isolation of process equipment procedure rev 0.doc

8/13/2019 Isolation of Process Equipment Procedure rev 0.doc

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Isolation of Process Equipment

Document ID PR-1076

Document Type Procedure

Security Unrestricted

Discipline Engineering and Operations

Owner UOP Functional Production anager

Issue Date a! "01"

Revision 6#0


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This document is the property of Petroleum Development Oman, LLC. either thewhole nor any part of this document may !e disclosed to others or reproduced,stored in a retrieval system, or transmitted in any form !y any means "electronic,mechanical, repro#raphic recordin# or otherwise$ without prior written consent ofthe owner.


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i Revision History

The following is a brief summary of the 4 most recent revisions to this document. Details of allrevisions prior to these are held on file by the issuing department.

Revision No. Date Author Scope / Remarks

6.0 May-1 !obin "orman #$%6 &nterim 'mendments incorporated andprocedure aligned with (our &solation%hilosophy. (ee 'ddendum 10 for details

).0 $ct-10 !obin "orman #$%6 *+tensive changes. !efer to 'ddendum ,for changes

4.0 Mar-10 !obin "orman #$%6 !e-issued. !efer to 'ddendum 6 forchanges

1.0 (ept

#$%/1 (&-6 rewritten to new format with minorcomments incorporated.

ii Related Business Processes

Code Business Process (PB! ".#$

*%.,1.0 $perate ells and acilities

iii Related Corporate !ana%ement &rame 'ork (C!&$Documents

The related 2M Documents can be retrieved from the 2M 3usiness 2ontrol %ortal.

2%-11) $perate (urface %roduct low 'ssets 2o%

Reference are included in Appendix 4


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AB) *& C*NNS

i !evision istory....................................................................................................................... 5

ii !elated 3usiness %rocesses....................................................................................................5

iii !elated 2orporate Management rame or 72M8 Documents.........................................5

1 &ntroduction.............................................................................................................................. 6

1.1 3acground........................................................................................................................ 6

1. %urpose............................................................................................................................. 6

1.5 Distribution / Target 'udience...........................................................................................6

1.4 2hanges to the Document.................................................................................................6

1.) (tep-out 'pproval.............................................................................................................. 6

1.6 '9'!%............................................................................................................................... 6

!oles and !esponsibilities....................................................................................................... ,

5 &solation of %rocess *:uipment...............................................................................................

5.1 (cope.................................................................................................................................

5. Terminology.......................................................................................................................

5..1 Ma;or or..................................................................................................................

Table 1 < Minimum &solation !e:uirements......................................................................... 10

5.. Minor or................................................................................................................11

5..5 3attery 9imits.............................................................................................................11

5..4 3aseline &solation (tandard.......................................................................................11

5..) 3oundary &solation.....................................................................................................11

5..6 ydrocarbon (ervices................................................................................................11

5.., a=ardous (ubstance / (ervice.................................................................................11

5.. "on-a=ardous (ervice.............................................................................................11

5.. ( / To+ic (ystem...................................................................................................1

5.5 >uidance "otes for &solation........................................................................................... 1

5.5.1 &ssue of %T to %ermit older..................................................................................1

5.5. %ositive &solation of *:uipment for Maintenance.......................................................1

5.5.5 !emoval and !eplacement of !elief ?alves on @9iveA (ystems................................1

5.5.4 &solation of Moving Machinery...................................................................................1

5.5.) &solation of ?essels....................................................................................................15

5.5.6 &solation of Tans.......................................................................................................15

5.5., &solation of *:uipment 2ontaining (.....................................................................155.5. #se of 3reathing 'pparatus.......................................................................................15

5.5. &mmobilising Devices.................................................................................................15

5.4 >eneral *+ceptions.........................................................................................................14

5.) %recautionary 2onsiderations for &solation......................................................................14

5.6 Typical &solation and De-isolation %rocess...................................................................... 16

igure 1 < %rocess *:uipment &solation %rocess.................................................................16

'ppendi+ 1 < %ositive &solation 'rrangements........................................................................1

'ppendi+ < 'bbreviations..................................................................................................... 5

'ppendi+ 5 < Tan %ressure / ?acuum ?alve 2hangeout......................................................4

'ppendi+ 4 < !eference Material............................................................................................


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'ppendi+ ) - #ser eedbac %age..........................................................................................

'ddendum 1 < 2hanges at !evision .1................................................................................. 50

'ddendum < 2hanges at !evision 5.................................................................................... 51

'ddendum 5 < 2hanges at !evision 5.1................................................................................. 5

'ddendum 4 < 2hanges at !evision 5.................................................................................. 55

'ddendum ) < 2hanges at !evision 5.5................................................................................. 54

'ddendum 6 < 2hanges at !evision 4.0................................................................................. 5)

'ddendum , < 2hanges at !evision ).0................................................................................. 56

'ddendum < &nterim 'mendment May 011........................................................................5,

'ddendum < &nterim 'mendment (eptember 011.............................................................5

'ddendum 10 < 2hanges at !evision 6.0............................................................................... 5


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+ ,ntroduction

+.+ Back%round

henever process plantB e:uipment or systems re:uire to be taen out of service forma;or maintenanceB repair or modificationB then positive mechanical isolations shall beprovided between the process plantB e:uipment or system and any potential ha=ardousenergy source. %ositive Mechanical &solations re:uires the insertion of a spade / blindin the lineB or the removal of a spool 7if re:uired8B @downstreamA of the last tight isolation

valve to physically isolate the potential @energy source.

