DRIL 23001 Unit A - Maintenance PDF

DRILLING RIG OPERATIONS DRIL 23001 Unit A- Maintenance Course Requirements All students must ensure to read the chapters and course notes before the start of the preceding class session. All assignments and course projects must be completed according to course schedule and time...

DRILLING RIG OPERATIONS DRIL 23001 Unit A- Maintenance Course Requirements All students must ensure to read the chapters and course notes before the start of the preceding class session. All assignments and course projects must be completed according to course schedule and timelines. Students are encouraged to review additional reading material and make notes on same. Ensure to pay attention to the review sections on each slide which will tie in the presentations to the resources made available. 2  Course Objectives – Tools, Rigging and Inventory Unit A- Maintenance Training Total Area of Unit Hours Tested Objectives Resources Objectives Focus [T|P] Describe the fundamentals of maintenance for Maintenance Fundamentals PG. 11- drilling technicians By R. Keith Mobley 24 IADC KSAS knowledge, skills PG 8-70 Describe the roles and responsibilities of the drilling and ability for rig crews and rig crew in maintenance rig supervisory personnel SPE/IADC-189407-MS. pg 1-11 Sustainable Maintenance in Maintenance 5 45[21|24] Describe the types and elements of maintenance Drilling Operations. New programs Risks, changing standards and Codes The Auxiliaries: Rotary pgs. Describe the maintenance of auxiliary systems on Drilling- 3rd Edition Unit 1 6,23,40- the rig Lesson 9 46,53 Perform maintenance according to maintenance Practical Activity schedule Objective: Describe the fundamentals of maintenance for drilling technicians Describe the fundamental requirements of effective preventative maintenance; Describe what are thresholds in PM; Define lubrication; Describe the importance of lubrication; Describe the development of lubrication program; Define calibration; Describe estimation of time, labour cost, materials and scheduling; Describe PM records keeping. Fundamental of Effective Maintenance Effective maintenance is not magic, nor is it dependent on exotic technologies or expensive instruments or systems. Instead, it is dependent on doing simple, basic tasks that will result in reliable plant systems. These basics include the following: Inspections - Careful inspection, which can be done without ‘‘tearing down’’ the machine, saves both technician time and exposure of the equipment to possible damage Human Senses - are able to detect large differences but are generally not sensitive to small changes. Time tends to have a dulling effect Sensors - humans are not continually alert or sensitive to small changes and cannot get inside small spaces, especially when machines are operating, it is necessary to use sensors that will measure conditions and transmit information to external indicators.  Thresholds- instrumentation is becoming available to measure equipment performance, it is still necessary to determine when that performance is ‘‘go’’ and when it is ‘‘no go.’’ Most manufacturers will run equipment until failure in their laboratories as part of their tests to evaluate quality, reliability, maintainability, and maintenance procedures. Such data are necessary to determine under actual operating conditions how much stress can be put on a device before it will break. Lubrication The friction of two materials moving relative to each other causes heat and wear. Technology intended to improve wear resistance of metal, plastics, and other surfaces in motion has greatly improved over recent years, but planning, scheduling, and control of the lubricating program. Anything that is introduced onto or between moving surfaces to reduce friction is called a lubricant. Oils and greases are the most commonly uses substances, although many other materials may be suitable. Other liquids and even gases are being used as lubricants. Air bearings, for example, are used in gyroscopes and other sensitive devices in which friction must be minimal The Functions Of A Lubricant Are To: 1. Separate moving materials from each other to prevent wear, scoring, and seizure 2. Reduce heat 3. Keep out contaminants 4. Protect against corrosion 5. Wash away worn materials Lubrication Program Development Developing lubrication specifications can come from four main sources: 1. Equipment manufacturers 2. Lubricant vendors 3. Other equipment users 4. Individuals’ own experience. Primary Functions And Steps Involved In Developing The Program Are To: 1. Identify every piece of equipment that requires lubrication 2. Ensure that every major piece of equipment is uniquely identified, preferably with a prominently displayed number 3. Ensure that equipment records are complete for manufacturer and physical location 4. Determine locations on each piece of equipment that need to be lubricated 5. Identify lubricant to be used 6. Determine the best method of application 7. Establish the frequency or interval of lubrication 8. Determine if the equipment can be safely lubricated while operating or if it must be shut down 9. Decide who should be responsible for any human involvement 10. Standardize lubrication methods 11. Package the above elements into a lubrication program 12. Establish storage and handling procedures 13 Maintenance Fundamentals 14. Evaluate new lubricants to take advantage of state of the art 15. Analyze any failures involving lubrication and initiate necessary corrective actions Calibration special form of preventive maintenance whose objective is to keep measurement and control instruments within specified limits. A ‘‘standard’’ must be used to calibrate the equipment. Ohmmeters are examples of equipment that should be calibrated at least once a year and before further use if subjected to sudden shock or stress. The purpose of a calibration system is to provide for the prevention of tool inaccuracy through prompt detection of deficiencies and timely application of corrective action. This description should cover the measuring of test equipment and standards, including the following: 1. Establishment of realistic calibration intervals 2. List of all measurement standards 3. Established environmental conditions for calibration 4. Ensuring the use of calibration procedures for all equipment and