Rev.

3 Inspection and Certification of Equipment Procedure

Petroleum Development Oman LLC

TWX - High Pressure Operations Procedure

Inspection and Certification of Equipment

Procedure Number: HP-WT-004

Livelink Number: PR-1454

Keywords: inspection, certification, equipment, well pulling hoist, mobile flowline,

pressure vessel, wellhead, piping, audit, contractor, mobilisation.
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or transmitted
in any form by any means (electronic, mechanical, reprographic recording or otherwise) without prior
written consent of the owner.

PR-1454 Page i Aug. 2004

Rev. 3 Inspection and Certification of Equipment Procedure

Authorised For Issue

Signed:............................................................. Date:.........................................
Suhail Al-Riyami, TWX/6
Senior Well Engineering Exploration
Frac & Testing

Signed:............................................................. Date:.........................................
Salim Al-Rawahi, TWX
Head Well Engineering Exploration

Approved:........................................................ Date:.........................................
Eamon Gorman, TWM
Well Engineering Manager

The following is a brief summary of the four most recent revisions to this document. Details of
all revisions prior to these are held on file by the issuing department.

PR-1454 Page ii Aug. 2004

Rev. 3 Inspection and Certification of Equipment Procedure

Rev. Date Author Scope / Remarks

No.
0 14/10/1998 TM Services – OTW/1 Initial Issue
1 01/01/2002 TWM/92 Initial Issue, post merger of Well
UOW 1 Services & Well Engineering.

2 13/07/2003 TWB/213 - Karunanidhi Updated Well Pulling Hoist Equipment

(2.2.5.2)
3 16/08/2004 Updated by: I.K.Naamani, TWX/91 Checked by: Suhail Al-Riyami,
TWX/6

PR-1454 Page iii Aug. 2004

Rev. 3 Inspection and Certification of Equipment Procedure

Contents

1 Introduction...........................................................................................................................1
1.1 Background.....................................................................................................................1
1.2 Purpose............................................................................................................................1
1.3 Distribution/Target Audience..........................................................................................1

2 Procedure...............................................................................................................................2
2.1 Scope...............................................................................................................................2
2.2 Procedure Description.....................................................................................................2
2.2.1 General.....................................................................................................................2
2.2.2 General Requirements for Well Services Equipment..............................................2
2.2.2.1 Inspection and Certification...........................................................................2
2.2.2.2 Pressure Containing Equipment.....................................................................2
2.2.2.3 Lifting Equipment..........................................................................................3
2.2.2.4 Documentary Evidence..................................................................................3
2.2.3 Pressure Test Bay.....................................................................................................3
2.2.4 Well Test Equipment................................................................................................4
2.2.4.1 Pressure Vessels (Separators, Surge Tanks)...................................................4
2.2.4.2 Wellhead Equipment (Choke Manifolds, Data Headers, SSV’s, etc)............5
2.2.4.3 Piping (Chicksans, Flowlines, etc.)...............................................................5
2.2.4.4 Lifting Equipment..........................................................................................5
2.2.5 Well Pulling Hoist Equipment.................................................................................5
2.2.5.1 General...........................................................................................................5
2.2.5.2 Inspection Requirements................................................................................6
2.2.6 Wireline Equipment.................................................................................................7
2.2.6.1 General...........................................................................................................7
2.2.6.2 Inspection and Certification Requirements....................................................7
2.2.6.3 Pressure Control Equipment..........................................................................8
2.2.6.4 Wireline Management System.......................................................................9
2.2.6.5 Wireline Tools................................................................................................9
2.2.7 Mobile Flowline and Accessory Equipment............................................................9
2.2.7.1 General...........................................................................................................9
2.2.7.2 Material Specification..................................................................................10
2.2.7.3 Equipment Identification.............................................................................10
2.2.7.4 Inspection Requirements..............................................................................10
2.2.7.5 Documentation.............................................................................................11
2.2.7.6 Inspection Details........................................................................................12
2.2.8 Audit of Contractor’s Equipment..........................................................................14
2.2.8.1 Initial Mobilisation Audit.............................................................................14
2.2.8.2 Certificates and Other Documentation........................................................14
2.2.8.3 Callout Mobilisation....................................................................................15
2.3 Identified Hazards/Threats............................................................................................16
2.4 Roles and Responsibilities.............................................................................................17
2.4.1 Equipment User.....................................................................................................17
2.4.2 Contractor..............................................................................................................17
2.4.3 PDO Well Services Representative........................................................................17
2.5 Related Forms and Reports...........................................................................................18
2.5.1 Inspection, Testing and Certification Documentation...........................................18
2.5.2 Two-Monthly Hoist Inspection Report..................................................................18
2.6 Related Business Control Documents...........................................................................18
2.7 Review and Improvement.............................................................................................18
2.7.1 Well Services Procedure Variance Form...............................................................18
2.8 Step-out and Approval...................................................................................................20

PR-1454 Page iv Aug. 2004

Rev. 3 Inspection and Certification of Equipment Procedure

Appendices.................................................................................................................................21
A Glossary of Terms, Abbreviations & Definitions..........................................................21
B User Feedback Form.....................................................................................................23
C Step Out & Approval Form...........................................................................................24

PR-1454 Page v Aug. 2004

Rev. 3 Inspection and Certification of Equipment Procedure

1 Introduction
1.1 Background
Equipment used in Well Services operations is mostly either pressure containing and/or load
bearing. As such, it is essential that this equipment be maintained in a fit-for-purpose
condition in order to prevent failure and accident that could result in danger/injury to
personnel, threat to well integrity or damage to Company assets.
It is a requirement by local regulations and safe Company practices that the equipment is
subject to regular inspection and certification to verify that it is safe to use.
Most of this is covered by relevant International Codes and Recommended Practices. Whilst
limited in their guidance on specific mobile flow line equipment, the various components
related to good oil field practices have been extracted and incorporated in this procedure.

1.2 Purpose
This procedure sets out to establish the standards and certification required for initial
acceptance of Well Services equipment, and the periodic inspections and re-certifications
required so that to ensure the equipment continues to perform safely and within specification
during Well Services operations conducted on PDO operated wells.
It also sets out definitive PDO requirements on material specifications and identification.
It provides the basic framework for a Safety Management and Inspection (SMI) System in
order for contractors who perform Well Services operations on behalf of PDO shall apply to
ensure that the equipment supplied and used by them is maintained in a satisfactory and safe
condition.

1.3 Distribution/Target Audience

This Well Services Procedure document will be distributed to all PDO Section Heads who
have interfaces with the Well Services Operations, all Well Services Supervisors and
Contractor Supervisors.
The document will also be available via the Livelink system on the PDO web site.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 1 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

2 Procedure
2.1 Scope
This Procedure is applicable to all equipment, owned and/or used by PDO or Contractor, used
during Well Services operations conducted on any production well operated by PDO.

2.2 Procedure Description

2.2.1 General

Proper initial and subsequent routine inspection of Well Services equipment is essential to
prevent equipment failure resulting in possibly injury to personnel, equipment damage, loss of
well control etc.
It is a requirement by local legislation and PDO safety regulations that this equipment has up-
to-date certificates and inspection records to prove that it is safe to use.
The majority of equipment used during Well Services operations is owned by the Contractor
conducting the operations on behalf of PDO under the terms of a service contract. The
requirements expected of the Contractor shall normally be written into the scope of services
terms of the service contract.

