Professional Documents
Culture Documents
Rev. 2.0, '20
Rev. 2.0, '20
Rev. 2.0, '20
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HSE-RSRMP/GW103/R-1.0
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HSE-RSRMP/GW103/R-1.0
Contents
1.0 PURPOSE............................................................................................................................................07
2.0 SCOPE..................................................................................................................................................07
3.0 DEFINITIONS.......................................................................................................................................09
4.8 RIGGERS’(FLOORMEN)..................................................................................................................12
5.0 STANDARDS.......................................................................................................................................16
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7.9 COMMUNICATION........................................................................................................................23
7.12.1 Responsibilities.....................................................................................................................25
7.13.1 Responsibilities:....................................................................................................................28
7.13.2 Cranes...................................................................................................................................29
7.13.5 Forklifts.................................................................................................................................31
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12.3 WELL TO WELL RIG MOVE IN DIFFERENT AREA(NEED TO MOVE MAIN CAMP):...........................66
15.0 REFERENCE.....................................................................................................................................67
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HSE-RSRMP/GW103/R-2.0
1.0 PURPOSE
Rig move activity including rig up and rig down is a hazardous critical operation . The purpose of
this document is to establish minimum requirements to be implemented during the rig,
associated rig equipment and camp movement operations. This procedure illustrates and
specifies the sequence, methods, procedures and responsibilities for performing rig moves on all
Great Wall Workover rigs. All the rig move operation should be in accordance with GWDC
Kuwait and KOC Standards and Requirements and Kuwait regulations.
This procedure is intended to avoid all accidents, to make personnel & assets safe and to
improve HSE performance of GWDC Kuwait. Also, it mentions minimum guidelines to the Rig
Move for preparing the rig specific Rig Move plans etc.
2.0 SCOPE
This procedure applies to all concerned GWDC Kuwait Rigs loading/moving/offloading/Rig
up/Rig down. Also this procedure applies to the concerned parties who are the part of rig move
activities in providing associated support services.
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Rig Specifications
A) General Rig Specifications
1.Draw-works(Type) SJ Petro Machinery CO.-Model:SDW750
2.Derrick(type&Height) HYDRUCALY RAISED TELESCOPIC,38.6m(126.6 ft) & Model:JJ180/38
3.Hook Load(Capacity) 396.832lbs(with 10 lines)
4.Top Drive(manufacture Model) N/A
5.Rotary Table(Type) Model:ZP275 & Size:27-1/2"
6.Blocks(Type&Size) Model:YG180,S/N:140910,10 lines size 1 1/8"
7.Swivel(Type&Size) Model:SL225 & S/N:14128 & WT:5512 lbs
8.Sub-Structure(Clearance Ground-Rotary) Clearance Ground -Rotary:5.5 m(18.04 ft)
9.Geolograph(Type) N/A
B)Rig Power System
1.Engine Power 2*540HP, CAT C15 & S/N :NO.1:JDY00698 NO.2:JDY00696
2.Draw-works 750 hp
3.Mud Pumps 800 hp, 596kw
4.Rotary 750 hp
5.Top Drive N/A
C)Mud System & Pump
1.Mud pumps (# of ,Type & Capacity) Type:BOMCO F-800 39.58L/S @150r/min
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3.0 DEFINITIONS
GWDC Kuwait Work Permit procedures: shall be followed when work is performed on all
Critical Lifts for cranes whose booms, when calculated at full extension and with attachments,
could be operating within 10 meters (33 feet) or less of energized power-lines.
Critical Lift Plan: Document that identifies a specific load and the operating restrictions.
Pertinent information includes all weights on hook blocks and attachments.
Priority Loads: Rig Loads that are essential to power up the rig and spud the well at the
next well location without affecting the operation at the present well site.
Critical Lifts: Lifts with crane weighing more than 50 tons, exceeding 75% of rated crane
capacity, tandem lift involving more than one crane, involving crane movement within the
minimum distances from High voltage power lines (as per API RP 54), Blind Lift, personnel lifts
in personnel baskets, lifting of - BOP equipment, mud pump, mast, sub-structure and any
part of a crane whose boom or boom attachment is working within 10 meters (33 feet) of any
hydrocarbon and/or pressurized piping areas. All critical lifts need lifting plan implemented.
Non-Essential / Pre Move Loads: Rig load that can be moved at any convenient time during
the rig move. Rig loads that are not required for finishing/completing the well and which therefore
can be moved to new location prior to rig release, but after location inspection and release letter
from KOC. (Eg. Pre-Mix tanks). Usually, those non-essential loads are pieces of equipment that
can be rearranged at the rig site to expedite the rig move process.
Critical Equipment: Equipment and other systems determined to be essential in preventing the
occurrence of, or mitigating the consequences of an uncontrolled event. Such equipment may
include mast, sub-structure, mud pumps, main rig engines, BOP equipment, wellheads and
related valves, safety & fire protection equipment.
Rig Move: Rig down, Movement of - Rig, associated rig equipment & camp from one well
location to another well location & rig up.
Rig Down: Lowering of mast, sub-structure & other associated rig equipment prior to rig move.
Rig Up: Raising of mast, sub-structure & other associated rig equipment after rig move.
Job Safety Analysis: Job Safety Analysis is a tool to analyse each job by breaking down into a
sequence of steps / tasks identifying potential hazards as well as assessing the degree of risk
against each step and accordingly recommend precautionary measures to control the risk before
the job is performed. It is also referred as Job Hazard Analysis.
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Truck Pusher: The rig contractor or their sub-contractor supervisor are responsible for the
transportation & movement of rig and associated equipment including camp from one well
location to another well location.
Risk: The term Risk in this procedure refers to Safety Risk only. It is the likelihood of a hazard
occurrence resulting in an undesirable consequence. Risks can be expressed in terms of impact
of consequences and probability or frequency.
Banksman / Signaler (and / or Rigger): A skilled and formally trained person who directs the
operation of lifting, shifting equipment which includes the selection, preparatory inspection and
attachment of the gear to be used for lifting the load up to the time when load is detached.
Operator: A trained and experienced person who operates lifting, shifting and material handling
equipment. He should be minimum 21 years of age. The operator shall be skilled and possess
3rd Party training certificates for the equipment he is assigned to operate. Additionally the lifting
& shifting operators must be capable to demonstrate their skill and competency to their
supervisors satisfactorily. Besides, the operator shall possess valid license to drive the prime
mover (in case the lifting, shifting and material handling equipment is driven on road). Note: For
3rd Party Training - refer KPC Approved General HSE Training Providers or KOC Category for
Approved List of Safety Consultants.
Driver: A trained and experienced person who is capable by practice and enabled by granting a
permission of a legal system to drive equipment for the purpose of transporting personnel and /
or materials from one place to other. The Driver shall at all-time possess valid license to drive
the prime mover. At any given time such driver shall not be allowed to perform as “Operator” of
lifting, shifting and material handling equipment unless, he fulfills the requirement of Operator as
defined above.
Responsible to ensure that the route survey has been carried out by GW102 before
each rig move and route survey checklist is filled as per sample provided as
Attachment A.
After initial route survey, in case of any constraints/ issues for rig move are reported,
KOC Rig supervisor or his designate will conduct route survey.
Responsible to ensure that the rig move plan has been prepared and reviewed by
STP and Rig superintendent about the route survey findings for each location of rig
move.
To ensure that the well-to-well rig move plan prepared is reviewed and
recommendations/ comments provided prior to rig release for implementation by rig
contractor during the rig move operations. Assistance of rig KOC HSE Supervisor
may be taken by KOC Rig Supervisors for review of rig move plan during their visit to
rig.
To ensure that the rig move plan is implemented during operations.
