MAST & SUBSTRUCTURE

ASSEMBLY: TEMPLATE AND

INSTRUCTION GUIDE

EDITION: 1
RELEASE DATE: February 22, 2016
MAST & SUBSTRUCTURE ASSEMBLY TEMPLATE AND INSTRUCTION GUIDE:
INSTRUCTIONS

INTRODUCTION
The purpose of this resource is to provide a template and instruction guide to CAODC
drilling member companies that is meant to assist in the development of an assembly
instruction manual for the mast and substructure. Upon completion, a company’s mast
and substructure assembly manual should provide a systematic approach for rigging up
the mast and substructure components necessary to the drilling of an oil and gas well.
Additionally, in accordance with Part 14 of the Occupational, Health and Safety
Regulation in British Columbia, the development and implementation of a mast and
substructure assembly manual will help CAODC drilling members further achieve
regulatory compliance regarding the requirement to ensure an approved method of rig
assembly is readily available to any affected workers.
Note: the implementation of a mast and substructure assembly manual is not exclusive
to drilling companies with operations in B.C. All CAODC members are encouraged to
establish similar practices regardless of what province(s) they operate in.
This template and guide is meant to be flexible in application and intended to provide
guidance to users rather than act as a prescriptive solution. The template provided
herein is not exhaustive and should, at every opportunity, be tailored to suit the
individual needs and practices of each company. Additionally:
i. For the purposes of drafting a company specific mast and substructure assembly
instruction manual, the use and adoption of this specific Guideline/template is not
a requirement. Companies that have already established a similar assembly
instruction manual are encouraged to carry on with their current practices and
procedures;
ii. Assembly instruction manuals can either standalone as an internal company
resource, or be incorporated into the company’s health and safety management
system documents.

CAODC Mast & Substructure Assembly Template and Instruction

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Guide: Instructions
 MAST & SUBSTRUCTURE ASSEMBLY TEMPLATE AND INSTRUCTION GUIDE:
INSTRUCTIONS

INSTRUCTIONS
The content of this template and guide is based on the assembly instruction of a teledouble
rig. As such, companies using other rig styles will be required to develop their manuals
accordingly;
The template in this guide has been developed using the format below:

1. TASK
Identify and describe the task required and explain the purpose for completing this
task.

DEFINITIONS
Describe and define the key and/or standard components required to fulfill the
purpose, noting that the explanation and content must be rig specific and
intended for the end user. Whenever possible, include:

i. Equipment specifications;
ii. Load weight definitions;
iii. Maximum load specifications that may apply when hoisting, etc.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

If applicable, list the equipment and/or third party services required to complete
the task.

Note: step-by-step directions must accompany all third party tool, equipment,
machine or device being provided from a supplier to be used at a workplace
by workers.

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

Describe all safety requirements and/or precautions that should be noted during
the completion of this task.

PROCEDURE
Explain the procedure in a step-by-step format. Whenever possible, work with the
original equipment manufacturer (OEM) or internal engineer department to
provide step-by-step instructions.

For all sections and sub-sections, users are encouraged to use images, diagrams and
pictures whenever possible.

CAODC Mast & Substructure Assembly Template and Instruction

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Guide: Instructions
 <COMPANY LOGO>

ASSEMBLY INSTRUCTIONS

for

<RIG NAME and MODEL#>

including

<MAST NAME and MODEL #>

and

<SUBSTRUCTURE NAME and MODEL #>

applicable to

<COMPANY NAME>

<LIST OF APPLICABLE RIGS>

MAST & SUBSTRUCTURE ASSEMBLY INSTRUCTION MANUAL

<COMPANY NAME>

MAST & SUBSTRUCTURE ASSEMBLY INSTRUCTION MANUAL

TABLE OF CONTENT

1. TASK - SET RIG MATTING...................................................................................1

2. TASK – POSITION SUBSTRUCTURE..................................................................2
3. TASK – POSITION AND SQUARE THE PONY SUBSTRUCTURE RISERS.......3
4. TASK – INSTALLATION OF THE MAST ONTO THE DRAWWORKS.................5
5. TASK – INSTALLATION OF THE MAST ONTO THE DRAWWORKS.................7
6. TASK – RAISE THE MAST....................................................................................8
7. TASK – TELESCOPE THE MAST.......................................................................10

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 1: SET THE RIG MATTING

1. TASK - SET RIG MATTING

Explain the purpose for setting the rig matting (i.e. to distribute ground pressure
from the weight of the drilling rig).

