IADC/10-01 Dropped Object – guide collar segment separates from winch line and falls into the water
On a floating rig the guide collar for a down-hole pump assembly was separated into its 2 segments for lifting to the rig floor from the moon pool platform. The master bushings were removed and a winch line was lowered and attached to a rig made handle on the first segment. There was no lifting eye. (See photos below). Although there was a spotter with UHF radio in the moon pool area and a spotter at the rotary table to signal the winch operator, as the guide collar segment entered the rotary table, it caught on the diverter housing.The handle broke off and the 25 kilogram guide collar fell and struck the moon pool equipment support beams then fell into the water. Since personnel had been evacuated from the drop zone, there were no injuries.
IADC/10-02 Mud pump piston change-out results in RWC
The rig crew was attempting to repair the mud pump and at the time of the incident, the crew began to remove the piston from the mud pump liner. In order to remove the piston, the Derrickman (injured person)was using a sledgehammer. While swinging the sledge hammer, the injured employee missed the piston and his left middle finger was caught between the mud pump liner and the sledge hammer handle. The injured employee sustained a fracture to the finger and lacerations to the top and bottom side of the finger.
IADC/10-03 Improper guarding results in MTO
While checking the radiator of a standby generator for overheating, the injured employee placed his hand on the top, the middle, and then the bottom of the radiator. When he placed his hand on the bottom of the radiator his thumb was stuck by the unguarded fan. The injury resulted in the thumb requiring stitches.
IADC/10-04 Large container lifted by helicopter downdraft
During a scheduled helicopter landing, the helicopter’s downdraft caused a large container weighing around200 kilograms (440 pounds) to be lifted over handrails and then fall around 10 metres (33 feet) to the deck below. The container had been in place for some months and had experienced several similar helicopter landings without incident. The container was placed on the roof of a structure adjacent to the helipad on wooden battens and was not secured. The container was damaged in the fall. While no injuries were sustained, there was significant potential for serious injury.
IADC/10-05 Dropped Objects result in two LTI’s
Two lost time incidents occurred on separate occasions when employees were struck by falling rubber guides from Top Drive Back Up Wrenches (BUW).
Incident one : The rig had finished drilling the well and was in process of making a wiper trip. The driller attempted to break a stand at the top drive connection. The BUW was positioned incorrectly grabbing one part of cross -over sub. The torque boost was used to break the connection at the upper well control valve safety clamp. This caused the clamp to fall on top of the BUW. The driller proceeded to pick up the stand and to make the connection at the rotary table. The driller started pulling the drill string when the lower safety clamp on the bottom part of the BUW caught the stabbing rubber guides and the holding bolts were sheared off thus; allowing the rubber guides to fall 95 feet to the rig floor striking the IP.
Incident two : While pulling out of the hole to make up a new bottom-hole assembly, the Assistant Driller broke out the TD connection at monkey board. The driller then picked up the blocks to check to see that the top drive was screwed out of the stand. He then lowered the blocks hitting top of the drill pipe stand. The rubber guide’s holding bolts sheared off allowing it to fall to the rig floor (approximately 100 feet). The IP was struck in the face and cheek.
IADC/10-06 Near Misses involving Rig Braking systems
Recently a company has experienced several serious incidents that are of a kind you can describe as a “Driller’s worst nightmare”.
1. One driller had miscommunication with a crewman who, instead of opening the valves to fill the trip tank, disengaged the auxiliary brake handle. Because the electric auxiliary brake was not engaged, the drawworks brakes overheated resulting in the driller not being able to stop the blocks, which ran into the top drive rail stops.
2. On another rig the driller turned the hydromatic brake water valve the wrong direction. This resulted in shutting off the water supply to the auxiliary hydromatic brake which caused the drawworks brakes to overheat. He was unable to stop the descent of the blocks and the elevators which struck the rotary table, bending the joint of pipe in the elevators.No injuries resulted from these incidents and each could have been far worse.
