HAZARD IDENTIFICATION & RISK ASSESSMENT AT

CBM DRILLING SITE

A Project Report Submitted in Partial Fulfillment of the

Requirements for the award of the Degree of

MASTER OF TECHNOLOGY

IN HEALTH, SAFETY AND ENVIRONMENT

By

MANSOOR SHAH KHAN

Under the Esteemed Guidance of

Dr. Nihal Anwar Siddiqui (Internal Guide) Assistant Professor, College of Engineering, U.P.E.S, Dehradun

Mr. Akbar Ziauddin Grad IOSH, MIIRSM. (External Guide) Executive - HSE & Trainer, Shiv-Vani Oil & Gas Exploration Services Limited. New Delhi.

DEPARTMENT OF HEALTH, SAFETY AND ENVIRONMENT COLLEGE OF ENGINEERING

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES DEHRADUN 2007 – 2009

HAZARD IDENTIFICATION & RISK ASSESSMENT AT

CBM DRILLING SITE

A Project Report Submitted in Partial Fulfillment of the

Requirements for the award of the Degree of

MASTER OF TECHNOLOGY

IN HEALTH, SAFETY AND ENVIRONMENT

By

MANSOOR SHAH KHAN

Under the Esteemed Guidance of

Dr. Nihal Anwar Siddiqui (Internal Guide) Assistant Professor, College of Engineering, U.P.E.S, Dehradun

Mr. Akbar Ziauddin Grad IOSH, MIIRSM. (External Guide) Executive - HSE & Trainer, Shiv-Vani Oil & Gas Exploration Services Limited. New Delhi.

DEPARTMENT OF HEALTH, SAFETY AND ENVIRONMENT

COLLEGE OF ENGINEERING

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES DEHRADUN 2007 – 2009

CERTIFICATE This is to certify that Mr. MANSOOR SHAH KHAN, a student of M.Tech. (Health, Safety

and Environment) of UNIVERSITY OF PETROLEUM AND ENERGY STUDIES, DHERADUN has undergone his Project Work at SHIV-VANI OIL & GAS EXPLORATION SERVICES LIMITED, Bokaro (Jharkhand) from 01/06/2008 to 31/07/2008. His study on HAZARD IDENTIFICATION & RISK ASSESSMENT AT CBM DRILLING SITE is noteworthy.

During the project period, he was found very punctual and disciplined.

I wish him all success in life.

Akbar Ziauddin, Grad IOSH, MIIRSM. Executive - HSE & Trainer. Onkar Mal. GM - Training & Development.

CERTIFICATE This is to certify that Mr. MANSOOR SHAH KHAN, a student of M.Tech. (Health, Safety

and Environment), at UNIVERSITY OF PETROLEUM AND ENERGY STUDIES, DHERADUN has carried out final semester project titled HAZARD IDENTIFICATION & RISK ASSESSMENT AT CBM DRILLING SITE, at Shiv-Vani Oil & Gas Exploration

Services Limited, Bokaro (Jharkhand), during the period 01.06.2008 to 31.07.2008. The

work is certified to be bonafide.

Dr. NIHAL AMWAR SIDDIQUI (INTERNAL GUIDE) ASSISTANT PROFESSOR COLLEGE OF ENGINEERING, UNIVERSITY OF PETROLEUM AND ENERGY STUDIES, DEHRADUN.

CONTENTS

Chapter No Title Page No

1. HSE Policy & Objectives 1

2. Preface 2

3. Executive Summary 4

4. Introduction 5

5. Objectives 8

6. Literature Review 9

7. HSE Management Systems in Shiv-Vani 12

8. Drilling Operations 15

9. Blowout Preventor (BOP) 21

10. Methodology 33

11. Observations & Recommendation 39

12. Conclusion 50

Reference

Annexure – 1, HIRAC - CBM Drilling Site.

 

1  

HSE POLICY

The HSE policy is implemented through the company's strategies, action plans, management

commitment and loyal & active employee support. We carry out the following activities in order to:

• Ensure a safe & healthy work environment for all.

• Ascertain prudent use of natural resources and minimum environmental impact.

• Assure that all equipment and machinery are ready for safe & efficient operations.

• Comply with all applicable laws, regulations and permits.

• Encourage continual and progressive improvement in workplace safety, health and

environment.

HSE OBJECTIVES

The goal is to ensure that the HSE excellence at Shiv-Vani remains a continuous process so that we

may provide our customers with best industry performances. The HSE objectives for each E&P

solution are designed to eliminate lost time accidents and minimize environmental impacts. Our

objectives include:

• Ensuring employee protection against occupational risks, accidents, health hazards and

dangerous situations.

• Establishing a work environment that conforms to world-class health & safety standards.

• Integrating safety and health measures at every level - be it rig design, operational activities

or maintenance.

• Setting up Major Hazards Registers at all units.

• Implementation of OISD (Oil Industry Safety Directorate) standards (designing and

operations) at all units as per the Petroleum (Amendment) Rules, 2005.

• Providing adequate training on Health, Safety and Environmental responsibilities, ensuring

high training standards and building overall awareness.

• Encouraging active employee participation for enhancing work conditions and environment

management.

2

PREFACE

The oil and gas exploration and production arena is a diverse landscape of differing operating

and business environments, some with national regulations, some without and numerous

authorities regulating a variety of aspects of onshore activities. Many Drilling Contractors find

it challenging to satisfy the differing internal and external stakeholder expectations related to

HSE management each time their units are moved from one geographical location to another.

Drilling Contractors, Oil and Gas Producers and Authorities have seen the benefit of adopting

and sharing a consistent harmonized approach in providing HSE Management assurance to

meet various requirements.

Drilling contractors have historically managed HSE and operational risks. During the 1990’s,

many Drilling Contractors recognized that in order to achieve a step-change improvement in

safety and operational performance, they would have to formalize their long term experience

and work practices within a structured framework represented by a management system.

The development of an effective management system was to ensure appropriate risk

management efforts would be consistently applied by people at the worksite to manage Major

and Other Workplace Hazards to ensure safe and reliable operations.

In order to further improve the efficiency and effectiveness of business results, many Drilling

Contractors have integrated the management of HSE risks into their remaining business

activities.

HSE Management has two primary purposes:

1. Demonstrate internal assurance within the Drilling Contractor’s organization that its

management system’s risk reducing controls related to the Health, Safety and

Environment aspects of its operations, meets its senior management’s expectations.

2. and, where applicable: demonstrate to other interested / concerned parties, that the

risk reducing controls in the Drilling Contractor’s management system meet their

expectations too.

3

Purpose of hazard identification and risk assessment:

1. Identification of the sources of the HSE hazards included in the Drilling Contractor’s

Scope of Operations.

2. Assessment of the risks associated with hazards and sources of hazards and

effectiveness of the controls within the Drilling Contractor’s management system

(Documented and experienced based work practices). Verification to ensure that

identified risks are reduced to a level that does not exceed the Drilling Contractor’s

tolerability limits for safe operations

3. Verification of compliance with applicable regulatory and contractually agreed HSE

requirements

4

EXECUTIVE SUMMARY

Shiv-Vani Oil & Gas Exploration Services Limited is a leading exploration and production

service provider of India. The company has made a major entry into the largest project for

exploration of CBM resource in the country with the awarding of the largest contract in

collaboration with Express Drilling Services, LLC & MECL.

CBM Drilling Site is a hazardous place. Most of the activities involved working at heights,

machines, compressed air units, etc. which have major hazard potential it is necessary that

approved measures to be taken to ensure safety of personnel, equipment is taken into

account and safe work practices are there in the site. It is also necessary that environmental

impacts likely air water, soil, noise pollution arising from drilling activities be minimized.

The project basically looks into Hazard Identification and Risk Assessment at CBM Drilling

site, there potential impacts, and strategies for minimization were developed. An effort was

made to check and improve the safety at the workplace and also to improve the safety at the

workplace and also to improve the environmental, and safety awareness of people carrying

out various tasks.

5

INTRODUCTION

Incorporated in 1989, Shiv-Vani has rapidly evolved to emerge as a key player in the upstream

sector of the hydrocarbon industry. Headquartered in New Delhi (India), the company offers a

wide spectrum of services in the field of oil and natural gas exploration and production. From

shot hole drilling and seismic surveying through to directional drilling, well development, down-

hole operations, engineering and logistics - specialize in every area of onshore and offshore

operations, as well as in natural gas compression & allied services. The only integrated CBM

services provider in India and has successfully pioneered horizontal and directional drilling in

the country to enhance CBM procurement. The professional expertise combined with exclusive

know-how and advanced equipment, enables our clients to accomplish their objectives on time

and within budget.

Shiv-Vani commenced its operations in 1990, providing shot-hole drilling services to ONGC -

the largest and most prominent state-owned oil and gas exploration and production company,

in India. Over the next 10 years, the company has gained a position of strength and acquired a

large number of shot-hole drilling and workover rigs. Today, Shiv-Vani owns the largest fleet of

onshore rigs in India and has successfully diversified into other crucial activity areas such as

seismic surveying, gas compression services and offshore drilling & logistics.

At Shiv-Vani, we leverage latest technologies, invest extensively in people and infrastructure,

and build upon organizational capabilities to deliver world-class performance in operational

excellence and cost reduction - so that our valued clients may benefit from maximum flexibility

and optimum results. Our operational plans and strategies are well aligned with best industry

practices and conform to relevant quality standards to help corner success in each specific

business area. Shiv-Vani is an ISO 9001: 2000 certified company and its implementation

methodologies are constantly tested against market competition and re-aligned further for

sustained competitive performance.

To sustain its leadership position and win new markets, Shiv-Vani is aggressively pursuing

growth initiatives including global & domestic market expansion, diversification and revenue

generation. The company is listed with the Bombay Stock Exchange and the National Stock

Exchange of India, and has recently floated foreign currency convertible bonds (FCCB's) listed

on the Singapore Stock Exchange. Our strategic tie-ups and alliances with conglomerates in

Russia, USA, China, Malaysia, UAE, Canada and Germany, and the extensive business build-

up in the Middle East provide ample indication that we are moving towards the right direction.

Besides its strong presence in India and extensive working relationships with key corporations

like ONGC and Oil India Ltd., Shiv-Vani is pre-qualified to work for more than 25 oil and gas

exploration and production companies at home and abroad. The company is pre-qualified for

6

drilling and workover service contracts in such countries as Oman, Syria, Iraq, Sudan, Qatar

and Indonesia and seismic services in several countries like Iran. We are also targeting the

western markets such as the USA and the CIS.

