Blowout Preventor Blowout Preventor

Re-certification Study

Steve Smith, Drilling Technical Dept.

INTRODUCTION:

• DEFINE CERTIFICATION and RECERTIFICATION

• GENERALLY ACCEPTED INDUSTRY PRACTICE

• SAUDI ARAMCO POLICY• SAUDI ARAMCO POLICY

• PURPOSE OF THE STUDY

• STUDY METHODOLOGY

• RESULTS

• DISCUSSION AND SUMMARY

DENINITIONS:

• CERTIFICATION:• Generally refers to new equipment.

• It includes (at a minimum):• API Monogram

• Statement (Certificate) of Compliance

• RE-CERTIFICATION• Refers to used equipment.

• Retains the API Monogram (where applicable)

• Includes (at a minimum):• Inspection Reports

• Work Performed to bring to ‘as new’ condition.

• Test Reports.

• Statement (Certificate) of Compliance/Re-Certification

INDUSTRY PRACTICE:

• 3 – 5 YEAR ‘MAJOR INSPECTION’ (Re-Certification)

• Disassemble and Inspect according to Manufacturer’s Guidelines (API RP-53)

• Inspection and Documentation requirements vary with the Manufacturer and the Operator

• No Original Equipment Manufacturer (OEM) Requirement

SAUDI ARAMCO POLICY:

• 3 YEAR RE-CERTIFICATION TO ‘AS NEW’ CONDITIONPolicy established in 1998

• Must be performed by the OEM or their Licensee

• Disassemble and Inspect; Including:• Full Dimensional Inspection• Full Dimensional Inspection

• MPI/DP Welds, Bodies & Bonnets

• Hardness Check

• Sealing Surfaces for Corrosion & Erosion

• Complete Remanufacture to ‘As New’ Condition• Weld, Machine & Heat Treatment as needed

• Assemble with new consumable components e.g.: elastomer seals etc.

• Complete Hydro-Test

• Retain API Monogram (as applicable)

• Issue Certificate of Compliance Certificate (Re-certification Certificate)

RECERTIFICATION STUDY:

• EVALUATE SAUDI ARAMCO’S 3 YEAR POLICY

Does the condition of the BOP after 3 years of service justify full remanufacture, recertification of the equipment?

• Review Recertification Records for a 4 year period Identifying:• Previously Recertified BOP or 1st Recertification (BOP 3 years old)

• Type of Repair • Welding (Cavity and, or Bore) CONSIDERED MAJOR REPAIR!

• Machining (Skim Cutting Ring Grooves etc.)

• Area Where Repair was Required• Flanges/Ring Grooves

• Body

• Bonnets

• Operating System

RECERTIFICATION STUDY:• RAM BOP's

• Records for 389 Ram BOP Cavities Reviewed47 Had Been Previously Certified• 2 - 7" 5M

• 3 - 11" 3M

• 22 - 11" 10M

• 123 - 13-5/8" 3 & 5M

• 140 - 13-5/8" 10M

• 40 - 20-3/4" 3M

• 2 - 21-1/4" 2M• 2 - 21-1/4" 2M

• 57 - 26-3/4" 3M

• ANNULAR BOP's• Records for 21 Annular BOP's Reviewed2 Had Been Previously Certified• 4 - 11" 10M

• 1 - 13-5/8" 3M

• 8 - 13-5/8" 5M

• 2 - 13-5/8" 10M

• 2 - 21-1/4" 2M

• 4 - 30" 1M

RESULTS:

• RAM BOP's

• 98.5% Required Weld Repair: (6 units out of 389 did not)• 91% Required Weld Repair of the Cavities

• 45% Required Weld Repair of the Bore

• 66% Required Weld Repair of the Flanges/Ring Grooves

• 44% Required Skim Cutting of Ring Grooves• 44% Required Skim Cutting of Ring Grooves

• ANNULAR BOP's• 95% Required Weld Repair: (1 unit out of 21 did not)

• 33% Required Weld Repair of the Seal Bore

• 19% Required Weld Repair of the Through Bore

• 62% Required Weld Repair of the Flanges/Ring Grooves

• 52% Required Skim Cutting Ring Grooves

RESULTS:

• RAM BOP's

• 100% of 11" & 13-5/8" Required Major Repair

• 92% of 26-3/4" and 26-3/4" Required Major Repair

• ANNULAR BOP's• ANNULAR BOP's• 93% of 11" & 13-5/8" Required Major Repair

• 100% of 21-1/4" and 30" Required Major Repair

• OPERATING SYSTEM• 43% Of All BOP's Required Operating System Repairs

DISCUSSION & SUMMARY:

• All Of These BOP's Pressure Tested Before Being Returned For Re-CertificationReturned For Re-Certification

• Indication That 3 Year Re-Certification is Required

• 3 Years Should be Maintained Regardless of BOP Size or Working Pressure