DRILL FLOOR SAFETY

Best Practice Guide to Handling Tubulars

Introduction / List of Contributors 1. Pre-Job Planning 2. Toolbox Talk Onsite Risk Assessment 3. Executing the Job 4. Post Job Analysis 5. Supervisors Tips 6. Resources 7. Background & References

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Revision No. 1-2003

In November 1998 a workgroup consisting of cross industry representatives reviewed incident reports relating to handling tubulars on the rig floor. Underlying causes of incidents were listed and recurring ones ranked. Using this ranked list, a questionnaire based on ten common, but different, incidents was devised. Each of the incidents occurred due to one or more of the ranked underlying causes. After 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. The questionnaire was enthusiastically received and Step Change would like 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 Onsite Risk Assessment 3. Executing the Job 4. Post Job Planning 5. Supervisors Tips

The rig floor is still one of the most dangerous place on a drilling rig, and those who took part have made a valuable contribution to improving rigfloor safety. Step Change are aware of areas outwith the Rig 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. Also its contents can play an important part in rig floor competence and assessment.

List of Contributors
Global Santa Fe Maersk Contractors Noble Drilling Transocean Diamond Offshore ConocoPhillips Shell BP KCA/Deutag Franks UK 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. During 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.
These procedures are seen to be the essential starting point for an effective Toolbox Talk and Risk Assessment. 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
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overlooked by experienced hands who carry out the repetitive tasks under constant, normal operations.

1.6 Solid Teamwork is Essential

Solid/experienced teamwork is vital to safe operations. Teamwork is the basis for good communication and vice versa, good communication during the operation significantly contributes to a safe working environment.

1.4 Time Out for Safety Culture should be in Place

A well embedded Time Out for Safety culture helps to significantly reduce risks by allowing all members of the workforce to make an individual assessment that a situation needs to be stopped and discussed before the operation continues.

1.7 Keep Rig Floor as Clear as Possible

The rig floor should never be overloaded or congested with tools, equipment or people. Both supervisory and tubular handling personnel should be made aware of the potential problems inherent with overloading and congestion and use good housekeeping techniques to avoid them. Remove all excess equipment as soon as it is no longer needed. Keep to hand only that which is required.

1.5 Communication Needs to be Free-flowing

There must be a free flow of communication between the Driller, Floormen and Derrickman and any other concerned parties i.e. Casing crews. The Driller should also have a clearsight of the complete operation on the rig floor as well as at monkeyboard level. Communication is the most powerful tool for good, safe operations. Raise your concerns if youre not sure of anything!

1.8 Allocate Sufficient Storage Space and Use It!

Allocate enough storage space on the pipe deck, etc., for equipment storage, and ensure that everyone knows where things are supposed to be kept. Develop a culture of putting things in the correct storage space as soon as they are no longer required.

1.9 Create a Good Housekeeping Attitude

Plan sufficient time to clean and tidy up during the operation. Create an atmosphere where tidiness is expected and not considered nice to have. Remember, tidiness is an integral part of the job.

areas where a fall from the drill floor is possible.

1.12 Individual Competence is a Major Contributor

Individual competence is seen as a major contributor to rig floor safety. Competence systems need to really establish individual competence and not just satisfy the legal requirement. Individuals must feel able to say when they do not feel competent to do a job. Good supervisors 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. The issue of competency should be raised during all Toolbox Talks and Time Out for Safety meetings

1.10 Plan Equipment Requirements Well Ahead

Discuss as part of the Toolbox Talk/Risk Assessment what equipment is needed and what isnt required on the drillfloor. Use flush mounted slips to keep the rig floor clear of bulky and unwieldy work platforms which only add to rig floor congestion. Ensure that there is adequate detailed 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 to be readily available on the Rig Floor. Consideration should be given to stowage of back up equipment in other areas throughout the installation.

1.13 Use Experienced Roughnecks plus only one Green Hand at a time
Encourage a buddy system. It should always be the case that experienced personnel form the basis of the team. (This applies in all operations). All personnel should be made aware of the requirement to look after the green hands and conversely the green hands should be given the tools and forum to recognise their experience/knowledge limitations within the operation. Its often the case that new, keen personnel will try to carry out operations without full knowledge and experience. Use reliefs only for simple tasks, and preferably
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1.11 Draw and Stand in Quadrants on Rig Floor

Develop safe area map/quadrants which can be utilised to highlight hazardous and safe areas on the drill floor. This can be used as an overview tool in safe positioning training techniques e.g. highlight positions where equipment is moving overhead or

dont use Roustabouts at all (i.e. Floormen should break in shifts if there are sufficient available). However, if Roustabouts must be used, use them for the least hazardous tasks and preferably not during BHA (Bottom Hole Assembly) work. Derrickmen reliefs should be Floormen who are properly trained to be Derrickmen.

the joint enters drill floor. The use of inflatable casing protectors is also recommended as they dont just protect the threads of the pipe, but also restrict the rope from dropping off the bottom of the pipe as it is travelling. Many of the manual handling problems discussed here are eliminated when pipe is tailed using a small winch located near the V-door. Some rigs already use these winches which are relatively cheap. More sophisticated controlled feeding winches are now also available.

