P3: Pressure Pipe Principles Carl Thunem, EHS Audit Manager
Encana Services Company, Ltd.
Presenter
Presentation Notes
The P3 project was developed after a number of critical incidents and near hits indicated that our existing efforts and systems were not managing the risks sufficiently. Two fatalities occurred in the US Division in 2012 Further review showed Canada and the USA operations have experienced significant incidents and near hits related to pressure and piping issues
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Pressure and Piping Project (P3) - Origins The P3 project was developed after a number of critical incidents and near hits indicated that our existing efforts and systems were not managing the risks sufficiently. •Two fatalities occurred in the US Division in
2012 •Further review showed Canada and the USA
operations have experienced significant incidents and near hits related to pressure and piping issues
December 2-3, 2014
Presenter
Presentation Notes
This is why we’re here. Also, we had different roll-outs in different areas and are now going back and making sure everyone is on the same page with the materials. The P3 project was developed after a number of critical incidents and near hits indicated that our existing efforts and systems were not managing the risks sufficiently. Two fatalities occurred in the US Division in 2012 Further review showed Canada and the USA operations have experienced significant incidents and near hits related to pressure and piping issues
Pressure and Piping Project (P3)
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Six key principles:
• Expectations surrounding well shut-ins • Managing personnel in ‘line of fire’
areas • Ensuring integrity of piping and
pumping equipment – including pipe restraints
• Safely managing flowback operations • Adherence and conformance to
established procedures • Enhanced application of our stop work
program
December 2-3, 2014
Presenter
Presentation Notes
Point out that the amount of force in each case is the same, but the pressure and volume (area) are significantly different.
Pressure Defined Pressure is the continuous physical force exerted on or against an object by something in
contact with it: the force exerted per unit area.
Pressure = Force per unit of Surface Area
Surface Area of a Pipe = PI x dia2 ÷ 4
• Force = Pressure x Surface Area • Low Pressure plus large area equals a greater force
When we compare 100 psi to 10,000 psi, it is much lower, but the reality of 100 psi and the force it can exert is not as harmless as it sounds.
December 2-3, 2014
December 2-3, 2014
Example 1 Example 2
Examples of Pressure/Force Calculations
• Pipe diameter 12”
• Pressure is 100 psi
• Area = π x dia² ÷ 4
• A=3.1415 x 12² ÷4
• A=113 sq in
• 100 psi X 113 sq in =
11,300 lbs of force
• Pipe diameter 3”
• Pressure is 10,000 psi
• Area = π x dia² ÷ 4
• A = 3.1415 x 3² ÷4
• A = 7.06 sq in
• 1600 psi X 7.06 sq in=
11,296 lbs of force
Presenter
Presentation Notes
These calculations came from “Low Pressure Operations Alert” which happened on July 5th. The incident occurred as the contractor was filling, inspecting, and pressure-testing the low pressure side of their water distribution system in preparation for a hydraulic fracture treatment. Two small leaks were identified at the attachment point of the end cap/plate to the manifold piping, which was operating at low pressure. The cap/plate blew off and the force of the water stream pushed the contractor backwards into some adjacent equipment. Recommendations: Pre-job planning and JSA’s should identify and evaluate the risks of low pressure systems to people. Ensure we effectively communicate danger of leaks in low pressure systems in pre-job safety meetings Always de-pressure leaking piping systems and conduct a new JSA prior to any approach. Keep personnel out of the immediate line of fire. Point out that the amount of force in each case is the same, but the pressure and volume (area) are significantly different.
Incident Prevention
• What controls are used to try and prevent hazards and incidents in the workplace
• Hierarchy of Control – Engineering – Administrative – PPE
• Energy Source Management – Elimination – Control – PPE/Space
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Prior to work
Immediately prior to and during work
December 2-3, 2014
Presenter
Presentation Notes
Hierarchy – pre-planned, typically well before work begins. Energy management – might be written before hand, but is done during the work. Both are important!! Let’s discuss each.
We manage pressure by: – Eliminating it – Controlling it, and/or – Protection against contact
These are covered in your FMEA’s, SOP’s, and
JSA’s!
Managing Energy Sources
December 2-3, 2014
Presenter
Presentation Notes
INCIDENT PREVENTION Using standard good safety practices, we manage energy sources three ways. The best way to manage energy is to eliminate it completely, so it is gone, it does not exist. Second we control the energy, it is still there but it is controlled to where it can not harm us. And, as a last resort, we protect ourselves from it with the use of barriers such as distance, PPE, or a guard. KEY POINTS The preferred methods of managing energy are listed in order of effectiveness, the process moves from one to the next only after all practical avenues have been ruled out. PPE is the last resort for protection. It is a “barrier of last resort” - usually a piece of plastic or cotton - between you and some form of energy.
