Failure

Failure

David Kocher

Published by David Kocher at Smashwords

Copyright 2010 David Kocher

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Prologue

Hey big Herm, are you going to get that engine done today or do you need me to get a rookie in here to do it for you? Sonny yelled across the deck. Big Herm was just that, big. He was in his late twenties, about five feet ten inches, and according to his last physical two hundred and ninety five pounds. He was bald and wore a beard on his face. The beard was longer at the bottom creating a goatee. He had tattoos down his arms and one on his neck. Sonny didn’t dare to ask where else the big guy might have some. Despite his size, big Herm was in excellent health. He was the motorman on board the semi submersible drilling rig named Ocean Glory.

I’ll have it done today. Big Herm replied, tossing a wrench onto the floor and wiping his hands on a red rag that was stained with black grease. This girl needed a full overhaul. The damn crankshaft was starting to bend right in the middle. If I hadn’t torn into this thing, we could’ve been looking at a serious problem.

Well, good job finding the problem but I need that engine up and running ASAP. Sonny reaffirmed. That thing is costing us a lot of money right now.

Don’t worry boss, I’ll have her back. I just got the new crankshaft from Robert and now I gotta’ get this girl back together. You should feel lucky that we got the part so fast, it could’ve been weeks instead of days. I don’t know how he does it sometimes.

Yeah, he has his ways. Sonny looked down the deck of the massive oil rig platform and noticed Melissa approaching in the morning sunlight. Alright Herm, keep it up. I’ll check back a little later.

You got it boss. Herm turned back to his pile of parts and tools.

Good afternoon Melissa. Sonny said as he met her partway. Melissa was twenty five years old, only a few years out of college. She had gone to college for a business degree and was having trouble finding work after she graduated. She ended up working as a receptionist for a small manufacturing firm, and learned a lot about their safety measures. Through that job she met up with some people who worked in the oil industry that were in need of safety personnel for both on and offshore rigs. She spent the next two years training and now here she was, rig safety and training coordinator. She was the youngest one in the company that held this position. When Sonny first heard that he was going to have a female aboard the rig, he was really nervous about the way it would work out. After all it was a group of about fifty men at times, on board a rig, miles out in the ocean, with no female contact. He had every reason to be nervous about that. But it all worked out in the end. Melissa was a real tomboy. It turned out that she could hold her own among the boys. She was a little overweight and she didn’t wear any makeup or skirts. She was always dressed in some loose fitting jeans and an oversized tee-shirt. Another thing that Sonny liked about her was her demeanor. A lot of safety coordinators in this field were too strict. She approached people with an upbeat attitude rather than getting upset with people. It was important to keep good attitudes on board the rig.

Good afternoon back. Melissa replied. Are we going to do our walkthrough? They did a daily safety walkthrough of the rig. This was done on every day shift and every night shift. Safety was the most important thing out here in these elements.

Yeah let’s do it. Sonny replied. Sonny was in his forties and had been working on this rig since its debut drill, fifteen years ago. He was a skinny guy, about six feet tall, a hundred and sixty pounds. No one ever saw him with a cup of coffee, but he was always very hyper active and jittery. He was the offshore installation manager. He had worked his way up over the years from a derrick man to a leader. He couldn’t ask for a better job. A few weeks on the rig followed by a few weeks off and the salary couldn’t be beat. He really liked the fact that he couldn’t spend any of that hard earned money while he was out here on the rig. It helped him save for retirement. But at this point in his life, he was happy to call the Ocean Glory his home.

The safety walkthrough consisted of working their way through the rig, usually starting at the most important area, the mast. The mast was a large pillar of steel construction rising up out of the center of the rig. It was where most of the action took place. There was a system of pulleys and winches built inside of the mast which were used to raise and lower the drill pipes and top drive. All of these components were inspected at each use. A log was kept of the condition of these systems. For the purpose of the safety walkthrough, Sonny and Melissa would check over these logs and ask the operators if there were any complaints or issues with their area. Also while walking through they would be looking for any obvious (or sometimes not so obvious) safety hazards, such as things that may be tripped over, oil spills, or employee’s safety gear. Their walkthrough would continue on to the rotary table and the driller’s console. Also while here they would check the iron roughneck. This was one of the most valuable pieces of equipment on the ship. Over the years it had automated a lot of the work that needed to be done to make and break the pipe joints. Without proper safety guidelines surrounding it though, it could cause some serious injuries.

