PR-1076 - Isolation of Process Equipment Procedure

Petroleum Development Oman L.L.C.
Isolation of Process Equipment
Document ID PR-1076
Document Type Procedure
Security Unrestricted
Discipline Engineering and Operations
Owner UOP Functional Production Manager
Issue Date May 2012
Revision 6.0
Revision: 6.0
Petroleum Development Oman LLC Effective: May-12
This page was intentionally left blank
This document is the property of Petroleum Development Oman, LLC. Neither the whole nor any part
of this document may be disclosed to others or reproduced, stored in a retrieval system, or
transmitted in any form by any means (electronic, mechanical, reprographic recording or otherwise)
without prior written consent of the owner.
Page 2 PR-1076 - Isolation of Process Equipment Printed 14/07/17

The controlled version of this CMF Document resides online in Livelink. Printed copies are UNCONTROLLED.
Revision: 6.0
i Document Authorisation
Authorised For Issue May 2012

Revision: 6.0
ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.
Revision No. Date Author Scope / Remarks

6.0 May-12 Robin Norman UOP6 Interim Amendments incorporated and
procedure aligned with Sour Isolation
Philosophy. See Addendum 10 for details
5.0 Oct-10 Robin Norman UOP6 Extensive changes. Refer to Addendum 7
for changes
4.0 Mar-10 Robin Norman UOP6 Re-issued. Refer to Addendum 6 for
changes
1.0 Sept UOP/1 SI-26 rewritten to new format with minor
98 comments incorporated.
iii Related Business Processes

Code Business Process (EPBM 4.0)
EP.71.02 Operate Wells and Facilities
iv Related Corporate Management Frame Work (CMF)

Documents
The related CMF Documents can be retrieved from the CMF Business Control Portal.
CP-115 Operate Surface Product Flow Assets CoP
Reference are included in Appendix 4

Revision: 6.0
TABLE OF CONTENTS
1 Introduction........................................................................................................................... 7
1.1 Background..................................................................................................................... 7
1.2 Purpose........................................................................................................................... 7
1.3 Distribution / Target Audience.......................................................................................... 7
1.4 Changes to the Document............................................................................................... 7
1.5 Step-out Approval............................................................................................................ 7
1.6 ALARP............................................................................................................................. 7
2 Roles and Responsibilities.................................................................................................... 8
3 Isolation of Process Equipment........................................................................................... 10
3.1 Scope............................................................................................................................ 10
3.2 Terminology................................................................................................................... 10
3.2.1 Major Work.............................................................................................................. 10
Table 1 Minimum Isolation Requirements............................................................................11
3.2.2 Minor Work.............................................................................................................. 12
3.2.3 Battery Limits.......................................................................................................... 12
3.2.4 Baseline Isolation Standard....................................................................................12
3.2.5 Boundary Isolation.................................................................................................. 12
3.2.6 Hydrocarbon Services.............................................................................................12
3.2.7 Hazardous Substance / Service..............................................................................12
3.2.8 Non-Hazardous Service.......................................................................................... 12
3.2.9 H2S / Toxic System.................................................................................................. 13
3.3 Guidance Notes for Isolation......................................................................................... 13
3.3.1 Issue of PTW to Permit Holder...............................................................................13
3.3.2 Positive Isolation of Equipment for Maintenance....................................................13
3.3.3 Removal and Replacement of Relief Valves on Live Systems.............................13
3.3.4 Isolation of Moving Machinery................................................................................14
3.3.5 Isolation of Vessels.................................................................................................14
3.3.6 Isolation of Tanks.................................................................................................... 14
3.3.7 Isolation of Equipment Containing H2S...................................................................14
3.3.8 Use of Breathing Apparatus....................................................................................15
3.3.9 Immobilising Devices..............................................................................................15
3.4 General Exceptions....................................................................................................... 15
3.5 Precautionary Considerations for Isolation....................................................................15
3.6 Typical Isolation and De-isolation Process....................................................................17
Figure 1 Process Equipment Isolation Process...................................................................17
Appendix 1 Positive Isolation Arrangements...........................................................................20
Appendix 2 Abbreviations........................................................................................................ 25
Appendix 3 Tank Pressure / Vacuum Valve Changeout...........................................................26
Appendix 4 Reference Material............................................................................................... 30
Revision: 6.0
Appendix 5 - User Feedback Page............................................................................................. 31

Addendum 1 Changes at Revision 2.1....................................................................................32
Addendum 2 Changes at Revision 3.......................................................................................33
Addendum 8 Interim Amendment May 2011...........................................................................39
Addendum 9 Interim Amendment September 2011................................................................40
Addendum 10 Changes at Revision 6.0..................................................................................41

Revision: 6.0
1 Introduction
1.1 Background
Whenever process plant, equipment or systems require to be taken out of service for
major maintenance, repair or modification, then positive mechanical isolations shall be
provided between the process plant, equipment or system and any potential hazardous
energy source. Positive Mechanical Isolations requires the insertion of a spade / blind
in the line, or the removal of a spool (if required), downstream of the last tight isolation
valve to physically isolate the potential energy source.
IMPORTANT: A double block and bleed arrangement on its own is not
considered positive mechanical isolation without the insertion of a spade /
blind.
1.2 Purpose
The purpose of this procedure is to provide a safe and consistent method for the
isolation of process equipment prior to and during maintenance / modification / repair.
1.3 Distribution / Target Audience

