IADC/13-16 Whipping of Cable (stored energy) Results in Injury
While changing out the wire on the crane winch shown in the photo, the Injured Person (IP) was positioned next to the winch so as to facilitate the securing of the cable on the drum. One clamp had been placed on the cable when it was discovered that the cable needed to be adjusted. The clamp was then slackened to allow for this adjustment. Due to the non-rotating characteristics, composition, and bend of the crane wire, there was a great deal of mechanical energy stored in the wire at the securing location. This stored energy caused the wire to spring back when the adjustment was made. The IP was positioned in direct line of the wire movement resulting in the end of the wire hitting him in the forehead, just above his eye. Even though the IP was wearing PPE at the time, the incident resulted in a small cut just above his eye, which had to be treated at the local emergency room.
IADC/13-17 Fall from Height Results in Fatality
The derrick had been lowered to the ground for disassembly and two of the three cranes were set up to start taking apart the substructure. A crane rigger and four other rig employees went up to the substructure to start knocking pins out of the spreaders so the crane slings could tie on to them and lower them to the ground. The first piece that needed to be removed from the substructure was the off-driller-side rotary beam.The crane rigger had attached the crane chains/cables to the rotary beam and,using hand signals, notified the crane operator to begin lifting the rotary beam. As the beam was being lifted, the crane rigger noticed that the chains were not centered, thus causing the beam to be lifted unevenly, which caused it to get in a bind. The crane rigger signaled for the crane operator to stop his lift and slack off so he could re-position the chains on the beam. The crane rigger then stepped out onto the beam; when he did, the beam came free and fell, allowing him to fall approximately 30 feet (9m) to the matting boards below. Despite the efforts of co-workers and EMS, the crane rigger died from his injuries sustained in the fall.
IADC/13-18 Body Positioning Near Suspended Load Results in Medical Treatment Case
A member of the rig crew was assisting with breaking down the BOP assembly during a rig move. He was standing under the substructure holding a cable out of the way while the choke lines were being removed out from under the substructure by the forklift. Once the choke lines became free, they swung in his direction and knocked his feet out from under him. The injured employee was seen at the local hospital where he received minimal treatment. X-rays taken of his shoulder revealed a small fracture within the rotator cuff of the left shoulder.
IADC/13-19 Conflicting Procedures Results in Restricted Work Case
A third party surveyor, who was not assigned to the rig, attended the rig during a five (5) year survey. The surveyor wanted to test the lifeboat with an “on-load” release to the water. The Assistant Barge-Master (ABM) was assisting the surveyor to conduct the test and was sitting on a crew seat near the coxswain's seat with his hand flat on the seat to brace for impact. When the life boat was released "on-load," it fell and impacted the water. Upon impact, a small 1kg (2.2lbs) fire extinguisher, which manufacturer fitted near the coxswain’s seat, released from its bracket and fell hitting the ABM’s right hand and injuring his finger. The ABM was treated at a local hospital, placed on work restriction, and returned to work.
IADC/13-20 Dropped Object results In Near Miss
A half-moon clamp insert weighing 1.9kg (4.9lbs) had been identified as redundant equipment and was being removed from a hose. The work party, who removed the clamp, was not aware that the assembly contained inserts. It was assumed that the inserts were integral to the swaged end fitting of the hose. However, the inserts were held on by friction and had “weathered” in place. Two days later, one of the clamp inserts fell 12 meters (39 feet) from the compensator fluid hose to the drill floor. Even though this incident could have resulted in a fatality, no personnel were struck by the dropped object and the remaining half-moon insert was safely removed and brought to the drill floor.
IADC/13-21 Iron Roughneck “Struck By” Incident results in Fatality
While the rig crew was tripping drill pipe out of the well, a floorhand was struck by an iron roughneck and suffered fatal injuries. At the time of the incident the floorhand was fitting a collar clamp around a drill collar. Witnesses state that a remotely operated iron roughneck was engaged to extend while the worker was in its path. Attempts to warn the person and stop the iron roughneck failed.Even though this incident is subject to an ongoing investigation, this alert provides guidance for the industry on the risk factors and hazards identified during the preliminary investigation.
IADC/13-22 Equipment Failure During Perforating Results in Near Miss
While removing the spent perforating gun from the hole after perforating the 5th stage of a horizontal hydraulically fractured completion, the wire rope parted from the rope socket allowing the gun to fall to the ground. There were no injuries or damage. The lubricator had been lifted from the wellhead and positioned 50 feet (15.24 meters) above the ground to lower the 30 foot (9.14 meters) long spent perforating gun. The gun was lowered out of the lubricator to within 1 foot (30.5cm) of the ground when the rope socket failed thus allowing the gun to drop vertically to ground level and then fall over onto the ground.
IADC/13-23 Failure to Torque Drill Pipe Results in Serious Near Miss Event
The crew had made up a stand of drill pipe in the mousehole. After hoisting the stand out of the mousehole, and while it was still hanging in the elevators, the crew began to make up a float sub to the bottom of the stand using the iron roughneck. Unknown to them, when the stand was originally made up in the mousehole, the connection (tool joint) between the top and middle joints did not get fully torqued thereby creating a “loose” connection. When the iron roughneck was engaged to spin the bottom joint of the stand to make it up into the float sub, it also backed out the “loose” connection between the middle joint and top joint of drill pipe, separating the bottom two joints of the stand from the top joint. The bottom two joints fell damaging the hand rails on the rig floor before continuing off the floor and coming to rest against the substructure. No injuries occurred.
