Post on 04-Dec-2015
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Hazard Analysis and Risk Control Record
Doc ref: BPTT AMHERSTIA Task/Process Assessed: DST/TCP Shoot and Pull Using BHF/HDF firing head
Revision: 1.0 Location: Offshore
Date: September-2015 Assessment Team: Michael Showers, Lorenzo Sahadeo,Jason Wiltshire,Kerron Mohamed, Andell Grant,
Operation: DST/TCP Shoot and Pull Approved by:
Activity Steps
HAZARD INITIAL RISK CONTROL MEASURES RESIDUAL RISK
Hazard Descriptionand Worst Case
Consequences with no Prevention or Mitigation
Measures in Place
Loss Category/
Population Affected L
ikel
iho
od
Sev
erit
y
Ris
k L
evel
List all Current and Planned Control Measures, taking into Account all Contributing and Escalating Factors
Lik
elih
oo
d
Sev
erit
y
Ris
k L
evel
Current and Planned Prevention Measures to reduce Likelihood
Current and Planned Mitigation Measures to reduce Severity
On-site preparation
Pressure
Unexpected release of pressure during function test leading to personnel injury
Electrical
Use of no intrinsically safe laptop to program tools on the pipe deck. This can cause an explosion leading to injury or death of personnel, loss of SLB and Client assets.
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Like
ly (
4)
Cat
astr
ophi
c (-
4)
IInto
lera
ble
(-1
6)
Caution off area before starting process.
Only trained personnel allowed to perform function test.
Only qualified SLB personnel allowed within the cautioned off area during the function test.
Perform gas test with certified gas meter before powering on laptop and keep gas monitor on as long as the laptop is in use.
ERP in place
Medevac in place
Confirm all PPE is available and used per SLB standards
ERP in place
Medevac in place
Pos
sibl
e (3
)`
Maj
or (
-3)`
Un
des
irab
le (
-9)
HARC Record Page 1 of 10 Template Revised: 28-Sep-15
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On-site preparation
Explosives, Gravitational Potential Energy (Stepping, Handling, Lifting), Mechanical Lifting
Dropped / rolling gun leading to injury or fatality to personnel.
Gun detonation during Explosives handling leading to personnel injury or death.
Working on top of racked tubulars with risk of fall from height, crushing injuries.
Container handling or Dropped objects with associated risk of; personnel injury, equipment damage.
Contamination with chemicals.
Inability to deliver service as required.
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Like
ly (
4)
Cat
astr
ophi
c (-
4)
IInto
lera
ble
(-1
6)
On site safety briefing with all crew and company man, including PTW procedures
Reconfirm well details and job program.
Review rig capabilities with driller, casing and wellhead max rating – ensure compatibility with job plan and contingency planning.
Ensure rig’s handling equipment for SLB tools are on the rig and are in good working order.
Ensure the pipe is going to be drifted prior running in hole.
Confirm with company man – tool preparation and witness tests: tool operation ranges and max planned pressures.
Communicate to all personnel on rig TCP procedures:
No lifting operations during gun handling operation.
Authorized personnel present during gun handling operations.
Use management of change procedure for job plan changes
Inform crew of program changes/amendments
Rig walk through, safety/handling, equipment /explosive placement
Review document man riding capabilities
Assign responsibilities/ handovers and work roster
Record QA data of actual RIH equipment, assets, run order etc.
Contingency planned communicated to all personnel.
Confirm all PPE is available and used per SLB standards
Pos
sibl
e (3
)`
Maj
or (
-3)`
Un
des
irab
le (
-9)
Reconfirm deviation, mud, temp, packer setting depth, casing collars
Recalculate rupture discs and tool operating ranges.
Instruct on trapped pressure procedures, roles and responsibilities.
Confirm the well is full and static.
Obtain work permits
HARC Record Page 2 of 10 Template Revised: 28-Sep-15
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On-site preparation
Explosives, Gravitational Potential Energy (Stepping, Handling, Lifting), Mechanical Lifting
Dropped / rolling gun leading to injury or fatality to personnel.
Gun detonation during Explosives handling leading to personnel injury or death.
Working on top of racked tubulars with risk of fall from height, crushing injuries.
Container handling or Dropped objects with associated risk of; personnel injury, equipment damage.
Contamination with chemicals.
Inability to deliver service as required.