This procedure is intended for use Production Operations, Maintenance, Well Services,
EMC/ODC personnel and any other parties tasked with carrying out the work requiring
isolation on equipment and systems in PDO.
1.4 Changes to the Document

Responsibility for the upkeep of the Document shall be with the Functional Production
Team Leader UOP, the Owner. Changes to this document shall only be authorised and
approved by the Owner.
Users of the Document who identify inaccuracy or ambiguity can notify the Custodian
or his/her delegate and request changes be initiated. The Requests shall be forwarded
to the Custodian using the User Feedback Page provided in this Document.
The Document Owner and the Document Custodian should ensure review and re-
verification of this procedure every 3 years.
1.5 Step-out Approval

This procedure is mandatory and shall be complied with at all times. Should
compliance with the procedure be considered inappropriate or the intended activity
cannot be effectively completed or safely performed, then step out authorisation and
approval must be obtained in accordance with PR-1001e Operations Procedure
Temporary Variance prior to any changes or activities associated with the procedure
being carried out.
1.6 ALARP
ALARP is the acronym for As Low As Reasonably Practicable which simplified means,
reducing the risk to a level at which the cost and effort (time and trouble) of further risk
reduction are grossly disproportionate to the risk reduction achieved. Full Compliance
to PDO Standards and Procedures is a key element in achieving ALARP.
For more details refer to ALARP Definition

Revision: 6.0
2 Roles and Responsibilities

Production Coordinator To be accountable for the isolation(s) to be carried
out.
Approve methods for isolations.
Specifying frequency of isolation integrity checks (if

required).
Responsible Supervisor Check isolations are in compliance with the
approved standard and procedure
Initiate variance procedure where proposed isolation
is out of compliance
Agree isolations with the Permit Applicant
Inspect the work site with Permit Applicant to
identify all hazards (mandatory for Class A permits)
Carrying out integrity checks of isolations
Authorises Permit to Work (PTW)
Production Operator and Perform or oversee the isolation and sign the
Area Authority necessary Isolation Certificate (Mechanical /
Electrical)
Carryout isolations integrity checks and maintain the
isolation records
Maintain the Override Log
Carryout or oversee depressurisation, draining, gas
freeing and gas testing
Supervise the worksite
Maintenance Personnel Witnessing isolations
Performing electrical, mechanical, rotating
equipment and major isolations associated with work
being undertaken
Requesting any changes to the approved isolation
from the Responsible Supervisor
Permit to Work Completing Section 1 of the Permit to Work
Applicant Certificate
Carryout site inspection and identification of hazards
with Responsible Supervisor
Agree the mechanical, electrical and instrument
overrides required to carry out the work with the
Responsible Supervisor
Produce Job Safety Plan and specific procedures

Revision: 6.0
Permit Holder Conducting TRIC discussions and completing TRIC

with personnel carrying out the work
Ensure that any changes to work scope or conditions
are captured and implemented before work is
allowed to continue
Maintain safe working conditions and practices
Witness and / or apply isolations / overrides with
attendance of the Area Authority
Witness and / or remove isolations / overrides with
attendance of the Area Authority

Revision: 6.0
3 Isolation of Process Equipment
3.1 Scope
This procedure covers the mandatory administration and mechanical isolation of
process equipment prior to maintenance or engineering work.
For major maintenance or engineering work the minimum requirement for process
equipment shall be;
shut down;
depressurised to atmospheric pressure;
drained and flushed (if required);
freed of flammable or toxic gases
Positive isolation shall be applied once the above have been completed between any
adjacent systems that may, or may not, remain live during the work.
3.2 Terminology
3.2.1 Major Work

Positive isolation shall be required for all Major Work. For the purpose of this
procedure major work will be considered as any intervention that results in spools or
equipment being removed from a process line (including non-hydrocarbons), Confined
Space entry, or Hot Work (including cold cutting) being carried out.
Examples:
Valve removal / replacement (including RV changeout);
Spool removal / replacement;
Equipment i.e. pump, changeout;
Vessels / tank inspections:
IMPORTANT NOTE: There may be exceptions to the above e.g. relief valves
changeout, and these shall be addressed on an individual basis after risk assessment.

Revision: 6.0
Table 1 Minimum Isolation Requirements

System System Description Major Work
I System in service, of ANSI Positive isolation by a single proven

class 300# and below. valve (Note1) and a swung spectacle
blind/spade or removable spool (Note
For flashing liquids and 2).
toxic see II below.
II System in service, of ANSI Double block and bleed plus a

class 600# and above. spade/blind.
All systems containing

toxic fluids (Note 3).
Systems containing
flashing liquids above
ANSI 300, (Note 4) i.e.
ANSI 600 and above.
NOTE 1 Provided the line upstream of the required isolation is depressurised,

drained, flushed and hydrocarbon free then a single proven valve will provide sufficient
isolation for Major Work.
NOTE 2 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 the isolation valve and the
spade/blind.
NOTE 3 For the purposes of this requirement, toxic in the case of H2S
is defined as more than 500 ppm H2S in the process stream.
NOTE 4 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, section
1.6.7, table 1.2.

