Military reference books and manuals (2009-2023, Volume 4)

Procedure for Hydrogen Sulphide

Page 2 of 14

TABLE OF CONTENTS

PURPOSE / SCOPE

1.1

PURPOSE

1.2

SCOPE

DEFINITIONS

GENERAL REQUIREMENTS

3.1

BP AZSPU REQUIREMENTS

3.2

LEGISLATION & STANDARDS

3.3

STOPPING UNSAFE WORK

3.4

DEVIATIONS

3.5

LANGUAGE FACILITATION

RESPONSIBILITIES

4.1

SITE MANAGER (SM) / SITE CONTROLER (SC) / OFFSHORE INSTALLATION MANAGER (OIM)

4.2

AREA AUTHORITY (AA)

4.3

HSE MANAGER

4.4

HS&E ADVISORS

HYDROGEN SULPHIDE HEALTH & SAFETY REQUIREMENTS

5.1

HYDROGEN SULPHIDE DESCRIPTION

5.1.1

Where Hydrogen Sulphide Can Occur

5.1.2

Properties and Characteristics of Hydrogen Sulphide

5.1.3

Toxicity

5.1.4

Corrosiveness

5.1.5

Pyrophoric Scale

5.2

SHYDROGEN SULPHIDE DETECTION KNOWN H₂S AREAS

5.2.1

Known H₂S Areas

5.2.2

Hydrogen Sulphide Fixed Detection System

5.2.3

Hydrogen Sulphide Portable Detection Equipment

5.2.4

Areas Not Currently Producing H2S

5.2.5

Other Areas

5.3

HYDROGEN SULPHIDE PRECAUTIONS

5.3.1

Classification of H2S Risk Areas

Warning: Notices warning of the presence of H₂S and stipulating access requirements must be posted at

the perimeter of medium and high-risk areas, and at every access point

5.3.2

Breathing Apparatus Training

5.3.3

Contingency Planning

5.3.4

Planning for a Hydrogen Sulphide Release

5.3.5

Training of Personnel

5.3.6

Monitoring the Presence of H2S

5.4

HYDROGEN SULPHIDE FIRST AID

DOCUMENTS REFERENCES

APPENDIX A: CLASSIFICATION OF PHYSIOLOGICAL RESPONSES TO HYDROGEN

SULPHIDE

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Procedure for Hydrogen Sulphide

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PURPOSE / SCOPE

1.1

PURPOSE

This Safe System of Work contains the information and guidelines necessary to assist in

reducing the risks encountered when working with Hydrogen Sulphide to as low as

reasonably practicable.

1.2

SCOPE

The contents of this procedure are applicable to all BP owned and managed sites /

installations in Azerbaijan and Georgia. Contractors working on BP owned or managed

sites / installations are also responsible for alignment with this procedure.

This document does not replace the procedures prepared and adopted by specialist

contractors. Neither does it supersede any national regulatory requirements.

This procedure contributes to compliance with Group Control of Work (CoW) standard that

the Hazards associated with BP activities are identified and that the risks are assessed and

managed.

All guidelines contained shall be regarded as the minimum requirements for BP owned or

managed sites / installations in Azerbaijan and Georgia.

The scope covers defined activities of BP and Contractors at all BP AzSPU sites and

installations.

For detailed procedures to be followed during drilling, well testing and well servicing

operations, refer to the BP Drilling Operations Guidelines (EUR-D-001), Hydrogen Sulphide

(H₂S) Procedures.1120/GEN.

DEFINITIONS

Refer to document AzSPU-HSSE-DOC-00021-2 HSE Definitions for definitions common to

this Procedure. Definitions specific to the Procedure are included below.

Site Manager

Site Controller

OIM

Offshore Installation Manager

Area Authority

Performing authority

TRA

Task Risk Assessment

H₂S

Hydrogen Sulphide

PSA

Production Sharing Agreement

ALARP

As Low as Reasonably Practicable

CoW

Control of Work

UTG

Upstream Technology Group

SRB

Sulphate Reducing Bacteria

PPM

Parts Per Million

Mg/l

Milligrams Per Litre

LEL

Lower Explosive Limit

AGT

Authorised Gas Tester

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Procedure for Hydrogen Sulphide

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ERT

Emergency Response Team

OES

Occupational Exposure Standard

LTEL

Long Term Exposure Limit

STEL

Short Term Exposure Limit

TWA

Time Weighted Average

GENERAL REQUIREMENTS

3.1

BP AZSPU REQUIREMENTS

It is a company requirement that all tasks are subjected to an assessment of risk to

demonstrate that risks have been reduced to as low a level as reasonably practicable

(ALARP). This can be achieved by complying with the BP existing standards. Where

compliance with BP standards cannot reasonably be achieved, a formal level 2 Risk

Assessment will be undertaken to identify any additional controls and demonstrate that

risks remain as low as reasonably practicable, whether by compliance with BP Standards

or through level 2 Risk Assessment.

- Operating Management System OMS Essentials 3.2.1 and 4.5.1

3.2

LEGISLATION & STANDARDS

This procedure complies with applicable national law. Applicable national law is national law

as amended by project specific agreements, e.g. the ACG Production Sharing Agreement

(PSA), and relevant International Conventions, if any, in force in Azerbaijan or Georgia, as

applicable.

In the absence of national legislation, or where national legislation is inconsistent with the

requirements of project specific agreements, BP Group Standards or applicable

requirements from UK or US legislation will be complied with.

Where requirements conflict, legal advice has been obtained and a defendable compliance

position adopted.

The standards and practices contained in this procedure are consistent with those

internationally recognized within the petroleum industry.

3.3

STOPPING UNSAFE WORK

To stop the continuation of potentially unsafe work at the earliest possible stage, the

Control of Work (CoW) Policy and this procedure for Hydrogen Sulphide make it very clear

that all personnel are obliged and have the authority to “STOP” the work that they consider

to be unsafe.

3.4

DEVIATIONS

This procedure is written in sufficient detail that it should be able to be applied consistently

at all sites / installations. There may still be the requirement for some local rules covering

site

/ installation specific logistical/administrative arrangements and local variations in

responsibilities to reflect differences in organisational arrangements. These local rules

should not deviate from the core processes within this document. Any form of deviation

from this procedure, including but not limited to local rules, shall be requested and

authorised in accordance with SSOW, Deviations from Regulations and Procedures (Doc.

No: AZSPU-HSSE-DOC-00011-2).

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Procedure for Hydrogen Sulphide

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3.5

LANGUAGE FACILITATION

Due to the various languages spoken at sites / installations, there is a necessity to assist all

with “an ease of understanding”.

RESPONSIBILITIES

4.1

SITE MANAGER (SM) / SITE CONTROLER (SC) / OFFSHORE INSTALLATION MANAGER

(OIM)

The Site Manager / Site Controller / Offshore Installation Manager shall be responsible and

accountable for the application of this procedure in his area of responsibility. He shall

ensure:

 That adequate number of Competent responsible persons are appointed to manage

and maintain the requirements of this procedure

 The assessment and management of health risks on the site / installation

 Review of Risk Assessment findings and recommendations

 Systems are in place to implement and track the actions resulting from the Risk

Assessment

 Sufficient monitoring systems and equipment is in place and there is adequate

equipment available on site e.g. BA.

 Such mechanisms are in place to communicate the findings, recommendations and

requirements of the Hydrogen Sulphide Risk Assessment to all relevant personnel

(including contractors, visitors, etc).

4.2

AREA AUTHORITY (AA)

Area Authorities shall ensure that:

 Hydrogen Sulphide Risk Assessments are carried out before any related tasks are

undertaken or begun where H2S may be present

 Personnel working under their supervision are aware of the risks involving Hydrogen

Sulphide and are aware of the necessary precautions.

 Personnel working under their supervision are trained in the use of monitoring

devices and other protective systems.

4.3

HSE MANAGER

The HSE Manager is responsible for:

 Maintaining this Safe System of Work

 Ensuring Company training programmes comply with the requirements of this Safe

System of Work

4.4

HS&E ADVISORS

HS&E Advisors are responsible for providing technical support, guidance and advice,

whenever required.

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Procedure for Hydrogen Sulphide

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HYDROGEN SULPHIDE HEALTH & SAFETY REQUIREMENTS

5.1

HYDROGEN SULPHIDE DESCRIPTION

5.1.1 Where Hydrogen Sulphide Can Occur

Hydrogen Sulphide can occur naturally:

 In crude oil and gas

 During the decomposition of organic materials, including sewage

 In de-oxygenated seawater, which encourages the growth of Sulphate Reducing

Bacteria (SRB)

In addition, Hydrogen Sulphide can be produced as a by-product:

 While processing hydrocarbons that contain Sulphur

 From the chemical action of acids on metallic sulphides; for example, during the

chemical cleaning of equipment containing Iron Sulphide deposits.

H₂S is generated by bacteria in seawater, which thrives in conditions of oxygen deficiency

and, together with organic materials as a nutrient, reduces the sulphate in seawater to

hydrogen sulphide

5.1.2 Properties and Characteristics of Hydrogen Sulphide

Principle characteristics of H₂S are:

 Highly toxic, colourless, flammable gas which, in relatively low concentrations, can

quickly cause unconsciousness

 Approximately 20% denser than air and therefore can accumulate in depressions

around an area where the gas is present

 Has an auto-ignition temperature of 260^oC, is flammable in the range of 4.3% to

45% volume in air and burns with a blue flame to produce sulphur dioxide, which is

also toxic

 Is highly corrosive to certain metals. In particular, materials containing copper should

never be used due to the possibility of an explosive reaction with H₂S

 In air, concentrations are measured in parts per million (ppm) on a volume-to-volume

basis. In water, concentrations are measured in milligrams per litre (mg/I)

5.1.3 Toxicity

Warning: Hydrogen Sulphide is highly toxic and can cause unconsciousness and

death at quite low concentrations.

Hydrogen Sulphide is an irritant and an extremely toxic gas, between five and six times as

toxic as Carbon Monoxide. After exposure to Hydrogen Sulphide, symptoms usually begin

immediately:

 Lower level exposure causes irritation of the eyes, nose and throat

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Procedure for Hydrogen Sulphide

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 Moderate exposure levels can cause headaches, dizziness, nausea and vomiting

as well as coughing spasms and breathing difficulties within 15 minutes

 Higher exposure levels can cause shock, convulsions, coma, and damage to the

heart, brain damage and death.

Very low concentrations of Hydrogen Sulphide can be detected by the offensive odour of

rotten eggs. However, personnel working in areas where Hydrogen Sulphide is present

may become accustomed to the smell because prolonged and repeated exposure will

cause the sense of smell to tire (not being able to smell it, may mean that concentration of

H₂S has increased, not decreased). Higher concentrations of Hydrogen Sulphide can

paralyse the sense of smell immediately and cause rapid loss of consciousness. Death

may result within minutes unless the casualty is moved to fresh air and resuscitated.

