Rig Processes

The Wee Land Rig handbook An introduction to safer land based drilling operations

Peter Aird.. December 2008 Rev 1

.

The Wee Land Rig Handbook. The oil and gas industry employs hundreds of thousands of people and is a vital component of the World economy. Drilling quality, safety, health and environmental accidental loss control prevention is thus vital to the success of this industry. This documents intent is to introduce drilling tasks and activities in order persons to be enabled to identify the common work hazards and risk management controls needed to reduce, mitigate and prevent accidental loss, unplanned events and personal injuries from occurring on a day to day basis. I hope it aids to do simply this. Peter Aird. December 2008 rev 1.

An introduction to safer land rig drilling operations

The Wee Land Rig Handbook.

Introduction All companies in the oil and gas industry have individual operational standards, instructions, health, safety and environmental programs. This document does not replace these solely providing only an overview to the typical operational tasks, key aspects and activities needed to be safely managed and control the hazards and risks that may exist at the worksite Ref. disclaimer on page 3 This document principle intent is for use in familiarization training, educational and personal development to better understand, comprehend and realize the workplace hazards that exist to enable persons to apply corrective solutions to their daily operational activities. This document cannot identify all the hazards, risk and solutions that exist, serving only as a guide. Finally the focus of this document is prevalent to land based operations only. Worker safety awareness is necessary to prevent all accidental loss at the workplace including personal injury prevention during all phases of drilling and servicing operations. Procedures and processes will include safety meetings, Job Safety Analyses, risk assessments and general and task-specific training. At the end of many sections, typical hazards and potential solutions are identified to provide more details needed to be considered to assure safe work practices and procedures are followed at all times.


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Disclaimer This document is not a standard, nor regulation, and creates no new or otherwise legal obligations. The document service only as an advisory guide, where all informational contained in content is intended to assist employers and employees in providing a safe, healthful and environmentally complaint workplace through effective prevention programs adapted to the needs of each place of employment tools, equipment, practices and procedures used. . Health Acts will exist in each specific operating region, location and/or environment and will require employers and employees to comply with hazard-specific safety and health standards. In addition, employers must provide their employees with a workplace free from recognized hazards likely to cause equipment failure malfunction, injury, serious loss or physical harm. Employers can also often be cited for violating statutory rules and regulations if there is a recognized hazard that they then do not take steps to prevent or abate the hazard. However, failure to implement such guidelines is not, in itself, a violation. Oil and Gas Industry Disclaimer: Although the document was developed from recognized and credible sources, it is not to be construed as an industry consensus standard as indicated in the following disclaimer. "Nothing contained herein shall be construed to establish an industry-accepted standard of drilling or energy servicing safe operating procedures. No suggested method, practice, precaution or program set forth in this guide should be relied upon to establish a legal standard of conduct or a legal duty, the violation of which would constitute culpability of any degree in any legal proceeding. Information and/or data provided is for informational assistance only and should not be utilized or considered as a comprehensive safety and health program or accepted industry standard."



Table of contents The Wee Land Rig handbook ............................................................................................. 1 Introduction......................................................................................................................... 3

Disclaimer ....................................................................................................................... 4 Table of contents............................................................................................................. 5 Safety and health program .................................................................................. 9 Hot work/Welding................................................................................................... 13 H2S ............................................................................................................................... 20 Release of H2S.............................................................................................................. 21

Site preparation ................................................................................................................. 24

Leveling site.................................................................................................................. 24 Excavation and trenching.............................................................................................. 25 Conductor hole, rat-hole and mouse-hole.................................................... 26

Transporting equipment .................................................................................................... 28

Transporting equipment by truck.................................................................................. 28 Unload at drill site......................................................................................................... 29

Drilling.............................................................................................................................. 30

Rigging Up.................................................................................................................... 30 Drilling ahead................................................................................................................ 41 Rotating Systems .......................................................................................................... 48 Rotating Systems .......................................................................................................... 49 Making a connection..................................................................................................... 51 Mud circulating system................................................................................................. 57 Drilling Fluids............................................................................................................... 63 Drilling Fluids............................................................................................................... 64 Tripping in and out........................................................................................................ 66

Casing operations.............................................................................................................. 75

Installing casing tools ................................................................................................... 76 Running casing into the hole......................................................................................... 77 Installing casing accessories ......................................................................................... 78 Circulating and cementing ............................................................................................ 79

Introduction to well control .............................................................................................. 81

Blowout Prevention Program........................................................................................ 84 Monitoring and Maintaining Mud System.................................................................... 85 Installing BOPs, Accumulator, and Choke Manifold ................................................... 86 Testing BOPs Accumulators, and Choke Manifold...................................................... 88 Maintaining Surface Control System............................................................................ 88


The Wee Land Rig Handbook. Maintenance activities ...................................................................................................... 89

Rig floor ........................................................................................................................ 89 Drilling line maintenance..................................................................................... 91 Wire rope maintenance........................................................................................ 92 Mud circulation system ........................................................................................ 93 Generators, electrical motors and electrical systems .................................................... 94 Engines.......................................................................................................................... 95 Derrick equipment maintenance ................................................................................... 96

Appendices........................................................................................................................ 97

Appendix 1: Physical properties of H2S....................................................................... 97


The Wee Land Rig Handbook. Abbreviations

ADP Aluminium drill pipe MST Magnetic steering toll AFE Authority for expenditure MW Mud weight API American Petroleum Institute MWD Measurement while drilling B/U Bottoms up NDT Non destructive testing BHA Bottom hole assembly NMDC Non-magnetic drill collar BHO Sub Bottom hole orientation sub NPT Non productive time BHP Bottom hole pressure OBM Oil based mud BOD Basis of Design OD Outside diameter BOP Blow out preventer OIM Operation's installation manager CBL Cement bond log OWE Offshore well engineer CHH Casing head housing P&IDS Piping and instrumentation diagram CLP Choke line pressure PBR Polished ball receptacle CMC Carboxymethylcelluose PCWD Pressure control while drilling - rotating diverter

/ head DC Drill collar PDC Polycrystalline diamond compact DDR Daily drilling report PDHG DIMS Drilling information management system PDM Positive displacement mud motor DMS Drilling management system PFD Process flow diagram DP Drill pipe POB Personnel on board DS Drill string standard POBM Pseudo oil based mud DST Drill string test POOH Pull out of hole DSV Down hole safety valve PPG Pounds per gallon DSV Drilling supervisor PSI Pounds per square inch ECD Equivalent circulating density PTW permit to work ECP External casing packer PVT Pit volume totaliser ECPICV External casing packer internal control

valve RDM Regional drilling manager

EMW Equivalent mud weight RIH Run in hole ESD Emergency shut down ROV Remotely operated vehicle - robotic submarine FG Formation pressure equivalent density RPM Revolutions per minute FIT Formation integrity test RTTS Retrievable packer FMS Flush mounted slips SCR Slow circulation rate FMS Formal method statement SCSSV Sub surface safety valve FRAC Fracture SF Safety factor GOR Gas oil ratio SICP Shut in casing pressure HAZOP Hazard and operability analysis SIDPP Shut in drill pipe pressure HCR High closing ratio SPM Strokes per minute HP High pressure SSP Stand pipe pressure HPE Hydrostatic pressure equivalent of 1bbl

mud in well TCL Tubing conveyed logging

HPHT High pressure high temperature TFA Total force area HWDP Heavy weight drill pipe TIW Texas iron works IBOP Internal blow out preventer TOC Top of cement ID Internal diameter TRSSSV Tubing retrievable sub surface safety valve. IFG Influx density TVD Total vertical depth ISP TVDRKB Total vertical depth rotary Kelly bushing IWCF International well control forum UBD Under balanced drilling JSA Job Safety Analysis UBHOsub Universal bottom hole orientation sub KOP Kick off point ULSEL Ultra-long spaced electronic log KPI Key performance indicator VBR Variable bore rams KT Kick tolerance WOH Weight on hook LCM Lost circulation material W&W Wait & weight well kill method LMRP Lower marine riser package WBM Water based mud LOT Leak off test WEG LP Low pressure WOB Weight on bit LTI Lost time incident WWD World wide drilling LWD Logging while drilling MAASP Maximum annular allowable surface

pressure

MD Measured depth MMSCF/D Million standard cubic feet per day


The Wee Land Rig Handbook. MODU Mobile offshore drilling unit MPI Magnetic particle inspection MPLT MR Migration rate

Note: The drilling industry is characterized by abbreviations and names which can sound weird or mean multiple things. To avoid misunderstandings please ask if in doubt



General health and safety The following pages list general safety and health concerns. Each topic is linked to a page with more information about the activity and sources of information.

