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Petroleum Development Oman HLD OTTP handout

Table of contents
Page No.
Mod 14 Equipment Isolation

14.1 Introduction
2

14.2 General requirement for Isolation


2

14.3Devices
3

14.4 Process Isolation


4

14.5 Selection of Device


7

14.6 Isolation of Equipment for maintenance 12

14.7 General Procedure of Isolation


14

14.8 Equipment Isolation


19

14.9 Confine Space Entry Procedure


32

14.10 Preparation for internal work


33

14.11 Work on Tank Roof


34

Mod No. 15 PURGING & FLUSHING

15.1 Purging & Flushing 38

15.2 Water Flushing 46

15.3 Purge procedures 48

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14.1. Introduction

What is isolation?
It is Company policy that maintenance or modification work to process plant requires that the
plant concerned is effectively isolated from all sources of energy and hazardous materials, and
made safe before work is allowed to proceed. Controls are provided for the purpose of plant
isolation to ensure the safety of personnel and the protection of company assets and
environment.

Scope:

To isolate process plant prior to maintenance or engineering work. Under normal


circumstances, this requires that a process unit is shut down, depressurised to atmospheric
pressure, drained, purged free of flammable or toxic gases, and then effectively isolated from
any adjacent systems that may, or may not, remain live during the work.

14.2. General requirements


Isolation of any equipment that may cause a hazard to personnel, the environment or damage
to the company's assets shall be accomplished to provide the safest environment to carry out
any work on that equipment. The method of isolation depends on such factors as the type of
work involved, e.g., of major, routine or minor nature; the properties of the process fluid and
the temperature and pressure of the fluids in the system. To provide the most positive means
of isolation, inserted spades, closed spectacle blinds or blind flanges shall be used. All isolation
work shall be carried out under the Permit to Work System. Work will be authorized by the
Area Coordinator or his delegated representative. However for some minor work such as
replacing a faulty instrument on a vessel, (subject to the approval of the site maintenance and
production supervisors,) the required isolation on liquid containing systems (not gas) may be
effected by closing valves only since isolation failure i.e. leaking valve, poses no greater risk to
personnel while performing the work than while carrying out the spading operation. For work
of longer duration or where fittings and accessories remain removed for an appreciable period,
i.e., overnight or longer, the equipment shall be isolated by spades or blinds. Actuating valves
can only be used for isolation if all motive power of the valve has been physically disconnected
from the actuator. Relying on a switch is not adequate.

The following requirements apply to all isolation:

Competency:
The responsible Supervisor must ensure that the person nominated to do
isolation is competent for the task.

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Security:
Each isolation is to be secured in the required position so that the
accidental release of energy source is prevented.

Labeling:
The isolation is to be labeled with a high visibility “Isolation Label” so that
anyone can immediately see why that isolation is in place, and should not
be tempered with.

Recording:
Isolation is to be recorded on the Permit for the work or on the separate
isolation Certificate. For complex isolation, marked-up P&Ids or line
diagrams should be attached to the isolation Certificate. ALL isolation
work SHALL be carried out under the Permit to Work system.

Integrity:
It is essential that Operators and Supervisors being constantly vigilant
during the work or in the case of a long-term isolation maintain the
integrity of isolations for the entire period of any works by formal auditing
of such isolations at pre-defined intervals.

Hazards:
Hazards SHALL be identified, detailed and controlled by proper use of the
Permit to Work system. Isolation of any equipment that may cause a
hazard to personnel, the environment or damage to the Company's
assets SHALL be accomplished to provide the safest environment to carry
out any work on that equipment.

Authority:
All work SHALL be authorised by the Production Co-ordinator or his delegated
representative.

Method of Isolation:
The method of isolation depends on such factors as the type of work involved, e.g. of
major, minor or routine nature, the properties of the process medium and the
temperature and pressure of the process system.

Block and Bleed:


Double block and bleed arrangements will provide a measure of
protection when used in conjunction with spades or blinds. However,
they should never be considered as an acceptable replacement for
mechanical isolation for major work, unless physical isolation (by
removing pipe work) is agreed.
When the piping and valve arrangement of process equipment does not
allow for double block and bleed, the Production Co-ordinator will
determine if isolation can be safely accomplished by an alternative

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method. In this event, the procedure to be followed will be clearly


illustrated and written on or attached to the Work Permit.

Minor work:
Such as replacing a faulty instrument on a vessel (subject to the approval
of the site maintenance and production supervisors), the required
isolation on liquid containing systems (not gas) may be affected by
closing valves only

Longer duration:
For work of longer duration or where fittings and accessories remain
removed for an appreciable period, e.g. overnight or longer, spades or
blinds SHALL isolate the equipment.

Long term isolations:


For long term isolations where a piece of equipment, or a system, is
taken out of service for a considerable period, e.g. months, yet the
adjacent plant remains live, it is essential that proper records are kept.
(e.g. spade/blind/valve checklist) and a record kept of the status of the
isolation and its continuing integrity. Such isolations SHALL be audited
and checked for integrity at a frequency defined by the Production Co-
ordinator.

Electrical Systems:
All electrical isolations are to be done in accordance with the Electrical
Safety Rules (ESRs) and Electrical Safety Operation Procedures (ESOPs)

14.3. Different devices used for Isolation:


Spectacle blind:
A solid circular plate connected to a circular plate with a hole in it by a straight handle. The
plates are designed to be bolted between flanges on piping and equipment. The first will block
off flow and the second will pass normal flow. The plate shall be thick enough to withstand
the anticipated maximum differential pressure. The advantage of this device is that no
additional mechanical stress is applied to the equipment when it is changed between the open
and closed position.

Spectacle Blind

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Slip Blind or Spade:


A circular flat plate with a handle which can be bolted between two flanges to block off flow.
The handle should extend outside the flanges. The plate shall be thick enough to withstand
the anticipated differential pressure which need not be the flange rating pressure.

Spade

Blind/Blank Flange:

Blind / Blank Flange

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A solid flange which can be bolted to a flanged connection on pipes or equivalent to block off
flow from it. The flange shall be of the same rating.

Block Valve:

A valve which controls the passage of a liquid through a pipe with the intention that it permits
either full flow or no flow.

Bleed Valve:

A small vent valve, usually immediately downstream of a block valve, which can be opened to
release the pressure and to ascertain whether there, is pressure on the downside of the block
valve when closed.

B leed V alve

Abbreviations:

ANSI - American National Standards institute

API - American Petroleum Institute

CC - Corrosion Coupon

CPI - Corrugated Plate Interceptor

DEP - Design and Engineering Practice (SIPM)

DN - Nominal Diameter

ERD - Engineering Reference Document (PDO)

ESD - Emergency Shutdown.

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FB - Full Bore

FIG - Figure

IP - Institute of Petroleum (UK)

LC - Locked-Closed or Level Controller

LG - Level Gauge

LO - Locked-Open

LIC - Level Indicating Controller

LZA - Level Emergency Alarm

NC - Normally Closed.

NO - Normally Open

OHD - Open Hazardous Drain

PdS - Pressure Differential Switch

PIC - Pressure Indicating Controller

PG - Pressure Gauge

RO - Restriction Orifice

SIPM - Shell International Petroleum Maatschappij BV.

Typ - Typical

UZ - Emergency Shutdown

XI - Pig Signaler

14.4 Process Isolation


Wells are closed in for observation purposes.

 Production Programmers together with Area Petroleum Engineering


Teams SHALL determine the actual status of each individual well to
be closed in. This status then determines the procedure to be
followed regarding the associated flow and gaslift lines.
 When a well is to be closed in for less than two months, or is on a
production ‘swing’ list or stopcock, its flow and gaslift lines SHALL
be left partly pressurised (i.e. to station manifold/separator
pressure) ready for use.
 When a well is to be closed in for more than two months and it is
not on a production ‘swing’ list, its flow and gaslift lines SHALL be
suspended and isolated from the well.
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 When a well has no future production / injection potential (e.g. it


has been or is to be abandoned or used as an observation well) its
flow and gaslift lines SHALL be physically removed.
 If there is no future use for the well, the well is suspended from use
by following WSP-71 ‘Suspension of Wells and Completion
Operations’, Manual 2350.

 Suspended flow and gaslift lines, once isolated, SHALL be left with
an inert medium for corrosion prevention purposes.

 If the well is to be kept on the ‘swing list’ or closed in for less than
two months the following steps must be followed:
Ø Close gaslift manifold
Ø Close in the well.
Ø Leave gaslift lines/flowline pressurised to station
manifold/separator pressure.

 If the well is to be closed in for more than two months but SHALL
have future use, the following steps must be followed:

Ø Isolate gas lift from manifold side


Ø Close in all wellhead valves
Ø Depressurise gas lift line to flow line from wellhead end to
station.
Ø Close the location valves of both gaslift and flow line.
Ø Disconnect Gaslift / flowline from Xmas tree.
Ø Install blank flange on Xmas tree.
Ø Flush flowline with potable water (1.5 x line volume).
Ø Purge the flowline with nitrogen until free of liquid.
Ø Install blind flanges on both end of flowline.
Ø Leave 150-kPa nitrogen pressure in flowline.
(Refer the above fig.)

Tagging of Isolation:

Every valve, spade, switch, breaker etc. used in isolation (except for isolation that does not
require isolation certificate) must be marked with the correct type of tag label. Different tags
are available for the isolation of Valves, Spades, and Electrical Equipment.

All tags have three parts. The first part is to be attached to the isolation point. The other two
parts are to be attached to the permit Issue Point copy of the permit or isolation Certificate
and kept at the issue Point until the isolation is removed.

When the isolation is removed the tags that have been removed must be compared with those
at the Permit Issue Point to confirm that all isolation has been removed. The third part of the
tag (the smallest part) is provided to assist in the removal of complex isolation. This part is
kept attached to the middle part of the tag at the issue point until de-isolation is required. The
third parts can be detached and taken to the site by the de-isolator to ensure he only de-
isolates the correct valves/switches.

