Petroleum Development Oman L.L.C.

Unrestricted Document Number : CP-114

July 1999 Filing key : A-72

Maintain Surface Product Flow

Assets

Code of Practice
Keywords:

This document is the property of Petroleum Development Oman L.L.C. 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.

Cameron Mitchell
UOM/1
Version 3.0 Maintain Surface Product Flow Assets Code of Practice

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Maintain Surface Product Flow Assets Code of Practice Version 3.0

Authorised For Issue 28/7/99

Signed : ...........................................................
Naaman Al-Naamani, UOM
CFDH - Maintenance

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

Version No. Date Author Scope / Remarks

3.0 July. '99 Cameron Mitchell, UOM/1 Revision & inclusion of Marine Asset
Maintenance and Integrity definitions.
2.0 Jul. '98 Shaun Wilson, OTI/34 Revision.
1.0 Mar. '98 Shaun Wilson, OTT/331 New Code of Practice - Initial Issue.

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CONTENTS

CONTENTS................................................................................................................................ii

1. INTRODUCTION.................................................................................................................1
1.1. BACKGROUND....................................................................................................1
1.2. PURPOSE...............................................................................................................1
1.3. TARGET AUDIENCE...........................................................................................1
1.4. STRUCTURE OF THIS DOCUMENT.................................................................1

2. SCOPE AND OBJECTIVES...............................................................................................3

2.1. SCOPE....................................................................................................................3
2.2. AIMS AND OBJECTIVES....................................................................................3
2.3. FUNDAMENTALS FOR THIS CODE OF PRACTICE......................................3
2.4. RELATED STANDARDS.....................................................................................4
2.5. REVIEW AND IMPROVEMENT........................................................................4

3. ROLES AND RESPONSIBILITIES...................................................................................5

3.1. ROLES AND RESPONSIBILITY MATRIX........................................................5

4. PRACTICES TO BE FOLLOWED....................................................................................6
4.1. COMPUTERISED MAINTENANCE SYSTEMS................................................7
4.2. PIPELINES...........................................................................................................11
4.3. STATIC EQUIPMENT........................................................................................15
4.3.1. TANKS AND VESSELS.....................................................................................15
4.3.2. ON-PLOT PIPEWORK........................................................................................19
4.3.3. RELIEF VALVES................................................................................................23
4.4. ROTATING EQUIPMENT..................................................................................26
4.5. INSTRUMENTATION........................................................................................29
4.5.1. SAFEGUARDING...............................................................................................29
4.5.2. PROCESS CONTROL.........................................................................................33
4.5.3. METERING..........................................................................................................36
4.6. ELECTRICAL EQUIPMENT.............................................................................39
4.7.1 MARINE EQUIPMENT......................................................................................43

5. APPLICATION AND STEP-OUT APPROVAL............................................................47

5.1. APPLICATION....................................................................................................47
5.2. STEP-OUT APPROVAL.....................................................................................47

APPENDICES...........................................................................................................................48
A1. GLOSSARY OF TERMS, DEFINITIONS AND ABBREVIATIONS..................48

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1. INTRODUCTION
1.1. BACKGROUND

In order to assure Asset Integrity, it is necessary to show that the Design Integrity of an asset is
maintained throughout its life-cycle such that, under specified operating conditions, the risk of
a failure endangering the safety of personnel, the environment or the asset value is as low as
reasonably practicable. To be able to show that the Design Integrity of an asset is being
maintained, a framework is necessary to set out the activities that are required to be carried
out. This framework is described in detail in the Product Flow Asset Integrity Management
System (PFAIMS), Reference MS-1001.

In practice, the management of asset integrity, for commissioned assets, lies with the
individual Product Flow Asset Teams (PFAT’s). They are responsible for the integrity of the
assets which they manage and for implementing the Codes of Practice and associated
procedures that set the standards required by PDO. To support the PFAT’s, two Steering
Committee’s have been created to deal with high risk issues and to provide the necessary
support to ensure that the PFAT’s continue to operate the assets in the most optimal way. The
Steering Committees are the Surface Integrity Steering Committee which is chaired by the
Operations Functional Director (UOD) and the Pipeline Integrity Steering Committee which is
chaired by the Engineering Functional Director (UED).

1.2. PURPOSE

The purpose of this 'Maintain Surface Product Flow Assets Code of Practise' is to provide a
link between the PDO Product Flow Asset Integrity Policy which states that "Product Flow
Assets shall be designed, operated, maintained and abandoned in a manner that safeguards
their integrity and ensures their planned availability throughout their life-cycle" and the
individual Procedures, Specifications and Guide-lines that specify how maintenance activities
should be carried out.

In addition to this Code Of Practice, there are two other key Codes Of practice that should be
referred to regarding the integrity management of surface assets. These are the “Operate
Product Flow Surface Assets, CP-115” and the “Project Engineering, CP-117” Code Of
Practice.

1.3. TARGET AUDIENCE

The primary target audience of this Code of Practise comprises the Discipline Maintenance
Supervisors and Service Provider Maintenance Supervisors and Engineers, including
contractors.

The secondary target audience is the Asset Holders/Managers, Service Provider Managers and
Area Co-ordinators.

1.4. STRUCTURE OF THIS DOCUMENT

This document is structured to enable the reader, who may not be totally familiar with how the
maintenance process works in practice and wishes to either read the complete document for an
overview, or refer to a specific section as a point of reference, to be able to understand the
requirements of the maintenance process.

Section 1 Contains an introduction to the document.

Section 2 Defines the scope and objectives of the document.

Section 3 Outlines the roles and responsibilities of key personnel concerned with the
document.

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Section 4 Details the practises to be followed when executing relevant activities. This
section is arranged by discipline and maintenance process activity. The
Corporate Discipline Focal Point (CDFP) for each discipline being the owner
of their respective section.

Section 5 Contains information concerning the application of the document and the rules
governing non-compliance and step-out approval.

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2. SCOPE AND OBJECTIVES

2.1. SCOPE

The scope of this Code of Practise is limited to the technical and administrative activities
required to maintain the Design Integrity of commissioned surface assets. This includes the
roles and responsibilities of Area Co-ordinators, Discipline Maintenance Supervisors, Service
Providers, Corporate Functional Discipline Heads (CFDH's) and Corporate Discipline Focal
Points (CDFP's). Sub-surface assets, including well-heads and trees, are covered by the Well
Integrity Code of Practice, reference CP-118.

2.2. AIMS AND OBJECTIVES

The Code of Practise describes how the various maintenance processes applied in PDO work
and provides a clear link between Corporate Policies and the Procedures, Specifications and
Guide-lines, both existing and those that need to be developed, to support the maintenance
process. A key objective is to avoid duplication of content from other documentation and to
demonstrate that a clear and logical documentation hierarchy exists, from the Corporate
Management Framework (CMF) to Procedures, Specifications and Guide-lines. An integral
function of this document is to set out the strategies followed in executing the maintenance
process and activities, in order to meet PDO Corporate objectives.

2.3. FUNDAMENTALS FOR THIS CODE OF PRACTICE

The Code of Practise addresses the functional and process requirements of the maintenance
discipline. It expands on the basic concept that certain individuals are deemed technical
experts in a particular specialist discipline and details the particular methodologies that are to
be followed in order to achieve the PDO Corporate objective of facilitating structured integrity
management across the PFAT’s.

The full listing of the Functional Directors, CFDH's and CDFP's is given in Appendix 8.1 of
the Product Flow Asset Integrity Management System, but for clarity, those relevant to this
Code of Practise are repeated below;

DISCIPLINE FUNCTIONAL CFDH CDFP

DIRECTOR REF IND REF IND

Maintenance UOD UOM

Computerised
Maintenance Systems OTB/1
Rotating Equipment
Maintenance UOM/2 (OTT/41)
Static Mechanical
Maintenance UOM/3 (OTT/14)
Electrical
Maintenance UOM/4 (OIE/3)
Instrument
Maintenance UOM/5 (OTT/32)
Pipeline
Maintenance UOM/6 (OTT/24)
Reliability UOM/7 (OTT/31)

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2.4. RELATED STANDARDS

The documents which specifically relate to this Code of Practice in the standards hierarchy are
presented below:

Management System Product Flow Asset Integrity Management System MS-1001

Policy Product Flow Asset Integrity. PL-32
Codes of Practice Operate Surface Product Flow Assets. CP-115
Project Engineering CP-117
Well Integrity CP-118
Specification Refer to the 'Discipline Standards' quoted within
section 4 of this document.
Procedure Refer to the 'Discipline Standards' quoted within
section 4 of this document.
Guide-line Maintenance Management Guide-line. EP93-0750

2.5. REVIEW AND IMPROVEMENT

This Code of Practise shall be reviewed and updated on a regular basis in order to ensure that
the document reflects the current position with regard to Corporate Policies, Management
Systems, Procedures, Specifications, Guide-lines and Organisation structure.

The CDFP for each discipline is responsible for the content and upkeep of their respective
sections. Feedback from relevant parties is welcome at any time and should be addressed to
the Functional Maintenance Engineer UOM/1. Such feedback will be reviewed by the CFDH,
CDFP(s) and other relevant individuals as necessary and a decision communicated back to the
originator. Enhancements originating from feedback or otherwise, shall be incorporated as
and when required.

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3. ROLES AND RESPONSIBILITIES

3.1. ROLES AND RESPONSIBILITY MATRIX

A summary of the roles and related responsibilities that are required to both implement and
manage the Code of Practice is given in the following matrix:

ROLE RELATED RESPONSIBILITIES

Document Authority : Accountable for the development of all Policies associated with the
UOD Maintenance discipline. Responsible for specifying the priority of
the COP document, the life span in years, the security class, the
allowable media and appointing the Document Custodian.
CFDH Maintenance: Accountable for establishing maintenance direction to achieve and
UOM adhere to relevant Corporate Policies. Accountable for the content
and update of the COP document.
Document Custodian : Responsible for managing, issuing, and recording the update of the
UOM/1 COP document and associated Procedures, Specifications and
Guide-lines.
CDFP's Maintenance Responsible for the content and update of the discipline specific
sections of the COP document and associated Procedures,
Specifications and Guide-lines.
Area Coordinator Responsible for ensuring compliance to the COP and associated
Procedures, Specifications and Guide-lines.
Area Team Discipline Responsible for executing maintenance activities as specified in the
Supervisor and Service COP and associated Procedures, Specifications and Guide-lines and
Provider Supervisor ensuring that activities are carried out by suitably competent
personnel.

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4. PRACTICES TO BE FOLLOWED
This section details the practises to be followed when executing maintenance activities. It is
divided into sub-sections, with each sub-section being dedicated to a particular discipline and
owned by the relevant CDFP. The layout of each sub-section is derived from 'The
Maintenance Process' flow chart, shown below and utilises the principles prescribed in the EP
Maintenance Management Guide-line Volume 1, reference SIPM EPO/5.

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4.1 COMPUTERISED MAINTENANCE SYSTEMS

As a start of the Maintenance process, Computerised Maintenance Systems (CMS) are

required to be in place and supported by the CMS Support Section OTB/1. The current
portfolio consists of the packages EPMARS (Exploration and Production Maintenance
Administration and Reporting System) and Pacer-CM (Corrosion Management). OTB/1 is the
system custodian for EPMARS, whilst OTB is the system owner for EPMARS and OTT/1 is
the system custodian and the system owner for Pacer-CM.

The services as provided by the CMS sections to the Asset Holders and CDFP’s, e.g. data
loading in EPMARS and/or Pacer-CM, are defined in the OTB Department Service
Agreement. As an integral part of system user support, EPMARS Procedures are developed,
regularly updated and stored in the EPMARS Practices and Procedures manual. Copies of
these manuals are available to key system users. The registration process of new EPMARS
users is documented in EPMARS Procedure PO-120. It is the responsibility of individual
Discipline Supervisors to ensure that their staff is properly trained and have the right access
level, as defined in Procedure PO-120. In the event that EPMARS is unavailable for such an
extended period that the maintenance and inspection process is affected, reference should be
made to EPMARS Procedure PR-1245 for fallback arrangements.

ESTABLISH/UPDATE ASSET REGISTER

EPMARS is the Asset Register for all surface production and maintenance critical equipment
in PDO. The criticality and therefore applicability for registration in EPMARS for all
equipment is defined per equipment type by the CDFP’s. The EPMARS Asset Register
consists of individual assets of more than 170 differing equipment types. These equipment
types are all given an individual 'Equipment Code', the descriptions of which are 'Owned' by
the relevant CDFP.

Every new tag (equipment position) shall therefore be reviewed for registration, based on
these equipment types. If applicable, the tag will be registered and linked to an UNO
(equipment unique number) and will have generic details recorded, e.g. manufacturer,
commissioning date, etc. In addition to the generic tag details, every equipment type has also
equipment type specific design and technical details, e.g. bearing size, discharge pressure, etc.
For an overview of the existing equipment types and generic tag details, refer to the EPMARS
Data Codes Guide (GU-110).

Responsibility for the data entry of new asset tags and the update of existing ones, is defined
in EPMARS Procedures PO-161 and P153. When the Asset Holder accepts the handover of
new equipment from Engineering, the accountability for the correct registration of this
equipment and the associated data, also passes to the Asset Holder. The Asset Holder may
however, delegate this responsibility to the appropriate Discipline Supervisor. Where
equipment becomes redundant, the Asset Holder shall be held accountable for updating all
relevant data in EPMARS accordingly, refer to PR-1164.

