Military reference books and manuals (2009-2023, Volume 5)

AZSPU-HSSE-DOC-00054-2

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9 APPENDIX B - HIGH POTENTIAL INCIDENT NOTIFICATION PRO-FORMA

BP HIGH POTENTIAL INCIDENT ANNOUNCEMENT URGENT

BP CONFIDENTIAL: contains BP confidential business information - do not forward

Business Unit:

Contact:

Country:

Location of Incident:

Date of Incident:

Time of Incident:

Brief Account of Incident: (Report as fact only what you are clear is fact. Specify the status of anything

else which you report, e.g., a belief or an estimate):

Potential Outcome:

Actions Taken:

BP Person in Charge of Response/Investigation:

Control Tier:

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APPENDIX C - MODEL TERMS OF REFERENCE TEMPLATE

INCIDENT INVESTIGATION TEAM

The following Investigation Team members and leadership have been agreed by the

President; Performance Unit Leader and Manager, HSE.

Name

Position

6...etc

The Team Leader appointed by (Position

) is (Name

The Team Leader will:

 provide methodology guidance for the Investigation Team

 ensure compliance with the Terms of Reference

 ensure compliance with BP references for incident investigation

 ensure consensus among Team Members regarding report contents

 ensure persons accountable for actions agree with action(s) and date(s)

 report directly to (position), who is the Owner for this Investigation Team

 provide daily progress updates to the Owner for the duration of the investigation.

OBJECTIVES

1. Identify and review immediate causes of the incident.

2. Identify and analyze relative people, positions, parts and papers.

3. Identify and review system causes of the accident.

4. Map evidence; establish chronological list of events to identify critical factors.

5. Utilize “Comprehensive List of Causes; A Tool for System Cause Analysis” to analyze the

incident.

6. Develop recommendations, corrective actions and lessons learned for the Owner‟s review

and approval.

Focus is on prevention of recurrence of a like-in-kind incident and communications of

positive optics.

_______________________________(Owner)

Control Tier:

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12 APPENDIX E - DEFINITIONS

Definitions in this procedure, where appropriate, are identical to BP Group HSE Reporting

Definitions, which can be found at <http://fcanda.bpweb.bp.com/default.asp?p=1642 >.

Prompt reporting of incidents is essential. Before we can report we must be able to

accurately classify our incidents. The Injury and Illness Reporting Decision Tree in Appendix

F is an aid in this effort. In order to be accurate we must consider:

Work Related Incident

An incident must be considered work-related if an event or exposure in the work environment

caused or contributed to that incident occurring. For injury or illness, an incident must be

considered work-related if the event or exposure caused or contributed to the resulting

condition or significantly aggravated a pre-existing injury or illness. Work-relatedness is

presumed for injuries and illnesses resulting from events or exposures occurring in the work

environment unless one of the following exceptions applies in its entirety:

 Occurs when the employee was present in the work environment as a member of the

general public

 Results solely from voluntary participation in a wellness program or in a medical,

fitness, or recreational activity

 Involves signs or symptoms that surface at work but result solely from a non-work

related event or exposure

 Is solely the result of an employee eating, drinking, or preparing food or drink for

personal consumption

 Is solely the result of an employee doing personal tasks at the establishment outside

of the employee‟s assigned working hours

 Is solely the result of personal grooming, self medication for a non-work-related

condition, or is intentionally self-inflicted

 Is caused by a vehicle accident and it occurs on a company owned parking lot or

road while the employee is commuting

 Is the common cold or flu; and/or

 Is a mental illness (unless it is post-traumatic stress syndrome where it can be tied to

a specific workplace incident, or are Incidents where the employee voluntarily

provides an opinion from a physician or other licensed health care professional

stating the employee‟s mental illness is work-related).

Further information is available in form of the

“Occupational Injury and Illness

Information - Accurate Determinations & Consistent Reporting” booklet. This guide is

available by request to the Business Unit Resource Safety Team.

BP Work Environment

The establishment and other locations (including marine vessels and vehicles) where one or

more BP Employees and or BP Contractors are working or are present as a condition of their

employment/contract. The work environment includes not only physical locations, but also

the equipment or materials used by the employee or contractor during the course of his or

her work.

Specifically included are:

 Vehicles driven by a BP Contractor where the vehicle is dedicated to BP‟s business

use. Dedicated means that the vehicle has been designated, normally under

contractual terms, to be exclusively available for the provision of goods and or

Control Tier:

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services to BP during a period of time covering multiple journeys (or deliveries). This

also means that during this period of time, the vehicle is unavailable for business use

by other parties.

(This is equivalent to Vehicle Category 2 of the BP Driving Safety

Standard).

 Any hire / rental vehicle being used on company business.

 A private vehicle on company business for which a member of the workforce is

reimbursed.

 Any location where a BP Employee is engaged in Business Travel or where a BP

Contractor is engaged in Business Travel on behalf of BP

Specifically excluded are:

 Locations where a Contractor is working and where that location is controlled by their

employer, their employing contractor, or themselves.

 Vehicles or marine vessels that have been spot chartered. This means that vehicles

or vessels are not dedicated (as defined in the inclusion above), and that they are

regularly used by other third parties. The phrase „spot charter vehicle‟ is synonymous

with „common carrier‟ or „voyage charter‟.

(This is equivalent to Vehicle Category 3 of

the BP Driving Safety Standard.)

Employment status

We count both Company and Contractor incidents that are work related. Accounting for

Contractor incidents is a function of premises, as well as the nature of work and whether it is

at a 3rd Party fabrication site. A definition for Contractor follows in the next section.

BP Workforce

The BP Workforce comprises all BP Employees, all BP Contractors and all BP Directors.

Employee

An individual who has a current contract of employment with BP plc or one of its subsidiary

companies.

Contractor

An individual under a contractual relationship to supply BP plc or one of its subsidiary

companies with goods and/or services.

A contractual relationship covers:

 All individuals contracted directly or sub-contracted

 All employees of companies contracted directly or sub-contracted

 All situations where a contract has not been raised but BP‟s procurement policy

would normally expect there to be a contract in place. This applies to all levels

including sub-contracted relationships.

Note: For the purposes of HSE reporting any sub-contractor is to be treated as if they held a

contract directly with BP plc or one of its subsidiary companies.

Third party

Control Tier:

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Anyone who is not a BP Employee or a BP Contractor as previously defined in this

document.

Members of the BP Workforce may be classified as third parties under specific

circumstances. Three of the most common are:

 They are present in the BP Work Environment as a member of the general public (for

example, an office worker refueling their car at a BP Retail Station).

 They are present in the BP Work Environment but are still commuting to work under

OSHA definitions

Those periods on a business trip when they are not deemed to be working under OSHA

definitions - for example, during their temporary commute or when residing at their home

away from home

Incident

An unplanned event or occurrence that affects or has the potential to affect the health or

safety, or security of:

 people, or

 assets, or

 the environment.

Near Miss

An undesired event that, under slightly different circumstances, could have resulted in harm

to people, damage to assets, environmental harm or unplanned operational shutdown. A

near miss is an incident involving the unintentional transfer of energy but has no negative

consequence.

First Aid Case

An incident is classified as a First Aid if the treatment of the resultant injury or illness is limited

to one or more of the 14 specific treatments below.

These are:

1. Using a non-prescription medication at non-prescription strength

2. Administering tetanus immunizations

3. Cleaning, flushing or soaking wounds on the surface of the skin

4. Using wound coverings such as bandages, gauze pads, etc; or using butterfly

bandages

5. Using hot or cold therapy

6. Using any non-rigid means of support, such as elastic bandages, wraps, non-rigid

back belts, etc

7. Using temporary immobilization devices while transporting as accident victim

8. Drilling of a fingernail or toenail to relieve pressure, or draining fluid from a blister

9. Using eye patches

Control Tier:

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10. Removing foreign bodies from the eye using only irrigation or a cotton swab

11. Removing splinters or foreign material from areas other than the eye by irrigation,

tweezers, cotton swabs or other simple means;

12. Using finger guards

13. Using massages, or

14. Drinking fluids for relief of heat stress.

If the treatment type isn‟t on the list then the case should be considered as medical treatment

and will be counted as a recordable injury or illness.

