Kiewit Bridge & Marine

Best Safety Practices and Safety Policy Manual

SECTION 2.28

DIRECTIONAL DRILL RIG SAFETY

When directional drill rigs are in use by Kiewit Bridge & Marine and any subcontractors, procedures in compliance with the following shall be developed and followed. Prior to the start of work, all utilities will be positively located and marked in compliance with the provisions in Section 2.11 (Excavation and Trenching Safety Rules). A detailed bore plan shall be developed and used in conjunction with the attached Bore Permit. Directional drill rigs shall have working radio communication between the drill rig operator and the rig hand. If and when radio communication is interrupted the equipment will immediately be shut down and work stopped. All personnel working with the drilling operation will clear the area until radio communications are re-established. The field superintendent shall designate one person as the designated radio person. Only one employee will give radio instructions to the drill rig operator. If the designated person is not on the work site, the rig superintendent will name another trained employee to assume the duties. The drill rig operator shall be informed of the change in designated personnel and accept instructions from this person only; except in the event of an emergency stop. Follow Equipment Lockout/Tagout procedures as found in Section 2.9 when adding or removing drill heads and/or reamers. All work performed to equipment shall be done with the equipment turned off and locked out. As an added protection, the designated radio person will notify the drill operator to shut down the machine, lock it out, and step away from the controls. The drill rig operator will stop the machine operation by engaging the emergency shut-off control or by killing the engine, and then step away from the controls. Prior to restarting the machine, the driller will be informed by the designated radio person that the situation is all clear and it is safe to resume work. Some of the directional drill rigs are equipped with an electronic lockout system. These rigs still require radio communication from the receiving pit to the machine operator. Due to the high risk of injury associated with this type of work all drilling operations shall follow these safety controls: A documented daily safety meeting (written in a toolbox meeting book or on the back of the timecard) that includes a discussion on the following: safe lifting procedures, weather conditions, designated radio person, maintenance of 3-point contact getting on or off the machine, use of pipe wrenches on drill rods/drill steel, drill steel rotation, prohibition of loose clothing around equipment, and identification of first-aid trained personnel on the crew. A grounding rod shall be installed on each drill rig. The procedure and hazard analysis shall be reviewed each week at a minimum. Update the hazard analysis as conditions change. A traffic control plan that complies with the MUTCD or is agreed to by the local authorities must be used. Proper containment and disposal of drill mud. Drill mud shall not be permitted to enter into any waterway, storm drain, sewer, etc.

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Section 2.28 / Directional Drill Rig Safety

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Kiewit Bridge & Marine

Best Safety Practices and Safety Policy Manual

DIRECTIONAL DRILLING PERMIT

Step 1 Superintendent
C O N T R A C T O R Starting Date: Contractor: Starting Location: Location: Township: Superintendent: Crew: Work Plan Completed Permits Obtained: JHA Completed ROW MOT Plan Completed Environmental Other: County: Operator: State: Ending Station: Expected Completion Date:

Step 2 Utility Locate Engineer

C O N T R A C T O R Call Before You Dig / Dig Safe Ticket Number: Activation Date: Visual Check for Utilities Completed: Overhead Wires that may interfere with operation: Dangerous Utilities: I, the Utility Locate Engineer, verify that all requirements have been completed and this area was properly located and potholed. Utility Locate Engineer: Date:

Step 3 General Superintendent / Segment Manager

K I E W I T Bore Profile on file and reviewed: Approved Pay Length: Notes: Superintendent: Segment Manager: Date: Date: By:

Step 4 Superintendent
Checklist: 1. 2. _____ _____ Confirm Active Dig Ticket for Area Review All Utility Locate Information with Utility Engineer Pothole Drawings Utility Company Information Utility Emergency Contact Information Lockout / Tagout Procedure Reviewed with Crew? Confirm Mark-out and Pothole Information in the Field All Discrepancies must be reviewed with Utility Engineer Barrier placed over utility to Alert Construction Crew Utility Representative Onsite prior to Excavation (if required)

C O N T R A C T O R

3. 4. 5. 6. 7.

