Rig Mover Training Course

1. Introduction to Rig Movement Operations

1.1 Rig Movement Fundamentals

• Overview of rig types including (conventional land rigs, mobile rigs, and modular systems)

• Rig movement classifications including (short moves, long-distance transport, and cross-border operations)

• Key stakeholders including (rig owner, operator, transport contractor, and regulatory bodies)

• Economic considerations including (move time, cost factors, and operational efficiency)

• Critical path scheduling including (sequence optimization, parallel activities, and milestone planning)

• Regional considerations including (Middle East terrain, climate factors, and infrastructure limitations)

• Rig mobility design features including (skid systems, trailer mounting, and self-propelled units)

1.2 Regulatory Framework and Standards

• International standards including (IADC guidelines, API RP 4G, and ISO requirements)

• Local regulations including (transportation permits, road restrictions, and environmental compliance)

• Health and safety requirements including (risk assessment, safety management systems, and emergency planning)

• Documentation requirements including (movement plans, load tickets, and permits)

• Competency standards including (personnel qualifications, certification requirements, and training validation)

• Insurance and liability considerations including (coverage requirements, responsibility boundaries, and risk transfer)

• Compliance verification including (audit procedures, inspection protocols, and approval processes)

2. Pre-Move Planning and Preparation

2.1 Rig Assessment

• Rig inventory documentation including (component listing, dimensional data, and weight information)

• Load categorization including (oversized loads, heavy loads, and standard transportable units)

• Structural condition assessment including (load-bearing capacity, structural integrity, and wear evaluation)

• Maintenance verification including (critical systems, transportation fixtures, and lifting points)

• Equipment certification including (lifting equipment, pressure systems, and specialized tools)

• Disassembly planning including (sequence determination, critical interfaces, and preservation requirements)

• Historical move data analysis including (previous challenges, time performance, and lessons learned)

2.2 Route Planning and Logistics

• Route survey methods including (physical inspection, satellite mapping, and government resources)

• Infrastructure assessment including (road conditions, bridge capacities, and overhead clearances)

• Permit requirements including (oversized loads, weight restrictions, and jurisdictional variations)

• Logistics coordination including (convoy management, support vehicles, and crew transportation)

• Scheduling considerations including (weather windows, daylight restrictions, and traffic patterns)

• Resource allocation including (transport equipment, personnel, and support services)

• Contingency planning including (alternative routes, equipment failures, and weather delays)

2.3 Move Plan Development

• Move sequence determination including (critical path analysis, parallel activities, and optimization opportunities)

• Load distribution planning including (truck allocation, weight distribution, and stability considerations)

• Resource scheduling including (equipment mobilization, personnel rotation, and third-party services)

• Timeline development including (realistic durations, buffer allocation, and milestone definition)

• Communication plan including (reporting structure, progress updates, and stakeholder coordination)

• Risk management including (hazard identification, mitigation measures, and emergency response)

• Documentation package including (drawings, procedures, checklists, and reference materials)

3. Site Preparation and Management

3.1 Location Assessment

• Site survey including (dimensional verification, soil conditions, and existing infrastructure)

• Environmental factors including (drainage patterns, weather susceptibility, and stability issues)

• Access evaluation including (road quality, turning radius, and staging areas)

• Utility assessment including (power availability, water sources, and waste management)

• Adjacent facilities review including (proximity issues, simultaneous operations, and safety zones)

• Regulatory compliance including (environmental restrictions, setback requirements, and local regulations)

• Historical site data review including (previous operations, known issues, and regional challenges)

3.2 Site Engineering and Preparation

• Site layout optimization including (component positioning, workflow efficiency, and safety considerations)

• Foundation design including (load-bearing requirements, settlement prevention, and stability assurance)

• Access road construction including (material selection, width requirements, and maintenance provisions)

• Drainage systems including (water diversion, erosion control, and flood prevention)

• Utility installation including (power distribution, water lines, and communication systems)

• Environmental protection including (spill prevention, erosion control, and habitat protection)

• Quality control including (inspection procedures, testing protocols, and acceptance criteria)

3.3 Site Safety and Security

• Hazard identification including (overhead lines, buried utilities, and environmental risks)

• Safety zone establishment including (lifting operations, traffic management, and personnel restrictions)

• Emergency response planning including (access routes, muster points, and communication protocols)

• Security measures including (perimeter control, access management, and valuable asset protection)

• Weather monitoring including (alert systems, mitigation measures, and suspension criteria)

• Simultaneous operations management including (activity coordination, communication protocols, and control measures)

• Safety management system including (risk assessment, permit to work, and safety briefings)

4. Rig-Down Operations

4.1 Rig-Down Planning

• Sequence optimization including (critical path analysis, dependency mapping, and risk assessment)

• Resources allocation including (personnel requirements, equipment needs, and specialized tools)

• Time estimation including (activity durations, contingency allowances, and schedule development)

• Interface management including (contractor coordination, handover points, and responsibility matrix)

