DRILL FLOOR SAFETY
Best Practice Guide to Handling Tubulars
Introduction / List of Contributors
2
1. Pre-Job Planning
3
2. Toolbox Talk Onsite Risk Assessment
7
3. Executing the Job
10
4. Post Job Analysis
15
5. Supervisors Tips
17
6. Resources
19
7. Background & References
20
R evision N o. 1-200 1-2003 3
1
In N ovember 1998 a workgroup consisting of cross industry representatives reviewed incident
reports
relating
to
handling
tubulars on the rig floor. U nderlying causes of incidents were listed and recurring ones ranked.
U sing
this
rank ed
list,
a
questionnaire based on ten common, but
T he rig floor is still one of the most
different, incidents was devised. Each of
dangerous place on a drilling rig, and those
the incidents occurred due to one or more
who took part have made a valuable
of the rank ed underlying ca uses. A fter
contribution to improving rigfloor safety.
considering a description of the incident, the reader was asked to describe how his rig team - or company systems - currently prevented
this
type
of
incident.
T he questionnaire was enthusiastically received and S tep C hange would lik e to thank the respective companies for their contribution. The material in this bestpractice guide is taken from the replies and tips
that
came
out
of
the
returned
questionnaires. These replies have been categorised into five distinct stages: 1. Pre-Job Planning 2. Toolbox Talk O nsite R isk A ssessment 3. Executing the Job 4. Post Job Planning 5. Supervisors Tips
2
Step C hange are aware of areas outwith the R ig Floor where handling of tubulars have resulted in injury to personnel, however the intent of this booklet is to focus on the areas of concern as highlighted by the responses received in the industry questionnaire. The information contained in this booklet will be of use, not only at safety meetings and toolbox talks, but also for presentations and personal use. A lso its contents can play
an
important
part
in
rig
floor
competence and assessment.
List of Contributors • G lobal Santa Fe
• C onocoP hillips
• M aersk C o ntractors
• Shell
• N oble D rilling
• BP
• Transocean
• K C A /D eutag
• D iamond O ffshore
• Franks U K Ltd
1.1 Ensure Toolbox Talks are held Toolbox talks are an ideal method of capturing and communication of safety issues at the worksite. Variation in who leads the discussion is seen as a plus and there is a growing acceptance throughout the industry that a Toolbox Talk is seen as an integral part of the risk assessment process. D uring the Toolbox Talk the risks to each individual involved in the job should be considered and discussed.
1.2 Rig Specific Procedures should be in place to cover all aspects of the operation. T hese procedures are seen to be the essential starting point for an effective Toolbox Talk and R isk A ssessment. The procedures should be of such quality to be useable and easily understood during the Toolbox Talk.
1.3 Hold 10 minute Pre-Job Talk prior to any operation Pre-Job Talks should be unique for every operation. They should draw on previous experience from similar operations and learning points from other rig crews, and be given where the full participation of all team members can be obtained (old experience and new experience) . A new set of eyes can
sometimes
highlight
hazards 3
overlooked by experienced hands who carry
out
the
repetitive
tasks
1.6 Solid Teamwork is Essential
under Solid/experienced teamwork is vital to safe
constant, normal operations.
operations. Teamwork is the basis for good
1.4 Time Out for Safety Culture should be in Place
communication and vice versa, good communication
during
the
operation
significantly contributes to a safe working A well embedded “ T ime O ut for Safety”
environment.
culture helps to
1.7 Keep Rig Floor as Clear as Possible
significantly reduce risks by allowing all members of the workforce to
The rig floor should never be ‘overloaded’
make an
or ‘congested’ with tools, equipment or
individual
people. Both supervisory and tubular
assessment that a
handling personnel should be made aware
situation needs to be stopped
of the potential problems inherent with
and discussed before the
overloading and congestion and use good
operation continues.
housekeeping techniques to avoid them. R emove all excess equip ment as soon as it
1.5 Communication Needs to be Free-flowing
is no longer needed. K eep to hand only that
T here must be a free flow of communication
1.8 Allocate Sufficient Storage Space and Use It!
between
the
D riller,
Floormen
which is required.
