22 Oil Gas Industry Guidelines

Transcript

Oil and Gas Industry Guidelines Module 22 What standards are enforceable?  OSHA standards  By industry and type of operation  Take precedence over industry standards  Standards incorporated by reference  Only the parts concerning health and safety  Recognized hazards  Generally accepted industry standards  OSHA guidance documents can interpret ambiguities 2 ©2006 TEEX Elements Required to Prove Violation of General Duty Clause  The employer failed to keep the workplace free of a hazard to which employees of that employer were exposed  The hazard was recognized  The hazard was causing or was likely to cause death or serious physical harm  There was a feasible and useful method to correct the hazard Reference: FIRM Chapter III (C)(2)(c)  Not the lack of a particular abatement method  Not a particular accident 3 ©2006 TEEX SIC 1300 Standards Cited by OSHA Compliance Officers under 5(a)(1) October 2005 through September 2006  API RP 54: 19 different sections, some multiple times  API RP 4G: 5 citations  ASME/ANSI B30 series: 3 citations  API 9B: 1 citation  NEC: 1 citation  Company safety practices: 3 citations  Operating manuals: 5 citations 4 ©2006 TEEX Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operation API RP 54 1 General 1.1 Purpose: recommend practices and procedures for promotion and maintenance of safe working conditions for personnel engaged in drilling operations and well servicing operations, including special services 6 ©2006 TEEX 1 General 1.2 Scope: rotary drilling rigs, well servicing rigs, special services  Operations on location  Not seismic or water well drilling  Not site preparation or site abandonment 1.3 Responsibility:  Each employer trains own employees  Operator and contractor share information  Immediate supervision of authorized person with authority to commence, modify, cease or improve 7 ©2006 TEEX 2 References       API standards ACGIH TLVs ANSI standards ASME Boiler and Pressure Vessel Code NFPA standards Incorporated for special topics 8 ©2006 TEEX 3 Definitions  3.1.88 shall: Recommended practice has universal application to specific activity  3.1.89 should: Recommended practice  Safe comparable alternative available  May be impractical or unnecessary under certain circumstances 9 ©2006 TEEX 4 Injuries and First Aid 4.1 General – immediate reporting and treatment; follow-up reporting; cause investigation and prevention 4.2 Medical services – Information available and arrangements made 4.3 First aid – CPR trained individual and first aid kit at worksite 4.4 Emergency eye or body wash stations where exposed to injurious materials 10 ©2006 TEEX 5 Personal Protective Equipment (PPE) 5.1 General:  Wear PPE when there is reasonable potential for prevention of harm  PPE only used when engineering or administrative controls impractical 11 ©2006 TEEX 5.2 Wearing Apparel  Hard hat: each person  Eye protection where probable injury  Safety-toe footwear  Alternative practice for extreme cold  Gloves, apron, boots, other appropriate PPE for chemical handling  No loose or poorly fitted clothing 12 ©2006 TEEX 5.2 Wearing Apparel  Never work in clothing saturated with flammable, hazardous, or irritating substances  Never wear jewelry that could be snagged or hung  Keep hair contained if long enough to cause hazards  Hair/beard must not interfere with PPE 13 ©2006 TEEX 5 Personal Protective Equipment (PPE) 5.3 Hearing protection 5.4 Respiratory protection 5.5 Fall protection for work 10 feet above rig floor or other working surface  Guardrail, net, or PFAS  Alternative fall protection plan if infeasible 14 ©2006 TEEX 6.1 Operations – General  Well control maintained at all times  Rig floor attended by person qualified in well control  “Horseplay and careless acts” not permitted  Training and safety program  Unsafe conditions reported to supervisor and relayed between shifts 15 ©2006 TEEX 6.1 Operations – General  Pipe threads cleaned with brush to prevent finger wounds  Hazardous substances properly labeled; users trained  Blowout prevention where necessary; well control drills  