Posted on 05/13/2010 9:59:26 AM PDT by Ernest_at_the_Beach
Leading officers of BP, Transocean, Halliburton and Cameron appeared before the Subcommittee on Oversight and Investigations, a Sub-committee of the Committee on Energy and Commerce today. There are a number of documents available at the Committee Site, including the opening statements of Chairman of the Committee Waxman, and Congressman Stupak, Subcommittee chair. I am largely going to review the documented information on the Sub-committee web site, since it included virtually all of the information that was also gone over in the subsequent questioning of the witnesses. I am also going to use more extensive quotes than usual, since there was significant information given at the hearing that is useful to know.
In his opening remarks Congressman Waxman focused on four issues. The first was that while the cementing operation of the well may have passed the first positive pressure test, it may not have passed the following negative pressure test. The second related to the pressure monitors and what they told the people on the rig. He then noted that the blowout preventer that sat on the top of the well at the sea bed had, according to Cameron who made it, a leak in a crucial hydraulic system and a defectively configured ram. And the fourth area being examined is the response of the companies to the spill of oil.
To illustrate his concerns he used a submission from BP called “What we Know.”
The first bullet says: “Before, during or after the cement job, an undetected influx of hydrocarbons entered the wellbore.” What this means is that there was a breach somewhere in well integrity that allowed methane gas and possibly other hydrocarbons to enter the well.
The second bullet says: “The 9 7/8” casing was tested; the 9 7/8 “casing hanger packoff was set and tested; and the entire system was tested.” BP explained to us that this refers to a positive pressure test in the well. What this means is that fluids were injected in the well to increase pressure and to monitor whether the well would retain its integrity. The well passed this test.
Rigs like the Deepwater Horizon keep a daily drilling report. Transocean has given us the report for April 20, the day of the explosion. It is an incomplete log because it ends at 3:00 p.m., about seven hours before the explosion. But it confirms that three positive pressure tests were conducted in the morning to early afternoon.
The next bullet says: “After 16.5 hours waiting on cement, a test was performed on the wellbore below the Blowout Preventer.” BP explained to us what this means. Halliburton completed cementing the well at 12:35 a.m. on April 20 and after giving the cement time to set, a negative pressure test was conducted around 5:00 p.m. This is an important test. During a negative pressure test, the fluid pressure inside the well is reduced and the well is observed to see whether any gas leaks into the well through the cement or casing.
According to James Dupree, the BP Senior Vice President for the Gulf of Mexico, the well did not pass this test. Mr. Dupree told Committee staff on Monday that the test result was “not satisfactory” and “inconclusive.” Significant pressure discrepancies were recorded.
As a result, another negative pressure test was conducted. This is described in the fourth bullet: “During this test, 1,400 psi was observed on the drill pipe while 0 psi was observed on the kill and the choke lines.”
According to Mr. Dupree, this is also an unsatisfactory test result. The kill and choke lines run from the drill rig 5,000 feet to the blowout preventer at the sea floor. The drill pipe runs from the drill rig through the blowout preventer deep into the well. In the test, the pressures measured at any point from the drill rig to the blowout preventer should be the same in all three lines. But what the test showed was that pressures in the drill pipe were significantly higher. Mr. Dupree explained that the results could signal that an influx of gas was causing pressure to mount inside the wellbore.
Another document provided by BP to the Committee is labeled “What Could Have Happened.” It was prepared by BP on April 26, ten days before the first document. According to BP, their understanding of the cause of the spill has evolved considerably since April 26, so this document should not be considered definitive. But it also describes the two negative pressure tests and the pressure discrepancies that were recorded.
What happened next is murky. Mr. Dupree told the Committee staff that he believed the well blew moments after the second pressure test. But lawyers for BP contacted the Committee yesterday and provided a different account. According to BP’s counsel, further investigation has revealed that additional pressure tests were taken, and at 8:00 p.m., company officials determined that the additional results justified ending the test and proceeding with well operations.
Congressman Stupak began with a list of recent incidents that BP had been involved in, including problems on the North Slope and in Texas City. He focused on problems with the BOP, specifically
Our investigation is at its early stages, but already we have uncovered at least four significant problems with the blowout preventer used on the Deepwater Horizon drill rig.
First, the blowout preventer apparently had a significant leak in a key hydraulic system. This leak was found in the hydraulic system that provides emergency power to the shear rams, which are the devices that are supposed to cut the drill pipe and seal the well.
I would like to put on the screen a document that the Committee received from BP. This document states: “leaks have been discovered in the BOP hydraulics system.”
The blowout preventer was manufactured by Cameron. We asked a senior official at Cameron what he knew about these leaks. He told us when the remote operating vehicles (ROVs) tried to operate the shear rams, they noticed a loss of pressure. They investigated this by injecting dye into the hydraulic fluid, which showed a large leak coming from a loose fitting, which was backed off several turns.
The Cameron official told us that he did not believe the leak was caused by the blowout because every other fitting in the system was tight.
We also asked about the significance of the leak. The Cameron official said it was one of several possible failure modes. If the leak deprived the shear rams of sufficient power, they might not succeed in cutting through the drill pipe and sealing the well.
Second, we learned that the blowout preventer had been modified in unexpected ways. One of these modifications was potentially significant. The blowout preventer has an underwater control panel. BP spent a day trying to use this control panel to activate a variable bore ram on the blowout preventer that is designed to seal tight around any pipe in the well. When they investigated why their attempts failed to activate the bore ram, they learned that the device had been modified. A useless test ram – not the variable bore ram – had been connected to the socket that was supposed to activate the variable bore ram. An entire day’s worth of precious time had been spent engaging rams that closed the wrong way.
