OISD-RP-182

August, 2000

Recommended Safe Procedures & Guidelines

For

Workover and Well Stimulation Operations

Prepared by:

COMMITTEE ON ABOVE SUBJECT

OIL INDUSTRY SAFETY DIRECTORATE

ND
KAILASH, 2 FLOOR
26, K.G. MARG
NEW DELHI – 110 001
 FOREWORD

The purpose of these guidlines are to assist the oil well servicing industry in prevention of accidents.

It is recognised that these guidline cannot possibly cover all the problems which may arise in the
operation and maintenance of oil well servicing equipment. Owners of servicing equipment and their
employees should constantly be alert to unforeseen hazards and realise that changing conditions will
present new exposures which must be met with appropriate precautions. These guidelines should,
however, assist each individual worker to improve his work methods and reduce accidents.

The recommendations should be used only when applicable and with modifications as necessary due
to operating conditions, type of equipment, etc. Nothing herein shall be deemed to constitute the
setting up of minimum or maximum standards for the oil well servicing operations, or to regulations.

Suggestions are invited from the users after it is put into practice to improve the document further.
Suggestions for amendments to this document should be addressed to:

The Coordinator
Committee on Recommended Safe Practices for
Workover and Stimulation Operations
OIL INDUSTRY SAFETY DIRECTORATE
ND
KAILASH, 2 FLOOR
26, K.G. MARG
NEW DELHI – 110 001

These Guidelines are in no way supersedes the statutory requirements of bodies like DGMS, CCE or
any other Government Body which must be followed as applicable.
 COMMITTEE
ON
RECOMMENDED SAFE PRACTICES FOR WORKOVER AND STIMULATION OPERATIONS

S.No. Name Organisation

1. Shri P.K. Borthakur ONGC Leader

2. Shri Gulab Singh OISD Coordinator

3. Shri A.K. Verma ONGC Member

4. Shri T.H. Mazumdar OIL Member

5. Shri A. Satyanarayana ONGC Member

6. Shri A.K. Mathur ONGC Member

7. Shri P.S. Hyanki ONGC Member

 CONTENTS
---------------------------------------------------------------------------------------------------------------------------
SECTION PAGE NO.

1.0 INTRODUCTION 1

2.0 PURPOSE AND SCOPE 1

3.0 DEFINITIONS 1

4.0 RECOMMENDED SAFE GENERAL OPERATING PRACTICES 3

5.0 PRE-OPERATION CONFERENCE & SAFETY MEETINGS 8

6.0 RIGGING UP AND RIGGING DOWN 8

7.0 WELL SERVICING EQUIPMENT AND PROCEDURES 9

8.0 WELL SUBDUING 15

9.0 WELL CONTROL EQUIPMENT AND OPERATIONS 15

10.0 PULLING AND RUNNING TUBINGS 17

11.0 WIRELINE OPERATIONS/PERFORATION / LOGGING 18

12.0 REMEDIAL CEMENTING 19

13.0 WELL STIMULATION 20

14.0 WELL ACTIVATION 28

15.0 WELL TESTING 29

ATTACHMENT-1

ANNEXURES
 OISD SAFE PROCEDURE &
GUIDELINES FOR WORKOVER AND
WELL STIMULATION OPERATIONS

1.0 INTRODUCTION 2) to provide recommended procedures &

guidelines to safe transportation, rigging
Workover operations carried on wells after up/rigging down, operation of well
initial completion for purpose of maintaining , stimulation & workover and related
restoring or increasing the productivity of equipment.
well .
3) To provide safety norms for
Well workover operation shall be conducted mobilization/Demobilization of WSS units,
in a manner to protect against harm, their placement at site, laying
damage to human, coastal, marine down/rigging up equipment and pumping
environment, property, natural resource. of Stimulation/Well Servicing fluids.

Workover operation involves : 2.2 T h e G u idelines covers recommended

safe practices for carrying out the
1. Repair /replace defective /malfunctioned workover and stimulation jobs
downhole equipment
2. Casing leak repair 2.3 For training to the crew on workover
3. Squeezing cement operations for onland /offshore operations
4. Water & gas control refer OISD -STD-154 and 176.
5. Sand clean out from well
6. Layer transfer
7. Change of completion from single to Dual 3.0 DEFINITIONS
completion or vice versa
8. Installing sand control devices · Workover rig
9. Installing artificial lift T h e d e r r ick or mast, drawworks and
10. Deepening /sidetracking of wells necessary surface equipment of workover
11. Drainhole drilling unit.

During workover operations following jobs may · Rigging up/ down

be required to be performed :
To assemble a workover rig and place
1. Rig building /dismantling onshore mobile auxiliary equipment at appropriate location
rigs to start the workover operation.
2. Well subduing Rig down is to dismantle a workover rig and
3. Perforation and logging auxiliary equipment following the completion
4. Running in /Pulling out of tubular of workover operations.
5. Cementing
6. Well stimulation · Running in
7. Well activation/ Well Testing
To lower the drill stem, tubing, casing,
sucker rods etc. into the well bore.
2.0 PURPOSE & SCOPE
· Pulling out
2.1 Purpose and Scope :
The purpose and scope of these To pull the drill stem, tubing, casing, sucker
procedures and guidelines are : rods etc. out of the well bore.

1) to provide recommended procedures and

guidelines to safeguard the life, limb and
health of employees and employers in the
oil and gas well servicing industry; and
· Cementing In this technique, the acid is injected into the
well at pressures and rates sufficient to
The application of liquid slurry of cement, cause the formation to crack of fracture.
additives and water to various points inside
or outside the casing. · SURFACTANT/SOLVENT
TREATMENT
· Squeeze cementing
Damage such as water-blocking, emulsion
The forcing of cement slurry by pressure to blocks, and oil wet-ability can occur during
specified points in a well to cause seals at production or work over jobs etc. Surfactant
the points of squeeze. It is a secondary treatment is needed to solve these types of
cementing method that is used to re-cement problems for restoration to original state.
channeled areas or to block off an un-
cemented zone, to isolate a producing · COILED TUBING SERVICES(CTU)
formation, seal off water, repair casing leaks
and so forth. The Coil Tubing services are a second-
generation workover system employing
· Squeeze point continuous string tubing to carry out various
work over and well maintenance jobs on live
· The depth in a wellbore at which cement wells. The continuous tubing is stored on
is to be squeezed. a ‘reel’ and coiled upon itself in the same
manner as the flexible cable of a logging
· Stimulation unit. The tubing is straightened and lowered
in the hole by an ‘injector’, installed directly
A process undertaken to enlarge old on the well head through a ‘stripper’ which
channels or to create new ones in the allows lowering and pulling out of coiled
producing formation for enhancing tubing under pressure.
productivity of a well
(e.g. acidizing or formation fracturing).
· HOT OIL SERVICES
· Hydraulic Fracturing
This service involves pumping of hot crude
The objective of hydraulic fracturing in well oil or water through the well flow line or
stimulation is to increase well productivity by production tubing. It is very effective
creating a highly conductive path some treatment when flow lines or production
distance away from the well bore. The tubings are partially or completely choked
fractures are created by use of hydraulic due to wax deposition. It is also useful in
force, and the conductivity is maintained by circulating and heating a tank.
propping with sand / proppant to hold the
fracture faces apart. · SAND CONTROL

· Matrix Acidising Sand control is the technique of arresting

the sand while taking the production from oil
It is the technique of injecting acid into the or gas wells. The sand production is
formation below the pressure at which controlled with the use of gravel pack
fracture is opened. This technique is applied screens utilizing over the top system/gravel
primarily to remove skin damage caused by pack packer with the help of rig.
drilling, completion, work over or plugging
caused by precipitation of deposits from · WATER SHUT OFF
produced water or oil.
Water shut off techniques involves pumping
· Acid Fracturing of the cement slurry/ chemicals/polymer
systems to arrest / prevent water coning
Treatment of this nature is designed to near water oil contact and breakthrough of
improve the flow capacity of lime-stone or water through high permeability streak in
dolomites over a considerable distance from water drive reservoirs
the wellbore.

2
4.0 RECOMMENDED SAFE GENERAL cleaned up promptly to eliminate slipping
OPERATING PRACTICES hazard to personnel as well as fire hazard.

4.1 General Safe operating practices 13. Do not leave timbers or planks laying with
nails.
1. Good housekeeping on the job is essential
to successful accident control and fire 4.2 Personnel - Individual Responsibility
prevention. Keeping everything in its place
promotes efficiency, quality and good work. 1. All employees are responsible for prevention
Tools, equipment and working areas should of accidents to men working with them. Any
be kept clean, neat and orderly. employee using unsafe tools or work
2. Thorough safety inspection should be made practices or encourage other employees to
of well servicing equipment and foundation do so should be prohibited.
before starting job. 2. Lift weights properly, with your legs and not
with your back. If the load is beyond your
3. Men on the floor should stand clear when safe capacity, get help.
rigging up or repair work is in progress
overhead. 3. In the event of a personal injury, no matter
how small, the Supervisor is to make out a
4. When drinking water is transport e d a n d full report at the end of the shift on an
stored for use of crew on location, it should approved accident form and handover to the
be in a clean shatterproof container and Driller I/C/Tool Pusher.
individual drinking cups provided. Drinking
water should be labeled "Drinking Water 4. Hard hats and safety boots should be worn
Only". when working outside accommodation/
bunkhouse.
5. Riding catline is prohibited except in an
emergency. 5. Loose and flopping clothing is prohibited

6. Unsafe or otherwise dangerous conditions 6. Hair of such length that it might become
no matter how small., should immediately entangled in moving or rotating machinery
be reported to supervisor in charge for should be contained in a suitable manner.
corrective action. Correction of unsafe Beards and sideburns of employees should
condition may take one of three forms - be kept in such conditions and of such
remove, guard or warn. lengths so as not to interfere with the proper
use of gas masks, air masks, or other safety
7. Never leave well unattended unless it is apparel or equipment.
safely shut in
7. Drinking alcohol/intoxicated substance on
8. Upon completion of job, clean equipment the job or to and from the work is prohibited.
and load neatly and safely on tool truck/box.
8. It is the responsibility of all employees to
9. All occupational injuries, no matter how train men under their supervision, in the
small, will be reported promptly to the safest and most efficient way to work.
supervisor in charge.
9. An employee should never operate any
10. In the event equipment, guy wires, etc. are machinery, including a cathead, until he is
present which create a hazard on roads of well acquainted with the operation.
any kind, signs, flagging, lights or flares
should be used to give warning. 10. It is the employee's responsibility to report
all unsafe conditions to his immediate
11. Scuffing, practical joking, or horseplay of supervisors
any nature among employees on duty is
inconsistent with safety and is positively 11. As servicing jobs are frequently done at
prohibited. remote areas where medical aid is not
readily available, it is strongly recommended
12. Control must be maintained over leaks and that all employees take a course in first aid.
spills; however, if they occur, they should be

3
12. Unauthorized personnel should not be 5. Eye protection :
permitted at the work location.
· Safety glasses, shields and goggles shall be
13. There will be no smoking at the well-site. All worn anytime & eye hazard exist like when
smoking materials, matches, lighters, etc., chipping, grinding, hammering, cutting
are to be left in a pre-determined safe area. wireline, changing tong dies, scrapping
(30 meters beyond cellar pit) paint, using a drill machine, operating a
press, a lathe machine, and for any other
14. Do not depend on others. Whenever activity which may result foreign body in the
possible, check conditions for yourself. eye.

