Download - Saudi Aramco Presentation From Steve Smith
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