BP told us the modifications on the BOP were extensive. After the accident, they asked Transocean for drawings of the blowout preventer. Because of the modifications, the drawings they received didn’t match the structure on the ocean floor. BP said they wasted many hours figuring this out.
Third, we learned that the blowout preventer is not powerful enough to cut through joints in the drill pipe. We found a Transocean document that I would like to put on the screen. It says: most blind shear rams are “designed to shear effectively only on the body of the drillpipe. Procedures for the use of BSR’s must therefore ensure that there is no tool joint opposite the ram prior to shearing.”
This seemed astounding to us because the threaded joints between the sections of drillpipe make up about 10% of the length of the pipe. If the shear rams cannot cut through the joints, that would mean that this so-called failsafe device would succeed in cutting the drillpipe only 90% of the time.
We asked the Cameron official about the cutting capacity of the blowout preventer on the Deepwater Horizon. He confirmed that it is not powerful enough to cut through the joints in the drillpipe. And he told us this was another possible explanation for the failure of the blowout preventer to seal the well.
And fourth, we learned that the emergency controls on the blowout preventer may have failed. The blowout preventer has two emergency controls. One is called the emergency disconnect system or EDS. BP officials told us that that the EDS was activated on the drill rig before the rig was evacuated. But the Cameron official said they doubted the signals ever reached the blowout preventer on the seabed. Cameron officials believed the explosion on the rig destroyed the communications link to the blowout preventer before the emergency sequence could be completed.
In other words, the emergency controls may have failed because the explosion that caused the emergency also disabled communications to the blowout preventer.
Still, the blowout preventer also has a “deadman switch” which is supposed to activate the blowout preventer when all else fails. But according to Cameron, there were multiple scenarios that could have caused the deadman switch not to activate. One is human oversight: the deadman switch may not have been enabled on the control panel prior to the BOP being installed on the ocean floor. One is lack of maintenance: the deadman switch won’t work if the batteries are dead. The deadman switch is connected to two separate control pods on the blowout preventer. Both rely on battery power to operate. When one of the control pods was removed and inspected after the spill began, the battery was found to be dead. The battery in the other pod has not been inspected yet.
And one appears to be a design problem. The deadman switch activates only when three separate lines that connect the rig to the blowout preventer are all severed: the communication, power, and hydraulic lines. Cameron believes the power and communication lines were severed in the explosion, but it is possible the hydraulic lines remained intact, which would have stopped the deadman switch from activating.
These are not the only failure scenarios that could impair the function of the blowout preventer. The Cameron official we met with described many other potential problems that could have prevented the blowout preventer from functioning properly. Steel casing or casing hanger could have been ejected from the well and blocked the operation of the rams. The drill pipe could have been severed successfully, but then dropped from the rig, breaking the seal. Or operators on the rig could have tried to activate the shear rams by pushing the shear ram control button. This would have initiated an attempt to close the rams, but it would not have been successful. The shear rams do not have enough power to cut drill pipe unless they are activated through the emergency switch or the deadman switch.
The BP document on what we know notes that BP are focusing on
Cementing – design and execution
Casing - design and installation
Casing Hanger – design and installation
BOP-- configuration, maintenance and operation;
Well Control Practices
Halliburton provided the well log for the last two hours of the rig operation
*******************************SNIP*************************
This is a very good piece. Explains a lot for those with some knowledge of the OilPatch.
Climbing harnesses are manditory if you work more than head-high.
This thing sure sounds like T/O cut a few corners and tried to save a buck or two. BP Inspectors should have stopped T/O as BP probably didn’t get any discount.
I know a Safety Eng, with T/O, haven’t talked with him, but will bet your booty they are doing a whole lot of review and revision of Safety Procedures and probably wholesale replacements of rig and Safety management.
Helluva 2-wheeler they got, huh?
>http://en.wikipedia.or/wiki/Bridger_Mountains_%28Montana%29
http://en.wikipedia.org/wiki/Sacajawea_Peak
If I look in the mirror...we’re not talking Everest....
I don’t know, the view from the top looks pretty good to me.
I’m going to hit the rack. 3:30AM will be upon me shortly for early work schedule. Have a great upcoming day.
Yeah, yeah... It was the certified pros that made the mess in the first place.
My gut says it's going to turn out that BP was the one in a hurry wanting to take shortcuts.
Abbreviated cement set time, no CSL logs done (tests setting of cement), questionable negative pressure tests, displacing the riser before setting the top cap. All of those take time (=money), and BP is the one paying.
Contactors like Halliburton and Transocean had no (financial, at least) incentive to forego the procedures that apparently were not done.
You are likely right. When I worked for KerrMcGee out there, KM was terrible about well safety. When Camille came along 1/2 our wells didn’t have storm chokes because KM didn’t want them and we did get some broken well heads and leaks.
OK. Here’s the test then:
Let’s get a bunch of post-modernist lit crit types out of your choice of Ivy League university.
Let’s see how quickly they solve the problem.
There are a class of problems where I wish more of us engineers would get more assertive with these clowns. We should start some of these discussions with this:
“Do you have an engineering degree? Do you have a PE license? If you have neither of these things, your greatest contribution can be made if you would please go over in that corner and STFU. Thank you.”
That is exactly what happened to the former head of NASA.
When the Obama transition team person (a previous associate administrator for PR) began to argue with the head of NASA about the safety of Ares I, he said something like: Do you have an engineering degree? If not, you don’t have a right to an opinion.”
Needless to say, the day Obama took office, he was out.
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