SOP Vol1

OIL INDIA LIMITED
SAFE OPERATING PROCEDURES
Date of Issue Prepared by Issued by
Prepared by
Mine Safety Officers,
Departmental Safety Officers and
Officers of S&E Department Sri C. Bose
30-03-2012 Head (S & E)
A publication of
SAFETY & ENVIRONMENT DEPT.
Oil India Limited
Duliajan, Assam
Cover Designed by :
Sri Rudra Dutta, Personnel Department
OIL INDIA LIMITED
Section – 1 : HSE Management
– 2 : Geophysical Activities
– 3 : Drilling & Workover Activities
– 4 : Production – Oil Activities
– 5 : Production – Gas Activities
– 6 : Chemical and R & D Activities
– 7 : Well-Logging Activities
– 8 : LPG Department Activities

OIL INDIA LIMITED
Revision History
Sl. Date of Issue Rev. No. Reasons & Prepared by Issued by
No. Issue No Nature of Rev.
01 11-11-2005 1 0 1st Issue Sri. A.K. Acharya Sri S. Bora
02 30-03-2012 1 1 1st Issue Mine Safety Officers, Sri C. Bose

Departmental Safety
Officers and
Officers of
S & E Department
Message
Message
OIL/D(HR & BD)/01
Message
January 17, 2012
Modern industry is replete with technological breakthroughs on one hand and

technological obsolescence on the other. Whether state-of-the art or world class, technology
will keep changing for the better but what will always remain constant is the technology-human
interface. This takes a critical dimension for a technology intersive E & P company such as
ours in all our vaied functions and operations. Safe management of man, machine and
technology and sustaining a culture of safety has therefore remained a prime prerogative for
comprehensive Safety policy, Safety Management Manuals, compilation of Safe Operating
Procedures (SOP), Safety Training programmes are all aimed at helping our workforce imbibe
safety culture in their behavior and practicing ‘Safety first’ at workplace.
Documentation of Safe Operating Procedures (SOP) listing out the step-by-step
instructions for doing a job or task the right way, is vital step towards ensuring safe operations.
I am extremely happy to see that Safety and Environment Department, in consultation with
other concerned groups, is now bringing out a revised edition of the SOP Manual. This manual,
amongst others, provide specific information on the hazards and associated risks involved and
the precautions to be ensured before commencement of different operations. The overarching
goal of this initiative is to minimize human error at work, prevent injury, damage or accident
and maintain a smooth technology-human-machine interface.
My ardent request to all our employees to keep oneself abreast of these safety procedures,
adopt them individually and collectively and create a safe and accident-free workplace.
Let SAFETY be a value and a way of life for each and every OIL Indian. Our families
very heavily depend on our safe being.
(N. K. Bharali)
Director (HR & BD)
Message
Foreword
Preface
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
Functional Committee for preparation / compilation of SOPs
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
pertaining to various operational / field departments.
12345678901234567890123456789012123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234567890121234567890123456
Sl. No. Name Department
1. Sri S. K. Dutta N.E.F.

2. Sri P. Borthakur Production (Gas)
3. Sri G. V. J. Rao Geophysics
4. Sri R. Borkakati Chemical
5. Sri Jayanta Bordoloi S&E
6. Sri B. N. Sahoo S&E
7. Sri S. Kumar Eletctrical
8. Sri R. Bhowmik F. E.
9. Sri P. Gogoi W/L
10. Sri A. Gogoi Production (Oil)
11. Sri A. Baruah Transport
12. Sri B. Bhuyan Instrumentation
13. Sri A. Das Drilling
14. Sri A. Bairagey Civil
15. Sri R. K. Singh S & E (FS)
16. Sri R. Dutta Drilling (TS)
17. Smt. M. B. Sarma S&E
18. Sri B. K. Buragohain LPG
19. Sri H. Phookan S&E
TEN LITTLE WORKERS
Ten little workers feeling fit and fine,
One worked under the boom
Then there were nine,
Nine little workers thought they would be late,
One took a short cut,
Then there were eight.
Eight little workers looking up to heaven,
One fell off the rig floor,
Then there were seven,
Seven little workers putting in hard licks,
One struck at the gas,
Then there were six,
Six little workers glad to be alive,
One forgot his goggles,
Theni there were five,
Five little workers standing near the door,
One thought that wire was dead,
Then there were four,
Four little workers, one cut his knee,
Didn’t go to first aid,
Then there were three,
Three little workers with nothing to do,
One indulged in horseplay,
Then there were two,
Two little workers took stairways on the run,
One missed his footing,
Then there was one,
One little worker, thought of the other nine,
Began to practice safety,
Now he’s doing fine.
HSE Management
OIL INDIA LIMITED
Safe Operating Procedures
Volume - I
Section - 1
HSE MANAGEMENT
ACTIVITIES
Safe Operating Procedures – Oil India Ltd. 1
HSE Management
VOLUME - I SECTION - 1
HSE MANAGEMENT ACTIVITIES

CONTENTS
SL. NO. DESCRIPTION PAGE NO.
HSE Management System
1.0 Management’s Concern for HSE Management ............................................ 1
2.0 DefinedHSEPolicy....................................................................................... 2
3.0 Company’slaiddownprocedures................................................................. 4
4.0 Internal Safety Organization (ISO) set up for HSE Management .................. 4
5.0 Accident/Incident/Dangerous occurrence reporting system ......................... 5
6.0 HazardIdentification&Control....................................................................... 5
7.0 PersonalProtectiveEquipment..................................................................... 6
8.0 EmergencyPreparedness............................................................................. 6
9.0 Employees Participation in HSE Management .............................................. 7
10.0 Safety Audit..................................................................................................... 7
11.0 Safety Training, Education & Awareness Programme ................................... 8
12.0 OccupationalHealthService.......................................................................... 9
13.0 Environmental Protection Measures & Continual Improvement .................... 9
14.0 RecordKeeping/Documentation................................................................... 11
15.0 Duties & Responsibility as per Mines Act/OMR - 1984 ................................. 11
Annexure - A
Annexure - B
] (Channel for Reporting work accidents) .............................. 16
Annexure - C (List of Bound Paged Books) ................................................... 21
Annexure - D (List of StatutoryDiary)............................................................ 22
Annexure - E (List of Statutory Forms/Records) ........................................... 23
Annexure - F (Hot Work/Cold Work/Electrical Permit) .................................. 24
VARIOUS STATUTORY FORMS
Safety
Form A Notice of Commencement & end of work ............... 27
Form B EmployeesBio-data................................................ 28
Form E Persons employed in mines ................................... 29
Form F CompensatoryOff.................................................. 30
Form G Leave Account......................................................... 31
Form H Leave Wages Account............................................ 32
Form I Registerofovertime................................................ 33
Form J Report on reportable accident ................................. 35
Form K ReturnofMinoraccident......................................... 36
Form U SpotInspectionReport............................................ 37
Form IV-A Notice of Accident / Occurrence ........................... 38
Form IV-B Particulars of Deceased / Injured Person ............... 40
Form IV-C Particulars of Injured Person Returned to Duty ...... 41
Form VI Notice of Construction of or Alteration in GGS ........ 42
Form VII SafetyReport.......................................................... 43
Form VIII Permission for laying Pipeline ................................. 45
Environment
Form II Bio-Medical Waste................................................... 50
Form IV Filling Returns Regarding Handling of Hazardous Waste................ 51
Form V Environmental Statement for the Financial Year....... 52
Form VIII Filling Returns for Bulk Consumers of Batteries...... 54
2 Safe Operating Procedures – Oil India Ltd.
HSE Management
HSE MANAGEMENT SYSTEM
The ultimate goal of HSE Management is to reduce the degree of risk in the oil field activities and
prevention of losses due to accidents/ incidents. The issues of HSE management are not only
limited to the fulfillment of statutory requirement but also it encompasses the achievement of HSE
standards in the entire gamut of the company’s activities and operations. Hence an integrated
approach to Health, Safety and Environmental Management in a comprehensive manner is the
need of the hour. HSE functions & systems have been made as a part of the total management
and work culture of OIL INDIA LTD. The system also provides structured paths for improvement of
communication, accomplishment of goals, development of personnel and overall improvement of
business process. Following are the few technical principles and practices to be followed in oil
field areas as the elements of HSE management system.
1) Management’s concern for HSE Management.

2) Defined H.S.E. Policy.
3) Company’s laid down procedures.
4) Organisational set up for HSE management.
5) Accident reporting, investigation & analysis.
6) Hazard identification & control.
7) Personal Protective Equipment.
8) Emergency preparedness.
9) Employees participation in HSE management.
10) Safety Audit.
11) Training, Development & awareness programme.
12) Occupational Health Services.
13) Environmental protection measures & continual improvement.
14) Record keeping/documentation.
15) Duties & Responsibilities as per statutory requirement (Mines Act-1952, OMR -1984 etc.)
1.0 MANAGEMENT’S CONCERN FOR HSE MANAGEMENT
A great deal of emphasis is given by the Board of Directors displaying their commitment and
concern for Safety, Environment and Occupational Health Services. Enhancement of HSE
standards in our oil field activities is one of the prime corporate objectives as well as vision of our
Company.

HSE Management
In the changed scenario of liberalization of economy and globalization of trade & business, OIL
management gives priority to HSE functions by guiding and supporting HSE management group
and the line management personnel. A system exists to review the HSE management objectives
and achievement by periodical monitoring & follow up.
2.0 DEFINED HSE POLICY :
A well defined HSE policy was approved and adopted at the Board level. The same has been
reviewed and updated in the context of changed scenario and adopted by the Board of Directors
on 17.11.2003 in the 344th Board Meeting held at New Delhi.
The policy gives broad guidelines on the corporate approach and individual approach to ensure
safer, cleaner and healthier work environment. The policy has been widely circulated to all concerned
to develop awareness amongst all sections.
The HSE policy covering Occupational Health, Safety and Environment aspects is given
overleaf .
HSE in mind and action,

Provides complete Protection.

HSE Management

HSE Management
3.0 COMPANY’S LAID DOWN PROCEDURES
Company’s laid down procedures are considered to be an effective tool in achieving HSE
management. All the concerned employees must follow and implement these laid down procedures
in our oil field activities. These procedures help in implementing HSE policy of our company by
providing various guidelines and practices. Following are the few broad laid down procedures,
which are not exhaustive. In addition to these procedures, prevailing standing orders of various
departments/sections are also to be taken into account.
3.1 Safe Operating Procedure.

3.2 Departmental Safety Meeting & Management Safety Meeting.
3.3 Pre-commissioning stage inspection of new installation.
3.4 Pre-spudding Safety Audit and Pre-Workover Safety Audit.
3.5 Siting clearance on existing/modification of installation.
3.6 Implementation of external & internal Safety audit recommendations.
3.7 Statutory record keeping.
3.8 Mock drills.
3.9 Resolving Pollution complaints (inhouse & outsourcing external experts).
3.10 Initial & Periodical Medical Examination.
3.11 Monitoring of various environmental parameters.
3.12 Taking consent & approval from statutory authorities.
3.13 Liaisoning with statutory & advisory bodies.
3.14 Work Permit System.
3.15 Pit Level Safety Meeting & Tool Box Meeting.
4.0 INTERNAL SAFETY ORGANIZATION (ISO) SET UP FOR HSE MANAGEMENT
4.1 The Internal Safety Organisation at Duliajan plays the role of recommending strategies for
continuous improvement in Safety, Health & Environmental performance by developing and
maintaining HSE management systems, working on the principle of management of risks &
reduction of losses. These systems are designed to follow & complete the management
cycle i.e. “PLAN, DO, CHECK, ACTION” for achieving the objectives.
4.2 The Mines organization has been made based on the activity and the Mines Manager is
appointed in each mine to exercise direct control on the mining activity or operation. Mines
Safety Officer (MSO) against each mine has been appointed to assist the Mines Manager
on day to day works and in reporting system.
Apart from Mines Safety Officer, there are Departmental Safety Officers (DSOs) to take
care of HSE aspects of departmental activities in oil field operation.
The MSOs and DSOs work in close co-ordination with Internal Safety Organization i.e.
ISO.

HSE Management
5.0 ACCIDENT/INCIDENT/ DANGEROUS OCCURRENCE REPORTING SYSTEM
A system as per Annex-’A’& ‘B’ have been adopted for reporting the accident/incident to
statutory/advisory bodies to cut down avoidable delays within our organization. (Circular
No. S&E / 17/ 459 of 04.09.1996 & S&E/S/17/386 of 26.05.1999).
5.1 DEFINITIONS
5.1.1. Loss : Avoidable waste of any resource.

5.1.2. Hazard : A condition or practice with the potential for accidental loss.
5.1.3. Accident : An event which results in unintended harm or damage.
5.1.4. Incident : An unplanned event (occurrence, condition or action) which did
or could have resulted in unintended harm or damage.
5.1.5. Near Miss : An incident which does not result in any injury or damage to property
but has the potential to result in injury and/or property damage.
5.1.6. Safety : Safety is defined as freedom from accidents or the condition of
being safe from pain, injury, illness or loss.
5.2 INCIDENT/ACCIDENT INVESTIGATION & ANALYSIS
Every incident/dangerous occurrence/nearmiss/accident is to be investigated by the team

constituted by the management. The team should study the accident/incident, the probable cause
of the accident/incident and suggest the remedial measures to avoid recurrence of such incident/
accident in future. The management in turn will advise the concerned deptts to take immediate
action to reduce such risks in oil fields within a stipulated time frame.
The minimum broad outlines of the analysis report should include the following :
5.2.1. Date/time of incident & location of the incident.

5.2.2. Description of the incident.
5.2.3. The factors contributing to the incident.
5.2.4. Recommendations resulting from the investigation.
6.0 HAZARD IDENTIFICATION & CONTROL
The identification of potential hazards in vulnerable areas and specific hazards is the
fundamental pre-requisite to loss prevention. This is an ongoing activity starting from the
drawing board stage to commissioning, operation and maintenance stages of the
equipment.
A regular Safety / Environmental audit and Occupational Health Hazard Survey help in
critical examination with the objective of identifying strength, weakness & main areas of
risk hazards. These techniques predict the requirement of modification or additional features
to enhance HSE standards of our installations.

HSE Management
Such type of audits may be carried out departmentally, then by ISO and also sometimes by
outsourcing expert services. There is every need to develop inhouse team to take such
assignment in form of risk analysis/HAZOP study etc.
7.0 PERSONAL PROTECTIVE EQUIPMENT (PPE)
The best way of preventing accidents is undoubtedly by elimination of hazards or controlling

the hazards as close to the source as possible but it is necessary to provide an important
line of defence to each employees in the form of Personal Protective Equipment (PPEs).
Various types of PPEs as listed below are to be used by the employees while at work at site
to safe guard themselves from the risks/hazards depending upon the requirement While
selecting such PPEs assessment of risk, various standards, guidelines & Rules/Acts etc.
must be referred. All Personal Protective Equipment as the name implies, fit the person in
question, otherwise its value becomes purely cosmetic and the employee is given a false
sense of security.
7.1 Personal Protective Clothing (Overall) :- The Personal Protective clothing must provide
adequate protection against the specific hazard. The clothing must be light to wear and
durable, and should cause the minimum discomfort but allow maximum mobility etc.
7.2 Eye/Ear Protection :- Suitable type of Eye/Ear protection should be used to protect the
eyes/ears as per the requirement.
7.3 Safety Shoes :- Every employee at work must wear safety shoes provided by the company.
Ordinary leather/canvas shoes should not be allowed to be used by the employees at work
sites since safety shoes with built-in steel toes caps and with steel soles inside the leather
ones protect against accidents caused by heavy objects failing on the feet, protruding nails,
metal and acid etc.
7.4 Gloves :- The types of gloves required will vary according to the injury to be prevented such
as cut, heat burn, chemical burn & electrical shock etc. Proper gloves as provided by OIL
should be used while at work.
7.5 Helmets :- It is mandatory and statutory to use helmet to prevent injury caused due to flying/
failing object. Any one entering into “hard hat area” should put on a hard hat i.e. helmet.
7.6 Safety belt :- Approved type safety belt provided by the company should be used while
working on height. Any other special type personal protective equipment as per the
requirement should be used. Besides above mentioned PPEs. Any other special type
personal protective equipment time to time as per the requirement should be used.
However, special kinds of PPE for specific nature of works may be used after risk
assessment.
8.0 EMERGENCY PREPAREDNESS
8.1 In addition to the Fire Contingency Plan available in each installations as per Regulation 72
of OMR 1984, in every installation, an approved copy of Emergency Plan named as “ON-
SITE EMERGENCY RESPONSE PLAN” should be available covering following informations:
8.1.1. Action to be taken in the event of any major accident/dangerous occurrence.

HSE Management
8.1.2. Duties & responsibilities of each key personnel including measures to be adopted to avert
or minimize the consequence of emergency.
8.1.3. Alarm & communication system including the system of notifying concerned authorities.
8.1.4. Equipment plan viz: Make, type, capacity, location of operation & operating procedure for
each equipment.
8.1.5. Plan for training of personnel.
8.1.6. Mock drills.
Time to time the ON-SITE Emergency Plan may be modified/updated depending upon the
requirement.
8.1.7 Similarly a copy of District level crisis management plan called OFF-SITE EMERGENCY
RESPONSE PLAN (popularly known “Mutual Aid Scheme”) for the hazardous industries
located within Dibrugarh & Tinsukia Districts should be made available at each installation.
This copy should contain the informations on the requirement of resources to manage a
crisis situation (depending upon type and magnitude of the emergency), resources available
in neighbouring industries, list of member industries & their contact numbers, role &
responsibilities of various co-ordinators and financial aspects of Mutual Aid Scheme etc.
9.0 EMPLOYEES PARTICIPATION IN HSE MANAGEMENT
OIL has taken utmost care to involve the employees in Safety circle & Safety culture through
their obligations and commitment towards achieving HSE performance.
- Different Safety motivation programme/competitions are conducted.
- Employee’s participation in Pit level safety committee meeting & Departmental Safety
Committee meeting, Management Safety committee meeting & Tripartite meeting.
- Suggestion schemes.
10.0 SAFETY AUDIT
Internal Safety Audit should be carried out by a multi-disciplinary team of personnels having
adequate experience in operation and maintenance of the facility, plant or installation.

HSE Management
Following methodology needs to be followed.
10.1 Every installation should be audited at least once in a year.
10.2 A calendar in this respect should be prepared and circulated.
10.3 Areas to be audited should be logically grouped based on the functions.
10.4 Detailed guidelines & checklist should conform to OISD-145.
10.5 A timebound action plan should be prepared by the respective I.M./ MSO/DSO for
implementing audit recommendations.
10.6 Implementation status to be reviewed on quarterly basis.
11.0 TRAINING, DEVELOPMENT & AWARENESS PROGRAMME
11.1. TRAINING & DEVELOPMENT ACTIVITIES
11.1.1 The Training & Development department was established to cater to the various training &
developmental needs of the employees of the organization. The department functions from
Management Training & Development Center (MTDC) complex.
11.1.2 The mission of the department is to align T&D processes with the corporate-strategy and
plan of the company in the changing business scenario.
The Objective of OIL’s Training & Development (T&D) policy are to:
Develop employee skills and competencies and improve performance.
Develop people to take on higher responsibilities.
Reduce the learning time for taking up assignment.
11.1.3 T & D department plays a catalytic role to make OIL a truly knowledge driven organization
by drawing line managers and business heads into a close partnership with T&D. This is
integrated with the other HR systems in our company, such as job rotation and succession
planning, to ensure that the necessary Human Resources development activity takes place
at the point where it is required.
11.1.4 The T&D department caters to the need of development of the workforce by organizing
various types of training programs based on training Need Identification. They are
categorized as under
In house: Training organized in House with reputed External Faculties and Internal
Faculties. In house training may be - Technical, Behavioral, Managerial, Safety
related including various statutory training such as Mines Vocational Training
(MVT), Refresher training, Gas Testing, First Aid training and specialised training
in particular discipline or area etc.
In Country :Based on need; technical as well as behaviour & managerial, employees are
trained at various reputed agencies in the country.

HSE Management
Overseas : For specialized technical and managerial courses, employees are sent
Overseas for training.
In addition to above, on-site safety trainings are also organized in co-ordination with S & E
Department through external faculty.
The department also caters to the need of the various apprentices passed from the ITI’s
and Polytechnics by providing them training. Summer training is also provided to students
from different institutes/Universities.
11.2 AWARENESS PROGRAMME

Various methods are adopted to develop awareness amongst the employees as well the
family members.These are -
)
i Displays of statutory/prohibitory signboards/warning signs.
i) 5 minutes safety talks at the beginning of shiftparticularly at the starting of job. (Tool
Box meeting)
iii) Pit level safety committee meeting.
iv) Departmental safety committee meeting.
v) Observation of Safety Week/World Environment Day etc. once in a year. (Which
includes programme for children & family members)
vi) Counselling the employee who meets with accident/dangerous occurrence.
vii) Safety bulletin/Publication of articles in inhouse journals and intranet.
viii) Family awareness programme on HSE.
12.0 OCCUPATIONAL HEALTH SERVICES
The successful implementation of Management Plans and Policies greatly depend on the
adaptability by the employees, who are the prime movers of the progress of company.
Maintaining their health is very much vital for productivity & effectiveness. To promote the
health of our employees, OIL has made a structured Occupational Health Monitoring system
so as to have scientific basis for decisions aimed at protection of employee’s health from
any possible adverse consequences of exposure to occupational health hazards. Following
systems are followed in OIL towards providing Occupational Health Services.
12.1. An OHS (Occupational Health Service) Centre is established at Duliajan.
12.2. Various activities co-ordinated are pre-employment, periodical and pre-retirement medical
examination.
12.3. Administering special tests like Lung Function Test, Audiometry Test and Vision Test etc.
for identified target groups.
12.4. Conducting First Aid Training & other awareness programme related to Occupational Health
Hazards & remedial measures.
12.5. OHS in peripherial areas are provided through dispensaries located in our Oil fields at
Moran, Jorhat and Sonapur etc. The scope of Occupational Health Services will be widened
in due course to encompass all the dimensions of health services.
13.0 ENVIRONMENTAL PROTECTION MEASURES & CONTINUAL IMPROVEMENT
The exploration and production activities involve various operations in oil field areas having
a direct bearing on the environment, OIL INDIA LTD. is always concerned about the

HSE Management
disturbance which may be caused due to its operations in upsetting all sorts of balance
that exist between the living creatures and the environment for sustainable existence.
Environment is OIL’s common heritage. OIL has adopted following few measures to
conserve, preserve and protect the clean and green environment in and around our field
areas.
13.1 DRILLING INSTALLATIONS
13.1.1.The conditions of Environmental clearance and consent to operate are to be complied with.
13.1.2.Effluent pits are scientifically designed with compartmentalization and provided with
impervious lining for effective mopping of floating oil and helps in avoiding contamination of
all the pits.
13.1.3.The water management and preservation of water sources is carried out by following
Recycle system.
13.1.4.Central effluent pit/Emergency pit has been identified for pumping effluent from the drill site
to cope up with the situation of heavy rain & prolonged monsoon.
13.2 PRODUCTION INSTALLATIONS
13.2.1 Formation water is disposed off in the disposal well drilled for the purpose or re-injected
into the formation for reservoir pressure maintenance.
13.2.2.Monitoring wells are drilled for close monitoring of water sample to cheek any contamination.
13.2.3.W ater oil clarification plants are installed wherever necessary to reduce the oil content
less than 1 0 ppm.
13.2.4.Oil Soluble Demulsifiers are used with proper flocculants to maximize the oil separation
for safe disposal.
13.2.5.Flare pits are properly designed with multiburner facilities with arrangement of abundant
supply of air for proper combustion,
13.2.6.Proper enclosure around the flare pit helps in combating the effect of heat & light on the
crops/environment.
13.2.7.Efforts are taken to reduce the gas flaring further by effective utilization and getting up low
pressure boosters/compressors.
13.2.8.Oily sludge is recycled through registered recyclers. Oily sludge is also bioremediated
wherever required.
13.3 NOISE POLLUTION
13.3.1.Regular noise survey carried out in high noise prone areas.
13.3.2.Noise attenuators/barriers provided at the source.
13.3.3.Ear plug/Ear muff are used by the employees while working in high noise prone areas.
13.4 SOLID WASTE DISPOSAL
The solid waste and biomedical waste are disposed as per Municipal Solid Waste Rules &
Bio-medical Waste Rules.

HSE Management
Apart from the above measures, OIL undertakes various environmental projects sush as
bioremediation, phytoremediation, GHG emission & carbon footprint mapping, E-Waste
management etc. to assess the effect of OIL’s operation on the flora, fauna and wide bio-
diversity.
14.0 RECORD KEEPING /DOCUMENTATION
14.1 The record keeping is an important aspect of HSE Management System. The records
helps us in visualizing the actual status of man, machine and materials. This is also
considered as a reference guide to the people reminding the history of the past incidents
and lessons learnt in those incidents. Record keeping is the best mean to communicate
information and avoid waste of time in duplication of effort. The written report prompts
people to remember what they have to and how to do it. This shows people’s commitment
and concern for HSE aspects of the installation.
14.2 The list of some important records/documents are given in Annexure - ‘C’ to Annexure - ‘F’
including various forms as per the requirement of first schedule of Mines Rule - 1955 and
OMR - 1984
15.0 DUTIES & RESPONSIBILITIES AS PER STATUTORY REQUIREMENT (MINES ACT-
1952, OMR-1984 ETC.)
1) It shall be the duties & responsibilities of the line management and field personnel to achieve
the best safety standards and HSE performance in the area of their functioning.
2) It shall be the responsibility of the line management to create, operate effective HSE
management system to achieve HSE standards set by the company.
3) The role of ISO (internal Safety Organisation) i e: Safety & Envt. Deptt. is to assist the field
groups/line management to bring down accidents in our oil field activities & to reduce
losses. ISO will advise, study, monitor, cooperate, inspect, inform the line management for
attaining goal set by the company. ISO will also apprise the top management.
However, the primary responsibilities for achieving the goal will lie on the line management/
operational groups.
4) The goal for HSE performance shall be set by the top management.
5) ‘Duties & responsibilities’ as per OMR-1984 for a few Mines Officials such as Mines Manager,
Installation Manager, Mines Safety Officer, Fire Officer and Workmen Inspector are given
for ready reference. However duties and responsibilities of all the Mine Officials/competent
persons are not covered in the following chapters. Hence respective Mines Rule/Regulation/
Acts should be referred.
15.1 DUTIES OF MINES MANAGER (REGULATION NO. 19 OF OMR-1984)
(1) The manager, shall be responsible for the safe and proper working of the mine by exercising
supervision and control.
(2) The manager shall see that sufficient supply of proper material, and appliances for the
purpose of carrying out the provisions of the Act., the regulations and orders made there
under and for ensuring the safety of the mine and persons employed therein is always
provided at the mine; and if he is not the owner or agent of the mine he shall report in
writing to the owner or agent when anything which he is not competent to order, is required
for the aforesaid purpose.
HSE Management
A copy of every such report shall be recorded in a bound-paged book kept for the purpose.
(3) The manager shall assign to every competent person and official his specific duties and
no his appointment make over to him a copy of the regulations, rules and bye-laws and any
orders made there under which affect him and he shall take all possible steps to ensure
that every such person understands, carries out and enforces the provisions contained
therein in a proper manner.
(4) The manager shall examine all reports, registers and other records required to be made or
kept in pursuance of the Act, the regulations and orders made there under and shall
countersign the same and date his signature. He may, however, by an order in writing
delegate this duty to an installation manager or other official.
(5) The manager shall pay attention to and cause to be carefully investigated any specific
representation or complaint that may be made to him in writing by a work person of the
mine as to any matter affecting the safety or health of persons in or about the mine.
(6) When an accident resulting in any serious bodily injury to any person or in loss of life
occurs in a mine, the manager shall inspect the site of accident immediately and shall also
either himself or through safety officer have an enquiry made into the causes of and
circumstances leading to the accident. The results of every such enquiry and a plan and
section of the site of the accident showing the details shall be submitted to the Regional
Inspector within seven days of the date of occurrence.
(7) The manager shall perform such other duties as have been specified in this behalf under
this Act, the regulations and orders made there under.
(8) The manager may suspend or take such disciplinary action as he thinks fit against the
work persons for contravention of any provision of the Act, regulations and orders made
there under.
(9) The manager shall maintain in a bound-paged book kept for the purpose, a diary, and shall
record therein the findings of each of this inspections and also the action taken by him to
rectify the defects mentioned, if any.
15.2 DUTIES OF INSTALLATION MANAGER (REG. NO. 20 OF OMR-1984)
The Installation Manager shall carry out the following duties:
(1) He shall have responsible charge and control of such installations and shall carry out such
duties, as may be assigned to him by the manager.
(2) He shall see that a notice of his appointment is posted at a place in the installation in such
a position that in can be easily and conveniently read.
(3) He shall see that in the installation assigned to him, all work is carried out in accordance
with the provisions of the Act and the regulations and orders made there under.
(4) (a) He shall visit and examine the installations under his charge on every working day to
see that safety in every respect is ensured.

HSE Management
(b) He shall maintain a detailed record of the results of each of his inspections and also the
action taken by him to rectify the defects noticed, if any.
(5) He shall see, when any drilling rig, work-over rig and associated equipment or production
equipment or pipeline is shifted or newly installed, that it is given a trial-run before it is put
into use and shall be present during every such trial-run.
(6) He shall see that all persons employed at the installation are thoroughly instructed and
familiar with the provisions of the standing orders made under these regulations relating to
prevention of blow-out and fire.
(7) He shall see that the provisions of the Act and the regulations or orders made there under
relating to the installation, maintenance, operation or examination of machinery and
equipment are properly carried out by himself or by competent persons or work persons,
as the case may be appointed for the purpose.
(8) (a) When, during the construction of an installation or any operation threat, there is an
emergency or apprehended emergency endangering the life or the safety of any person
or the stability and safety of the installation, he shall himself take or cause to be taken
such measures as are necessary or expedient to avoid the emergency.
(b) No requirement in these regulations shall be taken as prohibiting or restricting the

taking of such measures.
15.3 DUTIES OF SAFETY OFFICER (REGULATION NO. 21 OF OMR-1984)
The Safety Officer shall carry out the following duties
(1) He shall inspect, as often as may be necessary, the installations of the mine with a view to
identify the dangers which may cause bodily injury or impair health of any person.
(2) He shall advise the manager on measures necessary to prevent dangerous situations.
(3) He shall enquire into the circumstances and causes of all accidents whether involving
persons or not and advise the manager on measures necessary to prevent recurrence of
such accidents.
(4) He shall collect, compile and analyse information in respect of accidents and dangerous
occurrences with a view to promote safe practices and improvement of working environment.
(5) He shall organise regular safety education programmes and safety campaigns to promote
safety awareness amongst persons employed in the mine.
(6) He shall see that all new workers and workers transferred to new jobs receive adequate
safety training instructions and guidance.
(7) He shall maintain a detailed record of work performed by him every day.

HSE Management
(8) If any duties other than those specified above are assigned to the safety officer by the
manager, a written notice thereof shall be sent to the Regional Inspector within three days
of such assignment.
15.4 DUTIES OF FIRE OFFICER (REGULATION NO. 22 OF OMR-1984)
The Fire Officer shall carry out the following duties:
(1) He shall ensure the observance of the provisions of the Act, regulations and orders made
there under concerning fire-detection and fire-fighting systems and shall advise the manager
on measures necessary to ensure adequate protection against fire.
(2) He shall ensure proper layout, installation and maintenance of fire-fighting equipment.
(3) He shall see that contingency or emergency plan for likely fire situations are prepared.
(4) (a) He shall organise regular training of persons incharge of fire-fighting duties with
particular reference to contingency or emergency plan for fire, correct assessment
and handling of fire problem.
(b) He shall see that persons incharge of fire-fighting duties undertake simulated fire drills
at least once in every month to study promptness of response and effective tactics.
(5) He shall examine at least once in every quarter all devices and equipment of fire detection
and fire-fighting systems in the mine and report any defect in the same to the manager.
(6) He shall exercise a general supervision and co-ordination during control and extinguishment
of any fire in the mine.
(7) He shall enquire into the causes and circumstances of all fires with a view to prevent
recurrence.
(8) He shall maintain detailed record of work performed by him every day.
(9) If any duties other than those specified above are assigned to the fire officer by the manager,
a written notice thereof shall be sent to the Regional Inspector within three days of such
assignment.
15.5 DUTIES OF WORKMEN’S INSPECTOR (MINES RULE-29R OF MINES RULE-1955)
(1) The duties of the Workmen’s Inspector shall be -
(a) to inspect all shafts, inclines, roads, work places and the equipment there including
the equipment for conveyance and transport of workers.
(b) in case of any urgent and immediate danger that come to his notice -
(i) to inform the manager and the Inspector about same and ; and
(ii) to suggest remedial measures necessary to avoid the danger; and
(c) to accompany the Inspector in the course of complete inspection of the mine and also
during such other inspections as may be considered necessary by the Inspector.

HSE Management
(2) The Workmen’s Inspector shall record a full report of the matters ascertained as a result
of his inspection in an interleaved, paged and bound register kept for the purpose at the
mine in Form U. The Workmen’s Inspector making the entry in the register aforesaid shall
duly sign such entries with date and take a copy of the entries for his record.
“Safety has no Destination,

It is a Continuous Journey.....”

HSE Management
ANNEXURE - ‘A’
SAFETY AND ENVIRONMENT DEPARTMENT
OIL INDIA LIMITED
CHANNEL OF REPORTING FOR WORK ACCIDENT
WORK ACCIDENT WITH PHYSICAL INJURY
Immediate action
MSO/DSP/I.M. to fill up ACCIDENT REPORT FORM in ERP (SAP) AND SEND TO Medical
Department for classification. Departmental Officer to liaise with Medical Department personally to
know the extent of injury. Simultaneously Department should inform S&E Department over telephone.
Immediate action
Medical Department to inform Department concerned and S&E Dept. over telephone whenever
work accident cases are received.
MINOR ACCIDENT SERIOUS/FATAL ACCIDENT

No further statutory Forthwith
Formalities required
Fax/Telegram/Telephonic message to DMS, Guwahati & DDG, Sitarampur, District Magistrate
by the concerned deptt. (MSO/DSO) in liaison with S&E Dept.
Within 24 hours
FORM IV-A to be filled by MSO/DSO/I.M. in consultation with S&E Dept. The concerned deptt.
would forward the same to the statutory authorities.
Within 7 days (For Serious Accident only)
FORM IV-B to be filled by MSO/DSO/I.M. in consultation with S&E Dept. The concerned deptt.
Within 7 days (For both Serious & Fatal Accidents)
Enquiry report with sketch to be prepared by MSO/DSO/I.M. Enquiry Committee would be
constituted either by the Agent/Mines Manager/GM concerned/HOD depending of the severity
of the accident. Concerned dept. would forward it to the statutory authorities.
Within 15 days after resumption of duty
(For Serious Accident only)
FORM IV-C to filled up by MSO/DSO/I.M. in consultation with S&E Dept. The concerned deptt.
MSO - Mines Safety Officer
DSO - Departmental Safety Officer
IM - Installation Manager
NOTE : (i) Copies of all correspondence/returns to be sent to GM (F&A) & Head-ER for assessment
of compensation as per Workmen Compensation Act and also to lodge insurance claims and
also to the Agent, Mines Manager, Head - S&E.
(ii) Sample copies of reporting formats are given in Annexure - ‘G’ to Annexure - ‘I’

HSE Management
ANNEXURE - ‘B’
SAFETY AND ENVIRONMENT DEPARTMENT

OIL INDIA LIMITED
FIRE ACCIDENT/DANGEROUS OCCURRENCE
Forthwith
Fax/Telegram to DMS, Guwahati and DDG,

To inform OISD, PCBA
Sitarampur, District Magistrate OR Telephonic
and CCE depending upon
message. Department concerned would do the same
the severity of the
in liaison with S&E Dept.
incident. S&E dept. would
take necessary action in Within 24 hours.
this regard.
FORM IV-A to be filled up by MSO/DSO/IM in
consultation with S&E Dept. The concerned dept.
would forward the same to the Statutory
authorities.
Within 7 days
Enquiry report with sketch to be prepared by DSO/

IM. Enquiry Committee would be constituted either
by the Agent/Mines Manager/GM concerned/HOD
depending on the severity of the incident.
Concerned dept. would forward it to the statutory
authorities.
MSO - Mines Safety Officer
IM - Installation Manager
Note : (i) A circular or guideline in this respect for reporting the incidents to OISD is given in
Annexure - B1
(ii) Sample format copy is given in Annexure - B2

HSE Management
ANNEXURE - B1
GUIDELINES FOR FILLING THE OISD QUARTERLY INCIDENT REPORT
1. All Major, Minor and Near miss incidents shall be reported in the quarterly report.
2. Incident Reporting form shall be filled up for all Major, Minor and Near miss incidents.
3. Summary report shall be enclosed with every quarterly report.
4. Investigations shall be carried out for all Major, Minor and Near miss Incidents.
5. Investigation report of all Major incidents shall be submitted to OISD. An incident shall be
treated as Major if any of the following occurs ;
Fire for more than 15 minutes.
Explosion/Blowout
Fatal Incident
Loss above Rs. 5.0 lac.
Cumulative man-hours lost more than 500 hrs.
Plant Shutdown/Outage due to the incident.
6. Loss time accident shall be monitored till the affected person joins duty. In case the affected
person is yet to join the duty, then the status of report submitted will be preliminary. Final
report against the same Incident shall be sent once he joins duty and the man-hours lost are
known.
7. All columns must be filled up.
8. For any additional information use separate sheets as required.
9. Quarterly report shall be sent to OISD within 45 days of end of the quarter.
10. Immediate reporting of incident through fax/telephone shall continue as per the prevailing
system.

HSE Management
ANNEXURE - B2
OISD INCIDENT REPORTING FORM
1. Organization 2. Sector :
3. Location 4. Incident Sr.no:
5. Date of Incident 6. Time of Incident
7. Major / Minor / Nearmiss 8. Report - Preliminary / Final
9. Fire / Accident 10. Duration of fire - hrs / min
11. Type of incident with loss of life/injury ; Fire, Explosion, Blowout,

Electrocution, Fall from Height, Inhalation of Gas, Driving, Slip/Trip, Others, NA
12. Location of the Incident (Name of the Plant / Unit / Area / Facility /
Tank farm / Gantry / Road / parking area etc.)
13. Whether plant shutdown / caused outage of the facility ? Yes / No.
14. Fatalities nos. a) Employee = b) Contractor = c) Others =
15. Injuries nos. a) Employee = b) Contractor = c) Others =
16. Man-hours lost a) Employee = b) Contractor = c) Others =
17. Direct Loss due the incident (Rs. in Lacs). Loss to

equipment / Machinery as per Insurance claim etc.
18. Indrect Losses : T’Put / Production Loss
19. Status of the Facility : Construction / Commissioning /
Operation / Shutting down / Turn around, Maintenance /
Start up / Any others.
20. Brief Description of the Incident
including post incident measures.
(Attach details in separate sheet)
21. Whether Similar Incident has
occurred in past at the same location,
If yes, give brief description of the
incident and attach details in separate
sheet
22. Whether Internal Investigation
has been completed. If no, likely
date by which it will be completed.
23. Whether internal investigation
report (Major Incident) has been
submitted to OISD. If no, likely
date by which it will be submitted.
Continued.....

HSE Management
INCIDENT REPORTING FORM
24. Cause of the incident (Tick the most relevant cause preferably one, maximum two)
a) Deviation from Procedures i) Not using the PPE
b) Lack of Job knowledge j) Equipment failure
c) Lack of supervision k) Poor design / Layout etc.
d) Improper Inspection l) Inadequate facility
e) Improper Maint (Mech/EI/Inst) m) Poor house keeping
f) Improper material handling n) Natural Calamity
g) Negligent Driving o) Pilferage / Sabotage
h) Careless walking/climbing etc. p) Any other (give details) : Carelessness &
Lack of Co-ordination
25. Cause of leakage - Oil, Gas or Chemical (Tick one only) - N/A
a) Weld leak from equip / lines e) Leakage due to improper operation
b) Leak from flange, gland etc f) Leak due to improper maintenance
c) Leak from rotary equipment g) Normal operation-Venting/draining
d) Metallurgical failure h) Any other
26. Cause of ignition leading to fire (Tick only one cause) - N/A
a) Near to hot work f) Static Electricity
b) Near to furnace / flare etc g) Hammering / Fall of object
c) Auto-ignition h) Heat due to friction
d) Loose electrical Connection i) Lightning
e) Near to hot surface j) Any other (pyrophoric etc)
27. Was the incident Avoidable ? (Yes / No)
28. The incident could have been avoided by the use of/or by;
(Tick the most relevant point preferably one, maximum two)
a) Better supervision f) Personal Protective Equipment
b) Adhering to specified operating procedure g) Better equipment
c) Imparting Training h) Management Control
d) Giving adequate time to do the activity i) Adhering to specified maintenance
through proper planning. procedure
e) Adhering to the work permit system j) Adhering to specified Inspection /
Testing procedures.
k) Any other :
By being careful & proper co-ordination amongst the working personnel.

HSE Management
ANNEXURE - C
LIST OF BOUND-PAGED BOOKS (BPB) TO BE MAINTAINED
AS PER OIL MINE REGULATION
SL OMR BRIEF DESCRIPTION PERIODICITY REMARKS/CP

NO. WHEREVER REQD.
1. 9-(4) List of all plans, sections, field books, To be updated in case of Installation Manager
other notes required changes made
2. 16-(3) Copies of all appointments made under As & when appointments Installation Manager
16(1) & duties assigned to competent made
persons.
3. 19-(2) Copy of reports written to the owner or As & when required
agent when anything which he is not
competent to order is required for
ensuring the safety of the mine and
persons employed therein.
4. 19-(9) List of findings during inspection and As & when inspected. Inspection by Mines
actions taken to rectify the defects Manager
5. 28-(3) Inspection of every part of emergency Once in every day Rig in-charge
escape device on every derrick
6. 36-(1) Visual examination of all casing lines Once in 7 days Rig-in charge
and the condition of the wire as to
wear, corrosion, brittleness & fracture
shall be noted.
7. 36-(3) Cutting of at least 30 mts. of casing After every 3000 ton-km Driller
lines of wearing points. or at shorter intervals
where necessary
8. 44-(3a) Function testing of BOP Once in each trip (Blind) Driller
Once daily (pipe ram)
Once every weak (Bag)
Pressure testing BOP After initial installation, Driller
re-installation, following
repair & before drilling
out cement plug
9. 55-2(b) Pressure testing of storage tanks after Wherever installed or Installation Manager
installation or re-installation & before reinstalled
use
10. 55-4(b) Effectiveness of earthing of storage tanks Once in 12 months Electrical Supervisor
11. 58-2(b) Inspection of X-mass trees for leakage Once in 30 days Field Supervisor
12. 66-(3) Detection of flammable gas (Place & As and when detected Field Supervisor/
time) and its percentage OCS Operator
13 69-(2) Copies of Hot Work Permit issued Whenever issued Installation Manager
14. 69-(3) Measurement of gas concentration in Before any welding or Field Supervisor/
hazardous area before starting of cutting works in OCS Operator
welding & cutting works in those areas hazardous area
15. 70-5(b) Examination of Fire extinguishers. Once in 3 months Fire officer
16. 78-(3) Hydraulic testing of all pressure vessels Once in 3 years Installation Manager
17. 78-4(c) Testing of Safety valves on pressure Once in 6 months Installation Manager
vessels.
18. 81-(4) Thorough inspection of all machinery Once in 7 days Mechanical Engineer/
and plant in use Electrical Engineer/
Concerned Engineer
19. 97-3(b) Examination of fencing around wells Once in 7 days Field Supervisor

HSE Management
ANNEXURE - D
LIST OF DIARY MAINTAINED BY RESPECTIVE PERSONS
AS PER OIL MINES REGULATIONS
SL OMR BRIEF DESCRIPTION PERIODICITY RESPECTIVE

NO. PERSON
1. 19-(9) Findings of each of his inspections As and when inspected Mines Manager
and also actions taken by him
to rectify the defects mentioned, in any
2. 20-4(b) Detailed record of the results of Every working day Installation Manager
each of his inspections and also the
actions taken by him to rectify
the defects noticed, if any.
3. 21-(7) Detailed record of work performed Every working day Safety Officer
by him
4. 22-(B) Detailed record of work performed Every working day Fire officer
Each one, Teach one,

Safety is best one

HSE Management
ANNEXURE - E
STATUTORY FORMS TO BE MADE AVAILABLE AT SITE OFFICE
(Various forms as per the requirement of First Schedule of Mines Rule)
SL. FORM TITLE REFERENCE : MINES

NO. RULE/OMR
1. FORM - A Notice of commencement & end of Rule - 48 (1)
2. FORM -B BIODATA Rule - 48(3), 51 77 & 77-A(2)
3. FORM -E Persons employed in the mine Rule - 48(3) & 78
4. FORM - F Compensatory days of rest Rule - 49 (4)
5. FORM - G Register of leave Rule - 53
6. FORM - J Return of Reportable Accidents Rule - 76 (1)
7. FORM - U Workmen Inspector’s Inspection Report Rule - 29 (R)
8. FORM - VI Construction & Alternation of GCS/OCS OMR : Reg 51
& Production Set up
9. FORM - VII Safety Report OMR : Reg 51
10. FORM - VIII Permission for laying new pipeline OMR : Reg 61
Sample copies of above forms such as Form - ‘A’ to Form ‘U’ are enclosed.

HSE Management
ANNEXURE - ‘F’
OIL INDIA LIMITED
(A Govt. India Enterprise)
COLD WORK PERMIT

HSE Management
ANNEXURE - ‘F’

HSE Management
ANNEXURE - ‘F’

HSE Management
ANNEXURE - ‘F’
OIL INDIA LIMITED
(A Govt. India Enterprise)

HSE Management
ANNEXURE - ‘F’

HSE Management
ANNEXURE - ‘F’

HSE Management
ANNEXURE - ‘F’

FORM - A
[See Rule 48 (1)]
Notice of Commencement and end of work Name of Mine........................................
Name of Owner.....................................
It is hereby notified that persons employed at this mine shall begin and end their period of work between the hours set out
below.
Serial Class or Sex Place of work Set or 1. Set or Relay A B C D Etc.
No. kind of Above Ground/Open cast Relay
employment working/Below ground Number 2. Shift 123 123 123 123
(ABC
etc.)
1 2 3 4 5 Period of work
Safe Operating Procedures – Oil India Ltd.

3. Begins A.M
P.M.
Ends*
A.M
*Interval
P.M.
for rest if any
A.M
4. Begins*
P.M.
A.M
Ends*
P.M.
5. System of
change of
shifts
6. Date on which this notice was first exhibited
Signature of Magager
33
Date........................................
HSE Management
34
FORM - B
[See Rules 48 (3), 51, 77 and 77-A (2)]
1. Serial No.
2. Name and surname of the employee.
HSE Management
3. Father’s or Husband’s name.

4. Age and sex.
5. No and date of the certificate, if any, held, under the Mines Vocational Training Rules, 1966.
6. a) Designation of the employee.
b) Nature of employment (whether above or below ground, and if above ground whether in open cast working or other-wise)
c) Whether employment is permanent or temporary or casual.
7. Home Address of the employee, giving Village, Thana, Post Office and District.
8. Date of commencement of employment.
9. Date of first appointment, with the present owner.
10. Date of termination or leaving of employment.
11. In case of an adolescent reference to certificate of fitness granted under section 40.
12. Mark of identification on the body.
13. Name, address, relationship of person to be informed in case of accident / emergency.
14. Token number and other particulars by which the employee may be identified.
15. Passport size photograph of the person employed.
16. Signature or Thumb impression of the employee.
17. Remarks.
N.B. : A Photograph of the employee to be affixed. Signature of Manager

FORM - E
[See Rules 48 (3) and 78]
Register of person employed above ground [otherwise than in opencast workings] during the week commencing...........................................
andending.....................................20.............
NameofMine.............................................PartofSectionofmine................................................
Begins A.M
P.M.
A.M
Name of Owner...............................................................................................Hoursofshift Ends
P.M.
Serial Name and Age Class Relay Serial Time should be recorded against each entry Total
No. surname of & or kind or set No.
employee Sex of No. from No. of No. of

employ Form B -day -day -day days hours
-day -day -day -day
ment Regis- worked worked
Remarks
ter
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
In Out In Out In Out In Out In Out In Out In Out
W eekly Abstract Men Women
Total No.
or attendances
Tota No.
of absentees
35
HSE Management
FORM - F
36
NameofMine............................
[See Rules 49 (4)]
Name of Owner.........................
Register of Compensatory Days of Rest
Year..................
Name and surname of Class or No. of Dates on which weekly Dates on which com-
employee kind of days of days of rest have no pensatory days of rest
HSE Management
No. of
employ- compen beer allowed have been allowed compensatory
ment satory rest days or rest due Remarks
with set due in the on 31st
Register
or Relay previous December
June
Dec.
June
Dec.
Sept.
Sept.
March
March
No. calender
year
Serial No. from Form B

1st April to 30th
1st Oct. to 31st
1st April to 30th
1st Oct. to 31st
1st July to 30th

1st July to 30th
1st Jan. to 31st

1st Jan. to 31st
1 2 3 4 5 6 7 8 9 10 11 12 13 14

1
Register
Name and surname of
2
employee
Nature of employment,
3
mention whether above of

below ground
Category of employment,
4
mention whether monthly,

weekly, daily or piece-rated.
5
January
6
February
7
March
8
April
9
May
10
June
11
July
12
[See Rules 53]
FORM - G
August
13
September
14
October
Actual number of days worked during the year
15
November
Register of Leave Account during the Calendar Year
16
December
17 Total
Days of leave
18
entitiled
Arrears from
19
previous year
ensuing year
Total
20
Leave period due in
Remarks
21
Year..................
Name of Owner.........................
NameofMine............................
HSE Management
1
Register
Name and surname of
2
employee
Total leave period due in
3
the year (From Form G)

Calculated daily rate
of wages of earnings
4
including conces-
sions
Period of leave
5
availed
Calculated wages for
6
the period
Leave Instalment
Leave wages
7
actually paid
Date of payment
8

9
including conces-
sions
Period of leave
10
availed
11
the period
Leave Instalment
Leave wages
[See Rules 53]
FORM - H
12
actually paid
Date of payment
13

14
including conces-
sions
Note : The date of payment of arrears of leave wages shall be entered in this Remarks column.
Period of leave
15
availed
Register of Leave Wages Account during the Calendar Year
16
the period
Leave Instalment
Leave wages
17
actually paid
Date of payment
leave
18 19 20
Remarks Arrears of
21
Name of Owner.........................
NameofMine............................
HSE Management
1
Register
Name and surname of
2
employee
Nature of work above or
3
below ground
Class or kind of employ-
4
ment
5
Ordinary rate of wages

6
Overtime rate of wages

Date on which
7
overtime worked
Number of overtime hours
8
worked on that date

Number of overtime
9
hours in the week

Week ending
Overtime earning
10
11
Date of payment
Date on which
12
overtime worked
FORM - I
[See Rules 59]

13
worked on that date

Register of overtime Wages
Number of overtime
14
hours in the week

Week ending
Overtime earning
15
Date of payment
16
Date on which
17 overtime worked
18
worked on that date
Number of overtime
19
hours in the week
Week ending
Overtime earning
20
Date of payment
21
Owner........................................
NameofMine............................
Month.........................................
HSE Management
Date on which
22
overtime worked
Number of overtime
hours worked on
23
that date
Number of overtime
24
hours in the week

Week ending
Overtime earning
25
Date of payment
26
Date on which
27
overtime worked
[See Rules 59]
Number of overtime
hours worked on
28
FORM - I CONTD.
Register of overtime Wages
that date
Number of overtime
29
hours in the week

Week ending
30
31 Overtime earning
Date of payment
Remarks
32
Owner........................................
NameofMine............................
Month.........................................
HSE Management
FORM - J
[See Rules 59] NameofMine.................................
Return of Reportable Accident State................District....................
Owner..............................................
MineralWorked..............................
Quarterending...............................
Classification
case
worker
Sl. No.
Remarks
form in - B
of accident
Date of entry
accident
By Cause
Nature of injury
Name of injured
By place of
Date of return of
Date of accident
Time of accident
absence (in days)

Brief description of
Initials of attending
Part of body injured

Medical practitioner
Duration of enforced
Sl. No. from Register

Name of employment
injured person to work
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Instructions : Col. (5) : Specify as indicated in Annexure 1. Col. (6) : Specify as indicated in Annexure II.
Col. (7) : Give brief description the circumstances attending the accident.
Col. (11) : Specify whether simple wound, laceration, abrasion or fracture (only toes, fingers and thumb etc.)
Col. (14) : Mention the days intervening the days of occurence and day of rejoining and not including either the date of occurence of rejoining.
Col. (16) : In case of injury proves “Serious” or “Fatal” or when injured person proceeds on leave or leaves his employment, particulars should be entered
in this column.
Noto :– Copies of entries regarding persons injured in preceding quarter (s) and who continued to absent in this quarter should also be submitted separately.
41
HSE Management
FORM - K
42
[See Rules 76 (2)]
RETURN OF MINOR ACCIDENTS
NameofMine............................................................................................................................................................................................................
State.................................................................................................District...........................................................................................................
Owner.....................................................................................................................................................................................................................
HSE Management
MineralWorked............................................................................Quarterending.................................................................................................
Sl. No. Date of entry Date of accident Time of accident Classification Brief description of Name of injured
by place of by cause cause of accident worker
accident
1 2 3 4 5 7 6 8
1.
2.
3.
4.
5.
Sl. No. from Nature of Nature of Part of body Date of return Initials of attending Remarks
Register in employment injury injuured of injured person medical practitioner
Form ‘B’ to work
9 10 11 12 13 14 15
1.
2.
3.
4.
5.
Instructions :
Col. (5) : Specify as indicated in Annexure I to Form J.
Col. (6) : Specify as indicated in Annexure II to Form J.
Col (7) : Give brief description of circumstances attending the accident.
Col. (11) : Specify whether simple wound, laceration, abrasion, etc.
Col. (15): In case an injury proves ‘reporable’, serious or ‘fatal’ or when injured person proceeds on leave or leavs his employment,
particular should be entered in this column.
1. Subs. by G.S.R. 316, dated 14th April, 1986.

FORM - U
[See Mines Rules 29-R and 29-S]
Spot Inspection Report
NameofMine.......................................................................................Owner.......................................................................................................
Manager........................................................................................................................................................................................Place/Installation
Inspected...............................................................................................................................................................................................................
Inspected by...............................................................................................on........................................................................................................
Accompanied by.....................................................................................................................................................................................................
Observations Remedial measures suggested Action taken for remedial measures Date on which action taken Remarks

Signature of Workmen’s Inspector with date : .........................................................
Signature of mine official accompanying the Workmen’s Inspector :.............................
Date : Designation
43
HSE Management
HSE Management
FORM IV-A ANNEXURE - ‘G’

(See Regulation 7)
NOTICE OF ACCIDENT / OCCURRENCE

From
...................................................
...................................................
...................................................
To,
1. The Chief Inspector of Mines, Dhanbad-826001
2. The Regional Inspector of Mines
....................................Region...............................
3. The District Magistrate
4. The Electrical Inspector of Mines (in case of electrical accident only),
Dhanbad-826001
Sir,
I have to furnish the following particulars of a fatal accident/serious accident/dangerous
occurrence/major accident which occurred at..................mine of.................................... (Owner).
1. Particulars of the mine :
Situation of mine Name and postal address of owner
(Also state telephone & telex numbers)
Village
Post Office
Police Station
District
State
Place and location in mine (site) of accident/occurrence :
Nature of operation undertaken at the place of accident/occurrence :
2. Particulars of the accident/occurrence
(a) Date, shift and hour of accident/occurrence
(b) Classification of accident/occurrence (**)
(c) Cause, circumstance and description of accident/occurrence,
(If cause not yet established information to be sent as soon as possible).
3. Nature of extent of damage
Within the Outside the
establishment establishment
(i) Number of persons
—exposed to the accident/occurrence
—killed
—seriously injured
—affected by gas
(ii) Particulars of material damage
(iii) State whether the danger is still present/no longer exists.
1. Subs, by G.S.R. 399, dated, 9th September, 1996 (w.e.f. 21st September, 1996).

HSE Management
4. Particulars of injuries etc.