Note: When determining whether a prescription medicine was used the normal practise is to

apply the definitions used in the country where the incident occurred. However, when

making this classification it should be remembered that the intent is to distinguish those more

severe situations that require a medical practitioner to use strong antibiotics and painkillers

from those that only require simple first aid.

Medical Treatment Case

A case arising from an Incident, in which the management and care of the patient to address

the injury or illness is above and beyond First Aid. Medical Treatment does not include the

conduct of diagnostic procedures, such as x-rays and blood tests, including the

administration of prescription medications used solely for diagnostic purposes.

Medical Treatment cases include the following:

 Any loss of consciousness

 Significant injury or illness diagnosed by a physician or other licensed health care

professional for which no treatment is given or recommended at the time of

diagnosis. Examples include punctured ear drums, fractured ribs or toes, byssinosis,

silicosis and some types of occupational cancer.

 Needlestick injuries and cuts from sharp objects that are contaminated with another

person‟s blood or other potentially infectious material.

 Occupational hearing loss.

 Medical removal under a government standard.

Recordable Injuries and Illnesses

Includes all work-related BP workforce injury and illness incidents that result in a:

 Fatality

 Day Away From Work Case (DAFWC)

 Restricted Work or Job Transfer (RW/JT)

 Medical Treatment beyond First Aid (MT)

Restricted Work or Job Transfer (RW/JT)

An incident is classified as a restricted work or job transfer case when:

 The member of the BP Workforce is kept from performing one or more of the routine

functions of his or her job, or from working the full workday that he or she would

otherwise have been scheduled to work or is transferred to a different job for all or

part of his/her period of recuperation.

 A physician or other licensed health care professional recommends that the member

of the BP Workforce not perform one or more of the routine functions of his or her

job, or not work the full workday that he or she would otherwise have been scheduled

Control Tier:

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to work or is transferred to a different job for all or part of his/her period of

recuperation.

Guidance: Routine functions are these work activities the member of the BP Workforce

regularly performs at least once a week.

Days Away From Work Case (DAFWC)

A work-related injury or illness that would prevent the injured person from working on the day

following that which the injury occurred, whether or not he or she is actually scheduled to

work the following shift. If the medical professional declares that the individual is not fit to

return to work on the day following the injury, then the case is classified as a DAFWC even if

the following day is not a scheduled workday. If a person subsequently must have corrective

surgery or otherwise miss work as a result of the work related injury, and does so during a

scheduled absence then the injury is still considered a DAFWC.

High Potential (HiPo) Incident

An Incident or Unsafe/Unhealthy Condition or near miss, including a security incident, where

the most serious probable outcome is a Major Incident.

Major Incident (MIA)

An Incident, including a security incident, involving any one of the following:



1 or more fatalities associated with BP operations



10 or more injuries or health effects to BP workforce, either permanent or

requiring hospital treatment for more than 24 hours.

 Significant adverse reaction from authorities, media, NGOs or the general public

 Costs from accidental equipment and property damage, and/or loss of business

value equal to or exceeding US $ 5 Million

 Environmental Impact with A-E severity level (refer to Appendix G)

 Loss of Primary Containment with A-E severity level (refer to Appendix I-J)

Recordable Fatality

A fatality is deemed recordable unless the circumstances indicate that the event is not

relevant to the measurement of the health and safety performance of the Company.

Fatalities arising, for example, from suicide, inexplicable personal behaviour or natural

causes would normally be excluded.

Incident severity

All incidents should be reported. Incident severity is determined per the Traction Severity

Matrix or Severity Matrices in Appendices G-J.

Vehicle Accident

A work-related accident involving a motor vehicle that occurs on or off-road resulting in injury,

or loss/damage, or harm to the environment, whether this impacts BP and/or its contractor

directly, or impacts a third party This is irrespective of whether the accident was preventable

or non-preventable. It excludes all accidents where:

 The BP Workforce vehicle was legally parked

 The journey is to or from the driver‟s home and normal place of work

Control Tier:

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 Minor wear and tear is the case (e.g. stone damage to a windscreen, minor paintwork

damage)

 An Incident is the result of vandalism, or theft

 A company provided vehicle is being driven on non-work related activities (e.g.

private business, leisure).

References

1. Group Defined Operating Practice on Reporting HSSE and Operational Incidents (GDP 44-

00-01), which can be found on http://hsse.bpweb.bp.com/OMS/OMS-

Library/level3.aspx?404;http://hsse.bpweb.bp.com/OMS/OMS-Library/

2. Group Defined Operating Practice on Incident Investigation (GDP 44-00-02), which can be

found on http://hsse.bpweb.bp.com/OMS/OMS-

Library/level3.aspx?404;http://hsse.bpweb.bp.com/OMS/OMS-Library/

3. BP Group HSE Reporting Definitions, which can be found on

http://fcanda.bpweb.bp.com/default.asp?p=1638&mi=4445

Control Tier:

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13 APPENDIX F - INJURY AND ILLNESS REPORTING DECISION TREE

If in the work environment,

assumed work-related unless:

Gather

•

Member of general public,

Information

•

Signs & symptoms surface at

work but result solely from non-

work-related event or exposure,

•

Voluntary participation,

•

Eating, drinking, preparing own

food,

•

Doing personal tasks outside

Did the employee

working hours,

•

Personal grooming, self-

experience an

medication, intentional self-

injury or illness?

inflicted injury,

•

Company parking lot while

commuting,

•

Common cold or flu, or

Yes

•

Mental illness.

Other work-related exceptions:

Is the injury or

•

Home away from home &

•

Personal detour while on

illness work-

company business.

related?

General Reporting Criteria:

• Death,

Yes

• Days away from work,

• Restricted work or transfer to

another job,

• Medical treatment beyond first

Is the injury or

aid,

illness a new

• Loss of consciousness, or

case?

• A significant injury or illness

diagnosed by a physician or other

licensed health professional:

• Cancer,

Update the

• Chronic irreversible disease,

previously

• Fractured or cracked bone, or

• Punctured eardrum.

reported injury

or illness entry if

Yes

necessary.

First aid treatments:

• Non-prescription medication in

non-prescription strength,

Does the injury or

• Tetanus immunizations,

• Cleaning, soaking, flushing wounds

illness meet the

on surface of skin,

general reporting

• Use of bandaids, Steri-Strips or

butterfly bandages,

criteria or the

• Hot or cold therapy,

application to the

• Non-rigid means of support,

• Temporary immobilization devices

specific cases?

while transporting an accident

victim,

• Drilling finger or toe nail,

• Eye patch,

• Removing foreign bodies from eye

using irrigation or cotton swab,

Do not

• Removing splinters or other foreign

Report

material from places other than the

report

eye by simple means,

the injury

• Using finger guards,

or illness.

• Using massages, or

or illness.

• Drinking fluids for relief of heat

stress.

Control Tier:

Revision Date: 30 April 2008

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14 APPENDIX G. SEVERITY MATRIX - HSE IMPACT LEVELS

HEALTH AND SAFETY

ENVIRONMENTAL

SEVERITY

LEVEL

A-D

* 3 or more fatalities, acute or chronic, actual or

* Event with widespread or extensive damage to any environment

alleged.

and that remains in an "unsatisfactory" state for a period > 5 years.

*Event with widespread or extensive damage to a non-sensitive

* Identified onset of life threatening health effects in

environment and that can be remediated to a level that restores its

3 or more workers.

environmental amenity in a period of months or up to 1 year.

* Event with localized or extensive damage to a sensitive

* 30 or more injuries or health effects to BP

environment and that can be remediated to a level that restores its

workforce, either permanent or requiring hospital

environmental amenity in a period of months or up to 1 year.

treatment for more than 24 hours.