5.1.4 Corrosiveness

Hydrogen Sulphide is highly corrosive, especially in association with moisture or oxidizing

gases such as Oxygen and Carbon Monoxide. Iron and steel are particularly vulnerable.

Corrosion mechanisms associated with Hydrogen Sulphide include:

 General corrosion

 Pitting

 Crevice corrosion, including Sulphide Stress Corrosion Cracking which can lead to

sudden and catastrophic failure

 Hydrogen induced cracking, also known as hydrogen embrittlement

Any equipment likely to be exposed to Hydrogen Sulphide must be made of appropriate

materials, constructed and operated to take account of these corrosion problems.

5.1.5 Pyrophoric Scale

Carbon steel lines and equipment that carry gas or liquids containing hydrogen sulphide

may develop a layer of pyrophoric scale (iron sulphide) on their internal surfaces. When

these lines or equipment are opened up to atmosphere, oxygen from the atmosphere will

react with the pyrophoric scale to produce spontaneous burning. If hydrocarbons or other

combustible substances are present during this reaction, an explosion may result.

Warning: A by-product of this oxidising process is Sulphur Dioxide, which is also

toxic.

Whenever such lines and equipment are opened up to atmosphere, their internal surfaces

should be doused thoroughly with water or blanketed by steam in order that any pyrophoric

scale is rendered harmless.

Warning: Equipment and pipe work that has been on sour-gas duty (i.e. contains

more than 0.5% by weight of H₂S) should only be opened in one place at

a time unless the pyrophoric scale has been thoroughly wetted. Opening

the system in more than one place can cause through drafts capable of

igniting the scale.

If the introduction of water is not permissible, either due to corrosion potential or the risk of

freezing, a nitrogen purge followed by a further purge with a mixture of 5% oxygen in

nitrogen will allow controlled oxidation.

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Procedure for Hydrogen Sulphide

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Pyrophoric scale that has been removed from lines and equipment shall be placed in a

drum and immediately covered with water. It must then be disposed of by:

 Burying or burning in a suitable area as determined by legislation

(onshore

situations)

 Slurrying with water and storing in sealed drums, clearly marked „PYROPHORIC

SCALE‟, and manifested as dangerous goods and sent onshore (offshore situations).

Apart from the hazards to personnel, H₂S also poses a risk of sulphide corrosion and

hydrogen embrittlement to metals. Protection methods for metals are detailed in BP

Hydrogen Sulphide Technical Safety Aspects Guidance Note GN 91/30 (refer to BP

Engineering Standard GS 136-1.

5.2

SHYDROGEN SULPHIDE DETECTION KNOWN H₂S AREAS

5.2.1 Known H₂S Areas

In cases where H₂S is known to be present or may be present in well fluids, appropriate

measures shall be provided to prevent exposure of personnel to this hazard.

Procedures, especially those relating to breaking of containment, confined space entry and

gas testing, shall be the principle means of protecting personnel. Portable instruments may

be used together with procedures to monitor potential hazards in which personnel are

present.

The personnel using and relying on the detection equipment shall be trained in its use.

5.2.2 Hydrogen Sulphide Fixed Detection System

Note: It is BP policy that the protection of site personnel is primarily achieved by

the safe working practices defined in this document, not by the use of fixed

detectors. However, fixed detection methods may be installed for other

reasons.

Areas where an accumulation of H₂S is possible may be monitored by use of fixed

detectors that react to H₂S and give early warning of its presence. However, these should

not be relied on to prove the area is clear of an H₂S hazard. Personnel should not approach

an area where such a suspected release has taken place unless they are wearing self-

contained breathing apparatus.

Warning: There may also be a risk of ignition and explosion in such a scenario; if the lower

explosive limit (LEL) for H₂S or the LEL of other process gases has been reached or

exceeded, then personnel should not approach the area. Isolations should be applied

remotely.

5.2.3 Hydrogen Sulphide Portable Detection Equipment

Where a specific risk of H₂S has been identified, personnel are recommended to use

portable detectors or wear personal electronic detectors that alarm when H₂S level

reaches 5 PPM.

Portable Hydrogen Sulphide monitors must be provided so that in the event of a Hydrogen

Sulphide escape, the extent of the danger can be established.

Chemical sampling methods of Hydrogen Sulphide detection are preferred, because they

are much more reliable than instruments. It is important to ensure that the detector tubes

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Procedure for Hydrogen Sulphide

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used to monitor Hydrogen Sulphide are always within the test expiry date.

Note: Chemical sampling methods are not suitable in certain circumstances; for

example, for confirming that clean air has been reached when escaping

from a Hydrogen Sulphide hazard.

5.2.4 Areas Not Currently Producing H2S

In cases of producing sites, which at present do not have H₂S in their well fluids, sampling

shall be undertaken at defined intervals in order that any onset of H₂S is established early.

5.2.5 Other Areas

Appropriate measures shall be provided for non-process systems/areas, which have the

potential to produce H₂S. These measures shall be determined by suitable risk

assessment.

5.3

HYDROGEN SULPHIDE PRECAUTIONS

5.3.1 Classification of H2S Risk Areas

Warning: Notices warning of the presence of H₂S and stipulating access requirements

must be posted at the perimeter of medium and high-risk areas, and at every

access point.

5.3.1.1 High Risk Areas

High risk areas are those areas where Hydrogen Sulphide is likely to be continually present

above the 8 hour Time Weighted Average Long Term Exposure Limit of 5 PPM (see

Appendix A) for long periods during normal operations and where routine monitoring is

mandatory.

Note: It is usual BP practice to paint pipe work and vessels containing hazardous

concentrations of Hydrogen Sulphide yellow, or with yellow bands.

In areas where H₂S is likely to be encountered, sufficient self-contained (positive pressure)

breathing apparatus sets (working sets) shall be kept for all persons normally working in

that area. Two full spare air cylinders for each set shall be held in reserve in an open-air

safe area. Adequate numbers of 10-minute duration escape sets shall also be provided.)

If the presence of H₂S in the air is suspected or an alarm is activated, personnel must leave

the area immediately, if possible heading first 90 degrees to the current wind direction then

head upwind to a safe area.

Entry into such areas shall be permitted only under a planned entry procedure and a work

permit. Personnel, working in pairs, must wear self-contained positive pressure breathing

apparatus or an airline. A standby rescue team must be in attendance.

Consideration should be given to the installation of wind direction indicators (windsocks or

flags) in high-risk areas, to aid direction of escape upwind/across wind.

5.3.1.2 Medium Risk Areas

Medium risk areas are those areas where Hydrogen Sulphide may occur during certain

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Procedure for Hydrogen Sulphide

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planned operations and maintenance activities and where monitoring is carried out during

these operations.

Only authorized persons should enter these areas. Work shall be carried out under permit

to work procedures that must list precautions to be taken. The area should be monitored

with portable Hydrogen Sulphide detection equipment during these activities.

In both the above cases, it is vital that the source of any H₂S is clearly identified and an

assessment made of any potential for deterioration.

5.3.1.3 Low Risk Areas

Low risk areas are those areas where Hydrogen Sulphide is not likely to occur in normal

operations, and if it does occur it will exist only for a short time, e.g. system malfunction.

Personnel entering low risk areas must be made aware of the possibility of the presence of

Hydrogen Sulphide and the emergency arrangements in force at the site.

5.3.2 Breathing Apparatus Training

All personnel who are likely to work in an environment where there could be potential

exposure to Hydrogen Sulphide shall be given positive pressure breathing apparatus

training (self-contained and air-line sets). Only fully trained personnel shall be permitted to

wear breathing apparatus and they must receive local refresher training every six months.

Personnel should be trained where and when to remove breathing apparatus after

completing a job since there may still be Hydrogen Sulphide present. They should either

remove the set at a remote location or test the atmosphere adjacent to the job first.

Personnel‟s medical evaluation and fit test requirements must be taken into account and

met.

Training shall also be given in mouth-to-mouth resuscitation and the use of resuscitation

equipment.

On plant where high concentrations of Hydrogen Sulphide are likely, consideration should

be given to the use of escape breathing apparatus sets or H2S respirators. These can

either be carried by personnel or located at various parts of the plant.

5.3.3 Contingency Planning

It is not feasible to provide a single plan for every contingency at every site. Plans must be

prepared on a site by site basis, and should cover:

 Planning for a Hydrogen Sulphide release

 Personnel training

 Hydrogen Sulphide monitoring.

In addition, sites that have a Hydrogen Sulphide risk must have an alarm system that is

understood by all personnel.

If the presence of H₂S in the air is suspected, personnel must leave the area immediately.

The Area Authority, following Risk Assessment

(AZSPU-HSSE-DOC-00063-2),

accompanied by one other person trained to AGT Level 1 shall don breathing apparatus

and investigate, by using suitable test equipment, the concentrations of H₂S in the air.

Upon recognition of an H₂S gas hazard, (e.g. by smell) or on activation of personnel H₂S

detectors, as a minimum, the following steps should be incorporated into any response to a

H₂S release:

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Procedure for Hydrogen Sulphide

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1. Evacuate the area, moving upwind/across wind if possible.

2. If necessary, don an emergency BA escape set to effect safe escape.

3. Do not attempt to rescue other personnel from the H₂S area unless equipped with a

full duration BA set (leave it to the rescue team).

4. A person outside the H₂S risk area should oversee personnel working in an H₂S

atmosphere or on equipment where H₂S is present.

Reference should be made to Appendix B, for what to do on discovery of an H₂S leak or

finding a victim of H₂S exposure. (Any accidents/incidents shall be reported in accordance

with AZSPU-HSSE-DOC-00054-2, Accident and Incident Investigation and Reporting

Procedure).

5.3.4 Planning for a Hydrogen Sulphide Release

A site action plan should be prepared showing the location of safe areas according to

prevailing wind conditions. For onshore sites usually three safe Areas will be defined:

 Two areas will be in the open air on opposite sides of the site (so that at least one

will be up wind of any incident). These areas shall be used for mustering essential

personnel.

 The third area (at a remote off-site location) will be used to muster all non-essential

personnel.

On offshore Installations, there should be one suitable Temporary Safe Refuge (TSR)

where personnel can withdraw to in the event of a release of H₂S. This area of the facility

should have shutoff dampers on the Heating, Ventilation and Air Conditioning (HVAC)

system to prevent the ingress of H₂S.

Protective / emergency equipment should be stored or located near to the two Safe

Areas used for essential personnel. In addition, in areas where H₂S is likely to be

encountered, sufficient self contained positive pressure breathing apparatus sets shall be

kept for all persons normally working in that area. Two full spare air cylinders for each set

shall be held in reserve in an open-air safe area. Adequate numbers of escape sets shall

also be provided.

Where operations are being carried out in a known Hydrogen Sulphide area, and where

personnel may be required to wear breathing apparatus, it should be ascertained that

personnel have no obvious medical conditions that might endanger their health or

performance prior to breathing apparatus training.

