IADC/14-16 Improper Hand Placement Results in Amputation
The rig crew and a 3rd party company were running casing with a Casing Running Tool (CRT). After running the casing to the curve (kick-off point), the slips were set, the elevators were removed, and the CRT was lowered to fill up the casing. As the CRT was nearing the top of the casing in the rotary, a 3rd party casing employee (IP or injured person) grabbed the top of the casing for leverage. In an attempt to gain leverage, he placed part of his fingers inside the casing while pushing the elevator links out of the way with his other hand. As the CRT was lowered, his fingers were trapped between the CRT and the casing resulting in the amputation of his fingertips.
IADC/14-17 Line-Of-Fire Incident Results in Facial Injuries
The rig crew was attempting to manually latch a running tool onto the top of a tubing liner pump down hole. The crew installed a rod wheel onto the rod string. Employees, on the rig floor, held 10 to 15 turns of torque into the rod string with the wheel as the rod string was lifted. The running tool detached from the lock assembly thus causing the workers to lose their grip on the rod wheel. The release of torque caused the rod wheel to backspin in an uncontrolled manner. While spinning, the gate piece of the rod wheel broke away from the main body of the wheel and, struck a worker in the face, which resulted in major facial injuries.
IADC/14-18 Improper Confined Space Entry Results in Multiple Fatalities
Before the product was unloaded, an employee entered a water tank that contained a water / nitrogen mixture from the displacement of a rigless coil tubing operation and became incapacitated. A co-worker, in an attempt to rescue the first employee, entered the same tank and, for the same reason, was followed by two other co-workers. Realizing that four of his employees were inside the tank, the supervisor ordered the tank drained. He then asked two more of his employees to enter the tank to rescue the four personnel trapped inside by using a rope (safety line). Three of the rescued personnel were unconscious and one was semi-conscious. All four personnel were immediately evacuated to a local clinic. After performing first aid,the semi-unconscious employee was evacuated to a nearby hospital for further treatment. The three others were pronounced deceased by a local medical doctor.
IADC/14-19 Dropped Object Results in Near Miss
During tripping and laying down of the cementing pipe string, the drilling crew discovered a 25.4 cm (10 inch) diameter, 0.68 Kg (1.5 lbs) brass thrust washer lying on the rear of the drill floor. The washer had fallen from the inside of the top sheave in the crown assembly of the derrick, missing the nearest worker by 2 meters (6.5 feet). A visual inspection, performed by the crew from the ground using a camera with a telephoto lens, identified that the sheave pin (which forms the axle for the sheave) had moved laterally and the sheave was noticeably leaning from its normal, vertical position. A crane equipped with a man basket was mobilized so that personnel could access the crown to inspect, render safe, and repair the damage. At this time it was observed that the outer sheave locking plate bolts had sheared and the plate itself was seen resting on the edge of the crown assembly. These conditions created the potential for a more serious incident,necessitating a suspension of rig operations.
IADC/14-20 Hand Tool Left on CCU Results in Potential Dropped Object
When receiving baskets and containers from the vessel, the flagman on the platform observed a sledgehammer lying loose on top of a cargo carrying unit (CCU). The weight of the sledgehammer is 2.24 kg (~5 lbs). The possible drop height from the basket to the sea/vessel was estimated to be 60 meters (~197 feet), Impact=1318 J. The landing area on the platform was secured from entry during the cargo operation. The Master of the vessel received confirmation from the crew of the vessel that they were missing one sledgehammer. The last time the sledgehammer had been used was during preparations for loading water based mud at the quay (dock) when the vessel was in port and the bulk hose was connected-up by the vessel crew. During that operation, an object was discovered in the hose by the crew, who informed the bridge. The bridge then requested base personnel come on board to clear the hose. The operator from the base had borrowed a sledge hammer from one of the vessel’s crew and removed the object from the hose. After the cargo hose had been connected, the sledgehammer was inadvertently placed onto the CCU. The deck crew then connected the hose and opened the loading valve on orders from the bridge. One crew member was appointed as hose guard ensuring that there were no leaks or deviations in the operation. The sledgehammer had not been noticed by the vessel crew before the CCU was sent up to the platform offshore.
