Working with Nitrogen UKCS-SOP-018

Contents

Authorisation for Issue

Amendment Record
Amendment Summary
Distribution List
Preface

Paragraph Page
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1 Why Nitrogen is Used 1

2 Safe Working With Nitrogen 1

2.1 Procedures 1
2.2 Stored Energy 1
2.3 Pressure Protection 2
2.4 Nitrogen Venting and Depressurisation 2
2.5 Risk Assessments 2
2.6 Accountabilities 2
2.7 Isolations and HP/LP Interfaces 3
2.8 Installation Emergency Shutdown 5
2.9 Leakage Rates and Repair of Leaks 5
2.10 System Pressurisation 5
2.11 Guidance on Barriers 5
2.12 Test Packs 6

3 Shift Handover 6

4 Bunded Area Procedure 6

Addendum 1 Liquid Nitrogen Spillage Containment Procedure

Addendum 2 Nitrogen Leak Test Checklist

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 Working with Nitrogen UKCS-SOP-018

Authorisation for Issue

Issue Authority
Name: John Watson

Signature: ________________________________________________

Date: ________________________________________________

Position: Operations Delivery Team Leader, GFU

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Technical Authority
Name: Dave Wall

Signature: ________________________________________________

Date: ________________________________________________

Position: Operations Team Leader, CNS Gas, ELEA

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 Working with Nitrogen UKCS-SOP-018

Amendment Record

For Audit Use

Amendment Incorporated By
Checked
Number
Name Signature Date Signature Date
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AMOSAF.171

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 Working with Nitrogen UKCS-SOP-018

Amendment Summary

Issue No Date Description

Issue 1 September 2001 First issue.
Issue 1/AM01 March 2002 Paragraph 2.3 amended to reflect change in
procedure. Initially full flow relief PSV protection
was mandatory; this has now been relaxed. If full
flow relief PSV protection is not being provided,
then a Stage 2 risk assessment must be
completed.
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Minor changes to Paragraphs 2.6, 2.7, 2.10 and

2.11 to improve clarity of document.

March 2002 Issue 1/AM01 vii/viii

 Working with Nitrogen UKCS-SOP-018

Distribution List

Holders of Controlled Hard Copy

Copy Copyholder Location

01 Data Control Centre (DCC) ODL, Aberdeen

Virtual Copyholders

Copy Copyholder
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01 Document Issue Authority (John Watson)

02 Document Technical Authority (Dave Wall)
03 EoS Document Controller (Dave Taylor)
04 EoS Operations Excellence HSE Consultant (David Egan)
05 OOE, Magnus
06 OTL, North West Hutton
07 OTL, Thistle
08 Thistle/NW Hutton Field Support Team Leader (Colin Browning)
09 BSG SMS Co-ordinator (Peter Malcolm)
10 MNS SMS Co-ordinator (Peter Faulkner)
11 MNS SMS Co-ordinator (Peter Thompson)
12 MNS SMS Co-ordinator (Carl Thomessen)
13 MNS SMS Co-ordinator (Justin Haigh)
14 CNS SMS Co-ordinator (Jim Blacklaws)
15 NBU SMS Co-ordinator (David Robertson)
16 NBU EPU SMS Co-ordinator (David Egan)
17 NBU SMS Co-ordinator (John Beaumont)
18 NSI SMS Co-ordinator (Ann Rosbrook)
19 SBU SMS Co-ordinator (Malcolm Watson)
20 SBU SMS Co-ordinator (Simon Robinson)
21 MNS SMS Co-ordinator (Bruce Morrison)

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 Working with Nitrogen UKCS-SOP-018

Preface

Review and Update

This document will be subject to 12-monthly review and update, when document holders will
have the opportunity to express opinions and suggest improvements.
However, the document control system allows for continuous update of this document. As
such, any user may at any time identify an error or suggest an improvement using an
Amendment Proposal proforma which is available electronically on the UK Upstream SMS
website, from the Data Control Centre (DCC) Supervisor or from the Technical Authority.
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All holders of this document are registered so that they can be sent updates and be kept
informed of changes or reviews.