Pacer-CM, PDO's Corrosion Management System, also has an Asset Register that contains
corrosion related equipment types, including sub-surface equipment where applicable. Similar
to EPMARS, the Asset Holder shall be accountable for asset data quality in Pacer-CM. For
further details on the Pacer-CM Asset Register, refer to 'Corporate Operations Functionality
Specification for Pacer-CM', December 1996.

RANK BY CRITICALITY

The CDFP's define which assets and equipment types are to be entered into the EPMARS
system as a preliminary form of ranking. Those assets that are registered in EPMARS are then
subjected to a more formal ranking based on the corporate methodology for assessing risk.

For each tag a criticality field is available in EPMARS. For the current existing Criticality
Codes refer to the EPMARS Data Codes Guide (GU-110).

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DEVELOP MAINTENANCE REQUIREMENTS

The task here is to determine what maintenance activities need to be performed, why they
need to be carried out and when they need to be executed, in order to achieve the required
integrity, reliability and availability targets for each asset group. To do this, an appropriate
maintenance strategy must be determined for each asset group, by the relevant CDFP. Several
types of maintenance philosophies are available, refer Maintenance Management Guideline
EP93-0750. These are;

- Preventative Maintenance, calendar or run hour based.

- Condition Based Maintenance, on-line or off-line.
- Corrective or Breakdown Maintenance.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

EPMARS is also used as the Activity Register, containing all surface equipment related
maintenance activities. Routine maintenance activities for individual tags are maintained
under a Work Specification Number (WSN), which contains one or more services, each with a
specific frequency. Each service details the relevant Maintenance Craft Procedures (MCP's),
materials and resources required and specific planning details. For responsibilities related to
WSN's and MCP's refer to EPMARS Procedure PR-1032. The CDFP will be responsible for
developing and maintaining a generic WSN and MCP portfolio for all equipment types under
his discipline. It is the responsibility of the Discipline Supervisors and Area Planners to
ensure that, for all tags in their area, the WSN/MCP and associated planning data is correctly
detailed in EPMARS.

Inspection requirements for relevant tags are registered in EPMARS as a separate activity
category. Each inspection type will be generated and planned, based on a predefined due date.
The Asset Holder will be accountable for notifying the CDFP Static Equipment of any
operational changes to static equipment. The Asset Holder may however, delegate this
responsibility to the Discipline Supervisor or Area Planner. Refer to EPMARS Procedure
P156 for further details.

Data loading of routine maintenance and inspection requirements is, on request, co-ordinated
by the CMS Support Sections. Refer to EPMARS Procedures PO-161, PR-1032 and P156 for
data loading of WSN's, MCP's and inspection details.

Non-routine (Corrective) maintenance requirements shall be registered in EPMARS by the

relevant Discipline Supervisor, on behalf of the Asset Holder and/or Activity Executor, by
raising a Work Request (WR). This shall detail precisely, the equipment tag number, where
applicable the equipment deficiency and also the remedial action required. Non-routine
maintenance WR's raised for Asset Integrity deficiency restoration, shall be deemed 'TI
Critical' and assigned a 'T#' priority code, in lieu of the usual 'P#' priority code. For further
details regarding WR's and Work Order Numbers (WON's) refer to EPMARS Procedures P150
and P151.

EPMARS also contains modules for equipment history, technical data, spare part listings and
also allows access to the stock inventory in the EMA (Electronic Materials Administration)
system. The spare parts references are linked to the SPIR (Spare Parts Interchangeability
Record) system. For new equipment, the Spare Parts Analyst reviews the SPIR forms prior to
their implementation, in order to avoid stock item duplication, ensures that spares for new
equipment are available prior to commissioning and analyses stock turn-over in order to set
optimum stock levels. Refer to DEP.70.10.90.11-Gen. Spare Parts Manual.

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SCHEDULE MAINTENANCE AND INSPECTION

Activities registered in EPMARS, i.e. WON's, WSN's and Inspection activities, contain
important planning and resource details which form the basis for the area maintenance
planning process, i.e. the Integrated Activity Plan (IAP), the 90 Day Plan and the 14 Day
Schedule. The planning process itself is executed outside of EPMARS, but the planned
execution date of each activity is uploaded into EPMARS. This is the responsibility of the
Area Planning Engineer and Area Planner. For further details refer to the Planning Process
Description Manual, which forms part of SI-34 and EPMARS Procedure P154.

Scheduling flexibility and execution timing of activities is constrained with respect to the
activity due date. Maintenance and Inspection Activity Variance Control Procedure PR-1005
defines the acceptable ranges per equipment type.

PERFORM MAINTENANCE AND INSPECTION

EPMARS supports the execution of maintenance and inspection activities by providing work
details on system screen displays or WON print outs. For routine services, MCP details can be
printed out as required. Furthermore, EPMARS is used to update and monitor the progress of
these activities and to close out the WON when an activity is completed. As part of closing
out an activity, expended working hours and work history details are entered in EPMARS
against the relevant WON and/or tag/UNO. Correct progression and completion of a WON
and associated data quality issues are the responsibility of the Activity Executor, i.e. the
Discipline Supervisor for Asset Holder activities and the Campaign Supervisor for Campaign
Group activities. If any anomalies are found during routine activities, the Discipline
Supervisor shall review the need and scope for further corrective work, irrespective of whether
the Area Core Team or Campaign Group carried out the initial routine work. If applicable, the
Discipline Supervisor shall raise a new WR in EPMARS. For further information refer to
EPMARS Procedures P152, P153, P154, P156 and P160.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

EPMARS has standard reports, for the retrieval of data, to allow detailed analysis to be carried
out. The analysis of data on selected equipment and/or work execution performance, will be
the responsibility of the Discipline Supervisor. The CDFP will be responsible for carrying out
overall equipment type performance analysis, in order to maintain an optimal maintenance
strategy selection and WSN and MCP portfolio. If any special EPMARS reports are required,
the CMS Support Section should be contacted for assistance.

Pacer-CM also has a reporting tool, called 'Infomaker', which can be made available for users.
The CMS Support Section, OTB/1, should be contacted for further details.

ANALYSE AND IMPROVE PROCESS

The CMS Engineer, OTB/1, who is the system custodian of EPMARS and Pacer-, is
responsible for regularly reviewing and improving the Computerised Maintenance Systems
data integrity and the quality of user support. OTB/1 will therefore regularly discuss these
issues with Discipline Supervisors, Planners, CDFP's, and system owners.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

All MCP's are stored in EPMARS, but can only be viewed by either printing one specific
MCP, or all MCP's, for a given WSN. Changes to MCP's shall be authorised by the relevant
CDFP and updated in EPMARS by the CMS Support Section, OTB/1, upon request. For
further details refer to EPMARS Procedure PR-1032.

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RELEVANT STANDARDS

Corporate Operations Functionality 12/96

Specification for Pacer-CM.
Planning Process Description 6/97
Manual, Version 6.0.
DEP.70.10.90.11-Gen. Spare Parts Manual.
PR-1005 Maintenance and Inspection Activity
Variance Control.
EPMARS User Guide. 5/94 Rev. 007
EPMARS Codes Guide. 5/94 Rev. 008
EPMARS Practices and Procedures 7/92 Rev. 002 Index of Procedures and Directory
Manual Master Directory. Distribution.
Procedure PO-120 5/97 Rev. 001 EPMARS User Registration.
Procedure P-150 7/92 Rev. 004 Raising a Work Order.
Procedure P-151 7/92 Rev. 003 Approving a Work Order.
Procedure P-152 7/92 Rev. 003 Work Order Time Reporting and Job
Progress Reporting.
Procedure P-153 7/92 Rev. 002 Reporting Requirements for Supervisors.
Procedure P-154 7/92 Rev. 003 Work Order Scheduling Activity.
Procedure P-156 Rev. 001 Inspection Work within EPMARS.
Procedure PO-161 3/97 Rev. 001 MMS Asset and Activity Registration.
Procedure PR-1032 EPMARS Approval for Work
Specifications (WSN) and Maintenance
Craft Procedures (MCP).
Procedure P-163 2/96 Rev. 003 EPMARS Fallback.
#Practice P-100 7/92 Rev. 004 Raising a Work Order.
#Practice P-101 7/92 Rev. 003 Approving a Work Order.
#Practice P-102 7/92 Rev. 002 Work Order Time Reporting and Job
Progress Reporting.
#Practice P-103 7/92 Rev. 002 Reporting Requirements for Supervisors.
#Practice P-104 7/92 Rev. 003 Work Order Scheduling Activity.
#Practice P-106 Rev. 001 Inspection Work within EPMARS.
*Procedure P-130 7/92 Rev. 005 Equipment Movements.
*Procedure P-131 7/92 Rev. 004 System Supervisors Work Outline.
*Procedure P-132 Rev. 002 Data Loading / Validation Activity.
#To be integrated within the Procedures and/or User Guide during 1999.
*Only required for system support staff in OTB/1 section.

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4.2. PIPELINES

ESTABLISH/UPDATE ASSET REGISTER

All pipelines and flowlines shall be registered in EPMARS. For new lines, EPMARS
Procedure PO-161 shall be applied. As detailed in ERD-10-01, all pipelines and flowlines
shall be classified as either Class 1 or Class 2, depending on the consequence of their failure.
This classification should be registered in EPMARS. The Asset Register in Pacer-CM, which
is used to store and analyse corrosion data, shall be maintained as detailed in the Pacer-CM
User Support Guide.

RANK BY CRITICALITY

Pipeline risk is defined in ERD-10-01. Failure causes in PDO are mainly due to internal
corrosion, external corrosion or impact. Integrity action plans should ideally be based on a
quantitative risk ranking, but whilst pipeline failure consequences are reasonably known in
PDO, pipeline failure probabilities are not, and hence a proper risk ranking is not currently
feasible. The classification of pipelines and flowlines is therefore defined in terms of failure
consequences only, and does not take into account the probability of failure. The pipeline
maintenance and inspection plans however, are adapted to known corrosion mechanisms and
monitored defects. Over time therefore, the pipeline plans do address the probability of
failure.

All pipelines and flowlines shall be categorized into 1 of 2 classes, as defined in ERD 10-01;

Class 1;

Health and Safety;

- Lines in populated areas transporting hydrocarbons.
- Gas lines with an operating pressure of ANSI 16.5 900 lb. rating and above.

Environment;
- Lines in environmentally sensitive areas transporting liquid hydrocarbons.

Asset Value;
- Lines with an estimated replacement value exceeding US$ 1M.

Loss of Revenue;
- Lines transporting at least 1500 m3/d net oil.
- Government gas lines.
- Fuel gas, water injection or gaslift lines, with at least 1500 m3/d net oil production impact.

Class 2;

- All lines not in Class 1, i.e. most flowlines, gaslift lines and water lines.

DEVELOP MAINTENANCE REQUIREMENTS

As a result of criticality ranking, the differentiation between Class 1 and Class 2 determines
the initial maintenance (inspection) option, as defined in the Pipeline Integrity Management
ERD-10-01. For example, until experience is built up to judge otherwise, all Class 1 lines
shall be subject to intelligent inspection every three years, except dry gas lines, which shall be
inspected every 6 years, refer ERD 10-14. Therefore, if sufficient information is available, the
Discipline Supervisor will base the maintenance/inspection requirements upon this knowledge,
otherwise the requirements specified in ERD 10-01 shall prevail.

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The CDFP assures that an annual maintenance and inspection plan, based on ERD 10-01, GU-
256 and prior inspection and maintenance history, shall be drawn up for each pipeline and
group of flowlines. These plans, including activities and their cost, shall be issued to the Asset
Holder for approval, prior to budget preparation. Plans to maintain the long term integrity of
Class 2 lines shall include all activities for the forthcoming year, whilst plans for Class 1 lines
shall include all activities for five years. The Asset Holder approves the plan and commits to
raising the required budget funds.

The inspection method(s) and strategy for flowlines are in an early stage of development and
are based on a pragmatic approach. Using the 'Worst offender list' for prioritising the
appliance of the Magnetic Flux Leakage (MFL) inspection technique, the Service Provider
recommends partial or complete replacement to the Asset Holder. A multi-discipline team,
headed by an Asset Holder representative, will review these recommendations in view of
lifecycle cost. The team will propose the use of alternative materials where appropriate.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

EPMARS shall be used to store and generate work orders for, the following routine activities:-
Pipeline pigging, launcher/receiver maintenance, ESD and block valve maintenance, access
fitting installation/retrieval, cathodic protection monitoring, automated ultrasonic inspection,
pipeline intelligent tool internal surveys, corrosion inhibitor injection and skid maintenance,
pipeline right of way inspection, external coating surveys and HDPE line venting.

Corrective remedial actions are also stored in EPMARS. The Pipeline Group is responsible
for raising the corrective work orders, refer EPMARS Procedures P150 and P151, which shall
be assigned a 'T#' priority code and an associated planned completion date that are appropriate
in order to maintain asset integrity. The progress of corrective actions shall be monitored on
this basis. If corrective actions are to be carried out through an Internal Work Request (IWR),
then an EPMARS dummy work order shall be raised to allow the work to be tracked and
monitored as described above.

