Risk Assessment Data Directory

Report No. 434 8 March 2010

Mechanical lifting failures

International Association of Oil & Gas Producers

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Contents:
1.0 1.1 1.2 2.0 3.0 3.1 3.2 3.3 3.4 3.5 4.0 5.0 Introduction .......................................................................... 1 Application ...................................................................................................... 1 Definitions ....................................................................................................... 1 Summary of Recommended Data ............................................ 1 Guidance on use of data ........................................................ 3 General validity ............................................................................................... 3 Uncertainties ................................................................................................... 3 Use of the Data................................................................................................ 4 Consequence Analysis of Objects Dropped Into the Sea........................... 4 Kinetic energy ................................................................................................. 6 Review of data sources ......................................................... 7 References ............................................................................ 8

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Abbreviations:
BOP DNV HSE QRA UKCS WOAD Blowout Preventer Det Norske Veritas (UK) Health and Safety Executive Quantitative Risk Assessment (sometimes Analysis) United Kingdom Continental Shelf World Offshore Accident Databank

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1.0 1.1

Introduction Application

This datasheet presents information on the frequency of dropped objects resulting from the failure of lifting devices on offshore installations. Specifically it includes dropped load frequencies for the following types of lifting equipment: 1. Main cranes 2. Drilling derrick 3. Other devices The data are derived from offshore operating experience in the UKCS over the period 1980 to 1999. The data are intended to be applied in quantifying the risks from lifting operations worldwide. Consideration should be given to factoring the data up or down where there is reasonable justification that the management of lifting operations is significantly poorer or safer that UKCS operations.

1.2

Definitions
Dropped loads Refers to loads (objects) either unintentionally released from a lifting device or else swinging and impacting some part of the installation structure (or vessel, if the lift is to/from a vessel). Main crane, derrick main hoisting assembly, and other lifting devices (see below). BOP cranes, gantry cranes, tuggers, and a range of portable devices, e.g winches, sling blocks, wirelines. The data for mobile installations are gathered almost entirely from experience in the operation of mobile offshore drilling units (MODUs). These include semi-submersibles, jackups, and drill ships. The data for fixed installations are gathered from a range of types of production installation ranging from integrated platforms to wellhead platforms. The data also include experience from FPSOs (floating production, storage and offloading vessels) and FSUs (floating storage units).

Lifting devices Other lifting devices Mobile Installations

Fixed Installations

Main cranes and drilling derrick referred to in Section 1.0 are considered self explanatory.

2.0

Summary of Recommended Data

Dropped object probabilities per lift on offshore installations are tabulated below for mobile installations and fixed installations, for different load weights and by lifting device (main crane, drilling derrick, or other device). The data represent the probability of a dropped object per lift. Estimation of the dropped object frequency combines the probability of a dropped object per lift with the number of lifts carried out (for example, per year if the annual risk is required). Note that, for drops from the main crane, in general the frequency in the Total column is not the sum of the Installation, Sea and Vessel drop frequencies in the same row because not all main crane lifts are between vessel and installation (some are across
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the installation). Each frequency in the Total column is calculated from the total number of lifts, whereas the Sea and Vessel frequencies are calculated from the number of external lifts (between installation and vessel) only. Of the reported events on which the probabilities tabulated below are based, 10% of dropped objects on mobile installations and 20% of dropped objects on fixed installations resulted in all or part of the lifting device falling (see Section 1.2 above for the definition of lifting device).
Dropped Object Probabilities for Mobile Units (per lift) Load Weight <1 te Lifting device Main crane Drilling Derrick Other Device 1 20 te Main crane Drilling Derrick Other Device 20 100 te Main crane Drilling Derrick Other Device >100 te Main crane Drilling Derrick Other Device All Main crane Drilling Derrick Other Device Total All Installatio n 3.2 10 1.7 10 8.6 10 3.1 10 3.6 10 7.6 10 1.2 10 1.8 10 1.9 10 2.8 10 4.7 10 4.9 10 8.5 10 1.1 10 4.5 10 1.2 10
-5 -5

Drop Onto: Sea 8.8 10 7.3 10 1.1 10 2.0 10 4.6 10 2.9 10 7.1 10 0* 0* 0* 1.4 10 2.4 10 3.3 10 6.7 10 6.5 10 1.4 10
-3 -6 -7

Total Vessel 1.1 10 6.1 10 0* 3.0 10 0* 0* 9.5 10 0* 0* 0* 0* 0* 4.6 10 3.0 10 0* 9.4 10

