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Thank you for spending your afternoon with me yesterday at Rig 44. I also want to thank you for the invitation from
your Senior Manager, Mr Ali Rauf, to meet with you later this week at your Bardjazia camp. I accept the invitation,
and would like to take this opportunity to summarize the key elements of what I propose to discuss with you.
Summary
• General Impression
• HEMP – Hazard Effects Management Process [Hazard and Risk Register – to cover full scope of work]
• HSE & Q Competence
• Emergency Response Planning and Readiness
• Communication – [internal organization and external – co contractors / client]
• The Human Condition
• The Quality Consideration
The initial objective of the gap analysis exercise was to assess the management of HSE
aspects, in the real-world, on-site operations of IDC, [including rigs where IDC are using
Project Management contractors for support]. This became urgent, in the wake of an alarming
number of HiPo incidents, and continuous reports of high risk behaviors and conditions by way
of STOP or HOC cards, ZFOD team feedback, and obviously poor PMS [Preventative
Maintenance System] indicators. However, once the site visits began, it became clear there is
a significant Quality aspect that is stark by its absence. NPT – non productive time, is reliable
and serious indicator of this fact.
Recent meetings with IDC HSE representatives, provided an understanding that IDC are
committed to obtaining ISO 9001 certification for their management system. There is no
evidence that a ‘work scope specific’ Hazard and Risk Register [Aspects & Impacts – ISO 14001
Environmental Standard] is in place. This is the foundation of any Management System that is
genuinely committed to provision of a quality service to clients, and the process of continual
improvement. There is little REAL evidence of commitment to continual improvement, and
attention to the clients requests. Significant improvements at the rig sites in HSE [and Q] will
not be sustainable without significant improvements in the IDC support systems – Human
resources, competence and training, preventive maintenance, stores and supplies / inventory
management etc.
Communication - Organization
1. Separation of departments – IDC organization is not working together – there is no
sense that the success of IDC as a national organization, depends on the cooperation of
all departments, working together for the benefit and improvement of the company
2. Hierarchy of decision making on critical Loss Prevention [includes HSE and Quality]
aspects – suggestions from site personnel to senior management / logistics support
teams, are regularly ignored or over ruled, does not seem to matter if it comes from
OiLSERV, Heston, Sakson or IDC.
2|Page David Perkin – eni Well Ops HSE
3. Equipment ordered to execute specific operations does not get delivered / or is not in
stock or available – possibly the warehouse people don’t understand the importance of
location specific inventory management, or the members of the supplies / warehouses
do not know their own stock.
4. When senior management and support teams [electric or mechanical maintenance,
stores and supplies] deliberately ignore or reject requests from the field, they are
putting the field line team, whether IDC or the Project Management reps, in an
impossible situation, forcing them to execute work with unsafe equipment, or
conditions.
5. Failure to collaborate in this complicit unsafe practice, and the resulting unsafe
conditions, has been reported by IDC persons, as reason for removal or change of job
and responsibility [the clear message from IDC management is, don’t make trouble].
6. There is still a strong negative understanding of the value and application of HOC / STOP
card system. Participants [including Project Management reps, including senior IDC
person on location] have been threatened and bullied to the point they do not/will not
participate. This is a major reason why Line Managers must lead by example in this
programme.
7. The ‘Safety Law of SOC’ provides clear language and guidelines that empower line
managers to take action with employees who will not obey the mandatory rules of Safe
work. Employees who are not acting in a safe way, using the designated safety
equipment, following safety rules, can be dismissed from the location, with no
salary/wage for the day. The law is there, it MUST be communicated, applying discipline
if necessary, to see the workforce change behavior.
The assessment is bleak. However there are good people working for IDC and the
management contractors. They do care, and they do want to improve but there is a sense
from them that it is hopeless. Unfortunately the good people, with the best will in the
world will not be sufficient to make any substantial improvement if the status quo in the
large organization that surrounds them, does not change significantly. If they are provided
the tools and support they need they can begin to make a difference.