_____ _____ _____ _____ _____

I, the Superintendent, understand that I must perform the following actions to assure that every effort has been taken to minimize the chance of a utility strike. Require that a person from the crew performs blind sweeps with a locator in front of the digging crew. Keep good communication between the crews and the Utility Locate Engineer. Superintendent: Date:

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Kiewit Bridge & Marine

Best Safety Practices and Safety Policy Manual

LOCKOUT TAGOUT PROCEDURE This must be filled out, reviewed, and signed off on by the crew each day of drilling operations. It must also be present at the drill operation. All lockout-tagout procedures shall include: 1. Key shall be removed from the drill rig while crew is working on the end of the drill steel, and the operator shall stand away from the drill rig. 2. A Do Not Operate tag shall be placed on the controls of the drill rig. 3. The key shall be in the possession of the crew working at the end of the drill steel until they are done, except for unusual situations such as a heavy highway traffic or impassable stream. In these cases extra safety measures must be employed. 4. A flag system shall be used whereby a red flag shall be displayed at the end of the drill steel whenever men are working on it. A red flag shall also be displayed at the drill rig to indicate that the operator acknowledges the lockout is in place. 5. Radio communication shall be maintained between the drill operator and the workers at the end of the drill steel. 6. Communications to resume the drilling shall be given to the drill operator by the foreman at the end of the drill steel. 7. The drill operator must repeat the instructions and have clear approval before resuming drilling. 8. Drilling cannot resume until the red flag is removed at the end of the drill steel. 9. Drilling cannot resume until the red flag is removed at the drill, after it is removed at the end of the drill steel. The Lockout Tagout Procedure for this bore shall be:

Bore Crew Reviewed Above Procedure: 1. ________________________ 2. ________________________ 3. ________________________ 4. ________________________ 5. ________________________ Insert Hazard Analysis here:

Date: ___________________

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Kiewit Bridge & Marine

Best Safety Practices and Safety Policy Manual

KIEWIT BRIDGE & MARINE H.E.L.P. = HAZARD ELIMINATION THROUGH PLANNING

Job Name: Job #: Job Superintendent: Operation: STEP BY STEP PLAN
1. Verify all conflicting utilities/facilities 2. Create a detailed bore plan 3. Mobilize to work location 4. Stretch and Flex / Tool Box Meeting 5. Test Strike Alert and Eslok 6. Equipment check and warm up 7. Prepare entry pit and slurry control 8. Drill pilot bore and monitor circulation 9. Prepare exit pit and slurry control 10. Push out rods for preream 11. Remove dirt head / install prereamer 12. Preream and monitor circulation

SAMPLE

Foreman:

Engineer:

13. Prepare product for installation 14. Remove prereamer at rig & install product reamer at exit 15. Attach product to product reamer 16. Install product 17. Clean up equipment, bore pits and work location 18. Secure equipment and mobilize to next location

POTENTIAL PINCH POINTS ON TYPICAL HORIZONTAL DIRECTIONAL DRILLS

Equipment doors, latches, seat swivels, accessories Track drives, rollers, tensioners Rod loading shuttles, arms, baskets, boxes, rigging and rods Rotating gear box, drill string (rods), drill head, reamer Traveling gearbox, drill string, drill head, reamer, product pipe Flexible hose / cable carriage attached to gearbox Pivoting gearbox rack (drill rack) Rotating anchors / anchor motors, sliding anchor guides / posts Anchor Platform Pinching / rotating breakout wrenches Reciprocating high pressure mud pump Mud supply hoses (cam locks) High pressure hydraulic and mud hoses (vibration)

HIGH RISK ACTIVITIES WHILE WORKING ON OR NEAR A HORIZONTAL DIRECTIONAL DRILL

Working on drill string at the drill or at the exit side Working near rotating drill tooling at the drill or at the exit side Working near traveling drill tooling at the drill or at the exit side Handling loose drill pipe or baskets of drill pipe Breaking out / making up tool joints at the drill or at the exit side Working in or near open excavations Working with poor communications Working near the drill track drives, anchor platforms, or drill rack Working on pumps, hoses or drill string while under fluid pressure Working on or near hot muffler / engine / hydraulics Drilling across or parallel to existing utilities Working in congested urban areas or utility corridors Working under or near overhead power / communication cables Working near open water or unstable geology Walking on slopes or rough terrain between the drill and the exit side Manually lifting drilling tools, equipment and supplies Working in muddy conditions Working with poor visibility Working in inclement weather Working in areas exposed to pedestrian traffic Working near roadways or railroad track

