Petroleum Development Oman L.L.C.

Document Title: Process Leak Management

Document ID PR-1961

Document Type Procedure

Security Unrestricted

Discipline Engineering and Operations

Owner UOP – Functional Operations Manager

Issue Date November 2010

Revision 1.0

Keywords: This document is the property of Petroleum Development Oman, LLC. Neither the whole nor
any part of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
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i Document Authorisation
Authorised For Issue – November 2010

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ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.

Revision Date Author Scope / Remarks

No.

Apr-11 Robin Norman UOP6 Added Section 1.7 ALARP

1.0 Nov-10 Robin Norman UOP6 1st Issue of Approved Procedure
Draft Oct-10 Robin Norman UOP6 New Document

iii Related Business Processes

Code Business Process (EPBM 4.0)
EP.71 Produce Hydrocarbons
EP.72 Maintain and Assure Facilities Integrity

iv Related Corporate Management Frame Work (CMF)

Documents
The related CMF Documents can be retrieved from the CMF Business Control Portal.

Refer to Appendix 3

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TABLE OF CONTENTS
1 Introduction ............................................................................................................................ 6
1.1 Background ...................................................................................................................... 6
1.2 Purpose ............................................................................................................................ 6
1.3 Scope ............................................................................................................................... 6
1.4 Distribution / Target Audience .......................................................................................... 6
1.5 Changes to the Document................................................................................................ 6
1.6 Step-out Approval ............................................................................................................. 7
1.7 ALARP .............................................................................................................................. 7
2 Roles and Responsibilities ..................................................................................................... 8
3 Process Leak Management ................................................................................................... 9
3.1 Performance Standard ..................................................................................................... 9
3.2 Definition for Weeps and Seeps ....................................................................................... 9
3.3 Direct Response to Hydrocarbon Releases ..................................................................... 9
3.4 Delayed Repair of Weeps / Seeps ................................................................................. 10
3.5 Process Leak Management Charts ................................................................................ 11
3.5.1 Categorising the Leak ................................................................................... 11
3.5.2 Address the Leak .......................................................................................... 11
3.5.3 Repair the Leak ............................................................................................ 12
3.5.4 Register of Temporary Leak Repairs ........................................................... 13
3.6 Incident Recording and Reporting .................................................................................. 13
Appendix 1 - Monitoring Sheet for Weep / Seep Leaks (Delayed Repair) .................................. 14
Appendix 2 - Abbreviations.......................................................................................................... 15
Appendix 3 – Reference Material ................................................................................................ 16
Appendix 4 - User Feedback Page ............................................................................................. 17

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1 Introduction

1.1 Background
High level response procedures for Oil or Gas pipeline leaks is covered in PR-1066 -
Emergency Response Document Part III Contingency Plan Volume III - Production
Operations Sections 3.1.5 and 3.1.6. The details in these sections are for a major
emergency i.e. pipeline failure, where the immediate involvement of the Local
Emergency Base Controller (LEBC) would be notified and appropriate actions followed
as described in these sections.
Leaks within the facilities or in the immediate area of the facilities that would be
identified by operations as a normal part of their working routine are not effectively
covered in the Emergency Response Document and therefore a requirement exists to
address this situation and put in place contingency for dealing with such incidents.

1.2 Purpose
To provide concise instructions for indentifying, quantifying and addressing hydrocarbon
leaks within the facilities and associated flowlines.
NOTE: A sound awareness of the requirements of PR-1066 - Emergency Response
Document Part III Contingency Plan Volume III - Production Operations Sections 3.1.5
and 3.1.6 is required when using this procedure.

1.3 Scope
The scope of this procedure is;
 To ensure a uniform approach is applied to dealing with hydrocarbon leaks and
seeps / weeps
 To fulfil the PDO Corporate requirement for reporting leaks
 To ensure the safety of personnel and assets at all times when investigating
leaks

1.4 Distribution / Target Audience

The procedure shall be used by all Operations and Contract staff when indentifying and
reporting leaks (including 2 phase) on facilities, equipment and flowlines.

1.5 Changes to the Document

Responsibility for the upkeep of the Document shall be with the Functional Operations
Team Leader UOP, the Owner. Changes to this document shall only be authorised and
approved by the Owner.
Users of the Document who identify inaccuracy or ambiguity can notify the Custodian or
his/her delegate and request changes be initiated. The Requests shall be forwarded to
the Custodian using the “User Feedback Page” provided in this Document.
The Document Owner and the Document Custodian should ensure review and re-
verification of this document every 3 years.