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Proving of Isolation:

Whenever isolation is complete, the isolator must prove that the area
within the isolation is fully isolated from pressure/electricity. This can
normally be done by checks at vent valves or by the checks to prove
electrical equipment dead required by ESOPs/ESRs. If it is not possible to
check that a pressure system has been de-pressurised without unbolting
a flange, the work part must be aware of the possible pressure hazard.
The Job Safety plan must include clear instructions on controlling the
unbolting of the first flange to ensure that any pressure is released before
bolts have been removed.

Extended Period Isolation:

Extended period isolation (EPIs) are isolations, which must remain


although no work is being done within their boundary. They may be
required for two main reasons:

1) Where work has started but will be suspended for a period of short
time. For example, when awaiting spares for repairs.
2) Where equipment becomes redundant and is to be permanently
isolated.

Unrecorded Isolations:

It is not necessary to record mechanical isolations if BOTH of the following


conditions are met.

1) The isolation is to be done by a competent person from Operation


Department, nominated by the Responsible Supervisor, for the
purpose of calibration or minor repair/replacement work that he will do
himself, and
2) The isolation will be removed before the end of the working period.

Minor repair/replacement work is work that can be done without the


person leaving the worksite. Examples are pressure gauge replacement,
isolation for fault-finding etc.

Use of Locked Valves and Spectacle Blinds for Isolation:

Locked valves are used for safety purposes in process plant, either to ensure that a flow
pathway is maintained (in the case of a relief valve) or a system/vessel is securely isolated from
adjacent processing equipment. Similarly, ‘spectacle’ blinds are used for effecting positive
isolations between vessels and pipe work.
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Process plant that is taken out of service for maintenance, or isolated


long term for other reasons, is always subject to the insertion of spectacle
blinds and the locking of key valves which ensures the safety integrity of
the isolation.

The incorrect or unauthorised use of these isolation techniques, or a


change in their ongoing status, can compromise the safety of a facility. To
prevent this, and to ensure that these techniques are used correctly,
controls are provided for their authorisation and audit.

Procedure Description:
Definitions
Locked Valve:
A locked valve is a valve which is designated on the Process and
Engineering Flow Scheme (PEFS) as being either Locked Open (LO) or
Locked Closed (LC). Locked valves are those valves identified during
the design phase, or in subsequent reviews, as being essential to the
safety and integrity of the plant or facility. The changing of the
normal state of a locked valve must be controlled through the Permit to
Work System according to this procedure to assure the continued safe
operation of the facility.

Where valve is not required to be opened frequently then the


recommended method of locking is by the crimped wire system; else
chain and padlock shall be applied.

Spectacle Blind:
A spectacle blind is designated on the Process and Engineering Flow
Scheme (PEFS) as being either open or close. Spectacle blind positions
are identified during the design phase, or in subsequent reviews, as being
essential for positive isolation purposes and the safety of the
plant or facility. Changing the status of a spectacle blind must be
controlled through the Permit to Work System according to this procedure
to assure the safe operation of the facility.

Locked Valve Register and Spectacle Blind Status:

 A register of the change in position of all locked valves (as


defined above) shall be maintained on site, and shall be called the
Locked Valve Register.
 All temporary changes to the normal status of locked valves are to
be authorised by the Production Supervisor prior to the change
being made. Permanent changes must be handled through the
Facility Change Proposal (FCP) procedure.
 Any change to the normal status of a valve or spectacle blind shall
be recorded in the Locked Valve together with the reason for the
change and the number of the permit (if applicable) that authorises
the change.

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 ALL deviations from the approved status of locked valves or spectacle blinds
shall be recorded (for audit purposes) and reported to the Production Co-
ordinator and the Area Team Leader.
 The Production Supervisor shall audit the status of locked valves
once in every six months, and shall be accountable to ensure
that the status of locked valves are physically checked and recorded
once in every shift change – “shift” being a 2 week tour of duty.
Spectacle blinds shall be audited once every 12 months. The
plant operators shall check both against the latest PEFS/UEFS. A
file shall be kept of all audits for external checking.

14.5 Isolation of Equipment for Maintenance:


The most Important rule for isolation of equipment is "Stick to the Procedures! ". The
references at the end of this document give procedures for specific equipment. The simple
example drawings provide examples of acceptable Isolation configurations.

Organizing The Work:

The main hazard when working on equipment that has been isolated from live plant is that
isolation from a source of energy or hazardous fluid may be overlooked and the source then
activated. These hazards are identified, detailed and controlled by proper use of the permit to
work system. All isolation shall be authorized by a work permit. The production supervisor
or permit applicant shall write a site specific procedure for every piece of equipment to be
isolated from live plant and it shall be attached to the work permit, describing what
connections shall be disconnected, blocked or tagged before starting to open the equipment. A
spade and blind check list shall be made by the permit applicant and submitted with the work
permit to ensure the correct spades or blinds are closed during isolation and removed upon
completion of the work. This spade list will be signed off by the operator after isolation and
prior to equipment reinstatement after de-isolation.

The procedures for isolation as attached to the work permit can be straightforward when all
valves have a leak tight shut-off. However when valves do not have a tight shut-off, judgment
is required to decide how the work may be continued, and unless the person involved is
qualified to make such a decision, the work (also the installation of blinds) should be stopped.
This should be stated in the work permit.

Supervision of the work by the operator is required, particularly checking all isolation
points before starting, restarting and after finishing the job. The operator will verify spade and
blind positions with the list before the work is commenced and after the work is completed, he
will also supervise gas testing and purging as needed.

Isolation of Moving Machinery:

Moving machinery is defined here as any equipment using external motive force such as
Electricity, air, steam, or hydraulic fluid.

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The electrical, steam, hydraulic or other source of energy to the moving machinery, both flow
and return circuits, must be isolated from its drive unit and secured immobile before work
commences. For electrical isolation this must be done in accordance with ESOP.

Isolation of moving machinery from process fluids shall be accomplished by physical


disconnection of the machinery and the use of spades or blinds on the equipment side of inlet
and outlet block valves in order that maintenance may be carried out while the surrounding
facilities remain live.

Isolation of Vessels:

Design procedures indicate that normally open spectacle blinds should be installed on the
downstream side of the inlet block valve and the upstream side of the outlet block valve. If
practical these blinds should be mounted directly on the inlet flange. These blinds shall be
swung closed for maintenance work. If a spool piece is present between the blind and the
block valve it should be equipped with a vent or drain valve to allow the bleed off of any
pressure build up between the valve and the blind during maintenance before removing the
blind to reconnect the vessel.

Isolation of Tanks:

Blinds or spades should be inserted on the tank side of all inlet and outlet block valves. These
should be placed as close to the tank as possible. This also applies to blanket / purge gas lines,
tank balancing lines, vent lines to flare headers and water draw-off lines.

The cathodic protection electrical connections should be isolated to prevent any possibility of
a spark occurring.

Drain sumps should be routed to a closed drain header.

Isolation of Equipment containing H2S Gases:

Toxic gas is defined for isolation purposes as a gas containing more than 50 ppm of H2S. A
double block and bleed system is the minimum mandatory requirement for systems containing
toxic fluids.

Double block and bleed arrangements will provide a measure of protection when used in conjunction
with spades or blinds, however they should never be considered an acceptable replacement for
mechanical isolation for major work unless physical isolation by removing pipe-work is agreed
to be totally impractical by the Area Coordinator.

When double block and bleed systems are used in toxic service, the bleed connection shall be
hard-piped to a safe disposal location to ensure that the bleed itself does not create a hazard.
Acceptable disposal routes are to a remote vent or to a plant closed drain (or vent) system
provided that no live facilities are connected to the drain system while the double block and
bleed is in use.

Use of Breathing Apparatus:

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For work on equipment containing toxic gases, wearing positive pressure breathing apparatus
is mandatory when breaking flanges and opening equipment, this should be clearly stated on
the work permit.

Adequate isolation and purging shall be proven by a direct measurement, for both
hydrocarbons and the toxic component concerned (usually H2S), further work such as
opening the equipment for inspection will be carried out wearing a personal H2S monitor and
escape set.

Variation To Procedure:

When the piping and valve arrangement of process equipment does not allow for Double block
and bleed to comply with this procedure, the area coordinator will determine if isolation can
be safely accomplished by an alternate method. In this event the procedure to be followed will
be clearly written on or attached to the Work Permit.

Notes
1. The definition of minor and major work for any specific job will be determined by the
Production Supervisor.
2. Minor work is defined as a job of a routine nature e.g. control valve or pig-trap opening.
3. Major work is defined as a job of a complex nature e.g., inspection, maintenance shutdown
or vessel entry.

14.6 Minimum Isolation Requirements :


Table shows the recommended minimum isolation requirements.
Syste System Description Major Work
m
Class

A A shutdown, Positive isolation by a spade


depressurised and or remove spool and install
hydrocarbon free blind.
system.

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B System in service, of Single leak tight valve plus


ANSI class 600 and spade/blind (Note 1).
below.
For flashing liquids
and toxic see C below.

Double block and bleed plus a


C System in service, of
spade/blind.
ANSI class 900 and
above.
All systems containing
toxic fluids (Note 2).
Systems containing
flashing liquids above
ANSI 300, (Note 3) i.e.
ANSI 600 and above.

Note 1 A bleed connection should be installed between the valve and the
spade/blind for line sizes 6" and above. The purpose of the bleed is to
establish that positive isolation is achieved and to provide a means of
draining or depressurising the volume between spade/blind and isolation
valve.
Note 2 For the purposes of this requirement, toxic in the case of H2S is defined
as more than 50ppm H2S in the process stream.

Note 3 The definition of flashing liquids for the purposes of this Table is that given for
Cat. A fluids in Appendix B of the IP Code Part 15.

14.7 Location of blinds


Selection of Spectacle Blinds, Spades or Spools for isolation:
General
Wherever routine isolation of equipment is foreseen for maintenance or inspection, spectacle
blinds shall be installed irrespective of pipe diameter and rating as swinging a spectacle blind is
an easier operation than installing a spade. Furthermore, the isolation status is visually
apparent with a spectacle blind.

