BackDROPS FORUM - Kuala Lumpur, 17th March 2010
Present:
Johnny Yap, KCADeutag; Steve Allerton, Go Home Safe ltd; Gergely Varadi, Seadrill; Jimmy Nicol, Kencana Mermaid Drilling; Lee Hogan, Baker Hughes; Jimmy Ong, Kencana Mermaid Drilling; Joachim van der Meulen, Stopdrop Tooling; Abdul Rahmat Omar bin Mohamed Haniff, Kencana Mermaid Drilling; Fatimah Alzahrah binti Razak, Wise Innovations; Lance Costello, ModuSpec Engineering Asia; Abu Bakar bin Mat Silit, Wise Innovations; Chandran Singaram, Talisman Malaysia; Wengkai Lee, Drivefos; Sofian Zainal, Baker Hughes; Ku Abdullah Ku Osman, Clearways Offshore; Stanley Ling, Joffren Omar Company; Ahmad Hafeez bin Ramli, Baker Hughes; Ronny Yong Khen San, Enventure Global Technology; Ling Hsiao Ying, Cameron; Eric Lai Yon Soon, Pacific Advance Composites; Kong Yong Chin, Seadrill Ltd; Sofan Sofian Hj Othman, Halliburton; Frans Roemer, SMITH; Shane Ritchie, South Seas Inspection; Calvin Yang, SMITH; Rik de Bruijn, Shell; David John Woodruff, Maersk Drilling; Longchik Yaakob, Weatherford; Mohd Shaffie Mokhtar, Talisman Malaysia; Tia Siew Horng, BSP, TSW Department; Sanson Selva, GO HOME SAFE; Zuflin Nazli Mohd Ghazali, BHP Billiton Petroleum; Punitha d/o Kunasantar, Azmation Werks; Chai Win Yick, Talisman Malaysia; Nandagobalan Vengettasamy, Azmation Werks; Choo Teik Heng, Talisman Malaysia; Mohd Sabri Bin Abu Bakar, BJ Services; Perbagaran Jayabalan, MSTS Asia; Liong Sze Jon, Halliburton; Syahir Luthfi Chan, Schlumberger; Francis Tang Kah Mun, Halliburton; Feriansyah Abu Baker, BHP Billiton; Mohd Firdaus Modh Sharif, Schlumberger; Michael Slorach, NOV/SSI; Shahar Hashim, Schlumberger; Jean-Claude Jalet, Schlumberger; Kheiral Kamal, Schlumberger; John Hallcroft, Atwood; Parthiban, Talisman; Abdullah Ahmad, Trygo Minerals; Pavan Srivastava, Halliburton; Raphael Hawksby, PRA Global; Ahmad Sobhan Riclzuan, Halliburton; Aeland E Wong, Halliburton; Perbagaran, MSTS Asia.
Welcome, Safety Brief & Introductions – Lee Hogan, Baker Hughes
Lee Hogan, Drops Asia Chairman and HSE Director for Baker Hughes – opened the first independent DROPS Asia Forum and welcomed over 50 industry professionals – including representatives from drilling companies, oil majors, service companies and equipment suppliers. Throughout the forum the common theme of the presentations and discussions was to share best practices regarding Dropped Objects, and how we can work together to eliminate from our industry. Attendees also raised the need for a “common” industry standard for prevention of Dropped Objects.
DROPS Objectives / DROPS Asia – Lee Hogan, Baker Hughes
In his role for Baker Hughes, Lee frequently attends Industry HSE meetings throughout the region. Sadly one consistent trend throughout the Asia Pacific region is the increasing reported cases of dropped object incidents throughout our industry. Failure to take immediate & effective action throughout the industry may result in further serious injuries and fatalities.
Over 70 companies throughout the Oil & Gas industry have teamed up, via the DROPS initiative, in order to work together to eliminate dropped objects and improve our dropped object prevention performance. Lee stressed the need for Industry to work together to create a true interdependent safety culture to eliminate dropped objects. Instead of companies and individuals working in isolation regarding safety issues we should actively work together.