Revision: 6.0
3.2.2 Minor Work

Valved isolation shall be required for all Minor Work. For the purpose of this procedure
minor work will be considered as any intervention that does not require spools or
equipment being removed from a process line (including non-hydrocarbons), or where
there is no Hot Work.
Examples:
As a pre-cursor for major work;
Breaking flanges for draining of depressurised systems;
Insertion of blinds between flanges on depressurised systems;
Working on instrumentation lines.
NOTE: For Minor work the valve isolation will require to be appropriate to address the
risk i.e. double block and bleed for H2S or pressurised lines, and demonstrated tight.
3.2.3 Battery Limits

This term is often used loosely with the industry. The word battery is used to represent
a set of units. For the purpose of this procedure a battery limit is an agreed boundary
surrounding a processing unit or battery of units, along with related utilities and
services. Therefore the perimeter of a Battery Limit can form a single boundary
isolation or a number of boundary isolations within the defined limit.
3.2.4 Baseline Isolation Standard

The Baseline Isolation Standard is the minimum acceptable standard of final isolation
for intrusive and non intrusive maintenance against live plant under normal
circumstances as per the HSE guidelines, (UK HSE Publication Issue 2006 ISBN 0-
7176-6171-7 The Safe Isolation of Plant and Equipment) This standard is based
upon risk assessment. The Baseline Isolation Standard shall be one of the
following two isolation methods:
Positive Isolation: is the removal of a spool and fitting of blinds, or fitting
of a spade or spectacle blind to allow complete separation of the plant/
equipment to be worked on from other parts of the system
Proved Isolation: is a valved isolation where effectiveness of the isolation can be
confirmed via vent/bleed points before breaking into the system, and for the duration of
the isolation
3.2.5 Boundary Isolation

An isolation at any location where the defined Baseline Isolation Standard is
met.
3.2.6 Hydrocarbon Services

All systems containing hydrocarbons.
3.2.7 Hazardous Substance / Service

A substance or containing a substance which is able to cause harm or damage if loss of
containment occurs.
3.2.8 Non-Hazardous Service

Any service not classified as hazardous.

Revision: 6.0
3.2.9 H2S / Toxic System

High concentrations of H2S in the process fluid, requiring a high degree of protection
against leakage. For the purpose of this procedure an H 2S / Toxic System is defined as
having >500ppm in the process stream.
3.3 Guidance Notes for Isolation
3.3.1 Issue of PTW to Permit Holder

The Area Authority shall not release the PTW to the Permit Holder (authorisation to
commence work) until all isolation processes have been completed and verified.
3.3.2 Positive Isolation of Equipment for Maintenance

A spade and blind check list, marked up copies of the As-Built drawings etc, shall be
made by the Permit Applicant and submitted with the PTW to ensure the correct
spades or blinds are closed during isolation and removed upon completion of the work.
NOTE: This spade list will be signed off by the Operator / Area Authority after isolation
and prior to equipment reinstatement after de-isolation.
The positive isolation shall be reviewed and approved by the Responsible Supervisor.
The Area Authority shall apply or oversee the positive isolation for every piece of
equipment identifying the connections that will be isolated, disconnected and tagged
before starting to open the equipment.
The Area Authority shall 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
gas freeing / purging as required.
Locked Open / Locked Closed valves that are operated during isolation shall be
recorded on the Lock Open / Locked Closed Register.
Valves used as part of isolation shall be tight when shut off. Where this cannot be
demonstrated the Production Coordinator shall be informed and a variance raised in
accordance with PR-1001e Operations Procedures Temporary Variance.
NOTE: Butterfly valves shall not to be considered as tight shut-off valves.
3.3.3 Removal and Replacement of Relief Valves on Live Systems

The permit applicant shall write a site specific procedure for the removal and
replacement of Relief Valve(s) and attach a Risk Assessment signed by the appropriate
authority. The procedure shall be reviewed and approved by the Responsible
Supervisor and shall be attached to the PTW.
PTW shall be in accordance with PR-1172 Permit to Work Section 15.6
No authorisation for the work shall be given if:
The system that the relief valve is protecting does not have 100% redundancy;
The relief valve does not have as a minimum a double block and bleed
arrangement upstream. This includes interlock systems;
The relief valve is connected to a live vent and flare system that cannot be
isolated by one demonstrated tight valve
3.3.4 Isolation of Moving Machinery

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

Revision: 6.0
The electrical, air, steam, hydraulic or other source of energy to the moving machinery,
both flow and return circuits, shall be isolated from the drive unit and the drive unit
secured immobile before work commences.
Isolation of moving machinery from process fluids shall be accomplished by tight
valves and spades or blinds on the equipment side of inlet and outlet lines in order that
maintenance may be carried out while the surrounding facilities remain live. Where
H2S is present in the process stream double block and bleed and swung blind is the
minimum mandatory requirement.
Machinery brakes and brake locks are to be applied and the clutch (if applicable) is to
be disengaged.
3.3.5 Isolation of Vessels
Spades / blinds shall be installed on the downstream side of the inlet block
valve and the upstream side of the outlet block valve. Where practical these
spades / blinds should be mounted directly on the flange. Where H 2S is present
in the process stream double block and bleed and swung blind is the minimum
mandatory requirement. Non-compliance shall be in accordance with PR-
1001e Operations Procedure Temporary Variance.
NOTE: Refer to Table 1 for recommendations regarding isolation requirements.
3.3.6 Isolation of Tanks

