Repair & Certification of Blow Out Preventers in Argentina: Latin American Drilling Safety

REPAIR & CERTIFICATION OF
BLOW OUT PREVENTERS IN

ARGENTINA
LATIN AMERICAN DRILLING SAFETY
WILFREDO NUÑEZ
JORGE GOLDSACK
PREAMBLE
The essence of Well Integrity is the ability to guarantee the safe

containment of pressured subsurface formation fluids during a Well
Control.
BLOW OUT PREVENTERS are critical to the safety of the Crew, the
Environment and the Rig, thus Blowout Preventers are intended to be
Fail-Safe Devices.
A good repair and maintenance of certified B.O.P.´s is the building block

upon which Safety and Well Integrity are founded.
TIMELINE
INITIAL SITUATION
•Argentinean Custom laws made very difficult to import used or rebuilt parts or
tools for the oil industry (Including BOP’s). Therefore, the BOPs that need to be
exported to be repaired or certified cannot come back to the country; it’s allowed
importing NEW preventers, but it was complicated for used or rebuilt parts.
•Industrias Petroleras del Sur (IPS) in Neuquen with Cameron license, was the
single certified BOP repair workshop in Argentina and they were concentrated in
the Drilling BOP segment. IPS had the infrastructure to repair/certify about 8 BOP
´s a month. Most of them were Drilling BOP (11” & 13 5/8”).
•Wenlen had the infrastructure to repair it´s own BOP´s as Manufacturer, but in
the end of 90´s, the compañy dismantled the whole manufacture and repair line.
•Shaffer (BOP Manufacturer Company) tried to certify a repair shop, but did not
achieve any Tech-Economics deal with any workshop in Argentina.
2006
TIMELINE
INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.
2006
TIMELINE
THE PROBLEM:
•The large number of preventers needed to be serviced, urged the
contractors to hire improvised workshops and use not original or
homemade spares to repair the equipment.
•There were several incidents in Workover and Pulling Rigs related to

BOP´s failures .
•The situation generated a lack of confidence among operators.
2006 Late 2006

TIMELINE
THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.
2006 Late 2006

TIMELINE
THE REQUIREMENTS:.
•Pride International made a presentation at the 2007

Drilling Congress clearing up the situation with the BOP
(Drilling, Workover & Pulling) and the urgency of
“developing” certified workshops to address the problem.
•There were about 200 BOPs queuing to be repaired

•Only in WO & Pulling, the market demanded a minimum
of 5 BOP repairs a month. IPS capacity was 2 to 2.5.
2006 Late 2006 2007

TIMELINE
THE REQUIREMENTS:. A New certified workshop is requiered.
2006 Late 2006 2007

TIMELINE
Rig
Activity
Dropped
Early
2006 Late 2006 2007 2008
TIMELINE
The situation worsened: In 2008

the oil industry activity
Rig dropped and reduced the
IPS workload which
Activity
conducted a reduction in the
Dropped IPS staff and repair capacity.
IPS reduced it capacity
from 8 to 6 BOP´s per
month, between annulars
and rams.
Early
2006 Late 2006 2007 2008
TIMELINE
INITIAL SITUATION: Importation compicated, One Overloaded Workshop, Homemade supplies.
Rig
Activity
Dropped
Early
2006 Late 2006 2007 2008
TIMELINE
THE PLAN:.
•The problem was addressed by LADS

