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Petroleum & Gas Inspectorate | Alert | No.120 V 1 | 02 May 2025

Fall or release from height of polish rod clamp

Summary

  • A worker was almost struck by a lifting device that unexpectantly released during maintenance operation on a well.
  • Early investigation indicated that during the change-out operation of a polish rod the polish rod clamp used to lift the polish rod out of the well unexpectedly released (slipped off the end of the broken polish rod).
  • Investigations are continuing.

Issue Explained

  • The incident occurred in January 2025.
  • The release occurred after difficulty was encountered in raising the polish rod out of the well. Prior to the release multiple attempts were made to lift the rod with increased force (remaining within the lift plan) exerted on the polish rod and polish rod clamp.
  • After the unexpected release, the clamp landed approximately 2m behind one of the workers who was in proximity to the operation.
  • Wells that have downhole pumps installed utilise rods to transfer mechanical energy to the downhole pump which in-turn pumps fluid out of the well. The top rod (polish rod) of the rod string is part of the sealing structure used to contain fluids within the wellbore during pumping operations. This rod over time is susceptible to wear and requires periodic replacement to ensure the sealing surfaces are maintained.
  • The process of replacing the worn or damaged polish rod, involves lifting the rod string sufficiently out of the well such that the bottom connection of the rod can be accessed on surface, the worn rod removed and replaced with a new rod, the new polish rod is connected to associated surface drive equipment, wellhead components reinstated, and the pump brought back online.
  • Equipment used in this operation to lift these rod strings varies from workover rigs to cranes depending on the well type and conditions. The height at which the rods need to be lifted varies depending on rod length, and they typically range from 8 – 10m in length with total mass of the rod string varying depending on depth of the downhole pump.
  • Polish rod replacement operations can be affected by a range of hazards and conditions including, but not limited to:
    • Worn or deteriorated polish rod or rod components that may reduce effectiveness of lifting devices.
    • Fatigued polish rod or rod components that may fail under load
    • Stuck polish rod or rod components within the wellbore requiring excessive force to free.
  • There are significant consequences associated with the hazards identified above resulting in:
    • Fatality to workers struck by lifting equipment that unexpectedly releases from the polish rod under load, or the unsecured polish rod falling on the worker in the immediate vicinity of the lift.
    • Impalement of workers if the polish rod is released and a worker is within the immediate vicinity of the lifting zone
    • Fractures sustained due to being hit by falling polish rod or lifting equipment.

Learnings

An operator of operating plant, in this case a well or rig has duties under the Petroleum and Gas (production and safety) Act 2004 to ensure, so far as is reasonably practicable, that risks to workers of objects that may fall from heights are identified and managed. Effective control measures for managing risks associated with falling objects include a combination of controls. Some risk control measures can include but are not limited to the following examples.

  1. Exclusion zones – Effective exclusion zones, minimise the exposure of workers to the hazard of the potential falling object
  2. Securing loose items – Items that may become loose during the lift due to failure measures must be identified, and considerations taken to secure them to prevent them from becoming free to fall on workers.
  3. Review lifting plans and JSAs to consider the anticipated weight, the method which the rods are to be lifted, identify potential risks that may impact the effectiveness to the lift, identify the maximum loads the lift can be taken to and what to do in the event these loads are reached.
  4. Overhead protection – Providing workers with protection from dropped objects, for example workers that operate within the exclusion zones are further protected by being enclosed in a cab of a vehicle etc.
  5. Pre Lift checks – Inspection and verification of the lifting devices and equipment to ensure that the installation is correct. Identify if equipment is in serviceable condition.
  6. Communication protocols – Identify how the work party is operating during the lift, who is giving direction to the operator of the rig or crane during the lift.

Operators that conduct similar operations are to review their safety management systems to ensure that these risks are adequately controlled.

If an incident occurs, you’ll need to show the regulator that you have an effective safety management system that manages the risks associated at various stages of the operating plant’s life. These operator responsibilities are covered by the obligations outlined in the Petroleum and Gas (production and safety ) Act 2004.

It is a mandatory requirement of an operator’s safety management system to contain a formal safety assessment, to identify and control risk. The hierarchy of controls is used to help decide how to eliminate and reduce risks at your operating plant. The hierarchy of controls ranks types of control methods from the highest level of protection and reliability to the lowest. It’s a step-by-step approach to eliminating or reducing risks. You must work through the hierarchy of controls when managing risks, with the aim of eliminating the hazard, which is the most effective control.

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.

References and further information

  • Petroleum and Gas (Production and Safety) Act 2004
  • Petroleum and Gas (Safety) Regulation 2018
  • AS 4991: Lifting devices
  • Mobile Crane Code of Practice – Workplace health and Safety Queensland
  • API Specification 11B -Sucker Rods and Rod related Products
  • Recommended Practice 54 (RP 54), Occupational Safety and Health for Oil and Gas Well Drilling and Servicing Operations
  • API Recommended Practice 74 – Recommended Practice for Occupational Safety for Onshore Oil and Gas Production Operations

Authorised by Shoena Messner - Chief Inspector – Petroleum & Gas

Contact:

Issued by Resources Safety & Health Queensland

Safety: This information is a guide only and is issued to promote safety through experience. It is not to be taken as a statement of law and must not be construed to waive or modify any legal obligation.
Security: This information is a guide only and is issued to promote security through experience. It is not to be taken as a statement of law and must not be construed to waive or modify any legal obligation.
Placement: Place this announcement on noticeboards and ensure all relevant people in your organisation receive a copy.