Safe Practice

HSE MANAGEMENT SYSTEM
SAFETY
Chapter – 5
SAFE WORK
PRACTICES
Doc. No. ONGC/CHSE/51/HMS/Ch 5.0 March 2013 Page 90 of 567

SAFE WORK PRACTICES

SAFETY
Chapter – 5
SAFE WORK PRACTICES
1. DRILLING OPERATIONS:
1.1. SAFETY DURING RIG BUILDING/ DISMANTLING SYSTEM
Rig building operations involve dismantling of the structures in old location, transportation and erection
of the same at new location.The job involves handling of heavy loads upto 20-30tons using various
heavy material handling operations, transportation from location to location involves extreme risk
because of the extreme conditions and difficult terrains.
In ri g b uildin g th e ris ks of a c cid ent ar e th e re fo re invol ved in :
Use of heavy material handling equipment.
Transportation of heavy equipment from one location to another location. Rigging up
operations involve risks associated with work at height, handling tools in awkward
positions, danger of falling object on workers on the ground.
The recommendationsl i s t e d b elow serv e as a guid e for minimiz in g h azards d uri n g rigging
up and di smantlin g o perat ions.
1.1.1. Rig Dismantling
i. Chec k all she av es an d sh aft s o f t he hoisti n g s ys tem (z in pol es , hoisti n g sheav

es, equ aliz e r sh e av e, cro wn bl ock sh ea ves , t ra velin g blo ck she av es ) .
ii. Chec k all th e li ftin g ropes , casi n g lin es an d cl amps fitt ed o n lifti n g ropes.
iii. C hec k d ra w wor ks b r ak e, edd y c ur re nt b ra ke, h yd rom atic br ak e.
iv. Use Zi n pol es or M o le tru cks for dr a ggin g t anks and h e av y e quipme nt in
slush y ar ea s.
v. Gr eas e all t he th re a ded j oints an d cov er with t hr e ad p rot ect ors, gun n y b a g an
d pol yth en e to pro te ct j oints d urin g tran spo rt ation.
vi. Chec k t he lifti n g hoo ks f or a n y c ra cks o r d ama ge du rin g lifti n g and lo adin g. Do not
fix slin gs on an y oth e r ex tension s o r pip es, which ar e n ot meant for li ftin g.
1.1.2. Rigging Up
i. Do n ot mov e equi pm ent o ve r th e he ad of wor kin g pe rson nel du rin g ass embl y o f r i
g compo nents.
ii. Alw a ys use sa fet y pi ns, che ck nuts on f ast enin g d evi ces .
iii. Do not allow una uth oriz ed p e rson nel wit hout sa f et y kits o n r aise d str uct ur es
o r plat form s.
iv. Chec k liftin g rope for kinks, damage du e to an y fallin g o bjects o n wire rop e. Check
spelt er soc ket s, clam ps an d w ed ge bl ock s for an y d ama ge or c ra cks be fo re fix

SAFE WORK PRACTICES

SAFETY
in g the li ftin g ro pes.

v. C hec k quick releas e valv es of draw wo rks befo re hoi stin g the mast.
vi. Chec k for pr op er l oa d on th e amm ete rs, l oa d met er b efo r e r aisi n g the m ast .
vii. Perso ns not con ne cte d dir e ctl y with the jo b sho uld b e m ov ed b y at l e ast 1 0 mts f
rom the rai sin g m ast .
viii. Eve r y one invo lve d s hould kno w ho w to st op d ra w w ork s in c as e o f eme rgen c y.
ix. Test ri g pn eum atic s ystem at p r essu re 1.5 ti mes mo r e th an wo rkin g pr ess ur e.
x. Keep cr own en d o f th e d errick at level wit h the subst ru ctu re to minimize st rai n on
derri ck/m ast at th e ti me o f initi al li ft.
xi. Alw a ys wait until t he m ast h as com e t o a compl et e rest b efo re goi n g n e ar a
fr ame/ pe dest al fo r fixing of st a y bolts/pins.
xii. Le a v e no loos e to ols/ bolts o r an y oth er m at eri als on th e m ast m e mber s w hile raisin
g mast.
xiii. Raise mast ab out 3 0 cms abov e th e s addl e , ch e ck conditi on o f t he foun dati on
bolt s for an y c ra ck s, or si nkin g of foun dati on itself . Lower back the mast, r est
on th e saddl e and r ais e a ga in .
xiv. Raisin g of ma st sh all be d on e in a sl ow spe ed in th e lo west gea r.
xv. De rri ck d esi gned wit h gu y ro pes s hould be fast en ed wit h ste el gu y rop es. E a ch
gu y rop e s hould h av e a s e par at e d e ad en d f or a ncho rin g. Ens ur e th a t gu y ro pe is
fr e e o f kinks, cuts or an y oth er dam a ge b efo r e usi n g it a nd r epl a ce wh e n suc h obs
e rva tions oc cur r ed.
FO R MOBILE RI GS
i. C hec k th e h yd r auli c s ys t em fo r an y ai r tr ap s be fo re r aisin g th e m ast.
ii. Alw a ys dise n ga ge th e h yd raul ic pump be fo r e l eavi n g t he co nsol e.
iii. Press ur e in th e h yd r a ulic s ys te m sho uld no t be m or e th an stipul a ted p ressu re.
1.1.3. Rig Skidding Operation (Onshore)
On l and ri gs us ed to be skid de d f rom l oc atio n to loc ation usin g cr awl e r

pads.This pr a ctic e has b ee n sto pp ed l o n g b ac k. W ith th e la yin g off o f all su ch
ri gs scope fo r s uch op er ations is elimi nat ed. At p resen t elect rical ri gs and m
obile ri gs are b ein g s kidded for d rillin g cl uster lo cations at aistan ce of max imum
up to 15 mts. This ch apt er cov ers th e safety aspects th at n eed to be look ed into be
fo re t aki n g u p such op e rati on.
i. Break o ff and la y d o wn all th e drill st rin g and oth er h eav y arti cles b e fore startin g
an y skiddi n g o pe ratio n.
ii. Ensu re ri g to be fr ee fr om an y m e ch anical connections, i nterf eren ce wi th soi l or
foun dati on (Rat hol e, mouse hol e to be rem oved ).
iii. C lea r a re a all a roun d the ri g st ru ctu res o f mate rial s, c rud e oil, slush etc. to avoid
injur y to wor kin g pe r sonn el.
iv. Disc onn ect all gu y ro pes (i f a n y) , top ma n esc ap e lin e an d an y o ther i e ro pe s on
the mast.
v. In te r conn e ct th e t wo sub b as e st ru ctu res w ith c ross ti e m emb ers (w eld ed or pin ne d)
to av oid rel ativ e m ov eme nt.

SAFE WORK PRACTICES

SAFETY
vi. Ex tend el e ctri c al su ppl y c onn ecti on to dra w w ork s pow e r and dis co nn ect
th e rem ainin g w hile skid din g.
vii. Disconn ect al l th e ri g inst rum ent ation cables ex ten din g from the ri g to t he oth er
equipm ent .
viii. Ex tende d f ound atio n shall be in l ev el wit h the m ain fou nd ation.
ix. Skiddin g an cho r s ho uld b e grout ed withi n the ex ten de d f oun dation but not as
a separate block.
x. Ex tend all ea r thi n g c ables also.
xi. Chec k for a n y su bstr u ctur e m emb e r int er f er e wit h th e X-m as t re e.
xii. Ex tend cas in g li ne f ro m the spool f or ad equ ate len gth.
xiii. Allow no una utho riz e d/unw ant ed pe rson nel eith er on t he de r rick floo r o r n e ar
the ri g winc h, s kiddi n g th e ri g.
xiv. Le a v e no loo se tools or equi pme nt o n d e rri ck, as th er e i s d an ge r of i njur y to p ers
ons wor kin g bel ow t he derri ck floo r.
xv. Spee d o f sk iddin g s hould be s yn ch roniz ed to minimiz e vib r ations on the ri g
stru cture.
1.2. BLOWOUT CONTROL EQUIPMENT AND PRECAUTIONS
Duri n g th e p ro c ess o f d rillin g an d tri ppin g op er ation s in a well en cou nterin g of abno rm
al pr essu r e co nditions , mud loss , swab bin g o r r edu cin g of mud column d ue to inad equ at
e fill up i n the hol e lead to und er b alance situ ation w hich m a y i ndu ce a kick sit uati on a nd
in cas e p rim ar y cont rol of mud h yd r ost atic an d se cond a r y c ont rol of sur f ac e eq uipm ents
consistin g of w ell he ad an d BOP etc . is lost, a blow out m a y oc cur , w hic h is th e w orst a
cci de nt th at c an oc cur in su ch an op er ation. Th e fa ct t hat Blo w out h as o ccurred in onl y
sm all p ercentage of t he wells dri lled till tod a y is d ue to the e ff orts ma de b y the pet rol eum i
ndust r y fo r "w ell contr ols ".
A blow o ut is usu all y ac comp ani ed b y fir e and ex plosion. T he wor ke rs a r e ex pos ed to
ser ious d an ge r to t heir li ves , bu rns a nd poisoni n g. Th e h eat dest ro ys th e d er ri ck and inst
all ations .If t he ga s gushin g out f r om the w ell doe s not cat ch fi r e, the r e is also a risk of
ex plosio n.
Prev enti on o f t his dan ger rest s p rim aril y o n control o f an y ki ck in th e w ell bo re . A kick
means entr y o f formation flui ds into t he w ell bore in large enou gh qu antit y to req uire s
huttin g in t h e w ell und er press ure.It is p ossibl e t o d et ect th e ki ck. O nce the ki ck is d ete ct
ed, s teps can be t ak en to c ontrol ent r y o f fo rm at ion flui ds into th e wellbor e b y ov er b ala
ncin g th e ex pect e d bottomhol e pr ess ure with pr ope rl y condit ion ed mud an d install ation
o f sa fet y valv es. If th e e arl y si gns of a ki ck in the well a re i gno r ed, it m a y l ea d to a blo w
out , whi ch i s vio lent a nd unc ont rolle d flow of oil/ gas f rom a well bor e.
All prec auti ons in res pect of follo win g sh o uld be t ak en on all th e ri gs fo r det e ction of ki ck
in tim e and co ntrollin g th e well .
Prop er i nstr ume ntati o n like fl ow m et er wit h al arm in ch ann el, m ud vol ume

SAFE WORK PRACTICES

SAFETY
totalizer withalarm and trip ta nk.

Use of pr op er an d st a nda rd well c ontr ol eq uipmen ts, rin g ga ske t s,c ontr ol uni
ts etc .
Prop er upk ee p o f th es e equipm ent b y r e gul a r ma inte na nc e.
Prop er p r essu re t esti n g o f BOP equ ipme nts with w at er and i n ga s wells with
gas and wat er .
Re gul ar fu ncti on t esti n g o f BOP sta ck.
Condu ctin g r e gul a r BOP d rills fo r dif fe rent co ndition s like while d rillin g,
whil e trippin g d rill coll ar in prev ent er and strin g out o f hol e.
1.2.1. BLOWOUT PREVE NTERS (BO P)
When p rim ar y cont ro l of a w ell is lost du e to insu ffici ent h yd r ostati c p r essu re , it
becomes n ecess ar y to seal th e w ell b y som e mean s to p revent an uncontrolled fl
ow, or bl owo ut, o f fo rmat ion fl uids. Th eeq uip ment, whi ch se als t he well , is c alle d
th e blowo ut p re vent e r.
A. TYPE S O F BO Ps
Ra m typ e B O Ps
Thes e ar e desi gn ed to clos e th e wel l wit h t he h elp of r am ass em blies. H ow ev er, th e
siz e of th e r am ass em blies s houl d mat ch wi th the siz e o f d rill st r in g on whi ch ram
s ar e cl os ed. Th es e t ypes o f BOP s ar e also equip pe d with Blin d R ams ( whi ch
c an shut in o pen hol e), S he ar R am ( whi ch can she ar of f th e stri n g and clos e th e
w ell ) and V ari abl e Bo re R ams, whi ch can b e o per at ed on a gi ven ran ge o f d rill
strin g (e.g. 2-7/ 8" to 5").
Annular BO PS
Thes e a re d esi gn ed t o cl ose th e well on an y sh ap e and siz e of d rill stri n g.
In eme r gen c y it c an ev e n clo se the op en hol e.
String BO Ps/ Insid e BOPs
Thes e ar e d esi gned to be in stall ed on d rill strin g t o sto p th e fl o w, w hen th e w ell is
flowi n g th rou gh th e drill st rin g. So me o f strin g BOPs are K ell y co ck, NRVs , Fast
Shut of f cou plin gs , D rop -inch e ck v alv es e tc.
B. COMPONENTS AN D NO ME NCLAT URE O F BO P EQ UI PMENT
Blo wout pr ev ent er s ystem consi sts o f:
1. BOP sta ck
2. Choke lin e
SAFE WORK PRACTICES

SAFETY
3. Kill lin e
4. Choke a nd K ill m anif old
5. Closin g u nit
6. Divert er an d aux iliar y equi pment
BOP CO MPO NENT S ARE I DENTI FIED WITH FOLLO WING CODE S
A = Annul ar BOP (Sph eri cal t yp e)

G = R otar y st ripp er h ead
R = S ingle ram t ype pr ev enter
Rd = Doubl e ram t yp e p r ev ent er
Rt = Triple ram t ype preventer
S = Drillin g sp ool with si de o utlet s for co nnect in g chok e and
kill lines
M = 70 k g/ cm2 (1 ,000 psi ) rat ed wo rkin g p re ssu re.
C. BOP SELECTION CRITERI A

Fo r s el ectio n o f a BOP to b e us ed follo win g poi nts must b e t ak en i nto consi de ration.
1. Max imum ex pe ct ed w ellh ead p res sur e.

2. Size of casi n g, casin g han ger, bit an d ot her drilli n g t ools to b e l
owered t hro u gh the BOP sta ck .
3. Substru ctu r e h ei ght i. e. gap bel ow rot ar y t a ble from groun d l eve l .
4. Matc hin g fl an ge c on ne ction a c cor din g to siz e and pr essu r e r atin g
o f well h ea d flan ge .
5. Servi c e envi ronm ent i .e. 'H2S’ or 'no H2S ' e nviro nme nt.
D. BOP STAC K ARRANGEME NTS

The BOP st ack ar ra n gem ents m a y va r y depe ndin g o n the ex pect ed w ellh ead
pressu res and di ff erent drilli n g sit uati ons. Some of the arran g ements ar e n orm all y
used B OP sta ck s in m ost comm on situ atio n s. Th e p arti cul ar B O P stac k a rr an gem ent
is sp eci fie d f rom bott om to to p.
E. BOP RAM LO CKS
All pipe r am t yp e pr ev ente r a re equip pe d with ex tensi on ha nd whe els o r h yd raul
ic locks .
F. RE CO MME NDE D S PARE PA RT S
The foll owin g re com mend ed mi nimum sp a re pa rts fo r B OP , ap prov ed fo r i nten de d
ser vic e, shoul d b e av a ilabl e at e a ch ri g.

SAFE WORK PRACTICES

SAFETY
i. A compl ete s et o f drill pip e ram s and ram ru bbers fo r each s ize
d rill pi pe b ein g used .
ii. A com plet e s et o f bo nnet/d oo r se als fo r e ac h siz e and t yp e of
ram t yp e pr ev ent er bein g us ed.
iii. Plastic p acki n gs fo r b lowout pr ev ent er se co nda r y s e als.
iv. Ring gask ets to fit fl a n ge co nne ctio ns o f BOP.
v. App rop riat e s pa re p ar ts fo r annu la r p re ve nt er.
G. Gen eral C onsid er ations :
The foll owin g consid er ation sho uld b e m ad e whe n s ele ctin g w ell cont rol eq uipm ent:
The eq uipm ent shall be selected to withstand the m aximum anticipated su rf ace
pressu re.
The blo wout p re ven te r sta ck shal l consi st of rem otel y cont roll ed equipm ent
cap abl e of closin g th e well wi th or with out th e pip e in th e ho le.
W elded fl an ged o r h ub co nne ctio ns a re m and ato r y on all pr ess ure s s yst ems
a bov e psi a s app rov ed to thr e ade d co nn ecti ons.In som e a re as, w ell c ontr ol
equipm ent suit abl e for so ur servi ce ma y be re quired , in s uch cas es the
complete hi gh p r essu re BOP s ystem s houl d consist o f m etalli c mat eri als r esist
ant t o s ulphid e stre ss cr ac kin g.
Kill lin es must not be sm aller th an 2 " n ominal dia and shal l be fitted with
t wo valv es and an NR V.Choke li nes m ust not be sm alle r th an 3 " th rou gh bo re
and ar e to be c onn ect ed wi th two val ves t o the BO P stack o f whi ch th e oute r
val ve sh all b e h ydr auli c all y o pe r ate d. W h en ki ll a nd ch oke l ine s ar e emplo
yed, both line s must not b e smal le r th an 2" t hro u gh bor e and the o ute r v
alv e o f ea ch li ne s hall be h ydr a-ulically operated.
o In the BOP stack, bli nd/sh ea r rams sh all b e pro vid ed du rin g d ri llin g an d
wo rk ov er ope rati ons. Th e bli nd/sh ea r r ams sh all alw a ys b e c ap abl e o f
she a rin g th e drill pipe/t ubin g i n us e un der No -lo ad c onditi o ns an d
subs equ entl y provi din g a pr op er seal . P re fe r abl y du ri n g wo rk ov er
jobs, ri g must hav e s he a r r a ms.
o In t he st ac k, the bli nd ram shoul d be up pe r & pip e r am shoul d be low er .
This will fa cilit ate to ch an gi n g the blin d ram to pip e ram in case of n eed
and usin g l ow er ram as M ast er ram p re ve nt er.
Closin g s ys tem s of s urf a ce BOPs sh ould be ca pabl e o f closi n g ea ch r am
prev ent e r within 3 0 s eco nds, t he closin g time sho uld not ex ce ed 45 s ec

SAFE WORK PRACTICES

SAFETY
onds fo r a nnul ar pre ve nte rs o f 20 " and lar ge r.

Closin g s yst ems of s ubse a BOPs shoul d b e ca pa ble of closin g ea ch r am
prev ent er within 4 5 se con ds. Closin g tim e sho ul d not ex c e ed 60 s e cond s
fo r annul a r preventers.
All mast er and remot e op er atin g p an el ha ndles s hould , at th e times, b e in
the ful l open o r clos ed positi on, and b e fr e e to mo ve i nto eith e r po sitio n, i. e.
th e sh e ar r am ope rati n g h an dles sho uld not be lo ck ed.
All spa re o pe rati n g li nes a nd co nn ectio ns, whic h ar e not us ed in the s yste m,
shoul d be p rop e rl y bl oc ke d o ff with blind plu gs at the h yd r auli c op er atin g unit.
All 3 positi on 4 wa y v alv es s hould b e eith er in t he op en o r clos e
position , as req uir ed, th e y s hould not b e l eft i n th e lo ck ed o r n eut r al po sition.
o Drill pip e s afet y val v e (FOSV/ Kell y cock) shall be kept av ailab l e at ri g
floo r, which can b e con ven ti onall y fitt ed on drill pipe i n cas e kick o ccu rs
du rin g tri ppin g Op er ation s.
o In c as e o f oth e r tubul ar in th e hole , c han ge ove r s ub fr om Drill Pi pe t o
th at tu bu lar must be av ail a ble at De rri ck Fl oor .
1.2.2. Installation Requirements &Testing for Well head and BOP Equipment
The BOP equipment installation shall conform the following
Wellhead equipment should withstand anticipated pressure and allow for future
remedial operations.
Ram type preventers should be installed the correct way up.
All connections, valves fittings, piping etc. subject to well pressure, must be flanged,
clamped or welded and have a minimum working pressure equal to the related
working pressure of preventers.
Valves must be of the flush through bore type when in the open position. Screwed valves
and fittings are only acceptable on installations up to 2000 psi WP.
Always install new and clean API ring gaskets. Check for any damage before use. Ring
gaskets are not reusable.
All correct size bolts/nuts and fittings shall be in place and tight. All connection shall be
pressure tested before drilling is resumed.
All manually operated valves shall be equipped with hand wheels and be for immediate
use including the valves on the wellhead.
Ram type preventer on surface BOP stack shall be installed with extensions rod and hand

SAFE WORK PRACTICES

SAFETY
wheels connected and ready for use.

BOP equipment shall be function tested and pressure tested as per guidelines.
Kill line should not be used for routine fill up operations.
BOP TESTING
A. PURPOSE OF PRESSURE TESTING
Different well control equipment like BOP’s choke and kill manifold and koomy control units
are used for preventing blowouts. Some times, it is observed that one or the other element of
the system fails to function effectively during controlling a kick which can lead to a blowout. In
order to ensure that all the equipment are in proper working condition, its regular function and
pressure testing is a basic operation need.For testing equipment, we must know its proper
testing procedures. It not only ensure testing with recommended pressure limits but also
increase the reliability of equipment to ensure that it will function properly in case of a kick
encountered during the process of drilling.
B. FUNCTION TESTING
The function test of blow out preventers should be carried out on each round trip but
not more than once per day.
The test should be conducted while tripping the drill pipe with the bit inside casing. The
sequence of operation is as follows:
Install drill pipe safety valve.
Operate the choke line valves
Operate adjustable chokes.
Open adjustable choke and pump through each choke manifold to ensure that it is
plugged.
Close each preventer until all pipe rams in the stack have been operated (Blind and
shear ram should not be tested with pipe in hole).
Return all valves and preventers to their original position and conditions normal
operation.
Important Points to remember:
i. Annular preventer must not be closed in an empty hole.

ii. Blind ram should be operated for function test while string is out of hole.
iii. Pipe ram must be closed against correct size of pipe in the well.
iv. Annular preventers should not be operated on each round trip. They should
however, be function tested once in a week.
v. Operation of shear ram, if available in stack, should be kept to bare minimum.
vi. The valves on BOP stack, wellhead and choke-kill manifold (excluding the
hydraulic and adjustable chokes which are to be function tested on each
round trip) should be function tested at least once a week.
vii. Before function testing, all the lines are required to be flushed thoroughly by
water.

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SAFETY
C. PRESSURE TESTING
Clean water should be used as test fluid

D. Test frequency
BOP stack should be pressure tested
a. When installed
b. After setting each casing string
c. Prior to entry into a transition zone.
d. Not less than once a week
e. Following repairs that require breaking a pressure connection.
E. TEST PRESSURE
Both low pressure and high pressure testing procedure should be followed.
Low Pressure test
A low-test pressure in the range of 15-25 kg/cm (200 to 350 psi) should be carried out for
all ram type preventers, annual preventer hydraulically operated valve.
High pressure test
Once the equipment clears the low-pressure test, it should be tested to a pressure to be
decided as explained below:
On installation of the BOP stack, the test pressure should be minimum of the following:
o Rated working pressure of the preventer stack.
o Rated working pressure of the wellhead.
On subsequent tests as mentioned the BOP stack should be tested at atleast 70% of
the preventer rated working pressure but limited to the least of the rated working pressure
of the wellhead and the upper part of casing string. However, in no case the test
pressure should be less than the expected surface pressure. An exception is the annular
preventer which should be tested to 50 % of its rated pressure to minimize pack off
element wear or damage.
Note: BOP Function & Pressure Test formats as per OISD –RP- 174 are placed at Annexure –VI
1.3. SAFETY IN CASING AND CEMENTATION OF WELLS
1.3.1. Casing of wells
As drilling progresses, the well is provided with casing of different length and
diameter. The work of lowering th e casing in a well should be carried out in
accordance with the GTO/ plan.

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SAFETY
Casing lowering operations should be done very carefully. The following

recommendations provide guidance in this respect:
i. The rig I/C Tool pusher should familiarize himself with the inspection practices
specified in the standards by the manufacturer.
ii. Casing should be handled at all times on racks or wooden/metal surfaces free of
sand , dirt etc .
iii. Cleaning and visual inspection of casing threads should be done on rack and all
casing pipes should be provided with thread protectors on the rack.
iv. Floating equipments (float shoe, float collar ) should be properly checked
before installation.
v. Every joint should be drifted with a proper go-gauge.
vi. Locking compound should be used for float shoe, float collar and bottom 3-4
singles.
vii. In stabbing, lower casing carefully to avoid damaging the threads.
viii. Stab vertically preferably with assistance of a man on the stabbing board.
ix. Mast should be centered.
x. Slip and tong marks are injurious. Every possible effort should be made to keep such
damage at minimum by using proper up to date equipments .
xi. The length of the back up line of tong should be such as to cause minimum
bending stresses on the casing .
xii. Proper torque practices should be followed. Hydraulic tong should be used
for proper make up/ torquing of joint. The tong should be provided with a
reliable torque gauge.
xiii. In the initial stages of make up, any irregularities of make up or speed of make up
should be observed, since these may be indicative of cross threads or
damaged threads.
xiv. To prevent galling while makingup, the connections should be made up at a speed
not to exceed 25 rpm .
xv. Filling of casing during running in should be closely monitored.
xvi. Casing should be lowered in the well smoothly to avoid surge pressures.
xvii. Mechanical aids should be placed on casing in accordance with the plan .
xviii. Circulating sub with kelly and casing connections should be available at the
rig floor prior to start casing.
xix. Spiders are recommended for long casing strings and for heavier loads ( preferably
load more than 150 to ns).
xx. Last casing pipe on which BOP and safety equipment is to be installed should be
lowered with matching nipple having good threads in order to avoidany gas or oil
leakage.
xxi. Lower last two pipes with mud circulation and with low speed .
xxii. During cementation, if any sign of activity in the well is noticed, appropriate
protective measures should be taken to keep the well under control.
xxiii. A safety clamp should be used when running the first joint of casing.
xxiv. During running of casing, make intermediate circulation and ensure minimumgelation.
xxv. To get a good cement sheath cement slurry should be heavier than mud by 0 .2 to 0. 5
SAFE WORK PRACTICES

SAFETY
gm/ cc.
xxvi. Reciprocate/ rotate casing string during cementation for perfect uniform cement
bonding.
1.3.2. Pre departure safety check –Cementing Unit
The following checks should be performed before leaving for drill site.
i. Oil level, HSD level, radiator water level , steering oil level battery connections,tyre
pressure etc.
ii. After initial warm up of engine, check oil pressure, air pressure and brakes
application.
iii. Fire extinguishers and spark arrester should be there in all cementing units.
iv. Accessories like lines, valves, corners jet mixers, rubber hose should be clamped and
fastened to avoid loss and third party injury during traveling.
1.3.3. Safety precautions at the time of placement of vehicles and hooking up of

HP lines and preparatory works prior to cemening
i. All cementing personals should wear safety kits.

ii. All cementing units should be placed with can facing away from the rig and wood
en wedge should be placed behind wheels or parting brakes should be
applied to prevent movement of the vehicles during the cementing operation .
iii. The cementing units should be placed at minimum safe distance from well mouth .
iv. Area for placement of cementing units must be cleared from all unwanted material
to avoid obstructi on/injury during laying of HP lines and movement of cementing
personals during cementing oper ation.
v. HP line connections should be properly anchored and avoid crossing of two
discharge HP lines.
vi. All pin ends of the cementing heads should be protected by the use of protectors
during transportation and handling. The cementing head should be tightened
properly to the casing to avoid stripping of head during pressure application.
vii. Safety valves of cementing units/mud pumps should be check ed for operation
at stipulated pressure to ensure safety during operation.
viii. All HP lines should be pressure tested at 1.5 times the maximum pressure
expected during operation.Before testing of HP lines all persons should be vacated
from the vicinity of HP lines .If leakage is observed the pressure should be
released to repair the same.
ix. Entire cementing operation should be controlled by single person (job incharge) to
avoid any confusion during cementing operation.
x. Prior to starting of cementing operation, the job incharge should explain among the
officers and staff engaged in cementing operation about importance and
safety aspects of the job, which involves use of special additives , any expected
problem of the particular job.
xi. During the preparation of mixing water adequate precautions must be taken to avoid

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SAFETY
chemical/ additive contact with the skin, eyes or any part of the body. In case of new
chemicals, safety in handling the same should be briefed.
xii. All efforts should be made to avoid execution of the job in night.If cementation job
has to be taken in night adequate lighting arrangement should be made.
xiii. Pressurized lines should not be hammered in any case.
xiv. Prior to dismantling the HP line. Lines must be released to zero.
xv. Transportation of Chicksons HP line valves, cementing head from rig floor should be
done by winch line . Dropping down from rig floor should be strictly prohibited.
1.3.4. Routine testing of cementing equipments
i. All cementing heads, swivels, HP valves, reciprocating hoses and top plugs should be
tested periodically at specified pressure . Date of testing and details should be
recorded.
ii. All the fire extinguishers insid the cementing units should be checked for proper
functioning .
1.3.5. Safety in bulk handling plant
i. All cement silos and other pressurized vessel should be pr essure tested at 1.5 times
the working pressure. Safety valves attached to the vessel should be checked for
proper functioning.
ii. Leakage of pressure vessels like silos , loading pot and air reservoir should be
rectified only after releasing the pressure. All valves should be checked for proper
isolation.
iii. The discharge of air dust and cement from vent line should be directed away from
the main are a of operation and preferably in a water pit to avoid air pollution.
iv. Persnnel concerned with bulk handling plant should be equipped with all safety kit like
face mask, dust protectors etc.
v. Air dryer should be used to supply dry air free from moisture to silo which will prevent
checking of lines from lumps.
1.3.6. General safety instruction for cementing discipline
i. Cement mixers should not be moved with more than 12 MT of cement.Bunkers

loaded with 20 MT of cement at site should be kept on jack.
ii. All the persons not engaged in the cementing work should be kept away
from cementing operational are a mud/water supply line and main high - pressure
line .
iii. Smoking and light match in the premises of drill site should be prohibited .
iv. While lifting the cabin of cementing vehicles for chassis engine repair, no person
should be allowed to stand underneath the charging pump till the cabin is locke d
and properly clamped in position.

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SAFETY
1.4. WELL CONTROL
Refer Well Control Manual of IDT, Dehradun.
1.5. OTHER DRILLING OPERATIONS:
Refer Drilling Manual of IDT, Dehradun.
1.6. DRILLING EQUIPMENT
1.6.1. Derrick and masts
i. Every derrick or mast should be of sound construction and adequate strength,

be maintained in safe working order and should be adequately secured to prevent it
from overturni g because of wind velocit y. Wherever required, guy ropes should be
used and anchored properly as per the recommendations of the manufacturer.
ii. Hoisting of the load must be done at a speed of less than 1 meter/sec. Departure
and arrival of the load must be slow and gradual with no jerk .
iii. No welding jobs on derrick member are allowed normally.
iv. All bolt connections of derrick or mast should have lock nuts or split pins
and spring washers.
v. Derrick /mast bolted type should be inspected at least once in a fortnight by the
top man and he should particularly see whether the bolts are properly
tightened and lock nuts or split pins and spring washers are secured in position.
Similar checks on pin type derrick/mast should be made befor spudding of well.
vi. Once in every year, the welded joints of derrick/mast should be cleaned and
examined for any defect . Such checks should also be made immediately after any
untoward incident in the derrick that might affect its strength and rig should carry test
certificate from competent authority to this effect.
1.6.2. Draw works
i. The draw works on a rotary drilling rig serves to either lift pipe and casing out of
the well or low er into it.It is import ant that the d aw works controls are designed,
installed and maintained in such a manner as to provide a driller at his control panel
complete visibility, rapid control of hoisting operations and adequate protection
against moving equipment.
ii. The drum shafts and keys of the draw works should be provided with
suitable guards.
iii. At the Driller’s control panel a suitable device sho ld be provided to stop the draw
works in case of an emergency.
A. Guards and covers
i. During rigging up, guards and covers should be placed at least on moving shafts,
engines and transmissions.

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SAFETY
ii. Open holes on floor must be covered to avoid accident.

iii. When work is to be carri ed out at height exceeding 1.8 mts. for installation
of rotary hose, BOP well head etc. a portable working platform with non skid
surface and hand rails should be used .
iv. Guards and cover must be secured properly. Proper size of nuts and bolts with lock
pin/checknuts should be used when guard or cover is at height.
v. Guards/Covers should be of proper size and shape.
vi. A safety monitor system, which signals the potentially dangerous loss of control of
brake excitation shall be available.
B. Air Gap
If there is corrosion in the air gap between the rotor assembly and the pole faces of the
magnet assemblies due to the use of poor quality cooling water , this gap distance
may gradually increase to a point where peak torque will be reduced. In making any field
check of this gap distance, it is necessary to allow for any pitting and for any scale build-
up to determine the effective gap distance . Any scale present does not provide an
effective magnetic path so it must be deducted from the measurement. This air gap should be
checked monthly.
C. Overflow Outlet
i. In normal operations, water should never be coming out of this over flow. This
overflow needs to be checked daily.
ii. if the brake cooling water is shared with other remote machines, fresh water should
be added to prevent acquiring too much acid content. Also add corrosion resistant
chemicals as recommended by a water treatment specialist.
iii. If ironoxide flakes off the magnet and rotor, the air gap is increased. This
decreases the brake torque capacit y.The air gap should be as listed in the
specifications .If the air gap increases beyond 0.100 inch, return the br ake to
Baylo r for rebuilding. Remember to remove rust and scale before measuring the
air gap.
1.6.3. Rotary Table
i. The rotary table operating through drive bushings rotates the kelly and through it the drill
string and the bit.It also serves as supporting table for the string and to screw and
unscrew tool joints , connections of drill string, casing and tubing’s.
ii. The rotary table gear, driving chains and sprockets should be securely guarded.
iii. The Drilier should not engage the rotary clutch without watching the rotary table. He must
satisfy himself that persons are at a safe distance from the moving parts. The lock of
the rotary table should not be used to arrest its motion.
iv. Drilling crew must not put their foot on a moving rotary table. Periodical inspection
and maintenance should be car ried out as peroperational procedure and be
recorded.

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SAFETY
1.6.4. Crown Block
i. Crown block assembly should be securely bolted.

ii. The sheaves should be provided with metal guards where the clearance between the
sheaves and its guards should not be more than half the diameter of the ropes so as to
prevent the wire rope from jumping out of the sheaves.
iii. The crown block should be inspected regularly and preventive maintenance carried out
as per schedule and recorded.
iv. It should not be lubricated while in motion.
1.6.5. Traveling Block
i. The traveling block sheaves should be provided with suitable guards to prevent
fingers of drilling crew being drawn into it during operations.
ii. When any load is attached to the traveling block, it should not be left unattended.
iii. When not in use, the traveling block should be kept as near as possible to the
rotarytable and the brake lever of th e draw works should be securely locked to prevent
any inadvertent movement of the traveling block .
1.6.6. Hook
i. Every drilling hook should be equipped with locking device, which will prevent th e load
from being accidentally disconnected from the hook .
ii. The hook should be securely guarded during the round trip.
iii. Elevator links should be securely latched with the hook by lock nuts or suitable pins .
1.6.7. Kelly
i. The Kelly should be provided with Kellycocks at its upper and lower ends . K
ellycocks are valves installed between swivel and kelly and also between kelly and drill
pipes to control pressur e, should a high pressure back flow of fluid occur, thus
keeping the pressure off the swivel and rotary hose. The pressure rating of Kelly cocks
should be greater than the expected bottom hole pressure in the well being drilled.
The kelly cocks should be pressure tested before installation .The Kelly should not be
lifted from its rat hole until the swivel bail is securely latced to the hook. The rat hole
casing should be about 50 centimeters above the derrick floor.
ii. The upper left hand threads of Kelly should be checked at regular intervals.
iii. Any repairs to the swivel gooseneck or rotary hose should preferably be done when the
Kelly is in the rat hole.
iv. When drillin is in progres or string is in open hole, any repai r of swivel or wash pipe
should be done after pulling out the string in cased hole to avoid stuck up and keep
the hole full with mud all the times to avoid the kick situation.
1.6.8. Rotary Hose
i. The ends of rotary hose should be fitted with safety chains or safety clamps should

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SAFETY
be of proper size, should be placed 18 " or less from the hose end. Hose should
not be intentionally back twisted as it reduces the resistance of the hose to bursting and
kinking or steel wire ropes to provide support in the event of failure of normal
connection . The pump end of the hose should be secured with the derrick by a chain
atleast 1/2 " thick. Swivel end of the hose should be secured with a similar chain
fastened to the body of the swivel. In no case should the chain be fastened to the
swivel gooseneck because the gooseneck may bre ak.
ii. When circulating mud at high pressure, the drilling crew should remain at a safe distance
from the rotary hose .
1.6.9. Tongs
In drilling work, some of the most serious accidents are caused by the tongs used for making
up or breaking out the pipes, drill collars and casings. Some of the recommendations for safe
use of the tongs are as follows:
i. Make up and break out tongs should be used in pairs for tightening and loosening of pipe
joints.
ii. Tongs should be fitted with safety line of sufficient length to gain full benefit of pull from
the break out cathead, but should be short enough to prevent complete rotation of the
tongs.
iii. The ends of tongs safety line should be secured with at least three wire line clamps.
iv. Tong counter balance weight and lines should be adequately guarded to prevent
accidental contact.
v. The tong latches should be kept clean and lubricated; its dies should be checked for
wear. If tong dies are worn out, they should be immediately replaced.
vi. Welded tongs should not be used.
vii. When not in use tongs should be hooked back in the derrick corner.
viii. The back up tongs should be snubbed either to the substructure or to anchor posts
attached to it; it should not be snubbed to derrick leg.
ix. The strength of safety line of tongs should be more than the pull or break out line strength
of both the tongs.
1.6.10. Slips
i. Slips should be greased on its tapered side to facilitate its removal. Since a stuck slip
handle can cause injury to hand or fingers
ii. Slip handles should be lubricated.
iii. To grasp the slips, the palms of the hands should face the drill pipes.
iv. Slips of correct size should only be used.
v. In no case welded slips should be put into operation.
vi. The slips should be inspected regularly using a straight edge to detect uneven wear or
damage.
vii. Downward motion of the pipe must be arrested with the draw work brakes and not with
the slips.

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SAFETY
1.6.11. Elevator
i. Elevators should be securely latched to the pipe. as otherwi se a pipe dropped may
cause serious injuries to the drillin g crew working at the derrick floor.
ii. When latching an elevator in motion, the rig crew should place their hand around the pipe
only when the elevator has come to complete stop as otherwise it may result in injury to
the hands.
iii. The elevator hinge pin, hinge and latch mechanism should be lubricated for ease of
operation.
iv. When latching an elevator to a joint of pipe or casing lying in the “Vee” door, the rigman
should ensure that the elevator door is on the upper side of the pipe and it is securely
latched to the pipe or casing.
1.6.12. Cat Heads and Cat Lines
i. If the shaft on which a cat head is mounted, projects beyond the guard or other moving
parts of machinery, the shaft end or the key for securing the shaft, should be covered with
a smooth thimble.
ii. Cat head operated manually should be provided with a guide divider to ensure separation
of the first wrap of cat line form subsequent wraps. Cat heads should have reasonably
smooth surface.
iii. When the cathead is in use, the driller should remain at the controls, carefully watching
the lifting operations; he should be assisted by a signal man. In the event of any
emergency, the driller should immediately stop the rotation of the cat head.
iv. Damaged cat lines or jerk lines would not be used on a cathead and should be replaced.
v. The cathead operator should keep his operating area clear and should ensure th att
he portion of the catline not being used is kept neatly coiled or spooled . When not in
use, the catline should be neatly coiled and kept in a dry place.
vi. When not in use the catline should be neatly coiled and kept in a dry place.
1.6.13. Spinning Chains
i. Spinning chains used for screwing and unscrewing of pipes should be adequate
strength, of proper length and be maintained in good condition.
ii. It should be normalized and inspected periodically as per the recommendations of
the manufacturer.
iii. For smooth operation of spinning chains, roller guards mounted on bearings and fitted
with grease nipples should be provided at the derrick floor and should be so positioned
that the Driller, while at the controls, is not endangered due to the operations.
iv. The roller guards should be regularly lubricated.
1.6.14. Engines
i. Internal combustion engines of over 30 HP should be provided with means, other than
manual, for starting them.
ii. It should also be provided with a lock out device to ensure that the external source of
power, if started in advertently when the engine is under repairs, does not result in any
SAFE WORK PRACTICES

SAFETY
danger to persons undertaking the repairs.

iii. All moving parts of the engine ,which may pose danger to persons working the vicinity eg;
the cooling fan,shaft ends,flexible drives etc should be provided with suitable guards.
iv. The various compressed air cylinders shall be purged daily or even more often if
necessary.
v. The exhaust system of the engine should be fitted with silencer and spark arrestors to
prevent discharge of open flame and sparks from the exhausts unless the exhaust gases
are otherwise cooled and conditioned.
vi. The engine should be provided with emergency stop device and also fitted with an
control at driller's control panel ,so that the engine can be stopped whenever in
emergency it is needed.
1.6.15. Mud Pumps
i. The mud pumps provide fluids under high pressure to the drilling equipment and
should be fitted with safety pressure relief valve and pressure gauge.
ii. The relief valve should be set to discharge if the pressure exceeds 10% above the
working pressure.
iii. The discharge line from the pressure relief valve should be anchored and piped to a
place where it will not endanger persons .
iv. No valve should be installed between the pump and its safety pressure relief valve.
The safety valves must be frequently checked and cleaned, principally after the
pumps have been used for cementing.
v. The pump should also be provided with bleeder valve, so that if it is necessary to
release pressure in the mud system during drilling operations, it could be released
through the bleeder valve. For example, with the line under pressure if the kelly is to
be opened, mud will splash on the derrick floor, unless the pressure is first
released through the bleeder valve.
vi. Prior to spudding of well mud pump manifold system must be tested at 1.5 times the
working pressure of the s ystem.
2. WORK OVER OPERATIONS
Work-over operations are carried out on wells for maintaining, restoring or increasing the productivity of
well. Work-over operations should be aimed at protection against damage to human, environment
/natural resource and property and therefore operational safety is the foremost concern on work-over
rigs.
Safe and healthy working conditions, quality of equipment, safe transportation of equipment / personnel
to the well-site, safe operating procedures, proper training, compliance with safety regulations,
company-wide commitment to safety, periodic safety audits, timely inspection and appropriate repair
/maintenance play a major role in safety management and key factors in avoiding accidents. However,
the human factor plays the most vital role as most of the accidents are caused due to human failure.

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SAFETY
2.1. SAFE OPERATING PRACTICES IN WORKOVER OPERATIONS

2.1.1. House Keeping
i. Good housekeeping on the job is essential to successful accident control and fire
prevention. Keeping everything in its place promotes efficiency, quality and good work.
Tools, equipment and working areas should be kept clean, neat and orderly.
ii. Work places and stairs with handrails should be maintained reasonably clean and free of
debris, mud, oil or stumbling hazards.
iii. Scrap, waste and rubbish shall not be allowed to accumulate in work places of access or
egress.
iv. Hazardous leaks should be immediately stopped or spills should be promptly cleaned up to
eliminate personnel slipping and fire hazard.
v. If employees are required to work in a cellar pit, it should be kept reasonably clean of
water, oil or drilling fluid accumulation.
vi. Loose materials that are not required for use should not be placed or left so as to
dangerously obstruct work places and passage way.
vii. All projecting sharp edges and railing ends shall be properly bend over to prevent possible
injury.
viii. When placing equipment and tools on or around the rig floor and location, care should be
taken to leave egress routes open. Tools and equipment should be securely placed and
stored in a manner so that they may not fall.
ix. Portable equipment shall be returned after use to its designated storage place.
x. Equipment, tools and small objects shall not be left lying about where they could cause an
accident either by falling or causing person to trip.
2.1.2. Work-over Operation
i. Pre-workover conference to be attended by all key personnal, shall be held after rig
building at each well but prior to start of operations (removing X-mass tree, installation of
BOP, initial pulling out of string). All shortcomings shall be recorded & all precautions
required for particular work-over job shall be listed & discussed with the crew, assigning
duty to specific crewmembers to act in case of emergency.
ii. At the beginning of every shift, the instruments and controls at Driller’s stand, draw works,
mud pump, casing line, cat-line, and blowout preventer assembly etc. shall be examined
by the Shift in charge and he shall satisfy himself that these are in good condition. In case
of non operational of any instrument be recorded and corrective action should be taken
immediately.
iii. The Shift in charge shall see that no person remains in a position of danger at or near the
rotary table when set in motion.
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SAFETY
iv. Tools or other materials shall not be carried up or down a ladder unless properly secured
to the body leaving both hands free for climbing.
v. The casing line shall not be in direct contact with any derrick member.
vi. All high-pressure pipes fitted with flexible joints shall be suitably anchored and pressure
tested before commencement of any operation.
vii. For further details on Work-over and Cementing operation OISD-GDN-182 and OISD-STD-
175 respectively may be referred.
viii. Availability and display of instruction for the use and maintenance of personal protective
equipment.
ix. General safety education should be imparted through periodical safety meetings, company
publications and other educational media like video etc.
x. Unsafe and potentially dangerous conditions should be rectified and reported immediately
to the in-charge for further suitable action.
xi. The off-going shift in-charge shall inform the incoming in-charge for any known special
hazards on ongoing work that may effect safety of the crew and rig. Accordingly brief note
should also be recorded.
xii. Hazardous substances if any shall be stored at proper place, in proper containers and
properly labelled.
xiii. Employees required to handle or use hazardous substances shall be instructed regarding
their safe handling and use and are made aware of the potential hazards and personnel
protection required.
xiv. Smoking, spark producing jobs/ devices and naked light shall be prohibited at or in the
vicinity of operations that constitute a fire hazard. No person shall smoke or carry naked
light, spark producing jobs/ devices within 30-m radius of a well. In cluster locations
prohibition should be enforced for all operations. Locations should be conspicuously
posted with a sign, “NO SMOKING OR NAKED LIGHT” or equivalent.
xv. Field welding shall not be permitted on tongs, elevators, bails or heat-treated rig
equipment.
xvi. Never leave well unattended unless it is safely shut in. At least one trained person should
always be present on derrick floor to observe the well particularly when BOP is not closed.
xvii. Pipe threads should be cleaned with a wire brush.
xviii. Hand gloves should always be used for working on Rig floor, while handling of wire ropes
and tubular.
xix. Men on the floor should stand clear when rigging up or repair work is in progress
overhead.
xx. When drinking water is transported and stored for use of crew on location, it should be in a
clean shatterproof container and individual drinking cups provided. Drinking water should
be labelled "Drinking Water only".
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SAFETY
xxi. Unsafe or otherwise dangerous conditions, no matter how small, should immediately be
reported to supervisor in charge for corrective action. Correction of unsafe condition may
take one of three forms - remove, guard or warn.
xxii. Upon completion of job, clean equipment and load neatly and safely on tool truck/box.
xxiii. In the event equipment, guy wires, etc. are present which create a hazard on roads of any
kind, signs, flagging, lights or flares should be used to give warning.
xxiv. Scuffing, practical joking, or horseplay of any nature among employees on duty is
inconsistent with safety and is positively prohibited.
xxv. Control must be maintained over leaks and spills; however, if they occur, they should be
cleaned up promptly to eliminate slipping hazard to personnel as well as fire hazard.
xxvi. All employees are responsible for prevention of accidents to men working with them. Any
employee using unsafe tools or work practices or encourage other employees to do so
should be prohibited.
xxvii. Lift weights properly, with your legs and not with your back, using proper handling
technique. If the load is beyond your safe capacity, get help.
xxviii. In the event of a personal/ occupational injury, no matter how small, will be reported
promptly to the supervisor in charge. Supervisor is to make out a full report at the end of
the shift on an approved accident form and handover to the Driller I/C.
xxix. Hair of such length that it might become entangled in moving or rotating machinery should
be contained in a suitable manner. Beards and sideburns of employees should be kept in
such conditions and of such lengths so as not to interfere with the proper use of gas
masks, air masks, or other safety apparel or equipment.
xxx. Drinking alcohol/intoxicated substance on the job or to and from the work is prohibited.
xxxi. It is the responsibility of all employees to train men under their supervision, in the safest
and most efficient way to work.
xxxii. An employee should never operate any machinery, including a cathead, until he is
authorized and well acquainted with the operation.
xxxiii. It is the employee's responsibility to report all unsafe conditions to his immediate
supervisors.
xxxiv. As servicing jobs are frequently done at remote areas where medical aid is not readily
available, it is strongly recommended that all employees take a course in first aid.
xxxv. Unauthorized personnel should not be permitted at the work location.
xxxvi. There will be no smoking at the well-site. All smoking materials, matches, lighters, etc.,
are to be left in a pre-determined safe area.
xxxvii. Each employee should exercise caution to avoid falling, stumbling, or moving into or
against moving machinery.
xxxviii. Adequate lighting arrangement shall be provided during working.

