2011 moduspec audits for 8 winner rigs in the · pdf fileto work jointly (moduspec and petrom...

2011 MODUSPEC AUDITS FOR 8 WINNER RIGS IN THE DRILLING WORKS TENDERING + 1 BACK

UP RIG

DATE: 24/05/2012

IADC CONFERENCE

FLORIN CONSTANTINESCU

I. CHALENGES II. FINDINGS III. QA/QC TOP 2011 IV. IMPROVEMENTS V. QA/QC TOP 2011 UPDATED AT MARCH 2012 VI. QA/QC PROGRAM 2012

3 P&E, Drilling & Production Engineering

I. CHALENGES

► S.C. OMV PETROM AND MODUSPEC PERFORM THE INSPECTION TO WORKING LOCATION TO VERIFY IF THE RIGS ARE IN COMPLIANCE WITH THE EQUIPMENT SPECIFIED IN THE CONTRACT PROPOSALS AND DRILLING CONTRACT. ►THE SCOPE OF INSPECTIONS : 1. FULL CONDITION SURVEY THE SURVEY WAS CONDUCTED VIA A COMBINATION OF VISUAL INSPECTION AND FUNCTION TESTING OF EQUIPMENT 2. PREVENTIVE MAINTENANCE SYSTEM AUDIT AN AUDIT OF THE PREVENTIVE MAINTENANCE SYSTEM IS INTENDED TO ASESS THE AUDITABILITY OF EXECUTED MAINTENANCE INCLUDING KEEPING OF RECORDS,ACTIVE PREVENTIVE MAINTENANCE ROUTINES AND COMPLIANCE IN EXECUTION.THIS WILL INCLUDE THE CHECK OF CURRENT MAINTENANCE STATUS.


Control hydraulic handles without labels Main generator Nos. 1 and 2 had burnt Metal Oxide Varistors

II. FINDINGS


Exposed hexagon on the input shaft Breaking/Operation system is missing from BOP trolley carriage


Threaded/welded connection at discharge valve mud

pump

Unauthorized pad eyes welded at substructure


Unproperly tighten studs Improper chains at discharge mud pump flexible lines


Mud pump with excessive flakes wear at middle gear train

Mud pump contaminated oil with metal from gear train wear


Install protective covers on the alternator and fan belts Install back-up safety lines at all mast sheaves


Prior to commencing operations, completely tighten and torque all fasteners at the TDS torque adaptor tube

at the mast

Replace all threaded connections for welded or flanged connections on the standpipe manifold


.

Unprotected battery

Improper safety clamp and safety line at vibration hose


.

No cable gland No safety guard


.

Missing split pins No safe access provided to the monkeyboard


.

Pole of Ladsafe climb system too short to disconnect in a safe position on the crown platform

Tongs with worn hand grips and hand protection


“GENERAL” FINDINGS TO ALL DRILLING CONTRACTORS 1. BOP RAMS, BOP ANNULAR, BOP GATE VALVES, CHOKE AND KILL MANIFOLD AND HYDRAULIC

PRESSURE UNIT ARE NOT IN ACCORDING TO API REQUIREMENTS & H2S SERVICE (REF: API SPE. 16.D AND API RP53)

2. THREADED CONNECTION FOR RELIEF VALVE, CHOKE AND KILL MANIFOLD, MUD PUMPS AND STAND PIPE MANIFOLD.

3. TOP DRIVE SYSTEM IS MISSING/IMPROPER. 4. INSTALL A TRANSPORT SYSTEM CONSISTING OF A TROLLEY CARRIAGE ON TRACKS TO MOVE THE

BOP STACK AWAY FROM SUBSTRUCTURE. 5. ELECTRICAL EQUIPMENT WITHIN HAZARDOUS AREAS WERE NOT EX OR ATEX CERTIFIED, OR WAS

COMPLETELY MISSING. 6. THE CASING STABBING BOARD WAS NOT IN A PROPER CONDITION. NO LOAD TEST WAS

PERFORMED. AFTER 575 ANINOASA FATALITY WERE STARTED THE MAINTENANCE/TESTS PROCEDURES BUT IN THIS MOMENTS ONE OF THIS EQUIPMENTS DON’T WORK PROPER.

7. PREVENTIVE MAINTENANCE SYSTEM IS MORE OR LESS IN THE IMPLEMENTATION PHASE. 8. INSPECTIONS, FUNCTIONAL TESTS, LIFTING EQUIPMENTS, PRESSURE EQUIPMENTS TESTS, DROPPED-

OBJECTS INSPECTION, HIGH-PRESSURE HOSES WERE NOT FOUND OR REPORTED IN THE PREVENTIVE MAINTENANCE SYSTEM.

9. NONE OF DRILLING CONTRACTORS FULFILLED 100% REQUIREMENTS/DEAD LINE FOR START DRILLING OPERATIONS SO THEY PROMISED DURING TENDERING PROCESS.


