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Maintain Potential Facilities Offshore Long Term


Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

INDEX

INDEX ..................................................................................................................................................2
1. SCOPE AND PURPOSE ...........................................................................................................4
2. DEFINITIONS AND ACRONYMS .............................................................................................4
2.1 PROJECT DEFINITIONS 4
2.2 ACRONYMS 4
3. RESPONSIBILITIES AND OBLIGTIONS .................................................................................4
4. REFERENCE DOCUMENTS ....................................................................................................5
4.1 CODES AND STANDARDS 5
4.2 COMPANY DOCUMENTS 5
4.3 CONTRACTOR DOCUMENTS 5
5. PROCEDURE ............................................................................................................................6
5.1 OPERATING CONDITIONS 6
5.2 RISK ASSESSMENT 6
5.3 SAFETY DATA SHEETS 6
5.4 SITE SPECIFIC SAFETY 6
6. DESCRIPTION OF ERECTION WORK ....................................................................................7
6.1 MAIN ACTIVITIES 7
6.2 EXECUTION 8
6.3 COMPLETION OF ACTIVITY 10
7. ACCEPTANCE AND TESTING ............................................................................................. 11
8. APPENDICES AND REFERENCE DOCUMENTS ................................................................ 11

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 2 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

AMENDMENTS AND REVISIONS

Amendment Contractor
Date Page Description
and revision Representative
All
A1 31.01.2016 Issued for Internal review GC
Pages
All
B1 12.02.2016 Issued for Company Comments / Approval GC
Pages
Issued for Construction
Procedure approved with Comments as per Letter IPIU-L-
75/206 (Advance Copy), Comments as per letter has been
incorporated.
All
0 29.02.2016 GC
Pages
- Added NAS 1638 as reference Standard in Section 7
- Added Table from NAS 1638 hydraulic Fluid Cleanliness level
acceptance Criteria

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 3 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

1. SCOPE AND PURPOSE


This procedure defines the general requirement of hot oil flushing for tubing on the LTA – Maintain Potential
Facilities project. The acceptable fluid cleanliness specification will be NAS 6 or better.
Flushing will be done using FS500 flushing skid to circulate the oil and remove of any particles from the oil for a
more effective flushing. One micron filters will be used and the samples tested with particle counting equipment
to determine the cleanliness. Once the oil is clean, it will be transferred to the system and then circulated. A high
pressure pump will be used to achieve the velocity required to create turbulence inside of the pipework. The
flushing equipment will be connected to the system to be cleaned using temporary hoses. An on-board heater on
the FS500 unit will be used to raise the temperature of the oil for a more effective oil flush.
Contractor will provide onsite sampling to verify the cleanliness of samples taken from the system during the
flushing operation. This will allow the onsite supervisor to monitor the job progress and determine when the
required specification has been met. The acceptable cleanliness specification is NAS 6 or better.

2. DEFINITIONS AND ACRONYMS

2.1 PROJECT DEFINITIONS

PQP Project Quality Plan

SAPMT Saudi Aramco Project Management Team

2.2 ACRONYMS

COMPANY Saudi Aramco

CONTRACTOR Snamprogetti / STAR Consortium

STAR Saipem Taqa Al-Rushaid Fabricators Co. Ltd.

QC Quality Control

3. RESPONSIBILITIES AND OBLIGTIONS


Construction Department Perform the work as per the requirements of Contract Documents, IFC
Drawings, Aramco Standard and Quality Plan
Technical Representation/Supervision: 24 hour coverage of flushing service.

Equipment required to perform the hot oil flushing job scope as outlined in
this procedure, including filter bags.

Spill containment

Collection and analysis of samples during the hydraulic oil flush activity

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 4 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

QC Inspector Perform all inspections as per the ITP to verify the requirements as per IFC
Drawings and Aramco Standards. Prepare Inspection Reports
QC Supervisor Coordinate the inspection activities and verify the QC report for completion
and sign the document
Third Party Laboratories Perform the required inspection or test as per the requirements of
specification.

4. REFERENCE DOCUMENTS

4.1 CODES AND STANDARDS

ISO 9001:2008 Quality Management System – Requirements

NAS 1638 CLEANLINESS REQUIREMENTS OF PARTS USED IN HYDRAULIC SYSTEMS

4.2 COMPANY DOCUMENTS

DE-119892 Procedure for Material Receiving Handing and Storage

DE-119890 Procedure for Instrument and Control System Installation

DE-930526 Mechanical Completion Check List and Performance Testing and Acceptance

DE-119895 Quality Assurance and Quality Control

SAUDI ARAMCO Engineering Standard


SAES–J-901 Instrument Air Supply Systems
SAUDI ARAMCO Material System Specification
26-SAMSS-051 Hydraulic oil
SAUDI ARAMCO Typical Inspection Plan
SATIP-J-901-01 Instrument Air Supply System

4.3 CONTRACTOR DOCUMENTS

00-C0-C-CO-Q-P-045 Project Quality Plan

00-C0-C-CO-Q-P-007 Control and Monitoring of Measuring Device

00-C0-C-CO-Q-P-012 Quality Records Procedure.

