How NASA Balances Safety & Risk in
Harsh Environments
Trey Hall
The Rothe Companies
With Team Raytheon
Similarities – Space & Subsea
 Operating in Remote, Hostile Environments
 (Except weight and opposite pressure gradients)
Astronauts
& Divers
Subsea Fields &
Lunar/Mars
Settlements
Satellites &
Capping
Stacks
Historically
Common
Roots
We Have a Lot to Learn from
One Another
 We’ve grown up independently,
 But never really compared notes,
 Though we’re close neighbors.
 We’re learning tough lessons.
 We’re meeting the Challenges of Complex Modern
Systems.
 It’s time to compare notes….
Capturing Lessons-Learned &
Improving
 Benchmarking Best Practices
 Planning &
Execution
Challenger
 Command & Control
Architecture
Piper Alpha
 Simulations, Joint
Integrated Sims
Columbia
Macondo
 Teamwork, Coordination, &
Communication Protocol
 Emergency Response,
Crisis Mgmt
Murphy Evolves & Lives!
• Growing Systems
Sophistication Require
Sophisticated Systems
Engineering & Management
– Advanced Systems Take ~7
Combined Failures to Create
Catastrophic Results
• Yet, Our Human Nature Resists Change
•
•
•
•
Repeated Mistakes and Lessons-Learned
We Still Succumb to Budget & Schedule Pressure
We Still Engage in Group Think and Shared Rationalisms
We Still Create Faulty Consensus and the Illusion of
Invulnerability
Challenges & Course Corrections
• With System Advances and
Stubborn Human Tendencies,
We Must Remain Vigilant and
Aware
• Arrogance in the Face of Subtle
(and not-so-Subtle) Warnings
Can be Deadly
• Key Component: Humility
• Real Possibility that Comprehensive Worker Understanding may
Decrease with Growth in Systems Sophistication
• Separating Noise from Important, Actionable Data
Challenger & Columbia
• Similar Themes to Piper-Alpha, Macondo
• Key Contributor: Command & Control Architecture,
Communications Protocol, affected by different cultures in
Management, Engineering, & Operations
• Dissenting Opinions Were Not Effectively Heard or Listened To
• Intimidation Lead to Acquiescence
• Ultimate Consequences Were Realized
• Challenger Cold O-Rings  Blowby  Explosion
• Columbia Ice  Wing Leading Edge Crack  Plasma  Structural Failure
The Pull Towards Disaster
• The More Momentum that is Gained Towards a Decided
Action, and the Nearer it is in Time, the Harder it is to Change
Direction
– This is True Even in the Presence of New Information that Would Have
Otherwise Changed the Original Decision
• Challenger Launch Delayed Twice, Agency Under Schedule Pressure,
Funding Being Debated in Congress
• Cold Temperatures at the Launch Pad Were Below O-Ring Specifications
• Even After an Issue has been Identified, Blinders may Actively
Prevent Presentation of New Important Information or
Capabilities that Could Change the Ultimate Outcome
– Satellite Survey of Shuttle Wings Offered But Rejected
Change
• Because of Genuine Reflection, Self Study, and
Industry Best-Practices Benchmarking, NASA has
Reassessed Certain Practices
– Recognize, Elevate, and Evaluate Dissenting Opinions
– Institute Training to Identify and Avoid Group Think, and
Encourage Situational Awareness
• Create Open Communication Climate
• Avoid Isolation; Encourage Participation
• Implement Critical Evaluations; Independent Opinions (Devil’s
Advocates)
Technical Competence & Preparation
• Looking at Data From Multiple Viewpoints to Ensure
Understanding
• Safety Professional Credibility
– Earned Through Competency, Trust, Collaboration
• Ability to Recognize or Identify When Table-Top
Training or Computer Simulations Are Not Enough
• NASA Trains Astronauts for ExtraVehicular Activities using TableTop & Virtual Reality Training, But Also Underwater in a HighFidelity, 3-D Physically-Accurate Environment.
• Nothing Else Quite Compares, and More Sufficiently Identifies
Issues
Neutral Buoyancy Lab
 102’ wide x 202’ long x 40’ deep; 6.2M Gal FW;
~86 deg F.,
 Controlled, Instrumented Environment
 Reliable Up-Time, Even in Inclement Weather
 Vertically-Integrated Capabilities (Configuration,
Testing, Simulation, Animation, Engineering,
Manufacturing, Logistics, & Dive Staff)
ISO
9001-2008
Facility
World Class Safety
 OSHA VPP Star of Excellence multiple-awardee
 No Lost Time: In-water Dive
Ops: 183,622 + hours
 No Lost Time: Days Away
Incidents for 1792 + Days
 No Lost Time: Restricted
Work Cases for 2656 + Days
Safety Cultures are Similar
Safety & Test Readiness Reviews, Pre-Op & Post-Op Reviews
#’s as of June 2013
NBL Capabilities
 On-site Oceaneering
Millennium Working Class ROV
 Inspection-Class ROV
 Two High Bays for Integration,
Staging and Test
 Overhead/Overwater Bridge
Cranes, Jib and Davits
 Dive Ops/SCUBA; Nitrox, Air,
Surface-Supply
Underwater Video & Comm; Control Rooms; IT & Data
Systems; Conference & Classrooms.