PACER-CM shall be used to record inspection and corrosivity data for the prevalent operating
conditions and provide condition assessment and remnant life, based on assessed corrosion
rates, measured corrosion rates and remaining wall thickness, versus design code
requirements. Refer Pacer-CM User Support Guide.

IDAS shall be used to store the piping isometrics and key point locations.

SCHEDULE MAINTENANCE AND INSPECTION

Pipeline maintenance activities are included in the area plans (IAP, 90 Day Plan and 14 Day
Schedule). For activity scheduling, reference shall be made to the Planning Process
Description Manual.

Deviations from the due dates for pipeline activities and corrective actions registered in
EPMARS, shall be subject to the conditions of the Maintenance and Inspection Activity
Variance Control Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

Routine;

Routine pipeline maintenance and inspection activities, as per the EPMARS assigned tasks
and frequencies, are typically executed by contractor personnel. The Contractor is responsible
for reporting activity completion, findings and any recommendations for remedial work.

Line Derating;

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Depending on the outcome of inspections and surveys, the Pipeline Maintenance Engineer will
advise on line derating, including the latest completion date. Implementation of line derating
is the responsibility of the Asset Holder, who shall raise an FCP (Refer PR-1001a) to ensure
all required measures are taken, refer Pipeline Derating Procedure PR-1010.

Remedial Work;

All asset integrity related remedial actions required to remedy a medium or high risk
deficiency, as per the Risk Matrix, are proposed to the Asset Holder and shall include the
latest required completion date. The latest completion date is the date beyond which
secondary measures are required to assure the integrity of the line, refer Pipeline Remedial
Work Procedure PR-1011.

Depending on the kind and magnitude of the remedial action required and the input from the
Asset Holder, the remedial action is assigned either to the Maintenance Support Group or to
Engineering. Pipeline Remedial Work Procedure PR-1011 describes the process by which
corrective pipeline work is addressed and the key players involved.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

The following Performance Indicators exist for Pipelines, refer Corporate Indicator of Asset
Integrity Compilation Procedure PR-1012, to measure the compliance to and the effectiveness
of, the maintenance process:

- Occurrence of 'High Risk' loss of containment incidents.

- Number of loss of containment incidents against target.

The effectiveness of maintenance/treatment for individual pipelines is being assessed as part

of the development of the yearly plans.

ANALYSE AND IMPROVE PROCESS

The analysis of the effectiveness and efficiency of maintenance and inspection on individual
pipelines and flowline groups is carried out through the pipeline annual reviews. Overall
analysis of the effectiveness and efficiency of 'Maintain Pipelines' is carried out through the
Pipeline Integrity Workgroup, which reports to the Pipeline Integrity Steering Committee,
refer ERD-10-01. These forums intend to steer towards continuous improvement of the
process.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Pipelines shall maintain review and update the pipeline MCP's.

RELEVANT STANDARDS

GU-256 Guideline for the Inspection Of Static Equipment. Lists applicable

PDO Standards, DEP's and National/International Codes and
Standards.
ERD-10-01 Pipeline and Flowline Integrity Management.
PR-1146 Flowline Cold Cutting Procedure
ERD-10-13 Flowline Manual.
ERD-10-14 Intelligent Pig Inspection of Pipelines.
DEP 31.40.40.38 Hydrostatic Testing of Pipelines.
DEP 31.40.60.11 Pipeline Leak Detection.
DEP 31.40.60.12 Pipeline Repairs.
P150 Raising a Work Order.
P151 Approving a Work Order.
PO-161 MMS Asset and Activity Registration.
P162 Specification - Updating in EPMARS.

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PR-1005 Maintenance and Inspection Activity Variance Control.

PR-1010 Pipeline Derating.
PR-1011 Pipeline Remedial Work.
PR-1012 Corporate Indicator of Asset Integrity Compilation.

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4.3. STATIC EQUIPMENT

For the purposes of this Code of Practice the Static Equipment sub-section is divided into
three aspects, namely Tanks and Vessels, On-Plot Pipework and Relief Valves. This division
is required due to the dissimilar practises followed during the maintenance of each of these
asset types.

The mutually agreed working principles and services to be provided by the Static Equipment
Inspection and Maintenance Group, OTT/1, to the Asset Teams, are detailed in the OTT
Department Service Level Agreement.

4.3.1. TANKS AND VESSELS

ESTABLISH/UPDATE ASSET REGISTER

The Asset Register for tanks and vessels is contained within EPMARS. All coded/certified
pressure vessels, tanks and heat exchangers shall be included in the Asset Register, in
accordance with EPMARS Practices and Procedures.

The PACER Corrosion Management (PACER-CM) system is a database used to record and
provide analysis of the equipment condition. The static equipment database in PACER-CM
shall be taken directly from the Asset Register in EPMARS, so that the database is common
and relational. EPMARS however, remains the definitive Asset Register. The processes and
responsibilities for maintaining the PACER-CM monitored and fixed data, shall be in
accordance with PACER-CM User Support Guide.

RANK BY CRITICALITY

Unless otherwise determined, all tanks and vessels registered in EPMARS are considered to be
'Critical', with all items at a common level, since the principle failure mode will cause loss of
containment and affect asset integrity.

To enable the progression to risk and condition based inspection frequencies however, a more
detailed form of criticality ranking is required. The RBI methodology, utilising PACER-CM,
incorporates a consequence of failure assessment of equipment, as part of the process of
determining the next inspection due date.

DEVELOP MAINTENANCE REQUIREMENTS

To establish initial asset integrity, tanks and vessels are designed to operate within a specified
envelope for the duration of the design life, with suitable material selection and corrosion
mitigation measures applied as necessary. The continued asset integrity of the asset is assured
throughout its lifecycle by intrusive (off-stream) inspections, external inspections and
ultrasonic wall thickness surveys. Ultrasonic surveys shall generally be aligned with internal
inspection, during equipment shutdown, to provide a comprehensive assessment of the
equipment condition at that time. As specified by the CDFP Static Equipment, ultrasonic
inspection and other non-intrusive inspection techniques may also be specified, at interim
stages between equipment shutdowns, to verify the asset condition and to justify the internal
(off-stream) inspection interval. Equipment may be operated beyond the original design life
provided that its asset integrity is assured.

Historically inspections have been calendar based, but recently, in a move to determine
inspection frequencies using a condition based approach, fixed time intervals have no longer
been specified. Instead, the inspection intervals are specified by the Inspection Group, on the
basis of the asset's current condition and previous operating history. Where appropriate, and
as determined by the CDFP Static Equipment, the Risk Based Inspection (RBI) Module in
PACER-CM shall be applied to tanks and vessels, to determine the extent of inspection and
the next inspection due date. This is in accordance with Risk Based Inspection Process
Description Report No. RBI 001.

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All further maintenance requirements, i.e. coating repairs, mechanical repairs, etc. are derived
and determined from the inspection results, in the form of corrective actions.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

EPMARS contains the definitive Activity Register. All inspection and maintenance activities
for tanks and vessels are recorded and controlled through the inspection due dates,
Maintenance Craft Procedures and corrective action Work Orders. Refer EPMARS Practices
and Procedures.

Brief inspection and maintenance histories are contained within EPMARS, but in addition the
Inspection Group shall maintain for each equipment item, all inspection reports and equipment
history summaries per GU-256

Inspection and testing requirements for differing tank and vessel types and variants, including
their associated support structures, bund walls, etc. are contained within EPMARS in the form
of WSN's and associated MCP's. The inspection and testing techniques and procedures shall
be in accordance with GU-256 taking account of the identified threats to asset integrity. It
should be noted that EPMARS also contains MCP's for the preparation of tanks and vessels for
inspection, primarily related to man entry and other measures required to allow inspection to
be performed.

Corrective maintenance work orders shall be raised by the Inspection Group and stored in the
EPMARS system, refer EPMARS Procedures P150 and P151. Corrective work orders shall be
assigned a 'T#' priority code and an associated planned completion date that are appropriate in
order to maintain asset integrity. The progress of corrective actions shall be monitored on this
basis

PACER-CM shall be used to record inspection and corrosivity data for the prevalent operating
conditions and provide analysis of the equipment condition and remnant life, based on
assessed corrosion rates, measured corrosion rates and remaining wall thickness, versus design
code requirements, refer PACER-CM User Support Guide.

SCHEDULE MAINTENANCE AND INSPECTION

The Asset Holder has the responsibility for planning and scheduling all inspection and
maintenance activities, with the exception of ultrasonic inspection, the planning of which is
detailed below. The timing and scope of these activities should be aligned with the due dates
and activity requirements recorded in EPMARS, for each equipment item.

Inspection and maintenance activities are included in the area plans (IAP, 90 Day Plan and 14
Day Schedule), which shall be used by the Inspection Group to co-ordinate the inspection
activities and by the Asset Holders and Campaign Group, to co-ordinate the activities related
to the preparation of the equipment for inspection and its subsequent return to service. For
further details refer to the Planning Process Description Manual, which forms part of SI-34.

Ultrasonic inspection essentially compliments the internal inspection activity and will
generally be carried out during equipment shutdown. Being non-intrusive in nature however,
it may be carried out on-stream. The Inspection Group, as activity executor, is therefore
responsible for planning and scheduling ultrasonic inspection activities on behalf of the Asset
Holder.

Deviations from the due dates for inspection activities and maintenance corrective actions
registered in EPMARS, shall be subject to the conditions of the Maintenance and Inspection
Activity Variance Control Procedure PR-1005.

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PERFORM MAINTENANCE AND INSPECTION

Intrusive Inspection

The process for the preparation and execution of intrusive inspection activities and follow up
actions are given in the Static Equipment Maintenance and Inspection Procedure PR-1013.

Any preparation activities required to facilitate an inspection are carried out by the Asset
Holders and the Campaign Group. The inspection and the provision of resources to perform
the inspection, are the responsibility of the Inspection Group.

After referring to the relevant 90 Day Plan, the Inspector will liaise with the Campaign Group,
to ensure Inspection Group presence when the equipment becomes available for inspection
and that the correct test procedures are applied where required.

After each inspection the Inspector will produce an inspection report stating the inspection
findings and any remedial actions required. If no remedial actions are required, the Inspector
will unconditionally certify the equipment for continued operation until the next inspection
due date. Where corrective actions are required, the Inspection Group shall define the scope
of the repairs and in consultation with the Asset Holder, specify an acceptable completion date
for the repairs, in view of their impact on asset integrity. In extreme cases repair may be
required before the equipment is returned to service.

Remedial work shall be executed by a party nominated by the Asset Holder. During
execution, all remedial work shall be monitored by the Inspection Group for compliance with
the agreed workscope. Final acceptance inspection shall be carried out by the Inspection
Group and shall include handover of all the relevant quality control and quality assurance
documentation, for inclusion in the equipment history file . Quality control and quality
assurance of repair work, i.e. welded repairs and coating repairs, will be the responsibility of
the activity executor. Once the work is satisfactorily completed, the Inspection Group shall
issue a final inspection report, certifying the equipment for continued operation, until the next
inspection due date.

The Inspection Group will assign the next inspection due date, approved at the appropriate
authority level, in accordance with GU-256 , based on a judgement of the rate of deterioration,
the remaining life and the risk probability and consequence of the failure of the equipment.
To assist in this judgement, the PACER-CM RBI analysis shall be used whenever the
appropriate RBI input data is available.

Requirements for the compilation, approval and distribution of inspection reports and the
update of inspection records are given in GU-256 .

Non-Intrusive Inspection

The Procedure and process for the preparation and execution of ultrasonic inspection of tanks
and vessels and the follow up actions necessary are given in the Static Equipment
Maintenance and Inspection Procedure PR-1013.

If the inspection results indicate an unexpected deterioration in condition, then a thorough off-
stream inspection will normally be required to determine the scope of the required corrective
action.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

The following Performance Indicators exist for Tanks and Vessels, refer Corporate Indicator
of Asset Integrity Compilation Procedure PR-1012, to measure the compliance to and the
effectiveness of, the maintenance process:

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- Occurrence of 'High Risk' loss of containment incidents.

- Non-compliance of Tank and Vessel inspection against the permitted deviation band.

In addition, following the completion of inspection activities during a campaign maintenance

period at a production station or facility, the Inspection Group shall issue a close out report to
the Asset Holder. This shall detail a summary of recommended remedial actions and other
notable features of the inspection and maintenance effort, that were either particularly
successful or that could be improved. This information shall then be used to optimise future
maintenance and inspection by initiating improvements and eliminating unnecessary processes
or practices.

ANALYSE AND IMPROVE PROCESS

The Asset Holder has the responsibility to challenge inspection advice and recommendations,
to ensure that the Inspection Group has considered all alternatives and that the most
appropriate option for integrity assessment and remedial measures have been selected, taking
into account life cycle cost and business requirements, without compromising safety and asset
integrity. This shall be carried out through the review of reports and recommendations from
the Inspection Group.

As required the Asset Holder shall request predictions on repairs, renewals or upgrading, in
particular prior to shutdowns, to allow for timely allocation of contingency resources.

Where the condition of an asset has been established to be good, RBI shall be applied to
reduce the inspection and maintenance effort. This will enable movement from time based to
condition based inspection intervals, focussing inspection and maintenance efforts on critical
sections of the facilities where degradation is expected to occur. Part of this process shall be a
review, station by station, on a periodic basis, to identify increased or decreased corrosion
rates, as a result of changes in service conditions. The reviews shall be initiated by the Asset
Holder on the advice of the CDFP Static Equipment.

