role in maximising project net present value. If done well, asset management takes a long-term view of asset life-cycles–from concept and creation, to services that deliver production assurance and lower costs. While these principles are well understood across the market, asset data capture and analysis–a critical element to successful asset management–requires ongoing review. Accurate and comprehensive asset data is the basis on which all good asset-management decisions are made. Developments in geographic information systems, SAP, and cloud-based technology are redefining the way asset data is collected, stored, analysed, and fed back into asset-management decisions. Asset managers of oil and gas assets should, therefore, be asking themselves three important questions: Are we using the latest technology to collect, store, and analyse asset data? Which project stakeholders need to interact with the data? Do our existing or planned asset-management models have the capacity to integrate and evolve with new technology as it develops?

New Technology Spiral SAW Pipes for Onshore and Offshore Oil and Gas Pipelines

2002 ◽  
Author(s):  
Josef Avagianos ◽  
Kostas Papamantellos
Keyword(s):  
Oil And Gas ◽  
Quality Management System ◽  
New Technology ◽  
Large Diameter ◽  
Production Capacity ◽  
Oil And Gas Industry ◽  
Step Method ◽  
Line Pipe ◽  
Water Transportation ◽  
Welded Pipe

The world production capacity on large-diameter welded pipe amounts to more than 12 million tons per year 20–25% are produced as spiral sub-arc welded (SAW) pipes, with the balance of 75–80% being longitudinal SAW pipes (from plates). For most spiral-weld producers, a sizeable portion of line pipe is for water transportation, rather than hydrocarbon. In the past, the relative structural weakness of spiral-welded pipe, due to larger welded area, limited the growth of its use in the oil industry. With the development of more advanced production technology, the acceptance of spiral-welded pipes in the oil and gas industry has increased significantly. In this paper, the principals of the spiral manufacturing technology from coil by the two-step-method are introduced and the innovations of Corinth Pipework’s production facility are outlined in detail, including the sophisticated NDT techniques and the Quality Management System.

Logic Sequence Prevents Launching Devices Downhole Out of Sequence

2014 ◽  
Author(s):  
Ricardo de Lepeleire ◽  
Nicolas Rogozinski ◽  
Hank Rogers ◽  
Daniel Ferrari
Keyword(s):  
Latin America ◽  
Oil And Gas ◽  
New Technology ◽  
Specific Area ◽  
Oil And Gas Industry ◽  
Gas Industry ◽  
Logic Control ◽  
Drilling Operations ◽  
Common Operation ◽  
Increasing Demand

Within the oil and gas industry, significant costs are often incurred by the operating company during the well-construction phase of drilling operations. Specifically, the operators cost to drill a well can cost tens or hundreds of millions of USD. One specific area where significant changes in drilling operations have occurred is in the offshore environment, specifically operations from mobile offshore drilling units (MODUs). With the ever-increasing demand for oil and gas, operators globally have increased drilling budgets in an effort to meet forecasted demand. However, the increased budgets are often eroded or offset by increasing drilling costs. Therefore, operators are continually in search of new technology, processes, or procedures to help improve drilling operations and overall operational efficiencies. One Latin America operator identified a common operation as a possible area where operational cost could be easily reduced through the implementation of systems that allow the manipulation of valve manifolds remotely. Additionally, operating such valve manifolds remotely enhanced operational safety for personnel, which was an equally important consideration. This paper details the evaluation of existing equipment and procedures and a process used to develop a new remote-control system using a machine logic control (MLC) that has been designed, built, tested, and deployed successfully on MODUs operating in Latin America.

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