Importance Of Inspection, Maintenance And Testing Of Onshore Blowout Preventer’s (BOP’s) John Hoefler, Lloyd’s Register John.Hoefler@lr.org
Agenda Introduction Maintenance Maturity Drive Case Studies Conclusion
Maintenance System/ Awareness Maintenance System/ Awareness Maintenance Maturity Drive Overview Maintenance Maturity Drive Resulting In Independent 3 rd Party Review & Support Training and Qualification of Personnel Increased Reliability Reduced Downtime Integration into a Prevention Maintenance Program Safety & Environmental Following OEM Recommendations Priority Elimination of Infant Conforming to Standards Failures Awareness of Standards / Need for System Elimination of Well Control Incidents No Maintenance System / Awareness
Benefits of Maintenance & Testing With standards, we can reduce impacts to: Safety Reputation Environment
Case Study One Maintenance Performed Incorrectly Problem Rams were replaced, but mismatched resulting in failure Solution Standards and controls for testing, training, and maintenance
Case Study One: Maintenance Performed Incorrectly The crew performing Spare parts were stored Maintenance This well control This well control The BOP was properly as an assembly the maintenance was If there were I3P procedures and OEM situation could have situation could have pressure tested after with part and serial competent and well support rig manuals were numbers and followed by been avoided if: been avoided if: maintenance trained proper traceability protocol followed (8) Pressure test affected BOP components Verify that all drill pipe, work string, and tubing Rig manuals, including equipment drawings, Manufacturer operating and maintenance Qualified Personnel as defined by Section 5 – following the disconnection or repair of any well- documents, equipment owner PM programs, and planned to be installed in the hole is within the specifications, and bills of material, shall be at §250.737(d) 6.5.10.3.1 6.5.9.1.4 2.4.3 88 Qualified Personnel must supervise or perform all pressure containment seal in the wellhead or operating experiences shall be incorporated into specified design range of the pipe and variable the rig site to identify the equipment and assist repairs; BOP stack assembly with procuring correct replacement parts. bore rams installed in BOP stack. the site-specific procedures. Source: 30 CFR 250 Source: API Standard 53 Source: CAODC RP6.0 Source: API Standard 53 Source: I3P Inspection Point
Case Study Two BOP activated but failure to close Problem Obstructions, cylinder and system failures, incorrect settings Solution Function testing, alternate actuating methods, I3P support
Case Study Two: BOP activated but failure to close The hydraulic There were This well control The ram cavity and redundancies in place The BOP was function actuator was fully situation could have bore were inspected or alternate methods pressure tested tested properly been avoided if: for obstructions of actuating the BOP annually Chamber pressure tests shall be performed and Verify that the BOP control system has a minimum of two pump (9) Function test annular and pipe/variable bore Check general condition of ram cavities. Visually §250.737(d) systems (primary and secondary). At least one power source must be charted as follows: ram BOPs every 7 days between pressure tests inspect each cavity upper sealing area for or any independent from the power source for the primary accumulator- 6.5.3.4.3 119 79 a) at least once yearly, charging system. The independent power source must possess scratches. Note: A poor surface finish at the top (10) Function test shear ram(s) BOPs every 14 b) when equipment is repaired or remanufactured, §250.737(d) sufficient capability to close and hold closed all BOP components of the cavity reduces its effective life. days c) in accordance with equipment owner's PM program. under MASP conditions as defined for the operation. Source: I3P Inspection Checklist Source: I3P Inspection Checklist Source: 30 CFR 250 Source: Standard 53
Case Study Three Failure to Maintain Pressure Problem BOP rubbers failed to maintain pressure due to fluid incompatibility Solution Environmental Testing (Temperature, Drilling / Completion Fluid Compatibility, Natural Fluid Compatibility)
Case Study Three: Failure to Maintain Pressure Natural fluid compatibility such Combinations of This well control Drilling and as Hydrogen Sulfide (H2S), Temperature (low and these factors and situation could have completion fluid Carbon Dioxide (CO2), or High high) were reviewed Hazardous Hydrocarbons been avoided if: compatibility review pressure (HHH) The BOP elastomeric components that can be exposed to Elastomeric components are also subject to H2S attack. Nitrile Manufacturer/vendor shall provide material compatibility well fluids should be verified for compatibility with the Full Well Compatibility Verification (WCV) elastomeric components that meet other requirements can be suitable for testing results to the equipment owner, to ensure correct drilling fluids to be used and for the anticipated H2S service provided drilling fluids are properly treated. Service life 4.10.2 WCV including survey, fluid, pressure, temperature 5.2.10 7.6.6.11 shortens rapidly as temperature increases from 150 °F to 200 °F (65.6 °C fluid service rating and performance. This is critical if the temperatures to which it is exposed. Consideration should verification to 93 °C). In the event flowline temperatures in excess of 200 °F (93 °C) equipment owner plans well testing back to the rig. also be given to the temperature and fluid conditions during are anticipated, the equipment manufacturer shall be consulted. well testing and completion operations. Source: Standard 53 Source: Standard 53 Source: Full Compatibility Review From I3P Source: Standard 53
Conclusions Environmental Conditions Testing PM Program Procedures Training Leading to Incident Highest Level Environmental Avoidance of Safety Protection
Questions?
John Hoefler Biography 18+ years oil & gas experience Bachelor of Science, Texas A&M University Expertise in technical mgmt., R&D, API codes & standards DTE, Engineering & Compliance Manager with Lloyd’s Register
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