902 Well Site Preparation and Drilling Safety

Setting Up the Rig Floor and Mast or Derrick

Once the substructure is set in place and verified as level and secure, the process of setting up the rig floor begins. The rig floor serves as the primary work area for drilling operations and supports critical equipment, personnel movement, and the mast or derrick. Proper installation and inspection during this phase are essential to safe and efficient drilling.

Setting up the rig floor and mast or derrick is one of the most complex phases of drilling rig assembly. During this process, heavy equipment is lifted, structural components are assembled, and mechanical, electrical, and hydraulic systems are connected. Workers may be exposed to struck-by, caught-in, pinch point, fall, and suspended-load hazards. Rig-up activities should only be performed by trained and qualified personnel following the rig manufacturer's procedures and under the direction of a qualified supervisor.

Steps in this process are listed below:

1. Install Stairways, Handrails, and Guardrails: Once the substructure is securely in place, install all stairways, walkways, handrails, and guardrails that provide safe access to the rig floor and elevated work areas. Verify that stairs are securely fastened, walking surfaces are free of debris, and guardrails meet company and regulatory requirements (e.g., OSHA 1926.502 or company requirements such as 42" height, midrail, and toeboard where needed). Safe access should be established before workers perform additional rig-up activities on elevated surfaces.
2. Install and Secure the Drawworks: Position the drawworks on the rig floor or substructure using approved lifting equipment and rigging methods. Carefully align the unit with its mounting points and securely fasten it according to the manufacturer's specifications. Verify that all mounting bolts, pins, and supports are properly installed and tightened. Because the drawworks controls the hoisting system used throughout drilling operations, proper installation is critical for both safety and performance.
3. Install the Power System: Depending on the rig design, install the engines, electric motors, generators, or other power units that drive the drawworks and auxiliary equipment. On mechanical rigs, align and secure the engines before connecting power transmission components. On electric rigs, position generators and drive systems, then install and secure electrical cables in accordance with electrical safety procedures. Inspect all connections to verify they are properly supported and protected from damage.
4. Connect Mechanical or Electrical Drive Systems: Complete the connections between the power system and the drawworks. On mechanical rigs, install and align the compound, drive shafts, chains, clutches, and related components. On electric rigs, connect power cables, control systems, and drive equipment while following lockout/tagout procedures when required. After installation, inspect all drive components for proper alignment, secure mounting, and freedom from obstruction.
5. Position and Secure the Mast Base: Move the mast into its designated position on the rig floor or substructure using approved lifting or positioning equipment. Align the mast base with its hinge points or support structure and install all required hinge pins, locking devices, and structural fasteners. Inspect each connection to ensure it is fully seated and properly secured before raising operations begin.
6. Install the Monkeyboard and Required Mast Components: Install the monkeyboard, working platform, ladders, climbing systems, and other mast components that must be in place before the mast is raised. Verify that all structural members are securely pinned or bolted according to the manufacturer's instructions. Where required, install fall protection anchorage systems and inspect them for proper installation before workers climb the mast.
7. Organize Drilling Line, Cables, Hoses, and Equipment: Lay out the drilling line, electrical cables, hydraulic hoses, air lines, mud hoses, and other rig-up equipment in an organized manner. Proper routing helps prevent tangles, equipment damage, and interference during mast raising. Secure components where necessary to eliminate tripping hazards and prevent them from becoming caught in moving equipment.
8. Conduct a Pre-Raise Inspection: Before raising the mast or derrick, perform a comprehensive inspection of all structural components, rigging, lifting equipment, pins, bolts, braces, wire ropes, hydraulic systems, and mechanical connections. Verify that no tools, loose materials, or unnecessary personnel remain within the mast raising area. Confirm that weather conditions, communication systems, and emergency procedures are suitable for the operation.
9. Raise the Mast or Derrick: Raise the mast or derrick using the manufacturer's approved raising system, which may include the drawworks, a dedicated raising line, hydraulic cylinders, or other approved equipment. The operation should proceed slowly and under continuous observation. Maintain clear communication among the rig crew using established hand signals or radio communication. Keep all nonessential personnel outside the designated danger zone until the mast has been fully raised and secured. Confirm that weather conditions (especially wind speed) are within the manufacturer's limits before proceeding.
10. Pin and Secure the Mast: Once the mast reaches its fully upright position, immediately install all required locking pins, braces, retaining devices, and structural fasteners. Verify that each pin is fully inserted and secured with the appropriate retaining mechanism. Inspect the mast for proper alignment before releasing any lifting or raising equipment.
11. Install and Tension Guylines (If Required): Some mast designs require guylines to provide additional structural stability. Not all mast designs require guylines (e.g., some self-supporting or telescoping masts). Attach each guyline to its designated anchor point using approved hardware and procedures. Tension each line according to the manufacturer's specifications and verify that anchors are properly installed and capable of supporting the required loads. Inspect guylines periodically throughout operations to ensure they remain properly tensioned.
12. Install the Traveling Block and Hoisting Equipment: If not already installed, attach the traveling block, hook assembly, elevators, and associated hoisting equipment. Verify that all sheaves rotate freely, safety latches function correctly, and all pins and retaining devices are securely installed. Inspect the equipment for signs of wear, damage, or improper assembly before use.
13. Reeve and Tension the Drilling Line: Install the drilling line by reeving it through the crown block and traveling block according to the manufacturer's recommended pattern. Secure the deadline to the deadline anchor and spool the drilling line evenly onto the drawworks drum while maintaining proper tension. Inspect the wire rope for broken wires, kinks, crushing, corrosion, or other defects before placing the hoisting system into service.
14. Install the Derrick Emergency Escape Device: Install the derrick emergency escape device according to the manufacturer's instructions. Verify that the escape line is securely anchored, properly tensioned, and free from obstructions. Inspect the riding device, descent mechanism, and anchorage to ensure they function properly. Workers assigned to elevated work areas should receive training on the proper use of the emergency escape system before drilling operations begin.

These steps reflect generally accepted industry practices for portable land drilling rigs and emphasize that the exact sequence may vary depending on the rig type (mechanical, SCR, AC electric, telescoping mast, jackknife mast, or conventional derrick) and the manufacturer's rig-up procedures. They also align with OSHA's general requirements for safe rigging, fall protection, machine guarding, and worker training without implying a single mandatory sequence.

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