At Shiv-Vani, our corporate responsibility calls for total compliance with all relevant

environmental, health and safety laws, policies and procedures. While we focus on effective

environment management, the health and safety of our workforce and all those associated with

us also remain the highest priority. Based on the IADC (International Association of Drilling

Contractors) regulations and other standard international norms which govern upstream

activities, the company has formed a comprehensive HSE Policy to ensure better health

preservation and safe working environment. With Shiv-Vani as their partner in growth, global

corporations are assured of cost-effective, tailor-made services on par with international quality

standards, while we take great pride in our professionalism, social responsibility &

environmental commitment

Shiv-Vani offers a wide spectrum of services in the field of oil and natural gas exploration and

production. From shot hole drilling and seismic surveying through to directional drilling, well

development, down-hole operations, engineering and logistics - we specialize in every area of

onshore and offshore operations, as well as in natural gas compression & allied services. We

are the only integrated CBM services provider in India and successfully pioneered horizontal

and directional drilling in the country to enhance CBM procurement. Our professional expertise,

combined with exclusive know-how and advanced equipment, enables our clients to

accomplish their objectives on time and within budget. Our major service areas include:

• Core Services

o Seismic Data Acquisition, Processing and Interpretation

o Drilling

o Workover

o Reservoir Data Acquisition

o Pipeline Construction

• Specialized Services

o Cementing

o Stimulation

o Logging

o Well Testing

o Directional Drilling

o Mud Engineering

• Integrated Services

o Integrated Seismic Services

o Integrated Drilling and Workover Services

o Integrated Well Maintenance

7

o Integrated Services for Oil & Gas Field

o Integrated CBM Services

• Coal Bed Methane

• Gas Compression & Allied Services

o Natural Gas Compression

o Gas Collecting / Group Gathering Stations

o CNG Booster Compressor

• Offshore

o Logistics

o Platforms & Structures

o Drilling

8

OBJECTIVES & SCOPE

• Identify HSE Hazards. • Assess the magnitude and significance of hazards. • To determine HSE risk levels by assigning levels to the severity of each potential

consequence and to the probability of the consequence occurring. • To eliminate occupational health hazards. • To prevent all accidents. • To prevent accidental discharges to the environment. • To ensure that all hazards and effects are formally identified and assessed in a

structural manner an that effective control measures are identified and implemented. • Implement control techniques to eliminate or minimise the hazard. • To ensure sustainable compliance with legislation and policy. • To achieve, enhance and demonstrate sound Health, Safety and Environment

Performance built around the principle of continual performance improvement.

9

LITERATURE REVIEW

Hazard Identification and Risk Assessment of Skin & Eye Irritation in a Manufacturing Industry in the Philippines: Continuing Study JL Lu National Institutes of Health, University of the Philippines, Manila. Background. This was an investigative study that looked into the exposure assessment of the

high reports of skin and eye irritation in an industry that employs 1,000 workers. This health

case reports had been observed for three years already.

Methods. The chemicals that were found to exceed the threshold limit value included sulfuric

acid, ethylene chloride, ally alcohol with carbonucleic acid, and isopropyl alcohol [1]. For the

exposure assessment, the following methodologies were used; measurement of solvent

concentration, ventilation measurement, assessment of capture velocities of exhaust ventilation

systems, and the use of personal protective equipments [2]. All workstations were measured,

and identified for possible association between skin and eye allergies and exposure to these

risk factors [3].

Results. Result showed that there was a relationship between eye and skin irritations and

every increase of solvent concentration, lower capture velocities, higher ambient temperature

and lower ventilation reading in the workstations. Based on the results of the study, exposure –

rating index was developed to serve as a guide for determination of risk and exposure risks, as

well as in the formulation of programs to prevent and control factors associated with eye and

skin allergies.

Exposure Rating Definition

Very Low (A) Exposures are negligible.

Low (B) Exposures are controlled because of effective engineering, medical

and environmental control measures.

Medium (C) Exposures are under control but strategies of control are not

completely assured to prevent adverse exposures and health

effects.

High (D) Exposures are not adequately controlled and exceed the

recommended level and exposure time.

Very High (E) Exposures are excessive due to absence of control and prevention

strategies and the adverse health effect is oh high probability.

Table: Proposed Exposure Rating Index

10

Conclusions. The study has shown that skin and eye irritations can be implicated by solvent

exposures. There is a need for exposure rating index to classify the work hazard and work

exposure of workers which is the fist step towards control and prevention of work related

illnesses (3).

Acknowledgement. National Institutes of Health, Philippines

Reference. • American Industrial Hydiene Association. Odor thresholds for chemicals with

established occupational health standards, Akron, OH, AIHA, 1-5 (1989). • Bilban M. Mutagenic testing of workers exposed to toluene-disocyanates during

plastics production process, American Journal of Industrial Medicine 5, 468-74 (2004). • Lai Z., Bonilla G., Diaz I., and Nery J. Microstructural optimization of a zeolite

membrane for organic vapour separation, Science 300, 456 (2003). Hazard Identification and Risk Assessment at IFFCO_AONLA by N.C. Nigam, A.K. Maheshwari & N.P. Rao. For any industry to be successful, it has become essential to identify the Hazards, to assess

the associated risk and to bring the risks to tolerable level. Recognizing this, IFFCO-AONlA is

continuously putting efforts for controlling the risks which are arising from various Hazards such

that loss to Human life and property is negligible or zero. Its continuous best efforts to identify

the Hazards and to bring the risk levels to tolerable level in the organization are recognized by

several Government and safety regulating bodies. This paper describes briefly and various

types of hazards and their associated risks, how they are being controlled effectively through

risk analysis at IFFCO – Aonia unit.

In all plants, hazards and risk are identified time to time by using modern techniques. IFFCO

Aonia unit is OHSAS – 18001 certified company. So in all departments / section risk hazards

are find out by proper risk assessments. During this severity at various levels matched with

probability level. And find out the case of intolerable, substantial, moderate and tolerable risk.

Accordingly control measures at the place checked. Documentation done and records are

maintained.

At IFFCO Aonia unit, HAZOP, HAZAN study, Dow Index, Risk Analysis, FMIA, Fault Tree

Analysis are carried out at its inception level. At IFFCO Aonia unit, various risk assessment

procedures are followed. This has been done by Dow Index method and Consequences

methods. At the same time when any process modification done / needed, then also proper

HAZOP studies and any other risk analysis studies are carried out to assess the risk due to the

effect of modification.

11

Now as IFFCO Aonia unit is OHSAS – 18001 certified company, in all sections / plants proper

hazards and risk assessment procedures and documentation done. Time to time. Plant /

section updates of this done and audited by other sectional persons. And again compliance

incorporated.

Conclusions. By effectively identifying the various types of hazards, doing the risk analysis

and controlling the risk, IFFCO-AONLA units is maintaining the accident free atmosphere for

both humans and plant / property.

12

HSE MANAGEMENT SYSTEMS IN

SHIV-VANI OIL & GAS EXPLORATION SERVICES LIMITED

HSE-MS encompasses the policies, programs, systems, procedures, standards, specification

etc. that are used to manage HSE activities. It describes the ways SVOGESL manages HSE

with respect to its stated objectives. The systems concentrate on critical activities and ensure

that they are properly controlled. Measurements are made and reported in order to monitor

performance and to identify areas for improvement if any.

Put simply, out HSEMS follows a QMS ISO 9001 – 2000 approach that strives to continuously

improve

• Plan : what needs to be done.

• Do : It.

• Check : it is being done.

• Review : To do it better.

At Shiv-Vani, we are fully aware that Health, Safety and Environmental protection remain the

responsibility of every individual and all our employees work dedicatedly towards this goal. The

company has set up an effective HSE Management System that closely follows the ISO 9000

standards and adheres to the regulations & guidelines of such globally acclaimed organizations

as the IADC. Based on reports and reviews, comprehensive HSE plans are chalked out every

month at the top management level and forwarded to all units/project sites for immediate

implementation. The company has further strengthened its HSE policy by introducing a

meticulous and well-integrated PTW System to regulate and monitor potentially hazardous

activities. In order to ensure adequate means for employee & environmental safety, Shiv-Vani

focuses on the following activities:

Risk Management

Identifying & evaluating HSE risks and implementing effective methods for risk reduction.

Safety planning

Planning and preparing safe working procedures so that measures can be taken immediately to

implement necessary changes and ensure emergency preparedness

Implementation and monitoring

Setting up performance indicators, implementing corrective actions and ensuring stringent

monitoring to measure HSE effectiveness.

13

Audits and reviews

Inspection and assessment of system performance as per the annual HSE plan.

HSE Manual / Handbook

Providing each Shiv-Vani team member with an HSE manual/handbook (H.S.E. for All) – a

concise, comprehensive and structured description of our HSE Management System. The

personnel handbook specifies each individual's responsibility for sound safety and

environmental management, thus enabling the field staff to comply with best possible safety

practices and procedures.

Organizing, sourcing and documenting crucial information/data

Gathering and documenting HSE achievements and incidents for a thorough analysis and the

subsequent, systematic improvement in compliance with the laws of the land and the

established principles of Quality assurance.

More Measures

Shiv-Vani has successfully conducted a series of Hazard Awareness Programmes at all project

sites to help minimize health, safety and environmental concerns and decrease regulatory

compliance costs. Our priorities include enhancing HSE commitment and reducing risk levels in

order to build a good safety culture within the organization. Effective input from Client's

Company Man and PE's also helps ensure that international standard safety norms are

developed, implemented and followed without the least deviation. To encourage active

participation, thorough comprehension and fail proof practice of impeccable safety rules, we

have also introduced inspirational awards such as safe Man of the Month and Best STOP

Observer of the Month for each project location.

The company employs Safety Training Observation Programmes (STOP) as the primary

accident prevention tool. We promote thorough training and impeccable risk management

processes to help improve safety & security and reduce waste & emissions. As a result, our

employees are able to identify worksite hazards even better and meet challenges proactively -

leading to lesser incidents reporting and overall decline in the injury rate for employees on

mobile and permanent installations. There has been a significant reduction in TRC's (total

recordable cases including restricted work cases, medical treatment cases, LTI's and other high

severity personal injury incidents) and subsequent improvement in LTIF (lost time injury

frequency).

In a bid to develop a more objective and measurable basis for incidents management, the

organization has developed a strong and effective Incidents Reporting Structure so that all

14

incidents may be reported round the clock. Detailed investigations of all incidents are carried

out without any delay and prompt corrective actions are taken to avoid similar occurrences. Our

wide experience and cutting-edge expertise have also taught us that hazards are highly

avoidable and zero incidents, along with enhanced environment management, will propel us to

peak performance.

15  

DRILLING OPERATIONS DRILL PIPES ARE ADDED TO THE DRILL STRING AS THE WELL GOES DEEPER. THE SEQUENCES OF OPERATIONS ARE AS UNDER:

1. The drill pipe to be added is measured and the threads on both box and pin are cleaned

and thread protector put on the pin end.