Name of person(s) Nature of employment Age Sex Nature of injury
(in block capital) and if fatal, cause
of death
Killed:
1.
2.
3.
4.
5.
Injured :
1.
2.
3.
4.
5.
5. Measures taken or envisaged :–
(a) to alleviate the effects of the accidents occurrence
(i) short term
(ii) medium or long term.
(b) to prevent recurrence of similar accident occurrence.
6. Any other relevant information ............................
Particulars in respect of every person killed or injured, in Form IV - B are enclosed/shall be
forwarded within a week.
Yours faithfully,
Signature
Designation/Owner/Agent/Manager
Date :
INSTRUCTION
(**) Under one or other of the following heads, namely :-

1. (a) Explosion of ignition of inflammable gas or liquid.
(b) Blow out.
(c) Out break of fire.
2. Hazardous emission of petroleum.
3. In drilling/workover rig.
4. Suffocation by gases.
5. Explosives.
6. Machinery.
7. Electricity.
8. Miscellaneous.
Attach separate sheet, where necessary.”;]

HSE Management
FORM IV-B ANNEXURE - ‘H’

(See Regulation 7)
PARTICULARS OF DECEASED / INJURED PERSON

(To be given separately in respect of every person killed or injured in an accident in the mine)
1. General
(i) Nameofmine................................................
(ii) Owner..........................................................
(iii) District.........................................................
(iv) State............................................................
2. Name of injured worker
3. Time of Accident.........................................................
(i) Date................................................................
(ii) Time..............................................................
(iii) Shift...............................................................
(iv) Number of shift worked per day at the mine ................................................
(v) Time when the worker began work on the day of the accident.......................................
4. Occupation and experience of the worker
(i) State the nature of job he was doing at the time of accident............................................
(ii) Was is his regular occupation?..........................................................
(a) If “yes” state length of experience at the occupation at your mine..................................
previous experience. If any.........................................
(b) Ifno,statehowlongemployedatthisjob................................................................
(iii) State totalexperienceinmining..........................................................
(iv) Give details of experience in mining work............................................
5. Place of accident :
6. Nature of injury :
(i) State whether fracture, amputation, laceration, bruise, sprain, crushing injury or other
(tobespecified).......................................
(ii) Part of body injured (to be specified precisely) ................................
7. Degree of disability :
(i) Iffatal, date and time of expiry..........................................
(ii) If permanent disablement, specify...................................................
(a) The part or parts of the body lost, if any...............................................
(b) The part or parts of body gone out of use...............................................
(c) Whether disablement was total or partial..................................................
(iii) If temporary disablement, state number of days forced to remain idle..........................
8. Responsibility for the accident :
(i) Was any safety provision(s) contravened.
(ii) If so, by whom ?
(iii) What action was taken against the offender ?
(iv) could the accident have been avoided ?
(v) If so, how ?
Signature..................................................
Designation: Owner/Agent/Manager
Date.............................

HSE Management
FORM IV-C ANNEXURE - ‘I’

(See Regulation 7)
PARTICULARS OF INJURED PERSON RETURNED

TO DUTY
(To be given separately in respect of every person within 15 days of his return to duty)
1. General
(i) Nameofmine................................................
(ii) Owner..........................................................
(iii) District.........................................................
(iv) State............................................................
2.Dateofaccident...........................................
3. Name of injured worker.........................................................
4. Return to duty :
(i) Datewhenreturnedtowork................................................................
(ii) Whether returned to regular job or some other job (Tobespecified...............................
5. Compensation
State amount of compensation paid or to be paid if any......................................................
Signature..................................................
Designation : Owner/Agent/Manager
Date.............................

HSE Management
FORM VI
(See regulation 51)
NOTICE OF CONSTRUCTION OF OR ALTERATION IN
A GROUP GATHERING STATION.
From
.....................................
.....................................
.....................................
TO,
..............................Region...............................
3. The District Magistrate,
....................................
....................................
Sir,
I hereby give notice of our intention to construct a new group gathering. station/carry out
alteration in .................................... group gathering station and furnish the following particulars in
that behalf :
(a) name and address of the mine to which the group gathering station belongs;
(b) name and address of the owner;
(c) name and full address of the site of group gathering station;
(d) date on which it is intended to commence the activity (for in case of an existing station,
date of commissioning thereof);
(e) information relating to the site, namely:-
(i) area of site covered by the group gathering station
(ii) name, location and maximum quantity of petroleum (gas/liquid) likely to be on the site;
(iii) constructional details of the installation and description of the process of storage/
handling of petroleum (in case of alteration, details thereof);
(f) organisational structure for the proposed activity and set up for ensuring occupational
safety and health and for testing, maintenance and patrolling of the installations and safety gad-
gets;
(g) information relating to the potential for major accidents (viz. fire, explosion, bursting or
failure of equipment, hazardous escape and accumulation of flammable substances etc.) namely:-
(i) identification of major accident hazard;
(ii) conditions or events which could be significant in causing a major accident;
(iii) brief description of the measures taken to prevent any major accident and to limit
the consequences thereof;
(iv) area likely to be affected by any major accident and population distribution therein;
(v) maximum number of persons likely to be present at any time on the site and of
whom the number likely to be exposed;
(h) arrangement for training of persons working on site and equipment necessary to ensure
their safety;
(i) providing persons off the site who are likely to be in an area liable to be affected by any
major accident, with the information about the nature of hazard and measures which should be
adopted in the event of an emergency arising therefrom
(j) any other relevant information
Signature ................................
Designation: Owner/Agent/Manager
Date ...................................

HSE Management
FORM VII
(See regulation 51)
SAFETY REPORT
From
........................
........................
To,
2. The Regional Inspector of Mines.
........................Region.........................
3. The District Magistrate
.........................
.........................
Sir,
I have to furnish the following particulars in respect of........................................... group
gathering station:
1. The name and address of:-
(a) Mine.
(b) Owner.
(c) Group-gathering station.
2. Description of the installation, namely:-
(a) site.
(b) construction design.
(c) identification of hazardous area and safety distances.
(d) accessibility of plant.
(e) maximum number of persons working on the site and particularly of those persons
exposec to the hazard,
3. Description of the process, namely
(a) technical purpose of the activity:-
(b) basic principles of the technological process.
(c) process and safety-related date for the individual process stages.
(d) process description,
(e) safety-related types of utilities.
4. Description of the hazardous substances namely:-
(a) quantities, substances data, safety-related date, toxicological date and threshold values.
(b) the form in which the hazardous substance may occur on or into which it may be
transformed in the event of the abnormal conditions.
(c) the degree of purity of the hazardous substance.
5. Information on the preliminary hazard analysis, namely:-
(a) type of accident.
(b) system elements or events that can lead to a major accident.
(c) hazards.
(d) safety-relevant components.

HSE Management
6. Description of safety-relevant units, amongst others :-

(a) special design criteria.
(b) controls and alarms.
(c) special and alarms.
(d) quick-acting valves.
(e) collecting tanks/dump tank.
(f) sprinkler-system.
(g) fire-fighting etc.
7. Information on the hazards assessment, namely:-
(a) identification of hazards.
(b) the course of major accidents.
(c) assessment of hazards according to their occurrence frequency.
(d) assessment of accident consequences.
(e) safety systems.
(f) known accident history.
8. Description of information of organisational system used to carry on the activity safety, namely:-
(a) maintenance,, and inspection schedules.
(b) guidelines for the training of personnel.
(c) allocation and delegation of duties for plant safety.
(d) implementation of safety procedures.
9. Information on assessment of the consequences of major accidents, namely:-
(a) assessment of the possible release of petroleum
(b) possible dispersion of released of petroleum.
(c) assessment of the effects of the releases (size of the affected area, health effects,
property damaged.)
10. Inforrnation on the mitigation of major accidents, namely :-
(a) fire bridgade.
(b) alarm system.
(c) emergency plan containing system of organisation used to fight the emergency the
alarm and communication routes, guidelines for fighting the emergency, information about
hazardous substance, examples of possible accident sequences.
(d) co-ordination with the district emergency authority and its off-site emergency plan.
(e) notification of the nature and scope of the hazard in the event of an accident.
(f) antidotes, if any, in the event of a release of a hazardous substance.
Signature ..................................
Designation: Owner/ Agent/ Manager.
Date ...........................

HSE Management
FORM-VIII
(See regulation 61)
PERMISSION FOR LAYING A NEW PIPELINE OR MAKING
ANY SIGNIFICANT ALTERATION IN EXISTING PIPELINE
From
........................
........................
TO,
..........................Region..........................
.....................................................................................
Sir,
I hereby submit my application for permission for laying of pipelinelqarrying out significant
alternation (a) in pipeline and furnish the following particulars in that behalf
(a) name and address of the mine to which the pipeline belongs;
(b) name and address of the owner;
(c) full postal addresses of the places where the pipeline would originate and terminate as
also of the places from where the pipeline activities would be controlled;
(d) constructional details of proposed pipelines including all associated works and appara-
tus;
(e) diameter and length of the pipeline and maximum quantity of petroleum gas or liquid
likely to be contained therein at any time and transported on any day;
(f) normal operating pressure and the pressure for which the pipeline designated;
(g) anticipated date and scheme of commissioning of the pipeline activity;
(h) organisational structure for the proposed activity and set up for ensuring occupational
safety and health including testing, maintenance and patrolling test pipeline and safety gadget;
(i) provision proposed to be made or steps to be taken for:-
(i) protection against uncontrolled escape of fluids from the pipeline;
(ii) prevention and control of fire or explosion or major emission of petroleum and
limiting consequences thereof;
(iii) providing to the persons working on the site with the information, training and
equipment required to ensure their safety; and
(iv) providing to persons off the site who are likely to be in an area liable to be affected
by any major accident, with the information about the nature of hazard and measures which
should be adopted in the event of an emergency arising therefrom;
(v) any other relevant information.
Signature ..................................
Designation:Owner /Agent/ Manager.
Date...........................

HSE Management

HSE Management

HSE Management

HSE Management

HSE Management

Geophysical
OIL INDIA LIMITED
Volume - I
Section - 2
GEOPHYSICAL ACTIVITIES

Geophysical
GEOPHYSICAL ACTIVITIES
CONTENTS
SL. DESCRIPTION Page

NO. NO.
1. INTRODUCTION 3
2. CHAPTER I SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “MAINTAINING SAFETY & HEALTHY
ENVIRONMENT AT CAMP SITE” 6
3. CHAPTER II SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “STORAGE OF MATERIALS AT CAMP SITE” 8
4. CHAPTER III SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “SURVEYING” 10
5. CHAPTER IV SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “SHOT-HOLE DRILLING” 13
6. CHAPTER V SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “SHOOTING” 16
7. CHAPTER VI SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “DATA RECORDING & VEHICLE USE” 18
8. CHAPTER VII SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “ELECTRICAL INSTALLATIONS” 21
9. CHAPTER VIII SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “WIRELESS COMMUNICATIONS” 24
10. CHAPTER IX SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “EXPLOSIVES HANDLING, STORAGE AND
TRANSPORTATION” 26
11 . CHAPTER X SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “EXPLOSIVES LIQUIDATION” 33
12. CHAPTER XI SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “BATTERY HANDLING & MAINTENANCE” 36
13. CHAPTER XII SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “TRAINING ACTIVITIES” 38
14. CHAPTER XIII SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “DISASTER MANAGEMENT” 40
15. CHAPTER XIV SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “SAFETY & ENVIRONMENT” 49
16. CHAPTER XV SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL
OPERATIONS – “GENERAL SAFETY” 50
17. ANNEXURE-I : TABLE SHOWING SAFETY DISTANCES WRT CHARGE SIZE 52
18. REFERENCES & ABBREVATIONS 53
Geophysical
“Know safety, No pain.

No safety, Know pain.”

Geophysical
INTRODUCTION
Ever since the evolution of civilization, the mankind has been in quest for hidden treasures
beneath the earth for making life more and more comfortable. The process of development of
civilization itself calls for more and more hydrocarbons day by day. Geophysical operations are
scientific means for discovery of hydrocarbon. The success of exploration largely depends upon
the quality of data acquired and finally interpretation of data. Seismic survey is the most widely
used method, out of all geophysical survey.
In seismic survey, holes are drilled to predetermined depth for placing energy source with
explosives or a vibrator is use to generate artificial vibration with the earth. The energy travels
across sub-surface in the form of seismic waves. From each interface between rocks having
different velocity and density, a part of energy is reflected back to the surface and recorded by
seismic recording equipment. The amount of energy reflected back to the surface is a measure of
rock properties above and below the interface and the time taken is a measure of depth of the
interface.
One of the objectives of this “SOP” is to guide the persons engaged in geophysical operation
about the safety aspectstaken during survey, drilling, shooting, and storage of explosives and
data interpretation. This SOP will help managers, supervisors, operators and contractors in further
improving the planning, execution and evaluation stages of geophysical operations.
Geophysical operations are covered under different acts like Mines Act, Indian Electricity Act,
Explosive Act, Motor Vehicle Act, Petroleum Act, Environment Protection Act, Contract labour
(Regulation and Abolition) Act etc. Utilizing the practical observations of geophysical survey and
guidelines issued by different Govt. agencies, this is an attempt to frame guidelines for safe working

Geophysical
by persons engaged in geophysical operations.
SCOPE
Operational safety should be the prime concern for an organization in order to reduce loss of
property, disruption in production and above all loss of life and limb.
On-land seismic operations involve handling and use of various kinds of explosive materials
at bases and in the field on regular basis. In seismic operations these explosives are used to
generate artificial elastic vibrations which travel across sub surface in the form of seismic waves.
All explosive materials are hazardous and must be handled and used with utmost care. It is the
responsibility of all personnel who handle explosive material to know and follow recommended
safety practices. This responsibility includes necessity of being familiar with observing international,
national and local rules and regulations governing explosive materials.
In India, use of explosives in Oil Industry is governed by Petroleum Storage Explosures (PESO),
Nagpur and overall activity by Director General Mines Safety, Dhanbad. A total review of existing
practices in ONGC, OIL and contract Service Companies operating in India for storage,
transportation and use of explosives has been taken to formulate these standards.
This document recommends the safe practices and procedures to be followed during handling
and use of explosives in seismic operations ON-LAND. The scope of these practices lies broadly
in following activities; but not limited to:- .
Seismic data acquisition ON-SHORE .
Storage, transportation & safe handling of explosives.
Disposal / liquidation of non-usable explosives.
The purpose of this “SOP” is to prevent accidents resulting in the loss to human life, property and
environment. All the safety aspects documented are already in practice based upon continuous
field experience and / or is a statutory requirement during the execution of all seismic operations.
Although, all efforts are make the present standard comprehensive in all respects, however,this

Geophysical
shall require up-dation in future to keep pace with fast changing technological advancements.
This “SOP” covers safety aspects during establishment of camp for persons and storing of material,
survey, safe drilling operations by rig and dheki system, safety aspects for storage and
transportation of explosives, shooting, seismic recording and data interpretation.
This “SOP” also covers Recommended Practices to be followed during fire drills and frequency
of these drills.
This “SOP” also covers training to company employees and contractor’s persons engaged in
geophysical operation.

Geophysical
CHAPTER I
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS - “MAINTAINING

SAFETY & HEALTHY ENVIRONMENT AT CAMP SITE”
Purpose : To ensure “Safety & Health” of all the Executives, Employees and WCLs posted at
Camps for Geophysical Data Acquisition activities.
Scope: This procedure covers all the Safety and Healthy measures of personnel posted at camp
site.
Responsible Officers: Party Manager (PM), Survey Officer & Department Safety Officer (DSO).
Procedure:
Normally geophysical operations are carried out in remote areas (includes logistically difficult
areas). For carrying out operations, it is essential to set up a camp for accommodating personnel,
storage of material, parking of vehicles, storage of explosive & detonators. Accordingly, camp is
established with tents or thatched houses for living and office accommodation, with all essential
facilities like cooking, bathing and public utilities.
Safety at camp comprises of health & safety of personnel and safety of material & equipment.
Following safety & health aspects should be followed at camp site:
1.0 General Safety at Camp
All employees / workers must observe the following safety measures at camp site:
Ø Camp should be properly fenced and guarded.

Ø Two feet distance between each tent/thatched house should be provided for easy
walking.
Ø There should be sufficient lighting arrangement. Fuse must be provided outside each
tent/thatched house. Another standby Generator for power supply should be available
in the camp.
Ø The fire fighting equipment should be in a ready to use condition.
Ø First aid box with complete kits should be kept at camp, at an easily accessible place.
Ø There should be adequate drainage and pits for disposal of water and waste material.
Ø Safety posters should be displayed to create safety awareness among field personnel.
Ø Trenches should be made all around the individual housing and officeunits for protection
from snakes, reptiles etc. DDT, Phenyl should be sprayed regularly.
Ø Field personnel must be trained in rendering first aid. A doctor should be designated to
be contacted at the time of Emergency.

Geophysical
Ø Surroundings inside the camp should be cleaned regularly.

Ø Safe, hygienic and comfortable living environment should be provided.
Ø Potable water should be provided in the camp for drinking. Non- metallic containers
should be used for storing drinking water.
Ø Nobody should be allowed to ignite fire in living tents. Important telephone Nos. of local
authorities such as Fire Station, Police Station, Hospital and headquarters should be
displayed at proper place.
Ø Zone of fire should be immediately isolated from the rest of area. Attempt should be -
made to keep away POL and other inflammable material from this area.
1.1 Healthy environment at Camp
1.1.0 Food Hygiene

It should be ensured that staff / workers engaged in preparing food are trained in good
hygiene practices, especially the following: -
ü Kitchen should be at least three meters away from living tents.
ü Vegetables and pulses are thoroughly washed with clean water before cooking.
ü Prepared food is to be kept fully covered to keep away from flies, dirt etc.
ü Food handlers should keep their nails and hairs short, clean and tidy.
1.1.1 Personal Hygiene

All employees / workers must observe the following personal hygiene measures:
ü Take a thorough bath every day.
ü W ash their hands before taking meals and after going to toilet.
ü Brush their teeth every morning and preferably at bedtime also.
ü Cover any exposed /cut/ abrasion with water proof dressing.
ü Use a proper towel to clean blood and body fluids.
ü Field staff should have access to clean drinking water Anybody getting cough,
cold, fever, rash etc. should cover his nose and mouth with cloth 1 mask while
sneezing. Such a person should be consulted with medical.
ü Anybody with above symptoms persisting for more than 3 to 5 days should
consult doctor. If Mumps, Measles, and Tuberculosis etc. are suspected /
diagnosed, such a person should be promptly isolated till he / she recovers.
Preferably he/she should be shifted to OIL hospital or other hospital near to the
camp.

Geophysical
CHAPTER II
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS -
“STORAGE OF MATERIALS AT CAMP SITE”
Purpose: Aim of the Materials Management is to protect, preserve and deliver materials in proper
time to ensure safe and smooth progress of Geophysical Operation.
Scope: This procedure covers all the safety and systematic steps for the personals in storing
materials at camp site.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Camp Clerk
and Stores In charge.
Procedure:
A large quantity of various equipment and materials are stored for smooth operations. The storage
of material is kept in a store made of thatch house or tent in an isolated place leaving safe distance
between residential area and storage tent. Inside tents various types of racks and partitions are to
be made to keep different items in a properly stacked manner. No material should be stored on the
ground in loose form.
Proper safety measures should be taken while storing seismic equipment / material.
Following safety measures should be followed:
Ø All the store items should be properly stacked in racks.
Ø All the items available in each box should be displayed on the box.
Ø First aid box with complete kits should be kept at proper place inside the
store.
Ø Storage of POL should be at a safe distance. Fire extinguishers and sand
buckets should be placed nearby to POL site.
Ø The magnetic tapes/cartridges are to be stored in wooden or cardboard
boxes.
Ø The sophisticated seismic equipment and recording equipment mounted
on a Truck for daily use is to be stored in a separate sheds specially
designed for it.
Ø Smoking should not be allowed near POL storage tanks.
2.0 Safety storage of Spares / Consumables:

ü Protect all spares from mechanical damage, loss, mix up and negligent
handling.
ü Store electronic spares at proper places after duly testing and labeling
them.
ü Electronic spares should be protected from sunlight, heat, dust, grease
etc. Handle electronic spares gently.

Geophysical
ü Provide proper foam or other padding to electronic components/

cards/PCBs and keep them in well protected boxes/ cases.
ü Do not top load electronic spares.
ü On electronic boxes, mark the proper side up.
ü When required store PCBs in static free coverings.
ü Keep magnetic tapes away from heat, dust and store them in a/c
environment.
ü Protect photographic paper from accidental exposure.
ü Containers having liquid consumables should be properly capped.

Geophysical
CHAPTER III
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS - “SURVEYING”
Purpose: To establish General Methods and practices related to the survey jobs in Geophysical
Field Parties.
Scope: This procedure covers all the safety aspects in carrying out survey jobs at operational
areas.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Survey Officer.
Procedure:
Line survey is the first operation of the geophysical data acquisition process after initial planning
work in office. This operation requires different type of equipment and manpower.
Surveying techniques depend upon the nature of the terrain. The terrain has the maximum
bearing on the operational aspects. Different surface conditions such as plain fields, desert, jungles,
mountains, swampy lands and transition Zone (land-water junctions) will demand different safety
requirements for safe and efficient operations.
Surveying is the operation for layout of planned profiles from map to ground. The crew has
to move to the virgin and inaccessible areas most of the time, to make way for subsequent
operations. The procedure of surveying is as shown.
Ø Collection of operational area map from Seismic Data Interpretation section
and relevant Topo sheets from map/Drawing section.
Ø The “restricted” Topo sheets should be kept under safe custody and the
responsibility lies with the person who received it from the map section.
Ø All proposed seismic coverage to be plotted in toposheet and copies to be
taken from GIS section.
Ø Reconnaissance work of the operational area.
Ø Fixing of GPS Control Points in the operational area.
Ø Generation of Area Map with Seismic Profile.
Ø Ranging of Seismic Profiles.
Ø Staking of Seismic Profiles and Generation of Traverse Maps.
Ø Release of uphole locations for Experimental work.
Ø Installing Pillars in the operational area.
Ø Generation of final Location Maps.
Ø Data Computerization.
3.0 Operational requirement for the task
The crew for land survey operations requires following equipment / materials:

Geophysical
ü Equipment
l Hand Compass.
l Measuring chain / tape.
l Totalstation with relevant accessories.
l DGPS receiver sets.
l Hand held GPS.
ü Material
l Wooden stakes (Bamboo pegs), paint, brush, red and white
flag, wood cutting knife or axe, spade, hammer etc.
l Adequate number of light and medium duty vehicles pliable
on barren terrain.
3.1 Safety measures in carrying out the task :

As mentioned above, the surveying operation is the initial operation where the crew has to face
the ground realities without much previous knowledge of the area of operation. This requires a
cautious and thoughtful approach from the surveying groups. They must be fully alert and equipped
with to meet any exigency 1 emergency situation in the field. Following norms must always be
adhered to by the surveying crew members for safe and accident free operations:
ü The crew must always carry a powerful torch or source of light while
surveying in jungle to scare the wild animals.
ü Before entering into thick forest area for survey operation, a din of
sound from drum should be made to drive away the wild animals.
ü Always keep a first aid box equipped with medicines and dressings
for cut/wound and also anti-venom medicines for snake and other
poisonous insects/reptiles bite.
ü Crew should be given first aid training.
ü Keep sufficient drinking water with the crew.
ü While working in transition zone areas or river torn terrain, use of
boats, preferably portable motor boats, to cross the river, are used.
Wooden logs should not be used.
ü Use of life jacket while traveling in portable rubber boat is a must.
ü Survey umbrella for protection of person & equipment from sun and
rain should be used.
ü While plying on barren land, the vehicle should be equipped with
four-wheel drive and wheel pressure should be lowered to avoid
skidding in sand/mud.
ü Driving must be at very low speed to avoid accidents.
ü Care should be taken to follow environment protection norms.
ü The equipment, particularly, DGPS, Total Station, SDRs and hand
held GPS with relevant accessories etc. should be carried in a dust/
waterproof container.

Geophysical
ü The traverse report must be provided to all crew heads invariably.

ü Detailed traverse report shall be prepared by surveyors to facilitate
smooth location indicating following points in particular:
l Position of overhead transmission lines
l Oil/gas/water or any other pipelines Main Road/Road
crossing and Embankment on the River.
l Location of permanent structures.
l Rivers / lakes/ ponds etc
l Populated areas.
ü The traverse report must be provided to all crew heads invariably.

Geophysical
CHAPTER IV
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS -

“SHOT-HOLE DRILLING”
Purpose: Procedure for Shot hole drilling to minimize the crop damage, air pollution, land
contamination and injury to the workers
Scope: This procedure covers all the safety aspects in carrying out seismic jobs - shot- hole
drilling at operational areas.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist,
Drilling Supervisor.
Procedure:
Shot hole drilling is a part of seismic operation. In this, hole of desired depth, varying from 5m to
20m are required to be drilled with shot hole drilling rigs. The holes are drilled at a predetermined
position for placing energy source with explosives. The diameter of the holes is around 7Omm.
Different kinds of shot hole drilling rigs are used, depending upon the logistic conditions of the
area to be studied. Shot hole drilling is mainly of two types.
Ø Mechanical (either Truck mounted or portable)
Ø Manual
4.0 Safety during Drilling

During the drilling process, following precautions are to be taken to avoid any mishappening:
ü Before start of operation all the crew heads should study the area, at
least, once and obtain traverse report from surveyor. This report
must be studied and discussed with all crew members for smooth
operation.
ü For critical and hazardous shot points, if any, the same should be
inspected jointly by representative of organization as well as
contractor. In case if there is a possibility of damage, the same shot
point should be skipped.
ü Villagers should not be allowed to come within 15 mts. of drilling site.
ü W ater Pumps should be checked and maintained daily before
operation.
ü Local administrative authorities to be informed beforehand about the
area of operation for seeking their permission to utilize it for the
operation. Also the compensation procedure followed by the partyis
conveyed and their consent is taken.
ü In case of shot hole drilling by shot hole drilling contractor,
responsibility of compensation solely lies with the contractor.

Geophysical
ü Farmers are informed in advance during Survey Staking work so

that damage of crops can be avoided.
ü Strict guidelines are given to the drilling crew for making single path
in the crop field and all the vehicles should follow the same path to
avoid damages.
ü After the drilling and blasting, the shot holes and water pits must be
filled and the ground leveled as before.
4.1 Safety with Mechanized rigs

In case of Mechanized system of drilling, following precautions are required to be taken:
ü While moving the drilling rig from one shot point to another shot point,
tis mast should be lowered down. After lowering, the mast should
be screwed properly.
ü Drilling rig should be parked at a safe distance from high voltage
power line.
ü Safety uniforms such as Safety shoes, helmets and hand gloves
are to be provided to the drilling crews.
ü Before raising the mast at site, locks should be unscrewed and it
should be ensured that the truck is in level position and there is no
obstruction like overhead transmission line etc. in its path. Wheel of
the truck should be firmly locked to prevent inadvertent motion during
drilling.
ü Sturdy wooden platform for operator and rotary man should be used.
ü Drilling platform should be regularly cleaned to avoid slipping of crew
member during operation.
ü The prime mover must be disengaged, if any repairing works are to
be done during operation.
ü Except crew member, no one should stand nearby drilling rig during
operation.
ü Main drilling clutch system should always be in perfect condition to
control the equipment in any emergency.
ü The mud pump should be provided with a pressure gauge and relief
valve. The discharge of the relief valve should be led through a pipe
to the ground. The mud lines should be secured to the mast.
ü The mud pumps should not be operated until the inlet and discharge
valves are checked and opened. In case the pump stops due to any
reason, the pressure should be released immediately by opening
the relief valve.
ü Hose, chains and lines should be inspected daily and in case of any
defect; these should not be put into use until the defect is removed.
The dues of slips and tongs should be checked and replaced, if
found necessary.

Geophysical
ü It should be ensured that drill cuttings are not allowed to clog the
hole. No attempt should be made to clean the cuttings manually
when drilling is in progress.
ü Drilling crew should be provided with personal protective equipment
line helmet, boots, earplugs and hand gloves.
ü All shafts, sprockets, gears and moving parts of machinery should
be securely guarded. Repair and maintenance of machinery should
not be done while the machine is in motion.
ü In case of any malfunctioning of vehicle during operation time, the
matter should immediately be reported to the chief of field crew or to
any executive present at the operational site and corrective measures
must be taken immediately.
4.2 Safety with Dheki system

In case of Dheki system of drilling, following precautions are required to be taken:
ü The wooden logs used for Dheki must be strong enough to withhold
the load and pressure, exerted by the top man and frill pipes. These
must be regularly checked ‘for sag and must be disposed of before
reaching the breaking point.
ü The top man must always be alert for jumping away in case of Dheki
collapse.
ü The drill stumps must be lifted only after the top man has come
down from the Dheki top.
ü The holes should be loaded only after removal of all the equipment
from the site.
ü Drilling crew should be provided with personal protective equipment
like helmet, safety shoes, safety belt and hand gloves.
ü During drilling, proper safety precautions should be taken of other
seismic equipment like cables, geophones, batteries, wireless sets
etc.

Geophysical
CHAPTER V
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS - “SHOOT-

ING”
Purpose: Safety procedures for shooting/Blasting the explosives placed in shot holes for seismic
operations
Scope: This procedure covers all the safety aspects in carrying out seismic jobs - shooting/
Blasting the explosives at operational areas for seismic activities.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist,
Shot Firers.
Procedure :
Firing of explosives, loaded in shot hole, to acquire data, is called shooting. Blaster / sysnchrophone
/ Machha system are used to blast the explosives lowered in shot holes, through main recording
system. Blaster / Synchrophone / Machha system are handled by licensed shot firers, specially
trained for the job.
The following safety measures need to be taken care during shooting operation.
Ø Shooting crew should strictly study the surveyor’s traverse report daily,
before going to field to know the assess route to the shot point, presence
of transmission lines, telephone lines, roads, permanent structures etc.
to avoid any damage / accident to property /manpower.
Ø No blasting operation should be carried out between the hours of sunset
and sunrise.
Ø Only authorized licensed person should be deputed to fire the shot hole.
Ø Every shot firer, deputed to charge shot hole, should use only wooden /
non ferrous tools for opening of boxes, charging and stemming shot holes.
Ø Before commencing shot firing, adequate warning to public should be
given by an efficient system of signals by putting up red flags in the dan-
ger zone i.e. 55 mtrs from the place of blasting.. It should be ensured that
persons, in the vicinity, have taken proper shelter.
Ø If shots are being fired in the vicinity of public places or property, adequate
precautions should be taken to guard against danger to the public.
Ø Never blast a shot hole near high-tension electric line.
Ø After blasting has been satisfactorily carried out, all clear signals should
be sounded.
Ø The entire shooting crew should wear helmets to guard against any failing
debris (especially in boulder bed/hard rock areas).
Ø The blasted holes must be filled with earth to avoid injury to people or
animals.
Ø Shooting operations should be suspended if there is any possibility of
lightning in a cloudy weather.

Geophysical
Ø In the event of misfire, no attempt should be made to re-bore or tamper

the hole that was charged with explosive or to withdraw the explosive
from the hole.
Ø In case of misfire, the re-loading of the misfired hole must be done
according to the Explosive Rule 1983.
Ø The moment, hole is blasted; the firing line must be disconnected from
the blasting system.
Ø The firing line must be kept shorted till it is connected to the blaster. Firing
line should be connected to blaster only after receiving instructions from
the observer.
Ø Before firing the shot, the observer should ascertain from the shooter the
shot point number, being fired and whether nearby persons are at safe
distance from shot hole. The shooter should move to the next location
only after obtaining clearance form the observer.
Ø The distance between shot hole and the places where explosives us kept
on the ground for stemming should be at least 55 mtrs. This should be
applicable for up-hole survey also.
Ø Instrument should be about 55 mtrs. away from the shot hole and in a
direction opposite to the place where the explosive is kept for stemming.
Ø The blaster / synchrophone should be at a safe distance from the shot
hole at the time of blasting. No person should be present near the shot
hole within the radius of 55 mtrs. at the time of blasting.
Ø In case of up-hole, the shooting wire after blasting should be pulled out
and taken away from the hole. Only then another charge with shooting
wire should be brought for loading. It should be ensured that there is no
mix up of wires.
Ø Before blasting the charge, the hole should be filled with mud and the
firing line at the mouth of the shot hole should be firmly spilled to the ground
so as to prevent firing line to go up.
Ø All communication should be kept in off position during blasting of hole.
Ø The left over explosives and detonators in the field must be deposited
back in magazine in the evening.
Ø A cap tester should be used to check the continuity of each detonator
before priming.
Ø All safety distances depending on charge sizes as per table given in
Annexure I need to be maintained
5.0 Misfires
ü No person should be allowed to approach the misfire sight
before the expiry of unsafe period.
ü Attempt should be made to blast with the help of fresh
detonators only after the expiry of unsafe period.
ü If a relieving hole is to be drilled, it should not be placed within
30 cms. from misfired hole. The relieving hole shall run parallel
to the misfired hole

Geophysical
CHAPTER VI
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS - “DATA

RECORDING & VEHICLE USE”
Purpose: Safety procedures for recording operations and vehicle usage.
Scope: This procedure covers all the safety aspects in carrying out seismic jobs - Recording
activities and vehicle usage at operational areas.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist-
Observer.
Procedure:
The recording operation is the main operation in seismic data acquisition which deploys a large
number of men, equipment and vehicles. It involves use of sophisticated electronic equipment
operated on electrical power, supplied from storage batteries or / and generators. In land areas,
depending upon the type of operational terrain, the recording equipment may be vehicle mounted
or manually portable. The safety requirements in seismic recording operations may be considered
from two angles.
Ø Truck mounted equipment

Ø Portable equipment
In both these cases the safety requirement of the crew on line (responsible for ground equipment
layout) will be the same, where as the safety requirements for recording equipment, transportation
crew and operators will differ a little bit in the two cases.
6.0 Safety while using Truck Mounted equipment
The recording site safety requirement is very important, both for operating personnel
and the equipment. Equipment safety is of paramount importance, as a little
carelessness may damage the equipment which is a very expensive asset of the
Company, resulting in suspension of operations. Some of the important safety aspects
of operations which require attention of the observer 1 operator while carrying out
recording operations are as follows:
ü The main recording equipment should be mounted in a cabin on back of a
Truck or a powerful four-wheel drive van.
ü The recording equipment is sensitive to temperature and humidity.To avoid
damage of equipment, the cabin should be air-conditioned. This requires
a power supply backed by a generator.
ü In the rainy season, during a rainy day, recording must be suspended and
instrument must be switched off if rain and thunder persists. It is essential,
both for quality of data recorded and for safety of the equipment.

Geophysical
6.1 Safety while using Portable Equipment

In case of portable equipment set up for recording, the equipment must be carried in waterproof
boxes and transportation must be done carefully by deploying sufficient man power. In case of
portable operations, following special safety norms must be complied with.
ü Instrument modules / panel must be set up in a properly cleaned dry place

for operations.
ü The set up must be covered on top to protect it from sun & rain i.e. it
should be under an open tent (without side walls).
ü The batteries for power supply to the instrument must be placed on wooden
planks and connector clips must be dry and clean.
ü Temperature should not exceed the prescribed limit for seismic equipment.
If weather is hot, operation should be carried out in early morning to avoid
temperature exceeding prescribed limit for seismic equipment.
6.2 Safety while using vehicles

Different types of vehicles are used in geophysical operation for transportation of men & material
from HQ to camp and from camp to area of operation. Heavy vehicles like drilling rig, Instrument
van, Vibrators, Explosive vans, Watertankers are used for geophysical operations. RTO & Safety
rules to drive the vehicles moving on Road and in cross-country should be followed.
Following guidelines for safe driving are to be followed during field operations:
ü Before taking out the vehicles from the camp, the vehicle should be properly
checked.
ü Before going to field the driver should check the working condition of lights,
breaks, wiper, diesel level, mobil, air pressure in tyres, water in radiator,
battery, and availability of First Aid Box.
ü Over loading of vehicles should not be allowed.
ü Drivers of the vehicles should maintain strict adherence to speed limit.
ü The driver should not be allowed to drive any vehicles in intoxicated

conditions.
ü Separate vehicle should be used for transportation of men and material

as per Vehicle Act.
ü Drilling rig should be parked at safe distance from high voltage power line.

Geophysical
6.3 Safety while using Vibrators

The vibrator is widely used as energy source for VIBROSEIS operation. The vibrator may be
mounted on conventional trucks or on specialized off-road vehicles. The following precautions
should be taken during service, maintenance and operation.
ü Personnel protective equipment such as helmet, safety shoes, safety
goggles, hand gloves, sun protector, ear protectors should be used.
ü At the time of checking always put the transmission in neutral, set the
brake, and apply safety locks provided.
ü Before servicing, adjusting or repairing vibrators lower the attachments to
their fullest extent. If necessary, to raise them for access to certain parts
and secure support by external means. Do not rely on controls of sup-
ports or position attachments for maintenance.
ü Keep maintenance areas clean and dry.
ü Before repairing the electrical system, make sure the batteries are dis-
connected.
ü Carefully inspect equipment for visual defect leaks in fuels, lubrication
and hydraulic systems.
ü Check levels of fuel, coolant, hydraulic fluid and lubricating oil.
ü Since the system works at very high pressure, system vibrator unit should
not be left unattended under high pressure.
ü The sequence of procedure to put the system into or off the operation
should be carefully followed.
ü While operating near villages or when profile crosses populated areas,
the drive percentage should be reduced to safe level so as to avoid any
damage to property.
ü The driving instructions mentioned in the manuals should be strictly fol-
lowed while moving in cross-country with highly undulated terrains.
ü All the pipes of servo mechanical system be checked properly before
starting the system for any leakage / cracks /breakage at the ends or in-
between, as it may lead to serious accidents.
ü Before starting, at any Vibro-Point, it should be ensured that the base
plates of all the vibrators are kept down making proper coupling with ground
and the system and lift cylinder pressures are at mentioned ratings. Ra-
dio is switched on to proper channel. Also, before moving to next vibro
point it should be ensured that the base plate is lifted up fully.
ü While crossing the power lines, antennas should be removed or lowered.
ü If vibrator is under repair, the radio of the vibrator is switched off or start
code be changed because start command from RU may initiate sweep.
ü No untrained person should be allowed to go near the vibrators while in
operations.
ü Stay at safer distance from the vibrators as the hot oil splash may create
serious burns, in case of pipe burst.

Geophysical
CHAPTER VII
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATIONS - “ELECTRICAL

INSTALLATIONS”
Purpose: Safety procedures in carrying Electrical Installations at camp site.
Scope: This chapter covers all the safety aspects in carrying out seismic camp jobs - Electrical
Installations.
Responsible Persons: Party Manager (PM), Department Safety Officer (DSO), Geophysicist,
Asst. Geophysicist, Jr. Geophysicist and Electrician.
Procedure:
Safety in Electrical System deserves maximum attention especially at the camps, where classified
hazardous atmosphere is normally encountered and electricity constitutes one of the major sources
of ignition (by arcs, sparks and hot surfaces) for fire accidents and explosions etc.
Besides injuries and fatalities to personnel due to electric shock and burns,
electrical hazards also include equipment damage and property loss. Alllateststatutory stipulations
such as Indian Electricity Act & Rules 1956 (latest revision), Petroleum Act & Rules etc., shall be
complied with, while carrying out electrical installations, their inspections, testing and
commissioning. Before commencement of electrical installations it should be checked that
equipment and other materials are received as per approved specifications and in full quantity as
ordered. Damaged item and/or missing component should be repaired/replaced as per
specifications. During installation all the accessories and loose items shall also be inspected
before their assembly/mounting.
7.0 Safety aspects during Camp electrification:

Ø Before commencement of electrical installations, the schemes and one line
drawings should be approved from the higher authorities.
Ø Before taking up any electrical equipment for commissioning, it should be ensured
that the entire installations and wiring connections etc. are carried out as per
approved drawings.
Ø During installation, special precaution, related to laying, and termination of cables/
wires to electronic/ communication / equipment and such other requirement,
shall be adhered to.
Ø Cable laying is done strictly as per Indian Standard.
Ø Cable routing is planned to be away from heat sources, gas, water, oil, drains
piping air-conditioning duct etc.

Geophysical
Ø The wires used for camp electrification should be of good quality and having ISI
mark. Three core PVC insulated and PVC sheathed wires should be used for
electric wiring.
Ø 2 core wires shall be used only for 24 volts and above this voltage, 3 core wires
shall be used.
Ø Fuse of proper rating must be used for each line.
Ø Only HRC fuses shall be used and not re-wirable type.
Ø Load of camp lighting is to be distributed properly to avoid accident.
Ø All electrical appliances are properly protected against rain, water, dust etc.
Ø Periodical monitoring of load is done to ensure compatibility with switch rating/
cable sizing.
Ø The switchboard must be neatly fitted with adequate number of: panels and
wiring must be properly fitted on that.
Ø Only approved make of switchboard shall be used.
Ø Meter room must be away from the living tents. Proper Schematic Diagram of
wiring inside the camp should be displayed near Meter room.
Ø No unauthorized addition of loads or modifications in the installations is carried
out without prior statutory clearances from higher authorities.
Ø Earthing is made as per standard IS : 3043
Ø Individual earth electrodes are provided for each lightning arrestor and lightning
mast.
Ø Accidents shall be notified to the Electrical Inspectorate (as per Indian Electricity
Rules) and State Government authorities and the recommendations of the
statutory bodies as a result of investigation, shall be complied with as required.
7.1 Safety aspects regarding Power Generators :
Ø Captive power generation (even installation of Diesel Generators) shall require
prior sanction of the Electricity Supply Authorities (as per the provisions of the
Electricity Supply Act)
Ø Manufacturers’ erection commissioningloperation and maintenance manuals
are available.
Ø Approach way to generator foundations is clear.
Ø All lifting tools and tackles are properly sized and tested.
Ø Onlylifting lugs designated for this purpose, on the generator, are used for lifting.
Ø Generator should be placed at one corner of the camp and should have sufficient
distance from residential areas to re uce po uti,on.
Ø Generator should be kept in separate shed.
Ø Proper mountings and earthing are to be provided at the time of installation.
Ø After placing Generator on foundation the following are recorded:
ü Insulation Resistance (IR) & Polarization Index (Pi) values of stator

and rotor.

Geophysical
ü Resistance and temperature of Stator and Rotor windings.

(Compare with test values recorded at manufacturer’s works after
making correction for temperature)
Ø Generator stator body earthing and rotor shaft earthing (if any).
Ø The direction of rotation is correct.
Ø All auxiliary equipment like lube oil pumps, cooling water for bearing are available
in good condition.
Ø Ventilation and cooling system.
Ø Mechanical and electrical checks as per IS 900 are carried out.
Ø Foundation bolts are of proper size.
Ø Guards should be fitted on fan and other moving parts.
Ø When pump and motor are not in the same base plate, both are independently
earthed.
Ø All metering devices are in good condition.
Ø Main switchboard should be facilitated with E.L.C.B. (Earth Leakage Circuit
Breaker).
Ø All interlocks (by simulation) are functioning properly.
Ø Rubber rnat should be provided near the electric control panel.
Ø All protective devices are functioning properly and that the inter- trippinglalarms
are OK, (by simulation)
Ø All auxiliaries of Generator like lube oil pumps, pilot exciter,rotating diodes (if
brushiess type), condensate pumps, demisters etc. are in order.
Ø All temperature and pressure gauges are tested.
Ø Muffler should be used to reduce the noise.
Ø “Danger Signs” should be displayed boldly all around POL site, Generator,
Charging room and electrical junction boxes.
Ø Generator room must have sufficient space and only authorized person should
be allowed to enter the room.

Geophysical
CHAPTER VIll
SAFETY PROCEDURES IN CARRYING OUT “WIRELESS COMMUNICATIONS”

GEOPHYSICAL OPERATION -
Purpose: Safety procedures for Communication (Wireless) at HOR, camp site and operational
areas.
Scope: This chapter covers all the safety aspects in carrying out seismic jobs - Communication
(Wireless).
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist-
Observer.
Procedure:
Wireless Communication means any transmission, omission or reception of signs, signals, writing,
images and sounds, or intelligence of any nature by means of electricity, magnetism, or Radio
waves or Hertzian waves, without the use of wires or other continuous electrical conductors
between the transmitting and the receiving apparatus. Wireless Communication plays an important
role in seismic data acquisition. Proper communication between observer, shooter (Licensed
person who initiates explosives) and cable layout crew may avoid miss firing, accident and
accelerate smooth functioning of seismic operations. It is also required to communicate between
field crew/survey crew to camp and camp to head quarter. Every seismic survey party uses HF
radio set for communication between Office, Head Quarter at Duliajan and Base Camp. While
W alkie-talkie sets are used for communication for the entire crew in the field during the seismic
survey operation.
8.0 Safety to be ensured while handling Wireless Communication sets.
Ø All the communication sets that were used in the operation should possess
a valid license provided by the Department of Telecommunications,
Government of India.
Ø After the expiry of the license, ensure that renewal of the existing license
is being done before the start of field operation.
Ø The radio sets are meant for communication purpose only.
Ø The radio sets should not be operated by anyone other than the operator.
Ø If in case, any radio set have been misplaced, information to the higher
authorities is to be provided immediately.

Geophysical
Ø The radio sets have to be protected from rain.

Ø For day to day use in field operations, the radio sets have to be charged
every day at the base camp.
Ø While taking the radio sets to the field for operation and when returning
them back to the base camp ensure that all the radio sets were returned
and a record needs to be maintained in this regard.

Geophysical
CHAPTER IX
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATION -

“EXPLOSIVES HANDLING, STORAGE AND TRANSPORTATION”
General : Geophysical Field Seismic Crew uses Explosives and Detonators in the process of
seismic data acquisition. Adequate safety precautions have to be taken during handling,
transportation and storage of explosives & detonators at camps sites and also at operational
areas.
Purpose: Safety procedures in handling, transportation and storage of Explosives and Detonators
at camp site and operational areas.
Scope:
Ø Handling of explosives & detonators in the operational area,
Ø Storage of explosives & Detonators at Magazines (Main & Portable).
Ø The scope also includes the transportation of Explosives from Main magazine to
Temporary Magazine, Temporary Magazine to Field and back.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist.
Procedure:
Explosive play an important role in seismic data acquisition as it is being used as energy source
to generate elastic waves. The most commonly used explosives are SG-80 (Special Gelatin)
sticks, CPT (Couplable Plastic Tubes) and electric detonators. Electrically fired detonator initiates
explosion in main explosive like SG-80 etc., which loaded in shot holes to create seismic elastic
waves into the earth formations. Explosives, being a hazardous material in nature, it requires lot
of precautions during transportation, storage and use. A minor negligence may cause danger to
human life and property.
Explosive Rule 1983, framed under the Indian Explosives Act, 1884 regulate use,
storage and transport of explosives in Geophysical operations. PESO is responsible for
enforcement of these statutory provisions, which should be carefully studied for safe Geophysical
operation.
9.0 Salient features and safety precautions in “Handling Explosives”.
Ø Only competent person, holding shot firers permit, granted under the
Explosive Rules, 1983 should be allowed to handle the explosives.
Ø A record should be maintained of explosives and detonators received,
consumed and balance at the magazine.
Ø As far as possible, priming of explosive is done under shadow to avoid
static charge.
Ø Cases containing explosives are not thrown or dropped down on ground.
Ø Empty cardboard boxes carrying explosives should be disposed properly.

Geophysical
Ø No person shall have in his possession matchbox or other appliances of

steel, which can cause spark.
Ø No person wears shoes with an iron heel.
Ø Detonators are required to be carried in wooden boxed duly locked. The
end of the detonator leads should be kept shorted.
Ø No detonator is taken out from its container unless; it is required for
immediate use. Separate vehicle 1 container must be used to carry
explosive and detonators.
Ø Explosive primed with detonator, should be immediately lowered into the
shot hole. No primed charge should be kept on the surface. The ends of
the wire attached to the primed explosive must be kept shorted, from the
time of primary loading, till the time; it is to be connected to firing line, for
blasting.
Ø While stretching the detonator leads, do not hold the detonator cap but
grip the wires at least 5 cms. away from the detonator cap with one hand
and stretch with the other.
Ø Keeping in view, the advancement of technology in manufacturing; safe
and good quality of explosives and detonators should be used.
9.1 Salient features and safety precautions in “Storing Explosives”.
Ø License is required to be obtained / renewed for permanent as well as
temporary (portable) magazine.
Ø Explosive should always be kept in a licensed magazine.
Ø Magazine should always be provided with lightening conductor with proper
earthing.
Ø The magazine should be with safe distances as per Explosive Rule.
Ø The construction of magazine must be as per the design approved by
PESO.
Ø Magazine must be properly fenced and protected round the clock by armed
guards.
Ø “No Smoking” and “danger” signs should be displayed along with red flag
at the temporary and permanent magazine sites.
Ø Smoking, fire or open flame should not be permitted in proximity to a place
where explosives are stored.
Ø Safe distance must be maintained between B type (explosive boxes) and
S type (Detonators) type boxes, as per explosive rules for storing explosive
and detonators respectively.
Ø Records of explosive and detonators must be maintained in a register
kept at explosive magazine and at HQR, or at camp.
Ø Magazine should be operated by authorized and competent persons only.
9.1.1 Major Reminder:
Do’s
ü Store explosives only in licensed magazine.
ü Always maintain magazine in good condition.
ü Always keep gangway of 60 cm between stack of explosives boxes
and wall.

Geophysical
ü Get all lightening conductors on magazine tested for continuity and

resistance once in a year.The resistance of lightening conductors should
less than 10 ohms.
ü Mark license no. and validity prominently on licensed premises.
ü Mark 12 mm thick red line 2.5 m above floor level inside the magazine
and do not stack explosives boxes above it.
ü Provide fencing at a distance of 15 m from magazine and keep the fenced
area free of vegetation.
ü Always keep stock of explosives within licensed capacity.
ü Always issue old explosives first.
ü Provide security guards round the clock.
ü Keep security guard’s shelter at a distance of 30 m from magazine.
ü Always report loss, theft or short receipt of explosives to controller of
explosives and police.
ü Always take precautions to prevent mechanical impact of any hard object
with explosives.
ü Always employ certified blaster for blasting operations.
ü Mark ‘Danger - Explosive’ and ‘Turn Off Radio Transmitter’ at the
site.
ü Sufficient warning like display of red flag, whistle sound shall be given to
public before blasting. Also display blasting time.
ü Suspend blasting operations during thunderstorms.
ü Blasting schedules should be arranged in such manners that all holes
charged with explosives are immediately blasted on the same day. In case,
for any reason, such charged holes cannot be blasted on the same day,
these sleeping holes charged with explosives should be properly guarded
from a suitable safe distance, till the same are blasted.
ü Always return unused explosives after day’s work to the magazine before
sunset.
ü Respect explosives.
Don’ts
× Don’t sell explosives to unauthorized person.
× Don’t undertake construction of building for manufacture or storage of
explosives unless you obtain construction approval from licensing authority
and NOC from district magistrate.
× Don’t abandon any explosive material after use at site.
× Don’t store explosives outside magazine.
× Don’t use sparking tools.
× Don’t throw, drop boxes of explosives.
× Never use bale hook during loading / unloading of explosives boxes.
× Don’t cut explosives cartridges or change description of explosives.

Geophysical
× Don’t deface markings on cartridge or box of explosives.

× Don’t store high explosives and detonators together.
× Don’t use misfired explosives.
× Don’t use deteriorated or exuded explosives.
× Don’t attach detonator to detonating cord until everything is ready for blast.
× Don’t use mobile phones/pagers near place of storage and use of explo-
sives.
× Don’t use iron implements during preparation of charges.
× Don’t deliver explosives unless photograph and signature of authorized
person are verified.
9.2 Salient features and safety precautions in “Transporting Explosives”.
Ø International / national and local rules must be honored while transporting explosives,
Schedule IV,Article 8 of Indian Explosive rule is applicable.
Ø The explosives are required to be transported in a vehicle approved by PESO.
Ø Never transport primary and secondary high explosive in the same containers or in
divided compartments of a container.
Ø If permitted primary and secondary high explosive may be transported in the same
van, provided they are placed in separate containers kept at least 1 meter apart. Use
of original package is most safe for transport.
Ø Loose charges, detonating cord or detonators must be kept in their designated con-
tainers and must be locked. End of detonating cord must be taped to avoid spillage of
powder.
Ø All containers must be properly secured to prevent movement during transport.
Ø Explosives may be delivered only to authorized consignee and removed from ship-
ping containers / vehicle as soon as it reaches destination.
Ø Explosives must be last thing to load and very first thing to unload.
Ø The explosive should be transported in their packing, under armed escort.
Ø Explosives and detonators must be transported during daytime only.
Ø No smoking during loading / unloading or conveying explosive or near to explosive /
explosive van.
Ø While loading / unloading of explosives in the vehicle, vehicle engine must be shut off
and should not be started until loading / unloading job is complete.
Ø The explosives van/jeep must display the ‘Danger’, ‘Explosive’ and ‘No Smoking’ signs.
Ø Two fire extinguishers should be provided with each of explosive van/jeep.
Ø All electrical wiring and battery cables of the vehicles should be fully enclosed and
maintained in good condition.
Ø The explosive van should be painted in aluminum (the explosive carrier part and red
(the rest of the body) colour to avoid over-heating and to display danger.

Geophysical
Ø Only optimum number of detectors is taken to work site (in any case not more than 2
detonators/run).
9.2.1 During Road Transport

ü Transportation of explosives must be done in a licensed / permitted vehicle/van
as perform 26 of Article 8, Schedule IV under rule 155 of Explosive Rule 1983.
ü A copy of license of van/jeep should always be carried in the vehicle.
ü Explosive Van must have a physical barrier (Fireproof screen) between explosive
and driver’s cabin.
ü The van must have approved fire extinguisher with enough capacity.
ü The van must have first-aid-box.
ü Batteries, dry cells and other source of electrical energy should not be carried in
the explosive vans.
ü The van must carry at least two reflective warning signals and have an explosive
warning label.
ü The van must have important emergency contact numbers boldly written in the
driver’s cabin.
ü The van must have one red-lensed battery operated search light lamp and one
clear-lensed lamp for front use in case of break down during dark.
ü The van should not have:
l Fuel leak
l Exhaust system leak
l Exposed open-ended truck wiring
l Excess Oil/grease on exposed surface
l Dirty interior
ü All precautions are intended to protect the explosives from spark flame, shock,
blows, corrosive attack or unauthorized access.
ü Vehicle carrying explosive must not carry any other hazardous cargo, extra fuel
or flammable liquid with explosives.
ü Van engine must not be running during loading/unloading of explosives or while
filling fuel in loaded vehicle.
ü Never carry explosives in driver’s cabin/passenger area.
ü Explosives and detonators should not be transported in towed vehicles.
ü Loaded guns with end protectors ‘on’ must not extend transporting vehicle body.
ü Transporting vehicle must have explosive sign in front and near both sides. The
vehicle must not be driver) rash or dangerously.
ü Explosive transporting vehicle must never be used to tow any other vehicle and
vice versa.

Geophysical
ü Never stop vehicle transporting explosives at places where security is

endangered.
ü If explosive van is to be parked overnight due to reasons beyond control the
parking place must be
• Away from open flame, high tension line, radio/T.V. tower etc.
• Away from habitation or any godown containing articles of flammable/
hazardous goods
• Nearest police station must be informed about the location of vehicle
parking.
ü Routes passing through dense habitation must be avoided as far as possible.
ü At any un-manned railway crossing or high way crossing the vehicle must be
stopped till safe clearance is available.
ü The original license/attested copy must be kept in the vehicle while going for a
job.
ü The van must have four wheel brakes.
ü If fire occurs on a vehicle containing explosives, the driver must take steps to
stop other vehicles/traffic at least 300m. away on all sides of road and that all
the persons are warned of the danger.
ü In case of van carrying explosive is involved in accident or fire or other mishap
following must be done:
• Comply with all legal requirements relating to road accident.
• Place warning signs for moving traffic at safe distance.
• Inform local police.
• Inform licensee who in turn must inform PESO giving full details of
accident.
• Arrange for safety and security of explosives till the inspection by Chief
Controller of Explosives (if needed) is done.
• Stay with the vehicle (if it is not a fire case).
• If vehicle is on fire use your judgment as to whether to try to extinguish it or
to get a safe distance.
9.2.2 Major Reminder:

Do’s
ü Always maintain transport vehicle in good mechanical & road worthy condition.
ü Always carry two fire extinguishers in explosives van.
ü In case of breakdown of explosives van, inform controller of explosives and
local police.
ü Always carry following documents during transport of explosives:

Geophysical
• Indent in form RE-11

• Pass in form RE-12
• Copy of explosives van’s license.
• Bill / invoice.
ü Two armed guard should always accompany explosives van during transport of
explosives. In sensitive area notified by ,MHA, the police armed guard shall be
provided.
ü Employ only trained driver and cleaner, whose antecedents are verified by police.
ü Always maintain 300 m distance between two vans carrying explosives.
ü Always load / unload explosives only when explosives van’s
• Engine of the vehicle is stopped.
• Wheels chocked.
• Hand brakes applied.
ü Always avoid routes passing through centre of dense habitation and municipal
limits.
ü Always give notice of accident to controller of explosives, District Magistrate
and police.
Don’ts
× Don’t stop explosives van unnecessarily or for longer duration during
transportation on road.
× Don’t transport flammable substance with explosives.
× Don’t transport detonators with other type of explosives.
× Don’t carry passengers while transporting explosives in van.
× Don’t employ any person:
• Who is below 18 yrs of age.
• Who is in state of intoxication.
• Who is mentally or physically challenged.
× Do not transport explosives in the night (from Sunset to Sunrise) in the sensitive
areas notified by Ministry of Home Affairs (MHA).

Geophysical
CHAPTER X
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATION “EXPLOSIVES

LIQUIDATION”
Purpose: Geophysical Field Seismic Crew uses Explosives & Detonators in the process of seismic
data acquisition. Adequate safety precautions have to be taken during liquidation or disposal of
unused explosives & detonators.
Scope: Safety procedures in disposal of Explosives and Detonators.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist
(Seismologist).
Procedure:
10.0 Salient features and safety precautions.
Ø Explosive materials shall be declared unusable depending upon their expiry date
if any or the physical condition.
Ø All unusable explosives (charges, prima cord and defective detonators) shall be
segregated / sorted out in a separate place in the magazine.
Ø Store defective / remnants of primary high explosives and secondary high
explosives in separate containers designated for each type of explosives in
Magazine at a predefined location away from good /usable explosive storage
area.
Ø These explosives must be properly packed and marked “NOT SUITABLE FOR
USE”. The area of disposable explosive must be marked “DISPOSABLE
EXPLOSIVE AREA”.
Ø A proper record of disposable explosive must be maintained at magazine.
Ø Written permission of PESO shall be obtained for disposal / liquidation of
unusable explosives.
Ø Disposal/ liquidation shall be carried out in the presence of Explosive Inspector
or any other official authorized by CCE.
Ø Disposal site shall be at a safe distance from dwelling houses, factories, gas
godowns, road & railway tracks etc. as specified in the explosive rules.
Ø Fire shall be applied through a channel from a point at a safe distance from the
burning pit as specified by CCE.
Ø Gelatin/Slurry and detonators shall be disposed off separately.
10.1 Disposal Method.