One of the first objectives of any company is to establish a safety and health program.

Employers should seek consultation and advice about potential hazards at their worksites, improve their occupational safety and health management systems, and particularly focus on behavioral safety programs for their employees.

Specific general health and safety topics covered here-in are:

General Safety and Health Resources Slips, Trips, and Falls Strains and Sprains Weather Conditions

Safety and health program

General safety and health resources

General safety and health resource subject matters to cover are:

Crane, Derrick, and Hoist Safety. Electrical. Fire Safety. Occupational Safety and Health Topics Page. Hand and Power Tools.


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The Wee Land Rig Handbook. H2S Controls

- Confined Spaces. - Pressure Vessels.

o Compressed Gas and Equipment. o Control of Hazardous Energy (Lockout/Tagout)

Hydrogen Sulfide Ventilation. Respiratory protection as it relates to oil fields.

- Hot Work - Welding - Control of Hazardous Energy (Lockout/Tagout) - Motor Vehicles Safety. - Powered Industrial Trucks.

Personal Protective Equipment (PPE)

Personal Protective Equipment (PPE). Eye and Face Protection. Personal Protective Equipment for General Industry. Noise and Hearing Conservation. Working at heights


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The Wee Land Rig Handbook. Slips trips and falls There are many ways to protect from slips, trips, and falls. Even so, they still happen and the following are means to either prevent slips, trips, and falls or to minimize the consequences if they should happen.

Wear personal protective equipment (such as hard hats, work gloves, safety shoes, and eye protection).

Be aware of the slipping and falling hazards when working on the drilling floor, servicing rig floors or other platforms.

Keep all work areas clean and clear of oil, tools, and debris. Use non-skid surfaces where appropriate. Provide guardrails and guards around work areas that are prone

to slips, trips, and falls. Install, inspect, and secure stairs and handrails. Instruct workers on proper procedures for using and installing

ladders. Use only ladders in good repair that do not have missing rungs. Do not install stairs with missing or damaged steps. Repair them

before installing them. Keep walkways clean and free of debris and tripping hazards. Keep all cords and hoses orderly and clear of walking spaces. Cover open cellars. Conduct a pre-job inspection to identify, then eliminate or

correct hazardous work surfaces. Walking/Working Surfaces Standard requires: Keep all places of

employment clean and in an orderly condition. Keep aisles and passageways clear and in good repair, with no

obstruction across or in aisles that could create a hazard. Provide floor plugs for equipment so power cords need not run across pathways.

Use waterproof footgear to decrease slip/fall hazards.



Strains and sprains General solutions for strains and sprains include:

Use proper lifting technique. Hoist slowly to limit pipe momentum. Seek assistance when moving awkward and heavy guards and

covers. Use proper stance and slip-lifting techniques. Slips have three

handles and should be lifted jointly by more than one person. Use lifting equipment and limit manual positioning of elevators. Practice proper hand placement and use of pullback (tail) ropes.

Use mechanical lifting aids, proper lifting techniques, and team lifting where appropriate.

Use proper hand and body positioning. Ergonomics.

Hand Injury Lifting Repetitive motions

Weather conditions Weather conditions can create hazardous working conditions: therefore it is necessary to monitor weather conditions and forecasts to allow time to prepare for such conditions as may occur. Lightning is especially hazardous and unpredictable. When lightning is present, crews must avoid situations where they could become part of potential current paths.



Hot work/Welding Hot work is any work that involves burning, welding, using fire- or spark-producing tools, or that produces a source of ignition. Welding and cutting operations are common to drilling and servicing operations. Test for flammable gases in the work area before starting any hot work. Potentially hazardous areas include, but are not limited to, well heads, fuel tanks, mud tanks, tank batteries, gas separators, oil treaters, or confined spaces where gases can accumulate.

Figure 1: Hot work welding

Hot Work, Fire, and Explosive Hazards Welding, Cutting and Brazing Cylinder Storage Grinding Well Site Ignition Sources

Hot work fire and explosive hazards

Figure 2: Welding with fire control.

Workers performing hot work such as welding, cutting, brazing, soldering, and grinding are exposed to the risk of fires from ignition of flammable or combustible materials in the space, and from leaks of flammable gas into the space, from hot work equipment. Potential Hazard:

Getting burned by fires or explosions during hot work.


The Wee Land Rig Handbook. Possible Solutions: The basic precautions for fire prevention are:

Perform hot work in a safe location, or with fire hazards removed or covered.

Use guards to confine the heat, sparks, and slag, and to protect the immovable fire hazards.

Special Precautions:

Do not perform hot work where flammable vapors or combustible materials exist. Work and equipment should be relocated outside of the hazardous areas, when possible.

Make suitable fire-extinguishing equipment immediately available. Such equipment may consist of pails of water, buckets of sand, hose, or portable extinguishers.

Assign additional personnel (fire watch) to guard against fire while hot work is being performed. Fire watchers are required whenever welding or cutting is performed in locations where anything greater than a minor fire might develop.

Fire watchers shall: Have fire-extinguishing equipment readily available

and be trained in its use. Be familiar with facilities for sounding an alarm in the

event of a fire. Watch for fires in all exposed areas, try to extinguish

them only when obviously within the capacity of the equipment available, or otherwise sound the alarm.

Maintain the fire watch at least a half hour after completion of welding or cutting operations to detect and extinguish possible smoldering fires.

Potential Hazard:

Getting burned by a flash fire or explosion that results from an accumulation of flammable gases, such as Methane or Hydrogen Sulfide, around the wellhead area.


The Wee Land Rig Handbook. Possible Solutions:

Monitor the atmosphere with a gas detector. If a flammable or combustible gas exceeds 10 percent of the lower explosive level (LEL), the work must be stopped.

Identify the source of the gas and repair the leakage. Additional References:

Applicable standards with reference to Flammable and combustible liquids Welding, cutting, and brazing - general requirements Oxygen-fuel gas welding and cutting Arc welding and cutting Resistance welding

American Petroleum Institute (API)

RP 54, Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations, Wireline Service.

Publication 2201, Procedures for Welding Or Hot Tapping On Equipment Containing Flammables, (1995).

Welding cutting and brazing All hot work is potentially hazardous and a hazard assessment should be performed to determine where the hazards exist. Potential Hazard:

Figure 3: Welding - Hot work.

Injury and illness caused by hot work (such as, welding fumes, UV light, sparks, noise, or skin injury).



Inspect the work area to ensure that all fuel and ignition sources are isolated by shielding, clearing the area, lockout/tagout, soaking flammable material with water.

Wear appropriate PPE, such as face shield, leather welder's vest, and gauntlet gloves. Use cotton or denim clothing.

Provide UV shielding for arc welding where practical. Inspect welding and cutting equipment before use (arc or gas

welding/burning). Leak test gas torches, gauges, and hoses. Review the hot work permit if available. Ensure the availability of adequate fire watch/fire protection

equipment. Ensure adequate ventilation from toxic welding and cutting

fumes.

Special Hazard:

Accumulation of toxic gases within a confined space.

A hazardous atmosphere exists in oxygen-deficient (atmospheric concentration of less than 19.5 percent) or oxygen-enriched (atmospheric concentration of more than 23.5 percent).

Possible Solutions:

Ventilate toxic metal fumes mechanically, if entering a confined space, such as inside of a mud tank, water tank, oil tanks, hoppers, sump, pit or cellar.