5.3.5 Training of Personnel

All personnel shall be informed of the hazards relating to Hydrogen Sulphide and they shall

receive instruction in the correct use of any personal safety equipment, Hydrogen Sulphide

detectors, warning systems and evacuation procedures.

Information relating to Hydrogen Sulphide safety measures shall be prominently displayed

at strategic points around the site / installation.

All personnel working in the crew and rescue team should be instructed in basic first aid

procedures applicable to victims of Hydrogen Sulphide exposure.

An Emergency Response Team shall be established. All ERT and rescue team members

should be instructed in basic first aid procedures applicable to victims of H₂S exposure.

Training exercises and drills must be carried out on a regular basis.

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Procedure for Hydrogen Sulphide

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5.3.6 Monitoring the Presence of H2S

Portable H₂S monitors must be provided so that, in the event on an H₂S escape, the extent

of the danger area can be established.

H₂S monitors should be set to current occupational exposure limits, i.e. 5PPM.

5.4

HYDROGEN SULPHIDE FIRST AID

Symptoms of acute Hydrogen Sulphide poisoning reduce rapidly when inhalation of the gas

ceases. It is therefore vital to get casualties into fresh air and to summon medical aid

immediately.

Casualties should be kept at rest. If their breathing is slow, laboured or impaired, artificial

resuscitation

(mouth to mouth or by the use of a mechanical resuscitator) may be

necessary.

Note: Before commencing mouth-to-mouth resuscitation, any gas in the casualty‟s lungs

should be first expelled by pressing down on the chest.

DOCUMENTS REFERENCES

This procedure shall, where appropriate, be used in conjunction with this suite of AzSPU

Procedures referenced below.

Document Number

Title of Procedure

AZSPU-HSSE-DOC-00011-2

Procedure for Deviations

AZSPU-HSSE-DOC-00060-2

Procedure for Permit To Work

AZSPU-HSSE-DOC-00063-2

Procedure for Task Risk Assessment

AZSPU-HSSE-DOC-00013-2

Procedure for Confined Space Entry

AZSPU-HSSE-DOC-00054-2

Procedure for Incident Investigation

AzSPU-HSSE-DOC-00021-2

HSSE Definitions

AZSPU-HSSE-DOC- 00002-2

Procedure for Control of Work

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Procedure for Hydrogen Sulphide

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12 October 2004

CHSSE Manager

Central Safety TL

Initial Issue

30 May 2008

Alan McNulty,

Abbas Islamov,

General:

AzSPU Central H&S

Central Safety TL

Through the Procedure the document

Manager

numbering for referred procedures has been

changed from UNIF to AzSPU.

Section 1. Introduction

The following are new inclusions to Section 1.

Legislation and Standards

Company Requirements

Stopping Unsafe Work

Deviations

Document Review

SSOW Cross Referrence

Language Facilitation

Considerable changes were made to paragraph

1.2 Scope.

Section 3. Roles & Responsibilities

3.1 One point added to SM/SC/OIM

responsibilities.

The recommended personnel’s behavior if H2S

is found to be in presence in air is strengthened

and made more precise - paragraph 6.1

In addition to Appendix A, new appendix is

add as follows:

Appendix B - Feedback & Improvements

Suggestions.

05 December 2008

Yuliy Zaytsev

Adalat Mamedov,

Authority position/name and custodian name

AzSPU Safety &

Central Safety TL

have changed to reflect org changes in

Compliance Systems

HSE&TD.

Manager

14 August 2009

Yuliy Zaytsev

Niyaz Mamedov

Appendix A - Change of terminology from

AzSPU Safety &

HSE Systems /

OES (Occupational Exposure Standards) to

Compliance Systems

CoW Adviser

WEL (Workplace Exposure Limits)

Manager

The procedure’s numbering is structurally

changed in accordance with Standardized

Document Control Procedure Template

requirements.

25 January 2011

Yuliy Zaytsev

Elman

Section 1 General Requirements

AzSPU Safety &

Shikhkerimov

Removed reference to Getting HSE right,

Compliance Systems

Safety

Golden Rules and replaced with OMS,

Manager

Systems/CoW Lead

Group requirements

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Procedure for Leak Testing of In-Service Equipment

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TABLE OF CONTENTS

1 INTRODUCTION

1.1

PURPOSE

1.2

SCOPE

1.3

LEGISLATION & STANDARDS

1.4

COMPANY REQUIREMENTS

1.5

STOPPING UNSAFE WORK

1.6

DEVIATIONS

1.8

NORMATIVE REFERENCES

1.9

LANGUAGE FACILITATION

2 ROLES AND RESPONSIBILITIES

2.1

OFFSHORE INSTALLATION MANAGER / SITE MANAGER / SITE CONTROLLER

2.2

AREA AUTHORITY

2.3

PERFORMING AUTHORITY

2.4

EMPLOYEES

3 COMPETENCY, TRAINING AND AWARENESS

3.1

COMPETENCY

3.2

UNDERSTANDING

3.3

AWARENESS

3.4

NEW INDIVIDUALS

4 SELECTION OF TEST TYPE

4.1

GENERAL

4.2

HYDRAULIC

4.3

NITROGEN

4.4

LIQUID FILL AND NITROGEN SQUEEZE

4.5

NITROGEN - HELIUM

4.6

SERVICE

4.7 POST-TEST INTEGRITY CHECKS

5 LEAK TESTING GUIDELINES

5.1

COMMUNICATION

5.2

TEST AREA ACCESS

5.3

TEST EQUIPMENT

5.4

TEST BOUNDARY

5.5

ISOLATIONS

5.6

VENTS AND SAFETY VALVES

5.7

APPLYING THE TEST

5.8

MONITORING AND INSPECTION

5.9

DEPRESSURISING AND RETURN TO SERVICE

5.10

REPAIRS OR ADDITIONS AFTER LEAK TESTING

5.11

SAFETY CONSIDERATIONS IN NITROGEN LEAK TESTING

6 RECORDS (CERTIFICATION)

7 REGISTERS

8 CONTRACTORS

9 AUDIT AND REVIEW

APPENDIX A - LIST OF DEFINITIONS

APPENDIX B - LEAK TESTING CHECKLIST

APPENDIX C - GUIDANCE NOTES

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Procedure for Leak Testing of In-Service Equipment

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INTRODUCTION

1.1

PURPOSE

The purpose of this document is to provide:

 Guidelines for assessing the risks and establishing the precautions to be taken

when carrying out leak testing of in-service equipment.

 Information that may be used as the basis for producing formal instructions for

specific pressure and leak testing activities.

Prior to re-instatement of plant or equipment, any leak testing operations shall

be conducted in accordance with this procedure.

A leak test (hydraulic where practicable) is performed to prove the pressure tightness (i.e.

fitness for service) of joints, seals and glands etc, whenever the integrity of containment

systems has been broken, either at hook-up/commissioning or post-operations phase. The

prevention of even minor leaks is vitally important where flammable or toxic fluids are

concerned.

Leak testing is carried out at a pressure of 110% of the maximum operating pressure

(MOP), or 95% PSV set pressure if PSV is provided in the system.

1.2

SCOPE

This applies to all leak testing operations carried out on BP owned and managed sites and

installations in AzSPU. This procedure does not include standard strength tests which are

conducted on individual items of equipment/systems. These tests are carried out to

separate item design codal requirements, and are completed before the items are installed

as part of the overall pressure retaining system. e.g. pressure vessels, valves etc.

Contractors working on BP owned or managed sites / installations are also responsible for

alignment with this procedure.

This procedure contributes to compliance with the “HSE expectations” contained in “getting

HSE right”, the „Golden Rules of Safety‟ and the Control of Work (CoW) standard that the

Hazards associated with BP activities are identified and that the risks are assessed and

managed.

All guidelines contained shall be regarded as the minimum requirements for BP owned or

managed sites / installations in Azerbaijan and Georgia.

The scope covers defined activities of BP and Contractors at all BP AzSPU sites and

installations.

1.3

LEGISLATION & STANDARDS

The aim of this Safe System of Work is to achieve ”no accidents”, “no harm to people” and

“no damage to the environment”. To achieve this aim, this SSOW complies with National

Legislation, the terms of the Production Sharing Agreement (PSA) and mandatory BP

Standards.

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Procedure for Leak Testing of In-Service Equipment

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The best International Oil Industry practice has been adopted to reduce the level of risk to

ALARP.

In the absence of local regulations, BP Group Standards will apply. In addition, appropriate

UK and US regulations and industry best practice have been considered in setting suitable

goals and targets.

1.4

COMPANY REQUIREMENTS

It is a company requirement that all tasks are subjected to an assessment of risk to

demonstrate that risks have been reduced to as low a level as reasonably practicable

(ALARP). This can be achieved by complying with the Company‟s existing standards.

Where compliance with Company standards cannot reasonably be achieved, a formal Level

2 Risk Assessment will be undertaken to identify any additional controls and demonstrate

that risks remain as low as reasonably practicable. Whether by compliance with Company

Standards or through Level 2 Risk Assessment, the Company‟s Golden Rules of Safety

must be complied with. Golden Rules are non-negotiable.

1.5

STOPPING UNSAFE WORK

To stop the continuation of potentially unsafe work at the earliest possible stage, the

Control of Work (CoW) Policy and this procedure for Leak Testing make it very clear that all

personnel are obliged and have the authority to “STOP” the work that they consider to be

unsafe.

1.6

DEVIATIONS

This procedure is written in sufficient detail that it should be able to be applied consistently

at all sites / installations. There may still be the requirement for some local rules covering

site

/ installation specific logistical/administrative arrangements and local variations in

responsibilities to reflect differences in organisational arrangements. These local rules

should not deviate from the core processes within this document. Any form of deviation

from this procedure, including but not limited to local rules, shall be requested and

authorised in accordance with SSOW, Deviations from Regulations and Procedures (Doc.

No: AZSPU-HSSE-DOC-00011-2).

1.8

NORMATIVE REFERENCES

The following normative documents contain requirements that, through reference in this

text, constitute requirements of this procedure. For undated references, the latest edition of

the normative document referred to applies.

American Society of Mechanical Engineers (ASME)

ASME B1.20.1

Pipe Threads, General Purpose

2006

ASME B31.3

Process Piping

2006

ASME B31.4

PIPELINE TRANSPORTATION SYSTEMS FOR

LIQUID HYDROCARBONS AND OTHER LIQUIDS

2007

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Procedure for Leak Testing of In-Service Equipment

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In addition, this procedure shall, where appropriate, be used in conjunction with the suite of

BP AzSPU SSOW Procedures referenced below.

