PR-1960 - Control of Portable Temporary Equipment
Short Description
PETROLEUM DEVELOPMENT-OMAN ELECTRICAL...
Description
Petroleum Development Oman L.L.C. Document Title: Control of Temporary Portable Equipment
Document ID
Document Type
Security
Discipline
Owner
Issue Date
Revision
PR-1960
Procedure
Unrestricted
Engineering and Operations
UOM - Functional Maintenance & Integrity Manager
November 2010
1.1
This document is the property of Petroleum Development Development Oman, LLC. Neither the whole nor any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior written consent of the owner.
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Document Authorisation
Authorised For Issue November 2010
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Revision: 1.1 Effective: Mar-11
Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all revisions prior to these are held on file by the issuing department.
Revision No.
Date
Author
Scope / Remarks
1.1
Mar-11
Robin Norman UOP6
See Interim Amendment March 2011
1.0
Nov-10
Robin Norman UOP6
New Document
Draft
Oct-10
Robin Norman UOP6
New Document
iii Related Business Processes Code
Business Process (EPBM 4.0)
EP.72
Maintain and Assure Facilities Integrity
iv Related Corporate Management Frame Work (CMF) Documents The related CMF Documents can be retrieved from the Corporate Business Control Documentation Register CMF . Refer to Appendix 3
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TABLE OF CONTENTS 1
Introduction ............................................................................................................................ 6 1.1
Background ...................................................................................................................... 6
1.2
Purpose ............................................................................................................................ 6
1.3
Objective .......................................................................................................................... 6
1.4
Distribution/Target Audience ............................................................................................ 6
1.5
Changes to the Document ................................................................................................ 6
1.6
Step-out Approval ............................................................................................................. 6
2
Roles and Responsibilities ..................................................................................................... 7
3
Process Control of Temporary Equipment ............................................................................. 8 3.1
Pre-Requisites for Installation / Use of TPE ..................................................................... 8
3.2
Scope ............................................................................................................................... 9
Figure 1 – FCP Vs TPE Decision Tree ...................................................................................... 9 3.3
Temporary Portable Equipment Registration Process ................................................... 10
Appendix 1 – Temporary Portable Equipment Site Form ............................................................ 12 Appendix 2 – Temporary Portable Equipment Register .............................................................. 14 Appendix 3 – Guidelines for Use of Portable Diesel Engines ..................................................... 15 Appendix 4 – Portable Diesel Driven Plant Checklists ................................................................ 18 Appendix 5 – Abbreviations and Reference Material .................................................................. 20 Appendix 6 - User Feedback Page ............................................................................................. 21 Interim Am endment March 2011 (Revision 1.1) .......................................................................... 22
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1
Introduction
1.1
Background
Revision: 1.1 Effective: Mar-11
In PDO the introduction and use of Temporary Portable Equipment (TPE) can present significant risk to a facility, in particular where it relates to hydrocarbons and / or a source of ignition; or where it could have an effect on safety critical systems.
1.2
Purpose The purpose of this procedure is to document a consistent method to manage TPE in PDO
1.3
Objective The objective of the controlling document is to ensure TPE in PDO is controlled, recorded and risk assessed prior to and during operation.
1.4
Distribution/Target Audience This procedure shall be referenced by all Operational Assets in PDO, and all parties with the responsibilities for the suitability for use, supply or transfer of TPE to an operational facility.
1.5
Changes to the Document Responsibility for the upkeep of the Document shall be with the Maintenance & Integrity Manager UOM, the Owner. Changes to this document shall only be authorised and approved by the Owner. Users of the Document who identify inaccuracy or ambiguity can notify the Custodian or his/her delegate and request changes be initiated. The Requests shall be forwarded to the Custodian using the “User Feedback Page” provided in this Document. The Document Owner and the Document Custodian should ensure review and reverification of this procedure every 3 years.
1.6
Step-out Approval This procedure is mandatory and shall be complied with at all times. Should compliance with the procedure be considered inappropriate or the intended activity cannot be effectively completed or safely performed, then step out approval must be obtained from the Asset Manager - using the PR-1001e – Operations Procedure Temporary Variance, prior to any changes or activities associated with the procedure being carried out.