15. Each employee should exercise caution to · In addition to the safety goggles, a face
avoid falling, stumbling, or moving into or shield shall be worn when handling
against moving machinery. corrosive or harmful products (solids or
liquids)
4.3 Safety Equipment
· Welding helmet or hand-held shield shall be
4.3.1 Personal Protective Equipment used when performing welding rather than
welding goggles.
1. Head protection :
· Welding goggles shall be worn when using a
(a) Safety helmets shall be worn by all cutting torch
personnel at all times while working
within working areas, outside · Provision for Eye wash with potable water
accommodation and offices. shall be available at least in the following
areas: rig floor, mud mixing area, mud pit
(b) Safety helmets shall be fitted with chin room, and shale shaker area (in offshore
strap, while working aloft, in windy areas rigs).
and on heli-deck .
6. Safety Belt :
(c) Safety helmets shall be made of non
conductive material. · All personal working at Monkey Board or
above 3 meter from derrick floor should
2. Clothing : wear an approved safety belt while working
(a) Overalls shall be worn by all personnel · Safety belts , life-liners & tail ropes should
working on rig. be maintained in good condition
(b) The unreasonably loose, poorly fitted or 1. Fall protection :
torn clothing should not be worn
An anti -fall coupled with safety harness/ belt
(c) Personnel clothing which has been shall be worn by personnel working on mast
saturated with flammable or toxic while exposed to a fall of 3 metrers or
substances to be removed and effected
greater or climbing unprotected vertical
skin area thoroughly washed. ladder with same exposure.
3. Hand Protection :
2. Topman Escape line & device :
(a) Safety gloves shall be provided to all Rig should have escape line & escape
personnel and worn as appropriate
device allowing topman to evacuate from
working platform level in case of emergency
(b) Rubber gloves shall be available and
worn by electrician while working
· Escape device for derricks should have a
seat (T Bar ) and a spring actuated cam
4. Foot protection :
brake which can be applied at any height
with finger tip pressure , both in good
Safety shoe or safety boots shall be worn by
working condition to control the descent.
personnel in working areas.

4
· Path of escape line should be free of Class D fires: occur in combustible metals
obstruction such as magnesium, titanium, zirconium,
lithium and sodium. Specialized techniques,
· The angle of the anchored escape line extinguishing agents and equipment must
should be in accordance with manufacturer's be used to control this type of fire.
specification.
4.3.4 Portable gas detectors

For offshore only 1. A portable gas detector capable of

determining monitoring level of combustible
4.3.2 Life saving equipment gases in air should be made available at
site.
All rigs shall be equipped with necessary life
saving appliances /equipment which shall be 2. The detector shall be regularly inspected
regularly inspected and maintained in and maintained in ready to use at all times
constant state of readiness. and should be calibrated regularly.
q Life boats
4.4 Fire Prevention and Protection (except
q Inflatable life raft while rigging up, rigging down and
q Life jacket moving)
q Work vest
q Life buoys (a) Fire fighting equipment is not tampered
with and is not removed for other than
(FOR DETAILS REFER SOLAS REGULATION its intended purpose.
1984 AND AMENDMENT THEREOF)
(b) Fire extinguishers and other fire fighting
4.3.3 Fire fighting equipment equipment are suitably located and
plainly labeled as to their type and
1. Fire- fighting equipment, suitable for fire method of operation
hazards involved, should be provided at
location. All fire protection equipment should (c) Used cleaning rags and combusting
be maintained for ready to use condition and waste materials are kept to a minimum
should be easily accessible at all times. stored in a metal container and
disposed of regularly.
2. All fire extinguishers shall be maintained,
inspected & hydrostatically tested in (d) Access to exits or fire extinguishers are
accordance with standards & tagged not blocked or obscured by clothing,
showing the date of inspection & date due materials or equipment
for next inspection/servicing.
(e) Well cellars, rig floors and ground areas
3. The fire extinguishers shall be marked with adjacent to derricks are kept reasonably
an identification symbol and the letter(s) that free from accumulation of oil which
indicate the class of fires they shall be used might create or aggravate fire hazards.
for.
(f) Fire protection and fire fighting
4. The fires shall be treated depending on their equipment are maintained in a
class : serviceable condition at all time
Class A fires : occur in common materials
etc. the quenching and cooling effect of (g) Records be kept showing the date fire
water or water solutions is recommended. extinguishers were last inspected,
Class B fires : occur in the vapor-air-mixture tested or refilled and by whom
over the surface of flammable liquids such
as gasoline, oil, grease, paints and thinners. (h) All fire extinguishers are maintained,
Class B fires are extinguished by limiting air inspected and hydrostatically tested in
(oxygen) or by providing combustion- accordance with standards
inhibiting agents.
Class C fires : occur in or near electrical (i) Carbon tetrachloride extinguishers are
equipment, Non-conducting extinguishing not permitted
agents must be used

5
(j) During welding operation, keep suitable A. Providing adequate safety equipments on
portable fire extinguishers in the vicinity. location
B. Proper training to personnel before posting
(k) Any engine being refueled should be C. Establishing strict operating and emergency
shut off during refueling. procedures
D. Creating general awareness of potential
(l) No smoking should be allowed within 30 Hazards of H2S.
meters of any flammable storage area,
or within 30 meters. of the handling of 1. Hydrogen sulfide concentrations for each
flammable liquids. location shall be determined by the well
operator. The detection shall be available
(m) There should be an adequate number of for determining level of H2S present in gas.
"No Smoking" signs conspicuously
displayed at each well location while 2. The Tool pusher or Production engineer
well service work is in progress shall be contacted prior to rigging up or
releasing pressure at a location that is
(n) No open flames should be allowed suspected of having hydrogen sulfide (H2S)
within 30 meters from the well or well 3. Characteristics of H2S :
bore.
(a) Extremely toxic (poisonous)
(o) Personnel shall be instructed for the
use of fire-fighting equipment during fire (b) Heavier than air and colorless
drills and training exercises
(c) Odor of rotten eggs in low
4.4 First Aid concentrations

- The information regarding availability of (d) Burns with a blue flame and produced
first aid kit should be made available sulphur dioxide (SO2) gas which is very
irritating to eyes and lungs, SO2 is less
- An adequate and approved first aid kit toxic than H2S but can cause serious
should be provided on each rig and injury or death.
should be conspicuously located .
(e) H2S forms explosive mixtures with air
- At least one person who is trained and
certified in first aid and basic rescue (f) H2S soluble in water and oil
techniques shall be available in each
shift. 4. Dangers of H2S :

- Posters demonstrating rescue, (a) The sense of smell cannot be depended

breathing & first aid should be displaced upon to detect H2S because the sense
at work place. of smell is deadened immediately in
high concentrations and in 2-15 minutes
- Emergency contingency plan should be in low concentrations.
available at site.
(b) Produces irritation to eyes, throat and
- The first aid kit shall have all medicines respiratory tract
as recommended by John Ambulance.
(c) At high concentrations suffocation may
4.5 Hydrogen Sulphide (H2S) occur after a few seconds of exposure
or death may occur from respiratory
Introduction : cardiac (heart) paralysis.
Although Hydrogen Sulphide (H2S) is
dangerous, deadly gas, its effects are
controllable and generally reversible, provided
appropriate action is taken in time.
The danger of exposure to H2S can not be
eliminated altogether but the potential of danger
can be minimised by :

6
5. First Aid for H2S :
(c) Protective breathing apparatus shall be
(a) Move the victim into fresh air at once maintained at the well site as required
(upwind from the source). NEVER
ATTEMPT TO RESCUE A VICTIM (d) Employees with facial hair in the form of
WITHOUT FIRST DONNING breads, long side burns, etc. that could
APPROPRIATE BREATHING interfere with the seal of a facemask
APPRATUS. shall not be allowed to work at exposed
site.
(b) If the victim is unconscious and not (e) A method for igniting the gas shall be
breathing, immediately apply mouth-to- provided in the event of an
mouth artificial resuscitation and uncontrollable emergency.
continue until normal breathings is
restored. If available, oxygen shall be (f) Automatic hydrogen sulfide detection
given through an inhaling apparatus by and alarm equipment that will warn the
an employee trained in the us e a n d crew of the presence of H2S shall be
operation of such equipment. installed on the rig. Portable detection
equipment will also be made available.
(c) Summon emergency help as quickly as
possible and transport the victim if (g) Poison gas signs shall be provided and
necessary. properly placed.

6. General Safety Precautions for H2S : (h) Safe briefing areas will be established
prior to the beginning of the work. All
(a) All employees are to be trained before employees will be informed to report to
rig up begins. the briefing area in case of a hydrogen
sulfide emergency. The briefing areas
(b) Wind direction indicators shall be must be established upwind from the
installed at strategic locations at the well well.
site.

