EXP-PR-DI030-EN-R0_2 - Roles and Procedures.pdf

MISCELLANEOUS COURSES ROLES AND PROCEDURES

TRAINING MANUAL Course EXP-PR-DI030 Revision 0.1

Exploration & Production Miscellaneous Courses Roles and Procedures

MISCELLANEOUS COURSES ROLES AND PROCEDURES CONTENTS 1. OBJECTIVES ..................................................................................................................5 2. INTRODUCTION .............................................................................................................6 3. THE OPERATOR TRADE ...............................................................................................7 3.1. ROLE ........................................................................................................................7 3.1.1. Observation ........................................................................................................7 3.1.2. Action..................................................................................................................8 3.1.3. Monitoring ...........................................................................................................9 3.1.4. Reporting ............................................................................................................9 3.1.5. Conclusion ..........................................................................................................9 3.2. THE OPERATOR'S DIFFERENT TASKS ...............................................................10 3.2.1. General Description ..........................................................................................10 3.2.2. Description of the tasks ....................................................................................10 3.2.3. Functional links .................................................................................................11 3.2.4. Line Manager....................................................................................................11 3.2.4.1. The role of the Chief Operator....................................................................11 3.3. EXERCISES............................................................................................................13 4. THE OPERATOR'S MAIN ACTIVITIES .........................................................................14 4.1. OPERATOR INSPECTION TOURS........................................................................14 4.1.1. Who does the inspection tours?........................................................................14 4.1.2. What inspection tours on rotating equipment involves?....................................15 4.1.3. What to do? ......................................................................................................15 4.2. OPERATION ACTIVITIES.......................................................................................22 4.2.1. Sampling...........................................................................................................22 4.2.1.1. Operating precautions ................................................................................22 4.2.1.2. Marking the samples ..................................................................................22 4.2.1.3. Special procedure: Sampling .....................................................................23 4.3. Works follow-up.......................................................................................................24 4.3.1. Works carried out by off-site personnel (contracted or not) ..............................24 4.3.2. Works carried out by on-site personnel (contracted or not) ..............................24 4.4. MAINTENANCE ......................................................................................................25 4.4.1. Terms and Definitions.......................................................................................25 4.4.2. The maintenance concept ................................................................................25 4.4.3. Maintenance operations ...................................................................................26 4.4.4. Classification in terms of maintenance levels ...................................................27 4.4.5. 1st level maintenance .......................................................................................28 4.4.5.1. Definitions ..................................................................................................28 4.4.5.2. General Principles......................................................................................28 4.4.5.3. Production personnel duties.......................................................................28 4.4.5.4. Maintenance personnel duties ...................................................................29 4.4.5.5. 1st level maintenance of surface facilities ..................................................29 Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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4.4.6. Machine monitoring ..........................................................................................34 4.4.6.1. Noise ..........................................................................................................34 4.4.6.2. Temperature increases ..............................................................................35 4.4.6.3. Driving power consumption ........................................................................35 4.4.6.4. Operating characteristic tracking................................................................36 4.4.6.5. Vibrations ...................................................................................................36 4.4.6.6. Lubricants...................................................................................................37 4.5. EXERCISES............................................................................................................38 5. THE MAIN SAFETY RULES..........................................................................................43 5.1. WORK PERMIT.......................................................................................................44 5.2. WORK ON POWER-SUPPLIED SYSTEMS ...........................................................44 5.3. WORK IN CONFINED SPACES .............................................................................45 5.4. TRENCHING ...........................................................................................................45 5.5. WORK AT A HEIGHT..............................................................................................46 5.6. HOISTING...............................................................................................................46 5.7. VEHICLES ..............................................................................................................47 5.8. CHANGE MANAGEMENT ......................................................................................47 5.9. SIMOPS ..................................................................................................................48 5.10. DEGRADED SITUATIONS ...................................................................................48 5.11. EXERCISES..........................................................................................................49 6. WORK PERMITS...........................................................................................................51 6.1. GENERAL PRINCIPLES.........................................................................................51 6.1.1. Work Permit System .........................................................................................51 6.1.2. Content of the Work Permit Procedure .............................................................51 6.1.3. Work Permit Forms...........................................................................................52 6.1.3.1. Basic Contents ...........................................................................................52 6.1.3.2. Various Work Permit forms ........................................................................53 6.2. SCOPE....................................................................................................................54 6.2.1. General case ....................................................................................................54 6.2.1.1. When Cold Work Permits are used ............................................................54 6.2.1.2. When Hot Work Permits are used..............................................................54 6.2.1.3. When Confined Space Entry Permits are used ..........................................54 6.2.1.5. When other permits are used .....................................................................54 6.2.2. Exceptions – Works subjected to work orders ..................................................55 6.2.3. Exceptions – Works performed based on verbal instructions ...........................55 6.2.4. SIMOPS Work Permit System ..........................................................................56 6.3. OTHER DOCUMENTS AND PERMISSIONS .........................................................57 6.3.1. Document and permission validity ....................................................................57 6.3.2. Isolation ............................................................................................................57 6.3.2.1. Electrical isolation ......................................................................................57 6.3.2.2. Process or utility isolation...........................................................................58 6.3.2.3. Cutting and Welding Permit........................................................................58 6.3.2.5. Access permit.............................................................................................58 6.4. KEY PERSONNEL ..................................................................................................59 6.5. WORK PERMIT PROCESS ....................................................................................60 6.6. EXECUTION PHASE ..............................................................................................61 6.6.1. (Re)validation between shifts............................................................................61 6.6.2. Permit management during works ....................................................................61 Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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6.6.3. Suspension of works.........................................................................................62 6.6.4. Closing phase ...................................................................................................62 6.7. WORK PERMITS DETAILS ....................................................................................63 6.7.1. The "request" phase .........................................................................................63 6.7.1.1. The requestor.............................................................................................63 6.7.2. The worker........................................................................................................64 6.7.3. The "preparation" phase ...................................................................................65 6.7.3.1. Conditions encountered and precautions to be taken ................................65 6.7.3.2. Persons in charge / associated isolation and permits ................................65 6.7.4. The "approval" phase .......................................................................................67 6.7.5. The "execution" phase ......................................................................................68 6.7.6. The "acceptance" phase ...................................................................................69 6.8. WORK PERMIT TASKS REQUIRED OF THE OPERATOR...................................70 6.8.1. Permit Preparation............................................................................................70 6.8.2. PID Mark-Up .....................................................................................................70 6.8.3. Initial Permit Opening .......................................................................................73 6.8.4. Daily permit management activities ..................................................................73 6.8.5. Permit closing ...................................................................................................74 6.9. MOST COMMON ANOMALIES REPORTED .........................................................74 6.11. WORK PERMIT FORMS.......................................................................................75 7. GLOSSARY ...................................................................................................................84 8. SUMMARY OF THE FIGURES .....................................................................................87 9. SUMMARY OF THE TABLES........................................................................................88 10. CORRECTIONS FOR EXERCISES ............................................................................89

Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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1. OBJECTIVES


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2. INTRODUCTION In this course, we shall be addressing the role of the operators on the facilities. We shall demonstrate that this role is essential to ensure the proper operation of the facility, and more importantly, to ensure optimum safety and environment conditions. To perform their duties in good conditions, operators will often be required to use procedures and work permits. We will also be addressing these subjects in this course. This course describes the generalities associated with the operator trade, but the level of responsibility may differ slightly according to the site structure and the subsidiary company with which it is associated. This position is the starting point of the operation trade. As the operator develops skills in this position, he will become eligible for appointment as Head Operator or Supervisor.


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3. THE OPERATOR TRADE 3.1. ROLE As mentioned above, the role of the operator is of fundamental importance to the sites. He acts as the "eyes and arms" of the control room. Furthermore, he is entrusted with the monitoring of all of the unit facilities and personnel, who works and move from unit to unit. Owing to his responsiveness, the experience gained and his knowledge in practice and in theory, he ensures the safe and proper operation of the facilities he is assigned to.

3.1.1. Observation This is permanent role of capital importance. The purpose of observation is to: Prevent accidents and damage to equipment. The Operator is required to anticipate any problems that may occur, by being able to identify abnormal changes. To do so, he needs to observe any changes in equipment performance, filling levels, changes in noise, pressure, temperature and ∆p levels, leakage, etc. To ensure the proper operation of equipment. By recording the functional parameters of the facilities on site (meters, levels, recorders, etc), he is able to inform his line manager of any deviation. The Maintenance is then able to take the necessary preventive measures. Moreover, this observation role will enable the operator to anticipate any changes in the process and therefore to point out any process malfunction that may not have been observed from the control room. To check the equipment start-up and shutdown phases (for example: Pump change-over) To ensure the cleanliness of the facilities (for example: Cloths left hanging around, fire hose unravelled, etc.)


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3.1.2. Action The operator is required to perform a certain number of tasks on a daily basis as well as others on an ad-hoc basis, in the event of an emergency or facility servicing/repairs. These actions involve: Process: Within the framework of the "process", he is required to position valves during efficiency testing, when facilities are started-up and shut down, or at the request of the control room operators. He will be responsible for taking samples from wells being tested, finished products, sea releases, etc. These samples will be used to determine the proper or improper performance of the units, after laboratory analyses. He will check that the chemical product injection pumps operate correctly and the volumes injected. He will take part in new equipment or facility testing. He will carry out specific operations (for example: Pigging).

Maintenance: As regards maintenance, it is he who, trained by a Chief Operator, will make available the facilities he is entrusted with. Likewise, he is required to reactivate the facilities after having ensured the maintenance operations have been successful and after having checked the equipment or facility has been connected to the appropriate supply lines. He will perform the preventive maintenance tasks for which he is responsible. (For example: cleaning filters on the process).

Safety: He will take an active part in safety drills. He will be fully aware of the locations of the fire system devices and will know how to use them. He will know how to use his own safety equipment (evacuation respirator, self-contained breathing apparatus, as well as the firefighting equipment).