1.14 Training is of Vital Importance

In terms of experience, training is an issue not so much in the competency arena, but more so within actual hands on knowledge and time with respect to the handling of tubulars and associated hazards on the drill floor. The training directed at the experience level should build upon peoples 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: Have casing suppliers paint a band around joints of casing approximately 10 feet from the end of the joint. This will enable the Driller to better time the entry of the joint into the drill floor, which in turn will enable him to control the rate at which
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 Vary the discussion leader to encourage participation from all members of the team Use the toolbox talk to make 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. Use the TBT 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. Thats why many contractors now use TRICs (Toolbox Talk Risk Identification Cards) and seldom mention the words Toolbox Talk (TBT) by themselves. In the following pages you will find some generic Toolbox Talk tips followed by more specific risk assessment tips. Ensure all crew members know their role in the job. Highlight the fact that everyone has an obligation to act as a lookout/observer to warn others of danger. Encourage crew members to call for a Time Out for Safety at any point in the operation, if any aspect of the work is unclear or considered hazardous. Commit to repeating the TBT if the job changes in any way (weather, equipment, plan, sequence crew make-up etc.)

2.1 Toolbox Talk

Ensure sufficient time is given to the preparation of the toolbox talk. Use written procedures and risk analysis as the basis of the talk. Have appropriate levels of supervision present during the Toolbox Talk

 Be explicit in the TBT about the techniques to be used for handling pipe: Mechanical means or aids such as rope should be used to manoeuvre tubulars whenever possible. Never grip a pipe with fingers around it, and keep fingers safe by: Crossing hands and pushing pipe away from you Clenching hands Holding pipe with palms only

Ensure a common understanding amongst crew members of all communications methods e.g. radio call signs, hand signals etc. particularly for those working aloft in the derrick e.g. pipe stabbers working on the stabbing platform. Take particular care to ensure reliefs are fully aware of the agreed communications. Ensure casing contractors equipment checks and rig-up (especially the stabbing platform), are covered, and understood by all. Make a proper note of the TBT and any key points raised. Get all involved to acknowledge attendance. Discuss 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 supervisors/crew members have sufficient Risk Assessment knowledge and training to carry out effective Risk Assessments? If not, consider/request additional training in this essential skill. Are written procedures available for the Tubular Handling task? Are the procedures relevant and up to date?

Using two people for stabbing operations. Make everyone aware of green hands and ensure a buddy is assigned. Ensure the rig-up and down of equipment is fully discussed, as well as the operation itself.
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 Is there anything about the conditions prevailing e.g. weather, crew make-up, equipment condition, tubular type etc., which might make the procedures invalid for this operation? Have all hazards been identified? Have all hazards been assessed? What controls are in place/are required to reduce the hazard? What are the recovery possibilities if a hazard is realised? Are the crew involved, competent for the work identified? Are sufficient crew available (including reliefs) for the job? Are there green hands involved, and if so who is identified to coach and look after them? Has suitable time for training/coaching been allocated if required? Are supervisors aware assessment of crews? of training/

Have all necessary equipment to hand, and checked and serviced. Ensure rig-up and down of equipment is assessed for risks, as well as the operation itself. Communicate fully and comprehensively to all crew members. Look for opportunities communications to improve

Test for understanding of all team members Consider rotation of crew members, and use of a Take 5 break Use Toolbox Talk as the primary (but not only!) tool for communicating work plans and intentions.

Is the workplace as tidy as it can be for the start of a new task e.g. Remove all excess equipment Clean rigfloor to reduce slipping hazard
For a full risk assessment refer to the Step Change in Safety Task Risk Assessment guide.

Reliefs should: Have a strong interest and have the right attitude to take on the role of relief Report to the Driller prior to relieving Be open and declare when they dont 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 all possible hazards and warning them of any danger. If the ongoing job is hazardous then stop the job and hold a Toolbox Talk prior to the relief taking over. In other words, make sure that the relief isnt thrown in at the deep end!