The significant changes – that will make a profound and lasting difference – are required in
the whole organization, in the way management think about doing their business. All of the
failures are a reflection of a management system that is not working, a work environment
that is not healthy. The necessary ‘cultural’ improvements must happen across the
organization . . . anything less will not be successful, it will be akin to treating lung cancer
with aspirin.
The value of each workforce at each rig becoming one team, where every member is
respected and valued, is a powerful and effective improvement. To achieve the most
positive outcome, there MUST NOT BE an opportunity for the more experienced and senior
people who may work for us and raise their competence in the improvement plan, to be
‘poached’ to a different location or project for another Client, letting the local situation
return to the previous unacceptable level.
Such incomplete implementation will seriously dilute the overall improvement result.
The Gap Analysis exercise resulted in an assessment of how the HSE and Q conditions may
be realistically improved.
There are 10 basic Improvement Actions broken down into Short Term, Medium Term and
Longer Term.
All of them need action taken. Failure to implement the improvement actions will allow an
intolerable or critically unsafe condition to exist.
They are provided in the attachment titled 0.2 Proposed Improvement Actions.
The attached zip file has information / examples for valuable reference to the contractors
with information on available resources to help with the international certification, and the
training to deliver the competencies identified for improvement.
1. In the short term, the Company should consider the options to reassess how the competence
standard for the Project Management contractors representatives can be improved.
Ultimately the Company has the greatest interest in seeing well maintained, safe equipment
and operations and well trained competent people working on the rigs that drill and workover
the company’s wells.
However, if we are locked into a relatively long term Contract directly with IDC [3 to 4 years]
we must find a way to engage IDC to improve, with a change to the contracts that will allow
strong competent well site management to be professionally respected by IDC. Failure by IDC
rig site managers and IDC support base to demonstrate cooperation to address safety
concerns with timely action, must result in financial penalty when delays in the response to
the improvement actions, result in increasingly dangerous unsafe conditions.
Deliverable 1.1: IDC shall review their HSE Policy statement to ensure the Management
expectations are explicit and understood – all employees from Rig Managers to roustabouts,
are committed to deliver continual improvements in Safety performance. It should make clear
reference to the laws of IRAQ, and the compliance standards of the Ministry of Oil. Failure to
comply, will be treated with the disciplinary action that is explicit in the law. IDC senior
management must deliver this message personally to the wellsite, making it very clear that
any practicable recommendation for improving safety will be acted on, whether or not the
person making the recommendation is from IDC, ZFOD, eni, or Project Management
contractors reps. Company to be provided with
b. a copy of the minutes of a special Safety Meeting in which the message is specified,
and signatures of attendees, particular senior line reps from each rig will
acknowledge acceptance and understanding.
1st Action by Nov 30, 2012
Deliverable 1.2: Company [eniZFOD], ZFOD SOC, IDC and Management Contractors produce a
formal agreement letter – to be a contract record – clearly indicating the seniority of final
decision making on location, that rig management operations decisions will not be made that
increase risks from existing hazards to intolerable / critical levels. 2nd Action by Nov 30, 2012
Deliverable 1.2: Project Management Contractors must establish a more robust screening
criteria for HSE Competence for their ‘on-site’ representatives [the FIC and team, including
support]. PM contractors will notify Company by formal letters – to be a contract record –
what actions are planned to significantly raise the profile and attention to HSE matters by
their site representatives. 3rd Action by Dec 15, 2012
2. IDC and /or Project Management contractors will agree to provide a plan to develop,
commission, test, alarm systems to demonstrate ability to provide audible / visual alarms
David Perkin – eni ZFOD Wells Operations - HSE
sufficient to warn all workforce for any foreseen emergency. All rigs without functioning
alarms will be identified. H2S detection alarm equipment must be installed on rig operations
that are considered at risk. Plan will include details on practice drills to measure workforce
response.
Deliverable 2.1: Formal letters to Company from IDC each PM contractor – to be a contract
record – identifying rigs to be equipped and commissioned [includes training of the workforce
in response]
1st Action by: Oct 31, 2012
Deliverable 2.2: All rigs [for eniZFOD] equipped with alarms 2nd Action by: Jan 31, 2013
3. IDC and /or Project Management contractors will assess local training providers in the Basra
area, or regional centers and select key members from their site management teams,
Company Men, Rig Managers, Toolpushers, Drillers, HSE, Mechanics, Electricians to
attend/receive training in good industry practice basic HSE skills, starting with Hazard
Identification and Risk Assessment, and then specific training based on the top Hazards
identified earlier.
