Last autumn Petrobras established its Operational Excellence Programme (PEO) to address offshore operational and safety performance. Moving forcefully on comprehensive safety measures, the Brazilian oil major is improving current operations while preparing for deeper waters.
In his Rio de Janeiro office, Exploration and Production Manager, South-Southeast, Carlos Tadeu de Costa Fraga is seated in the midst of change.
Says Tadeu, First of all our challenge is to continue going deeper, developing and applying new technology. Second, it is to develop in total compliance with our safety, health and environmental policy at all times. His words are already being put to the test. In the next three years, Petrobras will install six new floating production units.
To explain Petrobras safety philosophy, Tadeu quotes a song familiar to all Brazilians, E qualquer desatenção, faça não, pode ser a gota dágua, not knowing which drop is the last one that will make a cup spill over, one should always be attentive. Lack of attention even for a brief moment might cause one to miss that crucial last drop.
Learning from P-36
Sometimes several drops combine to create a ripple, as was the case with semisubmersible P-36. In March 2001, an accident onboard the platform in the Roncador Field offshore Brazil caused it to sink. The final Report concluded that not one single action or mistake caused the accident, and the avoidance of any of the main causes would have modified or completely prevented the accident. Says Tadeu, We needed to stop, reflect and behave differently. We discussed what we had learned with experts, what future incidents could occur, and created a programme to prevent such incidents. The PEO programme was initiated last November to improve the health, safety and environmental aspects of Petrobras offshore operations.
Strengthening the Class concept, guidelines and directives for the design of offshore production installations were also quickly approved and adopted.
Explains Tadeu, Improving safety is like everything we do. The lessons learned are an important part of the continuing process. It is all about cultural change. We are recognised experts on deepwater exploration. For us the P-36 accident was a shock. Petrobras had to restore a level of confidence: to bring back the morale of the entire company.
Petrobras dedicated more than 80 senior experts to the investigation. About 20 worked full time. Their engineering skills were crucial in tests and simulations to determine the accident causes. Union representatives, and university and DNV experts supported the investigation committee.
Says Tadeu, To conduct an accurate investigation, DNVs experience of other major industrial accidents was invaluable. Since the platform was a total loss, the accident was much more difficult to reconstruct. DNVs expertise was critical in building the right methodology.
Improving safety
At years end, the PEO programme will have implemented changes to engineering design, safety, ballast and stability, maintenance, operations and human resources.
Says Tadeu, The investigation analysis revealed important areas of improvement, in addition to some not related to the accident. We put together these aspects in the PEO programme, addressing all operational areas: design guidelines, operational procedures, organisation, training and an Emergency Response Plan.
Common to all areas is that they are supported by attention to the human element. The right people with the right skills are what make a successful business. They are the ones who make the procedures happen.
The programme affects more than 3,000 staff. Organisation has been pivotal. With fourteen main tasks to be implemented across business units, involving all Petrobras platforms in Brazil and abroad, responsibility needed to be divided clearly and delegated to each unit.
The central committee, of which Tadeu is a member, oversees project organisation and monitors the units implementation. Periodic audits are being performed according to a specific checklist protocol. Says Tadeu, What is crucial during these audits is to look at implementation. Feedback is sent to senior management to allow for any changes to the implementation process.
Valuable transparency
Petrobras has been extremely open with the P-36 investigation findings. Tadeu explains, We adopted the attitude to be totally transparent from the start. In the aftermath, we have shared the report throughout the industry and conducted workshops in the U.K., Norway and at this years Offshore Technology Conference in the U.S.A.
Involving its contractors is another Petrobras initiative. Says Tadeu, We have initiated a programme inviting our contractors to participate in our environmental efforts. From an environmental, health and safety perspective, we are pushing them to adopt a safety management process. We provide them with support and allow them to improve. The suppliers who participate and do improve are termed preferred suppliers.
All our business units provide workshops for the suppliers to help them improve. If they dont, they no longer do business with us.
Managing in deeper waters
Petrobras is moving now to greater depths with a broad base of technological know-how and safety programmes. In 2005, a semi-submersible to be called P-52 will begin production in the Roncador field, replacing the P-36 now resting on the ocean floor; its construction and future operations build on a foundation of hard-learned lessons.
And above all, the activities to improve Petrobras operations offshore have had a pivotal role in improving its ability to best manage future changes and challenges.
Text: cecilie.lone@dnv.com
Date: 2002-08-15