Dando DUKE STAGE IV Operating instructions

OPERATING AND MAINTENANCE MANUAL
DANDO DUKE STAGE IV
CABLE PERCUSSION RIG
TRAILER MOUNTED
SOCOTEC UK LTD.
DANDO DRILLING INTERNATIONAL LTD. REF.: SO/1950010
(PLEASE QUITE THIS NUMBER WHEN ORDERING SPARE PARTS)
DANDO DRILLING INTERNATIONAL LTD.
UNIT G, FORD AIRFIELD INDUSTRIAL ESTATE,
FORD, Nr ARUNDEL, WEST SUSSEX,
BN18 0HY, ENGLAND
E-MAIL: [email protected]
WEB SITE: http://www.dando.co.uk
TEL: [phone] FAX: [phone]

CONTENTS
SECTION 1 - GENERAL ..............................................................................................................................1
1.1 GENERAL SAFETY......................................................................................................................3
1.2 OPERATING AND MAINTENANCE MANUAL.............................................................................3
1.3 CODE OF SAFE DRILLING PRACTICE......................................................................................3
1.4 SAFETY PRECAUTIONS.............................................................................................................4
1.4.1 STARTING RIG ENGINE.........................................................................................................4
1.4.2 LEVELLING THE RIG..............................................................................................................4
1.4.3 MAST RAISING........................................................................................................................4
1.4.4 DRILLING OPERATIONS........................................................................................................4
1.4.5 WARNINGS..............................................................................................................................4
1.4.6 BATTERIES .............................................................................................................................5
1.4.7 TRAILER MOUNTED RIGS.....................................................................................................5
1.5 GUIDANCE NOTES ON SAFETY................................................................................................6
1.5.1 PERSONNEL...........................................................................................................................6
1.5.2 TRAVELLING TO, ON AND FROM DRILLING SITES............................................................6
1.5.3 DRILLING SITE PREPARATORY AND RESTORATION WORKS.........................................8
1.5.4 SETTING UP............................................................................................................................9
1.5.5 DRILLING OPERATIONS - GENERAL ...................................................................................9
1.5.6 DRILLING OPERATIONS –CABLE PERCUSSION.............................................................10
1.5.7 PLANT MAINTENANCE ........................................................................................................11
1.5.8 SITE ABANDONMENT ..........................................................................................................12
1.5.9 TRAINING..............................................................................................................................13
1.5.10 WELFARE AND PERSONAL PROTECTION........................................................................14
1.5.11 WIRE ROPES - GENERAL SAFETY AND MAINTENANCE.................................................16
1.6 RECOMMENDATIONS ..............................................................................................................20
1.7 WARNINGS................................................................................................................................21
SECTION 2 –TECHNICAL DATA..............................................................................................................23
2.1 RIG SERIAL NUMBER –............................................................................................................25
2.2 GENERAL DATA........................................................................................................................25
2.2.1 RIG DIMENSIONS –TRAILER VERSION ............................................................................25
2.2.2 RIG DIMENSIONS –TRACKED VERSION ..........................................................................25
2.2.3 DRILLING DEPTHS AND DIAMETERS .................................................................................25
2.2.4 POWER UNIT ........................................................................................................................26
2.2.5 COMPRESSOR .....................................................................................................................26
2.2.6 HYDRAULIC SYSTEM...........................................................................................................26
2.2.7 MAST .....................................................................................................................................26