1.1 DEFINITIONS
Define or describe the components required for setting the rig matting. For
example:

i. Matting boards - prefabricated ground mats of various lengths used

to cover the lease under the drilling rig.

 Insert a picture or diagram that supports this definition; include

relevant dimensions and weight of each matting board.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

If applicable, list the equipment and/or services required to complete this
task. For example:

i. Is heavy equipment such as trucks, trailers and/or forklifts used

during this task?

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

Describe all safety requirements and/or precautions when setting the rig
matting. For example:

i. If heavy equipment is onsite, does it present a risk or hazard (i.e.

moving machinery)?

 If a risk or hazard is presented, how is it mitigated (e.g. pre-job

safety meetings, use of hand signals etc.)?

PROCEDURE
Explain the step-by-step procedure for setting the rig matting.

i. Insert pictures or diagrams that support each step of the procedure.

For example:

 Arrangement of the rig matting; include relevant dimensions of

each matting section;
ii. Identify what affected areas are load rated and define suitable lifting
points.

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 2: POSITION THE SUBSTRUCTURE

2. TASK – POSITION SUBSTRUCTURE

Explain the purpose and importance of positioning the step-down substructure
onto the riser.

2.

DEFINITIONS
Define or describe the key and/or standard components required to position
the step-down substructure riser onto the riser. For example:

i. Substructure – component that provides support for the mast and

mast loading, and provides the necessary clearance beneath the rig
floor for the blowout preventer. Substructures may also include an
elevated loading skid and framework that side saddles over the
trailer.

 Insert a picture or diagram that supports this definition; include

relevant dimensions and fully dressed substructure weight.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

List the equipment and/or services required to position the substructure. For
example: ramps, tractor trailers or bed trucks?

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

If applicable, describe all safety requirements and/or precautions when
positioning the substructure. For example:

i. If heavy equipment is onsite, does it present a risk or hazard (i.e.

moving machinery)?

 If a risk or hazard is presented, how is it mitigated (e.g. pre-job

safety meetings, use of hand signals etc.)?
o Include how to mitigate the hazard presented by the
open cellar area.

PROCEDURE
Explain the step-by-step procedure for positioning the substructure. Insert
pictures or diagrams that support each step, and when applicable include
all maximum loads that may apply.

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 3: POSITION THE PONY
SUBSTRUCTURE RISERS

Note: not all substructures are equipped with pony substructures. The content of this
Section may vary from contractor to contractor.

3. TASK – POSITION AND SQUARE THE PONY SUBSTRUCTURE RISERS

Explain the purpose and importance for properly positioning the pony
substructure risers, and in a step-by-step procedure, how the riser boxes are
squared with the centre of the well.

3.

DEFINITIONS
Define or describe the key and/or standard components required to position
the pony substructure risers over the well center. For example:

i. Pony substructure riser – box component that may be equipped

with a moving system that includes a walking beam.

 Insert a picture or diagram that supports this definition; include

relevant dimensions and weights of risers (including fully
dressed panels);
ii. Gin pole - an A-frame structure located at the top of the mast that is
used to lift and lower the crown block into position.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

If applicable, list the equipment and/or services required to complete this
task. For example:

i. How are units loaded:

 Skidded using a loader or forklift?

 Handled with cranes or gin pole trucks using pickup rolls?

 Bed loaded?

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

If applicable, describe all safety requirements and/or precautions when
positioning the pony substructure risers. For example:

i. Are stairs removed or lifted prior to transport and positioning;

ii. Does the method of loading the unit present any risks or hazards?

 If so, how are they mitigated?

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 3: POSITION THE PONY
SUBSTRUCTURE RISERS

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 3: POSITION THE PONY
SUBSTRUCTURE RISERS

PROCEDURE

3.1.1 POSITIONING THE PONY SUBSTRUCTURE RISERS

Explain the step-by-step procedure for positioning the pony
substructure risers. Examples to consider:

i. Placement of substructure riser regarding well center. For

example:

 Do the well center markers on the risers need to align

with the well center?

 Does the well center need to be centered between the

risers?
Insert a picture or diagram that supports this step of the procedure.

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 4: INSTALLATION OF THE DRAWWORKS
SKID ONTO THE SUBSTRUCTURE

4. TASK – INSTALLATION OF THE MAST ONTO THE DRAWWORKS

Explain the purpose and importance of installing the mast onto the drawworks
skid.

4.

