Total SA

OPS/FP/MTH

To : C. RICHARD – TOTAL E&P Indonesia From : Philippe BOURDEAU – FP/MTH

Copy :
B. LUDOT – FP/DIR
G. DULOUT – FP/DIR
M. RYAN – FP/MTH Date : November 28th, 2014
L. VERVYNCK – FP/OFP
P. CUISNIER – HSE
J. BANNERMAN – HSE

Subject : DrillSAFE Audit report / Total E&P Indonesia /

Transocean Rig Constellation 1

1. Summary
The mission for the DrillSAFE Audit in Indonesia took place from 22nd of October to
12th of November 2014 onboard the Jack up rigs Transocean Constellation 1 and
Apexindo Raniworo then the Apexindo Swamp barges Yani and Maera.
This report is related only to the Constellation 1. The rig is a Friede & Goldman JU
2000 Jack-up with 548 ft x 3 legs built in 2003 and with a 3000 HP capacity.
The DrillSAFE Audit is a non-intrusive audit which focuses on Well Control
Equipment, Procedures and Practices. The objective is to evaluate the level of
compliance of our operations with the Company Referential and the Industry
Standards.
The list of points, which do not conform to the references used, is attached with
recommendations. The points are classified per degree of importance: Critical / Major
/ Minor. This list is sent to the Affiliate in an Excel format to be used as an action
follow-up list.
2. Conclusions
The audit was seriously considered by Total E&P entity and Transocean. A very good
participation was observed from all of the Transocean Supervisors onboard.
It has to be noted that there is a BOP Engineer onboard the rig as permanent staff
which is beneficial in all aspects related to well control equipments; documentation,
certification, rig order, stock mini/maxi, historic, specification, preventive
maintenance follow up, etc. The BOP Engineer has been available anytime when
required during the audit and has shown a reel interest for the survey.
An excellent communication between the Contractor and Company Representatives
was noted. The debriefing onboard was fruitful and attended by Total Company Man
and Transocean rig management. The last debriefing took place in Balikpapan with
Drilling Manager, Heads of Departments, Drilling Superintendents and Methods
Engineers. The time spent was also successful as we had time to review in detail the
list of points and especially the ones related to the BOP, pod control unit, rigid control
lines then HP closing unit’s function.

The global evaluation is considered as satisfactory.

It was noted that the documentation onboard was correctly filed, PMS system loaded
with the WCE up to date with traceability of the equipments, parts, rubbers and
historic plus planned next inspections duly prepared.
The software used for the management of the spare parts was found very proficient
with the possibility to search urgent part(s) required around the entire Transocean
fleet. The stock onboard for the WCE was found satisfactory and spare parts were all
found to be from OEM. Rubber parts were properly stored and labeled with date of
validity, T° rating, date of reception, etc.
Test procedures of BOP, HP closing unit, choke manifold, safety valves are well
established, tests are reported and filed.
Due to the complexity of the BOP set up for a surface stack with pod control unit,
HP closing unit without master control panel, remote panels, interaction between
valves (choke manifold) it is important that the new comers (Assistant Drillers to
OIM) get a proper induction upon arrival and have a comprehension of the system
as it is not a common system on a surface BOP stack.

As the system includes a single control pod unit next to the BOP and only one
operating manual function (shear ram) on the HP closing unit, it is recommended to
perform a risk assessment:
- to determine the real level of redundancy in controls,
- what can be done to secure the well in an emergency (black shut down, PLC
problem, control pod unit malfunction and position, absence of master panel at
HP closing unit, etc) and
- the impact of equipment exposure in an hazardous zone.

3. Main points
Findings: 16 (Critical = 3; Major = 5; Minor = 8)

Main findings:
- Master control panel at HP closing unit can only operate shear rams manually
(4 way valve)
- Pod control unit and hard piping control lines not fire proof as per API 16D
requirement for surface stack set up
- Presence of Weco unions (instead of flange connections) downstream ball
valves on diverter vent lines
 BOP stack set-up at time of audit (for reference):

Hydril 18-¾ x 10K Annular

Hydril 18-¾ x 15K stack

4. Follow-up of findings:
The list of points must be reviewed with the Contractor and a plan of actions decided.
It is requested to the affiliate to send, on a quarterly basis, the updated action list of
the rig showing all the remedial actions that have been realized or launched. This
action list shall be integrated in the Rig Action List (RAL) as required in the CR EP
FP 320 rule 12.
This action list (and any related correspondence) shall be addressed to the mailbox:
[email protected]