2.2.8 STABILISING OR LEVELLING JACKS .................................................................................26
2.2.9 MAIN FREE FALL WINCH.....................................................................................................26
2.2.10 TOOLING WINCH.................................................................................................................26
2.2.11 TYRES ...................................................................................................................................26
2.2.12 TOWING WEIGHTS –TRAILER VERSION..........................................................................27

2.2.13 FINE FEED BRAKE CONTROL.............................................................................................27
2.2.14 SPT HAMMER ASSEMBLY (OPTIONAL EXTRA)................................................................27
SECTION 3 –OPERATING INSTRUCTIONS ...........................................................................................29
3.1 ACCEPTANCE OF RIG..............................................................................................................31
3.2 TRANSPORT..............................................................................................................................31
3.3 CONTROLS................................................................................................................................31
3.3.1 FREE SPOOL WINCH BRAKE..............................................................................................34
3.3.2 FREE SPOOL WINCH CLUTCH ...........................................................................................35
3.3.3 ENGINE..................................................................................................................................35
3.4 ASSEMBLY OF RIG...................................................................................................................35
3.4.1 SITE PREPARATION ............................................................................................................35
3.4.2 ERECTING PROCEDURE.....................................................................................................35
3.4.3 TAKE-DOWN PROCEDURE.................................................................................................42
3.5 SPT AUTO HAMMER DEPLOYMENT.......................................................................................46
3.5.1 DEPLOYMENT PROCEDURE ..............................................................................................46
3.5.2 STOWING PROCEDURE......................................................................................................48
3.6 SPT HAMMER OPERATION......................................................................................................49
3.7 CABLE PERCUSSION OPERATION.........................................................................................49
SECTION 4 –RIG MAINTENANCE AND SERVICE .................................................................................51
4.1 ENGINE FUEL............................................................................................................................53
4.2 ENGINE OIL ...............................................................................................................................53
4.3 ENGINE COOLANT....................................................................................................................53
4.4 COMPRESSOR OIL...................................................................................................................53
4.5 BRAKE FLUID ............................................................................................................................53
4.6 TOOLING WINCH ......................................................................................................................53
4.7 BATTERY ..................................................................................................................................53
4.8 GREASING POINTS ..................................................................................................................53
4.9 HYDRAULIC SYSTEM...............................................................................................................54
4.9.1 HYDRAULIC HEADER TANK................................................................................................54
4.9.2 HYDRAULIC CHASSIS TANK...............................................................................................55
4.9.3 HYDRAULIC TANK BREATHER ASSEMBLY.......................................................................56
4.10 CONTROL CIRCUITS ................................................................................................................56
4.11 TO FIT NEW LEVELLING JACK CYLINDER.............................................................................56
