Pickup & Laydown Machine Property Damage

Rig T-562, December 25, 2023

Preliminary investigation
Incident Description:
On 25th December 2023, the operation was picking up and running in the hole with 9-5/8” casing with
CRT equipment and PU/LD machine.
The rig had run 95 joints. On joint 96, the PU/LD machine operator lowered the trough to the catwalk to
load a joint of casing by the machine’s hydraulic arms and into the trough. The loaded trough was then
hoisted by the PU/LD machine operator towards V-door when at approximately three-quarters of the
distance from the rig floor, the hoisting line attached to the trough by 4-parts shackle disconnected from
its mounting position causing the trough to descend backwards beyond operator’s control towards the
PU/LD machine stopper. The trough impacted against the PU/LD machine stopper, while the loose end
of the hoisting line jammed into the top snatch block and came to a halt.

Immediate Recovery Actions:

1. Stopped the operation, had stand up meeting with the crew. Developed JSA to recover the casing
joint in the trough, to release the tension in the fast line and rigged down the PU/LD machine
accessories.
2. Resumed the RIH 9 5/8” casing by crane.
3. Al-Gaith representative arrived on location for investigation.
4. KCA rig manager and HSE supervisor arrived on location for support.

Significant Findings during the preliminary investigation:

1. Rig had two PU/LD machines on location.
2. 1st unit (Unit A) was previously utilized for 13-3/8” casing job and was parked at the rig main camp
side. Unit A was not returned to Al-Gaith yard after 13-3/8” casing job completion.
3. A 2nd unit (Unit B) was dispatched to the rig upon Aramco Foreman equipment request. The Al-Gaith
crew decided upon confirming with their base coordinator to utilize Unit A that was on standby at
the rig site. Al-Gaith coordinator confirmed that both units are in good working condition and the
crew selected Unit A due to its better hoisting capability comparing it with Unit B.
- Unit A trough capable of handling casing sizes between 4-½” and 18-3/8”. Hoisting line 16mm;
Guy line 22mm
- Unit B trough capable of handling casing sizes between 4-½” and 13-3/8”. Hoisting line 16mm;
Guy line 22mm
4. Both PU/LD machines were not provided with the SWAP checklist for Casing/Tubing Running
Operation upon their dispatch to the rig from Al-Gaith base.
5. Split safety pin of the 4-parts shackle attaching the hoisting line to the trough broke off allowing the
shackle’s nut and pin to loosen up, detaching the hoisting line from the trough releasing it towards
the end of the catwalk (PU/LD machine side).

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 Fig. 1

6. Several split safety pins installed at other places of the PU/LD machine observed to be improperly
installed, only one side of the split pin was bent around the shackles bolt.

Fig. 2 Fig. 3

7. Al-Gaith crew was formed out of two operators. 1st operator who rigged up the unit worked till
24:00 hrs, then he was relieved by the 2nd operator. The 2nd operator confirmed during the
interview that he had visually checked the equipment condition during the crew change.
8. Al-Gaith inspection procedure does not clearly specify if the unit needs to be inspected periodically
during operation.

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 9. The design of the trough anchor point (pad eye) to fasten the hoisting line is making the swivel and
shackles to rub against the trough. A dent was observed on the trough side edge where the swivel-
shackle assembly are rubbing.

Fig. 4

Fig. 5

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 10. Deviation from the OEM unit design by installing the additional “horizontal” pad eye.

Fig. 6

Fig. 7

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 Timeline:
23rd Dec 23 During the working day the RSTC completed the 3rd party equipment checklist.

24th Dec 23  19:20:00 Rig up of the casing running equipment completed.

 19:30:00 Crew held PJSM and started running casing operations.
 19:45:00 Run in casing operation commenced.
 24:00:00 PU/LD machine operator tour change (60 jts in the hole).
25th Dec 23  00:05:00 2nd PU/LD machine operator completed the equipment check and
resumed operation.
 02:32:00 Crew managed to run 95 jts in the hole.
 02:33:00 PU/LD machine operator lowered the trough on the catwalk on its
loading position and the 96 JT was loaded in the trough.
 02:34:00 PU/LD machine operator started hoisting the trough loaded with the
casing JT towards the rig floor.
 02:34:30 The suspended trough reached 3/4 from its initial position to the rig
floor when the hoisting line detached from the trough and started descending
towards the PU/LD machine.
 02:34:35 The trough contacted the stopper plate and the trolling wire rope
jammed into the top anchor snatch block stopping the descending trough.

Potential Causal Factors:

 Inappropriate equipment design / hazard introduced by the design.
 Failure to identify the hazard.
 Inadequate equipment checks performed.
 Improper equipment installation (split safety pins)
 Inadequate risk assessment.

Preliminary corrective actions:

 In coordination with OEM for the troughs Al Gaith to verify all pad eyes installation/design for
further assessment for introduced hazards and correct similar set-ups.
 Al Gaith to implement OEM recommended intervals equipment checks to be performed by
competent person into their procedure.
 The inspections interval to be discussed during the PJSM and properly documented in the
combined JSA.
 KCA to update their “Third Party Equipment Inspection Checklist” to include the split safety pins
inspection for their condition and proper installation.
 Al Gaith to implement SWAP checklist for all their units.

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 Written Statement:

Off-duty operator statement

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 On-duty operator statement:

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 Site equipment inspections:
Unit-A PU/LD Machine

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 Unit-B PU/LD Machine

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 Al Gaith inspection procedure.

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 Revised JSA of Al Gaith including periodical inspection of all lifting accessories.

PU/LD machine OEM design

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 Operators competency certificates:

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