Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations

API RECOMMENDED PRACTICE 54 THIRD EDITION, AUGUST 1999

REAFFIRMED, JANUARY 2013

Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations

Upstream Segment

API RECOMMENDED PRACTICE 54 THIRD EDITION, AUGUST 1999

REAFFIRMED, JANUARY 2013

SPECIAL NOTES

API publications necessarily address problems of a general nature. With respect to partic- ular circumstances, local, state, and federal laws and regulations should be reviewed.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or fed- eral laws.

Information concerning safety and health risks and proper precautions with respect to par- ticular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or prod- uct covered by letters patent. Neither should anything contained in the publication be con- strued as insuring anyone against liability for infringement of letters patent.

Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect five years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Upstream Segment [telephone

1. 682-8000]. A catalog of API publications and materials is published annually and updated quarterly by API, 1220 L Street, N.W., Washington, D.C. 20005.

   This document was produced under API standardization procedures that ensure appropri- ate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or com- ments and questions concerning the procedures under which this standard was developed should be directed in writing to the general manager of the Upstream Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the general manager.

   API standards are published to facilitate the broad availability of proven, sound engineer- ing and operating practices. These standards are not intended to obviate the need for apply- ing sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices.

   Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such prod- ucts do in fact conform to the applicable API standard.

   
   

   All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher,

   API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005.

   Copyright © 1999 American Petroleum Institute

   
   

   IMPORTANT INFORMATION CONCERNING USE OF ASBESTOS OR ALTERNATIVE MATERIALS

   
   

   Asbestos is specified or referenced for certain components of the equipment described in some API standards. It has been of extreme usefulness in minimizing fire hazards associated with petroleum processing. It has also been a universal sealing material, compatible with most refining fluid services.

   Certain serious adverse health effects are associated with asbestos, among them the seri- ous and often fatal diseases of lung cancer, asbestosis, and mesothelioma (a cancer of the chest and abdominal linings). The degree of exposure to asbestos varies with the product and the work practices involved.

   Consult the most recent edition of the Occupational Safety and Health Administration (OSHA), U.S. Department of Labor, Occupational Safety and Health Standard for Asbestos, Tremolite, Anthophyllite, and Actinolite, 29 Code of Federal Regulations Section 1910.1001; the U.S. Environmental Protection Agency, National Emission Standard for Asbestos, 40 Code of Federal Regulations Sections 61.140 through 61.156; and the U.S. Environmental Protection Agency (EPA) rule on labeling requirements and phased banning of asbestos products (Sections 763.160-179).

   There are currently in use and under development a number of substitute materials to replace asbestos in certain applications. Manufacturers and users are encouraged to develop and use effective substitute materials that can meet the specifications for, and operating requirements of, the equipment to which they would apply.

   SAFETY AND HEALTH INFORMATION WITH RESPECT TO PARTICULAR PRODUCTS OR MATERIALS CAN BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER OR SUPPLIER OF THAT PRODUCT OR MATERIAL, OR THE MATERIAL SAFETY DATA SHEET.

   FOREWORD

   
   

   This recommended practice was prepared by the API Subcommittee on Occupational Safety for Oil and Gas Well Drilling and Servicing Operations. It represents the combined contributions of industry representatives from the oil and gas well drilling, production, and well servicing segments who served on this subcommittee. This Third Edition supersedes and replaces the Second Edition, May 1992. This pub- lication is under the jurisdiction of the American Petroleum Institute Upstream Department’s Executive Committee on Drilling and Production Operations.

   The goal of this recommended practice is to assist the oil and gas industry in promoting personnel and public safety. This publication has intentionally stressed recommended safe operating practices concen- trating on personnel and public safety as differentiated from equipment safety and operations efficiency. THE PUBLICATION DOES NOT, HOWEVER, PURPORT TO BE SO COMPREHENSIVE AS TO PRESENT ALL OF THE RECOMMENDED SAFE OPERATING PRACTICES THAT CAN AFFECT SAFETY IN OIL AND GAS WELL DRILLING AND SERVICING OPERATIONS.

   It is intended that this voluntary recommended practice will promote and maintain safe working con- ditions for personnel engaged in well drilling and servicing operations, including special services as they relate to the operation of drilling and well servicing rigs. Every effort has been made by API to assure the accuracy and reliability of data contained in this document. However, the Institute makes no representa- tion, warranty, or guarantee in connection with the publication of this recommended practice and hereby expressly disclaims any liability or responsibility for loss or application hereunder or for any violation of local, state, or federal laws with which the contents may conflict. INFORMATION CONCERNING SAFETY AND HEALTH RISKS AND PROPER PRECAUTIONS WITH RESPECT TO PARTICU- LAR MATERIALS AND CONDITIONS SHOULD BE OBTAINED FROM THE EMPLOYER, THE MANUFACTURER OR SUPPLIER OF THAT MATERIAL, OR THE MATERIAL SAFETY DATA SHEET (MSDS).

