shell exploration & production - pscfiles.tamu.edu october 23, 2006... · shell exploration...

Shell Exploration & Production

11/9

/200

6Fi

le T

itle

Cop

yrig

ht: S

hell

Exp

lora

tion

& P

rodu

ctio

n Lt

d.

Mars TLP Recovery Project

HSE & Technical Challenges


W. A. " Dup" Duplantis, HSE Advisor

Dave Knoll, Civil Engineering Advisor

Shell International Exploration and Production

W. A. " Dup" Duplantis, HSE Advisor

Dave Knoll, Civil Engineering Advisor

Shell International Exploration and Production

Acknowledge:EPW-SEPCO(Operator)BP (28.5% working interest)Worldwide Contractors


Summary

• The Storm and Assessment

• HSE Challenges

• Technical Challenges

• Project Management Challenges

• The Reward


Katrina - Storm

Katrina’s

Path / Wind Speed /Sea Surface Elevation

Katrina’s

Airborne Doppler radar-derived wind speed cross sections 2000 UTC 28 August

2005


Platform Motions Response

-320 -300 -280 -260 -240 -220 -20080

100

120

140

160

180

200

220

surge (ft)

sway (ft)

Aug 29, 0 AM - Aug 29, 1 AM


Damage

• Platform Survived

• Toppled Rig Substructure

– Vapor Recovery Compressor

– Field Gas #1 & Field Gas #2

– Glycol Recovery Skid

• Wave Run up Damage Lower Deck

• Not Habitable / Treacherous Environment


Platform & Production Wells Survived


Damaged by Rig Overturning

• Drilling Rig Major Damage

• Glycol Gas Dehydration Regeneration System

• Vapor Recovery Unit # 2 – (Upper Decks)

• Field Gas Compressor # 1 – (Top Deck Coolers)

• Field Gas Compressor #2 – (Exhaust, ICP & Gear Box)

• Structure Steel below Compressor #2

• ICP Piping connecting these systems

• Power & Control Cabling running through these areas

• Crane #2 Boom

• Flare boom


Toppled Rig Substructure


Damaged Compressor- VRU #1


Damaged Glycol System


Damaged by Wind, Waves & Water• Numerous Utilities Support Systems

– Survival Capsules, Qtrs utilities (sewage, water, etc.)

• Significant grading damage

• Structural damage to lower deck skid panels

• Crane # 1 boom

• Subsea Umbilical Control Panels on Tops of Columns

• Subsea Below Deck Flowline Piping Bend

• Most below lower deck piping systems significantly damaged

– Drains, Firewater, etc.

• Status of field mounted local control panels unknown

• Misc. water damage into most buildings


Wave Run Up – Structural Lower Deck


Wave Run Up – Survival Capsules


Wave Damage – Top of Columns


HSE Challenges

• High Risk Environment

• Diverse Staff

• HSE-MS

• Offshore Tools

• Results


Treacherous


Not Habitable


Diverse Staff


HSE-MS

SEPCO Brown Field Projects

• Operating Platform – Systems Damaged

• Assignment and Completion of HSE Critical Activities

• Incident Response


Offshore Tools – Basic Training• HSE Orientations – Over 1,300 personnel attended orientations

covering HSE expectations, roles and responsibilities of each individual concerning the work processes and HSE resources available on site.

• Fatigue Awareness – Nearly 900 personnel attended training sessions on fatigue awareness, recognition, and preventative measures.

• Fall Protection & Fall Rescue – Over 300 personnel attended training on fall protection/prevention with 134 of these receiving additional training in fall rescue techniques.


Offshore Tools – Process

• BBSM Process – Nearly 2,600 BBSM observations were conducted by the workforce and project management. These were tracked, trended and discussed during safety meetings and toolbox talks to communicate at risk behaviors and areas for improvement. Additionally, the BBSM cards identified 365 unsafeconditions.

• Permit to Work System – The SEPCO Permit to Work System was used to manage work tasks and help ensure compliance with guidelines adopted for simultaneous operations. Over 2,600 permits were developed in the course of the repair work on the TLP.


Offshore Tools – Continuing Education

• Daily Safety Meetings - Safety meetings were conducted twice daily to recap workplace HSE issues, best practices and discuss hazards associated with upcoming tasks.

• Formal Weekly Safety Meetings – Formal “structured” safety meetings were conducted weekly for both day and night crews. These meetings discussed HSE trends, HSE milestones and targets, recent incidents, workplace audit results and work scope. These forums were also used to formally recognize proactive HSE intervention.


Offshore Tools – Audits

• Management Walkthroughs – Over 75 Management Walkthrough audits were conducted and documented. This provided line management an opportunity to observe hazards and worksite conditions first hand. It also was a good demonstration of Management’s commitment to the HSE effort.

• JSEA & Formal Job Site Audits – Nearly 550 JSEA and Job site audits were conducted to identify gaps in the hazard analysis processes. Results were documented, tracked, trended and used as a coaching tool for area Foremen to promote continuous improvement.


Offshore Results – Incident History

MONTHLY TRENDS

05

1015

2025

30

OCT. N OV. DEC. JAN . FEB. M AR. APR. M AY

MONTH

Num

ber o

f Inc

iden

ts

FIRST AID NEAR MISSASSET DAMAGE TOTALLog. (FIRST AID) Log. (NEAR MISS)Log. (ASSET DAMAGE) Log. (TOTAL)


Offshore Results – Incident Stats

Steward9%

Fire Watch6%

Welder9%

Elect Tech9% Inst Tech

6%Scaffolder

16%

Riggers18%

Crane Operator9%

Pipefitter18%

Pipefitter Riggers ScaffolderInst Tech Elect Tech WelderCrane Operator Steward Fire Watch

Body Part

Torso15%

Finger/Hand27%

Head10%

Eye27%

Arm3%

Leg8%

Feet10%

Nightshift34%

Dayshift66%


Technical Challenges

• Quick & Reliable Engineering

• Rig Removal

• Flotel Mooring


Rig Removal - Plan


Rig Removal - Preparations


Rig Removal - Executed


Flotel


Project Management Challenges• Securing Critical Resources

• POB Management

Monthly POB Avg Jan Feb March AprilSafe Scandinavia 392 447 453 487Mars TLP 55 61 66 60Overall POB Avg 447 508 519 547


The Reward

TRCF: 0TRIR: 0

Mars Recovery Project HSE Statistics Thru May 15th

Fatalities

Lost Time Injuries

Restricted Work Cases

Medical Treatment Cases

First Aid Cases

Man-Hours

0

0

0

0

55

BBSM: 2600Near Miss: 21

67,273

BBSM- ObservationsNear Misses

0 Significant Environmental

1,028,795

Goals:TRIR: 1.88

Significant Environmental : 0

TRCF: 0TRIR: 0

Mars Recovery Project HSE Statistics Thru May 15th

Fatalities

Lost Time Injuries

Restricted Work Cases

Medical Treatment Cases

First Aid Cases

Man-Hours

0

0

0

0

55

BBSM: 2600Near Miss: 21

67,273

BBSM- ObservationsNear Misses

0 Significant Environmental

1,028,795

Goals:TRIR: 1.88

Significant Environmental : 0


Significant Repair Effort to Date……Key Drivers of Success:

• Management of HSE

• Technology Application

• Project Management

shell exploration & production - pscfiles.tamu.edu october 23, 2006... · shell exploration...

Documents