Case History of ISO 14224 Application in the QGOG Offshore Drilling Fleet

2016 IADC Asset Integrity & Reliability
Conference & Exhibition
Norris Convention Center, Houston, Texas USA,
August 30, 2016, Slide 1
© Reliability Dynamics LLC 2016
Case History of
ISO 14224 Application in the
QGOG Offshore Drilling Fleet
Thiago Amato
Asset Integrity Engineer,
Queiroz Galvão Óleo e Gás S.A.
(Brazil)
Tony Ciliberti
Principal Engineer
Reliability Dynamics
(USA)

QGOG Constellation Fleet
ISO 14224 taxonomy and
failure reporting
• Initiated in 2014 – Brava
Star
• Initiated the roll-out in
2015
Maintenance system
• IBM MAXIMO for Oil and
Gas
6 UDW
 3 SS and 3 DS
1 DW
 1 SS
2 MW
 2 SS
Operational
Offshore
Rigs
9

ISO 14224 Implementation Roadmap
Choose ISO 14224 methods
Implement ISO
14224 for first rig
Extend
functionality to
remaining rigs
Reconcile old
processes with
new methods
Learn how to
apply ISO 14424
methods

Technical Structure
TDX has 71 tags

Technical Structure

The Challenges
Data
• Incomplete tags lists
• Outdated technical drawings
Technical structure
• How to integrate the Xantic SFI index with ISO 14224
Standards content
• Many critical drilling equipment classes not in ISO 14224, Annex A
CMMS (IBM MAXIMO O&G)
• Content gaps and functionality
Personnel
• Training personnel

MAXIMO O&G - Failure Reporting

The Results
• Over 30,000 functional locations in place
• With extended content, over 80 equipment class definitions
• 200 failures class into MAXIMO O&G
Level Description
Alaskan
Star
Atlantic
Star
Olinda Star Lone Star
Alpha
Star
Gold Star
Amaralina
Star
Laguna
Star
Brava
Star
Total
Water depth Midwater Deepwater Ultra-deepwater
Rig type SS SS SS SS-DP SS-DP SS-DP DS DS DS
0 Corporate Level 1
1 Subsurface 1
2 Rig ID 1 1 1 1 1 1 1 1 1 9
3 SFI Main Group 8 8 8 8 8 8 8 8 8 72
4 SFI Group 68 68 68 68 68 68 68 68 68 612
5 SFI Subgroup 371 371 371 371 371 371 371 371 371 3339
6
ISO 14224
Equipment
448 527 572 1162 1183 1142 1352 1355 2201 9093
7 ISO 14224 Subunit 174 194 182 296 302 371 260 260 289 2257
8
ISO 14224
Maintainable Item
528 686 821 1274 1210 1186 1363 1362 4001 12318
C
Collective Failure
Reporting
187 135 144 180 188 200 197 190 17 1437
G
Equipment
Group/Type
79 64 94 111 143 149 186 192 497 1339
U
Unstructured
equipment
26 87 40 164 222 221 130 127 725 1476
Total 1890 2141 2301 3635 3696 3646 3936 3934 8239 31946

The Results
Improved quality in data collection:
• Developed training program
• Developed MAXIMO workflows
• Implemented a QA/QC process
The hierarchy gives flexibility in
evaluating failure rates at any point
in the structure
• E.g., component, equipment or process
level

The Benefits of Methodology
• Base for the root cause analysis process
• Base to KPIs. e.g. MTTR, Availability, MTBF
• Tracking the failure impact on equipment function
28.91
57.10
115.82
115.96
173.85
0 50 100 150 200
TOP DRIVE TDX-1250 MAIN
BLOWOUT PREVENTER #2
HYDRARACKER MAIN
HP MUD PUMP #4
AIR HANDLING UNIT #2
Days
MTBF
30%
45%
25%
Failure Impact on
Equipment Function - TDX
Critical failure
Degraded failure
incipient failure

The Benefits of Methodology
8%
8%
34%
50%
Failure modes
SPO - Spurious
operation
SER - Minor in-service
problems
STD - Structural
deficiency
ELU2 - External
leakage utility medium
67%
8%
25%
Causes type
OPSERR -
Operating Error
EXPWT - Expected
Wear and Tear
Others
68%
14%
18%
Losses (h)
OPSERR -
Operating Error
EXPWT - Expected
Wear and Tear
Others
What is causing more pain?

Next Steps
Do analysis / Reliability studies
Improve data collection
Consolidate QA/QC process
• Data
analysis
(KPIs)
• Changes’
evaluation
• Improve
maintenance
system and feed
the CMMS
• Identify
improvement
of
maintenance
system
P D
CA

Norris Convention Center
Houston, Texas USA
August 30, 2016
Application in Enterprise Software
ISO 14224 Methods

Primary Objective
How Failure Events Affect on the Bottom Line

Objectives
Equipment-Level Analysis

Objectives
Component-Level Analysis

Enterprise Software with ISO 14224 Methods

Construction of Technical Hierarchy
Technical Drawings

ISO 14224 Boundary Definition

ISO 14224 Equipment Subdivision

Functional Location / Equipment Relationship
ISO 15926-2, Section E.3.3, “Coincident Individuals”

Data Mapping per ISO 14224
One unique ID for each tag
throughout all systems, records, and
in the field
Use/Location Data
Equipment Subdivison

K-102 Boundary Definition

Use/Location Data

Malfunction Problem Report (Work Initiation)
Equipment-Level Notations

Malfunction Repair Report (Work Close-out)
Component-Level Notations

Consequence Assessment

Data Aggregation
Multi-Level Failure Reporting (MLFR®)

High-Quality Trusted Data
Quality Management Program
Quality assurance
• Technical hierarchy
• Structure defines equipment boundaries
and interrelationships
• Programmatic consistency checks
• Malfunction reporting
• Standard processes
• Minimum dataset for each event
• Failure data validations
Quality control
• Event record reviews
• Feedback to field
ISO 14224 gives guidance
• Clause 7: Obtaining Quality Data
Quality Management
Quality Assurance
Quality Control

ISO 14224 Application Challenges
Drilling Sector
Limited breadth (Annex A)
• Very limited content for drilling
equipment
• Only BOP and top drive
Limited depth
• ISO 14224 methods focus on primary
equipment
• Limited treatment for component/sub-
component failure details

Addressing the Limited Content Challenge
Extended ISO 14224 Annex A
Maersk Drilling initiative to
develop new taxonomy definitions
• Eighty new drilling equipment taxonomy
definitions consistent with Annex A
• Four approved for ISO 14224:2016
Participants
• Maersk Drilling (PG 1 member)
• Reliability Dynamics (PG 1 member)
• Severin Consulting ApS
Proposed as standard content for
drilling industry

Addressing the Limited Depth Challenge
Multi-Level Failure Reporting (MLFR®)
Technical hierarchy
• Technical tags mapped per ISO
14424 equipment subdivision
• Each technical tag has class
specific failure code sets
• More structural depth = more
detail
• No limit other than practicality!
Malfunction reporting
• Malfunction reporting at
component or equipment level
• Data aggregation at equipment
level

www.qgogconstellation.com
THANK
YOU

Relevant International Standards
ISO 14224:2006 - Petroleum, petrochemical and natural gas industries -- Collection
and exchange of reliability and maintenance data for equipment
ISO 15926-2:2003 - Industrial automation systems and integration -- Integration of
life-cycle data for process plants including oil and gas production facilities -- Part 2:
Data model

Case History of ISO 14224 Application in the QGOG Offshore Drilling Fleet

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Case History of ISO 14224 Application in the QGOG Offshore Drilling Fleet