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4.8 RIGGERS’(FLOORMEN)
They shall be responsible to perform the following activities include but not limited to;
Play the role of signalman for the crane operator to perform crane lift.
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Make sure that the components are safely distributed on trailers and assist the
Contract Drivers to secure the loads with ratchet boomers.
Shall apply good lifting practices, ensure tag lines are used on each load, exhibit
extreme caution when loading and off-loading trucks.
Make sure that all the lifting equipment is inspected and certified.
All category crew members and executing key personnel involved in each Rig Move activities
should be competent for carrying out specific Rig Move operations including rig up rig down. All
the members should have received related training and certification of HSE training stipulated in
Training Matrix.
Competency Requirements
GWDC Kuwait has set out the experience and competency requirements for the Key personnel
involved in rig move activities such as:
Rig Manager:
Relevant Experience:
Rig Manager has have experience of 2 Rig Moves of the rig that he is working on (Rig Specific)
Competency:
Tool Pusher:
Relevant Experience:
Rig Manager has to have experience of 2 Rig moves of the rig that he is working on (Rig
Specific).
Competency:
Truck Pusher:
Relevant Experience:
Truck Push should have the of 5 Rig moves that he is working on (Rig Specific).
Competency:
Note: (If the Truck Pusher is an SSE or he does not meet one of the above requirements, a
Transport Supervisor should be on site as senior supervisor.)
RIGGER:
Relevant Experience:
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2. Rigger should have the of 5 Rig moves that he is working on (Rig Specific).
Competency (Mandatory):
2. 3rd Party Training Certificate for Safe Rigging Practices, Slinging Techniques and Hand
Signals.
All Safety Officers / Engineers will have relevant experience and competent criteria outlined as
per KOC.GE.011 HSE Procedure for Exploration, Drilling & Work over Operations, Annexure – 9
and approved by the Team Leader for the relevant operations.
Forklift/crane operators and truck drivers shall be trained and certified in the respective
operations with valid license. All identified/designated crane operators, signal man / banks-man
and riggers shall be trained by 3rd Party on their roles and responsibilities, respective operations
like operational risk assessment, use of hand signals/ communication, lifting operations risks, lift
planning, risks in critical load lifts, rigging & slinging, inspection of lifting equipment/ tools and
tackles etc.
The Operator & Banks-man shall not have any physical limitation such as vision or hearing
impairment, etc. which prevents them from carrying out their jobs in a safe manner. They should
undergo medical examination such as vision test & audiometry test etc. before taking up jobs for
the first time and subsequently once every year. Records of such medical examination shall be
maintained by the Subcontractor. Each Fit-to-Work / Medical Certificates must be presented to
GWDC Kuwait prior to deployment of any subcontractor personnel involved in rig move
operations.
The newly assigned crew and Green Hands at all levels on the rigs shall be supervised and
mentored by trained and experienced crew of the concerned contractor Rigs for full
familiarization on rig activities for ensuring their competency and safe behaviour, before they are
assigned the job independently as per the GWDC-HSE-L2-010-Short service employee
management In kuwait v1.0. He must undergo all the mandatory HSE trainings as per GWDC
Kuwait and KOC requirements. The Short Service Employee Program must be strictly followed
throughout the duration of 90 working days or until the employee has been deemed competent
and qualified to be released from SSE status (GWDC-HSE-L2-010-Short service employee
management In kuwait v1.0.”
Defensive driving training shall be provided by GWDC Kuwait / Rig move Sub Contractors to all
rig move vehicle drivers to understand the hazards associated with driving. Preferably, Training
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to be imparted on their own language (Arabic, Hindi, Urdu etc.,) for better understanding.
Appropriate training shall be imparted to driver and crew about the safe load securement
methods. Driving Violations & Good driving performance shall be dealt as per KOC HSE/GWDC
Kuwait procedures on Driving.
GWDC Kuwait to provide training/awareness to all the rig move crew on the risks involved in the
operations and the necessary control measures taken.
GWDC Kuwait shall ensure that STOP training programs / Similar Programs are conducted for all
rig crew and their rig move sub- contractor personnel. GWDC Kuwait shall implement stop work
authority as mentioned in their HSE Policy/procedures, during rig move activities also. GWDC
Kuwait shall ensure that rig move sub-contractor also implement the stop work authority.
All training records such as training attendance register, test results and original certificates are
compiled in the employees training file maintained by the GWDC.
5.0 STANDARDS
The following standard outlines the process to be taken and planning considerations for an
upcoming rig move. It covers the preparations to be taken in the period leading up to the actual
move and finally the move itself. This plan is based on the planned fully assembled moves that
the rigs will normally be performing.
This standard is to be is to be reviewed for relevance prior to all rig moves by the Rig Manager
and other key personnel. The content is to be discussed at the pre rig move related safety
meeting.
At least 3 days prior to the Pre-Move commencement and subsequent Rig Release, there must
be a meeting held with KOC to go over the rig move plan and fill out this checklist. The meeting
shall be documented in the Pre-Move Safety Meeting Form (Attachment C).
The following GWDC Kuwait HSE & Operation Procedures and Standards are applicable to the
rig move operations and shall be adhered to accordingly: (See Attachment)
HSE-L2-066-Management Of Change Program
HSE-L2-013-Subcontractor Management
HSE-L2-009-HSE Handbook
HSE-L2-047-Permit To Work
GWDC-HSE-ATT-DW75-PTW Form v 2.0
HSE-L2-079-PPE
HSE-L2-077-JSA
HSE-L2-088-Drops Standard
HSE-L2-073-Working At Height Program
HSE-L2-036-Forklift Safety Work Instruction
HSE-L2-037-Crane Safety Work Instruction
HSE-L2-039-Manual Handling Program In Kuwait v1.0
HSE-L2-072-Lifting Program
HSE-L2-094-Incident Management Program
HSE-ATT-DW28-Training Matrix Sample v1.0
GWDC-HSE-L1-002 attachment - HSE Policy-Attachment A4 GWDC Kuwait Empowerment
To Stop Policy
HSE-ATT-DW12-Incident Investigation Report
HSE-ATT-DW35-Authorized Lifting Equipment Drawing Person Record
HSE-ATT-DW60-Management of Change Template
HSE-ATT-DW66-Subcontractor Crane Inspection Report
HSE-ATT-DW67-Subcontractor HGV Inspection Report
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Subcontractor will be audited as part of the on-going rig audit schedule of all areas
that GWDC Kuwait operates in. Additionally, stand-alone subcontractor and vendor
audits are to take place.
A Subcontractor training program further helps in the evaluation of the
subcontractor’s HSE management system and to determine the various training
requirements as per the job classification and their related third party competency
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The survey team should be constituted by Rig Manager and Truck Pusher. Once the
next location for drilling or work over is identified the Rig Manager and Truck Push shall
travel, inspect and complete a Rig Move Route Survey Checklist of the proposed rig
route / roads and conditions of the new location prior to rig move planning.
During the Rig Move route survey inspection, emphasis should be on the following:
1. Physical Obstacles (Power lines, Oil & Gas flow lines, KOC & Ministry of Interior
security fence,Camps / Cattle sheds outside KOC, security fence, bridges, 8
designated EOD areas etc.
2. Road Conditions (crossings, Width, Shoulder, Compaction level, sharp bends, road
washouts, road traffic etc.)
Following aspects shall be checked as a minimum while carrying out rig route survey;
1. In case of crossing overhead power lines, enough clearance underneath power line.
2. All corners or junctions in the road/ rig route are wide enough to accept the longest
and largest loads.
3. Sand accumulation at the road shoulders, to be recorded in the route survey
checklist by Rig Manager for communication to Truck Pusher for not driving close
through the road shoulders to avoid any incident.
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4. Any steep/inclination if existing at rig road/ route, need for additional prime mover has
to be noted and used as required.