   Users of this publication are reminded that constantly developing technology and specialized or lim- ited operations do not permit complete coverage of all operations or alternatives. Recommendations pre- sented herein are not intended to inhibit developing technology and equipment improvements or improved operational procedures. This document is not a substitute for qualified engineering analysis and judgment to fit the specific operations situation.

   The publication is available for review by federal and state agencies or authorities and possible use as a model safe practice to assist in preparation or revision of occupational safety codes or regulations. Rec- ommendations set forth in this publication are viewed as one satisfactory method for accomplishing a desired result. They should not be considered as the only method for achieving the desired results. This publication includes usage of the verbs “shall” and “should,” whichever is deemed most applicable for the specific situation. For the purposes of this publication, the following definitions are applicable:

   Shall: Denotes that the recommended practice has universal application to that specific activity.

   Should: Denotes a recommended practice: (1) where a safe comparable alternative practice is avail- able; (2) that may be impractical under certain circumstances; or (3) that may be unnecessary for person- nel safety under certain circumstances.

   Proposed changes in these interpretations and usages should be brought to the attention of the respon- sible authorizing committee to determine that the intent of the publication will be sustained.

   API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no rep- resentation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict.

   Suggested revisions are invited and should be submitted to the general manager of the Upstream Seg- ment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.

   
   

   CONTENTS

   
   