Ø Locate a flat area, clear and open far away from inhabited area and other buildings,
highways and railway tracks.
Ø No High-tension line should be crossing over the selected site. It must be grass
from preferable sandy oil as per rule No. 109 of Indian explosives Rule.

Geophysical
Ø Approval from local police and regional controller of explosives is sought for
disposal activity.
Ø A particular disposal activity must be well documented with proper clarification.
Ø Representative from the office of Controller of Explosives may be present during
disposal operation as per Form No. 36, item No. 5 of ER 1983.
Ø Following methods of disposal must be followed as per requirements.
10.1.1 Burning Pit:

Explosives materials shall be disposed off burning in pit as specified by CCE
depending upon the type and quality of explosives.
ü Burning pit is used for disposal of secondary high explosives.

ü Have a steel try of 3 to 4 mm thick plate and 1 x 1 x 0.15 cm.
Dimension having legs 20 cms. height.
ü Put steel tray in a pit of dimensions 1.5 x l.5x l.5 m.
ü In shaped charges where the above action is not feasible are to be
burnt as it is. Observe all safety precautions.
ü In general 50 charges each of 22 gm of grain load can be burnt in
one go.
ü Desensitize the explosives in Kerosene or diesel for a minimum
period of half an hour.
ü A thin layer of dry wood, paper, straw or cotton waste is kept at
bottom of tray.
ü Soaked explosives must be spread over entire tray. Ignite this
explosive either by electric igniter from a distance of 100m or by a
soaked diesel wick, which must be used from a safe distance. An
expanded metal cover must be placed over the pit to avoid any
projectiles.
ü The explosive / charges will burn with a roaring fire. Check if any un
burnt charges after two hours of cease of fire to avoid any danger.
ü In case of disposal of prima cord remnants or rnisfired, it must be
cut in small pieces of 6" to 8" (inches) and doused with Kerosene
for half an hour. Burn the doused prima cord in steel tray repeating
above mentioned step 7, 8, and 9.
10.1.2 Liquidation by Detonation:

ü It is always not possible to liquidate the explosives by burning. In
such case detonation can be used effectively to liquidate the
explosives.
ü Dig a trench of at least 0.6 m. deep.

Geophysical
ü String the charges with the prima cord at one-foot distance. Garland
of charges is placed inside the trench with all charges facing
downwards. One end of prima cord, must be attached with detonator
which in turn be connected with long electrical wires shored at other
end.
ü Top up the trench with soil and cover it with a metallic housing so
that splinters should not hurt anyone.
ü Move away all the personnel from trench at a distance of 200m.
ü Detonate the charges electrically from a distance of 100m.
ü Any charges that did not detonate in this process but got ruptured
must be burnt in subsequent operation.
10.1.2 Liquidation in an abandoned well :

ü Identify an abandoned well, which might never be targeted to be
opened in future. Specific gravity of the well fluid shall be less than
1.2.
ü Dump the damaged explosives in the well, using rigid containers.
ü Plug the well with bridge plug followed by cement plug as per OMR,
1984.
ü Note the event in Well Completion report/well history regarding
dumping of explosive its depth and depth of cement plug.
10.1.3 Liquidation by other Agencies:

In projects where suitable sites are not available for liquidation of the explosives
or approval of liquidation from regularly bodies is not easily available, one of the
following national agencies must be contacted for liquidation of explosives
depending upon convenience.
l Indian Explosive Ltd., Gomia
l Armament Development Establishment
l ICL Ltd., Mumbai
l Indian Detonator Ltd., Hyderabad
10.1.4 Liquidation of Detonators / Boosters:

ü Collect all the bad detonators along with booster cap if any.
ü Bundle detonators/booster around a small section of prima cord
with adhesive tape.
ü Put the bundle inside a deep pit. Fill the, pit with soil after attaching
the bundle with a good detonator connected with long wires shorted
at other end.
ü Move away all the personnel from pit to a safe distance.
ü Fire the detonators from a safe distance electrically.

Geophysical
CHAPTER XI
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATION - “BATTERY

HANDLING & MAINTENANCE”
Purpose: The purpose of this chapter is to outline the duties and responsibilities for routine operation
and care of lead-acid batteries.
Scope: Totally familiarize with battery handling, charging, and maintenance procedures and
precautions.
Responsible Persons: Party Manager (PM), Department Safety Officer (DSO), Geophysicist
(Observer) & Jr. Geophysicist.
Procedure:
General Safety to he ensured while handling Batteries.
Ø Read and observe “DANGER”, “CAUTION”, and “WARNING” labels on batteries and
chargers in battery room. Improper safety practices can lead to serious personal
injury and property damage.
Ø Keep open flames away from batteries. Hydrogen gas given off during charging could
ignite, causing an explosion. Use a flashlight to check cells. Do not smoke, create
open flames, or cause sparks.
Ø Wear goggles or face shield and rubber apron, gloves and boots when cleaning,
handling, checking, filling, charging, or repairing batteries.
Ø If eyes or skin are splashed with electrolyte, rinse immediately with large volumes of
clean water for 15 minutes and have the person see a doctor.
Ø Never lay tools or other conductive metal objects on top of a battery.Sparking, shorts
and possible explosion can result.
Ø When mixing acid and water, always add acid to water and stir constantly with a non
- conductor. Never add water to acid; a violent and potentially dangerous exothermic
reaction will take place.
Ø Make sure charging plugs and receptacles are properly locked. A loose connection
may cause sparking and possible explosion.
Ø Do not wear metallic jewellery while handling batteries. It may cause burns or shocks.
Charging.
Ø Ensure battery and charger is properly matched by verifying that the voltage of the
battery matches the voltage of the charger output.

Geophysical
Ø Maintain adequate ventilation in battery room during charging to safely dissipate

hydrogen gas.
Ø Make sure vent caps are functioning and securely in place during charging.
Ø Plug battery into charger and set timer to required hours of charging time.
Ø Give the battery an equalizing charge at least once a month but not more than once a
week. Extend normal charge by 3 to 4 hours at the finishing rate.
Ø Make sure charger is shut off before disengaging charging plugs and receptacles to
prevent arcing and contact damage.
Watering :
Ø Do not add water until after a charge has been completed.
Ø Use only distilled or approved tap water.
Ø Add water only; never add acid.
Ø Do not overfill cells. High level of fully charged battery should never be higher than 1/
4 inch below the bottom of the vent well.
Routine Maintenance:
Ø Maintain a complete record of every battery, including data such as battery model and
serial number, specific gravity of a selected pilot cell (use different pilot cell each time
battery is equalized), and the time and the temperature at both the start and finish of
the charge. Record additions of water and number of charging cycles.
Ø Give new batteries a 4-hour freshening charge before placing them in service. Check
specific gravity and level of electrolyte in all cells after a few days of service.
Ø Do not allow the battery to overdischarge. Continued overdischarging causes extended

recharge time, positive plate wear, shortened battery life, and poor equipment
performance.
Ø Keep cell tops clean and dry by brushing and watering off accumulated dirt with low
pressure water. Keep vent caps tightly in place while cleaning battery top. Apply soda
solution with a clean paint brush, working around the battery top and under connectors
until all ‘fizzing’ stops. Flush completely with low pressure water.
Ø Check battery once a week for pitted connector contacts, loose or leaking cells and
damage compound.
Ø Remove all damaged or shorted batteries from service immediately.

Geophysical
CHAPTER XII
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATION “TRAINING

ACTIVITIES”
Purpose: To impart training and develop competence for all work personnel in camps so as to
enhance their knowledge and skills and to enable them to discharge their assigned responsibilities
effectively.
Scope: The procedure covers the methodology of training and competence building of all the
work persons posted at Geophysical acquisition operations.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist
(Seismologist).
Procedure :
Safety education and training receives great attention in the E & P Industry.A variety of training
courses are conducted by the E&P companies intended to develop the skills and safety
consciousness of employees.
This document attempts to standardize the minimum safety inputs which should be
included in the Functional Training Programs. It is however, recognised that there could be areas
of training other than those identified in this document, where also the need to specify minimum
safety inputs would arise. To that end this document provides a basic framework for development
of suitable training programs.
12.0 Training Techniques:

Ø Appropriate training techniques on the following basis should be selected and
used in order to attain safe operating procedures. The techniques and their
application are given below :
ü Demonstration
The right way to do a job shall invariably be demonstrated to the workmen
in the first place. The right way is also the safe way. Hazards due to wrong
procedures, short cuts and their adverse effects etc. should also be
highlighted.
ü Lecture
This technique should be applied when it is required to transfer information
to an audience with controlled content and time.
12.1 Fire Fighting

Head of Seismic Field Party (Party Manager), Geophysicists, Survey Officers., Shot
firers, Surveyors and Staff posted in field party should be trained for :

Geophysical
ü Use, handling and operation of different types of firefighting equipment.

During training, actual operation should be demonstrated to trainees.
ü Making familiar with likely fire situations and the best means of tackling
them.
ü Duties to be carried out in case of fire.
12.2 Safe Handling of Explosive :

Training for safe storing, transportation and handling of explosives and detonators should be
arranged through Department of Explosives, Govt. of India or any other reputed agency to shot
firers, Party Managers, Geophysicists before assigning the job. Drivers engaged for transportation
of explosives and for operation of vibrators should be trained about hazards associated with
explosives, detonators and vibrators and evoke prompt response in emergency.
12.3 First Aid :

First aid training to be given to staff persons posted in the camp of geophysical parties, shot firers,
geophysicists and surveyors by OIL doctor or reputed agency.
12.4 Fire Drills :

Fire drills should be held before commencement of geophysical operations and thereafter once in
a month. During fire drill every person should carry out his duties as if emergency exists.
12.5 Refresher Course :

Refresher course for shot firers, geophysicist be arranged about the safety measures to be taken
in storing, transportation and handling of explosives once in every three years.
12.6 Briefing to Contractor Labours:
Contractor workers employed for seismic survey jobs should be briefed by their contractor’s
supervisors for a day or two to provide knowledge on the hazard associated with the respective
jobs in seismic survey operation, safe way to perform the job, safe handling of explosives and
detonators, equipment and housekeeping etc. should be imparted to them. Such contractor workers
should be engaged in the jobs for laying out and picking up lines for ground electronics in the field,
handling of explosives and detonators, loading of the same to the shot holes, only after briefing
and satisfactory response from the individual. Company representative should check such briefing
to labourers as and when required.

Geophysical
CHAPTER XllI
SAFETY PROCEDURES IN CARRYING OUT GEOPHYSICAL OPERATION - “DISASTER

MANAGEMENT”
Purpose:
The reporting of accidents / incidents is essential in that it helps in investigations of all accidents
/ incidents and in identifying substandard acts and substandard conditions. The purpose of an
investigation is to establish facts and circumstances, determining causes and assign remedial
actions for prevention of recurrence.
Scope: Operational requirement for all the persons at field camps.
Responsible Officers: Party Manager (PM), Department Safety Officer (DSO), Geophysicist.
Procedure:
The purpose of this “SOP” is to prevent accidents resulting in the loss to human life, property and
environment. Although, all efforts are made to make the present “SOP” comprehensive in all
respects, however, this shall require updation in future to keep pace with fast changing technological
advancements.
Operational safety should be the prime concern for an organization in order to reduce loss of
property, disruption in production and above all loss of life and limb. If any type of accident takes
place during the course of geophysical operation, certain specific procedures are to be followed
to report to the concerned authorities within a very short period of time after the accident so as to
avoid from further complicacies.

Geophysical
PESO

Geophysical
Note : Copies of all correspondence/returns to be sent to GM (F&A) & Head (ER), Head
(Personnel) for assessment of compensation as per Workmen Compensation Act and also to
lodge insurance.
DMS - Director of Mines Safety

PM/IM - Party Manager/Installation Manager

Geophysical

Geophysical
whether

Geophysical
5. Measures taken or envisaged:
(a) to alleviate the effects of the accident/ occurrence

(i) Short term
(ii) medium or long term
(b) to prevent recurrence of similar

accident/ occurrence
6. Any other relevant information ...................
Particulars in respect of every person

Killed or injured in form -IV B are
Enclosed/ shall be forwarded within a week.
Yours faithfully,
Signature ........................................
Designation/ Owner/ Agent/ Manager
Date ................................
INSTRUCTION:
(**) Under one or other of the following heads namely
1. ( a) Explosion or ignition of inflammable gas or liquid
( b) Blow-out
(c) Out break of fire
2. Hazardous emission of petroleum

3. In drilling/ work over rig
4. Suffocation by gases
5. Explosives
6. Machinery
7. Electricity
8. Miscellaneous
Attach Separate sheet where necessary.

Geophysical
FORM - IV B
(See regulation 7)
(To be given separately in respect of every killed or injured in an accident in the mine)
1. General
)
i Name of Mine : ____________________________________________________
i) Owner : _____________________________________________________
iii) District : _____________________________________________________
iv) State : _____________________________________________________
2. Name of Injured worker :
3. Time of Accident :
)
i Date ___________________ ii) Time _____________________________
iii) Shift ________________________________________________________
iv) Number of shifts worked per day at the mine
v) Time when the workers began works on the dayb of thr accident
4. Occupation and experience of the worker :

)
i State the nature of job he was doing at the time of accident.
___________________________________________________________
___________________________________________________________
___________________________________________________________
i) W as it his regular occupation ___________________________________
___________________________________________________________
a) If‘Yes’ state the length of experience at the occupation

at your mine _________________________________________________
Previous experience, if any : _____________________________________
___________________________________________________________
b) If ‘No’, state howlong employed at this job : ________________________
___________________________________________________________

i) State total experience in mining : ______________________________________
iii) Given details of experience in mining work : _____________________________

_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
5. Place of accident : _________________________________________________

6. Name of injured :
)
i State whether fracture, amputation, laceration, bruise, sprain, crushing injury
or other (to be specified) : ______________________________________
i) Put of body inured (to be specified preusely)
7. Degree of disability :
)
i If fatal, date and time of expiry :
i) If permanent disablement, specify :
a) The part or parts of the body lost, if any : ____________________
b) The part or parts of the body gone out of use : _______________
c) Whether disablement, state number of days forced to
remain idle : __________________________________________
8. Responsibility for the accident : _______________________________________

)
i W as any safety provision (s) contravened ? _______________________
i) If so, by whom ? _____________________________________________
iii) What action was taken against the offender ? ______________________
iv) Could the accident have been avoided ? __________________________
v) If so, how ? _________________________________________________
Signature______________________
Date : ________________________
FORM - IV C
( See Regulation - 7)
Particulars of Injured person returned to duty)
(To be given separately in respect of every person within 15 days of his return to duty)
1. General :
)
i Name of Mine : ____________________________________________________
i) Owner : ____________________________________________________
iii) District : ____________________________________________________
iv) State : ____________________________________________________
2. Date of accident : ______________________________________________
3. Name of injured worker : _______________________________________________
4. Return to Duty :
)
i Date when returned to work : ___________________________________________
i) Whether returned to regular job or some other job
(To be specified) _______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
_______________________________________________
5. Compensation :
State amount of compensation paid or to be paid
If any : __________________________________________________________
__________________________________________________________
Signature______________________
Date : ________________________
CHAPTER XIV
SAFETY PROCEDURE IN CARRYING OUT GEOPHYSICAL OPERATION - “SAFETY

& ENVIRONMENT”
Purpose : This procedure deals with identification, evaluation, an review of safety environmental
aspects and their impacts and assigns responsibilities to all individuals and prepare for effective
actions of operational areas.
Scope : Operational requirement for all the persons at field camps.
Responsible Officers: Party Manager (PM), Departmental Safety Officer (DSO), Geophycisist
Procedure :
The kind of materials quality of equipment timely inspection and appropriate repair/maintenance
plays a major role in safety management. However, the human factor plays the most vital role as
most of the accidents are caused due to human failure.
14.0 Keys to Safety
Safe and healthy working conditions.
Safe and proper equipment handling.
Safe use, storage & transportation of explosives/detonators to the work site.
Safe operating procedures.
Proper training
Company-wise commitment to safety.
Periodic safety audits.
14.1 Safety Programs
To conduct a safety meeting with all crew members fortnightly.
Periodic training on safety aspects.
To assess the difficulty in implementation of these programs and its suggestions.
14.2 Environmental Safety
Compulsory filling of shot holes after blasting.
No blasting close to ponds, lakes or rivers to protect the inhabitants.
Minimum cleanliness of under growth while surveying in the forest.
Obtaining all the permissions granted for operations from Local, State and Central
Government authorities.
CHAPTER XV
ANNEXURE
Drilling & Workover
OIL INDIA LIMITED
Volume - I
Section - 3
DRILLING & WORKOVER

ACTIVITIES

Drilling & Workover
DRILLING & WORKOVER ACTIVITIES

CONTENTS
1.1 General.......................................................................................................... 1
1.2 RigBuilding.................................................................................................... 1
1.3 Stackingoftubulars....................................................................................... 6
1.4 PPE............................................................................................................... 6
1.5 Guards/Covers.............................................................................................. 6
1.6 Platform......................................................................................................... 7
1.7 Welding......................................................................................................... 7
1.8 PrecautionsDuringWelding&Cutting........................................................... 7
1.9 EED............................................................................................................... 8
2.0 DrillingEquipment......................................................................................... 8
3.0 Blow-outControlEquipment.......................................................................... 15
4.0 DrillingOperations......................................................................................... 26
5.0 Wellcompletion............................................................................................. 29
6.0 Activationofwells.......................................................................................... 32
7.0 Testingofwells.............................................................................................. 33
8.0 Workoveroperation....................................................................................... 34
Appendix - A :SafetyInspection.......................................... 37
- B : Pre-spud Safety Audit check list .................. 41
- C : Safety Audit in work over wells ..................... 45
- D :ListofRecords............................................. 49
- E : Check list for Rig up/down ........................... 50
- F : Safety guide lines for cluster wells .............. 52
- G : Precaution during repair job ........................ 56
- H :Abbreviation................................................. 57
- I :QuickReference......................................... 58
- J : Best Practice Guide to Handling Tubulars... 61

Drilling & Workover
1.0 DRILLING
1.1 GENERAL
The prime purpose of oil well drilling is to make a hole up to oil/gas bearing
zone where from oil or gas is extracted. Other purpose of drilling may be
to construct water disposal wells or water injection wells. Rotary drilling is
the most common method used for this purpose.
1.2 RIG BUILDING
Before drilling, the derrick is constructed / mast is assembled for drilling.
The work is strenuous, particularly in rugged climatic conditions. Many
Oilfield installations are situated in places like tea garden, paddy field,
forest areas etc.
Rig building operations involve risks associated with working at height

and mechanical movement/lifting of heavy loads, danger of falling from
height, handling of tools in awkward positions and the possibility of dropping
tools and components on to ground where people may get hurt.
1.2.1 DERRICK AND MAST
(i) Every derrick or mast should be of sound construction and

adequate strength, be maintained in safe working order and should
be adequately secured to prevent it from overturning because of
wind velocity.
(ii) All bolt connections of derrick or mast should have lock nuts or
split pins and spring washers. Derrick/mast of bolted type should
be inspected at least once in a fortnight by the Rig Building crew
and they should particularly see whether the bolts are properly
tightened and lock nuts or split pins and spring washers are secured
in position. Similar checks on pin type derrick/mast should be made
as stated above. NDT of derrick & mast and substructure has to
be carried out with a frequency of 3-5 years. NDT should also be
carried out immediately after any untoward incident happens in
the derrick/mast that might affect its strength
(iii) Check lists for inspection of drilling rigs and other associated
equipment are given in Appendices A & B.
(iv) The recommendations listed below should serve as a guide for
minimizing hazards during rigging up and dismantling operations
of mast.
1.2.2 HAZARDS DURING ERECTION / DISMANTLING OF DERRICK AND

RAISING / LOWERING OF MAST
Safety precautions are needed to be practiced during assembling / dismantling

of mast/derrick because of the following reasons mainly.
(i) Rigging operation involve use of heavy earth moving machines.

These machines can cause accident which may sometimes be

Drilling & Workover
fatal to persons as well as heavy losses to costly properties.

(ii) In Rig up & Rig down operations, it often involves working at
height and therefore there is always danger of falling from a
height.
(iii) It also involves handling of tools in awkward position and possibility
of dropping tools and components on to workers on the ground.
(iv) Mechanical movement / lifting of heavy loads always carry danger
of fatal accident of men & machines.
(v) The carriage, handling and storing of bulky objects always involve
risks of injuries to hands, feet and back.
(vi) Rigging works require welding and cutting operations. Gas cutting
and welding can cause fires in oil field installation. Flame cutting
operations, especially when carried out at a height, result in
scattering of molten metal over a large area which can lead to
ignition of waste materials. Handling of oxygen and acetylene
gas cylinders always involves risks of fatal accident.
1.2.3 SAFETY MEASURES TAKEN DURING RIGGING OPERATIONS:
Personal Protective Equipment (PPE)
(i) All operating personnel should wear safety helmet, hand gloves,
safety boots and whenever required goggles and ear muffs during
rig building operations.
(ii) Non metallic helmets give protection from impact, falling objects
and to some extent burns and electric shock.
(iii) Hand gloves should be short and tight fitted
(iv) Safety shoes with hard toes and non-slipping soles should be
used.
(v) Wearing clothes should not be loose. It should be kept clean.
Oily clothes irritate the skin and are a fuel hazard.
Hand Tools:
(i) Only right and appropriate tools should be used which help reduce
accident. If someone is working at a height with hand tools, no
one should be allowed to work below.
(ii) Wrenches should never be tampered upon unless it is specially
designed for the same.
(iii) It requires skill to use a sledge hammer wrenches: should always
be pulled towards the open jaw side.
(iv) Never carry hand tools up/down the mast /derrick by hand. Tools
along with components including nuts, bolts and cleats should be
lowered safely or carried upward in single bundled or in bags/
containers. Also, while dismantling the rig; the well head should
be protected against damage from falling objects.
Safety Belts:
The danger of falling during work at heights makes it essential for safety
belts to be worn by persons during rigging up / dismantling. Every person

Drilling & Workover
who works above the first girt of a derrick should use approved type of
safety belt. It should be attached by means of a lifeline to a fixed anchor
and adjusted to allow a drop not exceeding 1.8 meters in case of a fall. The
safety belts should be tightened to fit the person as comfortably as possible.
The lifelines should be secured to some part of the derrick in a way that will
permit the worker to move as required but have no excess slack.
1.2.4 SAFETY PRECAUTIONS DURING ERECTION/DISMANTLING OF DERRICK
Heavy-duty winch (Tugger hoist) is mainly used for dismantling/erection of

derrick. In erection / dismantling of substructure, only transport crane service
is required. The following guidelines are to be followed during rigging
operations of derrick.
(i) Tugger hoist operator must be experienced and conversant with

rigging operation because during erection and dismantling of
derrick, precision handling and placement of heavy loads are
required
(ii) Before erection/dismantling, the tugger hoist operator must check
the condition of engine clutch & brake of heavy-duty winch.
(iii) Tugger-hoist operator must ensure that the heavy-duty winch
should not be loaded in excess of the recommended safe working
load.
(iv) Condition of guy lines and tugger hoist winch lines should be
checked before starting erection/dismantling of derrick
(v) Guy lines should be used and anchored properly as per
recommendations of the manufacturer.
(vi) All bolt connections of derrick should be properly tightened and
lock nuts and spring washers are secured in position.
(vii) While working, one should position one self in such a way that
he does not lose balance if a tight joint suddenly loosens or the
wrench slips.
(viii) Guy post for anchoring guy lines should be inserted at least 5
feet below ground level and grouted.
(ix) While raising / lowering of gin poles, crew (Top man) should take
position opposite to the resting of gin poles.
(x) In derrick rigging operation, signal plays a very vital role. Signaling
person should be an experienced one and he should take such a
position that both Tugger hoist operator and crew working on
derrick are visible to him. Operator and crew should follow his
signal only.
1.2.5 PRECAUTIONS TAKEN DURING ASSEMBLING/DISMANTLING OF MAST
In this operation people have to work at height more than 3 m from the
ground. Following precautions should be taken during above operation.
(i) People working at top must use safety belt.

(ii) People on the ground should not stand below the area where
mast part is joined together, since there are chances of heavy
pins falling from the top.

Drilling & Workover
(iii) Mast pins should be handled very carefully since these are very
heavy.
(iv) The sling should not be opened up until all the pins of the part are
properly inserted.
(v) While opening up the sling at top from a member, care should be
exercised that safety belt is properly tied with a fixed member.
(vi) Hand should never be kept in between two members when they
are joined.
(vii) Supervisor or one responsible senior crew only should signal the
crane operator. He is the link man between the crew and the
crane operator.
(viii) While the mast is rested on stand, care should be taken that
both legs of the mast rest equally on the stand.
(ix) No loose pin should be kept at the top of a member, which may
fall down due to vibration.
1.2.6 PRECAUTIONS TAKEN DURING RAISING AND LOWERING OF MAST
(i) As draw works is the main rigging equipment, before starting

operations, it should be checked to ensure that it is safe and of
adequate capacity. Rigging equipment should not be loaded in
excess of the recommended safe working load. Also it should be
ensured that air pressure is adequate (120 psi) and flow of water
to draw works for brake cooling purposes is continuous.
(ii) Brake flanges, bands and linings of draw works should be
inspected to ensure that they have not worn out excessively.
(iii) Draw works & rotary shafts should not have exposed key way
or keys that could catch clothing.
(iv) Draw-works rotary gears and chain drives should be enclosed
by well-constructed metal guards.
(v) Always ensure E.C. brakes / disc brakes are working during raising/
lowering of mast.
(vi) The conditions of mast bull lines and casing lines should be visually
inspected prior to raising/lowering of mast.
(vii) All sheaves should be checked before raising/lowering of mast
whether they are free and lubricated.
(viii) It must be ensured that all pins connecting the mast members
are fitted with safety pins.
(ix) Ensure whether weight indicator is installed and in working
conditions prior to rigging operation.
(x) All flowing wells of immediate vicinity are to be closed prior to
starting draw works till the end of the raising/lowering operations.
(xi) Well heads/X-mass trees are to be properly caged with sandbags
and with an iron cage (top cover) prior to raising and lowering of
mast.
(xii) Before lowering/raising mast, persons not connected directly with
the job should move away from the substructure region to a
safe distance, being equal to the height of derrick plus 10 m
(xiii) Before raising the mast, all loose materials / tools must be

Drilling & Workover
removed.
(xiv) No one should be permitted under the mast or on it during raising/
lowering of mast.
(xv) Lifting or lowering of mast should be done smoothly at the lowest
speed possible. The mast should first be lifted by about 30 cm
off the saddle and the condition at the foundation should be
watched for some time for development of any crack on
foundation or sinking of the foundation itself. The mast should
be lifted only there after if condition is found to be safe.
(xvi) In rigging operations, many jobs are done simultaneously with
many persons involved. So proper co-ordination and supervision
is required
(xvii) A Tool Box meeting should be organized for the operating people
to understand the entire job and their role in it. This will minimize
likely occurrence of any untoward incident
1.2.7 SLING
When using wire rope slings for lifting and moving of heavy loads, the
following precautions should be taken:
(i) The diameter of the wire rope used in slings should not be less
than its nominal diameter.
(ii) The wire rope should be free of kinks, cutting and should be of
adequate strength.
(iii) Wire rope loops should be fastened with required number of “U”
clamps. The following is recommended practice to make
fastening having approximately 80% of wire rope tensile strength.
Dia of rope Minimum number of clamps

1/7” : 3
5/6” : 3
3/4” : 4
7/5” : 4
1” : 4
1.1/8” : 5
The correct way to apply clamps to the rope is for the saddle of the clamp to
rest against the long or main rope and ‘U’ bolt upon the short end. All clamps
should face the same way equally spaced and of a size to fit the rope.
(i) The ‘U’ clamps should be checked and tightened immediately

before lifting of heavy loads.
(ii) All eye-splices should be provided with proper size thimble. Spliced
slings should be strengthened with at least one clamp.
(iii) When lifting sharp edged load, suitable padding should be inserted
between the sling and the sharp edges of the load.
(iv) Capacity of a sling should be carefully considered before lifting
any load with it.

Drilling & Workover
1.3 STACKING OF TUBULARS AT WELL SITE
The way drill pipes and casings are stored is important from point of view of
safety; they are placed in stacks and unless properly held in position by
strong wedge, it may lead to serious accident. The following precautions are
recommended:
(i) Tubular should not be laid directly on ground. Wooden planks

with proper end supports should be laid on ground where tubular
are to be stored.
(ii) Tubular with diameter not exceeding 300 mm should be stacked
up to a height not exceeding 3 m. The stack of tubular exceeding
300 mm in diameter should be built in the form of a pyramid up
to a height of 3 m only.
(iii) While storing tubular with couplings and tool joints, at least three
wooden planks/or damaged casing line should be placed across
each row of tubular and it should be ensured that weight of
upper row of tubular does not affect the couplings of tubular in
the lower row. Stacks should be so built that all couplings are at
one end and all pins on the other to avoid damage.
(iv) Passageway should be kept clear to provide for free and safe
movement of material, handling equipment or person. Persons
should not be allowed to move between pipe racks and the load
of pipe during loading, unloading and transferring operations.
1.4 PERSONAL PROTECTIVE EQUIPMENT (PPE)
All persons involved in rig building or rig dismantling job must wear appropriate
PPE.
SAFETY BELTS
The danger prevailing during work at heights makes it essential for safety
belts to be worn by persons during rigging up or rig dismantling or any
operations that involved risk of falling from a height.
(i) Every person who is exposed to the hazard of falling from heights,
should be provided with an approved type of safety belt, which
should be attached by means of a lifeline to a fixed anchor and
adjusted to allow a drop of not exceeding 1.8 m in case of a fall.
(ii) The safety belt should be tightened to fit the person as comfortable
as possible. The lifeline should be secured to some part of the
derrick in a way that will permit the worker to move as required
but have no excess slack.
1.5 GUARDS AND COVERS
i. During rigging up job it may not always be possible to provide

complete guarding but as soon as possible the guards should be

Drilling & Workover
placed. Open floor holes must be covered, even if only temporarily

to reduce the risk of accident.
ii. Machinery should be guarded as much possible considering the
function of the machine.
1.6 PLATFORM
Where work is to be carried out at height exceeding 1.8 m e.g. for installation
of rotary hose, BOP, wellheads, riser etc, a portable working platform with
non-skid surface and handrails should be used.
1.7 WELDING
Rigging work requires welding and oxy-acetylene cutting operations whose

occupational hazards are well known. Adequate care must be taken as per
standing regulations stated in OMR, 1984.
1.8 PRECAUTIONS DURING WELDING AND CUTTING
(i) The Manager / Installation Manager should only authorize welders

with adequate professional competence and qualification in writing
to carry out welding or cutting work.
(ii) The Manager / Installation Manager should issue a hot work
permit in prescribed form to the welder. The permit should be in
the form prescribed under regulations 69(2) of the Oil Mines
Regulations 1984. The precautions to be observed and the
procedure to be followed during welding or cutting work should
be specified in the permit.
(iii) No welding or cutting work should be undertaken in any
hazardous area unless the area is found free from gas. Such
examination should also be made at frequent intervals during
the time welding/cutting work is in progress to ensure that the
area is kept gas free. If during any such test, the gas percentage
in the atmosphere exceeds 20% of Lower Explosive Limit (LEL),
all welding/cutting work should immediately be stopped and the
work should not be restarted till the area is made gas free.
(iv) In the immediate vicinity of the place where welding or cutting
work is in progress, a warning sing “DANGER-WELDING IN
PROGRESS” should be prominently displayed.
(v) Fire fighting equipment: Hand portable fire extinguisher of foam
and dry chemical powder type should be kept readily available
for immediate use. The welder & his co-worker should be familiar
with the operations of fire extinguishers.
(vi) Welders should wear fire resistant gloves, aprons, helmets &
goggles with suitable filter lenses. When toxic fumes are likely to
be produced, the welder should be provided with suitable
breathing apparatus. It should be ensured that the welder is
adequately trained in the use of breathing apparatus. Where

Drilling & Workover
persons are likely to be exposed to harmful radiation or heat

rays from electric arc welding, they should be protected by
suitable screens.
(vii) All flammable material like oil, grease, oil soaked earth should
be removed from the area. No smoking or open flame or any
other source capable of igniting flammable vapor should be
permitted within 15 m of place of work.
(viii) No smoking or open flames or any other source capable of
igniting flammable vapor should be permitted within 15 m of
place of work.
(ix) A person should be specially deputed to keep a watch and prevent
likely fires to be initiated by sparks, slag or molten metal.
(x) Gas cylinders should be secured in up right position and kept
away from any external source of heat
(xi) Gas cylinders should be handled strictly in accordance with
manufacture’s instructions.
1.9 EMERGENCY ESCAPE DEVICE (EED)
Every derrick should be provided with an escape line and a slide so that a
person working at thribble board can come down safely in case of an
emergency. An escape should be fastened to the girt just above the board
level and should be anchored to the ground at a distance not less than 45 m
from the derrick base. The slide and line should be of adequate strength and
have a suitable fail safe braking device. The emergency escape device should
be installed & tested before the persons start working at thribble board.
2.0 DRILLING EQUIPMENT
2.1 DRAW WORKS
(i) The draw-works on a rotary drilling rig serves either to lift pipe
or casing out of the well bore or lower into it. It imparts rotation
to tubular through rotary table and Kelly bushing. It is important
that the draw-works controls are designed installed and
maintained in such a manner as to provide a driller at his control
panel complete visibility, rapid control of hoisting operations and
adequate protection against moving equipment.
(ii) The drum shifts and keys of the draw-works should be provided
with suitable guards.
(iii) At the driller’s control panel a suitable device (inertia brake) should
be provided to stop the draw-works instantly in case of an
emergency. It should have the provision of controlling rig engines
(engine kill) and mud pump.
(iv) The draw-works should be stopped for oiling and greasing, unless
external greasing nipples are available for lubrication.
(v) The draw-works, particularly its brakes, linkage and brake rims
should invariably be examined at regular intervals i.e. once at-
least in every 24 hours. If any defect is detected, the draw works

Drilling & Workover
shall not be used until such defect is remedied. The draw works
shall be provided with twin stop device to prevent hitting of the
crown as well as crash on the derrick floor by the traveling block.
The twin stop device should be adjusted on movement of casing
line. It should be tested for its functioning daily.
2.2 ROTARY TABLE
(i) The rotary table operating through drive bushings rotates the
Kelly and through it the drill string and the bit.
(ii) The rotary table gear, driving chains and sprockets should be
securely guarded.
(iii) Rotary brake should be checked before applying rotation
(iv) The driller should not engage the rotary clutch without watching
the rotary table. He must satisfy himself that the persons are at
a safe distance from the moving parts. The lock of the rotary
table should not be used to arrest its motion.
(v) No one should step in to a moving rotary table
2.3 CROWN BLOCK
(i) Crown block assemblies should be securely bolted, where such

provision exists to prevent the sheaves from jumping out of
bearing. The sheaves should be provided with metal guards; the
clearance between the sheaves and its guard should be more
than half the diameter of the rope so as to prevent the wire rope
from jumping out of sheaves.
(ii) The crown block assembly should be greased regularly. It should
not be lubricated while in motion.
2.4 TRAVELLING BLOCK/HOOK
(i) The traveling block sheaves should be provided with suitable

guards and fingers so that casing line does not overlap.
(ii) When any load is attached to the traveling block, it should not
be left unattended. When not in use, the traveling block should
be kept, as near as possible to the rotary table and the brake
lever of the draw works should be securely locked to prevent
any inadvertent movement of the traveling block.
(iii) Every drilling hook should be equipped with locking device, which
will prevent the load from being accidentally disconnected or
rotated from the hook. The hook should be securely guarded
during the round trip. Elevator links should be securely latched
with the hook by lock nuts or suitable pins.
2.5 KELLY
(i) The kelly should be provided with kelly cocks at its upper and
lower ends. kelly cocks are valves installed between swivel and

Drilling & Workover
kelly and also between kelly and drill pipes to control pressure,
should a high pressure back flow of fluid occur, thus keeping
the pressure off the swivel and rotary hose. The rating of kelly
cocks should be greater than the expected bottom hole
pressure in the well being drilled. The kelly cocks should be
pressure tested before installation. Kelly cocks operating handles
should be made handy on the rig floor.
(ii) The kelly should not be lifted from its rat hole until the swivel
bail is securely latched to the hook. The rat hole casing should
be about 50 cm above the derrick floor.
(iii) The upper left-hand threads of kelly should be checked at regular
intervals.
(iv) Any repairs to the swivel gooseneck or rotary hose should
preferably be done when the kelly is in the rat hole.
2.6 ROTARY HOSE
(i) The ends of rotary hose should be fitted with safety chains or
steel wire ropes to provide additional support in the event of
failure in normal connection. The top end of the hose should be
secured with the derrick/mast by a wire line or chain at least
½” thick. Swivel end of the hose should be secured with a
similar wire line or chain fastened to the body of the swivel. In
no case should the chain be fastened to the swivel gooseneck
because the gooseneck may break.
(ii) While circulating mud at high pressure, the drilling crew should
remain at a safe distance from the rotary hose.
2.7 TONGS
In drilling rigs, the tongs used for making-up or breaking-out of tubular causes
some of the most serious accidents due to high torque development. While
making up, the pipe is initially spinned by means of a manila rope operated
form the cathead, a process that entails risk for fingers and hands. Joints are
finally tightened by tongs. The tongs can be used singly or in pairs, in which
case they are placed opposite each other. The work consists in positioning
the jaws of the tongs around the tools joint of the pipe ensuring that they
are properly fastened to avoid slipping when the pull is exerted and in checking
the pull on the tongs themselves. It is most important for the person to be in
the right position when carrying out these operations, since he runs a risk of
serious injury.
The danger lies either in the slipping or opening of the jaws of the tongs
when the rope is pulled or in a sudden jerk caused by the violent release of
energy stored up by the elasticity of the component to be coupled or
uncoupled. Safety ropes controlling the movement of the tongs, limit the
extent of danger. If the ropes part, extremely serious back or chest injuries
could result.
(i) Make up and break out tongs with proper sizes of jaws should

Drilling & Workover
be used in pairs for tightening and breaking of pipe joints.

(ii) Tongs should be fitted with safety jerk line of sufficient length
to gain maximum benefit of pull from the break out cathead,
but should be enough to prevent complete rotation of the
tongs. At times the tongs fail to release the pipe and unless
held in check by the safety line, it rotates with the pipe, in that
event the drilling crew may be caught in the area of swing of
the tong and sustain serious injuries.
(iii) The ends of tongs safety line should be secured with at least
three wire line clamps.
(iv) Tong line pull gauges should be used to impart optimum torque
during making up and breaking off of pipe joints. If optimum
known torque is used for making up, it will be easier to break
off the joints. There will be no situation of applying excessive
torque causing any untoward incident.
(v) Tong counter balance weight and lines should be adequately
guarded to prevent accidental contact.
(vi) The tong latches should be kept clean and lubricated; its dies
should be checked for wear. If tong dies are worn out, they
should be immediately replaced.
(vii) Welded tongs must not be used.
(viii) The back-up tongs should be tied either to the Derrick Corner
clamp (in case of diesel rig) or to anchor posts attached to it.
It should not be tied to the derrick leg. If at all it is required to
do so, then corners of derrick leg should be guarded with half
round pipe so that snub line does not come in contact with
sharp edges.
(ix) At start of the shift, tong dies should be checked and replaced
if any. Eye protection glass should be used during hammering
out the worn dies or eyes should be kept away from the tong
dies.
2.8 ELEVATORS
Elevators should be securely latched on to the pipes, as otherwise the tubular

string may drop in hole causing serous injuries to the drilling crew working at
the rig floor.
(i) When latching an elevator in motion, the rig men should place
their hands around the pipe only after the elevator has been
brought to a complete stop, as otherwise it may result in
injury to the hands.
(ii) When latching an elevator to a joint of pipe or casing lying in
the “Vee” door, the rig man should ensure that the elevator
door is on the upper side of the pipe and it is securely latched
on to the pipe or casing.
2.9 HAND SLIPS
(i) Slips should be greased on its tapered side to facilitate its

removal since a stuck slip handle can cause injury to hands or
fingers.

Drilling & Workover
(ii) Slip handle hinges should be lubricated to keep them working

at ease
(iii) To hold the slip, the palms of the hands should be faced towards
the drill pipes because if the slips are held with the back of the
hands toward the pipe, and hands are caught by chance in
the slips and drawn into place by weight of the pipe, it would
be extremely difficult to release the hand free.
(iv) Slip of correct size should only be used. In no case welded
slips should be put into operation.
2.10 SPINNING ROPE
Spinning rope is mostly used to screw in drill pipes. One end of the rope is
pulled through the cat-head and the other end is wrapped around the pipe
and released by hand slowly. In the process, the risks involved for accident
are the fingers and hands. The recommendations listed below should provide
guidance on use of ropes.
(i) Hand gloves must always be used and changed from time to
time when it swells due to contact with mud, water etc.
(ii) Swelled up ropes should not be used.
(iii) Adequate turn around the pipe should be given for easy
operation.
(iv) One has to be careful when the pipe does not spin easily. This
might be caused due to cross threading. The rope snaps due
to high pull/tension that might cause accident.
(v) During use of spinning rope a responsible person must be in
the control panel who can stop the rotation of draw-works
instantly in case of any emergency.
2.11 CAT-HEAD AND CAT-LINE
(i) Cathead operated manually should be provided with a rope

guide divider to ensure separation of the each wrap of catline
manila from subsequent wraps. Catheads should have
reasonably smooth surface.
(ii) When a cat-head is in use, a responsible person (Shift Drilling

Engineer or Head man) should remain at the controls, carefully
watching the lifting / pulling operations; a signalman should
assist him. In the event of any emergency, the person in
control should immediately stop the rotation of the cathead
by applying inertia brake. Therefore, inertia brake should be
tested for its effectiveness before using cathead.
(iii) The Cat-line manila rope should be inspected regularly.

Damaged or frayed cat line should not be used for lifting
object.
(iv) The cathead operator should keep his operating area clear

Drilling & Workover
and should ensure that the portion of the cat-line manila not
being used is kept neatly coiled or spooled. The cat-line lock
should be checked intermittently for its effectiveness.
2.12 INSTRUMENTATION IN MUD SYSTEM
Continuous monitoring of condition of mud in the well bore provides

information useful for well control. One of the primary functions of the drilling
fluid is to prevent induction of formation fluid into the well bore. Proper
instrumentation in the mud system helps in determining the condition of the
mud and assessing symptoms for any impending danger. Accordingly,
adequate remedial measures can be taken well in time to keep the well
under control. Driller’s console should have gauges and meters including drillo-
meter, SPM meters, pump pressure gauge, rotary torque. The Record-o-
graph should record parameters like weight, SPM, pump pressure, rotary
torque, rate of penetration etc. Drillers console should be positioned in such
a way that Drilling Engineer can see all the gauges without any obstruction.
The following instruments and equipment are recommended for the drilling
mud system for this purpose.
(i) Mud / pit Volume Totalizer (MVT) should be installed at all the
active and reserve mud tanks to detect tank level’s increase
or decrease with an accuracy of +/- one barrel. It should be
connected with an audio-visual alarm near the driller’s control
panel.
(ii) Flow rate sensor should be installed for monitoring return
mud flow with high / low alarms.
(iii) A trip tank with float marking device to accurately measure
the volume of mud going into the well. This is useful to keep
the well filled with the required quantity of mud at all time.
(iv) A gas detector or explosive meter is installed at the primary
shale shaker and above rotary with an audio-visual alarm at
the driller’s control panel to indicate the presence of gas in
the well. At the driller’s control panel, there should be a control
device to shut the mud pump in case of emergency. Adequate
arrangements should be made to ensure continuous filling of
well with mud, during pulling out operations.
2.13 ENGINES
(i) Internal combustion engines of over 30 HP capacities should

be provided with means other than manual, for starting them.
It should also be provided with a lockout device to ensure
that the external source of power, if started inadvertently
when the engine is under repairs, does not result in any danger
to persons undertaking the repairs. All moving parts of the
engine, which may pose danger to persons working in the
vicinity e.g. the cooling fan, shaft ends, flexible drives etc should
be provided with suitable guards.
(ii) The exhaust system of the engine should be fitted with silencer
and spark arresters to prevent discharge of open flame and

Drilling & Workover
sparks from the exhausts, unless the exhaust gases are

otherwise cooled and conditioned. The engine should be
provided with emergency stop device and an accelerator with
its control at the driller’s control panel, so that the engine can
be stopped and speeded up whenever needed.
(iii) It is necessary to regulate and control noise generating from
engines and maintain the noise levels in ambient air or work
place as per the specified noise quality standards which is 75
dB in day time and 70 dB at night time for industrial area.
Therefore, the engine sound should be kept as low as possible.
If required, asbestos fence may be used to lower the intensity
of the sound.
2.14 MUD PUMPS
(i) The mud pumps provide fluids under high pressure to the
drilling equipment and should be fitted with Safety Relief Valve
(SRV) and pressure gauge. The SRV should be set to discharge
if the pressure exceeds 10% above the set pressure. The
discharge line from SRV should be anchored and piped to a
place (generally over suction tank) where it will not endanger
any persons. No valve should be installed between the pump
and its safety pressure relief valve.
(ii) The pump should also be provided with a bleeder valve, so
that if it is necessary to release pressure in the mud system
during any operation, it could be released through the bleeder
valve. The discharge line from the bleeder valve should be
taken to the suction tank and anchored firmly.
(iii) The high pressure delivery line and pump manifold should be
anchored/grouted properly before operating pump.
(iv) While carrying out maintenance job on any component of the
rig pump or its transmission system, proper isolation of the
source of power should be done. The prime moves should
preferably be shut off if situation permits. Tool Box meeting
should be carried out before the job and a board displaying
“SERVICING OF PUMP IN PROGRESS” should be installed near
by.
2.15 MUD TANKS
The top of the mud suction tanks should be covered with floor gratings to
avoid any untoward accident. All sides of the flooring have to be guarded with
railings. There should be walkways with railings along the mud ditches. It
should be free of mud, dirt etc. to avoid slippage. There should not be any
obstacle on the walkway so that people can move freely. The mud tanks
should be cleaned intermittently to remove solids. These should be cleaned
before rig movement also. Adequate precaution should be taken when any
work is carried out inside the mud storage tanks as it is considered to be a
confined area.

Drilling & Workover
3.0 BLOW-OUT CONTORL EQUIPMENT
In a well, after the surface casing is installed, the blowout prevention equipment
mentioned below should be installed and maintained before resuming drilling.
(i) For 2000 psi BOP stack it is recommended to use one double
or two single ram type preventers - one of which be equipped
with correct size pipe rams and the other with blind or blind/
shear rams.
(ii) For 3000/5000 psi BOP stack it is recommended to use a
stack comprising of, besides annular BOP, one double, or two
single ram type preventers - one of which should be equipped
with correct size pipe rams and the other with blind or blind-
shear rams.
(iii) For 10000 / 15000 / 20000 psi BOP stack it is recommended
to use a stack comprising of, besides annular BOP, three single,
or one double and one single ram type preventers: one of
which be should be equipped with blind or blind-shear rams
and the other two with correct size pipe rams.
(iv) Annular BOP is used for closing the well regardless of the size
of drilling string in the hole. It is advisable not to close the
BOP without any pipe in the hole, as elements of the BOP
may get damaged.
(v) Blind ram BOP is used for closing the well against an open
hole
(vi) Pipe ram BOP is used below the blind ram BOP for closing the
well with the drill string in the hole.
(vii) When the bottom ram preventer is equipped with proper size
side outlets, the kill and choke lines may be connected to the
side outlets of the bottom preventer. In that case the drilling
spool may be dispensed with.
(viii) In spite of the above, a drilling spool may be considered for
the following two advantages: a) Stack outlets at drilling spool
localizes possible erosion in less expensive drilling spool. b) It
allows additional space between preventers to facilitate
stripping, hang off, and / or shear operations.
(ix) In the early stages of drilling, due to shallow depth it is not
possible to install a regular blow out preventer stack because
the casing in the well is not strong enough to withstand high
pressure and the BOP stack together with the casing head
may be thrown off the well if any attempt is made to close
the well. Therefore, when gas is expected at shallow depth, a
diverter should be installed. A diverter can not close a well but
has outlets to divert the high pressure gas which can be flared.
(x) A tubing safety valve and a drill pipe safety valve should be
kept available at the derrick floor. These are full opening valves
with side outlet for circulation, which can be conveniently fitted
on a tubing or drill pipe in case a kick is detected during pulling
out of drill pipe or tubing.
(xi) Another useful equipment is an internal blowout preventer

Drilling & Workover
i.e. drop in check valve. It is a non-return valve, which can be

dropped into the drill pipe and pumped down to the drill bit
where it gets firmly lodged. It should be kept available at the
derrick floor for use in case of emergency
(xii) At the time of installation, the BOP should be fitted with slings
or chains attached to the lugs provided on the BOP, where no
such lugs are provided, slings should be put on the body of
the BOP.
(xiii) When placing the BOP in position, seal ring should be cleaned
and placed on the groove of the casing head. It should then
be secured with at least two diametrically opposite studs and
nuts before the sling is removed;
(xiv) The rams of the BOP must match the diameter of the drill
pipe being used. In deep drilling, pipes of different diameter
are used and since it is not practicable to install BOPs to match
every type of drill pipe. In such cases, one length of pipe of
such diameter as well fit the BOP installed, is pre-tested and
kept readily available at the drill site with suitable change over
substitutes for use in case of emergency.
3.1 Choke Lines and Choke Manifold Installation with Surface BOP
(i) The choke manifold consists of high pressure pipe, fittings,

flanges, valves, and manual and/or hydraulic operated
adjustable chokes. This manifold may bleed off well bore
pressure at a controlled rate or may stop fluid flow from the
well bore completely, as required.
(ii) For working pressure of 3000 psi and above, flanged, welded
or clamped connections should be used on the component
subjected to well pressure.
(iii) Choke line from BOP to choke manifold and bleeding line should
be of minimum 3 inch nominal diameter.
(iv) Down stream of choke line should be taken to mud tanks
through Mud Gas Separator (MGS) or degasser. Another line
from choke manifold should be routed to flare.
(v) The choke manifold should be placed in a readily accessible
location, preferably outside of the rig structure and secured
properly.
(vi) All the choke manifold valves should be full opening and
designed to operate in high pressure gas and drilling fluid
service.
(vii) All the connections and valves in the upstream of choke should
have a working pressure at least equal to the rated working
pressure of ram preventer in use.
(viii) Choke manifold should be pressure tested as per the schedule
as fixed for blowout preventer stack in use.
(ix) Pressure gauges and sensors compatible to drilling fluid should
be installed so that drill pipe and annular pressures may be
accurately monitored and readily observed at the station
where well control operations are to be conducted. These
should be tested / calibrated as per documented schedule.

Drilling & Workover
(x) Preventive maintenance of the choke assembly and controls

should be performed regularly, checking particularly for
corrosion, wear and plugged or damaged lines.
(xi) The following are the recommendations for choke installation
up to 5000 psi WP rating: i) Use two manually operated
adjustable chokes (out of two chokes, use of one remotely
operated choke is optional). Ii) At least one valve should be
installed in upstream of each choke in the manifold.
(xii) The following are the recommendations for choke installation
of 10000 psi WP and above rating: i. One manually operated
adjustable choke and at least one remotely operated choke
should be installed. If prolonged use of this choke is anticipated,
a second remotely operated choke should be used. ii. Two
valves should be installed in upstream of each choke in the
manifold. iii. The remotely operated choke should be equipped
with an emergency backup system such as a manual pump
or nitrogen for use in the event rig air becomes unavailable.
(xiii) A choke & kill manifold, consisting of valves and seamless
steel pipes-one for bleeding off the pressure and one for killing
the well. The design of pipes and valves should be as per the
anticipated pressure. The pipes should be straight and lead to
opposite sides of the drilling rig.
3.2 Kill Lines and Kill Manifold Installation with Surface BOP
(i) The kill line system provides a means of pumping into the
wellbore when the normal method of circulating down through
the Kelly or drill pipe cannot be employed. The kill line connects
the drilling fluid pumps to a side outlet on the BOP stack.
(ii) All lines, valves, check valves and flow fittings should have a
working pressure at least equal to the rated working pressure
of the ram BOPs in use. The equipment should be tested on
installation and periodic operation, inspection; testing and
maintenance should be performed as per the schedule fixed
for the BOP stack in use.
(iii) Line size should be minimum 2 inches nominal diameter.
(iv) Two full bore valves (manual / HCR) should be installed for up
to 3000 psi manifold. Use of check valve is optional.
(v) Two full bore manual valves and a check valve or one full
bore manual and one HCR valve should be used in kill line in
5000 psi and above pressure rating manifold.
3.3 BLOWOUT CONTROL AND PRECAUTIONS
Every drilling operation is a source of potential blowout, which is the worst

accident that can occur in such an operation. Fire and explosion usually
accompany a blowout. The workers are exposed to serious danger to their

Drilling & Workover
lives, burns and poisoning, the heat destroys the derrick and installation. If the
gas gushing out from the well does not catch fire, there is also a risk of
explosion.
Prevention of this danger rests primarily on control of any kick in the well
bore. A kick means entry of formation fluid into the well bore. If the early
signs of a kick in the well are ignored, it may lead to a blowout. It is therefore
essential, that the drilling crew including the chemists and geologists at the
well site are trained so that the warning signs of a kick can be recognized and
known what action must be taken immediately.
3.4 Control System for Surface BOP Stacks
(i) Control systems for BOP stack are typically simple closed
hydraulic control systems consisting of a reservoir for storing
hydraulic fluid, pump equipment for pressurizing the hydraulic
fluid, accumulator banks for storing power fluid, manifolding,
piping and control valves for transmission of control fluid for
the BOP stack functions.
(ii) A suitable control fluid should be selected as the system
operating medium based on the control system operating
requirements, environmental requirements and user
preference.
(iii) Two (primary and secondary) or more pump systems should
be used having independent power sources. Electrical and /
or air (pneumatic) supply for powering pumps should be
available at all times such that the pumps will automatically
start when the system pressure has decreased to
approximately ninety percent of the system working pressure
and automatically stop within plus zero or minus 100 psi of
the system design working pressure.
(iv) With the accumulators isolated, the pump system should be
capable of closing annular BOP on the drill string being used,
open HCR valve on choke line and achieve the operating
pressure level of annular BOP to affect a seal on the annular
space within 2 minutes.
(v) Each pump system should be protected from over
pressurization by a minimum of two devices designed to limit
the pump discharge pressure. One device should limit the pump
discharge pressure so that it will not exceed the design working
pressure of a BOP Control System. The second device
normally a relief valve, should be sized to relieve at a flow
rate of at least equal to the design flow rate of the pump
systems, and should be set to relieve at not more than ten
percent over the design pressure.
(vi) The combined output of all pumps should be capable of charging
the entire accumulator system from pre charge pressure to
the maximum rated control system working pressure within
15 minutes.

Drilling & Workover
(vii) The hydraulic fluid reservoir should have a capacity equal to

at least twice the useable hydraulic fluid capacity of the
accumulator system.
(viii) In the field, the pre charge pressure should be checked and
adjusted to within 100 psi of the recommended pre charge
pressure during installation of the control system and at the
start of drilling each well (interval not to exceed sixty days).
(ix) The BOP control system should have a minimum stored
hydraulic fluid volume, with pumps inoperative, to satisfy the
greater of the following two requirements: a) Close from a
full open position at zero well bore pressure, all of the BOPs in
the BOP stack, plus 50 % reserve. b) The pressure of the
remaining stored accumulator volume after closing all of the
BOPs should exceed the minimum calculated (using the BOP
closing ratio) operating pressure required to close any ram
BOP (excluding the shear rams) at the maximum rated well
bore pressure of the stack.
(x) All rigid or flexible lines between the control system and BOP
stack should be fire resistant including end connections, and
should have a working pressure equal to the design working
pressure of the BOP control system. All control system
interconnect piping, tubing hose, linkages etc. should be
protected from damage from drilling operations, drilling
equipment movement and day to day personnel operations.
(xi) The control unit should be installed in a location away from
the drill floor and easily accessible to the persons during an
emergency.
(xii) A minimum of one remote control panel accessible to the
driller to operate all system functions during drilling operations
should be installed at onshore rigs.
(xiii) All controls (including remote controls) of blowout preventers
should be clearly identified with suitable marks indicating
direction of rotation for closing/opening and number of round
required.
(xiv) Remote control panels should have light indicators to show
open/close/block position of each BOPS and Hydraulically
operated choke and kill valves. For onshore it is optional and
for offshore unit it is must.
3.5 Wellhead, BOP Equipment and Choke & Kill Lines Installation
(i) Wellhead equipment should withstand anticipated surface

pressures and allow for future remedial operations. Wellhead
should be tested on installation.
(ii) Prior to drilling out the casing shoe, the casing should be
pressure tested. Pressure test of all casing strings including
production casing / liner should be done to ensure integrity of
casing.
(iii) When the well head and BOP stack used are of higher working
pressure than the required as per design of the specific well,
the equipment may not be tested to its rated pressure.