5. Water accumulation/slush conditions on the road or in the new well site at the time of
rainy season.
6. Verify any obstacle for Rig Movement due to over-ground / underground services
and accordingly assure required precautions from the concerns.
7. Ensure that all vehicles are placed at a safe distance from any over ground &
underground oil & gas lines & electrical lines and other KOC property related to
production operations provided with permanent fixed barricades & markers (visible in
night) .
8. Potential traffic conditions and hazards likely to be encountered on the road during
Rig Move to be noted, for developing preventive measures by concerned
9. Any public road or KOC asphalt road crossings during Rig Move. It is recommended
to avoid crossings and movement on public road.
10. Crossing of KOC fence, security gate crossings, roundabouts and nearby flare pits
11. When Rig Move is planned with extended loads beyond the width of the trucks, any
potential risk for hitting KOC or third party asset & personnel in the rig road has to be
checked during road survey, and if any such risk is identified, it is to be noted and
addressed appropriately prior to Rig Move.
12. During the route survey, new location shall be inspected and any HSE hazards and
risks at location hindering the Rig Move shall be communicated to the KOC Rig
Supervisor. Corrective actions to be ensured by contractor prior Rig Move.
13. Any other physical barriers and height limits.
The route survey checklist sheet in line with KOC requirements of hazards identification
shall be prepared by Rig Manager considering all the listed minimum requirements
and signed by the persons who participated in it. If needed the route survey may be
repeated for verification of corrective actions from previous route survey. For any
constraints and corrective actions, Rig Manager shall report to Company Man. Further
the Company Man shall communicate the Rig move route survey Hazards to KOC for
action (Refer to Attachment A Route Survey Checklist)
Job Safety Analysis is a tool to analyze each job by breaking down into a sequence
of steps / tasks identifying potential hazards as well as assessing the degree of risk
against each step and accordingly recommend precautionary measures to control the
risk before the job is performed.
Rig moving is a combined work with high risk, it include lifting operation, work at high,
transport, and hot work. All these work will be full of hazards. We should find out
these critical hazards and make relevant control measures to reduce the risk of
accidents.
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The Rig Manager and safety officer should be responsible for the JSA. And a sheet
should be filled. (Refer to Attachment G JSA list of rig move)
During pre-job safety meeting, JSA shall be reviewed / discussed by Rig
Superintendent/Rig Manager/ Rig Manager/Rig Master/Truck Pusher in the presence
of activity supervisor along with the crew participating in the activity. However, for all
rig move activities on mast & substructure at old/new location, JSA shall be reviewed
by KOC Company man/his delegate along with the Rig Manager/Rig Superintendent.
During pre-tour meeting/ Tool box talk and pre job safety meetings, crew shall be
reinforced on the STOP work authority to STOP any unsafe jobs and on the company
HSE policies.
GWDC Kuwait shall identify all the risks in operations and present in
procedure/manual with different activities. The manual/procedure shall specify the
risk control measures and shall be implemented during particular activity of the
operation. All the rig move activities related to rig move operations and their
associated hazards, causes and control measures are outlined in the GWDC
Kuwait’s Risk Registers (Safety Risk Register, Environmental Aspect Register &
Health Risk Register) available at each rig worksite.
Once the Rig Move has been surveyed and approved, Rig Manger, Convoy Leader
and Contract Drivers shall hold a Pre-Rig Move Meeting.
This meeting will include but not limited to:
Sequence of loading as per the Load-out List. Additional equipment needed for the
move (example. Lifting equipment and their corresponding lift plans). Lessons
learned from the last Rig Move. Any special inspections (i.e. derrick) or repairs to be
completed before moving. Any first time employees or limited experience people
need to be identified and assigned tasks appropriate to their experience and ability.
GWDC Kuwait shall ensure the availability of Pre rig move meeting check list as per
KOC requirements (Refer to Attachment C Pre rig move meeting checklist)
Critical Jobs/High Risk activities to be done during the Rig Move shall be controlled
under the Permit to Work. This includes but not limited to:
o Nippling Down / Up BOP
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o Critical Lift
o Transfer of Fuel
o A Job Safety Analysis (JSA) is required for every job that requires Permit to Work.
o All permits including hoisting loads must attach the Standard Hand Signal Sheet.
Heavy load truck drivers working hours as per GWDC Kuwait & KOC standards.
At no time is the above statement optional and shall be strictly enforced by all Senior
Management involved in this operation.
All workers involved in this operation should wear the basic personal protective
equipments, such as coverall, boots, gloves, helmet. And personal working at height shall
perform the job with all necessary fall prevention and protection measures. All the
personnel involved in the rig move process shall be in compliance to the site PPE
requirements. A full body safety harness shall be used when working within the
substructure, in the mast, or any time a man is exposed to a fall of more than 6ft.
All banksman (signal man) and Truck Pusher must wear high visibility vest for easy
identification.
7.9 COMMUNICATION
The Rig Manager must inform daily to the Rig Superintendent of programmed tasks
and progress done on the rig move operation. And also the Rig Manager should
report the consequence of route survey to the relevant department of KOC for making
and arranging sufficiency measures to remove or reduce hazardous.
Proper communication shall be ensured by the Rig Manager during all activities of the
rig move.
When travelling in convoy formation with multiple trucks, each escort vehicle will be
equipped with a cellular phone or where necessary walkie-talkies.
For rig move on highways and public roads, Contractor shall communicate with
concern from ministries and shall be take necessary permissions as per their
requirements.
The Supervisor shall ensure clear and effective communication throughout the rig move
operation by chairing daily rig move planning sessions and safety meeting, at the
beginning of each day, to be held with all employees in attendance. The day’s objectives
and timelines will be discussed with special attention given to any hazardous work
conditions that may potentially exist and methods to control the identified risks (refer to
Pre-rig move meeting checklist Attachment C).
Pre-move safety meetings will be held prior to initiating rig move activities. The
meeting should be conducted by the Rig Manager and attended by the Rig Manager
Safety Officer, Drillers and Truck Pusher, to determine;
o Emergency contingency plan – a written plan must be available for each rig move
b. Daily rig move planning and safety meeting for every shift
All personnel involved in the operation shall attend safety meetings daily. The
meetings are to be conducted by the Rig Manager. The Rig Manager shall outline the
plan of activities and objectives for the day. Tasks will be designated to the crew
based upon the overall rig down process. A safety discussion in which the applicable
JSA’s will be reviewed shall be conducted relative to the nature of activities planned
for the shift. The potential for safety hazards shall be discussed at this time as well as
possible precautions to eliminate / minimize safety hazards. The rig move emergency
contingency plan must be reviewed during each daily Safety Meeting to refresh in the
employee’s minds what to do in the event of an emergency and to ensure that
conditions have not changed which may affect the effectiveness of the emergency
response plan (i.e. – weather conditions, access to medical facility, communication
barriers).
c. Toolbox Meetings
A Tool Box Talk (TBT) is essentially a brief safety discussion by the responsible
person prior to the start of a task, outlining all crew members’ responsibilities and
determining the level of understanding of the procedures and hazards involved.
A Toolbox talk will be conducted by the job supervisor prior to start of a fresh/ new
task. This meeting needs to be documented using Toolbox meeting record. This
meeting is not to be considered as a substitute for a JSA.
A Tool Box Talk may also be required to be conducted at any point during the job
when operations change, hazards change or if the Supervisor identifies the need to
re-organize the work crew.
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Make sure all electrical component covers are properly maintained and all plugs and
bolts are properly installed.
Make sure all labels for electrical breakers and switches are clearly labelled and
readable.
Make sure the electrical equipment is properly rated for the area and location.
Use GFCI (ground fault circuit interrupter) circuits for all electrical devices.
