Zysea Sop

Standard Operation Procedure
PT ZHONGYUAN SOUTHEAST ASIA

..........................................................................................................................................4
一. Picking Up and Laying Down Single Joints (Singling In / Singling Out)......................4
二. Picking Up and Laying Down Singles with Pick-Up / Lay-Down Machine..................5
三. Make-Up and Break-Out Procedures Using Rig Tongs...................................................9
四. Use of Rig Tongs with EZY- Torque..............................................................................10
五. Safety While Making Up and Breaking Out Bottom Hole Assemblies and Bits..........12
六. Running In and Laying Down Drill Collars..................................................................14
七. Making Connections While Drilling (Making a Connection).......................................20
八. Tripping..........................................................................................................................23
九. Trip Tank and Fill-Up Line Operations.........................................................................23
一〇. Removal and Installation of Rotary Bushings...............................................................23
一一. Maintenance of Elevators and Slips, Changing Slip Dies and Tong Dies.....................23
一二. Use and Inspection of Mud Box / Mud Saver...............................................................23
一三. Rigging and Testing of Chiksan Swivel Joints and Steel Hoses...................................23
一四. Operations with Top Drive Systems..............................................................................23
一五. Operating the Automated Roughneck............................................................................23
一六. Operating the Eddy Current Brake.................................................................................23
一七. Pumping Pills.................................................................................................................23
一八. Perform Flow Check......................................................................................................23
一九. Slow Circulating Rate – SCR (also Slow Pump Rate - SPR)........................................23
二〇. Shut-in Procedures.........................................................................................................23
二一. Conducting Leak-Off Test..............................................................................................23
二二. Working in the Derrick and Overhead Operations........................................................23
二三. Changing Winch Wire....................................................................................................23
二四. Changing Out Dead Line Stabilisers..............................................................................23
二五. Derrick Inspections........................................................................................................23
二六. Dead Line Anchor Maintenance....................................................................................23
二七. Slipping and Cutting Drilling Line................................................................................23
二八. Reeving on Drilling Line...............................................................................................23
二九. Adjusting and Testing the Crown-O-Matic....................................................................23
三〇. The Anti-Collision System (ACS).................................................................................23
三一. Nipple Up and Nipple Down BOP.................................................................................23
三二. Change Out BOP Rams..................................................................................................23
三三. Changing Valves on BOP...............................................................................................23
三四. Pressure Testing the BOP and the BOP System.............................................................23
三五. Handling of Wellhead Tie-down Bolts...........................................................................23
三六. Changing Liners on Mud Pumps...................................................................................23
三七. Changing Pistons on Mud Pumps..................................................................................23
三八. Changing Valves and Seats on Mud Pumps...................................................................23
三九. Resetting and Adjusting the HP Relief Valve................................................................23
四〇. Cleaning the Discharge Filter on Mud Pumps...............................................................23
四一. Mud Tank Set Up While Tripping..................................................................................23
四二. Entry Permit and Procedure...........................................................................................23
四三. Cleaning Mud Tanks......................................................................................................23
四四. Cleaning Mud Tanks After Drilling H2S Zone..............................................................23
四五. Moving Chemicals in the Storage Area.........................................................................23
四六. Monitoring a Mud System.............................................................................................23
四七. Changing Valves in the Mixing System.........................................................................23
四八. Changing Shaker Screens...............................................................................................23
四九. Operating Desanders, Desilters, and Mud Cleaners......................................................23
五〇. Operating the Degasser..................................................................................................23
五一. Operating the Poor Boy Mud Gas Separator.................................................................23
五二. Operating the Centrifuge................................................................................................23
五三. Using High Pressure Wash Down Guns........................................................................23
五四. Hazardous Areas and Zones...........................................................................................23
五五. Operation and Maintenance of Derrickman Escape Devices........................................23
五六. Laying Out and Preparing Casing..................................................................................23

五七. Operation and Maintenance of the Stabbing Board.......................................................23
五八. Running Casing / Liner / Tubing....................................................................................23
五九. Cementing Casing / Liner..............................................................................................23
六〇. Rigging Up Wireline Lubricator....................................................................................23
六一. Running and Pulling Downhole Plugs...........................................................................23
六二. Running Survey Tool with Rig Wireline Unit...............................................................23
六三. Kick Detectors................................................................................................................23
六四. Kick Drills......................................................................................................................23
六五. Shut-in Procedures.........................................................................................................23
六六. Killing Procedure Step by Step......................................................................................23
六七. Kick Control by Stripping and the Volumetric Method.................................................23
六八. Pressure Test Procedure for the High Pressure Test Pump............................................23
六九. Pressure Testing Wellhead Completion..........................................................................23
七〇. Use of Foster Hydraulic Tong........................................................................................23
七一. Pick Up, Wash Down, and Lay Down Kelly.................................................................23
七二. Running and Pulling Electrical Submersible Pump (ESP)............................................23
OPERATION PROCEDURE
壱. Picking Up and Laying Down Single Joints (Singling In / Singling

Out)
1. SPECIAL TOOLS AND EQUIPMENT
Drillpipe lifting cap(appropriate size) Drillpipe drift (appropriate size)
Soft brush and Cleaning solvent Pin and Box protectors
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Kelly cock with Wrench Circulating sub

Drillpipe dope Tape measure
Inside BOP Correct size Rig tongs
2. SAFETY INFORMATION
1. Ensure that escape routes ( doors, stairs, etc. ) are accessible at all times and
are not obstructed by hoses, tools, etc.
2. Special attention must be paid while lifting the drillpipe from the catwalk onto
the rig floor with the air tugger and lowering the travelling block at the same
time.
3. Nobody is allowed to stand between the single being brought in / laid down
and the joint in the rotary table. Nobody is allowed to stand with their back to
the V-door, during these activities.
4. The Floormen guiding the single across the rig floor must keep feet well clear
of the pin end of the single. Winch operators must not lower singles until they
are completely sure that feet are well clear of the pin end.
5. Keep feet well clear of the drillpipe pin end when the drift is still in the pipe
and the pipe is vertical.
3. STANDARD OPERATIONAL CONSIDERATIONS (DO'S AND DON'TS)
(1) This operation requires a Toolbox Talk, covering equipment use and positioning of
personnel.
(2) Ensure that all hoisting / lifting equipment, wires and lifting caps are in a safe
condition and conforms with the current ZPEB colour coding and have valid
inspection certificates.
(3) The air winch Operator shall ensure that the winch wire is moving freely in the
derrick (possibly guided by pulleys) to avoid any damage to the steel structure,
especially the fingerboard.
(4) Ensure that the correct grade of pipe is being picked up.
(5) When installing the lifting cap, ensure it is tight.
(6) Before and after operation, count the drillpipe (DP) on the pipe rack to verify tally
figures.
(7) Any damaged DP is to be painted red (highlighting the damage) and reported to
the Toolpusher for change of inventory status and transport back to base /
warehouse.
(8) When singling in, ensure pipe tally is updated as DP is being picked up. Number as
per ZPEB DP numbering system.
(9) If pipe is 5" in diameter or greater, tail the pipe using a rope as it clears the top of
the V-door and enters the rig floor. The use of a rope to tail in pipe of a smaller
diameter is at the Toolpusher's discretion.
(10) When singling out, ensure pipe tally is adjusted to reflect the pipe being laid down.
4. INSTRUCTIONS
4.1. Singling In
(1) Verify the size and current colour coding of the lifting cap.
(2) Clean and examine the threads and shoulders on box and pin ends, and inform the
Driller of any damage.
(3) Verify the grade of the drillpipe, measure length, record and inform the Driller.
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(4) Remove the protector from the box end, apply dope (thread compound), and install
the drift and lifting cap, ensuring the lifting cap is tight.
(5) Attach the air tugger to the lifting cap and lift the pipe off the catwalk.
(6) Tail the drillpipe with a rope as it swings through the V-door.
(7) Remove the pin protector and retrieve the drift, keeping feet well clear.
(8) Lower the drillpipe joint into the mouse hole, and remove air tugger and lifting cap.
(9) If the rig is equipped with a top drive, the Driller activates the linktilt towards the
joint in the mouse hole and the Floormen latch the elevators.
4.2. Singling Out
(1) After the connection has been broken out the Floormen pull the single over the
mouse hole.
(2) The Floormen dope the pin and install a pin thread protector.
(3) If a top drive is used, after the single has been broken out, the Driller uses the
linktilt to move the single towards and into the mouse hole.
(4) The elevators are opened when the joint stands up and then are held back from
swinging across the rig floor.
(5) The Floormen dope the box and install the lifting cap, attach the air tugger and lift
the joint clear of the mouse hole.
Note: The drillpipe can be cleaned and doped after it has been rolled off the catwalk.
(6) Tail / push pipe out of the V-door keeping feet well clear. Winch operator must
ensure that the last joint laid down is no longer on the catwalk and that the catwalk
is clear of personnel before slowly lowering the pipe out of the V-door.
Note: When running in or laying down a large amount of drillpipe, special attention must
be paid while working around the mouse hole. The Mouse hole shall be covered at
all times when not in use.
(7) Remove the lifting cap, install the box protector and roll the joint onto the pipe rack.
4.3. Special Considerations
(1) If applicable, during singling in, drillpipe casing protectors should be fitted as per
the Drilling Programme before putting the joint into the mouse hole.
(2) During singling out, the drillpipe casing protector should be removed, while being
pulled out of the mouse hole.
(3) When breaking out singles, any problem connection must be marked, recorded in
the Tally Book and reported to the Toolpusher.
弐. Picking Up and Laying Down Singles with Pick-Up / Lay-Down

Machine
PU / LD Machine Pipe wiper
Pipe rack / stops Drillpipe dope and brush
Fork lift truck Kelly cock
Gray valve Circulating sub
Stabbing guide Drillpipe drift
Protector box Sloping stands
Lifting subs Hazard tape
Automated Roughneck Spinning wrench
Correct size Rig tongs
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1. Area around the PU / LD machine must be cordoned off with hazard tape.
2. Do not stand between the pipe rack and the PU / LD machine.
3. Do not stand on the PU / LD machine.
4. Do not stand in the V-door between rotary and PU / LD transport trough.
5. Inspect all handling equipment. Ensure that the Working Load Limit (WLL) is
sufficient for the heaviest load.
6. Ensure that stops are used in the pipe racks.
7. Ensure that work area is free of obstruction and escape routes are clear.
8. Ensure that the drilling lines do not become entangled with the fingerboard
when lowering the travelling block.
3. STANDARD OPERATIONAL CONSIDERATIONS (DO’S AND DON’TS)
(1) Hold a Toolbox Talk before the operation begins.
(2) Ensure that all the pipe to be run is tallied as per ZPEB numbering system.
(3) The PU / LD machine is to be placed at about 15 metres (50 ft) from the V-door for
pipe handling operations.
(4) Ensure that the power lines for the PU / LD machine are safely stowed, to prevent
damage from falling pipe.
(5) Ensure that the drillpipe has protectors on both ends before picking up or laying
down.
(6) Ensure that the drillpipe is drifted as it is being picked up.
(7) Ensure that the rotary table is not locked while making up or breaking out pipe.
(8) Ensure that the drillpipe lifters are chained down to the catwalk.
(9) Place the remote control on the drill floor, ensuring that the Operator has total
visibility of the pipe rack and the drill floor.
(10) Ensure that only a properly trained crew member is assigned to the remote control
to operate the PU / LD machine.
(11) Ensure that the machine and the cables have been inspected, and the machine
has certificates of inspection.
(12) Ensure that the sloping racks are properly placed between the pipe rack and the
catwalk.
(13) Before the operation commences with drillpipe or drill collars, the PU / LD machine
will be rigged up, operated, and tested for proper operation.
(14) Ensure that a pipe wiper is installed on the drillpipe whenever picking up or laying
down to ensure nothing falls in the wellbore and to clean the pipe.
(15) Ensure that there is always a suitable kelly cock with wrench, an inside BOP (Gray
valve or equivalent) and a circulating sub on the rig floor.
4. INSTRUCTIONS
4.1. Picking Up Drillpipe / Drill Collars with PU / LD Machine
(1) The Floormen and/or Roustabouts roll a joint of drillpipe or drill collar gently off the
pipe rack, down to the racking arms.
(2) The Operator engages the racking arms and raises the joint of drillpipe or drill
collar into the transport trough.
(3) The Operator brings the joint of drillpipe or drill collar up to and through the Vdoor.
Note: Never stand in between the transport trough and the V-door.
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(4) After the drillpipe or drill collar has reached the rig floor, a Floorman removes the
box end protector, inserts the drillpipe drift, applies dope to the box end of the
connection and puts the protector in a container provided on the rig floor.
Note: If picking up a drill collar, the Floormen will install the lifting sub, after it is
delivered to the V-door (never on the pipe rack). Also, ensure the pin protector
OD is never larger than the drill collar OD.
(5) The Driller lowers the travelling block and the Floormen pull the elevators over the
drillpipe or drill collar lifting sub.
Note: If the rig is equipped with a top drive, the Driller activates the linktilt and the
Floormen latch the elevators.
Note: The Driller must not set any weight of the elevators on the drillpipe or the lifting
sub of the drill collar, as this will cause the joint of pipe to jump out of the transport
trough.
(6) Upon the Driller’s instruction, the Floormen latch the elevators around the drillpipe
or drill collar lifting sub.
(7) The Driller engages the drawworks and picks up the drillpipe or drill collar with the
travelling block.
(8) As the drillpipe or drill collar leaves the transport trough, the Floormen, using a tail
rope, snub and guide the pipe over to the rotary table.
(9) When the drillpipe or drill collar is in an upright position, the Floormen remove the
pin end protector and retrieve the drillpipe drift.
Note: Keep feet clear of pin end when retrieving the drift to prevent injury.
(10) The Floormen inspect the thread and the shoulder of the pin end of the drillpipe or
drill collar and inform the Driller of any damage.
(11) The Driller lowers the joint of drillpipe or drill collar.
(12) The Floormen, if applicable, use a stabbing guide, stab the joint of drillpipe or drill
collar into the string at the rotary table.
(13) The Driller lowers the travelling block until the elevators clear the tool joint or the
lifting sub.
Note:If making up drill collars, walk in the drill collar using the chain tongs, ensuring the
lifting sub is not unscrewing.
(14) The Floormen install the spinning wrench and make up the tool joint connection.
Note:If applicable, use the automated roughneck to make up the connections.
Note:The rotary table must be unlocked while making up connections.
(15) The Floormen install the rig tongs and the Driller torques the tool joint connection
to its proper torque limit, or if applicable, the automated roughneck is used to make
up the connection.
Note: If picking up drill collars, the Floormen will remove the safety clamp.
(16) The Driller engages the drawworks and lifts the string as the Floormen pull the
slips.
(17) The Driller lowers the joint of drillpipe or drill collar into the wellbore.
(18) At the Driller’s instruction, the Floormen set the slips.
Note: If picking up drill collars, the Floormen will attach the safety clamp.
(19) The Driller lowers the travelling block until the elevators clear the tool joint or lifting
sub.
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(20) The Floormen unlatch the elevators and pull away from the tool joint or lifting sub.
(21) The Driller engages the drawworks and lifts the elevators clear.
(22) Repeat steps (1) through (21) until all the drillpipe or drill collars have been picked
up or as per Fill-up Procedure.
4.2. Laying Down Drillpipe / Drill Collar with a PU / LD Machine
(1) The Driller engages the drawworks and lifts the drillstring up to the next tool joint.
(2) Upon the Driller’s signal, the Floormen set the slips around the drillpipe or drill collar.
Note: If laying down drill collars, the Floormen attach the safety clamp around the drill
collar, making sure it is secure.
(3) The Driller continues to slack off the travelling block until the elevators clear the tool
joint or the lifting sub.
(4) The Floormen attach the rig tongs around the tool joint connection and the Driller
engages the break-out cathead and breaks the connection.
(5) The Floormen install the spinning wrench around the tool joint connection and spin
out the top joint of drillpipe.
Note: If applicable, use the automated roughneck to break out the connection.
Note: When breaking out drill collars and the spinning wrench is not capable of
handling the size of the drill collar, chain tongs shall be used to walk out the connection.
(6) The Driller engages the drawworks and picks up the joint until the pin end is above
the box in the drillstring.
Note: If the drillstring is being pulled “wet”, then the mud box should be hung and
installed around the tool joint, until the joint is drained.
(7) The Floormen pull the joint away from rotary table and install a greased thread
protector onto the pin end, ensuring that it is the correct size and thread.
(8) The Floormen push the joint over to the transport trough as the Driller lowers the
joint into the transport trough with the travelling block.
(9) The Driller continues to lower the joint until it is lying fully in the transport trough.
(10) The Floormen can now open the elevators, ensuring that the pipe does not drop
into the transport trough.
(11) The Driller lifts the elevators clear of the joint.
Note: If laying down drill collars, the Floormen can now remove the lifting sub.
(12) The Floormen install a greased protector in the box end of the joint, ensuring that it
is the correct size and thread.
(13) The PU / LD machine Operator moves the transport trough out of the V-door.
Note: Never let the drillpipe or drill collar slide downwards. Do not use the end of the
transport trough as a stop.
(14) The Driller lowers the elevators down to the joint in the rotary table and the
Floormen close the elevators around the drillpipe tool joint or the drill collar lifting sub.
(15) When the transport trough is out of the V-door, the PU / LD machine Operator
positions the transport trough alongside the pipe rack.
(16) The Operator tilts the transport trough holding the joint of drillpipe or drill collar,
downward, where it will roll into the racking arms.
Note: Ensure that the racking arms are adjusted so that the falling height of the drillpipe
or drill collar joint is limited.
(17) The Operator moves the racking arms with the drillpipe or drill collar, downwards
8
until the drillpipe or the drill collar is on the pipe rack.

(18) The Operator then puts the racking arms in their upward position and moves the
transport trough back up to the rig floor.
(19) Repeat steps (1) through (14) until all drillpipe / drill collars are laid down.
(20) The drillpipe or drill collar on the pipe rack can now be cleaned inside and out with
water.
(21) The Fork lift truck Operator removes the drillpipe or drill collar from the pipe rack.
参. Make-Up and Break-Out Procedures Using Rig Tongs

Tong jaws Grease
Tong dies Grease gun
Correct size Rig tongs Tong pins
Safety latch springs Split pins
1. The Driller must ensure that the Floormen are outside the area of the tongs
before pulling on the tongs, if an abnormal amount of torque is to be applied
during make up or break out.
2. Snub lines for the rig tongs must be inspected and be in good working order.
3. Hanging lines for the rig tongs must be inspected and be in good working
order.
4. The Floormen must be instructed on proper placement of hands while
operating the rig tongs.
(1) Always use two sets of rig tongs of the proper size to break out or make up
connections.
(2) The Floormen must lubricate rig tongs at regular intervals, and always before and
after each trip.
(3) The slack in the rig tong safety line must be sufficient for the tong to obtain full
benefit from the pull of the cathead, but short enough to prevent half rotation of the rig
tong.
(4) Ends of the braided safety lines should be secured by thimbles which are properly
cast, spliced or talurit-clamped to prevent unravelling.
(5) Rig tongs must be kept clean to ensure proper operation.
(6) Rig tong dies must be inspect regularly and must be replaced when worn or
damaged. Ensure that the tong dies are secured with safety pins.
(7) Rig tong line pulleys and counterbalances must be inspected at regular intervals.
(8) Rig tong pins and hinges must be inspected regularly for wear and replaced if any
wear is observed.
(9) Rig tong pins, shackle pins and bolts must be secured with the proper size split pins.
4. INSTRUCTIONS
4.1. Breaking Out Connections with the Rig Tongs
(1) The Floormen remove the safety latch springs and the tong pins and change the
tong jaws to match the size of the pipe or tubular to be broken out.
(2) The Driller ensures that the safety latch springs are replaced on the tong pins.
(3) The Floormen set the slips, or where applicable, the Driller sets the automatic slips.
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(4) The Floormen engage the rig tongs on the drillpipe or tubular tool joint. (The
breakout tong is placed on the top tool joint and the makeup tong is placed on the
bottom tool joint).
Note: Special attention must be made to ensure the rig tongs are placed above the
hard facing on the tool joint.
(5) The Floormen make the rig tongs bite by pulling on the tong jaw and pushing on the
tong arm.
Note: The Floorman must properly place their hands on the rig tongs to prevent injury.
(6) The Driller engages the breakout cathead and pulls on the breakout tong. This will
cause the breakout tong to bite on the upper tool joint. At the same time, the makeup
tong bites on the bottom tool joint. The connection is then broken.
Note: The Driller must ensure that the cathead line is at right angle (90 degrees) to the
tong arm. The Driller must note the breakout torque and mark the joints for further
inspection if the breakout torque is not equal to or within less than 10% of the makeup
torque.
(7) The Floormen spin out the connection using the air spinner, or if applicable, the
Driller utilises the top drive to spin out the connection.
(8) The Floormen apply proper pipe dope into the thread box of the pipe joint.
(9) The Floormen remove the rig tongs and tie them back safely out of the way.
4.2. Making Up Connections with the Rig Tongs
(1) The Floormen remove the safety latch springs and the tong pins and change the
tong jaws to match the size of the pipe or tubular to be made up.
(2) The Driller ensures that the safety latch springs are replaced on the tong pins.
(3) The Floormen set the slips and the Driller picks up a joint or a stand of pipe.
(4) The Floormen apply pipe dope to the box and pin end of the connection thoroughly.
(5) The Floormen stab the pin end of the joint into the box of the joint in the rotary table.
(6) The Floormen rotate the pipe into the box utilising the air spinner or where
applicable, the Driller utilises the top-drive or the kelly spinner.
(7) The Floormen engage the rig tongs onto the drillpipe or tubular tool joint (The
makeup tong is placed on the top tool joint and the breakout tong is placed on the
bottom tool joint). The Floormen make the rig tongs bite by pulling on the tong jaws and
pushing on the tong arm.
Note: The Floorman must properly place their hands on the rig tongs to prevent injury.
(8) The Driller engages the makeup cathead, pulls on the makeup tong causing the
make up tong to bite on the top tool joint. At the same time, the breakout tong bites on
the bottom tool joint. The Driller continues to pull on the makeup tong until proper
torque is applied to the connection.
(9) After the connection has been tighten to proper torque, the Floormen remove the rig
tongs and tie them safely out of the way.
四. Use of Rig Tongs with EZY- Torque

1 x EZY-Torque with Pull line 2 x Rig tongs and Jaws
2 x ½ inch Suspension Lines 1 x Torque Meter / Load cell
Snatch block (optional) Pipe spinner
Snubbing or Safety line Chain tongs
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1. Some models of EZY-Torque are designed for up to 206.8 bars (3000 psi)
working pressures in the high pressure port. Do not connect the high
pressure hose to the low pressure port.
2. Safe load capacity, strengths and application limits of accessories and
components must be carefully checked.
3. EZY-Torque hydraulic catheads are designed for up to 20340 daN.m (150000
ft-lb.) of torque. If used for less than 5424 daN.m (40000 ftlb.) applications the
unit must be calibrated with a load cell.
4. Ensure the Floormen place hands on protective hand grip areas only. The
Floormen are not to place their hands, fingers and especially thumbs
between the tongs.
(1) When breaking out drillpipe, ensure that the tong dies grip the tool joint. Do not grip
on the hard banding or on the shoulder areas.
(2) Ensure that tongs, which are not in use, are hung (tied back) at the side of the floor.
(3) Suspension lines, pull lines, backup lines and snub lines should be inspected weekly
and before every job for specifications (job load ratings), wear limits, damage, or
improper installation.
(4) Ensure that the work force have been fully instructed on installation, function,
operation, maintenance and safety procedures / precautions.
(5) Do not stand behind rig tongs while they are in use.
(6) Any safety deficiencies or violations must be corrected immediately before
proceeding with operations.
4. INSTRUCTIONS
4.1. General - Pre Job Check List
(1) Fit the rig tongs with the correct jaws for the drillpipe tool joint or the drill collar.
Reinstall the safety lock springs.
(2) Ensure that the counter-weights are in balance with the tongs.
(3) The tong counter-weight must not rest on derrick sub floor, derrick substructure sills
or other obstruction. The counter-weights must be shielded to prevent crew members
from accidental contact with the lines or weights.
(4) Check all wire ropes on the back-up and make-up lines from the EZY-Torque for
frayed ends. Ensure the wire rope clips or sockets have been correctly applied as per
specifications / regulations.
(5) Check operation of the power unit for the EZY-Torque and for compliance with
engine / motor safety regulations and codes. Check for function controls, hydraulic
leaks and all safety shut down controls.
(6) When tightening joints, ensure that the backup tongs (on the lower tool joint) are
placed perpendicular (at 90° angle) to the snub line and to the load cell / torque meter.
(7) Connect the makeup line(s) and snub line to the rig tongs.
Note: The snubb line should be at least twice the size of the tong line.
(8) Remove the locking pin from the rotary table so that it rotates freely.
(9) Clean the dies in the jaws or change them if they are worn or rounded.
(10) The breakout tong should be snubbed, preferably to an anchor post.
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Note: Sometimes the tongs are snubbed to the derrick leg. This method should not be
used unless the derrick legs are designed to accommodate this installation.
(11) The backup tong should be snubbed to the substructure or to an anchor post
attached to the substructure. The backup tong must be attached to the lower tool joint
where the safety lines are at a 90 degree angle to the tong arm.
(12) The slack in the tong safety line for both the breakout and the makeup tongs must
be such that the tong can be set no more than 10 degrees past the right angle setting of
the tool joint.
4.2. Making Up (tightening) Joints
(1) Screw the properly cleaned and doped threads of the pipe to a snug condition using
pipe spinner and / or chain tongs.
(2) Latch the backup tong, with the snub line load cell / torque meter, on to the bottom
tool joint.
Note: Since a bending force is exerted on the pipe during make up, the tool joint
connection must be set in the slips as low as possible.
(3) Fit the makeup tong which is connected to the EZY-Torque on the top tool joint. The
Floormen pull the tongs around the pipe until the lines are firm.
Note: Keep thumbs inside the protective hand grips.
(4) The Driller now operates the EZY-Torque. The hydraulic cylinder slides out (up),
causing the jack line to be pulled by the rig tong. The torque meter will indicate the
torque line pull force.
(5) If the correct torque has not yet been obtained, the hydraulic cylinder must be
pushed in (down) and step (4) repeated.
Note: Application of the rotary brake before the EZY-Torque is released will keep the
snubb line on the back-up tong tight while the EZY-Torque is re-positioned
(6) When finished, the Floormen remove the pull lines from the tongs and hang the
tongs (tie back) at the side of the rig floor.
4.3. Breaking Joints
(1) Fit the rig tong again as described in instructions 5.2 (2) and 5.2. (3) above but
reverse the position (the backup tong now becomes the breakout tong).
Note: Since a bending force is exerted on the pipe during break out, the tool joint
connection must be set in the slips as low as possible.
(2) The Driller / Assistant operates the EZY-Torque and pulls until the two cables on the
tong are firm.
(3) The Floormen now move back and away from the rig tongs until the connection has
been broken.
WARNING: The Floormen should always be aware of the tremendous force that can be
applied and that the tongs could fly off suddenly, causing serious injury or fatality.
(4) When the connection is broken, unlatch tongs and unscrew the pipe using chain
tongs or pipe spinner.
Note: Hold or tie back the tongs so that they do not swing toward the pipe during
unscrewing.
伍. Safety While Making Up and Breaking Out Bottom Hole

Assemblies and Bits
12
Inside BOP (Gray valve or equivalent) Kelly cock and Wrench

Torque sensors / Gauges Circulating sub
Measuring tape Safety clamp
Non-slip Floor matting Rig tongs
Elevators Snub lines
Lifting subs Ring gauges
Bit breakers Slips
Crossovers Automated roughneck
1. All equipment and tools must be checked for valid colour code, safety and
load testing certification.
2. Rig floor work area must be clean and escape routes (doors, stairs, etc.) are
accessible at all times and are not obstructed by hoses, tools etc.
3. All equipment and tools must be visually inspected for damage and / or wear.
4. Do not use any drilling equipment that does not have certification.
Note: These safety instructions pertain to all work instructions and are to be applied to
all the Work Instructions in this manual. Always refer to the current HSE Manual.
(1) Before starting the job, hold a Toolbox Talk with the crew to discuss equipment,
tools, procedures and safety.
(2) Keep the rotary table and the mouse hole covered when not in use.
(3) Before opening the blind or shear rams, the pressure is to be bled off through the
choke line and all personnel kept away from the rotary table.
(4) When out of the hole, the Driller shall check for fluid level / flow. If the fluid level is
static, the blind / shear rams are to be closed.
(5) A description of the bottom hole assembly (BHA), in the hole and the next BHA to be
run, must be posted where it can be seen by the Driller and crew and recorded in the
tally book and the BHA book.
(6) While pulling the BHA through the rotary table, the Driller must stop when stabilisers
reach the table and have the Floormen remove the bushings.
(7) The Driller is to ensure all rig tongs have two snub lines attached for safety.
(8) Tie back the rig tongs after each use and close the jaws.
(9) Never reverse rotary table into the DC or any tubular when making up connections.
(10) When hoisting any large or heavy equipment off the catwalk always check the
Working Load Limit (WLL) of the air winch, or use the travelling block or crane if
available.
(11) The Driller and the Derrickman must be able to communicate at all times when the
Derrickman is working on the derrick board.
(12) The Drillers must exchange hand-over notes between each tour.
(13) The Toolpusher or Senior Driller must be on the rig floor whenever bits and bottom
hole assemblies are made up.
(14) The Senior Driller must ensure that the correct bit, dressed with appropriate size
jets, is ready to be picked up. The correct size and type bit breaker is to be on the rig
floor.
(15) All equipment being picked up and installed into the bottom hole assembly must
13
have the safety clamp secured and proper torque applied before picking up the next
piece of equipment.
(16) All equipment picked up must be visually inspected for damage with special
attention to threads on both the box and the pin ends.
(17) Observed damage on or to any equipment will be recorded in the tour book and
reported to the Driller and the Toolpusher.
(18) All threaded connections must be doped with API specified thread compound.
(19) All tubulars to be picked up must have serial numbers, special features, internal
diameter (ID), outer diameter (OD), length and fishing neck, where applicable, recorded
in the tally book.
(20) All third party equipment, such as downhole motors, MWD, stabilisers, drilling jars,
must have detailed fishing diagram available.
(21) Tubulars must be drifted with the appropriate size drift before being included in or
added to the drillstring.
(22) The Toolpusher or Senior Driller shall verify all stabilisers, reamers and bits will be
gauged with appropriate ring gauge to ensure proper size before running in the hole.
(23) The Driller shall ensure that all gauges and sensors, such as the weight indicator,
torque gauge, are inspected and calibrated.
(24) Use soft matting, wood or similar material as base for making up diamond or
Polycrystalline Diamond Compact (PDC) bits. Follow manufacturer’s instructions on
handling such equipment.
(25) When breaking out or making up 9 inch or larger DC, it is company policy to use
the DD tongs or if applicable the EZY-Torque.
(26) Ensure that pulling the pipe from the catwalk onto the rig floor and lowering the
travelling block at the same time is avoided.
(27) The Air winch Operator must ensure the winch wire is moving freely in the derrick
(preferably guided by pulleys) to avoid any damage to the steel structure especially the
fingerboard and that the air tugger is secured when not in use.
(28) Keep the gate at the V-door secured, except when lifting equipment or any tubulars
from the catwalk.
(29) Ensure that a suitable kelly cock with wrench, an inside BOP (Gray valve or
equivalent) and a circulating sub with appropriate crossover are available on the rig
floor, during a connection, drilling or while tripping.
(30) Ensure that all rotary table bushings / tapers are to manufacturer’s specifications
and are not worn.
(31) Whenever setting the slips , lower tubulars slowly to minimise shock loading.
Note: Improper fit between bushing and slips will cause uneven load damage to the
slips and pinching of the tubulars.
(32) Do not make up or break out the bit on a single joint of DC. If this is absolutely
necessary, always snub drill collar with the air tugger.
(33) When picking up or setting down drill collar stands larger than 6 1/4” on the floor
board, always snub with the air tugger.
六. Running In and Laying Down Drill Collars

Single sling with Hook Double sling and Hook
14
Drill collar Dope and Brush OD and ID Calliper

Tape measure Chalk or Marker
Lifting subs Elevators
Rig tongs Thread protectors
Sledge hammer Drill collar Slings
Drill collar Drift Safety clamp
Bar or Cheater bar Tag lines
Slips Crane
1. Never stand or work under a suspended load.
2. Do not block the view of the Driller or the Crane Operator.
3. A greater degree of care and attention is required to ensure the safety of new
personnel working on the rig during this operation.
4. During drifting of the drill collars ensure that the drift does not drop out of
the end of the joint and cause personal injury.
5. Always use tag line to guide the drill collar.
6. Ensure that all equipment and slings are in good condition with current
colour code.
7. Check the weight of the loads. Ensure the correct Working Load Limit (WLL)
of each sling, hook and air winch.
(1) Before starting the job, hold a Toolbox Talk with the crew and the Crane Operator,
to discuss equipment, procedures and safety.
(2) Prior to picking up any drill collar (DC), clean and inspect all lifting sub pins.
Damaged lifting subs will be marked and set aside. Notify the Driller and the
Toolpusher.
(3) Check the condition of the winch line and slings for wear and colour code
identification. Report any damage or equipment with wrong colour code.
(4) When lifting 9” collars or larger with the elevators, use the winch to restrain the
movement of the DC.
(5) After latching elevators always check and ensure the safety latch is engaged.
(6) Prior to picking up a DC joint, visually inspect the pin and box threads, the shoulders
and faces. Any problems and damage observed on threads or shoulders must be
recorded in the pipe tally book and reported to the Toolpusher.
(7) Measure and record DC features, outside diameter (OD), inside diameter (ID),
length, thread type, serial number and fishing neck in the pipe tally book.
(8) Prior to making up a lifting sub to a DC, dope the pin of the sub and the box of the
DC with proper dope (thread compound).
(9) After making up the lifting sub to the DC in the V-door or mouse hole, tighten the
sub with a bar or a cheater bar.
(10) Ensure that all threaded connections are cleaned, properly doped and thread
protectors installed. Ensure that the pin protector OD is not larger than the drill collar
OD.
(11) All DC connections are to be “walked in” with chain tongs. Rig tongs will be used
for final make up torque before run in the hole.
15
(12) Never rotate the rotary table to spin in or out a drill collar joint.
(13) Ensure that the box end protector is installed when the lifting sub is removed.
4. INSTRUCTIONS
4.1. Handling Drill Collars with Pick-Up Sling
4.1.1. Running In DC with Pick-Up Sling
(1) The Driller and the Floormen attach and secure a sling to the travelling block, long
enough to reach the catwalk.
(2) A Floorman inserts the DC drift into the box end of the drill collar on the catwalk,
dopes the box and installs a protector with a certified lifting eye or a lifting sub with the
correct thread.
(3) The Floormen attach and secure the sling to the shackle fitted into the hole of the
lifting sub or cap.
(4) A Floorman attaches the catwalk winch to the lift eye on the pin protector.
(5) The Driller engages the drawworks and carefully raises the drill collar up and
through the V-door as the Catwalk winch Operator snubs the drill collar.
(6) Once the drill collar is over the mouse hole, a Floorman removes the catwalk winch
from the eye of the pin protector.
(7) The Driller lowers the drill collar into the mouse hole.
(8) The Floormen remove the sling from the lifting eye. They then remove the box
protector from the drill collar and insert the lifting sub.
(9) Using a bar or a cheater bar through the hole of the lifting sub, the Floormen screw
the lifting sub into the drill collar and tighten.
(10) At the Driller’s instruction, the Floormen latch the elevator around the lifting sub.
(11) If using a top drive, the Driller activates the linktilt toward the joint in the mouse
hole and the Floormen latch the elevator.
Note: If picking up recessed drill collars, ensure that the drill collar elevator is the
correct size and the safety latch is engaged.
(12) The Driller engages the drawworks and lifts the drill collar up and out of the mouse
hole.
(13) The Floormen remove the drill collar pin protector and recover the drift.
Note: Keep feet away when the drift is removed to prevent injury.
(14) If using a top drive, the Driller retracts the linktilt and positions the drill collar over
the rotary table.
Note: If this is the bottom drill collar, then make up the bit (or other downhole tools,
such as hole opener, mud motor, core barrel, etc.), and remove the rotary
bushings if necessary.
(15) The Driller opens the blind rams (if BOP is installed), and lowers the drill collar
through the rotary table.
(16) The Floormen reinstall the rotary bushings (if removed), set the DC slips at the
Driller´s instruction, and secure the DC with the safety clamp.
Note: The elevators must never be opened before the safety clamp has been fitted and
secured.
(17) The Driller lowers the elevators and the Floormen unlatch the elevators.
(18) The Floormen remove the lifting sub and apply dope to the box.
(19) Repeat the steps (2) through (18) until all drill collars are picked up.
16
(20) The Floormen then remove the pick-up sling from the travelling block.
4.1.2. Laying Down DC with Pick-Up Sling
(1) The Driller and the Floormen attach and secure a sling to the travelling block, long
enough to reach the catwalk.
(2) When the top joint of the DC is at the rotary table, the Floormen set the DC slips,
install the safety clamp, break out the connection at the top drill collar, and dope the pin
and the box.
(3) The Floormen install a lifting cap or a lifting sub into the drill collar box and
tighten.
(4) The Driller lowers the travelling block and the Floormen latch the elevators on the
DC in the rotary table, and remove the safety clamp.
(5) The Driller picks up the string, the Floormen pull the slips.
(6) The Driller continues to pick up until the next joint comes to the rotary table, the
Floormen set the slips and install the safety clamp.
(7) The Floormen break the connection, dope the pin and the box, install a pin
protector, and put the drill collar in the mouse hole.
Note: If using a top drive, the Driller activates the linktilt toward the mouse hole and the
Floormen guides the collar into the mouse hole.
(8) The Floormen unlatch the elevator, attach the sling from the travelling block to the
shackle inserted in the hole of the lifting cap or sub.
(9) The Driller raises the travelling block until the drill collar is removed from the mouse
hole.
(10) The Floormen attach the catwalk winch shackle to the pin end.
(11) The Catwalk winch Operator pulls the pin end of the drill collar out the V-door as
the Driller lowers the travelling block.
(12) The Driller continues lowering as the Catwalk winch Operator pulls the collar until
the drill collar is resting on the catwalk.
(13) The Floormen remove the winch line and the sling line from the pin and box
protectors.
(14) Remove the drill collar from the catwalk before the next joint of drill collar is laid
down.
(15) Repeat steps (4) through (14) until all drill collars are laid down.
4.2. Handling Drill Collars with the Air Tugger
4.2.1. Running In DC with the Air Tugger
(1) The Driller ensures that the air tugger capacity is within the Working Weight Limit of
the drill collar to be picked up.
dopes the box and installs a protector with a lifting eye or a lifting sub with the correct
thread.
(3) The Floormen attach and secure the air tugger line to the shackle fitted into the
hole of the lifting sub or cap.
(4) A Floorman attaches the catwalk winch to the lift eye on the pin protector.
(5) The Air tugger Operator engages the air tugger and carefully raises the drill collar up
17
and through the V-door as the Catwalk winch Operator snubs the drill collar.
(6) Once the drill collar is over the mouse hole, a Floorman removes the catwalk
winch from the eye of the pin protector.
(7) The air tugger Operator lowers the drill collar into the mouse hole.
(8) The Floormen remove the air tugger line and the lifting eye from the drill collar and
insert the lifting sub.
(9) Using a bar or a cheater bar through the hole of the lifting sub, the Floormen screw
the lifting sub into the drill collar and tighten.
(10) At the Driller’s instruction, the Floormen latch the elevator around the lifting sub.
(11) If using a top drive, the Driller activates the linktilt toward the joint in the mouse
hole and the Floormen latch the elevator.
(12) The Driller engages the drawworks and lifts the drill collar up and out of the mouse
hole.
(13) The Floormen remove the drill collar pin protector and recover the drift.
the rotary table.
such as hole opener, mud motor, core barrel, etc.), and remove the rotary bushings if
necessary.
secured.
4.2.2. Laying Down DC with Air Tugger
(1) The Driller ensures that the air tugger capacity is within the Working Weight Limit of
the drill collar to be picked up.
(2) Break out the DC connection, install a pin protector with a lifting eye, and put DC in
the mouse hole, as described in paragraph 5.1.2. steps (2) through (7).
(3) A Floorman screws the lifting cap or sub into the box end of the drill collar and
attaches the air tugger line to the shackle inserted in the hole of cap or sub.
(4) The Air tugger Operator raises the drill collar until it is removed from the mouse
hole.
(5) The Floormen attach the catwalk winch to the shackle to the pin end.
(6) The Catwalk winch Operator pulls the pin end of the drill collar out the V-door as the
Air tugger Operator lowers the drill collar.
(7) The Air tugger Operator continues lowering as the Catwalk winch Operator pulls the
collar until the drill collar is resting on the catwalk.
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(8) The Floormen remove the winch line and the air tugger line from the pin and the box
protectors.
(9) The Floormen exchange the lifting protectors with ordinary protectors.
(10) Remove the drill collar from the catwalk before the next joint of drill collar is laid
down.
(11) Repeat steps (2) through (9) until all drill collars are laid down.
4.3. Handling Drill Collars with a Crane
4.3.1. Running In DC with a Crane
(1) The crane must be positioned where it can be well supported and give a safe and
level lift to the rig floor.
dopes the box and installs a protector.
(3) The Floormen attach and secure one crane line to the sling wrapped near the pin
end of the drill collar and attach a tag line.
(4) The Floormen attach and secure the other crane line to the sling wrapped near
the box end of the drill collar.
(5) Upon the Driller’s instruction, the Crane Operator carefully lifts the drill collar up and
into the V-door.
(6) While the Floormen, guide the drill collar onto the rig floor and the Floorman at the
catwalk holds the tag line, the Crane Operator then rests the drill collar safely on the rig
floor.
(7) The Floormen remove the box protector and insert the lifting sub and tighten.
(8) The Driller lowers the travelling block and elevator over the lifting sub, and upon his
signal, the Floormen latch the elevators.
(9) If using a top drive, the Driller activates the linktilt and the Floormen will latch the
elevators.
(10) The Floormen remove the crane sling and the tag line from the box end.
Note: Do not remove the crane sling from the pin end. Leave it on for added safety and
snubbing when DC is lifted with the travelling block.
(11) The Driller engages the drawworks and carefully raises the drill collar up, as the
Crane Operator snubs the pin end of the drill collar.
(12) After the drill collar has been raised to a vertical position, the Floormen remove the
pin protector, recover the drift and reinstall the protector.
(13) The Floormen remove the sling from the pin end of the drill collar.
(14) The Driller lowers the drill collar into the mouse hole where the lifting sub is
tightened using the rig tongs.
(15) The Driller then raises the drill collar out of the mouse hole and over to the rotary
table.
the rotary table.
such as hole opener, mud motor, core barrel, etc.), and remove the rotary bushings if
19
necessary.
secured.
4.3.2. Laying Down DC with Crane
(1) The crane is positioned where it can be well supported and give a safe and level lift
from the rig floor.
(2) Break out the DC connection, as described in paragraph 4.1.2. steps (2) through
(7). While DC is hanging from the elevators, install a pin protector and double wrap a
sling near the pin end of the drill collar.
(3) The Floormen attach the crane line to the sling and attach a tag line to the drill
collar.
(4) A Floorman, at the V-door, gives hand signals to both the Crane Operator and the
Driller.
(5) Upon the Driller’s “ready” signal, the Crane Operator pulls the pin end of the drill
collar out the V-door as the Driller lowers the elevators.
(6) The Driller continues to lower the elevators until the box end of the drill collar rests
at the V-door.
(7) The Floormen wrap the sling near the box end of the drill collar and attach the other
crane line.
(8) The Driller lowers the elevators and upon the Driller’s signal, the Floormen unlatch
the elevators.
(9) The Driller raises the travelling block and the elevators out of the way.
(10) The Floormen then remove the lifting sub and install a box protector.
(11) Upon the Driller’s instructions, the Crane Operator lifts and moves the drill collar
out the V-door and off the rig floor.
(12) The Crane Operator sets the drill collar on the pipe rack or at a suitable place to be
cleaned and inspected.
(13) Repeat the steps (2) through (12) until all the drill collars are laid down.
七. Making Connections While Drilling (Making a Connection)

Chain tong Stab-in guide
Drillpipe dope Torque gauge
Rig tongs Drift
Automated Roughneck Top drive (if applicable)
I.B.O.P. Kelly cock and Wrench
Proper size and type of Elevators and Slips Drillpipe screen
1. Nobody is allowed to stand between the mousehole and the joint in the rotary
20
table during these activities.

2. Floormen guiding drillpipe across the rig floor must keep feet well clear of
the pin end.
3. Do not stand behind the rig tongs while torque is being applied.
4. Hands must be kept clear of pin and box connections, while making
connections
3. OPERATIONAL DO'S AND DON'TS
(1) Ensure that all equipment to be used (tong dies, latches, tong lines, snub lines) are
in safe working condition.
(2) The Driller must record the length and serial number of each joint prior to the single
being picked up. The Floormen must clean and inspect the threads.
(3) Prior to making the connection, the kelly (or one stand, in case of top drive) should
be reamed down, unless specified in the Drilling Programme (e.g. Build section of
directional well)
(4) Both rig tongs or automated roughneck must be used to make up connections.
(5) The Driller must always maintain a clear and unobstructed view of the work area
during this operation.
(6) If the drillpipe single is new, follow the I.A.D.C. break-in procedure.
4. INSTRUCTIONS
4.1. Adding a Single with the Kelly
(1) The Driller lowers the string to connection depth and the Floormen set the slips.
Never set the slips on moving pipe.
(2) The Driller disengages the pumps and ensures that the pump pressure is bled
off. On the Driller's instruction, a Floorman closes the lower kelly cock.
(3) Break the connection using two rig tongs or automated roughneck.
(4) The Floormen remove the drillpipe screen, clean and insert into the single in the
mousehole and dope the box connection.
Note: If there is a strong back-flow, ensure the pin of the single being added is properly
doped.
(5) Also dope the kelly saver sub and pull kelly towards the single in the mousehole and
stab in.
(6) The Driller spins in the kelly using the kelly spinner or the Floormen use a chain tong
to "walk" it in.
(7) Using two rig tongs, make up the connection to its proper torque value. Ensure that
the tongs are at the proper angle.
(8) The Driller gives the instruction to open the kelly cock.
(9) The Driller picks up the kelly and the single out of the mouse hole
(10) The Floormen dope the pin and stab it into the string in the rotary table, using a
stab-in guide, (if applicable).
(11) The Driller, using the kelly spinner, spins in the single joint.
(12) The Floormen make up the connection to the required torque using two rig tongs.
(13) As the Driller picks up the string, the Floormen pull the slips and place them away
from the rotary table in their proper place.
(14) The Driller notes pick-up weight and establishes that the string is free.
(15) As the Driller raises the drillstring, he engages the pumps and ensures that
21
circulation is established and the pump pressure is correct.

