Vous êtes sur la page 1sur 23

Snubbing Unit Audit

Sonatrach
ENSP - Snubbing
HRS 154 - Snubbing Unit Audit
Well Number MD 629

Date: Thursday, January 27, 2011

B.P. 295 Z.I.


Hassi Messaoud,
Algeria
TEL No. 011-213-(0)-29-73-9538
TEL No. 011-213-(0)-29-73-8188
FAX No. 011-213-(0)-29-73-1911
Website www.bootsandcoots.com
Audit Report
Audit Name: Sonatrach, HRS 154 - Snubbing Unit Audit, Well Number MD 629
Audit Type: Snubbing Unit Audit
Audit Date: 2011/01/27
Completed By:
Comments: imported audit

Client: Sonatrach
Company Man: DJENANE
Snubbing Supervisor: TOUIL AMOR
Snubbing Contractor: ENSP
Country: Algeria
Field: HMD
Well Number: MD 629
Activity at Time of Audit: Clean out well
Chock Manifold Size:
Pressure Rating:
Number of Manual Chokes:
Number of Hyd. Chokes:
Mud/Gas Separator
Dimensions:
Hyd. Closing Unit Type: Power pack
No. of Bottles: 4
Wellhead Size: 4 1/16
Press. Rate-Lower Conn.: 5000
Mud Pumps / HP: SPM
Snubbing Unit Hydrrig
Manufacturer:
Snubbing Unit Number: HRS 154
Year Built / Retrofit: 1998
Max Lift Capacity: 150,000
Max Snub Capacity: 75,000
Max Rotary Torque: 500ft/lb
Unit Bore Size: 7 " x 4 1/16
Power Source: Deisel
BOP Config./Specifications: Stripper bowl,2 stripper rams,Pipe rams,Blind rams

Auditors: Guffey, Dennis

Page: 1 / 22
Executive Summary

Customer: Sonatrach
Location: HRS 154 - Snubbing Unit Audit, Well Number MD 629
Audit Name: Snubbing Unit Audit V1.1
Audit Date: 2011/01/27

Executive Summary:

Audit Comments:

The identification of risks associated with any business, and the management of those risks, are important aspects
of business management in todays competitive world. It is even more relevant regarding oil and gas exploration
and production. Boots & Coots Audit services help in addressing identified risks and it is used as an analysis tool to
proactively prevent loss of control. It helps to visualize and measure the present condition of the components. The
implementation of corrective action recommendations will ensure the equipment is in proper condition to prevent an
incident. Our Audits can help reduce the likelihood, severity and consequences of an incident and ensure the
integrity of your facilities, improve productivity and protect your assets, employees, the public, and the environment.
Around the world Boots & Coots Audits have saved many operators time and money by reducing the frequency of
critical events.
On 27 January 2011 a re-audit of the HRS 154 was completed. Some NDE inspections had been done since
previous audit but not for all critical components. The chains have been removed from guy wires and proper system
installed. Auditor did not go to workbasket because ladders remain unsecured and without proper fall protection.
Much of the non-compliance is in documentation. All testing, including function tests should be documented and the
document should be available at time of the audit.
The findings in this report are defined and weighted as follows for Non Compliance items:

Critical Findings
Critical findings are based on shortcomings found during an audit which have the potential to lead to loss of well
control.

Major Findings
Major findings are based on shortcomings which may lead to damage to essential equipment or have a detrimental
effect on well control operations as a result of inadequate use and/or failure of equipment.

Minor Findings
Minor findings are based on shortcomings which may lead to situations that contribute to an incident or to
circumstances in which the required standards of operation are not met.

Critical Non Compliant Findings


Are there both ground and work basket accumulator controls? (Repeat Finding)
Are there both ground and work basket accumulator controls clearly labeled?
Is the auxiliary BOP Accumulator routinely manned at critical stages such as pipe light conditions, crossing balance
point and pulling on stuck pipe?
Have the preventers been field disassembled and inspected in accordance with API Standards (3-5 yrs)? Provide
date of last inspection in narrative. (Repeat Finding)
Are rams, annular, hydraulic operated valves, and choke manifold low pressure tested (200-300 psi) before
pressuring up to the full test pressure? (Repeat Finding)

Page: 2 / 22
Major Non Compliant Findings
Is auxiliary equipment and auxiliary BOPs operated from an independent closed-hydraulic circuit? (Repeat Finding)
Is there a step set of illustrations showing how to test all BOP items? (Repeat Finding)
Are these steps followed after each nipple-up?
Are these steps followed at specified intervals after nipple up?
Are BOP and valve control handles on ground console and work basket console clearly labeled?
Does the blind rams accumulator control have a cover but not lock to allow the blind rams to be actuated from the
remote station and prevent accidental or unreasoned closure? (Repeat Finding)
In the work basket is there available a full opening TIW safety valve? (Repeat Finding)
Are mud pump pop-offs properly set?
Are all ladders clamped properly and extension ladders equipped with safety latches? (Repeat Finding)
Has inspection and certification been preformed to industry standards on all slip bowls in the past year? (Repeat
Finding)
Do Company Men, Supervisors and Operators have certificates of well control training for their positions? (Repeat
Finding)