2. Using a sling of manila rope or a lifter plug, the drill pipe is lifted and placed in the mouse

hole. Apply proper thread lubricant on the drill pipe threads.

3. After the Kelly length has been drilled, ream the hole, if considered necessary.

4. Stop mud pump and bleed the pressure in the high pressure line of mud by opening the

valve provided for bleeding pressure.

5. Lift the Kelly along with the drill string till the tool joint of the drill pipe just below the Kelly

appears above the rotary table. Remove Kelly bushings if not fitted with Kelly.

6. Rest the drill string on the slips so that height of the drill pipe tool joint is about 75 cm

above the rotary table.

7. Release drill string load so that the weight shown on the weight indicator is just equal to

the weight of the Kelly and travelling block.

8. Fix make up tong on the drill pipe tool joint and break out tong on the Kelly’s tool joint and

then break the joint.

9. After breaking the Kelly, lift it out and by giving a swing with hand bring it over the drill pipe

to be made up and then carefully stab the Kelly’s pin into the box of the drill pipe.

10. Using power sub or spinning rope tightens the Kelly to the drill pipe.

11. Lift the Kelly and the drill pipe out of mouse hole.

12. Open the thread protector from the pin end of the drill pipe.

13. Stab the drill pipe into the box of the drill pipe resting on the rotary after applying proper

thread lubricant.

14. Using spinning rope or power sub, tighten the drill pipe.

15. Lift the assembly and remove slip.

16. Lower the string and rest it on the slip when the box of the pipe to be added is about

75 cm above the rotary table.

17. Tighten the joint between Kelly and the drill pipe up to the required torque by using both

the tongs.

18. The weight on the drillometer will show increase as the threads are made up. It should be

released by slightly lowering the block so that the weight shown is equivalent to the weight

of the Kelly & block.

19. Lift the drill string and remove slip.

20. Lower Kelly and put Kelly bushes if not fitted to the Kelly.

21. Ensure that the Kelly rotates with the rotation of rotary table.

16  

PULLING OUT The process of removing the drill string out of the hole is called pulling out. The following steps

are taken while pulling the drill string out of the hole.

1. A slug of heavy mud of approximately 2-3 m3 is pumped into the drill pipe. It will ensure

that during the process of pulling out the rotary table remains dry while breaking out the

stands.

2. The mud pumps are stopped and bleeding valve is opened to bleed the pressure from

the drill string.

3. Kelly is lifted out of the hole and broken.

4. A thread protector is mounted on the threads of kelly saver sub. The kelly is kept in the

rat hole and the hook and the travelling block freed.

5. Elevator of proper size and rated capacity is suspended from the hook with the help of

links of required capacity.

6. Open the hook's swivel lock so that it can be rotated

7. The elevator is latched on to the drill pipe and the hook is lifted slowly till the snubber

spring comes in tension. After that the drill string is pulled to full load and the drill pipe

slip is removed.

8. Continue pulling out till one stand length has been pulled out.

9. Rest the drill s-ring on the drill pipe slip and release the load from the hook by lowering it

sufficiently. The drillometer readings will show to be equal to the weight of the empty

block.

10. Using both the tongs, crack the joint and remove lower tong.

11. Keeping the break out tong in tight position open the joint by the rotation of lower drill

string with the help of rotary table rotating in forward direction.

12. After the joint has been opened the drill pipe stand is lifted out.

13. The drill pipe stand should be pulled towards the finger side by the topman with the help

of manila rope.

14. The lower end of the drill pipe stand is pushed and set back at the racking platform by

the rig man.

15. After the drill pipe stand has been set at the racking platform, the driller should lower the

block so that the topman can unlatch the elevator.

16. The topman, after unlatching the elevator, pulls the pipe back to the proper position in

the finger board.

17. The elevator is again lowered on to the drill string and latched on the drill pipe resting on

the rotary table.

18. The process of pulling out drill pipe stand is repeated till the drill collar string reaches the

surface.

19. After pulling out 10 stands of drill pipes, the drill pipe wiper is installed. The hole should

be filled up to the top after pulling out every 5 stands.

17  

20. When the drill collar reaches the surface, the drill pipe slip is replaced by drill collar slip.

Before resting the drill collar on slip, drill pipe wiper is removed.

21. Put a safety clamp above the drill collar slip (in case of drill collar without recesses) and

break out the last drill pipe stand and stack the same.

22. If drill collars do not have a neck, lifting sub of the proper size is made up on the drill

collar and tightened properly after latching elevator on the lifting sub.

23. If elevators handling drill pipes cannot handle the lifting sub then change the elevator with

the one required.

24. Open safety clamp.

25. Pullout one stand of drill collars (the drill collar body should be washed with water).

26. After cracking the drill collar stand, open the joint by rotation of the upper drill collar stand

with the help of chain tong.

27. While opening the joint care should be exercised to ensure that the hook is kept in

sufficient tension to allow the rotation of the drill collar stand with the least load of it on to

the threads.

28. After the joint has been fully opened, the drill collar stand is lifted and stacked on the

racking platform.

29. Do not rest drill collar stand on rotary table to facilitate pulling of drill collar towards

topman. Use winch line for placing the drill collars at racking platform.

30. Continue pulling out the drill collars, filling hole after pulling out each stand.

31. If bit cannot be pulled out without removing the master bushings then the same are

removed and the bit is pulled out and master bushing put back in position.

32. Place the bit breaker corresponding to the bit size in the rotary drive bushing. Lower the bit

into the bit breaker. Lock the rotary table. Break off the bit connection by jerk line pun on

tong latched around the drill collar. Unscrew the old bit manually keeping bit breaker on

the rotary table.

NOTE: The working joint should be changed on each trip. This means that on one trip we should

end up with a full stand in the block when the bit is pulled through the rotary table. On the

next trip two joints should be hanging in the block. On the third trip again one full stand is

left on the block. This is done so that each connection is re-Lubricated every third trip and

prevents galling of the shoulder on connection.

18  

RUNNING IN The following steps are followed for running in:

1. Raise the drill collar to facilitate making up of the bit, and the substitute.

2. Place the new bit to be made up in the bit breaker.

3. Place the baffle plate of proper size on the pin end of the bit with wider face down.

4. Make up the new bit by hand initially and then tighten up to the required torque.

5. Lift this assembly of bit and drill collar.

6. Remove the bit breaker.

7. If bit is of bigger size than master bushing of the rotary than remove the master bushing

from the rotary table.

8. Run in the bit and put back the master bushing.

9. Rest the drill collar on the rotary table with the help of drill collar slip and safety clamp.

10. Open and lay down the lifting.

11. Raise the elevator up to the monkey board. Meanwhile topman should draw the drill collar

to be lowered next.

12. As the elevator reaches in level with the monkey board, the topman should give signal to

the driller to stop the elevator at the desired height.

13. The topman carefully latches the elevator over the lifting sub neck of the drill collar.

14. Slowly lift the drill collar.

15. Stab in the drill collar stand's pin into the box of the drill collar resting in the rotary table.

16. Initial tightening should be done using chain tong:;

17. Make up the joint up to the required torque.

18. Open the safety clamp and lift the drill collars assembly and lower it in the well.

19. Reduce the speed of running-in as the elevator approaches rotary table and gradually land

the drill collar assembly on the slip.

20. Repeat the process of lowering drill collars till all the drill collars have been lowered.

21. Changes over substitutes are made up in between whenever different sizes of joints have

to be made.

22. Different drill collar slips for different sizes of drilling collars are used.

23. If needed, elevators are changed when the drilling pipes are to be lowered.

24. Pick up the first stand of drilling pipe.

25. Use spinning rope for initial tightening of the drilling pipe stand and then tightens up to the

required torque using both the tongs.

26. As the drill pipe stands are lowered into the well the process of running in becomes

simple.

27. After the drill string is rested on the slips, the block is lowered slightly down so that the

elevator becomes free and it is unlatched.

28. Rig man should pull the elevator slightly to one side so that the elevator does not touch the

tool joint while being lifted up.

19  

29. The elevator is lifted up and as it reaches in level with the monkey board, the topman

throws the drill pipe stand on the elevator and latches it.

30. The drill pipe stand is lifted and made up with the drill string member resting on the rotary

and lowered in to the well.

31. The cycle of running in drill pipes is repeated.

32. Engage hydromantic brake or use electromagnetic brake when it becomes difficult to hold

the drill string with the help of mechanical brake alone.

33. After the last stand of pipe has been run in as per plan, the elevator is either removed or

latched empty and the Kelly is lifted and made up with the drill string.

NOTE: Speeds of running in and pulling out are governed by the well bore conditions.

BASIC OPERATIONS The driller should familiarize himself with the various operations as detailed below.

1. LIFTING UP OF THE BLOCK

Every draw works is provided with the following clutches:

i. Transmission clutches-low and high.

ii. Hoisting clutches-slow and fast.

On engaging the transmission clutch power is transmitted to the main shaft of the draw

works from the engines or from the electric motors. Power can be directed to the

hoisting drum on which the casing line is spooled with the help of a hoisting clutch.

When the hoisting clutch is engaged the drum starts rotating in the clockwise direction

from the drillers position and the drilling line starts getting spooled on the drum. As the

line is spooled on to thedrum the travelling block gets lifted up. By using the

combination of different transmission and hoisting clutches different speeds of

travelling block are obtained.

2. LOWERING THE BLOCK

On the draw works a braking mechanism is provided. It essentially comprises a flexible

steel band on which asbestos friction blocks are fixed, which are heat and wear

resistant. One end of this band is permanently anchored while the other end is movable

and attached to a lever by means of which the band can be tightened or loosened. As

the band is loosened, the drilling line gets unspooled from the hoisting drum because of

20  

the weight of the travelling block. The hoisting drum rotates in the anticlockwise

direction (viewed from the driller’s panel) and the block gets lowered.

If the block is carrying drill string through a system of hook, links and elevator, the

same can be lifted up or lowered down as the block moves up or down.

3. BRAKE OPERATION

The brakes are important units of draw works assembly as they are called upon to stop

the movement of large weights being lowered into the hole. When a round trip is being

made the brakes are almost in constant use.

The mechanical brakes form an integral part of the hoist and provide principal braking

system. Brake bands encircle the brake flanges for about 2700. Brake lining consists of

brake blocks composed of asbestos fibre compounded with a bonding agent

interwoven with copper wire.

Brake blocks are bolted to the brake bands with deep countersunk brass bolts on the

inside of the circle of the brake bands so that the bolts cannot come in contact with the

brake surfaces.

