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Reliability of Deepwater Subsea BOP Systgems and Well Kicks

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Reliability of Deepwater Subsea BOP Systgems and Well Kicks ES 201252 - Unrestricted REPORT Reliability of Deepwater Subsea BOP Systems and Well Kicks Unrestricted Version Per Holand and Hammad Awan August 2012 www.exprosoft.com Reliability of Deepwater Subsea BOP Systems and Well Kicks, Final report, Unrestricted Version REPORT Title ExproSoft AS Enterprise no.: NO 881 559 692 Reliability of Deepwater Subsea BOP Systems and Well Main office - Trondheim Kicks Location: Prof. Brochs gt 2 Postal Address: P.O. Box 6095 Sluppen, N-7434 Trondheim, Norway Unrestricted Version Tel.: (+47) 73 200 400 Fax: (+47) 73 200 401 Author(s) Branch office – Stavanger/Sandnes: Per Holand Location: Vågsgata 33, Sandnes Hammad Awan Postal address: P.O.Box 700, N-4305 Sandnes , Norway Tel.: (+47) 51 67 63 70 FAX: (+47) 51 67 63 71 ExproSoft, Inc. 363 N. Sam Houston Parkway E., Suite 1100, Houston, Texas 77060 Tel.: +1.281.820.7808 FAX: +1.281.820.9310 Classification CLIENT(S) Unrestricted BSEE, Michael Else Report no. Eni, Morten Perander ES 201252/02 Reg. no. Date Project Manager sign. 2012-08-21 Per Holand No. of pages No. of appendices Quality Assurance sign. 148 1 Marvin Rausand Summary Deepwater BOP reliability and well kick data have systematically been collected for wells spudded in the period 2007 – 2009 in the US GoM OCS. The main source of information for the study has been the well activity reports (WARs) in the BSEE e-Well system. A total of 259 wells (when regarding sidetracks and by-pass as separate wells) have been included in the study. All the wells are drilled in waters deeper than 2000 ft (610 meters). Only the periods of the well when the BOPs are located on the wellhead have been included in the study, so shallow gas incidents or shallow water flows have not been considered. Keywords English Keywords Norwegian Reliability Pålitelighet Offshore Offshore Blowout Preventer Utblåsningssikring Kick Brønnspark Reliability of Deepwater Subsea BOP Systems and Well Kicks, Final report, Unrestricted Version Reliability of Deepwater Subsea BOP Systems and Well Kicks, Final report, Unrestricted Version Preface ............................................................................................................................................ 9 Summary and Conclusions ......................................................................................................... 10 List of Abbreviations ................................................................................................................... 17 1 Introduction ........................................................................................................................ 19 1.1 Background ................................................................................................................ 19 1.2 Objective .................................................................................................................... 20 2 Data Collection Methodology ........................................................................................... 21 2.1 Data Sources ............................................................................................................... 21 2.1.1 Application for Permit to Drill/modify ........................................................ 21 2.1.2 Well Activity Report (WAR) ....................................................................... 21 2.1.3 Daily Drilling Report ................................................................................... 22 2.2 Statistical Estimation Procedure and Assumptions .................................................... 22 3 Subsea BOPs ....................................................................................................................... 24 3.1 System Description and Boundary Conditions .......................................................... 24 3.2 Relevant Definitions ................................................................................................... 27 3.3 Operators and Wells ................................................................................................... 27 3.4 Rigs and Water Depths Evaluated .............................................................................. 28 3.5 Overview of BOP Failures ......................................................................................... 29 3.6 Comparison with the Previous BOP Deepwater (Phase I & II DW) studies ......................................................................................................................... 32 3.7 Year to Year Trends in Failure Rates and Downtime ................................................ 34 3.8 Effect of Water depth on Reliability of BOP ............................................................. 36 3.9 Rig Specific Performance ........................................................................................... 37 4 BOP System Specific Reliability ....................................................................................... 40 4.1 Flexible Joint .............................................................................................................. 40 4.2 Description of Flexible Joint Failure .......................................................................... 40 4.3 Annular Preventer Reliability ..................................................................................... 41 4.3.1 Failed to Close Failures ................................................................................ 42 4.3.2 Fail to Fully Open Failures .......................................................................... 42 4.3.3 Internal Hydraulic Leakage (control fluid part) ........................................... 43 4.3.4 Internal Leakage (leakage through a closed annular) .................................. 44 4.3.5 Other and Unknown Failures ....................................................................... 45 4.3.6 Manufacturers Included in the Study ........................................................... 46 4.4 Hydraulic Connector Reliability ................................................................................ 46 4.4.1 External Leakage Failures ............................................................................ 47 4.4.2 Failed to Lock Failures ................................................................................. 47 4.4.3 Failed to Unlock ........................................................................................... 48 4.4.4 Spurious Unlock ........................................................................................... 48 4.4.5 Unknown Failure Modes of Connector ........................................................ 49 4.4.6 Manufacturers Included in the Study ........................................................... 49 4.5 Ram Preventer Reliability .......................................................................................... 50 4.5.1 External Leakage .......................................................................................... 51 4.5.2 Failed to Close .............................................................................................. 52 4.5.3 Failed to Fully Open ..................................................................................... 52 4.5.4 Failed to Open .............................................................................................. 52 Page 5 of 148 Reliability of Deepwater Subsea BOP Systems and Well Kicks, Final report, Unrestricted Version 4.5.5 Internal Leakage (leakage through a closed ram) ........................................ 53 4.5.6 Other ............................................................................................................. 54 4.5.7 Unknown ...................................................................................................... 54 4.5.8 Manufacturers Included in the Study ........................................................... 54 4.6 Choke and Kill Valve Reliability ............................................................................... 55 4.7 Choke and Kill Line Reliability ................................................................................. 56 4.8 Main Control System Reliability ................................................................................ 58 4.8.1 Loss of all Functions Both Pods ................................................................... 61 4.8.2 Loss of all Functions One Pod ..................................................................... 61 4.8.3 Loss of One Function Both Pods ................................................................. 64 4.8.4 Loss of One Function One Pod .................................................................... 64 4.8.5 Loss of Several Functions One Pod ............................................................. 66 4.8.6 Other Failures ............................................................................................... 67 4.8.7 Failure Mode “Unknown” ............................................................................ 70 4.8.8 Manufacturer Exposure and Rig Specific Failure Rates .............................. 71 4.8.9 Age of Multiplex Control System vs. Reliability ......................................... 73 5 Failure Criticality in Terms of Well Control .................................................................. 75 5.1 When are BOP Failures Observed? ............................................................................ 75 5.2 Safety Critical Failures ..............................................................................................
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