DRILL FLOOR SAFETY

Best Practice Guide

to Handling Tubulars
Introduction / List of Contributors 2

1. Pre-Job Planning 3

2. Toolbox Talk Onsite Risk Assessment 7

3. Executing the Job 10

4. Post Job Analysis 15

5. Supervisors Tips 17

6. Resources 19

7. Background & References 20

Revision No. 1-2003 1

 In November 1998 a workgroup consisting
of cross industry representatives reviewed
incident reports relating to handling
tubulars on the rig floor. Underlying causes
of incidents were listed and recurring ones
ranked. Using this ranked list, a
questionnaire based on ten common, but The rig floor is still one of the most
different, incidents was devised. Each of dangerous place on a drilling rig, and those
the incidents occurred due to one or more who took part have made a valuable
of the ranked underlying causes. After contribution to improving rigfloor safety.
considering a description of the incident,
Step Change are aware of areas outwith the
the reader was asked to describe how his
Rig Floor where handling of tubulars have
rig team - or company systems - currently
resulted in injury to personnel, however the
prevented this type of incident.
intent of this booklet is to focus on the areas
The questionnaire was enthusiastically
of concern as highlighted by the responses
received and Step Change would like to
received in the industry questionnaire.
thank the respective companies for their
The information contained in this booklet
contribution. The material in this best-
will be of use, not only at safety meetings
practice guide is taken from the replies and
and toolbox talks, but also for presentations
tips that came out of the returned
and personal use. Also its contents can
questionnaires. These replies have been
play an important part in rig floor
categorised into five distinct stages:
competence and assessment.
1. Pre-Job Planning
List of Contributors
2. Toolbox Talk Onsite Risk Assessment
• Global Santa Fe • ConocoPhillips
3. Executing the Job
• Maersk Contractors • Shell
4. Post Job Planning
• Noble Drilling • BP
5. Supervisors Tips
• Transocean • KCA/Deutag

• Diamond Offshore • Franks UK Ltd

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1.1 Ensure Toolbox Talks are held

Toolbox talks are an ideal method of

capturing and communication of safety
issues at the worksite. Variation in who
leads the discussion is seen as a plus and
there is a growing acceptance throughout
the industry that a Toolbox Talk is seen as
an integral part of the risk assessment
process. During the Toolbox Talk the risks to
each individual involved in the job should
be considered and discussed.

1.2 Rig Specific Procedures should

be in place to cover all aspects
of the operation.

These procedures are seen to be the

essential starting point for an effective
Toolbox Talk and Risk Assessment.

The procedures should be of such quality

to be useable and easily understood during
the Toolbox Talk.

1.3 Hold 10 minute Pre-Job Talk

prior to any operation

Pre-Job Talks should be unique for every

operation. They should draw on previous
experience from similar operations and
learning points from other rig crews, and be
given where the full participation of all team
members can be obtained (old experience
and new experience). A new set of eyes
can sometimes highlight hazards
3
 overlooked by experienced hands who 1.6 Solid Teamwork is Essential
carry out the repetitive tasks under
constant, normal operations. Solid/experienced teamwork is vital to safe
operations. Teamwork is the basis for good
1.4 Time Out for Safety Culture communication and vice versa, good
should be in Place communication during the operation
significantly contributes to a safe working
A well embedded “Time Out for Safety” environment.
culture helps to
significantly reduce 1.7 Keep Rig Floor as Clear
risks by allowing as Possible
all members of
the workforce to The rig floor should never be ‘overloaded’
make an or ‘congested’ with tools, equipment or
individual people. Both supervisory and tubular
assessment that a handling personnel should be made aware
situation needs to be stopped of the potential problems inherent with
and discussed before the overloading and congestion and use good
operation continues. housekeeping techniques to avoid them.
Remove all excess equipment as soon as it
1.5 Communication Needs to be is no longer needed. Keep to hand only that
Free-flowing which is required.

