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Audit of working environment, logistics, maintenance management, electrical installations and safety systems - Haven

During the period 1–2 March 2011, the Petroleum Safety Authority Norway (PSA) conducted an audit of the jack-up hotel facility Haven, while it was docked at Nymo's premises in Eydehavn. The activity covered the technical disciplines working environment, logistics, maintenance management, electrical installations and safety systems.


The audit is part of the PSA's processing of OSM Offshore AS' (OSM's) application for an Acknowledgement of Compliance (AoC) for Haven.

Objective
The objective of the audit was to follow up the quality of executed conformity measurements of technical matters as well as, through audit of certain selected areas, ensure that the facility is built in accordance with applicable requirements in the petroleum regulations.

Result

Working environment
Since commissioning of the facility had not been completed, much work remains to fully verify the individual working environment conditions vis-á-vis the applicable requirement basis.

The audit identified nonconformities related to difficult materials transport in several areas inside and outside the living quarters. This is mainly due to high thresholds which complicated transport with trolleys.

Clear requirements could not be established for information presentation on screens in the control room. Some screens were difficult to understand due to unfortunate use of colours. The control room lacked flexible lighting as required by the regulations.

MMI verifications have yet to be carried out in the control room. We found a number of ladders without self-closing gates and, in several areas, access routes did not satisfy the requirements for necessary width and height.

The recreation area for smokers was located directly adjacent to the smoke-free recreation area. Smoke can thus enter smoke-free zones.

Unfortunate circumstances were identified relating to the design of some areas, with a view towards preventing that employees are exposed to hazardous chemicals.

Logistics
During the audit of logistics, which concerns materials handling, lifting appliances, lifting equipment and safe use of this type of equipment, nonconformities and improvement items in relation to the regulations were identified. The circumstances are mainly related to deficient commissioning of facilitation for safe materials handling.

The materials handling study is still underway and it has still not been decided how all materials handling will be carried out. Identification and evaluation of needs and solutions, and implementation of design, fabrication and installation remain. A schedule for commissioning was not available.

Observations are also related to deficiencies in the design of loading and storage areas for provisions and helifuel, and materials handling using the knuckle boom crane installed on top of the office module.

Preparation of the overview of permanent lifting points, lifting equipment and lifting appliances as well as certification status had not begun, with the exception of the pedestal crane.

Maintenance management
The audit was carried out in the form of verifications, random checks on the facility and storage areas, review of the company's governing documents and procedures, as well as conversations with involved personnel.

Circumstances related to training/familiarity with the STAR maintenance system and the history of initiated equipment was also verified. We had no comments regarding this.

During the audit, several nonconformities in relation to the regulatory requirements, in addition to nonconformities in relation to the company's own governing documents and procedures were identified. This applies particularly to the area of preservation.

Electrical junction boxes were open and exposed to grinding dust at the same time as installation work was underway close to this equipment. Some of these junction boxes were live. The probability of a short circuit, followed by a fire, can be significant in such situations.

In addition, we noted that previously identified circumstances from other audit activity by the PSA had not been carried out as described in the feedback from the company, cf. Item 5.4.3 in the letter dated 13 November 2009.

As mentioned during the summary meeting, deficient preservation could cause major financial consequences in that new, unused equipment must be replaced before it can be used. In addition, the project could be delayed, as well as planned use of the facility in accordance with specified plans.

As regards other matters regarding maintenance management, we see that there is still some work remaining, e.g. relating to tagging and loading of maintenance data in STAR.

During the audit we also observed that some equipment was installed and did not appear to be maintenance friendly.

Electrical and safety systems
Over the last year, several analyses and calculations had been carried out, which had resulted in modifications of parts of the electrical systems, which is assumed to have contributed positively to providing more robust solutions. The technical quality of some of the electrical work, which was carried out before the facility came to Norway, was not satisfactory. Therefore, work was underway to remedy some of these weaknesses.

During the verifications of some of the design documents, we noted that the requirements had not been safeguarded in all areas. In particular, we would mention the firefighting system on the helicopter deck and associated tank system for helifuel.
As regards fire detection in the engine room and the philosophy for shutdown of the emergency generator, we identified weaknesses that require additional investigation.

Some work was underway on board on commissioning the systems, but so far, little equipment had been tested. Preparation of commissioning procedures was underway. Verified procedures showed deficiencies as regards testing of performance requirements for some systems.