Eliminate the energy (pressure) - make sure that the pressure is not present!
Remove the pressure by • Discharging pressure • Disconnecting lines • Draining lines
Managing Energy Sources
December 2-3, 2014
Presenter
Presentation Notes
ELIMINATE Eliminate the energy, make sure that the energy is not present. Remove the energy, discharge electricity or pressure, disconnect lines, drain lines. If you eliminate the energy it can no longer hurt you. KEY POINT Discuss with the group the methods of eliminating energy sources in their work place. BE CAREFULL TO DIFFERENTIATE BETWEEN ELIMINATION AND CONTROL - this can be an easy mistake to make. For elimination the energy source must no longer exist. Blocks, guards, and safety cables are controls, the energy is still there but controlled.
Eliminate - Example
December 2-3, 2014
Presenter
Presentation Notes
ELIMINATE Lockout tools A power disconnect lockout eliminates the source of the energy, however residual energy may exist in capacitors and batteries. After lockout, the power disconnect must be tested to ensure the energy has been eliminated. Lockout procedures specific to your work area should be reviewed and followed prior to working on electrical equipment. KEY POINT Procedures should be followed by competent personnel to perform lockouts in most facilities.
Control the energy- the pressure is still present but it is under control!
• Close line
• Stop energy flow
• Modify the rate of release
Control - Example
December 2-3, 2014
Presenter
Presentation Notes
CONTROL THE ENERGY The energy is still present but under control. Close the lines, stop the energy flow, or modify the rate of release. Blocking up heavy equipment is an example of control, the hazardous energy is still present but controlled. Double block and bleed is an example of controlling an energy source. KEY POINTS Controlling energy sources does not eliminate the energy. Energy controls must be planned carefully to ensure the proper level of protection.
Control - Example
December 2-3, 2014
Presenter
Presentation Notes
CONTROL Pressure relief valve Pipe chock A proper functioning pressure relief valve is an example of controlling energy. Bypasses and vent lines if properly sized and monitored can be used to control an energy source. KEY POINT Control systems must be carefully planed to ensure they provide the proper level of protection.
Protect against contact with pressure hazards using a barrier!
• Distance from the pressure source or potential line of fire
• Personal Protective Equipment
Managing Energy Sources
December 2-3, 2014
Presenter
Presentation Notes
PROTECT Protect yourself against contact with energy with a barrier, Personal Protective Equipment, guards on belt drives, or mechanical stops. A key item is distance from an energy source which is also a form of barrier. Hand rails and guard rails provide barriers. PPE alone may not be enough to protect a person. PPE must be capable of withstanding the force of the energy to which it is exposed. If you put on all the PPE that you can find and then step out in front of a bus going 40 miles an hour, it won’t provide you with much protection from the impact. The energy source is much greater than the equipment is designed to protect you from. KEY POINT PPE is the last resort for protection from energy hazards.
GROUP EXERCISE • What tools and resources do
you have to help you manage pressure?
• List them
14 December 2-3, 2014
Presenter
Presentation Notes
A common thought here may be “This is all common sense.” There is NO SUCH THING as common sense, except to you! Everyone has their own. Assuming someone will do the things the way you do, or that they know what you know, is a very common reason why people get hurt at work! Never assume, especially if it’s a new person. What we’re really after here is “common knowledge” – when we’ve all been trained well, use the same SOP’s, etc, then we’re headed in the right direction. Interesting discussion – examples of common knowledge in NRBU?? Picture – use your real “common senses” to identify energy sources, then manage them (center of octagon) so they don’t hurt you.
Pressure Hazard Resources Encana Tools and Resources available to make informed
Encana provides the necessary tools and resources to assure we have a safe work environment for employees, contractors, service providers and the public. Prevent - Protect
Pressure Hazard Types Pressure Hazard Consequences Pressure Hazard Mitigations Pressure Hazard Site Assessment and Strategy Tools and Resources Roles & Responsibilities
December 2-3, 2014
Presenter
Presentation Notes
Superintendents and Wellsite Supervisors, who have the greatest immediate impact on the site, will review and discuss mitigation, assessments and strategies to eliminate or reduce pressure hazard risks. Next to a worker making a personal choice to stop work in unsafe conditions, it is the Wellsite Supervisor with a supportive Superintendent who can proactively create a safe work site and establish a degree of confidence so workers enact their right to stop work in unsafe conditions. Continued and ongoing site assessments will give clear understanding of the obvious and not so obvious pressure hazards possible on site.
GROUP EXERCISE
• You will be given a picture with several questions.