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Ensuring that all rigging and slinging safe work procedures of the company are
adhered to at all times and that inspections are conducted at annual intervals.
Authorize and/or issue of permits to work as required.
Ensuring that the Lifting Equipment Register ( Refer to Attachment ZT Lifting
Gear Register ) is maintained, accurate and that all equipment in use
complies with the current color code.
Ensuring that certification documentation for all on-site lifting equipment is
available, current and valid.
b) Crane Operator
Operate the forklift in a safe and responsible manner ensuring the safety of co-
workers while moving equipment and materials.
Ensuring that all lifting gear used in association with the forklift is certified and
color coded as per the GWDC Kuwait color code matrix requirements.
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7.13.2 Cranes
Refer To GWDC-HSE-L2-037-Crane Safety Work Instruction In Kuwait V1.0
Cranes are critical for operations during rig-up and rig down. A catastrophic crane
failure could result in serious injury to either the crane operator or personnel involved
in working around the crane. In order to minimize the potential for such injury, the
following will be observed:
Cranes being used at GWDC Kuwait worksites must have functional certified
weight indicators on the main block, anti-two block and boom cut-off devices.
The cranes are to be maintained in compliance with the following:
a) Manufacturer’s specifications
b) Government regulations
c) API and Industry standards regarding inspections, certifications of crane
(Load Testing – once per year and Visual Inspection every 6 months by
both 3rd Party KOC Approved Party) and personnel.
Only trained and competent personnel will be allowed to operate a crane
during rig move operations. The assigned Crane Operator must be fully aware
of all safety procedures contained in procedure GWDC Kuwait-HSE-L2-037-
Crane Safety Work Instruction In Kuwait v1.0 found in the GWDC Kuwait HSE
Management System available at every GWDC Kuwait Drilling work site.
Prior to using any crane, at the start of each shift the Crane Operator must
perform an inspection of the crane using the GWDC Kuwait Drilling Crane Pre-
use Inspection Checklist.(Refer to Attachment ZP-GWDC-HSE-ATT-DW78-
Crane Pre-use Checklist v1.0)
Lift plans for every critical load must be developed before the loading starts. A
safety meeting will be held and critical load data sheets will be elaborated to
ensure the safe handling of the loads.
Only authorized personnel who have been trained in the safe use and
operation of cranes will be permitted to operate the crane.
The crane operator shall be responsible for those operations under his direct
control. Whenever there is any doubt as to safety, the crane operator shall
have the authority to stop the operation, re-plan the details, and continue as
safety dictates.
When handling loads, the crane operator shall never start machine movement
unless the load is within his range of vision and he has been given the
appropriate signal. The Crane Operator shall ensure that he operates the
equipment at a safe and controlled speed to ensure that the task is performed
safely and efficiently without incident.
The crane operator shall respond to the signals only from the appointed signal
person but should obey an emergency stop signal at any time no matter who
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gives the signal. Hand signals will be in accordance with those shown on the
crane hand signals chart posted on the crane and around the rig.
The qualified person directing the lift shall determine that the load is secured
and properly balanced in the sling or lifting device before it is lifted and that the
lift and swing paths are clear of obstructions and personnel.
No external forces shall be applied to suspended loads which will result in side
loading of the boom. Care shall be taken when swinging the crane so as to
minimize the pendulum action of the hook and suspended load.
When two or more cranes are used to lift one load, one qualified person shall
be responsible for the operation. The responsible person must analyze the
operations and instruct all personnel involved in the proper positioning, rigging
of the load and the movements to be made. This qualified person must prepare
a critical lift plan in order to perform this task.
All safety equipment on the crane must be present and functional including tag
lines, fire extinguisher, back-up beeper, load charts, load limiter and boom
angle indicator.
Tag lines will be attached to each load for the safe positioning of the load. See
tag lines paragraph further in this section.
7.13.3 Crane Signalman
Cranes can be dangerous machines in the wrong hands and, as such, require
skilled persons to operate them. As well as the actual Crane Operator, at least
one more important and essential member is required to make up the team. It
is the Rigger/ Crane Helper/ Slinger and his duties include:
Ensure that both he and the Crane Operator are familiar with the method of
signaling to be used.
Be aware of the wind speed and direction.
Know the weight of the load.
Be familiar with the line capacities of the crane in use.
Check that the lifting gear being used is in good condition, certified for use,
correctly color coded and of sufficient capacity to carry out the lift.
Ensure that tag-lines are attached to any long or awkward loads to facilitate
easier handling.
Be aware of any obstructions within the crane's radius and working area.
Check that the area around the load to be lifted is clear and that the load is not
attached to the deck, transportation cradle, or adjacent equipment.
Ensure his hands are free from lifting gear and stand clear before the crane
takes the strain.
If using hand signals, stand in a position where the Crane Operator can clearly
see you and you can maintain visual contact with the load.
Always use clear and distinct signals (either by hand or by radio) to control
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Tag lines will be used to control all suspended loads. If tag lines are impractical
during final positioning of the load, caution should be taken to ensure that no
part of the person's body guiding the load be between the load and any
stationary object.
Hand-held tag lines will be constructed of a non-conductive material such as ½
inch rope or a 1inch nylon strap. Chains or steel cables are not acceptable.
Never attempt to guide a load with the tag-line wrapped around your hand or
waist.
Never use a tag line with a knot in the end.
A tag line should be of sufficient length to insure that no part of the person
guiding the load be under the load at any time.
The person holding the tag line should never position themselves between a
suspended load and a stationary object.
7.13.5 Forklifts
Refer to GWDC-HSE-L2-036-Forklift Safety Work Instruction
Only trained and competent personnel will be allowed to operate the forklift.
The assigned driver must be fully aware of all safety procedures contained in
procedure HSE-L2-036-Forklift Safety Work Instruction found in the GWDC
Kuwait HSE Management System available at every GWDC Kuwait Drilling &
work over work site.
Prior to using the forklift at the start of each shift the Forklift Operator must
perform an inspection of the forklift using the GWDC Kuwait Drilling Forklift
Pre-Use Inspection Checklist.
API and Industry standards regarding inspections, certifications of forklift (Load
Testing – once per year and Visual Inspection every 6 months by both 3rd
Party KOC Approved Party) and personnel.
Absolutely no personnel are allowed to ride on the forklift other than the driver
and no worker shall be allowed to use the bucket or forks as an at height
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working platform.
The forklift will have a back-up alarm and rotating beacon light on top. These
must be in good working condition.
When loading or unloading tubular goods, the operator of the forklift will ensure
that no one is within a 20 foot (6m) radius of the forklift or the truck.
When a forklift is left unattended, the load will be fully lowered, the controls will
be neutralized, the power shall be shut off, and brakes set.
When the forklift operator is unable to see his forks, then he will receive
instructions from the signaler before proceeding.
The forklift shall not be driven forward when carrying a load too high or wide as
to obstruct the view of the driver.
The forklift shall not be driven forward while the lift prongs are raised higher
than 12 inches (300mm) off the ground.
The forklift shall be parked, and secured when weather conditions deteriorate
and the vehicle cannot operate safely.
All personnel working around the forklift must remain alert to the vehicle's
presence and remain out of its path of travel.
Surfaces where the vehicle is to travel must be kept as dry as possible. The
vehicle will be parked when the surface becomes too slick for safe operation.
The forklift must have an overhead guard to protect the operator from being hit
by falling objects; the guard must not block visibility.
Holes shall not be burned or drilled in the ends of the lift forks to attach chains,
wire rope, or other devices for lifting purposes.
The forklift operator must remain alert and aware to the presence of other
traffic around the worksite, pressure vessels, pressure and fuel lines, or fuel
compartments, and exercise caution while maneuvering the vehicle in such
areas.