Sonny usually handled interviewing the lead guys in all of the areas and Melissa mostly kept records of everything. If they did find a safety issue, they would immediately get the supervisor of the area or the person responsible for the area and get the safety issue solved with no delay. If safety guidelines were not followed by someone, there was a zero tolerance policy and that person would not be brought back onto the rig. Usually this means termination, as the company didn’t have many other options. Once satisfied that the drilling floor was up to safety standards, they moved on to the mud pits. Here there was a mud separator, shale shakers and a mud system to return mud back to the drilling hole where it was used to keep the active drill bit cool. This system was very dirty and required a lot of maintenance to keep the pumps clear and running. As they approached the mud system they could see Robert Fullshear, the maintenance supervisor clamoring around getting very dirty. What’s going on Robert? Sonny yelled out.

Just had a clog, Robert said pulling his mud covered arm from the depths of a small tank. Pretty normal, but I usually clear them myself; the other guys don’t seem to take the time to get it all out of there. Robert was about thirty years old; he had an average build and a bushy black beard. He always wore a uniform similar to a mechanic’s.

Any other problems that you know about right now? Sonny asked.

Well, just the usual little stuff. Some painting and some lights out, but I got crews on it. I’m thinking about going and helping big Herm with the power stroke here in a minute. Looked like he was moving pretty slow when I brought him the crankshaft earlier.

Yeah, we just saw him. He looked like he could use a hand. We really need to get that engine up and running. Sonny said.

Did you finish your daily log from yesterday? Melissa asked Robert.

Yeah I left it in your box this morning. Robert replied.

Oh good, I didn’t look in there yet. Thanks.

Yeah, Robert said shortly. He hated doing that log sometimes. He understood it was necessary but when he wrenched on things all day and then had to sit down and finish a log of every wrench he turned for the day, it was really tiring.

Alright Robert, we’ll let you get to it. Let me know if something comes up, see ya’. Sonny said as he and Melissa began walking away.

No problem and I’ll let you know when we get that engine going. Robert called to them as they left.

Thanks. Sonny said holding his hand up over his shoulder acknowledging.

From here the two went on to check the rest of the rig. It was no light task. The full walkthrough would take over an hour if there were no problems. Some days it could take up to two or three hours, and round out their day. They checked over the SCR house which contained the generator and electrical housing. They checked the decks and moors. They checked the BOP controller (blow out preventer), they checked the pipe racks, the living quarters and even the kitchen. In each area they would check the logs and speak with the supervisor.

As they were coming back up to the doghouse, which was an office building that looked like a trailer home on the deck of the rig near the drilling floor; they came up on Jackson Brown. Jackson was coming out of his quarters and there was an unmistakable blue light emanating from his door as he shut it behind him, blocking the light from escaping. Jackson did not work for the oil rig company. He worked for the oil company. On board, he was known as the Company Man. He was there to make sure the best interests of the oil company were being fulfilled on board the rig. He was a black man in his mid thirties and took things very seriously. Sonny always assumed that Jackson’s demeanor was just to keep his status clear on the rig. He was not there to make friends. And when it came down to it, if the oil company wasn’t employing the rig, they would all be out of a job. What’s the latest Sonny? Jackson said as their paths met.

Not much Jackson. We just got through with our safety walk; everything seems to be on schedule still. Of course on schedule in their world simply means no further delays. They were never truly on schedule.

How about that engine? Jackson asked.

It’s coming along. Sonny replied. We got the new crankshaft today and two of my best guys are working on it. It should be operational by nightfall.

Oh good, I have a conference call here in a few minutes with the mainland. You know they’ll be asking.

You got it. Anything else I can help you answer? Sonny asked.

No that should be the brunt of it. Jackson replied. Any safety issues or concerns? He directed to Melissa.

Nothing recordable. Melissa replied, keeping it short.

Alright then, I’ll see you guys. Jackson said moving on down the hallway.

Sonny and Melissa continued up to the dog house. There Sonny would meet up with the night foreman to fill him in on all of the events of the day. Melissa would collect the last of her paperwork. Then the two of them could call it a day and get some dinner. The food on board the rig was really quite good. They had a very talented camp boss who was in charge of all the cooking and serving of the food. He had designed a really good menu and managed the cooks well. After dinner Sonny would typically hit the gym and go for a long run on the treadmill, five to six miles a day. After that he would shower and retire to his room. The accommodations on board the rig were comparable to a five star hotel. His room contained a queen bed, a flat screen TV with cable and movies, a mini-fridge, and a microwave. It also had a desk with wireless internet access. He spent a lot of his nights reading books, and talking to his wife via an internet service. There was no alcohol allowed on the rig so no one drank, until they hit the shore anyways. Sometimes life could get pretty lonely on board. But most of the guys were aware of that before they took the job and found ways to keep themselves busy.

1.

