WE Report

Audits



SLB

No person selected

Report No.

8537
Maintenance review – DSY cement unit

Type of audit

External Audits
SLB

Auditee/Customer

SLB
OKEA

Date

2025/04/02

249 days ago

Findings

7
Number of findings

Status

Registered
External Audits


Maintenance review – DSY cement unit
Summary

Purpose:
Maintenance verification compliance towards NORSOK standard Z-008 (Risk based maintenance and consequence classification) of Deepsea Yantai Cement Unit for the Bestla drilling operations and the Vale PP&A operation.

Summary:
The review meeting was held in SLB premises with the attendance of all relevant discipline personnel to demonstrate and confirm the status of the topics covered by the verification scope.

The review team was received in a welcoming and positive atmosphere where questions were answered in an open and honest way. SLB had prepared a very good presentation that supported the verification scope and demonstrated a transparent overview and mutual interest to meet the requirements.

A safety moment was held at the start of the meeting addressing the significant impact sleep has on body and mind.
Encouraging all to prioritise between 7 and 9 hours each day to perform safely and sustainably.

The SLB team appreciated to be subjected to the 3rd party review by the Operator, which is not common.

A brief introduction to the upcoming projects Bestla and Draugen with key deliverables from a cementing standpoint was held.

SLB informed that this type of cross rental agreements between the cementing companies are common on the Norwegian Continental Shelf. SLB have a cement unit handover every 1-2 months, and they have good relationships with both Baker and Halliburton. The Baker Seahawk cement unit installed on DSY is known to SLB and they have experience with the model. All 6 senior cementers planned for the project have previous experience with the Seahawk unit. One of them has experience from DSY. SLB presented that competency is managed in three independent systems in the SLB; Step, Degreed and QUEST.

A mixing error incident in 2023 on Askepott with the same type of unit resulted in several weeks of downtime. When asked about this incident, SLB explained that they have good knowledge of cause and mitigations as this was openly shared by Halliburton who was operating the unit. This demonstrates that continuous improvement, through experience sharing is implemented between Halliburton, SLB and Baker. Whether this experience has led to a change of the maintenance program was on the other hand not known. SLB confirmed that non-productive time on the cement unit is investigated, where the maintenance organization is included to ensure that any learning from the incident will lead to an evaluation of the risk-based maintenance program. Failure mode analysis on equipment components will be initiated should an equipment component fail. Performance analysis of parts is thus used to updated and review the maintenance program.

SLB demonstrated statistics indicating that their focus on quality and technical performance in close cooperation with customers have resulted in significant improvements over the recent years. Non-productive time is reduced significantly from 941 hrs in 2022 to 97 hours in 2024, with 2 hrs of accumulated NPT currently reported YTD.

Equipment bulletins from 3rd party vendors are received by the maintenance manager. However, SLB does currently not have a system to ensure structurally report, manage and follow up those bulletins. It was agreed in the meeting that this is an improvement which should be implemented across the maintenance organization to ensure that equipment bulletins are managed and followed up with the necessary level of quality.

The SLB maintenance organization was presented from a roles and responsibilities view and the risk-based maintenance escalation philosophy outlined and explained with examples. Management of non-conformances and deviation, exemptions are controlled through the HSE standard. Deferred maintenance towards safety critical components falls under the exemption process which is a risk assessed and formally approved in the QUEST system. MOC’s are a non-risked assessed approval process in QUEST. The drilling contractor confirmed that the cement unit on DSY is not part of the IFS maintenance system, and that the maintenance supervisor receives a status of the cement unit maintenance. However, it was confirmed during the meeting that deferred maintenance, whether safety critical or non-safety critical is not communicated to the drilling contractor who has the overall maintenance ownership of the mobile drilling unit. Typical documentation that is shared and entered IFS is maintenance records. This concludes that the asset owner does not have a full barrier status overview on the mobile drilling unit and has no detailed knowledge what mitigating actions are defined during the exemption process to reduce the risk of overdue maintenance to an ALARP level. Agreed during the meeting that in cooperation with OD a document shall be prepared which defines the level of documentation which is required to be shared by the cementing service company on a weekly basis. The SLB team explained that the FMEA documentation for the Baker unit is made available for them, and that work is planned to incorporate the DSY unit into SLB CMMS, Maximo, based on these analyses and the recommended PM regime from Baker. Equipment service will be built up by Service levels SL0 – SL4 built from a reliability centred maintenance approach with PM detail and frequency adjusted to reflect expected failure data. Currently the DSY cement unit hierarchy is not part of the Maximo maintenance system, although SLB has operated the cement unit historically.
Provided that OKEA will commence operations with DSY in July 2025, the review team requested that a project schedule and allocated resources will be discussed regulatory to ensure that the maintenance program on the DSY cement unit meets the regulatory requirements and is in compliance with NORSOK Z-008.

