Shared Learning Opportunity - Hot Tapping - IP 100

What happened?

   Hot Tap technicians failed to complete a small bore hot tap on 150 PSI / 370 ^oF / steam project.

What went wrong?

    The technicians failed to inspect the dogs on the IP100 when mounting the cutter assembly on the boring bar thus the 4” hot tap on a 6” pipe 150# flanged  system the entire shell cutter / driver / pilot bit & coupon fail into pipe when backing out of the cut.

Investigation Results

     Technician did not stop after making the connection with the “D” ring into the boring bar noticing there was good bit of rocking and twisting movement  between the bar and cutter driver.

     Pre-job planning did not address how to proceed if there was slop in the final connection of boring bar and cutter.

            Two bad boring bar photos   

   Two good boring bar photos

 

How do we prevent it from happening again?

  Always follow the written procedures. If something does not look right or requires any deviations all Furmanite have the responsibility to utilize their “STOP WORK AUTHORITY”.  Any planned activity or job can be rescheduled so the issues can be addressed with the customer. Do NOT continue until all changes and concerns have been addressed and resolved.

What actions do I take?

                 Furmanite’s Pipe Line Intervention Engineers need to modify the IP100 procedures so as to put a go no go step in the form that states what is acceptable gapping in the dogs on the boring bar. This will allow technicians to have a more complete procedure to follow.

                 Review this Shared Learning with all employees

 

 

ON-SITE MACHINING (OSM) CASE STUDY

Line Boring Jackup Oil Rig Platform - Chain Beam Assembly

OVERVIEW

Furmanite recently earned a contract to perform on-site line boring on the new construction of a Jackup Platform Chain Beam Assembly. In the early 1950's, the "Scorpion" designed by R. G. LeTourneau for Zapata Off-shore Company (owned by George H. W. Bush), was the first Jackup platform manufactured to provide a stable and secure floating structure  in which the entire platform could raise to a safe operating height in often treacherous open waters.  Today the Gulf Region is host to over 500 operating Jackup platforms.

SOLUTION AND IMPLEMENTATION

In setting the Jackup platform, the main assembly, at 77 feet in length and weighing in at 120,000 pounds, pays out and reels in an enormous chain which in turn lowers and raises the legs of the platform. The critical bores (being machine in photo at left) hold the shaft upon which the chain sprocket rotates. Furmanite's scope entailed machining five sets of bores, removing 2" of material diameter (1" per side) from each 3.5" long bore.

RESULTS

Furmanite was required to complete all five sets of bores in less than ten days. Furmanite scheduled a two man day crew and a two man night crew to work around the clock, completing the project in less than nine days. The customer was pleased with both the quality of the work, and the efficiency in which it was executed.