,!P*RAN- A doule lock and leed0 arran%ement on its o1n is notconsidered positive mechanical isolation 1ithout the insertion o2 a spade /lind.

+.3 Purpose

The purpose of this procedure is to provide a safe and consistent method for theisolation of process e:uipment prior to and during maintenance / modification / repair.

+.4 Distriution / ar%et AudienceThis procedure is intended for use %roduction $perationsB MaintenanceB ell (ervicesB*M2/$D2 personnel and any other parties tased with carrying out the wor re:uiringisolation on e:uipment and systems in %D$.

+." Chan%es to the Document

!esponsibility for the upeep of the Document shall be with the unctional %roductionTeam 9eader #$%B the $wner. 2hanges to this document shall only be authorised andapproved by the $wner.

#sers of the Document who identify inaccuracy or ambiguity can notify the 2ustodianor his/her delegate and re:uest changes be initiated. The !e:uests shall be forwarded

to the 2ustodian using the C#ser eedbac %age provided in this Document.The Document $wner and the Document 2ustodian should ensure review and re-verification of this procedure every 5 years.

+.5 Step6out Approval

This procedure is mandatory and shall be complied with at all times. (houldcompliance with the procedure be considered inappropriate or the intended activitycannot be effectively completed or safely performedB then step out authorisation andapproval must be obtained in accordance with PR-1001e Operations ProcedureTemporary Variance prior to any changes or activities associated with the procedurebeing carried out.

+.7 A)ARP

'9'!% is the acronym for @'s 9ow 's !easonably %racticableA which simplified meansB@reducing the ris to a level at which the cost and effort 7time and trouble8 of further risreduction are grossly disproportionate to the ris reduction achievedA. &ull Complianceto %D$ (tandards and %rocedures is a ey element in achieving '9'!%.

or more details refer toALARP Definition
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3 Roles and Responsiilities

%roduction 2oordinator To be accountable for the isolation7s8 to be carriedout.

'pprove methods for isolations. (pecifying fre:uency of isolation integrity checs 7if

re:uired8.

!esponsible (upervisor 2hec isolations are in compliance with theapproved standard and procedure

&nitiate variance procedure where proposed isolationis out of compliance

'gree isolations with the %ermit 'pplicant &nspect the wor site with %ermit 'pplicant to

identify all ha=ards 7mandatory for 2lass ' permits8

2arrying out integrity checs of isolations 'uthorises %ermit to or 7%T8

%roduction $perator and

'rea 'uthority

%erform or oversee the isolation and sign thenecessary &solation 2ertificate 7Mechanical /*lectrical8

2arryout isolations integrity checs and maintain theisolation records

Maintain the $verride 9og 2arryout or oversee depressurisationB drainingB gas

freeing and gas testing

(upervise the worsiteMaintenance %ersonnel itnessing isolations

%erforming electricalB mechanicalB rotatinge:uipment and ma;or isolations associated with worbeing undertaen

!e:uesting any changes to the approved isolationfrom the !esponsible (upervisor

%ermit to or'pplicant

2ompleting (ection 1 of the %ermit to or2ertificate

2arryout site inspection and identification of ha=ardswith !esponsible (upervisor

'gree the mechanicalB electrical and instrumentoverrides re:uired to carry out the wor with the!esponsible (upervisor

%roduce Eob (afety %lan and specific procedures


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%ermit older 2onducting T!&2 discussions and completing T!&2with personnel carrying out the wor

*nsure that any changes to wor scope or conditionsare captured and implemented before wor isallowed to continue

Maintain safe woring conditions and practices itness and / or apply isolations / overrides with

attendance of the 'rea 'uthority

itness and / or remove isolations / overrides withattendance of the 'rea 'uthority


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4 ,solation o2 Process 8uipment

4.+ Scope

This procedure covers the mandatory administration and mechanical isolation ofprocess e:uipment prior to maintenance or engineering wor.

or ma;or maintenance or engineering wor the minimum re:uirement for processe:uipment shall beF

shut downF

depressurised to atmospheric pressureF

drained and flushed 7if re:uired8F

freed of flammable or to+ic gases

%ositive isolation shall be applied once the above have been completed between anyad;acent systems that mayB or may notB remain live during the wor.

4.3 erminolo%y

3 2 !a9or 'ork%ositive isolation shall be re:uired for all !a9or 'ork. or the purpose of thisprocedure ma;or wor will be considered as any intervention that results in spools ore:uipment being removed from a process line 7including non-hydrocarbons8B 2onfined(pace entryB or ot or 7including cold cutting8 being carried out.

xamples!

Val"e remo"al # replacement $includin% RV c&an%eout'(

)pool remo"al # replacement(

*uipment i+e+ pump, c&an%eout(

Vessels # tan inspectionsG

IMPORTANT NOTE! T&ere may .e exceptions to t&e a.o"e e+%+ relief "al"esc&an%eout, and t&ese s&all .e addressed on an indi"idual .asis after ris assessment+


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ale + : !inimum ,solation Re8uirements

System System Description !a9or 'ork

I System in service, of %SIclass &''( and !elow.