   Page

   1. GENERAL 1

      1. Purpose 1

      2. Scope 1

      3. Responsibility 1

   2. REFERENCES 1

   3. DEFINITIONS. 2

      1. General Definitions 2

   4. INJURIES AND FIRST AID 7

      1. General 7

      2. Medical Services 7

      3. First Aid 7

      4. Emergency Eye or Body Wash Stations 7

   5. PERSONAL PROTECTIVE EQUIPMENT (PPE) 7

      1. General 7

      2. Wearing Apparel 7

      3. Hearing Protection 8

      4. Respiratory Protection 8

      5. Fall Protection 8

   6. OPERATIONS 9

      1. General 9

      2. Over Water Operations 10

      3. Preliminary Rig-Up Operations 10

      4. Blowout Prevention Equipment for Drilling and Well Servicing Operations . .10 6.5 Housekeeping 11

1. Hydrogen Sulfide Environment 11

2. Confined Space, Excavations, or Hazardous Environments 11

3. Machinery and Tools 12

4. Lockout/Tagout 12

5. Auxiliary Escape 13

6. Personnel Lifting Systems 13

7. Racking Tubulars and Drill Collars 13

8. Handling Drilling Fluid Chemicals and Additives 13

1. FIRE PREVENTION AND PROTECTION 13

   1. Fire Prevention 13

   2. Fire Protection 14

2. FLAMMABLE LIQUIDS 14

   1. Containers 14

   2. Fuel and Oil Transfers and Refueling 14

   3. Liquefied Petroleum Gas (LPG) 15

   4. Storage 15

3. DRILLING AND WELL SERVICING RIG EQUIPMENT 16

   1. General 16

   2. Derricks and Masts 16

   3. Ladders, Stairways, and Platforms 16

   4. Drawworks 17

   5. Catheads and Lines Powered by the Cathead 18

   6. Hoisting Lines and Other Wire Rope 18

   7. Hoisting Tools, Hooks, Bails, Elevators, and Other Related Equipment 19

   8. Rotary 19

   9. Drill String Handling Equipment 19

   10. Weight Indicators 20

   11. Drilling Fluid Tanks 20

   12. Pipe Racks and Pipe Tubs 20

   13. Pressure Equipment 20

   14. Generators, Motors, and Lighting 21

   15. Internal Combustion Engines 21

   16. Inspection of Critical Equipment 21

4. DRILLING AND WELL SERVICING RIG ELECTRICAL SYSTEMS 21

   1. Work in Proximity to Exposed Energized Power Sources 21

   2. Rig Electrical Systems Equipment 22

   3. Classification of Areas 22

5. PUMPING UNITS 22

   1. Well Pumping Units 22

6. SPECIAL SERVICES 23

   1. General 23

   2. Equipment 23

   3. Communications 23

   4. Discharge Line (Temporary Treating or Cementing Lines) 23

   5. Lubricator Operations 23

7. WIRELINE SERVICE 24

   1. General 24

   2. Placement and Handling of Wireline Service Units 24

   3. Gin Poles (Telescoping and Single Poles) 25

   4. Rope Falls (Block and Tackle) 25

   5. Wellheads, Wellhead Connections, and Adapters 25

   6. Lubricators and Wireline Blowout Preventer Equipment 25

   7. Wireline Operations 26

   8. Perforating 26

   9. Swabbing 27

   10. Bailing 27

8. STRIPPING AND SNUBBING 27

   1. General 27

   2. Operations 27

9. DRILL STEM TESTING 28

   1. General 28

   2. Preliminary to Drill Stem Test 28

   3. Performing the Drill Stem Test 28

10. ACIDIZING, FRACTURING, AND HOT OIL OPERATIONS 28

    1. General 28

    2. Pumping Operations 29

11. CEMENTING OPERATIONS 29

    1. General 29

    2. Pumping Operations 29

12. GAS, AIR, OR MIST DRILLING OPERATIONS 29

    1. General 29

    2. Training 29

    3. Equipment 30

    4. Procedures 31

    5. Minimizing Sources of Ignition 31

13. HOT TAPPING AND FREEZING OPERATIONS 31

    1. General 31

    2. Hot Tapping Operations 31

    3. Freezing Operations 32

14. HOTWORK, WELDING, AND FLAME CUTTING OPERATIONS. 32

    1. General 32

    2. Personal Protection Equipment (PPE) 32

    3. Fire Protection 32

    4. Equipment 33

    5. Welding Fumes and Ventilation 33

APPENDIX A ASSOCIATIONS AND GOVERNMENT AGENCIES 35

Figures

1. Guyline Anchor Locations Outside the Fall Zones 24

2. Example of Sample Catcher Recommended to Protect Personnel

from Deflected Solids 30

Tables

1. Maximum Permissible Noise Exposures 8

2. Recommended Minimum Clearances Between Power Lines and Derricks,

Masts, or Guylines 22

vii

Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations

1. General

   1. PURPOSE

      The purpose of this document is to recommend practices and procedures for promotion and maintenance of safe work- ing conditions for personnel engaged in drilling operations and well servicing operations, including special services.

      
      

   2. SCOPE

      These recommendations apply to rotary drilling rigs, well servicing rigs, and special services as they relate to operations on location. The recommendations are not intended to cover seismic drilling or water well drilling operations. These rec- ommendations do not apply to site preparation and site aban- donment operations.

      
      

   3. RESPONSIBILITY

      These recommendations are made recognizing that owners, operators, contractors, and their personnel have separate responsibilities that may be contractual in nature. In the safe performance of work covered by these recommendations, each employer should provide training and instruction for its per- sonnel. It is not the intent of these recommendations to alter the contractual relationship(s) between the parties. The well owner or operator should provide and the contractor should seek per- tinent information that is known or assumed and that the con- tractor may need to assure a safe operation. At all times, the specific work activity being performed should be under the immediate supervision of an authorized person who has the authority to commence, modify, or cease the work methods or operations, as necessary, to ensure the safety of affected per- sonnel. The authorized person should observe changing condi- tions and improve, whenever required, the work methods to promote increased protection for the personnel.

      
      

2. References

The most recent editions of the following documents are referenced in this publication.

Spec 8A Drilling and Production Hoisting Equipment

RP 8B Inspection, Maintenance, Repair, and Reman- ufacture of Hoisting Equipment

Spec 8C Drilling and Production Hoisting Equipment (PSL 1 and PSL 2)

RP 9B Application, Care, and Use of Wire Rope for Oilfield Service

RP 14F Design and Installation of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class 1, Divi- sion 1 and Division 2 Locations

Spec 16A Drill Through Equipment

RP 49 Safe Drilling of Wells Containing Hydrogen Sulfide [out of print]*

RP 53 Blowout Prevention Equipment Systems for Drilling Operations

RP 55 Conducting Oil and Gas Producing and Gas Processing Plant Operations Involving Hydro- gen Sulfide

RP 67 Oilfield Explosives Safety

RP 68 Well Servicing and Workover Operations Involving Hydrogen Sulfide

RP 500 Recommended Practice for Classification of Locations for Electrical Installations at Petro- leum Facilities Classified as Class 1, Division 1 and Division 2

RP 505 Recommended Practice for Classification of Locations for Electrical Installations at Petro- leum Facilities Classified as Class 1, Zone 0, Zone 1 and Zone 2

API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair and Alteration

RP 2003 Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents

Std 2015 Safe Entry and Cleaning of Petroleum Storage Tanks

Publ 2201 Procedures for Welding or Hot Tapping on Equipment in Service

ACGIH1

API

RP 2D Operation and Maintenance of Offshore Cranes

RP 4A Steel Derricks (Including Standard Rigs) [out of print]*

ANSI2

Threshold Limit Values and Biological Indices

for 1997–1998

Industrial Ventilation, A Manual of Recom- mended Practice, 22nd Edition

RP 4D Guyed Portable Masts [out of print]*

RP 4E Drilling and Well Servicing Structures [out of print]*

Spec 4F Drilling and Well Servicing Structures

RP 4G Maintenance and Use of Drilling and Well Servicing Structures

Spec 6A Wellhead and Christmas Tree Equipment

B15.1 Safety Standard for Mechanical Power Trans- mission Apparatus

1American Conference of Governmental Industrial Hygienists, 1330 Kemper Meadow Drive, Suite 600, Cincinnati, Ohio 45240-1634. 2American National Standards Institute, 11 West 42nd Street, New York, New York 10036.

1