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3.1.3. Monitoring This is an important role for the operator as it is the means by which he will be able to detect any hazards. This monitoring duty is associated with a temporary activity. It concerns: The facilities The operator will perform his monitoring duties to prevent accidents during operations such as works (for example: grating not stored away once the works have been completed).

Personnel He will be in charge of monitoring the persons working on the site. He will ensure the equipment used by the works and maintenance teams conforms to the regulations. He will flag and control hoisting and gamma ray level gage operations. He will monitor newcomers and will contribute to their training by coaching them.

3.1.4. Reporting Reporting is one of the Operator's key roles. The report must be as clear and concise as possible. Correct implementation of the actions taken in response to the report depends on the accuracy of the report submitted.

3.1.5. Conclusion To carry out all of his roles successfully, the operator is required to draw on his own knowledge and experience regarding facilities. Moreover, owing to the physical and theoretical (physics, chemistry) knowledge gained during his training period, he will be unquestionably capable of performing all of these tasks.


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3.2. THE OPERATOR'S DIFFERENT TASKS In this chapter, we shall not only be addressing the operator's tasks, but also those of the Chief Operator (C.O.), to clearly distinguish the tasks incumbent on each. Moreover, the position of C.O. is directly above that of the operator. This means they will often be required to fulfil these duties during their career. The information that follows does not constitute a set of rules and may differ from one subsidiary to another.

3.2.1. General Description The operator is responsible for the production facility inspections carried out to make daily recordings and to adjust operating parameters. He is also responsible for maintenance and 1st degree response.

3.2.2. Description of the tasks Reactivating the facilities in accordance with the general operation and safety instructions. Recording the daily parameters and changing the charts. Drawing up the reports in the absence of the Chief Operator, writing the inspection reports. Adjusting the operating parameters according to instructions: Pressure, flow rates, temperatures, product injections. Performing maintenance and 1st degree response operations. Carrying out the scraper launching and acceptance procedures. Participating in safety tests. Ensuring the wells are tested in accordance with the schedule. Taking samples according to the operating instructions. Participating in the provisioning of equipment for works, in accordance with the safety instructions that he follows and ensures are adhered to by companies contracted for works. Performing safety equipment checks and maintenance. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Participating in the repairs of production equipment. Ensuring the cleanliness of the facilities. Checking and tracking chemicals. Participating in special SIMOPS. Participating in the start-up of new facilities. Collecting any information needed to draw-up specific reports as well as daily, weekly and monthly reports Notifying his superior of any anomalies detected.

3.2.3. Functional links The SCDAR personnel, the wire line operators, the contracted parties

3.2.4. Line Manager The Chief Operator or the Leadman 3.2.4.1. The role of the Chief Operator

General Description: The Chief Operator is responsible for ensuring proper facility operation and safety. The Chief Operator is responsible for all of the agents he is in charge of.

Description of the tasks: Monitoring, organising and checking the work of the operators under him. He may be required to perform tasks usually entrusted to his operators. Checking and signing the daily reports. Submitting requests for materials, tools and consumables. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Signing and managing work permits. In collaboration with his superior, being responsible for the safety and discipline of all of the personnel working on the facilities. In collaboration with his superior, stopping any works that prove to be hazardous to personnel or facilities. Being responsible for the cleanliness of the facilities. Checking the proper operation of the equipment and carrying out delicate tasks when anomalies have been detected on the facilities. Checking product injection adjustment Seeing to the write-up and forwarding of instructions Ensuring facilities are made available to companies subcontracted for works, in accordance with the work permits. Notifying his superior of any anomalies detected. If necessary, controlling the facilities locally or remotely using an NCS. Participating in special SIMOPS. Participating in the start-up of new facilities.

Functional links: The SCDAR personnel, the wire line operators, the contracted parties, the logistics, the works, the safety, the laboratory.

Administrative duties: Keeping a time-record of the personnel under him on the daily report Preparing specific reports as well as daily, weekly and monthly reports Participating in the assessment and training of his personnel

Line Manager: The Leadman or Foreman Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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3.3. EXERCISES 1. List the main roles of the operator:

2. Which of the tasks below are not incumbent upon the operator? Reactivating the facilities Recording the daily parameters Submitting requests for materials, tooling and consumables Adjusting the operating parameters according to instructions Performing maintenance and 1st degree response operations Signing and managing work permits Participating in safety tests Participating in the provisioning of equipment for works Checking and signing the daily reports Ensuring the cleanliness of the facilities


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4. THE OPERATOR'S MAIN ACTIVITIES 4.1. OPERATOR INSPECTION TOURS The equipment installed on a petrochemical site or a refinery is subject to wear, and even under normal operating conditions, wear is inevitable. This is one of the reasons for which the equipment needs to be monitored. Wear is heightened in these conditions, and may result in equipment breakdown with substantial consequences (leakage, fire risk, unavailability of equipment, unit shutdown, etc.) The conditions of equipment use may change and deviate from standard values of use (temperatures, pressures, product qualities) until they become completely abnormal (cavitation, unpriming, lack of lubrication, etc). The monitoring of equipment must enable rapid detection of operating incidents that are already apparent (packing, seal leakage, etc.) This is the part of the monitoring activity associated with safety. Rapid detection of abnormal operating conditions (process or mechanical) should enable the prevention of mechanical incidents. This is the part of the monitoring activity associated with prevention. Moreover, daily inspection tours enable the operator to report progress on machine availability (emergency pumps), to ensure equipment maintenance and servicing is adequate (filter clogging, etc.), to ensure the safety of the unit (odours, noise, leaks, etc) and to rapidly detect any operating anomaly (gland-oil obstructed, cavitation, etc). When performing his role of observation, it is important that the operator does several inspection tours, as he is required to memorise a number of observations, and will thus be able to notify his superior of any "abnormal" changes, even if he does not spot the origin of the phenomenon to begin with.

4.1.1. Who does the inspection tours? To smell H2S, hear a bearing roll, observe a joint leakage or touch the cooling water outlet pipe of a packing box, you need to be on the field. To witness the progress of certain parameters (intensity, pressure, etc), you need to be aware of the various parameters (process) and monitor them frequently.


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The operators on shift match these requirements, as monitoring has always constituted an important part of their duties. Systematic readings on critical machines remain the same in terms of both content and frequency. Those doing inspection tours will take these recordings as often as their unit routine requires. The difference lies in the way in which the rotating equipment is approached.

Figure 1 : Process pump

4.1.2. What inspection tours on rotating equipment involves? Nowadays: Inspection tours are done in all units, and the safety procedures carried out within the framework of these inspection tours has proven to be very effective. However, the detection of operating anomalies could be improved, by developing a more thorough understanding of the equipment (purpose of this course) Figure 2 : Rotating equipment: Pump

4.1.3. What to do? As regards the rotating equipment, while doing his tour, the operator is required to: Electric Motors o Touch the bearings to detect:

abnormal temperature

vibrations


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o Check the oil level of the bearings (and refill if necessary) o Identify any leakage. o Check to ensure the intensity has not exceeded the normal value (maxi). Figure 3 : Rotating equipment: Pump

Turbines Caution: Before any turbine is started up, purge the bearings (Presence of water) o Check:

The oil level of the bearings (and refill if necessary)

For vapour leaks on the gland packing

The lubrication oil pressure Figure 4 : Oil level

Centrifugal Pumps (All Types) o Machines in operation:

Check the overall sound level of the machine: (innate operator skills!) •

Bearing noise and vibrations

•

Cavitation noise (filter or process anomaly)

Check the suction filter - Perform pump change-over if necessary.

Check the temperature of he pump bearings (touch)

Check the bearing vibrations


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Check the oil level (and refill if necessary with the machine stopped)

Check there is no water in the bearings

Translucent purger (purge the water if necessary)

Identify any oil leakages.

Check the operating pressure, etc. Figure 5 : Centrifugal pump

o Machines shut down:

Check the oil level (and refill if necessary)

Check there is no water in the bearings

Translucent purger (purge the water if necessary)

Identify any oil leakages.

Check the reheating efficiency of pumps on heavy-end tail. (Move your hand closer: the heat radiates)

o Mechanical Packing (All Types)

Cooling of packing box: Check the efficiency of the cooling water systems (by touching).

Flushing : o Check the circulation of the product (by touching, CAUTION: hot products). o Check to ensure this system is always in use regardless of whether the machine is ON or OFF.

Sweep quench: o Check the setting, and adjust if necessary (light vapour cloud)

Safety quench:


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o This system must only be used in the event of a packing leak (dilution).

Figure 6 : Mechanical packing

o Liquid/Liquid double packing Or Pressurised Liquid/Liquid Tandem Packing

Sealing liquid pressurisation system: o Check the system pressure (value between the MIN and MAX). Values often indicated on the pressure gauge. o Refill if necessary using the make-up system (hand pump or hydraulic unit).

For packings on a network (continuous make-up), the pressure must be maintained at a fixed value. o Check the circulation of the sealing liquid (inlet/outlet temperature difference) o Check the efficiency of the sealing liquid cooling system.


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Figure 7 : Double packing Multistage Centrifugal Pumps o Check the axial displacement indicated by the shaft end lamp (should be in the middle position) o Check the equalisation pressure (P suction + 1 Bar)

Figure 8 : Multistage centrifugal pump Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Reciprocating Compressors o Check the efficiency of the cylinder cooling (touch the cylinder body) o Check the efficiency of the packing cooling (if any): o Check the lubrication oil pressure o Check the casing oil level (and refill if necessary) o Check the overall sound level o Check for packing leaks (touch the degassing vents) o Monitor the vibrations of adjoining piping (risk of support rupture) o Check the oil level and operation of the Quervel mechanical lubricator o Check the operation of the packing eductor (if any)

Figure 9 : Reciprocating Compressors


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Centrifugal Compressors o Check the axial displacement o Check the temperature of the bearings (particularly on the thrust side) o Check the sound level. o Check the casing oil levels (and refill if necessary) o Check for any lubricant oil leakages.