Minor Non Compliant Findings


Are sufficient fall protection devices in place? (Repeat Finding)
Are sufficient fall protection devices periodic inspection documents available?
Are the pressure settings of these items monitored daily and recorded? (Repeat Finding)
Are the auxiliary controls effective if the work basket unit is destroyed? (Repeat Finding)
Is the remote accumulator panel checked every shift to confirm proper pressure settings?
Are Weco 1502 hammer unions installed on prior casing valves? (Repeat Finding)
Is the BOP closing ratio known?
Is there a safety-latch between slip-control handles to prevent opening slips simultaneously but not interfere with
closing both slips simultaneously? (Repeat Finding)
Is there a safety-latch between stripper rams-control handles to prevent opening rams simultaneously but not
interfere with closing both simultaneously? (Repeat Finding)
Are "while tripping" drills held at intervals, timed and recorded on the IADC Daily Drilling Report? (Repeat Finding)
Are approved well killing worksheets available on location? (Repeat Finding)
Are approved well killing worksheets updated after mud density changes?
Is there a BOP manual available with a list of necessary expendables that should always be on hand?
Has there been any NDE inspections performed on critical components within the last year? (Repeat Finding)
Is evidence on file of the inspections done? (Repeat Finding)
Are all critical components fully documented with traceable material specifications in line with ISO-9000 standards?
(Repeat Finding)
Do other crew members have certificates of well control training for their positions? (Repeat Finding)

Page: 3 / 22
Actual Possible Actual Desired
Section Section Header Score Score Compliance % Compliance %

1 Job Procedures 10.00 20.00 50.00 % 100.00%

2 Power Pack 25.00 30.00 83.33 % 100.00%

3 Accumulator 185.00 260.00 71.15 % 100.00%

4 Blowout Preventer 185.00 275.00 67.27 % 100.00%

5 Choke 0.00 0.00 % 100.00%

6 Gas Separation 0.00 0.00 % 100.00%

7 Inside BOP, Back Pressure Valves 55.00 65.00 84.62 % 100.00%


and Floats
8 Control Console 30.00 40.00 75.00 % 100.00%

9 Access Window 0.00 0.00 % 100.00%

10 Pipe Guides 20.00 20.00 100.00 % 100.00%

11 Stripping Rubber 30.00 30.00 100.00 % 100.00%

12 Rental Equipment 0.00 0.00 % 100.00%

13 Tripping Procedures 20.00 20.00 100.00 % 100.00%

14 Drills 0.00 5.00 0.00 % 100.00%

15 Unit Specifications 290.00 350.00 82.86 % 100.00%

16 Crew Training 20.00 35.00 57.14 % 100.00%


Totals 870.00 1,150.00 75.65 % 100.00 %

Rating Scale:
90 - 100: Industy Leader
80 - 89: Average Performer
70 - 79: Exercise Caution, Mitigating and Corrective Action (CAR Closure)to be implemented immediately
0 - 69 : Re-evaluate use of this contractor and/or implement strict controls
Caution, Mitigating and Corrective Action (CAR Closure)to be implemented immediately

100 350

300
80
250
Compliance %

60
200
Score

150
40

100

20
50

0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Section

Actual Score Possible Score Actual Compliance % Desired Compliance %

Page: 4 / 22
Summary of Non Compliance Findings and Recommendations

Critical Findings:

3-0-1 Are there both ground and work basket accumulator controls?

3-0-2 Are there both ground and work basket accumulator controls clearly labeled?

3-0-7 Is the auxiliary BOP Accumulator routinely manned at critical stages such as pipe light
conditions, crossing balance point and pulling on stuck pipe?

4-0-24 Have the preventers been field disassembled and inspected in accordance with API Standards
(3-5 yrs)? Provide date of last inspection in narrative.

4-0-29 Are rams, annular, hydraulic operated valves, and choke manifold low pressure tested (200-300
psi) before pressuring up to the full test pressure?

Major Findings:

3-0-3 Is auxiliary equipment and auxiliary BOPs operated from an independent closed-hydraulic circuit?

4-0-12 Is there a step set of illustrations showing how to test all BOP items?
No step set of illustrations and no low pressure test
4-0-13 Are these steps followed after each nipple-up?

4-0-14 Are these steps followed at specified intervals after nipple up?

4-0-17 Are BOP and valve control handles on ground console and work basket console clearly labeled?

4-0-23 Does the blind rams accumulator control have a cover but not lock to allow the blind rams to be
actuated from the remote station and prevent accidental or unreasoned closure?

7-0-1 In the work basket is there available a full opening TIW safety valve?