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 5 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

5. PROCEDURE

5.1 OPERATING CONDITIONS


Prior to setting the system up for the hydraulic oil flushing operation, shall have carried out all required
preparations and approvals.
A preliminary walk-down of the tubing system will be made. The identification and correction of the system
boundaries, vent points, fill points and other conditions shall be made.
All sensitive components (instrumentation, valves, flow elements etc.) that are not to be subjected to the oil flush
are to be disconnected, bagged and attached to the equipment during the duration of the test. The job
supervisor will advise the pipe-fitting crew that each broken flange or connection is covered to preserve them
from dust, particulate, moisture, etc

5.2 RISK ASSESSMENT


Risk management is a mechanism to help predict and deal with events that might cause harm to personnel,
equipment or the environment during the execution of the services. Risk management also addresses potential
situations which would lead to schedule delays or cost escalations.
Risk assessments are an integral part of the risk management plan, studying the probability, the impact, and the
effect of every known risk on the project, as well as the corrective action to take should that risk occur.
Contractor performs Risk Assessments on each service line to mitigate any negative impacts on the job. It is
also advisable to perform a review of the included Risk Assessment on site prior to the job execution to address
any new or unforeseen situations. See the Appendix1 for the Oil Flushing specific Risk Assessment.

5.3 SAFETY DATA SHEETS


See Appendix 5: for Material Safety Data Sheet for the following materials:
Shell Tellus 68 hydraulic oil

5.4 SITE SPECIFIC SAFETY


Safety Briefing / Tool Box Talk: A tool box talk / pre-job safety meeting will be conducted before undertaking
any operation. The flushing operation presents some unique hazards and can affect a significant portion of the
pump house area. For this reason the audience for this tool box talk must include all personnel involved in the
work.

Red Ribbons and Tags: Sufficient red ribbon will be installed to inform personnel that the oil system is being
flushed and that access is restricted to personnel directly involved in the operation. Tags will be posted on the
ribbon listing the hazards and contact information of the job supervisor. Site safety personnel will be walked
through the area and the control measures pointed out for comment and enforcement.

Spills and Leaks: The job supervisor will ensure that sufficient spill containment systems are erected in the area
of the flushing equipment and the temporary system. Spill containment materials will be available on site for use
by all personnel involved as required. Personnel not involved in the flushing operation will be requested to

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 6 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

report all leaks to flushing personnel and not to undertake any repairs themselves. The job supervisor will
determine how leaks are to be mitigated or repaired.

Chemicals: Contractor personnel will be responsible for ensuring that any chemicals required are handled by
trained personnel employing the proper PPE and handling techniques. MSDS sheets will be available on site for
all materials used in the hydraulic flushing operation. Copies of the MSDS will be provided to the client, and the
pipe-fitting supervisor before flushing begins and can be made available to piping foreman interested in
providing them to their crews.

Waste Handling / Disposal: All waste generated by the flushing operation and post-operational cleaning shall
be contained within approved waste storage containers located near the containment areas. An inventory of
waste material volumes and contents shall be provided to the client following the flushing operation. The client
shall be responsible for the disposal of all waste material generated by the flushing operation.

Sample Handling: The job supervisor, or his designate, will be responsible for determining the locations from
which samples will be taken for testing. In addition to ensuring that these samples are indicative of the entire
system cleanliness level the job supervisor will ensure that the samples are handled safely and only by
personnel wearing the proper PPE. Because of the high temperature of this fluid protective gloves and high-
temperature rated containers must be used. Locations from where samples are to be taken to shall be agreed to
by the onsite Client Representative.

6. DESCRIPTION OF ERECTION WORK

6.1 MAIN ACTIVITIES

Step Action

The Construction Supervisor shall inspect the jobsite prior to the arrival of equipment on site.
1 Determine the equipment layout and the sequence of arrival so as to minimize congestion and impact
on other site work.

Inspect the system to confirm the location of the injection and discharge points and to determine how
pipes and hoses can be routed to minimize the impact on other work being conducted on the site.
2
Locate the flushing equipment so that there is short access to the system in order to reduce heat loss
and required hoses.

Before the equipment arrives build a containment area to house the FS500 pumping/filtration unit, HP
3 pump and manifolds in the event that a spill or leak of flushing fluid occurs. The bunding shall be built
to protect the equipment from contamination.

4 Place the flushing equipment inside the bunds built to house it.

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 7 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

Step Action

Place oil within a containment area to facilitate transfer of the fluid. Locate the air driven diaphragm
5
pumps and air supply near the tote tanks.

Create a loop on the ground with the FS500 to make the oil circulate through the skid to remove any
6
particle in the oil prior to flush it on the system.

Run hoses from the HP skid to each deck level of the platform where shall be installed the manifolds
to make the system circulate for each loop performed as per the P&ID’s provided. Due to the small
7
diameter of the pipes, short loops shall be created for each connection to be able to achieve the
proper turbulence inside to the pipes or tubing.

During the rig up pay special attention to preserve and protect the client’s equipment and
instrumentation. Advise the pipe-fitting crew that each broken flange or connection is covered
8 (wrapped up or blinded) to preserve them from dust, moisture, etc. Furthermore, all instrumentation,
fittings, orifice plates, gaskets, etc removed from the oil system should be bagged and attached to the
skid. Keep them there until the later reinstatement of the system.