Use a written permit system to document authorization to enter, the work to be performed, and the results of the gas monitoring where there is a potential for toxic, flammable, or oxygen-deficient atmosphere. Both a hot work and confined entry permit may be required for welding, cutting or brazing within a confined space.



Cylinder storage Figure 4: Properly stored cylinders

Potential Hazard:

Falling or rolling injuries from improper gas cylinder storage

Possible Solutions:

Ensure cylinders are properly stored in an upright position and chained in separate racks.

Store full and empty cylinders separately.

Potential Hazard:

Valve opening or break off, exposing workers to toxic fumes and flammable gas, caused by improper gas cylinder storage

Possible Solutions:

Store cylinder properly.

Always remove gauges and regulators, and install protective valve caps before transporting.

Potential Hazard:

Gas cylinders causing fires or explosions

Possible Solutions:

Store cylinders in a dry, well-ventilated location.

Avoid storing flammable substances in the same area as gas cylinders.

Avoid storing cylinders of oxygen within 20 feet of cylinders containing flammable gases.

Store all cylinders upright and chained in separate racks.

Store full and empty cylinders separately.


The Wee Land Rig Handbook. Grinding Potential Hazard: Figure 5: Hand Grinding

Grinding (that results in sparks, noise, eye and skin injury from flying metal filings, grinding wheel pieces, etc.).

Having fingers or hands caught in the grinding wheel, resulting in amputation.

Being struck by portable grinder.

Possible Solutions:

Wear appropriate PPE, such as face shield. Use cotton or denim clothing.

Inspect grinding equipment before use.

Review the hot work permit if available.

Ensure the availability of adequate fire watch/fire protection equipment.

Ignition sources There are a number of potential sources of ignition for flammable gases and liquids on the drill site. It is necessary to provide for a general ignition safety program which could pre-empt potential hazards of fire and explosion. Potential Hazard:

Ignition and explosions of flammable gases or vapors from:

Internal-combustion engine sparks

Open flames from any source

Smoking

Welding operations

Electric power tools

Two-way radios


The Wee Land Rig Handbook. Vehicles with catalytic converters

Portable generators

Possible Solutions:

Provide spark arrestors for internal-combustion engines.

Post "NO SMOKING" signs wherever a flammable gas or vapor hazard exists.

Locate "spark producing" equipment or facilities well away from potential hazard areas.

Prohibit vehicles with catalytic converters from the immediate vicinity of the rig.

Prohibit open flames from the vicinity of the rig.


The Wee Land Rig Handbook. Additional Information:

American Petroleum Institute (API). RP 54, Recommended Practice for Occupational Safety for

Oil and Gas Well Drilling and Servicing Operations, Wireline Service.

RP 500, 3rd Edition, Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class 1, Division 1 and Division 2.

RP 505, 2nd Edition, Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class 1, Zone 0, Zone 1 and Zone 2.

Accident Prevention Reference Guide. International Association of Drilling Contractors (IADC).

H2S Note: It is not the intent of this section to create an H2S contingency plan. Hydrogen Sulfide or sour gas (H2S) is a flammable, colorless gas that is toxic at extremely low concentrations. It is heavier than air, and may accumulate in low-lying areas. It smells like "rotten eggs" at low concentrations and causes you to quickly lose your sense of smell. Many areas where the gas is found have been identified, but pockets of the gas can occur anywhere. Iron sulfide is a byproduct of many production operations and may spontaneously combust with air. Flaring operations associated with H2S production will generate Sulfur Dioxide (S02), another toxic gas. Active monitoring for hydrogen sulfide gas and good planning and training programs for workers are the best ways to prevent injury and death. Also see: NIOSH Classification of H2S Hazard Areas.

Figure 6: Hydrogen sulfide warning sign: Warning Hazardous Area is in yellow letters on a black background. In black letters on a yellow background, the sign says Hydrogen Sulfide, Extreme Health Hazard, Fatal or Harmful if Inhaled




Release of H2S All personnel working in an area where concentrations of Hydrogen Sulfide may exceed the 10 Parts Per Million (PPM) should be provided with training before beginning work assignments. Potential Hazard:

H2S exposure greater than the Permissible Exposure Limit (PEL)

Possible Solutions: Implement an H2S contingency plan (see API) including, but not limited to:

Appropriate instruction in the use of hydrogen sulfide safety equipment to all personnel present at all hydrogen sulfide hazard areas.

Gas detection where hydrogen sulfide may exist.

Appropriate respiratory protection for normal and emergency use. Respiratory Protection Standard for (H2S).

For emergency response information, refer to Hazardous Waste and Emergency Response standards.

Figure 7: SCBA


The Wee Land Rig Handbook. Comprehensive training should be provided for workers in H2S operations. Example topics include:

Identification of the characteristics,

sources, and hazards of Hydrogen Sulfide.

Proper use of the Hydrogen Sulfide detection methods used on the site.

Recognition of, and proper response to, Hydrogen Sulfide warnings at the workplace.

Symptoms of Hydrogen Sulfide exposure.

Proper rescue techniques and first-aid procedures to be used in a Hydrogen Sulfide exposure.

Proper use and maintenance of personal protective equipment. Demonstrated proficiency in using PPE should be required.

Worker awareness and understanding of workplace practices and maintenance procedures to protect personnel from exposure to hydrogen sulfide.

Wind direction awareness and routes of egress. Confined space and enclosed facility entry procedures. Locations and use of safety equipment. Locations of safe briefing areas. Use and operation of all Hydrogen Sulfide monitoring systems. Emergency response procedures, corrective action, and

shutdown procedures. Effects of Hydrogen Sulfide on the components of the Hydrogen

Sulfide handling system. The importance of drilling fluid treating plans prior to

encountering Hydrogen Sulfide. Additional Information:

RP 49, Recommended Practice for Drilling and Well Servicing Operations Involving Hydrogen Sulfide. American Petroleum Institute (API), (2001, May/Reaffirmed 2007, March). Includes well drilling, completion, servicing, workover, downhole maintenance, and plug and abandonment procedures conducted with hydrogen sulfide present in the fluids being handled.

Figure 8: Gas detector


The Wee Land Rig Handbook. Metal Fatigue Metal fatigue, including hydrogen embrittlement or sulfide stress cracking, can result in a release of hydrogen sulfide gas. Potential Hazard:

Being exposed to Hydrogen Sulfide.

Getting Injured due to equipment failure.

Possible Solutions:

Select materials in accordance with the MR0175/ISO15156 criteria for H2S service.

MR 0175, Metals for Sulfide Stress Cracking and Stress Corrosion Cracking Resistance in Sour Oilfield Environments. National Association of Corrosion Engineers (NACE), (2003, December) [Also ISO 15156, Petroleum and natural gas industriesMaterials for use in H2S containing environments in oil and gas production, International Standards Organization (ISO)].

About MR 0175. Reviewed and approved 15 proposals for change to the standard.

Treat drilling fluids to chemically reduce corrosion failures.

Accumulation of H2S It is possible for hydrogen sulfide gas to accumulate in any low or enclosed area, such as a gas venting system, mud system, cellars, pits, and tanks. Potential Hazard:

Being exposed to Hydrogen Sulfide. Possible Solutions:

Provide adequate ventilation for the removal of any accumulation of H2S.

Implement effective confined space entry program.

Figure 9: H2S metal failure


Site preparation Figure 10: Clearing the site Site preparation for an oil and gas well, in most instances, looks like any other construction site. Safety and Health Regulations for Construction are used to assess safety compliance during this phase of the development of a drilling site. Once the location for the site has been established, the area is prepared for drilling, with the following steps

Leveling site The site is leveled (if necessary) with a bulldozer and/or a grader. Potential Hazards: Figure 11 : Levelling uneven ground

Damaging buried pipelines and cables.

Unpredictable weather changes can create unexpected hazards.

Irritant and toxic plants, pollens, and other entrained materials.

Uneven ground may cause bulldozers to roll over.

Possible Solutions:

Perform a site line location survey. Plan for hazards due to unpredictable changing weather. After weather changes, conduct inspections for new hazards.


