Risk. Analyzing Petrobras DP Incidents

Transcription

1 Risk Analyzing Petrobras DP Incidents Marcelo Santa Rosa Costa and Gilberto Behuhn Machado Petrobras October 17-18, 6 Return to Session Directory

2 Analyzing Petrobras DP Incidents Marcelo Santa Rosa Costa Gilberto Beduhn Machado E&P-SERV/US-SS/CPSE

3 Petrobras Scenario 8% of the Brazilian oil and gas production is extracted from the sea. Different working environments - some of them specific to the Brazilian offshore fields. DP rigs, a successful tool used to drill, complete and carry out workovers in sub sea wells.

4 Situation before 199: Poor operational procedures and lack of contingency plans; Inappropriate operational safety limits; Engineers were unfamiliar with DP rigs details. Petrobras started carrying out DP vessel studies. 199 => DPPS (Dynamic Positioning Safety Program) is created in partnership with contractors - to avoid incidents or, at least, to minimize their consequences by using a proactive policy => The number of DP vessels started increasing rapidly.

5 DP Vessels Operating for Petrobras rd Period nd Period 1st Period

6 Projects being developed by DPPS 1 - Weather Forecasts - DP Incidents Data Bank (BDIP) - Restrictions Diagram - Procedure Prior to Arrival on Location 5 - Position Reference 6 - EDS and Degraded Status Criteria 7 - Contingency Plans for Uncontrolled Drift (blackout situation) 8 - DP Rig Audit 9 - Non-conformities Data Bank (SPS) 1 - Bid Requirements 11 - Key DP Personnel Log Book 1 - DP Training for Petrobras Representative on board 1 - New Projects

7 - DP Incidents Data Bank (BDIP)

8 Objectives: to avoid repeating occurrences - an useful and practical tool to improve reliability on DP Vessels; to keep an updated source for contracts renewals and for DPPS risk management purposes.

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12 WARNING START Definition of Incident NO OFF SETS With OFF SETS NORMAL STATUS DEGRADED STATUS % WD 6% WD D Y R YELLOW ALARM STATUS X X X RED ALARM STATUS DISCONNECTION CAUSE EFFECTS CONSEQUENCE - Loss of Redundancy Progressive loss of station keeping capability Sudden loss of station keeping capability (ex: black out) Degraded Yellow Alarm/ Red alarm Straight Red Alarm Without loss of position - Possible cease of operations (Critical Operation) Loss of position under control preparing for disconnection => disconnection Loss of position without control => Immediate disconnection

13 PETRÓLEO BRASILEIRO S.A. PETROBRAS DP Incidents Total: 79 Total: Degraded Status Yellow Red Blackout

14 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm vs Disconnections -199/ Red Rig Connected Rig Disconnected Unsuccessfull Disconnections 7

15 PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Type of Incident -199/5 7 Total: Straight Red Alarm Red Alarm Yellow Alarm

16 Yellow Alarm vs. Working Hours ,,97 6 5, , ,9 5,61 5,6 7 1,9, 1,5,1 5,7 9,51 1,77,9 1, 1,5,9 7,67 5,59, Rate,9 1,6 6,9,61,,97 5,6 1,9, 1,5,1,7,51,77,9 1,,5,9,67,59,5 # Alarms

17 Red Alarm vs. Working Hours , , , 1,1 6,9 5,61 9,8 6 1,9 1, ,5,85,,1 6,6,7 1,98 1,7 1,6,9 7,59, Rate,,1 6,9,61 1,51 17,,8 1,9 1,78 1,5,85,,1,6,7 1,98 1,7 1,6,9,59,5 # Alarms

18 Disconnections vs. Working Hours ,51 1, ,,1 5,,61,1 1,9 1, 1,5 6 6,7,,5 1,55,1 1, 1,6 1,, ,15 1,17 1 Taxa,,1 5,,61 1,51 1,7,1 1,9 1, 1,5,7,,5 1,55,1 1, 1,6 1,,8,15,17 Nº Desconexões

19 9 Blackouts vs. Working Hours ,,1,5,,,58 5,89,,,5 1 1, 1, 6 5,5 1,77 1,16 1,1,5,5,67,59, Rate Blackou Rate,,1,,,5,58,,,89,5 1, 1,,5,77 1,16 1,1,5,5,67,59, Blackout

20 Failure Root Causes & Trigger s and Points

21 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger -199/ Total: Power Environment DP Propulsion PRS Sensors Others

22 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Power -199/5 Trigger Point 1 1 Total: Protection Generator PMS Diesel Engines Bus Bar Fuel Controllers UPS Cooling

23 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Root Cause - 199/5 5 Total: Human Error Environment Poor/Lack of Maintenance Protection Project andcontrol Software Commissioning Lack of Procedures Technological Limitation Component Failure Scintillation

24 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger -/5 9 Total: Power Environment DP Propulsion PRS Sensors Others

25 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Power -/5 Trigger Point Total: PMS Generator Protection Bus Bar Diesel Engines Fuel Controllers Cooling

26 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Root Cause - / Total: 5 Total: Human Error Poor/Lack Maintenance Prot Syst C & S Environment Lack of Procedures Software Project and Technological Commissioning Limitation Component Failure

27 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger - Human Error - / Total: Power DP Propulsion Sensors (Gyro)

28 PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger Point - Human Error - /5,5,5 1, ,5 Bus Bar Fuel PMS Thrusters - Electrical Protection Cooling DP Software DP Hardware Sensors - (Gyro)

29 PETRÓLEO BRASILEIRO S.A. PETROBRAS DP Incidents Total: Degraded Status Yellow Red Blackout

30 PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Trigger Point -199/5 1 1 Total: Protection Generator Bus Bar PMS Diesel Engine Fuel Control Cooling UPS

31 PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Root Cause - 199/ Total: Protection Human Error Poor / Lack of Maintenance Project and Commmisioning Lack of Procedures

32 PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Root Cause - / Total: 6Total: 6 6 Human Error Protection Poor / Lack of Maintenance Project and Commissioning Lack of Procedures

33 HUMAN ERROR WORKGROUP Objective: to look for root causes for incidents classified as human error on DPoperated vessels suggesting an action plan to avoid them to happen. Components: Petrobras + Schahin + Diamond + Transocean + Noble + Pride + Ventura

34 HUMAN ERROR WORKGROUP 1. Ineffectiveness of on-job-training for DPO / SDPO as well as for new DPO Certification. High turnover among companies or even within the same company. Few opportunities for practicing or not enough time to be familiar with the system. Inadequate supervision Theoretical training for DP/ECR personnel Practical training on board for DP/ECR personnel Training on DP/VMS simulators Make DP/ECR a worthy team DP personnel hiring as part of a bigger process

35 HUMAN ERROR WORKGROUP 5. Poor handover causing incidents due to the lack of details about ongoing operations. Improve handover 6. Poor communication process among departments (DP / Rig Floor and DP / ECR). Improve communication process among DP/ECR/RIG FLOOR by cross training. 7. Stressful situations caused by less experienced operators combined with more activities/responsibilities. 8. Long time in front of the console (DP, VMS, etc). 9. High noise, lack of attention, amusement for chatting in close coffee shops (Bridge, ECR). Improve work conditions for DP/ECR personnel

36 HUMAN ERROR WORKGROUP 1. Poor motivation or attitude 11. Experienced people s overconfidence 1. Lack of specific procedures Improve confidence/motivation by HR programs. Create procedures making them available 1. Poorness/Absence of manuals especially after upgrades Organize and update technical documentation 1. Poor automation asking for human interference Automate non-critical DP/ECR systems

37 Thank You!

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