No field welding on tongs, elevators, bails, or heat treated rig equipment 16 ©2006 TEEX 6.1 Operations – General  Vehicles not involved in operations: at least 100 feet or derrick height away from wellbore, or other safety measures if not possible  Ground rig substructure, derrick, mast, and other equipment as appropriate 17 ©2006 TEEX 6.2 Over Water Operations  Instruction in abandonment procedures, emergency signals, water entry   2 emergency escape means to water  Personal flotation devices & ring buoys   2 life floats or alternatives  Cold water attire  Basket stretcher or litter, and instruction 18 ©2006 TEEX 6.2 Over Water Operations  Rules for crane transport of personnel  API RP 2D for offshore pedestal cranes  No crane operation during helicopter takeoff or landing  Personal flotation devices for crane or swingrope transfer to/from boats  Tag lines to steady all loads 19 ©2006 TEEX 6.3 Preliminary Rig-Up Operations  Review planned arrangement to avoid hazardous conditions  Pipelines  Utility lines  Rig up safely before commencing well operations  Locate change rooms and outbuildings far enough from boilers and fuel tanks 20 ©2006 TEEX 6.3 Preliminary Rig-Up Operations  Check well for pressure, and remove it or operate safely under pressure  All personnel out of derrick or mast and cellar and stand clear when  Subsurface pump is being unseated or  Initial pull on tubing is made 21 ©2006 TEEX 6.4 Blowout Prevention Equipment  Blowout prevention equipment installed and tested where well might flow  Install, operate, maintain: API RP 53  Rig personnel must understand and be able to operate blowout preventer  Discuss in pre-job meeting  Drills under variety of conditions  Anchor choke and kill lines – prevent whipping 22 ©2006 TEEX 6.5 Housekeeping  Clean work areas; remove trip hazards  Avoid / clean up wet floors (from leaks, spills, or pulling wet pipe)  Keep cellar clear of fluids or loose equipment/material  Keep egress routes unblocked  Store tools & equipment to avoid falling  Keep fire fighting equipment accessible 23 ©2006 TEEX 6.6 Hydrogen Sulfide Environment  Safety guidelines referenced  API RP 49, 55, 68  Protect personnel and general public 24 ©2006 TEEX 6.7 Confined Space, Excavations, or Hazardous Environments  Where unusually hazardous gases present, advise employees, contractors, and service company supervisors of hazards  Fill the cellar if it is not needed  Definition of confined space  Testing, permit system before entry  Declassification of confined spaces 25 ©2006 TEEX 6.7.5 Excavations  If deeper than 4 feet and may contain a hazardous atmosphere:  Test for oxygen, flammable gases/vapors, toxic air contaminants  Evaluate whether excavation is a confined space, and permit if necessary  Precautions to prevent exposures  Emergency response procedures 26 ©2006 TEEX 6.8 Machinery and Tools  Personnel only operate machinery on which they are qualified  Belts, drive chains, gears, and drives must have guards installed  Except rotary table, catheads, kelly  Guards in place and properly maintained for operation  Maintenance: report to rig supervisor 27 ©2006 TEEX 6.8 Machinery and Tools  Moving parts guarded or stopped before cleaning, lubrication, or repair  Maintain tools in safe condition  Double insulate or ground tools; Use GFCI  Electric or pneumatic tools: deadman switch or starting switch that cannot be locked in  Secure materials to body when carrying them up a ladder 28 ©2006 TEEX 6.9 Lockout/Tagout  Locks/tags identify equipment or circuits being worked on  Critical systems: include identity of worker  Train and discipline personnel  Lock/tag removed by person who installed it, or authorized replacement  If neither available, supervisor may remove after ensuring no hazard created 29 ©2006 TEEX 6.10 Auxiliary Escape  Land rigs: derrick or mast must have auxiliary means of escape before work in the derrick  Securely anchored escape line attached to derrick or mast for escape from derrickman’s platform (Geronimo line)  Wire rope with safety buggy with braking or controlled descent device  Safety buggy releases when weight is applied 30 ©2006 TEEX 6.10 Auxiliary Escape  Tension on escape line:     Periodically checked and adjusted 6-12 feet of sag in middle Ground anchor point distance 2x height Ground anchor point should withstand 3000 lb pull  Alternate fast escape if line is infeasible  Training on use  Never ride except in emergency 31 ©2006 TEEX 6.11 Personnel Lifting Systems  Never ride the elevators.  