2.2.2 General Requirements for Well Services Equipment

2.2.2.1 Inspection and Certification

All equipment used in Well Services Operations, either contractor owned or supplied by PDO
shall be subject to regular visual inspection.
All load bearing and pressure containing equipment shall be inspected and certified/re-
certified, on an annual basis as a minimum, by a Company approved inspection agency in
accordance with:
 PDO ERD-07-01 “Code of Practice for the Inspection of Static Equipment”.
All equipment that has been exposed to hostile environments (extreme temperatures,
chemicals, corrosive environment, etc.) shall be re-inspected and re-certified before re-use
The Contractor shall keep inspection records of all equipment on the basis of a unique code,
which shall be clearly marked on the Equipment by means of a plate, stainless steel strap or
other wise.
All Inspection and Certification documentation, including manufacturer's certification, design
and material Specification Certification, shall be made available to the Company at Initial
Mobilisation. Subsequent re-certification documentation and inspection reports shall be made
available within one month after re-inspection.
Under no circumstances shall Equipment be provided, or be used in the performance of
Services for the manufacturer's certification, of which design and material Specification and
certification are absent or expired.
Reference shall also be made to:
 GU-458 PDO “Well Engineering Combined Operations”

2.2.2.2 Pressure Containing Equipment

In addition to inspection and certification, all pressure containing components and pressure
control equipment (e.g. lubricators, BOP's, stuffing boxes, pump discharge lines, pressure
vessels, pressure relief valves, circulating head valves, crossovers, pumping tees, etc.) shall be
tested in accordance with:
 PDO ERD-07-01 “Code of Practice for the Inspection of Static Equipment”;
and
 PDO ERD-07-02: “Methods for Non-Destructive Examination”.
Tests shall include hydraulic pressure testing and ultrasonic wall thickness examination
similar to that given in section 2.2.7 for mobile flow lines and accessory equipment.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 2 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

All pressure testing of equipment shall be conducted in a dedicated test bay, or alternatively
and underground dedicated pressure test cellar to ensure the safety of personnel.

2.2.2.3 Lifting Equipment

Lifting equipment shall also be tested in accordance with:

 SP-1239 “Lifting Equipment Specification”.
 PDO DRS 130-05 “Drilling Equipment Inspection Manual”.
The Contractor shall also submit to the Company for approval a Hoist Drill Line Replacement
Programme. This shall be either a periodical complete line replacement programme or a 'slip
and cut' programme. Either programme shall be based on routine visual inspections and/or
'ton-mile' concept and shall include a statement on maximum service life of the drill line.

2.2.2.4 Documentary Evidence

The Contractor shall maintain documentary evidence and/or computer records in an SMI
system or similar, of all such tests.
Documentary evidence together with the regulations, procedures and standards of the tests
shall be subject to audits by the Company.

2.2.3 Pressure Test Bay

All hydrostatic pressure testing of equipment shall be conducted in a dedicated pressure test
bay that meets the following specifications:

 It must have four external walls independent of the main workshop (or other
similar building) structure.
 All walls shall be internally steel-reinforced both vertically and horizontally.
 All walls shall be of sufficient height to contain flying debris in order to protect
personnel, outside the test facility, from injury.
 Doors and observation windows shall be capable of withstanding a direct impact
from within the facility.
 Pressure lines form the test pumps shall be secured to the walls of the test bay –
loose lines shall be kept as short as possible.
 Test bay floors shall be adequately drained to allow work to continue in a
relatively dry and clean environment.
 All devices for holding equipment (e.g. vices, clamps, etc.) shall be firmly
secured.
 High-pressure test pumps shall be enclosed within the test facility (if possible)
with only the control panel externally positioned.

The pressure test bay shall also be equipped with a fail-safe warning system with flashing
lights to alert personnel that equipment is under pressure test. The system shall automatically
dump the pressure on the equipment as soon as the test bay door is opened. Energizing the
system shall be dependent upon the locking of the door, without which pressurization shall be
unable to commence.
An acceptable alternative to a walled room test bay will be an underground pressure test
cellar, provided that the above criteria, as appropriate, are complied with.

2.2.4 Well Test Equipment

2.2.4.1 Pressure Vessels (Separators, Surge Tanks)

Acceptance Testing and Certification

Acceptance of any pressure vessel shall be contingent upon delivery of a valid certificate from
a competent certifying body (e.g. ABS, DNV, Bureau Veritas, Lloyds) verifying that it has
been designed and manufactured in accordance with the requirement of:

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 3 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

 ASME “Boiler and Pressure Vessel Code of Practice”, Section VIII, Division 1.
Certificates shall also verify that all materials used in the manufacture conform to the
requirement of the following. Full traceability of materials is required.
 SP-1146 “Materials Selection - Sour Service”; and
 NACE MR0175-90 “Standard Sulphide Stress Cracking Resistant Metallic
Materials For Oilfield Equipment”.
All pressure vessels shall be fully certified that they have undergone all non-
destructive testing as required under ASTM code and in accordance with:
 PDO ERD-07-02: “Methods for Non-Destructive Examination”.

Specifically, all welds shall undergo 100% radiography and the radiographs shall be
independently certified as conforming to the requirements. Magnetic particle inspection shall
be performed on all welds and independently certified.
An ultrasonic wall thickness map shall be supplied showing that the wall thickness is in
accordance with the approved design including additional thickness to allow for corrosion as
specified in the ASME code Appendix E. This additional thickness shall be 1/8" for the
pressure vessel and 1/10" for all associated piping.
All pressure relieving devices shall be supplied with certificates of conformance, including
relevant set pressures and relief capacity, to the requirements of:
 SIEP DEP 80.45.10.10 “Pressure Relief, Emergency Depressurising & Flare
Systems”

Pressure vessels shall be pressure tested using water or water/glycol mixture as follows:
i. Raise pressure to maximum working pressure (MWP) and hold for minimum 15
minutes.
ii. Bleed down to atmospheric pressure.
iii. Raise pressure again to MWP and hold for a further 15 minutes.
iv. Pressure charts confirming successful testing shall be supplied.

Periodic Inspection and Re-certification

All pressure vessels shall undergo annual inspection and re-certification by a competent
independent authority (e.g. ABS, DNV, Bureau Veritas, Lloyds or similar organisation
authorised and approved by PDO). Testing and certification required is as follows:
 Ultrasonic wall thickness test;
 Pressure test to MWP;
 Relief valve set pressure test certificate.

If for whatever reason, a pressure vessel should undergo any repair involving welding, this
shall be done in conformance to the requirements of the ASME code. All welds shall undergo
inspection and the pressure vessel shall undergo a pressure test similar to that detailed above,
except that the test pressure shall be 1.5 times MWP.

2.2.4.2 Wellhead Equipment (Choke Manifolds, Data Headers, SSV’s, etc)

Acceptance Testing and Certification

Acceptance of choke manifolds, data headers, surface safety valves and wellhead connections
shall be contingent upon delivery of a valid certificate of conformance to:
 API Spec 6A “Wellhead and Xmas Tree Equipment”,
and that all materials utilised conform to:
 NACE MR0175-90 “Standard Sulphide Stress Cracking Resistant Metallic Materials For
Oilfield Equipment”.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 4 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

All Non-destructive and pressure testing shall be performed in conformance with the above
specification and:
 PDO ERD-07-02: “Methods for Non-Destructive Examination”.

