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10. Building safety assurances into the construction and operation of a new drillship underpins an excellent safety performance in the Gulf of Mexico
In 1998, as the Company moved ahead with its oil and gas exploration efforts in the Gulf of Mexico, a project team began working with our selected drilling contractor on the construction of a new drillship designed for ultra-deepwater drilling. From the commencement of design, the goal was to achieve ‘best in class’ operational capabilities with outstanding safety performance. The CR Luigs spud its first well in April 2000 and has been employed on our operations for all but nine months since.
The CR Luigs can operate in water depths up to 9000 feet, with a drilling capability of 35 000 feet. It carries a crew of around 130 and operates 24 hours a day. Under our agreement with the drilling contractor, we charter the rig with crew and associated services on a project-by-project basis.
The drilling operations can run from 30 days to 120 days, depending on the depth and complexity of the well. Some of the ultra-deepwater projects in the Gulf of Mexico have been in water depths close to 9000 feet, with drilling depths greater than 25 000 feet. They are among the deepest wells in the world.
To ensure the rig would meet our operational and safety requirements, we assembled a team of Company personnel and specialist consultants to work collaboratively with the drilling contractor during the design and construction of the CR Luigs. Our team included engineers with expertise in rig building, subsea drilling, and ship commissioning and maintenance, as well as health, safety and environment professionals. As construction progressed, they conducted detailed assessments of the drilling plant and vessel systems and also helped develop the rig's operating procedures and management systems.
Following the launch, a detailed safety management system audit was conducted. At that time, we also commenced a program of frequent visits to the rig by the project team, to address issues directly with rig management and the crews and to ensure effective lines of communication are maintained. Our senior management also visit the rig at least quarterly to re-emphasise the commitment of the Company to our health, safety, environment and community obligations.
Of the 130 or so crew on the CR Luigs, typically about 75 are employees of the drilling contractor, and the remainder work for the ten or more companies providing onboard services. Around three of our supervisors and superintendents will also be on board at any one time. A lot of work goes into creating a common safety culture on board, through a series of practical and behavioural-based training programs. Progress is monitored and continuous improvements are implemented. As well, all crewmembers attend a weekly safety meeting to review incidents, conduct job safety analyses and discuss ideas for safety improvements. Drilling superintendents also schedule periodic themed audits of the safety systems to check how the systems are being implemented.
Because crew on a drillship are mostly working beneath suspended loads, the main safety hazard is dropped objects. We have developed a Dropped Object Prevention Program for the CR Luigs that is considered world's best practice. Initially, every item that could drop was catalogued and reviewed in terms of its purpose, necessity and ability to be secured. Unnecessary items were removed. For all the others, methods for securing them or catching them were developed, ranging from retaining pins to safety slings. A maintenance system was then developed, requiring that every item be frequently checked. Crewmembers participated throughout this process and now have a real sense of pride in the program and ownership of its implementation, a factor that has contributed significantly to its success.
With every well there is a bonus scheme based on safety performance. If the project is completed without an alternate duty injury (ADI), every crewmember receives a US$150 debit card redeemable at a popular recreational goods store. The cards are also used as an incentive to participate in an Unsafe Acts and Conditions Reporting Program as part of the regular safety audits, which are conducted up to 20 times per month. Crewmembers submit suggestions for improving safety, and the best are rewarded with debit cards.
The need for rigorous attention to safety on drilling projects is underlined by an incident off Trinidad in 2001. An uncontrolled gas release resulted from a breach of policy following a malfunction. Thankfully no injuries or environmental harm occurred from the incident. As a learning experience, this near miss led to improvements in training and auditing that have since been incorporated in our standard operating procedures.
Well control and dynamic positioning procedures are part of the stringent safety systems and programs in place on the CR Luigs, which is recognised in the industry as a high-performing rig in terms of both efficiency and safety. With a reputation among crews as a ‘happy rig’, it is the rig of choice in the Gulf of Mexico.