The Wee Land Rig Handbook. Protect employees engaged in site clearing from hazards of

irritant and toxic plants. Teach the employees about available first aid treatments.

Provide rollover guards on all equipment used in site clearing operations.

Provide overhead and rear canopy guards on rider-operated equipment.

Excavation and trenching Figure 12: Mud pit The scale and duration of excavating and trenching are very minor and site-specific. On some drilling sites, a below-ground-level cellar may be excavated. This is where the main borehole is to be drilled. A reserve and settling pits may also be excavated and are used for water or drilling fluid (mud) discharges. Potential Hazards:

Dust and other airborne contaminants can cause respiratory problems or allergic reactions. Figure 13: Excavation on a land rig site

Damaging buried pipelines and cables.

Possible Solutions:

Wear appropriate respiratory protection.

Perform a site line location survey.



Conductor hole, rat-hole and mouse-hole Figure 14: Conductor hole Prior to commencing the rig-up

process, the conductor, rat-hole and mouse-hole are completed. Special companies may be hired to begin drilling these three holes:

Conductor hole and conductor pipe

Rathole Mouse hole

Conductor hole and conductor pipe This is a largest diameter hole, lined with pipe, also called a starter hole, variant in depth e.g. down of tens of feet to a few hundred feet depending on the local geology. Figure 15; installing conductor hole

Some sites e.g. where geology permits, do not require a conductor hole. Potential Hazard:

Being struck by hoisting line or suspended drill or casing.

Possible Solutions:

Wear Personal Protective Equipment: hard hats, safety glasses, safety toe boots, and work gloves.

Keep employees away if they are not working at this job.


The Wee Land Rig Handbook. Rat-hole A rat-hole is a hole emanating from the rig floor, then 30 to 35 feet deep below the drill floor, lined with casing that projects above the floor, into which the kelly and/or tubulars are placed when tubular hoisting or lowering operations are in progress. This is either done by the portable rig that drills the conductor hole or can be done by the primary rig after rigging-up. Potential Hazard:

Falling or stepping into an uncovered rathole.

Possible Solution:

Cover the hole until it is lined with casing or other material during rigging-up.

Mouse-hole Figure 16: General conductor mouse and rat-hole arrangement.

A mouse-hole is a shallow bore hole under the rig floor, usually lined with pipe, in which joints of drill pipe are temporarily placed. This is either done by the portable rig that drills the conductor hole or can be done by the drilling rig after rigging-up. Potential Hazard:

Falling or stepping into an uncovered mousehole.

Possible Solution:

Cover the hole until it is lined with casing or other material during rigging-up



Transporting equipment Depending on the location of the

well, access to the site may require preparation of a road bed. A site, and its access road, must accommodate a large number of temporary and semi-permanent structures and tanks, all brought in by truck. The tasks are:

Figure 17: Transporting equipment

Transporting equipment by truck

Unload at drill site Transporting equipment by truck Equipment is loaded on trucks at the previous drill site or storage yard, secured and transported to the new drill location. Potential Hazards:

Figure 18: Transporting the derrick

- At a newly prepared drill site, the soils may not be compacted sufficiently to support the incoming load. This could cause the load to become unstable

- The load may not be secured properly, causing it to shift or the tie-downs to fail.

- In slick conditions, the truck may slide off the road Possible Solutions:

Make sure that the access road and drill pad at the drill site has been properly prepared before attempting to drive on it.

Drive slowly; always being cautious of shifting weight. Loads should be tied down with proper devices and inspected

before and during transport. General rules for protection against shifting or falling cargo generally exist and should be consulted.

Always drive with caution, whatever the conditions.



Unload at drill site Equipment is unloaded and placed approximately where it will be rigged up.

Figure 19: Unload doghouse at drill site location Potential Hazard:

Improperly secured loads could cause equipment to slide or collapse during unloading.

Possible Solution:

Inspect loads before loading or unloading.



Drilling Figure 20; Typical land drilling rig Worker safety awareness is necessary for injury prevention during all phases of drilling operations. Procedures and processes will include safety meetings and general and task-specific training. At the end of each card, resources are identified which provide more details for establishing safe work practices and procedures.

Rigging Up Rigging up is placing and assembling the various parts of equipment that make up the rig, and preparing the rig for drilling.

There are many rig designs, and this document does not cover each type individually. This document therefore focuses on the common hazards and solutions that many rig designs share. During assembly of the rig, some equipment may be handled and set with crane, rig up trucks, or forklift, depending

on the size of the rig. It should

be noted that overhead hazards such as high voltage power lines may be present. There may be two or more crews (teams) working together in the rigging up process. The rigging up process includes the following steps, some of which are done simultaneously: (See servicing rigging up.)

Figure 22: Hoisting the drilling mast

Figure 21: Setting up the substructure.



Setting up the substructure Equipment is unloaded and positioned at or near the exact location that it will occupy during operations. The substructure is assembled, pinned together, leveled, and made ready for other rig components on the floor. Equipping the cellar begins but can be done throughout the rigging up process. This includes welding on a drilling nipple to the conductor pipe and attaching a flow line. Potential Hazards:

Being struck by the crane, load, truck, or forklift tipping.

Pinched fingers when assembling equipment.

Burns from cutting and welding on the drilling nipple.

Temporary eye irritation from welding light flash.

Falling from heights.

Possible Solutions:

Instruct all workers in safety procedures and ensure that they are knowledgeable about job hazards. This can be done during pre-job safety meetings or JSA briefings.

Instruct workers to stand clear and keep hands and other body parts away from pinch points.

Wear proper long sleeve clothing to protect from burns.

Wear proper welding eye/face protection.

Avoid looking directly at the flame or arc when welding.

Wear fall protection when working from heights.



Setting up the rig floor and mast or derrick Once the substructure is set in

place, the process of setting up the rig floor begins. Begin by installing stairways and guardrails to allow access to the rig floor. Then, the draworks is set in place and secured to the substructure. On mechanical rigs, the engines are set in place and the compound and associated equipment connected to the draworks. On electric rigs, the electric cables (lines) are strung to the draworks.

The bottom of the mast is raised to the rig floor and pinned in place. The crown section is then raised into place on the derrick stand. The "A-legs" are raised and pinned into place. The monkey board is pinned in place on the mast and all lines and cables are laid out to prevent tangling when the mast is raised. A thorough inspection of the mast

should be made before raising the mast/derrick. The mast is now ready to be raised. The engines are started, and the drilling line is spooled onto the draworks

drum. Once the mast has been raised and pinned, the remaining floor equipment can be set into place. If the rig has safety guy-lines, they must be attached to the anchors and properly tensioned prior to continuing the rigging up process. A derrick emergency escape device is installed on the mast.

Figure 25: Setting the crown on the derrick stand

Figure 23: Setting the mast on the rig floor

Figure 24: Raising the doghouse and drill floor


The Wee Land Rig Handbook. Figure 26: Rigging up the mast Potential Hazards:

Falling or tripping during rigging up.

Falling from rig floor. Being struck by swinging

equipment. Being struck by falling

tools. Being crushed or struck

by equipment due to failure or overloading of hoisting equipment.

Getting entangled in lines during raising of the derrick or mast. Failure to properly install derrick emergency escape device.

Possible Solutions:

Figure 27: Raising the mast Install, inspect, and secure stairs and handrails.]

Do not use guardrails for anchor points or for lifting or supporting loads.

Use fall protection when installing or removing guardrails.

Use a tag line to guide equipment, rather than positioning yourself under suspended loads.

Check the derrick for unsecured tools before raising it. Allow only the operator raising the mast to be on the rig floor. Uncoil all lines so that they are clear of all workers when the

mast or derrick is raised. Attach safety lines to all tools hanging from the rig. Keep a safe distance from moving equipment. Install derrick emergency escape device properly in accordance

with manufacturers recommendations.



Installing handrails, guardrails, stairs, walkways, ladders Handrails, guardrails, stairways, walkways, and ladders are installed where they are needed for safety and access. Potential Hazards:

Figure 28: Stairways, guardrails and ladders

Falls from ladders. Falls or slips from ladders

and stairs due to damaged or missing rungs or steps.

