Update of Crane Workgroup Activities and Crane Accidents

	In May 1998, a workgroup was assigned to review MMS regulations and to examine what actions could be taken to improve the safety of crane operations on fixed OCS platforms.
	In March 2000, MMS published a technical amendment (65 FR 15862) to update and reaffirm various documents incorporated by reference under section 30 CFR 250.198. These included MMS inspection criteria for cranes and other material handling equipment and for the training of riggers, crane operators, and inspectors according to the American Petroleum Institute (API) Recommended Practice (RP) 2D, Fourth Edition.
	On April 1, 2001, MMS started checking for compliance with the rigger training requirement detailed in API RP 2D, Fourth Edition.
	MMS recently co-sponsored the Offshore Crane Operations and Safety Conference along with, Offshore Operators Committee, International Association of Drilling Contractors, Offshore Marine Service Association, National Ocean Industries Association, and American Society of Mechanical Engineers.
	On February 14, 2003, MMS published a final rule (68 FR 7421) incorporating API Specification 2C, Fifth Edition, into MMS regulations. API Spec 2C, Specification for Offshore Cranes Fifth Edition, April 1, 1995, establishes detailed requirements for the design and construction of new pedestal mounted cranes for fixed OCS platforms. It provides a uniform method of establishing rated loads for cranes. This rule also requires lessees to equip all existing cranes installed on fixed OCS platforms with anti-two block safety devices.

Crane Accidents: August 2000 through December 2003

MMS has identified 53 offshore crane and material handling incidents for this time period. The more serious of these incidents are discussed below.

A very serious injury occurred on March 10, 2000 when a derrick hand had both hands caught in the air hoist sheave while servicing the crown block. He had three fingers amputated on his left hand and three fingers partially amputated on his right hand. A second serious injury occurred on April 2, 2001, when an employee’s hand was pulled into the sheaves by the cabling system while working in the derrick. Two fingers were amputated.

A fatal incident occurred on August 16, 2000 when a floorhand was air-hoisted into the derrick to assist another employee secure a stand of drill pipe that had fallen across the derrick. At a height of approximately 80 feet above the rig floor, the employee’s body harness/boatswain’s chair became detached from the hook of the air hoist line. The employee fell to the rig floor and sustained fatal injuries.

The second fatality occurred on March 9, 2001, when a roustabout was crushed to death when a gantry crane struck the riser cart and knocked it off track. The riser skate struck him in the chest and pinned him against the wind wall. He received fatal injuries from this incident

The third fatality occurred on May 5, 2002, when construction operations were underway to install a new flare boom and to remove the old, 18,000-pound flare boom from the platform. While the load was being swung around the northeast corner of the platform prior to lowering it onto the boat, the welded base of one of the rental crane’s two support braces failed. This caused the crane suddenly to be uprooted from the platform and be pulled overboard. The movement of the crane overboard caused the death of one crewmember that was in the path of the falling crane.

This fatality occurred on December 6, 2003, when an employee was caught between a bundle of 5-inch drill pipe and the pipe rack resulting in his death.

OCS crane incidents continue to injure personnel working in or around offshore cranes. Twenty-six injuries occurred during the 53 incidents. Most of these injuries resulted in broken bones. The injured included 15 riggers, 3 crane operators, 3 riders in a personnel basket and 5 workers indirectly associated with the crane activities.

Damages from these incidents ranged from no damage to major. The most significant damage occurred on January 26, 2000, when a crane operator exceeded the capacity of the crane, ripping it from its foundation. This incident was estimated to have resulted in damage of at least $220,000.

Human error and equipment failure continue to play a role in most of the accidents. These categories were listed as the cause of 61 of the 64 crane incidents. They were also listed as the cause of the 7 materials-handling equipment incidents.

Description of the Crane Material Handling Incidents
November 1999 – December 2003

Accident

Date

Injury/ Fatality

Injury/ Damage/
Fatality

Report Prepared

Cause

A missing keeper bolt caused crane cab to shift forward while attempting to make a lift of 15,000 lbs.

11/15/99

None

None

Yes

HEIEC

MSOP

Crane operator lost control of load, and allowed the boom to get too far ahead of load during lifting operations.