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1.6 Step-out Approval

Not applicable to this document.

1.7 ALARP
ALARP is the acronym for ‘As Low As Reasonably Practicable’ which simplified means,
‘reducing the risk to a level at which the cost and effort (time and trouble) of further risk
reduction are grossly disproportionate to the risk reduction achieved’. Full Compliance
to PDO Standards and Procedures is a key element in achieving ALARP.
For more details refer to ALARP Definition

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2 Roles and Responsibilities

Operations Manager
TA2 Pipelines and
Static Equipment
Production Coordinator
Production Supervisor
Area Authority
 Authorise repairs on major process leaks
 Review repair method proposals for major and minor
process leaks and approve
 Review repair proposals for weeps and seeps and
approve
 Oversee the Process Leak Management process at the
location of the leak
 Assist the Production Coordinator to review repair
proposals
 Take control of leak management major and minor leaks
 Control and monitor the activities of the investigation
teams during leak identification and location
 Assist the Production Supervisor in the control of leak
management major and minor leaks
 Ensure site evacuation when required is carried out and
all personnel are mustered
 Shutdown process or systems / equipment as required /
instructed
 Ensure weeps and seeps are monitored and recorded
correctly

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3 Process Leak Management

3.1 Performance Standard

 No accidental breach of the hydrocarbon envelope / loss of containment is
acceptable
 Zero tolerance to hydrocarbon leaks
WARNING: All gas leaks have a flammable volume in proximity to the leak source.

3.2 Definition for Weeps and Seeps

Hydrocarbon releases below a defined level are termed ‘weeps’ or ‘seeps’. Such
releases are sufficiently small that immediate action may not be required.
Gas (and 2 phase)
<20% LEL measured at 0.1m from the leak source
OR
<0.1 litre per second (0.0001m 3/sec)
Liquid
<4 drops per minute
OR
<1 litre per 24 hour period

3.3 Direct Response to Hydrocarbon Releases

IMPORTANT
 Personal safety is paramount at all times in the event of hydrocarbon releases
 If there is any doubt about the atmosphere, work parties should withdraw
immediately from the affected area. This action shall be immediate if a gas
detector has gone into alarm
1. In the event of an alarm on portable monitors or fixed detection equipment,
personnel shall immediately evacuate the area of a suspected leak and initiate a
process shutdown if required. The detected or suspected leak must be
immediately reported to the Station Control Room or the Central Control Room,
the Production Supervisor and the Production Coordinator.
2. Risk assessment shall be carried out by the production Supervisor and Area
Authority / Senior Operator to determine the safest method of ongoing response;
a. Isolate equipment in affected area (if possible) or;
b. Obtain suitable safety equipment and investigate the source of the leak
The risk assessment shall consider the type of leak, accumulation possibilities
(gas) especially in enclosed modules; the availability of escape routes; wind
strength and direction
NOTE: If the leak is gas and it contains H2S urgent action shall be taken to
reduce the potential risks (where detection indicates the release is greater than
the allowed weep / weep level and the wind strength and direction would direct
the cloud to populated areas.

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WARNING: Personnel shall not investigate any gas leak, which has initiated a
process or station Shutdown, until the Production Coordinator has given
authorisation that the area is safe to enter.
A minimum of two persons shall investigate, appropriate PPE and safety
equipment i.e. SCBA, masks, face visors etc, shall be worn as necessary. One
person must be an authorised gas tester and carry a portable flammable gas
detector to detect the leak. This shall be in compliance with PR-1154 - Gas
Testing Procedure. The investigation team will remain in close proximity of each
other. The personal monitors shall ensure that each person’s atmosphere is
monitored as breathable. This will help identifying borders of Hazardous Zone.
If at any time the monitors alarm, either because the breathable atmosphere
reaches 10% LEL, or through detection from the leak, then the area shall be
evacuated and the location recorded.
Once the leak is detected; surrounding area should be barricaded and marked
with adequate warning signs. Considering the wind direction gas detection shall
be established outside the barricaded area to insure limitation of exposure.
NOTE: When investigating a suspected hydrocarbon leak, radio contact shall be
maintained with the Station Control Room or Production Supervisor / Coordinator
overseeing the operation.
The investigation team shall ensure that they are safe at all times whilst
investigating the source of the leak and that they have identified a direct escape
route in the event that the situation deteriorates. If any portable gas detector fails
(or cannot be trusted), the team will evacuate to a safe area and replace it.
3. If the source of the leak cannot be located or conditions surrounding the leak get
worse then the investigation team shall be recalled and the situation re-assessed.
This may require handing the incident over to the LEBC as detailed in PR-1066 -
Emergency Response Document Part III Contingency Plan, Volume III Production
Operations