SECTION 5 –SPARE PARTS ILLUSTRATIONS AND LISTINGS............................................................61
200105418 - TRAILER MODULE
200105417 - DRAW BAR ASSEMBLY
200105453 - TANDEM BRAKED SUSPENSION UNIT ASSEMBLY
200105420 - WHEEL MODULE
200105320 - MUD GUARD ASSEMBLY
200100922 - OFFSIDE REAR TRAILER CANOPY & LIGHT ASSEMBLY
200100923 - NEARSIDE REAR TRAILER CANOPY & LIGHT ASSEMBLY
200105610 - BRAKE ASSEMBLY
200105573 - BELLY PLATE ASSEMBLY [TRAILER]
200105153 - CORE RIG
200105282 - A-FRAME ASSEMBLY
700200256 - 0.375IN HOSE BURST VALVE ASSEMBLY [VUBA380 & VUBA61100088]
200105965 - MAST ASSEMBLY

200105253 - MAST SUB-ASSEMBLY
200101191 - CROWN WIRELINE RETAINER ASSEMBLY
200105526 - MAST HYD GUARD ASSEMBLY
200105403 - INNER MAST WEAR STRIP ASSEMBLY
200105404 - MAST RAISE BRACKET ASSEMBLY
200105999 - OVERRUN DEVICE ASSEMBLY
200105258 - WHIP CHECK ASSEMBLY
200105238 - OUTER LEG SUB-ASSEMBLY [RIGHT]
200105798 - OUTER LEG SUB-ASSEMBLY [LEFT]
200105959 - MAST FOOT ASSEMBLY
200105513 - MAIN MAST LIGHTING ASSEMBLY
200105715 - 0.44 TONNE WINCH ASSEMBLY [NP05 - DANDO DUKE]
200105963 - TIE BAR SUPPORT ASSEMBLY
200105110 - HOISTING REEL ASSEMBLY
200105131 - HOISTING DRUM ASSEMBLY
200105132 - CLUTCH ASSEMBLY
200105133 - BRAKE ASSEMBLY
200105204 - BRAKE BEARING ASSEMBLY
200105555 - DRUM SAFETY GUARD ASSEMBLY
200105795 - MOTOR ASSEMBLY
200108466 - GREASER EXTENSION ASSEMBLY
200105191 - HEADACHE POST ASSEMBLY
200105348 - HEADACHE POST SEAT ASSEMBLY
200105520 - HEADACHE POST CANOPY NS ASSEMBLY
200105171 - LEVELLING JACK ASSEMBLY
200105357 - FUEL TANK ASSEMBLY (44L)
200105358 - FUEL TANK LID ASSEMBLY
200105365 - FILLER ASSEMBLY (44L FUEL TANK)
200105783 - HYDRAULIC TANKS ASSEMBLY
200105375 - HYDRAULIC HEADER TANK ASSEMBLY
200105770 - HYDRAULIC CHASSIS TANK ASSEMBLY
200109147 - HYDRAULIC TANK BREATHER ASSEMBLY
200800297 - DANDO DUKE RETURN MANIFOLD ASSEMBLY
200800305 - HYDRAULIC PUMP ASSEMBLY
200105501 - ELECTRICAL CONTROL ASSEMBLY
200800237 - COMPRESSOR MODULE
200105510 - BATTERY ASSEMBLY
200105355 - GUARD ASSEMBLY [HYD OIL TANK]
200105152 - ENGINE ASSEMBLY
200100925 - DUKE EXHAUST MK2 ASSEMBLY
200800504 - ENGINE OIL DRAIN EXTENSION ASSEMBLY
200105457 - CANOPY ASSEMBLY
200105411 - FRONT CANOPY ASSEMBLY [OS]
200105408 - FRONT CANOPY SUB-ASSEMBLY [OS]
200105449 - 1/2" BSP HYD QUICK CONNECT ASSEMBLY
200105663 - FRONT CANOPY DOOR AND PANEL ASSEMBLY [OS]
200105412 - FRONT CANOPY ASSEMBLY [NS]
200105907 - FRONT CANOPY SUB-ASSEMBLY [NS]
200105914 - FRONT CANOPY [NS] DOOR AND PANEL ASSEMBLY
200105917 - FRONT CANOPY [NS] DOOR ASSEMBLY
200105919 - FRONT CANOPY DOOR AND PANEL ASSEMBLY [NS]
200105415 - REAR CANOPY ASSEMBLY
200105414 - REAR CANOPY SUB-ASSEMBLY
200105416 - REAR CANOPY DOOR & PANEL ASSEMBLY
200105194 - REAR CANOPY DOOR ASSEMBLY [NS]
200102246 - UMBILICAL DOOR ASSEMBLY
200105428 - REAR CANOPY DOOR ASSEMBLY [OS]
200105483 - CONTROL CONSOLE ASSEMBLY
200105473 - RECEIVER TANK ASSEMBLY
200106329 - SAFETY LATCH ASSEMBLY
200105452 - LIFTING EYE ASSEMBLY
200105460 - AIR HOSE REEL ASSEMBLY

200109131 - FINE CONTROL BRAKE ASSEMBLY
200109130 - LEVER ASSEMBLY
200109136 - FINE CONTROL CLEVIS ASSEMBLY
200115119 - BRAKE RESERVOIR HOSE ASSEMBLY
200115120 - BRAKE CALIPER HOSE ASSEMBLY
200108353 - STOWAGE ASSEMBLY - SPREADER BAR
200108355 - CLAMP BRACKET ASSEMBLY - SPREADER BAR
200109000 - CASING JACK ASSEMBLY [MEDIUM]
200109101 - CONSOLE & RAM ASSEMBLY [CASING JACK]
200109102 - CASING JACK KIT [MEDIUM]
200108315 - CORE EXTRACTOR ASSEMBLY
200105970 - STOWAGE ASSEMBLY (MULTI-HEIGHT SPT HAMMER)
200106333 - SPT STOWING WINCH ASSEMBLY
200105329 - STRAP GUIDE ASSEMBLY (SPT)
200106815 - MULTI-HEIGHT SPT HAMMER ASSEMBLY
200106304 - SPT HAMMER ASSEMBLY
200106201 - DRIVE CHAIN ASSEMBLY
200106816 - MULTI-HEIGHT SPT KIT
SECTION 6 –HYDRAULIC CIRCUIT ......................................................................................................261
SECTION 7 –ELECTRICAL CIRCUITS ..................................................................................................265
APPENDIX A –ENGINE PERKINS 403D-15...........................................................................................285
APPENDIX B –COMPRESSOR DYNASET HK450/8-14........................................................................397
APPENDIX C –TOOLING WINCH DINAMIC OIL NP05 .........................................................................463
APPENDIX D –PNEUMATIC CLUTCH WPT POWER TRANSMISSION CORP. W14-OC-202............501
APPENDIX E –PNEUMATIC BRAKE WPT POWER TRANSMISSION CORP. W14-OE-218...............539
APPENDIX F –REFERENCES................................................................................................................551
APPENDIX G –TEST REPORTS............................................................................................................555

SECTION 1
GENERAL
1

2

SECTION 1 - GENERAL
1.1 GENERAL SAFETY
As Designers, Manufacturers and Suppliers of Specialised Equipment, Dando
Drilling International Ltd ensure so far as it is reasonable that our products are
safe and without risk to health when properly used.