Highlight during the Toolbox Talk that a relief is present Treat reliefs as high risk and with caution Driller should slow down operations and be vigilant Assign one competent crew member to look after (mentor) the relief until the relief is fully confident and competent Continually coach the relief (preferably one-on-one) Scrutinise the relief well, take time to determine the knowledge and skill level of the relief and assign tasks accordingly. If Roustabouts must be used, use them for the least hazardous tasks and preferably not during BHA (Bottom Hole Assembly) work. Derrickmen reliefs

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3.3 Communication Needs to be Excellent

Does your team need to communication? Refer to 1.5. improve

3.4 Keep the Rig Floor as Clear as Possible

Make both supervisory and tubular handling personnel aware of the potential problems inherent with overloading and congestion!

3.5 Keep the Work Area Clear

should be Floormen who are properly trained to be Derrickmen. Prior to tripping operations, clear the space of all equipment not required for the operation and ensure that there are no slip/trip hazards present. After breaking connections place the mud bucket, tongs or iron roughneck well out of the way. Clear a path from the V-Door to the rotary table to ensure free passage for joints tailed and the person tailing joints. As room is limited during casing operations its vitally important that all space available is clear and utilised. Remove all excess equipment as soon as it is no longer needed. Keep to hand only that which is required. Do you allocate sufficient time to clean up as and when required? Clean during regular stops after each sequence of operations. At least every trip there should be an assessment of what is and isnt needed, and time taken to make any adjustments to tools and equipment required.
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3.2 Maintain a Clear Line of Sight for the Driller

This doesnt mean that you should stay out of his sight! There must be a free flow of communication between the Driller, Floormen and Derrickman. The Driller 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 Drillers restricted view. It is also essential that the Driller maintains communication with the tubular handling personnel and highlights any visibility problems within the operation

3.6 Time Out for Safety

If anybody at any time is not sure of their task, is uncomfortable with the operation in anyway, or observes an unsafe act or situation, - then STOP!! Take time to discuss and correct the situation before continuing.

3.9 Use the Right Method

Allow the rope to slide through your gloved hands - dont try to hold the weight as the rope takes the bite. Gradually increase pressure on the rope as it passes through your hands until it stops where you want it to (this method is for use with lighter pipe).

3.7 Positioning needs to be taught via Training/Buddy System

All personnel need to be aware of Safe Positioning in relation to tubular handling. It is also important to emphasis the buddy system approach, whereby personnel alert each other of potential danger areas and appropriate safe areas.

3.10 Use a Rope along with a Shackle

When tailing in from the V-Door, secure the dead end of the rope to one side of the VDoor and thread the rope through a shackle attached to the opposite side of the V-Door. When tailing heavy casing into the floor, use 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 prevent the rope slipping off the bottom of the pipe being tailed in. Check that the rope is double wrapped around the other securing point when heavy pipe is being tailed. Always replace worn or mud contaminated rope. Take the time to learn how to tie and use proper knots such as: the Bowline and the Round turn and two half hitches.

3.11 Use Flush Mounted Slips

Do you use flush mounted slips to keep the rig floor clear of bulky and unwieldy work platforms?

3.12 Beware of Temporary Equipment

Temporary equipment, because of its very nature, MUST undergo pre-operational checks. On your rig there should be a temporary equipment system in place: the best systems include manufacturers and regularly updated rig contractors check lists. These check lists should be reviewed during the post job review, and updated if

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required. Prior to using this equipment also check the Certificates and ensure they will not run out prior or during the use of the equipment.

3.15 Always Beware!

Pipe can bounce off like a spring if it strikes a racked pipe. If it looks as if the guided pipe will swing hard against racked pipe then LET GO, and stay well out of the way. Very few people can restrain a wild pipe so DO NOT TRY!!

3.13 Concentrate on the Job

Supervisors - do you notice when crew members drift? Its vital to give people a break or change out team members when they lose concentration.

3.16 Load Hoisting Operations Tips

Clearly 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. Prior to leaving his position, the derrickman should close all monkey board fingers. Always stay clear of suspended loads. When pipe is being lifted by a sling, ensure slings are always double wrapped around the pipe. Single wrapped slings can slip with potentially disastrous consequences.

3.14 Supervisors should encourage Feedback

Do you encourage team members to speak up and listen to what they have to say?

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3.17 Individual Competence

Individual competence is seen as a major contributor to rig floor safety. Competence systems need to really establish the level of individual competence and not just satisfy the legal requirement. Individuals must feel that they can say when they do not feel competent to do a job. Good supervisors 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.

