Well Test 1 Course

Global Training Course

Rigging up and Down

Rigging Up
Safety is of paramount importance, and therefore EXPRO
have in place operational and safety guidelines which
should be adhered to at all times.
Should it be necessary to deviate from these guidelines
then a full evaluation of the risks must be carried out before
commencement of any new operations or procedures.
It will be necessary to reduce these risks zero or within an
acceptable limit.

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Global Training Course
Rigging up and Down

Prior to starting rig-up a Tool Box Talk must be held.

What is discussed at this Tool Box Talk?
• The operation of rig-up and associated operational
procedures.
• A detailed step by step procedure, discussing the risks
involved and how to eliminate or minimize the risks.
• Allotment of responsibilities to the personnel, making sure that
persons carrying out work are trained and competent.
• Make sure that the personnel from the rig who will be involved
with the rig up attend the Tool Box Talk.
• A record of the Tool Box Talk form is kept. (EXPRO Form
HSE/GRP/FRM/007.4)

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Global Training Course
Rigging up and Down

What does the Tool Box Talk form look like?

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Rigging up and Down

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Global Training Course
Rigging up and Down

Once the Tool Box Talk is finished, what is the next

step?

The supervisor must arrange for a Permit to Work, covering

for his shift, all work to be carried out.
Rig personnel must be informed that rigging up is talking
place and overhead crane work will be necessary.
A copy of EXPRO’s Permit to Work is contained in the
manual. It is a very good representation of a permit to
work, and should be used at all times when working in the
base.

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Global Training Course
Rigging up and Down

When rigging up what is the first thing that happens?

Laying out of equipment according to drawing.

This will entail a lot of crane work. The crane operator and
banksman will be in charge of this operation and Well Test
personnel must be in constant communication with the
banksman.
Because of the lack of room associated with the laying out
of equipment a strict control of the movement of equipment
must take place.

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Global Training Course
Rigging up and Down

How do you control a load when it is off the deck?

By using a tag line.

What is a tag line?
Pieces of rope attached to the corners of equipment.
How long should a tag line be?
Long enough so that if anything were to happen to the load then you
would be far enough away from it to be safe.
The tag line will allow you to turn and place the load in the exact
position required.

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Global Training Course
Rigging up and Down

If for any purpose the positioning of the equipment must be

altered from the agreed drawing, then this must be
discussed before positioning.
If the adjustment is sufficient to change the hazardous
area boundaries, a drawing change request should be
submitted and the change authorised by onshore
management before proceeding
This will stop overloading of the deck.
Allow for enough space to work in.
Be away from any potential hazards, or create potential
hazards.

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Global Training Course
Rigging up and Down

Allow for access and exit routes.

Under no circumstances must the rig up deviate from the

P&ID drawing

This includes ( but is not limited to) the removal or re-

positioning of safety devices, such as relief valves level
alarms, pressure pilots.

Care must be taken to ensure line specifications match the

P&ID for all sections of the rig up.

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Global Training Course
Rigging up and Down

Surface Test Tree.

• The Surface Test Tree in its basket should be positioned as close to

the rig floor as Possible.
• It should be removed from its basket and examined to make sure no
damage has occurred in transit.
• It should then be function tested and pressure tested before lifting
onto the rig floor. Count the number of turns on each manual valve.
Operate the ESD shut in flow wing valve.
• The Swivel should be rotated to make sure it is free.
• Mark the swivel clearly across its top connection so you can identify
if it has backed off during setting of the packer.

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Global Training Course
Rigging up and Down

You should pressure test the STT before setting in place.

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Rigging up and Down

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Global Training Course
Rigging up and Down

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Global Training Course
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Global Training Course
Rigging up and Down

Lifting the STT to the Rig Floor.

• During the flow head lifting

process to rig floor, it is
mandatory that everybody stay
alert, avoiding putting
themselves underneath or
between the flow head and
fixed objects.
• Conduct pre job toolbox talk
and review specific task.
• When rigging up the STT on
semi-submersible installations
or boats, consideration must
be given to the weather, sea.