You are requested to take the necessary steps to ensure that the appropriate
information is made available to all those involved with the proper use of our
products, or to anyone who may work on, purchase, or otherwise acquire such
products for their own use.
1.2 OPERATING AND MAINTENANCE MANUAL
Dando Drilling International Ltd support all new products being supplied to
their customers with a comprehensive Operator Manual which clearly defines
mandatory instructions for the operation, safe use and maintenance of the
products. Further, where proprietary items are incorporated into products of
Dando Drilling International Ltd, comprehensive Operators Manuals on these
items are also supplied, together with the Operating Manuals etc. on any
vehicle or other carrier supplied as part of a contract.
It is the responsibility of the owners or hirers of such products to ensure that
operators are provided with these Manuals and are suitably instructed
regarding the purpose of these Manuals and safety instructions. In addition,
operators should be suitably and adequately trained in the use of the product.
1.3 CODE OF SAFE DRILLING PRACTICE
It is the responsibility of the owners and hirers of this equipment to ensure
that the operators of the equipment are aware that drilling sites can be
potential hazardous environments, and that safe drilling practice should
always be adhered to.
Dando Drilling International draw your attention to the Code of Safe Drilling
Practice as published by the British Drilling Association [Ref 1], and would
recommend that all operators are fully conversant with all aspects covered by
this publication and take the necessary steps to become B.D.A. Accredited
Drillers. For operators outside the United Kingdom, we would recommend
that their national equivalent to the B.D.A. publication is adhered to.
The Guidance Notes on safety that follow are extracted from the British
Drilling Association’s publication “Code of Safe Drilling Practice”, and Dando
Drilling International would like to acknowledge with thanks their permission
to reproduce this section. Further guidance on percussion drilling can be
found in Guidance for the Operation of Cable Percussion Rigs and
Equipment also published by the British Drilling Association [Ref 2].
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1.4 SAFETY PRECAUTIONS
WARNING. BREATHING DUST IS DANGEROUS TO HEALTH
1) Operate in a well-ventilated place and use appropriate extraction
equipment or a damp cloth to remove dust.
2) Dampen all dust.
3) Dispose of waste in heavy gauge plastic sacks in accordance with
legislative requirements.
GENERAL INSTRUCTIONS AND WARNINGS
1.4.1 STARTING RIG ENGINE
Check that all controls are in a neutral/disengaged/minimum position.
1.4.2 LEVELLING THE RIG
Before attempting to raise the mast, ensure that the rig is set up on a firm level
base, and all jacks are in contact with the ground.
1.4.3 MAST RAISING
CAUTION: Before attempting to raise the mast, ensure that the mast
framework is clear of any obstructions.
1.4.4 DRILLING OPERATIONS
Before commencing any drilling operations, ensure that the spreader bar and
stay bars are fitted and secured.
1.4.5 WARNINGS
THIS RIG IS FITTED WITH AN ALTERNATOR
DO NOT disconnect batteries when engine is running.
DO NOT turn ignition key to '0' position on switch while the engine is running.
IF ANY ARC WELDING takes place on the rig DISCONNECT BOTH
BATTERY AND ALTERNATOR. When brazing, soldering or welding, it is
essential that any excessive heat source is kept away from the vicinity of the
alternator and any nylon piping or rubber hose.
FAILURE TO COMPLY WITH THESE WARNING WILL LEAD TO
COMPONENT DAMAGE AND MAY CAUSE INJURY.
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1.4.6 BATTERIES
Ensure that the correct battery polarity is maintained at all times, reversed
battery or charger connections may damage the alternator rectifiers. Never
disconnect the battery whilst the engine is running.
DO NOT use a naked light when examining the electrolyte level.
When charging the batteries from an external source ensure that the vent
covers are removed.
Always disconnect the earth lead from the battery negative (-) terminal when
working on the rig engine.
Avoid spilling battery acid on the paintwork. Wash off with water immediately if
this occurs.
1.4.7 TRAILER MOUNTED RIGS
WARNING: The trailer on which the rig is mounted is designed with a load
carrying capacity for the rig only, unless otherwise specifically
stated. Do not add platforms etc. for carrying additional items as
this will overload the trailer, contravening the Road Traffic
Construction and Use regulations in the United Kingdom.