)or flashin# li*uids andto+ic see II !elow.

%ositive isolation by a single provenvalve 7"ote18 and a swung spectacleblind/spade or removable spool 7"ote8.

II System in service, of %SIclass ''( and a!ove.

%ll systems containin#to+ic fluids "ote &$.

Systems containin#flashin# li*uids a!ove%SI &'', "ote -$ i.e.%SI '' and a!ove.

Dou!le !loc and !leed plus aspade/!lind.

/OT 1 Pro"ided t&e line upstream of t&e re*uired isolation is depressurised,drained, flus&ed and &ydrocar.on free t&en a sin%le pro"en "al"e ill pro"ide sufficientisolation for a2or 3or+

NOTE 2 A bleed connection should be installed between the valve andthe spade/blind for line sizes 6" and above. The purpose of the bleed is toestablish that positive isolation is achieved and to provide a means ofdrainin or depressurisin the volume between the isolation valve and thespade/blind.

NOTE ! or the purposes of this re#uirement$ to%ic in the case of &2'is defined as more than ()) ppm &2' in the process stream.

NOTE * The definition of flashin li#uids for the purposes of this Tableis that iven for +at. A fluids in Appendi% , of the - +ode art ($ section.6.0$ table .2.


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3 2 2 !inor 'ork?alved isolation shall be re:uired for all !inor 'ork. or the purpose of this procedureminor wor will be considered as any intervention that does not re:uire spools ore:uipment being removed from a process line 7including non-hydrocarbons8B or wherethere is no ot or.

xamples!

As a pre-cursor for ma2or or(

reain% flan%es for drainin% of depressurised systems(

5nsertion of .linds .eteen flan%es on depressurised systems(

3orin% on instrumentation lines+

/OT! 6or inor or t&e "al"e isolation ill re*uire to .e appropriate to address t&eris i+e+ dou.le .loc and .leed for 78) or pressurised lines, and demonstrated ti%&t+

3 2 3 Battery )imitsThis term is often used loosely with the industry. The word battery is used to representa set of units. or the purpose of this procedure a battery limit is an agreed boundary

surrounding a processing unit or battery of unitsB along with related utilities andservices. Therefore the perimeter of a @3attery 9imitA can form a single boundaryisolation or a number of boundary isolations within the defined limit.

3 2 4 Baseline ,solation StandardThe 3aseline &solation (tandard is the minimum acceptable standard of final isolationfor intrusive and non intrusive maintenance against live plant under normalcircumstances as per the (* guidelinesB"01 2S3 Pu!lication Issue 4'' IS5 '6787687867 The Safe Isolation of Plant and 3*uipment$ This standard is basedupon ris assessment. The 5aseline Isolation Standard shall !e one of thefollowin# two isolation methods9

Positi$e Isolation%is the removal of a spool and fittin# of !linds, or fittin#of a spade or spectacle !lind to allow complete separation of the plant/e*uipment to !e wored on from other parts of the system

Pro$ed Isolation% is a valved isolation where effectiveness of the isolation can beconfirmed via vent/bleed points before breaing into the systemB and for the duration ofthe isolation

3 2 5 Boundary ,solation%n isolation at any location where the defined 5aseline Isolation Standard ismet.

3 2 6 Hydrocaron Services'll systems containing hydrocarbons.

3 2 7 Ha;ardous Sustance / Service' substance or containing a substance which is able to cause harm or damage if lossof containment occurs.

3 2 8 Non6Ha;ardous Service'ny service not classified as ha=ardous.


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3 2 9 H3S / oalves on )ive0 SystemsThe permit applicant shall write a site specific procedure for the removal andreplacement of !elief ?alve7s8 and attach a !is 'ssessment signed by the appropriateauthority. The procedure shall be reviewed and approved by the !esponsible(upervisor and shall be attached to the %T.

%T shall be in accordance with PR-11;8 Permit to 3or(ection 1).6

"o authorisation for the wor shall be given ifG

The system that the relief valve is protecting does not have 100I redundancyF

The relief valve does not have as a minimum a @double bloc and bleedA

arrangement upstream. This includes interloc systemsF

The relief valve is connected to a live vent and flare system that cannot be

isolated by one @demonstratedA tight valve

3 3 4 ,solation o2 !ovin% !achineryMoving machinery is defined here as any e:uipment using e+ternal motive force suchas electricityB airB steam or hydraulic fluid.

The electricalB airB steamB hydraulic or other source of energy to the moving machineryBboth flow and return circuitsB shall be isolated from the drive unit and the drive unit

secured immobile before wor commences.
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&solation of moving machinery from process fluids shall be accomplished by tightvalves and spades or blinds on the e:uipment side of inlet and outlet lines in order thatmaintenance may be carried out while the surrounding facilities remain live. here

( is present in the process stream double bloc and bleed and swung blind is the

minimummandatoryre:uirement.

Machinery braes and brae locs are to be applied and the clutch 7if applicable8 is tobe disengaged.

3 3 5 ,solation o2 >essels

(pades / blinds shall be installed on the downstream side of the inlet bloc

valve and the upstream side of the outlet bloc valve. here practical these

spades / blinds should be mounted directly on the flange. here ( is present

in the process stream double bloc and bleed and swung blind is the minimum

mandatory re:uirement. "on-compliance shall be in accordance with PR-

1001e Operations Procedure Temporary Variance+

/OT! Refer to Ta.le 1 for recommendations re%ardin% isolation re*uirements+

3 3 6 ,solation o2 anks3linds / spades shall be inserted on the tan side of all inlet and outlet bloc valves.These shall be placed as close to the tan as possible. This also applies to blanet /purge gas linesB tan-balancing linesB and vent lines to flare headers and water draw-offlines.

