The drill pipe elevator failed at Rig DFXK-1000 due to the auxiliary brakes not functioning properly. An investigation found the maintenance management system was ineffective as the brakes had not been properly maintained, inspected, and tested. Additionally, the mechanic lacked training to maintain critical safety components like the brakes, and there was no standard practice or procedure for maintaining the auxiliary brakes. To address these issues, recommendations included inspecting and testing the brakes during shift changes, providing maintenance training, developing a computerized maintenance system, and creating standard procedures for brake maintenance.
Original Description:
LLD
Original Title
LLD_IN-20161222-003 Drill Pipe Elevator Failure at DFXK-1000 Rawat-2
The drill pipe elevator failed at Rig DFXK-1000 due to the auxiliary brakes not functioning properly. An investigation found the maintenance management system was ineffective as the brakes had not been properly maintained, inspected, and tested. Additionally, the mechanic lacked training to maintain critical safety components like the brakes, and there was no standard practice or procedure for maintaining the auxiliary brakes. To address these issues, recommendations included inspecting and testing the brakes during shift changes, providing maintenance training, developing a computerized maintenance system, and creating standard procedures for brake maintenance.
The drill pipe elevator failed at Rig DFXK-1000 due to the auxiliary brakes not functioning properly. An investigation found the maintenance management system was ineffective as the brakes had not been properly maintained, inspected, and tested. Additionally, the mechanic lacked training to maintain critical safety components like the brakes, and there was no standard practice or procedure for maintaining the auxiliary brakes. To address these issues, recommendations included inspecting and testing the brakes during shift changes, providing maintenance training, developing a computerized maintenance system, and creating standard procedures for brake maintenance.
Lesson Learned Document Description: On 22nd December, 2016 at 1115 hours while Running in 6“ BHA with 3-1/2 drill pipes the elevator hit the rotary table base due to failure of auxiliary brake. Driller picked up string by applying the draw works clutch. Due to sudden hit one of the drilling lines slipped out from the crown block sheaves and stacked in between two sheaves. WHAT WENT WELL: LESSON LEARNED / RECOMMENDATIONS: • No injuries to personnel • Every shift change Tool Pusher and Driller must inspect brake system. Run a test to verify the safe working of the system • Every shift change inspect Floor Saver and Crown Saver make sure WHAT WENT WRONG: equipment is working good • Auxiliary brakes did not function • Maintenance Training must be provided to the Mechanic on the • Maintenance of brake system not effective Electrical systems of the Draw works • Proper procedure for maintenance of brakes not • Maintenance plan should be reviewed to ensure SCE are checked available against checklist before each shift change • Incident to be shared with other rigs and all concerned to learn from it SUMMARY OF CRITICAL FACTORS: • Develop and implement an effective Computerized Maintenance Immediate Causes Management System at rig DFXK 1000 HP for the planning and [CF-1] Ineffective Maintenance Management system management of critical rig equipment/parts – The auxiliary brakes did not function • Develop and implement a SPP for rig DFXK 1000 HP maintenance of auxiliary brake System Causes [CF 2] Lack of Expertize to maintain a Critical Safety component of the rig – The Mechanic was not trained on the brake system
[CF 3] Lack of SPP (Standard Practice / Procedure)
– No procedure for maintenance of auxiliary brakes