BP HSE COMMUNICATION Lessons Learned Report

Type of Incident: Business/Performance Unit: Country: Location of Incident: Date of Incident: Offshore Platform Fire & Spill Egypt GUPCO Joint Venture Egypt October Complex Platform Ras Shukheir, Egypt 6 May 2001 Some platform crew ignored evacuation orders from shore, necessitating emergency team mission

What Went Well: Platform ESD worked well once activated Platform fire deluge system worked well Emergency team response coordination efforts Lessons Learned & Actions Underway: GUPCOs operational HSE efforts had been focused on developing & upgrading Safe Systems of Work procedures and were not emphasizing assurance of use The existing offshore organizational structure provided no clear line of accountability for overall platform management a new OIM development program including UK training sessions has now been implemented for all major offshore complexes Revised Permit to Work and Isolation Procedures under development were implemented during operations resumption efforts and have substantially improved control and accountability offshore GUPCOs Management Team has reviewed their assurance process to identify an appropriate frequency for external SMS audits for each major installation GUPCO has commenced providing an extensive offshore operator competency training programme provided by Baker International for offshore staff GUPCO requested assistance from BP to conduct a Major Hazard Review Study, now under progress
Key Message: The effectiveness of any management system is only proportional to the extent it is utilized. Having a structured, scheduled assurance process is also vital

Brief Account of Incident: A fire occurred on the GUPCO

October offshore production complex in the Gulf of Suez during a planned maintenance activity to replace a Safety Relief Valve (SRV) on the 103 Production Separator. There were no direct injuries from the initial incident but a large number of staff required first aid treatment after being involved in the emergency response and fire fighting efforts. The fire caused extensive damage to one area of the production facility, including the glycol reboiler skid, an aerial cooler for a gas lift compressor and extensive damage to localized piping and wiring. There was an environmental impact that came from an estimated release of 50 barrels of oil to the Gulf of Suez during the fire. The spill fully dissipated and is not considered to have caused any damage to any environmentally sensitive areas. The platform was shut down for a total of 18 days with lost production of over 60,000 BOPD and remained at less than full production rates for approximately six months after the event. Potential Outcome: The extent of the platform damage could have been much worse with significantly greater loss of production capability. Workers on board the platform during and after the incident could have suffered more serious injury. What Went Wrong: Isolation procedures were not being fully utilized to safely isolate the vessel under maintenance No evidence of lockout/tagout systems in use Platform personnel did not feel empowered to activate ESD system when initial leak started Operator error resulted in live production fluids entering vessel being maintained with Pressure Safety Valves removed MOC process not effective, P&IDs outdated Personnel on Board (POB) info was inaccurate