IADC/11-17 Finger injury during 9-5/8” casing run
The rig crews were working along with the casing contractor crews to run 9 5/8'' casing into the well. After stabbing in the 20th stand of casing, the injured person (IP) was guiding the tong to the stabbed casing by holding onto the right side handle of the power tong. Unfortunately, the IP's left middle finger was trapped between the power tong handle and the casing surface injuring his finger tip resulting in open wound. He immediately went to the rig clinic where he received first aid treatment and referred to the onshore medical clinic for further medical evaluation where he was administered sutures. X-rays also confirmed that there were no fractures.
IADC/11-18 Dropped Object - Pin falls from Top Drive results in a Near Miss
While laying down 5” Drill Pipe, the upper pin of the top drive link support assembly came loose and fell approximately 15-18 feet to the rig floor near the driller’s side. No injury was reported.
IADC/11-19 Drilling Line slips out of retainer clamp results in rig downtime
While tripping in the hole, the driller was hoisting the top drive and empty elevators to latch a stand when aloud “slapping” noise was heard from the drawworks and severe vibration was noted in the brake handle. The block’s travel was stopped, and a large “bird’s nest” was seen on the drawworks drum. The rig floor was cleared of all personnel and a risk assessment was performed. It was decided to install a short hang-off line in the mast to hang the traveling block in its then-current position. When the drilling line was inspected, it was discovered that the drilling line had pulled out of the drilling line clamp in the drawworks. The loose end of the drilling line striking the drawworks guards was determined to have been the cause of the “slapping” noise heard at the time of the incident. The damaged drilling line was removed from the drum, and a newline clamp was installed including new bolts, nuts and lock washers. The line was spooled back onto the drawworks and the blocks were lowered and re-hung at the normal height for slipping and cutting drilling line. A thorough inspection of the drawworks, top drive, mast and drilling line were then performed. Minor damage was repaired on grease lines and crown-saver air lines. The crown-saver was tested and the rig resumed normal operations. This event resulted in 13hours of rig repair time; no injuries were reported.
IADC/11-20 Drill line pulls through wire rope snake while stringing blocks
While in the process of stringing the travelling blocks with brand new drill line, the 1-3/8 inch drill line came free from the Wire Rope Wire Mesh Snake Grip and dropped to the rig floor from approximately 20 meters. The line and snake grip had been reeved through all three sheaves on the off driller’s side and had passed through the first two sheaves on the driller’s side of the travelling block. There was one last sheave on the travelling block to spool.
The snake grip was in good condition and was the correct type for the line. The drill line had been fully inserted into the 1 inch - 1-1/2 inch snake grip right to the rubber boot and then 3 x hose clamps were used to secure the snake grip. The clamps were then covered with tape for about 6 inches on each. The snake grip was then attached to a 3/8 inch wire rope line by back splicing the line’s dead end through the snake grip's soft eye. The 3/8 inch wire rope is used to pull the drill line through the crown and travelling block sheaves.
There were four essential people involved in the job on the rig floor but none were near the drop zone. The pre job held emphasized the need for the rig floor to be clear. There was no potential for injury.
IADC/11-21 Near Miss – Lack of inspection results in dropped Iron Roughneck
While the Iron Roughneck was extended, the cylinder shaft pulled from the clevis on the extender end of the cylinder. This allowed the extender unit to fall outward onto the rig floor landing against the drill pipe stump.When the extender unit fell, it narrowly missed two employees. Fortunately, no employees were directly between the unit and the drill pipe stump and no injuries resulted from the incident.
IADC/11-22 Failure of BOP ram yoke results in a natural gas release from BOP
A rigless snubbing unit was preparing to stage a production tubing string into a well. The average well bore pressure was recorded at 28mPa (4000 psi). At that pressure it is required to snub the tubing using the ram to ram staging method. As the snubbing operator was staging the coupler of joint #44 into the staging chamber of the snubbing unit, he closed the lower stripping Quick Ram Change (QRC) rams, de-pressurized the chamber, and opened the upper stripping QRC rams. Immediately after the upper QRC rams were opened there was a natural gas release from the closed annular blowout preventer (BOP) on top of the snubbing stack. The operator closed the upper QRC rams and investigated the cause of the release. It was noticed that the lower stripping QRC rams had malfunctioned and did not close properly. The operating yoke of the QRC stripping ram was found to be broken on the left side. This made it impossible to apply the correct closing pressure to the QRC stripping pipe ram to achieve a seal on the tubing. The tubing hanger was staged in using the upper stripping QRC rams and the damaged QRC rams were removed from the snubbing stack and sent for analysis of the failure.
