Dropped Object - Fatal Accident

Accident Location: Onshore Drilling Rig 302, Saudi Arabia

Date : 25 November 2015
Activity: Casing Operation
Personnel involved: Saipem personnel
Dropped Object - Fatal Accident
Accident Description
On 25 November 2015 at approximately 21:12 hrs. a fatal
incident occurred on the Saudi Arabian Saipem onshore
drilling Rig 302, where a floorman sustained a fatal head
injury due to impact by a falling slips segment from a
casing spider elevator.

The accident occurred during running the 24” casing Stabber Dislodged Slipped Segment
running operation, performed by a team from the Casing
Service Company and Saipem rig floor crew.

The 40th casing joint was lifted to the rig floor, stabbed
into the string and made-up by the casing power tong.
The single joint elevator was unlatched by the stabber,
who gave a signal to the driller to lower the spider
elevator, in order to latch it onto the casing joint.

While lowering the block, the casing spider elevator was

passing the casing collar, one of the casing spider Tong Operator
DROPS RED
elevator’s slips segment was dislodged and ejected from ZONE

the top of the spider elevator. The 79 kg. slips segment Saipem Driller
Floorman
of the casing spider elevator fell from a height of (IP)

approximately 45 feet striking the floorman on the head,

resulting in a fatal injury.
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Saipem
Floormen
Dropped Object - Fatal Accident
Accident Dynamics
 Casing power tong was operated, when the casing
spider elevator was being lowered above the collar of
casing joint#40.
 Casing joint collar, which was being rotated clockwise
(by the power tong), caught the extruded slips
segment which was pushed upward, twisting the
hanger bottom pin hole area.
 As result of the double forces (upward and twisting
clockwise), the lower link pin slipped out from the
hanger leaving the slips segment detached, which was
ejected from the upper side of the casing spider
elevator.

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Dropped Object - Fatal Accident
Causes:
 The inner components of the spider elevator were not inspected (MPI certificates provided only
for elevator bails lifting eyes only).
 Specific inspection check list for the spider elevator was not provided by the third part company.
 There was no common JSA of Saipem and third party company regarding the associated risks of
the operation.
 The hands-free communication system between the driller and stabber was not effective.
 Due to equipment engineering of drilling rig the injured person was allowed to stay on the rig
floor in order to hold the pressurized air hose to operate the spider elevator.
 No OEM secondary restraining provisions for the spider elevator slips segments.

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Dropped Object - Fatal Accident
Recommendations
 Address to SA D&WO a recommendation, that the service companies providing tubular
handling services on SAS drilling project to develop / improve inspection criteria for tubular
handling equipment in accordance with API and OEM recommendations.
 Suggest to SA D&WO to initiate the Bridging Document between the SAS Drilling and Service
Company Provider, to interface a combined team activities, in terms of associated hazards,
controls measures, equipment integrity assurance, critical task responsibilities and minimum
competency requirements.
 Review the existing SAS drilling project QA/QC plan to verify compliance with OEM and API8B
recommendations for inspection Categories 1, 2, 3 & 4.
 Implement the revised SAS drilling project QA/QC plan and PMS for tubular handling
equipment with reference to OEM and API8B recommendations for Categories 1, 2, 3 &4
inspections.
 Review SAS drilling project existing PMS to verify compliance with OEM and API8B
recommendations for tubular handling equipment maintenance.
 Schedule and conduct internal rig QMS audits to verify implementation of the corrective
actions stated in the investigation report.
 Rig and service provider companies MUST bridge both companies JSAs prior starting any joint
operation.

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Dropped Object - Fatal Accident
Recommendations
 Install/ repair as required the hands-free talk-back communication system between the
driller-stabber (stabbing board) and driller-derrick man (monkey board).
 Implement PMS for inspection of hands-free talk-back communication system between the
driller- stabber (stabbing board) and driller-derrick man (monkey board).
 Install the foot operated switch for stabber panic alarm to alert the driller and rig crew for
any unsafe/emergency conditions related to stabbing board activity.
 All rigs to review the JSA relevant to stabbing board and monkey board operations, to
include mandatory requirement for use of the hands-free talk-back communication system
between the driller-stabber (stabbing board) and driller-derrick man (monkey board).
 Incorporate intermediate visual inspections of casing spider elevator into the JSA. The
inspections to be performed by the power tong operator on the rig floor level after each
joint is set in the spider slips or after any abnormal condition occurs.
 Install a permanent rigid line with flexible air hose ( ½ / 50 feet) at 45 feet above the rig
floor to supply air to casing spider elevator, when in use. Modification I installation to be
done via approved MOC.
 Develop and cascade the awareness presentation related to "Restricted Areas Management
Process" (Red, Yellow and Green Zones).
 Schedule and conduct internal rig DROPS Audits, including the restricted areas management
implementation process.

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Dropped Object - Fatal Accident
Recommendations
 Share the accident lessons learned
with major spider elevator OEMs (NOV,
B+V, Dencon etc.)and advice research
or feasibility study for provision of
secondary restraining for the spider
elevator slips segments, to prevent it
from accidental fall in the event of
failure of primary securing means.

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Dropped Object - Fatal Accident
Recommendations
 Rig and service provider companies MUST bridge both companies JSAs, prior starting any
joint operation. In addition, JSA for Casing Running Operations should incorporate the below
recommended safety control measures:
o For rigs with cyber chair control, due to the brake lag time, it’s required that the driller to
engage the first gear for the entire casing job.
o The driller must be required to stop the elevator above the top of casing, prior to pass the
spider elevator over the casing collar. The Driller will then slowly lower the elevator over
the casing to the correct pick up position.
o During lowering the elevator above the casing collar, the stabber needs to monitor and
maintain continuous hand signal (lower/lift/stop) and be ready to signal emergency stop by
voice and hand if a segment is out of place or the elevator is not positioned correctly.
o A clear line of sight to be maintained between the Driller and Stabber. This could be
through a camera aids if direct visual contact is obstructed.
o A hands free communications system shall be in place, turned on and working effectively.
The talk back communications system must not be disabled at any time during casing run.
o Casing power tong not to be operated, when the spider elevator is passing over the casing
joint collar.
o Visual inspection of casing spider elevator to be performed by the power tong operator on
the rig floor level after each joint is set in the spider slips.

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Questions?