5

1.5 GUIDANCE NOTES ON SAFETY
1.5.1 PERSONNEL
a. Drilling may entail the employment of men inexperienced in this class of
work. Care should therefore be taken to explain and enforce safety
precautions, and to teach good practice in the handling and use of equipment
and plant.
b. No workman should be employed on any work unless he has been adequately
instructed and trained in that work and is competent to do that work without
supervision, or he is working under the instruction and supervision of some
person competent to give instruction in and supervision in the doing of that
work. This is especially important when employing young persons on drilling
sites.
c. Alcohol should not be consumed on the site and persons who have been
drinking
should not be allowed on the site.
d. Pranks and horseplay are a common cause of accidents and should be
forcefully
discouraged. Safe successful work requires serious attention and good
teamwork.
e. Operators should not lift, carry or move any load which is so heavy as to be
likely to cause injury. When lifting, it is recommended that the person should
stand squarely with a solid footing and should lift the load slowly by
straightening the legs rather than the back.
f. Care should be exercised when handling weights which must be moved with
artificial means, such as pipe used for casing etc.
g. If pipe is to be moved by rolling by hand, this must be done from the ends
and the person must ensure that the hands are kept out of the ends of the
pipe. Whenever possible the pipe should be rolled away from the person
rolling it.
h. In general, care should be exercised whenever lifting something, be it heavy
or light. In the case of lifting and moving heavy weights, chains, ropes and
pipe hooks should be checked to ensure that they are in good condition and
employees should never stand under a raised load.
i. Visitors to the drilling site are in more danger that the operators, and should
be steered clear of operational areas unless the nature of their visit demands
otherwise. If necessary, operations should be suspended until visitors have
been moved to a safer part of the site.
1.5.2 TRAVELLING TO, ON AND FROM DRILLING SITES
a. Vehicles travelling on public highways must comply with the Highway Code,
relevant Road Traffic Acts and with the appropriate Motor Vehicle
Regulations currently in force in the United Kingdom or other E.C. country.
6

b. Before travelling, checks should be made to all vehicles for road worthiness,
giving special attention to lights, indicators, screen wipers, registration plates,
brakes, brake lights, steering, security of loads, particularly overhanging
loads, tyre pressure and wear and lack of mud before proceeding onto a
public highway.
c. Important: It is drawn to your attention that the Dando Duke models of drilling
rigs are NOT trailers and should not be loaded with drilling equipment during
travel from drilling site to drilling site.
d. It is important that checks are made of the coupling and/or hitching of the
drilling rig to any towing vehicle.
e. Where required, long vehicle signs, caution or towing boards should be
securely attached.
f. When towing equipment, correct towing speeds, reversing and manoeuvring
procedures should be observed and assistance obtained where necessary.
Due regard should be paid to road conditions and visibility at all times. Care
should be taken when towing in icy conditions as “jack-knifing” can occur.
The safe towing speed should not be exceeded as there is a risk that
“snaking” may suddenly develop, which may cause the trailer to lose a wheel.
g. Consideration should be given to other road users who may become
impatient and take risks - it is advisable to pull into the side occasionally to let
them pass.
h Where wide, long or heavy loads are to be moved it is advisable to have all
lights on for road travel, even in broad daylight.
i. On arrival at the site, ground conditions should be checked before driving in,
and a watch kept for temporary overhead obstructions.
j. If necessary, an assistant should be used to control traffic if safety dictates.
k. Passengers should not be carried on or around the machine.
l. The driver of the vehicle should check for all round visibility before
commencing any manoeuvre, especially reversing. If necessary, an
assistant should be used to signal. The presence of an assistant does not
relieve the driver of his responsibility, so he should constantly check the rear
view in his mirror, and by direct sight.
m. When manoeuvring vehicles, due regard should be paid to soft ground,
potholes, gradients, slippery grass and mud, and overhead cables. Special
care should be taken when crossing dykes with improvised bridges. At all
times, personnel should keep well clear of moving vehicles in case they
overturn. Where winches must be used, a watch should be kept for flying
ground anchors and rope failures.
n. Loading and un-loading the plant should only be carried out on firm level
ground.
7

o. The vehicle’s driver should act as assistant during loading and un-loading
operations. Signals should be agreed beforehand and standard procedures
followed.
p. When loading or un-loading on a public highway, assistants should be used
to hold back traffic. These men should be responsible to the vehicle driver
only.
q. Where the access to and from the site does not have good visibility in all
directions, traffic leaving the site should be controlled by a person nominated
for that purpose.
r. Vehicles should not reverse out of the drilling site onto a public highway.
