Risk Analyzing Petrobras DP Incidents Marcelo Santa Rosa Costa and Gilberto Behuhn Machado Petrobras October 17-18, 6 Return to Session Directory
Analyzing Petrobras DP Incidents Marcelo Santa Rosa Costa Gilberto Beduhn Machado E&P-SERV/US-SS/CPSE
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.
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. 1996 => The number of DP vessels started increasing rapidly.
DP Vessels Operating for Petrobras rd Period nd Period 1st Period
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
- DP Incidents Data Bank (BDIP)
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.
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
PETRÓLEO BRASILEIRO S.A. PETROBRAS DP Incidents 199-5 5 5 Total: 79 Total: 79 5 15 15 1 5 69 5 Degraded Status Yellow Red Blackout
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm vs Disconnections -199/5 1 15 1 8 76 6 9 Red Rig Connected Rig Disconnected Unsuccessfull Disconnections 7
PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Type of Incident -199/5 7 Total: 5 5 15 1 1 5 Straight Red Alarm Red Alarm Yellow Alarm
Yellow Alarm vs. Working Hours 1985-5 5,,97 6 5,9 15 1 1,6 1 1 5 6,9 5,61 5,6 7 1,9, 1,5,1 5,7 9,51 1,77,9 1, 1,5,9 7,67 5,59,5-5 1985 1986 1987 1988 1989 199 1991 199 199 199 1995 1996 1997 1998 1999 1 5 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 1 1 5 6 7 5 9 1 1 7 5
Red Alarm vs. Working Hours 1985-5 18 17, 19 16 1 1,51 1 1 1 11 11 1 8 6, 1,1 6,9 5,61 9,8 6 1,9 1,78 8 8 8 1,5,85,,1 6,6,7 1,98 1,7 1,6,9 7,59,5 1985 1986 1987 1988 1989 199 1991 199 199 199 1995 1996 1997 1998 1999 1 5 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 1 5 9 19 6 8 8 6 8 1 1 11 11 7
Disconnections vs. Working Hours 1985-5 16 1 1,51 1,7 15 1 11 1 1 9 1 9 8 7 8 7 6,,1 5,,61,1 1,9 1, 1,5 6 6,7,,5 1,55,1 1, 1,6 1,,8 1985 1986 1987 1988 1989 199 1991 199 199 199 1995 1996 1997 1998 1999 1 5,15 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 9 15 7 8 7 6 11 1 1 9 6 1 1
9 Blackouts vs. Working Hours 1985-5 8 8 7 6 5 1,,1,5,,,58 5,89,,,5 1 1, 1, 6 5,5 1,77 1,16 1,1,5,5,67,59, 1985 1986 1987 1988 1989 199 1991 199 199 199 1995 1996 1997 1998 1999 1 5 Rate Blackou Rate,,1,,,5,58,,,89,5 1, 1,,5,77 1,16 1,1,5,5,67,59, Blackout 5 1 1 6 8 5
Failure Root Causes & Trigger s and Points
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger -199/5 6 5 51 Total:15 19 17 1 1 1 Power Environment DP Propulsion PRS Sensors Others
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Power -199/5 Trigger Point 1 1 Total: 51 1 1 1 8 6 7 6 6 1 Protection Generator PMS Diesel Engines Bus Bar Fuel Controllers UPS Cooling
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Root Cause - 199/5 5 Total: 15 19 17 15 15 1 1 9 5 5 1 1 Human Error Environment Poor/Lack of Maintenance Protection Project andcontrol Software Commissioning Lack of Procedures Technological Limitation Component Failure Scintillation
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger -/5 9 Total: 5 5 15 1 6 6 6 5 1 1 1 Power Environment DP Propulsion PRS Sensors Others
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Power -/5 Trigger Point 6 6 6 Total: 9 5 5 1 1 PMS Generator Protection Bus Bar Diesel Engines Fuel Controllers Cooling
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Root Cause - /5 16 15 Total: 5 Total: 5 1 1 1 8 6 8 6 6 1 Human Error Poor/Lack Maintenance Prot Syst C & S Environment Lack of Procedures Software Project and Technological Commissioning Limitation Component Failure
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger - Human Error - /5 1 9 8 7 6 5 1 Total: 15 1 1 Power DP Propulsion Sensors (Gyro)
PETRÓLEO BRASILEIRO S.A. PETROBRAS Red Alarm - Trigger Point - Human Error - /5,5,5 1,5 1 1 1 1 1 1,5 Bus Bar Fuel PMS Thrusters - Electrical Protection Cooling DP Software DP Hardware Sensors - (Gyro)
PETRÓLEO BRASILEIRO S.A. PETROBRAS DP Incidents 199-5 5 5 Total: 79 5 15 1 5 69 15 5 Degraded Status Yellow Red Blackout
PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Trigger Point -199/5 1 1 Total: 5 1 1 8 6 6 5 1 1 Protection Generator Bus Bar PMS Diesel Engine Fuel Control Cooling UPS
PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Root Cause - 199/5 1 1 1 Total: 5 1 1 9 8 7 6 Protection Human Error Poor / Lack of Maintenance Project and Commmisioning Lack of Procedures
PETRÓLEO BRASILEIRO S.A. PETROBRAS Blackout - Root Cause - /5 1 9 8 7 6 5 1 1 Total: 6Total: 6 6 Human Error Protection Poor / Lack of Maintenance Project and Commissioning Lack of Procedures
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
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
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
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
Thank You!
Questions? You can send your questions or comments to: gbeduhn@petrobras.com.br