15-0-6 Are mud pump pop-offs properly set?


No pop off on pump
15-0-30 Are all ladders clamped properly and extension ladders equipped with safety latches?

15-0-50 Has inspection and certification been preformed to industry standards on all slip bowls in the past
year?

16-0-1 Do Company Men, Supervisors and Operators have certificates of well control training for their
positions?

Page: 5 / 22
Minor Findings:

1-0-3 Are sufficient fall protection devices in place?

1-0-4 Are sufficient fall protection devices periodic inspection documents available?

2-0-4 Are the pressure settings of these items monitored daily and recorded?

3-0-4 Are the auxiliary controls effective if the work basket unit is destroyed?

3-0-10 Is the remote accumulator panel checked every shift to confirm proper pressure settings?
No remote exists
4-0-6 Are Weco 1502 hammer unions installed on prior casing valves?

4-0-16 Is the BOP closing ratio known?

8-0-1 Is there a safety-latch between slip-control handles to prevent opening slips simultaneously but
not interfere with closing both slips simultaneously?

8-0-5 Is there a safety-latch between stripper rams-control handles to prevent opening rams
simultaneously but not interfere with closing both simultaneously?

14-0-1 Are "while tripping" drills held at intervals, timed and recorded on the IADC Daily Drilling Report?

15-0-1 Are approved well killing worksheets available on location?

15-0-2 Are approved well killing worksheets updated after mud density changes?

15-0-26 Is there a BOP manual available with a list of necessary expendables that should always be on
hand?

15-0-39 Has there been any NDE inspections performed on critical components within the last year?
Some NDE exists but not for all critical components.
15-0-40 Is evidence on file of the inspections done?

15-0-41 Are all critical components fully documented with traceable material specifications in line with
ISO-9000 standards?

16-0-2 Do other crew members have certificates of well control training for their positions?

Page: 6 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Job Procedures
Desired Compliance - (100.00%)
1-0-3 Are sufficient fall protection devices in place? 0.00 / 5.00
( Repeat Finding )
No
REF:
Best Industry Practice. OSHA Appendix C to 1910.66 Sec. 1-Mandatory. (4). API RP
54. 5.5

Criteria:
"The attachment point has to be designed to withstand a 5000 pound shock load.
Lanyards will be in use when working above 6 feet or 1.83 meters off of the ground."
"On a weekly basis a competent person shall physically inspect and document the
inspection of all fall protection equipment on each job and in each department."
"(4)Self-retracting lifelines and lanyards which automatically limit free fall distance of
2 feet or less shall have components capable of sustaining a minimum static tensile
load of 3,000 pounds applied to the device with the lifeline or lanyard in the fully
extended position."
"All personnel, when engaged in work above 10 feet shall be protected at all times
by a fall protection safety device."

Consequence Analysis:
1) Failure of equipment inspection or lack of could lead to injury of personnel or loss
of life. (2) Being out of compliance to recognized industry standards.
1-0-4 Are sufficient fall protection devices periodic inspection documents available? 0.00 / 5.00
No
REF:
Best Industry Practice. OSHA Appendix C to 1910.66 Sec. 1-Mandatory. (4). API RP
54. 5.5

Criteria:
"The attachment point has to be designed to withstand a 5000 pound shock load.
Lanyards will be in use when the distance is above 6 feet or 1.83 meters off of the
ground."
"On a weekly basis a competent person shall physically inspect and document the
inspection of all fall protection equipment on each job and in each department."
"(4)Self-retracting lifelines and lanyards which automatically limit free fall distance of
2 feet or less shall have components capable of sustaining a minimum static tensile
load of 3,000 pounds applied to the device with the lifeline or lanyard in the fully
extended position."
"All personnel, when engaged in work above 10 feet shall be protected at all times
by a fall protection safety device."

Consequence Analysis:
1) Failure of equipment inspection or lack of could lead to injury of personnel or loss
of life. (2) Being out of compliance to recognized industry standards.

Page: 7 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Section Score: 10.00 / 20.00

Section Findings Total: 2/4

Power Pack
Desired Compliance - (100.00%)
2-0-4 Are the pressure settings of these items monitored daily and recorded? 0.00 / 5.00
( Repeat Finding )
No
REF:
Best Industry Practice.

Criteria:
Inspection / Documentation sheet. "Pressure settings should be recorded on the
daily report."

Consequence Analysis:
Proper settings for well program procedures may change daily. By-passing or failure
to confirm a protective safety device could result in injury to personnel, damage to
equipment or loss of well control.

