Config Stack DFMA Report

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Configurable Stack Fixtures
Pressure
Control
Group
Subsea
Stack
Project
Manufacturing
for
Excellence

Configurable Stack Design
Modularity
• 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
Lower Stack Legs
Upper Spider
Lower Spider
Mini Spiders

Major Structural Components
LMRP 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 Fixtures 
Benefits
■ 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 Fixtures 
Benefits 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

■ 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

■ 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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