Slips or falls on walkways due to debris or uneven surfaces.

Falls from heights. Falling into the mud pit or mixing tank.

Figure 29: Stairways Possible Solutions:

Follow established procedures and best work practices.

Instruct workers on proper procedures for using and installing ladders.

Use only ladders in good repair that do not have missing rungs.

Do not install stairs with missing or damaged steps. Repair them before installing them.

Keep walkways clean and free of debris and tripping hazards. Use proper fall protection. Place guardrails in place prior to working in elevated areas.



Installing the power system Installing the power system is usually done simultaneously with setting up the rig floor, because power is needed to operate the equipment. Today there are generally two types of rigs being used on land. A mechanical rig is powered by engines and compound. An electric rig is powered by engines and generators. This type supplies power to electric motors, which drive the machinery. All power cords, belts, and chains need to be connected to the machinery from their associated power source. Simultaneously, the fuel lines and tanks need to be hooked up. Then, start the engines.

Figure 30: Engines and generators

Potential Hazards:

Tripping on power cords and hoses.

Slips and falls on slick walking services.

Getting caught in pinch points.

Exposure to chemical hazards.

Being shocked or electrocuted.

Possible Solutions:

Keep all cords and hoses orderly and clear of walking spaces.

Clear and clean all walkways and walking surfaces of slipping hazards.

Use caution around all chain and belt pinch point areas. Install all guards.

Figure 31: Power house

Use proper PPE when working with chemicals.

Use proper lockout/tagout/ procedures



Rigging up the circulating system While one crew finishes preparing

the rig floor, another crew might be rigging up the mud circulating system. This is further explained in a separate section. The mud tanks and mud pumps are set into the predetermined location. The mud lines are then connected and electric cords are strung. Potential Hazards:

Figure 32: Mud pumps

Being struck by or crushed by equipment being set into place. Getting caught in pinch

points.

Figure 33: Mud system

Being struck by crane, load, truck or forklift tipping.

Being struck by hammer when connecting mud line unions.

Possible Solutions:

Keep a safe distance from equipment that is coming together or moving.

Maintain a safe distance from all pinch points. Stand clear of workers that may be swinging hammers.



Installing the Auxiliary Equipment All remaining drilling and auxiliary equipment must be set into place and installed where needed. The catwalk and pipe racks are positioned and the pipe and drill collars are set on the racks. Potential Hazards:

Figure 34: Tubulars on pipe racks

Getting struck or pinched by, or caught in between, tubulars being loaded onto racks.

Having feet pinched or crushed when setting up the pipe racks and catwalk.

Figure 35: V-door, pipe ramp, pipe-rack & catwalk

Possible Solutions:

Keep a safe distance from equipment that is coming together.

Use a tag line to guide the pipe racks and catwalks into position.



Inspecting the rig Perform a complete inspection of the rig before operating. The driller and/or rig

Figure 36: Inspecting the rig

Superintendent / toolpusher / manager should walk around the entire rig and inspect for missing or loose pins and bolts, equipment guards, adequate guard railings, proper line and cable placement, and unclear walkways. Potential Hazards:

Figure 37: Inspecting rig equipment

Falling from the rig.

Tripping on power cords and hoses.

Slipping and falling on slick walking services.

Possible Solutions:

Use proper fall protection.

Keep all cords and hoses orderly and clear of walking spaces.

Clear and clean all walkways and walking surfaces of slipping hazards.



Rigging down After production casing is run and cemented, the rig is taken down and moved to another site. The rigging down process is basically the reverse of rigging up. The hazards and solutions are similar to those for rigging up. Figure 29 presents a land rig rigged up and ready to commence operational activities. In addition figure 30 further presents a more modern modular land rig and all its components. Figure 38: Typical light land rig.


The Wee Land Rig Handbook. Figure 39: A modular land rig schematic with all modules as numbered.



Drilling ahead

Handling Tubulars The pipe is unloaded from trucks onto the pipe-rack. The floor crew brings pipe from the pipe rack and catwalk, using the cat-line, air hoist or hydraulic winch, up to the drilling floor and places it in the mouse-hole. This is done for every connection. Note: The rig supervisor should hold a pre-job meeting with the crew to review responsibilities and to coordinate the operations to be performed. Potential Hazards:

Being struck by rolling or falling tubulars.

Figure 40: Loading Tubulars

Being struck by or caught between tubulars and other objects during movement (for example, being struck by tubulars being tailed into the rig floor).

Slips, trips, and falls.

Possible Solutions: Figure 41: Cat-walk, pipe-rack and V-door

Use powered industrial truck (forklift) properly.

Work the tubulars from the ends from ground level.

Chock or pin tubulars on the racks properly.

Level your pipe racks properly.

Stand clear of suspended, hoisted, or moving loads. Be aware of tubulars or equipment being lifted through the V-door.


The Wee Land Rig Handbook. Potential Hazards:

Getting struck by falling tubulars due to lifting equipment failure. Possible Solutions:

- Instruct workers in the need for proper use, inspection, and maintenance practices. Before each tour inspect the:

- Wire rope and slings, - Cat-line ropes and knots (do not allow a rope to lie in standing

water), and - Chains and hooks. - Stand clear of suspended, hoisted or moving loads and be aware

of your surroundings.

Figure 42: Typical drilling 'Mud' fluid Preparing the drilling fluid Drilling fluid is an important component in the drilling process. A fluid is required in the wellbore to:

Cool and lubricate the drilling bit,

Remove the rock fragments, or drill cuttings, from the drilling area and transport them to the surface,

Counterbalance formation pressure to prevent formation fluids (i.e. oil, gas, and water) from entering the well prematurely (which can lead to a blowout), and

Prevent the open (uncased) wellbore from caving in.

Figure 43: Mixing pump and hopper

The mud is monitored throughout the drilling process. A mud engineer and/or the Derrickman may periodically check the mud by measuring its viscosity, density, and other properties.


The Wee Land Rig Handbook. Potential Hazards:

Figure 44: Typical chemical mixing container

Burns, or physical injury caused by contact with skin or eyes.

Being exposed to explosions or violent reactions from chemicals mixed improperly.

Being exposed to inhalation hazards. Receiving strains and sprains. Slips, trips and falls.

Possible Solutions:

Ensure workers follow the safe handling procedures found in Material or appropriate Chemical Handling Safety Data Sheets

Wear appropriate personal protective equipment, including, eye and face protection.

Wear appropriate respiratory protection when handling chemicals and/or mud additives.

Provide an eyewash station and other appropriate flushing apparatus as recommended by the MSDS.

Provide adequate ventilation. Use proper mixing procedures. Use designated containers for mixing certain chemicals (for

example, baffled container with lid). Substitute less hazardous materials or use pre-mixed mud.

Note: Tank cleaning is a high-hazard operation requiring confined space entry procedures, training for personnel, PPE, and specialized equipment.



RP54, Occupational Safety for Oil and Gas Well Drilling and Servicing Operations. American Petroleum Institute (API), (1999, August 1). Includes procedures for promotion and maintenance of safe working conditions for employees engaged in rotary drilling operations and well servicing operations, including special services. Applies to rotary drilling rigs, well servicing rigs, and special services as they relate to operations on locations.

Accident Prevention Guide. International Association of Drilling Contractors (IADC).

Drilling Technology Series, Petroleum Extension Service (PETEX), University of Texas at Austin.

Unit I: The Rig and Its Maintenance Unit II: Normal Drilling Operations Unit III: Non-routine Operations Unit IV: Man Management and Rig Management

Starting Drilling Figure 45: Lowering the drill bit on a drill collar

To start drilling, a surface drill bit is attached to a bottom-hole drill collar, which is in turn attached to heavy weight drillpipe and then drillpipe until the required length of drillstring** is run to the bottom of the wellbore where the kelly is then finally made up and attached. Once the complete drillstring and all the required components are made up made up, the driller attached the kelly and lowers the drillstring and kelly through the rotary table and engages the mud pump(s) to check for leaks and other abnormalities. The driller lowers the drill string and the kelly busing is set in the rotary drive bushing and the rotary table or top drive is then engaged. The driller then slowly lowers the rotating drillstring and bit to bottom and begins the drilling operation. # ] ** A drillstring can be made up to typically consist of of: Bit, Drill collars, MWD tools, LWD tools, Stabilizers, Floats, Heavy Weight Drill Pipe, and Drill pipe. MWD = Measurement while drilling tools LWD = Logging while drilling tools.