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Roles and Responsibilities Originator EMC / ODC / Operations Engineering
Specify the type of TPE required
Source the supplier
DTL
Production Coordinator
Production Supervisor
Maintenance Coordinator
Station Operator / Responsible Person
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Ensure compliance to PDO Standards. Reject if noncompliant Ensure a competent inspector is assigned to check compliance Ensure all documentation is available and accompanies the TPE Conduct all scheduled / recommended maintenance / services specified by supplier / vendor Carry out periodic review of TPE register Review the TPE Site Form and authorise the use of the TPE Enter the TPE in the ‘Temporary Portable Equipment Register’ Nominate the Responsible Person to monitor the TPE and specify inspections to ensure com pliance Check inspection release documentation and organise the initial inspection of the PTE to ensure that it meets PDO compliance standards. Reject if non-compliant Review the maintenance / service requirements with users / supplier / vendor and ensure compliance is planned Initiate mechanical / electrical ‘spot’ checks if PTE is to be used for longer than 28 days Carryout scheduled compliance inspections of the TPE as agreed with Production Supervisor Report back findings on the Section 11 of TPE Site Form and notify Production Supervisor of any non-com pliance Notify Production Supervisor when the PTE is no longer on site or no longer in use
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3
Process Control of Temporary Equipment
3.1
Pre-Requisites for Installation / Use of TPE
Revision: 1.1 Effective: Mar-11
The following requirements shall be required prior to installation / use of TPE on site. Prior to deployment to site the TPE requires have been inspected, either as part of an ongoing inspection program or as part of pre-deployment, by an ‘approved inspection body’. The inspection report and evidence of rectification of any faults found will be made available to the contract holder or responsible supervisor. When deploying the TPE to site the following documentation as a minimum shall be required;
A list of certificates detailing testing authorities approval for the TPE including expiry dates of test certificates;
Good quality drawings for reference during installation and connection;
Operating and maintenance manuals (O&M);
If applicable i.e. air compressors, generators, evidence of past operating history and inspection / calibration records; Lifting plans with shackle and lifting strop loading limits; Equipment that does not meet the ‘hazardous zoning’ requirements for operation shall be ‘Risk Assessed’ and operated under a Permit to Work. When not in operation the TPE all energy sources shall be isolated and disconnected.
The remainder of this p age has been left blank intentio nally
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Scope When determining whether the controls detailed in this procedure are applicable or Field Change Proposal (FCP) should be considered necessary the Decision Tree in Figure 1 shall be applied. EQUIPMENT REQUIRED
NO
YES
IS THE EQUIPMENT
TPE PLANNED >12 MONTHS?
COVERED IN THE
TO BE RETAINED FOR
NO
IS THE PLANT DESIGNED TO INTERFACE WITH THE TPE?
YES
ARE THERE ANY NEW PERMANENT OR TEMPORARY TIE-IN ARRANGEMENTS / FLUIDS REQUIRED NOT PREVIOUSLY USED OR DESIGNED ?
YES
NO
NO
WILL THE EQUIPMENT REMAIN
Notes: 1. Where the use of TPE requires an installation modification, the FCP Process shall be used 2.Where items of TPE are required in order to implement an FCP process change the TPE process shall be applied for those items 3. At working day will typically be 12 hours from morning till evening
ONSITE AT THE END
OF THE WORKING DAY?
YES
EQUIPMENT
DOES NOT REQUIRE
TO BE REGISTERED AS
PROPOSED EQUIPMENT IS CONSIDERED TPE AND SHALL BE
TPE BUT
MUST CARRY MAINTENANCE AND INSPECTION CERTIFICATION
CONTROLLED AND RECORDED AS SUCH
IMPLEMENT THE FCP PROCESS REFER TO PR-1001 A FIELD CHANGE PROPOSAL
Figure 1 – FCP Vs TPE Decision Tree
Page 9
1.
Equipment that is to be installed and maintained for a period greater than 12 months will not usually be considered as Tem porary.
2.
If the plant has been designed to accept the additional equipment in such a manner that the equipment will become part of the plant then it will not be considered Temporary.
3.
If interfacing the equipment with the existing plant requires additions or modification to the plant, then it will not be considered temporary.
4.
Equipment that is not to be kept onsite at the end of the working day shall not be considered as TPE (no necessity to register) but it shall still be required to carry the maintenance and inspection certification where appropriate.
PR-1960 - Control of Temporary Portable Equipment
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Temporary Portable Equipment Registration Process The following process briefly illustrated below shall be used to register TPE at a facility. TPE may be required to be installed on-site for any of the following reasons;
Temporary back-up or standby for fixed installation e.g. generators, air compressors etc; Provide support for undertaking maintenance or repair e.g. floodlights mounted on power generator, forced draught fans for ventilation or extraction; pumps etc; Provide support for temporary installations e.g. temporary accommodation etc;
TPE Registration Process EMC / ODC / Operations Engineering
Production Coordinator
Production Supervisor
Maintenance Coordinator
Station Operator (Responsible Person)
Raise ‘TPE’ Site Form and complete sections 1 thru 10 Ensure inspection complete
Clarify or respecifiy
Review the TPE Site Form
Are all details correct and understood?
