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Deepwater Challenges - Course Outline
 
5 Day Seminar
 
(Brookshire, Texas)
 

 

This five-day seminar will focus on known and prospective problems associated with drilling in ever deeper water, including an added section examining some recently introduced equipment. With the knowledge presented in this seminar, you will learn of downtime others have suffered, which will help you to look for and avoid repeating the same costly events.

Experts from our in-house staff are used to present topics in their field of expertise. For instance, Greg Childs presents many ram locking system issues, Ed Lewis presents BOP control systems, and Michael Montgomery topics such as riser management and predictive testing.

Learning objectives for each module are stated in the course outline.

Please bring the pertinent API Specifications and RP's to use as a reference during the seminar.

Workshops: Immediately following lunch, three workshops will be given which have previously received fantastic evaluations.

1) Shearing, presented by Greg Childs
2) Dropped Stack, presented by Ed Lewis
3) Secondary Intervention, presented by Ed Lewis

SECTION I- INTRODUCTION

Introduction, Seminar Basis and What's Different

 
1.
Safety in the "Cotton Gin"
 
2.
Understand WEST's information systems
 
3.
ITP's = "Inspection and Test Procedures" - Information available
 
4.
Anomaly Data Base - Lesson's learned, so as not to be repeated
 
5.
"RigLore" - Engineering Bulletins and Product Alerts "at your fingertips"
 
6.
Where and when does downtime occur in deepwater drilling?
 
7.
Standards to which we assess
 
8.
Direct and indirect costs (What does it cost to pull a stack?)
 
9.
Risk analysis and how to minimize downtime

SECTION II - QUALITY MANAGEMENT

  1. Let's be a learning industry; product performance reports, reference API Spec 16A, API RP 53 ISO 9000; API Q1 program
  2. Document control: O & M manuals, engineering bulletins and product alerts
  3. Operational management
  4. Why are the API quality systems not working? (API Q1, API RP 53 and API Spec 16A)
  5. Regulatory issues and industry standards
  6. What should your response be when they say "Certified"?

SECTION III - HYDRAULIC CONTROLS - MUX

BOP Control Systems - Schematic Review and Introduction

Due to Cameron's market share with deepwater systems, this control system is our focus during Deepwater Challenges, DWC. The WEST "Drill Through Equipment" course highlights the Shaffer/Koomey control system, because of the market share with piloted control systems.

  1. Hydraulic power units (HPU), five components of a control system
  2. Control components and their symbols
  3. Accumulators
    a. bladder type
    b. float type
    c. effects of deep water on subsea accumulator useable volume
  4. Pods and their operation
  5. Valves
    a. solenoid, shear seal and multi-position
    b. pod designs, regulators and shuttle valve designs
  6. Quick response systems
  H. Hydraulic hoses
  G. Simple hydraulic circuits

Cameron Multiplex Control Systems - Hydraulic Part #1

  1. Introduce 5,000 psi components of the system
  2. Fluid cleanliness - NAS levels and bacteria
  3. Control panels and alarms
  4. Cable reels, level wind and slip rings
  5. Cameron Safety Alert #1820078 (Float Type Accumulators)
  6. High flow rates and flowmeters
  7. Learn the internal components of a Cameron multiplex pod
  8. BOP Stack hoses or hard pipe? Learn from the experiences of others

Accumulator Volume

  1. Describe Accumulator functions
  2. List requirements of standards and regulations
  3. Review changes to deepwater drilling
  4. Review calculation methods and assumptions
  5. Compare methods
  6. Dynamic hydraulic modeling and thermo adiabatic corrections
  7. API Spec. 16D and usable fluid & shearing requirements
  8. Make recommendations

Cameron Multiplex Control Systems - Part #2

  1. Solenoid valves, Type 15 vs. Type 63
  2. Pod valves and 70 durometer o-ring extrusion
  3. Double piloted control valves
  4. Manual 5,000 to 3,000 psi regulators
  5. Biased shuttle valve applications
  6. Gilmore shuttle valves and applications
  7. Flow rates and flow restrictions
  8. Regulator circuits and shear bypass
  9. Pre-qualification of control valves
  10. Cold start of dead pods
  11. Cameron's Premium Valves

