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NEI-NO--1117 0 1 NO9905154 Mette Suzanne Hnsemoen Bridging operation and design The encounter between practical and discipline-based knowledge in offshore platform design \ to hfi<u m -if universitet Trondheim I NTNU telmisk-naturvitenskapelige ft 3 >5 Norges Q o V_______ J 15 DISCLAIMER Portions of this document may be illegible in electronic image products. Images are produced from the best available original document. NTNU Norwegian university of Science and Technology BRIDGING OPERATION AND DESIGN The Encounter Between Practical and Discipline-Based Knowledge in Offshore Platform Design Doctoral thesis by Mette Suzanne Husemoen Trondheim 1997 INSTITUTT FOR INDUSTRIELL 0KONOMI OG TEKNOLOGILEDELSE NORGES TEKNISK-NATURVITENSKAPELIGE UNIVERS1TET DEPARTMENT OF INDUSTRIAL ECONOMICS AND TECHNOLOGY MANAGEMENT NORWEGIAN UNIVERSITY OF SCIENCE AND TECHNOLOGY w ■'iH Si Preface The last three years I have been part of the INPRO research program (Integrated production systems in the process industry) at the Norwegian University of Science and Technology. The program has involved a faculty of five professors and post­ graduate researchers and nine Ph.D. candidates from three different departments - Engineering Cybernetics, Chemical Engineering, and Industrial Economics and Technology Management. It has been a valuable experience to be part of this multi ­ disciplinary research effort trying to bridge different the fields of knowledge in the area of process plant operations. Lisbeth 0yum, Henning Jakobsen, Ludvig Stendal, Karin Aslaksen, and Professor Morten Levin at the Department of Industrial Economics; Catharina Lindheim, Jahn Olaf Olsen, and Professor Kristian Lien at the Department of Chemical Engineering; Jo Simensen, Kjell Stele-Hansen, and Professor Bjame Foss at the Department of Engineering Cybernetics; Thoralf Qvale at the Work Research Institute (API), and Roger Kiev at IFIM, SINTEF made the core of this group. Jorid 0yen and Tove Krokstad, helped to arrange many of the INPRO activities. It has been an interesting journey into the land of operations, design, and Norwegian process industry. I am especially grateful to my advisor, Professor Morten Levin, for guiding me through the process. He has been of great support and has always given me excellent feedback in the developing of the thesis. I am also greatly indebted to my co-advisor Thoralf Qvale. His experience from large-scale offshore projects in the North Sea has directly influenced the scope of my work. I have been lucky to be part of a larger group of graduate students at the Department of Industrial Economics and Technology Management. I want to thank Lisbeth 0yum and Henning Jakobsen, in particular, for giving valuable feedback on early draffs and final chapters of the thesis. Gaute Knutstad, Ingrid Anette Wulff, Karina Aase, Berit Moltu, and Jan Terje Karlsen are other Ph.D. candidates I have had the opportunity to - m - •V 3#w x- Bridging Operation and Design interact with. It was good to have Gaute there to consult with in the final stage. I am also thankful to Kari Kapstad and Merethe Anthonsen for reading through and commenting on some of the chapters. In my work I have been associated with the Phillips Petroleum Company Norway. Former Vice President Rolf Wiborg and Strategic Business Performance Manager Helge Vollan took an active part in defining the research problem. Their emphasis on taking operational experience into account in the Ekofisk II project corresponded well with INPRO’s focus on operational effectiveness of process plants. I especially want to thank the operations representatives participating in the design, Leif Gilje, 0yvind Dahle, Dagfinn Hatleskog, and Arild Mtehlum, who willingly shared their time and experience with me. They also read through and gave valuable feedback on the final chapters of the thesis. Thanks also to Stig Kvendseth in Phillips for lending me the Ekofisk photos, and 0yvind Roth for being the INPRO contact in Phillips. I would like to thank the Leaders For Manufacturing Program (LFM), MIT Sloan School of Management, for being my host as I spent one semester with them as a visiting researcher. Janice Klein read though my preliminary drafts and gave valuable feedback while I was there. Finally, I want to thank Professor Zhang Zhixiang, chief master and founding president of Chinese Society of Yuanji Science, for the opportunity to study at the Yuanji Medicine Hospital in the world headquarters of Yuanji Science, Ezhou, Hubei, China; and ChengLin Will Zhang, Y.M.D., founding president of American Society of Yuanji Science, Inc., Boston, for introducing me to Yuanji, this gem of traditional Chinese culture. The INPRO program is co-funded by the Norwegian Science Foundation, the Federation of Process and Manufacturing Industries (PIL), the Norwegian Oil Industry Association (OLF), and the participating companies in the INPRO program. Trondheim March 1998 - 1V - Contents Contents Preface iii List of figures viii Abbreviations ix Summary x CHAPTER 1 INTRODUCTION 1 1.1 Main research question 3 1.2 Why focus on operations and design ? 