Drilling & Workover
(iv) When ram type preventers are installed the side outlets should
be below the rams.
(v) All connections, valves, fittings, piping etc. exposed to well
pressure, should be flanged or clamped or welded and must
have a minimum working pressure equal to the rated working
pressure of the preventers.
(vi) Always install new and clean API ring gaskets. Check for any
damage in the ring as well as grooves before use.
(vii) Correct size bolts/nuts and fittings should be used and
tightened to the recommended torque. All connections should
be pressure tested before drilling is resumed.
(viii) All manually operated valves should be equipped with hand
wheels, and always be kept ready for use.
(ix) Ram type preventers should have locking arrangement manual
or auto lock.
(x) Wellhead side-outlets should not be used for killing purpose,
except in case of emergencies.
(xi) Kill lines should not be used for routine fill up operations.
(xii) All sharp bends in high pressure lines should be of targeted
type.
(xiii) All choke and kill lines should be as straight as practicable and
firmly anchored to prevent excessive whip or vibration. Choke
and Kill manifolds should also be anchored.
(xiv) All control valves of BOP control unit be either in the fully
close or open position as required and should not be left in
block or neutral position during operations.
(xv) Control valve of blind / blind–shear ram should be protected
to avoid unintentional operation from the remote panel.
(xvi) Recommended oil level should be maintained in the control
unit reservoir.
(xvii) Outlets of all sections of well head should have at least one
gate valve.
3.6 TESTING OF BLOW-OUT PREVENTION EQUIPMENT
A. FUNCTION TEST
(i) All operational components of the BOP equipment systems

and diverter (if in use) should be function tested to verify the
components’ intended operations.
(ii) BOP Function test should be performed on each round trip
(though OMR 1984 says at least once daily for ram type
BOP), In case of annular (bag type) preventers, at least once
in seven days on the drill pipe.
(iii) Annular preventer should be tested while string is in hole.
(iv) Blind ram should be operated for function test while string is
out of hole
(v) The test should be preferably conducted when the drill string
is inside casing.
(vi) Both pneumatic and electric pump of accumulator unit should
be turned off after recording initial accumulator pressure.

Drilling & Workover
(vii) All the blow out preventers and hydraulically operated remote
valve (HCR) in choke / kill line should be function tested. Closing
time of rams and opening time of HCR should be recorded
(viii) For surface BOP stack closing time should not exceed 30
seconds for each ram preventers and annular preventers
smaller than 18¾” and 45 seconds for annular preventers of
18¾” and larger size.
(ix) Operating response time for choke and kill valves (either open
or close) should not exceed the minimum observed ram BOP
close response time.
(x) Function test should be carried out alternately from main
control unit / rig floor panel / auxiliary panel.
(xi) Record final accumulator pressures after all the functions. It
should not be less than 1200 psi or 200 psi above the
recommended pre charge pressure of accumulator bottles.
(xii) All the gate valves and blow out preventers should be returned
to their original position before resuming operations.
(xiii) All the results should be recorded in the prescribed format
and mention should be made in DPR
(xiv) During test, if any blowout prevention equipment is found to
be defective, drilling operation should not be resumed until
the defect has been remedied.
B. PRESSURE TESTING OF BOP
(i) All blowout prevention components that may be exposed to

well pressure should be tested first to a low pressure and
then to a high pressure. These include blowout preventer stack,
all choke manifold components, upstream of chokes, kill
manifold / valves, Kelly valves, drill pipe and tubing safety
valves and drilling spools (if in use). Pressure test (both low
and high) on each component should be of minimum 5 minutes
duration, each. All the results should be recorded in the format.
(ii) Test BOP using cup tester or test plug.
(iii) Before pressure testing of BOP stack, choke and kill manifold
should be flushed with clean water.
(iv) Clean water should be used as test fluid. However for high
pressure gas wells, use of inert gas such as N2 (nitrogen) as
test fluid is desirable.
(v) High pressure testing unit with pressure chart recorder be
used for pressure testing.
(vi) Well control equipment should be pressure tested: a. When
installed. b. After setting each casing string. c. Following repairs
that require breaking a pressure connection. d. But not less
than once every 21 days.
(vii) Low pressure test should be carried out at 200-300 psi for 5
minutes on each component
(viii) Once the equipment passes the low pressure test, it should
be tested to high pressure.
(ix) Initial pressure test of blowout preventer stack, manifold,
valves etc. should be carried out at the rated working pressure

Drilling & Workover
of the preventer stack or wellhead whichever is lower. Initial

pressure test is defined as those tests that should be
performed on location before the well is spudded or before
the equipment is put into operational service.
(x) Subsequent high pressure tests should be carried out at a
pressure greater than maximum anticipated surface pressure.
Exception is the annular preventer which should be tested to
70% of its rated pressure or maximum anticipated surface
pressure whichever is lower.
(xi) The pipe used for testing should be of sufficient weight and
grade to safely withstand tensile, yield, collapse, or internal
pressures.
(xii) Precaution should be taken not to expose the casing to
pressures in excess of its rated strength. A means should be
provided to prevent pressure build up on the casing in the
event the test tool leaks (wellhead valve should be kept open
when pressure testing with test plug).
(xiii) Pressure should be applied from the direction in which all the
BOPs, choke and kill manifold, FOSV / Kelly cock etc. would
experience pressure during kick.
3.7 BOP DRILL
BOP drill should be conducted with the aim of preparing the operating personnel
to handle the real kick situation.
(i) BOP drills should be conducted once a week with each crew.
(ii) Drills should be initiated without prior warning during routine
operation.
(iii) Drills should be initiated at unscheduled times when operations
and hole condition permit.
(iv) The reaction time from sounding the alarm to the designated
crew member’s readiness to start the closing procedure should
be recorded and response time should not be more than 60
seconds.
(v) Total time taken to complete the drill (raising alarm to closing
ram) should not be more than 2 minutes.
3.8 CIRCUMSTANCES LEADING TO A KICK IN A WELL BORE
The primary control of a kick is to keep the hydrostatic head of the drilling fluid
greater than the formation pressure. The primary control can be lost in the
following situations.
(i) While tripping, if the hole is not kept full with the required
volume of mud.
(ii) If there is reduction in-hydrostatic pressure in the well due to
swabbing, which may be caused if the drilling string is pulled
out too fast or by a balled up or clogged bit, which is indicated

Drilling & Workover
by insufficient filling of mud.

(iii) If the density of the drilling fluid is not maintained as per
program.
(iv) If there is loss of circulation, which may be caused either due
to running-in too fast, thereby causing the weak horizons of
the well to break or while drilling though a formation with
cracks or cavity.
3.9 DETECTION OF A KICK
A kick generally refers to the entry of formation fluids in to a well bore when
the mud hydrostatic pressure becomes lower than the formation pressure. A
kick can be gas or oil or water. The kick has to be controlled immediately by
using the secondary control (BOPE) and killing methods. If not, the kick will
become uncontrollable and turn in to a blow out. A kick in the well bore can be
detected if the operating people remain alert. The following are the signs or
indications of a kick:
(i) A drilling break i.e. sudden increase in the rate of penetration

(ii) Decrease in pump pressure and increase in pump strokes.
(iii) Increase in flow rate of mud
(iv) Reduction in mud density
(v) Self-flowing of mud i.e. mud flowing out of the well even after
the pump is shut off.
(vi) Gain in volume of mud in the tank.
(vii) Changes in flow line temperature
(viii) Change in the size and shape of drill cuttings in the return
mud; generally larger than normal size of cuttings
(ix) Changes in the properties of mud like reduction in density,
increase in viscosity, change in chloride contents and presence
of gas-cut mud.
(x) Loss of mud, indicated by mud pit level indicator, which may
lead to a kick
(xi) Oil or gas show
3.10 CONTROL OF A KICK
A. When a kick occurs during drilling, the Drilling Engineer is shift should
take the following actions:
a) Stop drilling
b) Lift up Kelly above the rotary table
c) Stop pump
d) Watch the situation carefully
Ø In case there is no flow of mud in the channel, there is no apparent

danger and the operation may be resumed.
Ø In case there is flow of mud in the channel, the following steps
should be taken:

Drilling & Workover
(i) Close BOP. Note the stand pipe shut-in drill pipe/tubing pressure
and the casing shut-in pressure. The excess pressure indicated
by the stand pipe pressure gauge is the extra pressure exerted
by the formation fluid, which is to be over balanced by extra
weight of mud.
(ii) Appropriate measures to kill the kick should then be taken
accordingly. The Drilling-in charge should be informed
immediately about the situation. Information should also be
sent to higher authorities so that the contingency plan can be
implemented.
(iii) A contingency plan for dealing with such situations should be
at well site. The plan should specify the action to be taken
and role of each person employed on the rig and such other
officers as may be needed during the emergency. Regular
BOP drill should be practiced so that persons who are to
perform specific duties under the contingency plan clearly
understand their roles and responsibilities.
(iv) It should be ensured that each person employed on a rig has
adequate understanding of the warning signs of a kick, the
emergency procedure of operation and control of blowout
prevention equipment.
B. When a kick occurs during pulling out or running in pipes/tubing, the

Drilling Engineer in shift should take the following actions:
(i) Attempt to go down the hole as much as possible safely and

connect the Kelly. If it is not possible to go down, even then
connect Kelly. Depending on the depth close BOP and record
shut in drill pipe/tubing pressure and casing pressures.
Alternatively, the drill pipe/tubing safety valve should be fitted
on the drill pipe/tubing with its bore full open. The BOP should
then be closed and thereafter, the safety valve should also be
closed.
(ii) The Drilling-in Charge should be informed immediately;
information should also be sent to higher authorities so that
the contingency plan can be implemented.
(iii) In such a situation, the annulus pressure is expected to
increase and a close watch is to be maintained. Although the
appropriate action is to pump in heavy mud and bleed off
excess pressure from the annulus, these measures should
only be taken under the direct personal supervision of the
Drilling-in-charge.
3.11 PRECAUTIONS BEFORE PULLING OUT
(i) Drilling fluid should be conditioned prior to tripping / pulling

out. This should include: a. No indication of influx of formation
fluids. b. The drilling fluid density in and out should not differ
more than 0.024 gm/cc (1.5 pcf) in open hole. In cased hole
there should not be any difference.
(ii) Trip tank shall be lined up and function tested. Trip sheet should

Drilling & Workover
be made ready.
(iii) Full Opening Safety Valve (FOSV) with matching pipe
connections and size should be available on the rig floor. It
should be kept ready in ‘open’ position for use with operating
wrench. Operating wrench should be kept at a designated
place.
(iv) An inside BOP, drill pipe float valve or drop in check valve
should be available for use whenever tripping is required to be
done.
(v) As far as possible tripping out should be dry. If tripping out is
wet, proper mud box should be used enabling mud to flow
back to the return channel.
3.12 PRECAUTIONS DURING PULLING OUT
(i) Well should be checked for swabbing during pulling out. If

positive, tripping speed may be reduced.
(ii) Trip tank volume should be monitored and same should be
recorded in the trip sheet
(iii) If hole is not taking proper amount of mud (as per trip sheet),
stop tripping and conduct flow check to ensure whether the
well is self-flowing. If positive, shut the well, record the
pressures and circulate out the kick by suitable well control
method. If no self flow is observed, run back to the bottom
and circulate and condition the drilling fluid.
(iv) Flow checks should be carried out: i. Prior to all trips out of
the hole. ii. During first 10 stands. iii. At the casing shoes. iv.
Prior to tripping out of drill collars through BOP stack.
(v) If pulling out is interrupted, safety valve should be installed on
the drill string.
3.13 PRECAUTIONS DURING RUNNING IN
(i) Regular flow checks and monitoring of level in annulus should

be done. Where situation requires trip tank may be used to
monitor drilling fluid loss/gain.
(ii) Circulation should be established at near bottom of the hole
to break gel of mud. This is more important when dealing
with in deep wells and where heavy mud is used.
(iii) With a float valve (BPV) in the string, drill pipe should be filled
up intermittently.
3.14 PRECAUTION AFTER A BLOW OUT HAS OCCURRED
On the appearance of signs indicating that a well is blowing out, all persons
except those who are required in controlling the well should be immediately
withdrawn from the well. During the whole time that any work of controlling a
blowout is in progress, the following precautions should be taken.
(i) An area within 500 meter of the well should be demarcated

Drilling & Workover
as danger zone, all electrical installations within the danger

zone should be de-energized and only approved type of safety
lamps or torches should be used. No smoking, open flame or
vehicular traffic should be permitted within the danger zone.
(ii) The presence of inflammable gas should be determined with
explosive meter at regular intervals so far as safety of persons
is concerned.
(iii) Persons engaged in controlling the well should be provided
with gas masks and temperature resistant clothing.
(iv) Adequate fire fighting equipment should be kept readily
available for use. Water umbrella should immediately be
created.
4.0 DRILLING OPERATIONS
The following precautions are recommended during drilling operations:
(i) The rig floor should be kept free from mud and oil so as to
prevent persons from slipping. Any opening on floor should
be covered. When pulling out pipes, a mud box should be
used to avoid splashing of mud on floor.
(ii) Any plank on rig floor or drill pipe raft found damaged should
be replaced immediately.
(iii) Tools like FOSV (Full Opening Safety Valve), poor-boy swivel,
Kelly-cock, shut-in valve, string BOP, drop-in check valve and
assorted subs etc. should be readily available with operating
handles (if provided for) on the floor and should be kept
properly.
(iv) At the beginning of the shift, the instruments and controls at
the driller’s control panel, draw-works, mud pump, hoisting
line and blowout prevention equipment should be carefully
examined by the Shift Drilling Engineer (SDE) and he should
satisfy himself that these are in good working order.
(v) The derrick ladders should be properly constructed and securely
fastened and should be fee from any obstruction; the steps
should have non-skidding surface.
(vi) Thribble board for racking pipe stands should be securely bolted
to the mast. The pipe racking fingers should be provided with
safety wire line secured to the rack to prevent it from falling
down the derrick in case of failure.
(vii) The top man when working on the thribble board must wear
a safety belt attached to a lifeline. The end of the lifeline should
be secured to the derrick in such a way as to allow free
movement of the top man, but the line should not get
entangled with the monkey board snub line. The snub line
(manila rope) which the top man uses to pull or release pipes
should not be secured to the same girt of the derrick as the
lifeline.
(viii) Shift Drilling Engineer (SDE) should ensure the functioning of
the BOP control unit before/during resuming his duty. He should
ensure that the pressure switch of the unit is working and it is

Drilling & Workover
pressurized up-to the required level.

(ix) He should ensure that all persons at site are using appropriate
PPE and take necessary action, if needed.
(x) He should ensure that all safety measures are taken to prevent
any sort of accident at well site in all working areas.
(xi) First Aid Box is available with all medicines
(xii) Emergency vehicle is at site
(xiii) Fire fighting system is in order
(xiv) Communication system is in order
(xv) Prohibit use of cellular phones
4.1 MANAGEMENT OF COMPLICATIONS DURING DRILLING
The well policy generally provides adequate instructions for carrying out drilling
operations. However, it should be kept in mind that during operation if the
situation so warrants, suitable changes in the drilling program could be made
in consultation with the Geologist and Chemist. In case of any complication,
the Drilling Engineer should take necessary steps to ensure that the situation
does not does not go beyond his control.
During drilling, complications may arise. For example:- fishing, stuck pipe, well
kick, drill pipe failure, casing failure, loss circulation etc. Drilling Engineer should
undergo short orientation program and IWCF well control training so as to
develop the competence and skill to handle such complicated situations.
The following recommendations are made for guidance in complicated
operations:
(i) In case any part of drilling assembly is left in the well, the fish
top should not to be disturbed so that top of fish is not
damaged.
(ii) The pump pressure and string weight must be recorded
correctly for any complications in a well.
(iii) The sketch of bottom hole assembly must be readily available.
(iv) Detailed specification of the tubular, stabs, cross over in the
BHA should be kept in readiness
(v) In case of stuck up, the string must be worked on initially
within 10 tons, unless otherwise instructed by Drilling In Charge.
(vi) Attempts to rotate pipe should be avoided unless instructed
to do so.
(vii) After engaging fish, do not disconnect the pipes by rotating
the rotary table.
(viii) While pulling out through suspected tight zones, use lowest
hoisting speed
(ix) In case of mud loss, effort must be made to top up the well.
In an emergency, even water should be used.
(x) Pumping should be done at low pump speed
(xi) In case of a flowing well, pulling out operations should be
stopped.
(xii) Pulling out with wet pull should be avoided. Mud has to be
conditioned and pulling out may be resumed.
(xiii) In case of backing off, tight pulls and jarring etc, minimum
number of persons required should be present on the derrick

Drilling & Workover
floor and utmost precaution should be taken to avoid any

likely accident
(xiv) On an open well mouth no repair should be carried out.
(xv) While oil spotting, ensure that sufficient hydrostatic head on
the formation is available, unless expert advice is available.
4.2 CASING AND CEMENTING
As drilling progresses, the well is provided with casing of different length and
diameter. The annular space between casing and the wall of the hole is
cemented. Cementing should be done very carefully, as poor cement job
often leads to many problems. The following recommendations provide
guidance in this respect:
(i) Running in casing/cementing should be carried out in

accordance with the drilling program unless otherwise
instructed.
(ii) All casing pipes should be provided with thread protectors
properly made up. Casing should be lowered in the well
smoothly to avoid surge pressure and as far as practicable
jerks should be avoided. Where collar type elevators are used,
these should have even surface to prevent them from jumping
off the couplings due to side lift. Wherever possible slip
elevators and spiders should be used. Every joint of casing
should be drifted with a proper go-gauge prior to running in
casing.
(iii) During running-in, weight of casing and mud return rate should
be monitored continuously. Casing and annulus should be
topped up if needed.
(iv) Casing joints should not be allowed to get cross-threaded
and proper/same torque should be given to all joints.
(v) The person working on stabbing board must use safety belt.
(vi) Care should be taken while lowering the casing to avoid hitting
of the stabbing board.
(vii) Cementing head and line should be tested to 1.5 times the
maximum expected pressure. The cementing line should be
securely fastened. The ends of the cementing line coupled
together should be held with safety chains to prevent them
from flying out in case of accidental disconnection.
(viii) The cementing unit wherever engaged should be provided
with a pressure release safety valve and pressure gauges
should be inspected carefully before deploying it in use.
(ix) It is desirable to carry out cementing operation during day
light hours. In case it is necessary to continue the operation
after sunset, adequate flameproof lifting arrangements should
be provided.
(x) Since cementing job is a time-bound operation, it should be
carefully planned so that the work may proceed without
interruptions. The working area should be kept in tidy condition
and free from any obstruction. No other operation should be
carried out simultaneously at the site, which may interfere

Drilling & Workover
with the cementing job.

(xi) In case of any repair or cleaning of the cementing unit, its
engine should be shut off.
(xii) During cementing if any sign of active well is noticed,
appropriate protective measures should be taken to keep
the well under control.
5.0 WELL COMPLETION
5.1 GENERAL
After drilling is completed, a well is prepared and fitted with control equipment
so that the well can safely produce oil/gas or meet the intended aim The
operation is known as well completion and involves the following activities:
Ø Hermetical testing of casing

Ø Perforation through casing
Ø Activation of well
Ø Well testing, to ascertain the flow of fluids.
5.2 HERMETICAL TESTING OF CASING
(i) The casing head and casing should be pressure tested

separately to the maximum pressure expected in the
formations. The annular space between two conservative
casings should be connected to valves. It should not be
plugged otherwise the casing may be subjected to a pressure
higher than that intended. The valves should be tested to
working pressure.
(ii) X-mas tree assembly should be completed in all respect as
per recommendations of the manufacturer. It should be tested
to a pressure 1.1/2 times the working pressure before
installation.
(iii) Pressure gauges with suitable cocks should be installed for
release of pressure during the test. Every wellhead assembly
should be provided with suitable arrangement for recording
tubing and annulus pressure.
5.3 PERFORATION
Perforation is the process of making holes on the casing with the help of
explosive devices. Perforation of casing is required to establish communication
between the casing and the desired formation. Firing of explosive charges at
appropriate horizon is done with the help of perforating gun. Perforation is
carried out mainly in two conditions:
(i) Through casing i.e. prior to running production tubing

(ii) Through tubing i.e. after running in production tubing and
installation of X-mas tree.
(iii) In the first case perforating gun is lowered in casing full of

Drilling & Workover
desired fluid of proper density. When the formations are to be

perforated through the tubing, a string of explosive capsules,
sealed individually, is lowered down the hole. In this operation,
the hazard is that of blowout if the formation fluid entering
the well bore is not kept under control. Hazards due to use of
explosives and danger of fire also exist.
5.4 TRANSPORT, HANDLING AND USE OF EXPLOSIVES:
(i) Explosives meant for use in well perforation should be stored

in magazines constructed in accordance with the Indian
Explosives Act 1888. Explosive cartridges and detonators
should be kept separately in suitable containers, duly locked
and transported in vehicles duly licensed by the competent
authority.
(ii) Persons authorized for the purpose should only handle
explosives. The persons should undergo an instruction
program in handling and use of explosives, before they are
so authorized.
(iii) Explosives should be primed with detonators only at the well
site, at a place, earlier assigned for the purpose. The place
should be clean, dry and free from flammable materials. It
should also be ensured that there is no danger due to falling
materials.
(iv) Explosives should not be primed under conditions of lightning
and thunder.
(v) The explosives should be suitable for the temperature
condition expected at the bottom of the hole.
5.5 PRECAUTION AGAISNT BLOW-OUT
(i) When perforation is done through casing a double rams i.e. a

set of blind and pipe ram preventer should be installed and
tested to the expected bottom hole pressure. The blowout
preventer should be equipped with remote control.
(ii) In addition, a master gate valve with tubing head and a short
length of tubing should be pre-assembled and kept readily
available at the site. It can be used to control the well in case
any sign of activity in the well is noticed after perforation and
while running in tubing.
(iii) When perforation is being done through the tubing a wire line
blowout preventer should also be installed. In case of a kick,
the well can be closed with the perforation wire line tool in
the hole. Otherwise it may have to be snapped and allowed
to drop in the well, if the wire line tool is not pulled out of the
hole in time. The master gate valve on the X-mas tree can
be operated to close the well.

Drilling & Workover
5.6 PRECAUTION BEFORE COMMENCEMENT OF PERFORATION
(i) The hole is filled with mud or other suitable fluid up to such a
level so as to over-balance the expected bottom hole
pressure.
(ii) The blowout prevention equipment is function tested and is
in safe working order.
(iii) The perforating gun can be safely lowered down the hole.
(iv) In case of through tubing perforation, a lubricator, duly
pressure tested, is installed. It should be provided with a
valve to release pressure before disconnection
(v) The insulation resistance of the electro logging cable is not
less than one mega ohm. After the check, the cable should
be shorted otherwise residual electric charges may detonate
the explosives.
(vi) Every person employed on a perforation job has a clear
understanding of the warning sign of a kick and of the blowout
prevention equipment and is able to operate the controls for
blowout prevention.
(vii) Standing orders are framed specifying the action to be taken
as soon as a kick is detected and of the duties of each person
employed in the perforation job and the instructions are
clearly understood by all concerned for prompt action in case
of emergency.
5.7 GENERAL PRECAUTIONS DURING PERFORATION:
The following recommendations provide guidance for fire and other hazards
during perforation:
(i) Perforation should avoided during night hours or under

conditions of thunder, lightning, high winds and heavy rains.
(ii) At the well site, all operations not directly connected with
perforation should be kept suspended till the perforation job
is satisfactorily completed.
(iii) All equipment including drilling rig used for perforation should
be efficiently earthed and electric bonding should be established
between the equipment and wellhead before connecting
explosive charge.
(iv) Persons not directly connected with perforation job should
remain at a safe distance not less than 30 meters from the
well.
(v) No radio devices/electric generator should be allowed to
operate during arming of the perforation gun or any explosive
devices, such as string shot, SHC, gum, WLPSA etc till the
gun is lowered to a depth of 100 meters.
(vi) Same procedure to be followed before pulling out the gun or
other similar devices out of the hole.
(vii) An area within 30 meters of the well should be demarcated
as danger zone in which no smoking or open fire should be
permitted and all electric installations should be de-energized.

Drilling & Workover
(viii) Effective means of communication between the derrick floor

and perforation unit should be provided Proper trilingual display
board indicting perforation must be displayed at proper places.
(ix) Adequate fittings of flow lines and tanks should be provided
to safely collect the well products before production casing is
perforated.
(x) Adequate number of self contained portable hand lamps of
approved type should be kept available for use in emergency.
(xi) Fire tender should be present at the well site during perforation
(xii) Adequate arrangement for killing the well in case of emergency
must be made.
6.0 ACTIVATION OF WELLS
6.1 GENERAL
After a well is perforated it is activated to induce flow of formation fluids into

the well. This is done by the following method:
(i) Injection of nitrogen gas at high pressure down the annulus.

In the process the hydrostatic head in the well is gradually
reduced by displacing the column of fluids in the well. As the
hydrostatic head is reduced, formation fluids enter the well
bore and initiate flow.
6.2 AIR AND NITROGEN INJECTION
In this operation the main hazards are due to blowout and fire. In case of
compressed air injection, once the well comes in, the compressor is stopped
and annulus pressure is reduced through a bean to induce formation fluid into
the well.
The following precautions are recommended:
A. During the operation, a close watch should be maintained at the pit

or tank for fluids flowing out of the well. If there is any indication of
flow of fluids, the compressor should be stopped and the well should
be allowed to flow through a proper choke to ensure controlled flow
of fluids. If the bean is to be changed, the pressure in the line should
be released through the bleeding valve.
B. The annular pressure should be reduced gradually through a bean

otherwise a large volume of formation fluid may enter the well an
gush out of it.
C. In case of any interruption in injection of compressed air, the well
should be closed immediately.

Drilling & Workover
6.3 PRECAUTION AGAINS FIRE
(i) The compressor should be located at a distance not less than 30

meters from the wellhead on the upwind side.
(ii) An area within 30 meters of the wellhead should be treated as
danger zone in which no smoking or open flam should be permitted
and all electrical equipment should be de-energized.
(iii) Adequate arrangements for fire fighting should be made.
(iv) Adequate number of self-contained portable hand lamp of
approved type should be kept readily for use in case of
emergency.
7.0 TESTING OF WELLS
The final stage of well completion operation is the testing of wells. The purpose
of the test is to ascertain the potential of the perforated horizon to produce
hydrocarbon. In the beginning when a well starts producing oil and gas the
products are led through a bean in the line to a tank but immediately thereafter
portable separators and tanks are connected to the well. Oil and gas are
separated in the separator; the gas is diverted to a flare line and burned. Flow
is then diverted to near by EPS/OCE.
The flow rate of oil is thus measured. The bean regulates and controls the
flow and pressure of fluid from the well.
The main hazard in the operation is due to fire as gas and oil flow from the
well and the following precautions are therefore recommended.
(i) The separator should be located at a distance of not less than

30 meters from the well head.
(ii) Flare should be located at a distance not less than 45 meters
from the well head as well as from the production tank.
(iii) The safety of the separator should be checked to ensure that it
is in a good working order.
(iv) An area within 30 meters of the well should be marked as danger
zone with proper warning signs at prominent places.
(v) In the danger zone, no smoking or open flame should be
permitted; entry of un-authorized persons should be checked
and all electrical equipment should be de-energized.
(vi) Testing of well should be done during daylight hours, since at
night, unburned gases may settle near ground level and cause
danger. Flare should be lighted to burn the gases.
(vii) Adequate fire fighting arrangements should be made. It should
be ensured that persons deployed for well testing are conversant
with the use of fire extinguishers.
(viii) Before the gate valve of the well is opened, all persons should be
withdrawn to safety. The valve should be opened fully; otherwise
it may be damaged due to throttling and may leak thereafter.
(ix) Bleed of line to the tank should be anchored properly.
(x) During production testing all other activities at the well should be

Drilling & Workover
suspended to the extent possible.

(xi) Preheating arrangement should be made in case of testing of
gas well.
(xii) Proper arrangement including connection should be made to kill
the well in case of any eventuality.
(xiii) Fire tender should be present during production testing.
8.0 WORK OVER OPERATION
8.1 GENERAL
The work-over or well servicing means to perform some of remedial

operations on a producing oil well in the hope of restoring and increasing
production. It may have other objectives too. Examples of such operation
are resetting of gas lift valves, plugging back, re-perforation, squeeze
cementing, acidising etc.
The hazards are similar to those in drilling i.e. handling of pipes and rods,
falling objects, mechanical failure of hoisting equipment, fire, blow-out and
danger from inflammable gas and falling from a height.
Most of the safety practices may be followed what have been prescribed for
drilling operation. However, following may be considered for safe operations.
8.2 MAST, RIG FLOOR/WORKING PLATFORM AND HOISTING EQUIPMENT
The safe practices for use of derrick/mast hoisting equipment, tongs, elevators,
slips and catheads are the same as mentioned in respect of deep drilling in
this SOP and those directions should be carefully followed in all workover
operations. EED (Emergency Escape Device) and FPD (Fall Prevention Device),
Twin stop, Engine kill should be installed in the rig for safety.
8.3 PRECAUTIONS AGAISNT BLOWOUT
In workover operations, the possibility of blowout cannot be ruled out, because

the operations are meant to induce flow of formation fluids into the well
bore. Therefore control of well during different phases of operation should
be the major concern for safety.
8.4 EQUIPMENT
(i) A double ram BOP with one set of blind ram and one set of pipe
ram should be mounted on the wellhead.
(ii) A tubing safety valve with connections for circulation of fluid should
be provided. This is a lightweight equipment and can be
conveniently fitted on top of tubing in case of emergency. FOSV
in open condition should be kept readily available with operating
lever in designated place known to all.
(iii) Otherwise, a master gate valve, a tubing hanger with a short
length of tubing, should be pre-assembled and kept readily
available at the derrick.

Drilling & Workover
8.5 BOP DRILL
Every person employed in a work-over rig should have adequate

understanding of a warning sign of a kick, the blowout prevention equipment
and should able to operate the control for blowout presenters. Blowout
prevention drills should be conducted for this purpose once in seven days.
8.6 TESTING OF BOP
The blowout preventers should be tested to full working pressure at the

time of initial installation.
The blowout preventer equipment including pipes ad control vales should be

function tested once every day.
8.7 WELL CONTROL
(i) Every work-over rig should be provided with a recording type

weight indicator, coupled with pressure gauge.
(ii) Before commencement of work-over operation, the well should
be kept full of workover fluid of adequate density so as to over
balance the bottom hole pressure. After pulling out every five
stands the hole should be filled to over-balance the bottom hole
pressure.
(iii) While running in or pulling out tubing, the crew must maintain a
close watch for any sign of kick in the well. As soon as any sign
of activity in the well is noticed, the tubing safety valve/FOSV
should be mounted on the tubing. The blowout preventer should
be closed and thereafter the tubing safety valve/FOSV should
also be closed to control the well.
8.8 PRECAUTIONS AGAINST FIRE
In work-over operations, gas is released from the well and fire may take
place unless the sources of ignition are carefully controlled.
The following recommendations should be observed:
(i) An area within 30 meters of the well should be treated as danger

zone and no smoking or open flame should be permitted and all
electrical equipment should be de-energized within the danger
zone in case of emergency.
(ii) Adequate arrangements for fire fighting should be provided. It
should be ensured that persons engaged in work-over operations
are conversant with the use of fire fighting system and fire
extinguishers.
(iii) Adequate number of self-contained portable hand lamps of
approved type should be kept available for immediate use.

Drilling & Workover
8.9 GENERAL PRECAUTIONS
(i) All operating people should use PPE

(ii) Emergency vehicle should be at site
(iii) Availability of proper communication system
(iv) First Aid box should be filled with medicines
(v) People should be trained in MVT, FAC and Fire fighting
(vi) All key personnel should be trained in IWCF well control
(vii) Spark arrestors should be mounted on all engine exhaust
(viii) Display of warning boards
(ix) Display of blow out contingency plan
(x) Proper house keeping
(xi) Availability of gas detectors
(xii) A standard railing should guard every open sided derrick floor of
a work-over rig 1.8 meters or more above ground level or
adjacent floor.
(xiii) Every work over rig should be provided with ladder arrangements
with suitable hand railings to ensure safe access to all elevated
walking and working platforms.
(xiv) The well head should be protected against damage from falling
objects.
(xv) Before dismantling the lubricator, it should be ensured that the
pressure inside it is released through the release valve.
(xvi) Equipment tools and small objects and other loose materials,
which are not required for use, should not be left lying on the
derrick floor so as to dangerously obstruct work places and
passage ways.
(xvii) The rig floor should be kept reasonably clean of oil, mud etc, so
as to prevent persons from slipping.

Drilling & Workover
APPENDIX - A
SAFETY INSPECTION OF ONSHORE DRILLING RIGS
RIG NAME………………………………………… WELL NO. ………………….

INSPECTION DATE …………………………. SHIFT ………………………..
SHIFT INCHARGE……………………………. INSTALLATION MANAGER………………
CHECK LIST FOR ROTARY DRILLING RIG
CODE: SATISFACTORY (Y/N), CORRECTION (X), NOT APPLICABLE (NA)
1. ENTRANCE AREA & BOARDS
(a) Whether site plan has been properly displayed?

(b) Display of Prohibitory signs
“No smoking”
“No naked light”
“Photography prohibited”
“Unauthorized entry prohibited”
“Use of mobile phone prohibited”
“Wear PPE”
(c) Whether Contingency plan prepared for tackling the emergency?

(d) If Contingency plan prepared, whether the name of officials to be
contacted in emergency is displayed?
2. MUD PUMP AREA
(a) Is the Safety Relief Valve (SRV) in working condition?

(b) Is the SRV tested?
(c) Is SRV Line to mud tank secured?
(d) Is Bleed line to mud tank secured?
(e) Availability of Eyewash Facility over mud tanks
(f) General House Keeping
3. BLOW-OUT PREVENTERS
(a) Whether properly installed and tested?

(b) Whether controls accessible?
(c) Condition of gauges
(d) Whether hydraulic Lines protected?
(e) Whether wheels & stems in place?

Drilling & Workover
(f) Whether choke manifold skid & line secured?

(g) General house keeping
4. PIPE RACK AREA
(a) Whether end supports provided?

(b) Whether layers of pipes properly stacked?
(c) Whether pipe rack leveled?
(d) Catwalk condition & level with racks
(e) Vee Ramp condition
(f) General house keeping
5. DERRICK FLOOR & THRIBBLE BOARD AREA
(a) Condition of Derrick floor

(b) Twin-stop safety device: Whether available & in working condition?
(c) Condition of pipe raft.
(d) Whether Upper & lower Kelly cock & FOSV available?
(e) Whether Fire extinguisher available?
(f) Whether Emergency Escape Devise (EED) installed?
(g) Whether Fall Prevention Device (FPD) installed?
(h) Condition of the pipe racking facility at thribble board
(i) Whether Stand pipe secured?
(j) Whether Full body harness and lanyard (life line) available?
6. ELECTRICAL EQUIPMENT, LIGHTING & WIRING
(a) Earthing of electrical motors

(b) Earthing of electrical switchboards/panels
(c) Display of danger signs on electrical equipment/controls
(d) Wires up / Off the ground and properly secured
(e) All wires properly spliced & connected
(f) All lights properly protected
(g) Receptacles & Plugs condition
(h) Proper earthing of Generator Skid
(i) FLP Fittings in Zone I & II
(j) Whether insulation checked?
(k) Condition of PCR
(l) General house keeping
7. TONGS/ELEVATORS /SLIPS ETC.
a) Condition of Snubbing Line

b) Condition of Jerk line
c) Three Clamps on all snub & jerk lines properly used
d) Condition of the rig tong dies
e) Tong handle safety pin in place
f) Proper anchoring of tong back up lines
g) Rig tong body and jaw condition
h) Tong counter weights : whether properly anchored and safe
i) Condition of elevators

Drilling & Workover
j) Condition of slips & other tools
8. CATHEAD DRUM & AIR WINCH
(a) Smooth & guarded both sides

(b) Condition of cathead
(c) Condition of Cat line and winch line
(d) Provision of cathead divider
(e) Twin stop safety device checked regularly
(f) Air winch brake condition
9. FLOORS, STAIRS & HANDRAILS
(a) Whether flooring /stairs/steps non-skid

(b) Whether stairs leveled & secured
(c) Condition of rails on stairs, rig floor & mud tanks
(d) Derrick floor area condition
(e) Whether rig floor free of holes & covered up
(f) Floor free of grease & slipping hazards
(g) Toe-board (height 10 inch and flushed with rig floor) provided or not
10. EQUIPMENT GUARD
(a) All engine transmissions system guarded

(b) All rotating shafts & couplings properly guarded
(c) Rotary drive chain guarded
(d) Mud pump drive chain/belt guarded
(e) Shale Shaker guards in place
11. DOG HOUSE & OTHERS
(a) At least two doors opening out

(b) Dog house clean/tidy
(c) Crew house clean/tidy
(d) Supply storage house clean
(e) First Aid Kits in Dog House: availability with medicines
12. SAFETY EQUIPMENT AND WARNING SIGNS
(a) Availability of DCP, CO2 & foam extinguishers in designated places

(b) Whether Fire extinguishers charged, tagged (date of expiry) and
visible?
(c) Availability and condition of gas detectors
(d) Availability of Mud Volume Totalizer (MVT)
(e) Availability of First Aid Box with medicines, anti snake bite, eye wash,
stretcher, splints
(f) Whether the names of First Aid & Fire Fighting trained personnel
during the shift displayed?
(g) Whether warning signs and SOP for unloading diesel placed near
Diesel tank?

Drilling & Workover
(h) Whether all vessels labeled as to contents?

(i) Whether high voltage signs used?
(j) Display of all warning/statutory signboards
13. PERSONAL PROTECTIVE EQUIPMENT
(a) Proper clothing worn

(b) Hard hats worn by all rig operating personnel
(c) Hard hats used by visitors
(d) Hearing protection being used
(e) Safety goggles available
(f) Safety hand gloves worn
(g) Safety shoes used
(h) Availability of spare safety belt
(i) Electricians using proper safety kit
14. MISCELLANEOUS
a) Hammers & wrenches free of defects

b) Ladders on location in good condition
c) Tools in place
d) Plinth condition of the location
e) Bulletin boards orderly
f) Oil leaks cleaned up
g) Electricians / welders using proper tools/gears
15. GENERAL
(a) Provision of safe drinking water

(b) Provision of Full Body Harness of approved design
(c) Is PPE used by all rig operating personnel?
(d) Availability and condition of emergency vehicle
(e) Whether Drillometer & other instrumentation in working condition?
(f) Condition of engines exhaust and lagging
(g) Provision of spark arrester on each engine
(h) Proper storage of Oxyacetylene Cylinder
(i) Display of first aid action plan for electric shock
(j) Condition of effluent pit
(k) Availability of proper drainage system
(l) Fencing around site
(m) Communication system with important telephone numbers on display
(n) Availability of relevant OISD standards
(o) Proper house keeping
16. RECORDS :
17. REMARKS:
Signature of Inspecting Officer
Name : ___________________
Designation : _______________

Drilling & Workover
APPENDIX-B
CHECK LIST FOR PRE-SPUD SAFETY AUDIT OF DRILLING LOCATION
RIG NAME………………………………………… LOC/WELL NO. ……………………………….

INSPECTION DATE …………………………. SHIFT ……………………………………………..
ENTRANCE AREA & BOARDS
1. ENTRANCE
1.1 Is the area properly fenced with gate at the entrance?

1.2 Is the location manned by Security/CISF?
1.3 Display of Prohibitory signs:
(a) “Site plan”

(b) “No smoking”
(c) “No naked light”
(d) “Photography prohibited”
(e) “Unauthorized entry prohibited “
(f) “Use of mobile phone prohibited”
(g) “Carrying match box/lighters prohibited”
(h) “Wear PPE”
(i) “Name of key personnel”
(j) “Emergency telephone numbers”
1.4 Provision of fire fighting system at site
2. EMERGENCY ESCAPE DEVICE
2.1 Whether the device is installed or not

2.2 If installed, is it in operating condition or not
2.3 Condition of anchor
2.4 Is safety clamps used on escape line as per norms?
2.5 Has the landing platform been provided?
2.6 Condition of the track rope
2.7 Condition of the haulage rope
2.8 Condition of the pulleys
2.9 Condition of the hand brake
2.10 Condition of the centrifugal brake
3. DERRICK FLOOR AREA
3.1 Condition of derrick floor

3.2 Condition of the pipe raft
3.3 Condition of rotary table cover

Drilling & Workover
3.4 Condition of rotary chain guard

3.5 Condition of Driller’s control panel
3.6 Condition of guard rails around derrick floor
3.7 Provision of toe board (height 10 inches and flushed with rig floor)
around derrick floor
3.8 Condition of emergency shut-off controls (draw works and engines)
on Driller’s control panel
3.9 Availability of Kelly cocks & FOSV
3.10 Are adequate numbers of fire extinguisher placed near dog house?
3.11 Condition of mast/derrick ladder
3.12 Condition of gauges on drillometer panel
3.13 Condition of pipe racking facility (finger post and sliding board)
3.14 Condition of dead man anchor
4. TONGS / ELEVATORS / SLIPS
4.1 Condition of snubbing lines

4.2 Condition of jerk lines
4.3 Are clamps used on jerk line/back up line/cat line
4.4 Condition of tong back-up line
4.5 Proper anchoring of tong back up lines
4.6 Condition of body and jaw of tongs
4.7 Tong counter weights: whether properly anchored and safe
4.8 Condition of tong dies
4.9 Condition of elevators
4.10 Condition of slips
5. CAT HEAD DRUM AND AIR WINCH
5.1 Is the cat-head drum smooth and guarded?

5.2 Is cat-head divider provided?
5.3 Condition of casing-line and wire line
5.4 Condition of draw-works brake band
5.5 Condition of twin stop device
5.6 Condition of cat line, out line and air winch line
5.7 Condition of the winch brake
6. RIG ENGINES
6.1 Are spark arrestor provided on the engines?

6.2 Is lagging provided on exhaust pipe?
6.3 Have appropriate and adequate fire extinguishers provided near the
engines?
6.4 Does the engine emit smoke in the working area?
6.5 Provision of side rails around engine floor, if elevated
6.6 Condition of stairs from derrick floor to the plinth onwards.
7. MUD PUMP
7.1 Is Safety Relief Valve (SRV) in working condition?

7.2 Is the SRV tested?

Drilling & Workover
7.3 Is the delivery line from SRV to the tank properly anchored?
7.4 Is the bleed line to mud tank properly hooked up?
7.5 Is the area surrounding the pump safe for working?
7.6 Are adequate numbers of fire extinguishers placed near the pump?
7.7 Is the pump delivery line grouted?
8. CAT WALK / PIPE RUNNERS
8.1 Condition of cat walk

8.2 Condition of Vee Ramp
8.3 Condition of stairs from rig floor to the catwalk
8.4 Condition of railings on above stairs
8.5 Condition of casing / pipe runners
8.6 Are end rests provided on the runners?
8.7 Condition of the pads below the runners
8.8 Is the pad made of steel plates?
9. GUARDS / HAND RAILS / STAIRWAYS ETC.
9.1 Are all transmissions guarded?

9.2 Are all rotary shafts and coupling properly guarded?
9.3 Is rotary drive chain guarded?
9.4 Are guards of shale shaker belt driven in position?
9.5 Are compressor drive guards in position?
9.6 Condition of guards on pump drive belt/chain
9.7 Condition of guards on motors of mud agitators on the suction tanks
9.8 Condition of stairs
9.9 Whether stairs are leveled / well secured and clean
9.10 Whether side rails of stairs, mud tanks and walk-ways around mud
ditch in position.
10. GENERAL
10.1 Whether Permission obtained from MoEF (Ministry of Environment

& Forest) & State Pollution Control Board?
10.2 Provision of safe drinking water
10.3 Provision of Full Body Harness of approved design
10.4 Is safety helmet/shoe used by all rig operating personnel?
10.5 Availability and condition of emergency vehicle
10.6 Availability of DCP, CO2 & foam extinguishers in designated places
10.7 Whether fire extinguishers charged, tagged (date of expiry) and
visible?
10.8 Availability of First Aid Box with medicines, anti snake bite, eye
wash, stretcher, splints
10.9 Whether the names of First Aid & Fire Fighting trained personnel
10.10 Communication system with important telephone numbers on
display
10.11 Are nearby wells properly isolated?
10.12 Condition of effluent pit. Whether HDPE lining provided ?
10.13 Availability of proper drainage system

Drilling & Workover
10.14 Availability of Mud Volume Totalizer (MVT)

10.15 Availability and condition of gas detectors
10.16 Condition of engines exhaust and lagging
10.17 Provision of spark arrestor on each engine
10.18 Provision of side railings over LDO tank and diesel tank
10.19 Condition of ladder to top of both the above tanks
10.20 Availability of warning signs and SOP for unloading diesel placed
near Diesel tank
10.21 Proper storage of oxycetylene cylinders
10.22 Availability of relevant OISD standards
10.23 Proper house keeping
10.24 Availability of twin stop device.
Signature Signature Signature
Name______________ Name____________ Name_____________

Designation_________ Designation________ Designation________
Name______________ Name____________ Name_____________

Name______________ Name____________ Name_____________


Drilling & Workover
APPENDIX-C
CHECK LIST FOR PREWORK SAFETY AUDIT AT WORKOVER WELLS
RIG NAME………………………………………… WELL NO. ………………….

INSPECTION DATE …………………………. SHIFT ………………………..
1 ENTRANCE
1.1 Is the area properly fenced with the gate at the entrance?
1.2 Is the gate manned by Security/CISF?
1.3 Display of:
(a) “No smoking”

(b) “No naked light”
(c) “Photography prohibited”
(d) “Unauthorized entry prohibited”
(e) “Use of mobile phone prohibited”
(f) “Carrying match box/lighters prohibited”
(g) “Wear PPE”
(h) “Name of Key personnel”
(i) “Emergency telephone numbers”
1.4 Provision of fire fighting system at site
2. EMERGENCY ESCAPE DEVICE
2.1 Whether the device is installed or not?

2.2 If installed, is it in operating condition or not?
2.3 Condition of anchor
2.4 Is safety clamps used on escape line as per norms?
2.5 Has landing platform been provided?
2.6 Condition of track rope
2.7 Condition of haulage rope
2.8 Condition of pulleys
2.9 Condition of hand brake
2.10 Condition of centrifugal brake
3. WORKOVER RIG FLOOR/PLATFORM AREA AND OUTFIT CARRIER
3.1 Condition of rig floor/working platform

3.2 Condition of guard rails around the rig floor/working platform and side
platform around the rig
3.3 Provision of toe board (height 10 inches and flushed with rig floor/
working platform) around derrick floor/working platform
3.4 Condition of working platform posts and hinges
3.5 Condition of driller’s control panel

Drilling & Workover
3.6 Condition of emergency shut-off controls (draw works and engines)

on Driller’s control panel
3.7 Condition of the pipe raft
3.8 Condition of weight indicator
3.9 Condition of gauges on drillometer panel
3.10 Condition of dead man anchor
3.11 Condition of mast ladder
3.12 Condition of pipe racking facility (finger post and sliding board)
3.13 Condition of all the jacks
3.14 Is stabilizer beam properly placed?
3.15 Are all the Jacks Locked?
3.16 Availability of Kelly cocks & FOSV
3.17 Condition of rotary table cover if in use
3.18 Condition of rotary chain guard if in use
3.19 Are adequate numbers of fire extinguishers placed near dog house?
4 TONG / ELEVATOR / SLIP
4.1 Condition of snubbing lines.

4.2 Provision of tong back up line
4.3 Condition of body and jaws of tongs.
4.4 Condition of tong dies.
4.5 Condition of elevators
4.6 Condition of slips
5 CATHEAD DRUM AND AIR WINCH
5.1 Is the cat-head drum smooth and guarded?

5.2 Is cat-head divider provided?
5.3 Condition of casing-line and winch line
5.4 Condition of draw-works brake band
5.5 Condition of twin stop device
5.6 Condition of cat line and air winch line
6 RIG ENGINES
6.1 Are spark arrestors provided on the engines?

6.2 Is lagging provided on exhaust pipe?
6.3 Have appropriate and adequate fire extinguishers provided near the
engines?
6.4 Does the engine emit smoke in the working area?
6.5 Provision of side rails around engine floor
6.6 Condition of stairs from engine floor to the plinth
7 PUMP
7.1 Is Safety Relief Valve (SRV) in working condition?

7.2 Is the SRV tested?
7.3 Is the delivery line from SRV to the tank properly anchored?

Drilling & Workover
7.4 Is the bleed line to mud tank properly hooked up?

7.5 Is the area surrounding the pump safe for working?
7.6 Are adequate numbers of fire extinguishers placed near the pump?
7.7 Is the pump delivery line grouted?
8 GUARDS / HAND RAILS / STAIRWAYS ETC.
8.1 Are all transmissions guarded?

8.2 Condition of guards on pump drive belt/chain
8.3 Condition of stairs/steps
8.4 Whether stairs are leveled / well secured and clean?
8.5 Whether side rails of mud tanks, walk-ways and stairs around in
position?
9 GENERAL
9.1 Provision of safe drinking water

9.2 Provision of Full Body Harness of approved design
9.3 Is PPE used by all rig operating personnel?
9.4 Availability and condition of emergency vehicle
9.5 Availability of DCP, CO2 & foam extinguishers in designated places
9.6 Whether fire extinguishers charged, tagged (date of expiry) and
visible?
9.7 Availability of First Aid Box with medicines, anti snake bite, eye wash,
stretcher, splints
9.8 Whether the names of First Aid & Fire Fighting trained personnel
9.9 Provision of concrete pad under tubing rack
9.10 Communication system with important telephone numbers on display
9.11 Are nearby wells properly isolated?
9.12 Availability and condition of gas detectors
9.13 Provision of spark arrestor over each engine
9.14 Condition of guy line anchors
9.15 Are the guy lines anchored as per design?
9.16 Are safety clamps fitted as per norms?
9.17 Condition of guy lines.
9.18 Condition of mast
9.19 Is the bleed off line from well properly grouted?
9.20 Condition of effluent pit
9.21 Availability of proper drainage system
9.22 Condition of engines exhaust and lagging
9.23 Provision of spark arrestor on each engine
9.24 Availability of relevant OISD standards
9.25 Proper house keeping

Drilling & Workover
Name______________ Name____________ Name_____________

Name______________ Name____________ Name_____________

Name______________ Name____________ Name_____________


Drilling & Workover
APPENDIX-D
LIST OF RECORDS/REGISTERS/FORMS/DISPLAY
TO BE MAINTAINED AT WELL SITE
1. Pressure test of BOPE and choke & kill manifold

2. BOP function test
3. BOP drill
4. Fire Drill
5. Hot work/cold work permit
6. Casing line inspection / ton mileage
7. Training record (FF, FA, MVT, Well control)
8. PME of employees
9. NDT of mast & substructure and handling tools
10. All mechanical equipment records by TS Section
11. All Electrical records by Electrical Engg. Deptt
12. Periodical inspection of equipment
13. Display of all statutory signboards
14. Display of Blow out contingency plan
15. Display of Fire contingency plan
16. Display of First Aid trained personnel during the shift
17. Display of Fire Fighting trained personnel during the shift
18. Display of First-Aid Action for electric shock
19. Minutes of all safety audit including pre spud / pre workover
20. Minutes of Pit level safety meeting & Tool Box meeting
21. Safety circulars
22. Copy of OMR
23. Copies of Relevant OISD standards
24. Copy of Safe Operating Procedure (SOP)
25. Copy of GTO (Geo-technical order) / Well Policy
26. Copy of DPR (Daily progress report)
27. Installation manager’s instruction book
28. BOP kill sheet
29. Trip sheet
30. Form-B (Register of employee’s bio-data)
31. Form-E (Register of attendance)
32. Form-K (Return of Minor accidents)
33. Form-J (Return of reportable accidents)

Drilling & Workover
APPENDIX-E
CHECK POINTS DURING RIG UP & RIG DOWN OF MAST

(ELECTRICAL AC-SCR RIGS)
A. RIG UP
1. Inspect bull line spelter and pin condition visually,

2. Check lock spring of pins.
3. Check Draw works anchors, whether all clits are tightened or not
(Branham mast) and box type anchor bolts are fastened or not.
4. Check bull line pullies & movement.
5. Check cylindrical roller movements
6. Check Mast pulley anchoring bolts (both horizontal and vertical pulley)
7. Check Rig foundation for any crack and damage.
8. Inspect D/Works linkage, pins and equalizer centre pin
9. Check mast leveling bolts whether properly tight or not
10. Check dead-man anchor foundation bolt
11. Check weight indicator
12. Check E.C. brake & friction brake
13. Check water flow to D/Works
14. Check air pressure & gauges
15. Check proper reeving o floor bull line (SKYTOP Mast)
16. During lowering, check slippage of line pulley in strong back column
17. Check whether casing line is over floating sheave of strong back
column or not.
18. Check whether casing line is over floating sheave of A-frame or not.
19. Check whether casing line is properly reeved on crown block or not
20. Check whether diving board is properly tied back or not
21. Check crown railings.
22. Check whether all service lines are loosely tied up with mast or not
23. Check all engines and assure at least two engines are running or not
24. Check whether all SCRs are provided or not
25. Check air pressure of dolley board tyre (SKYTOP Mast)
26. Check dolley board movement area (SKYTOP Mast)
27. Inspect snubbing line condition
28. Check Mast legs for any foreign materials
29. Check whether floor pulling lines is properly anchored or not
30. Check whether bottom box is filled up with water or not (Branham
Mast)
31. Check sub base foundation level prior to placement of sub-base.
32. Check existence of split pin wherever applicable

Drilling & Workover
B. RIG DOWN
1. Check whether equalizer pulley is placed properly or not (Head should

face Draw works)
2. Inspect bull line spelter and pin condition visually
3. Inspect snubbing line whether any kind or damage is there
4. Check brake condition including air pressure, clutch condition, centre
pin of equalizer beam
5. Check E.C. brake
6. Check high stand and low stand condition including planks
7. Check whether service lines and R/hoses are properly tied or not
8. Check whether floor pulling line is properly anchored or not
9. Check whether the well is shut in or not
10. Check whether the well is properly caged or not
11. Check & remove all shim from Mast
12. Check whether Mast leveling bolts are tight or not
13. Check whether diving board is vertically tied up or not
14. Check bull line locking bolts
15. Check and position floating pulley with casing line
16. Check cross bracc position while lowering floors, whether they are
laid properly or not
17. Check whether flow line is properly laid or not
18. Check Dead-man anchor foundation bolts
19. Check whether bottom box is filled with water or not (Branham
mast)
20. Check existence of split pin wherever applicable.