-7 -6 -8 -6 -6 -5 -8

4.1 10 1.8 10 9.7 10 5.4 10 4.0 10 1.1 10 2.0 10 1.8 10 1.9 10 2.8 10 6.1 10 7.3 10 1.2 10 1.1 10 5.2 10 1.4 10

-5 -5

-5 -6 -6

-5 -6 -7

-5 -6 -6

-6 -5 -6

-6 -6

-5 -5 -6

-6 -4 -3

-6 -4 -3

-4 -6 -5

-4 -6 -7

-4 -5 -5

-5 -5

-6 -6

-5 -5

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Dropped Object Probabilities for Fixed Installations (per lift) Load Weight <1 te Lifting device Main crane Drilling Derrick Other Device 1 20 te Main crane Drilling Derrick Other Device 20 100 te Main crane Drilling Derrick Other Device >100 te Main crane Drilling Derrick Other Device All Main crane Drilling Derrick Other Device Total All Drop Onto: Installatio n 3.8 10 1.7 10 1.0 10 4.7 10 2.7 10 1.4 10 1.0 10 1.2 10 2.6 10 9.3 10 0* 6.1 10 1.0 10 9.6 10 5.7 10 1.4 10
-4 -5 -6 -5 -5

Total Vessel

Sea 6.9 10 1.2 10 4.2 10 1.7 10 1.5 10 0* 6.2 10 0* 0* 0* 0* 0* 2.8 10 1.2 10 2.0 10 8.8 10
-6 -7 -6 -6 -7

1.1 10 1.2 10 6.1 10 5.1 10 0* 7.4 10 1.6 10 0* 0* 0* 0* 0* 6.4 10 6.1 10 5.8 10 1.6 10

-5 -7

4.5 10 1.7 10 1.0 10 7.9 10 2.9 10

-5 -5

-4 -6 -6

-6 -6 -7

-7 -6

-4 -6 -6

-5 -5 -6

-7 -5

1.5 10 2.0 10 1.2 10 2.6 10 9.3 10 0 6.1 10

-5 -5 -6

-5 -5

-5 -5

-4 -5 -6

-6 -8

1.5 10 9.7 10 6.0 10 1.6 10

-5 -5

-6 -7

-7 -6

-5 -5

In both of the above tables, either there are no recorded incidents, or the incident is not credible. If the analyst believes it is credible, then a suitable frequency could be obtained by pro rating a non-zero frequency, e.g. using the All frequencies.

3.0 3.1

Guidance on use of data General validity

The frequencies given are based on analysis of offshore lifting operations on the UK continental shelf (see Section 4.0). They may be applied to lifting operations in other offshore regions which comply with recognised industry good practice, as it is applied in the UKCS. The data for dropped objects from derricks may be applied to onshore drilling operations where these are similar to offshore drilling activities and equipment. The data for dropped objects from main cranes and other lifting devices are not applicable to onshore lifting operations because the equipment used is unlikely to be similar to that used offshore.

3.2

Uncertainties

Sources of uncertainties in the data include statistical variation and the similarity between the operations and equipment under analysis and those represented by the database.

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The calculated frequencies are derived from 1637 dropped object events in a total experience of 3063 installation-years. This implies a total of about 111 million lifting operations. For fixed platforms there were 690 dropped objects in 1857 platform years, for mobile installations 947 events in 1206 installation-years experience. Therefore the statistical uncertainty in the overall frequencies is relatively small. Some of the specific risks are calculated from the experience of a small number of representative dropped object accidents and correspondingly the uncertainty in the risk will be more significant. The risks with the higher uncertainty are those with the lower likelihoods shown in Section 2.0. The data in the database reflect lifting equipment in operation in the UKCS. While there is a degree of variation in the equipment used in the UKCS, it is similar in that the vast majority is maintained and operated in accordance with international certification and UK legal requirements. Competence requirements for operations and maintenance personnel are generally enforced, and all operations are conducted in accordance with documented procedures reflecting good industry practice. Where operations outside the UK can be assumed to follow a similar standard of operation and maintenance, it is reasonable to assume the data are valid for assessment of the dropped object risks.

