latin american drilling safety repair & certification of blow out preventers in argentina...

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


TIMELINE

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

2006 Late 2006


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



TIMELINE

THE REQUIREMENTS:. A New certified workshop is requiered.

2006 Late 2006 2007



TIMELINE

2006 Late 2006 2007

Rig

Activity

Dropped

Early

2008




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




Rig

Activity

Dropped

TIMELINE

2006 Late 2006 2007Early

2008

INITIAL SITUATION: Importation compicated, One Overloaded Workshop, Homemade supplies.



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




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



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




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




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 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”

http://en.wikipedia.org/wiki/File:Hydril_Annular_BOP_Patent_App.jpg

http://en.wikipedia.org/wiki/File:Cameron_EVO_BOP_Patent.jpg

TIMELINE





THE ACTIONS:.



Drilling; 50; 37%

Workover; 38; 28%

Sin Datos; 47; 35%

Drilling; 64; 23%

Workover; 124; 44%

Pulling; 31; 11%

Sin Datos; 63; 22%



No Data No Data

2006 Late 2006 2007 2008 2009

TIMELINE





THE ACTIONS:.


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%




No Data

TIMELINE





THE ACTIONS:.


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%




No Data

2006 Late 2006 2007 2008 2009

2006 Late 2006 2007 2008 2009

TIMELINE





THE ACTIONS:.


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%




No DataNo Data

TIMELINE


THE ACTIONS:.

2006 Late 2006 2007 2008 2009Early

2008




•Perform a BOP´s inventory.•Select Potencial workshops•Help to develop the candidates to Establish procedures, policies and standards.

Rig

Activity

Dropped

TIMELINE





THE ACTIONS:.


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 ACTIONS:.

2006 Late 2006 2007 2008 2009Early

2008




•Perform a BOP´s inventory.•Select Potencial workshops•Help to develop the candidates to Establish procedures, policies and standards.

Rig

Activity

Dropped

TIMELINE





THE ACTIONS:.


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 ACTIONS:.BOP´s, candidates development.

2006 Late 2006 2007 2008 2009Early

2008




Rig

Activity

Dropped

TIMELINE

2006 Late 2006 2007 2008 2009 2012


THE ACTIONS:.BOP´s, candidates development.

THE FINAL RESULT

Early

2008




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 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 FINAL RESULT

•REPAIR STAGE


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 FINAL RESULT

•TEST STAGE


THE FINAL RESULT

•DELIVERY STAGE


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

latin american drilling safety repair & certification of blow out preventers in argentina...

Documents

overloaded workshop

bops failures

timeline initial situation

new certified workshop

homemade supplies

importation complicated

disappointed operators

homemade spares