(16) While the Driller lowers the drillstring, he notes the slack-off weight.
(17) After the kelly bushing is engaged with the rotary table, the Driller starts the rotary
and notes the rotating weight and torque of the drillstring.
(18) The Driller resumes drilling as per the Drilling Programme.
4.2. Adding a Single Joint or Stand with Top Drive
(1) The Driller lowers the drillstring to the connection depth and the Floormen set the
slips. Never set the slips on moving pipe.
(2) The Driller disengages the pumps and ensures the pump pressure is bled off.
(3) The Driller closes the inside BOP (I.B.O.P.) on the top drive, breaks out the
connection using the top drive pipe grabber and spinner.
(4) The Floormen remove the drillpipe screen, clean and place it into the screen
receptacle mounted on the top drive for the Derrickman at the monkeyboard.
(5) While the Driller raises the elevators to the monkeyboard, the Floormen check and
dope the box of the connection in the table.
Note: The box connection of the stand in the derrick will have been doped prior to being
set back.
(6) The Derrickman retrieves the drillpipe screen from the receptacle and inserts it into
the drillpipe stand.
(7) The Driller activates the linktilt as the Derrickman moves the stand of drillpipe into
the elevators (using the pipe handler where available), ensuring that the elevators are
shut and the safety latch is properly closed.
Note: If applicable, use the Tesco Top Drive automatic elevator.
(8) The Driller, engages the drawworks and raises the drillpipe stand, as the Floormen
guide the stand over to the rotary table, using a tail rope.
(9) The Driller retracts the linktilt, lowers the stand, the Floormen dope the pin and stab
it into the joint in the rotary table, using a stab-in guide (if applicable).
(10) The Floormen latch the back-up tong on the joint in the rotary table.
(11) The Driller lowers and stabs the saver sub into the box of the uppermost
connection.
(12) The Driller, if using the Tesco Top Drive, utilises the top drive spinner and pipe
grabber to make up the top connection.
(13) The Driller releases the pipe grabber and spins in the connection at the rotary
table.
(14) The Floormen then install the makeup tong on the connection and the Driller
torques the connection to its specified torque.
(15) The Floormen unlatch the rig tongs, close the jaws and hang them back.
Note: If the rig is equipped with a Varco top drive:
(a) The Floormen place the backup tong on the bottom tool joint,
(b) The Driller lowers the saver sub into the drillpipe stand and makes up the top and
bottom connections (at the same time) to their proper torque.
(16) As the Driller raises the drillstring, he notes the pick-up weight and establishes that
the string is free. The Floormen pull the slips and place them well clear in their proper
place, at a safe distance from the rotary table.
(17) The Driller opens the I.B.O.P., commences rotation and then engages the pumps
22
and ensures that circulation is established and that the pump pressure is correct.
(18) Before lowering the drillstring, the Driller notes the rotating weight and torque of the
string.
(19) While the Driller lowers the string, he notes the rotating slack-off weight.
(20) The Driller then resumes drilling as per the Drilling Programme.
(1) If the drillpipe single is brand new, the I.A.D.C. break-in procedure should be
followed.
(2) Upon the Toolpusher’s instructions, if downhole problems are likely (differential
sticking, hole sloughing), the string in the slips must be continuously rotated at slow
speed, except for actually breaking and making the connection.
八. Tripping
Bit breaker Mud box
Tong jaws (DP / DC) 6 metre x 1/2 inch Manila rope
Inside BOP (Gray valve or equivalent) Kelly cock and Wrench
2-metre Measuring stick Insert bushing lifting set
Hand / Auto-slips (DP / DC) Pipe wipers
Elevators and balance strap (DP / DC) Chain tong
Non-slip Floor matting Thread dope and Brushes (DP / DC)
Pipe spinner Trip tank monitor
Automated Roughneck Top Drive
Safety clamps
Hand tools to change out DP / DC elevators and tong jaws
Cross-over for all drill string and BHA component thread types
1. Before opening the blind rams, the Driller shall ensure that any pressure
below the blind rams, is bled off through the choke line and the choke
manifold.
personnel (green hard hats) working on the drill floor.
3. The mouse hole must be kept covered at all times when not in use.
4. Although the majority of kicks are taken while pulling the drill string from the
hole, it is also possible for kicks to occur while tripping in.
5. Ensure the trip tank is never filled 100% when POOH in order to detect an
influx.
(1) Hold a Toolbox Talk before starting the trip. Ensure that rig crew is fully instructed
on correct work procedures and the safety precautions to be observed.
(2) The trip tank must be run continuously over the hole to monitor the volume of mud
taken by the hole or displaced on all trips.
(3) The Driller must always perform a 15 minute fluid level / flow check before pumping
the weighted slug to pull out of hole. Another 15 minute fluid level / flow check will be
made when the bit is inside the shoe of the last casing set.
(4) If hydrocarbon bearing zones are exposed, perform an additional 15 minute fluid
23
level / flow check prior to pulling the BHA from the hole. Refer to the Drilling
Programme for special procedures.
(5) The Driller is to trip off bottom and out of the hole at a speed that will not cause
swabbing. Tripping into the hole will be at a rate that will not cause excessive surge
pressure. Check the Drilling Programme for specifics.
(6) Install the drillpipe wipers when the Driller is satisfied with the condition of the hole
and that swabbing is not taking place or when the bit is inside the casing.
Note: It may be necessary for the Driller to visually monitor the mud level in the hole, or
to run in to the bottom of the hole at short notice. Until drillpipe wipers are installed, a
tie-back rubber can be used to wipe the pipe.
(7) Auto-slips may be installed at the Driller’s discretion when there is sufficient hanging
weight to prevent accidental opening.
(8) It is the Derrickman's responsibility to ensure that all tubulars, fixtures and fittings
are secure in the derrick at all times. In particular, before leaving the mast he must
ensure that all tubulars are secured with good quality rope or chain.
(9) The Driller must log on the trip sheet, and record in the tour book:
(a) any over-pulls and the depth interval while pulling out of hole,
(b) the taking of weight and / or reaming of bridges while tripping in the hole, and
(c) back reaming, excess drag, ledges, washing, and other unusual parameters.
(10) Drills for kick control procedures (Kick Drills), when required, will be performed with
the drill string inside the casing shoe.
(11) If flow is encountered while tripping,
(a) stab in the kelly cock or Inside BOP, in the open position, and make up with proper
torque.
(b) Close in well and prepare kelly for well control procedures.
Note: If rig is equipped with a top drive, stab in and make up the top drive to the
required torque.
(12) All damaged or unusable tubulars and materials identified during the trip will be
clearly marked, reported and laid down.
4. INSTRUCTIONS
4.1. General Pre-trip Check List
(1) Ensure correct jaws are installed in the rotary tongs and the automated roughneck.
(2) Ensure that the required rig service and equipment service is performed before
starting out or in the hole.
(3) Ensure that all elevators, slips and tongs are checked for worn hinge pins, dies, and
other defects and the elevators are secured with safety pins.
(4) Ensure that all tools and equipment are in their proper places in a clean and
serviceable condition and no loose equipment or parts can fall in the hole.
(5) Ensure that the rig floor is clean and free of obstruction. Use adequate non-slip floor
matting to provide safe footing.
(6) Ensure pertinent ton-mile calculations are made for the drilling line. If required, cut
the drilling line with the bit inside the last set casing shoe.
(7) Ensure the BOP test schedule is checked and prepared for as per regulations and
the Drilling Programme.
(8) Ensure BHA and tubular inspection schedule is checked and planned for in the
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tripping schedules.
(9) Ensure the trip tank is lined up and recording instruments, (including gas detector)
are operating properly in order for the Driller to monitor and record displacement and
replacement of fluid volumes to the hole.
(10) Ensure the Gray valve (or equivalent), the kelly cock, and the Inside BOP are in
open position and, readily available on the rig floor. All of them should be dressed with
correct crossover corresponding to the threaded box in the rotary table.
(11) Ensure drawworks brakes are adjusted, drawworks powertrain controls and
switches are operating correctly.
(12) Ensure that the ACS and/or the Crown-O-Matic safety device is tested and
operating properly.
(13) Ensure that the Eddy Current brake is permanently engaged at all times during
tripping operations.
(14) Ensure that escape routes (doors, stairs, etc.) are accessible at all times and are
not obstructed by hoses, tools and other objects.
(15) Ensure that alternate "stand breaks" are performed on each trip to make sure that
all tool joint threads and connections are broken and made once every three trips.
(16) Ensure that the mud processing equipment is secured for tripping. Prepare the
valves for monitoring fluid levels in the active surface mud system.
(17) Ensure that a BOP stack diagram is posted marking the position and size of the
pipe rams.
(18) Ensure the correct hole covers for the required pipe size are available.
4.2. Tripping out of Hole
Note: The Toolpusher / Night Toolpusher is to be present on the rig floor while the first
10 stands of drillpipe are pulled and until the tripping operation is judged to be in a
normal routine.
The Toolpusher / Night Toolpusher is also to be present on the rig floor whenever any
bottom hole assembly (including HWDP) components are being handled.
(1) Prepare rig and floor for tripping, measure out the kelly (or stand in case of a Top
Drive system) to determine the bit depth.
(2) The Driller must perform a flow-check for 15 minutes and ensure the hole is static,
prior to starting to pull out of the hole.
(3) Check pipe tally to determine the number of singles to lay down for rotation of "stand
breaks" and to allow washing back to bottom.
(4) Prepare the weighted slug pill, to pump after the first 10 stands or when the hole is
static.
(5) Drain, clean and fill trip tank to 75% capacity with mud from active tanks. Check
calibration and line up valves, pumps and recording mechanisms.
Note: A full trip tank will not allow gains to be measured accurately.
(6) Turn the elevators so they point at the Derrickman and the set back area. If not
using a top drive, the hook is to be unlocked while the pipe is in the open hole.
(7) With the drillpipe in the slips, the Driller and the Floormen break off the kelly, drain
and set back in the rat hole.
(8) If top drive is installed, the top connection is broken first, with the top drive torque
wrench and spinner. If the string is wet first break out the bottom connection using the
25
mud bucket.
(9) As the Driller picks up on the drillstring with the elevators, the Floormen will pull the
slips and place at a safe distance from the rotary. As the Driller continues to raise the
string, the Floormen will commence to wipe the pipe.
(10) While raising the drillstring, the Driller must observe the weight indicator for
overpull at all times and monitor the trip tank for swabbing and well flow indications.
(11) The Driller applies the drawworks brake and stops the string when the elevators
are past the fingerboard and within the reach of the Derrickman.
(12) The Derrickman loops the pull-back rope around the stand.
(13) The Floormen set the slips on the Driller’s signal, never while pipe is in motion.
(14) When the Floormen have engaged both the breakout and the backup tongs,
ensuring the automated roughneck is fully retracted, the Driller will break the
connection, noting the breakout torque. The automated roughneck will be utilized to
break the connection, if available.
Note: Rotary shouldered drillstring connections are designed to breakout at 90% to
100% of the make-up torque. If excess break-out torque is encountered, the Driller is to
record the stand and connection in the trip sheet.
(15) The Floormen will remove the rig tongs, attach the spinning wrench to the stand in
the elevators, and spin out from the connection in the slips. If applicable, the automated
roughneck will spin out the connection after breaking it.
(16) The Floormen will remove and secure the spinning wrench (or retract the
automated roughneck).
(17) The Floormen will swing and close the mud box around the connection, if the pipe
is being pulled wet.
(18) The Driller raises the stand out of the string and sets the drawworks brake.
(19) The Floormen unlatch and remove the mud box (if used) after the mud has
drained, pulling it back to be secured out of the way.
(20) While the Driller slowly lowers the travelling block, the Floormen push the bottom of
the stand over to the setback area.
(21) The Driller lowers the stand onto the setback area as the Floormen position the pin
in the proper spot. One Floorman will number the stand with chalk.
(22) The Driller continues to lower the travelling block until the elevators disengage the
top tool joint.
(23) At this instant, the Derrickman opens the elevators and pulls back the stand to rack
in the fingerboard, (if using a top drive, the Driller will activate the linktilt to assist the
Derrickman).
(24) The Driller ensures that the Derrickman has removed the top of the stand and then
retracts the linktilt (with a top drive) so that the elevators will not collide with the
fingerboard.
(25) The Driller lowers the elevators down to the rig floor while one Floorman applies
pipe dope to the thread and shoulder of the tool joint in the rotary.
(26) The Floormen are to pull the elevators away from the top of the joint in the rotary,
and then close the elevators around the pipe.
(27) The operation is then repeated from steps (9) through (26) until the last stand of
drillpipe above the HWDP. Visually check the drillpipe hardbanding for wear.
26
(28) Pull and break out the HWDP, following steps (9) through (25). The Floormen, if
needed, use the air tugger winch to pull back the stands to the set back area. Remove
the drillpipe wiper and flow check the well before the BHA enters the BOP.
(29) After pulling the last stand of HWDP, the Floormen will switch to drill collar slips
and jaws and attach safety clamp on the drill collar at the rotary table.
(30) The Floormen will then break out the crossover connection using the rig tongs with
drill collar jaws. After the last stand of HWDP is set back, the Floormen will change the
elevators, slips and pipe dope from drillpipe to drill collar type.
Note: Always use the safety clamp on drill collars and BHA components. Always install
and secure the safety clamp before opening the elevator.
Note: Always reset the ACS and/or the Crown-O-Matic after having set back an
extratall stand.
(31) If necessary, remove the rotary table bushings to allow the stabilisers, reamers or
the bit to pass through the rotary table.
(32) Balled-up stabilisers and / or reamers are to be cleaned, calipered and gauged.
(33) If using 9 inch or larger drill collars or if over torqued drill collar connections are
encountered, pick up size DD rig tongs. Use a double line to break out the connection.
Walk out the connection with chain tongs.
Note: Spiral drill collars are not to be broken or made up with the automated roughneck
as not to overload the bearings of the rollers.
(34) The lifting subs of the drill collars must be torqued up to proper torque.
(35) If there are jars in the string, install its safety collars before setting them back.
(36) The Driller is to ensure that the hole is full when the bit is out of the hole and then
close the blind (shear) rams and that the wellbore is covered.
(37) Remove the bit using the proper bit breaker. The bit is then gauged and graded.
(38) Remove survey tool, check Totco ring (crows foot), inspect, clean and replace as
per requirements.
(39) Check and ensure that the number of stands is correct and corresponds with the
pipe tally.
4.3. Tripping in the Hole
Note: The Toolpusher/NTP is to be present on the rig floor while the bit and bottom hole
assembly (including HWDP) components are being handled.
The Toolpusher/NTP is also to be present on the rig floor for the last 5 stands before
reaching total depth and the break-in of the bit.
(1) Prepare the rig and the rig floor for tripping in hole. Review Pre-Trip check list. Line
up the trip (tank to receive all returns from pipe displacement).
(2) Function test the downhole tools as per the Drilling Programme if applicable.
(3) Dress the bit with correct size nozzles, as per the Drilling Programme.
(4) With the elevators pointing at the setback area and the first stand of collars hanging
from the blocks, make up the bit, using the proper bit breaker. The rotary bushings are
removed as required to allow BHA components to pass through.
(5) The Driller will open the choke line and bleed any built up pressure through the
choke manifold, before opening the blind / shear rams. When the rams are opened, re-
align the choke manifold for soft or hard shut-in procedures as specified in the Drilling
Programme.
27
(6) The Driller cautiously lowers the bit, first drill collar stand and stabilisers through the
BOP stack to prevent damage to BHA or the BOP equipment.
(7) The Floormen replace the bushings, set the slips, and install and secure the safety
clamp.
(8) The Derrickman readies the next stand, utilising the collar winch and the pull back
rope.
(9) The Floormen unlatch the elevators and hold them away from the joint in the table.
The Driller raises the elevators up to the Derrickman level and engages the linktilt, if
using a top drive.
(10) The Floormen remove the lifting sub, visually inspect the shoulder and threads.
The proper drill collar thread dope is then re-applied to the box.
(11) The Derrickman sets the stand into the elevators and closes same.
(12) The Driller picks up the stand off the set back area.
(13) The Floormen guide and tail the drill collar stand over to the table with a rope or air
tugger, the Driller retracts the linktilt, if applicable.
(14) The Floormen stab the stand into the connection at the rotary and make up the
connection with the automated roughneck or the rig tongs to the correct torque.
(15) The Floormen remove and secure the tongs or retract the automated roughneck.
(16) The Floormen remove the safety clamp.
(17) As the Driller raises the drill string, the Floormen remove the slips and place at a
safe distance from the rotary.
(18) The Driller slowly lowers the string into the hole.
(19) On the Driller’s signal, the Floormen reset the slips, install and secure the safety
clamp.
(20) The Floormen attach the rig tongs and brake the lift sub connection.
(21) The Floormen unlatch the elevators and hold them away from the joint in the
rotary. The Driller raises the blocks to the Derrickman level and engages the linktilt, if
installed.
(22) Repeat steps (10) through (21) until all the drill collars are in the hole. The Driller
is to check the weight indicator and record the weight of the BHA.
Note: While handling the jars at the rig floor, the Driller is to ensure that jar safety collar
is always installed until the jars are run in the hole. After the jars are made up, the
Driller is to note the weight of the BHA above and below the jars and record in the tour
book.
(23) The Floormen change out elevators, tong jaws and slips for the HWDP. Change
out thread dope as specified for each different type thread or joint requirements.
(24) Continue running in with the HWDP. When all the HWDP is in the hole, the Driller
is to check the weight indicator and record the weight of the total BHA.
(25) The Driller continues running in the hole with the drillpipe while observing the
weight indicator for any tight spots or bridges.
(26) Proceed running in with drillpipe until the last two singles or where mud circulation
is required. Pick up kelly or make up top drive and set pump stroke counter. Prepare
surface mud system for mud processing.
(27) The Driller initiates upward pipe motion or pipe rotation when breaking circulation.
The Driller is to record pump pressure and ensure that full returns are received at the
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flow line. Wash down the last two singles, or as hole conditions dictate.
(28) Tag and wash bottom of hole before applying weight on bit or rotating on bottom.
The Driller is to check and update the pipe tally.
(29) The Floormen clean the rig floor, check pipe, lubricate equipment as per
requirements and prepare to drill new hole as per the Drilling Programme.
九. Trip Tank and Fill-Up Line Operations

Hammer unions 36” Pipe wrench
24” Wrench Pipe valves
Hammer
1. To prevent or detect kicks at an early stage, the trip tank shall be used and
monitored continuously when tripping in and out of hole. Transfers of mud in
and out of the trip tank shall be immediately reported to the Driller.
2. Due to kick control considerations ensure that returns / flow is routed
directly to the trip tank.
(1) Ensure the pump, lines and valves in the fill line systems are free of dry mud, solids
or ice. Check for any settled barite or debris which would hinder the operation of the
valves, trip tank sensors or recording mechanisms.
(2) Ensure that the suction filter of the trip tank pump is clean.
(3) Check all connections, lines, valves, tanks and pumps for leaks.
(4) Ensure the control switch, centrifugal pump and sensors are operating correctly.
(5) Instruct all crew members in the use of and purpose of the trip tank, components
and monitoring system. (Refer to Figure 1 for a typical trip tank setup)
(6) Ensure that all mud monitoring devices are calibrated.
(7) Mud / fluid capacity of trip tanks is recommended to be 6 to 15 m3.
4. INSTRUCTIONS
4.1. Pulling Out of Hole
(1) Set up the valves on the flow line to direct return flow to the trip tank.
(2) Open the discharge valve of the trip tank fill-up pump.
(3) Close the dump line valve to the flow line.
(4) Set up the valves on the hole fill up line so that the hole fill-up pump will circulate
over the hole continuously.
(5) Line up the standpipe manifold to fill the trip tank periodically.
(6) Check that the mud treatment equipment has been switched off unless mud
processing is being performed under surveillance / supervision.
4.2. Running in the Hole
(1) Set up the valves on the flow line to direct returns to the trip tank.
(2) Set up the valves on the hole fill up line so that the hole fill-up pump will empty the
trip tank back to the active pits when required.
(3) Check that the mud treatment equipment has been switched off unless the returns
are routed over the shale shaker and the system is under surveillance.
Note: Check the displacement volume and capacity of tanks if mud mixed, treated or
added during trip and record on the chart.
29
壱零. Removal and Installation of Rotary Bushings

Lifting frame and Hooks Safety cage
Proper size Adapter for installing 20 inch bushings
1. Ensure that the rig floor is clean and free of obstruction. Use adequate floor
matting to provide safe footing.
2. Watch that the winch line does not become entangled in the derrick, on the
blocks or on the elevators.
3. Do not raise the bushing higher than necessary to safely clear the surface of
the rotary and the floor. A bushing that swings out of control or falls over
could crush a foot.
3. STANDARD OPERATIONAL CONSIDERATIONS (DO´S AND DON'TS)
(1) If the drill string is in the hole it must be kept stationary while removing or replacing
split or hinged type bushings.
(2) Block and elevators must be raised high enough to give safe clearance for the lifting,
swinging and moving of the winch line load.
(3) Ensure that the Floormen have no articles in their pockets that can fall into the hole.
(4) The rig floor must be kept clear of any object that could fall into hole.
(5) Visually inspect the lifting tools such as winch, winch line, lifting frame, and hooks.
(6) If there is no drillstring in the hole and the master bushings have been removed,
install a safety cage in the rotary.
4. INSTRUCTIONS
4.1. Removing the Inner Bushings (Inserts)
(1) Attach the winch line to the lifting frame for the bushings by inserting the lifting frame
hooks into the openings in the bushing or bushing segment.
(2) Winch up the inner bushing high enough to clear the table. Guide the bushing from
the rotary table to the drill floor and set down carefully in an upright position.
(3) If the rotary table is equipped with a split or two-piece bushing, remove the second
bushing segment in a similar manner.
Note: If the drillstring is not centred in the rotary table, removing or replacing split
bushings may require the rotation of the table up to 180 degrees.
4.2. Removing the Master Bushings
(1) Remove the inner bushings as described in paragraph 4.1.
Note: Ensure the inner bushings are locked before removal.
(2) Place the lifting hooks in the slots provided.
Note: Remove the pin on hinge type bushings
(3) Lift the bushing in one piece if it is solid or hinged. Each section must be picked up
individually if it is the split type (two-piece).
(4) Winch up the master bushing high enough to clear the table. Guide the bushing from
the rotary table to the drill floor and set down carefully.
4.3. Installing 20 Inch Bushings
(1) To prepare for running large size casing, pull the drillstring out of the hole.
(2) Remove the inner and master bushings as described in paragraphs 4.1 and 4.2.
(3) Lower the adapter into the rotary table opening and set in place using the winch.
30
Note: Be aware that a 20 inch split type bushing can fall through the rotary table if not
properly lifted.
(4) Pick up and place the 20 inch bushing in the adapter using the winch line.
壱壱. Maintenance of Elevators and Slips, Changing Slip Dies and

Tong Dies
Hammer and Chisel Tong dies and Drift
Slip dies and Drift Calliper to measure ID
Die retaining pins Die removal tool
Safety goggles Split safety pins
Wire brush Pliers
Grease Face shields
1. Protective clothing, especially safety goggles or a face shield must be worn
during these operations
2. Only remove your safety gloves when it is unavoidable, only. To install the
locking split pins.
3. Ensure that the working area is clean and clear of obstruction.
4. All tools must be clean and in a serviceable condition.
(1) The tongs and slips are to be visually inspected and serviced every tour and after
every trip.
(2) Never work close to the hole where something might fall in.
(3) Always use correct size tools to change out slip and tong dies. Never use only a
hammer to change out tog dies, always use a die driver.
(4) Ensure correct size dies are being installed in slips and tongs and that there are
enough in stock.
(5) Check that certificates and or test reports are supplied with any rental tools.
(6) When changing dies, if one set is worn, replace all of them.
(7) Ensure that the work area is tidy, check if there is any interference with other work
performed at the same time
4. INSTRUCTIONS
4.1. Elevator Maintenance
(1) Using the air hoist, the Floormen set the elevators at a safe distance from the hole.
(2) Clean the elevators thoroughly of dirt and grease.
(3) Check the spring tension on the latch and latch lock.
Note: Do not dismantle the latch mechanism if it does not function after lubrication.
Take the elevator out of service.
(4) Check for excessive wear on the latch, latch spring, latch lock and latch pin.
(5) Check for excessive wear on the door catch and hinge pin.
(6) Examine the body for wear, visual cracks and evidence of misuse
(7) Measure the minimum internal diameter (ID) of the elevators for wear using the ID
calliper and check against the API specifications.
(8) Grease the elevators, paying particular attention to the hinge pin and latch
assembly.
31
Note: If excessive amount of play is observed after greasing the hinge pin and latch
assembly, the elevator must be taken out of service.
(9) Ensure that the elevators are properly marked for ease of identification with size and
ID number.
4.2. Slip Maintenance and Changing Slip Dies
(1) The Floormen set the slips at a safe distance from the hole.
(2) Clean the slips thoroughly of dirt and grease.
(3) Examine the slip body for cracks, wear and evidence of misuse.
(4) Examine the handles and handle retaining pins for cracks and evidence of misuse,
ensuring that the retaining pins have split safety pins.
(5) Check the slip die segments for wear. Change out the slip dies if wear on the facing
exceeds 50 percent of the original (perform a slip test using test paper if in doubt).
(6) If the slips are in good condition stop here.
(7) If the slip dies to be replaced, take the slips to the workshop and remove the hinge
pins that separates each slip segment, paying particular attention to the ID number of
each slip segment.
(8) Secure one slip segment and remove the split safety pins and the die retaining pins
(or ring).
(9) Using the die removal tool and a hammer, remove each die, in turn, by striking the
tool solidly with the hammer.
(10) Clean the die channel and inspect for cracks or damage. Apply a thin film of
grease.
(11) Ensure that the slip die segments are the correct size and make of the slip being
used, fit new dies into slip segment. The new slip dies should slide into position with
little resistance.
(12) Fit new retaining pins (or replace the retaining ring) and secure with new spilt
safety pins.
(13) Repeat the steps (8) through (12) for each slip segment.
(14) After each slip segment has newly replaced slip die segments installed, refit the
slip segment hinge pins and secure with new safety split pins.
(15) Grease the hinge components and coat the backs with good quality lubricant.
4.3. Maintenance of Rig Tongs And Changing out Tong Dies
(1) The rig tongs are to be kept clean at all times and kept well lubricated.
(2) The rig tong counter-balance line should be inspected at a regular interval.
(3) Rig tong counter-balance should be kept at a weight where one man can move rig
tong up and down with minimal effort.
(4) The rig tongs should be hanging level at all times.
(5) The rig tongs hinge pin, latch lock and springs must be inspected at regular intervals
and changed out if excessive wear is encountered.
(6) When changing out tong dies, the tongs are to be tied back well away from the
rotary table and secured.
(7) Remove tong die retaining equipment, (bolts or pins).
Note: For safety reasons, except for the person striking the die driver, all personnel
should keep a safe distance in case the tong die splinters.
(8) Remove the tong die with a tong die driver and a hammer by striking downward on
32
the channel.
Note: It is better to hold the die driver with a pair of pliers when striking with the
hammer.
(9) Install new tong dies and replace the retaining bolts and safety pins.
壱弐. Use and Inspection of Mud Box / Mud Saver

Reinforced fabric or rubber Hose Mud box and Drain hose
Rubber gasket material Hammer and Chisels
Files and Grinder Safety goggles
Wrenches Pliers
1. Improperly functioning mud box can expose personnel to hot mud,
hazardous slippery floor and potentially harmful drilling fluid chemicals.
2. Maintenance must be carried out in a safe area off the rig floor.
3. Eye protection must be used when using hand tools.
(1) Ensure that the mud box is tied back and safely out of the way or removed from the
work area, when not being used.
(2) Remove drain line hose or tie hose to box when not in use, for personnel safety and
to prevent damage to the drain hose.
(3) Ensure that the hang off or suspension line is directly above the mud box tie back
area.
(4) If mud box is suspended from a winch line ensure that the line does not become
entangled with blocks, hook or elevators.
(5) Ensure the mud box rubbers are greased periodically to keep them from drying out
and cracking.
(6) Ensure that any personnel doing any repair, replacement, hammering, chiselling,
grinding or filing has protective safety equipment.
(7) Ensure the Mud Box drain line contains and discharges the captured mud back into
the mud processing / containment system.
4. INSTRUCTIONS
4.1. Use of Mud Box / Mud Saver
(1) Attach the winch line to the mud box and release the tie back.
(2) Attach the drain hose and clamp it on the mud box or release the hose if it is already
attached.
(3) Insert and fasten the other end of the drain hose into the mud drain line. Now the
mud box is ready to use.
(4) The Driller breaks connection and backs off the pipe with the kelly spinner or the
Floormen spin out the pipe using the spinning wrench.
(5) The Floorman operating the winch raises the mud box while the other Floorman
guides the mud box toward the rotary table ensuring that the winch wire is free.
(6) The Floorman opens the clamp-seal latch and positions the mud box around the
drillpipe connection and closes the latch.
(7) The Driller picks up the stand just enough for mud to drain from the stand and sets
brake and waits.
33
(8) The Floormen wait until the mud is drained from the mud box, through the drain
hose before releasing clamp-seal latch.
(9) The Floorman guides the mud box out of the work area and ties it back, safely out of
the way.
(10) The Driller picks up the stand and the Floormen guide and set the stand back on
the mat.
(11) Remove any mud leakage from the rotary table with a rubber squeegee to avoid
slipping.
(12) Disconnect mud box and drain line hose and clean when finished.
4.2. Inspection of Mud Box
(1) Visually inspect the mud box after each use (tripping wet pipe).
(2) Check for the installation of the proper size gaskets for the drill pipe in use.
(3) Check mud box for upper and lower drill pipe sealing when the box is closed. Adjust
or replace defective seal gaskets.
(4) Compression or lap seal gaskets are to give an effective seal of the mud box on
closure (when latched), replace if defective.
(5) Check for proper hinge alignment. Adjust or replace the hinge, clean and lubricate.
(6) Check clamp-seal latch mechanism. Function test and adjust, then clean and
lubricate.
壱参. Rigging and Testing of Chiksan Swivel Joints and Steel Hoses
5/8 inch safety line Martin Decker Recorder
Rubber ring seal Grease
Hazard tape Wire brush
Shackles Sledge hammer
Pump truck or High Pressure Test Pump
1. Check the pressure rating / working pressure and the last test dates of each
of the Chiksan sections, ensuring that they have been tested in the last 360
days. Refer to the COMPASS System for annual certification requirements.
2. Check for correct thread engagement and interface when making up the
hammer union connections of the Chiksan sections.
3. Ensure that the sections (swings and attachments) all have a valid test band
and serial number.
4. Ensure that no one is in the vicinity of lines, manifolds, etc. when they are
under (high) pressure.
5. Check and ensure that all sections are fitted with a standard 5/8 inch safety
wire line or equivalent safety chain with current colour safety code.
6. Do not attempt to tighten or loosen a Weco hammer union if it is under
pressure.
7. The test area shall be marked off with hazard tape.
8. For H2S applications, ensure that H2S is stamped on the test band,
identifying it as H2S suitable.
9. When testing temporary piping, ensure that the pressure is applied slowly
and in stages.
34
10. Do not attempt to break out frozen Chiksan high pressure swing joints or
tubing. Wait until pressure has been relieved and the joint has thawed out.
11. Do not use piping with improperly fitted couplings. Ensure that the couplings
are integral welded.
(1) A Toolbox Talk shall be held with all personnel involved before this operation
commences.
(2) The Driller must verify that the Chiksan swivel joints and lines are the proper type for
the intended use, inspected by independent company prior to use and have valid test
certificates.
(3) The Driller must ensure that the Chiksan sections are rigged up properly, are kept
as short as possible and flushed with water prior to testing.
(4) Each Chiksan must be banded and have a serial number to allow tracing to the
certificate of conformity.
(5) Check and ensure that the correct rubber ring is fitted in the threaded section of the
Weco hammer union and that it is in good condition.
(6) Clean all joint threads with a steel brush and inspect threads for damage.
(7) Grease all joints and threads.
(8) After laying out all swings, ensure that escape routes and walkways are completely
free of obstructions.
Note: It is preferable to place wooden seals or blocks underneath the test line to help
brace the line.
(9) Ensure that there is a properly fitted 5/8 inch safety line on each of the Chiksan
sections and that each section has current colour coding.
(10) Inspect the swivels to ensure that the ball-plugs and the snap rings are in place
and are correctly fitted.
(11) Ensure that the unions are not bearing the whole weight of the temporary piping.
(12) Before any pressure is applied to the Chiksan lines, visually inspect the rig-up and
ensure that movement of the line has been considered and accommodated for.
4. INSTRUCTIONS
4.1. Rig Up of Chiksan Swivel Joints and Steel Hose Sections
(1) Ensure that the connections and type of chiksan are the same, and are cleaned
and greased.
(2) Lay out the tubing sections for the job.
(3) Manually screw the coupling nut of the swing onto the threaded section of the
following swing as tightly as possible.
(4) Tighten the hammer union coupling using a sledge hammer.
(5) Connect the entire line system.
(6) Attach all safety tie down lines or chains. Ensure that they are secure.
4.2. Pressure Test Chiksan High Pressure Hoses
4.2.1. Testing with Pump Truck
(1) Lay out the Chiksan lines from the pump truck to the kill line of the BOP.
(2) Attach and secure the Chiksan line and the Martin-Decker High Pressure Recorder
to the circulating T at the pump truck manifold.
(3) Attach and secure the Lo-Torque valve (open position) at the end of the Chiksan
35
line.
(4) Connect and tighten the remaining Chiksan sections, ensuring that the safety lines
are secured at a secured point.
(5) The pump truck Operator fills the Chiksan line with water or mud, ensuring that all
air is removed.
(6) Close the Lo-Torque valve at the end of the chiksan line.
(7) Instruct the pump truck Operator to slowly bring the pressure up to 69 bars (1000
psi.) and stop.
(8) Inspect the line for leaks and check the pressure recorder operation.
(9) If there are no leaks, continue to bring the pressure up slowly until the
predetermined test pressure is achieved.
(10) Hold and record the pressure for minimum of 15 minutes.
(11) If the test and recording is satisfactory, slowly release the pressured fluid back to
the pump truck.
4.2.2. Testing with the High Pressure Test Pump
(1) Connect the High Pressure Test Pump to the rig pump manifold.
(2) Attach the Martin Decker High Pressure Recorder to the circulating T at the High
Pressure Test pump.
(3) Lay out the specified number of Chiksan lines from the rig pump, securing each
section with a safety line to a secured point.
(4) Attach and secure the Lo-Torque valve (open position) to the end of the Chiksan
line.
(5) Use the rig pump and pump through the lines from the pump manifold to the Lo-
Torque valve, ensuring that all air is removed.
(6) Close the Lo-Torque valve.
(7) Using the rig pump, slowly pump into line until pressure increases to 69 bars (1000
psi.)
(8) Inspect the line for leaks and check the operation of the recorder.
(9) Use the High Pressure Test Pump and pump up the pressure slowly to the
predetermined test pressure.
(10) Hold and record the pressure for minimum of 15 minutes.
(11) If the test and recording is satisfactory, release the pressure slowly at the High
Pressure Test Pump or the Lo-Torque valve.
壱四. Operations with Top Drive Systems

Automated roughneck Top drive system
Dope and brush Drillpipe screen (if applicable)
Rig tongs Mud box
Slips
1. Stands shall not be made up in the mousehole with top drive while drilling.
2. Maximum break out torque of the torque wrench is top drive specific. Check
the technical manual of your top drive.
3. Ensure that all hoses of the top drive system are secured with a safety line or
chain.
36

(1) The top drive (TD) is to be operated only by the Driller or the Assistant Driller.
(2) The TD is to be maintained and serviced at manufacturer’s prescribed intervals.
(3) When installing safety valve and the saver sub, special attention must be given to
lengths. Distance between rotating shaft and the elevators is 91 cm (3 ft).
(4) Before running casing, the short elevator links must be changed out for the longer
ones.
(5) While operating the TD, check the hydraulic unit on general performance, oil
pressure and check for any leakage.
(6) Before applying torque on connections, the torque limit switch must be turned back
to zero.
(7) Tong dies must be changed out regularly.
(8) A drillpipe wiper must be used at all times to prevent objects falling into the wellbore.
4. INSTRUCTIONS
4.1. Make Up of a Stand of Drillpipe During Drilling
(1) The previously added stand is drilled down until the TD is at the correct height, just
above the drill floor.
Note: During some drilling operations, the Driller may pick up the full stand and ream
the stand back to bottom, as per the Drilling Programme.
(2) The Driller picks up the string.
Note: If hole problems dictate, the Driller may rotate the drillstring as he picks up the
drillstring.
(3) The Driller lowers the string to the connection depth and upon the Driller’s
instruction, the Floormen set the slips.
Note: Never set the slips on moving or rotating pipe.
(4) The Driller disengages the pump.
(5) After ensuring that the pump pressure is bled off, the Driller closes the I.B.O.P. on
the TD and breaks the saver sub connection using the TD system torque wrench.
(6) The Driller, using the rotating head, spins out the connection.
(7) If applicable, a Floorman removes the drillpipe screen, cleans and puts it in the
drillpipe screen ring or basket mounted on the TD.
(8) A Floorman applies dope to the saver sub pin.
(9) The Driller, engages the drawworks and raises the elevators of the TD to the finger
board.
(10) The Derrickman, utilising a safety belt, retrieves the drillpipe screen and installs it
in the stand of drillpipe.
(11) The Driller activates the linktilt and the Derrickman moves the stand into the
elevators and latches (using the pipe handler where available). The Derrickman
ensures that the safety latch is properly closed.
Note: The Driller should be watching this procedure with the help of a camera on the
monkey board and a monitor in the driller's console.
(12) The Driller retracts the linktilt and picks up the stand while the Floormen guide it
over to the rotary table.
(13) The Driller lowers the stand, the pin is doped and two Floormen stab it into the joint
in the rotary table.
37
(14) The Floormen latch the break out tong onto the box end of the joint in the table.
(15) The Driller, (with the aid of the monitor), lowers the saver sub into the box of the
stand in the slips and makes up both the top and the bottom connections to full make-
up torque.
(16) The Driller uses the TD brake to release the torque in the stand in a controlled
manner.
(17) The Floormen unlatch the break out tong.
(18) The Driller raises the string to allow the Floormen to pull the slips. The Driller notes
the pick-up weight and establishes that the string is free.
(19) The Driller commences rotation, opens the I.B.O.P., and then engages the pumps
and ensures that circulation is established.
(20) The Driller, after checking that the pump pressure is correct, lowers the string and
resumes drilling as per the Drilling Programme.
4.2. Make Up of Single Joint While Drilling
(1) The Driller drills the previously added stand or single down, until the TD is at the
correct height, just above the drill floor.
Note: During some Drilling operations, the Driller may pick up the stand or single and
ream back to bottom, as per the Drilling Programme.
(2) The Driller picks up the string.
(3) The Driller lowers the string to the connection depth and upon the Driller’s
instruction, the Floormen set the slips.
(5) After ensuring that the pressure is bled off, the Driller closes the I.B.O.P. on the TD,
and breaks the saver sub connection, using the TD system torque wrench.
(6) The Driller spins out the connection using the rotating head.
(7) A Floorman removes the drillpipe screen, cleans and installs it in the drillpipe in the
mousehole.
(8) A Floorman applies dope to the saver sub pin.
(9) The Driller, engages the drawworks and raises the elevators clear of the tool joint.
(10) The Driller lowers the travelling block / TD until the elevators are at a level equal to
the joint in the mousehole.
(11) The Driller engages the linktilt toward the joint in the mousehole.
(12) The Floormen latch the elevators around the tool joint.
(13) The Driller engages the drawworks and lifts the joint of pipe out of the
mousehole.
(14) The Driller continues lifting until pin end of joint is above the joint in the rotary table.
(15) The Driller releases the linktilt and lowers the joint as the Floorman stabs the joint
into the tool joint box at rotary table.
(16) The Driller continues lowering until saver sub is stabbed into the upper tool joint
box.
(17) The Driller engages the TD spinner and makes up the top and the bottom
connections, then applies torque with the torque wrench.
(18) The Driller raises the string to allow the Floormen to pull the slips, notes the pickup
weight and establishes that the string is free.
38
(19) The Driller commences rotation, opens the I.B.O.P., engages the pumps and
ensures that circulation is established.
(20) The Driller, after checking that the pump pressure is correct, lowers the string and
resumes drilling as per the Drilling Programme.
4.3. Tripping Out While Reaming
(1) The Driller picks up the drillstring while reaming and circulating. When the
connection clears the rotary table, rotation is stopped.
(2) On the Driller’s instruction the Floormen set the slips.
(4) The Driller closes the I.B.O.P. on the TD, breaks out the top connection using the
TD system torque wrench and spinner.
(5) The Driller raises the travelling block, until the elevators reach the tool joint.
(6) The Floormen attach the rig tongs to the tool joint connection at the rig floor, (or the
automated roughneck if available).
(7) The Driller engages the break-out cathead and breaks the connection.
(8) The Floormen attach the pipe spinners or the automated roughneck to the stand of
pipe and spin out.
(9) The Floormen install the mud box if the stand is wet.
(10) The Driller engages the drawworks and lifts the stand clear of the tool joint in the
rotary table.
(11) After the stand has drained, the Floormen remove the mud box.
(12) As the Driller lowers the travelling block, the Floormen guide the stand to the
setback area and set it down.
(13) The Driller continues lowering the travelling block until the elevators clear the top
tool joint.
(14) The Driller activates the linktilt, moving the elevators toward the finger board.
(15) If applicable, the Derrickman removes the drillpipe screen and places in the
drillpipe ring on the TD.
(16) The Derrickman unlatches the elevators and moves the stand of drillpipe into the
finger board.
(17) The Driller deactivates the linktilt and lowers the travelling block and TD back to the
joint in the rotary table.
(18) If applicable, the Floormen retrieve the drillpipe screen and place it into the joint at
the rotary table.
(19) The Driller lowers the travelling block while the Floormen stab the saver sub into
the tool joint box.
(20) The Driller, using the TD system spinner and torque wrench, makes up the
connection between the saver sub and the drillstring.
(21) The Driller opens the I.B.O.P. and engages the pumps.
(22) As the Driller picks up on the drillstring with the travelling blocks, the Floormen will
pull the slips.
(23) The Driller starts rotation as he lifts the drillstring.
(24) The operation is then repeated until reaming is no longer needed.
39
壱伍. Operating the Automated Roughneck

Jaw set for pipe-OD : 3¾” - 7¾” Jaw set for pipe-OD : 5¾” - 9¾”
8” Adjustable wrench Grease gun
1. When the automated roughneck is not being used, ensure that it is stored
away at the end of the rail, with the lock pins engaged.
2. Ensure that the air is turned off and the supply disconnected prior to
servicing this equipment. Operate both jaw and chain functions to ensure
that all air is bled off.
3. Prior to servicing, shut off electric power with emergency stop buttons, on
the automated roughneck, in the doghouse and on the Driller’s console.
(1) Diligently implement the automated roughneck (AR) standard maintenance program.
(2) The AR must be inspected and lubricated before and after each trip.
(3) The AR’s sensors must be kept clean and free of any dirt or grease.
(4) The AR must be handled by at least two Floormen during Manual Mode operations.
(5) Only trained and experienced Floormen will be allowed to operate the AR.
(6) Ensure that the correct size tong dies are installed for the pipe selected.
(7) The Operator must operate only one function at a time. Each function must be
operated in its complete sequence.
(8) The Driller must ensure, before operating the AR, the correct torque values must be
determined and listed for each size of tubular to be handled.
(9) Ensure that the calculated torque is being applied. Check the torque pistons and
ensure that they are not at the end of their stroke.
(10) Do not use the spinning wrench on the tool joints.
(11) Ensure that nobody is in between the drillstring and the AR while it is in operation,
or on the rails of the AR.
(12) During operation of the AR, no tools are allowed on top of the cover plate.
(13) Refer to the Drilling Programme on whether AR will be used for tubing or casing
running.
4. INSTRUCTIONS FOR VARCO AR-3200 AUTOMATED ROUGHNECK
(Refer to Varco service manual for detailed information)
4.1. Manual Control
Manual switch setting Function description
Well Centre: Moves AR towards well centre.
Setback: Moves AR away from well centre.
Up: Adjusts carriage up.
Down: Adjusts carriage down.
Auto / manual: Switches machine mode from the "automatic sequence control" mode to
the manual "one switch one function" mode.
Vertical / tilt: Normal operation is in the vertical mode. The tilt mode is used for making
mousehole connections. The function tilts the torque wrench and spinning wrench up to
7° to align with the mousehole.
Select system pressure
(2000 / 2500 psi)
40
If the required torque is in excess of 8136 daN.m (60,000 ftlbs), select the 2500 psi
mode. The 2500 psi selection will also reduce flow to the spinner to allow slow spinning
of collars.
Spin in / out: The rollers spin either in or out.
Clamp / un-clamp: Clamp or un-clamp the spinning wrench.
Break out / make up: Cycles the upper torque wrench body in the break out or make up
rotation.
Clamp / un-clamp: Clamp or un-clamp both the upper and lower torque wrench and
wrench jaws.
Normal / back up: Mode to allow jaw to be used to provide back up torque wrench.
When the back up mode is selected, only the lower jaw will clamp. When Clamp TW is
selected, the upper jaw will not cycle with the break out / make up switch.
Note: Once these initial settings have been checked, the operation in the manual mode
consists of simply using the appropriate switches to control the position of the AR, the
spinning wrench, and the torque wrench.
(1) Set the auto / manual mode switch to manual.
(2) Ensure that the emergency stop switches on the AR and on the Driller's console
have been reset (pulled out).
(3) Set the make-up torque by adjusting the torque adjust knob. This adjustment must
be made while making up a joint. Turn clockwise to increase torque; turn counter-
clockwise to decrease torque. The actual torque will be shown on the torque gauge.
4.2. Automatic Control
Note: The Automatic Control allows the Operator to run the AR through a sequence of
operations to either make up or break out a connection using just a single button.
To operate the tool in the automatic mode, check the following settings:
(1) Set the auto / manual mode switch on the control box to auto.
(2) Ensure that the emergency stop switches on the tool and on the Driller's console
have been reset (pulled out).
(3) Ensure that the torque wrench and spinning wrench switches are set to neutral
(centre, off) position.
(4) Set the make up torque by adjusting the torque adjust knob. The actual torque will
be shown on the torque gauge.
(5) Set the operation mode by selecting make up or break out.
(6) Set the appropriate tool joint length by selecting 8", 10" or 12".
Note: Once these initial settings have been checked, operation in the automatic mode
consists of simply pushing the start button.
Make Up / Break Out Operation Switch.
The make up / break out operations switch allows the Operator to choose between a
make up or break out sequence.
4.2.1. Break Out
To initiate a break out sequence the Operator must push the start button. A break out
sequence consists of the following steps:
4.2.1.1. Break Out - Tool Joint Detector Enabled.
(1) Move to well centre: The AR moves to well centre and positions itself so that the
joint is located in the rear of the torque wrench.
41
(2) Adjust torque wrench to the tool joint: The AR raises the carriage until the upset
of the tool joint is detected. Then the tool drops 5", 3" or 1" depending on the setting of
the tool joint length switch (8", 10" or 12").
(3) Break out: The torque wrench jaws are clamped and the joint is broken out a full
28° of rotation. When the procedure is completed, the torque wrench upper jaws un-
clamp partially.
(4) Spin out: The spinning wrench is clamped on the pipe and the joint is spun out.
When spin out is complete, the spinning wrench will un-clamp. If the tool does not
detect the spin out, it automatically recycles.
(5) Move back to stand by: The tool moves back to the stand by position and cycles
the torque wrench to be prepared for the next sequence.
4.2.1.2. Break Out - Tool Joint Detector Disabled.
(2) Adjust torque wrench to the tool joint: The Operator must position the torque
wrench to correct height using the height adjustment buttons. When the height is
correct the Operator must push the start button to continue with the sequence.
(3) Break out: The torque wrench jaws are clamped and the joint is broken out a full
28° of rotation. When the procedure is completed, the torque wrench jaws are un-
clamped.
(4) Spin out: The spinning wrench is clamped on the pipe and the joint is spun out.
When the spin out is completed, the spinning wrench will un-clamp. If the tool does not
detect the spin out, it automatically recycles.
(5) Move back to stand by: The tool moves back to the stand by position and cycles
4.2.2. Make Up
To initiate a make up sequence the Operator must push the start button. A make up
sequence consists of the following steps:
4.2.2.1. Make Up - Tool Joint Detector Enabled.
(2) Adjust torque wrench to the tool joint: The tool raises the carriage until the upset
of the tool joint is detected. Then the tool drops 5". 3" or 1" depending on the setting of
the tool joint length switch (8", 10" or 12").
(3) Stab: The sequence halts and waits for the new stand or joint to be stabbed into the
box in the rotary table. When this is completed, the Operator must push the start
button.
(4) Spin in: The spinning wrench is clamped on the pipe and the joint is spun in. When
completed, the spinning wrench is un-clamped. If the AR-3000 does not detect that the
joint has been shouldered, the Operator can push the start button. and the spinning
wrench will un-clamp and continue on to the next step.
(5) Make up: The torque wrench jaws are clamped and the joint is made up to the
desired torque. When the Driller confirms the torque, the Operator pushes the start
button causing the torque wrench jaws to un-clamp and the sequence to continue. If the
desired torque is not reached in the full rotation of the upper jaw, the tool will
42
automatically re-stroke.
(6) Move back to stand by: The AR moves back to the stand by position and cycles
4.2.2.2. Make Up - Tool Joint Detector Disabled.
(2) Stab / adjust torque wrench to the tool joint: The Operator must position the
torque wrench to correct height using the height adjustment buttons. When the height is
correct and the new stand has been stabbed, the Operator must push the start button
to continue with the sequence.
(3) Spin in: The spinning wrench is clamped on the pipe and the joint is spun in.
When completed, the spinning wrench is un-clamped. If the AR-3000 does not detect
that the joint has been shouldered, the Operator can push the start button and the
spinning wrench will un-clamp and continue on to the next step.
(4) Make up: The torque wrench jaws are clamped and the joint is made up to the
desired torque. When the Operator confirms the torque, pushing the start button will
cause the torque wrench jaws to un-clamp and the sequence to continue. If the desired
torque is not reached in the full rotation of the upper jaw, the tool will automatically re-
stroke.
(5) Move back to stand by: The AR moves back to the stand by position and cycles
4.3. Auto / Manual Height Adjustment.
(1) The auto / manual height adjustment mode selection switch allows the
Operator to choose between manual or auto positioning of the torque wrench to the
correct height in the automatic machine mode.
(2) Manual positioning requires the Operator to adjust height using the height
adjustment buttons on the manual control box.
(3) Auto positioning uses the tool joint detector and vertical height encoder to position
the torque wrench at the correct height on drillpipe.
(4) In the manual positioning mode the Operator has to operate the functions.
(5) In the auto positioning mode, the first press of the start button will cause the AR to
move to well centre and scan up to find the tool joint.
Note: If a make up sequence is in progress, the AR will stop to allow the pin to be
stabbed.
(6) The second press of the start button will continue with the normal cycle.
Note: If a break out sequence is in progress, the tool will continue with the normal cycle
without stopping.
4.3.1 Tool Joint Length
(1) The tool joint length selection switch is used to input the tool joint box length of the
current string of drillpipe.
(2) In the auto positioning mode the AR-3200 uses this input to correctly position the
torque wrench on the box section.
(3) This input has no effect when the manual height adjustment mode is selected.
4.3.2. Horizontal / Vertical Position Adjustments
(1) In the automatic mode all manual control switches are disabled with the exception of
43
the four position adjustment buttons.

(2) These buttons can be used to adjust the AR towards or away from well center and
to raise and lower the carriage while the AR is in the automatic mode.
4.4. Maintenance
4.4.1. Weekly
(1) Isolate the unit prior any work by turning the air off and disconnecting the supply.
(2) Grease rollers at back side.
(3) During and after tripping, open the door at the back of the automated roughneck and
check hydraulic hoses for leaks.
(4) Check the grease hose to clamps. Ensure that the hose is not stuck between
clamps.
4.4.2. Daily (if in use)
(1) Clean and grease spinner guide rollers.
(2) Grease spinner and motor.
(3) Grease between the clamps.
(4) Grease drive wheels and motor.
(5) Grease manifold at front side (3 strokes is sufficient).
(6) Check wear or die clamps.
壱六. Operating the Eddy Current Brake

Not-Applicable
1. The Eddy Current Brake will not stop the drawworks with load under any
circumstances, but only slows the rotation of the drawworks.
2. The Eddy Current Brake shall not be disengaged from the drawworks while
any lifting or lowering of the travelling blocks is being done.
(1) Ensure that the electric brake cooling system is properly maintained and that the
brake is receiving the proper amount of coolant water.
(2) Ensure that the warning light on the Driller’s console for the electric brake is
functional.
(3) Ensure that the wiring from the Driller’s control unit to the electric brake is
maintained from damage, (cuts, mashed cables, or shorts).
(4) Ensure that proper lubrication of the rotor shafts of the electric brake is maintained
daily, according to COMPASS System.
(5) Ensure that the electric brake has its own independent circulating pump.
(6) Ensure that the circulating rate of the coolant pump is equal to or more than the
capacity of the brake.
4. INSTRUCTIONS
Note: When the ACS is correctly adjusted, the ACS will control the drum speed.
4.1. Operation While Raising and Lowering
(1) Before picking up any load, the Driller will ensure that the electric brake control unit
on the Driller’s console is released.
(2) While tripping out of the hole, the Driller will control the descent of the empty
travelling block with the electric brake. Use the mechanical brake to bring the travelling
44
block to its actual stop.