For substantial runs of smaller diameter piping (DN 150 and below) of lower pressure classes
(ANSI 300 and below) where there is sufficient flexibility in the pipe work for easy flange
spreading, then spades are an acceptable and convenient isolation method. For larger diameter
and higher rated piping or for cases of more rigid piping systems, permanently installed

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spectacle blinds are more convenient and impose less strain on the pipe work during the
isolation operation.

For the isolation of vessels and tanks where nozzle inspection is required, isolation may also
be provided by complete removal of an upstream piping spool with the resultant free end of
the potentially live pipe work being closed with a blind flange.

Dimensions Of Spades And Spectacle Blinds:


The spade or spectacle blind shall be of sufficient thickness to provide pressure containment
capability equivalent to the piping class in which it is installed. If there is a specification break
at the spectacle blind, then the blind shall be rated for the higher piping class.

Details of the correct dimensions of spades and spectacle blinds for ANSI pressure ratings are
given respectively in SIPM Standard Drawings S38.042 and S38.011 (see DEP 00.00.06.06-
Gen).
Double Block And Bleed:
Any process stream which is considered sour in accordance with PDO-ERD-08-04 shall be
provided with a double block and bleed system for isolation. The bleed system shall be
connected to a closed drain/flare system.

Double block and bleed shall be provided for isolation in all 600# and higher rated gas or
liquid systems, which may involve maintenance/inspection activities which use the block valves
for isolation against the upstream or downstream system.

Double Block and Bleed

C C

Isolation By Spool Piece Removal:


Positive Isolation can be done by removing the spool pieces and blinding the open flange of
the line connected to the live line.

Spool Removal

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Location of Spectacle Blinds:

The actual location of spectacle blinds will normally be determined during detailed design of
the Facilities based upon the agreed maintenance philosophy. This should consider whether
periodic maintenance/inspection will be implemented on individual equipment items, trains,
units or the plant as a whole. Consideration of these factors will indicate the required number
and best locations for installation of the spectacle blinds.
Below figure shows the isolation requirements at wellhead.

Swab Valve

Wing Valve

Location Valve
SSV

Master Valve

Isolation with Spectacle Blind


Fig. 1
Fig. 2 represents the isolation requirements of a pig launcher/receiver. If the piping
specification calls for welded valves, separate flanges shall be provided to accommodate the
spectacle blind. Figure - 2
Isolation Requirements for Pig Receiver and Launcher at Facilities

FOR LIQUID SERVICE


TO FLARE/VENT TO OPEN HAZARDOUS DRAIN
TO FLARE/VENT TO FLARE/DRAIN OR CLOSED DRAIN (rEF erd 08 10
XX
PG XX XX
XXX PG PG
XX XX
Xi XXX XXX Xi
NC NC XXX XXX

NC FB

NC FB
Note -1 INLET OR OUTLET
NC

NC NC NC

TO CLOSED DRAIN

NC

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NOTE - 1 : DOUBLE BLOCK AND BLEED REQUIRED FOR SOUR SERVICE AND 600# AND ABOVE RATED SYSTEM
NOTE - 2 : REFER ERD 08-11 (LATES VERSION ON WALLCHART) FOR THE LATEST UPDATE OF THIS DIAGRAM
Petroleum Development Oman HLD OTTP handout

Refer to Fig. 3 and Fig. 4 for general requirements of isolation for vessels.

Vessel Isolation - Preferred Arrangement

TO VENT HEADER

NC C

C
LG
LIC

MANUAL
NC DRAIN NC NC NC
C

C NC

Figure – 3 CLOSED DRAIN HEADER

Vessel Isolation Requirements (Sour Services)


TO FLARE HEADER

DEPRESSURISATION TO FLARE
N.C
XX UZ XXX
VAPOUR OUTLET
XX PIC XXX

INLET
H

LG LIC LZA

TO CLOSED DRAIN

N.C NC NC NC NC
LIQUID OUTLET

N.OTE : REFER ERD 08-11(LATEST VERSION


NC NC
ON WALLCHART) FOR THE LATEST
TO CLOSED
UPDATE OF THIS DIAGRAM DRAIN HEADER

Figure - 4

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Fig. 5 represents the isolation requirements for tanks. If a spool is used for isolation at tank
inlet nozzle, the spool shall be straight and its length shall not exceed I meter.

Drain arrangements shall be followed as per PDO-ERD-08- 10.

Automatic depressurising lines shall not have any block valves upstream or downstream.
Manual depressurising lines should be equipped with normally closed block valves having the
open spectacle blinds upstream; the spectacle blind should preferably be located at the
equipment flange.

For isolation of electrical equipment and moving machineries the electrical, steam, hydraulic,
fuel or other source of energy to the moving machinery, both flow and return circuit, must be
isolated. Alternatively the moving machinery must be isolated from its drive and secured
immobile.

Vent and Flare Header Isolation

HEADER

C C

Rotating equipment shall be provided with spectacle blinds at equipment side of inlet and
outlet isolation valves as each may be subjected to maintenance while the surrounding facilities
remain live.

There shall be no isolation valve at the inlet and outlet of safety relief valves.

For all cases in 600# and above and in sour service the double block and bleed requirement
shall be followed.

14.8 Pipe Line Isolation By Plugging:

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Gas-Barrier Plugs:
The gas barrier plugging technique involves cutting and parting the line before installing one of
a variety of plugging materials or devices into the open ends of the pipeline. Most of the work
is done manually so little specialised equipment is needed. This is a fast and practical plugging
method which is most often used in the repair of short run, small diameter and low vapor
pressure liquid pipelines.

This method of plugging has several disadvantages:

- the line must be shutdown,

- drainage volumes and product losses are likely to be greater,

- gas barrier plugs will not retain liquids or pressure exerted by vapor or gas. Venting,
blinding and other precautions are necessary to minimize the possibility of liquid or gas
bypassing or ejecting the plug from the line,

- any debris (grass, sticks, rocks, etc.) in mud or clay plugs may be harmful to meters,
seals and other pipeline components.

Types of gas barrier plugs are:

- earth, mud or clay plugs


- drilling mud plugs
- dry ice (carbon dioxide) plugs
- line packers, seal plugs and expandable plugs
- inflatable rubber spheres

Pressure-retaining plugs:
The pressure-retaining plugging method involves setting one or more plugs in the line by
mechanical means through connections hot-tapped onto the pipeline. These plugs will retain
pressure and will allow continued operations through bypasses at the work site. Preliminary
preparations can be made with little or no disruption of operations. The length of the line to
be isolated and drained is largely optional and minimizes drainage volumes and product losses.
Venting and clean up requirements are minimal. This can be the most practical method for
repairing LP-gas pipelines.

Disadvantages associated with mechanical plugging include:

- the large amount of specialized and expensive equipment


needed,
- The requirements for experienced personnel to be on hand to supervise the use of the
equipment,
- the time required for preliminary preparations and for obtaining the necessary
equipment.

Equipment Isolation:
A) Well-head Isolation: (PR 1037)

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Requirement to carry out work on the wellhead (i.e. Christmas Tree) or at the down hole, it is
necessary to isolate the wellhead from the downstream as well as from the upstream.
Sometime wellhead can be found on the ground or below the ground level in the Cellar. While
isolating wellhead with the Cellar, precaution should be taken as confine space entry to
minimise the hazards.

Well head flowline that is taken out of service for maintenance or isolated long term for other
reasons, is always subject to the insertion of spectacle blinds and tagging of valves which
ensures the safety integrity of isolation

Well integrity is dependent upon the proper functioning of the wellhead


valves and associated safety shutdown system. Routine preventive
maintenance is essential to maintain this functionality. Standards for the
scheduling and conducting of this activity are necessary to ensure safe
execution of the maintenance activities.
Valve failures threaten the integrity of a well and these should be
replaced in a properly executed manner. It may also be required to
replace valves or Xmas trees to effect modification or updating of
equipment.

W ell C ontrol
Swab Valve

W ing Valve

SSV

M aster Valve
Control Line for SSV
Control L ine for
SC SSV

Control Line

C asing
Tubing

SCSSV

Isolation of Well-Head:

Prior to commencing any isolation at a wellhead location, the following


steps and checks shall be taken:
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 Obtain a Well Location Custodian ship Transfer Form to carry out the
work.
 A gas test shall be carried out on arrival at the wellsite.
 Oxygen levels in the well cellar shall also be checked if work is to be
done in this area and on H 2S designated locations, a test shall also
be conducted to ensure that the H2S level is below 10 PPM

Note: If either test is outside acceptable limits, BA sets shall be worn whilst working
in the areas concerned. Refer to:
 PR-1042 “General Operational Safety”;
 PR-1044 “H2S Environment”.

 A warning sign shall be erected at the location entrance and


designate an emergency assembly point on the upwind side of the
wellhead. All crewmembers shall wear their PPE and, in H 2S areas,
activate their personal H 2S monitors and deploy their BA escape
sets close to where they are working. Refer to the following for
general safety and H2S specific requirements to be applied during
maintenance activities:
 PR-1042 “General Operational Safety”;
 PR-1044 “H2S Environment”.

 Prior to the commencement of work on pumping wells (beam pump,


screw pump and ESP) the electrical supply shall be isolated properly
by a competent electrical person and an isolation certificate
authorised.

 All maintenance work on the wellhead shall commence with a


thorough visual check for leaks and inspection of the general
wellhead condition. If the wellhead is dirty and/or contaminated
with oil, it shall be cleaned with a steam cleaner or other
appropriate means prior to carrying out further activities

 The condition of the ball catcher and location valves shall be


checked and reported.

 A check and report shall be made of the general cellar condition, in


particular the following:
 Cellar grating - no work shall be carried out on a well without
adequate cellar grating;
 Sand or oil fill - removal of sand or oil to be carried by vacuums
truck

 The tubing and annulus pressures shall be measured and recorded.