TOXICITY TABLE FOR H2S

1 ppm Minimal perceptible odor

10 ppm Obvious and un-pleasant odor. Occupational Safety and Health Administration
(OSHA). Threshold limit value Time Weighted Average (TLV-TWA) for a
normal 8 hours workday or 40-hour workweek to which most employees may
be repeatedly exposed, day after day, without adverse reactions. This is the
maximum amount of continuous exposure allowed without the use of
protective breathing equipment
15 ppm OSHA Short Term Exposure Limit (STEL) for a 15 minute period provided that
no more than four excursions per day are permitted with at least 60 minutes
between exposure periods and also provided the TLV-TWA is not exceeded
100ppm Deadens sense of smell in 3 to 15 minutes. May cause coughing and burning
of the eyes and throat
200ppm Kills sense of smell and stings eyes and throat after one hour of exposure
500ppm Respiratory difficulty in 2 to 15 minutes. May cause dizziness and
unconsciousness
700ppm Loss consciousness will occur rapidly. Breathing will stop and death may
occur if not rescued promptly.
1000ppm Immediately unconsciousness. Death may occur even if the individual is
removed to fresh air promptly.

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5.0 PRE-OPERATION & MONTHLY 6.0 RIGGING UP AND RIGGING DOWN
SAFETY MEETINGS AND DRILLS
6.1 RIGGING UP
Pre-operation meetings
Before raising mast to vertical position :
1. Prior to commencing of any Workover
operation, a meeting shall be held with all · Level the rig from side to side
personal involved, covering procedure for · Get the mast free and ready to raise
operation, hazards associated and (hoses, cables, lines, etc.)
emergencies. · Check the hydraulic fluid level
· Bleed the air out of all erect cylinders and
2. No subjects of controversial matter, circulate the oil
employment difficulties, complaints, · Make sure derrick and guylines will not
criticism or similar matters should be come within close proximity to power lines
brought up at the safety meeting. Matters · Park automobiles out of fall lines
relating to the safety of crew personnel, · Assign an employee to watch if the mast
the prevention of equipment damage or
comes close to overhead power source.
similar subjects should be discussed.
· All hoisting lines &sand lines to be
inspected thoroughly & special care
3. On the job safety meeting may cover
should be taken for checking condition of
following:
line at crown block.
· A short safety meeting whenever the While mast is raising :
workover job changes to the extent that
instructions are necessary or other § All employees, except the crew chief,
circumstances that might warrant a should be at least 3 meters from the rig
meeting. carrier.
§ Keep block positioned in its cradle during
· The meeting shall cover safe procedures this operation
for operation, hazards associated & § No employees should be allowed in
emergencies. derrick before mast are engaged
§ Keep lines free while mast is raising.
The Driller-in-charge should instruct other
crew members for proper use of any Telescoping mast up :
equipment on the rig. The crewmembers
periodically should perform safety § Check again to insure that all wire lines
inspection of the rig and associated stay clear
equipment. § Secure mast properly to the base section
§ Operator should keep the travelling block
Safety meetings: Safety meetings in close to the floor at all times during the
addition to pre-operation meting should be operation
conducted weekly and discuss various § All employees should still be at least 3
safety aspects of operations. meters from rig center
§ Move ram stabilizers into place and
Some topics of Safety Meeting are : properly secure the telescoping ram
cylinder
· Personal protective equipment (hard hats,
safety shoes, face protection etc) After mast is up :
· Operation of new equipment
· Fire extinguisher demonstration § Climb the derrick (with a ladder climbing
· Emergency first aid procedures device) to visually inspect load latches are
· First Aid engaged and properly locked .
· Equipment inspection procedures § Operator should crack control valve to
· Well control methods/procedures "lower position to relieve pressure on
telescoping cylinder.
Date and time of General safety meetings § Tighten load guys with equal tension
shall be recorded and available at the facility. § Space out crown wind guys according to
manufacturer's specifications
§ Lock mast erection control valve in neutral

8
§ Align block and hook with well center hoisting lines from being displaced from
§ Inspect guylines for the required number the sheaves during operations or when
of clamps being raised or lowered from the operating
position
6.2 RIGGING DOWN
5. A visual inspection of the service unit
Before telescoping top section down : should be made by an experienced
person before the derrick or mast is raised
§ Release all guy lines to allow easy or lowered.
retraction of load
§ Bleed air from rams and circulate hydraulic 6. An experienced person should be made
oil before releasing load latches in charge of raising or lowering a derrick.
§ Uncouple all electric and air lines in mast
and free all other lines 7. Before any derrick is raised or lowered, all
§ Remove tools from derrick tools and material not secured to the
§ Unlock the mast locking system derrick should be removed from t h e
derrick.
While telescoping down:
8. The derrick should be level and plumb
§ Keep employees 3 meters from rig carrier before guys are tightened
during entire process
§ Stop mast motion if lines hang up 9. Before any load is put on the derrick, all
crown guys should be properly tightened.
Preparing to road the rig:
10. No employee should be allowed on the
§ Secure mast to the carrier carrier when it is being raised or lowered
§ Proper pads shall be available at mast 11. E a c h d e r r i c k platform should be
rest. constructed, maintained, and secured to
§ Secure all matting boards, cables, etc. the derrick to withstand the weight of
§ Secure traveling block in its cradle employees or other stresses, which may
§ Check air pressure of tyres normally be placed upon it.
§ Ensure that jacks are retracted to
maximum. 12. Finger boards should be attached to the
derrick to keep them from falling if jarred
7.0 WELL SERVICING EQUIPMENT AND loose or broken
PROCEDURES
13. Unattached tools or material of any kind
7.1 Derricks should not be kept in the derrick above the
derrick floor unless there is occasion for
All equipment installed in derrick /Mast their immediate use.
shall be secured with safety line of
appropriate strength to prevent them from 14. No employee should be in the derrick or
falling on the rig floor when the initial pull is made
1. Each derrick or mast should show name of on the rods or tubing or when working or
manufacturer and safe load capacity jarring stuck rods or tubing.

2. No derrick or mast should be subjected to 15. All masts should be equipped with locking
a compression load greater than the safe devices with sufficient strength to prevent
load limit shown on the manufacturer's the mast from bending at the hinge points.
plate The locking device should be approved by
the rig manufacturers. The mast will be
3. Derricks, mast guying and foundations locked as soon as the mast is in position
should comply with the standards for and remain locked until the mast is to be
guylines, anchors and foundation bases lowered.
for well servicing units, as per
manufacturer's recommendations. 16. Derrickman on first ascent into derrick will
visibly inspect locking devices or pawls
4. Derricks and masts should be equipped and install safety devices if applicable.
with guards which should prevent the

9
17. The crown block shall be protected by
bumpers which shall be snubbed , and 2. All hoisting lines and sand lines should be
when made of wood , covered with wire visually inspected when in use by a
mesh. qualified person and a record made of any
defects noted. At this time a determination
7.2 Hoisting Lines (Casing Lines) should be made as to whether the hoisting
line should be cut to bring new line into the
1. A d e a d -man anchor for hoisting line system, or replaced. In no event should
should be so constructed, installed and the hoisting line or sand line be allowed to
maintained that its strength should be at remain in service when the following
least equal the working strength of the numbers of broken wires appear in any
hoisting line.Inspect dead line anchor on a section of the line.
daily basis for weld failure, metal fatigue,
or other signs of possible failure.

Construction Number of broken wires in Number of broken wires in

one rope lay one strand in one lay
6X7 7 3
6 X 19 seal 11 4
6 X 21 Seal or FW 13 5
6 X 25 18 6
6 X 31 19 6
6 X 36 21 7
18 X 7 18 3
19 x 7 18 3
8 X 19 Seal 16 4
8 x 25 FW 25 6

3. In addition to above criteria , hoisting line or 4. Travelling block and similar equipment
sand line should be removed from service should be inspected and maintained in good
when any of the following condition exists: working condition and the applied load
Ø When marked corrosion appears should never exceed the manufacturer's
Ø When there is evidence of kinking, crushing listed rating.
or min. of 10% increase in length of lay
4. On any drum on which a hoisting line is 5. Travelling block safety device crown-o-matic
wound, the end of the hoisting line should be shall be installed in order to prevent the
fastened securely to the drum and there block hitting the crown block accidentally.
must be a reasonable number of wraps of
the line on the drum to eliminate any strain 7.4 Weight Indicators
on the fastening to the drum.
1. Every well-servicing rig should be equipped
7.3 Hoisting Block with a reliable weight indicator.

1. Travelling block should be properly guarded 2. A weight indicator should be used to indicate
the suspended load
2. Any slip hook used for lifting should be
equipped with a safety latch or safety cable 3. Weight indicators should be safety secured
and pinned. and should be easily visible to the
equipment operator
3. Travelling block, elevators, elevator links or
similar equipment should be reasonably free 4. The manufacturer's rated load capacity of
of projecting bolts, nuts, pins or other parts the servicing unit should not be exceeded.
upon which clothing of workmen may be
caught.

10
7.5 Draw-works 14. When the cathead is unattended, no rope or
line should be left wrapped on or in contact
1. A visual inspection of the draw-works and its with the cathead.
working parts should be made each day or
shift before operations begin. 15. When the cathead is in use there should be
an authorised employee at the draw-works
2. All guards and covers should be in place control .
before operations begin 16. The friction surface and flanges of a cathead
on which a rope is manually operated should
3. If lubrication fittings are not outside of be reasonably smooth.
guards, machinery should be completely
stopped for oiling and greasing 7.6 Mud Pits and Tanks

4. When it becomes necessary to remove a 1. All fixed mud guns used for jetting should be
guard, the draw-works should be completely pinned or hobbled when unattended.
stopped and engine shut off
2. Hoses used for jetting operations should be
5. All air compressors should have at least one manned, and there should be an employee
pressure control for proper airflow. Use stationed at the pump controls to shut down
proper pins in relief valve. the pressure in the event of emergency.

6. The safety pressure relief valve on main air 3. All discharge lines should be safely secured.
tank should be checked periodically and All hoses under pressure should be properly
kept in proper working order. hobbled.

7. All valves kill switches and other working 4. Portable tanks should be located where it is
devices should be kept in proper working not possible for personnel or equipment to
order. come into contact with overhead power
lines.
8. Safety pressure relief valves on hydrostatic
lines should never be set higher than the 5. All portable tanks in excess of 2 meters in
design rating of the hydraulic system or the height used in testing and treating, should
manufacturer's listed rating of the lines, be equipped with a fixed metal ladder.
whichever is less.
6. Some frac tanks have hatch openings large
9. The brakes, linkage and brake flanges on enough for a person to enter the tank. All rig
the draw-works should be tested visually personnel should be instructed to not enter
and inspected each day. any frac tanks for any reason.