1.5.3 DRILLING SITE PREPARATORY AND RESTORATION WORKS
a. It is of greatest importance that a proper site appraisal should be made
before any work is commenced. The results, together with any records of
any underground installations, services, workings, etc., should have been
made available to the drilling contractor who in any event should take all
reasonable steps to obtain them.
b. A plan of the site showing the location of hazards to site preparatory work
and to drilling operations should be prepared before any equipment is taken
on site.
c. The drilling contractor should always act with competent engineering advice
and assess the general hazards which may arise during construction and
drilling due to the nature of the ground, the existence of high water, gas or oil
pressures in the strata, surface and underground installations and services.
d. The site should be inspected before rig entry to find a safe approach route to
the proposed drilling position. Some guidance may be required for winching
or lowering rigs on steep slopes and in setting up in marshy or other soft
areas.
e. It should be ascertained that the load bearing quality of the proposed site is
adequate for safe working conditions. Hazardous situations such as old rock
fill, unstable material, surface soils on sloping rock surfaces, under
dangerous banks or quarry sides and on quarry edges should be avoided.
f. A clear access to and from the site should be provided with good visibility in
all directions. If this is not possible, traffic leaving the site should be
controlled by a person nominated for that purpose.
g. The working area should be suitably prepared and where necessary levelled,
surfaced and drained. Means should be provided to trap any escape of
petrol, diesel fuel or oil which might leak into the water courses, fields or
public drains, before it leaves the site.
h. The site should be adequately fenced and warning notices posted, with
separate fencing and warning notices being provided for any mud or slurry
pits.
8

i. Where working platforms are required to support men, equipment and/or
materials, the platform should be properly constructed. It should be of
adequate dimensions, and if over 2 metres above ground, should have guard
rails and tow boards so placed as to prevent falls of persons or articles from
the platform. Similar guard rails and tow boards may be considered
desirable on platforms constructed at lesser heights in some circumstances.
The platform construction and stability should be checked weekly for defects.
1.5.4 SETTING UP
a. The site must be kept in a well organised tidy state and clear of all debris and
extraneous material.
b. It is preferable for acoustic barriers to be constructed of non-flammable
material.
c. It should be ensured that all relevant machine guards have been installed
before starting up any machine.
d. Bulk stocks of fuel, oil and gas cylinders should be stored in a designated
compound remote from the immediate working area.
e. Rods, Casings etc. should be neatly stacked, preferably on appropriate racks
and maintained in a clean condition.
f. Threads and connectors should be regularly cleaned and greased, and
preferably protected with thread protectors.
g. Tools and materials should be laid out according to requirements and in
order of use.
1.5.5 DRILLING OPERATIONS - GENERAL
a. Drilling may entail the employment of some personnel inexperienced in this
class of work. In such circumstances, particular care should be taken to
explain and enforce safety precautions, and teach practice in the handling
and use of equipment. It is important that safe working systems of work are
adhered to by all personnel.
b. Inexperienced men should always remain under expert supervision.
c. At the commencement of each shift the incoming crew should make certain
that the equipment is in a useable and safe condition. Unsafe conditions and
any significant change in operating conditions should be reported in the
driller’s log book and any action taken thereon should also be logged.
d. Each operation must have its set routine, each team member knowing
exactly what part he is to play.
e. Under no circumstances must a rig be operated by one man.
9

f. High noise level areas should be identified and hearing protection worn
where necessary.
g. Where engine noise or other sounds prohibit verbal communication, a clear
set of signals which are clearly understood and known by each team member
should be used. This will also apply when ear defenders are worn.
h. It should be ensured that the winch operator has a clear view of men
operating equipment at all times.