Teamwork Tips
TEAM stands for TOGETHER EVERYONE ACHIEVES MORE! Looking after each other is an essential aspect of safe teamwork, which must be practiced throughout rig floor activities. Teamwork means making sure that all work areas, escape routes and emergency equipment are clear at all times. Teamwork also means communicating more than you think you need!

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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

At the end of an operation a debrief or wash up meeting should occur. All 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. Ask 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

Develop the habit of cleaning all tools and equipment after each job and putting them back in their correct places. If something is damaged, worn or needs replacing, fix it before you put it away. If you dont have the time or spare parts, make a note in the Handover Book so that everyone knows then it wont be an unwelcome surprise next time its needed!

How did it work best? Why did it work? What did not work well? Why did it not work well? What can we do to improve next time?

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4.4 Learn from the Teams experience

After 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

Keep a tally of what worked well and what needs improvement. Incorporate these into the next planning or Risk Assessment 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. PLAN, EXECUTE, MEASURE & LEARN

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 Supervisors should be suitably experienced. Regular assessments of supervisors abilities, job knowledge, strengths and weaknesses are required to ensure that the highest levels of supervision are maintained. Risk assessment skills are an essential part of a supervisors capabilities. Where a weakness is identified, training should be given to rectify the situation. Supervisors should ensure full participation in Toolbox Talks, encouraging crews to actively contribute in discussing all aspects of the actual 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. This in turn should promote teamwork as success is achieved. Supervisors should allocate sufficient time for feedback at Toolbox Talks and that the TBT leader is rotated. Supervisors should encourage 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! Mentoring or Buddy Systems are much valued by rig crew members:

5. Supervisors Tips
Good supervisors are the catalysts for enhancing teamwork 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. All supervisors must lay the foundation for the crew to perform tasks by fully explaining what is required to complete them. All available information, materials and tools must be identified prior to starting the task. Supervisors should lead by example: they must be aware of all procedures and regulations concerning the task and pass this information on to the work force.

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 The mentor can assist the supervisor in the assessment of a persons competence The mentor can assist in the recording of progress in the log book or competency passport The mentor can assist in the identification of further training needs

use crew rotation or a Time out break to effect an improvement. Supervisors must provide good quality instruction and guidance. Supervisors must allow the not-yetcompetent person to carry out only simple tasks on the rig floor until he is deemed to be more competent. The rig floor supervisor must be involved in the assessment of a persons competency. A persons competence can only be effectively assessed by means of thorough observation. An assessment must also consider a persons experience, ability, knowledge and skill.

The buddy system can be put to good effect if experienced personnel communicate with one another and, more importantly, if experienced personnel communicate with green hands. This is important! The appointment of a lead roughneck on the rig floor is seen positively on some rigs. It is essential that they are well experienced and have the respect of the crew. Individual alertness will always play a part in safety standards. Supervisors need to be on the lookout for drifting attention due to complacency or excessive stress, and

Training Tips: Adequate time must be allowed for training Training needs must be identified by the supervisor and/or mentor Records of training and assessment must be maintained (e.g. a log book or passport) Refresher or repeat training needs must be considered A mentor should support the provision of on-the-job training

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The following information posters relating to drill floor tubular handling operations are available for download from the Step Change in Safety website. www.stepchangeinsafety.net Manual Tongs: - Dos and Donts Manual Tongs: - Rig Floor safety Power Tongs: - Rig Floor safety Toolbox Talk:- Crew involvement posters

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In January 1998, 56 international drilling professionals, representing 23 operator and drilling contractor organisations convened in Houston for the first global, industry wide drilling Safety Leadership workshop. These leaders represented a cross section of operators, drilling contractors and service companies. They created the Houston Declaration which is a formula for step change based on personal commitment, leadership and behaviour:We pledge our commitment to work together to achieve a Step Change in safety performance in all the areas where we have 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 Houston Declaration 29th January 1998

The result is a global drilling safety leadership campaign. The aim of this campaign is to create a permanent cultural change in safety throughout our industry. Regional work groups have been formed to develop plans of action for achieving a step change in safety in their area and a steering group has been formed to help continue the effort. Common themes form the backbone of strategic plans. Five common themes which emerge are: Safety Leadership - common principles to provide consistency People standards common expectations and

Behaviour - cross industry networks sharing information Training - common training standards and competency levels Procedures - common measures and benchmarks performance

http://www.stepchangeinsafety.net is the website of the Step Change in Safety initiative. There are a large number of excellent resources available from the site, both drilling specific, and more general safety tools and improvement ideas.

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website www.stepchangeinsafety.net email info@stepchangeinsafety.net telephone 01224 881272 fax 01224 882350 address P.O. Box 10406 Aberdeen AB12 3YL