(Argentine Chapter) which appointed a technical
Rig
committee
Activity
•The objectives were identified and a list of
Dropped
tasks was made
Early
2006 Late 2006 2007 2008
2008
TIMELINE
OBJECTIVES:.
Critical Equipment
INITIAL SITUATION:
1. Importation forbidden, One Overloaded Workshop, Homemade supplies.
BOP Valves
2.
THE PROBLEM:Conection
Incidentsbetween BOPBOP´s
regarding - Chokefailures,
Manifolddisappointed operators.
3. Choke Manifold
4.THEAccumulators
REQUIREMENTS:. A New certified workshop is requiered.
and BOP actuators.
Planned Tasks: THE PLAN:.
1. Developed a BOP´s country inventory.
•The problem was addressed by LADS
2. Develop of inspection and repair procedures.
(Capitulo Argentina) which appointed a
3. Perform Handling, maintenance and field pressure test
procedures.
technical committee
4. •The objectives
Define documentation to provide traceability. .were identified and a list of
5. tasks
Establish a list of suppliers wasthe
that meet made
requirements.
6. Help to develop new repair workshops.
Early
2006 Late 2006 2007 2008
2008
TIMELINE
THE PLAN:. Technical committee appointed, list of objectives.
Rig
Activity
Dropped
Early
2006 Late 2006 2007 2008
2008
TIMELINE
THE PLAN:. Technical committee designed, list of objectives.
THE ACTIONS:.
Rig •Perform a BOP´s inventory.
Activity •Select Potencial workshops
Dropped •Help to develop the candidates
to establish procedures, policies
and standards.
Early
2006 Late 2006 2007 2008
2008 2009
TIMELINE
There were near 500 B.O.P. units in Argentina

THE INITIAL SITUATION: Importation forbidden, one workshop overcharged, homemade supplies.
Sort
THE byPROBLEM:
Rig Type Sortregarding
Incidents by BrandBOP´s malfunction,
Sort by Size Sort byoperators.
unconformity among Pressure
THE REQUIREMENTS:.
Annular Type “A” Pride Presents the problem, new workshop
Ram Type “R” is requiered.
THE ACTIONS:.
•Perform a BOP´s inventory.
•Select Potencial suppliers
candidates.
•Help to develop this candidates
according policies and
standards.
135 units (32%) 282 units (68%)

TIMELINE

Sort
THEbyPROBLEM:
Rig Type Incidents
Sortregarding
by BrandBOP´s malfunction,
THE
Annular REQUIREMENTS:.
Type “A” Pride Presents the problem,
Ram Type new
“R”workshop is requiered.

Drilling; 64;
No Datos;
Sin Data 23%
Sin
No Datos;
Data Drilling; 50; 63; 22%
THE ACTIONS:.
47; 35% 37%
Pulling; 31;
11% candidates.
Workover; 38; standards. Workover;
28% 124; 44%
2006 Late 2006 2007 2008 2009

TIMELINE

Sort
THE byPROBLEM:
THE
Ram Type new
Sin
No Datos;
Data 1;
1% Cameron; 6;
Otras; 11; 8% Otras; 31;
4%
THE ACTIONS:.
11% Cameron; 40;
Wenlen; 0; 0% 14%
Wenlen; 36;
Shaffer; 28;
13% •Select Potencial suppliers
Hydrill; 33;
21% candidates. 12%
standards.
Hydrill; 89; Shaffer; 142;

66% 50%
TIMELINE

Sort
THE byPROBLEM:
THE
Ram Type new

NoDatos;
Sin Data
10; 7% 13-5/8"; 41;
THE ACTIONS:.
15%
7-1/16"; 46; 2"; 1; 0%
13-5/8"; 30;
34% •Perform a BOP´s inventory.
22%
candidates.
11"; 52; 18% according policies and
9"; 5; 4% 7-1/16"; 184;
9"; 4; standards.
1%
66%
11"; 44; 33%
2006 Late 2006 2007 2008 2009

TIMELINE

Sort
THE byPROBLEM:
THE
Ram Type new

Sin
NoDatos;
Data 2;
Sin
No Datos;
Data 9; 10.000 psi; 8; 1%
7% 3000 psi; 28; THE ACTIONS:. 3%
21%
3000 psi; 85;
30%
candidates.
5000 psi; 98;
standards.
5000 psi; 187;
66%
72%
2006 Late 2006 2007 2008 2009

TIMELINE
THE ACTIONS:.
Dropped •Help to develop the candidates
to Establish procedures, policies
and standards.
Early
2006 Late 2006 2007 2008
2008 2009
TIMELINE
THE SUPPLIER CANDIDATES

THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.
•Several workshop
THE were selected. During
REQUIREMENTS:. a fewthe
Pride Presents meetings, the workshop
problem, new technical is requiered.
support was offered but also, the responsibility in case of some incident
involving repaired equipment was explained too.
THE ACTIONS:.
•After this stage only two suppliers continue with•Perform a BOP´s inventory.
the process. ACYS, located
in Mendoza city, and Wenlen that has the capacity to repair its own BOP´s
candidates.
also.. •Help to develop this candidates
standards.
TIMELINE
THE ACTIONS:.
Dropped •Help to develop the
candidates to Establish
procedures, policies and
standards.
Early
2006 Late 2006 2007 2008
2008 2009
TIMELINE
THE PROCEDURES
THE PROBLEM: Incidents regarding BOP´s malfunction, unconformity among operators.

•Help the supplier with the repair procedures: disassembly, cleaning, sandblasting,
THE REQUIREMENTS:. Pride Presents the problem, new workshop is requiered.
dimensional and hardness analysis, assembly & testing, etc.
•The procedure was tested several times byTHEcommittee members of and amended by
ACTIONS:.
the company, until the definitive procedure was reached.
candidates.
•ACYS applied to Shaffer approval but they can´t achieved any Tech-Economics deal;
•Help to
hence, decided to apply to the ISO 9001-2000 certification, develop to
according this
thecandidates
requirements of API 16° Annex 8 and recommendations according
API RPpolicies andmanaged to
53”, which
attain in June 2009. standards.
TIMELINE
THE ACTIONS:.BOP´s, candidates development.

Rig
Activity
Dropped
Early
2006 Late 2006 2007 2008
2008 2009
TIMELINE
THE ACTIONS:.BOP´s, candidates development.

Rig
Activity THE FINAL RESULT
Dropped
Early
2006 Late 2006 2007 2008
2008 2009 2012
THE FINAL RESULT
THE REBUILDING PROCESS
•EVALUATION STAGE
After arriving the BOP to the workshop a tag number is assigned and an evaluation check
list is performed, involving the related tasks and responsibilities
Tasks:
Identification of every single piece and valve. Dimensional evaluation; Visual and not-
destructive tests, hardness test, Nital.
After the BOP is evaluated, the customer receives a budget and a detailed report
including,photographic records of the parts to be replaced or repaired.
THE FINAL RESULT
•EVALUATION STAGE
THE FINAL RESULT
•REPAIR STAGE
Once the client accepts the budget, the repair stage begins.
This stage could include Welding filler, heat treatment, forged, etc.
The policy of the shop is always to asks the client for new spare parts to repair the BOP
THE FINAL RESULT
•REPAIR STAGE
THE FINAL RESULT
•TEST STAGE
After the repair is done, the equipment is ensembles and tested
The tests are conducted with calibrated manometers and tools, hydraulic unit and a
multiplier booster (able to bring the pressure up to 9000 psi.)
THE FINAL RESULT
•TEST STAGE
THE FINAL RESULT
•DELIVERY STAGE
CONCLUSION
THE REPAIR ACTIVITY OF ACYS
•In 2009 8 BOP´s were repaired and certificated.

•In 2010 23 BOP´s.
•In 2011 27 BOP´s.
•In 2012 42 BOP´s so far.
•The total BOP´s at ACYS as today: 98.
CLIENTS: Nabors, Key Energy, Archer DLS, Ensign, ENAP (Chile) EMEPA,
Skanska, Petroneu and SAI (Bolivia)
CONCLUSION
THE REPAIR ACTIVITY OF IPS
Amount of BOP´s per year:

•Certifications RP-53/97”…………………………..60 / 70 units
•Preventive maintenance in 5 year period……….20 /25 units
•Rebuilded Brands:
Shaffer Hydril Cameron
Rams 40% 10% 50%
Annulars 20% 70% 10%
•The average rebuilding time is 90 days, since 2006 there were

near 450 BOP´s repaired.
CONCLUSION
THE REPAIR ACTIVITY OF WENLEN
Rebuild Yr Client BOP

