Beruflich Dokumente
Kultur Dokumente
Edition 2011
The following Rules come into force on May 1st, 2011 Germanischer Lloyd SE GL Noble Denton Brooktorkai 18, 20457 Hamburg, Germany Phone: +49 40 36149-750 Fax: +49 40 36149-280 glo@gl-group.com www.gl-group.com "General Terms and Conditions" of the respective latest edition will be applicable (see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys). Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd SE GL Noble Denton. Published by: Germanischer Lloyd SE, GL Noble Denton Printed by: Gebrder Braasch GmbH, Hamburg
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Table of Contents
Section 1 ................................................................................................................................................................. 3 Certification of Blowout Preventers .................................................................................................................... 3 1. 2. 2.1 2.2 2.3 2.4 2.5 3. 3.1 3.2 4. 4.1 4.2 5. 5.1 5.2 5.3 6. Scope of Equipment.................................................................................................................................. 3 Certification Process................................................................................................................................. 3 Basis for Certification............................................................................................................................... 3 Scope of Certification ............................................................................................................................... 3 Issue of Certificate.................................................................................................................................... 3 Operational Records ................................................................................................................................. 3 Validity of the Certification...................................................................................................................... 3 Certification of BOPs Built under Witness of GL .................................................................................... 6 General Notes ........................................................................................................................................... 6 Witness during Manufacture..................................................................................................................... 6 Certification of BOPs not Built under Witness of GL .............................................................................. 6 General Notes ........................................................................................................................................... 6 Certification Procedure ............................................................................................................................. 6 Inspections to Maintain the Validity of a Certificate ................................................................................ 7 Types of Inspection................................................................................................................................... 7 Explanations and General Requirments.................................................................................................... 7 Performance of Inspections ...................................................................................................................... 7 Quality Management and Workmanship .................................................................................................. 7
Section 2 ................................................................................................................................................................. 8 Principles, Normative References, Conditions, Documents .............................................................................. 8 1. 2. 2.1 2.2 3. 4. 4.1 4.2 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 General Principles..................................................................................................................................... 8 Rules and Regulations to be Considered .................................................................................................. 8 Rules of Germanischer Lloyd ................................................................................................................... 8 Internationally Recognised Codes and Standards..................................................................................... 8 Safety, Environmental and Process Conditions ........................................................................................ 9 Documents for Examination ..................................................................................................................... 9 Types of Documents ................................................................................................................................. 9 Components and Subassemblies ............................................................................................................... 9 Failure Mode and Effect Analysis (FMEA)............................................................................................ 10 General.................................................................................................................................................... 10 Description of Subsystems Relevant for the Analysis ............................................................................ 10 Block Diagrams of Relevant Subsystems ............................................................................................... 10 Analysis of the Relevant Subsystems ..................................................................................................... 10 Tabular Worksheet.................................................................................................................................. 11 Assumptions and Defined Limits for the FMEA .................................................................................... 11 Management of Change .......................................................................................................................... 11 Conclusions ............................................................................................................................................ 11 FMEA-based Test Program .................................................................................................................... 11
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Section 3 ............................................................................................................................................................... 12 Design and Manufacture of Blowout Preventers.............................................................................................. 12 1. 2. 2.1 2.2 2.3 2.4 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.8.1 5.9 6. 6.1 6.2 6.3 6.4 7. Scope ...................................................................................................................................................... 12 BOP Stack............................................................................................................................................... 12 Pipe Rams ............................................................................................................................................... 12 Blind Shear Rams ................................................................................................................................... 12 Annular BOP .......................................................................................................................................... 12 Connectors .............................................................................................................................................. 12 Guide Frame Structure............................................................................................................................ 12 Equipment under Pressure ...................................................................................................................... 12 Control Systems...................................................................................................................................... 13 Design Review........................................................................................................................................ 