*Event with widespread or extensive damage to a non-sensitive

environment and that can only be remediated to a "satisfactory" /

agreed state in a period of 2 - 4 years.

*Event with extensive

damage to a non-sensitive environment and that remains in an

"unsatisfactory" state for a period > 5 years.

*Event with widespread or extensive damage to a sensitive

environment and that can only be remediated to a "satisfactory" /

agreed state in a period of 2 -4 years.

* 1 to 2 fatalities, acute or chronic, actual or alleged.

* Event with localized damage to a non-sensitive environment and

that can be remediated to a level that restores its environmental

* 10 or more injuries or health effects to BP

amenity in a period of @ 1 year.

workforce, either permanent or requiring hospital

* Event with extensive damage to a non-sensitive environment and

treatment for more than 24 hours.

that can be remediated to a level that restores its environmental

amenity in a period of months.

* Event with localized damage to a sensitive environment and that

can be remediated to a level that restores its environmental

amenity in a period of months.

* Event with extensive damage to a sensitive environment and that

can be remediated to a level that restores its environmental

amenity in a period of days or weeks.

* Permanent partial disabilities

* Event with localized damage to a non-sensitive environment and

that can be remediated to a level that restores its environmental

* Sever al non-permanent injuries or health impacts

amenity in a period of months.

* Event with immediate area damage to a sensitive environment

* DAFWC

and that can be remediated to a level that restores its

environmental amenity in a period of months.

* Event with extensive damage to a non-sensitive environment and

that can be remediated to a level that restores its environmental

amenity in a period of days or weeks.

* Event with localized damage to a sensitive environment and that

can be remediated to a level that restores its environmental

amenity in a period of days or weeks.

* Single or multiple recordable injury or health

* Event with immediate area damage to a non-sensitive

effects from common source/event

environment and that can be remediated to a level that restores its

environmental amenity in a period of months.

* Event with localized damage to a non-sensitive environment and

that can be remediated to a level that restores its environmental

amenity in a period of days or weeks.

* Event with immediate area damage to a sensitive environment

and that can be remediated to a level that restores its

environmental amenity in a period of days or weeks.

* First aid.

* Event with immediate area damage to a non-sensitive

environment and that can be remediated to a level that restores its

* Single or multiple over-exposures causing

environmental amenity in a period of days or weeks.

noticeable irritation but no actual health effects

Control Tier:

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15 APPENDIX H. SEVERITY MATRIX - BUSINESS IMPACT LEVELS

SEVERITY

EQUIPMENT DAMAGE, BUSINESS VALUE

LEVEL

PRIVILEGE TO OPERATE

LOST

* Public outrage or brand damage in major markets

where we have presence or aspiration.

* Global or Regional media coverage or Severe National

A-D

*>$100m Equipment/Property Damage and/or BVL

Outrage.

* Actual or threatened Loss of License to Operate.

* Likely to lead to change of local, national or

international regulations.

* Localised or limited “interest-group” outrage in major

market.

*$5m to $100m Equipment/Property Damage and/or BVL

* Public or investor outrage in non-major markets.

* Significant enforcement action against one or more

material assets in a significant market (e.g. US, Europe).

* Prolonged local media attention.

* Other enforcement action against one or more material

*$500k-$5m Equipment/Property Damage and/or BVL

assets in other market (not US or Europe) with a

foreseeable end date.

* Short term local media coverage.

* Some disruption to day to day lives (e.g. loss of single

*$50k -$500k Equipment/Property Damage and/or BVL

road access less than 24 hours).

* Fines or other penalties significant to a BU.

* No community notification.

* Isolated and short term complaints from neighbours

*<$50k Equipment/Property Damage a nd/or BVL

(e.g. complaints about specific noise episode).

* Code of Conduct violation that does not lead to higher

severity level consequence.

Control Tier:

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16 APPENDIX I. SEVERITY CLASSIFICATION - LOPC OF FLAMMABLE GASES,

LIQUIDS AND OTHERS

Loss of Primary Containment - POTENTIAL Severity

Classification

If a substance has more than one associated hazard (e.g. flammable/explosive and toxic),

use the predominant physical characteristic

Type of

Flammable Gases and

Flammable liquids, and liquid

Other hazardous

Substance

Vapours

escaping above auto-ignition

categories including

temperature

combustible or corrosive

gases / fluids / vapours or

solids

* Onshore

* Onshore,

* Offshore -

* Onshore - loss

* Onshore/offshore - loss of

confined

unconfined

loss of

of primary

primary containment

releases *

releases

primary

containment

Offshore

*Offshore

containment

releases -

manned

unmanned

facilities

Definitions

Definition of flammable gas:

Definition of flammable liquid:

A comprehensive list of

substances is available under

Gaseous material or gaseous

Any liquid having a flashpoint less

the categorization of Packing

material that is a liquid under

than or equal to 38 °C.

Group III materials as defined

pressure and has a flash point

by UN Dangerous Goods

below 22.8 °C (73 °F).

A comprehensive list of substances

definitions

is available under the

A comprehensive list of

categorization of Packing Group II

(e.g. Crude oil, corrosives,

substances is available under

materials as defined by UN

organic peroxides, pyrophoric,

the categorization of Packing

Dangerous Goods definitions

combustible liquid >38C flash

Group I materials as defined by

point)

UN Dangerous Goods

definitions

Level A -D

> 5000 kgs

> 50000 kgs

> 10000 kgs (or

> 100000 kgs (or

>1000 bbls (fluids)

>100 bbls)

>1000 bbls)

>100,000 kgs

(gas/vapors /solids)

Level E

500 < 5000 kgs

5000 < 50000

1000 < 10000

10000 < 100000

100 <1000 bbls (fluids)

kgs

10,000 <100,000 kgs

(gas/vapors/solids)

Level F

50 < 500 kgs

500 < 5000 kgs

100 < 1000 kgs

1000 < 10000

1 <100 bbls (fluids)

kgs

2000 <10,000 kgs

(gas/vapors/solids)

Level G

5 < 50 kgs

50 < 500 kgs

10 < 100 kgs

100 < 1000 kgs

0.1 < 1 bbl (fluids)

200 < 2000 kgs

(gas/vapors /solids)

Level H

< 5 kgs

< 50 kgs

<10 kgs

< 100 kgs

< 0.1 bbl (fluids)

< 200 kgs (gas/vapors /solids)

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Incident Investigation and Reporting

17 APPENDIX J. SEVERITY CLASSIFICATION - LOPC OF TOXIC SUBSTANCES

Toxic Substances⁴

Lower Toxicity

Medium Toxicity

Higher Toxicity

Acutely Toxic

Substance

Class

(Class D)

(Class C)

(Class B)

(Class A)

All gas, vapor, mist or aerosol LOPC, regardless of location

Level A-D

> 4000 kgs

> 2000 kgs

> 1000 kgs

> 50 kgs

Level E

2000 < 4000 kgs

1000 < 2000 kgs

250 < 1000 kgs

15 < 50 kgs

Level F

200 < 2000 kgs

100 < 1000 kgs

25 < 250 kgs

5.0 kg < 15 kgs

Level G

50 < 200 kgs

25 < 100 kgs

5 < 25 kgs

0.5 < 5.0 kgs

Level H

< 50 kgs

< 25 kgs

< 5 kgs

< 0.5 kgs

⁴ From proposed CCPS and API guidelines based on UN Dangerous Goods definitions,

November 2007

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Incident Investigation and Reporting

19 APPENDIX L. Onshore Operations External Notification Requirements

What

When

By Whom

To Whom

Major Incidents (MIAs)

<24hrs (verbal)

AzSPU CHSSE (Az) or

In-country Regulators

C&EA (Geo) (during

<3 days (written)

office hours) or Duty

Incident Commander

(out of office hours)

<2 days

PUL

Partners (BTC or SCP)

<3 days

BTC Commercial

BTC Lenders (BTC

MIAs only)

High Potential

<24 hrs (verbal)

AzSPU CHSSE (Az) or

In-country Regulators

Incidents (HiPos)

C&EA (Geo) (during

<3 days (written)

office hours) or Duty

Incident Commander

(out of office hours)

<2 days

PUL

BTC or SCP Partners

<3 days

BTC Commercial

BTC Lenders (BTC

HiPos only)

Any other Incident (that

<5 days

Onshore PU E&S

BTC Lenders

is not an MIA or HiPo)

Manager

(Environmental

Incidents only)

Spill / material release

24 hrs verbal

CHSSE External

Regulatory notification

to the environment (i.e.

