latin american drilling safety repair & certification of blow out preventers in argentina...
TRANSCRIPT
LATIN AMERICAN DRILLING SAFETY
REPAIR & CERTIFICATION OF BLOW OUT PREVENTERS IN
ARGENTINA
WILFREDO NUÑEZJORGE GOLDSACK
PREAMBLE
The essence of Well Integrity is the ability to guarantee the safe containment of pressured subsurface formation fluids during a Well
Control.
BLOW OUT PREVENTERS are critical to the safety of the Crew, the Environment and the Rig, thus Blowout Preventers are intended to be
Fail-Safe Devices.
A good repair and maintenance of certified B.O.P.´s is the building block upon which Safety and Well Integrity are founded.
TIMELINE
•Argentinean Custom laws made very difficult to import used or rebuilt parts or tools for the oil industry (Including BOP’s). Therefore, the BOPs that need to be exported to be repaired or certified cannot come back to the country; it’s allowed importing NEW preventers, but it was complicated for used or rebuilt parts.
•Industrias Petroleras del Sur (IPS) in Neuquen with Cameron license, was the single certified BOP repair workshop in Argentina and they were concentrated in the Drilling BOP segment. IPS had the infrastructure to repair/certify about 8 BOP´s a month. Most of them were Drilling BOP (11” & 13 5/8”).•Wenlen had the infrastructure to repair it´s own BOP´s as Manufacturer, but in the end of 90´s, the compañy dismantled the whole manufacture and repair line. •Shaffer (BOP Manufacturer Company) tried to certify a repair shop, but did not achieve any Tech-Economics deal with any workshop in Argentina.
INITIAL SITUATION
2006
TIMELINE
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
2006
TIMELINE
THE PROBLEM:
•The large number of preventers needed to be serviced, urged the contractors to hire improvised workshops and use not original or homemade spares to repair the equipment.
•There were several incidents in Workover and Pulling Rigs related to BOP´s failures .
•The situation generated a lack of confidence among operators.
2006 Late 2006
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
TIMELINE
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
2006 Late 2006
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
TIMELINE
THE REQUIREMENTS:.
•Pride International made a presentation at the 2007 Drilling Congress clearing up the situation with the BOP (Drilling, Workover & Pulling) and the urgency of “developing” certified workshops to address the problem.
•There were about 200 BOPs queuing to be repaired
•Only in WO & Pulling, the market demanded a minimum of 5 BOP repairs a month. IPS capacity was 2 to 2.5.
2006 Late 2006 2007
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
TIMELINE
THE REQUIREMENTS:. A New certified workshop is requiered.
2006 Late 2006 2007
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
TIMELINE
2006 Late 2006 2007
Rig
Activity
Dropped
Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
TIMELINE
2006 Late 2006 2007
The situation worsened: In 2008 the oil industry activity dropped and reduced the IPS workload which conducted a reduction in the IPS staff and repair capacity. IPS reduced it capacity from 8 to 6 BOP´s per month, between annulars and rams.
Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
TIMELINE
2006 Late 2006 2007Early
2008
INITIAL SITUATION: Importation compicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
TIMELINE
THE PLAN:.
•The problem was addressed by LADS (Argentine Chapter) which appointed a technical committee
•The objectives were identified and a list of tasks was made
2006 Late 2006 2007 2008Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
•The problem was addressed by LADS (Capitulo Argentina) which appointed a technical committee
•The objectives were identified and a list of tasks was made
THE REQUIREMENTS:. A New certified workshop is requiered.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
INITIAL SITUATION: Importation forbidden, One Overloaded Workshop, Homemade supplies.
TIMELINE
THE PLAN:.
2006 Late 2006 2007 2008Early
2008
OBJECTIVES:.
Critical Equipment
1. BOP Valves
2. Conection between BOP - Choke Manifold
3. Choke Manifold
4. Accumulators and BOP actuators.
Planned Tasks:
1. Developed a BOP´s country inventory.
2. Develop of inspection and repair procedures.
3. Perform Handling, maintenance and field pressure test procedures.
4. Define documentation to provide traceability. .
5. Establish a list of suppliers that meet the requirements.
6. Help to develop new repair workshops.
TIMELINE
THE PLAN:. Technical committee appointed, list of objectives.