(3) When tripping in the hole, the Driller, after picking up off the slips, will release the
drum clutch and engage the electric brake.
(4) The Driller will control the descent of the travelling block and the drillstring, with the
electric brake in a deliberate manner, engaging the electric brake more as he nears the
drill floor.
(5) In conjunction with the electric brake, the Driller will utilise the mechanical brake to
bring the drillstring to a controlled stop at the rotary table.
(6) The Driller will never try to stop the drillstring solely with the electric brake.
(7) The Driller will never drop the travelling block at a high rate of speed and then
engage the electric brake.
(8) The Driller must remember, at all times, that the electric brake is not a stop brake,
but an auxiliary brake designed to slow the velocity of the descending drillstring. The
mechanical brake is engaged to stop the drillstring.
4.2. Maximum Drum Speed
Note: The maximum speed of the drawworks drum is limited by:
(a) the Eddy Current Brake,
(b) maximum allowable rubbing speed of the brake blocks, and
(c) the maximum drilling line speed.
The Maximum drum speed is as follows:
Rating Example Drum speed, RPM
Up to 1,000 HP (i.e. National 80B) 410 RPM
Up to 1,500 HP (i.e. National 110) 380 RPM
Up to 2,000 HP (i.e. National 1320, Emsco C2) 350 RPM
Up to 3,000 HP (i.e. Emsco C3) 300 RPM
4.3. Cooling of the Eddy Current Brake
(1) Make sure that the Eddy Current Brake cooling system is working properly. Measure
the amount of cooling water and adjust same to the manufacturer’s requirements.
(2) A corrosion inhibitor, NALCO 2000 (Ident-No. 014 463.7), is required to avoid
damages on the cooling system.
(3) Only 3% to 6% by volume of the corrosion inhibitor be added to the cooling system.
This percentage value must be kept, otherwise, the fluid becomes corrosive and
damages the system in a short time.
(4) Check the percentage value of the corrosion inhibitor on a regular basis with the
Test-Kit (Ident-No 133 198.0).
(5) In areas where ambient temperatures can drop below 0C, an anti-freeze, (Ident-
No 006 722.7), is to be used.
Note: Anti-freeze is also a corrosion inhibitor with a concentration of 30% (for freezing
protection to -15C), and may not be used with NALCO.
壱七. Pumping Pills

Pump stroke counter Pump stroke totaliser
1. A viscous pill will not give a good slug to dry the pipe.
2. Pills for slugging pipe can best be mixed with barite or hematite. Calcium
45
carbonate can be used but if it is a coarse grind, settling may cause pipe
plugging problems.
3. If weight material is mixed rapidly some very thick or settled hematite or
barite may be on the bottom of the slugging tank.
4. Pump pressure pop-off valve may be activated if a viscous pill is pumped too
fast.
(1) All actions will be taken on the instructions of the Driller.
(2) The Driller is to observe the pump stroke counter while pumping and chasing the
pill.
(3) Run the pump very slowly at the beginning of the operation.
(4) Keep an eye on the pressure gauge.
(5) Re-set pump and check stroke counter before beginning operation.
(6) Ensure the pump output efficiency has been checked and calibrated.
(7) For down hole pills required by the Drilling Programme or supplement to the Drilling
Programme, follow the specific procedures given.
4. INSTRUCTIONS
Note: Keep the drillstring in motion during the following steps:
(1) Driller will inform the Derrickman when to line up the pump to the pill tank.
(2) Ensure that the equaliser valves on the pill tank are closed.
(3) Close all the pump suction valves to the mud system tanks.
(4) Open the pill tank suction valve.
(5) The Derrickman will visually check or mark the pit level.
(6) The Derrickman will inform the Driller that the pump is lined up on the pill tank.
(7) Run the mud pump very slowly.
(8) Observe the pump discharge pressure; the mud may be heavy and thick.
Note: If the discharge pressure increases rapidly, stop the pump. Check for a closed
valve in the system.
(9) Gradually increase the speed of the pump.
(10) Using the pump stroke counter, pump the required volume from the pill tank
(double check with the Derrickman's manual measurement).
(11) Stop the pump.
(12) Driller will instruct the Derrickman to line up the same pump to the mud system
tanks.
(13) Close the pill tank suction valve.
(14) Open the active mud system tank suction valve.
(15) Inform the Driller that the pump is lined up for the displacement.
(16) Start the pump and displace pill, monitoring displacement values using pump
stroke counter and check the stroke counter.
(17) If spotting a down hole lost circulation pill or a soaking pill on stuck pipe, then
follow the Drilling Programme supplement for correct procedures.
壱八. Perform Flow Check

Flow line sensor Flashlight
Mud Pit Level sensor Pressurised Mud Balance
46
Trip tank
1. During a flow check, at the first indication of flow, close in the well as per the
Shut-in Procedure in W.I. Section 11.12.
2. Follow the procedures in Work Instruction Section 11.12. (or the Drilling
Programme) for closing in the well and in recording the shutin pressures.
3. If “gas-cut” mud conditions are present, the shale shaker area and the rig
floor can potentially accumulate extremely explosive gas or toxic vapours
during the flow check.
4. Ensure that the crew is trained in the emergency safety shut down of diesel
engines in the event of any gas in the air intake.
(1) Routine flow checks will be performed in the following circumstances or as called for
in the Drilling Programme:
Before pulling out of the hole for a trip or check trip;
(a) Perform the flow check before pumping a slug.
(b) In the last casing shoe and or at the highest point of the check trip.
(c) Before pulling the bottom hole assembly out of the hole.
(d) Whenever a drilling break or pit gain is observed.
(e) In the event of loss of circulation or pit volume drop.
(2) Whenever picking up the kelly or the top drive for a flow check, the Driller will space
a joint of drillpipe tube across the BOP stack (ensure that there are no tool joints across
the rams or the annular preventer).
Note: When differential sticking is a possibility, rotate drillstring at 10-20 rpm during flow
check or move the string up and down to the same position while having the kelly cock
closed.
(3) A flow check must be performed after penetrating a maximum of 1.5 meters (5 feet)
into any “drilling break”.
(4) Flow check of each drilling break and its results must be reported on the I.A.D.C.
drilling report, along with the mud weights at both the flow line and in the pump suction.
(5) A “reverse drilling break” (slowing of penetration rate) may indicate a hard gas sand
that the bit will not drill rapidly and also requires a flow check.
(6) The Mud Tester must mark, monitor, and report the active mud pit, tank or
compartment fluid levels independently of Mud Loggers.
(7) A flow check on bottoms up after drilling a gas bearing formation could indicate a
“false flow “ due to gas expansion (foaming & frothing) when there is no actual flow.
Note: Gas cut mud will be produced by gas expansion and may have very little effect
on reducing bottom hole pressure. In such instances, a pressurised mud balance
should be used to obtain the true mud density, especially during long horizontal
sections.
4. INSTRUCTIONS
(1) With pumps on, pick up the drill string until the kelly valve is above the rotary table.
With a top drive, pick up until the first tool joint is above the rotary.
(2) Position the drill string where no tool joint is across the pipe rams and shut off the
mud pumps.
47
(3) Ensure the pumps are off and note the standpipe pressure.
(4) Look down the bell nipple, and if necessary, remove the insert bowls.
(5) Observe the mud in the bell nipple or the flow line. Do not rely on the flow-show or
electronic sensors.
(6) If any flow is detected, close-in the well as per the Shut-in procedure.
Note: Follow the procedures in Work Instruction Section 11.12. (or the Drilling
Programme) for closing in the well and in recording the shut-in pressures.
(7) If the well is not flowing, resume drilling, closely watch pit volume and note time for
bottoms up from the first flow check.
(8) Do not make a bit trip until bottoms up from any drilling break / flow check has been
circulated out of the hole.
(9) Record on the drilling report the bottoms up gas from any flow check.
(10) If a pressured hydrocarbon zone is expected to be encountered at the depth of the
drilling break and the initial flow check is negative (no flow), the flow check
may be repeated after drilling an additional 1,5 meters (5 feet).
Note: The ECD (Equivalent Circulating Density) while circulating during the drilling
process may exceed the formation pressures due to annular friction losses.
When the pumps are ÿÿÿÿed off to make a connection, theÿÿormaÿÿon pressurudmay
exceed the hydrostatic pressure of the mud and influx of wellbore fluid may occur.
Therefore, consider every connection during normal drilling operations as an
instantaneous flow check.
壱九. Slow Circulating Rate – SCR (also Slow Pump Rate - SPR)
Pump stroke counter Stop Watch or Timer
1. Refer to the Drilling Programme for Kick Control techniques, procedures or
overbalance requirements.
2. Maintain an approved IWCF Surface BOP Kill Sheet with hole geometry, drill
string geometry, casing data, fluid data, rig equipment data, reservoir data
and formation characteristics.
3. All pump pressures at respective slow pump rates will be recorded on the
I.A.D.C. Drilling Report form.
4. During drilling operations, slow pump rate pressures will be taken at the
beginning of each tour with each pump.
5. Slow pump rate pressures will be updated after drilling 150 metres (500 feet)
of new hole, after changing the mud weight by 0.02 sp. gr. (0.2 ppg) or more,
and when bits or jets are changed.
(1) Do not take slow pump rates while the bit is on bottom or while experiencing
excessive drag or hole cleaning problems.
(2) Do not take slow pump rates while losing circulation, during weighting up or while
changing out the mud system.
(3) Report the pressure gauge used (standpipe, Driller's console, etc.) for the slow
pump rate pressure. Utilise the gauges that will be used when circulating out a
kick.
48
(4) Slow circulating rate pump pressures have to be re-recorded when the pump liner
size is changed.
(5) Slow circulating rate pump pressures have to be recorded on all downhole pumps
separately.
4. INSTRUCTIONS
(1) Determine the desired slow pump rates for kick control procedures based on weight
material and equipment mixing capacities.
(2) Use the slow circulating rates (SCR) specified in the Drilling Programme.
(3) If the Drilling Programme does not specify any slow circulating rates, take SCR at
40, 50 and 60 stroke per minute, and record in the daily report and kick control
worksheet.
(4) If the rig and / or pump motor configuration have a stall rate speed or pressure
function limit, note on the I.A.D.C. Drilling Report and kick control worksheet.
(5) Identify the mud pumps by the rig numbering system.
(6) Determine and note the pump discharge and tank suction alignment if on a manifold.
(7) Isolate each mud pump, one at a time, and record the stabilised pump pressure at
the pre-determined slow circulating pump rate.
弐零. Shut-in Procedures

1. RESPONSIBILITY FOR IMPLEMENTATION
The shut in procedure and the preferred kick killing method to be used, is to be
made known to the crew by the operator, not later than the spud meeting.
Ensure the procedure and the method are in accordance with the Deutag policy.
Refer to the “Shut-in Procedure - Position of Valves During Drilling” diagram
issued by ZPEB.
Remember! YOU are responsible for:
(a) The safety and well-being of the personnel
(b) Protecting the environment
(c) Protecting Deutag drilling rig and it’s associated equipment.
Mud Tester / Shakerman: To inform the Driller if any variances in mud returns and / or
gas cut or oil contaminated mud is coming over the shakers.
Derrickman: To monitor the active mud volume in the tanks at all time and inform the
Driller of any variances.
During killing operations: Weight up the kill mud according to Mud Eng. instructions.
Assistant Driller: Line up and when necessary start the degasser and assist the
Derrickman or the Driller during killing operations according to Driller's instruction.
Driller: To monitor his instrumentation and evaluate any changes and information given
to him by the Mud Tester and Derrickman.
Perform flow check and if well is flowing, shut in the well and inform the Toolpusher.
Note: Do not flow check when drilling in formations containing H2S. Close in the well.
Prepare a IWCF (International Well Control Forum) Surface BOP Kill Sheet and
compare same with Toolpusher's Kill Sheet, to avoid mistakes.
During killing operation, follow the pumping schedule in accordance with the IWCF
Surface BOP Kill Sheet and Toolpusher's instructions.
Record pressures, pump rate, volume pumped, and time.
Compare the actual parameters with the kill graph and if any significant changes alert
49
the Toolpusher.
Toolpusher: To maintain full control over the behaviour of the well to prevent blowout
from happening.
Notify the Company Representative, the Mud Engineer, the Drilling Engineer and
Manager.
Evaluate borehole situation upon presumed influx. Select the correct killing procedure
as stated below, depending on the type of kick and hole size.
Calculate his IWCF Surface BOP Kill Sheet and compare same with the Driller's, the
Company Representative's, and / or the Drilling Engineer's to avoid any mistakes.
Be in charge of the killing operation, controlling back pressure and timing.
Drilling Engineer: To assist the Toolpusher in evaluating borehole situation, calculate
independently IWCF Surface BOP Kill Sheet and compare same with the Toolpusher's.
Assist the Toolpusher during killing operations.
Manager: To approve the killing procedure proposed by the Toolpusher.
Control Manager: To implement the instructions outlined in the Deutag Rig Crew
Manual on all Deutag rigs in his area.
Head of Division: To ensure that the procedures are followed.
2. SHUT IN PROCEDURE WHILE DRILLING
(1) Once a kick has been detected, or is suspected, the decision must be made to shut
the well in as quickly and as safely as possible. The success of the well control
operation depends upon the response of the crew at this most critical phase.
(2) The well is shut in:
(a) to prevent further formation fluid influx,
(b) to protect the rig and the crew from an uncontrolled flow, and
(c) to organise the kill procedure after the stabilised shut in DP and Annulus pressures
and the pit gain are determined.
2.1. Stop Drilling and Raise the Kelly / Top Drive
(1) Stop rotating the string.
(2) Raise the drillstring to a convenient position where no tool joints are at the pipe rams
or annular preventer(s).
Note: When a kelly is in use, raise the string until the lower kelly cock is above the drill
floor.
(3) Gradually slow down the mud pumps.
Note: Some extra back pressure on the formation due to the friction losses of the
circulating mud in the annulus is thus maintained. This in turn, offsets the swabbing
effect when raising the string and reduces the possibility of a further influx entering the
well.
2.2. Stop Pumps and Observe Well for Flow
(1) Ideally the pump should be gradually slowed down during the raising of the last 3
metres of the drillstring and then finally stopped. By doing so the upper part of the influx
will be thoroughly diluted by the mud, and may even be carried up inside the casing
shoe.
(2) Only the bottom of the hole will contain neat formation fluid, which will continue to
flow after the well has been closed in until the BHP equals the formation pressure.
2.3. Open the Hydraulically - operated Choke Line Valve
50
(1) Shutting in the well by opening the choke line valve before closing the BOP is known
as a “soft shut-in”.
(2) The alternative is a “hard shut-in” which is achieved by closing the BOP on the
closed choke line valve.
2.4. Close the Appropriate BOP (Top Pipe Ram or Annular Preventer)
(1) A pipe ram closes faster than the annular preventer, however care must be taken to
correctly position the tool joint.
(2) If there is any doubt about the position of tool joints or if casing – drillpipe protectors
are in use, the annular preventer should be closed.
2.5. Close the Hydraulically - operated Choke Line Valve
(1) The well is now shut in! Observe the closed-in annular pressure (Pa) and the
closed-in drillpipe pressure (Pdp ) and record the pit gain.
(2) Complete the applicable IWCF Surface BOP Kill Sheet, and prepare to kill the well.
3. SHUT IN PROCEDURE WHILE TRIPPING
(1) The less drillpipe there is in the hole, the greater the danger in not being able to
control a kick, should one occur.
(2) The main object when a kick is detected or suspected should be to get the well
closed in as quickly and as safely as possible. The extent to which that can be achieved
depends upon the rate of mud flow from the well.
(3) If the well flows strongly form the time of discovery of the kick and there is some
drillpipe in the hole, the first priority must be to install a lower kelly cock on the drillpipe
and close it; then close in the well.
(4) If it is at all possible, the drillpipe in the hole should be lifted out of the slips before
closing the rams.
(5) However, if the well flows and there is no drillpipe in the hole, then open the
hydraulic-controlled valve in the choke line and close the blind / shear rams.
(6) Before deciding on the method of killing the well, consideration should be given as
to whether the drillpipe should be stripped into the well or not.
(7) The feasibility of the stripping operation depends on the flow rate, the pressures
observed and the condition of the BOP seals.
(8) If it is decided to strip the drill string to bottom continue as follows:
(a) Close the kelly cock and bleed off any pressure from top drive.
(b) Disconnect the top drive and remove the pup joint from the kelly cock.
(c) Install the Gray valve and connect the top drive.
(d) Open the kelly cock and test the Gray valve.
(e) Prepare to strip in.
Note: When preparing to strip in ensure the surge bottle pre-charge pressure has been
checked on the annular BOP and open the valve on the surge bottle. Remove the vent
plug on the opening chamber on the Cameron D annular preventer.
Note: Variations can occur to the above procedure when:
(a) pumping a dart to a receiving sub in BHA
(b) there is a positive float in the string
(c) accurate and regular slow circulating rates (SCR) are not available.
(9) Connect / disconnect kelly cock to crossover for DC's as and when required on trip.
51
Shut-In Procedure
• Stop drilling and raise kelly / top drive.
• Raise kelly / top drive until lower kelly cock is above drill floor.
• Stop pumps and observe well for flow.
• Open hydraulically-operated choke line valve (valve Nr.4).
• Close appropriate BOP (top pipe rams).
• Observe and record the closed-in drill pipe pressure (Pdp) and the closed-in
annulus pressure (Pa).
• Prepare to kill the well.
• Install spare RH kelly cock in open position.
• Close RH kelly cock.
• Open hydraulically-operated choke line valve (valve Nr.4).
• Close appropiate BOP (top pipe rams)
• Pick up and install short pup joint.
• Connect top-drive to pup joint.
• Open RH kelly cock.
• Observe and record the closed-in drill pipe pressure (Pdp) and the closed-in
annulus pressure (Pa).
• Close RH kelly cock, bleed off pressure from Topdrive.
• If stripping, disconnect topdrive, remove pupjoint from RH kelly cock.
• Install Gray valve, connect topdrive and test Gray valve.
• Prepare to strip-in.
弐壱. Conducting Leak-Off Test

Low volume High Pressure pump Calibrated Pressure Gauge with Recorder
1. No one is to tighten or loosen any connections under pressure.
2. Ensure that chiksan lines are secured with a safety line or chain when they
are fitted.
3. Clear communications are essential during testing process.
4. All personnel are to be informed when testing is to take place.
5. Ensure all test gauges and recorders have valid Dead Weight Tester
calibration certificates.
3. STANDARD OPERATIONAL CONSIDERATIONS (DO´S AND DON´TS)
(1) Ensure the leak-off test is carried out under the direct supervision of the Toolpusher,
or the Driller and the Company Representative.
(2) The Driller and the Toolpusher are to ensure the piping and the valves are correctly
lined up.
(3) All leak-off tests must be carried out with mud of the same density as the mud in the
hole.
(4) Ensure the formation is not fractured.
(5) Ensure all air has been expelled from the test lines before the test commences.
(6) The Company Representative or the Drilling Engineer will plot the pressure versus
volume pumped, in real time.
(7) The Toolpusher / Driller / Company Representative will maintain chart recordings of
52
all pressure tests.

(8) If a limit test is performed, use the last recorded pressures for calculations.
4. INSTRUCTIONS
Note: Leak-off tests are to be performed on all wells below the casing shoe when
drilling has to be continued below the casing string. This also includes the conductor
string if a BOP or diverter has to be installed.
Note: Data obtained from leak-off tests should be treated with care. The data obtained
is used for well killing procedures.
It should not be presumed that the formation can support the pressure
continuously with the gradient indicated by the leak-off test.
The following sequence should be adhered to when conducting leak-off tests:
(1) Drill out the cement, cement plug and casing shoe plus 5m (or 15 ft) of formation.
(2) Circulate and condition the mud until the mud properties (density, viscosity, etc.) are
the same, going in and out of the well.
(3) Pull the bit back into the casing shoe.
(4) Ensure the hole is full, then:
(a) line up the test pump on the kill line,
(b) pump small volume to flush out all the lines and circulate mud all the way around;
(c) open the HCR valve on the choke line,
(d) close the remote controlled choke and the valve immediately upstream from the
choke,
(e) close the pipe rams around the drillpipe, and then
(f) close in the lower kelly cock.
(g) Open the annulus between the current and the previous casing strings, where
applicable.
(5) Pump mud slowly using a high pressure, low volume pump until the pressure builds
up to approximately half the anticipated maximum surface pressure.
Note: Mud pump or rig gauges are not accurate enough for these measurements.
Calibrated pressure gauges must be used, covering various pressure ranges and
preferably mounted on a special manifold.
Note: Rig pumps are not suitable for conducting leak-off tests.
Note: Rig pumps must be isolated from the wellbore pressures with the Lower Kelly
Cock or the IBOP. Rig pumps are not back pressure valves.
(6) Pump uniform increments of 16 Liters to 40 Liters (0.1 to 0.25 bbl.) and wait for 2
minutes or the time required for the pressure to stabilise.
(7) Note and record the cumulative mud volume pumped, the final pumping and final
static pressure on the Leak-Off Test report (Figure 4).
(8) Repeat items (6) and (7) and plot pressure versus cumulative mud volume curves
for each increment of pumped volume.
(9) Continue this procedure until the trend of the final pumping pressure curve deviates
from that of the final static pressure curve after an appropriate waiting time, or until a
predetermined pressure has been reached.
(10) Keep the well closed in for a sufficient time (15 minutes) to verify that a constant
pressure has been obtained.
(11) Bleed off the pressure back to the tank of the high pressure pump unit and note
53
and record the volume of any mud lost to the formation.

(12) Open the valve immediately upstream from the choke and open the choke.
(13) Open the pipe rams, close the HCR and realign the choke manifold.
(14) If the BHA contains a restriction, such as, mud motor, MWD or a bit with small
nozzles, bleed the well pressure back to the tank of the high pressure pump unit via the
annulus, with the HCR open, through the choke to avoid plugging the small flow areas.
Measure the volume of mud recovered.
(15) Complete and sign the Leak-Off Test report.
弐弐. Working in the Derrick and Overhead Operations

Inertia reel safety device 1” rope
Safety climber 1/2” rope
Safety harness Balancing strap (elevators)
Escape line with anchor blocks
1. All safety lines and life lines attached to the safety harness of the Derrickman
are to be hung in such a manner that will prevent the lines from coming into
contact with the travelling block or TDS.
2. Ensure that the safety climber is in good condition.
3. Ensure that a safety line from the safety harness is used at all times, and is
hooked into the anchor point at the fingerboard.
4. If the Derrickman must remove his safety harness for work on the opposite
side of the derrick, he must tie the life line to a proper place on the derrick,
allowing enough freedom of movement to do the job.
5. ZPEB Personnel are only to use the safety harness provided by ZPEB. There
should not be any tool bags attached to the safety harness unless
construction takes place or repairs are carried out.
6. When overhead repairs or construction takes place, and the danger of falling
objects exists, the drill floor and the direct vicinity must be cleared.
(1) Prior to starting any overhead work in the derrick, inform the Driller.
(2) Check the condition of the ropes, chains and air winch on the finger board.
Note: A sufficient length of 1/2” rope or chain is used to secure the stands.
(3) Adjust the Crown-O-Matic and the Anti-Collision System (ACS) each time after
being disengaged for any reason.
(4) Ensure that the Derrickman escape line is properly secured to the anchor blocks
and to the derrick structure.
(5) Check the test date on the Derrickman escape line. The line must be replaced once
a year, or sooner based on inspection results or as per the COMPASS System.
(6) Visually inspect the fingerboard for buckled fingers and split welds.
(7) There must never be any loose articles or lengths of rope lying on the fingerboard.
(8) Ensure that the Derrickman escape line is tested every rig move or every month,
whichever is sooner or as per the COMPASS System.
4. INSTRUCTIONS
4.1. Working in the Derrick
54
(1) The Derrickman puts on the safety harness and attaches his safety harness to the
safety climber before climbing up the derrick ladder.
(2) When the Derrickman reaches the monkeyboard, before unhooking from the safety
climber, he attaches his safety harness to the inertia reel safety device.
(3) Alternatively, before unhooking from the safety climber, the Derrickman attaches his
safety line to a point on the derrick structure.
(4) The Derrickman must always attach his safety harness to the inertia reel safety
device or static line.
4.2. Pulling Stands
(1) Turn the hook and elevators so they point at the Derrickman and the setback area.
(2) The Driller picks up on the drillstring with the elevators.
(3) When the elevators are past the fingerboard and within reach of the Derrickman, the
Driller applies the drawworks brake and the Floormen set the slips.
(4) The Driller continues to lower the elevators until they are free from the tool joint.
(5) The Derrickman loops the pull back rope or winch around the stand.
Note: Never loop the pull back rope or winch around the drillpipe stand until the slips
are set and the elevators are clear from the tool joint.
(6) After the bottom connection is broken and spun out, the Driller picks up the drillpipe
stand out of the box of the tool joint.
(7) The Driller slowly slacks off on the drawworks brake, while the Floormen push the
bottom of the stand to the setback area.
Note: While the stand is being spun out, ensure that the pull back rope or winch line
does not become entangled.
(8) The Driller continues to slack off until the elevators disengage the top tool joint.
(9) At this point, the Derrickman pulls the stand by the rope against the monkeyboard
and fingers (if using a top drive, the Driller activates the linktilt to assist the Derrickman).
(10) The Derrickman opens the elevators as soon as they are within his reach.
(11) The Driller ensures that the Derrickman has removed the top of the stand, and then
retracts the linktilt, in case of a top drive.
Note: Ensure the elevators will not hit the fingerboard.
(12) The Derrickman places the stand between the rearmost fingers in the board and
secures it with the 1/2” rope or chain.
(13) The operation is then repeated from steps (2) to (12) until all the stands are pulled.
4.3. Tripping in Stands
(1) With the elevators pointing at the setback area, the Derrickman hangs the first stand
to be run in the pull-back rope. If a DC stand is set, the Derrickman uses the air tugger
winch and a rope to hold back the DC stand.
Note: A catcher rope should be used to prevent a stand from falling across the derrick,
in case the elevators are missed by the Derrickman.
(2) The Floormen install a balancing strap between the hand-grip and the link on the
elevators.
(3) The Driller raises the travelling block.
(4) As soon as the elevators are within his reach, the Derrickman:
(a) sets the stand into the elevators, using the groove on the hook block as a guide,
(b) removes the pull-back rope, and
55
(c) closes the elevators.

Note: Ensure that the elevators are properly closed. If not, warn the Driller immediately.
The Driller must immediately stop the upward movement of the block and lower the
stand.
(5) If a top drive is used, the Driller activates the linktilt to assist the Derrickman.
(6) While the Driller picks up the stand slowly, the Derrickman
(a) guides the stand with the catcher rope until it is hanging straight above the rig floor,
and then
(b) removes the catcher rope.
Note: If a top drive is being used, the Driller retracts the linktilt after picking up on the
drillpipe stand.
(7) After the connection is made up, the Driller runs the stand in the hole.
(8) When the travelling block is below the fingerboard, the Derrickman readies the next
stand.
(9) The operation is then repeated from step (3) to (8).
4.4. Overhead Operations
(1) If connections have to be made at hights above rotary table, use a safety sling to
prevent a loosened connection from falling to the rig floor.
(2) Mark connections with chalk to observe that back-off does not occur during makeup
of joints.
(3) Joint make up to be performed with chain tongs. Power tongs used only for final
make-up.
(4) Never rely on a hammer union, always snub and attach to a safety sling.
弐参. Changing Winch Wire

Reel of new wire Hydraulic wire cutter
A-frame for the reel Man riding winch
3 x Two-way radios Safety harness
Wireline snake Soft wire
Warning signs and Hazard tape Set of Allen keys
Wire brush and Detergent fluid Tape
Wire rope grease
1. Direct communication between all personnel is essential during this
operation.
2. All crew members working in the derrick must wear safety harness.
3. The rig floor access must be restricted to all other personnel. Use warning
signs and hazard tape.
4. The new wire rope must be certified.
3. STANDARD OPERATIONAL CONSIDERATIONS(DO’S AND DON’TS)
(1) To avoid damage to the wireline, the wireline reel is to be lifted only by slings and
not by wrapping the tugger line around the wire rope.
(2) The wireline reel must be set up on a A-frame or similar horizontal axis, so that it is
free to rotate as the wire is being spooled off.
(3) Check the hook, swivel and shackle certificates and test dates and replace if
56
necessary.
(4) Check that the wireline is long enough, after being strung, to reach the end of the
catwalk, and still leave 1 layer of wireline on the drum.
(5) Care must be taken to prevent kinks in the wireline as it is un-spooled.
(6) Tension should be maintained on the wireline as it leaves the reel.
(7) The wireline crown sheaves should be stationed as close to the V-door side as
possible.
(8) The controls on the air tugger should be marked as to up, neutral and down (9)
Ensure that the air tugger has a line guide and a guard attached
4. INSTRUCTIONS
(1) Mount the A-frame on the rig floor and install the reel of new wire.
(2) Using the hydraulic wire cutter, cut the end of the wire and clean it with detergent
fluid and a wire brush.
(3) Cut the eye at the end of the old tugger line and clean it with detergent fluid and a
wire brush.
(4) Connect the old wire with the new wire using the wireline snake.
Note: Alternatively, splice (weave) the two ends together, wrap with soft wire and tape
the entire length.
(5) Tape or tie the ends of the snake to the wire.
(6) Test the strength of the connection by a test pull.
(7) The Derrickman is positioned at the crown sheaves and one Floorman is at the
derrick board, equipped with two-way radios.
(8) The Driller, equipped with a two-way radio, positions himself at the air tugger with
the Air tugger Operator.
(9) The Air tugger Operator, at the Driller instruction, slowly lifts up the new cable in the
derrick.
Note: The Driller maintains continuous direct communication with the Derrickman and
the Floorman in the derrick, using the two-way radio.
(10) The Floorman at the derrick board ensures that the wireline does not become
entangled on the derrick or the derrick board as the snake passes both going up and
going down.
(11) The Derrickman ensures that the snake passes through the crown sheaves.
(12) When the snake passes the derrick board without any problems the Floorman
returns to the rig floor.
(13) The Driller stops the operation when the snake has reached the floor.
(14) The Driller and the Floormen secure the new wire to the rig floor and remove the
snake.
(15) The Floormen and the Air tugger Operator slowly un-spool the old wireline off the
air tugger onto the rig floor or back on the old reel.
(16) The Driller attaches the new line to the air tugger drum and secures the wireline to
the drum with Allen screws.
(17) The Air tugger Operator engages the tugger and slowly spools while the Floormen
guide the wireline onto the drum.
Note: Ensure that the wireline is spooled onto the drum in tension and wound properly.
(18) The Air tugger Operator stops when there is one complete layer on the drum.
57
(19) The Floormen spool off enough wireline from the reel to reach to the end of the
catwalk, and cut wireline off using the hydraulic line cutter.
(20) The Driller ensures the counterbalance chain, hook, swivel and shackle are in good
working condition.
(21) After plating an eye into the wireline, the Floormen install the counterbalance
chain, hook, swivel and shackle to the wireline.
(22) The Floormen stretch out the wireline and attach a weight to the hook.
(23) The Air tugger Operator slowly spools the wireline onto the drum using the line
guide, while a Floorman applies grease on the wireline.
(24) The Air tugger Operator stops when the wireline hook has reached the rig floor.
弐四. Changing Out Dead Line Stabilisers

2 x 12 inch Pipe wrenches 1/2 inch Rope
Screwdriver Safety harness
Pliers
1. Safety harness must be worn at all times during this operation. Ensure that
they are checked and are in good working condition.
3. STANDARD OPERATIONAL CONSIDERATIONS ( DO’S AND DON’TS)
(1) The Driller / Assistant Driller must supervise this operation.
(2) Restrict access to the rig floor during this operation.
(3) Use the riding belt only with rigs equipped with a man riding winch.
(4) Ensure that all hand tools are tied to the safety belt.
(5) Ensure that all non-essential personnel are off the rig floor during this operation.
4. INSTRUCTIONS
(1) The Derrickman or a Floorman positions himself at the dead line clamp and secures
his safety belt and life line to the derrick (mast).
(2) The Derrickman ties a 1/2 inch rope below the rubber guide to keep the insert from
falling when the clamp is opened.
(3) He then opens the clamp and removes the rubber.
(4) Using the 1/2 inch rope, the Derrickman pulls the dead line away from the insert and
then removes the insert.
(5) The Derrickman is to inspect the guide clamp itself for proper operation.
Note: The clamp hinge should move freely.
(6) The Derrickman installs a new rubber insert into the guide.
(7) The dead line is re-installed, ensuring that the dead line is in the centre of the insert.
(8) The Derrickman centres the dead line and the rubber insert as necessary before
closing and tightening the clamp.
弐伍. Derrick Inspections

Man riding basket Adjustable spanner wrenches
Riding belt Ring spanners
Safety harness Grease gun
Safety chain Locking pins
58
Hand tools
1. Check the Drilling Programme for Operator's safety regulations.
2. Extreme caution must be exercised during bad weather.
3. The rig floor is a restricted area while inspection or operational maintenance
is being performed in the derrick.
4. Ensure that any time there is work / personnel in the derrick that someone is
watching and can give an immediate emergency alert.
5. Prior to ascending the derrick, do the following:
(1) Prior to climbing into the derrick inform the Driller, a work permit may be
required. When the work in the derrick is finished inform the Driller as well.
(2) Inspect all lifting gear for current colour code.
(3) Check for the presence of oil, mud or ice on the derrick and tools. Clean
or remove where applicable.
(4) Inspect safety harness and life line for damage before they are used.
(5) Damaged harness or lines must be replaced with valid colour coded
items.
(6) Put on and adjust safety harness to a snug fit. Attach and secure life line
when working in the derrick at all times.
(7) All tools or equipment carried above the drilling floor must be in the tool
bag, attached to the safety harness when not being used. When working
above the drilling floor for inspection purpose only, do not carry any tools.
(8) The safety climber must always be used when climbing or descending the
derrick ladder.
RULE: Derrick Inspection is required as follows:
(1) Prior to drilling operations - after rigging up
(2) Once a week during operations - minimum
(3) After jarring operations
(1) All inspections will be documented, with particular emphasis on safety codes.
(2) Never climb the derrick without certified, colour coded safety harness and life line.
(3) All procedures will be in compliance with the COMPASS Maintenance System.
(4) Report all deficiencies, potential hazards and items requiring load testing and or re-
certification.
(5) All derrick components will be inspected after each rig move or jarring operation.
(6) A clear space, free of obstructions will be maintained at the base of the derrick
climbing ladder.
(7) Remove all hazards to safe footing or a secure handhold.
(8) Special tools or equipment used above the drilling floor will be raised and lowered
by securing them to the elevator, hook, hand-line, or winch line.
(9) Inspect for any indications of damage, for example warping or peeling of paint.
(10) Inspect the automated roughneck’s hoses and cables hang off points.
(11) Inspect the Top Drive System (TDS) hoses hang off point in the derrick.
(12) Inspect the TDS blower installation, making sure that everything is secure.
4. INSTRUCTIONS
59
4.1. Inspection
(1) Check that all hand-rails and hoop-rails around ladders are secure and in good
condition.
(2) Generally examine the derrick for distorted beams and loose bolts, ensure that all
components are secured.
(3) Report and / or remove all debris (loose ropes, slings, clamps, rags, etc.).
(4) Inspect drill-line guide and guide rollers for wear and security.
(5) Ensure that all the electrical cables, wire and lighting fixtures are checked:
(a) Check that there is no water seepage into light fixtures, re-seal or replace as
necessary.
(b) Ensure that all electrical cables are safely located, secured and are in good
condition.
(c) Ensure that the derrick floor lights on wind walls are properly focused on floor work
area.
(6) Examine the casing stabbing board with special attention to the following:
(a) Check the general condition of the stabbing board.
(b) Check the condition of the rear guard rails.
(c) Check the safety line and ensure that it is properly secured.
(d) Ensure that the hinges are in good condition.
(e) Check the winch line guide roller condition and ensure that the mounting bracket is
secured.
(f) Ensure that the winch line is not touching or coming in contact with any metal parts.
(g) Check the test date of the winch cable, chain and hook.
(h) Check the condition of the safety brake and test before each use.
(7) Examine the fingerboard and the monkeyboard with special attention to the
following:
(a) Ensure that the fingers are properly welded and secured with a safety chain where
applicable.
(b) Ensure that the monkeyboard is straight, and secured with a safety chain.
(c) Ensure that the monkeyboard mats are tied down securely.
(d) Check the operation of the hinged deck at the front of the platform and ensure that it
functions properly.
(e) Check the condition of the tie back chains (or ropes) for drill collars and drillpipe,
ensure that they are in good condition and secure.
(f) Check the condition of the tugger line guide roller and the mounting bracket.
(g) Ensure that the tugger line does not contact or rub against any metal parts. Test the
tugger brake.
(h) Check the oil level of the winch, the remote control and its air hose for leaks.
(i) Check the condition of all rope work and safety chain.
(j) Test the intercom (paging or tannoy) system and ensure operation for two way
communication.
(k) Check the speaker and paging box and secure if necessary.
(l) Ensure that all shackles are locked with safety pins and the safety line attachment is
in good condition.
(m) Ensure that the emergency breathing apparatus is secure and functional. Refer to
60
the Drilling Programme for requirements.

(n) Check that eye wash bottle is clean, secure and sealed in its proper container.
(8) Examine the deadline stabiliser and note as follows:
(a) Ensure that all bolts and nuts are tight.
(b) Check the condition of the rubber guides and mark for replacement if necessary.
(c) Ensure that the safety line of the deadline stabiliser is properly secured to the
derrick.
(d) Ensure that the deadline is not touching the derrick (bolts or other metal
projections).
(9) Check the standpipe manifold, report and repair as follows:
(a) Ensure that all piping is securely clamped.
(b) Ensure that all hammer unions are tight and secure.
(c) Check that all hose connections and hoses are in good condition.
(d) Check that the safety line is as short as possible from hose to derrick and is properly
located and secured.
(10) Check the kelly spinner power supply piping / hose condition and safety line.
(11) Examine the Derrickman escape line and note the following:
(a) Ensure that the colour code certification is visible and it is current.
(b) Check the wire connection and clamp, ensure that they are operable and in good
condition.
(c) Ensure that the main shackle securing point is not damaged.
(d) Ensure that load tests are done at specified intervals.
(12) Inspect the safety climber and ensure the following:
(a) The safety wire or rail is properly and firmly secured.
(b) The safety climber is in good condition, not corroded and moves freely on the wire
or rail.
(c) The sheave and its mounting bracket on the crown block are secure and
satisfactory. Grease if necessary.
(d) Ensure that the safety climber is functioning properly.
(e) Check the date of the last test.
(13) Inspect rig tongs suspension / counterbalance lines as follows:
(a) Check pulley for freedom of movement and alignment.
(b) Ensure that the safety tieback strap is undamaged and serviceable.
(c) Ensure that there is free movement when the tongs are raised and lowered from full
up to full down position.
(d) Check for damaging wear to the suspending wire and ensure that the clamps are
properly secured.
(14) Examine the items below the water table and report on the condition of the
following:
a) Check for damage to the wooden buffer and the safety wire mesh.
b) Ensure that the safety wires are properly secured (i.e. on the deadline guides).
c) Check the tugger winch pulley, groove wear, alignment and bracket condition.
(15) Check the water table and the crown block as follows:
(a) Remove excessive tar on the crown sheaves.
(b) Check that all crown block / derrick bolts are tight.
61
(c) Ensure that the crown block bracket, frame and guides are aligned and secure.
(d) Check crown sheaves every three months or during rig move with calliper, look for
irregular wear or flat spots.
(e) Check recorder (geolograph) wire if installed. Ensure that the wire is in good
condition.
(16) Check block and sheaves for operational integrity and freedom of movement.
(17) Check hook, bails and latch mechanisms for damage or excessive wear.
(18) Check swivel and rotary hose integrity and safety line condition.
(19) Check the V-door rollers and grease them.
(20) If applicable, check the camera in the derrick, ensure that the special mounting of
the camera is working. Clean the lens of the camera.
(21) Report all equipment or installations in the derrick not included in this Work
Instructions.
4.2. Maintenance
(1) Refer to the COMPASS Maintenance System for periodic certification requirements.
(2) Grease and lubricate in compliance with COMPASS.
弐六. Dead Line Anchor Maintenance

Measuring tape or nozzle gauge Fitted wrench
W-15 (Martin Decker fluid) Clean, non-fluffy cloth
YA-2 (Martin Decker) hand pump Sensator gauge
No Special Safety Instructions
(1) Inform Toolpusher / Driller and Mechanic prior to starting task.
(2) Ensure that the W-15 fluid and the hand pump are clean.
(3) Ensure that nothing is hanging on the block, (unless rig is equipped with a top drive).
(4) The Assistant Driller / Driller / Toolpusher is required to check:
(a) The gap on the sensator.
(b) The proper working of the dead line anchor.
4. INSTRUCTIONS
(1) With the drillstring resting in the slips, check gap using the gauge on the sensator;
this should be 16 mm (5/8”) approximately. If gap decreases to 9 mm (3/8”), then the
system is low on fluid.
(2) Pump up the sensator:
(a) Remove the protection nut.
(b) Ensure that the hand pump and the fluid are perfectly clean.
(c) Install the hand pump, then fill the pump piston with W-15 fluid.
(d) Pump air out of the system by bleeding air at the tubing connection on the gauge.
(e) Continue pumping until the Martin Decker needle gauge starts to move.
(f) Overcharge the system then push a thin clean rod into the valve and bleed off
excess until the weight indicator shows block weight equivalent to the rig’s block weight
(sensator gap approximately 16 mm or 5/8 inch).
(g) Refit the protection nut.
(3) Anchor checks:
62
(a) Ensure that the anchor is free to move and it is greased at regular intervals.
(b) Ensure that the anchor pins are kept free of paint and corrosion. The pins and
sensator must be removed for inspection, cleaning and greasing, at least once on each
well.
(c) Check the anchor movement by using a lever between the wheel and the anchor
stop. When force is applied, the gauge needle should move rapidly.
弐七. Slipping and Cutting Drilling Line

Socket set and ratchet Torque wrench
Hydraulic line cutter Hydraulic fluid and Hand pump
Dedicated hanging line 2 x Safety harness
Wire brush Detergent
Soft wire
1. Never cut and slip the drilling line with the drillstring in the open hole or with
the drillstring out of the hole.
2. Under all circumstances, visual inspection of the drilling line must take
precedence over the predetermined slip and cut procedure.
3. Upon completion of any operations involving the drilling line, ensure that a
minimum of 9 full wraps of drilling line remain on the drawworks drum, with
the elevators at the rotary table.
4. Prior to lowering the top drive system or rigging down, ensure that sufficient
wraps of drilling line remain on the drum.
5. The clamp assembly on the fast line end as a whole must be changed out
each time a new cable is installed.
6. Safety harness must be worn by all personnel working on the travelling block
or the top drive.
3. OPERATIONAL DO’S AND DON’TS
(1) Hold a Toolbox Talk before starting the task and ensure that the work force is fully
instructed on the correct procedures to be followed and the safety precautions to be
observed.
(2) The drill floor must be cleared of all personnel not associated with the task.
(3) Always slip and cut the drilling line with the drillstring in the cased hole and the bit is
at or near the casing shoe.
(4) Ensure that all hanging devices (shackles, strops, etc.)have been inspected and are
of the correct size.
(5) Ensure that all tools and equipment are in a clean and serviceable condition.
(6) Ensure that the dedicated hang-off line is inspected and has the current colour code.
(7) When the drilling line is completely removed from the drawworks drum, the lebus
grooves are to be inspected for any wear or damage.
(8) Ensure that the front drawworks guard is put back in place when the operation is
complete.
(9) The Driller is to record the slip and cut operation in the tour book.
4. INSTRUCTIONS
4.1. Slipping the Drilling Line
63
(1) The Driller sets the drillstring in the slips.

(2) The Driller lifts the elevators clear and the Floormen install the kelly cock in the open
position on the tool joint at the rotary table.
(3) The Floormen unwinds sufficient drilling line (about 15 metres) from the storage
spool.
(4) All extra personnel clear the rig floor.
(5) The Derrickman or a Floorman, secured with a safety harness, attach the dedicated
hanging line to the travelling block or the top drive.
(6) The Driller slowly hangs off the travelling block or top drive in accordance with the
Derrickman’s or Floorman’s signal.
(7) Utilising the socket torque wrench, the Floormen loosens the six nuts on the dead
line anchor clamp. Ensure that the clamp is not totally removed.
(8) The Floormen loosen the clamps of the weight indicator diaphragms, so they are
able to slide the drilling line as it is being reeved on the drawworks drum.
(9) Three Floormen at the dead line anchor, feed the drilling line through the dead line
anchor clamp.
(10) The Driller engages the drawworks in forward drive and slowly spools the correct
length (based on Ton Mile calculations) of drilling line onto the drum, while the
Floormen continue to feed the drilling line through the dead line anchor clamp.
(11) Upon the Driller’s instruction, the Floormen tighten and torque the nuts on the dead
line anchor clamp with the socket torque wrench.
(12) Never lubricate the dead line anchor itself.
(13) The Driller slowly picks up the travelling block or top drive and the Assistant Driller
and a Floorman release the dedicated hanging line and tie it safely away.
(14) The Floormen tighten the weight indicator diaphragm clamps back on the dead
line.
(15) Check the spacing of the dead line sensor on the dead line anchor.
Note: The gap between the top and the bottom cells should be 16 mm (5/8 inch) with
the travelling block or top drive hanging on its own weight. If the gap is less than 9 mm
(1/2 inch), then refer to W.I. Section 3.7.: Dead Line Anchor Maintenance.
(16) The Driller restores the power to the Crown-O-Matic safety device or the ACS unit,
adjusts, and tests the braking system.
(17) The Floormen remove the kelly cock from the drillstring.
(18) The Driller resumes normal drilling operations.
4.2. Cutting the Drilling Line
(1) The Driller sets the drillstring in the slips.
(2) The Driller lifts the elevators clear and the Floormen install the kelly cock in the open
position on the tool joint at the rotary table.
(3) All extra personnel clear the rig floor.
(4) The Derrickman or a Floorman attach the dedicated hanging line to the traveling
block or the top drive.
(5) The Driller slowly hangs off the travelling block or top drive in accordance with the
Derrickman’s or Floorman’s signal.
(6) The Floormen remove the front cover of the drawworks.
(7) The Driller counts the wraps of drilling line from fast line and marks this length
64
corresponding to the specific length for the slip and cut programme.
(8) Two Floormen secure the drilling line (fast line) on one side of the drawworks.
(9) The Driller engages the drawworks in reverse drive and
(a) sets throttle at minimum speed,
(b) engages the low clutch and slowly un-spools the drilling line off the drawworks drum.
(10) At the same time, the Floormen guide the drilling line until the mark on the drilling
line reaches the floor.
(11) The Driller disengages the drum clutch and secures the drawworks.
(12) The Driller ensures that the drilling line is wrapped with the soft wire or tape at both
sides of the mark before cutting the drilling line with the hydraulic line cutter.
(13) After the drilling line has been cut, the Floormen pull remaining fast line out of the
way.
(14) The Driller engages the drawworks in reverse drive and the Floormen guide the
remaining drilling line on the drum down the V-door.
(15) The Driller disengages the drum clutch when there is 1 or 2 wraps left on the drum.
(16) The Floormen remove the drilling line from the anchor clamp and dispose of the old
drilling line.
(17) A Floorman cleans the end of the newly cut drilling line (fast line) with a wire brush
and detergent.
(18) Install newly cut drilling line into the drawworks drum and fasten the clamp with the
torque wrench.
(19) The Driller engages the drawworks in forward drive and (a) sets the throttle at
minimum speed (b) engages the low clutch and slowly spools the drilling line on the
drawworks drum.
Note: Ensure that the drilling line is in tension at all times. Slack in the drilling line can
not be tolerated
(20) The Driller slowly picks up the travelling block or top drive and the Derrickman or a
Floorman release the designated hanging line and secure it safely out of the way.
(21) Ensure that the drilling line is snug-tight in grooves of the drawworks drum.
(22) The Floormen reinstall the guards over the drawworks drum.
(23) The Driller restores the power to the Crown-O-Matic safety device, adjusts, and
tests the ACS breaking system.
(24) The Floormen remove the kelly cock from the drillstring.
(25) The Driller then resumes normal operations.
弐八. Reeving on Drilling Line

3 Two-way radios Snatch block and slings
1-1/2 inch Snake and Swivel Safety goggles and Gloves
Torque wrenches 365 metre 1” manila Rope
Drawworks Anchor clamp 60 metre x 1/2 inch Rope
Hydraulic line cutters Cleaning fluid detergent
Wire brush Safety harness
Nails, Soft wire, and Tape
1. Direct communication between all personnel is essential during this
65
operation.
2. The drawworks anchor clamp assembly on the fast line end must be changed
out, as a whole, each time a new cable is installed.
3. Travelling block hanging strops and shackle, snake and safety harness must
be inspected before this operation commences.
4. All crew members working in derrick must wear safety harness.
5. A visual inspection of the drilling line is to be done before the procedure
commences.
3. OPERATIONAL / DO'S AND DON'TS
(1) Toolbox Talk must be held before the reeving operations commence.
(2) Check and ensure the proper size and specifications of the replacement drilling line.
(3) Correct size and positioning of the hanging equipment for the weight of traveling
blocks is essential.
(4) New drilling line must always be spooled from bottom of the storage spool.
(5) Avoid scrubbing the new drilling line against the derrick and the substructure.
(6) The new drilling line must be reeved on to the drawworks drum under tension.
(7) The new drilling line should never be allowed to touch the ground where dirt or sand
could be picked up.
(8) Special care must be taken when the snake travels through the crown sheaves and
the travelling block in order not to separate line from snake.
(9) Inspect crown sheaves for wear prior to installation of drilling line.
(10) Special care shall be taken to ensure the drilling line is not kinked.
4. INSTRUCTIONS
4.1. Reeving on Drilling Line from New Spool to Replace Existing Drilling Line.
(1) Hang off the drillstring in slips and install the kelly cock (in the open position), on the
drillpipe,
(2) Disengage the Crown-O-Matic and/or ACS safety device.
(3) Hang off and secure the travelling block with the dedicated hang-off line.
(4) Remove the remaining drilling line from the old storage spool.
(5) Dismantle the chain drive from the old storage drum.
(6) Cut off the excess drilling line from the old storage spool using the hydraulic line
cutter, leave a sufficient length to attach a snake to the old drilling line.
(7) Remove the old storage spool from the skid and install the new spool.
(8) Thoroughly clean the sections of both the new and old drilling lines to be spliced
with the snake, and remove any grease or oil (the snake line depends on friction to
function).
(9) Connect the old and the new drilling lines with the snake.
Note: Ensure that the snake is correctly in place over its full length.
(10) For added holding and pulling strength, drive four nails through the snake at both
ends of drilling line, and wrap the snake with soft wire and tape the entire length.
(11) Release the clamp from the dead line anchor and remove the old drilling line.
(12) Install the proper size snatch block with strops at or near the dead line anchor.
(13) Insert the drilling line that was removed from the dead line anchor into the snatch
block.
(14) The Derrickman, positioned at the crown block, is to advise the Driller when the
66
snake is coming through the crown sheaves.