SLB will implement Key Performance Indicators to monitor the maintenance performance of the cement unit. From the presentation it was however not obvious that Maximo is easily able to report overdue, and deferred maintenance status for planned and corrective maintenance work orders for high, medium and low criticality. As part of the mentioned level of documentation requirements the review team requested that those KPI’s as a minimum shall be made available to OD completed with approved Exemptions and MOC.

It was also observed that estimated work hours for preventive and corrective maintenance workorders are not defined in the maintenance system. The maintenance review team highlighted that overdue PM’s in itself are not representing a transparent picture of the overdue maintenance. To achieve a transparent overview of overdue maintenance, work hours shall be defined in the maintenance system to ensure that the correct actions will be taken to correct this.

An outline of the Audit regime was explained in the meeting, with annual QMS self-audits and HQ audits every 3rd year.
Quality verifications of SLB third parties are scheduled and managed by the SLB procurement organization based on criticality.
The SLB maintenance team could not demonstrate that the procurement team has any quality verifications or audits planned in 2025 towards third parties with critical deliveries of cement unit components.

Critical spare parts were also discussed in the meeting. SLB plan to be fully compliant with NORSOK Z-008 Risk based maintenance and consequence classification. SLB elaborated on the three levels of critical spare parts based on severity, occurrence and detectability.

Barrier strategy and performance standards were discussed as part of the agenda. SLB presented a general bow-tie approach and presented various SLB standards where performance criteria were defined. However currently SLB does not meet the performance standard requirement towards technical barrier elements on the cement unit as per Norsok Z-008 and Norsok S-001.

Conclusions:
Since SLB is currently not operating the cement unit on DSY, the review team is not able to define any finding as nonconformances towards regulatory and contractual requirements with respect to Risk Based Maintenance. Significant improvement suggestions have been observed during the review which, if not corrected in due time before the commencement date of the rig contract towards OKEA, will automatically lead to red risk non-conformities. As such those observations shall be corrected before OKEA starts the Bestla development campaign with DSY.

The full list of improvement suggestions and observations are listed below, as were discussed and agreed as follows below during the close-out of the meeting.

Findings

  • Improvement

    Open

    Open
    Deadline was:

    IS-1: Interface between SLB, Baker and 3rd party contractors not structurally managed.

    SLB received equipment bulletins from Baker and other 3rd party companies.
    SLB currently has not implemented a system to manage and follow up those bulletins in a structured manner.

    Implement a follow-up system for equipment bulletins.

  • Observation

    Open

    Open
    Deadline was:

    O-1: Interface between Odfjell and third party equipment hired by the Operator.

    DSY have weekly Maintenance meetings between Technical section Leader, DSV and service
    personnel.
    Status on maintenance and safety critical equipment, upcoming WO, etc. are communicated in the
    meeting. The TSL has a list of last maintenance status.
    An action tracker sheet is used for follow-up. Odfjell does not receive documentation from service company before the meeting.

    In cooperation with OD a document should be developed which defines the documentation requirements provided by the operator of the cement unit.
    Apart from the maintenance records a summary of maintenance KPI’s, MOC’s and exemptions shall be shared with OD.

  • Observation

    Open

    Open
    Deadline was:

    O-2: Maintenance system Maximo

    It will take a considerable amount of work to set up the entire maintenance system in Maximo, i.e. to
    review the FMECA and set up the entire hierarchy with the work orders, criticalities, etc.

