Sopa Drilling Rig

For Internal Circulation Only
Oil and Natural Gas Corporation Limited

Equipment Management, Technical Services
Issue : 1 - 2014
STANDARD OPERATING PRACTICES
Table of Contents
1. Preface .................................................................................................................................... 3
2. Introduction .......................................................................................................................... 4
3. Standard Operating Practices – SOPs ........................................................................... 6
3.1 Components ...................................................................................................................... 7

3.2 References ......................................................................................................................... 7
3.3 Common SOP reference ................................................................................................ 7
4. Risk Management ................................................................................................................ 9
5. Drilling Rigs – Summary ................................................................................................. 12
6.1 Diesel Engine .................................................................................................................. 13

6.2 Mud / Slush Pump ......................................................................................................... 17
6.3 Draw Works ..................................................................................................................... 20
6.4 Crown Block .................................................................................................................... 22
6.5 Travelling Block .............................................................................................................. 24
6.6 Hook Assembly ............................................................................................................... 26
6.7 Swivel ................................................................................................................................ 27
6.8 Rotary Table .................................................................................................................... 29
6.9 Top Drive System .......................................................................................................... 31
6.10 Shale Shaker ................................................................................................................ 33
6.11 De-Sander Assembly ................................................................................................. 36
6.12 De-Silter Assembly ..................................................................................................... 38
6.13 Mud Cleaner Assembly .............................................................................................. 40
6.14 Mud Agitator ................................................................................................................. 42
6.15 Air Compressor ............................................................................................................ 44
6.16 Centrifugal Pumps ...................................................................................................... 47
6.17 Hopper Pump & System ............................................................................................ 49
6.18 Allison Transmission................................................................................................... 51
6.19 Eddy Current Brake .................................................................................................... 53
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ONSHORE DRILLING RIG EQUIPMENT
6.20 Synchronous AC Generator...................................................................................... 55

6.21 Electric AC Motor ......................................................................................................... 59
6.22 Electric DC Motor ........................................................................................................ 63
6.23 Pneumatic Winch ......................................................................................................... 67
6.24 Diesel Transfer Pump ................................................................................................. 69
7. Annexures............................................................................................................................ 71
7.1 Norms and Policies Issued by Technical Services ............................................... 71

7.2 OISD references – Relevant for Drilling Rigs ........................................................ 71
7.3 DGMS References – Details of regulations / guidelines .................................... 73
7.4 Central Pollution Control Board................................................................................. 73
7.5 Electrical Related Standards – A Reference .......................................................... 73
7.6 Selected Applicable Standards – Drilling Rig Equipment .................................. 74
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1. Preface
ONGC is a capital intensive organization having Plant and Machinery Assets of more than
Rs.67000 Crores.
Crores ONGC stands as No.1 E&P Company of India with its operation in various
parts of the country and in other countries through OVL. The management of this large
volume of capital asset demands an effective and efficient Equipment Management System
in place. The Equipment Management includes planning, procurement, operation,
maintenance, overhaul, health, performance and finally its reliability, safety and discards of
equipment. A systematic approach to equipment management (Inception to Discard) finally
results in an effective equipment life cycle management.
ONGC a “MAHARATNA” has been managing a large number of equipment at its installation
spread across various parts of India with qualified executives managing operation and
maintenance to a global level. ONGC with its foresight to effectively manage its equipment
set up “Directorate of Equipment Management” in the year 1982 and presently being
referred as “Technical Services” since 2004.
Technical Services as a service provider,

provider is responsible for the effective Equipment Life
Cycle Management by framing norms, policies and guidelines for equipment maintenance &
replacement. Primarily, these include Technical & Energy Audit, spares management, up-
gradation of technical skills, and standardization of specifications, quality assurance
services, failure analysis and promotion of creative and innovative skills.
A step forward with objective to meet global standards, Technical Services is introducing
“Standard Operating Practices” (SOP) to upgrade present equipment management system.
The SOP shall bring a structured approach towards equipment operation & maintenance,
equipment & employee safety and timely action for maintenance and overhaul planning.
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2. Introduction
EQUIPMENT MANAGEMENT was instituted in the year 1982 and has been instrumental in
bringing out approved norms, policies and guidelines for equipment operation, maintenance,
overhaul, replacement and numbers of equipment requirement as stand by for
uninterrupted operation. The equipment management in any organization starts from
purchase equipment to its disposal, the period in between includes its operation &
maintenance. The function in brief is projected by the sequence as under.
ONGC being a large organization with work centres referred as Assets, Basins & Plants,
located across various parts of the country, the function of equipment life cycle
management also becomes part of Work Centres. Technical Services, being a service
provider in the organization, is assigned with role of providing guidelines for primarily
managing equipment life. This function is achieved by different arms of technical services.
As per image above, all the functions are part of Work Centres operating the equipment. At
organization level, the preventive maintenance and overhauling requirement are centralized
through application of SAP Module. The SAP Module has been updated with equipment
preventive maintenance program and overhaul program based on fixed periodicity &
operating hours. The details of spares of equipment (Bill of Material), consumption for
preventive maintenance & overhauling are also part of this module to provide support for
the installations and Work Centres to monitor actions carried out and to be carried out.
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The focus of Technical Services is, therefore, aligned with monitoring function of repairs and
reliability analysis. The details of availability at installations, performance, maintenance
compliance etc. are being monitored by the departmental audits in the form of technical and
energy audits.
Department of Equipment Management, Technical Services, Dehradun has already issued

norms, policies and guidelines and the details are produced below for reference.
1. Capital repair norms for onshore drilling rigs.
2. Equipment replacement life norms for drilling rigs.
3. Equipment Health check-up for Onshore Drilling and work over Rig.
4. Life cycle period of major equipment for LCC (Life cycle cost) based equipment
purchases.
5. Replacement policy for critical equipment.
6. Standby norms for onshore drilling rigs.
7. Norms for Noise and Exhaust emissions for rotating equipment
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3. Standard Operating Practices – SOPs

SOPs
SOPs are written instructions that document a routine or repetitive activity for equipment in
use by an organization. It addresses all requirements to be safely performed as
recommended. For effective equipment management SOPs need to be enforced and also
reviewed periodically.
The abbreviation “SOPs” stands for
Safe Operating Procedures / Practices
Standard Operating Procedures / Practices
SOPs ensure Equipment and personnel safety through compliance with recommended
procedures, guidelines issued for –
1. Equipment installation as recommended by manufactures / suppliers.
2. Equipment start-up checks / steps for safe starting.
3. Equipment Operations including monitoring of operating parameters and taking

corrective action in case of deviations.
4. Preventive maintenance activities as per approved/ recommended schedule.
5. Equipment Overhaul to restore/ maintain equipment health, efficiency, reliability

and performance.
The equipment health, efficiency, reliability, safety and performance depend on its
condition. If equipment is operated within recommended limits of load and operating
parameters, it shall result in higher availability & reliability during its complete lifecycle.
The scope of this manual is to issue “STANDARD OPERATING PRACTICES” for equipment
and personnel safety covering all aspects of equipment lifecycle, from its inception to
disposal.
For all equipment, however big or small, the OEM/ OES issues a manual covering guidelines
and procedures for equipment pre start checks, operation and maintenance. In a single
document, the Safe Operating Practices shall cover all areas of equipment management
including equipment installation, pre-start, operation, preventive maintenance, overhaul,
safety and regulatory requirements.
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3.1
3.1 Components
a. Identification of equipment being used.
b. Identification of its operational, maintenance and overhauling requirements.
c. Engineering control to include work environment, stores and spares management at

installation, compliance to preventive & overhauling program, restrictions and
approvals for deviations
d. Administrative control to include issue of guidelines / norms for equipment

maintenance, overhaul, replacement and requirement.
e. Safe practices to include use of PPE as per field operations / requirements.
3.2
3.2 References
a. ONGC Norms, Policies and Guidelines circulated by Technical Services or any other
authority /agency.
b. Original Equipment Manufacturer (OEM) manual / guidelines of operation,

maintenance & overhauling and safety requirement during equipment maintenance.
c. IADC Safety Manual for drilling operations.
d. OISD – Oil Industry Safety Directorate (Safety Standards)
e. DGMS – Directorate General of Mines and Safety Regulations.
f. OMR – Oil Mines Regulations.
3.3
3.3 Common SOP reference
ONGC operations are different from a manufacturing and assembly lines. In case of On-
shore drilling rigs, the rig is dismantled into selective assemblies and transported from one
location to another to resume drilling process at new location after assembly. Further all the
equipment are not always in operation as additional equipment are installed as standby to
sustain smooth operations. It calls for special care and action indicated as under.
a. The installation and start-up checks indicated for all the drilling equipment shall be
complied for resuming drilling operation with safety and desired performance.
b. The standby equipment shall be operated at least once in 15 days for sufficient
duration to stabilize its operating parameters and its operating parameters be
recorded. It ensures satisfactory start-up of equipment whenever required and
timely action needed in case of deviations in its operating parameters.
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c. The operation and maintenance activities of all ONGC Installations including Drilling
Rigs shall comply with statutory regulations / guidelines issued by central, state
government and regulatory bodies. In some cases the prevailing international
standards are also applicable for equipment operation & maintenance. The
references to these are indicated in approved norms / policies / guidelines issued by
Technical Services and reference to latest statutory requirements issued by OISD,
DGMS and other agencies are added as annexure and shall be reviewed for
compliance as applicable.
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4. Risk Management
ONGC has rolled out a structured risk management process across the organization. All
SBUs (Assets, Basins, Plants, Institutes and Select Services) are aware of the risk
management process. Risk owners, risk controllers and risk coordinators have already been
nominated at all SBUs and risk register is being filled up on quarterly basis.
The risk identification, categorization, assessment and mitigation plan across the life cycle
of all equipment has to be worked out for every installation, i.e. drilling rig/ workover rig in
association with identified stakeholders. The risks so identified must then be maintained as
a risk register for "Onshore drilling rig/ work over rig equipment".
The risk can arise from:
OIL & NATURAL GAS CORPORATION LIMITED
RISK REGISTER - SERVICES
Work Centre Asset, Basins
Risk Description Equipment failure
Root causes Mitigating Factors Remarks
Wrong Selection of The desired rating, capacity and application should

equipment be as per standards API/ASTM/BIS.
Statutory requirements Equipment should meet all prevailing standards and

not met regulations.
Manufacturer should provide complete specifications,

Improper equipment
instructions for installation; start-up, maintenance
specification and
and storage for compliance by users for efficient and
operating instructions
safe equipment operation.
Equipment shall be installed and located as per

Improper equipment
recommended instructions for space above and
installation
around equipment for maintenance activities.
Inadequate preventive Preventive maintenance will be carried out as per

maintenance manufacturer’s recommendation.
Delayed Equipment Overhauling will be carried out as per manufacturer’s

Overhaul recommendation.
Inadequate Equipment Protection to rotating parts and hot parts of the

Protection equipment.
All safety requirements as per equipment design, its

Failure to comply with
checking, calibration and testing and as
Equipment Safety
recommended by OEM should be strictly adhered to.
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Risk management, just like safety, requires active participation of employees. The above
table provides some known risks for which mitigating factors have been mentioned. The
mitigating factors should be strictly adhered to. Risk is a dynamic process and every
employee is requested to participate in this process and any risk perception may please be
brought to the notice of Head – Maintenance / HDS/ HWS. The block diagram shown below
will be the communication protocol to be followed in the event of risk being perceived by the
employee:
RISK
RISK PROTOCOL (COMMUNICATION):
CHIEF RISK OFFICER
HEAD – SBU (AM/BM/PH/HOI) RISK CONTROLLER
HEAD – MAINTENANCE / DRIL SERV/ RISK OWNER

WELL SERV
ASSET / BASIN (SBU) RISK ORIGIN
CHIEF RISK OFFICER:

OFFICER COMPANY SECRETARY, NEW DELHI
HEAD - SBU:
SBU UNIT LEVEL
HEAD – MAINTENANCE (RISK OWNER):

OWNER) UNIT LEVEL
RISK MANAGEMENT PLAN:
Action plan for the perceived risk reported will be

RISK OWNER formulated by the risk owner. He will categorize and
validate risk and state the risk in the GRC module of SAP.
Monitoring of action plan and mitigating factors.