Rig auditor: Thierry VINAY

Appendix A: List of findings on Constellation 1

Appendix B: DrillSAFE Terms of Reference

 Appendix A

List of findings / Constellation 1

 Contractor:
Affiliate: Total E&P Indonesia Transocean
Date of audit:
Rig: Constellation 1 5-8 November 2014
Issued: 25/11/2014 Updated:
Action list following DrillSAFE audit
Criticality Actual status / Recommended
actions Status of Date of
Item Expectation References (C=Critical; Action decided
M=Major; action completion
m=Minor)
Vent lines will be monobore, as straight as possible, CR EP FP 452 / 7.2.1 Weco union at diverter lines are not allowed because
reinforced on any bent parts, strongly the diverter piping will tend to whip and vibrate during
fastened and slightly sloping down to avoid blockage. a shallow gas situation. Flanged connections are
1 Quick connections on vent lines are not allowed. C required to secure for erosion, flow resistance, fluid
solid settling points, and associated back pressure.
Weco union shall be replaced by flange
connection
Thickness of the diverter lines shall be >0.75” CR 452 / 7.3 Thickness >0.75” shall be confirmed
2 C
Control systems for surface BOP stacks shall be API std 53 / 6.3; CR There is no master control panel on the unit. Only
designed, manufactured, and installed in accordance 440 / 7.2.1; CR 440 / shear rams can be operated from the master control
with API 16D. API std 53 / 6.3. See API 16D 5.1 d; The 7.3.1 panel. For surface stack, the primary control system
hydraulic control unit with the master control panel (master control panel) is considered as the main
shall be located in an easily accessible safe non- BOP control system which allow performing all of the
hazardous area, protected against dropped objects BOP functions by manual activation. The system
3 and fire. Control panels located: one in DMC (air or C onboard does not comply.
electric), in addition to the master control panel at
the hydraulic unit. Offshore, a 2nd panel in a safe
area (T/P office or on the tender in case of platform
tender assisted mode).

Original certification package by the OEM holding CR 440 / 10.1 Original certification package could not be found
a valid API monogram, API manufacturing and shall be provided for the Diverter
documentation, NACE certification including raw
4 material traceability shall be provided. M
Manufacturers must provide full traceability of WCE
and spare parts.

Two valves shall be mounted directly on the BOP API 53 / 6.2.2 There are adaptors 4 1/16 to 3 1/16 between
5 side outlets. One of these two valves shall be M valves and outlets.
remotely controlled.

All rigid or flexible lines between the control CR 440 / 7. 2. 3; API Pod control unit and control lines shall comply to
system and BOP stack shall meet the fire test std 53 / 6.3.11.2.5 API 16D for fire test requirement. Power and
requirements of API 16D, including end connections, communication at pod control unit shall be
6 M
and shall have RWP equal to the RWP of the BOP confirmed Hazardous area Class 1 Div 1 Zone 1.
control system.

Choke manifold; Two gate valves shall be directly CR 440 / 6.3.2 There is only one valve upstream of each choke.
7 upstream of each choke. M

Page 1
 Contractor:
Affiliate: Total E&P Indonesia Transocean
Date of audit:
Rig: Constellation 1 5-8 November 2014
Issued: 25/11/2014 Updated:
Action list following DrillSAFE audit
Criticality Actual status / Recommended
actions Status of Date of
Item Expectation References (C=Critical; Action decided
M=Major; action completion
m=Minor)

Casing / drill pipe pressure gages and pump stroke CR 440 / 6.3.2 There were no pressure gauges / sensors at the
counter shall be installed at the choke manifold manual choke line. There is no pump stroke
8 enabling a kick to be controlled from the manifold M counter installed.
whatever choke is selected.

Buffer chamber to provide exits to: mud return CR 440 / 6.3.2 Direct exit from buffer to the stripping tank is
system, MGS, horizontal flare (onshore), burner recommended.
boom(s) and overboard line (offshore). Exit to
9 m
stripping tank is recommended. Exits must have
same WP rating as downstream part of CM.