There must be a free flow of communication 1.8 Allocate Sufficient

between the Driller, Floormen and Storage Space and Use It!
Derrickman and any other concerned
parties i.e. Casing crews. The Driller should Allocate enough storage space on the pipe
also have a clearsight of the complete deck, etc., for equipment storage, and
operation on the rig floor as well as at ensure that everyone knows where things
monkeyboard level. Communication is the are supposed to be kept. Develop a culture
most powerful tool for good, safe of putting things in the correct storage
operations. Raise your concerns if you’re space as soon as they are no longer
not sure of anything! required.

4
1.9 Create a Good Housekeeping areas where a fall from the drill floor is
Attitude possible.

Plan sufficient time to clean and tidy up 1.12 Individual Competence is a

during the operation. Create an atmosphere Major Contributor
where tidiness is expected and not
considered ‘nice to have’. Remember, Individual competence is seen as a major
tidiness is an integral part of the job. contributor to rig floor safety. Competence
systems need to really establish individual
1.10 Plan Equipment Requirements competence and not just satisfy the legal
Well Ahead requirement. Individuals must feel able to
say when they do not feel competent to do
Discuss as part of the Toolbox Talk/Risk a job. Good supervisors should know the
Assessment what equipment is needed strengths and weaknesses of their team,
and what isn’t required on the drillfloor. Use and not ask someone to do a job for which
flush mounted slips to keep the rig floor they are not qualified or competent. The
clear of bulky and unwieldy work platforms issue of competency should be raised
which only add to rig floor congestion. during all Toolbox Talks and Time Out for
Ensure that there is adequate detailed Safety meetings
planning well ahead of the operation of
what equipment is required and when. 1.13 Use Experienced Roughnecks
Personnel should be encouraged to plus only one ‘Green’ Hand
challenge the need for back up equipment at a time
to be readily available on the Rig Floor.
Consideration should be given to stowage Encourage a buddy system. It should
of back up equipment in other areas always be the case that experienced
throughout the installation. personnel form the basis of the team. (This
applies in all operations). All personnel
1.11 Draw and Stand in Quadrants should be made aware of the requirement
on Rig Floor to look after the green hands and
conversely the green hands should be
Develop safe area “map/quadrants” which given the tools and forum to recognise their
can be utilised to highlight hazardous and experience/knowledge limitations within the
safe areas on the drill floor. This can be operation. It’s often the case that new, keen
used as an overview tool in safe positioning personnel will try to carry out operations
training techniques e.g. highlight positions without full knowledge and experience. Use
where equipment is moving overhead or reliefs only for simple tasks, and preferably
5
 don’t use Roustabouts at all (i.e. Floormen the joint enters drill floor.
should break in shifts if there are sufficient
available). However, if Roustabouts must be • The use of inflatable casing protectors is
used, use them for the least hazardous also recommended as they don’t just
tasks and preferably not during BHA protect the threads of the pipe, but also
(Bottom Hole Assembly) work. Derrickmen restrict the rope from dropping off the
reliefs should be Floormen who are bottom of the pipe as it is travelling. Many
properly trained to be Derrickmen. of the manual handling problems
discussed here are eliminated when pipe
1.14 Training is of Vital Importance is tailed using a small winch located near
the V-door. Some rigs already use these
In terms of experience, training is an issue winches which are relatively cheap. More
not so much in the competency arena, but sophisticated controlled feeding winches
more so within actual hands on knowledge are now also available.
and time with respect to the handling of
tubulars and associated hazards on the drill
floor. The training directed at the
‘experience’ level should build upon
people’s own existing experience of tubular
operations. It is also worth noting that for
green hands, mentoring by experienced
hands who share their knowledge is an
essential part of green hand training.

1.15 Investigate and Incorporate

New Ideas

Investigate and incorporate new ideas, for

example:

• Have casing suppliers paint a band

around joints of casing approximately 10
feet from the end of the joint. This will
enable the Driller to better time the entry
of the joint into the drill floor, which in turn
will enable him to control the rate at which
6
 • Vary the discussion leader to encourage
participation from all members of the
team

• Use the toolbox talk to make all those,

both directly and indirectly, involved in
the operation fully aware of the total job.

• Encourage all crew members to get

actively involved in the TBT, by adopting
a constructive and questioning
approach.

