OISD
STD – 190
(August 2000)
For Restricted Circulation
DERRICK FLOOR OPERATIONS
(ONSHORE DRILLING / WORKOVER RIGS)
Prepared by
Committee on “Derrick floor Operation”
Oil Industry Safety Directorate
2nd Floor, Kailash
26, K.G. Marg
New Delhi-110001
FOREWORD
The Oil Industry in India is more than 100 years old. Because of various collaboration agreements, a variety of international codes, standards and practices have been in vogue. Standardisation in design philosophies and operating and maintenance practices at a national level was hardly in existence. This coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council assisted by the Oil Industry Safety Directorate(OISD) staffed from within the industry in formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safe operations. Accordingly, OISD constituted a number of functional committees of experts nominated from the industry to draw up standards and guidelines on various subjects.
The present standard on " Derrick Floor Operation " (Onshore Drilling / Workover rigs)was prepared by the Functional Committee on " Derrick Floor Operation” (Onshore Drilling / Workover rigs) This document is based on the accumulated knowledge and experience of industry members and the various national and international codes and practices.
This standard is meant to be used as supplement and not as a replacement for existing codes and practices.
It is hoped that provisions of this standard if implemented objectively, may go a long way to improve the safety and reduce accidents in Oil and Gas Industry. Users are cautioned that no standard can be a substitute for the judgement of responsible and experienced Engineers.
Suggestions are invited from the users after it is put into practice to improve the document further. Suggestions for amendments to this document should be addressed to the Coordinator, Committee on " Derrick Floor Operation” (Onshore Drilling / Workover rigs),Oil Industry Safety Directorate, 2nd Floor, Kailash, 26 - Kasturba Gandhi Marg, New Delhi - 110 001.
This standard in no way supercedes the statutory requirements of bodies like DGMS, CCE or any other Government Body which must be followed as applicable.
COMMITTEE FOR
STANDARD ON
"DERRICK FLOOR OPERATION"
(ONSHORE DRILLING / WORKOVER RIGS)
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NAME DESIGNATION & POSITION IN
ORGANISATION COMMITTEE
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S/SHRI
1. D.BORKAKOTY OIL, LEADER DULIAJAN
2. RAM SHANKER ONGC, IDT MEMBER
DEHRADUN
3. R.G.GOEL ONGC, P&E MEMBER
DEHRADUN
4. P.K. JAIN ONGC, MEMBER
MUMBAI
5. KULBIR SINGH ONGC MEMBER
AHMEDABAD
6. a P.K. GARG OISD CO-ORDINATOR
b JAYANT AHUJA OISD
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CONTENTS
SECTION DESCRIPTION PAGE NO.
1. INTRODUCTION 5
2. SCOPE 5
3. TOOLS AND ACCESSORIES FOR OPERATIONS 5
4. PRE- SPUD / WORK OVER CONFERENCE 6
5. GENERAL SAFETY PRECAUTION ON RIGS 6
6. SAFETY PRECAUTONS IN DRILLING OPERATIONS 11
7. SAFETY PRCAUTIONS DURING 14
PRODUCTION TESTING
8. SAFETY PRECAUTIONS DURING 17
WORKOVER OPERATIONS
19
19
9. INSPECTION AND MAINTENANCE SCHEDULE 18
19
10. GLOSSARY 25
11. REERENCES 26
12. ANNEXURES 27
19
1.0 INTRODUCTION
Operational safety is the foremost concern while working on Drilling / work-over rig. Derrick floor is the center stage of all the operations and it is most susceptible to accidents. Safety precaution with utmost care is required to be taken as per the prevailing regulation and practice so that accidents can be avoided. Due to advancement in technology, number of equipment have been developed over a period to cater the need of smooth operation on derrick floor. Various standards are required to be referred to cover the variety of equipment used for safe operation in oil industry and became cumbersome at times to refer for each equipment. Under these circumstances, it was felt necessary to have one safety standard which would cover various safety aspects related to Derrick floor operations.
2.0 SCOPE
This standard has been prepared keeping in view to cover various operations. Pre spud / work-over conference is required to be conducted before taking up drilling/ work-over operation for all the rigs. The various points to be checked during Pre spud / Workover conference have been compiled as a checklist for the convenience of field personnel .
This standard covers recommended Inspection schedule of various equipment used on a derrick floor at the drilling / work-over rigs specifying frequency of inspection under various categories. Safe practices and precautions required to be observed for various operations have been dealt in this standard.