3.3

Use of the Data

The dropped object probability values are an input to QRA and are used to calculate the frequency of the initiating event for dropped object risks. The consequence of dropped objects depends on the impact energy and the people, equipment and structures impacted by the objects dropped. For an object falling through air, the impact energy is calculated as the product of the mass of the object, the height and acceleration due to gravity ( 10 m/s2). Generally, people struck by falling objects can be assumed to be fatally injured, and objects striking hydrocarbon equipment will cause a hydrocarbon release. Damage to structures or other equipment struck by dropped objects may require a specific assessment of the resistance of the object impacted and/or the potential for a release from live equipment struck. However, incidents involving hydrocarbon releases are already included in the hydrocarbon release frequencies, so such an assessment is only recommended where the analyst identifies a particular vulnerability to dropped objects, or a stand-alone dropped objects study is being carried out. When using dropped object risks in a total risk assessment for a facility, the risks to people from dropped objects may also be included in the statistical data on occupational accidents. Where this is the case, it is appropriate to disregard the calculated dropped object risk for immediate fatalities. In the event of a dropped object, the lifting equipment will be out of service until the incident can be investigated and any repair can be implemented. An operational risk assessment should take account of this. Even for minor dropped objects with no apparent damage, equipment downtime will be of the order of several days. In the event of a fatality or major equipment damage, the equipment is likely to be out of service for several weeks.

3.4

Consequence Analysis of Objects Dropped Into the Sea

The calculation of the consequences of objects dropped into the sea is more complex. For heavy lifts (e.g. BOP or xmas tree) over the sea it is standard practice that these are not carried out over vulnerable subsea equipment. Thus care is required in assessing

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whether a dropped BOP or other heavy load can cause damage to subsea equipment or if the precautions carried out are adequate. For other lifts, the following approach can be followed to calculate locations at risk from dropped object impact. Heavy, dense objects (such as BOPs) can be assumed to fall vertically and will damage any infrastructure immediately beneath the drop site. Some other objects, such as pipe sections and scaffolding poles, may travel a significant horizontal distance through the water as they descend. The following model is taken from a DNV Recommended Practice [4]. The analysis assumes that the excursion made by a dropped object can be represented by a normal distribution:

where x is the horizontal excursion and the standard deviation. The standard deviation is sensitive to the weight and shape of the object, and the water depth (d). The derivation of is given by: Here is the spread in the descent angle given in Table 3.1. Table 3.1 Calculation of Descent Angles
Case Object Shape Description Weight (tonnes) 1 2 3 4 5 6 7 Box/round shaped Box/round shaped Flat/long shaped <2 28 >8 <2 28 >8 >> 8 Descent Angle Spread (deg) 15 9 5 10 5 3 2

The probability that the object lands within a horizontal distance, r, of the drop point is given by the equation:

When considering object excursion in deep water the spreading of long/flat objects, cases no. 1 to 3, will increase down to a depth of approximately 180 m. Below this depth spreading does not increase significantly and may conservatively be set to be vertical. For a riser, any vertical sections will complicate the hit calculations. One way of calculating the probability of hit to a riser is to: 1. Split the riser into different sections (normally into vertical section(s) and horizontal section(s)), and 2. Calculate the hit probability of these sections at the respective water depths. The final probability is then found as the sum of all the probabilities for the different sections. The effect of currents will become more pronounced in deep water. The time for an object to hit the seabed will increase as the depth increases. This means that any

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current may increase the excursion (in one direction). At 1000 m depth the excursion is found to increase 10 to 25 metres for an average current velocity of 0.25 m/s and up to 200 m for a current of 1.0 m/s. The effect of currents may be included if one dominant current direction can be identified. This may be applicable for rig operations for shorter periods, for example during drilling, completion and intervention/construction above subsea wells. However, for a dropped object assessment on a fixed platform, seasonal changes in current directions may be difficult to incorporate. When establishing a "safe distance" away from activities the effect of currents should be included. A conservative object excursion should be determined, including consideration of the drift of the objects before sinking, uncertainties in the navigation of anchor handling vessel, etc.

3.5

Kinetic energy

A dropped object from a crane and hitting the topsides will have a kinetic (impact) energy Ek given by: Ek = m.g.h where: Ek m g h = kinetic energy at impact (J) = mass of the object (kg) = gravitation acceleration (9.81 m/s2) = height from release point to point of impact (m)

The maximum impact force depends on the object itself and the orientation when hitting, and can be found from structural collapse calculations. The impact resistance of structures can be found from deterministic structural strength calculations. The kinetic energy of a dropped object on subsea installations depends on the velocity through the water, the shape of the object and the mass in water. After approximately 50 - 100 metres, a sinking object will usually have reached its terminal velocity. The terminal velocity is found when the object is in balance with respect to gravitation forces, displaced volume and flow resistance. When the object has reached this balance, it falls with a constant velocity, its terminal velocity. This can be expressed by the following equation:

where: m g V water CD A vT

= mass of the object (kg) = gravitation acceleration (9.81 m/s2) = volume of the object (the volume of the displaced water) (m3) = density of water (typically 1025 kg/m3 for the North Sea) = drag coefficient of the object = projected area of the object in the flow-direction (m2) = terminal velocity through the water (m/s)