Document Number

Title of Procedure

AZSPU-HSSE-DOC-00011-2

Deviations from Regulations and Procedures

AZSPU-HSSE-DOC-00054-2

Incident Investigation and Reporting

AZSPU-HSSE-DOC-00060-2

Permit To Work

AZSPU-HSSE-DOC-00012-2

Authorisation

AZSPU-HSSE-DOC-00063-2

Task Risk Assessment

AZSPU-HSSE-DOC-00048-2

Energy Isolations-Electrical

AZSPU-HSSE-DOC-00049-2

Energy Isolations-Process

AZSPU-HSSE-DOC-00013-2

Confined Space Entry

AZSPU ENG STP 36-101-01

Bolted Joint Integrity Management

1.9

LANGUAGE FACILITATION

Due to the various languages spoken at site, there is a necessity to assist all with “an ease

of understanding”. Therefore, the development and use of information tools are available.

ROLES AND RESPONSIBILITIES

2.1

OFFSHORE INSTALLATION MANAGER / SITE MANAGER / SITE CONTROLLER

The Site Manager / Site Controller / Offshore Installation Manager shall be responsible and

accountable for the application of this procedure in their area of responsibility. They shall

ensure:

 That adequate numbers of Competent responsible persons are appointed to manage

and maintain the requirements of this procedure

 That only competent and authorised personnel are involved in pressure testing

activities

 That this procedure is strictly adhered to for all occasions when it is identified that

leak testing activities are to take place.

 That formal records of all risk assessments are maintained in accordance with this

procedure

 That only suitably qualified and experienced personnel are appointed to the roles of

Performing Authority, responsible engineer / person in charge of leak testing

 That formal records of all pressure tests and leak tests are maintained in accordance

with this procedure

2.2

AREA AUTHORITY

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Procedure for Leak Testing of In-Service Equipment

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The Area Authority shall:

 Be responsible for ensuring that the requirements of this procedure are adhered to

for all work involving leak testing activities in his area of responsibility

 Ensure that leak testing operations comply with the guidelines within this document

and/or ensure that any deviations from those guidelines are documented and

authorised

2.3

PERFORMING AUTHORITY

The Performing Authority shall ensure:

 Have such practical experience and theoretical knowledge of the equipment to be

tested so that he will be able to detect defects or weaknesses highlighted by the test

and assess their importance to the integrity and function of the equipment. The

Performing Authority must be qualified and trained to a standard sufficient to meet

any applicable regulations.

 Ensure that leak testing operations comply with the guidelines within this document

and/or ensure that any inability to comply with the conditions of the Permit result in a

re-assessment of the task

 The compliance of all personnel under their supervision with this procedure when

involved in leak testing activities

 That a risk assessment has been performed and a toolbox talk conducted

 That all personnel are informed of, and understand, the risks associated with the task

they are performing, and any associated works that may affect their work activity

 That the activity is executed in accordance with this procedure

 That leak testing activities are halted if an unsafe situation occurs

 That good housekeeping practices are implemented at all work areas

 That work activities have been reviewed and pertinent information exchanged with all

other affected parties

2.4

EMPLOYEES

ALL EMPLOYEES SHALL BE RESPONSIBLE FOR:

 Compliance with this procedure when involved in leak testing activities

 Implementing good housekeeping practices at the work site

 Informing their immediate Supervisor should any unsafe situation occurs

 Awareness of other personnel and ongoing works in their area

COMPETENCY, TRAINING AND AWARENESS

3.1

COMPETENCY

BP‟s employees, and those of it‟s Contractors must provide adequate training for all

personnel likely to be involved in Leak Testing, to ensure that they possess the correct

levels of competency.

All individuals shall be able to and be prepared to demonstrate their levels of competency to

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Procedure for Leak Testing of In-Service Equipment

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the Performing Authority, Supervisor and / or Leak Test Supervisor

This shall be demonstrated through individuals understanding, knowledge and the skills

necessary to safely perform their assigned duties together with certifiable evidence of their

competency.

3.2

UNDERSTANDING

All individuals shall be fully conversant with the:

 Scope of work and the potential hazards associated within their scope of work to

ensure that they understand the hazards of the task in hand and all associated

controls

 Safe systems of work (SSOW) elements associated with their scope of work,

including but not limited to: PTW, Energy Isolations., purging and / or ventilation

procedures

 Relevant scope of work task risk assessments

3.3

AWARENESS

All individuals shall be fully aware of:

 What they need to do in the event of an emergency on site

 What they need to do in the event of an incident related to their scope of work

 How to use the relevant communications equipment

 Self rescue

 How to use continuous gas monitoring equipment

 All aspects of the proposed Leak Test activities with focus on their particular duties

3.4

NEW INDIVIDUALS

New individuals shall not be assigned to the above tasks, unless under training and

accompanied by a competent person (maximum 2 new starts to 1 supervisor) who is

familiar with the hazards of Leak Testing.

SELECTION OF TEST TYPE

4.1

GENERAL

A liquid medium (hydraulic) is the preferred means of testing and shall be used for leak

testing wherever possible, in order to minimise the stored energy.

The preferred liquid medium is water. However, the effect of the water, and any additives,

on the metallurgy of the pressure envelope, and the effect of any residual water/additives

on the process (eg formation of hydrates), shall be considered (eg when testing austenitic

stainless steels, the water should be distilled or demineralised and contain <30ppm of

chloride ions).

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Selection of liquids other than water should take account of:

 The possibility of explosion resulting from the „diesel‟ effect

 The boiling point relative to the test temperature

The flammability of the liquid, the flash point of which should not be less than 65°C, and at

least 10°C above the maximum test temperature.

4.2

HYDRAULIC

 Weight must be considered, particularly in context of equipment support e.g. pipe

hangers, foundations

 Care must be taken with draining the test fluid on completion - in some cases the

equipment may require flushing and/or drying.

 Some test fluids, typically water, may be incompatible with equipment materials

 Generally considered to be a “safe” test medium due to low levels of stored energy

 Internal leakage, e.g. through valves at the boundary, may require continuous

pressuring of the equipment. In severe cases this can prevent a successful test

 Detection of leakage is typically by observation of fluids leaking to atmosphere at

joints/connections under test. In cases where joints/connections are not visible then

pressure drop off can be used as an indicator.

4.3

NITROGEN

Note! Pneumatic leak-testing should not be carried out before the integrity of the equipment

has been confirmed by a standard pressure test.

 Relatively high levels of stored energy

 Large volumes may require supply of bulk nitrogen

 Considerable time may be needed to pressurize and/or vent

 Vent location(s) must be carefully selected so as to avoid any risk of asphyxiation to

personnel

 Detection of leakage is typically by means of bubble test at joints/connections.

4.4

LIQUID FILL AND NITROGEN SQUEEZE

Combination of both sets of attributes mentioned in sub sections 4.2 and 4.3.

4.5

NITROGEN - HELIUM

 Addition of a small proportion of helium (known as a tracer) enhances the searching

qualities of nitrogen. Normally 99% nitrogen, 1% helium.

 Typically supplied in bulk by a specialist contractor. Usually used for large-volume

tests e.g. post shutdown

 Detection - Requires specialist detection equipment - can give a quantitative output

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4.6

SERVICE

For process hydrocarbon systems, although it is not the preferred means of testing, under

certain conditions it may be considered appropriate to carry out testing with the service fluid

(ie liquid or gas) rather than with water, nitrogen or some other medium. This should only be

considered where it can be clearly demonstrated that it is impractical to carry out leak testing

due to the configuration of the system and that the hazards associated with the introduction of

high-pressure testing equipment etc would be greater than the hazards associated with the

service testing.

Where this method is proposed, a written justification must be recorded on a Level 2 Risk

Assessment.

The following criteria and precautions should be considered as the minimum in support of

carrying out service tests on hydrocarbon system;

 The number of joints that have been broken shall be small to guarantee the ability to

control and monitor the test.

 A competent technician shall have witnessed the joints being re-made in accordance

with the Guidance on Certification (GOC) Procedure for Critical Joint Installation.



Pressurisation should be controlled via a designated pressurisation route where

possible, e.g. a small bore line fitted with a globe valve.



Pressurisation shall be in small incremental steps (5.bar max) where possible.



Depressurisation routes shall be specified and if possible both local/manual

depressurisation and remote depressurisation from the control room shall be designed

into the leak boundaries.

 The boundary isolation valves for the service test shall be controlled under the ISSOW

isolation control.

Once it has been decided to carry out a service test, a formal procedure shall be developed

including marked-up P & ID‟s defining the service test and detailing compliance with the

above criteria.

4.7 POST-TEST INTEGRITY CHECKS

After hydrocarbons or hazardous utilities have been introduced, an initial visual check of

joint integrity shall be made for all broken joints and any other joints that may have been

disturbed. Further checks shall be carried out every 12 hours until the plant has reached its

normal operating pressure and temperature. Checks shall be carried out for at least 2 days.

Note: Where a service test has been completed on a hydrocarbon system, these

post-test integrity checks must be repeated at each pressure increase of 5 barg

above the original service test pressure.

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LEAK TESTING GUIDELINES

5.1

COMMUNICATION

 Effective communication must be established between sites whenever the test

envelope extends beyond one site, for example, pipelines.

5.2

TEST AREA ACCESS

Access to the test area shall be limited to essential personnel only. In particular, before the

test commences compliance is required with the following points:



The area shall be cordoned off (using tape, shields or barriers, etc) at an adequate

distance from the equipment to be tested,



Warning signs and barriers shall be posted at access ways, at other strategic

positions, and on the equipment to be tested (including the doors of test workshops

or other designated areas.



Wherever possible, warnings of an imminent pressure test shall be broadcast.



When testing, the test area boundaries shall be patrolled to ensure that no

unauthorised personnel enter the area.

5.3

TEST EQUIPMENT



Pressuring equipment shall be provided with suitably calibrated pressure control /

regulator devices.



Suitably calibrated pressure indicating device(s) shall be provided in a location

clearly visible to the person controlling the pressure. Account should be taken of

pressure variation caused by elevation changes inside the envelope.



Pressuring equipment and plant/equipment shall not be left unattended at any time

during the test.



Pressuring equipment shall be isolated from the equipment under test and where

practicable disconnected, when the test pressure has been reached. The

pressurising valve should be locked in the closed position.



All hoses are fully secured with tie-down devices capable of withstanding the forces

used in the test. Each hose end is to be fitted with whip check cables.

5.4

TEST BOUNDARY



A Competent Person shall inspect the equipment to be tested, prior to testing, to

ensure the equipment is free from any obvious flaws



Within the test boundary, there should be an accessible and operable means of

quickly and safely de-pressuring the test in the event of equipment failure etc.



Prior to any hydraulic pressure test taking place it must be established that the

foundation and supports of the equipment under test are rated and capable of

withstanding the combined weight of the equipment and the liquid required to fill it.

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Procedure for Leak Testing of In-Service Equipment

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

The volume of equipment under test must be kept as small as possible so to

minimise the stored energy within the pressurised system.