Periodic Inspection and Re-certification

All wellhead equipment shall undergo annual inspection and re-certification conforming to
API Spec 6A, including radiographic inspection and ultrasonic examination as applicable for
wellhead equipment.
Pressure testing shall be to MWP unless the equipment has been subject to modification
involving welding, or other physical change, when the subsequent first pressure test shall be to
1.5 times MWP.

2.2.4.3 Piping (Chicksans, Flowlines, etc.)

Regarding all piping and accessories: acquisition, certification, annual and bi-annual
inspections and re-certification:
A certificate of conformance shall be required regarding:
 material traceability;
 conformance to ANSI B 31.1 and NACE MR0175-90;
 non-destructive testing in accordance with PDO ERD-07-02;
 pressure test to MWP.

2.2.4.4 Lifting Equipment

Any lifting equipment assigned to Well Test Units shall be inspected in accordance with:
 SP-1239 “Lifting Equipment Specification”

2.2.5 Well Pulling Hoist Equipment

2.2.5.1 General

WPH equipment belonging to a contractor will normally be inspected by a certified and

approved third party inspection company, but it may be inspected by a designated PDO
Inspector, on an occasional urgent basis.
For each item of WPH equipment in use, a properly completed, authorised inspection
certificate shall be available on the WPH site for verification purposes. If no valid up-to-date
certificate can be presented, the equipment shall not be used.
All modifications, repairs or alterations to load or pressure bearing equipment shall be
inspected by appropriate methods and verified and certified accordingly. Consultation with
the manufacturer for approval of materials and methods shall be required prior to proceeding
with such planned work.
For identification purposes each item shall have a unique serial number stamped on it.
Inspection reports/certificates shall refer to this number.

2.2.5.2 Inspection Requirements

General

The inspection requirements in this procedure are largely based on the following and modified
where necessary to suit the equipment in use on WPH's:
 DRS 130-05 PDO “Drilling Equipment Inspection Manual”.

The inspection requirements and proper procedures for testing of WPH equipment are
indicated in the following tables, which in turn refer to Testing Technique Data Sheets in the
Drilling Standard Instructions. Test frequencies for critical area NDT inspections are also
indicated together with the required frequency for fully disassembled.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 5 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

The Testing Technique Data Sheets, together with the relevant NDT procedures, are also
contained in the Hoist Equipment Inspection Requirement Manual, held in the Well Services
Section Head office in Marmul. An additional copy of this manual will be made available to
WPH Contractor Supervisory Staff on request.

Subsurface Equipment

ITEM DATA CRITICAL AREA FULLY DISASSEMBLED

SHEET NDT INSPECTION INSPECTION
NUMBER FREQUENCY FREQUENCY
Kelly Valve A.1.1 6 Monthly 2 Yearly
Overshot (Bowen) A.1.2 Each Use Annually
Spears (Bowen) A.1.3 Each Use Annually
Tapered Tap A.1.4 Each Use N/A
Inside BOP A.1.5 Each Use Annually

Surface and Hoisting Equipment

ITEM DATA SHEET NUMBER CRITICAL AREA FULLY DISASSEMBLED

NDT INSPECTION INSPECTION
FREQUENCY FREQUENCY
Hoist Mast B.1.1 Annually 3-5 Yearly
Crown Block B.1.2 Annually 3 Yearly
Travelling Block B.1.3 Annually 3 Yearly
Clevis Hook B.1.4 6 Monthly 2 Yearly
Links B.1.5 6 Monthly N/A
Elevators B.1.6 6 Monthly Annually
Spiders B.1.7 N/A 6 Monthly
Tongs B.1.8 N/A 6 Monthly
Brake Bands/Brake B.1.9 When Blocks Annually after Last
Equaliser Beam Changed Inspection
Tubing Board B.1.10 6 Monthly Annually
S/R Basket B.1.11 6 Monthly Annually
Deadline Anchor Plate B.1.12 6 Monthly 2 Yearly
Lifting Subs/Slings/ B.1.13 N/A 6 Monthly
Shackles
Sub Structure API RP4G, App A Annually 4 Yearly
ASTM E165 ASTM E709

Pressure Containing Equipment

ITEM DATA CRITICAL AREA FULLY DISASSEMBLED

SHEET NDT INSPECTION INSPECTION
NUMBER FREQUENCY FREQUENCY
Riser Spools C.1.1 Annually N/A
BOP Equipment C.1.2 Annually 3 Yearly
Shooting Nipple C.1.3 N/A Annually
Chicksan Line / N/A N/A Annually*
Swivels
Circulation Head, C.1.5 6 Monthly Annually
Swivels
Air Receivers C.1.6 N/A 2 Yearly
Brake Water Splash C.1.7 N/A Annually
Tank
Relief Valve Inspection C.1.8 3 Monthly 2 Yearly
Manifolds C.1.9 Annually* 5 Yearly

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 6 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

Gate Valves C.1.10 Annually* N/A

Notes: * Pressure test to MWP after re-assembly, except after weld repairs when test to 1.5
times MWP.

2.2.6 Wireline Equipment

2.2.6.1 General

Equipment used for PDO wireline operations either belongs to PDO or to the wireline
contractor, depending upon size. The Wireline Contractor is responsible for ensuring that this
inspection and re-certification is conducted accordingly.
Most of the equipment used is pressure containing, e.g. BOP’s (wireline valves), crossovers,
lubricators, stuffing boxes, circulating head valves, pumping tees, well head connectors,
BPV’s, etc.
This equipment shall be subject to inspection and certification/re-certification before first use
and shall also be re-inspected and re-certified at periodic intervals. Equipment that has been
subjected to over-pressure or exposed to hostile environments (extreme temperatures,
chemicals, corrosive environment, etc.) shall be re-inspected and re-certified immediately,
before re-use
Refer also to:
 PR-1482 “Wireline Operations”

2.2.6.2 Inspection and Certification Requirements

General

A third party inspector shall inspect and certify new equipment. Full documentation shall
include, but not be limited to material physical/chemical properties, hardness and full material
traceability.

Initial Equipment Acceptance

This shall require full documentation of :-

 visual inspection;
 ultrasonic wall thickness measurements;
 magnetic particle inspection of all welded/forged sections;
 hydrotests to 1.5 times WP;
 material traceability
 material certification to NACE MR0175-90

Annual Re-certification

The following actions shall be carried out with a certified inspection system or certified third
party:
1. Visual inspection of external surfaces for wear, cracks and damage.
2. Visual inspection of internal surfaces for erosion.
3. Magnetic particle inspection of welds.
4. Pressure test to rated working pressure.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 7 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

Note: The test pressure/working pressure ratio may be varied as per

manufacturer’s recommendations.
5. Ultrasonic wall thickness measurement shall be carried out every 2 years.
Complete certification documentation shall be provided.

Pressure Testing

Equipment that has been subject to modification (especially involving welding) shall be
pressure tested immediately afterwards to the same pressures as the Initial Acceptance Test,
according to recognised industry standards.
All pressure tests shall be conducted using water or water/glycol mixture, as follows:
i. Raise pressure to test pressure and hold for minimum 15 minutes.
ii. Bleed down to atmospheric pressure.
iii. Raise pressure again to test pressure and hold for a further 15 minutes.
iv. Pressure charts confirming successful testing shall be supplied.