• Use the TBT to get ‘buy-in’ from all crew

members to the approach to the job.
These days, more often than not, risks of a
• Ensure all crew members know their role
job are assessed during the Toolbox talk.
in the job.
That’s why many contractors now use
TRICs (Toolbox Talk Risk Identification • Highlight the fact that everyone has an
Cards) and seldom mention the words obligation to act as a lookout/observer to
‘Toolbox Talk’ (TBT) by themselves. warn others of danger.

In the following pages you will find some • Encourage crew members to call for a
generic Toolbox Talk tips followed by more ‘Time Out for Safety’ at any point in the
specific risk assessment tips. operation, if any aspect of the work is
unclear or considered hazardous.
2.1 Toolbox Talk
• Commit to repeating the TBT if the job
• Ensure sufficient time is given to the changes in any way (weather, equipment,
preparation of the toolbox talk. plan, sequence crew make-up etc.)

• Use written procedures and risk analysis

as the basis of the talk.

• Have appropriate levels of supervision

present during the Toolbox Talk

7
 • Be explicit in the TBT about the • Ensure a common understanding
techniques to be used for handling pipe:- amongst crew members of all
• Mechanical means or aids such as rope communications methods e.g. radio call
should be used to manoeuvre tubulars signs, hand signals etc. particularly for
whenever possible. those working aloft in the derrick e.g.
pipe stabbers working on the stabbing
• Never grip a pipe with fingers around it, platform. Take particular care to ensure
and keep fingers safe by:- reliefs are fully aware of the agreed
• Crossing hands and pushing pipe away communications.
from you
• Clenching hands • Ensure casing contractors equipment
checks and rig-up (especially the
• Holding pipe with palms only
stabbing platform), are covered, and
understood by all.

• Make a proper note of the TBT and any

key points raised. Get all involved to
acknowledge attendance. Discuss start
up of operation with caution, until all
personnel are comfortable with their
individual task.

2.2 Risk Assessment

Be satisfied that the following questions can

be suitably addressed otherwise complete
a full risk assessment.

• Do supervisors/crew members have

• Using two people for stabbing operations. sufficient Risk Assessment knowledge
and training to carry out effective Risk
• Make everyone aware of green hands Assessments? If not, consider/request
and ensure a buddy is assigned. additional training in this essential skill.

• Ensure the rig-up and down of equipment • Are written procedures available for the
is fully discussed, as well as the operation Tubular Handling task?
itself.
• Are the procedures relevant and up to
8 date?
• Is there anything about the conditions • Have all necessary equipment to hand,
prevailing e.g. weather, crew make-up, and checked and serviced.
equipment condition, tubular type etc.,
which might make the procedures invalid • Ensure rig-up and down of equipment is
for this operation? assessed for risks, as well as the
operation itself.
• Have all hazards been identified?
• Communicate fully and comprehensively
• Have all hazards been assessed? to all crew members.
• Look for opportunities to improve
• What controls are in place/are required to
communications
reduce the hazard?
• Test for understanding of all team
• What are the recovery possibilities if a members
hazard is realised? • Consider rotation of crew members, and
use of a “Take 5” break
• Are the crew involved, competent for the
work identified? • Use Toolbox Talk as the primary (but not
• Are sufficient crew available (including only!) tool for communicating work plans
reliefs) for the job? and intentions.

• Are there “green hands” involved, and if

so who is identified to coach and look
after them?

• Has suitable time for training/coaching

been allocated if required?

• Are supervisors aware of training/

assessment of crews?

Is the workplace as tidy as it can be for the

start of a new task e.g.

• Remove all excess equipment

• Clean rigfloor to reduce slipping hazard For a full risk

assessment refer to the Step
Change in Safety ‘Task Risk Assessment’
guide. 9
 Reliefs should:

• Have a strong interest and have the right

attitude to take on the role of relief

• Report to the Driller prior to relieving

• Be open and declare when they don’t feel

confident

• Be identified by a special helmet (green

colour) or jacket

• Initially only concentrate on one facet of

the job.