Except in extreme emergency, as determined by supervisor, with full fall protection and no pipe or other equipment  Bosun’s chair attached to traveling block or tugger line for inaccessible location  Hydraulic or air winch lines allowable under certain conditions 32 ©2006 TEEX 6.12 Racking Tubulars and Drill Collars  Secure rods, tubulars, drill pipe, drill collars when racked or hung in derrick or mast to keep from falling  Safety clamps removed before hoisting continues  Use stops, pins, or chocks to keep round equipment from rolling off storage rack  Prevent/remove ice plugs in tubulars 33 ©2006 TEEX 6.13 Handling Drilling Fluid Chemicals and Additives  Never use asbestos as additive  Instruct personnel handling fluid and additives in handling, disposal, and PPE 34 ©2006 TEEX 7.1 Fire Prevention  Store combustible and flammable materials safely  Prevent rubbish accumulation  No smoking, or source of ignition, near operations that could cause fire hazard – signs necessary  Change rooms in safe areas for smoking 35 ©2006 TEEX 7.1 Fire Prevention  Potential ignition sources located at safe distance from wellhead or flammable storage areas  Only safety-designed heaters near rig floor, substructure, or cellar  Do not allow oil and gas accumulations  Store oily waste in covered metal containers 36 ©2006 TEEX 7.1 Fire Prevention  Never use natural gas or LPG to operate spray guns or pneumatic tools  Cleaning solutions: flash point 100°F  Conductive containers (e.g. metal) to handle, store, or transport flammable liquids  Ground and bond any plastic containers  NFPA 77 and API Publication 2003 37 ©2006 TEEX 7.2 Fire Protection  Fire fighting equipment not tampered with or removed  Fire fighting water system may be used for wash down if capacity is not compromised  Equipment accessible, plainly labeled  Equipment inspected & maintained  Crew familiar with location & use 38 ©2006 TEEX 7.2 Fire Protection  Drilling rigs: at least 4 20-pound BC extinguishers, depending on operation  Well servicing rigs: at least 2 20-pound BC extinguishers, depending on operation  Fire fighting equipment near all welding  Fire watch for welding/cutting outside designated welding area 39 ©2006 TEEX 8 Flammable Liquids  Approved portable containers  Tanks and Drums properly labeled  Refueling operations:  Procedures for over water transfers  Shut down engines while refueling unless shutdown causes greater hazard  Assign a person to monitor filling tank to prevent spillage  Ground during refueling 40 ©2006 TEEX 8.3 Liquefied Petroleum Gas (LPG)       Follow NFPA 58 Ignition source control Protective caps on cylinders Usual cylinder precautions No temperatures >125°F, no direct heat Protective gloves for refilling or replacing bottles: freeze burns ©2006 TEEX 41 8.4 Flammable Liquid Storage  Storage area requirements: ventilation, exits, housekeeping, warning, extinguishers, classification  On land:  Not within 50 feet of wellbore, or equivalent safety measures  LPG tanks >250 gallons at least 150 ft from and parallel to closest side of rig; labeled  Offshore: appropriate precautions 42 ©2006 TEEX 9.1 Drilling and Well Servicing Rig Equipment – General  Openings in rotary table kept covered when not occupied  Rathole and mousehole openings kept covered when not occupied with equipment 43 ©2006 TEEX 9.2 Derricks and Masts  Substantial, well designed & maintained  Permanent name plate:  Manufacturer  Model and serial number  Rating including static hook load capacity with number of lines  Recommended guying pattern if applicable  If not noted, guy according to API 4G 44 ©2006 TEEX 9.2 Derricks and Masts  Raising and lowering masts:  Not moved while raised (except for skidding)  Visual