Design of Inert Gas Systems

February 14, 2013 mycheme

Inert gases, such as nitrogen are used on process plants for
a number of purposes such as purging equipment and
inerting equipment. The most common inert gas used in
industry is nitrogen, but carbon dioxide and argon are also
encountered. Although usually non-toxic, inert gases can
displace oxygen creating an asphyxiating atmosphere. As
the common inert gases are colourless, odourless and
tasteless, they can build up in the atmosphere without the
victim being aware. This makes them very dangerous. This article provides some guidance on safe
inert gas system design.
It should be noted that this is only an introduction to the subject. The reader is advised to seek
professional support when designing an inert gas system.

Why Inert Gases are Used

Inert gases are used to create a non-reactive atmosphere, it must be non-flammable and should prevent
any adverse chemical reaction. For example, providing an inert environment to prevent the decay of
food. Several industrial gases are used for inerting. The most common is nitrogen, as it is cheap
however argon and carbon dioxide are also used. Other inert gases include the other noble gases (i.e.
helium, krypton, neon and xenon) although these are only used in specialized applications.

The main use of nitrogen in the process industries is to purge air or hydrocarbons from equipment
before start-up, during normal operations and during shutdown. It also has a range of other specialist
applications, such as in the manufacture of semiconductors, applications in the pharmaceutics and to
regenerate catalysts.
Argon is much less frequently used than nitrogen because it is more expensive. However in some
applications, nitrogen is insufficiently inert (e.g. nitrogen can cause nitriding of metals), in which case
argon can be applied. Its main use is as a shield gas for welding. For some applications, such as in the
food industry, carbon dioxide is used for inerting. However, its use is limited as it is mildly corrosive
when wet.

Dangers of Inert Gases (Asphyxiation)

Inert gases are dangerous. Whilst these gases are generally non-toxic, they do displace air, making
them asphyxiants. Accidents caused by oxygen depleted atmosphere can be very serious, and

sometimes prove fatal. Normal oxygen content of air is 21% (volume basis). Breathing air at levels
only a few percent below normal will result in impaired judgement. At oxygen concentrations below
10%, there is a risk of asphyxiation leading to death in a matter of minutes.
To make matters worse, there is generally little warning. As nitrogen and argon are both colourless,
odourless and tasteless, the gas can build-up without the victim being aware. In addition, the absence
of carbon dioxide suppresses the breathing reflex. Thus the victim can suffer asphyxiation suddenly
without even realising it.
In addition to asphyxiation, some inert gases present other hazards. Liquid nitrogen can cause cold
burns, whilst carbon dioxide is toxic. Further discussion of these subjects is outside the scope of this
article.

Inert Gas System Design

Introduction
The designer must aim to reduce the dangers of asphyxiation as far as possible. The most effective
approach is to eliminate the hazard completely can the use of an asphyxiant gas be avoided? If the
inert gas has to be used, can the hazard be reduced?
The designer should then consider how to isolate the gas from the working environment, as well as the
use of engineering controls, such as gas detectors linked to system shutdown. Finally, if these options
are not sufficient, the plant needs to develop safe operating procedures. This can be achieved by
protecting workers using Personal Protective Equipment (PPE), supported by safe systems of work.
The following should be considered during the design of the inert gas system.

Mechanical Integrity
Equipment and pipework containing the inert gas should be robust and should meet best engineering
practice. Flanges should be avoided as they can leak. Pipelines should be welded as far as possible.
Equipment and pipework should be pressure tested before use, as well as after maintenance. Any
unused pipelines should be physically disconnected from the live system.
The operating pressure of the inert gas system should be kept as low as possible. In the event of a leak,
this lowers the rate of gas release.

Location
The designer should consider where inert gases are likely to accumulate. Gases that are heavier than
air (such as argon) will settle at floor level and at low points. The release of gases with similar
densities to air (such as nitrogen) will tend to result in localised regions of depleted oxygen. Particular
locations to consider are the following:
1. Gas storage areas

Inert gases are often stored in liquefied form. Spillages of liquefied gas will rapidly vaporise, releasing
large quantities of gas. Ideally, storage areas should be well ventilated and away from working areas.
Access to the gas storage area should be restricted. The area should be equipped with gas monitoring
and display warning signs.
2. Relief and ventilation system outlets
Relief and vent lines should be clearly identified and should be piped to a safe open air location, away
from working areas.
3. Rooms where inert gases are used
Use of inert gases in enclosed areas should be avoided if at all possible. They should be well ventilated
and equipped with oxygen monitoring equipment. Access should be restricted to trained operators,
preferably not working alone.
4. General access areas
General access areas (e.g. corridors) present a particular hazard as there is no means of restricting who
enters. General access areas and inert gases not mix.
Other useful links
Gas pressure drop calculator spreadsheet
Electronic steam tables spreadsheet
Types of Pressure Relief Device

Ventilation
The designer needs to consider the likelihood of an escape of inert gas and whether it will be
adequately dispersed. Inert gas systems which are outdoors rely on natural ventilation to dilute and
disperse the gas. For indoor areas, dispersion has to be done using reliable forced ventilation.
Ventilation rates to disperse the gas may need to be above that required for human comfort. The design
of the ventilation system is not straightforward and the designer is advised to seek professional advice.

Operation and Maintenance

Whilst the hazards from the use of inert gases can be reduced during the design, often they cannot be
eliminated. The remaining hazards must be managed by operating procedures.

Confined Space Working

Confined spaces are areas which are not usually occupied and where asphyxiant gas could build-up. A
common example is a vessel which is normally inerted and needs worker access for maintenance. The
best approach is to avoid entry in the first place for example, it may be possible to clean vessel or
take samples remotely. Unfortunately, this is not always possible.
Confined space working is a potentially dangerous activity and needs to be planned carefully. It is
outside the scope of this note. Before planning confined entry, the reader should seek professional

advice.