Regular Team Members should:

• Highlight during the Toolbox Talk that a

3.1 Ensure Reliefs get a Good
relief is present
Handover
• Treat reliefs as high risk and with caution
Let reliefs watch the job in hand first. Then
one of the regular team members should • Driller should slow down operations and
explain the job clearly to them, describing be vigilant
all possible hazards and warning them of
any danger. If the ongoing job is hazardous • Assign one competent crew member to
then stop the job and hold a Toolbox Talk look after (mentor) the relief until the relief
prior to the relief taking over. In other words, is fully confident and competent
make sure that the relief isn’t thrown in at
• Continually coach the relief (preferably
the deep end!
one-on-one)

• Scrutinise the relief well, take time to

determine the knowledge and skill level
of the relief and assign tasks accordingly.
If Roustabouts must be used, use them
for the least hazardous tasks and
preferably not during BHA (Bottom Hole
Assembly) work. Derrickmen reliefs
10
 3.3 Communication Needs to be
Excellent

Does your team need to improve

communication? Refer to 1.5.

3.4 Keep the Rig Floor as Clear as

Possible

Make both supervisory and tubular

handling personnel aware of the potential
problems inherent with overloading and
congestion!

3.5 Keep the Work Area Clear

Prior to tripping operations, clear the space

should be Floormen who are properly of all equipment not required for the
trained to be Derrickmen. operation and ensure that there are no
slip/trip hazards present. After breaking
3.2 Maintain a Clear Line of Sight
connections place the mud bucket, tongs
for the Driller or iron roughneck well out of the way. Clear
This doesn’t mean that you should stay out a path from the V-Door to the rotary table to
of his sight! There must be a free flow of ensure free passage for joints tailed and the
communication between the Driller, person tailing joints. As room is limited
Floormen and Derrickman. The Driller during casing operations it’s vitally
should also have a clear sight of the important that all space available is clear
complete operation on the rig floor as well and utilised. Remove all excess equipment
as at monkey board level. Personnel should as soon as it is no longer needed. Keep to
be made aware of the problems associated hand only that which is required. Do you
with the Driller’s restricted view. It is also allocate sufficient time to clean up as and
essential that the Driller maintains when required? Clean during regular stops
communication with the tubular handling after each sequence of operations. At least
personnel and highlights any visibility every trip there should be an assessment of
what is and isn’t needed, and time taken to
problems within the operation
make any adjustments to tools and
equipment required.
11
 3.6 Time Out for Safety 3.9 Use the Right Method

If anybody at any time is not sure of their Allow the rope to slide through your gloved
task, is uncomfortable with the operation in hands - don’t try to hold the weight as the
anyway, or observes an unsafe act or rope takes the bite. Gradually increase
situation, - then STOP!! Take time to pressure on the rope as it passes through
discuss and correct the situation before your hands until it stops where you want it
continuing. to (this method is for use with lighter pipe).

3.7 Positioning needs to be taught 3.10 Use a Rope along

via Training/Buddy System with a Shackle
All personnel need to be aware of Safe When tailing in from the V-Door, secure the
Positioning in relation to tubular handling. It dead end of the rope to one side of the V-
is also important to emphasis the buddy Door and thread the rope through a shackle
system approach, whereby personnel alert attached to the opposite side of the V-Door.
each other of potential danger areas and When tailing heavy casing into the floor, use
appropriate safe areas. a double wrap of rope on the shackle to
increase friction.
3.8 Use Rope to Restrain Pipe
3.11 Use Flush Mounted Slips
Tie the rope onto a high securing point to
prevent the rope slipping off the bottom of Do you use flush mounted slips to keep the
the pipe being tailed in. Check that the rope rig floor clear of bulky and unwieldy work
is double wrapped around the other platforms?
securing point when heavy pipe is being
tailed. Always replace worn or mud 3.12 Beware of Temporary
contaminated rope. Take the time to learn Equipment
how to tie and use proper knots such as:
Temporary equipment, because of its very
the Bowline and the Round turn and two
nature, MUST undergo pre-operational
half hitches.
checks. On your rig there should be a
temporary equipment system in place: the
best systems include manufacturer’s and
regularly updated rig contractor’s check
lists. These check lists should be reviewed
during the post job review, and updated if
12
required. Prior to using this equipment also 3.15 Always Beware!
check the Certificates and ensure they will
not run out prior or during the use of the Pipe can bounce off like a spring if it strikes
equipment. a racked pipe. If it looks as if the guided
pipe will swing hard against racked pipe
3.13 Concentrate on the Job then LET GO, and stay well out of the way.
Very few people can restrain a “wild” pipe
Supervisors - do you notice when crew so DO NOT TRY!!
members ‘drift’? It’s vital to give people a
break or change out team members when 3.16 Load Hoisting Operations Tips
they lose concentration.
• Clearly identify roles of staff when lifting
3.14 Supervisors should encourage and hoisting, including that of an
Feedback observer.