RISK CONTROLLER He will report the risk, root causes and mitigating factors
to the CRO for updating of risk register of ONGC.
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The risk to equipment operation and maintenance can be minimized if parameters defined in
SOP are complied. The SOP document is issued so that the recommended practices of OEM,
OES, norms and policies of ONGC, statutory requirements and OISD guidelines are followed.
SOPs are a very vital part of risk management process where in many of the O & M
parameters are standardized and provide a uniform O & M template to personnel working in
field and offices across the organization. Work performed in line with the indicated SOP for
respective equipment shall result in not only an effective equipment life cycle management
but also minimize the risk of equipment failure.
Non-compliance to indicated SOP may result in:
1. Time and Cost Over-run – The planned maintenance program by manufacturers are
indicated in the equipment manuals depending on operating hours, rate of component
wear and change in component performance due to variable thermal cycles. The action
taken and components replaced are to keep the equipment performance to its designed
level. Any delay in attending to the indicated maintenance activity may result in
increased cost of repairs and longer stoppage than planned. The risk may lead to
decreased output, performance and overall installation process.
2. Equipment Failure – There may be unscheduled equipment stoppages, breakdowns that

may force decreased output or even shut down of complete installation.
3. Failure to deliver services – Health of the equipment is important to meet its designed
capacity. The capacity of equipment decreases if planned maintenance and overhauls
are not carried out. Equipment may not be efficient in absence of compliance to planned
maintenance process.
4. Failure to meet expected quality-The recommended inspections, maintenance schedules

should be strictly adhered to with original spares. Schedule overruns / incomplete
maintenance with non-recommended spares/lubes will affect the reliability and
availability of equipment.
5. Obsolescence – The document is primarily focussed on equipment life cycle

management. If equipment has completed its life, it may not be feasible to carry out
expected maintenance activities if OEM/ market support for spares and services are not
available. In such case, the equipment shall be planned for replacement at the earliest
opportunity.
SOP provides a standard template for practices to be followed, to establish a robust

Operation and Maintenance of rig equipment. Compliance to SOP shall result in enhanced
equipment reliability, efficiency, output and overall performance and shall prevent any
operational complications in operation. Non-compliance can in turn cause increased cost of
operations and reduced profitability to the company.
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5. Drilling Rigs – Summary

The details of onshore drilling rigs are tabulated below, indicating make / type / series with
nos. in operation for reference.
Sl. Make /Type Series & Id Number Nos.

No.
1 ARMCO 1320-UE-1 & 2 02
2 BHEL 450-M1 01
3 BHEL 750-M1 & 750-M2 02
4 BHEL 900-M1 01
5 BRANHAM BI-1500-1 01
6 BRANHAM BI-2000-1 & 2 02
7 BHEL-1400 E-1400-1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 13, 18

14, 16, 17, 19, 21, 23 & 24.
8 BHEL-2000 E-2000-1, 3, 4, 5, 6, 7, 8 & 9 08
9 BHEL-3000 E-3000-1 01
10 BHEL-760 E-760-1, 3, 5, 7, 8, 9, 10, 11, 12, 13, 14, 16

15, 16, 17, 18 & M.
11 F-3050 F-3050-2 01
12 ROMANIAN-4900 F-4900-1 01
13 ROMANIAN-6100 F-6100-1, 2 & 3. 03
14 CARDWELL-700 M1, M2, M4, M5, M6, M7, M8, M9 & M10. 09
Total 66
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6.1 Diesel Engine

Diesel Engine is used as prime-mover for various applications such as generation of electric
power, operating other equipment directly coupled to engine. As per requirement, engines
of different capacities, types and make are being used in organization. In drilling rig,
engines are used as power packs to generate electric power for operation of all equipment
at rig. There are 3 or 4 nos. of power packs at one rig depending upon type of the rig. A
power pack is complete with engine, alternator, exhaust muffler and associated auxiliaries
and is installed as single unit on an enclosed sturdy oil field skid for ease of transport and
reconnection.
The Diesel Engine basics includes various systems such as starting system, air intake
system, fuel system, lube oil system, cooling system and safety system.
INSTALLATION
1. Skid Mounted along with driven equipment and secured with recommended size of
hardware.
2. Skid mounted with vibration mounts for smaller applications.
3. Permanently secured with grouted hardware for a fixed location.
START UP CHECKS
Start-up checks are carried out to verify that engine can be operated without any problem,
it may include –
1. Lube oil level and/or draining of water from water separator (If provided).
2. Water / coolant level in radiator system.
3. Status / working of cooling system in case of heat-exchanger system.
4. Fuel level in case of day tank system.
5. Leakages from fuel, lube oil, air & cooling water piping and cylinder head.
6. Belt tension for radiator pulley
7. Movement of throttle linkage
8. Condition and indication status for fuel, oil and & intake filters and fuel tank
breather.
9. Operating status of engine safety system.
10. Operation of pre-lube & pre-fuel pumps to indicated pressure for distribution.
11. Air starting system lubrication.

12. Hydraulic start system – level of hydraulic oil.
13. Electric start system (If available) – condition of battery, terminals and its charging
indicators.
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OPERATION
Engine should be run at idle rpm to warm up and to allow its operating parameters to
stabilize. The engine shall be subjected to its rated load only after it attains stabilized
operating parameters. The parameters as per its display panel be recorded in log book.
These parameters include;
1. Lube oil pressure.
2. Lube oil temperature.
3. Fuel pressure.
4. Cooling water / coolant circulation pressure.
5. Cooling water / coolant temperature.
6. Engine RPM.
7. Engine run hour meter.
8. Differential pressure gauge of air intake filter.
9. Differential pressure gauge or indicators for lube oil filter (If available).
10. Engine is provided with emergency shutdown system to manually stop the engine in
case of emergencies. In general, for stopping an engine, it shall be allowed to
operate for some duration at idle rpm so that its temperature parameters stabilize
by circulation of oil / coolant across engine system. It helps prevent formation of hot
spots that may cause damage to engine.
PREVENTIVE MAINTENANCE
The preventive maintenance may include daily, weekly, fortnightly, monthly, quarterly, half-
yearly and annual program. The activities to be carried out are indicated by the
manufacturer in its operation and maintenance manual. It may be –
1. Engine servicing that include lube oil replacement, filters (lube oil & fuel)
replacement, cleaning or replacement of air intake filters, topping up or changing of
cooling system with de-mineralized water and inhibitors (If recommended) ,
cleaning of engine radiators, checking operation of thermostatic valves in cooling
system, checking/calibration of switches for lube oil, cooling water, air system and
over speed.
2. Run-hour based –
a. Lube oil analysis including wear debris analysis.
b. Tappet clearance checking and adjustment to recommended clearance.
c. Measurement of turbocharger axial movement.
d. Calibration of fuel injectors
e. Crankcase inspection for any abnormality or looseness.
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OVERHAUL
Engine is subjected to deterioration of its components during operation and need to be

replaced at scheduled interval. Engine health and performance can be restored by overhauls
that depend on operating hours. It may be –
1. Top Overhaul – It may include replacement of cylinder head components such as
valves, valve inserts, piston rings, cleaning of radiator/Heat exchanger, testing and
calibration of injectors etc.
2. Average Overhaul – It includes top overhaul and additionally piston, cylinder heads,
bearing and other components of cooling water pump, lube oil pump and inspection
of bearings.
3. Capital Overhaul – It includes average overhaul and additionally replacement of all

bearings, inspection of crankshaft & resize of bearing to next size if required,
cleaning / replacement of heat-exchangers, replacement of injectors, replacement of
lube oil and water pump components.
SAFETY SYSTEM
Safety system on an engine is provided to caution operation to take corrective measures in

case of deviation in its operating parameters and to protect engine from damage & failure.
The safety system is provided with alarm system and engine shut down system. The
parameters monitored and included in system are -
1. Lube oil: - Low pressure alarm & shut down.
2. Lube oil temperature: - High temperature Alarm & shut down.

3. Cooling system pressure: - Alarm & shut down.
4. Cooling system temperature: - High temperature Alarm & shut down.

5. Engine high Vibration alarm.
6. Lube oil low level alarm.

7. Engine over speed alarm & shut down.
8. To carry out any maintenance activity the work permit shall always be taken as per
organization policy / guidelines.
ENVIRONMENT & EMISSION CONTROL
1. Used lube oil, filters and other components if not disposed properly may damage the
environment. The guideline has been provided to return these items to designated
locations (Stores) for further disposal action. (Refer guidelines for storage, Handling
and Disposal of Lubricants issued by Technical service).
2. Similarly measurement of engine exhaust is to be carried out for complete burning

of fuel and to monitor contents of CO, CO2, SO2, NO2 etc. The central pollution
control board (CPCB) has issued guidelines for emission parameters depending on
the engine rating, location and application. Such guidelines if applicable shall be
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followed. (Refer guideline for Noise and Exhaust emissions for rotating equipment
issued by Technical service).
3. In case of deviations from prescribed limits of exhaust, corrective maintenance

actions shall be taken to correct the emission of gases.
STATUTORY / REGULATORY PROVISIONS
Any guidelines, norms issued for safe operation, maintenance by OEM and/ or regulatory
agencies shall be followed. Reference to some of the guidelines / regulations issued by
statutory agencies is enclosed as annexure.
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6.2 Mud / Slush Pump

The Standard Operating Practices covers all the Mud / Slush Pumps irrespective of make,
size and their application. These are reciprocating high pressure pumps used for circulation
of fluid called mud during oil well drilling operation. No drilling operation can continue in
absence of these pumps. The pumps is divided among drive system, power end, fluid end,
lubrication system, cooling system and dampner system,
INSTALLATION
Mud / Slush Pumps for drilling rigs of different make and capacity are normally skid
mounted along with drive motors / engine, properly aligned and secured with recommended
size of hardware along with its auxiliaries.
START UP CHECKS
Start-up checks are carried out to verify that pump can be operated without any problem, it
may include –
1. Lube oil level (Crankcase).