IADC/10-07 Tank Welding – High Potential Incident
The rig accumulator supply tank required maintenance which included the task of welding on the tank and piping. The rig site senior mechanic was walking within the vicinity of the job being performed and noticed the welder welding on the tank. The operation was immediately stopped by the mechanic when he realized the potential explosive atmosphere that existed. The tank itself had not been purged. The tank lid was still closed and secured in place. The contents of the tank had not been emptied nor cleaned prior to the welding taking place. The welder was not aware of the tank contents. There was not a well defined fire watch being utilized. A fire extinguisher or pressurized water hose was not within the working vicinity as required by policy and the Permit to Work procedure. Although a PTW document had been issued, the appropriate personnel were not involved. The document had been incorrectly filled out and many details were not followed as required, including the pre-job safety check off list. The designated fire watch for this maintenance work to be performed had become involved in other duties at the Rig-Site office. A replacement fire watch had not been confirmed either.
IADC/10-08 Rabbiting tubing with rig air results in an MTO
Tubing was being laid down and “rabbited” on the pipe rack. (“Rabbit” means to run a device (small plug)through a pipe or tubing to clean or test for obstructions.) To “speed up” the operation the rig personnel decided to blow the rabbit through the tubing with rig air (120 psi). A hose was attached to the box thread protector. The rabbit went through the tubing and bumped against the pin protector on the other end. The air pressure built up and the box end protector blew off the tubing striking an employee on the knee resulting in an injury that required seven stitches.The company previously had an identical incident where a roustabout was struck in the abdomen by the pipe protector and rabbit. This resulted in disemboweling him and shattering his hip. Eleven years later, he is still undergoing therapy for the injury.
IADC/10-09 Dropped Object – High Potential Near Miss
After a scraper run, the crew was tripping out of the hole with the scarper assembly. At the time of the incident the driller was racking a full stand of 31/8” diameter drill collars including a 4½” rotating scraper. After landing the full stand on the set back area, the derrickman unlatched the elevators and started pulling the stand into the monkey board racking fingers.At that moment the 4½” scraper broke apart and separated at the mandrel’s 1¼” service connection.The 2 upper joints of the drill collar stand fell through the mast hitting and dislodging a drill floor walkway and then stuck in the ground.
IADC/10-10 Welding operation results in a fire
The rig was in the shipyard for upgrades and repair. At the time of the fire, the shipyard crew was preparing leg #3 chord-B for the installation of an additional section of leg. The shipyard crew was working inside a welding tent that was made of light-weight tarps. The workers were grinding the mating surface of the leg when sparks created by the grinder ignited the tent surrounding the leg. The shipyard fire watchman attempted to extinguish the fire using the dry powder fire extinguisher while the fire fighting team connected the main deck fire hose to the manifold and sent it up to him. Once the fire watchman had the hose, the Crane Operator (Fire Team Leader) opened the fire hydrant valve on the main deck.He found that there was no water pressure at the hydrant so he went down to the Rig Engineer’s area and manually opened the fresh water pump valve linking it to the fire manifold on the main deck. With water to the hose, the fire was successfully extinguished.
IADC/10-11 Cuttings augur amputates leg of rig crew member
A crewmember was helping to change out shaker screens. The shaker had been isolated and the crewmember was working in the front of the shaker assembly. He had one foot in the shaker and the other foot in the cuttings slide. As he leaned toward the shaker in an effort to remove the shaker screen, his foot slipped and was caught in the auger. The auger amputated his right leg at the knee joint. The auger was shut down and the medical team was immediately notified.
IADC/10-12 “Struck By” incident on Monkey-Board results in a fatality
It was decided to pull three stands of 5” drill pipe out of the hole. Since the derrickman was unavailable, a floorman was assigned to work the monkey-board to rack back the drill pipe stands. The floorman unlatched the drill pipe from the elevators and used the remotely operated derrick winch to pull the drill pipe back to rack it. As the driller commenced lowering the travelling block, the winch wire suddenly became slack allowing the drill pipe to move into the path of the descending top drive system (TDS), making contact with it.The impact caused the drill pipe to deflect and move toward the other side of the monkey board; pulling the winch wire along with it. The floorman, was hit at the abdomen by either the pipe and the winch wire or only by the wire. While the injured person was under medical attention and monitoring by the rig doctor, he succumbed to his injuries about two hours after the incident.