3.4 Delayed Repair of Weeps / Seeps

Continued operation of a system or item of equipment shall not be permitted unless;
 A local Risk Assessment has been completed and approved;
 The leak rate / volume meets the criteria stated in Section 3.2 of this procedure;
 Any gas or vapour emissions cannot accumulate;
 A repair plan has been prepared and SAP work orders entered;
 The leak has a low potential of getting bigger;
 All potential ignition sources within the area are identified and isolated;
 Hot work activities are stopped within the potential area of the leak;
 Regular monitoring has been arranged and barriers erected to stop or contain
access, and;
 The leak is recorded and the record readily available to all operations personnel
on-site. The record shall show mitigating measures / deviation in force (where
applicable)
Repair of hydrocarbon leaks should only take place on a de-pressurised system, except
in circumstances where the equipment has been designed specifically for online repair
(for example some valve stem packing systems.)

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3.5 Process Leak Management Charts

3.5.1 Categorising the Leak

Leak Medium Major leak Minor leak Weep / Seep leak

Flammable > 1m3 < 1 m3 <20% LEL measured at

Gas OR OR 0.1m from the leak source
>0.1 m3/s for more than 5 0.1 m3/s for < 2 minutes OR
minutes <0.1 litre per second
(0.0001m3/sec)

Hydrogen ≥100ppm H2S measured at ≥5ppm and <100ppm H2S Rotten eggs smell or
Sulphide 1m from leak (or further measured at 1m from leak <5ppm H2S measured at
away) (or further away) 1m from leak

Crude oil > 60ltrs < 60ltrs <4 drops per minute
(excluding OR OR OR
water cut) >0.2ltrs/s for > 5 minutes 0.2ltrs/s for < 5 minutes <1 litre per 24 hour period

Water > 60ltrs < 60ltrs <4 drops per minute

Injection OR OR OR
>0.2ltrs/s for > 5 minutes 0.2ltrs/s for < 5 minutes <1 litre per 24 hour period

NOTES:
1.) A leak is ANY escape of fluid or gas from a process system
2.) Water injection systems include DWD, SWD and pressurised water injection

3.5.2 Address the Leak

Location of Major leak Minor leak Weep / Seep leak

Leak

Pipeline Off-  Evacuate affected  Evacuate affected  Shut in system

and On-Plot area (personnel,
ignition sources)
 Initiate ER if required
(PR-1066)
area (personnel,  Report in FIM
ignition sources)
and assess if ER is  Repair before start up
required

 Shut in system  Shut in system

 Report in FIM (tick  Report in FIM

API-reportable)  Investigation (PR-
 Investigation (PR- 1418)
1418)  Repair before start
 DTL to sign up
Statement of Fitness
before start up
Flowline Off-  Evacuate affected  Evacuate affected  Continue operating the
Plot area (personnel, area (personnel, flowline
NOTE: if the ignition sources) ignition sources)  Record in leak log
leak is near to  Initiate ER if  Shut in system  Raise SAP notification
an ignition required (PR-1066)  Report in FIM for repair
source (e.g.
 Shut in system  Repair before start  Deviation in FSR until
OHLs), road,
wadi or  Report in FIM (tick up repaired (high risk sour
building, then API-reportable) and gas flowlines only)
treat as a  Investigation (PR-
Pipeline. 1418)
 Repair before start
up

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Location of Major leak Minor leak Weep / Seep leak