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2.2. SAFETY EQUIPMENT

2.2.1. Personal Protective Equipment
A. Head protection:
No person shall go into or work or be allowed to go into work in a drilling rig or
workover rig or rig building or rig dismantling or at such other place of work where
there is a hazard from flying or falling objects unless he wears a helmet of such type
as may be approved by applicable regulatory authority.
The helmet shall be supplied free of cost at interval not exceeding three years by the
owner, agent or manager who shall at all times maintain a sufficient stock of helmets in
order to ensure immediate supply as and when need for the same arise;
Provided that when a helmet is damaged during its legitimate use, it shall be
immediately replaced free of cost.
Safety helmets shall be worn by all personnel at all times while working within working
areas, outside accommodation and offices.
Safety helmets shall be fitted with chin strap and shall be made of non conductive
material.
B. Clothing :
Overalls shall be worn by all personnel working on rig. Employees should wear
protective gloves, protective apron, or other protective equipment, as prescribed.
The unreasonably loose, poorly fitted or torn clothing should not be worn.
Employees should not wear jewellery or other ornament causing injury while in the
work area.
Personnel clothing, which has been saturated with flammable or toxic substances,
should be removed and effected skin area thoroughly washed.
C. Hand Protection :
Safety gloves shall be provided to all personnel and worn as appropriate, eg high
temperature resistant gloves for hot jobs.
Rubber gloves shall be available and worn by electrician while working
D. Foot protection :
Safety shoes/ boots shall be worn by personnel in working areas. No person shall go
into work or be allowed to go into work in a mine unless he wears a protective footwear
of such type as may be approved by applicable regulatory authority

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SAFETY
Protective footwear willl be supplied the owner, agent or manager at interval not
exceeding one year. However sufficient stock should be maintained
E. Eye protection :
Safety glasses, shields and goggles shall be worn anytime eye hazard exist like when
chipping, grinding, hammering, cutting wireline, changing tong dies, scrapping paint,
using a drill machine, operating a press, a lathe machine, and for any other activity
which may result foreign body in the eye.
In addition to the safety goggles, a face shield shall be worn when handling corrosive
or harmful products (solids or liquids).
Welding helmet or hand-held shield shall be used when performing welding rather than
welding goggles.
Welding goggles shall be worn when using a cutting torch.
Provision for eye wash with potable water shall be available at least in the following
areas: rig floor, mud/workover fluid mixing area etc.
F. Ear Protection/ Protection against noise:
The owner, agent or manager shall take reasonably practicable means to reduce the
noise level and to reduce the exposure of work persons to noise.
Persons entering high noise areas should wear ear/ hearing protection equipment in
an area in which the sound level is 90db(A) or more.
No person shall enter or be allowed to enter an area in which the sound level is
140dB(A) or more.
2.2.2. Safety Belt:
Every person who works above the first girt of derrick shall be provided with approved
type of safety belt & life line.
Safety belts , life-liners & tail ropes should be maintained in good condition.
The topman leaving the monkey-board shall take off his safety belt only when reaching
the exit of the monkey-board.
When the topman is changing out, the blocks shall be lowered and remain in vicinity of
the drill floor.
The topman's safety belt, when not used, shall always be located at the entrance of
the monkey-board, to allow the topman to put it on before starting to walk on the
platform.
A. Fall Protection.
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SAFETY
Where any person cannot be protected against falls from heights by other means, the
owner, agent or manager shall provide an approved safety belt suitable for the hazard
exposure which shall be attached by means of a lifeline to a fixed anchor and adjusted
to allow a drop not exceeding 1.8 metres in case of fall.
2.2.3. Topman Emergency Escape Device (TEED)
Rig should have escape line & escape device allowing topman to evacuate from
working platform level in case of emergency
Escape device for derricks should have a seat (T Bar) and a spring actuated cam
brake which can be applied at any height with finger tip pressure, both in good working
condition to control the descent.
Path of escape line should be free of obstruction.
The angle of the anchored escape line should be in accordance with manufacturer's
specification.
A competent person shall inspect every part of Emergency escape device/ Braking
system once at least every day. Record of such inspection be maintained.
2.2.4. Portable gas detectors
A portable gas detector capable of determining monitoring level of combustible gases

in air should be made available at site.
The detector shall be regularly inspected and maintained in ready to use at all times
and should be calibrated regularly.
2.2.5. Fire Prevention and Protection (except while rigging up, rigging down and
moving)
Fire fighting equipment should not be tampered with and should not be removed for
other than its intended purpose.
Fire extinguishers and other fire fighting equipment should be suitably located and
plainly labelled as to their type and method of operation.
Used cleaning rags and combusting waste materials are kept (to a minimum stored) in
a metal container and disposed of regularly.
Access to exits or fire extinguishers are not blocked or obscured by clothing, materials
or equipment.
Well cellars, rig floors and ground areas adjacent to derricks should be kept
reasonably free from accumulation of oil which might create or aggravate fire hazards.

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SAFETY
Fire protection and fire fighting equipment are maintained in a serviceable condition at
all time.
All fire extinguishers are maintained, inspected and hydrostatically tested in
accordance with standards.
A competent person shall once at least in every three months examine every fire
extinguisher and shall discharge and refill it as often as may be necessary to ensure
that is in proper working order.
Records be kept showing the date fire extinguishers were last inspected, tested or
refilled and by whom.
A report of every such examination or refilling shall be kept in a bound paged book
kept for the purpose and shall be signed and dated by the person making the
examination or refilling.
During welding operation, keep suitable portable fire extinguishers in the vicinity.
Any engine being refuelled should be shut off during refuelling.
No smoking should be allowed within 30 meters of any flammable storage area, or
within 30 meters of the handling of flammable liquids.
There should be an adequate number of "No Smoking" signs conspicuously displayed
at each well location while well service work is in progress.
Personnel shall be instructed for the use of fire-fighting equipment during fire drills and
training exercises.
2.2.6. First Aid
The information regarding availability of first aid kit should be made known to each
member.
An adequate and approved first aid kit should be provided on each rig and should be
conspicuously located.
At least one person who is trained and certified in first aid and basic rescue techniques
shall be available in each shift.
Posters demonstrating rescue, breathing & first aid should be displayed at work
place.
Emergency contingency plan should be available at site.
The first aid kit shall have all medicines as recommended by John Ambulance.
Emergency vehicle / ambulance should always be available at site during operations.

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SAFETY
2.3. WELL SERVICING EQUIPMENT AND PROCEDURES

2.3.1. Derrick Floor
i. Derrick floor chequered plates should be placed firmly and in such a way that there should
be no gap between them.
ii. Any opening in chequered plate like mouse-hole etc. should always be protected to avoid
injury to person. Plain and slippery chequered plate should be replaced immediately.
iii. Grease, dirt or mud spillage on the derrick floor to be cleaned with water jet or surfactant
during and after any operation on the floor. Grease, dirt, mud also be cleaned from the
steps of stairways/ladder to avoid slipping.
iv. Used cotton waste and all other dirty substance to be stored in the dustbin.
v. Stands of tubular racked in the derrick or mast should be rested on wooden raft and
properly secured to prevent them from falling.
vi. Proper stopper arrangement like steel chain shall also be provided at the end of the ‘Vee’
to avoid accidentally slipping of persons.
vii. Guardrails of minimum 3 ft. height should be installed on all platforms / walkways which
are more than 4 ft. above the ground level. Toe board of 6” shall be provided in addition to
handrail on operation of floors / platforms / walkways.
viii. A minimum of two (2) stair ways with hand rails shall be installed on rigs to provide
alternate exits from the rig floor to ground level when rig floor height is six (6) feet or more.
ix. Drill-pipe/ tubing kept for connection at inclined catwalk should be properly secured to
avoid slipping of the same.
2.3.2. Derricks
i. All equipment installed in derrick /Mast shall be secured with safety line of appropriate
strength to prevent them from falling.
ii. Each derrick or mast should show name of manufacturer and safe load capacity.
iii. No derrick or mast should be subjected to a compression load greater than the safe load
limit shown on the manufacturer's plate.
iv. Derricks, mast guying and foundations should comply with the standards for guylines,
anchors and foundation bases for well servicing units, as per manufacturer's
recommendations.
v. Derricks and masts should be equipped with guards which should prevent the hoisting
lines from being displaced from the sheaves during operations or when being raised or
lowered from the operating position.
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vi. A visual inspection of the service unit should be made by an experienced person before
the derrick or mast is raised or lowered. An experienced person should be made in charge
of raising or lowering a derrick.
vii. Before any derrick is raised or lowered, all tools and material not secured to the derrick
should be removed from the derrick.
viii. The derrick should be level and plumb before guys are tightened
ix. Before any load is put on the derrick, all crown guys should be properly tightened.
x. No employee should be allowed on the carrier when it is being raised or lowered.
xi. Each derrick platform should be constructed, maintained, and secured to the derrick to
withstand the weight of employees or other stresses, which may normally be placed upon
it.
xii. Finger boards should be attached to the derrick to keep them from falling if jarred loose or
broken.
xiii. Unattached tools or material of any kind should not be kept in the derrick above the derrick
floor unless there is occasion for their immediate use.
xiv. No employee should be in the derrick or on the rig floor when the initial pull is made on the
rods or tubing or when working or jarring stuck rods or tubing.
xv. All masts should be equipped with locking devices with sufficient strength to prevent the
mast from bending at the hinge points. The locking device should be approved by the rig
manufacturers. The mast will be locked as soon as the mast is in position and remain
locked until the mast is to be lowered.
xvi. Topman/Derrickman on first ascent into derrick will visibly inspect locking devices or pawls
and install safety devices if applicable.
xvii. The crown block shall be protected by bumpers which shall be snubbed, and when made
of wood, covered with wire mesh.
2.3.3. Hoisting Lines (Casing Lines)
i. A dead anchor for hoisting line should be so constructed, installed and maintained that its
strength should be at least equal the working strength of the hoisting line.Inspect dead line
anchor on a daily basis for weld failure, metal fatigue, or other signs of possible failure.
ii. All hoisting lines and sand lines should be visually inspected when in use by a qualified
person and a record made of any defects noted. At this time a determination should be
made as to whether the hoisting line should be cut to bring new line into the system, or
replaced. In no event should the hoisting line or sand line be allowed to remain in service
when the following numbers of broken wires appear in any section of the line.

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iii. Line cut off and shifting should be carried out as per the OISD-STD-187, “ Care and Use
of Wire Rope”
iv. In addition to above criteria, hoisting line or sand line should be removed from service
when any of the following condition exists:
a. When marked corrosion appears
b. When there is evidence of kinking, crushing or min. of 10% increase in length
of lay
v. On any drum on which a hoisting line is wound, the end of the hoisting line should be
fastened securely to the drum and there must be a reasonable number of wraps of the line
on the drum to eliminate any strain on the fastening to the drum.
2.3.4. Hoisting Block
i. Travelling block should be properly guarded.

ii. Any slip hook used for lifting should be equipped with a safety latch or safety cable and
pinned.
iii. Travelling block, elevators, elevator links or similar equipment should be reasonably free of
projecting bolts, nuts, pins or other parts upon which clothing of workmen may be caught.
iv. Travelling block and similar equipment should be inspected and maintained in good
working condition and the applied load should never exceed the manufacturer's listed
rating.
v. Travelling block twin stop safety device shall be installed in order to prevent the block
hitting the crown block and derrick floor accidentally.
2.3.5. Weight Indicators
i. To indicate the suspended load, every well-servicing rig should be equipped with a reliable
weight indicator.
ii. Weight indicators should be safety secured and should be easily visible to the personnel
on the brake.
iii. The manufacturer's rated load capacity of the servicing unit should not be exceeded.
2.3.6. Draw-works
i. A visual inspection of the draw-works and its working parts should be made each day or
shift before operations begin by a competent person. If any defect is noticed during such
examination, the draw works shall not be used until such defect is rectified.

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ii. All guards and covers should be in place before operations begin. If lubrication fittings are
not outside of guards, machinery should be completely stopped for oiling and greasing.
iii. When it becomes necessary to remove a guard, the draw-works should be completely
stopped and engine shut off.
iv. All air compressors should have at least one pressure control for proper airflow. Use
proper pins in relief valve.
v. The safety pressure relief valve on main air tank should be checked periodically and kept
in proper working order.
vi. All valves kill switches and other working devices should be kept in proper working order.
vii. Safety pressure relief valves on hydrostatic lines should never be set higher than the
design rating of the hydraulic system or the manufacturer's listed rating of the lines,
whichever is less.
viii. The brakes, linkage and brake flanges on the draw-works should be tested visually and
inspected each day.
ix. Personnel on the brake should not leave the brake without tying the brake down or
securing it with a catch lock.
x. The equipment operator should not leave the brake while hoisting drum is in motion.
2.3.7. Cathead and catline
i. The operator of cathead shall keep his operating area clear and shall keep the portion of
catline not being used coiled or spooled.
ii. Catheads, on which a rope is manually operated, should have a rope guide to hold the on-
running rope alignment with its normal running position against the inner flange.
iii. Cathead operated manually shall be equipped with a divider to ensure separation of the
first wrap of wire line or rope.
iv. The key seat and projecting key on a cathead shall be covered with a smooth thimble or
plate.
v. When a cathead is in use, a competent person shall be at the controls and in the event of
any emergency, he shall immediately stop the rotation of the cathead.
vi. When a rope or line is in use on a cathead, all other ropes or lines should be placed at a
safe distance, so as not to come in contact with the cathead or with the rope or lines used
on the cathead.
vii. When the cathead is unattended, no rope or line should be left wrapped on or in contact
with the cathead.
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viii. When the cathead is in use there should be an authorised employee at the draw-works
control.
ix. The friction surface and flanges of a cathead on which a rope is manually operated should
be reasonably smooth.
2.3.8. Mud Tanks
i. All fixed mud guns used for jetting should be pinned or hobbled when unattended.
ii. Hoses used for jetting operations should be manned, and there should be an employee
stationed at the pump controls to shut down the pressure in the event of emergency.
iii. All discharge lines should be safely secured. All hoses under pressure should be properly
hobbled.
iv. All portable tanks in excess of 2 meters in height used in testing and treating, should be
equipped with a fixed metal ladder.
2.3.9. Pumping Units and pressure lines
i. Each mud pumps shall have a pressure relief safety device, installed and maintained.
Relief valve and all open ended pressure relief lines shall be securely clamped to fixed
support.
ii. Bleed off valve shall be installed on discharged line/pipe of the pump, to allow the residual
pressure after isolation of the high pressure circuit to be safely relieved.
iii. All exposed moving parts shall have proper guard.
iv. All connections on chickson lines shall be snubbed with adequate means to prevent from
swinging or kicking in case of sudden release of pressure.
2.3.10. Material and Equipment Handling
i. Size up the load that you are about to lift and get help if necessary.
ii. While lifting load, keep your back as nearly straight and vertical as possible, bend the
knees and do the lifting with the leg and thigh muscles.
iii. Be sure you have a secure grip on whatever you are going to lift or carry and avoid jerking
and awkward positions
iv. Particular care must be exercised when doing group lifting or carrying to avoid injury. One
man in the group should give signals so that everyone will work in unison
2.3.11. Hand tools

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SAFETY
i. Wrenches should be inspected frequently to eliminate worn or sprung jaws, broken cages,
springs, faces and bent handles.
ii. Inspect driving faces of hammers, chisels, drift pins, bars, and similar tools frequently to
eliminate mushroomed heads, broken faces and other defects.
iii. In applying force to a wrench you should take a position so that you will not lose your
balance in case the nut or joint suddenly loosens or the wrench slips.
iv. Non-spark tools shall be used when in an explosive or flammable environment.
v. The wooden handles of hand tools shall be kept free of splinters and cracks and shall be
kept securely attached to the tools.
vi. Impact tools, such as drift pins, wedges, and chisels, shall be kept free mushroomed
heads.
vii. Hands tools shall never be left on ladders or elevated places.
viii. Employees shall not use hand tools, which have become dull.
ix. Hand tools shall not be used after being subjected to intense heat.
x. Electrical cords shall be checked and replaced if worn.
xi. Before rolling up or coiling pneumatic hoses, electrical cords or hydraulic hoses,
disconnect from the power source.
xii. Disconnect air and electrical tools from the power source before changing bits, sockets
and blades.
2.3.12. Ladder , Stairways, Floors & Platforms
i. Every scaffold, stage, walkway, working platform, stairway and ladder, whether temporary
or permanent, should be constructed and maintained in safe condition and should not be
altered or moved while in use.
ii. Work areas should be clean and free of debris.
iii. Walkways, stairways and exits should be kept clear to provide unimpeded ingress and
egress except during rigup, rigdown and moving.
iv. Every stairway, ladder, ramp, runway, floor and platform should be kept reasonably free of
objects and substances which may create a slipping or tripping hazard, or prevent or
hinder the escape of workmen in an emergency.
v. With the exception of exit and entrance openings, and loading and unloading areas, a
standard guardrail with mid-rail and a four inch toe board should be installed at the outer
edge of any floor, platform, walkway, ramp or runway which is four feet above the ground,

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SAFETY
or another floor or working level. Where guardrails are not feasible, chains, or wire rope
may be used.
vi. A guardrail used and/or needed for the purpose of actual or potential containment of
equipment or material should be of such construction and strength as to effectively contain
the full load or stress which may be anticipated to be applied upon it.
vii. Any temporary stabbing board, or other temporary boards, placed in derrick should be
securely fastened.
viii. A stairway with handrails should be installed beside the ramps which should extend from
the ground to the derrick floor.
ix. Every opening in a derrick floor should be removed or guarded when not being used.
x. A derrick floor, derrick walk or engine room floor should not be used as a storage platform
for equipment or material that is not required for immediate use unless the material or
equipment is properly racked or stored, and does not cause congestion of work areas or
walkways.
xi. Proper slope from derrick to ground shall be maintained for quick & safe evacuation during
emergency.
2.3.13. Anchoring and Wind Guy lines
i. Every rig should be equipped with the number and size of guy lines as recommended by
the manufacturer.
ii. Every guy line recommended by the manufacturer should be utilized according to the
manufacturer's specifications.
iii. Guy lines should not be any closer than 3 meters from lower lines, and in no case should a
guy line be extended above or below a power line and/or power be turned off and locked
out.
iv. All chains clamps and tensioning devices that will remain in the working guy line must have
as much strength as the guy line. Those chains, boomers, clamps and tensioning devices
not of sufficient strength should be bypassed by continuing the guy line through or around
the anchor, then back to the guy line again. The guy line should be properly secured with
at least 3 U –bolt as per OISD-STD-187.
v. A thorough inspection of all guy lines in use should be made prior to each installation and
no guy lines should be spliced.
vi. Where the number, size and utilization of guy lines are recommended by the derrick
manufacture, anchors should be used to secure the guy lines, except when other means or
methods of anchoring the guy lines are recommended by the manufacturer which are at
least as effective as these standards.

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vii. Expanding anchors, pipe anchors, concrete anchors, or other approved techniques should
be used as recommended by the rig manufacturer.
viii. If any anchor wire creates a blockage or road or access, proper signages/ flags should be
displayed to give warning.
2.3.14. Fencings
i. The protected area surrounding every drilling or work over installation shall be provided
with fence of not less than 1.8 metres in height.
ii. Precautions shall be taken to prevent any unauthorised person from having access to any
place which has been duly fenced.
2.3.15. BOP Accumulator Unit
Shift in-charge should ensure that BOP accumulator unit is charged and sufficient oil is filled in
oil sump. BOP assembly should be function & pressure tested regularly and proper well control
practice shall be complied with in accordance to OISD-RP-174.
2.4. WORKOVER OPERATION AT CLUSTER WELL SITE
Workover operations undertaken on one of the cluster wells simultaneously producing other wells/
scrapping / bottom hole studies / activation on the nearby wells. The hazards associated with workover
operations are fire due to spark and gas leakage, uncontrolled flow of oil / gas, perforation hazards,
heavy objects handling and accidental rupture of flow lines, damage to wellhead, X-mas tree etc.
As per OISD-GDN-182, the following guidelines are suggested for safe operation at cluster well
location:
i. A steel structure, removable type, strong enough to withstand impact load is to be erected
around the production well head, up to a height of at least one foot above the X-mas tree. The
structure should be reinforced on all sides except one for operating the valves. The
reinforcement should be either double layer sand bagging or prefabricated portable wall of
M.S. plate or non-flammable light materials. Alternately the three sides should be enclosed by
brick wall (at least 10" Thick).
ii. The roof should be safe guarded either with removable type prefabricated M.S. plate or good
quality 3" thick plank which can be removed during well servicing/scrapping operation.
iii. There must be minimum three 10 kg. DCP portable extinguishers near the producing well all
the time during combined operation.
iv. The producing well should be checked for any leakage of gas/oil before movement of rig
equipment in/around the area. In charge of the area/well should be informed in advance for the
rig movement through their area.
v. Flow line from the producing well should be welded and no chickson joint be used.
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SAFETY
vi. Surface control and check valves be installed near the effluent pit with suitable protection.
vii. Flow line and gas input line to the producing well should be at a suitable distance away from
load carrying activities / vehicular movement.
viii. Caution notice board mentioning "DANGER - High pressure Gas Line" should be displayed at
2/3 appropriate places.
ix. Caution board mentioning "DANGER - Well on production" should be displayed at the
producing well.
x. Ensure there is a provision for killing the other well in case of emergency.
xi. If one well is in drilling and remaining wells under production, continuous monitoring for the
presence of the gas be undertaken at the following sites and corrective actions be taken as
necessary and record should be maintained.
Near the producing well

At cellar pit of drilling well
At rig pump area
At derrick floor
2.5. MOVEMENT OF LAND RIG IN OIL FIELD
The movement of rig takes place when any workover operation is required to be undertaken on a well
located inside or near the on land production installation or passing near or through the production
installation where the rig movement requires crossing over or moving parallel to the flow lines etc. Risk
involve are damage to flow lines, fire and pollution.
i. During transportation over the pipeline, the vehicle should pass/cross over with utmost care.
ii. All vehicles, heavy earth moving equipment and the cranes should be fitted with spark arrestor.
iii. Flow line and gas input line to the producing well should be at a suitable distance away from
load carrying activities / vehicular movement.
iv. Check surface and underground pipelines prior to the movement of the rig / heavy load.
2.6. DRILLS AND TRAINING

2.6.1. BOP Drills
i. BOP drills should be conducted once a week with each crew.

ii. Drill should be initiated at unscheduled times when operations and hole condition permits.

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iii. To conduct drill, a kick should be simulated.

iv. The reaction time from the moment kick is simulated to the designated crew member's
readiness to start the closing procedure should be recorded and response time should not be
more than 60 seconds.
v. Total time taken to complete the drill should be recorded and it should not be more than 2
minutes.
vi. Following drills should be performed:
On bottom drill
Trip drill
Drill collar in blowout preventer drill
String out of the hole drill
2.6.2. Fire Drill
i. A fire drill should be conducted at least once in a fortnight.

ii. Drills should be so conducted as to ensure that crew who could not participate in a fire drill on
one date will participate in the same drill held at the next date.
iii. The observer of the fire should immediately report to driller to sound alarm (continuous
intermittent rings) and should make an attempt to put out the fire by applying the nearest
suitable extinguishing agent.
iv. Each rig should have designated fire fighting teams. The fire fighting/ rescue team (consists of
six persons) should muster at the fire station closest to the fire. After checking type of fire, they
should use appropriate equipment to extinguish the fire. However all personnel should be
assigned specific duties to be carried out in the event of a fire drill and should be trained in the
use of fire fighting equipment as per classifications of fire.
v. Especially in an offshore rig all the other persons who are not involved in fighting the fire or
critical rig operation should muster as per the station bill. Head count should be taken and
reported to the in charge of safety/DIC.
vi. The DIC be responsible for clearly indicating what additional action would be taken in the event
of a real fire, such as the posting of a fire watch to guard against rekindling, restoring of fire
fighting equipment and other necessary topics.
vii. Report of each fire drill should be prepared by DIC and a copy of the same should also be sent
to the base office.

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SAFETY
viii. Fire fighting pumps and stations should be inspected at intervals not exceeding seven
days. A record of inspection should be maintained both on the rig and at the base office.
2.6.3. Training
For training rig crew on "Well Control" refer OISD-STD-154 & OISD-STD-176.
Assistant Driller, Driller, DIC, Area In-charge should receive training on well control operations
from reputed institute at interval not more than 3 years.
2.6.4. Contingency Plan ( As per OMR 1984)
The manager shall frame a contingency plan for fire and submit a copy thereof to the Regional
Inspector who may approve it either in the form submitted to him or with such additions or
alterations as he may deem fit.
The contingency plan shall contain:
i. Organization plan clearly stating the line of command and the responsibilities of each person
involved in case of emergency situations;
ii. Equipment plan clearly stipulating the equipment’s make and type, capacity, location, correct
operation and field of operation;
iii. Action plan clearly stipulating –
Alarm and communication system,
System of notifying the authorities,
The duties and responsibilities of each key personnel including measures to
be adopted to avert or minimise the consequences of the emergency,
When and how the equipment shall be used and when and how the action
shall be carried out, and
Help or information that would be available from associated and external
agencies including government agencies,
Guidelines for terminating the action; and
Plan for training of personnel and for mock-drills.
2.7. INSTRUMENTATION / ELECTRICAL SYSTEM
i. Shift In-charge should ensure in every shift that all instruments are in functional order.
ii. Electrical Engineer of Rig should ensure that earthing is done on rigs as per the
recommendation of IS: 3043 code of Practice for Electrical Earthing and the Indian Electricity
Rules 1956 & amendment thereon, if any.
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SAFETY
iii. The lighting provided in a mine shall as far as possible be so arranged as to prevent glare or
eye strain. Adequate general lighting arrangement shall be provided during working hours at
the following places, ensuring that Flame proof lights are fitted on the Mast & within 15 metres
of well.
Where natural lighting is insufficient
Derrick floor
Driller’s stand
Monkey board
Every engine and pump house
Derrick sub structure near blowout preventer controls
Every place where persons are to work
Every means of escape, access or egress
a. Electric lighting
Every electrical lighting apparatus shall be of a type approved by the Chief
Inspector.
The lighting system installed in the mine shall comply with the provisions of
the Indian Electricity Rules, 1956.
Every electrical lighting apparatus shall be so fitted as to protect it from
accidental damage.
b. Standards of lighting
The Chief Inspector may from time to time by notification in the Official
Gazette specify the standards of lighting to be provided in any specified area
or places in a mine.
c. Emergency lighting
Adequate number of self contained portable hand lamps of approved type
shall be made and kept available for immediate use in emergency.
2.8. COMMUNICATION
Efficient means of audio communication shall be provided and maintained in good working
order between manned installations/rig and the office of the manager and other places of work.

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Wherever possible this shall be complemented with video communication as well. At any point
of time, two or more different channels of communication systems should be in place.
The communication and signalling system installed in the mine shall comply with the provisions
of the Indian Electricity Rules, 1956.
2.9. INSPECTION STRATEGIES

2.9.1. Inspection of System
A. Dynamic Equipment
Scheduled inspections from Manufacturers’ recommended maintenance schedules.

The equipment are required to be inspection periodically as recommended by
manufacturer and updated as per our experience on the equipment.
Annual Inspection: These inspections are carried out while conducting technical audit
on each rig and will be augmented by application of condition monitoring equipment for
reporting on the condition and performance.
B. Static Structure, Rig Floor Handling Tools,And Tubulars, (Mast And Sub-
Structure And Other Miscellaneous Structures):
i. During rig building operations, rig crew members shall visually inspect bolted
connections, bent members and welded joints.
ii. Annual inspection through technical audit: General corrosive condition of members,
components, alignment of Derrick and various structures including tankages will be
reported on.
iii. Rig floor handling tools and tubular (Drilling) shall be inspected annually or as per
standing instructions.
iv. NDT inspection by hand held tools: These inspections will be carried out initially after
five years and subsequently once in every 3 to 5 years.
C. Pressure Vessels Tankages, Lifting Equpt & Electrical Equipment/Lights

For Hazardous Areas:
These inspections shall be carried out as per relevant factory/Mines Safety

Regulations.
D. Bop Accumulator, High Pressure Valves, Choke Manifold Chickson Joints

And Other Safety Equipment:
i. Inspection at the time of rig building/installation of BOP.

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ii. Inspection on every change of rams.

iii. Periodic inspection for operational readiness as per frequency circulated from time
to time.
iv. Annual inspections with NDT capabilities.
E. Annual Safety Inspections/Audits:
In addition to the above inspections carried out under the relevant Factory/Mines Safety
Regulations, the annual safety inspections will cover safety systems/ special safety
devices on equipment and structures. High Pressure valves, High pressure manifolds,
Chick son and other high pressure joints for leaks etc. These inspections will also cover
all safety equipments installed on the rig for handling emergencies including fire-fighting
emergency.
F. Special Inspections in Exceptional Happenings:
Accidents
Blowouts
Down Hole complications
Fire
Natural calamities
In the event of one of the above happenings, the affected structure, equipment/systems
will be subjected to thorough check to sustain the rated load/design parameter.
3. SPECIFIC WELL TESTING AND COMPLETION

3.1. WELL COMPLETION
Once the design well depth is reached, the formation must be tested and evaluated to determine
whether the well will be completed for production, or plugged and abandoned.To complete the well
production, casing is installed and cemented and the drilling rig is dismantled and moved to the next
site.A service rig is brought in to perforate the production casing and run production tubing. If no further
pre-production servicing is needed, the christmas tree is installed and production begins.
Well completion activities include:
o Conducting Drill Stem Test
o Setting Production Casing
o Installing Production Tubing
o Starting Production Flow
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o Beam Pumping Units

After production starts, the well may need further servicing.If it's decided that the well will not be
completed, then it will be plugged and abandoned.
3.2. METHODOLOGY OF PRODUCTION TESTING OF EXPLORATORY WELLS IN OFFSHORE
The offshore exploratory wells in Mumbai offshore area are presently being drilled either by jack-up rigs
or floater rigs depending on water depth, underwater current, soil data etc. at the exploratory well
location.
The following are the salient features of production testing procedures usually adopted in Mumbai
offshore area:-
3.2.1. Production Testing Facilities:
The production testing of all the exploratory wells, except the deep water wells where water
depth is more than 400m, are being carried out departmentally with some inputs from hired
services depending on the methodology of testing adopted.
3.2.2. Conventional Testing:
Conventional testing of the objects is carried out by Exploratory Well testing team of Well
Services Group, Mumbai region with departmentally available equipments such as control
heads, choke manifolds, separators, burners, oil & gas manifolds, flexible steel hoses, tubings
and WIRE LINE SET PERMANENT PACKERS and bridge plugs, stimulation items etc.
Some of the companies that provide wire line services such as conventional perforation,
setting of permanent packers and bridge plugs are M/s Schlumberger and M/s Halliburton.
These services are, however, hired by the Logging Services Group of Mumbai Region.
The reservoir studies involving recording of bottom hole data, gradient survey, PVT sampling
are carried out departmentally by Reservoir Data Acquisition Group (RDAG) of Mumbai
Region.
The conventional mode of testing has certain limitations such as inability to provide requisite
drawdown, longer time required for activation of sub-hydrostatic formations, absence of
additional down hole safety during testing of high pressure and H2S wells, inability to lower
sand screens for testing of sand incursion prone objects and carrying out wire line jobs for
bottom hole formation pressure recording and PVT sampling on floater rigs.
The above limitations can be overcome by testing the objects either with TCP or DST methods.
However, testing with TCP / DST / TCP & DST string has major limitation of reliability when
used in heavier specific gravity mud that result in non-operation of annulus pressure operated
DST tools, string stuck-up etc.

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3.2.3. Testing With Tubing Conveyed Perforation System (TCP-Shoot &

Pull):
Some of the objects in exploratory wells are tested with TCP because of the following
advantages:-
i. Minimal formation damage caused by drilling fluid invasion since the object is opened for flow
immediately after perforation.
ii. Suitable for testing tight as well as sand incursion prone formations because of the perforations
with increased shot density @ 12 SPF, deeper penetration and double helix profile.
iii. Provision for selective / controlled drawdown for faster activation of sub-hydrostatic formations.
iv. Long perforation intervals (up to 40 m) in a single run, thereby reducing the number of runs
required for conventional perforations and saving costly rig time.
v. Suitable for non expendable wells requiring re-entry at a later date due to ease of completion
as permanent packers need to be milled for production from lower objects.
vi. A typical TCP assembly consists of TCP guns, bar drop activated as well as hydraulic pressure
activated firing head, debris sub, retrievable packer, safety joint, hydraulic jar, reversing tool
and radioactive marker.
3.2.4. Testing With Drill Stem Test (DST) System:
Presently, most of the objects in exploratory wells are being tested using either DST tools
alone or DST tools along with TCP perforation system due to the following additional
advantages over conventional and TCP test systems:-
i. Additional down-hole safety for testing of high pressure (surface pressure up to 8000 psi) and
high H2S (concentration > 40, 000 ppm) wells.
ii. Use of down-hole electronic pressure and temperature gauges for accurate recording of down-
hole data.
iii. Faster attainment of reservoir parameters since the well is closed down hole, very near to the
perforated intervals of the formation, thereby reducing the testing time.
iv. The DST tools consist of retrievable packer, down hole electronic pressure and temperature
gauges, safety joint, hydraulic jar, Hydrostatic Reference Tool (HRT), Pressure Controlled
Tester Valve (PCTV), Single Ball Safety Valve (SBSV), Multi Cycle Circulating Valve (MCCV),
Single Hydraulically Operated Reversing Tool (SHORT), radioactive marker and slip joints. All
the above tools are fullbore tools.

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These tools & services are presently being provided by M/s Schlumberger and M/s Halliburton
under contract with Logging Services Group. Depending upon the service provider, the
nomenclature for tools differ however, the function of the tool remains same.
3.3. ADDITIONAL EQUIPMENT FOR FLOATER & DEEP WATER RIGS:
In addition to above, the following contracts have been hired by Well Services Group, Mumbai region,
to meet specific testing requirements :-
3.3.1. Sub Sea Test Tree (SSTT) Equipment & Services:
Sub Sea Test tree (SSTT) is a mandatory safety equipment for use during testing on floater
rigs which allows the subsurface closure of well, delatching of the string and moving away of
the rig from location in case of any emergency such as blowout, adverse weather condition.
Once the emergency is over, the testing can be resumed by moving the rig on location and
latching the string.
Presently, SSTT equipments & services have been hired from M/s Expro. M/s Schlumberger
and M/s Halliburton also provide these equipments & services.
3.3.2. Deep Water SSTT & Production Testing Surface (PTS) Equipment and
Services:
In order to test all deep water exploratory wells drilled by floater rig Sagar Vijay, one set of DW
SSTT and PTS equipments and services have been hired from M/s Halliburton by Well
Services Group, Mumbai region.
3.4. PRODUCTION TESTING METHODOLOGY – SEQUENCE OF OPERATIONS:
3.4.1. Conventional Testing:
Generally, the following sequence of operations has been practiced during the conventional
testing of an object:-
i. Clearing and scraping of the hole to the required depth – usually 10 mts below the bottom most
perforation of the object.
ii. Recording of CBL-VDL log to ensure proper cement bond / isolation above and below the
object under test.
iii. Hermetical testing of the production casing / liner in water to the maximum expected surface
pressure.
iv. Changing over to mud of specific gravity used during drilling and its conditioning.

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v. Conventional perforation of the object, junk basket trip and setting of permanent packer at
suitable depth through wire line of logging contractor.
vi. Running in of production string, packer testing and spacing out. (RIH SSTT, in case of floater
rig).
vii. Rigging-up of surface equipments and lines and then pressure testing of the same.
viii. Displacement of string volume with cushion fluid (diesel / water) depending upon the expected
formation pressure and drawdown to be provided.
ix. Flowing back the well.
x. Reservoir studies (Virgin pressure recording, 3 bean studies, build-up studies, gradient survey,
PVT sampling) to be carried out in case the well becomes active. Stimulation job, if required,
for skin removal.
xi. In case, well does not become active, then pressure surging and keeping the well under
observation. Reversing out for bottom hole sample collection.
xii. After conclusive testing of the object, killing of well by bulldozing the well fluid into the
perforation interval of the object tested.
xiii. Conditioning of the mud. Pulling out the production string.
xiv. Isolation of the object by bridge plug / cement squeeze into object perforation.
xv. Repetition of steps no. v to xiv for the next object in case of isolation by bridge plug. In case of
cement squeeze to isolate the object, the well is to be cleared by cement drilling, if required,
and scraping up to 10 mts below the bottom interval of the next object before repeating steps v
to xiv.
3.4.2. Testing With TCP (Shoot & Pull):
object under test.
pressure.
v. Running in hole tubings single by single for tubing flex trip to check the pressure integrity of
tubings and also to remove the debris, tubing scales from tubings.

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vi. Running in of TCP string filled with requisite column of cushion fluid to provide required
drawdown. In case, complete string is to be filled with cushion fluid, then the string can be
displaced with cushion fluid prior to setting the retrievable packer instead of filling the string
intermittently.
vii. Correlation with CCL-GR tool so as to ensure that the TCP guns are against desired depth.
Spacing out based on correlation run.
viii. Rigging-up of surface equipments and lines and then pressure testing of the same.
ix. Setting of retrievable packer; testing of packer.
x. Dropping of TCP bar to fire the guns and perforate the object interval.
xi. Flowing back the well.
xii. Reservoir studies (Virgin pressure recording, 3 bean studies, build-up studies, gradient survey,
for skin removal. After conclusive testing of the object, killing of well by bulldozing the well fluid
into the perforation interval of the object tested. Opening SHORT.
xiii. In case, well does not become active, then pressure surging and keeping the well under
observation. Reversing out for bottom hole sample collection through SHORT.
xiv. Reverse circulation of one string volume. Unseating the retrievable packer.
xv. Conditioning of the mud. Pulling out the production string.
xvi. Isolation of the object by bridge plug / cement squeeze into object perforation.
xvii. Repetition of steps no. vi to xvi for the next object in case of isolation by bridge plug. In case of
and scraping up to 10 mts below the bottom interval of the next object before repeating steps vi
to xvi.
3.4.3. Testing With DST:
object under test.
pressure.

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vi. Conventional perforation of the object through wire line of logging contractor.
vii. Running in of DST string filled with requisite column of cushion fluid to provide required
drawdown.
ix. Setting of retrievable packer.
x. Pressurizing the annulus to open down hole PCT valve.
xi. Flowing back the well.
xii. Reservoir studies (Virgin pressure recording, 3 bean studies, build-up studies, gradient survey,
for skin removal.
xiii. In case, well does not become active, then pressure surging and keeping the well under
observation. Reversing out for bottom hole sample collection through MCCV.
xiv. After conclusive testing of the object, killing of well by bulldozing the well fluid into the
perforation interval of the object tested.
xv. Opening SHORT. Reverse circulation of one string volume. Unseating the retrievable packer.
xvi. Conditioning of the mud. Pulling out the production string.
xvii. Isolation of the object by bridge plug / cement squeeze into object perforation.
xviii. Repetition of steps no. vi to xvii for the next object in case of isolation by bridge plug. In case of
to xvii.
3.4.4. Testing With TCP & DST (Shoot & Test):
object under test.
pressure.
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vi. Running in of TCP& DST string filled with requisite column of cushion fluid to provide required
drawdown.
vii. Correlation with CCL-GR tool so as to ensure that the TCP guns are against desired depth.
Spacing out based on correlation run.
ix. Setting of retrievable packer.
x. Pressurizing annulus to open PCTV. Making dummy run to confirm PCTV is open.
xi. Dropping of TCP bar to fire the guns and perforate the object interval.
xii. Flowing back the well.
xiii. Reservoir studies (Virgin pressure recording, 3 bean studies, build-up studies, gradient survey,
for skin removal. After conclusive testing of the object, killing of well by bulldozing the well fluid
into the perforation interval of the object tested. Opening SHORT.
xiv. In case, well does not become active, then pressure surging and keeping the well under
observation. Reversing out for bottom hole sample collection through MCCV.
xv. Reverse circulation of one string volume. Unseating the retrievable packer.
xvi. Conditioning of the mud. Pulling out the production string.
xvii. Isolation of the object by bridge plug / cement squeeze into object perforation.
xviii. Repetition of steps no. vi to xvii for the next object in case of isolation by bridge plug. In case of
to xvii.
3.5. COMPARISON OF TESTING METHODOLOGY CONVENTIONAL V/S TCP/DST/TCP & DST
During the nineties, most of the objects in exploratory wells were being tested conventionally.
However, the conventional mode of testing had certain limitations such as formation damage due to
mud filtrate invasion into formation after conventional perforation, activity problems during running in
hole of production string, inability to provide requisite drawdown, longer time required for activation of
sub-hydrostatic formations, absence of additional down hole safety during testing of high pressure and
H2S wells, inability to lower sand screens for testing of sand incursion prone objects and carrying out
wire line jobs for bottom hole formation pressure recording and PVT sampling on floater rigs.

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3.5.1. Additional Operations Required To Be Carried Out In TCP / DST / TCP

& DST Methodology Over Conventional Testing:
i. Tubing flex trip to check the pressure integrity of tubings and also to remove the debris, tubing
scales from tubings. ( TCP / DST / TCP & DST )
ii. Intermittent filling of string with cushion fluid and testing of the string to provide requisite
drawdown. ( TCP / DST / TCP & DST )
iii. Correlation with CCL-GR tool so as to ensure that the TCP guns are against desired depth. (
TCP / TCP & DST )
iv. Pressurizing annulus to open PCTV. Making dummy run to confirm PCTV is open. (TCP &
DST)
v. Dropping of TCP bar to fire the guns and perforate the object interval.(TCP / TCP & DST)
The above operations being additional in nature over conventional testing, more time is required, in
general, to test objects with TCP / DST / TCP & DST.
Also, testing with TCP / DST / TCP & DST string has major limitation of reliability when used in heavier
specific gravity mud that result in malfunctioning or non-operation of annulus pressure operated DST
tools, string stuck-up etc. Instances of tool malfunctioning and stuck-ups have been observed even
when used in low specific gravity mud. A lot of costly rig time has been wasted due to these failures.
It has also been observed that at each and every well where the TCP & DST tools have been used,
additional time has been lost owing to waiting on these tools and spares prior to and during testing
operations as well as redressing of tools in between testing of two consecutive objects.
In addition to resulting in costly rig time loss, all the above factors have defeated the very
purpose for which the TCP & DST tools were used over conventional testing.
3.6. WELL STIMULATION JOBS
3.6.1. Hydraulic Fracturing
To induce and increase flow of hydrocarbons held in a tight reservoir, oil-based or water-
based or emulsion fluids are injected under high pressure to fracture formations. the
fractures thus created are propped up with sand to sustain flow.
In this operation, since the formation is fractured with flammable fluids, there is danger of
fire. The other hazards are due to high pressure in equipment and handling of acids
and other chemicals. Liquid nitrogen is also used for injection into wells.
In this operation two to four pumping units, a blender and storage tanks are deployed. Diesel
engines provide the motive power.
The recommendations listed below provide guidance for safe operations.
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SAFETY
A. Safe location of equipment

i. The pumping unit and blender should be located at least 30 meters away from the well head
on the upwind side.
ii. The tanks containing fluids should be located further away, at least 45 meters from the well
head.
iii. There should be a clear and walkable passage between the pumping and other units and the
width of the passage should be atleast one metre.
B. Precautions against fire
i. An area within 30 meters of the wellhead should be treated as danger zone in which no
smoking or open flames should be permitted and all electrical equipment and transmission lines
should be de- energised.
ii. The exhaust of diesel engines should be discharged on the upwind side. The engine exhaust
system should be provided with spark arrester.
iii. Fire fighting crew and fire tender should be standing by. It should be ensured that persons
engaged in the operations are conversant with the use of fire extinguishers. See details under
the head " Fire extinguishers".at page no
C. Safety of Pressurised Vessels and Pipelines
i. It should be ensured that the wellhead connections are of such pressure rating as would be
suitable for the expected pressure for fracturing the formations.
ii. The fracturing unit, connecting lines and control valves should be tested to a pressure. The
suction line should provide positive suction and should be tested to pressure of 2.5
Kg/cm2 or as recommended by the manufacturer. The pumping lines should be provided with
non-return valve near the wellhead and also a bleeder valve with its discharge end leading to an
open tank or pit. the bleed-offline should be securely anchored at every five-metre interval. The
discharge line should not be led into a closed vessel because the vessel may not withstand
pressure built up due to excessive flow of fluids and may fail.
iii. The relief valve and pressure gauge of the pump should be checked to ensure that these are in
good working order.
iv. The pipelines on surface upto the last valve near the well head, should be tested to a pressure
which is 10% more than the maximum fracturing pressure but does not exceed the test
pressure of equipment.
D. Handling of Acid Chemicals.
i. A safety meeting should be held before the operation and every person present on the location
should attend the meeting. The precautions to be taken during fracturing operations should be

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explained to all persons during this meeting and it should be ensured that the directions are
clearly understood by all.
ii. The operation should be carried out during day light hours only.
iii. Persons not connected directly with fracturing operations should remain at a distance of not less
than 50 mts.
iv. All persons should be provided with the wear personal protective equipment suitable for the
work.
v. At times radioisotopes are used to ascertain whether formations at the appropriate depth are
fractured and also the extent of fracture, Radioactive substance should be handled and used in
accordance with instructions given under the head "Radiological safety".
vi. Containers of acids, chemicals and radioactive substance should be properly labelled and
stored. Warning signs should be posted to denote high pressure lines. Risks involved
on handling corrosive substances, should be marked on container label.
vii. A first aid box and persons trained in first aid should be available at the site. Refer under the
head "First Aid service".
viii. If operations are to be carried out at a well where sucker rod pumping unit is installed, the later
should be disconnected from its prime-mover to prevent any inadvertent motion.
ix. Where rig is deployed at the well, the travelling block of the rig should be safely secured to the
leg of derrick/mast.
x. During operations, no attempt should be made to tighten the wellhead fitting or injection line
connections. All repairs should be undertaken only after the pumping units have been stopped
and the system has been depressurised.
xi. On completion of the job, the control valve at the wellhead should be closed and the pressure in
the pipeline should be bleed-off before the lines are disconnected.
3.6.2. Acidization
A. General
This is a process in which oil bearing formations are treated with acid and chemicals to
increase production of oil and gas, Hydrochloric acid, some times mixed with hydrofluoric
acid also, is pumped down in the well at high pressure.
The hazards associated with the operation are similar to those connected with hydraulic
fracturing and additional hazards are due to handling of acid and chemicals. In addition to
the precautions mentioned in respect of fracturing operations, the following precautions are
also recommended:
B. Safe Handling of Acid
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SAFETY
i. Acid container should be stored in a well ventilated place. Chemicals which can react with
acid should be stored separately. Acid storage tanks should conform to IS standards, See
IS:6164-1971.
ii. Storage and container area of acid should be properly labelled and warning signs
should prominently to denote "Danger-Acid".
iii. Smoking should not be permitted at the place where acid is stored and suitable warning
signs should be posted to this effect.
iv. Carboys or other containers of acid should be carefully lifted, preferably by mechanical means.
v. Adequate quantity of lime should be kept readily available near the site where acid is
stored to neutralise acid spills.
vi. Persons handling acid should be provided with suitable personal protective equipment. Refer,
for more details, under head "Personnel Protective equipment".
vii. Whenever it is required to dilute acid, the acid should be added to water. In no case, water
should be added to the acid.
C. First Aid
The first aid box and personnel trained in first aid should be available at the site. Adequate
supply of clean and fresh water should also be available.
Procedure for washing eyes and skin affected by acid
If eyes, skin or other parts of body are affected by acids, wash it off with fresh and clean
water at once. Remember that the first few minutes are most critical for washing off splashed
acid. Do not use (except fresh water) any other solution to wash the eyes.
To wash the eyes, and eye wash bottle filled with fresh water should be used for
atleast 15 minutes. Use the thumb and forefinger of both hands to open the eye lids as
wide as possible to permit free flow of water around the eyes. Do not attempt to close the
eye-lids or rub them. The injured should immediately be taken to a doctor and till that time,
washing of eyes with eye wash bottle must continue. Reference be made under head " First
Aid Service".
3.6.3. Wire Line Operation :
During the whole time any wire line operations is in progress, a warning sign should be
displayed at the X-mas tree with the following inscriptions:
"Wire Line Operation On, Do not Operate Valves."
i. Before dismantling the lubricator, it should be ensured that the pressure inside it is
released through the release valve.
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SAFETY
ii. Equipment tools and small objects and other loose materials which are not required for use
should not be left lying on the derrick floor when rig is in place so as to dangerously obstruct
work places and passage ways.
iii. There should be atleast two persons at the site during wire line operation, one at the controls
and the other at the well.
iv. A lubricator of suitable length to accommodate the wire line tools should be installed on the
crown valve. It should be ensured that there is no leakage at the crown valve otherwise
during installation of lubricator, it may be thrown off due to pressure of gas.
v. The winch mounted vehicle for wire line jobs should be secured to the ground to prevent it
from skidding forward. The unit should be located atleast 30 meters from the well head on
the upwind side. All persons should stay away from the wire line when it is in motion.
vi. It should be ensured that the wire line tools, the wireline and the brakes of the wire line unit
are in good working order. In case any defect is noticed, it should not be put into use until
such a defect has been removed.
3.6.4. Endless Tubing Unit (ETU) Operations:

A. General:
The endless Tubing Unit (ETU) is a mobile equipment used for various well servicing jobs. It
has an one inch endless tubing stored on a reel and coiled upon itself. An injector, a
mechanical device - connected to the well head through a blowout preventer and stuffing
box, is used for lowering and hoisting the tubing. The tubing is used for circulation of
fluids, chemicals & nitrogen for cleaning a well, spotting acid, cleaning out test string during
DST etc.
In the CTU/ETU service, the hazards are due to pressure in the well, as well as that in the
endless tubing failure of tubing under pressure, blow out, fire and crane operations.
The recommendations given below may be referred for guidance.
B. Safe Practice :
i. Before commencement of work, all persons not directly connected with CTU/ETU
operations should be removed for safety.
ii. A safety meeting should be held on location by the person in-charge of the operations
and all persons connected with CTU/ETU operations should attend the meeting. The job
procedure, possible hazards and safety precautions should be clearly explained to the persons
and it should be ensured that the instructions are fully understood.
iii. Each set of rams in the blow out preventer stack should be cycled before every job to ensure
that the BOP is fully operational.
iv. The CTU/ETU should not be positioned in line with the flow arm valve to ensure that a line or
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SAFETY
the valve itself were to break, the gas flowing out of the well would not be aimed directly
at the operator's cab or the truck exhaust.
v. The crane should be fully serviced once in a month in accordance with the
recommendations of the manufacturer. The cable should be particularly cared for because
persons are required to work underneath the tubing injector while it is hanging from the crane.
The cable should be periodically slipped to ensure that there is not an excess of wear on the
cable.
vi. Before cutting Endless Tubing it should be ensured that any pressure inside the tubing is
safely released.
vii. While working on live wells, a non-return valve should be used at the down-hole end of the
endless tubing.
viii. The tubing injector should be so installed and secured that the wellhead does not support
its weight nor does it experience any bending forces from the coiling process.
ix. Regular maintenance of BOP's stack, stuffing box and tubing injector should be
undertaken in accordance with the recommendations of the manufacturer.
3.6.5. Precautions During Handling Of Nitrogen :

Liquid nitrogen is stored at - 195° C and requires extreme care in handling it.
i. The vacuum in the nitrogen tank should be less than 50 microns and it should be checked
once in three months and also whenever any frosting on the tank is noticed. The relief
valve on the storage tank should be checked regularly to ensure that it is in good working
order. Frosted line should not be touched with bare hand.
ii. Any cutting/welding or repair on the outer surface of the nitrogen tank should be undertaken
only after obtaining authorisation in writing from the competent authority.
iii. Persons engaged in handling liquid nitrogen should be imparted clear instructions in safe
handling of nitrogen and it should be ensured that they understand the same.
3.6.6. Well Maintenance Jobs :

A. Flushing of flowlines
Flushing of flowline is done in order to keep the flowline free from paraffin deposition to
facilitate free flow of oil from wells to installations. High pressure pumping units are used
for these jobs with water as service liquid. In few wells these operations are done with hot oil
also. Following precautions should be followed while carrying out such job.
B. Safe location of equipment :
i. The pumping unit and the tanker should be placed at safe distance from the well (minimum15
mts.)
ii. A clean and walkable passage between the pumping unit, tankers and well shall be
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SAFETY
maintained and the width of passage should be adequate to permit free movement of
operators.
C. Precautions against Fire :
i. In case of flushing job done with hot oil, fire tender and fire fighting crew shall always be kept as
stand by till the completion job.
ii. Crude oil carrying tankers / hot oil pumping unit shall be provided with flame / spark arrester in
their exhaust system.
iii. A portable fire extinguisher should be provided with each oil tanker/pumping unit.
Extinguisher shall have to be periodically charged and certified.
D. Operating Safety
i. All temporary connections shall be done properly and all studs, units of standard length and size
shall be properly tightened in order to prevent any leakage during operations.
ii. The safety relief valve and pressure gauge of the pumping unit shall be tested at regular intervals
to ensure their proper operations.
iii. The line connection from pumping unit to the last valve shall be tested minimum 1.5 times of
expected operating pressure before commencing the job. In case any leakage is observed it
shall be rectified.
iv. No attempt shall be made to tightened any fittings or flow lines or pumping line connections under
pressure. All such jobs shall be under taken only after bleeding the pressure of whole working
system.
v. On completion of job control valve of well head shall be closed and temporary pumping line shall
be depressurised. It should be ensured that no pressure is trapped and then only the temporary
lines are to be disconnected.
vi. All operations shall be carried out only during day light hours. Necessary safety kits like safety
shoes, helmet, hand gloves, apron etc. should be worn by operating personnel.
Note :The above safety measures shall have to be followed during water circulation/well
subduing jobs also.
E. Steaming Jobs
Following steaming jobs are generally done:
a. Flow line steaming - To keep the flow line free from paraffin deposition.
b. Annulus steaming for clearing paraffin deposition inside the tubing/annulus.
c. Tubular maintenance-for clearing of chocked tubings with mud cake/paraffin.