Hazard and risk identification shall, as a minimum, consider:

o the stability of components such as expansion joints and spring hangers

o any interfaces with lower pressure systems or equipment (including heat exchangers,

gauges, instruments etc) and must ensure measures are in place to ensure that such

systems cannot be over-pressurised

o any connected high pressure equipment such as pulsation dampers and

accumulators.

5.5

ISOLATIONS



Blanking devices such as spades, blinds and screwed plugs, etc. shall conform to

the equipment specification. All plugs must have a minimum thread engagement

length as per ASME B1.20.1.



Where testing is carried out against closed valves it must be assumed that the

valves leak, and downstream equipment must be protected against subsequent over

pressuring. This should be done by opening of suitable vents or by monitoring of

downstream pressures

5.6

VENTS AND SAFETY VALVES



Where the source pressure of the pressurising medium is greater than the test

pressure, a safety valve should be fitted to the equipment/system being tested, set

to relieve at a pressure that will prevent over pressurisation.



Sufficient venting / draining points shall be provided in order to prevent trapping of

pressurising medium behind non-return valves, check valves, between isolation

valves, or within dead legs of the pressure envelope.



When filling equipment/plant, adequate venting must take place at all high points or

dead ends to release entrapped gas.

5.7

APPLYING THE TEST



Pressure must be increased gradually to the final pressure, and sufficient time

should be allowed for equipment and test medium to reach equilibrium.

o Raise pressure to 25% test pressure and allow to settle.

o Increase to 50% test pressure.

o Increase to 75% test pressure.

o Final increase to the full test pressure.



The pressure should be maintained sufficiently long for an Inspection Engineer to

examine the entire system, and for any defects to have time to manifest themselves.



Equipment must not be subjected to any form of shock loading during testing.



When any equipment/plant is left under pressure for decay or leak observation,

consideration must be given to the ambient temperature changes, particularly in

respect to thermal expansion of liquids in a closed system.

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5.8

MONITORING AND INSPECTION



Pressure monitoring shall extend to any adjacent systems that are not positively

isolated.



Close examination of equipment at above design pressure shall not take place until

the pressure has been held for 30 minutes. In any event, extreme care should be

exercised until the pressure has been reduced to the design pressure.



If an inspection is required within the hold period, then pressure should be reduced

to the Design Pressure.

5.9

DEPRESSURISING AND RETURN TO SERVICE



Extreme care shall be taken to ensure that all pressure has been relieved before

opening any system that has been subject to pressure or leak test.



On completion of the test, the pressure shall be reduced gradually and under

controlled conditions until approximately atmospheric pressure is reached. More

rapid draining of the test fluid can then take place.



When draining equipment, adequate vents at the highest point must be opened to

prevent drawing a vacuum. The drainage system must be capable of handling the

flow from the pressurized equipment/plant without itself over pressuring.



Consideration must be given to the possibility of test fluids being trapped behind

non-return valves; it may often be necessary to vent or drain the test fluid from more

than one point.



Special consideration should be given to test fluid which may be contaminated with

oil or contain corrosion inhibitor or other chemical. The method of disposal of test

fluid must be included in Work Permit.



Clamps or bolts on flanges shall not be loosened while the system is still under

pressure. Clamps shall only be removed by competent personnel who have been

trained in such procedures.



Depending upon the test medium used, the return of equipment/plant back into

service may produce additional hazards. In particular:

o Residual water after draining may contaminate the product, or cause problems if the

equipment is on high or low temperature service.

o Systems containing air need to be inert prior to the introduction of process fluids.

o Inert gas must be vented to an area where personnel cannot be affected by it.



Consideration must be given to the flushing and preserving of systems that are not

being taken back into re-use immediately.

5.10 REPAIRS OR ADDITIONS AFTER LEAK TESTING

If repairs or additions are made following the leak test, the affected piping shall be retested,

except that for minor repairs or additions, the retest requirements may be waived when

precautionary measures are taken to assure sound construction. (B31-345-2.6)

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Procedure for Leak Testing of In-Service Equipment

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5.11 SAFETY CONSIDERATIONS IN NITROGEN LEAK TESTING

Nitrogen can asphyxiate, therefore great care should be taken to avoid gross leakage of

nitrogen or nitrogen/helium. Particular care should be taken when opening up vessels that

have been nitrogen purged or when the venting of nitrogen is taking place.

Pressure shall be introduced gradually into the system allowing adequate time for

temperature equalisation; in this respect special attention is drawn to the cooling Joule-

Thompson effect which occurs when letting down high-pressure nitrogen into the system to

be tested. Nitrogen leak testing is performed with gases at high pressure. Therefore

attention is drawn to the hazards of a possible release, with explosive force, of energy

stored in the system. Systems under test shall be depressurised prior to bolt re-tightening,

tensioning or other remedial action to improve leaks, the only exceptions to this being valve

glands, which may be adjusted but not re-packed whilst the system is still pressurised.

The possibility of brittle fracture shall be considered when conducting a nitrogen leak test at

metal temperatures near the ductile/brittle transition temperature of the steel. It is

recommended that nitrogen leak testing should not be carried out when the ambient

temperature is below 7°C on equipment and piping constructed from non-impact tested

carbon steel materials with nominal thickness of >3/4in (19mm), (ie API 5L, A 106, A 105, A

216, etc). For non-impact tested carbon steel materials with nominal thickness >3/4in, a

Competent Person shall specify the minimum metal temperatures for leak testing, based on

requirements of either RP 42-1 or BS 5500. Sites are advised to identify any systems

containing non-impact tested carbon steel and prepare the appropriate local test

procedures.

Introducing nitrogen to a system introduces a large energy source, far greater than the

energy stored in an equivalent liquid leak test. To minimise this stored energy, vessels

which normally operate with a liquid level should be water filled (ensure water filling of the

vessel is acceptable with respect to corrosion and scaling) prior to pressurising with

nitrogen.

When a specialist contractor is contracted to carry out nitrogen leak testing rather than leak

testing with nitrogen quads or low volume pumps the following additional measures apply:

 There will be a Pump Operator who will be in radio contact with the Leak Test

Supervisor who will monitor system pressure. The pumping unit will be manually

shut down on the instruction of the Leak Test Supervisor. The leak test crew should

have a written procedure for radio protocol

 There will be an automatic pump trip (Overpressure Protection Device (OPPD)) that

will shut down the pumping unit. The OPPD will be located close to the injection

point so that it can monitor the highest pressure that will be seen in the Installation

system

 Full flow (of test medium injection rate) pressure relief will be available via Pressure

Safety Valves

(PSVs). It is acceptable and appropriate for the PSVs on the

Installation system/plant to be used for this purpose. However, if full flow pressure

relief is not available via a plant system, then Full flow pressure relief will be

available via Pressure Safety Valves (PSVs). It is acceptable and appropriate for the

PSVs on the Installation system/plant to be used for this purpose. However, if full

flow pressure relief is not available via a plant system, then consideration should be

given to the use of temporary PSVs supplied by the leak test contractor. Any system

PSV‟s used for this purpose shall be within their re-certification date. Any contractor

supplied PSV‟s shall be certified and calibrated, with certification available for

examination at site. If full flow pressure relief is not provided, then a Level 2 Risk

Assessment should be completed and assurance gained that there is sufficient

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Procedure for Leak Testing of In-Service Equipment

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control in place to manage the HP/LP interface

 If it has been identified that the leak test contractor will have to supply PSVs,

consideration should be given to the location that these PSVs would vent to in an

emergency. The vent location should be surveyed and approved by the Installation

Area Authority with guidance from the leak test contractor on expected nitrogen

plume

 Contractor Method Statement shall be thoroughly examined and approved

RECORDS (CERTIFICATION)

All pressure / leak test results shall be formally certificated and recorded where necessary

and all certificates included with the relevant equipment records.

REGISTERS

A register will be held on site of all personnel deemed competent for all the roles

associated with Leak testing, and will be managed by the Site Manager / Site Controller /

Offshore Installation Manager.

CONTRACTORS

In cases where leak testing is contracted to a specialist third party, the contract shall, as a

minimum, specify the need to observe the requirements of this procedure and in addition

the:

 Roles and responsibilities of the relevant BP and contractor personnel

 Authority for approval of procedures

 Required competency of the contractor personnel and the means of controlling

compliance

 Keeping of test records

 Means of monitoring the contractor‟s safety management system.

AUDIT AND REVIEW

Business Units shall periodically review pressure and leak testing activities to verify general

compliance with this procedure and with any local procedures. Such reviews shall include

checks to verify compliance with any statutory requirements for periodic strength tests of

equipment to demonstrate its continued fitness for service.

Independent audit of pressure / leak testing procedures and records shall be undertaken

periodically at the request of the Site Manager / Site Controller / Offshore Installation

Manager.

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Procedure for Leak Testing of In-Service Equipment

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APPENDIX A - LIST OF DEFINITIONS

In-Service

Equipment installed as part of a system, the individual components of

Equipment

which have been subject to Codal Pressure/Strength Testing. This applies

to equipment included in systems where the integrity of containment has

been broken, either at hook-up/commissioning or post-operations phase.

Blank /

Installation of a piping specification rated device such as a blind flange,

Blanking:

spade or spectacle blind for the purpose of achieving positive isolation.

Boundary

Isolations that define the boundaries of a discrete pressure envelope.

isolations:

Competent

A person having such practical experience and theoretical knowledge of

Person:

the equipment to be pressure tested so that he will be able to detect

defects or weaknesses highlighted by the pressure test and assess their

importance to the strength and function of the equipment.

Competent Persons must be qualified and trained to a standard sufficient

to meet any applicable regulations.

Design Pressure

The maximum pressure at which the system is designed to operate at.

This is usually the maximum operating pressure plus a small margin

(typically 10%).

Application of pressure to a system in which the integrity of individual

Leak test:

components has already been proven by a pressure test so as to identify

leakage and leakage rates from component connections, valves etc. Leak

testing is carried out at a pressure of 110% of the maximum operating

pressure (MOP), or 95% PSV set pressure if PSV is provided in the

system.

Local

Site specific or Business Unit specific procedures that address the

procedures:

arrangements in place for the implementation of recommended and

statutory practices.

Maximum

The maximum pressure expected during normal systems operation.

Operating

Pressure (MOP)

Maximum

The maximum pressure which a component can safely withstand. Note

Allowable

that this is often greater than the design pressure, due to components

Working

being manufactured from thicker material than that required for the design

Pressure

pressure.

Pressure/

A test involving the application of pressure to a system so as to apply a

Strength test:

load greater than the maximum load generated in service but less than

would cause physical damage. The test provides evidence that the system

can safely withstand the service pressure. Test pressures may vary

between individual components within the same system due to differing

codal design requirements.

Initial Service

A leak test undertaken when a system is brought into normal service,

leak test:

completed at operating pressure for Category D fluids only (refer to ASME

B31.3 para 300.2).