The kinetic energy of the object, ET, at the terminal velocity is:

Combining these to equations gives the following expression for the terminal energy:

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In addition to the terminal energy, the kinetic energy that is effective in an impact, EE, includes the energy of added hydrodynamic mass, EA. The added mass may become significant for large volume objects such as containers. The effective impact energy becomes:

where ma is the added mass (kg). Tubulars are assumed to be waterfilled unless it is documented that the closure is sufficiently effective during the initial impact with the surface, and that it will continue to stay close in the sea. Intact, sealed containers may not sink at all. The drag and added mass coefficients are dependent of the geometry of the object. The drag coefficients will affect the objects terminal velocity, while the added mass only has influence as the object hit something and is brought to a stop. Table 3.2 gives typical values of these coefficients. Table 3.2 Drag and Added Mass Coefficients
Object Case (as Table 3.1) 1,2,3 4,5,6,7 All Description Slender shape Box shaped Misc. shapes (spherical to complex) Cd 0.7 - 1.5 1.2 - 1.3 0.6 - 2.0 Cm 0.1 - 1.0 0.6 - 1.5 1.0 - 2.0

It is recommended that a value of 1.0 is initially used for Cd, after which the effect of a revised drag coefficient should be evaluated. Small equipment items (fittings, scaffolding clamps, etc.) are unlikely to do any damage to subsea equipment if they fall into the sea.

4.0

Review of data sources

The recommended probabilities of dropped objects presented in Section 2.0 have been calculated by combining recorded incidents of dropped objects from the WOAD [1] and the UK HSEs ORION databases with data on the number of lifts carried out. The incidents have been analysed by DNV and full reports are available in HSE research reports [2] and [3]. The numbers of lifts per year for mobile installations (Table 4.1) are based on observed data collected for DNV by a drilling contractor. The number of lifts per year on fixed installations (Table 4.2) are estimated by interpretation of the data on mobile installations combined with reasonable assumptions and consequently should be treated with more caution. The numbers of installation years represented by the ORION and WOAD data are provided by the HSE from primary records. The experience data for mobile installations were collected over the period 1980 to 1998; those for fixed installations were collected over the period 1991 to 1999. Of the main crane lifts, 46% were to or from a supply vessel and 54% were across the installation. Of the lifts to and from supply vessels, 75% were of containers, baskets and tanks; the remainder were casing, drillpipe, collars, etc.

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Table 4.1 Observed Frequencies of Lifting Operations on Mobile Installations Lifting Device Main Crane Drilling Derrick Other Lifting Device Total Lifts per Year 24,480 28,670 3,650 56,800

Table 4.2 Calculated Frequencies of Lifts using Main Crane on Fixed Installations (per year) Type of installation Fixed (no drilling) Fixed (drilling for 6 months / year) Wellhead platform Lifts to / from Vessels 5520 8400 552 Internal Lifts 8,674 10,937 867

The UK HSE has also published accident data for more recent period up to and including 2004/2005 [5, 6. 7] These data have not been subjected to the same detailed statistical analysis as the data presented in this report and for this reason the more recent experience is not included here. However a review of the data over the period 1980 to 2005 shows that although there is considerable variation from year to year, the average frequency of dropped objects per installation-year remains approximately constant. This is consistent with the observation that the technology and lifting procedures used on offshore installations have not changed to any great extent over the period the data were collected.

5.0

References

1. DNV, 2006. WOAD, Worldwide Offshore Accident Databank, version 5.0.1. 2. DNV, 1999. Accident statistics for mobile offshore units on the UK continental shelf in 1980-98, HSE Offshore Technology Report OTO 2000/091 / DNV Report No. 99-2490. 3. DNV, 2002. Accident statistics for fixed offshore units on the UK Continental Shelf 19911999, HSE Offshore Technology Report OTO 2002/012. 4. DNV, 2002. Risk Assessment of Pipeline Protection, Recommended Practice No. DNVRP-F107 (amended). 5. HSE, 2006. Offshore Injury, Ill Health and Incident Statistics 2004/2005 (provisional data), HID Statistical Report HSR 2005 001. 6. HSE, 2005. Accident statistics for Floating Offshore Units on the UK Continental Shelf 1980-2003, Research Report 353, prepared by Det Norske Veritas for the Health and Safety Executive. 7. HSE, 2005. Accident statistics for Fixed Offshore Units on the UK Continental Shelf 1980 2003, Research Report 349, prepared by Det Norske Veritas for the Health and Safety Executive.

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