Section Score: 25.00 / 30.00

Section Findings Total: 1/4

Accumulator
Desired Compliance - (100.00%)
3-0-1 Are there both ground and work basket accumulator controls? 0.00 / 15.00
( Repeat Finding )
No
REF:
American Petroleum Institute, (API) 53, Recommended Practice Blow Out
Prevention Recommended Equipment Systems for Drilling Wells, Sec 12.1E and
12.8 and Sec 12.5.3
IADC K Section 2,1.b

Criteria:
12.1E "The elements of the BOP control system normally include remote control
panels for operating the hydraulic manifold from remote locations"
12.8 "The installation should be equipped with an auxiliary remote control panel
such that the operation of each auxiliary BOP and control valve can be controlled
from position readily accessible from a designated remote station. Considerations
should be given to the need of a remote control station a safe distance from the well
bore."
12.5.3 "Control valves must be clearly marked to indicate which preventer or choke
line valve each control valve operates and the position of the valves; i.e. open,
closed, neutral."
Sec.2,1.b."The main accumulator with its hydraulic control manifold, separate

Page: 8 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

hydraulic manifold, or hydraulic panel should be installed in a safe area protected


from falling debris or gas accumulations during a blowout. All of the control functions
should be operable from the work basket and/or designated auxiliary BOP control
station by use of a remote control panel."

Consequence Analysis:
A) Increased closing time which allows a greater influx. B) When controls are not
clearly labeled there is a potential for closing the wrong BOP. For example, closing
the blind rams with tubulars in the hole.
3-0-2 Are there both ground and work basket accumulator controls clearly labeled? 0.00 / 15.00
No
REF:
American Petroleum Institute, (API) 53, Recommended Practice Blow Out
Prevention Recommended Equipment Systems for Drilling Wells, Sec 12.1E and
12.8 and Sec 12.5.3
IADC K Section 2,1.b

Criteria:
12.1E "The elements of the BOP control system normally include remote control
panels for operating the hydraulic manifold from remote locations"
12.8 "The installation should be equipped with an auxiliary remote control panel
such that the operation of each auxiliary BOP and control valve can be controlled
from position readily accessible from a designated remote station. Considerations
should be given to the need of a remote control station a safe distance from the well
bore."
12.5.3 "Control valves must be clearly marked to indicate which preventer or choke
line valve each control valve operates and the position of the valves; i.e. open,
closed, neutral."
Sec.2,1.b."The main accumulator with its hydraulic control manifold, separate
hydraulic manifold, or hydraulic panel should be installed in a safe area protected
from falling debris or gas accumulations during a blowout. All of the control functions
should be operable from the work basket and/or designated auxiliary BOP control
station by use of a remote control panel."

Consequence Analysis:
A) Increased closing time which allows a greater influx. B) When controls are not
clearly labeled there is a potential for closing the wrong BOP. For example, closing
the blind rams with tubulars in the hole.
3-0-3 Is auxiliary equipment and auxiliary BOPs operated from an independent 0.00 / 10.00
closed-hydraulic circuit?
( Repeat Finding )
No
REF:
Best Industry Practice

Criteria:
"Auxiliary BOP control consoles are used for direct control of the auxiliary BOP's not
controlled from the work basket. The auxiliary control console's placement, rig-up
and proper marking is required to help prevent bodily injury and/or equipment
damage."

Consequence Analysis:

Page: 9 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

During a well control event control of lower BOPs (safety and or blind rams) may not
be possible or have a delayed reaction if operation is from the work basket resulting
in death or injury to personnel, damage to equipment and/or loss of well control.
3-0-4 Are the auxiliary controls effective if the work basket unit is destroyed? 0.00 / 5.00
( Repeat Finding )
No
REF:
Best Industry Practice

Criteria:
"Hoses of sufficient length to allow placement of the remote console at least 50'
from the wellhead."
"The recommended placement is to the rear of the pipe rack and on the opposite
side of the pipe rack from where the helper runs the pipe to eliminate trip hazards.
Place up-wind if possible."

Consequence Analysis:
An independent closed hydraulic circuit operating the auxiliary BOPs are needed. If
a common BOP hydraulic system is in use a failure in the work basket would cause
the ground unit inoperable leading to loss of well control.
3-0-7 Is the auxiliary BOP Accumulator routinely manned at critical stages such as pipe light 0.00 / 25.00
conditions, crossing balance point and pulling on stuck pipe?
No
REF:
Best Industry Practice

Criteria:
"Consideration should be given to manning the auxiliary BOP consoles during critical
stages of the job. These critical stages will be dictated by specific job conditions and
should be discussed during pre-job planning meetings and daily 'tool-box' safety
meetings. Critical stages may include, but are not limited to, starting in the hole,
crossing balance point, pulling on stuck pipe or high pressure wells."

Consequence Analysis:
During critical operations delayed function of lower BOPs (safety and or blind rams)
could result in death or injury to personnel, damage to equipment and/or loss of well
control.
3-0-10 Is the remote accumulator panel checked every shift to confirm proper pressure 0.00 / 5.00
settings?
No
REF:
Best Industry Practice

Criteria:
This action to be added to the "Operator's hand over checklist" notes.