• System isolation procedures including (electrical, hydraulic, pneumatic, and fluid systems)

• Pre-disconnection verification including (system depressurization, deenergization, and fluid drainage)

• Documentation requirements including (component tagging, configuration recording, and preservation instructions)

4.2 Rig-Down Execution

• Pre-job safety meetings including (hazard review, task assignment, and emergency procedures)

• Systematic dismantling including (top-down approach, structural stability maintenance, and sequential disconnection)

• Lifting operations including (crane positioning, lift planning, and load control)

• Component preparation including (cleaning, preservation, and securing for transport)

• Load assembly including (component grouping, weight distribution, and securement)

• Quality verification including (inspection points, acceptance criteria, and sign-off procedures)

• Progress tracking including (milestone completion, schedule adherence, and reporting protocols)

4.3 Special Considerations for Component Disassembly

• Mast/derrick dismantling including (section separation, pin removal, and sequential lowering)

• Substructure breakdown including (box-on-box separation, support removal, and component isolation)

• Equipment removal including (mud pumps, engines, generators, and auxiliary systems)

• Drill floor disassembly including (rotary table, drawworks, and control systems)

• Pipe handling equipment including (pipe racks, catwalk machine, and tubular handling tools)

• Living quarters and auxiliary buildings including (utility disconnection, weight reduction, and preparation for transport)

• Preservation requirements including (weather protection, corrosion prevention, and critical component care)

5. Transportation Operations

5.1 Load Preparation and Securement

• Load distribution principles including (center of gravity, stability considerations, and axle loading)

• Tie-down methodologies including (chain arrangements, tensioning devices, and securement points)

• Protection measures including (damage prevention, weather protection, and preservation techniques)

• Specialized equipment including (low-beds, extendable trailers, and heavy haulers)

• Pre-departure inspection including (load security, dimension verification, and documentation review)

• Escort requirements including (flag vehicles, police escorts, and route management)

• Documentation verification including (permits, load tickets, and transportation manifests)

5.2 Transport Execution

• Convoy management including (vehicle spacing, communication systems, and coordination procedures)

• Speed management including (safe operating limits, terrain considerations, and weather adjustments)

• Route navigation including (waypoint verification, obstacle management, and deviation handling)

• Communication protocols including (regular updates, incident reporting, and stakeholder notification)

• Rest and refueling management including (schedule planning, secure locations, and vehicle maintenance)

• Progress monitoring including (milestone tracking, schedule updates, and arrival coordination)

• Problem solving including (mechanical failures, route obstacles, and weather challenges)

5.3 Special Transportation Challenges

• Oversized loads including (width restrictions, height limitations, and escort requirements)

• Overweight components including (bridge capacity, road surface limitations, and permit management)

• Remote location access including (unpaved roads, challenging terrain, and limited infrastructure)

• International borders including (customs clearance, documentation requirements, and regulatory compliance)

• Urban area navigation including (traffic management, time restrictions, and narrow passages)

• Adverse weather operations including (rain effects, wind limitations, and temperature extremes)

• Night transportation including (visibility concerns, safety measures, and regulatory restrictions)

6. Rig-Up Operations

6.1 Rig-Up Planning

• Sequence optimization including (critical path analysis, parallel activities, and resource allocation)

• Layout verification including (component positioning, spacing requirements, and orientation confirmation)

• Resource planning including (personnel requirements, equipment needs, and support services)

• Schedule development including (activity durations, dependencies, and milestone establishment)

• Pre-job briefings including (task assignments, hazard awareness, and quality requirements)

• Drawing and procedure review including (assembly sequences, torque specifications, and critical interfaces)

• Quality control plan including (inspection points, testing requirements, and acceptance criteria)

6.2 Rig-Up Execution

• Foundation verification including (leveling, stability confirmation, and load-bearing capacity)

• Substructure installation including (component positioning, alignment, and connection integrity)

• Mast/derrick erection including (section assembly, raising operations, and guying/securing)

• Equipment installation including (power generation, mud system, and auxiliary equipment)

• System integration including (hydraulic, pneumatic, electrical, and control systems)

• Functional testing including (operational verification, system integrity, and safety device testing)

• Commissioning activities including (system startup, performance verification, and acceptance testing)

6.3 Special Considerations for Component Assembly

• Lifting operations management including (crane positioning, lift planning, and personnel coordination)

• Connection integrity including (bolt torquing, pin installation, and structural validation)

• Alignment verification including (component interfaces, operational clearances, and functional alignment)

• System pressurization including (hydrostatic testing, pneumatic testing, and leak detection)

• Guywire installation including (tensioning sequence, load balancing, and anchor verification)

• Critical safety equipment including (fall protection systems, emergency shutdown systems, and fire detection)

• Weather considerations including (wind limitations, lightning protection, and precipitation management)

7. Safety in Rig Moving Operations

7.1 Hazard Identification and Risk Assessment

• Common hazards including (falling objects, pinch points, and suspended loads)