Note: The Driller and the Derrickman must remain in constant radio contact.
(15) Two Floormen, located at the new drilling line spool, are to reeve off the drilling
line.
(16) One Floorman shall stand close to the spool to inform the Driller with a two-way
radio when there is no loose drilling line coming off the spool.
(17) The Driller is to proceed cautiously and not pull excessive tension that could
separate the snake.
(18) When all personnel are ready, the Driller engages the drawworks in forward drive
and starts reeving in the new drilling line.
(19) The Driller spools slowly and with extreme caution not to over-tension the snake
until at least 9 wraps of new drilling line are on the drawworks drum.
(20) On the Driller's instruction, the Floormen secure the new drilling line to the side of
the drawworks.
(21) Wrap the new drilling line on the dead line anchor (2-3/4 wraps). Install the clamp
on the dead line anchor and torque until securely tight.
Note: Ensure there is no kink in the drilling line between the deadline anchor and the
drilling line reel. Should this occur, raise the reel and turn it to undo the kink.
(22) The Floormen remove the front guard of the drawworks drum.
(23) The Driller engages the drawworks in reverse drive.
(24) The Driller reeves off the new drilling line from the drum until the snake is reeved
off.
(25) The Floormen then remove the snake from the drilling lines.
(26) The Driller reeves off the old drilling line from the drawworks to the rig floor or down
the V-door.
(27) When the old drilling line is reeved off, remove the drawworks anchor clamp.
(28) A Floorman cleans the end of the drilling line using a wire brush and detergent
fluid.
(29) The Driller checks the end of the new drilling line for damage, and any defective
section is cut off, using a hydraulic line cutter.
(30) Feed the new drilling line (fast line) through the side of the drawworks drum.
(31) Install a new drawworks anchor clamp (bulldog clamp). Orient the clamp and
ensure that it will fit through the slot on the side of the drawworks drum.
Note: Some drawworks are equipped with a fixed clamp on the side of the drum.
(32) Set the anchor clamp into the drum by manually pulling the new drilling line back
through the drum, while a Floorman is guiding it into the drum.
(33) Release the new drilling line from the side of the drawworks.
Warning: Ensure that no personnel are inside the loop of the drilling line during the
next step.
(34) The Driller engages the drawworks in forward drive and reeves the new drilling
line back onto the drawworks drum, minimum of 9 wraps with the elevators on the
rotary table.
Note: The Driller must ensure that the drilling line is reeved in under tension and that
the drilling line is properly seated in the drum grooves. There is no tolerance for any
slack in the drilling line reeved on the drum.
67
(35) If the new drilling line was not reeved on to the drawworks drum tight, then tighten
the drilling line as follows:
(a) Release the travelling block from the dedicated hang off line.
(b) Lower the travelling block until minimum of 3 wraps remain on the drum.
(c) If the travelling block is not at the rotary table with 3 wraps remaining on the drum,
then slip the drilling line until the travelling block is at the rotary table.
(d) Raise the travelling block to where at least 9 wraps are on the drum and confirm that
the elevators are at the rotary table.
(36) The Driller picks up the weight of the travelling block to verify that the drilling line is
tight on the drawworks drum.
(37) Install the covers on the drawworks.
(38) Engage the Crown-O-Matic and/or ACS safety device and test.
(39) Remove the kelly cock from the drillstring.
(40) Resume operations per the Drilling Programme.
4.2. Reeving on New Drilling Line on Empty Sheaves with a Standing Derrick
(1) Disengage the Crown-O-Matic and/or ACS safety device, place the travelling
block on the rotary table and remove the sheave guards.
(2) Anchor the proper size snatch block at or near the dead line anchor and secure.
(3) Insert the drilling line from the spool through the snatch block up to the rig floor and
secure.
(4) Thoroughly clean the section of the new drilling line to be spliced with the snake,
and remove any grease or oil (the snake line depends on friction to function).
(5) Attach a 1-1/2 inch snake to the drilling line.
(6) For added holding and pulling strength, drive four nails through the snake and the
drilling line, and wrap the snake with soft wire and tape the entire length.
(7) Raise one end of 60 meter 1 inch manila rope to the crown block with air tugger.
(8) Reeve the 1 inch manila rope through the first crown sheave.
(9) Lower the 1 inch manila rope to the rig floor and reeve into the first sheave of the
travelling block.
(10) Repeat steps (7) through (9) until all the sheaves are reeved in. Ensure the
predetermined number of sheaves are used.
(11) Remove the front guard cover of the drawworks.
(12) Lower the 1 inch manila rope down the fast line sheave and wind on the drawworks
drum.
(13) Manually reeve 6 wraps of the 1 inch manila rope on to the drawworks drum.
(14) Attach the other end of the 1 inch manila rope to the snake on the drilling line.
(15) The Derrickman, positioned at the crown block, is to advise the Driller when the
snake is coming through the crown sheaves.
Note: The Driller and the Derrickman must remain in constant radio contact
(16) Two Floormen, located at the new drilling line spool, are to reeve off the drilling
line.
(17) One Floorman shall stand close to the spool to inform the Driller with a two-way
radio when there is no loose drilling line coming off the spool.
(18) The Driller is to proceed cautiously and not pull excessive tension that could
68
separate the snake.

(19) When all personnel are ready, the Driller engages the drawworks in forward drive
and starts reeving in the new drilling line. At the same time, two Floormen guide the 1
inch manila rope off the drawworks drum and onto the rig floor and down the V-door.
Note: The Driller will spool slowly and with extreme caution, not to over-tension the
snake until the new drilling line is on the drawworks drum.
(20) When the drilling line reaches the drawworks drum pull through 9 wraps of the
drilling line to enable the drilling line to be threaded onto the drawworks drum.
(21) The Driller must ensure the fast line is securely tied off so that it cannot unreeve by
itself.
(22) With the fast line tied off, remove the snake from the drilling line, and remove the 1
inch manila rope from the drawworks drum.
(24) Set the anchor clamp onto the drum by manually pulling the new drilling line back
through the drum, with a Floorman guiding it into the drum.
Warning: Ensure that no person is inside the loop of the drilling line during the next
step.
line back onto the drawworks drum minimum of 9 wraps with the elevators on the rotary
table.
(26) Secure the drilling line to the dead line anchor (2-3/4 wraps) and torque.
(27) With the new drilling line properly reeved on to the drawworks drum, pick up the
weight of the travelling block, test the drawworks brake, and verify that the drilling line is
tight on the drum.
(28) Install the covers on the drawworks.
4.3. Reeving in the Drilling Line to Raise the Derrick
(1) Secure the travelling block to the catwalk, with the sheaves aligned with the crown
and the hook pointed upward, with the raising line attached.
(2) Attach a proper size snatch block at or near the dead line anchor and secure.
(3) Feed the drilling line through the snatch block near the dead line anchor and back to
the travelling block to install the snake.
(4) Thoroughly clean the section of the drilling line to be covered with the snake and
remove any grease or oil (the snake line depends on friction to function).
(5) Attach the 1-1/2 inch snake to the drilling line.
(7) Remove the sheave guards on the travelling block.
(8) Pull the 1 inch manila rope inside the derrick and feed and reeve through the first
69
crown sheave.
(9) From the crown sheave, manually pull and reeve the 1 inch manila rope through the
first sheave of the travelling block.
(10) Repeat steps (8) and (9) until all the sheaves are reeved in. Ensure the
predetermined number of sheaves are used.
(11) Next, reeve the 1 inch manila rope through the fast line sheave and pull back to the
A-Frame, over the A-Frame sheave, and down to the drawworks drum.
(12) Remove the front cover of the drawworks.
(13) Manually reeve 6 wraps of the 1 inch manila rope on to the drawworks drum.
(14) Attach the other end of the 1 inch manila rope to the snake on the drilling line.
(15) The crew members are positioned as follows:
the Derrickman is at the crown block,
two Floormen are at the drilling line spool, and
two Floormen are at the drawworks drum.
Note: Direct two-way radio communication is essential from this point forward.
(16) The Driller engages the drawworks in forward drive and pulls the 1 inch manila
rope onto the drawworks drum.
(17) At the same time, two Floorman at the drawworks guide the 1 inch manila rope
coming from the drawworks back onto the rig floor or down the V-door.
(18) The Driller continues pulling in the drilling line until the crown and traveling blocks
have been completely reeved, plus 9 wraps of excess drilling line to be wrapped onto
the drawworks drum.
(19) The Driller must ensure the fast line is securely tied off so that it cannot unreeve by
itself.
(20) With the fast line tied off, remove the snake from the drilling line, and remove the 1
inch manila rope from the drawworks drum.
fluid.
(26) Release the new drilling line from the side of the drawworks.
step.
rotary table.
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(29) Install the front drawworks guard cover.
(30) Install the travelling block sheave guards.
4.4. Reeving from 10 Lines to 12 Lines
(1) Hang off the drillstring in slips and install the kelly cock (open position), on drillpipe,
(2) Disengage the Crown-O-Matic and/or ACS safety device.
(3) Hang off and secure the travelling block with the dedicated hang-off line.
(4) The Driller engages the drawworks in reverse drive and slowly spools the drilling
line from the drawworks drum.
(5) The Floormen guide the drilling line coming from the drawworks drum and spool the
drilling line on the rig floor.
(6) The Driller continues spooling off the drilling line until the last 2 wraps.
(7) Tie-off and secure the drilling line at the drawworks and then remove the drawworks
anchor clamp (the bulldog clamp).
(8) Based on Ton Mile calculations, cut off the proper length of drilling line.
(9) Attach the 1-1/2 inch snake to the drilling line. Ensure that the snake is correctly in
place over its full length.
(10) Thoroughly clean the section of the new drilling line to be spliced with the snake,
and remove any grease or oil (the snake line depends on friction to function).
(11) Attach the 1 inch manila rope to the other end of the snake on the drilling line.
(13) The drilling line is now taken off the dead line anchor and attached to a proper size
snatch block secured at or near the dead line anchor.
(14) Using the air tugger motor installed on the storage spool, the drilling line is untied
and spooled onto the storage spool.
(15) Stop when the drilling line and the snake leave the fifth sheave in the traveling
block. Secure the drilling line at the travelling block and then remove the snake from the
1 inch manila rope.
(16) Manually reeve the 1 inch manila rope over the fifth sheave of the crown block,
drop down to the travelling block.
(17) Pull the 1 inch manila rope up and over the fifth sheave in the crown block and
back down to the travelling block.
(18) Manually reeve the 1 inch manila rope through the fourth sheave of the traveling
block.
(19) Attach the 1 inch manila rope to the snake and the drilling line. See step (12)
above.
Note: All sheaves are now reeved and ready for spooling.
(20) Spool the 1 inch manila rope 12-1/2 wraps around the drawworks drum.
(21) The Driller engages the drawworks in forward drive and spools the 1 inch manila
rope onto the drawworks drum, using extreme caution. At the same time, the two
Floormen feed off the manila rope onto the rig floor.
(22) The Driller continues until the drilling line is completely reeved around the travelling
and the crown block sheaves and down to the drawworks drum. Stop when at least 9
wraps of the drilling line are on the drawworks drum.
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(23) The Driller ensures that the drilling line is securely tied at the drawworks.
(24) Remove the snake and the 1 inch manila rope.
(25) The Driller engages the drawworks in reverse drive and unspools the drilling line
until all the drilling line is on the rig floor.
fluid.
step.
rotary table.
(33) With the new drilling line properly reeved on to the drawworks drum, pick up the
weight of the travelling block and verify that the drilling line is tight on the drum.
(34) Remove the travelling block from the dedicated hang-off line.
(35) Adjust the weight indicator scale from 10 lines to 12 lines.
(36) Install the front drawworks guard cover.
(38) Remove the kelly cock.
(39) Resume operations as per the Drilling Programme.
弐九. Adjusting and Testing the Crown-O-Matic

Adjustable spanner Small pipe wrench
35 m Rope
1. While adjusting the pilot toggle on the drawworks, ensure that the drawworks
power is shut off.
2. Ensure that the Crown-O-Matic testing is carried out only in the area of the
fingerboard to avoid hitting the crown.
3. While testing the Crown-O-Matic, ensure that legs are kept well away from
the brake handle. Keep rig floor free of personnel not needed for the test.
4. When the crown-o-matic system is bypassed an audible or visual warning
must be activated
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(1) Ensure that the Crown-O-Matic is adjusted and tested each time the drilling line is
slipped or slipped and cut.
(2) Ensure that the Crown-O-Matic system is function tested before each trip.
(3) Ensure that the Driller is at the drawworks controls, whenever test procedure is
carried out.
(4) Ensure that after the Crown-O-Matic is engaged, the relief valve on the control panel
is operating properly.
(5) Test results are to be reported in the tour book.
4. INSTRUCTIONS
4.1. Adjusting the Crown-O-Matic Braking System
(1) Pick up a stand of drillpipe with the travelling block and position the pin end of the
stand approximately 2 metres above the tool joint in the rotary table.
(2) Mark the position of the drilling line on the Crown-O-Matic valve rail over the
drawworks drum.
(3) Stab the stand into the string at the rotary table and chain down the brake.
(4) Shut off the drawworks.
(5) Slide the Crown-O-Matic valve assembly (pilot toggle) along the rail to the mark
which was made to indicate the drilling line position in Step (2) above. Tighten the
locking bolts.
(6) Screw the adjustable nipple on the pilot toggle in or out so that the nipple makes
contact with the topmost wrap of the drilling line. Tighten the counter-bolt on the nipple
to lock.
(7) Make up the connection and pick up the drillstring until the drilling line makes
contact with the nipple and activates the Crown-O-Matic breaking system.
Note: The Crown-O-Matic valve position may have to be adjusted for drilling and for
handling bottom hole assemblies.
4.2. Monthly Testing of the Crown-O-Matic as per COMPASS
Note: This test is to be conducted monthly, as well as after major modifications of the
drawworks, like changing the brake bands or after changing the number of lines strung
in the derrick.
(1) Lower the travelling block and when feasible attach approximately 35 metres (or the
required length) of rope onto hook, 25 metres (or less) rope for doubles-mast.
(2) Raise the top edge of the travelling block to the fingerboard.
(3) Adjust the position of the pilot toggle over the drawworks drum so that it makes
contact with the topmost wrap of the drilling line.
(4) Mark the height of the travelling block on the rope, from the top edge of the rotary
table.
(5) Lower the travelling block and spool the rope properly on the rig floor.
(6) Raise the travelling block with a safe rate of speed, to the pre-determined height to
engage the Crown-O-Matic.
(7) After the Crown-O-Matic has engaged and dropped the brake handle, mark the new
position of the travelling block on the rope and measure the brake distance between the
two markings at the rope.
(8) With a signal man up in the derrick hoist the travelling block slowly close to the
crown and mark the rope again.
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Set up the toggle valve at the right position (measured braking distance plus 0,5 metres
safety distance).
Note: If the brake distance is longer than the available space between the longest
stand and the crown, please contact immediately department TG.
参零. The Anti-Collision System (ACS)

1. INTRODUCTION
(1) The Anti Collision System (ACS) is designed to improve safety and efficiency of the
movement of the Travelling Block Assembly during hoisting and lowering operations.
(2) The drawworks can be equipped with three individual braking systems. The
sequence of applying the various braking systems are as follows:
(a) The drawworks d. c. motor regenerative braking where applicable
(b) Eddy Current Brake
(c) Disc brake or Band brake
(3) Braking requirements are determined by dual Programmable Logic Controller (PLC)
units located within the ACS system cubicle.
(a) The PLC units obtain information from the drawworks associated sensors and
compares actual braking requirements with the braking power available.
(b) The PLC algorithm will calculate the degree of braking required and provide the
relevant signals to the braking systems and to a warning light and acoustic alarm where
applicable.
(4) The main regenerative braking system will be the primary braking system (only PT-
2000) but is supplemented by the Eddy Current Brake under conditions determined by
the PLC logic.
(5) The ACS provides analysis of the kinetic energy of the Hoisting System taking into
account the braking capacity of the entire system, hook load, speed and position of the
Travelling Block Assembly.
(6) It avoids collisions with the crown block and rig floor.
(7) As an operational system, it provides relief for the Driller during routine
operations like tripping, bringing the Travelling Block Assembly to an accurate and safe
stop at predetermined and programmable working positions.
Note: Except on the PT-2000, it is the Driller’s responsibility not to rely solely the ACS.
(8) The ACS reduces to a minimum severe damage of equipment and possible injury to
rig floor personnel.
(9) The system provides the operator with a user-friendly interface and allows (Teach
In) working positions to be defined.
(10) The system is capable of interlocking (handshaking) with other systems i.e.
Automated Roughneck, Star Racker, to provide inhibits for anti-collision algorithms.
2. GENERAL FEATURES OF THE SYSTEM
(1) Only qualified personnel is to carry out maintenance and repairs on the ACS
system.
(2) The Anti Collision System is a System which operates in conjunction with the
Drawworks-Control (for upward movement) and the Eddy Current Brake System and
Emergency Braking System.
(3) All sensor measurements and input data from the control and monitoring unit are
controlled independently by two microprocessors.
74
(4) Both microprocessors calculate independently, Hook-Position, Speed, Hook- Load

and Braking Distance.
(5) According to their Control Algorithm both microprocessors are able to apply
independently the Eddy Current Brake System and the Emergency Brake System
taking into account the kinetic energy of the system and the braking capacity of the
Drawworks Braking System.
(6) Parameters like Hook-Position and Braking Distance are continuously checked and
compared by both microprocessors and any discrepancy will be regarded as an ACS
“System fault” and will activate the Eddy Current Brake System and the Emergency
Brake (optional).
(7) A visual and acoustic alarm will alert the Driller of automatic braking. Both
microprocessors check continuously:
(a) Any discrepancy between the two speed and position sensors
(b) Fault load sensor
(c) Fault range of travel sensor
(d) PLC-control fault
(e) Power-supply PLC low
(f) PLC-system fault
(g) Brake-rotor-speed value missing
(h) Hardware fault PLC-contacts
(i) Hook position > 100%
(j) Hook position < 0%
(8) All above mentioned faults will be regarded as a total “system fault” and the Eddy
Current Brake will be applied and where applicable the Emergency Brake.
(9) In Automatic Mode the system calculates the braking distance automatically, taking
into account, actual speed and load, and upper and lower set points to optimum
conditions.
(10) The Driller will be alerted automatically when the system algorithm determines
according to speed, load and position 200% of available braking distance.
(11) At a level of 100% braking distance available, the system will automatically apply
the Eddy Current Brake. In addition, according to control algorithm, the System can
automatically apply the Emergency Brake (if fitted) when braking is necessary.
(12) Resetting the Screen: Press “TROUBLE RESET” button.
(13) Help Text: For the typical malfunction(s), the relevant help text shows up on the
display screen when the “HELP” button is pressed. One can scroll through the help text
by pressing the “HELP” button or by pressing the “arrow down” and “arrow up”
buttons simultaneously.
(14) Corrective Action: A corrective action can be activated by pressing the
“TROUBLE RESET” button.
Note: If the “TROUBLE RESET” button does not reset the malfunction, then switch
system to “MANUAL” mode.
Note: The Eddy Current Brake remains at 100% automatically, when a malfunction
occurs or the emergency brake is activated when applicable.
(15) Switching the system to Manual Mode: Always switch the system to MANUAL
MODE whenever maintenance is done on the drilling line, such as reeving, cutting and
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slipping.
(16) Manual Mode Operations: When the ACS is in the “Manual” mode there are no
“Stop Limits” unless the brake is manually activated by the Driller. The Working Position
High (WP High) limit, The Working Position Low ( WP Low) limit, and the Hook Position
indicators are non-operative.
(17) Adjusting the ACS: If the “TROUBLE RESET” button does not reset the
malfunction, and every time the system is switched from “MANUAL” mode to
“AUTOMATIC” mode, follow the instructions in Paragraph 5.1., “Basic Adjusting of the
Anti-Collision-System (ACS)” in the Work Instruction section relevant to your
particular rig or the Manufacturer’s Service Bulletin specific to your rig.
参壱. Nipple Up and Nipple Down BOP

Sledge hammer Safety belts and Life lines
BOP Lifting beams and winches Hammer wrenches
Hydraulic torque tool Grease and Cleaning rags
Ring gaskets Studs, nuts and bolts
High pressure washer Cutting Torch
BOP work platform Hazard tape
Turnbucles to align BOP stack Double stud adapter (DSA)
Correct size and pressure BOP Drilling spool
Wellhead equipment
1. Obtain a work permit for Hot Work. Fire equipment must be readily available
whenever the cutting torch is be used.
2. Safety harnesses with safety lines attached to the safety chains hanging
from under the rotary table must be worn when crew members are working at
heights.
3. All lifting and hanging equipment must have current colour codes, inspected
for Working Load Limit (WLL).
4. Working area should be clear and clean.
5. Toolbox Talk must be held before operation begins. Discuss the operational
procedure, the equipment, tools and safety.
6. Working equipment should be clean and in good working condition.
7. Work area must be roped off with Hazard Tape. During movement of BOP,
non-essential personnel must retreat to a safe area.
(1) Supervision must be carried out by the Drilling Supervisor / DDSV during complete
operation.
(2) Ensure that the space out data / measurements are known before operation begins.
(3) Ensure that the flange is clean and dimensions are checked on the flow nipple / bell
nipple.
(4) Ensure that all wellhead, adapter and spool flange ring groves are cleaned,
examined and oiled.
(5) Ensure that the flanges of BOP are cleaned, inspected and oiled before installation.
(6) Check all ring gaskets for size, type and pressure rating and ensure that only new
76
gaskets are used.

(7) Check the hammer wrenches for size and serviceability.
(8) Check hang-off chains and lifting ring.
(9) Ensure that all stud bolts, nuts and threads are clean, free from damage or
corrosion.
Note: Ensure that the DSA / drilling spool are the correct size and pressure rating.
(10) Do not throw metal objects, such as hand tools, nuts, bolts, etc., up or down.
Always use rope, winch or ladder to carry tools.
(11) While stacking the BOPs, one section at a time, a work platform should be erected
at each break.
(12) Visually inspect the overhead lifting beams and ensure that the running beam is
clear of all obstructions.
(13) Ensure that the BOP hoist are operational and have been inspected and certified.
4. INSTRUCTIONS
4.1. Transport and Nipple up of 21-1/4" 2000 psi BOP
(1) Prepare for the installation of 21-1/4” BOP for running 20" casing (connect the
hydraulic lines and charge the accumulator).
Note: Always check size and type of rams that are installed in a BOP and record in the
I.A.D.C. report.
(2) After the 20" casing has been cemented, drain, jet and wash all cement from the
conductor above the cut off point.
(3) Remove the flowline and fill up lines.
(4) Activate and function test the BOP hoist.
(5) The 20" casing landing joint is then backed out and laid down.
(6) Move the BOP hoist over to the Flow Riser and attach.
(7) Raise the conductor with the BOP hoist to access the 20” casing.
(8) Remove the conductor from the cellar area and laid down.
(9) Install the wellhead on the 20 inch casing and tighten.
(10) Remove oil from wellhead ring groves and place new ring gasket.
(11) Install the drilling spool with BOP hoist or travelling block.
(12) With the BOP hoist, pick up and move the 21-1/4", 2000 psi BOP over the top of
the drilling spool.
(13) Clean the flanges and ring grooves and install the new ring gasket.
(14) Lower the 21-1/4” BOP stack on to the drilling spool and insert a minimum of four
studs and rig up complete stack before tightening the studs and nuts.
(15) Screw on nuts to leave the same number of threads showing above each nut.
(16) Torque the nuts in a sequence; the opposite ones first, then the ones which are
separated at 90 degree angles, then 45 degrees, etc.
Note: Proper make up with hammer wrenches or torque wrenches will ensure the gap
between flanges is even and that the exposed threads are equal above each nut. When
using a torque wrench ensure the correct lubricant and torque values are applied.
(17) Install the kill and choke lines.
(18) Install the flow nipple / bell nipple on top of the BOP stack.
(19) Attach lines to the BOP stack with turnbuckles to adjust and align with the rotary
table opening.
77
(20) Nipple up the hydraulic actuator (Koomey) lines.

(21) Install the fill-up and flow lines.
(22) Function test the BOP stack and then pressure test as per specifications and
record the results. Refer to the Drilling Programme.
Note: Do not install wear bushing before the complete stack assembly is tested.
4.2. Removal of the 21-1/4" BOP and Nipple-up of the 13-5/8" BOP
(1) Remove wear bushing, run 13-3/8” or 13-5/8” casing and cement.
(2) Open the drilling spool valve and thoroughly wash the inside of the BOP stack jetting
to waste pit.
(3) If applicable, wait on cement as per the Drilling Programme.
(4) Remove guide lines, fill-up line and hydraulic lines from the 21-1/4" BOP stack and
attach protectors to the lines.
(5) Remove the flow line, choke and kill lines.
(6) Position the BOP hoist over the 21-1/4" BOP, attach lifting chains and pick up to
remove slack from the chains.
(7) Remove the nuts and stud bolts from the drilling spool and put away for cleaning
and greasing.
(8) Pick up the 21-1/4” BOP one meter above the drilling spool with the BOP hoist.
(9) Wrap the slip and seal assembly around the 13-3/8” or 13-5/8" casing and hang,
and set as per the Drilling Programme.
Note: If using a cactus wellhead, use the cactus setting tool.
(10) Set the 21-1/4" BOP back down and pull the excess 13 3/8” or 13 5/8" casing and
lay it down.
(11) Remove the flow nipple / bell nipple and set back out of the way with air tugger.
(12) Pick up the 21-1/4" BOP and move to its transport frame.
(13) Lower the 21-1/4" BOP onto the transport frame or lift out by crane first, install and
tighten the bolts and nuts in preparation for transporting.
Note: Ensure that the ring grooves are cleaned and a new ring gasket is used on the
test stump.
(14) Install 13-3/8” or 13-5/8” casing head.
(15) Using the air tuggers, lift, install and make up the DSA on the casing head.
(16) Tighten the studs and nuts on the DSA and casing head.
Note: Testing of the wellhead and seal assembly will be done by the wellhead Service
Representative.
(17) Move the BOP hoist to a position above the 13-5/8" BOP.
(18) Attach The BOP hoist to the stack and secure connections.
(19) Remove bolts from 13-5/8” transport frame.
(20) Lift 13-5/8” BOP, gently, (snub with air tugger if needed) to proper height and move
over to the spool and DSA.
(21) Clean the oil from the sealing area of the 13-5/8" BOP and the spool with a soft
cloth.
(22) Check ring grooves for damage, scratches and corrosion pitting.
(23) Clean and dry gasket thoroughly.
(24) Install a new ring gasket in ring groove.
(25) Gently lower the 13-5/8" BOP onto the DSA, ensuring the alignment of the studs
78
and holes on the BOP flange and make up hand-tight.

separated at 90 degree angles, then 45 degrees, etc., using the hammer wrenches or
the torque wrench.
Note: Proper make up will ensure the gap between flanges is even and that the
exposed threads are equal above each nut.
(27) Attach and tighten the choke and the kill lines.
(28) Attach hydraulic lines from the Koomey unit, fill-up line and guide lines.
(29) Install the flow nipple and the flowline.
(30) Function test the BOP stack and then pressure test as per specifications and
record the results. Refer to the Drilling Programme.
4.3. Nipple Up on BOP after Running 9-5/8” Casing
(1) Run 9 5/8" casing, wash and clean the BOP, jet the mud and / or cement.
(2) Open or remove the drilling spool valve and drain the stack, wash the inside of the
BOP and jet cellar.
(3) Loosen the nuts on the spool to DSA and the nuts on the DSA to the BOP. Pick up
the BOP with the BOP winches, ensuring that both seals are broken.
(4) Lower the BOP and remove all the nuts from the bottom flange.
(5) Pick up the BOP and set the slips and seal assembly around the 9 5/8" casing.
(6) Lower the BOP, ensuring that the studs align with the holes.
(7) With the air tugger, remove the 9 5/8" casing.
(8) Disconnect the flow line and remove the flow nipple.
(9) Remove the nuts from the top flange (DSA to BOP) and lift the BOP with the BOP
hoist.
(10) Attach the air tugger to the suspended BOP and pull to one side.
(11) Attach the air tugger to the DSA and remove.
Note: The seal assembly will be tested by the well head Service Representative.
(12) Install a new ring gasket on the wellhead and lower the 11” spool with the DSA
onto the 11" casing head.
(13) Install a new ring gasket in the DSA and lower the BOP on to the DSA ensuring the
alignment of the studs and holes.
separated at 90 degree angles, then 45 degrees, etc.
Note: Proper make up will ensure the gap between flanges is even and that the
exposed threads are equal above each nut.
(15) Attach and tighten the choke and the kill lines.
(16) Attach hydraulic lines from the accumulator (Koomey) unit and install the fill-up
line. Connect turnbuckles and guide lines to the stack.
(17) Install the flow nipple and the flowline.
(18) Test the BOP stack as per specifications and record the results. Refer to the
Drilling Programme.
Note: The 11" casing head, BOP and annular preventer must be tested prior to
installation of the wear bushing.
4.4. Nipple Down of the 13 5/8" BOP
(1) Wash and clean the BOP inside and outside before starting to nipple down. Use the
79
high pressure washer to clean the inside with the BOP doors open.
(2) Flush all surface equipment with fresh clean water (kill line, choke line, choke
manifold and stand pipe manifold).
(3) Clean and clear entire work area around BOP.
(4) Pull wear bushing.
(5) Remove the hydraulic (Koomey) lines, fill-up line and guide lines.
(6) Disconnect the flow line and remove the flow nipple.
(7) Remove the kill line and the choke line.
(8) Loosen the nuts on the spool to DSA and the nuts on the DSA to the BOP. Pick up
the BOP with the BOP hoist, ensuring that both seals are broken.
(9) Lower the BOP and remove all the nuts from the bottom flange.
(10) Lift and move the BOP over to the transport frame utilising the BOP hoist.
(11) Clean and inspect the ring grooves on the BOP.
(12) Install new ring gasket on the transport frame and lower BOP onto the transport
frame.
(13) Install BOP with bolts and nuts on to its transport frame.
(14) Position BOP hoist and attach to the DSA.
(15) Remove the nuts on lower flange and lift the DSA off the wellhead.
(16) Remove the DSA from the wellhead. Clean and grease the DSA and replace the
nuts.
(17) Clean wellhead flange, ring grove and cover up to protect from debris.
(18) Make preparations to install production tree.
参弐. Change Out BOP Rams

Impact wrench / Sockets Hammer wrenches
Sledge hammer Air winch
Hole covering Ram rubbers
Bonnet seals Grease
Air hoist Tail rope
Eyebolt Test plug
Setting / Retrieving tool
1. Ensure that no one is on or near the BOP, when opening or closing the BOP
bonnets.
2. BOP must be closed by Toolpusher, Driller, or Assistant Driller.
3. BOP and work area must be clean and clear of obstructions.
4. Ensure that the Blind Rams are closed at all times.
5. Ensure that the well bore is full of mud.
6. Ensure that there is adequate lighting at work area if working at night.
7. Good communication between the air tugger Operator and the Floormen at
the BOP is essential.
(1) Ensure that the appropriate rams are ready.
(2) Ensure that the ram rubbers are in good shape and are the right size.
(3) Ensure that the wellbore is properly covered when the BOP bonnet doors are open.
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(4) Ensure the rams used for H2S wells are marked for H2S.
(5) Inspect the bonnet seals on the BOP when the doors are open.
(6) Before installing rams, clean inside the BOP thoroughly and apply grease.
(7) Inspect all lifting equipment and ensure that it is in good working order and has
current colour code.
4. INSTRUCTIONS
4.1. Changing Top Pipe Rams
(1) Fill the well up to the blind rams and close the well in with the blind rams.
(2) Move everything out of the way which may hinder opening the BOP doors.
(3) Loosen and unscrew all the bolts in the bonnet doors using a hammer wrench or the
hydraulic torque wrench (or an air impact wrench) until they can be removed by hand.
Note: It is best to remove bolts from both sides at once.
(4) Ensuring that there is no one by the BOP, the Driller opens the bonnets by setting
the control lever for the pipe rams on the Hydraulic closing unit to close position.
Note: For safety, the 4-way valves must be either fully open or fully closed.
(5) Once the bonnets are open, the Floormen wash inside the BOP thoroughly.
Note: Place a hole covering over the BOP cavity above the blind rams to insure nothing
falls inside.
(6) Screw an eyebolt into the pipe ram body. Attach the hook of the air hoist or the
hydraulic winch and tie a tail rope to prepare for the move.
Note: Communication between the Floormen at the BOP and the air hoist Operator is
very important. It is frequently impossible for the air hoist Operator to have a direct view
of the Floormen at the BOP. Therefore, the Driller must co-ordinate the operation.
(7) When the Driller receives a signal from the Floorman, he instructs the air hoist
Operator to pull up the ram slowly, while a Floorman guides the ram body off the ram
shaft using the tail rope.
(8) Lift the ram body over the BOP and set down away from the cellar.
(9) Repeat the steps (6) through (9) for the other ram.
(10) Screw an eyebolt into the pipe ram body to be picked up. Attach the hook of the air
hoist or the hydraulic winch and tie a tail rope to prepare for the move.
(11) Upon the Driller’s instruction, the air hoist Operator lifts the ram up to the BOP,
while the Floorman guides the ram with the tail rope.
(12) The Driller co-ordinates with the air hoist Operator and the Floormen to lower the
ram onto the ram shaft.
(13) Repeat the steps (10) through (13) for the other ram.
(14) Once both rams are installed, apply grease inside the BOP and both rams.
(15) The Driller inspects the bonnet seals for damage and replaces if necessary.
(16) Remove the hole covering that was placed over the BOP.
(17) Ensuring that there is no one by the BOP, the Driller closes the bonnets by setting
the control lever for the pipe rams on the Hydraulic closing unit to open position.
(18) Install the bonnet bolts back into the BOP and make up the bolts hand tight. Then
torque the bolts with the hammer wrench or the hydraulic torque wrench.
Note: If a hammer wrench is used, secure the hammer with a rope or sling while
striking.
(19) Prior to opening the blind rams, the Driller ensures that there is no pressure build-
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up beneath the blind rams, and bleed off through the choke if necessary.
(20) The Driller opens the blind rams and function tests the pipe rams.
(21) The pipe rams and the bonnet seals are then pressure tested to their prescribed
pressure rating.
4.2. Changing Bottom Pipe Rams
(1) Make up the test plug setting / retrieving tool to the pin end of a stand of drillpipe.
Note: The connection between the setting / retrieving tool and the stand of drillpipe
must be tightened with the rig tongs.
(2) Install the test plug onto the setting tool.
(3) Remove the rotary bushings using the air tugger.
(4) Open the annulus valve on the wellhead and drain the BOP stack. Close it back
after it has drained.
(5) Inspect the tie-down bolts, ensure that they are fully retracted.
(6) The Driller inspects inside of the BOP and ensures that the BOP is completely open.
(7) The Driller lowers the stand of drillpipe with the test plug assembly attached slowly
into the BOP, while the Floormen guide the assembly, to prevent hanging up on the
BOP.
Note: A Floorman shall measure the drillpipe while it is being lowered to set the test
plug.
(8) Land the test plug in the well head.
(9) A Floorman will open the locking nuts and screw in the riser tie-down bolts.
Note: Count the number of turns on the tie-down bolts. They should turn easily,
approximately 5 turns. When they become tight, apply torque with a wrench 1/8” turn
only.
(10) The Driller lowers the travelling block, clearing the tool joint.
(11) The Floormen turn the drillpipe, with the chain tongs and unseat the test plug from
the setting / retrieving tool.
(12) The Driller engages the drawworks and slowly lifts the stand of drillpipe with setting
/ retrieving tool as the Floormen guide the joint out of the BOP stack.
(13) A Floorman covers the wellbore opening at the rotary table.
(14) The Driller and the Floormen proceed with changing out the blind rams as
described in paragraph 5.1 above.
(15) After pressure testing the pipe rams and the bonnet seals, the Driller and the
Floormen retrieve the test plug with the setting / retrieving tool.
参参. Changing Valves on BOP

Socket wrench set Adjustable wrench
Hammer wrench Ring gaskets
Pressurised Grease gun Seat / Gate
Hammer Valves
Grease
1. Before commencing operation, a "Man Working" sign must be placed on the
Driller's control panel and not removed until job is finished.
2. After changing or repairing BOP valves, the new or repaired valve must be
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tested to the full working pressure of the BOP, before the drilling operations
continue.
3. Manual BOP valves are not to be used for choking pressure, they are either
fully opened or fully shut.
4. The BOP valves are to be isolated before any work or repair is performed.
5. Ensure that all pressure has been bled off the valve, before any work is
started.
(1) Authorisation and supervision by the Toolpusher is required.
(2) Hold a Toolbox Talk and discuss job requirements, roles of individuals, tools and
equipment, and safety procedures.
(3) Ensure that all studs, nuts, and ring grooves are cleaned and inspected for damage
and corrosion.
(4) Ensure that all the BOP valves are taking grease when being lubricated.
(5) Ensure that the valve to be installed is the correct working pressure for the BOP
equipment.
(6) Ensure that all replacement parts are the manufacturer’s specified parts.
4. INSTRUCTIONS
4.1. Gate Valve Inspection and Maintenance
(1) Ensure that the gate valve is totally isolated from pressure.
(2) Open the gate valve to the full open position.
(3) Remove the bonnets nuts, and firmly pull on the hand-wheel (or close the valve
again) to separate the bonnet / gate assembly from the body.
(4) Inspect the gate assembly for damage or distortion to the gate and the gate seat.
(5) Remove the gate seat and clean the valve body.
(6) Examine the valve body for wear and damage.
(7) Replace any part that is defective.
(8) Check the bonnet gasket and replace if necessary.
(9) Examine the stem and replace if threads are damaged.
(10) Fill the valve body with Cameron or appropriate grease and install the gate seat.
(11) Lift the bonnet / gate assembly and lower down slowly into the valve body.
(12) Align the bonnet and tighten the nuts.
(13) Grease the stem and valve, as the valve is slowly opened and closed.
(14) Test the valve as per specifications.
4.2. Replacing the Valve
(1) Remove the flange bolts or stud nuts with hammer and hammer wrench.
(2) Clean the flange bolts with a wire brush and inspect for damage, replace if
necessary.
(3) Remove the old valve.
Note: Never lift the valve using the hand-wheel, attach slings behind the flanges.
(4) Clean and examine the connecting valve flange (or flange ring groove) for pitting
and corrosion.
(5) Position the new valve in place with the new ring gaskets.
Note: Always replace the ring gaskets. Do not apply grease when installing.
(6) Install the flange bolts / stud nuts, ensuring the flanges are made up evenly and
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equal number of threads showing on both side of the flange.

(7) Tighten the bolts / stud nuts using the socket wrench.
(8) Test the valve as per specifications.
参四. Pressure Testing the BOP and the BOP System

Martin-Decker recorder Perforated sub / drillpipe
Pin x Pin sub (IF connection) Setting / Retrieving Tool
T.I.W. Valve with Wrench Plug type tester
Cup type tester Chiksan lines
Test pump Circulating T Sub
Lo-Torc valve Kelly cock (with valve)
Pipe dope Safety lines or Chains
Crossover sub Chain tongs
Pup joint Wear bushing
Blind sub Kelly test sub
Hazard tape Hand-held radios
Note: “Permit to Work” must be obtained prior to commencing these procedures.
1. The pressure rating of each item to be tested must be verified. The lowest
pressure rating of the components to be tested determines the maximum test
pressure to be used.
2. No one is to tighten or loosen any connection under pressure.
3. Ensure that all chiksan lines are fitted with a safety line or chain.
4. Ensure that no person is in the immediate vicinity of components under test
pressure.
5. The test area is to be cordoned off with Hazard Tape.
6. Clear communications are essential during testing procedure.
7. All personnel are to be informed when testing is to take place.
8. Check the COMPASS System and ensure that the certification on all the
chiksan piping and attachments are not more than 1 year old.
9. Ensure all test gauges and recorders have valid Dead Weight Tester
calibration certificates.
10. Annular BOP's are not to be tested over 70% of their rated operating
pressure.
3. STANDARD OPERATIONAL CONSIDERATIONS ( DO’S AND DON’TS)
(1) Ensure that the BOP test is carried out under the direct supervision of the
Toolpusher.
(2) Hold a Toolbox Talk and ensure that the correct test pressures are used.
(3) The Driller is to carry out a function test of the BOP before the pressure test
commences.
(4) All BOP tests must be carried out with water, unless the Drilling Programme dictates
otherwise.
(5) Ensure that all air has been expelled from the test lines before the test commences.
(6) The Driller will maintain chart recordings of all pressure tests.
(7) The Driller is to ensure that the wellhead valves are open before the pressure test of
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the BOP stack begins.

(8) Ensure that salt water is used for testing if freezing weather conditions exist.
(9) All pressure tests should be maintained for 15 minutes.
(10) The test shall be accepted provided that after 15 minutes there is no pressure
drop.
(11) If any pressure drop is observed, the test shall be accepted only if:
(a) the pressure drop is less than 10% of the initial test pressure, and
(b) after the observed drop in pressure, the test pressure remains constant over the
next 15 minutes.
(12) If any component fails to hold the test pressure, that component will be repaired or
replaced, and re-tested.
(13) Manually operated chokes are not shut-off devices, therefore they always should
be left in the open position.
4. INSTRUCTIONS
4.1. Pre-test Check List
(1) The Toolpusher and the Driller are to ensure that all testing equipment is on
location, have test code certifications, and are in good working order.
(2) The Toolpusher and the Driller are to ensure that all test plugs are the correct size
and pressure rating.
(3) The Toolpusher and the Driller are to review the applicable Regulations and the
Drilling Programme requirements ahead of the scheduled test.
(4) The Driller must have detailed drawing of the specific BOP and casing head / spool
on the rig floor.
(5) The Driller is to ensure that there are spare BOP rubbers, valve parts, and new ring
gaskets.
(6) The Driller is to ensure that the pipe used in testing is the correct size and grade,
and able to withstand the applied internal pressure.
(7) When using the "Multi-Setting tool" ensure the 1/2" pipe plug is installed in this tool.
4.2. Frequency of Testing
(1) The BOP, wellhead, choke manifold, and related equipment are to be tested on a
weekly basis.
(2) The period between tests may be extended to 14 days, maximum, depending on the
well operations and the specifications in the Drilling Programme and the applicable
Regulations.
(3) The accumulator is to be tested prior to the first test of the BOP, or any time after
repairs are made to the accumulator unit.
(4) The accumulator bottles pre-charge pressure shall be checked before drilling out the
casing shoe or every 4 weeks.
4.3. Daily Function Tests
(1) The upper and the lower pipe rams shall be function tested during a trip and
recorded in the tour book.
(2) Any exceptions to the daily function test will be recorded in the tour book.
4.4. Testing the Hydraulic Accumulator System
(1) Verify and record the hydraulic unit operating pressures:
Hydraulic unit: should be:
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Accumulator operating pressure 3000 psi / 207 bar

Accumulator manifold pressure 1500 psi / 103 bar
Annular BOP closing pressure 1200 psi / 83 bar (for all Hydril Models)
Annular BOP closing pressure 1500 psi / 103 bar (Cameron Type D)
(2) If these pressures are not attained, investigate cause and repair.
(3) Commence test by slowly bleeding down the pressure of the hydraulic unit to zero
pressure.
(4) Observe and verify that:
When ... then ...
Hydraulic accumulator operating pressure is reduced to 2700 psi or 190 bar the
electrical charge pump is automatically activated (the charge pump must kick in at 90%
of operating pressure of 3000 psi or 207 bar).
Hydraulic accumulator operating pressure is reduced to 2600 psi or 183 bar the air
pumps to charge the unit are automatically activated
(5) Switch off the electrical power to the hydraulic unit and close the air valve to the air
pumps after bringing hydraulic unit back up to pressure.
(6) Using the hydraulic unit, close and open the BOP rams, the annular BOP and the
HCR valve.
During this process:
(a) Note the time taken to close and open each with a stop watch and record.
(b) Note the remaining pressure on the Hydraulic unit and record.
(7) Close and open the annular BOP and one set of pipe rams a second time, note and
record the time taken and the pressure remaining on the hydraulic unit.
(8) The electrical power and the air supply are turned back on the hydraulic unit.
(9) Observe and record the time needed to pressure up the hydraulic unit to 3000 psi or
207 bar operating pressure.
(10) At the conclusion of the above tests verify that:
(a) All the handles on the Hydraulic unit are correctly marked.
(b) All the lights on the buttons of the remote control panel are operative.
(c) The manual levers at the Hydraulic unit are left in the correct position.
(11) Any deficiency noted during the above testing must be corrected prior to resuming
normal operations.
4.5. Testing the Choke Manifold
(1) Line up the chiksan line from the test pump to the choke manifold.
(2) Flush water through the choke manifold before starting the test.
(3) To prevent air entrapment, the valves to be tested will be closed slowly while
flushing. As soon as a pressure increase is observed, stop pumping.
(4) Check the level of fluid at the test unit and ensure that there is ample fluid for
testing.
(5) At the Driller’s instructions, the correct sequence of valves on the choke manifold
are to be closed.
(6) The sequence of choke manifold pressure tests, based on the valve locations shown
in Figure 1 must be as follows:
Test sequence with the only valves closed test to full rated pressure:
first number 15 5000 or 10,000 psi / 345 or 690 bars
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second numbers 16, 17, and 18 5000 or 10,000 psi / 345 or 690 bars
third numbers 9,13,14 5000 or 10,000 psi / 345 or 690 bars
fourth numbers 10 and 12 5000 or 10,000 psi / 345 or 690 bars
fifth number 11 5000 or 10,000 psi / 345 or 690 bars
(7) Maintain test pressure on each test for 15 minutes.
(8) At the Driller’s instruction, the test pump Operator slowly and progressively builds
up the test pressure as follows:
When pressure reaches ... then stop and observe for...
500 psi / 35 bar one minute.
1000 psi / 70 bar 30 seconds.
2000 psi / 140 bar 30 seconds.
the next 1000 psi / 70 bar increment 30 seconds.
the full test pressure 15 minutes.
(9) The test pump operator then will bleed off the test pressure through the choke.
(10) The test pump Operator will advise the Driller when the pressure has been reduced
to zero.
(11) The choke manifold is returned to its normal set up for drilling as follows:
Valves Open: 2 3 11 12 14 18 - - - -
Valves Closed: 1 4 9 10 13 15 16 17
(12) The Driller will complete a BOP test report and submit to the rig manager and client
representative, enclosing the pressure graphs.
4.6. Testing the High-pressure Mud System
Note: The reduced pressure rating of the Buffer Manifold must be used.
(1) Close the valve at the standpipe manifold to the rig pumps.
(2) Test the high pressure mud line in pressure increments as per procedure 5.5.,
above, work step (8). Observe the test pressure for 15 minutes.
(3) The Test pump Operator will then the pressure off at the rig pumps.
(4) The Test pump Operator will advise the Driller when the pressure has been
reduced to zero.
4.7. Testing the Standpipe Manifold (SPM) and the Kelly
(1) Close the standpipe valve to isolate the kelly hose and the TDS.
(2) Open the bleed-off valve and flush the SPM.
(3) The Driller is to check and ensure that the pressure gauge reading is zero.
(4) The Floormen connect the Lo-Torc valve and the chiksan line from the test pump to
the fill up line or the spare line on the SPM.
(5) Test the SPM valves in pressure increments as per instructions 5.5., above, step
(8). Observe the test pressure for 15 minutes.
(6) Install the kelly test sub beneath the kelly and connect the test line from the test unit
to the kelly test sub.
Note: If the rig is equipped with a top drive, the Driller will pick up a stand of drillpipe
and make it up to the top drive and install the test sub to the stand of drillpipe and
pressure test the top drive IBOP.
Note: Always pressure test the lower and upper kelly cocks from beneath.
(7) Test the kelly in pressure increments as per procedure 5.5, above, step (8).
Observe the test pressure for 15 minutes.
87
(8) The Driller will complete a BOP test report and submit to the Rig Manager and the
Client Representative, enclosing the pressure graphs.
4.8. Testing the BOP Stack
(1) Back off the packing nuts and unscrew the tie-down bolts to release the wear
bushing.
(2) Retrieve the wear bushing from the wellhead.
(3) If using a plug type tester, the seals on the plug type tester shall be checked,
cleaned and lubricated prior to running.
(4) The connection above the plug type tester shall be hand tight only, all other
connections are to be made up to the required torque.
(5) The plug type test assembly shall be made up as follows:
Item: Components:
1 2 stands HWDP or 1 stand DCs
2 kelly cock (Open)
3 4 1/2 inch IF sub, pin / pin
4 plug type tester
5 DP to surface
6 TDS
(6) If using a cup type tester, the seals on the cup type tester shall be checked, cleaned
and lubricated prior to running in.
(7) The connection above the special cup type tester (left hand threaded) shall be made
up hand tight only, all other connections to the required torque.
(8) The Driller and the Floormen shall make up the cup tester assembly as follows:
Item: Components:
1 2 stands HWDP or 1 stand DCs
2 kelly cock (Open)
3 4 1/2 inch IF sub, pin / pin
4 cup type tester
5 perforated single
6 DP to surface
7 crossover sub and Lo-Torc valve)
(9) The Driller will lower in the test assembly and land the test plug or the cup tester in
the wellhead.
Note: For a given wellhead (i.e., Ingram Cactus or Cameron), utilise the special test
plug provided by the wellhead manufacturer. When using the "Multi-Setting tool"
ensure the 1/2" pipe plug is installed in this tool.
(10) The drillpipe is to be spaced so that no tool joint is across the BOP stack (use a
pup joint if necessary).
(11) Ensure that all the riser tie-down bolts are secure and that the stand-off over each
packing nut from the riser flange is approximately 5 cm, or 2 inches (± 1/8”).
(12) Open the casing spool valves to avoid pressurising the casing.
(13) Connect the circulating head crossover to the BOP. Install the Lo Torc valve and
connect the chiksan line to the test pump.
(14) Unseat the kill line check valve.
(15) Test the chiksan lines as per W.I. Section 1.13.
88
(16) Instruct the Test pump Operator to establish circulation and flush the system to
ensure removal of all air from the lines.
(17) Test the BOP and wellhead system in pressure increments as per procedure 5.5,
above, step (8). Observe each test pressure for 15 minutes.
(18) The initial test after nippling up, should be to the maximum casing spool working
pressure or BOP working pressure, whichever is lower.
(19) If using a 21-1/4 inch, 2000 psi BOP stack, the test sequence is as follows:
Test: Description; Pressure
(1) Surface lines against Lo-Torc valve 500 psi / 35 bar full rated pressure
(2) Pipe rams and outer kill and choke valves 500 psi / 35 bar full rated
pressure
(3) Pipe rams and inner kill and choke valves 500 psi / 35 bar full rated
pressure
(4) Hydril, kill line check valve, and valve no. 1 on the choke manifold 500 psi / 35
bar full rated pressure
Note: If using a cup type tester, the perforated single shall be backed off from the test
tool, and picked up above the BOP stack, to allow the Blind Rams to be shut-in.
(5) Blind rams 500 psi / 35 bar full rated pressure
(20) If using a 13-5/8 inch, 10,000 psi BOP stack, the test sequence is as follows:
Test: Description; Pressure
(1) Surface lines against Lo-Torc valve 500 psi / 35 bar full rated pressure
(2) Upper pipe rams and outer kill and choke valves 500 psi / 35 bar full rated
pressure
(3) Upper pipe rams and inner kill and choke valves 500 psi / 35 bar full rated
pressure
(4) Lower pipe rams 500 psi / 35 bar full rated pressure
(5) Hydril, kill line check valve, and valve no. 1 on the choke manifold
500 psi / 35 bar
full rated pressure
Note: If using a cup type tester, the perforated single shall be removed from the test
tool, and picked up above the BOP stack, to allow the Blind Rams to be shut.
(6) Blind rams 500 psi / 35 bar full rated pressure
(21) Bleed off the pressure.
(22) Close the casing side outlet valves.
(23) Re-seat the kill line check valve.
(24) Back off packing nuts from the riser flange.
(25) The Driller will ensure that all BOP rams are open.
(26) Lower the cup tester 3-5 meter ton unseat the cup, remove and lay down the test
tool assembly.
(27) Install the wear bushing and tighten the packing nuts on riser flange.
(28) The Driller will complete a BOP test report and submit to the Rig Manager and the
Client Representative, enclosing the pressure graphs.
4.9. Testing the BOP on the Test Stump
(1) With the BOP on the test stump, install the blind sub and test pipe inside the BOP
Stack.
89
(2) Fill up the BOP stack with water.