Post signs to inform all personnel in the area that the piping in the system being flushed is hot.
Temperatures at points in the system may reach as high as 75 degrees Celsius during the flushing
9
operation. Put up red ribbon and signage to keep non-authorized personnel away from the piping
and hose.

Once the rig in has been completed and before any operation begins, make sure that the Site Safety
10 Representative is aware that flushing operations are about to begin and invite the Safety
Representative to review the set up and spill containment.

The job supervisor will walk through the equipment and the system with the Client Representative to
ensure that all parties are satisfied with the equipment layout and the containment barriers erected.
11
The job supervisor and client representative should then sign the operations report to indicate that the
system is ready for operations to commence.

6.2 EXECUTION
When the system setup is complete and reviewed by the client and Contractor representatives and all parties are
satisfied with the arrangements the oil flushing operation can commence.

Step Action

Conduct a gross leak test of the system and all attached hoses, manifolds, and valves using air to
1 bring the system pressure up in stages from 0 psig while gradually bringing the pressure up to 30
psig. Observe all connections during the pressurization for leaks.

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 8 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

Step Action

1. Start pressure test between the pump and the supply manifold with dry air from a compressor or
use instrument air. Pressurize system to 15 psig and hold for 10 minutes then visually inspect for
any leaks.
2. If leaks are observed, depressurize the system and repair leaks. Ensure there is zero energy on
the system prior to repairing leaks
3. If there is no leak on the system, open the valve and slowly begin pumping air into the system in
a controlled manner until the pressure reaches 30 psig.
2
4. Upon reaching the leak test pressure, cease pressurization and stabilize the system Hold the
pressure for at least 10 minutes while visually inspecting that there is no pressure drop
(gauges). If pressure drop is observed, depressurize the system and repair leaks.(Repeat steps
3 and 4)
5. If no leaks are detected, proceed to slowly bleed the system to zero pressure. The testing
supervisor must confirm that there is no trapped pressure remaining in the system.
The job supervisor will note that a satisfactory leak test has been performed on the Operations Report
and state in writing that he considers the system to be ‘Ready for Flushing’.

Initial Oil Filtration: Slowly fill the FS500 skid with the flushing oil. The oil shall be pumped into the
3
system using a temporary pump.
The oil will be heated up and circulated through the FS500 skid to clean it. Use high point vents to
4
bleed entrapped air and evolved gases from the oil system as required.
Bypass the filter pot when the flushing pump is running when the circulation begins until sufficient
5
fluid temperature (ie fluid viscosity) has been reached to prevent damage to the filters.
Turn on the heater on the flushing skid to raise the temperature of the oil to 70°C. Once the oil is up
6
to temperature the flow can be fully directed through the filters.
Should emulsification be seen in the returning oil due to the presence of water, the Contractor will
7 consult with the client representative on methods for removing: e.g evaporation, dry air / nitrogen
injection.
Take oil samples at the Contractor discretion from the system and analyze them for cleanliness using
8 a microscope or electronic particle counter. Analysis will assist the Flushing Supervisor to determine
the duration of the flushing operation.

When the oil meets the NAS 6 requirement it will be transferred to the HP skid to begin flushing the
9
hydraulic system.

Flush each leg of the oil system as per the looping diagrams. Pay particular attention to ensure that
each leg and valve of the oil system has had sufficient flow through them to achieve the cleanliness
10
specification required. Cycle valves to induce hydraulic shock and use soft percussion hammers at
welds and joints to dislodge foreign material.

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 9 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

Step Action

Continue cycling through the loops and flushing under the direction of the Contractor Supervisor until
11 the oil samples show that the system is clean. At the point that the Contractor Supervisor deems the
system to be clean ask the Client Representative to witness the sample.

12 If third party analysis is to be performed it will be done at this stage.

Should the Flushing Supervisor and Client Representative agree that the cleanliness specification
13
has been met and that flushing is complete both parties will sign the required papers to that effect.

Contractor Supervisor will proceed with draining the oil system of fluid. It is recommended that a
14
clean, dry air or nitrogen source is used for this process to avoid re-contaminating the system.

Pay special attention to protect each pipe end on the cleaned system from possible contamination
15
before final reinstatement.

With the system drained of oil, organize post-operational hose and adapter disconnection and
16
preparation for cleaning of the flushing unit and used hoses, valves, and manifolds.

Post Operational Cleaning: Conduct post operational cleaning of the FS500 flushing unit and the
17 hoses, valves and manifolds used to flush the oil system. Supply of clean water and disposal of
spent cleaning materials will be the responsibility of the Client.

Add degreasing chemicals to the water circulation to aid in cleaning the equipment. Contractor
18 Supervisor will direct the cleaning operation and ensure that all effluent is captured in waste storage
tanks on-site for later disposal by Client.

The Flushing Supervisor shall be responsible for determining when the cleaning operation is
19
complete and for recording and handing over the effluent materials to the Client.

Steps 17-21 above should not be required when moving the equipment between the different
20
platforms. It will be required on final completion or if a long gap is required between work scopes.