Drill Collars Drill-collars DC as illustrated in figure 36 are heavy, large diameter pipe. Their primary purpose is to provide both stiffness and rigidity to dampen dynamic drillstring effects as weight is applied to the bit. e.g. vibration, side loadings etc. Drill-pipe itself is not able to withstand any compression, as the pipe would buckle. Therefore it is important to keep the drill pipe in tension at all times particularly in vertical wells. This is achieved by use of the stiffer more rigid Drill Collars that can be placed in compression with minimal detrimental effects. Also by keeping the neutral point of the drill string within the drill collars the drill pipe will always be in tension and thus not prone to unwarranted cyclic stress or fatigue loadings. Figure 46: Typical dril collar

Stabilizers Stabilizers as presented in figure 37 are used to keep the drill string in the centre of the hole. A bit will always be of a larger diameter compared to the drill collars. Stabilizers can also be sized and shaped for directional drilling needs to allow the drill string the ability to follow a certain build or drop in angle bend as a result in change of RPM and weight on Bit. Figure 47: Drillstring stabilizer


Heavy Weight Drill Pipe Figure 48: Heavy weight drillpipe (HWDP) Heavy weight drill pipe HWDP are used as the transition pipe between the Drill Collars and the Drill pipe. This is due to the stiffness of the drill collars and the flexibility of the drill pipe. In higher angle and horizontal wellbore more HWDP will be run and less drill collars in the bottom hole assembly.

Drill Pipe Drillpipe constitutes the longest section of the drill string and serves two primary functions i.e.

1. Provides a conduit for the drilling fluid (mud), to be able to transport the mud from surface down to the bit.

2. Allows transmission of rotation power via a rotary table or top drive to drillstring, ultimately allowing the bit to be rotated so drilling can ensure.

Average drill pipe sizes are: 3-, 4-1/2, 5, 5-, 5-7/8 and 6-5/8. Drill pipes are also available in different steel grades and weights. E.g. E-95, S-135. Weight is expressed in pounds per foot e.g. 5DP @ 19.5lbs/ft. The drill pipe used is also dependent on the diameter of the hole and the tensile strength required. The wall thickness of drill pipe is quite small, 1/2. This does leave much material to cut thread in, so therefore both end of the pipe are fitted with special threaded end. These ends are called a tool joint. Potential Hazards:

- Being struck by the tongs, the make-up chain, or pipe. - Being caught between collars and tongs, spinning chain, and

pipe.



Implement an effective pipe handling, make-up, break-out procedure:

Stand outside the tong swing radius when breaking pipe. Use proper tong latching techniques and use proper hand

and finger placement on tong handles Stand clear of the rotary table when it is rotating. Use a tail rope on the spinning chain to keep hands away.

Potential Hazards:

Receiving strains and sprains during lifting or controlling movement of drill collars, bit breaker, pipe, and tongs.

Possible Solutions:

Use proper lifting technique. Hoist slowly to limit pipe momentum. Use mechanical lifting aids such as a rig floor winch. Use tail rope to guide as necessary.

Potential Hazards:

Slips, trips, and falls. Possible Solutions:

See slips, trip and falls in general health and safety section. Potential Hazards:

Encountering shallow gas Possible Solutions:

See well control Ref. Blowout prevention program.



International Association of Drilling Contractors (IADC), (2006) and other bodies e.g. IWDF. ensure that well control training schools adhere to a core curriculum developed by industry.

Bits

Bits can be of different designs, depending on their purpose. The roller cone bit illustrated in figure 40 is a milled tooth type with tungsten carbide insert cutters. PDC bits as illustrated in figure 42 i.e. Poly-crystalline diamond compact bit are also used to provide more durability as illustrated above.

Figure 49: Roller Tri-cone bit Figure 50: Pumping through bit at surface

Figure 51: PDC bit


The Wee Land Rig Handbook. Rotating Systems A conventional rotating system consists of:

1. Rotary table 2. Master bushing with insert bushings 3. Swivel Kelly and Kelly drive bushing.

Figure 52: Top drive system 'TDS' All these components are now on modern rigs and new builds been mainly replaced with one piece of equipment called the TOPDRIVE (NOV) or as Maritime Hydraulics calls it: The Derrick Drilling Machine.

A top-drive consists of an electric or hydraulic motor, sometimes two, which, via a gearbox, drive a small piece of pipe called a Quill. Underneath the Quill the IBOP and the Lower Safety Valve (Kelly valve) are connected. Lower Safety valve is like the

IBOP a ball valve;

however this one is operated manually.

Figure 53: Master bushings

Nowadays rigs are still fitted with a rotary table but it is not used for driving purposes anymore. It is only used in rare occasions, for example during BHA handling. Inside the rotary table a set of master bushings is placed and within the master bushings a set of inserts bushings is placed.


The Wee Land Rig Handbook. Between the lower Kelly Valve and the drill pipe a saver sub is placed. The saver sub is intended as a sacrificial thread to protect the thread of the Kelly valve connection and to act as a crossover between the Kelly valve and the drill pipe.

Figure 54: Full operating safety valve

To shut of the drill string we either float valves installed deep in the string, near the bit. Or at surface an IBOP, Kelly Valve or full operated safety valve on the Top-drive or just below the swivel.

There are also tools available for closing the drill string when the top-drive is unable to screw into the drill-pipe.

Figure 55: IBOP stab in valve.

For example during tripping operations (this is when the string is pulled out of the hole) and the Top-drive is in the top of the derrick. In such a case a safety valve is manually stabbed on top of the string and on top of that a one-way valve is fitted. (IBOP).



Making a connection Figure 56: Setting the drillstring slips into the rotary table bushings

Preparing to break out the pipe The driller stops the drill string from rotating, and hoists the drill string with the draworks until the kelly is out of the rotary table. The driller then shuts down the mud pump(s). The floor hands set the slips around the joint of pipe. The tongs are then latched onto the tool joints above and below the connection. Potential Hazards:

Pinching fingers or other body parts between slips or slip handles and rotary table.

Experiencing muscle strain from improper lifting technique.

Pinching fingers when latching the tongs onto the pipe.

Possible Solutions:

Implement effective, safe work procedures for using slips and tongs, which include:

Proper finger and hand placement on slip handles and tong handles

Proper stance and slip lifting techniques. Proper tong latching techniques



Breaking out the pipe The tongs and cathead are used to break out the pipe. Either the rotary table top drive or kelly spinner is used to spin the drill string or kelly to unscrew it from the drill pipe joint.

Figure 57L Breaking out drillpipe using the rig tongs Potential Hazards:

Being struck by:

- Swinging tongs if the tong dies fail, or the tong counterweight lines were to break

- The slip handles if the rotary table is used to spin the drill string

- Reverse backlash of tongs (backbiting) during spinning out operations

- The tongs if a snub line breaks or the tongs come unlatched

- Pipe Figure 58: Drill floor hazardous layout area diagram when using rig tongs

Possible Solutions:

Inspect tong dies, counterweight cables, and snub lines prior to each usage.

Implement an effective spinning out pipe procedure:

Personnel other than tong operators stand outside the tong swing radius when breaking pipe.

No one should stand in the red zone Ref. fig 37

Use proper tong latching


The Wee Land Rig Handbook. techniques and use proper hand and finger placement on tong handles.

Stand clear of the rotary table when it is rotating. Use special operational procedures when using a high torque

connection. Maintain good communication between floor crew and driller.

Potential Hazards:

Release of excess drilling mud resulting in skin contact, loss of footing, etc.

