handling tubular s

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Best Practice Guideto Handling Tubulars

DRILL FLOOR SAFETY


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Introduction / List of Contributors 2

1. Pre-Job Planning 3

2. Toolbox Talk Onsite Risk Assessment 7

3. Executing the Job 10

4. Post Job Analysis 15

5. Supervisors Tips 17

6. Resources 19

7. Background & References 20

Revision No. 1-2003 1


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In November 1998 a workgroup consisting

of cross industry representatives reviewed

incident reports relating to handling

tubulars on the rig floor. U nderlying causes

of incidents were listed and recurring ones

ranked. U sing this ranked list, a

questionnaire based on ten common, but

different, incidents was devised. Each of

the incidents occurred due to one or more

of the ranked underlying causes. A fter

considering a description of the incident,

the reader was asked to describe how his

rig team - or company systems - currently

prevented this type of incident.

The questionnaire was enthusiastically

received and Step C hange would like to

thank the respective companies for their

contribution. The material in this best-

practice guide is taken from the replies and

tips that came out of the returned

questionnaires. These replies have been

categorised into five distinct stages:

1. Pre-Job Planning

2. Toolbox Talk O nsite R isk A ssessment

3. Executing the Job

4. Post Job Planning

5. Supervisors Tips

The rig floor is still one of the most

dangerous place on a drilling rig, and those

who took part have made a valuable

contribution to improving rigfloor safety.

Step C hange are aware of areas outwith the

R ig Floor where handling of tubulars have

resulted in injury to personnel, however the

intent of this booklet is to focus on the areas

of concern as highlighted by the responses

received in the industry questionnaire.

The information contained in this booklet

will be of use, not only at safety meetings

and toolbox talks, but also for presentations

and personal use. A lso its contents can

play an important part in rig floor

competence and assessment.

List of Contributors

G lobal Santa Fe C onocoPhillips

M aersk Contractors Shell

Noble D rilling BP

Transocean K C A /D eutag

D iamond O ffshore Franks U K Ltd

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1.1 Ensure Toolbox Talks are held

Toolbox talks are an ideal method of

capturing and communication of safety

issues at the worksite. Variation in who

leads the discussion is seen as a plus and

there is a growing acceptance throughout

the industry that a Toolbox Talk is seen as

an integral part of the risk assessmentprocess. D uring the Toolbox Talk the risks to

each individual involved in the job should

be considered and discussed.

1.2 Rig Specific Procedures should

be in place to cover all aspects

of the operation.

These procedures are seen to be the

essential starting point for an effective

Toolbox Talk and R isk A ssessment.

The procedures should be of such quality

to be useable and easily understood during

the Toolbox Talk.

1.3 Hold 10 minute Pre-Job Talkprior to any operation

Pre-Job Talks should be unique for every

operation. They should draw on previous

experience from similar operations and

learning points from other rig crews, and be

given where the full participation of all team

members can be obtained (old experience

and new experience) . A new set of eyes

can sometimes highlight hazards

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overlooked by experienced hands who

carry out the repetitive tasks underconstant, normal operations.

1.4 Time Out for Safety Culture

should be in Place

A well embedded T ime O ut for Safety

culture helps to

significantly reduce

risks by allowing

all members of

the workforce to

make an

individual

assessment that a

situation needs to be stopped

and discussed before the

operation continues.

1.5 Communication Needs to be

Free-flowing

There must be a free flow of communication

between the D riller, Floormen and

D errickman and any other concerned

parties i.e. C asing crews. The Driller should

also have a clearsight of the complete

operation on the rig floor as well as at

monkeyboard level. C ommunication is the

most powerful tool for good, safe

operations. Raise your concerns if youre

not sure of anything!

1.6 Solid Teamwork is Essential

Solid/experienced teamwork is vital to safe

operations. Teamwork is the basis for good

communication and vice versa, good

communication during the operation

significantly contributes to a safe working

environment.

1.7 Keep Rig Floor as Clear

as Possible

The rig floor should never be overloaded

or congested with tools, equipment or

people. Both supervisory and tubular

handling personnel should be made aware

of the potential problems inherent with

overloading and congestion and use good

housekeeping techniques to avoid them.Remove all excess equipment as soon as it

is no longer needed. K eep to hand only that

which is required.

