DrillSafe Forum, Perth Western Australia - 5th March 2009

The Relationship between RigThe Relationship between Rig Safety and Maintenance & y

Integrity Management

Speaker : Alastair Krebs

Relationship ?DrillSafe Forum, Perth Western Australia - 5th March 2009

Well Well…… What is the relationship What is the relationship

between Safety and Maintenance and Integrity

Management?Management?

ll d dDo we really understand this?

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this?

Myths of Maintenance & Integrity Management?DrillSafe Forum, Perth Western Australia - 5th March 2009

• Why should we involve maintenance in the design of o assets?in the design of our assets?

• If it ain’t broke don’t fix it!

• Maintenance is a cost burden!

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Myths of Maintenance & Integrity Management?DrillSafe Forum, Perth Western Australia - 5th March 2009

• We manage maintenance because clients legislation and standards clients, legislation and standards dictate us to do so!

O t et i to t ithi the • Our target is to stay within the budget!

O M i t i OEM b d! • Our Maintenance is OEM based! What else do we need?

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How Bad Is It ?DrillSafe Forum, Perth Western Australia - 5th March 2009

A study was carried out by ModuSpec of rig equipment failures over a data set of rig equipment failures over a data set of 80 onshore/ offshore rigs over the period 2004 -2008 2004 -2008

This study indicated that approx 70% of equipment failures could have been prevented by suitable maintenance and inspection activities.

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Is Maintenance Safety Related?DrillSafe Forum, Perth Western Australia - 5th March 2009

Drilling into shallow gas pockets

Geological surveys and seismic data

Bubble Watch Flow meters and alarm Pump Heavy Mud Diverter System BOP

Bow Tie 01 (H-01.02): Hydrocarbons

Inaccurate data

Reputable vendors Area Data comparison

Not seen / reported) y

in formationCompetent personnel

Malfunction of flow meters

Testing Maintenance (PMS)

False reading (e g

AL-KHOR: Loss of well control

False reading (e.g., mud or cuttings

buildup)Visual inspection Competent Driller

Audible flow alarm bypassed

Supervision Pre tour checklist

Mud doesn't work

Mud Engineer

Run out of Mud

Pre-planningPre-planning

Fails

Testing Maintenance (PMS)

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Fails

Testing Maintenance (PMS)

Is Maintenance Safety Related?DrillSafe Forum, Perth Western Australia - 5th March 2009

Poorly maintained equipment will not equipment will not function when it is requiredrequired.

This BOP was painted to look as if it had been poverhauled, but required over 2,000 psi to open the bonnets. A BOP in good condition would need

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gonly 200 psi.

Is Maintenance Safety Related?DrillSafe Forum, Perth Western Australia - 5th March 2009

From a heavily corroded plug on a ¾-inch fitting plug on a ¾-inch fitting during a 5,000-psi pressure test the pressure test, the thread of the plug failed and blew out The and blew out. The technician hit by the plug was hospitalized plug was hospitalized.

Imagine the effect of a much larger object such as a pipe or 2 inch blind plug blowing out at that as a pipe or 2-inch blind plug blowing out at that pressure. Beware of poorly maintained

i t!8

equipment!

Is Maintenance Safety Related?DrillSafe Forum, Perth Western Australia - 5th March 2009

Braking failed on a Kenworthtruck whilst going down hill. The truck was pulling a Power Trailer truck was pulling a Power Trailer during a rig move operation.

h d d dThe driver tried to gear down to slow the truck but the gearbox overheated and caught fire.

Naturally the driver jumped clea of the t ck b t as clear of the truck but was caught under the wheels of the trailer.

Correct truck maintenance would have ensured the brakes

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were fully operational.

What can be done?DrillSafe Forum, Perth Western Australia - 5th March 2009

• Maintenance involvement with design: S f t C iti l E i t P f Safety Critical Equipment Performance standards FMEA (Failure Mode & Effect Analysis) to build FMEA (Failure Mode & Effect Analysis) to build maintenance strategy around equipment functional failure.

• Structured and effective Maintenance & Integrity Management System and support

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What can be done?DrillSafe Forum, Perth Western Australia - 5th March 2009

Adaptive Maintenance Programme• Adaptive Maintenance ProgrammeMaintenance Programme that adapts to the operating context of the rig and its location operating context of the rig and its location. I.E. A maintenance programme specific to the contracted drilling programme complementing OEM

d irecommendations.

• Continuous Improvement • Continuous Improvement Programme

• Trained and competent personnel

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p p

Current Initiatives - OngoingDrillSafe Forum, Perth Western Australia - 5th March 2009

Two - Australian Based Oil & Gas Operators:

C tl i i M i t • Currently reviewing Maintenance and Integrity Management of their Drilling Contractors. At the Rig Site and from a corporate support Site and from a corporate support

• The aim is to work with the Drilling Contractors for safer more reliable equipment

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equipment

Current Initiatives - OngoingDrillSafe Forum, Perth Western Australia - 5th March 2009

Two major International Drilling Contractors:Contractors:

• Have carried out a review of their current Have carried out a review of their current maintenance and integrity management systems across their worldwide systems across their worldwide organisations.

Thi i l d th ff ti f th i • This includes the effectiveness of their maintenance activities and one case a

t t f th i competence assessment of their crews.

• Both are currently undergoing a full

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Both are currently undergoing a full improvement programme.

In ConclusionDrillSafe Forum, Perth Western Australia - 5th March 2009

There is an undisputable link between the quality of maintenance management & quality of maintenance management & Safety and Integrity

Reliable Equipment is safe equipment.

To ensure reliability of equipment, maintenance & integrity management must address more than just the OEM recommendations for equipment.

Maintenance and Integrity Management is not just the drilling contractors responsibility. It is a joint responsibility between the Operator Drilling Contractor

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responsibility between the Operator , Drilling Contractor and all other parties involved in the drilling of a well.

THANK YOUDrillSafe Forum, Perth Western Australia - 5th March 2009

A Well Maintained Rig isMaintained Rig is

S f Ria Safe Rigg

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