Drilling & Workover
APPENDIX-F
SAFETY GUIDELINES FOR CLUSTER WELLS
In a cluster drilling location, after completion of drilling and production testing of the
first wells, the well, the mast and substructure of the rig is dismantled, moved to the
next i.e. 2nd location by dragging or lifting. The mast and substructure are finally
rigged up in the second location and made ready for spud-in. the following guidelines
have been formulated for safe operation at cluster well locations.
(A) Rig-Down (for 1st well). Rig movement and Rig-up (for 2nd well)
a. During this period, most of the activities will involve movement of heavy
equipment in and around the well head of the 1st (production) well.
Therefore the following Safety measures are to be taken:
b. The production well should be kept shut-in till the rig-up of the Rear
Floor in the 2nd location is completed. Once the Rear Floor is rigged up
in the 2nd (drilling) location, the production well can be opened. But only
after all the points mentioned in para ( C) to (E) are taken care of.
c. A steel structure of at least 2.1/2” dia pipe (preferably removable type)
is to be erected around the production well head up to a height of at
least one ft. (1’) above the X-mas tree. The structure should have
reinforcement with two layers of sand bag. The top opening should be
covered with properly supported good quality wooden planks. To facilitate
scrapping operation of the well, one or two sides (front & rear sides) or
the well should be left open depending on the convenience for the
scrapping operation.
d. Well flow-line & gas input line at the well plinth should be protected from
mechanical damage by burying the same underground with clear marking.
Any other valve/control valve in the well plinth should be protected with
proper & strong cover.
e. Caution board (with the following caption should be displayed at suitable
locations in addition to other similar boards displayed in the drilling well.
“Danger-Well on Production”
f. The dimension of the letters should not be less than 6”
(B) 1st Well in production phase, no scrapping required 2nd well in drilling phase.
Irrespective of whether the wells are 9 m or 18 m apart, both drilling and

production operation may be carried out simultaneously by taking the
precautions mentioned in para (A) above. Additionally, the following action
should be taken by the Installation Manager or his representative gas testing
should be carried out at least twice in each shift throughout the drilling operation.
Record of the same should be maintained in a bound paged register at the
site. Some of the selected sites for the gas testing would be near to the
production well head, cellar pit, rig pump areas, chemical hut, derrick floor etc.
in case the gas reading is found to be above the permissible limit, the source

Drilling & Workover
of gas leakage should be identified and necessary preventive measures are to

be taken forthwith. However the case of major leakage of gas / oil at the
plinth, drilling operation should be stopped immediately (after critical assessment
of the situation).
(C) 1st Well in Production Phase scrapping required, 2nd well in drilling phase
(I) Production well to be kept shut down. Only drilling operation can be
carried out by taking precautionary measures as stipulated in para (A)
& (B) above.
As an alternative arrangement, both drilling and production activity can

be carried out simultaneously if servicing of the production well is done
by any method other than mechanical scrapping that will not liberate
any gas at the well head.
(II) Well 9 m apart, scrapping required every alternate day or at greater

intervals.
Scrapping to be done only when drilling operation is totally suspended,

i.e. draw works motors and rig pump motors are not run.
For this proper co-ordination between Drilling & Production deptt. Will
be required, and all safety precaution stipulated in para (A) & (B) above
and (D) below are to be strictly followed.
(III) Wells 18m apart, scrapping required everyday/ alternate day or at

greater intervals.
Simulataneous scrapping operation and drilling operation may be carried

out with proper co-ordiantion between Drilling & Production deptts.
And by strictly following the safety measures stipulated in para (A) &
(B) above & (D) below:
(D) Precaution to be taken during scrapping operation at the cluster well locations.
(a) Hot Work Permit to be Issued by the Installation Manager or Shift

Drilling Engineer prior to the commencement of scrapping job.
(b) Regular gas monitoring to be done by the production gang at vulnerable
locations during scrapping job & venting of gas.
(c) Scrapping winch to be placed at least 18 mtrs. Away from the producing
wells.
(d) During scrapping no welding cutting or other hot work would be
permitted.
(e) 2/3 nos. additional DCP portable extinguishers are to be keep ready at
the well site to be used at the time of doing the scrapping job.
(f) Vehicular movement is to be restricted at the time of scrapping
operation.
(g) Gas venting to be done 30mtrs. away from the well head and the
same should be done slowly in a controlled manner. A standby observer
must be present at the venting point to ensure that venting is done in a

Drilling & Workover
safe manner.
(h) Gas venting should not be done at the drilling effluent pit. Instead a
separate smaller pit should be made for the purpose.
(i) Regular collection of oil from the venting pit should be done by the
Production Deptt.
(j) Any leakage of gas through the stuffing box gland should be immediately
attended to by the scrapping gang.
(k) In case of presence of gaseous atmosphere (beyond 15 mtrs. From
the well head being scrapped) with the flammable limit or in the event
of uncontrolled release of fluid from the well under scrapping, all engines
are to be stopped forthwith.
(l) All Service Deptts. Engineers/supervisors i.e. Electrical, mechanical,
Mechanical Chemical, transport etc are to be suitably advicsed by the
Shift Driller, so that in case of any emergency during the scrapping
operation the running of engines, motors and other sparking type
equipment can be stopped without delay.
(m) Venting of gas should not be done from the flow-line, instead a separate
½’’ or ¾” line should be hooked up from the well head. This will avoid
spillage of crude oil.
(E) For all subsequent wells at cluster location (e.g. 3rd & 4th well etc) similar
precautions are to be observed as mentioned in para (A) to (D) above.
(F) In similar lines, for all work-over jobs in a cluster well location all the precautions
as indicated above for a drilling well, are to be observed as may be applicable.
(G) The Master valve in the well head of a production well should have provision
for operation by a pneumatically controlled system from a remote location in
addition to the arrangement for mechanical opening and closing of the valve.
(H) Possibility of installation of continuous gas monitoring system with a panel at
driller’s console connected to gas detecting probes placed at specific locations
at the well plinth, may be looked into.
(I) The 4” flow-line on the well plinth is to be laid minimum 1.2 m under ground
during the plinth construction stage itself by Civil Engg Deptt in liaison with
Production (OIL) Deptt. / Pipeline-Field Deptt.
(J) A separate pilot pit of min size 8 m x 1.5 m has to be made. This pit will be
exclusively used by production (oil) Deptt for well testing. The accumulated
oil from this pit has to be lifted regularly by Production (Oil) Department.
(K) A pad for placing the scrapping vehicle is to be made by Civil Engg Deptt
towards the DICs office at a safe distance from the well.
(L) To generate working space for scraping operation near the well head, the
Annular & Ram BOPs are to be placed away from the well head or may be
removed from the well-head area. In case removal of BOPs are not possible
at this stage, annular BOP should be placed towards bit rack side.
(M) A prohibitory board preventing vehicular movement during scraping operation
beyond the scraping winch area to be displayed. This board has to be displayed
by Prodn. (Oil) deptt. & the scraping gag should carry the board with them. A
road barrier also to be installed before the scraping job is started.
(N) The cellar to be covered by MS Grating/PSP sheet to prevent fall of man &
material during scraping operation.
(O) Since the scraping has to be done over the derrick base in some cases of
cluster wells, the truck mounted wire-line winch may be deployed for scraping
purpose in such locations in order to maintain the wire line height.

Drilling & Workover
(P) The scraping schedule of producing wells on the cluster plinth is to be given in
a monthly basis by the concerned Production Engineer to the DIC of the
nearby drilling well.
(Q) The Production Crew is to inform the Drilling Engineer in shift regarding the
scraping of well before they start the scraping operation in cluster locations.
The above points are some of the general guidelines and specific instruction, (if
necessary) will be issued from time to time depending on the locations/conditions.

Drilling & Workover
APPENDIX-G
PRECAUTION TO BE TAKEN DURING REPAIR JOB:
For safe operation the following action plan have been formulated during repair job
at well site by Rigbuilding Section.
1. Before taking any repair job related to Rigbuilding sec. at first Shift Engineer
should inform concern SED/R.B. Engineer/Jr. Engineer.
2. The Shift Engineer after getting concurrence from concern authority viz
SED/R.B. Engineers, hand over the outfit for repairing after elaborating the
problem to Rigbuilding Jr. Engineer/Headman at site.
3. Based on the nature of the jobs one man preferably the Mechanic (D/
Works headman) in absence of Rigbuilding Jr. Engineer should be made in
charge and every body should follow him while carrying out the repair job.
4. For carrying out repair job on rotating component, source of power should
be isolated by both manual and remote control device in consultation with
Shift Engineer and confirm it prior to resuming the job. All clutch both
manual and preumatic must be isolated before starting of any operation.
5. On completion of repair jobs, the testing of the equipment should be
carried out in consultation with Shift Engineer/ Rigbuilding Engineer.
6. Testing by remote control should be avoided as far as possible and for
initial testing local control should be used.
7. Control of operation in D.Es console should be under the supervision of
Shift Engineer/Rig Engineer. In absence of D.E., R/B headman should be on
control of D.E.’s console under the supervision of R/B Jr. Engineer.
8. For any repair job at night hours proper light arrangement should be
made. One responsible person should be always near the D.Es console so
that nobody can operate the control levers.
9. As it is not possible for a Rigbuilding Engineer to be present during repair
job, hence Shift Engineer should be in touch with a Rigbuilding Engineer
over phone when the repair job is going on.
10. To enhance the job knowledge, training of Rig people needs to be arranged
in OTI / well site at regular intervals.
11. After isolating the source of power physically, isolation tag with caution
notes such as “NOT TO BE STARTED”, “REPAIR JOB IN PROGRESS”,
“DANGER” etc to be displayed at required places.
12. Any repair of major equipment at site should be recorded.
13. Similar Precantion should be taken for Repair job done by other sections/
Departments at well side.

Drilling & Workover
APPENDIX-H
SOME ABBREVIATION GENERALLLY USED IN SAFETY ASPECTS
GTO : Geo Technical Order
PPE : Personal Protective Equipment
NDT : Non-Destructive Test
ESA : External Safety Audit
PME : Periodical Medical Examination
SLI : Safe Loading Indicator
SOP : Safe Operating Procedure
SWL : Safety Working Load
MCB : Miniature Circuit Breaker
OMR : Oil Mines Regulations
OISD : Oil Industry Safety Directorate
DGMS : Directorate General Mines Safety
DMS : Director Mines Safety
DDMS : Deputy Director Mines Safety
MVT : Mines Vocational Training / Mud Volume
Totalizer

Drilling & Workover
APPENDIX-I
SAFETY PRECAUTIONS DURING CEMENTING
Silos:
1) Regular health check up of silos and associated piping / valves shall be en-
sured
2) All the inlets, outlets and vent lines from the silos should always be kept
clean to avoid any blocking /chocking.
3) The silos should be equipped with suitable safety valves which are to be
tested periodically.
4) While storing cement for a long time in silo, either on site or in bulk handling
plants, cement should be transferred from one silo to another, at least once
in a month
Cementing Heads:
1) The Cementing Head should be cleaned, greased and serviced after every
cement job.
2) Cementing head should be equipped with positive lever type indicator for plug
release.
3) All ‘O’ rings should be cleaned and checked for any cuts or damages.
4) The cementing head should be handled and made up carefully. Crew must
ensure that the cementing plug is loaded and the retaining spindle is fully
inserted and locked in position.
High Pressure lines and manifolds:
1) All high pressure lines and cementing manifolds shall be of pressure rating
minimum 1.5 times the maximum anticipated working pressure.
2) The manifold, chicksan lines must be flushed and inspected prior to final con-
nection. The pumping line should be pressure tested as above prior to the job.
During high pressure testing nobody should be present near the line unless if is
essential.
Batch Mixer:
1) Batch Mixer shall be able to prepare homogeneous cement slurry of desired

specific gravity to achieve design properties.
2) It shall be provided with proper facility for cleaning after each job.
Mobile Pneumatic Bulk Carrier:
1) Regular health Check up of Mobile Pneumatic bulk carrier and associated pip-
ing/valves shall be ensured.

Drilling & Workover
Gauging Water Tank:
1) A separate tank should be provided for mixing of cement additives with suction
facilities from bottom by centrifugal pump and with delivery line to hopper/
Cementing Unit displacement tank.
2) Jetting guns should be provided for proper mixing of chemicals in tanks.
3) The tank should be provided with proper facility for mixing.
Pre flush:
1) The design should be to achieve 10 minutes contact time.

2) Weight of Pre flush should be 10% more than that of mud.
Blending of additives with Bulk Cement:
1) Cement absorbs moisture from its surroundings, which adversely affects its
properties.
2) During blending of cement with dry additives, verify weight calculations, quantity
and name of each additive going into the cement with the design composition.
Count the additives sacks and cement sacks for each blend.
3) Visually inspect the empty silos prior to transferring blended materials to ensure
that they are completely empty.
4) To ensure proper blending, transfer the blended material at least twice between
silos before loading on mobile silos.
5) At well site, transfer dry blend to empty tank and back to original tank just
before the job. If extra tank is not available on site, then fluff or inject/percolate
air through each tank from the bottom for 15-20 minutes for even distribution
of additives.
6) When different blends are used, each blend and corresponding tank should be
clearly identified.
7) Collect and save sample for testing if failure occurs.
Pre Cementing Job arrangements:
A) Hook up:
1) A detailed plan indicating the step by step job sequence duly approved by the
drilling in charge should be prepared and circulated to all concerned prior to the
cementation job.
2) After arrival at site, the cementing engineer should independently calculate the
slurry volume and displacement volume required using actual parameters and
also total water requirement including the water needed to flush the cementing
equipment.
3) Ensure that the discharge rates of both mud and water required for the job are
sufficient for uninterrupted operation.
4) The following parameters should be verified with the drilling in charge: mixing
and displacement rates, pressure to apply when the plug lands, volume of mud
that will be pumped.
5) Availability of both the pumps should be ensured. Also volumetric efficiency of
mud pump and functioning of stroke counter should be ensured.

Drilling & Workover
6) Conduct a pre hookup meeting to review equipment placement, lay out of high
pressure lines, mixing and pumping sequence, pump rates, slurry densities and
safety hazards during pumping operation and maximum allowable pressure.
7) Check air compressor operation, fluff the cement silos.
8) The compressor should be placed at a safe distance and the exhaust should be
directed away from the well.
9) Check cementing Heads, plug release mechanism, plug dropping indicator and
review the number and placement of rubber plugs in proper sequence.
10) Only skilled people should make pumping lines and operate valves.
11) All should wear applicable PPE
Cementing Equipment:
1) Check the Cementing unit, rig pumps, compressor, silos and surge tank to
avoid any break down during operation.
2) Pressure test the all cementing lines at 1.5 times the maximum pressure
expected during the job.
Cement slurry mixing and pumping:
1) Pressure tests the silo at 15-20 psi just prior to starting of mixing of cement.
2) Start pumping operation to establish circulation to ensure that the casing shoe
is open and check the mud return.
3) Check the slurry weight.
4) Use pre flush to achieve 10 minute contact time.
5) Do not open cementing head to drop top plug as it will allow the well to suck in
air and cause honey co mbing of cement around the shoe joint.
6) The cement slurry bleed off line from the rig pump must be anchored properly.
Displacement:
1) Determine displacement rate on the basis of the type of casing string to be

cemented. Turbulent flow displacement is usually accepted .However when
turbulence all around the casing is not achievable mainly due to stand off,
pump or fracture gradient limitations, then the maximum permissible / attain-
able discharge for high laminar flow is recommended during displacement.
2) Cement displacement should be as high as possible to attain annular velocity
of 6 ft/sec.
3) Casing reciprocation should be on a two minute over 4 to 6 meter length
4) Continue pipe movement until the top cementing plug is bumped or casing
tends to become stuck.
5) Monitor the displacement and bumping of plug. Check the back flow after plug
bumping. Leave casing open during waiting on cement (WOC).A small amount
of back flow is expected because of thermal expansion and cement reaction.
6) In the event of failure of BPV, the casing should be kept closed at pressure
equal to differential pressure till the cement slurry thickens.
7) All specific events occurring throughout the cementation job must be recorded
along with other relevant points for post job evaluation.
8) Prepare a summary of job completed.

Drilling & Workover
APPENDIX-J
DRILL FLOOR SAEFETY
Source : Step Change in Safety

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Drilling & Workover

Production-Oil
OIL INDIA LIMITED
Volume - I
Section - 4
PRODUCTION - OIL
ACTIVITIES

Production-Oil
PRODUCTION - OIL ACTIVITIES

CONTENTS
Chapter - 1
Production Installation
1.1.0 Definition.......................................................................................................... 1
1.2.0 Permission from Statutoryauthorities.............................................................. 1
1.3.0 Wellheadinstallation........................................................................................ 1
1.4.0 Oil Collecting Station........................................................................................ 1
1.5.0 Central TankFarm.......................................................................................... 2
1.6.0 Identificationofinstallation&physicalhazards............................................... 2
1.7.0 Hazardinproductioninstallation..................................................................... 3
1.8.0 Safepractices................................................................................................. 4
1.9.0 Checklistsforproductioninstallation............................................................. 7
1.10.0 Hazardousareas............................................................................................. 7
1.11.0 Precautionagainstfire.................................................................................... 8
1.12.0 Disposal of gas through flare system ............................................................. 9
1.13.0 Additionalprecautionsforgaswells............................................................... 10
Chapter - 2
Storage Tanks
2.1.0 Definition........................................................................................................ 11
2.2.0 Safety features to be incorporated during construction stage ...................... 11
2.3.0 Safetyfeaturesforoperationalpurpose........................................................ 12
2.4.0 Cleaningandmaintenance........................................................................... 13
2.5.0 Testing of tanks............................................................................................. 15
2.6.0 Inspection...................................................................................................... 15
2.7.0 Procedurefortankrepair.............................................................................. 15
2.7.0 Procedurefortankrepair.............................................................................. 15
2.8.0 Earthingoftanks........................................................................................... 16

Production-Oil
1.0 PRODUCTION INSTALLATION

1.1.0 GENERAL :
Oil & gas produced from wells are generally collected in a wellhead set up / early production
set up / oil collecting station through flow lines. The function of such set up is to separate oil, gas
& water from the well fluid.
1.2.0 Permission from statutory authorities :
(a) When it is intended to construct any new EPS/ Oil Collecting Station, Agent or Manager
should apply to DGMS, DMS and District Magistrate in form VI of OMR 1984 at least 90 days
before commencement of such construction, covering the following major points.
.i Name of the location, area of site, capacity and construction details etc.
i
. Organizational structure for ensuring occupational safety and health etc.
ii
. Information relating to the potential for major accidents.
i
v. All major establishment lying within 500 meters of such installation.
(b) If petroleum gases or liquid handling capacity exceeds 300 tones per day and 100000 tones
per day respectively the above application should accompany a safety report in form VII of
OMR 1984.
1.3.0 Wellhead Installation (EPS/QPS) :
A well head installation is a temporary set up during the initial stage of production in a new
area. One or more wells may be connected in such set up and the production may vary on
the basis of its design. The installation generally consists of indirect heater. gas oil separator,
oil storage tank and loading facilities and in some cases water knock-out set up is also
installed.
1.4.0 Oil Collecting Station (OCS) :
This is a centrally located permanent unit where flow lines from various production wells are
connected to group of manifolds in respective headers. Fluid then flow to the series of
separator through indirect bath heaters where oil and gas is separated.
a) The emulsified (wet) crude flows to heater treater where it is demulsified and dehydrated.
b) The separated oil flows to oil storage tanks and then pumped to central tank farm through
crude oil despatch pump.
c) The separated water from the heater treater is collected in the water disposal tanks for
further disposal in the disposal wells.
d) The gas separated at separators is used in the following ways:
.i As fuel for all IH, heater treater, prime movers, boilers etc. and instrument controlled
by gas.
i
. Compressed in gas compressor station and sent to various consumers.
ii
. As lifting gas for gas lifting system after compressing to around 90 kg/cm2.
iv. Used on injection gas under pressure maintenance technique after compressing it to
around 250 kg/cm2.

Production-Oil
1.5.0 Central Tank Farm (CTF)

This is storage unit for crude oil received from different OCS / EPS. The oil stored at the
Central Tank Farm is pumped through trunk pipelines to refinery.
1.6.0 Identification of lnstallation & physical hazards
1.6.1 General :
Identification of oil field installation is considered as a good visual aid to safety. Identification
of physical hazards by safety colour and safety signs, attracts attention rapidly to hazardous
situations and objects and thus helps in prevention of accidents and health hazards.
It is with this idea that the following recommendations are made.
1.6.2 Identification of installation on land
a. Every oil or gas well should be identified by a name or number and an identification panel
should be put up at the well head indicating the name, number and nature or product (oil or
gas) and status of well (producing, discontinued or abandoned).
b. Every production installation should be identified by a name or number and an identification
panel should be prominently displayed at the installation.
c. At every production installation a standard colour coding of pipeline should be adopted to
prevent accidents due to faulty manipulation of valves etc. and to promote greater safety.
Lettering as a mode of identification is also recommended. Arrows should be used to indicate
direction of flow.
The following standard colour code is recommended. (IS 2379)
Contents Ground Colour Band colour
Cooling water Sea Green French blue
Steam Silver Grey — — — — —
Compressed air over Sky Blue Signal red
15 kg/cm2
Oil Light Brown Brilliant green
Gas Canary yellow Signal red
Foam Canary yellow Light gray
1.6.3 Safety colours
There are four safety colours as follows
a. Signal red
b. Canary yellow
c. Brilliant green
d. French blue

Production-Oil

Production-Oil
2. Back flow of fluid from the separator to wellhead/tank to separator :

The back flow of fluid may cause serious operation problem and safety hazards to the
installation.
3. Hydrate formation :
Hydrate formation in production system and wellhead needs to be prevented by taking suitable
measure.
4. Fire hazards :
Flammable matter like oil and gas are constantly present at the installation and unless
source of ignition like naked lights, fractional sparks, electric sparks, static electric charges,
lighting etc. are carefully controlled, fire could be a major hazard.
5. Accumulation of oil vapour :
Oil vapour, which is heavier than air tends to settle down above the open pit containing oil
and around storage tank, loading points etc. The accumulated oil vapour can easily be
ignited and may even explode.
6. Explosion hazard :
A part of unused gas is burnt in the flare pit. But in case of flare is extinguished, large
quantities of unburnt gas are discharged into the atmosphere which may lead to an explosion.
7. Pollution due to effluents produced in the installation :
Surface pollution may occur in the surrounding area of the installation if the effluent produced
in the installation is not handled and disposed properly.
8. Corrosion :
Corrosion may also pose severe safety hazard with uncontrolled release of hydrocarbon
from any pressurized system / pipeline.
1.8.0 SAFE PRACTICES :
The following recommendations should provide guidance for safety in the light of hazard
mentioned above:
(i) Enclosure:
a) The protected area surrounding every production installation should be enclosed by wall a
barbed wire fencing not less than 2.5 meters in height with gates which can be duly locked
Security guards should be posted at gate to restrict entry of unauthorized persons. There
should be a wicket gate in the opposite side of the entrance gate.
b) A Green-belt area of 30 mts should be kept all around inside the boundary wall.
ii) Safety distances :
a) Inter-unit safety distances to be maintained as per the OISD Std. 118
b) Smoking/ Naked light/ Open flame/ Spark is not permitted within 30 mts of any well or
Petroleum storage tanks.

Production-Oil
c) Flare shall be sited not less than 90 mts from any part of petroleum storage tanks well.
(iii) Hydraulic Testing:
(a) All manifolds, separators, connecting lines, valve flow lines etc. should be hydraulically tested
to 1.5 times of maximum working pressure and the records to be kept in the installation.
(b) All pressure vessels, heater treater should be periodically hydraulically tested once in 3
years to 1.5 times of operating pressure for about 12 hours duration.
(c) Thickness test of all the pressure vessels and piping to be done at least once in every three
years.
(iv) Safety Relief Valves (SRV)
(a) Every separator should be provided with safety valve. The SRV set pressure should be 10%
above the maximum allowable working pressure.
(b) Safety valve should be installed directly on the separator and no valve should be fitted between
the vessel and the line connecting the safety valve.
(c) In case of 2 safety valves used in a vessel OISD STD - 106 to be followed.
(d) SRV is to be installed on the crude oil delivery line and in any other discharged line of
positive displacement pump.
(e) The discharged line of every safety valve should be connected to flare line for safe disposal
of gas release from it.
(f) Safety valves should be tested at least once in every six month.
v) Non Return Valve (NRV)
(a) At the manifold header, a non-return valve should be provided in each flow line connected to
well.
(b) The product lines should be provided with NRV to avoid back flowing from the storage tank.
(c) NRV should be provided in the crude oil delivery line to avoid back-flowing.
(d) If two or more outlets (gas or oil), operated in different operating pressures are connected to
a common header/ line, NRV should be used in the low pressure outlets to avoid back-
flowing.
(e) If two or more tanks are connected from the same header, NRV should be installed in all the
low height tanks to avoid back flowing.
vi) Electrical earthing
Double earthing connections to be provided in all header manifold, heater treater, Indirect
Heater, pressure vessels, pumps and tanks to dissipate static electricity.

Production-Oil
vii) Thermal Insulation :
Thermal insulation should be provided in the indirect heater and heater treater and also on
the exhaust pipes of these units, prime mover of crude oil pump, generating set etc. to a
height of at least 3 meters from the ground level to avoid accidental burning.
viii) Adequate workinq space for safe operation :
All the processed areas should have space for safe working of operators. In case of
interference of pipelines, suitable walkways should be provided.
ix) Corrosion protection :
All the lines are to be laid at least 30 cm above the ground level to avoid corrosion and
should be fixed with supports with the help of pipe clamps and the underground pipes should
have proper protective coating.
x) Colour code :
All the processed pipelines should be painted with proper colour code and direction of flow
also to be painted on the body of the pipeline at regular interval for easy identification.
xi) Approach road :
Approach road for fire tenders inside the installation should be in good condition and there
should not be any interference from any flow lines, overgrowth of grass etc.
xii) Steam trap :
Steam trap should be provided in the pipeline before entering the storage tank.
xiii) Pressure monitoring device :
Each flow line gas-oil separator, Heater treater vessels, pump delivery lines should be
provided with a pressure monitoring device (pr. Gauge / pressure recorder) for monitoring
pressure.
xiv) Flame arrestor :
All the fired vessels should be provided with Flame Arrestor.
xv) Effluent handling facilities :
The processed water in the installation should be led to an oil-water separator through a
closed piping system for further processing / treatment to avoid surface pollution and the
storm / rain water should be allowed to flow through the surface drainage system for disposal
in the natural stream.
xvi) Communication System :
The installation should have full-proof communication facilities.

Production-Oil
1.9.0 CHECK LIST FOR PRODUCTION INSTALLATIONS :

A checklist for safety inspection of production installations is appended in Chapter
14.0.
1.10.0 HAZARDOUS AREAS :
The Classifications of Hazardous area should be as per the Classified circular issued by
DGMS time to time. Following classifications are based on the the circular issued by DGMS
in the year 2001. (circular No. I(G) 2011 - Genl. / 3604-3753 dated 12th Sept, 2001)
1.10.1 Classification of Zones :
The areas inside a production installations are classified in different zones.
a) In every Zone- 1 hazardous area, only intrinsically safe of flame proof electrical
apparatus and equipment should be used.
b) In every Zone-2 hazardous area only flame proof or increased safety or pressurised
electrical apparatus and equipment should be used.
The extent of classified hazardous area should be as follows -
i) Effluent pit and Open sump :
a) The free space above the level of flammable liquid within the effluent pit or sump shall be
zone-I.
b) The free space lying up to 3m in horizontal direction from the edge of the pit and 0.5m
vertically above shall be Zone-2.
ii) Flowing well :
a) An area below ground level is Zone-1.
b) Area lying up to 3m horizontal direction from the edge of the cellars, trenches or sump shall
be Zone-2.
iii) Well servicing operation :
a) The area within a radius of 10 m in all direction from a well servicing shall be Zone-2.
iv) Gas vent :
a) The area within a radius of 1.5m from open end of the vent extending in all direction shall be
Zone-1.
b) Area lying within a radius beyond Zone up to 3m of the vent shall be Zone-2.
v) Gas oil separator/ fired vessel :
a) The area within a radius of 3m from any oil-gas separation vessel, and fired vessel shall be
Zone-2.
vi) Safety relief valve :
a) The area within a radius of not less than 3m from discharge of a relief valve extending in all
directions shall be Zone-2.
vii) Pig trap :

Production-Oil
a) The area within radius of 1.5m of the pig launching/receiving trap extending in all directions
is Zone-1.
b) And the area lying beyond Zoned up to radius 3m in all direction of the trap is Zone-2.
viii) Crude oil pump :
a) Area lying up to 3m in all direction from the pump is Zone-2.
ix) Storage tank :
a) The area inside the tank and within a radius of 1.5m from all opening including breather
valve, dip hatch, thief hatch is Zone-1.
b) And the area beyond Zone-1 up to 3m in all directions from the shell and roof is Zone-2.
X) Dyke :
a) The sump in the dyke shall be Zone-1.
b) And an area extending vertically up to a height of the dyke and horizontally up to physical
boundary of the dyke shall be Zone-2.
1.11.0 PRECAUTIONS AGAINST FIRE :
.i Smoking is strictly prohibited inside the production installation. Prohibitory sign for this
precaution should be displayed on the panel board near the entry gate. Any person entering
the installation with any smoking apparatus like cigarettes, matches and lighter must deposit
the same at the gate.
i
. The installation should have an emergency exit.
ii
. Hand tools used should be of non-sparking type.
i
v. The prime mover used for the crude oil service should be FLP type. If gas or diesel engine
is used the same should be separated with the pump with a sealed wall.
v) Ignition of indirect heater and heater treater should be done through remote ignition device.
vi) Proper size of canopy should be provided on the exhaust of chimney.
vii) Flame failure fuel cut off device should be installed in the I. Heater, heater treaters and all the
fire vessels should be provided with flame arrestor.
viii) While loading and unloading oil in road tankers, its engine should be stopped and battery
isolated from the electric circuit. The engine should not be re-started and the battery should
not be connected to the electric until all tanks and valves have been securely closed.
ix) At the loading arm, all oil pipelines, filling and delivery hoses, metallic-loading arm, swivel
joints, tank and chassis of tank vehicle should be electrically continuous and be efficiently
earthed.
x) Hot work permit should be issued to the concerned persons by shift In charge with approval
from I M, prior to commencement of any hot job inside the installations.
xi) Efficient earthing of all vessels and equipment should be done to take care of static charges.
Earthing connections should be checked every 6 month and measured values should be
recorded in a register. Earthing pits should be clearly marked for inspection.

Production-Oil
xii) Spillage of flammable liquids should be minimized to mitigate risk of fire and should be
immediately cleared.
xiii) All fire fighting equipments should be maintained in good condition.
xiv) Electrical control room, switch gear room, computer room etc. should be maintained in
good condition. There should be rubber mats in electrical control room and switch gear
room and cables should properly led in trenches. Lighting fixtures should be permanent and
no hanging wires or naked bulbs permitted.
xv) Vessel entry permit is to be issued by Installation Manager prior to taking cleaning /
maintenance jobs in any vessel. Fire hydrants, water sprinkler system, foam lines of storage
tanks should be inspected regularly to ensure their smooth functioning.
xvi) Regular inspection of well head fittings is to be carried out for any leakage of gas/oil. To
prevent unauthorized entry to the wells, periodical inspection of fencing is to be done.
xvii) Keep flammable material away from source of heat and store them in suitable cans and at
proper place.
xviii) All the wells should be clearly marked for easy identification
xix) Electrical equipment and fittings should be maintained properly.
xx) Easy access to fire extinguishers and learn how to operate them.
xxi) First aid items should be maintained properly.
xxii) Regularly removal of accumulated waste material like dry vegetation is to be ensured.
xxiii) Routine maintenance of all machinery should be ensured.
xxiv) Close supervision of premises at all times is to be ensured.
xxv) There should be proper drainage system in process areas. Necessary sumps should be
available in all operating areas like pump house, storage tanks, separator platforms etc. to
collect and recover spilled oil.
xxvi) W ater supplies should be adequate.
xxvii) Prohibitory caution signs should be displayed at all critical places.
1.12.0 Disposal of gas through flare system :
.i A flare line should be laid from the production installation to a flare stack /flare pit located at
distance of not less than 90 meters from the production installation.
i
. The flare line should terminate with a vertical riser pipe of not less than 9 meters in height or
in a flare pit enclosed with proper wall.
ii
. When the gas flow is intermittent, the flare line should be provided with a pilot burner with
remote control electrical ignition device to ensure that the pilot burner is continuously lighted.
i
v. At the flare stack, a water seal drum should be provided to prevent ingress of air into the
flare line to be ensured.
v. Leakage of gas if any in flare line and in the flare stack should be attended on priority basis.

Production-Oil
vi. There should not be any seepage of effluent from effluent evaporation pit located in gas
flared area.
vii. Effluelnt evaporation pit should be produced with suitable masonry boundary wall and
asbestos, enclosed to prevent seepage and transmission of heat respectively.
viii. Passage-to flare should be kept accessible and free from dry vegetation.
1.13.0 Additional Precautions for Gas Wells :
1. High GOR wells connected to oil collecting stations should be provided with Hi-Low pressure
safety device and should be regulated so that in case of drop in pressure in line either due to
failure of pipeline, or drop in separator pressure there is no excessive discharge of gas. On
the other hand, in case of any development of high pressure in the system, there should be
no back flow from the gas collecting station to the well.
2. High pressure gas is allowed to flow through a bean, as a result, on the downstream end,
there is a drop in pressure resulting in conversion of water vapour into ice/gas hydrate
which clogs the line and causes back pressure. It should be removed regularly with the use
of steam jacket / indirect heater / suitable inhibitors. In no case the pipe should be heated
with open flame to remove the blockage.

Production-Oil
2.0 STORAGE TANKS

2.1.0 GENERAL :
Storage tanks for crude oil are installed at well testing stations, Oil collecting stations (OCSs)
and central tanks farms. The capacity of these tanks varies from 30 to 50 M3 at wellhead to
over 1000 M3 at oil collecting station. These tanks are made of welded heavy steel sheets.
2.2.0 SAFETY FEATURES TO BE INCORPORATED DURING CONSTRUCTION STAGE :
The following safe practices are recommended during the construction of crude oil storage
tank.
1. Every tank for the storage of petroleum in bulk should be constructed of Iron or Steel in
accordance with codes or specifications approved by the competent authority.
2. The storage tanks should be erected on firm foundation or supports of non-combustible
material in accordance with sound engineering practice.
3. The height of a storage tank shall not exceed one and half times, its diameter or twelve
meters, whichever is less. (Refer Regulation 56 (C) of OMR, 1984)
4. An air space of not less than five percent of the total capacity of the tank or the space
prescribed in the code whichever is less should be kept in each tank.
5. Petroleum storage tanks shall be located in dyked enclosure with roads all around the
enclosure. Aggregate capacity of tanks located in one dyked enclosure shall not exceed
following values.
For group of floating roof tank — 120,000 M3
For group of fixed roof tanks — 60,000 M3
If a group of tanks contain both fixed and floating roof tanks then it shall be treated as group
of fixed roof tanks for the purpose of above limits.
6. Dyked enclosure should be able to contain the complete contents of the largest tank in the
tank farm in case of any emergency. Enclosure capacity shall be calculated after deducting
the volume of tanks (other than largest tank) up to the height of the enclosure. A free board
of 200 mm above the calculated liquid level shall be considered for fixing the height of the
dyke.
7. The distance between the nearest tanks located in two dykes shall be equivalent to the
largest tank diameter or 30 meters whichever is more.
8. The dykes should be of earthen/concrete construction having trapezoidal cross section.
The dykes shall not have slope steeper than 1-1/2 horizontal to 1.0 vertical. The top flat
surface of dykes shall be at least 600mm wide for dykes up to 1 meter. height, for dykes
above 1 meter. height, top flat surface size has 1000 mm width. Brick or stone masonry
wall may be provided where space does not permit construction of earthen dykes.
9. Piping from/to any tank located in single dyked enclosure should not pass through any
other dyked enclosure. Piping connected to tanks should run directly to outside of dyke to
the extent possible to minimise piping within the enclosures.

Production-Oil
10. No fire water/foam ring main shall pass through dyked enclosure.
11. The minimum distance between a tank shell and the inside face of the dyke wall shall not be
less than 5mts and the maximum height of the tank should not exceed one and half time
diameter of the tank.
12. When persons are required to work at a height of more than 1.8 meters above ground,
suitable working platform with standard railing and hand rails should be provided.
13. While painting a storage tank, the scaffold should be suspended from the tank railing and
persons working on the scaffold should be provided with safety belts and life lines.
14. Tofacilitatelifting of steel plates, these are provided with hooks welded in place, it should be
ensured that the hooks are securely welded in position to prevent accidental disconnection.
15. Persons engaged in construction of tanks should be provided with protective footwear and
helmets.
16. During the construction of storage tanks in the existing production Installations, the following
precautions are to be taken :
a. The area should be free from any flammable material.
b. The area to be barricaded with asbestos enclosure.
c. Gas concentration cheeks to be carried out regularly and to be recorded on the permit.
d. All hot jobs involved in construction of tanks should be carried out after obtaining Hot work
permit from the competent Authorities/Installation Manager.
e. Adequate number of portable fire extinguishers should be made available at the site.
.
f Adequate availability of water for fire fighting should be ensured.
g. The safe inter-distances between the tanks/offsite facilities should be as per OISD-1 18.
2.3.0 SAFETY FEATURES FOR OPERATIONAL PURPOSE :
In the operation of storage tanks, the hazards are due to failure of tank under pressure,
ignition of vapour and fire. The recommendations listed below should be followed for safe
operations:-
i) General :
1. A breathing valve should be installed on the tank roof which should open at any pressure
differential, both positive and negative, thereby maintaining stable conditions inside the tank.
2. Each tank should be fitted with level with suitable type i.e. dip-stick flow gauge, hydro static
gauge.
3. The gauge hatch should be lined with non-ferrous material to prevent sparking.
4. Manholes should be provided in the tank roof as also in the lower shell, to facilitate cleaning.
5. Suitable stairways with non-skidding surface and hand railing should be provided up to the
tank roof.

Production-Oil
6. Every storage tank above ground with a capacity up to 500 M3 should be enclosed with a
dyke or bundh constructed above the ground level with a containment volume equivalent to
the maximum capacity of the largest tank within the enclosure.
7. Every tank should be provided with isolation valve both at the inlet and outer side.
8. Pipelines connected to storage tanks should be laid on supporting blocks of concrete.
9. Steam lines should be provided with steam trap device.
10. Every storage tank, including its roof and all metal connections, should be electrically
continuous and be efficiently earthed. Earthing connections are to be checked once in every
six months and a record to be maintained thereof.
11. Proper illumination to be made all around the Tank farm.
ii) Drainage :
1. All enclosure surrounding above ground tanks should be provided with proper drainage
facilities in such a way that no water is allowed to accumulate in the enclosure.
2. No part of the enclosure referred aforesaid should be below the level of the surrounding
ground within the protected area.
3. Where drainage is effected by means of a pipe, the same shall be fitted with a valve which
is capable of being operated from the outside of the enclosure or with any other arrangement
as approved by the Competent Authority.
4. All valves and other openings for draining off water should be kept closed except when
water is being drained off.
5. There should be separate drainage system for Storm and processed water to avoid pollution
problem.
iii) Precautions Against Fire :
1. There should be water drenching system in the tanks more than 500m3 capacity.
2. Fixed connections for foam injection should be provided in the tanks of more than 500m3
capacity.
3. Fire monitors to be fitted on the all sides of the tank farm area.
4. A ring-road to be provided around the tank farm for easy access during emergency.
iv) Protection against corrosion :
All tanks for storage of petroleum in bulk installed on the ground or below the ground, should
be protected against corrosion by the use of protective coatings or cathodic protection or by
any other means approved by the Competent Authority.
2.4.0 CLEANING AND MAINTENANCE :
Cleaning and maintenance work inside storage tanks can be hazardous due to presence of
flammable vapours which can cause fire or asphyxia to persons engaged in such work.

Production-Oil
During cleaning of petroleum storage tanks, the recommendations, listed below provided
guidance in this respect :
1. a. The work should be undertaken with written permission of the officer-in-charge and in
case involves welding, a hot work permission should also be obtained by the person
undertaking cleaning and maintenance work.
b. Prior to commencement of any maintenance/cleaning jobs inside the tank, a detailed

plan of work should be made by Installation Manager/ competent authority.
2. Before the tanks are opened, it should be ensured, that the appropriate valves have been
securely closed blind flanges installed and warning notices “Tank repair in progress - Do not
operate valves” are displayed. The tank should be positively isolated.
3. The tank and its control equipment should be flushed with water or inert gas before undertaking
work inside it.
4. During the whole time of maintenance and repairs are carried out, a competent person
authorised for the purpose should be present at the site to ensure that work is carried out in
accordance with the instruction and permit issued.
5. A team of atleast three persons should be entrusted with the work. While one person carries
out the work, another should closely watch that there is no danger, the third person should
remain outside the tank ready to assist; in case of any danger all persons should promptly
withdraw to safety.
6. No person should enter a tank for cleaning or maintenance, unless the tank is first examined
by competent person and found to be gas-free and safe for entry.The term “gas-free” means,
the concentration of inflammable and/or toxic gases as measured with suitable instruments
in any tank, is within safe prescribed limit value of the gas being measured, for persons
enter.
7. When it is necessary to enter into a tank which is not gas free or in which oxygen contained
is less than 1 9%, persons who are required to enter the tank should be provided with self
contained breathing apparatus or a full face piece mask with a pressure supply of respirable
air by means of a hose pipe.
8. Persons required to use breathing apparatus and hose-pipe gas mask, should have adequate
training in the use of such apparatus and ensure that the equipment control valves are in
good working condition and there is no leakage in the air supply system.
9. When working inside the tank, persons should be provided with safety belts and life lines.
The free end of the life-line should be held by the person (outside the tank) who should be
conversant with the distress signals, which a person working inside the tank may transmit.
It such event, immediate steps should be taken to rescue the person to safety.
10. During the time any work a qualified person to administer artificial respiration and first aid
should be present on the spot.
a) A competent person, who is qualified to administer artificial respiration and first aid should
be present on the spot.

Production-Oil
b) Adequate number of self-contained portable hand lamps of approved type should be provided
and used inside the tank.
c) Adequate arrangement for fire fighting should be made. It should also be ensured that persons
engaged in the work are conversant with the use of fire extinguishers.
2.5.0 TESTING :
Storage tanks after being installed and secured in the final position or after undergoing re-
installation or any major repair should before being put into use be tested by water pressure
by a competent person. The water used for testing should be free from petroleum oil.
2.6.0 INSPECTION OF STORAGE TANKS :
OISD-1 29 deals with the Inspection of various types of storage tanks. Areas to be Inspected,
facilities for Inspection, the Inspection procedures and frequency, methods of repairs and
likely cause of deterioration of storage tanks in service have been specified in this standard.
i) SAFETY IN INSPECTION OF STORAGE TANKS :
1. A person shall not go alone on the roof of storage tanks for inspection.
2. No walking shall be done on the roof plates where thinning/perforations are observed.
Necessary planking may be provided for walking on such roofs. Ultrasonic thickness
measurements shall not be carried out when the tank is receiving or despatching.
3. No hot work shall be carried out inside the tank prior to gas freeing of the same. Hot work on
bottom plate shall be done under strict supervision where perforation and/or lead are
observed.
4. All leaded tanks must be completely shot blasted and thoroughly cleaned before entering.
5. Safety belts shall be worn while working at height.
2.7.0 SAFE WORKING PROCEDURE FOR TANK REPAIR :
Although the procedure for repair to be adopted will necessarily depend upon the condition
of the tank bottom, the type and extent of hot work repairs to be performed and the result of
inspections, some guidelines are given here :
The precautions against presence of flammable vapours and arrangements for fire fighting
mentioned above should be adopted.
i) Minor Repairs :
The type of hot work usually involves the welding of corrosion points, patches or other repair
jobs over small areas. The following procedure may be adopted when welding supports of
braces, if the bottom not in good condition.
1. Drill and tap a hole for 13 mm (1/2") pipe adjacent of the repair area, connect a supply of
carbon dioxide or other inert gas to the tap by metal tubing. Some device, such as manometer
or flow meter, should used to prevent over pressurising the tank bottom.
2. Maintain a flow of inert gas to ensure that, before work has begun and during the course of
work, the atmosphere in the area of welding will not support combustion of any flammable
vapour that may be present.
3. Remove tubing, plug hole tapered pin or other device and back-weld promptly, as required.

Production-Oil
ii) Major Repairs :

When repair jobs involving most of the tank bottom are planned, the flammable liquids and/
or vapour in the tank should be flushed out with water. Watch for leakage in the tank and plug
leaks temporarily to keep the tank bottom dry. Remove nipples, plug holes with tapered pin
or other device and back-weld as required after repairs are completed.
iii) Perimeter Repairs :
When is intended to undertaken repairs around the periphery of a tank, the excavation should
extend to atleast 30 cm beyond the point of any hot work and wide enough for a person to
work in safety and comfort.
a) Seal off all openings between the floor plates and the tank foundations by packing with mud
or some other suitable material. Such packing should be checked from time to time to
ensure that the seal remains intact.
b) Presence of flammable vapours should be checked with gas detectors near excavations
and seals between floor plates and foundations.
c) A portable air blower should be used for ventilation.
iv) Sectional repairs :
When making sectional repairs to tank bottoms, the following methods may be used :
a) Cold-cut the tank bottom to be replaced, using a hand or air-operated tool and remove. A
coolant should be applied continuously to the cutting edge of such tools to reduce the heat
of friction. Remove earth from under the sections to be replaced. Fill with damp sand and
seal the perimeter of the patch area with or some other suitable non-corrosive material.
b) Cheek leakage of gas with gas detector to ensure that an effective seal has been made.
c) When large sections of the bottom must be replaced and it is questionable that the seal will
remain effective it is better to maintain an inert atmosphere under the patch area when hot
work is being done during installation of a new section. This may be accomplished by using
C O2 or other inert gas.
2.8.0 EARTHING :
1 Every storage tank should be electrically connected with the earth in an efficient manner by
not less than two separate and distinct connections placed at the opposite extremities of
such tank.
2. The connection and contacts required should have as few joints as possible. Alljoints should
be riveted welded or bolted and also soldered to ensure both mechanical and electrical
soundness.
3. The resistance to earth should not exceed 7 ohms and the resistance to any part of the
fitting to the earth plate or to any other of fitting should not exceed 2 ohms.
2.8.1 Testing Of Earth Connections :
1. The connections and contacts of the storage tanks should be inspected and tested by a
competent person at least once in every 6 months by means of a direct reading instrument
such as meggar.
2. A record of such inspections and tests should be maintained properly.

Production-Oil
3.0 SAFETY DEVICES FOR ON-SHORE PRODUCTION

INSTALLATION
3.1.0 Manifolds :
)
i Non return valve (NRV) in each flowlines to avoid backflow to well.
i) Pressure gauge/recorder in each flow line to monitor the pressure of the wells.
iii) Double earthing to dissipate static electricity.
iv) Demarcation of each well connected to the manifold for easy identification.
3.2.0 Indirect heater :
)
i Temperature gauge in both incoming and outgoing stream.
i) Thermal insulation on the IH body as well as up to 3m height of the chimney to avoid accidental
burnt.
iii) Flame arrestor on the burner side to prevent backfire.
iv) Low temperature fuel shut off valve to cut off the fuel supply to the burner in case of accidental
put off of pilot burner.
v) Remote ignition system for lighting the heater.
vi) High temperature shut-down device to cut off the fuel supply if the temperature of the water
/fluid goes beyond its presented temperature.
vii) Double earthing to dissipated static electricity.
viii) Proper sizes of canopy on the exhaust of the chimney to contain the spark/shoot that may
be generated inside the chimney.
3.3.0 Heater Treater / Emulsion Treater :
)
i Thermal insulation on the body and up to 3 meters height of the chimney to avoid accidental
burning.
i) Flame arrestor on each burner to prevent backfire.
iii) Remote ignition system for lighting the burner.
iv) Low temperature fuel shut-off valve to cut off the fuel supply to the burner in case of accidental
put-off of pilot burner.
v) High temperature shut down device to cut off the fuel supply if the temperature of the fluid
goes beyond its preset temperature.
vi) Double earthing to dissipate static electricity.
vii) High liquid level dumping valve to maintain a constant liquid level inside the vessel.
viii) Safety relief valve (SRV) of adequate size.
ix) To lead the safety valve discharge to a safety distance through a closed piping system.

Production-Oil
x) A bundh around the vessel to avoid spillage of crude in case of accidental leakage of the
vessel.
xi) A suitable shed over the vessel.
xii) Gauge glasses to monitor the liquid level of the vessel.
xiii) Pressure gauge/recorder to monitor the pressure of the vessel.
xiv) Separate fuel and servo control lines with isolation valves to cut the fuel supply in case of
emergency.
3.4.0 Unfired vessel / Gas oil separator :
1. S RV (preferably two) in each gas oil separator.
2. Pressure gauge to monitor the pressure of the separator.
3. Double earthing of separator to dissipitate static electricity.
3.5.0 Tank Farm :
)
i Suitable enclosure for containment of crude in case of leakage of tank
i) A valve on the drainage system to control the outlet of drain.
iii) Sufficient electrical earthings to dissipitate static electricity.
iv) Foam pourer system to generate a foam carpet over the fluid surface in case of fire.
v) W ater drenching system to cool the surface of the tank in case of fire.
vi) Breather valve with flame arrestor on the roof of the tank to breath in/out at the time of filling
/ evacuating.
vii) Automatic tank dip level gauge to monitor the fluid level of the tank.
viii) Separate drainage systems for process water and effluent water to arrest surface pollution.
ix) Fire monitors around the tank area.
x) Ring road around the tank area.
xi) Proper illumination.
3.6.0 Crude oil dispatch pump :
)
i A barrier wall (with proper seal) separating the prime mover with the pump.
i) Spark arrestor on the exhaust of the prime mover.
iii) SRV on the pump delivery line.
iv) Check valve in the delivery line.
v) Guard on all the rotating parts.
vi) Thermal insulation on the exhaust pipe of the engine to avoid accidental burning.
vii) Connection of SRV outlet to the pump suction line to avoid spillage of crude. Pressure
monitoring device on the delivery side of the pump.

Production-Oil
3.7.0 Flare Pit :
)
i A boundary wall made of fire brick wall of minimum 5 mts. height all around with a door at the
entrance with locating device.
i) A suitable earthen bund inside the pit to arrest effluents.
iii) A pilot burner for lighting the flare.
iv) Manifolding of flare was to avoid jesting action of the gas.
v) The bottom & sides of the flare pit should be of RCC construction.
3.8.0 Formation water disposal pump :
)
i Rubber mat on the floor of electrical operating panel.
i) Proper guard over the all rotating part.
iii) Sand filling on the electrical cable Trench.
3.9.0 Pig Trap :
)
i Pressure monitoring device.
i) Pressure release valve
iii) Pig launching / receiving indicators.
3.10.0 RECORDS TO BE MAINTAINED IN A PRODUCTION INSTALLATION :
1. DGMS’S A P P R O VAL LETTER OF THE INSTALLATION
2. IMS APPOINTMENT LETTER FROM COMPETENT AUTHORITY
3. APPOINTMENT LETTER OF COMPETENT PERSONNEL.
4. PRESSURE TEST RECORD OF THE VESSELS.
5. PRESSURE TEST RECORD OF THE SAFETY VALV E S
6. EMPLOYEES PERMANENT ADDRESS BOOK (FORM-B)
7. EMPLOYEES LEAVE POSITION RECORD (FORM-G)
8. ALL MAJOR REPORTABLE ACCIDENT RECORD (FORM-J)
9. RECORD OF MINOR ACCIDENT(F-K)
10. RECORD OF ALL NEAR-MISS INCIDENTS
11. HOT & COLD WORK PERMIT RECORD.
12. MOCK FIRE DRILL RECORDS
13. PERIODICAL MEDICAL EXAMINATION RECORD(FORM-O)
14. RECORD OF FIRST-AID TRAINED PERSONNEL

Production-Oil
15. RECORD OF FIRE FIGHTING TRAINED PERSONNEL
16. RECORD OF MINES VOCATIONAL TRAINED PERSONNEL
17. LIST OF COMPETENT PERSONNEL OF THE OCS DULY SIGNED BY THE MINES
MANAGER.
18. RECORD OF PERIODIC TEST OF GAS BY EXPLOSIMETER
19. RECORD OF THE INSTALLATION MANAGER’S DIARY
20. FIRE CONTINGENCY PLAN
21. PERIODIC CALIBRATION / INSPECTION RECORDS OF ALL THE INSTRUMENTS,

GAUGES, CONTROLLERS ETC.
22. PERIODIC HEALTH CHECK UP OF THE INSTALLATION SUCH AS THICKNESS

DETECTION, RADIOGRAPHIC TEST
23. PERIODIC ELECTRIC RESISTANCE TEST FOR TANKS.
24. MAINTENANCE RECORD OF CODP/FWDP/GEN SET ETC.
25. A BIND BOOK COVERING MONTHLY EXAMINATION REPORT OF X-MASS TREE ON

TEMPORARY SHUT WELL
26. A SUPERVISOR’S MONTHLY REPORT BOOK SPECIFYING THE CONDITION OF EACH

WELL INCLUDING PRESSURE
27. EXTERNAL SAFETY AUDIT RECORD
28. INTERNAL SAFETY AUDIT RECORD
29. SAFETY MEETING RECORD

Production-Oil
4.0 OPERATING PROCEDURE OF A PRODUCTION

INSTALLATION :
4.1.0 General :
Before starting up/commissioning of a production installation completion of the following
jobs are to be ensured :
1 Completion of piping job in all respect.
2. Blind flange / plug on each open ended piping connection.
3. Working of fire fighting system including water monitors.
4. Installation of all safety and operating devices in each unit.
5. Hydraulic testing of the units and functioning of the SRV of all units.
6. Adequate manpower with a vehicle to facilitate opening up / closure of wells at wellhead,
preferably with wireless communication system.
7. The operation is to be carried out in day light only.
4.1.1 Manpower :
IM, 2 competent persons and minimum 2 persons from the operating staff should be present
during commissioning stage of a new installation. Also the personnel from the Instrumentation
Department should be available during the commissioning of a new installation.
4.2.0 STARTING UP :
4.2.1 LIGHTING PROCEDURE OF INDIRECT HEATER / EMULSION TREATER
(1) Ensure the closure of all the valves and check the water / fluid level in the indirect heater /
emulsion treater.
(2) Crack open the fuel valve in pilot line and put the ‘low temperature shut down switch’ to
starting position. Gas will start leaking through the pilot burner.
(3) light the pilot burner through remote ignition system and adjust the flame if required (through
mixture).
(4) Once the pilot flame heated the thermostat of the “Low temperature shut down switch”
switch will automatically come to its running position.
(5) Open the valves on the main fuel line to light the main burner and adjust the air mixture if
required.
(6) Check the function of the temperature controller by increasing the temperature of the fluid to
the setting temperature. At this point the temperature controller installed in the main fuel line
will cut off the fuel to the main burner.
(7) Check the function of low ‘temperature shut down switch’ by putting off the main burners as
well as pilot burners and let both gas to be leaked through the burners. After a minute the low
temperature shut down switch will discontinue air supply to the fuel control valve and thus
cut off fuel to the main burner as well as to the pilot burner.

Production-Oil
4.2.2 Shut down procedure of Indirect heater / Emulsion treater :

a) Cut-off fuel supply to the main burner and pilot burner by shutting down the main fuel valve.
4.3.0 Procedure for Lighting of flare :
1. Ensure closure of all the valves leading to flare pit.
2. Open the pilot line valve partially.
3. Light the pilot burner with the help of remote ignition device/by other safety means.
4. Open the valve and allow the gas to enter flare pit and thus to burn the gas.
4.3.1 Procedure for shut down of flare :
1. Open the valves in the vent lines
2. Close all the valves (including pilot valve) leading to the flare and thus put off the fire.
4.4.0 Operating procedure for running crude oil dispatch pump (CODP) :
)
i To ensure the POL and water level in the prime mover and pump.
i) To ensure disengagement of clutch
iii) To ensure opening of suction, delivery and circulating lines of the pump.
iv) To ensure opening of suction valve of the storage tank and valve on the main delivery line.
v) To ensure the proper functioning of the pressure recorder / pressure gauge (preferably fluid
packed).
vi) Open the fuel line of the prime mover.
vii) Start the engine and observe for few minutes.
viii) To inform receiving section (Tank farm).
ix) Engaged the clutch to run the pump and observe for few minutes.
x) Close the circulating (by pass) valve slowly with a closed observation on the pressure gauge.
After shutting down the by pass valve completely observe the pressure at least for 10 min.
4.4.1 Shut-down procedure for stopping CODP :
)
i Dis-engaged the clutch to stop the pump.
i) Shut the fuel supply valve of the prime mover to stop the engine.
iii) Close the delivery valve of the unit.
iv) Open the by pass valve.
v) Close the suction valve.
4.5.0 Operating procedure of formation water disposal pump :
)
i Open the suction valve / valves of the Tanks and Pump.
i) Ensure opening of water line for cooling the bearing.

Production-Oil
iii) To start the pump and observe the pressure developed and ensure the current drawn in
acceptable limit.
iv) Open the delivery valve of the pump gradually to discharge in the disposal well/wells
maintaining the delivery line pressure.
4.5.1 Shutdown procedure of stopping FWD pump :
1. Shut the delivery valve of the pump
2. Switch off the motor of the pump.
3. Shut the suction valve of the pump.
4.6.0 COMMISSIONING OF A NEW INSTALLATION :
4.6.1 Dry stream :
)
i Filled up the Servo air / gas (supplied through an air compressor/taken from gas distribution
system) in the servo system and to make ensure function of the control gears/LL controller
etc. in all the vessels/units in the installation.
i) Check the water level in the indirect heaters and fire the Indirect Heater (as given in 4.2.1
above), if the gas is taken from the distribution network or to wait till the gas is available in
the servo system after opening up of the well) and make sure that all the control and safety
gears are working properly. Set the temperature of the I/Heater in the desired level.
iii) To make sure the opening of all valves in the oil and gas flow stream (up to the tank in case
of oil and up to the flare / compressor station / distribution network in case of gas) and
closure of all by-pass and drain valves of the separators, Indirect Heater & tanks.
iv) Light pilot burner in the flare-pit.
v) As per advise of IM, the production personnel will open up a particular well in the wellhead
very slowly and the man deputed in the manifold will also open up the manifold valve after
ensuring pressure in the manifold through the pressure gauge of the flow line.
vi) The flow stream will get preheated as it passes through the indirect heater.
vii) There will be gradual pressure build up in the system. Set the back pressure of the separator
by adjusting the gas controller in the gas outlet line and thus continue the process in the next
set of separators till the gas goes to the distribution system/flare pit.
viii) Maintain the fluid level of the separator by adjusting the Liquid Level Controller (LIC). Continue
the same process in the next series of vessels till the oil is collected in the crude oil tanks.
4.6.2 Wet stream :
)
i Same as process (i) to (vii) mentioned above.
i) The wet crude coming out from the HP wet separator will enter the three phase separator
(TPS) where the fluid is separated in three phases. The operating procedure of TPS is as
follows :
a) Ensure the proper doze of demulsifier in the inlet.
b) Maintain the pressure in the TPS by adjusting the gas controller at gas outlet. Close the

Production-Oil
control valve of water outlet and maintain the oil level in the separator by adjusting the LLC
of gas/oil interface. The separated fluid then go to Emulsion treater for further processing.
c) After maintaining the oil level in the separator, wait till the water-oil level in the separator is
attained to the desired level. Open up the control valve in the water out let line and adjust the
LLC in oil-water interface to discharge the water to the formation water storage tank.
4.7.0 Emulsion Treater :
The fluid enters Emulsion Treater is treated thermo-chemically for separation from each
phase. The following are the steps to be adopted during the commissioning of Emulsion
treater
1. Light the Emulsion treater (as mentioned in 4.2.1 above) and ensure the proper functioning
of all control gears.
2. maintain the pressure of the Emulsion treater after adjusting the gas controller in the gas
outlet line.
3. adjust the oil level by adjusting the LLCs of both the chambers in gas-oil interface.
4. Adjust the water level in the vessel after adjusting the LLC of both chambers in oil-water
interface.
4.8.0 Manual Tank Dipping Procedure :
GENERAL : Manual dipping of crude production tank have now been replaced by automatic
tank level gauge particularly in permanent type of production installation like OCS, tank
farm. The system of manual dipping should be avoided to the extent possible as it involves
safety hazard in releasing the trapped rich gas of the storage tank.
However the following procedure may be adopted in manual dipping of crude oil tank.
(i) Working personnel should inform the shift in charge at the time of going for dipping.
(ii) Climb-up to the top of the tank. Loosen the locking key/nut of the lid of the dipping hole and
allow the gas to release completely.
(iii) After releasing the gas the lid should be removed and the dip gauge should be inserted
slowly into the tank through the holes till it touches the bottom of the tank. In no case the dip
weight should be dropped from a height.
(iv) Pull out the gauge and note the fluid level of the tank from the mark on the dip gauge.
(v) Position the flapper/lid over the hole and lighten the lock key/nut.
(vi) Climb down from the tank.
(vii) Gauger should ensure that there is no cotton waste and any other wiping/foreign material is
thrown at the top of the tank.
(viii) No gauging and sampling of tanks should be undertaken during thunder and hail storm.
(ix) Dip should not be taken during filling and evacuation of the tank.