12/09/99

1 injury

None

Yes

HTCC

HEIEC

While booming down, boom brake failed and boom fell.

12/16/99

None

Supply boat and crane boom damaged.

No

EF

Roustabout injured while being lowered in a personnel basket.

1/15/2000

1 injury

None

No

HE

While lifting a load of cement weighing 14,000 lbs; crane broke off structure and went overboard.

1/26/2000

None

Entire crane ripped from pedestal along with attached tank of calcium chloride. Est. cost ($220,000)

Yes

HEIEC

HE

Person injured when struck by an overboard hose when the rope that attached the hose to the crane hook broke.

2/11/2000

1 injury

None

No

EF

A derrickhand had both hands caught in an air hoist sheave resulting in the amputation of three fingers.

3/10/2000

1 injury

None

Yes

HE

HTCC

Crane operator was attempting to lift a 25 bbl. Tank of calcium bromide with crane boom fully extended. Crane broke off pedestal and fell on vessel below.

3/21/2000

1 injury

Supply boat, tank and crane boom damaged.

Yes

HEIEC

HE

While booming down, ball was pulled into sheaves and caused the wire rope to be pulled out of the swedge on the ball.

3/29/2000

None

Generator package on supply and handrails on supply boat.

Yes

EF

HE

Boom cable parted causing boom to fail.

3/31/2000

1 injury

Crane boom and grating and crane cable.

Yes

EF

A 40-ton rental crane lost control of its’ load when boat could not hold position under crane. Boom went to "0" degrees and load went into water.

4/09/2000

None

The tool storage building received structural damage. Est. cost ($5,000.00)

Yes

MSOP

HE

Crane slings parted, dropping load into water due to poor condition.

4/27/2000

None

Missing equipment and broken slings. Est. cost ($400.00)

Yes

HEIEC

EF

While picking up 5" drill pipe with an air hoist the drill pipe struck the top drive causing it to be released and striking a floorhand.

5/21/2000

1 injury

None

Yes

HE

MSOP

Clutch or torque converter failed, causing boom collapse.

6/18/2000

None

None

No

EF

Crane load cable parted dropping building into Gulf waters.

7/18/2000

None

Galley building received structural and water damage. Est. cost ($65,000.00)

Yes

HEIEC

EF

MSOP

Pad eye on cable located above slings parted causing wireline unit to fall into Gulf waters.

8/08/2000

None

Damage to wireline unit and slings.

No

EF

A floorhand was being lifted into the derrick by an air hoist using a full body harness when he fell 80 feet to the rig floor.

8/16/2000

1 fatality

None

Yes

EDOM

MSOP

HE

Roustabout operating a crane fuel valve was pinned between stairs and handrail when crane rotated.

8/22/2000

1 injury

None

No

HE

While unloaded three 55-gal drums, crane operator bumped rail of boat causing drums to fall into Gulf waters.

9/01/2000

None

Lost all three drums of inhibitor fluid.

No

HE

While offloading casing, crane operator lost control of load pinning rigger between deck and casing.

9/03/2000

1 injury

None

No

HE

Crane operator dropped a 24" caisson causing cable to unspool striking him in the head.

9/11/2000

1 injury

None

No

HE

While booming up, crane did not respond to control imputes to stop boom up action.

10/02/2000

None

Damaged boom.

No

EF

Crane operator lost control of swinging load pinning rigger between I-beam and load.

11/28/2000

1 injury

None

No

HE

Rig crane boom struck rig derrick’s wind wall injuring rig worker.

1/26/2001

1 injury

None

None

HE

Roustabout fell 6 feet from personnel basket to deck of workboat due to rough seas.

1/29/2001

1 injury

None

None

WTX

STF

Rig worker received fracture to leg when it got caught between frame riding basket and a steel beam.

2/05/2001

1 injury

None

None

HE

Crane operator left crane in running mode with clutch engaged, resulting in boom failure.

2/08/2001

None

Damaged boom.

None

HEIEC

HE

EF

While being offloaded rough seas struck bottom of personnel basket causing employee out of basket onto boat.