Adequate spacing (between UPR and BSR) shall be CR 440 / 4.1. Possibility of 5” at middle rams & VBR at lower
provided to be able to hang-off the string and shear rams shall be reviewed to optimize hang-off using
the drill pipe above Tool Joint. The BOP outlet below fixed rams
10 the lowermost ram is a potential single point failure. If m
it gets washed there is no other means to secure the
well.

MGS; The design and specifications of such CR 440 / 9.1 The engineering calculation and performance /
equipment should comply with the API SPEC 12 J. limitation / max. gas flow venting could not be found
on the original documentation and shall be
11 m
requested to the manufacturer. Compliance with
API 12 J to be provided.

Analog pressure measurements shall be made at API Std 53 / 6.5.3.6 A low pressure gauge with an isolation valve
12 not less than 25 % and not more than 75 % of the full m shall be added to the gauge 20 000 psi
pressure span of the gauge.

Drawdown test format shall be reviewed to match API std 53 and CR An overall hydraulic control unit and accumulator
with API std 53 and CR 440 & 441 requirements 440 & 441 function and pressure test includes: Switch on/off
test, Depletion test, Emergency test (not
13 m systematically), Residual pressure after hang off &
closing BSR (not systematically). Refer to proper
format given in Rig Tool Box.

Emergency battery pack (UPS) to supply electric CR 440 / 7.3.1 As per documentation the emergency battery
power to operate the BOP CS (when electrical type) pack is for a 3 hours duration.
14 for up to 24 hours. The battery pack shall supply m
power to electric control panels (API requires 2 hours)

Page 2
 Contractor:
Affiliate: Total E&P Indonesia Transocean
Date of audit:
Rig: Constellation 1 5-8 November 2014
Issued: 25/11/2014 Updated:
Action list following DrillSAFE audit
Criticality Actual status / Recommended
actions Status of Date of
Item Expectation References (C=Critical; Action decided
M=Major; action completion
m=Minor)

Pressure gauges / sensors made up with WECO Reco FP/MTH Weco connection's shall be confirmed to be sour
unions are not recommended. Gauges / sensors gas. One "T" piece x 2 in. X weco connection at one
15 flanges are preferred. m of the pressure sensor connection shall be integral
better than welded (see photo at debriefing slides).

All chokes to discharge directly into a 3” ID erosion CR 440 / 6.3.2 As per documentation they are spacers only.
16 nipple (referenced in API as a wear nipple) at least 3 ft m
long and 1-1/4” thick.

Page 3
 Appendix B

DrillSAFE Terms of Reference

 DrillSAFE Audit
Terms of Reference

Introduction
The DrillSAFE audit will concentrate on Well Control Equipment, Procedures and Practices.
The Rig Audit Team (FP/MTH/SOA) will perform the audit. The audit will be managed
around the ongoing rig programme and conducted according to Company Standards.

Objective
The objective is to assess the level of compliance with Company Rules and Industry
Standards in force on Rig(s) and referenced in well programs of the affiliate’s FP Entity.

References
1. The compliance with the following Company Rules shall be thoroughly verified:
CR EP FP 440: Well Control Equipment
CR EP FP 441: Pressure and Function Tests of Well Control Equipment
CR EP FP 443: Well Control Procedures
CR EP FP 452: Shallow Gas (if applicable)
CR EP FP 471: Safety reserves of mud products and mud volumes
CR EP FP 250: HSE training for Drilling & Well operation personnel (Well Control
training part only)

2. The implementation of lessons learnt from recent Industry’s major well control events,
which were communicated recently for immediate application, shall be verified
(reference to memo “How to further improve the Safety of our Operations” addressed
to all affiliates by FP/DIR on February 22nd, 2011)
Note that these lessons are under process of being integrated in Company Rules and
are considered as such.

3. The application of Industry Standards, for all aspects not specifically addressed in
Company Rules (see note below), shall be assessed. The considered Standards include
API Specifications 16A/C/D, API Recommended Practices 53/59/64 and main
Recommendations part of above Company Rules. This part will bring a qualitative
evaluation of follow-up and preparedness of Drilling Contractor (and Company) in all
aspects of Well Control.

Note:
Reference to CR EP FP 440 / § 2.2:
“The minimum requirements are dictated by the API RP 53 standard. This rule retains
the main points of this standard but aims to highlight any specific points that diverge
from API or are more stringent. Points not addressed shall be in accordance with
the API standard.”