In “Interdependent” cultures employees must not only be responsible for their own safety but also the safety of co-workers as well. Employees at all levels “own” HS&E. Once we successfully create an Interdependent Safety Culture throughout our industry zero HS&E incidents will no longer a target, instead an expectation that people do not get injured while conducting business. Lee encouraged all attendees to become actively involved with DROPS Asia so that we can effectively raise awareness regarding dropped objects and successfully eliminate dropped object incidents from our industry.
Follow this link to download the presentation.
DROPS Implementation in South East Asia – Rich de Bruijn, Shell
Shell has identified dropped object to be the major cause for incidents throughout their operations in the world. To reduce these incidents, Shell has launched a DROPS campaign in their operations. A plan and deliverables to implement Shell’s Global Standard for Dropped Object Prevention (DROPS Standard) was developed. Managers, supervisors, operations staff and contractors are to use the DROPS Standard on a day-to-day basis. In the Asia Pacific region the Standard is adopted by 25+ work locations covering rigs, well services worksites and logistics operations.
DROPS regional and local focal points are appointed to run campaign at their location and to ensure compliance with mandatory requirements. Awareness is raised through frequent meetings and presentation, articles for internal and external publications, the DROPS website and posters. Shell organises cascaded learning sessions across office, well site, contractors. DROPS Leads to run the campaign at their location and train/coach staff. Awareness videos and practical exercises are used to convey key knowledge and skills. Prevention of Dropped Objects Manual and an ABC Guide to Dropped Object Prevention were developed and presented to all contractors.
Campaign topics are rolled out each quarter:
Q1 2010: Tools at height
Q2 2010: Tubular handling
Q3 2010: Red Zones and No Go Zones
Q4 2010: Handling lubricators and tool strings
Q1 2011: Drilling equipment
Q2 2011: Job safety analysis.
Dropped Object Incident presentation - Dave Woodruff – Maersk Drilling
When Dave suggested to his local Management that he present details of a Dropped Object incident they experienced on the Maersk Completer at the DROPS Asia Forum, they were initially not very excited about the idea. Why would they want to hang out their dirty laundry for the whole industry to see?
The fact is, Dropped Objects happen on every rig. When they happen, there is a risk that individual workers may try to cover up the incident in fear of repercussion. Their Supervisors may be tempted to do the same, as incidents do not reflect well on their performance record. However, this negative safety culture does not help in preventing future incidents of any kind including Dropped Objects.
At Maersk Drilling every incident, Dropped Objects included, is reported and investigated, regardless of the severity. This particular incident involved a steel wedge dropping from a height of about 13 meters. Fortunately no one got hurt as a thorough Safe Job Analysis had been carried out and the necessary controls put in place before starting the operation. Barriers isolated the area around and below the work area as a precautionary measure. As a preventive measure against similar incidents such as this in future, Dave ordered a tethered wedge from Stopdrop Tooling. Stopdrop Tooling did not have any tethered wedges as no one before Maersk Drilling had ever asked for one. Stopdrop Tooling explored and discussed the various options for securing a wedge with Dave and we presented a prototype during the DROPS forum.
By exhibiting transparency in reporting the incident, following up on remedial action recommendations and developing a tethered wedge, dropped objects of a similar nature are less likely to occur again on the Maersk Completer. By sharing the incident at the DROPS forum, other contractors have the knowledge to prevent similar incidents on their rigs.
Follow this link to download the alert.
Animated Video Presentation - Steve Allerton, Go Home Safe
English is the main language spoken on drilling rigs around the world. For many employees English is not their first language. This creates a language barrier that has to be overcome on a daily basis. When it comes to safety, drilling contractors cannot afford their employees not to understand. At the same time they struggle to get the message of safety, which is often seen as a “boring” subjects, across to their employees.
Go Home Safe has developed a range of language free animated videos focussing on dropped object prevention and other safety issues. The “fun” elements of the videos grab the attention of the audience while effectively displaying safety behaviour needed to prevent dropped objects. Steve demonstrated their latest Tools at Height video that is used by Shell in their global DROPS campaign. For further information, please contact Go Home Safe directly via the Go Home Safe Website.
Potential Problems implementing DROPS - Kong Yong, SeaDrill
Kong has worked in the HSE field for 19 years and dropped object prevention has always been a part of that. Several years back, Seadrill started to implement the drops campaign on their rig in Brunei.