At the front of the hoist the brake bands are fastened with heavy duty pins or bolts to a

dead anchor that constitutes an equalizer connected to each brake band on both ends

and anchored to the unit frame in the centre of the drum. This equalizer functions to

assure that when the brake lever is pressed each brake band will have equal tension in

the braking process. It also has an adjusting and locking device for adjustment of the

brakes. The rear or under part of the brake band is fastened to the brake lever with a

cam type shaft to the other offside brake band. This is close to the base and designed

so that when the brake lever (about 51" long) is pressed with about 150 psi

(10.6kg/cm2) pressure there is a tension of about 2,460 Ibs (1120 kgs) applied to both

brake bands causing a gripping of the brake flanges around 270° of the brake flange

having a braking effect on the rotation of the drum.

As the wear varies around the circumference of the brake flange the maximum wear is

adjacent to the dead end at the equalizer where maximum pressure is applied on the

lining due to the direction of the rotation. The wear decreases around the

circumference to the point of leverage (the moving end)

21  

BLOWOUT PREVENTERS (BOP)

When primary control of a well is lost due to insufficient hydrostatic pressure, it becomes

necessary to seal the well by some means to prevent an uncontrolled flow, or blowout, of

formation fluids. The equipment which seals the well is called the blowout preventer.

1. TYPES OF BOPs

a. Ram type BOPs These are designed to close the well with the help of ram assemblies.

However, the size of the ram assemblies should match with the size of drill

string on which rams are closed. These types of BOPs, are also equipped with

Blind Rams(which can shut in open hole), Shear Rams(which can shear off the

string and close the well) and Variable Bore Rams which can be operated on a

given range of drill string (eg. 27/8" to 5").

b. Annular BOPs

These are designed to close the well on any shape and size of drill string. In

emergency it can even close the open hole. String BOPs/Inside BOPs .These

are designed to be installed on drill string to stop the flow, when the well is

flowing through the drill string. Some of string BOPs are Kelly cock, NRVs,

Fast Shut off couplings, Drop-in-check valves etc.

2. COMPONENTS AND NOMENCLATURE OF BOP EQUIPMENT Blowout preventer system consists of

a) BOP stack

b) Choke line

c) Kill line

d) Choke and Kill manifold

e) Closing unit

f) Diverter and auxiliary equipment.

BOP COMPONENTS ARE IDENTIFIED WITH FOllOWING CODES. A = Annular BOP (Spherical type)

G = Rotary stripper head

A = Single ram type preventer

Ad = Double ram type preventer

At = Triple ram type preventer

22  

S = Drilling spool with side outlets for connecting choke and kill

lines

M = 70 kg/cm2 (1,000 psi) rated working pressure.

3. BOP SELECTION CRITERIA

For selection of a BOP to be used following points must be taken into

consideration.

a) Maximum expected well head pressure.

b) Size of casing, casing hanger, bit and other drilling tools to be lowered

through the BOP stack

c) Substructure height i.e. gap below rotary table from ground level. extension

hand wheels or hydraulic locks.

d) Matching flange connection according to size and pressure rating of well head

flange.

e) Service environment i.e. 'H2S' or 'no H2S’ environment.

4. BOP STACK ARRANGEMENTS

The BOP stack arrangements may vary depending on the expected well head

pressures and different drilling situations.

5. BOP RAM LOCKS

All pipe ram type preventers are equipped with extension hand wheels or hydraulic

locks.

6. RECOMMENDED SPARE PARTS

The following recommended minimum spare parts for BOP, approved for intended

service, should be available at each rig.

a) A complete set of drill pipe rams and ram rubbers for each size drill pipe being

used.

b) A complete set of bonnet / door seals for each size and type of ram type

preventer being used.

c) Plastic packings for blowout preventer secondary seals.

d) Ring gaskets to fit flange connections of BOP.

e) Appropriate spare parts for annular preventer.

23  

7. BOP SIZES IN USE The following table shows the various sizes of BOP in use in the industry.

Table: Common BOP Sizes and Features

RATED  WORKING PRESSURE(kg/cm2) 

FLANGE  OR HUB SIZE (in) 

MINIMUM VERTICAL  BORE (in) 

RING JOINT GASKET 

RX  BX 

35.2(0.5M)  291/2  291/2  ‐‐  ‐‐ 140.8(2M)  16  163/4 65  ‐‐ 

20  211/4 73  ‐‐ 263/4  263/4  ‐‐  ‐‐ 

211.2(3M)  6  71/16 45  ‐‐ 8  9  49  ‐‐ 10  11  53  ‐‐ 12  135/8 57  ‐‐ 20  203/4 74  ‐‐ 263/4  263/4  ‐‐  ‐‐ 

352(5M)  6  7 1/16 46   10  11  54   135/8  135/8 ‐‐  160 163/4  163/4  ‐‐  162 183/4  183/4    163     ‐‐  165 

704 (10M)  7 1/16    ‐‐   9      157 11    ‐‐  158 135/8    ‐‐  159 163/4  163/4  ‐‐  162 163/4  183/4  ‐‐  164 211/4  211/4  ‐‐  166 

1056 (15M)  7 1/16  7 1/16    156 9  9  ‐‐  157 11  11  ‐‐  158 135/8  135/8  ‐‐  159 

1408 (20M)  7 1/16  7 1/16  ‐‐  156 1M =1000psi

24  

8. BOP INSTALLATION CHECKS

To install a new or used/repaired blowout preventer following field checks must be

carried out prior to installations

a. Visually inspect the ring groove of flange connection for rust, mud erosion,

damage, wear and pitting.

b. Visually inspect body (vertically, horizontally and through ram bore). Vertical bore

wear due to drill string and drill-tools should not exceed 6.3 mm (1/4") on the

diameter in any area.

c. Check ring joint gasket for wear or damage. Used ring joint gasket shall never be

reused.

d. Check studs and nuts for rust, thread damage, size (Diameter and length), threads

per inch (TPI).

e. Visually inspect wear, pitting or damage to the bonnet or door seal area, bonnet or

door seal grooves, ram bores, ram connecting rod and ram operating rod.

f. Check for packing/sealing element wear and its excessive hardness.

g. Measure ram bore and ram to check for maximum vertical clearance according to

manufacturer's specifications. This clearance is dependent on type, size and trim of

the preventers.

h. If preventer has secondary seals, it should be inspected. Remove the plugs to

expose plastic packing injection ports used for secondary sealing purposes.

Remove the plastic packing injection ports used for secondary sealing purposes.

Check valve in this injection port. Also check plastic packing to ensure that it is not

energizing the seal. If required, replace plastic packing.

8.1 RAM POSITION SELECTION

Selection of ram positions with inherent advantages/disadvantages is discussed

below. A simple case of two single ram preventers with a drilling spool is

considered. Any of the ram BOPs can be fitted with pipe ram or blind ram. There

can be four possible ways of fitting.

Ram position 1st case 2nd case 3rd case 4th case

Top Rb Rb Rp Rp

Middle S Rp Rb S

Bottom Rp S S Rb

Where,

Ab = Blind Ram

Ap = Pipe Ram

S = Drilling Spool

25  

8.2. ADVANTAGES OF DIFFERENT ARRANGEMENTS

a) In case (1) during kick control with pipe inside, if drilling spool flanges leak,

lower ram (Rp) can be closed and repairs could be done to avoid any

condition of uncontrolled flow.

b) In cases (1) & (2), upper blind ram can be replaced with pipe ram and used

to. keep lower pipe ram as a safety back-up.

c) In case (1) under contingency, upper blind ram can be replaced with a pipe

ram and drill pipe string can be stripped in hole under well pressure.

d) In case (1), if a leak in surface equipment or on string above rotary table is

observed, the string can be lowered and drill pipe tool joint can be

suspended on pipe ram and blind ram closed.

This will allow possible repairs as well as circulation.

e) In case (2), surface leaks can also be repaired after allowing to rest DIP

tool joint on lower pipe ram if tool joint height is sufficiently less than the

gap between two rams.

f) In case of arrangements (1 ), (2) and (3) , outlets of drilling spool can be

used for well control operation even when blind rams are closed.

g) In case (2) & (3) drilling spool can be eliminated if substructure height is

less by providing double ram BOP (Ad) with side outlets for choke and kill

manifolds.

h) With arrangements (2) & (3) well can be closed by either of ram with full

control on kill operations.

i) With the arrangements (2), (3) & (4), under pipe rams closed conditions,

side outlets of drilling spool can be used for kick control.

j) For cases (3) & (4), the pipe rams can be changed after closing blind rams.

k) In case (4), drilling spool and pipe ram BOP can be repaired/changed

when blind ram is closed.

l) Minimum numbers of flanges are exposed to well pressure in case (4)

when blind ram is closed.

m) If severe leakage is observed in the upper stack the string can be dropped

into the well and blind rams can be closed in case (4).

8.3. DISADVANTAGES OF THE STACK ARRANGEMENTS

a) In case (1 ),(2) & (3), if blind rams are closed the leakage in drilling spool

cannot be repaired till well is killed by some other means.

b) In case (2) & (3), with any of the rams closed leakage in drilling spool

cannot be repaired till well is controlled by some other means.

26  

c) More number of flanges will be exposed to pressure under cases (2) & (3).

for just closing the well.

d) In case (1 ), if lower pipe ram is closed, circulation can only be established

through side outlets of casing head spools.

e) In case (4), if lower blind ram is closed, well control will be possible only

through casing head spool outlets.

f) In cases (2), (3) & (4), it is not possible to lower and rest tool joint on pipe

ram and close blind ram with continuous possible circulation. Such

situation may arise during leakage in surface equipment above rotary table

while controlling well kick.

8.4. RECOMMENDATIONS FOR STACK CONFIGURATION

Position BOP Stack element Symbol

Top Blind Ram Rb

Middle Pipe Ram Rp

Bottom Drilling Spool S

For three ram BOP’S with drilling spool following two better arrangements are recommended

Position BOP Stack element Symbol

Top Pipe ram R

Upper middle Blind Ram Rb

Lower Middle Drilling Spool S

Bottom Pipe Ram Rp

(With double and single BOP)

Position BOP Stack element Symbol

Top Pipe ram Rp

Upper middle Blind Ram

Pipe Ram

Rb Rs

Lower Middle Drilling Spool Rp

Bottom Pipe Ram S

With Triple BOP

27  

9. CHOKE MANIFOLD An equipment assemblage with chokes, valves, lines, connected to side outlet of

drilling spool or casing head spool and used for the purpose of well control is called

choke manifold.

SELECTION AND INSTALLATION GUIDELINES

a. The upstream including chokes should have rated working pressure equal to the

highest rated working pressure of BOP in the stack.

b. For working pressure requirement of 3M and above flanged, welded or clamped

connections should be used on components subjected to well pressure.

c. The upstream and down stream choke line should be:

I. As straight as practicable and if turns are required they should be targeted.

II. Of sufficient bore size to prevent excessive erosion.

III. Anchored to avoid vibrations during kick control.

d. The minimum recommended choke line size is 7.5 cm (3 inch) nominal diameter.