6.3 COMPLETION OF ACTIVITY

Step Action
When the post-operational flush has been completed the Contractor Supervisor will direct the remove
1 of all equipment. Disassemble the equipment and pack it in a manner that will protect it during
transport from the jobsite.

2 Any remaining paperwork shall be signed off by the client representative before leaving site.

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 10 of 11
UNCONTROLLED COPY
Maintain Potential Facilities Offshore Long Term
Agreement
Contract No.6600019096
Doc.No.
00-C0-C-CO-Q-P-071
Date
GENERAL PROCEDURE FOR OIL FLUSHING Rev. 0
29.02.16
Original Doc
FQET2135.15-PR-OF-01

7. ACCEPTANCE AND TESTING


The fluid cleanliness shall be NAS 6 or better. Contractor will provide equipment and personnel for performing
this testing. The fluid samples shall be taken from the system at locations representative of the total system
cleanliness as per Table in accordance with NAS 1638 standard “ Appendix 6 Hydraulic Fluid Cleanliness levels”

8. APPENDICES AND REFERENCE DOCUMENTS


Appendix 1: Risk Assessment Oil Flushing
Appendix 2: Listing of Tubing to be cleaned
Appendix 3: Client Supplied Drawings
Appendix 4: Flushing Sketches
Appendix 5: Shell Tellus 68 MSDS
Appendix 6: Hydraulic Fluid Cleanliness Levels

This document is CONFIDENTIAL and the sole property of SNAMPROGETTI/ STAR CONSORTIUM. It shall not be shown to Third Parties nor used for purposes other than those fo which it was prepared..
Page 11 of 11
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Appendix 1 Lube Oil Flush Risk Assessment

Risk Assessment Methodology:


Step Description
1 Generate list of hazards.
2 For each hazard estimate the probability of occurrence.
3 Estimate severity of potential injury, equipment damage or environmental damage.
4 Use Risk Rating Table to assign Initial Risk Rating.
5 Assess risk tolerability / acceptance.
6 Introduce control measures to mitigate risk.
7 Reassess risk tolerability / acceptance with new control measures implemented.
8 Assign new risk rating and assess Risk Tolerability / Acceptance
9 If Residual Risk Rating is adequate continue and assess next hazard.
10 If Residual Risk Rating is not adequate the hazard must be re-evaluated.

PROBABILITY OF OCCURRENCE
High Probability Regular occurrence within the area of operations to which it refers, with the possibility of RISK RATING TABLE Low Probability Moderate Probability High Probability
being realized once per day/shift. Low Severity 1 Low Risk 2 Tolerable Risk 3 Moderate Risk
Moderate Occasional occurrence with the possibility of being realized once per
Probability job/project/contract/month. Moderate Severity 2 Tolerable Risk 3 Moderate Risk 4 High Risk
Low Probability Unlikely to occur but known to have occurred in the relevant industry/operation/type of work High Severity 3 Moderate Risk 4 High Risk 5 Unacceptable Risk
it refers to.

INJURY SEVERITY
High Severity Major Injury/Disablement/Fatality – Examples: Amputation, major fracture, poisoning, RISK TOLERABILITY / ACCEPTANCE TABLE
multiple injuries, occupational cancer or other severe life shortening diseases, acute fatal Risk Rating Remedial Action and Timescale
diseases. 5 Unacceptable Risk Work shall not be started or continued until the risk has been reduced. If it is not possible
Moderate Severity Lost Time Injury – Examples: Lacerations, burns, concussions, serious sprains, minor to reduce the risk even with unlimited resources, work shall remain prohibited.
fractures, deafness, dermatitis, asthma, work related upper limb disorders, ill health leading to 4 High Risk Work shall not be started until the risk has been reduced. Considerable resources may be
permanent minor disability. required to do this. Where the risk involves work in progress, urgent action shall be
Low Severity First Aid Injury, Medical Aid Treatment Injury - Examples: Return to work after onsite taken.
treatment of superficial injuries, minor cuts/bruises, eye irritation, headaches or temporary 3 Moderate Risk Work may proceed but efforts should be made to reduce the risk below this level. The
discomfort. resources/costs required for prevention should be carefully measured and limited. Risk
reduction measures and remedial action shall be implemented as soon as practicable and
EQUIPMENT SEVERITY within one month as a maximum. Where the moderate risk (level 3) involves high
High Severity Replacement equipment costs (direct / indirect) exceed $100,000 severity consequences, further assessment may be necessary to establish the likelihood
Moderate Severity Replacement equipment costs (direct /indirect) between $5,000 and $100,000 more precisely and determine the need for improved control measures.
Low Severity Replacement equipment costs (direct / indirect) less than %5,000 2 Tolerable Risk No additional costs are required. Consideration may be given to more cost effective
remedial actions or improvements that involve no additional resources/cost burden.
Monitoring is required to ensure that controls are maintained and in place.
ENVIRONMENTAL SEVERITY 1 Low Risk Risk Acceptable. No action required.
High Severity Environmental damage is catastrophic and/or involves prosecution, severe damage to
company image and substantial costs.
Moderate Severity Environmental damage external to local area and/or damage to company image and
profits.
Low Severity Environmental damage is local and has minimal external impact.