10. The equipment operator should not leave 7.7 Pumping Units and pressure lines
the brake without tying the brake down or
securing it with a catch lock. 1. Each mud pumps shall have a pressure
relief safety device, installed and
11. The equipment operator should not leave maintained.
the brake while hoisting drum is in motion
2. Relief valve & all open ended pressure
12. Catheads on which a rope is manually relief lines shall be securely clamped to
operated should have a rope guide to hold fixed support
t h e o n -running rope alignment with its
normal running position against the inner 3. Bleed off valve shall be installed on
flange. discharged line/pipe of the pump, to
allow the residual pressure after
13. When a rope or line is in use on a cathead, isolation of the high pressure circuit to
all other ropes or lines should be placed so be safely relieved.
as not to come in contact with the cathead
or with the rope or lines used on the 4. All exposed moving parts shall have
cathead. proper guard.

11
 5. All connections on pressure surface 8. Always keep your hands and feet in the
circulation (Chickson) lines shall be clear of any pipe that is suspended in a
snubbed with adequate means to derrick.
prevent from swinging or kicking in case
of sudden release of pressure. 7.10 Hand tools

7.8 Material and Equipment Handling 1. Wrenches should be inspected

frequently to eliminate worn or sprung
§ Size up the load that you are about to lift jaws, broken cages, springs, faces and
and get help if necessary. bent handles.

§ Inlifting, keep your back as nearly 2. Inspect driving faces of hammers,

straight and vertical as possible, bend chisels, drift pins, bars, and similar tools
the knees and do the lifting with the leg frequently to eliminate mushroomed
and thigh muscles. heads, broken faces and other defects.

§ Be sure you have a secure grip on 3. In applying force to a wrench you should
whatever you are going to lift or carry take a position so that you will not lose
and avoid jerking and awkward positions your balance in case the nut or joint
suddenly loosens or the wrench slips.
§ Particular care must be exercised when
doing group lifting or carrying to avoid 4. Avoid striking one hammer with another.
injury. One man in the group should Hammers are made of hardened steel.
give signals so that everyone will work Slivers of steel are likely to fly off and
in unison cause serious injuries. Instead, use a
bar, chisel, drift pin, etc.
7.9 Handling pipe :
5. Do not carry tools up and down the
1. When pipe is lifted, lowered and carried, ladder. Always have both hands free for
team work is essential. Pipe should be climbing.
lifted and lowered at a given signal. 6. All tools used in derrick should be
hobbled to prevent them from falling.
2. Pipe should be rolled from ends or from
behind in order to get out of the way if 7. Tools should be lowered to floor as soon
the joint gets out of control as derrick man has finished with each
3. Hands should be kept out of the ends of one.
pipe at all times
8. The proper tools, in good conditions,
4. No employee will go between loading or shall be used for the job being
unloading skids unless necessary. If the performed.
work necessitates getting between
skids, notify fellow workman in order 9. Non-spark predicting hammers (brass)
that pipe will not be released. shall be used when in an explosive or
flammable environment.
5. When unloading pipe, make sure that
skids are securely fastened. 10. The wooden handles of hand tools shall
be kept free of splinters and cracks and
6. Stacking strips or "stripping" should be shall be kept securely attached to the
used between the ends of each layer of tools
pipe for spacers. These strips should
be cut off flush with the stack 11. Impact tools, such as drift pins, wedges,
and chisels, shall be kept free
7. Pipe racks will be fitted with stoppers at mushroomed heads
both ends to prevent tubing 12. Hands tools shall never be left on
accidentally rolling off the racks or ladders or elevated places
trucks.
13. Employees shall not use hand tools,
which have become dull.

12
 14. Hand tools shall not be used after being condition and should not be altered or
subjected to intense heat moved while in use.

15. Electrical cords shall be checked and 2. Work areas should be clean and free of
replaced if worn debris.

16. Before rolling up or coiling pneumatic 3. Walkways, stairways and exits should
hoses, electrical cords or hydraulic be kept clear to provide unimpeded
hoses, disconnect from the power ingress and egress except during rigup,
source rigdown and moving.

17. Disconnect air and electrical tools from 4. Every stairway, ladder, ramp, runway,
the power source before changing bits, floor and platform should be kept
sockets and blades. reasonably free of objects and
substances which may create a slipping
7.11 Power tongs, slips & elevators or tripping hazard, or prevent or hinder
the escape of workmen in an
1. Tong shall be quipped with proper emergency.
backups for the size tubing being
handled 5. With the exception of exit and entrance
openings, and loading and unloading
2. When usual strain is taken on the tongs areas, a standard guardrail with mid-rail
all crew members except the the person and a four inch toe board should be
required to operate the drawworks shall installed at the outer edge of any floor,
stand in the clear..An unusual strain is platform, walkway, ramp or runway
defined as pull or bind of 70% or greater which is four feet above the ground, or
of the safe working strength of weakest another floor or working level. Where
part of the tong system ie tong , snub guardrails are not feasible, chains, or
line or chain , shackles or snub point wire rope may be used.

3. Tubing tong shall be securely attached 6. A guardrail used and/or needed for the
and anchored with stiff arm , purpose of actual or potential
containment of equipment or material
4. A snub line will be separate from stiff should be of such construction and
arm attachment as a back-up on tubing strength as to effectively contain the full
tong. load or stress which may be anticipated
to be applied upon it.
5. Power tong pressure lines shall be
equipped with a safety relief valve and 7. Any temporary stabbing board, or other
pressure shall never exceed the temporary boards, placed in derrick
manufacturer's specification should be securely fastened.

6. When tripping in or out of Hole , hands 8. A stairway with handrails should be

shall never be placed on or around the installed beside the ramps which should
link eyes where elevators can pinch extend from the ground to the derrick
floor.
7. Rotary slips shall be set using handles 9. Every opening in a derrick floor should
with hand palms up . It is forbidden to be removed or guarded when not being
kick the slips into the rotary table bowl. used.
8. When finishing a trip or a connection,
the rotary slips shall be set back well 10. A derrick floor, derrick walk or engine
clear of rotary table room floor should not be used as a
storage platform for equipment or
7.12 Ladder , Stairways,Floors & Platforms material that is not required for
immediate use unless the material or
1. Every scaffold, stage, walkway, working equipment.
platform, stairway and ladder, whether
temporary or permanent, should be -- is properly racked or stored, and
constructed and maintained in safe

13
 -- does not cause congestion of work around the anchor, then back to the guy
areas or walkways line again. The guy line should be
properly secured with at least 3 U-bolt or
7.13 Anchoring and Wind Guy lines fist grip clamps of proper size, or their
equivalent, at both ends.
a) Every rig should be equipped with the
number and size of guy lines as e) A thorough inspection of all guy lines in
recommended by the manufacturer use should be made prior to each
installation and no guy lines should be
b) Every guy line recommended by the spliced.
manufacturer should be utilized
according to the manufacturer's f) Where the number, size and utilization
specifications. of guy lines are recommended by the
derrick manufacture, anchors should be
c) Guy lines should not be any closer than used to secure the guy lines, except
3 meters from lower lines, and in no when other means or methods of
case should a guy line be extended anchoring the guy lines are
above or below a power line and/or recommended by the manufacturer
power be turned off and locked out. which are at least as effective as these
standards.
d) All chains clamps and tensioning
devices that will remain in the working g) Expanding anchors, pipe anchors,
guy line must have as much strength as concrete anchors, or other approved
the guy line. Those chains, boomers, techniques should be used.
clamps and tensioning devices not of
sufficient strength should be bypassed h) For inspection of guy lines refer section
by continuing the guy line through or on Hoisting lines(casing line)

Clip Size in Minimum Number of Length of Rope to Turn Torque in Foot Pounds
Inches Clips Back in Inches
1/2
3/8 2 6 45
7/16 2 7 65
1/2
1/2 3 11 65
9/16 3 12 95
5/8 3 12 95
3/4 4 18 130
7/8 4 19 225
1 5 26 225
1 1/8 6 34 225

NUMBER OF CLIPS AND DISTANCE BETWEEN

Diameter of Drop Other Minimum Diameter of Drop Other Minimum

rope, in forged clips distance rope, in forged clips distance
clips between clips between
1/2* 3 4 3" 1 5 6 6"
3/4" 1/8 3/4"
5/8 3 4 3 1 6 6 6
1/2" 1/4 1/2"
3/4 4 5 4 1 6 7 7
1/4" 3/8 1/4"
7/8 4 5 5 1 7 7 8
1/2
1 7 8 9"

*WIREROPE SIZES LESS THAN 1/2 INCH REQUIRE 3 CLIPS

14
7.14 Auxiliary Escape Well subduing

Topman's Escape line & device 1. The line shall be tested 1 1/2 times the
expected STHP or rated working
Rig shall have escape device allowing pressure which ever is less.
Topman to evacuate from racking
platform level in case of emergency 2. No hammering shall be done on
pressurized line .
· All derricks should be equipped with a
rigged device line , free of kinks, broken 3. Check the parametrs of kill fluid (eg
wires or a coating of a grease. weight of fluid etc)

· Escape device for derricks should have 4. Monitor pump pressure during
a seat and a spring actuated cam subduing.
brake which can be applied at any
height with finger tip pressure , both in 5. Monitor & check the parameters of
good working condition to control the return fluid during circulation till well is
descent.. properly conditioned & stabilized.

· The angle of the anchored escape line 6. Check for short circulation or quick
should be in accordance with pressure build during subduing
manufacturer's specification. operation

· Path of escape line should be free of 7. In offshore wells additional precaution

obstruction. should be taken by installing Back
pressure valve in the tubing hanger .
SCSSV shall be in closed condition
while X-mas tree is nippled down .