The cathodic protection electrical connections should be isolated to prevent anypossibility of a spar occurring.

Drain sumps should be routed to a closed drain headerB collection tan or suitable openpit 7refer to %!-10,5 (ection.

3 3 7 ,solation o2 8uipment Containin% H3S!eference PR-10;< - 7ydro%en )ulp&ide ana%ement Procedurefor classifications of

( ris.or isolations on e:uipment containing ( a double bloc and bleed system andswung blind is the minimum mandatory re:uirement. ?ariance to this re:uirementshall be in accordance with PR-1001e Operations Procedure Temporary Variance.

or double bloc and bleed systems used on ( service the bleed shall be hard-pipedto a safe disposal location to ensure that it does not create a ha=ard. 'cceptabledisposal routes are to a remote vent or to a plant closed drain system. hen usingclosed drains systems checs shall be made to ensure that reverse flow does not occurin the system.

3 3 8 ?se o2 Breathin% Apparatus

&t is mandatory to wear positive pressure breathing apparatus when breaing flangesand opening e:uipment containing to+ics. This shall be clearly stated under @orDescriptionA on the or %ermit.

'de:uate isolation and purging s&all be proven by a direct measurement 7using gasdetector8 for both hydrocarbons and the to+ic component concerned 7usually (8.urther wor such as opening the e:uipment for inspection will be carried out wearing apersonal ( monitor and escape set. !efer to PR-114< ntry into a =onfined )pacefor conditions allowing entry into a confined space.

3 3 9 ,mmoilisin% DevicesThere are a number of proprietary devices used in the industry for immobilisationBhowever %D$ has standardised with @pro-locA securing device.
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4." =eneral


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108 'ctuated valves shall only be used as part of the positive isolation if the failsafe condition is closed and all motive power to the valve has been physicallydisconnected from the actuator.

'ARN,N=- Reliance on s1itches shall not e acceptale under anycircumstances.

118 Double bloc and bleed arrangements provide positive isolation when used incon;unction with spades or blinds.

here the insertion of spades and blinds in con;unction with double bloc andbleed is considered impractical i.e. not possible to brea containment orsuitable spading and blinding locations not availableB the use of the doublebloc and bleed may be authorised by the %roduction 2oordinator provided avariance is raised in accordance PR-1001e Operations ProceduresTemporary Variance.

or minor worB such as replacing a faulty instrument on a vessel a single@demonstratedA tight valve may be allowed if authorised by the %roduction2oordinator. or to+ic and high pressure applications double bloc and bleedshall be considered a minimum re:uirement. here the piping and valvearrangement of process e:uipment does not allow this to be met a varianceshall be raised in accordance with PR-1001e Operations ProceduresTemporary Variance. &n addition the wor shall be completed during a woringshiftB all valves employed for isolation shall be @demonstrated tightA and the

wor site shall not be left unattended while the wor is in progress.or wor of longer durationor where fittings and accessories remain removedfor an appreciable periodB e.g. overnight or longerB spades or blinds shall beemployed to provide positive isolation.

18 or long term1isolations where a piece of e:uipmentB or a systemB is taen outof service for a considerable periodB e.g. monthsB yet the ad;acent plantremains liveB it is essential that proper records are ept. 7e.g. spade / blind /valve checlist8 and a record ept of the status of the isolation and itscontinuing integrity. This should be carried out on an *+tended %eriod &solationand verified regularly.

(uch isolations shall be audited and checed for integrity at a fre:uencydefined by the %roduction 2oordinator.

158 'll process isolations shall be recorded on the %rocess &solation all.

148 'll electrical isolations must be done in accordance with (%-110 - *lectrical(afety $perational %rocedures.

The most important rule for isolation of e:uipment is @(tic to the %roceduresA. orguidanceB the schematic diagrams in 'ppendi+ 1 should be used for reference totypical isolation arrangements.

1Depending on the type of long term isolation @moth ballingA may be considered.
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4.7 ypical ,solation and De6isolation Process

&i%ure + : Process 8uipment ,solation Process

The following process shall be followed to isolate and de-isolate process e:uipmentprior to and on completion of maintenance / repair / modification wor.

1. The %ermit 'pplicant (hall complete the relevant sections of the %T certificateand define the isolation re:uirements on an 's 3uilt drawing 7%*(8.

The mared up 's 3uilt drawing and the %T shall be submitted to the!esponsible (upervisor.

. The !esponsible (upervisor shall review and discuss the %T and isolation

re:uirements with the %ermit 'pplicant. The positive isolation proposed on themared up 's-3uilt drawing shall comply to this procedure and )P-118> )pecification for t&e 5solation of Process *uipment. here compliance has been
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demonstrated the %T shall be authorised by the !esponsible (upervisor.

5. &solations that do not comply with this procedure shall re:uire to have a varianceraised against them in accordance with PR-1001e Operations ProceduresTemporary Variance. The %roduction (upervisor and the %ermit 'pplicant shallagree the minimum isolation that can be used to address the riss. The !is'ssessment and the variance shall be reviewedB endorsed and authorised by theDT9 and $perations Manager before further wor can be planned.