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Appendix 1 Lube Oil Flush Risk Assessment

RISK RESULT HARM TO INITIAL RISK CONTROLS RESIDUAL RISK


TASK / JOB STEPS Equipment, Property, Risk Describe controls to employed to mitigate risk. Procedural, Risk
Potential action or event causing harm Consequences resulting from hazard situation Severity Probability
Rating
Severity Probability
Rating
Environment, Personnel engineering, PPE, etc
Prepare detailed work Improper identification of piping Possible utility heat medium release. Personnel in vicinity of M H 4 Procedure will be checked and approved by three parties: M L 2
procedure circulation subsystems. operations. Environment Procedure writer, Job Supervisor and Client Representative
Prepare detailed work Loops not properly sized for flow. System Plugging of heat trace lines or Process equipment, piping M M 3 Procedure will be checked and approved by three parties: M L 2
procedure not fully cleaned. damage to process equipment on start freezing. Procedure writer, Job Supervisor and Client Representative
up.
Preparation for lube oil Connecting and moving equipment. Possibility of spills and injuries. Personnel in vicinity of M H 4 Minimize equipment connections and movement. Use M L 2
flush operations. Environment trained personnel and approved equipment.
Preparation for lube oil Incorrect piping connected to circulation Contamination of other piping. lube Environment. Process H M 4 System will be checked by contractor and client before H L 3
flush paths. oil spill. equipment. filtration procedure starts.
Preparation for lube oil Filling system with lube oil. Splashing and spilling of lube oil. Environment M M 3 Use care when transferring fluids. Secure hoses. Use proper M L 2
flush PPE. Use containment. Refer to MSDS
Preparation for lube oil Incomplete filling of system with lube oil. Possible air trapped in piping causing Process equipment M M 3 Each high point will be monitored during lube oil filling. M L 2
flush pump cavitations. Points will be check before circulation begins.
Preparation for lube oil Rigging up temporary equipment for flush. Slips, trips and falls. Incorrect lifting, Personnel involved in M H 4 Make personnel aware of hazards. Team or mechanical M L 2
flush pinch points. operation. lifting. Route equipment to minimize tripping hazards.
Pre-job walk-down and Work area not flagged off or signed. Unauthorized entry into flushing Process, environment. M M 3 Verify red tape up before starting pumping operations. Keep M L 2
inspection area. Equipment modified. a watch for unauthorized personnel in the area. Use LOTO.
Proving loops. Piping not cross connected properly. Spill or contamination of adjacent Process, environment. H M 4 Follow provided work procedure. Field verify all H L 3
system. connections prior to system circulation.
Lube oil flush System pressurized and circulating. Leaky connections Environment, personnel H M 4 System checked for any changes before starting pump. Use H L 3
only approved hoses for connections.
Lube oil flush Changing loops; close wrong valve. Dead head the flow. Process equipment. M M 3 Follow procedure; always open valves for next loop before M L 2
closing valves.
Lube oil flush Changing loops; close wrong valve. Pipe hammering. Process equipment M M 3 While changing loops, monitor pump flow and pressure. M L 2
Open valves slowly.
Lube oil flush Pipe frozen. No or low flow. Dirty equipment Process H M 4 Monitor the temperature of the fluid being flushed. Check H L 3
after the flush. the flow in each pipe in the loop.
Lube oil flush Purging heat trace manifolds. lube oil spills and splashes. Personnel, environment. M H 4 Open valves with caution. Use proper containment. Use M L 2
proper PPE. Use trained personnel.
Lube oil flush Heating equipment lines. Hot lines and severe burns Personnel M H 4 All temporary piping insulated. Area flagged off and signs in M L 2
place.
Finish lube oil flush Closing valves Improper isolation leading to lube oil Personnel, equipment, M H 4 Ensure all valves seat properly. Check drains and vents. Use M L 2
release and spills. environment. containment when breaking system.
Rig out from filtration Breaking joints, draining lines. Uncontrolled spills. Personnel, environment, M H 4 Ensure lines are properly drained. Walk out hoses before M L 2
equipment. disconnecting.
Rig out from filtration Breaking system connections. Contamination of clean piping. Process M M 3 Mark the line as clean in the field. M L 2
Rig out from filtration Drain and disconnect temporary equipment Spills Personnel, environment. M H 4 Check all vents and drains. Use proper containment and M L 2
equipment (vac truck).
Rig out temporary Lifting heavy equipment Swinging loads, pinch points, Personnel, equipment M H 4 Use proper lifting procedures and equipment. Ensure all M L 2
equipment damage to equipment personnel are informed of operations.
Rig out temporary Congested work areas Slips, trips and falls. Personnel M H 4 Keep work area clear. Clean up hose, equipment, etc. M L 2
equipment