The forklift shall travel with loads lowered as close to the driving surface as
feasible.
When driving backwards and rounding corners, the forklift shall be slowed
down and the horn sounded as a warning. The reverse alarm shall not be
disabled or removed from the vehicle. A flashing light on the cab, or other
warning device required by host country regulations, must be working at all
times.
The forklift shall not be used to pull or drag equipment, material, etc. Its
primary function is to lift loads.
The forklift shall not be driven fast. Care should be exercised while carrying a
load, or when turning corners.
The forklift must not be parked in an enclosed room or confined area with the
engine running.
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All shackles shall be Grade “S” minimum. Large Dee or Bow, Alloy, safety pin
shackles shall be used for all lifts which are transported by sea and permanent
attachment of slings to loads. Safety pin shackles installed on equipment such as
containers where the use is of a “permanent” nature must always have split pins
fitted to secure the nut.
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PROHIBITED!
Testing Requirements
All shackles (or batch of shackles) should have a unique identifying serial number
and trace ability to an original test certificate as per relevant International
Standards. All items found in unsatisfactory condition or missing original test
certification must be tagged and removed from service and destroyed.
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The distance between clamps should be equal to six rope diameters. The U-bolts of
all clamps should always be in contact with the short (dead) end of the rope. When
three or more clips are required, space additional clips equally between first two,
take up rope slack and tighten nuts on each U-Bolt evenly, alternating from one nut
to the other until reaching recommended torque, see Table 1 below. The saddle
piece should be in contact with the live end / loaded part of the rope as shown in
figure 3 below.
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WARNING – Wire rope grips should not be used for lifting purposes and are not
intended for the permanent fastening of a rope that is subject to high dynamic
loading. Wire rope grips should not be used on hoist wires, break-out line and hang
off wires. International Standards do not recommend Wire Rope clip (U-bolts)
terminations for elevator, personnel hoist and scaffold applications.
Failure to read, understand, and follow the manufacturer’s instructions may cause
death or serious injury. Read and understand those instructions before using clips.
Match the same size clip to the same size wire rope and prepare wire rope end
termination only as instructed. Do not use with plastic coated wire rope.
All wire rope and lifting slings are to be inspected at a frequency of every six
months and the following GWDC Kuwait color code system is to be implemented to
aide in the easy identification of compliance to inspection procedures.
c) Slings – General
Slings are generally one of six types: chain, wire rope, metal mesh, natural fiber
rope, synthetic fiber rope, or synthetic web. In general, use and inspection
procedures tend to place these slings into three groups: wire rope & mesh, fiber
rope web and Chain (Chains are only to be used to secure loads). Each type has its
own particular advantages and disadvantages. Factors that should be taken into
consideration when choosing the best sling for the job include the size, weight,
shape,
temperature, and sensitivity of the material to be moved, as well as the
environmental conditions under which the sling will be used.
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i) Wire Rope
The most common type of sling is made of wire rope. Wire rope is composed of
individual wires that have been twisted to form strands. The strands are then
twisted to form a wire rope. When wire rope has a fiber core, it is usually more
flexible but is less resistant to environmental damage. Conversely, a core that is
made of a wire rope strand tends to have greater strength and is more resistant to
heat damage.
ii) Wire Rope Sling Selection
When selecting a wire rope sling to give the best service, there are four
characteristics to consider: strength, ability to bend without distortion, ability to
withstand abrasive wear, and ability to withstand abuse.
1) Strength - The strength of a wire rope is a function of its size, grade, and
construction. It must be sufficient to accommodate the maximum load that will
be applied. The maximum load limit is determined by means of an appropriate
multiplier. This multiplier is the number by which the ultimate strength of a wire
rope is divided to determine the working load limit. Thus a wire rope sling with
a strength of 10,000 pounds and a total working load of 2,000 pounds has a
design factor (multiplier) of 5. New wire rope slings have a design factor of 5.
As a sling suffers from the rigors of continued service, however, both the
design factor and the sling's ultimate strength are proportionately reduced. If a
sling is loaded beyond its ultimate strength, it will fail. For this reason, older
slings must be more rigorously inspected to ensure that rope conditions
adversely affecting the strength of the sling are considered in determining
whether or not a wire rope sling should be allowed to continue in service.
2) Fatigue - A wire rope must have the ability to withstand repeated bending
without the failure of the wires from fatigue. Fatigue failure of the wires in a wire
rope is the result of the development of small cracks under repeated
applications of bending loads. It occurs when ropes make small radius bends.
The best means of preventing fatigue failure of wire rope slings is to use
blocking or padding to increase the radius of the bend.
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A permanent kink in a wire rope sling causes loss of strength. Discard the
sling.
In bird caging, the wire rope strands are forcibly untwisted and become spread
outward. Therefore, in order to prolong the life of the sling and protect the lives
of employees, the manufacturer's suggestion for safe and proper use of wire
rope slings must be strictly adhered to.
5) Corrosion - Severe corrosion of the rope or end attachments which has
caused pitting or binding of wires should be cause for replacement. Slight
external rusting usually does not affect the strength of a sling.
iii) Wire Rope Life
Many operating conditions affect wire rope life. They are bending, stresses,
loading conditions, speed of load application (jerking), abrasion, corrosion,
sling design, materials handled, environmental conditions, and history of
previous usage.
In addition to the above operating conditions, the weight, size, and shape of
the loads to be handled also affect the service life of a wire rope sling.
Flexibility is also a factor. Generally, more flexible ropes are selected when
smaller radius bending is required. Less flexible ropes should be used when
the rope must move through or over abrasive materials.
iv) Wire Rope Sling Inspection
Wire rope slings must be visually inspected before each use. The operator
should check the twists or lay of the sling. If ten randomly distributed wires in
one lay are broken, or five wires in one strand of a rope lay are damaged, the
sling must not be used. It is not sufficient, however, to check only the condition
of the wire rope. End fittings and other components should also be inspected
for any damage that could make the sling unsafe.
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To ensure safe sling usage between scheduled inspections, all workers must
participate in a safety awareness program. Each operator must keep a close
watch on those slings he or she is using. If any accident involving the
movement of materials occurs, the operator must immediately shut down the
equipment and report the accident to a supervisor. The cause of the accident
must be determined and corrected before resuming operations.
v) Field Lubrication
Wire rope slings can provide a margin of safety by showing early signs of
failure. Factors requiring that a wire sling be discarded include the following:
Severe corrosion
Localized wear (shiny worn spots) on the outside
A one-third reduction in outer wire diameter
Damage or displacement of end fittings - hooks, rings, links, or collars -
by overload or misapplication
Distortion, kinking, bird caging, or other evidence of damage to the wire
rope structure Excessive broken wires
viii) Chains
Chains are commonly used because of their strength and ability to adapt to the
shape of the load. Care should be taken, however, when using alloy chain
slings because they are subject to damage by sudden shocks. Misuse of chain
slings could damage the sling, resulting in sling failure and possible injury to an
employee. For this reason, chains are not allowed for lifting purposes at GWDC
Kuwait. They may only be used for securing loads. The only exception is if
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ensure that there is no sling damage prior to making the lift. Next, position the
hook directly over the load and seat the sling squarely within the hook bowl.
This gives the operator maximum lifting efficiency without bending the hook or
overstressing the sling. Wire rope slings are also subject to damage resulting
from contact with sharp edges of the loads being lifted. These edges can be
blocked or padded to minimize damage to the sling.
b) Safe Working Loads (SWL)
The following chart indicates the tonnage pull on each leg of the sling from 0°
to 120°. When lifting with multi-leg slings, they are rated at a certain tonnage
from 0 to 90 and this SWL should not be exceeded even if the angle is less
than 90°. When using single slings in pairs you must always be aware of the
increased loading in the slings when lifting at an angle. Care should be taken
that the safe working load of a sling is not exceeded.
