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    Cold Cutting

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    Subbu Abu
    Three high potential incidents involving cold cutting occurred over two months for PDO and its contractors. On February 1st, a contractor placed a cold cutter on the wrong pressurized line. On March 4th, a contractor operator was cutting a pressurized gas line and was injured when gas was released. On March 29th, a contractor cut the wrong live oil line during cleaning work. These incidents show the need for vigilance when cold cutting to ensure the correct lines are isolated and cut.

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    © All Rights Reserved
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    Cold Cutting

    Uploaded by

    Subbu Abu
    89 views14 pages
    Three high potential incidents involving cold cutting occurred over two months for PDO and its contractors. On February 1st, a contractor placed a cold cutter on the wrong pressurized line. On March 4th, a contractor operator was cutting a pressurized gas line and was injured when gas was released. On March 29th, a contractor cut the wrong live oil line during cleaning work. These incidents show the need for vigilance when cold cutting to ensure the correct lines are isolated and cut.

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    Three high potential incidents involving cold cutting occurred over two months for PDO and its contractors. On February 1st, a contractor placed a cold cutter on the wrong pressurized line. On March 4th, a contractor operator was cutting a pressurized gas line and was injured when gas was released. On March 29th, a contractor cut the wrong live oil line during cleaning work. These incidents show the need for vigilance when cold cutting to ensure the correct lines are isolated and cut.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    89 views14 pages

    Cold Cutting

    Uploaded by

    Subbu Abu
    Three high potential incidents involving cold cutting occurred over two months for PDO and its contractors. On February 1st, a contractor placed a cold cutter on the wrong pressurized line. On March 4th, a contractor operator was cutting a pressurized gas line and was injured when gas was released. On March 29th, a contractor cut the wrong live oil line during cleaning work. These incidents show the need for vigilance when cold cutting to ensure the correct lines are isolated and cut.

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    © All Rights Reserved
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    You are on page 1of 14

    SAFETY WORK-STOPPAGE

    APRIL 2015

    1
    Safety work-stoppage

    A VERY DISTURBING CHAIN OF EVENTS

    PDO & its contractors have suffered THREE high potential incidents
    involving cold cutting in the last TWO months.

    NOW IS NOT THE TIME


    FOR COMPLACENCY

    2
    Cold cutting incidents
    1

    A contractor was dismantling a redundant flow line when one of its operators
    placed the cold cutter on the wrong / pressurised line.
    (1st February 2015)
    2

    As part of shutdown activities a contractor was performing cold cutting on a 12” HP


    wet gas pipeline, as the operator was about to finish cutting through the pipe,
    pressurized gas (estimated at between 5-10 bar) was released from the cutting
    point hitting and causing him to fall to the ground with injuries to his face.
    (4th March 2015)
    3

    A contractor was engaged in cleaning operations when the Permit Holder decided
    to cold cut a redundant line (not mentioned in the PTW) however, the crew placed
    the cutter on the wrong line causing damage to the line.
    (29th March 2015)
    3
    1 Contractor places cold cutter on wrong pressurised line

    Learning from Incidents


    For PDO staff and contractors

    A contractor was dismantling a redundant flow line when one of its


    operators placed the cold cutter on the wrong / pressurised line.
    (1st February 2015)

    4
    1 Contractor places cold cutter on wrong pressurised line

    What happened :
    On 1st February 2015 at approximately 0800 hours a
    crew was involved in a high potential cold-cutting
    incident, in Yibal Area.

    The crew was mobilised to continue the dismantling


    of the remaining section of the redundant Y-514 flow
    line that was partially completed in previous days.
    The work started after the morning Tool Box Talk
    when the fitter placed the cold cutter on the wrong /
    pressurised section of the newly replaced flow line
    and started cutting the line. Immediately, a member
    of the second crew intervened to STOP the activity
    when he realized the cutter had been placed on the
    wrong flow line.
    The cut mark depth on the flow line was found to be
    ~ 0.5mm of the 4.8mm wall thickness.