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Appendix 2

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Appendix 3

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Appendix 3

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Appendix 3

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Appendix 4

To Flushing Skid

D-0001 Pressure Sense

From Flushing Skid

D-1011 Pressure Sense

To Flushing Skid

D-0002 Pressure Sense

From Flushing Skid

D-0003 Pressure Sense

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Appendix 4

To Flushing Skid

D-0006 Pressure Sense

From Flushing Skid

D-0010 Pressure Sense

To Flushing Skid

D-0004 Pressure Sense

From Flushing Skid

D-0005 Pressure Sense

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Appendix 4

Run back to flushing unit

From Flushing Unit

D-0007 Pressure Sense

Jumper over ESD Hand


Station

From ESD Panel


To hydraulic return to ESD Panel

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Appendix 4
To Manifold / Flushing Skid

Neutralization Tank
From Flushing Skid
To Manifold / Flushing Skid

Slops Pump
From Flushing Skid

To Manifold / Flushing Skid

Slops Tank
From Flushing Skid

To Manifold / Flushing Skid

Corrosion Inhibitor
From Flushing Skid

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

1. MATERIAL AND COMPANY IDENTIFICATION

Material Name : Shell TELLUS OIL 68


Uses : Hydraulic oil

Manufacturer/Supplier : SOPUS Products


PO BOX 4427
Houston, TX 77210-4427
USA
MSDS Request : 877-276-7285

Emergency Telephone Number


Spill Information : 877-242-7400
Health Information : 877-504-9351

2. COMPOSITION/INFORMATION ON INGREDIENTS

Highly refined mineral oils and additives.


The highly refined mineral oil contains <3% (w/w) DMSO-extract, according to IP346.

3. HAZARDS IDENTIFICATION

Emergency Overview
Appearance and Odour : Light brown. Liquid at room temperature. Slight hydrocarbon.

Health Hazards : High-pressure injection under the skin may cause serious
damage including local necrosis.
Safety Hazards : Not classified as flammable but will burn.
Environmental Hazards : Not classified as dangerous for the environment.

Health Hazards : Not expected to be a health hazard when used under normal
conditions.
Health Hazards
Inhalation : Under normal conditions of use, this is not expected to be a
primary route of exposure.
Skin Contact : Prolonged or repeated skin contact without proper cleaning can
clog the pores of the skin resulting in disorders such as oil
acne/folliculitis.
Eye Contact : May cause slight irritation to eyes.
Ingestion : Low toxicity if swallowed.
Other Information : High-pressure injection under the skin may cause serious
damage including local necrosis. Used oil may contain harmful
impurities.
Signs and Symptoms : Oil acne/folliculitis signs and symptoms may include formation
of black pustules and spots on the skin of exposed areas. Local
necrosis is evidenced by delayed onset of pain and tissue
damage a few hours following injection. Ingestion may result in
nausea, vomiting and/or diarrhoea.

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

Aggravated Medical : Pre-existing medical conditions of the following organ(s) or


Condition organ system(s) may be aggravated by exposure to this
material: Skin.
Environmental Hazards : Not classified as dangerous for the environment.
Additional Information : Under normal conditions of use or in a foreseeable emergency,
this product does not meet the definition of a hazardous
chemical when evaluated according to the OSHA Hazard
Communication Standard, 29 CFR 1910.1200.

4. FIRST AID MEASURES

General Information : Not expected to be a health hazard when used under normal
conditions.
Inhalation : No treatment necessary under normal conditions of use. If
symptoms persist, obtain medical advice.
Skin Contact : Remove contaminated clothing. Flush exposed area with water
and follow by washing with soap if available. If persistent
irritation occurs, obtain medical attention. When using high
pressure equipment, injection of product under the skin can
occur. If high pressure injuries occur, the casualty should be
sent immediately to a hospital. Do not wait for symptoms to
develop. Obtain medical attention even in the absence of
apparent wounds.
Eye Contact : Flush eye with copious quantities of water. If persistent
irritation occurs, obtain medical attention.
Ingestion : In general no treatment is necessary unless large quantities
are swallowed, however, get medical advice.
Advice to Physician : Treat symptomatically. High pressure injection injuries require
prompt surgical intervention and possibly steroid therapy, to
minimise tissue damage and loss of function. Because entry
wounds are small and do not reflect the seriousness of the
underlying damage, surgical exploration to determine the
extent of involvement may be necessary. Local anaesthetics or
hot soaks should be avoided because they can contribute to
swelling, vasospasm and ischaemia. Prompt surgical
decompression, debridement and evacuation of foreign
material should be performed under general anaesthetics, and
wide exploration is essential.

5. FIRE FIGHTING MEASURES

Clear fire area of all non-emergency personnel.

Flash point : Typical 223 °C / 433 °F (PMCC / ASTM D93)


Upper / lower : Typical 1 - 10 %(V)(based on mineral oil)
Flammability or
Explosion limits
Auto ignition temperature : > 320 °C / 608 °F
Specific Hazards : Hazardous combustion products may include: A complex
mixture of airborne solid and liquid particulates and gases
(smoke). Carbon monoxide. Unidentified organic and inorganic
compounds.

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

Suitable Extinguishing : Foam, water spray or fog. Dry chemical powder, carbon
Media dioxide, sand or earth may be used for small fires only.
Unsuitable Extinguishing : Do not use water in a jet.
Media
Protective Equipment for : Proper protective equipment including breathing apparatus
Firefighters must be worn when approaching a fire in a confined space.

