TARIF DEEP-1

SERVICE PARTNERS QA PERFORMANCE

Rig EDC 56 – Tarif Deep-1 – EGYPT

November 2017
 AGENDA

●General Information

●Operational execution

●Recommendation & Lessons learnt

Service Partners QA Performance .TARIF DEEP-1. TOTAL EGYPT. NOVEMBER 13, 2017 2
GENERAL INFORMATION
Title of FEEDBACK : Service Partners QA Performance
Well : Tarif Deep-1.T1
Affiliate : TOTAL E&P EGYPT
Environment : HPHT Exploration Onshore
Rig : EDC 56 HP land rig
Spud Date 30th April 2017
End Date 3rd of November 2017

CONTACT
Marc LEFRANCQ [email protected]

Executive summary
This FEEDBACK presents the explanations of service providers QAQC performance
during tarif deep-1 exploration campaign.

Service Partners QA Performance .TARIF DEEP-1. TOTAL EGYPT. NOVEMBER 13, 2017 3
 OPERATIONAL EXECUTION

● From an early stage (First Load out) it was clearly obvious the level
of compliance from Main Service Providers on their capability/ability
to conform to their QMS Systems was of a poor standard.
● Poor communication was another factor and improved as we moved
forward with campaign.
● Possibly if QA resource had been involved earlier on project with
direct Vendor visits targeting the right people as a high priority would
have made life easier to get across our expectations and gauge their
level of compliance to QMS.
● Four incidents where Service Partners failed to have equipment
ready on time, EDC, SLB, Halliburton, and Weatherford MPD.
● Author had slight advantage with Egypt Operations having
previously been involved on exploration project in poor
compliance/communication was no great surprise.

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 RECOMMENDATIONS AND LESSONS LEARNT

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 EDC

● Extremely hard going during Rig-Mob. They didn’t quite grasp the whole concept of the QA,
Equipment Integrity aspect in the beginning but slowly came onboard and once we had
identified the key personnel and met face to face rather than bat back and fore with emails
exchanges things did improve slightly.
● One Lowlight of note was with the Top Drive refurbishment/upgrade, We repeatedly
requested a full work scope which we never did receive, they ended up shipping the Top
Drive to Rig site where it was found (Total Superintendant) that the lower connection of the
Quill Shaft was defective and required to be recut.(Excessive material removed by grinding
in the Stress Relieve Groove Area. Turnaround Time 7 days)
● As always you need to look back at this and think what could QA Team have done
differently/better during the Top Drive Refurbishment at EDC workshop, Better Time
management maybe in the early stages of project, clearly identify and list your priorities,
Identify at an early stage the key players and intended work scopes as it was neither QA
nor the rest of the Total Team were aware that Quill Shaft had to be replaced due to a
crack detected on the original one.
● Looking back EDC although they have equipment PMS this wasn’t always followed and
sadly it was a case of If It Not’s Broke Don’t Fix It.

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 SCHLUMBERGER MWD/LWD

● Several QA and equipment issues captured during first load out (27 ½”) Equipment was still
in the process of build/maintenance less than 12 hrs before requested load out.
● QA walkabout of facility with SLB personnel found that none of their bucking units were
fully operational. (Unable to record/store/print) make ups.
● Calibrated OD Ring Gauges were Non Existent.
● Non Compliance with SWI on API Rotary Shoulder Connection surface finish (Non
Mag/Steel) Bead Blast of Non Mag connections is Mandatory requirement as per SWI.
● Documentation packs presented were incomplete.
● QA captured SLB were providing wrong OD Stabilizers, request was for 27 3/8” and not 27
¾”!!!,Luck was with them as due to Rig Acceptance delays load out was postponed or they
were facing some serious NPT as it took approx 5 days to have the correct size Stabilizers
made available.
● After successful load out of equipment SLB Senior Management met with Total Team to
discuss all of the above along with concerns going forward SLB management agreed that
they fell short and were agreeable to place an improvement plan. Some things were
improved and closed out but they are still Non Compliant to connection surface finish at the
end of project. Future load outs did not improve and were still last minute.com affairs which
are never an ideal scenario if we have equipment rejected.
● QA had concerns with SLB in house Sub Contract inspection team who were not fully
working to SLB SWI and reporting format.
● My thoughts are that they never had sufficient supply of tools in country to meet Total and
their other ongoing operations. Possibly this could have been captured in the early stages
of project by verifying what tools were physically had in country or what they planned to
mobilize from another SLB asset as support.