Vertically-Integrated Capabilities: Engrg thru Mfg.
 Real-Time Brainstorming & Problem Solving
 Rapid Prototyping, Design-Fab-Test Cycles
 Concept ROV-Operable BOP Panels
 Fully-Functional Intervention Interfaces
NASA Use & Background
 NASA Enhances
Simulation, Virtual Reality,
and Table Top Training with
In-Water “0-g” Training
 Complex Operations in
Remote, Hostile
Environment
 High Consequence
Operations Requiring High
Confidence and Control
 Process/Procedure Development, Optimization
 Key Steps to Success
 Nominal Task, Off-Nominal Response
 Anticipated & Prepared-For in Advance
 Makes the Unexpected More Manageable
Why is the NBL Available?
 Shuttle Retired
 Space Station Assembly is
Complete
 Less Astronaut Training
 Creating “Excess Capacity”
Pipeline
Inspection
Test
Articles
 We’re making this National
Asset available to external users
 Oil & Gas is a Natural Fit
 The NBL is a great Test Basin
for O&G
Mfg Facility
Why Use the NBL?
 Computer Sims and Dry SITs are Incredibly
Valuable, but Sometimes Not Enough for Complex
Systems and Tasks.
 Computer Sims can add environmental
conditions (current, turbidity), large-scale
functionality, but can be idealistic
 Augment Sims and Dry SITs with 3-D, Hi-Fi
Submerged Test Environment (Wet SITs)
 Improve Safety
 Save Time
 Reduce Expense
 Vessel Mob/DeMob, Vessel Day Rates,
Execution Delays, Work Replanning, Re-Work
Why Use the NBL?
 Improve Confidence; Increase Test Realism
 Accelerate Critical Project Schedules
 Optimize Productivity & Efficiency of Key HoustonBased Resources
 Maximize Situational Awareness
 Improve Wet SIT Reliability
 Near 100% Facility Uptime
 Increase Simulation and Training Fidelity
 Actual Underwater Environment
 Buoyancy, Resistance, Added Mass
 Full Use of System Controls
 Thrust, Tool Behavior, System Response
Reduce Operational Risk
 Define Task Requirements, Refine Processes
and Procedures, Optimize Timelines, Perform
Efficiency Trade Studies
Why Use the NBL?
 Improve Preparation; Ensuring
Operational Readiness prior to
moving to deepwater environment.
 Enhance Project Execution;
 Improve Data upon which to base
real-time decisions
 Improve Ability to React to
Unexpected Events
Diver Supported Testing
 Optimize Training to Verify
Competency in Advance
 Example: Agbami West Africa Subsea Project
 36 Missions: 18 As-Planned; 15 Modified RealTime; 3 Failures Totally Re-Planned Real Time
Applications in Oil & Gas and
Deep Offshore Technology
 Autonomous
Underwater Vehicle
Testing &
Development
 3-D Mapping
 Subsea Technology
Research &
Development Testing
 Pipeline
Inspection, Down
Hole Sensors, Etc.
 Atmospheric Dive Systems Tests & Certification
 Lloyd’s Certification
Applications in Oil & Gas and
Deep Offshore Technology
 Cascade Chinook
FSHR Buoyancy Can
Chain Inspection and
Repair Feasibility &
Solution Trade Studies
 Prototyping &
Hardware Production
 10 day SIT
 Thunder Horse Water Injection Process
Development; 22 day SIT
 Working Class ROV Systems
Integration Testing
Applications in Oil & Gas and
Deep Offshore Technology
 OPITO-approved Safety & Survival
Training, including HUET, BOSIET, Major
Emergency Management (MEM)Training

(Similar to NASA Flight Controller Training)
 Underwater Systems Integrated Ops:
AUVs, ROVs, ADSs
 Integrated Engineering and
Manufacturing
 Animation & Simulation
Future Applications in Oil & Gas




Broad Scale Joint Integrated Sims
Compliance for ROV Pilots (BOP Intervention)
ROV Test &Training Center of Excellence
Best of All Worlds – Training, Simulation, Wet SITs,
Competency, Confidence
Where? In Your Backyard
Only 22
Miles from
Downtown
Houston
Conclusion
Over the Years, NASA – like Offshore Oil & Gas – has
Learned Valuable Lessons in Managing Risk and
Improving Safety Through Communication, Recognition of
Human Traits, Maintaining Vigilance, and Improving
Preparation Through High-Fidelity Simulations.
When There is Only One
Chance to Safely Do It Right, or
as an Intermediate Step to Sea
Trails, Enhance Preparation and
Execution with High-Fidelity Wet
SITs in a Local, Reliable,
Controlled Environment, Saving
Time and Resources.
Reduce Complex Operations
Risk in Hostile, Remote
Environments.
You’re Invited; Come See Us!
Contact information
Trey Hall, V.P./C.O.O.
The Rothe Companies
NBL External Customer Office Manager
Trey@Rothe.com
C: 713-829-7466
www.Rothe.com
Or, Contact NASA or any of our Team Mates