For the above reason, the SWL of a pair of single slings decreases as the angle
between them increases.
30° SWL = SWL of one sling x 2 x 0.966 SWL = SWL of one sling x 2 x 1.93
60° SWL = SWL of one sling x 2 x 0.866 SWL = SWL of one sling x 2 x 1.73
90° SWL = SWL of one sling x 2 x 0.707 SWL = SWL of one sling x 2 x 1.414
120° SWL = SWL of one sling x 2 x 0.5 SWL = SWL of one sling only
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SWL CHECKED
▼
CLEAR COMMUNICATIONS
▼
NO LOOSE OBJECTS
▼
LOAD SECURED
▼
ESCAPE PATH
▼
CONFIRM WEIGHT
▼
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the mobile equipment (cranes/Trucks/ forklifts etc.) used during the rig move should
be as per GWDC Kuwait & KOC guidelines/ HSEMS Procedures/ General conditions
of Contract/ rig contractual MOU.
o GWDC Kuwait shall list out all the critical equipment used and specify the periodic
third party inspection schedule for certification and color coding e.g. lifting gears, load
bearing points like lifting pad eyes etc.
o Ensure availability of all maintenance manual and develop schedule for PMS all
equipment utilized in Rig move operations.
o GWDC Kuwait shall prepare the standard Operating Procedures – Procedures
essential for safe operations for rig move.
o All Vehicle equipment used for Rig Move shall be maintained appropriately and fit for
use. And all lifting equipment such as crane, forklift, and loader should be inspected
daily. As a minimum, maintenance of lifting and road transport equipment (Prime
movers, Trailers Cranes, Forklifts, Pick up etc.,) shall be conducted in accordance
with the OEM specifications. Vehicle Pre-Move Safety Check shall be carried out
prior to Rig Move. Pre-Trip Vehicle Inspection Checklist (Attachment M) shall be used
for this purpose and such records shall be made available for KOC inspection.
o Make sure vehicles are in good condition. Necessary safety equipment and spare
parts must be provided in all vehicles. This includes, but is not limited to:
o Safety belts for drivers and passengers
o Fire extinguisher - First aid equipment
o Spare tire
o Warning signs and necessary maintenance tools
o ABS brakes and dual airbags at front
o For four wheel drive vehicle on difficult terrain, the vehicle should be equipped with a
frame specified to protect the driver and passengers in case of a full 360-degree roll-
over.
o Except for regular maintenance, the vehicle should be examined carefully by the
driver prior to using:
o Operation system
o Brake system
o Lights
o Dashboard
o Tire pressure
o Safety and warning signs
o For rigs which are towed using rig tyre assemble, rig crew shall carry out periodic
maintenance for the tyre assembly, steering mechanism etc. as per OEM
requirements.
o Pre-start and periodic inspections shall be conducted and documented by
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drivers/operators.
The rig site Safety Officer/Engineer shall collect and verify all Mobile Equipment
Inspection Checklists to ensure that they are accurate and that all equipment is in
good working condition. Any deficiencies noted shall be reported immediately to the
Rig Manager in order to be repaired or minimize the mitigating risks. The Safety
Officer has the authority to stop operations to ensure the health and safety of all
employees and equipment.
The Rig-Site Safety Officer shall collect all Mobile Equipment certification and third
party inspection documentation and audit the validity of all third party mobile
equipment inspections and certifications. The records will be maintained on the rig
site for audit purposes.
The Rig Site Safety Officer shall ensure that all equipment Operators have proper
training certificates, Driver’s Licenses and are authorized appropriately to operate the
equipment for which they are assigned. The records will be maintained on the rig site
for auditing purposes.
All third party equipment shall keep schedule of last and next maintenance
performed. The subcontractor will provide detailed maintenance records of individual
equipment within 24 hrs. if requested.
HSE Department shall also conduct periodic audits of the worksite during rig move
operations
Performed by Supervisory Staff to ensure that crews are conducting rig move
operations as per the Rig Specific Procedures.
All incidents occurring during rig move operations are reportable to the client and
must be reported immediately to the client representative. All the incident, near miss
and hazardous conditions identified during rig move operations shall be reported and
investigated.
In the absence of the client representative the Rig Manager is responsible to
immediately inform to ERC 160 on occurrence of any incidents and subsequently
report the same to the client Rig Supervisor.
In the event of a serious or major incident occurring during rig up, rig down and rig
move operations, all key personnel and crew involved during the activities and all
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witnesses to be made available in Kuwait until all company and client investigations
have been completed and workers are released.
Safety Alerts / Lessons Learned / Investigation Recommendations from the rig move
incident investigations at the rig and other sites (as received by the client) shall be
discussed and implemented at all rigs where similar operations are conducted/carried
out.
STOP cards are available on site for the crew to report any safe or unsafe behavior
observed on the rig site. All findings are entered into a corrective action register
attached to the safety officer’s daily report. The findings are reviewed and corrective
actions to mitigate the unsafe acts. Any immediate threat shall be handled
immediately.(See Attachment E STOP CARD Register)
Upon completion of well operations & installation of Christmas tree, before lowering
mast & sub-structure, BPV shall be installed on well head. After rig down and
movement of rig from well position to a safe distance, further Rig Move shall be
carried out after the removal of the BPV installed in the well head.
BPV installation and removal shall be carried out as per approved procedures under
the supervision of Rig Manager and KOC Rig Supervisor, with PTW endorsed by
KOC Rig Supervisor. Inspections, maintenance and testing of lubricator, T Rod &
BPV to be carried out as per OEM requirements.
Similarly before moving work over rig or completion rig to an existing well with
Christmas tree, BPV shall be installed on well head.
During pre-job safety meetings for each Rig Move activity, roles and responsibilities
of the crew involved shall be discussed.
GWDC Kuwait shall ensure that the OEM procedure/ recommendation, API RP 54 &
API RP 4G applicable requirements are documented for rigging up/down the mast,
substructure and draw works. Refer to Attachment L Rig up and Rig down
Procedures)
GWDC Kuwait shall ensure that inspection, maintenance, testing and repair of mast,
substructure, auxiliary brakes & draw work assembly (including all operating system)
used for safe raising/lowering are to be carried out as per KOC, OEM and API
requirements.
The rig specific Safe Operating Procedures (SOP) and JSA’s shall be developed for
the rig up and rig down operations based on the above requirements mentioning the
roles & responsibilities. The same shall be implemented with appropriate training to
Senior Crew involved in the rig up & rig down operations. GWDC Kuwait shall utilize
relevant PTW system for rig up and rig down operations. (Refer to Attachment G JSA
for Rig move Procedures)
Operations such as lowering and raising of mast, substructure and draw works, shall
be carried out under the supervision of Rig Superintendent or his designee and KOC
Rig Supervisor during day light hours only. During emergencies, if such operations
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GWDC Kuwait shall arrange the convoy move while moving the wide, tall, heavy or
otherwise oversized loads. Escort vehicle shall be provided by GWDC Kuwait or/Rig
Move Sub Contractor with designated driver & Supervisor in the front and rear side of
the convoy. The list of loads/ rig equipment that are part of rig move convoy shall be
listed in the Rig move plan.
If it is necessary to cross any public road/ blacktop road, one signal man/ signalar
should be posted with proper communication and flags on the each side of road for
traffic coordination with the support from KOC security Team to stop/alert the public
until the convoy crossed the road. Ensure that rig move convoy avoids rush hours on
all busy roads.
Night time rig moves must be avoided as much as possible. The Rig Manager has
the responsibility and the authority to shut down any night move when in his opinion
conditions make it unsafe to continue. Furthermore, loading and moving oversized
loads is not permitted during night time hours or after dark.