IADC/13-24 Unrecognized Hazard Results in Laceration to Leg
A derrickman was instructed to empty the brine column tank on the rig. Prior to commencing the job, the derrickman planned the job, ensured a permit-to-work was in place, and completed a job safety analysis. The equipment he was going to use included a 1 inch (2.5cm) water hose and a “jockey” pump. When the brine tank was empty, the derrickman decided to flush the hose and the pump using the 1 inch (2.5cm) water hose. He connected the hose to the outlet on the pump and pressurized it. To avoid spilling the brine, he choked the hose (Picture #1). The distance from pump outlet to the pump house was approximately 10meters (33ft). While moving against the pump, the pressure built up inside the hose resulting in the hose slipping out of his hand. The hose made an uncontrolled swing and hit the derrickman in his leg. He continued to work until the end of his shift and it was not until after his shift that he realized the hose nozzle had cut his leg.
IADC/13-25 Struck-by Incident While Running Casing Results in Fatality
While running casing, an employee (Injured Person– IP) was backing out a cross threaded 18-5/8inch (46cm) casing joint when he was struck on the right side of his head by the casing power tong.This impact caused his head to hit against the top drive rail lifting eye and then he fell 3 feet (91cm) down to the rig floor.
IADC/13-26 Failure of Lifting Eyebolt Results in Dropped Object
The deck crew was attempting to move an electric motor weighing approximately 200kg (440 pounds) from the shelter deck into a sea container. The motor was lifted using a crane. The banks-man signaled the crane operator to pick up the motor and lift it to the container, which was 5 meters (16 feet) away. The motor was lifted and moved to a height of approximately 2.5 meters (8 feet). When the motor approached the container at a height of about 60cm (2 feet), two roustabouts entered the container to position the motor from inside using taglines. As the motor was being pulled into the sea container it tapped the wall of the container. The motor casing parted at the eyebolt anchor mount allowing the motor to fall to the floor. The crane operator stopped the job and informed the Supervisor. No personnel were injured.
IADC/13-27 Pipe Dropped from Side Door Elevator
While pulling and laying down 4 1/2" (11cm) tubulars, a crew member closed and secured the elevators with the verification pin and the Driller hoisted the tubing up to the next connection to be broken. Once the connection was landed in the slips, the tongs were engaged and the connection was backed out. A crew member grabbed the tubing and began to guide it to the lay-down machine. He was in the process of asking the Driller to hoist the tubing up when it fell down to the stabbing mat and came to rest against the rig floor. The rig crew members observed that the elevator was open with the verification pin still in the hole in which it had been placed.
IADC/13-28 Sudden Ice Plug Release Results in Struck-By Injury
While converting from air to mud, the employee was attempting to reinstall the pressure gauge on the standpipe manifold. When he removed the bull plug from the manifold, he noticed ice had accumulated inside the two-inch (5cm) line. He notified the Driller and then attempted to remove the ice using a hand tool. Trapped pressure existed inside the lower section of the standpipe. As the ice dislodged from the line, it struck the employee in the ribs on the right side, causing internal injuries. He sustained further injuries when he fell back into the handrail striking his shoulder.
IADC/13-29 Complacency with a Common Job Task Results in Injury to the Derrickman
The morning tour crew had just arrived to work on the last day of their hitch and would begin their shift by continuing trip out operations that were commenced by the daylight crew. The Driller was watching the Derrickman via a CCTV monitor. After verifying that the rope around the stand was secure and that the elevators were unlatched, he floated the top drive link tilt cylinders back towards well center and began slacking off the top drive to get another stand of pipe.
The Driller then looked up towards the fingerboard to verify that the stand had cleared the top drive and, after noticing it had not cleared, he quickly released the brake control joystick to apply full air pressure to the draw works brake to stop the load. The box (top) end of the stand had hung up somewhere on the top drive between the pipe handler stabbing guide and the link tilt actuator. The downward travel of the load had stacked weight on top of the stand and had put a “bow” in the pipe.
It was discovered that the Derrickman’s rope had become lodged between the spring-loaded latch handle and the body of the elevators, which was the reason why the stand had not cleared the top drive. Rather than letting go of the rope and moving to a safe position, the Derrickman attempted to free the rope by “jerking” on it. Instantaneously, the stand came free from its lodged position underneath the top drive and the stored energy in the “bow” of the pipe immediately shot the stand out towards the fingerboard and directly into the off-driller’s side (ODS) alleyway, where it forcefully struck the Derrickmanin the mid-section and drove him into the back hand rails of the fingerboard.Due to the extent of his injury, the injured employee was transported to a medical facility.
IADC/13-30 Failure to Torque Lift Sub Results in Dropped Monel Drill Collar
During tripping operations, the crew was in the process of making up the bottom hole assembly. The monel drill collar was brought up to the rig floor by the pipe-cat. A lifting sub was placed into the box end of the monel drill collar and screwed together with chain tongs. The drill collar was then picked up with the top drive elevators and pushed out of the way so a stabilizer could be picked up and placed in the mouse hole. The monel drill collar was then placed into the stabilizer, made up and torqued with the iron roughneck. The bottom hole assembly (BHA) was picked up out of the mouse hole with the top drive and pushed out of the way so a float sub could be brought to the rig floor. The float sub was then stood up and placed in the jaws of the iron roughneck and the monel/stabilizer assembly was stabbed into it. Chain tongs were used to make up these two sections while the iron roughneck was used as back up on the float sub.The iron roughneck was then used to make up the float sub to the stabilizer.
At some point while the crew was making up the float sub to the stabilizer, the lift sub unscrewed from the monel. When the iron roughneck was removed, the BHA, which was sitting on the rig floor, fell out of the V-door and land on the pipe-cat.