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Global Training Course
Rigging up and Down

What to do now.

• Once the crane has placed the STT on the rig floor,
remove the crane hook from the 2 STT block lift points
and transfer these to 2 rig floor winches.

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Global Training Course
Rigging up and Down
• If running Subsea Test Tree, make the necessary number of wraps in the
Subsea Test Tree control line around the tubing joint hanging in the rotary
table to allow right hand rotation setting of the packer.
• Pick up the STT level with the 2 winches and the rig crane. Move the STT
towards the rotary table until the elevators can be latched around the
handling sub. Secure the elevators so that they cannot be released.
• Slowly have the driller pick up the STT with the block. The 2 rig floor
winches should be kept in tension to prevent the STT from flipping over.
• The rig crane should keep the bottom of the STT assembly from dragging
on the rig floor, but should slowly slack off until the STT is in the vertical
position.

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Global Training Course
Rigging up and Down

• Once STT is in the vertical position release the rig crane and the 2
rig floor winches.
• Remove the bottom STT thread protector and stab the connection.
Make-up and torque the connection (the block may need to be
locked in position to prevent it rotating during make-up).
• The STT should be kept as vertical and central as possible during
make-up of this connection to prevent damage to the threads and to
prevent binding of the connection.
• Make-up pipework or Flexible hoses to the flow and kill wing of the
STT.
• Hoses should be fitted with saver subs to prevent damage to the
hose end fittings. Respect the Minimum Bend Radius (MBR) of the
hoses (normally 12 x ID of line).

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Global Training Course
Rigging up and Down

Pipework.

• Handling of pipework should be kept to a minimum, the shortest runs

possible and with as few bends as possible (especially downstream of the
Choke Manifold).
• Manual Handling techniques should be used at all times. During these
operations several risks are particularly prone:
• Lifting and lowering of pipework puts severe strain on anyone carrying
pipework.
• When positioning the pipework for connection there is possibility of pinch
points.
• When using a hammer everyone must keep clear and the hammer must be
in good condition.
• DO NOT WORK WITH DAMAGED OR BROKEN TOOLS
• All pipework must be tied down used the proper 11mm wire rope.

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Global Training Course
Rigging up and Down

Pipe tie-downs.

Different areas around the world require different

connections. In the North Sea, EXPRO uses 10 foot
lengths of wire rope that has swaged fittings on the end
and joined together by shackles.

• SPM Syste
m

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Global Training Course
Rigging up and Down

What do they use for tie-downs

Elsewhere?

Any of the methods shown is

acceptable, for joining cables.

• All relief pipework should have

if possible pipe Clamps fitted
and they should be welded to
the deck. They should be tight
enough that no movement of
the pipework is allowed.
• Relief lines should be in
positions agreed upon as
these have been designated
as safe areas.

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Global Training Course
Rigging up and Down

Auxiliary Equipment Rig Up.

What is necessary to connect this equipment?
Some equipment requires either specialist help or special
treatment, the following talks about some of these potential
problems.

• Electrical Cables
• Air Hoses
• Steam Hoses
• Burner Booms

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Global Training Course
Rigging up and Down

Electrical Cables.

• All electrical connections should be carried out by a qualified

electrician only. He must be qualified to work on the rig. All cables
should be run in such a way as to avoid trip hazards if possible and
damage caused by other operations.
• All equipment must be checked that it is functioning properly before
operations commence.
Air Hoses.

• All hoses must be connected properly and have “R” clips fitted and
whip checks. Again try to identify passageways and if possible keep
them clear of trip hazards. If any trip hazards exist then they should
be identified and marked clearly.

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Global Training Course
Rigging up and Down

Steam Hoses.

