Incidents Associated with Oil and Gas Operations

Outer Continental Shelf 1997

Incidents Associated with Oil and Gas Operations

Outer Continental Shelf 1997

Authors: Data Collected By District Personnel Database Managed By Regional and District Personnel Publication Compiled By L. John Chadwell Cheryl Blundon Cheryl Anderson

This report can also be obtained on MMS’s homepage at http://www.mms.gov

Foreword The following is a compilation of incidents that occurred on the Outer Continental Shelf (OCS) for the year 1997. This report lists all of the incidents separately by Region and then by type of event. (Note: There is no section for the Alaska Region in this report because no incidents occurred there during the 1997 reporting period.) After the listing of the individual incidents we have a section that presents the information graphically.

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 performing multiple analyses and by checking paper records on file in Minerals Management Service’s (MSS’) headquarters office in Herndon, VA. TIMS is a large database created by MMS for both internal and public use. In addition to containing information on OCS incidents, TIMS also includes data on the following items: platforms, number and type of wellbores, seismic analysis, leasing data, production rates, and royalty management.

One of the major concerns with the incident component of TIMS is data quality. Both MMS and industry are placing increased emphasis on operator performance and safety. With this increased attention to safety, 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, the potential impact of the incident information contained in TIMS will also increase.

As shown in the report, there are a large number of events caused by human error. Due to the wide scope of this definition, MMS will be working in the future to narrow the definition of this field.

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Contents Foreword ......................................................................................................................................... iii

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

Executive Summary.......................................................................................................................... vii

Introduction.......................................................................................................................................1 I. Authority.........................................................................................................................1 II. Importance and Relation to Other Aspects of Safety Program...........................................1 III. Accident Reporting Requirements and Policies.................................................................1 IV. General Incident Trends ..................................................................................................2

Gulf of Mexico OCS Region Blowouts 1997 ......................................................................................................................5 Fatalities 1997 .......................................................................................................................8 Collisions 1997....................................................................................................................13 Explosions 1997 ..................................................................................................................17 Fires 1997 ...........................................................................................................................21 Injuries 1997........................................................................................................................63 Pipeline Events 1997............................................................................................................82 Significant Pollution Events 1997 ..........................................................................................88 Other Events 1997...............................................................................................................90

Pacific OCS Region Fires 1997 ...........................................................................................................................98 Injuries 1997......................................................................................................................100 Significant Pollution Events 1997 ........................................................................................101

Appendix – Graphical Summary of OCS Incident Data - 1997 OCS Fatalities Reported to MMS 1967 - 1998 ................................................................ A-1 Other Causes 1997........................................................................................................... A-2 Injury Causes 1997........................................................................................................... A-3 Fire Causes 1997.............................................................................................................. A-4 Blowout Causes 1997....................................................................................................... A-5 Type of Activity During Incidents....................................................................................... A-6 Operations During Incidents .............................................................................................. A-7 Incident Causes................................................................................................................. A-8 Fatality Causes 1997......................................................................................................... A-9 Collision Causes 1997..................................................................................................... A-10 Explosion Causes 1997................................................................................................... A-11

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Abbreviations and Acronyms AC -Alternating Current bbl(s) -Barrel(s) Bcf -billion cubic feet BOP -Blowout Preventer BOPD -barrels of oil per day BWPD -barrels of water per day CFR -Code of Federal Regulations CT -coil tubing CTM -coil tubing measurement CO2 -Carbon Dioxide ESD -Emergency Shut Down ft -Foot (feet) FTP -flowing tubing plug G/L -Gas / Liquid gal -Gallon GOM -Gulf of Mexico H2S -Hydrogen Sulfide HI -High Island in -Inch LEL -Lower Exposure Limit LSH -Level Safety High LSL -Level Safety Low MCC -Master Control Center MCFD -thousand cubic feet per day MD -Measured Depth MM -million MMS -Minerals Management Service MOU -Memorandum of Understanding M/V -Mobile Vessel NE -Northeast NRC -National Response Center OCS -Outer Continental Shelf OCSLA -Outer Continental Shelf Lands Act POV -Pressure Operated Valves Ppg -Pounds Per Gallon PSE -Pressure Safety Element PSH -Pressure Safety High psi -Pounds Per Square Inch PSL -Pressure Safety Low PSV -Pressure Safety Valve

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RTU -Remote Terminal Unit SCADA -Supervisory Control and Data Acquisition SCSSV -Surface Controlled Subsurface Safety Valve SM -South Marsh Island SS -Stainless Steel SSSV -Subsurface Safety Valve SW -Southwest TD -Total Depth TIMS -Technical Information Management System TLP -Tension Leg 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 1997. 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, year, type, and sorted by date.