Relations (Az) or C&EA

72 hrs written

that breach secondary

Teams (Geo)

containment) that is not

an MIA or HiPo

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REVISION/REVIEW LOG

Revision Date

Authority

Custodian

Revision Details

23 February 2006

McNuilty Alan

Islamov Abbas

Initial Issue

09 July 2007

McNuilty Alan

Islamov Abbas

The major changes made in the document

cover the following areas:

 Clarity on individual Roles and

responsibilities and incident owners based

on severity of incident

 Process for notification of MIA/HiPo

incidents to Group and AzSPU Senior

Management

 Clarity on the procedure for classification

and initiation of DAFWC/HiPo/MIA

investigations

 Actions setting and prioritization - note

change from targets based on prescriptive

dates to agreed timescales between

actionee and action owner

 Approval process - owner and approver is

now the same person

 Removal of "Spheres of Influence"

 Roles and responsibilities

 MIA/HiPo notification

 Investigation Process

 Actions setting and prioritization

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Incident Investigation and Reporting

30 April

2008

McNuilty Alan

Mamedov Rufat

The major changes made in the document

cover the following areas:

 Tr@ction and MIA/HiPo Database

recording requirements

 Incident Notification Requirements clarified

in Figure 3.1

 Included Figure 4.1 “Guidelines to Assess

Potential Severity”

 Update to figure 4.2 “HiPo determination

flowchart” in light of new Group severity

matrices

 Included section on ABC Analysis

 Requirements for AzSPU outside

distribution requirements for HiPlus,

Lessons Learned one pager and similar

documents.

 New Comprehensive List of Causes (CLC)

Chart

 Appendix E renamed to “Definitions” and

definitions were updated in light of new BP

Group F&CA HSE Definitions and OMS

GDPs 44-00-01 and GDPs 44-00-02

 new severity matrices

 Export PU Internal Notification

requirements for illegal taps

 Onshore Operations External Notification

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

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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 pressure may vary according to the test medium being used, but shall never

exceed 110% of the maximum operating pressure (MOP). Initial service leak tests, using

instrument air, are often used at an early stage of hook-up/commissioning as a means of

identifying large leaks, prior to performing the standard leak tests.

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

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Procedure for Leak Testing of In-Service Equipment

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Standards.

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

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Procedure for Leak Testing of In-Service Equipment

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ASME B31.4

PIPELINE TRANSPORTATION SYSTEMS FOR

LIQUID HYDROCARBONS AND OTHER LIQUIDS

2007

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

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Procedure for Leak Testing of In-Service Equipment

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2.2

AREA AUTHORITY

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

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Procedure for Leak Testing of In-Service Equipment

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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

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,

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Procedure for Leak Testing of In-Service Equipment

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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).

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.

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 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

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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Procedure for Leak Testing of In-Service Equipment

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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

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Procedure for Leak Testing of In-Service Equipment

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



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,

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

respect to thermal expansion of liquids in a closed system.

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,

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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)

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

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Procedure for Leak Testing of In-Service Equipment

Page 15 of 23

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

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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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%).

Leak test:

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

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

leakage and leakage rates from component connections, valves etc.

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,

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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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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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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

detected in 60 seconds for flanges up to

monitoring for surface bubbles. For all large

and including 4in NB and 90 seconds for

diameter flanges (>6” NB), the joint should be taped

flanges above 4in NB.

and the leak 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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APPENDIX D - FEEDBACK & IMPROVEMENT SUGGESTIONS

Procedure Feedback & Improvement Suggestions

Project Name: _____________________________

Date: _____________________________________

Name: ____________________________________

Badge Number:

___________________________

Procedure Reference: ______________________

Procedure Title: ___________________________

Improvement Suggestions (Write below your improvement suggestions)

Signature: _____________

Forward your Improvement Suggestion to

the H&S Manager at the Central HSSE Office,

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Procedure for Leak Testing of In-Service Equipment

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Hyatt Tower 2, 6th Floor

REVISION/REVIEW LOG

Revision Date

Authority

Custodian

Revision Details

9 September 2004

Alan McNulty

Esmira Akhundova

Initial Issue

8 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.

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Procedure for Lifting Operations

Page 2 of 54

TABLE OF CONTENTS

INTRODUCTION

Document Purpose

Document Scope

Legislation & Standards

Stopping Unsafe Work

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 CCU‟s

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 (CCU‟s)

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

COMPETENCY

7.1

Competencies and Training of Personnel

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Procedure for Lifting Operations

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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. It presents the BP standards applicable to the safe use of lifting

equipment in Azerbaijan Strategic Performance Unit (AzSPU as defined in appendix C).

U.K. Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) came into force on

5th December 1998. These regulations implement 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 are used as source of reference (See

References 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 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.

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:

¾ Ensure that 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 Ensure that lifting operations are carried out in a safe manner.

Control Tier:

<<2>>

Revision Date: 18 June 2007

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

Print Date: 7/24/2010

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Procedure for Lifting Operations

Page 5 of 54

¾ Ensure that the 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 Ensure that equipment, procedures and standards of competency etc. are identified

and managed in a safe manner.

¾ That roles and responsibilities for all lifting operations and activities are clearly defined.

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.

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 (CoW) 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

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 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).

1.6

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.

1.7

SSOW Specific Cross 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

Deviations from Regulations and Procedures

Control Tier:

<<2>>

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

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Procedure for Lifting Operations

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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 Baskets

AZSPU-HSSE-DOC- 0002-2

Control of Work Standards

1.8

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

1.9

Language Facilitation

Due to the various languages spoken at sites / 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

the 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)

DEFINITIONS & ABBREVIATIONS

ACO: Approved Code of Practice for LOLER

ASNT: American Society of Non-Destructive

Testing

AzSPU: Azerbaijan Strategic Performance

CITB: Construction Industry Training Board

Unit

CCU: Cargo Carrying Unit

EMTA: Engineering and Machines Training

Association.

ECITB: Engineering and Construction

IMR: Inspection maintenance routine

Industry Training Board.

Control Tier:

<<2>>

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

Print Date: 7/24/2010

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Procedure for Lifting Operations

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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

PU: Performance Unit

PUWER: Provision and Use of Work

Equipment regulations 1998, S.I.2306

RACI: Chart detailing who is Responsible,

RTITB: Road Transport Industry Training.

Accountable, needs to be Consulted and

who requires to be informed for a list of

actions.

SI: Statutory Instrument

SSOW: Safe System of Work

SVQ: Scottish Vocational Qualification

SWL: Safe Working Load

CCU: Cargo Carrying Unit

EMTA: Engineering and Machines Training

Association.

ECITB: Engineering and Construction

PMR: Planned Maintenance Routine

Industry Training Board.

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 device which is used to connect a load to a lifting appliance e.g. Shackles, Wire rope

slings, Chain slings, Swivels, Turn buckles, Plate clamps etc ( Below the Hook ). This

category of lifting equipment shall be examined and recorded at 6-monthly intervals by a

suitable trained competent person.

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

“Rigging Loft”.

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

relevant Site specific lifting controls and procedures.

Control Tier:

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

Print Date: 7/24/2010

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Procedure for Lifting Operations

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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

Mobile Equipment is equipment that is on wheels or tracks and is self propelled or

specifically designed to be attached to or pulled by a vehicle.