Cooling towers o Check the sound level (belt tension) o Check the temperature of vibrations of the motor bearings (touch)

Figure 10 : Cooling towers

Mixer Impellers o Check the sound level. o Check the temperature of the reducer bearings o Check for any packing leakages o Check the oil level

Figure 11 : Mixer Impellers


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4.2. OPERATION ACTIVITIES These activities involve complying with and fulfilling the orders issued by the control room or the Chief Operator. They include testing wells, isolating circuits, checking for proper valve operation, taking samples, etc. In this chapter, we will also describe the sampling methods to be used depending on the type of sample required. To perform these tasks, a thorough knowledge of the facilities is essential to be able to identify, locate and manoeuvre them. The Operator's responsibilities will continue to amplify over time. His tasks will become increasingly complex as his knowledge of the site develops.

4.2.1. Sampling 4.2.1.1. Operating precautions The Operator's meticulousness and judgement are required for every sample taking. Safety and hygiene: be very careful with the flammability and toxicity of products (breathing vapours, contact with skin) If possible, take the sample from the vessel which is to be dispatched. This operating method is essential for volatile products. Close the vessel as soon as possible after sampling is completed, and check it is sealed properly. For safety reasons and with respect to operating requirements, if the vessel is left open, specify the degassing time on the follow-up data sheet.

4.2.1.2. Marking the samples To identify the samples correctly, it is mandatory to use: The sampling label (to be filled in by the operator immediately); The follow-up data sheet (to be filled in by the Supervisor before the sample is dispatched for analysis). Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Comments: Use a stub notebook Label the vessel as soon as the sample has been taken, and number the sample. Put the label in a plastic pouch and attach it to the neck of the vessel (avoid sticking the label on the vessel itself). 4.2.1.3. Special procedure: Sampling The following recommendations must be adhered to when taking liquid sample from an effluent that may contain H2S: Wear integral chemical cartridge respirators around the neck, with the blind washer in position, or self-contained breathing apparatus. Wear a portable H2S detector, of the MICRO PAC HLS type, switched ON To avoid facing the wind Take samples following the normal procedure If the portable detector alarm sounds: Put the respirator on immediately (remember to remove the protection plug at the bottom of the cartridge) Ensure the sampling valve is closed properly Leave the area immediately, paying attention to the wind direction. Leave in the opposite direction Alert the Control Room A more accurate measurement of the H2S content will need to be taken at the sampling point. This measurement shall be taken by the SEO (safety and environment officer) equipped with a self-contained breathing apparatus. If this measurement confirms a H2S content > 10 ppm.v, the sample will need to be taken using a fresh air respirator (self-contained breathing apparatus, etc). Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Note: If a gas sample needs to be taken (in a PVT type bomb), the same procedure shall be applied, but operators are required to use self-contained breathing apparatus rather than a chemical cartridge respirator. Samples are to be stored outdoors, in a well-ventilated area, not indoors. Before taking the sample, ensure the detectors of the area concerned have been isolated, and the inhibition recorded in the relevant file. After taking the samples, do not forget to put back the safety devices correctly.

4.3. Works follow-up There are two types of works: Works carried out by off-site personnel (contracted or not) Works carried out by on-site personnel (contracted or not)

4.3.1. Works carried out by off-site personnel (contracted or not) In this case, the risk of accidents is increased as the personnel: Are not familiar with the facilities Are not always informed of the risks associated with the site Do not always react in a quick and self-sufficient way when problems arise. (For example: Closing a valve on their work site). For these reasons, it is essential that an Operator is present when works are carried out on site.

4.3.2. Works carried out by on-site personnel (contracted or not) Even if the intervening personnel are well aware of the rules and risks of each intervention, any "non-routine" works must be carried out in the presence of an operator who liaises between the workers and the control room. He must be ready to intervene at all times (anomaly during the activity). Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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He must act as an operational representative. He monitors activities visually and ensures the special safety conditions specified on the work permit are fulfilled. He ensures the works are carried out through to completion and that the area is properly cleaned (returned to its condition before the works).

4.4. MAINTENANCE In this chapter, we shall be covering the Operator's maintenance duties. We shall not only be addressing those incumbent upon the Operator, but also those for which maintenance is of capital importance, and for which it is imperative to respect the roles of each of the persons involved. The maintenance activities described below do not constitute standard rules, as they may differ according to site or subsidiary. Operators learn how to pinpoint problems and determine their origins through the maintenance activities they perform. Moreover, these activities confer responsibility upon the Operators, making their work more interesting.

4.4.1. Terms and Definitions The Maintenance is the organization that ensures the performance and service life of a production tool required to meet production schedules is optimised at minimum cost. The Maintenance is required to focus on ensuring the amount of equipment required to meet the production schedule and the operating costs involved are kept to a minimum. It also constitutes the measures taken to maintain or restore the specified condition of a piece of equipment, or to provide a given service at optimum cost.

4.4.2. The maintenance concept Predetermined criteria==> to reduce the probability of failure or deterioration. Preventive Maintenance: Maintain before it breaks! Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Systematic: operation log==> operation time Conditional: dependent on a revealing event type (sensor, wear, analysis of daily readings...)

Corrective maintenance: carried out after a failure

4.4.3. Maintenance operations Preventive maintenance operations: Inspection Checks Maintenance inspections Testing Corrective maintenance operations: Detection Localization Diagnosis Troubleshooting Repairs Improvement Other operations: Revision Reconditioning Reconstruction Modification Standard part replacement Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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4.4.4. Classification in terms of maintenance levels

FIRST LEVEL: Operating Company Action Simple adjustments recommended by the manufacturer using means accessible without dismounting or opening the equipment, that do not require tooling, or any specific spare parts.

SECOND LEVEL: Troubleshooting by standard replacement of parts provided for such and minor preventive maintenance operations carried out by an authorised technician, using the tooling specified in the maintenance procedures.

THIRD LEVEL: Fault identification and diagnosis Repairs by replacement of components or functional parts, made by a qualified technician, using the tooling specified in the maintenance procedures. These repairs are made either on site or in the workshops.

FOURTH LEVEL: All important corrective and preventive maintenance works except reconditioning and reconstruction, carried out by highly qualified personnel in specialised workshops equipped with the necessary specific tooling.

FIFTH LEVEL: Reconditioning, reconstruction or substantial repairs entrusted to a specialised workshop, carried out under the supervision of the manufacturer with the means defined by the latter.


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4.4.5. 1st level maintenance 4.4.5.1. Definitions Simple adjustments recommended by the manufacturer using means accessible without dismounting or opening the equipment, that do not require tooling, or any specific spare parts. These activities are usually incumbent upon the Operations department. 4.4.5.2. General Principles The production personnel have full control of their own facilities, whether directly associated with the extraction, treatment or movement of effluents, or whether they contribute indirectly to these processes by providing the necessary energies and utilities. The Maintenance ensures the follow-up of surface equipment condition, informs Production of results, and takes the appropriate steps. 4.4.5.3. Production personnel duties The production personnel perform all management operations, for which they are required to have obtained the necessary skills and training. Production personnel are provided with adapted documentation: operating instructions and operating methods. Normal management operations namely include periodic emergency equipment testing and the change-over of redundant equipment. The participation of other departments is recommended if it is deemed judicious in terms of facility safety and reliability. The production team assumes full responsibility in this case. The production team monitors facilities and their equipment using instruments they keep at hand at all times. If necessary, the maintenance team can provide support and assistance using additional temporary means. To ensure operational reliability, maintenance specialists repeat their recommendations, giving instructions and requesting special procedures whenever appropriate.


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They perform 1st level maintenance tasks for which they give specific updated procedure instructions. Tasks may differ according to the degree of line automation. Preventive measures regarding production and maintenance are managed using operation schedule lists and routing sheets on OPTIMIS software. 4.4.5.4. Maintenance personnel duties All other operations on facilities in use are carried out under the responsibility of the maintenance team, using their specific means. The production team is required to grant authorization for these operations by issuing a work permit or a work request. If, under particular circumstances, a SCDAR contract has been drawn up (SubContract with Duty to Achieve a given Result): The MC handles 1st level maintenance, with the exception of the process facilities for which the Operating Company is responsible. 4.4.5.5. 1st level maintenance of surface facilities As we have just seen, the role of the operator also involves maintenance tasks. We are now going to describe the maintenance tasks that fall within the scope of the Operator's duties. These activities will be described in terms of the facilities involved.

Wellheads and wells: Valve lubrication Instrument inspection Bolting maintenance Cabinet maintenance Hydraulic panel maintenance Monitoring of parameters Monitoring of annular spaces Chemicals injection Product inventory management Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Replacement of chokes and auto choke checks Sampling

WELLHEADS OPERATIONS Valve lubrication Instrument inspection Bolting maintenance ESDV, SSV, ROV maintenance Cabinet maintenance SCSSV hydraulic control maintenance

1st level maintenance 1st level maintenance 1st level maintenance 1st level maintenance 1st level maintenance 1st level maintenance

ACTIONS Production Production Production Production Production Production

Table 1: Wellhead maintenance

Capacities: Separators, Desalters, Scraper traps, Settlers, Floatation chemicals, Sump Caisson, Purge tank, Scrubber, Vacuum tower, Hydrocyclone, Filters Cleaning of gauge glasses Cleaning of recorders Cell purging Controller lubrication Leakage checks Manual valve lubrication Zero checks Plant air checks Outlet manipulation Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Loop testing Replacement of gauges Chemicals injection Product inventory management

SEPARATORS OPERATIONS

ACTIONS

Cleaning of gauge glasses

1st level maintenance

Production

Cleaning of recorders


Production

Cell purging


Production

Controller lubrication


Production

Monitoring

Production


Production

Zero checks

Monitoring

Production

Plant air checks

Monitoring

Production

Line

Production

Maintenance

Maintenance

Monitoring

Production

Maintenance

Maintenance


Production

Leakage checks Manual valve lubrication

Outlet manipulation Instrument calibration Loop test Loop checks and adjustment Replacement of gauges

Table 2: Example of capacity maintenance


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Heat engines: Periodic tests Fuel management Water and oil level checks Start-up system checks

HEAT ENGINES OPERATIONS

ACTIONS

Monitoring

Pro. / Maint.