IADC/10-13 Failure to secure sling results in dropped object
The rig had been going into the hole with 5" drill pipe and the driller was washing down the last stand of drillpipe. During this process a wire rope sling dropped from derrick-board to rig floor (about 26 m [85 feet]). The sling had been used to secure a snatch block to the derrick board handrail and it appeared that derrick-man decided to take the snatch block off but he did not secure the wire rope to the derrick or snatch block.This allowed the wire rope sling to drop to the rig floor.
IADC/10-14 Rig Move – Rotary Table fell off truck
During rig move a subcontractor truck was loaded with the rig’s rotary table which weighs approximately eight tons. It was secured to the truck with four boomer type chain binders. At 70 km (43 miles) from the old location and 500 meters (1640 feet) before entering the gate to the new location, one of the chain binders broke which allowed the other three chain binders to loosen. The rotary table fell off the right side of the truck and hit the black top causing damage to the road surface. The rotary table skid took all the impact and will be inspected before being back into service
IADC/10-15 Lifeboat Property Damage incident
An offshore rig recently experienced a property damage incident when a lifeboat davit component failed while performing a scheduled weight test of a lifeboat. Water bags were used to apply necessary weight to achieve maximum lifeboat capacity for the function test of release gear and davit components. As required by procedure, all personnel involved with the job remained onboard the rig and in a position of safety, limiting the actual severity of this incident to property damage. The lifeboat and davit arrangement consisted of two release hooks on the lifeboat supported by two davit fall/wires. When test weight was achieved, the brake was released at the davit to initiate a controlled descent of the lifeboat. The brake was set to stop the descent of the lifeboat approximately 6 feet above the water to check distance. The brake was again released to continue lowering the lifeboat and after descending another 6 inches, the threads of a sheave tensioning bolt used to adjust the sheave and secure it to the davit structure stripped. The bolt thread failure allowed the sheave to detach/separate from the davit structure creating 20 foot of slack in the bow fall wire.The slack wire allowed the bow of the lifeboat to drop into the water and the weight/force was transferred to the supporting fall/wire at the stern. This incident caused severe damage to the stern lifeboat deck area.
IADC/10-16 Use of an improper tool results in hand injury
The rig activity at the time of the incident was pulling out of the hole and laying down 16” BHA. The drill crew was up to the Near Bit Reamer (NBR). The rig crew started to retrieve the float from the NBR which was still in the elevators. A floor crewman had a hex wrench with a 13-5/8” 3mm ring gasket welded onto it and hooked it into the float to act as a puller.
The derrickman was using a sledge hammer to hit the 13-5/8” ring gasket to knock-out the float. The derrickman placed his hand on the handle next to the head of the hammer. When he swung the hammer, he missed the ring that he was attempting to hit and his finger was caught between the handle of hammer and the ring. The impact caused swelling to his right index finger.
IADC/10-017 Windy conditions results in LTI
After the injured person (IP) finished his work in a tank he was going to the accommodation via staircase on the outside of the accommodation unit. On the last staircase and when approaching the top of the stairs, the IP felt his hardhat being lifted by the wind (wind speed was 40 to 45 knots) so he put both hands on his hardhat to stop it from blowing off. The IP then lost his balance and slipped down the stairs backwards, his feet bouncing on each step going down. He stopped at the bottom against life jacket box. The IP sustained a broken left foot and a sprained right ankle.
IADC/10-18 Making up sub assembly results in a Fatality
The rig crew was using the top drive and back-up tong to make up the sub assembly. The pin end of the crossover sub was set into the bit breaker plate. As torque was applied to the sub assembly with the top drive, the crossover sub pin released from the bit breaker plate allowing the drill string and tongs to strike the rig floor crewman pinning him against the “A” leg of the derrick.