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E-C.2.4-HQ-PRO-001 Process and Mechanical Valving and Isolation Philosophy
E-C.2.4-HQ-PRO-001 Process and Mechanical Valving and Isolation Philosophy
Document Class
Procedure
Main Document
Regulation Title
Objective
Specifies the minimum requirements for a Process/Mechanical Valving & Isolation, with
specific consideration for design.
Target Group
OMV E&P GmbH and all its subsidiaries where OMV is shareholder of developed
and/or producing assets as well as Petrom S.A. E&P.
Editor:
EP-F
Org. Unit
Wiston Rodriguez
First- Last Name
Signature
Date
G. Williamson
First- Last Name
Signature
Date
S. Lens
First- Last Name
Signature
Date
N. Whatson
First- Last Name
Signature
Date
Effective as of:
1 July 2014
Date
In the interests of simplicity and readability, the language of this statement is gender neutral to the extent possible.
Where applicable, the masculine includes the feminine. Print-out is only valid on the date printed. Check for the latest
version in the Regulations Platform. In case of conflict, the document in its Master Language must be applied.
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Contents
1. INTRODUCTION................................................................................................................. 3
1.1. Scope and Applicability .............................................................................................. 3
1.2. Purpose ........................................................................................................................ 3
1.3. Definitions ................................................................................................................... 4
1.4. Abbreviations .............................................................................................................. 4
2. ISOLATION METHODS ...................................................................................................... 5
2.1 Methods ....................................................................................................................... 5
2.2 Positive Isolation ......................................................................................................... 5
2.3 Valve Isolation ............................................................................................................. 6
2.3.1 Double Block & Bleed (DB&B) ................................................................................ 6
2.3.2 Single Block & Bleed (SB&B) .................................................................................. 7
2.3.3 Single Block (SB) & Double Block (DB) .................................................................. 7
2.4 Valve Isolation Selection ............................................................................................ 7
2.5 Securing Valve Position .............................................................................................. 8
3. STANDARD BLOCK VALVE SELECTION .......................................................................... 9
4. SYSTEM VALVING AND ISOLATION ............................................................................... 9
4.1 Venting / Depressuring ............................................................................................. 10
4.2 Draining ..................................................................................................................... 10
5. EQUIPMENT ISOLATION ................................................................................................ 11
5.1 Pressure Vessels ....................................................................................................... 11
5.2 Atmospheric Tanks and Vessels .............................................................................. 12
5.3 Pumps ........................................................................................................................ 12
5.4 Compressors ............................................................................................................. 12
5.5 Heat Exchangers ....................................................................................................... 13
5.6 Heater Treaters.......................................................................................................... 13
5.7 Engineered Package Units........................................................................................ 13
5.8 Pig Launchers and Receivers ................................................................................... 13
6. INSTRUMENT ISOLATION .............................................................................................. 14
6.1 Level Instrumentation ............................................................................................... 14
6.2 Pressure Instrumentation ......................................................................................... 14
6.3 Control Valves ........................................................................................................... 14
6.4 Relief Valves .............................................................................................................. 14
7. TEMPORARY VS. PERMANENT ARRANGEMENTS ...................................................... 15
8. SUPERSEDED REFERENCE COMPANY STANDARDS .................................................. 15
9. EXAMPLES OF TYPICAL ARRANGEMENTS .................................................................. 16
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1.
INTRODUCTION
1.1.
Deviations from this philosophy are allowed provided they are discussed with the
relevant Technical Authority, do not compromise safety and are cost justified.
1.2.
Purpose
The main drivers/priorities followed within this standard, in order of precedence:
Production
Cost
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1.3.
Definitions
Where the terms Shall, Must, Should and May have been used within this
document they have the following meanings:
Shall and Must mean that the action described is mandatory.
Should means that the action described is strongly recommended.
May means that the performance of the action is discretionary
Valve Isolation
Provision of valving to isolate a system or item of equipment. Normally provided
such that positive isolation can be established.
Secure isolation
Isolation that once made will not be rendered ineffective by careless or inadvertent
action.
Positive isolation
Isolation by means of a fixed barrier, such as a spade, spectacle blind or removable
spool piece and associated blind flanges.