Line

Production

Water and oil level checks

Monitoring

Production

Start-up system checks (air, battery)

Monitoring

Production

Maintenance

Maintenance

Periodic tests Fuel management

Periodic maintenance (draining, filters, injector setting)

Table 3: Heat engine maintenance


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Rotating machines: Shutdown, start-up, speed change, checks: Noise, Vibrations, Leaks, Temperatures, Filters, Levels Performance parameter recording ROTATING MACHINES (in general)

Shutdown, start-up, speed change Noise, vibration, leak, temperature, filter, level checks Performance parameter recording Status parameter recording

OPERATIONS

ACTIONS

Line

Production

Monitoring

Production

Line

Production

Monitoring

Production

1st level maintenance 1st level maintenance

Oil make-up Lubrication

Production Production

Draining

Maintenance

Maintenance

Filter replacement


Maintenance

Monitoring

Production

Stuffing box adjustment


Maintenance

Packing replacement

Maintenance

Maintenance

Monitoring

Production

Monitoring

Maintenance

Maintenance

Maintenance

Packing checks

COMPRESSORS Purging of scrubbers, drums, cylinders GAS TURBINE Starting compressor washing programme Compressor washing

Table 4: Maintenance of rotating machines, compressors, gas turbines Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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4.4.6. Machine monitoring Machine monitoring encompasses any method, practice, process or technique used, while the machines are in operation, to diagnose the condition of equipment, to determine what is happening, what will happen and what may happen to increase machine availability and to reduce costs. The production operator undertakes periodic inspection tours of the facilities. When he does his inspection tour, he records parameters on record log sheets to note the proper operation of machines. The production operator is required to make the most of these "compulsory tours" to ensure the machines are monitored accurately. We are now going to look at how machines can be monitored accurately. Means available: Noise Temperature increases Driving power consumption Operating characteristic tracking Lubricants Vibrations 4.4.6.1. Noise Of all of the machines monitored, the most efficient and reliable machine that is far from breakdown and that is likely to have a long service life is always the machine that makes the least noise, as silence is a revealing sign of efficiency. No two machines will ever generate the same noise. Moreover, the geographical location of a machine will alter the noise generated by a given machine, as their standing positions always differ, and consequently, echoes are obstructed by elements in the immediate environment, altering the initial noise emitted. As one becomes familiar with general machine noises and the purring of its engines, anomalies can be detected innately. Abnormal noises generated by a machine are a revealing sign of malfunctioning that may result in damage. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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It is important to be able to identify the different types of noise: Soft purring

Bearing in good condition, well-mounted, welllubricated and operating without overload

Squeaking

Lack of lubricant

Tinny effect

Not enough clearance

Clear, regular sound

Recesses on the ring track

Modulated noise

Damaged inner ring

Intermittent noise

Damaged bearing part

Rattling

Solid foreign body or cavitation Table 5: Noise monitoring

4.4.6.2. Temperature increases Friction creates heat energy. Any bearing, casing, reducer or large device incorporating a lubricant tank must be fitted with a temperature indicator that must be checked periodically. If it is not fitted with a temperature indicator, manual periodic check (inner side tolerated on the bearing =+/-55°) may usually suffice as oil oxidation only becomes severe at 70°. The cause of any anomaly (temperature rises) must be determined without delay (grinding, overload, lack of lubrication, misalignment, etc), failing which, the machine must be shutdown for inspection and overhaul as temperature increases are detrimental to the lubricating properties of the oils. 4.4.6.3. Driving power consumption This must be monitored periodically with meticulous care as any breakdown process increases the driving power from the onset (friction of rings, bearings, impeller, mechanical packing, etc.) Moreover, changes in the driving power consumption of a given machine has an impact on machine life (decrease in energy due to grinding, increase in energy with part wear) Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Caution! A change in machine load established by the Operating Company may cause variations in driving power consumption that are far more significant than those caused by mechanical phenomenon.

4.4.6.4. Operating characteristic tracking Analysing any changes in machine operation characteristics enables operators to determine the condition of these same machines. These characteristics namely comprise: Discharge pressure, flow rate, temperatures, quantity of removed condensates, intensity. These values can be recorded using the machine instrumentation that must be kept in good condition and calibrated on a regular basis.

4.4.6.5. Vibrations Vibration is a relatively complex phenomenon that is characteristic of each machine. Analysis of vibratory phenomena requires very specific training and equipment that is often expensive. Nevertheless, the occurrence of vibrations that can be heard, felt (hands on the ground), or detected using sensors, is always a sign of damage that can have extremely rapid consequences. The three main causes of vibrations are: Unbalance Misalignment Poor ground attachment


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4.4.6.6. Lubricants Quantitative Check: Any deviation between the maximum and minimum level must be explained. Beyond the maximum value, excess oil (or foreign liquid) may hinder or prevent correct lubrication. Below the minimum, a lack of oil can quickly result in an incident caused by rupture of the lubricating film.

Qualitative Check Periodic checks of colour and viscosity, analysis of deposits and chemical composition and solid deposit checks may be carried out under the supervision of the maintenance team to verify the quality and characteristics of the lubricants, to check bearing wear and to determine phases of degradation. The Production Operator can make a diagnosis before damage is aggravated or a breakdown occurs, by performing a visual check (presence of foam, for example), or by touching (smoothness or foreign body). This type of diagnosis is, however, too basic to be reliable.


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4.5. EXERCISES 3. What is the main reason for which equipment must be monitored?

4. To detect the smell of H2S, to hear un bearing roll, or to observe a joint leakage, the operator is required to: Be in the control room Be on the field 5. What is the purpose of monitoring parameters frequently?

6. Generally, operation anomaly detection procedures provide good results. True False 7. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly electric motors.

8. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly centrifugal pumps in operation.


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9. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly centrifugal pumps not in operation.

10. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly reciprocating compressors.

11. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly centrifugal compressors.

12. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly cooling towers.

13. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly mixer impellers.

14. List 4 precautionary measures to be taken when sampling.


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15. What are the 4 recommendations that must be adhered to when taking liquid sample from an effluent that may contain H2S?

16. 1st level maintenance consists of: Repairs by replacement of components or functional parts, made by a qualified technician, using the tooling specified in the maintenance procedures. These repairs are made either on site or in the workshops. Simple adjustments recommended by the manufacturer using means accessible without dismounting or opening the equipment, that do not require tooling, or any specific spare parts. Troubleshooting by standard replacement of parts provided for such and minor preventive maintenance operations carried out by an authorised technician, using the tooling specified in the maintenance procedures. 17. Periodic emergency equipment testing and the change-over of redundant equipment are tasks incumbent upon the operator. True False 18. List 3 tasks that the Operator is required to carry out whilst working on wellheads.


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19. List 3 tasks that the Operator is required to carry out whilst working on capacities.

20. List 3 tasks that the Operator is required to carry out whilst working on heat engines.

21. List 3 means by which the Operator can monitor the machines whilst doing his tour.

22. Of all of the machines monitored, the most efficient and reliable machine that is far from breakdown and that is likely to have a long service life is always the machine that makes the least noise. True False 23. Friction does not create heat energy. True False


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24. An increase in driving power, without changes in load made by the Operating Company, is a revealing sign of the start of a fault. True False 25. Analysing any changes in machine operation characteristics does not enable operators to determine the condition of these same machines in any case. True False 26. Name one of the main causes of vibrations:

27. What are the two checks that need to be carried out on lubricants?


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5. THE MAIN SAFETY RULES Safety management is one of the main concerns of the Total Group. Our different activities manage industrial risks of all kinds, associated with reservoir development and hydrocarbon production. Safety is focused on the protection of personnel performing everyday tasks at their respective workstations. Each different job involves specific risks. This is why we have established ten rules that shall be described in this chapter, and that are based on experience. These cover the most frequently encountered situations of Exploration & Production sites. Compliance with these rules will significantly contribute to preventing accidents in this field. These rules should be respected in the interest of each and every one of us on a day-today basis. By making every endeavour to meet the safety improvement objective that is a decisive vehicle of progress, together, we can continue to improve results. These ten rules will contribute to the development of our HSE culture within the field of Exploration & Production. Most of the works we carry out include tasks that, although routine, can be dangerous. The 34 deaths suffered by Exploration & Production personnel since 1998 were due to: Vehicle accidents

35 %

Explosions / burns

26 %

Trapping

11 %

Falling

11 %

Drowning

9%

Electrocution Impact due to falling objects

4% 4%

Adhering to these simple rules can prevent accidents and save lives.


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5.1. WORK PERMIT All works carried out on site, other than ‘"routine" works (defined in an official list disseminated throughout the company) require a Work Permit. The permit issuer ensures the works and tasks are clearly mentioned and that an analysis of the operational risk is carried out, if requested, specific additional permits (pertaining to confined spaces, isolation of power-supplied systems, trenching, etc.) may be issued by an authorised person before the work is undertaken, to perform several distinct tasks on one piece of equipment, the person in charge establishes a link between all of the associated permits and documents, the on-site works supervisor ensures all of the conditions prior to permit issuance have been met, before and during the works, The Work Permit system formalises the return to normal operations.

5.2. WORK ON POWER-SUPPLIED SYSTEMS Works requiring the isolation of energy sources (hydraulic, mechanical, electric, process, etc.) may only be undertaken if the following conditions have been fulfilled: prior identification of all of the tasks for which isolation is necessary, to ensure operations are strictly controlled, definition of the method to be used to isolate and discharge the energy stored, discharge of the energy, use of a fail-safe locking and labelling system that authorises over-isolation when there are several distinct tasks, checking for proper initial isolation and regular efficiency checks, recording of the isolation start and finish time in a specific log.