4. The authorised %T with the mared up 's 3uilt drawing shall be handed to the%ermit older who shall give them to the 'rea 'uthority.

The 'rea 'uthority shall complete the Mechanical &solation 2ertificate from theapproved positive isolation on the 's 3uilt drawing. isolation as detailed on theMechanical / *lectrical &solation 2ertificate authorised by the responsible(upervisor.

,!P*RAN N*G "o %T shall be validated by 'rea 'uthority until there:uired isolation process is completed.

Mechanical isolations that are to be put in place shall be listed on the Mechanical&solation 2ertificate or Mechanical &solation 2ontinuation (heet and attached to the%T. These certificates shall be used to verify that all mechanical isolations havebeen removed.

/OT! lectrical and )afe%uardin% 5nstrumentation isolations are recorded on

separate =ertificates and 6orms and are attac&ed to t&e PT3 accordin%ly+ .

%ositive isolation shall re:uire having spades or blinds / spectacle blinds placedinto the lines. This shall involve breaing pipewor at flanges and shall be recordedin a specific procedure / method study for the wor.

'll precautions and safety points shall be recorded in the (afety %lan before anybreas are made to the system / e:uipment integrity

). The 'rea 'uthority shall witness all gas freeing and gas testing operations.

The wor re:uired to be undertaen can be progressed as soon as the isolation hasbeen establishedB checed and the %T is issued.

The 'rea 'uthority shall validate the %T and hand it to the %ermit older toundertae the wor.

6. &f the e:uipment is re:uired to be test run this should be carried out under a @De-&solation for Test 7DT8 procedureA using the reverse side of the Mechanical and /or *lectrical &solation 2ertificates

,. Depending on the length that the isolations will be appliedB integrity checs shall bedefined. The integrity checs shall be carried out by the 'rea 'uthority and%roduction (upervisor who will ensure that the isolations are correct and intact.

The positive isolation shall be checed before the %T is revalidated.

Any violations shall e reported to Production Coordinator and a 2ountain,ncident raised. he 1ork 1ill e stopped until an investi%ation has eencarried out.

. $n completion of all worsB commissioning and testing the process e:uipment canbe de-isolated5. The de-isolation should be checed off against the Mechanical&solation 2ertificate and the mared up 's-3uilt drawings.

. hen the de-isolation is completed by the 'rea 'uthority the %T can be closedout by the %ermit older.

'll isolated valvesB spadesB blinds etcB shall be tagged with the C5 %art Tag. The ndpart ofthe tag shall be attached to the %T and the 5 rdpart of the tag shall be placed on the %Tboard. The valve spade etcB should be secured with @pro-locA fittings.

5 This includes de-spading and re-instating blinds / spectacle blinds into their operatingpositions.


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Appendi< + : Positive ,solation Arran%ements


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Appendi< 3 : Areviations

The following abbreviations are used in this %rocedure.

'"(& 'merican "ational (tandards &nstitute

2D% 2orporate Discipline ocal %oint

2D 2orporate unctional Discipline ead

DT De-isolated for Test

*%& *+tended %eriod &solation*($% *lectrical (afety $perational %rocedures

92 9oced 2losed

9$ 9oced $pen

"2 "ormally 2losed

"$ "ormally $pen

%*( %rocess *ngineering low (chematic

%D$ %etroleum Development $man 992

%! %rocedure

%T %ermit to or

%?? %ressure ?acuum ?alve

!'M !is 'ssessment Matri+

T!&2 Toolbo+ Tal !is &dentification 2ard


24/39

Appendi< 4 : ank Pressure / >acuum >alve Chan%eout

+. !andatory Re8uirements

- &nventory in the tan shall be reduced to low low level

- &f a second tan is available production shall be lined up to this tan. &f second tanis not available production shall be diverted around the tan

'ARN,N=- ,n sin%le tank operation i2 production cannot e diverted 2rom thetank then the activity shall not e allo1ed to proceed. Similarly@ i2 a spare valve

is not availale@ the activity shall not proceed.

- Tan must be isolated on the inlet in accordance with PR-10;? 5solation ofProcess *uipment

- %ressure in the tan shall be vented to atmospheric via the flare / vent line or viaan atmospheric vent to a safe area

- $perations or wor in the vicinity of the tan shall be suspended for the duration ofthe changeout

- or shall be undertaen in accordance with PR-11;8 Permit to 3or )ystem

- The minimum number of personnel re:uired to undertae the wor safely shall beemployed on or around the tan

- ' T!&2 discussion shall be conducted prior to any wor being commenced and theT!&2 completed and attached to the %T

- &f an unsafe operation is observed or monitored then wor must be stoppedimmediately and the area made safe

3. Precautions to e *served

=as estin%

>as testing shall be carried out in accordance with PR-11>4 @as Testin%

Procedure. 'll gas tests shall be undertaen by authorised gastesters as re:uired by PR-11;8 Permit to 3or )ystem.

Breathin% Apparatus

3reathing apparatus supplied from an e+ternal air source shall be re:uired.

3reathing apparatus may be (elf 2ontained 3reathing 'pparatus 7(23'8B apositive pressure hood supplied from an e+ternal air source or a combination ofthe two.