(3) Test the BOP as per procedure 5.8., steps (15) through (19).
(4) After the BOP is installed on the wellhead, run test tools, and test the wellhead and
the mating flange to the BOP.
(5) The Toolpusher and the Driller will complete a BOP test report and submit to the Rig
Manager and the Client Representative, enclosing the pressure graphs.
参伍. Handling of Wellhead Tie-down Bolts

Adjustable wrench Socket set
1. To avoid damage to the wear bushing, the position of the tie-down bolts must
be known.
2. Over-tightening of the tie-down bolts can damage the wear bushing, making
it hard to retrieve.
(1) Ensure that the tie-down bolts are not damaged.
(2) Ensure that the tie-down bolts are the same length, and screw in to the same depth.
(3) Ensure that the tie-down bolts are easy to screw in and out.
(4) Ensure that the packing nuts are secure after the tie-down bolts are tightened.
4. INSTRUCTIONS
(1) Before installing the wear bushing, ensure that the tie-down bolts are retracted to
their full opening position.
(2) After landing the wear bushing, screw in the tie-down bolts evenly until they are fully
engaged.
(3) Measure the stand-off of each tie-down bolt to ensure they are the same height.
(4) Tighten the packing nuts.
Note: When retrieving the wear bushing, the same careful considerations should be
taken when backing off the packing nuts and tie-down bolts, ensuring they are evenly
and fully retracted.
参六. Changing Liners on Mud Pumps

Correct size Liner and Gaskets Grease and Molycote
Hammer wrench Wear plate
7/8” Wrench Crow bar
Air wrench Chain hoist
Hammer “Man Working” sign
1. This work can only be carried out under a Permit to Work order.
2. All necessary electric power must be isolated.
3. Before this task commences, a “Man Working” sign must be posted on the
Driller’s control panel.
4. Isolate the mud pump from pressured mud lines.
5. Bleed off the pressure in the mud pump before starting the work.
90
(1) Ensure that all valves are shut on the pump (suction and discharge).
(2) Ensure that the centrifugal pump valve is shut.
(3) Ensure that the bleed-off line valve is open.
(4) Ensure that proper liner and gasket are ready to be installed.
(5) Ensure that all the necessary tools and equipment are readily available.
4. INSTRUCTIONS
4.1. Dismantling the Pump
(1) A Floorman or the Derrickman disconnect the liner cooling water hose.
(2) A Floorman will remove the piston rod clamp.
(3) After the rod clamp has been removed, a Floorman will turn the pump, (utilising a
crank installed on the pump shaft) until the pony rod comes free of the piston rod.
(4) Position the chain hoist above the liner and hammer the liner lock ring until it is
loose.
Note: On some pumps the liner lock ring is bolted instead of threaded.
(5) A Floorman removes the liner lock ring and connects the chain hoist to the liner.
(6) Utilising the crow bar, and chain hoist, the liner is removed from the fluid end of the
pump.
(7) Utilising the chain hoist, the liner is then removed from the pump and then lowered
to the side.
(8) A Floorman removes liner seal from the end of the liner or from inside the fluid end.
(9) He inspects the wear-plate for wear or damage and replaces if necessary.
(10) A Floorman inspects the piston rod and piston for wear or damage and replaces if
necessary.
(11) A Floorman will thoroughly clean the liner cavity and all necessary pump parts.
4.2. Assembling the Pump
(1) A Floorman will apply a thin film of grease on the inside of the liner and on outside of
the piston.
(2) A Floorman will apply Molycote to the inside of the liner cavity of the pump.
(3) Install the liner seal gasket in the liner cavity of the pump or at the end of the liner.
(4) A Floorman, using the chain hoist, picks up the liner with the piston and rod inside,
and positions the liner at the liner cavity.
(5) Ensuring that the liner seal gasket is in place, the Floormen slide the liner into the
liner cavity of the pump until it is properly seated.
(6) The liner lock ring is then positioned around the liner and screwed or bolted to the
pump and tightened with the hammer.
(7) A Floorman connects the piston rod clamp to the pony rod and the piston rod.
(8) The cooling water hose is installed and the water valve opened to ensure proper
operation.
4.3. Upon Assembly of the Pump
Note: Do not start the pump. the Toolpusher / Driller must inspect the mud pump prior
to starting up.
(1) De-isolate the pump (electrically or mechanically).
(2) Open the suction line and the centrifugal line.
(3) Cycle the pump and bleed off.
(4) Stop the pump and close the bleed off line.
91
(5) Upon the Driller’s instruction, open the discharge line.

(6) The pump is now ready for operation.
4.4. Checks after putting the pump in operation
(1) Check the pump for fluid leaks.
(2) Listen for "Bypass Hissing".
(3) Listen for knocking.
Note: Knocking can be due to cavitation, air, plugged suction or discharge filter, or the
pulsation dampener.
(4) Check and ensure that the cooling water system is working.
(5) Check the pump pressure, and verify the pressure reading with the rig floor pressure
reading.
(6) After a few running hours check the clamps on the pony rod and the piston rod.
(7) Ensure that the liner lock ring is still tight.
参七. Changing Pistons on Mud Pumps

Proper size piston Hammer wrench
7/8” Wrench Hand-crank
Piston rod Grease
“Man Working” sign
1. Ensure the Lock-out is installed.
2. Follow the specific safety precautions listed in the Work Instruction 5.1.
3. Before this task commences, a “Man Working” sign must be posted on the
4. Isolate the mud pump from pressured mud lines.
5. Bleed off the pressure in the mud pump before starting the work.
3. STANDARD OPERATIONAL CONSIDERATIONS (DO'S AND DON’TS)
(1) Ensure that all tools and equipment necessary to perform the work are in
serviceable condition and are readily available.
(2) Ensure that all valves are shut on the pump (suction and discharge).
(3) Ensure the pump is isolated from the electrical or mechanical power as per the
requirements of the Permit to Work System.
(4) Ensure that the bleed off line is open while work is being performed on the pump.
4. INSTRUCTIONS
4.1. Dismantling the Pump
(1) The Derrickman and Assistant Driller, with the Mechanic present, will disconnect the
liner spray manifold and remove it from the liner.
(2) Clean and inspect the spray nozzles and replace if necessary.
(3) Close the valve on the direct cooling water line.
(4) Disconnect the coolant line hose.
(5) Remove the piston rod clamps, and the sub-rod.
(6) Using a hand-crank on the main drive shaft of the pump, rotate the pump until the
intermediate piston rod is in the rear stroke position.
Note: Most pumps have a two-piece rod, intermediate piston rod and sub-rod.
(7) Ensure that the hand-crank on main drive is removed from the pump shaft.
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(8) Remove the piston rod and piston from the liner.
(9) Flush and clean the liner with water and examine the liner for wear or damage.
(10) Take this opportunity to rotate the liner 90o and record this in the pump book
including the rotation direction.
4.2. Assembling the Pump
(1) Apply a thin film of grease on the inside of the liner and on the outside of the piston.
(2) Insert the new piston and rod into the liner.
(3) Install the sub-rod and the rod clamps, and tighten to the specified torque, using the
hammer wrench.
(4) Reconnect the liner spray manifold.
(5) Install the coolant line hose.
(6) Open the valve on direct cooling water line and ensure that spray manifold is
operating properly.
(7) Ensure that the hand-crank on main drive is removed from the pump shaft.
(8) Replace the covers
4.3. Upon Assembly of the Pump
Note: Do not start the pump, as per Deutag Permit to Work System, the Assistant
Driller will inspect the mud pump after de-isolation.
(1) De-isolate the pump as per the requirements of the Permit to Work System.
(2) Open the suction and centrifugal lines.
(3) Cycle the pump and bleed off.
(4) Stop the pump and close the bleed off line.
(5) Upon the Driller’s instruction, open the discharge line.
(6) The pump is now ready for operation.
4.4. Checks after Putting the Pump in Operation
(1) Check the pump for fluid leaks.
(2) Listen for “Bypass Hissing”
Note: Knocking can be due to cavitation, air, plugged suction or discharge filter, or the
pulsation dampener.
(4) Check and ensure that the cooling water system is working.
(5) Check the pump pressure, and verify the pressure reading with the rig floor pressure
reading.
(6) After a few hours running, check the clamps on the pony rod and the piston rod.
参八. Changing Valves and Seats on Mud Pumps

New Valve and seat 1 metre long Iron bar
Valve cover gasket Valve seat driver
Shop hammer T-Bar for valve cover plug
Hydraulic valve seat puller Fine sand paper (Emory cloth)
Grease “Man Working” sign
1. This work can only be carried out under a Permit to Work.
2. Before this task is started, a 'Man Working' sign shall be placed on the
Driller’s control panel. This sign must not be removed until the task is
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completed.
3. Prior to beginning work, ensure that all the specific electrical and mechanical
isolations are in place for the particular pump.
4. Prior to starting work, inform the Driller.
(1) Seats are never to be cut out with cutting torch.
(2) Isolate the mud pump electrically and physically as per the procedure of the specific
drilling rig from the system which is usually as follows:
(a) Press in and pin the “Lock Out” button on the electric motor on that particular pump.
(b) Close the discharge manifold valve from that pump.
(c) Close the suction line valves on that pump.
(d) Open the bleed off line valve on that pump.
(3) After any repair, the mud pump must be thoroughly inspected by the Driller prior to
applying power.
(4) Ensure that the pump is properly primed before placing back into operation. Even a
few strokes of a piston in a dry liner will damage the piston seals.
(5) Valve bodies, springs, and seats should be replaced as a set when the normal wear
is at the limit allowed by the manufacturer or fluid cutting damage is observed.
Rule: A worn valve must not be used in a new seat, nor a new valve in a worn seat.
(6) Valve guides should be inspected for erosion wear and replaced if any wear is
evident.
Note: If worn, the valve guides allow valves to cock, thus causing uneven wear,
possible sticking, and washing out of the valves and the seats.
(7) Drain the pump to a level just below the valve cover seal, then tighten the cover.
Valve cover caps should never be made up in a valve pot full of drilling mud.
(8) Always check the springs for signs of corrosion, lack of proper spring tension, or any
other defects.
(9) Never re-install used valves, seats, and valve springs, except for emergency
situations.
4. INSTRUCTIONS
4.1. Pulling the Valve Assembly
(1) Tap and loosen the quick change cap with the bar and hammer.
(2) Screw the T-bar into the valve cover plug.
(3) Remove the valve plug by pulling upwards on the T-bar.
(4) Take out the valve cover gasket.
(5) Remove the valve spring.
(6) Remove the valve and examine its condition. If there is normal wear in excess of 1,6
mm (1/16”) or any sign of pitting, scoring, or other damage on the Teflon disc, then
replace the valve.
(7) If replacing the discharge valve and seat, also replace the valve spring.
(8) To pull the seat, install the hydraulic valve seat puller in the following manner:
(a) Install the correct type of puller below the seat, and screw in the threaded pulling
stem.
(b) Install the hydraulic piston cylinder over the pulling stem.
(c) Ensure that the piston is completely compressed.
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(d) Screw the securing nut on the stem down to the cylinder.
(e) Secure the piston to the pump with a chain. Caution: A stuck seat can cause the
hydraulic cylinder to jump when it comes free.
(10) Attach the hydraulic pump to the hydraulic piston cylinder and pump up the
pressure until the seat becomes free. It may be necessary to tap the stem with a
hammer to loosen the valve seat.
(11) Remove the valve seat and examine for signs of fluid erosion and if any damage or
erosion is observed do not use the seat.
(12) Wash and clean the valve bed. Inspect for damage or foreign matter.
4.2. Installing New Valve and Seat
(1) Before installing the new seat, use a fine sand paper (Emory cloth) and smooth out
the valve bed with circular motions. Do not use any up and down motion. If the seat
area is very rough it can be dressed using a T-bar and an old seat with fine grinding
paste.
(2) Remove the preservation grease from the seat and place the seat in the valve bed.
(3) Tap the valve seat into position with the valve seat driver and sledge hammer,
making sure it is seated properly.
Note: It is extremely important that the seat is properly set in the valve bed. Improper
setting of the seat will wash out the fluid end.
(4) After ensuring that the new valve and seat match, install the valve into the seat and
install the spring.
(5) Prime the pump by filling the valve pot with mud up to the threads (never over the
threads).
(6) Insert a new gasket in the valve pot.
(7) Grease the valve cover plug and install in the valve pot.
(8) Grease the valve cover cap threads and screw the cap into position.
(9) Tighten up the valve cover cap using the 0,75 Meter (2 ft) long bar and sledge
hammer.
4.3. After Completion of Installation
(1) Open the suction valve from the mud tanks to the pump.
(2) Leave the pump bleed-off line valve open.
(3) Remove the pin and release the pump “Lock Out” at the pump.
(4) Cycle the pump slowly back to the pits, until it is properly primed.
(5) Stop the pump.
(6) Close the bleed-off line valve.
(7) Inform the Driller the pump is ready to be put into operation.
Note: The pump can not be put back into operation until the other pump(s) pressure
has been relieved.
(8) Upon the Driller’s instruction, Open the discharge manifold valve at the pump.
(9) Inform the Driller when the valve is OPEN.
(10) After the pump has been put back into operation, remove the warning sign from the
4.4. Checking the Pumps
When the mud pump is put into operation, the following checks must be performed:
(1) Inspect for leaks.
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(2) Listen for bypass hissing.

Note: Cavitation can cause a knocking sound.
(4) Ensure that circulating pressure is normal.
(5) Check the valve cover cap after 1 hour of operation for looseness and re-tighten if
necessary.
参九. Resetting and Adjusting the HP Relief Valve

Adjustable or 1-1/16" spanner Allen key
1. A relief bypass line that is short, without bends and rigidly anchored should
be installed to return fluid back to the mud tanks.
2. A warning sign alerting personnel to the location of the pressure relief
bypass line should be installed on the mud pit hand-rails.
3. Some pumps in service may still be equipped with "pin type" HP relief
valves. Due to inherent risks with shear pins, these valves should be
replaced with Spring Type valves.
4. Some pumps still in service may be equipped with threaded type relief
valves, these valves should be converted to flange type.
Note: Some rigs are equipped with electrical safety shut off mechanism which will shut
off the power to the pump when the pump pressure nears the pop-off setting of the
relief valve.
(1) Before starting the work, inform the Driller and find out the required pressure setting
of the HP valve.
Note: Communication is extremely important between the Driller / Assistant / Mechanic
prior to resetting the relief valve.
(2) Check relief valve setting against the maximum pressure rating of the liner.
(3) Check and ensure that the relief valve by-pass line is clamped, and ensure that the
clamps are secure and free from rust.
(4) Ensure that all tools and equipment necessary to perform the work are ready.
(5) Ensure that the mud pump is isolated from the electrical system,(lock-out switch is
activated and tagged).
(6) Ensure that the mud pump is isolated from the circulating system.
4. INSTRUCTIONS
4.1. Resetting the Spring Type Pressure Valve After it Has Been "Tripped"
(1) Push the reset lever approximately 1/8 of a turn in the direction of the arrow.
Note: A direction arrow is stamped on the reset lever. If the lever cannot be reset by
hand, notify the rig Mechanic.
(2) When the reset lever is released, it returns to the original position.
(3) Check the release indicator button, ensuring that it is pushed out.
Note: The position of the release button indicates whether the relief valve is open or
closed. When the button is pushed in, the valve is fully open, when the button is pushed
out, the valve is closed.
(4) Repeat step (2) if the indicator button is not pushed out.
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(5) Check the reading on the pressure range plate indicated by the pointer arm, and
ensure that it does not exceed the pressure rating of the liners.
(6) Report the reset pressure setting of the relief valve to the Driller and the Toolpusher.
(7) Adjust the valve only if the pressure setting is different from that required.
4.2. Adjusting the Spring Type Pressure Relief Valve
Identification num. Valve Model Type Adjustable Pressure Range
Note: The adjuster nut is turned clockwise to increase pressure setting and
counterclockwise to decrease pressure setting.
(1) Turn the adjuster nut completely counter-clockwise to its minimum setting.
(2) Ensure the valve is operational and the bypass flow line is not blocked by starting
the pump and cycling on low capacity and low pressure until the relief valve is tripped.
This test should be done after every BOP test.
(3) Carefully turn the adjuster nut by hand until the pointer arm indicates the required
pressure setting.
(4) Inform the Driller and the Toolpusher when the adjustment is complete.
4.3. HP Relief Valve Maintenance
4.3.1. Monthly Maintenance
(1) Cap screws should be checked to ensure they are torqued to 40 lbs-ft (5 kg-m or 55
N-m).
(2) Connecting flange bolts should be checked to ensure they are torqued to 250 lbs-ft
(35 kg-m or 340 N-m).
(3) All re-set relief valves should be checked to ensure that they are functioning
properly. The valves should be tripped by striking the release button, then resetting by
using the reset handle. This should be done a number of times.
4.3.2. Every 3 Months (or after each time the valve has been activated or liners
changed)
(1) Complete testing and re-calibration of the valve should be carried out.
(2) It should be tested using the lowest pump pressure possible, as well as the least
number of strokes possible.
4.3.3. Every 12 Months
(1) The relief valve should be completely disassembled / repaired, and at this time all
cap screws should be replaced.
(2) This assembly / disassembly / repair work is only to be carried out by a company
recognised by ZPEB.
(3) Checks as per operation and service manual:
(a) check individual markings
(b) piston seals and lower valve body parts (check for damage or wear)
(c) cushion ring (check for damage or wear)
(d) bonnet and linkage assembly (check for damage or wear)
(e) lower links (check for straightness)
(f) link and crank pins (check for straightness and chipping or pitting)
(g) pressed in pin bushings (check for looseness, chipped edges, and warping)
(h) piston and piston stem (check for excessive wear)
(i) load springs (check for yielding)
(j) spiral springs (check for yielding)
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(4) Before re-assembly, ensure all parts are cleaned and properly lubricated (if needed).
(5) The valve has to be re-calibrated and tested to the maximum pressure using a hand
pump or suitable testing facilities.
(6) Record the installation date of all new cap screws.
(7) Record any maintenance carried out on the valve (including the type of work carried
out, the date, any parts which were replaced etc.).
(8) For any repair or maintenance work use only brand name spare parts.
(9) All valves have to be individually marked in such a way that the repair date, and
repair company can be easily identified.
(10) Any repair work must have a proper document of certification.
四零. Cleaning the Discharge Filter on Mud Pumps

Hydraulic torque wrench Cameron spanner
Discharge filter (if needed) “Man Working” sign
Filter cover seal (if needed) Grease
Sledge Hammer
1. Follow the specific safety precautions listed in the Work Instruction 5.1.
Always refer to Deutag HSE Manual for general safety rules.
2. Ensure that the pump has been isolated from the pressure in the lines and
the bleed off line is open to the pits.
3. A “Man Working” sign shall be placed on the specific pump control on the
Driller’s console.
(1) Do not start the work without the Driller's permission.
(2) Ensure that all tools and equipment necessary to perform the work are ready.
(3) Ensure that the mud pump is isolated from the electrical system and the lock out
switch is pinned.
(4) Ensure that the mud pump is isolated from the circulating system and that the bleed
off line is open.
(5) The size of the holes in the filter (strainer) Should be the same size as the nozzles.
4. INSTRUCTIONS
(1) The Floormen, utilising hammer wrenches or a torque wrench will remove the nuts
on the filter cover, (some covers are threaded).
(2) Remove the filter cover, and place it in a safe place.
(3) Flush the inside of the filter housing with water.
(4) Remove the discharge filter and place it in an area where it can be cleaned, and
steamed if necessary.
(5) Clean the filter carefully and check for damage. Replace if badly damaged.
(6) Also clean the inside of the filter housing.
(7) After the filter housing is completely clean, install the filter.
(8) Check the cover seal and replace it if it has any damage.
(9) After inspection, lightly grease the cover seal.
(10) Clean and install the filter cover.
(11) Secure the filter cover nuts and tighten evenly to 237 daN.m (1750 lbs-ft) torque
98
using the hammer wrenches or the torque wrench.

(12) Close the bleed-off valve and reset the electrical isolation.
(13) Inform the Driller when the operation has been completed.
四壱. Mud Tank Set Up While Tripping

Pit level Indicator and recorder (Pit Volume Totalizer, PVT)
2 SAFETY INFORMATION
1. While tripping, all replacement and displacement of hole fluid will be
monitored and recorded.
2. Trip tank monitor and chart will be used for all trips out of and back in the
hole including check trips, bit trips, BHA trips, wireline operations, etc.
3. All filling, draining or transfer of trip tank fluid will be at the direction of the
Driller.
4. The Driller is responsible for a manual backup contingency plan for any
automation failures of the trip tank and / or monitors.
(1) Mud fluid capacity of trip tanks is recommended to be 6 - 15 m3.
(2) All pit and tank volume monitors are to be functioning properly.
(3) Driller must verify trip tank, monitor and recorder operation before any trip.
(4) The Driller will notify the Toolpusher and / or the Company Representative
immediately when there is any irregularity in fill or displacement volumes.
(5) The active surface mud system must be isolated from the trip tank and hole volume
during tripping.
(6) After pumping a pill or slugging the pipe, isolate the pill tank.
(7) Continuously check the mud system for any leaks.
4. INSTRUCTIONS
4.1. Tripping Out
(1) The Derrickman / Mud Tester is to isolate the surface mud system keeping
mechanical pit mixers operating. All water to pits (dilution) will be turned off.
(2) Shut down shale shakers and solids control equipment.
(3) Close the trip tank dump line valve and check the trip tank pump.
(4) The Driller is to fill the trip tank as needed through the standpipe from the surface
system.
(5) The Derrickman / Mud Tester is to align trip tank pump and valves to circulate
continuously over the hole.
Note: If there are fluid returns from the hole they will be circulated through the trip tank.
4.2. Tripping In
(1) The Derrickman / Mud Tester is to check the surface volume and ensure that there
is sufficient pit space for mud displaced by the new drillstring configuration.
(2) Align trip tank pump and valves to circulate continuously over the hole.
Note: All fluid returns from the hole will go in the trip tank, and if the hole takes fluid it
will come from the trip tank.
(3) When drillstring displacement fills the trip tank, upon the Driller’s instruction, the
Derrickman / Mud Tester will empty the trip tank back to the active tank system.
Note: The shale shakers are to process the mud from the trip tank. Bypassing the
99
shakers can allow floating trash (from pipe protectors or mud motors, etc.) and cuttings
into the active surface system.
(4) After tripping, the Derrickman / Mud Tester is to flush and wash solids from pit level
floats and the trip tank system.
(5) After tripping, the records obtained from the trip tank recorder, the Pit Volume
Totalizer, the Mud Logger and the Mud Technician should be compared.
四弐. Entry Permit and Procedure

1. All work inside tanks of any kind or confined spaces is subject to the Permit
To Work System.
2. An atmospheric test (gas test) must be carried out from outside the tank.
3. Isolate all electrical services in job area and lock off switches with padlocks.
4. A 'Man Working' sign shall be placed on the mechanical mixer switch for the
appropriate tank for the duration of the task.
5. The work area shall be roped off and 'Grating Removed' signs displayed
where applicable.
6. A crew member must be designated as Stand By Man and must remain
positioned outside the tank to assist or call for assistance in the event of an
emergency.
7. Waste disposal requirements will be as stated in the Drilling Programme or
Waste Management Procedures.
Rig Mud Tank Entry Decision - Onshore, Confined Area Entry
(1) A Toolbox Talk must be held to ensure that all personnel involved are aware of the
work to be carried out and of the precautions necessary. This must also be documented
on the permit.
(2) All electrical operations / equipment must be isolated by a competent person (Senior
Electrician), and all mechanical operations / equipment must be isolated by a
competent person (Derrickman or Assistant Driller).
(3) All isolated valves should be tagged and all electrical switches (agitators) must be
locked out with pad locks.
(4) When the mud pumps are running, nobody is allowed to enter or work in a tank, into
which the mud pump relief lines run.
(5) Before entry into tanks personnel will have at the work site:
(a) a copy of Cold Work Permit / Entry Certificate.
(b) a copy of Standby man Instructions.
(6) An Atmospheric Test and Work Permit is only valid for 12 hours. Old permits must
be signed off as per procedure.
(7) Work Permit / Entry Certificate is not transferable.
(8) A new atmospheric test must be carried out and a new permit detailing
necessary precautions must be issued.
(9) Permit may be extended for 2 hours on the authorisation of the Toolpusher, if the
work is:
(a) to take longer than the validity period authorised on the permit,
100
(b) to be completed by the same personnel who started the work.

4. INSTRUCTIONS
(1) Fill out completely a Serial Numbered Work Permit for entry into an area with a
hazard potential.
(2) The person in charge of the work site will complete the safety check list and put his
initials where required.
(3) The person in charge of the work site completes the remainder of the permit, after
ensuring that all precautions are in place and isolations or requirements are as stated
on the permit. He also fills in the time, date and signs the form.
(4) The Gas Tester will verify with the Toolpusher if breathing apparatus is required.
(5) The Gas Tester will perform atmospheric tests from outside the tanks, complete the
relevant section of the permit with the time and result of the gas test. He also fills in the
date and signs the form.
(6) On the advice of the Gas Tester, further gas tests may be carried out during the
work.
(7) The person in charge of the work site will ensure that he has restored the work site
to a safe condition and all isolations restored.
(8) On completion of work, sign off all relevant copies of the permit and submit them to
the Toolpusher.
四参. Cleaning Mud Tanks

Personal Protective Equipment (PPE) Rubber gloves and rubber boots
Eye protection (goggles) Respiratory Protection
Eye Wash Bottle Slicker suit
'GRATING REMOVED' sign 'MAN WORKING' sign
Squeegee Shovel
Wash down hose / High Pressure cleaner
1. All work inside tanks of any kind is subject to the Permit To Work System.
Refer to the W.I. Section 6.3. for tank entry permit and procedures.
2. Use ladders or built in steps for decent into and ascent from open tanks.
3. When the mud pumps are running, nobody is allowed to enter or work in a
tank, into which the mud pump relief lines run.
4. Ensure the mud pumps are isolated mechanically and electrically prior to
entering a tank where the mud pump relief valve discharges.
3. STANDARD OPERATIONAL CONSIDERATION ( DO'S AND DON'TS )
(1) Hold a Toolbox Talk to discuss operational guidelines, equipment and safety
procedures.
(2) Inform the Driller when job is about to start.
(3) Tanks are to be washed down as much as possible from the top of the tank before
any person enters the tank.
(4) Wear protective clothing and footwear against mud and dirty water spray.
(5) Wear protective goggles to prevent mud spray and solids from entering eyes.
(6) Ensure that the ladders are properly secured before entering tanks.
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4. INSTRUCTIONS
(1) Designate a Person in Charge of the Work site and a Stand By Man.
(2) Review the precautions necessary for the work (gas test, isolations, safety barriers
and review of Material Safety Data Sheets). Fill out a Permit to Work form.
(3) The Toolpusher inspects the work site and authorises the work by signing the
permit.
(4) Inform the Driller when ready for the operation.
(5) Flush out all lines into the tank to be cleaned.
Note: Where vacuum trucks are used, any mud remaining in the tank is sucked to the
truck. After washing down the tank from outside the tank, this fluid is also then sucked
to the truck, before any person enters the tank.
Where vacuum trucks are not used the tank is filled and flushed to remove as much of
the mud as possible, before any person enters the tank.
(6) Remove access grating from the tank to be cleaned and install a safety barrier at the
removed grating.
(7) Put on all required personal protective equipment (including goggles).
(8) Enter the tank and clean with hose and nozzle or high pressure cleaner.
(9) With the water hose or high pressure cleaner, wash down the sides of tank to
remove solids to the bottom of the tank and into the waste disposal.
(10) If needed, use shovels to dig out settled solids for removal from the tank bottom to
the solids waste area.
(11) Dump and wash out the sand trap under the shale shaker. Shovel solids into a
container for removal, if they cannot be washed out.
(12) Once the cleaning has been completed, make sure that all hoses, shovels, buckets
etc. are removed from the tank.
(13) Refit the grating.
(14) Remove all signs and ropes.
(15) The Person in Charge of the Work site arranges for the de-isolation of equipment
and ensures that the work site has been returned to a safe condition.
(16) Return the permit to the Toolpusher for signing off.
(17) Inform the Driller that the operation is completed.
四四. Cleaning Mud Tanks After Drilling H2S Zone

Personal Protective Equipment (PPE) Rubber gloves and rubber boots
Eye protection (goggles) Respiratory Protection
Eye Wash Bottle Slicker suit
'GRATING REMOVED' sign 'MAN WORKING' sign
Beeper / Multi-warn Squeegee
Shovel Wash down hose / High Pressure cleaner
Self Contained Breathing Apparatus (SCBA) - 30 minute sets
1. All work inside tanks of any kind is subject to the Permit To Work System.
Refer to the W.I. Section 6.3. for tank entry permit and procedures.
2. A crew member must be designated as Stand By Man and will remain
positioned outside the tank with SCBA to assist or call for assistance in the
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event of an emergency. Use the “ Beeper” and or “ Multi-Warn” constantly.

3. H2S is highly flammable and is an EXPLOSIVE poisonous gas, which is
heavier than air.
4. There could be a poisonous gas release during clean up, if there was H2S
during drilling with an alkaline water based mud containing caustic soda or a
continuous oil phase mud containing alkaline materials.
5. Cleaning tanks after encountering H2S must only be carried out by personnel
wearing SCBA.
6. Do not use industrial ammonia to scavenge H2S without special equipment
and training.
7. Use proper ladders or built-in steps for getting into and out of open tanks.
8. When the mud pumps are running, nobody is allowed to enter or work in a
tank, into which the mud pump relief lines run.
9. Ensure the mud pumps are isolated mechanically and electrically prior to
entering a tank where the mud pump relief valve discharges.
3. STANDARD OPERATIONAL CONSIDERATION (DO'S AND DON'TS)
(1) Hold a Toolbox Talk to discuss operational guidelines, equipment and safety
procedures. The Material Safety Data Sheets (MSDS) for the chemicals in the mud will
also be discussed.
(2) Safety procedures and the Drilling Programme requirements must be fully
understood and followed.
(3) Inform the Driller when job is about to start.
(4) Tanks are to be washed down as much as possible from the top of the tank before
any person enters the tank.
(5) Wear protective clothing and footwear against mud and dirty water spray.
(6) Wear protective goggles to prevent mud spray and solids from entering eyes.
(7) Ensure that the ladders are properly secured before entering tanks.
4. INSTRUCTIONS
(1) Designate a Person in Charge of the Work site and a Stand By Man.
(2) Review the precautions necessary for the work (gas test, isolations, safety barriers
and review of Material Safety Data Sheets).
(3) Fill out a Permit to Work form.
(4) The Toolpusher inspects the work site and authorises the work by signing the
permit.
(5) Inform the Driller when ready for the operation.
(6) Flush out all lines into the tank to be cleaned.
Note: Where vacuum trucks are used, any mud remaining in the tank is sucked to the
truck. After washing down the tank from outside the tank, this fluid is also then sucked
to the truck, before any person enters the tank. Where vacuum trucks are not used the
tank is filled and flushed to remove as much of the mud as possible, before any person
enters the tank.
(7) Remove access grating from the tank to be cleaned and install a safety barrier at the
removed grating.
(8) Put on all required personal protective equipment plus Self Contained Breathing
Apparatus (SCBA).
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Warning: Continuous monitoring for H2S will be necessary under these conditions.
(9) Enter the tank and clean with hose and nozzle or a high pressure cleaner.
(10) With the water hose or high pressure cleaner, wash down the sides of tank to
remove solids to the bottom of the tank and into the waste disposal.
(11) If needed, use shovels to dig out settled solids for removal from the tank bottom to
the solids waste area.
(12) Dump and wash out the sand trap under the shale shaker. Shovel solids into a
container for removal, if they cannot be washed out.
(13) Once the cleaning has been completed, make sure that all hoses, shovels, buckets
etc. are removed from the tank.
(14) Refit the grating.
(15) Remove all signs and ropes.
(16) The Person in Charge of the Work site arranges for the de-isolation of equipment
and ensures that the work site has been returned to a safe condition.
(17) Return the permit to the Toolpusher for signing off.
(18) Inform the Driller that the operation is completed.
四伍. Moving Chemicals in the Storage Area

Fork lift truck “Drum gripper” / Barrel clamp
Fork extension arm Big bag handling device
Goggles Dust mask
“Hazardous Chemical” sign
1. Where the driver has an obstructed view he must be guided by at least one
person at all times.
2. Only certified fork-lift truck drivers are allowed to drive Deutag fork lift
trucks.
3. No passengers are allowed to be carried on the fork lift truck, unless there is
a seat and seat belt provided for them.
4. Riding on the forks or running board of a fork lift truck is forbidden at all
times.
5. As with cranes, nobody is allowed to stand under a suspended load. Drivers /
Operators must be constantly on the look out for personnel entering or
standing in their “work area”.
6. An approved audible “reversing alarm” must be fitted and operational. A
flashing / rotating warning light may also be required in particular situations.
7. All spilled chemicals will be cleaned up and properly disposed of.
8. Stacking of pallets must be done with full pallets only. When individual sacks
are removed from a pallet, an unstable weight distribution will occur.
NOTE: Fork lift trucks are required to be inspected daily.
3. STANDARD OPERATIONAL CONSIDERATION (DO’S AND DON’TS)
(1) Special precautions, appropriate personal protective equipment (PPE) and
emergency procedures applicable to hazardous chemicals are to be identified on the
Material Safety Data Sheets.
(2) Ensure that hazardous chemicals are appropriately labelled, stored separately, and
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identified with a “Hazardous Chemical” sign.

(3) Any questions regarding storage, handling, packaging, mixing and use of hazardous
chemicals should be referred to the Material Safety Data Sheets.
(4) All spillage is to be reported to the Toolpusher and is to be cleaned up in
accordance with the Material Safety Data Sheets / Waste Management Procedures.
(5) Disposal of containers / drums / sacks that have contained hazardous material must
be carried out in accordance with the Material Safety Data Sheets / Waste Management
Procedures.
(6) Do not transfer to or store chemicals in unlabelled containers.
(7) Ensure that the chemical storage area is flat and in good condition.
(8) Providing sufficient space is available, store chemicals so that every type of
chemical is readily accessible.
(9) Do not stack different types of chemicals together.
(10) Badly stacked pallets are dangerous when being moved. They must always be re-
stacked.
(11) Broken pallets are to be replaced.
(12) Ensure room to manoeuvre the fork lift truck, for loading and unloading.
(13) Large trucks will have their brakes set and wheels chucked before starting to load
or unload.
(14) Check the fork lift truck and it’s safety devices before operating.
(15) Use extreme caution when using an extension arm on the forks, as the Working
Load Limit (WLL) is drastically reduced.
(16) Always keep the forks close to the ground (20 cm or less) when moving about.
(17) Big bags must only be transported using the appropriate lifting device.
(18) Transport single drums tilted back and in a horizontal position on the forks.
4. INSTRUCTIONS
4.1. Unloading Chemicals (Receiving)
(1) Ensure chemical labels are of the correct type.
(2) Prepare and tidy up the chemical storage areas before receiving materials.
(3) Check the delivery ticket against materials received.
(4) Check the Material Safety Data Sheet for precautions and warnings.
(5) Unload one pallet at a time with the fork lift truck.
(6) Stack pallets of chemicals straight and not more than two pallets high.
(7) Providing sufficient room, leave space between rows of pallets.
(8) Stack and store pallets according to the chemical type for future accessibility.
(9) Replace the “Hazardous Area” signs after unloading.
4.2. Loading chemicals (returning)
(1) The Mud Engineer is to list the chemicals to be returned and ensure that drums,
sacks, etc. are in good condition and can be transported safely.
(2) Ensure that hazardous chemicals are properly marked / labelled and treat them as
required, in a safe manner.
(3) Check if the chemicals are stacked safely on the pallets before move, and the
pallets are secure on the truck.
(4) Replace the “Hazardous Area” signs after loading.
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四六. Monitoring a Mud System

Fire extinguishers Eye wash fluid and cup
Anti-slip matting Long Sleeve Rubber gloves
Breathing mask - Toxic vapour Breathing mask - Dust
Goggles Wash sink
Towel or Rags Marsh funnel
Measuring cup Pressurised mud balance
pH paper
Note: The above list of Special Tools and Equipment are essential for any drilling
operation.
1. Material Safety Data Sheets on hazardous and toxic chemicals must be
obtained from the Drilling Fluid Service Company and must be on file at the
wellsite.
2. Electrical and high pressure hazards exists on and around the mud tanks
and the crews must be trained to be aware of these at all times.
3. Do not use high pressure wash down guns on electrical equipment or wires /
cables.
4. Mud chemicals are very slippery and dangerous when spilled on floors or
walking surfaces.
5. The shale shaker area can have accumulation of extremely explosive gas or
toxic vapours when drilling with gas cut mud.
6. Refer to Deutag H2S Gas Protection Manual, if drilling through H2S interval.
7. Breathing any chemical mud materials and their vapours must be avoided.
(1) Ensure that after service company (Mud Logging Company or the Mud Tester) is on
the location, their alarm system is installed and tested.
(2) A mud tank diagram will be posted on the rig floor, showing the position of all valves
on the tank system and their operational position (open or closed). (Refer to W.I.
Section6.1.)
(3) The mud tank system must be well lighted so that all monitoring operations can be
carried out in a safe manner at night.
(4) All handrails and steps are to be put up and secured to the pits.
(5) All safety equipment and fire extinguishers are to be placed at their proper stations
and checked for valid certifications.
(6) The mud weight and the funnel viscosity will be monitored as per the Drilling
Programme, Mud Programme section, and recorded in the tour book.
(7) The active mud pit, tank and compartment fluid levels will be marked and monitored.
(8) The reserve mud and storage will be recorded and posted on the rig floor.
(9) At the beginning of each tour, all planned mud treatment requirements will be noted
by the Driller and implemented by the Derrickman / Mud Tester.
(10) The Derrickman / Mud Tester will report all major changes in the monitored
parameters to the Driller and the Mud Engineer.
(11) The Derrickman / Mud Tester will check his calculated mud pit volumes with the
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volumes shown by the Mud Loggers to insure their equipment calibration is correct.
(12) The Derrickman / Mud Tester will work with the Mud Loggers and Mud Engineer as
a team but must not solely rely on their monitoring of the mud system parameters.
(13) At the end of each tour the Derrickman / Mud Tester shall hand over a copy of his
notes concerning the mud tank alignment, the mud flow routing through the tanks, the
recorded mud properties, the status of solids control equipment, and the status of any
chemical mud treatments to the Driller and his relief.
4. INSTRUCTIONS
4.1. Items to be Monitored by the Derrickman / Mud Tester
(1) The flowline returns and mud flow to shakers shall be observed and noted every 30
minutes or every 15 minutes in formation transition zones.
(2) The shakers screens shall be checked to ensure the correct carrying capacity of
each screen is being utilised.
(3) The sand trap shall be dumped as often as necessary to keep solids from
overflowing into the rest of the mud tanks.
(4) The dilution volume is to be checked regularly to ensure the proper amount is being
added.
(5) The operation of the degasser, the desanders, the desilters and the mud leaners will
be checked for performance and any plugging.
(6) The centrifuge operation shall be monitored to ensure the dilution and the feed mud
pumps are operating properly.
(7) The mechanical mixers (agitators) are to be maintained and kept in good operating
condition.
(8) Check and ensure that the floats on the volume sensors are operating properly.
(9) The alignment of the gas separator valves is to be recorded and posted on the rig
floor and the gas separator operational readiness maintained at all times.
(10) The Derrickman / Mud Tester will ensure the centrifugal pumps on the mud tank
system and solids control equipment are operating properly.
(11) The Derrickman / Mud Tester shall ensure the chemical barrel and mud mixing
operations are carried out in a safe and prescribed manner, with the correct chemicals
and amounts being added.
(12) The mud and barite mixing hoppers are to be maintained in good operational
condition at all times.
(13) The Derrickman / Mud Tester will inspect and ensure that the mud pumps are
operating properly, carry out the routine maintenance and that there is sufficient
expendable parts readily available for each pump.
(14) The alignment of the trip tank and its fluid volume are to be reported before and
after each trip.
(15) The alignment of the pill tank / slugging pit to the active mud pumps are to be
checked and reported to the Driller.
4.2. Items to be Recorded
(1) The mud weight and the funnel viscosity, at the flowline and at the pump suction, will
be checked and recorded every 15 / 30 minutes and a continuous record maintained on
the well.
(2) The alignment of the choke manifold valves will be recorded and posted on the rig
107
floor and the valves maintained in operational readiness.

(3) An accounting record of all drilling fluids inventory, materials consumption, and
effluent and pit volumes is mandatory and will be kept on the rig floor and in the
Toolpusher’s office.
(4) The shale shaker operations, screen integrity and shaker replacement parts and
screens shall be checked and recorded.
(5) The Driller will keep a record of mud or chemicals added to the mud system in the
tour book.
(6) The reserve mud volume is to be monitored and recorded each time mud is added
or taken from storage.
(7) All mud volume dumped to waste shall be reported and recorded in the tour book.
(8) The mud capacity of each tank or compartment of the mud system is to be recorded.
(9) The mud volume lost at the surface (valve leaks, pump packing gland leaks, etc.)
shall be reported and recorded.
四七. Changing Valves in the Mixing System

New valve (as replacement) 2 Ring spanners
Kopr-Kote grease “Man Working” sign
Shop hammer Piece of wood (to drift out old valve)
Jacking bolt (stud with nuts)
1. This procedure shall be carried out in compliance with the Permit to Work
System.
2. Ensure that electrical isolations are carried out in accordance with
regulations.
3. Isolate the relevant pump switch and put a “Man Working” sign on the pump
switch, during maintenance.
(1) Notify the Driller of need to change valve. Do not proceed without proper
authorisation.
(2) Ensure that the valve being replaced is isolated from the system and any pressure
that may be trapped is bled off.
(3) Ensure that a ‘Man Working’ sign is placed on any pump switch which could affect
the valve under repair.
(4) Verify that the correct size valve is to be installed and all tools are readily available.
(5) Never drive or force valve between the flanges using a hammer.
4. INSTRUCTIONS
(1) Remove the valve securing bolts, then remove the valve. Use the wooden drift and
the hammer to assist removal.
Note: Remember the position of the valve handle to indicate open or close positions.
(2) Clean the pipe flanges.
(3) Refit the two lower bolts to provide support for the new valve.
(4) Check the space between the flanges against the replacement valve size, the gap
may be increased using the jacking bolts if necessary.
(5) Fit the new valve, positioning the handle as noted at step (1).
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(6) Adjust the position of the new valve so that it opens and closes freely. Then release
the jacking bolts.
(7) Coat the bolts with Kopr-Kote grease and refit.
(8) Tighten the bolts evenly and progressively ensuring equal number of threads show
on either side of the bolts.
(9) Test the flanges for seal integrity by running mud, at normal pressure, through the
open valve.
Note: There is no requirement to test the valve for leakage in the closed position.
四八. Changing Shaker Screens

Adjustable spanners Torque wrench (1 inch socket)
Breathing mask Anti-slip matting
Eye wash materials Scraper
Grease Grease gun
1. Ensure that the power is turned off and locked out before commencing any
repairs on the shakers.
2. Maintain good air circulation and ventilation around the flow line and the
shale shakers, because of potentially explosive gas or toxic vapours.
3. Ensure that there is grating or matting around shaker area, to provide good
footing, while working on the shakers.
(1) Inform the Driller immediately when shale shaker screens break, are torn, or
develop holes.
(2) Do not run shale shakers when there is no fluid moving across the screens.
(3) Ensure that when circulation is stopped prior to a trip, before the shakers are turned
off, the screens are washed off and inspected for damage.
(4) Ensure that when necessary to control screen blinding (plugging of mesh holes),
high pressure wash down of shaker screens are done with water and a solvent.
(5) Ensure that, unless a water spray is absolutely necessary to control screen blinding,
water will not be used on the shaker screen surface, while circulating.
(6) Ensure that all electrical wiring, lights and motors are sealed, explosion proof and
protected from accidental damage that could cause a spark.
(7) Ensure that all bolts and tension nuts are tightened to shaker manufacturer’s
specific instructions.
(8) Check the drive belts for proper tension according to shaker manufactures specific
instruction.
(9) Ensure that the shakers are never bypassed unless lost circulation material is in the
mud, or changing to a finer or coarser screen.
(10) Ensure that the shale shakers and their sand traps will be continually monitored
while drilling.
(11) Ensure the use of the finest mesh screen capable of handling the full circulating
volume.
(12) Always maintain the covers, shields, guards and protective grating on, around and
between shakers.
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(13) Ensure that stiff or steel bristle brushes are not used on shale shaker screens.
(14) Ensure a proper screen size to keep 2/3 to 3/4 of the screening surface covered
with mud when drilling.
(15) On adjustable deck shakers, always keep deck angle such that cutting and solids
are easily removed.
(16) When excessive mud is lost over the end of the shakers ensure the screens are
not blinded off, install screens with greater flow through capacity (larger mesh size
openings).
4. INSTRUCTIONS
Note: The following procedure is for a Thule shale shaker. Refer to specific shaker
manufacturer’s service manual if different shaker is being used.
4.1. Screen Fitting (Installation)
4.1.1. Top Deck - Hook Strip Screens
(1) Loosen the top frame tension rail bolts.
(2) Ensure that the top frame extrusion rubbers are in place and clean.
Note: These rubbers are fitted to two support rails running from the front to the back of
the shaker. At installation, these rubbers should be greased for easier removal later.
(3) With the tension rails loosened fully, slide the hook strip screen onto the tension
rails, ensuring that the back edge of the screen is seated properly against the back
support rail.
(4) Hand tighten the tension bolts, pulling the screen down onto the rubber supports.
(5) Adjust the tension bolts such that the screen is central to the side rails.
(6) Tighten the tension bolt nut, using a torque wrench to apply the correct torque.
Note: Tighten the bolts in the sequence shown below. Lock the tension nuts using
threaded cover nuts.
Screen Bolt Position (from back to front) Applied Torque:
Size Left Right Lb.-ft N-m
8 Mesh (3) (4) 35-38 47-52
10 Mesh (7) (8) 35-38 47-52
20 Mesh (1) (2) 32-35 43-47
30 Mesh (9) (10) 32-35 43-47
4.1.2. Primary Screens (Lower Deck)
(1) Turn the pneumoseal ball valve to the vent position (Thule shakers).
(2) Withdraw one of the front screen 10 degree wedge pieces from the front of the
basket, leaving it to rest on the side support rails.
(3) Slide the rear screen, with the U-channel facing to the front, over the wedge piece
onto the rear screen rails.
(4) Continue to slide until the screen is up against the back of the basket.
(5) Slide the wedge piece forward.
(6) Slide the front screen over the wedge piece until the back edge of the screen is
firmly located in the U-channel.
(7) Slide the wedge piece forward until the locating dowels on the underside of the
wedge piece fit in the holes in the basket rails.
(8) Repeat the procedure with the second wedge piece.
4.1.3. Secondary Screens (Drying Screens)
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(1) Turn the pneumoseal ball valve to the vent position.