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5.3. WORK IN CONFINED SPACES Entering a confined space is strictly prohibited, and no work may be carried out therein unless the following requirements have been met with: all other options have been dismissed and the appropriate authorities have been notified of the reasons for entering a capacity, a work permit has been established and approved, and includes all information pertaining to the intervention and emergency plan, all sources of energy and fluids have been isolated and secured, atmosphere tests have been completed, checked and repeated as often as necessary. The results of the latter have been recorded, an agent (or team) with the appropriate training and equipment shall stand guard, ready to act, all unauthorized access shall be prevented.

5.4. TRENCHING It is strictly prohibited to commence any trenching works (i.e. ground penetration exceeding 300 mm of depth), whether manual or mechanic, including sea or river dredging, until the following conditions have been fulfilled: an appropriate work permit has been established and approved with all of the adequate plans, all underground hazards (lines, cables, etc.) have been identified, located and marked on site, and if necessary, isolated, the ground movement prevention methods (such as cave-in of trench walls) have been assessed and finalised, the trenching work has been conceived with consideration for confined space specificities, and the related safety precautions will be applied.


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5.5. WORK AT A HEIGHT It is strictly prohibited to undertake any work at a height (involving a potential fall from a height of over 2 metres) without supervision, and without: a fixed platform or scaffolding with guardrails, checked by a qualified person before use and at regular intervals. An established labelling system for inspections and access control shall be provided, or a movable platform, designed and manufactured for personnel use, or fall arrester equipment, comprising a safety harness and an appropriate anchorage point (ideally at a height). The equipment must incorporate a shock absorption system and must limit any fall to less than 2 metres, the transfer of personnel by cable is authorised in exceptional cases only, and this type of operation is carried out under the following conditions: validated work permit, specially adapted and certified hoisting equipment, stoppage of simultaneous operations of any type, permanent supervision by a qualified employee.

5.6. HOISTING No work involving a crane, a hoist or any other such mechanical devices, including lift trucks, may be initiated if the following conditions have not been fulfilled: the hoisting equipment and method have been defined by an authorised person, the persons participating in the operation are qualified and trained. The cranes, lifts and trucks are manoeuvred by certified personnel, all of the safety devices for the hoisting equipment are in proper operating condition, all of the hoisting devices and accessories (slings, shackles, etc.) have been inspected and certified as suited for use, a colour-marking, or similar system is used for identification of equipment, the load has been determined and does not exceed its maximum capacity, each item of hoisting equipment has been visually inspected before use.


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5.7. VEHICLES Excess speed is not acceptable, even for operating reasons. The following precautions shall be taken for all vehicles: the drivers will respect the driving rules, regulations and policies in force, speed limits will be strictly adhered to, all vehicles must be suited for the scheduled operation, inspected and authorised for use, any person driving a company vehicle must have completed a preventive driving course and revision lessons as required, each passenger will be allocated a seat, and will wear their seat-belt fastened when the vehicle is in motion, passengers and goods will not be transported in the same vehicle compartment, the use of mobile phones and walkie-talkies is prohibited when driving, special precautions will be taken to provide for risky situations or conditions that may be hazardous when driving.

5.8. CHANGE MANAGEMENT The possible impact that any changes may have on the working conditions on site must be determined, using an appropriate means of risk assessment or by implementing compensatory measures, if necessary. These changes may include: modifications made to an operational site, to its safety devices and equipment, modifications made to the operating and safety conditions or parameters, organisational changes, change-over of personnel, particularly at positions that are critical for safety, changes in procedure, changes in materials or substances used.


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5.9. SIMOPS All SIMultaneous OPerationS of production and construction, and production and drilling, (SIMOPS) are likely to increase risk levels. Consequently, these SIMOPS must not commence until: authorised representatives have completed preliminary inspection of the facilities, the risks involved have been identified, assessed and analysed, all of the recommendations derived from risk analysis have been implemented, the responsibilities for the SIMOPS have been allocated and a SSEM (site environment safety manager) has been appointed, SIMOPS-specific meetings have been scheduled and organised, the SIMOPS file has been submitted and approved, formal authorization to proceed with the operations has been granted by the Operations Manager (or Technical Manager) pursuant to site inspection.

5.10. DEGRADED SITUATIONS Any situation in which the risk level has been temporarily increased in comparison with the normal situation must be treated as a ‘"degraded situation" in accordance with the following principles: the management team is formally notified of the situation, the risks involved are identified and analysed, compensatory measures to reduce these risks have been defined and approved, enforced and checked on a regular basis, a list of "degraded situations" is updated every day on the site and made available to the personnel concerned.


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5.11. EXERCISES 28. The ten rules listed in this chapter cover the most frequently encountered situations on the Exploration & Production sites. These rules are based on experience feedback. True False 29. List 5 of the causes of the deaths suffered by Exploration & Production personnel.

30. All works carried out on site, other than "routine" works (defined in an official list disseminated throughout the company) require a Work Permit. True False 31. Works requiring the isolation of energy sources (hydraulic, mechanical, electric, process, etc.) may be undertaken once the isolation has been checked, and if its efficiency is checked regularly. True False 32. Nobody is allowed to enter a confined space and no works may be carried out therein without an agent (or team) with the appropriate training and equipment standing guard, ready to act. True False Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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33. It is strictly prohibited to undertake any work at a height (involving a potential fall from a height of over 20 metres) without fall arrester equipment comprising a complete safety harness and an appropriate anchorage point. True False 34. No work involving a crane, a hoist or any other such mechanical devices, including lift trucks, may be initiated unless all of the hoisting devices and accessories (slings, shackles, etc.) have been certified as suited for use after inspection. True False


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6. WORK PERMITS Work permits are essential documents for Operators. Operators handle these documents several times a day. Operators need to understand the general principles of the work permit, its scope, the documents and permissions associated therewith, how it is established and the personnel concerned, to be able to read it and understand the ins and outs of it. Reminder: This document is not any form of substitute for the "specific work permit" training. Although relatively detailed, it represents a general view intended to present the work permit mechanisms. The essential work permit requirement is thorough understanding of facility operation. Operators can therefore anticipate any untimely phenomena during the works and take the measures required to remedy inconvenient situations (for example: A length of cable has been isolated for works; what "process" change could possibly occur that would render the isolation inefficient?

6.1. GENERAL PRINCIPLES This chapter describes the work permit and comprises extracts from CR EP HSE 036 (07/05).

6.1.1. Work Permit System All of the works to be completed within the framework of operations carried out by an entity shall be governed by the risk management principles established in CP EP HSE 031, and namely on the basis of a consistent Work Permit.

6.1.2. Content of the Work Permit Procedure The Work Permit procedure: describes the overall process and the various stages included before an intervention is carried out: Preparation, approval, execution and closing; identifies the main participants, their prerogatives and their respective roles in this process; defines the type, the model and the content of the various Work Permit forms, as well as their respective scopes, the restrictions and the exceptions for use. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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6.1.3. Work Permit Forms 6.1.3.1. Basic Contents The Work Permit procedure uses dedicated forms, that comprise or formalise: a detailed description of the work entailed. It includes the identification of the worksite, of the unit or the equipment involved as well as the resources required (team or service company contracted, list of the specific tools and equipment to be used), the duration of the work, etc. the hazards involved in the HSE field. These include all of the risks associated with the intervention, with the work area and with the neighbouring facilities as well as any potential interference with other works or operations; the precautionary and operational measures (mitigation and rescue) deemed necessary, and the checks performed to ensure effective implementation of the latter at the onset of the works and between shifts; the references of all relevant documents: preliminary meeting reports, risk assessment and safety analyses, procedures, drawings, associated permits, associated inhibition/isolation certificates, etc; the signature of the personnel involved in the preparation, consolidation and approval of the permit, with mention of the permit validity period; (re)validation between shifts by the personnel in charge of performing and monitoring the works; provisioning of facilities or equipment required by the team of workers before works are initiated, and return of to operations unit when the works are completed; the measures required to ensure full acceptance of the work and the checks performed to ensure effective implementation of these measures; the official Work Permit closing.


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6.1.3.2. Various Work Permit forms The Work Permit procedure is based on various forms that are easily distinguishable. Three different types of form will be available: a standard form (the most commonly used) referred to as the Cold Work Permit. a specific form covering all hot work, referred to as the Hot Work Permit. This Hot Work Permit form must clearly distinguish between hot work involving "Open flame" and hot work involving “No Open Flame“, A specific form covering all types of access to a confined space, referred to as the Confined Space Entry Permit. Depending on the organisational context and the nature of the operations, the different entities may consider developing and implementing other forms: specific Work Permit forms with special check-lists used to identify and assess the risks involved in certain types of work, as a replacement for the "standard" Work Permit forms; a simplified form, referred to as the Work Order.


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6.2. SCOPE 6.2.1. General case Usually, all works require the use of one or several permits. The one or several appropriate forms will be chosen according to the nature of the various tasks to be completed, as described below. Exceptions to this rule are given in § 4.2.2 and 4.2.3. 6.2.1.1. When Cold Work Permits are used The Cold Work Permit form always applies to all types of work other than that covered by a more specific form. 6.2.1.2. When Hot Work Permits are used A Hot Work Permit is required instead of (or, if necessary, in addition to) the Cold Work Permit when the work involves real or potential ignition sources, particularly: open flame sources, generating sparks or heat (such as flame cutting, welding, grinding), unless these are used in workshops or areas designed specifically for this purpose, and located at a safe distance from hazardous areas. On the corresponding Hot Work Permit , the “Open Flame” checkbox must be selected; other potential sources of ignition (such as hand tools, equipment that is not or no more intrinsically safe) located or used within or near to a hazardous area that cannot be isolated. On the corresponding Hot Work Permit , the “No Open Flame” checkbox must be selected; 6.2.1.3. When Confined Space Entry Permits are used A Confined Space Entry Permit is required in addition to the Cold Work Permit or the Hot Work Permit when the works involve entering a capacity or tank under pressure, or require the presence of personnel in a confined space - i.e. a space with limited natural ventilation and in which a hazardous atmosphere exists or could develop. 6.2.1.5. When other permits are used For the other forms likely to be developed and used within the entity, the scope must be specified by the Work Permit procedure in the same way.


