WHAT I HAVE DONE TO IMPROVE SAFETY IN MY AREA

Presented By: Hussein Fneish Department: Hydro-testing / Pre-commissioning Project: GSF (GAS SWEETENING FACILITIES)

SAFETY HINTS RELATED FOR PRESSURE TESTING:

During hydro-testing and pressure testing operations incidents sometimes happen. There are some typical examples which can be used as an aid in highlighting the hazards and dangers involved of what are often seen as routine operations: 1. Filling a new line Ensure that the line is well prepared with proper ventilation 2. Emptying a line Control of the rate of draining as well as vents are open with plugs 3. Pressurizing a line Well allocating of testing gears as pressure gauges, pressure relief valves, manifolds, etc and never exceed the specified test pressure.

EXAMPLES OF PAST SITE INCIDENTS DUE TO TESTING:

ROLES, RESPONSIBILTIES AND COMPETENCIES IN PRESSURE TESTING AS A TEST ENGINEER IN TERMS OF SAFETY:
Roles: 1. Ensure that the work is performed in a safe manner Responsibility: 1. Supervise the successful implementation of tests 2. Define the interfaces required between groups in order not to have any conflict during pressurizing different tests at same area Competence: 1. Comprehend pressure ratings and technology 2. Communicate with others to ensure the transfer of information for safe testing execution 3. Develop Risk assessments and mitigate consequences 4. Prepare safety plans

MYSELF:
1. Organize my self mentally and physically to be fully committed with the positive approach for the safe work execution

2. Create a safe place/environment for my work force by offering them a a regularly safety tool box as well as a daily site safety guidance.
3. Generate a well communication within the testing crews to vanish the hazards while working with most hazardous environment in the manner of tools, materials and equipments utilized for testing commencement. 4. Well implementing for all the safety procedures 5. Focusing on all the minor items related to our activities from safety aspect.

SAFETY TOOL BOX:

MY WORK FORCE :
1. Guide them about the risk control techniques associated with pressurized systems. (For Example: Never tighten any fittings connections or flange under pressure as it may lead to serious injuries) 2. Enhance them about the installation of warning signs and proper barricading following the below formula:

Safe distance = (0.15) x (D) x (a)^0.4 x (p) ^0.6 Where D = internal diameter (m) a = length/diameter of the piece (m)
p = test pressure bar

3. All test equipments, testing gears (manifolds, pressure hoses with whip check, fittings) must be inspected for suitability and not having any wear or damage.

MY WORK FORCE (CONT.):

As a Golden Rule / Massage Passed to our Work Force on daily basis:

Tests may be a routine operation pressure for you, however, do not forget that in fact pressurisation is energy storage. Its instantaneous release works as a bomb and may cause severe damage to persons and equipment.
As for most of the operations, good preparation is essential to avoid incidents. It is recommended to use the following check list as a refresher for our team: (Refer to the Check-List at Slide # 9) Well disposal of water to the proper location avoiding any cause of vacuum

TESTING PRE-TEST CHECK LIST Witnessed CCIC/ TCC PIL Signature Date Signature

Item

Description A- Main line Receipt of approval to test Blind flange location / thickness verified Valve fully opened Flanges tight Bonnets tight Valves packing tight Bellows tie rods in test position Flanges Taped and pin holed Non return valves in proper position Leak test fluid available Tools available B- Fill line / Manifold

Remarks Date

1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5

System blown clean Leak test completed Fill line valve configuration verified Vents in operational condition Fill manifold valves locked C- Pressure gauge Manifold Connections tight Pressure tested Relief valve calibrated Gauge recorder calibrated D- General safety Adequate radio Exclusion zone identified Personnel excluded Compressor, PG. manifold barricade Safety / first aid notified

1 2 3 4

1 2 3 4 5

AREA OF RESPONSIBILITY
From Technical point of view Am in-charge for all testing/blowing/torque activities at AGRP From Safe Point of View Am in-charge for all site activities as our responsibility as senior staff is to recognize the fault and risk and try to eliminate them no matter who is responsible, when and why.