2.2.6.3 Pressure Control Equipment

Testing and Certification Requirements

All pressure control equipment (lubricators, control heads, BOP's, etc.) shall be tested as
above to ensure it performs its designated task within specification. In addition to this all
lubricator sections shall be drifted to check full bore.
A semi-permanent record of this testing, in the form of a metal band with test date, test and
working pressure of the item shall be attached to each item of equipment. The band shall also
indicate if the item is rated for H2S use.
All pressure control equipment shall be identified with a unique serial number to ensure
control and record keeping. Marking shall be done in a manner that does not reduce the
maximum rated working pressure of the item.
All relevant certification relating to material selection, traceability and re-certification by
Company or third parties shall be available for inspection at any time.

Items Containing Sealing Elements

Pressure testing of items containing sealing elements (BOP rams, stuffing boxes grease
injection control heads) shall be performed in two stages:

1. Test of body integrity

This shall be performed to the test pressures given above with suitable blanking plugs to
contain the pressure, and not utilising the seals

2. Test of sealing capability

The test of sealing capability of elastomer sealing elements (BOP rams, stuffing box numbers)
shall be performed to Working Pressure only using a polished rod of diameter equal to the
cable for which the seals are designed. It shall never be performed with a stranded line, as the
seals may be damaged when closed on the cable and pressure is applied. The polished rod
shall have suitable end pieces to ensure it is held correctly in position.

2.2.6.4 Wireline Management System

In order to prove the integrity of the wireline, the contractor will implement a wireline
management system as detailed in:
 PR-1482 “Wireline Operations”, section 2.2.7

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 8 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

2.2.6.5 Wireline Tools

All wireline tools shall be maintained and inspected as per the manufacturer’s best practices, design
and maintenance instructions (BDMI). This will include regular visual inspection, critical dimension
checks and tool maintenance.

2.2.7 Mobile Flowline and Accessory Equipment

2.2.7.1 General

Mobile flowline and accessory equipment has wide usage within the oilfield where high-
pressure non-permanent flow paths for well fluids, kill fluids, stimulation fluids, and workover
fluids are required. Areas of use include well testing, well stimulation, well control and
workover operations.
The mobile flowline and accessory equipment referred to in this procedure includes:
 mobile flowline joints;
 chiksans - loops and swivels;
 manifolds and crossovers;
 check/plug valves.

All mobile flowline equipment shall be rated for 70,000 kPa (10,000 psi) maximum allowable
working pressure (MAWP) and sour service except for the flowlines used for interconnecting
well testing equipment downstream of the choke manifold that need only be rated for 35,000
kPa (5,000 psi).
All hammer unions fitted to mobile flowline equipment shall be of figure 1502 design and be
butt-welded or integral forged.
The Exploration Well Test Units have mobile vent and flare lines that are made from used 3½
inch and 4½ inch EUE tubing with 3 inch and 4 inch figure 602 hammer unions with MAWP
of 14,000 kPa (2,000 psi).
All pumping equipment from the check valve to the Xmas tree shall be rated for 70,000 kPa
(10,000 psi) MAWP and sour service. Equipment from the pumps to the check valve need not
meet the H2S requirement.
The WPH kill pump has a maximum pressure rating of 21,000 kPa (3,000 psi) and is protected
by a relief valve. Therefore, the MAWP rating for WPH kill lines and any wellhead that the
WPH will rig up on is 21,000 kPa.
All equipment shall be fitted with safety snubbing lines through clamps. These lines shall be
of sufficient strength to withstand impact load if failure of equipment occurs and shall be
inspected as lifting equipment.

2.2.7.2 Material Specification

New equipment shall be purchased against design and fabrication codes such as ANSI B31.1
or similar recognised specifications. All equipment shall be suitable for sour service in
accordance with:
 NACE MR0175-90 “Standard Sulphide Stress Cracking Resistant Metallic
Materials For Oilfield Equipment”.

Quality control shall follow BS 5750 “ Quality Systems” Part 1 or similar specifications.

2.2.7.3 Equipment Identification

Tagging

All equipment shall be identified by means of a stainless steel band, attached to individual
items, containing the following information:
 identification number;
 working pressure;

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 9 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

 sour service (if applicable);

 date of last full inspection.
The steel band shall be at least 20 mm wide, free moving and of such construction that it
cannot be removed from the item without cutting.

Colour Codes for Pressure and Service Rating

All equipment shall have its base colour denoting the equipment pressure rating.
 for 70,000 kPa (10,000 psi) rating this shall be BLACK with a 1 metre WHITE
band in the centre of each joint;
 for the 10,500 kPa (1,500 psi) with the exception of Well Test vent and flare lines,
the base colour shall be BLACK.
All equipment having a service rating for H2S shall be painted with a 10 cm circumferential
ORANGE band; for flowlines at their mid length, and at the pin end for all accessories.

2.2.7.4 Inspection Requirements

General

A third party inspector shall inspect and certify new equipment. Full documentation shall
include, but not be limited to material physical/chemical properties, hardness and full material
traceability.

Initial Equipment Acceptance

This shall require full documentation of:-

 visual inspection;
 ultrasonic wall thickness measurements;
 magnetic particle inspection of all welded/forged sections;
 hydrotests;
 material certification to NACE MR0175-90

Equipment Re-certification

For PDO owned equipment, full inspection for all equipment re-certification shall be carried
out annually by PDO, or a recognised third party, and comply with API Recommended
Practices or similar codes of practice.
For Contractor owned equipment, full inspection carried out by the contractor with a certified
inspection system or certified third party.
Requirements of the re-certification are:
 visual inspection;
 ultrasonic wall thickness measurement at key points;
 magnetic particle inspection of all welded/forged sections;
 hydrostatic test to rated working pressure.
Chiksans, manifolds, check valves, plug valves, etc., shall be disassembled during full
inspection to visually check all parts and to replace elastomers. Valves shall be function and
leak tested at rated working pressure.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 10 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

Interim Inspection

A six-monthly inspection of all equipment, limited to visual and wall thickness checks, shall
be carried out by PDO or a recognised third party. This inspection may be carried out at work
site.
Additional monthly visual recorded inspections of all equipment shall be performed by the
user as part of routine planned maintenance.
Note: Any equipment unable to meet the inspection requirements shall be immediately
removed from service.

2.2.7.5 Documentation

A complete set of initial equipment acceptance documentation shall be held by the user.
The user shall also keep service and inspection records of each PDO owned item in EPMARS
and copies of re-certification and interim inspection documents on file, available for
immediate inspection.
Service companies shall maintain similar records to the above, available for immediate
inspection by PDO whenever required.

2.2.7.6 Inspection Details

Annual Re-certification

The following actions shall be undertaken:

1. Swivels shall be fully disassembled and rebuilt.
2. Visual inspection of external surfaces for wear, cracks and damage.
3. Visual inspection of internal surfaces for erosion.
4. Visual inspection of unions for damage and cracks
5. Check rotation of swivel for roughness.
6. Ultrasonic wall thickness inspection – maximum erosion allowable is 20% of
nominal wall thickness.
7. Magnetic particle inspection of welds.
8. Pressure test to rated working pressure.

Annual inspection shall be carried out at a PDO approved workshop.