1.8 Allocate Sufficient

Storage Space and Use It!

A llocate enough storage space on the pipe

deck, etc., for equipment storage, and

ensure that everyone knows where things

are supposed to be kept. D evelop a culture

of putting things in the correct storage

space as soon as they are no longer

required.

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1.9 Create a Good Housekeeping

Attitude

Plan sufficient time to clean and tidy up

during the operation. C reate an atmosphere

where tidiness is expected and not

considered nice to have. R emember,

tidiness is an integral part of the job.

1.10 Plan Equipment Requirements

Well Ahead

D iscuss as part of the Toolbox Talk/R isk

Assessment what equipment is needed

and what isnt required on the drillfloor. U se

flush mounted slips to keep the rig floor

clear of bulky and unwieldy work platforms

which only add to rig floor congestion.

Ensure that there is adequate detailedplanning well ahead of the operation of

what equipment is required and when.

Personnel should be encouraged to

challenge the need for back up equipment

to be readily available on the R ig Floor.

C onsideration should be given to stowage

of back up equipment in other areas

throughout the installation.

1.11 Draw and Stand in Quadrants

on Rig Floor

Develop safe area map/quadrants which

can be utilised to highlight hazardous and

safe areas on the drill floor. This can be

used as an overview tool in safe positioning

training techniques e.g. highlight positions

where equipment is moving overhead or

areas where a fall from the drill floor is

possible.

1.12 Individual Competence is a

Major Contributor

Individual competence is seen as a major

contributor to rig floor safety. C ompetence

systems need to really establish individual

competence and not just satisfy the legal

requirement. Individuals must feel able to

say when they do not feel competent to do

a job. G ood supervisors should know the

strengths and weaknesses of their team,

and not ask someone to do a job for which

they are not qualified or competent. The

issue of competency should be raised

during all Toolbox Talks and T ime O ut for

Safety meetings

1.13 Use Experienced Roughnecks

plus only one Green Hand

at a time

Encourage a buddy system. It should

always be the case that experienced

personnel form the basis of the team. (This

applies in all operations). A ll personnel

should be made aware of the requirement

to look after the green hands and

conversely the green hands should be

given the tools and forum to recognise their

experience/knowledge limitations within the

operation. Its often the case that new, keen

personnel will try to carry out operations

without full knowledge and experience. U se

reliefs only for simple tasks, and preferably

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dont use Roustabouts at all ( i.e. Floormen

should break in shifts if there are sufficient

available) . However, if R oustabouts must be

used, use them for the least hazardous

tasks and preferably not during B H A

(Bottom H ole A ssembly) work. D errickmen

reliefs should be Floormen who are

properly trained to be D errickmen.

1.14 Training is of Vital Importance

In terms of experience, training is an issue

not so much in the competency arena, but

more so within actual hands on knowledge

and time with respect to the handling of

tubulars and associated hazards on the drill

floor. The training directed at the

experience level should build upon

peoples own existing experience of tubular

operations. It is also worth noting that for

green hands, mentoring by experienced

hands who share their knowledge is an

essential part of green hand training.

1.15 Investigate and Incorporate

New Ideas

Investigate and incorporate new ideas, for

example:

H ave casing suppliers paint a band

around joints of casing approximately 10

feet from the end of the joint. This will

enable the Driller to better time the entry

of the joint into the drill floor, which in turn

will enable him to control the rate at which

the joint enters drill floor.

The use of inflatable casing protectors is

also recommended as they dont just

protect the threads of the pipe, but also

restrict the rope from dropping off the

bottom of the pipe as it is travelling. M any

of the manual handling problems

discussed here are eliminated when pipeis tailed using a small winch located near

the V-door. Some rigs already use these

winches which are relatively cheap. M ore

sophisticated controlled feeding winches

are now also available.

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These days, more often than not, risks of a

job are assessed during the Toolbox talk.