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Like
ly (
4)
Maj
or (
-3)
Into
lera
ble
(-1
2)
Check off equipment against manifest
Prepare equipment, test and document, including witness (if required)
Inspect gun boosters, o rings and plastic transfer components prior to picking up
Log explosives used and secure remnants and excess explosives
Prepare HDF/BHF firing head in Dog house, pin and fill sub. All the pre assembly checks must be done according to the TCP FOM.
Strap all tools, guns and record with ID and ODs. Prepare final string drawing
Advise client review and sign off procedures, string drawing and calculations.
Secondary specialist to verify correct preparation
Lay out guns and tools per pick up assemblies and label.
Clear drifting, pipe dope, handling, tool make, arming up to be given
PPE in use as per SLB Standard.
Pos
sibl
e (3
)
Maj
or (
-3)
Un
des
irab
le (
-9)
HARC Record Page 3 of 10 Template Revised: 28-Sep-15
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Pick up equipment
Explosives, Gravitational Potential Energy (Stepping, Handling, Lifting), Mechanical Lifting
Dropped / rolling gun leading to injury or fatality to personnel.
Gun detonation during Explosives handling leading to personnel injury or death.
Working on top of racked tubulars with risk of fall from height, crushing injuries.
Container handling or Dropped objects with associated risk of; personnel injury, equipment damage.
Contamination with chemicals.
Inability to deliver service as required.
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Pos
sibl
e (3
)
Cat
astr
ophi
c (-
4)
Into
lera
ble
(-1
2)
JSA with all concerned parties; rig crew, SLB crew, company man. Distribute string drawing to driller, tool pusher, Co man, OIM
SLB explosive training and procedures to be followed at all times (Ref TCP FOM C200463)
Area below rotary barred off, no personnel until guns are 200 ft below seabed.
All lifting operations to be conducted by competent rig crew / deck crew personnel with technical assistance were required from SLB crews.
Ensure equipment to be RIH and checked off as per the BHA well sketch. If something is left out or added this will affect the space out.
No primary high Explosives in the guns
Confirm BOP ram and Hydril space out
Check for check valves in kill line to BOP,
Remove check valve or read/bleed annulus through choke side
Ensure all tool and gun handling equipment is available on rig floor
All lifts to the rig floor must be done with fixed shackle
Prior to lifting guns, ensure the rams/Hydril is open, stand clear
Certified lifting subs in use
Driller to monitor make up line (chalk line) for possible back off while guns are made up
Correct positioning and manual handling techniques by SLB and rig crew for handling slips and guns
Ensure correct clamp and positioning of safety clamp
Handling caps removed and installed only under SLB supervision (Ref TCP FOM)
All unnecessary equipment and hand tools to be keep clear of the area
Ensure use of correct hole cover
Personnel in correct positions and aware of escape routes
Prior to make up SLB supervisor check for any foreign objects in either box or pin connector and to directly control gun make up operation
Ensure all booster spacing has been checked on the deck and are with-in allowable tolerances
SIPP techniques to be followed during make up focusing on hand position and pinch points
Safety spacer ensures top shot below rotary table
Unl
ikel
y (2
)
Maj
or (
-3)
Un
des
irab
le (
-6)
HARC Record Page 4 of 10 Template Revised: 28-Sep-15
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Run in hole with guns
Explosives, Machinery /Equipment, Human (Communication), Personnel Gravitational Potential Energy (Stepping, Handling, Lifting)
Off depth perforation resulting in loss of well,
Loss of Reputation
Personnel injury.
Reputation (SLB), Assets (Customer and SLB)
Environment
Unl
ikel
y (2
)
Cat
astr
ophi
c (-
4)
Un
des
irab
le (
-8)
SLB explosive training and procedures to be followed at all times (Ref TCP FOM C200463)
Barriers to remain in place until guns have passed 200ft
Make an announcement after 200ft
Running speeds and make up practices as per SLB guidelines
No Explosives are exposed to atmosphere
Use Teflon rabbit to drift the work string (Do not rabbit over well bore).
Set and come off slips smoothly and slowly to minimize water hammer effect on firing head.
Utilize correct clamps on guns.
Cover the tubing while RIH to avoid anything from dropping on top of the Firing Head.
Pipe dope applied only on the pin.