(2) Withdraw the wedge piece 20 to 30 cm from front of the basket, leaving the front
primary screen in position.
(3) Remove the four M10 set screws from the secondary screen carrier.
(4) Place the secondary screen into the carrier frame, with the silicon strips facing the
front.
(5) Replace and tighten the four M10 set screws.
(6) Slide the wedge piece fully home, ensuring that the locating pins on underside of the
wedge are in position.
(7) Repeat the procedure with the second wedge piece.
4.1.4. Shale Shaker Unit Start-Up Instruction
(1) Ensure that the rig air supply is available with the pressure regulator set at between
80 and 90 psi.
(2) Turn the ball valve to the on position, check that the pneumoseals are fully inflated.
(3) Switch the remote push-button starter unit to the on position.
(4) Open the sluice gate on the header box / feed chute.
(5) Adjust the flow until the level of fluid is approximately 15 to 18 inches from the edge
of the front screen.
(6) The fluid level can be adjusted by controlling the volume of fluid entering the feed
chute, or by careful selection of the mesh size.
Note: Do not attempt to operate the shale shaker with a higher level of fluid than has
been recommended. To do so could result in screen overload and premature screen
failure.
Note: Where secondary screens are in use, solids from the primary screens will fall
onto the lower secondary screens for further drying. This feature is particularly useful in
areas where oil-base mud (OBM) is used.
Note: Secondary screens are available in 2 mesh sizes and are generally of a coarser
mesh than the upper deck primary screens.
4.1.5. Shale Shaker Unit Shut-Down Instruction
(1) Close the sluice gate on the header box / feed chute.
(2) Continue to run the unit until the mud already on the screens has been processed.
(3) Clean the screens thoroughly using the appropriate fluid. For water based mud use
stream or high pressure water. For oil based mud use the base oil gun.
(4) Switch the remote push-button starter unit to the off position.
(5) Turn the ball valve to the vent position and leave the air on.
Note: When the unit is out of use for long periods, all screens should be removed and
cleaned thoroughly and either re-boxed or stored in a safe, dry area.
4.2. Maintenance Instruction
(1) Visually examine the shale shaker unit for signs of wear and or damage, and repair /
replace as necessary.
(2) Apply three shots of grease to each main drive shaft bearing. There are four nipples,
two on each side of the vibrator unit.
Note: Do not over lubricate the bearings.
(3) Check the tension of the triple V-belt drive arrangement. Adjustment is made by
moving the belt tensioner.
111
(4) Check the bearings and roller assemblies on the belt tensioners for wear. Repair or
replace if necessary.
(5) Inspect the grease nipple assemblies and associated piping.
(6) Visually examine the electric drive motors for wear and / or damage.
(7) Remove any build-up of solids from fan end of the electric drive motors.
四九. Operating Desanders, Desilters, and Mud Cleaners

Mud balance Viscosity funnel
Viscosity cup Stop watch
Torque wrench (1 inch socket) Welding rod or similar tool
1. Ensure that the grating around all the solids control equipment on the pits is
secure and has non-slip matting (coco mats when using oil-based mud).
and the crew must be trained to be aware of these at all times.
4. Ensure that the cabinet containing H2S safety / protection equipment is
installed on the pits.
5. Ensure that the area around the solids control equipment on the pits is well
ventilated in case of gas-cut mud or toxic vapours.
(1) Ensure that each solids control equipment is sized to process 100% to 150% of the
maximum anticipated circulating volume from the previous solids control equipment
discharge compartment.
(2) Ensure that the impellers on the centrifugal pumps are turning the correct direction,
the right size to produce the appropriate flow rate and at the same time small enough
not to overload the electric motor.
(3) All solids control equipment should have working head pressure gauge installed on
the feed manifold, with a valve to allow gauge replacement.
(4) All solids control equipment is to be operated at the manufacturer’s recommended
feed manifold pressure (usually between 60 to 90 feet-head of pressure).
Note: Too low a feed pressure decreases efficiency, while too high a pressure shortens
the life of the cones.
Note: If using a pressure gauge with bar or psi scale, ensure that the conversion to
working head pressure is calculated for the mud weight in use.
(5) Ensure that the solids control equipment operates with a spray discharge and not a
rope discharge. A rope discharge cuts cone efficiency in nearly half and causes cone
plugging (See Figure 1).
(6) Ensure that periodically the mud weight, the viscosity and other mud properties are
checked downstream of each piece of equipment to monitor equipment performance.
(7) Ensure that all solids control equipment have spare cones and screens of the right
size on location.
(8) Ensure that all valves are operational on the pumps and the solids control
equipment.
4. INSTRUCTIONS
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4.1. Guidelines for Installation

(1) The desander is to be installed downstream of the shale shaker and the degasser.
(2) The desilter is to be installed downstream of the desander.
(3) The mud cleaner is to be positioned on the pit or a separate platform downstream of
the desilter.
(4) The suction line of the desander pump is to be taken from the compartment past the
sand trap (or alternatively from the sand trap, itself) and discharged into the next tank
compartment.
(5) The desilter suction is to be taken from the tank compartment receiving fluid
processed from the desander.
Note: Do not use the same pump to feed both the desander and the desilter. Each
equipment should be installed in series and have its own centrifugal pump.
(6) The mud cleaner suction is to be taken from the tank compartment receiving the
desander or the desilter processed fluid.
(7) The centrifugal pump suctions should have a guard screen installed to prevent large
trash from entering and plugging the hydrocylone cones.
(8) All suction and discharge lines are to be kept as short as possible and no smaller
than the discharge manifold.
(9) Install a low equaliser line for back-flow to the desilter suction compartment.
(10) Install a low equaliser line for back-flow to the mud cleaner suction compartment.
(11) The desander, desilter and the mud cleaner is to be positioned high enough on the
pit so the overflow manifold will gravity feed fluid into the next downstream tank
compartment at an angle of approximately 45 degrees.
(12) The discharge line is to be kept above the surface of the mud to avoid creating a
vacuum in the line.
(13) The under-flow trough is to be directed in such a manner that the solids are easily
transported to the waste pit.
(14) The cone under-flow of the mud cleaner is to be fed to a single point on the screen,
with minimal use of the available screen area.
Note: Capacity and efficiency suffer with multiple feed points on the screening surface.
(15) The fluid under-flow of the mud cleaner screen should be returned to a well
agitated spot in the tank compartment to prevent concentrated barite from settling in the
mud tank.
4.2. Operating the Desander
(1) Before starting the centrifugal pump, ensure that the suction valve on the centrifugal
pump is open. As soon as the pump is running, open the discharge valve slowly.
(2) Engage the start button on the centrifugal pump of the desander.
(3) After ensuring that the pump is primed, check the feed manifold for the correct
pressure (60 to 90 feet-head of pressure).
(4) Ensure that the cones of the desander are not plugged and keep the under-flow
trough clear.
(5) The Derrickman / Mud Tester adjusts the flow so that the desander has a spray
discharge and not a rope discharge.
(6) Operate the desander continually while drilling with unweighted mud.
(7) Check the cones of the desander regularly to ensure that the discharge orifice is not
113
plugged. Use a welding rod or similar tool to unplug the cones if necessary.
(8) After the desander has been taken out of service after drilling the top section of the
hole, flush out the feed manifold of the desander.
4.3. Operating the Desilter
(2) Engage the start button on the centrifugal pump of the desilter.
pressure (minimum of 75 feet-head of pressure).
Note: As mud weight increases, the observed feed pressure will also increase.
(4) Ensure that the cones of the desilter are not plugged and keep the under-flow trough
clear.
(5) The Derrickman / Mud Tester should adjust the flow so that the desilter has a spray
discharge and not a rope discharge.
(6) Operate the desander as per the Drilling Programme.
Note: The desilter is not to be used with weighted or oil-based muds since an
appreciable amount of barite and fluid is lost during the operation of the desilter.
(7) Check the cones of the desilter regularly to ensure that the discharge orifice is not
plugged or flooding. Use a welding rod or similar tool to unplug the cones if necessary.
(8) If the cone is flooding, check the feed. The feed may be partially plugged or the
bottom of the cone is worn out. Inform the Driller prior to commencing repairs.
(9) Flush the feed manifold of the desilter at the end of the well or when it is taken out of
the mud processing operation.
4.4. Operating the Mud Cleaner
(2) Ensure that the cones of the mud cleaner are not plugged and the screen is clean of
all dried mud and free of holes and or damage.
(3) Adjust the screen tension properly with a torque wrench, if necessary.
(4) Select the number of cones to be operated and the particular mesh screen to be
used according to drilling conditions.
Note: The mud cleaner has to be operated within the limits of the screen capacity. If the
cone under-flow exceeds the screen capacity, flooding and high mud additive losses
result.
(5) Engage the start button on the vibrating screen of the mud cleaner.
(6) Engage the start button on the centrifugal pump.
pressure (80 to 90 feet-head of pressure).
Note: Do not use excessive feed pressure. Excessive pressures will result in reduced
efficiency, greater barite loss, and severe cyclone wear.
(8) The Derrickman / Mud Tester will ensure that the mud cleaner has a spray
discharge and not a rope discharge (see Figure 1).
(9) Operate the mud cleaner continuously on the full circulating volume to achieve
maximum drilled solids removal.
(10) Check cones regularly for bottom plugging or flooding and adjust the cones to
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maintain a spray discharge.

(11) Check cones for excessive wear and replace parts as necessary.
(12) Check the feed manifold for plugging of the cone feed inlets and clean each as
necessary.
(13) After the mud cleaner has been taken out of service, flush out the feed manifold.
伍零. Operating the Degasser

Fire Extinguishers Eye Wash Fluid
Mud Balance Marsh Funnel
Measuring Cup pH Paper
Pressurised Mud Balance Held Gas Meter
1. While the degasser is in operation, no open flames or sparks are allowed in
the vicinity of the mud tanks.
2. Breathing gas vapours must be avoided.
3. Gas cut mud flowing across a shale shaker will release gas fumes that may
be toxic and also could reach explosive and flammable concentrations.
4. Upon the start-up of the degasser, check for leaking equipment and
connections.
5. Degasser area must be well ventilated, due to explosive and toxic gases and
vapours evolving from the mud.
(1) The mud degasser is to be located on top of the mud tanks, processing the mud
from the first compartment past the sand trap.
(2) Verify that the degasser capacity is large enough to process 100-150% of the
planned circulating rates.
(3) Ensure that the degasser is not operated in parallel with any other solids control
equipment.
(4) Ensure that the degasser is properly vented.
(5) Since the degasser is only utilised on a need to operate basis when gas or air cut
mud is encountered, it has to be carefully maintained so that it will operate properly
whenever it is needed in service.
(6) The degasser should be test run each shift and any problems reported to the
Toolpusher and recorded in the drilling report.
(7) In some mud tank systems, the degasser suction compartment is isolated and left
empty of any drilling fluid to prevent solids settling and plugging of the suction pump or
the degasser itself with solids when it is put into service.
(8) In some tank systems, the degasser suction compartment can not be isolated from
the active system and drained. If so, operate the degasser for 10-15
minutes each day to verify that it is functioning and to prevent the pump suction from
becoming blocked by settled solids.
(9) All mud checks should be done from the degasser discharge compartment while
processing gas-cut mud.
(10) Ensure that the degasser is flushed with clean water at the end of the drilling
interval and at the end of the well.
115
(11) Clean and maintain the degasser unit as per the manufacturers service manual.
(12) The Assistant Driller / Mud Tester is responsible for the proper maintenance and
operation of the degasser.
4. INSTRUCTIONS
4.1. Preparation to Route Mud Through the Degasser Compartment
(1) Inform the Driller and the Toolpusher before the degasser is activated.
(2) Ensure that the gas discharge line is connected to the degasser vent line.
(3) Open the weir gate from the mud ditch to the degasser suction tank.
(4) Close off the downstream side of the mud ditch, to direct all of the mud flow to the
degasser suction tank.
(5) Ensure that the by-pass valve from the degasser suction tank compartment to the
downstream tank compartment is closed.
(6) Ensure that the end of the mud discharge line is submerged below the mud level in
the downstream tank compartment.
4.2. Starting Up the Degasser
(1) Press the start switch at the degasser local control panel to start the compressor.
(2) Verify that the motor or the centrifugal pump are operating properly. The degasser
should develop the normal flow rate within 15 seconds.
(3) While the degasser is running, pump 15 to 20 shots of the recommended grease
into the gearbox.
(4) Inspect the mud discharge line to see that it has full mud flow.
(5) Check the effectiveness of the degasser by measuring the mud density with the
normal mud balance at the degasser suction and discharge compartments and
comparing to the mud weight measured with the pressurised balance.
(6) Ensure that the mud is conveyed by the overflow weir from the sand trap to the
degasser suction compartment and that there is back-flow from the degasser discharge
compartment back to the degasser suction compartment.
(7) Control the level of mud in the suction tank by opening the by-pass valve between
the suction tank and the discharge tank.
4.3. Shutting Down the Degasser
(1) Inform the Driller and the Toolpusher before shutting down the mud degasser.
(2) If the degasser compartment will be left empty to prevent solids settling, direct the
mud flow down the mud ditch by closing the degasser suction tank weir gate and close
off the back-flow weir.
(3) Allow the suction tank to be emptied by the degasser.
(4) Turn off the centrifugal pump motor switch when the compartment is nearly dry.
(5) If the degasser compartment can not be isolated from the active system, turn off the
pump switch when the degassing operation is completed.
(6) If the degasser compartment can not be isolated, operate the degasser for 10 to 15
minutes each day to verify that it is functioning properly and to prevent the pump
suction from becoming blocked by settled solids.
伍壱. Operating the Poor Boy Mud Gas Separator

Not Applicable
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1. All mud gas separators have pressure and volume limits which must be
known and observed.
2. Inform the crew before gas is discharged from the system.
3. When an open-ended bottom poor boy mud gas separator discharges in a pit
where the mud level is low, danger of gas blowing through exists.
4. Ensure that the mud level in the tank is sufficient, at all times, to form mud
seal and prevent gas from blowing through.
5. Take wind direction in consideration when the mud gas separator is
operational.
(1) The Toolpusher is to direct all operations of the poor boy mud gas separator and to
decide when to direct the flow stream through the mud gas separator back to the shale
shakers.
(2) Typically the poor boy mud gas separator is located between the choke manifold
and the shale shakers, and has a straight discharge to the vent line.
(3) Normally, the poor boy mud gas separator is installed to work from the choke
manifold only. Ensure the line from the choke manifold to the poor boy mud gas
separator is clean and free from obstructions.
(4) The poor boy mud gas separators are designed for processing mud with large
amounts of dissolved or free gas which will be expanding at atmospheric conditions.
(5) A rule of thumb for poor boy mud gas separator size is that it must be able to handle
5 times the planned circulating rate.
(6) The poor boy mud gas separator inlet line size should be the same or larger than
the choke manifold discharge line.
(7) The poor boy mud gas separator mud discharge line should be the same size as the
flow line or larger and discharge into the shale shaker feed manifold or the possum
belly.
(8) The gas discharge line to the vent should be 200 mm (8 inches) or larger in
diameter.
(9) Ensure that there are no valves installed on the gas vent line.
(10) The poor boy mud gas separator gas discharge line must be securely anchored.
(11) During freezing weather, the poor boy mud gas separator clean-out valve (when
equipped with valve), located on the bottom, should be kept open to prevent any fluids
inside from freezing and plugging the mud gas separator.
(12) Ensure the bottom of the pit is not obstructed by settlement when a poor boy mud
gas separator is in use with an open-ended bottom section installed inside the pit.
(13) When circulating out gas over the choke manifold it is important to keep the mud
level as high as possible. (i.e. overflowing into the active pit)
(14) Ensure equalising valves to other pits will are closed before starting to circulate
through the poor boy mud gas separator.
(15) Do not run desanders and desilters in order to maximise the mud seal.
(16) When required a Watchman is to observe the mud level / mud seal.
4. INSTRUCTIONS
4.1. Operation for Circulating out a Kick
(1) When the well has been shut-in after a kick, while the kick calculations are being
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finalised and the choke manifold is being lined up to circulate out the kick, the mud gas
separator also has to be lined up for operation.
(2) When applicable close the poor boy mud gas separator clean-out valve and the U-
tube drain valve, if installed.
(3) Check the vent line safety tie-down lines or chains.
(4) Ensure that the mud logging unit gas sampler is secure.
(5) Open the choke manifold discharge valve to the poor boy mud gas separator.
(6) When the well control procedures commence, the annulus returns will be going
through the choke manifold and then to the mud gas separator, with the separated gas
being vented and the mud returned to the shale shakers.
(7) During its operation, continuously monitor the poor boy mud gas separator and the
returns to the shale shaker tank.
(8) After the kick has been killed and the BOP is opened, close the choke manifold
valve to the mud gas separator.
(9) Open the poor boy mud gas separator drain valve and flush all cuttings to the waste
pit.
(10) If using a “U-tube” type separator, open the U-tube drain valve and flush with
water. Flush all solids to the waste pit.
(11) Clean, flush and check all manifolds, lines and valves. Reset the choke manifold
and the mud gas separator for soft or hard shut-in as prescribed in the Drilling
Programme.
伍弐. Operating the Centrifuge

Mud balance pH paper
Marsh funnel Measuring cup
Stop watch
1. Material Safety Data Sheets on hazardous and toxic chemicals must be
obtained from the Drilling Fluid Service Company and must be on file at the
wellsite.
and the crews must be trained to be aware of these at all times.
3. Mud chemicals are very slippery and dangerous when spilled on floors or
walking surfaces.
5. Breathing any chemical mud materials and their vapours must be avoided.
6. The centrifuge must be rigged up and serviced by qualified technicians from
the supplier of the equipment.
(1) Ensure that the centrifuge is set up and serviced as scheduled by the supplier of the
equipment.
(2) Ensure that the Derrickman / Mud Tester and the Mechanic are trained in the
operation of the centrifuge.
(3) Ensure that the centrifuge is run when the mud properties (i.e. the specific gravity,
solids, pH, or the viscosity) reaches the established maximum and stopped when the
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specified mud properties reach the established minimum, as specified in the Mud
Programme section of the Drilling Programme.
Note: The maximum and the minimum limits on the mud properties to be adjusted with
the centrifuge should be established as part of the overall mud program section of the
Drilling Programme.
(4) If the solids under-flow from the centrifuge is being returned to the mud system (in
the barite recovery mode), the centrifuge discharge is positioned so that the under-flow
falls into a well-stirred area of the mud tank.
(5) Ensure that the centrifuge returns are not positioned at or near the rig pump suction
line.
(6) Ensure that there is sufficient working space provided for routine maintenance and
operating adjustments.
(7) Ensure that the liquid effluent lines have a constant downward slope.
(8) Ensure that the trip switch is correctly positioned.
4. INSTRUCTIONS
(1) The centrifuge is installed downstream from all other solids control equipment.
(2) The centrifuge suction should be taken from the tank compartment that receives the
processed fluid from the desilter or the mud cleaner.
(3) Ensure that the flow in and out of the centrifuge is controlled by two properly sized
positive displacement pumps, one for mud feed and the other for dilution water.
4.1. Starting the Centrifuge
Note: Depending on the type or brand of the centrifuge, the Derrickman / Mud Tester
will have to refer to the Manufacturer’s Operating Manual for starting and shutting down
instructions.
(1) Establish that the suction and discharge valves are open to the feed pumps.
(2) Turn on the dilution water feed pump.
(3) Then, engage the centrifuge start button, ensuring the bowl of the centrifuge is free
to turn.
(4) Once the centrifuge is running, turn on the mud feed.
(5) Adjust the mud feed and dilution water flow rates, and the differential speed of the
centrifuge for optimum performance, taking care not to overload the centrifuge with too
much feed mud.
(6) Check that the fluid pool depth inside the centrifuge is correct.
4.2. Shutting Down the Centrifuge
(1) First, shut off the mud feed into the centrifuge and turn off the feed pump.
(2) Allow the centrifuge to run on clear dilution water until it is completely cleaned out.
(3) Then turn off the centrifuge.
(4) After the centrifuge has stopped, turn off the dilution water feed.
(5) Close off the isolation valves.
伍参. Using High Pressure Wash Down Guns

Safety Helmet with face visor or Goggles
Safety harness and Life line (if working at heights)
Pressure pump washing apparatus, Hose and Wash down gun
Rubber gloves
119
1. Never operate the supply equipment with the covers removed.
2. Do not subject the hose to any abuse. Improper use or mishandling of the
hose may result in hose failure and possible injury to personnel.
3. Never point the wash down gun, nozzle, or fluid on to any person. Do not put
your hand, fingers, or any part of your body over the spray nozzle. NEVER
use the wash down gun to clean boots / gloves, if these are still being worn
by someone.
4. Use extreme care and avoid any eye, ear, or nose contact with cleaning
chemicals. If the chemical does contact the skin, or enters the eyes, flush
immediately and thoroughly with water then seek medical attention.
5. Ensure that the wash down gun is fitted with sufficient length hose, so that
the cleaning unit can be positioned outside any hazardous areas.
(1) A Toolbox Talk shall be held before the cleaning operation begins.
(2) Ensure that the power supply is the correct rating for the pump motor.
(3) Do not repair high pressure hose but replace when damaged.
(4) Do not clean shale shaker screens with the high pressure wash down gun.
(5) If connecting to the Hot System, only the Mechanic / Electrician is to make the
connection.
(6) Do not ever use washing equipment to spray paint or other flammable liquids.
(7) Protective clothing / equipment will be worn by the Operator.
(8) DO NOT apply high pressure water, chemicals or spray on electric equipment,
motors or electric cable.
(9) The working area must be free of all obstructions and hazards.
(10) Only specified / recommended cleaning agents are to be used and no substitutes
or alternatives.
(11) When using the equipment outdoors, the Operator should always stand with his
back toward the prevailing wind.
(12) Check the entire hose for damage. Cuts, leaks, abrasions, bulging or loose
couplings are unacceptable and hose replacement is required.
(13) Ensure that there is firm footing for the wash down gun Operator.
(14) The Operator must have a safety harness and safety line if working at heights.
(15) Ensure that proper drainage is provided for removal of polluting compounds.
(16) Service company personnel need permission to use the HP wash down gun
4. INSTRUCTIONS
(1) The Operator inspects the equipment to be washed and check for anything that
could cause damage to the high pressure hose.
(2) The Operator turns on the power washer and goes to where washing down is to
take place ensuring the high pressure hose is safe and out of the way.
(3) The Operator braces himself against the back thrust before he engages the wash
down wand.
(4) The Operator must ensure that the pressure hose does not become entangled while
the washer is in use.
(5) The Operator must be aware of any overhangs or any hazardous footing in the area
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in which he is working.
(6) After the job is complete, the Operator turns off the power washer, rolls up the
pressure hose, and stores the wash down gun.
伍四. Hazardous Areas and Zones

Not Applicable
1. No smoking will be allowed in Zone 1 and Zone 2, and only in designated
areas of the location.
2. A Hot Work Permit is required for all work inside the Hazardous Areas.
3. Refer to the Hazardous Zone Map for your current rig position issued by
Deutag HSE Department.
(1) Independent Ventilation: Air intake must be located outside a 15 meter radius
around the wellbore and a 7,5 meter radius around the mud tanks containing gas-
contaminated mud.
(2) Diesel Tanks: Diesel tanks with a capacity of 10 - 30 m3 are to be considered
hazardous within a radius of 10 meters. This area is to be treated in the same way as
the 15 meter hazardous area around the wellbore.
(3) Closing Units: It must be possible to close the BOP from the rig floor, as well as
from the closing unit itself, which should be located at a safe distance from the wellbore.
(4) Welding Equipment: Cutting torches, welding apparatus, etc. may be used inside
hazardous areas only after approval of the Toolpusher and Drilling Supervisor and a
Hot Work Permit has to be issued.
(5) Common Rooms and Workshops: May only be placed outside the 30 meterradius
hazardous area.
(6) Vehicles: Vehicles with petrol engines may be driven in these hazardous areas only
after approval of the Toolpusher.
(7) Gas Bottles:Gas bottles are only allowed to be stored in their designated area
(preferably in open air). If designated storage area is enclosed, no other material or
equipment can be stored within 2 meters from the ventilation openings and the
entrances.
4. INSTRUCTIONS
4.1. Hazardous Area Classification
Note: Refer to Figure 1 for a typical hazardous area classification. Always check the
Hazardous Zone Map specific to your current rig position .A sample is shown in Figure
2.
4.1.1. Zone 1 (Areas in which there is an increased risk of gas explosion).
Note: In these areas, there is a high probability that an explosive mixture may be
present.
(1) 3 meters: Hemisphere around the wellbore, downwards to the surface of the
ground.
(2) 3 meters: Hemisphere around the tanks containing non-degassed mud.
Note: In addition, in poorly ventilated rooms partially located in Zone 2.
4.1.2. Zone 2 (Areas in which there is a risk of gas explosion).
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Note: Allowances must be made in these area for the presence of an explosive mixture.
Note: The vertical extent of Zone 2 area shall be measured from the top of the derrick
or the top of the lubricator down to the ground level.
(1) 15 meter: Circular area around the wellbore up to a height of 15 meter above the
top of the derrick.
(2) 15 meter: Hemisphere around tanks containing non-degassed mud.
(3) 7.5 Meter: Hemisphere around tanks containing degassed mud.
(4) 3 meter: Hemisphere around storage tanks.
4.2. Equipment Prohibited in Zones 1 and 2.
(1) Transformer stations and high-tension switching installations
(2) Generator sets
(3) Electrical supply system that is not explosion-proof
(4) Compressor plants
(5) Sheds, workshops steam cleaners, welding apparatus, angle grinders, drilling
presses.
Note: Exceptional Authorisation (Hot Work Permit) = Non explosion-proof equipment
may be used within the fire hazard areas, Zones 1 and 2, only with the written approval
of the Toolpusher, indicating, at the same time, the required safety precautions. This
approval always applies only to a particular case.
伍伍. Operation and Maintenance of Derrickman Escape Devices

Safety harness Riding Belt
Mechanical slides
1. All escape lines must be replaced once a year, no matter how good of
condition it is in.
2. The brakes on the mechanical slide (RG-10) must be replaced after two
descents.
3. After rigging up the escape line, carry out a test with a 75 kg weight.
(1) The escape devices are to be used only in an emergency situation.
(2) Ensure that the escape line is properly secured to the derrick or mast and not to the
monkeyboard.
(3) Ensure the escape line is substantially anchored at the ground level and properly
secured.
(4) Ensure that the escape line is positioned at a location on the derrick that provides
easy access for the Derrickman from the monkeyboard and to the mechanical slide.
(5) Ensure that the mechanical slide is installed on the escape line and properly tied off
at the Derrickman’s entry point
(6) Ensure that the escape line angle of descent is no more than 30 degrees with the
ground, since steeper angles cause excessive descent speed.
(7) Ensure that the area around the ground anchor point is kept clear and free of
obstructions. Everything that can hinder the safe descent and escape of the Derrickman
must be removed.
(8) Ensure that all safety harnesses and riding belts are Deutag Safety Approved.
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4. INSTRUCTIONS
4.1. Operation of the Mechanical Slide
(1) In an emergency situation, the Derrickman will place his legs over the sitting
frame of the escape device.
(2) Grasp the RG-10 frame with the left hand and place right hand on the brake.
(3) Release the securing rope.
(4) Push upwards on the brake until the brake release.
(5) In a controlled manner, further release the brake until a steady rate of descent is
obtained.
(6) The Derrickman will pull back on the brake if the rate of descent is too fast.
(7) As the Derrickman nears the anchor point, he pulls back and fully engages the
brake.
4.2. Maintenance of the Mechanical Slide
(1) After rigging up the escape line, the Rigging Supervisor or the Driller will carry out a
test with a 75 kg weight.
(2) The mechanical slide is to be inspected and tested at intervals of 1 month by the
Driller or after any alteration of the escape device and examined by the manufacturer
every 4 years.
(3) Complete the monthly checklist as per the COMPASS System.
伍六. Laying Out and Preparing Casing

Two adjustable spanners Small pipe wrench
API casing thread compound Wooden wedges
High pressure cleaning gun Crane or Fork lift truck (pipe clamp)
Two air hoses, complete with valves 2 x 14 m (45 ft) 1/2" manila rope
30 m (100 ft) Flex line (plumbers snake) Canister with 14 m (45 ft) twine or string
Cleaning fluid and Drip pan Steel measuring tape and Paint stick
Timber for separating rows Eye protection - Hearing protection
Dope brushes, Soft bristle brush API Casing drift (appropriate size)
Hammer (air hammer) and pliers Centralisers, stop collars and nails
Set of drain rods Hazard tape
1. Work area access shall be restricted with Hazard Tape.
2. During transfer of casing joints from the trucks to the pipe racks, the area
around the pipe rack must be kept clear of personnel.
3. Do not stand or work under a suspended load.
4. Personnel should not position themselves between casing joints being
moved or rolled on the rack.
5. During drifting casing, take care to ensure that the drift does not drop out of
the end of the joint and cause personal injury.
3. STANDARD OPERATIONAL CONSIDERATIONS (DO'S AND DON’TS)
(1) The Toolpusher must call out casing and associated equipment in time to avoid any
downtime.
(2) The Toolpusher must confirm that the casing, float equipment, and casing
attachments being delivered are the correct size, weight, grade as specified in the
123
Drilling Programme.
(3) Hold a Toolbox Talk with the crews, the Crane Operator, the Fork lift truck Operator
and all involved personnel to discuss safety and the job objectives before starting.
(4) Ensure that casing joints are placed on the pipe rack with the box end of tool joints
facing the rig.
(5) Ensure that the end joints in every row are securely wedged against rolling.
(6) Ensure that joints which are damaged are clearly marked and separated.
(7) Ensure that joints which cannot be drifted are clearly marked.
(8) Protectors must always be fitted to pin and box ends, when casing is being moved.
(9) Ensure that the threads, (particularly the box end), do not get damaged during the
drifting operations.
4. INSTRUCTIONS
4.1. Laying Out and Preparing Casing
(1) Lay out the rows of casing with the box ends in line for easy access.
Note: If different grades are to be run in the same string, the Toolpusher will verify the
layout sequence.
(2) Box and pin end protectors should be removed before starting the next layer.
(3) Each joint shall be visibly marked / painted with a sequential number. The
number is to be painted or marked on the box end of the joint, where it will be
easily visible.
(4) Measure and record the length from the last thread on the pin (threads off) to the
end of the box of each joint.
Note: Float equipment, stage collars, and crossovers to be entered separately on the
tally sheet.
Note: Casing lengths must be verified independently by the Client Representative using
a different measuring tape.
(5) Planks or pieces of timber (strips) are positioned on the top of the first layer of
casing.
Note: The lumber should be placed so as to facilitate the rolling and measuring of
casing joints as well as thread cleaning and thread protector removal and attachment.
Note: The timber should measure at least 4 x 2 inches (4 x 4 inch or even 12 x 12 inch
timbers may be safer for 20 inch or larger casing).
(6) Repeat steps (1) to (4) until all of the casing is laid out.
(7) Wedge the last pipe at each end of every row.
(8) Remove the remainder of the protectors and clean the pin and box threads on all the
joints using detergent cleaning fluid, dope brush (and a high pressure cleaning gun).
(9) Ensure that the drip pan is correctly positioned to catch any drips.
(10) Ensure that no detergent fluid remains on the threads.
Note: Do not use wire (steel) brushes for the cleaning of premium connections. Only
use soft bristle brush.
(11) After the threads have been cleaned, and prior to running, each pin and box
connection should be visually inspected before being lifted to the rig floor.
(12) Application of any thread compound should be as per the Drilling Programme and
or Manufacturer’s speciality connection guidelines.
4.2. Drifting Casing
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4.2.1. Using Drain Rods

(1) Ensure that the rods are screwed together tightly.
(2) Ensure that the drift is the correct size for the size / weight / grade of casing to be
drifted and attach enough rods to allow the longest joint to be drifted (approximately 14
metres - 45 ft).
(3) Drift the casing by pulling or pushing the drift through each joint of casing, using the
drain rods.
Note: Ensure that the drain rods do not trip anyone or whiplash while being handled.
(4) Once all joints have been drifted, clean the protectors and put them back on the
casing.
Note: Use a scaffold or work platform if required.
4.2.2. Using Air Lines
(1) Ensure that the air lines and valves are in good condition. Secure connections with
safety lines / clamps.
(2) Instruct all personnel to keep well clear when air is being blown through the casing
(isolate the area with hazard tape).
Rule: Eye and hearing protection must be worn.
(3) Connect the twine or string to a suitable canister to help blow the drift through the
casing and attach the drift to the rope.
(4) Pull the twine / rope / drift through the casing.
(5) Repeat the process until all joints have been drifted.
casing.
4.2.3. Using Flex Line
(1) Two Crewmen, one at each end of the casing joint, pass the flex line through the
casing from the pin end to the box end.
(2) Pull the drift through the casing with the flex line.
(3) Insert the flex line into the next joint of casing as the drift is being pulled through.
(4) Repeat steps (1) to (4) until all joints of casing is drifted.
casing.
4.3. Fitting Centralisers and Stop Collars
Rule: Eye and ear protection must be worn.
(1) Centralisers and stop collars can be installed while the casing is on the pipe rack in
accordance with the installation design from the Drilling Programme.
(2) Stop collars (newer models) are to be secured in the required position using an allen
screw mechanism. Older model stop collars may be supplied with the manufacturer’s
nails and are to be secured in the required position using at least two nails, driven at
opposite direction on the stop collar.
(3) If using nails, insert the nail provided by the manufacturer into the hole provided and
tap in about 2-3 cm. Use an air hammer, if available, to drive the nail in as far as it will
go.
(4) Centralisers are to be positioned by slotting a nail from the top (box end), through
each of the hinges on the open side. A hammer may be needed to tap them in.
Once the nail has been slotted through, bend back the end sticking out and push it
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against the side wall of the joint.

Note: If this is being done on the rig floor, the rotary table area must be covered with a
cloth or similar, to prevent any nails etc. falling down the hole.
伍七. Operation and Maintenance of the Stabbing Board

Full safety harness Inertia reel safety device
Thin rope for securing tools Air line or bar for operating Spider elevator
Oil and Grease Grease gun
1. ZPEB standard safety harness must be visually inspected, must be in good
condition, and must be worn at all times.
2. Ensure that the inertial reel is be secured to the derrick / mast structure and
not to the stabbing board itself.
3. Ensure that there is no work done on the rig floor during testing of the
stabbing board.
4. Ensure that the Driller and the Stabber are both completely familiar with the
hand signals that are to be used.
5. Ensure that the Driller and the Stabber have good visual contact.
(1) A Toolbox Talk must be held before the stabbing operation begins.
(2) Inspect the hoisting wire, sheaves, safety brake wire / dogs and air hoses.
(3) A log of the checks and maintenance of the stabbing board shall be kept as part of
the rig maintenance system. All ropes / cables shall be checked weekly, and routine
lubrication shall be carried out.
(4) Prior to climbing the derrick / mast, the Stabber must inform the Driller.
(5) The designated Stabbing Board Operator (the Stabber) shall be trained in the
operation of the equipment, and shall check it independently as soon as possible after
coming on shift.
Note: On some rigs there is little room between the stabbing board and the top drive
and in some cases the front of the board has to be raised to allow the top drive past.
(6) Ensure that there is adequate lighting so the Driller is able to see the Stabber clearly
during work at night or in poor light conditions.
(7) Ensure that there are no loose objects on the stabbing board and on the Stabber
himself.
(8) Whenever the stabbing board has not been used for 14 days or more, the ropes /
cables and lubrication system shall be completely checked, the stabbing board
examined and all its motions tested.
(9) Stabbing Board wire shall be changed out yearly, regardless of operational hours.
4. INSTRUCTIONS
4.1. Normal Operation
(1) Turn on the stabbing board air supply.
(2) The Stabber will check the function of the board, by raising and lowering the board
to the proper height.
(3) The Stabber will ensure that wires / safety and air lines are not tangled and cannot
become caught, when raising or lowering the board.
126
(4) The Driller will check the harness and the clothes of the Stabber and ensure the
Stabber wears a chin strap on his hard hat, before allowing him to climb the derrick.
(5) The Stabber must use the safety climber, and climb to the stabbing board.
(6) Before entering onto the stabbing board, the Stabber will first fasten the inertia reel
safety wire to the safety harness, and only then, unhook from the safety climber.
(7) The Stabber will ensure that the body belt / front hand rail is in good condition and
secure.
(8) The Stabber will ensure that the stabbing board surface is not slippery.
(9) After entering, the Stabber ensures that the access gate to the stabbing board is
shut.
(10) The Stabber will pull the overhead operating cord to have the winch raise or lower
the platform to the optimum height to stab each casing joint.
(11) The Driller must await the Stabber’s “all clear” signal, each time, before picking up
the string.
(12) The Stabbing Board is to be retracted to its non-operating position after the job is
completed.
4.2. Greasing / Lubricating, Checking and Testing
(1) Check all the grease points and nipples of the stabbing board, and lubricate if
necessary.
(2) Check the oil level of the hoist and fill if necessary.
(3) Check the oil level in the lubricator, (if present) in the air supply and fill if
necessary.
(4) Check the bottom stopping point and the top stopping point, and test both.
(5) Check the connection points, the bolts and nuts of the stabbing board.
(6) Test the function of the board, by raising and lowering the board to the proper
height.
(1) If stabbing board is electrical, test during daylight hours.
(2) If the stabbing board is electrical, all electrical lines must be inspected. A
springloaded
reel must be assembled onto the electrical lines to keep them out of the way.
伍八. Running Casing / Liner / Tubing

BOP Ram elements for each size tubulars being run
Casing, Tubing, Liner hanger with Seal assembly (with backups in remote locations)
2 sets Side-door elevators for each size tubulars being run
2 sets Single joint elevators for each size tubulars being run
2 sets Hand slips for each size tubulars being run
1 set Spider slips (Flush Mounted Spider if available) & Spider elevator (complete) for
each size tubulars being run
2 x Spider air hoses or suitable handle / lever for manual use, (one secured in the
derrick for the spider elevators)
2 back-up Tongs and Jaws for each size tubulars being run
1 Hydraulic casing tong and Jaws for tubular size being run plus one complete set of
equipment as backup
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1 Hydraulic unit for running Hydraulic tong plus one complete set of equipment as
backup
1 Circulating head and / or 1 Swedge for crossing over to drillpipe / chiksan lines (with
one backup)
1 Crossover from drillpipe to liner plus one backup
6 loops of 2 inch Chiksan lines with Couplings and with safety wires or Flexible
pressure hose with suitable valve and safety wire
Tubular grease (API approved HP modified thread compound)
Tubular spears for all weights of tubulars, where not supplied by 3rd party
Crossover to / from lower kelly cock or TIW valve (when running tubing/ liner)
Barytes, detergent water, soft bristle brush to clean pin / box of tubulars
Insert Bowls for rotary for each size tubulars being run
Heavy duty / Extra long links
Thread locking compound (Bakerlok)
5 Clamp-on protectors
2 x 15 m (50 ft) x 1 inch Manila rope
Work platform for hydraulic tong operator if Flush Mounted Spider not available
Safety Clamps for all size tubulars being run
Casing fill up line / Continuous Casing Fill up System (La Fleur or equivalent)
Rig crane / Fork lift truck with Pipe clamp
4 x 4 ton Casing slings
2 Explosion-proof hand-held Torches (Flashlights)
Pick-up / Lay-down machine (if applicable)
All casing accessories to be installed on the rig floor
Container (for protectors removed from casing)
1. Do not stand between the tubular joint coming on to the drill floor, and the
joint in the rotary table. Never stand with back to V-door, while joints are
being brought in.
2. Do not stand between the hydraulic tong and rotary table.
3. When operating the hydraulic tong, hands are only to be placed on the
handles provided. Never place hands between the jaws.
4. Do not attempt to repair, or adjust, moving parts of a hydraulic tong when
still under power.
5. When steadying tubular joints, never place fingers over the shoulders of the
pin or box.
6. The Driller and the Stabber must be completely familiar with the hand signs
that are to be used.
7. The Derrickman / Stabber shall keep hands clear when the Driller lowers the
elevators.
8. Extreme care should be exercised during bad weather conditions and derrick
operations should be reviewed, where deemed to be necessary, by the
Deutag Toolpusher on site.
personnel (trainees etc.) working on the rig floor.
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3.1. General Safety Precautions
(1) Hold a Toolbox Talk before starting the job and ensure that the work force have
been fully instructed on the correct procedures to be followed and the safety
precautions to be observed. Refer to the safety information above and advise on all
points relating to the task, with special attention towards lifting / handling equipment,
and including the following:
(a) Start the job slowly until each crew member is fully aware of the sequence of events
and duties and responsibilities of individuals.
(b) Safety and reduced handling time depend on teamwork and constant awareness.
(c) For night time operations ensure that the stabbing board is fully illuminated.
(d) The Driller must await the Stabber’s “all clear” signal and verify that the Stabber has
raised the stabbing platform and is not leaning out, before picking up the string each
time.
(e) Nothing shall be allowed to drop into the string while it is being run.
(2) Ensure that all tools and equipment are in a clean and serviceable condition.
(3) Ensure that the work area is clean and free of obstruction.
(4) Ensure that adequate non-slip floor matting is laid to provide safe footing.
(5) Ensure that the Driller has an unobstructed view of the entire work area and the
stabbing board.
(6) Ensure that the drillpipe and the drill collars are racked in a manner that provides an
unobstructed view of the rig floor by the Driller.
(7) Ensure that all third party handling equipment has valid certificates.
3.2. Lifting Equipment - General
(1) Ensure that all the lifting equipment, including the blocks, drilling line and breaking
system, to be used is visually inspected, and is in clean and in serviceable condition.
(2) Only certified and colour coded slings and shackles meeting Deutag’s specifications
are to be used.
(3) The safe working load (SWL) must be checked and equipment without an SWL
marking is not to be used.
(4) Ensure that slings and shackles are compatible and of similar / equal SWL ratings.
(5) Any lifting equipment not certified or colour coded or rejected for any reason must
be either destroyed or kept under lock and key until they can next be inspected.
(6) Monitor the condition of all lifting and handling equipment throughout the casing
running operation.
3.3. Single Joint (SJ) and Casing Elevators
(1) Use only the correct size and type elevators for the size of tubular being run.
Note: The SWL of the single joint elevator (SJ) is only tested for one joint plus safety
factor.
(2) Inspect the latch, hinge pin and body of the SJ elevator for any defects.
(3) Physically check the fit of the single joint (SJ) and the casing elevators on the first
joint of tubular, on the pipe rack (prior to picking up).
(4) Ensure that SJ elevator has the latch with a retaining split pin, in good condition,
correct size, and is securely attached to the elevator body.
(5) Ensure that the shackles are not worn and that nuts have retaining pins.
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(6) Ensure that the SJ elevator pick up slings are not damaged, and that the swivel is in
good condition.
3.4. Inspection of Winches
(1) Check the condition of the wire. Look for kinks, broken wires, flat spots or where the
core is visible. Always spool the wire onto the drum properly as this ensures minimum
damage.
(2) Check the condition of the eye at the end of the winch wire. A hard eye (with steel
guard on the inside of the eye loop) should be used.
(3) Check the condition of the counter weight chain (at the end of the tugger line) and
ensure that the links are not stretched, worn or twisted.
(4) Check the condition and operation of the brake. Brake rims and bands should be in
good condition and the linkage operating freely. Prevent bands from becoming
contaminated with oil or mud.
3.5. Running Tubulars - General
(1) Running tubulars safely is very much a TEAM EFFORT. High levels of awareness
and communications are essential if the operation is to be carried out smoothly and
safely.
(2) A Toolbox Talk (TBT) must be held, to ensure that all personnel are aware of the
operation to be carried out and of their duties. In addition to the general safety
considerations, the following points should be discussed:
(a) Awareness - all personnel need to be aware of what is happening around them.
Each person shall look out for himself and for other crew members. No daydreamers, or
horseplay.
(b) Communication - know your own job and that of others. If unsure, ask. Do not let
dangerous situations develop. Tell your supervisor.
(c) Be careful where you stand. Do not put yourself in a position where you could be
trapped and crushed if the joint swings free. Select a position that allows an escape
route.
(d) Whenever flush-joint tubulars (such as MUST Casing and / or non-upset tubulars)
are being run, a spider elevator and lifting sub must be used from the first joint on.
3.6. Rigsite Preparation
(1) On the last trip out of the hole accurately measure the drillpipe and verify the hole
depth and the pipe tally. Isolate the drillpipe to be used in running liner on the other side
of pipe rack board.
(2) The Toolpusher ensures that the landing joint length is such that the collar of the
preceding joint can be set below the casing head housing while still leaving adequate
pipe above the rotary to clear elevators / spiders and to have the cementing head in a
convenient height after landing the casing.
(3) Ensure that (where applicable) the wear bushing is removed before starting to run
the tubulars and that the rotary table is unlocked.
(4) Ensure that centralisers, casing / tubing / liner hanger will pass through rotary table,
bell nipple and the annular preventer.
(5) Ensure that all the cementing plugs are compatible with the float equipment (same
manufacturer, and same type, such as rotating and non-rotating type).
(6) The Toolpusher is to ensure that the ton-mile calculations are checked and that a
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cut and slip operation will not be necessary during the casing running operation.
(7) The Toolpusher will determine whether to reeve (string) drilling line from 10 lines to
12 lines.
(8) The Toolpusher is to calculate the maximum allowable setback weight.
(9) Ensure that the brakes and auxiliary brakes are checked.
(10) After rigging up the casing equipment, the Driller will operate and test the
functioning of all the spiders, including the flush mounted spider. Only the Driller is to
operate the flush mounted spider.
(11) Ensure availability of storage volume mud for casing displacement (precalculate).
(12) While running in the hole with the casing, monitor actual fluid displacement by
using a trip sheet to record volume gained.
4. INSTRUCTIONS
4.1. General Instructions
Note: The Deutag Toolpusher is to ensure that the casing is “run-in” efficiently and
safely and that the string is of correct composition (shoe and accessories at correct
depths). Therefore, the Toolpusher is to be present on the rig floor during the following
stages of the operation:
(a) when running the first 10 joints,
(b) when string is being run through the shoe of the last casing set,
(c) when running the last 10 joints before landing the string, and (d) as operational and /
or hole problems are encountered.
(1) Before picking up the first joint of casing, the wear bushing has to be retrieved
(where applicable).
(2) Ensure that the upper rams have been changed to tubular size being run and the
BOP bonnets have been tested to specified pressure as per the Drilling Programme.
(3) Ensure that suitable (capacity / length) elevator links are installed and the derrick
camera is turned on, if one is installed.
(4) Rig up the Casing Crew equipment, the crane, and all associated equipment.
(5) Lift the shoe joint up and into the V-door (use pick-up / lay-down machine, if
available).
(6) Close the side door elevator around the joint, double check the safety latch. Check
and make sure that there is nothing inside the joint.
(7) Remove the crane sling from the box end of the joint.
(8) Using the main travelling block, lift the joint, trailing with the crane line on the pin end
(shoe joint).
(9) Move the shoe joint over to the rotary table and remove the crane sling.
(10) Install the casing shoe to the joint and Bakerlok, if not pre-installed.
(11) Run the shoe joint in and set the hand slips.
(12) Fill the joint with fluid and check and ensure that the float shoe is operational.
(13) Install a spare single joint elevator as a safety clamp, or a DC safety clamp, for 9-
5/8 inch casing and larger sizes of tubulars.
Note: This procedure should be followed until minimum of 7.5 tons of hanging weight is
recorded on the weight indicator.
(14) Lift the second / next joint up and into the V-door. (Check and make sure that there
is nothing inside the joint).
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(15) Engage and close the single joint elevator around the joint, double check the safety
latch.
(16) Remove the crane sling from the box end of the joint.
(17) Utilising the main travelling block, commence lifting the joint.
(18) Release the trailing crane line and utilising the rope stretched across the V-door,
secure and guide the joint over to the rotary table.
(19) Hold the joint away from the joint in the table and remove the rubber thread
protector, apply Bakerlok to both pin and box.
(20) Stab into the box sitting in the rotary table and slack off elevators.
(21) When the hydraulic tong is in place, the Operator will spin in the joint, ensuring that
the threads are engaged.
Note: If not using the new style hydraulic tong with combination jaws and backup, grip
the joint in the table with the backup tong, ensuring that the table is unlocked.
(22) The Stabber releases the SJ elevator and the Casing Crew operates the hydraulic
tong.
(23) The Derrickman will release the SJ elevator, and the Operator will apply proper
makeup torque to the connection or until the triangle markings are reached (for buttress
connections).
Note: If Torque / Turn equipment is being used, pre-calibrate to ensure proper torque is
being applied.
(24) Remove the back-up and hydraulic tongs.
(25) Remove the safety clamp. Verify the Stabber signals “all clear”, lift the tubular out
of the slips and run in the hole.
(26) Reset the hand slips and the safety clamp.
Note: Ensure that the hand slips sit squarely in the rotary table at an even height all
around the joint.
(27) Bakerlok and makeup the float collar utilising the backup and hydraulic tongs to
proper makeup torque.
Note: If centralisers and stop collars have to be fitted while running in, ensure that the
rotary is covered with cloth or similar to prevent anything falling down the hole. The
preferred procedure is to install all centralisers before picking up the tubulars.
(28) Pick up the third joint and repeat the steps (14) through (26).
(29) After setting the third joint in the slips, utilising the fill up line, fill the joint.
(30) Verify that the float equipment is functional by checking the mud level, then picking
up the string 3 to 5 metres (10 to 15 feet) and re-checking the mud level when the string
is lowered and set in the slips.
(31) Continue running tubular by repeating the steps (14) through (26), for each
additional joint.
(32) If using continuous fill-up equipment (such as La Fleur), fill joints as you lower the
casing.
Note: If using conventional fill-up line, add as much mud as possible between adding
joints of casing. Refer to casing fill-up recommendations in the specific drilling program.
(33) For the speed at which each joint of tubulars (running speed) refer to specific
section in the Drilling Programme.
(34) Proceed running the tubulars until either the overall string weight necessitates the
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use of spider slips and elevators, or the tubular string depth approaches the previous
casing shoe.
(35) At this time switch to the spider slips and elevators. The Driller is to take extreme
care when the centralisers are passing through the spider slips.
(36) The procedure for changing out the spider slips:
(a) Set the tubular joint approximately 1-1/2 metres (5 ft) above the rotary with the hand
slips.
(b) Remove the side door elevator and install the spider elevator to the block using
slings.
(c) Raise the block and the spider elevators over the collar of the joint in the slips,
ensuring that the collar does not get damaged, by holding the spider back using an air
winch.
(d) Set the spider elevator down on blocks of wood.
(e) Attach the spider elevator to the links.
(f) Set the spider elevator and lift the tubular approximately 5 to 6 metres (15 to 20 ft)
using the travelling block.
(g) Remove hand slips and the rotary insert bowls - place away and well clear of the
rotary area.
(h) Lift the open slip spider using (two) air winch(es) and hang it around the tubular
joint.
(i) Close the spider.
(j) Lower the string and set in the spider slips.
(k) Erect a staging work platform around the spider slips.
(37) Always wash two or more joints to bottom as hole conditions dictate.
Note: Break circulation slowly and take the pressure up in stages.
(38) Land the casing at the depth specified in the Drilling Programme. Normally 1 to 3
metres (3 to 10 ft) off bottom.
4.2. Special Considerations for Running Liner.
(1) Prior to running the liner, each stand of drillpipe must be drifted.
(2) The liner string is run in as described above.
(3) Pick up the liner hanger and place it in the mousehole and secure it with the safety
clamp.
Note: The liner hanger is made up to the last joint of liner to be run in. The liner hanger
is made up of slip and seal elements. The upper section is so shaped that running tools
can later be easily run through. A liner setting tool is also provided with the liner hanger
and this serves as the connection between the liner string and the drillpipe string, used
to run the liner in the hole.
(4) Pick up a joint of drillpipe and make it up to the liner hanger / PBR (Polished Bore
Receptacle).
(5) Pick up the joint and the liner hanger and make it up to the liner in the slips.
(6) The liner is now run in the hole on drillpipe
(7) If a rotating hanger is not being used it is important to ensure that while connections
are being made up the string is not rotated, as this will cause the liner hanger to set.
(8) Run in the hole at 1 to 2 minutes per stand when inside casing, and 2 to 3 minutes
per stand when in open hole. Refer to the Drilling Programme for wellspecific
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procedures.
Note: Liner running speeds must be controlled precisely to avoid damage to the liner
hanger and to avoid a pressure build up under the hanger, due to extremely small
clearance in the annulus between hanger and previously set casing string.
(9) The cement head should be made up on a joint of drillpipe before running the liner
into open hole.
(10) When running MUST Casing, verify the size of the crossover joints and use the
right size slips and elevators.
(11) The liner hanger is run to the specified depth and set according to manufacturers
instructions.
伍九. Cementing Casing / Liner

Guide shoe Float shoe
Float collar Stab-in nipple
Stage collar Cement plugs
Cement unit or Pump Circulating / Washing Tool
Cementing head (for top joint of DP or casing)
False Slip bowl and Slips Chiksan piping and Valves
Martin Decker Pressure Recorder Pressurised mud scales
2 x Circulating heads for kelly rigs (for top joint of DP or casing)
1-1/2” Tubing (for Top Job Contingency for surface casing)
1. All cementing lines must be flushed and tested before cementing operations
begin.
2. While reciprocating the casing string, the chiksan lines must be suspended
by tugger lines, so that none of the connections bear any of the load.
3. All cementing lines must have valid inspection certificates. All connections
and lines must be secured with safety lines or chains.
4. Ensure that there is enough length of chiksan piping attached to the
cementing head to allow the casing to be reciprocated.
5. All valves must be function tested before cementing operation begins.
(1) A Toolbox Talk must be held with all personnel associated with the cementing
operations.
(2) Ensure that the cementing head and chiksan lines are placed on the rig floor and
ready for immediate hook up.
(3) Ensure that the pressure recorder has been calibrated and has valid test certificates.
(4) Ensure that the mud tanks have sufficient capacity to receive the mud and casing
displacement.
(5) Ensure that the top and bottom plugs have been installed properly in the cement
head and they are of the same brand and model as the float collar.
(6) Ensure that all casing cementing accessories (cementing plugs, DV tool, etc.) are on
location and are the correct size and same brand and model.
Rule: Always use the same brand or type of cementing equipment and accessories.
(7) Verify that the rig pumps are in good working order and determine the pump
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efficiency, if the displacement of cement is to be made with the rig pumps.

