Deepwater Challenges - WEST Engineering Services

Deepwater Challenges - WEST Engineering Services

P.O. Box 577
Brookshire, TX 77423
U.S.A
Tel: (281) 375-5515
Fax: (281) 934-1600
west@westengineer.com
ISO 9001 Certified
Deepwater Challenges
Detailed Seminar Outline
Note: The outline of the seminar may vary depending on instructors and new material.
Manuals provided during the seminar are the following:
• Deepwater Challenges seminar manual
• Presentation notebook
Introduction
Seminar Basis & What’s Different
1.
2.
3.
4.
5.
6.
Safety and building layout
Seminar basis and definitions
Current deepwater location and capabilities
Rig capabilities, studies and results
Lessons Learned - so not to be repeated
Lessons Learned - shipyard shortcomings, newbuild
issues
7. Industry standards - let’s be a learning industry
8. Regulatory issues and industry standards
9. WEST information systems
Section I - BOP Control System
A. BOP control systems – schematic review & introduction
Note: The WEST Subsea Drill Through Equipment course highlights the
Shaffer®/Koomey control system because of its high market share with piloted control
systems. Due to Cameron’s market share with deepwater systems, Cameron’s control
system is the focus of DeepWater Challenges. The differences between various control
system manufacturers will be discussed.
1. Basic hydraulic symbols
2. Surface accumulators
a. Weight and spring type
b. Piston and bladder type
3. Basic components of a MUX (multiplex) control system
a. Surface-mounted equipment
b. Fluid reservoirs
c. Hydraulic power unit
d. Diverter panel HPU (hydraulic power unit)
4. NAS (National Aerospace Standards) class of fluid cleanliness
a. Bacteria/fungi
b. Testing fluid samples
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WEST Deepwater Challenges Seminar
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5. BOP remote panels
6. MUX cables and MUX cable reels
a. Slip rings
b. MUX cable connectors
c. MUX cable clamps
7. Subsea mounted accumulators
a. Accumulator bladder and float failures
b. Depth-compensated accumulator bottles
8. Flowmeter issues
9. BOP stack hose and tubing maintenance
B. Multiplex Control Systems
1. Cameron MUX controls
a. Pod stack stingers
b. Female receptacles
c. Solenoid and shear seal valves
d. Manual pod regulator
2. Manual 5,000 to 3,000 psi regulators
3. Shaffer® MUX controls
a. SPM (sub-plate mounted) valves
b. Shaffer® 5th generation MUX pod
4. Hydril MUX controls
5. Gilmore shuttle valves
a. Biased shuttle valves
6. New problems or new people?
a. Diesel in the mix tank
b. Multi-million dollar plug
7. Stack-mounted accumulators
a. Accumulator bottle charging valve issue
8. Shaffer® CCSV (chamber-compensated solenoid valve) failures
a. CCSV go-no-go gauge
C. Accumulator volume
1. Review accumulator functions and define usable volumes
a. Subsea accumulators for deepwater applications
b. Defining minimum operating pressure
2. List requirements of standards and regulations…API (American Petroleum
Institute), MMS (Minerals Management Service), NPD (Norwegian Petroleum
Directorate)
3. Review calculations methods and assumptions
4. Compare methods
a. Compare methods A, B and C
5. API software demonstration
a. API 16D accumulator volume software
demonstration
6. Make recommendations
D. Alternative systems
1. SID (Subsea Isolation Device)
a. SID control system
b. SID disconnect
2. MoRPH (Modifying oil rigs to Poke Holes)
a. MoRPH control system
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WEST Deepwater Challenges Seminar
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b. Surface to subsea equipment
c. Field operations
3. Deepwater piloted controls
a. Subsea components: regulator, quick dump valve, SPM valve
b. Response time curves
4. MODSYS™
a. MODSYS™ features
b. MODSYS™ upgrades
E. AADE (American Association of Drilling Engineers) water
hammer presentation (time permitting)
