Petroleum and gas safety alert no. 61 | 14 March 2014 | Version 1
Automated machinery systems on drill rigs
What happened?
A fatality and a number of high potential incidents have occurred in Queensland involving failed or inadequately controlled automated machinery on drill rigs.
Key issues
- insufficient HAZOP and risk assessments
- inappropriately designed controls
- failure of safety functions or components
- lack of understanding of programmable logic controller (PLC) systems and human to machine interfaces
- training not specific to systems and equipment being operated
- workers in areas where automated systems are in use, without appropriate higher level controls
- security and access to PLC software
- poor change management processes (no risk assessments, not understanding operating philosophy, not updating operating manuals and insufficient training).
Recommendations
- Undertake HAZOP and formal risk assessments for automated machinery operated via a PLC.
- Ensure the SIL of any safety instrumented functions are verified by competent people.
- Hardware and software should be designed in accordance with relevant standards.
- Commissioning is to be undertaken by people who are competent to verify, test and certify automated machinery systems.
- Workers training in automated systems should be supervised by people competent in the task they are supervising and workers required to operate automated systems must be competent.
- Effective standard operating and maintenance procedures need to be in place.
- Compliance with relevant safety requirements (standards and codes) under the Petroleum and Gas (Production and Safety) Act 2004 and the Petroleum and Gas (Production and Safety) Regulation 2004.
Investigations are ongoing and further information may be published as it becomes available. The information in this publication is what is known at the time of writing.
We issue Safety Notices to draw attention to the occurrence of a serious incident, raise awareness of risks, and prompt assessment of your existing controls.
Advances in drill-floor technology have resulted in a greater reliance on electronic systems to initiate automated functions, including those that may be safety related, on machinery such as pipe handlers, top drives and iron roughnecks.
Automated systems must be designed with regard to the drilling process, in accordance with recognised standards and after a comprehensive hazard and operability study (HAZOP). All risks must be identified, eliminated or controlled to ensure risk is as low as reasonably practicable (ALARP). The safety integrity level (SIL) or machinery performance level (PL) must be assessed for any safety functions having regard to relevant standards such as AS 4024, AS 61508, AS 62061 and ISO 13849. Designs must be verified and certified by competent people before installation and during commissioning.
Contact: Chief Inspector, Petroleum and Gas gassafe@dnrm.qld.gov.au
Issued by Queensland Department of Natural Resources and Mines
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