Articles

Could a PSM program have prevented the Deepwater Horizon incident?

September 15, 2024

The Deepwater Horizon disaster of 2010 was a catastrophic event that exposed multiple safety failures and highlighted the critical importance of robust safety management systems in high-risk industries. This incident, which resulted in 11 deaths, 17 injuries, and the largest oil spill in U.S. waters, serves as a powerful reminder of the consequences of inadequate risk management and safety practices.

Key Safety Failures

Inadequate Risk Assessment and Management

BP and its contractors failed to properly assess and mitigate major accident risks associated with the Deepwater Horizon rig and Macondo well. The U.S. Chemical Safety Board (CSB) investigation found no evidence that BP performed formal risk assessments of critical operational decisions made in the days leading up to the blowout^[3].

Equipment Failures and Poor Maintenance

Several equipment issues contributed to the disaster:

The blowout preventer (BOP) system had multiple failures, including faulty wiring, a dead battery, and a bent pipe.
There was poor maintenance of electrical equipment that may have ignited the explosion.
Gas alarms and automatic shutdown systems were bypassed, preventing early detection of problems.

Flawed Well Design and Testing

BP and Halliburton did not properly design and cement the well to control formation pressures and fluids. Additionally, BP failed to conduct an accurate pressure integrity test of the well^[1].

Insufficient Training and Emergency Preparedness

Personnel lacked proper training on when and how to shut down engines and disconnect the rig from the well in an emergency^[3].

Systemic Issues

The disaster revealed systemic failures in BP's safety culture and management systems:

BP applied lower safety standards to contracted rigs compared to its own facilities.
There was a focus on production over safety, with a culture described as "running it until it breaks".
The Safety Management System failed to provide proper risk assessment, adequate maintenance, and process safety adherence.

The Role of Process Safety Management (PSM)

Implementing a robust Process Safety Management program, even when not required by regulations, could have potentially prevented or mitigated the Deepwater Horizon disaster. Key PSM elements that could have made a difference include (but are not limited to):

Process Hazard Analysis (PHA)

A thorough PHA would have identified potential risks associated with the well design and cementing process, leading to better risk mitigation strategies.

Mechanical Integrity

Regular inspections and maintenance of critical equipment, such as the blowout preventer, would have been mandated under a PSM program, potentially preventing equipment failures.

Management of Change

A formal management of change process would have ensured that any alterations to the well design or drilling procedures were thoroughly evaluated for potential safety impacts.

Contractor Management

PSM requirements for contractor management would have improved oversight and coordination between BP, Transocean, and Halliburton, ensuring all parties adhered to the same high safety standards.

Incident Investigation

Previous near-misses and smaller incidents would have been thoroughly investigated, potentially revealing systemic issues before they led to a catastrophic event.

Lessons Learned and Path Forward

The Deepwater Horizon disaster underscores the importance of applying PSM principles to all high-risk operations, even when not explicitly required by regulations. By adopting a comprehensive approach to safety management, companies can:

1. Enhance safety culture across the organization

2. Systematically identify and manage process hazards

3. Improve emergency preparedness and response

4. Better coordinate between operators and contractors

5. Continuously improve safety systems and procedures

As the oil and gas industry continues to push boundaries with deeper drilling and operations in challenging environments, it is absolutely crucial to prioritize safety and risk management and take it seriously. The implementation of rigorous safety management systems (such as a PSM program even if not regulated), regular testing and maintenance of critical equipment, and fostering a strong safety culture are essential steps in preventing future disasters.

The Deepwater Horizon incident serves as a powerful reminder that there are no shortcuts to safety in high-risk industries. Let us all learn from this tragedy and implement comprehensive safety management practices so we can work towards preventing similar catastrophes in the future.

Sources:

1. https://www.workboat.com/offshore/deepwater-horizon-blowout-preventer-failed-due-to-unrecognized-pipe-buckling-report-says

2. https://www.auditcomply.com/2018/07/18/story-risk-management-failure-deepwater-horizon/

3. https://safety4sea.com/cm-learn-from-the-past-deepwater-horizon-oil-spill/

4. https://www.theguardian.com/environment/2014/jun/05/bp-deepwater-horizon-spill-report-failures-risks

Citations:

[1] https://www.workboat.com/offshore/deepwater-horizon-blowout-preventer-failed-due-to-unrecognized-pipe-buckling-report-says

[2] https://www.auditcomply.com/2018/07/18/story-risk-management-failure-deepwater-horizon/

[3] https://safety4sea.com/cm-learn-from-the-past-deepwater-horizon-oil-spill/

[4] https://www.theguardian.com/environment/2014/jun/05/bp-deepwater-horizon-spill-report-failures-risks

[5] https://www.identecsolutions.com/news/oil-rig-safety-what-was-learned-from-the-deepwater-horizon-disaster

[6] https://appel.nasa.gov/2011/05/11/aa_4-4_acs_deepwater_horizon_lessons-html/

[7] https://www.icheme.org/media/18486/lpb285_pg07.pdf

[8] https://www.theguardian.com/business/2012/jul/24/bp-missed-hazards-deepwater-horizon

Disclaimer: This is not legal advice and shall not be construed as such.

Note: I do not discuss the entirety of the incident in this article.