SECTION IV - MARINE DRILLING RISER

New, Interchangeability and Quality

  1. How much down time do we experience with riser?
  2. Understand the API Specification 16R load rating categories
  3. Drill-Quip main tube cracking in new riser
  4. Sour gas considerations for riser, API RP 16Q and NACE
  5. Toughness - charpy impact testing and modulus of resilience
  6. ABB Vetco MR 10 main tube cracking in new riser
  7. SSQR-F Riser - Stewart and Stevenson riser failure (threaded insert)
  8. Cameron's CamCheck riser inspection capabilities
  9. Riser interchangeability issues, new and replacement (Does Vetco
MR 6D = SS or Shaffer?)
  10. Industry standard for allowable C/K box pitting
  11. RP 16Q, riser operating manuals

Handling, TJ's, Spiders and Support Rings

  1. Introduce riser and telescopic joint handling systems
  2. Telescopic joint support rings and improved efficiency
  3. TJ locking systems for semi's and drill ships
  4. Dynamic load factors on riser handling tools
  5. Wellhead torque induced from tensioner support ring

Tension, Collapse, Buoyancy and Keyseating

  1. Brief review of riser tensioning
  2. Hydralift 250K inline tensioners
  3. Field repair of Hydralift tensioner rods
  4. Effective riser tension vs. theoretical riser tension
  5. Instrumentation joints and riser control boxes (RCB's)
  6. Buoyancy modules and IADC safety alerts
  7. Riser collapse considerations and variable
  8. Fill up valve designs and installation locations
  9. Collapse resistance of c/k hoses at depth, reference API Spec. 16C, section 9.14.10
  10. Buoyancy placement, fairings and high current considerations - VIV
  11. DEA Study #137 - Deepwater Keyseating Frequencies

SECTION V - ANNULARS

Annular Preventers and Flex Joints

  1. Hydrostatic head, annulars and shuttle valves: what do they have in common?
  2. Design Verification Testing, or the lack of it, hits us again
  3. Pro's and Con's of closing an annular during an EDS
  4. The effects of hydrostatic head on closing pressure required

SECTION VI - RAMS

Packer Pressure, Shearing and Design Verification

  1. Ram reliability - define decrease in reliability
  2. Effects of mud weight and wellbore pressure on closing ratio's
  3. Sealing characteristics tests, API Spec 16A
  4. Factors effecting probability of shear - review shearing data
  5. Mississippi Canyon, "Why we need ram locking systems"
  6. Design verification testing, API 16A
  7. Hang-off and stripping capabilities
  8. When hydrostatic head is greater than wellbore pressure
  9. Hydrostatic head hits us again, casing shear rams
  10. How has tool joint design changed hang-off?

Cameron - "ST" Locks

  1. Brief review of Cameron locking systems
  2. "ST" locks and sequencing valves
  3. Bearing issues and upgrades introduced
  4. Predictive testing ST locks
  5. "Backlash" of locking systems

Cameron - "RamLocks"

  1. Control circuits
  2. Case histories
  3. Backlash issues
  4. Do we still have manufacturing quality issues with Swarf?

Shaffer - UltraLock™

  1. How we got to the II B design, will there be a II C?
  2. Advantages of the 5½ degree taper, review modifications and case histories
  3. Understand the sequence of operation with an UltraLock animation
  4. Understand why operating pressures have been limited on the IIA design

Predictive Testing - Hydril MPL LOCKS and Cameron ST Locks and UltraLocks

  1. Case history - predictive testing is better than money in the bank
  2. Hydril MPL case study - testing predicted failure within 10 cycles
  3. Slip-ease bearing and the Hydril MPL locking system
  4. Cameron ST predictive testing success
  5. How acoustic testing is useful on all equipment
  6. Understand how backlash effects ram packer pressure
  7. Slip force review and how it applies to RamLocks and UltraLocks
  8. Sealing characteristics tests - prudent equipment operators should have this information
  9. Learn how API suggests we qualify ram locking systems, 12 cycles are required

SECTION VII - SHEAR WORKSHOP

Case I - Cameron TL 18 ¾" 15K

Case II - Hydril BOP 18 ¾" 15K

Case III - Shaffer SLX 18 ¾" 15K

SECTION VIII - CONNECTORS and END CONNECTIONS

  1. Review Cameron's connectors and the preferred "Everslick" actuator ring coating
  2. Learn the relationship between locking pressure, lubrication (coefficient of friction) and preload
  3. Review "Backdriving"
  4. Why Cameron EB 842 rev. B1 recommends a secondary lock on connectors
  5. Understand the relationship between lubricating your connector, POCVs and continuous latching pressure
  6. Discuss the advantages of having a third regulator for connectors, reference Cameron EB 687C
  7. Vetco Connectors, OSP #335 and how the coefficient of friction changes over time
  8. Compare and understand bending moment capacities of various connectors/ end connections
  9. Understand options available for hydrate exclusion
  10. Review a failure related to hydrostatic head, reference Cameron EB 848M
  11. Cameron C & K Connectors and damaged gaskets