Thats why many contractors now useTR IC s (Toolbox Talk R isk Identification

C ards) and seldom mention the words

Toolbox Talk ( TBT ) by themselves.

In the following pages you will find some

generic Toolbox Talk tips followed by more

specific risk assessment tips.

2.1 Toolbox Talk

Ensure sufficient time is given to the

preparation of the toolbox talk.

U se written procedures and risk analysis

as the basis of the talk.

Have appropriate levels of supervision

present during the Toolbox Talk

Vary the discussion leader to encourage

participation from all members of the

team

U se the toolbox talk to make all those,

both directly and indirectly, involved in

the operation fully aware of the total job.

Encourage all crew members to get

actively involved in the TBT, by adopting

a constructive and questioning

approach.

U se the TBT to get buy-in from all crew

members to the approach to the job.

Ensure all crew members know their role

in the job.

H ighlight the fact that everyone has an

obligation to act as a lookout/observer to

warn others of danger.

Encourage crew members to call for a

T ime O ut for Safety at any point in the

operation, if any aspect of the work is

unclear or considered hazardous.

Commit to repeating the TBT if the job

changes in any way (weather, equipment,

plan, sequence crew make-up etc.)

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Be explicit in the TBT about thetechniques to be used for handling pipe:-

M echanical means or aids such as rope

should be used to manoeuvre tubulars

whenever possible.

Never grip a pipe with fingers around it,

and keep fingers safe by:-

C rossing hands and pushing pipe away

from you

C lenching hands

Holding pipe with palms only

Using two people for stabbing operations.

M ake everyone aware of green hands

and ensure a buddy is assigned.

Ensure the rig-up and down of equipment

is fully discussed, as well as the operationitself.

Ensure a common understandingamongst crew members of all

communications methods e.g. radio call

signs, hand signals etc. particularly for

those working aloft in the derrick e.g.

pipe stabbers working on the stabbing

platform. Take particular care to ensure

reliefs are fully aware of the agreed

communications.

Ensure casing contractors equipment

checks and rig-up (especially the

stabbing platform), are covered, and

understood by all.

M ake a proper note of the TBT and any

key points raised. G et all involved to

acknowledge attendance. D iscuss startup of operation with caution, until all

personnel are comfortable with their

individual task.

2.2 Risk Assessment

Be satisfied that the following questions can

be suitably addressed otherwise complete

a full risk assessment.

D o supervisors/crew members have

sufficient R isk A ssessment knowledge

and training to carry out effective R isk

A ssessments? If not, consider/request

additional training in this essential skill.

A re written procedures available for the

Tubular Handling task?

A re the procedures relevant and up to

date?8


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For a full riskassessm ent refer to the Step

C hange in Safety Task Risk Assessm ent

guide.

Is there anything about the conditions

prevailing e.g. weather, crew make-up,

equipment condition, tubular type etc.,

which might make the procedures invalid

for this operation?

Have all hazards been identified?

Have all hazards been assessed?

What controls are in place/are required to

reduce the hazard?

What are the recovery possibilities if a

hazard is realised?

Are the crew involved, competent for the

work identified?

A re sufficient crew available ( including

reliefs) for the job?

Are there green hands involved, and if

so who is identified to coach and look

after them?

Has suitable time for training/coaching

been allocated if required?

A re supervisors aware of training/

assessment of crews?

Is the workplace as tidy as it can be for the

start of a new task e.g.

Remove all excess equipment

C lean rigfloor to reduce slipping hazard

Have all necessary equipment to hand,

and checked and serviced.

Ensure rig-up and down of equipment is

assessed for risks, as well as the

operation itself.

C ommunicate fully and comprehensively

to all crew members.

Look for opportunities to improve

communications

Test for understanding of all team

members

C onsider rotation of crew members, and

use of a Take 5 break

U se Toolbox Talk as the primary (but not

only!) tool for communicating work plans

and intentions.

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3.1 Ensure Reliefs get a GoodHandover

Let reliefs watch the job in hand first. Then

one of the regular team members should

explain the job clearly to them, describing

all possible hazards and warning them of

any danger. If the ongoing job is hazardous

then stop the job and hold a Toolbox Talk

prior to the relief taking over. In other words,

make sure that the relief isnt thrown in at

the deep end!