Deliverable 3.1: 50% of Identified Key persons on each rig, receive training /certification from
in country training centers, IDC will provide a list of selected persons / training dates
1st Action by: Mar 01, 2013
Deliverable 3.2: Balance of key persons trained for each rig 2nd Action by: Aug 31, 2013
4. PPE and protection equipment for workforce: IDC and /or Project Management contractors
must ensure that sufficient and appropriate PPE will be available for all credible work
scenarios. Face shields, goggles, welding helmets integrated with hard hats, rubber boots,
gloves and aprons suitable for mixing hazardous chemicals, or cleaning mud tanks etc, will be
available and provided without restriction to the relevant workforce. Furthermore, IDC must
install fit for purpose eye wash stations, and shower stations for all rigs. At a minimum, one
located on the mud tanks near the mini mud lab, a second eye wash station adjacent to the
main chemical & mud mixing hoppers, and chemical shower stations also adjacent to the main
mixing hopper.
Water supply must be clean, fresh, [potable would meet basic requirements]. Serious
consideration must be given to providing protection from the sun, which can quickly heat the
water to a point that using it could result in 1st degree burns, particularly for eyes. Shade
designs and maximum heat reflectivity [polished stainless steel or white paint for example,
and awning/tents would be examples of improvements]. IDC must recognize this is critically
important, and mandatory safety equipment on every rig in their fleet. Good practice would
see eye wash stations / capability installed in workshops, where grinding and welding
operations typically take place.
Deliverable 4.1: 100% compliance - each rig, will have the minimum suggested equipment as
indicated, immediately. 1st Action by: Nov 15, 2012
5. IDC and /or Project Management contractors will, develop an medical emergency evacuation
plan that is appropriate for the real potential serious injuries that can occur
[head/brain/spinal trauma, thoracic trauma, internal trauma, orthopedic trauma, burn
trauma, H2S gas]. Medical emergency evacuation response, must ensure that seriously
injured persons can be competently handled and transferred to an appropriate treatment
center and specialist within one hour of injury occurrence. Sufficient trauma management
equipment must be on hand, and the evacuation plan must be tested [critical injury scenario
drills from rig floor, cellars etc] to ensure all members and equipment are fit for purpose.
Deliverable 5.1: Medical emergency evacuation plan[s] developed, including drill scenarios
and schedules submitted for Company review / approval. 1st Action by: Nov 15, 2012
6. IDC will select key competent persons,[Chief Mechanics, Rig Managers etc] ideally bilingual or
multilingual [English plus] to complete Lloyds Register Moduspec Rig Inspection training, and
Preventive Maintenance Management [or equivalent] in order to have in-house competence
for assessing major Safety Critical equipment on each rig. [IDC should recognize it is in their
interest to not limit this improvement to support teams of the rigs working for ZFOD].
It is very much to the benefit of IDC to have the earliest assessment of pending Safety Critical
failures, to anticipate and order the necessary preventive maintenance materials, or
replacement parts to ensure the equipment is operating at maximum efficiency and safely.
Routine rig inspections to be carried out with a frequency to be determined by rig condition –
perhaps monthly until the rigs are all fixed and operating properly, then less frequently.
Deliverable 6.1: IDC will submit a training plan and proposed training dates, identifying
competent people to be trained as Rig Inspection persons. – Training Plan w names
Deliverable 6.2: – Info - Persons trained 2nd Action– June 30, 2013
7. IDC Project Management must take positive action on the findings from the MODUSPEC
inspections from 2 years ago, as well as the most recent inspections. This may be as many as
8 rigs, and there are many “Critical and Major” assessments. Review of findings from 2 years
ago, indicate little or no attention has been paid to them. This is a clear indication of a lack of
commitment to operate according to good industry practice and with a real commitment to
managing the work safely.
Deliverable 7.1: Moduspec Inspections outstanding actions checklists closed out.
