Config Stack DFMA Report

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Configurable Stack Fixtures

Pressure Control Group

Subsea Stack

Project

Manufacturing for

Excellence


Configurable Stack DesignModularity • Product-Centered Approach • Reduce Re-Engineering • Customization without Redesign

Optimization • Rectangular Stack Design • Funnel Up Design • Improve LMRP to BOP Interface • Integration of Guidance System into Legs

Configurable Stack Design for Manufacturing & Assembly Meets Customer Needs Internal Goals Achieved: • Shift from project to product philosophy • Reduce Cost of ENG, MFG, & ASSEMBLY • Reduce structural weight • Achieve greater bottle capacity per stack

Customer Goals Achieved: • Customized stack for individual rig needs • Reduce time to market per stack • Minimize impact to envelop • Interchangeable structural components


Customer Demands

1) Market evolving to spare Subsea Stacks per Rig or operational area

2) Major components must be interchangeable with much closer tolerances

3) 24 Subsea Stacks to deliver in 2013, and expected 28 for 2014, and 2015 probable.


LMRP Spider

LMRP Legs

Upper Platforms

Lifting Beams

Lower Stack Legs

Upper Spider

Lower Spider

Mini Spiders


Major Structural ComponentsLMRP Assembly

● LMRP Spider ● LMRP Legs ● Upper Platforms ● Lifting Beams

Lower Stack Assembly ● Upper Spider ● Lower Stack Legs ● Lower Spider ● Mini Spiders


Example – LMRP (upper) Spider


Challenges

■ Interchangeability ● Extremely challenged based on current design and

manufacturing methods of major structural frame components ■ Actual fabricated tolerances now vary from ¼” best case to as much as ½” or more

variation ● To overcome variations, extra material stock, extra welding

and machining operations, as well as additional inspection points are added to check warping, then corrections are made during manufacturing and at the stack-pad. ■ Increases re-work at critical path assembly points on stack-pad;

further requiring hot work at height.


Configurable Stack – Major Structural Components Test Fixtures

■ Design & fabricate (in-house) Test Fixtures/jigs that allow fabrication of the main structural components in a precise frame.

■ Ex. LMRP (upper) Spider Pull Test Assembly.


Configurable Stack Test FixturesBenefits

■ Tolerances held from 1/32” to 1/16” ■ Cuts direct labor cost a minimum of $250K per stack -

multiplied by 24 stacks annually saves $6.07 million per year ■ Significant elimination of scrap, rework, and wasted non-value

added operations – quality built in by design ■ Greatly decreases potentially unsafe operations by moving

almost all welding away from stack pad operations (heights) to the production floor (ground level) at shop.

■ Contributes to overall reduction of Stack Pad Assembly cycle time from 10-12 weeks to 6-8 weeks target with new Configurable Stack Design.


Configurable Stack Test FixturesBenefits Continued

■ Reduced errors, greater efficiency, and uninterrupted work flow – work tasks in all departments performed the same way on every project with highly repetitive, known tasks

■ All but eliminates dependence on outside vendors for pull tests, smash tests, fabrication, and machining of major stack structural components

■ In house manufacturing and testing of components reduces cost and lead times, and improves quality

■ Stack assembly and alignment of components always ensured – no modifications, no delays, rework reduced; major structural components fit every time


Proposal & Return on Investment■ Equipment Needed - $2.78 Million Total

● $1.05M for 6 base frame fixtures – universal use for both LMRP and upper spider fabrication

● $330K for 3 leg fixtures – universal use for both LMRP legs and lower stack Legs fabrication

● $160K for 1 fixture for lower spider fabrication ● $810K for 3 pull test units, and lifting units for spiders,

LMRP, legs, and safety barriers ● $110K for various small alignment and fit up jigs and

templates ● $120K for 7 stack pad assembly stands ● $200K to move large floor mill and new foundation


Proposal & Return on Investment■ Investment $2.78 million ■ Annual Savings 24 Stacks $6.074 million

● $253.1K labor savings per stack ● 1,600 hours @ $107 per hour fabrication

reduction for LMRP & Spiders ● 280 hours @ $117 per hour stack pad welding

eliminated ● 420 hours @ $117 per hour stack pad assembly

eliminated


Proposal & Return on Investment■ Investment – $2.78 million ■ Annual Savings 24 Stacks – $6.074 million ■ Payback Period – 0.7 Years ■ Internal Rate of Return – 142.03% ■ Net Present Value – 9.727 million ■ Net Cash Inflows

● 2012 – ($2.780 million) ● 2013 – $1.177 million ● 2014 – $5.133 million ● 2015 – $9.089 million

Config Stack DFMA Report

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