6. ACCIDENTAL RELEASE MEASURES

Avoid contact with spilled or released material. For guidance on selection of personal protective
equipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information on
disposal. Observe all relevant local and international regulations.

Protective measures : Avoid contact with skin and eyes. Use appropriate containment
to avoid environmental contamination. Prevent from spreading
or entering drains, ditches or rivers by using sand, earth, or
other appropriate barriers.
Clean Up Methods : Slippery when spilt. Avoid accidents, clean up immediately.
Prevent from spreading by making a barrier with sand, earth or
other containment material. Reclaim liquid directly or in an
absorbent. Soak up residue with an absorbent such as clay,
sand or other suitable material and dispose of properly.
Additional Advice : Local authorities should be advised if significant spillages
cannot be contained.

7. HANDLING AND STORAGE

General Precautions : Use local exhaust ventilation if there is risk of inhalation of


vapours, mists or aerosols. Properly dispose of any
contaminated rags or cleaning materials in order to prevent
fires. Use the information in this data sheet as input to a risk
assessment of local circumstances to help determine
appropriate controls for safe handling, storage and disposal of
this material.
Handling : Avoid prolonged or repeated contact with skin. Avoid inhaling
vapour and/or mists. When handling product in drums, safety
footwear should be worn and proper handling equipment
should be used.
Storage : Keep container tightly closed and in a cool, well-ventilated
place. Use properly labelled and closeable containers. Storage
Temperature: 0 - 50 °C / 32 - 122 °F
Recommended Materials : For containers or container linings, use mild steel or high
density polyethylene.
Unsuitable Materials : PVC.
Additional Information : Polyethylene containers should not be exposed to high
temperatures because of possible risk of distortion.

8. EXPOSURE CONTROLS/PERSONAL PROTECTION

Occupational Exposure Limits

Material Source Type ppm mg/m3 Notation

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

Oil mist, ACGIH TWA(Mist.) 5 mg/m3


mineral
Oil mist, ACGIH STEL(Mist.) 10 mg/m3
mineral

Exposure Controls : The level of protection and types of controls necessary will vary
depending upon potential exposure conditions. Select controls
based on a risk assessment of local circumstances.
Appropriate measures include: Adequate ventilation to control
airborne concentrations. Where material is heated, sprayed or
mist formed, there is greater potential for airborne
concentrations to be generated.
Personal Protective : Personal protective equipment (PPE) should meet
Equipment recommended national standards. Check with PPE suppliers.
Respiratory Protection : No respiratory protection is ordinarily required under normal
conditions of use. In accordance with good industrial hygiene
practices, precautions should be taken to avoid breathing of
material. If engineering controls do not maintain airborne
concentrations to a level which is adequate to protect worker
health, select respiratory protection equipment suitable for the
specific conditions of use and meeting relevant legislation.
Check with respiratory protective equipment suppliers. Where
air-filtering respirators are suitable, select an appropriate
combination of mask and filter. Select a filter suitable for
combined particulate/organic gases and vapours [boiling point
>65 °C (149 °F)].
Hand Protection : Where hand contact with the product may occur the use of
gloves approved to relevant standards (e.g. Europe: EN374,
US: F739) made from the following materials may provide
suitable chemical protection: PVC, neoprene or nitrile rubber
gloves. Suitability and durability of a glove is dependent on
usage, e.g. frequency and duration of contact, chemical
resistance of glove material, glove thickness, dexterity. Always
seek advice from glove suppliers. Contaminated gloves should
be replaced. Personal hygiene is a key element of effective
hand care. Gloves must only be worn on clean hands. After
using gloves, hands should be washed and dried thoroughly.
Application of a non-perfumed moisturizer is recommended.
Eye Protection : Wear safety glasses or full face shield if splashes are likely to
occur.
Protective Clothing : Skin protection not ordinarily required beyond standard issue
work clothes.
Monitoring Methods : Monitoring of the concentration of substances in the breathing
zone of workers or in the general workplace may be required to
confirm compliance with an OEL and adequacy of exposure
controls. For some substances biological monitoring may also
be appropriate.
Environmental Exposure : Minimise release to the environment. An environmental
Controls assessment must be made to ensure compliance with local
environmental legislation.

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance : Light brown. Liquid at room temperature.


Odour : Slight hydrocarbon.
pH : Not applicable.
Initial Boiling Point and : > 280 °C / 536 °F estimated value(s)
Boiling Range
Pour point : Typical -24 °C / -11 °F
Flash point : Typical 223 °C / 433 °F (PMCC / ASTM D93)
Upper / lower Flammability : Typical 1 - 10 %(V) (based on mineral oil)
or Explosion limits
Auto-ignition temperature : > 320 °C / 608 °F
Vapour pressure : < 0.5 Pa at 20 °C / 68 °F (estimated value(s))
Density : Typical 886 kg/m3 at 15 °C / 59 °F
Water solubility : Negligible.
n-octanol/water partition : > 6 (based on information on similar products)
coefficient (log Pow)
Kinematic viscosity : Typical 68 mm2/s at 40 °C / 104 °F
Vapour density (air=1) : > 1 (estimated value(s))
Evaporation rate (nBuAc=1) : Data not available

10. STABILITY AND REACTIVITY

Stability : Stable.
Conditions to Avoid : Extremes of temperature and direct sunlight.
Materials to Avoid : Strong oxidising agents.
Hazardous Decomposition : Hazardous decomposition products are not expected to form
Products during normal storage.