The CDFP Static Equipment shall develop and implement a programme to identify and
introduce improved inspection and maintenance techniques and technologies, where a cost or
improved integrity benefit can be established. The introduction of such techniques shall be
reflected in ERD GU-256 and the inspection MCP's. In parallel with this, the longer term aim
shall be to progressively monitor the condition of equipment, by non-intrusive techniques,
where suitable methods exist and only perform intrusive inspections when it is necessary, due
to indications of a deteriorated condition, or performance tail off.

The CDFP Static Equipment shall ensure the investigation and follow up of all loss of
containment incidents (leaks), due to the loss of asset integrity. The purpose is to establish the
cause and to identify and implement the necessary measures and actions required to prevent
future occurrences, on a company wide basis.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Static Equipment shall maintain review and update the tank and vessel inspection
MCP's.

RELEVANT STANDARDS

GU-256 Guideline for the Inspection Of Static Equipment. Lists applicable PDO
Standards, DEP's and National/International Codes and Standards.
P150 Raising a Work Order.
P151 Approving a Work Order.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1012 Corporate Indicator of Asset Integrity Compilation.
PR-1013 Static Equipment Inspection and Maintenance.
N/A Pacer-CM User Support Guide.

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N/A EPMARS Practices and Procedures Manual Master Directory.

Report No. RBI 001 Risk Based Inspection Process Description.

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4.3.2. ON-PLOT PIPEWORK

ESTABLISH/UPDATE ASSET REGISTER

The Asset Register for on-plot pipework is contained within EPMARS in the form of piping
tag numbers. On-plot pipework is defined as piping conforming to ANSI B31.3 and is
generally within the boundary fences of facilities. Piping designed in accordance with ANSI
B31.4 and 31.8, i.e. pipelines and flowlines, are covered separately. All ANSI B31.3 pressure
pipework shall be included and updated in accordance with EPMARS Practices and
Procedures.

Each piping tag registered in EPMARS shall have associated 'As-built' isometric drawing(s),
which shall be stored in the Electronic Document Management System (EDMS)

PACER-CM shall be used to provide analysis of the pipework condition. The on-plot
pipework database shall be taken directly from the Asset Register in EPMARS, so that the
database is common and relational. Corrosion monitoring key points, referenced in PACER-
CM, shall be indicated on the isometric drawings.. The processes and responsibilities for
maintaining the PACER-CM monitored and fixed data for on plot pipework, shall be in
accordance with Pacer-CM User Support Guide.

RANK BY CRITICALITY

In principle all on-plot pipework is considered to be 'Critical', with all tags at a common level,
since the principle failure mode will cause loss of containment and affect asset integrity.

The RBI methodology for on-plot pipework incorporates a risk and consequence of failure
assessment, as part of the process for determining the necessity to inspect specific piping tags,
the next inspection due dates and key point selection.

DEVELOP MAINTENANCE REQUIREMENTS

To establish initial asset integrity, on-plot pipework is designed to operate within a specified
envelope for the duration of the design life, with suitable material selection and corrosion
allowances applied as necessary. Continued asset integrity throughout its lifecycle, is assured
through on-stream external inspections, using ultrasonic testing or other non-destructive
techniques. Piping may be operated beyond the original design life provided its asset integrity
is assured. Except where determined otherwise by applying RBI, baseline surveys shall be
carried out on all on-plot pipework.

Re-inspection intervals are specified by the Inspection Group, on the basis of the assets current
condition and previous operating history. Where appropriate and as determined by the CDFP
Static Equipment, the RBI Module in PACER-CM shall be applied to determine the extent of
inspection and the next inspection due date, in accordance with RBI Process Description
Report No. RBI 001.

All further maintenance requirements, i.e. repairs, replacement, etc, will be derived and
determined from the inspection results, in the form of corrective actions.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

EPMARS contains the definitive Activity Register. All inspection and maintenance activities
for on-plot pipework are recorded and controlled through the inspection due dates,
Maintenance Craft Procedures and corrective action Work Orders. Brief inspection and
maintenance histories shall also be recorded in EPMARS. Refer EPMARS Practices and
Procedures.

The inspection and testing techniques and procedures shall be in accordance with GU-256,
taking account of the prevalent corrosion mechanisms. For re-inspections, PACER-CM RBI

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shall be used to determine which of the original key points on the piping spools shall be
surveyed.

Corrective maintenance work orders shall be raised by the Inspection Group and stored in the
EPMARS system, refer EPMARS Procedures P150 and P151. Corrective work orders shall be
assigned a 'T#' priority code and an associated planned completion date that are appropriate in
order to maintain asset integrity. The progress of corrective actions shall be monitored on this
basis.

PACER-CM shall be used to record inspection and corrosivity data for the prevalent operating
conditions and provide condition assessment and remnant life, based on assessed corrosion
rates, measured corrosion rates and remaining wall thickness, versus design code
requirements. Refer Pacer-CM User Support Guide.

SCHEDULE MAINTENANCE AND INSPECTION

Ultrasonic inspection of on plot pipework is generally carried out on-stream. The Inspection
Group, as activity executor, is responsible for planning and scheduling the inspection activities
on behalf of the Asset Holder. The Asset Holder however, has the responsibility for planning
and scheduling any follow-up maintenance activities derived from the inspection results. The
timing and scope of these activities should be aligned with the due dates and activity
requirements recorded in EPMARS, for each piping tag.

Deviations from the due dates for inspection activities and maintenance corrective actions
registered in EPMARS, shall be subject to the conditions of the Maintenance and Inspection
Activity Variance Control Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

The process for the preparation and execution of ultrasonic inspection of on-plot pipework and
any follow up actions necessary, are given in the Static Equipment Maintenance and
Inspection Procedure PR-1013.

Any preparation activities required to facilitate inspections are carried out by the Asset
Holders or the Campaign Group, at the request of the Inspection Group. Inspection and the
provision of resources to perform the inspection, are the responsibility of the Inspection
Group.

After each inspection the Inspector will produce an inspection report stating the inspection
findings and any remedial actions required. Where corrective actions are required, the
Inspection Group shall define the scope of the repairs and in consultation with the Asset
Holder, specify an acceptable completion date for the repairs, in view of their impact on asset
integrity. In extreme cases piping may be considered unsafe to remain in service without the
specified repairs being carried out.

Remedial work shall be executed by a party nominated by the Asset Holder. Quality control
and quality assurance of repair work, i.e. welded repairs, will be the responsibility of the
activity executor. Once the work is completed satisfactorily, the Inspection Group shall issue
a final inspection report, certifying the pipework for continued operation and will assign the
next inspection due date in EPMARS. This shall be approved at the appropriate authority
level in accordance with GU-256 . Requirements for the compilation, approval and
distribution of inspection reports and the update of inspection records are given in GU-256 .

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

The following Performance Indicators exist for On-plot Pipework, refer Corporate Indicator of
Asset Integrity Compilation Procedure PR-1012, to measure the compliance to and the
effectiveness of, the maintenance process:

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- Occurrence of 'High Risk' loss of containment incidents.

- Non-compliance of On-plot Pipework inspection against the permitted deviation band.

ANALYSE AND IMPROVE PROCESS

The Asset Holder has the responsibility to challenge inspection advice and recommendations,
to ensure that the Inspection Group has considered all alternatives and that the most
appropriate option for integrity assessment and remedial measures have been selected, taking
into account life cycle cost and business requirements, without compromising safety and asset
integrity. This shall be carried out through the review of the reports and recommendations
from the Inspection Group.

RBI shall be applied to reduce the inspection and maintenance effort where the condition has
been established to be good. This will enable movement from time based to condition based
inspection intervals, focussing inspection and maintenance efforts on critical sections of the
facilities where degradation is expected to occur. Part of this process shall be a review, station
by station, on a periodic basis, to identify increased or decreased corrosion rates as a result of
changes in service conditions. The reviews shall be initiated by the Asset Holder on the
advice of the CDFP Static Equipment.

The CDFP Static Equipment shall develop and implement a programme to identify and
introduce improved inspection techniques and technologies, where a cost or improved
integrity benefit can be established. The introduction of such techniques shall be reflected in
GU-256 and the inspection MCP's. In parallel with this, the longer term aim shall be to
progressively monitor the condition of equipment, by non-intrusive techniques where suitable
methods exist and only perform off-stream inspections when it is necessary, due to indications
of deteriorated condition, or performance tail off.

The CDFP Static Equipment shall ensure the investigation and follow up for all loss of
containment incidents (leaks), due to the loss of asset integrity. The purpose is to establish the
cause and to identify and implement the necessary measures and actions required to prevent
future occurrences, on a company wide basis.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Static Equipment shall ensure appropriate on-plot pipework inspection procedures
are in place.

NOTE :

ON PLOT PIPING VALVES

General

On plot piping valve bodies and internals are designed to be maintenance free and if they
become defective they are replaced. ( on-plot piping valves have flanged connections.)

There is no routine inspection for internal or external metal loss carried out on the valve
bodies on the basis that the valve body metal thickness’ are significantly over designed with
respect to their design pressures and significantly greater than that of adjacent pipe spools.
Pipe spools are subject to inspection which will give an indication of the valve body condition
and the need to carry out valve replacement if and when piping spools are replaced.

Actuated Valves

Actuated valves (ESDV’s , MOV’s and PCV’s etc ) are entered into EPMARS , inspected,
tested and maintained under WSN’s and MCP’s that are approved by the CDFP Control and
Automation.

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Manual Valves

Manually operated valves are not individually tagged and are not entered into EPMARS

Possible maintenance depends upon the valve type and design and is limited to lubricating the
shafts and external moving parts where there is facility to do so

For this reason any valve maintenance shall be carried out at the discretion of the asset
holders. On a station wise basis each line would have to be followed from the PEFS and by
site survey to identify and select the valves for maintenance.

As well as lubrication the maintenance routine would consist of stroking the valves (if only
partially to maintain flow) at a suitable interval (say every 6-12 months) Failure of the valve
to operate correctly would result in a corrective work order to replace the valve during the
next campaign.

RELEVANT STANDARDS

GU-256 Guideline for the Inspection of Static Equipment. Lists applicable PDO
Standards, DEP's and National/International Codes and Standards.
P150 Raising a Work Order.
P151 Approving a Work Order.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1012 Corporate Indicator of Asset Integrity Compilation.
PR-1013 Static Equipment Inspection and Maintenance.
N/A Pacer-CM User Support Guide.
N/A EPMARS Practices and Procedures Manual Master Directory.
Report No. RBI 001 Risk Based Inspection Process Description.

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4.3.3. RELIEF VALVES

ESTABLISH/UPDATE ASSET REGISTER

The Asset Register for relief valves, which includes safety relief valves and pressure vacuum
valves, is contained within EPMARS. All relief valves protecting static equipment, rotating
equipment and pipelines shall be included and updated in accordance with EPMARS Practices
and Procedures. This includes updating and recording relief valve movements to and from
associated tag positions.

RANK BY CRITICALITY

Unless otherwise determined, all relief valves registered in EPMARS are considered 'Critical'
and at a common level, because of their purpose and function to protect pressure containing
equipment from overpressure or vacuum conditions.

DEVELOP MAINTENANCE REQUIREMENTS

Maintenance and testing requirements shall be in accordance with GU-256 and Inspection
Procedure PR-1013. These require that all relief valves are regularly subject to off-stream
testing and overhaul. On-line test methods, e.g. Trevi-testing, may be adopted following
approval by the Inspection Group on a case by case basis, bearing in mind that such tests are
not equivalent to a full overhaul. The scope of work is determined from the test results, an
assessment of the valves condition and previous history, together with the manufacturers
service instructions. The normal off-stream testing and overhaul interval is two years, with
the possible extension based on 'Pre-pop' performance (as received test results versus set
pressure) and the valve condition at overhaul. Equally the performance and condition of some
valves, when overhauled and tested, may require that a reduced interval is specified.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

EPMARS contains the definitive Activity Register. All testing and overhaul activities for
relief valves are recorded and controlled by the inspection due dates, Maintenance Craft
Procedures, technical details and test certificates. Refer EPMARS Practices and Procedures.

SCHEDULE MAINTENANCE AND INSPECTION

The Asset Holder has the responsibility for planning and scheduling the inspection and testing
activities for relief valves. The timing and scope of these activities should be aligned with the
due dates and technical details recorded in EPMARS for each relief valve. Relief valve
activities are included in the area plans (IAP, 90 Day Plan and 14 Day Schedule), which shall
be used by the Area Teams and Campaign Group, as activity executors, to co-ordinate the
activities related to the preparation of equipment for relief valve removal, overhaul and
testing.

Deviations from the due dates for inspection activities and maintenance corrective actions
registered in EPMARS, shall be subject to the conditions of the Maintenance and Inspection
Activity Variance Control Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

Relief valves due for overhaul and testing are removed from their location and transported to a
test facility by the Campaign Group. The Inspection Group shall monitor and witness the
testing, determine the next inspection due date and certify the valves.

The process for the preparation and execution of relief valve overhaul, testing, re-certification
and follow up actions is given in Static Equipment Maintenance and Inspection Procedure PR-
1013.

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ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

Performance analysis shall be carried out for, but not limited to, the following areas:

- Overhauls planned versus actual and the number of overhauls overdue.

