BTC Pipeline Project, Azerbaijan

BTC Commissioning, Testing and Start-Up Work Control

May 26, 2005

Introduction:
Due to business needs, a more complex model for BTC construction, commissioning,
testing / start-up and operations is necessary, involving five separate, but interdependent
organizations. As construction progresses on the downstream end of the pipeline,
commissioning continues in the middle and operations has begun line-fill with nitrogen /
crude oil on the upstream end from Sangachal to IPA-1.

An incident occurred on 2nd May 2005, when 0.84 barg of air pressure was released
through an equalization bypass valve at PSA-2 downstream to an active tie-in crew at
KP-280. The air pressure exited the open end of the line pipe without injury to the crew.

A joint BTC Operations / Project team investigated the incident to determine actions to
prevent recurrence of like-in-kind activities, which in practice, constitutes continuous
simultaneous operations (SIMOPS). SIMOPS is usually risk assessed and planned as
individual events, therefore, recommended actions to prevent recurrence of continuous
SIMOPS are unique to pipeline construction. One of these actions is recommended for
management review as an industry best practice.

Purpose:
Lessons Learned from previous pipeline construction projects and the Genesis Report indicate
that lack of communications negatively effect efficient implementation of the BP Golden
Rules of Safety; i.e., Energy Isolation. The BTC Commissioning, Testing and Start-Up Work
Control process is extremely effective in eliminating communications gaps among
individuals, crews and organizations. The process requires:
MOC, with lessons learned, prior to similar activities in Georgia and Turkey.
Specific identification of roles and responsibilities among the organizations.
More formalized record keeping by each organization; i.e., PTW / Isolations.
Single Point of Contact whenever multiple organizations are working on the same
site.

Scope of Work:
The BTC Commissioning, Testing and Start-Up Work Control process was developed
and implemented to ensure adequate communications among different organizations; i.e.,
operations, control room, project pipeline, project facilities and commissioning, to
ensure work control processes are in place prior to pressure de-isolation of air, nitrogen
and crude oil in BTC facilities / Above Ground Installations (AGI) and the line pipe. The
work control process is simple, yet effective, in communicating to thirty nationalities,
who are involved in the five organizations. The process requires:
Daily multi-organization meetings to discuss individual / SIMOPS activities.
Daily distribution of a simple diagram, which communicates:
- Identified ownership of sections of facilities and line pipe.
- Locations of hydrocarbon, nitrogen and air.
- Forward plan.
- Identification of clashes (SIMOPS) and mitigations.
- Approvals necessary to proceed with work activities.
This diagram is comprehensive enough to communicate awareness of pending
conflicts of interest, yet simple enough for a Charge Hand to understand.

Conclusion:
This process represents an industry best practice for compliance with BPs Golden
Rules of Safety; i.e., Energy Isolation / MOC, because of its continuously applied
controls for SIMOPS, which is unique within facilities / pipeline construction.

Recommendations:
Bruce Webb; BTC Operations, Systems and Commissioning Manager is
recommended for a certificate of recognition and a spot bonus for efficiency
and innovation as the developer / implementer of the BTC Commissioning,
Testing and Start-Up Work Control process.
This process and the incident investigation report # BTC/Ops/Az/05/006
should be utilized during joint Azerbaijan Georgia and Georgia Turkey
MOCs for lessons learned and best practices.
This process and all lessons learned from the total BTC Execute to Operations
phases as related to this type of energy isolation should be documented and
shared throughout the BP Group and with Partners.

Respectfully submitted,

____________________
Ed Morgan
H&S Manager
BTC Pipeline Project, Azerbaijan
Re: Co-Root Cause Specialist for incident investigation # BTC/Ops/Az/05/006