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 SCHLUMBERGER DT & R (RHINO REAMERS & JARS)
● We didn’t get off to a good start and they were Non Compliant in several areas as per current
SWI.
● They were following SWI and using a reporting format which was about 2 years out of date.
● Unable to provide documentation for previous Rhino Reamer builds. (Lacked hard copy of
pressure tests) for body and cutter engagement.
● There is a way you can engage cutters without pressure testing (Time Saving) but out with SWI.
● No calibrated OD Gauge rings available.(As above)
● QA discussed all of the above with SLB management and after a time out to allow them to get
there house in order with latest SWI and get fully functional calibrated Pressure Test equipment
in place.
● Hydraulic Jars. Again as was the case with Reamers they were not following latest SWI and
reporting format.
● QA had concerns with SLB in house Sub Contract inspection team who were not fully working to
SLB SWI and reporting format.
● 9 ½” Jar Failure. The failure has been well documented by SLB and as it should be only took
approx 5 months to compile and share with Total Team.
● Didn’t answer all our original questions and highlighted some other issues we had potentially
overlooked.
● Failed Jar had been transferred from another SLB asset (Baku) at beginning of campaign which
answered one of our original questions on this Jar but unable to supply maintenance history
parts replaced etc. Jar was entered into service 2007 and had carried out approx 20 runs.

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 SCHLUMBERGER DT & R (RHINO REAMERS & JARS)
● In hindsight and in the case with MWD/LWD tools and for future operations we need to be
asking SLB on tool run/maintenance history.
● Failed Jar in question was never fully inspected/tested as per SWI prior to being RIH.
● Another issue which SLB failed to inform Total team after this failure was from the original 5
x 9 ½” Jars SLB had in country we were now down to 1 fully operational which was
currently in the BHA, SLB had to sub contract from another local service provider to meet
our requirements.

Overall disappointing start from SLB and only got better with QA intervention (Hard Going at
times) Drilling Engineers who are the contract holders never get the chance to see and
hear the right picture on SLB performance. Quality Assurance Resource helps provides
real time information on a daily basis allowing Engineers and rest of team to raise our
concerns at a higher level.

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 HALLIBURTON (VERSAFLEX & CMT HEAD)
● Again we didn’t get off to a promising start when we began Versa Flex Big Bore Tool Build;
Communication was a big problem, slow to respond to email & telephone calls.
● Extended delays due to Cones from both Primary/Back up tools were rejected at inspection
stage.
● Correct drift was not available and one had to be manufactured.(Makes you wonder what they
used in past builds)
● Not a one stop shop for Versa Flex build, Local Sub contractor required for final torque of
running tool assembly.
● Unacceptable Halliburton delays to have Systems ready to mobilize as per original date
requested. Mobilize Primary Tool on 30/05/17 with back up on 02/06/17.Both Primary and back
up tool builds were not completed until 13/06/17.Again downhole problems on this section
worked in their favor.
● From memory Halliburton tried to back charge 25 days for tool build and Ex Pat Supervisor (This
included 1 x day for tour of facility by Total Superintendant) anyway after some discussions they
agreed charge was excessive and they reduced it.
● Highlight. All Versa Flex Liner hangers were ran and set successfully.
● Lowlight. All tool builds were last minute.com.
● Lowlight. Problem with 11 ¾” Liner Hanger Dual Set Plug System (Already well documented,
Halliburton failure report submitted and closed out) From a QA perspective what they failed to
include in the report was the following,(a) 11 ¾”Back Up Plug Set modification although at first
glance looked to have been carried out, were in fact incomplete as pressure release
modifications had not been fully machine all the way thru.(b) No Modifications during the
manufacturing process had been carried out on Primary/Back Up 9 7/8” Dual Set Plug Systems
which demonstrates a complete breakdown of Halliburton QMS.

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 HALLIBURTON (VERSAFLEX & CMT HEAD)

● Lowlight. During ordering process communication surrounding Max temp and Lead times
along with Delivery updates was laborious (Welcome to the Halliburton World)
● Have experienced the ordering process problem numerous times and for sure Egypt has
more than its fair share of problems when you’re forced to bolt on to existing contracts and
Quality Plans, Slow internal communication between Sales and Manufacturing plant and a
complete lack of Production Updates from the plant.
● Total attempted to speed up the process by waiving TPI attendance which has its merits
but they are more than useful not only from a QA side of things but importantly they can
provide reports on any production delays which alerts Total Contact Holder to possible
impact at an early stage to his operation.

