OCS Report MMS 93-0030

Incidents Associated with Oil and Gas Operations

Outer Continental Shelf 1995-1996

Data Collected By Regional and District Personnel Database Managed By Regional and District Personnel Publication Compiled By L. John Chadwell With Assistance From Melinda Mayes Cheryl Anderson

This document can also be viewed electronically at: http://www.mms .gov

U.S. Department of the Interior Herndon, VA Minerals Management Service 1998

Foreword The following is a compilation of incidents that occurred on the Outer Continental Shelf (OCS) and were reported to the Mjnerals Management Service (MMS) for the years 1995 and 1996. This report lists the incidents separately by Region and then by type. (Note: There are no sections for the Atlantic and Alaska Regions in this report because no incidents occurred there during the 1995-1996 reporting period.) After the listing of the individual incidents, we have included a new section that summarizes the information graphically. For the purpose of this report, incident is defined as any event classified as a blowout, collision, explosion, fatality, fire, injury, pipeline release, or spill greater than 50 barrels.

Data in this report have been compiled from the Technical Information Management System (TIMS) database for the Pacific and Gulf of Mexico OCS Regions. It was cross-checked by performjng multiple analyses and by checkjng paper records on file in MMS's headquarters office in Herndon, Va. TIMS is a large database recently created by MMS , wruch contruns data gathered from many MMS sources for both internal and public use. In addition to contruning information on OCS incidents, TIMS also includes data on items such as: platforms, number and type of well bores, seisrruc analysis, leasing data, production rates , and royalty management.

As of 1995, all OCS incidents reported to MMS are entered into the TIMS database (older data are still mruntruned in other MMS databases and as paper copies). One of the major concerns with the incident component of TIMS is data quality. With the recent increase in operations in the Gulf of Mexico, both MMS and industry are placing increased emphasis on operator performance and safety. With thjs increased attention to performance, the quality of the incident data in TIMS takes on additional importance. As both MMS and industry rely more and more on incident data and data analysis as a component of performance measurement, the potential impact of the incident information contruned in TIMS will also increase.

In trus regard , MMS has made every effort to ensure that data taken from TIMS and contajned in thjs report are as accurate as possible. However, we rerrund users of this report that, as with any live database , MMS continues to update and amend the data as new information is obtained. The MMS welcomes any suggestions or corrections regarding this report in general or concerning specific data contruned in the report. Comments about this document may be sent to:

Mr. Joe Levine Chief, Operations Analysis Branch Minerals Management Service 381 Elden Street, MS 4022 Herndon, VA 20170-4817 Emrul: joseph.levine@mms.gov

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Contents Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Abbreviations and Acronyms . . ............. . ...... . ........... . ....... . ......... . v

Executive Summary ......... . ....... . ................ . . . .. . . . .. . .... . .... . .... vi

Introduction ........ . ..................... . ........... . .. . ................. . . . 1 I. Authority ................................... . . . .................. 1 II. Importance and Relation to Other Aspects of Safety Program . . .... .. . . . .. .. 1 ill. Accident Reporting Requirements and Policies .... . .. . ... . ..... . .... . . . .. 1 IV. OCS Activity 1995-1996 ... . .... .. ... . .... . . .. ...... . .... .. ... .. . . . . 2 V. Summary of OCS Incident Data and Trends 1995-1996 . . . . .. . . .. . . . . . .. . .. 2

Gulf of Mexico OCS Region Incidents Blowouts 1995 . . ... . ....... . . . ...... .. ... . ...... . .... . .................. 4 Blowouts 1996 .......... . . . .. . . . .. . .. .. .... .. . . . .. ....... . . . ... . . ... .. .. 4 Collisions 1995 . . . . . .. . ... .. . . . .. ... .. . . ................................ 7 Collisions 1996 .... . ...... . .......... .. . . ....... . .... . . ... . .. .. ...... . . . 9 Explosions 1996 .. . ... . . . . .. . .. . . . .. .... .. . ... .. . . . .. . .. . .. .. . .. ... .. ... 12 Fires 1995 .. . .. . ............ . .......................................... 16 Fires 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............. . .. 3 1 Fatalities 1995 ............. .. ... . ... .. ............. . . .. .. ... .. . .. ... . . . 62 Fatalities 1996 . .. .... ... .. ........ .. . . .. .. .... .. . ..... . . . . . ............ 65 Inj uries 1995 ........ . . . .. . .......... . .... . . . .......................... 68 Injuries 1996 .......................... . ............. . ..... . .. . .... . . . . 76 Significant Pollution Incidents 1995 ....... . ..... ... ... . ............... ... .. 94 Significant Pollution Incidents 1996 .. .. ... . .... . . . .... . .. .. ... . .. . .... . . .. . 96 Pipeline Incidents 1995 . ... ... .. . . . .. . .. .. ... .. . .... . .. . . ... . . .. ... . .. . . . 97 Pipeline Incidents 1996 ........ . ......................................... 98 Other Incidents 1996 ..... . ...... . .. .. .. .. .. ... . . ... .. .. .. ... . . . ...... . . l 0 l