If either the 'B' or 'C' annulus pressures are greater than 500 kPa
they shall be bled down below 500 kPa, providing this can be
achieved within a few minutes. This shall be done initially via the

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flowline then by a line to the downwind side the wellsite to the


point when liquids are produced, only
If the annulus pressures cannot be easily bled down this shall be
reported with a recommendation for the provision of additional
equipment, e.g. tanks, etc., or the need for further investigation of
the problem leading to the possibility of a workover in the severest
cases.
 Closed the SSSV (where ever applicable)
Types of SCSSSV
Two types of SCSSSV are available:
 Tubing retrievable (TR-SCSSSV)
 Wireline retrievable (WR-SCSSSV)
TR-SCSSV’s are normally full-bore, whereas WR-SCSSSV’s are
reduced bore thereby causing restriction in well flow and downhole
access for wireline and/or coiled tubing.
Both types are available as either flapper or ball mechanisms.
Surveys indicate that flapper valves are more reliable than ball
valves and that tubing retrievable valves are more reliable than
wireline retrievable.
Wells to be installed with an SCSSSV
It is PDO policy that SCSSSV’s shall be installed in the following
types of well:
 all free flowing oil or gas wells (including gas injection wells) with
a FTHP exceeding 10,000 kPa on a 3-inch choke (full bore case);
 all free flowing sour wells within the following FTHP and H 2S
concentrations:

FTHP H2S
(kPa) Concentration
(PPM by
weight)
300 – 500 > 20,000
500 – 2000 > 5,000
2000 – 5000 > 2,000
5000 - > 800
10000

Note: Sour wells with FTHP < 300 kPa do not require an SCSSSV.
 all exploration wells completed with a packer where there is the
possibility of H2S or CO2 being present;
 all free flowing, or having the ability to free flow, oil wells located
along areas of major surface water flow
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SCSSSV’s are normally controlled from the surface by means of a


hydraulic control line run outside the tubing string via the wellhead
to a control panel which is connected into the ESD system for the
well. This panel also operates the SSV on the wellhead (UMGV).

The panel is equipped with a pump to maintain hydraulic pressure


to keep the valves open and sensing devices that will bleed of the
pressure, thus shutting the valves, on the occurrence of abnormal
conditions.
The wellhead shut-in logic shall be designed such that SCSSSV’s are
never closed unnecessarily and the SSV shall always be closed-in
first and the SCSSSV only closed thereafter following a suitable time
delay
 Closed the Surface Safety Valves

Types of SSV
Surface safety valves (SSV’s) normally take the form of
hydraulically operated upper master gate valves (UMGV's) installed
in the Xmas trees of wells.
 Install a pressure recorder/gauge on the Xmas tree cap, ensuring
that the swab valve is close.
 Close the location valve and check for leaking by listening for noise
of fluids passing.
 Close in the well on the wing valve.
 Depressurise the flowline between the wing valve and the location
valve.
 Check leak rate across wing valve by monitoring the flowline
pressure builds up for 15 minutes.
 Close the lower master valves
 Close the Gas lift line location valve
 Close the casing wing valve
 Depressurise the gas lift line between location valve and casing
wing valve by connecting tubing between gas lift line to flow line.
 Once the line is fully depressurise reverse the spectacle blind to
close position at the up stream of flow line location valve and down
stream of gas lift location valve.
 Complete the PTW system.

B) Flow Line or Gas Lift line Isolation:

When a well or gas lift flowline is temporarily suspended from service or


abandoned altogether, the flowline must be prepared accordingly and left
in a safe condition. Arrangements are made either to leave the flowline
in a pressurised condition ready for return to service, or it is disconnected
from the well completely and isolated in the case of long term closure or
complete abandonment .

The purpose of this procedure is to ensure that any interruption in the operation of a well, and
its associated flow and gaslift lines, is performed in a controlled and safe manner.

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Procedure Description:

 Production Programmers together with Area Petroleum Engineering


Teams SHALL determine the actual status of each individual well to
be closed in. This status then determines the procedure to be
followed regarding the associated flow and gaslift lines.
 When a well is to be closed in for less than two months, or is on a
production ‘swing’ list or stopcock, its flow and gaslift lines SHALL
be left partly pressurised (i.e. to station manifold/separator
pressure) ready for use.

 When a well is to be closed in for more than two months and it is


not on a production ‘swing’ list, its flow and gaslift lines SHALL be
suspended and isolated from the well.

 When a well has no future production / injection potential (e.g. it


has been or is to be abandoned or used as an observation well) its
flow and gaslift lines SHALL be physically removed.

 If there is no future use for the well, the well is suspended from use
by following WSP-71 ‘Suspension of Wells and Completion
Operations’, Manual 2350.

 Suspended flow and gaslift lines, once isolated, SHALL be left with
an inert medium for corrosion prevention purposes.

 If the well is to be kept on the ‘swing list’ or closed in for less than
two months the following steps must be followed:

Ø Close gaslift manifold


Ø Close in the well.
Ø Leave gaslift lines/flowline pressurised to station
manifold/separator pressure.

 If the well is to be closed in for more than two months but SHALL
have future use, the following steps must be followed:
Ø Isolate gas lift from manifold side
Ø Close in all wellhead valves
Ø Depressurise gas lift line to flow line from wellhead end to
station.
Ø Close the location valves of both gaslift and flow line.
Ø Disconnect Gaslift / flowline from Xmas tree.
Ø Install blank flange on Xmas tree.
Ø Flush flowline with potable water (1.5 x line volume).
Ø Purge the flowline with nitrogen until free of liquid.
Ø Install blind flanges on both end of flowline.
Ø Leave 150-kPa nitrogen pressure in flowline.

C) Beam Pump Isolation:

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Regular servicing of beam pump units is required to minimise leaks and


possible damage to well head equipment due to malfunction. Prior to
commencing any isolation at a wellhead location, the following steps and
checks shall be taken:

 A gas test shall be carried out on arrival at the wellsite.


 Oxygen levels in the well cellar shall also be checked if work is to be
done in this area and on H 2S designated locations, a test shall also
be conducted to ensure that the H2S level is below 10 ppm.

Note: If either test is outside acceptable limits, BA sets shall be worn whilst working
in the areas concerned. Refer to:
 PR-1042 “General Operational Safety”;
 PR-1044 “H2S Environment”.

 A warning sign shall be erected at the location entrance and


designate an emergency assembly point on the upwind side of the
wellhead. All crewmembers shall wear their PPE and, in H 2S areas,
activate their personal H 2S monitors and deploy their BA escape
sets close to where they are working. Refer to the following for
general safety and H2S specific requirements to be applied during
maintenance activities:
 PR-1042 “General Operational Safety”;
 PR-1044 “H2S Environment”.

Procedure

 The power switch near the pump motor shall be switched off and
locked ensuring that the pump is stopped with the counterweights
at their lowest position. The electrical supply shall be isolated and
locked off the at the control panel by the Competent Electrical
Person who will sign the Isolation Certificate to that effect.

 Ensure that the master and swab valves are locked open to prevent
fouling of the pump rods. Also, one of the 'A' annulus valves may
be the exit point for a stainless steel PTS line, this should not be
closed either.

 The mechanical lock, if fitted, shall be applied or the counterweight


shall be secured to the pump base with chains or wire rope.

 The BOP rams shall be closed around the polished rod.

 The condition and tightness of the brake rod/cable shall be checked.


 If require close the location valve.

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D) Shipping Pump Isolation:The power switch near the pump motor shall be switched
off and locked ensuring that the pump is stopped. The electrical supply shall be
isolated and locked off the at the control panel by the Competent Electrical Person
who will sign the Isolation Certificate to that effect.

Once the pump is stopped it’s suction valve and Discharge valve gets
close if it is motor driven operated. Otherwise close the manual suction
valve and discharge valve.
Motor driven suction /discharge MOV electrical supply should be isolated
by CEP
with the isolation of main motor of the pump.
Drain the suction/discharge line and pump casing through manual drain
valves to the drain vessel.
Once it is ensure that complete content from the system has been
drained than isolate all drain valves.
Reverse the spectacle blind at:

 Down stream of Inlet suction valve of pump


 Upstream of Discharge valve of pump
 Up stream of drain valve of common drain header of the pump skid.
Than permission can be given for the plan maintenance to open up.
Isolation of Shipping Pump:

Recycle Line to Tank

Suction Header

Discharge Header
M

M
M

To Drain

E) Electrical Submersible Pump Isolation (ESP):

Prior to commencing any isolation at a wellhead location, common steps


and checks
Shall be carried out as discuss in wellhead isolation.
Procedure:
 The power switch on the pump motor panel shall be switched off
and locked to ensuring that the pump is stopped. The electrical
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supply shall be isolated and locked off the at the control panel by
the Competent Electrical Person who will sign the Isolation
Certificate to that effect.
 Close the master valve and check the THP
 Close tubing wing valve

 Close the casing wing valve

 Let the line get depressurise and then close the flowline location
valve.
 Isolate all installed safe guarding instruments on the flow line.

Isolation of ESP

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To Stn.

F) Gas Lift Compressor Isolation:

Basically there are two types of gas lift compressors.


Centrifugal compressor &
Reciprocating compressor.
A PSD of the gas compressor may be initiated from process upsets with in
the unit itself, or manually initiated via the control room or local panel.
The power switch on the compressor motor panel shall be switched off
and locked to ensuring that the compressor is stopped. The electrical
supply shall be isolated and locked off the at the control panel by the
Competent Electrical Person who will sign the Isolation Certificate to that
effect.
A gas compressor PSD causes closure of the ESD valves in the
condensate return lines to the production separators.
Drain the condensate from all the interstage scrubbers to a drain vessel.
Activate an ESD, makes the compressor inter stages to depressurise
through the
EDPV/ blow down valves between the stage
Isolation of moving machinery from process fluids SHALL be accomplished
by physical disconnection of the machinery and the use of spades or
blinds on the equipment side of inlet and outlet block valves in order that
maintenance may be carried out while the surrounding facilities remain
live.
Reverse the spectacle blind to close position at following location
 Down stream of Inlet block valve of compressor
 Upstream of Outlet block valve of compressor
 Up stream of Condensate header ESD valve to Bulk separator
 Up stream of drain valve of condensate header
 Up stream of drain valve of drain header from all scrubber
 Up stream of blowdown header LO/LC valve to flare header

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If the location is H2S designated than purging is required before opening


up the compressor’s internal. By following the Purging procedure PR- 1073
 Connect a supply of nitrogen to the equipment. Where the
equipment contains check valves (pipework, compressors etc.),
connect the nitrogen at the upstream end to allow the whole
system to be blown through. The point of connection should be
such that the purge gas will sweep the entire volume of the
equipment.