DEFINITIONS
Define or describe the key and/or standard components required when
installing the mast onto the drawworks skid. For example:

i. Drawworks skid – component that includes the drawworks, mast

raising cylinders, mast bunks and cable spool.
ii. Mast – component that includes top and bottom sections, crown
block, travelling block, reeved drill line and racking board. Masts
may also include upper torque tube and top drive.

iii. Lifting points - designated locations on a mast which are designed

to withstand the rigors of typical field transportation handling
operations. Mast lifting points must be designed for handling the
completely assembled mast and the disassembled mast sections.

For all definition, insert a picture or diagram that supports this definition;
include relevant dimensions and weight of the mast - as is and fully
dressed.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

If applicable, list the equipment and/or services required to install the mast
onto the drawworks skid.

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

Describe all safety requirements and/or precautions when installing the
mast onto the drawworks skid. If applicable, insert a picture or diagram that
supports each safety requirement or precaution. For example:

i. Are any of the components required to be transported separately?

ii. Can hoisting devices sufficiently lift to capacity and move identified
loads?
iii. Are there any precautions when lifting the mast onto a tractor-trailer
(i.e. only lift using lugs provided)?

<Company Name> Mast & Substructure Assembly Instruction

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TELEDOUBLE RIG ASSEMBLY - STEP 4: INSTALLATION OF THE DRAWWORKS
SKID ONTO THE SUBSTRUCTURE

iv. Can assembled sling systems sufficiently reach to a lift

angle of 45 degrees?
v. What fall protection requirements apply (e.g.is the installation of
hand rails required, have tie-off points been noted?);
vi. Are workers aware and knowledgeable of the total drawworks and
mast weight?
vii. Are workers ensuring the right pins have been installed on the mast
and are secure?

 Consider inserting a table that lists the pins used and picture
or diagram of where on the mast these pins are used. For
example:
Item Description Material Qty. Diameter Grip Length
# Mast pin 4340 HTSR 2 3” 5¾“

Note: item # is in reference to location on the picture or

diagram used.

PROCEDURE
Explain the step-by-step procedure for installing the mast onto the
drawworks skid. Insert pictures or diagrams that support each step, and
when applicable include all maximum loads that may apply (i.e. maximum
lifting loads for mast lugs).

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 5: INSTALLATION OF THE MAST AND
DRAWWORKS ONTO THE SUBSTRUCTURE

5. TASK – INSTALLATION OF THE MAST ONTO THE DRAWWORKS

Explain the purpose and importance of installing/removing the assembled mast
and drawworks skid on/from the substructure.

5.

DEFINITIONS
Define or describe the key and/or standard components required when
installing/removing the assembled mast and drawworks skid on/from the
substructure. For example:

i. Assembled mast and drawworks skid – combined assembled

components that include the mast (top and bottom sections, crown
block, travelling block, reeved drill line and racking board) and
drawworks skid (drawworks, mast raising cylinders, mast bunks and
cable spool).

 Insert a picture or diagram that supports this definition; include

relevant dimensions and weight of the assembled mast and
drawworks skid - as is and fully dressed.
ii. Substructure and riser – combined assembled components that
include the substructure and riser.

 Insert a picture or diagram that supports this definition; include

relevant dimensions and weight of the mast - as is and fully
dressed.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

List the equipment and/or services required to complete this task. Explain
why listed equipment and/or services are required (i.e. winch truck required
to pull mast assembly onto the substructure).

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

Describe all safety requirements and/or precautions associated with
completing this task. If applicable, insert a picture or diagram that supports
each safety requirement or precaution. For example:

i. Do winching operations present any risks or hazards?

PROCEDURE

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 5: INSTALLATION OF THE MAST AND
DRAWWORKS ONTO THE SUBSTRUCTURE

Explain the step-by-step procedure for installing the mast onto the
drawworks skid. Insert pictures or diagrams that support each step, and
when applicable include all maximum loads that may apply (i.e. maximum
lifting loads for mast lugs).

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 6: RAISE THE MAST

6. TASK – RAISE THE MAST

Describe the task. For example: raise the mast to a vertical position using mast
raising cylinders.

6.

DEFINITIONS
Define or describe the key and/or standard components associated with
raising the mast. For example:

i. Mast – assembled mast on the substructure.

 Insert a picture or diagram that supports this definition.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

List the equipment and/or services required to complete this task. Explain
why listed equipment and/or services are required (i.e. hydraulic power
unit).

