Technical Integrity Assurance – a game changer for the industry?

Drilling and rig training simulators may be developed to recreate more realistic well control scenarios.

The “systems” element of drilling facilities takes in equipment, emergency and safety systems, commissioning, the “design to build” interface, and inspection and testing. It is vital that major equipment items are specified, built, certified, and tested in line with appropriate regulations, standards, and codes. Instead of reviewing individual equipment, an approach should be implemented whereby a combination of inter-related equipment and processes are analyzed as a complete system.

Other critical issues are the communication interfaces between the various packages and the assurance that the system works as intended without the risk of unplanned events; and assurance of reliable and predictable operations under various operating and emergency scenarios with specific reference to drilling control and automation systems. Often, abnormal operating events are not fully assessed during the design phase; however, a targeted review of emergency and safety systems, including experienced drilling operations personnel, can help eliminate unexpected events during any emergency situation.

A detailed review and audit of the robustness of commissioning procedures and test records will minimize the risk of unrevealed faults coming to light post sail-away. Schedule constraints can lead to rigs leaving the construction yard incomplete and not fully tested. When the rig is on station, these areas are much harder to address and some may never actually be completed.

Items are frequently modified at the construction site without a full understanding of the consequences to the design: rarely are the modifications subject to the same scrutiny as the original design during the design phase. Also, many planned maintenance routines, inspection and test frequencies will be set at start-up when there is only limited availability of operating functional data. A review based on the latest knowledge, technology, and actual equipment historical performance will therefore reduce the risk of safety equipment not operating when required. The appropriate definition of acceptance criteria, confirmation of actual maintenance and testing, and the accessibility of existing records for all equipment on the installation, should also be part of any TIA program.

Training standards

Basic training, enhanced competence, and leadership all are intrinsic qualities necessary for drilling operations. Drilling personnel tend to be promoted into rig supervisory positions after demonstrating the right technical skills based on years of experience. In an emergency situation, positive and confident leadership skills are essential.

However, current regulatory requirements for basic well control training often focus on the individual “passing the exam” rather than gaining a thorough understanding of well control fundamentals. In some cases, well training consists of an on-line exam with no independent verification. This type of “training” can leave rig personnel exposed to a well control incident during actual drilling operations, when rapid, decisive, and appropriate corrective action is crucial.

The use of Drilling and Advance Rig Training simulators is an effective way to improve safety and operational performance through enhanced competence. Going forward, we see the industry extending the use of simulation training programs. This will increase the number of individuals and crews exposed to a realistic well control incident simulation in a safe and controlled environment. Rig personnel will then be better prepared for a situation they hope never to encounter – but, if they do, will be able to confidently employ the skills essential to bring a well under control. Nevertheless, the current training simulation system providers will need to broaden the scope of training offered and focus on giving the individual a thorough understanding of the principles and practices of well control.

Process issues

Process is the third and final technical integrity assurance core element. This includes failure mode and effect analysis, system redundancy, independent third party verification and audit, “as-built” status review, and HAZOP revalidation. A formal “what if” consequence-and-impact assessment is also advisable. Traditionally, drilling rigs are designed to deal with a single failure scenario; reviewing the impact of coincident and simultaneous failures and feeding back the findings to complete the design loop will increase the safety of the final system and rig design.

The “independence” and use of a suitably qualified and technically competent third party as part of the review, verification and audit process – at all stages from pre-concept to start-up – introduces a new challenge process and a demonstration to any client or regulatory body of a robust assurance program.

Over time, on-site modifications can result in key documentation essential for safe operation becoming out of date. However, assurance that all key documentation reflects the real status of the current facilities is feasible via actual detailed site surveys: the resultant output will be accurate “as-is” documentation such as P&IDs, electrical single line diagrams, fire and gas shutdown philosophies, cause and effects charts, and operating and emergency procedures.

While the original design and any major modifications will have undergone a number of HAZOPs, it is good practice to confirm continued safe operations via the revalidation and reassessment of HAZOP criteria as part of a five-year facility review (or more frequently, in the event of significant asset changes). In addition, it is our opinion that at global level, the industry will lean towards an approach similar to the UK-based Safety Case, and this type of document will need to be in place not only for fixed platform drilling facilities but also for mobile drilling rigs.

As an international drilling facilities engineering organization, RDS constantly communicates with oil and gas operators and drilling contractors across the globe. We have recently seen different approaches in TIA applied to differing operating depths. We have also seen significant variations in how each of the major oil and gas locations view and are dealing with the aftermath of theDeepwater Horizon incident.

As the causes and further consequences of recent events become clearer, we believe it is important for the industry to reach an appropriate level of alignment around our drilling facilities technical integrity practices. Harmonization and execution of these methods will present a significant challenge, but demonstrating a robust assurance program is something we all need to embrace and achieve. The industry is already starting to see a change in the relationship between operators and drilling contractors, and we expect the interaction to become more formalized.

A lack of prompt and aligned action by the industry may lead to other stakeholders forcing less appropriate and overly onerous legislation. Whatever else, we can be sure this will be a “game-changer” for us all!

The author

Mike Buckingham BSc, CEng, MIET, Eurlng., is a business manager with RDS, the rig facilities engineering design specialists and engineering division of international drilling contractor KCA DEUTAG. He has over 30 years experience in both technical and delivery senior management roles in the offshore and onshore oil and gas industry.