Pressure Safety Awareness

ObjectivesAfter completing this course you will be able to explain:How pressure is used in our daily lives at home and workSafe practices for line rigging and breakingSafe practices for pumping at the well siteThe importance of proper inspection and maintenanceThe applicable standards and guidelines

Pressure in useWhat types of pressure can you name?HydraulicPneumaticAtmospheric

Pressure in useHow do we use pressure?At Work?At Home?

Safe rigging and line breaking practicesDo:Know and follow HMS processesInspect all lines and connectionsWhen testing an item expect it to failUse LOTO where necessaryRun lines in low traffic areas when possible

Safe rigging and line breaking practicesKnow and follow your HMS processesRisk assessmentsControls

Safe rigging and line breaking practicesStop signs on process maps tie to Risk Analysis

Safe rigging and line breaking practicesInspect all lines and connectionsThreadsSealsGasketsOpenings

Safe rigging and line breaking practicesUse Lockout- TagoutLockout if possibleTagout if lockout not possible

Safe rigging and line breaking practicesDo not:Assume pressure is bled offWalk over pressurized linesHammer on lines under pressureHammer on frosted lines

Safe rigging and line breaking practicesDo not assume pressure is bled-offWhen in doubtAsk your SupervisorStay out of the bleed pathGauges may be brokenLines could be plugged or obstructedValves could be plugged or obstructed

Safe rigging and line breaking practicesDont hammer on equipment/lines under pressureLeaking wing nutsHatchesUnionsConnectionsFrosted linesAlways double check pressure is bled off before hammering on iron

Pressure safety at the well siteIs as dangerous as high pressureExerts tremendous forceMust be respectedF = P x A

Pressure safety at the well siteDo Not:Hammer on lines/equipment under pressureHammer on frosted linesFeel for leaks with bare handsWalk or stand over pressurized linesStand in front of valve stems being bled offUse Rubber hosesStand in flow path of bleeding pressure

Pressure safety at the well siteLiquid NitrogenExpansion ratio697-112 Feet of 3 treating iron full of N2 @ 10,000 psi has the same energy as 90 pounds of Nitroglycerin

Pressure safety at the well siteCheck the pressure rating60210021502200222021502 unions vs. 602 unionsUnions have numbers that identify the pressure rating

Pressure safety at camp locationsPressure test areasSignsFlashing lightsShieldingBarriersAuthorized personnel onlyAsk supervisor when in doubt

Pressure safety at camp locationsFlashing Lights

Pressure safety at camp locationsBarriers

Inspection and MaintenanceCheck for:CorrosionCracksPittingScarringVisible damageWelded areasReplace Damaged equipment

Inspection and Maintenance

Inspection and Maintenance

Inspection and Maintenance

Standards and GuidelinesC2-S6High Pressure Discharge HoseC4-S5Pressure Test facilitiesC5-S5Cryogenic MaterialsC5-S7Hydrogen SulfideEmployee HandbookPressure guidelines Page 41

ReviewDifferent types of Pressure:HydraulicPneumaticAtmosphericFollow HMS processesCheck all connections/threadsDont hammer on pressurized equipment/linesRespect pressurelow or high is dangerousTest areas limited accessAuthorized personnel onlyDistance/shielding when testingReplace unsafe pressure vessels/linesInspection/maintenance important When in Doubt, Ask Your Supervisor!

Upon completion of this course, the instructor is responsible for making certain that this training is entered in the appropriate training database (e.g. SAP, BTS, etc).COURSE NO.BTS: SAP 52136675Instructor Preparation Time Requirements - Total course time 30 minutes - 1 hourFacilities Requires classroom EquipmentOverhead projector and screen or PC and LCD projectorFlip chart and markersMaterials & SuppliesOne set of instructor notes for each instructorOne set of transparenciesCopy of notes pages for each studentCopy of test for each studentCopies of the Safety Alerts Listed on Slides 13 & 15 and any subsequent alerts after 5/2000Copies of the listed Standards and Guidelines C2-S6 High Pressure Discharge Hose, C4-S5 Pressure Test facilities, C5-S5 Cryogenic Materials, C5-S7 Hydrogen Sulfide, Employee Handbook Pressure guidelines Page 41. HES HMS Manifold Equipment Qualification, HES HMS Manifold Equipment Maintenance

