Blowout Preventor Re-certification Study

Steve Smith, Drilling Technical Dept.

INTRODUCTION:
DEFINE CERTIFICATION and RECERTIFICATION GENERALLY ACCEPTED INDUSTRY PRACTICE 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 Manufacturers 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 CONDITION Policy established in 1998 Must be performed by the OEM or their Licensee Disassemble and Inspect; Including:
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 ARAMCOS 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 Reviewed 47 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 57 - 26-3/4" 3M

ANNULAR BOP's
Records for 21 Annular BOP's Reviewed 2 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

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
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-Certification Indication That 3 Year Re-Certification is Required 3 Years Should be Maintained Regardless of BOP Size or Working Pressure