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Procedure for Leak Testing of In-Service Equipment

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APPENDIX B - LEAK TESTING CHECKLIST

A checklist to be used when planning leak tests is provided in Figure 1 below as a guide.

Note: This checklist in this appendix is provided as an aide memoir only, and is not intended for use

as an approved test certificate or an official document:

Leak/Pressure Testing Checklist

1.TYPE OF TEST:

STANDARD PRESSURE TEST:

LEAK PRESSURE TEST:

2.TESTING MEDIUM:

HYDRAULIC:

PNEUMATIC:

3.EQUIPMENT TO BE TESTED:

Codal Test Pressure (strength test)

Proposed Test Pressure:

Maximum Operating Pressure (leak test)

Incremental steps (%):

Duration each step:

Duration of Test Pressure:

Written procedure

YES

provided:

All threaded connectors, plugs, and caps secure and tight:

YES

All attachments unable to withstand Test pressure removed or isolated:

YES

Quality:

Temperature:

4. TEST ENVELOPE INSPECTION:

Visual

YES

MPI:

YES

Radiography:

YES

Other (specify):

YES

5. EQUIPMENT ISOLATED AT:

and at:

6. PRE-TEST PREPARATIONS:

Equipment vented for filling at:

and at:

Check facilities for venting trapped pressure from NRVs or between isolation valves

YES

Vents now SHUT

YES

Safety valves set to prevent test pressure being exceeded

YES

Calibrated test pressure gauge(s) fitted and visible to operator

YES

Any pipe support / expansion joints fitted with temporary restraints

YES

Pressuring equipment fitted with regulator and relief valve and is in sound condition

YES

Methods for upstream and downstream monitoring are in place

YES

Warning signs posted, barriers erected, and sentries in place

YES

PA announcement of proposed test has been organised / made

YES

7. ON COMPLETION OF TEST:

Vents are open for slow depressurisation at:

and at:

Drains are open for draining of test medium at:

and at:

8. EQUIPMENT HAS BEEN RETURNED TO PRE-TEST EXCEPT FOR:

and:

YES

9. CHECKLIST COMPLETED BY:

Name:

Signature:

Title:

Date:

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Procedure for Leak Testing of In-Service Equipment

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Test Plan / Programme

 If any pipeline or plant configuration changes then a MoC and relevant TA approval are required

 Design Pressure or Maximum Operating Pressure (MOP) defined

 Test Pressure defined

 Marked up P&ID‟s produced showing test boundaries

 Written test procedure developed

 Test medium selected (hydraulic considered rather than pneumatic)

 If pneumatic test planned, consider reducing the volume by water filling vessels

 Emergency depressurisation route identified

 Pressurisation / depressurisation procedures take account of the position of non-return valves

 Pressurisation procedure specifies hold points (25%, 50%, 75% of the test pressure)

Pre-test Preparation and Equipment Checks

 All threaded connections, plugs and caps are secure

 All attachments unable to withstand test pressure are removed/ isolated

 Facilities have been checked for means of venting trapped pressure

 Safety valve set to prevent test pressure being exceeded

 Calibrated test pressure gauge(s) fitted and visible to operator

 Any pipe supports/expansion joints fitted with restraints

 Pressure equipment is fitted with regulator and relief valve and is in sound condition

 Methods of upstream and downstream monitoring are in place

 Warning signs and barriers erected

 PA announcement of proposed test has been organised

 Contingencies for leakage have been made

 Overpressure protection device in place for specialist contractor nitrogen testing

 Pumping unit connected to ESD system where required

Post-test Checks

 Vents to be opened at high points during liquid depressurisation

 Pressure to be released gradually

 Inert gases vented to flare or alternatively to a safe area

 Confirm that there is no trapped pressure within test envelope

Figure 1. Leak Testing Checklist

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Procedure for Leak Testing of In-Service Equipment

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APPENDIX C - GUIDANCE NOTES

Leak Testing Acceptance Criteria

This section defines the allowable leak rates for different test medium and equipment type

and duty.

Acceptance Criteria for Hydraulic Testing

For hydraulic testing using water the test should be conducted for a minimum of

30 minutes. A test should be deemed successful if no significant reduction in pressure is

observed over the test period and all joints and connections have been visually inspected

for leakage. In some cases it may not be possible to maintain a constant test pressure due

to trapped air in the system or passing valves. In this case the visual inspection is vital in

confirming an acceptable test.

Acceptance Criteria for Nitrogen Testing

For nitrogen testing, depending on the scope of the test, there are two primary means of

confirming an acceptable test. These are:

 Bubble testing

 Leak rate measurement using a helium tracer

Helium tracer testing is normally used for large scale testing of plant or the installation of

new equipment involving a specialist contractor. Bubble testing is normally applicable when

carrying out smaller scale testing using nitrogen quads.

Bubble Testing Criteria for Hydrocarbons

Bubble Testing Method

Acceptance Criteria

Method

1 involves the application of a leak

No presence of continuous bubble growth

detection fluid e.g „Snoop‟ to the joint and monitoring

detected in 60 seconds for flanges up to

for surface bubbles. For all large diameter flanges

and including 4in NB and 90 seconds for

(>6” NB), the joint should be taped and the leak

flanges above 4in NB.

detection fluid applied to a pin hole in the tape.

Method 2 involves taping the joint and inserting a

5 bubbles/min.

1/4in diameter tube from the flange into a water

bucket and monitoring the number of bubbles

released.

Note:

5 bubbles/min approximates to 15scf/year from a 1/4in tube.

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Procedure for Leak Testing of In-Service Equipment

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Helium Tracer Testing

Leak rate measurement in the case of helium tracer testing involves taping of individual

flanges and measurement of leakage using a measurement probe. The following leakage

criteria apply:

Leakage Rates (scf/yr)

Helium Tracer Testing Method

Acceptance Criteria (scf/year)

Target

Maximum

Closed Module

Open Module

Oil

100

200

400

Gas <50barg

100

200

Gas >50barg

100

Acceptance of leak rates in the range between target and maximum allowable leakage is by

exception only and review by the appropriate Technical Authority. The review shall take into

account fluid type, location of joint and ventilation and subsequent monitoring programme.

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REVISION/REVIEW LOG

Revision Date

Authority

Custodian

Revision Details

9 September 2004

Alan McNulty

Esmira Akhundova

Initial Issue

08 April 2008

Alan McNulty

Abbas Islamov

General.

(AzSPU CH&S

(Central Safety TL)

Section 1. Introduction.

Manager)

Four new paragraphs are added to

Section 1:

1.3

Legislation & Standards

1.4

Company Requirements

1.5

Stopping Unsafe Work

1.6

Deviations

SSOW Specific Cross References

paragraph 1.5 is now Normative

References 1.8

Section 2. Roles and Responsibilities.

New paragraph is added 2.4 Employees

Section 4. Responsibilities. New

paragraph is added 4.7 Post-Test

Integrity Checks

Section 5. Leak Testing Guidelines.

New paragraph is added 5.10 Repairs or

additions after leak testing.

Appendix D. New appendix provides

opportunity for quick feedbacks and/or

improvement suggestions.

05 December 2008

Yuliy Zaytsev

Adalat Mamedov

Authority position/name and custodian

Safety & Compliance

Central Safety TL

name have changed to reflect org

Systems Manager

changes in HSE&TD.

23 April 2009

Yuliy Zaytsev

Niyaz Mamedov

Additional alteration made to Paragraph

Safety & Compliance

HSE Systems -

1.1 in regard to the maximum operating

Systems Manager

Control of Work

pressure

(MOP) and PSV. The same

Advisor

issue is accordingly reflected in

Appendix A - List of Definitions.

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Procedure for Lifting Operations

Page 2 of 55

TABLE OF CONTENTS

INTRODUCTION

Document Purpose

Document Scope

Legislation & Standards

Stopping Unsafe Work

Medical

Deviations

Document Review

SSOW Specific Cross References

Lifting Operations Golden Rules of Safety

Language Facilitation

Procedure Summary

DEFINITIONS & ABBREVIATIONS

LIFTING EQUIPMENT

3.1

Category 1: Portable Lifting Equipment (Lifting Appliances)

3.2

Category 2: Fixed Lifting Equipment

3.3

Category 3: Mobile Equipment

3.4

Category 4: Cargo Carrying Units

3.5

Category 5: Transit Slings

EXAMINATION PHILOSOPHY

4.1

Examination of Portable Lifting Equipment

4.2

Examination of Fixed Lifting Equipment

4.3

Examination of Transit Slings

4.4

Examination of CCUs

4.5

Examination of Mobile Lifting Equipment

REPORTS / RECORDS

5.1

Strategy

5.2

Storage & Availability of Records

CONTROL PROCESSES

6.1

Rigging Loft (Storage Area)

6.2

Colour Coding

6.3

Control of Portable Lifting Equipment

6.4

Control of Fixed Lifting Equipment

6.5

Control of Transit Slings

6.6

Control of Cargo carrying Units (CCUs)

6.7

Control of Mobile Lifting Equipment

6.8

Control of Third Party Contractor Lifting Equipment

6.9

Control of Uncertified Structural Components

1.10

Control of Webbing & Round Slings

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Procedure for Lifting Operations

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COMPETENCY

7.1

Competencies and Training of Personnel

ROLES and RESPONSIBILITIES

8.1

Site Manager / Site Controller / Offshore Installation Manager

8.2

Area Authority

8.3

Banksman

8.4

Rigger / Slinger

8.5

Crane Operator

8.6

Forklift Driver

8.7

Site Competent Person

8.8

Lifting Inspector

8.9

Site Lifting Coordinator

8.10

Mechanical Handling Contractor‟s (MHC) Technical Support Engineer

8.11

Lifting Technical Authority (LTA)

8.12

Senior Technical Authority (STA)

COMMUNICATIONS

RISK ASSESSMENT & PLANNING of LIFTING OPERATIONS

10.1 Strategy

10.2 Spheres of Responsibility

10.3 Planning Process

Appendix A: Glossary of Terms

Appendix B: Inspection & Certification of Temporary or New Cranes

Appendix C: References

Appendix D: Examples of Lifting Plans

Appendix E: Checklist for Pre-use - Mobile Crane Inspection Form

Appendix F: BP North Sea Lifting Rules

Appendix G: BP AzSPU References for Selection, Application & Control of Man Made Fiber

Slings for lifting Operations

Appendix H: Wind Force Scale

Appendix I: Procedure Summary

Appendix J: Feedback & Improvement Suggestions

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Procedure for Lifting Operations

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INTRODUCTION

1.1

Document Purpose

This document is based on the UK Lifting Operations and Lifting Equipment Regulations

1998 and SI 1998/2307 (LOLER). It presents the BP standards applicable to the safe use of

lifting equipment in Azerbaijan Strategic Performance Unit.