%rior to use the charges in the air cylinders must be checed and it shall be

ensured that sufficient suppliesB including reservesB are available to completethe wor.

&ire &i%htin% 8uipment

ire services shall be re:uested to be on station for the duration of the wor. &f

this is not feasible then a competent fire fighting team shall be employed to

man fi+ed firefighting e:uipment for the duration of the wor. i+ed and portable fire e:uipment shall be provided both on the tan roof and

at the wor site to enable a fire to be contained.

Sa2ety Harnesses and !an Basket

(afety harnesses and safety ropes shall be provided and issued to the woring

party prior to deployment on the tan roof.

(ecure anchor points for the harnesses shall be identified andmared prior to personnel moving to the tan roof.

' man baset 7intrinsically safe8 shall be provided with rated

lifting strops to evacuate causalities from the tan top inemergency.
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25/39

4. Preparation 2or ?ndertakin% the 'ork

Permit to 'ork

The %ermit 'pplicant and !esponsible (upervisor shall comply with PR-11;8

Permit to 3or )ystemand carryout a site inspection.

The %ermit 'pplicant shall prepare an (* Eob %lan and a !escue %lan which

shall be attached tothe %T.

' mared-up %rocess and *ngineering low (cheme shall be

completed to indicate all isolations.ools and Spares

' new gasetB boltsB nuts and washers shall be procured for the %?? and

bagged ready for use.

(panners and a suitable tor:ue wrench for removing and replacing bolting.

(crappers and brass wire brushes for cleaning and preparing the flange ;oint.

(olvents for cleaning 7D408 may be used provided they are suitable for theapplication. 'bsorbent cloths for cleaning the area and mopping small spills.

'll tools for the wor shall be bagged and a chec list provided to enable

accounting to be carried out on completion of wor.

The replacement %?? shall be checed to ensure it is correct for the

application and has been tested accordingly. The flanges of the replacement%?? shall be protected prior to lifting to the tan top.

Sa2ety 8uipment

The (23'As and air lines for the positive pressure hoods will re:uire to be

carried or lifted to the tan top.

%ersonnel woring on the tan top shall be issued with *mergency *scape

oods for evacuation.

)i2tin% 8uipment

' suitably rated 7)ton8 with sufficient ;ib e+tension will be locatedB preferablyup wind of the operationB on site. (uitably rated slings shall be provided to liftthe old and replacement %?? during changeout.

/OT! @as monitorin% s&all .e carried out .efore startin% t&e crane andcontinuously t&rou%&out t&e operation &en t&e crane en%ine is runnin%+

Permitry

&f the tan is in ( sour service all personnel involved in the operation shall

have an in date ( certificate.

%ersonnel using breathing apparatus 7(23'8 must be certificated.

(23' or positive pressure hoods shall re:uire to be worn by all personnel

woring on the tan top while the operation of changing out the %?? is beingcarried out.

Preliminary 'ork Prior to Removal / Replacement

a8 2lose inlet isolation valve and inlet *(D valve 7if provided8 to the tan that isto be wored on.

b8 Divert the flow to second tan 7if available8 by opening inlet isolation valve onthe receiving tan.

c8 !educe the level in the tan to be wored on to low low level.$verriding of safety critical alarms and trips shall be in accordancewith PR-1001c temporary O"erridin% of )afe%uardin% )ystems

d8 2omplete manual isolation of oil and drain outlet by closing the isolation valveson the tan to be wored on. !ecord the valves and positions on
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26/39

the %*(. #pdate @9oced $pen / 9oc 2losedA register for anynormally 9oced $pen / 9oced 2losed valves that are used.!efer to PR-10


27/39

.uild up due to temperature c&an%e can .e "ented safely $)ee5llustration .elo'+ A documented ris assessment s&all .e carried out ift&is met&od is employed+ T&e ris assessment s&all ensure t&at re%ularmonitorin% of t&e pressure %au%e and "entin% is carried out .yoperations for t&e duration t&at t&is flan%e is in place+

n8 !eplace the bolting and tor:ue down to specified tor:ue. (ee arningfollowing (tep i8.

o8 2arryout a gas test around the completed ;ob to ensure tightness.!epeat thegas test at intervals as woring pressure is established and when thetan is at normal operating pressure.

p8 2hec and confirm all tools are accounted for. 9ift and remove old %?? from

the tan top to the 2anter.:8 2arefully lift all remaining e:uipment from the tan top and secure the site.

r8 and the tan bac to $perations personnel to de-isolate and commission.


28/39

Appendi< " : Re2erence !aterial

PD* Documents

Code o2 Practice

=P-11> - Operate )urface Product 6lo Assets

Speci2ication

)P-110< - lectrical )afety Operatin% Procedures

)P-118> - 5solation of Process *uipment )pecification

)P-8080 - 6lan%e =onnections olt Tor*uin% and Tensionin%

Procedure

PR-1001e Operations Procedure Temporary Variance

PR-10;B - @as freein% and Pur%in% of Process *uipment $excludin% tans'

PR-10;; - Preparation of Tans and Vessels for 5nternal 3or

PR-10


29/39

Appendi< 5 6 ?ser &eedack Pa%e

PR6+#7 : ,solation o2 Process 8uipment ?ser &eedack Pa%e

'ny user who identifies an inaccuracyB error or ambiguity is re:uested to notifythe custodian so that appropriate action can be taen. The user is re:uestedto return this page fully completedB indicating precisely the amendment7s8recommended.