13 Hydraulic Control Units (HCU) ............................................................................................................. 13 Electrical Control Units .......................................................................................................................... 13 Subsea Control Pods ............................................................................................................................... 14 Umbilicals............................................................................................................................................... 14 Accumulators.......................................................................................................................................... 14 Surface Control Stations ......................................................................................................................... 14 Control Station Locations ....................................................................................................................... 14 Control Station Functions ....................................................................................................................... 14 Control System Response Times ............................................................................................................ 15 Contingency Systems.............................................................................................................................. 15 Remotely Operated Vehicles (ROVs)..................................................................................................... 15 Deadman System .................................................................................................................................... 15 Auto-Shear System ................................................................................................................................. 15 Acoustic Control System ........................................................................................................................ 15 Choke and Kill System ........................................................................................................................... 15
Section 4 ............................................................................................................................................................... 16 Inspection and Test of Blowout Preventers ...................................................................................................... 16 1. 1.1 1.2 1.3 1.4 2. 3. 4. 5. 6. Inspections during Manufacture and Assembly...................................................................................... 16 Quality Plan ............................................................................................................................................ 16 Inspection and Test Plan (ITP) ............................................................................................................... 16 Non-Destructive Testing (NDT) ............................................................................................................. 16 Pressure Test........................................................................................................................................... 16 Factory Acceptance Test (FAT).............................................................................................................. 16 Site Integration Test (SIT) ...................................................................................................................... 16 Annual Inspections ................................................................................................................................. 17 Inspections for Re-Certification.............................................................................................................. 17 Extraordinary inspections after Modification, Repair or Major Overhaul.............................................. 17
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These guidelines are applicable to the design, construction, and inspection of blowout preventers (BOPs), which are to be certified by Germanischer Lloyd (GL), including their power supply interfaces and control and monitoring system. Blowout preventers include: Main body and various types of hydraulic rams and/or seals and the guide frame structure, which together form the BOP stack; Hydraulic accumulators and electrical batteries forming the subsea power supply system; Interfaces to connect wellheads and lower marine riser packages/risers; Interfaces to connect umbilicals for external power supply, control and monitoring; Interfaces to allow underwater manipulation by a remotely operated vehicle (ROV); Choke and kill system including manually and remotely controlled valves; Power Supply and Control System.
After successful completion of the certification activities the certificate will be issued by GL. The certificate shall be kept on the site where the BOP is deployed. 2.4 Operational Records
A BOP is required to carry an operational record file in which details of the operational history (site, environmental and process parameters, maintenance, damages, repair) and BOP test reports are entered. The operational records shall be submitted to the GL inspector on request. 2.5 Validity of the Certification
(1) The validity of a certificate is limited to five years. The certificate will be maintained and extended in its validity as long as the BOP is subjected to all prescribed inspections and tests, and any modifications and repairs found to be necessary are carried out to the satisfaction of GL. (2) If the BOP is not subjected to the prescribed inspections and tests at their due dates the certificate will be suspended. However, when an inspection becomes due while the BOP is in use, the inspection may be deferred until the well is completed. (3) If the BOP has sufficient damage affecting the certification or if such damage may be assumed an inspection and test shall be conducted before the BOP is redeployed. GL shall be notified of such a situation in due course. (4) Where it is found that the BOP no longer complies with the requirements on which the certificate was issued, and if the operator fails to carry out the repairs or modifications considered necessary by GL within a specified period to be agreed upon, the certificate will expire. (5) If the repairs and modifications required by GL have been carried out and the BOP is subjected to a re-certification inspection or an extraordinary inspection the original certification may be reinstated. The inspection is to be carried out in accordance with the scope for re-certification inspections or extraordinary inspections respectively, refer to section 4, para 5 and para 6.
2.
Certification Process
The certification process comprises a design review and various stage inspections during the manufacturing of components, the assembly of the BOP stack and the commissioning of the completed system. Certificates issued need to be renewed and reconfirmed in regular intervals, at least every five years, after annual inspections have been regularly conducted with success. 2.1 Basis for Certification
The following guidelines constitute the basis for the certification of blowout preventers. For requirements not defined in these guidelines, other rules and guidelines of GL shall be applied as far as they are applicable. The latter include Rules for Materials and Welding as well as other Rules issued by GL.In addition, internationally accepted codes and standards form the basis of the certification. Details are referenced in Section 2, para 2.2. 2.2 Scope of Certification
Certification covers the entire BOP stack, including its machinery components, power supply, structural
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(6) The validity of a certificate of a laid-up BOP continues unchanged. On request, any inspections which become due may be deferred until the BOP is reactivated for service. In these circumstances, the total scope and extent of inspections and test required thereafter, shall be determined by GL on a case-to-case basis. (7) If a certificate has for some reason expired or has been withdrawn by GL, such a certificate shall
(8) Should the BOP and its systems have had any form of modification since its initial delivery from manufacturer, then a design review incorporating said modifications shall be conducted. (9) Any damage and subsequent repairs shall be subject to design review with the same parameters as a design review for modifications.