Responsibility of Copyholders
It is the responsibility of the registered copyholder of controlled hard copy versions to
maintain the accuracy of the document by ensuring that all updates are promptly
incorporated and acknowledged.
Furthermore, the registered copyholder of controlled hard copy versions must at all times
maintain custody of this document unless prior approval is given by the relevant
Technical Authority.
The roles and responsibilities of copyholders and ‘virtual’ copyholders are detailed in Section 1
of the Document Control Procedure (UKCS-DCM-001).

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 Working with Nitrogen UKCS-SOP-018

1 Why Nitrogen is Used

Nitrogen is used in the following offshore operations activities:
• Purging/inerting to gas or air-free equipment and so avoiding the potential for an
explosive mixture
• Leak testing to demonstrate the integrity of the hydrocarbon envelope prior to the
introduction of hydrocarbons
The advantages of using nitrogen are:
• The oxygen content is reduced to avoid an explosive mixture when hydrocarbons are
introduced
• The system is tested at, or close to, its working pressure with a gas, closely
simulating ‘live’ conditions. This also allows instruments to be calibrated or checked
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• Valuable production time is saved by being able to repair leaks prior to the ‘startup’
date and without the requirement to gas free
• Does not wet equipment surfaces and so reduces corrosion potential
• Used with helium tracer leak detection is reliable

2 Safe Working With Nitrogen

2.1 Procedures
BP will require that every leak test has a leak test procedure that will include:
• A written procedure for the leak test detailing test pressures
• Marked up Piping and Instrumentation Diagrams (P&IDs) showing the leak test
envelope, including valves which are to be locked and controlled via BP’s isolation
procedures and the position of all valves within the leak test boundaries

2.2 Stored Energy

Introducing nitrogen to a system introduces a large energy source, far greater than the
energy stored in an equivalent liquid leak test. To minimise this stored energy, vessels
which normally operate with a liquid level should be water filled (ensure water filling of
the vessel is acceptable with respect to corrosion and scaling) prior to pressurising with
nitrogen. Joints which operate in a liquid environment will be tested for water leaks, and
joints operating in a gaseous environment will be tested with nitrogen.
Nitrogen should not be used for pressure testing/strength testing. All pressure testing
should be done with a liquid medium. Prior to conducting a leak test, the pipework and
vessels in question must have been previously hydraulically tested to 1.5 times design
pressure. This hydraulic test will probably have been done during the initial Installation
build and for many Installations will be from many years earlier. Confirmation of system
pressure integrity should be obtained from the inspection records to gain assurance that
it is all right to leak test.

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UKCS-SOP-018 Working with Nitrogen

2.3 Pressure Protection

When completing a leak test or conducting a system purge, three levels of managing
pressure protection should be considered.
There will be a Pump Operator who will be in radio contact with the Leak Test
Supervisor who will monitor system pressure. The pumping unit will be manually shut
down on the instruction of the Leak Test Supervisor. The leak test crew should have a
written procedure for radio protocol.
There will be an automatic pump trip (Overpressure Protection Device (OPPD)) which
will shut down the pumping unit. The OPPD will be located close to the injection point
so that it can monitor the highest pressure that will be seen in the Installation system.
Full flow pressure relief will be available via Pressure Safety Valves (PSVs). It is
acceptable and appropriate for the PSVs on the Installation system/plant to be used for

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this purpose. However, if full flow pressure relief is not available via a plant system, then
consideration should be given to the use of temporary PSVs supplied by the leak test
contractor. If full flow pressure relief is not provided, then a Stage 2 risk assessment
should be completed, and assurance gained that there is sufficient control in place to
manage the HP/LP interface.
If it has been identified that the leak test contractor will have to supply PSVs,
consideration should be given to the location that these PSVs would vent to in an
emergency. The vent location should be surveyed and approved by the Installation Area
Authority with guidance from the leak test contractor on expected nitrogen plume.

