Product Overview

Summary: This Downhole Tools Inspection Safe Operating Procedure sets out a clear, defensible process for inspecting drilling and completion tools before they go downhole. It helps Australian oil and gas and drilling operations control critical safety risks, prevent costly failures, and demonstrate robust compliance with WHS and industry expectations.

Downhole tools operate in extreme environments where any failure can rapidly escalate into a serious safety incident, environmental release, or multi‑million‑dollar non‑productive time event. This Downhole Tools Inspection Safe Operating Procedure provides a structured, step‑by‑step framework for how tools are received, inspected, function‑tested, documented, and cleared for service before they are run in hole. It supports Australian drilling and well servicing operations in demonstrating due diligence under WHS legislation, while aligning with recognised petroleum industry practices.

The procedure details inspection requirements for common downhole equipment such as drill collars, stabilisers, jars, motors, MWD/LWD tools, fishing tools, plugs and packers, and other pressure‑containing or load‑bearing assemblies. It defines acceptance and rejection criteria, thread and connection checks, NDT requirements, pressure and function testing, cleanliness standards, and traceability controls. By implementing this SOP, organisations can standardise inspection practices across contractors and locations, reduce the likelihood of downhole failures, and provide clear evidence of equipment integrity for audits, incident investigations, and client assurance processes.

Key Benefits

• Reduce the risk of catastrophic downhole tool failures that threaten worker safety, well integrity, and the environment.
• Ensure consistent, auditable inspection practices across rigs, bases, and third‑party tool providers.
• Minimise non‑productive time (NPT) and costly fishing operations caused by preventable equipment defects.
• Strengthen compliance with Australian WHS obligations and petroleum industry due diligence requirements.
• Improve asset reliability and lifespan through systematic inspection, defect trending, and maintenance feedback.

Who is this for?

• Drilling Supervisors
• Rig Managers
• Well Site Leaders
• Toolpushers
• Downhole Tool Technicians
• Maintenance Supervisors
• WHS Managers
• Oil and Gas Operations Managers
• Onshore and Offshore Installation Managers (OIMs)
• Quality and Compliance Coordinators

Hazards Addressed

• Downhole tool mechanical failure leading to stuck pipe, dropped strings, or fishing operations
• Loss of well control due to failure of pressure‑containing components (e.g. packers, plugs, valves)
• Uncontrolled release of well fluids or hydrocarbons from compromised seals or connections
• Dropped objects and handling injuries during tool preparation, make‑up, and inspection activities
• High‑pressure testing hazards, including hose or connection failure and projectile risks
• Exposure to hazardous substances such as drilling fluids, hydrocarbons, and chemical residues on tools
• Pinch points, crush injuries, and manual handling strains when assembling or disassembling heavy tools
• Electrical and electronic hazards associated with MWD/LWD and other instrumented downhole tools

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Rig Crew, Workshop Technicians, Supervisors, WHS Personnel)
• 4.0 Competency and Training Requirements for Inspectors
• 5.0 Tools Covered by this SOP (Drilling, Completion, Fishing and Specialty Tools)
• 6.0 Pre‑Inspection Planning and Risk Assessment (JSA/SWMS)
• 7.0 Required Facilities, Equipment and Instrumentation
• 8.0 Personal Protective Equipment (PPE) and Safety Precautions
• 9.0 Receiving, Identification and Traceability of Downhole Tools
• 10.0 Cleaning, Decontamination and Preparation for Inspection
• 11.0 Visual Inspection Procedure (Body, Connections, Hardfacing, Wear and Damage)
• 12.0 Thread, Connection and Sealing Surface Inspection
• 13.0 Dimensional Checks and Measurement Tolerances
• 14.0 Non‑Destructive Testing (NDT) Requirements and Methods
• 15.0 Pressure Testing and Function Testing of Tools
• 16.0 Acceptance, Rejection and Repair Criteria
• 17.0 Documentation, Inspection Reports and Recordkeeping
• 18.0 Labelling, Tagging and Segregation of Non‑Conforming Tools
• 19.0 Handling, Storage and Transport of Inspected Tools
• 20.0 Integration with Maintenance, Calibration and Asset Management Systems
• 21.0 Environmental and Waste Management Considerations
• 22.0 Incident, Defect and Near‑Miss Reporting Related to Tool Integrity
• 23.0 Review, Audit and Continuous Improvement of the Inspection Process

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) – Part 5.1 Plant and structures
• Safe Work Australia – Code of Practice: Managing risks of plant in the workplace
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• AS/NZS ISO 31000:2018 Risk management – Guidelines
• AS/NZS 3788: Pressure equipment – In-service inspection (for pressure‑containing tools and pressure testing)
• AS/NZS 4024 series: Safety of machinery (for inspection equipment and handling systems)
• Petroleum industry guidance such as API Spec 7‑1 and API RP 7G (used as good practice references where applicable)