Name-

Re2 ,D Date-

Pa%e Re2- Brie2 Description o2 Chan%e Re8uired and Reasons

?*P

Custodian o2 Document Date-


30/39

Addendum + : Chan%es at Revision 3.+

Pa%e No. Chan%es / Additions

(ection 1. < 2hanged to CT&is procedure is mandatory and s&all .e complied it&at all times+ )&ould compliance it& t&e procedure .e considered inappropriate ort&e intended acti"ity cannot .e effecti"ely completed or safely performed, t&en stepout aut&orisation and appro"al must .e o.tained in accordance it& PR-1001e Operations Procedure Temporary Variance $supported .y Ris Assessment', priorto any c&an%es or acti"ities associated it& t&e procedure .ein% carried out.

(ection . - (wim 9ane (tep < 2hanged @flowlineA to @e:uipmentA

10 (tep , ndpara changed to CAll isolations t&at are to .e put in place s&all .e listedeit&er on t&e PT3, on t&e ec&anical 5solation =ertificate or ec&anical 5solation=ontinuation )&eet+ 5f t&e latter to are used t&ese s&all .e attac&ed to t&e PT3+T&ese certificates re*uire to .e "erified &en t&e isolations are remo"ed+

10 (tep 1stpara added after production (upervisor Cand t&e person &o is deemedcompetent to perform t&e isolation

ootnote added

10 (tep nd para changed to CAny "iolations s&all .e reported to Production=oordinator and a fountain 5ncident raised+ T&e or ill .e stopped until an

in"esti%ation &as .een carried out+11 (ection .5 (tep , < %roduction 2oordinator changed to %roduction (upervisor

1 (ection .5 (tep 15 9ast (entence C5n t&is e"ent, t&e procedure to .e folloed ill.e clearly illustrated and a 9step out: raised supported .y a Ris Assessment inaccordance it&%!-1001e < $perations %rocedures Temporary ?ariance.

1 (ection .5 (tep 14 1st para added to end CT&is s&ould .e carried out on anxtended Period 5solation and "erified re%ularly.

15 Remo"ed /ote 86or t&e purposes of t&is re*uirement, toxic in t&e case

of 78) is defined as more t&an >00ppm 78) in t&e process stream+

1) (ection .4.6 CTo+ic changed to C(our


31/39

Addendum 3 : Chan%es at Revision 4


6 (ection 1.1 following added

C'pproved @?ariancesA that have been !is 'ssessed shall be added whenappropriate in the 'ppendices of this procedure to enable infre:uent activities thatcan not meet compliance to this procedure to be undertaen. These approvedvariances shall be added and $perations notified by circular.

,!P*RAN- The 'pproved ?ariances are for the activities stated. $therinstances where compliance can not be met shall still re:uire the completion of aTemporary ?ariance in accordance with PR-11e ! Operations Pro"ed#reTemporary $arian"e

, (ection 1.6 removed and the 'bbreviations added to 'ppendi+

, !oles and !esponsibilities < %ermit older added Cpausing the wor at regularintervals to chec if any aspect 7affecting safe woring8 of the wor has changed

ootnote added C'll and Cblinds

10 (tep 10 added C&f the e:uipment is re:uired to be test run this should be carriedout under a @De-isolation for Test 7DT8 procedureA using the reverse side of themechanical &solation 2ertificate

'ppendi+ 5 - Tan %ressure / ?acuum ?alve 2hangeout procedure added

#ser eedbac %age moved to 'ppendi+ 4

5 'ppendi+ 5 Tan %ressure ?acuum ?alve 2hangeout


32/39

Addendum 4 : Chan%es at Revision 4.+


10 (tep 10 < 9ast para changed

C&f the e:uipment is re:uired to be test run this should be carried out under a @De-&solation for Test 7DT8 procedureA using the reverse side of the Mechanical and / or*lectrical &solation 2ertificates

15 'dded under (ection .4. - &solation of *:uipment for Maintenance

C9oced $pen / 9oced 2losed valves that are operated during isolation shall berecorded on the 9oc $pen / 9oced 2losed !egister.

14. 'dded (ection .4. < &mmobilising Devices

5 'ppendi+ 5 Tan %ressure ?acuum ?alve 2hangeout


33/39

Addendum " : Chan%es at Revision 4.3


(tep 1 '!"&"> < CSimilarly@ i2 a spare valve is not availale@ the activity shouldnot proceed. added

4-) )tep 4 after $n'

/OT! 5f t&e replacement of t&e PVV is &alted due to dama%e of misali%nment t&at illcause delay, a flan%e can .e fitted pro"idin% it is fitted it& a lo ran%e pressure %au%e

to monitor a pressure .uild up+ 5n con2unction it& t&e pressure %au%e, a tee piece it& a"al"ed "ent facility s&ould .e fitted, it& t&e "ent to a safe area or flare system so t&atany pressure .uild up due to temperature c&an%e can .e "ented safely $)ee 5llustration.elo'+ A documented ris assessment s&all .e carried out if t&is met&od is employed+T&e ris assessment s&all ensure t&at re%ular monitorin% of t&e pressure %au%e and"entin% is carried out .y operations for t&e duration t&at t&is flan%e is in place+