• Task-specific risk assessment including (job safety analysis, pre-task planning, and control identification)

• Environmental hazards including (weather conditions, terrain challenges, and wildlife interactions)

• Traffic management including (vehicle movement, pedestrian safety, and access control)

• Working at height including (fall protection, access methods, and rescue planning)

• Manual handling including (ergonomic principles, mechanical aids, and team lifting)

• Fatigue management including (work rotation, rest periods, and alertness monitoring)

7.2 Safety Management Systems

• Permit to work including (critical activities, authorization requirements, and control measures)

• Toolbox talks including (daily briefings, hazard awareness, and procedural review)

• Stop work authority including (empowerment, implementation, and response protocols)

• Near miss reporting including (identification, documentation, and preventive measures)

• Incident investigation including (root cause analysis, corrective actions, and lessons learned)

• Management of change including (deviation assessment, approval process, and risk evaluation)

• Competency verification including (skill assessment, supervision requirements, and training validation)

7.3 Emergency Response

• Emergency preparedness including (scenario planning, resource availability, and communication systems)

• Medical emergency response including (first aid capability, evacuation planning, and treatment facilities)

• Fire response including (prevention measures, detection systems, and suppression capabilities)

• Weather emergency including (monitoring systems, shelter provisions, and evacuation criteria)

• Equipment failure including (alternative methods, recovery techniques, and backup resources)

• Communication system including (alert methodology, contact information, and notification hierarchy)

• Practice drills including (scenario-based exercises, performance evaluation, and improvement identification)

8. Equipment and Tools for Rig Moving

8.1 Transportation Equipment

• Heavy haulers including (specifications, capabilities, and operational requirements)

• Specialized trailers including (lowboys, extendable trailers, and multi-axle systems)

• Self-propelled modular transporters including (SPMT operations, weight distribution, and control systems)

• Support vehicles including (pilot cars, maintenance trucks, and crew transportation)

• Loading equipment including (ramps, skidding systems, and winching devices)

• Securing devices including (chains, binders, softeners, and specialized restraints)

• Equipment certification including (inspection requirements, load rating verification, and maintenance records)

8.2 Lifting and Handling Equipment

• Mobile cranes including (selection criteria, positioning requirements, and operational limitations)

• Gin pole trucks including (raising capability, stabilization requirements, and operational procedures)

• Jacking systems including (hydraulic jacks, climbing systems, and stability requirements)

• Slings and rigging including (selection criteria, inspection requirements, and configuration options)

• Tuggers and winches including (pulling capacity, cable management, and anchor points)

• Personnel lifts including (man baskets, aerial work platforms, and safety requirements)

• Specialized tools including (torque wrenches, alignment tools, and connection verification devices)

8.3 Equipment Maintenance and Inspection

• Pre-use inspection including (visual examination, functional checks, and safety verification)

• Preventive maintenance including (scheduled service, component replacement, and lubrication requirements)

• Certification management including (expiration tracking, testing frequency, and documentation maintenance)

• Damage assessment including (evaluation criteria, repair protocols, and replacement guidelines)

• Testing procedures including (load testing, non-destructive examination, and performance verification)

• Record keeping including (inspection logs, maintenance history, and compliance documentation)

• Failure response including (quarantine procedures, investigation requirements, and corrective actions)

9. Documentation and Compliance

9.1 Required Documentation

• Movement plans including (sequence details, resource requirements, and schedule information)

• Transportation permits including (oversized load authorization, route approval, and weight allowances)

• Equipment certification including (lifting devices, pressure systems, and structural components)

• Inspection records including (pre-move assessment, in-transit verification, and post-move evaluation)

• Personnel qualifications including (training certificates, competency assessments, and authorization records)

• Risk assessments including (hazard identification, control measures, and approval signatures)

• Handover documentation including (completion certificates, acceptance records, and punch list items)

9.2 Reporting and Communication

• Progress reporting including (milestone achievement, schedule updates, and deviation notification)

• Incident documentation including (near miss reports, accident investigation, and corrective actions)

• Daily activity logs including (work completed, resources utilized, and challenges encountered)

• Management briefings including (executive summaries, critical issues, and decision requirements)

• Stakeholder updates including (operators, contractors, and regulatory authorities)

• Lessons learned including (successful practices, improvement opportunities, and knowledge transfer)

• Closeout reporting including (performance analysis, efficiency metrics, and recommendation development)

10. Case Studies & Group Discussions

• Successful rig moves including (efficiency techniques, innovative approaches, and time optimization)

• Rig move incidents including (root causes, consequences, and preventive measures)

• Special projects including (challenging terrain, extreme weather, and remote locations)

• Equipment failure scenarios including (recovery methods, alternative approaches, and contingency implementation)

• Regional case studies from Middle East operations including (desert conditions, infrastructure limitations, and local requirements)

• Problem-solving exercises including (route planning challenges, resource allocation, and schedule optimization)

• The importance of proper training in successful rig moving operations