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6.2.2. Exceptions – Works subjected to work orders Some works or tasks may only require a Work Order, as long as the conditions described below are fulfilled: the works are carried out regularly, several times a year, for example; the analysis of the risks involved clearly specifies that the works are not unusually dangerous and are not of high risk; the works are subjected to detailed procedures including an exhaustive list of all of the potential dangers and of the precautions to be taken, and these procedures have been thoroughly tried and tested and declared appropriate; the works are carried out by appropriately trained and experienced employees or contracted personnel who belong to the permanent on-site organization; the works are included on the "list of works subjected to a Work Order", duly approved by the entity's operational Management team. These permits apply, for example to recurrent preventive maintenance tasks.

6.2.3. Exceptions – Works performed based on verbal instructions Some activities may only require verbal instructions, and consequently no standard or specific work permit or Work Order - as long as the conditions described below are fulfilled: activities are part of the normal operation of facilities and equipment according to design specifications, and within the operating limits recommended by the manufacturers; they are supported by appropriate schedules, procedures, instructions, check-lists or operating manuals, they are carried out by appropriately trained and experienced employees or contracted personnel who belong to the permanent on-site organization; they are referenced on the "list of works not subjected to a permit", duly approved by the entity's operational Management team. The following activities are examples of this type of scenario: operational activities regularly carried out such as the adjustment of process parameters, the shutdown, start-up and replacement of equipment, crane and hoisting vehicle operations in dedicated handling areas, sampling using specific apparatus, facilities inspections and checks, etc. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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drilling and work-over activities covered by the corresponding drilling/work-over programme; regular logistics activities or marine operations such as cargo handling, transferring personnel, navigation, driving trucks or cars, etc, as long as the specified prerequisites have been fulfilled: acceptable weather/wind conditions and sea state, absence of potential interference with the facilities installed or with other operations carried out in the area, etc. all activities related to rescue and response to emergency situations. As these activities have not been formalised by means of a permit, it is important that they are carefully co-ordinated and supervised to prevent interference with other works.

6.2.4. SIMOPS Work Permit System When simultaneous operations are carried out, the Work Permit is adapted when the SIMOPS file is established so as to consider the highest risk levels involved. In particular: the lists of exceptions (works subjected to a Work Order", works based on verbal instructions) are revised and modified, if necessary; the interference between different works is reassessed with consideration for the SIMOPS requirements and any further restrictions or stricter rule - if necessary -is clearly identified; the Work Permit approval process is revised to conform to the organisational changes and to the responsibilities of the SSEM for the duration of the SIMOPS. It is important to ensure the SSEM responsible for the SIMOPS approves all of the permits and the associated daily log covering all of the works performed in the SIMOPS area.


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6.3. OTHER DOCUMENTS AND PERMISSIONS 6.3.1. Document and permission validity Isolation, permission to "get around using a vehicle", permission "for works" or "transport for degassing" are not necessarily associated with work permits. Other additional permissions or documents may only be obtained with a WP, and are associated therewith. The WP expiry date also applies to all of the additional permissions granted with this permit. Additional permissions may not be considered as a replacement for the WP.

6.3.2. Isolation Isolation includes all of the provisions necessary to lock-out a machine, device or facility such that its state can only be changed (restarting of a machine, closing of an electric circuit, opening of a valve, etc.) once the operating conditions have been restored and checked with the consent of all of the persons involved. An isolation sheet is used to formalise the process involving isolation and de-isolation, as it requires the attention of qualified and informed persons (Operating Company, electrician, mechanic). 6.3.2.1. Electrical isolation Once the electrical isolation is carried out, the Isolation Manager dates (date/time) and signs the record. The person carrying out the operation receives a red token (electrical or electrical lock-out isolation) that he keeps until the work has been completed, and gives back to the Isolation Manager to de-isolate the equipment. If a device or piece of equipment is subjected to several isolation operations (several tokens or certificates), it cannot be de-isolated until ALL of the isolation tokens or certificates have been handed in. The original (yellow) is posted up in the control room.


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Sheet 2 (pink) with a protective plastic cover may be attached to the label (on site), depending on the equipment, for process or utility isolation. Sheet 3 (blue) remains in the possession of the Operational Manager. 6.3.2.2. Process or utility isolation This type of isolation may be associated with a mechanical part or a fluid. The procedure is identical to that of electrical isolation. 6.3.2.3. Cutting and Welding Permit This is mandatory for all hot work (use of equipment generating, or likely to generate a heat source) carried out on facilities with a fire or explosion risk, outside of the permanent work points. Certain usual operations, that do not involve the use or generation of flames, may be exempt from Cutting and Welding Permits as long as a specific procedure has been drawn up. The procedure specifies the means implemented and the level of qualification of the operating personnel. It is issued by the Operations Supervisor (OS) It is signed by the OM and SEO. The OM and SEO are required to re-validate it along with the WP before each new task. Hot work may not be commenced until the following conditions have been fulfilled: the OM and OS have marked out the area of intervention, all precautions specified on the work permit have been satisfied, the atmosphere test has proven absence of explosiveness, the SEO has recorded the test results on the Cutting and Welding permit, Having acknowledged the results of the atmosphere test, the OM has signed the WP and the Cutting and Welding Permit.

6.3.2.5. Access permit This is mandatory for one or more external company agents to access a vessel. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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It is issued and signed jointly by the OS, the OM and the SEO. Permission to access a device may only be granted if the appropriate sign has been affixed to each of the access points. Red disk : access prohibited Yellow disk : access subjected to specific authorization by the OM and the SEO Green disk : access authorised The colour of the disk to be affixed to the access points is determined by both the OM and the SEO according to the atmosphere test results and to the works scheduled.

6.4. KEY PERSONNEL For each activity site or area, the Work Permit procedure identifies each job or position playing a key role in the Work Permit process, namely: the SSEM (or his representative) as defined in rule CR EP HSE 035 ; the Operational Manager, i.e. the person technically responsible for the operations carried out and for the entity's facilities in place on the work site, if any; the Permit Control Manager, i.e. the person responsible for preparing the permits, according to the work site organization requirements, (usually the permit coordinator, the Operational Manager or one of his appointed representatives); the HSE representative, i.e. the person responsible for checking the HSE aspects of the various activities conducted on the site (usually the HSE supervisor or advisor); the Shift Leader, i.e. the person responsible, for the duration of the shift, for the overall, continuous monitoring and supervision of the equipment and works within a given area; The Requestor, i.e. the person having requested the Work Permit; The Operations Supervisor, i.e. the person responsible for performing the works (usually a department leader or supervisor, a representative appointed by a service provider). Whenever possible, the Operations Supervisor will be he who requested the Work Permit. This guarantees his full commitment to the work preparation process.


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6.5. WORK PERMIT PROCESS The Work Permit process is governed by the following key principles: a permit expires 14 days after its approval, or 7 days after the start of the works, at the latest. A "open flame" Hot Work Permit expires 7 days after the date of issue, or 2 days after the start of the works, the first to occur. a permit is submitted for approval at least 24 hours before the date on which the works are scheduled to begin; a permit is issued for one job only, i.e. a set of interdependent tasks to be performed by one team in one area. Consequently, the following scenarios may not be covered by one common permit: tasks that are not directly related, works performed in 2 different places, the activities of 2 different service companies, etc; a permit holds the references of all associated inhibition / isolation permits, documents and certificates. Likewise, all inhibition / isolation certificates hold the references of all permits requiring such inhibition or isolations. According to rule CR EP HSE 031, a multiple inhibition / isolation system is implemented to ensure no inhibition, override mechanism, electrical, mechanical or process isolation is removed before all of the corresponding permits have been officially closed; a standard or specific permit approved by both the Operational Manager and the SSEM. A Work Order is approved by the Operational Manager.


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6.6. EXECUTION PHASE 6.6.1. (Re)validation between shifts Before works begin or are resumed with a new team, each standard permit, specific permit or Work Order is (re)validated. It is important to ensure the following conditions are fulfilled: the work permit has been approved, is still valid, and all associated documents are attached. It is noted "in progress" for the team in the latest register review; the persons involved have been informed of the various tasks required of them, the associated hazards and the measures to be taken, by means of meetings held before works begin or during the course of the works, of which any reports are attached to the permit; all resources are available, including the equipment and tools required for the works and the supervising team; the conditions associated with the works and facilities are those taken into account or provided for during the preparation phase; all of the compensatory measures (including inhibitions and isolations) have been checked carefully for proper implementation and efficiency, and the corresponding boxes have been selected in the Work Permit; t he Work Permit is (re)validated by the Shift Leader, the Representative of the Operational Manager (i.e. the team in charge of continuous or periodic supervision of the works, depending on the case) and the Operations Supervisor.

6.6.2. Permit management during works In addition to the original form, at least one copy of each Work Permit is systematically printed. While the works are in progress, the original copy of the Work Permit and the associated documents are posted up near to the work area. A copy is held in the permit control room (this may be the control room, if any, or the Shift Leader's office etc.), in the register dedicated to permits in progress. Should the works be discontinued, the original form is returned to the Shift Leader, who ensures it is kept with its copies in the permit control room, for future use.


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6.6.3. Suspension of works A permit must be suspended: in the event of a general alarm or specific instructions given by the Shift Leader, the Operational Manager or the SSEM; if risks can no longer be controlled in a satisfactory manner and/or one of the requirements stipulated in the permit is no longer met with. If works are suspended, the conditions in which they may be resumed are established and approved by the Operational Manager. Re-assessment of the work conditions and comprehensive revalidation between shifts are required at the very least.

