HSE IN DRILLING OPERATIONS

Introduction

Items being lifted or mechanically handled have the potential to cause serious injury. This has been seen in the last few years where a number of fatalities and serious accidents have occurred during lifting and mechanical handling operations. As a result of this, there is a strong desire within the oil and gas industry to improve the safety performance of such operationsThroughout all phases of any drilling or workover operation the RIG OPERATOR will be held accountable for the prevention of accidental losses, the protection of COMPANY interests and resources, and the avoidance of any contamination of the environment.It is the responsibility of both the owner of such equipment and the operator to constantly take a proactive approach to ensuring that unsafe conditions do not exist. It is the responsibility of owners and operators to immediately correct all hazards when brought to their attention. It is the responsibility of owners and operators to ensure that drilling equipment be used for the purpose for which it is intended, and that tolerances and limitations of the equipment not be exceeded. It is the responsibility of owners and operators of drilling equipment to stay in strict compliance with all local, state and federal regulations, governing any and all aspects of drilling operations or any related activities. This also applies to regulations set forth in any country where working owners and operators also carry the responsibility to properly train employees in safe operating procedures, and to make sure that such procedures are strictly enforced.

Supervisor’s Responsibility

Drilling Supervisors are responsible for insuring that day-to-day safety is maintained at all times during the drilling operation. The supervisor, foreman or driller must have first-hand knowledge of the entire drilling process. Likewise, he or she must be aware of and ensure that drilling equipment be used properly and that tolerances and limitations not be exceeded.

The bottom line is, that safety is everyone’s responsibility! No job is so important nor is any task so difficult that it cannot or should not be performed safely!

Take time to set the rig up properly!

Prior to lowering the offshore rig leveling jacks, It recommend that a timber or plank be placed beneath the jack. By performing this function, it will be less likely that the jacks will “sink into the ground." Even on asphalt, jacks could possibly, over time, sink down to the point that the rig might not remain level.Insure that the rig is level and everything is secured PRIOR to raising the mast. NEVER, under any circumstance, move the rig while the mast is raised! Also, make sure that

nothing is loose on the mast that would fall when the mast is raised to its upright position. Once the mast is raised, take measures to secure it properly.

Organize the work area PRIOR to commencing drilling operations.

Many times it is tempting to commence drilling before everything is unloaded and organized. This practice should be avoided. Drilling will progress more smoothly and accidents will be less likely if the driller takes the time to properly set up and organize first.

Perform a “pre-shift” safety inspection prior to commencing operations.

As described earlier, it is essential that a complete inspection be performed prior to commencing the actual drilling process. Be sure to check all shut-down devices at this time. Take great care to insure that the “infra-red” system is in proper alignment, clean and working properly. Work should never commence if any of these, or other safety features are inoperative!

Never disable or bypass any shut down device! Never operate the Rotary Table unless all guards are in Place and properly secured!

Constantly observe safe work practices during the drilling operation.

As the owner or operator, it is your responsibility to make sure that all workers are experienced and properly trained. Initially, new employees should be constantly observed to be sure that they are performing their tasks safely.During the drilling process some of the safe practices that should be observed and corrected if found to be deficient are:

Ensure that workers are wearing snug-fit clothing. Ensure that all workers are wearing personal protective equipment. Ensure that workers are never positioning themselves in a situation where they may

contact rotating or moving parts. If using a cathead in the operation, ensure that the driller is completely familiar with

its operation. Inspect the cathead to be sure that it is clean and free of burrs etc. Inspect the rope to be sure that it is in good condition. Finally, the operator must know the proper and safe technique for operating the cathead. Among the many safety requirements for operating a cathead is that the operator must make sure that he or she stands a safe distance from the cathead drum, and great care must be taken to ensure that the operator does not become entangled in the rope.

Ensure that the driller and helper are communicating with each other. This is a “critical” part of our business. Drillers often prefer to work with the same helper

from job to job because they have “learned how to communicate” with him or her. Many accidents are caused when the driller and helper fail to properly communicate their actions and movements to the other person. This concept should be taken very seriously and the owner/operator of the equipment must support and encourage effective communication between employees.

Make sure that the equipment is completely shut down prior to fueling, servicing, repairing or performing any other maintenance task on the drilling equipment.

Mechanical Handling Operations and Crane Operations

Mechanical Handling Operations are those activities which involve the movement of a load using work equipment. This work equipment can be that which is either manually operated or power operated. When a Mechanical Handling Operation requires a load to be raised or lowered then the required work equipment becomes lifting equipment and the activity can be considered to be a lifting operation. Examples of mechanical handling equipment which is not lifting equipment would be a wheeled trolley used to move a load or a tirfor used to pull a load on level ground. However if such equipment is used to move a load up or down an incline then this would become a lifting operation.

The Competent Person for Planning Lifting Operations

The Competent Person is someone who has the required level of competency to be able to produce written plans for the undertaking of lifting operations and be able to check and authorize plans that have been written by others. He must have the practical skills and theoretical knowledge to plan lifting operations, undertake risk assessments and conduct toolbox talks. The Competent Person may or may not supervise the lifting operation but he is the focal point for all the technical aspects associated with lifting operations and lifting equipment. He must know his own competency limitations and know when additional technical support is required and from where this can be obtained.