However for 2 M installations,5 cm (2 inch) line is acceptable.

e. The minimum recommended size for down stream vent lines"" 5 cm (2-inch)

nominal diameter.

f. For high volumes and air or gas drilling operations,10 cm (4 inch) nominal diameter

lines are recommended.

g. The vent line which bypasses chokes, should be of same diameter as the

upstream choke line.

h. For manifold arrangements with rated working pressures of 5 M and above, one of

the upstream choke line valves, should be remotely operated type and at least one

choke should be of remotely activated type.

i. There should be alternate flow route if one flow route is plugged or eroded. This

will allow continuous flow without interruptions.

10. KILL LINE MANIFOLD Kill line manifold is connected to BOP side outlet for well control operations. This line is

useful when flow through normal route i.e. through kelly has ceased or cannot be

employed.

Selection and Installation guidelines 

a. The general guidelines stated for choke manifold will be applicable for kill line

installations also.

b. The kill line, manifold valves, check valves and other fittings must have equal

or higher rated working pressure than the rated working pressure of BOP in the

stack.

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c. The manifold and line connections should be flanged, clamped or welded for

the rated working pressure 3M and above.

d. The size of kill line should not be smaller than 2-inch, nominal diameter.

e. The BOP side outlet valves in kill line should have pressure rating 5M or more.

f. A kill line should not be used as hole filling line. This may damage line or

valves either by erosion or mud cut.

g. All equipment should be tested with same test frequency as for BOPs.

h. In series 5000 psi (350 kg/cm2)and above two kill lines with check valves

should be fitted. One of the kill lines may be connected below lower BOP to a

high pressure pump and another with drilling spool to rig mud pumps.

11. BOP CONTROL UNIT The primary function of a BOP control unit is to allow closing and opening of individual

BOP and hydraulic valves without using any external energy. It is specified with four

main characteristics.

a. Nitrogen charging pressure

b. Maximum operating pressure

c. Minimum residual pressure

d. Total active volume.

 

11.1 ACCUMULATOR CAPACITY

The minimum fluid requirement for BOP control unit is that the closing unit should be

equipped with accumulator bottles with sufficient capacity to close all pipe rams,

annular BOP and diverter (if applicable) plus the volume to open / close the hydraulic

valve in choke line. This requirement should be fulfilled without charging pumps under

operation.

Usable fluid volume

The usable fluid volume is defined as the recoverable fluid from accumulator bottles

between accumulator operating pressure and 200 psi( 14 kg/cm2) above pre-charging

pressure. The operating pressure is the rated pressure to which accumulator bottles

are charged.

 

 

 

29  

Preventer stack

Make of preventer

Model/Type Stack size (inch)

Working Pressure kg/cm2(psi)

Volume required to close litres (gallons)

Annular Hydril GK 135/8 700(10,000) 141.3 (37.18)

Pipe ram Cameron U 135/8 700(10,000) 22 (5.80)

Blind ram Cameron U-Blind 135/8 700(10,000) 22 (5.80)

Pipe ram Cameron U 135/8 700(10,000) 22 (5.80)

Total = 207.3 (54.58)

11.2 ACCUMULATOR SIZE FACTOR 

The minimum volume of accumulator including nitrogen and operating fluid should be

calculated by multiplying the volume required to close one ram and annular BOP plus

opening volume for hydraulic valve of choke line by a factor called accumulator size

factor as tabulated below:

Table: Accumulator Size Factor

Accumulator operating pressure kg/cm2 (psi)

Precharge pressure kg/cm2 (psi)

Usable fluid volume (Fraction of bottle size)

Accumulator size factor

211 (3000) 70 (1000) 1/2 2

140 (2000) 70 (1000) 1/3 3

105 (1500) 53 (750) 1/8 8

 

11.3 CONTROL UNIT RESPONSE TIME

The BOP control unit should have capability to close each ram preventer within 30

seconds. For annular preventer it should not exceed 30 seconds, for preventer size

smaller than 20-inches and 45 seconds, for annular preventer size 20-inches and

above.

11.4 OPERATING AND PRECHARGE PRESSURE

The manufacturer's guidelines for operating pressure and pre-charging pressure limits,

should never be exceeded. Also Nitrogen should be used as charging gas.

30  

11.5 OPERATING FLUID

A suitable operating fluid as per the recommendations of manufacturer (Hydraulic oil or

fresh water containing lubricant) should be used. The use of kerosene, motor oil, chain

oil, diesel, or any other similar fluid is not recommended due to the possibility of

resilient seal damage.

Fluid Reservoir Capacity

The reservoir capacity for operating fluid storage should be at least twice the usable

fluid capacity of the accumulator system.

11.6 EQUIPMENT DETAILS

Valve and Fittings

All valves and fittings between closing unit and BOP should be of steel with rated

working pressure of stack up to 211 kg/cm2 (3000 psi). All lines should be made of

steel or fire resistant high pressure hose with end connections of same rated working

pressure.

Charger Pump Capacity

Charger pumps should have the capability to close annular preventer on drill pipe plus

open the hydraulic valve in choke line and obtain a minimum of 14.06 kg/cm2(200 psi)

pressure above accumulator pre-charge pressure within two minutes or less with the

accumulator system kept isolated from service.

Pump power requirement

a. Power for operating pumps of BOP control unit must be available at all times, such

that pump will start when the control unit pressure has dropped to less than 90% of

the accumulator operating pressure.

b. Two or three independent power sources should be available on BOP control unit. It

may be rig generator plus independent air source, dual electrical sources with

independent generator, compressor or dual air system.

c. On shallow wells, where the casing being drilled through is set at 152 m (500 ft) or

less and where surface pressures of less than 14 kg/cm2 (200 psi) are expected, a

back up source of power is not essential.

31  

11.7 LOCATION AND REMOTE CONTROL REQUIREMENTS

a. Location of control unit should be at safe place and easily approachable during

emergency. It should also be located to prevent excessive drainage or flow back

from operating lines to fluid reservoir.

b. Control unit should be installed with sufficient number of control panels so that

BOPs and valves can be operated by driller from a readily accessible position and

also from a safe distance from the rig.

11.8 INSTALLATION CHECK

a. The control unit prior to installation should be tested for precharge pressure. The

bottom valves of accumulator bottles should be opened and all fluid drained off to

reservoir. Check nitrogen precharge pressure on each accumulator bottle and if

required,it should be charged to recommended pressure. This should be done after

changing to new drill site.

b. Check reservoir fluid to be free from any foreign material or for bacterial growth.

Change reservoir fluid if required.

c. Pressure clean all the lines prior to installation.

d. Check for leakage from diaphragm and change if required.

e. Check air lubricator. Clean and fill up with the manufacturer's recommended

lubricating oil.

f. Check seal rings and air passage ports of remote control interface and interconnect

cable assembly for any damage and plugging.

g. Control unit should be tested each time when the BOPs are tested. It should be

done prior to pressure testing BOP stack. The test should be conducted with a drill

pipe lowered in the stack as follows:

• Record initial accumulator pressure and regulate operating pressure to preventer

to 53 kg/cm2 (750 psi).

• Switch off power supply to all pumps.

• Close annular preventer, and one ram BOP on pipe. Open the hydraulically

operated choke valve. All this should be done simultaneously.

• Record time required to close annular and ram BOPs as stated above and in

opening of hydraulic valve.

• Record final accumulator pressure. This should be at least 14.06 kg/cm2 (200

psi) above the pre-charge pressure.

12. CREW POSITIONS DURING WELL CONTROL OPERATIONS

• Engineer In charge of Rig/project. He will have the overall responsibility for the

supervision of well control operations.

32  

• DIC Tool Pusher. He will prepare kill sheet and direct the operations. He will

operate the choke during well killing operation.

• Shift In Charge. He is the main line of defence when a kicj occurs. He will be at

the derrick floor and follow the directions from Tool pusher / DIC and will be

responsible for:

Detection of kick.

Close the well in.

Operating the rig equipment (draw works, mud pump etc)

Monitor pressures.

• Shift Chemist. Shift Chemist will be responsible for:

Monitoring the mud properties, mudgain / loss and conditioning of

mud.

Preparation of proper mud weight as directed by Engineer In charge.

Handling the mud contaminated due to kick.

• Maintenance In-Charge. He will supervise the running of all rig equipment with

the help of mechanical crew at the drill site.

• Assistant shift In-Charge. He will assist the chemist / engineer in operating the

mud conditioning equipment (degasser etc). with the help of topman and rigman,

or as directed by Rig Incharge depending upon the situation of particular rig.

• Shift Geologist Annular BOPs. Stand by at Geological lab.

• Electrician / Mechanica. Standby for possible instructions.

• Rig Men (3 nos) They will be ready available on derrick floor to follow

instructions of the shift incharge.

• Topmen (2 nos) They will be ready available to follow the instructions of the

assistant shift incharge.

• Others All others will remain standby and readily available at safe distance and

wait for instructions from the rig incharge.

33 

 

METHODOLOGY

Procedure for Hazard Identification Risk Assessment and Control

Purpose:

To identify the OH & S hazards, assess the risk and plain risks and plan risk control measures and

review the risk control measures.

Procedure:

Significant risk will be identified and eliminated/minimised at planning stage by the

project OH& S Officer, Project Manager and Works Manager.

The Project senior Representatives and Line Supervisors along with Project OH& S

Officer will review high and medium risk activities in order to reduce the level of the

risk. Corporate Health and safety Department will be informed about actions taken to

contain the risk.

The risk assessment at project level will be carried out for every new activity

undertaken, when the project is ongoing and the measures identified for risk control

will be recorded in risk control document at the project site. New measures may be

required in the form of addition of new work methods/procedures/improved safety

equipment/additional OH & S training/safety signs/posters etc.

The five step process for risk control are

Step 1: Identification of hazards

The first step is to identify the workplace hazards, if any of the risk are relatively minor and /or

the hazard can be easily controlled, the activity can be attended automatically straight way.

That is, it may not be necessary to work through the assessment method. All other risk must

be assessed using a method such as the one presented in step 2.

Step 2: Assessing the Risks that may result because of the hazards.

The second step is to work out which hazards need attention first. The risk associated with

each hazard must be assessed. The method of assessing risk is as follows.

34 

 

Risk Assessment method:

For each of the risks:

• Estimate the likelihood of an incident occurring at the workplace, bearing in mind

existing control measures. Using the descriptive scale in the risk priority chart (below),

nominate the likelihood of an incident occurring at the workplace.

• Estimate the consequences of an incident occurring at the workplace, bearing in mind

existing control measures using the descriptive scale in the risk priority chart,

nominate the consequences and the incident occurring at the workplace.

• Determine the “risk score” by plotting consequences and likelihood estimates on the

risk priority chart

Using the scores obtained for the risks; develop a prioritized list of workplace risks requiring

risks.