Production-Oil
4.9.0 BLOWING OF SRV IN A PRESSURE VESSEL :
4.9.1 SRV of a pressurized vessel in a production installation may blow for many reasons. The
major causes are :
a. Sudden thrust of incoming fluid which may be due to opening up of the well at the wellhead
in uncontrolled manner.
b. Due to uncontrolled entry of input gas in intermittent lifting system.
c. Due to sudden change in well behaviour.
d. Restriction at the outlet of the gas controller.
e. Drop of wedge of the gate valve at the outlet.
.
f Closure of outlet valve due to operational mistake.
g. Inadequate size of orifice in gas outlet line.
4.9.2 Measures to be taken to overcome the problems :
i. Sudden thrust of incoming fluid :
Wells during opening in the wellhead should be opened up in very slowly and steadily to
avoid sudden thrust in the production installation. It may be done in the following ways:
(1) Check the closure of all the valves in the X-mass tree and also the flow line valve.
(2) Install required size of bean in the bean housing and close the housing.
(3) Open-up the master valve of the well fully, thereafter arms valve and side valve of X mass
tree should be opened. Open the flowline valve slowly in controlled manner.The well fluid
will start flowing through the flow line.
(4) Open-up the flow line valve gradually and observe the pressure in the flow line. The operation
should be repeated till the valve attains full open position.
ii. Uncontrolled rate of gas production due to improper faulty gas lifting system :
In gas lifting system high pressure lifting gas from the casing is allowed to enter tubing to lift
the fluid from the well. Improper functioning / design of the gas lift system may also lead to
problem of handling excessive gas and may lead to blow of SRV of the separators. To
overcome this problem the following actions should be taken.
(1) Installation of proper size of G/L valves at the sub-surface.
(2) Ensure the injection of required/calculated quantify of lifting gas in to the casing at suitable
interval by adjusting the interval and duration of the time cycle controller. (TCC).
(3) By optimizing the quantity of lifting gas i.e. the opening of TCC of the G/L wells in the area
should be set in such a way that two or more TCCs should not be opened simultaneously.
This will avoid the excessive gas handling problem in the pressure vessels and thus eliminate
the problem of blowing of SRV apart from the optimization of lifting gas.

Production-Oil
iii. Change in well behaviour :

There may be sudden change in behaviour of certain wells to convert into high gas producer
(high GOR). Producing such wells in the installation may be problematic and may lead to
blow of SRV.These wells should be identified and precautionary measures such as reducing
the size of flow-arm bean etc. are to be taken to avoid gas-handling problem in the installation.
iv. Gas controller :
Restriction in the gas controller causes obstruction of outgoing gas and may leads to blowing
of SRV.To overcome this problem the seat of the control valve should be cleaned from all
the foreign materials. All the rusts, cutting chips, welding waste etc. left inside the line at the
installation stage should be flushed out before commissioning.
v. Malfunctioning of gate valves :
The SRV may also blow due to malfunctioning of gate valves. Hence, all the valves used in
the installation should be of good quality and conform to API standard.
vi. Operational Mistake :
One of the reason for blowing of SRV is the mistake made by operational personnel. The
mistake may be minimized by adopting the following -
(1) All piping should be laid at least 30 cm above the ground level for easy identification.
(2) Piping should not be clumsy.
(3) Colour code including the direction of flow should be marked on the line for easy identification.
(4) Raising stem gate valve should be used in the installation for easy identification of the mode
of operation of the valves from a distance.
vii. Improper size of orifice at gas outlet line :
Sometimes improper size of orifice in the gas outlet line may restrict the flow and leads to
blow of SRV in an installation. In such case the orifice should be replaced with proper size
of orifice plate.
4.9.3 Procedure for attending a vessel during popping of Safety Relief Valve (SRV) :
1 Shift-in charge with his co-worker should rush to the site and identify the popped vessel. It
may be identified by the visual / audio control alarming system or by observing the pressure
gauge installed on the body of the vessel.
2. After identification the over pressurized vessel, the by pass valve of the gas controller is to
be opened and should be throttled in such a way that the pressure of the vessel dropped
down to normal pressure and the SRV stops popping.
3. At this time, the gas controller of the flare line may require to be by-passed to release the
excess gas in the system. While throttling the by-pass valve of the controller in the flare line,
in no case the upstream pressure should be bled off below the gas distribution pressure.
Otherwise, the gas from the distribution system will flow back to the flare.
4. Identify the problem and rectify the defects (as mentioned above).
5. Close all the by-pass and restore back to normal operation.

Production-Oil
4.10.0 LIQUID CARRYOVER IN PRODUCTION INSTALLATION :

Liquid carryover is a most common problem encountered in production installation. When
liquid phase of the flow enter the gas stream the phenomena is called liquid carryover.
4.10.1 Detection of Liquid carryover :
Liquid carryover may be detected with
1. Black smoke in the flare pit due to burning of liquid phase of hydrocarbon.
2. Malfunctioning of gas controller which may lead to blowing of SRV in the separator.
3. Sudden drop in gas reading in the gas flowmeter.
4.10.2 Factors contributing the Liquid carryover :
Liquid carryover may occur for the following reasons -
(i) More load on the separator than its capacity :
Gas-oil separators need some retention time for separation of gas from liquid phase. If the
quantity of incoming fluid is more than its design volume, the retention time will be less and
some amount of liquid will present in the outgoing gas and liquid carryover may occur.
(ii) Restriction / malfunctioning of motor valve/valve in the liquid outlet line of the
separator :
Liquid carryover may occur if the liquid outlet line of the separator is chocked and also due
to malfunctioning of motor valve / faulty valve.
(iii) Malfunctioning of Liquid level controller :
The level of liquid in a separator is controlled through LLC. If LLC does not work properly the
liquid level will rise inside the separator and may go along with the gas stream causing liquid
carryover.
(iv) Closure of tank inlet valve/faulty check valve in the production line :
The oil separated in separators is finally collected in the crude oil storage tank. If the inlet
valve to the tank is closed or the flapper of the check valve got chocked, fluid may enter to
the gas stream and liquid carryover may occur.
4.10.3 Action to be taken to prevent liquid carryover :
(1) To ensure that the proper preheating of inlet fluid. If required temperature controller of Indirect
Heaters should be re-set.
(2) Ensure that the servo control pressure is maintained at the recommended level (it may be
adjusted with the help of air/pressure regulator installed in the line) and there is no leakage
in the sensor line leads to the motor valve.
(3) Check the LLC and functioning of the liquid control valve (motor valve).
4.10.4 Action to be taken after the liquid carryover :
(1) Open the by pass of the liquid control valve (motor valve) and allow to drop down the liquid
level in the separator. Shut the by-pass valve after the float of the LLC come back to its
normal position.
(2) Flush out the liquid from the gas outlet line and clean the gas controller properly.

Production-Oil
4.11.0 SAFE PRACTICES FOR OPENING OF BEAN HOUSING
1) Isolate the bean housing (B/H) by shutting in. arm valves and side valves respectively.
2) Measure the pressure in the bean housing at the test cock on the housing.
3) Release the pressure in the bean housing through the test cock.
4) If the pressure is not found to be released, (probably the side valve or arm valve may be
leaking) shut the Master valve/ flowline valve. Note: Release of pressure of the bean housing
should be closely observed and proper judgement should be applied to ensure complete
release of pressure.
5) Slightly unscrew the bean cap by hammering with a non-sparking hammer.Then release
the pressure inside bean housing by hammering the top of the bean cap. Observe the
tightness of the bean cap. If the bean cap is loose then there is no pressure and if the bean
cap is tight then there is still some pressure. Repeated attempt should be made to release
the pressure.
6) Remove the bean cap once there is no pressure.
7) Remove the bean with the help of a bean wrench.
8) In case the bean housing is filled with sand/wax, then clean by standing in a safe position.
During cleaning operation of bean housing, nobody should stand infront of the exposed
bean housing in the same line.
9) Use safety goggles and hand gloves.
10) Incase, the pressure from the line cannot be released and there is heavy sand/wax deposition
inside the bean housing then report the matter to superior and suspend operation till arrival
of competent authority.

Production-Oil
4.12.0 SAFE OPERATING PROCEDURE
LINING UP OF WELL FOR TESTING
1. Check the latest information viz. SITP, FTHP,FA P Flow rate, GOR, water cut and the flowline
pressure at the manifold (upstream of manifold) etc. of the well to be tested.
2. Check for Pressure gauge in the flowline at the manifold of the well to be tested.
3. Ensure sufficient ullage at Test tank.
4. Lining up of High Pressure Well :
)
i The inlet valve to Testtank is in open position.
i) Ensure functioning of Oil Dump valve and the gas control valve of TU-II.. The inlet valve to
TU-II is in open position.
iii) Ensure functioning of Oil Dump valve and the gas control valve of TU-I. The inlet valve to
TU-I is in open position.
iv) Ensure functioning of the gas flowmeter and install proper orifice plate and meter chart.
v) The inlet valve to HPMS and LPMS are in open position
vi) The inlet and outlet valves of the Test Unit Indirect Heater are in open position and the, by-
pass valve in close position. Check the water level, light the main burner and raise the
temperature of the water bath to around 600C. Where Indirect heater is not available, ensure
the functioning of the Steam Jacket.
vii) Close the Group Valve of the well to be tested in the group manifold slowly and monitor the
flowline pressure at the manifold (Upstream of the Check Valve)
viii) Open the Test Valve of the above well in the test manifold slowly and observe the flowline
pressure as well as the TU header pressure. There may be a marginal increase in the
flowline pressure from the normal line pressure due to restriction at the test plug valve,
which is normally smaller in size to that of the Group valve. However, if the flowline pressure
begins to shoots up, open the Group valve and close the Test valve in the manifold. Do not
put the well on test unless and until the cause of increase of flowline pressure is identified
and rectified.
5. Lining up of Low Pressure Well :
Follow the procedure as mentioned in para 3.0 above except steps iii) & v) which are to be
followed as under -
iii) Ensure TU-I is by-passed
v) The inlet valve to LPMS is in open position

Production-Oil
5.0 TRANSPORTATION OF OIL AND GAS BY PIPELINE
5.1.0 GENERAL :
In an oil field, transportation of crude oil and natural gas by pipelines from wells up to refinery
or prime consumer point consists of three different types of pipelines.
Firstly the flow lines. These are 60 to 114mm diameter pipelines laid from wells to Oil Collecting
Stations (OCS). Secondly, the delivery/ collector lines which are generally 15Omm to 250mrn
diameter pipelines, laid from Oil Collecting Stations / Gas compression Station to Central
Tank Farm(CTF)/ Gas distribution network. Thirdly, the trunk lines, which are generally
30Omm to 600mm diameter pipelines, laid from central tank farm / Gas distribution network
to refinery or primary consumer points.
While flow lines and trunk / collector lines are laid over lengths of 1 km to 30 kms within the
oil field, the trunk line are cross country pipelines and run over several hundred kilometers.
1. Flow lines are 5O mm to 100 mm NB pipelines i.e. 2" to 4" NB
2. Collector/ delivery lines are 150 to 25Omm i.e. 6" to 1 0" NB.
3. Trunk pipelines are 300 to 600mm i.e. 12" to 24" NB.
5.2.0 Approval for Laying of Pipeline :
1. No new pipelines should be laid nor any significant alteration be carried out in any existing
pipelines system of pipelines except with the permission in writing of the competent authority
2. Every application for permission should be submitted in form-VIII to the Regional Inspector
of Mines Safety, and a copy thereof should also be sent to the Chief Inspector of Mines
Safety and District Magistrate.
3. The application should be accompanied by two copies of an up to date plan of the area
where the pipeline is proposed to be laid showing the extent of land over which right of use
has been established and route of the pipeline indicating the districts and states through
which the pipeline will pass.
4. A comprehensive project report accompanied by all necessary drawings, pipelines details
giving reference to recognised codes followed, giving full details of the design, construction
and testing of the pipelines its components, the route along which the pipeline will be laid,
the manner of laying, and provision of proposed to be made for the maintenance and patrolling
of the pipeline also should be submitted to the Competent Authority.
5.3.0 Construction :
In the construction of pipelines, the recommended safe practices are given below:
5.3.1 Standard of Construction :
Liquid petroleum transportation piping system should meet the requirements laid down by
the American National Standard Institute in its document ANSI-1 B 31.4. Natural Gas piping
system should meet with the requirements laid down by the American National Standard
Institute in its documents ANSI-B 31.8.

Production-Oil
5.3.2 Right of Way (ROW) / Right of Use (ROU) :

1. To prevent construction of any permanent structure on the ROW / ROU, aerial inspection
should be carried out at minimum 3 months interval.
2. Whenever there is a village in the vicinity of ROW, temporary fences should be erected to
prevent cattle failing into the trench during execution.
3. Top one feet soil should be kept separately which can be back filled in its original position, so
that land can be handed over to the farmer in its original condition.
5.3.3 Handling and Stringing :
1. During transportation of Line Pipes through road, they should be tied up securely with rope/
chain on trailers, to prevent toppling down of pipes on bumpy roads. The pipes should be
unloaded carefully to prevent damage at the ends / body of the pipe.
2. While keeping the pipeline on wooden skids, every third skid should be arranged in crossed
manner i.e. like a scissors to prevent toppling down of the pipeline section.
5.3.4 Trenching :
Trenching operation should be just ahead of welding operation. This will avoid deep trenches
remaining open for many days, creating safety hazard to villagers and their cattle.
5.3.5 Sand Blasting :
During sand blasting, sand ejected with high pressure compressed air can cause injury to
personnel. The following precautions should be taken.
1. Before commencement of work, warning notices should be displayed.
2. Signaling arrangement should be provided between the sand blasting machine and the
workers engaged in cleaning.
3. The workers should be provided with personal protective equipment.
4. Coarse sand should be used for sand-blasting and the pressure of the compressor should
be not less than 5kg/cm2.
5. After the work is completed, supply of air to air-receiver should be cut off and the receiver
should be depressurized.
5.3.6 Welding :
Welding of pipelines in the fields should be carried out in accordance with the requirement
of American Petroleum Institute Standard 1104. Before welding, each pipe joint should be
swabbed with proper size of swab (of drift diameter) to ensure soundness of the pipe.
Night- caps should be installed in all the ends of the welded sections after completion of
every day operation.
5.3.7 Coating and Wrapping :
In this operation, use of coal tar enamel heated to about 2500 C poses danger to workers.
The following precautions should be taken -
1. The workers engaged in handling hot coal tar should be provided with and use protective
outer clothing of asbestos or rubber, goggles, helmet and footwear.

Production-Oil
2. Coal tar should be heated up to a temperature of not more than 2700 C. The primer should
be prepared at a distance of about 50 meters from the place where coal tar is heated.
3. From Dope kettle heated coal tar should be taken out into the bucket, through a tap only and
should be poured from the top by a container.
4. Adequate steps should be taken to prevent hot coal tar from splashing or failing on personnel.
5. While applying insulation, buckets containing hot coal tar should be carefully handled as to
prevent spark.
6. The detector-scope (Holiday Detector), which operates at high voltage, may cause danger
due to electric shock, gloves and rubber boots should therefore be used. No attempt should
be made to check moist. The probe should be handled only after disconnecting it from the
source of power.
5.3.8 Lowering-in and Back Filling :
Before lowering the pipeline in the trench, it should be ensured that no person is present
inside the trench. In case the sides cave-in, the pipelines should be kept adequately supported
before removing loose soil from underneath.
Following precautions are to be followed during such jobs.
1. Special care should be taken while lowering the pipeline on a hilly terrain with a grading. Also
utmost care is to be taken while lowering the concrete coated heavy pipes under a water
course.
2. Utmost care is to be observed in deciding the number of Tripods with chain pulley blocks for
a particular section of pipeline to be lowered. Also the capacity of chain pulley block must be
minimum 1.5 times the weight of pipeline section it is going to lift.
5.3.9 Air-Testing :
1. After welding a section of the pipe line of around 2 to 3 kms, air purging should be carried out.
5.4.0 Laying of Pipeline :
1. Pipeline should be laid in the most favorable route, avoiding as far as possible, known
obstructions and areas in which unusual external condition prevail.
2. Pipelines should be laid below the ground level except where laying thereof above the ground
level is desirable for topographical economic or other special reasons.
3. Where an underground pipeline has to cross any existing underground water or gas line,
cable, drain or other services, the pipeline should be laid at least thirty centimeters below
such services in a manner that will not obstruct access to such services for inspection,
repairs or maintenance.
4. The number of bends in the pipeline should be kept to the minimum by proper grading of
trenches of supports at crossings and other obstacles.
5. The route of underground section of a pipeline should be indicated by markers and not less
than two such markers shall be visible from any point along the route.

Production-Oil
5.5.0 Hydrostatic Testing of Pipeline :

1. Before the pipeline is put into commission, it should be subjected to hydraulic test at a
pressure one and half times the maximum working pressure for a period of 24 hrs. The
result of every such test should be recorded by the person making the test.
2. Before pressurizing the pipeline, it should be ensured that it is devoid of all air inside by
using a vent point of sufficient height. The water used for the testing should be clean.
3. Pressure should be raised slowly and gradually in small increments. Proper: and appropriate
interval must be observed in between pressurizing the pipeline for pressure to stabilize and
also to avoid sudden stress/strains to the line pipe materials.
4. A pipeline or a section thereof showing any significant drop of pressure during the period of
testing should not be used for transporting petroleum until necessary repairs have been
carried out and a satisfactory retest is done.
5. If during such testing, the pipeline breaks in the vicinity of any railway line, public road,
residential area, immediate steps should be taken to warn persons from approaching the
site. Adequate steps should be taken to prevent smoking or open flame in the area. In case
of railways, the competent authority should be immediately informed about the occurrence.
6. The test should be carried out at least once every 12 months on each completed pipeline
section which crosses in area where there is danger of water pollution by any leakage.
5.6.0 Safety Features :
There are two important safe-guards relating to operation of pipelines. Firstly, the pipeline
should be provided with a safety device for protecting it from pressures in excess of those
for which the pipeline was designed. Secondly, in case of any damage due to uncontrolled
escape of fluids from the pipeline should be restricted to avoid the danger of pollution and
fire.
5.6.1 The recommendations listed below should be adopted for this purpose :
1. A shut-off valve and also a non-return valve should be provided on the pipeline.
2. In case of gas pipeline, automatic high/low safety valve should be provided in the flow line to
isolated well and should be set to operate in the event of change in the pressure within 1 0%
of the normal working pressure.
3. Where pipelines are to cross railways, river or road, extra-thick section pipes should be
used at the crossing. The pipelines should be provided with a casing extending up to 10
meters from the center of railway track on either side. The casing should be provided with
vent pipes. Isolation valves should be provided on either side of the crossing. The valves
should be provided with adequate fencing over an area of five square meter in size.
4. The route of underground section of pipeline should be indicated by suitable markers at
every 500 meters and also at all turnings and uncased crossings. At least two such markers
should be visible from any point along the route.
5. All oil and gas pipelines of any size must be laid underground only and should have outside
insulation.

Production-Oil
6. No over ground gate valve and tee points should be provided outside the installation in any
remote location in any case, to avoid tampering and sabotage of such points.
5.7.0 Operation and Maintenance :
5.7.1 Patrolling and Inspection :
Adequate arrangement should be made for patrolling along the route of trunk pipelines by
line walkers at regular intervals with the following objectives -
- To cheek any leakage of fluids from the pipeline.
- To check any construction or operation by a third party in the vicinity of pipeline which may
endanger its safe operation.
- To check presence of gas in waste pits along the pipeline.
- To cheek erosion of cover over the pipeline laid in river beds.
In the event of any leakage or other undesirable occurrence, the matter should be immediately
reported to the officer-in-charge for appropriate action.
6.7.2 Cathodic Protection :
1. Pipe to soil potential should be measured on underground pipelines as per the approved
schedule; in case any dangerous Zone of static current is detected, adequate remedial
measures should be taken.
2. Underground pipeline should be inspected for external corrosion as per approved schedule
Suitable inspection pits should be made at different points to assess effectiveness of cathodic
protection.
5.7.3 Removal of Paraffin Deposits from Flow Lines :
- In order to melt and remove paraffin deposits from flow lines a steam injection unit is normally
used.
- The unit should be located at a distance, not less than 25 metres from the wellhead. The
exhaust of the engine should be provided with a spark arrester.A safety valve should be
installed on the steam line to release pressure in the event of pressure in the line exceeding
10% of the working pressure.
- Before commencement of operation, the steam injection line should be tested to a pressure
not exceeding one and a half times the expected pressure during the steam injection operation
or the pressure rating of the steam unit, whichever is lower. During the test, persons should
remain at a safe distance from the steam Generator unit.
5.7.4 Emergency Procedure :
It is possible that oil and gas pipelines may become damaged during unforeseen
circumstances, due to an act of nature or as a result of third party activities close to the
pipeline.
In order to deal with any such circumstances, emergency procedures should be formulated
giving details of the action to be taken for safe-guarding the installations as well as the
interest of the public.
It should specify the actions to be taken in the event of the following :
l Uncontrolled escape of oil or gas from pipeline.

Production-Oil
l Fire in the pipeline.
l Bursting or damage to the pipeline.
The emergency procedure should also specify the following :
l Action required by an OIL employee discovering a fire, a leakage or a damage to the pipeline,
l General alarm and communication procedure and action required of persons receiving the
alarm and communication.
l Instructions for operation of emergency equipment. Instructions for rendering safety to the
affected pipeline.
l Duties of key personnel.
Accidents brings tears

Safety brings cheers.

Production-Oil
6.0 WELL STIMULATION OPERATIONS / WELL

MAINTENANCE JOBS
6.1.0 HYDRAULIC FRACTURING
To induce and increase flow of hydrocarbons held in a tight reservoir, oil-based or water-
based or emulsion fluids are injected under high pressure to fracture formations; the fractures
thus created are propped up with sand to sustain flow. In this operation, since the formation
is fractured with flammable fluids, there is danger of fire. The other hazards are due to high
pressure in equipment and hazards associated in handling of acids and other chemicals.
Liquid nitrogen is also used for injection into wells.
In this operation two to four pumping units, a blender and storage tanks are deployed. Diesel
engines provide the motive power.
6.2.0 The recommendations listed below provide guidance for safe operations.
6.2.1 Safe location of equipment
The pumping unit and blender should be located at least 30 meters away from the well head
on the upwind side. The tanks containing fluids should be located further away, at least 45
meters from the well head.
There should be a clear and walkable passage between the pumping and other units and
the width of the passage should be at least one meter.
6.2.2 Precautions against fire
1. An area within 30 meters of the well head should be treated as danger zone in which no
smoking or open flames should be permitted and all electrical equipment and transmission
lines within should be de-energised.
2. The exhaust of diesel engines should be discharged on the upwind side. The engine exhaust
system should be provided with spark arrester.
3. Fire fighting crew and a fire tender should stand by. It should be ensured that persons
engaged in the operations are conversant with the use of fire extinguishers. See details
under the head “Fire extinguishers”.
6.2.3 Safety of pressurised vessels and pipelines
1. It should be ensured that the wellhead connections are of such pressure rating as would be
suitable for the expected pressure for fracturing the formations.
2. The fracturing unit, connecting lines and control valves should be tested to a pressure. The
suction line should provide positive suction and should be tested to pressure of 2.5 kg/cm2
or as recommended by the manufacturer. The pumping line should be provided with a non-
return valve near the wellhead and also a bleeder valve with its discharge end leading to an
open tank or pit. The bleed-off line should be securely anchored at every five-meter interval.
The discharge line should not be let into a closed vessel because the vessel may fail due to
its inability to withstand pressure built up from excessive flow of fluids.

Production-Oil
3. The relief value and pressure gauge of the pump should be checked to ensure that these
are in good working order.
4. The pipelines on surface up to the last valve near the wellhead, should be tested to a pressure
which is 10% more than the maximum fracturing pressure but does not exceed the test
pressure of equipment.
6.2.4 Handling of acid chemicals, Refer section 4.2,2 “Safe handling of acids”
1. A safety meeting should be held before the operation and every person present at the location
should attend the meeting. The precautions to be taken during fracturing operations should
be explained to all persons during this meeting and it should be ensured that the directions
are clearly understood by all.
2. The operation should be carried out during day light hours only.
3. Persons not connected directly with fracturing operations should remain at a distance of not
less than 50 meters.
4. All persons should be provided with the personal protective wear & equipment suitable for
the work.
5. At times radioisotopes are used to ascertain whether formations at the appropriate depth
are fractured, instructions for which are given under the head “Radiological safety”.
6. Containers of acids, chemicals and radioactive substance should be properly labelled and
stored. Warning signs should be posted to denote high pressure lines. Risks involved in
handling corrosive substances, should be marked on the container label.
7. A first aid box and persons trained in first aid should be available at the site. Refer under the
head “First Aid Service”.
8. If operations are to be carried out at a well where sucker rod pumping unit is installed, the
later should be disconnected from its prime-mover, to prevent any inadvertent motion.
9. Where rig is deployed at the well, the traveling block of the rig should be safely secured to
the leg of derrick/mast.
10. During operations, no attempt should be made to tighten the wellhead fitting or injection line
connections. All repairs should be undetaken only after the pumping units have been stopped
and the system has been depressurised.
11. On completion of the job, the control valve at the wellhead should be closed and the pressure
in the pipeline should be bled-off before the lines are disconnected.

Production-Oil
7.0 ACIDIZATION
7.1.0 General :
This is a process in which oil bearing formation are treated with acid and chemicals to
increase production of oil and gas, Hydrochloric acid, some times mixed with hydrofluric
acid also, is pumped down the well at high pressure.
The hazards associated with the operation are similar to those connected with hydraulic
fracturing and additional hazards are due to handling of acid and chemicals. In addition to
the precautions mentioned in respect of fracturing, the following precautions are also rec-
ommended.
7.2.0 Safe handling of acid
1. Acid container should be stored in a well-ventilated place. Chemicals which can react with
acid should be stored separately.Acid storage tanks posted should conform to IS stan-
dards. See IS:6164-1971.
2. Storage and container area of acid should be properly labelled and warning signs should
prominently be displayed to denote “Danger-Acid”.
3. Smoking should not be permitted at the place where acid is stored and suitable warning
signs should be posted to this effect.
4. Carboys or other containers of acid should be carefully lifted, preferably by mechanical
means.
5. Adequate quantity of lime should be kept readily available near the site where acid is stored
to neutralise acid spills.
6. Persons handling acid should be provided with suitable personal protective equipment. Refer
for more details, under head “Personnel Protective Equipment”.
7. Whenever it is required to dilute acid, the acid should be added to water. In no case water
should be added to the acid.
8. Fire tender should be stand-by during acidisation job.
9. Acid storing and mixing area should be barricaded with a fluorescent/brightly coloured rib-
bon. No unauthorized person should be allowed inside the area.
7.2.1 First Aid
The first aid box and personnel trained in first aid should be available at the site. Adequate
supply of clean and fresh water should also be available.
7.2.2 Acidisation of wells :
1. Prior to the acid job, a pit level meeting should be conducted wherein the responsibility of
each person should be clearly told and the sign language to be used during the operation
should be explained to each of the person concerned.
2. The well site/working area should be temporarily fenced to restrict the entry of stray animal.
3. A wooden ramp/platform with proper ladder should be erected at the backside of the acid
mixing tank to facilitate storage and mixing of acid.

Production-Oil
4. A pit is to be dug to collect the return fluid/unspent acid coming from the well. The bundh
around the pit should be strong to avoid seepage of fluid to outside.
5. Prior to the acidization, the safety valves of the pumps delivery line should be tested
hydraulically to avoid any seepage during the operation.
6. All the unit required for job should be placed at the safety distances from the well head.
7. The pump delivery line should be properly anchored.
8. Sufficient amount of lime should be kept at the site to neutralize the acid in case of any
leakage during the operation.
9. After completion of the acidization, sufficient amount of lime should be added to the pilot pit
to neutralize the acid so to avoid pollution hazards. The neutralization to be confirmed by
testing (litmus test)
10. Prior to any acidization job pickling must be carried out to clean the tubing.
11. The unspent acid and the foreign materials produced during the acidization should be flushed
out completely through reverse circulation/CTU prior to starting injection operation.
7.3.0 PROCEDURE FOR WASHING EYES AND SKIN AFFECTED BY ACID
If eyes, skin or other parts of body are affected by acids, wash it off with fresh and clean
water at once. Remember that the first few minutes are most critical for washing of splashed
acid. Do not use (except fresh water) any other solution to wash the eyes.
To wash the eyes, an eye wash bottle filled with fresh water should be used for at least 15
minutes. Use the thumb and forefinger of both hands to open the eye lids as wide as possible
to permit free flow of water around the eyes. Do not attempt to close the eyelids or rub them.
The injured should immediately be taken to a doctor and till that time, washing of eyes with
eye wash bottle must continue. Reference may be made under head “ First Aids Service”.
The guidelines given in the MSDS should also be referred.

Production-Oil
8.0 WIRE LINE OPERATION

8.1.0 General
Wire line / slick line operation in any down hole is carried out for cleaning the tubing, to
measure the Bottom Hole Pressure (BHP), for recovering the fish, for setting down hole
equipment such as SSD, setting and recovering of G/L Valves etc. The unit consist of a
wireline which coupled to a prime mover and mounted on a trailer / vehicle which is taken to
various locations for operation.
8.2.0 Safety procedure during a wire line operation :
1. During the whole time any wire line operations is in progress, a warning sign should be
displayed at the X-mass tree with the following inscriptions
“Wire line operation on, do not operate valves”.
2. Before dismantling the lubricator, it should be ensured that the pressure inside it is released
through the release valve.
3. Equipment tools and small objects and other loose materials which are not required for use
should not be left lying on the derrick floor when rig is in place so as to dangerously obstruct
work places and passage ways.
4. There should be at least two persons at the site during wire line operation, one at the controls
and the other at the well.
5. A lubricator of suitable length to accommodate the wire line tools should be installed on the
crown valve. It should be ensured that there is no leakage at the crown valve otherwise
during installation of lubricator, it may be thrown off due to pressure of gas.
6. The winch mounted vehicle for wire line jobs should be secured to the ground to prevent it
from skidding forward. The unit should be located at least 30 meters from the well head on
the upwind side. All persons should stay away from the wire line when it is in motion.
7. It should be ensured that the wire line tools, the wireline and the brakes of the wire unit are
in good working order. In case any defect is noticed, it should not be put into use until such
a defect has been removed.
8. Don’t run the engine with the Safety Guards removed position.

Production-Oil
9.0 COIL TUBING UNIT (CTU) OPERATIONS:

9.1.0 General :
The Coil Tubing Unit (CTU) / Endless Tubing Unit (ETU) is a mobile equipment used
for various well servicing jobs. It has a 11/4 inch endless tubing stored on a reel and coiled
upon itself. An injector, a mechanical device-connected to the well head through a blowout
preventer and stuffing box, is used for lowering and hoisting the tubing. The tubing is used
for circulation of fluids, chemicals and nitrogen for cleaning a well, spotting acid, cleaning
out test string during DST etc.
In the CTU/ETU services, the hazards are due to pressure in the well, as well as that in the
endless tubing failure of tubing under pressure, blow out, fire and crane operations.
9.2.0 The recommendations given below may be referred for Guidance. 9.2.1 Safe practice
:
1. During CTU operation, only the persons related to the operation should be present at the
well site.
2. The whole operation will be carried out as per the instruction of CTU Engineer, who is also
the site-in-charge during the CTU operation.
3. The CTU should not be placed on the flow line / over the flow line valve or in a position that
would hit the operator’s console / truck exhaust directly in case of gas flows out of the well
accidentally.
4. Safety gears should be worn while working below the injector hanging by a crane.
5. Only one person should direct the crane operator.
6. All equipment raised by the crane should be tied with a tailing rope.
7. When rigging up on well head, flange connection should preferably be used.
8. A permanent depth flag should be used on the body of the tube about 300 ft before the end
of the tubing. This is used for verification of the depth and also a warning to the operator for
end of the coil.
9. A safety meeting should be held on location by the person in-charge of the operations and all
persons connected with CTU / ETU operations should attend the meeting. The job procedure,
possible hazards and safety precautions should be clearly explained to the persons and it
should be ensured that the instructions are fully understood.
10. Each set of rams in the blow out preventer stack should be checked before every job to
ensure that the BOP is fully operational.
11. The crane should be fully serviced once in a month in accordance with the recommendations
of the manufacturer.The cable should be periodically checked to ensure that there is not an
excess of wear on the cable.
12. Before cutting Endless Tubing (for any reason), it should be ensured that any pressure
inside the tubing is safely released.
13. While working on live wells, a non-return Valve should be used at the down-hole end of the
endless tubing.

Production-Oil
14. The tubing injector should be installed and secured in such a way that the wellhead does not
require to support its weight nor does it experience any bending forces from the coiling
process.
15. Regular maintenance of BOP’s stack, stuffing box and tubing injector should be undertaken
in accordance with the recommendations of the manufacturer.
16. Injector should be serviced / tested prior to each CTU job.
9.2.2 Precaution during handling of nitrogen
1. Liquid nitrogen is stored at - 1950 C and requires extreme care in handling it. The vacuum in
the nitrogen tank should be less than 50 microns and it should be checked once in three
months and also whenever any frosting on the tank is noticed. The relief valve on the storage
tank should be checked regularly to ensure that it is in good working order. Frosted line
should not be touched with bare hand.
2. Any cutting/welding or repair on the outer surface of the nitrogen tank should be undertaken
only after obtaining authorization in writing from the competent authority.
3. Persons engaged in handling liquid nitrogen should be imparted clear instructions in safe
handling of nitrogen and it should be ensured that they understand the same.
9.3.0 Well maintenance jobs :
9.3.1 Flushing of flowlines
Flushing of flowline is done in order to keep the flowline free from paraffin deposition to
facilitate free flow of oil from wells to installations. High pressure pumping units are used for
these jobs with water as service liquid. In few wells these operations are done with hot oil
also. Following precautions should be followed while carrying out such job.
a. Safe location of equipment :
.i The pumping unit and the tanker should be placed at safe distance from the well (minimum
30 mts).
i
. A clean and walkable passage between the pumping unit, tankers and well shall be maintained
and the width of passage should be adequate to permit free movement of operators.
b. Precautions against fire :
.i In case of flushing job done with hot oil, fire tender and fire fighting crew shall always be kept
as stand by till the completion job.
i
. Crude oil carrying tankers / hot oil pumping unit shall be provided with flame / spark arrester
in their exhaust system.
ii
. A portable fire extinguisher should be provided with each oil tanker/pumping unit. Extinguisher
shall have to be periodically charged and certified.
c. Operating safety
.i All temporary connections shall be done properly and all studs, units of standard length and
size shall be properly tightened in order to prevent any leakage during operations.
i
. The safety relief valve and pressure gauge of the pumping unit shall be tested at regular
intervals to ensure their proper operations.

Production-Oil
ii
. The line connection from pumping unit to the last valve shall be tested minimum 1.5 times of
expected operating pressure before commencing the job. In case any leakage is observed
it shall be rectified.
i
v. No attempt shall be made to tighten any fittings or flow lines or pumping line connections
under pressure. All such jobs shall be undertaken only after bleeding the pressure of whole
working system.
v. On completion of job the control valve at well head shall be closed and temporary pumping
line shall be depressurised. It should be ensured that no pressure is trapped and then only
the temporary lines are to be disconnected.
vi. All operations shall be carried out only during day light hours. Necessary safety kits like
safety shoes, helmet, hand gloves, apron etc. should be worn by operating personnel.
1. Note :
The above safety measures shall have to be followed during water circulation / well sub-
during jobs also.
9.3.2 Steaming jobs :
1. Following steaming jobs are generally done :
a. Flow line steaming - To keep the flow line free from paraffin deposition.
b. Annulus steaming for clearing paraffin deposition inside the tubing/annulus.
c. Tubular maintenance for clearing of chocked tubing with mud cake/paraffin.
ii) Following safety precautions shall have to be followed during the job :
.i Steaming unit shall be placed at a safe distance from the well (minimum 15 rnts).
i
. The steaming unit is to be placed in such a way that it can be moved quickly away from the
well in case of any emergency during the job.
ii
. Steaming point connection shall be done properly and all studs/units etc. shall be properly
tightened, so that there is no leakage during the job. It shall be ensured that pressure, if any,
is released before making any connections.
i
v. Pressure Relief valves and pressure gauges, temperature gauges shall be checked to ensure
that they are in good working conditions and need calibration at regular intervals.
v. Persons connected with the job at well/site shall wear all necessary protective kits without
fail like safety shoes, hand gloves, helmet etc.
vi. During operations no attempt shall be made to tighten the well head fittings or steaming line
connections. Repairs to be undertaken only after unit is shut and pressure in released.
vii. On completion of the job, control valve and head shall be closed and the pressure in the line
shall be released before lines are disconnected.
viii. Care shall be taken in handling the lines as the lines are very hot due to high temperature of
steam.

Production-Oil
ix. Operations shall be carried out during day light hours only.
x. Persons having Boiler operator license, shall alone be permitted to operate the boiler.
xi. Boiler shall be pressure tested once in three months and internal records to be maintained.
xii. Boiler shall have to be tendered for inspection to concern statutory authorities once in a year
and a certificate to be obtained.
9.3.3 Compressor jobs
Compressor applications are done generally for well activation purpose. In addition it is
used for Gas LiftValve (GLV) testing and water injection well washing. However, compressor
application for the above jobs are yet to be introduced in OIL.
Following safety precautions shall have to be followed during compressor application jobs:
.i Compressor shall be placed at a distance of 30 mts from the wellhead.
i
. Compressor shall be placed properly in such a way that there is no hindrance in movement
and compressor can be moved quickly from the well site in case of any emergency during
the job.
ii
. Compressor line connections to be made properly and studs/units to be properly tightened
so that there is not leakage during the job. It shall be ensured that pressure is released
before making any connections/disconnections.
i
v. No attempts shall be made to tighten wellhead fittings or line connections during the job. All
repairs to be under taken only after compressor is stopped and system is depressurised.
v. On completion of the job, control valve at wellhead shall be closed and pressure of line is
released before lines are disconnected.
vi. The operations shall be carried out during day light only and on no occasion activation job
shall be done after day light.
vii. All necessary protective kits to be used by attending team during operation.
viii. Portable fire extinguisher must be provided with compressor.
ix. Safety relief valve, air receiving pressure vessel and pressure gauge shall be tested once in
three months and records to be maintained.
9.4.0 Scrapping operations
Scrapping operations are carried out to keep the tubing free of paraffin deposition and to
facilitate smooth flow of well. Following safety precautions shall have to be followed during
the job:
.i Before fitting of lubricator, welding of steps to lubricator body must be checked and if anything
wrong is noticed then that lubricator shall not be used.
i
. All scrapping crew must use safety protective kits viz. Safety shoes and helmet during
scrapping jobs.
ii
. There should be no oil spillage in working area to avoid falling due to slippage.
i
v. After fitting of lubricator and tightening the cap, no person shall be on lubricator. Crown valve
shall be opened only after the person gets down from the lubricator.

Production-Oil
v. Depth-Counter-rneter shall be checked frequently and shall be set at zero before start of
scrapping in order to have correct depth control.
vi. Flame/spark arrester must be fitted in exhaust of vehicles.
vii. Scrapping operations shall be done in day hours only.
viii. The lubricator shall have to be pressure tested at well head pressure by opening the Crown
Valve before commencing the operations to ensure that there is not leakage at all from the
lubricator.
ix. Scrapping jobs done by contractor’s persons must be supervised by competent production
personnel in order to ensure all necessary safety precautions.
9.5.0 Hot Oil Circulation Jobs :
Hot oil circulation jobs are required to be taken periodically in order to clear the choked
tubing due to congealing of the oil due to flow characteristics of the crude oil particularly
where the atmospheric temperature is low. These are essential routine jobs to maintain
uninterrupted production from wells. The safety precautions while taking up hot jobs are as
given below.
1. The hot oil unit should be located at a distance of 30 meters from well towards upwind side.
2. All connections for hot oil circulation jobs shall be checked thoroughly prior to commencement
of the job.
3. Fire tender should be kept standby during entire operations.
4. The operators associated with such jobs must wear personnel protective equipment.
5. The connections made for hot circulation jobs should be disconnected only when the
temperature of flow lines comes down in safe limits after completion of jobs.
6. First aid box with essential medicines should be available at site.
9.6.0 Wire line operation :
1. During the entire wire line operation, a warning sign should be displayed at the X-mass tree
with the following inscriptions :
“Wire Line Operation On, Do Not Operate Valves”.
2. Before dismantling the lubricator, it should be ensured that the pressure inside it is released
through the release valve.
3. Equipment, tools and small objects and other loose materials which are not required for
used should not be left lying on the derrick floor if Rig is in place so as to dangerously
obstruct work places and passage ways.
4. There should be at least two persons at the site during wire line operation, one at the controls
and the other at the well.
5. A lubricator of suitable length to accommodate the wire line tool should be installed on the
crown valve.

Production-Oil
10.0 PRESSURE MAINTENANCE OPERATIONS
10.1.0 GENERAL
Pressure maintenance in reservoirs is carried out in order to maintain the oil production for
longer time and to achieve maximum ultimate recovery from the fields. It is carried out by
injection of water, gas or air in the formation.
Depending upon the reservoir, water injection is generally carried out at high pressure varying
from 1 00 kg/cm2 to 130 kg/cm2. The water used for water injections is treated with chemicals
to make it acceptable to the reservoir formations. Some of the chemicals commonly used
are NAOH, NaCl, Na2HS04 bleaching powder, caustic, alum etc. These chemicals are to be
handled carefully as some of them can be harmful to skin eyes etc. Following points must
be kept in mind while handling chemicals mentioned above:
(i) Wearing safety shoes and hand gloves.
(ii) Wearing of goggles.
(iii) Using chain pulley block while loading and unloading chemicals into and out of tanks.
10.1.1 While carrying out routine jobs on water injection wells following safety precautions
should be taken.
a) Use of personnel protective equipment is to be ensured.
b) Calibrated pressure gauges and proper hand tools should be used.
c) Status of valves both at the well and manifold should be confirmed prior to commencement
of any rectification jobs on water injection flow line.
d) Minimum two persons should be deployed for carrying out non routine jobs on water injection
wells or high pressure flow lines.
10.1.2 High-pressure positive displacement pumps are used for water injection purpose.
Following safety points must be ensured for safe operations of these high-pressure
pumps: -
(i) Floor area of pump house should be kept clean and dry. It is preferable to apply slipresistance
coating on the passage of pump house.
(ii) Coupling guards should be provided on high pressure water injection pumps.
(iii) Lay out of the pump house should ensure accessible escape routes and unobstructed
working space for free movement of operators.
(iv) During maintenance of pumps corresponding section and discharge valves should be kept
closed and motor should be de-energized from electrical sub-station.
(v) Before starting the pumps, corresponding section and discharge valves should be opened
as required for particular type of pump.
(vi) The pump should have pulsation dampener in the discharge line.
10. 1.3 General guidelines to be followed in water injection installations are :

Production-Oil
(i) Non return valves should be provided at injection manifold.

(ii) Since all the equipment and flow lines in water injection operations handle water on continuous
basis. Painting jobs are to be planned and carried out regularly to avoid corrosion.
(iii) Maintenance jobs on high pressure flow lines should be carried out after necessary isolation
and depressurization.
(iv) Disposal of unused chemicals should be carefully done to ensure safety of persons.
10.2.0 Starting procedure of water injection pumps :
The general procedure for running a water injection pump is given below :
a) Ensure the level of POL in the prime mover and in the pump set.
b) Ensure the disengagement of clutch of prime mover and the pump.
c) Run the prime mover and observed for around 5-1 0 minutes.
d) Ensure the proper setting of the Safety Relief Valve in the delivery line.
e) Ensure the opening of all valves in the delivery/discharge stream (including well head valve
of the injection well) except the pump delivery valve.
f
) To ensure sufficient pressure in the suction manifold by running adequate numbers of tube-
well.
g) Open the suction valve of the pump.
h) Open the By-Pass valve.
)
i Engaged the clutch of the pump set to run the pump.
)
j Throttle the By-Pass valve very slowly and observe the pressure to develop to around 60kg/
cm2.
k) Open the delivery valve slowly.At this point, the water will enter the injection line/manifold .
)
l Close the By-Pass valve completely.
m) Ensure the proper lubrication of all the lubrication points of the pump.
10.2.1 Stopping of Water Injection Pump :
a) Disengage the clutch.
b) After stopping of the pump shut the discharge valve.
c) Open the By-pass valve to release the trapped pressure to the suction side.
d) Shut the suction and By-Pass valve.
e) Stop the Prime -mover.
10.3.0 Procedure for injection of water in a well :
a) Open both the tubing and casing valve of the injection well and allow the injected water to
have a complete cycle of flushing to the nearby effluent pit before starting injection.
b) After ensuring the return of clean water at the surface, close the casing valve slowly to start
injection into the well.
c) The above procedure to be followed if the injection is discontinued in the well for more than
2 hours.

Production-Oil
10.4.0 HAZARDS
Injection of water into the formation involves handling of chemicals, distribution and injection
of water under high pressure. So extreme care should be taken in handling the chemicals
and also in working in high pressure lines,
10.5.0 SAFEGUARDS
The safeguards given below provide guidance. The operation manual/installation should be
referred to detailers.
1) A working platform, not less than 1 meter in width, should be provided over the water filter for
service of the water cleaning installations.
2) Personal protective equipment should be used for mixing chemicals.
3) Automatic pressure recorder should be installed on discharge line of pump to ensure that
the pressure does not exceed the rated capacity.

Production-Oil
1 1.0 Commissioning and Testing of New Wells :
11.1.0 General :
Wells may be divided into two categories -
a. Development wells
b. Exploratory wells
a) Development wells :
The development wells are the wells drilled in the developed area where the flowing and
other parameters of the reservoir is already known/established, (through the other wells
drilled in the reservoir).
b) Exploratory wells :
The wells are the wells drilled in a new area/new reservoir where most of the reservoir
parameter are not available/unknown.
11.2.0 PERFORATION :
Perforations are the entry points made on the casing to allow the reservoir fluid to flow in to
the wells bore. Perforation can be carried out either through tubing gun or casing gun.
a) Perforation through tubing gun :
This type of perforation is done by running the gun through X-mass tree and tubing and
generally carried out in an exploratory well. The advantage of this type of perforation is:
)
i Can be carried out without pulling out the tubing string.
i) More safe as surface control equipment are already installed on the well-head.
b) Perforation through casing gun :
This type of perforation is done in a hole through casing gun, prior to running in the tubing
string and generally carried out in development wells. After the perforation, tubing is run into
the well bore and then X-mass tree is rigged up. The well is then changed over to water and
unloaded (if required) through NPU/CTU or by swabbing to enliven the well.
)
i Depth of perforation is more in casing type perforation. Moreover, since the perforation is
multi-directional, more clear passage in the reservoir towards the well bore is obtained.
11.2.1 Precaution to be taken during the perforation :
)
i Stand by ‘A’class fire service should be available at the well site.
i) Perforation should be done in day light only.
iii) Switch-off all the voltage sources to eliminate possible stray voltage.(Gen-set, telephone
etc.) during gun priming.
iv) Lubricator assembly should be tested hydraulically to required pressure.
v) During casing gun perforation mud weight should be sufficient enough to suppress the
reservoir pressure developed due to perforation.

Production-Oil
vi) A killing line (connected to casing valve) with a kill pump and sufficient amount of killing fluid
should be kept ready at site.
vii) No welding/cutting, movement of vehicle should be allowed in the well site during perforation.
viii) Only authorized persons should be allowed to enter the Logging truck.
11.3.0 TESTING OF WELL :
A well is required to be tested after the perforation. The testing may be done at the well site
or in the nearby production installation in case of a developed field. The following units are
generally required for testing at well site.
)
i Heating arrangement (Boiler/ Indirect heater).
i) Ground X-mass tree
iii) Gas oil separator with all safety gears and accessories.
iv) Storage tank for produced crude
v) Flare pit at safe distance from the well-head.
11.3.1 Procedure for testing a well at site :
(1) Initial Well testing should be carried out in the day light only.
(2) No welding / cutting or movement of vehicle should be allowed at the well site during testing.
(3) Stand by fire service should be available at site during testing.
(4) A killing line connected to the casing valve of the well, killing pump and sufficient amount of
killing fluid should be available at site for emergency killing the well.
(5) The pit line should have proper anchoring
(6) All lines from the well head to the test separator should be hydraulically tested.
(7) Check the tubing and casing pressure of the well. Open the tubing in the pilot pit at a control
rate and unload the water/fluid till the oil/gas appeared in the unloaded stream. In case there
is no pressure build up in the tubing or the well does not displace, enliven the well with the
help of NPU/CTU/Swabbing.
(8) Divert the flow through the well-head testing unit is Ground X-mass tree, steam jacket, oil
water separator.Adjust the choke at the ground X-mass tree to control the flow.The oil will
be collected at the storage tank and the gas will be released and burnt at flare stack.
(9) Light the flare at the flare pit.
(10) The oil produced in the well-head may be transported to the unloading station through Bowser,
loaded at the Bowser loading point which is minimum 30 mtrs. distance from the well-head.
11.3.2 Testing a well at the existing production installation :
(i) Same as steps 1 to 7 under the heading “procedure for testing a well at site”.
(ii) Divert the flow to the flowline by opening the flowline valve in control manner.
(iii) At the production installation the flow should be tested in the testing stream.

Production-Oil
(iv) Flow line pressure, tubing and casing pressures should be monitored properly
(v) No High GOR or a gas well should be tested,in the production installation.
11.4.0 KILLING OF A WELL :
Killing of a well means filling-up the well bore with mud or other fluids to suppress the reservoir
pressure, so that no in flow can take place into the well-bore through the perforation.
11.4.1 Few of the important points to be followed during the killing of a well :
(i) W ell killing should normally be carried out in day light only.
(ii) Stand-by fire service is to be available at site.
(iii) No welding cutting/movement of vehicle should be allowed during the killing.
(iv) Well killing set-up should be made ready at site for emergency killing the well.
(v) Killing of well should generally to be done by pumping through tubing, as the hydro static
head required for suppressing the reservoir pressure is obtained after pumping tubing volume
of killing fluid only.
(vi) Killing line should have NRV to prevent back flowing.
(vii) The weight of the killing fluid should be enough to suppress the reservoir pressure.
(viii) Before rigging down the X-mass tree, the weight of the killing fluid should be properly balanced
and make ensure that there is no pressure at the tubing and in the casing.
(ix) The return line should be connected through the well-head testing set-up i.e. Ground X
mass tree, steam jacket.
(x) In case of a packer completed gas lifting well, the following killing procedure may be followed:
a) Released the casing and tubing pressure to Zero.
b) Filled-up the casing with killing fluid.
c) Pumped the tubing volume of killing fluid through tubing
d) Ensure that there is no pressure in the tubing and casing.
e) Rigged down the X-mass tree.
f
) Picked-up the Hanger flange and unset the packer. Cut one joint of tubing from the tubing
string and land the H/F again.
g) Connect a shut-off valve on the Hanger flange.
h) Circulate the killing fluid through the tubing till the return fluid is fully balanced
11.4.2 In case of killing a gas well :
)
i During the killing of a gas well sufficient back pressure should be applied to the formation to
avoid gas cut of the killing fluid. This can be done by throttling the valve in the return line.
i) Since the Surface pressures in case of a gas well is very high, the killing line valve at the well
head should be opened after developing sufficient pressure in the delivery line.

Production-Oil
11.5.0 Packer :
Packer is an equipment used in the downhole of a wellbore to seal the annulus (between
casing and tubing) from the producing Zone. The major function of packer is -
a. To avoid exertion of pressure in the casing from the producing zone.
b. To assist to flow the producing Zone well by restricting the entry of incoming fluid into the
annulus.
c. To isolate the damaged casing.
d. To isolate the producing Zone from the casing gas in G/L completion.
e. To isolate two producing Zone.
11.5.1 There are many types of packer and their setting procedures are different :
a. Mechanical set
b. Hydraulic set
c. Wireline set
11.5.2 The following measures are to be taken during the running in a packer :
a. The packer should be checked before running and run in the correct direction.
b. The running should be carried out at a uniform speed.
c. During transportation, the rubber seals of the packer should be covered to protect from any
mechanical damage and the cover should be removed only at the time of running into the
hole.
d. Packer should run and set in the clean fluid to the extent possible.
e. Before running in the packer, a casing scraper trip must be made up to the setting depth to
prove the drift diameter of the hole.
11.6.0 SWABBING :
Swabbing is a wire line operation carried out inside a tubing for:
a. Creating positive draw down across the reservoir and the well bore, thus to improve the
inflow.
b. Unloading fluid/acid from the well bore.
c. Lowering the fluid level in case of cased hole extract out oil from wells.
d. For cleaning the perforation in case of a disposal and water injection wells.
e. Enlivening water cut wells.
.
f Producing a well by stop-cocking.
Swabbing is generally carried out with the help of ‘sand line’ in a work-over/ drilling rig or by
the wire line of a Swabbing-hoist. Few sinker bars and two / three swab-cup fitted in a
mandrel connected to the end of the wire is run into the well bore below the fluid level. At the

Production-Oil
upward movement, the swab-cups got expanded due to the load on it and thus seals the
passage between the swab-cup and the tubing. Since the operation includes a lot of extensive
job involvement and safety hazard, the most of the above jobs are now carried out through
CTU/NPU.
11.6.1 Precautions to be taken during swabbing operation :
a. Sand line of the outfit/wire of the swabbing hoist to be checked before the operation.
b. Oil saver and wireline BOP must be used during swabbing operation.
c. Operating personnel should use all the protective gears during the operation.
d. Swabbed up and all the joints of the sinker bar Must be checked for its tightness and again
to be checked after each operation.
e. No working personnel should be present near the well head during running in and pulling out
operation.
.
f Marking (with paint or by any other means) should be made on the wireline after each length
of coil lowered to the well to calculate the depth of the running.
g. Operator (man at brake) should take extreme care during running the coil, particularly while
the swab cups touch the fluid level.
h. Fluid load on the swab cup should be within its limit, otherwise the cups may distorts resulting
in fishing of the swabbing mandrel.
.i There should be reasonable time gap between two swabbing operations. Operator should
closely monitor the rise in fluid level and lower the coil accordingly.
.j If a well seems to be enliven during pulling out operation, (feeling kick), the operator should
alert the other members and should try to pull out the string from the well uniformly and
advise his man to close the top master valve once the swab mandrel comes out of the hole.
k. Stand-by fire service should be present at well site during swabbing operation.
.l Swabbing should be carried out during day light only.
m. No Engine/welding/cutting job should be carried out or movement of the vehicle should be
allowed at the well site during swabbing operation.
n. A pit line should be laid from the well head to a pilot pit/effluent pit.
o. A competent person closely monitor the unloaded fluid at the pit and inform the operator if
there is presence of hydrocarbon in the fluid.

Production-Oil
12.0 ARTIFICIAL LIFTING OF OIL

12.1.0 GENERAL :
When the reservoir is not enough for the formation fluid to flow by itself to surface, artificial
means are adopted to produce oil from the well. The following methods are usually adopted
in OIL.
• Sucker Rod Pumps
• Gas Lift
12.2.0 SUCKER ROD PUMPS (SRP) :
In this method a reciprocating pump lowered on solid Sucker rod string to the well bottom
through the tubing and connected to the surface with a polished rod through a stuffing box.
The stuffing box contains rubber packings which seals around polished rod. The polished
rod is hung from the carrier box, which in turn is attached to horse head by a hanger rope.
The Horse head through an assemblage of walking Beam, Sampson post equalizer arm,
pitman arm and set of bearing is connected to the Gear Box. The complete assembly is
fitted on unit base and mounted on to a concrete foundation or a skid. The electric prime
mover mounted at the rear end of unit supplies power through V belts to the Gear Box. The
rotatory motion of the engine flywheel is converted into reciprocating motion with the
combination of crank arms Pitman arms & walking beam and transmitted to the sub Surface
pump through the polished rod and sucker rods.
In this operation, the main hazard is due to moving parts of the unit namely crank arms &
polished rod and prime mover with V-Belts. Fire hazard may occur from gas due to sparking.
Oil spillage through stuffing box is another potential hazard to environment. The following
recommendations provide guidance for safe operation.
12.2.1 GENERAL PRECAUTIONS :
2. The SRP unit with the well should be properly fenced so that no personnel or any animal
can approach while the unit is in operation.
3. proper earthing should be provided to the electric prime mover.
4. in case of any abnormal noise the unit should be stopped immediately and inform the
concerned maintenance teams.
5. in case of any problem with starter/switch boards, the jobs to be carried out by competent
electrical supervisors.
6. A non-return valve should be provided in the annular line for bleeding of accumulated gas
periodically.
7. Tadders/steps should be provided to the concrete foundation for easy approach to the prime
mover and crank end of unit.
8. Rod rotator should be provided on the polish rod in the wells with paraffination problem.
9. Anchor catcher / tail pipes should be provided on the rod string for proper positioning of the
pump.