standards 5. Coordinating the calibration system with all users 6. Ensuring that equipment is frequently checked by periodic system or cross- checks to detect damage, inoperative instruments, erratic readings, and other performance-degrading factors that cannot be anticipated or provided for by calibration intervals 7. Provide for timely and positive correction action 8. Establish decals, reject tags, and records for calibration labelling 9. Maintain formal records to ensure proper controls. A record system should be kept on every instrument, including the following: 1. History of use 2. Accuracy 3. Present location 4. Calibration interval and when due 5. Calibration procedures and necessary controls 6. Actual values of latest calibration 7. History of maintenance and repairs. Estimating Time Since inspection or preventive maintenance is a standardized procedure with little variation, the tasks and time required can be accurately estimated. Methods of developing time estimates include consideration of such resources as: 1. Equipment manufacturers’ recommendations 2. National standards such as Chilton’s on automotive or Means’ for facilities 3. Industrial engineering time-and-motion studies 4. Historical experience Estimating Labor Cost Cost estimates follow from time estimates simply by multiplying the hours required Estimating Materials Most parts and materials that are used for preventive maintenance are well known and can be identified in advance. The quantity of each item planned should be multiplied by the cost of the item in inventory. The sum of those extended costs will be the material cost estimate. Consumables such as transmission oil should be enumerated as direct costs, but grease and other supplies used from bulk should be included in overhead costs required labour rates Scheduling One of the advantages of doing preventive maintenance over waiting until equipment fails and then doing emergency repairs. In fact, the planning for inspections and preventive activities can be done days, weeks, and even months in advance to ensure that the most convenient time for production is chosen, that maintenance parts and materials are available, and that the maintenance workload is relatively uniform Scheduling is primarily concerned with balancing demand and supply. Demand comes from the equipment’s need for preventive maintenance. Supply is the availability of the equipment, craftspeople, and materials that are necessary to do the work. Record Keeping The foundation records for preventive maintenance are the equipment files. In a small operation with less than 200 pieces of complex equipment, the records can easily be maintained on paper. The equipment records provide information for purposes other than preventive maintenance. The essential items include the following:  Equipment identification number Equipment name Equipment product/group/class Location Use meter reading Preventive maintenance interval(s) Use per day Last preventive maintenance due Next preventive maintenance due Cycle time for preventive maintenance Crafts required, number of persons, and time for each Parts required. Objective: Describe the roles and responsibilities of the drilling rig crew in maintenance Describe knowledge, skills and ability of the following crews members: Roustabout Floorman Derrickman Crane operator Motorman mechanic Electrician, Driller and assistant driller Toolpusher Offshore installation manager (OIM) Health, safety and environment (HSE) Roustabout Floorman Derrickman Crane operator Motorman Mechanic Electrician Driller And Assistant Driller Toolpusher Offshore installation manager (OIM) Health, safety and environment (HSE) Objective: Describe the types and elements of maintenance programs Describe the need for a well designed maintenance program Discuss 12 key maintenance elements Describe major issues challenges Describe key objectives of Maintenance Program Describe types of maintenance programs: Preventative maintenance, Corrective Maintenance, Condition maintenance, Reliability Centered Maintenance. Well designed maintenance program: Adequate awareness to be provided to all employees for managing all possible risks that pertains to drilling operations considering the potential risks pertaining to health and safety of employees, equipment life environmental, reputational. Well defined maintenance program mitigates the potential hazard resulting from differed preventative maintenance by using some alternative maintenance methodologies, tool and techniques. Increased equipment life by practicing periodical inspections and residual life assessment programs.  Improved coordination with the operation team for releasing the equipment for preventative maintenance on timely basis. Identification of potential savings opportunities Robust awareness program for sharing with the employees educating them the advantage of maintaining state of the maintenance practices. Effective contactor management process for minimizing the incidents. Major challenge: not being able to maintain/ sustain the management processes, procedures and system required for effectively manage the investment made in state if the art hardware and software and Increase downtime due to poor maintenance practices. 12 key maintenance elements 1. Maintenance Strategy 2. Electrical Equipment 3. Rotating Equipment 4. Static Equipment 5. Information Technology Instructure 6. Health Safety and Environment 7. Tele- Communications Infrastructure 8. Instrument and Control 9. Piping 10. Pipelines 11. Laboratory 12. Process Safety Major Issues and Challenges: 1. Unplanned Maintenance 2. Absence of defined risk mitigation strategy 3. Inadequate corrosion monitoring plan 4. Obsolete technology 5. Inadequate maintenance analysis 6. Inadequate cost allocation 7. Inadequate corrective maintenance 8. Absence of risk assessment process 9. Absence of training / awareness programs 10. Synergy with inventory management 11. Inadequate monitoring of access 12. Equipment criticality 13. inadequate calibration of equipment 14. Inadequate root cause cause/ failure analysis 15. Inadequate review equipment master list 16. Absence of key performance indicators 17. Effective contractor management 18. Equipment bill of material (BOM) 19. Outdated procedure Key objectives of Maintenance Program Classification of equipment based on the latest standard, guidelines. It helps design the preventative maintenance plan to cover the high critical items on priority and more frequently. Establishing the preventative maintenance program with the effective utilization available systems/ software’s. Verifying the compliance to preventative maintenance program on periodical basis. Monitor and identifying potential cases where the equipment/ asset’s reliability or the consequence of failure poses an unacceptable risk to the plant operation.  