(8) Ensure that there is enough mixing water and displacement fluid on location.
(9) Prior to the job, the Rig Manager or Toolpusher will calculate the pick up load of the
casing, under circulating and cementing conditions, to verify rig hook load and setback
capacity.
(10) The Rig Manager or Toolpusher will independently calculate the pump strokes or
volume needed to bump the plug and compare to the cement company results.
(11) Do not disturb the casing or the cement by slacking off or pulling tension, until the
cement has set, or for the WOC time specified in the Drilling Programme.
(12) While waiting on cement (WOC), immediately commence those steps of the nipple
down / nipple up operations and the pressure testing of the choke manifold, the pump
lines, and other components that will not disturb the casing string or the cement while
its setting up.
4. INSTRUCTIONS
4.1. Inner String Cementing
(1) The Driller and the Floormen will install the circulating head (not the cementing
head) on the last joint of the casing in the V-door.
Note: If using a Circulating / Washing Tool, continue to use the circulating tool until
landing the casing, then install the circulating head.
(2) After landing the casing, the Floormen will connect the chiksan or flexible lines from
the cementing manifold to the circulating head on the casing.
Note: Ensure that the cementing manifold is on the rig floor for quick switch between
the cement unit and the rig pumps.
(3) The Driller will engage the pumps and pump slowly until circulation has been
established, with the flow rate as specified in the Drilling Programme.
(4) During circulation, the Driller will slowly reciprocate the casing in 2-3 meter strokes,
or as specified in the Drilling Programme.
(5) The Driller is to ensure that the chiksan lines do not become entangled while the
casing string is being reciprocated.
(6) The Derrickman is to monitor the mud returns to check for mud losses or gains, and
inform the Driller.
(7) While circulating, the Floormen will rig down and load out the Casing Tools and
release the Casing Crew.
(8) The Driller and the Floormen will then proceed to rig up the false rotary table:
(a) Clear the rig floor of all unnecessary tools and equipment.
(b) Rig up scaffolding on the rig floor around the casing.
Note: The scaffolding must be placed at a height that ensures easy and safe working
conditions around the casing while running in drillpipe stands inside of the casing string.
(9) After circulating the casing and the annular volumes as specified in the Drilling
Programme, the Driller will stop reciprocating, land the casing, and stop the pumps.
(10) The Floormen are to disconnect the chiksan lines from the circulating head.
(11) The Floormen will remove the circulating head.
(12) The Driller and the Floormen will remove the casing elevator and replace with the
drillpipe elevator.
(13) The Driller and the Floormen will pick up the first stand of drillpipe, make up the
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cementing stab-in tool and tighten with the rig tongs.

(14) The Floormen will place the false slip bowl into the casing.
(15) The Driller will engage the drawworks, and lift the stand up and over the false slip
bowl in the casing.
(16) The Driller will lower the first stand of drillpipe through the slip bowl, until the top
tool joint is at the slip bowl.
(17) On the Driller’s signal, the Floormen are to set the slips around the drillpipe.
(18) The Driller and the Floormen will proceed to trip the drillstring inside the casing to
the depth of the casing shoe, ensuring the pipe tally is correct.
(19) The Driller will slowly stab the drillpipe into the casing shoe receptacle.
(20) The Driller and the Floormen will install the cementing head on to the drillpipe and
connect the chiksan lines to the cementing head.
(21) The Driller and the Crewman will tie down the cementing string with chains or
maintain the necessary slack-off weight on the stab-in receptacle.
Note: If not held down securely, the cementing string can be pumped out of the casing
shoe receptacle when circulating or cementing.
(22) The Driller will engage the pump and circulate bottoms up or as specified in the
Drilling Programme, until the hole is clean.
(23) The Driller will shut down the pumps and the Floormen will connect the cementing
line to the cementing head.
(24) The Cementing Crew will pressure test the chiksan lines as per the Drilling
Programme and the Driller will witness the test.
Note: Ensure that all personnel is at a safe distance away from the chiksan lines during
the pressure testing.
(25) The cement unit will first pump the spacer.
(26) The cement unit will then mix and pump the cement slurry as per Drilling
Programme or until all the cement has been mixed and pumped.
(27) During the cement mixing and pumping operations, two Floormen or the Mud
Engineer will assist the Cementing Crew in weighing the cement slurry and catching
samples (wet and dry) as specified in the Drilling Programme.
(28) Also during this period, the Derrickman will line up the valves on the pits and
pumps to get ready for the displacement of the latch-down wiper plug.
(29) When all the cement has been mixed, the Cementing Engineer will release the
latch-down plug from the cementing head.
Rule: During cementing operations, all plugs to be released from the surface are to be
released by the Cement Crew.
(30) The Toolpusher will witness and verify the release of the plugs.
(31) Upon release of the latch down plug, the Driller will start pumping mud or water to
displace the cement until the latch-down wiper plug is landed.
Note: The Driller is to ensure that there is no waiting time to commence the
displacement process when the latch-down wiper plug is released.
(32) When the latch-down plug is landed, the Driller will pressure up and test as per the
Drilling Programme.
(33) On the Driller’s signal, a Crewman will bleed off the pressure on the drillpipe, at the
cementing manifold and check for back-flow.
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(34) If there is no back-flow, the Driller will pull the drillpipe stab-in tool out of the casing
shoe and the Driller and the Floormen will trip the drillpipe out.
(35) If there is back flow, immediately close-in the valve at the manifold and maintain
pressure on the drillpipe until the cement has taken set or as per the Drilling
Programme.
(36) If no cement returns were seen at the surface, the Driller and the Floormen will
prepare for a “Top-Off Cement” procedure, as specified in the Drilling Programme.
(37) Typically, the top job will be conducted with a small diameter tubing run in the
annulus between the conductor and the casing string down to the top of cement or to a
depth specified in the Drilling Programme.
lines, and other components that will not disturb the casing string or the cement while it
is setting up.
4.2. Single Stage Cementing
(1) The Driller and the Floormen are to install the circulating head (not the cementing
head) on the last joint of the casing (best done at the V-door).
Note: If using a Circulating / Washing Tool, continue to use the circulating tool until
landing the casing, then install the circulating head.
(2) After landing the casing, the Floormen are to connect the chiksan or the flexible
lines from the cement manifold to the circulating head on the casing.
Note: Ensure that the cementing manifold is on the rig floor for quick switch between
the cement unit and the rig pumps.
(3) The Driller is to verify that the rig pump valve is open on the cement manifold and
the valve to the cement pump is closed.
(4) The Driller will then engage the pumps and pump slowly until circulation has been
broken, then increase the circulating rate as per the Drilling Programme.
(5) The Derrickman is to monitor the mud returns to check for mud losses or gains and
inform the Driller.
(6) While circulating, the Floormen will rig down and load out the Casing Tools and
release the Casing Crew.
(7) During circulation, the Driller will reciprocate the casing in 2-3 meter strokes, or as
specified in the Drilling Programme and continue to do so during the cementing and the
displacement stages.
(8) The Driller is to ensure that the chiksan lines do not become entangled while the
casing string is being reciprocated.
(9) The Derrickman is to monitor the mud returns to check for mud losses or gains, and
inform the Driller.
(10) The Derrickman or the Mud Engineer will record the mud weight in and out.
(11) The Derrickman will line up the mix water for the cementing unit.
(12) After circulating the casing and the annular volumes as specified in the Drilling
Programme, the Driller will stop reciprocating, land the casing, and stop the pumps.
(13) The Floormen are to disconnect the chiksan lines from the circulating head.
(14) The Floormen will remove the circulating head and place it at a safe distance away
from the rotary table.
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(15) The Floormen will install the cementing head, re-attach the chiksan lines from the
cement manifold.
(16) The Cementing Crew will pressure test the secured chiksan lines as per the Drilling
Programme, and the Driller will witness the test.
(17) Ensure that the valves are lined up correctly on the cement manifold.
Note: Ensure that all personnel are at a safe distance away from the chiksan lines
during the pressure testing.
(18) The cement unit will pump the spacer.
(19) After the spacer is pumped, the Derrickman will line up the valves on the pits and
pumps for the displacement operation.
(20) The Cement Crew will release the bottom plug in the cementing head and pump
the lead scavenger.
(22) The cement unit will then mix and pump the cement slurry as per the Drilling
programme or until all cement has been mixed and pumped.
(23) During the cement mixing and pumping operations, two Floormen or the Mud
Engineer will assist the Cementing Crew in weighing the cement slurry and catching
samples (wet and dry) as specified in the Drilling Programme.
(24) When all the cement has been mixed and pumped, the Cementing Engineer will
release the top plug in the cementing head.
(26) After the top plug is released, the Cement Crew will open the rig pump valve on the
cement manifold, and close the cement line. The Driller is to verify.
(27) The Driller will re-set the stroke counter, start pumping mud or water to displace
the cement until the calculated number of strokes to land the top wiper plug.
(28) The Driller will pump at a maximum rate until displacement catches up to the
cement slurry.
Note: A pressure increase is observed when displacement has caught up to the cement
slurry.
(29) The Driller will adjust the circulating rate and pressure as specified in the Drilling
Programme.
Note: During displacement, use turbulent or plug flow, avoid laminar flow.
(30) The Derrickman will monitor the mud returns and check for losses or gains and
inform the Driller.
(31) Just before bumping the plug, the Driller will stop reciprocating the casing, slow the
pump rate, and check the pump strokes and monitor for pressure increase when the
plug lands.
Note: From this point forward the casing and the cement shall not be disturbed until the
cement has set up.
(31) After the plug has been bumped, increase the pump pressure to 35 bars (500 psi)
above the differential pressure or as per the Drilling Programme.
(32) Pressure test plugs as specified in the Drilling Programme.
(33) If the plug does not bump according to the calculated volume then stop pumping,
bleed off pressure, and check for back flow. Follow the Drilling Programme if different
procedure is prescribed at this point.
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(34) If there is back flow, this indicates the float equipment is leaking.
(35) If there is back flow, immediately close-in the cement manifold valve and hold
pressure on the casing until cement has set. Follow the Drilling Programme if different
procedure is prescribed at this point.
(36) If the plug has bumped and there is no back flow, this indicates the float is holding.
its setting up.
4.3. Multiple Stage Cementing
Note: Ensure that the casing tongs are placed only on the upper and lower 12 cm of
the stage collar while making up the multiple stage cementing collar.
Note: Casing tongs should not be placed on the inflatable or mechanical packer
elements of the cementing stage collars.
(1) Install the dual plug cementing head on the last joint of the casing string (best done
at the V-door).
(2) Follow the Paragraph 4.2 procedures, steps (2) through (16).
(3) The first stage is then cemented, top plug landed, and the casing tested as per the
Drilling Programme.
Note: From this point forward the casing and the cement shall not be disturbed until the
cement has set up.
(4) Upon the completion of the first stage cementing, the Cement Crew will release the
multiple stage collar bomb and at the same time, install the closing plug in cementing
head.
(5) The Toolpusher will witness and verify the plugs are released and reloaded.
(6) Depending on the wellbore angle, the Drilling Programme will specify whether the
bomb will be allowed to free fall or circulated down.
(7) After the bomb has had time to seat in the stage collar, the Driller will engage the rig
pumps and slowly build up pressure until the stage collar opens.
(8) The Drilling Programme will specify whether there will be continuous or intermittent
circulation through the open ports of the stage collar while the first stage cement is
setting up.
inform the Driller.
(10) The second stage is cemented following the same procedures as for the first stage
with the exception that the casing will be kept stationary.
(11) The cement unit will now pump the spacer for the second stage.
(12) After the spacer is pumped, the Derrickman will line up the valves on the pits and
pumps for the displacement operation.
(13) The Cement Crew will release the second stage bottom plug in the cementing
head and pump the lead slurry.
(15) The cement unit will then mix and pump the cement as per the Drilling programme
or until all cement has been mixed and pumped.
(16) During the cement mixing and pumping operations, two Floormen will assist the
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Cementing Crew in weighing the cement slurry and catching samples (wet and dry) as
specified in the Drilling Programme.
(17) When all the cement has been mixed and pumped, the Cementing Engineer will
release the second stage closing plug in the cementing head.
(19) After the closing plug is released, the Cement Crew will open the rig pump valve on
the cement manifold, and close the cement line. The Driller is to verify.
(20) The Driller will re-set the stroke counter, start pumping mud or water to displace
the cement until the calculated number of strokes to land the top closing plug.
(21) The Driller will pump at a maximum rate until displacement catches up to the
cement slurry.
Note: A pressure increase is observed when displacement catches up to the cement
slurry.
(22) The Driller will adjust the circulating rate and pressures as specified in the Drilling
Programme.
Note: During displacement, use turbulent or plug flow, avoid laminar flow.
inform the Driller.
(24) Just before landing the closing plug, the Driller will slow the pump rate and check
the pump strokes and monitor for pressure increase when the closing plug lands.
(25) After the closing plug has landed, increase the pump pressure to the
manufacturer’s specified differential pressure to close the stage tool circulating ports, or
follow the Drilling Programme instructions, if different.
(26) Pressure test the stage collar as specified in the Drilling Programme.
(27) If the closing plug does not bump according to the calculated volume then stop
pumping and hold pressure. Follow the Drilling Programme if different procedure is
prescribed at this point.
(28) If the closing plug has landed and closed the circulating ports of the stage collar,
commence waiting on cement and nipple down and nipple up operations.
its setting up.
4.4. Cementing the Liner
(1) Make up the liner assembly and trip in the hole as per W.I. Section 9.3.
(2) Install the cement manifold on the last joint of drillpipe and circulate at specified
depth in the Drilling Programme.
(3) After landing the liner at designated depth, circulate the hole as per the Drilling
Programme.
(4) Depending on the liner hanger type and the Drilling Programme specifications,
reciprocate or rotate the liner until ready to cement.
(5) Monitor the mud returns and check for losses or gains.
(6) Prepare the pit system valve arrangements for displacement of top plug.
(7) Ensure that the chiksan lines are free to move while the Driller reciprocates or
rotates the string.
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(8) Stop circulating and proceed with the liner setting procedure, directed by the liner
service representative.
(9) After setting the liner, release the liner setting tool and confirm the liner setting tool
has been released.
(10) Follow the liner cementing procedures of the liner equipment manufacturer or the
Drilling Programme in the method of releasing the wiper plugs and the liner movement
during the cementing operation.
(11) Cement the liner as per the Drilling Programme.
(12) Pick up off the liner, break the joint with the cementing manifold and set it in the
mousehole.
(13) Pull out the drillpipe to the specified depth in the Drilling Programme.
(14) As per the Drilling Programme, circulate the drillpipe either by reverse circulation or
through normal circulation.
(15) Pull out of the hole carefully with the drillpipe and the liner setting tool. Lay down
the setting tool.
(16) Keep the hole full while tripping out of the hole.
(17) While WOC, continuously monitor the wellbore for any signs of flow and prepare to
pick up the liner top cleaning assembly.
六零. Rigging Up Wireline Lubricator

Wireline BOP Lubricator lifting cap
4 inch OD Lubricator 7 inch OD Riser
Stuffing box crossover crossovers
Circulating head Swabbing head
Bleed-off valves Cable cutters
Hazard tape
1. The entire work area must be isolated with hazard tape.
2. Ensure all pressure is bled off the X-Mas Tree.
3. All equipment must be tested to its full working pressure.
4. All lifting equipment (lifting caps and slings) must be certified for Working
Load Limit (WLL).
(1) Hold a Toolbox Talk to cover operations, procedures and safety.
(2) Well Services Personnel must have relevant permits and certification.
(3) Ensure that there is good communication between all personnel involved in this
operation.
(4) Ensure all chiksan lines and pressure lines have been tested in the last 12 months
and have valid test certificates.
4. INSTRUCTIONS
(1) Lay out the 7 inch riser sections on the catwalk
(2) Pick up the first section, using the lifting cap and air tugger.
(3) On the rig floor, remove the pin protector and inspect the O-ring.
(4) Lower the riser in to the rotary table and set the slips.
(5) Pick up and make up the remaining section or sections of the riser.
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(6) Remove the X-Mas Tree cap, then lower the riser onto the Tree adapter.
(7) Make up the riser to the X-Mas Tree.
Note: Never set the slips around the riser once it is made up to the Tree.
(8) Install the crossover and the wireline BOP on the riser.
(9) Pick up the 4 inch lubricator and install on the wireline BOP.
(10) Connect the pressure test line from the cement pumping unit to the kill wing valve
(or from the lubricator test pump to the lubricator test / bleed sub).
(11) The unit is now ready for the initial pressure test.
六壱. Running and Pulling Downhole Plugs

Wireline unit Wireline BOP
Lubricator Lubricator lifting cap
Stuffing box crossover Swabbing head
Cable cutters 7 inch OD Riser
Shooting nipple Circulating head
Appropriate Plugs Sinker bars
Retrieving Running / string
Plug Retrieving / Running adapter / mandrel
1. All equipment must be tested to its full working pressure.
2. All lifting equipment (lifting caps and slings) must be certified for working
load limit (WLL).
(1) Hold a Toolbox Talk to cover operations, procedures and safety.
(2) Service Personnel must have relevant permits and certification.
(3) Ensure all relevant well and equipment information is available.
(4) Ensure the well can be shut in any time as needed.
(5) Ensure all internal tubing / casing restrictions are known.
4. INSTRUCTIONS
4.1. Running Wireline Plugs
(1) Prepare wellhead equipment for wireline operations (e.g. X-Mas Tree, SRT / LDO
heads, Nipple Up BOP).
Note: If a riser has been made up to the X-Mas Tree, never set the slips around the
riser.
(2) Install the crossover and the wireline BOP on the riser.
(3) Pick up the lubricator.
(4) Install plug on wireline (with mandrel), adapter, sinker bar, etc., as specified in the
Completions / Workover Programme, and install lubricator on the wireline BOP.
(5) Pressure test all surface equipment involved as per the Completions / Workover
Programme.
(6) Connect the pressure test line from the cement pumping unit or lubricator test pump
to the kill wing valve or the lubricator test / bleed sub.
(7) Run the wireline plug.
(8) Land, seat and test the plug as per specification.
4.2. Pulling Wireline Plugs
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(1) Repeat steps (1) through (5).

(2) Install plug retrieval equipment as specified in the Completions / Workover
Programme.
Note: With some plugs the pressure can be equalised across the plug (e.g. if pressure
build up occurs under the plug), an equalising port can be opened by means of a
running prong.
Alternatively there can be a shear disc which can be ruptured simply by pumping
against the plug.
4.3. Running and Pulling Plugs on Coil Tubing
Note: This procedure is usually carried out on a deviated borehole.
(1) Follow the manufacturers recommendation.
(2) Maintain all standard Safety and Operational procedures.
(3) When applicable, clean plug seating by circulating or reverse circulating.
六弐. Running Survey Tool with Rig Wireline Unit

1. SPECIAL TOOL AND EQUIPMENT
Two wireline sheaves Kelly cock
Thread protector Light oil
Wireline wiper Wireline cutter
Circulating sub / stuffing box Two safety slings
Depth counter Two pipe wrenches
Rope socket
1. Fingers and hands should be kept well away from the wireline spool. Never
walk under wireline during operation.
2. Good communication is essential during this operation.
3. Wireline should be flagged, in case depth counter fails.
4. Brakes and hydraulic unit should be inspected before operation begins.
(1) The Driller shall supervise the wireline operation.
(2) The wireline hydraulic unit, the spool and the braking system shall be inspected
before operation begins.
(3) Ensure that the wireline tool OD is smaller than the drifted diameter of the drillstring.
(4) Ensure that the depth counter is in good working condition and calibrated.
(5) The connection from the wireline to the survey tool barrel (rope socket) must be
inspected.
(6) Ensure that no personnel are around the rotary table while the wireline is being run
in or being pulled out of the hole.
4. INSTRUCTIONS
4.1 Running in the Survey Tool
(1) The rig wireline Operator starts the hydraulic power unit and checks the clutch and
the brake for proper operation.
(2) Install the kelly cock (in open position) in the box of the joint in the rotary table, and
make up an open ended thread protector in the box of the kelly cock.
(3) Install the rope socket onto the survey tool barrel and guide the barrel through the
tool joint in the rotary table while the Operator lifts the survey tool.
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(4) The Operator sets the depth counter to zero and lowers the survey tool into the
drillstring in a controlled manner and speed.
Note: If the string has any reduced ID, the Operator will slow the wireline before
reaching the depth of such restriction.
Note: The elevators can be latched onto the tool joint at any time if reciprocating the
drillstring is desired.
(5) When within 200 ft. of the landing depth, the Operator slows down the running
speed and proceeds slowly until the survey tool lands.
(6) The Driller keeps the drillstring steady for the survey and the Operator notes the
depth counter reading.
Note: Extreme caution must be exercised to minimise the time the drillstring is held
steady.
4.2 Pulling out the Survey Tool
(1) A Floorman installs a line wiper on the wireline.
(2) The Operator engages the clutch and spools the wireline on the drum while a
Floorman guides the line using the guide assembly on the spool.
(3) The Operator pulls the wireline in a controlled manner and speed.
(4) When the survey tool and the overshot (if used to recover the survey tool) are 500 ft.
(150 metres) below the rotary table, the Operator slows down the wireline unit until the
survey tool is at the tool joint in the rotary table.
Note: If reciprocating the drillstring, stop. Set the slips, unlatch the elevators, and pick
up the travelling block to create enough room to finish pulling the survey tool.
(5) Remove the line wiper and pull the survey tool above the drillstring and set back out
of the way.
(6) Remove the thread protector and the kelly cock from the joint in the rotary table.
(7) Turn off the wireline unit and pour a light weight oil over the wireline on the spool to
prevent rust.
4.3 Wireline Survey While Circulating
Note: When running the survey tool in a high angle deviated well the tool may have to
be pumped down to the bottom.
(1) Feed the wireline over the wireline sheave and through the stuffing box of the
circulating head.
(2) Secure the end of the wireline and lift the circulating head up into the derrick using
the air tugger.
(3) Attach the wireline to the survey tool.
(4) The wireline Operator picks up the survey tool to a height equal to the kelly cock in
the tool joint in the rotary table and a Floorman guides the tool into the
drillstring.
(5) Position the survey tool just below the tool joint and set the depth counter to zero.
(6) Lower the circulating head, stab into the tool joint and make up the connection to
specified torque.
(7) Attach the circulating line from the stand pipe manifold (SPM) to the circulating head
and tighten.
(8) The Driller engages the pump and establishes circulation.
(9) The wireline Operator lowers the survey tool and the operation continues as detailed
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in procedures 5.1 and 5.2. above.

Note: The drillstring can be reciprocated or rotated at low speed if needed.
六参. Kick Detectors

1. FLOW LINE RECORDER
(1) The flow line recorder is the best kick indicator because the flow line is the first point
at which an increase in flow from the well can be detected.
(2) When out of the hole, the flow recorder also makes it impossible for the well to
unload without warning.
(3) A flow recorder such as a "FLO-SHO" by Warren Automatic Tool Company,
operates on the principle of a rotating flap installed in the flow line. The greater the flow,
the greater the deflection of the flap.
(4) The degree of deflection of the flap is transmitted pneumatically to an indicator and
a recorder.
(5) Its prime application is to detect changes in the rate of flow but it can be calibrated
to measure flow volumes.
Note: Ideally, the measurement can be accurate to about 1%; but to achieve this the
flow line must have a fall of 1 in 10 (10%) and never be more than three-quarters full
(preferably half-full). Other makes of recorders are equally effective.
(6) An Indicating Dial and a Recorder are mounted where they can be seen by the
Driller, and the Indicator is fitted with adjustable high and low set points which control
warning lights and cause a horn to sound.
(7) Mud builds up on the apparatus, so frequent checking, cleaning and maintenance is
necessary to maintain its effectiveness.
2. PIT VOLUME TOTALISER (PVT)
(1) After the Flow Line Recorder, the PVT is usually the next significant kick indicator
since it gives warning of a change in the active mud pit level during drilling.
(2) During round trips the amount of fall or rise in the mud level is recorded and the
Driller can check at any time whether or not the borehole is taking or overflowing an
amount of mud equal to the volume of drillpipe steel being displaced or causing
displacement.
(3) The PVT such as the "Barrel-O-Graf" by Warren Automatic Tool Company, consists
of a float on a chain and sprocket installed on each of the active mud tanks. A
pneumatically operated sensor transforms the rotations of the sprocket into a direct
reading in barrels on the Gain-Loss Indicator and the Recorder mounted in front of the
Driller. Other makes of PVTs like BIS (Baker), floats with ultra sonic measuring device
and other resettable gain loss indicators are also effective.
(4) There is a facility for sounding an alarm if the mud level in the pit rises or falls
beyond pre-set levels.
(5) The degree of accuracy in measurement of the mud volumes in the tanks is related
to the surface area of the tanks.
(6) As with the flow line recorder, such results can only be obtained if the apparatus is
kept clean and in good working order.
(7) The theoretical and actual volume changes should be compared frequently to
ensure correct calibration.
3. GAS DETECTOR
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(1) The gas detector used on most rigs extracts a continuous sample of mud from the
ditch. The sample is agitated to enable the gas to separate out and it then passes
through armoured tubing to an instrument in the on-site laboratory where it is analysed,
measured and recorded.
(2) Refer to the manufacturer's bulletin for the gas detector installed on the rig.
4. MUD WEIGHT RECORDER
(1) The continuous mud weight or Specific Density (SD) recorder is not an instrument
which will give an early warning of a kick. The first indication would be when the gas or
salt-water cut mud reached the surface and, by that time, other instruments would have
indicated the warning signs.
(2) The SD recorder does, however, provide invaluable assistance during the
subsequent killing operation by recording the time of arrival of the kick at the surface,
the extent to which the mud is gas - or fluid - cut and the duration of the kick.
(3) One type of recorder consists of a narrow diameter tube with top and bottom
horizontal connections to one vertical leg of an inverted U-tube through which mud from
the choke manifold flows to the mud pits.
(4) The pressure exerted by the vertical column of flowing mud between the upper and
lower connections is relayed by means of a sensor and an electrically operated
pressure transmitter to a strip recorder and digital read-out device in the Driller's dog
house.
(5) The two latter instruments are calibrated to record and display the specific density of
the mud on a continuous basis whenever the mud in circulation is diverted through the
choke manifold.
(6) This device is especially useful for picking up the changes of density of the fluid in
circulation during the latter stages of a well killing operation. The apparatus is
manufactured by Electronic Construction Service - Dockhorn of Nordhorn, West
Germany.
5. MUD WEIGHT OR SD RECORDER MULTI-FUNCTION RECORDER
(1) The recorder located in the dog house might be a "Geolograph", Martin Decker,
Totco, or "Dril-Sentry" capable of recording up to six or more functions simultaneously
on a single strip chart. Typically, these include:
(a) Rate of Penetration - m/hr,
(b) Mud volume in pits (from the Barrel-O-Graph instrument) - cu metres,
(c) Pressure on the annulus (or choke) - bar,
(d) Pump pressure or pressure on the drillpipe (or standpipe) - bar.
(e) Pump speed - SPM,
(f) Rate of Circulation (from FLO-SHO apparatus) - litres/minute.
(2) These functions are direct aids in the detection of kicks:
(a) A sudden increase in the rate of penetration is a sure sign of a drilling break and
possible entry into a high pressure formation.
(b) An increase in mud volume in the pits during drilling indicates an inflow of gas or
formation fluid into the well.
(c) A reduction in pump pressure could indicate a flow of gas or salt-water into the
annulus.
(d) The pump speed should be checked before confirming that an increase in mud
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volume could only be caused by a kick.

(e) An increase in the rate of circulation apparent at the flow-line, again assuming no
change in pump speed, indicates an inflow from the formation and therefore a potential
kick.
(f) The drillpipe and the annulus pressures are essential to confirm and to estimate the
extent of a kick, once a flowing well has been shut in.
六四. Kick Drills

Chain tongs Kelly cock and Wrench
Crossovers Gray valve
Circulating sub Pup joint
Stopwatch
1. Ensure the rig floor is always clean and free of obstructions to act safely and
quickly in the event of a kick. Do not block escape routes.
2. Pay extra attention to new personnel, trainees, and service company
personnel.
3. Ensure everyone is familiar with the shutting-in procedure.
4. Ensure all personnel receive correct instructions.
5. Ensure this exercise is repeated at least once every week in different working
situations and on different shifts.
Note: Kick drills are designed to familiarise the rig crew with the tools and techniques
required to determine if the well is flowing, and if so, to get it shut-in as quickly as
possible.
Many kicks that later turned into blowouts, were often the result of failing to get the well
closed in quickly.
As well kicks are seldom encountered, the crew will not be able to close in the well
quickly unless these drills are performed regularly.
(1) Ensure equipment for blowout prevention is always operational and available.
(2) Ensure an up-to-date pre-kick record is available at all times.
(3) Check the capacity of the Koomey unit (must be at least sufficient to close and open
all preventers once and then to close the annular preventer and 1 ram type preventer
again).
(4) Check that the following are present:
(a) Adequate fluid in the accumulator
(b) Kelly cock (in open position) with wrench on the rig floor
(c) Crossovers on the kelly cock for tubulars in the drillstring or tubing
(d) Gray valve and matching circulating sub on the rig floor
(e) Back-up circulating equipment (hose and/or chiksan lines hooked up to standpipe
manifold.
(f) Short pup joint (to connect to top drive).
(5) Ensure the pit level and trip tank level indicators and the flow show are properly
adjusted and functioning.
(6) Ensure the audible alarm in the panel by the Driller is working.
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Note: The alarm must always be switched on.

(7) Ensure the well remains filled via the trip tank at all times.
(8) Place the wrench for closing the kelly cock within hands reach.
(9) Ensure the valves on the BOP, kill lines, choke lines and choke manifold are
correctly lined up according to the Deutag Shut-in Procedure.
(10) Ensure the indicators for monitoring closing / opening of BOP rams is working
correctly.
Note: Decide which tool to utilise to shut-in the drillpipe while tripping, the kelly cock or
the Gray valve.
4. INSTRUCTIONS
Note: The Driller / Assistant who operates the drawworks co-ordinates the initial actions
to be taken both during a kick drill and in the event of an actual kick.
4.1. During Tripping
(1) The Drilling / Workover Supervisor (or a designated person) gives a signal that a
'kick' drill will be carried out by telling the people on the rig floor.
(2) The Drilling / Workover Supervisor sounds the audible alarm at an unexpected
moment by pulling up the float of the pit level indicator on the mud / trip tank, and
presses a stopwatch as soon as the kick drill starts.
(3) When the alarm sounds, the Driller hangs the string suspended in the elevator as
quickly as possible with the top tool joint within hands reach.
(4) The Derrick man (if present) must immediately come down from the derrick.
(5) The Floormen set the slips, and open the elevators.
(6) The Driller raises the elevators a few metres and the Floormen stab the Kelly cock
on the pipe as quickly as possible and torque up same.
(7) Close the kelly cock using the wrench.
(8) The Driller opens the hydraulic valve on the BOP and then closes the appropriate
preventer.
Note: The times taken to install and close the kelly cock and to close the BOP
(including opening the hydraulic valve) must be recorded individually. The total time is
now filled in on the kick drill sheet.
(9) The well is shut in.
(10) Pick up and install the short pup joint.
(11) Connect the top drive to the pup joint.
(12) Open the kelly cock.
(13) Observe and record SIDPP and SICP.
Note: If it is decided to strip the drill string to bottom continue as follows:
4.2. During Drilling / Milling
(1) The Drilling / Workover Supervisor (or a designated person) gives a signal that a
'kick' drill will be carried out by telling the people on the rig floor.
(2) The Drilling / Workover Supervisor sounds the audible alarm at an unexpected
moment by pulling up the float of the pit level indicator on the mud tank, and presses a
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stopwatch as soon as the kick drill starts.

(3) The Driller / Assistant raises the drillstring to a convenient position where no tool
joints are at the pipe rams or annular preventer(s) or, when a kelly is in use, until the
lower kelly cock is above the drill floor.
(4) Stop the pumps.
(5) Open the hydraulic-operated choke line valve and close the appropriate preventer.
(6) The well is now shut in. Record the total time and fill in on the kick drill sheet.
Note: When drilling, the pressure in the annulus must not exceed the maximum
allowable annular surface pressure (MAASP) previously calculated on a pre-kick
record. In such a case let down the pressure via the choke until the first recorded
drillpipe pressure is reached.
(7) At the end of the kick drill restore the settings of all preventers and the hydraulic
valve to those which existed before the kick drill.
(8) Place kelly cock, sub, etc. back on the rig floor and make them ready for use again.
(9) Discuss the drill with the Supervisor. Pay particular attention to the aspects which
could still be improved.
六伍. Shut-in Procedures

1. RESPONSIBILITY FOR IMPLEMENTATION
The shut in procedure and the preferred kick killing method to be used, is to be
made known to the crew by the operator, not later than the spud meeting.
Ensure the procedure and the method are in accordance with the ZPEB policy.
Refer to the “Shut-in Procedure - Position of Valves During Drilling” diagram
issued by Deutag (Figure 1).
Remember! YOU are responsible for:
(a) The safety and well-being of the personnel
(b) Protecting the environment
(c) Protecting Deutag drilling rig and it’s associated equipment.
Mud Tester / Shakerman: To inform the Driller if any variances in mud returns and / or
gas cut or oil contaminated mud is coming over the shakers.
Derrickman: To monitor the active mud volume in the tanks at all time and inform the
Driller of any variances.
During killing operations: Weight up the kill mud according to Mud Eng. instructions.
Assistant Driller: Line up and when necessary start the degasser and assist the
Derrickman or the Driller during killing operations according to Driller's instruction.
Driller: To monitor his instrumentation and evaluate any changes and information given
to him by the Mud Tester and Derrickman. Perform flow check and if well is flowing,
shut in the well and inform the Toolpusher.
Note: Do not flow check when drilling in formations containing H2S. Close in the well.
Prepare a IWCF (International Well Control Forum) Surface BOP Kill Sheet and
compare same with Toolpusher's Kill Sheet, to avoid mistakes. During killing operation,
follow the pumping schedule in accordance with the IWCF Surface BOP Kill Sheet and
Toolpusher's instructions. Record pressures, pump rate, volume pumped, and time.
Compare the actual parameters with the kill graph and if any significant changes alert
the Toolpusher.
Toolpusher: To maintain full control over the behaviour of the well to prevent blowout
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from happening. Notify the Company Representative, the Mud Engineer, the Drilling
Engineer and Manager. Evaluate borehole situation upon presumed influx. Select the
correct killing procedure as stated below, depending on the type of kick and hole size.
Calculate his IWCF Surface BOP Kill Sheet and compare same with the Driller's, the
Company Representative's, and / or the Drilling Engineer's to avoid any mistakes. Be in
charge of the killing operation, controlling back pressure and timing.
Drilling Engineer: To assist the Toolpusher in evaluating borehole situation, calculate
independently IWCF Surface BOP Kill Sheet and compare same with the Toolpusher's.
Assist the Toolpusher during killing operations.
Manager: To approve the killing procedure proposed by the Toolpusher.
Control Manager: To implement the instructions outlined in the Deutag Rig Crew
Manual on all Deutag rigs in his area.
Head of Division: To ensure that the procedures are followed.
2. SHUT IN PROCEDURE WHILE DRILLING
(1) Once a kick has been detected, or is suspected, the decision must be made to shut
the well in as quickly and as safely as possible. The success of the well control
operation depends upon the response of the crew at this most critical phase.
(2) The well is shut in:
(a) to prevent further formation fluid influx,
(b) to protect the rig and the crew from an uncontrolled flow, and
(c) to organise the kill procedure after the stabilised shut in DP and Annulus pressures
and the pit gain are determined.
2.1. Stop Drilling and Raise the Kelly / Top Drive
(1) Stop rotating the string.
(2) Raise the drillstring to a convenient position where no tool joints are at the pipe rams
or annular preventer(s).
Note: When a kelly is in use, raise the string until the lower kelly cock is above the drill
floor.
(3) Gradually slow down the mud pumps.
Note: Some extra back pressure on the formation due to the friction losses of the
circulating mud in the annulus is thus maintained. This in turn, offsets the swabbing
effect when raising the string and reduces the possibility of a further influx entering the
well.
2.2. Stop Pumps and Observe Well for Flow
(1) Ideally the pump should be gradually slowed down during the raising of the last 3
metres of the drillstring and then finally stopped. By doing so the upper part of the influx
will be thoroughly diluted by the mud, and may even be carried up inside the casing
shoe.
(2) Only the bottom of the hole will contain neat formation fluid, which will continue to
flow after the well has been closed in until the BHP equals the formation pressure.
2.3. Open the Hydraulically - operated Choke Line Valve
(1) Shutting in the well by opening the choke line valve before closing the BOP is known
as a “soft shut-in”.
(2) The alternative is a “hard shut-in” which is achieved by closing the BOP on the
closed choke line valve.
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2.4. Close the Appropriate BOP (Top Pipe Ram or Annular Preventer)
(1) A pipe ram closes faster than the annular preventer, however care must be taken to
correctly position the tool joint.
(2) If there is any doubt about the position of tool joints or if casing – drillpipe protectors
are in use, the annular preventer should be closed.
2.5. Close the Hydraulically - operated Choke Line Valve
(1) The well is now shut in! Observe the closed-in annular pressure (Pa) and the
closed-in drillpipe pressure (Pdp ) and record the pit gain.
(2) Complete the applicable IWCF Surface BOP Kill Sheet, and prepare to kill the well.
3. SHUT IN PROCEDURE WHILE TRIPPING
(1) The less drillpipe there is in the hole, the greater the danger in not being able to
control a kick, should one occur.
(2) The main object when a kick is detected or suspected should be to get the well
closed in as quickly and as safely as possible. The extent to which that can be achieved
depends upon the rate of mud flow from the well.
(3) If the well flows strongly form the time of discovery of the kick and there is some
drillpipe in the hole, the first priority must be to install a lower kelly cock on the drillpipe
and close it; then close in the well.
(4) If it is at all possible, the drillpipe in the hole should be lifted out of the slips before
closing the rams.
(5) However, if the well flows and there is no drillpipe in the hole, then open the
hydraulic-controlled valve in the choke line and close the blind / shear rams.
(6) Before deciding on the method of killing the well, consideration should be given as
to whether the drillpipe should be stripped into the well or not.
(7) The feasibility of the stripping operation depends on the flow rate, the pressures
observed and the condition of the BOP seals.
(8) If it is decided to strip the drill string to bottom continue as follows:
(e) Prepare to strip in.
Note: When preparing to strip in ensure the surge bottle pre-charge pressure has been
checked on the annular BOP and open the valve on the surge bottle. Remove the vent
plug on the opening chamber on the Cameron D annular preventer.
Note: Variations can occur to the above procedure when:
(a) pumping a dart to a receiving sub in BHA
(b) there is a positive float in the string
(c) accurate and regular slow circulating rates (SCR) are not available.
(9) Connect / disconnect kelly cock to crossover for DC's as and when required on trip.
六六. Killing Procedure Step by Step

1. KILLING PROCEDURE - STEP BY STEP
(1) After the shut-in procedure, start reading and recording every two minutes:
(a) the shut-in drillpipe pressure - SIDPP
(b) the shut-in casing pressure - SICP
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(2) If a back pressure valve or drillpipe float (non-return valve) is installed in the string,
pump very slowly and stop as soon as the pressure increase is noted on the casing
side, then read the drillpipe pressure. Record this as SIDPP.
(3) Measure the pit-level increase.
(4) Record these data on the IWCF Surface BOP Kill Sheet.
(5) As quickly as possible, using the IWCF Surface BOP Kill Sheet make the necessary
calculations and determine:
(a) the mud density required to balance the formation pore pressure.
(b) the pumping speed (unless already determined), based on the preestablished
mixing rate of the barite; but not more than half the speed used
in normal drilling operations.
(c) The number of pump strokes required to displace the influx to the casing shoe.
Note: This is important if the influx is gas since, once it is inside the casing, there is little
danger of formation breakdown. However, this only applies if the well continues to be
killed correctly according to the IWCF Surface BOP Kill Sheet graph and no mistakes
are made.
(6) Prepare the killing graph to show the standpipe pressures to be maintained against
the elapsed pump strokes during the killing operation.
Note: While making the above calculations, the well should remain closed in. The
closed-in pressures must be observed continuously. If gas migration (percolation)
occurs, SIDPP and SICP will continue to rise simultaneously after the initial build-up
and, unless remedial action is taken, there is a danger that formation breakdown can
and will occur.
The shut-in drillpipe pressure should therefore not be allowed to increase by more than
a few bar. It if does, the gas must be allowed to expand by bleeding off the annulus at
the choke until the pressure on the drillpipe has fallen to just above the former SIDPP.
Depending on the MAASP, 3 to 5 bar is acceptable as safety margin.
(7) With the minimum of delay, open the choke slowly and start pumping mud of the
required density, at the selected pump speed.
(8) From this moment, the annulus pressure is now referred to as the choke pressure
Pch, and the drillpipe pressure is now referred to as the standpipe pressure Pst.
However, the pressures are read from the same pressure gauges.
(9) Adjust the choke opening until the choke pressure equals the closed-in annulus
pressure value.
(10) Read the standpipe pressure which will normally be close in value to the calculated
standpipe pressure derived from the pre-kick pump test circulating pressure plus the
closed-in drillpipe pressure. If it does not, consider the actual pressure to be the correct
one and use it to plot the killing graph on the IWCF Surface BOP Kill Sheet.
(11) Keep the pump rate constant throughout the killing operation. If after pump startup
the rate is not exactly as designated but is within 3 or 4 SPM, do not attempt to correct
it. (12) Adjust the choke opening to ensure that the actual standpipe pressure equals
the calculated standpipe pressure for the corresponding number of pump strokes.
These pressures to be read off the graph. Do not exceed the MAASP.
Note: When adjusting the choke, remember that there is a time delay before the
adjustment registers on the Pst gauge. The pressure transmission rate in mud is
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approximately 300 m/second; therefore, the pressure transmission time in a 3000 m

well is (3000 x 2)/300 = 20 seconds. This transmission time is dependent of a number
of factors.
(13) Check, maintain and record continuously the density of the mud pumped into the
drillstring or tubing. Ensure it is correct.
(14) Measure and record continuously the density and viscosity of the mud returns.
(15) Record the choke pressures continuously.
(16) De-gas, treat or discard all contaminated mud returns.
(17) When the heavy mud, appears at the surface and choke pressure has dropped to
zero, stop pumping.
(18) Open the choke fully and check that there is no flow. The well should now be dead.
(19) Open the pipe rams first, then the annular type preventer in order to bleed off
safely the pressure between them.
(20) Close the hydraulically-controlled side outlet valve ("HCR" or type "F") and check
flow line for possible flow.
(21) If there is any doubt as to whether the well is dead, carry out one more circulation
through the choke. Calculate new MAASP. Finally check that there is no flow.
2. POTENTIAL PROBLEMS WHILE KILLING
A number of problems, some of them difficult, can arise during a killing operation.
Those most likely to be encountered are discussed below, and are followed by a Quick
Check List. Also refer to W.I. Section 11.22 Trouble Shooting Chart. Since an operator
could be overwhelmed by the number of possible causes of an abnormality during the
killing operation, keep in mind that:
IF IN DOUBT, STOP PUMPS SHUT WELL IN OBSERVE PRESSURES
A logical analysis of the evidence available will almost invariably point to the solution
required.
2.1. Excessive Standpipe Pressure
(1) This could be due to plugged bit nozzles, plugged annulus below the influx or a
plugged choke.
(2) Evidence of the first two is an increase in standpipe pressure with no increase in
choke pressure.
(3) If both standpipe pressure and choke pressure increase, it is an indication of a
plugged choke.
(4) Suggested action to be taken in these circumstances can be found in the Trouble
Shooting Chart.
2.2. Drop in Circulation Pressure
(1) This could be due to loss of a bit nozzle, a leak in a tool joint or a wash-out in the
drillpipe, pump valve or piston, leakage in surface equipment.
(2) As before, suggested action to be taken can be found in the Trouble Shooting
Chart.
2.3. Lost Circulation
(1) If Pst and choke pressure do not respond to either opening or closing of the choke
and it is noted that the mud returns have decreased (or ceased).
(2) This may mean circulation has been lost either directly to the formation, or through a
bad cement, or a hole in the casing.
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(3) Possible courses of action are given in the Trouble Shooting Chart.
2.4. MAASP is reached
(1) Possible action is limited to two alternatives, both undesirable.
(a) Firstly, continue to apply the necessary choke pressure to maintain the correct
standpipe pressure , but this increases the risk of formation breakdown.
(b) Secondly, limit choke pressure to the MAASP, thereby allowing the BHP to fall,
possibly inducing a further influx.
(c) Consider the hidden safety factors.
The least damaging course will depend on the situation.
(2) Assessment of the possibility and degree of seriousness of formation breakdown
involves consideration of:
(a) depth of shoe or weak formation,
(b) quality of the primary cement,
(c) characteristics of the formation most likely to fail,
(d) period of time during which weak formation is at risk.
(3) Chances and severity of a second influx depend on:
(a) productivity of the reservoir being controlled,
(b) degree of underbalance involved,
(c) period of time until acceptable BHP can be restored.
Note: Formation breakdown and losses may develop into an underground blow-out; or
perhaps worse, broach to the surface outside the well and cause a crater. This is the
ultimate disaster scenario for a jack-up or platform rig with only conductor or surface
pipe set for that well.
2.5. Equipment Failure
(1) This usually involves a partial or complete failure of the pump or its prime mover.
In such a case, pumping should be discontinued (unless it has already been stopped)
and the well closed in until rapid repairs have been carried out or a second pump
brought into service (determine new standpipe pressure ).
(2) Once the well is closed in, SICP and SIDPP must be continuously observed. If both
start to show signs of an increase, it will be due to upward migrating gas.
(3) The gas should be allowed to expand by opening the choke until SIDPP reverts to
the closed-in pressure observed at the time of equipment failure (If circulation is
stopped after the kill fluid reaches the bit, SIDPP will normally be zero.)
(4) The re-starting of the killing procedure is described in Section 11.22.
3. QUICK CHECK LIST
Note: Consult this list if necessary before closing in the well.
(1) A jumping rotary hose or a surging pressure gauge are signs of a pump problem.
(2) If the standpipe pressure and the choke pressure both increase suddenly, the choke
or choke manifold is plugged.
(3) If only the standpipe pressure increases suddenly, a bit nozzle or the annulus is
plugged.
(4) If the standpipe pressure drifts downwards, there could be a leak or hole in the
drillstring.
(5) If the standpipe pressure and choke pressure do not respond to choke adjustment
and the pit level is falling, loss of circulation is occurring.
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六七. Kick Control by Stripping and the Volumetric Method

