903 Well Site Completion and Servicing Safety

Perforating, Fracturing Fluid, Blending, and Pumping

Possible Solutions

Perforating, fracturing fluid handling, blending, and pumping are critical steps in hydraulic fracturing that involve high-pressure equipment and hazardous materials, requiring strict safety measures to protect workers and prevent incidents.

• Conduct a pre-job inspection to identify and eliminate or correct hazardous work surfaces.
• Require all non-essential personnel to stand clear of the work zone.
• Fasten high-pressure lines together properly.
• Conduct adequate pressure tests on pump(s) and lines and ensure proper valve alignment before pumping. Install a check valve as close to the wellhead as possible.
• Use proper equipment inspection techniques that include hammer unions.
• Direct equipment operators to stay by their controls.
• Use proper equipment guards and covers.
• Provide adequate bonding and grounding for blending, pumping and sand transfer equipment.
• Use hose covers or shielding for transfer or suction lines containing flammable liquids to prevent them from being ruptured resulting in fires or explosions.
• Substitute less hazardous materials.
• Require the capping of unused fill ports (e.g., cam lock caps) on sand movers.
• Reduce the drop height between the sand transfer belt and T-belts and blender hoppers.

• Enclose points where silica dust is released. Use local exhaust ventilation to collect silica-containing dusts and prevent dust escape. Install dust collection systems onto machines or equipment that release dust.
• Where possible, use enclosed cabs or booths. Consider providing operator cabs and booths with HEPA filters and climate controls to further protect workers.
• Replace proppant transfer belts with screw augers on sand movers in new designs or retrofits.
• Ensure that workers follow the safe handling procedures found in SDSs.
• Use proper mixing procedures.
• Wear appropriate PPE, including respirators and eye, face and hearing protection.
• Provide an eyewash station and other appropriate flushing equipment as recommended by the SDS.
• Use mechanical lifting aids, proper lifting techniques and team lifting where appropriate.

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