    Set up Maximo to accommodate Risk Based Management according to NORSOK Z-008.

    Schedule periodical status meetings to demonstrate progress on schedule and allocated resourced to ensure that this observation shall be closed out and meeting the regulatory and Norsok requirements before commencement of operations on Bestla.

  • Observation

    Open

    Open
    Deadline was:

    O-3: Vulnerable handover process(es) between equipment owner and different users of the cement unit.

    Handover of the cement unit is a three-part handover process, i.e. Halliburton hands back to Baker, then the unit is being handed over to SLB. Risk is that handover issues and learnings are being lost along the way.

    Schedule to follow up what will be done structurally on a biweekly basis. This to assure the maintenance system is audible by the regulator and regrets on contract are addressed by the time the rig goes on contract.

  • Observation

    Open

    Open
    Deadline was:

    O-4: Performance standards for safety critical equipment (Technical barrier elements) on the cement unit and associated support systems.
    Currently no Performance standard for technical barrier elements in place for the cement unit.

    Create Performance Standard for the cement unit according to Havtil’s Barrier Memorandum (2017) and to comply with NORSOK Z-008 and S-001.

  • Observation

    Open

    Open
    Deadline was:

    O-5: Follow-up of critical third-party services.

    No Audit review or verification Plan towards 3 party companies of critical components on the cement unit could be demonstrated for 2025.

    SLB to share an overview of critical third-party verifications.

  • Observation

    Open

    Open
    Deadline was:

    O-6: Unclear whether working environment aspects for own, risk exposed personnel working at the cement unit have been mapped.

    Mapping of working environment aspects for own, risk exposed personnel/position categories working at the cement unit, i.e. noise, dust and vibration measurements and implementation of reduction measures.

    Make an evaluation of SLB risk exposed groups on the rig.

    Check status of implemented noise, dust or vibration measures to reduce exposure, and if it should be logged into the maintenance system for follow up.



Additional Documentation


MoM-Maintenance-review-DSY-cement-unit.pdf, DSY-Cement-Unit-Maintenance-Verification_Final.pdf




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SLB

No person selected

Report No.

8537
Maintenance review – DSY cement unit

Type of audit

External Audits
SLB

Auditee/Customer

SLB
OKEA

Date

2025/04/02

249 days ago

Findings

7
Number of findings

Status

Registered
External Audits


Maintenance review – DSY cement unit
Summary

Purpose:
Maintenance verification compliance towards NORSOK standard Z-008 (Risk based maintenance and consequence classification) of Deepsea Yantai Cement Unit for the Bestla drilling operations and the Vale PP&A operation.

Summary:
The review meeting was held in SLB premises with the attendance of all relevant discipline personnel to demonstrate and confirm the status of the topics covered by the verification scope.

The review team was received in a welcoming and positive atmosphere where questions were answered in an open and honest way. SLB had prepared a very good presentation that supported the verification scope and demonstrated a transparent overview and mutual interest to meet the requirements.

A safety moment was held at the start of the meeting addressing the significant impact sleep has on body and mind.
Encouraging all to prioritise between 7 and 9 hours each day to perform safely and sustainably.

The SLB team appreciated to be subjected to the 3rd party review by the Operator, which is not common.

A brief introduction to the upcoming projects Bestla and Draugen with key deliverables from a cementing standpoint was held.

SLB informed that this type of cross rental agreements between the cementing companies are common on the Norwegian Continental Shelf. SLB have a cement unit handover every 1-2 months, and they have good relationships with both Baker and Halliburton. The Baker Seahawk cement unit installed on DSY is known to SLB and they have experience with the model. All 6 senior cementers planned for the project have previous experience with the Seahawk unit. One of them has experience from DSY. SLB presented that competency is managed in three independent systems in the SLB; Step, Degreed and QUEST.

