The Right Stuff: Mitigating Human Factors — The Application of Crew Resource Management in Banyu Urip Drilling Operations

Abstract

Abstract Recent discussions and publications in the oil and gas industry (OGP 501 2014, OGP 502 2014) identify the significance of human factors in industry incidents (personnel safety, process safety, environmental, procedural discipline, etc.). Human factors are generally regarded as human performance limiting factors that, left unchecked, can lead and have led to high potential/high consequence events. Human factors include, but are not limited to, fatigue, stress, task overload, complacency, distraction, cognitive and physiological limits, as well as attitudes shaped by workplace/societal culture, education, and motivation. ExxonMobil Cepu Limited's Indonesia Drill Team (EMCL-Drilling) recognized that in order to achieve perfect or near perfect operations, including a completely hurt free and spill free environment while significantly improving performance efficiency, there needed to be a step change in the understanding and mitigation of human factors in its Banyu Urip drilling operations. EMCL-Drilling, in conjunction with PT. Ponco Oilfield Supplies & Services and Check-6, Inc. (Check-6), facilitated a 14-month, 2-rig program to assess and improve human factors awareness and modify team behaviors using Check-6's Performance Excellence® curriculum. This included application of Crew Resource Management (CRM), Plan Based Execution® (PBE), and After Action Review (AAR) principles. CRM PBE-AAR is recognized as a component of Performance Excellence and High Reliability Leadership (HRL) and a proven method for High Reliability Organizations (HROs) to improve operational discipline and achieve perfect days in our industry. Ultimately, EMCL-Drilling's application of CRM PBE-AAR produced significant days of perfect HSSE and operational execution. This paper provides background on initial workforce performance and behaviors, the introduction and continuous coaching and mentoring of CRM PBE-AAR, and the results achieved. EMCL-Drilling concluded over 20-rig months of operations with CRM PBE-AAR, with notable obstacles of language barriers and arduous rig moves in difficult terrain, where rigsite personnel and supervisors were assessed, human behaviors modified, and process controls improved with zero hurts, zero spills, and significant improvement in operational performance efficiency. As a result of workforce improvements and empowerment, new tools and technology were introduced to further ingrain learnings and capabilities. Rigsite teams demonstrated increased professional and personal pride in their work, taking ownership of processes, accepting responsibility and accountability for their actions and the actions of others, and most importantly developed a sense of empowerment knowing their voices and opinions were heard, respected, and acted upon. The culmination of these efforts resulted in EMCL-Drilling completing the final phase of its Banyu Urip drilling campaign completely hurt free, spill free, and with a perfect day efficiency of 95%.