Complete the TPE equipment Register for the appropriate Station / location Complete ‘TPE Compliance Inspection’ and schedule initial and periodic inspections (if required)
Carry out periodic compliance checks of all TPE in area of control
1.
The ‘Temporary Portable Equipment Site Form' shall be raised by anyone PDO or Contract staff who have a requirement to bring TPE on site i.e. Project Engineer, Permit Applicant etc. The originators shall be required to complete Sections 1 thru 10 of the form and submit it to the Delivery Team Leader or Production Coordinator for authorisation.
2.
The Production Coordinator shall review the Temporary Portable Equipment Site Form’ and ensure that it has been completed correctly and that all information has been included. If the Production Coordinator is unsure of any points on the Form clarification should be obtained from the originator of the Form (or from MSE 4 Team). The Production Coordinator shall sign to give authorisation for the TPE to be moved to and used at the intended station / location.
3.
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The Production Supervisor shall ensure that the TPE is entered in the ‘Temporary Portable Equipment Register’ (see Appendix) for the appropriate PR-1960 - Control of Temporary Portable Equipment
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station / location. The Production Supervisor shall nominate an operator to be the Responsible Person’. 4.
The Maintenance Coordinator shall organise the initial inspection of the TPE to ensure that it complies with PDO specifications. Subsequent periodic checks recommended by the supplier / vendor shall be planned either by the supplier / vendor / user or operations maintenance team.
5
The Station Operator nominated Responsible Person shall ensure the TPE is maintained in a safe condition and used for the purpose intended. Checks of TPE again the register should be conducted at periods not exceeding 2 weeks. The responsible person shall notify the Production Supervisor of any TPE on site that is no longer being used to ensure that the appropriate notification is given to remove it from site.
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PR-1960 - Control of Temporary Portable Equipment
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Appendix 1 – Temporary Portable Equipment Site Form Follow the LINK to the Temporary Portable Equipment Site Form. Copy and print as required.
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PR-1960 - Control of Temporary Portable Equipment
Revision: 1.1 Effective: Mar-11
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Appendix 2 – Temporary Portable Equipment Register The TPE Register is typical and can be reproduced for any facility.
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Appendix 3 – Guidelines for Use of Portable Diesel Engines 1.
General specifications which shall apply are:
2.
The person requesting or expediting the diesel engine for use on site will be the focal point for all communication with the supplier / vendor of the TPE; The person requesting or expediting the diesel engine will ensure that the equipment is suitable for the planned use; The supplier / vendor of the diesel engine will provide a safe and reliable unit which complies with the requirements of this procedure; The documentation detailed in Section 3.1 of this procedure shall be provided with the diesel engine and accompany the unit at all times; The supplier / vendor of the diesel engine shall undertake pre-delivery checks are to cover all requirements of Section 3.1; The diesel engine shall be checked by person requesting or expediting, or his / her delegate to ensure conformity to requirements prior to the diesel engine being installed on-site; An inspection of the diesel engine must be carried out on the relevant discipline CFDH or his delegate and by the responsible electrical person prior to connecting to the facility / station shutdown system (if applicable); PTE associated with PTW shall be inspected by the Permit Applicant and the Responsible Supervisor prior to use and thereafter at intervals not exceeding one working week (5 days). The inspection checklist shall be kept with the diesel engine; Suitable guard rails and shields shall be fitted, where required, to protect operators from moving parts e.g., drive shaft, cooling fans, etc; Consideration should be given to the provision of adequate ventilation;
Diesel Engines for Use in Non-hazardous Areas The minimum requirements are as follows:
The exhaust system shall be leak free and this, along with any associated acoustic insulation, shall be free of any combustible materials; Drip trays shall be provided to contain fuel oil or lubricating oil spillage. For containerised units, this should take the form of a fixed metal tray situated under the machine, complete with drainage facility. For open units, a floor mounted metal tray is acceptable;
All fuel lines shall be fire resistant;
An easily accessible fuel tank isolation valve shall be fitted;
All fan belts shall be fire-resistant anti-static type (FRAS);
The cooling fan shall be a non-metallic type, adequately guarded;
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General appearance - the units are to be well maintained, clean and with no oil/fuel deposits within the container;
The battery, if fitted, must be in good condition - fully charged and adequately secured with permanent clamps; All electrical connections shall be sound and tight;
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The electrical insulation integrity shall comply with the requirements of current IEE Regulations; All metal work is to be effectively electrically bonded together. Purpose bonds (6mm-2 minimum) stranded PVC covered cable are only required across insulated sections e.g., anti-vibration mounts. Elsewhere, fortuitous bonding via metal to metal contact is acceptable; Two earthing terminals (size M12) shall be provided at diagonally opposite ends of the base frame. These is to be clearly identified and suitably mounted on the main frame of the units large enough to take both the welding earth lead (if appropriate) and the installation earth bonding cable; If the unit is a welding set, the welding cables supplied are to conform to BS 638, Pt.4; A certified spark arrester shall be provided for the exhaust system. Preference shall be given to the fitting of a `cyclonic' type as opposed to the `filter' type which requires considerably more maintenance; An air inlet shutdown valve (Rig Saver), to prevent over speeding of the unit on gas ingestion, shall be fitted and its operation should be independent of the engine. This device is to be checked for operation at the pre-delivery checks and the cut-off speed recorded in the engine log-book; An emergency stop shall be fitted, which must be easily accessible from outside the unit and suitably protected to prevent inadvertent operation. The operation of the emergency stop shall be verified at the pre-delivery checks and during hook-up on site;
NOTE: The battery ammeter charge/discharge State should be checked with the unit Stationary to ensure no leakage current Exists.