and
D errickma n and any other concerned
4
parties i.e. C asing crews. T he D riller should
A llocate enough storage space on the pipe
also have a clearsight of the complete
deck, etc., for equipment storage, and
operation on the rig floor as well as at
ensure that everyone knows where things
monkeyboard level. C ommunication is the
are supposed to be k ept. D evelop a culture
most
safe
of putting things in the correct storage
operations. Raise your concerns if you’re
space as soon as they are no longer
not sure of anything!
required.
powerful
tool
for
good,
1.9 Create a Good Housekeeping Attitude
areas where a fall from the drill floor is
Plan sufficient time to clean and tidy up
1.12 Individual Competence is a Major Contributor
possible.
during the operation. C reate an atmosphere where
tidiness
is
expected
and
not
consid ered ‘ nice to have’. R ememb er,
Individual competence is seen as a major contributor to rig floor safety. C ompetence
tidiness is an integral part of the job.
systems need to really establish individual
1.10 Plan Equipment Requirements Well Ahead
competence and not just satisfy the legal requirement. Individuals must feel able to say when they do not feel competent to do
D iscuss as part of the Toolbox Talk /R isk
a job . G ood supervisors should k now the
A ssessment what equipment is needed
strengths and weaknesses of their team,
and what isn’t required on the drillfloor. U se
and not ask someone to do a job for which
flush mounted slips to keep the rig floor
they are not qualified or competent. The
clear of bulky and unwieldy work platforms
issue of competency should be raised
which only add to rig floor congestion.
during all Toolbox Talks and T ime O ut for
Ensure that there is adequate detailed
Safety meetings
planning well ahead of the operation of what equipment is required and when. Personnel
should
be
encouraged
to
challenge the need for back up equipment
1.13 Use Experienced Roughnecks plus only one ‘Green’ Hand at a time
to be readily available on the R ig Floor. C onsideration should b e given to stowage
Encourage a buddy system. It should
of back up equipment in other areas
always be the case that experienced
throughout the installation.
personnel form the basis of the team. (This applies in all operations). A ll personnel
1.11 Draw and Stand in Quadrants on Rig Floor
should be made aware of the requirement to
look
after
the
green
hands
and
conversely the green hands should be D evelop safe area “ map/quadrants” which
given the tools and forum to recognise their
can be utilised to highlight hazardous and
experience/knowledge limitations within the
safe areas on the drill floor. T his can be
operation. It’s often the case that new, keen
used as an overview tool in safe positioning
personnel will try to carry out operations
training techniques e.g. highlight positions
without full knowledge and exp erience. U se
where equipment is moving overhead or
reliefs only for simple tasks, and preferably 5
don’t use R oustabouts at all ( i. e. Floormen
the joint enters drill floor.
should break in shifts if there are sufficient available) . H owever, if R oustabouts must be used, use them for the least hazardous task s and p referably not during B H A ( B ottom H ole A ssembly) work. D errickmen reliefs
should
be
Floormen
who
are
• T he use of inflatable casing protectors is also recommended as they don’t just protect the threads of the pipe, but also restrict the rope from dropping off the bottom of the pip e as it is travelling. M any of
properly trained to be D errickm en.
the
manual
handling
problems
discussed here are eliminated when pipe
1.14 Training is of Vital Importance
is tailed using a small winch located near the V-door. Some rigs already use these
In terms of experience, training is an issue
winches which are relatively cheap. M ore
not so much in the competency arena, but
sophisticated controlled feeding winches
more so within actual hands on knowledge
are now also available.
and time with respect to the handling of tubulars and associated hazards on the drill floor.
The
‘experience’
training level
directed
should
at
build
the upon
people’s own existing experience of tubular operations. It is also worth noting that for green hands, mentoring by experienced hands who share their knowledge is an essential part of green hand training.
1.15 Investigate and Incorporate New Ideas Investigate and incorporate new ideas, for example: • H ave casing suppliers paint a band around joints of casing approximately 10 feet from the end of the joint. T his will enable the D riller to better time the entry of the joint into the drill floor, which in turn will enable him to control the rate at which 6
• Vary the discussion leader to encourage participation from all members of the team • U se the toolbox talk to mak e all those, both directly and indirectly, involved in the operation fully aware of the total job. • Encourage all crew members to get actively involved in the TBT, by adopting a
constructive
and
questioning
approach. • U se the TB T to get ‘buy-in’ from all crew members to the approach to the job. These days, more often than not, risks of a job are assessed during the Toolbox talk. T hat’s why many contractors now use
• Ensure all crew members know their role in the job.