This special section presents testing performed by Gilmore
concerning water hammer and the subsea effect
1. The cause of water hammer in modern control
systems
2. Understand the effects of water hammer as it relates
to shuttle valve oscillation
3. Latest improvements in shuttle valve design
Section II – BOP Stacks and
Equipment
A. BOP Stacks
1. Ram BOPs - downtime, characteristics and
deepwater issues
a. Review of ram BOP sealing
b. Review of ram packer pressures and closing
ratios
c. Making use of closing ratios in the field
d. Factors effecting probability of shear - review
shearing data
e. Sealing shear rams and casing shear rams
f. Casing shear ram issues
g. Design verification testing, API 16A, hang-off and
stripping capabilities
h. Hydrostatic head hits us again, casing shear ram
operator
i. How tool joint design changed hang-off
2. Functionality of gate and failsafe valves
a. Failsafe open vs. close
b. Effects of hydrostatic head
c. Sealing characteristics
d. Verifying correction valve function
e. Worldwide Oilfield Machinery valve operator issues
f. Failsafe assist circuits
B. Cameron ram BOPs
1. Cameron’s ram lock offering
2. Cameron locking systems
3. "ST" lock operation and sequencing caps
4. Bearing issues and upgrades introduced
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WEST Deepwater Challenges Seminar
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5. Sequence valves on ST Locks
6. Predictive testing of ST locks
7. Basic operation of RamLocks
8. Control circuit requirements
9. Sequence valves and RamLocks
10. RamLock case histories
11. Do we still have manufacturing quality issues with
swarf?
12. Cameron’s newest ram BOP – EVO, the EVO-LOC
13. Bi-directional test ram
C. Shaffer® ram BOPs
1. Shaffer® NXT ram BOP
2. NXT 22” PosLock operator – extreme shear force
3. Review of Shaffer® RamLock offerings
4. How we got to the UltraLock IIB design, will there
be more revisions?
5. Review UltraLock modifications and case histories
6. Understand why operating pressures have been
limited on the IIA design
7. UltraLock field issues
8. PosLocks with 18" boosters
9. Latest ram offerings
D. Hydril
1.
2.
3.
4.
ram BOPs
Review of Hydril ram BOP offerings
Details on Hydril’s latest, the Quik-Loq
Ramtel – ram block position monitoring
MPL (Hydril Multi-Position Lock) and predictive
testing
5. Seawater hydrostatic pressure bites us again
6. Bonnet seal and ram shaft seal modifications
rR
r Shea
Low e
p
ams O
en
9
12/21/9
5/2/00
5/4/00
psi
500
400
300
0
1.7
5
10
.5
12
.3
0
7
8.7
5
100
in M
Time
14
200
3.5
5.2
5
ure in
Press
E. Predictive Testing (as it relates to ram BOPs)
1. What is “predictive testing”? It's better than
money in the bank
2. Hydril MPL case study - testing predicted failure
within 10 cycles
3. Cameron ST predictive testing success
4. Understand how backlash affects ram packer
pressure
5. Slip force review and how it applies to RamLocks
and UltraLocks™
6. How listening is useful on all equipment
7. New MPL field test procedure
8. API sealing characteristics tests - prudent
equipment operators should have this information
inutes
F. HPHT – High Pressure, High Temperature (regarding ram BOPs)
1. Elastomer study
a. Review industry, manufacturers, WEST data
b. Elastomers don’t like high temperatures
c. Minimum extrusion gaps in packers are crucial
© 2011 WEST Engineering Services
WEST Deepwater Challenges Seminar
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d. API procedures should be revised
e. The industry needs to standardize
2. High pressure BOPs
a. New API RP: 6HP – for high pressure drill through equipment
b. Can you use a 15K (15,000 psi) BOP if your shut-in pressure will be 14.8K?
c. 20K BOP stack solutions and comparisons
d. The work continues…
Workshop: Shearing
Section III – Annular Preventers
1. Hydrostatic head, annulars and shuttle valves and
what they have in common.