8.0 WELL SUBDUING

9.0 WELL CONTROL EQUIPMENT AND
8.1 Well plan should be prepared well in OPERATIONS
advance and circulated to all concerned
including driller incharge , it should Following requirements apply during
contain following information but not workover operations with tree removed
limited to:
- Brief of earlier workover done Ø Well control fluids, equipment and
operations shall be designed utilized,
- Complications encountered during drilling maintained and/or tested as necessary
/workover to control the well in foreseeable
conditions and circumstances. The well
- Mud parameters during drilling/previous shall be continuously monitored during
workovers well workover operations and shall not
be left unattended at anytime unless the
- Details of downhole equipment , tubing well is shut-in and secured.
and X-mas tree
Ø When coming out of hole with drill pipe
- Casing and cementing details or workover /well completion string the
annulus shall be filled with well control
- Details of perforation fluid

- Bottom hole pressure of existing well and 9.1 Blow out Preventer equipment
expected Bottom hole pressure after
workover job . The BOP system, system components
and related well-control equipment shall
be designed used maintained and tested
in a manner necessary to assure well
control in foreseeable conditions and
circumstances

15
 of 200 to 300 psi and then to a high
The BOP systems for well workover pressure ie at the rated working
operations with the tree removed shall be pressure of BOP or to the rated
equipped with the following : working pressure of the wellhead on
which BOP is installed on , which ever
· One set of pipe ram, sized to the pipe is lower. When performing the low
being used. pressure test, do not apply a higher
pressure and bleed down to the low test
· One set of blind/ Shear blind ram pressure. The higher pressure could
initiate a seal that may continue to seal
· A h y d r a u l i c -actuating system that after the pressure is lowered and
provides sufficient accumulator capacity therefore misrepresenting a low
to supply 1.5 times the volume pressure condition.
necessary to close all BOP equipment
units with a minimum pressure of 200 ii) The initial high pressure test on
psi above the pre-charge pressure components that could be exposed to
without assistance from a charging well pressure (BOP stack) should be to
system. the rated working pressure of the ram
BOPs or to the rated working pressure
· Minimum two starting system of of the wellhead that the stack is
accumulator engine (manual, battery) installed on, whichever is lower. Initial
should be available. pressure tests are defined as those
tests that should be performed on
· Accumulator should be placed at a safe location before the well is spudded or
distance so that it can be operated in before the equipment is put into
case of emergency. operational service.
· Side outlets must be equipped with
valves of proper working pressure . iii) Each low pressure & high pressure
tests must hold required pressure for 5
9.2 Testing , and maintenance, records and minutes.
drills of BOP
9.2.1 Function Test iv) There may be instances when the
available BOP stack and / or the
i. Blowout preventer function test should wellhead have higher working
be performed on each round trip (but pressures than are required for the
not more than once per day) or once a specific well bore conditions due to
week whichever is earlier. equipment availability. Special
conditions such as these should be
ii. The test BOP pipe ram should be covered in the site-specific well control
conducted when the production string pressure test program.
is inside casing.
v) If the equipment does not hold the
iii. Pipe ram preventers should be required pressure during a test , remedy
function tested and closing time should the problem and retest the effected
be recorded. component

iv. Blind/Shear ram should be operated for vi) Test BOP using cup tester or test plug
function test while string is out of hole. or tubing hanger.

v. All the tests results & problems vii) Clear water should be used as test fluid.
observed during testing and any actions
taken to remedy the problem should be viii) All pressure tests on well control
documented equipment should be conducted at least
- Immediately upon installation.
9.2.2 Pressure Testing - After the disconnection or repair of
any pressure containment seal in BOP
i) All blowout prevention components that but limited to the affected component.
may be exposed to well pressure - Not exceeding 21 days
should be tested first to a low pressure

16
ix) All the tests results & problems · Use of power and manual slips
observed during testing and any actions · Use of various types of elevators
taken to remedy the problem should be · Speed-kit operation
documented. · Proper torque on tubing make-up
· Proper setting of various
9.2. 3 General Testing Consideration as per anchor/packers
API RP 53 may be followed.
9.2.4 BOP drills 3. Inspection & Briefing of following
equipments to the Crew about their use
- BOP drills should be conducted at before pulling out / Running in
unschedule times when operations and
hole conditions permit. · Safety belt and tail rope
- Drills must be conducted weekly (subject · Topman escape device
to BOP is installed on wellhead) to
· Weight indicator calibration
familiarize all personnel engaged in well
· Condition of elevators, slips and tubing
completion /workover operations with
tongs
appropriate safety measures.
· Blowout preventer
- All Crew members shall be instructed in
the operation of BOP system and their · Fire extinguishers
responsibility in the event of Blow out · BOP shall contain pipe rams sized to
- Total time taken to complete the drill the pipe being used
should not be more than 2 minutes. The · BOP Testing to be carried out as per
deficiencies/ delay in response be section 7.0
discussed for further improvement. · B o t h c rown-o-matic and floor-o-matic
- The drills should be documented in DPR. safety devices are to be checked for
their proper functioning.
10.0 PULLING AND RUNNING TUBINGS · Quick shut off valve
· Both pneumatic and hydraulic brakes
Pulling-out and running-in tubing is part are to be properly checked.
of well servicing work. Safe and proper · Also check the emergency kill provided
work methods should be used during at driller's panel.
each job to prevent accidents and avoid · The condition of both the mechanical
personal injury. and pneumatic slips is to be thoroughly
After proper subduing the well , Place the checked..
BOP on wellhead after Nippling down X- · Check the railings of monkey board and
mas tree top man safety belt.
· Place a rubber flapper on well head to
10.1 Before starting pulling out operations prevent any foreign material falling into
operations the well.
· Check the functioning of drillometer and
1. Equipment Necessary : links & elevators nuts & bolts / pins etc.

· Power tubing tongs · New topman starting to work for the first
· Tubing spider time at the monkey-board shall be
· Well head protective flange assisted by an experienced topman or
· Weight indicator the assistant driller.
· Quick shut -off valve · The monkey -board shall remain visible
· Blowout preventer to the driller, or be monitored by the
· Tubing wiper driller using a TV system.
· The blocks shall not be moved until the
2. Briefing to the crew before starting driller ensures that the topman has the
operations . safety harness on and properly
secured. The topman shall verbally
· Proper method of un-flanging well head confirm this to the driller.
and/or removal of "donut"
· Proper and safe set-up for power tubing
tongs
· Operation of power tubing tongs

17
10.2 During Pulling out / Running In · While picking up , laying down tubulars ,
operation . the Vee door stairs shall no be used by
· While keeping an eye on drillometer personnel.
start pulling of tubing string. · Rotary table shall not be used for final
· Carry out the initial pulling only in makeup or initial breakout of a pipe
singles so that the threads of each connection . Always use two ( 2) tongs
tubing (single) can be checked and if during makeup or breakout .
found defective should be discarded.
· Ensure the hole filled with kill fluid ..
· Also ensure that there is no swabbing 11.0 WIRELINE OPERATIONS/
action during P/O. PERFORATION / LOGGING
· The quality / quantity of the return fluid
is to be monitored cautiously so that Prior to commencing well perforation
any early sign of well's abnormal operations , a meeting shall be held with
behaviour can be checked appropriately all workover personnel involved , covering
and remedial action may be taken the procedures for operations , hazards &
immediately. emergencies. The meeting shall be
· The topman's safety harness(es), when conducted by Officer-in-C h a r g e o f
not used, shall always be located at the Logging Team.
entrance of the monkey-board, to allow
the topman to put it on before starting to 1. Person or employee not directly
walk on the platform. connected with perforation job should
· The topman leaving the monkey-board remain at safe distance from the well
shall take off his harness only when during the time the swab line or other
reaching the exit of the monkey-board. wire line is being run in the hole.
· When the topman is changing out, the
blocks shall be lowered and remain in 2. Perforation shall not be carried out
vicinity of the drill floor. during thunder, lightning.
· When making up or breaking out drill
3. There should be no radiophone
collars, personnel shall stay clear of the
lines when the tension is applied to the transmitters operated where there is a
tongs. All personnel shall clear the perforating program in progress; the
perforating company should provide
rotary table.
appropriate warning signs. Such signs
· When tripping in or out of the hole, the
should be conspicuously placed at the
floormen shall grasp the elevator horns
extrance(s) to worksite(s), near the site
and the elevator links approximately 0.4
of operation where perforating is being
meters up on the elevator links. Hands
done. Sign should read, " Warning.
shall never be placed on or around the
Perforating in Progress. No Radio or
link eyes where elevators can pinch.
Radio-Phone Transmitters Operated
· The rotary slips shall be set by using
Beyond This Point".
the handles with hands palms up. It is
forbidden to kick the slips into the rotary
4. Devices containing explosives and/or
table bowl.
radioactive material, such as perforating
· When finishing a trip or a connection, guns, logging tools, etc., should be
the rotary slips shall be set back well
handled only by qualified employees of
clear of the rotary table. the service contractor performing the
· Floor shall be kept slip-free through operation.
regular cleaning. Appropriate non-slip
material shall be used around the rotary 5. Upon completion of perforating
table. operation, the work area should be
· The driller's view of the rotary table and inspected and all explosive material and
set back areas should not be obstructed scraps should be placed in approved
at any time. containers for removal from the site by
· Pipe shall be racked by pushing against Service Company employees.
the outer face of the pipe when setting it
back. Feet shall be kept away from
beneath the pipe at any time.

18
12.0 REMEDIAL CEMENTING movement of line while pumping
operation.
The cementing of oil well is an important 8. Place cementing pump / bunkers / mobile
and highly critical operation which is silos at least 1.5 - 2 mtrs. apart from other
accomplished in a relatively short period cementing vehicles and at least 25 mtrs.
of time. Utmost care should be taken by distance from the well head.
the workover crew during cementing 9. Park all vehicles which are not required
for the job to safe areas from the well
During a pre-job safety meeting, head so as not to block the well site exits.
cementing in-charge must outline the job 10. In hooking of high pressure lines from
procedure, define pressure limits, discuss cementing units, avoid crossing of two
safety measures and additional briefing discharge lines. Lines should not be run
on emergency procedure or any unsafe under cementing trucks. Ensure proper
conditions to all personnel designated to anchoring of high pressure lines to
associate in the job. He should designate prevent accident in case of line failure.
the sequence and volume in which fluid 11. Use sufficient number of chicksans to
will be pumped and at what pumping rate provide more flexibility to discharge lines
and total time involved. Also duties of for reducing vibrations during cementing
each person during cementing job operations.
including equipment operation, mixing of 12. Only steel lines should be used for
chemical, operation of valves releasing pressure and checking back
flow from the wells.
He will also review communication system 13. High pressure lines should be tested with
which plays an important role in water at 1.5 times the maximum pressure
monitoring cementing job execution. expected in pumping operations. The
The cementing operational in-charge must pressure test will not exceed the safe
supervise line hook up work and working pressure of the equipment.
thoroughly inspect prior to testing lines. 14. Before, testing all persons should be
vacated from the vicinity of high pressure
Following are some distinctive features line. No one will be permitted to step
/areas of safety concern associated with across, stand on or straddle or hammer
cementing operations. on any pressurized line.
15. Do not allow any one to take up line
1. Simultaneous presence of a large crew of leakage repair operation until : –
different disciplines makes coordination i) Particular well site personnel are notified
extremely essential. by the cementing supervisor with the
2. Several liquid chemicals and cementing repair plan
additives used in cementation can cause ii] Pressure has been released from the line.
safety hazards which needs proper iii) The release valve is left open during
precautions while handling. repairs.
3. High pressure and air pressure involved iv) The flow has stopped from the bleed-off
in cementing job execution. line.
4. Simultaneous running of all equipment v) The cementing supervisor has personally
creating high level of noise pollution. observed and determined that the system
5. Special attention is required when is free of any pressure.
cementation is being carried out in night 16. Entire sequence of operation should be
time. controlled by cementing operational in-
6. Fire extinguisher, spark arrestor in charge (one single supervisor) to avoid
engine's exhaust pipes and a first-aid kit any confusion in following instructions
should be available in all cementing during cementation.
vehicles 17. In many offshore rigs, the cementing unit
7. Mobile cementing equipment positioning is placed in relatively congested closed
should be planned for quick removal from space. The cementing supervisor should
the work area in case of an emergency. ensure that all exhaust fans are working
All vehicles should be placed with cabin and that all the personnel p r e s e n t i n
facing away from the well and wooden the cementing room should wear air
wedge support should be placed behind filters (masks).
wheels to minimise vibrations and