34/39

Addendum 5 : Chan%es at Revision 4.4


4 !elated 2orporate Management rame or 72M8 Documents

'dded (%-00 to !eference Documents

5 'ppendi+ 5 - Tan %ressure / ?acuum ?alve 2hangeout < 4 !emoval and !eplacementadded / rewordedG

i8 #nbolt using the appropriate spanners.'ARN,N=- As the tank 1ill still contain hydrocarons the operation o2 re6oltin% on completion 1ill constitute hot6oltin%0 and 1ill re8uire theApproval o2 the Production Coordinator in accordance 1ith SP63#3# 6&lan%e Connections Bolt or8uin% and ensionin% Section +#.

s8 !eplace the bolting and tor:ue down to specified tor:ue. (ee arning following(tep i8.


35/39

Addendum 7 : Chan%es at Revision ".#


6 (ection . < (tep 6

C&solations that have been classified @ma;orA shall re:uire having spades or blinds /spectacle blindsplaced into the lines strategically to provide positive isolation. This shallinvolve breaing pipewor at flanges and should be covered in a specific procedure /method study for the wor and will re:uire an isolation to do the wor.

6 (ection . < (tep 6

C'll isolations that are to be put in place shall be listed on the Mechanical &solation2ertificate or Mechanical &solation 2ontinuation (heetand attached to the %T. Thesecertificates re:uire to be verif ied when the isolations are removed.

15 2hanged wording of .4. 1stpara @The permit applicant shall apply a process isolationfor every piece of e:uipment to be isolated from live plant describing the connectionsthat will be isolatedB disconnected and tagged before starting to open the e:uipment.The isolation shallbe reviewed by the 'rea 'uthorityB approved by the !esponsible(upervisor and attached to the %T.A

15 'dded new (ub-(ection .4.5 < !emoval and !eplacement of !elief ?alves on @9iveA(ystems.

'll following (ub-(ections renumbered.

1) (ection .4.

CThere are a number of proprietary devices used in the industry for immobilisationBhowever %D$ has standardised with @pro-locA securing device


36/39

Addendum : Chan%es at Revision 5.#


6 (ection 1.1 < &ntroduction

!educed the content to mae it concise and remove any source of ambiguity.

6 (ection 1.5 < Distribution and Target 'udience

'dded @ell (ervicesB *M2 and $D2A

(ection < !oles and !esponsibilities

Made additions and changes to %roduction 2oordinatorB %roduction (upervisorB $peratorand 'rea 'uthorityB and %ermit older

10 !emoved the word @%rocedureA from (ection 5 heading

!evised e+tensively the whole section and re-organised the order.

&nclusion of more specific te+t to cover ( operations

Typical &solation and De-isolation %rocess moved to (ection 5.4. %rocess flow chartrevised

1 'ppendi+ 1 all illustrations revised to show isolation re:uirement updates.

4 'ppendi+ 5 < 2hanges made to enhance safety when undertaing the procedure.


37/39

Addendum : ,nterim Amendment !ay 3#++


15 'dded (ection 5.5 >eneral *+ceptions

C'ny proprietary insertion or e+traction device e.g. eler/ 2$('(2$ retrievableprobesB Daniel $rifice 2arriers etcB used on @sweet systemsA up toB and inclusive ofB00J rating shall be allowed e+ception to the isolation re:uirements of this procedure.

/OT! T&is exception s&all .e alloed pro"ided t&e desi%n of t&e fittin%s is not

modified or c&an%ed and t&at re%ular maintenance and inspection is carried out+


38/39

Addendum : ,nterim Amendment Septemer 3#++


10 L 11 'dded (ection 5.1.1 Ma;or or L 5.1. Minor or

%ositive isolation shall be re:uired for all !a9or 'ork. or the purpose of thisprocedure ma;or wor will be considered as any intervention that results in spools ore:uipment being removed from a process line 7including non-hydrocarbons8B2onfined (pace entryB or ot or 7including cold cutting8 being carried out.

xamples!

Val"e remo"al # replacement $includin% RV c&an%eout'(

)pool remo"al # replacement(

*uipment i+e+ pump, c&an%eout(

Vessels # tan inspectionsG

IMPORTANT NOTE! T&ere may .e exceptions to t&e a.o"e e+%+ relief "al"esc&an%eout, and t&ese s&all .e addressed on an indi"idual .asis after risassessment+

?alved isolation shall be re:uired for all !inor 'ork. or the purpose of thisprocedure minor wor will be considered as any intervention that does not re:uirespools or e:uipment being removed from a process line 7including non-hydrocarbons8B or where there no ot or.

xamples!

As a re-cusor for ma2or or(

reain% flan%es for drainin% of depressurised systems(

5nsertion of .linds .eteen flan%es on depressurised systems(

3orin% on instrumentation lines+

/OT! 6or inor or t&e "al"e isolation ill re*uire to .e appropriate to address t&eris i+e+ dou.le .loc and .leed for 78) or pressurised lines, and demonstrated ti%&t+


39/39

Addendum +# : Chan%es at Revision 7.#


'dded (ection 5. Terminology. 'll subse:uent (ections renumbered accordingly.

!evised Table 1 < Minimum &solation !e:uirements in line with (our %ro;ects &solation%hilosophy