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 - These are defined as portable units for use in the transportation of

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

Only 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

- These are defined as 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)

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 2 yearly load test

and 6 monthly visual examinations as per industry standards.

CCU‟s permanently held onshore include rigging lofts, paints stores, temporary office units

etc.

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

ISO corner casting lifting points.

Control Tier:

<<2>>

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

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Procedure for Lifting Operations

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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 5 Metric Ton‟s (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 5 Metric Ton‟s 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 a fully approved lifting frame may be

used with a technical deviation.

Onshore - Single Point Lifts

CCU‟s or skids with single point lifts are not acceptable offshore in open seas form supply

boat to platform, however if correctly certified with correct centre of gravity (even lift) may be

lifted onshore or onto boats in harbour areas.

All CCU‟s 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 under this category are generally referred to as “transit slings”,

which are slings, shackles etc., used for general cargo handling and transportation duties.

This category of lifting equipment must only be used for cargo handling / boat transfer and

transportation duties only and must not be used on the installation 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, IT SHALL BE DESTROYED AND

REPLACED FOLLOWING ITS RETURN ONSHORE. Demonstratable management and

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

Transit slings shall only be used for lifting loads during delivery of equipment.

EXAMINATION PHILOSOPHY

Thorough Examinations will be carried out as per specific requirements defined in this

section.

All Thorough Examinations (as defined in Appendix B) of lifting equipment within AzSPU

shall be performed by an Authorized Lifting Equipment Inspector.

Control Tier:

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Procedure for Lifting Operations

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4.1

Examination of Portable Lifting Equipment

All portable lifting equipment must be thoroughly examined and recorded every 6 months.

Inspection

/ testing, maintenance procedures must be approved by Authorized Lifting

Equipment Inspector.

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.

It is the responsibility of rigging loft keeper or responsible person to implement 6-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 6-month

thorough examination and color-coding performed by authorized lifting equipment inspector.

All fixed lifting equipment must be registered in CMMS

(Computerized Maintenance

Management System) or equivalent complete with inspection and maintenance intervals

(including 6-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

All transit slings must be checked and examined prior to use by a competent person.

Offshore use:

Transit Slings shall not be used offshore for any other purpose than transit.

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 CCU’s

All CCU‟s with pad-eyes must be regularly inspected, tested and re-certified.

Offshore - CCU‟s must be manufactured to EN 12079, 2006 standard as a minimum, and

inspected every six months.

It is important to note that the lifting assembly fitted to CCU‟s are deemed to be accessories

for lifting and shall therefore be subjected to a 6 monthly thorough examination.

Control Tier:

<<2>>

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

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Procedure for Lifting Operations

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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 - CCU‟s permanently held on site, which are lifted on a regular basis or otherwise

in service, will be subject to a 2 yearly load test and 6 monthly visual examination‟s as per

industry standards.

CCU‟s permanently held onshore include rigging lofts, paints 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 CCU‟s 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).

Ensuring that certification can be located for all ropes, hook blocks, wedge sockets, crane

accessories and calibration or verification certificates for the load indicator. (SLI)

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 (MMS) and

Planned Maintenance Routine (PMR) schedules and Written Schemes of Examination

(WSE) or appropriate auditable method. (Standard check list Appendix E)

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 should be kept and maintained of lifting and rigging loft equipment. It should

include:

¾ Unique Identification Number

Control Tier:

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Procedure for Lifting Operations

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¾ Safe Working Load (SWL) or Working Load Limit (WLL)

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

Lifting Equipment Register must provide an adequate description of all lifting equipment on

the site.

Third party contractor‟s 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 (storage area)

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

Portable Lifting Equipment (PLE) 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

Before all items are released form the loft they must undergo a pre use inspection by a

suitable trained competent person.

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

section of the “Register and Control Document” Spread Sheet, 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.

Control Tier:

<<2>>

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

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Procedure for Lifting Operations

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For each shift a nominated competently trained responsible person will become the “Rigging

Loft Controller” and will hold the key for the rigging loft.

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

Color 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 color-coded.

The colour code system denotes that the equipment has been thoroughly examined in

the past six months and a valid examination report exists. It does not however

provide a guarantee that the equipment remains serviceable and must therefore be

visually examined prior to use.

Under no circumstances shall any portable lifting equipment be used which is

incorrectly coloured.

The valid color 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 & rigging equipment. An approved

site-specific procedure must be in place.

Each colour code shall run for a period of 6 months.

Colour coding should ONLY be carried out by a suitable trained and competent person i.e.

3rd party testing company.

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

(April 2007 to October 2007)

Blue

(October 2007 to April 2008)

Yellow

(April 2008 to October 2008)

Control Tier:

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Procedure for Lifting Operations

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Then back to Green

NOTE: Colour Codes for the 6 month period shall be clearly identified and posted in Permit

offices and security entrances to the site or facility.

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 their

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.

Rigging loft concept shall be used for management / control of Portable Lifting Equipment

(PLE) 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 of man-made fibre slings should be as follows:

1) Man-made fibre endless round slings and flat webbing slings:

Use of this type of equipment will automatically default to the category of lifting called

“Complicated”, unless an approved site specific procedure is in place.

Site Competent Person shall be appointed to inspect these categories of slings for damage

prior to use. If damage is evident or is suspected, the slings shall be physically removed and

destroyed. Certification for this type of sling is valid for 6 month only, after which it must be

destroyed.

No re-certification shall take place

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 must be properly identified (“Man-

riding”).

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 re-

certification of unused transit slings shall be the responsibility of the site manager / Site

Controller / Offshore Installation Manager.

Brown

(April to October)

Purple

(October to April)

Control Tier:

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Procedure for Lifting Operations

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6.6

Control of Cargo Carrying Units (CCU’s)

The Site Manager / Site Controller / Offshore Installation Manager is accountable for

ensuring a competent person is assigned for verification that all CCU‟s sent from the site are

in a safe condition and for obtaining of an accurate weight of all CCU‟s and ensuring that

such weights are not above the SWL.

The weight of each CCU shall be recorded on the outbound manifest and a copy made

available to receiving asset. All CCU‟s sent to operated sites should have a minimum of one

month certification period remaining.

For all installations and onshore sites there will be no stacking of containers, baskets, tanks

and half heights.

For designated installations where this is not practicable, stacking requires prior permission

of the relevant BP Business Unit Leader and:

¾ Equipment is specifically designed for that purpose, and clearly marked as suitable for

stacking.

¾ Stacking is confined to pre-designated areas.

¾ Risk assessment of stacking operations is performed and shows that the risk involved

is less than alternative practicable approaches.

¾ Stacked containers must have an additional pennant so that the crane hook can be

attached / detached while the load handler is standing at deck level.

¾ Stacking and de-stacking is controlled by permit.

6.7

Control of Mobile Lifting Equipment

No mobile equipment shall be used unless it has valid certification of thorough

examination.

6.8

Control of Third Party Contractor Lifting Equipment

Contractor‟s lifting equipment includes all items whether rented, or supplied free of charge,

as part of the Contractor tools of trade, including container sling assemblies.

Contractor‟s lifting equipment may arrive on a site by a number of different routes. It is the

Site Lifting Coordinator‟s responsibility to verify that equipment satisfies the requirements of

this SSOW.

The Contactor will be responsible for equipment certification and keeping a register for all

Lifting Equipment which shall be made available for Audit as and when required by the

Company.

6.9

Control of Uncertified Structural Components

Use of these components will automatically default the lift category to at least

“Complicated”, unless an approved site / installation specific procedure is in place.

Control Tier:

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Procedure for Lifting Operations

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If a rigging plan utilizes a structural component which has not been certified it is vital that

sufficient data is collated regarding the component in question. The assessment may require

engineering calculations with regard to stresses and strains that apply to the component in

question.

If this is the case as per the lifting plan decision tree the MHC Technical Support Engineer

shall become involved to provide engineering/technical expertise.