Rig Move shall be avoided adverse weather, such as dusty, rainy, heavy wind and
foggy during which the visibility is less than 100m. It is the Truck Pusher responsibility
to ensure prior to Rig Move that there is adequate visibility and favorable conditions.
In addition it is the Truck pusher`s responsibility to ensure that vehicle fog lights are
functioning and operated during rainy/foggy conditions.
Extended loads beyond the truck width shall only be permitted with beacon lights,
reflective stickers & danger flags or other visible hazard communication signs
indicating the extended portion of the load.
Experienced and designated drivers with Defensive Driving Training will be provided
by GWDC Kuwait to drive the designated escort vehicles. This is to provide guidance,
monitor and direct the rig move convoy safely particularly the traffic approaching
behind.
Wide loads are moved in a convoy with a lead escort vehicle and a follow escort
vehicle. Escort vehicles to be equipped with rotary beacon lights
The escort vehicle (pick-up, SUV, etc.) associated with rig move operation shall be a
four-wheel drive.
Drivers of the rig move convoy shall be designated and provided with necessary
training including defensive driving. Only experienced drivers in rig move shall be
allowed to operate the vehicles in the convoy.
Rig routes should be planned to avoid crossing any highways. If it is necessary to
cross a highway, then only authorized crossing points are to be used. The crossing of
public roads/highways shall not be conducted during heavy traffic hours and must be
done with extreme caution.
If it is necessary to cross any public road/ blacktop road, one signal man/ banksman
should be posted with proper communication and flags on the each side of road for
traffic coordination with the support from KOC security Team to stop/alert the public
until the convoy crossed the road. Ensure that rig move convoy avoids rush hours on
all busy roads.
Escort vehicles must be equipped with an adequate and immediate means of
communication so that the convoy can be stopped quickly in the event of an
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emergency or any other reason arising for stopping the convoy. This may require the
provision of mobile phones. If any vehicle in the convoy behind the lead escort
vehicle stops for any reason the following escort vehicle must radio ahead to stop the
remainder of the convoy.
When travelling in convoy each vehicle shall maintain a safe following distance away
from the vehicle in front of him and be alert watching for tools or equipment falling
from the vehicle ahead. In the event that something falls from the vehicle ahead the
driver shall stop his vehicle and alert the following escort vehicle to communicate to
the lead escort vehicle to stop the remainder of the convoy to pick up the fallen tool or
equipment.
When conducting long distance rig moves in convoy, the Rig Manager /Truck Pusher
shall designate an assigned schedule for the convoy to stop so that each driver in the
convoy can conduct a walk around inspection of his truck and load to ensure that no
new hazards have arisen and to let the tires cool off on the equipment to prevent the
tires from bursting due to excessive heat. At this time each driver will ensure that all
components of their loads are secured and have not come loose during the rig move.
The recommended schedule for stop check inspections is:
Summer – the convoy will stop every five kilometers to conduct inspection winter –
the convoy will stop every ten kilometers to conduct inspection.
It is the responsibility of the lead escort vehicle to measure the distances travelled
and stop the convoy appropriately when necessary.
When travelling in convoy or out of convoy, only the approved designated rig route
shall be followed, no deviations from the approved rig move route are permitted.
When travelling in convoy, no vehicle shall attempt to overtake any of the vehicles in
front of them! If necessary to stop the vehicle in front of them due to an identified
hazard the driver shall stop his vehicle and notify the following escort vehicle to
communicate with the lead escort vehicle to stop the convoy, in order to correct the
identified hazard.
All overhead cables are to be approached with caution. Each truck has to stop then
proceed slowly under the cables to avoid any excessive movement of the Truck
suspension.
The following is a table to determine whether the Rig can pass safely under the
overhead cables.
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KOC rig supervisor must be present during the rigging up/down of mast/substructure
at well position for ensuring well / Christmas tree / well head safety. After rig up, KOC
rig supervisor to ensure that the rig centered with respect to the well.
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Rig Superintendent, Rig Manager shall supervise and to be present during the raising
or lowering the mast and substructure. Only trained & experienced crew in lowering
and rising the mast shall be allowed to participate in the operations.
Fully Disassembled
Field Inspection (NDT-
Sl.# Description Inspection (Cat IV)
Cat III) Frequency (A)
Frequency (B)
Rotary
9 6 Months 2Year
table master bushings
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& inserts
A Critical Lift Plan is a document which identifies the specific load which is to be lifted
and the operating restrictions associated to lifting the load safely.
The Critical Lift Plan template provides an in-depth evaluation and plan for all critical
lifts and / or complicated lifts.
A Critical Lift Plan MUST be completed in advance of attempting any critical lift.
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The Critical Lift Plan MUST be completed by a competent person who is by definition
a person who is capable of identifying existing and predictable hazards in the
surroundings or working conditions and has the authority to correct them.
All Critical lifts must be performed by qualified person who is by definition a person
who, by extensive knowledge, training and experience has demonstrated his ability to
solve and resolve issues related to critical lifting.
It is mandatory to review the Critical Lift Plan at the site just prior to conducting the lift
and ensuring that a permit to work has been generated and approved prior to
conducting the critical lift.
*Refer KOC.SA.029 - Safety Procedure for Mechanical Handling of Loads
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Lifting and material handling equipment shall never be used on a soft or uneven
surface or on a slope unless precautions have been taken to ensure stability of the
equipment.
It is recommended to use pre and post loading checklist (Attachment ZL Pre Load &
Post Load checklist) for the Lifting safety.
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In case of extreme emergency, Rig Move during nighttime shall be carried out after
approval from concerned KOC drilling operations Team after detailed risk assessment
and implementation of risk mitigating control measures. Rig Superintendent should be
available during the night Rig Move.
Crane Operators must ensure that the ground in the lift area is suitable and can
support the weight of the lift otherwise additional outrigger matting may be necessary.
The Operator shall ensure that precautions are taken to ensure that lifting equipment
is clear of any underground piping or electrical cables, or where it is not possible,
underground piping and/or electrical cables are adequately protected to safeguard
against possible damage or release.
The Operator shall be familiar with all controls.
The Operator shall have a clear and unobstructed view of the load and operational
area. If not the Operator shall act only under the directions of a signalman who is
positioned to have a clear unobstructed view. The Operator and signalman shall
ensure that loads and the lifting gear are well clear of obstructions.
Signals conforming to the GWDC Kuwait Hand Signals Standard shall be used for
communication between the Operator and the signalman. A GWDC Kuwait Crane
Hand Signals sign board is posted at each worksite.
The Operator and the signalman must verify the weight of the load and the suitability
of all lifting gear before the load is lifted. When lifting a non-uniform load the Operator
must identify the center of gravity prior to lifting.
When lifting a load it shall initially be lifted just enough to clear the ground or
supporting surface and be brought to rest while the slings and balance of the load are
checked, prior to proceeding. Proper care shall be exercised by the Operator at all
times to avoid shock or side loadings on the boom. The Operator must not lift any
load unless it is properly slung and safe for lifting.
All persons shall be kept clear of loads which are to be lifted and also from suspended
loads. When lifting from a stack of material, all persons shall stand away from the
stack in case adjacent materials are dislodged.
After materials, buildings and/or equipment is loaded, the driver shall not move the
truck before securing the load with adequate tie downs and only after the completion
of the post loading inspection by the Truck Push. All loads must be adequately
secured to prevent any items from falling from the truck bed/trailer during
transportation.
Loads shall not be unsecured at the new location until such time as a forklift or crane
has been assigned to the job and the truck is in the unloading area.
The Truck Driver is responsible for removing all tie downs securing the load.
pockets) shall be checked for any damages and adequate strength to support the
load being transported.