Reliefs should:

Have a strong interest and have the right

attitude to take on the role of relief

R eport to the D riller prior to relieving

Be open and declare when they dont feel

confident

Be identified by a special helmet (green

colour) or jacket

Initially only concentrate on one facet of

the job.

Regular Team Members should:

H ighlight during the Toolbox Talk that a

relief is present

Treat reliefs as high risk and with caution

D riller should slow down operations and

be vigilant

A ssign one competent crew member to

look after (mentor) the relief until the relief

is fully confident and competent

C ontinually coach the relief (preferably

one-on-one)

Scrutinise the relief well, take time to

determine the knowledge and skill level

of the relief and assign tasks accordingly.

If R oustabouts must be used, use them

for the least hazardous tasks andpreferably not during BHA (Bottom Hole

A ssembly) work. D errickmen reliefs0


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should be Floormen who are properly

trained to be D errickmen.

3.2 Maintain a Clear Line of Sight

for the Driller

This doesnt mean that you should stay out

of his sight! There must be a free flow of

communication between the D riller,

Floormen and D errickman. The D riller

should also have a clear sight of the

complete operation on the rig floor as well

as at monkey board level. Personnel should

be made aware of the problems associated

with the D rillers restricted view. It is also

essential that the D riller maintains

communication with the tubular handling

personnel and highlights any visibility

problems within the operation

3.3 Communication Needs to beExcellent

D oes your team need to improve

communication? Refer to 1.5.

3.4 Keep the Rig Floor as Clear as

Possible

M ake both supervisory and tubular

handling personnel aware of the potential

problems inherent with overloading and

congestion!

3.5 Keep the Work Area Clear

Prior to tripping operations, clear the space

of all equipment not required for the

operation and ensure that there are no

slip/trip hazards present. A fter breaking

connections place the mud bucket, tongs

or iron roughneck well out of the way. C lear

a path from the V-D oor to the rotary table to

ensure free passage for joints tailed and the

person tailing joints. As room is limited

during casing operations its vitally

important that all space available is clear

and utilised. Remove all excess equipment

as soon as it is no longer needed. K eep to

hand only that which is required. D o you

allocate sufficient time to clean up as and

when required? C lean during regular stops

after each sequence of operations. A t least

every trip there should be an assessment of

what is and isnt needed, and time taken tomake any adjustments to tools and

equipment required.

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3.6 Time Out for Safety

If anybody at any time is not sure of their

task, is uncomfortable with the operation in

anyway, or observes an unsafe act or

situation, - then STO P ! ! Take time to

discuss and correct the situation before

continuing.

3.7 Positioning needs to be taught

via Training/Buddy System

A ll personnel need to be aware of Safe

Positioning in relation to tubular handling. It

is also important to emphasis the buddy

system approach, whereby personnel alert

each other of potential danger areas and

appropriate safe areas.

3.8 Use Rope to Restrain Pipe

Tie the rope onto a high securing point to

prevent the rope slipping off the bottom of

the pipe being tailed in. C heck that the rope

is double wrapped around the other

securing point when heavy pipe is being

tailed. A lways replace worn or mud

contaminated rope. Take the time to learn

how to tie and use proper knots such as:

the Bowline and the Round turn and two

half hitches.

3.9 Use the Right Method

A llow the rope to slide through your gloved

hands - dont try to hold the weight as the

rope takes the bite. G radually increase

pressure on the rope as it passes through

your hands until it stops where you want it

to (this method is for use with lighter pipe).

3.10 Use a Rope along

with a Shackle

When tailing in from the V-D oor, secure the

dead end of the rope to one side of the V-

D oor and thread the rope through a shackle

attached to the opposite side of the V-D oor.

When tailing heavy casing into the floor, use

a double wrap of rope on the shackle to

increase friction.

3.11 Use Flush Mounted Slips

D o you use flush mounted slips to keep the

rig floor clear of bulky and unwieldy work

platforms?