2. Oil pressure, temperature, pumps suction & discharge pressure.
3. Condition of safety/ pressure relief valve.

4. Nitrogen charging of its discharge dampener as per recommendation of OEM.
5. Nitrogen charging / pre-charging of its suction side dampener, as per

recommendation of OEM, where-ever applicable.
6. Suction and discharge connections and if flexible hoses are used, securing hoses
with metal chains to prevent injury to working personnel.
7. To ensure that suction and discharge line valves are in open status, if provided.
OPERATION
Pump operation is critical for smooth drilling operation. Mud flow volume and pressure are
controlled by the drillers regulating its RPM / strokes. Pump shall be started at low rpm and
gradually increased to desired spm to establish desired mud flow for safe drilling /
circulation requirement. The operating parameters of the pump shall be recorded in log
book. These parameters include –
1. Drive motor current.
2. Lube oil pressure/pressure across the filter.

3. Cooling water pressure, if provided.
4. Discharge pressure of pump.
5. RPM / Nos. of pump Strokes.
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6. Mud pump is normally stopped from the driller controls. Its lube oil pump / cooling
water pump, is then stopped manually or in auto-mode with recommended time
delay to circulate and stabilize temperature across bearings.
7. If mud pump is to be stopped for longer duration, its fluid end shall be opened and
flushed with water to prevent settling of mud in compartment.
MAINTENANCE
In normal operation of pump, regular maintenance activity is check and inspection of its
fluid end for smooth functioning of valves and to replace consumables as required, changing
the piston and liners to meet operational requirements. Other activities to be carried out
may be –
1. Cleaning of fluid end compartments, cleaning of sludge chamber to remove

deposited mud.
2. Inspection, replacement of dampner element and nitrogen charging of dampener as
required.
3. Checking & recording cross head, cross head pin, main bearing, crank pin bearing,
and pinion shaft bearing clearances.
4. Replacement of lube oil and its filters at scheduled interval.
5. Inspection and cleaning of magnetic filter.
6. Cleaning of heat-exchanger provided for lube oil cooling.
7. Inspection of oil distribution network for its distribution at provided locations.
8. Checking of gear backlash and its loading surface for cavities and damage.
9. Checking of gear and / or chain & sprockets for wear in drive system.
OVERHAUL
Mud / Slush Pump overhaul is carried out to replace its worn out components. The overhaul
may include replacement of bearings, shafts and gears as per its condition and damage.
Generally the overhaul is based on run hours or as per norms / policies issued by Technical
Services.
SAFETY SYSTEM
Safe operation of mud pump is as important as the safe drilling operation of an oil-well. The
safety includes –
1. Operating pump at desired RPM / within recommended operating pressure.
2. Maintaining dampener performance by timely inspection and preventive

maintenance.
3. Securing discharge hose connections with metallic chain / wire to prevent injury in
case of hose failure.
4. Scheduled check and calibration of pump discharge pressure safety valve.
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5. Any other safety features provided at the pump.
ENVIRONMENT CONTROL
The consumables / used components shall be disposed at designated places only or

returned to stores for disposal as per approved guidelines / regulatory requirements.
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6.3 Draw Works

The Standard Operating Practices covers all sizes of Draw Works used for different make
and capacity of drilling rigs.
INSTALLATION
Draw Works is installed at derrick floor of a drilling rig. It is a major equipment of hoisting
system. Correct positioning the draw works at beams of the derrick floor and using correct
size of hardware to secure in position shall be ensured. The control system is pneumatic
hence correct size and condition of air connections shall be ensured while installation.
Correct direction of rotation of drive motors and cooling water pump along with connections
shall be ensured .Lube oil pump direction of rotation and exact pressure & spray of
lubrication ( As recommended by OEM ) of chains shall be ensured.
The wire rope shall be of correct size, configuration and load rating. Wire rope test
certificate shall be checked and record maintained.
START UP CHECKS
Draw works bearings are grease/oil lubricated and sprocket/chains are oil lubricated. Water
cooling system is provided for brake cooling as well cooling of eddy current brake. It shall
be ensured that the lube oil and cooling water pumps are in operation. The bearing shall be
greased at recommended intervals.
OPERATION
Draw Works is a primary unit for operation of all the hoisting equipment. The operational
control is by operation of drive motors at different RPM, application of pneumatic clutches,
manual brake, disc brake and eddy current brake as and when required and controlling the
movement and function of all hoisting and drilling equipment. Reeving of wire rope shall be
in correct order and provision made for greasing of wire rope shall also be checked and
greased filled. Any mal-function in operation shall be attended at priority for smooth drilling
operation as well rig safety.
Draw-works is stopped from the driller controls. Its lube oil pump / cooling system, is then
stopped manually or in auto-mode with time delay to circulate and stabilize temperature
across bearings.
In normal operation of Draw Works, regular maintenance activity is -
1. Inspection, adjustment and replacement of brake, rim, band, pin and clutch shoes.
2. Check for corrosion on inside of brake band.
3. Inspection for proper water circulation for brake drum and adjustment of various
linkages.
4. Inspection, cleaning and servicing of pneumatic valves.
5. Greasing of bearings at scheduled interval.
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6. Replacement of lube oil.
7. Inspection of sprocket & chains for wear, damage and replacement.

8. Inspection and replacement of air & water line hoses.
9. Check and tighten all the foundation bolts.
10. Inspection of wire rope for greasing and deformity/looseness in wire strands,
11. Any abnormal sound in operation of draw works.
OVERHAUL
Overhaul is carried out to maintain equipment health and performance during its life cycle
and is carried out to replace its worn out components. It may include replacement of
bearings, shafts, chains, sprockets, components of brake and clutch assemblies depending
on their condition and damage. Generally the overhaul is based on run hours or as per
norms / policies issued by Technical Services.
SAFETY SYSTEM
Safe operation of draw works is as important as the safe drilling operation of an oil-well.
The safety includes –
1. Operating within specified load rating.
2. Timely inspection and adjustment of brake, clutch assemblies & Equalizer beam.
3. Inspection and adjustment of Crown O-Matic System or any other system provided
by Manufacturer.
4. Replacement of wire rope as per usage / ton-mile indicator guidelines.
5. Wire rope used for draw works shall be of correct size and configuration.
6. Wire ropes / manila ropes used for other applications such as material handling,
connection / de-connection of string assembly using cathead system shall be of
recommended size and shall be replaced if found damaged.
7. Any other safety features provided / recommended for draw works.
ENVIRONMENT CONTROL
CONTROL
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6.4 Crown Block

As the name specifies, the crown block is installed at top most end of rig mast structure
and is part of hoisting system. Wire rope from draw works is routed through crown block
pulleys and the complete string weight is supported on mast through crown block.
INSTALLATION
Crown block is installed at the top end of mast structure. The position of fast pulley shall be
in line with draw works wire rope position. Since the equipment cannot be repaired at its
location, the health of equipment shall be ensured at the time of installation.
START UP CHECKS
1. Greasing of pulley bearings is the top most priority at start up.
2. Wear of Sheaves be checked by go/no go gauge to get recommended life of rope.
OPERATION
The crown block is not provided with any driving equipment as it is one of hoisting
equipment and operated by draw works only.
The preventive maintenance activities are –

1. Periodic greasing of bearings as per schedule.
2. Checking of pulley profile for wear as uneven profile may damage the wire rope.
3. Checking for wear, damage and misalignment.
4. Block shall be free of projecting bolts, nuts, pins or parts.
5. Interchanging pulleys (fast end to dead end) for ensuring maximum life of sheaves
at intervals as recommended by OEM
OVERHAUL
Overhauling is replacement of pulleys and bearings; it may be depending on condition /

operating hours as per OEM recommendations or norms / guidelines issued by Technical
Services.
SAFETY
Crown block is provided with safety brackets at pulleys to prevent bumping of wire rope. It
shall be properly secured at the time of installation.
To carry out any maintenance activity the work permit shall always be taken as per
ENVIRONMENT CONTROL

22
23
6.5 Travelling Block

As the name specifies, the travelling block, a part of hoisting system, is a moving block to
lift up and lower down the drill string assembly through wire ropes. Wire rope from draw
works is routed through clown block pulleys to the travelling block pulleys and the block is
connected to further string assembly equipment.
INSTALLATION
INSTALLATION
Travelling block is not rigidly installed and is one of the moving hoisting equipment. Since
the equipment cannot be repaired at its location, the health of equipment shall be ensured
at the time of installation.
START UP CHECKS
Greasing of pulley bearings is the top most priority at start up.
OPERATION
The travelling block is not provided with any driving equipment as it is one of hoisting
equipment and operated by draw works only.
1. Periodic greasing of bearings as per schedule.
2. Checking of pulley profile for wear.
4. Block shall be free of projecting bolts, nuts, pins or parts
5. Interchanging pulleys (fast end to dead end) for ensuring maximum life of sheaves
at intervals as recommended by OEM
OVERHAUL
Overhauling is replacement of pulleys and bearings; it may be depending on condition /
operating hours as per OEM recommendations or norms / guidelines issued by Technical
Services.
SAFETY
Travelling block is provided with safety guard at pulleys to prevent bumping of wire rope,
spillage of wire rope grease & loose particles and safety of persons in case of wire rope
damage. It shall be properly secured at the time of installation.
ENVIRONMENT CONTROL
24

25
6.6 Hook Assembly

As the name specifies, the hook is connected to travelling block and is an equipment to
provide flexibility of different connections for string assembly as required during drilling
operation and to compensate the sudden loading of components. It is a part of hoisting
system.
INSTALLATION
Hook is not rigidly installed and is one of the moving hoisting equipment. Since the
equipment cannot be repaired at its location, the health of equipment shall be ensured at
the time of installation.
START UP CHECKS
Replacement of lube oil of appropriate grade and greasing of its moving joints / connections
shall be carried out before start up at new location.
OPERATION
The hook is not provided with any driving equipment as it is one of hoisting equipment and
is used for providing connections between travelling block and string assembly.
1. Periodic replacement/refilling of lube oil as per schedule.
3. Hook shall be free of projecting bolts, nuts, pins or parts.
4. Greasing of hook hinge / moving connections.
OVERHAUL
Overhauling is replacement of bearings and other components as required. It may be
depending on condition / operating hours as per OEM recommendations or norms /
guidelines issued by Technical Services.
SAFETY
Hook is provided with lock system to prevent opening of hook jaws during operation. It shall
be ensured that jaws are locked after hooking up swivel, top drive system or elevator
assembly.
ENVIRONMENT CONTROL
26
6.7 Swivel
The swivel is connected to hook. It facilitates rotation of string assembly during drilling
operation. The high pressure hose to circulate mud is also connected through the swivel. It
is a part of hoisting system.
INSTALLATION
Swivel is not rigidly installed and is one of the moving hoisting systems. Since the
equipment cannot be repaired at its location, the health of equipment shall be ensured at
the time of installation. It is stacked at derrick floor after connection with mud pump hose
and Kelley and is connected to hook as required for carrying out drilling of oil well.
START UP CHECKS
Replacement of lube oil of appropriate grade and greasing of its moving joints / connections
shall be carried out before start up at new location. The wash pipe assembly provided in
swivel to support mud connection and to allow rotation without any mud leakage shall be
checked/ greased and components replaced before start up. The condition of oil seals at
bottom & top should also be checked.
OPERATION
The swivel is not provided with any driving equipment as it is one of hoisting equipment and
is used for providing rotation support and mud flow support of drill string assembly.
1. Periodic replacement of lube oil as per schedule.
2. Greasing of oil seals / moving connections.
3. Check wash pipe integrity for swivel.
4. Greasing of wash pipe seal / packing assembly.
5. Replacement of wash pipe assembly and its seal assembly.
OVERHAUL

