Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations API RECOMMENDED PRACTICE 54 THIRD EDITION, AUGUST 1999 REAFFIRMED, JANUARY 2013 Recommended Practice[.]
Purpose
This document aims to recommend effective practices and procedures to ensure safe working conditions for personnel involved in drilling and well servicing operations, including specialized services.
Scope
These guidelines are relevant for rotary drilling rigs, well servicing rigs, and specialized services during on-location operations However, they do not pertain to seismic drilling or water well drilling activities, nor do they apply to site preparation and abandonment processes.
Responsibility
These recommendations acknowledge the distinct responsibilities of owners, operators, contractors, and their personnel, which may be defined by contracts Employers must ensure that their personnel receive adequate training and instruction for safe work performance The intent is not to modify existing contractual relationships Well owners or operators should provide relevant information that contractors need to maintain safe operations It is essential that all work activities are supervised by an authorized individual who can initiate, adjust, or halt operations to safeguard personnel This authorized person should continuously monitor conditions and enhance work methods to ensure maximum protection for all involved.
The most recent editions of the following documents are referenced in this publication.
RP 2D Operation and Maintenance of Offshore Cranes
RP 4A Steel Derricks (Including Standard Rigs) [out of print]*
RP 4D Guyed Portable Masts [out of print]*
RP 4E Drilling and Well Servicing Structures [out of print]*
Spec 4F Drilling and Well Servicing Structures
RP 4G Maintenance and Use of Drilling and Well
Spec 6A Wellhead and Christmas Tree Equipment
Spec 8A Drilling and Production Hoisting Equipment
RP 8B Inspection, Maintenance, Repair, and Reman- ufacture of Hoisting Equipment
Spec 8C Drilling and Production Hoisting Equipment
RP 9B Application, Care, and Use of Wire Rope for
RP 14F Design and Installation of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class 1, Divi- sion 1 and Division 2 Locations
RP 49 Safe Drilling of Wells Containing Hydrogen
RP 53 Blowout Prevention Equipment Systems for
RP 55 Conducting Oil and Gas Producing and Gas
Processing Plant Operations Involving Hydro- gen Sulfide
RP 68 Well Servicing and Workover Operations
RP 500 Recommended Practice for Classification of
Locations for Electrical Installations at Petro- leum Facilities Classified as Class 1, Division
RP 505 Recommended Practice for Classification of
Locations for Electrical Installations at Petro- leum Facilities Classified as Class 1, Zone 0, Zone 1 and Zone 2
API 510 Pressure Vessel Inspection Code: Maintenance
Inspection, Rating, Repair and Alteration
RP 2003 Protection Against Ignitions Arising Out of
Static, Lightning, and Stray Currents
Std 2015 Safe Entry and Cleaning of Petroleum Storage
Publ 2201 Procedures for Welding or Hot Tapping on
Threshold Limit Values and Biological Indices for 1997–1998
Industrial Ventilation, A Manual of Recom- mended Practice, 22nd Edition
B15.1 Safety Standard for Mechanical Power Trans- mission Apparatus
1American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Suite 600, Cincinnati, Ohio 45240-1634.
2American National Standards Institute, 11 West 42nd Street, New York, New York 10036.
S1.13-1995 Measurement of Sound Pressure Levels in
S12.6-1997Methods for Measuring the Real-Ear Attenua- tion of Hearing Protectors
S12.19-1996Measurement of Occupational Noise Exposure
S12.36 Survey Methods for the Determination of
Sound Power Levels of Noise Sources
Z87.1 Standard Practice for Occupational and Edu- cational Eye and Face Protection
Z87.2 Safety Requirements for Industrial Protective
Helmets for Electrical Workers, Class B
Z89.1 Safety Requirements for Industrial Head
Z117.1-1995Safety Requirements for Confined Space
Z358.1 Emergency Eyewash and Shower Equipment
Z359.1 Safety Requirements for Personal Fall Arrest
ASME Boiler and Pressure Vessel Code, Sections VIII and
Recommended Practice No ASNT-TC-1A
C-7 Guide to the Preparation of Precautionary
Labeling and Marking of Compressed Gas
Safety Publ No 20Safety Guide for the Prevention of
Radio Frequency Radiation Hazards in the
Use of Commercial Electrical Detonators
Recommended Practice for Radio Silence
When Conducting Wireline Services Involving the Use of Explosives
NACE 9 Std MR0175Requirements for Sulfide Stress Cracking
Resistant Metallic Material for Oil Field Equipment
NFPA 10 NFPA 9 Portable Fire Extinguishers
NFPA 30 Flammable and Combustible Liquids Code
*Out-of-print publications are available from:
15 Inverness Way East, Englewood, Colorado 80150 Telephone (800) 854-7179
General Definitions
This publication offers definitions to clarify specific terms used within the text It is important for users to understand that these terms may have different meanings or applications in other contexts beyond what is described here.
Acidizing involves injecting an acidic solution into a wellbore to eliminate materials from perforations, pipes, and the walls of the producing formation This process also enhances permeability by treating formations with the solution.
Adequate ventilation is essential for preventing fire and explosions, as it ensures that vapor-air mixtures do not accumulate in concentrations exceeding 10% of their lower explosive limit (LEL) This can be achieved through either natural or artificial ventilation methods.
3.1.3 annular space: Space surrounding pipe in the wellbore The outer wall of the annular space may be open hole or pipe.