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3.
3.1
(5) Upon completion of the assembly, the BOP, including all structural elements and assembled components, shall be tested in accordance with the details set out in section 4 of these guidelines. (6) To enable the GL inspector to fulfil his duty, he shall be granted free access to the BOP and to the workshops where parts requiring inspection and tests witnessed by GL are manufactured, assembled or tested. The necessary staff and equipment shall be provided.
(1) The application for certification of a BOP is to be submitted to GL in writing by the manufacturer or operator. (2) A document register shall be submitted as early as possible, indicating the specifications, calculations, drawings and data sheets, which are available, or will become available, for review in the course of the project. (3) All documents describing the BOP are to be submitted in triplicate to GL in case of paper copies. Alternatively, a single electronic submission for examination is acceptable. (4) Alterations to documents and drawings approved by GL are subject to a repeated approval of GL before any works commence. (5) An Inspection and Test Plan (ITP) is to be submitted to GL for approval and mark-up of intervention points (monitor, witness, hold) to be attended by a GL Inspector and the designated Inspection Office is to be advised in good time of tests to be performed under the witness of GL. (6) Upon the completion of the construction works and successful testing of the BOP, GL will issue the certificate. 3.2 Witness during Manufacture
4.
4.1
(1) The application for the certification of a BOP not built under the witness of GL is to be submitted to GL in writing. (2) All documents related to the BOP are to be submitted for examination with the application for certification. The scope and depth of examination will be in accordance with sections 2, 3 and 4 of this guideline. (3) Existing certification, its validity and any recommendations which have been made conditional upon the existing certification, are to be submitted together with the application. 4.2 Certification Procedure
(1) Materials for new constructions, replacements and repaired parts shall be tested as defined in the GL Rules for Materials, or other proven codes and standards acceptable to GL. (2) Parts of the BOP requiring inspection and tests witnessed by GL will be checked during manufacture for conformity with the approved documents. (3) The separate components of the BOP are to be tested in the manufacturers premises for mechanical strength and, where appropriate, for functionality. For components of novel design which do not yet have a proven track record when incorporated into a BOP, GL may demand more extensive tests. (4) The GL inspector will witness the assembly of the BOP stack and the installation of the machinery, control, monitoring and interfacing components as per the quality control plans and inspection and test plans. The workmanship will be examined and the required strength, tightness and functional tests shall be carried out in his presence.
(1) For admission to certification, the BOP shall be inspected in accordance with the provisions of an inspection for re-certification, refer to section 4, para 5. (2) If the BOP holds a valid certificate of another recognised Classification Society, the scope and depth of the inspections and tests of individual parts may be deferred to the due dates for annual inspection. (3) A certificate will be issued on the basis of satisfactory results from the examination of documentation and on the basis of satisfactory inspection and test results witnessed by a GL inspector and documented in relevant inspection reports. (4) Once a BOP has received a GL certificate, the same regulations will apply as for BOPs built under the witness of GL.
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5.
5.1
(1) A BOP, which is certified by GL is to be subjected to the following regular inspections, if the validity of the certificate is to be maintained: Annual Inspection, see section 4, para 4; Inspection for recertification after five years, see section 4, para 5; Extraordinary Inspection, where the BOP or some of its components have suffered damage liable to affect serviceability and, therefore, safety, see section 4, para 6. (2) GL reserves the right to demand extraordinary inspections. Such inspections may be credited against prescribed regular inspections. 5.2 Explanations and General Requirments
All inspections are to be performed in accor-dance with prescribed procedures against predefined acceptance criteria as outlined in inspection and test plans approved by GL. Where the operational and functional particulars differ from the standard case, the scope of inspection shall be adjusted accordingly in coordination with GL. The detailed scope of the inspections and tests is addressed in section 4 of this guideline.
6.
(1) The manufacturer/supplier of a BOP shall apply a valid quality management system, such as ISO 9001 or equivalent. (2) As far as required by such a QMS, all components shall be checked and inspected by the manufacturers own personnel for completeness, correct dimensions and faultless workmanship during fabrication, assembly and completion. (3) Afterwards, all components and equipment shall be presented to GL for inspection in suitable sections and with proper access; for pressure testing normally in uncoated conditions. (4) The GL inspector may reject components that have not been adequately prechecked and may require the resubmission upon successful completion of such prechecks and any resulting corrective actions. (5) All significant details concerning quality and functionality shall be reflected in the manufacturing documents and shall be presented to GL during inspections. (6) If, due to insufficient or missing information in the detail documents, the quality and functional particulars of a component are in doubt, GL may require improvements. This is valid for supplemental or additional parts even when at the time of document approval these were not required or could not be required due to lack of available information.