3.0 EQUIPMENT TOOLS / ACCESSORIES FOR OPERATIONS AT DERRICK FLOOR ON DRILLING / WORKOVER RIG
3.1 Well Control System
1. Remote Control Panel for BOP
2. Trip Tank
3. Upper and lower Kelly cock
4. Inside BOP
5. Mud check valve
6. Remote control panel for choke(In case of wellhead pressure rating of 10,000 psi and above)
3.2 Handling Tools
1. Rotary tongs along with counter weights & tong pull back
2. Drill pipe spinner
3. Kelly spinner
4. Air winch
5. Racking board air winch
6. Safety clamps for drill-collar
7. Waterline/Hose for cleaning Derrick Floor
8. Racking finger of monkey board
9. Kelly saver sub
10. Bit breaker
11. Bail type lifting plug for Bits and Tubular
12. Clamp on type casing thread protector
13. Drill pipe wiper
14. Elevator balancing strap
15. Casing line spooler ( Guide)
16. Mud fill up hose for casing
17. Drill pipe protectors
18. Safety clamp with chain for Rotary hose
19. Pup joints for handling slick drill-collars
20. Various sizes of substitutes
21. Elevators & Slips for all sizes of drill pipes , drill collars and casing pipes
22. Rotary hose
23. Rat hole digging device / Down hole motor
24. Ezy Torque
3.3 Safety System
1. Twin stop safety device (Crown-o-matic and Floor-o-matic)
2. Fall prevention device on mast ladder with safety belt
3. Emergency Escape Device for Top-man
4. First aid Box with Stretcher and Blanket
5. Fire bell / Siren
6. Emergency vehicle
7. Fire extinguishers
8. Flame proof portable hand lamp / Safety torch
9. Railing with toe board
10. Guards on all moving parts
11. Breathing apparatus (wherever required)
12. Gas detector for hydrocarbon gas & H2S gas ( If required)
13. Safety lines for Power Tongs
14. Rotary brake
15. Hoisting Brake lever with safety chain
16. Emergency shutoff system for Draw works
17. Safety chain for Inclined ramp( To prevent fall of any person)
18. Safety belt for Top-man with lane yard
19. Railing on stair case at mud tank/walkways and derrick floor
3.4 Accessories
1. Drill pipe raft/platform
2. Communication system between Top-man and driller
3. Wind direction indicator
4. Rain protection for driller
5. Bug blower
6. Mud bucket
7. Cellar pit cleaning pump
8. Pilot light on top of mast
9. Bit rack
3.5 Instrumentation on Driller’s Console
1. Weight indicator
2. Pressure gauge on Driller’s panel and on stand pipe
3. SPM gauges for mud pumps
4. RPM gauge for rotary table
5. Rotary torque meter
6. Tong line pull/gauge
7. Air pressure gauge
8. Trip tank volume indicator
9. Mud flow fill indicator
10. Mud volume totaliser for active and reserve tanks
11. Emergency stop switch for draw works
12 Mud pump-operating switches
13. Record-o-graph to record WOB, SPM for two pumps, RPM, Rotary torque, Pump pressure and ROP.
14. Well Deviation measuring tool
15. Emergency stop switch for Engines ( For Mobile and Work-over Rigs)
4.0 PRE-SPUD CONFERENCE
Pre-spud conference should be held before spudding with the participation of Rig In-charge, Mechanical Engineer, Electrical Engineer, Chemist, Civil Engineer, Rig building In-charge and Safety Officer at well site and they should confirm the compliance of safety norms as per checklist placed as a Annexure I
The observation of the audit teams and earlier recommendation (If any) must be rectified before spuding in.
4.1 Pre-Work Over Conference
Pre work over conference should be held prior to commencement of operation with the participation of Rig in-charge, Mechanical Engineer, Electrical Engineer, Chemist, Civil Engineer, and Safety Officer at well site and they should audit the compliance of safety norms as per checklist placed as Annexure II
The observation of the audit teams and earlier recommendation (If any) must be rectified before commencement of operation.