Do you encourage team members to speak • The observer should frequently look up
up and listen to what they have to say? during the lifting operation.

• Lower the load if/when the lift snags.

• Prior to leaving his position, the

derrickman should close all monkey
board fingers.

• Always stay clear of suspended loads.

• When pipe is being lifted by a sling,

ensure slings are always double wrapped
around the pipe. Single wrapped slings
can slip with potentially disastrous
consequences.

13
 3.17 Individual Competence Teamwork Tips

Individual competence is seen as a major TEAM stands for TOGETHER EVERYONE

contributor to rig floor safety. Competence ACHIEVES MORE! Looking after each other
systems need to really establish the level of is an essential aspect of safe teamwork,
individual competence and not just satisfy which must be practiced throughout rig floor
the legal requirement. Individuals must feel activities. Teamwork means making sure
that they can say when they do not feel that all work areas, escape routes and
competent to do a job. Good supervisors emergency equipment are clear at all times.
should know the strengths and weaknesses Teamwork also means communicating more
of their team, and not ask someone to do a than you think you need!
job for which they are not qualified or
competent.

14
 4.2 Create an Open Culture

Supervisors should foster and develop a

culture where operations are discussed
openly between all crews, so that the entire
rig team develops and progresses.

4.3 Take Time to Review

At the end of an operation a debrief or

‘wash up’ meeting should occur. All parties
must discuss report both successes and
failures. Supervisors should talk to all the
crews, floor hands, deck crew, service
hands and so on. Establish how they
thought the job went. Ask open-ended
questions to gain maximum information:
Who? - What? - Where? - Why? - When? -
How?

• What do you think happened?

• What worked well?

• “How did it work best?”

4.1 A Place for Everything
and Everything in its Place • “Why did it work?”

Develop the habit of cleaning all tools and • What did not work well?
equipment after each job and putting them
back in their correct places. If something is • Why did it not work well?
damaged, worn or needs replacing, fix it • What can we do to improve next time?
before you put it away. If you don’t have the
time or spare parts, make a note in the
Handover Book so that everyone knows -
then it won’t be an unwelcome surprise next
time it’s needed!
15
 4.4 Learn from the
Team’s experience

After all, together you did the work you all

planned! Incorporate constructive ideas
into future plans, re-think areas the team
constructively criticises.

4.5 Standardise and Incorporate

New Ideas

Keep a tally of what worked well and what

needs improvement. Incorporate these into
the next planning or Risk Assessment
exercise to ensure that a culture of
continuing improvement is created. To
make sure everybody learns, share these
ideas with both your back to back crew and
the crews on field break. PLAN, EXECUTE,
MEASURE & LEARN

16
 • Supervisors should be suitably
experienced. Regular assessments of
supervisors’ abilities, job knowledge,
strengths and weaknesses are required to
ensure that the highest levels of
supervision are maintained. Risk
assessment skills are an essential part of
a supervisors capabilities. Where a
weakness is identified, training should be
given to rectify the situation.