Revision 1 June 2000Discuss in detail with participantsRevision 1 June 2000We use pressure for a lot of tasks in our daily lives.Ask students to name the various types and some uses of pressure.examples:Hydraulic;fluid pressure, pumps, CylindersPneumatic, Compressed Air, Bulk tanks, Aerosol cans, Pressure cookersAtmospheric; lift of aircraft wing, storm pressures.Revision 1 June 2000As a form of energy, pressure is very useful to us.Hydraulic pressure to provide water to our homes, to run some of our pumps at work, Pneumatic pressure to inflate the tires we ride on, or move the Bulk materials we use on our jobs. Pressure to test the integrity of equipment. Many of our locations have designated areas where equipment is pressure tested.Test areas at facilities should be entered only by authorized personnel. These areas are clearly marked with signs and/or flashing lights. If in doubt, check with your supervisor. While we use pressure in many ways it is important to understand and respect pressure.

Revision 1 June 2000Instructor should provide a copy of HMS processes complete with risk assessments and briefly explain its use.Restate the bullets and explain that you will cover in detail in the following slides.Revision 1 June 2000 Safety starts with communication and planning. You should know and understand your job roles and what is expected of you. Your HMS processes will help you with safe work practices and identifying hazards during all phases of your job. During your pre-job safety meeting, discuss what you will be doing, what controls will be in place, and what the job responsibilities are. Include all affected parties in this meeting. Revision 1 June 2000Risk analysis allows us to identify, assess, and to control risk.Revision 1 June 2000Ask participants what they should look for when inspecting lines and connections. Record on FlipchartSigns of damage such as cracks, washed out areas, corrosion, pitting etc. should be listed.

Before rigging and pressurizing equipment/lines, check for signs of wear or damage. Be sure to check the threads, seals, gaskets and openings for cracks, washed out areas, corrosion, pitting etc. Check to make sure the seals and/or gaskets are in place and in good shape. Any damaged equipment should be tagged and taken out of service immediately for further examination. If you are ever in doubt, always check with your supervisor. Unsafe equipment should be taken out of service and disposed of/destroyed as applicable. When testing, stay clear of the area and keep others away until the all-clear is given.Revision 1 June 2000 If your HMS processes call for it, be sure to lock out equipment prior to breaking lines etc. for service, repair, replacement, rigging down Etc.Use barriers, signs etc. to control access around areas while pressure is present as dictated in your HMS processes. Running lines in low traffic areas helps reduce the potential for injury should a failure occur. When breaking lines for service/repair use lock out/tag out when required. Isolate by two valves when possible in the event one valve has a unknown leak or fails.Advise personnel to stay clear of area when lines/equipment is pressurized.

Revision 1 June 2000Never assume a line does not have pressure on it. Gauges may be broken, lines may be clogged, downhole tools could have trapped pressure. Always be cautious when breaking lines. Do not stand over or hammer on pressurized lines/equipment. Do not hammer on frosted ( ice covered lines) Remember, pressure must be treated with respect!

Revision 1 June 2000 Always assume pressure could be trapped in a line. Stay out of the path where pressure could be released. Do not stand or walk in front of fluid ends on pumps when the equipment is pressurized. Sudden pressure releases can cause severe injuries or death. Injection, amputation, projectile injuries can be devastating. If you are unsure if the pressure has been bled off, always check with your supervisor.Instructor should emphasize that the employee should ask their supervisor when in doubt.

Revision 1 June 2000Instructor should try to obtain local incident reports from their HSE representative to use as examples to discuss in class. Never hammer on pressurized equipment on lines. The shock of the blow could shatter the material that is already stressed from the pressure. This could result in a catastrophic failure and sudden pressure release. Always double check to make sure that the pressure is bled off before hammering on iron. If you are unsure, check with your supervisor.Revision 1 June 2000Example:Standard sized 1360 cu- ft Bulk tank with a 80 degree cone has a total area of 199,540 Sq-in area. (462 sq-ft in the cone, or 66,528 sq-in and 923 sq-ft or 132,912 sq-in in the shell.). 1 PSI exerts 199,540 lbs of force in this tank 2 PSI = 399080 etc. That is a lot of energy contained in a bulk tank. DO NOT HAMMER ON BULK TANKS . This weakens the steel and can result in a catastrophic failure. Emphasize this point to the participants. The standard hatch is 20 in in diameter. This equals 314 sq-in. 1 PSI exerts 314 pounds of force on the hatch..., 2 psi = 614 pounds, 3 psi = 942 pounds etc... the point is low pressure can still equal high danger if treated improperly. Some bulk tanks are rated to safely operate with up to 80 psi, the force exerted here is tremendous. Above formula is Force = Pressure x Area.