inspection of raising/lowering mechanism before use  Tools and unsecured materials removed from mast before raising/lowering  Base level and positioned before raising, lowering or telescoping, or tightening guylines  Qualified person in charge of raising/lowering 45 ©2006 TEEX 9.2 Derricks and Masts  Raising and lowering masts:  Bolts, nuts and pins secured  No extra personnel in/under mast unless fully raised or lowered  Guylines tensioned before load applied  During unusual loading:  Only essential personnel on rig floor  No one in derrick, mast, or cellar 46 ©2006 TEEX 9.2 Derricks and Masts  Platforms above rig floor maintained and secured to support stresses  Materials not kept above rig floor unless in use and secured against falling  No one on rig floor during overhead repair unless their help is needed  No unguarded openings big enough for person to fall except ladder opening between supports of crown block 47 ©2006 TEEX 9.2 Derricks and Masts  Bumper blocks:  Safety cable or strap along full length  Prevent wood fragment falling with screen  Counterweights:  Safety line anchored to derrick/mast if not encased or in permanent guides  Travel of tong counterweights limited to elevations needed for tongs  Safety devices for jacks 48 ©2006 TEEX 9.3 Ladders, Stairways, and Platforms  Fixed ladder from rig floor to crown block and to each intermediate platform  Ladders securely attached by manufacturer specifications  Ladders must not lean back from vertical  Minimum clearances for ladders  Side rails extend 42 inches past landing 49 ©2006 TEEX 9.3 Ladders, Stairways, and Platforms  Cages and platforms not required if PFAS is used  Platforms wherever ladders are offset, if PFAS is not used  Open stairways >4 risers:  Securely fastened  Handrails and midrails over entire length  Uniform, level stair treads 50 ©2006 TEEX 9.3 Ladders, Stairways, and Platforms  At least 2 stairway exits on drilling rigs from rig floor to ground level  Rig floor, ramps, stairways, ladders, platforms kept free of slip/trip hazards  Derrick platforms:  Inside mast, except stabbing board, must completely cover space from edge to legs  Secured to protect against dislodging 51 ©2006 TEEX 9.3 Ladders, Stairways, and Platforms  Well servicing rigs:  Work not at ground level is on a working platform large enough for 2 people  Safety fasteners when folded for storage  Finger board fingers bolted, welded, hinged-and-pinned, or equivalent, to beam 52 ©2006 TEEX 9.3 Ladders, Stairways, and Platforms  Guardrails at outer edge 4 ft. above ground or other working level  42 inch top rail, intermediate rail, posts  Except for  Personnel exits and entrances  Catwalk and V-door opening when being used  Work station used to rack tubulars  Alternate arrangements with equivalent safety  4 inch toe boards to prevent falling items 53 ©2006 TEEX 9.3 Ladders, Stairways, and Platforms  Floor and deck openings not left open  Floor holes people may walk into: securely covered with no more than 1 inch opening 54 ©2006 TEEX 9.4 Drawworks  Visual inspection once per day  Guard remains in place and in good condition during operation  Do not lubricate during operation  Do not leave brake without securing, unless equipped with automatic driller  Shut-down switches at drum control console 55 ©2006 TEEX 9.4 Drawworks  Brake systems inspected and maintained per manufacturer recommendations  Drilling rigs:  Double (auxiliary) braking system  Safety device to keep traveling block from striking crown block  Tested before each trip and after drill-line slipping or cutting operation 56 ©2006 TEEX 9.5 Catheads and Lines Powered by the Cathead  Shaft head covered by a thimble a rope cannot wind around  Rope guide for manually operated rope  Check for grooves >1/4 inch; rebuild and turn to avoid fouling  Keep lines from being entangled with cathead line  No rope or line on unattended cathead 57 ©2006 TEEX 9.5 Catheads and Lines Powered by the Cathead  Drawworks control attended while manual cathead is in use  No rope splices on cathead friction surface, except properly spliced endless rope  Headache post or guard