POTENTIAL PINCH POINTS ON TYPICAL DRILLING MUD MIXING / RECYCLING SYSTEMS

Equipment doors, latches, accessories Rotating pumps / pump drive motors Mud gates / valves / handles Folding ladders / catwalks Material handling, pallets, bags, pails Vibrating shale shaker Mud supply hoses (cam locks) Generator / engine rotating components High pressure water from washing unit

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Kiewit Bridge & Marine

Best Safety Practices and Safety Policy Manual

HIGH RISK ACTIVITIES WHILE WORKING ON OR NEAR DRILLING MUD MIXING / RECYCLING SYSTEMS
Working in dusty / windy conditions Using high pressure water washer Mounting and dismounting the unit Manually lifting bags, pails Working near rotating pumps and pump drives Operating mud gates / valves / handles 1. Verify all conflicting utilities / facilities A94 Potential Hazard: Owners cannot identify all expected facilities Damage caused to facilities during verification Precautionary Plan: Sweep area with all available devices Pothole across the running line at regular intervals until all expected facilities are verified Use care when hand digging or exposing the facilities using non-mechanical methods Notify Segment Manager and the respective utility owner if damage to facilities occur Secure Excavation Permit from Utility Superintendent before mechanical excavation Traffic, Pedestrians, trains Disturbing cultural / environmental resources 2. Create a detailed Bore Plan A61 Potential Hazard: Traffic, Pedestrians, trains Slips, trips and falls during investigation Injury from an animal, insect or plant Misrepresentation of existing utilities Precautionary Plan: Use traffic control, barricades, fencing, and positive protection from trains (flaggers) Proceed through wooded areas and across slopes with caution Proceed with caution, wear protective clothing, carry communication Accurately identify verified utilities on Bore Profile and include pothole drawings in Bore Plan -keep at site Use traffic control, barricades, fencing, and positive protection from trains (flaggers) Consult Action List to identify cultural / environmental locations and monitoring requirements Manually handling hoses when transferring mud / water under pressure Working on elevated platforms Working in slippery conditions Working near vibrating shale shaker Working on or near hot muffler + F44 / engine / hydraulics

3.

Mobilize to work location see Loading, Unloading, Parking and Equipment / Driving / Load Tie Down / Traffic Control Procedures Potential Hazard: Precautionary Plan: Use traffic control, barricades, fencing, and positive protection from trains (flaggers) Lock equipment and park it in front of trailer hitches or other equipment Erect a fence around the equipment, park parallel to roads, tracks Leave access for service vehicles to enter the right of way Park on high ground, not closer than 250' from the nearest access road Lower all raised implements, set parking brakes and chock trailer wheels Secure all loads and thoroughly inspect twice before moving

Traffic, Pedestrians, trains Theft or vandalism Future access Equipment inadvertently moving or rolling Equipment or loads shifting during transport 4.

Stretch and Flex Program / Tool Box Meeting see Stretch and Flex Manual Potential Hazard: Precautionary Plan: Participate to the extent of your physical capability Stretch to the point of comfortable extension, then relax, hold the stretch 5-15 seconds Stretching should not be painful, avoid straining muscles

Overexertion

Non-participation

Participate Stretch and Flex reduces muscle strains during regular working activities The Tool Box meeting identifies better ideas, work site hazards, safe work practices, etc.

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Kiewit Bridge & Marine

5. Test Zap-Alert and Eslok see Operator and Safety Manuals Potential Hazard: Electrocution, injury, death, equipment failure

Best Safety Practices and Safety Policy Manual

Precautionary Plan: LAY ground stake from drill rig on ground, do not allow to touch drill or other metal Connect one ZAP-Alert tester lead to the ground stake, the other to the drill frame Press the TEST button on the Zap-Alert tester, the Zap-Alert alarm will sound DO NOT hold both Zap-Alert tester leads and press the TEST button, shock will occur Press the RESET button on the drill to stop the alarm, repeat procedure DO NOT start drilling until proper operation of Zap-Alert is confirmed

