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Petrobras P-36Incident
Susana Leon Caceres
Master’s Student in Safety Engineering
Mary Kay O’Connor Process Safety Center
Texas A&M University, College Station.
January 14th , 2016
Steering Committee Meeting
Susana Leon Caceres• I was born and raised in Bucaramanga, Colombia
• Bachelor’s degree in Chemical Engineering at “Universidad Industrial de Santander”
• Safety Engineer at Ecopetrol in Cartagena’s Refinery
• Master’s Student in Safety Engineering at Texas A&M University (First Year)
01/14/2016 STEERING COMMITTEE MEETING 2
Source: Google maps[1]
Outline
• Background
• Petrobras P-36 incident description
• Sequence of events
• Investigation-what went wrong?
• Causes and root causes
• Conclusions and recommendations
01/14/2016 STEERING COMMITTEE MEETING 3
Floating Production Unit (FPU) Background
01/14/2016 STEERING COMMITTEE MEETING 4
• Original name: “Spirit of Columbus”
• Designed and constructed in 1984-1994 in Italy
• Original intent: oil drilling and small production unit [3]
• Contracted by Petrobras in 1996, and renamed to P-36
• Adapted into a large oil production platform (FPU) by Canadian Shipyard Davie Industry[3]
• Major changes:
Designed to operate at 500 m water depth adapted to 1360 m [4,5]
Capacity 180,000 bpd of oil and 7.2 million m3/day of gas
Installed buoyancy boxes to accommodate extra weight of topsides
Average production on March 15: 84,000 bpd of oil and 1.3 millions m3/day gas [4,5]
• Installed at the Roncador Field in 2000
Fig 1. Location of Campos Basin’s Rocandor field [1,2]
Accident Description [6, 7]
01/14/2016 STEERING COMMITTEE MEETING 5
When – 15th March, 2001
Where – Roncador field in Campos Basin, 125 km from the coast of Brazil
2 explosions in one of the support legs, followed by flooding of the leg
The FPU sank (on March 20th)
Consequences
• 11 fatalities
• Financial losses nearing 1 billion dollars
• Around 316,000 gal of diesel and 80,000 gal of crude oil spilled
Fig 2. P-36 platformsinking [8]
Fig 3. P-36 spill on the sea [9]
Accident Description
01/14/2016 STEERING COMMITTEE MEETING 6
Aft
D
C
B
Fire pumps (seawater pumps): A: Portside aftB: Portside foreC: Starboard foreD: Starboard aft
Fig 4. General view of P-36 [6] Fig 5. Semi-submersible platform modelAdapted from [10]
Platform Layout “Aerial view” [6,12]
01/14/2016 STEERING COMMITTEE MEETING 7
Starbo
ard
Aft
Portsid
e
Bow/Fore
Fire pumps: A: Portside aftB: Portside foreC: Starboard foreD: Starboard aft
A
BC
D
Emergency Drain TankFig 6. Emergency Drain Tank , Top view.Source: The Accident of P-36 FPS [6].
Fig 7. Special drawings created,
Platform aerial view.Source: Accident
Investigation Petrobras P-36 Sinking
(DNV) [12].
Sequence of events (March 10th - 20th, 2001 )[4,6]
01/14/2016 STEERING COMMITTEE MEETING 8
Causes
Incident day Salvage operations
Fig 7. Adapted general timeline of the P-36 accident.Source: Petrobras and Brazilian navy reports [4,6].