Consequence Analysis:
BOPs may not be functional.
No remote exists

Page: 10 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Section Score: 185.00 / 260.00

Section Findings Total: 6 / 29

Blowout Preventer
Desired Compliance - (100.00%)
4-0-6 Are Weco 1502 hammer unions installed on prior casing valves? 0.00 / 5.00
( Repeat Finding )
No
REF:
Best Industry Practices

Criteria:
"This must be a molded integral flanged connection. A snubbing unit works with
pressure, so line pipe connections are not acceptable."

Consequence Analysis:
Inability to rig up pump/flow lines quickly during a well control event.
4-0-12 Is there a step set of illustrations showing how to test all BOP items? 0.00 / 10.00
( Repeat Finding )
No
REF:
API Spec 16C Choke and Kill Systems Sec. 9.17.
API 53 Recommended Practices for Blowout Prevention Equipment Systems for
Drilling Wells Section 17.2.4
API Spec 7L Procedures to Mfg., Inspect, Repair, and Remanufacture Drilling
Equipment
Best Industry Practice

Criteria:
"The manufacturer shall prepare and have available an Operating Manual for each
model and size Choke and Kill System manufactured in accordance to this
specification. The operating manual shall contain the following information:
-Operation and Installation Instructions
-Seals information
-Maintenance and testing information
-Disassembly and assembly information
-Parts information
-Storage information "
"Technique and step by step or how to test procedure should be developed for each
rig because of varying equipment, different installation arrangements and well
specific drilling programs. The procedure for testing the BOP stack, drill string
safety valves, choke kill lines, and manifold upstream of the buffer chamber are
usually similar for most rigs. The mfg. operating and maintenance documents,
contractor maintenance programs, and operating experiences should be
incorporated into the specific tests procedures."
"Documented instructions and procedures for any system assembly, testing, and
commissioning that is required to be performed at the installation site shall be
available prior to commencing installation."
"The following minimum documents shall be prepared in conjunction with HWO
Page: 11 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

workovers: (1) Equipment stack drawing. (2) Plan view drawing of the HWO spread.
(3) Schematic piping diagram. (4) Time line."

Consequence Analysis:
Inefficient in testing of BOP components.
No step set of illustrations and no low pressure test

4-0-13 Are these steps followed after each nipple-up? 0.00 / 10.00
No
REF:
Best Industry Practices.

Criteria:
"The actual test sequence will vary depending on the BOP components and
configuration but all elements of the HWO system shall be tested after R/U, after
every 7 days and/ or repair."

Consequence Analysis:
Inefficient and confusion in testing of BOP components.
4-0-14 Are these steps followed at specified intervals after nipple up? 0.00 / 10.00
No
REF:
Best Industry Practices.

Criteria:
"The actual test sequence will vary depending on the BOP components and
configuration but all elements of the HWO system shall be tested after R/U, after
every 7 days and/ or repair."

Consequence Analysis:
Inefficient and confusion in testing of BOP components.
4-0-16 Is the BOP closing ratio known? 0.00 / 5.00
No
REF:
Best Industry Practices.
API RP 5312.3. (c.)

Criteria:
"Refer to testing procedures and HWO worksheet."
"The minimum calculated pressure to effectively close and seal a ram-type BOP
against a wellbore pressure equal to the maximum rated working pressure of the
BOP divided by the closing ratio specified for that BOP."

Consequence Analysis:
Not following manufacture recommended BOP operating pressures per well
pressure ratio may result in delay of closing times and damage to elastomeric
causing a well control event.
4-0-17 Are BOP and valve control handles on ground console and work basket console clearly 0.00 / 10.00
labeled?
No
REF:

Page: 12 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

API Recommended Practice 53 Blow Out Prevention Equipment Systems for Drilling
Wells, Sec 12.5.3.f
API 12 Sec 5.3(f) and IADC Ch K Sec 2 (1.C)

Criteria:
"Control valves must be clearly marked to indicate which preventer or choke line
valve each control valve operates, and the position of the valves." (open, closed,
neutral)

Consequence Analysis:
Possible function of incorrect BOP. If left in neutral, there may be a leak when the
accumulator is needed. Handle must remain in open or closed position.
4-0-23 Does the blind rams accumulator control have a cover but not lock to allow the blind 0.00 / 10.00
rams to be actuated from the remote station and prevent accidental or unreasoned
closure?
( Repeat Finding )
No
REF:
API Recommended Practice 53 Blow Out Prevention Equipment Systems for Drilling
Wells, Sec 12.5.3.f.

Criteria:
"The control valve handle that operates the blind rams should be protected to avoid
unintentional operation, but allow full operation from the remote panel without
interference."
"Included in the safety system of the well control system."

