IADC/10-19 Dropped Object results in Restricted Work Case
The rig crew was in the process of picking up 5" heavyweight. drill pipe. The floor man, who was operating the air hoist with his left hand, was also holding a pipe drift with his right hand. His right hand was resting on the outside border of the rig floor handrail. The drift slipped from his hand and fell from rig floor (13 m.height). The drift struck the injured person’s helmet and right shoulder.
IADC/10-20 Damage to starboard flare boom
Well testing operations were being conducted which required the installation of flare booms. Eighty-five foot flare booms were fitted to the pre-existing boom turntables of the port and starboard wing decks. The starboard flare boom was fitted first, followed by the port flare boom. Once the flare booms were installed additional heat suppression equipment was installed on both starboard and port flare booms.The starboard flare boom began rotating slightly on its longitudinal axis and was re-tensioned, which rectified the problem. The starboard flare boom was left extended for approximately 64hours before hydrocarbons were flared utilizing the starboard burner head for approximately 15 minutes.After approximately three hours crew members heard a bang from the starboard side of the rig and went to investigate. As a crew member made his way along the starboard side of the rig he noticed that the starboard flare boom burner head was submerged in the water, while the base was still attached to the wing deck with the king post lying almost horizontal above the boom.
IADC/10-21 Use of unsafe hammer results in RWC
An employee was attempting to open the valve caps on a mud pump using a valve cap removing tool and a hammer. A sliver of metal broke off the hammer head and lodged deep in his left forearm. The injured employee received five stitches to his forearm.
IADC/10-22 Welder’s flash (Photokeratitis)
While welders were making modifications to the lines and collector for an additional mud tank. A welder’s assistant was assisting the welder by holding the lines and collectors of the centrifuge pump so that they could be welded in place. The helper wasn’t wearing the appropriate PPE (welding shield) instead he improvised his own mask using his dark safety glasses and a piece of dark glass (obtained from a broken welder’s mask). Every time the welder struck an arc, the helper would place the improvised shield in front of his face. Due to the inadequate improvised shield, the worker later suffered welder’s flash (pain, sensation of dirt particles, photophobia, and difficulty opening eyes) in both eyes.
IADC/10-23 Repairing centrifugal pump results in a near miss
A welder was in the process of removing a seized threaded impeller from the 2-1/2” shaft of a centrifugal mud pump. To loosen the impeller from the shaft the welder used a welding torch to heat it. The impeller is screwed onto the shaft with right-hand threads and the threads are sealed inside the back of the impeller with an “O”-ring. When the shaft/impeller was installed previously, the threads were greased and cavity was filled with grease. As the impeller was being heated,the heat from the torch caused the grease to expand inside the impeller thread cavity. The expanding grease caused the cast center of the impeller to explode outward (see photo), striking a nearby welding machine.
IADC/10-24 Air valve malfunction results in High-Potential Near Miss
The driller was in the process of back reaming when the air supply to the drum clutch of the draw works suddenly bled off. This allowed the drum clutch to release and the top drive system, with a 5-inch drill string attached, to move down approximately 4-meters (13 feet). The drill pipe elevators came in contact with the rotary table resulting in damage to the bails and the link tilt hydraulic cylinders.
IADC/10-25 Welding on a truck tire rim results in a serious incident
A truck rim had a hairline crack and the maintenance personnel decided to repair it by welding. After welding on the rim, a new tire was mounted to the rim and pressured to 20 to 40 psi to test the weld. Leaks were found on the hub weld so the person in charge decided to weld the leaking areas from the hub side while pressure was inside the tire. A few minutes after the welds were completed a violent release of energy from the tire launched it from the floor of the shop to the roof. The incident occurred inside a transport maintenance workshop where support and maintenance activities were being performed. The explosion resulted in two (2) fatalities and two (2) injured persons among the (8) people that were in the workshop at the time, and 3 others who were nearby.
IADC/10-26 Crane lifting operation results in a fatality
The incident occurred on the starboard aft pipe deck and involved the removal of a non-magnetic drill collar from its transport basket and laying it out in the adjacent open bay. The injured party (IP) and another roustabout carried out the slinging of the collar in preparation for lifting. The injured party, who was the designated banksman (signalman), signaled the crane operator to lift the collar out of the basket. As the lift progressed, the other roustabout involved in the lifting operation realized that the boom was not properly positioned over the load and called for a stop. By this time the collar was clear of the basket and swung towards the injured party who was clear of it as it passed. The collar struck the protective beams, and on its return swing, the collar impacted the IP in the lower left abdomen area. The IP was transported onshore and received medical attention, but expired two days later.
IADC/10-27 Failure to follow lockout procedures results in a near miss
Rig personnel were cleaning the suction screen on a mud pump when the driller activated the mud pump.No injuries resulted since personnel were not working on the piston rods, bull gears, etc.