• Supervisors should ensure full

participation in Toolbox Talks,
encouraging crews to actively contribute
5. Supervisors Tips in discussing all aspects of the actual
• Good supervisors are the catalysts for method of performing the task. They
enhancing teamwork and should ask questions of the work party to
communication. Experienced, positive identify their levels of experience and job
supervisors who can communicate the knowledge. Planning as a team should
hazards, risks and instill the culture for help identify all the known hazards and
‘stepping back’ assessing the operation cultivate new ideas. This in turn should
and taking the necessary actions to promote teamwork as success is
ensure safe operations are essential. achieved.

• All supervisors must lay the foundation for • Supervisors should allocate sufficient
the crew to perform tasks by fully time for feedback at Toolbox Talks and
explaining what is required to complete that the TBT leader is rotated.
them. All available information, materials • Supervisors should encourage team
and tools must be identified prior to members to speak up and listen to what
starting the task. they have to say. Supervisors should use
• Supervisors should lead by example: they the experience of the workforce to
must be aware of all procedures and expand their own job knowledge. You are
regulations concerning the task and pass never too old to learn!
this information on to the work force. • Mentoring or Buddy Systems are much
valued by rig crew members: 17
 • The mentor can assist the supervisor in use crew rotation or a “Time out” break to
the assessment of a person’s effect an improvement.
competence
• Supervisors must provide good quality
• The mentor can assist in the recording of
instruction and guidance.
progress in the log book or competency
passport • Supervisors must allow the not-yet-
• The mentor can assist in the identification competent person to carry out only
of further training needs simple tasks on the rig floor until he is
deemed to be more competent.

• The rig floor supervisor must be involved

in the assessment of a person’s
competency.
• A person’s competence can only be
effectively assessed by means of
thorough observation.
• An assessment must also consider a
person’s experience, ability, knowledge
and skill.
• The buddy system can be put to good
effect if experienced personnel Training Tips:
communicate with one another and, more
• Adequate time must be allowed for
importantly, if experienced personnel
training
communicate with green hands. This is
important! • Training needs must be identified by the
supervisor and/or mentor
• The appointment of a lead roughneck on
the rig floor is seen positively on some • Records of training and assessment must
rigs. It is essential that they are well be maintained (e.g. a log book or
experienced and have the respect of the passport)
crew.
• Refresher or repeat training needs must
• Individual alertness will always play a part be considered
in safety standards. Supervisors need to
• A mentor should support the provision of
be on the lookout for drifting attention due
on-the-job training
to complacency or excessive stress, and
18
The following information posters relating
to drill floor tubular handling operations
are available for download from the Step
Change in Safety website.
www.stepchangeinsafety.net

Manual Tongs: - Do’s and Don’ts

Manual Tongs: - Rig Floor safety

Power Tongs: - Rig Floor safety

Toolbox Talk:- Crew involvement posters

19
 In January 1998, 56 international drilling The result is a global drilling safety
professionals, representing 23 operator leadership campaign. The aim of this
and drilling contractor organisations campaign is to create a permanent cultural
convened in Houston for the first global, change in safety throughout our industry.
industry wide drilling Safety Leadership Regional work groups have been formed to
workshop. These leaders represented a develop plans of action for achieving a step
cross section of operators, drilling change in safety in their area and a steering
contractors and service companies. They group has been formed to help continue
created the Houston Declaration which is a the effort. Common themes form the
formula for ‘step change’ based on backbone of strategic plans. Five common
personal commitment, leadership and themes which emerge are:
behaviour:-
Safety Leadership - common principles to
“We pledge our commitment to work provide consistency
together to achieve a Step Change in safety People - common expectations and
performance in all the areas where we have standards
activity. We believe that a ‘step change’ in
Behaviour - cross industry networks sharing
safety can be achieved through personal
information
commitment, leadership, the way we
behave and the way we work together” Training - common training standards and
Houston Declaration 29th January 1998 competency levels
Procedures - common performance
measures and benchmarks

http://www.stepchangeinsafety.net is the
website of the Step Change in Safety
initiative. There are a large number of
excellent resources available from the site,
both drilling specific, and more general
safety tools and improvement ideas.

20
 website www.stepchangeinsafety.net
email info@stepchangeinsafety.net
telephone 01224 881272
fax 01224 882350
address P.O. Box 10406
Aberdeen AB12 3YL