Big Herm and Robert were finally done putting the engine back together. The sun was beginning to set over the horizon of blue water and the shimmering deck of the Ocean Glory. They were standing and admiring their hard day’s work as the rebuilt engine reflected the sunlight from its oil stains. Well, let’s let her have it. Herm suggested.

Yeah fire it up. Robert replied.

Big Herm walked around to the back side of the engine and disappeared from sight for a minute hiding his massive frame behind the engines even larger frame. A few seconds passed before he came back around the front. He went to a control console about three feet from the engine and pressed the green button. Immediately they could hear the engine starting up. It didn’t turn over like a car engine. It spat out a small puff of black smoke and immediately roared to life. The engine was loud, but it didn’t affect the two men. They were both used to the noise. Come on baby! Herm said excitedly watching the engine vibrate as it warmed up. They continued to watch closely for any signs of problems. Robert held his hand out and felt the exhaust from the engine checking the temperature. He held his hand in it for a while to feel if the temperature would rapidly increase or stay the same. Herm put his hand against the housing of the engine, feeling the vibration coming from within. He was feeling for any irregular running and listening for any incongruous noise from it. When Robert was satisfied with the exhaust temperature, he went over and checked the load meter. It seemed to be fine. Well, all systems go captain! Robert yelled over the sound of the engine to Herm.

Yeah baby! Big Herm replied. There was a reason that he was the motorman on board the rig, because he really loved this kind of thing, the knowledge that with his own two hands he could take a dead hunk of steel and turn it into a roaring monster of an engine. It really made him feel useful in life, like he actually had a purpose to his existence. Satisfied that they had finished the job, they moved away from the engine in order to hear each other better.

Wow! Herm said removing the thick leather gloves that he had been wearing. The gloves had once been gray in color until Herm got a hold of them, now they were black. Thanks for coming up to help me with this today. I never would’ve made it without you, man.

No problem. Robert replied, grateful for the thank you. It was a long day and Robert was convinced that Herm was just as tired as he was. Projects like this never go as smoothly as they first imagine.

Well it’s a good thing I looked in there when I was inspecting the engines. If I hadn’t seen those metal shavings from that bearing, I wouldn’t have noticed the bent crankshaft and we could’ve had a really big problem then. Herm was now taking off the bandana that he had on his head to keep the sweat out his eyes while he worked. His weight really caused him to sweat more than most people. It never seemed to bother him though. He was very comfortable with himself. What do you say we go tell Sonny the sunny news? Herm suggested.

Sounds like a plan. And then I am going to go three S and lay down. Robert replied.

Three S?

Yeah; shit, shower and shave. Robert said.

Oh. Herm replied hesitating, You’re going to shave your beard? He asked looking down at Robert’s full black beard.

No. Robert replied.

I don’t want to know. Herm said shaking his head and laughing. They made their way to the doghouse, hoping to find Sonny in there. Sonny was walking out of the doghouse as they approached. Hey guys, I was just coming to check on you. What’s the word? He yelled while still a good hundred feet from them.

She’s purring like a kitten. Herm yelled back.

Alright! Why don’t you guys take the rest of the day off? He said chuckling since he knew their day was done anyways.

Gee boss you mean it? Herm asked pressing his hands together and doing a little curtsy.

Yeah really boss, can we? Robert followed suit.

Get out of here. Sonny said. I’ll be in my room if anyone needs me.

Well if you need us, call somebody else. Robert said.

Roger that. Sonny said as he walked away.

The two men continued on to put their paperwork in the box outside the main door of the doghouse and once they did, they headed down to their rooms for showers. They had taken a break a few hours ago and eaten their dinner so the rest of their night was time to relax, sleep and get ready for the early morning start. They were always out on deck ready to work long before the sun came up.

Herm got to his room and immediately went into his bathroom to hit the shower. The bathrooms were sufficient enough. Each had a standing shower with no tub, a man sized toilet (not those dinky ones that are often found in hotel rooms), and a single sink vanity area with just enough counter space for a razor and a toothbrush. As Herm was just starting to get his hair wet in the shower a loud alarm sound came through a couple of speakers located throughout his room. Damnit! He said cutting off the water and grabbing a towel. He was moving faster than he had for a long time. He threw his pants back on, not wasting his time getting any underwear and threw a muscle shirt on as he went out the door. The alarm was not just in his room but it was blaring through the entire rig. They had several different alarm sounds. Each was a series of loud beeps. He knew this sound better than the rest as it closely pertained to him. This time was three beeps. That meant that there was an engine alarm. Often times they would run drills for these alarms. Herm was going to kill Sonny if this was a drill. One beep was for a down-hole drill alarm, two for a weather alarm, they even had an alarm code for pirates. But no matter what code was sounded, it was the responsibility of the entire crew to respond. As Herm made his way down the hall, other crew members were already out and headed up to the deck area. Alarms were sounded multiple ways. The offshore installation manager could manually sound one, or any number of electronic system boards on the rig could also trigger an alarm based on certain criteria. Everyone was expected to respond because no matter what the alarm was, it could affect multiple systems. Despite that any one of the alarms could mean that all of their safety was at risk, they needed to be aware of each and every situation.

