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 (J harkhand), 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.

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 1990s,
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 Contractors organization that its
management systems risk reducing controls related to the Health, Safety and
Environment aspects of its operations, meets its senior managements expectations.

2. and, where applicable: demonstrate to other interested / concerned parties, that the
risk reducing controls in the Drilling Contractors 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 Contractors
Scope of Operations.

2. Assessment of the risks associated with hazards and sources of hazards and
effectiveness of the controls within the Drilling Contractors 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 Contractors
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 J ournal 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 Kellys 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 Kellys 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 m
3
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 drillers 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
HUBSIZE(in)
MINIMUM
VERTICAL BORE
(in)
RINGJOINTGASKET
RX BX
35.2(0.5M) 29
1
/
2
29
1
/
2

140.8(2M) 16 16
3
/
4
65
20 21
1
/
4
73
26
3
/
4
26
3
/
4

211.2(3M) 6 7
1
/
16
45
8 9 49
10 11 53
12 13
5
/
8
57
20 20
3
/
4
74
26
3
/
4
26
3
/
4

352(5M) 6 7
1
/
16
46
10 11 54
13
5
/
8
13
5
/
8
160
16
3
/
4
16
3
/
4
162
18
3
/
4
18
3
/
4
163
165
704(10M) 7
1
/
16

9 157
11 158
13
5
/
8
159
16
3
/
4
16
3
/
4
162
16
3
/
4
18
3
/
4
164
21
1
/
4
21
1
/
4
166
1056(15M) 7
1
/
16
7
1
/
16
156
9 9 157
11 11 158
13
5
/
8
13
5
/
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 1
st
case 2
nd
case 3
rd
case 4
th
case
Top R
b
R
b
R
p
R
p
Middle S R
p
R
b
S
Bottom R
p
S

S R
b
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 R
b
Middle Pipe Ram R
p
Bottom Drilling Spool S

For three ram BOPS with drilling spool following two better arrangements are
recommended

Position BOP Stack element Symbol
Top Pipe ram R
Upper middle Blind Ram R
b
Lower Middle Drilling Spool S
Bottom Pipe Ram R
p
(With double and single BOP)

Position BOP Stack element Symbol
Top Pipe ram R
p
Upper middle Blind Ram
Pipe Ram
R
b
R
s
Lower Middle Drilling Spool R
p

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.
28

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/cm
2
(psi)
Volume
required to
close litres
(gallons)
Annular Hydril GK 13
5
/
8
700(10,000) 141.3 (37.18)
Pipe ram Cameron U 13
5
/
8
700(10,000) 22 (5.80)
Blind ram Cameron U-Blind 13
5
/
8
700(10,000) 22 (5.80)
Pipe ram Cameron U 13
5
/
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/cm
2
(psi)
Precharge pressure
kg/cm
2
(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:














S
E
V
E
R
I
T
Y

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 Dos & Donts

Dos 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.

Donts 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 J ournal 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 P
Risk Level H-
M-L
Control 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 worn
Equipment striking the catwalk too hard
1 2 2 L
Slow pull and lower the equipment
Equipment or tool may fall away fromcatwalk
1 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, gumboots
Oil spill 1 3 3 L Spill to be controlled
Fire
4 3 12 M
Fire extinguisehers be placed / Permit
systemin place
Improper loading of material
3 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 fromtruck/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 maintenance
Chemical exposure 3 3 9 M Proper PPE, SWP / MSDS in place
Fire and explosion
5 3 15 H
Fire Extinguisehers be placed. / Other fire
control systemin 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
HAZARDIDENTIFICATION,RISKASSESSMENT&RISKCONTROLCBMDrillingSite.
Risk/Consequences
Hoisting Operations/Lifting equipments,tools
and tubulars up to the rig floor
1
2 Derrick Operations
3 Maintenance
4 Transportation
5 DG set operations
Personnel injury
Personnel injury
Personnel injury
Personnel injury
Equipment damage
Equipment damage,Injury to roustabouts
Equipment damage,Injury to roustabouts
Personal Injury
Personal Injury
Environmental problem
personal injury,property damage
Personal injury and equipment breakdown
Personnel injury
Personnel injury,property loss
Personnel injury,property loss
Health problems
Personnel injury and Equipment damage
Personnel injury
Personal injury and machinery loss
Persons falling in to the pit
Plastic sheeting - trip / slip hazard
Environmental problem
Personnel injury
Personnel injury(more than one),Equipment
damage,property loss
Health problems
S.No Activity / Operations Hazard Severity Probablity S P
Risk Level H-
M-L
Control measures to introduced to
reduce the risk
HAZARDIDENTIFICATION,RISKASSESSMENT&RISKCONTROLCBMDrillingSite.
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 fromheight 3 2 6 L Preoper PPE's
Wire line of the lifting armcan break which can result i
to physical hazard
4 2 8 M
Routine checkup to be done / operator to
inspect the machine before start of days
work.
Falling fromthe machine. 3 1 3 L Safe Working Procedures
Physical hazard fromthe use of improper slings and
shackles
4 3 12 M
Proper Slings to be used.
Burns fromthe sparks 1 4 4 L Face mask, hand gloves, coveralls
Physical hazard due to contact with hot shockups after
welding
1 4 4 L
Hand gloves
Physical hazard fromthe 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 heat
1 4 4 L
Avoide lond working intervals.
Physical hazard due to fall fromheight because of not
using proper PPEs(safety belt/helmet/safety shoes)
5 1 5 L
Proper PPE's
10 Handling Measured well drilling(MWD) tool Electric shock 2 2 4 L Rubber Gloves
Back strain 1 2 2 L Safe Working Practices
Back injury 2 2 4 L Safe Working Practices
Ergonomic 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 fromthe inhalation of toxic fumes in case o
damaged 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 Practices
Trapping of hands or legs in the rotary table 3 5 15 L Safe Working Practices
The floorman can come in contact with the rotating kell
/ tubular
2 5 10
M
Safe Working Practices. / Safe distance to
be maintained.
Falling fromheight 4 2 8 M Proper PPE's Guard Rails in place
Back sprain/Back injury 2 5 10 M Safe Working Practices
Over head falling objects 3 4 12 M Hard Hats
Flappers in open position and worker is unaware
3 4 12
M
Workers 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 available
Inhalation of chemical powder dus 2 3 6 L Proper PPE's, MSDS available.
17 High pressure line operations Leakage or burst of high pressure line
4 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 lithiumbatteries
8 Hydraulic cranes operations
Skin irritation
Eye 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 injury
Health problems
Personnel injury
Personnel injury
Personnel injury
Personnel injury/loss of life
Personnel injury
Personnel injury
Personnel injury
Personnel injury
Personnel injury,Equipment damage,property
loss
Health problems
Personnel injury
Personnel injury
Personnel injury
Personnel injury,Equipment damage,property
loss
Environmental problem
Personnel injury(more than one),Equipment
damage,property loss
Personnel injury
Personnel injury
Personnel injury
Personnel injury
Personnal injury
Personnel injury,Equipment damage,property
loss
Personnel injury
Personnel injury
S.No Activity / Operations Hazard Severity Probablity S P
Risk Level H-
M-L
Control measures to introduced to
reduce the risk
HAZARDIDENTIFICATION,RISKASSESSMENT&RISKCONTROLCBMDrillingSite.
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 fromAccumulator unit to BOP are
damaged.
5 4 20 H
Routine maintenance and inspection,
procedure in place, / The perssure line
fromaccumulator 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,property
loss
Personnel injury,Equipment damage,property
loss