SECTION IX- FAIL SAFE VALVES

  1. Learn the "Functional limitations of subsea valves" consider the Ocean Odyssey
  2. Learn "What is a failsafe valve", balanced vs. unbalanced valves
  3. Failsafe assist circuit - Understand deepwater hazards when pulling the stack and how to reduce them
  4. Understand the differences between a API Spec 6A and 17D valve operator
  5. Understand the MMS concerns for valves under the LPR. How to reduce this risk
  6. "Frame Flex Test" - Reduce bending moments to C/K outlets
  7. WOM "Magnum" valve pressure testing techniques
  8. Reliability of spring cartridges in gate valves

SECTION X - MUX CONTROLS - SPARKY

Electrical

  1. Progression of BOP controls from mechanical to MUX
    a. purely mechanical valve
    b. hydraulic / air remote operation
    c. electrical solenoid remote operation
    d. solenoids moved to bop stack 1975
    e. as functions increase, signals to solenoids are multiplexed in 1975 to reduce cable cost
    f. the future may bring AI, fuzzy logic, disappearance of MUX cable
  2. Definition of multiplex
  3. How a multiplex system works
  4. Why multiplex must be used for current subsea control technology
  5. Advantages of multiplex control systems
  6. Simple multiplex systems
  7. Subsea multiplex systems
  8. Architectures, system construction, and common problems of MUX manufacturers
    a. Cameron
    b. Shaffer
    c. Hydril
    d. ABB
    e. importance of integration with other shipboard systems - DP and drilling
    f. cables and connectors
      i. compliance with API Spec 16D
      ii. wet mate and dry mate connectors
      iii. service life of cables and splicing issues
      iv. connector choice, repair and replacement
      v. slip rings, cable reels, and strain relief
      vi. conductor size, cable construction, and voltage drop issues
      vii. cable and connector failure modes
      viii. Petrobras electrical connectors
    g. stack mounted sensors
    i. angle, pressure and temperature
      ii. current, flow, tension and position

SECTION XI - OPERATIONS / PROCEDURES

Dynamic Positioning

  1. Why and when dynamic positioning (DP) is used
  2. Advantages and disadvantages
  3. Basic overview of DP operations
  4. DP2 vs. DP3 and how this choice affects drilling and cost
  5. Importance of power management and blackouts
  6. Acoustic beacon arrays and acoustic interference
  7. DP watch circles and disconnect criteria
  8. Thruster induced rig motions and effect on drilling operations
  9. Riser / moonpool contact
  10. DP drilling operations planning - too complex to cover at this time, separate seminar required

SECTION XII - RISER RECOIL AND HARD vs SOFT HANGOFF

  1. Define the purpose of a riser recoil system
  2. Shaffer's - overview
  3. Hydralift - overview and advantages
  4. Is hard or soft the best answer? What are the issues?
  5. Telescopic joint contact with the moonpool, when does this occur
  6. Hang-off joints and Bardex riser centralizing systems
  7. Dynamic load factors for riser, shock absorbing spiders

SECTION XIII - SECONDARY INTERVENTION

Automatic Intervention

  1. What systems are available?
  2. Dead man, automatic mode function (AMF) Cameron system

Manual Intervention

  1. Acoustic Control
    a. What geographic areas use acoustic controls
    b. Explore reliability
    c. Nautronix, Sonardyne, Simrad
  2. EHBU (electro hydraulic back-up system) Shaffer system
  3. ROV
    a. ROV flow rate capabilities and intervention points
    b. Gap analysis - what additional ROV functions should you have on your stack?
      Are ROV's intervention points fit for purpose? Function testing

SECONDARY INTERVENTION WORKSHOP

SECTION XIV - CRISES MANAGEMENT

Dropped Stacks and Emergency Recovery

This module is a blast, we get plenty of interaction. Everyone has a story and appreciates learning from the experiences of others.

  1. WEST's "Dropped Stack Study", an overview
  2. MMS Safety Alert #186, Accidental LMRP Disconnect
  3. Are rams capable of closing and sealing on flowing wellbore fluids?
  4. The "Six P's" = prior planning prevents poor performance
  5. Slings, funnels and drill pipe recovery

DROPPED STACK WORKSHOP

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