2006 Late 2006 2007 2008Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
TIMELINE
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial workshops•Help to develop the candidates to establish procedures, policies and standards.
2006 Late 2006 2007 2008 2009Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
TIMELINE
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
There were near 500 B.O.P. units in Argentina
Sort by Rig Type Sort by Brand Sort by Size Sort by Pressure
135 units (32%) 282 units (68%)
Annular Type “A” Ram Type “R”
TIMELINE
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
Annular Type “A” Ram Type “R”
Drilling; 50; 37%
Workover; 38; 28%
Sin Datos; 47; 35%
Drilling; 64; 23%
Workover; 124; 44%
Pulling; 31; 11%
Sin Datos; 63; 22%
There were near 500 B.O.P. units in Argentina
Sort by Rig Type Sort by Brand Sort by Size Sort by Pressure
No Data No Data
2006 Late 2006 2007 2008 2009
TIMELINE
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
Hydrill; 89; 66%
Shaffer; 28; 21%
Wenlen; 0; 0%
Otras; 11; 8%Cameron; 6;
4%
Sin Datos; 1; 1%
Hydrill; 33; 12%
Wenlen; 36; 13%
Otras; 31; 11% Cameron; 40;
14%
Shaffer; 142; 50%
There were near 500 B.O.P. units in Argentina
Sort by Rig Type Sort by Brand Sort by Size Sort by Pressure
Annular Type “A” Ram Type “R”
No Data
TIMELINE
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
7-1/16"; 46; 34%
9"; 5; 4%
13-5/8"; 30; 22%
Sin Datos; 10; 7%
11"; 44; 33%
7-1/16"; 184; 66%
9"; 4; 1%
13-5/8"; 41; 15%
11"; 52; 18%
2"; 1; 0%
There were near 500 B.O.P. units in Argentina
Sort by Rig Type Sort by Brand Sort by Size Sort by Pressure
Annular Type “A” Ram Type “R”
No Data
2006 Late 2006 2007 2008 2009
2006 Late 2006 2007 2008 2009
TIMELINE
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
3000 psi; 28; 21%
Sin Datos; 9; 7%
5000 psi; 98; 72%
3000 psi; 85; 30%
5000 psi; 187; 66%
Sin Datos; 2; 1%10.000 psi; 8;
3%
There were near 500 B.O.P. units in Argentina
Sort by Rig Type Sort by Brand Sort by Size Sort by Pressure
Annular Type “A” Ram Type “R”
No DataNo Data
TIMELINE
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
2006 Late 2006 2007 2008 2009Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
•Perform a BOP´s inventory.•Select Potencial workshops•Help to develop the candidates to Establish procedures, policies and standards.
Rig
Activity
Dropped
TIMELINE
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
THE SUPPLIER CANDIDATES
•Several workshop were selected. During a few meetings, the technical support was offered but also, the responsibility in case of some incident involving repaired equipment was explained too.
•After this stage only two suppliers continue with the process. ACYS, located in Mendoza city, and Wenlen that has the capacity to repair its own BOP´s also..
TIMELINE
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
2006 Late 2006 2007 2008 2009Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
•Perform a BOP´s inventory.•Select Potencial workshops•Help to develop the candidates to Establish procedures, policies and standards.
Rig
Activity
Dropped
TIMELINE
THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
•Perform a BOP´s inventory.•Select Potencial suppliers candidates.•Help to develop this candidates according policies and standards.
THE PROCEDURES
•Help the supplier with the repair procedures: disassembly, cleaning, sandblasting, dimensional and hardness analysis, assembly & testing, etc.
•The procedure was tested several times by committee members of and amended by the company, until the definitive procedure was reached.
•ACYS applied to Shaffer approval but they can´t achieved any Tech-Economics deal; hence, decided to apply to the ISO 9001-2000 certification, according to the requirements of API 16° Annex 8 and recommendations API RP 53”, which managed to attain in June 2009.
TIMELINE
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.BOP´s, candidates development.
2006 Late 2006 2007 2008 2009Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
TIMELINE
2006 Late 2006 2007 2008 2009 2012
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.BOP´s, candidates development.
THE FINAL RESULT
Early
2008
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
THE REQUIREMENTS:. A New certified workshop is requiered.