19
 PUMPING JOB: 13.0 WELL STIMULATION
Safety precaution during stimulation services
1. All valves in discharge lines shall be checked which includes following jobs :
properly to see that they are open before · Acidization
orders are given to start pumping. · Hydraulic fracturing
2. No pumping should take place while any · Surfactant/solvent treatment
personnel is working on, above or below · Nitrogen application
floor level. · Coiled tubing
3. Flammable or combustible fluids are not to · Hot oil services
be placed in open displacement tanks on · Sand control
cementing equipment.
· Water shut-off
4. Acid pumping with cementing units should be
avoided, if possible. In case it cannot be
13.1 Precautions to be undertaken during
avoided, make extra sure that all the valves,
mobilisation, hooking-up etc
caps, lines etc. are fitted correctly and also
the least number of people should be
13.1.1 Mobilization of equipment
present in the vicinity. After the job, the
cementing unit and the lines should be
a. Before starting of engine:
washed thoroughly so as to remove even
- Visual inspection of entire unit for oil
traces of acid
leakage’s, condition of tyres, obstruction
5. When pumping into any system -
etc.
i) Be sure that you have an accurate
- Checking of water/coolant i n
pressure gauge.
radiators/cooling system.
ii) Be alert for closed valves also.
- Checking of various oil levels including
iii) Start slowly with little throttle to confirm
engine, transmission, steering etc.
that system is open.
- Checking of battery connections.
6. A pressure-chart to record pumping pressure
continuously should be made available for all
b. Starting of engines as per respective
cementing jobs. Pressure chart should be
procedures and checking of any abnormal
supplemented with pumping sequence
sound.
volume, time and rate.
c. Drive the unit as per instruction to the job
7. Surface pumping pressure should not
locations confirmed by Supervisor / Field
exceed the lowest pressure rating of the
Engineer in accordance with the law of
union and / or whatever connections used
the land.
such as chicksans, valves, cross-over etc.
8. When transferring or venting material
d. To follow speed limits recommended by
through an open ended hose, a "T" shall be
manufacturer and admissible under law.
affixed to the end of the hose to prevent the
hose from whipping around. The end of the
e. Ensure safe Rig / Derig the equipment
hose should be secured tightly to a
and hooking / dismantling of pumping lines
stationary object.
& placement of treating iron on the units
9. During slurry, mixing, chemical preparations,
etc.,
adequate precautions must be taken to
f. To follow the instructions of the Supervisor /
avoid chemical / additive contact with skin,
Field Engineer for safe execution of
eyes and clothing. Fumes of defoamer
respective jobs.
should not be inhaled while using. When
handling cement additives, appropriate
13.1.2 Placement of Equipment
safety goggles, respirators, dust or vapor
masks, face shield, rubber gloves, shoes and
a. Placement of equipment as far as
hearing protection should be worn.
possible with the guidelines shown at
10. Proper illumination with adequate flame
Fig No: 1. In upwind direction to
proof lighting arrangements should be
minimize the losses in the event of an
provided in the operational area especially at
accident. The guidelines exclude the
slurry mixing point and additive mixing
placement of Coil Tubing Unit.
system to ensure safe and effective job
b. Unit/ Units should be spaced to allow
coordination during night time.
avenues of escape and room to work
freely.
c. To ensure that all the persons directly
connected with the job to wear Safety

20
 kits & persons not involved with the 13.1.5 PRIMING PUMPS AND TESTING
direct operations to keep at safe TREATING LINES
distance. (Fig:1)
d. To survey the location for any nearby 1. Any time there is more than one pump, there
hazards and to take all possible must be way to isolate each pump (i.e., an
corrective measures thereof. isolation and bleed valve for each pump).
e. To conduct a pre-job safety meeting for Where one pump is used, the we11head
all service personnel. valve must act as the isolation valve. The
f. In the event of any accident or any master gate must be closed while priming
abnormal behaviour of the well to take pumps.Under no circumstances is a pump to
action as per contingency plan. be primed while filling the hole.

13.1.3 PRE -JOB SAFETY MEETING 2. During the prime-up procedure :

Following should be instructed clearly in a. Experienced personnel only should carry

safety meeting. out valve operations around pressure
Ø Outline the job procedure lines.
Ø Define pressure limits. b. All unnecessary personnel should be
Ø Give instruction for pressure testing clear of the well, treating lines and
lines. pumps.
Ø Discuss safety hazards, particularly c. We11head master valve must remain
unusual chemicals and/or highly closed.
flammable fluids near by hazards etc., 3 Care should be taken to ensue that once the
Ø Instruct on use of personal protective pumps are primed, they do not lose prime.
equipment.
Ø Instruct on emergency procedures. 4. Each triplex pump must be primed
· Define the escape route in the individually by first pressurizing with the
event of an accident or fire. blender and then pumping with the pump
· Define the assembly area. through an open bleed valve until all of the
· Define fire extinguisher air has been cleared from the pump.
placement.
· Outline procedure to be 5. Pressure up and test all connection to be
followed in case of screen out used to a pressure exceeding maximum
while carrying out hydraulic anticipated treating pressure before starting
fracturing operations. treatments. But do not exceed pressure
rating of the fluid ends or connection.
13.1.4 HOOKING UP
6. Line test pressure must not exceed the test
a. A pressure gauge must always be used. Pressure of the well equipment. Also, if line
b. Brass hammer should be used test pressure is to be greater that the
whenever there is possibility of gas working pressure of the we11head
flow. Equipment, a hammer valve should be used
c. Treating Iron Connections. while testing lines.
Ø All connections and pipe should
be either integral or non- 6. During testing all personnel should be
pressure union style. cleared from the area and supervisor should
Ø Swages and Changeovers. The inspect the lines and pumps. All other
o n l y h i g h -p r e s s u r e u n i o n personnel should remain clear of the area
connections, which are until it is determined if any repair should be
authorized for treating iron, made. Pumps must be shut down and the
shall be used. line bled off before people move to the area
Ø Maximum recommended to make repairs.
pumping rate through treating
lines should be followed as per 13.2 HYDRAULIC FRACTURING
manufacturers
recommendations. Ø Fracturing Tanks:
a) Must be in good condition – without leaks.

b) Must have workable shutoff valves.

21
 Ø BREAKING OUT:
c) Fracturing tanks should be provided with
suitable railing on the top for safety of the a. Be sure pressure is bled off treating
person who is stationed on the tank during lines before breaking out.
operation.
b. Before breaking out, flush all treating
Ø Blender lines with water when corrosives,
flammable or combustible fluids have
a. Check engine emergency kill to be sure it is been used. This is required when a
operational. ‘high risk’ fluid has been pumped.

b. Clean and dope all unions. Hoses and

connections must not leak.
c. Mixing or pumping of approved ‘high risk’
fluids is permitted only during daylight
hours.

Ø Stimulation pumpers :

a. Packing, valve inserts, suction a n d

discharge valves and valve seats, plungers,
pump lube oilers, and treating pipe I.D. must
be checked before job.
b. All pumps and lines, including standbys,
should be primed and tested before starting
job.

Ø Sand Truck :

a. Sand gates must be checked to be sure

they will open before positioning over
blender and lifting box.
b. Sand truck should not be moved into
position until all mixing has been completed.

Ø General Requirements :

a) Adequate fire fighting facility should be

available .
b) The first aid box and personnel trained in first
aid should be available at the site.

Ø EMERGENCY SHUTDOWNS

a. Shut down all pumping units and

blenders.

b. Evacuate all personnel from the well

area to the designated safe area,
following escape routes planned in the
safety meetings.

c. When team incharge determine that it is

safe to do so, return to well
and work on instruction of Team Incharge.

22
13.3 ACIDIZATION

13.3.1 HANDLING OF CHEMICALS

HYDROCHLORIC ACID :

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

The vapors irritate all parts of Avoid breathing vapors. Avoid Instruct others to keep at a safe
respiratory system. The vapors contact with eyes & skin . distance. Spread soda ash liberally
irritate & the liquid burns eyes Wear breathing apparatus, over the spillage & mop up
severely. goggles & gloves cautiously with water, Run this to
The vapor & liquid irritate & may waste diluting greatly with running
burn the skin If taken internally, water.
there would be a severe
damage & irritation.

ACETIC ACID

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

It is flammable and moderate Avoid breathing vapour. Shut off all possible sources of
fire hazard. Avoid contact with eyes & ignition, wear face shield & gloves.
The vapours irritates respiratory Skin. Mop up plenty of water & run to
system. waste diluting greatly with water.
The vapours irritate and the Ventilate area well to evaporate
liquid burns the eyes severely. remaining liquid.
The liquid is very irritating to
skin & can cause burns and
ulcers.

ACID CORROSION INHIBITOR :

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

It is a flammable liquid. Extreme It should be stored away from Shut off all possible sources of
Care should be exercised when flame, direct sunlight & other Ignition. Wear face shield &
Handling & storing the product heat sources. gloves. Mop up with plenty of
water. Ventilate area well to
evaporate remaining liquid.

