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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