6.10 Control of Webbing & Round Slings

Control of man-made fibre slings should be as follows:

1) Man-made fibre endless round slings and flat webbing slings:

Use of this type of equipment will automatically default to the category of lifting called

“Complicated”, unless an approved site-specific procedure is in place.

Site Competent Person shall inspect these categories of slings for damage prior to use. If

damage is evident or is suspected, the slings shall be physically removed and destroyed.

Certification for this type of sling is valid for 6 month‟s use only, after which it must be

destroyed.

COMPETENCY

7.1

Competencies and Training of Personnel

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

persons involved with lifting equipment, its use, operation, management, maintenance and

training, have received formal recordable training and experience that provides levels of

competency according to their tasks and responsibilities and at least to the level in the

following chart.

All personnel involved in mechanical handling and lifting operations on Azerbaijan and

Georgia AzSPU Installations and Sites, shall be trained to the relevant standard (North Sea

or equivalents) and formally assessed as competent in the tasks to be undertaken.

Documentary evidence of training and competence assurance will be required before any

person is authorized to perform lifting operations.

The Site Manager / Site Controller / Offshore Installation Manager shall ensure a register of

competent personnel authorized to undertake lifting operations shall be maintained.

Description of Role

Category of Lifting

Level of Competency

Operation

Banksman

Routine and Simple

Level 1 EAL / ECITB / CITB

Green Card or equivalent

Rigger/Slinger

All categories

Level 2/3 EAL / ECITB / CITB

Blue card or equivalent

Crane driver/operator

All categories

Offshore: Sparrows Stage 3

(Opito) or equivalent.

Onshore: CITB or equivalent

training; heavy goods vehicle

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Procedure for Lifting Operations

Page 17 of 54

drivers license.

Forklift driver

Forklift Operations

CITB / RTITB or equivalent

Site “Competent Person”

All categories

Level 2/3 EAL / ECITB /CITB

or equivalent

Lifting Inspector

Equipment Inspection

LEEA / NSL Module 1 or hold

current formal qualifications

with 3 years + lifting

experience

Site Lifting Coordinator

All categories

Level 2/3 EAL / ECITB / CITB

or equivalent

Lifting Technical Authority

Complicated /Complex

Relevant level of engineering

and leadership experience as

endorsed by Central

Engineering Senior Authority

ROLES & RESPONSIBILITIES

Every lifting operation must be:

¾ Properly planned by a competent person

¾ Appropriately supervised

¾ Carried out in a safe manner

Lifting activities usually involve several craft disciplines and authorities.

It is therefore important that any system set up to manage lifting operations safely, must

recognize this inherent complexity and must ensure that roles and responsibilities and the

competencies for each activity are clearly defined, recognized and that there is a shared

view of interfaces and boundaries. This section details the roles and responsibilities of these

“stakeholders”.

Given the differences in job titles for similar roles across the operations, contract strategies

etc., the roles listed below are generic. However, each site and installation must translate

and appoint the responsibility to suit its own organization.

With regard to lifting operations, some roles may be combined, e.g. Deck Foreman and the

Lifting Supervisor but it is essential that these roles are clearly stated at each site and

understood by all.

The generic “stakeholders” are:

¾ Site Manager / Site Coordinator / Offshore Installation Manager

¾ Area Authority

¾ Banksman

¾ Rigger/Slinger

¾ Crane Operator

¾ Forklift Driver

¾ Site Competent Person

¾ Lifting Inspector

¾ Site Lifting Coordinator

¾ Lifting Technical Authority

¾ Senior Technical Authority

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Procedure for Lifting Operations

Page 18 of 54

8.1

Site Manager / Site Controller / Offshore Installation Manager:

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 numbers of Competent responsible persons are appointed to manage

and maintain the requirements of this procedure

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

lifting operations are to take place.

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

procedure

He appoints a competent person to inspect and certify lifting equipment as safe to use

That no lifting equipment is allowed or used on site unless it is accompanied by all

relevant certification and in date test certificates

That adequate records are maintained for all lifting equipment, including certification,

examination and test reports

That Competent Persons are appointed to compile lifting plans and to perform lifts

That Competent Persons are appointed to control the issue and inspection of lifting

equipment

That all lifting operations are planned and that, where necessary, plans are recorded

8.2

Area Authority:

The Area Authority shall be responsible for ensuring that the requirements of this

procedure are adhered to for all lifting operations within his area of responsibility. He

shall be responsible for ensuring:

That the lifting operation has been risk assessed and planned

That all persons involved in lifting operations are instructed on the requirements of risk

assessment, permit to work conditions, and any risks or hazards associated with the

work activity

That regular inspection is performed on all lifting activities to confirm that conditions

are suitable and sufficient and, that all personnel are in compliance with this

procedure.

That the Task Lifting Supervisor performs Risk Assessments, and conducts Toolbox

Talks associated with lifting operations.

8.3

Banksman:

A Banksman is a person who has been properly trained, proven to be competent, and is

authorized to perform his duties.

The Banksman‟s duties are to ensure clear precise commands are given to the crane driver.

Depending on the complexity and importance of the load and lifting operation, the person in-

charge will supervise and act as Banksman for all movements and precision positioning lifts.

The Banksman shall at all times accompany and guide the crane assigned to them during all

its movements on site.

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Procedure for Lifting Operations

Page 19 of 54

Lifts are to be carried out only in the Banksman‟s presence and he/she is the ONLY

authorized person to give instructions to the crane driver and the crew during lifting

operation.

The Banksman must meet the following requirements:

¾ Should never be involved in lifting operation itself.

¾ Not touch the load. He/she must stand back from the load being handled in a

prominent position where he/she has a good view of the lifting activities.

¾ Remain in communication with the rigger/slinger and crane operator at all times.

¾ Keep the load handler in sight during the lifting operation.

¾ Be capable of understanding slinging/lifting arrangements suitable for the load to be

lifted.

¾ Understand fully the hand signal codes and be able to give clear and precise signals

and/or instructions.

¾ Be capable of directing the movements of the crane and load in such a manner as to

ensure the safety of personnel and plant equipment.

¾ Be known and clearly identifiable to all concerned by wearing high visibility

identification.

8.4

Rigger / Slinger:

The Rigger/Slinger shall prepare the load for lifting according to the lifting plan and:

¾ Stand clear while a load is lifted clear of the deck and landed, while slack is taken up

with or without a load on the hook and must confirm to the banksman that he is clear.

¾ Prepare load to be lifted using suitable lifting equipment (chain-blocks, slings, etc)

¾ Not touch a load being landed, until it is below his/her waist height and never attempt to

manually stop a swinging load.

¾ Be easily identifiable, and distinct from the banksman.

8.5

Crane Operator:

A Crane Operator is a person who has been properly trained, authorized, is competent and

fully conversant with all aspects of safe crane operation. In particular they must be familiar

with the controls and capabilities of the crane that they are to drive and operate.

The Crane Operator is responsible for ensuring that all servicing routines have been carried

prior to crane operation to ensure that the crane can function correctly and is available to

carry out the necessary lifting operations as required.

Crane operator must read and understand Lifting Plans and confirm crane capability with

regard to load and boom angles.

Offshore, crane operators shall be qualified to the Opito (Sparrows) stage 3 or equivalent.

The ultimate responsibility for loads being lifted or moved by the crane, resides with

the Crane Operator who should satisfy themselves that the operation in hand has

been risk assessed and included in the toolbox talk and that the appropriate PTW

(Permit To Work) and Lifting Plans are in place.

Control Tier:

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Procedure for Lifting Operations

Page 20 of 54

8.6

Forklift Driver:

A Forklift Driver is a person who has been properly trained, is authorized, competent and

fully conversant with all aspects of the machine safe operation.

No untrained person is allowed to operate a forklift.

8.7

Site “Competent Person”:

This person (e.g. deck foreman, site lifting and rigging supervisor) must have adequate

technical and practical knowledge and experience to visually inspect lifting equipment to

confirm continued fitness to use, answer queries about the suitability of lifting equipment, to

advise, develop and execute lifting plans.