11. TOXICOLOGICAL INFORMATION

Basis for Assessment : Information given is based on data on the components and the
toxicology of similar products.
Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rat
Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg , Rabbit
Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal
conditions of use.
Skin Irritation : Expected to be slightly irritating. Prolonged or repeated skin
contact without proper cleaning can clog the pores of the skin
resulting in disorders such as oil acne/folliculitis.
Eye Irritation : Expected to be slightly irritating.
Respiratory Irritation : Inhalation of vapours or mists may cause irritation.
Sensitisation : Not expected to be a skin sensitiser.
Repeated Dose Toxicity : Not expected to be a hazard.
Mutagenicity : Not considered a mutagenic hazard.
Carcinogenicity : Product contains mineral oils of types shown to be non-
carcinogenic in animal skin-painting studies. Highly refined
mineral oils are not classified as carcinogenic by the
International Agency for Research on Cancer (IARC). Other
components are not known to be associated with carcinogenic
effects.

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

Reproductive and : Not expected to be a hazard.


Developmental Toxicity
Additional Information : Used oils may contain harmful impurities that have
accumulated during use. The concentration of such impurities
will depend on use and they may present risks to health and
the environment on disposal. ALL used oil should be handled
with caution and skin contact avoided as far as possible. High
pressure injection of product into the skin may lead to local
necrosis if the product is not surgically removed.

12. ECOLOGICAL INFORMATION

Ecotoxicological data have not been determined specifically for this product. Information given is
based on a knowledge of the components and the ecotoxicology of similar products.

Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic
organisms. Expected to be practically non toxic: LL/EL/IL50 >
100 mg/l (to aquatic organisms) (LL/EL50 expressed as the
nominal amount of product required to prepare aqueous test
extract). Mineral oil is not expected to cause any chronic
effects to aquatic organisms at concentrations less than 1 mg/l.

Mobility : Liquid under most environmental conditions. Floats on water. If


it enters soil, it will adsorb to soil particles and will not be
mobile.
Persistence/degradability : Expected to be not readily biodegradable. Major constituents
are expected to be inherently biodegradable, but the product
contains components that may persist in the environment.
Bioaccumulation : Contains components with the potential to bioaccumulate.
Other Adverse Effects : Product is a mixture of non-volatile components, which are not
expected to be released to air in any significant quantities. Not
expected to have ozone depletion potential, photochemical
ozone creation potential or global warming potential.

13. DISPOSAL CONSIDERATIONS

Material Disposal : Recover or recycle if possible. It is the responsibility of the


waste generator to determine the toxicity and physical
properties of the material generated to determine the proper
waste classification and disposal methods in compliance with
applicable regulations. Do not dispose into the environment, in
drains or in water courses.
Container Disposal : Dispose in accordance with prevailing regulations, preferably
to a recognised collector or contractor. The competence of the
collector or contractor should be established beforehand.
Local Legislation : Disposal should be in accordance with applicable regional,
national, and local laws and regulations.

14. TRANSPORT INFORMATION

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

US Department of Transportation Classification (49CFR)


This material is not subject to DOT regulations under 49 CFR Parts 171-180.

IMDG
This material is not classified as dangerous under IMDG regulations.

IATA (Country variations may apply)


This material is not classified as dangerous under IATA regulations.

15. REGULATORY INFORMATION

The regulatory information is not intended to be comprehensive. Other regulations may apply to this
material.

Federal Regulatory Status

Notification Status

EINECS All components listed or


polymer exempt.
TSCA All components listed.
DSL All components listed.

SARA Hazard Categories (311/312)


No SARA 311/312 Hazards.

State Regulatory Status

California Safe Drinking Water and Toxic Enforcement Act (Proposition 65)

This material does not contain any chemicals known to the State of California to cause cancer, birth
defects or other reproductive harm.

16. OTHER INFORMATION

NFPA Rating (Health, : 0, 1, 0


Fire, Reactivity)
MSDS Version Number : 3.0

MSDS Effective Date : 07/03/2008

MSDS Revisions : A vertical bar (|) in the left margin indicates an amendment
from the previous version.
MSDS Regulation : The content and format of this MSDS is in accordance with the

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Appendix 5

Shell TELLUS OIL 68


MSDS# 402288L
Version 3.0
Effective Date 07/03/2008
According to OSHA Hazard Communication Standard, 29 CFR
Material Safety Data Sheet 1910.1200

OSHA Hazard Communication Standard, 29 CFR 1910.1200.


MSDS Distribution : The information in this document should be made available to
all who may handle the product.

Disclaimer : The information contained herein is based on our current


knowledge of the underlying data and is intended to describe
the product for the purpose of health, safety and environmental
requirements only. No warranty or guarantee is expressed or
implied regarding the accuracy of these data or the results to
be obtained from the use of the product.

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Appendix 6 : NAS 1638 Hydraulic Fluid Cleanliness Levels 

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