5.0 GENERAL SAFE PRACTICES ON RIGS
5.1 General Safety Awareness
i. Availability and display of instruction for the use and maintenance of personal protective equipment.
ii. General safety education should be imparted through periodical safety meetings, company publications and other educational media like video etc. ( If possible)
iii. Unsafe and potentially dangerous conditions should be rectified and reported immediately to the in-charge for further suitable action.
iv. The off-going shift in-charge shall inform the oncoming in-charge for any known special hazards on ongoing work that may effect safety of the crew and rig. Accordingly brief note should also be recorded.
v. Hazardous substances shall be stored at proper place, in proper containers and properly labeled.
vi. Employees required to handle or use hazardous substances shall be instructed regarding their safe handling and use and are made aware of the potential hazards and personnel protection required.
vii. Smoking and naked light shall be prohibited at or in the vicinity of operations that constitute a fire hazard. No person shall smoke or carry naked light within 30-m radius of a well. In cluster locations prohibition should be enforced for all operations. Locations should be conspicuously posted with a sign, “NO SMOKING OR NAKED LIGHT” or equivalent.
viii. A provision for smoking is kept at a safe distance.
ix. Field welding shall not be permitted on tongs; elevators, bails or heat-treated rig equipment.
x. At least one trained person should always be present on derrick floor even during shutdown period to observe the well particularly when BOP is not closed.
xi. Pipe threads should be cleaned with a wire brush.
xii. Hand gloves should always be used for working on Rig floor, while handling of wire ropes and tubular.
5.2 House Keeping
i. Work places and stairs with handrails should be maintained reasonably clean and free of debris, mud, oil or stumbling hazards.
ii. Scrap, waste and rubbish shall not be allowed to accumulate in work places of access or egress.
iii. Hazardous leaks should be immediately stopped or spills should be promptly cleaned up to eliminate personnel slipping and fire hazard.
iv. If employees are required to work in a cellar pit, it should be kept reasonably clean of water, oil or drilling fluid accumulation.
v. Loose materials that are not required for use should not be placed or left so as to dangerously obstruct work places and passage way.
vi. All projecting sharp edges and railing ends shall be properly bend over to prevent possible injury.
vii. When placing equipment and tools on or around the rig floor and location, care should be taken to leave egress routes open. Tools and equipment should be securely placed and stored in a manner so that they may not fall.
5.3 Wearing Apparel
i. Each person in the work area should wear a safety helmet.
ii. Safety shoes / gum-boots should always be worn by employees normally assigned to the work area.
iii. Employees should wear protective gloves, protective apron, or other protective equipment, as appropriate.
iv. Eyeglass, face shield or other appropriate eye protection equipment should be worn by employees engaged in any work in which there is a reasonable probability of injury to the eyes from flying objects, chemical, or injurious light or heat, rays that can be prevented by such equipment.
v. Loose or poorly fitted clothing should not be worn.
vi. Employees should not wear jewelry or other ornament causing injury while in the work area.
vii. Employees with hair of such length as to be a hazard in work areas should keep it contained in a suitable manner while performing their duties.
viii. Person entering high noise areas should wear hearing protection equipment.
5.4 Drilling Programme / Work Over Plan
Geo-technical order / drilling program indicating comprehensive drilling policy, casing policy, formations to be encountered, expected bottom hole pressure, temperature mud weight to be used and any hole problem expected to be encountered with reference to neighboring wells should be made available at well site. All the shift in-charge shall be aware of the content of such drilling / work-over plan. Similarly Work-over plan indicating details of operation to be carried out and well history be made available at site.
5.5 Derrick Floor
i) Derrick floor chequered plates should be placed firmly and in such a way that there should be no gap between them.
ii) Any opening like mouse hole etc. in chequered plate should always be protected to avoid injury to person. Plain and slippery chequered plate should be replaced immediately.
iii) Grease, dirt or mud spillage on the derrick floor be cleaned with water jet or surfactant during and after any operation on the floor.
iv) Grease, dirt, mud also be cleaned from the steps of stairways/ladder to avoid slipping.
v) Used cotton waste and all other dirty substance be stored in the dustbin.
vi) Stands of tubular racked in the derrick or mast should be rested on wooden raft and properly secured to prevent them from falling.
vii) Proper stopper arrangement like steel chain shall also be provided at the end of the ‘Vee’ to avoid accidentally slipping of persons.
viii) Guardrails of minimum 3 ft. height should be installed on all platforms / walkways which are more than 4 ft. above the ground level. Toe board of 6” shall be provided in addition to handrail on operation of floors / platforms / walkways.
ix) A minimum of two (2) stair ways with hand rails shall be installed on drilling rigs to provide alternate exits from the rig floor to ground level when rig floor height is six (6) feet or more.
x) Drill-pipe kept for connection at inclined catwalk should be properly secured to avoid slipping of the same.