Herm had gotten through the hallway from the living quarters and was now facing the staircase in front of him. This was going to hurt. He started to run his way up the stairs. The weight of his body was hard on his knees. He could feel the burning in his legs and sides after only a few stairs. Halfway up, his breathing was getting heavy and sweat was forming on his brow. Now at the top of the stairs, he was unsure of which direction to go. He swiveled his head searching. The other crewmembers were mostly scattered all around the deck. He knew it was an engine alarm but there were engines in more than one location on the rig. He figured it would most likely be the same engine that he worked on earlier, which was cause for even greater concern and more incentive to hurry. He only hoped that Robert or Sonny made it there first. As he rounded the corner at a jogging pace, he saw Robert standing next to Sonny, both looking onto the engine that they fixed earlier in the day. It’s giving us an overheat code! Robert yelled out to Herm as he approached. Herm moved up to the control panel pushing Sonny out of the way.

Come on girl, what the hell. Herm said to the engine as he looked at the alarm code. He quickly pushed past Robert and went over to the engine. He put his hand on the same spot that he had earlier. Only this time he barely touched his hand to it and quickly pulled it back; in case the engine was hot he did not want to get burned. The engine felt ok. He put his hand back on the housing and left it there for a second. It sounded fine and felt fine. Shut it down! Herm shouted over the noise of the engine and the surrounding crew mates who were all trying to diagnose the problem themselves.

Robert used the palm of his hand to smack the red button on the console locking it down and killing the engine. Herm kept his hand on the housing as the engine wound down. He didn’t feel anything unusual. I don’t get it. He said looking at Sonny and Robert. I don’t notice anything. Help me feel around on here and let’s see if we can find the hotspot. The three men started together and moved separate directions around the engine feeling for anything hot. Meanwhile the alarm quit sounding. Melissa had shown up and shut down the alarm. As Robert made his way around the backside of the engine, he noticed a light spray coming across his vision. The fluid was dark brown and hitting the backside of the engine. Hey, look at this." He said talking to the other two men. More than just the two men responded though as several other crew members moved in closer to get a better view.

Shit. Herm said bending down and grabbing his knees, still trying to catch his breath. There was a pipe fitting behind the motor that had sprung a leak. It was spraying oil out onto the backside of the engine. The oil hitting the backside of the engine must have been the cause of the overheating alarm.

I’ll get my gear. Robert said, heading off for his tool shed.

Man, am I glad that’s all it is. Herm said looking at Sonny. This shouldn’t be a problem. We’ll just put a patch on that fitting and we can get this baby going again.

Jesus, you guys really scared me on this one. Sonny said to Herm. He turned to the gathered crowd of onlookers. Just a leaky fitting everybody, nothing to worry about. You can all go back to your rooms. Good job getting out here, and doing your part. That’s exactly what we need to do in an alarm. Remember safety first and work as a team. Most of the men were walking away as he finished talking. Get some sleep everybody. He finished off.

Herm was following the pipe that was leaking and looking for the shut off valve. He located the valve and closed it off. The leak stopped spraying and now the oil was just dripping out slowly and eventually stopped. Robert returned with the necessary tools to fix it.

You guys want me to get the night crew to do this? Sonny asked looking at the two disheveled guys.

I don’t care I’m up now. Robert said.

We can do it. Herm volunteered them both. We’re already here anyways. Besides, if I went back to my room now, I don’t think I would be able to relax after that adrenaline rush anyways. Man I thought this thing was going to blow. And besides, this way you know it’s in good hands.

Alright, thanks guys. I’ll see you in the morning. Sonny took off leaving them to their task.

It’s always something on this rig isn’t it? Herm said to Robert.

Yeah that’s probably why we’re here. Robert speculated. We both would go crazy if it wasn’t for all this fun shit that happens here.

Yeah I suppose your right, never a dull day.

They continued to put a patch on the fitting. This consisted of cleaning and prepping the area and applying putty to it that would quickly seal and harden. The patch would not last forever but at least it should last a few days so they could get around to shutting the line down and changing out the fitting completely. They waited while the putty dried and hardened which took about an hour, and then