The Site “Competent Person” will:

¾ Manage and control the rigging and lifting loft inventory

¾ Maintain the register of generic and specific lifting plans and risk assessments for the

Site

¾ Maintain the register of persons authorized to perform lifting operations.

¾ Assist the Lifting Coordinator with the development of lifting plans.

¾ Develop lifting plans and risk assessments for all lifts.

¾ Continuously review the generic lifting assessments for routine lifts

¾ Act as the Performing Authority (under PTW if appropriate) for all lifting operations.

¾ Have the responsibility for all site lifting activities deck and/or boat handling

operations.

8.8

Lifting Inspector:

Lifting Inspector shall:

¾ Develop a thorough examination program for fixed lifting equipment

(excluding

offshore pedestal cranes).

¾ Carry out a thorough examination of fixed lifting equipment and ad-hoc inspection of

any other relevant types of lifting equipment.

¾ Be responsible for ensuring color-coding and certification of examined equipment.

¾ Ensure that all lifting equipment on site has a Certificate of Test and Examination

¾ Ensure that all lifting equipment on site and in use is within current test dates

¾ Ensure that all lifting equipment on site and in use is colour coded to indicate current

usage dates

¾ Ensure that all lifting equipment on site and not in use is stored according to

Manufacturers instructions

¾ Ensure that all lifting equipment on site is inspected either prior to issue or on return

from use

8.9

Site Lifting Coordinator:

Primary role is to provide continuous review of Lifting Practices to ensure compliance

with this AzSPU SSOW.

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Procedure for Lifting Operations

Page 21 of 54

Site Lifting Coordinator has a coordination role, being responsible for ensuring that a regime

is established and maintained on the installation/site such that lifting operations are carried

out safely. This will require:

¾ The authorization of all lifting plans and risk assessments for all categories of lifts by

the nominated Lifting Coordinator supported by the Lifting Authority and Mechanical

Handling Contractor‟s (MHC) support engineer as appropriate. This includes ensuring

that it is clear who is in charge of specific lifting operation.

¾ Ensuring by documentary evidence that all personnel involved with any lifting

operations on the site have been properly trained and assessed as competent to

SSOW standards and that a register of such personnel is maintained on the

installation/site. This includes resident site personnel and any ad-hoc personnel. The

person must also have an in-depth knowledge of the relevant legislation, regulations,

standards, company procedures, health and safety aspects, and industry best practice

8.10 Mechanical Handling Contractor’s (MHC) Technical Support Engineer:

The MHC Technical Support Engineer is nominated as the person responsible for providing

technical expertise in support of complicated lifts (where applicable) and ALL complex lifting

operations on the installation/site. This includes the endorsement of the scope of method

statements, lifting plans and task-based risk assessments, discussion with specialist

engineers and contractors. Ensuring all relevant engineering standards are applied during

the development phase of the work scope and that the output from the engineering

studies/assessments are documented and recorded.

8.11 Lifting Technical Authority (LTA):

The Lifting Technical Authority is responsible for providing the technical overview for lifting

operations on sites.

He/She is responsible for ensuring complicated lifts (where applicable) and ALL complex lifts

are engineered to the relevant standards.

LTA is the Technical Authority for this AzSPU SSOW.

8.12 Senior Technical Authority (STA)

Has overall technical responsibility for all Lifting and Rigging operations. STA is responsible

for nominating and ensuring competency of LTA.

COMMUNICATIONS

A uniform communication system clearly understood by all site personnel taking part in lifting

operations and including hand signals and where required radio sets, shall be established

and used in the process of all lifting operations.

The Communications that are required for lifting operations shall be specified in the lifting

plans.

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Procedure for Lifting Operations

Page 22 of 54

Note: In noisy areas, headsets for radios will be required. If radios are to be used crane

operators shall have hands-free sets.

Charts with standard hand signals for controlling lifting operations explaining the system of

signals used shall be conspicuously posted in the vicinity of the areas dedicated

permanently for lifting operations.

RISK ASSESSMENT AND PLANNING OF LIFTING OPERATIONS

10.1 Strategy

Risk Assessment

All lifting operations must undergo a risk assessment in accordance with Safe Systems of

Work procedure.

Generic lifting operations shall be reviewed on a regular basis to ensure that the original

Risk Assessments remain valid.

For all lifting operations, the degree of risk identified during the Risk Assessment shall

determine the level of supervision required for the operation and the required experience of

the personnel involved. In particular, the Risk Assessment should account for:

¾ Working under suspended loads

¾ Attaching and detaching the load

¾ Overloading

¾ Overturning

¾ Breakdown in communication during lifting (especially blind lifting)

¾ The environment and location

¾ Proximity hazards

¾ Pre-use checks by the operator

¾ Deterioration in the condition of lifting accessories

¾ The experience, competence and training of available personnel.

Risk Assessment shall specifically consider manning requirements for safe conduct of

complex and blind lifts to ensure clear communication between all team members

participating in the lifting operation.

Planning

Following a Risk Assessment, and the preparation of a standard instruction or procedure,

the person using the equipment can normally plan routine lifts on an individual basis. In any

event, the person planning the operation shall have adequate practical and theoretical

knowledge and experience of planning lifting operations.

The degree of planning will vary depending upon the:

¾ Type of lifting equipment

¾ Complexity of the lifting operation

¾ Degree of risk involved.

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Procedure for Lifting Operations

Page 23 of 54

As a minimum, the plan shall address the risks identified and should identify all resources,

procedures and responsibilities necessary to ensure a safe operation.

All lifting operations shall be:

¾ Properly planned by a competent person

¾ Appropriately supervised

¾ Carried out in a safe manner

In addition to the above requirement, the AZSPU-HSSE-DOC-00063-2 Task Risk

Assessment SSOW imposes a duty to carry out a suitable and sufficient risk assessment to

identify the nature and level of hazards associated with work.

No Lifting & Rigging Operations should be carried out without a lifting plan produced

by a competent person and approved by relevant authority, unless an approved site

specific procedure is in place and approved by the relevant Lifting Technical

Authority.

To remain cognisant of this SSOW, it is recommended that the asset management compile a

series of generic lifting plans to cover routine lifting duties.

Prior to the commencement of any lifting operation, a pre-job safety meeting shall be carried

out in order to assess the suitability of the Lifting Plan and to familiarize personnel involved

in the lifting operation with the risk identified. At this time, minor variations may be necessary

to take account of current conditions, e.g. wind speeds, wave height, position of people,

deck layout, etc.

Lifting plans involving cranes and supply boat operations should pay particular attention to

environmental conditions and the crane manufacturer‟s operating manual.

10.2 Spheres of Responsibility

The spheres of responsibility and interfaces are as shown below.

SITE

AUTHORITY

SUPERVISION

PLANNING

OPERATION

RISK

ASSESSMENT

CRANE OPERATOR

RIGGER

COMPETENT PERSON

SLINGER / BANKSMAN

DISCIPLINE ENGINEER

BASIC SLINGER

RIGGER

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Procedure for Lifting Operations

Page 24 of 54

10.3 Planning Process

Lift categories

To assist with the risk assessment process, lifting operations have been divided in four

categories, which are:

¾ Routine

¾ Simple

¾ Complicated

¾ Complex

Routine and simple lift:

This category of lifting operation is usually implemented using generic lifting plans and risk

assessments, each with clearly established criteria and limitations. The generic plan is then

reviewed at a toolbox talk prior to being implemented by appointed competent personnel.

Complicated lift:

This category of lifting operation requires a written method statement in addition to the lifting

plan, risk assessment and the approval of Site Lifting Coordinator and/or Mechanical

Handling Contract Technical Support or the Lifting Technical Authority. The specific plan is

then reviewed at a toolbox talk prior to being implemented by appointed competent

personnel.