6-Monthly Re-certification

Items 2 to 6 above shall be carried out on all equipment, this inspection may be carried out on
the work site.

Monthly visual inspection

Items 2 to 5 above shall be carried out on all equipment, this inspection may be performed on
site.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 11 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

Pipe

All pipe shall be inspected for erosion, cracks and damaged threads. The pipe shall then be
checked with the ultrasonic wall thickness tester at each end and the middle, to ensure that the
wall thickness is within the limits given in ANSI B.31.3, e.g. for 4130 low alloy steel sour
service pipe rated for 70,000 kPa WP and 300° F:

PIPE SIZE MINIMUM WALL THICKNESS

2" 0.220"
3" 0.330"

On parts where wear limits are not known, the limit for allowable wall thickness shall be taken
as 20% of the new wall thickness.
Pipe must be pressure tested to MWP. Union welds shall be inspected with MPI.

Valves

All valves shall be visually inspected for erosion, cracks and damaged threads. The valves
shall then be operated and sealing surface check for pitting and repaired as necessary.
The male sub end shall be checked with an ultrasonic thickness tester and the unit pressure
tested to working pressure.

Check Valves

Check valves shall be visually inspected for erosion, cracks and damaged threads. Check
valves must be stripped down and the sealing mechanism checked and repaired as necessary.
The valve body and the check mechanism must be pressure tested alternately to working
pressure. The male sub end shall be checked with an ultrasonic thickness tester.

Manifolds

The discharge arms shall be removed Manifolds, the unions disconnected and they shall be
checked internally, using a light, for excessive erosion.
The complete manifold shall be checked externally for any signs of cracks or wear on union
ends. The manifold shall then be checked with an ultrasonic thickness tester and pressure
tested to the MWP.

Loops and Swivels

Loops and swivels shall be visually inspected for erosion, cracks and damaged threads. The
swivels shall be disassembled and the parts checked with the ultrasonic thickness tester to
limits shown below:

WALL THICKNESS
CHICKSAN SIZE AS NEW MINIMUM

2" 0.450" 0.330"

3" 0.530" 0.420"

The unit shall then be pressure tested to the MWP. Union welds shall be inspected with MPI

Tees, Y’s, Laterals and Crossovers

Tees, Y’s, laterals and crossovers shall be visually inspected for erosion, cracks and
damaged threads. They shall then be checked at the male sub end with an ultrasonic
thickness tester to limits shown below:

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 12 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

WALL THICKNESS
SIZE AS NEW MINIMUM

2" 0.480" 0.360"

3" 0.540" 0.400"

The wear limits for segmented male subs shall be used to check Tee’s Y’s laterals and machine
crossovers.
The units shall then be pressure tested to MWP.

2.2.8 Audit of Contractor’s Equipment

2.2.8.1 Initial Mobilisation Audit

The Company shall, as and when notified by the Contractor that the Initial Mobilisation is
complete, conduct an audit of equipment and personnel at the field base or any other mutually
agreed location.
A Safety Management and Inspection (SMI) system should be in place to facilitate audits.
The audit shall evaluate and verify:
 certificates and associated documentation;
 quantity, type and operational status of equipment;
 availability of equipment and personnel to meet the required Well Services
resources;
 availability and operational status of site facilities;
 number and approval of personnel;
 implementation of the computerised database management system;
 implementation of HSE procedures and availability of HSE equipment.

The Contractor shall, to facilitate such an audit, ensure that approvals, documentation and
certificates are obtained and the equipment and personnel are mobilised well in advance of the
Commencement Date.

2.2.8.2 Certificates and Other Documentation

The Contractor shall obtain the approval of the Company for the following certificates and
documentation. Approvals shall be a necessary condition for satisfactory mobilisation.
 Certification of all pressure containing or load bearing equipment and
manufacturer's certificates on all equipment.
 Personnel and job descriptions.
 Safety plan and documentation, including certificates showing that all
personnel have been instructed in and have satisfactorily passed all safety
procedures and drills.

2.2.8.3 Callout Mobilisation

Where equipment and personnel required for a Callout have not been audited in particular call
off equipment and associated personnel and replacement equipment and personnel, all such
equipment and personnel shall be separately audited by the Company prior to mobilisation to
the well site.

These further audits shall evaluate and verify:

 certificates and associated documentation;
 quantity, type and operational status of equipment;

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 13 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

 approval of personnel;
 implementation of HSE procedures; and
 availability of safety equipment.

For each Callout, the Contractor shall be responsible to provide principal equipment and
personnel detailed in the Callout Order and to ascertain and to provide all additional
equipment and personnel deemed necessary to satisfactorily execute the required service at the
well site.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 14 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

2.3 Identified Hazards/Threats

The hazards or threats which have been identified as being prevalent during the process covered by this
procedure are shown in Appendix D. The related hazards or threats and the controls to be applied are
given in the Hazards Register, which forms section 5.9 of the “Well Engineering Combined Operations
V1&V2 GU-458”.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 15 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

2.4 Roles and Responsibilities

2.4.1 Equipment User

The equipment user, be it PDO or Contractor, is responsible for ensuring that all equipment
used is fit-for-purpose and properly certified.
The user is responsible to offer the equipment for full inspection at an earlier time than
normally scheduled when it has been used under severe conditions i.e. high gas flow rates,
sand production, high H2S and C02 concentrations etc.
The user shall co-ordinate inspection, testing and maintenance of equipment with other
relevant parties and maintain full documentation.
The user is also responsible for having sufficient spare parts available.

2.4.2 Contractor

The Contractor is responsible for providing equipment as required by the service contract that
satisfies the standards detailed in this procedure with regard to:
 identification tagging;
 material specifications;
 inspection and testing;
 certification.

Under no circumstances shall Equipment be provided, or be used in the performance of Well

Services operations for which design and material Specification and certification are absent or
expired.
The Contractor shall keep certification and inspection/testing records of all equipment,
including manufacturer's certification, design and material specification certification, which
shall be made available to the Company as required.
The Contractor shall maintain documentary evidence and/or computer records in an SMI
system or similar.

2.4.3 PDO Well Services Representative

The PDO Well Services Representative shall conduct audits of equipment and respective
documentation at the field base or any other mutually agreed location, as required.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 16 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

2.5 Related Forms and Reports

2.5.1 Inspection, Testing and Certification Documentation

The Contractor shall keep all certification and inspection/testing records of all equipment on
the basis of a unique equipment code.
All such documentation, including manufacturer's certification, design and material
Specification Certification, shall be made available to the Company at Initial Mobilisation and
at other times on demand.
Subsequent re-certification documentation and inspection reports shall, be made available
within one month after re-inspection.

2.5.2 Two-Monthly Hoist Inspection Report

The Contractor shall submit a Well Pulling Hoist Inspection Report, in a format approved by
PDO, every two months giving details of the routine inspection carried out on the hoist.
This will normally be produced by the contractor’s SMI system.