A mixing error incident in 2023 on Askepott with the same type of unit resulted in several weeks of downtime. When asked about this incident, SLB explained that they have good knowledge of cause and mitigations as this was openly shared by Halliburton who was operating the unit. This demonstrates that continuous improvement, through experience sharing is implemented between Halliburton, SLB and Baker. Whether this experience has led to a change of the maintenance program was on the other hand not known. SLB confirmed that non-productive time on the cement unit is investigated, where the maintenance organization is included to ensure that any learning from the incident will lead to an evaluation of the risk-based maintenance program. Failure mode analysis on equipment components will be initiated should an equipment component fail. Performance analysis of parts is thus used to updated and review the maintenance program.

SLB demonstrated statistics indicating that their focus on quality and technical performance in close cooperation with customers have resulted in significant improvements over the recent years. Non-productive time is reduced significantly from 941 hrs in 2022 to 97 hours in 2024, with 2 hrs of accumulated NPT currently reported YTD.

Equipment bulletins from 3rd party vendors are received by the maintenance manager. However, SLB does currently not have a system to ensure structurally report, manage and follow up those bulletins. It was agreed in the meeting that this is an improvement which should be implemented across the maintenance organization to ensure that equipment bulletins are managed and followed up with the necessary level of quality.

The SLB maintenance organization was presented from a roles and responsibilities view and the risk-based maintenance escalation philosophy outlined and explained with examples. Management of non-conformances and deviation, exemptions are controlled through the HSE standard. Deferred maintenance towards safety critical components falls under the exemption process which is a risk assessed and formally approved in the QUEST system. MOC’s are a non-risked assessed approval process in QUEST. The drilling contractor confirmed that the cement unit on DSY is not part of the IFS maintenance system, and that the maintenance supervisor receives a status of the cement unit maintenance. However, it was confirmed during the meeting that deferred maintenance, whether safety critical or non-safety critical is not communicated to the drilling contractor who has the overall maintenance ownership of the mobile drilling unit. Typical documentation that is shared and entered IFS is maintenance records. This concludes that the asset owner does not have a full barrier status overview on the mobile drilling unit and has no detailed knowledge what mitigating actions are defined during the exemption process to reduce the risk of overdue maintenance to an ALARP level. Agreed during the meeting that in cooperation with OD a document shall be prepared which defines the level of documentation which is required to be shared by the cementing service company on a weekly basis. The SLB team explained that the FMEA documentation for the Baker unit is made available for them, and that work is planned to incorporate the DSY unit into SLB CMMS, Maximo, based on these analyses and the recommended PM regime from Baker. Equipment service will be built up by Service levels SL0 – SL4 built from a reliability centred maintenance approach with PM detail and frequency adjusted to reflect expected failure data. Currently the DSY cement unit hierarchy is not part of the Maximo maintenance system, although SLB has operated the cement unit historically.
Provided that OKEA will commence operations with DSY in July 2025, the review team requested that a project schedule and allocated resources will be discussed regulatory to ensure that the maintenance program on the DSY cement unit meets the regulatory requirements and is in compliance with NORSOK Z-008.

SLB will implement Key Performance Indicators to monitor the maintenance performance of the cement unit. From the presentation it was however not obvious that Maximo is easily able to report overdue, and deferred maintenance status for planned and corrective maintenance work orders for high, medium and low criticality. As part of the mentioned level of documentation requirements the review team requested that those KPI’s as a minimum shall be made available to OD completed with approved Exemptions and MOC.

It was also observed that estimated work hours for preventive and corrective maintenance workorders are not defined in the maintenance system. The maintenance review team highlighted that overdue PM’s in itself are not representing a transparent picture of the overdue maintenance. To achieve a transparent overview of overdue maintenance, work hours shall be defined in the maintenance system to ensure that the correct actions will be taken to correct this.

An outline of the Audit regime was explained in the meeting, with annual QMS self-audits and HQ audits every 3rd year.
Quality verifications of SLB third parties are scheduled and managed by the SLB procurement organization based on criticality.
The SLB maintenance team could not demonstrate that the procurement team has any quality verifications or audits planned in 2025 towards third parties with critical deliveries of cement unit components.

Critical spare parts were also discussed in the meeting. SLB plan to be fully compliant with NORSOK Z-008 Risk based maintenance and consequence classification. SLB elaborated on the three levels of critical spare parts based on severity, occurrence and detectability.

