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Report following audit of the hotel facility Service Jack 1

The Petroleum Safety Authority Norway (PSA) has carried out an audit of Service Jack 1 which according to the plan will be used as a hotel facility on the Ekofisk field starting in the autumn of 2010. The audit identified several nonconformities and improvement items.


Service Jack 1 is being built at the Drydock World shipyard in Batam, Indonesia. Service Jack 1 will travel to Norway in the spring of 2010 where new deck cranes, an office module and a larger living quarters module (ALQ) will be lifted onboard the installation.

The completed facility will, according to the current plans, be put into service as a jack-up hotel facility (Jacktel) on the Ekofisk field in the autumn of 2010.

The project is called the JackTel project.

During the period 20 August to 27 August 2009, the Petroleum Safety Authority Norway (PSA) carried out, in agreement with O S M Offshore AS (OSM) as the future AoC applicant, advisory services and early phase follow-up within the technical disciplines technical safety, crane- and lifting operations, working environment and maintenance management related to engineering and construction of the jack-up facility Service Jack 1.

Service Jack 1 is being built at the Drydock World shipyard in Batam, Indonesia. Service Jack 1 will travel to Norway in the spring of 2010 where new deck cranes, an office module and a larger living quarters module (ALQ) will be lifted onboard the installation. The completed facility will, according to the current plans, be put into service as a jack-up hotel facility (Jacktel) on the Ekofisk field in the autumn of 2010. The project is called the JackTel project.

The audit mainly targeted issues related to the management and technical aspects of the Jacktel facility, as well as engineering and arrangement of deck cranes and a new living quarters module (ALQ).

The activities were carried out in the form of interviews and document review at Master Marine's project offices at Lysaker in Oslo, as well as at Drydock World/Master Marine's project office in Singapore and at the Drydock World shipyard in Batam, Indonesia. A subsequent clarification meeting was held at the offices of the PSA on 22 September 2009 related to some issues concerning layout.

The activity will be included as part of the administrative procedure for the future application for an Acknowledgement of Compliance (AoC).

Background
These follow-up activities are regarded by the PSA to be part of a future administrative process for an application for an AoC. OSM will according to the present plans apply to the PSA for an AoC for the facility in the spring of 2010, in connection with a planned operation for ConocoPhillips (COPSAS) on the Norwegian continental shelf. The AoC will be included as part of the documentation in COPSAS' future application for consent for the use of the facility as a hotel facility on the Ekofisk field.

Purpose of the audit
The objective of the activity was primarily to contribute to increasing the understanding of the regulations in the project by providing guidelines and information on some of the challenges which the PSA has experienced during the administrative procedures for previous applications for an AoC for other new-build projects. We have seen the utility value of providing such advice, particularly to new players who are building new facilities at shipyards with little or no experience of Norwegian regulations.

Apart from providing advice, the objective of this activity was to assess established management systems which Master Marine and OSM have used to ensure that technical aspects of the facility, within selected technical disciplines, are maintained according to the applicable regulatory requirements. The activity has included issues related to both engineering, fabrication and final completion of the facility.

Result of the audit
A review of Master Marine’s and Drydock World's management systems uncovered that many project documents were only issued with the document status WO (issued for review or IDC). The degree of completion of the governing documents was only to a limited extent in accordance with the completion degree of the project (progress).

The activity identified that scheduled audits had not been carried out according to the plans of the project. Of a total of 14 scheduled activities, at least six activities had not been carried out.
Furthermore, uncertainties regarding the status and use of various procedures in the project were identified.

Working environment
A lack of preparation of a working environment program to manage working environment activities, as recommended in the guidelines to the regulations was identified. In general, the project has initiated working environment analyses according to the recommendations in the regulations, but several of the analyses required further follow-up, as a number of issues had not been clarified at the time of the analysis. An organisation and staffing study to specify the staffing level and the extent of the activities in various areas on the facility could not be produced. Such information is necessary to carry out other working environment studies, for example noise prediction for 12-hour noise exposure for individual groups of personnel and chemical risk assessment studies for various personnel groups.

For handling of materials, a ”Material Handling Report”, which will constitute a good basis for achieving good material handling on board the JackTel, had been prepared and the document meets the intentions of the regulations to a large degree. This applies in particular to the facilitation of the cargo deck area and storage deck area for use with offshore cranes. However, during the audit we identified that some obstacles had been built and that the ceiling height was low in some transportation routes. In addition, improvement items were identified, which mainly concern the design of the cargo deck area, lifting through hatches and the design of hatches. However, these are still in the design phase, were being assessed and accordingly not completed.

Maintenance management
Within maintenance management, we noted that a final decision regarding the choice of a future maintenance management system had not been made. One consequence of this could be that the maintenance system will not be fully developed and operational for start-up on the Norwegian continental shelf.

For the safety systems in general the preparation of the strategy for fire and explosion protection as well as philosophy documents for the individual systems were being prepared, partially at the same time as the detailed engineering of the systems. The revised documents showed that the regulatory requirements in general had been complied with, but that there were minor nonconformities or improvements items in some areas in relation to the requirements in the regulations. In this regard we noted that although the company in general applies Section 3 of the Framework Regulations and maritime regulations, NORSOK S-001 was used in a few instances without documentation that the requirements in the Norwegian Maritime Directorate’s Fire Regulations had been complied with.

We noted that the recruitment of operational personnel who will work on the facility was slow to get started. At the time of our activity only three of a total of 66 persons had been recruited. This can result in challenges as regards ensuring that the personnel receives the necessary familiarisation and training, and ensuring that the necessary operating experience is considered during the in the construction and completion phase.

Clearer guidelines for safeguarding employee participation in the project were called for.

Observations
Please note that this report does not provide a balanced general impression of the condition of the facility and the work in the project. The purpose of our report is only to provide feedback on circumstances which require further attention from the project.

Management systems

Working environment

Logistics

The use of cranes is not a suitable means of opening hinged hatches as these easily can be ripped from their brackets. In addition, shafts must be designed for lifting and designed without obstacles that may cause the cargo getting hooked or cause the cargo to tip and fall down into the shaft.


Maintenance

Safety systems