Incident Cause Overall, the main cause of all incidents in 1997 was equipment failure followed by human error. Other Slip/Trip/Fall 5% The majority of these incidents 7% occurred during production Weather 7% operations. Fires were the most frequent type of incident reported to the MMS in 1997 followed by Equipment Failure 46% injuries. Both the number of fires and number of injuries recorded in TIMS doubled from 1995 to 1997. Part of this increase may be a result Human Error 35% of changes in Gulf of Mexico (GOM) recordkeeping requirements effective August 1996. The majority of the reported injuries were minor.

The primary cause of fatalities (11) Fatality Causes 1997

was human error followed by slip/trip/fall. Most fatalities occurred Other Equipment Failure during production operations, 9% 9%

followed by drilling, then well completion, and welding operations.

Blowouts (5) were mainly a result of equipment failure and human error Slip/Trip/Fall Human Error

resulting primarily from drilling 36% 37%

operations followed by well completion activities. Explosions mainly occurred during production activities and were caused by Weather 9%

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equipment failure and human error.

Another interesting thing to note is that although there was an increase in activity in water depths greater than 1000 ft there was a decrease in the number of incidents in those water depths.

Recently, the Workgroup from MMS Headquarters completed a review of crane incidents that occurred between January 1995 and August 1998. The report discusses the Workgroup's review and analysis of these accidents and makes recommendations for improving crane safety. The Workgroup looked at 34 crane incidents from 1995 to August 1998. These incidents resulted in 7 fatalities and 20 injuries. The most significant finding of the review was that crane riggers appear to be at the greatest risk during crane operations. During this time period, all 7 of the fatalities and most of the injuries involved crane riggers or other personnel working around cranes.

Blowout Causes 1997

Equipment Failure 33%

Other 50%

Explosion Causes 1997

Slip/Trip/Fall Other 0% 10% Weather 0% Human Error 17% Slip/Trip/Fall 0%

Weather Human Error 0% 20%

Equipment Failure 70%

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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 OTHER ASPECTS OF SAFETY PROGRAM

A primary mission of the MMS 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. 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.

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

III. ACCIDENT REPORTING REQUIREMENTS AND 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.

As of August 1997, MMS began revising Subpart A, including reporting requirements. MMS and the USCG are also beginning to move towards a joint reporting structure. They will put subpart A into a more logical order and respond to substantial changes requested by industry and generally improve the clarity of the regs.

In 1992, MMS instituted a basic policy for collecting accident data and conducting accident investigations. Under that policy, MMS must investigate all major accidents, some minor accidents, and all blowouts. The degree of investigation is left to the discretion of the District

Incidents Associated with Oil and Gas Operations – OCS 1997 1

2 Incidents Associated with Oil and Gas Operations – OCS 1997

Introduction

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 GOM Region implemented a more stringent policy. Since that date, the GOM Region investigates 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. The Pacific Region continues to follow the 1992 policy previously discussed. MMS completes an Accident Investigation Report (Form 2010) for all accidents investigated.

Operations During Incidents IV. GENERAL INCIDENT TRENDS

Motor Vessel Other 4% Workover The following are trends that were found in 6% 5% the data that were compiled for this report.

Drilling 18% • The primary causes of fatalities were human error (4), and slip/trip/fall (4).

Completion 2% • Most fatalities occurred during production operations, followed by drilling, then well completion, and welding operations. Production 65%

• Explosions were mainly a result of equipment failure (7) and human error (2) resulting primarily from production operations.

• Overall, the main cause of incidents in 1997 was equipment failure (120) followed by human error (88). The majority of these incidents occurred during production operations (162).

• There were 258 incidents on the OCS in 1997. At the same time there were 954 wells drilled on the OCS in 1997 (353 exploratory/601 development). There were 466 million barrels (MMBbls) of oil produced on the OCS in 1997. There were 5,222 billion cubic feet (Bcf) of gas produced on the OCS in 1997. There were .27 incidents per well drilled in 1997. There were .55 incidents per million barrels of oil produced on the OCS. There were .05 incidents per Billion cubic feet of natural gas produced in 1997.

• This compared with the 180 OCS incidents in 1996. There were 889 wells drilled on the OCS in 1996 (327 exploratory/562 development). There were 426 MMBbls of oil produced on the

Incidents Associated with Oil and Gas Operations – OCS 1997 3

Introduction

OCS in 1996. There were 5,066 Bcf of gas produced on the OCS in 1996. There were .20 incidents per well drilled in 1996. There were .42 incidents per million barrels of oil produced on the OCS. There were .04 incidents per Billion cubic feet of natural gas produced on the OCS in 1996.

• This compared with the 94 OCS incidents in 1995. There were 798 wells drilled on the OCS in 1995 (278 exploratory/520 development). There were 429 MMBbls of oil produced on the OCS in 1995. There were 5,015 Bcf of gas produced on the OCS in 1995. There were .12 incidents per well drilled in 1995. There were .22 incidents per million barrels of oil produced on the OCS. There were .02 incidents per Billion cubic feet of natural gas produced on the OCS in 1995.