– Schedule for execution submitted to Company 1st action– Nov 15, 2012
– Checklists with actions closed out and verified 2nd action– June 30, 2013
8. IDC and/or Project Management Contractors will select key competent persons [Rig
Managers / Toolpushers] for Person In Charge of lifting operations training. Alternatively,
subcontracting the services of a competent person from local/regional Contractors certified to
recognized good industry practice standards, that will provide this service, including the
inspection of all mobile lifting equipment, and accessories, and the attachment points for all
lifts.
Deliverable 7.1: Formal letter from IDC / and or Project Management Contractors to notify
improvement plan for Lifting competencies at well operations. Action by: Nov 30, 2012
9. IDC and/or Project Management Contractors will identify key competent persons
[Toolpushers / Drillers / Assistant Drillers /Derrick hands] for derrick rescue training. Target
requirement is two persons per tower/shift shall be qualified.
Deliverable 8.1: Training plan with the details of the training provider and course of
instruction. The names of 2 persons per shift / 4 persons per rig to receive this training.
Suggest one of the four persons is senior [Toolpusher] as they should be on location all the
time. 1st Action by Nov 30, 2012
Deliverable 8.2: At least one person per crew on tower is trained 2nd Action by Mar 01, 2013
Deliverable 8.3: Each rig has 2 x2 persons on tower trained 3nd Action by July 31, 2013
10. IDC will contract an international competent Risk Management Contractor [Risktec or
equivalent] to audit / assess IDC operations,
a. in the offices of Senior Management
b. in the logistics and support operations including
i. emergency response support [firefighting, oil spill, medical emergency]
ii. Contracts and Procurement [Contractor Management]
iii. warehouses
iv. parts depots
v. telecoms and IT support
vi. camps and welfare operations
vii. human resources
viii. transportation
c. drilling rigs
d. workover rigs
e. rigless operations
and prepare an improvement plan for development of an HSE & Q Management System, and
appropriate Safety Case for Land based drilling, workover, rigless operations in Iraq.
Deliverable 9.1: Formal letter from IDC to notify Company of the Contractor Mobilization date
to carry out the above approved Scope of Work. Action by: Dec 31, 2012
Deliverable 9.2: IDC present to Company the Improvement Plan/Schedule for implementation
developed by the Specialist Risk Management Contractor, and approved by IDC top
Management. Action by: Mar 31, 2013
Deliverable 9.3: IDC present to Company the final HSE& Q Management system, approved by
the Senior Management for implementation across Land Rig Operations in IRAQ.
Action by: July 31, 2013
Deliverable 9.4: IDC present to Company a schedule for the rollout [introduction to the
workforce and training for key users], adoption of the plan across the organization, including
the translation of work specific instructions, tools and rules, in Arabic for the benefit of the
end users – the work force. Verification by internal Audit Action by: August 30, 2013
To effectively complete the work proposed in this last deliverable 9.4, could easily take two years
or more, and will require serious commitment from senior management to see it implemented. It
will not be easy changing the culture of an organization where good industry practice has not
been known or applied for many years, if at all. This is a tremendous cultural challenge to
overcome. But the journey begins with the first step.
11. IDC / Project Management Contractors will contract an international competent service
provider [Moduspec example] to carry out Baseline survey of Safety Critical equipment on all
IDC rigs. Based on the surveys, an equipment inspection improvement plan, indicating
priority of actions, will be developed. The order of rigs to be inspected should be relative to
the planned work scope and the time frame. Action parties responsible, and time frame for
completion of the necessary improvement actions will be clearly defined.
Deliverable 10.1: Formal letter from IDC and/or Project Management Contractors to notify
the plan and schedule for specific rigs to be assessed by Moduspec. Action by: Jan 31, 2013
Deliverable 10.2: Formal letter from IDC and/or Project Management Contractors to inform
Company of the findings for the selected rigs including the /criticality/action plan with
accountable persons identified. Action by: July 31, 2013
Deliverable 10.3: Remedial actions from action plan, implemented and verified by Moduspec
[or competent person] on all rigs working for ZFOD Action by: Jan 31 2014