a. Hydril GX opening chamber head
b. High interflow shuttle valve
2. Design verification testing, or the lack of it
a. Shaffer SL 18-3/4” annular capability and new
packing elements
b. Most recent Shaffer spherical packer damage
c. Increase closing pressure for hydrostatic and
kicks
3. Testing head seal on the upper annular
4. Pros and cons of closing an annular during an EDS
Section IV - Hydraulic Connectors and End Connections
1. Cameron connector family
a. DWHC and HCH4 connectors
b. EVO connector
c. Mini collet connector
2. Vetco connectors
a. SHD H-4 connector
b. DWHD H-4 connector
c. H-4 bent retaining pins anomaly & solution
3. Bending moment capacities
a. Preload vs. locking pressure
b. Bending moments from flex joint tension
c. Cameron flanges
4. Dangers of mixing wellheads and connectors
5. Effects of hydrostatic head on connectors
a. Pressure relief grooves
b. Hydrostatic head and mini collet connectors
c. Effects of hydrostatic vs. wellbore pressure differential
6. Gasket issues
a. Mini connector AX gasket alignment problems and the use of retainers
b. Stuck VX gasket anomaly and solution
© 2011 WEST Engineering Services
WEST Deepwater Challenges Seminar
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Section V - Marine Drilling Riser
A. Current and deepwater riser issues
1. What are the major downtime causes with drilling riser?
a. Comparison of downtime - 1st SINTEF (independent Scandinavian research
organization) vs. 2nd SINTEF study
2. Understand the basics of API specification 16R and RP 16Q
a. RP 16Q, riser operating manuals, maintenance issues
3. Discuss Aker Kvaerner CLIP riser
a. CLIP riser breech block design
4. Problem - cracked pipe welds from most
major manufacturers
a. Cracking problems with Cameron Load
King, Dril-Quip “QMFC” riser, MR-10
Vetco riser
b. Riser load path fasteners
5. Why do you need to perform load path
fastener inspections?
6. Cameron's CamChec riser inspection
capabilities
a. Riser inspection with TOFD (Time Of
Flight Diffraction)
b. Cleaning procedure
c. Wave paths for the TOFD Arrangement
7. Why verify riser connector fit up?
a. Riser interchangeability issues, new and replacement (does Vetco MR 6D =
SS or Shaffer®?)
b. Correct and incorrect dog engagement
8. Understand other riser field and maintenance issues
a. Riser maintenance issues
b. Shaffer® FT riser fit up anomaly
c. Imperfections observed while running riser
B. BOP and riser handling systems
1. Review BOP transport systems
2. Riser joint handling systems
3. Riser handling/running tools
a. Vetco HMF mechanical and hydraulic handling
tool
4. Hydraulic spider and gimbal/shock absorbers
5. Running the stack
a. Latching telescopic joint to Cameron
tensioner ring
b. Unlatching tensioner ring from diverter
housing
6. Stowable support rings and maintenance inspection
a. Vetco SDL ring
b. Vetco SLS ring
c. Vetco KT ring
© 2011 WEST Engineering Services
WEST Deepwater Challenges Seminar
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7. Fluid bearings in tension ring, torque on riser string and annular
a. Torque loads due to heading change
b. Annular anti-rotation devices
Section VI - MUX Controls
A. Electrical - progression of BOP controls from
mechanical to MUX
1. BOP Controls - evolution
2. Why Use a multiplex control system?
3. What does a MUX control system do for us?
4. How basic multiplex system components
work
a. Toolpusher’s panel
b. Driller’s panel
c. UPS (uninterruptible power supply)
d. Blue and yellow SEM (subsea electronics
module)
5. The six manufacturers of multiplex BOP
controls
a. Cameron
b. NOV/Shaffer®
c. Hydril
d. Drilling Controls, Inc. (formally ABB)
e. Oceaneering
f. DTC International (new player)
6. Control panels
7. Problems with surface controls
a. Event/Data loggers
b. Multiplex cables
8. MUX cables, reels and connectors
a. Wet mate and dry mate connectors
a. Cable connector choice, repair, and
replacement
b. Cable reels
c. Compliance with API spec 16D
d. Seacon pressure-balanced, oil-filled
connectors on SEM, RCB (riser control box),
and STM (subsea transducer module)
