In this session of the DROPS Wells Forum, the NOV DROPS Taskforce took us through a decade-long journey of dropped object prevention.

Since 2012, the task force has maintained a continuous loop of improvement by conducting over 100 in-depth analyses of customer incident reports annually. The findings have led to product enhancements during manufacturing and recommendations to improve in-service equipment. Today, very few unique incidents are reported that could not have been prevented with previously recommended improvements. The NOV DROPS Taskforce will share some of the types of incidents frequently reported and their preventive measures. They will also provide information on where you can find the necessary resources to help identify and mitigate known dropped object risks with NOV equipment on your asset.

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DROPS Forum Agenda 29 October 2024

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AI generated summary of presentation:

The DROPS NOV Taskforce has been engaged in proactive measures to prevent incidents related to dropped objects within the oil and gas industry. This presentation outlines their approach, the challenges faced, and the ongoing efforts to address dropped object incidents, particularly focusing on top drive systems in drilling operations. Here’s a summary of the presentation and the key points discussed:

DROPS Mission and Purpose

The DROPS NOV Taskforce aims to prevent incidents of repeated dropped objects by adhering to Original Equipment Manufacturer (OEM) recommendations. With a commitment to safety and risk reduction, the taskforce’s mission is to identify and mitigate potential hazards associated with dropped objects, primarily by addressing deficiencies in design, manufacturing, and maintenance protocols. This presentation highlights significant incidents, such as dropped top drive components, that have occurred due to oversight of OEM guidelines.

Incident Overview and Root Cause Analysis

One of the core case studies presented involves a major incident where a top drive cooling blower guard fin fell from a height of 26 meters onto the rig floor during calibration. This object, an aluminum fin weighing approximately 350 grams, posed a severe risk to personnel on-site, categorized as a Lost Time Incident (LTI). The root cause analysis identified issues with weld type and quality, exacerbated by intense drilling activity. This incident highlighted the essential nature of OEM recommendations in identifying and rectifying equipment vulnerabilities before they result in incidents.

OEM Recommendations and Their Implementation

The DROPS NOV Taskforce emphasizes the need for strict adherence to OEM recommendations, which serve as preventive measures. However, industry compliance has been inconsistent, resulting in recurring safety incidents. OEM guidelines, such as those released in 2016 and updated in 2022, provide actionable insights on equipment maintenance and secondary retention methods to reduce dropped objects. The presentation suggests that failure to implement these recommendations remains a primary factor in repeated incidents. For example, modifications suggested by the OEM were not adopted across all sites, leading to continued risk.

Analysis of Incident Patterns and Industry Challenges

The presentation offers an in-depth analysis of patterns in dropped object incidents, showing that certain product families are more frequently associated with these events. The DROPS NOV Taskforce explored why these incidents recur, questioning whether the right personnel have access to necessary information and if there are industry-wide gaps in sharing and applying OEM guidance. This recurring issue underscores the importance of communication across teams and a streamlined system for disseminating OEM updates.

Recommendations for Prevention and Future Actions

To curb the recurrence of such incidents, the DROPS NOV Taskforce stresses a multi-faceted approach:
1. Design Review and Secondary Retention:** Regular design reviews are essential to incorporate preventive features like secondary retention, which can significantly reduce dropped objects.
2. Enhanced Communication Channels:** The taskforce encourages better communication, ensuring that all stakeholders are aware of, and can act on, OEM recommendations. Utilizing NOV’s internal dashboard and communication tools allows for consistent updates on safety protocols and incidents.
3. Industry Collaboration:** By fostering industry-wide collaboration, the DROPS NOV Taskforce aims to create a culture of shared responsibility, where companies work together to uphold safety standards and implement OEM directives consistently.

Conclusion and Call to Action

The DROPS NOV Taskforce concludes by reaffirming its commitment to preventing dropped object incidents. They emphasize that following OEM recommendations can dramatically decrease the risk of incidents and enhance the overall safety of drilling operations. The presentation closes with a call to action, urging companies to prioritize the implementation of OEM guidelines and collaborate across the industry to create a safer working environment.