certification std 03-maintenance presentation 3 4856800 01

WS QHSE Standard 03

Maintenance

Excellence in Execution

Well Services QHSE Standard 3: Maintenance

Learning Objectives Know the objectives and scope of the standard Understand the requirements for exemptions to the standard Understand the different responsibilities for the various functions of Well Services Explain the STEM process and the differences between STEM I, STEM II and STEM III Understand the purpose of Fleet Assistant and the importance of correct information and documentation Understand the maintenance work flow process Explain the difference between a Must-Do Maintenance Bulletin and a Maintenance Bulletin

Certification required by: All employees who are involved in the maintenance and operation of WS equipment Line management who utilize the Standard as a guide to operational practices Management who must notify and request approval for exemptions to the Standard



3.1. Statement of Standard The services we provide to our customers depend on the harmonious operation of a large variety of complex tools and equipment

used under difficult environmental and logistical conditions. The maintenance organization and maintenance processes within a facility shall be designed so that there is a well trained staff to perform the appropriate preventative maintenance on all Well Services equipment. This will ensure that, within given operating specifications, the equipment will operate safely, accurately, efficiently and without failure.

Well Services uses the STEM (standard equipment maintenance) methodology to ensure a systematic preventative approach towards maintenance of Schlumberger equipment.

3.2. Objective To maintain all Well Services equipment efficiently and uniformly, enabling the equipment to perform the task for which it is

designed, in the safest and most cost efficient manner.

3.3. Scope Follow this Well Services Maintenance Standard for all maintenance operations. Follow all applicable Schlumberger and Well

Services specific standards. If clients or regulatory agencies have additional standards, follow them as long as they meet or exceed the Schlumberger minimum requirements.


WS Std 3: Maintenance - Exemptions

3.4. Exemptions

Any deviation from this Standard is by exemption only:

― Schlumberger WHSE Standard S010: Management of Change and Exemptions (InTouch Content ID#: 3260269

― Well Services Appendix to QHSE Standard S010, InTouch content ID# 3999148.

For an exemption to be approved, the following must be completed:

― A complete hazard assessment and risk control (as per QHSE Standard S020: (Hazard Analysis and Risk Control), InTouch content ID# 3757610).

― Appropriate risk mitigation measures must be documented, discussed, and put in place.

Data has been removed & blanked out from this example


Std 3 - Responsibilities: Line Management

.• Quality Ops Support

Manager• Operations Manager• Location Manager

. • Maintenance Manager• Maintenance

Supervisor• Crew Leader

. • Field Service Manager• Cell Leader• Job Supervisor


Std 3 - Responsibilities: Sales, Logistics & Support


Std 3 - Responsibilities: Job Supervisor


Std 3 - Responsibilities: Employees Performing Maintenance

Mechanical &

Electronics Technicians

Equipment

Operators &

Drivers

Field Specialists & Field

Engineers



3.6. Definitions - 1

DVCR: Driver’s Vehicle Condition Report. Name used by Fleet Assistant for a STEM I Report.

Inspection: defined by the STEM procedures guideline. This could be STEM I, II, or III, and could also include requirements from a governmental agency.

Maintenance operation: Any action performed, either preventative or corrective, to ensure a unit or component will perform its designed function.

Meter Meters: used on Well Services equipment to capture usage. This would include hub-o-meters to capture vehicles miles or kilometers, and hour meters to capture engine running hours.

Preventative Maintenance (PM): Procedures necessary to obtain maximum life, optimal performance, and safe operation from a piece of equipment.

Repair Order (RO): used within the Fleet Assistant program, to document the work performed and capture the costs of parts and labor.

STEM: Standard Equipment Maintenance.

Unit: A Well Services truck, trailer, skid or individual piece of equipment.

Unit Number: Each Well Services unit has a unique unit number by which it is identified. The unit number can be a combination of the model code and asset number, or the actual asset number.



3.6. Definitions - 2

Facility: A term used to refer to the operating location used by WS. The facility contains buildings as well as storage and loading equipment for products used in the execution of WS pumping operations. A facility is also commonly referred to as a “base” or “location.”

Fleet Assistant: Commercially available software from Cetaris used to track and schedule maintenance, and manage the spares used on WS equipment.

Forecast: Units coming due for STEM inspection based on defined usage triggers.

FTE: Field Technical Equipment

Maintenance Bulletin: A notification that a unit or component-specific task needs attention. Maintenance bulletins are published through InTouch and distributed to the field locations for appropriate actions to be taken.

Must-Do Maintenance Bulletin: Same as Maintenance Bulletin; however, a Must Do Bulletin will have a specific deadline for completion.

Overdue: A unit which has accumulated usage meter readings in excess of the trigger points for STEM inspections is said to be overdue.

SCDP: Structured Career Development Program which describes the WS training and development program for maintenance technicians and engineers.


WS Std 03: Fleet Assistant

Fleet Assistant must be used in all WS facilities to:

• forecast and document STEM inspections and equipment certifications.

• document labor cost by unit associated with required maintenance.