B. EDS (Emergency Disconnect Sequence)
1. The theory behind a DP rig
2. What are the causes of an EDS?
3. DP watch circles
4. Progression of an EDS
a. EDS is activated
b. “Arm” command is sent to riser recoil
c. Wellbore is secured
d. LMRP separates from receiver plate
e. Proximity switch sends “fire” command to riser recoil as it loses contact with
the receiver plate
© 2011 WEST Engineering Services
WEST Deepwater Challenges Seminar
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5. Choke and kill connectors unlock for EDS
6. Normal EDS and a casing shear EDS
7. Deadman – AMF (automatic mode failure) system
8. A failure to disconnect could prove disastrous
9. EDS risk analysis close shearing blind rams
10. Proximity switch
C. Secondary intervention - what systems are available?
1. System types
a. Description of system types
2. ROV (remotely operated vehicle) intervention
a. ROV capabilities
b. Typical multi-function ROV control panel
c. Gasket running tool
3. Acoustic backup system capabilities
a. Acoustic pod assembly
4. Autoshear
a. When does autoshear function?
b. Typical autoshear circuit
5. BOP stack frame deflection
6. Deadman system
a. The difference between a deadman and an AMF
system
7. Key issues for consideration
Section VII – Wellbore Pressure
Testing with Oil-Based Mud
1
1. Good communication during pressure testing
2. Safety practices
3. Wellbore testing issues with oil-based mud
a. Thermodynamics
b. Pressure/temperature correlation
cem ent unit
tem perature
2
3
7
4
5
6
8
11
9
10
Section VIII - Dropped stacks and
emergency recovery
Note: This module is a blast! We get plenty of interaction.
Everyone has a story and appreciates learning from the
experience of others.
1. WEST’s dropped stack study - an overview
2. Sixteen dropped stacks or near misses presented
3. The “five P’s” = Prior Planning Prevents Poor
Performance
4. Slings, funnels and drill pipe recovery
© 2011 WEST Engineering Services
WEST Deepwater Challenges Seminar
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Section IX - Riser Recoil and Hard vs. Soft Hang-off
1. Define the purpose of a riser recoil system
a. Riser recoil considerations
b. Shaffer® riser recoil valve
c. Hydralift Riser Anti-Recoil System (RARS)
2. Discuss how the system works
a. Riser recoil system yo-yo, CCU (central control unit), throttle valve and riser
tensioner
3. Discuss inputs that can initiate the system and purpose
a. EDS signal can be proximity switch between LMRP and BOP
b. Progression of an EDS
4. What is the difference between hard and soft hang-off?
5. Which technique is best for your location?
Section X – Tension, Collapse, Buoyancy and Keyseating
1. Brief review of riser tensioning
2. Hydralift in-line tensioners
a. Maintenance and repair of riser
tensioners
b. Discuss Cameron split support ring
3. Riser tensioner efficiency and fleet angle
4. Composite air-pressure vessel (CAPV)
5. Buoyancy design and requirements, IADC
(International Association of Drilling
Contractors) safety alerts
a. Discuss damaged buoyancy modules
6. Riser collapse considerations and variables
a. Primary collapse variables
b. Collapse likelihood and other factors
c. Riser wall thickness issues
7. Fill-up valves - use them or not?
8. Tensioners and tension requirements
9. Vortex-induced vibrations, buoyancy placement, fairings and high current
considerations
10. DEA (Drilling Engineering Association) study #137 - deepwater keyseating issues
and solutions
Section XI – Risk Assessment
1. Why should you perform a risk
assessment or analysis?
2. Why stacks are pulled when they don’t
need to be
3. Planning ahead
4. Using a decision tree
5. Case study
© 2011 WEST Engineering Services