3.1.4 ANSI: American National Standards Institute. 3.1.5 API: American Petroleum Institute.
3.1.6 approved: Sanctioned, endorsed, accredited, certi- fied, or accepted by a duly constituted and recognized author- ity or agency
3.1.7 ASTM: American Society for Testing and Materials.
3Illuminating Engineering Society of North America, 120 Wall
Street, New York, New York 10005-4001.
4ASME International, 3 Park Avenue, New York, New York 10016-
5American Society of Nondestructive Testing, 1711 Arlington Lane,
6Compressed Gas Association, 1725 Jefferson Davis Highway, Suite
7Institute of Makers of Explosives, 1120 19th Street, NW, Washing- ton, D.C 20036.
8Institute of Petroleum, 61 New Cavendish Street, London W1M
9NACE International, 1440 South Creek Drive, P.O Box 218340, Houston, Texas 77218-8340.
10National Fire Protection Association, 1 Batterymarch Park, P.O Box 9101, Quincy, Massachusetts 02269-9101.
3.1.8 authorized person: A person assigned by an employer to perform or supervise the performance of a spe- cific type of duty or duties at the work site.
Backup in drilling operations involves preventing the rotation of one section of pipe or rods while another is being screwed in or out This term also applies to the process of screwing nuts on or off bolts A backup wrench is any tool used to secure the pipe, rods, or bolts, while backup tongs are specialized tongs suspended in the derrick to hold a section of pipe during the screwing process The crew member responsible for operating the backup tongs is known as the backup man, and the area where this individual works is referred to as the backup position.
3.1.10 blocks, crown, and traveling: The fixed upper and movable lower blocks, respectively, of the block and tackle assembly on a rig that raises and lowers the drill string or tubing.
3.1.11 blowout: An uncontrolled flow of well fluids and/ or formation fluids from the wellbore or into lower pressured subsurface zones (underground blowout).
A blowout preventer (BOP) is a crucial device connected to the wellhead or Christmas tree, enabling the well to be securely closed, whether or not a string of pipe or wireline is present in the borehole.
The blowout preventer remote control system consists of a set of tools designed to operate the blowout preventer from a remote location, typically from the rig floor or accumulator.
3.1.14 breaking out pipe: Operation of unscrewing a pipe section.
A 3.1.15 bypass is a pipe connection that allows fluid to flow around a valve or control mechanism This setup is essential for enabling the passage of fluid through the bypass line while maintenance or adjustments are performed on the bypassed control.
Casing is a crucial component in wellbore construction, typically cemented in place to maintain borehole dimensions and isolate hydrocarbon and water-bearing formations Surface casing is the initial pipe string installed to seal off surface sands, support blowout prevention equipment, and protect fresh water sources, extending below the fresh water zones Protective (intermediate) casing is used in deeper wells to balance drilling fluid under high pressure conditions, while production casing runs from the wellhead to the producing formation, sealing off productive zones A liner, which is a partial length pipe string, can also seal off producing zones and may or may not be cemented in place Lastly, tubing is installed within the casing strings, allowing for the flow of produced or injected fluids from the wellhead to the designated formation depth.
The catline is a line operated by the cathead, a concave, rotating pulley device located at the end of the cat shaft on the drawworks This system is essential for lifting or maneuvering equipment on a rig.
3.1.18 catwalk: Elongated platform adjacent to the rig floor where pipe is laid out and lifted into the derrick The catwalk is connected to the rig floor by a pipe ramp.
3.1.19 cellar: Excavation around the wellhead to provide space for items of equipment at the top of the wellbore.
Cementing involves creating a slurry of cement and pumping it into a wellbore to support casing, isolate formations behind the casing, protect fresh water sands, and seal perforations in the casing.
3.1.21 Christmas tree: The valves and fittings assem- bled at the top of a completed well to control the flow of hydrocarbons and other fluids.
3.1.22 circulate: Cycling fluid from the surface through the pipe and back to the surface through the annular space.
3.1.23 combustible liquid: Any liquid having a flash- point at or above 100°F (37.8°C).
The 3.1.24 conductor pipe is a large diameter pipe designed to maintain the integrity of the wellbore by keeping the top of the hole open It facilitates the return of upflowing drilling fluid to the surface drilling fluid system until the initial casing string is installed Additionally, the conductor pipe plays a role in well control and is typically cemented in place.
3.1.25 contractor: Any person or company that con- tracts to perform all or any part of oil and gas well drilling or servicing.
3.1.26 critical equipment: Equipment and other sys- tems determined to be essential in preventing the occurrence of, or mitigating the consequences of an uncontrolled event
Such equipment may include vessels, machinery, piping, blowout preventers, wellheads and related valving, flares, alarms, interlocks, fire protection equipment, and other moni- toring, control, and response systems.
The term "deadline" refers to the end of the drilling line that remains anchored, typically to the derrick substructure, and does not move when the traveling block is hoisted This fixed end of the drilling line is not reeled onto the rig's hoisting drum, marking the point where the drilling operation is controlled.
A derrick, also known as a mast, is a crucial steel component of drilling or well servicing rigs, designed to support the crown block, traveling block, and hoisting lines These structures can either be stationary, necessitating dismantling for relocation, or portable, allowing them to be laid down and raised fully assembled from ground level.
3.1.29 derrickman: Person whose work station is usually up in the derrick while pipe or rods are being hoisted or low- ered into the hole.
The driller serves as the first line supervisor, primarily responsible for overseeing crew activities and training members to effectively execute their assigned tasks.