27
SAFETY
Swivel is connected with mud pump high pressure hose connections and the hose is secured
through its length by chain to swivel to prevent injury in case of hose failure. It shall be
properly secured at the time of installation. Swivel is used during drilling operation and is
stacked at derrick floor and care shall be taken while stacking or reconnecting to the drill
string assembly.
ENVIRONMENT
ENVIRONMENT CONTROL

28
6.8 Rotary Table

The rotary table is equipment, installed at derrick floor and powers drill string assembly for
rotation to carry out oil well drill process. Various systems exist such as –
1. Rotary table driven by draw works through chain and sprocket system.
2. Rotary table driven by electric motor and being named as independent rotary drive
system.
INSTALLATION
Rotary table is rigidly installed at derrick floor beams and is connected to draw works by
chain and sprocket or directly to an electric motor. Since the equipment cannot be repaired
at its location, the health of equipment shall be ensured at the time of installation.
START UP CHECKS
Replacement of lube oil of appropriate grade and greasing of bearings (if provision exists)
shall be carried out before start up at new location. The rotary lock system to prevent
reverse rotation shall be checked for its effectiveness and rectified / replaced if required.
OPERATION
The rotary table is used to provide rotating movement to drill string assembly and facilitates
lowering / lifting up through adaptors / accessories. In case of power from draw works, the
rotation speed is controlled through draw works motors and in case of independent drive
system the rotation speed is controlled by varying motor revolutions.
1. Periodic replacement of lube oil as per schedule.

2. Greasing of bearings as per the recommendations.
3. Inspection for any looseness of rotary table installation system and corrective
action.
4. Periodic top up / replacement of lube oil for chain & sprocket system for its power.
5. Periodic replacement of lube oil of gear box provided in independent drive system.
6. Periodic inspection of rotary drive clutch in case of drive by draw works.

7. Repair and replacement of components of rotary table drive clutch assembly.
8. Replacement / repair of rotary table lock assembly.

9. Cleaning to remove mud splashes.
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OVERHAUL

SAFETY
The rotary table is provided with lock system to prevent reverse rotation. It is to prevent
opening of string assembly connections and safety of well in emergency situations. The
condition & performance of lock system shall always be checked and kept in working
condition.
ENVIRONMENT CONTROL

30
6.9 Top Drive System

The top drive system is in use at some of the drilling rigs and is equipment that replaces
swivel, rotary table and tooling required for string connections. It is connected to hook and
is used for drilling operation, connection & de-connections of string assembly. The control
system is combination of electrical, pneumatic and hydraulic and depends on type of
operation to be carried out.
INSTALLATION
The top drive system is connected with mud pump hose (properly secured with chains). The
connection shall be properly made to prevent any leakage and looseness during drilling
operation. Further for operation of top drive, the system is connected with power cables,
control cables, air line connections and high pressure hydraulic connections. These
connections are flexible and hence shall be secured and routed correctly with allowable
length required for movement during operation.
START UP CHECKS
Replacement of lube oil of appropriate grade, oil filter and greasing of bearings (if provision
exists), replacement of oil used for hydraulic controls & its filters, condition of electrical,
instrument & control cables, hydraulic hoses, pneumatic hoses installed for top drive
system, shall be carried out at new location before start up.
OPERATION
The top drive system is used during drilling operation and desired actions are controlled by
driller from driller’s console. The make-up / break out string pipe connection, rotating
string assembly at desired RPM is controlled using top drive system.

1. Periodic replacement of lube oil and filters as per schedule in main equipment.
2. Greasing of bearings if provision exist.

3. Periodic top up / replacement of hydraulic oil and filters used for other operations.
4. Inspection of electrical, instrument & control cables for deterioration / damage.
5. Inspection of hydraulic hoses and pneumatic hoses for leakages and reliability of
connections.
OVERHAUL

31
SAFETY
Top drive is connected with mud pump high pressure hose connections and the hose is
secured through its length by chain to prevent injury in case of hose failure. It shall be
properly secured at the time of installation. Correct size, capacity and rating of power
cables, control cables, hydraulic hoses and pneumatic hoses shall ensure operation safety
and prevent operational contingencies.
ENVIRONMENT CONTROL

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6.10 Shale Shaker

The shake shaker is an equipment of mud system and is used as a primary unit for
separation of solids (drilled formation cuttings). The mud circulated during drilling has to lift
up the cuttings of formation and bring it to surface and cutting is separated by shall shaker
so that mud can be reused. These cuttings are also used for study and analysis of formation
structure. The outline of the circulated mud is connected to shale shaker.
INSTALLATION
The shake shaker is installed at mud tank and is connected to the mud circulation line
coming out from the well. The connections shall be properly secured to prevent leakages
and shale shaker levelled for even distribution of mud.
START UP CHECKS
Shale shaker is used during drilling operation and parameters to be checked are –
1. Direction of rotation of vibrator motors.

2. Size of screen & its correct installation.
3. Angle of screen/deck slope.
4. Adjustment and settings of screen & vibrating elements.
5. Lubrication & greasing if required.
OPERATION
During operation of shale shaker the cleanliness and distributed flow of mud is to be
monitored for its performance. Inspection shall be carried out for any damage to screen,
adjustment of vibrating elements (if required) and tightness of hardware. There are
different make and models of shale shakers presently in application at drilling rigs. Some of
the operational requirements are summarized for additional reference as under.
1. Shakers should be operated with screens that will remove the maximum amount
of drill solids without excessively wet cuttings discharge or loss of whole mud
over the shakers.
2. Operate shakers at the lowest deck angle that can be run to maintain fluid coverage
over the screening surface of 50 % to 70% without loss of whole mud.
3. Check screen tension at least once a tour .
4. When circulation is interrupted for connections or surveys, wash screens with water
(or base oil) and inspect the screens.
5. A high pressure washer is more effective for cleaning screens and uses less fluid
compared to use of a rig hose.
6. Periodically probe the possum belly for build-up solids, and use a sparge pipe or rig
vac to evacuate the solids. Dumping the possum belly into the sump is bad practice
because solids will end up in the sand trap or active system.
33
7. In the event of sand blinding, try installing multi-layer screens of a finer mesh.
8. If poor solids conveyance is caused by sticky clays, try a finer screen to attempt to
reduce friction between solids and screen.
9. Check condition of decking rubbers every time screens are changed and replace any
that are worn or missing. Deck rubber condition is the most likely cause of poor
screen life. (Note that National Oil well mud cleaners have screen gaskets instead of
deck rubbers. This means that the deck rubbers are effectively replaced every time
screens are replaced.)
10. Keep fume hoods in place except when changing screens.
11. Avoid routine use of spray bars or excessive wash water to clean screens.
12. Never wash screens used for SBM or OBM with water.
13. Availability of Silicone adhesive is very important to repair torn shale shaker
screens which eventually will save Forex and increase life of screens
14. If tandem shakers are in use, always run finer mesh screen on the lower deck.
15. Never bypass shakers to prevent mud loss, change the deck angle or install coarser
screens to handle the flow.
1. Cleaning of unit when the shale shaker is not in operation.

2. Inspection and replacement of screens as per desired size and screen aperture (For
blindness or being plugged.
3. Checking of T bolt for screen looseness
4. Inspection/Checking of tension rail & channel rubber of screen for any damage.
5. Inspection and adjustment of vibrating elements such as – air bellows, springs,

hydraulic assemblies.
6. Inspection of Bypass valve and discharge gate for blockage due to dried mud.
7. Greasing of bearings or lube oil replacement as per provision exist. (Attention shall
be paid to the type if lubrication and its schedule for canister style vibrator motors).
8. Use recommended grease only for greasing of vibrator motors. Care shall be taken
not to over grease motor bearings.
9. Replace deck rubbers if wear, buckling or other damage is noticed.
OVERHAUL

34
SAFETY
Safety of shale shaker is compliance of recommended operating & maintenance practices

and inspection of its mounting on mud tank.
ENVIRONMENT CONTROL
35
6.11 De-
De-Sander Assembly
The de-sander assembly consists of set of hydro-cones and a centrifugal pump and is
equipment of mud system. It is used as secondary unit for separation of solids from the
mud that has not been separated by shale shaker. De-sanders are used in initial phase of
drilling only when coarser cuttings are mixed with mud. The principal of separation is
creating hydro-cyclone effect in cones to remove heavy particles that separate and exit from
bottom of cyclone and mud returned to tank from the top of cone assembly. The volume of
flow of mud and its pressure is important for effective separation of solids. Use of De-sander
should be avoided in case of Barites or a polymer is added in drilling mud or oil based
drilling mud is used.
INSTALLATION
De-sander assembly consist of a centrifugal pump and minimum two or more cones and it is
installed at mud tank next to shale shaker. The suction of the pump is from the mud tank
compartment of shale shaker discharge. The output is connected to a second compartment
in mud tank for further separation process.
START UP CHECKS
De-sander is operated during drilling operation and the mud flow from the centrifugal
pumps is set at desired level as per de-sander cone requirement and mud tank level. The
parameters to be checked are -
1. Direction of rotation of centrifugal pump.
2. Condition of hydro cones. (rubber cone is installed in metal cage that shall be
replaced if damage found to prevent damage to the metal body).
3. Pipe connection to prevent leakages.
OPERATION
1. During operation of de-sander, the flow of mud is to be regulated for effective
separation. The discharge from hydra cones is controlled by adjusting cone
discharge opening. The separated solids shall discharge from cone bottom as spray
and shall not consist of mud. Inspection of discharge particles is carried out for
adjustment and prevents any mud loss. Operate the de-sander with a spray
discharge rather than a rope discharge to maintain peak efficiency. Also operate de-
sander at recommended feed head (Usually 75 feet) as too low feed head decreases
efficiency while excessive feed head shortens life of hydro cyclones.
2. Run the de-sander continuously while drilling initial phase and shortly after
beginning a trip for catch up cleaning.
36

1. Cleaning of unit.
2. Inspection and replacement of hydro cones of de-sander (Due to excessive wear).
3. Inspection and adjustment of gland packing / mechanical seal of centrifugal pump.

