CRITICAL SPARES DATA BASE PROJECT

Critical Spares Data Base Project

1. Introduction2. Benefits3. How it works

CRITICAL SPARES DATA BASE PROJECT

1 - IntroductionThe back bone of a healthy and prosperous Offshore Drilling Rig is the operational excellence. In order to achieve such excellence (which is directly linked to the safety of crew embers and longevity of equipment) it is crucial that each critical equipment is properly identified and maintained.An efficient preventive maintenance program is directly dependent upon efficient and practical means of managing a healthy and accurate critical spare parts inventory.

The way a rig manages its spare parts inventory will determine how succesful its operations will be.

The following steps of this guide will present a project which aims directly to the core of a well succeeded critical spares management system. It consists on mapping all critical equipment directly responsible for keep the rig fully operational, identifying their related critical spares in order to determine adequate stock levels, managing the spares physical display and accomodation at the warehouse and allowing a practical and fast response when attempting to locate parts for maintenance use.

CRITICAL SPARES DATA BASE PROJECT

2 – Benefits2.1 – Managing Adequate Inventory and Stock Levels

The first step of the process consists on discussing equipment criticality with the Maintenance Coordinators on the vessel, in order to plan the task ahead. Since priorities are highlighted and list of critical equipment is obtained from Maintenance Management, the OEM Maintenance Manual related to the first Assembly on the list of Critical Equipment (Ex.: Main Engines) must be studied, and Drawings / Bills of Materials will be broken down in irder to start producing accurate spreadsheets listing all items related to a such equipment (The lists are broken down per equipment subassemblies, following the drawings/BOM´s sequence of related OEM Maintenance Manuals – we´ll see how that is down on the next chapters). Once the spreadsheets are completed with items available on the rig´s data base (and, most important, items not available), it is passed on to the related maintenance department along with the literature drawings / BOM´s used on the research. That way, the equipment “owner” can review Min/Max stock levels previously set for the existing items and add items still not available on the data base, determing desirable stock levels for those.This is one of the most important steps of the process, as it ensures that critical items which could be eventually out of the inventory are properly addressed and ordered for potential maintenance.

CRITICAL SPARES DATA BASE PROJECT

2 – Benefits2.1 – Managing Adequate Inventory and Stock Levels (Cont.)

During review of the spreadsheet, the equipment “owner” will be able to match the items listed on the spreadsheet to the actual OEM Maintenance Manual Drawings and BOM´s. That is accomplished through an hyperlink on the spreadsheet which will open the drawing and bill of materials related to the items being reviewed.The “owner” can then check the part numbers listed on the spreadsheet (which are followed by the drawing position) and identify them on the related Drawing / BOM, check the quantity used to “run” the subassembly in order to calculate the adequate inventory needs. Other criteria to be used during needed inventory level calculation:

If the item has a stock usage history (was purchased and used before) the owner needs to check how often such part was replaced and with what kind of interval between maintenance tasks (months, years, etc.)

The comercial factors – How long it took to have the previous purchasing delivered (from the day the previous PO was forwarded to the vendor, going through shipment – preferably Ocean Freight, which is the normal method for non-urgent issues – period and Customs Clearance (since 95% of mosts rigs critical spares come from abroad).

CRITICAL SPARES DATA BASE PROJECT

2 – Benefits2.1 – Managing Adequate Inventory and Stock Levels (Cont.)

During review of the spreadsheet, the equipment “owner” will be able to match the items listed on the spreadsheet to the actual OEM Maintenance Manual Drawings and BOM´s. That is accomplished through an hyperlink on the spreadsheet which will open the drawing and bill of materials related to the items being reviewed.The “owner” can then check the part numbers listed on the spreadsheet (which are followed by the drawing position) and identify them on the related Drawing / BOM, check the quantity used to “run” the subassembly in order to calculate the adequate inventory needs. Other criteria to be used during needed inventory level calculation:

If the item has a stock usage history (was purchased and used before) the owner needs to check how often such part was replaced and with what kind of interval between maintenance tasks (months, years, etc.)