The driller is responsible for operation of the drilling and hoisting equipment This person is also referred to as the
“crew chief” or “rig operator” in well servicing operations.
3.1.31 drilling (hoisting) line: The wire rope used in the rig’s main hoisting system.
3.1.32 drilling out: Refers to drilling and removal of material that normally remains in the casing or wellbore after cementing.
3.1.33 drilling rig: Equipment and machinery assembled primarily for the purpose of drilling or boring a hole in the ground.
3.1.34 drill pipe: The heavy seamless tubing used to rotate the drill bit and circulate the drilling fluid Usually in
30-ft lengths, the joints of drill pipe are coupled together with special threaded connections called tool joints.
The drill stem, which encompasses the complete drilling assembly from the swivel to the bit, includes components such as the kelly, drill string (work string), subs, drill collars, and various downhole tools like stabilizers and reamers This essential assembly is responsible for rotating the bit and transporting drilling fluid to the bit.
3.1.36 drill stem test: A test taken by means of special testing equipment run into the wellbore on the drill string
(work string) to determine the producing characteristics of a formation.
General
4.1.1 Every occupational injury or illness shall be immedi- ately reported to the supervisor The supervisor shall arrange for any necessary medical or first aid treatment.
4.1.2 A report should be prepared as soon as practical, to record information (or the circumstances) surrounding the injury or illness Additional reports to regulatory agencies and others may be required.
4.1.3 The cause of the injury or illness should be investi- gated and steps taken to prevent a recurrence.
Medical Services
4.2.1 Telephone numbers, location, and other relative information pertaining to availability of medical personnel, transportation, and medical facilities shall be available at all drilling and well servicing sites.
4.2.2 Prior to commencement of work in an area, provi- sions should be made for prompt medical attention in case of serious injury.
First Aid
A trained individual in first aid and cardiopulmonary resuscitation (CPR) must be present at the worksite to provide assistance This person should have completed approved training courses from recognized organizations such as the American Red Cross, American Heart Association, or equivalent programs.
A first aid kit must be maintained at the worksite, equipped with materials suitable for potential injuries It should be regularly inspected, replenished as needed, and always kept readily accessible.
Emergency Eye or Body Wash Stations
In areas where personnel may be exposed to harmful substances, it is essential to provide emergency eyewash and shower equipment For detailed guidelines on the installation and maintenance of this equipment, refer to ANSI Z358.1 standards.
General
Personnel must don personal protective clothing and utilize personal protective equipment (PPE) at work sites where there is a significant risk of injury, illness, or death that could be mitigated by such gear PPE should be employed only when it is not feasible to lower hazards to acceptable levels through administrative or engineering controls.
Wearing Apparel
All individuals in the work area must wear a safety hard hat that complies with ANSI Z89.1 or ANSI Z89.2 standards, ensuring proper head protection in industrial and electrical environments.
Personnel must wear appropriate eye protection equipment when there is a reasonable risk of eye injury from flying objects, chemicals, or harmful light and heat This protective gear should comply with the ANSI Z87.1 standards for occupational safety.
Educational Eye and Face Protection.
All personnel in the work area must wear safety shoes, safety boots, or toe guards It is essential that safety-toe footwear complies with ANSI Z41.1 standards for men's safety-toe footwear In extremely cold temperatures, alternative practices may be necessary.
5.2.4 Gloves, apron, boots, or other protective equipment, as appropriate, should be worn by personnel handling chemi- cals that may irritate or be absorbed through the skin.
5.2.5 Appropriate clothing should be worn at all times Loose or poorly fitted clothing should not be worn.
Personnel must avoid wearing clothing that is saturated with flammable, hazardous, or irritating substances It is essential to promptly remove such clothing and replace it with appropriate attire after thoroughly washing the affected skin area and providing any necessary treatment.
5.2.7 Personnel should not wear jewelry or other adorn- ments subject to snagging or hanging and causing injury while in the work area.
Personnel with long hair must secure it properly to prevent hazards in the workplace Additionally, hair and beard styles should not obstruct the proper functioning of any required protective equipment, including head, eye, face, or respiratory gear.
Hearing Protection
5.3.1 Protection against the effects of noise exposure shall be provided when the sound levels exceed those shown in
Table 1 For guidance on measuring sound levels, see ANSI
S12.19-1996: Measurement of Occupational Noise Exposure;
ANSI S1.13-1995: Measurement of Sound Pressure Levels in
Air; and ANSI S12.36-R1997 Table 1 For guidance on mea- suring sound levels, see ANSI S12.19-1996.
When personnel are exposed to sound levels above those specified in Table 1, it is essential to implement feasible administrative or engineering controls If these measures do not effectively lower the sound levels to within the limits of Table 1, appropriate personal protective equipment must be provided and utilized For recommendations on hearing protection equipment, refer to ANSI S12.6-1997: Methods for.
Measuring the Real-Ear Attenuation of Hearing Protectors.
5.3.3 Employers should consider the elements of a hearing conservation program as appropriate to protect the hearing of personnel.
Respiratory Protection
5.4.1 An industrial hygiene assessment of the work area should be done to identify the potential hazards that may require respiratory protection.
5.4.2 For respiratory protection practices, including equip- ment selection, use, medical surveillance, fit testing, storage, inspection, maintenance, and training, see ANSI Z88.2-1992,
5.4.3 Tight-fitting air purifying respirators shall be used only in areas where sufficient oxygen exists and where no toxic materials or vapors are present in hazardous concentra- tions.