• document the cost of parts by unit associated with required maintenance.

• document 3rd-party cost parts & labor by unit associated with required maintenance.

• document labor of maintenance technicians not applied to a specific unit (indirect labor).

• document compliance with Must-Do Maintenance Bulletins.

• manage equipment records and certifications.• manage M&S spares inventory.• and all other maintenance-related activities

See Fleet Assistant See web page with reports & information @ http://www.rd.oilfield.slb.com/emwd/fleet_assistant.htm

http://www.rd.oilfield.slb.com/emwd/fleet_assistant.htm



3.7.2. Maintenance Workflow

Each facility shall have a documented process that covers all maintenance scheduling and requirements arising from:

Preventative maintenance (STEM I, II, & III), Failures, Must Do and other Maintenance Bulletins.

This process must include RO close out and communication of unit status. Always comply with any specific or general Well Services maintenance requirements,

guidelines, and procedures when applicable.

Note: The process workflow must be prepared, followed and updated by the maintenance personnel of each maintenance location. Every location is different so there is no point is using the process map used in other locations. The workflow map should be validated by the GMM or AMM.


WS Std 3: Maintenance – STEM I Workflow Example

3.7.2. Maintenance Workflow - Example


WS Std 03: Maintenance – STEM II Process Flow Diagram


STEM I Process Map – Example for a typical WS location


Maintenance Process Map: Example


Maintenance Process Map – Example


Maintenance Control Board - ExamplesMaintenance Control Boards used as a simple and effective way to assign and display maintenance work orders in a District:

• To Be Done

• In Process

• Waiting on Parts


WS Std 3: Maintenance - Hand Tools

3.7.3. Hand Tools

Maintenance staff shall have the necessary and appropriate tools available to perform the maintenance activities required of them.

An inspection of all technician tool boxes shall be performed and documented at least annually.

A complete inventory of each technician tool box must be on file at the location.

All hand tools and shop tools must be in compliance with Well Services QHSE Standard 4: Facilities and Workshops, InTouch ID# 3313678.



3.7.3. Materials and Supplies (M&S)

Each MSV is responsible for obtaining the required material supplies for their respective maintenance facility.

MSV must keep in close communication with the store person to ensure that all necessary material and supplies to perform maintenance are available in appropriate quantities at all times.

See InTouch for WS M&S Inventory Guidelines, Content ID: 4795565


Location Assets and Equipment

3.8.1 Location Assets

Ensure every item of equipment in the location is:

• listed under its correct model code & unit number

• assigned to the correct location.

Useful references:• Well Services Model & File Codes (formerly - World-wide

Modeling Scheme & Equipment Models) http://intouchsupport.com/intouch/methodinvokerpage.cfm?caseid=3015638

• WS General Specification Sheets for FTE Assets http://intouchsupport.com/intouch/methodinvokerpage.cfm?caseid=4156460&method=iteview

• Well Services Equipment Manuals - Navigation Page http://intouchsupport.com/intouch/methodinvokerpage.cfm?method=iteview&caseid=4309030

http://intouchsupport.com/intouch/methodinvokerpage.cfm?caseid=3015638


http://intouchsupport.com/intouch/methodinvokerpage.cfm?caseid=4156460&method=iteview

http://intouchsupport.com/intouch/methodinvokerpage.cfm?caseid=4156460&method=iteview

http://intouchsupport.com/intouch/methodinvokerpage.cfm?method=iteview&caseid=4309030

http://intouchsupport.com/intouch/methodinvokerpage.cfm?method=iteview&caseid=4309030


WS Standard 3: STEM I Inspection

STEM I:

Performed by the driver or operator of equipment .

Designed to ensure the unit is:― job ready, and― in safe operating condition.

May include regulatory pre and post-trip inspections.


WS Std 03 Maintenance - Who performs STEM I & when?

Performed by the driver or operator of the unit or equipment. The operator may be an EO, FS, or FE.

Performed:― Before the start of a trip (pre-trip*)― Before the start of a job (pre-job)― After a job is completed (post-job)― In between jobs ― Any time when a unit needs some tlc.― Any time the maintenance status of a unit is unknown*Pre-Trip report is a regulatory requirement in some countries, (eg. DOT Pre-Trip Report in USA). Intended as a check to ensure unit is safe to drive. Must be performed in addition to a STEM I.

Designed to ensure a unit is job ready & is in safe operating condition.


WS Std 03 Maintenance – What is STEM I? A series of preventive maintenance checks, servicing

and basic repairs on all equipment & units to be used to perform a job.

Requires checks and work on:― Condition & appearance of equipment― Safety equipment & devices― All fluid levels & lubrication points/systems― Engines and transmissions― Chains, belts & drives― Hoses & connections (pneumatic, hydraulic, oils & fuel)― Electrical & electronic equipment, cables & connectors― Pumps (triplex, centrifugal, diaphragm, air, etc)― Treating equipment ― Gauges, controls, monitoring & recording devices― Documentation & compliance to WS standards.

STEM I may require regulatory pre- & post-trip inspections depending on local regulations.