4. Check cone regularly to ensure that discharge orifice is not plugged.
5. Greasing of bearings or lube oil replacement in pump.
6. Adjustment of cone discharge connections for correct discharge of separated

particles and to prevent mud loss.
OVERHAUL
SAFETY
Safety of de-sander is compliance of recommended operating & maintenance practices,

inspection of hydro-cyclones for any damage, rigidness of piping connections and inspection
of its mounting on mud tank.
ENVIRONMENT CONTROL

37
6.12 De-
De-Silter Assembly
The de-silter assembly consists of set of hydro-cones (of smaller ID usually 4 or 5 Inches)
and a centrifugal pump and is equipment of mud system. It is used as additional separation
unit for separation of solids from the mud. It is used in later phase of drilling, when finer
particle cutting are mixed with mud. The principal of separation is hydro-cyclone to remove
heavy particles from the mud. De-silter should be sized to process 110-125% of the full
drilling rig flow rate. A de-silter will discard an appreciable amount of barite because barite
particles fall within the silt size range and are not recommended for use with weighted mud.
Similarly, since hydro cyclones discard some absorbed liquid along with the drilled solids,
de-silter are not normally used with oil-base mud, unless another device (centrifuge or mud
cleaner/conditioner) is used to de-liquor the cone underflow.
INSTALLATION
It is installed at mud tank next to de-sander. The suction of the pump is from the mud tank
compartment of de-sander discharge. The output is connected to a third compartment in
mud tank for further separation process. Do not use the same pump to feed both the de-
sander and de-silter. If both pieces of equipment are to be operated at the same time, they
should be installed in series and each should have its own centrifugal pump. Keep all lines
as short and straight as possible and keep the end of the discharge lines above the surface
of the mud to avoid creating vacuum in the line.
START UP CHECKS
De-silter is operated during drilling operation and the pump discharge is set at desired level
as per de-silter cone requirement and mud tank level. The parameters to be checked are -
2. Check pumps suction screen and clear trash and debris. Discharge should be closed.
3. Condition of hydra cones.

OPERATION
During operation of de-silter, the flow of mud is to be regulated for effective separation. The
discharge from hydra cones is controlled by adjusting cone discharge opening. Inspection of
discharge particles is carried out for adjustment and prevents any mud loss. Operate the
cones with a spray discharge rather than with a rope discharge since a rope underflow
decrease cone efficiency in half or cause cone plugging and increases wears on cones.
Adjust the cone underflow openings to maintain a spray pattern. Run the de-silter
continuously while drilling and also for a short while during a trip. The extra cleaning during
trip can reduce overload conditions during the period of high solids loading immediately
after a trip.
38

2. Inspection and replacement of hydra cones of de-silter.
3. Checking cone regularly for bottom plugging or flooding or wear, since a plugged
cone allows solids to return to the mud system.

OVERHAUL

SAFETY
Safety of de-silter is compliance of recommended operating & maintenance practices,

ENVIRONMENT CONTROL

39
6.13 Mud Cleaner Assembly

Assembly
The mud cleaner is further advancement in mud control systems. It is in use at some of the
drilling rigs and replaces de-silter assembly. Mud cleaner is combination of de-silter and
linear motion screen provided to further separate finer particles of well cuttings and
retaining chemicals used for preparation of mud. Hence it is a duel system of hydro-cyclone
and finer screen assembly.
INSTALLATION
Mud cleaner is installed at mud tank in place of de-silter. Centrifugal pump get its suction
from de-sander compartment of shall shaker and discharge from mud cleaner after passing
through linear motion screen is discharged into tank. It shall be properly secured with
correct size of hardware and rigid piping connections.
START UP CHECKS
Mud cleaner is operated during drilling operation and the pump discharge is set at desired
level as per hydro-cone requirement and mud tank level. The parameters to be checked are
-
2. Condition of hydro cones.

4. Condition of screen and its linear motion system.
OPERATION
During operation of mud cleaner, the flow of mud is to be regulated for effective separation.
The discharge from hydra cones is controlled by adjusting cone discharge opening.
Inspection of discharge particles is carried out for adjustment and prevents any mud loss.
The screen size shall be as per operational requirement and its motion / slop set to meet
mud flow and separation desired.
2. Inspection and replacement of hydro cones.
3. Inspection and replacement of screen and linear motion system.

40
OVERHAUL

SAFETY
Safety of mud cleaner is compliance of recommended operating & maintenance practices,

ENVIRONMENT CONTROL
STATUTORY / REGULATORY
REGULATORY PROVISIONS
41
6.14 Mud Agitator

Mud is a fluid chemically prepared and is used during drilling operation and well control
activities in contingencies. Number of tanks, each of nearly 40 cu meter is deployed at a
drilling rig and the prepared mud shall be continually agitated to prevent sedimentation and
to keep mud active for emergency use. Each tank consists of 2 nos. of mud agitators that
keeps the mud active by agitator blades. A mud agitator assembly consists of agitator
(shaft, bearings and blades) gear box and drive motor.
INSTALLATION
Two numbers of agitators are installed at each tank. The moving blades / rotor keep the
mud active by centrifugal / axial action on mud and are driven by gear box mounted at the
top of mud tank.
START UP CHECKS
Before start up if the condition of mud is unknown, a manual rotation shall be given to the
agitator to ensure its freeness. Other start up checks is –
1. Lube oil level and condition of gear box.
2. Condition of couplings and shaft.
3. Direction of rotation of agitator.
OPERATION
During operation of mud agitator observe for effective agitation or movement of mud in
mud tank. Observe for any abnormal sound from agitating blades or gear box and check
drive motor current. Additionally agitator guns are provided connected with hopper pumps
for removing settled mud from the tank edges and corners. These shall be manually
operated as desired.
1. Replacement of lube oil and greasing of bearings on gear box as per recommended
schedule.
2. Alignment of shaft & its guide for maximum life .

3. Inspection and replacement of agitator blades and shaft if required.
OVERHAUL
42
SAFETY
Safety of mud agitator is compliance of recommended operating & maintenance practices,

inspection of coupling, coupling guards, bearing housings of agitator shaft assembly.
ENVIRONMENT CONTROL
43
6.15 Air Compressor

Various functions & operation of draw works are pneumatically operated. High pressure air
is also used for starting of engines, operation of air winch and air spinners. Air compressors
are installed to keep pneumatic system pressurised at desired pressure for different
application. There are two types of air compressors installed at drilling rigs.
1. Reciprocating air compressor.
2. Screw air compressor.
INSTALLATION
Air compressors are skid mounted in an enclosure along with air tank and moisture
separation system (Air dryer). Correct installation as per OEM recommendations, alignment
and use of correct size of hardware is to be ensured.
START UP CHECKS
Air compressor start up requires pre-checks and setting that may be manual or automatic.
The pre-start checks are -
1. Direction of rotation.
2. Condition of drive system that may direct driven, belt driven or through gear box.
3. Condition and lube oil level.
4. Cooling system that may be water cooled or air cooled.

5. Check that discharge valves are open.
6. Condition of air intake filter.

7. Status of air pressure safety valves for interstate pressure and discharge pressure.
8. Status of blow down valve.

9. Operation of no-load / auto load system.
10. Status of compressor safety system for alarm and shut down.
11. Condition of cooling tubes, fins and heat exchanger.
OPERATION
Air compressor operation depends on the air pressure that is to be maintained in air vessel.
The operation is carried out by setting the operating limits of minimum and maximum air
pressure. There are several parameters to be checked and monitored such as –
1. Drive motor current.
2. Air discharge pressure.

3. Inter-stage air pressure.
4. Air temperature at inter-stage and air discharge.
44
5. Lube oil pressure & temperature.
6. Cooling water pressure and temperature if system exists.
7. If the air compressor is to be stopped, it shall be allowed to operate for some duration under
no load condition (unload status) to allow its system temperature to stabilize. (Cooling of
valves, cross-heads and bearings).
1. Replacement of lube oil as per recommended schedule.
2. Servicing and replacement of suction and discharge valves and its components.
3. Servicing/replacement of air end (In case screw air compressor)
4. Servicing of air intake filters (Primary & secondary)

5. Servicing/ Calibration of discharge pressure control for maintaining air pressure in
the receiver through discharge check valve and pressure regulator valve before air/
oil separation.
6. Servicing/ Replacement of crankcase and bearing filters.

7. Servicing of compressor loader / unloader valve.
8. Draining of moisture from moisture trap of cooler/ heat exchanger
9. Servicing of Oil stop valve for preventing back flow.
10. Servicing of blow down valve, butterfly type inlet valve.
11. Cleaning of coolers / heat exchangers as exist in air compressor.
12. Oil carry over through discharge air of the air-oil separator system should not
exceed recommended limit.
OVERHAUL
Overhauling is replacement of bearings, piston, cylinder liners, cross-head liners (Or

compressor block – Air end including rotor screw in case screw air compressor) and other
components as required. It may be depending on condition / operating hours as per OEM
recommendations or norms / guidelines issued by Technical Services.
SAFETY SYSTEM
Safety system on air compressor is provided to prevent any damage in case of deviation in
its operating parameters. The safety system is provided with alarm and shut down system.
The parameters monitored and included in system are -
1. Lube oil low pressure alarm & shut down.
2. Lube oil temperature High Alarm & shut down.
3. Cooling system pressure alarm & shut down.
45
4. Cooling system temperature alarm & shut down.
5. High output (Air) pressure – Functioning of relief valve.

6. High Vibration alarm.
7. Lube oil low level alarm.
8. Pressure vessel / Receiver tank shall be tested as per statutory requirement.
ENVIRONMENT & EMISSION CONTROL

1. Used lube oil, filters and other components if not disposed properly may damage the
environment. The guideline has been provided to return these items to designated
locations (Stores) for further disposal action.
2. The consumables / used components shall be disposed at designated places only or
returned to stores for disposal as per approved guidelines / regulatory
requirements.

46
6.16 Centrifugal Pumps

The centrifugal pumps may be of different make and capacity but consist of basic pumps
components. Centrifugal pumps are used at drilling rigs for different applications, such as –
1. Water pump.
2. Supercharger pump as feed for mud pump and used during making up mud level in
well during drill operations.
3. De-sander and de-silter pumps for hydro-cyclone separation of solids.
4. Hopper pumps for preparation of mud by addition of different chemicals and for mud
circulation / transfer among tanks and for agitation activity in mud tanks through
guns.
INSTALLATION
Pumps are installed and skid mounted rigidly and drive motor connected through
flexible/rigid coupling, aligned. The suction and discharge connections are secured to
prevent any looseness. If mechanical seal is provided with water cooling system then the
cooling system connections shall be properly secured.
START UP CHECKS
Centrifugal pump shall be primed (its casing filled with water/ mud as per application),
adjustment of gland packing / mechanical seal, greasing / lube oil condition of bearings and
condition of drive coupling shall be checked before start. The discharge valve is to be
adjusted for desired flow.
OPERATION
Centrifugal pumps generally have trouble free operation. The operating status can be
observed by drive motor current and any flow fluctuations affect the current. Pump
discharge pressure is indicator of any damage or increased clearance across impeller /
casing. Other parameters to be checked are condition of pump bearings, adjustment of
gland packing / mechanical seal to arrest leakage if any and direction of rotation of motor.
1. Replacement of lube oil (For bearing housing) at scheduled interval or greasing of

bearings.
2. Replacement/Tightening of gland packing / mechanical seal components in case of

leakage from sealing system.
3. Inspection & replacement of sealing rings of impeller / casings as desired.
4. Vibration monitoring of bearings, unbalance, misalignment and corrective action as

desired.
47
5. Inspection/replacement of pump skid including foundations bolts (Due to

environment/mud)
OVERHAUL
Overhauling is replacement of bearings, impeller, and other components as required. Pump

skid may also be taken up repair/replacement during over haul (Condition based). It may be
SAFETY
Safety of centrifugal pump is compliance of recommended operating & maintenance
practices, gland seal system, inspection of coupling, coupling guards, bearing housings,
pump casing for any abnormality / damage. In case of pressure safety valve is provided in
discharge line, it shall be tested & calibrated at scheduled interval.
ENVIRONMENT CONTROL
48
6.17 Hopper Pump & System