The load shall be properly blocked and braced to prevent unintentional movement
during transport.
No knots exist in strapping devices and tie downs.
Loads must be distributed evenly on the trailers to prevent rolling/upset during
transport or while unloading.
All loads shall be independently secured with independent tie downs.
Tie down or component of Tie-down shall not used to secure cargo to vehicle unless
it is marked by manufacturer with respect to its working load limit.
Edge protection (rubber packing) shall be ensured to prevent abrasion and cutting of
tie down devices.
Truck side guards must:
a) Meet minimum height standards (4ft) and loads must not be higher than the side
guards.
b) Meet a minimum construction standard (width and length of pocket and made of
steel)
c) Must pass inspection requirements (no bent, cracked or distorted guards).
d) Be fitted into the pocket without play and shall be tightened into place with an
adequate mechanism as a screw and screw hole.
e) The side support pockets must not be used as anchor points for the tie downs.
f) The spacing of side supports shall not be more than one (1) meter.
Load straps must meet a minimum strength of 5,000 lbs.
Ratchets must be designed to release tension slowly.
Only ratchet style load binders are approved for use at GWDC Kuwait
worksites, lever type binders are prohibited,
Any small or loose objects shall be secured from unintentional movement or
placed in a basket or crate for transport.
g) All 3rd party/sub-contractor rig mover drivers shall be required to have “Road
Transport Cargo Securement” training prior to start of the job.
Figure 1 – Tie downs can be attached to the cargo and provide direct resistance to restrain the
cargo from movement.
Figure 2 – Illustrates how tie downs can be passed over or through cargo to secure. By doing
so, they create a downward force that increases the effect of friction between the cargo and
the deck. This friction restrains the cargo.
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Figure 3 – Each tie down must be attached and secured so that it does not become loose or
unfasten, open or release during transit. All tie downs and other components of a cargo
securement system must be located within the rub rails (when present). NOTE: This
requirement does not apply when the width of the load extends to or beyond the rub rails.
How many tie downs are required?
If a load is not prevented from forward movement (for example, by the headboard, bulkhead, or
other cargo, or tie down attached directly to the load), secure the load according to the
following requirements:
Figure 4 – a load measuring 1.52 m (5ft) or shorter with a weight less than 500 Kg (1,000 Lbs.)
requires a minimum of one tie down.
Figure 5 – a load measuring 1.52 m (5 ft) or shorter but over 500 kg. (1,000 Lbs.) must have
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Figure 6 – a load measuring more than 1.52 m (5 ft.) but less 3.02 m (10 ft.) requires a minimum
of two tie downs.
Figure 7 – all loads must have adequate securement which means one tie down for every 3.04 m
(10 ft.) Or part thereof.
9.4 Rig Loading Sequence Register
a. Critical lift – Lifts with crane weighing more than 50 tons, exceeding 75% of rated crane
capacity, tandem lift involving more than one crane, involving crane movement within the
minimum distances from high voltage power lines (as per API RP 54), blind lift, personnel
lifts in personnel baskets, lifting of - BOP equipment, mud pump, mast, substructure and
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any part of a crane whose boom attachment is working within 10 meters (33 feet) of any
hydrocarbon and / or pressurized piping areas. All critical lifts need lifting plan
implemented.
b. Pre-move lift / Non-essential lift - Rig load that can be moved at any convenient time
during the rig move. Rig loads that are not required for finishing/completing the well and
which therefore can be moved to new location prior to rig release, but after location
inspection and release letter from KOC. (E.g. Pre-Mix tanks). Usually, those non-essential
loads are pieces of equipment that can be rearranged at the rig site to expedite the rig
move process.
Once the criticality of each lift has been determined as per the legend above, equipment
items should be placed on the “Loading Sequence Register” in chronological order based
on which lift category they have been determined to be. Logic and experience will have to
be used to group lifts into the categories above. In addition, make sure to comply with any
contractual requirements when determining criticality of loads.
9.4.3 Determining Single “Loads”
Now that lift criticality has been established and sorted, load determination must be
established through combinations of lifts. Loads will be determined and limited to
transportation means in which rig moves will be achieved. For example, if rig moves will
take place using trucks with 40 – ton flat beds which are 40 ft long, then lifts will have to be
combined in a manner in which they comply with the length and weight requirements of
the truck beds. In essence, the following requirements must be adhered to when
combining lifts into loads:
a. Maximum weight allowance of the vehicle
b. Maximum dimensions of the vehicle.
Combine lifts into loads taking into account the requirements listed above. In order to
increase efficiency, combine as many lifts into a load as possible not exceeding the limits
mentioned above.
Once the loads have been determined, re-sort the information so that it is sorted by load
number (final column) in ascending order. You have now determined the number of loads
and combination of lifts into any single load. In addition, you have established which loads
can be moved prior to the actual rig move, which loads are critical to be moved during the
rig move and which loads can be moved as needed during the rig move.
9.4.4 Loading Sequence Register
The Loading Sequence Register provides you with the framework for all future rig moves,
providing critical information such as load dimensions and loading sequence. This register
can be adjusted as per your needs and priorities in future rig moves or if a more adequate
loading sequence is identified.(Refer to Attachment ZK Loading sequence Register)
All critical loads identified during the rig move must have a Critical Load Data Sheet
prepared in advance of the rig move.
The Critical Load Data Sheet contains all the necessary data required to prepare a critical
lift plan for lifting the equipment and loading onto the necessary rig move equipment.
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The Critical Load Data Sheet shall be prepared with the assistance of the experienced
Crane Operator and the Rig Site Safety officer.
Once the Critical Load Data Sheet is prepared it should not be necessary to revise the
document in the future and can be submitted as part of subsequent Rig Move Plans.
Each Critical Load Data Sheet MUST be accompanied by a site specific Critical Lift Plan
illustrating how the lift shall be conducted safely (a previous Critical Lift Plan can be used if
no changes to the positioning of the rig equipment is different and the placement of the
crane is the same).
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5) Pre-trip questionnaire;
6) Vehicle daily checks;
7) Roles and responsibilities of the Key people involved in the journey management plan;
8) Weather conditions;
9) Contacts Numbers in emergency
10) Mounting of monitoring system in all contractual rig vehicles and review the report on regular
basis GWDC Kuwait & KOC Driving Policy
Rig Move Plan should follow the KOC guidelines with- Number of days, distance of
move, scope of work, rig move sub-contractor details, personnel involved in rig move,
shift crew details, detail of road crossings/ fencing crossing sequence of move,
specification and number of material handling equipment, Rig move emergencies, risk
control etc.(Refer to Attachment ZU-Well to Well Rig Move Plan)
Emergency
S.N. contents old location new location Respon call Remark
se by
Transportation
Company
1 Crane 50T*2 50T*2 Operation
Dept.
Transportation
Company
Operation
2 Forklift 5T*1 5T*1 Dept.
Transportation
Company
3 Trucks 6*flat truck+6*low bed Operation
Dept.
1 Admin Dept.
5 Mini-bus
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HSE-RSRMP/GW103/R-2.0
Transportation
Company
Operation Dept.
2 Forklift 5T*1 5T*1
Transportation
6*flat Company
3 Trucks *flat Operation Dept.
truck+6*lowboy
4 pick-ups Admin.Dept.
5 Mini-bus Admin.Dept.
9 Food 50 50
persons persons
10 Internet Admin.Dept.
service
11 Medic Ambulance and Medic
Nurse
12 Carrier TBC Operation Dept.
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15.0 REFERENCE
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Attachment K Emergency
Attachment T HSE-L2-079-PPE
Attachment U HSE-L2-077-JSA
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Attachment ZS GWDC-HSE-ATT-DW06-RIG_Daily_POB
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