Blinds / spades shall be inserted on the tank side of all inlet and outlet block valves.
These shall be placed as close to the tank as possible. This also applies to blanket /
purge gas lines, tank-balancing lines, and 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, collection tank or suitable open
pit (refer to PR-1073 Section.
3.3.7 Isolation of Equipment Containing H2S

Reference PR-1078 - Hydrogen Sulphide Management Procedure for classifications of
H2S risk.
For isolations on equipment containing H 2S a double block and bleed system and
swung blind is the minimum mandatory requirement. Variance to this requirement
shall be in accordance with PR-1001e Operations Procedure Temporary Variance.
For double block and bleed systems used on H2S service the bleed shall be hard-piped
to a safe disposal location to ensure that it does not create a hazard. Acceptable
disposal routes are to a remote vent or to a plant closed drain system. When using
closed drains systems checks shall be made to ensure that reverse flow does not occur
in the system.
3.3.8 Use of Breathing Apparatus

It is mandatory to wear positive pressure breathing apparatus when breaking flanges
and opening equipment containing toxics. This shall be clearly stated under Work
Description on the Work Permit.

Revision: 6.0
Adequate isolation and purging shall be proven by a direct measurement (using gas
detector) for both hydrocarbons and the toxic component concerned (usually H 2S).
Further work such as opening the equipment for inspection will be carried out wearing a
personal H2S monitor and escape set. Refer to PR-1148 Entry into a Confined Space
for conditions allowing entry into a confined space.
3.3.9 Immobilising Devices

There are a number of proprietary devices used in the industry for immobilisation,
however PDO has standardised with pro-lock securing device.
3.4 General Exceptions

Any proprietary insertion or extraction device e.g. Welker/ COSASCO retrievable
probes, Daniel Orifice Carriers etc, used on sweet systems up to, and inclusive of,
900# rating shall be allowed by exception to the isolation requirements of this
procedure.
NOTE: This exception shall be allowed provided the design of the fittings is not
modified or changed and that regular maintenance and inspection is carried out.
3.5 Precautionary Considerations for Isolation

1) The main hazard when working on equipment that has been isolated from live
plant is that positive isolation from a source of energy or hazardous fluid / gas
may be overlooked or the isolation compromised, and the source then released
with serious consequences.
2) Positive isolation of equipment shall be accomplished to provide the safest
environment to carry out any Major Work on that equipment to reduce risk of
injury to personnel, damage to the Company's assets or the environment.
3) Production Supervisors and Operators shall ensure that the integrity of
isolations be maintained for the entire period of any work being carried out. The
isolation(s) and the EPI register shall be included in the shift change handover.
Long-term positive isolation shall be audited as part of the Level 2 Audit
conducted at 3-6 monthly intervals.
4) ALL isolation work shall be carried out under the Permit to Work system.
5) Hazards shall be identified, detailed and controlled by proper use of the Permit
to Work system.
6) All work shall be authorised by the Production Supervisor or his delegated
representative.
7) The method of positive isolation shall be in accordance with this procedure and
SP-1125 Specification for the Isolation of Process Equipment.
8) The use of home made spades require the explicit approval of the TA for
Static equipment.
9) All approved blinds that are fitted shall have all of their bolts set to correct
torque in accordance with SP-2020 Flange Connections Bolt Torquing and
Tensioning.

Revision: 6.0
10) Actuated valves shall only be used as part of the positive isolation if the fail
safe condition is closed and all motive power to the valve has been physically
disconnected from the actuator.
WARNING: Reliance on switches shall not be acceptable under any
circumstances.
11) Double block and bleed arrangements provide positive isolation when used in
conjunction with spades or blinds.
Where the insertion of spades and blinds in conjunction with double block and
bleed is considered impractical i.e. not possible to break containment or
suitable spading and blinding locations not available, the use of the double
block and bleed may be authorised by the Production Coordinator provided a
variance is raised in accordance PR-1001e Operations Procedures
Temporary Variance.
For minor work, such as replacing a faulty instrument on a vessel a single
demonstrated tight valve may be allowed if authorised by the Production
Coordinator. For toxic and high pressure applications double block and bleed
shall be considered a minimum requirement. Where the piping and valve
arrangement of process equipment does not allow this to be met a variance
shall be raised in accordance with PR-1001e Operations Procedures
Temporary Variance. In addition the work shall be completed during a working
shift, all valves employed for isolation shall be demonstrated tight and the
work site shall not be left unattended while the work is in progress.
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 be
employed to provide positive isolation.
12) For long term 1 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. This should be carried out on an Extended Period Isolation
and verified regularly.
Such isolations shall be audited and checked for integrity at a frequency
defined by the Production Coordinator.
13) All process isolations shall be recorded on the Process Isolation Wall.
14) All electrical isolations must be done in accordance with SP-1108 - Electrical
Safety Operational Procedures.
The most important rule for isolation of equipment is Stick to the Procedures. For
guidance, the schematic diagrams in Appendix 1 should be used for reference to
typical isolation arrangements.
1
Depending on the type of long term isolation moth balling may be considered.
Revision: 6.0
3.6 Typical Isolation and De-isolation Process
Figure 1 Process Equipment Isolation Process

The following process shall be followed to isolate and de-isolate process equipment
prior to and on completion of maintenance / repair / modification work.