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Following safety precautions shall have to be followed during the job :

i. Steaming unit shall be placed at a safe distance from the well. (minimum 15 mts.)
ii. The steaming unit is to placed in such a way, that it can be moved quickly away from the well in
case of any emergency during the job.
iii. Steaming point connection shall be done properly and all studs/units. etc. shall be properly
tightened, so that there is no leakage during the job. It shall be ensured that pressure if any is
released before making any connections.
iv. Relief valve and pressure gauges, temperature gauges shall be checked to ensure that they are
in good working conditions and need calibration at regular intervals.
v. Persons connected with the job at well/site shall wear all necessary protective kits without fail like
safety shoes, handgloves, helmet etc.
vi. During operations no attempt shall be made to tighten the well head fittings or steaming line
connections. Repairs to be undertaken only after unit is shut and pressure is released.
vii. On completion of the job, control valve and head shall be closed and the pressure in the line shall
be released before lines are disconnected.
viii. Care shall be taken in handling the lines as the lines are very hot due to high temperature of
steam.
ix. Operations shall be carried out during day light hours only.
x. Persons having Boiler operator licence, shall alone be permitted to operate the boiler.
xi. Boiler shall be pressure tested once in three months and internal records to be maintained.
xii. Boiler shall have to be tendered for inspection to concern statutory authorities once in a year and
a certificate to be obtained.
F. Compressor Jobs
Compressor applications are done generally for well activation purpose. In addition it is used
for Gas Lift Valve (GLV) testing and water injection well washing.
Following safety precautions shall have to be followed during compressor application jobs:
i. Compressor shall be placed at a distance of 15 mts. from the well head.
ii. Compressor shall be placed properly in such a way, that there is no hindrance in movement
and compressor can be moved quickly from well site in case of any emergency during the
job.
iii. Compressor line connections to be made properly and studs/units to be properly tightened
so that there is no leakage during the job. It should be ensured that pressure is released
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before making any connections/disconnections.

iv. No attempts shall be made to tighten well head fittings or line connections during the job.
All repairs to be under taken only after compressor is stopped and system is depressurised.
v. On completion of the job control valve at well head shall be closed and pressure of line is
released before lines are disconnected.
vi. The operations shall be carried out during day light only & on no occasion activation job
shall be done after day light.
vii. All necessary protective kits to be used by attending team during operation.
viii. Portable fire extinguisher must be provided with compressor.
ix. Safety relief valve, air receiving pressure vessel and pressure gauge shall be tested once in
three months and records to be maintained.
G. Scrapping Operations
Scrapping operations are carried out to keep the tubing free of paraffin deposition and facilitates
smooth flow of well. Following safety precautions shall have to be followed during the job.
i. Before fitting of lubricator, welding of steps to lubricator body must be checked and if
anything wrong is noticed then that lubricator should not be used.
ii. All scrapping crew must use safety protective kits viz. safety shoes and helmet during
scrapping jobs.
iii. There should be no oil spillage in working area to avoid falling due to slippage.
iv. After fitting of lubricator and tightening the cap, no person shall be on lubricator. Crown
valve shall be opened only after the person gets down from the lubricator.
v. Counter meter shall be checked frequently and shall be set at zero before start of scrapping
in order to have correct depth control.
vi. Flame/spark arrester must be fitted in exhaust of vehicles.
vii. Scrapping operations shall be done in a day hours only.
viii. The lubricator shall have to be pressure tested at well head pressure by opening the Crown
Valve before commencing the operations to ensure that there is no leakage at all from the
lubricator.
ix. Scrapping jobs done by contractor's persons must be supervised by concerned ONGC in-
charges, in order to ensure all necessary safety precautions.

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4. SAFETY IN ARTIFICIAL LIFT OPERATIONS

When the reservoir is not enough for the formation fluid to flow by itself to surface, artificial means
are adopted to produce oil from the well. The following methods are usually adopted.
Sucker Rod Pumps
Gas Lift
Electrical Submersible Pump
4.1. SUCKER ROD PUMPS (SRP)
In this method a reciprocating pump lowered on solid Sucker rod string to the well bottom through the
tubing and connected to the surface with a polished rod through a stuffing Box. The stuffing box
contains rubber packings which seals around polished rod. The polished rod is hung from the carrier
box, which in turn is attached to Horse Head by a hanger rope. The Horse head through an
assemblage of walking Beam, Sampson post equaliser arm, pitman arm and set of bearing is
connected to the Gear Box. The complete assembly is fitted on a unit base and mounted on to a
concrete foundation or a skid. The electric prime mover mounted at the rear end of unit supplies
power through V belts to the Gear box. The rotative motion of crank cranks arm is converted into
reciprocating motion with the combination of crank arms, Pitman arms & walking beam and
transmitted to the sub Surface pump through the polished rod and sucker rods.
In this operation, the main hazard is due to moving parts of the unit namely crank arms & polished rod
and prime mover with V-Belts. Fire hazard may occur by gas due to sparking. Oil spillage through
stuffing box is another potential hazard to environment.
The following recommendations provide guidance for safe operation.
A. General Precautions
i. The SRP unit with the well should be properly fenced so that no personnel or any animal
can approach it while the unit is in operation.
ii. Proper earthing should be provided to the electric prime mover.
iii. In case of any abnormal noise the unit should be stopped immediately and inform the
concerned maintenance teams.
iv. In case of any problem with starter/switchboards, the jobs to be carried out by competent
electrical supervisors.
v. A non-return valve should be provided in the annular line for bleeding of accumulated
Gas periodically.
vi. Ladders/steps should be provided to the concrete foundation for easy approach to the prime
mover and crank end of unit.

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vii. The polished rod should be clamped properly so that it does not hit the horse head and
stuffing box.
viii. When the horse head is at its lowest position the gap between the rod hanger (carrier bar) and
stuffing box should not be less than 20cms.
ix. The stuffing box should be tested hermetically to its rated pressure at the time of installation.
x. The switchboard/starter should be placed in a closed enclosure at a safe distance from the well.
B. Lowering of SRP subsurface pump
i. While lowering SRP Sub Surface Pump, rotary sleeve should not be gripped on barrel/plunger
of the pump.
ii. SRP BOP should be installed prior to running in or pulling out of SRP (Sub Surface Pump)
iii. All sucker rod joints should be greased prior to tightening.
iv. Tightening should be done with proper size tong against particular type of sucker rod.
v. Average torque applied for tightening should be 450 ft-lbs.
C. Maintenance of SRP unit
The following points should be kept in mind during maintenance of Sucker Rod Pumps:
i. Before attending to any inspection/maintenance jobs, the SRP units should be stopped and the
power supply to the switch board/starter should be cut off.
ii. A periodical greasing and the inspection of all bearings should be carried out viz. central
bearing, Tail bearing, crank pin bearing.
iii. A periodical inspection and the replacement of rubber packings of the stuffing box to be carried
out.
iv. A periodical checking and tightening of all nuts and bolts to be carried out.
v. The level of gear oil should be checked every day and a periodical replacement of the oil to be
done.
vi. In case, it is required to open the stuffing box, it is to be ensured that the SRP stripper (BOP) is
closed and that the hydrostatic head in the well over-balances the bottom hole pressure.
vii. While replacing or changing the position of Crank pin, the unit brake should be locked properly,
the Polished Rod should be unhooked from carrier bar and clamped properly.

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4.2. ARTIFICIAL LIFTING OF OIL BY GAS INJECTION

In this method High pressure Gas is injected in the annulus, through the reverse flow check valve and
gas lift valves into the tubing to induce flow of oil from the well. The gas injection is regulated
at the surface by Time cycle controller & Diaphragm motor valve or adjustable chokes.
A gas lift installation is usually unmanned and the main hazard is that due to fire. The other hazard
being the failure of pipe line and control valves due to high pressure.
The following precautions are recommended:
A. At the time of installation & commissioning:
While lowering the gas lift valve fitted to Mandrels, the rotary slips and tongs for tightening
should not be applied to the body of Mandrel or Gas lift valves.
While unloading the well by high pressure air compressor for checking the proper
functioning of gas valves, it should be ensured that the proper functioning of gas valves, it
should ensured that the discharge line is anchored properly. Also the compressor should be
placed at a safe distance away from the well.
After completion of unloading, the compressed air should be released properly from the
annulus.
B. In case of intermittent gas lift wells:
The time cycle controller & diaphragm should be placed in a safe encloser and at a safe
distance from well site for easy movement of workover rigs.
The gas injection line & flow lines alongwith control valves should be tested to a pressure of one
and half times the working pressure before hook up to ensure that there is no leakage in the
lines.
An area extending upto 15 mts. from the well head should be securely fenced to prevent entry
of unauthorised persons.
C. Maintenance and trouble shooting
The following precautions should be recommended while carrying out maintenance &
trouble shooting :-
The paraffin chocking of tubing in the gas lift wells should be cleared by use of coil tubing units
through tubing, using suitable liquid. Hot oil circulation & steaming through annulus are not
generally recommended as it might damage the unloading valves.
While carrying out rocking to rectify stymied valve by using high pressure air compressor, the
flow from the well is to be diverted to a single test separator. The separated air mixed with gas
to be routed directly to flare. For carrying out such operation, the personnel at GGS should be
alerted earlier and should be kept in readiness at the separator.
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For winding to timer clock & checking it's function, the servo gas line should be isolated and
depressurised before hand.
4.3. ARTIFICIAL LIFTING OF OIL BY ELECTRIC SUBMERSIBLE PUMPS (ESP):
In this system a set of Tendem pumps, pump intake & driving motor with connecting cable are
lowered in a well on tubing. The subsurface cable is connected through Pig Tails & mini mandrel of
the well head to the surface cable and then to switch board. The installation is generally
unmanned.
The hazards in this method of lift are due to electricity and fire.
The following precautions are recommended:-
A. When lowering the electrical submersible pump into the well, it
should be ensured that :
i. The rig mast should be perfectly centered for carrying out running in & pulling out
operation of ESP.
ii. The connections of cable to the motor are made properly as specified by the vendors.
iii. The couplings in between the sections of the complete assembly are properly fitted.
iv. The speed of lowering is not more than 1.5 mts per minute (one stand /10-12 minute).
v. The cable is clamped to the tubing at every 12-15 ft.
vi. Rotary slips and tubing tongs are not engaged to the cable.
vii. The cable is suitably guided from the drum so that it unwinds uniformly without overlap and
is not stretched by the movement of the elevator during running & pulling out
operations.
viii. It is to be ensured that no foreign material, particularly the cut piece of cable clamps do not
fall into the well, otherwise this will lead to stuck up during pulling out operation.
ix. When connecting & disconnecting tubings, the electric cable should be safely held by a
metallic hook connected to the derrick/mast.
B. Maintenance and trouble shooting
A frequent maintenance of this mode of lift is required for smooth operations. The following
precautions are recommended for maintenance and trouble-shooting of the pump:
i. For rectifying problems of switch board, the main power supply should be cut off.
ii. Competent electrical supervisors only to attend such electrical problems.
iii. The switch board (flame proof) with other surface electrical accessories should be placed
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inside a safe enclosure at the safe distance away from the well.
iv. In case of a paraffinic well besides regular mechanical scrapping, use of coil tubing unit
with suitable liquid is recommended to clear the tubing choking.
v. In case of circulation by liquid as required the pumping pressure into the annulus should not
exceed 60 kg/cm2. Otherwise, it may damage the subsurface cable connections and mini
mandrel at well head.
4.4. HOT OIL CIRCULATION JOBS
Hot oil circulation jobs are required to be taken periodically in order to clear the choked tubings due
to congealing of the oil due to flow characteristics of the crude oil particularly where the
atmospheric temperature is low. These are essential routine jobs to maintain uninterrupted production
from wells. The safety precautions while taking up hot jobs are as given below.
i. The hot oil unit should be located at a distance of 30 meters from well towards upwind side.
ii. All connections for hot oil circulation jobs should be checked thoroughly prior to
commencement of the job.
iii. Fire tender should be kept standby during entire operations.
iv. The operators associated with such jobs must wear personnel protective equipment.
v. The connections made for hot circulation jobs should be disconnected only when the
temperature of flow lines comes down in safe limits after completion of jobs.
vi. First aid box with essential medicines should be available at site.
5. SAFETY IN WELDING AND CUTTING JOBS

5.1. INTRODUCTION
Hot work is an activity which may produce enough heat to ignite a flammable air - hydrocarbon mixture
or a flammable substance in the oilfield installation. It includes welding, cutting and grinding. Flame
cutting operation, especially when carried out at a height, results in scattering of molten metal over
large area which can lead to ignition of waste material. In this operation the other hazard is from
handling of oxygen and acetylene gas cylinders.
5.2. QUALIFICATION OF WELDERS
Welders with adequate professional competence and qualification shall only be authorized in writing by
the Manager/ Installation Manager to carry out welding or cutting work. No person other than a
competent welder so authorized in writing shall carry out welding or cutting work requiring use of flame
or electric welding apparatus.

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5.3. HOT WORK PERMIT & PRECAUTIONS TO BE TAKEN DURING HOT JOB
In view of the hazards involved, it is essential that all hot jobs in any classified hazardous area are
regulated by a system of written permits to ensure that safe condition of work are established and
adequate steps are taken to meet any emergency.
i. Permit shall be issued only for a single shift and its validity shall expire at the termination of the
shift. However, where the work has to be continued, the same permit may be revalidated in the
succeeding shift, by authorized person after satisfying the normal checks.
ii. In instances like plant turn around or an activity where work is of continuous nature involving
round the clock activity, blanket Hot Work Permit could be given if the owner-in-charge is fully
satisfied that the conditions are totally safe for the multiple jobs to be performed. But this shall
not be resorted to, especially in highly integrated units.
iii. No welding or cutting work shall be undertaken in hazardous area unless the area is duly
examined and found gas free by a competent person authorized for the purpose. Such
examination shall also be made at frequent intervals during the time welding/ cutting work is in
progress to ensure that the area is kept gas-free. If during any such test, the gas percentage
in the atmosphere exceeds 20% of lower explosive limit (LEL), all welding/cutting works shall
immediately be stopped and the work shall not be restarted till the area is made gas-free.
iv. Before commencing the welding job, ensure that all the cables and earthing connections are as
per the standard welding codes/ practices.
v. During the welding and cutting operations, it shall be ensured that all flammable material, oil
grease, oil-soaked earth are removed from the area.
vi. No matches, lighters, or smoking apparatus or any other source capable of igniting flammable
gas shall be present at or around the place of hot work, except the use of any suitable device
for the purpose of lighting or re-lighting the welding torch.
vii. Adequate number of fire extinguishers and other fire fighting arrangements shall be kept
readily available for immediate use.
viii. Pyrophoric substances may be present in operating area / equipment handling hydrocarbon.
Iron sulphide scale is the most common pyrophoric substance encountered. These shall be
either removed to safe locations or kept wet all the time to prevent their auto-ignition.
ix. After completion or stoppage of the job, the person to whom the permit was issued, shall
thoroughly check the area for clearing of debris, removal of temporary electrical installations
etc. and then shall sign the work permit and return it to the issuer.
x. The issuer on receiving back the permit would satisfy himself regarding completion of the job
and that the area has been cleaned. Then he shall also sign the permit and keep the records
for two years.

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5.3.1. Welding in Confined Space

i. System should be positively isolated from source of hydrocarbon by blind flange or spectacle
blind. The vessel should be thoroughly washed by overflowing with water. The vessel should
also be tagged with process lock out tag.
ii. Adequate arrangement for ventilation and lighting with self-contained portable hand lamps
shall be made.
iii. The welder shall be provided with and use self-contained breathing apparatus, safety belt and
a life line. Entry with an air-supplied mask may be permitted with LEL of up to 20%. The
oxygen level should be at least 19.5 % vol. and the concentration of toxic gases below the
threshold limits
iv. When operations are carried out in confined space, adequate ventilation by mechanical means
is constantly provided to prevent accumulation of flammable gas.
5.3.2. Welding on piping
Before welding or cutting of piping, which contains flammable liquid or gas, the pipe shall be
disconnected and blinded. A closed valve should not be considered as a positive block.
Pipeline is required to be isolated, drained and purged with inert gas or filled with water before
undertaking hot work. Adequate precautions shall be taken against build-up of pressure in the
line while hot work is in progress.
5.3.3. Welding Booth (Safety Barrier)
During the welding and cutting operations, sparks and molten spatter are formal which
sometimes fly considerable distances. Sparks have also fallen through cracks, pipe holes, or
other small openings in floors and partitions, starting fires in other areas which temporarily may
go unnoticed. For these reasons, welding or cutting should not be done near flammable
materials unless every precaution is taken to prevent ignition.
Welding Booth:-
It is a facility, i.e. a room, designed for welding or a temporary compartment of flexible
non- combustible flame resistant curtains. It is used to separate flammables if any in
the surroundings from the welding arcs. It shall act as a Safety Barrier during welding
process.
Fire resistant curtain is to be used which should be in good & always in wet condition.
Preferably asbestos curtain are to be avoided.
The lower edges of the curtain walls are spaced at a distance above the floor to allow
free communication of air between the compartments such that outside air may be
drawn into the compartment from the area beneath the curtains. The temporary
compartment is to remain open from top. Thus, air drawn through a compartment will
proceed in an inward and upward direction directly past a work station within the
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compartment. The operator within the compartment is protected from inhaling the
fumes present in nearly all forms of welding operations.
Safety Guidelines:-
Welding sparks can cause fire or explosion and can easily go through small cracks
and openings or spray up to 35 feet to adjacent areas. Remove fire hazards from the
welding area or cover them with a fire-resistant shield if necessary. Do not weld near
unshielded fuel or hydraulic lines.
Booth construction shall not block access to any fire/life safety equipment and shall not
impede exit access, exit doors or aisles.
Booth shall be made before every welding job, where presence of flammables in the
surrounding area can not be totally eliminated.
Cross-ventilation should not be blocked, and welding should not be done in a confined
space without proper ventilation.
5.4. DOS AND DONTS FOR WELDING & CUTTING OPERATIONS:
Dos
i. Ensure that all flammable material, oil, grease, oil soaked earth are removed from the area
ii. Ensure that no matches, lighters which are not appropriate or smoking apparatus or any other
source capable of lighting flammable gas is present at or around the place of work
iii. Ensure adequate number of foam or dry chemical type fire extinguisher are readily available
for immediate use
iv. Ensure adequate ventilation while carrying out welding/ cutting job in confined space
v. While carrying out operations on pipelines which contained flammable liquid, ensure that the
pipe is disconnected or blinded, the line is isolated, drained or purged with inert gas or water
before welding or cutting job is done. Also take adequate precaution against built up of
pressure in the line.
vi. Ensure those flash back arrestors are fitted at the end of cutting torch & at the Gas cylinder.
vii. Ensure the proper earthing of portable Gen set, if power is used from portable generator during
welding/cutting job
viii. Ensure that pressure gauge on the oxygen & acetylene cylinder is in working condition before
the start of the job.
ix. Check the pressure of oxygen and acetylene cylinders prior to start the job.

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x. Always use approved Welding helmet and safety glasses, welding screen, face mask, gloves,
proper safety shoes and overalls while carrying out welding/ cutting job.
xi. Check the Work area, equipment and lines for combustible and/or toxic gas prior to starting the
welding/ cutting job.
xii. Always close the hot work permit once the welding/ cutting job is completed.
Don’ts
i. Do not carry any welding or cutting job in hazardous area unless hot work permit is issued by
the manager or installation manager.
ii. Do not carry out welding operation near oil soaked earth.
iii. Do not carry out welding/ cutting job unless you are a competent welder authorized in writing
by the mines manager or installation manager.
iv. Never carry out welding without using proper PPE.
v. Avoid rapid cooling of the weld area.
vi. Never undertake welding/ cutting job in hazardous area unless the area is duly examined and
found gas free.
5.5. PERSONAL PROTECTIVE EQUIPMENT & FIRST AID
i. Welders shall wear fire-resistant protective clothing and equipment such as fire-resistant
gloves, aprons, helmets and goggles, with suitable filter lenses.
ii. When toxic fumes are likely to be produced, the welder shall be provided with suitable
breathing apparatus. It shall be ensured that the welder is adequately trained in the use of
breathing apparatus.
iii. Where persons are likely to be exposed to harmful radiation or heat rays from electric arc
welding, they shall be protected by suitable screens.
iv. During radiography test after welding, persons handling the radiography equipments shall use
protective kits. Other person working there shall remain away (minimum 30 m from the source)
so that they are not exposed to radiation hazard.
6. SAFETY IN USE OF GAS/ AIR COMPRESSION SYSTEM

6.1. INTRODUCTION
Compressed air can cause severe personal injures, because of its pressure inside. As such it could
result in:

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Dust, swarf and grit blown into the eyes;

A burst hose whipping about and can cause severe physical injury.
If compressed air is applied to equipment not designed to take the pressure, severe
damage can result.
6.2. HEALTH & SAFETY HAZARDS
Compressed air is dangerous from health and safety point of view. The hazards associated with it are
described below:
i. Air forced into the tissues or blood stream via the skin can cause an air embolism, which can
be fatal if it reaches the heart, lungs or brain.
a. Air can enter the body through the pores of the skin
ii. Inflation injuries of the intestine can be caused by air being directed at the anus. The act of
horseplay can cause death.
a. Air blown into the mouth can, at merely 5 psi, rupture the esophagus, or the lungs
iii. Eye and ear injuries can occur from a blast of air or flying particles. These types of eye and ear
injuries can cause blindness and deafness.
a. The sound from a compressed air hose can reach 120-130 decibels, which is well
above permissible 90 dB permissible exposure limit.
b. 40 psi can blow out an eardrum 4 inches away from the ear, and possibly cause brain
damage.
c. As little as 12 psi can blow an eye out of its socket.
iv. Flying particles can cause cuts and bruises to any part of the body.
6.3. GENERAL REQUIREMENTS
i. All pipes, hoses, and fittings must have a rating of the maximum working pressure of the
compressor. Compressed air pipelines should be identified (psi) as to maximum working
pressure.
ii. Air supply shutoff valves should be located (as near as possible) at the point-of-operation.
iii. Air hoses should be kept free of grease and oil to reduce the possibility of deterioration.
iv. Hoses should not be strung across floors or aisles where they are liable to cause personnel to
trip and fall. When possible, air supply hoses should be suspended overhead, or otherwise
located to afford efficient access and protection against damage.
v. Hose ends must be secured to prevent whipping if an accidental cut or break occurs.
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vi. Pneumatic impact tools, such as riveting guns, should never be pointed at a person.
vii. Before a pneumatic device is disconnected (unless it has quick disconnect plugs), the air
supply must be turned off at the control valve and the tool bled.
viii. Compressed air must not be used under any circumstances to clean dirt and dust from clothing
or off a person’s skin. Shop air used for cleaning should be regulated to 15 psi unless
equipped with diffuser nozzles to provide lesser pressure.
ix. Goggles, face shields or other eye protection must be worn by personnel using compressed air
for cleaning equipment.
x. Static electricity can be generated through the use of pneumatic system. This type of
equipment must be grounded or bonded if it is used where fuel, flammable vapors or explosive
atmospheres are present.
xi. All components of compressed air systems should be inspected regularly by qualified and
trained employees.
6.4. SAFETY INSTRUCTIONS
Dos :
i. Inspect hoses and couplings before use, discard damaged items. Ensure that 'quick
couplings' are properly locked together.
ii. Ensure before connecting an airline that the equipment is designed to withstand the supply
pressure.
iii. Ensure that contamination of the air supply cannot occur through back flow from plant at a
higher pressure.
iv. Shut off the air supply and bleed off the pressure before disconnecting the hose.
v. Wear proper Personal Protective Equipment:
vi. Use Safety glasses with side shields, and preferably a face shield
vii. Use Hearing protection
viii. Use Respiratory protection, depending on the materials being worked with.
DO NOTs :
i. Improvise with jubilee clips, use only properly designed hose connectors.
ii. Use compressed air to clear up swarf, fillings, dust, etc. even low pressure can blow the
particles into eyes, ear or skin of people nearby.
iii. Dust yourself down with a compressed air line.
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iv. Indulge in 'horseplay' with the air hose.
7. LABORATORY SAFETY & CHEMICAL HANDLING SYSTEM

7.1. OBJECTIVE
The aim of this topic is to bring out the HSE aspects of “Laboratories of ONGC and guidelines to
take remedial measures”.
7.2. LOCATION & LAYOUT
i. While selecting the location, due consideration should be given for hazards from nearby plant
facilities assessed through Risk Analysis.
ii. The laboratory should have separately earmarked rooms for storage of chemicals, reagents,
samples, glassware & bottle washing. It is preferable to segregate testing facilities for
hydrocarbons & gases, water and effluents. The layout on the basis of a central corridor or
circulation aisle, with laboratory space/rooms on either side, is a preferred design.
iii. Microbiological section of the laboratory should be segregated and well-ventilated for
maintaining hygienic conditions.
iv. The sitting place for the investigators and other support personnel should be separate from
working area.
7.3. WORK BENCHES / FUME CUPBOARDS
i. The workbenches should be modular (equal size), moveable and adjustable for height keeping
in view good aesthetics and convenience. Workbenches should be fixture supported by
cupboards & drawers with room for knee space. Bench top should be made of material
resistant to fire and chemicals. Standard bench level height is 90 cm.
ii. Standing or sitting near workbench should neither cast a shadow on the bench nor should one
have to look up into the glare from the window. Workbenches should, therefore, be planned
always at right angles to the window wall and lighting should be accordingly oriented.
Sunscreen shades /films should be provided to minimise glare from windows.
iii. Facilities like shelves, fume cupboard etc. should be laid as per standard engineering practices
to avoid over-crowding. The reagents shelves should be easily accessible and should not be
unduly high. These shelves should be provided with beading to prevent bottles falling off due to
vibration. The shutter pans should be made of shatterproof / reinforced glass. The vent height
of the cupboard should be up to the top of the building.
iv. Floor should be resistant to fire & chemicals and made of anti-skid material. There should be
no fittings on the floor that would hinder / obstruct free movement. Sinks and drains should be
made of chemically resistant material and the drains should be properly trapped and vented.

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Labs handling mercury should have black granite flooring and where electrical equipments are
handled flooring should have rubber mats.
v. Each laboratory should be provided with efficient fume cupboards, sufficiently large to permit
complete enclosure of apparatus normally used and provide with a sink for the washing of the
apparatus used for handling toxic materials. For Laboratories where large numbers of
digestions are to be carried out, a separate enclosure equipped with efficient fume cupboard
may be provided. The cupboard should not be too deep to make the access difficult. The
controls of the service connections should be provided outside the cupboard. The fume
cupboard should have corrosion-proof fittings. It should be adequately illuminated. It is
preferable to provide a small window in the front shutter. This facilitates easy manipulation of
samples / equipment inside the fume cupboard, without lifting the main shutter always. The
cupboard should be designed in such a way that there is strong upward draught even when the
shutter is open and there is no chance of any fumes entering the laboratory. This can be
achieved by having baffle at the back. In rooms, where work with extremely poisonous gases is
done, it is advisable to have an air inlet at the bottom (balanced-draught cupboard) so
arranged as to sweep everything to exhaust. For fume cupboard, the exhaust fan should be
able to create a free velocity of 30 meter per minute at normal working height. Cupboard of
highly toxic materials require higher face velocities.
vi. Vapours of heavier hydrocarbons like waxy gas oil, LSHS, Furnace oil samples get condensed
and deposited on the top of the fume hood. RCR /CCR tests, involving naked flame should,
therefore, be carried out in a separate fume cupboard to prevent fire hazard. Hot concentrated
perchloric acid should be handled in separate fume cupboards where its vapour does not
contact any organic matter.
7.4. VENTILATION
i. Effective ventilation should be ensured for instant removal of hazardous vapours generated
inside the laboratory. Forced ventilation, single pass once-through type should be considered
with about 10-12 changes of whole air per hour, preferably by having in the layout a central
corridor or a circulation aisle. Rooms should be cool, dry and well ventilated. Exhaust ports for
bottom ventilation should be provided, wherever heavier gases are likely to be present /
generated. While designing the ventilation/ exhaust system, the following guiding points
should be taken into consideration:
ii. Exhaust facility should be capable of replenishing continuously fresh air for purging out the
hazardous fumes / vapours.
iii. The location of exhaust facility should be such that the light hydrocarbon vapours do not travel
to exhaust via high temperature side of the bench.
iv. Whenever a new test is introduced, prompt review should follow regarding its impact on the
exhaust system of vapours especially from safety and corrosion angle.
v. Fume hoods should be located in the lab at draught free position.

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vi. Bottle washing room should be well ventilated.

7.5. EMERGENCY EXIT
i. Emergency exits should be provided at strategic locations. If possible, each laboratory room
should have two easily accessible, hindrance free exits.
ii. All exits should be properly displayed and marked with self glowing signage.
iii. Doors to corridors from laboratory should swing in the direction of the exit.
iv. No material/ unused furniture should be stacked blocking emergency exit.
7.6. STORAGE AND HANDLING OF MATERIAL / SAMPLES
Guidelines are detailed in chapter on ‘Hazardous Chemicals’. However, some additional guidelines
are enlisted below:
i. Material Safety Data Sheet provided by the manufacturers should be used as guidelines for
safe storage of any chemical being handled in laboratory.
ii. Storage of hazardous/ inflammable materials should be need-based and limited to bare
minimum for carrying out the Laboratory work and as far as possible it should be stored away
from working area.
iii. The store should be protected from heat and direct sunlight. However, it should be well lit and
ventilated with proper exhaust to prevent built up of the concentration of hazardous/ poisonous
gases/ vapours.
iv. Store room for hydrocarbon samples requires special care due to flammable vapour generated
by low boiling point hydrocarbon. These vapours, generally heavier than air, are likely to build
up concentration at ground level. Bottom exhaust should be provided for release of such
flammable vapours. The racks and flooring should be made of material, which is resistant to
fire. Portable gas detector should be made available and maintained for periodically checking
the presence of hydrocarbon. Smoke detectors should be installed.
v. Electrical fittings as well as electrical equipment in store room where inflammable material is
stored should be flame-proof.
vi. Everyone working in Laboratory should be made aware of the adverse effects of hazardous
chemicals on potential exposure during their working in the laboratory.
vii. Based on the compatibility of chemicals, their storage must be planned. An illustrative list of
Incompatible chemicals is given in Annexure-I.
viii. Each bottle/container, whether big or small, having chemical in it, should be properly labelled
for its clear identification with name of the chemical, the concentration and the hazard colour
code etc. The colour codes for hazards should be in line with chapter no. 5.5 on handling of

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Hazardous Materials. Such information from original container should be transcribed on to the
tags on the secondary/smaller containers like spray bottles/ sample bottles.
ix. In case of storage & handling of poisonous substances, a separate stock & issue register
should be maintained and the inventory of poisonous substances should be kept bare
minimum for sustaining laboratory operations.
x. Since water reactive materials react spontaneously when comes in contact with water, it is
hazardous to fight fire in these chemicals using water; instead DCP should be used.. List of
chemicals / materials stored should be displaced at appropriate / prominently visible location.
7.7. DISPOSAL OF SAMPLES AND CHEMICALS
Safe disposal of hazardous and non-biodegradable waste is legal and statutory requirement. Therefore
a waste disposal procedure should be developed for safe disposal and incorporated in the operating
manual of QHSE document. Waste materials generated in a laboratory can be broadly classified as
‘Solid Wastes’ and ‘Liquid Wastes’. These can be further categorized as hazardous, biodegradable and
non biodegradable wastes. While the leftover gas samples like fuel gas should be discharged to safe
height through the fume hood.
A. Solid and Liquid wastes
All solid wastes generated in a laboratory should be carefully screened and segregated based
on their toxic effects to device proper disposal methodology/ procedure.
Segregated Hazardous waste including toxic chemicals, should be properly labelled and
disposed as per the safe disposal procedure meeting the statutory requirements. There are
MoEF guidelines and state pollution control board approved common hazardous waste
disposal agencies for safe disposal of Hazardous and non – biodegradable wastes. The
laboratory should take membership of such agency and dispose Hazardous and non–
biodegradable wastes through them only.
B. E – waste management
If e-waste generated in big quantity is not segregated properly and not disposed off safely, may
create severe environmental problems. The e-waste generated in laboratories mainly consists
of compact discs, empty printer cartridges/ toner cases, magnetic tapes etc. Efforts should be
made to re-use or recycle these e-wastes otherwise it should be disposed off through
authorized agency as per CPCB guidelines. An E-waste policy guideline has been issued by
CHSE, ONGC which may be reffered to:
7.8. SAFETY IN LABORATORY
A. Safety in geology processing lab
Processing Lab of Geology processes sediment samples for geological studies and uses some
harmful acids/ chemicals. The acidisation of sediment samples should always be done in

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fuming chamber. The lab should also have exhaust fans / proper ventilation system so that
fresh air is kept on circulation regularly.
B. Safety in core house
Core house of the geology laboratory is the depository of very much valuable cores collected
from exploratory wells for further geological studies. These require many safety precautions
while retrieving out and/ or putting back after taking certain portion for study. Following safety
precautions should be taken while handling the core boxes and cutting the core plugs:
i. Personnel must use safety shoes, helmet and cotton hand gloves while taking out or putting in
the core boxes from core racks.
ii. They must use wheeled trolley for the movement of core boxes from one place to other.
iii. While handling core boxes ladder safety rules as given below should be adhered.
iv. They must wear ear plugs/ muffs and safety goggles while cutting core plugs if noise level is
beyond permissible limits.
v. Regular pest control treatment should be carried out to control snakes and other pests.
7.9. SAMPLING / LABELLING / TAGGING
All samples should be properly tagged with date, time, type of product, source and test required.
Proper labelling/ tagging are very essential for maintaining unique identification of the sample.
7.10. SAFETY BRIEFINGS
Whenever a visitor visits the lab he/ she should be briefed about safety precautions to be taken by him
to avoid any untoward incident.
7.11. PERSONAL PROTECTIVE EQUIPMENT
i. The following equipment should be available for personal protection in a laboratory:
ii. Safety goggles and face/fume masks should be used appropriately while handling harmful
fumes/ vapours.
iii. Suitable type of aprons of PVC, rubber or cotton should be used to protect against specific
hazards.
iv. Protective hand gloves made of cotton, rubber, PVC, etc. should be worn while handling sharp
objects or hazardous substances including chemicals, glassware etc.
v. Proper gloves and face shield to be worn while handling extremely low temperature items and
materials like solid carbon dioxide or liquid nitrogen.
vi. Equipment like fire blankets, eye wash devices, safety showers, breathing apparatus, helmets,
first-aid kit and gas masks should be available for specialized protection and all personnel
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should be aware of their location and use. Equipment should be checked and maintained
regularly.
vii. Earmuffs/ plugs should be used in noise prone area like Core cutting room.
viii. Oxygen mask/ respirators should be used while handling with experiments which generate
harmful/ fatal gases like Hydrogen Sulphide, Ammonia etc.
7.12. OTHER RECOMMENDED PRACTICES
i. All chemicals in the laboratory are to be considered harmful. Avoid handling chemicals with
bare fingers. Do not taste, or smell any chemicals.
ii. Check the label on all chemical bottles twice before removing any of the contents. Never
return unused chemicals to their original container.
iii. The entire laboratory should be declared a "NO SMOKING ZONE" and should be prominently
displayed on important places.
iv. No employee should work alone in a laboratory while performing a task that is considered
usually hazardous in nature.
v. Lab may have National Board for Accreditation of Laboratories (NABAL) accreditation.
vi. A new test should be introduced only after review of the associated hazards, associated risk,
documentation and training.
vii. For operating equipment, the recommendations of the original equipment manufacturer should
be followed strictly.
viii. Rubber tubing used inside the laboratory for connecting equipment should be periodically
checked along with the associated valves and replaced, to prevent leakage of flammable
gases. Checking of leakage should be carried out with soap solution periodically.
ix. Report any accident (spill, breakage, etc.) or injury (cut, burn, etc.) to the safety officer/ In-
charge Lab immediately, no matter how trivial it seems. Do not panic. The guidelines given in
Chapter no. 5.15 on “Accident / incident reporting, investigation and analysis” of this HSE
Management System should be followed.
x. If a chemical splash in your eye(s) or on your skin, immediately flush with running water for at
least 20 minutes. Eatable should not be stored in areas where exposure to toxic material is
likely.
xi. Hands should be washed before eating and clothes should be changed immediately if they get
soaked with oil or chemical and affected part of the body should be flushed with sufficient
quantity of water.
xii. Skin contact or inhalation of harmful substances should be avoided.

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7.13. SPECIAL CHARACTERISTICS & INCOMPATIBILITY OF COMMON LABORATORY

CHEMICALS
i. Safe handling of chemicals require careful consideration of relevant characteristics like
spontaneous ignition, flash point, decomposition with catalyst and heat, explosive nature,
reactive, oxidising nature etc.
ii. HSE Audit of laboratory
iii. Periodic audit of HSE performance of lab should be conducted regularly and corrective &
preventive action should be taken on Observations / recommendations given by HSE audit
team. Timely ATR should be submitted on HSE audit observations.
8. MATERIAL HANDLING SYSTEM

8.1. MANUAL LIFTING- SAFETY TIPS
Protect Yourself
Use the correct hand protection; wear gloves to prevent cuts.
Wear safety shoes to prevent injury to your feet from a dropped item.
Size up the Load
Determine if you can carry a load comfortably; tip it on its side.
Get help if the load is too big or bulky for one person
Check for nails, splinters, rough strapping, and rough edges.
Lift It Right
Make sure your footing is solid.
Keep your back straight, with no curving or slouching.
Centre your body over your feet.
Get a good grasp on the object and pull it close to you.
Lift with your legs, not your back.
Move your feet to turn. Don’t twist your back.
Tough Lifting Jobs
Oversized Loads

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Don’t try to carry a big load alone. Ask for help.

Work as a team. Lift, walk, and lower the load together.
Let one person give the directions and direct the lift.
High Loads
Use a step stool or a sturdy ladder to reach loads that are above your shoulders.
Get as close as you can to the load.
Slide the load toward you.
Do all the work with your arms and legs, not your back.
Low Loads
Loads that are under racks and cabinets need extra care.
Pull the load toward you, and then try to support it on your knee before you lift.
Use your legs to power the lift.
Power Carrying Tips
Make sure your footing is firm.
Ensure enough clearance at doorways to keep your hands and fingers safe.
Check your route for hazards.
Take extra care at platforms, loading docks, ramps, and stairs.
Carry long loads on your shoulders, with front end high.
Make sure the next person has a firm grip before you hand off the load.
When you carry with others, everyone should carry the load on the same shoulder,
walk in step, and put the load down as a team.

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Back Safety Tips

Wear the right personal protective equipment for lifting and carrying.
Lift with your legs, not your back; pivot, don’t twist.
Get help with tough lifting jobs.
Spend a few minutes each day before work on power warm-ups.
Exercise regularly to keep your back strong and healthy.
Eat right, stay slender, and cut down on stress to avoid back injuries.
8.2. PERSONAL PROTECTION
Various types of hand gloves could be used while handling variety of materials:
Leather Handling of chemicals
Soft leather Welding work, Handling of ethylene, propylene or L.P.G. (to prevent cold
burns).
Rubber Electrical Work
8.3. MECHANICAL LIFTING
Safe Slinging
Do not exceed safe working load.
Select multi-leg slings and hook the slings.
Use correct pins in shackles.
All links should be free on hooks.
Ensure load is stable.
Ensure there are no sharp bends/kinks in wires.
Plumb crane over the load.
Use proper signals and never pass a load over another person's head.
Do not ride on the load being lifted.
Unload the load on safe foundation/ground.

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Other precautions are:

Select the right sling for the job.
Inspect slings prior to use, .
Remember the effect of sling angles on load capacities.
Properly store slings when finished to avoid damage.
8.3.1. Safe Use Practices
Slings should be stored off the floor and hung on racks whenever possible in a clean,
dry environment.
Never drag slings across the floor.
Always hook with a “closed hook” arrangement (hooks facing out).
Never shock load slings.
Keep loads balanced to prevent overloading slings.
Always lift loads straight up.
Never rest a load on a sling, or pinch a sling between the load and the floor.
Sling should not be pulled from under a load when the load is resting on the sling.
Make sure the hook is always over the center of gravity of the load before lifting it
Do not apply a load to a twisted, knotted or kinked chain.
Do not force or hammer hooks or chains into position.
Hands and Fingers shall not be placed between the sling and the load while the sling
is being tightened around the load.
Clean chains regularly as dirt and grit can cause excessive wear at the link bearing
points.
Never shorten a sling with knots, bolts or other makeshift devices.
Protect the chain’s surface from contact with sharp corners, which can cause
permanent damage through gouging or abnormal stress and wear

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8.3.2. Safe selection and use of ropes

A. Fibre Ropes
Ropes are of two types, fibre ropes and wire ropes. Fibre ropes are used extensively in
handling and moving materials. There ropes are generally made from manila or nylon.
i. Extreme care must be taken while selecting ropes from its different types, rope condition,
behaviour of ropes affected due to exposure to moisture, acids etc. and depending on the risk
factors to life and equipment or machineries.
ii. Ropes must be selected depending on its working load. But one must be very careful about the
dynamic loading of the rope. Dynamic loading occurs when a rope is used for lifting load and
while doing so the load is stopped, moved on swung. Hence the use of rope in making safety
belts, life lines, towing line etc. may be examined to ensure that its prescribed working load is
not crossed and in such use load it is often subjected to dynamic loading. The effect of
dynamic loading is more on the ropes made from manila than that made from nylon.
iii. Inspection procedure for ropes should include thorough checking of the ropes for any damage
or defect before being used. The inspection should be done on the entire rope length. Ropes
while subjected to regular use should be inspected once every month if used for normal lifting
purposes. But ropes used to hang sling scaffolds or any other use where dynamic loading is
possible, should be checked more often. The typical rope conditions for inspection could be a
wear, an abrasions, broken or cut fibres, displacement of strands, discolouration, rolting or size
variations etc.
iv. The ropes exposed to acids should not be used for any critical use. While in use, it is to be
seen that the fibre ropes are not dragged on ground to avoid any damage to the fibres due to
abrasions.
v. The most dangerous deteriorating condition of fibre rope is the “Kinking”. Kinking may stress
the fibres beyond its limit. So to avoid kinking of fibre rope while uncoiling it, rope should be
laid on ground with the bottom end up and should be unwounded anti-clockwise by pulling the
bottom end of rope.
vi. It has also been noticed that sharp bends over a cone surface can cause much rope tension
on fibres. It is for this purpose advisable to use round object for fastening the rope. If rope is
twisted, the twist must be retained in handling. In joining the ropes, help of splicing technique
should be used and in no case a knotting should be done, as it has been seen that splicing can
retain rope strength upto 100% , whereas knotting retains only 50% of its strength.
vii. Ropes, while not in use, should be stored in a dry place away from moisture and acid fumes.
Use of metal cladded ropes can be dangerous if used near power line.
viii. The most severe deterioration of fibre rope occurs when the rope is subjected to wetting and
drying alternately. Such conditions must be avoided for better use of rope.

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B. Wire Ropes
Wire rope has greater strength and has been more durable than the fibre rope. Wire rope does
not change its physical characteristic in conditions of moisture and acid fumes and in other
environment.Wire rope is composed of steel wires, strands and core. Wire rope can also
deteriorate due to various causes. These are:
i. Corrosion: It can occur when a rope is subjected to wetting and in presence of acids.
ii. Wear: Wear of rope is possible on the crown or outside wires.
iii. Kinks: Kinks is possible due to improper winding of a new rope.
iv. Fatigue: Fatigue can be caused by bending stresses from sheaves and drums of small
radii, due to vibration or torsion etc.
v. Lubrication dry out: Lubrication dry out can occur when the wire rope is subjected to heat
or pressure.
vi. Overloading: This is most dangerous cause of wire rope failure. Overloading occurs when
a wire rope is subjected to dynamic loading, as discussed earlier.
vii. Mechanical causes: Mechanical causes also deteriorate the wire rope condition. These
occurs due to careless handling (e.g. dragging on ground or on abrasive surface) of wire
ropes.
viii. Over winding: Over winding occurs when the length of the wire rope is more than the drum
can accommodate in one layer.
The above mentioned deteriorating causes for wire ropes must be eliminated for safe use of
rope.
8.3.3. Hook, Shackles, Eyebolts and Chains
i. Use crane hooks with sling within an angle of 900.
ii. Use a 'D' or 'Bow' shackle to connect more than two thimbles.
iii. Check that the angle of the slings is connected before lifting.
iv. Use a shackle or ring and a pair of shackles when fitting slings to a hook.
v. Fit a shackle between lifting hook and eye bolts to reduce strain on the hook.
vi. Always tighten eyebolts to the correct position.
8.3.4. Lift Trucks (LT) i.e. Cranes/Fork Lifts etc.
i. Consult and observe manufacturer's safe operating procedures for Lift Trucks.