Severe Service
The following will be considered "Severe Services" for the purposes of this
philosophy:
1.4.
a)
b)
c)
Non hydrocarbon systems at class ANSI 600 # flange rating and above.
d)
Abbreviations
BDV
DB
Double block
DB&B
E&P
SB
Single Block
SB&B
P&IDs
LO/LC
ICSS
ILO/ILC
H2S
Hydrogen Sulfide
NRV
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2.
PSV
SDV
Shutdown Valve
ISOLATION METHODS
2.1
Methods
Positive Isolation
The most secure valve isolation is provided by DB&B. Valve isolation is only secure under
supervision and for short time periods, typically a single shift. Its principal purpose is to
ensure that positive isolation can be safely achieved. Where necessary, positive isolation
will be provided to ensure secure isolation (to eliminate the risk of human error).
Generally, where it will take less time to do the job than to fit positive isolation (where
positive isolation would otherwise be required, e.g. level instrument bridle on a vessel)
then it is acceptable to use DB&B (see Table 2).
2.2
Positive Isolation
Positive isolation can be achieved by use of either of the following methods:
Removal of piping spool piece or valve and installation of fully rated blind
flanges to exposed ends of pipe/valves.
Single block valves used for fill, vent and drain on process systems and
equipment will be fitted with fully rated blind flanges.
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All vessels requiring entry will have the facility for installing a spectacle
blind or removable spool as close to the vessel as possible to ensure
positive isolation. Where the vessel forms part of a process train then it is
acceptable to provide positive isolation at the train boundary limits. If,
however, a process train has multiple connections to flare or other utilities
then a vessel may require dedicated isolation for these connections.
All hydrocarbon handling equipment will have the facility to be isolated
with a spectacle blind or removable spool. Wherever the Piping Material
Specification permits, spectacle blinds should be used in preference to
spades (if spades are used they shall be fully rated and certified).
Positive isolation shall also be considered to allow hydrostatic testing and
commissioning of parts of piping and systems while further hookup/construction activities continue.
Vents, drains and purging facilities will be provided as necessary to check
that the section of line is free from pressure and fluids before breaking
containment.
The selection of spectacle blinds or spade and spacers is size and rating
dependent and shall be in accordance with the relevant piping
specification.
2.3
Valve Isolation
Appropriate valve isolation will be provided, where required, to enable installation
and removal of positive isolation with minimum impact to remainder of the plant.
Shut down valves may be used as one of the block valves of a DB&B arrangement
provided that the isolation is not required frequently and the shutdown valve
actuator is disabled to prevent inadvertent valve opening.
There are various methods of valve isolation. Each type of isolation is briefly
described below in descending order of security.
2.3.1
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2.3.2
Single block and bleed will be used for severe services, ANSI 300 #, to
enable positive isolation to be made by swinging a blind.
2.3.3
2.4
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TABLE 1
Non-Hazardous
Utilities
Fresh/Potable Water
Cooling Medium
Plant/Instrument Air
Firewater
Seawater
Hazardous Utilities
Inert Gas
Fuel Gas
Heating Medium
Chemicals
Glycols
Methanol
Hydraulic Oil
Diesel
Hot Oil
Process Fluids
Hydrocarbon - Gas
Hydrocarbon - Liquid
Produced Water
The following table gives guidance on valve isolation selection for various fluid
classifications and operating pressures:
TABLE 2
Fluid
Operating Pressure
Barg
Rating
Valving to
install
positive
isolation
Valving to
work w/o
positive
isolation
NonHazardous
Utilities
< 20
150 #
SB
SB
20 - 55
300 #
SB&B
DB&B
Hazardous
Utilities
< 20
150 #
SB
SB *
20 - 55
300 #
SB&B *
DB&B *
> 55
600 #
DB&B *
DB&B *
< 20
150 #
SB&B *
SB&B *
20 - 55
300 #
SB&B *
DB&B *
> 55
600 #
DB&B *
DB&B *
Process
Fluids
Category
Also provision of facilities for a pressure build-up test and regular monitoring of isolation.
Continuous gas monitoring is required where there is a potential for hazardous gas
leakage.
From the above table, as a general quick rule, all systems ANSI 600 # and higher
shall be considered with DB&B valving arrangements for isolation.
2.5
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Securing the valve position may be achieved by one of the following methods:
Interlocked (ILO/ILC)
Any isolation must achieve and maintain effective containment. If positive
isolation is not utilised, isolation valves should be locked or otherwise
immobilised to prevent unauthorised operation.
