13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.

04 2008 © NSLT and author

Classification: Internal Status: Draft

13 th North Sea OFFSHORE CRANES & LIFTING

Conference
Experience regarding Maintenance and Inspection of
Offshore Cranes

StatoilHydro
Lifting deviations distributed on accidents, incidents and near miss

3500

3000

2500

2000

1500

1000

500

0
2002 2003 2004 2005 2006 2007
Near miss 202 419 860 1242 1561 1580
Incidents 1333 1228 1036 870 1162 1207
Accidents 399 333 372 333 352 341
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

StatoilHydro
Direct causes 01.01.2007 - 31.12.2007
700 100

90
600
80

500 70

60
400
50
300
40

200 30

20
100
10

0 0
Deviation in work
Load was innsufficient secured Technical failure
performance/procedure

Number of registrations 625 553 340

Frequency 14 27 34

Maintenance administration model

Design
Maintenance -
/inspection program

Operation

Spesifications Data Define

Evaluation
collection actions

No Yes
Identify
Deviation
Root-cause
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

Improvement of our operations

• To be able to verify if improvement activities is giving the expected result, one
should be able to measure the result of the activity.
• One should find a set of key parameters, that gives a description of the
situation before improvement starts.
• By comparing key parameters before and after starting the improvement
activity, one can establish if the activities has any effect, and also, the effect
can be quantified.

Key figures
• Failure rate (estimated failures pr. million operating hour)
• Critical failure rate (estimated critical failures pr. million operating
hour)
• MTBF (Mean Time (hours) Between a critical Failure)
• Number of Non Confirmities and Recommendations from 12 month
control
• Maintenance cost per crane per year
• Maintenance cost per crane per operating hour
• Relationship between Corrective Maintenance and Preventive
Maintenance
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

Key figures 2002 - 2007

Reliability of the datas ?
Operating hours:
• Our 54 cranes has registered over 47 000 operating hours in 2007. An average
of 900 operating hours pr. crane. A main offshore crane runs aprox 2000 hours
on a combined drilling an processing plattform.
Failures
• The number of registered failures at our cranes is going slowly down. Last
year we had a sum of 390 general failures. An average of 7 pr. crane pr. year
• The number of critical failures for all cranes has gone down last year to 20.
The average is 0.37 critical failure pr. year, or one critical failure pr. crane pr.
2,7 year. This is the first year we have registered an improvement.

Failure rate pr. million operating hours

20000

18000

16000

14000
Failures pr. million hour

12000

10000 Series1

8000

6000

4000

2000

0
1 2 3 4 5 6
Year
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

Critical failure rate pr. million operating hours

450

400

350

300
Critical failurespr. millionhour

250

Series1

200

150

100

50

0
1 2 3 4 5 6
Year

10

Mean Time Between Critical Failure

20000

18000

16000

14000
Meantime betweencritical failure

12000

10000 Series1

8000

6000

4000

2000

0
1 2 3 4 5 6
Year
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

11

Key figures 2002 - 2007

12 month control
• 5 Non Confirmities (NC) on 5 cranes in 2007. This is an increase
• 200 Recommodations (RC) on our offshorecranes. This is an average of 4 pr.
crane pr. 12 month control. This is an improvement from 2006.

12

Number of Non Confimities

6

4
Noof NC

3 Series1

0
1 2 3 4 5 6
Ye ar
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

13

Number of reccommendations
300

250

200
Noof RC

150 Series1

100

50

0
1 2 3 4 5 6
Year

14

Key figures 2002 - 2007

Economy
• Cost for Preventive Maintenance has gone up 25% and is now 13,2 million kr.
Aproximately 245 000 kr. pr. crane pr. year
• Cost for Corrective Maintenance has gone up 7% to aprox 25 million kr. For
2007. Aprox. 460 000 kr pr. crane pr. year
• Cost pr. operating hour has gone up 14%. To 800 kr.
• Corrective cost has come down to 2 times the preventive cost
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