Requires documentation on a STEM I Report form.


USA DOT Safety Regulations• Trucks, tractors, floats, flatbeds, etc. require additional

pre- and post-trip checks • Definite time or mileage intervals not specified• Must be a systematic inspection maintenance system• Unit numbers, DOT numbers, placarding, weight limits &

paperwork all important.• Driver’s Trip Report (Vehicle Inspection Report)

WS Std 03 Maintenance – USA DOT Regulations


WS Standard 3: STEM II Inspection

STEM II: Performed by the maintenance department at defined

maximum frequencies to identify problems before they result in failures during operation of the unit.

The following defined frequencies (whichever occurs first) are to be used.

― 400 engine hours― 180 calendar days― 6,000 vehicle miles/10,000 vehicle kilometers

Use of any frequency exceeding this maximum will require an exemption approved by line management.

Deadline for implementation of Maintenance Bulletins

For Coiled Tubing, specific equipment inspection frequencies are specified in the CT Surface Equipment Maintenance Program (InTouch content ID# 4196880).


WS Standard 3: STEM III Inspections

STEM III: The trigger for STEM III inspection is one

calendar year.

STEM III is also referred to as an “annual inspection”.

STEM III includes all the checks done on STEM II as well as regulatory requirements such as:

― tank testing and certification

― testing of air receivers & PRV’s

― state inspections required by various governmental agencies.


Maintenance & repair work to be performed

Each stage of the STEM process requires: Comprehensive inspection and servicing of equipment and components as per

recommended guidelines and STEM Reports from:― Well Services― Equipment manufacturer― Regulatory requirements

Identification and documentation of deficiencies and service provided

Repair of deficiencies

Documentation of labor performed and parts used for repair

Operations test to confirm repairs were successful and allow unit to be green tagged.


Completion of STEM: Red Tag / Green Tag

Red Tag indicates equipment:• is not job ready

• maintenance status is unknown• shall not be used or sent on a job• maintenance/repairs are in progress & incomplete• has a problem that needs to be fixed• is waiting on spare parts• has arrived in the base & is stored in red-tag area• needs a STEM I, II or III

Green Tag indicates equipment has been checked by a competent person and:

• is job ready

• maintenance status is known & documented• can be used or sent on a job• maintenance/repairs are complete• problem(s) have been repaired• is stored in green-tag area• has a STEM II or III scheduled for the future


WS Std 03: Must-Do and Maintenance BulletinsAs per Standard 03: Use completed RO’s in Fleet Assistant to report

compliance or completion of:• Maintenance Bulletins• Must-Do Maintenance Bulletins

Reasons to issue Maintenance Bulletins:• Raise awareness to the field for a known problem/failure

that has a known solution.

• Provide specific corrective actions to prevent further field failures/problems.

• Must-Do Maintenance Bulletins involve potentially catastrophic situations. Compliance within the determined maintenance deadline is mandatory.

• Required action items must be completed before or at the next STEM II inspection, or within 6 months, whichever comes first.

• May need to incorporate MB into routine STEM II. Process for Well Services Alert, Must-Do Bulletin and Bulletin Releases @ http://intouchsupport.com/intouch/methodinvokerpage.cfm?caseid=2040745



WS Std 03: Maintenance Performance Indicators

Performance Indicators

• Every location shall have defined performance indicators based on the documented maintenance workflow for that location.

• Performance indicators must be agreed upon annually by both the MSV/MM and line management.

• Performance Indicators are available from the Fleet Assistant website. Some of the indicators are:

i-District Participation Indicators

• Repair Order Processing• ROs in Process• ROs Closed• RO Closed with Promise Date• In-Service Date < 2 hours• Percent Promise Date (80% Min.)• Percent In-Service Date (80% Min.)

• PM Processing• Jobs Dispatched• Dispatched Units Overdue• Av. Units Overdue per Job


WS Std 03 Maintenance – Guideline 01STEM Inspection and Maintenance Procedures

• STEM inspection guide provides guidance by component or system. • The inspection process is the same (when an inspector gains the knowledge and skills required to inspect an

engine for example, it does not matter what size or where the engine is used. This applies to transmissions, hydraulic systems, etc…).

• Regular and thorough inspection and lubrication of equipment is the first requirement of a good preventive maintenance and safety program.

• Preventive maintenance can be defined as: "Procedures necessary to obtain maximum life, satisfactory performance, and safe operation from a piece of equipment, at minimum cost.“

• Instructions, check sheets and inspection schedules are provided as a guide to assist you in setting up a systematic inspection and maintenance program.

• Program also includes items that require periodic inspection by the USA DOT safety regulations. The USA DOT regulations do not specify definite time or mileage intervals. The fundamental requirement is that there be a systematic inspection and maintenance system and that some records be kept for each vehicle.

• The intervals indicated in the STEM II & III reports are based on our experience for average operating conditions. In some areas and under certain operating conditions, equipment may require less frequent or more frequent inspection and maintenance to keep it in safe, efficient and economical operating condition.

certification std 03-maintenance presentation 3 4856800 01

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