Approved self-contained or supplied-air breathing equipment must be utilized in environments where tests reveal the presence of toxic or hazardous gases at levels that are immediately dangerous to life or health (IDLH), or where the oxygen content is insufficient to support life It is important to note that air from the rig utility system should not be used as a source for breathing air supply.
Cartridge type respirators are not suitable for use in drilling and well servicing operations where hydrogen sulfide or sulfur dioxide may be present Instead, self-contained or supplied air positive pressure breathing apparatus should be utilized in these situations.
Personnel must receive training on the use and operation of breathing equipment present at the work site They should be informed about the potential dangers associated with flammable, hazardous, and oxygen-deficient atmospheres, as outlined in API RP 49.
For safe drilling of wells containing hydrogen sulfide, it is essential to follow the guidelines outlined in API RP 68, which focuses on well servicing and workover operations involving this hazardous gas Additionally, API RP 55 provides crucial recommendations for conducting oil and gas production and processing plant operations that involve hydrogen sulfides Adhering to these practices ensures the safety and efficiency of operations in environments where hydrogen sulfide is present.
Fall Protection
All personnel working at heights of ten feet or more above the rig floor must be protected from falls using guardrail systems, safety net systems, or personal fall arrest systems (PFAS) If the employer can prove that these systems are unfeasible or pose a greater hazard, an alternative fall protection plan must be developed to ensure personnel safety When utilizing PFAS, it is essential that personnel wear a full body harness that meets ANSI Z359.1 standards, and that PFAS is inspected before each use.
Table 1—Maximum Permissible Noise Exposures a
Duration per day, hours Sound level b dBA slow response
When daily noise exposure includes multiple periods of varying noise levels, it is essential to assess their combined impact rather than evaluating each period individually Additionally, exposure to impulsive or impact noise must not surpass a peak sound pressure level of 140 dB, measured on the A scale of a standard sound level meter with a slow response Furthermore, a full body harness should be secured using a lanyard equipped with double-locking snap-hooks, attached to an anchor or structural member that can support a minimum dead weight.
Each individual requiring a lanyard must use a separate one, which should be adjusted to allow a maximum fall distance of five feet Additionally, it is essential to adhere to the manufacturer's instructions for inspection and replacement.
General
6.1.1 Well control shall be maintained at all times Consid- eration shall be made to ensure appropriate equipment and materials are on location and operational before work com- mences.
6.1.2 The rig drill floor shall be attended by a person quali- fied in well control procedures at all times during operations.
6.1.3 Personnel should be trained in basic well control, as needed, in relation to their job duties.
6.1.4 Horseplay and careless acts shall not be permitted
6.1.5 Personnel should be familiarized with these recom- mended practices as they relate to their function in the job at hand and should abide by the pertinent recommendations.
6.1.6 Personnel should receive instruction in correct work methods to reduce chance of injury to themselves or fellow personnel.
A comprehensive safety program is essential for ensuring the well-being of crew members and equipment during operations and emergencies This program should encompass the responsibilities of the driller or crew chief in maintaining safety, as well as the thorough indoctrination of new personnel, regardless of their prior experience New rig members must receive clear job outlines, demonstrations, and ongoing performance observations until they can safely and effectively fulfill their roles Additionally, crew members should be instructed on work procedures and safe practices, with regular meetings to discuss potential hazards and safety measures Good housekeeping practices must be upheld, and personal protective equipment should be readily available, along with training on its use and maintenance Finally, general safety education should be promoted through safety meetings, company publications, and various educational resources.
6.1.8 Unsafe and potentially dangerous conditions should be eliminated or reported immediately to the supervisor in charge for corrective action
The offgoing tour supervisor must communicate any known special hazards or ongoing work to the incoming supervisor to ensure crew safety Additionally, incoming personnel should be made aware of any work in progress that may impact their safety.
6.1.10 To prevent incidents of finger wounds from sharp pipe threads or wickers, pipe threads should be cleaned with a brush.
Hazardous substances must be stored in suitable containers with proper labeling It is essential to store, label, and dispose of hazardous waste materials appropriately Mixing hazardous waste with nonhazardous waste is prohibited, as it renders the entire mixture hazardous and subject to strict disposal regulations.
Personnel handling hazardous substances must receive training on safe practices and be informed about potential risks and necessary protective measures For further guidance, employees should consult their employer or the substance manufacturer and review the material safety data sheets (MSDSs) It is essential that these MSDSs are accessible to all personnel at the workplace before and during the use of chemicals.
When there are signs that a well may flow, based on historical data, current well conditions, or intended operations, it is essential to install blowout prevention equipment Additionally, crews must perform well control drills to ensure preparedness.
During drilling or well servicing operations, if there are signs that a well may flow, it is essential to have a safety valve (stabbing valve) on the rig floor This valve must have connections compatible with all sizes and types of tool joints or tubing connections used in the operation For further guidance, refer to API RP 53: Recommended Practices for Blowout Prevention Equipment for Drilling Operations.
6.1.14 Field welding shall not be permitted on tongs, ele- vators, bails, or heat treated rig equipment
Vehicles not directly involved in rig operations must be positioned at least 100 feet (30.5 m) away from the wellbore or at a distance equal to the height of the derrick or mast, whichever is greater It is essential to implement appropriate safety measures when terrain or other conditions prevent maintaining this required spacing.
6.1.16 The rig substructure, derrick, mast, and other equip- ment as appropriate, shall be grounded to prevent accumula- tion of a static charge.