Revision: 6.0
1. The Permit Applicant Shall complete the relevant sections of the PTW certificate
and define the isolation requirements on an As Built drawing (PEFS).
The marked up As Built drawing and the PTW shall be submitted to the
Responsible Supervisor.
2. The Responsible Supervisor shall review and discuss the PTW and isolation
requirements with the Permit Applicant. The positive isolation proposed on the
marked up As-Built drawing shall comply to this procedure and SP-1125
Specification for the Isolation of Process Equipment. Where compliance has been
demonstrated the PTW shall be authorised by the Responsible Supervisor.
3. Isolations that do not comply with this procedure shall require to have a variance
raised against them in accordance with PR-1001e Operations Procedures
Temporary Variance. The Production Supervisor and the Permit Applicant shall
agree the minimum isolation that can be used to address the risks. The Risk
Assessment and the variance shall be reviewed, endorsed and authorised by the
DTL and Operations Manager before further work can be planned.
4. The authorised PTW with the marked up As Built drawing shall be handed to the
Permit Holder who shall give them to the Area Authority.
The Area Authority shall complete the Mechanical Isolation Certificate from the
approved positive isolation on the As Built drawing. isolation 2 as detailed on the
Mechanical / Electrical Isolation Certificate authorised by the responsible
Supervisor.
IMPORTANT NOTE: No PTW shall be validated by Area Authority until the
required isolation process is completed.
Mechanical isolations that are to be put in place shall be listed on the Mechanical
Isolation Certificate or Mechanical Isolation Continuation Sheet and attached to the
PTW. These certificates shall be used to verify that all mechanical isolations have
been removed.
NOTE: Electrical and Safeguarding Instrumentation isolations are recorded on
separate Certificates and Forms and are attached to the PTW accordingly..
Positive isolation shall require having spades or blinds / spectacle blinds placed
into the lines. This shall involve breaking pipework at flanges and shall be recorded
in a specific procedure / method study for the work.
All precautions and safety points shall be recorded in the Safety Plan before any
breaks are made to the system / equipment integrity
5. The Area Authority shall witness all gas freeing and gas testing operations.
The work required to be undertaken can be progressed as soon as the isolation has
been established, checked and the PTW is issued.
The Area Authority shall validate the PTW and hand it to the Permit Holder to
undertake the work.
6. If the equipment is required to be test run this should be carried out under a De-
Isolation for Test (DFT) procedure using the reverse side of the Mechanical and /
or Electrical Isolation Certificates
2
All isolated valves, spades, blinds etc, shall be tagged with the 3 Part Tag. The 2 nd part of the
tag shall be attached to the PTW and the 3 rd part of the tag shall be placed on the PTW board.
The valve spade etc, should be secured with pro-lock fittings.
Revision: 6.0
7. Depending on the length that the isolations will be applied, integrity checks shall be
defined. The integrity checks shall be carried out by the Area Authority and
Production Supervisor who will ensure that the isolations are correct and intact.
The positive isolation shall be checked before the PTW is revalidated.
Any violations shall be reported to Production Coordinator and a fountain
Incident raised. The work will be stopped until an investigation has been
carried out.
8. On completion of all works, commissioning and testing the process equipment can
be de-isolated3. The de-isolation should be checked off against the Mechanical
Isolation Certificate and the marked up As-Built drawings.
9. When the de-isolation is completed by the Area Authority the PTW can be closed
out by the Permit Holder.
3
This includes de-spading and re-instating blinds / spectacle blinds into their operating
positions.
Revision: 6.0
Appendix 1 Positive Isolation Arrangements

Revision: 6.0

Revision: 6.0

Revision: 6.0

Revision: 6.0

Revision: 6.0
Appendix 2 Abbreviations
The following abbreviations are used in this Procedure.
ANSI American National Standards Institute
CDFP Corporate Discipline Focal Point
CFDH Corporate Functional Discipline Head
DFT De-isolated for Test
EPI Extended Period Isolation
ESOP Electrical Safety Operational Procedures
LC Locked Closed
LO Locked Open
NC Normally Closed
NO Normally Open
PEFS Process Engineering Flow Schematic
PDO Petroleum Development Oman LLC

PR Procedure
PTW Permit to Work
PVV Pressure Vacuum Valve
RAM Risk Assessment Matrix
TRIC Toolbox Talk Risk Identification Card