Developing equipment preservation/ mothballing strategy. Assist the operation team for managing the sudden breakdown Performing the root cause analysis and sharing lessons learnt documents with the employees. Perform periodical inspection and ensure effective implementation of corrosion management plan Determine the residual life of equipment Preventative maintenance Actions performed on a time or machine run based scheduled that detects, preclude or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. Corrective Maintenance Basically the “run it till it breaks” maintenance mode. No actions or efforts are taken to maintain the equipment as the designer originally intended to ensure design life is reached. Condition maintenance Measurements that detects the onset of system degradation (lower functional state), thereby allowing casual stressors to be eliminated or controlled prior to any significant deterioration in the component physical state. Results indicates current and future functional capability. Reliability Centered Maintenance Process used to determine the maintenance requirements of any physical asset in its operating context. RCM methodology deals with the key issues not dealt with other maintenance programs. Equipment in the facility is not equal importance to either the process or facility safety. Equipment design and operation differs and that different equipment will have a higher probability to undergo failures for different degradation mechanism than others. Approaches the structuring of maintenance program recognizing that a facility does not have unlimited financial and personnel resources and that the use of both to be prioritized and optimized. Comparison of different maintenance programs Objective: Describe the maintenance of auxiliary systems on the rig Describe daily maintenance of kelly spinner Describe maintenance & calibration of indicators & sensors Describe the maintenance of vapor compression evaporators Describe the maintenance of reverse osmosis. Maintenance Daily maintenance of a Kelly spinner consist mostly of checking the lubrication system and greasing all lube points every trip. Specific Kelly spinner, consult the manufacture’s maintenance recommendations. Problems that may arise when using the Kelly spinner often have to do with a blockage of the air or hydraulic flow. Keep hoses straight and check connections to make sure its airtight. Preplace valves and seals as necessary. Maintenance and Calibration Indicators and sensors do not require much maintenance. Periodically check all fittings and hoses for tightness and for damage and to promptly replace worn or damaged parts Calibration are done by manufactures and therefore do not require adjustments in the field. Weight indicators are however an exception. the driller should calibrate the rig’s weight indicator after each move or whenever there is a reason to suspect that the reading is not accurate. An adjustment knob is provided on the instrument, which the driller can use to calibrate while following the manufacture’s printed instruction. Vapor Compression Evaporators (REVIEW) Uses electric motor to power pumps, a compressor and lubricating oil pump. Size of the unit can produce 4,800 to 16,800 gal of purified water per day. Has a heat exchanger , titanium plate that absorbs heat from the waste water leaving the unit and transmits it to the entering seawater. The heat preheats the seawater. Then sprayed over tubes carrying steam from the boiler. It then rises through the demister, then flows into the centrifugal compressor and onto tubes in the condenser carrying seawater on its way into the evaporation chamber. The vapor gives up its heat to the seawater. Centrifugal compressor works like a jet engine. Uses motor or engine to rotate an impeller that turns the drive shaft inside a housing or casing. Vapor Compression Evaporators (cont’d) Rotating impeller forces the water vapor that enters the compressor out and away from the blades. The energy of the rotating impeller transfers to the water vapor which increases pressure and temperature. Started manually but they work automatically until shut down manually or until automatic shut down by a safety shutdown system that senses trouble. These require a great deal of maintenance. Scale is made up of dissolved minerals in the water that do not evaporate. Injection a chemical solution into vapor compression unit can limit the scale content. Flushing the unit can also help reduce scale. Reverse Osmosis Watermakers (review) Filtration system for removing unwanted contaminants from water. Uses old and fairly simply technology. Permeability is a measure of the ease with which molecules flow through a substance. The permeable substance is usually a thin, pliable sheet called a membrane. If the membrane is permeable, molecules can flow though the openings in it. Some membranes are semipermeable which allows small molecules to flow through it but not large ones. Reverse Osmosis Watermakers Maintenance (review) Built in system to clean the permeators. Consist of mixing tank, filter, piping and valves that flush fresh water through the pump, piping and chambers after shutdown so the seawater is not left sitting in the unit. If sitting for a long period, seawater is very corrosive to the unit’s stainless steel part. Pumps needs inspection and lubrication. Objective: Perform maintenance according to maintenance schedule DRIL 23001GROUP ASSESSMENT: MAINTENANCE CHECKLIST (20%) Students are required to: Check coolant level Participate in toolbox and Check fuel level generate JSA Check anchor bolts for skip Assess and prepare work area Return equipment to rest and for maintenance. perform housekeeping Create checklist for the Complete and submit report for following checks: task Record model and serial number of generators Check battery and alternator connections