T R IC s (Toolbox Talk R isk Id entification
• H ighlight the fact that everyone has an
C ards) a nd seldom mention the words
obligation to act as a lookout/observer to
‘Toolbox Talk’ ( T BT ) by themselves.
warn others of danger.
In the following pages you will find some
• Encourage crew members to call for a
generic Toolbox Talk tips followed by more
‘T ime O ut for Safety’ at any point in the
specific risk assessment tips.
operation, if any aspect of the work is unclear or considered hazardous.
2.1 Toolbox Talk
• C ommit to repeating the T B T if the job
• Ensure sufficient time is given to the preparation of the toolbox talk.
changes in any way ( weather, equipment, plan, sequence crew make-up etc.)
• U se written procedures and risk analysis as the basis of the talk. • H ave appropriate levels of
supervision
present during the Toolbox Talk
7
• Be
explicit
in
the
TBT
ab out
the
techniques to be used for handling pipe:-
• Ensure amongst
a
common crew
understanding
members
of
all
• M echanical means or aids such as rope
communications methods e.g. radio call
should be used to manoeuvre tubulars
signs, hand signals etc. particularly for
whenever possible.
those working aloft in the derrick e.g. pipe stabbers working on the stabbing
• N ever grip a p ipe with fingers around it, and keep fingers safe by:• C rossing hands and pushing pip e away
platform. Take particular care to ensure
reliefs are fully aware of the agreed communications.
from you • C lenching hands • Holding pipe with palms only
• Ensure casing contractors equipment checks
and
rig-up
(especially
the
stabbing platform), are covered, and understood by all. • M ake a proper note of the TB T and any key points raised. G et all involved to ack nowledge attendance. D iscuss start up of operation with caution, until all personnel are comfortable with their individual task.
2.2 Risk Assessment Be satisfied that the following questions can be suitably addressed otherwise complete a full risk assessment. • Do • U sing two people for stabbing operations.
supervisors/crew mem bers have
sufficient R isk A ssessment knowledge and training to carry out effective R isk
• M ak e everyone aware of g reen hands and ensure a buddy is assigned. • Ensure the rig-up and down of equip ment is fully discussed, as well as the operation
A ssessments? If not, consider/request additional training in this essential skill. • A re written procedures available for the Tubular H andling task?
itself. • A re the procedures relevant and up to 8
date?
• Is there anything about the conditions prevailing e.g. weather, crew make-up,
• H ave all necessary equipment to hand, and checked and serviced.
equipment condition, tubular type etc., which might make the procedures invalid
• E nsure rig-up and down of equipment is assessed for risks, as well as the
for this operation?
operation itself. • Have all hazards been identified? • C ommunicate fully and comprehensively • H ave all hazards been assessed? • What controls are in place/are required to reduce the hazard?
to all crew members. • L ook
for
opp ortunities
hazard is realised?
im prove
communications • Test for und erstand ing
• What are the recovery possibilities if a
to
of
all
team
members • C onsider rotation of crew members, and
• A re the crew involved, competent for the work identified?
use of a “Take 5” break • U se Toolbox Talk as the primary ( but not
• A re sufficient crew availab le ( including
only!) tool for communicating work plans and intentions.
reliefs) for the job? • Are there “green hands” involved, and if so who is identified to coach and look after them? • H as suitable time for training/coaching been allocated if required? • A re
supervisors
aware
of
trai ning/
assessment of crews? Is the workplace as tidy as it can be for the start of a new task e.g. • Remove all excess equipment • C lean rigfloor to reduce slipping hazard
For a fullrisk assessm en t refer to the S tep C hang e in S afety ‘Task R isk A ssessm ent’ guide.
9
Reliefs should: • H ave a strong interest and have the right attitude to take on the role of relief • R eport to the D riller prior to relieving • B e open and declare when they don’t feel confident • Be identified by a special helmet ( green colour) or jacket • Initially only concentrate on one facet of the job.