Tubing will be filled while running in hole and the cushion will be trapped with the IRDV (AVC Command)
Minimum of 300 psi hydrostatic to drive firing pin on BHF, pressure pulse to activate HDF.
100 % firing heads backup
Ensure fluids levels are monitored during trip in hole for proper displacement
Impr
obab
le (
1)
Maj
or (
-3)
Acc
epta
ble
(-3
)
HARC Record Page 5 of 10 Template Revised: 28-Sep-15
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Tag, Place guns on depth, Correlate, And Space out
Explosives
Human (Communication, Personnel injury)
Machinery/Equipment/ Hand Tools
Off depth perforation resulting in loss of well,
Loss of Reputation.
Personnel injury resulting in lost time injury
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Pos
sibl
e (3
)
Cat
astr
ophi
c (-
4)
Into
lera
ble
(-1
2)
JSA with all concerned parties; rig crew, SLB crew, company man.
Open and honest communication between all parties in every aspect of gun positioning.
SLB explosive training and procedures to be followed at all times (Ref TCP FOM C200463)
Authorized personnel only, allowed access to work area during operation
Use hole cover to prevent anything from being dropped in well during correlation or space out
All lifting operations to be conducted by competent rig crew / deck crew personnel with technical assistance were required from SLB crews.
Ensure logging tool does not reach firing head if Wireline is used.
Packer will set when going to tag more than once. It needs to be unset before attempting to tag again.
The string WILL NOT be lifted using the flowhead.
Do NOT slack off more than 5,000lbs when tagging.
Verify correct tie in log being used to correlate with company rep sign off.
Company rep and SLB Engineer/Technician to be in complete agreement with space out and correlation results prior to proceeding.
Review string diagram with correlation engineer noting, depths, ID restrictions, and source to top shot distance
Unl
ikel
y (2
)
Maj
or (
-3)
Un
des
irab
le (
-6)
HARC Record Page 6 of 10 Template Revised: 28-Sep-15
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Rig up surface equipment and pressure test
Explosives
Machinery/Equipment
Assets
Human (Communication, Personnel injury)
Stepping, Handling, And Lifting.
Parting high pressure lines or equipment resulting in personnel injury
Perforating over balanced during pressure test resulting in inability to deliver service as required.
String jumping out of slips
Lost in hole.
Personnel (Customer and SLB), Reputation (SLB)
Assets (Customer and SLB)
Process (Customer and SLB)
Unl
ikel
y (2
)
Cat
astr
ophi
c (-
4)
Un
des
irab
le (
-8)
Toolbox meeting with all concerned parties; rig crew, SLB crew, company man.
SLB explosive training and procedures to be followed at all times (Ref TCP FOM C200463)
Authorized personnel only, allowed access to work area during operation
Personnel in correct positions, aware of responsibilities and escape routes
All lifting operations to be conducted by competent rig crew / deck crew personnel with technical assistance were required from SLB crews
Ensure annulus open and all valves lined up correctly prior to pressure test
Set packer and test packer elements and bypass seal
Use hole cover to prevent anything from being dropped in well during operation
If slips are being used ensure they are tied together
Test pump operator to make announcements over PA system to keep all personnel aware operations and hazards
No personnel allowed access to work area while pressure applied to surface equipment
Leaks to be monitored from test pump and pressure released prior to allowing personnel to repair leaks
PPE as per SLB standards.
SIPP Techniques followed at all times.
Impr
obab
le (
1)
Maj
or (
-3)
Acc
epta
ble
(-3
)
HARC Record Page 7 of 10 Template Revised: 28-Sep-15
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Perforate and control well
Explosives
Machinery/Equipment
Assets
Human (Communication, change management, Personnel injury)
Parting high pressure lines or equipment resulting in personnel injury
Firing head fails to initiate resulting in inability to deliver service as required.
Sticking guns (debris, underbalance, splitting).
Personnel overhead with drop bar
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Pos
sibl
e (3
)
Cat
astr
ophi
c (-
4)
Into
lera
ble
(-1
2)
JSA with all concerned parties; rig crew, SLB crew, company man. Discuss perforating sequence, flow back, and well kill procedures
SLB explosive training and procedures to be followed at all times (Ref TCP FOM C200463)
Authorized personnel only, allowed access to work area during operation
Personnel in correct positions, aware of responsibilities and escape routes
All lifting operations to be conducted by competent rig crew / deck crew personnel with technical assistance were required from SLB crews
Ensure Drop bar is of engineered design and designed for well conditions
Make sure to close swab valve as soon as the bar has dropped. IF Swab is not operating, close Master valve and fix swab valve with MV closed.