This implementation presented many challenges:
DROPS Audit
There are many companies providing dropped object inspection services. Most of the time, they do an excellent job, but they all work to their own standards. The dropped object surveys tend to focus on the identification of potential drops at that moment in time. It usually does not cover an assessment of the drilling contractor’s dropped object management system.
Question to DROPS: Can DROPS develop a standard for dropped objects audits standardize the process throughout the industry?
Service companies Vs. Drops and their equipment at height
Drilling contractors had DROPS awareness whereas the same level of understanding may be differ from one service contractor to another. In operational mode, many of these foreign bodies on the mast as introduced by service contractors are automatically becomes drilling contractors’ responsibility in term of inspection on daily/weekly basis. In most case, these foreign bodies are ONLY captured in the “Temporary Equipment Register”. Questions such as “is there any full inventory done on the specific equipment before rigging up onto the mast? In many cases, it is almost to none existing. Drops to consider to develop a standard to assist service contractors create an inventory of their equipment at height i.e. cement heads, stab master and etc. Only by working with all industry partners, can we come to a zero drops operation.
Another challenge is to bring DROPS “train-the-trainer” program over to BRUNEI. Considering DROPS into areas like helideck, crane, telecommunication tower and etc Dropped objects do not only occur when working on the Derrick, but most preventive efforts are focussed on that area. DROPS needs to do more research and on such areas and develop best practices and recommendations for these areas.
Contractors DROPS implementation - Dave Woodruff, Maersk Drilling
Maersk Drilling have developed a DROPS inspection manual specifically for their rigs operating in Brunei and South East Asia. They have identified all areas of potential dropped objects throughout the rig. The manual is not just limited to the Derrick, but all key areas of the rig that possess potential for contributing to Dropped Objects. It contains photographs of equipment in each of the areas with potential for Dropped Objects and specific instructions on how that equipment should be inspected and at what frequency.
In developing this manual, Maersk Drilling have strived to achieve a “ Best Practise “ strategy and build on the existing foundation of in house experience with recommendations such as those included in the DROPS workpack and lessons learned at the initial DROPS Asia Forum in October 2009.
Follow this link to download the presentation.
Frequently Identified Potential DROPS - Lance Costello, ModuSpec
ModuSpec has been in the business of rig inspections for over 20 years and dropped objects surveys have always been a natural part of that.
Some of the main Dropped Object contributors they have identified include:
• Corrosion
• Safety slings not installed or installed incorrectly
• Redundant brackets/clamps/cables/junk
• Missing/loose bolts
• Wrong type of shackles (2 part) or shackles not fitted with safety pins
• Missing toe boards or not properly installed
• Self locking/Secondary retention nuts not used
• Escape device not properly installed.
Besides looking for potential DROPS, ModuSpec looks for preventive measures in place such as:
• Effective maintenance systems to correct potential dropped objects asap
• Post jarring/Top Hole checklist
• OEM manuals and communications
• Work at Height Tool kits and Derrick register
• Risk assessments of different areas – to implement the correct management strategies
Recommendations - the easy fixes
• Use the DROPS work pack
• Have CEO/MD formally support the DROPS programme
• Make sure all understand your DROPS system
• Regular DROPS training including inductions
• Keep areas clear below workers
• Use hard barriers to keep areas people free
• Minimise exposure to high potential areas
Once a new dropped object item has been identified it should be included on the respective area checklist.
DROPS Management System - Shane Ritchie, NOV/SSI
South Seas Inspections are in the business of building and inspecting Derricks since 1993. An important part is of their business is supporting drilling contractors with their dropped object prevention. In close collaboration with Transocean, they have developed an extensive computerized dropped object management system. After a survey is completed, a dropped object prevention inspection routine is developed which the rig crew can execute themselves. The inspection routines are suitable for experienced as well as non-experienced crew. By means of pictures with descriptions that help identify an area, the crew are taken by the hand and explained how to inspect a piece of equipment. Areas of improvement are registered in the system as action items.
Senior management can view action items and that encourages the rig to find a solution fast. The system makes dropped object prevention a continuous process rather than relying on only following up on the recommendations of a 2 yearly inspection.