Regular Team Members should:
3.1 Ensure Reliefs get a Good Handover Let reliefs watch the job in hand first. Then one of the regular team members should explain the job clearly to them, describing
• H ighlight during the Toolbox Talk that a relief is present • Treat reliefs as high risk and with caution • D riller should slow down operations and be vigilant
all possible hazards and warning them of any danger. If the ongoing job is hazardous
• A ssign one competent crew member to
then stop the job and hold a Toolbox Talk
look after (mentor) the relief until the relief
prior to the relief taking over. In other words,
is fully confident and competent
make sure that the relief isn’t thrown in at the deep end!
• C ontinually coach the relief (p referably one-on-one) • Scrutinise the relief well, tak e time to determine the knowledge and skill level of the relief and assign tasks accordingly. If R oustabouts must be used, use them for the least hazardous tasks and preferably not during BHA (Bottom Hole A ssemb ly)
10
work.
D errick men
reliefs
3.3 Communication Needs to be Excellent D oes
your
team
need
to
im prove
communication? Refer to 1.5.
3.4 Keep the Rig Floor as Clear as Possible M ak e
b oth
supervisory
and
tubular
handling personnel aware of the potential problems inherent with overloading and congestion!
3.5 Keep the Work Area Clear Prior to tripping operations, clear the space should be Floormen who are properly
of all equipment not required for the
trained to be D errick men.
operation and ensure that there are no
3.2 Maintain a Clear Line of Sight for the Driller This doesn’t mean that you should stay out of his sig ht! T here must be a free flow of comm unication
b etween
the
D riller,
Floormen and D errickman. T he D riller should also have a clear sight of the complete operation on the rig floor as well as at monkey board level. Personnel should be made aware of the problems associated with the D riller’s restricted view. It is also essential
that
the
D riller
ma intains
communication with the tubular handling personnel and highlights any visibility problems within the operation
slip/trip hazards present. A fter breaking connections place the mud bucket, tongs or iron roughneck well out of the way. C lear a path from the V-D oor to the rotary table to ensure free passage for joints tailed and the person tailing joints. A s room is limited during
casing
operations
it’s
vitally
important that all space available is clear and utilised. R emove all excess equipment as soon as it is no longer needed. K eep to hand only that which is required. D o you allocate sufficient time to clean up as and when required? C lean during regular stops after each sequence of operations. A t least every trip there should be an assessment of what is and isn’t needed, and time taken to make
any
adjustments
to
tools
and
equipment required. 11
3.6 Time Out for Safety
3.9 Use the Right Method
If anybody at any time is not sure of their
A llow the rope to slide through your gloved
task, is uncomfortable with the operation in
hands - don’t try to hold the weight as the
anyway, or observes an unsafe act or
rope tak es the bite. G radually increase
situation, - then ST O P ! ! Take time to
pressure on the rope as it passes through
discuss and correct the situation before
your hands until it stops where you want it
continuing.
to (this method is for use with lighter pipe).
3.7 Positioning needs to be taught via Training/Buddy System
3.10 Use a Rope along with a Shackle
A ll personnel need to be aware of Safe
When tailing in from the V-D oor, secure the
Positioning in relation to tubular handling. It
dead end of the rope to one side of the V-
is also important to emphasis the buddy
D oor and thread the rope through a shackle
system approach, whereby personnel alert
attached to the opp osite sid e of the V-D oor.
each other of potential danger areas and
When tailing heavy casing into the floor, use
appropriate safe areas.
a double wrap of rope on the shackle to increase friction.
3.8 Use Rope to Restrain Pipe Tie the rope onto a high securing point to
3.11 Use Flush Mounted Slips
prevent the rope slipping off the bottom of
D o you use flush mounted slips to keep the
the pipe being tailed in. C heck that the rope
rig floor clear of bulky and unwieldy work
is double wrapped around the other
platforms?
securing point when heavy pipe is being tailed.
A lways replace
worn or
mud
contaminated rope. Take the time to learn
3.12 Beware of Temporary Equipment
how to tie and use proper knots such as: the B owline and the R ound turn and two half hitches.