Quan
tity Observations
2006 PERBRAS 7.1/16" 5000" Double Ram 2 Certified 16 A
2007 OXY 11" 3000# Double Ram 2 Certified 16 A
2008 EMEPA 7.1/16" 5000" Double Ram 2 Certified 16 A
2009 CAPEX 7.1/16" 5000# Single Ram 1 Certified 16 A
2009 UTENEU 7.1/16" 3000# Double Ram 2 Certified 16 A
2010 SAN ANTONIO 7.1/16" 5000" Double Ram 1 Certified 16 A
2010 ROCH 11" 3000# Double Ram 1 Certified 16 A
2010 CAPEX 7.1/16" 5000# Single Ram 1 Certified 16 A
2011 SERVIPETROL 13.5/8" 5000# Double Ram 1 Certified 16 A
2011 APCO-UTE 11" 3000# Double Ram 1 Certified 16 A
14
•In the last year no repairs were made.

CONCLUSION
FACTS
MOST OF THE BOPS THAT ARRIVES TO THE SHOP ARE IN VERY POOR CONDITION.
DAMAGES INCLUDE SHOCKS, CORROSION, EROSION,
SCRATCHED SLEEVES & DAMAGES STUDS
MOST OF THE DAMAGES ARE MADE BY MISHANDLING, POOR STORAGE

CONDITIONS, LACK OF PREVENTIVE MAINTENANCE AND POOR TRAINED PERSONNEL
THE VARIABLE THAT DETERMINES THE REPAIR TIME IS THE

GENERAL CONDITION OF THE BOP AT ARRIVING.
IMPROVING PREVENTIVE MAINTENANCE AND REINFORCING OPERATION PROCEDURES

WILL HELP TO REDUCE THE REBUILDING AND CERTIFYING TIME.
ACKNOWLEDGMENT
ACYS
WENLEN
IPS
LADS ARGENTINA

Repair & Certification of Blow Out Preventers in Argentina: Latin American Drilling Safety

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REPAIR & CERTIFICATION OF

BLOW OUT PREVENTERS IN

The essence of Well Integrity is the ability to guarantee the safe

A good repair and maintenance of certified B.O.P.´s is the building block

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

•There were several incidents in Workover and Pulling Rigs related to

•The situation generated a lack of confidence among operators.

2006 Late 2006

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

2006 Late 2006

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

•Pride International made a presentation at the 2007

•There were about 200 BOPs queuing to be repaired

2006 Late 2006 2007

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

2006 Late 2006 2007

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

The situation worsened: In 2008

INITIAL SITUATION: Importation compicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

•The problem was addressed by LADS

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

THE PLAN:. Technical committee appointed, list of objectives.

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

THE PLAN:. Technical committee designed, list of objectives.

There were near 500 B.O.P. units in Argentina

THE PLAN:. Technical committee designed, list of objectives.

135 units (32%) 282 units (68%)

There were near 500 B.O.P. units in Argentina

THE PLAN:. Technical committee designed, list of objectives.

2006 Late 2006 2007 2008 2009

There were near 500 B.O.P. units in Argentina

Hydrill; 89; Shaffer; 142;

There were near 500 B.O.P. units in Argentina

THE PLAN:. Technical committee designed, list of objectives.

2006 Late 2006 2007 2008 2009

There were near 500 B.O.P. units in Argentina

THE PLAN:. Technical committee designed, list of objectives.

2006 Late 2006 2007 2008 2009

INITIAL SITUATION: Importation complicated, One Overloaded Workshop, Homemade supplies.

THE PROBLEM: Incidents regarding BOP´s failures, disappointed operators.

THE REQUIREMENTS:. A New certified workshop is requiered.

THE PLAN:. Technical committee designed, list of objectives.

THE SUPPLIER CANDIDATES