Consequence Analysis:
Unable to close blind rams from auxiliary BOP console making the remote station
useless.
DSCN1139.jpg

4-0-24 Have the preventers been field disassembled and inspected in accordance with API 0.00 / 15.00
Standards (3-5 yrs)? Provide date of last inspection in narrative.
( Repeat Finding )
No
REF:
American Petroleum Institute 53 Recommended Practice Blow Out Prevention

Page: 13 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Recommended Equipment Systems for Drilling Wells, Sec. 17.10.3

Criteria:
"After every 3-5 years of service, the BOP stack, choke manifolds, and diverter
components should be disassembled and inspected in accordance with the
manufacturer's guidelines. Elastomeric components should be changed out and
surface finishes should be examined for wear and corrosion. Critical dimensions
should be checked against the manufacturer's allowable wear limits. Individual
components can be inspected on a staggered schedule. A full internal and external
inspection of the flexible choke and kill lines should be performed in accordance with
the equipment manufacturer's guidelines."

Consequence Analysis:
Surface failure.
4-0-29 Are rams, annular, hydraulic operated valves, and choke manifold low pressure tested 0.00 / 15.00
(200-300 psi) before pressuring up to the full test pressure?
( Repeat Finding )
No
REF:
API 53, Recommended Practices for Blowout Prevention Equipment Systems for
Drilling Wells Sec 17.3.2.1
IADC Chp.K.Sec.1.F.2.

Criteria:
"All blowout prevention components that may be exposed to well pressure should be
tested first to a low pressure of 200 to 300 psi (1.38 to 2.1 MPa) and then to a high
pressure."

Consequence Analysis:
BOP failure at low well bore pressure.

Section Score: 185.00 / 275.00

Section Findings Total: 9 / 39

Choke
Desired Compliance - (100.00%)

Section Score: 0.00 / 0.00

Section Findings Total: 0 / 17

Gas Separation
Desired Compliance - (100.00%)

Section Score: 0.00 / 0.00

Section Findings Total: 0/3

Page: 14 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Inside BOP, Back Pressure Valves and Floats


Desired Compliance - (100.00%)
7-0-1 In the work basket is there available a full opening TIW safety valve? 0.00 / 10.00
( Repeat Finding )
No
REF:
API 53 15.2

Criteria:
"A spare TIW type safety valve should be readily available (i.e., stored in open
position with wrench accessible) in the work basket at all times." All necessary
cross-over's must be readily available.

Consequence Analysis:
A) Unable to run wireline tools - bridge plug; B) It could lead to an inside drill pipe
blowout

Section Score: 55.00 / 65.00

Section Findings Total: 1/9

Control Console
Desired Compliance - (100.00%)
8-0-1 Is there a safety-latch between slip-control handles to prevent opening slips 0.00 / 5.00
simultaneously but not interfere with closing both slips simultaneously?
( Repeat Finding )
No
REF:
Best Industry Practices.

Criteria:
"Safety latch should be installed between slip control handles to prevent opening
slips simultaneously and losing control of the pipe."

Consequence Analysis:
Loss of control of pipe
8-0-5 Is there a safety-latch between stripper rams-control handles to prevent opening rams 0.00 / 5.00
simultaneously but not interfere with closing both simultaneously?
( Repeat Finding )
No
REF:
Best Industry Practices.

Criteria:
"Safety latch should be installed between stripper rams control handles to prevent
opening rams simultaneously resulting in an uncontrolled release of pressure."

Consequence Analysis:
Release of high pressure gas and or fluids, damage to elastomers.

Page: 15 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Section Score: 30.00 / 40.00

Section Findings Total: 2/7

Access Window
Desired Compliance - (100.00%)

Section Score: 0.00 / 0.00

Section Findings Total: 0/5

Pipe Guides
Desired Compliance - (100.00%)

Section Score: 20.00 / 20.00

Section Findings Total: 0/2

Stripping Rubber
Desired Compliance - (100.00%)

Section Score: 30.00 / 30.00

Section Findings Total: 0/4

Rental Equipment
Desired Compliance - (100.00%)

Section Score: 0.00 / 0.00

Section Findings Total: 0/2

Tripping Procedures
Desired Compliance - (100.00%)

Section Score: 20.00 / 20.00

Section Findings Total: 0/7

Drills
Desired Compliance - (100.00%)
14-0-1 Are "while tripping" drills held at intervals, timed and recorded on the IADC Daily Drilling 0.00 / 5.00
Report?
( Repeat Finding )
No

Page: 16 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

American Petroleum Institute 59 Recommended Practice for Well Control


Operation, Sec 11.3
MMS 250.408 (a) (5)

Criteria:
" Drills should be documented, executed, repetitive, and followed-up to correct
identified problems."
(5) " Tripping pipe. A drill conducted during a trip shall include the following as
practicable: (i) Detect kick and sound alarm; (ii) Install safety valve, close safety
valve; (iii) Position pipe, prepare to close annular preventer; (iv) Install inside
preventer, open safety valve; (v) Record time; (vi) Record casing pressure; (vii)
Check all valves on choke manifold and BOP system for correct position (open or
closed); (viii) Check for leaks on BOP system component and choke manifold; (ix)
Check flow line and choke exhaust lines for flow; (x) Check accumulator pressure."