Sequence of events (March 15th)[4,6]
01/14/2016 STEERING COMMITTEE MEETING 9
• First explosion (Mechanical explosion – pressure burst)― Due to pressure build-up in a drain tank
• Second explosion(Chemical explosion)― Due to ignition of released vapors
• Fire alarm system operations
Fig 8. Inclination six degreesSource: Acidente da P-36 –Explosao e Naufragio [11]
Investigation –what went wrong? [4,6,12]
01/14/2016 STEERING COMMITTEE MEETING 10
OPEN
CLOSE
Partially Close
HEADERVALVE
PRODUCTION HEADER
PORTEDT
STARBOARDEDT
BLIND FLANGE
ATMOSPHERICVENT
CAISSONVALVE
10 bar
Aft/Fore viewInitial conditions [4,6,12]
• Both tanks contained 50% of water• The pump of the Starboard-aft Emergency Drain Tank was removed for maintenance• 3 valves were closed and properly isolated with blind flanges• 1 valve was manually closed but no blind flange was installed(allowing liquid to enter)
Fig 9. Flow chart Emergency Drain tank system on the aft site (initial conditions on March 14th).Source: Adapted from [4,7,11,12]
BLIND FLANGE
Investigation –what went wrong? [4,6,12]
01/14/2016 STEERING COMMITTEE MEETING 11
HEADERVALVE
PRODUCTION HEADER
PORTEMERGENCYDRAIN TANK
ATMOSPHERICVENT
CAISSONVALVE
10 bar
Aft/Fore viewEmptying portside TDE [4,6]
• Port pump aligned towards the production header
• Outflow line valves (starboard) opened
• Delay to start up the drain pump of the port aft TDE
• Reverse flow during 54 min The
pressure started
increasing
STARBOARD EMERGENCYDRAIN TANK
Valve leaks
Fig 10. Flow chart Emergency Drain tank system on the aft site (unsuccessful activation of the port tank pump).Source: Adapted from [4,7,11,12]
OPEN
CLOSE
Partially Close
BLIND FLANGE
BLIND FLANGE
VA
PO
RO
ILW
ATE
R
Investigation –what went wrong? [6,11]
01/14/2016 STEERING COMMITTEE MEETING 12
HEADERVALVE
PRODUCTION HEADER
ATMOSPHERICVENT
CAISSON VALVE
10 bar
Aft/Fore view
Internal pressure reaches 10 bar
P (
bar
)
Min
ute
s
STARBOARD EMERGENCYDRAIN TANK
Water started
pumping out
19 barCapacity
Valve leaks
Fig 11. Flow chart Emergency Drain tank system on the aft site (Port tank pump start up).Source: Adapted from [4,7,11,12]
PORT EMERGENCYDRAIN TANK
OPEN
CLOSE
Partially Close
BLIND FLANGE
BLIND FLANGE
Investigation –what went wrong ? [6,11]
01/14/2016 STEERING COMMITTEE MEETING 13
Tank’s wall Rupture (Leakage) Tank’s wall Rupture (Gas Dispersion) Flooding in 4th Level (Oil and Water)
Fig 12. Adapted From Acidente da P-36 –Explosao e Naufragio.Source: Acidente da P-36 –Explosao e Naufragio (Petrobras – 15.03.2001)
.
3RD LEVEL 3RD LEVEL 3RD LEVEL
4th LEVEL 4th LEVEL 4th LEVEL
Investigation –what went wrong ? [6,12]
01/14/2016 STEERING COMMITTEE MEETING 14
• The fire alarm system was activated and the starboard pump was automatically started .
•Water reached the ventilation duct rupture, and filled the pump room (pontoon).
• Manholes connecting the pontoon with the stability box and ballast tanks were opened for inspection. Fig 13. Starboard aft column.
Source: Accident Investigation Petrobras P-36 Sinking (DNV) [12].
Cause and effect – (Fishbone) [4,6,7]
01/14/2016 STEERING COMMITTEE MEETING 15
Causes [4,6]
01/14/2016 STEERING COMMITTEE MEETING 16
Explosion
• Absence of a blind flange in the intake valve on the starboard aft tank
• The port pump was aligned towards production header, instead of caisson production.
Unit Sinking
• Failure of the ventilation system- watertight dampers actuators
• Manholes opened on the ballast tank and stability box
• Lack of training in emergency stability control
• Design of the sea-chest valve (fail mode)
Conclusions
01/14/2016 STEERING COMMITTEE MEETING 17
• Investigation results indicate that the most likely scenario was
overpressure in the starboard aft emergency drain tank, which caused
a mechanical explosion and lead to the rupture of the tank. This initial
event allowed the release of flammable hydrocarbon gas, which
eventually originated a second explosion.
• It was concluded that the main cause of these events was failure to
provide effective isolation in the intake valve at the starboard aft tank
during maintenance (i.e., absence of blind flange), which allowed
unexpected reverse oil and gas flow into the starboard aft tank.
Conclusions
01/14/2016 STEERING COMMITTEE MEETING 18
• Although there were many factors that contributed to the flooding
process of the unit. However, this process was accelerated because of
the fail mode / fail state of the sea-chest valves and because several
buoyancy boxes were open at the same time for inspection and thus
when water entered they flooded.