2.6 Related Business Control Documents

Document Co. No.
Wellhead and Xmas Tree Equipment, API Spec 6A
Boiler and Pressure Vessel Code of Practice, Section ASME
VIII, Division
Quality Systems, Part 1 BS BS 5750
Standard Sulphide Stress Cracking Resistant Metallic NACE MR0175-90
Materials for Oilfield Equipment, 1995
Drilling Equipment Inspection Manual PDO DRS 130-05
Code of Practice for the Inspection of Static PDO ERD-07-01
Equipment
Methods for Non-Destructive Testing PDO ERD-07-02
Lifting Equipment Specification PDO SP-1239
Material Selection – Sour Service PDO SP-1146
10. Wireline Operations PDO PR-1482
11. Well engineering combined operations PDO GU-458
12. Pressure Relief, Emergency De-pressurizing and SIEP DEP 80.45.10.10
Flare Systems

For a complete listing of all business control documents, related to Well Services Activities,
refer to the following document, which should be used in conjunction with this procedure:
 PR-1446 “General Operational Safety”, Section 2.2.

2.7 Review and Improvement

As this document is a live working document, it will be reviewed on a continuous basis and
updated to incorporate any major amendments as necessary resulting from changes in current
activity and/or changes in responsibility effected by reorganisation within PDO as soon as
practicable. It will be formally reviewed on an annual basis and any improvements and/or
minor amendments will be incorporated at this stage.
Any person discovering discrepancies or inadequacies in this document should report them to
TWX/6, for inclusion in the next update, using the ‘User Feedback Form’ included in this
document as Appendix. B

2.7.1 Well Services Procedure Variance Form

A Well Services Procedure Variance Form will be prepared by any person requesting a change
or amendment to this Procedures for any reason whatsoever.
The form will give details of the proposed amendment to this document together with a reason for the
proposal.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 17 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

The form shall be approved by the line section head, or Well Services Contract Holder in the case of
proposals submitted by the Contractor.
The TWX/6 who is Document Custodian, will authorise, prioritise and co-ordinate the amendments.

PR-1102 “Variance Control and Amendment”

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 18 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

2.8 Step-out and Approval

Well Services Operations are conducted following close liaison between the PDO Well
Services and the Contractor, who is bound by service contract
Well Services work, by its very nature, is open to several hazards and it is therefore necessary
to exert stringent controls on the quality of equipment used in order to minimise the risk and
consequences of failure.
However, it is recognised that deviations from standard procedures are required under special
circumstances and in order to rectify unplanned occurrences.
Any deviation requires authorisation by the TWX/6 or authorised delegate, who will discuss
the circumstances and consequences with the Contractor concerned, prior to giving his
approval.

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 19 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

Appendices
A Glossary of Terms, Abbreviations & Definitions

Term/Abbreviation Definition

ASME American Society for Mechanical Engineers

ASTM American Society for Testing Materials
CDFP Corporate Discipline Focal Point (as designated by
Section Head)
TWX/6 Senior Well Engineering Exploration Frac & Testing
Livelink Electronic Document Database on PDO web site
EPMARS Exploration & Production Administration & Reporting
System
EUE Externally Upset Ends (tubing)
ID Identification
MAWP Maximum Allowable Working Pressure
MPI Magnetic Particle Inspection
NACE National Association of Corrosion Engineers
NDE Non-Destructive Examination
NDT Non-Destructive Testing
SMI Safety Management and Inspection (system)
SSC Sulphide Stress Cracking
UWT Ultrasonic Wall Thickness
WP Working Pressure
WPH Well Pulling Hoist

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 20 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 21 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

B User Feedback Form

WELL SERVICES OPERATIONS PROCEDURES

USER FEEDBACK FORM

Any user who identifies an error, inaccuracy or ambiguity in these Operations Procedures documents is
requested to advise the TWX/6, by returning this page (or a copy) with their comments.

Document ID: PR-1454

Title: Inspection and Certification of Well Services Equipment

Procedure

SECTION NUMBER COMMENTS/ERRORS/SUGGESTIONS

FURTHER RECOMMENDATIONS:

New Procedure Required Yes / No

User Name: Ref. Ind:

Signed: Date:

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 22 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

C STEP-OUT APPROVAL FORM

Well Engineering Specification and Procedure

STEP-OUT APPROVAL

Requestor (SWE): Ref:Ind: Date

STEP-OUT Requested:

Reason:

Risk Mitigating
Action(s)

Agreed:

Agreed
TWX/6: _______________________________

Aprroved
TWM: ______________________________

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 23 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

D Identified hazards/threats

D.1
Hazard Top Event Potential Consequences Some Principle Control and Recover / Potential Risk
Haz Mitigation Measures (*note – not all listed)
No.(s) P A E R

H-01.02a Hydrocarbons in Loss of Well Injuries and fatalities Supervision, Procedures, Well Program, Training, D D D D
Formation / at Control / Blowout ERP, MEDEVAC, Medical Facilities 4 0 0 4
Surface (drilling ops)
Release with ignition resulting Instrumentation, Well Program, Training, Surveys, D D D D
in fire Fire Fighting Equipment, SSSV, ERP/BCP 4 4 3 4
Unignited release Well Program, Monitoring Equipment, Training, D D D D
LSA, ERP/BCP, Snubbing Equipment, SSSV 3 3 3 4
H-01.02b Hydrocarbons in Loss of Well Injuries and fatalities Training, Supervision, Well Program, Equipment D D D D
Formation / at Control / Blowout Selection, Procedures, MEDEVAC, ERP 4 0 0 4
Surface (well
Release with ignition resulting Instrumentation, Well Program, Training, Material D D D D
services)
in fire Selection, Fire Fighting Equipment, SSSV, ERP 4 4 3 4
Unignited release Monitoring Equipment, Procedures. Training, D D D D
Control of Ignition Sources, LSA, ERP, Shutdown 3 3 3 4
H-02.03 Diesel Fuel (fuel Loss of Injuries and fatalities PTW, Toolbox Talks, Training, Procedures, PPE, C C C C
source) Containment MEDEVAC, Medical Facilities, ERP 4 0 0 4
Release with ignition resulting Training, Lifting Restrictions, PTW, Detection, Fire C C C C
in fire Fighting Equipment, ERP 4 3 3 4
Unignited release Storage Requirements, PTW, Control of Ignition C C C C
Sources, ERP, Training, Detection 2 2 4 3
H-04 Explosives Uncontrolled Damage to well PTW, Training, Procedures, ERP, Communications C C C C
Detonation 0 5 3 4
Injuries and fatalities Procedures, Storage Requirements, PTW, Toolbox C C C C
Talks, Training, MEDEVAC, PPE, Restricted 5 0 0 4
Access

H-05.01 Bottled Gases Under Release of Asset damage Training, Storage Requirements, Bottles Secured D D D D
Pressure Contents Under 0 3 0 0
Pressure
Environmental damage Certified Equipment, Storage Requirements, Shut- D D D D
off 0 0 3 2
Injuries and fatalities Trained, Supervision, Procedures, MEDEVAC, ERP D D D D
4 0 0 4

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 25 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

D.2

Haz Hazard Top Event Potential Consequences Principle Control and Recover / Mitigation Potential Risk
No.(s) Measures
P A E R
H-05.04a Air Under High Uncontrolled Direct impact resulting in severe Training, STOP, Procedures, Supervision, PRV, C C C C
Pressure (drilling ops) Release injuries / fatality Maintenance, ERP, MEDEVAC, PPE, Medical 4 0 0 4
Facilities

High energy missiles resulting in Material Selection, Maintenance, Equipment C C C C

injury fatality Selection, Procedures, MEDEVAC, PPE, ERP 4 0 0 4
H-05.04b Air Under High Uncontrolled Direct impact resulting in severe Training, PRV, Procedures, PTW, Supervision, C C C C
Pressure (well Release injuries / fatality Maintenance, ERP, PPE, MEDEVAC, Medical 4 0 0 4
services) Facilities