- Pre-pop test performance.

ANALYSE AND IMPROVE PROCESS

The Asset Holder has the responsibility to challenge inspection advice and recommendations,
to ensure that the Inspection Group has considered all alternatives and that the most
appropriate option for integrity assessment and remedial measures have been selected, taking
into account life cycle cost and business requirements, without compromising safety and asset
integrity. This shall be carried out through the review of the reports and recommendations
from the Inspection Group.

RBI shall be applied to reduce the inspection and maintenance effort where the condition has
been established to be good. This will enable movement from time based to condition based
inspection intervals, focussing inspection and maintenance efforts on critical sections of the
facilities where degradation is expected to occur. Part of this process shall be a review,
station by station, on a periodic basis, to identify increased or decreased corrosion rates as a
result of changes in service conditions. The reviews shall be initiated by the Asset Holder on
the advice of the discipline engineer.

The CDFP Static Equipment shall develop and implement a programme to identify and
introduce improved testing techniques and technologies where a cost or improved integrity
benefit can be established. The introduction of such techniques shall be reflected in GU-256.
In parallel with this, the longer term aim shall be to progressively monitor the condition of
equipment, by non-intrusive techniques where suitable methods exist, and only perform off-
stream inspections when it is necessary due to indications of deteriorated condition, or
performance tail off.

The CDFP Static Equipment shall ensure the investigation and follow up of all loss of
containment incidents (leaks), due to the loss of asset integrity. The purpose is to establish the
cause and to identify and implement the necessary measures and actions required to prevent
future occurrences, on a company wide basis.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Static Equipment shall ensure appropriate relief valve inspection procedures are in
place.

RELEVANT STANDARDS

GU-256 Guideline for the Inspection of Static Equipment. Lists applicable PDO
Standards, DEP's and National/International Codes and Standards.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1013 Static Equipment Inspection and Maintenance.
N/A Pacer-CM User Support Guide.
N/A EPMARS Practices and Procedures Manual Master Directory.
Report No. RBI 001 Risk Based Inspection Process Description.

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For the purposes of this Code of Practice the Static Equipment sub-section is divided into
three aspects, namely Tanks and Vessels, On-Plot Pipework and Relief Valves. This division
is required due to the dissimilar practises followed during the maintenance of each of these
asset types.

The mutually agreed working principles and services to be provided by the Static Equipment
Inspection and Maintenance Group, OTT/1, to the Asset Teams, are detailed in the OTT
Department Service Agreement.

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4.4. ROTATING EQUIPMENT

ESTABLISH/UPDATE ASSET REGISTER

The Asset Register is taken directly from the Computerised Maintenance System, EPMARS.
The asset tag number identifies a collection of assets grouped to form a package. For
example, a compressor tag number identifies the collection of assets associated with the gas
engine (compressor, combustion chamber and turbine), the power turbine, pump or
compressor, as well as the auxiliary equipment, such as lube oil pumps and coolers.

Initiating the update of the Asset Register is normally carried out by the Asset Team
Mechanical Supervisor. For updates resulting from projects however, the Project Engineer
will provide the required data, in accordance with EPMARS Practices and Procedures.

RANK BY CRITICALITY

The CDFP Rotating Equipment defines which assets are to be entered into the EPMARS
system as a preliminary form of ranking. Those assets that are registered in EPMARS are then
subjected to a more formal ranking based on the Corporate methodology for assessing risk.
Unless otherwise defined, a default ranking for the rotating assets is used which prescribes all
major rotating assets as 'Critical'.

DEVELOP MAINTENANCE REQUIREMENTS

The maintenance strategy for rotating equipment has been developed by the CDFP Rotating
Equipment. It is predominantly a scheduled maintenance strategy, with some condition based
maintenance. The aim is to cost effectively maintain assets to ensure that they perform to
their intended function, whilst optimising their reliability and availability and preserving their
integrity.

The objective regarding rotating equipment maintenance, is to maximise the intervals between
major overhauls and product deferring activities, without impacting upon performance and
integrity. To this end, the dominant strategy followed is to execute major overhauls based on
asset condition and performance, whilst executing routine preventative maintenance between
the major overhauls, to preserve asset integrity.

During the period when the assets are shut-down for maintenance activities, routine
inspections, in the form of boroscopic and visual inspections, are performed. The findings
from these inspections, in conjunction with other information such as past performance,
previous inspection results, spare part availability, asset runhours, lube oil analysis and
vibration spectrum analysis, are used to determine the optimum time to carry out major
overhauls. The Condition Monitoring Supervisor makes a recommendation to the Asset
Holder, who initiates the major overhaul as he sees fit, i.e. if it is commercially acceptable
when weighed up against the other aspects of his business. In this way the Asset Holder
makes the final decision concerning how best to manage the risk of losing asset integrity and
the associated commercial and HSE losses.

The relationship between the Rotating Equipment Service Provider and the Asset Holders is
documented in the OTT Department Service Agreement.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

The results of assessments made by the CDFP Rotating Equipment, with regard to precisely
which maintenance activities need to be performed, are documented in the relevant MCP's.
EPMARS contains the full listing of maintenance activities agreed by the rotating equipment
section as necessary to ensure asset integrity. The major maintenance activities consist of
services based on run-hours per asset. Due to the constraints of when and who carries out the
activities however, these have been aligned to a calendar based schedule to facilitate effective
execution. The groupings are as follows;

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1. 6 monthly (previously the 4,000 hour service).

2. 1 yearly (previously the 7,500 hour or 8,000 hour service, depending on asset type).
3. 3 yearly (previously the 24,000 hour or 30,000 hour service, depending on asset type).

There are only two possible service combinations available, depending on the asset type;

A. 4,000 + 7,500 + 24,000 hour services.

B. 4,000 + 8,000 + 30,000 hour services.

Clearly, once every three years a 3 yearly service will coincide with a 1 yearly service. In this
instance the 3 yearly is executed and the 1 yearly rescheduled to the following year.

Corrective maintenance work orders shall be raised by the Asset Team Mechanical Supervisor
and stored in the EPMARS system, refer EPMARS Procedures P150 and P151. Corrective
work orders shall, where appropriate, be assigned a 'T#' priority code and an associated
planned completion date that are appropriate, in order to maintain equipment asset integrity.
The progress of corrective actions shall be monitored on this basis.

SCHEDULE MAINTENANCE AND INSPECTION

The maintenance of rotating equipment falls into two main categories; routine servicing and
major overhauls.

Routine servicing is the execution of existing MCP's by either the Asset Holder or the
Campaign Group, as previously detailed.

Major overhauls are planned based on the information received from the Condition
Monitoring Teams. Depending on the asset type, information such as boroscopic inspections,
vibration analysis, performance tests, lube oil analysis and equipment efficiency data is used
to determine the optimum time to carry out the overhaul and to determine and plan the
budgetary requirements. Determining the optimum timing and estimating the cost of the
major overhauls is a process which involves input from the Condition Monitoring Team, the
Asset Holder and the Campaign Group.

Depending on the asset type, the overhaul will be done either on site or overseas. Regardless
of the location however, the planning process is the same. A formal notification is made to
the Asset Holder, who, if he accepts the recommendation from the Condition Monitoring
Supervisor, raises a 'Work request' to initiate the work. The Campaign Group, together with
the Area Planning Engineer, then schedule the work, order any materials required and
determine the manpower requirements.

An additional factor in the scheduling of major overhauls is the availability of spare units as
replacements. Spare units are held in stock, for each asset type, to cover both planned and
unplanned maintenance requirements. The management of these spares is particularly
important when the overhaul/repair work needs to be carried out overseas, as turn-around time
can be critical.

The Condition Monitoring section perform scheduled data gathering routines that form the
basis for performance and condition analysis of the assets. As a guide, each asset is surveyed
at least once every ten days.

Deviations from the due dates for maintenance activities registered in EPMARS, shall be
subject to the conditions of the Maintenance and Inspection Activity Variance Control
Procedure PR-1005.

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PERFORM MAINTENANCE AND INSPECTION

Maintenance activities are executed by the Asset Teams and the Campaign Group, utilising
contractor labour and resources where required. The relationship between these groups is
documented in the OTT Department Service Agreement. In addition to this however, the
Condition Monitoring Teams also perform maintenance and inspection work on gas turbines
such as;

Boroscopic Inspection of Rotating Equipment.

Balancing of Turbine Rotors.
Lube Oil Sampling and Analysis.
Analysis of Rotating Equipment Performance.
Analysis of Rotating Equipment Efficiency.
Bearing Rebuild for Solar Compressors.

Remedial actions required to remedy equipment deficiencies are proposed to the Asset Holder
and include the latest suggested completion date, in order to maintain asset integrity.
Remedial work orders (correctives) are executed by the Asset Teams or the Campaign Group.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

Performance Indicators for Rotating Equipment exist, refer Corporate Indicator of Asset
Integrity Compilation Procedure PR-1012, to measure the effectiveness of the maintenance
process. Analysis of these indicators is carried out to demonstrate that the maintenance
routines contain the correct elements and are executed at the correct frequencies to ensure that
asset integrity is maintained.

ANALYSE AND IMPROVE PROCESS

Periodic reviews of the process described above are undertaken to seek ways of continually
improving the maintenance of rotating equipment. The reviews include interviewing our
customers to refine the services we provide, challenging the content and frequencies of
routine maintenance activities, ensuring that the latest technologies are applied throughout the
process and ensuring that communications and individuals' roles and responsibilities are
clearly understood.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Rotating Equipment shall maintain review and update the rotating equipment
MCP's.

RELEVANT STANDARDS

AOS/4/62.94 Asset Management Manual.

P150 Raising a Work Order.
P151 Approving a Work Order.
PR-1012 Corporate Indicator of Asset Integrity Compilation.
ISO 2372 Mechanical Vibration Evaluation of Machinery Vibration by the
(now ISO 10816) Measurement of Non-rotating Parts.

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4.5. INSTRUMENTATION

For the purposes of this Code of Practice the Instrumentation sub-section is divided into three
aspects, namely Safeguarding, Process Control and Metering. This division being required
due to the dissimilar practises followed during the maintenance of each of the three asset
types.

4.5.1. SAFEGUARDING

Instrumented Protective Functions (IPF’s) comprise all instrumented safeguarding devices for
the following safeguarding levels:

- Emergency Shut-Down (ESD) systems.

- Process Shut-Down (PSD) systems.
- Fire and Gas (F&G) Detection systems.
- Equipment safeguarding systems.
- Pipeline safeguarding systems.

The strategy for IPF's is to ensure their optimum reliability as a function of risk. The
combined techniques which are used to achieve this are Reliability Centered Maintenance
(RCM) and IPF Classification. IPF Classification is used to set reliability targets, whilst RCM
techniques are used to identify failure modes and their effects on the availability of IPF's, in
order to develop and maintain the optimum test procedures.

ESTABLISH/UPDATE ASSET REGISTER

Currently, safeguarding instrumentation is entered in EPMARS against dummy tag numbers at

station level. These tag numbers reflect an activity rather than a group of assets. For each
safeguarding type, only one tag number exists per station. In addition, some safeguarding
equipment, e.g. ESD valves, are entered under individual tag numbers. As part of an ongoing
activity to restructure the instrumentation Asset Register in EPMARS, inconsistencies in the
database will be resolved.

In order to enable better planning, activity monitoring and analysis of test results, an initiative
is ongoing to restructure instrument safeguarding within the Asset Register. Where possible,
instrumentation equipment should be entered in EPMARS against actual equipment packages.
If the instrumentation is not equipment specific, it should be entered against the station
package. For safeguarding instrumentation the following equipment types shall be used:

IPF - For Instrumented Protective Functions. The IPF's are entered as components of a tag
number, which consists of the equipment package tag name and an equipment type of
IPF.
XL - IPF valves are also in EPMARS as individual tag numbers, with an equipment type of
XL.

Initiating the update of the Asset Register is normally carried out by the Asset Team
Instrument Supervisor. For updates resulting from projects however, the Project Engineer will
provide the required data, in accordance with EPMARS Practices and Procedures.

RANK BY CRITICALITY

Safeguarding instrumentation can fail in two ways: revealed (evident) or unrevealed (hidden).
Unrevealed failures will generally result in loss of protection and revealed failures in the loss
of availability of production capacity. Safeguarding instrumentation shall therefore be
assessed for both asset integrity and cash flow criticality. Some safeguarding instrumentation
has been subject to criticality assessment as part of a RCM study. This assessment does not
however, include setting a reliability target per individual safeguarding function. The results
of the RCM exercise are currently being implemented.

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Initiatives are ongoing to classify all Instrumented Protective Functions. This IPF
classification is used to set reliability targets by assessing the consequences of failure and
probability that there is a demand on the IPF to execute its action.

The IPF classification methodology is mandatory for all new designs. For existing designs,
IPF classifications shall be carried out to establish reliability targets. As a temporary measure,
for existing designs where RCM has been applied, the reliability target shall be set in line
with:

- IPF class III for functions in non-H2S applications

- IPF class IV for functions in H2S applications

Reference: SP-1093 - Classification and Implementation of Instrumented Protective Functions

and SP-1094 – Instrument Protective Functions.

DEVELOP MAINTENANCE REQUIREMENTS

To provide evidence that IPF's meet the required reliability, the actual reliability must be
measured by testing. Another purpose of testing is to identify hidden defects and to restore the
function to its original condition.