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ii. Take stock of unladen weight, capacity, load, centre distance and maximum lift height,
before operating lift trucks.
iii. Never add to counter weight.
iv. Never run over cables as flexible pipes etc.
v. Do not allow persons to walk under loads.
vi. Travel slowly and carefully down slopes.
vii. Do not leave lift truck on gradients unattended.
viii. Never use L.T. as a working platform.
ix. Check L.T. before use every day.
x. Maintain the backward tilt of the mast (enough to stabilize load).
xi. Keep the jerk low (4 to 6 inches from the ground) and backward tilt, to aid stability of Fork
Lifts when laden.
xii. Get someone to guide on ramps.
xiii. Look in the direction of travel - for obstructions etc.
xiv. Avoid sudden starts, stop and turns.
xv. Watch backward when turning.
xvi. Check for weak floors, soft ground, pot holes and skid patches like oil, loose sand and
gravel etc.
xvii. Use extra care on high stacks and watch for unstable loads.
xviii. Park cranes/LTs with hand-brakes on, control forks flat on ground, ignition/power switched
off and key removed.
• While parking LTs, do not obstruct access to roads, working areas and
railways etc.
8.3.5. Chain-Pulley Blocks
i. Portable chain hoists are used for lifting purposes to raise or lower materials. But the chain
hoist should be hooked on a monorail trolley or originally fabricated with the trolley. Chain
hoists can be of spur- geared type, differential geared type and screw geared types.
ii. Spur geared type of chain hoists facilitates easy pick up of load. But the problem with this
type of hoist is that it is free running and load can come down easily, if not stopped by an

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automatic braking arrangement in order to hold back the load from coming down rapidly. In
this case also, periodic inspection of hooks, chains, brakes should be carried out.
iii. All lifting tools and tackles must be checked as per applicable regulations, codes &
requirements. The SWL should be marked on the chain hoist body. All such chain hoists
should be checked for wear, malfunctioning and damage.
8.3.6. Mobile Cranes
i. Accidents of different types, starting from hitting by the boom or load to over turning of
cranes or overrunning have occurred. Hence, adequate precautions must be taken for safe
use of mobile cranes. A crane boom should not be swung too fast so that it can cause
upset of crane and the swinging load may hit a person or an object. Cranes should not be
moved or operated on a soft ground or sloppy ground. Care for crane movement adjacent
to an excavated area should necessarily be taken, as it may cause trench or excavation
collapse.
ii. While lifting the load, the hook should be positioned at the centre of the load so that
swinging is avoided while lifting it. Cranes when operated at a high angle with the boom,
there is possibility for the load to hit the boom and damage it. Hence in such situation,
adequate care is to be taken by the operator.
iii. While operating the crane near any overhead power lines, extreme care should be taken to
see that the crane does not operate and the boom does not come within the safe
clearance from overhead lines. Such type of electrical accidents occurred in past. The
minimum safe clearance from electric power line is depended on the voltage. For example
for a 50 KV line, the minimum safe clearance would be maintained at least 3 meters.
iv. Another important aspect in safe crane operation is that the essential crane signalling
should be done by a competent person as any wrong signalling is bound to invite
accidents. While continuing the discussions on cranes being used near overhead power
lines, operator must be trained to act in the event of any accidental contact of the crane
boom with the overhead lines. It is advisable for the operator to stay on the crane only and
not to panic in such situation till he is rescued by others.
A. Operator’s Responsibility
Operators of cranes should be experienced and should meet the following requirements:
i. Be able to read and understand operating instructions.
ii. Be able to understand the load charged.
iii. Be able to understand about the functioning of the safety devices.
iv. Be able to understand hand signal code used.

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v. Have eye sight and hearing that are normal and have no known physical deficiency
such as epilepsy or heart condition that would be detrimental to safe operation of
cranes.
vi. Have proper muscular co-ordination, depth perception and reaction time.
B. Initial Inspection And Testing
All new or substantially repaired or altered cranes should be inspected by a competent person
and tested to ensure that they comply with manufacturers load rating and are operationally
satisfactory. The crane should be put to use only when the test results are satisfactory. The
results of every such inspection and test should be recorded in a register by the person making
the test.
C. Safe Working Load
Safe working load on the crane at each radius of the jib should be not more than 90% of the
test load, but in no case should the rated capacity loads be exceeded. The safe working load
of the crane should be legibly marked on it. A scale or weight indicator should be available
which can be used to determine weight or unknown load to be lifted.
D. Safety Features
i. Every crane should be provided with a ready means of escape from its operating cab.
ii. The crane should be equipped with audible warning system.
iii. A dry chemical power type fire extinguisher should be provided within easy reach of the
operator.
iv. First-aid-box with medicines should be available in the operators cabin and lights should
be provided on the crane boom/support structure.
v. Safety limit switches must be available in working condition in all the cranes and all
controls shall be operative.
vi. Couplings and gears shall be provided with adequate guards.
vii. The spark arrester is to be fitted in the exhaust silencer wherever applicable.
viii. Slings which are to be used for lifting should be checked and inspected whether any
damage, torn or twist.
ix. Wooden logs/planks used for jacking up should be pre-selected to withstand load.
E. Inspection & Maintenance
Daily Inspection

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The following items of crane should be visually inspected daily or before its use if not used
everyday, to ensure that the crane is in safe working order:
i. All controlled mechanism for mal-adjustment interfering with proper operation.
ii. All safety devices inspected for mal-function.
iii. Leakage in air or hydraulic system.
iv. Crane hooks for deformation or cracks.
v. Electrical apparatus for mal-function.
vi. Crane booms and running ropes to make sure they have not been accidentally damaged.
vii. Wire ropes and rope slings for excessive wear, broken wires and kinks.
Monthly Inspection
A complete inspection of each crane, its foundation and drive track should be made every
month and the results recorded in a register. The manufacturers' recommendation should be
kept in view. The following items should be carefully looked for:
i. Deformation cracked or corroded members in the crane structure, foundation and boom.
ii. Loose bolts or rivers.
iii. Cracked or worn sheaves and drums.
iv. Worn, cracked or distorted parts such as pins, bearings, shafts etc.
v. Excessive wear on brake and clutch system.
vi. Load hooks, for deformation and cracks.
vii. Excessive wear of chain drive sprockets and excessive chain stretch.
viii. All ropes for compliance with manufacturers' specifications, reduction in diameter due to
corrosion of wear.
F. Capacity of the crane
Capacity of the crane along with load testing date is to be displayed in bold letters on the boom
and super structure on both sides and front and rear of the crane.
G. Training
i. Training should be imparted about the crane operation and maintenance for crane
operators and technicians and supervisors at field site every year for safety awareness.
ii. The lifting capacity of the cranes should be periodically checked.
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iii. A periodical human physical ability test may be conducted for the driver and the crane
operator through reputed institute e.g. National Labour Institute or any other.
8.3.7. Offshore Crane Operations
The offshore crane operation and maintenance shall be governed by the API RP 2D.
General Safe Operating Procedures
A. Pre – use checks
i. Before starting the crane operator should verify the following:
The Pre-use(pre-start up) inspection has been completed
All controls are in the ‘Off’ or ‘neutral’ position
All personnel are away from the area.
ii. For mechanical cranes, Operator should operationally test the breaks each time a load to
be lifted is nearer to the rated load.
iii. Prior to lifting exposed breaks should be warmed and rusted surfaces on the drums
cleaned by raising and lowering the boom and load lines under slight pressure.
iv. Load should be within the operator’s range of vision.
v. Operator should respond to signals from authorized signaller only.
B. When left unattended for a prolonged period
i. Land any attached load
ii. Disengage the master clutch, where applicable
iii. Set all locking devices
iv. Put controls in the ‘Off’ or ‘Neutral’ position
v. Stop the prime mover
vi. Ensure no hindrance is caused by crane for helicopter operations
vii. Cranes should not be operated during helicopter landing and take offs.
C. In case of power failure
i. Set all breaks and locking devices
ii. Move all clutch to “off’ or ‘neutral’ position

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iii. Lower the load in a control manner

D. Sling use guidelines
i. Prior to use, all sings should be inspected
ii. Protection should be given between sling and the sharp surfaces of the load
iii. Proper storage to be provided, i.e. away from heat, corrosive conditions and loss of
lubrication.
iv. Slings should never be choked in the splice
v. Sharp kings or knots should not be permitted in wire rope slings
vi. Loads should not be lifted with one leg of multi-leg sling until the unused legs are secured
E. Moving the Load
i. Prior to lifting, ensure that the load is secured and properly balanced in the appropriate
sling.
ii. The path for lifting is clear from all obstructions
iii. Before starting to lift ensure that-
The proper sling is selected for the load to be lifted.
Load is free to be lifted
Multiple part lines are not twisted
The hook is brought over the load with minimum swinging
Fix any slack rope condition
iv. While lifting ensure that -
Speed control is made smooth
Shock loading (caused due to lowering at high speed) is avoided.
Any part do not come in contact with any obstruction
Controls are engaged smoothly to avoid excessive stress on crane machinery
Sudden stats and stops and excessive swinging are avoided when rotating the
crane.
F. Personnel Transfer
While making personnel lift, ensure that –
i. All hooks used for support of personnel have an operable latch.

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ii. Hooks designed to prevent the personnel basket sling from coming off the hook
accidentally should only be used.
iii. The load is under control in both up and down directions
iv. All personnel to be lifted on a basket using approved Personnel floatation Devices (PFDs)
when being lifted or lowered over water.
v. While using net type personnel basket, personnel standing on the outer ring facing inward.
vi. No over loading of basket
Direct transfer of personnel:
i. In fine weather, if the installation has a boat landing platform, personnel should transfer
directly, passengers must hold on to the "swing rope" fixed to the landing platform and
should wear life - jackets
ii. In case of the crew boat, the transfer should take place from the stern side of the boat after
it is tied on to the platform mooring bits. One can then easily step on to the landing
platform.
iii. Boat landing platform should be provided with ladders made of synthetic fibre rope of at
least 25 mm diameters with wooden stakes at every 30 cms. The length of ladder should
be such as to reach the sea surface at low tide.
iv. Boat landing, swing ropes and rope ladders should be inspected and tested at regular
intervals to ensure that these are in good working order.
Personnel transfer by basket
The personnel basket should be so constructed, that it is capable of serving as a temporary life
raft for the maximum number of persons that it is designed to carry. This feature will more
likely protect the passengers in case the basket drops into the sea. The basket should be
provided with a tail line.
The following precautions should be taken during transfer:
i. Permission should be obtained from the tool pusher/ FPS and master of the vessel before
the transfer starts.
ii. One person should be designated to be the sole in charge of the operation; he should
have an over all view of the crane, basket and the vessel, through out the operation.
iii. All persons riding on the basket should wear life jackets.
iv. The passengers on the basket should stand on the outer rim of the basket and hold on
ropes tightly. The centre of the net is for light luggage only.

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v. Passengers should position themselves so that there is even distribution of load around
the rim of the basket.
vi. No smoking rule should be strictly observed by the passengers.
vii. Each basket is designed for certain number of persons; in no case should this limit be
exceeded.
viii. The crane operator should raise the basket only high enough above the deck of vessel to
clear obstructions, swing it out over the water, raise it to a position slightly above landing
deck level, swing the basket over the landing area and gently lower it to the deck. The
same method should be followed while transferring personnel from the installations to the
vessel.
ix. In order to ensure that the crane hook does not injure the basket passengers, there should
be a suitable sling sufficient length and strength between the hook and the basket.
x. After use, the basket should be stowed at a safe place so that it does not suffer
deterioration. It should be inspected periodically and also each time before use by the
person in-charge of the operation. Only baskets in perfect condition should be used.
xi. All people being transferred should feel confident for using basket transfer
G. Transfer of material
i. No transfer of material should be undertaken unless necessary permission has been
obtained from the master of the vessel and the tool-pusher/FPS of the installations. The
operation will depend on the sea condition wind and operations in progress on the
platform.
ii. There should be one supervisor on the deck of the installation and another on the vessel
before any transfer operation begins. The supervisor should see that:
The loads are properly placed on the landing net/pallets and correctly slung before
they are picked up and suitably stowed once they are on board.
No one stands underneath the loads or suddenly comes underneath during
movements.
Loaded landing net/pallet/pipe is not raised or lowered directly over vessel or deck;
if the crane cannot, for some reason swing the load, net clear of the vessel, the
latter should be moved away in order to protect persons on board, should the
loaded net be dropped accidentally.
iii. Personnel taking part in the transfer operation should be able to communicate with one
another by use of suitable equipment (megaphone / walkie-talkie sets).
iv. If the work situation exposes personnel handling material to the risk of falling into the sea,
every person so exposed should wear a life jacket or work vest.
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9. ENERGY ISOLATION (LOCK OUT & TAG LOCK OUT)

9.1. INTRODUCTION
Lockout/ tagout is a hazardous energy control program used to ensure that machines and equipment
are totally isolated from all energy sources (electrical, hydraulic, pneumatic, kinetic, potential, thermal,
chemical, and radiation).
Locks will be used to secure switches and valves in the OFF or SAFE position. Tags will be attached
as a warning device indicating the equipment may not be operated until the tag is removed.
This guidelines shall be used to ensure that all machines and equipment are isolated from all
potentially hazardous energy (locked and/or tagged out) during and service and/or maintenance
activities where the unexpected energization, start-up, or release of energy could cause injury.
9.2. SCOPE
These guidelines will cover:-
i. Any maintenance and/or servicing activities in which employees may come in contact with
machines and/or equipment,
ii. Where the unexpected energization, start-up or release of energy could cause injury.
iii. Whenever an employee is required to by-pass a guard, place any part of his or her body into
an area on a machine or piece of equipment where work is actually performed (point of
operation), or where an associated danger zone exists during a machine operating cycle.
9.3. ENERGY CONTROL PROGRAM
Notification: Before lockout or tagout procedures begin, employees who operate the machine or
equipment or those who work in the area around the machine or equipment must be notified that a
procedure under lockout or tagout will be performed on their machine or equipment. The notification
may be made by the employee performing the work or by a designated ONGC employee following a
Permit –To-Work System.
Preparation for Shutdown: Before a machine or piece of equipment is isolated, the employee(s) who
will perform the lockout or tagout must have the knowledge of the type and magnitude of the energy,
the hazards of the energy to be controlled, the method or means of isolating and/or controlling the
energy, the means of verification of effective energy control, and the purpose of the procedures to be
used.
Machine or Equipment Shutdown: The machine or equipment must be shutdown in an orderly
fashion in order to avoid any additional or increased hazard(s) to employees or damage to the machine
or equipment as a result of the de-energization.

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Machine or Equipment Isolation: All energy isolating devices that are needed to control the energy to
the machine or equipment must be physically located and operated in such a manner as to isolate the
machine or equipment from the energy source(s).
Applying Lockout or Tagout Devices: The person(s) performing the lockout or tagout must attach a
lockout or tagout device to each energy-isolating device (e.g. a breaker or a electric fuse). These
devices must be placed in a manner so that they will hold the energy isolating devices in the safe or off
position. He will also sign the permit and record his actions for energy isolation.
i. If tagout devices are used, they must clearly indicate that the operation or movement of energy
isolating devices from the safe or off position is prohibited
ii. A tag shall never be used in place of a lock on an energy-isolating device that is capable of
being locked
iii. If a tag cannot be attached directly to an energy isolating device, it must be located as close as
safely possible to the device, in a position that will be immediately obvious to anyone
attempting to operate the device
iv. In case of Electrical isolation, a tag used without a lock (as permitted) shall be supplemented
by at least one additional measure that provides a level of safety equivalent to a lock: e.g.
removal of an isolating circuit element
locking of a Main switch
opening of an extra disconnecting device.
9.4. MULTIPLE LOCKOUT OR TAGOUT
When maintenance and/or service work is performed by more than one employee or in conjunction with
another department, group, or contractor, a procedure shall be utilized which affords each employee a
level of protection equivalent to that provided by the implementation of a personal lockout or tagout
device. The following requirements apply for multiple lockout or tagout:
i. When machine or equipment maintenance or servicing involves more than one employee
and/or more than one crew (including contractors) or department, one authorized employee
must be designated to take primary responsibility to coordinate the affected work and ensure
continuity of protection for all.
ii. The designated employee is responsible to coordinate activities for the entire group to ensure
that the Application of Lockout or Tagout procedure and the Release from Lockout or Tagout
procedure is followed by each participating authorized employee.
iii. The designated employee has primary responsibility for providing the group lockout and/or
tagout device(s) and all employee notifications.

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9.5. ZERO ENERGY STATE PROCEDURE ( ZESP)

In situations where multiple energy source machinery or equipment requires maintenance or servicing,
the authorized employee shall follow the procedures listed below:
Identification of the ZESP - before lockout or tagout procedures begin, locate the ZESP on the
machine or equipment. If no ZESP is found, the concerned department shall be notified immediately.
Use the ZESP to apply energy controls - before the energy on machinery or equipment is isolated,
review the information on the ZESP e.g. the type and location of the energy sources, the method to
control each energy source, and how to verify that each energy source is isolated. Then, follow the
procedure for Application of Lockout or Tagout.
Verify that no other energy sources exist - inspect the machine or equipment to ensure that there
are no additional energy sources to be controlled.
Perform required servicing or maintenance work.
Release the energy controls - when the servicing or maintenance work is complete, follow the
procedure for Release from Lockout or Tagout.
10. SAFETY IN CONFINED SPACE ENTRY

10.1. INTRODUCTION
In Petroleum industry, Confined Space is an area where movement is restricted and ventilation is
poor. A confined space can be a vessel, a tank, a pipeline, a manhole, sump, ducts, drains etc or
anywhere there is inadequate natural ventilation.
a. Hazards are compounded because of the activities being performed , such as generation
of by products, spills of oil, chemical reactions, oxidation by rusting of metals, rotting
decomposition and fermentation of organic material, mechanical reaction of welding,
cleaning, scrapping, shot blasting, inertizing with CO2 and N2.
10.2. PURPOSE
Hazardous atmosphere is an atmosphere that may expose employees to the risk of death,
incapacitation, interfere with an individual's ability to escape unaided from a space, or cause acute
illness from one or more of the following causes:
i. Flammable gas, vapors, or mists in excess of five percent (5%) of its Lower Explosion
Limit (LEL).
ii. Atmospheric oxygen concentrations below 19.5% or above 23.5%.

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iii. Atmospheric concentrations of any substance that could meet or exceed the permissible
exposure limit.
iv. Any other atmospheric condition that is immediately dangerous to life or health (IDLH).
10.3. CATEGORY OF HAZARDS
i. Oxygen deficient atmospheres
ii. Flammable & Toxic Liquid and Gas Hazards
iii. Thermal hazards
iv. Hazards posed by welding and cutting
v. Mechanical Hazards
vi. Electrical Hazards
vii. Presence of pyrophoric substances
10.4. ENTRY INTO ANY CONFINED SPACE CANNOT PROCEED UNLESS:
i. All other options to carry out the job from outside have been ruled out
ii. Permit is issued with authorization by a responsible person(s)
iii. Permit is communicated to all affected personnel and posted, as required
iv. All persons involved are competent to do the work
v. All sources of energy affecting the space have been isolated and system depressurized
vi. Testing of atmospheres is conducted, verified and repeated as often as defined by the risk
assessment
vii. All necessary safety & Life saving equipments are available at location.
viii. A stand-by person is stationed
ix. Unauthorized entry is prevented.
10.5. GENERAL REQUIREMENTS
i. All confined spaces where there is an opening that can easily be walked into (floor
openings, manhole openings, etc.) shall have a physical barrier (guardrail, gate, etc).
ii. When required, isolating energy sources to the confined space shall be performed in
accordance with the Energy isolation procedures.

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iii. If “hot work” conditions exist, precautions shall be taken in accordance with Welding,
Cutting, Hot-Work procedures.
iv. Cylinders of compressed gases are never permitted in a confined space.
v. No smoking is permitted in a Confined Space or near the entrance/exit area.
vi. Gas testing is required before entering any confined space. Regular gas testing in the area
to be ensured.
vii. Portable electrical equipment used in Confined Spaces, which have wet surfaces, shall be
supplied power through a ground fault interrupter or be battery powered.
viii. Special precautions to be taken to remove any pyropheric substances which are likely to
be present in the confined space.
ix. Communication must be continuous between standby person and person inside the
confined space.
10.6. RESPONSIBILITIES
Supervisors
i. Be aware of hazards of the space to be entered, and signs, symptoms, and consequences
of exposure, and specific space control procedures.
ii. Execute all requirements of this instruction before work begins within a confined space.
iii. Authorizes entry into a confined space when acceptable entry conditions have been met.
iv. Ensures that all personnel entering and leaving the confined space are accounted for.
v. Terminate entry and cancel the permit if conditions warrant.
vi. Verify that rescue services have been identified and that means for summoning them are
operable.
vii. Remove unauthorized individuals who enter or who attempt to enter the permit space
during entry operations.
Entrants (to be taught or they must know)
i. Know the hazards that may be faced during entry, including information on the mode,
signs or symptoms, and consequences of the exposure.
ii. Use all equipment as required by this instruction and the specific permit space entry
procedures.

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iii. Communicate with the attendant as necessary to enable the attendant to alert entrants of
the need to evacuate the space as required by this instruction and for attendantto be able
to monitor status of entrants.
iv. Alert the attendant whenever
The entrant recognizes any warning sign or symptom of exposure to a dangerous
situation, or
The entrant detects a prohibited condition.
v. Exit from the confined space as quickly as possible whenever
Order to evacuate is given by the attendant or the supervisor.
The entrant recognizes any warning sign or system of exposure to a dangerous
situation, or the entrant detects a prohibited condition or an evacuation alarm is
activated.
Attendants (must know)
i. Know the hazards that may be faced during entry, including information on the mode,
signs or symptoms, and consequences of the exposure.
ii. Be aware of the possible behavioral effects of hazard exposure in authorized entrants.
iii. Continuously maintain an accurate count of authorized entrants in the permit space and
ensure that the means used to identify authorized entrants in the permit under this
procedure accurately identifies who is in the permit space.
iv. Remain outside the permit space during entry operations until relieved by another
attendant.
v. Communicate with authorized entrants as necessary to monitor entrant status and to alert
entrant of the need to evacuate the space if conditions warrant.
vi. Initiate onsite rescue procedures and if necessary, summon additional rescue and other
emergency rescue services when self -rescue is not possible.
vii. Perform no duties that might interfere with his ability to monitor and protect the authorized
entrants.
viii. Monitor activities inside and outside the space to determine if it is safe for entrants to
remain in the space.
ix. Warn unauthorized persons to stay away and advise those who may have entered the
permit space that they must leave.
x. Inform authorized entrants and Entry Supervisor of unauthorized persons.

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10.7. PROCEDURE
10.7.1. Confined Space Entry Permit
i. Before entry is authorized, the entry supervisor shall document the safety measures taken in
order to enter the Confined Space by preparing a Confined Space Entry Permit as per the
procedure for issue of Permit to Work.
ii. Before entry begins, the supervisor identified on the permit shall complete and sign the entry
permit to authorize entry. Acceptable entry conditions must be met in order for entry to be
authorized.
iii. The completed permit shall be made available at the time of entry to all authorized entrants
iv. The duration of the permit may not exceed the time required to complete the assigned task or
job identified on the permit.
v. Supervisor shall terminate entry and cancel the entry permit when:
The entry operations covered by the entry permit have been completed or
A condition that is not allowed under the entry permit arises in or near the permit
space.
vi. Any problems encountered during an entry operation shall be noted on the pertinent permit so
that appropriate revisions to the program can be made.
vii. Once the permit is terminated/closed/canceled, the same is to be informed to the control
room/supervisor.
10.7.2. Gas Testing
i. The atmosphere within the space will be tested to determine whether dangerous air
contamination and/or oxygen deficiencies exist. Direct reading instruments, detector tubes, gas
monitors and explosive meters may be used. Calibration records shall be kept.
ii. The minimum parameters to be monitored are oxygen deficiency, LEL and, if applicable,
contaminants e.g. H2S and other harmful gases that may be present. When testing for
atmospheric hazards, first test for oxygen content, then for flammable gases or vapors and
lastly for toxic gases or vapors.
iii. The initial air readings shall be recorded on the Permit and kept at the work site for the
duration of the job.
iv. Prior to atmospheric testing, check air readings outside of the Confined Space to ensure
proper operation of the instrument and that air readings are within normal ranges. Record Air
test readings on the Permit.

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v. For Air testing for Confined Spaces having a top entrance (manholes, tanks, etc.) following
steps to be followed:
From each entrance, drop the sampling probe of the Meter to the bottom of the
space. Additionally, use other available openings, which would facilitate air testing
for that confined space.
Slowly raise the sampling probe, stopping at intervals of two feet to ensure that the
atmosphere is not stratified. The rate of sampling shall be slowed to accommodate
detector response due to the length of the sampling line and probe.
Record air testing data on the confined space permit.
vi. For Air testing for Confined Spaces having a side or bottom manway (ducts, tanks, etc.)
following steps to be followed:
From each entrance, move the sampling probe of the Meter to the opposite side of
the space. Use rods, poles or other means to extend the probe to the opposite side
of the space.
Slowly test all areas inside the Confined Space. The rate of sampling shall be
slowed to accommodate detector response due to the length of the sampling line
and probe.
Record air testing data on the confined space permit.
vii. The atmosphere within the space shall be periodically tested as necessary to ensure no
accumulation of a hazardous atmosphere. If conditions exist that could change the atmosphere
of the Confined Space, it will be necessary to monitor the atmosphere continuously during
occupancy. Air monitoring shall be performed at the actual work location in the confined space.
The results of this monitoring shall be documented on the confined space permit, at a
frequency.
10.8. CONFINED SPACE RESCUE
In the event of an emergency of any type in the confined space, entrants in the space shall
evacuate as quickly as possible. Injured employees are encouraged to use self-rescue when
applicable.
If rescue from within the confined space is required, the attendant should immediately inform
the emergency services.
10.9. TRAINING
i. All personnel involved with confined space activities shall receive training consistent with their
duties.
ii. Training shall be provided to each employee that may be intended to carry out functions of a
supervisor, entrant or attendant
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Before the employee is first assigned duties,

Before there is a change in assigned duties,
Whenever there is a change in confined space operations
Whenever there are any deviations from the confined space entry
procedures or employees have inadequate knowledge or use of these
procedures.
iii. Training content shall include:
Duties of Supervisor, Entrant and Attendants,
Confined Space procedures
Entry (Lockout/Tagout, Hot Work, etc.),
Hazards of Confined Spaces,
Use of Air Monitoring Equipment,
Use of ventilation equipment,
Emergency Action & Rescue Procedures,
Confined Space Entry Equipment, including Personal Protective Equipment
and
Legal Requirements
10.10. SAFETY INSTRUCTIONS
i. Follow all the instructions written on the permit, which may require you to wear breathing
apparatus or use safety equipment such as lifeline and harness and PPE.
ii. Ensure that a standby man is in attendance who is briefed to keep constant watch on entrant,
is equipped and able to raise the alarm if necessary.
iii. Do not enter the vessel if you are the standby man raise the alarm and await assistance
iv. Do not attempt to rescue anyone from a confined space unless you are a member of the
rescue team, fully equipped with breathing apparatus, etc.

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11. HELICOPTER SAFETY SYSTEM

11.1. GENERAL
The permission to fly helicopters and their flight plans are regulated under the Aircraft Rules 1937 and
CARs issued by DGCA from time to time. The Directorate General of Civil Aviation is the competent
authority in INDIA for this purpose.
Aviation by itself is not hazardous but it never forgives incompetence, care free attitude and
negligence. Thus, it becomes everyone's moral and legal obligation to give due regard to the
practices, procedures, contained as here under.
11.2. HELIDECK
i. The design and structure of the helicopter deck should be in accordance with specifications as
may be approved by the competent authority.
The Director General Civil Aviation, India follows standards approved by ICAO on
offshore helicopter operations.
The design, structure and the dimensions of the helicopter deck on offshore
installations has to be suitable for landing and taking off for a particular type of
helicopter based on dimensions, specification, landing and take off weights and the
number of helicopter that the heli-deck can accommodate. It is, therefore, necessary,
that based on such details, the type and design of helicopter which can be permitted to
land on helideck, should have prior approval of competent authority. Some important
relevant design parameters are enclosed at annexure.
ii. The deck should have a non-skid surface. A rope net should be stretched across the deck in
landing area to obtain the desired coefficient of friction.
(Refer CAR Section 4, Series B, Part III, sub clause 3.3.6 and CAP 437 2005 edition,
Chapter 3, Sub Clause 7)
iii. Adequate drainage facilities should be provided to prevent accumulation of liquids on deck.
(Refer CAR Section 4, Series B Part III, Sub clause 3.3.6 and CAP 437, 2005 edition,
Chapter 3, Sub Clause 7.2)
iv. There should be no obstruction on the helideck itself and within three meters of its perimeter,
and all high structures in vicinity of helideck should be lighted for night operation and painted
Superstructures above the height of the helideck should be provided with a red obstruction
light.
(Refer to CAR Section 4, Series B, Part III, Sub clause 3.1.15 to 3.1.21 and CAP 437,
2005 edition, Chapter 4 Sub-Clause 4, for guidance on this)

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v. The perimeter of the helideck should be provided with a safety net of sufficient strength
designed to prevent any person from falling overboard from the deck. The net should have a
maximum upslope of 10 degrees and be able to withstand a drop test of a weight (as
specified in CAP 437, 2005 edition, Chapter 3, Sub Clause 9) without bouncing the
weight upwards. The outer edge of the net should not rise above the edge of the helideck.
Each helideck should be subjected to regular periodical review by the safety Officer /
departments, for its serviceability and maintenance at all times to ensure smooth and safe
flight operation to and from the heli-deck. A self assessment on Helideck audit , time to time is
very important and necessary.
11.2.1. Access Routes
The deck should have both a main and an emergency personnel access route located as far
apart from each other as practicable.
At least one of the access routes should be connected to a covered passage to be used to
shelter personnel, house safety equipment and the communication and alarm systems.
11.2.2. Access Points
Many helicopters have passenger access on one side only and helicopter landing orientation in
relation to landing area access points becomes important because it is necessary to ensure
that embarking and disembarking passengers are not allowed to pass around or in near vicinity
of helicopter tail rotor or under the main rotor of those helicopters with a low profile rotor, such
as S-76 Series, when a ‘rotors-running turn-round’ is conducted, in accordance with normal
offshore operating procedures.
(Refer to CAP 437 2005 edition, Chapter 3, Sub Clause 10)
11.2.3. Day Markings
The helideck surface, perimeter and aiming circle of the helideck should be painted in
accordance with the specifications as a visual aid for the pilot. (CAR Section 4, Series B,
Part III sub clause 5.2.8, and 5.2.10).
11.2.4. Night Light
Every helideck should be fitted with green perimeter lighting order to enable the landing area to
be easily identified at night. The lights should be positioned around the perimeter of the deck
not more than three metres apart.
(CAP 437, Chapter 4, Sub-point 3)
11.2.5. Identification
An identification sign with the name of the offshore installation should be so displayed at an
appropriate place in accordance with CAR Section 4, Series B, Part III, Sub clause 5.2.9.2,
5.2.9.4, 5.2.9.5 and CAP 437, 2005 edition, Chapter 4, Sub Point 1, specifications on every

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offshore installation so as to ensure a clear and visible view to the pilot of an approaching
helicopter.
11.3. FIRE FIGHTING ARRANGEMENT
i. There should be a trained fire crew fighting team consisting of at least two persons who should
stand by immediately adjacent to the helideck when the helicopter is landing or departing.
They should be adequately trained in the use of fire fighting equipment and rescue tools
provided on the installation.
Fire fighting personnel must be dressed in fire suits for arrival and departure of
helicopter.
ii. Adequate quantity of water should be provided at a flow and pressure to enable foam
equipment to be operated for fire fighting.
iii. Adequate quantity of foam liquid and 4 × 6 kg dry chemical powder should also be kept
available.
(Refer CAR Section 4, Series B Part III Chapter 6).
11.4. RESCUE TOOLS
The following rescue tools for use in the event of an accident involving a helicopter should be provided
at a site easily accessible from the heli-deck:
1. Axe, aircraft type - 1
2. Crowbar, one metre long - 1
3. Hacksaw with two spare blades - 1
4. Knife, quick release type - 1
5. Hammer - 1
6. Bolt 1 cropper, 60 cm - 1
7. Grab hook - 1
8. Gloves, asbestos - 1
9. Blankets asbestos - 1
10. Ladder - 1
(Refer CAP 437, 2005 edition, Chapter 5 Sub point 7, for definitive list of equipment
required.)
Following Items Need To Be Provided on Helideck:
i. Chocks & tie down ropes

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ii. Weighing scales for weighing baggage’s/cargo/passengers before boarding the helicopter. The
weighing machines are liable to be certified by authorized agencies once in a year.
iii. Recording instruments/apparatus for ascertaining the correct data as a prerequisite for regular
operations
Wind speed/direction
Air temperature
Barometer pressure
Pitch, roll, heave in case of floating mobile installations.
11.5. WIND DIRECTION INDICATOR (WIND SOCK)
i. A wind direction indicator shall be located so as to indicate the wind condition over the final
approach and take-off area and in such a way as to be free from the effects of airflow
disturbances caused by nearby objects or rotor downwash. It shall be visible from a helicopter
in flight, in a hover or on the movement area.
ii. An indicator shall be a truncated cone made of lightweight fabric.
iii. The colour of the wind direction indicator shall be so selected as to make it clearly visible and
understandable from a height of at least 200 m (650 ft) above the heliport, having regard to
background. Where practicable, a single colour, preferably white or orange, shall be used.
Where a combination of two colours is required to give adequate complicity against changing
backgrounds, they shall preferably be orange and white, red and white, or black and white, and
shall be arranged in five alternate bands the first and last band being the darker colour. A wind
direction indicator at a heliport intended for use at night shall be illuminated.
(CAR Section 4, Series B, Part III, Sub Clause 5.1)
11.6. RE-FUELLING FACILITIES
i. A helicopter fuel storage tank should be installed in a location which is isolated from sources of
ignition and protected from possible impact from landing helicopters. The tank should be
provided with a pressure release valve, and should be electrically grounded.
ii. The fuel hose should be provided with a static grounding device and a dead man type nozzle.
The helicopter should be grounded with self-releasing ground cables.
iii. The fuel pump, storage tanks and hose storage area should be enclosed by curbs or drip pans
of catchments which drain into a sump with provision to prevent vapour return.
iv. There should be a written procedure for receiving, storage and dispatch of helicopter fuel.
v. Adequate number of trained personnel is available in handling of refuelling, storage and
maintenance of facility.

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Approved safe practices and operating procedures should be religiously followed and
vigilance exercised at all times while handling aviation fuel.
vi. The Offshore Installation (Operational Safety, Health and Welfare) Regulations impose severe
obligations on the Installation Manager.
a. There should be sufficient quantity of quality controlled helicopter fuel available
on board to carry out its tasks/mission safely.
b. The refuelling system is maintained in safe satisfactory and operating condition.
c. To provide requisite quality controlled ATF Fuel to Helicopter at offshore Heli-
deck on the demand.
vii. A quality control manual on storage & Distribution of ATF at MRBC offshore duly approved by
the Director General Civil Aviation, India has been prepared and issued for implementation
under the supervision of the Quality Control Manager (The Chief chemist) of marketing group
as approved by the DGCA. The same need to be implemented strictly to ensure the
availability of quality controlled ATF to helicopter at all times as a prerequisite of flight safety.
The FPS/Barge Engineer/Master/Safety Engineer of Vessels should ensure that the all
requirements of the Manual are complied with.
11.6.1. Safety Precautions to Be Observed During Helicopter Refueling At Offshore
Platforms
i. All refueling personnel shall be thoroughly trained in refueling procedures.
ii. Before refueling check the ATF sample from filter/Separator Sump and nozzle for colour,
sediments and water.
iii. Check main air supply is at 100 psi.
iv. Do not run out hoses or bonding wire before helicopter lands.
v. Ensure all passengers have disembarked from the helicopter and engine stopped.
vi. All movements from one side of the helicopter to the other will be via the nose of the
helicopter or under instruction from the pilot. Under no circumstances any personnel will
work in close proximity to the tail rotor. Personnel working under main rotors are to
exercise extreme caution.
vii. Check fuel delivery meter is set to zero.
viii. The fueling equipments and helicopter shall be earthed and bonded to avoid sparks due to
static electricity.
ix. While refueling check the differential pressure across the filter separators at maximum flow
rate and record.

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x. Refueling shall be stopped when any fuel spillage is noted and shall not be started until the
spillage is wiped up.
xi. The refueling pumps shall be switched off before the hose is disconnected from the
helicopter.
xii. After the refueling, record meter reading and reset to zero.
xiii. Check that fuel caps have been replaced and signal 'All clear' to pilot.
xiv. Contact of ATF with skin can cause irritation and infection. Thus always:
a) Wash off the skin with soap and water immediately.
b) Contaminated clothing, if any must be removed at once.
c) Never expose the skin to prolonged contact with ATF.
(Refer to “ATF OPERATIONS MANUAL”, developed by ONGC for its ATF operations
and was released by Director (Offshore) on 17/05/05.)(Refer CAP 437, 2005 edition,
Chapter 7 & and Chapter 8).
11.7. FLIGHT SAFETY EQUIPMENT
Every helicopter should be provided with adequate number of safety belts, ear muffs, sea survival
packs, inflatable life jackets and life rafts of approved standards in accordance with the
requirements listed in the ONGC Aviation Standard AS4 document..
11.8. PASSENGERS' BRIEFING
Many workers going offshore as and also visitors may not be aware of safety rules or the emergency
procedures for flights by helicopter over water. All passengers should be thoroughly briefed on safety
equipment and procedures, prior to the flight. Audio-visual aid should be used for briefing. Where audio
visual aids are not available, the aircrew must impart briefing. Leaflets containing instructions for
passengers should also be carried in the cabin and distributed for information. It should be ensured
that passengers fully understand what they have to do during the flight & also in the event of any
emergency.
Passengers should receive a formal safety briefing prior to each flight.
11.9. OPERATION
11.9.1. Communication
Radio communication must be established between the installation and the helicopter before it
landing on the installation.
11.9.2. Helideck Landing Officer (HLO)
Under the International Statutory requirements, the Offshore Installation Manager, Tool
Pusher, OIM ./Area Manager must ensure that competent and correctly trained Helicopter
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Landing Officer (HLO) is appointed at the installation to take responsibility for the control of
Helicopter operations in relation to the installation for achieving and ensuring proper helideck
management, refuelling System and also should maximize flight safety.
11.9.3. Helideck routine checks:
i. Check condition of landing area for proper upkeep, condition of tension of
landing net.
ii. Check condition of visual aids, marking, lights and wind sock for proper serviceability.
iii. Check condition of perimeter safety net.
iv. Check condition of safety notice board.
v. The HLO is under obligation to exercise checks at the helideck in following sequence and
operations:
30 minutes before receiving helicopter ETA
i. Receive details of ETA, incoming load and fuel require for the incoming flight from the Radio
officer.
ii. Ensure deck area is cleared to obstructions.
iii. Ensure availability of fire/crash equipment and to alert the FIRE TEAM for stand by duty.
iv. Ensure landing net is adequately secured.
10 minutes. before helicopter E.T.A. to
i. Prepare to stop crane operation which might obstruct or hazard the Helicopter's landing area,
area of approach and overshoot.
ii. Deploy fire fighting equipments, unlock crash boxes, prepare fire team.
iii. Restrict access of unwanted personnel to helideck.
iv. If fuel required, ensure fuel sample, its record sheet for appraisal to pilot to satisfy him for the
quality of fuel.
v. Ensure that stand-by vessel has been informed and crane operation have ceased.
Immediately before landing to
i. Confirm all crane operations have ceased
ii. Deploy fire crash team
iii. Clear helideck of all personnel

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11.9.4. General precautions to be followed by installation for I/C installation and

Radio Room:
i. Take-off and landing of helicopter on floaters during bad weather sometimes may not be
possible due to excess Pitch and Roll Limitations of the type of helicopter in operation.
ii. No take-off and landing of helicopter be allowed on/to jack up type drilling rigs while
jacking/preloading operations are in progress. However, in the event of an emergency
requirement, prior permission of Tool Pusher / Barge Engineer, be obtained in consultation
with insurance surveyor.
iii. No take off and landing be carried out without clearance from the concerned installation's
Radio Officer.
iv. Starting up of a helicopter during a gas alarm at offshore installation is strictly prohibited. If an
alarm occurs before shutting down the engine, ensure that the passenger are clear, take off
and proceed up wind to wait for further instruction from the installation Control Room/Radio
Room.
11.9.5. Helideck Attendant
At every offshore installation, a person should be designated as helideck attendant to carry out
the following duties before any helicopter lands or takes off. He should ensure that:
i. landing area is clear of any obstruction
ii. crane in the vicinity has ceased to operate
iii. there are no persons other than fire fighting crew is in the vicinity of the landing area
iv. Standby vessel to render assistance to the installation is informed that helicopter operations
are to take place.
v. Fire fighting equipment is manned by the fire crew.
vi. Safety net around the helideck is in good condition.
vii. There is no danger from any cloud of smoke or gas vented from the installation. In case any
danger is so apprehended, he should immediately bring it to the notice of the superior officer
for remedial action.
11.9.6. Medivac / Night Operation
Night offshore operation is the most difficult and challenging exercise for the offshore pilots.
The reflection of the sky on the water during moonlit night and total darkness on dark night can
cause disorientation. Also, during night, the pilot looses the sense of depth perception making
it an even more difficult environment as compared to day. The following is a guideline for night
offshore operations.

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11.9.7. Medical Clearance

A medical clearance by the operator may be required only when the operator has received
information that the passenger
suffers from any disease which is believed to be actively contagious and
communicable
who, because of certain diseases, or incapacitation may have or develop an
adverse physical condition which could have an adverse effect during flight and on
safety and emergency evacuation procedures
Would require medical attention and/or special equipment to maintain their health
during the flights.
There exists a possibility of medical condition aggravated during or because of the
flight.
11.10. EMERGENCY PROCEDURE
The emergency procedure to be adopted in case a helicopter is to ditch in the sea should be carefully
written down and the passengers should be instructed by the pilot about the emergency the procedures
to be followed.
11.11. SAFETY MANAGEMENT
The aircraft operator should have process for the investigation of accident/incident reported.
The ONGC and contractor should have safety reporting system that permits feedback from personnel
regarding hazards and safety related concerns and should include analysis and action by management
as appropriate to identify and address safety deficiencies. No passenger should occupy front seat of an
aircraft or any seat where flight controls are installed.
12. WORKING OVER & NEAR WATER

12.1. HAZARDS
There is a definite hazard of person(s) falling in the water during working over or near water in
offshore installations. Examples of such operations are:
Painting
Repair of structure
Platform and piping modifications
Installing a BOP for new wells

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12.2. REQUIREMENTS
A. Minimum Requirements:
I. All the work over water, where the hazard of the worker falling in to the water exists shall
be carried out under Permit to Work authorized by competent person.
II. Work over water within 3 meters of the water can be done using a work vest. However, a
stand-by person with a life ring must be present there to provide immediate assistance.
III. For work over water above the 3 meters level, acceptable safety nets, use of type I
flotation devices, safety harnesses and life lines or other acceptable alternatives measures
should be adopted.
IV. The standby vessel should be put on alert and be ready to provide immediate assistance
during any work over water.
V. Employees working over or near water, where the danger of drowning exists, shall be
provided with approved life jacket or buoyant work vests.
VI. Prior to and after each use, the buoyant work vests or life preservers shall be inspected for
defects which would alter their strength or buoyancy. Defective units shall not be used.
VII. Ring buoys with at least 90 feet of line shall be provided and readily available for
emergency rescue operations. Distance between ring buoys shall not exceed 200 feet. .
VIII. A safety net is to be provided wherever possible while a person is carrying out work over
water
B. Skill Requirements
The persons who require carrying out work over or near water should develop certain skills
for survival at sea in an emergency: Certain requirements are:
I. The skills of emergency water survival, how to use a personal floatation device if they fall
into the water;
II. The ability to inspect life vests for defects; to properly select a personal floatation device
and how to size, adjust and don the device.
III. The ability to explain and demonstrate how to swim/ maneuver about in the water
IV. How to use life rings and rescue bags to perform simple shore based rescues
V. How to use applicable communications equipment to summon emergency services to
render medical assistance
VI. How to employ special techniques to minimize injury if falling from a height into water

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13. CRANE OPERATION SAFETY

13.1. GENERAL
The safe practices given here relate to cranes used for door lifting and handling heavy equipment
and tubular goods on land.
13.2. CRANE OPERATOR
Operators of cranes should be experienced and should meet the following requirements:
i. able to read and understand operating instructions.
ii. able to understand the load charged.
iii. able to understand about the functioning of the safety devices.
iv. able to understand hand signal code used.
v. have eye sight & hearing that are normal and have no known physical deficiency such as
epilepsy or heart condition that would be detrimental to safe operation of cranes.
have proper muscular co-ordination, depth perception and reaction time.
13.3. INITIAL INSPECTION AND TESTING
i. All new or substantially repaired or altered cranes should be inspected by a competent person
and tested to ensure that they comply with manufacturers load rating and are operationally
satisfactory. The crane should be put to use only when the test results are satisfactory.
ii. The results of every such inspection and test should be recorded in a register by the person
making the test.
13.4. SAFE WORKING LOAD
i. Safe working load on the crane at each radius of the jib should be not more than 90% of the
test load, but in no case should the rated capacity loads be exceeded.
ii. The safe working load of the crane should be legibly marked on it. A scale or weight indicator
should be available which can be used to determine weight or unknown load to be lifted.
13.5. SAFETY FEATURES
i. Every crane should be provided with a ready means of escape from its operating cab.
ii. The crane should be equipped with audible warning system.
iii. A dry chemical power type fire extinguisher should be provided within easy reach of the
operator.

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iv. First-aid-box with medicines should be available in the operators cabin and lights should be
provided on the crane boom/support structure.
v. Safety limit switches must be available in working condition in all the cranes and all controls
shall be operative.
vi. Couplings and gears shall be provided with adequate guards.
vii. The spark arrester is to be fitted in the exhaust silencer wherever applicable.
viii. Slings which are to be used for lifting should be checked and inspected whether any damage,
torn or twist.
ix. Wooden logs/planks used for jacking up should be pre-selected to withstand load.
13.6. DAILY INSPECTION
The following items of crane should be visually inspected daily or before its use if not used
everyday, to ensure that the crane is in safe working order:
i. All controlled mechanism for mal-adjustment interfering with proper operation.
ii. All safety devices inspected for mal-function.
iii. Leakage in air or hydraulic system.
iv. Crane hooks for deformation or cracks.
v. Electrical apparatus for mal-function.
vi. Crane booms and running ropes to make sure they have not been accidentally damaged.
vii. Wire ropes and rope slings for excessive wear, broken wires and kinks.
In case any defect or damage is noticed, it should be immediately brought to the notice of the
superior officer and appropriate remedial action be taken.
13.7. PLANNING TO EXECUTE OPERATION
Most accidents can be avoided by careful job planning. Person Incharge, must have a clear
understanding of the work to be done, consider all danger at the job site, develop a plan to do the job
safely and then explain the plan to all the concerned.
i. What is the weight of the load to be lifted, the lift radius, boom angle and the rated capacity of
the crane?
ii. How will the signal man communicate with the operator?
iii. Are there gas lines, power lines or structures which must be moved or avoided?
iv. Is the surface strong enough to support the machine and load?
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v. How can the crane be positioned to use the shortest boom and radius possible?
13.8. OPERATIONAL PRECAUTIONS
Operator must be alert physically fit, free from influence of alcohol or medications that effect his eye
sight, hearing or reactions. Always avoid over loading of cranes, over loading would result by
Lifting of load more than rated capacity at the particular radius.
Booming down and increasing load radius.
i. Crane should be placed on jackets with proper wooden logs.
ii. While doing pick and carry operations keep the load as low the ground as possible.
iii. It should be ensured that while operating a crane person should be clear of having load.
iv. Ensure that enough room is available for rotation of the cranes.
v. Ensure that load being lifted is not stuck frozen or attached to something else which may
cause accident.
13.8.1. OPERATION
i. The code of hand signals adopted for use should be understood and observed by the
crane operator and his signal man.
ii. The crane should be properly jacked on a firm foundation and secured before lifting heavy
load.
iii. The crane operator should sound the audible warning before lifting any load.
iv. Suitable hooks or rope slings attached to the load should only be used for lifting loads.
v. Crane should not be used for dragging load on ground.
vi. The operator should ensure that during lifting of load, persons remain at a safe distance.
vii. The crane operator must not allow any person to ride on suspended load or remain under
a suspended load.
viii. There should be at least two wraps of cable of the drum at all times when operating the
crane to obviate the line load being applied to the fastening clamp at any time.
ix. Crane operator should ensure that no part of the crane approaches within three metres of
any electric transmission line.
x. When not in use, the hook of the crane should be firmly secured to the boom.