Risk Priority Chart

Risk Assessment Mathematical Model: For quantifications of the risk the following

mathematical models are used:

Severity Factor: - (S)

No impact Upon persons, environment or property

1 Minimal impact First aid, minor equipment damage

2 Moderate impact Non lost time accidents (LTA), damage require outside help or

minor delay

3 Serious impact LTA or serious injuries possible, damage /suspension of

operations

4 Major impact Life threatening , major equipment or operational damage

5 Catastrophic impact Loss of person(s), severe structural or environmental damage

35 

 

Probablity Factor: - (P)

0 Zero possibility

1 < 1 every 10,000 operations 1 every 10 years operating

2 < 1 every 10,00 operations 1 every operating years

3 < 10 every 10,00 operations 1 every month operating

4 < 10 every 100 operations 1 every week operating

5 Incident most likely will happen 1 every day operating

Risk = S × P (Severity × Probability)

Risk Score:

SEVERITY

5 0 5 10 15 20 25

4 0 4 8 12 16 20

3 0 3 6 9 12 15

2 0 2 4 6 8 10

1 0 1 2 3 4 5

0 0 0 0 0 0 0

0 1 2 3 4 5

PROBABLITY

36 

 

Risk Level:

Risk Level Consequences

Low risk (<6) (l) • Potential hazardous daily or routine task

• Regarded as acceptable with current control measures

• Use tool box task

Moderate risk (8-12) (m) • Hazardous non routine tasks

• High loss of potential

• Control measures are required to reduce the risk

• Permit to work and operating procedure

Significant risk (> 15) (h) • Potential disastrous or catastrophic operations

• Operations must be altered

• Significant safety control

STEP 3: DECIDING ON CONTROL MEASURES

In the workplace occupational health and safety risk management process involves deciding

on control measures to manage exposure to identified risks.

Control Priorities

Start at the top of the list and work down.

Firstly, try to eliminate the hazard

If it is not possible, prevent or minimise exposure to the risk by one or a combination of:

• Substituting a less hazardous material, process or equipment

• Redesigning equipment or work process

• Isolating the hazard

37 

 

(Note: These measures may include engineering methods).

As a last resort, when an exposure to the risk is not (or cannot be) minimized by other means:

• Introduce administrative controls.

• Use appropriate personal protective equipment

In many cases, it will be necessary to use more than one control measure to satisfactorily

manage a risk. Some control measures which are lower control priorities, may need to be put

in place until a permanent measure can be implemented.

The control measures selected should:

• Adequately control exposure to the risk.

• Not create another hazard; and

• Allow workers to do their work without undue discomfort or distress.

Step 4: Implementing Control Measures

Involves implementing selected control measures at the work place this means undertaking

those activities necessary to allow the measures to function or operate effectively.

Implementing control measures involves:

• Developing work procedures.

• Communication.

• Providing training and instruction.

• Supervision.

• Maintenance.

Step 5: Monitor and Review

The final step in the risk management process is to monitor and review the effectiveness of

measures .For this step, it can be useful to ask question to determine whether

38 

 

• Chosen control measures have been implemented , planned;

• Chosen control measures are working; and

• There are any new problems.

This involves:

• Consulting with workers, supervisors and occupational health and safety representatives.

• Measuring peoples exposure (e.g Taking noise measurement in the case of isolation of a

noise source); and

• Monitoring incident reports.

Review of Risk Assesment:

The hazard identification and risk assessment register should be regularly reviewed for incorporating

hazard due to any changes in the processes / activities and after any accident/incident/near misses.

39

OBSERVATIONS AND RECOMMENDATIONS The main aim for carrying the HIRAC was to Identify the hazard in CBM – drilling site of

Shiv-Vani Oil & Gas Exploration Services Limited, Bokaro.

The Observations & Recommendations are broadly presented.

After conducting HIRAC (Hazard Identification, Risk Assessment & Risk Contol), the

following activities were identified as high – risk level & have been tabulated along with

control measures.

Table: HIRAC of Activities Having High Risk.

S.No. Activity Hazard Consequence Control Measures

1. Derrick

Operations

Fall from

Height

Personal Injury or

Death.

Safety Belt to be

worn. / Only

skilled persons are

allowed to climb

the derrick.

2. Spillage of Oil

/ Hazardous

chemicals

Fire &

Explosion

Personnel injury (more

than one), Equipment

damage, property

loss.

Fire Extinguishers

be placed. / Other

fire control system

in place.

3. Hydraulic

Cranes

Operations

Over head

falling objects.

Crushing, loss of life,

property loss.

Use of hard hats /

SW procedures /

Skilled operator.

4. Bulk fuel oil

storage

Fire &

Explosion

Personnel injury (more

than one), Equipment

damage, property

loss.

Contingency Plan in

Place, Adequate use

of Extinguishers,

Media Available.

5. Rig Floor

Operations

Crushing Personnel Injury Safe Work

Practices.

6. High pressure

line operations

Leakage or

burst of high

pressure line

Personnel injury,

Equipment damage,

property loss

Maintenance,

pressure testing

after regular

intervals.

40

7. Pumping Blowout Serious injuries (more

than one) loss of life;

equipment damage

property loss.

The pump must

not exposed

maximum

pressure of mud

line., High

pressure line must

be secured to the

rig lines and hoses

must be

unexpected daily

and replaced if

work or damage.

Engage pump in

low gear than shift

subsequent higher

gears.

8. BOP

Controlling

Operations

Pressure lines

from

Accumulator

unit to BOP are

damaged.

Personnel Injury (more

than one), Loss of life.

(More than one

Property loss,

Equipment damage).

Routine

maintenance and

inspection,

procedure in

place. / The

pressure line from

accumulator unit

to BOP are

projected, / BOP

Tests to be done

regularly.

9. Tension in

Guy Wire

Guy wire got

loose, the rig

most becomes

unsuitable.

Personnel Injury (more

than one), Loss of

Life. (more than one,

property loss,

equipment damage.)

Regular inspection

of guy rope

diameter, position

of clamps, tension

in rope.

The detailed HIRAC (Hazard Identification, Risk Assessment & Risk Control), has been

presented in Annexure – 1.

41

It is requested to initiate time bound action plan by all the responsible persons for

liquidating the recommendations & implementation. Status of the action plan is to be sent

to Corporate Cell – HSE, for proper documentation of Compliance.

Some Useful Do’s & Don’t’s Do’s for Mobile and Hydraulic Rigs.

1. When raising derrick, the raising cylinders should be bled thoroughly (to remove

air). 2. Always disengage the hydraulic pump on leaving console.

3. When extending derrick, driller must see that all extending ram stabilizers fully

4. grip the ram as the upper section passes them so the ram is supported

horizontally. Otherwise, the ram may buckle causing upper section to drop.

5. Check location for overhead electrical power lines or similar obstructions. Be sure

Derrick & Guy lines clear power lines by at least 3 m to avoid the hazard.

Don’t’s for Mobile Rigs Raising pressure should not exceed the specified pressure limit for raising the mast.

HANDLING OF DRILL PIPES, DRILL COLLARS, KELLY

1. HANDLING OF DRILL PIPES 1.1 DO'S WHILE HANDLING DRILL PIPES

a. While loading of drill pipes for transportation on trailer, all box end be kept

on the same end of the trailer.

b. The first tier of the drill pipes should be stacked at least 12" high from the

ground to ensure good ventilation.

c. Pipe supports should be properly spaced to prevent bending of drill pipes.

d. Drill pipes should be stacked in such a way at rig site that the box ends

are facing the rig floor.

e. Wooden strips be used as separators between successive layers of drill

pipes so that no weight rests on the tool joint. Use at least 3 spacing strips

(one at middle, two at end points just before tool joint).

f. Remove rubber protectors while sorting drill pipes. Corrosion may form

circumferential groove on pipe body if rubber protectors are left on.

g. Thread protectors must be screwed on to both box and pin ends of drill

pipe while handling.

42

h. The pin and box threads should be lubricated with drill pipe thread

compound before mounting the protectors.

i. Always use recommended thread compound (compound containing 40-

60% finely powdered zinc by weight are recommended by IADC & API).

j. Length of all drill pipes should be marked and recorded.,

k. Pin and box threads and shoulders of tool joints should be thoroughly

cleaned before joint is made up.

l. After cleaning the tool joint check the following:

(a) Threads must be free from any foreign material.

(b) Threads must not be damaged.

(c) Tool joint shoulder be free from any cut mark or wash out.

m. If new drill pipes are to be used for the first time, threads should be

cleaned with suitable solvent and soft bristle brush, free from dirt.

n. The tool joint should be kept as close to the rotary slip as possible during

make up or break out.

o. Always use both the tongs while making up or breaking out drill pipes.

p. Always make up tool joints with appropriate recommended torque.

q. Downward motion of drill pipe must be stopped with brakes and not with

the slips.

r. In every third trip working joint 'of drill pipe stands must be changed to

facilitate the checking of nonworking joint threads.

s. Set back area should be cleaned before stacking the drill pipe stands in

fingers.

t. Mount thread protectors while laying down drill pipe on catwalk, keep

catwalk clear.

u. Threads and shoulders of box and pin of a dry connection should be

carefully checked.

v. Always remember the interchangeability of tool joint styles (NC, IF, FH,

XL...).

w. Always consider the torsional strength of a new tool joint as a function of

strength of steel, connection size, thread form, lead, taper and coefficient

of friction on mating surfaces, threads and shoulders.

x. Always consider that outside diameter affects box area and internal

diameter affects pin area and these control the effective torsional strength

of a used tool joint.

y. Read marking at base of pin as company symbol, month and year welded,

pipe mill and grade of pipe.

43

z. Read pipe weight code in 1/4" or 3/16" slot on pin side of standard weight!

heavy weight drill pipe.

aa. Consider torsional yield strength of drill pipe approximately as 57% of its

minimum yield strength.

bb. Always remember the strength of the pipe being used in terms of tension,

compression, torsion & bending.

cc. During transportation, the pipes be suitab!y tightened on trailers.

dd. Retighten the transporting load, after the load has travelled a short

distance, chains may become loose as a result of load settling.

ee. Place spacing strips/wooden planks at right angles to the pipe &. directly

over the lower strip, while storing the pipes.

ff. While storing, clear pipe bore and tool joint threads by clean water and put

antirust coating on it.

gg. Inspect periodically and examine the status of corrosion on stored pipes.

hh. Clean pin and box threads as well as shoulders thoroughly.

ii. Properly dry up' the connection threads before applying thread compound.

jj. Use shoulder dressing tool or file for minor repairs.

kk. Remember that a blow on the bevel can create highspot on the shoulder.