III. QA/QC TOP 2011- IMMEDIATELY AFTER AUDIT

NR. DRILLING CONTRACTOR - RIG - DATE MODUSPEC SURVEY AUDIT PREV. MAINTENANCE SYSTEM TODAY ASPECTS

SEVERITY IF SF % S1(%) CMMS S.F/T.F S2(%) POSITIVE NEGATIVE

1 Rig A/ 10.06.2011 CRITICAL 30 26 87

87,79 50%

0 / 8

50% BOP

MAJOR 48 42 88

ASIS MINOR 12 12 100 0%

2 Rig B/ 28.09.2011 CRITICAL 18 14 78

83,35 50%

0 / 11

50%

BOP MAJOR 21 20 95

ORACLE-SIVECO MINOR 24 24 100 0% THREADED CONN

3 Rig C/ 22.06.2011 CRITICAL 39 15 38

41,45 25%

0 / 12

25% BOP TDS MAJOR 78 31 40

PAPER - CMMS MINOR 13 10 77 0%

4 Rig D/ 24.12.2011 CRITICAL 21 13 62

65,63 50%

2. / 18

55% BOP ATEX??? MAJOR 32 23 72

RAM MINOR 17 14 82 5%

5 Rig E/ 22.05.2011 CRITICAL 21 20 95

96,67 50%

0 / 11

50% BOP MAJOR 56 56 100

EresMan MINOR 10 10 100 0%

6 Rig F/ 23.06.2011 CRITICAL 44 16 36

33,44 50%

1. / 11

55% BOP MAJOR 82 16 20


7 Rig G/ 24.05.2011 CRITICAL 25 23 92

92,31 25%

0 / 9

25% BOP MAJOR 88 80 91

EXCEL - EresMan MINOR 13 13 100 0%

8 Rig H/ 22.10.2011 CRITICAL 14 13 93

92,3 50%

0 / 8


EXPERT MINOR 33 28 85 0%

9 Rig I/ 25.09.2011 CRITICAL 32 25 78

75,17 25%

0 / 10


PAPER - CMMS MINOR 36 26 72 0%

IF - NUMBER OF INITIAL FINDINGS S1=SCORE=(0.7 X P CRITICAL)+(0.23 X P MAJOR)+(0.07 X P MINOR) SF - SOLVED FINDINGS S2=SCORE=CMMS PERCENTAGE+0.5 X (S.F/T.F PERCENTAGE) T.F - TOTAL FINDINGS CMMS - COMPUTER MAINTENANCE MANAGEMENT SYSTEM


FULL CONDITION SURVEY

1. Rig E 96 %

2. Rig G 92 %

3. Rig H 92 %

4. Rig A 87 %

5. Rig B 83 %

6. Rig I 75 %

7. Rig D 65 %

8. Rig C 41 %

9. Rig F 33 %

PREVENTIVE MAINTENANCE SYSTEM

1. Rig D 55 %

2. Rig A & Rig E 50 %

3. Rig B 50 %

4. Rig H 50 %

5. Rig F 50 %

6. Rig G 25 %

7. Rig C 25 %

8. Rig I 25 %


IV. IMPROVEMENTS “THE ALMOST FINDINGS WERE SOLVED TILL MARCH 2012”


“THE ALMOST FINDINGS WERE SOLVED TILL MARCH 2012”


V. QA/QC TOP 2011 UPDATED AT MARCH 2012

NR. DRILLING CONTRACTOR - RIG - DATE MODUSPEC SURVEY AUDIT PREV. MAINTENANCE SYSTEM TODAY ASPECTS SEVERITY IF SF % S1(%) CMMS S.F/T.F S2(%) POSITIVE NEGATIVE

1 Rig A/ 10.06.2011 CRITICAL 30 30 100

99,52 50%

5 / 8

81% BOP

MAJOR 48 47 98

ASIS MINOR 12 12 100 31%

2 Rig B/ 28.09.2011 CRITICAL 18 16 89

91,13 50%

7 / 11

82%

BOP MAJOR 21 20 95

ORACLE-SIVECO MINOR 24 24 100 32% THREADED CONN.

3 Rig C/ 22.06.2011 CRITICAL 39 37 95

94,64 50%

5 / 12


ASIS MINOR 13 13 100 21%

4 Rig D/ 24.12.2011 CRITICAL 21 20 95

96,67 50%

13 / 18

86% BOP MAJOR 32 32 100

RAM MINOR 17 17 100 36%

5 Rig E/ 22.05.2011 CRITICAL 21 21 100

100 50%

5 / 7

85% BOP MAJOR 56 56 100


6 Rig F/ 23.06.2011 CRITICAL 45 45 100

99,72 50%

5 / 7

85% BOP MAJOR 82 81 99


7 Rig G/ 24.05.2011 CRITICAL 25 25 100

99,74 50%

2 / 9

61% BOP MAJOR 88 87 99


8 Rig H / 22.10.2011 CRITICAL 14 13 93

93,69 50%

5 / 8


EXPERT MINOR 33 32 97 31%

9 Rig I/ 25.09.2011 CRITICAL 32 31 97

97,25 50%

6 / 10


CMMS MINOR 36 36 100 30%

IF - NUMBER OF INITIAL FINDINGS S1=SCORE= (0.7 X P CRITICAL)+(0.23 X P MAJOR)+(0.07 X P MINOR) SF - SOLVED FINDINGS S2=SCORE=CMMS PERCENTAGE+0.5 X (S.F/T.F PERCENTAGE) T.F - TOTAL FINDINGS CMMS - COMPUTER MAINTENANCE MANAGEMENT SYSTEM


FULL CONDITION SURVEY

1. Rig E 100%

2. Rig F 99 %

3. Rig G 99 %

4. Rig A 99 %

5. Rig I 97 %

6. Rig D 96 %

7. Rig C 94 %

8. Rig H 93 %

9. Rig B 91%

PREVENTIVE MAINTENANCE SYSTEM

1. Rig D 86 %

2. Rig E & Rig A 85 %

3. Rig B 82 %

4. Rig H 81 %

5. Rig F 81 %

6. Rig I 80 %

7. Rig C 71 %

8. Rig G 61 %


1. TO CONTINUE THE MODUSPEC AUDIT FOR OTHER THREE–FOUR RIGS

2. TO WORK JOINTLY (MODUSPEC AND PETROM TEAM) FOR CONDUCTING RIG START-UP AUDITS (AROUND 180 WELLS/2012)

VI. QA/QC PROGRAM 2012

Thank You!

2011 moduspec audits for 8 winner rigs in the · pdf fileto work jointly (moduspec and petrom...

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