Revision: 6.0
Appendix 3 Tank Pressure / Vacuum Valve Changeout

1. Mandatory Requirements
- Inventory in the tank shall be reduced to low low level
- If a second tank is available production shall be lined up to this tank. If second tank
is not available production shall be diverted around the tank
WARNING: In single tank operation if production cannot be diverted from the
tank then the activity shall not be allowed to proceed. Similarly, if a spare valve
is not available, the activity shall not proceed.
- Tank must be isolated on the inlet in accordance with PR-1076 Isolation of
Process Equipment
- Pressure in the tank shall be vented to atmospheric via the flare / vent line or via
an atmospheric vent to a safe area
- Operations or work in the vicinity of the tank shall be suspended for the duration of
the changeout
- Work shall be undertaken in accordance with PR-1172 Permit to Work System
- The minimum number of personnel required to undertake the work safely shall be
employed on or around the tank
- A TRIC discussion shall be conducted prior to any work being commenced and the
TRIC completed and attached to the PTW
- If an unsafe operation is observed or monitored then work must be stopped
immediately and the area made safe
2. Precautions to be Observed
Gas Testing
Gas testing shall be carried out in accordance with PR-1154 Gas Testing
Procedure. All gas tests shall be undertaken by authorised gas testers as
required by PR-1172 Permit to Work System.
Breathing Apparatus
Breathing apparatus supplied from an external air source shall be required.
Breathing apparatus may be Self Contained Breathing Apparatus (SCBA), a
positive pressure hood supplied from an external air source or a combination of
the two.
Prior to use the charges in the air cylinders must be checked and it shall be
ensured that sufficient supplies, including reserves, are available to complete
the work.
Fire Fighting Equipment
Fire services shall be requested to be on station for the duration of the work. If
this is not feasible then a competent fire fighting team shall be employed to
man fixed firefighting equipment for the duration of the work.
Fixed and portable fire equipment shall be provided both on the tank roof and
at the work site to enable a fire to be contained.
Safety Harnesses and Man Basket
Safety harnesses and safety ropes shall be provided and issued to the working
party prior to deployment on the tank roof.
Secure anchor points for the harnesses shall be identified and marked prior to
personnel moving to the tank roof.

Revision: 6.0
A man basket (intrinsically safe) shall be provided with rated lifting strops to
evacuate causalities from the tank top in emergency.
3. Preparation for Undertaking the Work
Permit to Work
The Permit Applicant and Responsible Supervisor shall comply with PR-1172
Permit to Work System and carryout a site inspection.
The Permit Applicant shall prepare an HSE Job Plan and a Rescue Plan which
shall be attached to the PTW.
A marked-up Process and Engineering Flow Scheme shall be completed to
indicate all isolations.
Tools and Spares
A new gasket, bolts, nuts and washers shall be procured for the PVV and
bagged ready for use.
Spanners and a suitable torque wrench for removing and replacing bolting.
Scrappers and brass wire brushes for cleaning and preparing the flange joint.
Solvents for cleaning (WD40) may be used provided they are suitable for the
application. Absorbent cloths for cleaning the area and mopping small spills.
All tools for the work shall be bagged and a check list provided to enable
accounting to be carried out on completion of work.
The replacement PVV shall be checked to ensure it is correct for the
application and has been tested accordingly. The flanges of the replacement
PVV shall be protected prior to lifting to the tank top.
Safety Equipment
The SCBAs and air lines for the positive pressure hoods will require to be
carried or lifted to the tank top.
Personnel working on the tank top shall be issued with Emergency Escape
Hoods for evacuation.
Lifting Equipment
A suitably rated (25ton) with sufficient jib extension will be located, preferably
up wind of the operation, on site. Suitably rated slings shall be provided to lift
the old and replacement PVV during changeout.
NOTE: Gas monitoring shall be carried out before starting the crane and
continuously throughout the operation when the crane engine is running.
Permitry
If the tank is in H 2S sour service all personnel involved in the operation shall
have an in date H2S certificate.
Personnel using breathing apparatus (SCBA) must be certificated.
SCBA or positive pressure hoods shall require to be worn by all personnel
working on the tank top while the operation of changing out the PVV is being
carried out.
Preliminary Work Prior to Removal / Replacement
a) Close inlet isolation valve and inlet ESD valve (if provided) to the tank that is
to be worked on.
b) Divert the flow to second tank (if available) by opening inlet isolation valve on
the receiving tank.