If not removed it could cause galling, a washout or a broken pin and a

fishing job.

ll. Pin threads meshed due to lack of protectors must be repaired or serious

trouble will result.

mm. Before spinning up be sure that connections are in alignment.

nn. If using a kelly spinner in mouse hole, extra care is necessary that

connection is clean, adequately lubricated and the joint does not wobble.

oo. For final torque measurement be sure that tong is at 90° to the make up

line.

pp. Always wash the tool joirt and drill string internally and externally with

fresh water to remove salt and like corrosive agents which might bring

about rapid deterioration.

qq. Apply a rust preventer in threads and shoulders specially when drill string

is to be stored for a long period.

rr. Check drill pipe for straightness.

ss. Always consider smooth sealing shoulders as more critical to tool joint

operation than gauge standoff.

tt. When refacing, remove minimum possible material.

uu. Repair minor damage to shoulders at rig floor like slight crowning of

shoulders due to wobble, slight leakage, dents, fins and galls.

44

vv. Use test ring to check conditions of shoulders before and after refacing.

ww. Take extreme care while refacing with a power tool as it is capable of

removing excess material within a very short period.

xx. See that pipes are not rolling off pipe racks.

yy. Use specially made API modified thread compound, only for special grade

pipe as recommended by API.

1.2 DON'TS WHILE HANDLING DRILL PIPES

a. Do not over load the trailer while transporting the drill pipes.

b. Do not place drill pipes directly on ground, roofs, street or concrete floor

while stacking.

c. While stacking drill pipes at the ground, height of stack should not be

more than 10 ft (3 m).

d. Do not load, transport or store drill pipes without thread protectors.

e. Check for any notch (i.e. slip mark, spinning chain marks, tong marks etc.)

on pipe body. If any circumferential or transverse notch is found on pipe

body, do not use the drill pipe.

f. Check for any longitudinal cracks on tool joint body because of heat

cracking. Do not use the drill pipe if such parallel longitudinal cracks are

present.

g. Do not run damaged connections in the hole.

h. Do not over use thin thread compound for ease of application.

i. Do not allow the pin end to strike the box shoulder while making

connection.

j. Do not spin pipe too fast. If joint wobbles and bends, high speed can burn

threads.

k. Do not use tongs on pipe body or on shoulders.

l. Do not let the slips ride thepipe. That may damage the slips and may

create other complications.

m. Do not use slips designed for one specific size of pipe on any other size of

pipe.

n. Do not use wrench or other sharp edged tool to jack drill pipe stand in

position on set back platform.

o. Never over torque the joint, it may cause failure while in operation.

p. Do not let pipe hit other objects on walk.

q. Do not reface a tool joint more than 1/32" off the shoulder of box and 1/32"

off the pin shoulder.

45

2. HANDLING OF DRILL COLLARS

2.1 DO'S WHILE HANDLING DRILL COLLARS

a. Thread protectors should be used and screwed fully on both pin and box

ends when handling drill collars.

b. Use cast steel protectors on pin and box end of drill collars while picking

up from catwalk to derrick floor.

c. Check that slips and elevator for handling the drill collars are of the proper

size.

d. A safety clamp should invariably be used while making up or breaking

plain drill collars.

e. Before make up clean the threads thoroughly, check for any burrs or

damage and lubricate properly.

f. Always use a good thread compound. Thread compound should contain

60% finely powdered metallic lead or 40-60% finely powdered metallic

zinc, with no more than 0.3% sulphur by weight.

g. If lift subs are used, its pin threads should be cleaned, checked and

lubricated on each trip. If it is damaged it may damage all the drill collars.

h. A new joint should be carefully lubricated, made up, broken out,

relubricated and made up again on initial make up.

i. Always use chain tong for initial tightening of drill collars.

j. A torque gauge should be used on tong line to measure the make up

torque.

k. Always make up drill collar connections to appropriate recommended

torque.

l. On every third trip drill collar stand should be pulled out in such a way that

nonworking joints become the working joints.

m. On each trip rotate top two stands of drill collars to work in drill collar string

below so that null point may not remain on the same joint.

n. Make close visual inspection of every nonworking joint while pulling out.

o. Consider that connection trouble begins when bending strength ratio

(BSR) falls below 2:1 ,due to OD (Outside Diameter) wear. So, always

check its OD for BSR.

46

p. Always apply thread compound to all threads and shoulders.

q. Measure line pull when line makes 90° to tong arm.

r. Always use thread protectors while laying down drill collars.

s. Before storing, drill collars should be cleaned and shoulders refaced with

a shoulder refacing tool. If necessary, fins be removed and good rust

preventive material should be applied.

t. Visually inspect full length to determine obvious damage and overall

condition.

u. Measure outside diameter and inside diameter of both ends during

inspection of drill collars.

v. Conduct Wet fluorescence magnetic particle inspection for detection of

cracks. Use magnifying mirror in crack detection of box threads.

w. Use profile gauge to check thread form and to check for stretched pin.

x. Check box counterbore diameter for swelling.

y. Check pin and box shoulders for damage. Only minor damage should be

repaired by refacing and bevelling.

z. Repairing of excessive damage should be done in reputed machine shops

with API standards.

2.2 DON'TS WHILE HANDLING DRILL COLLARS

a. Do not use rotary for making up or breaking out drill collar connection.

b. Do not over torque or under torque a drill collar connection during make

up. Insufficient torque or too much torque both may cause problem.

c. Do not jerk the line for applying pull for make up, give a long steady pull to

the tong line.

2.3 HANDLING OF KELLY

2.3.1 DO'S WHILE HANDLING KELLY

a. Always use new drive bushing roller assemblies for new kellys.

b. The rollers of drive bushing assemblies must be adjusted for minimum

clearance, if possible.

c. Drive assemblies should be replaced periodically to ensure minimum

clearance from wear.

d. Always use a kelly saver sub. It protects the lower connection threads

from excessive wear.

e. Lubricate the drive surfaces so that kelly slides freely through the drive

bushings.

47

f. Visual inspection at regular intervals should be made to check the wear of

drive bushing and Kelly corners.

g. Keep watch on upper joint to check its loosening.

h. Always examine junctions between upsets and drive sections for cracks.

i. Always check for kelly straightness.

2.3.2 DON'TS WHILE HANDLING KELLY a. Do not move or transport kelly without scabbard. It provides the support to

kelly.

b. Do not use crooked or bend kellys. Bend in kellys result in rapid wear of

kelly and drive rollers.

c. Do not weld on the corners of kelly for rebuilding worn kellys.

3. SOLIDS CONTROL EQUIPMENT 3.1 SHALE SHAKERS 3.1.1 DO'S WHILE USING SHALE SHAKERS

a. Have enough shakers or sceen area to run finest possible screens over

any significant hole interval.

b. For double deck shakers, run coarser screens on top and finer screens on

bottom. Upper screen should be coarser than the bottom screen.

c. Always watch for torn screens.

d. Make sure the components of the screen tensioning system including any

rubber supports, nuts, bolts, springs etc. are in place and in good shape.

e. Arrange for equal fluid and solids distribution when more than one shaker

is used.

f. It is always desirable to have a bypass channel at the shaker.

g. Use only temporary spray bars.

h. Cover 75 to 80% bottom screen with mud.

i. Cement contaminated mud should be allowed to bypass the shaker.

3.1.2 DON'TS WHILE USING SHALE SHAKERS a. Do not use permanent spray bars, use temporary spray bars only.

b. Do not bypass or operate with torn screens. These are main cause of

plugged hydrocyclones.

c. If using shaker with adjustable deck angle, do not run more than 3° uphill.

3.2 CENTRIFUGAL PUMP 3.2.1 DO'S WHILE U51NG CENTRIFUGAL PUMPS

48

a. Install the centrifugal pump with a flooded suction so that sufficient

submergence is available.

b. Install a removable screen over the suction to keep out large solids and

trash.

c. Suction and discharge lines should be properly sized and as short as

possible. Flow velocities should be in the range of 5 to 10 ftlsec (1.5 to 3

m/s).

d. Size the pump and drive to handle the highest anticipated flow rate and

heaviest mud requirement.

e. Make sure that the rotation of centrifugal pump's spinning impeller is in a

correct direction.

f. Check for loose packing or wear of pump. These are the most common

field problems.

3.2.2 DON'TS WHILE USING CENTRIFUGAL PUMPS a. Do not try manifolding. One suction and one discharge per pump are most

efficient and cost effective over a period of time.

b. Do not reduce the suction side of pump to adjust flow rate or pressure.

This can cause cavitation and destroy the pump rapidly.

c. Do not completely close off the discharge. This may cause seal damage.

3.3 HYDROCYCLONES 3.3.1 DO'S WHILE USING HYDROCYCLONES

a. Install suction screen to remove large solids.

b. Install centrifugal pumps with flooded suction.

c. Size pump impeller and motor to give the recommended head at the

hydroclone feed inlet.

d. Size suction and discharge piping in 5-10 ftlsec (1.5 to 3 m/s) range.

e. For serviceability, use quick-disconnect type hydrocyclones instead of

flanged hydrocyclones.

f. Provide space and walkways around to encourage proper service.

g. Install enough hydrocyclones to process 125% of maximum rig circulation

rate.

h. Always maintain a pressure gauge on the hydrocyclone feed inlet.

i. Always use correct fluid routing or plumbing.

j. Operate hydrocyclones in spray discharge.

k. Install hydrocyclones always in series with shale shaker.

49

l. Feed inlet to hydrocyclone should be sufficiently above the bottom of the

active mud tank.

3.3.2 DON'TS WHILE USING HYDROCYCLONEs a. Avoid manifolding, use single purpose pumps.

b. Do not bypass shale shaker or run with torn screens.

c. Do not operate hydrocyclones in rope discharge.

d. Do not install hydrocyclones in parallel with shale shakers.

e. Do not use polyurethane made hydrocyclones at higher surface

temperatures (i.e. more than 1500F) as polyurethane starts to soften at

temperature range of 150-175oF.For higher surface temperatures,use

cast iron hydrocyclone or Moca cured type polyurethane hydrocyclones.

3.4 CENTRIFUGE 3.4.1 DO'S WHILE USING CENTRIFUGE

a. Always have enough capacity to process a maximum of 13% to 15% of rig

circulation rate in mud making areas. Reduce feed rates in harder and

less mud making formations.

b. Run centrifuge constantly at a reduced feed rate on the active system

while drilling.

c. Add sufficient water and mud additives to the centrifuge feed to reduce

the API funnel viscosity of the centrifuge effluent to 35-37 sec/qt.

d. Have adequate supply of clean water.

e. Take centrifuge feed from a well agitated spot.

f. Always wash thoroughly on shut down.

g. Return the recovered barite to a well agitated spot before the mud mixing

section.

h. Maintain a high mud level in tank where under flow solids return for better

mixing.

3.4.2 DON'TS WHILE USING CENTRIFUGE a. Do not exceed manufacturer's maximum recommended feed rate for a

given mud weight.

b. Do not exceed manufacturer's maximum recommended rotational speed.