EGMBE ( ETHYLENE GLYCOL MONO BUTYL ETHER )

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

O
Flash point -74 C Handle in a well-ventilated. Shut off all possible sources of
Avoid contact with skin and ignition, wear face shield & gloves.
eyes
It can cause severe irritation of It should be stored away from Mop up with plenty of water.
the eyes & can be readily flame, direct sunlight & Other Ventilate area well to evaporate
absorbed through the skin.. heat sources remaining liquid.
Vapors can cause drowsiness
& serious irritation of respiratory
passages. Prolonged breathing
can cause liver & kidney
damage.

23
 BENZOIC ACID :

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

Only slight fire hazard when Avoid breathing vapors. Wear Extinguish fire withCO2 water &
exposed to heat or flame. face shield goggles & gloves.. dry powder
Moderate skin irritant. Avoid contact with skin and Shut off all possible sources of
Vapor Inhalation highly toxic. eyes ignition, wear face shield & gloves.
Severe Irritant to eye. Keep source of fire away.

ISOPROPYL ALCOHOL :

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

o
It has flash point of 112 C & Avoid breathing vapors. Shut off all possible sources & of
o
boiling point is 82 C. Wear face shield, goggles & ignition. Wear face shield & gloves.
gloves.
Inhalation of vapor in high Avoid contact with skin and Extinguish fire with water, dry
concentration & ingestion of eyes. powder & CO2.
liquid may result in headache May be disposed after mixing with
dizziness, nausea, vomiting, sand or flushed away to waste with
Mental depression, narcosis and water.
coma. The fatal doze is about
100 c.c. The liquid may damage
the eyes severely.

AMMONIUM BIFLORIDE

HAZARDS PRECAUTIONS SPILLAGE AND DISPOSAL

Highly toxic and strong irritant Avoid inhalation of dust. Special attention should be paid to
The dust irritates all parts of Prevent contact with eyes and the area around the fingernails.
respiratory tract. skin. Damage can be caused by the
It irritates eyes, skin and All exposed skin should be material conversion to Hydrofluoric
ingestion causes nausea, washed thoroughly after Acid as it dissolves in sweat or
vomitting, diarrhea & abdominal working with this chemical. body fluids.
pain.
Chronic effects are shortness of
breath, cough, elevated
temperature & cyanosis.

13.3.2 SAFETY PRECAUTIONS FOR suitable warning signs should be

STORAGE & HANDLING OF posted to this effect.
CHEMICALS
d) Carboys or other containers of acid
a) Acid containers should be stored in a should be carefully lifted, preferably by
well-ventilated place. Chemicals, mechanical means.
which can react with acid, should be
stored separately. e) Adequate quantity of lime / caustic
soda should be kept readily available
b) Storage area container of acid should near the site where acid is stored to
be properly labeled and warning signs neutralize acid spills.
should be posted prominently to
denote Danger Acid”. f) Persons handling acid should be
provided with suitable personal
c) Smoking should not be permitted at protective equipment.
the place where acid is stored and

24
g) Whenever it is required to dilute acid, - Jetting out fluid before perforation.
the acid should be added to water. In - Jetting out mud with foam.
no case water should be added to - Back flow in disposal and injection
acid. wells.
- Jet out spent acid after acid job.
h) The first aid box and personnel trained - Spotting or circulation aerated fluids.
in first aid should be available at the
site. Adequate supply of clean and 13.4.1 N2 SUCTION AND TRANSFER
fresh water should be available. CONNECTIONS

i) If eyes, skin or other parts of body are A. Stainless steel braided hose with
affected by acid, wash it off with water brass or aluminum connections
at once. Remember that the first few must be used.
minutes are most critical for washing B. Suction lines should be kept as
off splashed acid. Do not use (except short as possible.
fresh water) any other solution to C. The suction system must be
wash the eyes. equipped with a relief valve, which
j) At base: wash eyes on the eye wash should be set at 45 psi on location
stand where sufficient water is stored. and 10 to 15 on the road.
At site : sufficient water should be D. The suction system must be
available before start of the job. equipped with a pressure gauge to
be read at the transfer pump
k) Do not attempt to close the eye operating panel.
around them. E. All transfer hoses must be blown
l) The injured should immediately be out with gas and connected to the
taken to a doctor and till that time, N2 tank before opening tank liquid
Washing of eyes with eye wash bottle valve.
must continue. F. No valves on either transfer vessel
will be close until the transfer pump
13.4 NITROGEN APPLICATION is stopped or the bypass valve to
the delivery tank is opened.
In oil field operations Nitrogen is pumped as G. Transfer pumps are capable of
o
liquid at a temperature of - 196 C using high- higher pressures than the pressure
pressure cryogenic pumping equipment on rating of some transfer valves. Be
nitrogen pumping unit. However, the liquid sure the pump pressure does not
nitrogen is passed through heat exchanger to exceed the pressure rating of any
develop warm dry nitrogen has before injecting component in the system.
into the well. In brief, standard applications of
nitrogen is as follows:
13.4.2 HOOK-UP AND START-UP
- Displacement of well fluid.
- For Nitrified / automised fluids. 1. Before commencing any hook-up to a
- Foam generation. wellhead, make certain that master
- Purging of gas plant / flow lines / and wing valves are closed and all
vessels. pressure has been bled off at tie-
- Pressure testing of gas plant, end point.
pipelines etc. 2. When installing the swedge nipple.
- Gas well drilling and completions. Make certain the threads are clean
- Other miscellaneous uses e.g. and lubricated (Teflon tape or
injectivity testing, blowout simulation, thread compound).
freeing differentially stuck pipes, 3. After swage nipple is tightened,
setting hydraulic packer, casing continue rigging up the treating
insulation etc. lines from wellhead usually in this
order;
The nitrogen is also used in conjunction with - Short swing
CTU for various work over/service operations - A bleed valve
namely: - - Recorder connection, if
needed.
- Jetting for zone evaluation. - Check valve

25
 - Isolation valve, if needed. open. Do not bleed N2 through
- Another swing joint to relieve needle valves.
tension on lines. C. Before knocking out any discharge
4. Next the straight joints can be and suction lines, be sure all
connected; install swings to prevent pressure has been released from
bending or tension loads. all sections of all lines. Be sure all
5. Brass hammer should be used valves in all lines are open before
whenever there is possibility of gas hammering on any unions.
flow.
6. Operators to check that all points of
connection are tightened. 13.4.4 SAFETY PRECAUTIONS FOR
7. Other types of hook-ups follow the FLOWING THE WELL AFTER
general pattern as above and any NITROGEN PUMPING
modifications or the supervisor or 1. Use only steel flow lines.
Site Engineer will usually explain 2. Have flow lines securely
precautions. anchored. Crossed steel, deeply
8. When ready to start treatment, hold driven stacks every 4 to 5 mtrs.
safety meeting and advise tied with strong wire or chains. If
personnel of job procedure, job stacks are not practical, tie line to
safety and planned emergency some stationary object.
procedures, All crew members 3. Open well head valves slowly to a
should attend this meeting. position necessary to obtain
9. On energized fluid jobs pressure test desired flow rate.
treating line to wellhead with water 4. Do not place parts of your body
only. During pressure test of all infront of bleed off or sample
treating lines, all personnel must valves.
remain clear of pumps and 5. Avoid exposure to area where N2
discharge lines. After pressure test is being recovered to prevent
line, close control valves in main suffocation.
treating line. 6. Remove all other personnel to a
10. Leave main (fluid) treating line fluid safe distance from the flow line
filled and its control valve closed. before a well is opened
With N2 control valve also closed, 7. Have atleast one other person on
test N2 lines to maximum location, at a safe distance away,
anticipated pressure with nitrogen before opening a well
gas. Bleed off N2 pressure.
11. Nitrogen service supervisor or 13.4.5 GENERAL SAFETY
nitrogen unit equipment operator PRECAUTIONS FOR HANDLING N2
must keep constant communication
with the supervisor of pumping a) WARNING
services. Extremely cold liquid and gas.
Contact with liquid or cold gas
13.4.3 SHUTDOWN AT END OF causes frostbite. Protect
TREATMENT against over heating. Never
A. It is desirable to shut down N2 work on a pressured system.
pumper before fluid pumpers shut
down so that the main (fluid) b) DO’S
treating line will not contain N2 - Keep equipment area
However if displacing the well with well ventilated.
gas instead of fluids, simply shut - Read the labels of the
down the treating fluid pumps and containers and observe all
close the fluid line isolation valve. safety precautions.
After gas displacement is - Protect your eyes with
completed, shut the master control safety goggles or face shield.
valve and bleed all gas pressure - Protect your arms with
from the gas line before bleeding leather gloves.
pressures from the liquid line. - Use only equipment,
B. Open vents valves in N2 suction cylinders, containers and
and discharge line and leaves

26
 apparatus designed for use of the coiled tubing unit in servicing oil/gas
intended service. wells.
- Use a high pressure-
reducing regulator when with 13.5.1 SAFETY PRECAUTIONS TO BE
drawing gas from a cylinder or TAKEN DURING MOBILIZATIO AND
other high pressure source. OPERATION
- Dispose cryogenic Because CTU is awkward and ‘top-heavy’, it
liquid by discharging into a is important that extra care and caution is used
remote outdoor pit filled with during its movement.
gravel and allows it to 1) Under no circumstances unit
evaporate safely. should be allowed to be driven by
any other person than
c) DON’TS experienced & well versed driver.
- DO NOT touch frosted 1) Position the unit in upwind
pipes or valves with bare skin. direction as far as possible.
- DO NOT use the 2) Do not position coil tubing unit in
container if the identifying line with well head wing valve.
label is missing. 3) Check BOP rams by cycling for
- DO NOT release proper functioning, before
gases indoors. installing at well head.
- DO NOT use a 4) In case of acid job with CTU,
damaged regulator. adequate breathing apparatus
- DO NOT work on a must be available.
pressurized system. 5) In case of dewaxing job with oil,
- DO NOT enter any ensure that adequate firefighting
tank, pit, or other confined equipment with trained manpower
area where these gases may is available at site throughout the
be present until it has been job.
purged with air and tested for 6) Since all CTU personnel at one
breathable oxygen content. time or another are exposed to
danger of working under the
d) EMERGENCY ACTION tubing injector while it is hanging
In case of liquid spill on the crane, strict maintenance of
or gas release, shut off leak if the crane must be ensured to
without risk. Allow liquid to avoid any accident.
evaporate. Move leaking 7) Ensure all working personnel at
container to well ventilated site use safety kit viz. safety
area. shoes, hand gloves and helmets.
8) Never use rubber flow lines. Insist
e) FIRST AID on proper flow line and ensure
that it is properly anchored.
- If inhaled, remove victim to fresh air. Give 9) Do not exceed working pressure
artificial respiration if not breathing. Obtain on coiled tubing, as prescribed by
medical attention. manufacturer.
- In case of liquid contact, flush the affected 10) Working area around CTU should
portion with water for atleast 15 minutes. be kept free of by standers or idle
Obtain medical attention. worker to avoid accidents.
11) Proper record must be maintained
of life of cable on crane. Cable
13.5 COIL TUBING SERVICES must be slipped periodically to
The ability to circulate fluid e.g., water, oil, ensure that there is no excessive
acid, mud, cement slurry or gas through the wear of the cable to avoid
coiled tubing while the tubing is being lowered accidents.
or raised makes the coil tubing unit a very 12) Do not allow any other person in
versatile equipment to carry out sand clean operator’s cabin except the
out, paraffin plug removal, cement squeeze, operator, small distraction can
acid spotting jobs etc. The development of the cause serious accident.
downhole Dynadrill for light duty drilling 13) Before start of job, conduct a
operations has added another advantage to safety meeting. Explain to all