Hopper pumps are centrifugal pumps with additional hopper and cones provided for mixing
of chemicals in water / mud to the requirement for drilling operation. Further the discharge
is connected to network of pipe lines of tanks that is used for agitation of mud in tanks
through mud guns.
INSTALLATION
Pumps are installed; skid mounted rigidly and drive motor connected through flexible
coupling, aligned. The suction and discharge connections are secured to prevent any
looseness. If mechanical seal is provided with water cooling system then the cooling system
connections shall be properly secured. The hopper system shall be securely installed with its
platform for adding chemicals as per requirement.
START UP CHECKS
Centrifugal pump shall be primed (its casing filled with water/ mud as per application),
adjustment of gland packing / mechanical seal, greasing / lube oil condition of bearings and
condition of drive coupling shall be checked before start. The discharge valve is to be
adjusted for desired flow.
OPERATION
Hopper pump is generally having trouble free operation. The operating status can be
observed by drive motor current and any flow fluctuations affect the current. Other
parameters to be checked are condition of pump bearings, adjustment of gland packing /
mechanical seal to arrest leakage if any. The activity of chemical mixing is carried out by
allowing mud to flow through and convergent nozzle, creating suction for chemical flow and
mixing. Care shall be taken to prevent surge of mud in hopper during such operation.
1. Replacement of lube oil (Bearing housing) at scheduled interval or greasing of

bearings.
2. Vibration monitoring of bearings, unbalance, misalignment and corrective action as

desired.
3. Inspection and replacement of hopper nozzle and cleaning of hopper components to

prevent setting of mud / chemicals.
OVERHAUL

49
SAFETY
Safety of centrifugal pump is compliance of recommended operating & maintenance

practices, gland seal system, inspection of coupling, coupling guards, bearing housings for
any abnormality / damage. In case of pressure safety valve is provided in discharge line, it
shall be tested & calibrated at scheduled interval. The nozzle provided in hopper assembly
shall be installed to prevent surge of mud in hopper and injury to persons handling
chemicals.
ENVIRONMENT CONTROL

50
6.18 Allison Transmission

As the name specify, Allison Transmission is used in mechanical Rigs for draw works/Mud
Pumps. It is connected between drive motor /diesel engine to provide desired direction of
rotation and speed as per rig operation. The control for Allison transmission is hydraulic and
hence a hydraulic power unit is associated with Allison transmission.
INSTALLATION
Allison transmission is installed between drive motor / diesel engine and connected to both
ends as per recommended procedure. The control system is hydraulic and the hydraulic
power unit, hose connections and control cables shall be properly secured and checked.
START UP CHECKS
Allison transmission is used at rig to provide variable speed & rotation in both directions.
These actions are managed by hydraulically operated actuators. The high pressure hydraulic
system shall be checked for hydraulic oil, filters, pressure gauges and other functions. The
cooling system (air or water) shall be operational.
OPERATION
The operation of Allison transmission is carried out by driller from its control as per
operational requirement. The working of transmission, function of its actuators and
hydraulic system shall be checked for reliability and performance. The selection for speed
and its direction of rotation is managed by person operating the rig controls. The correct
selection shall be ensured to prevent any operational contingencies.
1. Replacement of hydraulic oil and filters as required.
2. Greasing of actuators, control levers and other components need greasing.
3. Condition of couplings.
4. Inspection of hydraulic hose (Leakages, deformation, cracks) and its connections
and replacement if required.
5. Tightness of hardware.
OVERHAUL
Overhauling is replacement of bearings, gears, shafts, valves, piston & cylinder and other
components as required. The overhauling may be required depending upon severity of
operation, run hours, observations during preventive maintenance activities.
51
SAFETY
Allison Transmission is used for operating equipment at variable speed. To ensure safety
during operation, it shall be correctly secured both with driver and driven equipment. To
change the speed, recommended procedure shall be followed for safety of equipment itself.
ENVIRONMENT CONTROL
52
6.19 Eddy Current Brake

The weight of drill string assembly is very high and the movement controlled by braking
action. In normal drilling of oil well, braking action is taken care by draw works brake
depending on differential load to be applied on drill bit. In case of run in and pull out
process, while lowering heavy string assembly, eddy current brake is used for smooth &
effective braking action, variable control over drill string speed. These brake work on
principal of reverse magnetic polarities and the energy loss is transferred in the form of heat
to be removed from eddy current brake assembly. These brakes are ruggedly built and
require very little in service attention. Eddy Current Braking (ECB) systems provide
optimum performance, reliability, and safety at a minimum maintenance cost.
INSTALLATION
The brake assembly is installed at derrick floor and coupled to draw works shaft. It is
provided with cooling water system to remove heat generated in braking action. Further
installation practice include –
1. While installing, required clearances should be maintained for working space and
cable terminal boxes.
2. The areas and surfaces to mount ECBs should comply with requirements and
installation tolerances recommended by manufacturer. Installation should be carried
out only when all conditions are satisfactory.
3. Electrical cables should be laid, routed and covered properly. Cable connections
should be done as per recommended procedure.
4. All installation checks should be completed according to manufacturer’s written
instructions.
START UP CHECKS
The electric power connections shall be checked. The cooling water inlet and outlet
connections shall be checked. The quality of water being used (if required inhibitors to be
added to prevent scaling) shall be as recommended by OEM. The braking action shall be
checked at no load condition.
OPERATION
The desired braking action is achieved by varying current to the coils in brake system and
regulated by driller as per operational requirement. The cooling water system shall be
checked for removing heat from the eddy current brake.
1. Inspection and condition of coupling.

2. Addition / replacement of cooling water with treated water as desired.
3. Greasing of bearings as per recommendation of OEM.
53
OVERHAUL

SAFETY
Eddy Current Brake is installed for safe operation of rig and for its expected performance,
compliance to recommended safety practices is essential.
ENVIRONMENT
Equipment grounding and noise attenuation practices for electrical and electromagnetic
interference should be properly followed and should be according to manufacturer’s
recommendations.
54
6.20 Synchronous AC Generator

The synchronous AC generators in Power Packs on drilling rigs of ONGC are alternating-
current machines, without rings or brushes. The alternators are cooled by the flow of air
through the machine.
The machine armature (stator) comprises low-loss steel laminations assembled under
pressure. The steel laminations are blocked axially by a welded ring. The stator coils are
inserted and blocked in the slots, then impregnated with varnish, and polymerised to ensure
maximum resistance to mould, excellent dielectric rigidity and perfect mechanical linking.
The revolving field coil (rotor) comprises a stack of steel laminations, stamped and cut to
reproduce the indentation of the projecting poles. The steel lamination stack-up is
terminated at each end with high-conductivity electrical plates. To enable parallel operation
between machines, and in order to ensure stability, high electrical conductivity bars are
inserted in holes crossing the poles from one side to the other. These bars are welded with
the stack end laminations in order to obtain a complete cage winding.
The excitation system is mounted on the side opposite the coupling. The excitation system
comprises of armature assembly on the rotor and field winding on the stator.
Excitation armature (rotor), generating a three-phase current, coupled with the three-phase
rectifier bridge (comprised of six diodes) supplies the excitation current (DC) to the
generator revolving field. The excitation armature and the rectifier bridge are mounted on
the synchronous generator rotor shaft and are interconnected electrically with the revolving
field of the machine. The diodes are protected against over voltage by rotating resistors, or
by varistors. The windings are enamelled copper wires, class "F" or "H" insulation.
Excitation field winding (stator) comprises a solid element and a winding. The excitation is
flanged on the rear end shield of the machine. The winding is made of enamelled copper
wires.
The synchronous machine is characterized by a self-ventilation system. A centrifugal fan is

mounted between the revolving field coil and the front bearing. Air intake is at the rear of
the machine and the exhaust on the drive end side.
The main terminal box of the machine is located on the top of the machine. The neutral and
phase wires are connected to the terminals, one terminal per phase and one terminal per
neutral line. The gland plates are made of non-magnetic materials in order to avoid
circulating currents. The connection of accessories is achieved by terminal strips.
The SOP for alternators is expected to ensure:

1. Safe operation
2. High efficiency and reliability
3. Low maintenance cost
4. Improved life cycle
5. Low noise pollution
55
Following documents should be diligently maintained at site:
1. Manufacturer’s instruction sheets

2. Manufacturer’s installation instructions
3. Manufacturer’s operating manual
INSTALLATION
Following practices should be followed with regard to installation:

instructions.
2. While accepting delivery of new alternators, it should be ensured that they are
received packed in secure cartons and covered for protection against dirt and
moisture during transit and outdoor storage.
3. Alternators should be stored in clean dry space, protected from dirt, fumes, water,
corrosive substances and physical damage.
4. Handling should be done with proper lifting equipment using lugs or eyebolts
provided by the manufacturer.
5. While installing, required clearances should be maintained for working space, cable
terminal boxes, coupling access and alternator cooling air.
6. The areas and surfaces to mount alternators should comply with requirements and
7. Fitting of coupling, alignment and electrical connections should be carried out strictly
as per manufacturer’s written instructions.
8. It has to be ensured that all protection devices are correctly connected and are in
good working order.
9. The power cables must not push, pull or bend the generator terminals.
10. Washers should not be added to the power supply cable terminals other than those
used by the manufacturer.
START UP CHECKS
Start-up checks are carried out to ensure that the alternators start smoothly and thereafter
operate without any problem. The start-up checks include:
1. All start up checks should be completed according to manufacturer’s written

instructions.
2. The commissioning checks should follow the sequence recommended by the
manufacturer.
3. Static checks include machine fixing, alignment, cooling, bearing lubrication,
electrical connections and insulation checks.
4. Rotating checks include running the alternator without excitation; running with
excitation (AVR manual and auto modes) at no load; adjustments of over voltage
relays, over current relays, differential protection relays, negative sequence relays;
running at full load. Vibration levels are recorded during the rotating checks.
5. Foundation bolts should be properly tight. Coupling to be in good condition.
56
6. Cable connections to be tight as per manufacturer’s instruction.