Pacific OCS Region Incidents Fires 1995 .................... .. .. . .... . ..... .. .... . ...... . .... . .. ... . 103 Fires 1996 .............. . ............. . ...... . ... . ....... .. ....... . ... 103 Injuries 1995 ..... .. .... .. ... .. .. . . . ... . .. . . . .......... . .. .. ... . .... .. 105 Injuries 1996 ............ . ... .. .... . .. . ...... . ......... .. . .... .... . . .. 108 Significant Pollution Incidents 1996 . ... . . . .. . .... .. .... . ....... . .......... 109 Other Incidents 1995 ... . .... . .. . ... . .. . . .. ..... . .... . ................ . . 110 Other Incidents 1996 ............. . .... . . ... . .. ... .. ... .. .. . .. ... . ... .. . 11 0

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Appendix - Graphical Summary of Incident Data

OCS Fatalities Reported to MMS 1967 - 1997 A-1

OCS Incidents Reported to MMS 1995 - 1996 A-2

Causes of OCS Fatal ities 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Causes of OCS Blowouts 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Causes of OCS Explosions 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Causes of Collisions with an OCS Facility 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

Causes of OCS Fires 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Causes of OCS Injuries 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

Total OCS Incidents/Causes 1995 - 1996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Summary of OCS Incident Causes 1995 - 1996 . ... .. ... . .. . . . .. . ... . . ... . . . . . . . . A-10

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Abbreviations and Acronyms AC -Alternating Current bbl -Barrel(s) BOP -Blowout Preventer CFR -Code of Federal Regulations C02 -Carbon Dioxide ESD -Emergency Shut Down ft -Foot (feet) GIL -Gas I Liquid gal -Gallon GOM -Gulf of Mexico H 2S -Hydrogen Sulfide HI -High Island in -Inc h LSH -Level Safety High LSHI.. -Level Safety High Low LSL -Level Safety Low MMS -Minerals Ma nagement Service MOU -Memorandum of Understanding MN -Mobile Vessel NE -Northeast NRC -National Response Center ocs -Outer Continental Shelf OCSLA -Outer Continental Shelf Lands Act POV -Pressure Operated Valves psi -Pounds Per Square Inch PSH -Pressure Safety High PSL -Pressure Safety Low PSV -Pressure Safety Valve RTU -Remote Terminal Unit SCADA -Supervisory Control and Data Acquisition SCSSV -S urface controlled subsurface safety valve SM -South Marsh Island SS -Stainless Steel SSSV -Subsurface Safety Valve SW -Southwest TD -Total Depth TIMS -Technical Informatio n Management System lLWP -Tension Leg Well Platform TSE -Temperature Safety Element (fusible material) TSH -Temperature Safety High USCG -U.S. Coast Guard VRS -Vapor Recovery System VRU -Vapor Recovery Unit WHRU -Waste Heat Recovery Unit

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Executive Summary The purpose of this report is to present OCS incident information for the years 1995 and 1996. Incident data are based solely on MMS's TIMS database, a nationwide OCS information gathering system. Incident information included in this report has been categorized by region, type, year, and sorted by date.

During 1995-1996, 285 incidents occurred on the OCS (see bar chart in the Appendix, p. A-2). Almost half ( 129) of these incidents were fires. Most of the fires were minor and resulted in little or no damage and no injuries. Almost one-third of the incidents were injuries, with 88 occurring during 1995-1996. The majority of these injuries were minor. Both the number of fires and number of injuries recorded in TIMS doubled from 1995 to 1996. Part of this increase may be a result of changes in GOM record-keeping requirements that became effective August 1996. Blowouts, explosions, fatalities, pipeline incidents, and incidents in the other categories have also shown some increase from 1995-1996. During 1995-1996, there were 5 blowouts, 8 explosions, 18 fatalities, 11 pipeline events, 8 significant pollution events (~ 50 bbls), and 7 incidents in the "other" category. There were also 11 collisions with OCS facilities during this period.

Overall, the most frequent cause of incidents in 1995 and 1996 was equipment failure; the second most frequent cause was human error. The majority of these incidents occurred during production operations.