27
 employees about the operations, Close master valve and valves
what must be done, hazards and on storage tanks
safety precautions to be followed.
14) All the exhausts of the engines 13.6 WATER SHUT OFF SERVICES :
must have spark arrestors fitted.
15) The coiled tubing operations For water shut-off jobs refer OISD
should be carried out in day light standard – 175 on cementing operation.
only. In very exceptional cases For handling of chemical used in water
these may be taken up provided shut-off jobs , follow recommendation of
control console, tubing reel, goose chemical manufacturer .
neck, Injector well head, pumping
unit have light for good visibility. 14.0 WELL ACTIVATION

13.5.2 HOT OIL SERVICES Safety precaution required during

SAFETY REGULATIONS FOR activation of wells by Air
USING“HIGH RISK” HYDROCARBON
FLUIDS. In this operation the main hazards are
due to blow out and fire.
A) Oil tankers:
The compressor and its supply line
a) Must be in good condition – should be provided with the following
without leaks. equipment :

b) Must have workable shutoff Û A pressure gauge, to indicate

valves. the pressure at each stage of
compression.
c) Tankers and well should be Û A self-recording pressure
crosswind or downwind from gauge, at the final stage of
equipment when possible. compression, to indicate if
c) Spot tankers a minimum 15 back pressure from the well
mts. from well. is acting against the
compressor
B) Hot oil pump Û A pressure release safety
a) Pump and lines should be valve should be installed
primed and tested before directly on the outlet of each
starting job. stage of compression
b) Clean and oil all unions. Û A device to automatically
c) All parts of the truck must be switch off the compressor if
at least 15 mts. from the temperature or pressure
we1lhead. exceeds the permissible limit
C) General Requirements: or if the pressure of the
a. An operable fire truck will be lubricating system falls below
on these jobs along with a the prescribed limit.
trained operator.
b. Use a special “Checklist for 1. A pressure gauge should be
pumping Flammables” to provided on the discharge line.
ensure that it is safe to start The discharge line should be
the job. securely anchored to the ground.

13.5.3 EMERGENCY SHUTDOWNS 2. The pipeline should be pressure

a. Shut down the unit. tested at the rated working
b. Evacuate personnel from pressure. The joints and
the well area to the hammer union should not be
designated safe area, opened or tightened unless the
Following escape routes pressure on the line is released.
planned in safety meetings.
c. When team incharge 3. In case of any interruption in
determine that it is safe to do injection of compressed air, the
so, return to well and

28
 well should be closed The main hazard in the operation is
immediately. due to fire as gas and oil flow the well
and the following precautions are
4. The compressors should be therefore recommended.
located at a distance not less
than 30 meters from the well- - The separator should be located
head on the upwind side. at a distance of not less than 15
mtrs. from the well head.
5. An area within 30 meters of the - The open pit and flare should be
well-head should be treated as located at a distance not less than
danger zone in which no 30 meters from the well head.
smoking or open flame should be - The safety of the separator should
permitted and all electrical be checked to ensure that it is in a
equipment should be de- good working order.
energised. - An area within 30 mtrs of the well
should be marked as danger zone
6. Adequate arrangements for fire with proper warning signs at
fighting should be made prominent places.
available - In the danger zone, no smoking or
open flame should be permitted;
8. Use only steel flow lines for entry of unauthorized persons
injection and release lines should be checked and all
9. Lines should be securely electrical equipment should be de-
anchored. Crossed steel, deeply energised.
driven stacks every 4 to 5 - Adequate fire fighting
meters. tied with strong wire or arrangements should be made
chains. If stacks are not practical, available . It should be ensured
tie line to some stationary object. that persons deployed for well
10. Release compressed air after the testing are conversant with the
application slowly through a bean use of fire extinguishers.
at a safe distance . - Before the the x-mas tree gate
11. Do not place parts of your body in valve of the well is opened, all
front of bleed off or sample valves. persons should be informed about
operation & safety procedures to
adopt in case of fire or
15.0 WELL TESTING uncontrolled flow. The valve
should be opened fully, otherwise
The final stage of well completion it may be damaged due to
operation is the testing of wells. The throttling and may leak thereafter.
purpose of the test is to ascertain the -
potential of the perforated horizon to - The flow line to be pressure tested
produce hydrocarbon. In the to the maximum expected shut in
beginning when a well starts pressure of well.
producing oil and gas the products are - In offshore flow line to the
led through a bean in the line to an connected to burner through
open pit but immediately thereafter choke manifold.
portable separators and tanks are - Adequate water sprinklers to be
connected to the well. Oil and gas are provided while well is being flared,
separated in the separator, the gas is in order to keep the surrounding
diverted to flare line and burned. Oil cool.
settles in the separator and when the
level of oil reaches a pre-set limit, it is
discharged automatically into a tank.
The flow rate of oil is thus measured.
The bean regulates and controls the
flow and pressure of fluids from the
well.

29
 ATTACHMENT -1

FOR STIMULATION JOBS

COMMON HAZARDS ON LOCATION

The following items mentioned are the causes of accidents or near misses in the past therefore they
should be checked properly. All personnel on location should be alerted to any problems and take
appropriate action.

1. Guy lines, stakes, flow lines and other obstructions.

2. Holes, ruts or obstruction in rigging up area.

3. Condition of ladders on tanks.

4. Safe Top of tanks i.e. free of oil and mud / slush.

5. Ladders and steps on rig secured and in good condition.

6. Working area or rig floor i.e. clear and clean?

7. Wellhead equipment pressure limits.

8. Backing of trucks.

9. Don’t use Non-WSS equipment in hookups.

10. Loose connections on wellhead.

11. Driving across flow lines on surface or buried very shallow.

12. Unfavorable wind direction.

13. Electric lines on and around rigs and across access roads to locations.

14. Working under rig floor.

15. Any engine nonessential to service job should be shut down. In the event of an emergency, there
may not be time.

16. Non use of safety equipment/ Kit and liveries.

30
 Annexure-

PRE-TREATMENT CHECKLIST FOR STIMULATION JOBS

Date ____________ Time _____________ Treatment No._____________

Type of job _______________ Project. _______________ Well no._________________

Column Heading: ‘A’ - Satisfactory; ‘B’ Deficiency: ‘C’ – Not Applicable

HOOKUP A,B,C

Equipment Location _______

Recorder Location _______
Check Valves _______
Flow-back Lines Secured _______
No Stiff Connections _______
Spotting of Tanks _______

PERSONAL SAFETY EQUIPMENT

Head Gear _______

Clothing _______
Footwear _______

FIRE CONTROL & MISC

Fire Extinguishers _______

No Smoking Areas _______
Vehicles Properly Parked _______

PRE-TREATMENT MEETING

Everyone Present _______

Instructions on Pressure Test _______
Pressure Limits _______
Outline Job _______
Discuss Hazards _______
Caution Bystanders _______
Save Personnel First. _______
Decide Line of Escape _______
Save Equipment Later. _______

PRESSURE TEST

Pressure Test completed ________

Signature of Supervisor/Team I/c

2
 Annexure-
WELL STIMULATION JOB

SAFETY CHECKLIST FOR PUMPING

“HIGH RISK”/ “FLAMMABLE” FLUIDS
(Attach this Checklist to Treatment Report)

A. PRE-HOOKUP AND PRE-GEL MEETING:

1. Smoking area designated _______

2. Fire tender on location. _______
3. Water available for prime-up, for testing
lines and for flushing lines. _______
4. Parking area specified. _______
5. Personal safety equipment for all personnel _______
6. Fire extinguishers dispersed. _______
7. All non-essential engines shut down. _______
8. No open flames on location _______
9 Blender densiometer calibrated
on location prior to pumping. _______
10 Eliminate manual operation of sand dump
doors to control sand concentration. Use
sand gates on blender. _______
11.Get a head count. Including all personnel
on location. _______
4. Review hookup. Hookup to be in
accordance with safety Standard _______
13.Check all equipment prior to job. _______
14.Review gelling or chemical mixing
procedure ________
15.Job assignments made ________
! 6.Observe wind direction
spot Equipment accordingly _________

SEFETY MEETING PRIOR TO PRIMING, TESTING LINES AND JOB PERFORMANCE.

1. Every one on location present. _________

2. Instructions given on prime up and
pressure testing. _________
3. Define pressure limits _________
4. Outline job. _________
5. Discuss hazards. _________
6. Restrict non-essential personnel to
parking area. _________
7. Job planning must include provisions
for screen out, bleed-off, fire, flammable
vapour leak, etc. _________
1. Review normal shutdown and breaking
out procedures. Remember to purge lines
withwater before breaking out. _________

3
 SAFE DISTANCES OF EQUIPMENT FOR STIMULATION JOBS

FIGURE: 1

WIND DIRECTION
UNUSED VEHICLES

SAFE AREA

30mt

AUXILLARY
WELL UNITS

15mt PUMPER

SMOKING AREA

NO PHOTOGRAPHY
NO SMOKING