1.5.6 DRILLING OPERATIONS –CABLE PERCUSSION
a. A firm and level working surface should be established for the erection of the
rig using timber sleepers where necessary. Mast guys, if applicable, should
be correctly positioned and securely anchored, properly tensioned and
frequently checked.
b. The equipment should always be operated in a safe manner and in
accordance with the manufacturer's instructions.
c. Cable tools which are not in use should be laid down horizontally on timber
grillage and should not be left in an upright position resting against the
derrick.
d. The correct tool should always be used for the operation being undertaken.
e. Personnel should keep clear of suspended equipment and use a rope, strap
or bail hook to swing tools away from the borehole. They should never look
down the borehole beneath a suspended tool.
f. When the drive clamps are suspended or in use the operator should not
place his hand on the drive head. When casing is being driven the drive
clamps should not be suspended above the operator's head. Short lengths of
casing can be used for this operation.
g. Tools should not be held in suspension be means of only the hand or foot
control when personnel are changing or working on them.
h. The winch operation should be in accordance with the manufacturer's
instructions, and should not be overloaded when pulling casing. When
additional force is required proper jacking equipment with positive
connections between jack head and casing should be employed, or an
appropriate casing jar.
i. Casing tubes and tool joints should always be screwed well home in order to
avoid damage to the threads and to prevent parting.
j. When driving casing, personnel should not place their fingers in tommy bar
holes or over the lip of the casing.
k. All worn or splintered drive heads, drilling tools, sinker bars. Etc. should be
replaced. Crushed, bruised or damaged wirelines should be removed
immediately.
10

l. Sheave Wheels shafts and pins should be checked daily, kept well lubricated
and replaced when worn.
m. Personnel should be alert for indications of broken strands of wire ropes and
of shackles becoming undone.
n. Cuttings or spoil at the hole collar should not be cleared by hand or any tool
unless the rig is in neutral and the clutch disengaged.
o. Slurry pits should be positioned so that they can be reached safely and easily
by the bailer/shell without danger to the drill crew or undue stress on the
bailing line. They should not be so close to the rig as to undermine the rig
grillages.
1.5.7 PLANT MAINTENANCE
a. Plant, machinery and structures should be inspected at regular intervals in
accordance with the manufacturer’s recommendations. In the case of plant
which is subject to corrosion, steps should be taken to effect repairs before
corrosion reaches dangerous limits.
b. A planned preventative maintenance system covering shift, daily, weekly and
periodic times should be established for the different types of machine used.
This should include the inspection of all pulleys, drum surfaces and ropes,
and should stipulate their regular cleaning and lubrication. The system should
include a three-part sequence of inspection, thorough examination and
testing. Results of each stage are to be recorded and signed.
c. Cleaning, repair, maintenance, oiling or greasing of machines or the topping
up of fuel tanks should not be carried out whilst a machine is operating.
d. If inspection involves the running of a petrol or diesel engine in an enclosed
space, all doors and windows to the workshop should be opened and even
then, the engine should only be run intermittently to avoid a dangerous build-
up of fumes.
e. All plant should be kept clean by the regular removal of mud and dirt and of
snow and ice in winter, if applicable.
f. When major dismantling of components is necessary, the correct lifting
equipment should always be used and it should be ensured that struts and
chocks are strategically placed as the process continues.
g. The ignition key should always be removed, and a notice placed in such a
prominent position that it cannot be missed, if it is necessary to work
underneath a machine, or to leave it in an incomplete unsafe state.
h. Moving parts of machinery are to be guarded where possible and such
guards should be in position when machinery is in normal operation. Guards
should not be removed except as required for maintenance purposes, in
which case the machine should be immobilised.
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i. Lifting machines and tackle should be inspected and tested at set intervals
and certified for the maximum permissible working loads, and these loads
should not be exceeded. Following any major repair, they should be re-
certified before being returned into service. The owner/operator should be
aware of current legislation in force in their own country and comply with all
regulations regarding re-testing of equipment.
j. Electrical installations should be effectively earthed.
k. Electrically operated hand tools, together with leads and earth wires, should
be inspected at regular intervals to ensure that they have been maintained in
good order, and such inspections should be recorded.
l. Trailing cables, except for hand-lamps and small portable tools should be of
a standard equal to BS 708. Pliable armoured cables are preferred.
m. When high pressure grease guns are used, protective gloves should always
be worn and care taken to avoid injecting grease under the skin.
n. Hoses used for steam cleaning should be of the type made for steam service.
The metal nozzle should always be securely clamped to the hose and
maintained in serviceable condition.
o. A flammable liquid within the classification of Class ‘A’ or Class ‘B’ petroleum
should not be used for cleaning purposes, except in very special
circumstances, and then by written permission only.
p. Loose boards and materials not in use should be removed from the derrick
floor.
q. Steps and guard rails, where applicable, should be maintained in good
condition. If it is necessary to remove them temporarily during installation of
the machinery, they should be replaced without delay when finished.
r. To eliminate slipping hazards, drilling rig floors, etc. should be kept as free of
mud and oil as practicable. Better footing is provided if the floor is washed
while the next stand of pipe is being picked up. Non-skid materials are useful
in some areas to prevent slipping.