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13.9. MONTHLY INSPECTION

A complete inspection of each crane, its foundation and drive track should be made every month and
the results recorded in a register. The manufacturers' recommendation should be kept in view. The
following items should be carefully looked for :
i. Deformation, cracked or corroded members in the crane structure, foundation and boom.
ii. Loose bolts or rivers.
iii. Cracked or worn sheaves and drums.
iv. Worn, cracked or distorted parts such as pins, bearings, shafts etc.
v. Excessive wear on brake and clutch system
vi. Load hooks, for deformation and cracks.
vii. Excessive wear of chain drive sprockets and excessive chain stretch.
viii. All ropes for compliance with manufacturers' specifications, reduction in diameter due to
corrosion of wear.
13.10. CAPACITY OF THE CRANE
Capacity of the crane is to be displayed in bold letters on the boom and super structure on both sides
and front and rear of the crane.
13.11. TRAINING
Training should be imparted about the crane operation and maintenance for crane operators and
technicians and supervisors at field site every year for safety awareness.
The lifting capacity of the cranes should be periodically checked.
A periodical human physical ability test may be conducted for the driver and the crane operator
through reputed institute e.g. National Labour Institute or any other.
14. H2S PROTECTION

14.1. INTRODUCTION
The d an ge r of exposure to H2S can not be eliminated altogether but the potential of danger can be
minimized by:-
i. Providing adequate safety equipments on location.
ii. Proper training to personnel before posting.

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iii. Establishing strict operating and emergency procedures.

iv. Creating general awareness of potential HAZARDS OF H2S.
14.2. HAZARDOUS DESCRIPTION
Sources and occurrence.
Characteristics and properties.
H2S effect on personnel.
Toxicity
Essential medical standards for working is H2S environment.
Detection
Planning Requirements for H2S working
Breathing air requirement for different activities and conservation of air.
Emergency rescue.
First Aid, artificial respiration
Dangers associated with its product of combustion.
Effects on metal.
Breathing protection and Rescue equipment.
Safety during operation and maintenance.
Safety in sampling.
14.2.1. Different names of H2S
Hydrogen Sulphide gas in referred to in Industry by a variety of names:-
H2S
Stink Damp
Sulfurated Hydrogen
Rotten Egg Gas
Hydro sulphuric Acid
Sulphur Hydride
14.2.2. Characteristics and Properties of H2S
i. H2S gas is toxic, irritant and asphyxiates. It is colorless, which at low concentrations is
accompanied by rotten egg odour.
ii. Detection of H2S, solely by smell is highly dangerous as sense of smell is rapidly paralyzed by
H2S.
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iii. It is more toxic than carbon monoxide and almost as toxic as Hydrogen cyanide gas.
iv. Heavier than air, specific gravity 1.189. Vapours may travel considerable distance to a source
of ignition and forms an explosive mixture with air in concentration between 4.3 and 46 % by
volume.
v. It has Auto ignition point of 260 degree centigrade.
vi. Burns with blue flame and evolves S02, which also is very toxic.
vii. Threshold Limit value - Time weighted average - 10 ppm.
viii. Threshold Limit value - Short Term Exposure limit - 15 ppm
ix. Corrosive to all electro-chemical series metal
x. Soluble in water, alcohol, petroleum solvents and crude petroleum
xi. Agitation or temperature increase produces toxic liberation.
xii. Melting point (-) 85.5 Degree Centigrade, Boiling point (-) 60.4 Degree centigrade.
xiii. Molecular weight: 34.08: Heat value: 3820 Cal/Kg.
14.2.3. Effects of H2S on personnel:
It depends on:-
a) Duration
b) Frequency
c) Intensity
d) Individual susceptibility
H2S goes in to the blood through lungs – To protect itself, body “ Oxidizes “ the H2S , which
body can not oxidize, builds up in blood and individual becomes poisoned. The nerve centers
in the brain which controls breathing are paralyzed. The lungs stop working and the person
asphyxiated. Other lower levels of exposure may cause the following symptoms individually or
in combination:
Headache
Dizziness
Excitement
Nausea
Coughing
Drowsiness

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Dryness and sensation of pain in nose, throat and chest.

14.2.4. Toxicity of H2S and effects:
10 ppm = 1/1000 of 1% - can smell, safe for 8 hours exposure
100 ppm = 1/100 of 1% - Kills smell in 3 to 15 mins, may sting eyes and
throat.
200 ppm = 2/100 of 1% - Kills smell shortly, stings eyes and throat.
500 ppm = 5/100 of 1% - Loses sense of reasoning and balance
- Respiratory paralysis within 30 to 40 mins.
- Needs prompt artificial Resuscitation.
1000 ppm = 1/10 of 1% - Unconsciousness at once.
- Permanent brain damage, if not rescued
promptly.
H2S is more deadly than carbon monoxide (CO) and almost as toxic as hydrogen cyanide
(HCN) gas, which is used for the execution of criminals in some countries.
1. Threshold Limit Concentration at which it is believed that all workers may be

repeatedly exposed day after day without adverse effects.
2. Hazardous Limit Connection that causes death.
3. Lethal Concentration Concentration that will cause death with short term exposure.
4. Threshold Limit (H2S) 10 ppm - 1972 ACGIH (American Conference of Governmental

Industrial Hygienists)
Sudden exposure to concentrations above 150 ppm, or continued exposure to lower
concentrations may retard or arrest the ability to detect the odour.
14.2.5. Essential medical standards for working in H2S area:
Employees working in areas, mentioned earlier, where H2S may be present or could
conceivably be likely to be found should be medically examined by a doctor to ensure that the
employees has no medical defects that might endanger his health or performance during a
possible H2S exposure. The examination should include heart, blood pressure, lung condition,
existence of performed ear drums, standards of health or mental anxieties.
Caution: H2S may pass through a perforated ear drum and enter the lungs.
Special problems in use of breathing apparatus (b.a) sets:

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a. facial hair : can prevent effective sealing to the wearers of b.a. sets.
b. contact lenses : contact lenses are a definite hazard and should not be worn while
wearing a respirator in a contaminated atmosphere.
14.2.6. Detection:
Philosophy of detector location is governed by
where leaks are most likely to occur and
where gas accumulations are most likely to be the greatest.
Knowledge of limitations and capabilities of leak and testing etc. high concentration of gas may
be encountered. Following are some of the common detection devices:
A. Fixed monitoring systems:
Sensors monitor H2S concentrations continuously at various locations. Alarms are actuated
when concentrations reach preset values. The H2S concentration is continuously indicated on
the analog digital display at the control room.
B. Personal electronic monitors:
The unit is hand held or attached to dress, to warn at preset values, when attended with
dosimeter, stores the individuals exposures to H2S and gives a print out, when required.
These can also be provided with system to relay the exposure levels to control room for
information and record.
C. Lead acetate ampules or coated strips:
These change of color (usually turn brown or black) in the presence of H2S. They should be
used as alternate method of detection.
D. Short term measurement with tube detectors:
The system consist tubes, the bellow pump and a scale that gives a reading of H2S presence
and amount of H2S on the tube is shown by length of colour change on the tube.
Do not rely on your nose to detect H2S the sense of smell is not reliable
detection method.
Know the cross sensitivities of gases with reference to your measuring devices.
14.2.7. Planning requirement for working in H2S environment
Working in a H2S or possibly contaminated H2S environment requires painstaking accurate
planning to insure maximum protection of human lives.
Planning considerations should include:-
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i. Contingency plan.
ii. Diagnosis of the work – site.
iii. Adequate and proper placement of safety equipments.
iv. Personnel training programme.
v. Personnel drills.
vi. Responsible supervision.
vii. Knowledge of working conditions.
viii. Emergency of working conditions.
ix. Adherence of all safe work practices etc.
Additional safety measures
When approaching the job site it is necessary to take the following precautious to ensure safe
entry:
i. Observe for audio/ visual alarms.
ii. Check for wind direction.
iii. Look for personnel and their activities.
iv. Enter job site slowly.
v. Look for the escape route.
vi. Continuous detection.
vii. Gas ignition hazards must be eliminated and “No smoking“
regulations strictly enforced.
viii. Reduce H2S exposure.
ix. H2S awareness training programme and regular drill are a must.
x. Continued observation of wind indicator is a must (In HGPC wind
direction changes many times a day, and seasonally too).
xi. During atmospheric contamination by H2S, move upwind or cross
wind from source, not down wind: as such you have to make yourself
always away from source.
xii. H2S is heavier than air, therefore avoid low lying area.

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xiii. Maintain and observe warning signs.

xiv. Maintain reliable communication systems.
xv. Know the emergency preparedness plan of HGPC.
14.2.8. Breathing air requirements for different activities:
Activity Cubic feet per minute Litres per minute

Sleep 0.2 6.0
Rest 0.3 9.3
Light work 0.7 19.7
Medium work 1.0 29.2
Medium Heavy work 1.4 40.0
Heavy work 2.1 59.5
Maximum work 4.6 132.0
14.2.9. How to conserve breathing air

i. Excitement, emotions and fears will cause the wearer of the B.A. Set to consume air at a
needless rate. The wearer must remain calm and relaxed in any and all situation to help
conserve air and to react and think logically.
ii. Work should be accomplished at a steady pace so as not to over exert and spend too much
energy and waste air.
iii. When BA Set not needed, the face piece can be removed.
iv. In depth training with the BA Set is an essential element.
Breathing air quality
As per API-RP-49, the requirements of breathing air quality shall be as follows:
Oxygen content 19.5 % - 23.5%
Hydrocarbon content – 5 mg/m3 of air or less
Carbon Monoxide(CO) content – 10 ppm or less
Carbon di-oxide(CO2) content - 1000 ppm or less
Lack of noticeable odour

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14.2.10. Emergency rescue in H2S:

The most important part of any rescue attempt at any time and especially in toxic H2S
environment is to protect yourself before attempting a rescue. A successful rescue can only
be accomplished by first being prepared for such an emergency.
Be prepared:
i. Make sure the proper respiratory equipment is being used.
ii. Check the air supply in the supply in the cylinder to ensure that there is sufficient air to
make the rescue and escape with the victim to a safe area.
iii. Before entry into the contaminated area, check the seal of the mask (negative pressure
test).
iv. Observe wind socks to determine where you will take the victims – UPWIND- SAFE AREA.
v. Always use the “Buddy system” when making a rescue.
Aids to be used:
i. If at all possible, at least two people should aid in a rescue.
ii. Make use of all rescue equipment that may be on location, Safety harness, ropes, slings,
stretchers etc.
Removing the victim:
i. If a victim is unconscious or is incapacitated, when wearing BA Set, drag the victim to
safety or use stretcher,
ii. If a victim is unconscious due to inhalation of lethal amounts of H2S, time is important.
The victim must be taken immediately to a safe area upwind from the contaminated area.
14.2.11. First aid for H2S poisoning:
Contact with Eyes:
i. Eye contact with liquid and/or gas containing H2S will cause painful irritation.
ii. Keep patient in a darkened room.
iii. Apply ice to eyes and put ice on forehead.
iv. Take him to a doctor.
Contact with skin:
In case of skin contact, the affected area should be thoroughly washed.

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Inhalation:
i. Get the victim to fresh air as quickly as possible.
ii. Keep him at rest and chilling should be prevented.
iii. If respiration is stopped, give artificial respiration (Mouth to mouth to mouth).
iv. Call a doctor/ take victim to a doctor.
v. If the stomach rises, gently press on it to remove air, it is recommended that the victim’s
head be turned to one side before doing this.
vi. Watch the victim’s chest. When you see it rise, stop blowing. Raise your mouth and turn
your head to the side the listen for exhalation. Watch the victim’s chest to see that it falls.
When the victim’s exhalation is finished, repeat the blowing cycle. As the victim attempts
to breath, co-ordinate your blowing with his breathing.
vii. After reviving the victim, watch closely and treat for shock. NEVER LEAVE THE VICTIM
ALONE; have some one else contact a doctor.
Note: A person properly trained in artificial respiration can save a life.
viii. The medical centre should have Anti-dot for H2S poisoning.
Occupational health monitoring:
Occupational Health Monitoring of employees should be carried out periodically (every 6
months for exposed personnel) apart from pre employment and pre placement check ups.
The employees working in H2S and other vulnerable locations should be monitored from
health point of view.
Dangers with the product of combustion:
When H2S is burnt, Sulphur dioxide (SO2) is produced. This gas is also toxic, but does not
suppress the sense of smell.
Here are some of characteristics of Sulphur Dioxide (SO2) gas:
Molecular weight: 64.06
Physical properties:
Colorless gas, pungent odour,
Boiling Point: -10 degree centigrade
Vapour density: 2.264 (air)
Solubility: Water, Ethyl alcohol, methanol ether, and Chloroform.
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Chemical properties:
Reacts with water and with steam and produces toxic and corrosive fumes.
Safe Exposure Limits: 5 ppm
Route of entry to the human body: Inhalation, Ingestion and skin contact.
Effect: Conjunctives, respiratory paralysis, in 6-12 ppm concentration, it causes
immediate irritation of nose and throat.
Emergency First Aid procedures:
In halation - Keep in fresh air upright and move to doctor.
Skin - Remove contaminated clothes, rinse skin with plenty of water or
shower and send to a doctor.
Eye - First rinse with plenty of water, transport to a Doctor.
Injection - Use 5% solution of Sodium carbonate ( Na2Co3) as aerosol for
Stomach wash, but under medical supervision only.
Breathing protection and rescue equipment:
Working in an H2S area requires availability of following types of Breathing Protection &
Rescue equipments. For smaller installations and rigs requirements can be further minimized.
BA Set (30 mins. & 20 mins.)
ELSA (Emergency Life Support Appliances) 10 mins.
Cartridge type Escape mask.
Airline Trolley.
Auto Resuscitator or Manual air Resuscitator.
Portable oxygen inhaler.
Oxygen cylinder assembly
Stretcher.
14.2.12. Operation & maintenance H2S environment/ entry in to equipment in H2S
area:
i. Where possible, entry into area / vessel which contains H2S should be avoided.
ii. For all entry situations, procedures for escape and rescue should be established prior to
starting the work.
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iii. Entry into vessels, hole pits or drains which contained H2S (and may still contain H2S or
H2S contaminated residue) shall be undertaken only after a vessel entry permit (confined
space entry permit) has been issued.
iv. The equipment shall be depressurized completely to atmospheric pressure.
v. For pressure vessels and other fully enclosed equipments draining of all free liquid from
the equipment is essential.
vi. Positive isolation of the equipment must be achieved.
vii. The equipment is purged to a safe location with inert gas, steam or water and then air
(until the concentration of H2S is below detectable level and that of oxygen is above 20%
by volume).
viii. Any possible residues, which may be pyrophoric be kept water wet.
ix. A flow of fresh air be established through the equipment.
x. A means of communication is established between the person entering the equipment and
coworkers.
xi. The person entering the equipment and the coworker shall wear full face self contained
breathing apparatus.
14.2.13. Maintenance in H2S environment / opening of equipment containing H2S
i. Established work-procedure is to be followed.
ii. Where the equipment can not be totally depressurized, (e.g. connections to flare headers),
the pressure be reduced to and maintained at the lowest practicable level.
iii. Any cleaned material from vessels/tanks handling H2S or sulphide compound e.g.
mercaptan etc.) shall be suitably disposed in wet condition, as these materials can catch
fire in dry condition.
iv. It should be noted that equipment which has contained H2S may contain iron sulphide.
This is known as ‘Pyrophoric Iron Sulphide Fire’. As this has auto-ignition temperature
almost equal to the ambient temperature, in the dry state, iron sulphide can spontaneously
ignite in an oxygen containing atmosphere and appropriate precautions ( like keeping it
water wet etc.) need to be taken.
14.2.14. Precautions in sampling:
i. Before proceeding for sampling, control room and other operating personnel shall have to
be informed.
ii. While sampling, stand in the upwind direction.

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iii. Protective clothing shall be worn to avoid any spillage on body.

iv. Breathing protection (e.g. Escape mask i.e. ELSA shall be used.)
v. Look before hand for the escape route.
vi. In case of any leakage, the isolation points shall be found out before hand for quick
isolation of the sampling point.
vii. Any other measures as per established practice shall be followed for specific areas.
14.2.15. H2S Protection in Drilling Operations
A. Detection and alarm system
The system comprises of H2S sensors located at predetermined points. The location should
satisfy the following rules.
In air conditioned or ventilated areas, detector should be installed at the fresh air inlets
(duct, entrance ways etc.)
Outside, detectors should be installed on gas carrying equipment (well nipple, shale
shaker, mud, pits drillers stands etc.) These should be located near potential leaks, such
as the shaft gland connection, flanges etc. It is pure alarm system with two warning stages
and cannot trigger emergency shutdown alone. The two levels of alarm are as follows:
o 10 ppm H2S low level alarm triggers a light signal but does not indicate
danger for all. Persons are required to stand by to check the installation after
announcement on public address system (PA) by the tool pusher, otherwise,
to proceed to the upwind side.
o 20 ppm H2S high level triggers a sound alarm and also red light on the control
panel. Emergency alarm is sounded by two short rings of bell intermittently.
This requires breathing equipments to be used immediately and the hazard
area to be vacated unless announcement on Public Address System (PA) by
the tool pusher provides other instructions.
B. Visual Warning Signs
In case of high level H2S alarm, the following warning signs should be displayed to alert
helicopter and vessels in the vicinity of the drilling rig.
Red flag 90cm X 60 cms on each side of the rig.
Danger boards painted yellow with black lettering 30 cms high indicating "DANGER H2S".
C. Muster stations and escape routes.

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Since H2S is heavier than air, it is likely to settle down at lower levels particularly in still air or in
light winds and cut off the natural escape route to the boat landing; this situation gives rise to
the following requirements:
Sufficient stair cases on the upwind side of prevailing winds for escape route up the stairs
or down to the lifeboat.
Muster stations for operating personnel in the event of gas alarm, areas in the open on the
upper deck which can be kept free of H2S by the wind.
D. Ventilation
Forced air ventilation to disperse any accumulation of H2S should be provided by fans (bug
blower) at the following points:
Mud shaker
Working platforms
Control rooms
E. H2S Kick control
The control of H2S kick may be achieved either by bulldozing gas back into formation or
circulating it out. The actual method to be adopted will depend upon the condition of the well.
When a gas kick occurs, estimate the quantity of H2S present taking adequate precautionary
measures of wearing self contained breathing apparatus (SCBA). The following procedure
should be adopted:
Close BOP, monitor SIDPP, SICP & pit gain.
If the concentration is high and cannot be circulated out due to H2S hazard in atmosphere,
bulldoze the gas into formation by pumping through kill line.
Raise mud wt. and PH as required.
Load H2S scavenger like zinc carbonate and ironite sponge as may be necessary in the
active mud pit.
Circulate the gas through choke and degasser and burn off the gas.
The following factors should also be kept in view:-
All persons on the drilling floor, shale shaker area, mud pump and tank should put on self
contained breathing apparatus when the kick is to be circulated out.
Persons who are not required for the control operation should be withdrawn to a safe area,
where adequate ventilation is arranged.
Frequent checks with portable H2S gas detector should be made.

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Supply vessels (in case of Offshore) should stay upwind on power and maintain
continuous radio and visual watch.
Note: The document "Contingency plan for drilling H2S well" issued by the Mumbai Region
is recommended for detailed guidance.
F. Specific well site checks
Check The Presence Of H2s
Wind Direction Indicators
Monitors And Alarms
Placement Of Breathing Apparatus
Placement Of Fire Equipments
Appropriate First Aid Equipment
G. Minimum Aspects for H2S Training
Any Training on H2S safety should include the following minimum aspects:
The hazards and characteristics of H2S and its product of combustion(SO2)
Sources of them
Use of detectors
Understanding and Response to the warning signals
Symptoms of H2S and SO2 exposures
Rescue techniques
First-aid procedures
Proper use and maintenance of Breathing apparatus
Wind direction awareness
Confined space and other work-permit procedures
Emergency response procedures
Locations and use of safety equipments
Escape routes
Safe briefing areas(assembly points)

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15. SAFETY IN WORKING WITH PRESSURIZED SYSTEM

15.1. INTRODUCTION
If pressure equipment fails in use, it can seriously injure or kill people nearby and cause serious
damage to property. Examples of pressure systems and equipment are:
Boilers and steam heating systems
Pressurized process plant and piping
Compressed air systems (fixed and portable)
Heat exchangers and refrigeration plant
Valves, steam traps and filters
Pipe work and hoses
Pressure gauges and level indicators
Gas Cylinders
15.2. MANAGING THE RISKS - SAFETY INSTRUCTIONS
To reduce the risks you need to know (and act on) some basic precautions,
15.2.1. Provide safe and suitable equipment
When installing new equipment, ensure that it is suitable for its intended purpose and that
it is installed correctly.
The pressure system should be designed and manufactured from suitable materials as per
applicable codes.
Ensure the system can be operated safely without having to climb or struggle through gaps
in pipe work or structures. For example, be careful when repairing or modifying a pressure
system. Following a major repair and/or modification, the whole system should be re-
examined before allowing the system to come back into use.
15.2.2. Know the operating conditions
Know what liquid or gas is being contained, stored or processed (e.g. is it
toxic/flammable?)
Know the process conditions, such as the pressures and temperatures.
Know the safe operating limits of the system and any equipment directly connected to it or
linked to it.

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Ensure there is a set of operating instructions for all the equipment and for the control of
the whole system including emergencies.
Ensure that appropriate employees have access to these instructions, and are properly
trained in the operation and use of the equipment or system
15.2.3. Fit suitable protective devices and ensure they function properly
Ensure suitable protective devices are fitted to the vessels, or pipe work (e.g. safety valves
and any emergency tripping devices which cause shutdown when the pressure,
temperature or liquid or gas level exceeds permissible limits).
Ensure the protective devices have been adjusted to the correct settings.
If warning devices (alarms) are fitted, ensure they are noticeable, either by sight or sound.
Ensure protective devices are kept in good working order at all times.
Ensure that, where fitted, protective devices such as safety valves and bursting discs
discharge to a safe place.
Ensure that, once set, protective devices cannot be altered except by an authorized
person.
15.2.4. Carry out suitable maintenance
All pressure equipment and systems should be properly maintained. There should be a
maintenance program for the system as a whole.
Look for signs of problems with the system, e.g. if a safety valve repeatedly discharges,
this could be an indication that either the system is over pressurizing or the safety valve is
not working correctly.
Look for signs of wear and corrosion.
Systems should be depressurized before maintenance work is carried out.
Ensure there is a safe system of work, so that maintenance work is carried out properly
and under suitable supervision.
15.2.5. Have the Pressurized System checked by a competent person
Have a detailed examination scheme and include the equipment/systems to be examined
Chose a competent person
Ensure that ultrasonic thicknesss measurement of pressurized vessel is done before
conducting the periodic hydro test to check whether the metallic thickness of vessel is
within permissible limit or not.

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Carry out checks

15.2.6. Make provision for appropriate training
Everybody operating, installing, maintaining, repairing, inspecting and testing pressure
equipment should have the necessary skills and knowledge to carry out their job safely.
Training should include all new employees, who should have initial training and be
supervised closely.
Additional training or retraining may be required if:
o The job changes;
o The equipment or operation changes; or
o Skills have not been used for a while.
15.2.7. Do’s & Don’ts
Do’s
Make sure pressure has been released before a pressurized system is opened.
Make sure any fittings added to a pressurized system are of the correct type and
rating.
Make sure screw threads used in pressurized systems are clean and in good
condition, and are fully engaged when done up.
Report immediately any defects you may notice.
Don’ts
Subject equipment under pressure to shock loads, such as hammering or being
dropped.
Apply heat to equipment under pressure, and never weld anything to such
equipment, whether under pressure or not, without proper approval.
Use pressurized equipment as a step or as a support for scaffolding and other
working platform.
Cut into any pipe work without first checking it is not part of a system under
pressure.
Not to close any valve of the pressurized system without prior knowledge.
Isolate safety valves.
Go near pressure testing operations unless part of the testing team.

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16. SAFETY IN WORKING AT HEIGHT

16.1. INTRODUCTION
This procedure deals with working at height including the erection and control of scaffolding structures
and ladders.
16.2. WORKING AT HEIGHT
Working at heights of 1.8 meters above the ground cannot proceed unless:
A fixed platform or scaffolding is used with guard or hand rails, verified by a
competent person(s) or
Fall arrest equipment is used that has:
o a proper anchor mounted, preferably overhead
o full body harness using double latch self locking snap hooks at each
connection
o synthetic fibre lanyards
o shock absorber;
Fall arrest equipment will limit free fall to 1.8 meters or less.
The swing radius of fall shall be restricted in order to protect personnel from hitting
against structures/ equipment in case of a fall.
A visual inspection of the fall arrest equipment and system is completed and any
equipment that is damaged or is taken out of service
Person(s) are competent to perform the work.
Work permit has been issued for the job.
16.3. SCAFFOLDING
16.3.1. Roles and Responsibilities:
The Site In-charge shall appoint a competent person to inspect and certify scaffolds as safe to
use.
Appointed Competent Person shall have prime responsibility for ensuring the following:
i. All scaffolding works must be carried out under the Permit-To-Work System.
ii. Ensure only competent scaffolders are used to erect, modify and maintain scaffolding
structures.
iii. All scaffolding is erected in accordance with the appropriate codes and standards
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iv. Materials used are in good condition and of an acceptable standard.

v. A register is maintained of all scaffolds erected and dismantled.
vi. Maintain a record of the inspection of all scaffolding structures.
vii. Maintain inspection records of all ladders on the site.
viii. Undertake weekly inspections of all erected scaffolding structures and report all deficiencies
ix. Carry out a detailed toolbox talk with all personnel involved in the erecting and dismantling of
any scaffold structure. Refer ‘Tool Box Talks’ for details.
Safety representative of contractor shall have the responsibility for:
i. Periodically auditing the scaffoldings, ladders and the associated permits and records to
ensure compliance with this procedure.
ii. Emphasise at safety meetings and toolbox talks the purpose and operation of the scaffolding
procedure to site personnel
iii. Safety representative of contractor shall be available at site during the working period.
ONGC HSE officer shall have the responsibility:
i. to ensure necessary permits have been issued;
ii. to randomly inspect to ascertain safety aspect
16.3.2. Prior to Erection
i. The job site shall be inspected to determine ground conditions or strength of supporting
structure and for proximity of electric power lines, overhead obstructions, wind conditions, the
need for overhead protection or weather protection coverings. Special care is needed when
scaffolding is to be erected on fill or other soft ground. These conditions must be evaluated and
provide inputs for JSA.
ii. A Job Safety Analysis as per JSA procedure shall be undertaken for all scaffolding operations
being undertaken.
iii. Consideration to access and egress shall be given and where practical two means of safe
egress shall be provided.
iv. Frame spacing and mud sill size can only be determined after the total loads to be imposed on
the scaffold and the strength of the supporting soil or structure are calculated and considered.
This analysis must be done by a qualified person.
v. All equipment must be inspected to see that it is in good condition and is serviceable.
Damaged or deteriorated equipment shall not be used.

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vi. Wooden planks shall be inspected to see that they are graded for scaffold use, is sound and in
good condition, straight grained, free from saw cuts, splits and holes. (Not all species and
grades of timber can be used as scaffold plank).
vii. The scaffold assembly must be designed by a competent person to comply with job
requirements. Manufactures load carrying information shall be used for design calculations.
viii. Suspended scaffolding or scaffolding designed solely for load bearing purposes shall be
subject to independent design and approval.
16.3.3. Inspection and Tagging
i. A competent person shall inspect scaffolding before it is first used and then at least once every
week. It shall be inspected following any alteration and also if it has been exposed to weather
conditions likely to affect its strength or stability. Details of inspections shall be recorded.
ii. “Scaffold tags” shall be used on all scaffold structures, whether complete or part complete/
dismantled to indicate that the scaffolding is or is not safe to use. Tags must be positioned
prominently at access points to scaffold structures. The erection, dismantling and alteration of
scaffolding must be carried out by competent workmen under competent supervision.
iii. When scaffolding is incomplete (whether partly erected or dismantled) or considered to be
unsafe for any reason, display the red ‘Do Not Use’ tag. In addition, access to the scaffold
shall be barricaded.
16.3.4. Use of Scaffolding
i. Competent person as authorized shall inspect the scaffold assembly before use to ensure that
it is assembled correctly, level and plumb, base plates are in firm contact with sills, bracing is in
place and connected, platforms are fully planked, guardrails in place, safe access is provided,
properly tied and/or guyed and that there are no overhead obstructions or electric lines within 4
meters of the scaffold assembly. He shall also check the correct scaffold tag is in place.
ii. All PPE identified in the Permit to Work or JSA shall be worn at all times during the scaffolding
operation.
iii. Safety belt with full body harnesses shall be used in conjunction with lifelines when working
above 1.8 metres.
iv. Loose articles and materials must be kept to an absolute minimum on scaffolding platforms. All
necessary precautions must be taken to prevent objects from falling from scaffolds, e.g. by use
of toe boards.
v. During erection scaffolding clips and equipment shall not be thrown. During dismantling of
scaffolding, poles and fittings shall not be dropped to the ground but always carefully lowered.
Poles shall be stacked flat and clips and fittings collected into bags or containers.

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vi. The use of “quick erect” aluminium scaffold systems can be used subject to local controls such
as restricting use to non-hazardous areas and appropriate storage.
vii. No visible scaffolding tag means No Access.
viii. Use only the safe means of access that is provided. Do not climb bracing or frames not
specifically designed for climbing. If such access is not provided, insist that it be provided.
ix. Climb Safely
x. Face the rungs as you climb up or down.
xi. Use both hands.
xii. Do not try to carry materials while you climb.
xiii. Be sure of your footing and balance before you let go with your hands. Keep one hand firmly
on frame or ladder at all times.
xiv. Do not work on slippery rungs.
xv. Do not overload platforms with materials.
xvi. Do not extend working heights should by planking guardrails or by use of boxes or ladders on
scaffold platforms.
xvii. Do not remove any component of a completed scaffold assembly except under the supervision
of a qualified person. Any component that has been removed should be immediately replaced.
xviii. At any given point of time at least one safety line has to be secured to a support while moving.
16.4. LADDERS
16.4.1. Portable Ladders
Ladders are potentially dangerous. Most accidents occur through ladder slipping.
Ladders may be used as a short-term alternative to scaffolding or as a mean of access to
scaffolding.
Before using a ladder, it shall be ensured that it is the correct type for the job in hand and
that it is in good condition.
Ladders shall be inspected and maintained by an authorized competent person. The
record of inspections shall be registered.
Aluminium ladders must not be used in hazardous areas (danger of sparks generating).
Any ladder that is defective in any way must be taken out of service immediately.

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16.4.2. Rules for Safe Use of Portable Ladders

i. Inspect ladder prior to EVERY use.
ii. Always place a ladder on a firm base, set the angle near to 70°-75° i.e., 30cm out for every
1.2m up.
iii. Make sure the ladder projects well above the level at which the user stands. Remember it must
extend at least 1metre above the landing or workplace
iv. Ensure sufficient overlap between stages of extension ladders.
v. Do not use ladders with structural defects.
vi. Every ladder shall have rungs equally spaced
vii. Properly tag defective ladders with "Do Not Use" and withdraw from service.
viii. Carry ladders parallel to the ground.
ix. Tie ladders down securely when transporting.
x. Maintain ladders free of oil, grease, and other hazards.
xi. Do not load ladder beyond maximum intended load.
xii. Use only for the purpose for which the ladder was designed (refer to manufacturer's labelling
and recommendations).
xiii. Barricade traffic areas in vicinity of ladder use, and lock, barricade, or guard doorways in which
a ladder is placed.
xiv. Keep area around the top and bottom of ladder clear.
xv. Do not move, shift, or extend ladder while occupied. NEVER 'WALK' A LADDER.
xvi. Safety belt with full body harnesses shall be used in conjunction with lifelines when working
above 1.8 metres, secured to a safe point.
xvii. Use only non-conductive ladders around live electrical equipment.
xviii. Do not use top or top step for standing/ stepping.
xix. Do not stand on cross bracing.
xx. Always face the ladder when ascending or descending.
xxi. Always maintain 3 points of contact with the ladder (2 feet/1 hand or 2 hands/1 foot should be
in contact with ladder at all times).

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xxii. Carry tools in pouches around waist; use a rope to raise or lower large items such as tool
boxes or materials.
xxiii. Do not overextend sideways. Use the belt buckle rule: keep your belt buckle positioned
between the side rails at all times, which will maintain your centre of gravity.
xxiv. Never allow more than one worker on the ladder at a time.
xxv. Do not erect ladders on sloping surface, leaning to one side or at to steep an angle.
xxvi. Do not erect ladders for use as a plank or bridge.
xxvii. Wooden ladders must not be painted, as paint could conceal any defects.
xxviii. Make certain that no overhead power lines are within your reach or within reach of the ladder.
Metal ladders must not be used where a there is a risk of accidental contact with live electrical
apparatus.
16.4.3. Fixed Ladders
The rules for correct and safe use of portable ladders apply equally when climbing or working
on fixed metal ladders. In addition:
i. Every derrick shall be equipped with a ladder arrangement ensuring safe access to all elevated
walking and working platforms.
ii. Access from ladder to working platforms shall be properly secured with railings and toe-boards.
iii. The top end of each ladder section shall extend not less than one metres above the platform.
iv. Landing platforms or cages shall be provided on ladders of more than 6 metres to a maximum
unbroken length of 9 metres.
v. All landing platforms shall be equipped with railings and toe-boards so arranged as to give safe
access to the ladder.
vi. All ladders leading from derrick platform to monkey board shall be provided with fall prevention
device or other such device to prevent persons from falling.
vii. Every person who works above the first girt of a derrick shall be provided with approved type of
safety belt and lifeline and shall use the same unless he is otherwise protected against the
danger of falling from height.
viii. No person shall work or travel from where he is likely to fall for more than 1.8m unless he is
protected by approved type of safety belt and lifeline and shall use the same whilst at work.

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17. SAFETY WITH PORTABLE TOOLS

17.1. HAND TOOLS
17.1.1. Hazards
Hand tools are non-powered. They include anything from axes to wrenches. The greatest
hazards posed by hand tools result from misuse and improper maintenance.
Some examples:
Using a screwdriver as a chisel may cause the tip of the screwdriver to break and fly,
hitting the user or other employees.
If a wooden handle on a tool such as a hammer or an axe is loose, splintered, or cracked,
the head of the tool may fly off and strike the user or another worker.
A wrench must not be used if its jaws are sprung, because it might slip.
Impact tools such as chisels, wedges, or drift pins are unsafe if they have mushroomed
heads. The heads might shatter on impact, sending sharp fragments flying.
The main causes of most injuries involving hand tools are the use of unsuitable tools, their
incorrect use or their incorrect storage.
17.1.2. Safety Instructions
DOs
i. Use the correct tool for the job - never use a spanner as a hammer.
ii. Use spanners that fit the nut or bolt head properly.
iii. Keep your hands behind the cutting edge when using cutting tools.
iv. Keep unsheathed knives, chisels and other sharp tools in a safe place, not in your pocket.
v. Keep your tools clean and in good condition. Protect the edges of sharp tools, both when
carried and in store.
vi. Wear eye protection when chipping, scaling, dressing stone or concrete, fettling and cutting
rivets or whenever there is a danger of flying particles-remember others, as stated in the
section on PPE.
DO NOT
i. Use damaged or worn tools: hammers with loose heads, files with loose or split handles,
chisels with "mushroom" heads, spanners or wrenches with splayed jaws.

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ii. Use a file without a handle-file tangs are dangerous.

iii. Place small tools on open grating floors - they may fall through and hit someone. Return them
to your toolbag after use
17.2. POWER TOOLS
17.2.1. Hazards
Employees using electric tools must be aware of several dangers; the most serious is the
possibility of electrocution.
Among the chief hazards of electric-powered tools are burns and slight shocks which can
lead to injuries or even heart failure. Under certain conditions, even a small amount of
current can result in fibrillation of the heart and eventual death. A shock also can cause the
user to fall off a ladder or other elevated work surface.
17.2.2. Safety Instructions
DOs
i. Make sure before using a portable electric tool that it is in good order-look for signs of
overheating, loss of speed and irregular running noises. Also inspect the cable for signs of
damaged insulation and connections. If in doubt as to the safety of the tool, report to your
supervisor.
ii. Use the right tool for the job.
iii. Keep electric cables away from water, oil, heat and sharp edges. If left in gangways, cables
may be cut or cause someone to trip-whenever possible they must be carried overhead.
iv. Ensure you have the correct length of electric cable or compressed air hose serving the
apparatus- if it is too short get a proper extension.
v. Check for tightness all joints in air hose to tools.
vi. Check with your supervisor whether it is safe to use a portable grinding machine that has been
dropped accidentally-damage may have been caused to the wheel, resulting in breakage when
it is brought up to speed.
vii. Wear suitable ear/eye protection when using power tools.
viii. Store tools, hand lamps, cables and hoses in a safe and tidy fashion.
ix. Use gloves and appropriate safety footwear when using electric tools.
x. Store electric tools in a dry place when not in use.
xi. Keep work areas well lighted when operating electric tools.

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xii. Ensure that cords from electric tools do not present a tripping hazard.
xiii. Remove all damaged portable electric tools from use and tag them: "Do Not Use."
xiv. Use Double-Insulated Tools.
xv. Keep cords away from heat, oil, and sharp edges (including the cutting surface of a power saw
or drill).
xvi. Disconnect tools when not in use, before servicing, and when changing accessories such as
blades, bits, etc.
DONT’S
i. Carry a tool by the cord.
ii. Yank the cord to disconnect it from the receptacle.
iii. Avoid accidental starting. Do not hold fingers on the switch button while carrying a plugged-in
tool.
iv. Use electric tools in damp or wet locations unless they are approved for that purpose.
v. Lift or drag power tools by their cables.
vi. Attempt to change or dress an abrasive wheel unless you are authorized and competent to do
so.
vii. Force a portable grinder against the work as dangerous flat spots on the wheel may develop.
viii. Take your eyes off the job.
ix. Alter, adapt or interfere with the design function of the tool.
x. Another potential hazard is using extension cords with portable tools. In construction, these
cords suffer a lot of wear and tear. Often, the damage is only to the insulation, exposing
energized conductors. When a person handling the damaged cord contacts the exposed wires
while holding a metal tool case or contacting a conductive surface, serious electrical shock can
result, causing a fall, physical injury, or death.
xi. Since neither insulation nor earthing protects from these conditions, use other protective
measures. One acceptable method is a ground-fault circuit interrupter (GFCI).
18. SAFETY FROM DROPPED OBJECTS

The activities primarily responsible for causing dropped objects and materials are:
While working at height
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While using portable tools

While carrying out material lifting operations
Equipment failure
Loose fittings
Rig Jack up / Jack down
Procedures for all the above mentioned activities can be referred for specific safety precautions to be
taken for them
18.1. MANAGEMENT OF DROPPED OBJECTS
All work centers of ONGC need to carry out a dropped-objects survey and management program
should be formulated. The following aspects should be looked into in order to manage this high
potential accident causing factor:
i. Use of proper PPE
ii. Identification of problems
iii. Inspection programmes
iv. Examination procedures
v. Means of continuous improvement, etc.
vi. Hand tool logbook
vii. Training of personnel
viii. Awareness campaigns
ix. Inclusion in toolbox talks, work permits, safety meetings, etc.
x. Poster campaigns
xi. Inventory of equipment
xii. Securing methods identification
xiii. Control of manufacturers' bulletins and alerts
xiv. Risk assessments for dropped objects
xv. Maintenance procedures
xvi. Records of modifications
xvii. Control of third-party equipment
xviii. Control of use of air hoists, operating procedures, etc.
xix. Continual improvement of control methods
xx. Incident reports
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xxi. Identification of redundant equipment

xxii. Identification of risks associated with equipments
xxiii. Collision management
19. SAFETY IN HYDROJETTING

19.1. PRECAUTIONS FOR WATER JET CLEANING ( HYDROJETTING )
i. All high pressure water jetting (hydrojetting) cleaning equipment shall be fitted with actuating
devices that require positive effort by the operator, (hand or foot) to keep the supply valve
open.
ii. Hoses used for high pressure cleaning shall have a bursting pressure at least 2.5 times that of
the intended operating pressure.
iii. Hoses shall be tagged to indicate working pressure, date brought into service and predicted life
expectancy.
iv. Hoses with exposed reinforcing wire shall be replaced immediately.
v. Damaged or faulty equipment shall not be used. It shall be tagged OUT OF SERVICE and
repairs organized.
vi. Care shall be taken when laying out hydro jet hoses on the ground to avoid constant pulsation
damage, especially from corners.
vii. Couplings shall be of such a design that they are unable to loosen or be accidentally dislodged
during operation.
19.2. HAZARDS
When high pressure water jet cleaning (hydrojetting) is in progress, the particular hazards are:
i. piercing of the skin by a water jet or cutting of the skin.
ii. flying debris from the cleaning operations,
iii. release of hazardous materials into the atmosphere from dislodged deposits,
iv. noise of the cleaning operation that may damage hearing or drown out the sound of an alarm,
v. difficulty in breathing in confined space due to the high water vapour content in the air,
vi. electrostatic charging of nozzles and lances.
vii. reactive force generated by the discharge of water, creating a backward thrust against the
nozzle holder.

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19.3. PRECAUTIONS DURING OPERATIONS

The following safety precautions shall be observed when high pressure water jet cleaning (hydrojetting)
is in progress:
i. All operating areas shall be barricaded off with suitable barriers to prevent accidental entry of
unauthorized personnel. Signs should have wording to the effect - DANGER HIGH
PRESSURE WATER BLASTING, KEEP OUT. AUTHORISED PERSONNEL ONLY. Red and
white bunting or tape and signs are to be used.
ii. Entry into the area must be authorized by the Responsible Officer.
iii. All high pressure equipment shall be earthed before work starts and during operation, to
prevent the development of electrostatic charges between the lance and the workplace.
iv. Appropriate personal protective equipment shall be worn when operating high pressure water
jet equipment. The PPE shall include:
Safety helmet,
Goggles and face shield,
PVC full protective overalls, or PVC jacket and PVC trousers,
Suitable gloves, and
Safety footwear.
v. All high pressure equipment shall be isolated before being left unattended.
vi. Correct safety instruction shall be provided before the use of any hired equipment being used
for high pressure water cleaning.
vii. Repair and maintenance shall be in accordance with manufacturer’s standards.
20. SAFETY IN LEAK SEALING

20.1. INTRODUCTION
Leak sealing is an allowable temporary measure for mitigating gasket and packing leaks. It may also be
employed to mitigate valve seat leaks when the measured seat leakage is within the Technical
Specification limit for seat leakage and system requirements permit the valve seat to be sealed.
20.2. INSTRUCTIONS
i. Evaluate leak sealing on risk-based criteria against other options.
ii. Consider and follow the guidance regarding the use of measures for pressure boundary
leakage.

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SAFETY
iii. Perform a structural integrity assessment of any pressure boundary modification or

replacement, such as hole drilling, adding structural or pressure retaining clamps, or removing
or replacing fasteners.
iv. Consider the effect of a borated environment (use of borated solution) or a higher temperature
on the fasteners.
v. Assess the most likely cause of the leak
vi. Perform calculations of fastener loading during sealant injection that consider operating
pressure, injection pressure, and the added pressure boundary area created by having the
sealant or system fluid acting in the annulus between the old gasket and the outside of the bolt
circle.
vii. Install positive stops on drill bits to control depth during drilling. Considered use of a drill guide
or a similar fixture to align the drill and better ensure that only the intended part of the
component is drilled.
viii. Prohibit use of pneumatic or other power tools when peening.
ix. Perform a consequence analysis posing "what if" a structural failure occurred as a result of
pressure boundary modifications or related activities.
x. Establish a mitigation plan
xi. Establish clear notification and communication with operations personnel before execution of
the work.
xii. Commit to replace the leaking element by the next refueling outage or perform an assessment
for deferral that is risk-based.
21. SAMPLING & DRAINING OF HYDROCARBON

21.1. SOUR GAS / NATURAL GAS / LPG SAMPLING
Before proceeding for sampling, inform control room and the operating personnel of the
respective plant.
While sampling stand in the upwind direction.
Wear protective kits like hand gloves, apron, and safety glasses.
Wear breathing protection (e.g. Escape mask like ELSA 10 minute sets).
Look before hand for the escape route.
In case of any leakage or uncontrolled emission, look before hand for the isolation points
for quick isolation of the sampling points.
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SAFETY
Before carrying out LPG sampling, be aware that LPG is a fast vaporizing liquid and can
cause cold burn (frost bite) so use hand gloves and sampling operation must be carefully
planned to avoid any spillage.
In case of excessive spillage of LPG call control room and fire station immediately and
simultaneously disperse LPG vapour with steam or water spray.
Remember that LPG is heavier than air and can get accumulated in low lying areas e.g.,
pits drains or at floor level, so do not sit or lie down in sampling area and remove all
ignition sources.
Follow other established sampling procedures for specific plant/unit area.
Pressure to be kept at 2 to 3 Kg/cm2 for Natural gas sampling
21.2. DRAINING PROCEDURES
Draining of chemicals containing liquid streams from process vessels etc. is considered as dangerous
operation, as it may cause splash of liquid on body and cause accidents. Here are some of the general
safety instructions that should be followed while undertaking draining operations.
Draining is to be done in closed system only.
Ensure all the equipment containing hazardous chemicals are connected to respective
sump by pipe line.
Where no connection to sump is given, connect nearest sump with hose and drain.
Before draining ensure that the line and/or the equipment is depressurized to flare
pressure (usually 0.2 kg/cm2).
Position yourself in upwind direction.
Drain the liquid to the sump slowly.
Keep watch on sump level.
21.2.1. For liquid hydrocarbon draining:
Liquid Hydrocarbon is to be drained only to flare in closed system under pressure.
Where no provisions for direct flaring exists, connect Hose to nearest flare line and
drain to flare after bringing down the pressure to around 2-3 Kg/cm2.
Pump the stable liquid collected in the flare KOD to slop tank.
21.2.2. For water draining:
Ensure the system is de-pressurized.

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SAFETY
Open vent and start draining either in PWS, OWS, or storm water and inform the
concerned department.
21.2.3. Caution:
Inform control room before any draining.
Ensure vacuum is not created during draining.
Always ensure depressurization before draining.
Do not try to de-choke drain line/ valve with wire/rod if the system is under pressure.
Use rubber hand gloves and eye goggles while draining any liquid.
Do not hit the drain line with hammer/ rod if line is very cold. At very low
temperature the line may become brittle.
22. ELECTRICAL SAFETY

22.1. INTRODUCTION
Use of electricity not in a proper way can result in personal injury, even death, fire and explosion and
ultimately results a disaster. There it is mandatory and essential that electricity is used as per standard
code, rules & regulation. The observance of all provisions of Indian Electricity Rule, OMR and
petroleum rules is statutory requirement. The use of electricity in hazardous, explosive environment
needs a clear understanding of the subject.
The presence of flammable products in air in the form of gas or vapour can occur due to any leakage
from gaskets valves etc. or during normal operations like venting or bleeding. These released gas/
vapour could pose a fire hazard in any process plant, by acquiring any ignition source from light fittings,
electrical equipment e.g. motors, generators etc. and sometimes also due to static electricity or a
lightning.
The extent of risk would depend on the concentration of flammables in the area and the potential of the
ignition source. It is therefore, necessary that in the event of a gas leak, the LEL level of a particular
gas should not be allowed to reach by way of dilution of the atmosphere or if it is not possible at least
all ignition sources should be removed.
22.2. COMPETENT PERSON
Only competent and authorized personnel are permitted to work in electrical system or maintain
electrical installation & equipment & control system. The competent person besides his professional &
statutory qualification should have thorough understanding of the relevant rules, regulation, standards
& guidelines.