The comercial factors – How long it took to have the previous purchasing delivered (from the day the previous PO was forwarded to the vendor, going through shipment – preferably Ocean Freight, which is the normal method for non-urgent issues – period and Customs Clearance (since 95% of mosts rigs critical spares come from abroad).

CRITICAL SPARES DATA BASE PROJECT

3 – The Data Base – How it Works

Every Company has its own Maintenance System (SAP, Maximo, Star, J.D. Edwards, etc.) and the main goal of the “Critical Spares Data Base” is not to replace any of those. The Data Base is not an “End” System, but a tool, a mean to better populate the Maintenance System on hand with accurate and meaningful information.However, if desired, the Data Base can be kept as a quick data reference guide, as it helps to locate every single part dedicated to the Unit’s range of Critical Equipment within a few clicks.

Bare in mind that the “Critical Spares Data Base” is a “live tool”, as it will require constant update, whenever new spares are added to a given equipment list (purchase of new items previously not included on inventory).

Let’s suppose that the Unit’s Subsea Engineer needs to know what the rig has in stock for the Shear Seal Solenoid Valves on the BOP Mux Control Pod (or needs to have access to the full list of parts on inventory for the Pods themselves).

See screen shots on next pages to see how such info is obtained through the Data Base:

To start looking for parts dedicated to the BOP Mux Pod Shear Seal valve, click on “Enter Data Base”

On the next screen of the Data Base you will need to choose the Equipment Family (BOP is Well Control). Click on “Well Control”.

The Well Control Equipment “Family” is divided into “Surface Equipment” (Drill String Compensator, Riser Tensioners, etc) and “Underwater Equipment” (BOP, Riser String, etc). Click on “Underwater Equipment” for BOP Mux Pod Spares.

Now you will see a breakdown of the Well Control Critical Equipment Family. Choose “BOP Mux Control Pods”.

The BOP Mux Pod Assembly is divided in two main sections: EH Section (Electro Hydraulic) and Lower Valve Unit. Click on EH Section for the Shear Seal Valves.

You are then taken to the full list of subassemblies extracted from the OEM Maintenance Manual related to BOP Mux Control Pods EH Section. Choose the desired Subassembly “60 VDC Solenoid / Shear Seal Valve Assy”.

Once you get on the “60 VDC Solenoid / Shear Seal Valve Assy” Screen, you can choose any one of the 4 different Bills of Materials related to spares dedicated to such subassembly. Click on “60 VDC Solenoid Assy” to access parts related to such BOM.

You are now on the BOM related to the 60VDC Solenoid Assy, where you will find all spares related to such item, including drawing position, part number, OEM Description, quantity used to run the assembly, stock levels and stock location. If you click on the Orange line (Subassembly title), you will have direct access to the OEM Drawing and parts list from the Maintenance manual.

After clicking on the Orange Subassembly title, you are directed to the OEM Drawing of the related item, plus original parts list. That way you can visualize the items listed in order to verify parts needed for maintenance of the 60 VDC Solenoid Assy.

Example of BOP Mux Pods Lower Valve Unity physical inventory arrangement as per OEM Manual BOM’s

Example of BOP Mux Pods Lower Valve Unity physical inventory arrangement as per OEM Manual BOM’s

Example of BOP Annular spares / Marine Riser spares physical inventory arrangement as per OEM Manual BOM’s

Example of BOP Annular spares / Marine Riser spares physical inventory arrangement as per OEM Manual BOM’s

CRITICAL SPARES DATA BASE PROJECT

3 – The Data Base – How it Works

The idea of this projec t is to map the Critical Equipment and their related spares of any Drilling or Production rig, develop the Critical Spares Data Base along with Maintenance and Materials Crew and provide training to all relevant personnel in order to obtain the better use of such tool and also provide training regarding the best practices to optimize the warehouse to reflect the accuracy of the info contained on the data base.

Thanks for the opportunity.

Respectfully,

Marcelo Azevedo – Materials Specialist