• In your group, discuss and write your answers on a flip chart
17 December 2-3, 2014
Presenter
Presentation Notes
Sources of Pressure: WHERE IS PRESSURE LOCATED? Hydarulics, Pleumatics, vessels, piping and valves, hoses, well control equipment, pumps, cementing equipment, etc. Hazards – struck by, caught between Contributers: faulty design, operator error, poor PM, exceeding safety levels, improper installation, erosion, fatigue, stress, line hit, etc. Potential consequences: death, injury, fire, down time, etc.
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What could go wrong?
• What are the pressure hazards?
• Where should workers be standing while doing this task?
• Are there other energy sources or hazards?
Replace Nozzle on Pressure Washer
December 2-3, 2014
Presenter
Presentation Notes
See if the learner can identify the low pressure risk behind the workers
Working around Pressured Piping
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What could go wrong? • What are the pressure hazards? • Where should workers be
standing while doing this task? • Are there other energy sources
or hazards?
December 2-3, 2014
Presenter
Presentation Notes
Talk about body positioning for different tasks involving Pressured Piping? FATALITY REVIEW Working on pressurized equipment.
20 December 2-3, 2014
Group Discussion: Personnel Placement
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What could go wrong?
• What is the pressure hazards?
• Is everyone positioned safely
to complete this task?
• Are there other energy
sources or hazards?
December 2-3, 2014
Presenter
Presentation Notes
FATALITY REVIEW Run the learner through these critical thinking questions when looking at this picture? What is the line of fire risk ? The photographer is positioned in the wrong place in a direct line of fire for the operation This is basically how a worker was killed on one of our sights…standing in the line of fire to take a picture.
Line of Fire: Consequences
Consequences
• Personal Injury or
Death
• Damage to
Equipment
22 December 2-3, 2014
Presenter
Presentation Notes
Instructor to choose one example of each of the consequences listed based on the IMS case studies as outline in the instructor guide Have a discussion with the learners about the consequences using these real life Encana examples Encana – Personal Injury Line of Fire Examples Worker hit in the leg by ice plug from a line – January 16, 2009 (I2009-00307) Worker tying into wellhead when hydrate released striking worker in hand – January 23, 2009 – (I2009-00242) Flow line connection blew backwards striking worker in hip – January 9, 2011 (I2011-00035) Broken leg due to line pipe tension and sprung - January 17, 2012 (I2012-00058) Regulator blew apart striking operator in the face – March 3, 2012 (I2012-00309) Broken Leg when struck by sales line – January 16, 2013 (I2013-00049) Encana – Property Damage Line of Fire Examples Hydrate smashed into slickline 10k Bops – October 10, 2011 (I2011-01307) Regulator blew apart striking operator in the face – March 3, 2012 (I2012-00309 Encana – Cascading Effect Line of Fire Examples Halliburton 15,000 psi Frac line Failure – June 27,2012 (I2012-00650) BOP Pressure test on coil BOP’s test bar was pushed out the top of BOP 300 feet in the air landing on a vehicle – August 15, 2012 (I2012-00811)
No Go Zones
23 December 2-3, 2014
Presenter
Presentation Notes
One of the mitigations Encana is working on implementing are No Go zones. Only authorized personnel should be in certain zones during different operations. Think about it…you don’t want someone in here who doesn’t need to be here.
Personal Risk Assessment
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• Stop THE Job, or • Stop YOUR Job
December 2-3, 2014
Take Away • In the field you may see
– A worker in an at-risk position while pulling a gauge – A piece of equipment arrives on site and stops in an unsafe
place – A group of workers in a non-routine activity who may have
not considered the line of fire • What are you going to do? • STOP the job or an OBSERVATION and ask them…
25 December 2-3, 2014
Presenter
Presentation Notes
Use these opportunities in the field as a teachable/coaching moment MUST STRONGLY ENCOURAGE STJ AND OBSERVATIONS!!!!!
December 2-3, 2014
• 10.08.2014 – Completions Lost Time Injury: While prepping to P&A a well, a mechanical failure occurred causing a high pressure release of gas and fluids (nipple between B-section and gate valve blew out launching gate valve 60+yds., and releasing casing pressure). resulting in the injury of two service provider employees, one seriously.
Serious Injuries Persist
December 2-3, 2014
• Interim P3 Awareness Plan developed and implemented: • P3 training for contractors, supervisors and employees • Safety management/expectations training for all supervisors • Safety Stand-Down for all operations • Adopt-A-Contractor refocus on P3 • Operations SOP Review/Revision
• Enterprise-wide reinvigoration on P3 Principles with many of same
elements above
Reinforcement Efforts Implemented
December 2-3, 2014
Efforts continue across company on communication, implementation, training, etc. from initial P3 launch
November / December monthly safety topic ECN Bulletin: Pressure Hazards and P3 • E-mail to COO organization (11/20/14) • EH&S Alert (12/1/14) • ISNetworld communication and contractor (12/31/14) / service