The BOP involved in the incident was within its 3 year required certification, having been inspected 1.5 years ago by a third party re-certification facility. No damage or irregularities were detected
IADC/11-23 Bent hinge pin results in near miss
The operation at the time of the incident was pulling out of the hole to change out the drill bit. The bottom-hole assembly (BHA) was 9 1/2” drill collars with a7-5/8” regular connection. This operation requires 110,000 foot pounds of torque. While the rig crew was breaking out the 28” reamer and the shock sub, the hinge pin in the manual tong had become bent. This resulted in the release of the tongs, which shot across the rig floor. The tong pin that was bent during this operation had been received in the company warehouse twelve days before the incident date.
IADC/11-24 Three dropped-object incidents occur while tripping out of the hole
Three incidents resulted in separate dropped-object incidents. They are:
1. While the driller was picking up the pipe in the slips, the hydraulic hose on the elevators came loose and the elevators opened.
2. During a trip out of the hole the driller was in the process of setting back a stand of pipe and he opened the hydraulic elevators before the stand was fully set back. This resulted in dropping the stand on the rig floor.
3. Following jarring operations, when pulling out of the hole, the cover on the elevator hydraulic fittings came loose and fell toward the floor. The derrickman noticed the cover had moved and caught it!
IADC/11-25 Defective clutch results in dropped Top Drive
While tripping out of the hole, a stand had been backed out by the Driller. The Tourpusher then relieved him to handover to his relief. With the Tourpusher running the rig, he discovered that the pipe threads had snagged. He slacked back off the stand to rotate the pipe out again. When he released the drum clutch, in order to slack off and rotate the stand, the clutch did not release thus causing the brake to loosely set. When the clutch did release, the added weight of the top drive on the brakes caused the assembly to descend. The top drive contacted the top tool joint and bowed out the stand of pipe. The Tourpusher applied the brake further, which stopped the top drive’s descent.
IADC/11-26 Inattention results in damaged monkeyboard
While pulling a stand of drill pipe from the mouse-hole the top drive hit the monkey board causing damage to the board and the top drive. The crew had just made up a stand of drill pipe in the mouse-hole and was pulling the stand up to make a connection. However, during this operation, the driller forgot to retract the top drive and while the stand was being lifted into place, the elevators/bails crashed into the monkey board.
IADC/11-27 Lack of proper tool results in finger injury
Recently, on-board an installation, a member of the maintenance crew suffered a finger injury while manually removing a section of steel grating in the Engine Room. The section of grating measured 3ft x 3ft and weighed approximately 46kg (~100lbs).
IADC/11-28 Dropped object – casing joint falls from elevators
While picking up 133/8 casing through the V-door using single door elevator with crane hooked at one end (Pin end), at approximately 20 feet (6 meters) above the rotary table, the casing coupling disconnected from the joint allowing the casing joint to slide down the V-door to the catwalk where it subsequently fell onto the ground. At approximately the same time the disconnected coupling dropped out the elevator to the rig floor. Luckily no injuries occurred.
IADC/11-29 Pipe used as anchorage point on rig floor becomes a projectile
The drill crew was in the process of placing the Tubing Hanger Running Tool (THRT) back into its transporting/handling skid. The tool was being held by air winches to control swing due to rig motion and high winds. The port bow winch line was strung behind an approximately 12 inch (0.31 meters) hold-backpipe on the Port side V-door King post. This 18 pound (8.2 kilogram) hold back pipe is normally used during this type of operation. Due to the tool weight and motion, the hold-back pipe broke off, flying approximately30 feet (9.1 meters) and striking the Chiksan® rack on the starboard wind wall. This action caused the THRT to swing and strike the transporting/handling skid,knocking it over. No one was injured but the pipe, which became a projectile as it broke off, passed within 4 feet (1.2 meters) of 3 different employees.
IADC/11-30 Accidental triggering of power washer results in foot injury
The injured person sustained a severe injury to his foot with the power washer while cleaning out the mud pit. The injured person was cleaning the mud pit and was using the power washer and super sucker to cut a path to the jet barrel. The sludge under the injured person’s feet gave way and the injured person lost his balance. In an attempt to catch himself, the injured person tried to use the wand as a cane. The injured person inadvertently placed the tip of the wand on top of his foot and while falling pulled the trigger spraying water set at 1500 psi through his boot and also through his foot. The foot was severely injured and the injured person was admitted to the hospital for observation and scheduled for surgery to remove the debris from his foot. The injured person could lose his foot if the infection doesn’t improve.
IADC/11-31 Pressure relief valve sprays dilute acid across location on a frac job
During a frac job, a hydraulically-activated pressure relief valve, which was protecting the iron between the pumps and the wellhead, opened unexpectedly and sprayed about 6 bbls of a diluted mixture of 15% HCL and gel across the wellhead, crane and open top tanks. There were no injuries and the spill was cleaned up.The emergency response went well. The diluted acid was further neutralized by spraying it down with soda ash and washed into the cellar where it was vacuumed up. Material Safety Data Sheets for the chemicals were onsite. A post-incident safety stand down was held to discuss the lessons learned and an investigation was conducted.