IADC/10-28 Mud pit dump valve handle
While closing a dump valve on a reserve mud pit, an employee was struck in the mouth with the handle of the dump valve. The incident resulted in a laceration to his upper lip and three broken teeth.
IADC/10-29 Near Miss – Dropped Tong Weight
After changing out the rig floor drill pipe tongs, a rig crew member went up the derrick to remove weight from the tong counter-balance weight bucket. He removed two steel weights and tied them to the rig floor winch line with sash cord. While lowering the weight to the floor, the sash cord broke, allowing the weights to fall 60 feet to the rig floor.
IADC/10-30 High Potential Dropped Object incident results in two LTI’s
Two lost time incidents occurred on two separate occasions where two employees were struck by falling rubber guides from the Top Drive Back Up Wrenches (BUW).
IADC/10-31 Mud pump repair results in fractured finger
The derrickman and the injured person (IP) were tightening the bolts of the mud pump pulsation damper. As the derrickman swung the hammer it slipped from his hands and struck the injured person (IP) on his left hand. The IP was holding the hammer wrench with his hands. The blow from the hammer caused a contusion to the index finger of the IP. The IP was taken to the hospital where they found a compound fracture to his index finger resulting in a restricted work case.
IADC/10-32 Horseplay results in injuries
Two roustabouts were cleaning a piece of equipment, one with a high pressure wash down gun and the other with a scrub broom. The roustabout with the wash down gun asked the other to move out of the way so he wouldn’t get sprayed. The roustabout with the scrub broom waved the broom in the face of the other,and oil base mud with soapy water and diesel splashed into the other’s face and ran down behind his glasses into his eye. The injured person had his eye flushed with water.Two roustabouts were cleaning mud pits, one roustabout was on top and the other was in the pit. The roustabout on top accidentally hosed the other employee,who in turn hosed down the man on top of the pits,and an argument ensued. The result was the worker who was in the pit picked up a rock and struck the other in the buttocks. The injured went to the medic and was given a pain reliever and bed rest for the remainder of the day.
IADC/10-33 Worker’s arm caught in mud bucket
The air slips were changed out because they were not setting properly. In order to pull the slips away from the rotary table, the air line from the mud bucket was removed and fitted to the rig floor winch. (The sole purpose of that particular air winch is for use with the air slips.) When the crew removed the air hose from the mud bucket and connected it to the air winch, they operated the control valves on the mud bucket to bleed off the residual pressure in the air line. The driller was setting down the weight of the drill string,getting ready to back out a stand of drill pipe when he observed a rig floor worker (Injured Person [IP])holding a dope brush with his hand inside the mud bucket. The driller shouted a warning and at the same time the mud bucket closed, trapping the man’s arm as the air supply to the bucket was turned back on.
IADC/10-34 Fatality occurs during offline cementing operations
The operation at the time of the incident was rigging down the cementing head and bonnet. It is believed that the crew started rigging down the ancillary parts of the cement head (hoses and a “T” piece) some hours before the final rig down job commenced. As part of this preparatory work the lower valve on the cement head was closed to prevent fluid leaking onto the deck after the return line was drained. This valve remained closed until the time of the incident. During the time between the closure of the valve and the removal of the cement bonnet, pressure continued to build up in the system due to the effects of thermal expansion from the cement job. The calculated pressure build up within the system was more than 140 psi. Later the Well Head Engineer (WHE) went to the dog house with the JSA (Job Safety Analysis) for the ‘Installation of the Xmas Tree’ (which followed the rigging down of cement head activity). The WHE discussed the JSA with the Tourpusher, who told the WHE to wait until the cementing supervisor arrived, so that all parties were present and the JSA could be conducted for all elements of the task, beginning with rigging the down of the cement head.
While waiting for the cementing supervisor, the WHE met with the Assistant Driller (AD), who was the supervisor responsible for assisting both Service Companies with the manpower and lifting capabilities for rigging down the cement head / bonnet and installation of Xmas tree. They went through the WHE’s JSA and then proceeded to the production deck and the well head in question. Prior to the arrival of the cementing supervisor and prior to conducting the pre-job meeting, the locking nuts from the cement bonnet were all released. There was no check and the personnel did not recognize that it was under pressure. As the last locking nut was loosened,the bonnet and cement head released from the well (pushed upwards)and toppled towards the AD, pinning him between the annulus valve on an adjacent well and the cement head. The AD was severely injured and passed away shortly after.
IADC/10-35 Deep Vein Thrombosis
After attending a conference in the United States an employee flew to London then on to Dubai. When arriving in Dubai the employee noticed severe swelling in his left leg. He entered the hospital and was diagnosed with deep vein thrombosis (DVT). There have also cases of DVT reported in the oil and gas industry that have occurred when a driver(s) spent a long time driving a vehicle without taking a break.