Revision 1 June 2000Never try to tighten a line under pressure by hammering on it, always isolate the pressure and bleed off first. Carbon steel becomes brittle at -40 degrees F. One blow from a hammer can shatter the line with catastrophic results.Rubber hoses cannot be used to pressure test or treat without management approval.Dont try to find leaks by feeling for them with your bare hand or stand in the path of bleeding pressure. Examples of accidents should be included here for discussion with the class. These can be obtained from your HSE representative. NOTE:You MUST not reveal specifics of accidents when discussing them. The lessons learned is what we want to focus on not who, what, when, where, etc. You cannot give names, dates, specific locations, or customer names.Revision 1 June 2000There are other hazards associated with liquid nitrogen that we are not going to discuss in this course. Our focus in this program is pressure safety. With an expansion ratio of 697-1 nitrogen can exert a tremendous amount of force. Trapped liquid nitrogen will absorb heat and can exert pressure in excess of 21 tons per square inch. This is why our pumping systems are designed using a primary safety valve and a secondary bursting disk assembly anyplace nitrogen can be trapped. Instructor should download and discuss with class the safety alerts referenced below.Pressure piping (energized fluids) failure during a nitrogen (N2) stimulation job Dec 30,1998Nitrogen mandrel failure from the use and maintenance of nitrogen charged testing tools October 8, 1999Nitrogen test failure March 15, 2000Revision 1 June 2000When rigging up at the wellsite, make sure to use the correctly rated iron for the job being performed. Iron has different pressure ratings, 602 - 6000psi , 1002 - 10,000psi,1502 - 15000 psi, 2002 - 20,000 psi, 2202 - 15000 psi Sour gas. Female 1502 male sub half wing nuts will make up on 602 or 1002 female thread halves, appear to be tight, and hold pressure for a time. Once the pressure reaches the give point, the connection will fail allowing the 1502 wing nut and whatever is attached to it blow off. This failure can occur well below the expected pressure. There have been multiple safety alerts issued by IADC (International Association of Drilling Contractors) on this topic. www.iadc.org/alerts/sa00-15.htm , www.iadc.org/alerts/sa98-1.htmwww.iadc.org/alerts/sa99-33.htmIf you are ever unsure about the connections always check with your supervisor.

Revision 1 June 2000 Pressure test areas should only be entered by authorized personnel. These areas are clearly marked with signs, barriers, flashing lights etc. When testing, employees in the affected area should be notified prior to beginning the testing process. When the pressure is bled off and the all clear is sounded, authorized employees may reenter the area. Revision 1 June 2000 Flashing lights and or PA systems are the most common means of communicating the testing process at Halliburton facilities. Many times mobile signs or barriers are erected as well.

Revision 1 June 2000Barriers are also used to control hazards.Revision 1 June 2000Check all seals, gaskets, and seal areas. Look for signs of wear/damage. Pitting, cracks, corrosion, unauthorized welding etc. Replace any damaged equipment. Always check with your supervisor if youre unsure.Instructor should try to provide examples of damaged equipment. Reference HSE alerts;

Discharge manifold equipment (DME) failure during pressure testing Dec 23,1998Malfunction of backpressure control and/or relief valves due to pressure testing October 22, 1999Dangers of fluids under pressure (i.e. hydraulic fluid) December 1, 1999Revision 1 June 2000Check the Hammer unions for wear. Each lug must have at least 1/8 inch of flat on the face. If there is less than 1/8 inch the union should be replacedRevision 1 June 2000Do not weld pressure hoses, chicksans, steel rotary hoses etc. Welding on pressure lines/equipment requires special equipment, training, certifications and authorizations. If you find a piece of pressure iron that has been welded on or modified, notify your supervisor immediately. Do not use it unless it is safe and has been cleared by your supervisor.Revision 1 June 2000Replace equipment that has been damaged. A recommended procedure is to cut up damaged and discarded equipment so it may not be repaired and reused.This destroyed equipment should be properly disposed of as scrap.Revision 1 June 2000Hand out copies of the standards and discuss.Revision 1 June 2000Review key points with the class. Administer the written test. Enter record of the training in the appropriate data base (I.e. SAP, BTS, etc.).Revision 1 June 2000