for drawworks control personnel when line is near operator 58 ©2006 TEEX 9.5 Catheads and Lines Powered by the Cathead  Training required before operation of cathead or lines  Maintain lines and automatic catheads in safe working condition  When lifting tubulars, use slings that will not slip off. 59 ©2006 TEEX 9.6 Hoisting lines and other wire rope  Visually inspect at least once per day; detailed inspection once per month  Remove when too many broken wires  Consider removal for corrosion  Remove lines with corroded, cracked, bent, worn, improper end connections  Remove for kinking, crushing, birdcaging, cutting, cold working 60 ©2006 TEEX 9.6 Hoisting lines and other wire rope  Hoisting line: End securely fastened; enough extra line on drum to avoid fastener strain  Anchors at least as strong as line  Ton-mile limits; see API RP 9B  Moving hoisting line not to come in contact with anything stationary except crown block sheaves and traveling block sheaves 61 ©2006 TEEX 9.6 Hoisting lines and other wire rope  Hoisting line not removed from drum until traveling block rests on rig floor or is suspended separately  Slings should be identified by size, grade, rated capacity, reach 62 ©2006 TEEX 9.7 Hoisting Tools, Hooks, Bails, Elevators, and Related Equipment  Good engineering practice; maintained safe. See API Spec 8A, 8B, 8C  Never exceed design load  Safety latch on hoisting hook to prevent accidental release  Traveling blocks guarded properly  Crown blocks secured to keep sheaves from jumping out of bearings 63 ©2006 TEEX 9.7 Hoisting Tools, Hooks, Bails, Elevators, and Related Equipment  Traveling blocks not moved while crown block is being lubricated  Fasten pump end of rotary hose to derrick/mast by cable or chain  Fasten swivel end of rotary hose to swivel with similar cable or chain  Inspect elevators, latches, latch locks, pins, springs; replace if worn/damaged 64 ©2006 TEEX 9.8 Rotary  Only engage power when rotary table is clear of all people and materials  Do not use rotary table for initial breakout of tool joints – only spinning out after initial breakout  Use smooth kelly bushings to prevent catching of people, clothes or material 65 ©2006 TEEX 9.9 Drill String Handling Equipment  Manual drill pipe slip handles:  Use manufacturer’s original or equivalent  Short enough to not project beyond master bushing  Lubricate tapered side of drill pipe slips  Do not kick slips into place  Attach tongs to fixed structure using wire rope or stiff arm 66 ©2006 TEEX 9.9 Drill String Handling Equipment  Maintain tongs properly  Tong safety lines: long enough to use breakout cathead, but short enough to prevent complete rotation of tongs  Power tongs:  Pressure systems: safety relief valve  Power input pressure line disconnected to work on tongs 67 ©2006 TEEX 9.10 Weight Indicators  Used for all rigs that manipulate tubulars  Maintained to register within 5%  Checked periodically for calibration  Gauge visible to operator  Protected from falling 68 ©2006 TEEX 9.11 Drilling Fluid Tanks  On land: Pits and tanks used to circulate flammables located 100 feet from well, or equivalent  Drilling fluid tanks treated as confined spaces  Ventilation, ventilation alarms, gas detectors  Blowers with appropriate electrical classification 69 ©2006 TEEX 9.12 Pipe Racks and Pipe Tubs  Pipe handled at the ends while loading, unloading, or transferring  Keep people out of the way during transfer or loading/unloading  Prevent pipe from rolling off: Load and unload by layers, with each layer blocked at all 4 corners.  Temporary supports to skid or roll pipe 70 ©2006 TEEX 9.13 Pressure Equipment  Pressure relief valve discharges located to prevent hazard with sudden discharge or piping movement  Lines and hoses secured to prevent unsafe movement  Never operate above rated pressure  Hammer unions must be the same thread – some look alike but will fail 71 ©2006 TEEX 9.13 Pressure Equipment  Pressure relief devices to discharge at or below rated pressure of components  Automatic air pressure controls for cleaning, sandblasting, etc.  