Over Water Operations
6.2.1 For over water operations, simultaneous operations shall be conducted according to operator guidelines.
When conducting work over water on a barge, work boat, MODU, or platform, it is essential to instruct personnel on abandonment procedures, emergency signals, designated abandonment stations, and water entry protocols.
6.2.3 A minimum of two emergency escape means from platforms to the water should be provided.
6.2.4 Personnel working over or near water where a danger of drowning exists shall be provided with approved personal flotation devices in serviceable condition.
6.2.5 Ring buoys should be provided and be readily avail- able for use in emergency rescue operations.
Each continuously manned platform must be equipped with a minimum of two approved life floats or their alternatives These life floats should have adequate capacity to safely accommodate all individuals present at any given time.
When conducting operations in cold water areas, it is essential to provide approved cold water survival attire This is crucial when anticipated personnel rescue times suggest that survival in normal work clothing may be inadequate during an emergency evacuation.
Crew members should be instructed in the donning and proper use of this equipment.
A basket stretcher or suitable litter for safely hoisting an injured individual must be readily available and properly maintained Additionally, designated personnel should receive training on its correct usage.
When transferring personnel over water using a crane, it is essential that all individuals wear approved personal flotation devices Additionally, personnel should only be transported on a designated personnel net or a device specifically designed for this purpose.
Crane operators must refrain from lifting or lowering personnel directly over a vessel, except when necessary to clear or land them It is essential that the load does not exceed the specifications set by the basket manufacturer Regular inspections of personnel baskets are crucial, and these baskets should be exclusively used for transferring personnel, prohibiting the lifting of equipment, materials, or supplies within them.
Cranes must not exceed their manufacturer’s rated load capacity Offshore pedestal cranes should be operated and maintained following API RP 2D guidelines During helicopter landings and takeoffs, crane operations must stop, and the boom should be safely positioned.
6.2.11 When personnel use a swingrope for transferring from boat to landing platform and vice versa, they shall wear approved personal flotation devices during such transfer operations.
6.2.12 Tag lines should be used to guide and steady all loads being lifted.
Preliminary Rig-Up Operations
Before starting rig-up operations, it is essential to review the planned arrangement of all equipment at the site to identify and eliminate any potential hazards Special attention should be given to the positioning of rig equipment in relation to pipelines and both overhead and underground utility lines to ensure safety before equipment is placed on the drilling site.
6.3.2 Well operations involving the rig shall not be com- menced until the rig is rigged up in a safe manner.
6.3.3 Change rooms and outbuildings should not be located immediately in front of or to the rear of boilers, nor in the near vicinity of rig fuel tanks.
Before starting well servicing operations, it is essential to check the well for pressure If pressure is detected, the operator's authorized personnel must be informed, and appropriate measures should be taken to either relieve the pressure or ensure safe operation under pressure before proceeding with the work.
Personnel must remain outside the derrick, mast, and cellar, maintaining a safe distance during the unseating of a subsurface pump or when the initial pull on the tubing is initiated.
Blowout Prevention Equipment for Drilling and Well Servicing Operations 10
During drilling or well servicing operations, if there are indications that a well may flow—based on previous records, current conditions, or planned work—it's essential to install and test blowout prevention equipment.
During drilling or well servicing operations on a well with indications of potential flow, it is essential for the rig to have a safety valve, specifically a stabbing valve, on the rig floor This valve must have connections compatible with all sizes and types of tool joints or tubing connections utilized in the operation.
6.4.3 Blowout prevention equipment, when required, should be installed, operated, and maintained in accordance with API RP 53 Also see API Spec l6A: Drill Through Equipment.
Designated rig personnel must possess a thorough understanding of the blowout preventer system and be capable of operating it effectively It is essential that new personnel receive training on the operation of the blowout preventer system as soon as possible.
6.4.5 The use of BOP controls, including remote control stations, shall be discussed in the pre-job meeting.
6.4.6 BOP drills should be conducted under a variety of conditions.
Blowout prevention equipment must undergo daily inspections while in service, with a preventer actuation test conducted on each round trip, but no more than once every 24 hours It is essential to document the actuation tests in the daily report, and annular blowout preventers should be tested following the manufacturer's guidelines.
6.4.8 When heavy weighted drilling fluids are in use, choke and kill lines should be flushed as needed to prevent plugging.
6.4.9 During cold weather conditions, choke and kill lines should be flushed to prevent freezing.
All pipe fittings, valves, and unions associated with blowout prevention equipment, well casing, casinghead, drill pipe, or tubing that are subjected to well pressure must have a working pressure rating that meets or exceeds the maximum expected well surface pressure Additionally, it is crucial that the BOP stack and its related riser connections are not short bolted.
(not less than three threads showing) and should be checked for properly torqued bolts.
6.4.11 All blowout preventer control lines and valves should be clearly identified.
6.4.12 When ram-type blowout preventers are being used, at least one ram preventer should be of proper size to fit the tubulars in use.
Prior to drilling out any casing string, excluding conductor or drive pipe, it is essential to conduct pressure testing of the blowout prevention equipment system Drilling operations must not commence until the blowout prevention equipment has been tested and confirmed to be in serviceable condition.
6.4.14 Personnel should stay clear of BOPs when BOPs are under well or testing pressures.
6.4.15 Personnel should stay clear of the rotary table when the BOP is operated.
When the blind ram preventer is closed for any reason, it is essential to open the valves on the choke or relief lines situated below the blind rams to release any pressure before reopening the rams.