LOLER implements the lifting provisions of the Amending Directive to the Use of Work

Equipment Directive (AUWED, 95/63/EC) and build upon the requirements of the Provision

and Use of Work Equipment Regulations 1998 (PUWER).

It is important to note that all work equipment, including that deemed to be „lifting‟ under

LOLER, shall require to be maintained in an efficient state, in effective working order and in

good repair, LOLER Regulation 5.

This document satisfies the requirements of lifting operations in the BP Golden Rules of

Safety. The BP North Sea Lifting Rules and other references are cited in Appendix C.

1.2

Document Scope

The contents of this procedure are applicable to all BP owned and managed sites /

installations in Azerbaijan and Georgia. Contractors working on BP owned or managed sites

/ installations are also responsible for alignment with this procedure.

This document does not replace the procedures prepared and adopted by specialist

contractors. Neither does it supersede any national and local regulatory requirements.

This procedure complies with the „HSE expectations‟ contained in „getting HSE right‟, the

Golden Rules of Safety, and the Control of Work

(CoW) standard that the hazards

associated with BP activities are identified and that the risks are assessed and managed.

All guidelines contained in this document shall be regarded as the minimum requirements for

BP owned or managed sites / installations in Azerbaijan and Georgia.

The scope covers defined activities of BP and Contractors at all BP AzSPU sites and

installations.

The contents of this document apply to work carried out by or on behalf of the AzSPU.

The scope of this document incorporates mechanisms to ensure:

¾ All items of work equipment covered by AzSPU identified as lifting equipment are

operated and maintained in a safe and fit for purpose condition

¾ Lifting operations are carried out in a safe manner

¾ Risks to plant equipment and personnel involved in lifting operations are identified,

appropriately assessed and mitigated to ensure that these are at all times as low as

reasonably practicable

¾ Equipment, procedures, and standards of competency etc. are identified and

managed in a safe manner

¾ Roles and responsibilities for all lifting operations and activities are clearly defined

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Procedure for Lifting Operations

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1.3

Legislation and Standards

The aim of this Safe System of Work is to achieve no accidents, no harm to people, and no

damage to the environment. To achieve this aim, this SSOW complies with Azerbaijani

legislation, terms of the Production Sharing Agreement (PSA) and mandatory BP Standards.

The best international oil industry practice and relevant goal setting legislation have been

adopted to reduce the level of risk to as low as reasonably practicable and therefore well

below that mandated by applicable statutory laws and regulations.

In the absence of local regulations, BP Group Standards will apply. In addition, appropriate

UK and US regulations and industry best practice have been considered in setting suitable

goals and targets.

1.4

Stopping Unsafe Work

To stop the continuation of potentially unsafe work at the earliest possible stage, the Control

of Work policy and this Lifting Operations procedure make it very clear that all personnel are

obliged and have the authority to STOP the work that they consider to be unsafe.

1.5

Medical

All operators of lifting machines i.e. cranes, forklifts, MEWPs etc must be medically fit to the

requirements of AZSPU-HSSE-DOC-00007-2 and section 4 of the Scope and Frequency

document.

1.6

Deviations

This procedure is written in sufficient detail that it can be applied consistently at all sites /

installations. There may still be the requirement for some local rules covering site

installation specific logistical

/ administrative arrangements and local variations in

responsibilities to reflect differences in organizational arrangements. These local rules

should not deviate from the core processes within this document. Any form of deviation from

this procedure, including but not limited to local rules, shall be requested and authorized in

accordance with SSOW, Deviations from Regulations and Procedures procedure (Doc. No.

AZSPU-HSSE-DOC-00011-2).

1.7

Document Review

This document will be reviewed on an annual basis when users from the sites / installations

will have an opportunity to propose changes to the existing processes and procedures. The

document Technical Authority will be responsible for coordinating this review.

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Procedure for Lifting Operations

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1.8

SSOW Specific Cross References

This procedure shall be used where appropriate in conjunction with the suite of AzSPU

Procedures referenced below.

Document Number

Title of Procedure

AZSPU-HSSE-DOC-00011-2

Deviations from Regulations and Procedures

AZSPU-HSSE-DOC-00054-2

Incident Investigation and Reporting

AZSPU-HSSE-DOC-00060-2

Permit To Work

AZSPU-HSSE-DOC-00012-2

Authorization

AZSPU-HSSE-DOC-00063-2

Task Risk Assessment

AZSPU-HSSE-DOC-00059-2

Man Riding Operations

AZSPU-HSSE-DOC- 0002-2

Control of Work Standards

1.9

Lifting Operations Golden Rules of Safety

Lifting Operations is one of BP‟s Golden Rules of Safety and states:

Lifting operations over „live‟ equipment may only be undertaken if all other options have been

considered and ruled out. Lifts utilizing cranes, hoists, or other mechanical lifting devices will

not commence unless:

¾ An assessment of the lift has been completed and the lift method and equipment has

been determined by a responsible person

¾ Operators of powered lifting devices are trained and certified for that equipment

¾ Rigging of the load and supervision of the lift is carried out by a competent person

¾ Lifting devices and equipment have been verified fit for use within the last 12 months

(as a minimum)

¾ Load does not exceed dynamic and / or static capacities of the lifting equipment

¾ All safety devices installed on lifting equipment are operational

¾ All lifting devices and equipment have been visually examined before each lift by a

competent person

¾ Non-essential personnel are out of any area where they might be injured by a falling or

shifting load

1.10 Language Facilitation

Due to the various languages spoken at different sites and installations, there is a necessity

to assist all with an ease of understanding. Therefore, the development and use of

information tools are available.

1.10 Procedure Summary

A Procedure Summary has been developed in a form of a leaflet, which can be carried by

line supervisors while conducting their day-to-day work tasks. The leaflet summarizes the

contents of this Lifting Operations procedure. The procedure summary can also be used as

a guideline for line supervisors to deliver their daily toolbox talk.

(See Appendix I)

Control Tier:

<<2>>

Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING. THE CONTROLLED VERSION OF

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Procedure for Lifting Operations

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DEFINITIONS & ABBREVIATIONS

ASNT: American Society of

ACO: Approved Code of Practice for LOLER

Non-Destructive Testing

AzSPU: Azerbaijan Strategic Performance

CITB: Construction Industry Training Board

Unit

EMTA: Engineering and Machines

CCU: Cargo Carrying Unit

Training Association.

ECITB: Engineering and Construction

IMR: Inspection maintenance routine

Industry Training Board.

LOLER: Lifting Operations and Lifting

MHC: Mechanical Handling Contractor

Equipment Regulations 1998, S.I. 2307

NDT: Non-Destructive Testing

NVQ: National Vocational Qualification

OPITO: Offshore Production Industry

PCN: Personnel certification in NDT

Training Organization.

PMR: Planned Maintenance Routine

PPE: Personal Protective Equipment

PUWER: Provision and Use of Work

PU: Performance Unit

Equipment regulations 1998, S.I. 2306

RACI: A document describing positions or

people who are Responsible, Accountable,

RTITB: Road Transport Industry Training.

Consulted, and Informed for actions.

SI: Statutory Instrument

SSOW: Safe System of Work

SVQ: Scottish Vocational Qualification

SWL: Safe Working Load

LIFTING EQUIPMENT

All lifting equipment shall be marked with a unique identifier, safe working load and portable

lifting equipment shall be colour-coded.

Lifting equipment and mechanical handling aids can be divided into four main categories,

which reflect different purposes, different re-certification methods and different areas of

responsibility.

These categories can be summarized as follows:

3.1

Category 1: Portable Lifting Equipment (Lifting Appliances, Accessories)

Portable lifting appliances are generally defined as:

Any mechanical device capable of raising or lowering a load e.g. chain blocks, pull lifts, Tirfor

machines, powered hoists, beam clamps, sheave blocks.

Portable lifting accessories are defined as:

Any below the hook device which is used to connect a load to a lifting appliance e.g.

shackles, wire rope slings, chain slings, sling sets, swivels, turnbuckles, plate clamps etc. A

suitably trained competent person shall examine and document portable lifting equipment at

six month intervals.

Control Tier:

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Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

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Procedure for Lifting Operations

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Clarification on four leg sling sets: Four leg sling sets must be fitted to a quad link assembly

and not four sling legs onto one link. The safety factor of the wire must be 5:1.

This equipment will be stored and issued from a designated storage area. This is generally

a cargo container modified for the purpose of storing lifting equipment, generally referred to

as a rigging loft.

Portable lifting equipment appliances will be supplied via the rigging loft and subjected to the

relevant site specific lifting controls and procedures.

3.2

Category 2: Fixed Lifting Equipment

Fixed lifting equipment are those items of lifting equipment permanently installed at the site

such as overhead cranes, hoists trolley beams, pad eyes, davits, swing jibs, man riding

winches, tugger winches, etc.

Maintenance schedules and records of inspection and testing shall be maintained through

Maintenance Management System (MMS) via the Planned Maintenance Routine (PMR)

schedules and Written Schemes of Examination (WSE) or appropriate auditable method.

3.3

Category 3: Mobile Equipment

Equipment mounted on wheels or tracks and is self propelled or specifically designed to be

attached to or pulled by a vehicle are defined as mobile equipment.

This category of lifting equipment includes but is not limited to:

¾ Mobile cranes

¾ Mobile forklifts

¾ Mobile working platforms

¾ Mobile knuckle boom cranes / hiabs

¾ Cargo handling equipment (fitted with load indicator)

3.4

Category 4: Cargo Carrying Units

Offshore Containers: Portable units for use in the transportation of goods or equivalent,

handled in open seas, to and from fixed and / or floating installations.

Units designed to the BS/EN

12079 standard are suitable for shipment to offshore

installations.

Units that do not comply with the EN 12079 should be examined in accordance with the BP

check list and if fit for purpose a technical deviation shall be applied for before shipment.

Examples of offshore Cargo Carrying Units (CCUs) are containers, lifting baskets, waste

skips, skids, and power packs etc.

Onshore Containers: Portable units for repeated use in the transportation of goods or

equivalent, handled via crane or forklift on shore based yards or in harbour areas (not lifted

to offshore installations).

Control Tier:

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Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

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Procedure for Lifting Operations

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Units used onshore or loaded onto boats in harbour areas do not need to conform to the

BS/EN 12079 standard but must be suitably fit for purpose and subject to a two yearly load

test and six monthly visual examinations as per industry standards.

CCUs permanently held onshore include rigging lofts, paint stores, temporary office units

etc.

Freight Containers - Units generally supplied with materials via coastal ports and fitted with

ISO corner casting lifting points.

Units fitted with ISO corner casting lifting points are not suitable for lifts to and from offshore

installations with a four or five leg sling arrangement.

As per the standard BS 3951-2 unit types A, B, C are not designed to be lifted by sling sets,

see BS 3951 - 2 section 6.3.1.

