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1 GLNG Incidents / Lessons Learnt CSG Safety Forum John Sargaison 14 August 2009.

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Presentation on theme: "1 GLNG Incidents / Lessons Learnt CSG Safety Forum John Sargaison 14 August 2009."— Presentation transcript:

1 1 GLNG Incidents / Lessons Learnt CSG Safety Forum John Sargaison 14 August 2009

2 2 Recordable Injuries - YTD * Date Severity Rating Nature of InjuryName of CompanyLocationType 06-Jan-091 Fracture to finger pinched between drilling tongs Atlas DrillingAtlas Rig #1Indirect 27-Jan-0910* Spinal Trauma caused by neck whiplash in truck due to potholes in the road FKGSpringwaterDirect 11-Feb-0910*Struck by falling drill pipeEWGCoxon Creek #8Indirect 18-Feb-091 Laceration to hand struck by sledge hammer DiversifiedFairview FieldDirect 05-Mar-091 Sprain to ankle, rolled ankle on edge of path Valve TechFairview PlantIndirect 16-Mar-091 Fracture to finger pinched between hole cover and equipment Mitchell DrillingFairview #408Indirect 25-Mar-0910 Amputation of L index finger tip Atlas DrillingFairview 83Indirect 31-Mar-091Laceration to fingerSelect ContractorsKimber Lane Yard RomaIndirect 11-Apr-091Laceration to fingerEWGFairview #71Indirect 15-Apr-091Laceration to fingerAtlas DrillingFairview #413Indirect 22-Apr-091 Laceration to hand while installing hose EWGEWG Rig 101Indirect 09-May-091Crush injury to fingerEWGEWG Rig 102Indirect 13-May-091Back strain handling pipeBresall DrillingCurtis IsDirect 15-May-091Fracture to fingerEWGEWG Rig16Indirect 16-May-0910Fractured vertebraeAtlas DrillingAtlas Rig #1Indirect

3 3 Recordable Injuries - TRCFR * A direct recordable injury is where GLNG has accountability for the safety of the activity being conducted when the injury occurred. GLNG Project recordable injury includes injuries where either GLNG or another Business Unit/Department has accountability for the safety of that activity (ie indirect plus direct recordable injuries).

4 4 LTI – Dropped Drill Collar IMS #38751 EWG Rig 102 – Coxon Creek 8 11 February 2009

5 5 Overview In preparation for spud, a 5-1/2” drill collar was picked up using the rig’s pipe handling system. The drill collar was latched in the elevators and raised to a near vertical position. When the drill collar was at the near vertical position, the collar slipped through the elevators. The drill collar subsequently landed on the rig’s pipe handling system before bouncing off and landing on the ground/rig floor. A Floorhand received a glancing blow to the lower back while exiting the rig floor by the drill collar as it landed on the rig floor.

6 6 Summary of Events  At 08:00 on 11 February 2009 the Assistant Driller asked the Mud Tester to gather all of the required equipment for spud. This included the manual 5-1/2” Drill Collar Elevators. -Manual Elevators were to be used due to a broken valve on the hydraulic elevators; The Rig Manager was waiting on confirmation that the hydraulic elevators could be used with the broken valve  The Mud Tester attached a sling to the 5-1/2” casing elevators and placed them at the front of the parts container. The Forklift Operator transferred the elevators to the V-Door.  At 10:00 the drill bit and bit sub were raised to the floor, along with the casing elevators.  The elevators were fitted to the bails by the Driller, Leasehand and Assistant Driller.  The drill bit and bit sub were made up. The drill collar was then raised to the floor by the pipe handler. The IP latched the casing elevators to the drill collar.  The drill collar was picked up in the elevators. As the drill collar neared the vertical position, the Driller noticed the collar slipping out of the elevators and raised the alarm.  The drill collar fell back to the pipe handler, bounced and fell to the ground and rig floor.  The IP received a glancing blow to the lower back while exiting the rig floor by the drill collar as it landed on the rig floor. The incorrect elevators were selected for the operation.

7 7 Overview 5-1/2” Casing Elevators Markings 5-1/2” DC Elevators Markings

8 8 Overview Final Position of 5-1/2” Drill Collar

9 9 Incident Root Causes Causal Factor: Manual elevators were selected for use instead of the hydraulically actuated automatic elevators Root CauseCorrective Action Equipment Difficulty - Tolerable Failure (failure of light on auto elevators) Procedures - Wrong - Situation Not Covered It is recommended that:  Review the requirement for the light actuating valve on the automatic elevators. Ongoing.  SOP to be updated to include the requirement for visual verification by the driller of correct elevator type in the event the automatic elevators are not used. Completed for EWG 102 and 101. Causal Factor: 5-1/2” casing elevators were on site, but were not actually used in normal operations Root CauseCorrective Action Management System - Oversight/Employee Relations - A & E lack depth It is recommended that:  A colour coding visual identification schedule for all elevators should be developed. Completed for EWG 102 and 101.  Equipment held on site and not commonly used to remove to the EWG Roma yard. In progress. The 5-1/2” casing elevators are currently tagged out and can not be used without approval from the rig manager