High energy missiles resulting in Material Selection, Maintenance, Equipment C C C C

injury fatality Selection, Procedures, MEDEVAC, PPE, ERP 4 0 0 4
H-05.07a Fluids Under High Uncontrolled Asset damage Dampeners, Equipment Selection, Maintenance, C C C C
Pressure (drilling ops) Release Procedures, Shut-Off Facility, Equipment Design 0 3 0 1
Environmental damage Procedures, Training, Equipment Selection, Clean-Up C C C C
Equipment, Shut-Off Facility 0 0 3 2
Injuries and fatalities Training, Procedures, Standardised Equipment, PPE, C C C C
MEDEVAC, Shut-Off Facility 4 0 0 4
H-05.07b Fluids Under High Uncontrolled Asset damage Dampeners, Equipment Selection, PRV, Maintenance, C C C C
Pressure (well Release Procedures, Shut-Off Facility 0 3 0 1
services)
Environmental damage Procedures, Training, Equipment Selection, Clean-Up C C C C
Equipment, Shut-Off Facility 0 0 3 2
Injuries and fatalities Standardised Equipment, Procedures, Training, PPE, C C C C
MEDEVAC, Shut-Off Facility 4 0 0 4
H-06.01a Personnel Working at Falling Person / Falling from height resulting in PTW, Training, Toolbox Talks, Procedures, Safety D D D D
Heights (drilling ops) Dropped Objects injury /fatality Harness, MEDVAC, ERP, Medical Facilities, 4 0 0 4
SCAFFTAG

Dropping tools resulting in asset Tool Lanyard, PTW, Training, Procedures, Critical D D D D
damage Equipment Protected 0 3 0 1
Dropping tools resulting in injury / Tool Lanyard, PTW, Training, Restriction in ‘Drop D D D D
fatality of personnel below Zone’, MEDEVAC, ERP, Medical Facilities 4 0 0 4

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 26 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

D.3

Haz No.(s) Hazard Top Event Potential Consequences Principle Control and Recover / Mitigation Potential Risk
Measures
P A E R
H-06.01b Personnel Working at Falling Person / Falling from height resulting in PTW, Training, Toolbox Talks, Procedures, Safety D D D D
Heights (well service) Dropped Objects injury /fatality Harness, MEDVAC, ERP, Medical Facilities, 4 0 0 4
SCAFFTAG

Dropping tools resulting in asset Tool Lanyard, Procedures, Supervision, PTW, D D D D

damage Critical Equipment Protected 0 3 0 1
Dropping tools resulting in injury / Tool Lanyard, Procedures, PTW, Training, D D D D
fatality of personnel below Restriction in ‘Drop Zone’, MEDVAC, ERP, Medical 4 0 0 4
Facilities

H-06.01c Personnel Working at Falling Person / Falling from height resulting in Training, Braking System, Procedures, D D D D
Heights (man riding Dropped Objects injury /fatality Communication, Harness, MEDEVAC, ERP 4 0 0 4
winch)
Dropping tools resulting in asset Tool Lanyard, Supervision, Procedures, PTW, D D D D
damage Critical Equipment Protected 0 3 0 2
Dropping tools resulting in injury / Tool Lanyard, Procedures, PTW, Training, Harness, D D D D
fatality of personnel below Restriction in ‘Drop Zone’, MEDEVAC, ERP 4 0 0 4
H-06.02 Personnel at Height <2m Tripping / Slipping Severe injuries Housekeeping, Training, STOP, Procedures, Pre- D D D D
– Slippery / Uneven / Falling Job Planning, PPE Requirements, MEDEVAC, 3 0 0 0
Surfaces Medical Facilities

H-06.03a Overhead Equipment Loss of Control of Asset damage Training, Maintenance, PTW, Procedures, Braking D D D D
(drilling ops) Loads System, Protection of Critical Equipment, 0 4 0 2
Restrictions

Injuries and fatalities Training, Procedures, PTW, Supervision, PPE, D D D D

Restrictions in ‘Drop Zone’, MEDEVAC, ERP 4 0 0 4
H-06.03b Overhead Equipment Loss of Control of Asset damage Training, Maintenance, PTW, Procedures, Braking D D D D
(well services) Loads System, Protection of Critical Equipment, 0 4 0 2
Restrictions

Injuries and fatalities Training, Procedures, PTW, Supervision, PPE, D D D D

Restrictions in ‘Drop Zone’, MEDEVAC, ERP 4 0 0 4
H-06.03c Overhead Equipment Loss of Control of Asset damage Maintenance, Training, Procedures, PTW, Braking D D D D
(crane, forklift, air winch Loads System, Protection of Critical Equipment, 0 4 0 2
ops) Restrictions

Injuries and fatalities Colour Code System, Training, Procedures, PTW, D D D D

STOP, Restrictions in ‘Drop Zone’, MEDEVAC, ERP 4 0 0 4

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 27 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

D.4

Haz Hazard Top Event Potential Consequences Principle Control and Recover / Mitigation Potential Risk
No.(s) Measures
P A E R
H-06.06 Elevated equipment Loss of Control of Equipment / asset damage Inspection, Procedures, Training, PTW, STOP, Racks C C C C
(tubulars on piperack Loads Layout, Stops at end of Rack, Protectors 0 4 0 4
or catwalk)
Injuries and fatalities Stacking Practice, Training, PTW, MEDEVAC, PPE, ERP C C C C
5 0 0 2
H-07.01 Objects under tension Release of stored Injuries and fatalities Procedures, Supervision, Training, PTW, MEDEVAC, C C C C
(wireline cable) energy PPE, ER P, Medical Facilities 4 0 0 4
Asset damage Maintenance, Equipment Selection, Training, Procedures, C C C C
Protective Cushion, Minimisation of Tension 0 3 0 2
H-08.01 Onland transport – Loss of control / Asset damage Monitoring Device, Fault Reporting, Training, Journey E E E E
onsite vehicles collision Management, Protection, Speed Restrictions, Site Layout 0 3 0 2
Injuries and fatalities Fault Reporting, Training, Journey Management, E E E E
Monitoring Device, MEDEVAC, Seatbelts, ERP, Medical 4 0 0 4
Facilities

H-08.05a Equipment with moving Entanglement / Personnel sustain injuries from Guarding, Training, PTW, Toolbox Talks, STOP, ERP, C C C C
/ rotating parts (ex drill missiles entanglement MEDEVAC, Shut-off Facility, Medical Facilities 4 0 0 4
floor equipment)
Personnel sustain injuries from Training, Maintenance, Guarding, Inspection, Equipment C C C C
missiles Selection, PPE, ERP, MEDEVAC, Medical Facilities 5 0 0 4
H-08.05b Equipment with moving Entanglement / Personnel sustain injuries as a MOPO, Housekeeping, Procedures, Training, PTW, PPE, C C C C
/ rotating parts (drill missiles result of being struck Guarding, MEDEVAC, Shut-off Facilities, ERP 4 0 0 3
floor equipment)
Personnel sustain injuries from Training, Procedures, Toolbox Talks, PTW, STOP, C C C C
entanglement Guarding, MEDEVAC, Shut-off Facilities, ERP 4 0 0 3
Damage to critical operation Training, Maintenance, Inspection, PTW, Guarding, Shut- C C C C
and safety equipment off Facility 0 5 0 2
H-08.06 Use of Hazardous Accident Using Personnel injury Training, Built-in Safety Features, Procedures, Work E E E E
Hand Tools Hand Tools Secured, PPE, MEDEVAC, Medical Facilities, ERP 2 0 0 2
H-08.09 Moving or Rotating Loss of Control of Asset damage Procedures, Standardised Equipment, Load Limiting D D D D
Equipment (drill floor) Equipment Devices, MOPO, Inspection & Certification, Shut-off 0 4 0 2
Facility