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 DrillSAFE Audit
Terms of Reference

Scope of Work
The audit will be non-intrusive. The main requirement is to have the BOP and control system
rigged up at time of audit. Specifically the audit will cover, but not be limited to, the
following:
• BOP and diverter equipment and control systems
• Well control equipment such as choke manifold, kill & choke lines, degassers, trip
tank, drill string safety valves and inside BOPs, etc
• Secondary and emergency equipment and control systems (when applicable)
• Well control equipment spare parts, inspections and maintenance
• Well control documentation including: manufacturers manuals, inspections and
certifications, drawings, records of maintenance, repairs and function/pressure tests
• Well control drills. Drills shall be initiated during the audit at discretion of
auditor(s) and if compatible with the ongoing operations
• Safety stocks of mud and bulks
• Standard Operating Procedures and Policies relative to well control
• Emergency procedures relative to well control
• Well control certifications of key personnel
• Approved derogations being subject to conditions

Preparation of Audit
1- To ease the unfolding of the audit and maximize the efficient time spent on the rig, it is
highly recommended to make the following documentation easily accessible in advance:
- Fully detailed drawings of the BOP (general arrangement, BOP rams space out),
choke manifold and BOP control system on the rig, including diverter and diverter
control system (Contractor)
- BOP & Well Control Equipment (WCE) and Well Control System (WCS)
documentation and certifications, including Diverter and Diverter control system
(Contractor)
- History of BOP, WCE and WCS previous tests and last 3-5 year re-certification tests
(Contractor)
- History of BOP, WCE and WCS maintenance records (Contractor)
- Documentation / certification(s) to prove that all the drill pipes used on rig (including
landing string) can be cut with the shear ram(s) fitted in BOP (Contractor)
- Standard Operating Procedures / Policies relative to Well Control, Well Shut-in, DP
shearing, BOP, WCE and WCS testing (Contractor and Company)
- Well Control related forms (kill / calculation sheet, driller's instructions to be posted,
trip sheet, etc) (Contractor and Company)
- Standard Operating Procedures / Policies relative to Well Control drills and personnel
training (Contractor and Company)
- Well Control certifications of Key personnel (Contractor and Company)
- A recent and typical Well Programme applied on the considered rig (Company)
- The last versions of HSE-MS Bridging Document and BOCP (Company)

2- The presence of Contractor’s qualified Engineer(s), to provide assistance to the auditor(s)

during the audit, is highly expected (mainly for Subsea BOP)

DrillSAFE_Terms_Reference Rev2 / Sep 2012 Page 2 of 3

 DrillSAFE Audit
Terms of Reference

End of Audit debriefing

A debriefing will be organized onboard prior to leaving the rig, to ensure that all findings are
relevant and agreed.
A meeting will take place after the audit in FP Entity Offices. The main findings will be
reviewed and, as a minimum, all the Critical points (if any) will be communicated by the
auditor(s).

Reporting
The Rig Audit Team will produce a report to the Affiliate’s FP Entity at the earliest possible
date, and not later than two weeks after the completion of the audit.
The report will include:
- The level of compliance for each topic considered and the global score.
- A detailed description of the non-compliant points of Company Rules. To produce a
risk profile of the deficiencies found, these points will be categorised into their
potential affect (Critical, Major and Minor).
- Recommendations for improvement as per assessment of Standards.

Definition of Categories:
Critical:
Relates to a serious failure of equipment, system, procedure or practice which has the
potential to compromise a well control situation and ultimately may cause injury to
personnel and/or damage to environment. Requires immediate action.
Major:
Relates to a significant failure of equipment, system, procedure or practice which has
the potential to cause capital equipment downtime or adversely affect a well control
situation. Must be addressed as soon as reasonably practicable within operational
constraints.
Minor:
Relates to an equipment, system, procedure or practice defect which cannot be
categorised as above and which does not meet the requirements of the referenced
Rules and Standards. Should be addressed within the routine maintenance
activities and procedures.

Audit Follow-up
Findings shall be integrated in a register for action tracking. Progress shall be communicated
to FP/MTH/SOA every quarter and reviewed on an annual basis during TCM.
All correspondence relative to Rig Audits & Inspections shall be addressed to the specific
mailbox: [email protected]

Rig Audit Team (FP/MTH/SOA)

DrillSAFE_Terms_Reference Rev2 / Sep 2012 Page 3 of 3