Note: The nature of the nitrogen supply will depend on the size of
the equipment. Cylinders of gaseous nitrogen may be used in most
cases, with liquid nitrogen being required for larger volumes.

 Blow approximately three times the total volume of the equipment


through with nitrogen, as quickly as the source will allow. The more
rapid the sweep, the better the purge. Where possible, the mixture
of gas and nitrogen should be routed to a remote vent system
(particularly in sour installations). In the case of rotating
equipment, bar the rotor over where feasible during the purging.
 Through a small (½") valve, insert the probe of a gas sniffer. If an
explosive gas concentration is detected, repeat the purging
described in the previous step. This SHALL be done either if the
needle remains in the explosive area or if it subsequently swings
back to zero (indicating a gas concentration above the Upper
Explosive Limit (UEL)). Between testing, withdraw the probe and
purge the sniffer with fresh air.

Once it is ensure that system is free of Hydrocarbon and H2S, work can
be started.

Isolation of Compressor

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G) Pressure Relief Valve Isolation and Locking Procedure: (PR 1093)

Pressure relief valves (PRV's) are fitted to process installations to protect


vessels and plant from inadvertent over pressurisation, which could result
in catastrophic mechanical failure. Isolation valves upstream and
downstream of PRV's have the potential to defeat the PRV protection if
they are closed at the wrong time.

Strict controls are necessary to ensure that PRV isolation valves are only
closed under specific circumstances and that they are securely set in the
OPEN position during normal operations.

This procedure is applicable to ALL situations where the isolation or de-


isolation of a Pressure Relief Valve (PRV) is required.

Pressure Relief Valve (PRV) - Isolation Valve Configurations:

 The recommended company practice is to use one relief valve per


vessel without any upstream isolating valve (Method I).
 Some older installations use a double Pressure Relief Valve system.
This incorporates both upstream and downstream isolation valves,
with Castle lock or padlock and chain methods of locking (Method
II).
 For installations where there is a combination of both Methods I and
II, care needs to be exercised to ensure that the plant is
operationally safe at all times, and that when a system shutdown is
required the correct sequence of valve isolation is employed.

Procedure Description:

Each PRV isolation SHALL be judged at local level to consider if any deviation from
the accepted isolation procedure is acceptable, and whether or not plant
modifications are justified (cost and time) to achieve the objectives of Method I.
above.

PRV Isolation - Shutdown Condition:


 During a shutdown, vessel PRV's SHALL be isolated by use of the
upstream and downstream isolation valves.

 All PRV 's SHALL be isolated under an appropriate permit, tagged /


labeled with permit number and isolation date.

 Where interlocking devices are provided (that ensure the PRV is


NOT isolated during service) these SHALL be DEFEATED for the
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purposes of vessel isolation. (Note: the mechanism must be re-


instated prior to de-isolation).

 Those isolation valves associated with an interlocking mechanism


SHALL be chained and pad locked in the CLOSED position.

 Where there are no interlock devices present, the PRV isolation


valve(s) SHALL be locked CLOSED by using the crimped wire
method.

 In cases where toxic fluid or gas are contained in the vessel (i.e.
H2S) and the vessel has to be temporarily isolated from a vent
header, double block and bleed isolation is the minimum
requirement if depressurisation, degassing, and disconnection of a
vessel is impractical.

 All PRV isolations SHALL be recorded in the appropriate log. (i.e.


locked open/locked closed valve register).

PRV De-Isolation:

 Where an interlock system is employed, all relief valve ISOLATION valves


SHALL be locked in their normal OPEN position by using chains and padlocks.
Caution: The Integrity and Safety of the Plant depend upon the correct setting of
these isolation valves.
 Where there is no interlock devices the isolation valve (s) SHALL be
locked OPEN by using the crimped wire method.

 The Production Supervisor SHALL undertake the responsibility for


documenting the reasons for any deviation from the preferred
standard of locking as defined above, and the alternative method
employed.

 All PRV de-isolations SHALL be recorded in the appropriate log. (i.e.


locked open/locked closed valve register).

Note 1 Any alternative method for locking SHALL ensure a positive foolproof
arrangement for isolation valves such that any chains or wire strops which may
be used, cannot be inadvertently removed from the handwheel /operating lever.

Note 2 If padlocks are used for securing chains, a different key for each padlock SHALL
be the accepted practice, the keys being kept on the station control room keyboard.

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Control Procedure - Activity Matrix


Business Process: Isolation of Process Equipment - Basic Requirements

Symbols:

nel
s
nel ion

son
r
Return from/forward

son erat
ato
Activity

Per
to another activity

din

Per O p
oor

ce
Decision MA Meeting Attendee

n
ctio

nan
aC

int e
du
Are

ST
E Start/End Continuation Pro

No. Abbreviated Activity Description 1 Ma 2 3 4 5 6 7 8 9 10 11

ST
1 Identify equipment to be isolated.

2 Identify hazards.

Major
3 Is the work major or minor?
Minor
Specify isolation by valves (if
4
appropriate).

Will workscope require long term No


5
isolation?
Yes

6 Specify isolation by spades or blinds.

7 Authorise permits.

8 Perform plant isolation (tag and label


valves, blinds, etc).

9 Execute planned workscope.

Define audit/integrity check


10
frequency (if appropriate).

11 Perform isolation audit.

12 _________________________________________________________________________________________
De-isolate when required.
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14.9 Entry Into A Confined Space:


General:
Definitions
Confined space means any enclosed or partially enclosed space, either above or below ground
or deck level, where entry is possible and where there is a risk of oxygen deficiency or the
accumulation of dust or gases which are flammable or hazardous to health.

Examples of confined spaces are:-

Process vessels and related equipment (vessel tower skirts and flare stacks), boilers, water
storage tanks, other tanks (including pontoons on floating roof tanks), bunds, tank cars and
trucks;

Spaces located below ground or deck level, nominally deeper than 1.5 m, such as drain pits,
sewage pits and associated tunnels, ducts, trenches, wells, shafts, cellars, vaults and
unventilated rooms which may be considered confined spaces under specific circumstances;

The cargo, ballast or void spaces onboard ships; (AOT Responsibility)

The support columns/legs/pontoons of fixed or mobile offshore installations.


Entry not only refers to complete body entry, but also to partial entry when only the head is
inserted, e.g. into manhole openings, hatches, pipe ends, etc.

The same type of risk may exist in close proximity to equipment which has already been
opened up, in which case some of the precautions which apply to entry would also apply. The

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assessment of this situation will be made by the Responsible Person. (e.g. Production
Supervisor.

Entry should only be considered when all specified safety precautions have been fully
observed. Where specific area or equipment conditions dictate, further additional regulations
and procedure will be supplied by the Responsible Person involved.

Principles Of Control:

General:
Entry into a confined space, for whatever purpose, shall only be contemplated after all
practical steps have failed to deal with the problem in a less hazardous way.

There are three key areas of control as indicated below, from which cascade the appropriate
company Procedures/Systems which shall be complied with:

a) Policy - Work Permit Systems


- Buddy System
- Confined Space Entry Certificate
- Personnel Familarisation
- Emergency Evacuation Planning
- Personnel Training.

b) Supervision - Definition of Tasks to be Performed


- Hazard Analyses
- Permit Procedures
- Check Lists
- Pre-Entry Conditions.

C) Isolation - As per instructions given on the


Work Permit Procedures.

Reference to ompany Codes And Procedures

All personnel who are required to issue/supervise the above documents, as well as those who
are required to enter confined spaces as defined in this procedure are required to fully
understand and comply with the following codes and procedures:

Supervisory Responsibilities

Responsible Person/Representative

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A Site Representative (approved Work Permit holder) fully authorised by the Responsible
Person (e.g. Tank and Vessel Supervisor) is to be present on the site at all times for any work
covered by this procedure, and he is responsible for:

- All co-ordination with the implementing Contractor.

- Ensuring that all "vessels" are checked for pressure prior to opening, and for all the
subsequent tasks to be performed.

- Arranging for preparation of the area for safe entry (refer section 1. 1 of this
procedure).

- Strict adherence to procedures by all personnel, including an appreciation of all


potential hazards, safety/health requirements, and emergency evacuation planning.

- Preventing re-contamination of the area.

- The issuing and control of all permits, check lists, pre-entry conditions, and isolations
for all facilities within the work area (GU 258 Permit to Work Systems).

- To ensure that personnel are fully trained in how to apply the appropriate safeguards in
controlling the hazards, and in the use of the test equipment for monitoring the hazards.

- The maintenance of all written records for audit purposes.

Supervisor of Men Entering the Confined Space (e.g. Contractor Supervisor)

Has responsibility delegated to him by the Representative for:

 Ensuring that the confined space has been safely isolated, and that he clearly
understands what tasks are done.

 Safety of the men entering the confined space (Refer to detailed check list in
"Guidelines for entry into Confined Spaces" Shell Safety and Health Committee
1992).(Custodian:- T.S.E. Department)

 Briefing and testing (either as a group or individually) his men to ensure the
whole squad know and clearly understand the methods and plans for
entering or leaving the Confined Space - and appreciate the safety regulations
being undertaken for means of escape, should an emergency arise.

 Ensuring strict adherence to all Safety Procedures and Work Instructions

 Obtaining “ Confined Space Entry Certificates” and complying with the specified
precaution on the permit.

 Returning signed copy of work permit to the Operations Representative on


Completion of job.

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 Maintaining a record of all persons and tools equipment inside the vessel and
for the removal of all fittings, scrap, waste at the end of the job, so as to leave the
area in a clean condition ready for re-commissioning.

Confined Space Attendants:

The duties of the Attendant(s) or Stand-by Person(s) (e.g. Foreman) outside the
Confined Space are specifically related to the safety of those inside the enclosed space
and include:

- To check persons into, and out of, the Confined Space.