3.
1.
2.
If an ESD valve is used for isolation, the actuator must be disabled or locked
to prevent inadvertent valve opening.
3.
Blowdown lines shall be isolated from the flare header with a LO manual
isolation valve.
4.
Multiple relief valves for vessels and systems will have LO isolation valves
on all the duty relief valves. The spare relief valve shall have the upstream
valve LC and the downstream LO.
5.
Isolation valves upstream of single relief valves are not allowed. They will
be provided downstream of single relief valves and will be LO.
6.
7.
8.
4.
Piping bleeds, vents and drains on utilities, produced water and gas
systems, shall be " gate valves. Drains on oil systems shall be 2 (for
viscous fluids minimum 1).
In general the use of butterfly valves shall be avoided (due to risk of passing
or leak).
Full bore valves shall be applied for isolation valves if PSVs, BDVs and for
piggeable lines.
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Any valve used for isolation must provide a reliable positive seal. Check valves are not
considered as block valves.
Depressuring, draining, venting and purging requirements shall be considered in
conjunction with isolation. Adequate facilities must be provided to ensure safe
depressurization and drainage, including facilities to check the isolation prior to breaking
line containment.
4.1
Venting / Depressuring
All vessels shall be fitted with a valved and blanked vent connection to atmosphere
for maintenance. This connection may be located directly onto the vessel or onto
the gas outlet upstream of the vessel positive isolation. It may be utilized as part of
inert gas purging of the vessel but not for the depressurization which is provided
by additional connections to the flare/vent system.
Generally pressure vessels shall be supplied with a 6 nozzle fitted with a 2 valve.
The 6 nozzle provides an adequate size for vapour exhausting or forced draught
ventilation.
Blowdown facilities (where provided) will be used for primary depressurization.
Manual depressuring connections shall, as a minimum, consist of a normally
closed globe valve downstream of a normally closed ball valve.
Valving for a typical blowdown arrangement is shown in the sketch below. The
restriction orifice and downstream valve and expander are close coupled to avoid
choking through the valve.
min.
BDV
FB
FO
FB
CSO
FO
Process spec. Flare spec.
4.2
Draining
Providing that the Closed Drain Drum is set below the level of the vessel being
drained then all pressurized equipment shall be depressurized prior to draining.
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To Closed Drain
Spec. break.
Any piping specification break between the system and drain header will be on the
downstream flange of the downstream isolation valve. The isolation valves and
downstream piping shall be suitable for the lowest temperature that can be
obtained while draining.
Since all vessels should be first depressurized to flare, no pressure draining is
required and valves can be gate or ball valves.
Frequent drainage, say once per shift or more, of atmospheric or non-hydrocarbon
systems will require permanent drain connections routed to the open drains
system via a single isolation valve and a drip tray or tundish. Other atmospheric or
non-hydrocarbon systems will be provided with a single isolation valve and blind
flange.
5.
EQUIPMENT ISOLATION
5.1
Pressure Vessels
Pressure vessels are low maintenance items of equipment and therefore, where a
vessel is in a process train, isolation of the train is sufficient. Specific vessels that
are common to the overall process facilities, e.g. flare drums, require a total
shutdown of the facility before maintenance.
Positive isolation is required for vessel entry. All positive isolation should be
located on or as close as possible to the vessel. Where inlet or outlet piping is
manifolded, such as to be connected to more than one nozzle, a single positive
isolation method located at the manifold isolation valve is acceptable rather than
positively isolating each vessel nozzle, provided it is clearly visible from the vessel.
Positive isolation of a relief valve discharging to a closed system shall be achieved
with a removable spool.
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5.2
Vent Header
Blanket Gas
positive isolation:
Liquid outlet on tanks which have sizes 12 and below shall have no spectacle
blind. Isolation can be achieved by springing the line and inserting a blind or
isolation by removing a spool at the pump suction. Liquid outlets 14 and above
shall have a ring spacer.