Ensure all valves lined up correctly prior to activating firing system
Use hole cover to prevent anything from being dropped in well during operation
If no indication at surface. If formation is taking fluid, the formation was perforated, if not, it wasn’t. Wait for indication at surface. Note the bubble hose located at the choke manifold.
If there is no indication of the guns detonating, follow contingency to POOH with live guns: Fish the bar and call town.
All involved parties to familiar with perforating, flow back, and well kill contingencies prior to commencing operation
Unl
ikel
y (2
)
Maj
or (
-3)
Un
des
irab
le (
-6)
HARC Record Page 8 of 10 Template Revised: 28-Sep-15
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Pull Guns out of well
Human (Communication), Explosives,
Pressure, Machinery/Equipment/ Hand Tools
Well still coming after finishing kill procedure
Perforate off depth
Bringing live guns to surface
Swab in well resulting well control situation
Contamination of personnel with well fluids.
Personnel (SLB and Customer)
Assets (Customer and SLB),
Process (Customer and SLB)
Like
ly (
4)
Maj
or (
-3)
\Into
lera
ble
(-1
2)
Make certain all valves are lined up correctly
Rig to monitor returns
Flow check, when client is satisfied, rig down flowhead and install a TIW with pumping sub. Unset packer and do a flow check again. Once client is satisfied continue POOH
Guns must be treated as live for this case
Ensure SLB and Client are aware of situation and risks have been addressed prior to pulling live guns
JSA with all concerned parties; rig crew, SLB crew, company man.
SLB explosive training and procedures to be followed at all times (Ref TCP FOM)
Running speeds and break out practices as per SLB guidelines
Set and come off of slips smoothly and slowly to minimize water hammer effect on firing head
Contingency planning for pulling live guns.
Stop operation and hold JSA when guns reach 200’ from mud line or surface prior to proceeding with live guns
Proper PPE for well fluids
Unl
ikel
y (2
)
Maj
or (
-3)
Un
des
irab
le (
-5)
Report Compilation/ Data Submission to Client
Human (Training and competence
Unsecured Data/Info
Incorrect data sent to client
Data sent to wrong client
Data altered to cover up problems
Report not Quality Checked containing misspellings, wrong format for plots, incorrect depths, etc.
Personnel (SLB and Customer)
Assets (Customer and SLB)
Reputation
Pos
sibl
e (3
)
Maj
or (
-3)
Un
des
irab
le (
-9)
Insure properly trained personnel perform or supervise the entire report compilation.
Utilize existing RQC forms to ensure 100% compliance with reporting procedures.
Never alter data for any reason.
Use correct format for data including header information.
Insure data is kept in secure location following IT security guidelines.
Open attachments prior to sending reports or data to client to confirm correct files being sent
Insure all client contacts (specialist, FSM, Ops Mgr, Sales, etc) have latest revision of any data submission and all are speaking the same story.
Unl
ikel
y (2
)
Ser
ious
(-2
)
Acc
epta
ble
(-4
)
HARC Record Page 9 of 10 Template Revised: 28-Sep-15
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Job debrief Human (Training and competence
Unsecured Data/Info
Equipment not properly tagged (green tag still on used equipment)
Client Data or reports left in unsecured location
Job paperwork incomplete or missing
Client feedback lost or not communicated at district
Personnel (SLB and Customer)
Assets (Customer and SLB)
Reputation
Pos
sibl
e (3
)
Maj
or (
-3)
Un
des
irab
le (
-9)
Insure all equipment is properly tagged as to its state of readiness and in its proper location
Follow IT security guidelines for all documents containing client information
Follow local SLB procedures and policies for job paperwork. Insure all pertinent paperwork is completed.
Communicate to EIC or FSM the feedback provided by the client. Also, any upcoming opportunities or improvements requested by client.
Insure client debrief is performed with all Schlumberger levels in the loop.
Unl
ikel
y (2
)
Ser
ious
(-2
)
Acc
epta
ble
(-4
)
HARC Record Page 10 of 10 Template Revised: 28-Sep-15