50

CONCLUSION

Over all Health, Safety & Environmental Management System is adequate. The main

hazards are fall from height; fire & explosion; over head falling of objects; crushing;

leakage or burst of high pressure line; blowout etc.

If the system is followed, drilling activity is expected to continue free from environmental

problems and accident free throughout the project.

Great emphasis is given by management for awareness of health, safety and environment

of employees and contract labors.

Training system, safety promotion system and other safety system are found to be good

and are to be continued.

REFERENCES • “Emplacement Gantry Gap Analysis Study”, Bechtel Saic Company LLC, May

2005.

• “HSE Manual”, Shiv-Vani Oil & Gas Exploration Services Limited, Delhi.

• “Safe Working Practices”, Shiv-Vani Oil & Gas Exploration Services Limited, Delhi.

• “Safety and Environmental Management System – ISO 14001 & OHSAS 18001

GAP Analysis”, National Energy Board, 2002.

• Sami Karna.: “Analyzing Customer Satisfaction and Quality in Construction – The

Case of Public and Private Customer”, Nordic Journal of Surveying and Real

Estate Research, Special Series, Vol. 2 (2004).

• “The Clean Water and Drinking Water Infrastructure GAP Analysis”, United States

Environmental Protection Agency, 2002.

Web Sites:

• www.epa.gov/safewater

• www.google.com

• www.jacqueswhitford.com

• www.shiv-vani.com

S.No Activity / Operations Hazard Severity Probablity S × PRisk Level H-

M-LControl measures to introduced to reduce the risk

Crushing

3 1 3 L

Hard hats to be worn, proper planning of

the activity, worker should be aware of the

operation going on.Overhead falling objects 4 1 4 L Hard hats to be wornEquipment striking the catwalk too hard 1 2 2 L Slow pull and lower the equipment

Equipment or tool may fall away from catwalk1 2 2 L

Proper planning of the activity, workers

should be aware.

Damaged slings

3 2 6 L

Routine checkups procedure for slings in

place. / use of appropriate sling according

to load requirement.

Fall

5 4 20 H

Proper PPE's to be worn. / only skilled

persons are allowed to climb the derrik.Weather 1 3 3 L Adequate Supply of water, shades

Physical hazard 3 3 9 M Use of PPE's / Safe Working Procedures.

Electrical 4 3 12 M Rubber gloves to be worn, gum bootsOil spill 1 3 3 L Spill to be controlled

Fire 4 3 12 M Fire extinguisehers be placed / Permit system in place

Improper loading of material3 2 6 L

Experienced Supervisor to be developed at loading point. / Experienced Operator should operate the machine.

Fast movement of vehicles 4 3 12 M Observe Speed limits. / Use seat belts and blow horn.

fall of material from truck/trailer 2 2 4 L Material should be loaded as per body capacity

Unbalanced during unloading of material

3 2 6 L

To keep the vehicle on level ground. / unloading instructions clearly understandable to driver. / No one standing on the backside.

Noise generation 1 2 2 L Earmuff be used when working near

Cable bursting 4 3 12 M Routine checkup of cable condition required.

Improper walkway 1 2 2 L Good house keeping practice to be implemented.

Fire due to cable short-circuting 4 3 12 M Fire Extinguishers shall be provided.

Persons falling in to the pit 3 2 6 L Proper fencing of pits.

Plastic sheeting-trip/slip hazard 2 2 4 L Proper fencing of pits.Soil pollution 2 2 4 L Routine Checking / Routine maintenanceChemical exposure 3 3 9 M Proper PPE, SWP / MSDS in place

Fire and explosion5 3 15 H

Fire Extinguisehers be placed. / Other fire control system in place.

Inhalation of hazardous fume 2 2 4 L Proper PPE, SWP / MSDS in place.

6 Working near water pit/cleaning of mud resorvior pits

7 Spillage of oil and/or hazardous chemical

HAZARD IDENTIFICATION, RISK ASSESSMENT & RISK CONTROL ‐ CBM Drilling Site.

Risk/Consequences

Hoisting Operations/Lifting equipments,tools and tubulars up to the rig floor1

2 Derrick Operations

3 Maintenance

4 Transportation

5 DG set operations

Personnel injuryPersonnel injury

Personnel injuryPersonnel injury

Equipment damage

Equipment damage,Injury to roustabouts

Equipment damage,Injury to roustabouts

Personal InjuryPersonal Injury

Environmental problem

personal injury,property damage

Personal injury and equipment breakdown

Personnel injury

Personnel injury,property loss

Personnel injury,property lossHealth problems

Personnel injury and Equipment damage

Personnel injury

Personal injury and machinery loss

Persons falling in to the pitPlastic sheeting - trip / slip hazard

Environmental problemPersonnel injury

Personnel injury(more than one),Equipment damage,property loss

Health problems

S.No Activity / Operations Hazard Severity Probablity S × PRisk Level H-

M-LControl measures to introduced to reduce the risk

HAZARD IDENTIFICATION, RISK ASSESSMENT & RISK CONTROL ‐ CBM Drilling Site.

Risk/Consequences

Over head falling objects 5 4 20 H Use of hard hats / SW procedures / Skilled operator.

Physical hazard due to collision with vehicle 4 3 12 M Skilled Driver / Horns be used.

Physical hazard due to fall from height 3 2 6 L Preoper PPE's

Wire line of the lifting arm can break which can result ito physical hazard

4 2 8 MRoutine checkup to be done / operator to inspect the machine before start of days work.

Falling from the machine. 3 1 3 L Safe Working ProceduresPhysical hazard from the use of improper slings and shackles 4 3 12 M

Proper Slings to be used.

Burns from the sparks 1 4 4 L Face mask, hand gloves, coverallsPhysical hazard due to contact with hot shockups after welding 1 4 4 L Hand gloves

Physical hazard from the falling of tools/material when working at height 3 1 3 L Safe Working Procedures & Practices.

Chemical hazard due to inhalation of smoke 1 5 5 L Use of PPE's

Electric hazard due to electric shocks 3 3 9 M Rubber Gloves be used.

Physical hazard due to space constraints 2 3 6 L Avoid long work hours.

Physical hazard due to excessive heat1 4 4 L

Avoide lond working intervals.

Physical hazard due to fall from height because of not using proper PPEs(safety belt/helmet/safety shoes)

5 1 5 LProper PPE's

10 Handling Measured well drilling(MWD) tool Electric shock 2 2 4 L Rubber GlovesBack strain 1 2 2 L Safe Working PracticesBack injury 2 2 4 L Safe Working PracticesErgonomic hazard 1 3 3 L Safe Working Practices.

12 Tightening of the tool joints by rinche Physical hazard 1 2 2 L Safe Working Practices.Fire and explosion hazard in case of handling of damaged batteries 4 2 8 M Safe Working Procedures / MSDS in

place.Hazard from the inhalation of toxic fumes in case odamaged batteries 1 4 4 L Proper PPE's MSDS in Place.

Spillage/ leakage 3 3 9 M

Fire and explosion 4 4 16 H Contigency Plan in Place, Adequate use of Extinguishers, Media Available

Slipping & tripping hazard due to bad housekeeping practices on the rig floor 2 5 10 M

Good house keeping practice to be implemented.

Pinch points 1 5 5 L Safe Working PracticesTrapping of hands or legs in the rotary table 3 5 15 L Safe Working PracticesThe floorman can come in contact with the rotating kell/ tubular 2 5 10 M

Safe Working Practices. / Safe distance to be maintained.

Falling from height 4 2 8 M Proper PPE's Guard Rails in placeBack sprain/Back injury 2 5 10 M Safe Working PracticesOver head falling objects 3 4 12 M Hard Hats

Flappers in open position and worker is unaware 3 4 12 MWorkers have clear understanding of the place.

Crushing 4 4 16 H Safe Work Place.

Skin contact 1 3 3 L Proper PPE's, MSDS available.

Eye contact 2 3 6 L Proper PPE's, MSDS availableInhalation of chemical powder dus 2 3 6 L Proper PPE's, MSDS available.

17 High pressure line operations Leakage or burst of high pressure line4 4 16 H

Maintenance, pressure testing after regular

intervals.

16 Chemical mixing in mud tanks through hopper operation

14 Bulk fuel oil storage

15 Rig floor operations

9 Welding operations

11 Manual lifting of MWD tools

13 Handling lithium batteries

8 Hydraulic cranes operations

Skin irritationEye irritation,loss of sight

Health problems

Personnel injury

Personnel injury

Crushing, loss of life, property loss

Personnel injury,Equipment damage,property loss

Personnel injury

Personnel injury

Personnel injuryHealth problems

Personnel injury

Personnel injury

Personnel injury

Personnel injury/loss of lifePersonnel injuryPersonnel injury

Personnel injuryPersonnel injury

Personnel injury,Equipment damage,property loss

Health problems

Personnel injury

Personnel injuryPersonnel injury

Personnel injury,Equipment damage,property loss

Environmental problemPersonnel injury(more than one),Equipment

damage,property loss

Personnel injuryPersonnel injuryPersonnel injury

Personnel injury

Personnal injury

Personnel injury,Equipment damage,property loss

Personnel injury

Personnel injury

S.No Activity / Operations Hazard Severity Probablity S × PRisk Level H-

M-LControl measures to introduced to reduce the risk

HAZARD IDENTIFICATION, RISK ASSESSMENT & RISK CONTROL ‐ CBM Drilling Site.

Risk/Consequences

Improper slings used 3 3 9 M Skilled Persons to be deployed for operations.

Improper way of using the slings 3 3 9 M Skilled Persons to be deployed for operations.

Tag line not used 3 2 6 L No operation without tag line used.

19 Pumping Blowout 5 4 20 H

The pump must not exposed maximum

pressure of mud line., High pressure line

must be secured to the rig lines and hoses

must be unexpected daily and replaced if

work or damage. Engage pump in low gear

than shift to subsequent higher gears.

20 BOP Controlling Operations

Pressure lines from Accumulator unit to BOP are

damaged.

5 4 20 H

Routine maintenance and inspection, procedure in place, / The perssure line from accumulator unit to BOP are projected, / BOP Tests to be done regularly.

21 Tension in Guy Wire

Guy wire got loose, the rig most becomes unuitable.

5 3 15 H

Regular inspection of guy rope diameter,

position of clamps, tension in rope.

18 Loading and unloading operations

Serious injuries (more than one) loss of life; equipment damage property loss.

Personnel injury,Equipment damage

Personnel Injury (more than one) Loss of life.

(more than one, property loss, equipment

damage.)Personnel Injury (more than one) Loss of life.

(more than one, property loss, equipment

damage.)

Personnel injury,Equipment damage,propertyloss

Personnel injury,Equipment damage,propertyloss