6.6.4. Closing phase The permit is closed once all of the works have been completed, the validity period has expired or the works have been suspended and revalidation unauthorized (in the last two cases, the works cannot be resumed unless a new permit has been requested and issued). Once all of the works have been completed, the acceptance process is formalised under the responsibility of the Operational Manager and includes, if applicable and relevant: tests, inspections and checks including a visit to and visual inspection of the work site; identification of the inhibitions and isolations to be maintained and those to be removed before equipment and facilities may be reactivated re-start instructions and the associated precautions; no load/on load operating tests; The provisioning or acceptance certificate, including any reservations. The signatures of the Operations Supervisor and Operational Manager are required to close the permit. Once closed, the original copy of the Work Permit, its appendices and associated documents are filed for at least one year.


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6.7. WORK PERMITS DETAILS The Work Permit breaks down into five sections, which are detailed in this chapter: the request the preparation the approval the execution the acceptance Reminder: For any scheduled work, the Work Permit will be established at least 2 days in advance.

6.7.1. The "request" phase This section is completed by: The requestor The worker 6.7.1.1. The requestor "1" in the figure This is a person with knowledge of the works to be carried out (external or TFEA line position). He is required to: clearly specify: the work to be completed, the equipment to be used, the workteam staffing. clearly specify: Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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the facility concerned, the level (e.g. 22 m) the equipment (e.g. DS201) describe the available documents and data (procedures, WOM, sketches, etc) specify the dates and times of operation (7 days max.)

6.7.2. The worker "2" in the figure This will be the person in charge of conducting the works (Performance Manager) on the field. In practice, it is the Leadman or the Site Foreman of the company with Leadman authorization. He is required to: enter his surname, forename and position (Leadman or Site Foreman) the main equipment to be used the workteam staffing

Figure 12 : Work Permit: The "request" phase


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6.7.3. The "preparation" phase This comprises two sections as shown in figures 13 and 14. conditions encountered and precautions to be taken. persons in charge / associated isolation and permits 6.7.3.1. Conditions encountered and precautions to be taken These sections ("A" and "B" in figure 13) are filled in by any person involved in the preparation of the work to be completed and aware of the conditions encountered and precautions to be taken. The following will be specified: the special risks associated with the work to be carried out the associated precautions and protective measures to be taken on site

Figure 13 : Work Permit: The "preparation 1" phase Reminder: The information in A and B is determined collectively 6.7.3.2. Persons in charge / associated isolation and permits This section is completed by: The Performance Manager The Operational Manager The Safety and Environment Officer Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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THE PERFORMANCE MANAGER "3" in the figure WEM : This is the TFEA line supervisor assuming the responsibilities of project manager (e.g. FOC, TVX, ING, etc ) He confirms the execution of this work in the required conditions, and add his own recommendations. WEM: specific cases SCDAR: It is the Site MC Manager that acts as the WEM Wire line : It is the WL TFEA steward (FOC Luanda) Diving: on the Terminal : STAPEM chief diver Others: It is an INSP Sce agent

THE OPERATIONAL MANAGER "4" in the figure OM: It is the facility manager (Leadman), unless otherwise required. He may appoint an agent to represent him on site. As the facility manager, he specifies the recommendations (e.g. process isolation) necessary for the work and checks any possible interferences, the availability of resources and the provisioning of facilities;

THE SAFETY AND ENVIRONMENT OFFICER "5" in the figure SEO: This is a safety technician working at the request of the SEM, or systematically for all Cutting and Welding Permits and Access Permits. He interprets and completes the necessary S/E recommendations according to the work to be carried out and the environment (classified zones).


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Figure 14 : Work Permit: The "preparation 2" phase

6.7.4. The "approval" phase This section is filled in by the Safety and Environment Manager ("6" in the figure) It is the titular SSEM or the SSEM appointed by the GM in special SIMOPS cases. In these last cases, the site SSEM (EXP) acts as the OM throughout the duration of the SIMOPS. He checks the information on the WP added by the different participants, and adds his own comments if necessary. He then checks to ensure that there is no incompatibility with other activities and the environment in which the identified work is to take place. He issues the final authorization for execution of the work.

Figure 15 : Work Permit: The "approval" phase Reminder: The SSEM is required to give his approval within the 24 hours (no longer) that precede the start of the works. Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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6.7.5. The "execution" phase This WP phase cannot begin until the SSEM has given his approval. It ("7" in the figure) is completed by: Worker : this is the company Leadman OM : himself, or his appointed representative Health and Safety Manager (HSM) : appointed by the SSEM if necessary SEM: depending on revalidation selected by the SSEM They ensure the information on the WP corresponds to the works scheduled. They do not authorize the works to begin until the required conditions have been fulfilled.

Figure 16 : Work Permit: The "execution" phase Reminder: The phrase at the top of the table is of major importance!! "The undersigned agree that they have acknowledged the aforementioned requirements, and undertake to adhere to them before and during the execution of the work".


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6.7.6. The "acceptance" phase This phase ("8" in the figure) is completed by: The OM : within the time limits and for all types of work carried out (except those below) Or the SSEM : only in SIMOPS phases On site, the OM (or SSEM) must ensure: that the work is thoroughly completed, that the work carried out conforms to requirements, the cleanliness of the worksite, He then validates the reactivation of the facility and adds any reservations.

Figure 17 : Work Permit: The "acceptance" phase Reminder: Circulation of the WP sheets: the OM or the SSEM returns the "white" WORKER copy to the Site SEO as soon as the completed work has been accepted. the OM keeps the "green" OPERATING COMPANY copy the site SEO files the "pink" SAFETY copy and the "white" WORKER copy


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6.8. WORK PERMIT TASKS REQUIRED OF THE OPERATOR The tasks described below will usually already have been completed by the operators, although there may be a few differences according to the sites and subsidiaries. The purpose of this chapter is to describe the operator's specific role during the Work Permit phase.

6.8.1. Permit Preparation He assists the Production Foreman / Chief Operator in the development of procedures, the preparation of PID mark-up, the provisioning of facilities - This task is optional and remains at the discretion of the Production Foreman.

6.8.2. PID Mark-Up PID Mark-Up enables, during permit preparation, to determine the risks involved in the process and hence the lines to be isolated (blinds, spectacle blinds, manual valves, SDV, ESDV, etc) to work in safety. Blinds, spectacle blinds and any other items shall be numbered on this PID. These elements, listed in table as shown below, can then be tracked. This table will allow tracking progress during plating Blinding plan No.

Line

1

12"

2

8"

3

10"

4

3"

5

2"

6

2"

7

2"

8

12"

9

8"

10

2"

Fitting Date

Signature

Removal Date

Signature

Table 6: Blinding table Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Likewise, this type of table can be used to specify and track the valves and systems locked out during this operation. This makes the Operator's task easier when provisioning the device. Different colours can also be used to specify the hydrocarbon pressurised lines, the noninerted depressurised lines, and the inerted depressurised lines. All of these documents will be attached to the Work Permit to facilitate work follow-up. An example of a PID Mark-Up for works carried out on a Hydrocyclone located on a production water treatment facility is shown below. It shows the number of the blinds used and the number of the spectacle blinds turned.


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Figure 18 : Hydrocyclone PID Mark-Up Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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6.8.3. Initial Permit Opening The area Operator must be on the worksite with the workers when the permit is first opened, before the works commence. He must then ensure that: All of the required authorities have signed the permits and associated documents. The worker is aware of the risks associated with his work, The persons involved have acknowledged and taken the precautions listed on the risk analysis sheet. If this is the case, he will then sign the risk analysis sheet, The tooling to be used by the worker is adequate and in good condition. He will also inform the workers of attached works/permits and the risks associated with these permits. The Area Operator responsible for performing process isolation, if requested in the Work Permit, must respect: The isolation phase by fitting a robust means of isolation of the "cablet" type (marking tape is to be avoided at all costs). The identification phase by attaching labels with the date, the operator's name and the Work Permit number. He will validate process isolation by signing all of the necessary documents, isolation sheet, valve/plate table, etc

6.8.4. Daily permit management activities The area Operator must regularly visit the sites associated with all of the current works/permits in his area, including permits previously opened. These regular visits include a "morning inspection" and an "afternoon inspection" at the least. During the visits: He will introduce himself to the workers (again), He will check that the precautions listed on the risk analysis sheet have been acknowledged and implemented, Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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He will inform the workers of related permits/works and the risks associated with these permits.

6.8.5. Permit closing When the permits are closed, the area Operator must ensure the worksite is cleaned thoroughly before he and the worker sign the permit closing section at the bottom of the sheet. It is important to ensure the site is clean and this phase is of absolute necessity.

6.9. MOST COMMON ANOMALIES REPORTED missing signatures (validation, work completion date, ... etc.) WP with deletions (dates, texts, etc.) WP with no defined validity period WP covering: several different operations, several different teams, ... etc. WP signed several times by one same person WP submitted at the last moment failure to return the original WP when the work is completed


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6.11. WORK PERMIT FORMS The present appendix includes some classic forms recommended as a support for the Work Permit procedure. Please remember that the predefined lists of hazards and precautionary measures in the forms are given for information only. These lists are limited to the most common scenarios and may not be considered comprehensive. It is important to remember this when identifying hazards or determining the necessary precautions.