1. GENERAL CONSIDERATIONS
(1) Well control by the volumetric method is a technique where bottom hole pressure
is maintained slightly in excess of pore pressure while the gas influx is allowed to
expand as it migrates to the surface.
(2) The technique is a temporary well control method to be used until and if better
methods can be used to restore primary well control.
(3) The volumetric method is applied initially when the well is closed in and when
conventional circulation is not possible, and when bullhead squeezing can not be
considered or is not recommended.
Note: This method does not kill the well, it only removes the influx by a very lengthy
process.
(4) The preferred method is to circulate out the influx with the bit on bottom. To
accomplish this the drillstring has to be stripped back to bottom.
(5) When applying the combined stripping and volumetric method a worst case
estimation of the pressures acting along the wellbore can be obtained by using
the formula in paragraph 4.
(6) Actual pressures during volumetric killing operations will depend on the following:
(a) The influx is fragmented and dispersed in the mud instead of remaining as a
single slug.
(b) The influx is probably not on bottom at the time of closing in the well.
(7) The gas migration rate has to be established and depends on variables such as:
(a) Hole size
(b) Difference in density of gas and well fluid
(c) Depth of the gas (shallow, and/or low density gas has faster migration rates)
(d) Viscosity of the well fluid
(e) Single bubble influx or separate smaller bubbles
(f) Type of well fluid
(8) As a rule of thumb, an estimated migration rate is between 150 to 300 m / hr (500 to
1000 ft / hr ) in water based mud. Migration rates in brines are much higher.
1.2. Volumetric Method with the Bit Off Bottom
(1) Close in the well, record Pa and determine the volume of the influx (V influx).
(2) Prepare to strip back to bottom if possible. If not, proceed as stated below.
Note: When the bit and DCs enter the influx, a dramatic loss of hydrostatic head will
take place. This loss of hydrostatic head should be anticipated and additional back
pressure should be added at the very start of the stripping operations.
(3) Make a kill graph and fill in the IWCF Surface BOP Kill Sheet.
(4) Allow the pressure to build up to Pchoke where:
Pchoke = Pa + Ps + Pw
Pa = Initial closed in annulus pressure before second build up has taken place.
Ps = Allowance for loss of hydrostatic pressure as the gas rises from below the
bit to around the DC's
Ps = (Vinf /(OH / DC cap.) - Vinf /(OH cap.) ) x (p1 - pinf) kPa, bar or psi
Vinf = Initial influx volume, (litre, m3 or bbl)
OH / DC cap = Open hole / DC annular capacity, (m3/m, l/m or bbl/ft
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OH cap = Open hole capacity, (m3/m, l/m or bbl/ft)

P1 = Mud gradient, (kPa/m, bar/m or psi/ft)
Pinf = Estimated influx gradient, (kPa/m, bar/m or psi/ft)
Pw = Working pressure increment.
Example to calculate Ps
Vinf = Initial influx volume, 2400 litre
OH / DC cap = Open hole / DC annular capacity, 33 l/m
OH cap = Open hole capacity, 77 l/m
P1 = Mud gradient, 0.141 bar/m
Pinf = Estimated influx gradient, 0.027 bar/m
Ps = (2400 / (43.6) - (2400 / (77)) * (0.141-0.027) = (2400 / (43.6-12.4)) * 0.114
Ps = 193 * 0.114 = 22 bar
Note: Convenient values for working pressure increments are between 350 to 700 kPa
(50 to 100 psi or 3.5 to 6.5 bar) depending on scale divisions on the pressure gauges.
In critical cases where a low MAASP does not allow excessive pressures to be applied
to the well bore, a smaller pressure increment could be used until the influx is above the
DC's.
(5) Bleed off mud (V1) from the well, while maintaining Pchoke constant.
V1 = Pw * (OH / DC cap) / p1
(6) When the additional mud volume has accumulated in the trip tank the well is closed
in until Pchoke rises, under the influence of the migrating gas influx, by one increment
of Pw.
(7) By repeating step (5) and (6) as often as necessary, gas is allowed to migrate
upward and expand while a nearly constant BHP is maintained.
(8) When gas is considered to be above the bit (calculated by migration rate), use a
conventional well killing to remove the influx from the well.
(9) If conventional well killing is still not possible, the method has to be continued until
gas has reached the surface.
(10) Gas has to be replaced with mud by pumping mud into the well intermittently
through the kill line. This procedure is called “Lubricating”.
(11) Pump mud V2 = Pw * (CSG/DP cap.) / (pmud in use ) into the annulus.
(12) Allow the gas to migrate to the surface again.
(13) Bleed off gas ONLY until the choke pressure (the pressure prior to pumping V2
mud) is reduced by one Pw increment.
(14) Repeat the lubricating exercise until all gas has been replaced with mud and the
well is under control (The well is NOT dead).
(15) Strip back to bottom and kill the well by using the Driller's Method (after solving the
initial circulation problems).
(16) Make flow check and if well is static open the BOP.
(17) Circulate bottoms up.
(18) Perform a check trip.
(19) Resume operations.
Note: Proper records should be kept during the well killing operation:
(a) Pchoke versus time to identify an increase in the number of pressure build ups
which is an indication of gas entering annular capacities.
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(b) Pchoke versus V to maintain the correct BHP.

1.3. Volumetric Method with the String Out of Hole
(1) Close in the well, record Pa and determine V influx
(2) Prepare to strip back to bottom if possible, if not, proceed as stated below.
(3) Make a kill graph and fill in the IWCF Surface BOP Kill Sheet.
(4) Allow the pressure to build up to Pchoke where:
Pchoke = Pa + Pw + safety margin
Vinf = Initial influx volume
Note: Convenient values are between 350-700 kPa (50 to 100 psi or 3.5 to 6.5 bar)
depending on scale divisions on the pressure gauges.
A safety margin of 700-1400 kPa (100 to 200 psi or 6.5 to 13 bar) is recommended to
reduce the chance of the well becoming underbalanced.
The safety margin should be reduced for critical wells, such as where a low MAASP
does not allow for excess pressure to be applied to the well bore.
(5) Bleed off mud (V1) from the well, while maintaining Pchoke constant.
V1 = Pw * (OH cap) / p1
(6) When the additional mud volume has accumulated in the trip tank the well is closed
in until Pchoke rises, under the influence of the migrating gas influx, by one increment
of Pw.
(7) By repeating steps (5) and (6) as often as necessary, gas is allowed to migrate
upward and expand while a nearly constant BHP is maintained.
(8) The method has to be continued until gas has reached the surface.
(9) Gas has to be replaced with mud by pumping mud into the well intermittently
through the kill line. (Lubricating)
(10) Pump mud V2 = Pw * (CSG cap.) / (pmud in use )
(11) Allow the gas to migrate to the surface again.
(12) Bleed off gas ONLY, until the choke pressure (the pressure prior to pumping V2
mud) is reduced by one Pw increment.
(13) Repeat the lubricating exercise until all gas has been replaced with mud and the
well is under control (The well is NOT dead).
(14) Strip back to bottom and kill the well by using the Driller's Method (after solving the
initial circulation problems).
Note: Proper records should be kept during the well killing operation:
(a) Pchoke versus time to identify an increase in the number of pressure build ups
which is an indication of gas entering annular capacities.
(b) Pchoke versus V to maintain the correct BHP.
2. KICK CONTROL BY USING COMBINED STRIPPING AND VOLUMETRIC
METHOD
(1) When the drillstring is partly or completely out of the hole, and we have a kick
situation, then we must try to get the bit as far back to bottom as possible, while, at the
same time, maintaining well control. The well can be most effectively killed with the bit
on bottom.
(2) The string needs to be stripped back preferably through the annular preventer.
157
This should be a smooth and efficient operation. It requires knowledge of equipment

and procedures used by all rig crew.
(3) When applying the combined stripping and volumetric method, estimates of worst
case pressures applied to the wellbore can be calculated by using the well control
formula in the volumetric method.
2.1. Bit off Bottom
(1) Shut-in the well and monitor the pressure and the kick volume.
(2) Whenever possible, make preparation to strip in the hole as indicated below.
(3) Be sure everything is prepared before starting the stripping process. Prepare a form
for the "Pressure and volume Records During Stripping" and the “Stripping Check
Sheet” for the operation.
3. STRIPPING
3.1. Stripping with the Annular Preventer
(1) Shut in the well as per the shut-in procedure.
(2) Ensure the surge bottle pre-charge pressure been checked on the annular BOP and
open the valve on the surge bottle. Remove the vent plug on the opening chamber on
the Cameron D annular preventer.
(3) Line up the choke manifold outlet to the trip tank.
(4) Calibrate the trip tank and the strip tank.
(5) Ensure the annular preventer operating pressure is adjustable between 100 and
3000 psi.
(6) Empty the trip tank to approximately 50%, measure the distance top strip tank - top
fluid level.
(7) Install the inside BOP on the kelly cock, open the kelly cock and ensure the inside
BOP is holding the pressure.
(8) Adjust closing pressure on the annular BOP but prevent leaking past the tool
joints and DP.
(9) After stripping back to bottom readjust the closing pressure to the recommended
pressure.
(10) Close ram type preventer, due to wear on the annular preventer when on bottom.
3.2. Stripping with the Annular Preventer and one Ram Preventer
(1) If kelly-cock / inside BOP or other string components will not strip through the
annular preventer, try to bring the tool joint to above the annular preventer.
(2) Close bottom ram preventer.
(3) Bleed off pressure in between annular and ram preventer.
(4) Open annular preventer. Remember the vent line in 3.1 step (2).
(5) Decrease the closing pressure of the ram preventer.
(6) Strip pipe into hole until tagging the closed ram preventer.
(7) Close annular preventer again.
(8) Pressure up between annular and ram preventer to wellbore pressure.
(9) Open ram preventer. Increase ram preventer closing pressure to recommended
pressure.
(10) Continue stripping through the annular preventer.
3.3. Stripping Ram to Ram
(1) Are additional preventers and spools installed?
158
(2) Close the top rams, bleed off to approximately 800 psi closing pressure and observe
for leaks.
(3) Strip in and tag the top rams. Pick up the string in tension before closing the bottom
rams.
(4) Close the bottom rams. Check if they are closed.
(5) Bleed off all pressure between the rams.
(6) Open top rams. Check they are fully open.
(7) Strip in and tag bottom rams. Pick up the string in tension before closing top rams.
(8) Close top rams. Check if they are fully closed.
(9) Pressure up between the rams to the well pressure.
(10) Open the lower rams. Check if they are fully open.
(11) Continue to strip in the hole by repeating steps (4) through (11) in sequence.
(12) Make a kill graph.
(13) Commence stripping. Allow the pressure to build up to Pchoke without bleeding off
any mud.
Pchoke = Pa + Ps + Pw
Ps = Allowance for loss of hydrostatic pressure as the gas rises from below the bit to
around the DC's
Ps = (Vinf / (OH / DC cap.) - (Vinf / (OH cap.)) * (p1 - pinf) (kPa / bar / psi)
Where:
Vinf = Initial influx volume, (litre, m3 or bbl)
OH / DC cap = Open hole / DC annular capacity, (m3/m, l/m or bbl/ft
OH cap = Open hole capacity, (m3/m, l/m or bbl/ft)
P1 = Mud gradient, (kPa/m, bar/m or psi/ft)
Pinf = Estimated influx gradient, (kPa/m, bar/m or psi/ft)
Note: Convenient values for working pressure increments are between 350 to 700 kPa
(50 to 100 psi or 3.5 to 6.5 bar) depending on scale divisions on the pressure gauges.
In critical cases where a low MAASP does not allow excessive pressures to be applied
to the well bore, a smaller pressure increment could be used until the influx is above the
DCs.
(14) Once the required choke pressure is reached, Pchoke is kept constant while the
drillpipe is stripped back in the hole. Excess pressure is bled off via the choke manifold
into the trip tank.
(15) The closed-end pipe displacement of each stripped in stand of drillpipe is then
drained from the trip tank into a stripping tank.
(16) The string is then stripped into the hole until a volume of V1 has accumulated in
the trip tank.
V1 = Pw x (OH / DC cap) / p1
(17) Once the correct mud volume (V1) has entered the trip tank, the choke is closed
and the annular pressure is allowed to rise by Pw by means of stripping DP into the
hole.
Note: The closed end displacement volume should NOT be bled off from the trip tank
into the stripping tank during this operation.
159
(18) It is recommended to strip the complete stand in the hole for each phase of the
operation (whilst maintaining Pchoke constant, or when increasing Pchoke by Pw ) to
simplify the bleeding off process from trip tank to stripping tank and to improve the
accuracy of V1 measurements which directly results in improved BHP.
Note: As a result of stripping the complete stand, higher then required choke pressures
will occasionally be obtained which should be taken into account when next Pw
increment needs to be added.
(19) Steps (15) through (18) are repeated as often as necessary, until:
(a) Bit is on bottom.
(b) Gas has reached surface.
(c) Stripping is no longer possible due to excessive pressures, BOP stack problems
open hole resistance, etc.
(20) Stripping is then stopped and the well is killed conventionally, if the influx is above
the bit.
Note: The chance to have to kill the well with the bit off bottom is small, since the
migration of gas in mud is such that the bit normally can be stripped back to bottom
before the gas reaches the surface.
Note: Migration rates of gas in workover fluids are much higher and should be taken
into consideration before deciding to start stripping into the hole.
(21) When the bit is back on bottom, the well can be killed conventionally (Driller's
Method) by using following procedure:
(a) If not already done, fill up the string with mud.
(b) By using last SCR, calculate circulation pressure and Pchoke. Add 3,5 bar (50 psi)
to the calculated pressure to compensate for pressure drop in the inside BOP.
(c) Circulate the string content, by maintaining a constant BHP.
(d) After the string contents has been pumped; close in the well and check for trapped
pressures. Leave about 3,5 bar (50 psi) in standpipe pressure.
(e) Continue to kill the well by using the Driller's Method. If it is a swab kick, the normal
mud can be used as it is proven (during drilling) that it was overbalanced.
3.4. String Out of the Hole
(1) If the string is out of the hole when an influx is detected and the closed in surface
pressure allows lowering the first stands of DCs or DP into the well, stripping should be
started as it will improve the well control situation. The kelly or the top drive may have to
be used for extra weight on the first stands.
(2) The maximum surface pressure that can be overcome by the weight of the first
stand, ignoring the friction between the annular preventer and the string is:
Max. surface pressure = ( Weight of first stand in mud )
(Cross sectional area of the stand)
(3) Install a bit sub with float valve on the first stand of DC or an inside BOP on the first
stand of DP when stripping with DP only.
(4) When stripping with DC, make up a bit without nozzles to reduce the chance of
plugged nozzles.
(5) Lower the stand to the top of the blind / shear rams and close the annular preventer.
(6) Open the blind / shear rams and strip through the annular preventer. Allow the
choke pressure to increase by Pw, and maintain it constant thereafter.
160
(7) Fill the string with mud.

(8) If DCs are used instead of DP, Continue stripping the slick BHA and maintain a
constant choke pressure. Do NOT use more than three stands of DCs.
(9) Allow the choke pressure to increase to (Pa + Ps + Pw) without bleeding off any
mud when stripping in the first stands.
(10) Continue the combined volumetric method as described above.
Note: If it is not possible to strip the string into the hole and gas migration is indicated,
the volumetric method or bullhead squeezing may have to be employed.
六八. Pressure Test Procedure for the High Pressure Test Pump
High-pressure Testing pump High-pressure Flexible hose ¼"
Chiksan high-pressure Steel hose 2 x Low-torque valves
Hazard tape
1. Ensure the Chiksan swings and attachments have valid test certificates and
are not more than 1 year old.
2. Ensure that after the test is completed, the pressure is bled off, using the
hydraulic valve and choke.
3. Ensure that no one is in the vicinity of lines, manifolds, etc. under (high)
pressure.
4. Ensure that leaking couplings are not tightened, while under pressure.
5. Ensure that no "home-made" attachments are used.
6. The test area shall be cordoned off with hazard tape.
(1) Hold a Toolbox Talk with all personnel involved, before the test commences.
(2) Ensure that the test lines have been flushed and air bled off prior to testing.
(3) Ensure that the Test pump Operator knows the test pressures before the test
commences.
(4) Ensure that all chiksan swings are fitted with safety wireline, chain or equivalent.
(5) Ensure that none of the connections of the chiksans support any of the load of the
test lines.
(6) Ensure that all connections of the test lines have been tightened and test line is tied
down and secured.
(7) Ensure that there is ample fluid for the test pump.
(8) Protect the pump when freezing conditions exist.
4. INSTRUCTIONS
(1) Bleed off the pressure from the high-pressure pump plungers.
Note: The reducing valve must be completely unscrewed (open) before the pump is
started.
(2) Connect the test line and the low torque valve to the high pressure pump.
(3) Install a low-torque valve on the rig pump and attach to the test line, upstream of the
test pump.
(4) Shut the low-torque valve on the test pump and open the low-torque valve on the rig
pump.
(5) The rig pump can be used to bring the pressure up to 100 bar (1500 psi).
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(6) Shut the low-torque valve on the rig pump.

(7) The Test pump Operator will then start the test pump and bring the pressure up to
100 bar (1500 psi.).
(8) After reaching 100 bar, the Test pump Operator will open the low-torque valve on
the high pressure pump.
(9) The Test pump Operator proceeds to bring pressure up to the predetermined test
pressure.
(10) Once the test pressure has been obtained, the Test pump Operator will shut the
low-torque valve and stop the high pressure pump.
(11) The Test pump Operator opens the adjusting valve (reducing valve).
(12) Hold the test pressure as per the Drilling / Completion / Workover Programme.
(13) Bleed the test pressure through the choke of the BOP stack.
Note: Never release the pressure of the test lines back through the test pump in to the
suction tank. Back-flow will cause serious damage to the plunger seats of the pump.
Note: Maximum return pressure to the high pressure pump is normally 50 bar (750.
psi), limited by a safety cut-out. Maximum capacity is 22 litres per minute (5,8 gallon per
minute).
六九. Pressure Testing Wellhead Completion

High pressure test pump Pressure recorder (0-700 bar)
Pressure recorder charts ½” or 1” High-pressure hose
Safety wireline 2” or 1” Hammer union
½” API x 1” or 2” test nipple Adjustable wrench
Adjustable spanner Hydraulic torque wrench
Liquid O-ring (green grease) Working platform
Hazard tape
1. Prior to pressure testing taking place, the area around the equipment / flow
lines being pressure tested should be cordoned off using Hazard Tape.
2. All non-essential personnel should remain clear of the surface test
equipment area during pressure testing operations.
3. Verify that the test dates for small crossovers, attachments and pressure test
lines are within 12 months.
4. Verify that all hoisting equipment is in good condition, checked for working
load limit (WLL), and has a valid certificate.
5. Ensure that the pressure test lines are tied down and clamped, and secured
with safety lines.
(1) A Toolbox Talk is to be held with all personnel involved, before the operation begins.
(2) Ensure that the cellar is covered at all times.
(3) Ensure all tools and equipment to be used, are in good condition and are readily
available.
(4) Always bleed off pressure prior to loosening or breaking out pressurized
connections. If any leaks are discovered, pressure should be bled off prior to remedial
action taking place.
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(5) Open the valve on the casing

4. INSTRUCTIONS
Note: The SRT seal assembly or LDO rams have already been pressure tested from
below to 70 bar at the same time as the annulus.
4.1. Pressure Testing SRT Seal Assembly
(1) Using the adjustable wrench, remove the hexagonal screw from the top flange of the
SRT head.
Note: If necessary, also remove the hexagon socket bolt in this opening.
(2) Screw a ½” x 1” API swedge, greased with liquid O-ring into the ½” opening in the
flange.
(3) Screw the threaded half of the 1” hammer union onto the 1” x 1/2” swedge.
(4) Screw the hammer union of the high-pressure line onto the connector on the
swedge (do not tighten).
(5) Switch on the high pressure test pump and flush the test line and then switch off the
pump.
(6) Tighten the hammer union and attach the safety wireline to the wellhead.
(7) Using the high pressure test pump, pressure test the SRT seal assembly to the
predetermined pressure as per the Drilling / Completions / Workover Programme.
(8) Bleed off the pressure after 15 minutes if the test is successful.
(9) Remove the 1/2” x 1” swedge and replace the hexagon socket bolt and hexagonal
nut in the flange.
Note: The SRT seal assembly is now pressure tested.
4.2. Pressure Testing Metal to Metal Seal, Packings and Temporary Adapter
(1) Connect the high pressure test pump to the ½” x 1” API swedge of the intermediate
flange.
(2) Pressure test the gap between the SRT seal assembly or LDO rams and the metal
to metal seal against the hanger and ring joint as described in paragraph 5.1. above.
(3) Connect the high pressure test pump to the ½” NPT connector in the bottom flange
of the temporary adapter.
(4) Pressure test the gap between the two O-rings in the temporary adapter against the
hanger as described above.
(5) Connect the high pressure test pump to the ½” needle valve on top of the X-Mas
Tree cap on the temporary adapter.
(6) Open the needle valve.
(7) Pressure test the temporary adapter against the upper O-ring around the hanger
and the F or A plug in the hanger.
(8) Remove the A plug after pressure testing or pump through the F plug.
(9) Connect the high pressure test pump to the metal to metal seal.
(10) Pressure test the control line against the ball valve dummy and the metal seal
against the hanger.
(11) Blank all pressure testing openings with a ½” blanking plug and install a pressure
gauge in the needle valve on the X-Mas Tree cap.
(12) Close the casing head housing valve.
七零. Use of Foster Hydraulic Tong

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Foster tongs Tong jaws and dies

5/8” Safety line Adjustable wrench
Allen wrench set Grease insert
Wire brush Tong back-up jaws and dies
3/4” Suspension line Swivel on suspension line
Pins for tong with spares Grease and grease gun
Safety pin for back-up Tong hydraulic ram
Drag rings and spring (nylon plugs)
1. Ensure that both the tong and the back-up jaws are fully retracted before
lowering or raising the pipe.
2. Ensure that hands and feet are clear of the tong when pipe is being lowered
or raised.
3. Ensure that the emergency stop for the Foster power unit is on the rig floor
within close reach of the person operating the tong.
4. Whenever repairs are being made on the Foster tongs, ensure that the power
unit is turned off using the emergency stop.
5. Never use the hydraulic lift cylinder for lifting anything else but the Foster
Tong. Never try to pull slips with the aid of this hydraulic cylinder.
6. Ensure that a 5/8” safety line is securely attached to the torque arm and the
back-up post.
(1) Hold a Toolbox Talk with all personnel involved before this operation.
(2) For leased Foster tongs, always check the contents of the box containing parts and
spares, upon receiving the equipment and prior to shipping back (Figure 1).
(3) In order to avoid a surcharge, ensure that the contents of accessories with the
rented tongs are complete, including the worn jaws being returned.
(4) Ensure the correct size bow shackle has been used for hanging the Tongs.
(5) Ensure the Tongs are suspended by one single sling.
(6) Check the condition of the steel pins securing the torque arm to the tongs and back-
up post.
(7) Always use original manufacturer’s pins. Never use bolts in place of pins.
(8) Ensure that the tong dogs are placed correctly for tripping in and out of the hole.
(9) Ensure that the tong and back-up jaws are always placed on the upset of pipe.
(10) After pulling a wet string, always change the oil in the tongs.
4. INSTRUCTIONS
4.1. Pre-Job Inspections
(1) Check and level the tongs by:
(a) Adjusting the stiff arm back or front;
(b) Adjust up and down by adjusting the set screw on top of the tongs.
(c) Ensure that all set screws are in place and tight.
(d) Check the set screws after going in and coming out of hole.
(2) Check and ensure that there is an adequate supply of oil in the reservoir of the
power unit.
(3) Check the oil in the tongs. Change the oil if it is milky looking.
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(4) Check the couplings and lines for leaks and repair or replace, if leaking.
(5) Clean and inspect the dies in the tongs and the back-up. Replace, if worn.
(6) Ensure that the tong cylinder movement is sufficient (both high and low) to correctly
perform the job procedure.
(7) Check to ensure that the back-up handles are in good working condition.
(8) Ensure that the back-up pin is safely secure.
(9) Ensure that the torque gauge is set at the correct torque setting of the pipe being
made up or broken out.
(10) If the torque is incorrect, reset by adjusting the torque set screw on top of the valve
body.
4.2. Function Testing the Tongs
Note: Never stand with your feet beneath the tong when lowering it.
(1) Operate the lever for moving the hydraulic arm up and down. To move the hydraulic
arm ... move the lever to the ... up, front position. down, rear position.
(2) Operate the lever for rotating the crown gear with the jaws.
(3) Ensure that the jaws turn inwards during rotation. If proper movement is not
observed during the rotation:
(a) Check the spring for wear, replace if necessary.
(b) Tighten or replace the nylon plugs in the drag ring.
(c) The dogs in the make-up and back-up tongs should be adjusted if they do not retract
all the way back.
4.3. Tightening or Replacing the Nylon Plugs
(1) Ensure that the wellbore is covered.
(2) Place the tongs on the rig floor or secure the type 54 tongs to the windbreak with a
rope.
(3) Stop the power unit by pressing the emergency stop button on the rig floor.
(4) Using a hexagon socket key of the appropriate size:
(a) Remove the hexagon socket screw,
(b) Lift the drag ring up out of the tong body,
(c) Check the spring and replace, if necessary,
(d) Change out the plugs, replace the drag ring in the tong,
(e) Adjust the drag ring by tightening the hexagon socket screw,
(f) Remove the socket key and rotate tong to ensure the correct setting,
(g) Re-assemble.
4.4. Changing the Jaws
(1) If possible, remove the tongs from the pipe and place them on the rig floor or hang
the type 54 tong to one side.
(2) Turn the jaws inwards.
(3) Stop the power unit.
(4) Remove the securing bolts from the cover.
(5) Place the cover on the floor alongside the tongs.
Note: If Tongs are still attached to the pipe, tie a nylon rope to the cover and the
retaining ring, lift and suspend both with the air hoist.
(6) Remove the retaining ring on top of the jaws, by hand, and lay down.
(7) Remove all the jaws, by hand.
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(8) Check all the pins in the drag ring for wear, replace the worn ones before installing
new jaws.
(9) Fit the new jaws so that they are oriented in the same position with respect to the
crown gear.
Note: For the type 54 tongs, the jaws must be fitted so that a mark on the teeth of the
jaw is opposite a similar mark on the crown gear.
(10) Fit the retaining ring and the cover, secure the cover with four bolts.
(11) Reset the emergency stop and switch the power unit on.
(12) Rotate the tongs so that the jaws are fully turned against the crown gear.
(13) Refit the tongs around the pipe.
4.5. Changing the Back-up Jaws
(1) Remove the tongs and set off to one side.
(2) Remove the safety pin and drop out the back-up jaws.
(3) Remove the top cover by unscrewing the 5 bolts
(4) Remove the jaws by hand and also check the pins in the back-up for wear, if worn,
replace before reinstalling jaws.
(5) Fit the new jaws so that they all assume the same position with respect to the back-
up gear.
(6) Fit the cover back and tighten the 5 bolts.
(7) Lift back-up back into place and secure with the safety pin.
4.6. Changing the Tong and the Back-up Tong Dies
(1) Using a hexagon socket key of the appropriate size, unscrew the 2 bolts in the back-
up jaws.
(2) Now remove the die.
(3) Fit the new die in place and tighten the bolts are securely to ensure that the bolts will
not back out while in operation.
(4) Next, remove the tong jaws, repeat the same procedure as in steps (1) to (3).
七壱. Pick Up, Wash Down, and Lay Down Kelly

Fork lift truck Chain tongs
Crane Air hoist
1 Soft sling (red coded) Rig tongs
Adjustable wrench Upper kelly cock
Pipe Dope 1 3/4” Wire rope sling
Saver Sub Lower kelly cock
Kelly Bushing Chains and Boomer
2 SAFETY INFORMATION
1. Inspect all lifting equipment and verify that the working load limit (WLL) is
safe for the maximum weight load to be picked up.
2. Never work under a suspended load.
(1) Hold a Toolbox Talk before the operation begins.
(2) Ensure that the entire work area is clear of all obstructions.
(3) Verify the swivel tonnage and pressure capacity (it must be equal to or greater than
the rig capacity).
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(4) Ensure that the swivel washpipe and packing are in good shape.
(5) Check the oil level in the swivel, change if necessary.
(6) Ensure that the fingerboard is protected by the guard rail in front.
(7) Ensure that while washing the kelly down, that the run-off water is directed to sump
pit.
(8) Verify that the swivel gooseneck thread has a thread protector.
(9) Ensure that the kelly hose is secured at both ends by safety lines.
(10) Verify that all subs and valve threads are cleaned and inspected before installing
on the kelly.
4. INSTRUCTIONS
4.1 Picking Up the Kelly
Note: Should the height of the substructure not allow to set the kelly in the rotary table
proceed as follows:
(1) Ensure sufficient length of drilling line is on the drawworks drum.
(2) With a crane or the travelling block, lift the swivel and place in the rotary table.
(3) The Driller then lowers the travelling block to a level just above the swivel.
(4) One Floorman unlatches the hook of the travelling block.
(5) A Floorman attaches the air tugger to the bail of the swivel, (do not use the eye of
the bail).
(6) The bail of the swivel is then lifted to a standing position, using the tugger.
(7) The Driller lowers the travelling block hook to a level equal to the swivel bail.
(8) As the Floorman operating the tugger lowers the swivel bail, two Floormen push the
bail into the open hook on the travelling block.
(9) The Driller slowly lifts the travelling block until the hook latches completely.
(10) The air tugger is then removed from the swivel bail.
(11) The crane sets the kelly and the shuck (case of the kelly) in the V-door.
(12) The Floormen secure the kelly at the V-door with chains attached to the V-door
posts and tightened with a boomer.
(13) The thread protector is then removed from the kelly, and the threads are cleaned,
inspected for damage and then doped.
(14) The kelly cock is then lifted by the air tugger and stabbed into the kelly.
(15) The kelly cock is then screwed into the kelly, using the chain tongs, leaving a 1/8
inch gap at the connection.
Note: All connections above the kelly are left-hand threaded.
(16) The air tugger is then attached to the pin end of the swivel, and the pin end lifted to
the level of the box end of the kelly cock.
(17) After doping the box of the kelly cock, the Floormen push and guide the pin end of
the swivel into the box of the kelly cock.
(18) After stabbing the swivel into the kelly cock, the Floormen attach a chain tong to
the kelly, as a back-up.
(19) The Floormen then screw the swivel into the kelly cock with the chain tongs.
(20) The Floormen stop screwing the swivel when there is an 1/8 inch gap left at the
connection.
(21) A Floorman then wraps soft line around the connections on the swivel-kelly
assembly.
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(22) The connections are made up the rest of the way, and tightened as much as
possible.
(23) The mud hose is picked up, using a sling and air tugger, and positioned at the
swivel gooseneck union, where a Floorman screws the union together and tightens with
a hammer.
(24) While tightening the union, ensure that the mud hose is positioned properly and the
safety lines are attached.
(25) The Floormen release the boomer and chains securing the kelly in the V-door.
(26) The Driller and the Floormen secure the shuck to the kelly.
(27) The Driller engages the drawworks and slowly lifts the travelling block and brings
the kelly and shuck up to the V-door.
(28) The Floormen, using a tail rope, snub the kelly and the shuck as it clears the
Vdoor.
(29) The Floormen remove the floor covering, and guide the kelly and shuck over to the
opening, using the air hoist and snatch block to pull the kelly.
(30) The Driller lowers the travelling block until the kelly and shuck are in place.
4.2 Washing Down the Kelly
(1) The Floormen remove the cover plate in the floor of the substructure.
(2) Two Floormen use the air hoist and snatch block to pull the kelly together with the
shuck towards the hole in the side platform while the Driller lowers the Kelly together
with the shuck.
(3) The Driller lowers the kelly together with the shuck down into the hole made in the
asphalt.
(4) The Driller engages the rig pump and begins to pump slowly.
(5) The Driller lowers the kelly together with the shuck into the sand.
(6) The Driller washes the kelly together with the shuck down to the required depth and
stops the pump.
Note: Use as low a pump flow rate as possible. If the kelly does not want to descend it
can sometimes help to twist the shuck using the rig tongs.
Note: If, despite all attempts, the kelly will not descend, stop to prevent the washing out
of the rat hole below the asphalt. This can cause subsidence of the asphalt beneath the
rig.
(7) The Floormen then release the kelly from the kelly shuck.
(8) The Driller engages the drawworks and lifts the kelly out of the shuck.
(9) The Driller and Floormen then install the kelly bushing, kelly cock and kelly saver
sub on the kelly.
(10) The Driller and the Floormen then tighten and torque the entire kelly assembly to
each connections specified torque while taking care not to bend the kelly.
4.3 Laying Down the Kelly
(1) Using the rig tongs, the Driller and the Floormen break the kelly cock and swivel
connections, without backing them out, while there is still some string weight hanging.
Note: On H2S wells, the kelly connection is broken without any weight hanging on the
kelly.
(2) The Driller then lifts the travelling block and the Floormen remove the Kelly bushing,
the kelly saver sub, and the lower kelly cock.
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(3) Two Floormen pull the kelly to the rat hole, with the air hoist and snatch block, while
the Driller lowers it into the shuck.
(4) The Driller and the Floormen then secure the kelly to the kelly shuck.
(5) The Driller engages the drawworks and lifts the kelly and shuck up and out of the rat
hole.
(6) The Driller must pay close attention to the weight indicator while pulling the Kelly
shuck.
(7) Once the shuck is above the rig floor, the catwalk air tugger or the crane sling is
attached to the end of the shuck.
(8) The kelly shuck is moved out the V-door.
(9) Once the kelly shuck has passed through the V-door, the Driller lowers it gently until
the kelly and the swivel are resting at the V-door.
(10) The Driller and the Floormen then attach the tugger line to the mud hose, knock it
loose, unscrew the union, and remove the safety lines.
(11) The mud hose is then removed and set out of the way.
(12) A Floorman attaches a sling and the air tugger to the kelly and shuck.
(13) A chain tong is then attached to the kelly for a back-up.
(14) The Driller and the Floormen then unscrew the swivel and the upper kelly cock
from the kelly.
(15) Once the swivel and the kelly cock have been removed, a thread protector is
installed in the box of the kelly.
(16) Either with the crane or using both tuggers, one tugger lifts the kelly and shuck as
the other catwalk tugger or the crane pulls the kelly and shuck clear of the Vdoor.
(17) The air tugger Operator lowers the kelly and shuck onto the catwalk.
(18) The tugger lines can be removed, and the crane or forklift can remove the Kelly
and shuck.
七弐. Running and Pulling Electrical Submersible Pump (ESP)

Foster tongs and back-up Empty reel including Drip tray
Landing joint with crossover Flat guide strips for flat cable
“H” plug and Setting tool Various centralisers
Kelly cock and wrench Circulating sub and Crossover
Gray valve F Spider
Wood blocks Chain tongs
Slips with a gap for the cable Stainless steel ties / ESP-tubing clamps
Spooler trailer Safety clamps
Hexagon socket keys Impact wrench
Ring spanners Guide wheel
Pipe dope and Brush Pair of cable cutters
Pipe wiper Pop joint
1. Ensure that the Foster tong jaws and back-up are kicked out before lowering
or raising pipe.
2. If using Foster tongs ,ensure that it is suspended by a single sling and a 5/8”
safety line is attached to the torque arm and secured.
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3. Isolate the electrical components before starting, and ensure they are
properly grounded.
3. STANDARD OPERATIONAL CONSIDERATIONS ( DO’S AND DON’TS )
(1) Hold a Toolbox talk with all personnel involved before this operation.
(2) Place the spooler trailer containing an empty reel at a safe distance (about 30 m)
away from the well.
(3) Ensure that the spooler trailer is properly grounded before connecting the power.
Check all the functions and ensure they operate properly.
Note: Lock the wheels and secure the draw bar to a firm place, such as a concrete
block.
(4) Ensure that the correct ESP cable is on location, and that the Service Contractor
has measured the cable length.
(5) Measure the ESP components (motor, protector, pump, etc.) to be run and make a
drawing and record in the tour book.
(6) Ensure that the supplied equipment specifications (number of pump stages, motor
RPM, round or flat cable, ratings , etc.) correspond to those given in the Workover /
Completion Programme.
(7) Ensure that the well is “killed”.
(8) Check that the following are ready on the rig floor:
(a) kelly cock with appropriate size wrench crossover to the tubing size,
(b) Gray valve and appropriate size circulating sub, and
(c) the cable cutters.
(9) The Driller must know the weight of the string before pulling commences.
(10) Switch on the trip tank pump and adjust the tank level meter and flow meter.
(11) Remove the surplus equipment from the rig floor and store it.
4. INSTRUCTIONS
4.1. Pulling the ESP
(1) Screw the proper crossover(s) to a landing joint of sufficient length.
(2) Using the chain tongs, the Floormen screw the landing joint into the Boll-Weevil
(BW) hanger and unscrew the tie down bolts in the BW spool.
(3) The Driller lowers the elevators and the Floormen latch the elevators onto the
landing joint.
(4) The Driller raises the travelling block and pulls the tubing string until the BW hanger
is above the F spider.
Note: The Driller must pay attention to the weight indicator and not exceed the overpull
limit.
(5) The Floormen unscrew the cable plug at the bottom of the hanger, using a hexagon
socket key, unplug the cable from the socket in the hanger and pull the cable free.
(6) The Driller lowers the tubing string and the Floormen set the slips.
Note: Ensure that the slips are not setting or resting on the ESP cable. Use the correct
slips with a gap to prevent cable damage.
(7) The Driller and the Floormen remove the landing joint and the hanger from the
tubing string and then lay them down on the catwalk.
(8) Engage the elevators and set the slips higher above the F spider to accommodate
the pipe wiper and Foster tongs.
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(9) A Floorman unlatches the elevators and the Driller raises the travelling blocks and
the elevator out of the way.
(10) The Floormen install the pipe wiper and Foster tongs over the tubing, the Driller
lowers the elevators and the Floormen latch the elevators back onto the tubing.
Note: Make sure that the ESP cable does not shift relative to the tubing.
(11) As the Driller slowly raises the tubing string, a Floorman, using the wire cutter,
removes the stainless steel ties or the ESP-tubing clamps fastening the ESP cable to
the tubing (Figure 1).
(12) When enough tubing and cable has been pulled from the hole, install a guide
wheel and suspend it from the safety hook of the air hoist.
(13) The Floormen feed the ESP cable through the guide wheel.
(14) Continue pulling the tubing and the cable until the ESP cable can be attached to
the empty reel on the spooler trailer.
Note: While pulling the tubing, one Floorman operates the spooler trailer so that the
cable is wound evenly on the reel.
(15) Using the air hoist, raise the guide wheel and the cable into the derrick until the
Derrickman is able to secure the guide wheel to the fingerboard.
Note: Use a wire rope sling, not a soft sling, or it could be cut through by sharp edges.
(16) The Floormen remove the steel ties as the string is being pulled and the cable is
being spooled onto the reel.
(17) The Driller and the Floormen pull the tubing string until the ESP assembly is above
the rotary table and it is possible to remove the cable from the motor.
(18) The Driller closes the blind rams and a Floorman covers the wellbore.
(19) The Derrickman attaches the air winch hook to the guide wheel at the fingerboard
and releases the sling.
(20) The Air winch Operator safely lowers the guide wheel to the rig floor.
(21) The Floormen unscrew the hexagon socket bolts in the plug on the ESP motor and
pull the plug, and then fully wind the ESP cable onto the reel.
(22) The Driller and the Floormen assist the Service Contractor with the dismantling of
the anode / centraliser (if fitted), the motor, protector, separator, and the pump.
Note: A special safety clamp is to be attached to every component to be removed from
the rig floor, and the safety hook of the air hoist inserted into this clamp before removal.
(23) Lay down all the components on the catwalk for the Fork lift truck Operator to
remove.
Note: Ensure proper handling of all components and avoid any damage in case the
equipment may be used after reconditioning.
(24) If the ESP cable is not to be re-used, remove the reel from the spooler trailer and
place it in the drip tray for transport.
4.2. Running the ESP
(1) Place a full reel with ESP cable (if new) in the spooler trailer.
(2) The Fork lift truck Operator places the pump, the separator, the protector and the
motor on the catwalk, one at a time, and the Floormen attach safety clamps on all
components before hoisting.
(3) Using the air winch, the Floormen hoist the ESP components to the rig floor, one at
a time, and lay them on wood blocks.
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(4) The Floormen make up a pup joint onto the top of the pump, and latch on the
elevators.
(5) The Driller lifts the pup joint and the pump, clearing the rig floor.
(6) Using the air winch, The Floormen hoist the separator, and hold it upright.
Note: Keep the hoist line hooked to the safety clamp until the separator has been
assembled below the pump, and that there is no further risk of it falling over. Slack off
the hoist line just enough to work safely.
Note: If the separator is of such a length that the assembly of the pump will have to be
carried out too high above the rig floor, then lower the separator through the spider into
the BOP. Keep the blind rams closed. Close the spider only when advised to do so by
the Service Contractor.
Note: When running a 7 or 8" OD pump the separator and pump can be set in the
mouse hole with a safety clamp attached.
(7) The Driller carefully lowers the travelling block with the pump until the splined shaft
of the pump slides into the shaft of the separator.
(8) The Service Contractor can now connect the pump and separator using the
hexagon socket bolts.
(9) The Service Contractor spools the ESP cable and the plug on the guide wheel, and
puts the plug into the motor securely.
(10) The Driller raises the elevators sufficiently high to clear the separator off the spider.
(11) Using the air winch, the Floormen pick up the motor and hold it upright, and the
Driller lowers the elevators until the bottom of the separator mates with the motor
(12) The Service Contractor can now connect the separator and the motor using the
hexagon socket bolts.
(13) Using the air hoist, install the guide wheel at the fingerboard in the derrick, while a
Floorman by the spooler trailer allows the ESP cable to unwind during hoisting.
(14) Using flat guide strips, the Service Contractor attaches the flat cable to the
protector, the separator and the pump.
(15) The Service Contractor applies oil to the protector.
(16) Ensure there is a pipe wiper installed on the tubing string before going into the
hole.
(17) Run the pump combination on tubing to the desired depth. Attach the ESP cable to
the tubing using stainless steel (SS) ties below and above each box and in the middle
of each joint or use the ESP-tubing clamps.
(18) The Floorman at the by the spooler trailer ensures that the ESP cable is spooling
freely through the wheel.
Note: Before setting the slips, ensure that the ESP cable is centred so the slips do not
set or rest on the cable. Prevent accidental setting of the slips.
(19) Install the BW hanger with the electric connector into the tubing string.
(20) The Service Contractor attaches the right plug with about 5m cable to the electric
connector at the bottom of the hanger.
(21) Using chain tongs, the Floormen screw a pup joint with the special crossover into
the hanger.
Note: Make sure that the pup joint is fitted with a circulating sub.
(22) The Driller raises the string, the Service Contractor holds the cable from the plug
172
against the tubing and mark the ESP cable which has been run at the end of the plug
cable.
(23) The Driller lowers the string and then the Service Contractor removes the plug.
(24) The Derrickman attaches the air winch hook to the guide wheel at the fingerboard
and releases the sling.
(25) The Air winch Operator safely lowers the guide wheel to the rig floor.
(26) The Driller raises the tubing string until the marked point on the ESP cable is lying
on the ground at least 15 m away from the wellhead. Cut the cable at this point.
(27) The Service Contractor splices the ESP cable to the cable plug.
(28) The Driller lower the string and the Floormen attaches the ESP cable to the tubing
with SS ties.
(29) The Service Contractor attaches the plug to the connector in the hanger and
secure the plug by tightening a hexagon socket bolt into the coupling nut.
(30) The Service Contractor tests the leads of the ESP cable to check that the cable is
still intact. He then screws a blanking cap on the electric connector at the top of the
hanger.
(31) The Driller lowers the tubing string and hangs off the string in the BW spool.
(32) The Floormen remove the landing joint and lay it down.
(33) The Floormen then install the “H” plug.
(34) The Driller and the Floormen reinstall the landing joint and circulating sub, and
pressure test the “H” plug.
Note: Turn the string so that the connector in the hanger is located at the side where
the above-ground power cable runs from the power unit.
(35) After fitting the wellhead completion, unscrew the blanking cap from the connector
and connect the above-ground power cable.
(36) A certified Electrician connects the power cable to the power unit, after which test
pumping can be carried out.
(37) The Service Contractor and the Electrician, check the direction of rotation of the
ESP and the amperage against the pre-calculated amperage, and record same.
173

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Standard Operation Procedure

PT ZHONGYUAN SOUTHEAST ASIA

五六. Laying Out and Preparing Casing..................................................................................23

壱. Picking Up and Laying Down Single Joints (Singling In / Singling

Kelly cock with Wrench Circulating sub

弐. Picking Up and Laying Down Singles with Pick-Up / Lay-Down

until the drillpipe or the drill collar is on the pipe rack.

参. Make-Up and Break-Out Procedures Using Rig Tongs

四. Use of Rig Tongs with EZY- Torque

伍. Safety While Making Up and Breaking Out Bottom Hole

Inside BOP (Gray valve or equivalent) Kelly cock and Wrench

六. Running In and Laying Down Drill Collars

Drill collar Dope and Brush OD and ID Calliper

七. Making Connections While Drilling (Making a Connection)

table during these activities.

circulation is established and the pump pressure is correct.

九. Trip Tank and Fill-Up Line Operations

壱零. Removal and Installation of Rotary Bushings

壱壱. Maintenance of Elevators and Slips, Changing Slip Dies and

壱弐. Use and Inspection of Mud Box / Mud Saver

壱四. Operations with Top Drive Systems

3. STANDARD OPERATIONAL CONSIDERATIONS (DO’S AND DON’TS)

壱伍. Operating the Automated Roughneck

the four position adjustment buttons.

壱六. Operating the Eddy Current Brake

block to its actual stop.

壱七. Pumping Pills

壱八. Perform Flow Check

弐零. Shut-in Procedures

弐壱. Conducting Leak-Off Test

all pressure tests.

and record the volume of any mud lost to the formation.

弐弐. Working in the Derrick and Overhead Operations

(c) closes the elevators.

弐参. Changing Winch Wire

弐四. Changing Out Dead Line Stabilisers

弐伍. Derrick Inspections

the Drilling Programme for requirements.

弐六. Dead Line Anchor Maintenance

弐七. Slipping and Cutting Drilling Line

(1) The Driller sets the drillstring in the slips.

弐八. Reeving on Drilling Line

snake is coming through the crown sheaves.

separate the snake.

弐九. Adjusting and Testing the Crown-O-Matic

参零. The Anti-Collision System (ACS)

(4) Both microprocessors calculate independently, Hook-Position, Speed, Hook- Load

参壱. Nipple Up and Nipple Down BOP

gaskets are used.

(20) Nipple up the hydraulic actuator (Koomey) lines.

and holes on the BOP flange and make up hand-tight.

参弐. Change Out BOP Rams

参参. Changing Valves on BOP

equal number of threads showing on both side of the flange.

参四. Pressure Testing the BOP and the BOP System

the BOP stack begins.

Accumulator operating pressure 3000 psi / 207 bar

(2) Fill up the BOP stack with water.

参伍. Handling of Wellhead Tie-down Bolts

参六. Changing Liners on Mud Pumps

(5) Upon the Driller’s instruction, open the discharge line.

参七. Changing Pistons on Mud Pumps

参八. Changing Valves and Seats on Mud Pumps