Onshore - Units weighing less than five metric tons (gross) maybe lifted with a four or five

leg sling arrangement, if fit for purpose and the original manufactures data plate is intact.

Shore based units over five metric tons (gross) should be lifted with a suitable spreader

beam to ensure only vertical loadings are applied on the main structure or a lower twist lock

spreader beam arrangement my be used, if fit for purpose and the original manufactures

data plate is intact.

Offshore - Under controlled and planned conditions, an approved lifting frame may be used

with a technical deviation.

Onshore - Single Point Lifts

CCUs or skids with single point lifts are not acceptable offshore in open seas form supply

boat to platform. CCUs or skids that are properly certified with correct centre of gravity for

an even lift may be lifted onshore or onto boats in harbour areas.

All CCUs must be regularly inspected, tested and a valid certificate to be in place prior to

use.

3.5

Category 5: Transit Slings

Lifting equipment accessories such as slings and shackles referred to as „transit slings‟ are

generally used on offshore facilities for general cargo handling and transportation duties.

Transit slings are used for cargo handling, boat transfer, and transportation duties and must

not be used for general lifting operations.

Due to the particular duty and environmental conditions to which this category of equipment

is subjected, i.e. shock loading and corrosive atmosphere, transit slings shall be used once

and then quarantined for back load and destroyed and replaced when returned onshore.

Transit slings shall not be reused for a return trip. Demonstrable management and

adherence to the one time use policy is to be asset specific.

Control Tier:

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Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

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Procedure for Lifting Operations

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Transit slings shall only be used for lifting loads during delivery to an offshore facility or back

loaded to shore. Unbundled drill pipe or tubulars shall be fitted with new slings / bulldogs /

tie wraps for the return journey.

EXAMINATION PHILOSOPHY

A statutory examination known as a Thorough Examination will be carried out as per specific

requirements defined in this section.

An Authorized Lifting Equipment Inspector shall perform all Thorough Examinations (as

defined in Appendix A) of lifting equipment within AzSPU.

4.1

Examination of Portable Lifting Equipment

A Thorough Examination of all portable lifting equipment shall be conducted and

documented every six months. An Authorized Lifting Equipment Inspector must approve

inspection, testing, and maintenance procedures.

All portable lifting equipment must have original certificate (birth certificate). Where the

original or an approved copy is not available or out of date, re-certification will be necessary.

A competent person must inspect portable lifting equipment prior to issue and use.

The rigging loft keeper or responsible person shall implement the six monthly thorough

examination and colour coding of equipment, control of equipment, control quarantine area

and pre use examinations of all equipment signed out from his control.

4.2

Examination of Fixed Lifting Equipment

All fixed lifting equipment (excluding offshore pedestal cranes) is subject to a six monthly

thorough examination and colour coding performed by authorized lifting equipment

inspector.

All fixed lifting equipment must be registered in Computerized Maintenance Management

System (CMMS) or equivalent complete with inspection and maintenance intervals (including

six month thorough examination).

It is responsibility of an Authorized Lifting Equipment Inspector to develop inspection /

maintenance / certification program based on regulations, established best practices and

history information (excluding offshore pedestal cranes).

A BP approved inspection and maintenance program for offshore pedestal cranes should be

developed and performed by company responsible for crane management through CMMS or

equivalent.

4.3

Examination of Transit Slings

A competent person must examine all transit slings prior to use.

Transit Slings shall not be used offshore for any other purpose than a single transit or

delivery to or from a facility.

Control Tier:

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Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

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Procedure for Lifting Operations

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Due to the particular duty and environmental conditions to which this category of equipment

is subjected, i.e. shock loading and corrosive atmosphere, it shall be destroyed immediately

following its return onshore.

4.4

Examination of CCUs

All CCUs with pad-eyes must be regularly inspected, tested, and recertified.

Offshore - CCUs must be manufactured to EN 12079, 2006 standard as a minimum and

inspected every six months and load tested every two years.

It is important to note that the lifting assembly fitted to CCUs are deemed to be accessories

for lifting and shall therefore be subjected to a six monthly thorough examination.

Units that do not comply with the EN 12079 should be examined in accordance with the BP

check list and if fit for purpose a technical deviation shall be obtained before shipment.

Onshore - CCUs permanently held on site, which are lifted on a regular basis or otherwise

in service, will be subject to a two yearly load test and six monthly visual examinations as

per industry standards.

CCUs permanently held onshore include rigging lofts, paint stores, temporary office units

etc.

Freight Containers - Units fitted with ISO corner casting lifting points shall comply with BS

3951.

Records of examinations of these units shall be kept with the Site Controller and a register

detailing the location and the next examination due dates maintained.

All CCUs must be appropriately checked prior to use.

4.5

Examination of Mobile Lifting Equipment

All mobile lifting equipment must be supplied, maintained, inspected, certified as per

manufacturer recommendations and relevant standards

(BS

7121, ASME B30.5 or

equivalent, see references in appendix C). Ensure that certification can be located for all

ropes, hook blocks, wedge sockets, crane accessories and calibration or verification

certificates for the load indicator.

Temporary or new cranes, forklifts, cherry pickers, hiabs and load cargo handling equipment

to sites must be checked and fully inspected prior to use by a registered or approved

competent person, additionally all certification should be reviewed to ensure items meet

required standards (Standard check list Appendix E).

Daily checks should be made on mobile / crawler cranes, forklifts and cherry pickers by

operator and recorded on a check sheet; these check sheets should be issued to the

maintenance department to form part of the Maintenance Management System and Planned

Maintenance Routine schedules and Written Schemes of Examination or appropriate

auditable method. (Standard check list Appendix E)

Control Tier:

<<2>>

Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

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Procedure for Lifting Operations

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REPORTS / RECORDS

5.1

Strategy

Each site must have a complete register of all lifting equipment.

Hard copies of all the lifting equipments original certification, all Thorough Examination

certificates shall be kept on site with the Site Lifting Coordinator or Superintendent.

A register of lifting and rigging loft equipment including the information below should be

maintained.

¾ Unique Identification Number

¾ Safe Working Load or Working Load Limit

¾ Description sufficient to identify the item

¾ Location

¾ Original test certificate details

¾ Date of last Thorough Examination and certificate number

¾ Name of inspector carrying out examination

¾ Name of company carrying out examination

¾ Date of additional thorough Examinations and certificate numbers

¾ Date of next Thorough Examination

¾ Any remedial work or areas not inspected (internal parts)

¾ Quarantined / defect report number if applicable

The lifting equipment register must accurately describe all lifting equipment on site.

Third party Thorough Examination reports shall be held on the asset, by the relevant

supervisor, until such times as the equipment is returned to the supplier.

The register shall be regularly audited. It shall be the responsibility of the competent person,

to check the relevant lifting equipment register to confirm the current status of the equipment

prior to use.

5.2

Storage and Availability of Records

The Site Manager / Site Controller / Offshore Installation Manager shall ensure that the

records are properly maintained and are in order.

CONTROL PROCESSES

6.1

Rigging Loft

A rigging loft concept shall be used for pre use inspection, management, and control of

portable lifting equipment appropriate to the work site.

The rigging loft will consist of a secure controlled storage area providing the following:

¾ Storage of new equipment

¾ Quarantine of defective equipment

¾ Inspection area / Document control

Control Tier:

<<2>>

Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

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Procedure for Lifting Operations

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Any items are released form the rigging loft must undergo a pre use inspection by a suitably

trained competent person.

A competently trained responsible person will become the Rigging Loft Controller and will

hold the key for the rigging loft for each shift.

Lifting equipment issue will be recorded by the rigging loft controller in the equipment issue

section of the „Register and Control Document‟ spreadsheet, detailing the date issued, pre

use inspection has been carried out, equipment plant number and description, location or job

site, signature of person, name and company of personnel using the item, date returned and

return inspection comments.

All items of equipment including slings, shackles, and eyebolts will be registered.

All returned items shall be subject to a receiving inspection by the rigging loft controller prior

to release into the rigging loft stock.

Items awaiting inspection will be held in the designated inspection area of the rigging loft.

The rigging loft keeper is also responsible for the control and management of the quarantine

area.

For BP operations sites this process is detailed in document OPSB-OPS-PRC-063.

Contractor sites must operate under an approved controlled operational procedure for

rigging lofts.

6.2

Colour Coding

All portable lifting equipment shall be colour coded to give visual indication of its certification

status prior to use. Some fixed lifting equipment may be colour coded.

The colour code system denotes a thorough examination within the past six months and that

a valid examination report exists. Conduct a visual examination prior to use, as colour

coding does not guarantee that equipment is in serviceable condition.

Incorrectly coloured portable lifting equipment shall not be used under any

circumstances.

The valid colour codes boards shall be visibly evident at all sites.

Colour coding, listed in section 6.3, is an established industry practice. Any other coding

convention must be discontinued.

All sites shall adopt a strict colour code system for lifting and rigging equipment. An

approved site specific procedure must be in place.

Each colour code shall be valid for a period of six months.

A suitably trained and competent person i.e. third party testing company should carry out

colour coding.

Control Tier:

<<2>>

Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

Print Date: 2/1/2011

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Procedure for Lifting Operations

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6.3

Control of Portable Lifting Equipment

On BP controlled sites / installations the following colour code cycle will be used on portable

lifting equipment of categories 1 and 2 to indicate that they have been examined and fit for

use for a six-month period:

Green

(October 2008 to April 2009)

Blue

(April 2009 to October 2009)

Yellow

(October 2009 to April 2010)

Then back to Green

NOTE: Clearly identified colour codes for the six month period shall be posted in Permit

offices and security entrances to the site or facility.

NOTE: Colour Coding shall be clearly demonstrated against black backg2round

Portable and fixed lifting equipment and accessories that have been rejected on post use

examinations must be stored in the quarantined area of the rigging loft and will have the

colour coding painted over with white paint and tagged „Do Not Use‟ until such time that

the item is returned to the supplier for repair or replacement.

The Rigging loft concept shall be used for management and control of portable lifting

equipment appropriate to the work site.

The rigging loft will consist of a secure controlled storage area providing the following:

¾ Storage of new equipment

¾ Quarantine of defective equipment

¾ Inspection area / document control

6.4

Control of Fixed Lifting Equipment

All Fixed Lifting Equipment shall have a unique visible identification number or reference

number entered into CMMS or equivalent.

All fixed lifting equipment approved for personnel transfer (manriding) must be properly

identified.

6.5

Control of Transit Slings

All transit slings will be colour coded as shown below. This will ensure that all lifting

equipment is easily identified and kept separate from the transit slings. The control and

recertification of unused transit slings shall be the responsibility of the Site Manager, Site

Controller, or Offshore Installation Manager.

Brown

(April to October)

Purple

(October to April)

Control Tier:

<<2>>

Revision Date: 27 April 2010

Document Number: << AZSPU-HSSE-DOC-00056-2>>

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Military reference books and manuals (2009-2023, Volume 4) - page 40