- To be alert to all situations which may adversely affect those inside.

- To maintain continuous contact (visually or verbally) with personnel inside.

If at any time whilst inside a vessel the contact with the Stand by man outside fails, the vessel
must be vacated immediately and may only be re-entered if this contact has been restored.

- To agree with those inside on signals for immediately leaving the confined space.

- Know who to summon and get the necessary help if anyone inside gets into
difficulties, e.g. via radio communications to a control room. This communication
link shall be actively tested at the commencement of each shift.

To assist in any rescue that might be necessary.

To alert the men inside the vessel or Confined Space of hazards that may cause air and life
lines to foul; give normal assistance in the handling of materials, tools, messages etc.

Note: 1.
A Stand-by man will not leave his post at the point of entry, or enter the vessel himself,
for any purpose whatever, without properly handing over to another Stand-by man,
except for emergency rescue after first calling for and receiving aid.

Note:2
On no account must the attendant / Stand-by person attempt to enter the space before
additional help has arrived.

Invalid Permit Conditions:

If any person considers that there is a hazard present or the conditions set up for a particular
job change for any reason, the work must stop and the men must leave the Confined Space
until such conditions have been re-appraised by the Supervisor or his Representative.

After each change of shift, or a break in the operation of more than thirty minutes the
Supervisor has to ensure himself that conditions are still safe before allowing re-entry.

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General Instructions For Supervisors:


Potential Confined Space Hazards:

Before entering confined spaces, the following particular hazards may need to be considered
and safeguard against:

- Oxygen deficiency or enrichment.

- Flammability, fire and explosion.

- Residual liquids and associated toxic or other noxious gases.

- Chemical hazards.

- Physical hazards.

- Other hazards, e.g. poor visibility, persons becoming trapped in the event of
an accident etc.

Tanks And Vessels:


Tanks, tank trucks, road tankers, pressure vessels, etc., must be thoroughly washed, steamed if
necessary, drained and ventilated, and gas-freed as required on the permit (purged with
Nitrogen if required).

Process And Service Lines:


All process and service lines to vessels must be spaded, blanked off or disconnected (and
blanked off) to ensure complete isolation of the equipment. All blanks or "spades" must be
inspected tagged/registered, and approved by authorised work supervisor before being
installed.

A complete schedule of all blanks/spades used shall be made to ensure isolation, and the same
schedule used to ensure reinstatement of the plant at the end of the work.

Flammable Substances:
Where there is any possibility of the existence of flammable liquids or vapours, a competent
operator, authorised by the Responsible Person must test the area with an explosimeter,
witnessed by the representative and the work supervisor. A full record of these results must be
recorded on the Work Permit. This competent gas tester operator remains responsible for
continued testing and recording as specified on the Work Permit.

If a reading greater than 0% is indicated the Responsible Person or his representative must be
notified who will specify any restrictions or precautions to be taken on the "Confined Space
Entry Certificates".

Toxic Substances:
Where toxic liquids or vapours or other dangerous substances may be present, positive
pressure respiratory protection must be worn by each man in the tank or vessel, or the
equipment must be well ventilated by use of an air diffuser or blower-exhausted system, until it
is certified as safe for personnel to enter without breathing apparatus.
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Atmosphere-Oxygen Level:
Tanks, vessels and confined spaces may only be entered when the atmosphere inside has been
certified as having a safe oxygen content as indicated by recognised PDO detection apparatus.
This test will be conducted only by a competent gas tester permit holder who has been
formally instructed in the use of oxygen detectors.
If the oxygen content is sufficient this must be noted on the "Confined Space Entry
Certificates". If the oxygen content is less than 20% the vessel must not be entered.

Attendants (Stand-By Man) / Breathing Apparatus:


A Stand-by man trained in the use of and equipped with self-contained breathing apparatus
must be stationed outside the vessel and must maintain permanent contact by predetermined
means. When there are more than two men inside, additional Stand-by men are required, each
tending a maximum of two men.

Safety Harness/Life Line:


Where ever possible a safety harness with life must be worn by each man entering the tank,
and an extra harness, life line and resuscitator must be in the care of the standby man.

Use Of Arc Or Open Flame:


The use of arc or open flame within or near tanks and vessels must be authorised by a "Hot
Work Permit" (refer GU 258 Permit To Work System). A water hose and/or a specified
number of dry chemical type fire extinguishers must be present for immediate use. A fire
extinguisher cannot be used whilst men are still inside the vessel. The equipment must be well
ventilated by use of an air diffuser or blower-exhauster system to avoid gas pockets and
remove fumes. Care should be taken to ensure that no flammable or toxic vapours are drawn
into the confined space by the apparatus, i.e. vapours from adjacent tanks, vehicle or
compressor exhausts, etc.

Respiratory Protection
Respiratory protection for each man in the confined space, and for the Stand-by man must be
provided where the representative/work supervisor consider it necessary, and recorded on the
Work Permit. At least one properly connected air mask shall be available on the outside, for
rescue purposes.

Protective Clothing:
Goggles, gloves, rubber/safety boots, safety helmet and special clothing shall be worn as
directed by the Responsible Person on the Work Permit.

Closure Of Vessel:
The operations representative will not authorise the closure of the vessel until he has received
a copy of the permit signed by the Work Supervisor that the work is complete and that all men
and equipment are out of the vessel.
The representative should make a final check inside the vessel prior to closure and acceptance
of the vessel back for service.

Electrical Equipment:

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(i) Extension cords and portable electric hand tools/equipment must not exceed
50 volts and must be explosion proof rated for use in potentially hazardous
hydrocarbon environments.

(ii) Temporary lighting facilities will normally be provided by hand held battery
units and shall be intrinsically safe.

(iii) Pneumatic equipment shall be used instead of low voltage equipment, where
this is a practical alternative.

(iv) Any special electrical equipment rated above the voltage requirements of this
section including:

Spark testers, magnetic drill holder, etc. may only be used if it is done under
close supervisory control, and be authorised by a "Hot Work Permit".

14.10,14.11 Preparation for internal work & Work on Tank Roof

Tanks and Vessels Isolation

It is frequently a requirement to carry out work inside a tank or vessel, whether it is for
routine scheduled inspection or for repair to known defects. As entry into enclosed spaces is a
potentially hazardous activity careful preparation of the tank/vessel and application of entry
controls are required to minimise the hazards.

Purpose:
The purpose of this procedure is to specify and describe the steps necessary for the
preparation of a vessel/tank for internal work or inspection, and the controls that must be
exercised during cleaning.

Procedure Description:

General Preparation/Isolation:

 Complete isolation permits formalities.

 Take vessel/tank out of service, depressurise and drain as much


fluid as possible.

 Disconnect cathodic protection 24 hours prior to man entry to the


tank, and allow tank to de-polarise such that its voltage, relative to
earth, is zero and the danger of static sparks is therefore removed.

Note: The clothing of personnel entering the vessel/tank


should not contain nylon or polyester since these generate
static electricity.

 Isolate the vessel/tank completely from live process streams.


Spading or removal of valves/sections of line and the full-face
blanking of open flanges shall do this.
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 Isolation by valves only, even if it is a block and bleed system, is


not permitted for man entry.

 The following methods of isolation are available, the most


appropriate should be selected when considering each and every
live line joining the vessel/tank.

 Physically remove part of the connecting live line (e.g. valve,


spool piece) and fit a full-face blank flange (of the correct rating)
to the live side of the 'gap'. This is the preferred method of
isolation.
 Swing an installed spectacle blind to the closed position.

 Insert a suitably rated blind between two flanges (i.e. same class
as the flange).

Removal of Hydrocarbons:

 Wash out, flush out, steam out, ventilate and, in general, use the
most effective method in the circumstances to remove
hydrocarbons from the vessel/tank.

 Steaming is very effective in the removal of hydrocarbons, but loses


its effectiveness in direct proportion to the size of the vessel/tank.
This is because the increased surface area of a larger vessel/tank
allows substantial condensation of the steam, and the internal tank
temperature never becomes high enough to 'steam distil' off the oil,
etc.

 If steaming is carried out, great care must be exercised during the


cool-down period since the ingress of insufficient quantities of air
will cause a vacuum inside the vessel/tank with the danger of the
vessel/tank roof or sides collapsing. All top vents, pressure/vacuum
valves, manholes, etc. must be unrestricted.

CAUTION: During vessel/tank cleaning operations, large quantities of


hydrocarbon vapour may be released over a relatively short period
of time. As a consequence, areas some distance away from the
vessel/tank may become hazardous and hot work should be stopped
or heavily restricted.

 Keep vessel/tank internals wet in case pyrophoric ferrous sulphide (FeS) is present.

 Using the approved methods, test the atmosphere within the


vessel/tank for the following:
 Toxic gas (H2S).
 Flammability (LEL).
 Minimum oxygen content (21%).
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 Prepare work/entry permit specify precautions and allow work to commence for
sludge removal.

Sludge Removal:
 Before maintenance/inspection work can be carried out there will almost certainly be
the need to remove sludge and solid deposits from within the vessel/tank. Sludge
containing hydrocarbons shall be removed using spark-proof tools.

CAUTION: When sludge is disturbed, the atmospheres above the sludge will
become contaminated with hydrocarbon vapour and quickly become
unsuitable for working without breathing apparatus. In some tanks
H2S may be released at hazardous levels. Personnel removing sludge
deposits from vessels/tanks must wear breathing apparatus at all
times while inside the vessel/tank. Sludge containing lead is subject
to additional, special precautions. A proper suit, rubber gloves and
boots are to be worn in all cases of sludge removal.

 Identify if the removal of sludge is necessary and make arrangements for


containment/disposal.

 Remove sludge from vessel/tank using best practicable method


(personnel wear BA).

 Consider all sludge removed from a vessel/tank to be pyrophoric


until proved otherwise, keep wet and dispose of in a safe manner.

 Prepare work/entry permit specify precautions and allow work to


commence for inspection/maintenance.