Injuries and fatalities Procedures, Training, PTW, Inspection & Certification, D D D D

MOPO, MEDEVAC, Shut-off Facility, Personnel 5 0 0 4
Restriction, ERP, Medical Facilities,

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 28 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

D.5

Haz Hazard Top Event Potential Consequences Principle Control and Recover / Mitigation Potential Risk
No.(s) Measures
P A E R

H-13.02 Liquid Nitrogen Loss of Contact resulting in severe Handling Procedures, Training, MSDS, Toolbox Talks, C C C C
Containment burns Handling Equipment, PTW, PPE, ERP, MEDEVAC 4 0 0 2
Formation of high oxygen Storage Procedures, Ventilation, Purpose Built C C C C
atmosphere resulting in fire / Containers, Ignition Control, Fire Fighting Equipment, 5 4 4 4
explosion ERP

Spillage on steel resulting in Storage Procedures, Purpose Built Containers, Training, C C C C

structural failure Handling Procedures, Detection 0 5 0 3
H-15.02 Voltage >50 to 440V in Contact with Injuries and fatalities Isolation Procedures, PTW, Training, Maintenance, D D D D
Equipment Electricity Testing, Failsafe Devices, Overload Shut-off, ECBs, 4 0 0 4
MEDEVAC, PPE, ERP

H-15.03 Voltage >440 Volts Contact with Injuries and fatalities Procedures, PTW, Training, Toolbox Talks, STOP, C C C C
Electricity Supervision, Overload Shut-off, MEDEVAC, PPE, ERP 3 0 0 2
H-17 Open Source Radiation Release of Contamination of reservoir or Procedures, Purpose Built Storage Containers, PTW, C C C C
Radioactive aquifer resulting in poisoning Training, Discharge Procedures, Monitoring Program, 3 0 5 5
Sources Water Testing Program, Lining to Prevent Ground
Seepage

Excessive exposure resulting in Training, Handling Procedures, Shielding, Purpose Built C C C C

immediate health problems Storage Containers, Health Monitoring Program, PPE, 5 0 0 4
MEDEVAC, Medical Facilities, ERP

Long term health problems Handling Procedures, Shielding, Purpose Built C C C C

Containers, Health Monitoring Program, PPE 4 0 0 2
H-18 Closed Source Release of Contamination of reservoir or Storage \Procedures, Training, Supervision, Inspection C C C C
Radiation Radioactive aquifer resulting in poisoning and Certification of Storage Containers, Discharge 3 0 5 5
Sources Procedures, Lining to Prevent Ground Seepage, Water
Testing Program

Excessive exposure resulting in Training, Handling Procedures, Inspection and C C C C

immediate health problems Certification of Storage Containers, PPE, MEDEVAC, 5 0 0 4
Medical Facilities

Long term health problems Training, Supervision, Handling Procedures, Health C C C C

Monitoring Program, PPE Requirements 4 0 0 4
H-19.01 Insufficient Oxygen Asphyxiation Heat exhaustion Natural and Forced Ventilation, Temperature Checks Prior D D D D
Atmosphere – to Entry, Supervision/Buddy System, Work Regime, Fluids 3 0 0 1
Confined Space Entry Available, Medical Facilities, Rescue Capabilities

Loss of consciousness with Training, PTW, Supervision/Buddy System, Remote C C C C

potential fatality Clean-out, Ventilation, Pre-Entry Gas Detection, Isolation 4 0 0 2
Procedures, Rescue Capabilities, ERP, PPE, Evacuation
Training

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 29 Aug. 2004
Rev. 3 Inspection and Certification of Equipment Procedure

D.6

Haz Hazard Top Event Potential Consequences Principle Control and Recover / Mitigation Potential Risk
No.(s) Measures
P A E R

H-20.01 Hydrogen Sulphide Toxic Gas Release with ignition resulting Training, PTW, Instrumentation, Restoration Checks C C C C
Release in fire following Maintenance, Procedures, Fire Fighting 5 4 3 4
Equipment Available, ERP, Drills and Exercises

Injuries and fatalities PTW, Training, Procedures, Monitoring, Buddy System, C C C C

Emergency Drills and Exercises, H2S Escape Sets, ERP, 5 0 0 5
Medical Facilities, MEDEVAC

Unignited toxic vapour cloud Procedures, Training, Monitoring, Inspection and D D D D

Maintenance, Prior Identification of Sour Well, Control of 4 0 2 4
Ignition Sources, ERP, Emergency Drills and Exercises

H-23.01 Hydrofluoric Acid Loss of Formation of corrosive acid Chemical Management Procedures, Training, Handling C C C C
Containment fumes resulting in an Procedures, PTW, MSDS, Ventilation, PPE Requirements, 3 0 0 2
asphyxiation hazard Personnel Detection, Medical Facilities, MEDEVAC, LSA

Formation of hydrogen with Handling Procedures, PTW, Training, Storage C C C C

ignition resulting in fire Requirements, Material Selection, Ignition Sources 5 4 3 5
Controlled, Fire Fighting Equipment, ERP

Personnel contact resulting in Handling Procedures, PTW, MSDS, Training, Transfer C C C C

severe health effects Procedures, Emergency Shower and Eyewash Facilities, 3 0 0 2
Health Monitoring, MEDEVAC, Medical Facilities, PPE

H-23.02 Hydrochloric Acid Loss of Environmental damage Storage Requirements, Inspection and Certification of C C C C
Containment Storage Containers, MSDS, Handling Procedures, 0 0 4 3
Training, PTW, Discharge Procedures, Bunding, Ground
Testing Program, Lining to Prevent Ground Seepage

Formation of hydrogen with Handling Procedures, PTW, Training, Storage C C C C

ignition resulting in fire Requirements, Material Selection, Ignition Sources 4 4 0 4
Controlled, Fire Fighting Equipment, ERP

Personnel contact resulting in Handling Procedures, PTW, MSDS, Training, Transfer D D D D

chemical burns Procedures, Emergency Shower and Eyewash Facilities, 4 0 0 3
MEDEVAC, Medical Facilities, PPE Requirements

H-25.01 Manual Materials Loss of Control of Damage to equipment Manual Handling Procedures, Training, Restriction on E E E E
Handling Loads Lifting Around Critical Equipment, Equipment Protectors 0 3 2 2

Personal injury Training, Handling Equipment, Handling Procedures, PPE E E E E

Requirements, Medical Facilities, ERP 3 0 0 2

FOOT NOTE:
ALL INSPECTION CERTIFICATE WILL BE ATTACHED WITH A SKETCH OR
DRAWING SHOWING AREA INSPECTED
PR-1454 Page 30 Aug. 2004