5.3
Pumps
Removable piping spool pieces shall be provided for maintenance purposes on the
suction and discharge nozzles of each pump. Blind flanges shall be fitted on
suction and discharge piping when spools are removed. Pump casings shall be
fitted with vent and drain connections. If the pump's inventory is significant and/or
contains liquid with a vapour pressure greater than atmospheric at maximum
operating temperature, casing vents and drains shall be hard-piped to the
flare/vent and closed drain systems respectively. Otherwise the vent and drain
connections shall be valved and fitted with a blind flange.
5.4
Compressors
Facilities shall be provided to positively isolate individual compression trains from
all sources of hydrocarbons in order to allow maintenance whilst production
continues. This isolation will include all equipment relating to the compression
train (i.e. suction scrubbers and aftercoolers etc.) provided that production can be
maintained. For compressors on common driveshafts, no maintenance isolation is
required among the different compression stages. Casing vents and drains are
provided as necessary by the compressor supplier.
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5.5
Heat Exchangers
To facilitate the removal of the exchanger tube bundles and plates for inspection
and cleaning, spool pieces will be provided as positive means of isolation as
appropriate. Vents and drains will be provided from the associated pipework,
wherever possible, and will be hard piped, where appropriate, to permit safe
depressurization and draining prior to maintenance. Chemical clean-out
connections, if required, will be provided on the required side of the exchanger,
between the exchanger and isolation blind.
5.6
Heater Treaters
Isolation for Heater Treaters shall be the same as pressure vessels (see section 5.1)
5.7
5.8
Closed Drains
Any local vent shall be fitted with a block valve and vented to a safe
location.
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6.
INSTRUMENT ISOLATION
6.1
Level Instrumentation
Unless the vessel can be taken out of service without affecting production or
essential services, on line maintenance of level instruments shall be enabled by
providing isolation from their associated vessel in accordance with tables on
section 2.3. It shall be acceptable to use the train isolation capability of parallel
equipment to avoid installation of double block and bleed valves on level
instruments within the trains.
All instruments and standpipes shall be fitted with vents and drains. Instrument
drains shall be combined where location permits, to reduce the number of valves
required. Level instruments on vessels in other (i.e., non-hazardous) services shall
have a single drain valve and blind flange only.
6.2
Pressure Instrumentation
All pressure instrumentation piping connections in hydrocarbon service (other than
diesel) shall be provided with a SB&B or DB&B depending on the pressure rating.
All diesel system and non-hydrocarbon system connections up to and including
300lb rating shall have a single valve isolation.
6.3
Control Valves
Where a control valve is provided with a bypass, a single isolation valve will be
provided on each side of the control valve together with a vent or drain. For fail
closed valves, drain connections shall be installed on each side of the control valve
inside the block valves. For fail open or fail in position valves, a drain valve shall be
provided on the upstream side of the control valve only.
For control valves rated 600# and above and for which on line maintenance is
required, double block and bleed shall be provided.
Additionally, where potential for scale formation exists (downstream heating
equipment), the provision of injection and drain valves around control valves
should be considered, to allow cleaning on-line.
6.4
Relief Valves
Relief valves require to be inspected at regular intervals to ensure safe operation
and may require replacement if they leak. Changing out a relief valve, if no spare
relief valve is provided, will require the protected equipment/system to be taken
out of service.
Where removing equipment from service results in a severe loss of production,
this is considered undesirable. To avoid this all relief valves on equipment that is
critical to continued plant operation are spared.
Spared Relief Valves
Maintenance of spared relief valves will generally be undertaken during shutdown
periods and therefore single isolation valves upstream and downstream of the
relief valves are adequate for isolation. Alternatively, on line PSV changeout may
be undertaken provided the upstream operating pressure is below the guidelines
set out in tables on section 2.3. Spared relief valve arrangements shall be as below.
Maintenance of spared relief valves will generally be undertaken during shutdown
periods and therefore single isolation valves upstream and downstream of the
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relief valves are adequate for isolation. Alternatively, on line PSV changeout may
be undertaken provided the upstream operating pressure is below the guidelines
set out in tables on section 2.3.
Sets of multiple relief valves which include a spare relief valve shall have CSO
valves to ensure that at least one PSV is always open to the flare. Operating
procedure shall be implemented to ensure this is accomplished. Interlocked valves
may be considered on a case by case basis.
PSV
PSV
To Flare
CSO
LO
LO
CSO
CSO
LO
CSC
LC
RS
7.
8.
TO-HQ-02-134-00
TO-HQ-02-034-00
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9.
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