Barrier strategy and performance standards were discussed as part of the agenda. SLB presented a general bow-tie approach and presented various SLB standards where performance criteria were defined. However currently SLB does not meet the performance standard requirement towards technical barrier elements on the cement unit as per Norsok Z-008 and Norsok S-001.

Conclusions:
Since SLB is currently not operating the cement unit on DSY, the review team is not able to define any finding as nonconformances towards regulatory and contractual requirements with respect to Risk Based Maintenance. Significant improvement suggestions have been observed during the review which, if not corrected in due time before the commencement date of the rig contract towards OKEA, will automatically lead to red risk non-conformities. As such those observations shall be corrected before OKEA starts the Bestla development campaign with DSY.

The full list of improvement suggestions and observations are listed below, as were discussed and agreed as follows below during the close-out of the meeting.

Findings

  • Improvement

    Open

    Open
    Deadline was:

    IS-1: Interface between SLB, Baker and 3rd party contractors not structurally managed.

    SLB received equipment bulletins from Baker and other 3rd party companies.
    SLB currently has not implemented a system to manage and follow up those bulletins in a structured manner.

    Implement a follow-up system for equipment bulletins.

  • Observation

    Open

    Open
    Deadline was:

    O-1: Interface between Odfjell and third party equipment hired by the Operator.

    DSY have weekly Maintenance meetings between Technical section Leader, DSV and service
    personnel.
    Status on maintenance and safety critical equipment, upcoming WO, etc. are communicated in the
    meeting. The TSL has a list of last maintenance status.
    An action tracker sheet is used for follow-up. Odfjell does not receive documentation from service company before the meeting.

    In cooperation with OD a document should be developed which defines the documentation requirements provided by the operator of the cement unit.
    Apart from the maintenance records a summary of maintenance KPI’s, MOC’s and exemptions shall be shared with OD.

  • Observation

    Open

    Open
    Deadline was:

    O-2: Maintenance system Maximo

    It will take a considerable amount of work to set up the entire maintenance system in Maximo, i.e. to
    review the FMECA and set up the entire hierarchy with the work orders, criticalities, etc.

    Set up Maximo to accommodate Risk Based Management according to NORSOK Z-008.

    Schedule periodical status meetings to demonstrate progress on schedule and allocated resourced to ensure that this observation shall be closed out and meeting the regulatory and Norsok requirements before commencement of operations on Bestla.

  • Observation

    Open

    Open
    Deadline was:

    O-3: Vulnerable handover process(es) between equipment owner and different users of the cement unit.

    Handover of the cement unit is a three-part handover process, i.e. Halliburton hands back to Baker, then the unit is being handed over to SLB. Risk is that handover issues and learnings are being lost along the way.

    Schedule to follow up what will be done structurally on a biweekly basis. This to assure the maintenance system is audible by the regulator and regrets on contract are addressed by the time the rig goes on contract.

  • Observation

    Open

    Open
    Deadline was:

    O-4: Performance standards for safety critical equipment (Technical barrier elements) on the cement unit and associated support systems.
    Currently no Performance standard for technical barrier elements in place for the cement unit.

    Create Performance Standard for the cement unit according to Havtil’s Barrier Memorandum (2017) and to comply with NORSOK Z-008 and S-001.

  • Observation

    Open

    Open
    Deadline was:

    O-5: Follow-up of critical third-party services.

    No Audit review or verification Plan towards 3 party companies of critical components on the cement unit could be demonstrated for 2025.

    SLB to share an overview of critical third-party verifications.

  • Observation

    Open

    Open
    Deadline was:

    O-6: Unclear whether working environment aspects for own, risk exposed personnel working at the cement unit have been mapped.

    Mapping of working environment aspects for own, risk exposed personnel/position categories working at the cement unit, i.e. noise, dust and vibration measurements and implementation of reduction measures.

    Make an evaluation of SLB risk exposed groups on the rig.

    Check status of implemented noise, dust or vibration measures to reduce exposure, and if it should be logged into the maintenance system for follow up.



Additional Documentation


MoM-Maintenance-review-DSY-cement-unit.pdf, DSY-Cement-Unit-Maintenance-Verification_Final.pdf



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