7. Proper earthing/ grounding of alternator for safety as per recommended statutory
code of practice.
8. Alternator bearings to be properly lubricated.
9. Personal Protective Equipment for operating personnel to be available. Use of
Rubber mats etc. should be ensured.
OPERATION
The factors to be checked and monitored are:

1. Dirt and Corrosion
2. Winding Insulation
3. Heat, Noise and Vibration
4. Lubrication
Written record in the form of Log Books, indicating date, items inspected, services
performed and alternator condition help in quick identification of specific problems. These in
turn provide quick solutions thereby helping in avoiding breakdowns and downtime losses.
The suggestions and recommendations of manufacturer regarding the preventive

maintenance schedule are to be followed as closely as possible in order to maintain the
machine efficiency and in order not to reduce the service life of the machine.
The Preventive Maintenance activities of alternators includes –
1. Stator – Checking winding temperature; Bolts tightening; Cleaning of air inlet and
outlet; checking Insulation and Polarisation index
2. Rotor – Checking Insulation, cleaning diodes, diodes tightening, checking
Polarisation index
3. Terminal Box – Cleaning of terminal box, maintenance of regulator assembly, bolts
tightening.
4. Bearings – Re-greasing; checking bearing temperature
OVERHAUL
Alternator overhaul decision shall be either based on OEM recommendations or on the basis
of condition detected during inspection. The activities during overhaul shall be some or all of
the following:
1. Bearing replacement.
2. Servicing/ replacement of switchgear components.
3. Servicing/ replacement of rotating diodes and resistors.
4. Repair/ replacement of space heaters.
5. Cleaning/ re-varnishing of windings if required.
6. Replacement of vibration dampeners.
7. Painting of external surface of alternator.
57
SAFETY
For safe operation of alternator, compliance to recommended safety practices is essential.

This includes:
1. Electrical connectors and terminals should be tightened according to cable and

terminal manufacturers’ recommended torque values.
3. Proper earthing/ grounding of alternator for safety as per recommended statutory
code of practice.
ENVIRONMENT
1. The noise attenuation practices for electrical and electromagnetic interference

should be properly followed and should be according to manufacturer’s
recommendations.
2. CPCB norms for noise and exhaust gas emission to be followed/ complied with.

58
6.21 Electric AC Motors

On drilling and work-over rigs in ONGC, all AC motors irrespective of size are Squirrel Cage
Induction Motors. AC motors are used as drives for various applications such as pumping,
lifting, rotating etc. As per the power need, motors of different HP/ KW capacities are being
used on rigs. The following SOP covers all AC motors irrespective of make, size and their
application and is expected to ensure:
1. Safe operation

INSTALLATION
On drilling rigs, AC motors are generally installed on the same skid as the driven
equipment.
1. While accepting delivery of new motors, it should be ensured that they are received
packed in secure cartons and covered for protection against dirt and moisture during
transit and outdoor storage.
2. Motors should be stored in clean dry space, protected from dirt, fumes, water,
corrosive substances and physical damage.
terminal boxes, coupling access and motor cooling air.
5. The areas and surfaces to mount motors should comply with requirements and
6. Technical features and parameters of AC motors like ambient conditions, duty cycle,
starting and running torque demands etc should be coordinated with the power and
control circuits to which they are connected.
7. Electrical cables should be laid, routed and covered properly. Cable connections with
motor should be done as per recommended procedure.
8. The foundation should be rigid to minimise vibration and to maintain alignment
between motor and load shaft. AC motors should be connected and aligned with
driven equipment with coupling of recommended size & capacity and according to
59
manufacturer’s written instructions. The shims and foundation bolts shall be of

proper size.
9. Flexible couplings for direct drive or belt drive alignments should be carried out as
per their respective manufacturer’s instructions.
10. It should be ensured that motors are designed for operation in either direction of
rotation without any physical change in the motor.
instructions.
START UP CHECKS
Start-up checks are carried out to ensure that the motors start smoothly and thereafter
2. Motor rating to match application requirements. Flame proof equipment to be used
in hazardous classified zones.
4. Winding insulation integrity to be tested with a megger.
5. Proper earthing/ grounding of motor for safety as per recommended statutory code
of practice.
6. Motor bearings to be properly lubricated.
8. Power should be applied to verify direction of rotation. If necessary, load should be
decoupled before this test to ensure safety of load equipment in case of reverse
rotation. The direction of rotation to be changed if necessary and retested.
instructions.
OPERATION
Routine inspection and servicing can generally be done without disconnecting or

disassembling the motor during operation. The factors to be checked and monitored are:

4. Lubrication
Written record in the form of Log Books indicating date, items inspected, service performed
and motor condition, help in quickly identifying specific problems in each application. These
in turn provide quick solutions thereby helping in avoiding breakdowns and downtime
losses.
60
Preventive Maintenance activities of electrical motors includes –

1. Greasing of bearings with periodicity and methodology as per recommendation of
manufacturer.
a. Both over/ under greasing are detrimental to motor performance.
b. No impurity should be allowed to get inside the bearing.
c. Only grease of recommended type and viscosity should be used.
2. Measurement of winding insulation resistance.
3. Measurement of earth resistance.
4. Checking condition of drive coupling; replacement of flexible elements if damaged/
at scheduled intervals.
5. Condition monitoring of motors, if facility exists.
6. Testing of switchgear and calibration of protective relays.
7. Condition of electric supply cables. Proper lay of cables in trays and fixing of tray
covers.
8. Checking condition of space heaters.
OVERHAUL
Motor overhaul decision shall be either based on OEM recommendations or on the basis of
condition detected during inspection. The activities during overhaul shall be some or all of
the following:
2. Replacement of cooling fan.
3. Cleaning of cooling fins / ducts.
7. Painting of external surface of motor.
SAFETY
For safe operation of motor, compliance to recommended safety practices is essential. This
includes:
1. Recommended type of cable glands should be installed according to statutory

guidelines/ instructions.
2. Correct motor cable size should be selected based on standard code of practice.
3. It should be verified that the rated voltage, frequency and full load current is
matching with drawings, specifications and application requirements.
4. It should be verified that motor overload protection devices are installed as required
by Indian Electricity Rules.
5. It should be ensured that motor power and auxiliary cabling is according to safety
and statutory requirements for electrical systems.
6. Grounding of all equipment should be proper and according to manufacturer’s
recommendations.
61

ENVIRONMENT
Equipment grounding and noise attenuation practices for electrical and electromagnetic
interference should be properly followed and should be according to manufacturer’s
recommendations.
62
6.22 Electric DC Motor

DC motors are used to power the main drives like the draw-works and mud pumps on land-
based and offshore drill rigs used by the oil and gas industry.
The SOP for DC motors is expected to ensure:
1. Safe operation

INSTALLATION
1. DC motors need to be selected, installed, operated and maintained by personnel

who are thoroughly familiar with special requirements of DC machines.
instructions.
3. While accepting delivery of new DC motors, it should be ensured that they are
received packed in secure cartons and covered for protection against dirt and
moisture during transit and outdoor storage.
4. DC motors should be stored in clean dry space, protected from dirt, fumes, water,
corrosive substances and physical damage. Motors located in damp and moist
environments should have space heaters switched on to protect against
condensation when motors are not operating.
terminal boxes, coupling access and DC motor cooling air. Sufficient clearances
should be provided on all inlet and outlet openings to provide for unrestricted flow of
air.
7. The areas and surfaces to mount DC motors should comply with requirements and
8. Fitting of coupling, alignment and electrical connections should be carried out strictly
as per manufacturer’s written instructions.
9. It has to be ensured that all protection devices are correctly connected and are in
good working order.
63
10. It has to be ensured that all guards are properly installed to guard against personal
injury caused by contact with rotating parts.
11. The power cables must not push, pull or bend the DC motor terminals.
12. Washers should not be added to the power supply cable terminals other than those
used by the manufacturer.
START UP CHECKS
Start-up checks are carried out to ensure that the DC motors start smoothly and thereafter
instructions.
2. The commissioning checks should follow the sequence recommended by the
manufacturer.
3. Static checks include machine fixing, alignment, cooling, bearing lubrication,
electrical connections and insulation checks.
4. Rotating checks include running the DC motor. Vibration levels are recorded during
the rotating checks.
7. Proper earthing / grounding of DC motor for safety as per recommended statutory
code of practice.
8. DC motor bearings to be properly lubricated.
OPERATION
The factors to be checked and monitored are:

4. Lubrication
Written record in the form of Log Books, indicating date, items inspected, services
performed and DC motor condition help in quick identification of specific problems. These in
turn provide quick solutions thereby helping in avoiding breakdowns and downtime losses.
The suggestions and recommendations of manufacturer regarding the preventive

maintenance schedule are to be followed as closely as possible in order to maintain the
machine efficiency and in order not to reduce the service life of the machine.
64
The Preventive Maintenance activities of DC motors includes –
1. It must be ensured that the DC motor blower is running and is rotating in the proper
direction. Entry of blower duct must be kept clean to ensure full volume of cooling
air.
2. Brushes and brush holders should be clean so that brushes are free to move in the
holders. Brushes should be replaced before the worn out brushes/ rivets/ pigtails
scratch and damage the commutator. It is best to change complete set of brushes
together.
3. Commutator should be maintained in good condition and all cleaning resurfacing
etc. should be done as per manufacturer’s written instructions.
4. Dirt or dust on the windings should be removed by wiping with a clean cloth or by
blowing with clean, dry, low pressure air or by vacuum cleaner.
OVERHAUL
DC motor overhaul decision shall be either based on OEM recommendations or on the basis
of condition detected during inspection. The activities during overhaul shall be some or all of
the following:
5. Replacement of vibration dampeners.
6. Painting of external surface of DC motor.
SAFETY
For safe operation of DC motor, compliance to recommended safety practices is essential.

This includes:
3. Proper earthing/ grounding of DC motor for safety as per recommended statutory
code of practice.
ENVIRONMENT
The noise attenuation practices for electrical and electromagnetic interference should be
properly followed and should be according to manufacturer’s recommendations.
65
66
6.23 Pneumatic Winch

Drilling rig operation involves material handling for continuation of its operation. Drill string
assembly that is made up of drill collars and drill pipes each of 9 meter length are added to
increase string length as the drilling depth increases. Most of such material handling
activities from ground to derrick level is managed using pneumatic winch 2 tons capacity.
The winch is air operated through motor with installation of wire rope and braking system.
It can be operated in both the directions for lifting and lowering of materials.
INSTALLATION
Pneumatic winch is installed at derrick floor. It is provided with air connection driven
through reversible air motor with lubricator and strainer. Wire rope of recommended size
and configuration shall be used. The lifting shackles connected for material handling shall be
of desired load rating. Air outlet connection (silencer/muffler) shall be directed to prevent
any impact on persons operating the winch or involved with handling of material. Air winch
is provided with overload sensing and shut off device for safety and protection.
START UP CHECKS
Before operation of air winch, lube oil shall be filled in air lubricator, brake shoes and
throttle valve shall be checked and adjustment carried out for effective braking action. The
operation of winch shall be checked at no load before deploying for material handling
activities.
OPERATION
As the air winch is used for material handling operation, the winch is operated by crew
deployed for drilling process. Persons operating winch shall take necessary precautions for
the material being lifted / lowered and safety of other crew members associated with.
MAINTENANCE
1. Replacement / topping up of oil in air lubricator.
2. Inspection of air motor or pump
3. Cleaning / replacement of filter or strainer, if exist.
4. Greasing of actuators, throttle valve, control levers and other components need
greasing.
5. Inspection of air line connections and replacement if required.
6. Inspection of air silencer/muffler at exhaust port for any blockage.
7. Inspection of wire rope and replacement if found damaged/worn out/slippage.
8. Inspection of overload sensing and shut off device
67
OVERHAUL
Overhauling is replacement of bearings, shafts, clutch assemblies, actuators, valves,

filters/strainers and other components as required. The overhauling may be required
depending upon severity of operation, run hours, observations during preventive
maintenance activities.
SAFETY
Since air winch is used for material handling, person operating the winch shall ensure safety
of material handled and person involved. The ropes, slings, belts, hooks, overload sensing
and shut off device etc. used shall be of approved rating and recommended for use.
ENVIRONMENT CONTROL
68
6.24 Diesel Transfer Pump

Drilling rigs are operated at remote locations and the power source is by operation of diesel
engine driven power packs and generator sets. Diesel is primary requirement for operation
of engines. Rig is provided with diesel storage facility, unloading of diesel and transfer from
one tank to another along with filter package. These are gear pumps with piping
connections from tanks and filter bank.
INSTALLATION
Diesel transfer pump is installed at skid along with pipe connections and filter bank. Only
diesel tanks are to be connected using flexible hoses to complete the package at new
location. One diesel tank is used for unloading and 2nd diesel tank can be used as day tank
to monitor diesel consumption.
START UP CHECKS
The pumps are operated during unloading of diesel from mobile tank and during transfer
from main storage tank to day tank of diesel engines. The diesel can be passed through
filters so that clean diesel is available for operation of engines. Connection & setting of
valves in line shall be checked before starting diesel pump.
OPERATION
In operation of pump attention is required to check for any leakage and overflow of tanks.
Check condition of diesel filter and if required replacement shall be carried out.
1. Replacement of diesel filters elements of appropriate rating (micron size).