15

Preventive Maintenance costs

16000000

14000000

12000000

10000000
Costs

8000000 Series1

6000000

4000000

2000000

0
1 2 3 4 5 6
Ye ar

16

Corective maintenace costs

35000000

30000000

25000000

20000000
Costs

Series1

15000000

10000000

5000000

0
1 2 3 4 5 6
Year
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

17

Average cost pr. operating hour pr. crane

1200

1000

800
Cost pr. operatinghour

600 Series1

400

200

0
1 2 3 4 5 6
Year

18

Relation between corrective maintenance and preventive

maintenance
4

3,5

3
Corrective/Preventivemaintenance

2,5

2 Series1

1,5

0,5

0
1 2 3 4 5 6
Year
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

19

Key figures
Safety :
• Tecnical failure is the second most dominant cause for lifting deviations with an
offshorecrane
• 11% of reported lifting operation incidents, involving an offshore crane in 2007
was caused by technical failure.

20

StatoilHydro offshore platforms

Offshorecranes – Direct causes - 01.01.2007 – 31.12.2007
15 100

90

80

70
10
60

50

40
5
30

20

10

0 0
Deviation in work
Technical failure Narrow/difficult work area
performance/procedure
Number 14 12 12
Frequency 14 25 37
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

21

Experiences
• The number of critical faults on our offshore cranes are to high
• The volume of corrective maintenance is twice as high as the volume of
preventive maintenance.
• RCM based programs is more ekstensive than a traditional ”eksperience”
based program and has the potential to reveal more faults than a traditional
program.
• Development of a RCM based maintenance program is a large job!

22

Maintenance improvement activities

• Developed Reliability Centered Maintenance program for 3 cranes in 2005
• Developed of a ”Recomended Practice ” for ”Maintenance and inspection of
Offshore Cranes” in 2005
• Introducing Reliability Centered Maintenance program for 21 newer cranes in
2008 and 2009
• Plan to develope a Recomended practice for ”Administration of offshore
cranes” in 2008
• In cooperation with manufacturer, develop condition monitoring methodes for
offshore cranes.
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

23

RCM based maintenance (BS 5760-5)

Each component in the crane is evaluated for following criteria:
• Which failures modes can occure with this component
• Which impact has this failure mode on the cranes safe performance
• How critical is this impact (1,2 or 3)
• What activity has to be done to prevent the failure to happen.

The main activities in our RCM based programs is:

1. Maintenance activity to prevent a component failure
2. Inspection-, testing-, condition monitoring- activities to reveal if a component
is about to loose its function
3. Change out program for components, before they fails

24

Improved safety- and cost- effective maintenance

$
Repair the
equipment after it
Correctivfails
e
Maintain the
equipment before
Preventive it fails

Identify and fix

problems before they
Condition can cause the
equipment to fail.
based Eliminate potential
problems before they
start to be a problem
Reliability based that can cause the
equipment to fail.

Effectiveness
13th North Sea Offshore Cranes & Lifting Conference, Aberdeen 15.-17.04 2008 © NSLT and author

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General requirements for an offshorecrane

Regulations from Petroleum Safety Authority at Norwegian sector.
The Facilities regulation
§4 ”Design of facilities”
c) failure of a component, a system or one single mistake shall not lead to
unacceptable consequences,
In §70 “Lifting appliances and lifting gear” reference is made to EN-13852-1 for
offshore cranes.
EN-13852-1, Item 5.6.1
The control system shall be such that no single fault/failure shall result in
uncontrolled movement of the load, parts of the crane or the entire crane.

26

Concerns regarding todays standards and design

• Load wire and boom wire, inkluding end terminations
• Splines for winch engines and hydraulic pumps
• Hydraulic hoses

Will the existing design of offshore cranes prevent, that a

singel fault, can lead to unacceptable consequences?
Is this design the optimal safe design?