Production-Oil
10. The polished rod should be clamped properly so that it does not hit the horse head and
stuffing box.
11. When the horse head is at its lowest position the gap between the rod hanger (carrier bar)
and stuffing box should not be less than 200cms.
12. The stuffing box should be tested hermetically to its rated pressure at the time of installation.
13. The switch board/starter should be placed in a closed enclosure at a safe distance from the
well.
12.2.2 Startinq procedure of SRP Unit :
)
i Ensure the opening of BOP.
i) Open all the flowline valves
iii) Check the POL of the prime-mover and the pumping unit.
iv) Dis-engaged the brake of the unit.
v) Ensure the disengagement the clutch of the set.
vi) Run the prime mover and observe for few minutes
vii) Engaged the clutch after attaining the pump to desired RPM.
12.2.3 Problems of SRP Unit :
The following are the major problems faced during the operation of a SRP Unit.
)
i Failure of bearings.
i) Leakage in the Gland-packing.
iii) Parting out of rods.
iv) W orn out of Scraper.
v) Pump seal leak / damage.
vi) Standing valve / Traveling valve leak.
vii) W orn out of pump plunger.
While the first two problems are related to the unit at the surface, the rest are subsurface
problem and needs pulling out of the string.
12.2.4 Pullinq out of SRP Subsurface Pump :
For pulling out the SRP Subsurface pump the following procedure to be followed:
)
i Dis-engaged the clutch.
i) Stop the prime-mover and the pump.
iii) Lock the brake of the pumping unit.
iv) Close the flow line and the casing valves and release the casing and tubing pressures at the
wellhead pilot pit.

Production-Oil
v) Rigged down the horse-head of the unit.
vi) The guy-rope of the swabbing hoist / any other mast engaged for pulling out operation should
be properly tightened and the mast should be centered and leveled properly.
vii) The operation crew members must wear all protective gears during the operation.
viii) The stuffing box should be installed and BOP ramp should be close after suspension of
every day operation.
12.2.5 LOWERING OF SRP SUBSURFACE PUMP :
.i While lowering SRP Sub Surface Pump, rotary sleeve should not be gripped on barrel /
plunger of the pump.
i
. SRP BOP should be installed prior to running in or pulling out SRP (Sub Surface Pump).
ii
. All sucker rod joints should be greased prior to tightening.
i
v. Tightening should be done with proper size tong against particular type of sucker rod.
V. Average torque applied for tightening should be 450 ft-lbs.
12.2.6 MAINTENANCE OF SRP UNIT :
The following points should be kept in mind during maintenance of Sucker Rod Pumps:
1. Before attending to any inspection/maintenance jobs, the SRP units should be stopped and
the power supply to the switch board/starter should be cut off.
2. A periodical greasing and the inspection of all bearings should be carried out viz. central
bearing, tail bearing, crank pin bearing.
3. A periodical inspection and the replacement of rubber packings of the stuffing box are to be
carried out.
4. A periodical checking and tightening of all nuts and bolts to be carried out.
5. The level of gear oil should be checked every day and a periodical replacement of the oil to
be done.
6. In case, it is required to open the stuffing box, it is to be ensured that the SRP stripper (BOP)
is closed and that the hydrostatic head in the well over-balances the bottom hole pressure.
7. While replacing or changing the position of Crank pin, the unit brake should be locked properly,
the Polished Rod should be unhooked from carried bar and clamped properly.
12.3.0 GAS-LIFT OPERATION :
12.3.1 GENERAL :
In Gas-lift operation, high pressure natural gas is injected into the tubing string at
predetermined depth through gas lift valve. As the gas expends with decreasing pressure
energy from the gas transfer to the well fluid and the fluid column gets lightened and flows
up the tubing and finally to the surface.

Production-Oil
12.3.2 SCOPE :
This chapter covers recommended practices for safe handling, servicing, testing, lowering
and unloading through GL system.
GAS-LIFT VALVE (GLV) :
12.3.3 Transportation and Storage :
a. G LVS, should be properly protected against mechanical damage during transportation.
b. Threads of GLV should be covered with thread protector during transportation and storage
of the GLV.
c. G LV should not be dropped from height.
d. The GLV should be covered during transportationi.e. All the joints of GLV should be properly
tightened.
e. The calibrated valves should be tagged properly indicating the well no, set pressure and
depth before transporting them to the well.
12.3.4 Servicing and Testing :
(i) Before dismantling the GLV for servicing/repair, bellow / dome should be depressurised.
(ii) Vice or pipe wrench should not be used on the body of the GLV except in the grooved
provided for the purpose. If no groove is provided, then strap wrench are only to be used.
(iii) While dismantling, bellows should be handed with utmost care to avoid physical damage
and it should never be stretched or bent side way.
(iv) It is to be ensured that the silicon fluid is not lost during servicing of GLV.
(v) All the test equipments used for testing the GLV should be conformed to recommended
standard. The system should be tested for no leakage with dummy valve in place and should
be depressurised before inserting or taking out the valve in the test fixture.
12.3.5 lowering and Unloading :
(i) During the lowering of GLV with mandrels, sequence of mandrels, serial wise depth should
be clearly marked on the mandrels
(ii) The fluid to be unloaded through the GLV should be cleaned and free from foreign materials.
(iii) Utmost care should be taken during unloading of fluid through GLV to avoid damage to the
seat. It should be unloaded in slow manner.
(iv) While the well is unloaded into the pit, all the joints and pit line should be tightened and
anchored properly.
(v) No unauthorized person should be allowed in the area.
(vi) A bend should be fitted to the end of the unloaded pipeline, so that flow is always directed
downwards into the pit.
(vii) No engine/spark producing equipment should run at well site during unloading operation.

Production-Oil
(viii) Fire service should be kept stand by at well site during the unloading operation.
(ix) Gas input line connected to the well head should be tested properly prior to put in operation.
(x) The fluid unloaded in the pit should be picked up at the earliest to avoid pollution/safety
hazard.
Unsafe Menu,
Accident Venue.

Production-Oil
13 TRANSPORTATION OF OIL BY ROAD
13.1.0 GENERAL
Oil from well head installations to Central Bowser Unloading Station (CBUS) / Oil collecting
stations are often transported by road tankers. In this operation, there could be hazard due
to fire and explosion unless adequate safety measures are adopted.
Recommendations given below provide guidance in this respect.
13.2.0 ROAD TANKER
1. Road tankers should be duly approved by the Chief Controller of Explosives (CCE) in using
for transportation of crude oil.
2. A valid permit form competent authority with a certified drawing of the tanker should be
available with every road tanker. In case of any doubt, the officer-in-charge of the installation
should examine the permit and the drawing to ensure that the tanker is in safe condition for
use.
3. The exhaust pipe of the tanker should be fitted with spark arrester approved by CC
4. The light fittings of the tanker should be adequately sealed to prevent open spark.
13.3.0 LOADING / UNLOADING TERMINAL
1. The loading/unloading terminal should have adequate space for accommodating tankers.
Congestion of vehicles in loading area should be avoided.
2. The terminal area should be provided with adequate lighting arrangement.
3. All electrical fittings in the terminal area should be flame proof.
4. An earth connection in the form of flexible cable with robust clamping device should be
installed close to the loading arm.
5. Anti-static hoses of sound construction should only be used for loading or unloading tankers.
6. Portable ‘HC’ detection system / explosive-meter should be available at loading terminal for
monitoring the gas concentration at a regular interval.
7. Loading area should be well away from ‘HC’ storage and other operational plant areas as
per OISD Standard.
8. Steam hoses to be provided to facilitate unloading of tanker particularly during the winter
season.
9. There should be proper communication system between loading areas and pump house.
10. Ensure there are no leaks from any part of body of fitted tanker before leaving the loading
area.
11. ‘HOT’ jobs near the loading gantries should be undertaken under work permit system.
12. Tanker loading area should be cleared of any spilled oil/oil effluent prior to the commencement
of loading / unloading operations.

Production-Oil
13. Loading area should be inspected by a Safety Audit Team prior to ascertain the preparedness
for carrying out the job.
14. Adequate arrangement for fire fighting should be provided. For this purpose, portable for
extinguishers of DCP/FOAM type are to be deployed at gantries.
15. Fixed fire fighting system also should be provided. This system (water sprinkler) to be checked
periodically once in a month to ensure its reliability.
16. All chambers of the bowser / tanker should be properly sealed after loading.
13.4.0 PRECAUTIONS DURING LOADING / UNLOADING
1. No tanker should be loaded if it is found to be leaking or otherwise in unsafe condition.
2. Every road tanker while it is being loaded or unloaded and until its valve is shut-off, filling
pipe and discharge faucet closed, should be attended by a competent person authorized for
the purpose. The competent person should particularly ensure that there is no fire hazard
during loading/unloading operation.
3. No smoking or open flame should be permitted within 30 meters of the loading point within
the protected area of the terminal.
4. The tanker, filling hoses and the chassis of the tanker should be efficiently bonded, and
connected to the earthing system by metal wire or tape. Earthing connection should be kept
intact until loading operation is completed and all valves and discharge faucets have been
securely closed.
5. Before commencement of loading / unloading operation, the engine of the road tanker should
be stopped and its battery isolated from the electric circuit. The battery should not be
reconnected until the tanks and valves have been securely closed.
6. In case of tankers with pump fitted in it for loading and unloading of oil, where the engine of
the tanker drives the pump itself and it can not be switched off, it should be ensured that the
exhaust of the engine is provided with suitable spark arrester in good working order.Adequate
arrangement for fire-fighting should also be made.
7. In the loading/unloading areas adequate arrangement for ventilation should be made to
prevent accumulation of flammable vapour near ground level due to low ambient temperature.
8. Every road tanker while it is being loaded should be attended by a competent person
authorized for the purpose. The competent person should particularly ensure that there is
no fire hazard during loading unloading operation.
9. No smoking or open flame should be permitted within 30 meters of the loading point and
within the protected area of the loading terminal.
10. It is absolutely prohibited to leave a tanker unattended during loading, unloading and
transportation.
11. The tanker should be checked for its fitness and safe condition before loading.
12. The tanker shall not be loaded (or) unloaded except in a place approved for the purpose in
writing by the competent authority provided that the tankers may be unloaded at any other
place with all due precautions and under adequate supervision if such unloading is
necessitated by an accident or breakdown.

Production-Oil
13. Tankers should not be loaded if the driver is found to be in toxic / under the influence of
alcohol.
14. Night-loading should be avoided to the extent possible. If the loading is to be carried out in
the night hours, the loading and the unloading area should have proper illumination and the
gas measurement should be carried out in every hour and should be recorded in a bound-
book.
13.5.0 GENERAL SAFETY GUIDELINES
1. The tanker shall not be used for carrying passengers or any article for which it is not meant
for.
2. Any one attending the vehicle which is carrying the product is forbidden,
√ To smoke
√ To carry matches
√ To carry artificial lights of igniting product vapours
√ To carry anything capable of causing fire and explosion (like burning incense sticks)
3. The tanker vehicle shall not be allowed to be repaired by welding, soldering, brazing or
riveting until its tanks compartments, pipes and valves have been thoroughly cleared and
examined by a competent person and certified by him in writing to be free from inflammable
vapour or oil.
4. Drivers and cleaners present at the loading station should wear cotton clothes. Persons
present at the loading station should also wear cotton clothes.
5. Any accident, fire or explosion occurring in the tanker in the 0IL premises which is attended
with loss of human life or serious injury to person or property shall be immediately reported
to the nearest Magistrate or to the officer in charge of the nearest police station having
jurisdiction and by telegram to the DGMS (Dhanbad)
6. In case of spillage or leakage
a. Non-sparking tools must be used
b. Adequate ventilation must be provided
c. All hot jobs are to be stopped in the near vicinity
d. Call the fire personnel to cordon the area and to cool the area with water sprinklers or any
other means.

Production-Oil
14.0 CHECK LISTS FOR ONSHORE PRODUCTION

INSTALLATION
Yes [ √ ] No. [ x ]
A. Entrance area :
a. Whether the installation have proper enclosure []
b. Whether there is wicket gate in the installation []
c. Whether there is Green belt area of 30m width all along the boundary wall []
B. Drawing :
a. Whether site plan has been properly displayed []
b. Whether line diagram of the installation is displayed []
c. Whether Electrical line diagram displayed []
C. Signboard / Display Board :
a. Whether prohibitory sign boards/statutory boards displayed []
b. Whether No-smoking signboard displayed []
c. Whether signboards for using the protective gears are displayed []
d. Whether the names of the officials and their telephone numbers as per the
contingency plan has been displayed []
e. Whether name of the first Aid trained personnel has been displayed []
.
f Whether name of the fire fighting trained personnel has been displayed []
D. Documentation :
Whether following records are maintained in the installation and made up to date (wherever
applicable):
a. DGMS approval letter of the installation []
b. IM’s appointment letter from competent authority []
c. Pressure test record of the vessels []
d. Pressure test record of the safety valves []
e. Employees permanent address book (form-B) []
.
f Employees leave position record (Form-G) []
g. All major reportable accident record (Form-J) []
h. Record of minor accident (F-K) []
.i Record of all near-miss incidents []

Production-Oil
.j Hot & cold work permit record []

k. Mock fire drill records []
.l Periodical medical examination record (Form-0) []
m. Record of first aid trained personnel []
n. Record of fire fighting trained personnel []
o. Record of mines vocational trained personnel []
p. List of competent personnel duly signed by the mines manager []
q. Record of periodic test of gas by explosimeter []
r. Record of the installation manager’s diary []
s. Fire contingency plan []
.
t Periodic calibration/inspection records of the instruments, controllers etc. []
u. Periodic health check-up of the installation such as thickness detection, []
radiographic test.
v. Periodic electric resistance test for tanks []
w. Maintenance record of CODP/FWDP/Gen set etc. []
x. A bound book covering monthly examination report of X-mass tree on []
temporary shut wells.
y. A supervisor’s monthly report book specifying the condition of each well []
including pressure.
z. Appointment letter of competent personnel issued by mines manager []
aa. Record of ND test. []
E. Manifold area :
a. Whether there is non-return valve in each flow line []
b. Whether there is pressure gauge/recorder in each flowline []
c. Whether there are double earthing on each manifold []
d. Whether well nos. are marked on the flow streams for easy identification []
F. Indirect heater / Emulsion treater area :
a. Whether temperature gauges are installed in the inlet and outlet stream []
b. Whether flame arrestor is installed in all the fired vessels []
c. Whether vessels are fired through remote ignition device []
d. Whether low temperature fuel shut off valve is installed and in working condition [ ]
e. Whether thermal insulation is done on the body of the vessels and also in the []
chimneys to the reachable height.

Production-Oil
.
t Whether double earthing is made on the vessels []
g. Whether high temperature shut-down device has been installed in all the vessels [ ]
h. Whether there is canopy on the exhaust of the chimney for all the vessels []
.i Whether safety valve outlet of the treater vessels is discharged at a safe distance [ ]
.j Whether there is a bundh around the treater vessels to contain the spillage of oil [ ]
k. Whether the servo and fuel lines are connected from the supply line []
through separate isolation valves.
G. Processed area / Gas oil separators :
a. Condition of the SRV []
b. Condition of pressure gauges []
c. Whether double earthing is erected in each gas oil separator []
d. Any oil / gas leakage []
H. Tank farm area :
a. Condition of the bundh []
b. Condition of the valve on the drainage system and whether it is closed condition [ ]
c. Whether electrical earthing resistance record is maintained []
d. Whether foam hydrant system is installed []
e. Whether drenching system is in working condition []
.
f Condition of breather valve []
g. Condition of automatic tank dip level gauge []
h. Whether fire monitors are in working condition []
.i Condition of the ring road around the tank area cleanliness []
I. Crude oil dispatch pump :
a. Whether proper sealing exist on the barrier wall between the []
prime mover and pump side.
b. Whether there is spark arrestor in the exhaust of the prime mover []
c. The condition of SRV []
d. Whether there is check Valve (NRV) in the pump delivery line []
e. Whether there is guard over all the rotating parts []
.
f Whether there is thermal insulation on the exhaust to the reachable height []
g. Whether SRV outlet is connected to the suction side of the pump []

Production-Oil
h. The condition of the pressure gauge/recorders []
.i Cleanliness []
.j Oil leakage []
k. Electric earthing []
J. Formation water disposal pump :
a. Whether rubber mats have been provided on the floor of electrical switch gears [ ]
b. Whether guards have been provided over the rotating part of the pump set []
c. Whether cable trench is filled with sand []
d. Cleanliness []
e. Oil / water leakage []
.
f Proper earthing []
K. General :
a. Whether there is adequate illumination in the installation []
b. Whether there is adequate walkways in the installation []
c. Whether the piping are provided with proper supports []
d. Whether the colour code is followed in the installation []
e. Whether direction of flow is marked on the pipings []
.
f Whether there is guards over the all rotating parts []
g. Whether protective painting is applied on the pipings at regular interval []
h. Whether there is covers over the oil water traps pits/leader drains in the []
installation
.i Whether there is guard/hand railing on the walkways more than 1.8mts height []
.j Whether there is hand-blown siren in the installation []
k. Whether rubber mats have been provided on all the electrical switch gears in []
the installation.
.l Whether the Safety Torch is there in the installation. []
m. Whether the explosimeter in the installation is in working condition []
n. Whether procedure of lighting the burner in the fired vessel is displayed near []
the site

O. First aid Box :
Ø Whether the box contains all the medicine as per the statutory requirement []
Ø Whether the brief application of medicine is mentioned in the box []
Ø Whether it is refilled at regular interval []
(p) Protective Gears :
Whether the following protective gears are available and used in the installation:
√ Hand gloves []
√ Safety shoes []
√ Helmet []
√ Ear muff []
√ Safety belt []
√ Gojjles []
(q) Fire fighting equipment :
Ø Whether mock fire drill is carried out in the installation once in every month []
Ø Whether water drenching system is run once in every day []
Ø Whether there is adequate numbers of fire fighting equipment in the installation [ ]
Ø Whether the fire fighting equipment are checked and refilled periodically []
(r) Safety meeting :
w Whether pit level safety meeting is conducted in the installation once in []
every month
w Whether departmental safety meeting is conducted in every month/bi-monthly []
(s) House keeping :
w Cleanliness []
w Drainage system []
w Spillage of POL []
w Proper stacking of drums of chemical/flow improver/ POL []
w Grass cutting and its removal []

Production-Gas
OIL INDIA LIMITED
Volume - I
Section - 5
PRODUCTION - GAS ACTIVITIES

Production-Gas
PRODUCTION - GAS ACTIVITIES

CONTENTS
1.0 Preamble......................................................................................................... 1
2.0 General............................................................................................................. 1
3.0 HazardsinGasProcessingInstallation........................................................... 4
4.0 SafePractices................................................................................................. 5
5.0 GasProcessingInstallation.............................................................................. 6
6.0 GasProductionsetup(GPS)..........................................................................10
7.0 GlycolDehydrationPlant................................................................................. 10
8.0 CondensateRecoveryPlant........................................................................... 10
9.0 TransportofGasthroughPipeline.................................................................. 11
10.0 PrecautionsagainstFire................................................................................. 15
11.0 Precautions against Accidents....................................................................... 16
12.0 Hazardousarea.............................................................................................. 17
13.0 Safedistance................................................................................................. 18
14.0 GasFlareSystem.......................................................................................... 18
15.0 PPE and Non Sparking Tools......................................................................... 18

Production-Gas
1.0 PREAMBLE
1.1 Production Gas Department in involved in production, operation, utilization and supply of
natural gas and carries out all the activities required such as separation, compression,
transportation, measurement, computation, monitoring and marketing including
developmental activities. Broadly it has the following objectives:
a) Comperssion of associated natural gas available from OCS (Oil collecting stations) to higher
pressure at GCS (Gas compressor stations) for the following activities.
)
i Low pressure boosting for feeding to the distribution network.
i) Dehydration of gas and compression, with gas lift compressor for supplying dry gas
at a requisite pressure for the network for crude oil production by artificial lifting method.
iii) Compression with storage / injection compressors for conserving in the depleted
reservoirs of any surplus gas.
b) Production of natural gas from Non-Associated Gas (NAG) reservoirs for supplying gas to
consumers along with associated gas.
c) To supply gas for meeting natural gas fuel requirement for various gas fuelled equipment
deployed in the fields.
d) Evacuation arrangement to the main grid network of gas from newly developed/ exploration
areas for utilization.
e) Development of gas field and production to meet total natural gas requirement.
1.2 It needs to follow safe practices while carrying out above activities for safety of man, materials
and environment. The following Paras highlight the safe practices to be followed in respect
of processing/handling natural gas.
2.0 GENERAL
2.1 Associated gas : Natural gas that is released from crude oil or produced along with oil is
known as associated gas.
2.2 Choke (Bean) : The choke (bean), normally installed at the wellhead controls the flow of a
well.
2.3 Condensate Recovery Plant : The plant extracts gas condensate from gas through
refrigeration method.
2.4 Contactor Tower : It is a vertical pressure vessel utilized for absorption of moisture from
gas through cross flow of gas and tri ethylene glycol (TEG).
2.5 Control valves : Diaphragm operated valves used for allowing flow of gas or liquid at a
controlled rate. Control valves may be of three types as per their utilization as under:

Production-Gas
)
i Pressure control valve : For controlling pressure at desired level. Pressure controllers
actuate it.
i) Level control valve/Liquid Dump Valve (Liquid/Oil, Valve) : For maintaining desired
level of liquid in a vessel. Level controllers actuate it.
iii) Flow control valve : For maintaining desired flow of liquid or gas. Flow controllers
actuate it.
2.6 Flare Pit : Flare pit is used for flaring unutilized associated gas.
2.7 Flow controller : It is used for controlling flow (quantity) of gas through a pipeline and
operates a flow control valve. It is operated pneumatically.
2.8 Gas Compressors : Machines that compress gas from low to high pressure are known as
Gas Compressors. OIL operates mostly two stage balanced opposed reciprocating double
acting gas compressors run by either gas engines with spark ignition or electric motors.
2.9 Gas Compressor Station : Gas Compressor Station is an installation where gas is
compressed to desired pressures through Gas Compressors.
2.10 Gas Hydrates : White crystalline solids formed in natural gas in presence of moisture
below hydrate point. Gas hydrates can block the gas flow through pipes if it forms inside a
pipeline.
2.11 Gas Well : A well completed in gas reservoir to produce non-associated gas is known as
Gas well.
2.12 Gas Well Production Setup (GPS) : Gas Well Production Setup (GPS)s are used for
production and processing non-associated gas through Heater Separator Units / indirect
Heaters.
2.13 Gas pipe line : Gas pipe lines are used for transportation of gas from one place to other
under pressure. Pipe sizes vary from 50 mm NB to 600 mm NB. These pipe line are named
after their purpose of use as under;
a) Gas distribution line : Used for transportation of gas for internal utilization or
consumers’ supply from source to delivery point. Normal operating pressure varies
from 1 0 Kg/Cm2 to 17.5 Kg/Cm2. (in Kathaloni it is 1 9 kg/Cm2. In Shalmari it is 17kg/
Cm 2)
b) Gas lift gas line : Used for transportation of gas lift gas to gas lift wells.Normal operating
pressure is 85-90 Kg/Cm2. (in Kathaloni it is l9kg/Cm2)
c) Gas injection line : Used for transportation of gas to gas injection/conserver wells.
Normal operating pressure varies from 100 Kg/Cm2 to 200 Kg/Cm2.
d) Flow line : Used for transporting high pressure well fluid from the well head to the gas
well production setup (GPS). Normal operating pressure may vary between 50 Kg/
C m2 to 300 Kg/Cm2 depending upon the well head pressure.
e) Fuel line : Used for transporting fuel gas. Normal operating pressure is 2.1 Kg/Cm2.
f) Servoline : Used inside an instailation for process instrumentation gas. Normal
operating pressure is 2.1 Kg/Cm2.
2.14 Glycol Dehydraition Plant : The plant is utilized for dehydrating gas to supply dry gas to
gaslift wells for production of crude oil through artificial lifting. The process used is absorption
through TEG (Triethylene glycol)

Production-Gas
2.15 Glycol Reboiler : It is used for removal of water from rich (Water saturated after absorption)
TEG through heating of saturated glycol.
2.16 Heater Separator Unit (HSU) : Heater Separator Unit is a modular designed for heating
and separation facility for processing high pressure gas well fluid. This unit is designed to
obviate freezing/hydrate problem normally associated with gas wells production.
2.17 High & Low Pressure Shutdown Valve : It is a positive shut off valve installed at the X-
mass Tree that activates to shut off the well in the event of increase or decrease in normal
well flowline pressure.
2.18 Hydrate point : It is the temperature at which gas forms hydrate in presence of moisture.
2.19 Liquid level controller : Liquid level controllers control the liquid level inside a vessel.
Normally, pneumatic operated level controllers are used in OIL.
2.20 Liquid Level Gauge : It is a glass tube installed in a pressure vessel with three way valves
for looking at liquid level inside the vessel.
2.21 Meter run : Meter run is used for measuring gas flow through a pipeline with differential
pressure flow recorders. It has provision for installing orifice plate and recording differential
pressure, static pr. & Temperature across the orifice plate as per A G A (American Gas
Association) guidelines.
2.22 Natural gas liquid (NGL) : Gas liquid that forms naturally in gas reservoirs is known as NG
L or gas condensate. Gas condensate may also be extracted from gas through refrigeration
or expander process.
2.23 Non-associated (free) gas : Gas produced directly from the gas reservoir is known as
non-associated gas. It may be produced along with natural gas liquid (gas condensate)
and/ or formation water.
2.24 Non Destructive Testing (NDT) : It is the process for health check up of a facility (pipeline,
pressure vessel or any structure) without damaging the facility. NDT of various facilities
includes ultra-sonic measurement of wall thickness, radio-graphic inspection, ultra-sonic
flaw checks and 100% wet fluorescent magnetic particle inspection.
2.25 Pressure Controller : It controls the operating pressure of a vessel or a pipeline and operates
the pressure control valve. It is pneumatically operated.
2.26 Pressure gauge : It measures the static pressure in a pressure vessel or pipeline. Pressure
measured by pressure gauge is called gauge pressure.
2.27 Pressure vessels (unfired) : Pressure vessels (Separators/knock out vessels) are utilized
for separation of ga from liquids. Operating pressure of the vessels varies from 0.7 kg/
2 2
C m to 135 Kg/ Cm .
2.28 Safety valve : It is a pre-set valve designed to release gas / liquid from a facility where it is
installed. It is set at 10% higher than maximum operating pressure.
2.29 Valves : Valves are installed in a pipeline for isolation of flow stream or providing uni-direction
to the flow.Various valves used in a gas processing plants and pipline are as under.
)
i Suction Valve : The valve installed at inlet of a compressor is termed as Suction Valve.

Production-Gas
i) Delivery Valve : The valve installed at outlet of a compressor is termed as Delivery

Valve.
iii) Bypass Valve : The valve installed at the inter-connection of suction and delivery
lines is termed as Bypass Valve.
iv) Check (Non-return) Valve : The valve is installed for providing one way flow in a
pipeline.
2.30 X-mass Tree : X-mass Tree is an assembly of valves, pipe fitting and choke installed above
the well head production spool. The designed pressure of X-mass Tree are either 351.0 Kg/
C m2 or 702.0 Kg/ Cm2.
3.0 HAZARDS IN GAS PROCESSING INSTALLATIONS
3.1 Gas leakage : Leaks in various pipelines used for gas transportation, gas lift gas, gas
injection etc and in other production facilities cause gas leakage and condensate spillage.
This can lead to fire and cause pollution in surrounding area. Therefore, any leakage, needs
to be repaired or rectified on priority basis.
3.2 Failure of facilities : Bursting of pressure vessels or pipelines is a potential safety hazard.
It may occur due to operating the facilities above designed pressure or material corrosion/
erosion.
3.3 Overheating : Overheated surface can cause fire hazard or injury to persons. The probable
sources are the discharge pipe of high-pressure Air and Gas compressors particularly
exhaust mufflers/silencers and manifolds of Engines / surfaces of chimneys of both heaters
and heat exchangers etc.
3.4 Skidding or failure of tools & implements : Failure of tools and implements is a common
cause for sustaining injury during execution of jobs. Failure of cranes used for heavy
equipment leads to bodily injury to persons present at the work site. Skidding of implements
like tri-pods used for lifiting pipes and equipment is another source of accidents.
3.5 Slippery or wet surface : Free fall due to slippery surface is another source of safety
hazards. Accumulation of lube oil, water etc makes surface slippery that leads to free fall.
Freezing of surfaces due to high-pressure drop in gas pipelines also makes pipe surface
and surrounding area slippery.
3.6 Gas/Condensate discharge due to blowing of Safety Valve : Gas/condensate discharged
from safety valves creates a hazardous atmosphere. Unless discharge is controlled timely it
may cause fire and health hazards or discharge to be diverted to flare pit through pipe lines.
3.7 Accumulation of condensate vapour : Gas Condensate vapour exists in the surrounding
while gas is released from a pipeline or when condensate accumulates in pit, cellar,tank
etc. The accumulated condensate vapour is ignited very easily and spreads very fast. In
confined space, it makes the atmosphere deficient in oxygen and cause breathing problern
(asphyxiation) and/or adverse physiological effects.
3.8 Fire Hazards : Flammable materials like condensate and gas are always present in a gas
processing installation or gas transporation pipelines and therefore fire hazards exist
constantly in such installations. This calls for strict control of sources of ignition like naked
lights, frictional and electrical sparks, static electric charges, lighting etc.

Production-Gas
3.9 Explosion hazards : Discharge of large quantity of gas into the atmosphere may cause an
explosion. This may occur in flaring gas, when the flare extinguishes suddenly, but gas
discharge continues. This may also occur in GDU Re-boilers and Gas/Diesel Engines muffler/
silencer.
4.0 SAFE PRACTICES
Guidelines for safe practices in gas processing installations and gas transportion pipelines
are enlisted in the following paras
4.1 Approval for Construction of a Gas Processing Plant
4.1.1 Permission in Form - VIll shall be obtained from the Director General of Mines Safety for
construction of any new petroleum processing plant as per OMR 1984. Copies of application
should be forwarded to District Magistrate and Deputy Director of Mines Safety.
4.1.2 The application should accompany up to date plan of the area where the installation is
proposed to be constructed showing the extent of land over which ownership has been
established.
4.1.3 A comprehensive project report with all -necessary drawings and contingency plan should
be submitted along with the application.
4.2 Installation of Pressure Vessels and other Facilities :
4.2.1 The legs of tri-pod used for lifting materials and pipes should be secured properly with ropes
to prevent skidding.
4.2.2 Pipes should not be lifted by holding at the middle. A pipe should be held on its ends.
4.2.3 Proper wedge should be inserted while pipes are kept on skid or pipe rack.
4.2.4 Lifting of materials with cranes should be done as per guidelines for crane operation.
4.2.5 W elding jobs should be carried out as per API Standard 1104
4.2.6 Guidelines for welding and cutting should be followed strictly.
4.2.7 All the over-ground pipelines must have suitable CC/pipe supports with clamps. Contact
between pipe support and the pipe should be minimum to prevent accumulation of water at
the contact point.
4.2.8 No pipe should be semi-buried. It should be either buried with proper insulation (wrap and
coat) or over-ground with proper painting. Sufficient extension of insulation should be
maintained above the ground level, where a pipeline becomes over-ground.
4.3 Periodic Testing of Pressure vessels and pipelines :
4.3.1 Visual inspection of all pressure vessels and pipelines shall be carried out at regular interval
and records shall be maintained in a bound book.
4.3.2 Ultra-sonic thickness measurement of the wall of pressure vessels and pipelines shall be
carried- out once in three years.

Production-Gas
4.3.3 Pressure vessels shall be tested hydraulically once in three years and documented thereof.
4.3.4 Safety valves shall be tested, once in six months and record thereof to be maintained.
4.4 Emergency Procedure
4.4.1 Emergency procedures (Contingency plan) should be formulated to deal with unforeseen
circumstances due to bursting of pressure vessel/pipeline or sabotage to the installation. It
should contain details of actions to be undertaken for safe guarding the installation as well
as the public in the following circumstances.
)
i Uncontrolled release of oil or gas from the pressure vessel or pipelines.
i) Fire in the installation
iii) Bursting of or damage to the pressure vessels or pipelines.
4.4.2 The emergency procedure should also specify the following :
)
i Action to be taken by an employee in case of discovering a fire, leakage or damage to
the installation.
i) General alarm and communication procedure and action to be taken on receiving the
alarm and communication.
iii) Instructions for operation of emergency equipment like fire extinguishers/First aid
medicines/equipment.
iv) Instructions for rendering safety to the affected installation.
v) Duties of key personnel.
vi) Important telephone numbers (like fire, medical, security, services and other key
personnel and nearest police stations)
vii) Schematic diagram of the installation with location of key isolation valves.
5.0 GAS PROCESSING INSTALLATION
5.1 Pressure vessels and pipelines :
5.1.1 All the facilities of an installation used for gas processing such as pressure vessels,
connecting pipelines, flow lines, gas transportation lines and valves & pipe fitting shall be
tested hydraulically to one and half times the maximum working pressure of the facilities.
The installation / pipelines shall be commissioned on satisfactory test results only.Any

leakage identified during hydraulic testing shall be repaired and re-tested hydraulically until
the facilities hold pressure at desired level.
Hydraulic testing of the installations and pipelines shall be documented properly and inscripted
on the body of the facility clearly with date of testing, due date of testing etc.
5.1.2 Every pressure vessel shall be provided with atleast one safety valve. The safety valve shall
be set to operate atleast 1 0% above the operating pressure of the facility.

Production-Gas
The safety valve shall be installed directly on the pressure vessel or pipeline.
No valve should be installed between the facility and the safety valve.
5.1.3 The safety valve discharge of pressure vessels and pipelines should be connected to flare
header for prevention of hazardous atmosphere in case of safety blow.
5.1.4 Suitable working platform with staircase should be provided for maintenance of pressure
vessels and Gas compressors/Engines.
5.1.5 Process areas like separator vessels, control valves, meter runs, HSU skids etc should
have sufficient passage for safe movement of operators. In case interference by pipelines,
suitable walk ways should be constructed for free movement of working personnel.
5.1.6 Approach road for fire tenders inside the installation shall be in good condition and free from
overgrowth of grass etc.
5.2 Safety shutdown and monitoring devices :
5.2.1 Gas compressors shall be equipped with either Pneumatic or Electro-pneumatic operated
safety shutdown system with audible alarm. Important operating parameters that should be
provided with safety shutdown are as under:
)
i Engine overspeed.
i) High engine temperature
iii) High compressor interstage/delivery temperature & pressure
iv) Low suction/high delivery pressure
v) Low engine/compressor lube oil pressure
vi) High engine/compressor lube oil temperature
vii) High engine exhaust temperature
viii) Low water level / No water flow
ix) High engine/motor/compressor vibration
x) Motor overload (in case of electrical motor driven unit)
xi) High bearing temperature (optional)
5.2.2 Suitable indicators shall be provided for all the improtant parameters as under:
)
i Speedometer for engine/motor speed.
i) Engine temperature indicator
iii) Compressor suction/interstage/delivery temperature indicator
iv) Suction / interstage / delivery pressure indicator
v) Engine / compressor lube oil pressure indicator
vi) Engine/compressor lube oil temperature indicator
vii) Engine exhaust temperature indicator

Production-Gas
viii) W ater level indicator (Gauge glass)
ix) Ampere meter for electric motor current
x) Bearing temperature indicator (optional)
5.2.3 All the safety shoutdown devices, instruments, alarms and trip signals should be tested/
calibrated at a regular interval to check their effectiveness. Any deviations should be corrected
immediately. Such tests/ calibrations/corrections should be properly documented.
5.3 Compressor operation :
5.3.1 Compressor start up, operation and shutdown shall be carried out as per operation guidelines.
5.3.2 All the important operating parameters shall be recorded regularly.
5.3.3 If any abnormality like excessive noise, vibration, oil or water leaks, low oil pressure, high
water temperature, gas leaks etc is observed, STO P THE COMPRESSOR IMMEDIATELY
5.4 Safety implements at the station :
5.4.1 The following safety implements shall be kept at the station,
)
i Safety torch should be kept in the station in operating condition
i) Portable gas detector should be kept and calibrated regularly.
iii) First aid box should be kept as per requirement and fill up as and when required. No
medicine beyond expiry date should be kept at the first aid box. The stretcher should
be tested at a regular interval for its efficacy.
iv) All the bound paged books, records, contingency plan should be maintained properly.
5.5 Safety provisions in a Compressor Station :
5.5.1 Proper safety valves should be provided at suction and interstage scrubber vessels and
compressor delivery pipeline. No valve should be installed in between scrubber vessels/
pipeline and the safety valves.
5.5.2 Incoming and outgoing gas pipelines should be provided with suitable shut off valves. The
valves should be demarcated clearly for easy identification to operate the valves on
emergency promptly.
5.5.3 All the discharge pipelines (except gas booster delivery which is connected to gas distribution
network) shall be provided with an over pressure release control valve. The over pressure
release control valve should be connected to the suction pipeline. The over pressure release
valve shall be tested at regular interval and test result documented.
5.5.4 Portable gas detector shall be used at regular interval for cheeking any gas leakage from
pipe or compressor flanges.

Production-Gas
5.5.5 The inter-cooler and after-cooler should be maintained in airtight condition Inter-cooler and
after-cooler should be cleaned at regular interval.
5.5.6 The fuel line and the ignition system should be disconnected for cranking the engine for
checking.
5.5.7 Necessary precautions should be taken for making the gas liquid and solid free, which are
major deterrents for compressor damage.
5.5.8 Knock out vessels should be provided at inlet pipeline to separate oil/condensate/water
from gas. Knock out vessels should be provided with automatic dumping valves and level
indicator for automatic dumping of liquids.
5.5.9 Liquid dumping pipelines shall be connceted to the high or low pressure manifolds of the
nearby oil collecting station as per desired pressure rating. Proper indicator/sticker shall
be provided at the manifold stating pipeline from compressor station.
5.5.10 Welded and flanged joints should be used in a gas compressor station. Screwed joints
should be avoided as far as practicable.
5.5.11 Non-return valve should be provided at the discharge of each compressor.A suction valve
shall be installed at suction of each compressor.
5.5.12 A bypass valve shall be installed between suction and discharge of each compressor.
5.5.13 Flameproof electric motors/starters/cables shall be used as per recommendations for

use of electrical items in hazardous areas.
5.5.14 Cable trenches shall be properly marked and shall be free from any other gas/service
pipelines.
5.5.15 Cables shall be laid as per recommendations (for laying of cables) in hazardous areas.
5.5.16 Gas compressor sheds shall be open on all sides for proper ventilation.
5.5.17 Emergency shut down switch shall be installed at a prominent place away from the
hazardous area for shutting down the station on emergency.
5.5.18 Positive shut out of gas to be done before any major work in compressor end.
5.6 Emergency Procedure :
5.6.1 Emergency in a Gas Compressor Station is declared when fire, bursting of pipeline/pressure
vessel (separators)/uncontrolled release of gas, oil or condensate take place in a station.
Only authorised competent person can declare emergency in such a situation
5.6.2 The following actions should be taken in case of emergency at a Gas Compressor station
)
i Shut all the compressors down by operating the emergency shut down switch of the
station.
i) Blow the siren to caution people surrounding the station.
iii) Inform fire service at Duliajan
iv) Shut all the inlet and outlet isolation valves to prevent gas flow to the station.

Production-Gas
v) Operate fire extinguishers in case of fire as per instructions.

vi) Keep the fire extinguishers ready in case of uncontrolled gas release
vii) Inform installation manager, control room and security, medical at Duliajan.
viii) Provide first aid to any injured persons.
6.0 Gas production set up (GPS)
6.1 Suitable control system should be installed to regulate gas from a gas well production
setup in case of fluctuation of pressure in gas distribution network.
6.2 An automatic hi-low pressure safety shutdown valve should be installed at the well head to
shut off flow in case of fluctuation of pressure in flowline.
6.3. In case of production of a gas well through multi choke (bean)s, suitable measures should
be taken to prevent freezing in flowline. Regular monitoring of flowline should be carried
out to check freezing problem.
6.4 A non-return valve shall be provided in each flow line at the inlet to the heater separator unit.
6.5 A non-return valve shall be provided at the gas outlet from the setup.
6.6 Thermal insulation shall be provided through proper lagging of bath heaters and heater
chimneys. Insulation on chimney should be at least to a height of 1.80 metre from ground
level.
6.7 Remote ignition system should be used for lighting pilot burner system of the indirect bath
heater of heater separator unit.
6.8. Burner system of Heater Separator Unit must be equipped with suitable flame arrestor.
6.9 Start up, operation and shut down procedures must be followed as per operation guidelines.
All the operating parameters shall be recorded regularly at one hour interval.
7.0 Glycol Dehydration Plant :
7.1 All the heating surfaces of the glycol re-boiler should be insulated properly or provided with
guards.
7.2 Glycol inlet and outlet pipelines should be checked regularly for any leakage.
7.3 The contactor tower should be charged with gas at a very slow rate to prevent damage of
bubble tray caps inside the vessel.
7.4 Glycol should be handled carefully as per guidelines for chemicals. Eyewash should be
provided for cleaning eyes immediately in case of eye contact with glycol.
7.5 The glycol re-boiler should be serviced regularly and tested for any leakage of fire tube, still
column etc.
8.0 Condensate Recovery Plant :
8.1 Condensate is a highly flammable heavier hydrocarbon. It propagates along the ground
level to a long distance, if leakage takes place. Therefore, pipeline-transporting condensate
should be leak-proof and checked for the same at regular interval.

Production-Gas
8.2 All the operation guidelines shall be followed during start up, operation and shut down of a
condensate plant.
9.0 Transportion of Gas Through Pipeline :
9. 1 Approval for Construction of Pipeline :
9.1.1 No new pipeline shall be laid nor any significant alteration is carried out in any existing
pipeline except with permission in writing from the concerned authority.
9.1.2 Permission in form - VIII shall be obtained from the Director General of Mines Safety and
copies thereof shall be sent to the Deputy Director of Mines Safety and the Di-strict
Magistrate for construction of any new pipeline.
9.1.3 The application for permission shall be accompanied by copies of up to date plan of the
area where the pipeline is proposed to be laid showing the extent of land over which right of
use or right of way has been established.
9.1.4 A comprehensive project report, accompanied by all necessary drawings and pipeline
design details shall be submitted along with the application for permission for construction
of the pipeline as per OMR 1984
9.2 Construction of Pipeline :
9.2.1 Standard of Construction: Recommended code of construction for gas piping system
should conform to ANSI B31.8
9.2.2 The number of bends in the pipeline should be kept to the minimum by proper grading of
trenches.
9.2.3 Where an underground pipeline needs to cross any existing pipeline, cable, drains etc, the
pipeline should be laid at least 30 centimetres below such facilities in such a manner that
it will not obstruct access to such facilities for inspection, repairs or maintenance.
9.2.4 Where pipelines are to cross railways, river or road extra strong pipes should be used at
the crossing. The pipeline should be provided with a casing extending up to 15 metres on
either side of the crossing. Isolation valves should be provided on either side of the crossing.
Casing should have proper vent pipe.
9.3 Right of Way (ROW)
9.3.1 Pipeline should be laid in the most favourable route, avoiding as far as possible known
obstructions and areas in which unusual external conditions prevail.
9.3.2 The route of the underground section of a pipeline should be indicated by markers and not
less than two such markers shall be visible from any point along the route.
9.3.3 Inspection of the ROW shall be carried out once in 3 months. Records of such inspection
shall be maintained in a register.
9.3.4 ROW shall be fenced properly during excavation of trench in case it fails within a village to
prevent stray animals failing into it.
9.3.5 Any isolation valve on the pipeline in ROW shall be fenced with lockable gate.

Production-Gas
9.4 Handling and stringing :

9.4.1 During transporation of pipes, they should be tied up securely with rope/chain on to the
trailer, to prevent failing down of pipes.
9.4.2 Proper obstruction should be placed at the pipe ends towards drivers’ cabin to prevent
axial movement of the pipes during sudden halt of the carrier.
9.4.3 Red flag should be tied at the overhung end of the pipe on trailer as a warning signal.
9.5 Trenching :
9.5.1 There should not be long time gap between trenching and welding jobs. It should be done
just ahead of welding job. This prevents failing of stray animals or people into the deep
trench.
9.6 Sand blasting :
9.6.1 Durings sand blasting sand ejected with high pressure compressed air may cause injury
to working personnel. Precautions to be taken for the same are as under,
)
i W arning notice should be displayed during the work
i) Proper signal mechanism should be followed between the persons working in the
machine and pipe cleaning.
iii) Workers should wear proper personal protective equipment.
iv) After the work is completed, air to air receiver should be cut off and the receiver
should be depressurised completely.
9.7 Welding :
9.7.1 W elding job should be carried out as per API Standard 1104
9.7.2 Guidelines for welding and cutting should be followed strictly.
9.8 Coating and wrapping :
9.8.1 Very high temperature coal tar enamel used in this operation causes safety hazards. The
following safe practices should be followed to prevent the same.
)
i The workers shall wear protective outer clothing of asbestos or rubber, goggles, helmet
and footwear.
i) Coal tar should be heated up to a maximum temperature of 2700 C. The primer should
be prepared at a distance of about 50 metre away from the place where coal tar is
heated.
iii) Coal tar should be taken into bucket. through a tap only and should not be poured from
the top of the container.
iv) Adequate precaution should be taken to prevent hot coal tar from splashing or failing
on working personnel.
v) While applying insulation, buckets containing hot coal tar should be carefully handled
to prevent splashing.

Production-Gas
9.9 Lowering and Back-filling :

9.9.1 It should be ensured that no one is inside the trench at the time of lowering the pipeline.
9.9.2 In case of cave-in, removing of loose soil from underneath should done after providing
suitable support under the pipeline.
9.9.3 Special care should be taken while lowering pipeline in a hilly terrain with slope.
9.9.4 Utmost care should be taken for lowering concrete coated pipes under watercourse.
9.9.5 In case of use of chain pulley block for lowering pipeline, proper support should be used
Capacity of the chain pulley block must be 1.5 times of the pipe weight to be lifted.
9.9.6 Back filling should be done in such a way that original ground level is maintained properly.
9.10 Testing :
9.10.1 After completion of back filling the pipeline should be tested hydraulically at a pressure of
1.5 times the maximum working pressure of the pipeline for a period of 24 hours. The test
result must be recorded with proper recorder chart. Details of hydraulic test should be
documented properly.
9.10.2 Precautions should be taken to fill the pipeline with water completely for hydro testing. Air
should be purged off completely.
9.10.3 Pipeline should be pressurized gradually and slowly in small increments to avoid application
of sudden stress/strain to the pipeline material.
9.10.4 If the pipeline breaks during the testing near public road and/or railway track, the concerned
authority should be informed immediately.
9.10.5 The pipeline section, that does not hold pressure should be repaired / replaced and retested
satisfactorily before putting into operation.
9.10.6 In case of a pipeline with pigging facility, water/air should be displaced by using a pig.
Pipeline without pigging facility should be filled with oil/gas very slowly to displace waterlair/
from inside the pipeline.
9.11 Safe practices : Recornrnended safe practices are given under :
9.11.1 The pipeline should have sufficient safety devices for its protection against higher than the
normal operating pressure. Some of the safety devices are as follows.
)
i Use of safety valve at strategic points like inlet, outlet etc.
i) Use of over pressure control valves for release of excess gas to flare.
iii) Use of shut off valve at well heads for shutting off the well in case of high pressure in
the flowline.
iv) Use of hi/low pressure safety valve at the well head, set to operate in case of change
in flowline pressure.
v) Continuous monitoring of major distribution pipelines with the help of Supervisory
Control and Data Acquisition (SCADA) System.

Production-Gas
9.11.2 The pipeline should be isolated from the operating system immediately in case of damage
to and / or leakage of oil/gas from the pipeline. Check valve, should be installed at the entry
point to the mains to prevent back flow in such situation.
9.11.3 All oil/gas pipelines should be laid underground and have outside insulation.
9.11.4 Isolation valves and other nozzles on the pipeline, if installed in remote areas, should be
fenced properly. It should be provided with lockable gate.
9.11.5 Casing vent on any pipeline crossing should be checked at regular interval for presence of
any gas leakage.
9.11.6 Adequate arrangement should be made for patrolling along the pipeline route at regular
interval to check the following.
)
i Any leakage of oil/gas from the pipeline
i) Any unauthorised encroachment of the ROW
iii) Damage of boundary fence of over ground pipeline valves.
iv) Tampering of gas & condensate pipelines by miscreants.
9.11.7 In case of any leakage or other undesirable occurrence, the matter should be attended
immediately.
9.11.8 Underground pipeline should be inspected for external corrosion at approved. Non
Destructive Testing (NDT) should be carried out to find out the health of the pipeline at all
interval.
9.11.9 Suitable inspection pits should be provided for the pipelines with cathodic protection. Pipe
to soil potential should be measured in case of detection of zone of static current.
10.0 PRECAUTIONS AGAINST FIRE :
10.1 The protected area of all gas processing installations shall be enclosed by boundary wall
or barbed wire fencing not less than 1.80 metre in height with lockable gates. Guards shall
be posted at the gates for preventing unauthorised entry of persons. Suitable procedure
shall be in force for restricting entry of any unauthorised person.
10.2 Smoking is strictly prohibited inside any gas processing installation, Prohibitory signboards
shall be displayed at the gate for this purpose.
10.3 Anyone entering the Installation shall deposit any smoking apparatus like cigarettes, matches,
lighters etc. (if any) at the entrance gate.
10.4 Emergency exit : It should be ensured that the emergency exit is unobstructed and easily
accessible. There shall be at least two escape ways, if any job is taken up in an enclosed
area.
10.5 Non-sparking tools shall be used for any work carried out in a hazardous area.
10.6 The chimneys, bath heaters, heat exchangers, engine exhausts shall be adequately
insulated. Inter-coolers should be provided for reducing temperature of compressed gas/
air.
Suitable guards should be provided for preventing easy contact of hot surfaces with operating
personnel

Production-Gas
10.7 Hot Work Permit shall be issued to the concerned person by the competent person/
installation in Charge for carrying out hot works inside the installations.
10.8 Efficient earthing of all vessels and equipment shall be done to take care of static charges.
Earthing shall be clearly marked for inspection. Earthing connections shall be checked at
regular intervals. Earth resistance shall be measured as per norms and records shall be
maintained in a register.
10.9 Spillage of flammable liquids shall be cleared immediately.
10.10 Flammable materials shall be kept away from the source of heat or hazardous areas.
These should be stored in proper cans at a place ermarked for the purpose.
10.11 All fire fighting equipment shall be tested regularly and maintained in good condition. Fire
fighting equipment shall be placed in easily accessible areas. Access to the fire extinguishers
must not be obstructed. People on duty must learn to operate fire extinguishers.
10.12 Fire hydrants, water-monitoring system shall be inspected for smooth functioning.
10.13 First aid items shall be maintained properly.Any medicine beyond expiry date must be
replaced from the first aid box.
10.14 Dry vegetation shall be removed.
10.15 Adequate water shall be stored as per norms and supply system should be maintained
properly.
10.16 Prohibitory Sign boards shall be displayed at all critical places.
10.17 Regular monitoring of wellhead assembly shall be carried out for checking any leakage of
gas /condensate. Wells shall be properly fenced with lockable gates for prevention of
unauthorised entry of persons or stray animals to the wells. Gates shall be locked properly.
Wells shall be clearly marked for easy identification. Periodic inspection of fence shall be
carried out.
10.18 Vessel entry permit shall be issued by Installation-in-Charge with due approval of the Mines
Manager for cleaning/maintenance of any vessel.
11.0 Precautions against accidents :
11.1 Preventive maintenance of the machines shall be carried out as per schedule.
11.2 Close supervision of machines on operation shall be ensured. Records of all-important

parameters shall be maintained in a register.
11.3 Function test of the control panels of the machines shall be carried out and records of the
same shall be maintained.
11.4 Drainage system should be sound in the process area. Proper sumps should be available
at strategic points in the drainages system for collection of spilled oil/lube oil Sump pump
should be installed for removal of spilled oil, if required.
11.5 Work area should be kept clean and undesired materials should be removed.

Production-Gas
11.6 Adequate area illumination should be provided in all gas processing installations. Adequate
number of portable hand lamp approved by the statutory authority should also be kept at
the stations.
11.7 The pipeline and pressure vessels for different types of fluid and pressure shall be painted
as per standard colour code.
11.8 Moving machinery, drive belts shall be provided with metallic guards.
11.9 When a person needs to work at a height of 1.5 metre above ground, a suitable working
platform with staircase and railing shall be used for carrying out such works.
11.10 No electrical maintenance or testing job shall be undertaken in any hazardous area unless
the area is made gas free and certified by the authorised person.
11.11 All the operating personnel shall ensure use of personal protective equipment.
11.12 The installation manager or competent personnel shall issue work permit for all cold or hot
work before commencement of any repair or maintenance work.
11.13 Bare minimum work person shall be at the work site for carrying out any work in a hazardous
area.
11.14 Register should be maintained at the gas processing installation for recording any safety
violation and its rectification thereof.
12.0 Hazardous area (Refer SOP on Electrical Engineering Activities) :
12.1 The hazardous areas are classified as under.
12.1.1 Zone - 1 : The area where a hazardous atmosphere is likely to occur in normal operating
condition.
12.1.2 Zone - 2 : The area where a hazardous atmosphere is likely to occur in abnormal operating
condition
12.2 The extent of hazardous area as under :
12.2.1 Zone - 1 :
)
i Any cellar of pit below ground level and located in Zone 2 area.
i) Area within the radius of not less than 1.5 metres from the open end of any vent
extending in all directions.
iii) An area within a radius of not less than 1.5 metres of the pig launching/receiving trap.
iv) Area surrounding a floating roof tank within 3 metres of the tank shell, ends of roof and
inside the enclosure up to the level of the enclosure wall.
v) In case of fixed roof tank, the area surrounding the tank within 3 metres from the tank
shell ends or the roof end inside the enclosure up to its top level.

Production-Gas
12.2.2 Zone-2 :
)
i An area within a radius of 3 metres from any separator vessel, heaters,
treaters,dehydrators, stabillizers, hydrocarbon recovery unit, gas compressors, subject
to the condition that any fired box forming integral part of such equipment is fitted with
an equipment that will eliminate the vessel or unit from become a source of ignition
i) An area within a radius of not less than 3 metres from the open end of the gas vent
extending in all directions.
iii) An area within a radius of not less than 3 metres from the discharge of a relief valve,
extending in all directions, subject to the condition that there will be no electrical
equipment in direct path of the discharges.
iv) An area within a radius of not less than 3 metres of the pig launching / receiving trap.
v) Area extending 3 metres horizontally in all directions of machines handling flammable
liquid and natural gas.
vi) The entire interior area of a adequately ventilated building where machines are installed
for processing oil and gas.
12.3 Any electrical equipment that is to be installed in a hazardous area shall be done as per
guidelines for installation of electrical equipment.
13.0 Safe distances :
13.1 Smoking is strictly prohibited within 30 metres of any well, separator, petroleum storage
tank or other sources of flammable materials.
13.2 No naked light or open flame or spark is permitted within 30 metres of any well or any place
where pertroleum product is processed or stored.
13.3 No fired vessel shall be installed within 30 metres of any well, separator, pertoleum storage
tank except where such fired vessel is fitted with a flame arrestor.
13.4 Flare shall be constructed not less then 90 metres from any part of petroleum processing
or storage installations.
14.0 Gas Flare systern :
14.1 A flare shall be installed at a safe distance from the installation as per recommendation.
14.2 Provision should be kept for draining out any liquid accumulation in the flare line and any
liquid accumulation in the line should be drained.
14.3 Pilot burner should be provided at the flare pit with remote ignition facility.
14.4 W ater seal drum should be provided in the flare line to prevent air entry in to the flare line.
14.5 Leakage should be attended on priority basis.
14.6 Suitable masonry boundary wall should be constructed surrounding the flare.
14.7 No seepage should take place from the effluentpit. Any seepage noticed should be repaired
on priority basis.

