Page 153 - Pipeline Risk Management Manual Ideas, Techniques, and Resources

6/130 Incorrect Operations Index
Table I Ideally, the operator should know exactly what knowledge he is
expected to possess. The test should confirm that he does
Qirulity level of indeed possess this knowledge. If the test indicates deficien-
the information Description cies, he may be retested (within reasonable limits) until he has
mastered the body of knowledge required for his job. Testing
Level D Information is collected from existing utility programs vary greatly in technique and effectiveness. It is left
records without field activities to verify the to the risk evaluator to satisfy himself that the testing achieves
information. The accuracy or cornprehensive- the desired results.
ness of the information cannot be guaranteed;
consequently, this least certain set of data is the
lowest quality level. Topics Covered Regardless of their specific jobs, all pipeline
Level C Adds aboveground survey data (such as manholes, operators (and arguably, all pipeline employees) should have
valve boxes, posts, and meters) to existing utility some basic common knowledge. Some of these common areas
records. The Federal Highway Administration may include the following:
Office of Engineering estimates that 15-30
percent of level C facility information pertinent Product characteristics. Is the product transported flamma-
to highway construction is omitted or plotted
with an error rate ofmore than 2 feet. ble, toxic, reactive, carcinogenic? What are the safe exposure
Level B Confirmed existence and horizontal position of limits? If released, does it form a cloud? Is the cloud heavier
facilities are mapped using surface geophysical or lighter than air? Such knowledge decreases the chances of
techniques. The Wo-dimensional, plan-view an operator making an incorrect decision due to ignorance
map is useful in the construction planning phase about the product she is handling.
when slight changes to avoid conflicts can Pipeline material stresses. How does the pipeline material
produce substantial cost savings by eliminating react to stresses? What are indications of overstressing?
the relocation of utilities. What is the failure mode ofthe material? What is the weakest
Level A Vacuum excavation is used to positively verify
both the horizontal and vertical depth location of component in the system? Such basic knowledge must not be
facilities. confused with engineering in the minds of the operators. All
operators should understand these fundamental concepts to
help to understand and avoid errors only-not to replace
engineering decisions. With this knowledge though, an oper-
common topics in which all pipeline employees should be ator may find (and recognize the significance of) a bulge in
trained. A point schedule can be developed to credit the pro- the pipe indicating yielding had occurred. All trainees may
gram for each aspect that has been incorporated. An example gain a better appreciation of the consequences of a pipeline
(with detailed explanations afterwards) follows. failure.
Pipeline corrosion. As in the above topic, a basic understand-
Documented minimum requirements 2 pts ing of pipeline corrosion and anticorrosion systems may
Testing 2 pts reduce the chances of errors. With such training, a field oper-
Topics covered: ator would be more alert to coating damage, the presence of
Product characteristics 0.5 pts other buried metal, or overhead power lines as potential
Pipeline material stresses 0.5 pts threats to the pipeline. Office personnel may also have the
Pipeline corrosion 0.5 pts opportunity to recognize a threat and bring it to the attention
Control and operations 0.5 pts of the corrosion engineer, given a fundamental understand-
Maintenance 0.5 pts ing of corrosion. A materials handler may spot a situation of
Emergency drills 0.5 pts incompatible metals that may have been overlooked in the
Job procedures (as appropriate) 2 pts design phase.
Scheduled retraining 1 Pt Control and operations. This is most critical to the employ-
ees who actually perform the product movements, but all
Documented minimum requirements A document that specif- employees should understand how product is moved and
ically describes the body of knowledge that is expected of controlled, at least in a general way. An operator who under-
pipeline workers is a good start for a program. This document stands what manner of control is occurring upstream and
will ideally state the minimum knowledge requirements for downstream of his area ofresponsibility is less likely to make
each pipeline job position. Mastery of this body of knowledge an error due to ignorance of the system. An operator who
will be verified before that position is worked by an employee. understands the big picture of the pipeline system will be
For example, a pump station operator will not be allowed to better able to anticipate all ramifications of changes to the
operate a station until she has demonstrated a command of all system.
of the minimum requirements of that job. This should include Maintenance. A working knowledge of what is done and why
station shutdowns, alarms, monitors, procedures, and the it is being done may be valuable in preventing errors. A
ability to recognize any abnormal conditions at the station. worker who knows how valves operate and why maintenance
is necessary to their proper operation will be able to spot
Testing A formal program should verify operator knowledge deficiencies in a related program or procedure. Inspection
and identify deficiencies before they pose a threat to the and calibration of instruments, especially safety devices, will
pipeline system. Tests that can be passed with less than 100% usually be better done by a knowledgeable employee. Given
correctness may be failing to identify training weaknesses. that many maintenance activities involving excavation could