3.12 Beware of Temporary

Equipment

Temporary equipment, because of its very

nature, M U ST undergo pre-operational

checks. O n your rig there should be a

temporary equipment system in place: the

best systems include manufacturers and

regularly updated rig contractors checklists. These check lists should be reviewed

during the post job review, and updated if2


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required. Prior to using this equipment also

check the Certificates and ensure they will

not run out prior or during the use of the

equipment.

3.13 Concentrate on the Job

Supervisors - do you notice when crew

members drift? Its vital to give people a

break or change out team members when

they lose concentration.

3.14 Supervisors should encourage

Feedback

Do you encourage team members to speak

up and listen to what they have to say?

3.15 Always Beware!

Pipe can bounce off like a spring if it strikes

a racked pipe. If it looks as if the guided

pipe will swing hard against racked pipe

then LET G O , and stay well out of the way.

Very few people can restrain a wild pipe

so DO NO T TRY ! !

3.16 Load Hoisting Operations Tips

C learly identify roles of staff when lifting

and hoisting, including that of an

observer.

The observer should frequently look up

during the lifting operation.

Lower the load if/when the lift snags.

P rior to leaving his position, the

derrickman should close all monkey

board fingers.

A lways stay clear of suspended loads.

When pipe is being lifted by a sling,

ensure slings are always double wrappedaround the pipe. Single wrapped slings

can slip with potentially disastrous

consequences.

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3.17 Individual Competence

Individual competence is seen as a major

contributor to rig floor safety. C ompetence

systems need to really establish the level of

individual competence and not just satisfy

the legal requirement. Individuals must feel

that they can say when they do not feel

competent to do a job. Good supervisorsshould know the strengths and weaknesses

of their team, and not ask someone to do a

job for which they are not qualified or

competent.

Teamwork Tips

TEA M stands for TO G ETHER EVERYO NE

AC H IEVES M O RE! Looking after each other

is an essential aspect of safe teamwork,

which must be practiced throughout rig floor

activities. Teamwork means making sure

that all work areas, escape routes and

emergency equipment are clear at all times.Teamwork also means communicating more

than you think you need!

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4.1 A Place for Everything

and Everything in its Place

Develop the habit of cleaning all tools and

equipment after each job and putting them

back in their correct places. If something is

damaged, worn or needs replacing, fix it

before you put it away. If you dont have the

time or spare parts, make a note in the

Handover Book so that everyone knows -

then it wont be an unwelcome surprise next

time its needed!

4.2 Create an Open Culture

Supervisors should foster and develop a

culture where operations are discussed

openly between all crews, so that the entire

rig team develops and progresses.

4.3 Take Time to Review

At the end of an operation a debrief or

wash up meeting should occur. A ll parties

must discuss report both successes and

failures. Supervisors should talk to all the

crews, floor hands, deck crew, service

hands and so on. Establish how they

thought the job went. A sk open-ended

questions to gain maximum information:

Who? - What? - Where? - Why? - When? -

How?

What do you think happened?

What worked well?

How did it work best?

Why did it work?

What did not work well?

Why did i t not work well?

What can we do to improve next time?

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4.4 Learn from the

Teams experience

After all, together you did the work you all

planned! Incorporate constructive ideas

into future plans, re-think areas the team

constructively criticises.

4.5 Standardise and IncorporateNew Ideas

K eep a tally of what worked well and what

needs improvement. Incorporate these into

the next planning or R isk A ssessment

exercise to ensure that a culture of

continuing improvement is created. To

make sure everybody learns, share these

ideas with both your back to back crew and

the crews on field break. PLA N , EXEC U TE,

M EASURE & LEARN

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5. Supervisors Tips

G ood supervisors are the catalysts for

enhancing teamwork and

communication. Experienced, positive

supervisors who can communicate the

hazards, risks and instill the culture for

stepping back assessing the operation

and taking the necessary actions to

ensure safe operations are essential.

A ll supervisors must lay the foundation forthe crew to perform tasks by fully

explaining what is required to complete

them. A ll available information, materials

and tools must be identified prior to

starting the task.

Supervisors should lead by example: they

must be aware of all procedures and

regulations concerning the task and pass

this information on to the work force.