Possible Solutions:

Use a mud bucket to direct mud down into the rotary table. Close the mud saver valve on the kelly (if present).

Figure 59: Making connection in mouse hole Making up pipe in mouse-hole The crew swings the kelly out over the mouse-hole and stabs it into a new joint of pipe. The driller then spins up the kelly using the kelly spinner or spinning chain and the crew uses tongs to torque the joint. Potential Hazards:

Being struck or pinched by the kelly.

Losing footing while swinging the kelly out over the mouse hole and stabbing it into a new joint of pipe.

Being struck by or caught in the spinning chain.



Figure 60L Pipe in mouse hole ready for next connection Use proper hand placement

Keep the work area around the rotating table clean and clear of mud, ice, snow, debris and other materials that may cause slipping or tripping.

Inspect chain for broken or distorted links. Chains with the metal reduced by wear at any point less than 90 percent of its original cross section area should be discarded.

Lubricate and maintain guide rollers to prevent undue wear on the chain or cable.

Raising the kelly and making a new connection The driller uses the draworks to raise the kelly and attached joint out

of the mouse hole.

Potential Hazards:

Figure 61: Raising the travelling equipment and kelly to make a connection

Being struck by debris or overhead objects if the traveling block runs into the crown block or if the traveling block or swivel hits the derrick.

Being struck by kelly or pipe.

Possible Solutions:

Install a crown safety device on the draworks and ensure proper functioning.

Keep personnel clear of the potential swing path of the kelly and pipe.



Adding pipe to the string The new joint is guided over to the drill hole, the tool joint is doped, and stabbed into the end of the pipe suspended in the rotary table with the slips. The joints are threaded together using the pipe spinner, kelly spinner, or spinning chain. Final torque is provided by the tongs. The draworks lifts the kelly and attached string to facilitate removal of the slips. Potential Hazards:

Figure 62: Applying dope to a tubular connection

Being struck by: Swinging kelly and pipe Figure 63: Pulling slips Tongs if the stabber

misses the stump The jerk or spinning chain

Being caught between the swinging pipe and the tongs.

Being caught between the joint of pipe being stabbed and the stump.

Getting pinched between tongs or pipe spinner and pipe. Slips, trips, and falls.

Possible Solutions:

Never step over a jerk chain and stay clear of spinning chain when a connection is being made.

Keep hands away from end of stump or inside of pipe. Keep feet and legs away from underneath tongs when the pipe is

being stabbed. Use proper tong latching techniques and hand and finger

placement on tong handles. Never stand or walk under suspended loads.


The Wee Land Rig Handbook. Keep the work area around the rotary table clean and clear of

drilling fluids, mud, ice, snow, debris, and other materials that may cause slipping or tripping.

Inspect chains for worn or damaged links, and replace a chain having a broken or distorted link with the metal reduced by wear at any point less than 90 percent of its original cross section area.

Resuming drilling Figure 64: Lowering the kelly bushing into the rotary table to resume Rotary Drilling Operations

The driller starts the pump and picks up off the slips. The drill

crew then removes the slips. The driller lowers the string until the kelly drive bushing engages the master bushing. Once the bushings are in place, the driller begins rotating the drill string, lowers the bit back to bottom, and continues making hole. Potential Hazards:

Being thrown off the rotary table when engaged.

Getting caught by loose clothing.

Possible Solutions:

Stand clear of the rotary table.



Mud circulating system Mud serves a couple of important functions within the drilling process:

- Well control, a column of mud of the correct mud weight keeps the well stable. The mud weight is always chosen to provide sufficient overbalance in relation to the formation pressure.

- Cooling the Bit - Transport Cuttings to surface

A mud circulation system as illustrated in figure 24 would typically consist of the following components:

Figure 65: Mud circulation system

1. Mud pits 2. Charge pumps 3. Mud pumps 4. Standpipe manifold 5. Standpipe hose 6. Swivel , wash pipe 7. IBOP (Mud Saver

Valve) in Top drive 8. Drill string 9. Annulus 10. B.O.P. 11. Flow line, 12. Flow divider 13. Shakers 14. Treatment tanks

Mud pits Mud Pits can be seen as plain storage tanks. They have a couple of connections to various suction lines (described later on) and a couple of return lines. They are also fitted with big mixers which will prevent the barite from falling out. Barite is the weighting material used for increasing the mud weight.

Charge pumps Charge pumps are connected to the mud pits and provide mud to the mud pumps. Charge pumps are needed since a gravitational feed directly from the pit will not provide the mud pumps with sufficient flow.



Figure 66; Example of a triplex mud pump Mud pumps Mud pumps can be described as big triplex plunger pumps. They can operate up to 7500 psi; can be AC or DC driven with a power range up to 2200hp. The loc400 is fitted with 800hp pumps with a Pmax of 5000psi with 4liners.

Figure 67: Cross section of a triplex mud pump



Standpipe manifold / Standpipe The Standpipe manifold is located on the drill-floor; from here the driller can line-up the mud pumps to the Top-drive or kelly. This is also the place where the gauges are fitted which shows the driller the mud pressure, also referred to as the Standpipe Pressure.

Standpipe hose The standpipe hose connects the standpipe to the top-drive or kelly.

Swivel, wash pipe

The top drive or rotary table and kelly via a kelly master bushing is rotating the drill string.

Figure 68: Wash-pipe

The wash pipe provided a circulating conduit link needed between the high pressure circulating system mud pumps the rotating system and the drillstring. It does this by providing a high pressure swivel and sealing capability between the stationary part (where the standpipe hose is connected) and the rotating part to which the drill string is connected.



Drilling fluid flow path Figure 69: Fluid flow through bit and wellbore annulus As illustrated in the circulating system the

drilling fluid is pump via the mud pits, circulating lines down the drillstring through the drilling assembly and eventually exiting out of the bit. Here, the bit is fitted with nozzles of a specific size. Nozzles clean the bit and the bottom of the wellbore thereby increasing the efficiency and effectiveness of the cutting removal process by jetting the cuttings from the bit and bottom of the well. Once fluid flow exits the bit is then enter what is termed the wellbore annulus.

The annulus is geometrical section clearances that exist between the bottom-hole assembly, drillstring, drill pipe etc and the wellbore formation or casing, riser, diameters.

Separating mud from cuttings

To re-clarify Drilling mud is therefore used to control the subsurface pressures, lubricate the drill bit, stabilize the well bore, and carry the cuttings to the surface, among other functions.

The mud flow path is for Mud to be pumped from the surface through the hollow drill string, exits through nozzles in the drill bit, and returns to the surface through the annular space between the drill string and the walls of the hole.

As the drill bit grinds rocks into drill cuttings, these cuttings then become entrained in the mud flow and are carried to the surface. In order to return the mud to the re-circulating

Figure 70: Recirculation system.


The Wee Land Rig Handbook. mud system as illustrated in figure 61 and to make the solids easier to handle, the solids must be separated from the mud.

On top of the BOP low pressure piping is fitted. A funnel shaped piece is fitted at the top and serves as a guide for the tools which are lowered into the well. This is also called the Bell Nipple.

Figure 71: Drilling mud exiting the surface flowline

On the Bell nipple side outlets are fitted which permit the drilling fluids to flow though the flow-line to the flow divider.

The flow line is just a large diameter pipe which connects the bell-nipple to the flow divider. Figure 72: Flow divider prior to shale shakers

The Flow divider is meant to provide each shaker with an equal amount of mud, this to prevent one shaker to overflow whilst the others are not getting any mud at all.

The first step in separating the cuttings from the mud involves circulating the mixture of mud and cuttings over vibrating screens called shale shakers.

The liquid mud passes through the screens and is recirculated back to the mud tanks from which mud is withdrawn for pumping down-hole. The drill cuttings remain on top of the shale shaker screens; the vibratory action of the shakers moves the cuttings down the screen and off the end of the shakers to a point where they can be collected and stored in a tank or pit for further treatment or management.


The Wee Land Rig Handbook. Figure 73 : Shale shakers removing cuttings from drilling mud

Often two series of shale shakers are used. The first series (primary shakers) use coarse screens to remove only the larger cuttings. The second series (secondary shakers) use fine mesh screens to remove much smaller particles.