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SAFETY
22.3. RULES, REGULATIONS, STANDARDS & GUIDELINES

Primarily all provisions of Indian Electricity Rules 1956 and as amended from time to time and in
particular reference to chapter X of the said Rule for additional precautions to be adopted in mines and
oil fields to be followed in true letter and spirit.
Besides this following OISD standards, practices & guidelines to be referred:
OISD-STD-113 – Classification of areas for electrical installations at
Hydrocarbon processing and handling facilities
OISD-RP-147 – Inspection and safe practices during electrical installations
OISD-STD-137 – Inspection of electrical equipment
OISD-RP-149 – Design aspects for safety in electrical system
OISD-RP-148 – Inspection and safe practices during overhauling electrical
equipment
OISD-STD-173 – Fire prevention and protection system for electrical installations
OISD-STD-216 – Electrical safety in onshore Drilling & Work over Rigs
OISD-RP-110 – Recommended practices on static electricity
OISD-RP-146 -- Preservation of idle electrical equipment
OISD-GDN-180 – Lightning Protection
Offshore
For offshore operations, in addition to the above, API RP 14F – Recommended practice for design and
installation of electrical systems for fixed and floating Offshore petroleum facilities for unclassified and
class I, Division 1 and Division 2 locations to be referred.
22.4. DOS & DONTS GENERAL ELECTRICAL SAFETY
DOs
i. Always use electrical equipment including electrical illumaries in Hazardous area which are
Approved by Regulatory authorities.
ii. Always use proper PPE such as safety shoes, helmet, and gloves while carrying out electrical
work.
iii. All extension cords used must have explosion proof ends (connectors)
iv. All equipment and buildings must be grounded according to the applicable electrical
regulations

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SAFETY
v. Before loading or unloading any fluid/material by hose or piping, the truck/equipment must be
grounded and bonded to prevent static electricity hazard.
vi. When samples are taken in a container, the operator must ensure the container is in contact
with the filling nozzle or bonded by cable. When drawing samples in a glass bottle, the filling
nozzle must be in contact with the liquid in the bottle.
vii. When Draining or Depressurising fluid/material into a container, the container must be bonded
to the drain and depressurising valve.
viii. Before starting any excavation job in the vicinity of underground power cable, check and locate
for the underground cable and ensure that electrical power cable are in shut off mode.
ix. Batteries used and/or stored in enclosed spaces must be vented to remove hydrogen gases.
Sealed, maintenance free batteries are excluded from this requirement.
x. All electrical panels should be identified as to the equipment they control.
xi. Appropriate signs should be posted on electrical switch gear cabinets, sub-stations and rooms
to warn personnel of electrical danger.
xii. An “Equipment Starts Automatically” sign must be displayed on equipment which starts
automatically.
xiii. While working over ground, Minimum clearance from an overhead power line must be
ensured.
xiv. Ensure that the generator shall be earthed by two separate and distinct connections with
earth.
xv. Ensure that all metal castings or metallic coverings containing or protecting any electric supply-
line or apparatus shall be connected with earth and shall be so joined and connected across all
junction boxes and other openings as to make good mechanical and electrical connection
throughout their whole length.
xvi. All storage tanks including HSD storage tank on the Rig need to be earthed separately as per
electrical specifications "IS-3043-1966, IS-7689 - 1994 and OISD-RP-108.
xvii. All equipment and buildings must be grounded according to the applicable electrical
regulations.
xviii. Bonding and grounding are effective only when applied to conductive bodies. Bonding and
grounding systems should be inspected regularly for good mechanical condition.
xix. Always remember that serious harm can result from electricity with relatively low voltages if
equipment is not properly grounded.
xx. Always ensure that flame proofs light are used in Hazardous Zone no. 1.

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SAFETY
xxi. Ensure that grounding/ earthing is always done as per duly approved earth lay out diagram.
xxii. While checking earth resistance values, analyse the earth resistance values to see that they
are within permissible limit.
xxiii. Ensure that the calibration of electrical relays is done at prescribed interval.
xxiv. Always keep the emergency light and safety torch in working condition.
xxv. Shock chart must be displayed at relevant locations such as PCR room.
xxvi. The single line diagram & earth lay out diagram approved by competent authorities must be
displayed at relevant location
xxvii. Ensure to follow the electrical “Lock out” and “Tag out” procedure when ever it is required.
xxviii. When ever disconnection or reconnection of power supply is done, issue the electrical lock out
permit.
xxix. Ensure that electrical lock out permit is issued during perforation job on the well.
Don’ts
i. Never by pass any electrical safety device (MCBs, relays etc.) without prior approval from
competent authority.
ii. Never try to touch any cable or wire unless ensuring that it is de-energised.
iii. Never use measuring equipment such as Meggar & Earth testers which are not calibrated.
iv. Never leave the earth pits unmarked.
v. Never allow unauthorized persons to handle the electrical equipment.
vi. Never use damaged electric cable for earthing/ grounding of equipment,
23. HAZARDOUS AREA AND ITS CLASSIFICATION

A hazardous area may be defined as an area in which an explosive atmosphere is, or may be
expected to be, present in quantities such as to require special precautions for the construction,
installation and use of electrical apparatus.
Area classification is a method of analyzing and classifying the environment where explosive gas
atmospheres may occur so as to facilitate the proper selection and installation of apparatus to be used
safely in that environment, taking into account gas groups and temperature classes.
The main reasons for classifying the installation into hazardous areas are as follows:

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i. To ensure that sources of ignition are segregated from sources of flammable gas or vapor
ii. To assist in the appropriate location of air inlets and outlets for ventilation systems or
combustion equipment
iii. To define the extent of flammable gas level from vents
iv. To ensure that life saving appliances, radioactive stores and emergency control points are
located in non-hazardous areas,
v. To determine the location of flammable gas detectors
vi. To determine the maximum allowable surface temperature for particular areas,
vii. To assist in the location of escape routes
23.1. CLASSIFICATION OF HAZARDOUS AREA
The National Electrical code (NEC) describes hazardous locations by Class, group and division:
Class - I Combustible material in the form of gas or vapour.
Class - II Combustible material in the form of dust.
Class - III Combustible material in the form of fibres.
23.1.1. Gas Groups
Gases and vapours are categorized in terms of their ignition energy. This categorization leads
to the Gas Groups:
American System British System Indian System Gases

(Groups) (Groups) (Groups)
A IIC IIC Hydrogen, Acetylene

B IIC IIC --do--
C IIB IIB Ethylene, Ether, Coke Oven gas
NH3, CO, Propane, Butane,
D IIA IIA
Pentane, Hexane
E --- --- Metal Dust
F --- --- Coal Dust
G --- --- Grain Dust

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The American method combines the traditional groups A and B into a single group IIC, making
the requirements for acetylene gas the same as for hydrogen and other highly flammable
gases.
Notes:
Group I - Covers underground mines (Fire Damp) under all three systems.
Group IIC is the most severe group. Hazards in this group can be ignited very easily
indeed
Dusts and fibers are also defined in terms of their ignition properties including dust
cloud ignition properties.
23.1.2. Zonation
There are three zones for gases and vapours in India (as also followed under British system):
Zone-0: An area where flammable substances exist continuously. In other words,
flammable atmosphere highly likely to be present - may be present for long periods or even
continuously.
Zone-1 : An area where flammable substances exist under normal conditions or
intermittently due to operation, maintenance in which discharge of flammable gases / vapours
is possible, but unlikely to be present for long periods.
Zone-2 : Areas in which hazards do not exist normally, but may be encountered during any
abnormal condition of handling flammable products. It means that the flammable atmosphere
unlikely to be present except for short periods of time - typically as a result of a process fault
condition
23.1.3. Divisions
Under American system, there are two divisions:
Division - 1
Divison-1 location is a location:
in which ignitable concentrations of flammable gases or vapours exist under normal
operating conditions; or
in which ignitable concentrations of such gases or vapours may exist frequently
because of repair or maintenance operations or because of leakage; or
in which breakdown or faulty operation of equipment might release ignitable
concentrations of flammable gases or vapours, and might also cause simultaneous
failure of electric equipment.

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Division - 2
Division-2 location is a location:
in which volatile flammable liquids or flammable gases are handled, processed, or
used, but in which the liquids, vapours or gases will normally be confined within closed
containers or closed systems from which they can escape only in case of accidental
rupture or breakdown of such containers or systems or in case of abnormal operation
of equipment; or
in which ignitable concentrations of gases or vapours are normally prevented by
positive mechanical ventilation, and which might become hazardous through failure or
abnormal operation of the ventilating equipment; or
that is adjacent to, Division 1 location, and to which ignitable concentrations of gases
or vapours might occasionally be communicated unless such communication is
prevented by adequate positive-pressure ventilation from a source of clean air, and
effective safeguards against ventilation failure are provided.
In short it may be said that in Division 1, location, the flammable gases in explosive proportion
may be present under normal operating condition whereas in Division 2, location, the
flammable gases in explosive proportion may be present only in abnormal situation.
Accordingly, Division-1 & Division-2. Division-1 corresponds to both Zone-0 & Zone-1, whereas
Division-2 corresponds to Zone-2.
23.1.4. Safe Area
The area not falling under any of the above classified category is to be considered as safe
area.
23.1.5. Temperature Classes
When deciding the maximum surface temperature for apparatus which is to operate in an area
endangered by a particular gas it should be seen that the maximum surface temperature of the
apparatus should not exceed the ignition temperature of the gas or vapour. The permitted
maximum surface temperatures of electrical equipment have been classified as below:
T-Classes under all three Hazards which will not ignite at

Standards temperatures below
T1 450°C
T2 300°C
T3 200°C
T4 135°C
T5 100°C
T6 85°C

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23.1.6. Classification of Hazardous areas in oil Mines under Regulation 74 of Oil

mines Regulation 1984. No 1(6)2001-Genl/ 3604-375 dated 12th Sept 2001
For installations being operated under Mines Act, 1952 and OMR 84, latest DGMS circular
describes the extent of hazardous area/ zonations which is reproduced below:As per DGMS in
onshore operation,hazardous area is classified into Zone-1 & Zone-2.Zone -1 includes Zone-0
& Zone-1 discibed earlier.
A. Well-head area
When the derrick is not enclosed and the substructure is open to ventilation:
i. The area in all directions from the base of rotary table extending up to 3m shall be zone-2
hazardous area.
ii. Any cellar, trenches and pits below the ground level shall be zone-1 hazardous area;
iii. The area lying with in 3m in horizontal direction from the edge of any cellar, trenches or pit
and 0.5m vertically above the cellar shall be zone-2 hazardous area.
When the derrick floor and substructure are enclosed:
i. The enclosed sub structure below the derrick floor including cellar, pits or sumps below the
ground level, shall be zone-1 area,
ii. The enclosed area above the derrick floor shall be zone-2 hazardous area.
B. Mud tank/ Channel
i. The free space above the level of mud in tank and channel shall be zone-1 hazardous
area
ii. The area in a radius of 3m in all directions from the edge of mud tank and channel shall be
zone-2 hazardous area.
C. Shale shaker
i. The area within a radius of 1.5m in all directions from the shale shaker in open air shall be
ii. The area beyond 1,5m and upto 3m in all directions from the shale shaker shall be zone-2
hazardous area.
iii. When the shale shaker is located in an enclosure, the enclosed area shall be zone-1
hazardous area to the extent of the enclosure and
iv. The area out side Shale shaker and up to 1.5m in all directions from the shale shaker shall
be Zone-2 hazardous area.

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D. Degasser
i. The area with in a radius of 1.5m from the open end of the vent extending in all directions
shall be zone-1,
ii. The area beyond 1.5m and up to 3m in all directions from the open end of the vent shall be
E. Desander and Desilter
The area within a radius of 1.5m in all directions from the desander and desilter located in
open air shall be zone-2 hazardous area
F. Effluent Pit and open Sump:
i. The free space above the level of flammable liquid with in the effluent pit or sump shall be
zone-1 hazardous area;
ii. The free space lying upto 3m in horizontal direction from the edge of any effluent pit or
sump and 0.5m vertically above the effluent pit or open sump shall be zone-2 hazardous
area.
G. Oil Wells
Flowing Well
i. An area below the ground level shall be zone-1 hazardous area;
ii. The area lying up to 3m in horizontal directions from the edge of any cellar, trenches or pit
and 0.5m vertically above the cellar, trenches or sump shall be zone-2 hazardous area.
Artificially lifted well
i. An area in wells equipped with sucker-rod pump upto 3m above the ground level and up to
3m horizontally in all directions from the well-head shall be zone-2 hazardous area.
ii. In case of cellar, an area below the ground level shall be zone-1hazardous area; the area
lying upto 3m in horizontal direction from the edge of any cellars and 0.5m vertically above
the cellars shall be zone-2 hazardous area.
iii. The area in wells driven with submersible electric motor driven pumps or hydraulic sub-
surface pump or gas lift well shall be same as specified in clause B(1) when the well is
provided with cellar or sump.
Well under production test
i. The area with in a radius of 8m from an open discharge of petroleum bearing fluid from a
well under production test, shall be zone-1 hazardous area.

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ii. The area beyond zone-1 hazardous area for a further distance of 8m in all directions shall
be zone-2 hazardous area.
H. Well servicing operations
i. The area within a radius of 10m in all directions from a well pulling and other such well
servicing shall be zone-2 area.
ii. Provided that where cellar or sump is present, the area with the cellar or sump shall be
iii. And the area lying upto 3m horizontal direction from the edge from any cellars or sump
and 0.5m vertically above the cellars or sump shall be zone-2 hazardous area.
I. Gas Vent
i. The area within a radius of 1.5m from open end of the vent extending in all directions shall
be zone-1 hazardous area, and
ii. area lying within a radius beyond zone-1 hazardous area upto 3m of the vent shall be
J. Oil and Gas processing and Storage equipment
Oil–gas separation Vessel, Fired vessel, Dehydrator, stabilizer hydrocarbon recovery unit;
i. The area within a radius of 3m from any oil-gas separation vessel, fired vessel dehydrator,
stabilizer and hydrocarbon recovery unit shall be zone-2 hazardous area.
ii. Any trench or pit below ground level shall be zone-1 hazardous area and
iii. The area lying up to 3m in horizontal direction from the edge of any trench or pit shall be
K. Gas Vent
i. The area within a radius of 1.5m from open end of the vent extending in all directions shall
be zone-1 hazardous area, and the area lying with in a radius
ii. Beyond zone-1 hazardous area upto 3m of the vent shall be zone-2 hazardous area.
L. Relief Valve
The area within a radius of not less than 3m from discharge of relief valve extending in all
directions shall be zone-2 area subject to the condition that there shall be no electrical
equipment in the direct path of discharge from relief valve.
M. Pig Trap

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SAFETY
i. The area with in a radius of 1.5m of pig launching/receiving trap extending in all directions
shall be zone-1 area. The area lying beyond zone-1 hazardous area and
ii. upto a radius of 3m in all directions from pig launching/receiving trap shall be zone-2
hazardous area.
N. Pumps/Gas Compressor
i. Where a pump handling flammable liquid or gas compressor is located in open, air or well
ventilated shed without walls, the area lying upto 3m in all directions from pump or
compressor shall be zone-2 hazardous area.
ii. Where a pump or compressor is located in an adequately ventilated building, the entire
interior of such building including an area with in 1.5m of the vent shall be zone-2
hazardous area.
iii. Pits, sumps, trenches below the ground level shall be zone-1 hazardous area and the area
lying upto 3m in horizontal direction from the edge of any trench or pit and 0.5m vertically
above the pit sumps or trenches shall be zone-2 hazardous area..
O. Storage Tank
In case of a floating roof tank
i. the space above the floating roof and inside the enclosure upto top level of enclosure wall
shall be one zone-1 hazardous area;
ii. the area beyond zone-1 hazardous area and up to a radius of 4.5m in all directions from
tank shell and shell top be zone-2 area.
iii. In case of a dyke, zone-2 hazardous area shall extend vertically up to the height of the
dyke and horizontally up to the physical boundary of the dyke.
In case of fixed roof tank
i. the area inside the tank and with in a radius of 1.5m from all openings including breather
valve, dip hatch, thief hatch and safety valve shall be zone-1 hazardous area.;
ii. the area beyond zone-1 hazardous area and upto radius of 3m in all directions from shell
and roof of the tank shall be zone-2 hazardous area.
iii. In case of a dyke, the sump in the dyke and horizontally u to physical boundary of the dyke
shall be zone-2 hazardous area.
P. General
Where ever sampling cock or feed valve is fitted, the area upto 1.5m in all directions from
the release point shall be zone-2 hazardous area.

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SAFETY
Q. For process plants governed under Factory Act

For process plants and other areas IS: 5572 and OISD-RP-149 should be referred.
However, certain examples are given in the table on next page:
Area Extent of The Area Area

Classificatio
n
Storage vessels • within 1.5 m in all directions from the Zone - 1

discharge orifice of fixed liquid level gauges,
rotary or dip gauges etc.
• up to 1.5 m above ground level and within

max.30 m of a fixed source of Zone - 2
ignition(depending on the capacity of storage
vessel)
Relief valve discharge • within 1.5 m in all directions from the Zone -1
discharge point.
Zone-2
• Beyond 1.5 m but within 4.5 m
Tanker loading and • within 1.5 m in all directions from a point of Zone - 1
unloading connection or disconnection for
loading/unloading.
• Beyond 1.5 m but within 4.5 m from a point Zone - 2

of connection or disconnection.
Pumps and compressors in • within 1.5 m in all directions. Zone - 1

outdoor at or above ground
level
• beyond 1.5 m but within 4.5 m in all direction Zone - 2
Note: where there exists a high standard of

maintenance of pump and pump seals, the
extent of hazardous area would be zone -2 upto
1.5 m in all directions.
Pumps and compressors The entire room and any adjacent room not Zone-1
indoor with adequate separated by a vapour tight partition
ventilation

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R. Offshore Applications
For Offshore applications the hazardous area classifications to be done as per provisions
of API RP 500
23.1.7. Protecting Electrical Apparatus to make it suitable for use in hazardous
areas
Electrical apparatus for use in hazardous areas needs to be designed and constructed in
such a way that it will not provide a source of ignition. There are ten recognized types of
protection for hazardous area electrical apparatus. Each type of protection achieves its
safety from ignition in different ways and not all are equally safe.
In addition to the equipment being suitable for the Gas Group and the Temperature Class
required, the type of protection must be suitable for the zone in which it is to be installed.
The different types of protection and the zones for which they are suitable are tabulated
below:
Methods of Protecting Equipment For Use in Hazardous Areas:
Ignition protection method Principle and typical applications
Oil immersion The ignition source is constantly immersed in oil. Used in switch
devices and transformers.
"O"
Pressurised enclosure A protective gas contains the ignition source.

"P" Used in machines, collector motors, switch cabinets, control rooms,
monitors, keyboards and pads and analysers.
Sand filling The fine grained filling surrounds the ignition source and therefore
an arc from the inside of the housing cannot ignite the surrounding
"q" combustible atmosphere.
Used in capacitors, ballasts for lamps and measurement apparatus.
If an ignition occurs inside the enclosure, the enclosure must be

Flameproof enclosure able to withstand the pressure and contain the internal explosion
(s-gap width)
"d"
Used in heavy current applications, switches and components that
arc. This method can be used for load cells, motors and weighing
terminals.

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SAFETY
Ignition protection method Principle and typical applications
Increased safety Measures that reduce the chance of arcing and increased
temperatures. No ignition source can be present during normal
"e" operation.
Used in connection systems (motors).
Non sparking Apparatus which in normal operation is not capable of igniting a

surrounding explosive atmosphere, and in which a fault capable of
“n” causing ignition is not likely to occur
Encapsulation The ignition source is embedded in an encapsulating compound in

such a way that it cannot ignite a hazardous explosive atmosphere.
"m" Used in measuring apparatus and variable speed drives.
Intrinsic Safety The energy in the circuit is limited to values which do not result in
unacceptably high temperatures and/or arcs of sufficient energy to
"i" cause an explosion.
Used in instrumentation and control technology
The Indian standard in intrinsic safety defines two categories:
i) Category ‘ia’ : This category apparatus shall be incapable of
causing ignition under normal operation or with a single fault or with
any combination of two faults.
ii) Category ‘ib’ : This category apparatus shall be capable of
causing ignition under normal operation or with any single fault
applied.
Technical Features
Flame Proof (Type `d’) Enclosures
The flame proof enclosures must be strong enough to withstand explosion pressure which may occur
inside. The design of FLP enclosure must be such that internal explosions can not come out via
flanges, glands, spindles and other joint surfaces. These mating surfaces are known as “Flame Path”
which cools the flame when it comes out of the enlosure.

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Maintenance of FLP Enclosures

i. FLP enclosure to relieve the pressure from inside the enclosure developed due to any
explosion. Details of design characteristics of such safe apparatus are given in IS code. In
addition to this, it is equally important that the maintenance engineer should have a clear
understanding of the problem of maintenance of such apparatus. Certain impotant features
are;-
ii. Alteration of a FLP enclosure shall be prohibited.
iii. The dimensions of the joint and clearances shall have to be maintained.
iv. Painting shall be necessary to save from corrosion. Aluminium paint shall not be used,
since this may give rise to dangerous frictional sparking on impact.
v. Adequate care shall be taken in maintaining flame proofness of the equipment. The force
for tightening of the bolts, nuts and screws should not be more than necessary.
vi. The designed flame proof gap should never be disturbed while dismantling and
reassembling equipment.
vii. Cracked or broken glass windows shall be promptly replaced.
viii. Non-metal to non-metal flame path is not permitted.
ix. External connection to the apparatus should normally be indirect i.e. through an integral
terminal box.
x. Cable entry devices like compression glands should be independently explosion proof in
the sense that flame should not travel through gap between non-metallic cable sheath and
neoprene ring used for compressing the cable.
xi. The wall thickness should be adequate enough to withstand explosion pressure
xii. Glass window and glass cover in the case of light fittings should be toughened and
adequately sealed to the metal housing.
xiii. All separate housing pertaining to an apparatus should be independently flameproof i.e.
explosion should not travel from one enclosure to another through cable entry devices
present in the partition wall.
xiv. Aluminium conductor cable shall not be used in hazardous areas because, the word
“Mining” is not imbedded, printed or embossed through out the length of cable as required
in the standard. Heavy duty cable means armoring conductivity to be 75% and also the
copper conductors so that the current rating is better and is more suitable for rough and
tough mining uses. The copper has also got better flexibility than aluminium.

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24. SAFETY IN WELL LOGGING OPERATIONS

24.1. GENERAL
Once a well is drilled in an oilfield, it is necessary to collect information about characteristics of the
formations, location and thickness of oil sands, type and nature of hydrocarbon deposits etc. The
information is obtained by field geophysical parties. Special well logging tools are lowered by
wireline into the well and these are operated and controlled electrically from an instrument truck,
radioactive substances are also used for logging.
Logging is done either in an open hole i.e. when casing has not been set or in a well which is
already producing oil. While the former is known as open hole logging, the latter is called
production logging. In either case, of course, the purpose is the same, i.e. to obtain information
about oil bearing sand zones and other formation parameters.
In well logging, the main hazards are due to handling of heavy and long logging tools, which are of
3-6 metres long and weigh upto 100 kgs; other hazards are due to blowout, use of electricity and
radioactive substances. In production logging, there is fire hazard also.
The recommendations listed below, provide guidance for safe operation in the light of hazards,
mentioned above.
24.2. HANDLING OF WELL LOGGING TOOLS
A suitable hoister should be used for lifting the well logging tools. The tools should be kept in the racks
provided in the logging truck and securely fastened with clamps and latches.
24.3. PRECAUTIONS AGAINST BLOW-OUT
The well should be filled properly with well conditioned mud so as to overbalance the bottom hole
pressure. At least two complete cycles of mud should be circulated. Before pulling out the drill string, the
quality of the mud should be checked to ensure that it is free from cuttings and that specific gravity and
viscosity are in accordance with the Geo-Technical Order (GTO). If the condition of the mud is not
proper, the logging tool may get stuck in the well and fail to reach the desired depth.
A double ram Blowout preventer, one set each of pipe ram and blind ram, should be installed at the well
head. The blow-out preventer and its lines should be tested as per OISD-RP-174. It should be provided
with a lever to control wheel at not less than 10 meters from the well for remote operation. The control
wheel should be guarded by a screen for safe operation. Instructions for operation of the BOP should be
prominently displayed.
Persons employed on the job should be familiar with the warning signs of kick in the well and operation
of blowout preventer equipment.
24.4. ELECTRICAL SAFETY
i. The insulation of electrical equipment and cable for logging should be checked before
the operation to ensure that the insulation resistance is in order.

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ii. A proper earthing pit should be provided at the well site. Earth continuity between the earthing
pit and the source of power for the logging truck should be ensured. Suitable socket
and plug arrangement should be made for power and light connections.
iii. The logging winch and laboratory should be earthed.
iv. The cable should be guided over pulleys while lowering the tool into the well and it should
be ensured that after the tool reaches the expected depth, there is adequate length of cable on
the drum for safe operation.
v. No logging job should be undertaken under conditions of storm, lightning and thunder.
24.5. GENERAL PRECAUTIONS
i. During the round trip operation all persons should remain at a safe distance from the moving
cable.
ii. The catwalk of the derrick should be kept free from obstructions as may be safe for persons
carrying heavy loads; proper foot holds should be provided on the catwalk.
iii. During logging operation, no other activity should be undertaken simultaneously in the
operational area which may interfere with safe conduct of work.
iv. The logging tool should be run in the hole at a controlled rate. Running in should be periodically
stopped, but not for long so as to prevent it from getting stuck in the hole. The motion should be
reciprocated to ensure free descent of the tool.
24.6. PRODUCTION LOGGING
i. In this operation, there is additional hazard due to fire and oil spillage.
ii. The logging tool is sent down through a lubricator, wire line blowout preventer and x-mas tree.
In case of any activity in the well, if it is possible to put out the logging tool, the well can be
closed with the BOP. When the tool is still inside the well and it is necessary to close the well,
the wire line BOP can be closed on the wireline itself.
iii. Before commencement of operation, it should be ensured that the valves of the x-mas
tree assembly are in good condition and there is no leakage. Any oil spillage at the well should
be cleaned.
iv. If a grease injector pump is installed to compensate for the bore hole pressure and safe
lowering of logging tool, it should be ensured that the pump can be operated from a safe
distance of not less than 10 metres from the well head.
24.7. FIRE PRECAUTIONS
i. An area within 30 metres of the well head should be treated as danger zone in which no
smoking or open flame should be permitted, and all electrical equipment should be de-
energised.
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ii. Adequate number of fire extinguishers should be kept readily available at the site. It should be
ensured that the persons are conversant with the use of fire extinguishers.
iii. Adequate number of self contained portable hand lamps of approved type should also be
provided for use in case of emergency.
iv. Flow studies, with production logging unit in oil, gas and gas condensate wells should be carried
out as per the plan approved.
v. The well head assembly should be checked for its pressure rating before commencement of
any flow studies.
24.8. RADIOLOGICAL SAFETY
In nuclear well logging devices a neutron source or a gamma ray source is used alongwith nuclear
radiation detectors for carrying out logging. Radioactive source are all sealed sources, doubly
encapsulated as per specifications. In some cases, liquid isotopes are also used.
In order to use radioactive source for well logging, application should be made to the Director, Division of
Radiological Protection, Bhabha Atomic Research Centre, Trombay, Bombay 400 085. In the
application, details such as nature and use of radioactive source, storage, transportation, handling
facilities and availability of radiation survey instruments should be mentioned.
The personnel handling radioactive sources should be enrolled with the personnel monitoring services
conducted by the Divn. of Radiological Protection (DRP) DRP, BARC. They should also be trained in
radiation safety aspects by conducting special training courses in collaboration with the DRP, BARC.
24.8.1. Radiation Hazards
The radiological hazards from radioactive source used in well logging are of three types.
Firstly, hazards from neutron source, secondly the hazards from gamma source and thirdly the
hazards due to leakage.
Hazards from neutron sources increase with the kinetic energy of these source and cause
biological damage. All radioactive neutron sources are also associated with gamma ray
intensities. Hazards from gamma sources are due to gamma rays which are
electromagnetic radiation and cause biological damage penetrating the body tissues.
Hazards due to leakage are from alpha emitters contained radioactive neutron source. The
alpha emitters are the most dangerous one when injected or inhaled because of their high
toxicity. Therefore, it is necessary to periodically check whether such a source is leaking as it
poses a serious contamination hazard.
24.8.2. Storage
The radioactive source should be stored in a container duly approved by BARC. The source
container should be labelled and kept in a room or enclosure under lock and key. The keys of
the room should be in the custody of a person authorized for the purpose, to prevent

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unauthorized removal of the source, theft or accidental exposure to radiation. The container
should be used for storing source upto its rated capacity.
The label of the source container should indicate the activity, half-life, date of measurement of
activity and the identity of the source i.e. its source number particularly in case of source loaned
out by BARC. The label should be legible and durable. Radiation symbols should be pasted
outside the source container and the room housing it.
Adequate precautions should be taken against danger from fire or explosion at the place where
a radiation source is stored. Explosives and inflammable material should not be stored, not even
temporarily, at a place where any radioactive source has been stored.
24.8.3. Transport
The radioactive sources are transported in storage-cum transport container duly approved
by BARC. These containers should be secured to the logging truck during transportation. The
truck should be locked and radiation warning symbols should be posted conspicuously on the
truck.
The part of the truck in \which the source contained is placed, should not be used for personnel
transport. The seat near the instrument panel should be occupied only during actual logging
operation. Entry of unauthorized person into the logging truck should be strictly prohibited.
When a logging truck containing radioactive source is not in use, it should be parked in a
garage. If it is parked in open space, it should be ensured that there is no unauthorised person
in the vicinity.
24.8.4. Handling
The sources should always be handled with remote handling tongs. When a source is removed
from its container and is exposed to outside atmosphere, appropriate signs and barriers should
be provided. All work should be done strictly under the direct personal supervision of a person
authorized for radiological protection at the site.
The transfer of the source from its container to the source holder in the logging device should be
completed in as little a time as practicable. The logging tool should be lowered into the well
immediately after the radioactive source is loaded into it. Similar care should be taken while
unloading the source from the logging device and putting it back into its container.
A record of inventory and utilization of radioactive source should be maintained by the person
authorized for the purpose.
In case of liquid isotopes contained in ampules, surgical gloves should be worn while handling it.
It should be ensured that the liquid is not spilled.

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24.8.5. Emergency Procedure

In the following cases emergency action should be taken:
i. When a radioactive source contained in a logging tool is lost in a well.
ii. When a source is lost or misplaced during storage or transport.
iii. In case of a fire or explosion in a well while a radioactive source is either inside the
well or is on surface near the wellhead.
iv. Leakage or rupture of radioactive source.
In the event of any emergency as indicated above, the Director, Divn. of Radiological
Protection, BARC, Bombay 400 085 should be contacted..Remedial measures should be
carried out in accordance with his directions.
The following recommendations provide necessary guidance in emergency situations:
Loss of source in the well bore
In case the wireline of the logging tool is stuck or snapped to any reason and the logging
tool containing radioactive source drops or gets stuck into the well bore. Action should be
taken as follow :
i. Attempt to retrieve the source by fishing operations should be started under the
direct personal supervision of the officer incharge of well logging operations.
ii. During fishing operation, in the area surrounding the well frequent checks for
radioactive contamination should be made.
iii. If the logging device is retrieved, it should be checked for contamination and the
source integrity verified under the supervision of BARC officials.
iv. If the source is not retrieved, it should be immobilised and sealed in place with
cement plug, after obtaining necessary authorisation from BARC.
A permanent identification plaque should be put at the well bore. The plaque
should contain such information as may be advised by BARC.
v. In the well where a radioactive source is lost and cemented, no drilling should be
undertaken below the plug back depth, neither any attempt should be made to enlarge
the well bore without prior permission of the Director, Divn. of Radiological Protection,
BARC.
Loss of source during storage or transportation
If a source lost during storage or transportation is retrieved, its integrity should be checked
before it is put into use again. If, however, the lost source cannot be traced, the Director, DRP,

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BARC should be informed immediately and further action should be taken as per his advice.
Fire or explosion in well where radioactive source exists
If fire or explosion occurs in a well in which radioactive source is present, it should be treated
as lost in the well and should be abandoned. If however, the source is at the surface
immediate steps should be taken to retrieve it.
Leakage or rupture of radioactive source
The chances of leakage of radioactive source, however, small, do exist because of a
likely manufacturing defect. In the event of rupture the source and its encapsulation break
apart or are torn open thus allowing a source radiation to spill out. In such an event, steps
should be taken to limit the spread of contamination and isolate the leak or ruptured source.
Such a source should not be re-used. It should be disposed of as per the procedure laid down
by BARC. Decontamination operations should be undertaken on approval by the Director, DRP,
BARC.
24.8.6. Radiation Monitoring
i. Radiation survey instruments should always be available at the storage site, in the logging truck
and also at the well where logging operations are undertaken with radioactive source.
ii. Moderated thermal neutron detector should be used for measuring neutron/dose equivalent at
various distances from source in the storage container.
iii. Gamma radiation survey meters should be used to measure doses to gamma rays.
Contamination monitors should be used to check leakage of the source by performing wipe
tests.
24.8.7. Personnel Monitoring
i. All personnel handling radioactive neutron source with low gamma intensities should use
neutron film badges.
ii. Personnel working with gamma sources only, should wear beta gamma badges.
25. SAFETY IN GEOPHYSICAL SURVEY

25.1. GENERAL
Geophysical surveys are part of exploration for petroleum resources. In this process, shot holes of
about 100 mm in diameter are drilled upto depths of 2-60 mtrs below ground or mini hole patterns or 1m
or less are dug and explosive charges are fired to generate elastic waves which are reflected from
different interfaces beneath the surface. These reflected waves are picked up as signals with the
help of geo-phones planted in the ground and recorded with a digital seismograph mounted in a
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vehicle. Seismic surveys are thus carried out in widely varying terrain conditions throughout the
country by geophysical parties.
The field parties operate from camps, which are often set up in remote areas. A party has its own
fleet of vehicles for exploration work. Proper maintenance and safe operation of vehicles are very
important.
The field personnel must be regularly trained in rendering first aid to injured persons. Besides a
monthly first aid drill will keep the field personnel ready to handle effectively an emergency
situation warranting first aid.
For camp establishment following considerations in additions to established good practices would be
helpful.
25.1.1. Amenities
Besides civil amenities within a manageable distance it should be ensured that the camp would be able to
sustain the vagaries of changing climate throughout the duration of operation in the area.
If doctor is not available within half an hour drive from the camp, a doctor should be employed by the party
for regular visits to camp who would also supervise first aid training and drills. Anti venom may also be
kept handy potable water should be provided in camp and at the sight of work.
Fire fighting equipment should be in a ready to use condition. Safety should also be conducted in this
regard. Storage of petroleum products should be done carefully and in accordance with the statutory
guidelines.
The safe practices against hazards due to drilling shot hole with truck mounted rigs and use of explosives
are given below:
25.2. LOCATION OF SHOT POINTS
The shot points to be drilled and fired are fixed at specified intervals along the seismic lines shown on
the project map.In this Surveyor's traverse report, access routes to the shot points as also
presence of electric transmission lines, telephone lines, road, buildings etc. in the vicinity of
proposed shot points are indicated. Copies of the traverse report should be available with the
observer, driller and shooter. It may be necessary to locate the shot hole and the quantity of
explosive charge away from the installations mentioned above to prevent damage and obstructions. In
case of any doubt the competent authority controlling the installation should be consulted.
25.3. SHOT HOLE DRILLING
The recommendations listed below provide guidance in this respect:
i. While moving the drilling rig, its mast should be lowered down.. Before raising the mast at site,
it should be ensured that the truck is in level position and there is no obstruction like
overhead transmission line etc. in its path. The wheels of the truck should be firmly
blocked to prevent inadvertent motion during drilling.

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ii. The mud pump should be provided with a pressure gauge and relief valve, the discharge
of the relief valve should be led through a pipe to the ground. The mud lines should be
secured to the mast.
The mud pump should not be operated until the inlet and discharge valves are
checked and opened. In case the pump stops due to any reason, the pressure
should be released immediately by opening the wash hose valve.
iii. Hose, chains and lines should be inspected daily and in case of any defect, it should not be put
into use until the defect is removed. The dies of slips and tongs should be checked and in
case these are worn, same should be replaced. It should be ensured that drill cuttings are not
allowed to clog the hole. No attempt should be made to clean the cuttings manually when
drilling is in progress.
iv. Drilling crew should be provided with personal protective equipment like helmet, boots and
hand gloves.
v. All shafts, sprockets, gears and moving parts of machinery should be securely guarded.
Repairs and maintenance of machinery should not be done while the machine is in motion.
25.4. TRANSPORT, STORAGE AND USE OF EXPLOSIVE
Explosive Rules 2008 framed under the Indian Explosives Act 1884 regulate transport, storage and use
of explosives used in geophysical operations. Chief controller of Explosives is responsible for
enforcement of these statutory provisions, which should be carefully studied. Salient features and
safety precautions are however mentioned below:
25.4.1. Storage
Explosives are to be stored in magazine after obtaining license from the competent authority.
The magazine should be sited at a safe distance away from roads, public places and
high voltage electric transmission line. For example, a magazine for storing 454 kg. of high
explosive should be atleast 45 meters away from roads and public places and atleast 90
metres from factories, public buildings, schools etc. The construction of the magazine should
be as per the design approved by the competent authority.
25.4.2. Transportation and handling of explosive
Explosives should be transported in mechanically propelled vehicles duly approved and
licensed by the competent authority.
i. The competent person, holding shot firer's permit granted under the Explosives Rule 1983,
should be present and conduct the loading, unloading, handling of explosives in general.
He should maintain a correct record of explosives received, used and returned by him.
ii. He should see that.cases containing explosives are not thrown or dropped down on ground.
iii. No smoking or open flames or fire are permitted in proximity to a place where explosives

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are stored.
iv. No person has in his possession any match box or other appliances of steel which can cause
spark.
v. Mobile phones should not be used during handling of explosives.
vi. No person wears shoes with an iron heel unless such shoes bare covered so as to prevent
sparking.
vii. Detonators are carried in wooden boxes duly locked. The end of the detonator leads
should be kept shorted.
viii. No detonator is taken out from its container unless it is required for immediate use. Explosive
and detonator should not be carried in the same container.
ix. Explosives primed with detonator should be immediately lowered into the shot hole. No
primed charge must be kept at the surface. The ends of the wire attached to the primed
explosive must be kept shorted from the time of priming, loading till the time it is connected to
firing line for taking record.
25.4.3. Shooters and shot firing tools
i. Every person required to fire explosives should be conversant with the handling and
use of explosives and hold shot firer permit under the Explosive Rules 2008
ii. Every shooter or the person required to charge shot holes should be provided with a tool
made of wood suitable for charging and stemming shot holes and a pricker made of wood
or non ferrous metal for preparing explosive cartridges with detonator.
25.4.4. Charging and firing of shot holes
i. No blasting operation should be carried out between the hours of sunset and sunrise.
ii. The preparation of charges, charging of holes and firing shots should be carried out by or in
the presence of person holding shot firers permit granted under the Explosive Rules 2008.
iii. No smoking or any source of naked light or fire or electricity like battery of a motor vehicle,
should be allowed in or near the place where explosive charges are being prepared or kept.
iv. Before exploding of any blasting charge, a strong lattice of non ferrous metal, sufficiently heavy
should be placed over the shot hole and spiked to the ground so as to provide protection
against flying fragments or missiles or loading wire. At the same time it must also be ensured
that the shooting wire ejected after blasting the hole is sufficiently away from any electrical line,
failing which a serious risk of electrocuting is involved to the personnel and equipments having
anything to do with the seismic spread.
v. Before commencing shot firing, adequate warning to the public should be given by an efficient
system of signals and by putting up red flags in the danger zone i.e. 200 mtrs from the place of
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blasting. It should be ensured that all persons in a vicinity have taken proper shelter.
vi. If shots are being fired in a vicinity of any public road, adequate precautions should be taken to
guard against danger to the public.
vii. After blasting has been satisfactory carried out, all clear signal should be sounded. The entire
shooting crew should wear helmets to guard against any falling debris. The blasted holes should
be filled with earth to avoid injury to people or animals.
viii. Shooting operations should be suspended if there is any possibility of lightning in a cloudy
weather.
ix. In desert operations all the loading crew must wear cotton dungarees to avoid static discharge
from synthetic cloths. Antistatic detonators must be used in desert operations.
25.4.5. Misfire
i. In the event of misfire no attempt should be made to re-bore or tamper the hole that was charged
with explosive or to withdraw the charge from the hole.
ii. In cases of misfire, the re-loading of the mis-fired hole should be done according to the Explosive
Rules - 2008.
25.4.6. Destruction of explosive
i. If any explosive escapes from the package in which it is contained or is split or otherwise
damaged and is rendered unfit for use such explosive should immediately be carefully collected
in a suitable container and stored in an isolated place, where there is no danger of fire or
explosion till it is finally destroyed in consultation with the competent authority.
ii. It is dangerous to attempt destruction of explosives by incompetent persons and without following
the prescribed procedures for safe destruction of explosives.
25.4.7. Blasting with high voltage blaster
i. In geo-physical surveys, using explosives, shots are fired by a high voltage blaster from near the
shot point. The blaster has both automatic as well as manual control device. Once the blaster is
armed and ready to deliver high voltage the shooter communicate 'Ready to shoot' to the
observer and the observer starts the recording system and almost simultaneously the explosive is
blasted in the hole. If the shooter sees any risk he should immediately go to the unarmed position
of the blaster and inform the observer of the same.The process is resumed when the obstruction
is removed.
ii. The blaster should be overhauled once in six months.
iii. The shooter should have clear view of the safety zone around the shot hole.
iv. The firing line should be coiled in a spool and kept at the shot hole with its other end short
circuited to prevent accidental firing of shot.
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v. Effective means of communication should be provided among the shooter and his crew at the
shot point area and the observer at the instruments van. The observer should not fire shot unless
he is satisfied by his communication with the shooter at the shot point area that the conditions are
safe for firing.
vi. As soon as a hole is blasted, the firing lines should be disconnected from the blaster.
vii. A cap tester should be used to check the continuity of each detonator before its use.
25.5. RECORDING
The Seismic signals generated by firing of explosive charges are recorded in an instrument cabin by
the observer, who also switches on the shot firing circuit.
The recommendations listed below should provide guidance for safe recording.
i. The instruments van should be driven after switching off the recording instruments. The batteries
of the instrument panel, should be secured in position. It should be made sure before making
battery connections that the gas vent has been opened and any accumulated hydrogen is vented
out. Failure to do so may cause explosion of the battery if a sparking takes place during battery
cable connection.It is better to avoid wearing rings in the fingers while making battery
connection.
ii. The van should be parked at a safe place, away from overhead transmission lines, free from
obstructions and open fire. The van and the recording instrument should be efficiently earthed.
iii. Before firing the shot, the observer should ascertain from the shooter over field telephone, the
short point number being fired and whether persons have taken adequate shelter. After the shot
is fired, the observer should ascertain whether the shot hole has been fired safely. The shooter
should move to the next location only after obtaining clearance from the observer.
iv. The instrument cabin should have a dry powder type fire extinguisher.
25.6. VIBROSIS SURVEY OPERATIONS
The vibrosis survey operations utilise a servo Hydraulic Vibrator which acts as energy source for
seismic survey. The signal sent into the earth by the base plate of vibrator is controlled sweep
frequency. It involves:
I. Several vibrator trucks travelling along a line parallel to the seismic line.
II. At each location, a number of sweeps (vibrator/signals) are sent to the ground and reflected
sweeps are recorded.
III. The data from all sweeps/locations within the distance range are composited into a single
channel by digital seismic units.
IV. The composited data for all channels is transferred to tape.

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The hazards are due to operations of the vibrator truck in thickly populated areas, in the
vicinity of buildings, electric and water supply lines and amidst vehicular traffic.
The other hazard is due to equipment under pressure. The vibrator is charged upto a
pressure of 300 p.s.i.
The following precautions are therefore recommended.
i. The vibrator should be pressurised and operated only by the authorised personnel.
ii. During the operations, it should be ensured that persons not required for the
operations and pedestrians remain at a safe distance away from the vibrator.
iii. While undertaking any repair of changing of tyres etc., it should be ensured that the
vibrator pad and axles are properly blocked to prevent inadvertent motion.
iv. Once the vibrator is pressurised, it should not be left unattended.
v. Regular maintenance of the vibrator unit should be carried out in accordance
with the recommendations of the manufacturer and under the supervision of expert
mechanical engineer.
25.7. SAFETY FROM LOGISTIC/CLIMATIC POINT OF VIEW
The geophysical surveys are done in diverse geographical area which have unique features relating to
safe negotiations in transit and during operations. It is required to prepare a possible list of
hazards and a hazard map indicating a real and temporal variations due to changing terrain and
climate.
25.8. SAFETY CONSIDERATIONS FOR SURVEY CREW
The following points are relevant:
i. Only wooden ranging rods should be used to avoid electrocution from any low hanging
electrical supply lines.
ii. It is also incumbent upon the survey crew to take help of available map/information from local
people/local administration and any other relevant source of information to assess and avoid
any probable hazards and inform other crews which access the worksite later.
* As per the directives of 273rd EC meeting of EC of ONGC, “Safety Manual for Handling of
Explosives” prepared in 2005 is also to be followed, by geophysical field parties.

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26. SAFETY IN RESERVOIR STUDIES

26.1. GENERAL
In our oilfield, studies are regularly undertaken to ascertain various reservoir parameters of a well,
whether producing or static. In these studies, known as bottom hole studies, pressure, temperature
and flow rate in the well are recorded and sample of well fluids are drawn periodically. Generally, the
operation involves installation of a 2.1 mtrs. (in special cases 4 mtrs) long lubricator on top of the
Christmas tree and lowering the instrument and samplers with the help of a winch and pulley,
through the stuffing box. A winch operator, two helpers and fitter generally do the job. The main
hazards in this operation are as follows :-
i. If the cellar pit is filled with oil, mud and water and the area is water logged, it is difficult
to install the lubricator safely on the well head.
At times the top of the well head assembly may be as much as 6 metres
above ground and access to the top is difficult.
ii. Leakage in the X-mas tree valve assembly.
iii. Possibility of fire.
26.2. SAFE PRACTICES
i. The site should be prepared for bottom hole studies. Any accumulation of water, mud and oil
should be cleared from the area.
ii. To facilitate safe installation of lubricator and lowering of instruments down the hole, every well
should be provided with suitable working platform with non-skid surface. The platform should
be so designed and erected that it can be easily dismantled whenever necessary.
iii. A careful check of the x-mas tree valves should be made in advance to ensure that there is no
leakage.
iv. A lubricator of adequate capacity should be used.
v. An area within 30 metres of the well should be treated as danger zone and no smoking or open
flame should be permitted within the danger zone. All electrical equipment within the danger
zone should be de-energised.
vi. When reservoir studies are to be carried out in remote locations or on unmanned
offshore platforms adequate arrangement for communication and transportation, for use
in case of emergency, should be provided before starting the studies.
vii. When these studies are being carried out, it should be ensured that there is no leakage of gas
through the system. A suitable gas detector should be used to check the presence of
flammable gas within the danger zone.

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27. EXPLOSIVE & RADIO ACTIVE MATERIAL

27.1. EXPLOSIVES:
27.1.1. Introduction
All explosive materials are hazardous of nature and required to be handled with utmost care.
It is therefore, imperative to identify areas of concern regarding handling (storage,
transportation and usage) of explosives in Geophysical and Logging operations. It is also
intended to reflect and adopt the international practices in handling explosives. The
personnel responsible for managing and handling explosives must follow the recommended
safe practices mentioned in this HSE Management System.
27.1.2. Objective
The basic objectives of this document are:
i. To create awareness among the personnel regarding various aspects of safety and security
while working / attending the explosives related activities.
ii. To assist in understanding the hazards involved in the explosives related activities and
setting/ensuring standard safe practices.
iii. To create awareness towards safe working and elimination of accidents related with
explosives.
iv. To provide all information required for getting licenses and documents required to be
maintained for storing, transportation and usage of explosives.
v. To put up the enforcing procedures to ensure the safety precautions and regulatory
requirements.
vi. To establish and maintain the highest safety standards in handling explosive materials, during
all phases concerned i.e. transportation, storage, and use.
27.1.3. Scope
The scope includes safety procedure and precautions during, storage, handling & usage of
explosives in Geophysical and logging operations.
27.2. RADIO ACTIVE MATERIAL
27.2.1. International classification of hazardous substances
Radioactive materials are covered under class 7 of International classification of hazardous
substances
27.2.2. Radioactive Materials:

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All explosives and radioactive materials are hazardous in nature and required to be handled
with utmost care. The recommended dose limits of exposure / radiation by Health, Safety and
Environment Group of Bhabha Atomic Research Centre is given in Table - 1. Industrial and
medical uses of radiation do not present substantial radiation risks to workers provided the
safe practices are followed. The industrial workers should not lead to radiation exposures in
excess of such recommended level of the radiation dose. Otherwise, accidents may lead to
higher exposures and subsequently lead to biological hazards.
Note: Refer ONGC safety manual for handling of Explosives & Explosive rule 2008
28. SAFETY IN OFFSHORE PLATFORMS

28.1. GENERAL
Offshore production platforms are of three type. Firstly, the well platforms which are set up over wells
and have only testing facilities for the well products, consisting of a separator, utility storage tank and
chemical injection pump. Secondly, the well-cum-process platforms constructed over a group of
wells with facilities for three stage separation of oil and gas, pumping of crude oil down the
submarine pipeline and flare tripod connected to the platform. Thirdly, the process platform to which
several well platforms are connected, the top side facilities consist of oil and gas separators, pumps
for the main oil line and gas compressor in which processed gas is compressed to high pressure
and sent down the submarine gas line; the platform either has built-in living quarters or is connected to
living quarters.
The process platforms and some of the well-cum-process platforms provided with living quarters are
manned round-the clock on a 12 hour shift basis. The other platforms are not manned round- the-
clock & the persons work at these installations as and when required.
The self-contained manned process platforms are also provided with utilities like potable water,
electricity, sewage & garbage disposal and communication system etc.
28.2. HAZARDS ON PRODUCTION PLATFORMS
The release of hydrocarbons on a production platform is the major threat to safety which can lead to
fire and environmental pollution.
In a process component, hydrocarbon is released due to any of the undesirable events like over
pressure, leak, liquid overflow, gas blow by high temperature etc.
28.3. SAFETY SYSTEM
In designing production platforms, the primary consideration is the safety of personnel
environment and facilities. The design is based on API RP-14; a careful study of this document is
recommended. However, its salient features are mentioned hereafter.
Shut in the process or affected part of the process to stop the flow of hydrocarbons

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to a leak or over flow if it occurs.