1997 Crane Incidents

There were at least 10 crane incidents in 1997 according to Accident/Incident forms and Accident Investigation Reports (referred to as reports for the rest of this paper) contained in our TIMS. Incidents ranged from minor personnel injuries and minor property damage to two accidents resulting in two fatalities.

Crane pedestals failed on two occasions causing major damage to the cranes and one serious injury. Mechanical failure caused these two incidents.

Two other incidents damaged crane booms as a result of improper lifting techniques. One boom failed due to overloading because the wrong boom angle was used to offload a rig. In the other, the boom damage occurred when the boom pawl brake failed, and the boom pivoted to the surface of the Gulf. Both of these incidents may have been caused by crane operator error. Fortunately there were no injuries in these two incidents.

Slings were involved in three incidents. Twice slings failed during the lifting operation, one failure resulted in a fatality. In that fatality, the floor hand handling the tag line was underneath the load when the sling failed. A second fatality occurred when a sling snagged and broke off the valve on an accumulator bottle, and the escaping pressure blew the rigger across the rig floor. According to the report, the probable cause of this accident was that the communication between the crane operator and the rigger was not appropriate.

The other three incidents involved minor injury to a rigger, minor injury to a person exiting a personnel basket, and minor damage to an offloaded box of cuttings. These incidents are likely due to human error.

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Introduction

1997 Deepwater Incidents

There were at least 10 deepwater incidents in 1997 according to the Accident/Incident forms and the Accident Investigation Reports contained in our TIMS database. Incidents were mostly minor involving personnel injuries and minor fires. There was one large 72 bbl spill. There were 4 fires and 3 injuries. The two events that were classified under other were an infectious pneumonia outbreak and smoke but no fire on a platform.

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Gulf of Mexico Region Blowouts - 1997

Date: 10-Jan-1997 Operator: BHP Petroleum, Inc.

Investigation: Complete Activity: Exploration

Lease: G14550 Event(s): Blowout

Area: South Timbalier Operation: Drilling

Block: 299 Cause: Other – Diverter

Rig/Platform: Rowan Gorilla 2 Water Depth: 337’

Remarks: The operator was drilling at 2428 ft on 01/10/97 when they encountered a shallow gas pocket. The mud weight in the hole was 9.6 ppg. The operator opened up the diverter valve on the starboard side of the rig to release the gas to the atmosphere. The operator started pumping 1500 bbls of 11.0 ppg mud into the well. This was followed by 500 bbls of 12.4 ppg mud. The well was still blowing gas at this point. While waiting on more mud and weight material to arrive at the rig, the operator started pumping seawater into the well at a rapid pump rate. Firefighters were called and non- essential personnel were evacuated at 1330 hrs. The operator then at 1130 hrs received 900 bbls of 13.8 ppg liquid mud on the rig. Flow appeared to be diminishing from the well at 1330 hrs. The operator started pumping 11.0 ppg mud into the well at 1640 hrs and received bottoms up at 1840 hrs. At 1900 hrs the well was under control. The operator built the mud weight level in the hole to 10.2 ppg. They then pumped seawater into the well to fill the hole. The well was static at this point, no longer flowing. The mud losses were treated with lost circulation material. The operator raised the mud weight in the hole to 10.6 ppg and resumed drilling.

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Gulf of Mexico Region Blowouts - 1997

Date: 04-Mar-1997 Operator: Shell Offshore, Inc.

Investigation: Complete Activity: Development

Lease: G05646 Event(s): Blowout

Area: South Timbalier Operation: Drilling

Block: 295 Cause: Other

Rig/Platform: Pool 18 Water Depth: 288’

Remarks: On well A-29 at approximately 0100 hrs the 13 3/8-in surface casing was cemented in place at 4950 ft MD. At 0400 hrs, while in the process of nippling down the diverter, a flow was observed on the backside of the casing within the 13 3/8 X 18 5/8 annulus. The 18 5/8-in casing is set at 1614 ft MD. The diverter was nippled back up and the well was put back on diverter while pumping sea water down the annulus. At 0915 hrs the well was shut in while sea water was continuously pumped. Previously, 400 bbls of 11.8 ppg kill weight mud was mixed and pumped at 1100 hrs with more mud enroute to the rig.

Date: 01-Apr-1997 Operator: American Exploration Company

Investigation: Pending Activity: Development

Lease: G10638 Event(s): Blowout / Fire

Area: East Cameron Operation: Production / Drilling

Block: 328 Cause: Equipment Failure / Human Error

Rig/Platform: Pride 1001E Water Depth: 243'

Remarks: Prior to the blowout, the crew had set and cemented casing. The BOP stack was being nippled down with four bolts remaining when annular flow was observed. All personnel were safely evacuated. The rig and platform were on fire and the derrick collapsed. There was a sheen on the water. A relief well was spudded. The well eventually bridged over. The operator used a snubbing unit to plug and abandon the well. The relief well was also plugged and abandoned. Other wells were damaged on the platform.

Incidents Associated with Oil and Gas