2. To check condition of flexible hoses and replace if required.
3. Cleaning of diesel gauge system so that correct measurement can be carried out for
receipt of diesel and consumption of engines.
OVERHAUL
Overhauling is replacement of bearings/bushes, gears, shafts, and other components as

required. The overhauling may be required depending upon severity of operation, run hours,
observations during preventive maintenance activities.
SAFETY
Diesel is flammable material and any spillage may be a fire hazard. Any leakage shall be
arrested with top priority and availability of recommended portable fire extinguishers at
location be ensured before any operation of diesel pumps.
69
ENVIRONMENT CONTROL

70
7. Annexures
7.1 Norms and Policies Issued by Technical Services
1. Capital repair norms for onshore drilling rigs.
2. Equipment replacement life norms for drilling rigs.
3. Equipment Health check-up for Onshore Drilling and work over Rig.
4. Life cycle period of major equipment for LCC based equipment purchases
5. Norms for replacement of old diesel engines on drilling rigs.
6. Replacement policy for critical equipment.
7. Standby norms for onshore drilling rigs.
8. Norms for Noise and Exhaust emissions for rotating equipment
7.2 OISD references – Relevant for Drilling Rigs
OISD CURRENT
Sr.
Standard/GDN/RP STANDARD NAME EDITION IN
No.
No VOGUE
1 OISD-STD-105 Work Permit System Sep-2004
2 OISD-STD-106 Pressure Relief & Disposal System Oct-2010
3 OISD-RP-110 Recommended Practices on Static Electricity Aug-1999
Classification of Area for Electrical Installations

4 OISD-STD-113 Oct-2013
at Hydrocarbon Processing & Handling Facilities
Selection, Operation and Maintenance of

5 OISD-STD-119 Jul-2008
Pumps

Compressors
Selection, Operation and Maintenance of Fans,

7 OISD-RP-122 Jul-2008
Blowers, Gear Boxes, Agitators & Mixers
71
Sr. OISD STANDARD NAME CURRENT

No. Standard/GDN/RP EDITION IN
No VOGUE

Rotary Equipment Components
Specific practices for installations and

9 OISD-RP-126 Aug-2007
maintenance of Rotating Equipment
Selection, Operation, Inspection & Maintenance

of Diesel Engines
11 OISD-STD-132 Inspection of Pressure Relieving devices Jul-2012
Oct-2010(Under
12 OISD-STD-137 Inspection of Electrical Equipment
Revision)
13 OISD-RP-146 Preservation of idle electrical equipment Aug-2000
Inspection & safe practices during electrical

14 OISD-RP-147 Oct-2002
installations
Inspection & safe practices during overhauling

15 OISD-RP-148 Aug-2000
electrical equipment
Preservation of Idle Static & Rotary Mechanical

Equipment
17 OISD-GDN-180 Lightning Protection Jul-1999
Standard on Replacement of Personal

18 OISD-STD-184 Aug-2000
Protective Equipment & Life Saving Appliances
19 OISD-STD-187 Care And Use Of Wire Rope Aug-2000
Standard On Fire Fighting Equipment For

20 OISD-STD-189 Drilling Rigs, Work Over Rigs And Production Jul-2012
Installations
Derrick Floor Operations (Onshore Drilling / Aug-2000(Under

21 OISD-STD-190
Workover Rigs) Revision)
Inspection of Drilling and Workover Rig Mast / Oct-2002(Under

22 OISD-GDN-202
Sub-Structure Revision)
Operation, Maintenance & Inspection Of

23 OISD-GDN-203 Sep-2003
Hoisting Equipment
72
Sr. OISD STANDARD NAME CURRENT

No. Standard/GDN/RP EDITION IN
No VOGUE
Electrical Safety in Onshore Drilling &

Workover Rigs
Guidelines For Safe Rig- Up & Rig- Down Of

25 OISD-GDN-218 Oct-2004
Drilling And Work-Over Rigs
7.3 DGMS References – Details of regulations / guidelines
- OMR – Oil Mines Regulation
7.4 Central Pollution Control Board
- Guidelines issued for noise and emission from Gen-sets.
7.5 Electrical Related Standards – A Reference
OISD
Sr. CURRENT EDITION
Standard/GDN/RP STANDARD NAME
No. IN VOGUE
No
1 OISD-RP-110 Recommended Practices on Static Electricity Aug -1999
Oct-2010(Under
2 OISD-STD-137 Inspection of Electrical Equipment
Revision)
3 OISD-RP-146 Preservation of idle electrical equipment Aug-2000
Inspection & safe practices during electrical

4 OISD-RP-147 Oct-2002
installations
Inspection & safe practices during overhauling

5 OISD-RP-148 Aug-2000
electrical equipment
6 OISD-GDN-180 Lightening Protection July-1999
7 OISD-STD-216 Electrical Safety in Onshore Drilling & Work Over Rigs Oct-2010
- Indian Electricity Rules 1956.
- OMR
73
7.6 Selected Applicable Standards – Drilling Rig Equipment
Sr. CURRENT EDITION

Standard STANDARD NAME
No. IN VOGUE
Technical Capital overhauls norms for onshore drilling rig

1 Jan-2013
Services equipment
Technical Equipment Health check-up for Onshore Drilling

2 Jan-2009
Services and work over Rig
Technical
3 Replacement policy for critical equipment Jan-2013
Services
Technical Norms for Noise and Exhaust emissions for

4 Nov-2010
Services rotating equipment
5 OISD-STD-105 Work Permit System Sep-2004
6 OISD-STD-119 Selection, Operation and Maintenance of Pumps Jul-2008

Compressors
Selection, Operation and Maintenance of Fans,

Blowers, Gear Boxes, Agitators & Mixers
Selection, Operation and Maintenance of Rotary

Equipment Components
Specific practices for installations and

10 OISD-RP-126 Aug-2007
maintenance of Rotating Equipment
Selection, Operation, Inspection & Maintenance

of Diesel Engines
Preservation of Idle Static & Rotary Mechanical

Equipment
13 OISD-STD-187 Care And Use Of Wire Rope Aug-2000
Operation, Maintenance & Inspection Of

14 OISD-GDN-203 Sep-2003
Hoisting Equipment
Guidelines For Safe Rig- Up & Rig- Down Of

15 OISD-GDN-218 Oct-2004
Drilling And Work-Over Rigs
74
Feedback & Suggestions
To
Chief Technical Services, New Delhi.

Head Equipment Management, New Delhi

Sopa Drilling Rig

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3. Standard Operating Practices – SOPs ........................................................................... 6

3.1 Components ...................................................................................................................... 7

5. Drilling Rigs – Summary ................................................................................................. 12

6.1 Diesel Engine .................................................................................................................. 13

6.20 Synchronous AC Generator...................................................................................... 55

7.1 Norms and Policies Issued by Technical Services ............................................... 71

Technical Services as a service provider,

Department of Equipment Management, Technical Services, Dehradun has already issued

1. Capital repair norms for onshore drilling rigs.

2. Equipment replacement life norms for drilling rigs.

5. Replacement policy for critical equipment.

6. Standby norms for onshore drilling rigs.

7. Norms for Noise and Exhaust emissions for rotating equipment

3. Standard Operating Practices – SOPs

The abbreviation “SOPs” stands for

Safe Operating Procedures / Practices

Standard Operating Procedures / Practices

1. Equipment installation as recommended by manufactures / suppliers.

2. Equipment start-up checks / steps for safe starting.

3. Equipment Operations including monitoring of operating parameters and taking

4. Preventive maintenance activities as per approved/ recommended schedule.

5. Equipment Overhaul to restore/ maintain equipment health, efficiency, reliability

b. Identification of its operational, maintenance and overhauling requirements.

c. Engineering control to include work environment, stores and spares management at

d. Administrative control to include issue of guidelines / norms for equipment

e. Safe practices to include use of PPE as per field operations / requirements.

b. Original Equipment Manufacturer (OEM) manual / guidelines of operation,

c. IADC Safety Manual for drilling operations.

d. OISD – Oil Industry Safety Directorate (Safety Standards)

e. DGMS – Directorate General of Mines and Safety Regulations.

f. OMR – Oil Mines Regulations.

The risk can arise from:

OIL & NATURAL GAS CORPORATION LIMITED

RISK REGISTER - SERVICES

Work Centre Asset, Basins

Risk Description Equipment failure

Root causes Mitigating Factors Remarks

Wrong Selection of The desired rating, capacity and application should

Statutory requirements Equipment should meet all prevailing standards and

Manufacturer should provide complete specifications,

Equipment shall be installed and located as per

Inadequate preventive Preventive maintenance will be carried out as per

Delayed Equipment Overhauling will be carried out as per manufacturer’s

Inadequate Equipment Protection to rotating parts and hot parts of the

All safety requirements as per equipment design, its

CHIEF RISK OFFICER

HEAD – SBU (AM/BM/PH/HOI) RISK CONTROLLER

HEAD – MAINTENANCE / DRIL SERV/ RISK OWNER

ASSET / BASIN (SBU) RISK ORIGIN

CHIEF RISK OFFICER:

HEAD – MAINTENANCE (RISK OWNER):

RISK MANAGEMENT PLAN:

Action plan for the perceived risk reported will be

Monitoring of action plan and mitigating factors.

Non-compliance to indicated SOP may result in:

2. Equipment Failure – There may be unscheduled equipment stoppages, breakdowns that

4. Failure to meet expected quality-The recommended inspections, maintenance schedules

5. Obsolescence – The document is primarily focussed on equipment life cycle

SOP provides a standard template for practices to be followed, to establish a robust

5. Drilling Rigs – Summary

Sl. Make /Type Series & Id Number Nos.