6.4.17 Blowout prevention equipment that utilizes remote control systems should be installed so that failure of one set of controls does not affect the operation of the backup sys- tem.
6.4.18 The choke line(s) and kill line(s) should be anchored, tied, or otherwise secured to prevent whipping resulting from pressure surges.
6.4.19 BOP equipment shall never be heated or welded on by rig personnel.
6.4.20 Unnecessary engines and motors that are not critical to the operation should be shutdown during kill operations.
Housekeeping
6.5.1 Work areas should be maintained clean and free of debris and tripping hazards.
6.5.2 Means should be provided to convey any fluids away from the rig floor while pulling wet strings of pipe.
6.5.3 Leaks or spills should be promptly cleaned up to eliminate personnel slipping and fire hazards.
To ensure safety in the cellar, it must be kept free of water, oil, or drilling fluid accumulation Additionally, only equipment and materials that are currently in use or about to be used should be present, with no loose items allowed.
When arranging tools and equipment on the rig floor, it is essential to maintain clear egress routes All items should be securely stored to prevent any risk of falling, and firefighting equipment must remain accessible and unobstructed.
Hydrogen Sulfide Environment
Safety guidelines for drilling operations involving hydrogen sulfide or sulfur dioxide gas are outlined in API RP 49, along with additional recommendations in API RP 55 and API RP 68 Implementing these procedures is essential to ensure the safety of personnel and the public during applicable operations.
Confined Space, Excavations, or Hazardous Environments
Operators must inform personnel, contractors, and service company supervisors about the potential hazards associated with the presence of hydrogen sulfide, sulfur dioxide, or other unusually hazardous gases.
6.7.2 When it is not necessary to maintain a cellar, the cel- lar should be filled to eliminate a possible confined space hazard.
6.7.3 A confined space is one that: a Has limited openings for entry and/or exit. b Could contain known or potential hazards. c Is not intended for continuous occupation. d Has insufficient natural ventilation.
Before entering any confined space, it must be isolated and entry prohibited until internal atmospheric testing is completed to determine safety conditions.
2 Acceptable level of flammable gases/vapors.
Entry for testing must adhere to atmospheric testing procedures specific to confined spaces It is essential to activate a Confined Space Entry Permit System whenever hazardous atmospheres are present or may potentially arise This system should encompass the necessary safety measures and protocols.
2 Evaluation of permit space conditions.
5 Assignment of attendants and entry supervisors.
10 Review practices. c Declassification of confined space based on removal of all hazards or control of hazards through adequate ventilation.
Note: To maintain nonpermitted space requirements, tests shall be conducted and the results documented to demonstrate why the space is non-permitted.
See ANSI Z117.1-1995, Safety Requirements for Confined
Spaces; and API Publ 2015, Safe Entry and Cleaning of
Petroleum Storage Tanks, for additional safety guidelines for working in confined spaces.
Excavations deeper than four feet that may contain a hazardous atmosphere must be tested for oxygen, flammable gases, and toxic air contaminants If classified as a confined space, confined space permit procedures must be adhered to Additionally, measures should be implemented to eliminate potential hazards and prevent exposure to hazardous atmospheres, with established emergency procedures and safe practices in place for such conditions.
Machinery and Tools
6.8.1 Personnel shall only operate machinery that they are qualified to operate.
All belts, drive chains, gears, and drives must be equipped with guards to ensure personnel safety by preventing contact with moving parts For detailed construction specifications and clearance requirements for these equipment guards, refer to ANSI B15.1: Safety Standard for Mechanical Power Transmission Apparatus.
Machinery must not be operated unless all guards are securely in place and properly maintained Qualified personnel may conduct limited testing without guards during maintenance or repair work.
6.8.4 Maintenance personnel should report to the rig super- visor prior to beginning repairs They should report hazards that may be introduced They should report when repairs are completed.
Personnel must refrain from cleaning, lubricating, or repairing machinery with moving parts until the machinery is completely stopped or the moving parts are adequately guarded to prevent contact hazards.
6.8.6 Hand power tools and similar equipment, whether furnished by the employer or personnel, should be maintained in a safe condition.
6.8.7 Electrical hand tools shall be double insulated or grounded as required by NFPA 70: National Electrical Code Ground fault circuit interruption protection should be used.
6.8.8 Electric or pneumatic hand tools shall have a dead- man switch or be arranged so that the starting switch cannot be locked in.
6.8.9 When personnel are climbing rig ladders, any tools or other such materials they are carrying should be secured to the person’s body.
Lockout/Tagout
A lockout/tagout program must be implemented to ensure safety during maintenance This involves placing locks or tags on equipment or circuits to clearly identify them, including the identity or job title of the person responsible for the lock or tag Personnel must receive training and adhere to strict protocols to prevent accidental operation of energy-storing equipment that could cause injury Only the individual who installed the lock or tag, or an authorized replacement, should remove it If neither is available, a rig supervisor may remove the lock or tag after confirming that no hazards will arise from re-energizing the equipment or circuits.
Auxiliary Escape
All land rigs must be equipped with an auxiliary means of escape for the derrick or mast before personnel begin work This escape route should consist of a specially rigged and securely anchored escape line connected to the derrick or mast, ensuring a quick and convenient exit from the derrickman’s working platform.