If the Zap-Alert sounds, ALL PERSONNEL ON THE GROUND MUST REMAIN STATIONARY AND NOT CHANGE THE ELECTRICAL STEP POTENTIAL OF THEIR BODY BY MOVING FEET OR HANDS FROM THEIR CURRENT POSITION. The driller should press the Zap-Alert RESET button. If the Zap-Alert continues to sound, an electrical fault has likely occurred. The driller should then pull back the drill string as far as necessary, while pressing the Zap-Alert button at the end of each rod, until the Zap-Alert alarm stops. GROUND PERSONNEL SHOULD NOT MOVE UNTIL THE ELECTRICAL UTILITY OWNER DE-ENERGIZES THE ELECTRICAL CIRCUIT. See Utility Strike Procedure and PPE Procedure. The Zap-Alert alarm may sound inadvertently during drilling operations. If the Zap-Alert alarm stops when the driller presses the Zap-Alert RESET button, ALL GROUND PERSONNEL MUST REMAIN STATIONARY while the possible presence of electrical utilities is assessed. Normally, underground electrical circuits have a time-delay fuse that will RESET within 30 seconds of a fault. If the Zap-Alert alarm does not sound again, and the electrical utility owner does not report the presence of underground electrical facilities in the area, the driller should then move the drill string back and forth to determine if the Zap-Alert will sound again. If it does not sound, the electrical utility owner approves, AND there is NO EVIDENCE OF THE PRESENCE OF ANY OTHER UNDERGROUND FACILITIES, drilling operations can continue and ground personnel can begin regular activities. Drilling in close proximity to electrical facilities can inadvertently activate the Zap-Alert alarm. Getting caught in rotating drill string or tooling The drill will not operate if the Eslok Belt Transmitter and Receiver / Transceiver box on the drill are not communicating. If the Belt Transmitter battery fails, or if the signal between the Belt Transmitter and the Receiver / Transceiver (drill) is interrupted it will not operate After starting the drill, the large RED Eslok indicator FAULT light on the Receiver / Transceiver box (beside the driller's seat) should be illuminated and the thrust and rotary functions should not operate To RESET the Eslok system, the Belt Transmitter must have a charged battery and a small GREEN light in the upper left corner (press the GREEN button on the Belt Transmitter to get a GREEN light in the upper left corner of the Belt Transmitter). The RESET button on the Receiver / Transceiver box on the drill must then be pressed to illuminate the GREEN light on the Receiver / Transceiver and activate the drilling functions. The Eslok system should be tested at the beginning of each shift, before working on the drill string at the drill rig, and before working on the drill string at the exit side of every bore. DO NOT start drilling until proper operation of Eslok system is confirmed The Eslok system is NOT a replacement for RADIO COMMUNICATION between the operator and the exit side personnel. Drilling operations MUST NOT proceed without BOTH the Eslok and positive RADIO COMMUNICATION.

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Kiewit Bridge & Marine

6. Equipment check and warm up see Daily Visual Checks handbook Potential Hazard: Head, eye, hand injury during Visual Checks

Best Safety Practices and Safety Policy Manual

Precautionary Plan: Wear hard hat and safety glasses, use caution when using hands, turn ENGINE OFF if possible Lock all safety features, apply parking brake, lower all equipment, block tires, NO OPERATOR ON MACHINE WHEN ENGINE RUNNING

Engine failure causing toxic spill

Check ground, frame, engine block, turbo for oil / water / coolant leaks Check engine oil and radiator water / coolant levels Check air intake systems for damage, leaks, restrictions Allow engine to warm up before engaging full load operation

Moving equipment causing injury or death Equipment failure causing injury or toxic spill

Apply all brakes and safety lock outs, lower raised equipment before Visual Checks Check engine exhaust for leaks, loose bolts, rain caps Check fuel tanks and hoses for leaks, breathers and fuel caps, fuel separators / filters Check hydraulic tank, hoses, cylinders, motors, valves, pumps for damage or leaks Check hydraulic oil level and clarity of oil Check hydraulic system for smooth operation Check alternator belt, ammeter, battery, battery cables, lights, evidence of broken wires

Equipment failure causing injury

Check for loose belts, cracked welds, bent or damaged frame / shrouds / guards Check for worn tires / tracks and inflation / tension Check operation of gauges, controls, and condition of warning / identification decals Lubricate all lube points, check for wear on slides, gears, rollers, break out wrenches

Equipment failure causing injury / environmental spill

Check circulating pumps for packing wear / adjustment Check shale shaker screens for deterioration, tears, holes Check mud tanks for leaks, excessive rust Check operation of mud valves and condition of mud hoses / connections Check condition of electrical cords / hydraulic hoses and submersible pump Check condition of fall protection and non-slip surfaces Check mud pump for leaks, wear, packing adjustment, power end oil Clean all water / mud filters / screens

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Section 2.28 / Directional Drill Rig Safety

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