(1) The designated inspection office is to be given timely notice when regular inspections become due or when it is intended to carry out repairs or modifications, so that the work can be witnessed. (2) Equipment and components are to be arranged so that they are accessible for inspections on board. Where this is either not possible or would involve inappropriate efforts, inspections may also be performed, upon application, in the manufacturers works or in another authorised workshop. (3) The results of each inspection together with any special requirements upon which the maintenance of certification or its validity is conditional, will be attached to the certificate. (4) Where parts are damaged or worn to such an extent that they no longer comply with the requirements of these guidelines or the applicable codes and standards, they shall be repaired or replaced. (5) Where defects are repaired on a temporary basis or where GL agrees that repairs or replacements are not immediately necessary, the certificate and its validity may be confirmed for a limited period of time. Such limitation will be attached to the certificate and will be removed once all the necessary works have been carried out.
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(1) BOPs are to be designed and constructed in such a way that failure of single component cannot give rise to a safety critical situation. (2) BOPs and their components shall be designed to meet the service conditions stated in the specification. (3) BOPs shall be designed and built to ensure safe operation and facilitate adequate inspection, maintenance and repair. (4) A consistent set of codes and standards shall be selected for the design and construction of BOPs, avoiding overlaps, gaps and contradictions. (5) The codes and standards applied should be the latest revision available.
Codes and standards applicable to the certification of subsea well control equipment may include: API Spec 6A/ISO 10423, Specification for Wellhead and Christmas Tree Equipment; API Spec 16A/ISO 13533, Specification for Drill-through Equipment; API 16C, Specification for Choke and Kill Systems; API Spec 16D, Specification for Control Systems for Drilling, Well Control Equipment, and Control Systems for Diverter;
2.
API Spec 16F, Specification for Marine Drilling Riser Equipment; API Spec 17D, Subsea Wellhead and Christmas Tree Equipment; API RP 49, Recommended Practice for Drilling and Well Servicing Operations Involving Hydrogen Sulphide; API RP 53, Recommended Practices for Blowout Prevention Equipment Systems for Drilling Wells; API RP 59, Recommended Practice for Well Control Operations; ISO 13628-4, Petroleum and Natural Gas Industries - Design and Operation of Subsea Production Systems - Part 4: Subsea Wellhead and Tree Equipment ISO 13628-5, Petroleum and Natural Gas Industries - Design and Operation of Subsea Production Systems - Part 5: Subsea Umbilicals ISO 28781, Petroleum and Natural Gas Industries - Drilling and Production Equipment - Subsurface Barrier Valves and Related Equipment NACE MR 01-75, Petroleum and Natural Gas Industries Materials for Use in H2SContaining Environments in Oil and Gas Production.
BOPs and their components shall always be designed, built, and operated to meet the national laws and statutory requirements in force in the respective countries where they are to be used. Some examples of relevant legislation are referenced in appendix 1. 2.1 Rules of Germanischer Lloyd
The following GL Rules are valid as additional requirements for the certification of BOPs: GL-Rules II - Materials and Welding, Parts 1 - 3 GL-Rules IV Industrial Services, Part 6 - Offshore Technology GL Rules I Ship Technology, Part 5 Unmanned submersibles (ROV, AUV) and Underwater Working Machines Designs differing from GL-Rules may be permitted, if they provide equivalent levels of safety. (1) Where the design of a BOP or its components is based on new principles or technologies, which have not yet been sufficiently tested in practical operation, GL reserves the right to demand additional submission of documentation and the execution of additional special tests.
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3.
The documents listed above shall be submitted for: (1) BOP stack comprising, but not limited to: Annular BOP Pipe Rams Shear Rams Bonnets Actuators and Stems Connectors to Wellheads and Lower Marine Riser Package Guide Frame Structure
All safety, environmental and process conditions shall be submitted with the application, based on the codes and standards mentioned above. If information is not known or complete at time of submittal, GL shall be notified when such data can be expected.
4.