IADC/14-21 Lack of Communication/Failure to Stop Job Results in Fatality
The rig crew was in the process of running casing. They had reached a point where a marker joint needed to be picked up and placed into the pipe handling system so that it could be made up in the casing string. The crew retrieved the forklift that had been rented for use on this location. They tilted the fork carriage forward so that the forks could be spread out. As the forklift operator tilted the 600pound (272 kilogram) fork carriage forward, and because the hydraulic pins on the bottom were not attached to the carriage, the entire carriage swung free and was suspended only by the hooks. The crew attempted to hammer the pins out, not realizing they were hydraulic. Their intent was to pin the carriage correctly. The night company man was observing the operation and, after a discussion with the employees, it was agreed that the lift would be used in its “as is” condition to place the marker joint into the pipe handling system; and that the forklift would be corrected later. One employee was positioned in front of the forks in order to slide it over while two other employees pushed on the bottom section of the fork and away from the carriage. One employee stated to the employee, who was ultimately fatally injured, “Hey, you are in a bad spot” as he was standing directly underneath the carriage. The employee replied, “This is only going to take a second.” As they pushed on the bottom section of the fork, the fork carriage was pushed free of its hanging points and the entire fork carriage fell off of the lift. As the fork carriage fell, it struck the employee who was standing directly underneath the carriage on the head, thereby knocking and pinning him to the ground. He sustained fatal injuries.
IADC/14-22 Self-Retracting Lifeline (SRL) Anchor Post Failure Results in Near Miss
The rig crew was drilling ahead when a third party employee drew their attention to the rig’s crown.The crew looked up and noticed that the SRL anchor post was hanging from the retracting line to the side of the mast. Operations were immediately stopped and the crew discovered that the SRL anchor post had fractured at the top of the gusset. It then apparently fell towards the mast and came to rest when it impacted the SRL. The cable was tied to an SRL and the SRL was lying over the top of the crown.
IADC/14-23 Improper Pulling of Rotary Table Bushing Results in Partial Finger Amputation
The crew was in the process of pulling the rotary bushing using the bushing puller that was attached to the winch line. The two bushing puller hooks were each attached to a bushing half. When the rotating bushing halves "popped free", one half of the bushing swung toward the console. An employee attempted to catch the bushing with his left hand. As the bushing half made contact with his hand, the momentum of the bushing pushed his hand into the derrick thereby partially amputating his left ring finger. In this case, proper PPE was not in question.
IADC/14-24 Three Instances of Uncontrolled Descent of the Traveling Block Assembly
During troubleshooting of a Drawwork's brake alarm there was an uncontrolled descent of the travelling block assembly to the rig floor resulting in equipment damage. The maintenance team was troubleshooting the Drawwork's system for a brake status alarm that was preventing the top drive from breaking the upper connection. The initial understanding within the maintenance team was that the Drawwork s brakes were set. Throughout the troubleshooting the maintenance team did not seek a clear understanding as to the condition of the brakes. This was further compounded by a Public Address announcement, which occurred during a critical phone call that resulted in the ongoing still believing that the brakes were set. As a direct consequence of those events, both drives were reset under the faulty assumption that the parking brakes were set. With no drives holding the load, and none of the brake calipers set, the travelling assembly descended to the floor.
IADC/14-25 Shifting Load During Operation Results in Medical Treatment Case
A fly lift for crown sheaves was being prepared using a fly skid. The Load Master requested that the crown sheaves be transferred to a lifting basket due to a shortage of chains for securing. During the re-loading of the sheaves into the basket, an employee climbed into the basket to re-position the sheaves for the lift. During the lift for re-positioning of the crown sheaves, one of the sheaves flipped unexpectedly and uncontrollably, trapping the employee’s leg and causing severe lacerations and a puncture wound. The injured person (IP) was treated on location but required a Med-Evac to the hospital for advanced medical treatment.