Pump houses with 2 exit doors in different directions to outside  Shear-pin relief valves enclosed to prevent flying pins 72 ©2006 TEEX 9.14 Generators, Motors, and Lighting  Generators 100 feet upwind of wellhead or equivalent  Overload safety device to protect from shorting and burnout  Adequate illumination, by safe portable lights if necessary. Headlights are not sufficient.  Extension cords insulated; plugs in good condition 73 ©2006 TEEX 9.14 Generators, Motors, and Lighting  Lighting and fixtures of appropriate electrical classification (RP 500 & 505)  Enclosed and gasketed if not covered by 500/505  ANSI/IES RP7 1988: Industrial Lighting  Class I, Division I safeguards for shale shaker motor and area within 5 feet  Lockout/tagout before repairing electrical equipment  Ground motors, generators, control panels 74 ©2006 TEEX 9.15 Internal Combustion Engines  Diesel engines require emergency shutdown devices to shut off air  Actuation check the rig power emergency shut down devices 1x/week  Check all other internal combustion engine shutdown devices 1x/30 days  Spark arrestors or equivalent within 100 feet of wellbore 75 ©2006 TEEX 9.16 Inspection of Critical Equipment  Periodically inspected by manufacturer recommendation or good engineering practice  Certified inspectors use recognized methods for nondestructive testing  Qualified personnel for other inspection types 76 ©2006 TEEX 10.1 Work in Proximity to Exposed Energized Power Sources  Minimum clearances to power lines:     Operating rig: 10 ft + 4 in/10 kV over 50 kV Lowered mast: 4 ft + 4 in/10 kV over 50 kV Individual designated as observer Consider lines live unless owner report or test by qualified person says non-energized 77 ©2006 TEEX 10.2 Rig Electrical Systems Equipment  Designed for use in hazardous locations if used there  Maintain: manufacturer recommendation  Flexible cord, resistant to dampness and petroleum  Protect wiring from damage; replace or properly repair when insulation damaged  Offshore: API RP 14F 78 ©2006 TEEX 10.3 Classification of Areas  See API RP 500 and 505 and NFPA 30  Adequate ventilation defined  <10% of lower explosive limit (LEL)  Enclosed areas: 1 cubic foot/minute per square foot, but at least 6 air changes per hour  Natural or mechanical 79 ©2006 TEEX 11.1 Well Pumping Units  Electric power deenergized during well servicing and, if necessary, during rig moves and rig-up or rig-down  For well servicing:  Pumping unit turned off  Brake set  Power source locked/tagged out 80 ©2006 TEEX 11.1 Well Pumping Units  Prevent unintended counterweight movement  Use strong enough sling to handle horsehead  Installation: bolt or latch as recommended  Maintain brake systems in safe working order  Reinstall guards before startup 81 ©2006 TEEX 12 Special Services     General Equipment Communications Discharge Line (Temporary Treating or Cementing Lines)  Lubricator operations 82 ©2006 TEEX 13 Wireline Service           83 General Placement and Handling of Wireline Service Units Gin Poles (Telescoping and Single Poles) Rope Falls (Block and Tackle) Wellheads, Wellhead Connections, and Adapters Lubricators and Wireline Blowout Preventer Equipment Wireline Operations Perforating Swabbing Bailing ©2006 TEEX 14 Stripping and Snubbing  General  Operations 84 ©2006 TEEX 15 Drill Stem Testing  General  Preliminary to Drill Stem Test  Performing the Drill Stem Test 85 ©2006 TEEX 16 Acidizing, Fracturing, and Hot Oil Operations  General  Pumping Operations 86 ©2006 TEEX 17 Cementing Operations  General  Pumping Operations 87 ©2006 TEEX 18 Gas, Air, or Mist Drilling Operations      General (All other requirements apply) Training Equipment Procedures Minimizing Sources of Ignition 88 ©2006 TEEX 19 Hot Tapping and Freezing Operations  General  Hot Tapping Operations  Freezing Operations 89 ©2006 TEEX 20 Hotwork, Welding, and Flame Cutting Operations  General  Written safety work permit system  Avoid being a source of ignition  Certified welders for equipment whose primary function is to contain hydrocarbons     90 Personal Protective Equipment (PPE) Fire Protection Equipment Welding Fumes and Ventilation ©2006 TEEX