4 13 D eveloping the research question 6 1.4 Structure of the thesis 8 CHAPTER 2 OPERATIONS AND DESIGN 11 2.1 What constitutes knowledge in operations and design ? 11 2.1.1 THE OPERATIONS AND DESIGN COMMUNITIES-OF-PRACTICE 11 2.1.2 DIFFERENT KINDS OF KNOWLEDGE 14 2.1.3 KNOWLEDGE IN ENGINEERING EDUCATION AND DESIGN 19 2.1.4 KNOWLEDGE IN OPERATIONS 22 2.2 HOW TO TAKE OPERATIONAL KNOWLEDGE INTO ACCOUNT IN DESIGN? 30 2.2.1 Bringing operations into design 30 2.2.2 Sharing practice in operations and design 35 2.2.3 interaction of tacit and explicit knowledge 40 2.2.4 D ialogue as a mode of transforming tacit knowledge 44 2.2.5 The dynamics of dichotomous relationships 49 23 Research questions revised 51 2.3.1 Bridging knowledge in operations and design 51 2.3.2 Knowledge in operations and design 53 CHAPTER 3 INTRODUCTION TO PHILLIPS AND EKOFISK H 5§ 3.1EKOFISKI 55 3.2 EKOFISK H 59 3.2.1 EKOFISK II PROJECT BACKGROUND 59 3.2.2 THE EKOFISK II CONCEPT 61 3.2.3 EKOFISK 2/4X 63 3.2.4 EKOFISK 2/4 J 66 33 EKOFISK H MANAGEMENT STRATEGY 68 CHAPTER 4 EKOFISK 2/4 X 73 4.1 DESIGN AT AOP 73 4.1.1 Willingness to listen and involve operations in design 73 4.1.2 Experienced operations personnel available in design 76 4. l .3 Having informal rather than formal influence on design 78 - v - V ; : Bridging Operation and Design 4.2 D esign at Hitec 80 4.2. l functioning as an integrated , autonomous team 80 4.2.2 Operations committedly in charge of design 82 4.2.3 Knowing both operations and design 85 4.3 THE 2/4 X TOPSIDE ALLIANCE 87 4.3.1 Formation of the alliance 87 4.3.2 THE ALLIANCE ORGANIZATION 90 4.3.3 Work in the alliance 93 4.3.4 Fabrication reviews 96 4.4 Resulting design and operational experience loo 4.4.1 EKOFISK 2/4 X operational EXPERIENCE 100 4.4.2 The innovating aspects of 2/4 X 102 4.4.3 Operations vs . drilling on 2/4 X 108 4.4.4 Reflections on operations involvement in design 110 CHAPTER 5 EKOFISK 2/4 J 115 5.1 Operations not knowing design 115 5.1.1 Operations involved not knowing design 115 5.1.2 Too few operations resources made available to the project 120 5.2 D istance in design 122 5.2. l Initial tension 122 5.2.2 Phillips and Kv /erner working separately in design 125 5.2.3 D esign controlling design 130 5.2.4 Operations knowledge not fitting into the structure of design 132 5.3 Status of the Ekofisk 2/4 J project 136 5.3.1 Fabrication , commissioning , and start -up of Ekofisk 2/4 J 136 5.3.2 Operations ’ impact on 2/4 J 138 CHAPTER 6 KNOWLEDGE IN OPERATIONS AND DESIGN 145 6.1 The operations community -of -practice 145 6.1.1 Practical knowledge 146 6.1.2 Availability and access to equipment 149 6.1.3 Simultaneous knowledge 153 6.1.4 Tacit knowledge 157 6.2 The design community -of -practice 162 6.2.1 D iscipline -based knowledge 162 6.2.2 Sequential knowledge 165 6.2.3 Explicit knowledge 168 63 Knowledge in operations and design 172 CHAPTER 7 BRIDGING KNOWLEDGE OF OPERATIONS AND DESIGN 175 7.1 Bridging knowledge of operations and design 175 7.1.1 Mutual sympathy , trust , and respect 175 7.1.2 Physical integration of operations and design 181 7.1.3 Knowing both operations and design 186 7.2 Creating better production systems in design 189 - vi - Contents CHAPTER 8 CONCLUSION 125 8.1 Findings 196 8.1.1 D ifferent kinds of knowledge in operations and design 196 8.1.2 Bridging knowledge of operations and design 198 8.2 ACTION RECOMMENDED 202 8.2.1 Operations 202 8.2.2 D esign 203 8.3 Further research 205 APPENDIX A METHOD 207 APPENDIX B THE INPRO PROGRAM 232 REFERENCES 235 Bridging Operation and Design List of figures Figure 2. l Tacit and explicit knowledge as two kinds of knowledge ......................................17 Figure 2.2 the Y uanji diagram ............................................................................................................ 50 Figure 2.3 the Y uanji diagram of operations and design .............................................................51 Figure 3. l The Greater Ekofisk Area ................................................................................................56 Figure 3.2 Ekofisk production and water injection wells...........................................................57 Figure 3.3 The Ekofisk Tank in 1973 and 1989................................................................................. 57 Figure 3.4 The Ekofisk Complex in 1994............................................................................................58 Figure 3.5 The Ekofisk II Complex ..................................................................................................... 60 Figures . 6 Ekofisk II project schedule ..............................................................................................61 Figure 3.7 Ekofisk 2/4 X and Ekofisk 2/4 J........................................................................................62 Figure 3.8 Ekofisk II complex layout ................................................................................................63 Figures .
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