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

Describe all safety requirements and/or precautions associated with
completing this task. If applicable, insert a picture, diagram or sample graph
that supports each safety requirement or precaution. For example:

i. Does the operation and/or monitoring of a hydraulic power unit

present any risks or hazards?
ii. Are there any tie downs that need to be removed prior to the mast
being raised?
iii. Are there cables, lines, hoses etc. that may be affected by the mast
being raised?
iv. Are there any precautions to consider regarding the racking board
wind panels (i.e. should they be folded out prior to raising the mast,
or will they fold out as the mast is being raised)?
v. Are there any precautions that need to be taken if raising cylinders
are being operated for the first time (i.e. checking hydraulic tank
levels)?
vi. Are there any pressure limits that need to be observed/monitored
during each stage that the mast is being raised?

<Company Name> Mast & Substructure Assembly Instruction

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TELEDOUBLE RIG ASSEMBLY - STEP 6: RAISE THE MAST

 Insert a table that summarizes maximum operating pressures

for bore cylinders, and can be used to crosscheck actual
pressures with expected pressures listed in the table. For
example:

Summarization of the Maximum and Design Operating Pressures for x” Bore Cylinders
1st Phase Pressure 2nd Phase Pressure 3rd Phase Pressure
x” Cylinder At At At
At Pump At Pump At Pump
Cylinder Cylinder Cylinder
Maximum Pressure
Design Operating
Pressure – no torque
tube or top drive
Design Operating
Pressure – torque tube
only
Design Operating
Pressure – torque tube
& top drive
Actual pressures for
this rig:

PROCEDURE
Explain the step-by-step procedure for raising the mast. Insert pictures or
diagrams that support each step, and when applicable include all maximum
loads that may apply (i.e. maximum lifting loads for mast lugs).

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 7: TELESCOPE THE MAST

7. TASK – TELESCOPE THE MAST

Explain the purpose and importance of telescoping the mast.

7.

DEFINITIONS
If applicable, define or use an image or picture to describe the key and/or
standard components required when telescoping the mast. For example:

i. Fully functioning drawworks – component on the rig that consists of

a large-diameter steel spool, brakes, a power source and assorted
auxiliary devices. The primary function of the drawworks is to reel
the drill line in and out in a controlled manner.

EQUIPMENT AND/OR THIRD PARTY SERVICES REQUIRED

List the equipment and/or services required to telescope the mast. Explain
why listed equipment and/or services are required (i.e. fully functioning
drawworks).

SAFETY REQUIREMENTS AND/OR PRECAUTIONS

Describe all safety requirements and/or precautions associated with
completing this task. If applicable, insert a picture or diagram that supports
each safety requirement or precaution. For example:

i. Identify the minimum number of drill line wraps required around the
drum before raising/lifting the mast. Briefly explain why there is a
minimum requirement;
ii. Can mast pins cause serious damage if they are not fully retracted
before telescoping the mast?
iii. Are workers competent in operating and monitoring the drawworks
unit?

 Should workers monitor the mast telescoping load? If so,

how? For example:

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY - STEP 7: TELESCOPE THE MAST

Maximum SAFE and Theoretical Mast Raising Loads

Company:
Rig #:
Bridle line diameter:
Bridle line style:

Maximum safe mast raising load: lbs. / daN

Theoretical mast raising load:
Basic mast, block and drill lines: lbs. / daN
With top section torque tube: lbs. / daN
With top drive: lbs. / daN

Actual mast telescoping load: lbs. / daN

 What are the hazards if the actual mast telescoping load

changes?

 Are there any company specific bridle line specifications and

requirements in place?

PROCEDURE
Explain the step-by-step procedure for telescoping the mast. Insert pictures
or diagrams that support each step, and when applicable include all
maximum loads that may apply (i.e. maximum lifting loads for mast lugs).

<Company Name> Mast & Substructure Assembly Instruction

Manual
TELEDOUBLE RIG ASSEMBLY – ADDITIONAL RECOMMENDATIONS

Upon completion of the mast and substructure assembly instruction manual, CAODC
drilling members are encouraged to develop an additional assembly instruction
manual that details the set up and tie in of all additional rig components and auxiliary
systems including fuel, air, electrical, hydraulic, water and steam systems. For
example:

 Mud tanks;

 Mud pump buildings;

 Doghouse/water tank combination buildings;

 Fuel tank/tool house/generator combination buildings:

 Top drive and top drive buildings

 Boilers for winter operation;

 Catwalks and pipe racks;

 Blowout preventers (BOP);

 Degasser tank/manifold;

 Identification of each onsite hammer union and connection type, including size
caliber, quantity and location;

 Lock out/tag out procedures.

<Company Name> Mast & Substructure Assembly Instruction

Manual