observations and trends in bop maintenance reliablity and compliance - v9

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Observations and Trends in BOP Maintenance,

Reliability & Compliance

Covey Hall,

Johan van ‘t Hul,

Lloyd’s Register Energy – Drilling Integrity ServicesLloyd’s Register Drilling Integrity Services Inc, 1330 Enclave Parkway, Suite 200 - Houston, Texas 77077 Visit www.lr.org/drilling

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Observations and trends in BOP maintenance,

reliability & compliance

Agenda

• Observations & trends

• Case studies and improvement initiatives

• BOP maintenance and reliability opportunities

• Standards and regulatory developments

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Innovations in the last five years

MPD, DGD, ECD

Drill pipe advances

Dual stacks

Spare pods

API standards

Well Control Institute

JIPs for BOP failure reporting

Improved Well Control Training

Competency initiatives

Capping stacks

20k BOP

Stack hopping

Reliability departments

OEM reliability-driven efforts

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Distribution of BOP failure trends in the GoM

Pre-Macondo Post-Macondo

2004-200884 reported failures subsea

2011-2015169 reported failures subsea

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Case study - maintenance program effectivenessOptimised RCM

OEM Recomm

No PM

PM Review Rig 1 Rig 2 Rig 3 Rig 4 Rig 5

Diverter

BOP

Control Unit

Choke Manifold

HP Mud System

IBOP

MGS

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Case study - maintenance experience gap

Source: Forbes Magazine, May 4, 2015

The Great Crew Change

Source: Odfjell Drilling

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Maintenance maturity drive

Achieving Excellence

Highly Effective

Integration

Conform to Standard

Awareness

No system/awareness

Reactive Maintenance

Planned Maintenance

Precision MaintenanceEliminate

Defects &Work

ImproveEfficiency

2015 IADC Asset Integrity & Reliability Conference & Exhibition

How effective is your maintenance program?

X

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunities

• Basic failure patterns

Source:  Nowlan & Heape, John Moubray

Sources of Defects/Failures

Design Errors

Early wear-outHigh frequency of random failures

Manufacturing Infant failuresInstallation Infant failures

Commissioning Infant failures

Operation

Infant failuresEarly wear-outHigh frequency of random failures

MaintenanceInfant failuresEarly wear-out

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunities

• Basic failure patterns

Source:  Nowlan & Heape, John Moubray

Sources of Defects/Failures

Design Errors

Early wear-outHigh frequency of random failures

Manufacturing Infant failuresInstallation Infant failures

Commissioning Infant failures

Operation

Infant failuresEarly wear-outHigh frequency of random failures

MaintenanceInfant failuresEarly wear-out

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunities

• Reliability data collection and utilization

• CMMS master data configuration

• Standardized failure codes

• Work order input simplified

ISO14224

Failure Mode

Failure Mechanism

Failure Cause

FMEA or

RCM

Failure Codes

WO History

RCA

Trending Analysis

Adjust Strategy

FRACAS

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunitiesBOP Fluid

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunitiesSurface Controls

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunitiesPods & Components

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunitiesAccumulators

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunitiesAnnular and Ram BOPs

2015 IADC Asset Integrity & Reliability Conference & Exhibition

BOP maintenance and reliability opportunitiesBWM and Surface Testing – retrieval and pre-deployment

• Sequence is key for early troubleshooting, efficiency• Testing sequences, stations

• Have seen instances where procedure sequence masked problems

• Management of 1, 2, 5 year tasks during BWM • Planning • Critical path sequence• Adequate spares on hand and prepped• Bag/tag components c/o, record condition & location

• Treat like you are commissioning – early detection of infant failures• Minimize introduction of operations/maintenance induced defects

• Stack hopping considerations

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Standards and regulatory issues

Development in regulatory regime:

API

• Standard 53

• Spec 16A

• Spec 16D

• Standard 16AR

• Spec 16RCD

2015 IADC Asset Integrity & Reliability Conference & Exhibition

How effective is your Well-Control maintenance?

Thank you for your interest

2015 IADC Asset Integrity & Reliability Conference & Exhibition

Observations and Trends in BOP Maintenance,

Reliability & Compliance

Covey Hall, Johan van ‘t Hul

Lloyd’s Register Energy – Drilling Integrity ServicesLloyd’s Register Drilling Integrity Services Inc, 1330 Enclave Parkway, Suite 200 - Houston, Texas 77077 Visit www.lr.org/drilling