Temporary equipment, because of its very nature, M U ST
undergo pre-operational
checks. O n your rig there should b e a temporary equipment system in place: the best systems include manufacturer’s and regularly updated rig contractor’s check lists. T hese check lists should be reviewed during the post job review, and updated if
12
required. Prior to using this equipment also check the C ertificates and ensure they will not run out prior or during the use of the equipment.
3.15 Always Beware! P ipe can bounce off lik e a spring if it strik es a racked pipe. If it looks as if the guided pipe will swing hard against racked pipe
3.13 Concentrate on the Job
then LET G O , and stay well out of the way. Very few people can restrain a “wild” pipe
Supervisors - do you notice when crew
so D O N O T T R Y ! !
members ‘drift’? It’s vital to give people a break or change out team members when they lose concentration.
3.14 Supervisors should encourage Feedback D o you encourage team m embers to speak up and listen to what they have to say?
3.16 Load Hoisting Operations Tips • C learly identify roles of staff when lifting and
hoisting,
including
that
of
an
observer. • The observer should frequently look up during the lifting operation. • Lower the load if/when the lift snags. • P rior
to
leaving
his
position,
the
derrickman should close all monkey board fingers. • A lways stay clear of suspended loads. • When pipe is being lifted b y a sling,
ensure slings are always double wrapped around the pipe. Single wrapped slings can
slip
with
potentially
disastrous
consequences.
13
3.17 Individual Competence
Teamwork Tips
Individual competence is seen as a major
TEA M stands for TO G ETH ER EVERYO NE
contributor to rig floor safety. C omp etence
A C H IEVES M O R E! Looking after each other
systems need to really establish the level of
is an essential aspect of safe teamwork,
individual competence and not just satisfy
which must be practiced throughout rig floor
the legal requirement. Individuals must feel
activities. Teamwork means making sure
that they can say when they do not feel
that all work areas, escape routes and
competent to do a job. Good supervisors
emergency equipment are clear at all times.
should know the strengths and weaknesses of their team, and not ask someone to do a job for which they are not qualified or competent.
14
Teamwork also means communicating more than you think you need!
4.2 Create an Open Culture Supervisors should foster and develop a culture where operations are discussed openly between all crews, so that the entire rig team develops and progresses.
4.3 Take Time to Review A t the end of an operation a deb rief or ‘wash up’ meeting should occur. A ll parties must discuss report both successes and failures. Supervisors should talk to all the crews, floor hands, deck crew, service hands and so on. Establish how
they
thought the job went. A sk open-ended questions to gain maximum information: Who? - What? - Where? - Why? - When? How? • What do you think happened? • What worked well?
4.1 A Place for Everything and Everything in its Place D evelop the habit of cleaning all tools and
• “How did it work best?” • “Why did it work?” • What did not work well?
equipment after each job and putting them back in their correct places. If something is damaged, worn or needs replacing, fix it
• Why did i t not work well? • What can we do to improve next time?
before you put it away. If you don’t have the time or spare parts, make a note in the Handover Book so that everyone knows then it won’t be an unwelcome surprise next time it’s needed! 15
4.4 Learn from the Team’s experience A fter all, together you did the work you all planned! Incorporate constructive ideas into future plans, re-think areas the team constructively criticises.
4.5 Standardise and Incorporate New Ideas K eep a tally of what worked well and what needs improvement. Incorporate these into the next planning or R isk A ssessment exercise to ensure that a culture of continuing improvement is created. To make sure everybody learns, share these ideas with both your back to back crew and the crews on field break. P LA N , EX EC U T E, M EA S U R E & L EA R N
16
• Sup ervisors
should
be
suitab ly
experienced. R egular assessments of supervisors’ abilities, job knowledge, strengths and weak nesses are required to ensure
that
supervision
the
highest
levels
are
maintained.
of
R isk
assessment skills are an essential part of a supervisors capabilities. Where a weakness is identified, training should be given to rectify the situation. • Supervi sors participation
and
communication. Experienced, positive supervisors who can communicate the hazards, risks and instill the culture for ‘stepping back’ assessing the operation and taking the necessary actions to ensure safe operations are essential. • A ll supervisors must lay the foundation for the crew to perform tasks by fully explaining what is required to complete them. A ll available information, materials and tools must be identified prior to starting the task. • Supervisors should lead b y exam ple: they must be aware of all procedures and regulations concerning the task and pass this information on to the work force.