Selection of Lifting Equipment

The Competent Person will have identified the appropriate lifting equipment and accessories required. It is essential that the equipment being used is certified, fit-for-purpose and visually checked for any defects etc before being used. The Competent Person must take into consideration:

The technical specification and integrity of equipment The place where it will be used The conditions under which it will be used The purpose for which it will be used Inherent risks to health and safety as a result of its use Ergonomic risks Manual handling.

Lifting Slinging Requirements for Rig Site Operations

A. Inspect sling (chain, cable and attachments) before use, as indicated by the manufacturer. In addition, look for evidence of link stretching and the appearance of cracks on lifting chain. Chain and cable slings including hardware must be tagged by the manufacturer with the proof-tested maximum weight capacity. B. Thorough inspections of alloy steel chain slings should be done at least once a year. Check for wear, defective welds, deformation and increase in length. Items to check the chain and attachments for are:

Hook throat opening greater than 15%. Hook tip bent or twisted greater than 10%. Hook eye bent or twisted. Cracked hook body. Shackles with chemical, corrosion, or heat (welding on or in a fire) damage. Shackles deformed or incorrect pin. Cracked or deformed master link. Chain link wear, bent, gouged or stretching exceeding the manufacturers

specifications. Chain (links) that may have been heated to 1000 degrees F should be immediately

removed from service. C. Cable slings should be thoroughly inspected on a regular basis, at a minimum of every six months. A record of inspection should be maintained. Items that should be checked for:

Two or more broken wires at the socket end of the cable. Ten or more broken wires in one length of lay or five or more broken wires in one

strand in one length of lay. Cable found with kinking, crushing, un-stranding, bird caging, main strand

displacement, core protrusion or any other distortion of wire rope structure should be removed from service immediately.

Cable with evidence of heat damage as indicated by blue or brown in an area, weld slag on five or more clustered wires should be removed from service.

Cable with abrasive reduction of one-third of the original diameter of outside individual wires should be removed from service.

Hook throat opening greater than 15%. Hook tip bent or twisted greater than 10%. Hook eye bent or twisted. Cracked hook body. Cracked or deformed master link. Shackles with chemical, corrosion, or heat(welding on or in a fire) damage. Shackles deformed or incorrect pin.

D. Maintain a record of the most recent month in which each sling was thoroughly inspected. E. Alloy chain or cable slings should be used when making overhead lifts. One exception may be for attaching to catlines. The manufacturer should tag such chain, cable, and hardware with permanently affixed durable identification tag with applicable. F. Use only alloy chain and attachments for making repairs to alloy chain slings.

G. Ensure that hooks, rings, oblong links, pear shaped links, welded or mechanical coupling links or other attachments have a rated capacity at least equal to that of the alloy chain with which they are used. H. Chain sling capacity must be reduced to that of the weakest component(s) in the chainI. Never exceed the safe working limit of lifting chain, cable or attachments. J. Lift and lower loads slowly and smoothly. Avoid shock loading. K. Know the center of gravity and angle of the lift. L. Twisting, knotting and kinking decreases the safe working load limits. Free all twists, knots and kinks before using. M. Do not point-load hooks. The load should rest on the bowl of the hook. N. Protect chain with padding when lifting sharp edged loads. O. Use transport chains as safety chains on vehicles being towed and as tie-down chains.

Lifting Operations By Drilling Equipments

The following factors should be considered while Drilling Operations and these precautions could be taken to avoid any accidents during lifting operations by Rig Components

Drill Pipe / Collar Slips and Elevators

A. Rig supervisors should instruct personnel in the proper use and maintenance of slips and elevators on the rig. B. Slips and elevators should not be modified or welded on. C. Keys, pins, dies, handles and bodies on all pipe and collar slips should be checked frequently for wear or damage. D. Rig personnel should keep their hands and feet, as well as chains, ropes, etc., away from slip handles when rotary or top drive is in motion. E. Slips should be properly positioned out of the way when not in use. F. Slip handles should be used to raise and lower slips. Handles should be grasped with palm up. Slips should NOT be kicked into the rotary bushing. G. Using proper lifting techniques, at least two employees should pull slips. H. Latches, latch springs, hinge pins and elevator shoulders should be inspected periodically and maintained as necessary. These areas should be checked for cracks and deformities. I. Riding the elevators as a means of personnel transport should be prohibited. J. The elevator ear locks should be fitted with proper size steel bolts as recommended by the manufacturer. Bolts should be checked often to ensure tightness. K. The elevators or bales should not be grasped in the area of the link eyes. L. Only the elevator horns or rear handle or the elevator links (bails) at approximately 18” up on the elevator links (bails), should be used to control the elevator. M. The load bearing areas of elevators and links (bails) should be inspected for wear as per company policies and procedures developed in consideration of the manufacturer’s recommendations.

