902 Well Site Preparation and Drilling Safety

Rigging Up the Circulating System

While one crew completes preparation of the rig floor, another crew may simultaneously rig up the circulating system. The circulating system is a critical component of drilling operations, as it moves drilling fluid (mud) through the drill string and back to the surface to cool the bit, carry cuttings, and maintain well control.

Rigging up the circulating system involves positioning major components and making mechanical and electrical connections so the system can safely and efficiently move drilling fluid. Proper alignment and secure connections are essential to prevent leaks, equipment failure, and injuries.

• Mud tanks and mud pumps are set into their predetermined locations using cranes, forklifts, or rig-up trucks.
• Mud lines, manifolds, and hoses are connected between tanks, pumps, and the wellbore, and electrical cords are routed and secured to power the system.

Potential Hazards

• Being struck by or crushed by heavy equipment such as mud tanks, mud pumps, manifolds, or piping while components are being lifted, moved, or positioned into place. Workers may also be caught between equipment and fixed objects during placement.
• Caught-in or pinch-point hazards while aligning mud pumps, connecting mud lines, installing manifolds, or tightening fittings. Hands, fingers, and other body parts can become caught between mating components or moving equipment.
• Being struck by cranes, suspended loads, rig-up trucks, or forklifts used to transport and position circulating system components. Workers are also exposed to hazards if lifting equipment becomes unstable, shifts unexpectedly, or tips over.

• Slips, trips, and falls caused by mud, drilling fluid, water, hoses, electrical cords, tools, or other materials on walking and working surfaces. Slippery or cluttered rig floors increase the risk of falls and other injuries during rig-up operations.

Possible Solutions

• Maintain a safe distance from equipment that is being moved, lifted, or positioned, and stay clear of suspended loads.
• Keep hands, fingers, and body parts away from pinch points when equipment is coming together.
• Stand clear of workers who are swinging hammers or using impact tools, and ensure adequate spacing between workers.
• Use proper lifting techniques and approved rigging equipment for all lifting operations.
• Wear appropriate Personal Protective Equipment (PPE), including hard hats, gloves, eye protection, and safety-toe boots.
• Maintain good housekeeping by cleaning up spills and keeping walkways clear.

Hammer Unions

A hammer union is a specialized pipe connection used to quickly connect and disconnect sections of high-pressure piping, hoses, and equipment. Because hammer unions often contain fluids under high pressure, they present significant hazards if improperly used.

Possible solutions include:

• Verify the union is the correct pressure rating and size.
• Inspect threads, seals, and sealing surfaces for wear or damage.
• Never mix components from different manufacturers or pressure ratings unless they are specifically designed to be interchangeable.
• Ensure the connection is fully made up before pressurizing.
• Depressurize and isolate the line before loosening a hammer union.
• Stand clear of the strike zone and wear appropriate PPE, including eye protection, gloves, hard hat, and safety footwear.
• Use the correct hammer and striking technique to reduce the risk of hand injuries and flying metal fragments.

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