Currently all instrument safeguarding functions are tested at fixed intervals, however
initiatives are ongoing to optimise test intervals to meet reliability targets. Concurrently, the
existing equipment specific MCP’s for safeguarding system testing are being converted to
generic MCP’s.

The test methodology shall be based on Failure Mode and Effect Analysis (FMEA) and laid
down in generic MCP’s per equipment type. The test coverage factor shall be as high as is
reasonably practicable. The development of test methodologies and MCP’s is done by the
Control and Automation Support Group. Initial test intervals are taken from RCM analysis
using the reliability targets from IPF Classification. IPF’s which have not been classified are
tested at their current intervals which are based upon current industry practice. To provide
evidence that settings are sufficiently accurate, the actual trip settings shall be verified during
the tests. Approved and certified test equipment shall be used to ensure traceability to
recognised standards, refer Calibration of Instrumentation Procedure PR-1021. All test results
shall be recorded and filed.

To ensure that IPF's are in an operable condition, the use of override devices must be closely
controlled. Override devices (MOS, jumpers and mechanical overrides) defeat the
functionality of IPF's. Their use shall therefore be closely controlled, refer to Use of
Maintenance Override Switches PR-1022. The use of Maintenance Override Switches (MOS)
is continuously alerted to the operator and in the event of the process value passing the trip
setting, is still alarmed. Other override devices do not have such features and may therefore
result in forgotten, dormant override situations, without the operator being alarmed. They
shall therefore be treated differently from MOS. The use of such override devices shall be
logged and the Override Log shall be reviewed on a regular basis to ensure that overrides are
removed when no longer required. Logging overrides and reviewing these logs, is the
responsibility of the Asset Team Instrument Supervisor, refer PR-1001c.

To eliminate the unavailability of safeguarding functions due to defects, defective IPF's shall
be restored to full working order as soon as possible, through a corrective work order with
appropriate priority. The repair shall be carried out such that the original (design)
requirements are met.

The relationship between the Control and Automation Control and Automation Support Group
and the Asset Holders is documented in the OTT Department Service Agreement.

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LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

All maintenance activities are listed in the Activity Register in EPMARS. Currently all
instrumented safeguarding test routines are generated against the station dummy tag numbers.

Once the restructuring of the instrumentation database is completed (refer “Establish/update

Asset Register”), all equipment specific instrumentation routines (WSN's) will be generated
against the relevant IPF-tag of that particular equipment package. Only station generic
routines which cannot be made equipment specific will be generated per station IPF-tag. For
routines which are normally carried out during campaigns, frequency intervals of six-months
or multiples thereof, are preferred.

All non-routine and corrective maintenance work orders shall be raised by the Asset Team
Instrument Supervisor and stored in the EPMARS system, refer EPMARS Procedures P150
and P151, against the lowest asset level in EPMARS, i.e. against the specific equipment tag if
possible and not against the equipment package or station. Corrective work orders shall,
where appropriate, be assigned a 'T#' priority code and an associated planned completion date
that are appropriate, in order to maintain equipment asset integrity. The progress of corrective
actions shall be monitored on this basis.

SCHEDULE MAINTENANCE AND INSPECTION

The Asset Holder has the responsibility for planning and scheduling all test and maintenance
activities. The test activities are normally included in the area plans (IAP, 90 Day Plan and 14
Day Schedule). Corrective actions are normally scheduled in the 14 Day Plans.

Deviations from the due dates for maintenance activities registered in EPMARS, shall be
subject to the conditions of the Maintenance and Inspection Activity Variance Control
Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

Routine test and remedial action maintenance is executed by the Asset Holders and the
Campaign Group, utilising contract resources where required. Test results shall be recorded
and test reports produced, by the person carrying out the test. Equipment history reporting in
EPMARS is by “reporting by exception” and only includes details of any anomalies, i.e. IPF’s
that have failed to operate properly, even if the defect was resolved during, or immediately
after the test, refer Procedure PR-1094 Instrumented Protective Functions testing Procedure.

Remedial actions required to remedy equipment deficiencies are proposed to the Asset Holder
and include the latest suggested completion date, in order to maintain asset integrity.
Remedial work orders (correctives) are executed by the Asset Holder or the Campaign Group
and shall be carried out in such a manner that the original design requirements are met.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

The test results are reviewed by the Asset Team Instrument Supervisor to identify any defects
and to ensure that the tests have been carried out correctly. Corrective work orders are raised
for the repair of any defects. Refer Procedure PR-1094 Instrumented Protective Functions
testing Procedure.

Any impracticalities or errors noted in PM routines and MCP’s shall be reported to the
Instrument Supervisor for his review and action. This will enable the correction and
enhancement of PM routines and MCP’s.

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ANALYSE AND IMPROVE PROCESS

The following Performance Indicators exist for Safeguarding system testing, refer Corporate
Indicator of Asset Integrity Compilation Procedure PR-1012, to measure the compliance to
and the effectiveness of, the maintenance process:

- Number of tests actually carried against number of tests due.

- Actual versus target reliability.

From the analysis of test results by the Control and Automation Support Group, Bad Actors
shall be identified and assessed individually. Where the actual settings of IPF's during test are
frequently found to be outside the acceptance limits, the design shall be reviewed and an
inherently more accurate design shall be considered. Where IPF's do not meet the reliability
target, the performance shall be improved by reducing the test interval. A reduced test
interval will normally result in an increased reliability of the IPF. There may be limiting
factors in reducing the test interval, for instance unacceptable deferment and adverse effects
on other equipment. If a reduction of test interval is not acceptable or economical, a design
with greater inherent reliability shall be considered. Where IPF's have a significantly higher
actual reliability than the target, the test interval should be increased. Refer PR-1094
Instrumented Protective Functions testing Procedure.

The Override Log shall be analysed on a regular basis by the Control and Automation Support
Group, to review the availability of IPF's.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Instrumentation shall maintain, review and update generic safeguarding MCP’s.

RELEVANT STANDARDS

SP-1093 Classification and Implementation of Instrumented Protective

Functions.
SP-1094 Instrumented Protective Functions
PR-1094 Instrumented Protective Functions Testing Procedure
PR-1001c Temporary Override Of Safeguarding System Procedure
P150 Raising a Work Order.
P151 Approving a Work Order.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1012 Corporate Indicator of Asset Integrity Compilation.
PR-1021 Calibration of Instrumentation.
PR-1022 Use of Maintenance Overrides.
PR-1155 Removal/Inspection/Installation of Standard Flanged Orifice Plates.

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4.5.2. PROCESS CONTROL

This section comprises:

- Control and automation systems;

: Supervisory Control and Data Acquisition (SCADA).
: Distributed Control System (DCS).
: Programmable Logic Controllers (PLC).
: Microprocessor Based System (MBS).
- Field instrumentation.

The strategy for process control is to ensure optimum reliability as a function of costs. The
technique which is used to achieve this is Reliability Centered Maintenance.

ESTABLISH/UPDATE ASSET REGISTER

Process Control instrumentation is entered in EPMARS mainly as components, where possible

against actual equipment packages. If the instrumentation is not equipment specific, it should
be entered against the station package. In addition some instrumentation, e.g. control valves,
analysers and control and automation systems, are entered under individual tag numbers and
specific equipment types. As part of an ongoing activity to restructure the instrumentation
Asset Register in EPMARS, inconsistencies in the database will be resolved. In addition, not
all control and automation systems are currently entered in EPMARS. In an ongoing activity
to restructure the Instrumentation Asset Register, these systems will be entered.

Initiating the update of the Asset Register is normally carried out by the Asset Team
Instrument Supervisor. For updates resulting from projects however, the Project Engineer will
provide the required data, in accordance with EPMARS Practices and Procedures.

RANK BY CRITICALITY

Instrumentation should be assessed for both asset integrity and cash flow criticality. Some
instrumentation has been subjected to criticality assessment as part of RCM. The results of
the RCM exercise are currently being implemented.

DEVELOP MAINTENANCE REQUIREMENTS

The general strategy for instrumentation is to carry out the appropriate level of maintenance in
relation to consequences and probability of failures. Based on the outcome of the criticality
ranking, instrumentation will be subject to:

- A full RCM analysis

- Failure Mode and Effect Analysis
- No analysis

As a result of the RCM and FMEA analysis, optimised PM routines will be in place for critical
equipment. As far as possible the MCP's will be generic. Where analysis is not carried out
because of a low criticality ranking, breakdown maintenance will suffice. The development of
test methodologies and MCP’s is carried out by the Control and Automation Support Group.

Measuring equipment shall be calibrated using calibration equipment which is traceable to

recognised standards, refer Calibration of Instrumentation Procedure PR-1021 and PR-1099
Metering Flow Factor Update Procedure.

Unless determined by a RCM/FMEA analysis, other instrumentation will not normally be

subject to periodical maintenance. The opportunity for overhaul or calibration during
equipment package shutdown, e.g. for static inspection or relief valve testing, shall be
considered.

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The maintenance strategy for control and automation systems (SCADA, DCS, PLC and MBS)
has two main objectives. The first objective is to ensure optimum availability of system
functionality. For this purpose regular preventative maintenance shall be carried out. The
scope and intervals of the PM routines is initially based on the manufacturers
recommendations and adjusted according to experience. The second objective is to prevent
loss of configuration data, which can result in significant loss of capital and prolonged
unavailability of the system concerned. Loss of configuration data is prevented by
maintaining an extensive system of back-ups of actual and historical software, refer Control
and Automation Systems Software Back-up Procedure PR-1023.

Maintenance Contracts for DCS and SCADA systems are in place for the provision of vendor
maintenance services and support. The contract usually includes the provision and
management of (vendor owned) prioritised spare parts and supply of consumed parts. These
maintenance contracts are held by the Control and Automation Support Group.

The relationship between the Instrumentation Control and Automation Support Group and the
Asset Holders is documented in the OTT Department Service Agreement.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

All maintenance activities are listed in the Activity Register in EPMARS. Once the
restructuring of the instrumentation database is completed (refer “Establish/update Asset
Register”), all equipment specific instrumentation routines (WSN's) will be generated against
the relevant tag of that particular equipment package. For routines which are normally carried
out during campaigns, frequency intervals of six-months or multiples thereof, are preferred.

All non-routine and corrective maintenance work orders shall be raised by the Asset Team
Instrument Supervisor and stored in the EPMARS system, refer EPMARS Procedures P150
and P151, against the lowest asset level in EPMARS, i.e. against the specific equipment tag if
possible and not against the equipment package or station. Corrective work orders shall,
where appropriate, be assigned a 'T#' priority code and an associated planned completion date
that are appropriate, in order to maintain equipment asset integrity. The progress of corrective
actions shall be monitored on this basis.

SCHEDULE MAINTENANCE AND INSPECTION

The Asset Holder has the responsibility for planning and scheduling all maintenance activities.
The PM routines are normally included in the area plans (IAP, 90 Day Plan and 14 Day
Schedule). Corrective actions are normally scheduled in the 14 Day Plans.

Deviations from the due dates for maintenance activities registered in EPMARS, shall be
subject to the conditions of the Maintenance and Inspection Activity Variance Control
Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

The PM routines and corrective activities are executed by the Asset Holders and the Campaign
Group, utilising contract resources where required. Reporting on maintenance activities is
achieved through Equipment History in EPMARS.

PM activities for SCADA and DCS systems are carried out by the respective Field Automation
Support Sections, normally utilising contract resources. If the activity is carried out on a
critical system, escalation/fall back procedures shall be in place to cope with unforeseen
problems.

First line corrective maintenance for SCADA and DCS systems is typically carried out by the
Asset Holder. Second (troubleshooting) and third line (vendor assistance) support is provided
by the Field Automation Support Sections.

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ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

Any impracticalities or errors noted in PM routines and MCP’s shall be reported to the
Instrument Supervisor for his review and action. This will enable the correction and
enhancement of routines and MCP’s.

ANALYSE AND IMPROVE PROCESS

From the analysis of PM results and Corrective activities by the Control and Automation
Support Group, Bad Actors shall be identified and assessed individually.

The results of PM activities for SCADA and DCS systems shall be reviewed by the Control
and Automation Support Group, on an annual basis during the contract review meetings, to
identify improvements.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Instrumentation shall maintain, review and update generic process control MCP’s.

RELEVANT STANDARDS

P150 Raising a Work Order.

P151 Approving a Work Order.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1021 Calibration of Instrumentation.
PR-1023 Control and Automation systems software back-up.
PR-1099 Metering Flow Factor Update Procedure.

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4.5.3. METERING

The strategy for metering is to ensure that the required accuracy for metering is achieved.

ESTABLISH/UPDATE ASSET REGISTER

Metering instrumentation is entered into the EPMARS Asset Register mainly as components,
where possible against actual equipment packages. If the instrumentation is not equipment
specific, it should be entered against the station package. Critical metering, as defined below,
is entered under individual tag numbers and specific equipment type. Currently, all field
export meters are entered into EPMARS. As part of an ongoing activity to restructure the
instrumentation Asset Register in EPMARS, inconsistencies in the database will be resolved.

Initiating the update of the Asset Register is normally carried out by the Asset Team
Instrument Supervisor. For updates resulting from projects however, the Project Engineer will
provide the required data, in accordance with EPMARS Practices and Procedures.