2.4 Nitrogen Venting and Depressurisation

If possible, the Installation flare and vent system should be used for depressurisation
following leak testing. If this is not possible and it is necessary to vent to atmosphere, a
risk assessment of this activity should be conducted and the leak test contractor should
also provide a procedure detailing how their personnel will be protected during such a
depressurisation event.
An emergency depressurisation route should be identified for every leak test. This will
ideally be a remote operated blowdown valve which is an integral part of the leak test
envelope and which will operate automatically on an Installation trip and blowdown
event. If this is not possible, a manual blowdown route should be identified and both the
BP Isolating Authority and the leak test contractor should be aware of its location.
The implications of Non-return Valves (NRVs) in the system should be understood in
relation to pressurisation and depressurisation.

2.5 Risk Assessments

Every individual leak test will be subjected to a risk assessment. The risk assessment
team should include a minimum of the BP Area Authority, the BP Isolating Authority and
the leak test contractors involved in the leak test.
A separate risk assessment should be completed for the operation of the leak test
contractor equipment, which should include the use of temporary PSVs and safe
vent locations.

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 Working with Nitrogen UKCS-SOP-018

2.6 Accountabilities
The BP Area Authority will be accountable for the Installation plant and equipment and
ensuring that BP standards have been applied prior to commencement of the leak
testing activity.
The BP Area Authority will be accountable for managing the overall activity on their
Installation but will be specifically accountable for valve line-up and control of valves.
The leak test contractor will be accountable for their leak test equipment and working to
their company standards and procedures. The leak test crew are normally held
accountable by their companies for valve checks and ensuring valve line-up is as detailed
in the procedure. This will not detract from the accountabilities of the BP Area Authority
with respect to the management of the BP plant and equipment. The BP Area Authority
should ensure that a BP Isolating Authority has checked the position of all valves in the
system prior to the introduction of nitrogen.
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The BP Area Authority will approve the leak test procedure prior to the leak test.
Prior to pressurisation, the BP Area Authority or delegate and Leak Test Supervisor shall
walk through the system to be tested with the marked up P&IDs and verify
the following:
• Battery limits are as specified
• Isolations including valve positions are as specified
• Secondary isolations are as specified
• Injection points are as specified
• Overpressurisation protection and monitoring positions are as specified
• Sufficient provision is made for the rapid and safe depressurisation of a system
should it be required as indicated on the P&IDs
• The test area is adequately barriered off
• Leak test contractor’s relief valve is on line and settings are as specified
• Overpressure protection skid is set to the pre-determined setting
• All precautions specified on the permit are in place

2.7 Isolations and HP/LP Interfaces

Isolations for leak testing are not specifically addressed in the SIRP handbook.
The primary intent of the isolations for a leak test is to prevent pressurisation of
upstream and downstream systems and to ensure that the leak test envelope is
protected from overpressurisation. This in principle demands a different approach to the
isolations detailed in the SIRP handbook, which are targeted at providing a safe working
environment for intrusive maintenance.

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UKCS-SOP-018 Working with Nitrogen

If there is work ongoing on a system that is directly upstream or downstream of the

system under test, this work will be protected by isolations dedicated to that work and
not the isolations that are in place as part of the leak test. The biggest danger is that
during a major Installation outage, standards of isolation for maintenance work may have
been relaxed on the basis of an outer boundary isolation which is being used to isolate
any source of hydrocarbon pressure, the isolations within this boundary may have been
relaxed to single valve isolation.
All isolations should be included as part of the risk assessment prior to commencing the
leak test.
The following key principles should be applied to isolations for nitrogen leak testing:
• The boundary of the leak test envelope must be locked and managed under the
isolation control procedures for the Installation

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• The manual valves in the safety routes, PSVs and depressurisation routes should be
locked under Installation isolation control
• High Pressure/Low Pressure (HP/LP) interfaces (with the exception of interface to
flare and pressure rated closed drains systems) should be protected by double block
and bleed isolation
• Attached HP systems can be isolated by single valve isolation but there must be a
locked open vent path under Installation isolation control to ensure there is no
pressure buildup in the attached system
Note: The following drawing is an example only.