3.
Diesel Engines for Use in Zone 2 Hazardous Areas
All temporary diesel engines for use in a Zone 2 area shall comply with the requirements of 2 above, and the following: All plant shall be Zone 2 certified; O
The maximum surface temperature is to be no greater than 250 C (or where temperature class is specified, Class T3); Fitted with an inlet flame arrester (flame trap); The unit shall be attended at all times or fitted with a device which will automatically stop the machine on a change of site conditions; An inlet shut-off valve which should automatically operate on; -
High exhaust gas temperature.
-
Engine overspeed.
-
High coolant temperature.
-
Low lubricating oil pressure.
Fitted with an exhaust flame arrester (flame trap); The starting system shall be non-electric, i.e. hydraulic, pneumatic or mechanical.
IMPORTANT NOTE : Spring coil inertia starters must be certified for hazardous areas.
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Any ancillary electrical equipment e.g., gauges, to be appropriately certified for use in hazardous areas. PR-1960 - Control of Temporary Portable Equipment
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Cases Where Automatic Shutdown Should Not be Used Where the diesel engine under consideration is that of a portable crane, fork lift truck, or a unit involved in critical Well Servicing activities, then no automatic shutdown due to a change of site status shall apply, thus allowing manual shutdown by the unit operator, but the units must be continuously manned throughout these operations. High exhaust temperature, low lubricating oil pressure and high coolant temperature should alarm only, allowing manual shutdown by the unit operator. This is to ensure that there is no direct unwanted interference during a critical operation. The overspeed shutdown, however, shall be automatic. For critical Well Servicing operations, and with the prior agreement of the Production Coordinator, when a change of status occurs shutdown shall be instructed by the person in charge of the worksite, who must be in contact with the Control Room at all times. NOTE: Typical critical operations where diesel plant is used in Well Operations include, but are not limited to, wireline winches, coiled tubing units, nitrogen converters and pumping units performing operations like acid jobs, sand fracs, sand clean-outs and circulating through coiled tubing.
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Appendix 4 – Portable Diesel Driven Plant Checklists Follow the LINK to the Non-Hazardous and Zone 2 Portable Diesel Engine Driven Plant Checklists. Copy and print as required.
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PR-1960 - Control of Temporary Portable Equipment
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Appendix 5 – Abbreviations and Reference Material DTL
Delivery Team Leader
FCP
Field Change Proposal
TPE
Temporary Portable Equipment
CP-115 – operate Surface Product Flow Assets - CoP PR-1001e – Operations Procedure Temporary Variance
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Appendix 6 - User Feedback Page PR-1960 – Control of Temporary Portable Equipment User Feedback Form Any user who identifies an inaccuracy, error or ambiguity is requested to notify the custodian so that appropriate action can be taken. The user is requested to return this page fully completed, indicating precisely the amendment(s) recommended. Name: Ref ID
Page Ref:
Date:
Brief Description of Change Required and Reasons
UOM2 Custodian of Document
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Date:
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Interim Amendment March 2011 (Revision 1.1) Page 9 Figure 1 – Added decision box “Will the equipment remain onsite at the end of the shift?” Page 9 – Added Item 4 “Equipment that is not to be kept onsite at the end of the working shift shall not be considered as TPE (no necessity to register) but it shall still be required to carry the maintenance and inspection certification where appropriate” Purpose for changes / additions – Clarification of when TPE shall be registered.
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