The escape line route should be kept clear of obstructions. a The escape line on masts or derricks should be a 7 /16-in
A minimum diameter wire rope of 11.5 mm in good condition is essential It is important to install a safety buggy with a reliable braking or controlled descent device on the wire rope, positioned at the derrickman’s working platform, and secured to ensure it releases when weight is applied.
To ensure a safe landing for users, it is essential to periodically check and adjust the tension on the escape line, maintaining a sag of six to twelve feet in the middle based on the cable run length The ground anchor point should be positioned at least twice the height of the work platform away from the derrick or mast and must be capable of withstanding a pull of at least 3,000 lb If the rig's configuration does not allow for the escape system, an alternative emergency exit method from the derrickman's working platform to a safe location must be provided.
6.10.2 Personnel shall not ride the safety buggy or escape equipment except in an emergency Personnel shall be trained in the proper procedure(s) for escaping the derrick or mast.
Personnel Lifting Systems
6.11.1 Personnel engaged in drilling or servicing opera- tions shall not ride the elevators.
In extreme emergency situations, supervisors may allow personnel to use elevators with the necessary fall protection equipment However, it is essential that the elevators are free of pipes and other equipment during these rides.
A bosun’s chair or equivalent, securely attached to a traveling block or tugger line, can be utilized to access hard-to-reach areas Personnel lift devices, such as hydraulic or air winch lines, are acceptable if they adhere to specific criteria: they must be self-centering with a locking or braking mechanism, the control lever must be monitored continuously during lifting or lowering operations, the lifting cable must have a minimum diameter of 3/8 inches, and all hoisting equipment should support a minimum workload of 4,000 pounds, with all connections compliant with ANSI standards.
Racking Tubulars and Drill Collars
6.12.1 Any rods, tubulars, drill pipe, and drill collars racked or hung in the derrick or mast should be secured to prevent them from falling across the derrick or mast.
Safety clamps on drill collars, flush-joint pipes, or similar equipment must be removed before hoisting resumes to prevent accidental falls into the well when not secured by elevators.
To ensure safety, it is essential to implement precautions that prevent round-shaped equipment, such as pipes and drill collars, from rolling off storage racks Utilizing stops, pins, or chocks can effectively secure these items in place.
To prevent the formation of ice plugs in racked tubular goods, it is essential to ensure proper drainage An unexpected ice plug can pose a serious risk to crew members when entering the hole Therefore, in conditions favorable to ice plug formation, it is advisable to use a rabbit to confirm that the tubular stands are clear of ice before running the pipe into the hole.
Handling Drilling Fluid Chemicals and Additives
Asbestos must not be utilized as an additive in drilling fluids due to its association with negative health effects for personnel It is essential to replace asbestos with alternative materials in the drilling fluid system For more information on the dangers of asbestos and suitable substitutes, please refer to the Foreword and the asbestos warning page in this publication.
Personnel responsible for managing drilling fluid and additives must receive training on safe handling, disposal methods, and personal protective procedures Resources for proper handling and disposal are accessible from various sources, including the manufacturer's Material Safety Data Sheets (MSDS) and relevant regulatory agencies.
Fire Prevention
7.1.1 Safe storage and location of combustible and flam- mable materials and the prevention of accumulation of rub- bish are important to fire prevention.
7.1.2 Smoking shall be prohibited at or in the vicinity of operations that constitute a fire hazard Such locations should be conspicuously posted with a sign, “NO SMOKING OR
7.1.3 Smoking shall be permitted only in areas designated for smoking.
7.1.4 Change rooms and other buildings where smoking is permitted should be located in areas designated safe for smoking.
7.1.5 Matches and all smoking equipment should be left in areas designated safe for smoking.
In areas where smoking is prohibited, no sources of ignition are allowed unless deemed safe by the supervising authority or their designated representative.
7.1.7 Potential sources of ignition should be permitted only in designated areas located at a safe distance from the well- head or flammable liquid storage areas.
7.1.8 Only safety-designed (nonopened flame) heaters shall be permitted on or near the rig floor, substructure, or cel- lar The safety features of these heaters shall not be altered.
7.1.9 Equipment, cellars, rig floor, and ground areas adja- cent to the well should be kept free from oil and gas accumu- lations that might create or aggravate fire hazards.
7.1.10 Combustible materials such as oily rags and waste should be stored in covered metal containers and the covers kept in place.
7.1.11 Natural gas or liquefied petroleum gas shall not be used to operate spray guns or pneumatic tools.
7.1.12 Material used for cleaning should have a flash point of not less than 100°F (38°C)
When handling, storing, or transporting flammable liquids, it is essential to use metal or other conductive material containers Using plastic containers for flammable liquids poses a risk due to the potential buildup of static charges.
Metal components in plastic containers must be securely attached to the fill connection When using plastic containers, it is essential to insert a conductive fill connection or a grounded rod before filling with flammable liquids, in accordance with NFPA 77: Static Electricity and API RP guidelines.
2003: Protection Against Ignition Arising Out of Static,
Fire Protection
Fire fighting equipment must remain untouched and should only be used for fire protection and fighting purposes The fire fighting water system can be utilized for washing down and other utility functions, provided that its fire fighting capabilities are not jeopardized.
7.2.2 Fire extinguishers and other fire fighting equipment shall be suitably located, readily accessible, and plainly labeled as to their type and method of operation.
7.2.3 Fire protection equipment shall be periodically inspected and maintained in operating condition at all times
A record of the most recent equipment inspection shall be maintained.