2/09/2001

1 injury

None

None

WTX

STF

Contract employee was injured when he fell of crane personnel basket onto boat.

3/05/2001

1 injury

None

None

HE

Employee using a riding belt was inadvertently pulled into the pipe rack system resulting in a fracture upper leg.

3/05/2001

1 injury

None

None

HE

MSOP

A roustabout was crushed to death by riser cart while crossing catwalk.

3/09/2001

1 Fatality

None

None

HTCC

HEIEC

MSOP

HE

While slipping and cutting a 2" drill line the primary clamp failed while being hoisted by the rig crane. The line fell striking an employee.

3/16/2001

1 injury

None

Yes

EF

HE

While working in the derrick an employee’s hand was pulled into the sheaves by the cabling system. Two fingers were amputated.

4/02/001

1 injury

None

Yes

HE

While attempting to offload cargo, contents on basket shifted causing items to be lost overboard.

4/21/2001

None

Miscellaneous 5-gallon buckets, hoses, and ladders were lost.

None

HE

Crane operator lost control of swinging load pinning rigger between load and drip pan.

4/23/2001

1 injury

None

None

HE

While attempting to lift a compressor a hydraulic hose burst, causing the crane boom to fall with the load into the Gulf waters.

5/02/2001

None

Compressor unit is water damaged.

Yes

EF

While suspending a pump and generator package, with the crane the cable snapped striking the electrician in the head. He was flown into Terrebonne General Hospital and later pronounced dead.

11/21/2001

Fatality

None

Yes

EF

Under investigation by MMS

While using the auxiliary hoist (fast line) to offload a full 500 gal. diesel transporter tank. The weight was approximately 4000 lbs. When the load was approx. 3 ft. off the boat deck the cable snapped.

12/17/2001

None

None

No

HE

Crane operator boomed up until boom hit boom stops. When he attempted to boom down the boom did not respond, instead it reverse itself raised-up slightly causing the boom stops to bend.

2/24/2002

None

Minor

No

HE

The #2 North crane had just offloaded equipment and rigging down the load when the crane boom hoist cable fell and the boom tip fell into the water.

3/20/2002

None

Boom damage

No

EF

While attempting to install a new flare boom the crane was overloaded and fell into the Gulf.

5/10/2002

1 fatality

Major equipment damage

No

EF

HE

Crane operator was preparing to hook up personnel basket when he noticed that the crane boom motor stayed engaged the boom continued to boom up and over backward and cradled over the top of the crane.

5/10/2002

None

Major equipment damage

No

EF

Rigger was hooking up vent pipe to be lifted by crane when the tag line wrapped around his arm lifting him of the platform. This resulted in a fractured or strained arm

7/11/2002

1 injury

None

No

HE

Contract personnel were removing the engine from a platform crane using a knuckle boom crane. After detaching the engine from the crane, the knuckle boom crane

started to tilt. This happened because the crane was not properly secured. The knuckle boom then turned over hanging on the side of the upper deck. The crane engine that it was holding fell in the Gulf.

8/05/2002

None

Crane and equipment damage

Yes

HE

EF

Employee broke his right arm and injured his back during a personnel transfer lift from the boat to the platform.

11/02/2002

1 injury

None

No

HE

Work crews were dismantling the platform crane for removal from the platform. The studs were rusted and corroded and had to be removed by an air impact wrench. Upon removing several studs, the crane shifted and fell into the Gulf.

11/02/2002

None

Crane lost over board

Yes

HE

A deckhand was injured while offloading 1000 gal. chemical tank from the boat. While attempting to offload the tank the hook got caught on the tank’s frame. Lifting it off the deck and pinning the deckhand, this resulted in a broken leg, pelvis and fractured wrist.

11/092/002

1 injury

None

No

WTX

While transferring diesel fuel from the pedestal crane to the production process stream. A diaphragm pump with natural gas fuel supply was being used. During the process the pump exhaust ignited and a mechanic was burned.

12/16/2002

1 injury

Minor

Yes

HE

A cargo box was being moved as the box was being lifted it hung up on the handrail lifting it out of its sockets causing it to fall overboard.

1/02/2003