Consequence Analysis:
A) Failure to react properly during a well control event since the crew is not well
trained; B) Failure to detect kicks before escalating into much larger well control
situation.

Section Score: 0.00 / 5.00

Section Findings Total: 1/2

Unit Specifications
Desired Compliance - (100.00%)
15-0-1 Are approved well killing worksheets available on location? 0.00 / 5.00
( Repeat Finding )
No
REF:
API 59, Recommended Practice for Well Control Operations, Sec 9.1. Sections a-h

Criteria:
"Complete the well control worksheet (Refer to Appendix B)" of API 59
"Drilling densities should be recorded on the well control worksheets."
"Review and update pump output and hole data and complete the suggested well
control worksheet."

Consequence Analysis:
A) Improper Kill technique when responding to a well control situation; B)
Unnecessary fluid lost to the formation; C) Additional influx
15-0-2 Are approved well killing worksheets updated after mud density changes? 0.00 / 5.00
No
REF:
API 59, Recommended Practice for Well Control Operations, Sec 9.1. Sections a-h

Criteria:
"Complete the well control worksheet (Refer to Appendix B)" of API 59
"Drilling densities should be recorded on the well control worksheets."
"Review and update pump output and hole data and complete the suggested well
control worksheet."
Page: 17 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

Consequence Analysis:
A) Improper Kill technique when responding to a well control situation; B)
Unnecessary fluid lost to the formation; C) Additional influx
15-0-6 Are mud pump pop-offs properly set? 0.00 / 10.00
No
REF:
IADC J. J12-3. II. C.

Criteria:
"Usually, relief valves are set to exceed rated pressure by some given amount."

Consequence Analysis:
A) Liner failure; B) Stand pipe and rotary hose failure
No pop off on pump

15-0-26 Is there a BOP manual available with a list of necessary expendables that should always 0.00 / 5.00
be on hand?
No
REF:
API 53 Recommended Practices for Blowout Prevention Equipment System for
Drilling Wells, Sec 6.4

Criteria:
"The following recommended minimum BOP spare parts (for the service intended)
should be carefully stored, maintained and readily available:
a. a complete set of ram rubbers for each size and type of ram BOP being used.
b. a complete set of bonnet or door seals for each size and type of ram BOP being
used
c. plastic packing for BOP secondary seals
d. ring gaskets to fit end connections
e. a spare annular BOP packing element and a complete set of seals
f. a flexible choke or kill line if in use."

Consequence Analysis:
Loss of rig time waiting on BOP expendables. Could lead to surface failure in event
of a kick.
15-0-30 Are all ladders clamped properly and extension ladders equipped with safety latches? 0.00 / 10.00
( Repeat Finding )
No
REF:
OSHA 1910.26 C (3)(vi)

Criteria:
"Ladders must not be tied or fastened together to provide longer sections. They
must be equipped with the hardware fittings necessary if the manufacturers
endorses extended uses."

Consequence Analysis:
Personnel injury.

Page: 18 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score
DSCN1137.jpg

15-0-39 Has there been any NDE inspections performed on critical components within the last 0.00 / 5.00
year?
( Repeat Finding )
No
REF:
Best Industry Practice. API RP 53. 17.10.3. 17.13.2.

Criteria:
"This is defined as jobs falling due depending on calendar time or running hours."
"(I.e.)After every 3-5 years of service the BOP stack, choke manifold and
components should be disassembled and inspected in accordance with the
manufacturer's guidelines."
"Where required, copies of the manufacturer's equipment data book and third party
certification should be available for review."

Consequence Analysis:
Equipment failure.
Some NDE exists but not for all critical components.

15-0-40 Is evidence on file of the inspections done? 0.00 / 5.00


( Repeat Finding )
No
REF:
Best Industry Practice. API RP 53. 17.10.3. 17.13.2.

Criteria:
"This is defined as jobs falling due depending on calendar time or running hours."
"(I.e.)After every 3-5 years of service the BOP stack, choke manifold and
components should be disassembled and inspected in accordance with the
manufacturer's guidelines."
"Where required, copies of the manufacturer's equipment data book and third party
certification should be available for review."

Consequence Analysis:
Equipment failure.

Page: 19 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

15-0-41 Are all critical components fully documented with traceable material specifications in line 0.00 / 5.00
with ISO-9000 standards?
( Repeat Finding )
No
REF:
Best Industry Practice.

Criteria:
"ISO standards are implemented by individual businesses, corporations, and
government organizations, the ISO 9000 'family' also provides auditing tools to make
sure that you have properly implemented the standards and are meeting the quality
requirements."

Consequence Analysis:
Equipment failure.
15-0-50 Has inspection and certification been preformed to industry standards on all slip bowls in 0.00 / 10.00
the past year?
( Repeat Finding )
No
REF:
Best Industry Practice.