Accumulate and recover hydrocarbons and disperse gases that escape from process.
Prevent ignition of released hydrocarbons.
Shut the process in the event of a fire.
Prevent undesirable event that could cause release of hydrocarbon from equipments
other than that in which the event occurs.
The system provides two levels of protection i.e. primary and secondary to prevent or to
minimize the effects of an equipment failure within the process.
Once a production platform with a suitable designed safety is installed, the focus should be on the
maintenance of the system so that the designed level of protection is available at all times.
28.4. WELL CONTROL SAFETY SYSTEM
In order to protect wellhead installations of producing wells, Sub-Surface Safety Valve (SSSV) is
installed in a well, below the well head, designed to prevent uncontrolled well flow when actuated, in
case the wellhead is sheared off or is otherwise damaged. The SSSV is controlled from the
surface by hydraulic means and hence is known as Surface Control Sub-Surface Valve (SCSSV).
A surface safety valve (SSV) is also installed on the well-head to shut off the well actuated.
These valves should be regularly checked, as indicated in Annexure to ensure that these are
maintained in good working order.
In case the SCSSV is found to be defective during such checks in an unmanned platform, the
installation should be manned till the SCSSV is repaired or replaced so that the SSV can be closed
manually in case of emergency or storm choke should be installed over & above the leaking SSSV.
28.5. EMERGENCY SHUTDOWN SYSTEM (ESD)
An emergency shutdown system (ESD) is a system of manual control, located on a platform,
which when activated will initiate shutdown of all well and other process systems.The ESD system
provides a means for personnel to initiate platform shutdown when an abnormal condition is detected
28.5.1. ESD Stations
The ESD stations should be conveniently located but should be protected against
accidental activation. It should be clearly identified. The shutdown position of the valve
handle should be prominently indicated.
The stations are generally located at helidecks, exit stairways, boat landings, muster
stations, near driller's console during drilling and work-over operations and near the
main exits of living quarters. ESD buttons should be located on all decks and at spider
deck at points above the monsoons storm damage zone.
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28.5.2. Emergency Conditions

In the following emergency conditions, the ESD system should be actuated by
any person on board fire on a platform
leakage in main oil/gas line
blow out
leakage of sweet gas in excess of 60% of LEL.
Leakage of sour gas, H2S concentration of 20 ppm or above in environment.
In the following cases the ESD system should be actuated only if the (FPS) field
production superintendent so decides :
Cyclone and severe weather conditions,
Fire in a nearby installation,
Oil spills around the installation,
Collision involving the installation,
Rupture of pipe/uncontrolled gas or oil leakage.
28.5.3. Testing of ESD system
Once every six months, the ESD system should be function tested under the direct
personal supervision of the field production superintendent.
29. SAFETY IN ONSHORE PRODUCTION INSTALLATIONS

29.1. GENERAL
Oil and Gas produced from wells are collected at production Installations.
When it is intended to construct any new production Installation, or carry out alterations, the notice
of such intention should be sent to DGMS Authorities and District Magistrate in Form-IV of oil Mines
Regulation '84 (Amended) alongwith following documents atleast 90 days, before such construction, 2
copies of an upto date plan of the proposed site of the production Installation, showing:
i. Name and location of the Installation.
ii. The name and location of any other prod. Installation and all pipelines lying within a radius
of 500 meters there from.
iii. The name of each well connected to the proposed Installation.
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iv. The extent of the land over which right of use has been established.
v. Any railway, public road, public works etc. lying within 60 meters of such installation.
If the oil and gas handling capacity exceeds 300 tonnes and 1,00,000 tonnes respectively,
the above-stated notice should accompany a Safety Report in Form-VII of OMR'84 (Amended)
layout of oil and gas installation may be referred in OISD-STD-118.
29.1.1. Well Head Installation
A well-head installation handles about 30-40 tonnes of oil per day produced from wells.
The installation consists of an oil and gas separator, a water bath heater to heat the oil and
a heater treater to demulsify and dehydrate the crude oil, i.e. The water is separated from
crude oil by passing it through a heated water bath. The oil from the separator and
collected in horizontal storage tanks and there is a loading arm facility for loading crude oil
into road tankers.
29.1.2. Group Gathering Station (GGS)
This is a centrally located unit where flow lines from various production wells are connected
to manifold in the respective header. Crude Oil/ Emulsion flows on its own pressure (or with
artificial lift means) from the wells to the separators, through indirect bath heaters. In these
separators oil is flashed to separate gas from liquids (emulsion-oil and water).
i. Emulsion from separators flows under its own pressure to heater treater where it is
demulsified and dehydrated. The separated oil from heater treater flows to
storage tanks. Separated water is sent to effluent treatment plant for further
treatment necessary for separating mist of oil from water before its disposal.The
gas separated at separators is used in the following ways:Used as fuel in indirect
bath heater, heater treater, boilers and captive power plants for internal use.
ii. Compressed and sent to various consumers.
iii. Compressed and used for artificial lifting of oil by gas lift. Excess gas which is
not utilised is flared in flare stack.
29.1.3. Central Tank Farm (CTF)
This is a storage unit for crude oil received from different group gathering stations. The
capacity of storage tank in the unit is 1000-5000 cubic meters.
The oil stored at the Central Tank Farm is pumped through trunk pipelines to the refinery.
29.1.4. GAS COLLECTING STATION (GCS)
Gas which is produced with the oil is known as associated gas. It is soluble in oil and is
separated from it as the pressure is reduced at well head installations and group gathering
stations. But in the reservoir dry and free gas is also held at high pressure. The high pressure
gas is obtained from gas wells and collected at gas collection station. Gas is passed through
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separators to separate gas and condensate, the later is piped to storage tank whereas gas
at high pressure (40-60kg./cm2) is sent through pipeline to consumers and also used for
artificial lifting of oil by gas lift techniques.
29.2. HAZARDS IN PRODUCTION INSTALLATIONS
In different production installations mentioned above separators and pipelines under pressure,
storage tanks and heater-treaters, are the basic facilities. Leakage from flow lines inside production
installation and also incoming and out going lines can result into oil spills/gas leakage. This can
lead to fires and can cause pollution in surrounding areas. Therefore any oil spill/gas leakage is to be
rectified on priority. The safety hazards common to these installations are as follows :
29.2.1. Pressurised Vessels & Pipelines
Separators operate at different ratings (0.5 to 40 kg/cm2 or even higher). The safety
valves, pressure gauges and liquid level controls of seperators need frequent checks. The
separator and its safety valves unless tested and maintained properly can result in bursting of
separator with serious consequences. The safety valve should be tested once insix months
Back flow of fluids from separator to wellhead can also be hazardous.
Hydrate formation in production systems and well heads needs special attention by taking
suitable remedial measures.
29.2.2. Fire Hazards
Flammable matter like oil and gas are constantly present at the installations and unless
sources of ignition like naked lights, frictional sparks, electrical sparks, static electric
charges, lightning. Overheated surfaces, are carefully controlled, fire could be a major
hazard. In some cases, even auto ignition takes place.
29.2.3. Accumulation Of Oil Vapour
Oil vapour which is heavier than air tends to settle down and accumulate near loading
and unloading point for road tankers, open pits containing accumulation of oil and around
storage tanks, particularly during winter. The accumulated oil vapour can be easily ignited
and may even explode. In a confined space, they tend to make the atmosphere leaner in
oxygen content-confined to difficulty in normal breathing (asphyxiation) and/or adverse
physiological effects (with more than 0.1% concentration of hydrocarbons).
29.2.4. Explosion Hazard
Large quantities of gas released from separators is generally piped away from the
installation and flared, but in case the flare is extinguished, large quantities of unburnt gas is
discharged into the atmosphere, which may lead to an explosion. Pyrophoric iron sulphide in
lines and vessels can also cause an explosion when coming in contact with air.

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29.3. SAFE PRACTICES

Recommendations listed below should provide guidance for safety in the light of hazards
mentioned above.
29.3.1. Separators and Pipelines
i. A. Separators, connecting lines, valves, flowlines and collector lines should be
hydraulically tested to one and half times the maximum working pressure and the
installation should not be commissioned unless the test results are satisfactory.
B. Separators, heater treater, bath heaters and other pressure vessels should be
periodically hydraulically tested once in 3 years at 1.5 times the max permissible
working pressure and a record should also be maintained thereof.
C. Thickness measurements of all pressure vessels should be done at least once in 3 year.
ii. A. Every separator should be provided with a safety valve. The pressure leaving safety
device shall be set to open at a pressure not exceeding 10% of the maximum allowable
working pressure.
B. The safety valve should be installed directly on the separator and no valves should be
fitted between the vessel and the line connecting the safety valve. Every safety valve
should be provided with an arrangement for testing its efficiency.
C. Suitable working platforms with stair cases and hand rails should be provided
for maintenance of separators and its safety valves. The discharge line of every safety
valve should be connected to the flare line for safe disposal of gas released from it.
D. Safety valves of the pressure vessels like separators, scrubbers, heater, treaters etc.
should be tested at least once in six months and record thereof.
iii. At the header manifold, a non-return valve should be provided in each flow line connected
to well.
iv. In each flow line, an emergency shut-off valve should be installed on the upstream side of
the non- return valve, which can be closed manually in case emergency.
v. At the overhead crossing of a steam pipeline, a condensate trap should be provided just
before such crossing, otherwise the condensate may cause severe hammer in the pipeline.
A. A steam trap should also be provided in the pipeline immediately before it enters the
storage tank.
vi. Thermal insulation with asbestos rope should be provided in the exhaust pipes of bath
heater and heater treater at least up to a height of 1.8 meters from ground level.
vii. Process areas like separators platform, heater treater area, pump house, tank farm etc.
should have free passage for safe working of operators. In case of interference by
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pipelines, in the free movement of operator, suitable walk ways should be made.
viii. Approach road for fire tenders inside production installation should be in good condition
and there should not be any interference from any flow lines, overgrowth of grass etc.
29.3.2. Precautions Against Fire
i. The protected area surrounding every production installation should be enclosed by
boundary walls or barbed wire fencing, not less than 1.8 meters in height, with gates
which can be duly locked. Guards should be posted at the gates when so required, to
prevent entry of unauthorised persons.
ii. Smoking is strictly prohibited inside any production installation. Prohibitory sign for
this precautions should be displayed at the gate on the panel board. Any body
entering production installation and if carrying any smoking apparatus like cigarettes,
matches and lighters etc. must deposit the same at the gate.
iii. Emergency exit : In an enclosed area, before undertaking any operation, it should be
ensured that there are at least two escape ways, unobstructed and easily accessible,
available for use in case of any emergency.
iv. Hand tools used for loosening or tightening etc. Should be of non-sparking type.
The following precautions should be taken to prevent electrical spark:
1. In every zone-1 hazardous area (hazardous zone classification may be
reffered as detailed in pre-pages section 23) from only intrinsically safe of
flame-proof electrical apparatus and equipment(s) should be used, whereas
In every zone-2 hazardous area, only flame-proof or increased safety or
pressurised electrical apparatus and equipment should be used.
2. Every production installations should be protected against lightning by suitable
lightning arresters which should be installed as per I.S. standards. (IS: 4850-1968).
Lightning arresters should not be installed directly on storage tanks.
3. While loading and unloading oil in road tankers, its engine should be stopped and
battery isolated from the electric circuit. The engine should not be re-started and the
battery should not be connected to the electric until all tanks and valves have been
securely closed.
4. At the loading arm, all oil pipelines, filling and delivery hoses, metallic loading arm, swivel
joints, tank and chassis of tank vehicle should be electrically continuous and be
efficiently earthed.
5. Over heated surfaces can cause fire. The probable sources are, the discharge line of
compressed air at high pressure, exhaust pipe of diesel and gas engines, chimneys of
the emulsion heater treater, water bath heater and steam lines going to storage tanks.
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The chimneys should be adequately insulated. The compressed air

discharge lines should be connected to inter-coolers with automatic
temperature recorder alarm, which should sound a warning if the temperature
exceeds the prescribed limit.
In case of diesel engine, the exhaust gas should be conditioned so as to reduce its
temperature.
6. Hot work permit should be issued to the concerned persons by shift Incharge with
approval from area Incharge, prior to commencement of any hot job inside the installations.
7. Efficient earthing of all vessels and equipments should be done to take care of static
charges. Earthing connections should be checked every year and measured values
should be recorded in a register. Earthing pits should be clearly marked for inspection.
8. Spillage of flammable liquids should be minimised to mitigate risk of fire and
should be immediately cleaned.
9. All fire fighting equipments should be maintained in good condition.
10. Electrical control room, switch gear room, computer room etc. should be maintained in
good condition. There should be rubber mats in electrical control room and switch gear
room and cables should be properly led in trenches. Lighting fixtures should be permanent
and no hanging wires or naked bulbs are permitted. There should not be-any leakage
of water from ceiling in electrical control room and switch gear room. Starter panels of
all equipments should be in good condition and rear doors should be closed when
equipments are in operation.
11. Use of electrical equipment including lighting fitting is prohibited in zone-0 hazardous
area. Flame proof and intrinsically safe lighting fitting/equipments should be used in Zone-
I and Zone- 2 hazardous area as per IS - 2148 - 1968 and IS - 8289 - 1976 and IS - 2206 -
1976.
12. Vessel entry permit is to be issued by area incharge with due approval of mines
manager prior to taking up cleaning / maintenance jobs in any vessel.
13. Fire hydrants, water sprinkler system, foam lines of storage tanks should be inspected
regularly to ensure their smooth functioning.
14. Regular inspection of well head fittings is to be carried out for any leakage of gas/oil. To
prevent unauthorised entry to the wells, periodical inspection of fencing is to be done.
15. Keep flammable material away from source of heat and store them in suitable cans and
at proper place.
16. All electrical equipments and fittings should be maintained properly.
17. Don't obstruct access to fire extinguishers and learn how to operate them.

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18. First aid items should be maintained properly.

19. Regularly removal of accumulated waste material like dry vegetation is to be ensured.
20. Routine maintenance of all machinery should be ensured.
21. Close supervision of premises at all times is to be ensured.
22. There should be proper drainage system in process areas. Necessary sumps should be
available in all critical areas like pump house, storage tanks, separator platforms etc. to
collect and recover spilled oil.
23. Water supplies should be adequate.
24. Prohibitory caution signs should be displayed at all critical places.
25. All the wells should be clearly marked for easy identification.
29.3.3. Precautions Against Accumulation of Oil Vapour
Loading and unloading points and open pits into which oil is discharged are the possible
locations where oil vapours may accumulate. It may also accumulate near the storage tank.
Regular checks with explosive meter should be made for presence of flammable vapours,
particularly in the night hours and in winter months. Whenever any dangerous accumulation
of flammable vapours is observed, immediate steps should be taken to remove such
accumulation by arranging adequate ventilation in the area. Suitable air blowers may be used
for the purpose.
29.3.4. Disposal of Gas Through Flare System
1. A flare line shall be sited to a flare stack not less than 90 meters from any part of the
production installation or petroleum storage tanks.
2. As far as practicable, the flare line should be laid below ground. It should be provided with a
bleeding valve and a knock-out drum to drain condensate from the line. In case of any
overhead crossing, the bleeding valve should be located immediately before such crossing
on the upstream side. Regular draining of the flare line is essential, as other wise
accumulation of liquid in the line may restrict passage and create a back pressure at the
separators which may in turn lead to failure of the system.
3. The flare line should terminate with a vertical riser pipe of not less than 9 meters in height.
4. When the gas flow is intermittent, the flare line should be provided with a pilot burner with
remote control electrical ignition device to ensure that the pilot burner is continuously lighted.
5. At the flare stack, a water seal drum should be provided to prevent ingress of air into the flare
line.
6. Leakage of gas if any in flare line and in flare stack should be attended on priority.
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7. There should not be any seepage of effluent from effluent evaporation pit located in gas flare
area.
8. Effluent evaporation pit should be prepared with suitable masonry boundary wall and
asbestos enclosure to prevent seepage and transmission of heat respectively.
9. Passage to flare area should be kept accessible and free from dry vegetation.
29.3.5. Additional Precautions-Gas Collecting Station
1. Gas wells connected to gas collecting stations should be regulated so that in case of drop in
pressure in the line either due to failure of pipeline or drop in separator pressure there is no
excessive discharge of gas. On the other hand, in case of any development of high pressure
in the system, there should be no back flow from the gas collecting station to the well. An
automatic high/low safety valve should be installed at the well -head for this purpose.
2. High pressure gas is allowed to flow through a bean, as a result, on the downstream end,
there is a drop in pressure resulting in conversion of water vapour into ice/gas hydrate which
clogs the line and causes back pressure. It should be removed regularly with the use of
suitable inhibitors. In no case the pipeline should be heated with open flame to remove the
blockage.
29.3.6. Installation of Separators and other facilities
Separators and other similar facilities of production installations are installed on concrete
floor with the help of tri-pods and chain pulley block system. Skidding of tripods used for
lifting loads can cause an accident. Further the pipings of these installations are often
placed over temporary wooden skids during erection and there is risk of toppling of pipes.
The following precautions should be taken:
1. The legs of the tri-pod used for lifting pipes and other material should be tightly secured with
ropes to prevent splaying.
2. Pipes should be held in position on wooden skids suitably blocked with wedges. A pipe
should be held on its sides. It is dangerous to lift the pipe from its ends. Heads should not
be inserted inside flanges of pipes.
3. The separator and similar units are lifted with cranes safe operation of cranes is
dealt with separately in this code, which may be sent for guidance.
4. The safety valve discharge lines of pressure vessels shall be routed away from separator
platform preferably to low pressure flare header to avoid spillage of oil in separator platforms
area.
5. No valve should be fitted in the line connecting the separator vessel and the safety valve.
Every safety valve should be provided with an arrangement for testing its functionality.
6. Suitable working platforms with stair-cases and hand rails should be provided for
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maintenance of separators and its safety valves.

7. At the header manifold, a non-return valve should be provided in each flow line connected to
well.
8. In each flow line, an emergency shut-off valve should be installed on the upstream side of
the non- return valve, which can be closed manually in case of emergency.
9. At the overhead crossing of a steam carrying pipeline, a condensate trap should be provided
just before such crossing to prevent the condensate to cause severe hammering in the
pipeline.
10. A steam trap should also be provided in the pipeline immediately before it enters the storage
tank to heat the crude.
11. Any person permitted to enter the production installation, if carrying any smoking apparatus,
cigarettes and matches must deposit the same at the gate. Suitable notice to this effect
should be prominently displayed at the gate.
12. The protected area surrounding every production installation should be enclosed by walls or
barbed wire fencing not less than 1.8 meters in height with gates which can be duly locked.
Security guards should be posted at gate to restrict entry of unauthorised persons.
13. In an enclosed area, before undertaking any operation, it should be ensured that there are at
least two escape ways (emergency exits), unobstructed and easily accessible for use in
case of any emergency.
14. Hand tools used for loosening or tightening nuts etc. should be non sparking type.
15. Every production installation should be protected against lightning by suitable lightning
arresters which should be installed as per Indian standards. (See IS: 4850 - 1968). Lightning
arrester should not be installed directly on storage tanks.
16. The chimney and steam lines should be adequately insulated.
17. The compressed air discharge lines should be connected to inter-coolers with
automatic temperature alarm system.
18. The diesel engine exhaust gas should be conditioned so as to reduce its temperature.
19. Loading/Unloading points, open pits and storage tanks are the possible locations for
vapour accumulations. Regular checks with explosive meter should be made for presence
of flammable vapour. Immediate steps should be taken to remove such accumulation by
arranging adequate ventilation in area with suitable air blowers.
29.4. SAFE DISTANCES
1. Smoking is strictly prohibited within 30 meters of any well, separator, petroleum storage tank or
other sources of flammable gases.
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2. No naked light or open flame or spark should be permitted within 30 meters of any well or any
place where petroleum is stored.
3. No flame type, treater, crude oil treater or other flame type equipment should be placed within 30
meters of any well, separator, petroleum storage tank except where such flame type equipment
is fitted with a flame arrester.
4. Flare should be sited not less than 90 meters from any part of production installation or petroleum
storage tanks.
29.5. LPG INSTALLATION
The plant is a production processing plant for oil & gas and needs the same safeguards in section
However, some general safeguards are indicated for guidance:
1. LPG liquid, if it leaks gives a large volume of LPG vapour which is hazardous. Hence
special attention for leaks is to be accorded.
2. LPG liquid and vapour is colourless but when the liquid evaporates, the cooling effect
causes condensation and even freezing of moisture in the air which forms a white cloud,
which would thus indicate a leak.
3. LPG vapour is heavier than air and hence it may accumulated near ground level.
Adequate ventilation should be provided to prevent such accumulation.
4. LPG vapour mixed with air between 1.9% to 9.5% forms an inflammable/explosive mixture
and hence requires utmost care. Outside this range, the mixture is either too weak or too rich to
ignite.
5. At LPG plants the following measures may be found useful :
a. A buffer safety zone, 80-100 meters wide, beyond the perimeter wall/fence
should be provided. Trees may be planted in this zone.
b. There should be two exits from the enclosed area, for emergency.
c. A perimeter road and road around processing and storage vessels for easy
access and fire fighting should be provided.
6. A contingency plan for the LPG must be formulated.
7. In air-conditioned or ventilated areas detector should be at the air inlets,
8. In outside area, detector should be installed on gas carrying equipment for example,
wellhead installation, gas compressors and also near potential leaks such as shaft glands and
connection flanges.
9. The detector should be maintained in good working order.

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30. SAFETY IN STORAGE TANK

30.1. GENERAL
Storage tanks for crude oil are installed at well testing stations, group gathering stations and central
tanks farms. The capacity of these tanks vary from 30 to 50 M3 at well-head to over 5000 M3 at
central tank farm. These tanks are made of welded heavy steel sheets.
The storage of LPG is done in specially constructed vessels called HORTON SPHERE of capacity
ranging from 1000-1300 MT NGL / Kerosene is stored in Fixed/floating roof tanks having capacity
ranging from 8,000-10,000 MT.
30.2. INSPECTION OF STORAGE TANKS
OISD-STD-129 deals with the Inspection of various types of storage tanks. Areas to be
Inspected, facilities for Inspection, the Inspection procedures and frequency methods of repairs and
likely cause of deterioration of storage tanks in service have been specified in this standard.
i. A person shall not go alone on the roof of storage tanks for inspection.
ii. No walking shall be done on the roof plates where thinning/perforations are observed.
Necessary plankings may be provided for walking on such roofs.
iii. Ultrasonic thickness measurements shall not be carried out when the tank is receiving
or despatching.
iv. Entry on to the deck of a floating roof shall be restricted when the floating roof is more than
5meters below the top angle ring.
v. H2S may be present inside the storage tanks in hydrocarbon services. In case of floating
roof tanks, H2S may be present above roof also. Necessary safety precautions shall be
taken while inspecting such tanks.
vi. No hot work shall be carried out inside the tank prior to gas freeing of the same.
Hot work on bottom plate shall be done under strict supervision where
perforation and /or leaks are observed.
Air test pressure shall never exceed the specified limits.
vii. All leaded tanks must be completely shot blasted and thoroughly cleaned before entering. API
publications no. 2015, 2015-A, 2015-B & 2202 shall be referred for the storage tanks containing
leaded petroleum products.
viii. Safety belts shall be worn while working on Bosun's chair.
30.3. SAFE WORK PROCEDURE FOR TANK REPAIR
Although the procedure for repair to be adopted will necessarily depend upon the condition of the tank
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bottom, the type and extent of hot work repairs to be performed and the result of inspections, some
guidelines are given here.
The precautions against presence of flammable vapours and arrangements for fire-fighting
mentioned above should be adopted.
30.3.1. Minor repairs
This type of hot work usually involves the welding of corrosion pits, patches or other repair
jobs over small areas. The following procedure may be adopted when welding supports of
braces, if the bottom is not in good condition.
Drill and tap a hole for 13 mm (½") pipe adjacent to the repair area connect a supply of
carbon dioxide or other inert gas to the tap by metal tubing. Some device, such as
manometer or flow meter, should be used to prevent over pressurising the tank bottom.
Maintain a flow of inert gas to ensure that, before work has begun and during the course of
work, the atmosphere in the area of welding will not support combustion of any flammable
vapour that may be present.
Remove tubing, plug-hole tapered pin or other device and back-weld promptly, as required.
30.3.2. Major repairs
When repair jobs involving most of the tank bottom are planned, the flammable liquids and/
or vapour in the tank should be flushed out with water. Watch for leakage in the tank and plug
leaks temporarily to keep the tank bottom dry.
Remove nipples, plug holes with tapered pin or other device and back-weld as required
after repairs are completed.
30.3.3. Perimeter repairs
When it is intended to undertake repairs around the periphery of a tank, the excavation
should extend to atleast 30 cm beyond the point of any hot work and wide enough for a person
to work in safety and comfort.
Seal off all openings between the floor plates and the tank foundations by packing with mud
or some other suitable material. Such packing should be checked from time to time to ensure
that the seal remains intact.
Presence of flammable vapours should be checked with gas detectors near excavations and
seals between floor plates and foundations. A portable air blower should be used for ventilation.
30.3.4. Sectional Repairs
When making sectional repairs to tank bottoms, the following methods may be used :
i. Cold-cut the tank bottom to be replaced, using a hand or air-operated tool and remove. A

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coolant should be applied continuously to the cutting edge of such tools to reduce the
head of friction. Remove earth from under the sections to be replaced. Fill with damp sand
and seal the perimeter of the patch area with or some other suitable noncorrosive material.
ii. Check leakage of gas with gas detector to ensure that an effective seal has been made.
iii. When large sections of the bottom must be replaced and it is questionable that the seal will
remain effective it is better to maintain an inert atmosphere under the patch area when hot
work is being done during installation of a new section. This may be accomplished by using
Co2 or other inert gas.
30.4. EARTHING
i. Every storage tank should be electrically connected with the earth in an efficient manner by
not less than two separate and distinct connections placed at the opposite extremities of such
tank.
ii. The connection and contacts required should have as few joints as possible. All joints
should be riveted, welded or bolted and also soldered to ensure both mechanical and electrical
soundness.
iii. The resistance to earth should not exceed 7 ohms and the resistance to any part of the fitting
to the earth plate or to any other part of fitting should not exceed 2 ohms.
30.4.1. Testing Of Earth Connections
i. The connections and contacts of the storage tanks should be inspected and tested by a
competent person at least once in every 12 months by means of a direct reading instrument
such as meggar.
ii. A record of such inspections and tests should be maintained properly.
30.5. LAYOUT OF LPG FACILITIES : LPG STORAGE
A. Grouping :
i. Vessels shall be arranged into groups each having a maximum of six vessels.
Capacity of each group shall be limited to15,000 cu.mt. Each group should be
provided with a curb wall.
ii. Any vessel in one group shall be separated from a vessel in another group by a
minimum distance of 30.0 mts.
B. Locations :
i. Longitudinal axes of horizontal vessels (Bullets) should not point towards other vessels,
vital process equipment and control room.
ii. Storage vessels should be located down wind of process units and important buildings and
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facilities.
iii. LPG storage vessels shall not be located within the same dykes where other flammable
liquid hydrocarbons are stored.
iv. Storage vessels shall be laid out in single row both in case of the spheres and bullets.
Storage vessels shall not be stacked one above the other.
C. Spills and Leaks
i. Spillage collection shallow sump shall be located at a distance where the flames from
sump fire will not impinge on the vessel. This distance shall not be less than the diameter
of the nearest vessel or 15 mts whichever is higher. The capacity of the collection sump
shall be 10 min. pumping capacity of the LPG pump serving the storage vessels. The
sump shall have adequate drainage facilities.
ii. Curve wall around the storage tank shall have a minimum height of 30 cms. However, it shall
not exceed 60 cms at shallow sump position, as otherwise evaporation of spilled LPG may
get affected.
iii. There shall not be any depressions, large ditches and low lying areas around LPG storage
as the leaked gas can be accumulated being heavier than air. Top surface of the vessels
installed in a group should be on the same plane so that safety blowout from one vessel
does not affect the other vessel. This will also minimise the chance of overfilling of adjoining
vessels due to gravitation.
D. LPG/ NGL STORAGE
General
i. Hydrocarbon storage area should be at safe distance from operating area (refer
OISD-STD-118 for details).
ii. Storage of LPG & NGL should be subjected to the approval of CCE' under petroleum rules,
1976.
iii. A fixed gas detector should be installed near the storage area to detect any leakage.
iv. Any Hot Jobs planned in the vicinity of storage area, it is to be carried out under the work-
permit system.
v. There should be proper communication system between storage & control room to take
prompt action in case of eventuality.
vi. The vehicles should not be allowed near the storage area without vehicle entry permit.
vii. The storage area should be fenced (1.8m) to restrict unauthorised entry.
viii. The storage area should be provided with adequate lighting arrangement.

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ix. Dry vegetation & other combustible material should not be allowed in the storage area.
x. The fire water network (Hydrants, monitors) around the storage area is as per OISD-
STD-116, O I S D - S T D - 117. Hydrants monitors should be checked periodically (once a
month).
xi. Operating crew should be familiarized with the operation of drencher system.
LPG Horton Sphere
i. Each LPG Horton sphere should consist of
Two PSV's of adequate capacity.
Level, pressure, Temperature Indicators at field and C/Room.Level per alarm and
level hi-hi (LSHH) Alarms to be provided. Int. logic to close the Inlet valve with a
activation of 'LSHH' to avoid over filling.
Insulation by fire resistant coating on the spheres.
Automatic/manual sprinkler, drencher system.
Provision to operate inlet/outlet valves flow C/Room.
Load bearing structures should have fire proof.
ii. These system to be checked periodically to ensure their operatibility.
LPG can cause severe cold burn on spillage on the body. Protective clothing
eg.gloves and goggles should be worn.
iii. There should be atleast one wind sleeve/sock near the 'LPG' storage to know the wind
direction.
NGL Storage
i. Each NGL/ Kerosene Tank Consists of
Level indicator at C/Room & field.
Fixed detection system.
Sprinkler system.
Foam power system
Proper earthing.
ii. These are to be checked periodically (once a month) to ensure their operatibility.
iii. A common drainage system be available for large size 'NGL' storage with provision to pump
back the NGL.

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iv. Storage area should be adequately protected by a concrete earthen land of adequate
capacity to contain spilled liquid.
v. Petroleum storage tanks shall be located in dyked enclosure with roads all around the
enclosure.
31. PIPELINE SAFETY

31.1. GENERAL
In an oil field, transportation of crude oil and natural gas by pipelines from wells upto refinery or
primary consumer point consists of three different types of pipelines.
Firstly the flow lines, these are 60 to 114mm diameter pipelines laid from wells to group
gathering stations. Secondly, the collector lines which are 125 to 212 mm diameter pipelines, laid from
group gathering station to central tank farm. Thirdly, the turn lines which are 300 to 350 mm
diameter pipelines laid from central tank farm to refinery or primary consumer points.
While flow lines and collector lines are laid over lengths of 10 to 30 kms within the oil field, the trunk
lines are cross country pipelines and runover several hundred kilometers.
Collector lines are 150mm to 200 mm i.e. 6" to 8" ND.
Trunk pipelines are 300 mm to 600 mm i.e. 12" to 24"ND.
31.2. APPROVAL FOR LAYING OF PIPELINE
i. No new pipeline should be laid nor any significant alteration be carried out in any existing
pipeline or system of pipelines except with the permission in writing of the competent authority.
ii. Every application for permission should be submitted in form-VIII to the Regional Inspector
of Mines Safety, and a copy thereof should also be sent to the Chief Inspector of Mines
Safety and District Magistrate.
iii. The application should be accompanied by two copies of an upto date plan of the area where
the pipeline is proposed to be laid showing the extent of land over which right of use
has been established and route of the pipeline.
iv. A comprehensive project report accompanied by all necessary drawings, pipelines details
giving references to recognised codes followed, giving full details of the design, construction
and testing of the pipelines and its components, the route along which the pipeline will be laid,
the manner of laying, and provision proposed to be made for the maintenance and patrolling
of the pipeline also should be submitted to the Competent Authority.
31.3. CONSTRUCTION
In the construction of pipelines, the recommended safe practices are given below:
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31.3.1. Standard of Construction

Liquid petroleum transportation piping system should meet the requirements laid down by
the American National Standard Institute in its document ANSI - B 31.4. Natural Gas piping
system should meet with the requirements laid down by the American National Standard
Institute in its documents ANSI - B 31.8.
31.3.2. Right of Way (ROW)
i. To prevent construction of any permanent structure on the ROW, aerial inspection
should be carried out at minimum 3 months interval.
ii. Whenever there is a village in the vicinity of ROW, temporary fences should be erected to
prevent cattles falling into the trench during execution.
iii. Top one feet soil should be kept separately which can be back filled in its original position,
so that land can be handed over to the farmer in its original condition.
31.3.3. Handling and Stringing
i. During transportation of Line Pipes through road, they should be tied up securely with
rope/chain on trailors, to prevent toppling down of pipes on bumpy roads.
ii. While keeping the pipeline on wooden skids, every third skid should be arranged in
crossed manner i.e. like a scissors to prevent toppling down of the pipeline section.
31.3.4. Trenching
Trenching operation should be just ahead of welding operation and not very far ahead. This
will avoid deep trenches remaining open for many days, creating safety hazard to villagers
and their cattles.
31.3.5. Sand Blasting
During sand blasting, sand ejected with high pressure compressed air can cause
injury to personnel. The following precautions should be taken.
i. Before commencement of work, warning notices should be displayed.
ii. Signalling arrangement should be provided between the sand blasting machine and the
workers engaged in cleaning.
iii. The workers should be provided with personal protective equipment.
iv. After the work is completed, supply of air to air-receiver should be cut off and the receiver
should be de-pressurised.
31.3.6. Welding
Welding of pipelines in the fields should be carried out in accordance with the requirement
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of American Petroleum Institute Standard 1104.

Guidelines for safe welding mentioned under welding and cutting chapter should also be
kept in mind.
31.3.7. Coating and Wrapping
In this operation, use of coal tar enamel heated to about 2500 C poses danger to
workers. The following precautions should be taken:
i. The workers engaged in handling hot coal tar should be provided with and use
protective outer clothing of asbestos or rubber, goggles, helmet and footwear.
ii. Coal tar should be heated upto a temperature of not more than 2700C. The primer
should be prepared at a distance of about 50 mtrs. from the place where coal tar is heated.
iii. From Dope kettle heated coal tar should be taken out into the bucket, through a tap
only and should not be poured from the top by a container.
iv. Adequate steps should be taken to prevent hot coal tar from splashing or falling on
personnel.
v. While applying insulation, buckets containing hot coal tar should be carefully
handled as to prevent splashing.
vi. The defecto-scope, which operates at high voltage, may cause danger due to
electric shock, suitable gloves and rubber boots should therefore be used. No attempt
should be made to check moist insulation.
The probe should be handled only after disconnecting it from the source of power.
31.3.8. Lowering-In And Back Filling
Before lowering the pipeline in the trench, it should be ensured that no person is present
inside the trench. In case the sides cave-in, the pipelines should be kept adequately
supported before removing loose soil from underneath.
Following precautions are to be followed during such jobs:
i. Special care should be taken while lowering the pipeline on a hilly terrain with a
grading. Also utmost care is to be taken while lowering the concrete coated heavy pipes
under a water course.
ii. Utmost care is to be observed in deciding the number of Tripods with chain pulley
blocks for a particular section of pipeline to be lowered. Also the capacity of chain
pulley block must be minimum 1.5 times the weight of pipeline section it is going to lift.

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31.3.9. Testing
i. Before the pipeline is put into commission, it should be subjected to hydraulic test at a
pressure one and half times the maximum working pressure. The result of every such
test should be recorded by the person making the test.
ii. In case gas pipeline, it should be filled slowly with gas to displace air from inside the pipe.
The displacement is considered complete if the oxygen content in the line does not exceed
2%.
iii. Before pressurising the pipeline, it should be ensured that it is devoid of all air inside and
pipeline is full of portable water only.
iv. Pressure should be raised slowly and gradually in small increments. Proper and
appropriate interval must be observed in between pressurising the pipeline for pressure to
stabilise and also to avoid sudden stress/strains to the line pipe materials.
If during such testing, the pipeline breaks in the vicinity of any railway line, public
road, residential area, immediate steps should be taken to warn persons from
approaching the site. Adequate steps should be taken to prevent smoking or open flame in the
area. In case of railways, the competent authority should be immediately informed about the
occurrence.
31.3.10. Laying of Pipeline
i. Pipeline should be laid in the most favourable route, avoiding as far as possible,
known obstructions and areas in which unusual external condition prevail.
ii. Pipelines should be laid below the ground level except where laying thereof above the
ground level is desirable for topographical economic or other special reasons.
iii. Where an underground pipeline has to cross any existing underground water or gas
line, cable, drain or other services, the pipeline should be laid at least thirty centimetres
below such services in a manner that will not obstruct access to such services for
inspection, repairs or maintenance.
iv. The number of bends in the pipeline should be kept to the minimum by proper grading of
trenches of supports at crossings and other obstacles.
v. The route of underground section of a pipeline should be indicated by markers and not
less than two such markers shall be visible from any point along the route.
31.3.11. Hydrostatic Testing of Pipeline
i. Before transporting petroleum for the first time, each pipeline or completed sections thereof
should be filled with water and the pressure in the line or section, as the case may be
raised to 1.1 times of the designed internal pressure and maintained for a period of 24
hours. A pipeline or a section thereof showing any significant drop of pressure during

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the period of testing should not be used for transporting petroleum until necessary
repairs have been carried out and a satisfactory retest done.
ii. The test specified in sub-rule (10) should be carried out at least once every 12 months
on each completed pipeline section which crosses in area where there is danger of
water pollution by any leakage.
31.4. SAFETY FEATURES
There are two important safe-guards relating to operation of pipelines. Firstly, the pipeline should be
provided with a safety device for protecting it from pressures in excess of those for which the pipeline
was designed. Secondly in case of any damage due to uncontrolled escape of fluids from the pipeline
should be restricted to avoid the danger of pollution and fire.
The recommendations listed below should be adopted for this purpose.
i. At the well-head, a shut-off valve and also a non-return valve should be provided on the
pipeline.
ii. In case of gas pipeline, automatic high/low safety valve should be provided in the flow line
to isolate the well and should be set to operate in the event of change in the pressure within ±
10% of the normal working pressure.
iii. Where pipelines are to cross railways, river or road, extra-thick section pipes should be used
at the crossing. The pipelines should be provided with a casing extending upto 15 mtrs. from
the center of railway track on either side. The casing should be provided with vent pipes.
Isolation valves should be provided on either side of the crossing. The valves should be
provided with adequate fencing over an area of five square metre in size.
iv. The route of underground section of pipeline should be indicated by suitable markers at every
500 mtrs. and also at all turnings and un-cased crossings. At least two such markers should
be visible from any point along the route.
v. All oil and gas pipelines of any size must be laid underground only and should have
outside insulation.
vi. No overground gate valve and tee points should be provided outside the installation in any
remote location in any case, to avoid tampering and sabotage of such points.
31.5. OPERATION AND MAINTENANCE
31.5.1. Patrolling and Inspection
Adequate arrangement should be made for patrolling along the route of trunk pipelines by
line walkers at regular intervals with the following objectives :
i. To check any leakage of fluids from the pipeline.
ii. To check any construction or operation by a third party in the vicinity of pipeline
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which may endanger its safe operation.

iii. To check presence of gas in waste pits along the pipeline.
iv. To check erosion of cover over the pipeline laid in river beds.
v. In the event of any leakage or other undesirable occurrence, the matter should be
immediately reported to the officer in-charge for appropriate action.
31.5.2. Cathodic Protection
i. Pipe to soil potential should be measured on underground pipelines as per the approved
schedule; in case any dangerous zone of static current is detected, adequate remedial
measures should be taken.
ii. Underground pipeline should be inspected for external corrosion as per approved
schedule. Suitable inspection pits should be made at different points to assess
effectiveness of cathodic protection.
31.6. REMOVAL OF PARAFFIN DEPOSITS FROM FLOW LINES
In order to remove paraffin deposits from flow lines a steam injection unit is normally used.
The unit should be located at a distance, not less than 25 metres from the wellhead. The exhaust of the
engine should be provided with spark arresters. A safety valve should be installed on the steam line to
release pressure, in the event of pressure in the line exceeds 10% of the working pressure. Before
commencement of operation, the steam injection line should be tested to a pressure not exceeding
one and a half times expected pressure during the steam injection operation or the pressure
rating of the steam unit, whichever is lower. During the test, persons should remain at a safe
distance from the steaming unit.
31.7. EMERGENCY PROCEDURE
It is possible that oil and gas pipelines may become damaged through unforeseen circumstances,
due to an act of God or third party activities close to the pipeline.
In order to deal with any such circumstances, emergency procedures should be formulated giving
details of the action to be taken for safe-guarding the installations as well as the interest of the
public.
It should specify the action to be taken in the event of the following :
Uncontrolled escape of oil or gas from pipeline.
Fire in the pipeline.
Bursting or damage to the pipeline.
The emergency procedure should also specify the following:

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Action required of an ONGC employee discovering a fire, leakage or damage to the

pipeline.
General alarm and communication procedure and
Action required of persons receiving the alarm and communication.
32. HOUSE KEEPING

32.1. HOUSEKEEPING TIPS / SAFETY INSTRUCTIONS
To keep your work area safe, maintain daily housekeeping tasks and use the following tips:
i. Wipe up accidental spills immediately.

ii. Stack materials neatly place heavy or bulky items on the bottom.
iii. Keep cabinet doors and drawers closed.
iv. Return equipment and tools to their proper place after use.
v. Provide an adequate number of waste receptacles at accessible locations throughout all work
areas.
vi. Properly dispose of waste and scrap as it collects, and ensure that it is placed in the
appropriate receptacle. This includes flammable liquids, oily and paint covered rags and paper
trash.
vii. Keep floors free of clutter.
viii. Keep floors clean; dry (dry as possible); slip-resistant; and free of waste, unnecessary material,
oil and grease, protruding nails, splinters, holes, or loose boards
ix. Keep stairs, aisles, and walkways clear and clean, dry, and free of waste, well-lit, and provided
with adequate hand rails and treads that are in good condition.
x. Keep aisles at least 3 feet wide where necessary for reasons of access to doors, windows, or
standpipe connections.
xi. Ensure that exits are clearly marked and free of obstructions.
xii. Do not overfill racks, bins, and storage areas.
xiii. Repair broken tools or report them to your supervisor.
xiv. Follow cleaning and maintenance routines including lockout / tagout procedures.
xv. Be sure guards and interlocks are secure and in good working order.
xvi. Ensure that pipes or containers that hold hazardous substances are leak free.

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xvii. Ensure that tools, especially those with sharp edges or pointed tips, are stored properly when
not in use.
xviii. Keep sprinkler heads and fire extinguishers free of obstructions.
xix. Always choose footwear that is appropriate for the work area.
xx. Ensure that there is proper lighting in the work area.
xxi. Provide adequate ventilation to all work areas to keep air free of dust and other contaminants.
xxii. Maintain and clean all ventilation systems and HVAC systems at regular intervals.
xxiii. Dispose of unwanted items promptly.
xxiv. Keep a firm footing, maintain your balance, and allow enough time.
xxv. Take shorter steps, especially on damp surfaces.
xxvi. When carrying objects, make sure they can be carried comfortably and vision is not blocked.
xxvii. Keep ladders and step stools in good condition and use them properly.
33. MOTOR VEHICLE OPERATION

33.1. GENERAL
In oilfield operations on land, large number of vehicles is deployed for carrying passengers and cargo.
Safe operation of these vehicles is vital for efficient conduct of work. Driving of vehicles, particularly
heavy vehicles like trucks and trailers, calls for exceptional skill and alertness on the part of drivers.
Motor vehicle operations are particularly hazardous in adverse weather condition, bad roads, cross-
country drives, as also during night. In such situations if the driver is not really competent and well
prepared for any emergency, it may lead to accidents.
Recommendations listed below provide guidance in this respect.
It is also necessary that drivers attend refresher courses in safe driving practices.
33.2. DRIVER
i. Selection, medical fitness and training of drivers should receive due attention and the
following steps should be taken :
ii. Every driver should undergo a driving test to ensure that he is capable of handling the
type of vehicle assigned to him.
iii. Every driver should undergo thorough medical examination once every year with
special reference to vision, night and colour blindness.

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33.3. SAFE PRACTICE FOR DRIVER

i. Consumption of alcoholic beverages while driving motor vehicle is illegal and
expressly prohibited. No driver should be under the influence of alcohol when he is
required to operate a motor vehicle.
ii. It is unsafe for a driver to drive a vehicle when he is heavily fatigued and physically ill.
iii. Safe driving implies that the driver should be prepared to compensate for unsafe acts of
other drivers on the road.
iv. Drivers should be fully familiar with the traffic laws of the area and in case of doubt, he
should seek guidance from his superior official.
v. The speed limit admissible under the law should be adhered to, subject to conditions of
road, weather and traffic.
vi. It is dangerous to follow the vehicle ahead of the driver too closely, maintain the same
distance as per the safe breaking distance limit of the vehicle the driver should judge the
following distance so that he can safely stop his vehicle if the vehicle ahead stops
suddenly.
vii. Overtaking of vehicles can be extremely dangerous unless the situation is carefully
judged. The driver should overtake only when he is assured of safe passage and clear
passage the opposite direction.
33.4. MAINTENANCE OF VEHICLES
While every vehicle should under go thorough maintenance as per approved schedule, it is the driver to
check the condition of his vehicle before taking it out on the road. The daily check should include the
following items :
Steering wheel - no excessive play should be allowed.
Brakes - brake should be fully efficient.
Tyres - adequate air pressure and good tread surfaces, worn out tyres
affect braking efficiency.
Battery condition - good terminal contacts, top-up with distilled water.
Fuel, oil and water supply should be adequate.
Horn - test for correct operation.
Lights - check high and low beams.
Wipers - check smooth operation.
To check/tightening of all wheel bolts and nuts.
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In case of any defect, the matter should be immediately attended to or reported to the competent person
for remedial action.
33.5. DRIVING ON WET ROADS
While driving on wet roads, the main hazard is skidding of the vehicle. The following precautions are
recommended.
slow down when going round the bend.
keep speed at safe level
avoid sudden braking
avoid overtaking unless the situation is carefully judged.
check brakes properly and push the brake paddles after the vehicle is driven
through water logged area two or more times (if required to dry the brake
lining/disc before increasing, the speed of the vehicle).
in case of skidding, proper safeguard is to drive/steer towards the direction of the
movement of the skidding vehicle.
33.6. DRIVING AT NIGHT
i. It should be ensured that all the lights are in good working order.
ii. Keep the wind screen clean.
iii. Avoid glare of head-lights of approaching vehicle and keep to your left.
33.7. DRIVING IN DESERT
i. Drive along known or familiar tracks, as any deviation could be treacherous.
ii. If you get lost, stop and look around without going any further, if possible back-track until you
know where you are.
iii. If the vehicle is stuck, dig sand slowly in the direction of travel from both front and rear wheels to
allow room for rocking the vehicle, some air can be let out of the types to provide friction.
iv. In no case leave your vehicle, since it is easier to spot a vehicle than an individual either from the
ground or from the air. Headlights and mirrors of vehicles can be used for signalling.
33.8. REVERSING OF VEHICLE
While reversing a vehicle, the driver should ensure that he has clear view of the track on which the
vehicle is being reversed. In case of heavy vehicles, the drivers should be assisted by a signalman
while reversing.