• Steam Hoses as with air hoses should be secured

properly, and must be identified as being dangerous and
high temperature.
• Steam return lines when degassers are not fitted must
go overboard and not return to the Steam Generator.
This is to prevent any hydrocarbons returning to the
boiler should a coil in the Well Stream Heater leak.

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Global Training Course
Rigging up and Down

Burner Booms.

• Before going onto the burner boom the following should be in place:
• The rig must be informed of work taking place on the burner boom and a permit to work issued.
• The standby boat must be present during these operations and the sea state, must allow rescue
craft to be deployed.
• The person/persons going onto the boom, must have a brightly coloured vest and or safety
jacket and harness.
• There must be a standby person who does not go onto the boom. This person should be in
direct contact with the standby boat.
• If there is high winds or a possibility of high winds then there should be a risk assessment carried
out. Normally if the wind speed is over 30 knots then no work on the burner booms can take
place.
• If any person should be working out with the safety barrier of the boom, he must attach himself
by his fall arrest harness securely to the boom.
• Night activities on the burner boom are not advisable, but should it become necessary, extra
safety cautions must be taken. (See risk assessment and rig mandatory regulations.) This will
include sufficient lighting both on the boom and below the boom.
• NOTE: UNDER NO CIRCUMSTANCES SHOULD THE STANDBY PERSON LEAVE THE
LOCATION WITH PERSONS ON THE BOOM. THEREFORE UNDER NO CIRCUMSTANCE
SHOULD PERSON/S BE ON THE BOOM WITHOUT A STANDBY PERSON PRESENT.

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 • 2. Working on Burner Booms
• Before any overboard work on the flare booms shall commence the following guidelines shall be adhered too. By ensuring
that the following guidelines are followed will thus reduce any potential incidents that may occur as a result of working on
and around the burner boom assembly.
• NOTE: Prior to going out on the boom, the standby boat must be called in to close watch, and the weather
conditions must permit the launching of the rescue craft (e.g. the Zodiac) to pick up any man in the water.
• 1. The permit-to work system for a particular installation must be in place before going out on the boom.
• 2. A bright coloured work vest is to be worn when working on the boom.
• 3. A buoyancy aid (e.g. Billy Pugh/Helly Hansen) shall be worn along with an safety harness (it is recommended to attach
the lanyard to the boom structure when working over or outside the handrail e.g. fitting blanking plug to burner heads) for
work behind the burner and within boom handrail this is discretionary.
• 4. A second person must observe the personnel on the boom at all times from a suitable vantage point, with radio contact to
the standby boat.
• 5. At no point must the watchman leave his post whilst the technician is on the boom, if he is required to fetch tools etc from
the test area then the operator on the boom will be required to come inboard until the watchman’s return.
• 6. Whilst working on the boom it is recommended that tools and hammers be tied off to the boom thus preventing any
potential dropped objects from falling. If an item/tool falls into the sea you must notify your supervisor as it may cause
damage or obstruct any subsea tree/piping.
• 7. Once work is completed it is essential that you notify the radio room and standby boat so they may stand down. (During
overboard work the standby crew are dressed in survival suits in readiness for rescue and therefore will appreciate being
notified of work completion, in order that they can change.)
• NOTE: The watchman should be aware of the position of the rescue equipment (life belt and line), should this be
required, and the man overboard procedures.

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 • 8. No person is permitted to go on the boom in high winds (probably if there was high winds then the rescue craft
could not be launched). It is not possible to be specific about a definition of ‘high winds’ as each situation will be
slightly different and have to be judged on it’s merits. However, it is recommended that the situation be reviewed
when wind speeds exceed 30 knots (Force 7 ‘Near Gale’).
• NOTE: When within the handrail, it is not required to tether the safety harness/line.
• 9. It is not recommended that personnel have access to the boom at night, however where access is necessary, it
is essential that an observer be present and in direct radio contact with the standby boat and radio room, if an
employee is requested to go on the boom at night prior approval must be granted by the installation
manager/toolpusher however no maintenance shall be carried out during the hours of darkness the only
interaction will be to orientate valves light burners essential work, etc.
• 10. Also the area around and below the boom should have adequate lighting to enable the man to work and be
spotted in the water if he should fall.
• NOTE: In the event of an emergency the watchman must not leave his post and should raise the alarm by
contacting the standby boat/radio room by walkie talkie. The radio room should then raise the man
overboard alarm the boom watchman at this point shall not leave his post, he must maintain visual
contact with the person in the water at all times, if required he may need to utilise a buddy system and
ask other personnel to track the person in the water.