NOTE: Refer previous Drawings of Isolation of Different Equipment and
Vessels

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FIGURE 1 - Tank Isolation, Sour Service


TO FLARE
HEADER
LO
BLANKET GAS

LO

BALANCE LINE

NOTE -1
LG
OIL OUT
TANK
INLET

WATER OUT
NC

SUMP
NC DRAIN NC
NC

NC

TO CLOSED
NOTE - 1 : ENSURE DOUBLE BLOCK AND BLEED ON THIS LINE FOR TANK ISOLATION DRAIN HEADER
NOTE - 2 : REFER TO ERD 08-11(LATEST VERSION ON WALL CHART) FOR THE LATEST UPDATE
OF THIS DIAGRAM

15.0 PURGING AND FLUSHING


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Introduction:

Purging and Flushing of piping and equipment are most important as they used in oil
and gas industry for the processing of hydrocarbons. When they need to take out of
service for the maintenance purpose or for the annual service, it is require to make sure it
is gas free before carrying out any type of jobs. As hydrocarbons are handle by these
equipments and pipeline, when they are open to atmosphere, air is getting mixed with the
hydrocarbon gas and make the explosive mixture which is very danger and thing can explode if
there is a presence of ignition. To avoid this potential risk, purging or flushing operation need
to carry out with the help of WATER or NITROGEN gas.

Background

Piping and equipment used in Oil and Gas industry for the processing of
hydrocarbons are routinely taken in and out of service due to
maintenance work or annual inspection of the vessels. During which time
there is a possibility of an explosive mixture of gas and air forming within
the equipment. To remove this potential risk, the equipment is subject to
make gas free prior to removal or open and make air free prior to return
to service. To avoid this potential risk, purging or flushing operation need
to carry out with the help of WATER or NITROGEN gas.

15.1 NITROGEN GAS:


Nitrogen gas is the most ideal gas for replacing hydrocarbon gas before any equipment
or pipelines are to be opened up. N2 is the non-toxic, non-flammable non-corrosive gas.
Nitrogen gas is safe to handle and readily available through out the world and is inexpensive.
It neither involved with chemical reaction nor it works as catalyst in any
process.
It is called Inert Gas. To replace the hydrocarbon with the help of nitrogen
is called PURGING of the vessel or the equipment.

Scope

This procedure covers the steps necessary in removing and returning


hydrocarbon process equipment to service, such that the occurrence of
explosive gas/air mixtures within the equipment is prevented.

The procedure covers the purging and leak testing of the following
equipment types:
 Separators
 Scrubbers
 Tanks
 Filters and other vessels of a similar size and nature
 Pumps of all types
 Gas compressors of all types
 On-plot pipe work and all associated valves and fittings.

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It excludes instrumentation and other equipment, which may contain


relatively small volumes of hydrocarbons and as such present little
hazard.
Note: Although the inventory is small, sufficient care must still be
taken when depressurising instrument impulse lines.

15.2 Water Flushing:


Water flushing is sometimes necessary to allow maintenance or engineering work to take place
on a flowline, e.g. to make a tie-in. Before this type of work can proceed, flow lines must be
flushed with water to a level whereby they are substantially free of hydrocarbons. The
oil/water flushing subsequently produced must be contained and disposed of in an
environmentally responsible manner.

Procedure Description:

 The Production co-ordinator will decide on the direction in which a


flowline is to be flushed (wellhead to gathering station or vice
versa).

 Factors to be considered during the planning phase of the task are


as follows:

 Determine flushing water availability (the wellhead may be close to


water well).

 Ease of disposal of flushed liquids using an environmentally safe


method.

 Differences in elevation.

 Whether the displaced oil will contain high levels of H 2S. If so,
observe H2S procedures for handling sour crude.

 Whether temporary storage (e.g. drilling crew tanks moved in prior


to workover) is available at the wellhead.

 All line flushing SHALL be collected in a suitable container and


disposed of in an environmentally responsible manner.

 Oil in flowline flushing shall be recovered by using the oil saver


system and pit as far as practicable.

 To ensure that the most effective flush is performed, the flushing


water needs to be turbulent. Use a high water velocity for a short
period.

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C o n tr o l P r o c e d u r e - A c tiv ity M a tr ix

B u s in e s s P r o c e s s : F lo w lin e F lu s h in g F ig . 1

S y m b o ls :

ons
R e tu rn fr o m /fo r w a r d
A c t iv it y

tor

son rati
t o a n o th e r a c tiv ity

ina

Per Ope
nel
d
D e c is io n M A M e e tin g A tte n d e e

oor

tion
aC

duc
Are
ST
E S ta r t/E n d C o n t in u a t io n

Pro
No. A b b r e v ia t e d A c t iv it y D e s c r ip t io n 1 2 3 4 5 6 7 8 9 10 11

R e q u ir e m e n t f o r f lo w lin e f lu s h in g ST
1
id e n tif ie d .

2 D e c id e o n d ir e c t io n o f f lu s h .

3 C h e c k f lu s h in g w a t e r a v a ila b ilit y .

A r r a n g e f o r e n v ir o n m e n t a lly s a f e
4
d is p o s a l/c o n t a in m e n t o f f lu s h in g s .

C h e c k f o r d if f e r e n c e s in e le v a tio n
5 b e t w e e n w e llh e a d s it e a n d d is p o s a l
p o in t.

No
6 W ill o il c o n t a in h ig h le v e ls o f H 2 S ?
Yes

I m p le m e n t H 2 S p r o c e d u r e s f o r
7
h a n d lin g o f s o u r c r u d e .

8 F lu s h f lo w lin e .

C h e c k f lo w lin e f o r r e s id u a l
9
h yd ro c a rb o n s .

F lo w lin e r e a d y t o h a n d o v e r t o
10 E
M a in t e n a n c e / E n g in e e r in g D e p t s .

11

12

13

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15.3 Purging Procedures


This procedure covers the steps necessary in removing and returning
hydrocarbon process equipment to service, such that the occurrence of
explosive gas/air mixtures within the equipment is prevented.
The procedure covers the purging and leak testing of the following
equipment types:
 Separators
 Scrubbers
 Tanks
 Filters and other vessels of a similar size and nature
 Pumps of all types
 Gas compressors of all types
 On-plot pipe work and all associated valves and fittings.

A) Purging procedure of Process Equipment and Vessels: (PR


1073)

De-commissioning:
De-commissioning is the process of removing equipment from service,
draining all hydrocarbons and purging with an inert gas (nitrogen) prior to
allowing air to enter. The following procedure prevents the occurrence of
an explosive mixture of gas and air.

 Ensure that all Permit to Work formalities have been completed, and that a Job
Safety Plan is in place.

 Shut the equipment down.

 Drain as much liquid from the equipment as possible to the drains system, using
any residual pressure to assist the process. If internal jetting systems are installed
(as is the case with some separators) use these to loosen and remove any sludge.
Drain the resulting slurry.

 Once draining is complete, fully depressurise the equipment to the vent header.

 Isolate the main process lines of the equipment (excluding the vent line) in
accordance with PR-1076 and any conditions stipulated on the Work Permit.

 Connect a supply of nitrogen to the equipment. Where the equipment contains


check valves (pipe work, compressors etc.), connect the nitrogen at the upstream
end to allow the whole system to be blown through. The point of connection
should be such that the purge gas will sweep the entire volume of the equipment.

Note:The nature of the nitrogen supply will depend on the size of


the equipment. Cylinders of gaseous nitrogen may be used in most
cases, with liquid nitrogen being required for larger volumes.

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 Blow approximately three times the total volume of the equipment through with
nitrogen, as quickly as the source will allow. The more rapid the sweep, the better
the purge. Where possible, the mixture of gas and nitrogen should be routed to a
remote vent system (particularly in sour installations). In the case of rotating
equipment, bar the rotor over where feasible during the purging.

 Isolate the remaining vent lines of the equipment in accordance with procedure PR-
1076 and any conditions stipulated on the Work Permit.

CAUTION: The equipment is now depressurised and purged with inert gas. However, the
equipment may still contain some residual liquid and/or pyrophoric iron deposits. Due
caution SHALL be exercised when opening the equipment. Where it is known that
pyrophoric iron deposits exist, the equipment SHALL be flooded with water to ensure
that any such deposits are wetted to prevent combustion. Until the deposits have been
removed or the equipment has been returned to service, the deposits SHALL be kept
wet.

 The isolation details SHALL be logged and filed by the Area Co-ordinator, until
the equipment is returned to service.

 The equipment is now ready for maintenance/engineering work under an appropriate


Permit to Work.

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C o n tr o l P r o c e d u r e - A c tiv ity M a tr ix

B u s in e s s P r o c e s s : G a s F r e e in g , P u r g in g & L e a k T e s tin g : D e c o m m is s io n in g

S y m b o ls :

nel
tors
R e tu rn fro m /fo rw a rd

son
tors
A c tiv ity

era
to a n o th e r a c tiv ity

Pe r
a
din

Op
D e c is io n M e e tin g A tte n d e e

ce
M A

oor

tion

nan
aC

duc

inte
Are
ST
C o n tin u a tio n

Pro
E S ta rt/E n d

Ma
No. A b b r e v ia te d A c tiv ity D e s c r ip tio n 1 2 3 4 5 6 7 8 9 10 11

S e le c t e q u ip m e n t to b e ST
1
d e c o m m is s io n e d .

2 C o m p le te P e r m it to W o r k f o r m a litie s .

3 S h u t th e e q u ip m e n t d o w n .

4 D ra in e q u ip m e n t c o m p le te ly .

D e p r e s s u ris e e q u ip m e n t to v e n t
5
h e a d e r.

6 Is o la te th e e q u ip m e n t.

7 C o n n e c t n itro g e n s u p p ly .

P u r g e e q u ip m e n t th o r o u g h ly w ith
8
n itr o g e n .

Y es
9 G a s d e te c te d b y te s tin g ?
N o

10 Is o la te r e m a in in g v e n t lin e s .

11 F ile is o la tio n d e ta ils /p e r m it.

12 E q u ip m e n t re a d y f o r m a in te n a n c e . E

13

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Re-commissioning:

Re-commissioning is the process of purging (air filled) equipment with an inert gas (nitrogen)
and leak testing it in readiness to accept hydrocarbons. The following procedure prevents the
occurrence of an explosive mixture of gas and air.