Rig
Activity
Dropped
THE FINAL RESULT
•EVALUATION STAGE
After arriving the BOP to the workshop a tag number is assigned and an evaluation check list is performed, involving the related tasks and responsibilities
Tasks:
Identification of every single piece and valve. Dimensional evaluation; Visual and not-destructive tests, hardness test, Nital.
After the BOP is evaluated, the customer receives a budget and a detailed report including,photographic records of the parts to be replaced or repaired.
THE REBUILDING PROCESS
THE FINAL RESULT
•EVALUATION STAGE
THE REBUILDING PROCESS
THE FINAL RESULT
•REPAIR STAGE
Once the client accepts the budget, the repair stage begins.
This stage could include Welding filler, heat treatment, forged, etc.
The policy of the shop is always to asks the client for new spare parts to repair the BOP
THE REBUILDING PROCESS
THE FINAL RESULT
•REPAIR STAGE
THE REBUILDING PROCESS
THE FINAL RESULT
•TEST STAGE
After the repair is done, the equipment is ensembles and tested
The tests are conducted with calibrated manometers and tools, hydraulic unit and a multiplier booster (able to bring the pressure up to 9000 psi.)
THE REBUILDING PROCESS
THE FINAL RESULT
•TEST STAGE
THE REBUILDING PROCESS
THE FINAL RESULT
•DELIVERY STAGE
THE REBUILDING PROCESS
CONCLUSION
•In 2009 8 BOP´s were repaired and certificated.
•In 2010 23 BOP´s.
•In 2011 27 BOP´s.
•In 2012 42 BOP´s so far.
•The total BOP´s at ACYS as today: 98.
THE REPAIR ACTIVITY OF ACYS
CLIENTS: Nabors, Key Energy, Archer DLS, Ensign, ENAP (Chile) EMEPA, Skanska, Petroneu and SAI (Bolivia)
CONCLUSION
Amount of BOP´s per year:
•Certifications RP-53/97”…………………………..60 / 70 units
•Preventive maintenance in 5 year period……….20 /25 units
•Rebuilded Brands:
Shaffer Hydril Cameron
Rams 40% 10% 50%
Annulars 20% 70% 10%
•The average rebuilding time is 90 days, since 2006 there were
near 450 BOP´s repaired.
THE REPAIR ACTIVITY OF IPS
CONCLUSION
Rebuild
•In the last year no repairs were made.
THE REPAIR ACTIVITY OF WENLEN
Yr Client BOPQuant
ity Observations
2006 PERBRAS 7.1/16" 5000" Double Ram 2 Certified 16 A
2007 OXY 11" 3000# Double Ram 2 Certified 16 A
2008 EMEPA 7.1/16" 5000" Double Ram 2 Certified 16 A
2009 CAPEX 7.1/16" 5000# Single Ram 1 Certified 16 A
2009 UTENEU 7.1/16" 3000# Double Ram 2 Certified 16 A
2010 SAN ANTONIO 7.1/16" 5000" Double Ram 1 Certified 16 A
2010 ROCH 11" 3000# Double Ram 1 Certified 16 A
2010 CAPEX 7.1/16" 5000# Single Ram 1 Certified 16 A
2011 SERVIPETROL 13.5/8" 5000# Double Ram 1 Certified 16 A
2011 APCO-UTE 11" 3000# Double Ram 1 Certified 16 A
14
CONCLUSION
MOST OF THE BOPS THAT ARRIVES TO THE SHOP ARE IN VERY POOR CONDITION.
DAMAGES INCLUDE SHOCKS, CORROSION, EROSION,
SCRATCHED SLEEVES & DAMAGES STUDS
MOST OF THE DAMAGES ARE MADE BY MISHANDLING, POOR STORAGE
CONDITIONS, LACK OF PREVENTIVE MAINTENANCE AND POOR TRAINED PERSONNEL
THE VARIABLE THAT DETERMINES THE REPAIR TIME IS THE
GENERAL CONDITION OF THE BOP AT ARRIVING.
IMPROVING PREVENTIVE MAINTENANCE AND REINFORCING OPERATION PROCEDURES
WILL HELP TO REDUCE THE REBUILDING AND CERTIFYING TIME.
FACTS
ACKNOWLEDGMENT
ACYSWENLEN
IPSLADS ARGENTINA