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 HALLIBURTON (VERSAFLEX & CMT HEAD)
CMT HEAD
● QA issues captured early in that CMT head swivel capability was not functioning, Further QA
checks on maintenance as per SWI and documentation revealed they were not in compliance,
they responded well and quickly had the CMT Head fully functional and in compliance with SWI.
● Lowlight. No proper Halliburton SWI in place for the FOSV placed above and below the CMT
Head and they were mistakenly pressure testing them incorrectly using the side entry feature on
the CMT Head which will only test the Upper FOSV from below and the Lower FOSV from
above. Without dedicated Halliburton SWI they should have resorted to manufactures guidelines
for the correct procedures which states carry out (a) Body test with valve a ¼ turn open.(b) Close
valve and test from above.(c) With valve closed test from below.
● One other problem was that Halliburton Pressure test bay had some limit restrictions in place
and Max Pressure was set at 7.5k.

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 HALLIBURTON TOOLS & TESTING (UNDER REAMERS)

● 18 1/8” & 14 ¼” Hole Section no issues with Tool Builds, Certification or Downhole
application.(XR1200 Tool Type)
● 12 ¼” Hole Section again as above no problem with Tool Build & Certification (New Tools
XR 1000 Type)
● Under Reamers are built & maintained in their Alexandria base which is not ideal as to
witness is a 2 day affair, They do not have in house torque capabilities and rely on local
sub contractor to provide.
● Tool Technicians very knowledgeable on this product line.
● Lowlight. Downhole problems on 1 run where Cutter Arms could not be fully opened
st

and pressure maintained (POOH) 2 nd run unable to pass thru TOL. Both tools returned to
Halliburton Cairo Base for investigation. Tool 1 fully stripped down and the only thing to
note was some washed out areas on various parts, Tool 2 nothing to report. Detailed
Failure Investigation from Halliburton failed to identify find Root Cause problem with Tool
1.worth mentioning Halliburton stated in all the years XR1000 have been operating they
have never seen this type of problem or have any information on their QMS of failure ?
● Overall poor start with Halliburton they need to improve on communication, be more pro-
active on tool builds. Quick to respond/rectify any issues which where Total QA had
concerns.

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 WEATHERFORD (TRS, FISHING, MPD, MACHINE SHOP)

● MPD. Didn’t get off to the best of starts when I made initial visit to review equipment
status/readiness and to review documentation. Majority of equipment had to be retested as they
had not followed Weatherford SWI or even close to Standard Oil Field best practices. Inspection
documentation was incomplete & lacked detail.
● TRS & Fishing. No major QA issues however they share a common trait with our
other Service providers in Cairo. Equipment readiness last minute.com
● Machine Shop. One of our Top providers always ready to go that extra yard to
assist and deliver quality products on time, usual chase/follow up with documentation but
its Egypt!!
● TRS. Fishing. MPD Communication replying to emails/responding to phone calls is
definitely not one of their strong points.
● Inspections Documentation submitted requires in- house improvement and reviewed prior
to submitting to Total QA.
● TRS. Fishing. MPD. Equipment availability/readiness as with other Service Partners
insufficient fully maintained equipment in country to meet Total and other ongoing
operations that they were involved with.
● Weatherford/Tomax. No issues to report Tools always delivered on time and
Certification received in advance of mobilizing to rig.

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 BAKER WIRELINE

●Wire line. Ops. No QA issues to report, good communication and required

●Bits. Early days of project slow with delivering Bit Certification prior to mobilizing, once
they understood our QA requirements this improved and documentation received in
advance.

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 ● Smith Bits
Early days of project slow with delivering Bit Certification prior to mobilizing, once they
understood our QA requirements this improved and documentation received in advance.

● JMS (Hydraulic Wrench Ops)

● Poss (Cold Cutter, Fill up Tool & BOP Lift Frame Manufacture)
Cold Cutter. Apart from some minor problems with equipment calibration/certification at
beginning of project which were quickly corrected no major concerns.
Fill Up Tool. No major concerns to report.
BOP Lift Frame manufacture. Excellent performance and work carried out to a
high standard complete with full QA certification package.

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 QA DISCREPANCY REPORT

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