In general, the separated drill cuttings are coated with a large quantity of drilling mud roughly equal in volume to the cuttings.

Figure 74: Mud tank storage Additional mechanical processing is often used in the mud pit system to further remove as many fine solids as possible because these particles tend to interfere with drilling performance. This mechanical equipment usually belongs to one of three types: 1) Hydro-cyclone-type de-silters and de-sanders, 2) mud cleaners (hyd-rocyclone discharging on a fine screened shaker), and 3) rotary bowl decanting centrifuges. The separated fine solids are combined with the larger drill cuttings removed by the shale shakers.


The Wee Land Rig Handbook. Figure 76: Vertical cuttings dryer Figure 75: Example of Dried cuttings

If the solids collected by the shale shakers are still coated with so much mud that they are unsuitable for the next reuse or disposal step or if the used mud is valuable enough to collect as much of it as possible, the solids can be further treated with drying shakers utilizing high gravitational separation, vertical or horizontal rotary cuttings dryers, screw-type squeeze presses, or centrifuges. The cuttings dryers recover additional mud and produce dry, powdery cuttings.

Figure 77: Centrifuge


The Wee Land Rig Handbook. Drilling Fluids

Drilling fluid functions Drilling fluid is an important component in the drilling process. A fluid is required in the wellbore to: Figure 78: Drilling Fluid (mud) in a mud pit

- Cool and lubricate the drill bit

- Remove the rock fragments, or drill cuttings, from the drilling area and transport them to the surface,

- Counterbalance formation pressure to prevent formation fluids (such as oil, gas, and water) from entering the well prematurely (which can lead to a blowout), and

- Prevent the open (uncased) wellbore from caving in.

Drilling fluids types There are several types of drilling fluids used depending on the drilling conditions encountered:

- Water-based muds are used most frequently. The base may be either:

o fresh water, or salt water. - Oil-based muds. - Synthetic materials. The oil and gas extraction industry has

developed many new oleaginous (oil-like) base materials from which to formulate high-performance drilling fluids.

- A general class of these fluids is called synthetic materials, such as

o The vegetable esters, o Poly alpha olefins, o Internal olefins, o Linear alpha olefins, o Synthetic paraffins, o Ethers, and others.

- Air and foam fluids may be used in drilling wells. o These fluids are less dense than drilling muds.


The Wee Land Rig Handbook. Drilling Fluid additives Drilling muds typically have several additives. (Air and foam fluids typically do not contain many additives because the additives are either liquid or solid, and will not mix with air and foam drilling fluids.) The following is a list of the more significant additives:

- Weighting materials, primarily barite (barium sulfate), may be used to increase the density of the mud in order to equilibrate the pressure between the wellbore and formation when drilling through particularly pressurized zones. Hematite (Fe2O3 ) sometimes is used as a weighting agent in oil-based muds (Souders, 1998).

- Corrosion inhibitors such as iron oxide, aluminum bisulfate, zinc carbonate, and zinc chromate protect pipes and other metallic components from acidic compounds encountered in the formation.

- Dispersants, including iron lingosulfonates, break up solid clusters into small particles so they can be carried by the fluid.

- Flocculants, primarily acrylic polymers, cause suspended particles to group together so they can be removed from the fluid at the surface.

- Surfactants, like fatty acids and soaps, de-foam and emulsify the mud.

- Biocides, typically organic amines, chlorophenols, or formaldehydes, kill bacteria and help reduce the souring of drilling mud.

- Fluid loss reducers include starch and organic polymers and limit the loss of drilling mud to under-pressurized or high-permeability formations.



Tripping in and out Tripping refers to the process of removing and/or replacing tubulars to or from the well when it is necessary to change the bit, Downhole tools or equipment or when preparing to run certain tests in the well bore. The activities that comprise tripping are outline in this section

Figure 79: Setting back a stand of tubulars in the drilling derrick

Every time a connection has to be made, the top drive or kelly has to be disconnected from the drill string. To make this possible, the drill string is hung of in the rotary table. This is done by means of the slips. Slips are wedge shaped devices which are fitted with dies. The insert bushings of the rotary table have the same wedge shape and provide support to the slips. Once the slips bite the driller can unscrew the top drive or kelly and hoist it all the way up into the derrick. The Drill pipe is brought to the drill floor by use of a winch or pipe handler. This is an automated piece of equipment. On manual rigs pipe was pulled up the floor by use a tugger and placed onto the drill-string by hand. The new joint is placed on top of the drill-string and will be made up with the manual rig tongs or with an automated roughneck



Tripping out Setting the slips The floor crew sets slips around the drill stem.

Figure 80: Setting the slips Potential Hazards:

Getting fingers or other body parts pinched between slips or slip handles and rotary table.

Receiving muscle strain from improper lifting technique.

Possible Solutions:

Use proper hand placement when setting slips.

Use proper stance and slip lifting techniques. Slips have three handles and should be lifted jointly by more than one person.


The Wee Land Rig Handbook. Breakout the kelly and set it into the rat-hole. Potential Hazards:

Figure 81: Kelly set in its rat-hole in readiness to trip pipe - Release of excess drilling mud

resulting in skin contact, loss of footing, etc.

Possible Solutions:

- Shut down the mud pumps before breaking out the kelly.

- Close the mud saver valve on the kelly (if present).

- Use a mud bucket to divert flow of excess mud.

Potential Hazards:

Being struck by the slip handles if the rotary table is used to spin the drill string.

Possible Solutions:

Stand clear of the rotary table when it is rotating.

Consider other technologies (such as a pipe spinner, kelly, top drive unit ) to eliminate this hazard.

Potential Hazards:

Being struck by the kelly if the pullback line unhooks when kelly is being pulled toward the rat-hole.

Possible Solutions:

Implement an effective pullback line attachment procedure. Ensure workers stand in a safe location away from the pullback

line and rat-hole during this pullback operation.


The Wee Land Rig Handbook. The crew attaches elevators to the drillstring.

Potential Hazards:

Figure 82: Example of elevators and elevator links

Being pinched by the elevator links while attaching elevators (or attaching elevator links to the hook).

Being struck by the elevators. Receiving strains and sprains.

Possible Solutions:

Use proper hand placement when attaching elevator links. Ensure workers stand away from swing-path of the elevators and

elevator links. Use lifting equipment and limit manual positioning of elevators. Use proper mounting procedures.


The Wee Land Rig Handbook. The floor crew latches the elevators onto the pipe. Potential Hazards:

Getting hands or fingers pinched in elevators. Being struck by elevators not securely latched. Getting hands or fingers caught between elevators and stump.

Possible Solutions:

Ensure workers are instructed in proper latching procedure, including the use of handles on elevators as they are descending into place over the stump or tool joint.

Inspect and maintain elevators.

Figure 83: Climbing derrick ladder to monkey-board Working in the monkey board The derrick-man climbs up the derrick to the monkey board. From here he unlatches the elevators and guides the stands of pipe into the fingerboard. The elevators are then lowered and attached to the next stand of pipe. Potential Hazards:

Falling while climbing up or down the ladder.

Falling from monkey board or fingerboard. Slips, trips, and falls. Falling during an emergency descent.

Possible Solutions:

Use climb assist device. Wear appropriate fall protection including a full body harness.

For Fall Protection guidance, consult, Fall Protection when working from platforms documents.

Reference appropriate Fall Protection guidelines. Wear the proper Personal Protective Equipment (PPE) such as: Hard hat Work gloves Safety-toed footwear


The Wee Land Rig Handbook. Practice 100% tie-off while

working in the derrick. Figure 84: Monkey board layout birds nest view

Use slip-resistant coatings or materials on working surfaces.

Train personnel in use of emergency escape device.

Potential Hazards:

Being caught between pipe and other objects

Receiving strains and sprains. Figure 85: Handling pipe on the monkey-

board

Possible Solutions:

Practice proper hand placement and use of pullback (tail) ropes.

Potent

Rig Processes

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