Recommendations [4,6,14]
01/14/2016 STEERING COMMITTEE MEETING 19
Petrobras Inquiry Commission
• Improve offshore operations and enhance safety on board offshore units.
• Do not install pressure vessels and atmospheric tanks connected to the production
process facilities (i.e. hydrocarbons) inside columns or pontoons: Re-assess the risk and
review the design of the units that operate with these design issues.
Brazilian Governmental Petroleum Agency (ANP) & Brazilian Port Administration
(DPC)
• Review the criteria for a number of simultaneous work permits in offshore activities.
• Review the content of the current contingency plans.
Key Recommendation: Creation of the Operational Excellence Program – PEO
Engineering design/ Safety/ Ballast and Stability/ Maintenance/ Operation/ Human Resources
Recommendation
01/14/2016 STEERING COMMITTEE MEETING 20
Budget cutting – needs Risk Based review
Understand impacts of cuts in budgets in important areas such as
SAFETY and QUALITY
References
01/14/2016 STEERING COMMITTEE MEETING 21
1. Google Map 2016 [cite 2016 01/11]; Available from: https://www.google.it/maps/place/Colombia/@4.18406,-77.4395073,6z/data=!3m1!4b1!4m2!3m1!1s0x8e15a43aae1594a3:0x9a0d9a04eff2a340
2. Noticias Internacionais – International Oil and Gas News 2014 [cite 2016 01/11]; Available from:http://blogonip.blogspot.com/2014_07_16_archive.html
3. Mogensen, V., Worker Safety under Siege: Labor, Capital, and the Politics of Workplace Safety in a Deregulated World. ILR Review, 2008.61(2): p. 82.
4. (ANP), B.G.P.A.-. and B.P.A.-. (DPC), CASUALTY OF PLATFORM "P-36". 2001: p. 29.5. Henriques, C. and M. Fachetti. Roncador Field: Transport of P-36 and Installation of the Mooring System. in Offshore Technology Conference.
2000. Offshore Technology Conference.6. Barusco, P. The accident of P-36 FPS. in Offshore Technology Conference. 2002. Offshore Technology Conference.7. Whelan, S., Petrobras P-36 Accident. Proto-Type, 2013. 1.8. Mail Online 2010 [cite 2016 01/11]; Available from: http://www.dailymail.co.uk/home/moslive/article-1328470/Britains-latest-offshore-
investment-The-Brazilian-oil-boom.html9. Gulf Oil Disaster with enormous oil plume as much as 300 feet thick in place-from Deepwater Horizon crude oil drilling accident 2010 [cite
2016 01/11]; Available from: https://cricketdiane.wordpress.com/tag/oil-spill-in-gulf-of-mexico/10. Keel 2016 [cite 2016 01/11]; Available from: http://keelsolution.com/project/semi-submersible/#11. Acidente da P-36 –Explosao e Naufragio (Petrobras – 15.03.2001). 2015 [cite 2016 01/11]; Available from <
https://www.youtube.com/watch?v=Oz10Rsw_bJc>12. Pitblado, R., Accident Investigation Petrobras P-36 Sinking 2001.13. Videiro, P.M., et al. The Accident of the P-36 Platform: The Rupture of the Emergency Drainage Tank. in ASME 2002 21st International
Conference on Offshore Mechanics and Arctic Engineering. 2002. American Society of Mechanical Engineers.14. da Costa Fraga, C.T. and C.F. Mastrangelo, Petrobras Operational Excellence Programme. paper, 2002. 28605: p. 24-27.15. Berends, W.R., $PRICE AND PROFIT %, The Essential Guide to Product and Service Pricing and Profit Forecasting. 2004. p. 6116. Hancock, C., M. Jarvis, and N. Vineall, PETROLEO BRASILEIRO SA (“PETROBRAS”) Appellant - and - PETROMEC INC Respondent. 2012.
Acknowledgement • Dr. Sam Mannan
• Dr. Clementina Ramirez
• Dr. Robin Pitblado
• Mr. Jim Pettigrew
• Ms. Valerie Green
• Wen Zhu
10/26/2015 STEERING COMMITTEE MEETING 22
• Logan Hatanaka
• Zohra Halim
• Tatiana Flechas
• All members of SC
• All members of MKOPSC
Thank you!
Questions?
January 14th, 2016
Steering Committee Meeting