Production-Gas
14.8 Passage to flare should be unobstructed and free from dry vegetation.
15.0 PPE and Non Sparking Tools :
HSE Management System, Volume -1, Section -1 may be referred for personal
Protective Equipment and use of Non Sparking Tools.
“Your Safety means

The Safety of your family”

Chemical and R & D
OIL INDIA LIMITED
Volume - I
Section - 6
CHEMICAL & R & D

ACTIVITIES

Chemical and R & D
CHEMICAL AND R & D ACTIVITIES

CONTENTS
1.0 Safe operating procedure of chemical operations in Drilling & W.O. Wells..... 1
2.0 Safe work practices in Chemical Laboratory.................................................... 2
3.0 Safety activities related to Bottom Hole Operations....................................... 3
4.0 Safety Precautions in carrying out PVT experiments & sampling works......... 4
5.0 SOPforR&Dactivities................................................................................... 5

Chemical and R & D
1.0 SAFE OPERATING PROCEDURES OF CHEMICAL OPERATIONS IN

DRILLING / WORKOVER WELLS
Following Safe Operating Procedures to be followed in chemical operations in drilling and workover
wells
1.1.0 STACKING OF CHEMICALS :
1.1.1 Proper storing and housekeeping should be maintained in the storing place/chemical
godowns etc. Drum chemicals should be identified and names should be displayed with
legible sign boards. Any spillage from the drums should be immediately cleaned up.
1.1.2 While Stacking chemical bags/drums on top of one another, care should be taken so that
the stacks on the lower parts are properly levelled and secured and there is no likelihood of
spillage.
1.1.3 Chemicals like Bentonite. CMC etc. are potentially slippery when wet. Hence, spillage of
these chemicals in the store and hopper area should be cleaned up at the earliest. Any torn
bags should be taken out and stacked separately for use at the first opportunity.
1.2.0 HANDLING OF CHEMICALS/MUD PREPARATION AND OTHER CHEMICAL

OPERATIONS IN DRILLING WELLS.
1.2.1 Addition of caustic soda directly into the hopper and pits should be avoided. It should
preferably be added as an aqueous solution through a drum. Canvas gloves are not
sufficiently protective specially when wet for handling caustic soda. Use safety goggles,
rubber apron and PVC gloves while handling caustic soda.
1.2.2 Use dust mask, eye protection in addition to other PPE when adding chemicals like bentonite,
barites, cement, CFLS etc and other finely powdered chemicals. Eye washes to be installed
and connected for availability of enough clean water in case of any exigency.
1.2.3 Rectify loose electrical fittings if any and check for proper insulation before using electrical
equipment like Mud agitations, solids control equipment etc.
1.2.4 Used chemical bags should be disposed in the designated disposal pit only and the working
area should be kept clean.
1.2.5 Agitations in the mud tanks should be stopped and disconnected by informing Electrical
personnel before any tank cleaning operation is done. Mud disposal after completion of
drilling operation should be done as per the approved policy (in the designated pit or in the
effluent pit).
1.2.6 Proper PPE along with dust mask, eye protection, PVC apron, hand gloves should be

Chemical and R & D
used for sample collection during cementing operation.
1.2.7 MSDS should be made available at well sites and recommended procedures to be followed.
1.3.0 HANDLING OF ACIDS/CHEMICALS IN WORKOVER WELLS
1.3.1 Acid jars should be covered with proper lids and never left uncovered and should be
transferred/handled with care. If spillage takes place, wash with plenty of water immediately
and neutralize with lime, soda or calcium carbonate. If spilled on the skin wash the area
with plenty of water and soap and seek medical advice.
1.3.2 While diluting acids never add water to concentrate acid in the tanks. Spluttering may take
place. Always add the acid to water.
1.3.3. Some surface tanks defoamers, corrosion inhibitors etc. can produce irritation of the skin
and the vapours can irritate the eyes. When handling such chemicals wear appropriate
personnel protective equipment like gloves, aprons and goggles. If spilled on the skin wash
the area with plenty of water and soap and seek medical advice.
1.3.4 Persons engaged in handling for preparation of workover fluids (Sodium Chloride/Calcium
Chloride) both at Mud plants and well sites should wear safety boots, rubber hand gloves
and safety goggles.
1.3.5 Persons engaged in acidisation jobs should wear rubber apron, rubber hand gloves,
acidisation musk, gum boots and goggles.
2.0 : SAFE WORKING PRACTICES IN CHEMICAL LABORATORY
2.0.0 WHILE HANDLING HAZARDOUS CHEMICALS &ACIDS :

2.0.1 To read the level before opening the container.To ensure about the type and strength of the
acid.
2.0.2 To consider the hazards including violent reaction with other chemicals and use appropriate
protective clothing and equipment .
2.0.3 To open the container carefully in well ventilated area and near available running water
system.
2.0.4 Totake care while extracting and using hazardous chemicals and use proper methods as
per the Material Safety Data Sheet’& proper gadgets like aprons, handgloves, safety glasses,
nose mask etc to reduce the risk of inhalation, ingestion and contact with skin, eyes and
clothing.
2.0.5 To avoid using contaminated apparatus and instruments.
2.0.6 Not to eat, drink or smoke while using and handling chemicals.
2.0.7 To wash hands and exposed areas regularly and change contaminated clothing in case of
any possible spillage.

Chemical and R & D
2.0.8 Users must have good awareness about the chemical’s use.
2.1.0 WHILE STORING HAZARDOUS CHEMICALS AND ACIDS
2.1.1 To store in well ventilated area, protected from extremes of temperature and sources of
ignition.
2.1.2 To secure chemicals from unauthorized use.
2.1.3 To inspect stock from time to time and dispose the deteriorated materials.
2.1.4 To segregate stocks to reduce hazard in case of accident.
2.1.5 Not to smoke where flammable chemicals are stored.
2.2.0 WHILE USING PRESSURIZED CYLINDERS
2.2.1. To ensure that the pressure regulators of the pressure gauge manifold are closed before
opening the pressurized cylinder.
2.2.2. To keep the pressurized cylinder in a well-ventilated space away from the working area.
2.3.0 WHILE HANDLING SOME PARTICULAR EQUIPMENT
2.3.1. HP/HT Equipment : The following measures should be adopted while handling HP/HT
equipment.
l Electrical points should be checked before operation. Insulated gloves should be used
while checking/inspecting.
l Pressure gauges should be calibrated periodically to avoid false indication.
l High pressure lines & valves, Low pressure lines & valves should be checked
periodically.
l Nitrogen cylinder should be kept away from main switch.
l Fire extinguisher should be placed within 50 feet of the equipment.
l Operational procedures (Starting and shutting down) should be hanged at a place
from where it can be read easily and should be strictly followed.
l 75 cm (minimum) clearance should be kept between the instrument & main electric
switch.
l Periodically test the safety relief valve of the manifolds.
Note : While using HPHT filter press at higher temperature (1800 F), the temperature of the
mud in the cell must be reduced before opening after completion of the test. After the cell
is cooled adequately, the pressure from the cell is to be bled by opening the inlet valve
stem with the cell in an upright position.
2.3.2 Hot-Roller Oven:Aging cell in hot roller oven should be allowed to cool to room temperature
before removing from the oven chamber. It should be further cooled in tap water and the
cell should be opened only after release of pressure and the opening end should not face
the operations body.

Chemical and R & D
2.3.3. IP Distillation: While carrying out IP Distillation the operator should be careful about any
probable pressure buildup inside the flask due to the presence of higher %age of light ends
which might result in sudden spillage causing accidental injury.
2.3.4. W ater bath:The heating element of the water bath should be well insulated against water
vapour to prevent electrical shock.
2.3.5. W ater content determination of crude oil : While using Xylene & Toluene for determination
of water content in crude, the exhaust fan should be run continuously to eliminate the
vapor which are hazardous to health.
3.0.0 SAFETY PRACTICES RELATED TO BOTTOM HOLE OPERATIONS
)
i Bottom hole operators and other working persons in the site should wear safety gears
like safety helmets, safety boots, protective eye-wears, hand gloves etc. Tool box
meeting should be conducted before every operation.
i) Piano wireline should be torsion tested after every 05 normal BHP operations and
always after every special operation when the wire line is in the hole for long duration.
iii) Wire line winches used in BHP operations should be well maintained. The engine of
the winch should be periodically serviced at yard. Wire line should be kept clean &
lubricated and covered to avoid rusting, premature failure etc.
iv) Gin poles should be used whenever necessary (depending on the height of the x-
mass tree, well head pressure or sophistication of the tool being used) for safe rig- up
of heavy/ high-pressure lubricators, BOP etc.
v) All well head equipment should be pressure tested to the maximum working pressure
frequently.
vi) Wire line BOP should be used.
vii) Proper working platform should be provided at the wellhead for safeworking condition
to the personnel.
4.0.0 SAFETY PRECUATION IN CARRYING OUT PVT EXPERIMENTS, SAMPLING

WORKS & CORE LABORATORY WORKS
)
i Job Safety analysis is to be initiated, discussed and reviewed prior to commencement
of any PVT studies/core studies.
i) PVT cell and the high-pressure connections and other ancillary equipment in both
laboratories are to be pressure tested to the working pressure prior to each experiment
and should be recorded properly.
iii) Working personnel should be extremely careful while handling mercury other
hazardous chemicals like chloroform in the laboratory as it can create health hazard.
iv) Mercury vapour should be monitored in the PVT laboratory frequently by Hg-vapour
analyser so that it is maintained at the minimum safe level.

Chemical and R & D
v) Proper house keeping in the laboratory where mercury is used is a must. If there is
any spillage of mercury during the course of experiment, the same should be removed
immediately.
vi) All personnel working in the PVT laboratory/core laboratory should use aprons, safety
goggles, hand gloves and hard shoes.
vii) Gas sample cylinders and condensate cylinders should be hydrostatic pressure tested
as per stipulation. Cylinders should be certified by an authorised testing station/
competent person.
viii) Gas and condensate cylinders should be cleaned properly with toluene or other
appropriate solvents prior to every sampling as per standard procedure.
ix) While sampling, appropriate safety precautions should be taken to minimise risk.
Sampling personnel should use appropriate protective equipment like safety glasses
or other approved protective eye-wear, steel toed safety boots, protective coveralls,
hard hat, gloves and ear protectors.
Make Safety a Habit to remember,

From January to December

Chemical and R & D
5.0: SAFE OPERATING PROCEDURE (SOP) FOR R&D ACTIVITIES
Sl.
R & D Activities Safe Operating Procedure
No.
1. Handling of Hazardous Chemicals like : a. Personnel handling above must be careful
Acids like Sulphuric Acid, Nitric Acid, and use required PPES like wearing hand
Hydrochloric Acid etc.; Alkalis like Sodium glove, gas mask, face shield, protective
Hydroxide, Potassium Hydroxide etc.; clothing etc.
Toxic chemicals like Phenols, Aniline, b. W arning labels on hazardous chemicals
Aromatic solvents etc and many other should be put
organic compounds; Carcenogenic c. Periodic inspection of chemical storage for
compounds like Benzene; Gases like prpoer labels, ventilation etc.
Carbon Monoxide, Hydrogen, Hydrogen d. Emergency water supply and eyewash
Sulphide, Sulphur Dioxide etc and Any fountains should be there where irritant and
type of compressed gases. corrosive chemicals are being handled.
e. Fume Hoods should be used with
adequate ventilation while working with
hazardous chemicals.
2 W orking with High Temperature a. Insulated gloves must be used while

Equipment like Gas burners, Muffle handling hot equipments.
Furnaces, Heating Mantles, Air ovens, b. High Temperature equipments should be
W ater baths, Distillation Apparatus etc. kept at sufficient distance to avoid heating
of other stored chemicals.
c. Rate of heating must be controlled while
doing any distillation job to avoid overflow
and explosion.
3 Working with Cryogenic liquid like liquid a. While handling cryogenic liquids like liquid
nitrogen and releasing high pressure gas. Nitrogen use face shield and other
protective clothing, gloves and equipment
to protect eyes, skin contact and splashes.
b. High flow rate of gas should be avoided to
prevent sudden refrigeration and
frostbiting.
4 Working with radioactive materials like Redioacitiviy protecting badge should be

Nucleonic Density Gauge in Coal used while working with such
liquefaction plant. instruments.
5 Working with Electrical / Electronic a. Regular inspection, testing and

equipment. maintenance of electrical equipments,
power supply boards and main power
source should be done.
b. Insulated gloves should be used while
inspecting/repairing.

Chemical and R & D
Sl.
R & D Activities Safe Operating Procedure
No.
c. All tingles or slight shocks from any
equipment must be immediately reported
and corrective measures must be taken
before using that equipment again.
d. Personnel must know that contact with
electrical circuits may cause from slight
sensitization, to painful shock to life
threatenning conditions like cardiac arrest,
damage to central nervous system and
burning.
6 Working with High Pressure and Low a. Pressure gauge should be calibrated
Pressure equipment like high pressure periodically to avoid false indication.
pumps, vacuum pumps, high Pressure b. Protective outer shield for gas cylinders
gas cylinders etc. and regulators to control gas flow should
be used.
7 Working with / Handling Inflammable a. Limiting Ignition Source (Ventilation/

substances like hydrogen gas and various Exhaust Fan)
organic liquids. b. Limiting Oxidiser Availability (Strong
oxidizers like nitric acid, sulphuric acid be
kept in safe place.)
c. Limiting Fuel availability (Oil, Organic
solvents etc. should be kept in safe place)
d. Detecting Fire and Smoke (Automatic Fire
and Smoke Detectors may be installed)
e. Extinguishing Fire (Suitable Portable Fire
Extinguishers)
DON’T TAKE
CHANCES !
IT IS DANGEROUS !!

Well-logging
OIL INDIA LIMITED
Volume - I
Section - 7
WELL LOGGING ACTIVITIES

Well-logging
WELL - LOGGING ACTIVITIES

CONTENTS
1.0 Introduction...................................................................................................... 1
2.0 SafeOperatingProcedure............................................................................. 1
3.0 GeneralSafetyRequirement.......................................................................... 1
4.0 Storage, Transportation & Safe Handling of Explosive Mateials .................... 2
5.0 Radiological Safety Aspects in WellLogging................................................. 9
6.0 WirelineRig-up/LoggingOperations............................................................ 12
7.0 SafetyatLoggingBase.................................................................................. 18
8.0 Safety with Pressure Control Equipment ...................................................... 19
9.0 SafetyDuringFishingOperations................................................................. 20
10.0 PrecautionsagainstFire................................................................................. 15
11.0 Precautions against Accidents....................................................................... 16
12.0 Hazardousarea.............................................................................................. 17
13.0 Safedistance................................................................................................. 18
14.0 GasFlareSystem.......................................................................................... 18
15.0 PPE and Non Sparking Tools......................................................................... 18

Well-logging
LOGGING OPERATIONS
1.0. INTRODUCTION
Once a well is drilled in an oilfield, it is necessary to collect information about characteristics
of the formations, location and thickness of hydrocarbon bearing sands, type and nature of
Hydrocarbon deposits etc. Well Logging tools are lowered by wireline or otherwise into the
well to collect the same.
Wireline Well Logging operations involve handling of surface equipment, heavy down hole
tools, various kinds of explosives and radioactive sources at the bases or at the drill sites on
a regular basis
Physical activities involving the use of machinery, tools, electrical and mechanical equipment,
radioactive & explosive material are potentially hazardous and highly risk prone, Safety is of
utmost importance in handling the above materials.
All the explosive materials and radioactive sources are dangerous and must be handled
with great care. All the users must know and follow all approved safety procedures. World
over, logging companies have formulated safety rules to ensure safety of personnel during
logging operations including handling of hazardous goods without violating the statutory
regulations.
2.0 SAFE OPERATING PROCEDURE
The scope of these procedures lies in the following activities
1) Wireline Well Logging Operations.
2) Perforation using wireline.
3) Wire line Bridge plug/packer/cement retainer setting.
4) Puncture/cutting/severing of casing, drill pipes & collars, tubing etc.
5) Side wall coring.
6) Free point Indicator/String shot of explosives.
7) Storage, transportation & safe handling of explosives.
8) Radioactive logging operations like density, neutron etc.
9) Storage, transportation & safe handling of radioactive materials.
10) Disposal/liquidation of non-usable explosives and radioactive materials.
The sole purpose of these procedures, is to prevent accidents resulting in the loss of human
life, property and environment.
3.0 GENERAL SAFETY REQUIREMENT
The quality of equipment, timely inspection and appropriate repair/maintenance play a major
role in safety management. However, the human factor plays the most vital role as most of
the accidents are caused due to human errors. :
KEYS TO SAFETY :
1) Safe and healthy working conditions.
2) Safe and proper equipment.
3) Safe transportation of equipment and personnel to the well-site.

Well-logging
4) Safe operating procedures.

5) Emergency / Disaster handling / contingency plans,
6) Proper training.
7) Compliance with safety regulations.
8) Company-wide commitment to safety.
9) Periodic safety audits / Surprise checks,
4.0 STORAGE, TRANSPORTATION & SAFE HANDLING OF EXPLOSIVE MATERIALS
4.1 GENERAL
1) Know and obey all local, national and international regulations and warnings about the
explosives in use.
2) Never let any unauthorized person/employee to handle explosives.
4.2 GUN LOADING AT SHOP
1) Shop must have a fixed gun loading area and limited storage of associated explosives
with suitable security arrangement.
2) Head of Logging Services (Base) must make sure that the loading area meets all
local, state, national and international statutory requirements.
3) Display “EXPLOSIVES” and “NO SMOKING AREA” signs in local, Hindi and English
languages prominently.
4) While handling in shop
• Do not subject explosives to blow (shock) or confining pressure.
• Do not subject explosives to heat.
• Primary and secondary explosives shall be stored separately.
5) Keep away unauthorized people.
6) Gun loading area must be well lit.
7) Load the gun with as few people as possible.
8) Clean the area after loading the gun. Return all the scrap material to Magazine.
4.3 FIELD OPERATIONS
Follow safety procedures of this section for all services that use tools containing electrically
fired detonators, such as : -
- Perforating guns/strips
- Side wall core guns
- Bridge Plugs and packers
- Chemical/Jet cutters
- Dump bailers
- Back-off shots

Well-logging
- Pipe Severing tools

- Junk shots etc.
4.3.1 Pre-departure Check
1) Cheek that all equipment/carrying cases that contain explosives are properly labeled
with appropriate warnings on them. Safety Tube, Explosives Remnant Box, casing to
Rig Voltage Monitor, Safety meter for testing detonators and Safety grounding device
of Truck/Unit with C - Clamp must be loaded before departure to the field.
2) Following Warning/Sign Boards in Hindi, English and Regional language must be taken
to field for display.
- ‘DANGER ZONE, EXPLOSIVES IN USE’.
- ‘TURN OFF ALL RADIOS AND MOBILE PHONES’.
- ‘TURN OFF ALL GENERATORS’.
- ‘TURN OFF ALL WELDING MACHINES’.
4.3.2 Arrival at Well Site
1. Look out for hazards in and around well site/workover/mast. Correct it.
2. Hold Safety meeting with Drilling Engineer/Supervisor/Production Engineer.
3. Cheek all Safety Equipment. Organize them.
4. Display Warning signs in Hindi, Local Language and English. One at the site and one
at each entrance to the site.
5. Get all the Arc/gas Welding Machines and cathodic protection equipment off
.
6. Get Radio Transmitters/Receivers mobile phones and all generators turned off within
300 m. of work area well before arming the explosive device and shall remain switched
off till the device is 200m. down inside the well.
7. Power connection to Sucker Rod Pump within 30 m. from Well Head must be switched
off.
8. If the work area, has high tension line running over or underground, power has to be
disconnected.
9. If a large transmitter (radio or television) exists within 4 km. from the site, it must be
ensured that the same is switched off.
10. In case transmitter (radio or television) can not be switched off in such case Radio
frequency protected detonator (like RED) must be used.
11. Look for the possibility of thunder stormlsand storm. If such a case, suspend operation
till it subsides.
12. All open fires must be put off.
13. Cheek for BOP testing, working of cat line and clear parking/working place in front of
rig/mast/workover.
14. Ensure that the hole is completely filled with completion fluid except in cases of under
balance perforations.

Well-logging
4.3.3 Gun Loading

1. Mark the area for gun make-up.
2. Do not allow any unauthorized person in the area.
3. Do not allow smoking in work area. Display ‘NO SMOKING ZONE’.
4. Follow procedures discussed for gun loading at shop.
5. Do not install detonators in gun loading area. Connection of ignitors/detonators is to
be carried out only just before lowering in the well.
6. Cheek gun wiring continuity and insulation, with an approved blasting galvanometer/
blasting multimeter only.
7. Do not attach gun firing head to guns stored in the racks.
8. Store loaded guns neatly on racks at a safe distance from arming area, out of, line of
fire. Direct the charge path towards the least inhabited area.
9. Keep all magazines locked. Keep an accurate count of all explosives and loaded
guns.
10. Put excess orjunk explosives in the appropriate remnant boxes. Keep these boxes
closed and locked. Never mix primary high explosives with other explosives.
4.3.4 Rigging-Up
1. The perforating unit must not have an open face electric heater.
2. W atch out for open ended (exposed) electrical wiring at site near work area or inside
unit before connecting the gun head to cable. If any, remove or disconnect it.
3. Be sure of wireline to equipment grounding. Following must be checked.
- Logging computer or panel rack properly grounded to unit chassis.
- Auxiliary generator, if used, grounded to unit chassis with heavy cable.
- All metallic structures that might touch logging cable, grounded together to the logging unit.
4. Remove any rig wiring guidelines etc. that could touch the logging cable.
5. Install casing to rig voltage monitor: Check voltage between rig, casing and cable armor.If
any voltage exceeds 0.25 volt, investigate the cause. Eliminate before proceeding. The
voltage level must be less than 0.25 volt. Use Rig Voltage monitor regularly for this purpose.
6. When residual voltage is less than 0.25 volt install safety grounding cable between unit/
truck to rig and casings. Leave the voltage monitor connected between rig and casing.
W atch the meter during whole operation.
7. Check cable insulation and continuity with approved meters only. Discharge the cable after
insulation check.
8. The engineer performing hot check/CCL check shall have full view of the gun assembly.
9. Once again check for all safety warnings points that welding, Cathodic protection equip-
ment, high tension lines, radio, T.V., transmitter are turned off in and around the work area.
10. After confirming the above cheeks turn offA/C generators. Engage the safety lock to “SAFE”
position in the perforating panel and remove the key.The key should be in the personal
custody of Logging In-charge at the site, All safety measures inside the unit at this juncture
should be rechecked.

Well-logging
11. Clear non-essential personnel out of the logging unit. No one should be allowed to enter the
logging unit till the explosive device is lowered in the well.
12. Check again the voltage in casing to rig voltage monitor. It should be less than 0.25 volt.
13. Clear all non-essential personnel from the Cat-walk. Bring the explosive device/charged
gun at Cat-Walk. Keep all personnel out of line of fire.
14. Before attaching the explosive device, short the central conductor of cable head with cable
armor. In case of any spark, recheck with blasting galvanometer. No stray voltage should
exist on central conductor of cable.
15. Attach the explosive device to the cable head. Safety key must be securely kept by Logging
in-charge at the site.
4.3.5 Arming the Device
1. Only the person “in-charge of Logging” at site must arm or disarm any explosive device.
2. Do not arm a device if a helicopter approaches.
3. Bring the detonator from detonator box in Safety tube near the explosive device. Never carry
Detonators loose in your pocket or tool box.
4. Test the detonator in Safety Tube with Approved Safety meter by removing shunt.
“DO NOT USE ANY KIND OF ELECTRICAL METER FOR THIS TEST.”
5. W ith detonator in Safety tube, arm the gun electrically. First connect the ground wire, then
connect central conductor of logging cable to the lead wire from detonator and insulate
them.
6. Take out detonator from Safety Tube. Cut excess detonating (prima) cord using wood block
and sharp edged cutter or prima cord cutter.
7. Push the detonator on to the detonating (prima) cord until it seats nicely or crimp it to detonating
cord using approved crimper. Fix the detonator at proper place in the explosive device.
8. Use hermetical sealing sleeve on exposed detonators.
9. Ensure that no pull on detonator lead wires is applied while putting hermetical sealing sleeve.
10. Run the device in the well at least 100 m. below ground level. Turn on safety switch and
restore AC power. Insert the cable jack to collar locator socket for depth tie-up.
11. The gun shall always be pulled out upto 100 m. below the well head, keeping cable to safe
position on shooting panel and observing full safety precautions.
4.3.6 Disarming the Device when rnisfired or armed Device pulled out due to held up.
1. Check cable position, it must be in “Safe” position.
2. Pull the device slowly (500 m.lhr.) till 100 m. below well head.
3. Switch off generators and apply circuit breakers.
4. Re-confirm closure of Rig generators.
5. Verify the easing to rig voltage monitor connection and its reading less than 0.25 volt. If a
helicopter /any Air craft at low altitude approaches keep the device in the well till it departs.
6. Inspect the gun for any hole or cracks in port plugs (in case explosive device is a gun).
Disarming of the device should be done by a competent person i.e. by the same person
who has armed it.

Well-logging
7. Check carefully for trapped pressure inside the HSC gun while disassembling the device.
8. Remove detonating cord from detonator by cutting it. Put the detonator inside the HSC gun
while disassembling the device.
9. Disconnect central wire (live) of cable, from detonator first.
10. Disconnect ground connection of cable from detonator.
11. Short both wires of detonator and put it into Detonator remnant Box.
12. Disconnect gun from quick change assembly and check gun for any water entry.
13. Check cable continuity and insulation observing total safety.
4.4 SAFETY PRECAUTIONS DURING PERFORATING & OTHER JOBS
1. Operations involving use of primary high explosives (Detonator, Booster) shall be undertaken
only during daylight hours.
2. Do not lubricate detonating cord prior to loading. Lubricants can desensitize booster powder
and cause misfires of perforating charges.
3. While charging, enough care should be taken so that the prima cord is not twisted to avoid
kinks or voids or air gaps.
4. Under no circumstances shall the prima cord be cut by metal contact.
5. Never join two incompatible prima cords, for example, RDX with HMX. As the detonating
velocities and pressures are different, it may lead to an improper detonation.
6. Handle loaded guns as smoothly as possible and avoid shocks. This is particularly important
when dealing with guns that have misfired and contain explosives that have been subjected
to high temperature for an extended period of time.
7. Charges and detonating cord exposed to well environment for one hour must not be re-
used.
8. If there is water entry in side the HSC gun. All such charges must be discarded. They should
never be re-used.
9. Use of detonating fuses immune to radio & electrical noises shall be preferred.
4.5 EXPLOSIVES STORAGE FACILITIES AND CONTAINERS ONSHORE
1. All storage facilities magazines and containers must meet all local and national regulation
and specific terms of any necessary permit(s).
2. The explosive type and amount determine the container or facility type. All the containers or
outside packaging carrying such containers must be marked with required information
including hazard warning labels.
3. Primary high explosive (detonators, some boosters) must be stored separately from
secondary high explosives, low explosive and flammable solids (power charges). The
separate storage can be separate containers or separate compartments. This above storage
requirement also applies for faulty or junk explosives with label “Not suitable for field use”.
4. The building for land storage of explosives must be completely separated from living and
work areas. The Explosives rules must be honored while constructing magazines. It must
be constructed way from radioactive source storage.

Well-logging
5. Explosives storage facilities must be clearly marked with weather resistant signs in the
local, Hindi and English languages :
: DANGEROUS EXPLOSIVE
: NO SMOKING
: USE OF FIRE OR LIGHTNING DEVICES PROHIBITED.
6. Record keeping is necessary and mandatory as per explosives rules.
7. Never allow unauthorized personnel to enter magazines.
8. Magazine must be guarded for security purpose.
9. Magazine premises must be neat and clean for easy approach in case of any emergency.
10. Fire fighting facilities like water field pit, fire extinguisher etc. shall be available in the magazine
premises.
4.6 EXPLOSIVE TRANSPORT
1. International/national and local rules must be honored while transporting explosives.
2. Never transport primary and secondary high explosive in the same container or undivided
compartments of a container.
3. If permitted primary and secondary high explosives may be transported in the same van in
separate containers kept at least one meter distance apart. Use of original package is most
safe for transport.
4. The loose charges, detonating cord or detonators must be kept in their designated containers
and must be locked. End of detonating cord must be sealed to avoid spillage of powder.
5. All containers must be properly secured to prevent movement during transport.
6. No smoking during loading/unloading of explosives or near to explosive/explosive van.
7. Unless permitted, explosive and radioactive material must never be transported together.
8. Explosive must be the last items to load and the first items to unload.
4.7 ROAD TRANSPORT
1. Transportation of explosive must be done in a licensed/permitted vehicle/van.
2. Explosive van must have a physical barrier (fire proof screen between explosives and drivers
cabin).
3. The van must have approved fire extinguisher with enough capacity and first aid box.
4. Van must carry at least two reflective warning signals and have explosive warning label.
5. The van must have emergency contact telephone numbers boldly written on the driver’s
cabin.
6. Never carry explosive in the driver’s cabin/passenger area.
7. Only optimum nos. of detonators be taken to worksite (in any case not more than two
detonators per run.)
8. Unarmed, loaded guns must be carried only on racks or in tubes designed for the purpose
after they are properly secured/tied with racks/tubes.
9. Loaded guns with end protectors must not extend transporting vehicle body.

Well-logging
10. Transporting vehicle must have explosive signs on its front and rear sides. The vehicle
must not be driven rashly or dangerously.
11. Explosive transporting vehicle must never be used to tow any other vehicle and vice versa.
12. Never stop vehicle transporting explosive at places where public security is endangered.
13. If explosives van is to be parked overnight due to reasons beyond control, the parking place
must be
a) Away form open flame, high tension line, radio/TV tower etc.
b) Away form habitation or any godown containing articles of flammable/hazardous goods.
c) Nearest police station must be informed about the location of vehicle parking.
14. At any unmanned railway crossing or highway crossing, the vehicle must be stopped till
safe clearance is available.
15. The original license/company authorization letter’s attested copy must be kept in the vehicle
while going for a job.
16. If fire occurs on a vehicle containing explosives, the driver must take steps to stop other
vehicles/traffic at least 300 m away on all sides of road and that all the persons are warned
of the danger.
17. In case of van carrying explosives is involved in accident or fire or other mishap, following
must be done.
a) Place warning signs for moving traffic at safe distance.
b) Inform local police.
c) Comply with legal requirements relating to road accidents.
d) Inform licensee, who intern, must inform Chief Controller of Explosives giving full details
of accident.
e) Stay with the vehicle (if it is not a fire case).
18. In case explosives to be transported by wireline logging truck
a) License (Prior permission) from competent authority must be obtained for transporting
explosives by wireline truck.
b) Follow all the guide lines of explosive transport by explosive van and general transport
rules while transporting explosives by wireline logging truck.
4.8 LIQUIDATION OR DISPOSAL
1. Segregate/sort-out non usable explosives (charges, prima cord and defective detonators).
2. Store defective/remnants of primary high explosives and secondary high explosives in
separate containers designated for each type of explosives in the magazine at a pre-defined
location away from good/usable storage area.
3. These explosives must be properly packed and marked “Not suitable for use”. The area of
disposable explosives must be marked “ Disposable explosives area”
4. A proper record of disposable explosives must be maintained at magazine in addition to that
at the base.

Well-logging
5.0. RADIOLOGICAL SAFETY ASPECTS IN WELL LOGGING
5.1. STORAGE AT BASE
1. All radiation sources should be stored in properly shielded containers and appropriately
labeled indicating the source activity etc.
2. Storage facility should be in non- residential area with proper water proofing storage go-
down.
3. The source shall be stored in a storage area which is approved by BARC and radiation level
at the fence shall be limited to 2 m Rem/hr.
4. Sources must be kept in storage room under double locking system. ie area where all
sources and radiation materials are stored must carry the sign “CAUTION RADIATION
AREA.”
5.2. INVENTORY
1. Physical cheeks of serial numbers of shield (containers) and sources must be conducted
at regular intervals.
2. Proper records must be maintained at the base for the inventory of the radioactive materials
and their movement.
3. Status to be reported to BARC (in their prescribed Performa) once in every six months as
per AERB requirement.
5.3 TRANSPORTATION
Sources must be transported from the main storage area to sites in their original designated
in dependent shielded and approved transport containers with labels displayed in accordance
with the AERB transport regulation.
5.4 SAFETY PRECAUTION
1. The transport container must be made an integral part of the vehicle (logging unit). (Bolted/
fixed firmly by suitable means to the unit).
2. If transported in a separate vehicle other than logging unit, the containers must be chained
and locked to be an integral part of the vehicle until the sources are removed for use at the
well site or for storage at the location.
3. Radiation warning signals must be prominently displayed on the vehicle carrying the
radioactive sources.
4. Radioactive sources must always be the last item to be loaded on to the vehicle (just prior
to departure) from the main storage area and the first item to be unloaded from vehicle
imediately upon arrival at the base.
5. Physical security of the sources during the transport must be ensured at all times.
6. The driver of the vehicle carrying the sources must have clear instructions regarding the
steps to be taken in case of an emergency like road accident or fire during transportation.
Instruction card must be available in the vehicle.

Well-logging
5.5 RADIATION MONITORING

1. Gamma radiation monitors should be used to measure radiation exposure due to gamma
rays.
2. There must be at least one calibrated radiation survey equipment for each type of radiation
in good working order.
5.6 AREA MONITORING
1. Area monitoring devices capable of monitoring radiation levels from 2 rnsv/hr. to 50 msv/hr
are to be used to assess radiation level at occupied areas and for general radiation survey
around installations.
5.7 MEDICAL SURVEILLANCE OF RADIATION WORKERS
1. All the radiation workers must wear the appropriate radiation monitoring badges and these
badges shall be checked quarterly by BARC and any follow up suggested by BARC should
be complied with.
2. Medical records of all radiation workers shall be maintained properly at each operational
base which will include medical and radiation exposure history,details of accidental exposure
if any and their periodic dose evaluation results.
5.8 LEAKAGE
Leakage in the radio-active sources may occur due to their exposure to the hostile down-
hole pressure and temperature.
1. Every source must be treated as a potential leaky source.
2. Physical inspection for checking cracks, ‘O’ ring damage etc. on the source capsule is
mandatory before every down-hole run of the source.
3. Contamination monitors to be used to perform the WIPE TEST of the same once in every
six months.
4. After use in hostile logging conditions the sources must be subjected to wipe test.
5. A source found leaky in wipe test must be withdrawn from use immediately and should be
sent to the original supplier for disposal with prior authorisation from BARC.
5.9 EMERGENCY PROCEDURES
Emergency action is called for under the following situations
1. Well logging device falls into the well along with the radioactive source.
2. Source is lost or misplaced during storage or transportation.
3. Road accident or fire or explosion during transportation.
4. Fire or explosion in the well or drilling rig.
5 Leakage or rupture of the radioactive source or its container.
In any of the above emergency situations, BARC must be contacted immediately and the
procedures as advised by BARC must be strictly followed.
If a tool containing a source is lost in a well all efforts must be made to fish it out, failing which
sources are to be left in the well, sealed with a thick concrete plug. Guidelines regarding this may
be obtained from BARC. In case a radiation source is lost elsewhere or damaged BARC have to
be immediately informed, in no case, later than 24 hrs. from such occurrence.

Well-logging
5.10 SAFE HANDLING

1. When a source is not in use, it must remain inside the locked carrying container. When a
source is in the tool, the carrying container must remain unlocked with the lead open.
2. All calibrators must be locked in the truck when not in use.
3. Before a source is removed from the source container for loading into the tool the following
procedure must be adopted
a) Well mouth must be covered
b) All non-essential personnel must be cleared form the rig floor area.
c) Appropriate signs and barriers shall be provided in the controlled work areas.
d) Source housing of the tool and all equipment necessary to the transfer must be checked
before hand to eliminate delay.
e) The sources must always be handled with recommended and remote handling tools with
minimum possible time.
f
) For all collimated (directional) sources, the radiation should be directed away from the persons
transferring the sources and also from the persons present.
g) After inserting the source into the tool, all locking mechanism in the source holder of the tool
must be thoroughly activated and rechecked using approved locking pin wherever applicable.
h) Once the logging tool is loaded with the source, it should be lowered as soon as possible.
)
i Under no circumstances is the tool with a source in place be handled directly with the hands
within one ft. of the source.
)
j The well site in the vicinity of the operating area shall be surveyed when logging tools are
removed from the well and after the sources has been removed from the logging tools, to
ensure the source is back in the safe position.
5.11 ABANDONMENT PROCEDURE
Wells in which radioactive sources are abandoned, shall be mechanically equipped so as to
prevent either accidental or intentional mechanical disintegration of the radio-active source.
1. Sources abandoned in the bottom of the well shall be covered with a substantial standard
color dyed (red iron oxide) cement plug on top of which a whip stock or other approved
deflection device shall be set. The idea is to alert the re-entry operator prior to encountering
the source.
2. Upon abandoning the well in which a logging source has been cemented in place behind a
casing string above total depth, a standard colour dyed cement plug shall be placed opposite
the abandoned source and a ship stock or other approved deflection device placed on top of
the plug.
3. In unavoidable circumstances, when a logging source is to be abandoned in a producing
zone, a standard colour dyed cement plug must be set and a whip stock or other approved
deflection device placed above to direct the sidetrack atleast fifteen (15) feet away from the
source.
Upon permanent abandonment of any well in which a radioactive source is left in the hole, a
permanent plaque shall be attached in such a manner that re-entry can not be accomplished
without disturbing the plaque.

Well-logging
6.0: WIRELINE RIG-UP/LOGGING OPERATIONS

6.1: RIG-UP EQUIPMENT CERTIFICATION
All load-bearing equipment used during wireline rig-up (and associated operations such as fishing
for logging or perforating equipment) requires certification and should be appropriately marked it
the same way as other lifting equipment.
This equipment included, but is not limited to, the following
1. Upper and lower sheave wheels.
2. Tie-down chain
3. Sheave hanger
4. Load cell (tension device)
5. Shackles
6. Safety slings
7. T-bar
6.2. SAFETY MEASURES
1. Only rig-up equipment that has been certified within the required interval of time is permitte
at the wellsite.
2. No item of rig-up equipment shall be issued or used unless it is of good construction, sound
material, adequate strength, and free from obvious defects.
3. All rig-up equipment tests and inspections must be done by competent personnel according
to recommendations of the manufactures.
4. Do not use new rig-up equipment until you have its certification in hand.
5. Each location must keep the details of all lifting equipment, including certificates, test result
and examination results in a register.This register must be available for inspection upon
request of an appropriate authority at any time.
6. Each location must have access to copies of relevant statutory or customer regulations
governing use, examination and testing of lifting equipment.
7. Each location must be able to show that its equipment complies with all relevant statutory
user regulations.
6.3: WIRELINE UNIT PLACEMENT
ONSHORE
1. Truck should be parked on a hard surface, atleast 25 m. away from the well head.
2. Winch drum should be aligned with centre of the well mouth.
6.4: RIG-UP EQUIPMENT USE, MAINTENANCE & STORAGE
1. Use rig-up equipment only for rig-up.
2. Do not load rig-up equipment beyond its marked safe working load. Safe working load should
be inscribed on the rig-up equipment.
3. All rig-up equipment must be regularly inspected and kept in good operating condition to
comply with manufacturers recommended schedule.

Well-logging
4. Inspect each rig up equipment item for cracks and wear before and after each operation.
Replace damaged or badly worn equipment immediately.
5. Clean and grease (and repaint, if appropriate) equipment as soon as possible after each
operation to pre-vent corrosion.
6. No welding on any rig-up equipment is acceptable.
7. Calibrate the load cell at least yearly and mark it with the calibration date. Cheek the load cell
electrically and operationally before each operation.
8. Hydraulic fluid used in load measuring device must be as specified by OEM.
6.5. CHECK THE FOLLOWING SHEAVE WHEEL ITEMS
A) Correct for line size.
B) Wireline grooves within permissible limits.
C) Swivel operation and condition.
D) Bearing lubrication and operation.
E) Protection panel do not compromise sheave wheel strength.
F) Sheave guards strength.
G) Sheaves clean.
H) - Do not paint tie-down chains.
- Do not paint a sheave hanger.
- Never use a wire sling that has frayed kinked or broken wires.
- Never shorten a safety sling or a sling used for hanging the top sheave from the
derrick by knotting.
- Never join chains together with nuts and bolts .
- Use only proper lock pins, bolts and safety pins in shackles.
6.6. SAFETY AT THE WELLSITE
GENERAL
Always wear approved safety equipment:
- Hard hat
- Steel toed boots
- Eye and ear protection when needed
- Gloves
- Radiation monitoring badge
a) Keep loose clothing, rags, or any such objects away from moving parts, such as the winch
drum, depth counter and drive chains.
b) Always communicate and cooperate with other rig personnel for your safety as much as for
theirs.
c) Always notify the concerned representative of any abnormal operation particularly those
considered hazardous.

Well-logging
d) Do not go onto the rig floor unless absolutely necessary and leave as soon as your work is
complete.
6.7 : WINCH OPERATION
1. Be sure the winch drum is fitted with a proper guard.
2. Assign only one person to signal the winch operator.
3. Only mutually agreed signaling procedure shall be adopted.
4. Always keep tension on the cable when putting cable in or out.
5. Do not overload the cable in the winch drum.
6. Keep the winch in gear, when lowering a tool.
7. Do not let personnel stand or work near the winch while it is moving
6.8 : LIFTING RIG UP EQUIPMENT TO THE RIG FLOOR
1. As far as possible, avoid carrying equipment to the rig floor by hand. Use cat lines or cranes.
2. If equipment is lifted manually, follow safe load lifting procedure. When carrying equipment,
be careful to avoid slippery surfaces and obstacles.
3. Logging personnel shall not operate cat lines or cranes.
4. Keep all non-essential personnel away from the lifting area before operation of the cat line.
5. Never walk or stand under a lifted load.
6. Never try to restrain a lifted load by hand.
7. Only one person to signal the cat line/crane operator. But the crane operator should comply
with a stop signal given by any person.
6. 9 : DRILL FLOOR SAFETY
1. Never use drill floor as a short cut to traverse from one area of the well site to another area.
2. Always wear your hard hat. Be vigilant on possible failing tools, mud and other objects.
3. Do not start operation until the derrick floor is clear of mud, oil or grease.
4. If derrick floor opening is unguarded, ask the driller to cover mouse holes, inspection holes,
etc.
5. Never touch wireline cable while it moves to avoid possible broken stands.
6. Never walk directly underneath or step over the wireline during logging.
7. Stay at a safe distance during operations of the pressure control equipment to avoid high
pressure hazardous.
8. Keep away by appropriate safe distance while opening blind rams to avoid trapped well
pressure.
6.10: SAFETY DURING WIRELINE RIG UP
1. Rig up must be started after completion of drill floor cleaning and removal of all drilling
equipment.
2. Hold a brief safety meeting before rig up.
3. Ensure clear visibility to lower sheave and well mouth from the logging unit.

Well-logging
4. Be sure that well head is always covered.

5. Be sure that you can always see all rig floor activities clearly.
6. Keep clear of the well/borehole during opening blind rams.
7. Be sure the rig crew locks the rotary table before lowering wireline equipment and keep it
locked during the entire operation except during free point indicator or back up operation.
8. Ensure locking of traveling block swivel by the rig crew before the top sheave is positioned.
9. Use a suitable line wiper to avoid bringing mud up onto the drill floor.
10. Never attempt to clean a moving wireline by hand. Notify the driller before going under the rig
floor. When performing vertical make up always ensure good communications between the
unit and the rig floor.
6.11: LOWER-SHEAVE INSTALLATION
1. Secure the lower sheave to the rig with the tie-down chain or an equivalent device with an
approved safe working load.
2. Attached the tie-down chain’s shackle end to the lower sheave eye nut. Never attach the tie
down chain to the sheave handle, as this could cause serious damage to the sheave and
endanger personnel on the derrick floor.
3. Wrap the tie down chains hook end around a principle member of the rig structure and tie it
with a double nut. Secure the hook to the chain and tap it.
4. Do not attach the chain to the rig at both end of the chain such that the sheave wheel is
suspended at the middle of the chain. Any angle formed by the chain will reduce its strength.
5. Never double the tie down chain to shorten it. Tie extra knots if necessary.
6. Locate the tie down chain anchor point as nearly as possible in line between the logging unit
and the borehole centerline. This will bring the upper sheave, lower sheave and the logging
cable drum centre in the same vertical plane to minimize any cable tension lateral component.
7. The lower sheave position, with the logging tension applied to the cable should be such that
the cable between the upper and lower sheave, is close to vertical to minimize any cable
tension horizontal component on the upper sheave. Adjust the chain as necessary.
8. Ensure that ample room exists between the racked drill pipe and the lower sheave to work
safely If not ask for help to move tools safely through that opening.
9. If the logging unit is far from the drill floor or if a restriction exists on the height of the upper
sheave, load cell can be installed between the lower sheave and the tie down chain.
10. Secure all shackles with wire or locking clips to prevent pin loosening caused by shock or
vibration.
6.12: UPPER SHEAVE INSTALLATION
1. Suspend the upper sheave from the elevators by the sheave hanger. Normal installation is
with the load cell between the sheave hanger and the upper sheave.
2. Be sure the elevators are small enough to support the sheave hanger’s larger end on both
the shoulders.
3. Be sure that the traveling block swivel is locked.

Well-logging
4. After the sheave-hanger installation, thread a wire rope through the elevator handles and tie
it to prevent accidental opening. Also thread a safety sling through the sheave-hanger eye
and the bails, and secure it with a shackle. This sling must be strong enough to support the
full weight of the cable if the elevators are open .
5. Always suspend the upper sheave by the clevis, not by the sheave handle. Check for smooth
rotation about the pivot.
6. After threading the logging head and cable, position the cable guides to prevent the cable
from jumping the sheave. Tighten the T-nut securely to prevent guide movement. Stop
operation, and reposition the guides, if they rub against the cable.
7. Secure all shackles with wire or locking clips to prevent pin loosening caused by shock or
vibration.
8. The logging in-charge must make a final check of upper sheave configuration and all safety
precautions taken before raising the sheave.
9. Clear all personnel away from both lower sheave and logging cable before starting to raise
the upper sheave.
10. Position the upper sheave as high as possible in the derrick for a safety margin when pulling
long tool strings out of the well.
11. Logging personnel should never climb up the rig mast for any rig up operations. It must be
done only by drilling personnel.
6.13: PICKING UP AND LAYING DOWN TOOLS
1. Assign one person to give signals to the winch operator.
2. Check any available intercom thoroughly before depending upon it for communications.
3. Protect the cable and cable head with a gooseneek .
4. Use a snubbing rope, if necessary, to ease logging tools gently up and over the V-door.
5. When raising tools, especially on the first trip, be alert for jerks as the tie down chain takes
the strain.
6.14: RIGGING DOWN
1. Before rigging down , clear the drill floor of all non-essential personnel.
2. To prevent damage to logging and load-cell cables wind them in as you lower the upper
sheave.
3. If you wind in the logging cable with the winch as you lower the upper sheave, secure the
logging head to the drill floor or hold it firmly to prevent it from being pulled onto the derrick.
Be sure that the winch man and driller can communicate easily.
4. Use cat line/service winch to rig down material from derrick floor to cat walk.
6.15: SAFETY DURING WIRELINE OPERATIONS GENERAL
1. A high standard of safety in wireline operations will be achieved when well-designed and
well-maintained logging and completion equipment is operated by well-managed and well-
trained personnel. Proper planning, efficient communication, and individual commitment at
all organization levels are vital elements for safe operations.

Well-logging
2. During wireline operations, ensure that the number of drilling crew members on the rig floor
is kept to a minimum.
3. Whenever lowering or raising a wireline into or out of the well, check from the drill floor that
the well fluid is at the correct level.
4. It is recommended that the driller be advised to keep the blind rams closed before and after
each wireline run, when the wireline device is confirmed out of the hole. This prevents tools
or logging equipment from being inadvertently lost in the hole (This may not always be
possible for long strings requiring vertical make-up. In these cases, be sure to coordinate
closely with the driller to ensure that the rams are not closed on a sonde suspended by the
vertical make up plate.)
5. Ensure that the entire wireline crew is especially vigilant when a trainee engineer or operator,
or other new crew member, is introduced to working at the well site or on the drill floor.
6.16 : SURFACE EQUPMENT
1. In some panels, power is present any time when the AC power cord is plugged in, even if the
panel is not turned on.Disconnect the ac power cord or turn off power to the outlet it is
plugged into, when working inside surface panels.
2. Disconnect power to the rack and panel before attempting to check, service connect/
disconnect cables and fuses. Be extremely careful while working on the panel with the
power on.
3. Many of the circuit cards in the panels are sensitive to static electricity. Handle the cards by
the edges and avoid touching the edge connectors or circuitry. Wear anti-static band.
4. Remove power before changing printed circuit boards, to prevent short circuiting or integrated
circuit components.
5. Some panels have an open frame design which increases the possibility of personnel injury
and/or equipment damage. When the panel is not mounted in an equipment rack, be careful
to avoid contacting energized circuits or components, and shorting of internal parts by
dropping hand tools, wire, or other objects in the panel.
6. Be sure that the panel rack-mount screws and face plate are secure when traveling to or
from job.
7. The corners and front doors of some panels are sharp. Be careful while working around the
system panels, especially with the front door open.
DOWNHOLE TOOLS
General :
1. Avoid dropping or unnecessary rough handling of downhole equipment.
2. Do not lift heavy tools or tools section all by yourself. Get help. Observe proper techniques
for handling heavy equipment. Lift with load on your legs not your back. Be careful with your
fingers and toes.
3. Most electrical logging tools require electrical power. Because the voltages involved are
high, carelessness while using such tools can result in serious injury.
4. Avoid electrical shock by following these precautions:
.i Disconnect power to a tool before servicing the tool.
i
. W ork in a protected, clean uncluttered, dry area out of weather.

Well-logging
ii
. Do not work on wet floor or wet ground.
i
v. Do not touch the tool during testing.
5. If it becomes necessary to work on the tool with the power on (testing electrical circuits
etc.), be sure to observe the following:
.i W ork in a protected, clean uncluttered, dry area out of weather.
i
. Do not work on wet floor or wet ground.
ii
. Keep unauthorized personnel away from the work area.
i
v. Do not touch the tool during testing.
v. Understand the ac power distribution in the tool and exercise necessary care, while
troubleshooting high voltage boards.
6. Avoid mechanical system hazards by following these precautions:
7. Keep all unauthorized personnel clear of the caliper arms.
8. Do not stand near the tools while closing the caliper arms. Never try to hold the arms open
to prevent closing.
9. Keep hands firm between caliper pads and calibration rings when calibrating the tool.
10. Most caliper tools use AC voitages. Remove all the power before handling a caliper tool.
11. Do not touch the tool during opening and closing of the caliper, if there is a defective circuitry
it will make the housing “live”.
12. The outer case of the pressure balance sonde is fiberglass and must be supported properly
to prevent flexing when the tool is lifted. Severe flexing could damage the sonde, the case,
or both.
13. Only trained and qualified personnel may install and remove the radioactive sources from
Logging Tools using RA sources. Plan activities involving the sources, to minimize personnel
exposure . Clear the area from unnecessary personnel.
14. When a source is installed in the tool, handle the tool as little as possible. Stay away from
the direction of collimation/exposure from the source/tool.
15. Any sample bought to the surface by formation tester may be under pressure and/or may
contain hydrogen suifide(H2S) gas. Only properly trained and equipped personnel should
retrieve samples.
16. Testing/Calibration & purging shall be done in the area designated for pressure testing of
equipments.
7.0: SAFETY AT LOGGING BASE
1 Do not place equipment, power cables, air hoses etc. where they will block walkways,
stairs, ladders, or access to safety appliances.
2. Keep waste, particularly combustible waste, in its container, not on the floor or work bench.
Pay particular attention to the material that tends to accumulate behind work benches or
underneath machinery.
3. Place containers for combustible Material well away from any combustion source (e.g.
welding equipment, electric motors etc.). Empty such containers daily.
4. Clean up oil and chemical spills immediately with saw-dust and detergent as required.

Well-logging
5. Never leave a radioactive source in the workshop unattended. Always replace it in its carrying
shield and return it to the storage pit/magazine immediately after use or during breaks such
as holidays.
6. All pressure control equipment shall be periodically tested to their rated working pressure in
the designated area with proper bafflingfacility.
7. Temperature testing of downhole tools shall be carried out only in recommended oven in a
designated area.
8.0: SAFETY WITH PRESSURE CONTROL EQUIPMENT
Every operation performed against well pressure presents potential safety hazards. To ensure
safe and hazard free operations well-trained, experienced personnel and well maintained high
quality equipment are prerequisites for all pressure jobs. Wireline pressure control can be divided
into two categories:
1. Non-grease equipment may be used for low pressure cased-hole jobs or precautionary
pressure control in open-hole jobs.
2. Grease injection equipment must be used for all high pressure cased- hole jobs, especially
in high GOR / gas wells.
8.1: SAFETY MEASURES
1. All equipment including adapters, must be rated minimum 5000 psi working pressure.
2. In case of high pressure wells/extreme underbalanced perforation, availabilityofappropriate
pressure rated equipment shall be ensured.
3. Cheek the table for kinks and broken strands while running in.
4. Correct size adapter (Flange) shall be used to install well head pressure control equipment
on the well-head/X-mass tree.
5. Grease injection equipment must be deployed if high pressure flow is expected.
6. For grease injection jobs, a sufficient volume of approved grease for entire operation shall
be made available at the site.
7. Pressure control equipment is NOT to be used above the rating of the lowest rated item in
the complete string.
8. Whenever rig BOP is used in conjunction with wireline BOP,distance between the two shall
be not less than the total tool length to be run.
9. Length of the lubricator pipes shall be minimum 1 m. more than the length of the tool string.
10. All the pressure control equipment shall be inspected for smooth operation before use.
11. Rubber element or pack-off and rams of BOP shall be inspected thoroughly and tested with
cable piece before actual use.
12. A tool trap above the wireline BOP shall be use in all pressure control jobs as it gives clear
indication of the tool entering the lubricator pipe while pulling out.
13. A suitable number of sinker bars shall be used depending upon the cable diameter and
expected well pressure.
14. Never smoke in the prohibited area
15. All spark/heat generating equipment shall be parked at least 15 m. upwind from the well
mouth.

Well-logging
16. In H2S environment, the crew members must be equipped with detectors and gas rnasks
17. On high pressure/gas wells particularly at unrnanned wells, a fire tender shall be deployed.
9.0: SAFETY DURING FISHING OPERATIONS
INTRODUCTION
W ireline fishing operations are complex and hazardous. A meeting of logging and fishing crew
shall be held to decide the method & modalities of fishing (cable snapping or cut & thread) depending
upon the nature of stuck up and downhole tool. The information regarding cable/cable head/bride
history and well history shall be gathered before taking up the fishing operation.
SAFETY PRECAUTIONS
The following safety precautions shall be adhered to during fishing operation.
1. Only experienced logging personnel shall be deputed.
2. Upper and lower sheave shall be checked.
3. Do not go onto the drill floor unless it is absolutely necessary.
4. All personnel involved in the operation shall,be well equipped with the safety equipment.
5. There shall be a proper communication between derrick floor and logging unit through
suitable means.
6. All pad sections of tools shall be closed and tool power switched off.
7. Cable tension shall be monitored continuously during cable snapping as well as cut
as thread procedure.
8. When a tool along with radioactive source gets stuck, all out efforts shall be made to
fish out the tool along with the source. If it is not possible to fish out, the abondonment
procedure as per BARC / AERB recommendation shall be followed.
9. In case winch power is insufficient to snap the cable, rig power shall be used for
snapping at weak point. An additional tie back chain shall be used at the lower sheave.
Safety is Evrerybody’s Business

LPG Dept.
OIL INDIA LIMITED
Volume - I
Section - 8
LPG DEPARTMENT
ACTIVITIES

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

LPG Dept.

SOP Vol1

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SOP Vol1

Uploaded by

Copyright:

Available Formats

OIL INDIA LIMITED

SAFE OPERATING PROCEDURES

Date of Issue Prepared by Issued by

SAFE OPERATING PROCEDURES

Section – 1 : HSE Management

– 3 : Drilling & Workover Activities

– 4 : Production – Oil Activities

– 5 : Production – Gas Activities

– 6 : Chemical and R & D Activities

– 8 : LPG Department Activities

SAFE OPERATING PROCEDURES

01 11-11-2005 1 0 1st Issue Sri. A.K. Acharya Sri S. Bora

02 30-03-2012 1 1 1st Issue Mine Safety Officers, Sri C. Bose

Modern industry is replete with technological breakthroughs on one hand and

Sl. No. Name Department

1. Sri S. K. Dutta N.E.F.

OIL INDIA LIMITED

Safe Operating Procedures

HSE MANAGEMENT ACTIVITIES

HSE MANAGEMENT SYSTEM

1) Management’s concern for HSE Management.

1.0 MANAGEMENT’S CONCERN FOR HSE MANAGEMENT

Safe Operating Procedures – Oil India Ltd. 3

2.0 DEFINED HSE POLICY :

HSE in mind and action,

4 Safe Operating Procedures – Oil India Ltd.

Safe Operating Procedures – Oil India Ltd. 5

3.0 COMPANY’S LAID DOWN PROCEDURES

3.1 Safe Operating Procedure.

4.0 INTERNAL SAFETY ORGANIZATION (ISO) SET UP FOR HSE MANAGEMENT

6 Safe Operating Procedures – Oil India Ltd.

5.0 ACCIDENT/INCIDENT/ DANGEROUS OCCURRENCE REPORTING SYSTEM

5.1.1. Loss : Avoidable waste of any resource.

5.2 INCIDENT/ACCIDENT INVESTIGATION & ANALYSIS

Every incident/dangerous occurrence/nearmiss/accident is to be investigated by the team

5.2.1. Date/time of incident & location of the incident.

6.0 HAZARD IDENTIFICATION & CONTROL

Safe Operating Procedures – Oil India Ltd. 7

7.0 PERSONAL PROTECTIVE EQUIPMENT (PPE)

The best way of preventing accidents is undoubtedly by elimination of hazards or controlling

8.0 EMERGENCY PREPAREDNESS

8.1.1. Action to be taken in the event of any major accident/dangerous occurrence.

8 Safe Operating Procedures – Oil India Ltd.

8.1.5. Plan for training of personnel.

8.1.6. Mock drills.

9.0 EMPLOYEES PARTICIPATION IN HSE MANAGEMENT

- Different Safety motivation programme/competitions are conducted.

10.0 SAFETY AUDIT

Safe Operating Procedures – Oil India Ltd. 9

Following methodology needs to be followed.

10.1 Every installation should be audited at least once in a year.

10.2 A calendar in this respect should be prepared and circulated.

10.3 Areas to be audited should be logically grouped based on the functions.

10.4 Detailed guidelines & checklist should conform to OISD-145.

10.6 Implementation status to be reviewed on quarterly basis.

11.0 TRAINING, DEVELOPMENT & AWARENESS PROGRAMME

11.1. TRAINING & DEVELOPMENT ACTIVITIES

Develop employee skills and competencies and improve performance.

Develop people to take on higher responsibilities.

Reduce the learning time for taking up assignment.

10 Safe Operating Procedures – Oil India Ltd.

11.2 AWARENESS PROGRAMME

Safe Operating Procedures – Oil India Ltd. 11

MSO - Mines Safety Officer

DSO - Departmental Safety Officer

Fire for more than 15 minutes.

Loss above Rs. 5.0 lac.

Cumulative man-hours lost more than 500 hrs.

Plant Shutdown/Outage due to the incident.