Best Practices in New Product Development

While there are various engineering standards that address high-pressure, high-temperature (HPHT) equipment, none of these specifically address the combinations of challenges unique to the oil and gas industry. BSEE considers API 17 TR8 to be one of the best guiding documents for the construction of valves in HPHT applications. API 17 TR8, however, does not address all concerns associated with valve construction, either. BSEE and API guidelines currently identify HPHT wells as having a maximum rated working pressure greater than 15,000 psig and temperatures over 350°F (177°C). Current market demands are driving for the development of well equipment to 20,000 psig (subsea) and 30,000 psig (surface) with temperatures as high as 450°F (232°C).

Stage 1 – Material Solution Analysis

This begins with collecting voice of the customer (VOC) data. During this process, the goal is to acquire tangible, quantifiable answers to produce profitable results. After this VOC is collected, the development team establishes technical opportunities that define the goals, end state, key performance indicators (KPIs) and key performance parameters (KPPs) of the project. This beginning helps establish a basis on which future successes can be evaluated and helps identify if/when a project needs to be put on hold or completely cancelled.

The next step is to perform a material solution analysis to assess the potential solutions. Part of this includes an analysis of alternatives (AoA) procedure to evaluate the effectiveness, suitability and total-cost-of-ownership associated with alternative solutions. During this process the technology readiness level (TRL), manufacturing readiness level (MRL), failure modes evaluation and critical analysis (FMECA), and risk are all evaluated.

Stage 2 – Technology Maturation and Risk Reduction

The second stage of the process is identified as the technology maturation and risk reduction phase. The primary objective of this stage is to reduce the risks associated with the technology and to determine the appropriate set of technologies that will be integrated into the final system. There are many steps which must be completed in this phase, such as developing prototypes of the different system subsets, developing a test and evaluation plan, performing a more robust technology readiness assessment (TRA), and refining the KPPS and KPIs. All the hard work completed in this phase will be culminated in preliminary design review.

The TRA is a formal, systematic, metrics-based process that asses the maturity of critical hardware and software to be used in a system and assigns a TRL. This process focuses specifically on the technologies within the project that have major risks. Different organizations have specific requirements to identify the TRL ratings, but as a general rule, a TRL of zero (0) or one (1) identifies the very basic, unproved technology phase and nine indicates a proven technology. If the TRA determines the TRL is below three (3), a plan needs to be developed to determine the cost and time required to mature the technology.

Stage two also includes the testing and evaluation of the master plan, a systems engineering plan, and a programmatic environment, safety, and occupational health evaluation.

Stage 3 – Engineering and Manufacturing Development

During the engineering and manufacturing development phase, the system is designed and developed before entering into production. This includes the development of a system or increment of capability, complete system integration, the development of an affordable and executable manufacturing process, a complete system fabrication, and the testing and evaluation of the system.

A critical design review evaluates the system’s design maturity to determine if the design is ready and if it should proceed to low-rate initial production.

Stage 3 also includes a test readiness review to ensure all KPIs, KPPs and FMECA risks will be evaluated by the proposed test plans, a functional configuration audit to examine the functional characteristics of the system and a production readiness review.

Stage 4 – Production and Deployment

After all the testing has been completed and the system meets the user requirements, the manufacturing process is ramped-up to 80% of maximum capacity and enters into full-rate production. At this point, Kaizen and 6 Sigma activities continue, but the majority of the manufacturing problems have been resolved and a good manufacturing process has been established.

Stage 5 – Operations and Support

The final stage in the process is the operations and support phase. This is a sustaining phase that takes place after the product has been produced successfully. However, the planning for this stage begins in stage 2 (technology maturation and risk reduction) to ensure the proper support and resources exist to maintain the product.

After Ben Wilkerson served as an engineer with the U.S. Air Force, he attained a Master’s degree in Aeronautical Engineering with an emphasis in hypersonics and satellite design. Wilkerson is currently a reliability engineer at Cameron’s Valves & Measurement group. Reach him at Benjamin.Wilkerson@c-a-m.com.

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