Supervisors should be suitably

experienced. R egular assessments of

supervisors abilities, job knowledge,

strengths and weaknesses are required to

ensure that the highest levels of

supervision are maintained. R isk

assessment skills are an essential part of

a supervisors capabilities. Where a

weakness is identified, training should be

given to rectify the situation.

Supervisors should ensure full

participation in Toolbox Talks,

encouraging crews to actively contribute

in discussing all aspects of the actual

method of performing the task. They

should ask questions of the work party toidentify their levels of experience and job

knowledge. Planning as a team should

help identify all the known hazards and

cultivate new ideas. This in turn should

promote teamwork as success is

achieved.

Supervisors should allocate sufficient

time for feedback at Toolbox Talks and

that the TBT leader is rotated.

Supervisors should encourage team

members to speak up and listen to what

they have to say. Supervisors should use

the experience of the workforce to

expand their own job knowledge. You are

never too old to learn!

M entoring or Buddy Systems are much

valued by rig crew members: 17


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The mentor can assist the supervisor in

the assessment of a persons

competence

The mentor can assist in the recording of

progress in the log book or competency

passport

The mentor can assist in the identification

of further training needs

The buddy system can be put to good

effect if experienced personnel

communicate with one another and, more

importantly, if experienced personnel

communicate with green hands. This is

important!

The appointment of a lead roughneck on

the rig floor is seen positively on some

rigs. It is essential that they are well

experienced and have the respect of the

crew.

Individual alertness will always play a part

in safety standards. Supervisors need to

be on the lookout for drifting attention due

to complacency or excessive stress, and

use crew rotation or a Time out break to

effect an improvement.

Supervisors must provide good quality

instruction and guidance.

Supervisors must allow the not-yet-

competent person to carry out only

simple tasks on the rig floor until he is

deemed to be more competent.

The rig floor supervisor must be involved

in the assessment of a persons

competency.

A persons competence can only be

effectively assessed by means of

thorough observation.

A n assessment must also consider a

persons experience, ability, knowledge

and skill.

Training T ips:

A dequate time must be allowed for

training

Training needs must be identified by thesupervisor and/or mentor

R ecords of training and assessment must

be maintained (e.g. a log book or

passport)

R efresher or repeat training needs must

be considered

A mentor should support the provision of

on-the-job training

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The following information posters relating

to drill floor tubular handling operations

are available for download from the Step

C hange in Safety website.

www.stepchangeinsafety.net

M anual Tongs: - Dos and D onts

M anual Tongs: - R ig Floor safety

Power Tongs: - R ig Floor safety

Toolbox Talk:- Crew involvement posters

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In January 1998, 56 international drilling

professionals, representing 23 operator

and drilling contractor organisations

convened in H ouston for the first global,

industry wide drilling Safety Leadership

workshop. These leaders represented a

cross section of operators, drilling

contractors and service companies. They

created the H ouston Declaration which is aformula for step change based on

personal commitment, leadership and

behaviour:-

We pledge our commitment to work

together to achieve a Step C hange in safety

performance in all the areas where we have

activity. We believe that a step change in

safety can be achieved through personalcommitment, leadership, the way we

behave and the way we work together

Houston Declaration 29th January 1998

The result is a global drilling safety

leadership campaign. The aim of this

campaign is to create a permanent cultural

change in safety throughout our industry.

Regional work groups have been formed to

develop plans of action for achieving a step

change in safety in their area and a steering

group has been formed to help continue

the effort. C ommon themes form thebackbone of strategic plans. Five common

themes which emerge are:

Safety Leadership - common principles to

provide consistency

People - common expectations and

standards

Behaviour - cross industry networks sharing

information

Training - common training standards and

competency levels

Procedures - common performance

measures and benchmarks

http://www.stepchangeinsafety.net is the

website of the Step C hange in Safety

initiative. There are a large number of

excellent resources available from the site,

both drilling specific, and more general

safety tools and improvement ideas.

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website

email

telephone

fax

address

www.stepchangeinsafety.net

[email protected]

01224 881272

01224 882350

P.O. Box 10406Aberdeen AB12 3YL

handling tubular s

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