 Ensure that all Permit to Work formalities have been completed, and
that a Job Safety Plan is in place.

 Ensure that the equipment is fully boxed up and that it is ready to


be re-pressurised.

 De-spade the equipment but keep all lines isolated by means of closed valves (or
seated relief valves).

 Connect a supply of Nitrogen to the equipment. Where the equipment contains


check valves (pipe work, compressors etc.), connect the Nitrogen at the upstream
end to allow the whole system to be blown through. The point of connection
should be such that the purge gas will sweep the entire volume of the equipment.
The nature of the Nitrogen supply will depend on the size of the equipment;
cylinders of gaseous nitrogen may be used in most cases, with liquid Nitrogen
being required for larger volumes.

 Blow approximately three times the total volume of the equipment


through with Nitrogen, as quickly as the source will allow. The more
rapid the sweep, the better the purge. Where possible, the mixture
of air and Nitrogen should be routed directly to the atmosphere via
a local vent. In the case of rotating equipment, bar the rotor over
where feasible during the purging.

 Close the vent and pressurise the equipment to its normal working
pressure or to the highest pressure attainable with the Nitrogen
source (whichever is the LOWER). Check the equipment for leaks.
If any are found, depressurise, repair the leaks and repeat the
pressure test.

 If replacement of gaskets is necessary to arrest a leak, Nitrogen


purging SHALL be repeated, as breaking a line will allow air to enter.

 De-isolate all lines by means of opening valves and carry out a final
visual check to ensure that all spades and blinds have been
removed.

 The equipment is now (partially) pressurised and purged with inert


gas, and may be returned to service.

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C o n tr o l P r o c e d u r e - A c tiv ity M a tr ix

B u s in e s s P r o c e s s : G a s F r e e in g , P u r g in g & L e a k T e s tin g : R e c o m m is s io n in g

S y m b o ls :
R e tu rn fro m /fo rw a rd

rs
A c tiv ity

ors

ato
to a n o th e r a c tiv ity

per
dina
D e c is io n M e e tin g A tte n d e e

nO
M A

oor

tio
aC

duc
Are
ST
E S ta rt/E n d C o n tin u a tio n

Pro
N o. A b b r e v ia te d A c tiv ity D e s c r ip tio n 1 2 3 4 5 6 7 8 9 10 11

S e le c t e q u ip m e n t to b e ST
1
r e c o m m is s io n e d .

2 C o m p le te P e r m it to W o r k f o r m a litie s .

3 B o x u p e q u ip m e n t f u lly .

D e s p a d e e q u ip m e n t. K e e p v a lv e s
4
c lo s e d .

5 C o n n e c t n itro g e n s u p p ly .

P u r g e e q u ip m e n t th o r o u g h ly w ith
6
n itr o g e n .

7 P r e s s u r is e e q u ip m e n t u s in g n itr o g e n .

No
8 D o a n y g a s k e ts le a k ?
Yes

R e p la c e a n y le a k in g g a s k e ts a n d
9
r e p r e s s u r is e w ith n itr o g e n .

10 D e - is o la te a ll lin e s .

11 S ig n o f f P e r m it to W o r k .

12 R e tu r n e q u ip m e n t to s e r v ic e . E

13

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B) Purging of Tanks: ( PR 1079)

De-commissioning:

 Ensure that all Permit to Work formalities have been completed, and
that a Job.

 Safety Plan is in place.

 Prepare spade checklist as per plan.

 Isolate the main process lines of the equipment (excluding the vent
line) in accordance with PR-1076, Isolation of Process Equipment,
and any conditions stipulated on the Work Permit.

 If water is present, raise the interface level to maximum to aid


removal of oil from the tank walls.

 Fill up the tank with water by using the minimum flow line of a
water booster or water injection pump.

 Pump down the liquid to the minimum level and shut the tank
down.

 Produce a steady supply of blanketing gas to the tank. Where


possible, this should be sweet gas to minimise the possibility of H 2S
gas pockets being left inside the tank.

 Pump out as much water as possible.

 Drain as much liquid from the tank as possible to the drains system.
Draining of the tank(s) should be done in accordance with the Plant
Operating Manual(s).

 If internal jetting systems are installed, use these to loosen and


remove any sludge.

 Whenever possible, flood the tank with (produced) water to wash


out as much of the remaining residue as possible (fill to 1 to
2m. height).

 Drain the resulting slurry and use a vacuum truck to remove as


much sludge as possible.

Note 1:Take care when draining to a closed drain system so that no overfilling of the drain
vessel takes place (pump capacity may be exceeded by draining too quickly, resulting in the
system backing up).

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Note 2: SD actions SHALL NOT be overridden when the tank is connected


to the process. However, when the tank is disconnected from the
process, level trips can be over-ridden to prevent nuisance trips of other
equipment. During this period the alarms should remain on line to
provide a warning of overfilling.

 Isolate any cathodic protection systems on the tank to remove


potential ignition (sparking) sources.

 Isolate the vent line and blanket gas line of the tank in accordance
with PR-1076 and any conditions stipulated on the Work Permit and
spade all the lines as per the check list.

 Once full, isolate the vent line and blanket gas line of the tank in
accordance with PR-1076 and any conditions stipulated on the Work
Permit

 Remove the top covers on the tank, open any hatches and install an
air mover on one of the open top covers. Use the air mover to
circulate fresh air through the tank to disperse the blanket gas.
Fogging nozzles should be used where pyrophoric deposits are
known to exist.

 Remove the bottom manhole covers.

Note: If the air supply into the tank becomes blocked during draining,
there is a danger of the tank collapsing.

 Prior to tank entry, test for combustible gas, H 2S (if relevant) and
oxygen levels in accordance with the stipulations made on the
Vessel Entry Certificate (see PR-1154, Gas Testing).

Re-commissioning:

 Ensure that all Permit to Work formalities have been completed, and
that a Job Safety Plan is in place.

 Ensure that the tank is fully boxed up, all instruments and switches
are re-connected and that the tank is ready to be re-commissioned.

 De-spade the tank but keep all lines isolated by means of closed
valves (or seated relief valves - although these should not be relied
upon as isolation valves).

 If feasible, filling the tank should be considered. This can be


achieved using hydrant water or injection water by opening the
pump minimum flow valve. However, in most cases this will not be
possible or may require excessive water and time.

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 Open the blanket gas supply and, if previously filled with water,
drain the tank.

CAUTION: If the blanket gas supply into the tank becomes blocked during draining, there
is a danger of air being drawn into the tank, or of the tank collapsing.

 De-isolate all remaining lines by means of opening valves and carry


out a final visual check to ensure that all spades and blinds have
been removed.

 De-isolate any cathodic protection systems on the tank.

 The tank is now filled with blanket gas, and may be returned to
service.

C) Re-instatement of Gas-Lift Compressor:(e.g. Saih-Rawl Cent.


Compressor)

 Check instrument air supplies available to all instrumentation and


control loops.

 Check Electrical supplies available for all motors, instrumentation


and control.

 Check that fire detection and alarm system for the gas compressor
area is operational.

 Check that all pre commissioning inspections and tests are


completed
Note: the pre commissioning includes Nitrogen purge and leak test
and leaves the system under nitrogen pressure at 250kpa(g).

 Before the initial start-up, Flushing must be carried out and the
initial lube oil charge introduced to the system.

 Run the lube oil pump on circulation till the require temperature of
lube oil achieved.

 Put the main oil pump into operation, set the auxiliary pump on
automatic control.

 Make sure oil cooler and oil filter air lock has been removed by
venting.

 Check the automatic cutting-in of the auxiliary oil pump by


depressurising pressure switch.

 Switch off auxiliary oil pump and set pump start to “Automatic”

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 Verify that:
 Flare system ready for operation.
 Drain system ready for operation.
 Gas system ready for operation.
 Manual gate valves up stream of compressor, down stream
of blow down, intermediate block valves in common drain
header of scrubbers in open position.

 Reset the trip relays(By authorised electrical person)

 Inform the respective powerhouse control room.

 Close the manual gate valve at compressor discharge.

 Reset starts permissive at local panel.


 Blow down valve close.
 Min suction line ESD valve bypass open.

 Start main motor


 Motor fans start automatically.
 Oil cooler fans start automatically
 Process gas cooler fans start after time delay.
 Suction valve opens, and bypass valve closes.
 Discharge valve opens.

 Initiate ESD at local panel (then twist ESD button to reset it)
 Discharge valve closes.
 Isolation valve closes.
 HP section blows down valve opens to HP flare.
 Suction valve closes.
 LP section blows down valve opens to LP flare.

 Check gas composition and repeat flushing cycle as necessary.

 Open manual gate valve at battery limit isolating compressor


discharge line.

 Gas system to be ready for operation. Ensure at least enough


volumes of gas available from bulk separators.

 Set the Suction and Discharge pressure set point to require value.

 Check set point of all scrubber level at 50%.

 Compressor discharge cooler temperature controllers to be set at


60’ C

 Check gas recycles valve of compressor on Auto.

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 Drain the compressor casing and suction low point drain by


operating each manual drain valve. Make sure individual casing
drain valves must be kept closed after raining.

 Wait till pressure between compressor and suction header is less


than 50 kPa.

 Start main Motor


 Oil cooler fans start.
 Motor fans start

 Main Motor is now on line. Verify:


 Process gas cooler fans start.
 Compressor suction valve starts opening 9provided there is
a DP is less than 50 kPa) suction bypass valve closes.
 Compressor discharge valve opens
 Load control system starts ramping up to set point.
 Anti surge valve starts to close

 Compressor is now in Operation. Monitor discharge and suction


pressure.

 After reaching load set point, ADJUST load to required flow and
discharge in accordance with compressor curves.

 Closely observe the change of parameters, and ensure the design


values are being attended when on full load.

 Record operation of compressor by monitoring following


parameters.
Load, Speed, Vibration, pressure/temperature at intermediate and
final stages, bearing temperature, Verify flow of seal gas.

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