10 10 Incident Root Causes Causal Factor: The Driller was not aware that the 5-1/2” casing elevators were on site, and so did not check the elevators himself Root CauseCorrective Action Human Engineering - Human – Machine Interface - Labels NI It is recommended that:  A poster showing the colour coding system is to be posted in the elevator storage area and in the driller’s cabin. Completed for EWG 102 and 101. Causal Factor: Manufacturers labelling on the elevators was similar for both sets of elevators Root CauseCorrective Action Human Engineering - Human – Machine Interface - Labels NI It is recommended that:  A colour coding visual identification schedule for all elevators should be developed. Completed for EWG 102 and 101.  Equipment held on site and not commonly used to remove to the EWG Roma yard. In progress. The 5-1/2” casing elevators are currently tagged out and can not be used without approval from the rig manager  A poster showing the colour coding system is to be posted in the elevator storage area and in the driller’s cabin. Completed for EWG 102 and 101.

11 11 Corrective Actions 5-1/2” Casing Elevators Tagged Out Elevator Colour Coding

12 12 High Potential (HiPo) Incident Summary Task - reassembling BOP Suspended load lowered into place and sling was slack IP considered that the load was no longer suspended IP moved under the jib and commenced to tighten securing bolts Loader operator gets air hose to clean out loader cab Air hose catches on jib control lever causing it to lower Re-enactment of IP under jib

13 13 LTI – Back Injury IMS #42241 Atlas Rig 1 – Fv122_OB1 13:25 16 May 2009

14 14 Overview Maintenance was being carried out on the BOP during rig move. While replacing the kill line valve, the IP positioned himself under the loader jib. Coincidental with this, the loader operator pulled a compressed air line through the window of the loader to clean the cab. The air line made contact with the loader controls causing the loader jib to descend. The loader jib stopped when it made contact with the valve it was previously suspending. The loader jib pinned the IP in the crouched position causing two fractured vertebrae. The IP was evacuated to Injune hospital for medical treatment and later to Toowoomba for precautionary MRI scan.

15 15 Summary of Events  At 13:00hrs the work party commenced re-assembly of the kill line valve block back onto the BOP. The kill line valve block was manoeuvred into position a using loader stinger jib and soft sling.  With correct alignment achieved, the flange was fitted onto the studs. Under direction, the loader jib was lowered slightly causing the sling to slacken, indicating weight of the valve block was now being fully taken by BOP studs. Derrickman and Floorman commenced tightening nuts onto flange.  Loader Operator steped out of loader to grab compressed air line to “blow” clean loader cab. Operator routed hose through cab window with hose passing close to jib control levers.  Loader Operator climbed back into cab and commenced cleaning the loader cab.  Derrickman positioned himself under the loader jib to tighten nuts onto the valve block flange.  At 13:24hrs, the Floorman noticed the loader jib descending at approximately 150mm/sec. The Floorman attempted to get attention of Loader Operator to alert him.  IP becomes pinned in the crouched position beneath loader jib and BOP stump skid. The end of the jib contacts the valve block flange surface preventing further downwards travel.  IP evacuated from site. IP sustained two fractured vertebrae.

16 16 Overview Re-enactment if IP’s position under jib. Photo showing air hose path through cab RHS window and across control levers

17 17 Overview  Step-back conducted before operation  Loader Operator (Driller) had Forklift Licence and ~25 years loader experience  Crew did not consider loader jib as a suspended load

18 18 Incident Root Causes Causal Factor: Driller runs air hose through RHS window of loader cab - across control levers Corrective Action Loader operator considered his part of the job to be over once the valve was secured. Loader operator was focused on a a second task (not the position of the jib). It is recommended that: - Loader Operations Procedures be revised to include warnings regarding operator attention during use. - High impact sign in cab warning of hazards of inattention and leaving cab whilst loader running. - The inclusion of a special section on loader safety as part of Level 3 induction - Confirmation of safety systems running as part of loader pre-start checks - A training refresher for all loader drivers in field - A review of the controls layout for all loaders in field - Distribution of a Haz Alert followed by a visit to all rig crews by Santos Field Safety Advisor to discuss

19 19 Incident Root Causes Causal Factor: IP positioned under loader jib Corrective Action IP did not consider loader jib to be a suspended load once valve was removed. It is recommended that: - A warning be placed on the jib warning of the dangers of working under suspended loads and unexpected operation of the loader - The inclusion of a special section on loader safety as part of Santos Level 3 induction - Distribution of a Haz Alert followed by a visit to all rig crews by Santos Field Safety Advisor to discuss


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