TO OPP CHART
RECORDER

TO FLARE

TO FLARE

LO LO LO

PSV TO FLARE

LO

FROM WELLS
HP SEP
LC

TO LP SEP

LC LC
NITROGEN
INJECTION LO
UKCSSOP018.008

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 Working with Nitrogen UKCS-SOP-018

2.8 Installation Emergency Shutdown

The pumping unit control and shutdown panel should be connected to an Installation
welding socket or other suitable location so that automatic shutdown of the pumping
unit will occur when the platform has an emergency scenario which initiates the
shutdown of the associated power support systems.

2.9 Leakage Rates and Repair of Leaks

The maximum leak rate for BP Installations which will trigger a requirement to effect a
repair is 40scf/year. All leaks detected above this figure shall be recorded.
It is not recommended but if a leak rate above 40scf/year is to be accepted this must be
the subject of an Installation risk assessment and approval of the OIM. As a minimum:
• A repair job must be logged in the maintenance database
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• The joint will be marked and tagged

• All joints will be recorded in an Installation leaks register
• The joint will be checked once every shift until a repair has been effected
Repair of leaks must only be done with the system fully depressurised.

2.10 System Pressurisation

Initial pressurisation of any system must always be performed in a slow and controlled
manner, stopping initially at 5barg or 25% of the final test pressure if the final test
pressure is less than 20barg. The pressure should then be increased in increments
equivalent to 25% of the final test pressure, in order to allow the system to stabilise and
to check all joints and flanges for visible or audible leakage at each step change in
pressure. Pressurisation shall be halted at these intervals (ie 25%, 50% and 75%) and
visual and audible inspection checks carried out. Pressure drop time assessments should
be carried out at each stage to satisfy the BP Area Authority of leak test envelope
integrity. Once system integrity is established then pressurisation will recommence and
continue in 25% increments of the final test pressure, with all checks carried out as
previously stated until an acceptable leak situation has been established at 100% system
test pressure.
If any leakage is detected whilst a system is being pressurised, pressurisation must
cease immediately and that system must be totally depressurised via the approved
venting point and left open to atmosphere. Confirmation that the system pressure is at
0barg must be confirmed by the BP Area Authority or his delegate prior to any remedial
works commencing.

2.11 Guidance on Barriers

Warning signs stating ‘CAUTION – HIGH PRESSURE TESTING – NO ENTRY’ must be
posted at all points where the barriers cross a gangway, door entrance or other access
points. Warning signs must also be posted at regular intervals around the circumference
of the test barriers.

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UKCS-SOP-018 Working with Nitrogen

A minimum safe practical distance for barriers shall be set at a distance where it is
physically impossible for an individual to touch any part of the system under pressure
without crossing the barrier.
A maximum safe practicable distance must be maintained in all circumstances given the
nature and location of the pressurising medium.
The BP Area Authority or his delegate will walk through the system to be tested and
agree the location of all of the barriers to ensure the above standards are satisfied.
Tannoy announcements should be made prior to commencing the leak test and at
regular intervals throughout the leak test programme.

2.12 Test Packs

Test packs should be completed at the end of the job and a copy held by the Installation

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for 1 year after the leak test has been completed.
The completed test pack shall include the following information:
• Marked up P&IDs showing the detected leaks location
• Certificate of test completion
• Leak description reports
• Pressure recorder chart (where applicable)

3 Shift Handover
At every shift change the leak test contractor will be expected to conduct a verbal and
written account of the previous shift’s operations. The oncoming BP Isolating Authority
for the area of plant under leak test must attend the shift handover.
The shift handover period should include (when appropriate) a complete ‘walk through’
of the systems under test in order to identify strategic areas or points.

4 Bunded Area Procedure

Containment of the pumping unit and nitrogen tanks is required to insulate the steel
deck from the extremely low temperature of the liquid nitrogen (-196°C) and so protect
the steel deck from any shrinkage and subsequent cracking.
Addendum 1 details the containment standard recommended by BP.