1.5.8 SITE ABANDONMENT
a. Every uncompleted borehole should be fenced or temporarily capped in a
safe manner when the rig has moved off and until the hole is finally capped.
b. Unless a borehole is required to be kept open for some specific purpose, it
should be infilled, consolidated and capped in such a manner that there will
be no subsequent depression at ground surface due to settlement of the infill
material.
c. Surface standpipe should be withdrawn or cut at least one metre below
ground level prior to infilling the borehole.
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d. Capping pads should be placed at least one metre below ground level.
e. Mud and slurry pits should remain adequately fenced and signposted until
emptied, backfilled and consolidated. Any impervious membrane should be
removed prior to restoration.
f. The site should be left in a safe, clean and tidy state, with all gates and
fences left as found.
1.5.9 TRAINING
a. The most important factor of all on site safety is the full education and
practical technical training of all drill crew members in all aspects of drilling
and associated operations.
b. Such training should include not only basic safety precautions, but also a
thorough understanding of the correct use of all plant, equipment and tools.
c. In addition, knowledge should be given of the forces of both energy and
mass which the crew control through the medium of the drill rig.
d. The prime concept of this training is to teach each crew member to do his
own job efficiently and safely, and to so work with the other members of the
crew that good and safe team work becomes instinctive.
e. This not only results in steady and safe progress, but secures higher
production.
f. All training whatever the size of the organisation, should be formally
programmed throughout the number of stages required by the personnel
concerned. Each step in the training module or syllabus should be monitored
by a fully trained instructor, and duly recorded towards the eventual
certification of the trained crew member upon completion of the course
concerned.
g. Training should be so presented that the stimulation of personal interest and
the known attainment of craft and skill achievement is a main aim and result.
Such training therefore should be initiated and encouraged by both
management and supervisory staff.
h. Emphasis should be made on the value of efficient teamwork towards the
goal of high and safe production.
i. It cannot be too strongly stressed that the operatives’involvement and
outlook is dependent upon the quality and support of the employer.
j. The responsibility for all aspects of site safety rest with all levels of management.
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1.5.10 WELFARE AND PERSONAL PROTECTION
a. The Health and Safety at Work Act 1974 (United Kingdom) requires
every employee, while at work, to take reasonable care for the health
and safety of himself and of other persons who may be affected by his
acts or omissions at work. In this regard, personal and site safety and
hygiene are most important.
b. Adequate and suitable protective clothing should be provided for any person
employed who, due to the nature of his work, is required to continue working
in the open air during rain, snow, sleet or hail.
c. Adequate accommodation for personnel to take shelter during bad weather,
for the storage, drying and changing of clothing and for taking of meals
should be available. Such accommodation should include the facility for
boiling water, heating food and the provision of washing facilities to permit
personal hygiene. Personnel should be encouraged to wash before
partaking of food.
d. Washing and kitchen waste water should be discharged into a pit or sump
dug into the ground remote from ditches and water courses.
e. Empty tin cans, bottles, plastic containers, drums and scrap metal, wire rope
etc., should be placed in containers for transport to recognised waste
disposal sites.
f. Suitably ventilated chemical toilets housed to provide privacy, should be
available. These should be regularly serviced and contents disposed of in
accordance with manufacturer’s instructions. Personnel should be
encouraged to wash after using these facilities.
g. Potable/drinking water should be available and containers clearly marked as
such to distinguish from non-potable/non-drinkable water.
h. Oil saturated clothing is a fire risk, and also a health risk in that it irritates the
skin. They should be changed as soon as possible.
i. Advice should be sought from the local water authority and their medical
officer of health prior to working in sewers or on waste disposal sites. When
working in these situations rubbing of the nose or mouth with the hands
should be avoided. On completion of the work, hands and forearms should
be thoroughly washed with soap and clean water with an added disinfectant.
Any clothing or boots that have become contaminated should be washed,
cleaned or disinfected. Any cut, scratch or abrasion should be cleaned,
treated with antiseptic and completely covered until quite healed.
j. The possibility of existing excavations transmitting bacteria carrying liquids
into a working area should not be overlooked.
k. It is advisable that drilling crews should receive regular anti-tetanus
injections, and always carry their anti-tetanus injection card with them.
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