Toolbox
full Talks,
in discussing all aspects of the actual
• G ood supervisors are the ca talysts for teamwork
in
ensure
encouraging crews to actively contribute
5. Supervisors Tips
enhancing
should
method of performing the task. They should ask questions of the work party to identify their levels of experience and job knowledge. Planning as a team should help identify all the known hazards and cultivate new ideas. T his in turn should promote
teamwork
as
success
is
achieved. • Supervi sors should allocate sufficient time for feedback at Toolbox Talks and that the TBT leader is rotated. • Sup ervisors should
encourag e team
members to speak up and listen to what they have to say. Supervisors should use the experience of the workforce to expand their own job knowledge. You are never too old to learn! • M entoring or B uddy Systems are much valued by rig crew members:
17
• T he mentor can assist the supervisor in the
assessment
of
a
person’s
competence
use crew rotation or a “Time out” break to effect an improvement. • Supervisors must provide good quality
• T he mentor can assist in the recording of
instruction and guidance.
progress in the log book or competency • Supervisors must allow the not-yet-
passport • T he mentor can assist in the identification
competent person to carry out only simple tasks on the rig floor until he is
of further training needs
deemed to be more competent. • T he rig floor supervisor must be involved in
the
assessment
of
a
person’s
competency. • A person’s comp etence can only be effectively
assessed
by
means
of
thorough observation. • A n assessment must also consider a person’s experience, ability, knowledge and skill. • The buddy system can be put to good effect
if
experienced
personnel
communicate with one another and, more im portantly, if exp erienced p ersonnel communicate with green hands. This is
important!
Training T ips: • A dequate time must b e allowed for training • Training needs must be identified by the supervisor and/or mentor
• T he appointment of a lead roughneck on the rig floor is seen positively on some
• R ecords of training and assessment must
rigs. It is essential that they are well
be maintained (e.g. a log book or
experienced and have the respect of the
passport)
crew. • Individual alertness will always play a part in safety standards. Supervisors need to be on the lookout for drifting attention due 18
to complacency or excessive stress, and
• R efresher or repeat training needs must be considered • A mentor should support the provision of on-the-job training
The following information posters relating to drill floor tubular handling operations are available for download from the Step C hange in Safety website. www.stepchangeinsafety.net M anual Tongs: - D o’s and D on’ts M anual Tongs: - R ig Floor safety P ower Tongs: - R ig Floor safety Toolbox Talk :- C rew involvement posters
19
In January 1998, 56 international drilling
The result is a global drilling safety
professionals, representing 23 operator
leadership campaign. The aim of this
and
organisations
campaign is to create a permanent cultural
convened in H ouston for the first global,
change in safety throughout our industry.
industry wide drilling Safety Leadership
R egional work groups have been formed to
workshop. These leaders represented a
develop plans of action for achieving a step
cross
drilling
change in safety in their area and a steering
contractors and service companies. They
group has been formed to help continue
created the H ouston Declaration which is a
the effort. C omm on themes form the
formula
backbone of strategic plans. Five common
drilling
contractor
section
personal
for
of
‘step
operators,
change’
commitment,
based
leadership
on and
themes which emerge are:
behaviour:Safety Leadership - common principles to “We pledge our commitment to work
provide consistency
together to achieve a S tep C hange in safety
People
performance in all the areas where we have
standards
activity. We believe that a ‘step change’ in safety can be achieved through personal commitment,
leadership,
the
way
we
behave and the way we work together” H ouston D eclaration 29th January 1998
-
common
expectations
and
Behavi our - cross industry networks sharing information Training - common training standards and competency levels Procedures
-
common
performance
measures and benchmarks http://www.stepchangeinsafety.net is the website of the Step C hange in S afety initiative. There are a large number of excellent resources available from the site, both drilling specific, and more general safety tools and improvement ideas.
20
website www.stepchangeinsafety.net email
[email protected] telephone 01224 881272 fax 01224 882350 address P.O. Box 10406 Aberdeen AB12 3YL