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Figure 19 : Example of a Work Permit Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Figure 20 : Example of a Work Order


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TOTALFINAELF E & P ANGOLA

Figure 21 : Example of an isolation sheet Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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TOTALFINAELF E & P ANGOLA

Figure 22 : Example of a Cutting and Welding Permit


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Figure 23 : Example of a Cold Work Permit Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Figure 24 : Example of a Hot Work Permit Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Figure 25 : Confined Space Entry Permit Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Figure 26 : Example of a Work Order Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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7. GLOSSARY WRA Work Risk Analysis (carried out prior to the Work according to the Risk level) (you may come across WSA - Work Safety Analysis - on old forms) SEO Safety/Environment Officer WO Work Order: simplified version of a Work Permit, used for common work requiring a special operating procedure Isolation All of the provisions required to lock-out a machine, device or facility such that its state can only be changed (restarting of a machine, closing of an electric circuit, opening of a valve, etc.) once the operating conditions have been restored and checked with the consent of all of the persons involved. The following types can be distinguished: Process or utility isolation Mechanical isolation Fluid isolation Electrical isolation Isolation procedures are performed by an Isolation Manager. De-isolation: restoring and checking the operating conditions Requestor Representative of the entity requesting the performance of the work subjected to a WP or WO PPE Personal Protective Equipment Worker Person in charge of performing the Work


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Entity Any unit of the DGEP placed under the responsibility of a General Manager appointed by the President of Exploration & Production The DGEP itself, a subsidiary or a project group are also considered as entities. Service company: Company to which the entity has entrusted a work project of which the execution is governed by a contract entered into between both parties. HAZID HAZard IDentification. HAZOP HAZard OPerability study. HSE Hygiene Safety and Environment. WP Main Work Permit, which may be associated with additional permits: Cutting and Welding Permit, Trenching Permit or Access Permit Cutting and Welding Permit Mandatory additional permit for any hot work Trenching Permit Additional Permit issued when the work involves earthmoving, the digging of a trench, granting ditch or pipeline access to personnel, well, excavation, the positioning of piles or any other type of ground penetration. Access Permit: Mandatory additional permit when the work requires persons to physically enter a closed capacity. WEM Work Execution Manager, who may delegate to the WORKER OKM Operation Kick-off Meeting OM Operational Manager representing the Production authority He may appoint a representative to authorize execution of the works on the site (signature). WOM Worksite Opening Meeting


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SSEM Site Safety and Environment Manager OS Operation Supervisor: Any heavy works or capital repairs requiring the presence, at the facility or nearby, of a supervisor in charge of the operation. For any other type of intervention, the necessity for an Operations Supervisor will be determined case by case. He supervises the work on behalf of the WEM or the WORKER When a permanent contract has been established (Maintenance Service Contracts such as SCDAR), the OS is a representative of the WORKER. SIMOPS SIMultaneous well and production OPerationS Hot Work Work involving a flame or a flame source, or a heat source that could cause a facility with gas or hydrocarbons to explode or catch fire.


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8. SUMMARY OF THE FIGURES Figure 1 : Process pump....................................................................................................15 Figure 2 : Rotating equipment: Pump ................................................................................15 Figure 3 : Rotating equipment: Pump ................................................................................16 Figure 4 : Oil level ..............................................................................................................16 Figure 5 : Centrifugal pump ...............................................................................................17 Figure 6 : Mechanical packing ...........................................................................................18 Figure 7 : Double packing ..................................................................................................19 Figure 8 : Multistage centrifugal pump ...............................................................................19 Figure 9 : Reciprocating Compressors...............................................................................20 Figure 10 : Cooling towers .................................................................................................21 Figure 11 : Mixer Impellers ................................................................................................21 Figure 12 : Work Permit: The "request" phase...................................................................64 Figure 13 : Work Permit: The "preparation 1" phase.........................................................65 Figure 14 : Work Permit: The "preparation 2" phase.........................................................67 Figure 15 : Work Permit: The "approval" phase.................................................................67 Figure 16 : Work Permit: The "execution" phase ...............................................................68 Figure 17 : Work Permit: The "acceptance" phase ............................................................69 Figure 18 : Hydrocyclone PID Mark-Up .............................................................................72 Figure 19 : Example of a Work Permit ...............................................................................76 Figure 20 : Example of a Work Order ................................................................................77 Figure 21 : Example of an isolation sheet ..........................................................................78 Figure 22 : Example of a Cutting and Welding Permit .......................................................79 Figure 23 : Example of a Cold Work Permit.......................................................................80 Figure 24 : Example of a Hot Work Permit.........................................................................81 Figure 25 : Confined Space Entry Permit ..........................................................................82 Figure 26 : Example of a Work Order ................................................................................83


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9. SUMMARY OF THE TABLES Table 1: Wellhead maintenance ........................................................................................30 Table 2: Example of capacity maintenance .......................................................................31 Table 3: Heat engine maintenance ....................................................................................32 Table 4: Maintenance of rotating machines, compressors, gas turbines ...........................33 Table 5: Noise monitoring ..................................................................................................35 Table 6: Blinding table .......................................................................................................70


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10. CORRECTIONS FOR EXERCISES 1. List the main roles of the operator: observation action monitoring reporting 2. Which of the tasks below are not incumbent upon the operator? ; Submitting requests for materials, tools and consumables. ; Signing and managing work permits. ; Checking and signing the daily reports 3. What is the main reason for which equipment must be monitored? Wear 4. To detect the smell of H2S, to hear un bearing roll, or to observe a joint leakage, the operator is required to: ; Be on the field 5. What is the purpose of monitoring parameters frequently? To track progress 6. Generally, operation anomaly detection procedures provide good results. ; False 7. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly electric motors. Touch the bearings Check the bearing oil levels Identify any leakage Check that the intensity has not exceeded the nominal value (maxi).


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8. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly centrifugal pumps in operation. Check the overall sound level of the machine Check the suction filter Check the temperature of the pump bearings (touch) Check the bearing vibrations Check the oil level (and refill if necessary) Check there is no water in the bearings Translucent purger (purge the water if necessary) Identify any oil leakages. Check the operating pressure, etc. 9. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly centrifugal pumps not in operation. Check the oil level (and refill if necessary) Check there is no water in the bearings Translucent purger (purge the water if necessary) Identify any oil leakages. Check the reheating efficiency of heavy-end tail pumps. (Move your hand closer: the heat radiates) 10. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly reciprocating compressors. Check the efficiency of the cylinder cooling Check the lubrication oil pressure Check the casing oil level Check the overall sound level Check for any packing leakages Monitor the vibrations of adjoining piping 11. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly centrifugal compressors. Check the axial displacement Check the temperature of the bearings (particularly on the thrust side) Check the sound level. Check the casing oil levels (and refill if necessary) Check for any lubricant oil leakages. 12. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly cooling towers. Check the sound level (belt tension) Check the temperature of vibrations of the motor bearings (touch) Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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13. List two tasks that the operator is required to complete whilst doing his tour, concerning rotating equipment and particularly mixer impellers. Check the sound level. Check the temperature of the reducer bearings Check for any packing leakages Check the oil level 14. List 4 precautionary measures to be taken when sampling. Safety and hygiene If possible, take the sample from the vessel which is to be dispatched Close the vessel as soon as possible after sampling is completed, and check it is sealed properly. For safety reasons and with respect to operating requirements, if the vessel is left open, specify the degassing time on the follow-up data sheet. 15. What are the 4 recommendations that must be adhered to when taking liquid sample from an effluent that may contain H2S? To wear a chemical cartridge respirator To wear a portable H2S detector To avoid facing the wind To take samples following the procedure 16. 1st level maintenance consists of: ; Simple adjustments recommended by the manufacturer using means accessible without dismounting or opening the equipment, that do not require tooling, or any specific spare parts. 17. Periodic emergency equipment testing and the change-over of redundant equipment are tasks incumbent upon the operator. ; True 18. List 3 tasks that the Operator is required to carry out whilst working on wellheads. Valve lubrication Instrument inspection Bolting maintenance Cabinet maintenance Hydraulic panel maintenance Monitoring of parameters Monitoring of annular spaces Chemicals injection Product inventory management Replacement of chokes and auto choke checks Training Manual EXP-PR-DI030-EN Last revision: 31/05/2007

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Sampling 19. List 3 tasks that the Operator is required to carry out whilst working on capacities. Cleaning of gauge glasses Cleaning of recorders Cell purging Controller lubrication Leakage checks Manual valve lubrication Zero checks Plant air checks Outlet manipulation Loop testing Replacement of gauges Chemicals injection Product inventory management 20. List 3 tasks that the Operator is required to carry out whilst working on heat engines. Periodic tests Fuel management Water and oil level checks Startup system checks 21. List 3 means by which the Operator can monitor the machines whilst doing his tour. Noise Temperature increases Driving power consumption Operating characteristic tracking Lubricants Vibrations 22. Of all of the machines monitored, the most efficient and reliable machine that is far from breakdown and that is likely to have a long service life is always the machine that makes the least noise. ; True 23. Friction does not create heat energy. ; True


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24. An increase in driving power, without changes in load made by the Operating Company, is a revealing sign of the start of a fault. ; False 25. Analysing any changes in machine operation characteristics does not enable operators to determine the condition of these same machines in any case. ; True 26. Name one of the main causes of vibrations: Unbalance Misalignment Poor ground attachment 27. What are the two checks that need to be carried out on lubricants? Quantitative Qualitative 28. The ten rules listed in this chapter cover the most frequently encountered situations on the Exploration & Production sites. These rules are based on experience feedback. ; False 29. List 5 of the causes of the deaths suffered by Exploration & Production personnel. Vehicle accidents Explosions / burns Trapping Falling Drowning Electrocution Impact due to falling objects 30. All works carried out on site, other than ‘"routine" works (defined in an official list disseminated throughout the company) require a Work Permit. ; True 31. Works requiring the isolation of energy sources (hydraulic, mechanical, electric, process, etc.) may be undertaken once the isolation has been checked, and if its efficiency is checked regularly. ; True


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32. Nobody is allowed to enter a confined space and no works may be carried out therein without an agent (or team) with the appropriate training and equipment standing guard, ready to act. ; True 33. It is strictly prohibited to undertake any work at a height (involving a potential fall from a height of over 20 metres) without fall arrester equipment comprising a complete safety harness and an appropriate anchorage point. ; False 2 metres 34. No work involving a crane, a hoist or any other such mechanical devices, including lift trucks, may be initiated unless all of the hoisting devices and accessories (slings, shackles, etc.) have been certified as suited for use after inspection. ; False 2 metres


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EXP-PR-DI030-EN-R0_2 - Roles and Procedures.pdf

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