Using the cause determinations from the initial incident reports, the primary cause of fires was equipment failure, the second most frequent was human error. For injuries, the primary cause was human error, the second most frequent was slip/trip/fall, and the third most frequent cause was equipment failure. The primary causes of fatalities were human error and slip/trip/fall. Most fatalities occurred during production operations. The second most common operation was drilling, and the third was well completion and welding operations. Blowouts were mainly a result of equipment failure and human error, occurring primarily during drilling operations and secondly in well completion activities. Explosions mainly occurred during production activities and were primarily caused by equipment failure and human error. Collisions with OCS facilities were caused primarily by human error and equipment failure. Pie charts showing the causes of these incident categories can be found in the Appendix of this report.

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INTRODUCTION I. AUTHORITY

The Outer Continental Shelf Lands Act (OCSLA) requires that either MMS or the U.S. Coast Guard (USCG) prepare a public report for all deaths, serious injuries, major fires, and major oil spillages (>200 barrels within 30 days) resulting from OCS mineral operations. To carry out the requirements in OCSLA, the MMS and the USCG have signed a Memorandum of Understanding (MOU) that provides guidelines for identifying the agency that will normally conduct the investigation and prepare the report. Joint investigations can also be conducted.

II. IMPORTANCE AND RELATION TO O THER A SPECTS OF S AFETY PROGRAM

The MMS mission is to manage OCS resources in a safe and environmentally sound manner. Safety of operations has always been a key element of the Federal Government's offshore program. Looking at the number of fatalities for the past 30 years (see graph in the Appendix, p. A-1 ), there is an indication that OCS operations are generally safer now than they were in the past. Many factors have contributed to improved safety and environmental protection over the years, including: the development of operating regulations, increased regulatory oversight, improved industry safety programs, and improved technology.

Due to recent record lease sales in the GOM and the resulting increase in activity, especially in deep-water areas, increased attention has been placed on the performance of operators, including the occurrence of incidents. With the rise in activity, the potential for a major incident increases and the importance of accurate data and analytical techniques also increases.

Accurate reporting, record-keeping, and analysis of incident information is an integral component of a properly functioning regulatory program and a safe OCS oil and gas industry. Incident data are used to identify operational trends and fluctuations from the norm. Evaluation of this information are then used as a benchmark to evaluate the performance of the industry. Based on this evaluation, areas of concern are identified and addressed through a variety of measures including regulatory changes or new research initiatives.

III. ACCIDENT REPORTING REQUIREMENTS AND I NVESTIGATION POLICIES

MMS regulations at 30 CFR 250.19 (a) specify industry accident reporting requirements. They require OCS lessees to notify MMS of " ... all serious accidents, any death or serious injury, and all fires, explosions or blowouts connected with any activities or operations on the lease." All spills of oil or other liquid pollutants must also be reported to MMS. These regulations also address the preparation of public accident reports and procedures used in conducting accident investigations.

In 1992, MMS revised a basic internal policy for collecting accident data and conducting accident investigations. Under that policy, MMS must investigate all major accidents, and some minor accidents. The degree of investigation is left to the discretion of the District Supervisor. Major accidents are fires and explosions that result in damage of $1 million or more, liquid hydrocarbon spills of 200 barrels or more during a period of 30 days, or accidents involving a fatality or serious injury that causes substantial impairment of any bodily unit or function.

The regions followed this policy until August 1996 when the MMS implemented a more stringent policy. Since that date, the MMS conducts an onsite investigation for all fires and explosions, all blowouts, all spills greater than 1 barrel, all accident-related fatalities, all collisions involving structural damage to OCS facilities, and injuries and accidents requiring repairs on a case-by-case basis. The degree of investigation is still left to the discretion of the District Supervisor. In some cases an accident investigation panel will be formed and a more detailed report will also be prepared. During 1995-1996, over 50 percent of all incidents had a completed Accident Investigation Report.

IV. OCS ACTIVITY 1995-1996

The Federal OCS encompasses about 1.4 billion acres. MMS has divided this area into four regions: Atlantic, Alaska, Gulf of Mexico (GOM), and Pacific (POCS). At the present time, most of the OCS activity is taking place in the GOM and POCS Regions . At the end of 1996, there were over 3,800 production facilities installed in the GOM. As of this same date, 23 production facilities were installed in the POCS. To date, no production facilities have been installed in either the Atlantic or Alaska Regions. Also, during the period of this report ( 1995­ 1996), no exploratory drilling operations occurred in the Atlantic Region. During the same period, two wells were spudded in the Alaska Region . No incidents were reported from the Atlantic and Alaska Regions during 1995- 1996.

V. SUMMARY OFOCS INCIDENT DATA AND TRENDS 1995-1996

This section briefly summarizes the incident data presented in the body of this report. The graphs