RANK BY CRITICALITY

Metering should be assessed for its criticality. Guide-lines for the criticality assessment are
laid down in the Production Metering Philosophy, reference BOS/038/94.

DEVELOP MAINTENANCE REQUIREMENTS

The strategy for metering is to carry out the appropriate level of maintenance in order to meet
the required accuracy. Accuracy requirements shall be defined and documented. Appropriate
MCP's shall be developed and maintained. These MCP's shall be based upon measurement
error analysis and should preferably be generic. It should be noted that accuracy and
statistical confidence level are interrelated. Accuracy’s are expressed at 95% confidence level
unless otherwise mentioned.

Critical measuring equipment shall be calibrated using calibration equipment which is

traceable to a recognised standard, refer to Calibration of Master Meter Prover for Fiscal
Metering Procedure PR-1024 and Fiscal and Hydrocarbon Accounting Metering Procedure
PR-1025. The calibration interval should be based upon the criticality, accuracy requirements
and type of instrument. The development of test methodologies and MCP’s is done by the
Control and Automation Support Group.

Updating of flow factors is governed by the Metering Flow Factor Update Procedure PR-1099.

The requirements for fiscal flow measurements are laid down in the respective contract or
sales agreements, references;

- Oman Export Blend Crude Sale/Purchase Agreement; June 1992.

- Crude Oil Delivery and Residue Operating Agreement between ORC and PDO; 31/05/86.
- General Crude Oil Metering Manual for Third Party entering into PDO Pipeline; 13/02/93.
- Third Party Transportation Agreements (Japex, Occidental and Elf).
- Third Party Operating Guide-lines (Japex, Occidental, Elf).
- STD 85904/35 Design Basis for Government Gas Pressure Reduction Terminals in the
Sultanate of Oman; January 1987 (Ministry of Petroleum and Minerals, Department of Gas
Affairs).
- Government Gas system Customer/Supplier Agreement.
- DEP 32.32.00.11-Gen Turbine Fiscal Metering Systems for Liquid Hydrocarbon.

The relationship between the Instrumentation Control and Automation Support Group and the
Asset Holders is documented in the OTT Department Service Agreement.

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LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

All maintenance activities are listed in the Activity Register in EPMARS. Once the
restructuring of the instrumentation database is completed (refer 'Establish/Update Asset
Register'), all equipment specific instrumentation routines (WSN's) will be generated against
the relevant tag of that particular equipment package. For routines which are normally carried
out during campaigns, six-monthly intervals, or multiples thereof, are preferred.

All non-routine and corrective maintenance work orders shall be raised by the Asset Team
Instrument Supervisor and stored in the EPMARS system, refer EPMARS Procedures P150
and P151, against the lowest asset level in EPMARS, i.e. against the specific equipment tag if
possible and not against the equipment package or station. Corrective work orders shall,
where appropriate, be assigned a 'T#' priority code and an associated planned completion date
that are appropriate, in order to maintain equipment asset integrity. The progress of corrective
actions shall be monitored on this basis.

SCHEDULE MAINTENANCE AND INSPECTION

The Asset Holder has the responsibility for planning and scheduling all calibration and
maintenance activities. The calibration activities are normally included in the area plans (IAP,
90 Day Plan and 14 Day Schedule). Corrective actions are normally scheduled in the 14 Day
Plans.

Deviations from the due dates for maintenance activities registered in EPMARS, shall be
subject to the conditions of the Maintenance and Inspection Activity Variance Control
Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

The PM routines and corrective activities are executed by the Asset Holders and the Campaign
Group, utilising contract resources where required. Reporting on maintenance activities is
through Equipment History in EPMARS and via calibration reports, if required, according to
the relevant calibration procedure.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

Test results are reviewed by the Instrument Supervisor to identify any defects and to ensure
that the activities have been carried out correctly. Corrective work orders are raised for the
repair of defects. From the analysis of calibration results by the Control and Automation
Support Group, Bad Actors shall be identified and assessed individually. Where the actual
accuracy’s are frequently found to be outside the acceptance limits, the design shall be
reviewed and an inherently more accurate design shall be considered.

Any impracticalities or errors noted in PM routines and MCP’s shall be reported to the
Instrument Supervisor for his review and action. This will enable the correction and
enhancement of routines and MCP’s.

ANALYSE AND IMPROVE PROCESS

From the analysis of PM results and Corrective activities by the Control and Automation
Support Group, Metering deficiencies shall be identified and assessed individually.

The results of PM activities for Metering systems shall be reviewed by the Control and
Automation Support Group, on an annual basis during the contract review meetings, to
identify improvements.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Instrumentation shall maintain, review and update generic metering MCP’s.

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RELEVANT STANDARDS

STD 85904/35 Design Basis for Government Gas Pressure Reduction Terminals in
the Sultanate of Oman; January 1987 (Ministry of Petroleum and
Minerals, Department of Gas Affairs).
OP-08 Flow Factor Update.
DEP 32.32.00.11-Gen. Turbine Fiscal Metering Systems for Liquid Hydrocarbon.
P150 Raising a Work Order.
P151 Approving a Work Order.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1021 Calibration of Instrumentation.
PR-1025 Fiscal and Hydrocarbon Accounting Metering.
PR-1024 Calibration of Master Meter Prover for Fiscal Metering.
PR-1099 Metering Flow Factor Update Procedure.
N/A General Crude Oil Metering Manual for Third Party entering into
PDO-pipeline.
BOS/038/94 Production Metering Philosophy.

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4.6. ELECTRICAL EQUIPMENT

ESTABLISH/UPDATE ASSET REGISTER

The Asset Register for electrical equipment is contained within the Corporate Computerised
Maintenance System, EPMARS. In addition to the generic tag details, every tag is linked to
an UNO (equipment unique number). Each equipment type has equipment specific design and
technical details. In some locations, the asset tag number identifies a collection of assets that
form a package grouped together, for example, a gas turbine identifies the collection of
auxiliaries associated with gas turbines, which are the turbine, generator, lube oil pumps and
coolers. In other locations, the asset tag number identifies the individual package such as
transformers, circuit breakers, protection relays and switchboards.

Initiating the update of the Asset Register is normally carried out by the Asset Team Electrical
Supervisor. For updates resulting from projects however, the Project Engineer will provide
the required data, in accordance with EPMARS Practices and Procedures.

RANK BY CRITICALITY

The CDFP defines which assets are to be entered into EPMARS as a preliminary form of
ranking. Those assets that are registered in EPMARS are then subjected to a more formal
ranking based on the Corporate methodology for assessing risk.

All electrical equipment items registered in EPMARS are considered as 'Critical', as any
failure will result in a loss of asset integrity of the system, cause oil deferment and/or restrict
cash flow.

DEVELOP MAINTENANCE REQUIREMENTS

Maintenance activities, as defined in terms of what needs to be performed, why they need to
be done and when they need to be carried out, in order to achieve the agreed integrity,
reliability and availability targets for each asset group. Maintenance requirements are
developed and detailed in the Electrical Maintenance Management Manual (EMMM), utilising
an appropriate strategy for each asset group. Several types of maintenance approach are
available:

- Planned Preventative Maintenance.

- Condition Based Maintenance.
- Corrective Maintenance.

Generally, with the exception of Overhead Line (OHL) live line washing, preventive
maintenance of all electrical equipment is calendar based. The maintenance frequency is
based on the manufacturer's recommendation and experience gained though continuous review
of performance and breakdown records. Realignment of calendar based activity of electrical
auxiliaries are necessarily done to suit run hour based intervals applied for the major item for
maintenance planning on a package or associated electrical equipment of major equipment or
associated power system equipment of production facility to co-ordinate with, and in most
cases is determined by, the requirements of the major equipment or facility.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

A complete inventory of the routine maintenance and inspection routines and their frequency
is stored, in the form of WSN's and MCP's, in the Activity Register of EPMARS.

Non-routine and corrective maintenance work orders shall be raised by the Asset Team
Electrical Supervisor and stored in the EPMARS system, refer EPMARS Procedures P150 and
P151. Corrective action maintenance of Over Head Lines is derived from the inspection
report submitted by the contractor. Corrective work orders shall, where appropriate, be
assigned a 'T#' priority code and an associated planned completion date that are appropriate, in

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order to maintain equipment asset integrity. The progress of corrective actions shall be
monitored on this basis.

SCHEDULE MAINTENANCE AND INSPECTION

The Asset Holder has the responsibility for planning and scheduling the inspection and
maintenance activities. The timing and scope of these activities should be aligned with the
due dates and activity requirements recorded in EPMARS, for each equipment item.
Inspection and maintenance activities are included in the area plans (IAP, 90 Day Plan and 14
Day Schedule), which are used by the Inspection Group to co-ordinate the inspection activities
and also by the Asset Holders and Campaign Group to co-ordinate the preparation of
equipment for inspection and its subsequent return to service.

Deviations from the due dates for maintenance activities registered in EPMARS, shall be
subject to the conditions of the Maintenance and Inspection Activity Variance Control
Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

Four distinct groups of electrical equipment are identified:

A) Rotating Equipment (Motors, Generators and Turbines)

Condition Monitoring Teams carry out analysis of critical equipment on a monthly basis and
on completion of major maintenance or overhaul work. The Asset Holder is responsible for
ensuring that analysis of the observations is carried out and that reports are compiled and duly
submitted.

Major overhauls are planned from the information received from boroscopic inspections
carried out during the yearly and three yearly service routines. Additional data is then used to
determine the optimum time to carry out the work, depending on the asset type, refer to
Section 4.4 Rotating Equipment.

Routine services, which are detailed in MCP's, are executed by either the Asset Holders, the
Campaign Group, or by contractors. Refer to section 5.12 of the EMMM.

B) Hazardous Area Equipment.

Hazardous Area equipment is identified in EPMARS and subjected to 2 yearly preventative

maintenance, which is carried out by the Campaign Group, refer to section 5.8 of the EMMM.

C) Electrical Scada System.

Refer to Section 4.5.2. Instrumentation, Process Control.

D) Transmission and Distribution Systems (Transformers, OHL's, Switchgear, etc);

This category covers all the remaining electrical equipment, including 132 kV (HV) through
220V (LV) systems. Routine maintenance and inspections for this type equipment are detailed
in the equipment MCP's and are executed by either the Asset Holders, the Campaign Group or
by contractors. Refer to section 5 of the EMMM for maintenance details.

Electrical relay testing shall be included in the maintenance schedule programme, as detailed
in PR-1101 Electrical Protective Systems. The test records shall be held by the Asset Team
Electrical Maintenance Supervisor. In order to ensure functionality, testing of each type of
relay shall be carried out, as prescribed by the relevant MCP, which shall be approved by the
CDFP Electrical Equipment Maintenance. Maintenance record sheets shall be prepared for
recording the test results. Testing of electrical protection relays should be scheduled to co-

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ordinate with circuit breaker maintenance and any other work required to be carried out on the
main package.

Live line cleaning work on 132kV and 33kV OHL's is carried out periodically, based on
condition, refer 132 kV and 33kV OHL Live Line Washing Performance Monitoring
Procedure PR-1026.

Thermographic or partial discharge tests on switchboards, circuit breakers and over head lines,
should be part of a regular predictive maintenance programme. The inspection should be
carried out as part of the 6 monthly and yearly inspection programme, as detailed in
EPMARS.

Remedial actions required to remedy equipment deficiencies are proposed to the Asset Holder
include the latest suggested completion date, and where appropriate a 'T#' priority code, in
order to maintain asset integrity. Remedial work orders (correctives) are executed by the
Asset Holder or the Campaign Group. Reporting on maintenance activities is through
Equipment History in EPMARS.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

The impact of carrying out the maintenance routines, such as asset availability, reliability and
efficiency, is highlighted by performance indicators. The intention is to be able to
demonstrate that the maintenance routines contain the correct elements and are done at the
correct frequency, to ensure that integrity of the assets is being maintained.

ANALYSE AND IMPROVE PROCESS

The following Performance Indicators exist for Electrical Protection Relay testing, refer
Corporate Indicator of Asset Integrity Compilation Procedure PR-1012, to measure the
compliance to and the effectiveness of, the maintenance process:

- Number of tests actually carried against number of tests due.

- Actual versus target reliability.

Loss of plant or equipment is normally reported through the Electrical Fault Reporting
System, as stipulated in ESOP-18 of Electrical Safety Operational Procedure SP-1108 and
Electrical Equipment Fault / Failure Report as detailed in section 3.6 of Electrical
Maintenance Management Manual (EMMM). The follow up of any recommendations made
shall be carried out by the Asset Holder and reported to the CDFP. The Discipline Engineer
shall ensure that an investigation is carried out, to establish the cause of any fault and
subsequently implement any recommended measures required to prevent any reoccurrence.
Loss of power supply is similarly reported by utilising the Electrical Fault Reporting System,
as detailed in ESOP 18 of Electrical Safety Operational Procedure SP-1108.

Equipment failures and damage shall be reported in EPMARS work history. Work orders are
generated and assigned to the relevant team for investigation and action. On completion of
the work, all actions taken are reported in EPMARS equipment history.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

The CDFP Electrical Equipment shall maintain, review and update the electrical equipment
MCP's.