IADC/14-26 Line-of-Fire Incident Results in Medical Treatment Case
The crew of a hybrid well service rig had pulled the lubricator to the surface to bleed off the pressure in it. An operator was using an aerial lift to unthread the "Otis" connection on the 10 k stack. The operator unthreaded the nut, and then the rig manager attempted to separate the connection by lifting up on the injector/lubricator assembly. The lubricator was binding on top of the BOP, and the operator in the aerial lift remained in position behind the assembly to direct the rig manager as to which way to move the injector carriage to free the lubricator. The rig manager was following the operator's directions, and as there was weight pulled into the lube assembly, when the rig manager hit the correct spot, the lubricator assembly sprung free of the BOP stack and sprung backwards, thus striking the operator in the aerial lift in the face and knocking him down. The operator was able to regain his stance and bring the aerial lift down to the ground under his own power. He was evaluated by the on-site medic and sent for further medical treatment. The operator underwent an MRI, was diagnosed and underwent surgery to repair a fractured cheekbone and misaligned orbital socket. His recovery time is estimated to be 4 weeks, after which a light duty program should be able to be instituted.
IADC/14-27 Dropped Object: Hammer is Kicked from Work Basket
An employee was operating a work basket inside the substructure while doing various tasks in preparation to nipple down the annular. He had used a 5pound (2.3kg) shop hammer several minutes prior to the incident in order to break out the annular hydraulic lines. After he completed the task, he dropped the hammer to the bottom of the man-basket. While he was moving throughout the basket to arrange the BOP handler (chain hoist), the 5pound (2.3kg) hammer was accidentally “kicked” out of the basket. It was “launched” approximately 10 feet (3 meters) down to the Driller’s side of the substructure where it struck another employee on the hard hat. The impact of the hammer created a pinch point between the hard hat and his safety glasses thus resulting in a laceration below his left eyebrow.
IADC/14-28 Fall from Equipment onto a Trailer Results in a Laceration
Once loaded onto a trailer for transport to a new location, the “toe” extension on the Driller side substructure base was removed due to it extending too far off the trailer because the driver was concerned about maneuvering the load to the new location. With the extension secured, two employees climbed up inside of the substructure to remove the pins. After the extension was removed, the employees then climbed down. While descending, one employee slipped off of a tool box, which was fabricated into the substructure. He fell approximately 5 feet (1.5m) to the ground and landed on his right side. Shortly thereafter, he noticed a laceration in his arm pit that required sutures to close. It appears that the employee may have struck a keeper pin as he fell from the substructure.
IADC/14-29 Personnel Basket Failure – Serious Near Hit
While lifting a Floorhand in a personnel basket to perform scheduled maintenance on the Pipe Racking System inside the derrick, the curved lifting pipe used to suspend the basket partially separated when the basket hung up on an obstruction.The basket and rider were approximately 110 feet above the rig floor when the incident occurred. The rid er felt the basket tilt and called “all stop” over a handheld radio he was using to communicate with the banksman.The basket continued to tilt and the rider repeated the command “all stop”. The basket stopped just as the lifting pipe partially failed.
A separate derrick winch line had been anchored to the rig floor, adjacent to the path the basket would travel, to serve as a guideline for the rider. Following the failure, the rider gave the command to lower the basket. He supported his weight by holding onto the guideline as the basket was lowered to the floor. When the basket reached the rig floor, the lifting pipe parted completely from the basket.
IADC/14-30 Casing Thread Protector Dropped During Hi-Line Operation
Having already transferred 40 joints of casing with the Hi-line from the Drill Floor to the Main Deck,another single joint of casing was in the process of being transferred to the Main Deck.While being transferred, the thread protector (900 grams) for the pin end of the joint came loose and dropped onto two cutting skips located 3 meters below. No personnel were in the vicinity of the area when the drop occurred.