Hoists (Winches / Tuggers)

A. Rig supervisors should ensure that personnel are trained in the proper use and maintenance of hoisting devices. B. Only those personnel, who through experience and training, are determined by the rig supervisor to be competent should be allowed to operate the rig floor hoist(s). C. All hoists should be equipped with a drum guard and line guide. D. The hoist operator should check the hoist mechanism, brake, drum guard, and line guard to ensure proper working order prior to each lift. E. All hoisting lines should be inspected periodically. (See 3.5 C for inspection of lines.) F. The hoisting line should not be in contact with any derrick member. G. Loads lifted by the hoist and wire rope should not exceed the manufacturer’s recommendation. The rated load capacity of the hoist should be posted on or near the hoist. H. Rig personnel should stand clear of suspended loads. I. The hoist operator should set the drum brake anytime a load is in suspension. The operator should not leave the hoist unattended. J. The hoist-operating lever should return to the neutral locked position when the operator releases it. K. The hoist should not be used to lift personnel until the procedures laid out in Section 19 are carried out. L. The hoist should be equipped with an emergency shut-off valve within easy reach of the operator.M. The hoist operator should raise the load at a slow, steady rate and stay alert to the situation and flagman at all times. N. Continuous communications should be maintained either through direct sight, through a flagman or via two-way radio. Should communications fail, the operation should be stopped immediately and not resumed until communications has been re-established.

Drilling Line, Crown Block and Traveling Block A. Rig supervisors should ensure that personnel are instructed in the proper use and maintenance of drilling line crown block and traveling block. Derrickmen should never touch the active line while traveling blocks are moving. B. Drilling lines should be visually inspected daily for wear and breaks. C. The drilling line should not be allowed to rub against other objects that may cause damage. D. Drilling line is stiff and can flip when being cut. Employees should use caution when handling the drill line. E. The deadline anchor bolts should be checked periodically to ensure that they are properly torqued. In addition, all the drilling line retainer bolts should be in good condition and in place through the anchor drum. F. All excess drilling line should be spooled up off the ground or deck. G. Crown sheaves and traveling block should be inspected and lubricated each day. H. The crown block and traveling block sheave grooves should be checked periodically for proper gauge. I. A slip-and cut-program should be followed. Calculate the ton-miles and follow the slip-andcut program as recommended by the drilling line manufacturer.

J. The line guide cable and rollers should be inspected each tour to determine their condition.

Tips to improve safety of rigging, lifting operations

The planning of a lifting operation must always be completed to ensure that all the hazards and risks have been identified and the relevant safe systems of work employed. T he level of planning should reflect the complexity of the task. The lifting operation must also be appropriately supervised and carried out in a safe manner.

Personnel should have the adequate practical and theoretical knowledge and experience to plan the lifting operation. They should identify the resources required, the procedures to be followed, stipulate personnel responsibilities and include safety precautions

Competence can only be achieved and recorded through training, experience and assessment . Lifting operations must only be carried out by competent personnel. It is essential that a competent person engaged in this work must be aware of current regulations, best industry practices and their own company procedures or safe systems of work.

Operators using man-riding winches must be adequately trained and aware of the safe systems of work and procedures needed . W inches must be fitted with independent brakes on the hoist winch drum, overload / over-hoist protection systems, an increased factor of safety and a means to lower personnel safely, in case of power failure

When slinging tubulars, each lift must be lifted level and slung using 2 slings of the same length and the same safe working load. The safe working load of each sling shall be equal to or greater than the gross weight of the load. Slings should be double-wrapped and choke approximately 25% in from the ends of the load with a maximum angle, of the 2 slings, no greater than 45° from the horizontal. When applying the double wrap and choke, personnel must never push down the bite of the choke and be aware not to cross the slings on the underside of the bundle.When personnel are required to fit taglines, they must always do so in accordance with company procedures. A tagline is a soft line used to aid in the control of the load. When used correctly, they enable personnel to safely position themselves away from the load. However, they do have a tendency to draw personnel underneath the load, when the tagline is first used. Many accidents are caused when the tagline is attached to the lifting equipment. It is unfortunately human nature for the handler to attach the tagline to sling, instead of applying that little bit of extra effort required to attach it correctly to the load.

Lifting and handling incidents

The following accidents/incidents take place at Total E&P from May 2009 until April 2010, 35 lifting and handling incidents with potential severity ranging from 4 to 5 have been recorded in the Synergi data base (the cases related to the direct use of specific drilling equipments such as elevators, hoists, tongs, TDS, etc… are excluded from this figure).

Crane Failure A rig crane boom fell down due to the failure of the main gear. Due to lack of inspection & maintenance.

Lifting of Drill Pipe During the lifting of a 5” drill pipe bundle from the rig deck, the tag line made a loop around roustabout right ankle; the roustabout hung up, his back and head hitting the tubing rack (restricted workdaycase).

Load Fall On To The Deck Whilst moving a bundle of completion screens, the rupture of a nylon sling caused the load to fall onto the deck.