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33.9. TRANSPORTATION OF OVERSIZE LOADS

i. The load should be uniformly placed on the trailer and secured to its body with chain,
clamps and side supports.
ii. Sufficient number of chain should be used for tubular goods for lashing.
iii. Loads extending over the rear of the truck, should be flagged during day with a piece of
red flag, a red light should be displayed at night.
iv. When a cargo after being loaded on the vehicle stands more than 4.2 meters above
ground level, the vehicle should be accompanied by a pilot vehicle carrying a
Supervisor. The Supervisor should ensure that there is adequate clearance ahead
for the loaded vehicle to pass safely, particular attention should be paid for adequate
clearance under electric transmission lines.
33.10. TRANSPORTATION OF DANGEROUS GOODS
i. When transporting dangerous goods by road like gas-cylinders, carboys of acid,
chemicals and toxic substances, the following precautions should be taken :
ii. All dangerous goods to be transported should be securely packed to prevent spillage
or damage.
iii. The goods should be clearly labelled to indicate contents like, INFLAMMABLE GAS,
OXIDIZING AGENT, ACID etc.
iv. The containers should be carried on trailer or barrows when loading into vehicles.
v. Oxidising substances should not be loaded alongwith other dangerous goods.
34. FIRE FIGHTING SYSTEM

34.1. INTRODUCTION
In hydrocarbon industry, the risk of fire is always present right from exploration, drilling, production, and
processing to distribution. The fire hazards are ought to be controlled by better methods of supervision;
use of rapid detection system coupled with sound and safe operating practices but there remains
always a possibility for occurrence of a fire. Any small fire at initial stage may lead to a major disaster.
Therefore all persons deployed in oil and gas installations are to be individually responsible for fire
prevention and should be capable of giving alarm and simultaneously taking necessary emergency
action in case of fire. This means that every person engaged in hydrocarbon industries has to be a
"fireman" and must receive information and training to tackle fire emergency at once.
34.1.1. Standard, Guidelines & Norms
i. Oil Mines Regulations (OMR) 1984/ Factory Act’1948
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ii. National Fire Protection Association (NFPA) codes

iii. Oil Industry Safety Directorate (OISD) standards
OISD-STD-189 (Standard on fire fighting equipment for drilling rigs, work
over rigs and production installations)
OISD-STD-116 (Fire protection facilities for petroleum refineries and oil/
gas processing plants)
OISD-STD-117 (Fire protection facilities for petroleum depots, terminals
and pipeline installations)
OISD-GDN-115 (Guidelines on fire fighting, equipment and appliances in
petroleum industry)
OISD- STD-142 (Inspection of fire fighting equipment and systems)
iv. Bureau of Indian Standards (BIS) relevant standards

v. Safety of life at sea (SOLAS)
vi. Marine Mercantile Services (MMS)
vii. European Norms (EN)
viii. American Petroleum Institute (API)
API RP 14G (Recommended practice for fire prevention and control on
fixed open-type offshore production platforms)
ix. Recommended practices and local Building Bye-Laws based on NBC
34.2. WHAT IS FIRE?
A chemical reaction initiated by presence of heat energy in which a substance combines with oxygen in
the air and emits energy in the form of heat, light and sound. Three elements are essential before a fire
can occur:
A combustible substance, i.e. fuel (solid, liquid, gaseous)
Oxygen
Source of heat i.e. applied heat e.g. spark, flame etc.
Absence of any one of these three will result in
extinguishing of the fire when it is already burning.
For fire to happen all the three elements should be
present. The combustion process gets initiated when
sufficient source of heat is continuously available to
initiate and support the reaction, some of this heat is
absorbed by the fuel which gives off the flammable
vapour, that in turn mixes with oxygen available in the
surrounding atmosphere (air) and fire starts. This
reaction in turn releases a further amount of heat
associated with light and sound energy. At this stage
even if the source of heat is removed, the fire will

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continue.
With the advent of dry chemicals and halon extinguishing agents which extinguish the fire by inhibiting
action (breaking the chain reaction), a new factor has been introduced in the fire triangle. This fourth
factor – chain reaction has now led the fire engineers to describe the phenomenon through use of a
fire pyramid or tetrahedron.
One face of the triangle represents temperature, second
fuel and third at the back of the fire pyramid, represents
the process of chain reaction. The base represents the
phenomenon of oxygen supply (which in true sense
should include the other gases like chlorine and nitrogen
as certain materials like magnesium may burn in nitrogen
also). The removal of any one face of the fire will cause
the fire to extinguish. It should be remembered that some
fuels such as cellulose nitrate contain their own oxygen
and removal of atmospheric oxygen then may not be
sufficient to extinguish the fire.
34.3. DEVELOPMENT OF FIRE
All objects in the environment lose or gain heat, in an attempt to achieve thermal equilibrium. A fuel can
be heated to a temperature below its ignition temperature without the possibility of combustion taking
place. In some cases an increase in temperature further to this will result in instantaneous combustion
over the whole surface of the fuel (i.e. any content of building subject to heat input). This stage is
known as “Flash Over.” This will occur only when that element has been preheated.
Rate of Combustion is dependent on the ability of fuel and oxygen to mix together in the appropriate
proportion which depends upon the condition of the surrounding atmosphere. At one extreme the most
rapid rate of combustion will give rise to an explosion and a slow rate may result in a small point fire
known as “smouldering.”
The stages in the development of fire are as under:
I. Incipient Stage
A region where preheating and gasification (slow pyrolysis) are in progress. Invisible
pyrolysis products in the form of gas and some micron size i.e. aerosols are being
generated and transported away from the source by Brownian motion, diffusion, back
ground air movement and sometimes a very weak convective movement induced by the
buoyancy of the pyrolysis products.
II. Smouldering Stage
A region of fully developed pyrolysis which begins with ignition and includes the initial
stage of the combustion reaction. Invisible aerosols and visible smoke are being generated
and carried away by moderated convective movement and background air movement. All

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fires in smouldering stage (often lasting four hours) give out smoke and combustion gases.
Gradually, the fire is built up and substantial heat is generated which results in bursting of
flame radiation.
III. Flame Stage
A region of first reaction which covers the period from initial occurrence of flame to a fully
developed fire.
a. Flame Radiation
Radiant energy emitted by the flame is transmitted hemi-spherically to distant
locations independently of the convection movement.
b. Convective Heating
It becomes important only in the later phases of Fire development where large
quantities of thermal energy have been released. Appreciable temperature rise at
the ceiling level is produced.
IV. Heat Stage
At this stage, large amount of heat, flame, smoke and toxic gases are produced. The
transition from flame to heat stage is rapid and takes a few seconds.
Development of fire after flash over has occurred in an enclosed space could be regarded
as happening in three phases:
a. Ignition and temperature
b. Fully developed fire
c. Decay of fire
34.4. CLASSIFICATION OF FIRE
Based on the Indian standard code of practice (IS: 2190-1992) and OISD-STD-116 standard, fires are
classified into four classes. This classification system helps us to determine the hazard and application
of the most effective type of extinguishing agent.
Class A fire: Involves ordinary combustible materials: wood, paper and cloth. Class A fire is
usually slowly in their initial development and growth because these materials are solids and
they are somewhat easier to contain. Class A fires leave an ash after the material has been
consumed.
Class B fire: Involves flammable and combustible liquids such as crude oil, diesel, petrol,
kerosene etc. These fires usually develop and grow very rapidly. Class B materials are fluid in
nature, which allows them to flow and move. This makes dealing with them somewhat more
difficult then class A material. These fires typically do not leave an ash.

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Class C fire: Involves flammable gases under pressure including liquefied gases such as
natural gas, LPG etc., where it is necessary to isolate the burning gas at a fast rate with an
inert gas, powder or vaporizing liquids for extinguishment.
Class D fire: Involves combustible metals such as magnesium, titanium and zirconium. These
materials are usually difficult to ignite but create intense fire once started. Class D fires are
very difficult to extinguish but fortunately they are relatively uncommon in most industries.
Electrical fire: According to the latest concepts, the electrical fires do not constitute a
particular class. Any fire involving electrical equipment in fact is a fire of class A or class B. The
normal procedure in such fire is to cut off the electricity and use of extinguishing method
appropriate to the burning material. Special extinguishing agent which is non-conductor of
electricity and non-damaging to the electrical equipments such as carbon dioxide and DCP
(Dry Chemical Powder) should be used. Water in the form of hose system should in no case
be used in electrical fires unless positive isolation of electric supply has been ensured.
34.5. FIRE EXTINGUISHMENT
The acts of fire extinguishment are a combination of physical skill, mental acumen, technical
knowledge and professionally trained manpower. All of the methods we use to control and extinguish
fires are based on the fire tetrahedron. We focus on removing one or more of the elements that allow
the fire to extinguish.
The most common extinguishing method is to remove the heat. This is usually done with water. The
goal is to apply water to the burning materials in sufficient volume so that the water absorbs more heat
than the fire is generating. If this is done, the burning materials will cool enough to drop below their
ignition temperature and fire will go out.
Breaking down the chemical reaction is probably the second most common extinguishing method. Dry
chemical powder, halon or halon replacement agents function this way. They inhibit the ability of the
materials involved to sustain a chemical chain reaction. If this reaction cannot be maintained, the fire
will go out.
Removing the oxygen is also relatively common method of extinguishment. Carbon dioxide agent
works this way, as do simple techniques like putting a lid on pan. They work because they remove
oxygen.
The last method, which is usually confined to special types of fire, is removing the fuel. One example is
a fire involving flammable gas. The ideal way to extinguish that kind of fire is to shut off the gas flow.
34.5.1. Extinguishing agents
WATER: Water is by far the most commonly used and readily available extinguishing agent. It
is used in portable fire extinguishers, installed system and a base for foam water system.
Water works well because it has a large capacity for absorbing heat, which cools the burning
materials to below its ignition temperature, thus causing the fire to go out. Water absorbs the
most heat during its conventions to steam.

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DRY CHEMICAL POWDER: Dry chemical

powders are finely powder (about the
consistency of talcum powder) that is based on
several chemical compounds. They are available
into two
categories:
regular dry
chemical
powder
which may be used on class B and Class C fires and
multipurpose dry chemical agents for the use on class A,
B and C fires. They both function primarily by
interrupting the chemical chain reaction. The
multipurpose dry chemicals are compounds that allow
the agent to adhere to surface, which is why they are
effective on class A fires. This agent class generally
provides the most rapid knock down of flammable liquid
fire available. Dry chemicals are used in portable fire extinguishers, wheeled fire extinguishers,
vehicles and fixed fire fighting system. The most common regular dry chemical agent is sodium
bicarbonate. The most common multipurpose dry chemical powder is based on the
Monoammonium phosphate base.
FOAM: Foam is general category of extinguishing agents that includes a wide variety of
specific foams for special purpose application. Foam is used in portable fire extinguishers,
wheeled extinguishers, fixed system and fire tenders. Mixing water with a specific proportion of
foam concentrate to form foam solution creates mechanical foam. Several types of
proportionating devices are used. Connection is made between foam concentrate tank and
water flow line through eductor. The passing water creates a venturi, which draws the foam
concentrate into the stream. The metering valve controls the percentage of concentrate to
ensure a proper mixture. Air is introduced to the foam solution at the nozzle in a process called
aeration to form the finished foam. The finished foam is a bubbly substance that is similar to
soap suds in appearance.
Foam is suitable for use on class A and class B fires, but is specifically designed for class B
fires. Foam involves several of the extinguishing methods as it is mostly water, so it offers
cooling capability, to float on the surface of a flammable liquid, forming barrier between the fuel
surface and the air, so it excludes oxygen, this barrier acts to remove the fuel from the fire
situation by sealing it.
Aqueous film forming foam (AFFF) is free flowing foam that provides rapid fire control. It is the
most common type of foam in general use and can be employed effectively on a wide variety
of fire situations. It provides more rapid fire control in most situations than the other types of
foam. Another major advantage of AFFF is its compatibility with dry chemical powder. This
allows the use of these agents in combination, typically called twin–agent system, which
increases the effectiveness of each. Dry chemical powder offers more rapid-fire knock down

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than foam and foam can secure the fuel surface against reigniting. It does not require
application with special foam equipment.
HALON: Halogenated hydrocarbon agents, usually referred to as Halon, are a group gaseous
agent that is effective in fire control. The two most common Halon used for the fire control are
bromo chloro difluro methane (1211) and bromo trifluro methane (1301). Halon 1211 is
typically used in portable extinguishers for local application and 1301 is normally used in fixed
fire fighting system. The Halon agents extinguished fire primarily by interrupting the chemical
chain reaction. Their major advantage is that they leave no residue, which makes them
specially suited to computer and delicate equipments protection. Halon is stored under
pressure as a liquid. When discharged it rapidly vaporized to a gas. This behaviour is referred
to as a vaporizing liquid. Another advantage of these agents is their holding ability. If a room is
filled to the proper concentration with Halon, usually about 7%, a fire cannot burn as long as
that concentration is maintained. The main disadvantage of Halon is its environmental impact
and cost. Halon is one of the chemicals connected with the depletion of the ozone layer. Under
clean air act (CAA), the production and import of virgin Halon banned in the developed country
and it will be applicable for the developing country from 2010 in compliance with the Montreal
Protocol.
34.5.2. Suitability of different types of fire extinguishers for different class of fires
Types of Fires For live Electrical

Sr.
Type of Extinguisher equipment
No. A B C D involved in fire
Fire Extinguisher water type gas

1. S NS NS NS NS
cartridge (IS : 940/76)
Fire extinguisher, water type

2. S NS NS NS NS
constant Air Pressure (IS:6234/71)
Fire extinguisher, Mechanical foam

3. S S NS NS NS
type (IS : 933/76)
Fire extinguisher, dry chemicals

4. NS S S NS(A) S
Powder (IS: 2171/76)
5. Fire extinguisher ABC Type S S S S S
Fire extinguisher carbon-di-oxide

6. S S S NS S
type (IS: 2878/76)
S - suitable
NS - not suitable

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(A) Suitable if special dry powder for burning metal is used viz. TEC - Ternary Entectic
Chloride.
34.5.3. The design criteria and fire protection facilities

Onshore drilling rigs, work over rigs, group gathering stations/ oil collecting stations, gas
compressor plants/ gas compressor stations, early production set-up, quick production
set-up/ well head installation should be in line with OISD-STD-189.
Onshore Central tank farm, Central processing facilities, petroleum depots and
terminals should be in line with OISD-STD-117.
LPG storage, handling and bottling plants Marketing & Pipeline Terminals with their
loading / un-loading/ pumping and handling facilities should be in line with OISD-STD-
117.
Offshore Installations should be in line with API-RP-14G.
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Design of fire protection systems as per NFPA Codes

34.5.4. How to use portable fire extinguishers
Portable fire extinguishers are the first line of defence and are useful only in the incipient
stages of a fire. It is important that all personnel know how to operate fire extinguishers
provided in their area of work.
Where more than one type of extinguisher is provided, specific instructions must be given and
exhibited for the correct choice and proper method of operation. To fight a fire, take up a
position where access to the fire is unrestricted but where a quick and safe retreat is possible.
In an indoor fire, stay close to the door. In an outdoor fire, stay on the upwind side of the fire. A
crouching posture will minimize the effects of smoke and heat. It will also help to approach the
fire. Care should be taken to ensure that the fire is completely extinguished and that it is not
left smouldering. Attempt to use a fire extinguisher should be made only if it is safe to do so; if
the fire shows signs of going out of control, it is best not to try to use an extinguisher. The fire
brigade must be called at the earliest.
Water type extinguishers
This is commonly available in 9 liters capacity and weighs about 14 kg when fully charged.
This extinguisher contains water stored at atmospheric conditions. A CO2 Gas Cartridge is
fitted with cap assembly. The extinguisher is filled to a predetermine level with water. Fire
extinguishers are available in cylindrical shape. It is useful for Class A fire involving wood,
textile, paper, etc.
Operational Procedure
I. Remove the extinguisher from the
bracket/ boxes.
II. Carry the extinguisher near the fire.
Keep a safe distance.
III. Remove safety clip
IV. Strike the knob over the cap assembly
to puncture the gas cartridge.
V. Hold the extinguisher handle by one
hand and support from the bottom with
another hand.
VI. Direct the jet on the seat of fire and
move ahead towards the fire.

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Mechanical foam type extinguishers:

This is commonly available in 9 liters capacity. This extinguisher contains premixed solution of
water and AFFF within the container. A CO2 gas cartridge is fitted with cap assembly. The
foam produced is known as mechanical foam and used for class B type fire i.e. flammable
liquids.
bracket/boxes.
II. Carry the extinguisher near the
fire. Keep a safe distance.
III. Remove safety clip and miniature
foam making branch from its
holder and hold it.
IV. Strike the knob over the cap
assembly, to puncture the gas
cartridge.
V. Hold the extinguisher handle by
one hand and support from the
bottom with another hand
VI. Direct the jet on the wall of the
burning material to permit the
natural spread over the burning
liquid and move ahead towards
the fire.
Carbon dioxide type fire extinguisher

Carbon dioxide (CO2) is the most commonly utilized compressed gas in this particular type of
fire extinguishers. This type of fire extinguisher is primarily intended for use on fires of B and C
class. It is effective on class “A” fire also to some extent. Carbon dioxide is effective as an
extinguishing agent because it reduces the oxygen content of the air (smothering effect) to a
point where it will no longer support combustion and thus fire extinguished.
Carbon dioxide fire extinguishers are available in varied sizes i.e. 2, 4.5, 6.8 and 22.5 kg. CO2
is retained in a heavy metal shell (cylinder) in a liquid stage at a pressure of 64 to 70 kg/cm2 at
a temperature below 310 celsius. The extinguisher consists of pressure cylinder, a siphon
tube, valve for releasing the carbon dioxide gas, a discharge horn or a combination of
discharge horn and hose. The siphon tube extends from the valve to almost bottom of the

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cylinder, so that normally only a liquid carbon dioxide reaches the discharge horn until about
80 percent of the content is discharged.
The remaining 20 percent of the content enter in the siphon tube as a gas. It is only in the
discharge horn that liquid carbon dioxide vaporizes as CO2 gas and thus the discharge horn
plays a very vital role on CO2 type fire extinguisher. The rapid expansion from a liquid to a gas
when the CO2 leaves the discharge horn produces a refrigerating effect that converts about 30
percent of the liquid to a solid “Snow Ice” which soon sublimes into a gas.
This extinguisher has a limited range that varies from 1 to 1.5 m. This extinguisher also
requires the skill of operation. On fire involving electrical equipment discharge should be
directed into the source of the flame. It is important to de-energize the electrical equipment as
soon as possible to eliminate potential source of re-ignition.
Operational procedure:
bracket/ boxes.
II. Carry the extinguisher near the fire.
Keep a safe distance.
III. Remove locking pin.
IV. Operate the wheel valve in anti –
clockwise direction.
V. Hold the extinguisher handle or trolley
by one hand and the insulated handle
of the discharge horn by other hand.
VI. Direct carbon dioxide at the base of
flame by sweeping action and
gradually progress forward as the
flames are extinguished.
DCP type extinguishers

DCP is recognized for its usual efficiency in extinguishing fires in flammable liquids and gases
i.e. B and C type fires. Being electrically non conductive it can be used in fire involving live
electrical equipment.
DCP fire extinguishers of 5, 10 and 25 kg capacity are operated by CO2 gas cartridges,
whereas in order to cover high fire risk, trolley/ trailer mounted DCP fire extinguisher of 50, 75,
300 kg capacity are available at various locations.

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DCP of predetermined level is charged in the extinguisher. A CO2 gas cartridge is threaded
into a puncture valve which is part of cap assembly. The cartridge is placed in an inner
container which leads to the bottom of DCP container. The inner container is having small
holes over which plastic tube is fitted to function as a valve tube. The DCP is discharged
through a hose attached to upper portion of the outer container. This point is fitted with a
siphon tube inside the outer container. A squeeze grip nozzle at the end of the hose controls
discharge of DCP. While operating the extinguisher, it is required to be carried/ lifted with one
hand and the DCP is to be released and directed on to the seat of fire with other hand.
Operator’s action in using this type of fire extinguisher counts a lot in efficient extinguishing of
the fire as the total discharge time of extinguishing agent is very short. Sweeping action is
more desirable for better cloud formation. Maximum effectiveness can be achieved when the
wind is at the back of operator. Because of instant extinguishing action, this type of fire
extinguisher is extensively used in our oil and gas Installations.
Trolley / Trailer mounted DCP Extinguisher work on the same principle. However CO2 gas is
supplied from the cylinder of higher capacity attached with the trolley/ trailer.
I. Remove the extinguisher from
the bracket/boxes.
II. Carry the extinguisher near the
fire. Keep a safe distance.
III. Remove Safety Clip and
squeeze grip nozzle from its
holder and hold it.
IV. Strike the knob over the Cap
Assembly, to puncture the gas
cartridge, as shown in the
figure.
V. Squeeze the nozzle and direct
the powder at the base of the
fire flame with sweeping
motion and move ahead
towards the fire.

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34.5.5. General fire fighting procedures and techniques

i. Report all fires, no matter however small.
ii. Ensure that the fire fighting equipment installed in your section are visible, properly
maintained and easily accessible.
iii. The used fire extinguisher should be replaced immediately after its use.
iv. All hot jobs shall be suspended when fire siren is sounded.
v. If you suspect any defect/ deficiency in the fire fighting equipment, report it to the fire
station without any delay.
vi. Breathing apparatus should be worn, whenever necessary, to protect against toxic gases.
vii. Any crew of fire fighting personnel, stationed in hazardous position, should have an
observer attached to it, whose task will be to warn the men in case of danger. A
prearranged signal for this purpose should be agreed upon. The observer can be an officer
of the Installation with adequate technical knowledge and awareness of the hazards. A
path of retreat should be planned, if necessary, and kept clear of all obstructions. The path
should be properly illuminated.
viii. In case of storage tank fires, men should not work inside a bund wall if there is any danger
of boil-over or a slop-over. When it is necessary to work within a bund, point of escape
should be agreed upon.
ix. Wherever necessary, men should be protected from radiated heat by improvised shields,
and relief should be arranged at frequent intervals. This protection should be given even if
the heat does not make it immediately necessary, because a change of wind may easily
increase the heat. Men working in extreme heat may be kept cool by water spray.
x. Men should not be allowed on tank roofs unless absolutely necessary, and neither on
empty tanks which are on fire. If it is necessary to go on a tank roof, they should take
walkie-talkie along with the life-lines with them.
xi. When there is a probability of a boil over, no one should be allowed within a considerable
distance from the tank. If there is any danger of being trapped by an oil wave, men should
not take shelter behind tanks or building.
xii. The possibility of filled pipelines or drums of oil, involved in the fire, splitting or exploding
must not be overlooked. When oil is held between two closed valves, a relatively small
amount of heat will cause a considerable pressure rise with the possibility of a fracture.
xiii. Park the vehicles, which are not involved in emergency operation, at least 100 meters
away from the periphery of the affected area. These vehicles should not obstruct the
movement of fire fighting vehicles / persons engaged in handling emergency.
xiv. Do not keep the fire station telephones engaged unnecessarily.
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34.5.6. Fire fighting procedures and techniques in special fire situations

Blow out fire:
Types of Blowout: For the purpose of fire fighting operations the blowout have
been classified into three categories:
i. Oil blowout, ii. Gas blowout & iii. Gas-Oil blowout.
i. In case of oil blowout, the flow contains greater quantity of oil (i.e. more than 50%) and
lesser quantity of gas (i.e. less than 50%). The oil that blows out from the well does not get
completely burnt in the flame but spills around.
ii. In case of gas blowout, the quantity of gas is as high as 95% to 100%. The blowout with no
smoke or with little quantity of smoke resulting from burning of condensate belongs to this
category.
iii. In case of gas-oil blowout the quantity of gas is more than 50% with oil contents of less
than 50%. All the oil that blows out from the well gets completely burnt in the flame and
does not spill around, belongs to this category. This gas-oil blowout can also be
differentiated from gas blowout by their dark red flames and formation of great quantity of
smoke.
In order to select appropriate measures for controlling blowout fire (of any type), it is
necessary to determine the following factors:
i. Rate of flow of the blowout.
ii. The distance between the well head and the base of the flame.
iii. Height of the flame.
iv. Temperature around the well head.
After the above mentioned data are obtained, one can determine quantity of various
materials required for controlling the fire.
Common types of fire on blowout:
On the basis of the nature of flame obtained after the well head is cleared of all the obstructions
and the place is made ready for conducting fire fighting operations, blowout fires can be broadly
classified into three types.
A. Blow out fire with straight flame:
I. In this type of fire, the gusher has a compact flow when the well flows through conductor,
technical or production casing. The well head fittings do not create any obstacle in the free
flow of oil-gas from the well.
II. Depending upon the rate of flow, the gushers under this category of fire can be divided into
the following categories:
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Weak gushers, which have a rate of flow up to 5000 M3 of gas or 250 tons of
oil per day
Medium gushers, which have a rate of flow between 500,000 M3 to 2,500,000
M3 of gas or between 250 to 1250 tons of oil per day.
Powerful gushers, which have a rate of flow of more than 2,500,000 M3 of gas
or more than 1250 tons of oil per day.
III. Knowing inside diameter of the casing, well depth, specific gravity of the product from the
well, stability of the formation during flow etc., one can also determine the rate of flow of
the gusher.
IV. In practice, rate of flow during fire fighting operations on a gusher is determined on the
basis of the height of the flame. The height of the flame increases with the increase in the
flow of gas or oil in the following pattern. The relation between the height of the flame and
the rate of flow on gushers frequently encountered is shown in the following table:
(The information contained here is based on practical experience and not on any
calculation).
Even while making a rough estimate of the rate of flow of an oil gusher, the
quantity of unburnt oil should be taken into account. The height of flame can be
determined either by an instrument capable of measuring angle in the vertical
plane (e.g. theodolite, viewfinder etc.) or by the photographs of the burning
gusher.
V. For the purpose of extinguishing fire, the distance between the well head and the base of
the flame is of prime importance. It has been established that the distance between the
well head and the base of the flame varies within the range of 0.4 to 3.2 meters and
depends upon the rate of flow, produce of the well and the diameter of the well.
While extinguishing fire, great importance is attached to the heat around the well
head which in turn depends upon the rate of flow, and well diameter. Heat does
not remain uniform around the flame. It depends upon direction and speed of
the wind. The intensity of the heat is substantially reduced on the up-stream side
of the wind even when it blows at a very low velocity (e.g. 3 to 4 m/sec). The
intensity of heat decreases when water jet guns are directed at the flame;
maximum drop in the intensity of heat is reached when the water jet guns lift the
flame to a height of about 6 to 8 meters from the level of the ground.
The intensity of heat with 15 cal/cm2 may cause burns within only 3 seconds. It
is, therefore, necessary to pay special attention to the intensity of heat. Even low
intensity of heat can cause heat stroke if a person is exposed to it for a long
time.

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The intensity of heat from fire at a distance of 10 meters from the well head of a
well having 250 mm inside diameter and flowing at a rate of 2.5 m3/sec of gas,
is as follows:
When no water is poured onto the flame = 26.6 cal/cm2 min;
When water is poured at the lower portion of the flame = 7.1 cal/cm2 min
B. Blowout fire with scattered flame
I. The flame takes the scattered shape when any equipment is there at the well head and
causes obstruction to the free flow of the product from the well. The scattered flame of this
type can be converted into compact flame by removing the obstruction from the well head.
In case it is not possible to remove the obstruction by usual means, assistance from the
artillery should be sought. After converting the flame into compact one the same procedure
is followed as mentioned in blow out fire with straight flame.
II. In this type of fire, behaviour of the drilled horizons and the extent of reliability of the casing
should be taken into account while deciding the mode of extinguishing fire.
III. When the well head on a gusher is completely damaged it becomes a difficult task to kill the
well. Extinguishing the fire without killing the well creates a hazardous situation for nearby
installations. The fire in this case should not be extinguished because otherwise it will pollute
the surrounding area with inflammable gas, and will create a dangerous situation.
IV. In case of gushers where the well flows in surges and throws out water and formation matter
along with gas or oil, there is a possibility of formation collapse as a result of which the well
bore may choke and the gusher may stop by itself.
C. How to organize fire fighting operations in blow out
I. Besides measures for protecting nearby installations, the Head of the fire fighting operations
should engage his men and material mainly on those places where the fire is spreading.
II. In the first instance, water jet guns, as a general rule, should be directed on equipment and
other materials which could still be saved.
III. During fire fighting operations, the Head of the fire fighting team should not forget that the
derrick tends to collapse within 10-20 minutes of fire.
IV. The nearby equipment should be covered with moistened felt or earth with a view to protect
them from damage.
V. After necessary instructions are issued, the Head of the fire fighting team should examine
the following:
How far the protection to nearby equipment is reliable?
How far it is possible to shift the valuable equipment to a safer place?

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What is the condition of well head and its fittings?

What is the nature of gusher/ blowout?
What is the source of water supply and actual stock of water?
If need be, the head of the fire fighting team should ask for additional fire fighting units.
VI. A “fire Fighting Committee” should also be organized. Apart from fire fighting staff, this “Fire
Fighting Committee” should consist of engineers and technicians of various departments of
the project where fire fighting operations are being carried out so as to ensure technical
assistance.
VII. In certain cases of powerful and complicated blowouts a “Special Committee” should be
formed which should be headed by the chief of that field and should consist of, as a general
rule, head of the fire fighting team, chief of “Fire Fighting Committee” and the heads of those
departments who could be of assistance in the execution of fire fighting operations and
controlling of blow out.
VIII. This Special Committee should chalk out its programme of work stage wise in the following
order:
Stage 1 – Make preparations for extinguishing fire and arrange equipment for
controlling the flow. Both these jobs should be carried out
simultaneously.
Stage 2 – Extinguish fire and take measures so that the flow does not flare up
again.
Stage 3 – Install necessary equipment on the well head.
Stage 4 – Kill the well, if necessary.
IX. Fire fighting operations sometimes continue for days and even weeks. It is, therefore,
necessary to make arrangements for the following at a distance of 200 - 250 meters from
there; food and drinking water, first aid, bath and showers, sleeves, hoses and other
necessary materials. The site for these services should be located at a place which may not
be endangered by the gases formed when the fire is extinguished.
D. Preparatory work for extinguishing fire on a gas/ oil gusher:
Preparatory work for extinguishing fire on a gusher can be grouped into three main headings:
Clearing the place of fire
Creating the necessary stock of water
Deployment of fire fighting equipment
I. Clearing the place of fire: As a general rule, fire fighting staff removes the equipment
and material from the place of fire together with the drilling staff. While dragging the
equipment, 18-25 mm wire ropes, hooks, links etc., should be made use of.

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During work on a gusher, the working personnel should wear canvas dresses, hand
gloves, boots and helmets. For protection of ears from the effects of noise from the gusher,
they should use ear muff or ear plug and cover their ears with them suitably.
Before getting down to clear the place of fire from overlying equipment and material and to
prepare the place for fire fighting operations, the staff, posted for dragging the equipment,
should be given safety instructions. At this time, the order of dragging the equipment and
sign signals for instructions should also be finalized. After the approaches and equipment
are suitably cooled with water, the working personnel should sufficiently drench
themselves with water prior to proceeding with the job. During the operations also, they
should be given constant protection by water shower. Before the operations are started,
one or two water jets and stand guns should be directed on the flame of the well in order to
reduce its heat.
In case of major blowouts, the operational staff should be gradually acclimatized to the
heat around the well head. This way their organisms will become used to high
temperatures and the chances of injury from heat stroke will be reduced.
At least an area of 50 meters in radius around the well should be cleared for the purpose
of fire fighting operations.
In case it is found that the equipment cannot be removed from the well head by tractors,
assistance from the artillery should be sought.
While placing the artillery gun at the firing range it should be so aimed that no damage is
done to the well head. The authority conducting this operation should make sure that the
place selected for firing the gun is the most suitable and that no undesirable damage will
be done to the well head. For attaining accuracy in aim, the gun should be placed at a
distance of 80 – 120 meters from the well head and all precautionary measures should be
taken to save people from the splinters of the shells (the splinters fly upto about 120
meters. The firing guns should be placed in a pit.
In case drill pipes are there in the well and deformed Kelly and swivel are lying on the floor,
people sometimes resort to parting of drilling string. Protected fire weakens thread
connection between the kelly and the drill pipes and assists in parting the string at this
joint. In this case even the first attempt to remove Kelly results in parting of the drilling
string and the well then starts giving a compact flow. Sometimes artillery also has to be
called in for releasing drilling string from the well head. But drilling tools should be dropped
into the well only as the last resort, i.e., only when it is found that fire cannot otherwise be
stopped. Normally, keeping of drilling tools intact is found useful during fire fighting
measures.
While clearing the well head from unnecessary equipment and material, the question of
providing approach to the place of fire should also be looked into.
II. Creating the stock of water: The stock of water maintained should be sufficient so as to
ensure supply of water during various stages of work i.e. during preparatory work before
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SAFETY
the fire is actually extinguished, during the process of extinguishing fire and for cooling the
area after the fire is extinguished.
Process fire:
Fires in process plant are a serious hazard to both life and property. It is therefore,
essential to understand the ways in which fire can occur and develop. Normally fire occurs
as a result of leakage or spillage of fluid from the Plant. Large leaks may occur due to the
failure of a vessel, pipe or pump, and smaller ones from flanges, sample and drain points
and other small bore connections.
If the leak gives rise to a gas or vapour cloud which grows for a period before it is ignited,
the resultant effect may be either of vapour cloud, a flash fire, or a vapour cloud explosion.
In a flash fire, the gas cloud burns, but does not explode. A typical flash fire may cause
quite extensive damage, particularly to vulnerable items such as electric cables, but may
leave the main plant equipment relatively unharmed. However, a flash fire does cause a
sudden depletion of oxygen, and this effect can be lethal to personnel.
If the leak forms a liquid pool on the ground, this may ignite and burn. The flame may be
substantial and may do damage by direct impingement or by radiation. If the release
results from fire engulfment of a vessel, a fire ball may be formed. Prevention of fire in
process areas is primarily a matter of preventing leaks and avoiding sources of ignition.
The storage tank fire is considered to be of very serious and catastrophic nature of
process fire.
Storage tank fire:
Extinguish fire surrounding the tank before attempting to extinguish fire within the tank.
Cooling the tanks (the contents of which have not ignited but which are exposed to the
heat of an adjacent fire) by means of water spray and drenchers applied to the roof and
shell, prevents excessive vaporization and lessens the danger of fire spreading.
When burning, all crude oils, fuels develop a ‘Heat Wave’ that travels downwards at a rate
of 15 to 50 inches per hour. Temperature of the oil in this heat wave may reach 2600 C to
3150 C.
When this heat wave reaches the tank bottom, where water is generally present, it will
cause a violent boil-over. Burning oil first erupts and then falls, spreading even beyond the
fire-walls of the tank. The column of the flame can be very widely spread at the base as
much as 300 to 400 ft. The beginning of a boil-over is indicated usually by both increase in
brightness of the flames immediately prior to the actual eruption of the boiling oil. If this
occurs, action should be taken to immediately evacuate all personnel from the affected
and nearby areas. A boil-over is a violent eruption. A “slop-over” results from expansion or
frothing of the heated liquid, but is not as severe as a boil-over.
If extinguishment has failed by the time heat wave has reached a point 5 ft above a known
bottom water level (which can be roughly judged by the peeling off/ blistering of the

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SAFETY
external painting of the tank shell), evacuate all personnel immediately from the area. Be
on guard against successive boil-over from a burning tank as this can often recur.
Conduct all necessary works within the firewall area during the early part of the fire so that
if the fire progresses, extinguishments operation can be carried out from a safer distance.
Care must always be taken NOT to get water in a heavy oil tank while fighting a fire thus
reducing the possibility of boil-over.
Cone roof tank fire:
I. Extinguish fires with foam to reduce heat input to tank contents
II. Apply cooling water streams to the tank shell and to the intact portion of the roof, if the roof
has not blown clear. Ensure that water does not enter into the tank either from run-off or
from the water stream, as this will destroy the foam blanket.
III. Apply foam inside the tank, either through fixed foam chamber connections or through
other available equipments.
IV. Open tank dyke drain valves, as necessary, to avoid flooding of the tank dykes. However,
care should be exercised not to spread hydrocarbons to surrounding areas.
V. Apply cooling water to other adjoining tanks exposed to heat or fire.
Floating roof tanks
I. Fires of this type should be extinguished, if possible, by applying foam. If this is not
possible, extinguishment may be accomplished by using water fog and working in opposite
directions around the roof edge to a “pinch out” point. Fire fighting personnel should not go
down on the floating roof of a partially filled tank except in extreme circumstances. If it is
absolutely necessary, proper safety appliances such as safety belt, life line, breathing
apparatus etc. must be used.
II. If cooling water is required, as indicated by blistering of paint on the shell, it can be applied
to the outside of the shell or the inside of the shell above the floating roof. However,
precaution has to be taken to avoid water stagnation on the float, lest the float may
become unbalanced. Avoid directing heavy streams of water into the flammable material of
the roof edge. This may splash burning product into the roof and increase the seriousness
of the fire.
LPG storage vessel fires
I. Do not extinguish flames except by fuel elimination, as described in the following
paragraphs, because accumulation of leaking gas can result in an explosion due to
accidental ignition. Isolate flamed part from the tank, if possible.
II. Apply cooling water streams to the top valve assembly and to the top of the vessel so that
the run-off water will cover the shell. Cooling streams should be continued after flame
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extinguishments until all danger of re-ignition from hot steel has been eliminated. Apply
cooling streams in an adequate, manner to the other adjacent vessels/ spheres also.
III. Stop immediately movement of product to/ from the tank.
IV. Pump out the tank contents to unaffected storage vessels, if possible.
V. When product pump-out has reached the limit as determined by available storage space,
stop pumping operation and refill the tank with water to float all remaining flammable
material to a point above the leakage, whenever possible. Exercise all precautions to
avoid forcing flammable liquid under pressure through the leak and if the opening is not
excessive, a rapid rate of water fill can be employed to float the flammable liquid above the
leak. By this procedure the flames will be extinguished when water covers the leak.
H2S fire
I. Hydrogen sulphide is a flammable gas which burns with a blue flame giving rise to sulphur
dioxide. Mixture of hydrogen sulphide and air in the explosive range may explode violently,
since the vapours are heavier than air, they may accumulate in depression or spread over
the ground to a source of ignition. When exposed to heat, it decomposes to hydrogen and
sulphur and when the contact with oxidizing agents, such as nitric acid, chlorine trifluride,
etc., it may react violently and ignite spontaneously.
II. Extinguishing agents recommended for the fighting of H2S fires include carbon dioxide, dry
chemical powder and water sprays.
Fire Protection for Radioactive Materials
The life hazard introduced by an escape of radioactive dusts and vapours during a fire
makes it vitally important to take all practical steps to prevent a fire from involving these
materials. The hazard is affected by the form of the material, i.e., whether solid, liquid, or
gas and by the container in which it is kept or handled.
Radioactivity can cause loss of life, injuries and damage to and extended loss of materials
used, as well as damage to equipment and buildings. Manual fire fighting may be limited
by the danger to fire fighters from exposure to radioactivity. Salvage work and resumption
of normal operations at a property may be delayed where a fire or explosion causes loss of
control over radioactive substances. The need to decontaminate buildings, equipment a d
materials presents a serious and complicated problem.
Smoke and products of combustion from fires in places where there are radioactive
materials must be controlled. The runoff of water used in fighting fires must also be
controlled. Fire fighters require protective clothing and respiratory protection equipment.
Fire control must be thoroughly preplanned. With radiation hazards, automatic sprinklers
are preferable to measures requiring manual fire fighting. This lessens the amount of
radioactive smoke or products of combustion and water runoff to be dealt with manually.

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Helicopter fire
In offshore installations, the major risk of fire and explosion is with landing and take-off of
helicopters. These are twin engine choppers having a fuel load up to 9450 liters with flash
point of 400C. The common metals used in the construction of the helicopter are Mg, Al, Ti
and SS. Mg reaches the burning temperature upto 30000C, Al burns at 6000C whereas Ti
and SS at 20000C. Hence, there exists a potential fire hazard during the helicopter
operations.
The exhaust coming out from the engines of the helicopter can prove to be an ignition
source for the hydrocarbons present all around. So, all fire protection measures are always
kept ready during helicopter operations, like keeping the fire water cum foam monitors,
foam water hose reel, DCP hose reel charged with a fireman in fire suit on stand-by duty at
the helideck during helicopter operations.
The various fire fighting and rescue tools available at the helideck are as under:
I. Fire water cum foam monitor
II. DCP hose reel
III. Foam water hose reel
IV. Trolley mounted DCP / CO2 fire extinguishers
Helicopter rescue kit containing the following:
I. Fireman Axe: It should have insulated handle and suitable for snap live electric cables and
tested to 20,000 volts as per IS-928-1970 with amendments or equivalent international
standards.
II. CROWBAR (WRECKING BAR): The length of the Crowbar should be 24” and should be
as per IS-704 or equivalent international standards. It should have chisel point at one end
and a notch at the other end.
III. GRAB HOOK: It is used for rescue of men and material in the event of fire or other
emergency. It should have wooden handle. The length of the pole should be 4500 mm
(approx) supplied in two halves joined by brass joint. The metal portion of the grab hook
should be 400 mm.
IV. QUICK RELEASE KNIFE: It should be capable to cut seat belts and harness without risk
of injury to persons. Knife should have cone shape and length of the blade should be 6”
and knife to be properly fitted with handle. It also should be as per IS 5486-1969 with
latest amendments or equivalent international standards.
V. BOLT CROPPER/CUTTER: The length of the bolt cropper/cutter will be 24” center cut type
consisting of high tensile steel laws. It should be recommended as fire and rescue
equipment.

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SAFETY
VI. SLUDGE HAMMER: It should have 24” length wooden handle with protective metal shield
below non-wedging portion head.
VII. HEAVY DUTY HACKSAW (WITH BLADES): It should consist of 1” blade, coarse or
medium cut and suitable for offshore and helipad use.
VIII. FIRE PROXIMITY SUIT (Preferred in two piece pattern): Aluminized fire proximity suit shall
be of overall combination type with hood/head gear, and gloves and foot wear. Head gear
(hood) shall be firmly connected with the suit. Inside the hood there should be helmet
fitting over the strapping of mask. Gold plated lenses should be provided for thermal
protection. Provision shall be made for accommodating breathing apparatus within the
overall. The layer of the suit shall be: Outer layer – Aluminized glass fibre for protection
against radiated heat. Intermediate layer Polutherane/ Neoprene coating wool layers or
vapour barrier inner layer. Cotton with flame retardant. The suit shall be stitched with
Kevlar thread and suit the withstanding capacity of fire suit. The suit shall be as per En-
469/ NFPA-1971/ CEES certified material.
IX. SAFETY TORCH: Safety torches shall be suitable for use in hazardous area it should be
suitable for marine environment and should be explosion proof and intrinsically safe.
Safety torches to be used with 3 nos. leak proof standard dry cells. Its body should be
made from non-metallic, non abrasive and impact resistance plastic material.
Building fires
The most serious fire with respect to both loss of life and damage, are those which occur in
buildings. All though fire in buildings does not have the same relative significance for
process area, it is still important, because there are many Plants which need to be housed
in building and there are on virtually all sites a range of other buildings from laboratories,
workshop and offices, to stores and warehouses.
The problem of fire in buildings falls under three main headings:
Hazard to life.
Hazard of damage to the building
Hazard of exposure to nearby buildings
From a safety standpoint, all fire fighters should have a basic knowledge of the principles
of buildings construction. Knowledge of the various types of building construction and how
fire react in each type give the fire fighter an edge in planning for an safe and effective fire
attack.
Fire Protection of Buildings, as in the plants, is based on combination of passive measures
such as structural design, and active ones, such as fire fighting systems. The maximum
size of fire which can develop in a building depends on the amount of material available for
combustion. The fire load, as the determinant of the severity of a fire, is a total heat which
can be generated by the combustible material within the building. It is the product of the

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SAFETY
mass of material and its heat of combustion, or calorific value. The fire load density is the
heat per unit area of the floor which can be generated.
A scheme for the fire grading of building which is based essentially based on the concept
of fire load and the time temperature curve has been elaborately explained in NBC. Fire
fighters should use their knowledge to monitor building conditions for signs of structural
instability. Any problem that is noted should be reported to incident commander as soon as
possible. Fire fighters must be aware of the dangerous condition created by a fire, as well
as dangerous condition that may be created by fire fighters trying to extinguish the fire. A
potentially serious situation can be compounded if fire fighters fail to recognize the
seriousness of the situation and take actions that only make the situation worse.
The longer a fire burns in a building the more likely it will collapse. Fire weakens the
structural support system until it becomes incapable of holding the building weight. Fire
fighters should be aware of the following indicators of building collapse and be on the
lookout for them at every fire.
Cracks or separation in walls, floors, ceilings and roof structures.
Evidence of existing structural instability such as the presence of tie roads and
stars that hold walls together.
Loose bricks, blocks or stones falling from buildings.
Deteriorated mortar between the masonry.
Walls that appear to be leaning.
Structural members that appear to be distorted.
Fires beneath floors that support heavy machinery or other extreme weight
loads.
Prolonged fire exposure to the structural members.
Unusual creaks and cracking noises.
Structural members pulling away from walls.
Excessive weight of building contents.
Fire fighting operation also increases the risk of building collapse. Improper vertical
ventilation techniques can result in cutting of structural supports that could weaken the
structure. The water used to extinguish the fire aids extra weight to the structure and can
weaken it. Water only a few inches deep over a large area can add many tones of weight
to an already weakened structure.
Fully sprinkled high rise buildings have an excellent life safety record. The fire protection
features of high rise buildings as laid down in NBC Code would make these buildings
reasonably safe. However, the life safety equation in high rise building would depend on
the people who operate and the people who live and work in these buildings.

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SAFETY
The building staff must inspect and maintain the fire protection equipment. Equipment such
as the sprinkler system, stand pipe system, fire alarm, PA system and emergency power
system should be clearly marked, well maintained and tested frequently.
Exits, including the corridors and aisles leading to them, must be free and clear of
obstruction. Stairwells must clearly be marked and doors should never be propped open.
All high rise buildings are required to have an emergency evacuation plan, approved by
the local fire brigade authorities. All persons in high rise building should know the
evacuation plan for their building and what to do in the event of any alarm.
Fire mock drills are important part of any high rise building emergency plan. Well
maintained fire protection equipment along with planning and practice are the keys to life
safety in high rise buildings.
34.6. FIRE DRILLS

The following points should be kept in view when organizing fire drills:-
a Every person in the installation should be made familiar with likely fire situations in the
work sites and best means of tackling them. They should know to use handling and
operation of different types of fire fighting equipment and their limitations.
b New employees should receive training in fire protection soon after their employment.
c Every person who has been assigned duties under the contingency/ emergency plan for
fire should be made familiar with the duties and the procedure.
d Fire drills should be held at least once in a month at every installation and annually
involving the fire crew. During the drill every person should carry out his duties as if an
emergency is existing. The only exception being that the installations can continue
operating under minimum supervision.
e An observer should be present during the drill and he should suggest improvement
wherever necessary. In the next drill, suggestions of the observer should be incorporated.
f The fire drill should occasionally be conducted during odd hours also i.e. between 10 pm –
06 am to ensure preaparedness level during odd hours.

Safe Practice

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HSE MANAGEMENT SYSTEM

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i. Chec k all she av es an d sh aft s o f t he hoisti n g s ys tem (z in pol es , hoisti n g sheav

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in g the li ftin g ro pes.

On l and ri gs us ed to be skid de d f rom l oc atio n to loc ation usin g cr awl e r

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1.2. BLOWOUT CONTROL EQUIPMENT AND PRECAUTIONS

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totalizer withalarm and trip ta nk.

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A = Annul ar BOP (Sph eri cal t yp e)

C. BOP SELECTION CRITERI A

1. Max imum ex pe ct ed w ellh ead p res sur e.

D. BOP STAC K ARRANGEME NTS

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onds fo r a nnul ar pre ve nte rs o f 20 " and lar ge r.

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wheels connected and ready for use.

A. PURPOSE OF PRESSURE TESTING

i. Annular preventer must not be closed in an empty hole.

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Clean water should be used as test fluid

1.3. SAFETY IN CASING AND CEMENTATION OF WELLS

1.3.1. Casing of wells

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Casing lowering operations should be done very carefully. The following

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1.3.3. Safety precautions at the time of placement of vehicles and hooking up of

i. All cementing personals should wear safety kits.

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1.3.4. Routine testing of cementing equipments

1.3.5. Safety in bulk handling plant

1.3.6. General safety instruction for cementing discipline

i. Cement mixers should not be moved with more than 12 MT of cement.Bunkers

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1.4. WELL CONTROL

Refer Well Control Manual of IDT, Dehradun.

1.5. OTHER DRILLING OPERATIONS:

Refer Drilling Manual of IDT, Dehradun.

1.6. DRILLING EQUIPMENT

1.6.1. Derrick and masts

i. Every derrick or mast should be of sound construction and adequate strength,

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ii. Open holes on floor must be covered to avoid accident.

1.6.3. Rotary Table

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1.6.4. Crown Block

i. Crown block assembly should be securely bolted.