    5
    1 Contractor places cold cutter on wrong pressurised line

    Why do we think it may have happened?


     Fitter failed to follow the marking marked for cold cutting.
     The fitter could not distinguish between the lines (the redundant and live line).
     The supervisor did not confirm that the crew has placed the cutter on the required
    line prior to cutting.

    6
    2 Contractor operator cuts through pressurised gas line

    Learning from Incidents


    For PDO staff and contractors

    As part of shutdown activities a contractor was performing cold cutting on a 12” HP wet
    gas pipeline, as the operator was about to finish cutting through the pipe, pressurized
    gas (estimated at between 5-10 bar) was released from the cutting point hitting and
    causing him to fall to the ground.
    (4th March 2015)

    7
    2 Contractor operator cuts through pressurised gas line

    What happened :

    On 4th March 2015 as part of shutdown activities the IP was performing cold cutting on a 12”
    HP wet gas pipeline in the GGP Yibal manifold area. At around 1855 hours, as the IP was
    about to finish cutting through the pipe, pressurized gas (estimated between 5-10 bar) was
    released from the cutting point hitting the IP and causing him to fall to the ground a meter or
    so away. The fire & gas detection set off the emergency alarm and the site was evacuated.
    The Permit Holder who had been supervising the work informed the PDO Area Authority who
    found the IP, gave first aid and sent for the rescue team (ambulance).

    8
    2 Contractor operator cuts through pressurised gas line

    Why do we think it may have happened?


     Five Class A permits were issued to the contractor on 4th March between 7:30 am and 10:30am, each permit
    contained more than one tie-in, in total around 51 tie-ins were grouped into five permits. Isolation certificates
    were not issued with the permits.
     The Permit Holder had completed his allocated work ahead of the schedule, the Lead Piping Manager instructed
    him to start the cold cutting for Tie in 552B, assuming that all the tie-in locations were already fully isolated and
    safe to work. This assumption was shared by most contractor personnel.
     The job was executed without the Permit Holder amending & validating his permit.
     The pressure gauge on the line was not checked prior to commencing cutting the line.

    9
    3 Contractor cold cuts line during cleaning operations

    Learning from Incidents


    For PDO staff and contractors

    A contractor was engaged in cleaning operations when the Permit


    Holder decided to cold cut a redundant line (not mentioned in the
    PTW) however, the crew placed the cutter on the wrong line causing
    damage to the line.
    (29th March 2015)

    10
    3 Contractor cold cuts line during cleaning operations

    What happened :

    At about 1415 Hrs, Mechanical crew were engaged in site cleaning activity (shifting and
    removal of cut pipes). During the process the Permit Holder decided to cold cut the
    redundant MM265 line (which was not mentioned in the permit) however, the crew placed
    the cold-cutting device on the live oil flowline MM264 which was running parallel to
    MM265. The crew stopped the activity after seeing drops of oil coming out from MM264.

    11
    3 Contractor cold cuts line during cleaning operations

    Why do we think it may have happened?


     The crew could not distinguish between the lines
    (the redundant and live line).
     The permit holder did not confirm that the crew
    has placed the cutter on the required line prior to
    MM264
    cutting.
     The job was executed without the Permit Holder
    amending & validating his permit. MM265

    12
    Intervene

    Safety day video clip: Intervene

     http://pdointernet/hseforcontractors/SafetyDay2015/Safety%20Day%202015.mp4

    13
    Discussion Points

    Discussion:

    • How do you ensure you are cutting the correct flowline/pipeline?

    • How do you know if the line is live or not?

    • What are the topics to be discussed in the Toolbox Talk before cold-cutting activity takes place?

    • How do you find out the correct steps for the cold-cutting activity?

    • Do you have a valid permit to work/authorization to start cold-cutting activity?

    • Are the flowlines to be worked on marked clearly and correctly?

    • How do you supervise the cold-cutting task?

    • Are you familiar with the cold-cutting procedures PR-1146 & PR-1991?

    14

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