Complex lift:

If a lifting job involves divers or sub-sea work or the plan indicates the selected route for the

load to travel is over live plant or a confined space, it will be classed as complex. This

category of lifting equipment requires a written method statement in addition to the Lifting

plan, risk assessment and the approval of Site Lifting Coordinator and/or the Mechanical

Handling Contract Technical Support or the Lifting Technical Authority.

Minimum number of people required to carryout the complex or complicated lifts

safely shall be risk assessed and established prior to start the lifting operation.

Note: Where the lifting activities - routine, simple, complicated or complex - are likely to be

repeated, the assessments, lifting plans and method statements should be held on file for

subsequent review and re-use.

Routine activities by definition are repetitive and as such, the method statements, risk

assessments, plans and any supporting procedures should be held on file.

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Procedure for Lifting Operations

Page 25 of 54

Lifting Plan Decision Tree.

Lifting Operation Required

Review Library of

Approved Lifting plans

Has the lift been carried

Yes

and Risk Assessments

out before?

Categorise Lifting Operations (review all

Is plan and risk

lifting categories to determine the

assessment still

appropriate category)

applicable?

Yes

Proceed with Lift

Is it a Routine Lift?

Is it a Simple Lift?

Is it a Complicated Lift?

Is it a Complex Lift?

(Use lifting category

assessment)

Plan & Risk Assessment

Plan & Risk Assessment &

Plan & Risk Assess. &

approved by Nominated

Method Statement

Competent Person

approved by Nominated

Competent Person

Lifting Co-ordinator

Authorisation/Decision

Authorisation

If required

Plan & Risk Assessment endorsed

by LTA, MHC Engineer

Lifting

LTA / MHC

Lifting Coordinator

Coordinator

Authorisation

Authorisation (including

Authorisation

Generic lifting plans)

Proceed with Lift

Hold toolbox talk &

Hold toolbox talk & proceed

Hold toolbox talk &

proceed with the

proceed with the Lifting

with the Lifting Operation

proceed with the Lifting

Lifting Operation

Operation following the

following the specified Lifting

Operation following the

following the

specified Lifting plan

plan and site controls

specified Lifting plan and

specified Lifting plan

and site controls

site controls

and site controls

Lift Supervised by

Rigger with

Rigger/Technician

Competency

with Competency

Level 1 (min)

Level 3 (min)

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Procedure for Lifting Operations

Page 26 of 54

Wind Speed Limitations

No cranes shall be operated out of manufacturers recommendations

It is responsibility of the Site Lifting Coordinator to ensure that accurate and realistic wind

speed readings using anemometer set in appropriate location are utilized.

Lifting operations shall be suspended when average wind speeds reach:

¾ Onshore - 25 knots (12.86 m/sec)

¾ Offshore - 35-40 knots (18 - 20.5 m/sec)

Lifting operations may be allowed to re-commence following:

¾ A formal task specific risk assessment involving Site Manager, Site Lifting Coordinator

and HSE advisor taking into consideration site conditions, industry guidelines, crane

manufacturers recommendations, type/weight/shape/ of load being lifted

¾ An upgrade of the lift to at least “complicated”.

¾ Continuous monitoring of the weather/site conditions including wind gust speeds.

It is the accountability of the Site Manager / Site Controller / Offshore Installation

Manager to ensure that if lifting operations are re-commenced that the above items

shall be considered and the appropriate limits set, understood, recorded and adhered

to.

Risk Assessment - guidance notes:

This section is for guidance purposes only. Whilst it tries to incorporate the main hazards

associated with lifting operations, these notes are not intended to be exhaustive. Other

equally significant hazards may be present.

Where other hazards are identified, these shall be assessed in a similar fashion to those

identified on the notes, with due consideration to possible causes, consequences and

appropriate solutions.

Planning for the worst-case scenario should ensure that all hazards have been brought to

ALARP Level and the necessary mitigation actions are in place.

Important:

Lifting more than one dedicated “load” at a single time (“Piggy backing”) is strictly

prohibited and should not be carried out under any circumstances.

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Procedure for Lifting Operations

Page 27 of 54

RISK ASSESSMENT GUIDANCE NOTES

1) The load

HAZARD

POSSIBLE CAUSE

CONSEQUENCE

SOLUTION

Load heavier

Incorrect weight on manifest

Equipment failure

Trial lift

than expected

Weight unknown - incorrect

Load falling

Dynamometer

estimate

Equipment instability/ collapse

Ensure personnel

Lifting equipment overloaded

Personal injury

emergency access

route

Centre of

Incorrect information supplied

Load swinging

Reposition lifting

gravity not as

Incorrect slinging

Load striking person

equipment

expected

Cargo shifting in transit

Load striking plant

Trial lift

Personal injury

Ensure personnel

emergency access

route

Fit tag lines

Physical

Insufficient head room

Load striking plant

Consider alternative

dimensions

Nearby plant and machinery

Load handling problems

slinging method.

Personnel injury

Use specialised lifting

equipment e.g. low

headroom hoist

Use of additional

banks man/ radios

Fit tag lines

Load damaged

Transit damage.

Falling objects

Consider alternative

Sharp corners.

Load falling.

slinging method.

Personnel injury.

Pre-lift check

Ensure emergency

access route.

Correct PPE.

2) The environment

HAZARD

POSSIBLE CAUSE

CONSEQUENCE

SOLUTION

Adverse weather

Excessive wind speeds.

Load swinging.

Fit tag lines

conditions

Poor visibility - light, mist or

Load striking person

Use of additional

fog.

Load striking plant.

banksman/radios.

High sea states.

Personnel injury.

Correct PPE.

Rain, sleet or snow showers,

Snatch load.

Do not carry out lift.

Ice on load and deck/ground.

Crane overload.

Slips trips and falls.

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Procedure for Lifting Operations

Page 28 of 54

3) Controlling the area

HAZARD

POSSIBLE CAUSE

CONSEQUENCE

SOLUTION

Pedestrians

Unaware of lifting operation.

Load striking person.

Barrier off area.

Ignore barriers.

Personnel injury.

Use of additional

Unaware of risks

Banksman assistance

/radios.

Keep people away.

Persons involved in lifting

Lifting over the heads of

Consult Permit issuing

Other work

operation not aware of other

persons involved in other

Authority.

activities in the

nearby work activities.

work front in the vicinity.

Check area prior to

vicinity.

Load striking person.

operation.

Personnel injury.

Breakdown in

Untrained personnel.

Load swinging.

Use suitably trained

communications.

Radio problems.

Load striking person.

personnel.

Blind lifts.

Load striking plant.

Use of additional

Personnel injury.

banksman assistance /

radios

4) The lifting equipment

HAZARD

POSSIBLE CAUSE

CONSEQUENCE

SOLUTION

Incorrect SWL.

Incorrect selection of

Equipment failure.

Double check SWL

equipment.

Load falling.

required prior to lifting.

Incorrect assessment of weight

Personnel injury.

Use dynamometer.

of load.

Remember to include

Incorrect calculations of forces.

weight of accessories

for lifting.

Lifting

Incorrect selection of

Load falling.

Pre-use check.

accessories not

equipment.

Personnel injury.

Ensure tie-rap/safety pin

attached

Human error.

fitted to shackles.

correctly.

Shackles of containers

unscrewed in transit.

Safety latch of hooks damaged.

Mechanical

Lack of maintenance.

Equipment failure

Pre-use check.

damage.

Incorrect use of equipment.

Load falling.

Review and correct

Contact with sharp edges.

Personnel injury.

maintenance plan.

General wear and tear.

Review and correct

storage method.

Incorrect fleet

Lifting appliance not positioned

Load swinging.

Re-position lifting

angle.

directly over load.

Load striking person.

appliance prior to

Load striking plant.

operation.

Personnel injury.

Equipment out of

No pre-use check.

Equipment failure.

Pre-use check.

date.

Violation of procedure.

Correct color code.

Check certification.

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Military reference books and manuals (2009-2023, Volume 5) - page 34