Leak

Process  Evacuate affected  Evacuate affected  Continue operating the

Equipment area (personnel, area (personnel, system
On-Plot ignition sources) ignition sources) &  Record in leak log
 Initiate ER if assess if ER is
required  Notification in SAP for
required (PR-1066) repair
  Shut in system
Shut in system  Deviation in FSR until
 Report in FIM (tick  Report in FIM repaired
API-reportable)  Repair before start
 Investigation (PR- up
1418)
 DTL sign Statement
of Fitness before
start up
NOTES:
Colour coding indicates an initial potential risk level using RAM
Massive leaks (e.g. pipeline/vessel/tank ruptures, very large flammable or toxic gas
clouds, etc.) are not covered in this procedure but should be referenced in PR-1066 -
Emergency Response Document Part III Contingency Plan Volume III - Production
Operations and should be rated as red potential risk on the RAM

3.5.3 Repair the Leak

Location of Major leak Minor leak Weep / Seep leak
Leak

Pipeline Off- Pipelines TA-2 to approve Pipelines TA-2 to approve Approved by Prod./Maint.
and On-Plot Coordinator
 Actions and repair shall  Clamping
be evaluated case by Pipelines TA-2 to approve
case and authorised  Partial replacement wrapping / clamping
after approval by the
Operations Manager  Composite wrapping  Tightening of flanges
using FCP process.
 Clamping

 Partial replacement

 Composite wrapping
Flowline Off- Static Mech. TA-2 to Static Mech. TA-2 to Approved by Prod./Maint.
Plot approve approve Coordinator

 Clamping  Clamping Pipelines TA-2 to approve

 Partial replacement
Process Static Mech. TA-2 to
Equipment approve
On-Plot
 Actions and repair shall
be evaluated case by
case and authorised
after approval by the
Operations Manager.
wrapping / clamping
 Partial replacement
 Clamping
Static Mech. TA-2 to Approved by Prod./Maint.
approve Coordinator
 Clamping Pipelines TA-2 to approve
wrapping / clamping
 Partial replacement
 Tightening of flanges
 Composite wrapping
 Clamping

 Partial replacement

 Composite wrapping

NOTE: ALL leaks should be actioned according to this procedure

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3.5.4 Register of Temporary Leak Repairs

Each Asset shall be required to maintain an active register of process leaks and the
temporary repairs carried out.
The register shall identify the method used to make the repair and the date by which a
permanent repair effected.
Risk Assessments shall be undertaken to mitigate risks to ALARP.
Hazardous (liquid and / or gas) leaks and leaks that affect the performance of SCE’s
shall be entered on the FSR (flagged).
Ownership shall be the responsibility of the Production Supervisor or a nominee.
Leaks shall be allocated a unique repair ID. Number.
The register shall contain as a minimum the information detailed on the example below.

3.6 Incident Recording and Reporting

All hazardous leaks should be recorded in the Fountain Incident Management (FIM)
system. Leaks recorded in FIM will be investigated in accordance with the ‘incident
reporting and follow-up requirements’. The following shall be recorded as a minimum;
 The release flow-rate and quantity (volume) where possible;
 Leak levels shall be classified as Major, Minor;
 All leaks that can have an environmental impact shall be recorded in FIM.
NOTE: Weeps / seeps which do not have an environmental impact i.e. water, no-toxic
fluids etc, shall be recorded in the Station Leak Register and Daily Report.

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Appendix 1 - Monitoring Sheet for Weep / Seep Leaks (Delayed

Repair)

Link to Master Form

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Appendix 2 - Abbreviations

DWD Deep Water Disposal

ER Emergency Response
FIM Fountain Investigation Management system
FSR Field Safety Report
LEBC Local Emergency Base Controller
LEL Lower Explosive Limit
SWD Shallow Water Disposal
TA Technical Authority

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Appendix 3 – Reference Material

PDO Code of Practice

 CP-114 - Maintenance & Integrity Management Code of Practice
 CP-115 - Operate Surface Product Flow Assets - CoP
PDO Specifications
 SP-2020 - Flange Connections Bolt Torquing and Tensioning
PDO Procedures
 PR-1066 - Emergency Response document Part III Contingency Plan, Volume III
Production Operations
 PR-1146 – Flowline Cold Cutting
 PR-1154 – Gas Testing Procedure
 PR-1418 - Incident Notification, Reporting and Follow-up Procedure Part 1
PDO Guidelines
 GU-379 - Pipeline Emergency Repair Manual

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Appendix 4 - User Feedback Page

PR-1961 – Process Leak Management User Feedback Page

Any user who identifies an inaccuracy, error or ambiguity is requested to notify

the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID Date:

Page Ref: Brief Description of Change Required and Reasons

To: UOP7

Custodian of Document Date:

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