Criteria:
"This is defined as jobs falling due depending on calendar time or running hours."

Consequence Analysis:
Catastrophic failure with possible injury to personnel or well bore.

Section Score: 290.00 / 350.00

Section Findings Total: 9 / 53

Crew Training
Desired Compliance - (100.00%)
16-0-1 Do Company Men, Supervisors and Operators have certificates of well control training 0.00 / 10.00
for their positions?
( Repeat Finding )
No
REF:
American Petroleum Institute Specification 54 Recommended Practice for
Occupational Safety for Oil and Gas Well Drilling Servicing Operations, Sec 6.1.3
American Petroleum Institute Specification PI T-6 Training and Qualifications for
Well Control Equipment and Techniques for Wire line Operations on Offshore
Locations Sec. 2.2 (c)
API 51 Onshore Oil and Gas Production Practices for Protection of the Environment,
Sec 6.1.8
IADC HSE Case Guidelines Part 2 Land Drilling Units, Issue 1.0, October 2007, Sec
2.2.4.3 Competence Assessment and Records

Criteria:

Page: 20 / 22
Audit Report
Detailed Non Compliance Findings Actual Possible
Score Score

"Personnel should be trained in basic well control, as needed, in relationship to their


jobs."
"To demonstrate that personnel have the necessary knowledge, skills, and abilities
to meet their responsibilities and perform their job safely and effectively."
"Establishing arrangements for identifying both the general and specific ( e.g. well
control, fire team leader, etc.) competencies required to meet the responsibilities for
each job function."
"Maintaining records of each assessment and appraisal."

Consequence Analysis:
Inability to properly handle or respond to a well control event resulting in a blowout
16-0-2 Do other crew members have certificates of well control training for their positions? 0.00 / 5.00
( Repeat Finding )
No
REF:
American Petroleum Institute Specification 54 Recommended Practice for
Occupational Safety for Oil and Gas Well Drilling Servicing Operations, Sec 6.1.3
American Petroleum Institute Specification PI T-6 Training and Qualifications for
Well Control Equipment and Techniques for Wire line Operations on Offshore
Locations Sec. 2.2 (c)
API 51 Onshore Oil and Gas Production Practices for Protection of the Environment,
Sec 6.1.8
IADC HSE Case Guidelines Part 2 Land Drilling Units, Issue 1.0, October 2007, Sec
2.2.4.3 Competence Assessment and Records

Criteria:
"Personnel should be trained in basic well control, as needed, in relationship to their
jobs."
"To demonstrate that personnel have the necessary knowledge, skills, and abilities
to meet their responsibilities and perform their job safely and effectively."
"Establishing arrangements for identifying both the general and specific ( e.g. well
control, fire team leader, etc.) competencies required to meet the responsibilities for
each job function."
"Maintaining records of each assessment and appraisal."

Consequence Analysis:
Inability to properly handle or respond to a well control event resulting in a blowout

Section Score: 20.00 / 35.00

Section Findings Total: 2/5

Audit Total Score: 870.00 / 1,150.00

Audit Compliance: 75.65%

Findings Total: 33 / 192

Page: 21 / 22
Actual Possible Actual Desired
Section Section Header Score Score Compliance % Compliance %

1 Job Procedures 10.00 20.00 50.00 % 100.00 %

2 Power Pack 25.00 30.00 83.33 % 100.00 %

3 Accumulator 185.00 260.00 71.15 % 100.00 %

4 Blowout Preventer 185.00 275.00 67.27 % 100.00 %

5 Choke 0.00 0.00 % 100.00 %

6 Gas Separation 0.00 0.00 % 100.00 %

7 Inside BOP, Back Pressure Valves 55.00 65.00 84.62 % 100.00 %


and Floats
8 Control Console 30.00 40.00 75.00 % 100.00 %

9 Access Window 0.00 0.00 % 100.00 %

10 Pipe Guides 20.00 20.00 100.00 % 100.00 %

11 Stripping Rubber 30.00 30.00 100.00 % 100.00 %

12 Rental Equipment 0.00 0.00 % 100.00 %

13 Tripping Procedures 20.00 20.00 100.00 % 100.00 %

14 Drills 0.00 5.00 0.00 % 100.00 %

15 Unit Specifications 290.00 350.00 82.86 % 100.00 %

16 Crew Training 20.00 35.00 57.14 % 100.00 %


Totals 870.00 1,150.00 75.65 % 100.00 %

Rating Scale:
90 - 100: Industy Leader
80 - 89: Average Performer
70 - 79: Exercise Caution, Mitigating and Corrective Action (CAR Closure)to be implemented immediately
0 - 69: Re-evaluate use of this contractor and/or implement strict controls
Caution, Mitigating and Corrective Action (CAR Closure)to be implemented immediately

Page: 22 / 22