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 Working with Nitrogen UKCS-SOP-018

Addendum 1
Liquid Nitrogen Spillage Containment Procedure

The purpose of the containment facility is to fully contain any liquid nitrogen in the unlikely
event of a spillage from the bulk storage vessels, cryogenic hoses, pipework and connections.
The containment area insulates the steel deck from the extremely low temperature of the liquid
nitrogen (-196°C) and therefore protects the steel deck from any shrinkage and subsequent
cracking. The containment facility should be large enough to house the nitrogen storage tanks,
the nitrogen pump unit and the liquid nitrogen transfer hoses that connect these two items.
A charged fire hose should also be onsite to help vaporise any spillage within the bund.
The following procedure should be followed to ensure compliance with the above:
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(1) Cover the steel deck of the equipment laydown area with timber (scaffold boards).
These should be placed as flat as possible so as not to create a trip hazard to personnel.

Liquid Nitrogen Spillage Containment Procedure

September 2001 Issue 1 Add 1-1
UKCS-SOP-018 Working with Nitrogen

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(2) Build the outer perimeter of the containment facility up by a further two scaffold boards
in height.

(3) Place tarpaulins over the entire area on top of the scaffold boards. Allow the tarpaulin to
drape over the raised boards at the perimeter of the containment facility.

Liquid Nitrogen Spillage Containment Procedure

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(4) To help retain the tarpaulin in position, place further scaffold boards onto the perimeter,
trapping the tarpaulin between the scaffold boards.

(5) The nitrogen equipment can now be placed in position leaving sufficient space between
the units to allow access.

Liquid Nitrogen Spillage Containment Procedure

September 2001 Issue 1 Add 1-3
UKCS-SOP-018 Working with Nitrogen

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(6) Further scaffold boards should be placed around the operating panel (inside containment
facility) to prevent personnel slipping on a wet tarpaulin.

Liquid Nitrogen Spillage Containment Procedure

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 Working with Nitrogen UKCS-SOP-018

Addendum 2
Nitrogen Leak Test Checklist

NITROGEN LEAK TEST CHECKLIST

The following points are the key points that should be applied when working with nitrogen. They have been
extracted from each of the sections in this document:

Nitrogen should not be used for strength testing.

Equipment should have been hydraulically strength tested or have a historical record of this prior to
nitrogen leak testing.
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Check the inspection records to confirm the system pressure envelope integrity is good.
Reduce the volume of nitrogen by liquid filling vessels when possible.
There should be three levels of system pressure protection – manual pressure monitoring and pump
control, automatic shutdown via an Over Pressure Protection Device and full flow PSV relief.
If the leak test contractors temporary PSVs are used, a site survey should be conducted to determine
a safe location for emergency venting.
Ideally, depressurisation should be via the platform flare system.
An emergency depressurisation route should be identified and ideally this depressurisation route will
be remote operated and automatically operated on a platform trip and blowdown event.
Check for NRVs in the system and understand the implications of their position relative to
pressurisation and depressurisation.
Every leak test will be individually risk assessed.
The BP Area Authority is accountable for valve line-up and isolation on BP equipment and for the final
approval of the leak test procedures.
Decanting of nitrogen from one system to another will be subject to a written procedure approved by
the Process Engineering Technical Authority.
The isolations for the leak testing should be reviewed in the risk assessment. Leak test isolations may
deviate from the SIRP procedures as the leak test isolations are not intended to make plant safe for
intrusive maintenance.
The pumping unit shutdown system should be connected to a platform power source that will
automatically trip the unit during a platform emergency.
The recommended maximum acceptable leak rate is 40scf/year.
Leaks should only be repaired with the system fully depressurised.
System pressurisation should be done at an initial low pressure to check for gross leakage followed
by 25% increments of final test pressure.
Barriers should be erected around the leak test site with warning signs at all access points and at
suitable points around the boundary.
Shift handovers will include the attendance of the BP Isolating Authority for the area being tested.

UKCSSOP018.007

Nitrogen Leak Test Checklist

September 2001 Issue 1 Add 2-1/2