Drilling rigs must be equipped with at least four 20-pound capacity fire extinguishers that have a Class BC rating, as specified by NFPA 10: Portable Fire Extinguishers These extinguishers should be easily accessible and maintained in good operating condition Depending on operational needs, additional or larger fire extinguishers may be required.
7.2.5 Well servicing rigs shall have readily accessible, in good operating condition, a minimum of two (2) 20 pound capacity fire extinguishers with a Class BC rating (see NFPA
10) This is a minimum requirement and operations may dic- tate use of more equipment or larger size equipment.
Fire fighting equipment must be easily accessible near all welding operations In cases where welding or cutting occurs outside of the designated welding area, a designated fire watch must be assigned Additionally, it is essential to coordinate welding or cutting activities with other operations at the site to ensure safety.
7.2.7 Portable fire extinguishers shall be tagged with a durable tag showing the date of the last inspection, mainte- nance, or recharge Inspection and maintenance procedures shall comply with NFPA 10.
Crew members must be well-acquainted with the locations of fire control equipment, including drilling fluid guns, water hoses, and fire extinguishers, and selected personnel should receive training on how to effectively use this equipment.
Containers
8.1.1 Hand portable containers for storing flammable liq- uids should be Underwriters Laboratories (UL) or Factory Mutual (FM) approved, or equivalent
8.1.2 Tanks, drums, and other containers containing flam- mable liquids should be properly labeled to denote their con- tents See API Publ 2003: Protection Against Ignition Arising
Out of Static, Lightning, and Stray Currents.
Fuel and Oil Transfers and Refueling
Hydrocarbon-fueled engines must be turned off during refueling operations, except when shutting them down could jeopardize well integrity, particularly during critical activities like well control procedures, tripping, or casing handling operations.
8.2.3 One person should be designated to gauge or monitor fuel tanks while they are being filled to prevent overfill and spillage.
8.2.4 During refueling operations, the filling nozzle should be kept in contact with the intake pipe to ensure grounding and prevent fuel spillage.
8.2.5 Equipment being refueled shall be grounded See
Liquefied Petroleum Gas (LPG)
8.3.1 Handling, connecting, and transfer operations involv- ing liquefied petroleum gas (LPG) shall conform to NFPA
58: Standard for the Storage and Handling of Liquefied
Petroleum Gases, and NFPA 55, Compressed and Liquefied
8.3.2 Ignition Source Control Smoking or open flames shall not be permitted within 20 ft (6.1 m) of any area where flammable, oxidizing, pyrophoric, or toxic compressed gases are stored or used.
Protective caps must be kept on compressed gas cylinders at all times, except during filling or when connecting for use, to ensure safety and compliance with regulations.
Users must ensure that gas-tight valve outlet caps or plugs are always in place on the valve outlet, except during the filling or connection of compressed gas cylinders for use.
8.3.5 Compressed or liquefied gas cylinders in use or in storage shall be secured to prevent them from falling or being knocked over.
8.3.6 Compressed gas cylinders should be transported, stored and used in an upright position.
8.3.7 Compressed gas cylinders exposed to fire shall not be used until they are requalified in accordance with the pressure vessel code under which they were manufactured.
8.3.8 Containers that show denting, bulging, gouging, or excessive corrosion shall be removed from service.
Repairs or modifications to containers must adhere to the regulations, rules, or codes applicable to their original fabrication Additionally, welding is only allowed on saddle plates, lugs, or brackets that have been affixed to the container by the manufacturer.
Compressed gas cylinders must be labeled according to CGA C-7 guidelines, which provide instructions for the preparation of precautionary labeling and marking of these containers It is essential that these markings or labels remain intact and are not removed.
8.3.11 Compressed gas cylinders shall not be placed where they could become a part of an electrical circuit.
8.3.12 Compressed gas cylinders shall not be exposed to temperatures exceeding 125°F (38°C) Cylinders shall not be subjected to direct heating to increase vapor pressure.
Stoves and heaters powered by LPG fuel must be operated in well-ventilated spaces to ensure safety It is essential for personnel to verify adequate ventilation before igniting the heater or stove Additionally, regular inspections of all hoses and connections in LPG systems are crucial to prevent leaks.
Only qualified personnel are permitted to refill LPG bottles, and it is essential to wear protective gloves during this process This precaution is necessary to prevent freeze burns that can occur if propane comes into contact with the skin.
Storage
Flammable liquids storage areas in buildings or sheds must be well-ventilated to the outside, have clear exits, and be maintained with fire safety in mind, including proper housekeeping and material storage These areas should be clearly marked as hazardous with appropriate warning signs, and a Class BC fire extinguisher must be readily accessible Additionally, electrical installations must comply with API RP 500 or API RP 505 classifications, and if dispensing occurs in the area, it should be classified as Class 1, Division 1.
Paint and solvents must be kept in a well-ventilated space, away from heat and ignition sources It is essential to store containers labeled as "flammable" securely when they are not in use.
Flammable liquids must be stored at least 50 ft (15.2 m) away from the wellbore on land, with the exception of fuel in operating equipment tanks If the terrain or location prevents maintaining this distance, equivalent safety measures should be implemented In offshore settings where this guideline is challenging, suitable precautions must be adopted.
8.4.4 On land locations, liquefied petroleum gas (LPG) tanks larger than 250 gal (0.95 m 3 ) should be placed at least
150 ft (45.7 m) from and parallel to the closest side of the rig, if terrain and location configuration permit LPG tanks should be labeled to denote their flammable contents.
9 Drilling and Well Servicing Rig