RELEVANT STANDARDS

Electrical Maintenance Management Manual (EMMM)

SP-1104 Electrical Safety Rules. (ERD-64-02)
SP-1108 Electrical Safety Operational Procedures (ERD-64-07, ESOPs 1-25).
PR-1181 to 1219 Switch gear Operating Procedures.(SOP)

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PR-1224 to 1231
P150 Raising a Work Order.
P151 Approving a Work Order.
PR-1005 Maintenance and Inspection Activity Variance Control.
PR-1012 Corporate Indicator of Asset Integrity Compilation.
PR-1026 132 kV and 33kV OHL Live Line Washing Performance Monitoring.
PR-1101 Electrical Protective Systems.

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4.7. MARINE EQUIPMENT

ESTABLISH/UPDATE EQUIPMENT REGISTER

All Terminal Marine

Equipment is registered in
the EPMARS database. This
register of marine equipment
forms the scope of routine
maintenance work for the
Marine Maintenance
Contractor. Because the
Marine Equipment is
different from other
equipment, it is classified
differently in the Equipment
Register. See Fig 1. Marine
Operations Equipment means
tanker loading/unloading
facilities and consists of
Single Buoy Moorings
(SBMs) and Conventional
Buoy Moorings (CBMs).
Crude Oil Operations
Equipment is the SBMs 1 &
2. Product Operations Equipment is SBM3 and the two CBMs.
The SBM and CBM equipment includes the associated pipelines
and subsea hoses from the shore to the SBMs and CBMs and the
floating hoses from the SBMs and CBMs to the tanker. Support
Equipment means Pollution Control Equipment, Specialised
Maintenance Support Equipment, and Navigational Aids. See Fig
1. EPMARS Procedure PO-161 applies for new equipment. As
detailed in ERD-10-01, all pipelines and hoses are classified as
Piping Class 1 because of the severe economic and environmental
consequences of their loss of containment. This classification is
registered in EPMARS. Corrosion monitoring data from the
offshore pipelines is stored in the Pacer-CM Asset Register.
Corrosion monitoring data for the other offshore equipment is
stored in the Terminal Central Files.

RANK BY CRITICALITY

All Marine Crude Oil Operations Equipment is ranked 'Critical- Category 1'. A failure in this
equipment can result in loss of containment and/or loss of structural integrity. Either will
immediately reduce the Company’s crude oil export capacity. Th Maintenance Support
Equipment is also ranked as 'Critical- Category 1'. This equipment is necessary for the
execution of the normal maintenance activities and the immediate restoration of the offshore
equipment after failure. There is no readily available substitute for this maintenance support
equipment.

Failure of the pollution control equipment can seriously damage the Company’s reputation and
is ranked as ‘Critical- Category 2'. The Company is the national resource for this equipment
and is committed to providing pollution control assistance to other parties in the region.
However, failure of this equipment will not normally jeopardise the Company’s crude oil
export capacity. The product export/import SBM (SBM3) is ranked as ‘Critical- Category 2.

Other Marine operating equipment such as the CBMs and other support equipment such as
navigational aids are classified as ‘Critical- Category 3’.

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DEVELOP MAINTENANCE REQUIREMENTS

Because all Marine equipment is ranked as critical, the maintenance and inspection
requirements are the same for each of them. The differentiation between Category 1,
Category 2, and Category 3 determines the maintenance response in case of equipment failure.

The CDFP assures that the maintenance and inspection plan is executed for each piece of
Marine equipment. This plan, including all activities and their cost, shall be issued to the
Asset Holder for approval, prior to budget preparation. The annual plan to maintain the
integrity of the equipment will include details of all activities for the forthcoming year, whilst
the general plan for the equipment maintenance and inspection shall include all major
activities for five years. The Asset Holder approves the annual and general plan and commits
to raising the required budget funds.

LIST AND STORE MAINTENANCE AND INSPECTION REQUIREMENTS

EPMARS is used to generate and store work orders for all routine maintenance and inspection
activities performed on Marine equipment. This includes equipment inspection/maintenance
above the water line, equipment inspections/remedial work below the water line, underwater
piping inspections, support equipment maintenance, marine hose changeouts, and marine
lifting equipment inspection and changeout.

PACER-CM is used to record inspection and corrosion data, and provide condition assessment
and remnant life. This is based on assessed corrosion rates, measured corrosion rates and
remaining wall thickness, versus design code requirements. Refer Pacer-CM User Support
Guide.

IDAS is used to store the equipment drawings.

SCHEDULE MAINTENANCE AND INSPECTION

The Marine Maintenance Contractor is responsible for submitting a 90 Day Maintenance and
Inspection Plan, and a 14 Day Maintenance and Inspection Schedule.

Marine Equipment maintenance and inspection activities submitted by the Marine

Maintenance Contractor are included in the Terminal plans (IAP, 90 Day Plan and 14 Day
Schedule). For activity scheduling, reference is made to the Planning Process Description
Manual.

Deviations from the due dates for Offshore Equipment maintenance activities and corrective
actions registered in EPMARS are subject to the conditions of the Maintenance and Inspection
Activity Variance Control Procedure PR-1005.

PERFORM MAINTENANCE AND INSPECTION

Routine Work

The Marine Maintenance Contractor personnel typically execute routine Marine Equipment
maintenance and inspection activities, as per the EPMARS assigned tasks and frequencies.
The Contractor is responsible for reporting activity completion, findings, and
recommendations for repair work.

Repair Work

Repair work is divided into three categories- 1) Breakdown or Emergency work, 2) Scheduled
Repairs or Overhauls, and 3) Improvements. All repair work is covered by an EPMARS
Corrective work order. Repair Work for execution by the Maintenance Contractor is initiated
by filling out an Internal Work Request (IWR) form and entering it into EPMARS. A
Corrective Work Order is then issued by and stored in EPMARS. The Marine Operations

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Team is responsible for approving the Corrective Work Order, refer to EPMARS Procedures
P150 and P151. A Corrective Work Order shall be assigned a 'T#' priority code and a planned
completion date. The progress of the corrective action shall be monitored on a criticality and
completion date basis. If another contractor performs the corrective work through a Work
Order, then an EPMARS ‘dummy work order’ is raised. The Marine Maintenance Contractor
attaches the other contractor’s to the dummy work order for approval. This provides for
approval and monitoring of the work.

General

EPMARS supports the execution of maintenance and inspection activities by providing work
details on system screen displays or WON print outs. For routine work, MCP details can be
printed out as required. Furthermore, EPMARS is used to update and monitor the progress of
these activities and to close out the WON when an activity is completed. As part of closing
out an activity, expended working hours and work history details are entered in EPMARS
against the relevant WON and/or tag/UNO. Correct progression and completion of a WON
and associated data quality issues are the responsibility of the Marine Maintenance Contractor.
If any non-conformity is found during routine maintenance or inspection activities, the Marine
Maintenance Contractor shall review the criticality and scope of the repair work. If necessary,
the Marine Maintenance Contractor shall raise a new IWR in EPMARS. For further
information refer to EPMARS Procedures P152, P153, P154, P156 and P160.

ANALYSE PERFORMANCE OF MAINTENANCE ACTIVITIES

EPMARS has standard reports, for the retrieval of data, to allow detailed analysis to be carried
out. The analysis of data on selected equipment and/or work execution performance, will be
the responsibility of the Discipline Supervisor. The CDFP will be responsible for carrying out
overall equipment type performance analysis, in order to maintain an optimal maintenance
strategy selection and WSN and MCP portfolio. If any special EPMARS reports are required,
the CMS Support Section should be contacted for assistance.

Pacer-CM also has a reporting tool, called 'Infomaker', which can be made available for users.
The CMS Support Section, OTB/1, should be contacted for further details.

ANALYSE AND IMPROVE THE PROCESS

The CMS Engineer, OTB/1, who is the system custodian of EPMARS, Pacer-CM and Schema,
is responsible for regularly reviewing and improving the Computerised Maintenance Systems
data integrity and the quality of user support. OTB/1 will therefore regularly discuss these
issues with Discipline Supervisors, Planners, CDFP's, and system owners.

MAINTAIN/UPDATE GENERIC MCP REGISTER PER ASSET TYPE

All MCP's are stored in EPMARS, but can only be viewed by either printing one specific
MCP, or all MCP's, for a given WSN. Changes to MCP's shall be authorised by the relevant
CDFP and updated in EPMARS by the CMS Support Section, OTB/1, upon request. For
further details refer to EPMARS Procedure P162.

RELEVANT STANDARDS

Corporate Operations 12/96

Functionality Specification
for Pacer-CM.
Planning Process Description 6/97
Manual, Version 6.0.
DEP.70.10.90.11-Gen. Spare Parts Manual.
PR-1005 Maintenance and Inspection Activity Variance Control

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EPMARS User Guide.

EPMARS Codes Guide.
EPMARS Practices and Procedures Manual Master
Directory. Index of Procedures and Directory
Distribution.
Procedure PO-120 EPMARS User Registration.
Procedure P-150 Raising a Work Order.
Procedure P-151 Approving a Work Order.
Procedure P-152 Work Order Time Reporting and Job Progress Reporting.
Procedure P-153 Reporting Requirements for Supervisors.
Procedure P-154 Work Order Scheduling Activity.
Procedure P-156 Inspection Work within EPMARS.
Procedure PO-161 MMS Asset and Activity Registration.
Procedure PR-1032 EPMARS Approval for Work Specifications (WSN) and
Maintenance Craft Procedures (MCP).
Procedure P-163 EPMARS Fallback.
#Practice P-100 Raising a Work Order.
#Practice P-101 Approving a Work Order.
#Practice P-102 Work Order Time Reporting and Job Progress Reporting.
#Practice P-103 Reporting Requirements for Supervisors.
#Practice P-104 Work Order Scheduling Activity.
#Practice P-106 Inspection Work within EPMARS.
*Procedure P-130 Equipment Movements.
*Procedure P-131 System Supervisors Work Outline.
*Procedure P-132 Data Loading / Validation Activity.

#To be integrated within the Procedures and/or User Guide during 1999.

*Only required for system support staff in OTB/1 section.

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5. APPLICATION AND STEP-OUT APPROVAL

5.1. APPLICATION

The Maintain Surface Facilities Code of Practice is applicable to all commissioned assets
under the control of the Product Flow Asset Managers. As such, the COP and the associated
Procedures, guide-lines and specifications are mandatory and shall be adhered to by all
maintenance activity executors.

5.2. STEP-OUT APPROVAL

Typically, rules governing deviation from the requirements specified in the COP and the
associated Procedures, Specifications and Guide-lines are covered in the discipline specific
sections of the documents. In general however, these deviations are covered by the following:

DEVIATION TYPE PROCEDURE REFERENCE

Change in the timing of a Activity Variance Control Procedure PR-1005.
maintenance or inspection task.
Operation outside the design Operation Procedure Temporary Variance PR-
envelope. 1001e.

Operations Variance and Change Control PR-

1001x.

Facilities Change Proposal PR-1001a.

Temporary Override of Safeguarding System

Procedure PR-1001c

Trip/Alar,/SCADA Settings Change Procedure

PR-1001b

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APPENDICES
A1. GLOSSARY OF TERMS, DEFINITIONS AND ABBREVIATIONS

Asset Register A record listing and detailing equipment.

Availability The proportion of a given time interval that an item or system is able to fulfil its
function.

Breakdown Work carried out on equipment to address a defect which prevents the equipment from
Maintenance being able to fulfil its function.

Campaign Maintenance activities carried out by roving maintenance teams. These activities
Maintenance have a periodic frequency of at least 6 months.

CDFP Corporate Discipline Focal Point.

CFDH Corporate Functional Discipline Head.

CMS Computerised Maintenance System.

Corrective Work carried out on equipment to address a defect which does not immediately
Maintenance prevent the equipment from being able to fulfil its function.

DCS Distributed Control System.

EDMS Electronic Data Management System.

EMA Electronic Materials Administration System.

EPMARS Exploration and Production Maintenance Administration and Reporting System.

ESD Emergency Shutdown.

F&G Fire and Gas System.

FMEA Failure Mode and Effect Analysis.

IAP Integrated Activity Plan.

IDAS Integrated Drawing and Information System.

IPF Instrument Protective Function.

IWR Internal Work Request.

MBS Microprocessor Based System.

MCP Maintenance Craft Procedure.

MFL Magnetic Flux Leakage.

MOS Maintenance Override Switch.

OHL Overhead Line.

Pacer-CM Computerised Corrosion Management System.

Planned Maintenance The maintenance organised and carried out with forethought, control and the use of

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records, to a pre-determined plan.

PLC Programmable Logic Controller.

PM Preventative Maintenance Routine.

Reliability The ability of an item to perform a required function under stated conditions for a
stated period of time.

Reliability Centred A structured and auditable method for establishing the appropriate maintenance
Maintenance (RCM) strategies for an asset in its operating context.

Risk Based Inspection An auditable method for establishing the frequency of equipment inspection, based on
(RBI) the combined effect of the probability of the occurrence of an undesirable event and
the magnitude of the event.

Routine Maintenance Maintenance work of a repetitive nature which is undertaken on a periodic basis.

SCADA Supervisory Control and Data Acquisition.

Scheduled Preventative maintenance carried out to a pre-determined interval of time or number

Maintenance of operations, e.g. run hours.

SPIR Spare Part Interchangeability Record.

UNO Equipment Unique Number.

WON Work Order Number.

WR Work Request

WSN Work Specification Number.

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