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Description of Issue
Control fluid cleanliness and condition is considered essential by all control system manufacturers, yet
access to the control fluid tanks is uncontrolled on many rigs. In addition, newly hired, untrained
people are often assigned the job of keeping the storage tanks full.
Here is a description of an incident that cost millions of dollars and months of time to repair:
When a subsea BOP stack was retrieved for standard maintenance, multiple pod functions
were found with swollen and damaged Nitrile O-rings.
The three control pods were shipped to the OEM for repairs. The repairs consisted of replacing
3,000 O-rings. Cost of the work at the OEM was $3,000,000, and it required over three
Despite the latest laboratory test techniques, there was no way to definitively identify the
source of contamination. The contaminant was probably introduced and then flushed through
normal operations before the BOP stack was pulled. This single incident reportedly resulted in
a total, gross charge to the program of about $19,000,000.
In another case, fire-fighting fluid was inadvertently added to the control fluid concentrate tank. By
the time it was found, the fire-fighting fluid had contaminated the entire system and a full flush was
required.
Some Solutions
Some suggestions for avoiding this issue include the following:
Label hoses and tanks Clear labels and color coding of the hoses and tank openings will
make it easier for personnel to keep things in order.
Control access to reservoirs - Lock the control fluid tanks and valves to limit access to
and inspection.
Test the BOP control fluid on a daily basis Train subsea personnel to test the fluid for
included in the analysis, in addition to the standard pH, concentration, alkalinity and viscosity.
Ensure compliance of water supply In at least one case a poorly maintained rig water
system was producing unsuitable water. Have the water supply monitored and remedied if
necessary. An often overlooked issue is the calcium content of water from boats. Calcium is
very harmful to modern control systems. Dissolved solids like calcium may precipitate out,
especially after mixing with control fluid additives. Note: If the water supply is via work boat,
always verify the condition of the water. Tanks are often not cleaned correctly, and water may
be contaminated with completion fluids or other substances.