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Global Training Course
Rigging up and Down

What happens after you rig-up the equipment?

It is necessary to prove the integrity of the equipment.

This will consist of pressure testing the pipework and equipment.

Before starting the pressure test procedure you must do the following:
• Hold a Tool Box Talk, discuss the Risk Assessment and assign jobs.
• Fill out a Permit to Work. The will be filled out at the Control Room.
• Erect warning barriers.
• Announce over the PA system that Pressure Testing is about to commence.
• Ensure that all non-essential personnel have left the area. A person will be
delegated to make sure that no-one enter the area during testing.
• All pipework that is to be tested is tied down.
• Make sure that the fittings and lines to the pressure test pump are of the
right pressure rating.

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Global Training Course
Rigging up and Down

Pressure Test.

• During the pressuring up of the equipment/pipework, all personnel should

keep clear. The pump should be positioned in such a way as to protect the
pump operator.
• Increase pressure in increments of 20%, the pressure should be held for
several minutes to make sure there are no problems, then increased.
• Inspection of equipment should only take place one pressure has stabilized.
• Do not pressure equipment past it’s WP.
• If rupture discs are fitted then only test to 90% of WP.
• Relief valves should not be activated during Pressure Testing. If they do,
then they must be removed and replaced.
• If any fault occurs during Pressure Testing, (Leaks etc), then pressure
should be bled off immediately to zero and faults fixed before continuing.
• When Pressure Test Completed, a thorough check to make sure that no
residual pressure is present in any of equipment.

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Global Training Course
Rigging up and Down

Rigging Down.
THE NEXT JOB STARTS AT THE END OF THE LAST JOB....
What do we mean by that?

When you are finishing a job it is just as important to follow all the procedures
and not just throw everything into baskets and send to shore.
Before you rig down you must take the following in to consideration:
• All pressure should be bled from the system
• The well is secure. In other words the equipment is isolated from the
tubing/reservoir pressure.
• Authorization has been given to start rigging down the equipment.
• The equipment has been thoroughly emptied and flushed as necessary.
• Spill kits should be strategically placed around the site before rigging down.

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Global Training Course
Rigging up and Down

As with rigging up a risk assessment must be carried out before hand and then a tool box
talk. Once this has been carried out then the following should be carried out.

• All instrumentation should be removed prior to knocking pipework apart.

• All tools should not be damaged or broken
• All drains on vessels should be closed and sealed where necessary.
• All male and female thread ends should have protectors fitted or if none available
should have grease tape wound round to prevent damage.
• Pipework should be secured in pipe racks with bars.
• Any loose objects must be either stored or secured to there equipment.
• Tools should be put back into containers and secured.
• Sand filter davits should be securely tied down
• Make sure that all valve handles are secured to the various equipment.
• When placing equipment in baskets it should be packed with care and secure. (no
loose objects within the baskets). Do not overfill baskets, they have a weight
restriction.
• When packing labs/workshops, it must be done with care. Keep your equipment tidy.
• Wrap all electrical cables and secure them to the equipment.

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Global Training Course
Rigging up and Down

Finally you must check the Well Test Area.

• It is clear of all debris.

• No oil or other liquid has been left on the deck.
• All equipment has been shipped back to the base.
• Any faults pertaining to the rig have been reported.
• Permits have been handed back.

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