Revision: 6.0
c) Reduce the level in the tank to be worked on to low low level. Overriding of
safety critical alarms and trips shall be in accordance with PR-1001c
temporary Overriding of Safeguarding Systems
d) Complete manual isolation of oil and drain outlet by closing the isolation valves
on the tank to be worked on. Record the valves and positions on the PEFS.
Update Locked Open / Lock Closed register for any normally Locked Open /
Locked Closed valves that are used. Refer to PR-1086 - Locked Valve Control
Requirements.
e) Isolate the blanket gas line (if provided) on the tank to be worked on.
f) Blow down / vent the residual gas inside the tank to be worked on to via the
flare / vent line or atmospheric vent line, to atmospheric.
NOTE: Use suitable sited pressure gauge on the tank to confirm condition.
g) PTW validated by the Area Authority
h) Hand-over the isolated tank to maintenance team.
4. Removal and Replacement
a) Bring lifting crane on site adhering by all precautions of the PTW. Position the
crane up-wind of the work site if possible.
NOTE: All lifts involving the crane shall be in accordance with the lifting plan
attached to the PTW.
b) Bring Canter on site adhering by all precautions of the PTW. Position the
Canter adjacent to the tank and within safe lifting range of the crane.
c) Make ready the replacement PVV for lifting on the back of the Canter.
d) Position the air line breathing apparatus trolley adjacent the tank. Check all
connectors and check face mask operation.
NOTE: This should be undertaken by the personnel who will require wearing the
equipment. Check the correct operation of the face mask.
e) Using the crane lift the SCBA, air hose(s) and tools to the tank top location.
f) Lift replacement PVV and blind flange to the tank top location.
g) The Area Authority wearing a SCBA shall carry out gas testing.
NOTE: The results of the gas testing shall dictate whether personnel will require to
wear SCBA or positive pressure hoods to perform preparatory work. Continuous gas
testing shall be carried out while preparatory work is being undertaken. Clean the
threads on the bolts securing the PVV. Apply solvent cleaner if required.
h) Unbolt using the appropriate spanners.
WARNING: As the tank will still contain hydrocarbons this operation and the
operation of re-bolting on completion will constitute hot-bolting and will
require the Approval of the Production Coordinator in accordance with SP-
2020 - Flange Connections Bolt Torquing and Tensioning Section 10.
i) Attach lifting strop to the PVV. Attach to crane hook in readiness of lift.
At this point a further gas test should be carried out and positive pressure hoods worn
by all personnel in the direct vicinity of the work. All other personnel should be moved
away from the PVV. A rescuer in a SCBA shall be made ready while the PVV is not in
place. For added safety all work should be undertaken if possible up wind of the
opening.
j) Un-bolt the PVV flange and carefully lift from the tank skin. Move to a suitable
laydown on the tank top.
k) Prepare the replacement PVV for lifting.
l) Clean and prepare the flange for fitting of the new gasket. Fit new gasket.
Revision: 6.0
m) Lift the replacement PVV into position, ensuring that the gasket is not
damaged.
NOTE: If the replacement of the PVV is halted due to damage of misalignment that
shall cause delay, a flange can be fitted providing it is fitted with a low range
pressure gauge to monitor a pressure build up. In conjunction with the pressure
gauge, a tee piece with a valved vent facility should be fitted, with the vent to a
safe area or flare system so that any pressure build up due to temperature change
can be vented safely (See Illustration below). A documented risk assessment shall
be carried out if this method is employed. The risk assessment shall ensure that
regular monitoring of the pressure gauge and venting is carried out by operations
for the duration that this flange is in place.
n) Replace the bolting and torque down to specified torque. See Warning
following Step i).
o) Carryout a gas test around the completed job to ensure tightness. Repeat the
gas test at intervals as working pressure is established and when the tank is at
normal operating pressure.
p) Check and confirm all tools are accounted for. Lift and remove old PVV from
the tank top to the Canter.
q) Carefully lift all remaining equipment from the tank top and secure the site.
r) Hand the tank back to Operations personnel to de-isolate and commission.

Revision: 6.0
Appendix 4 Reference Material

PDO Documents
Code of Practice
CP-115 - Operate Surface Product Flow Assets
Specification
SP-1108 - Electrical Safety Operating Procedures
SP-1125 - Isolation of Process Equipment Specification
SP-2020 - Flange Connections Bolt Torquing and Tensioning
Procedure
PR-1001e Operations Procedure Temporary Variance
PR-1073 - Gas freeing and Purging of Process Equipment (excluding tanks)
PR-1077 - Preparation of Tanks and Vessels for Internal Work
PR-1086 - Locked Valve and Spectacle Blind Control
PR-1148 - Entry into a Confined Space
PR-1154 - Gas Testing Procedure
PR-1172 - Permit to Work
Guideline
GU-256 - Static Equipment Inspection Guidelines

Revision: 6.0
Appendix 5 - User Feedback Page
PR-1076 Isolation of Process Equipment User Feedback Page
Any user who identifies an inaccuracy, error or ambiguity is requested to notify

the custodian so that appropriate action can be taken. The user is requested
to return this page fully completed, indicating precisely the amendment(s)
recommended.
Name:
Ref ID Date:
Page Ref: Brief Description of Change Required and Reasons
UOP7
Custodian of Document Date:

Revision: 6.0
Addendum 1 Changes at Revision 2.1

Page No. Changes / Additions
8 Section 1.8 Changed to This procedure is mandatory and shall be complied with
at all times. Should compliance with the procedure be considered inappropriate or
the intended activity cannot be effectively completed or safely performed, then step
out authorisation and approval must be obtained in accordance with PR-1001e
Operations Procedure Temporary Variance (supported by Risk Assessment), prior
to any changes or activities associated with the procedure being carried out.
9 Section 2.2 - Swim Lane Step 8 Changed flowline to equipment
10 Step 7 2nd para changed to All isolations that are to be put in place shall be listed
either on the PTW, on the Mechanical Isolation Certificate or Mechanical Isolation
Continuation Sheet. If the latter two are used these shall be attached to the PTW.
These certificates require to be verified when the isolations are removed.
10 Step 8 1st para added after production Supervisor and the person who is deemed
competent to perform the isolation
Footnote added
10 Step 9 2nd para changed to Any violations shall be reported to Production
Coordinator and a fountain Incident raised. The work will be stopped until an
investigation has been carried out.
11 Section 2.3 Step 7 Production Coordinator changed to Production Supervisor
12 Section 2.3 Step 13 Last Sentence In this event, the procedure to be followed will
be clearly illustrated and a step out raised supported by a Risk Assessment in
accordance with PR-1001e Operations Procedures Temporary Variance.
12 Section 2.3 Step 14 1 st para added to end This should be carried out on an
Extended Period Isolation and verified regularly.
13 Removed Note 2 For the purposes of this requirement, toxic in the case
of H2S is defined as more than 500ppm H2S in the process stream.
15 Section 2.4.6 Toxic changed to Sour

Revision: 6.0
Addendum 2 Changes at Revision 3

6 Section 1.1 following added
Approved Variances that have been Risk Assessed shall be added when
appropriate in the Appendices of this procedure to enable infrequent activities that
can not meet compliance to this procedure to be undertaken. These approved
variances shall be added and Operations notified by circular.
IMPORTANT: The Approved Variances are for the activities stated. Other
instances where compliance can not be met shall still require the completion of a
Temporary Variance in accordance with PR-1001e Operations Procedure
Temporary Variance
7 Section 1.6 removed and the Abbreviations added to Appendix 2
7 Roles and Responsibilities Permit Holder added pausing the work at regular
intervals to check if any aspect (affecting safe working) of the work has changed
9 Footnote added All and blinds
10 Step 10 added If the equipment is required to be test run this should be carried
out under a De-isolation for Test (DFT) procedure using the reverse side of the
mechanical Isolation Certificate
Appendix 3 - Tank Pressure / Vacuum Valve Changeout procedure added
User Feedback Page moved to Appendix 4
23 Appendix 3 Tank Pressure Vacuum Valve Changeout

Revision: 6.0

10 Step 10 Last para changed
If the equipment is required to be test run this should be carried out under a De-
Isolation for Test (DFT) procedure using the reverse side of the Mechanical and / or
Electrical Isolation Certificates
13 Added under Section 2.4.2 - Isolation of Equipment for Maintenance
Locked Open / Locked Closed valves that are operated during isolation shall be
recorded on the Lock Open / Locked Closed Register.
14. Added Section 2.4.8 Immobilising Devices
23 Appendix 3 Tank Pressure Vacuum Valve Changeout

Revision: 6.0

22 Step 1 WARNING Similarly, if a spare valve is not available, the activity should
not proceed. added
24-25 Step 4 after (n)
NOTE: If the replacement of the PVV is halted due to damage of misalignment that will
cause delay, a flange can be fitted providing it is fitted with a low range pressure gauge
to monitor a pressure build up. In conjunction with the pressure gauge, a tee piece with a
valved vent facility should be fitted, with the vent to a safe area or flare system so that
any pressure build up due to temperature change can be vented safely (See Illustration
below). A documented risk assessment shall be carried out if this method is employed.
The risk assessment shall ensure that regular monitoring of the pressure gauge and
venting is carried out by operations for the duration that this flange is in place.

Revision: 6.0

4 Related Corporate Management Frame Work (CMF) Documents
Added SP-2020 to Reference Documents
23 Appendix 3 - Tank Pressure / Vacuum Valve Changeout 4 Removal and Replacement
added / reworded:
i) Unbolt using the appropriate spanners.
WARNING: As the tank will still contain hydrocarbons the operation of re-
bolting on completion will constitute hot-bolting and will require the
Approval of the Production Coordinator in accordance with SP-2020 -
Flange Connections Bolt Torquing and Tensioning Section 10.
s) Replace the bolting and torque down to specified torque. See Warning following
Step i).

Revision: 6.0

6 Section 2.2 Step 6
Isolations that have been classified major shall require having spades or blinds /
spectacle blinds placed into the lines strategically to provide positive isolation. This shall
involve breaking pipework at flanges and should be covered in a specific procedure /
method study for the work and will require an isolation to do the work.
6 Section 2.2 Step 6
All isolations that are to be put in place shall be listed on the Mechanical Isolation
Certificate or Mechanical Isolation Continuation Sheet and attached to the PTW. These
certificates require to be verified when the isolations are removed.
13 Changed wording of 2.4.2 1st para The permit applicant shall apply a process isolation
for every piece of equipment to be isolated from live plant describing the connections
that will be isolated, disconnected and tagged before starting to open the equipment. The
isolation shall be reviewed by the Area Authority, approved by the Responsible
Supervisor and attached to the PTW.
13 Added new Sub-Section 2.4.3 Removal and Replacement of Relief Valves on Live
Systems.
All following Sub-Sections renumbered.
15 Section 2.4.9
There are a number of proprietary devices used in the industry for immobilisation,
however PDO has standardised with pro-lock securing device

Revision: 6.0

6 Section 1.1 Introduction
Reduced the content to make it concise and remove any source of ambiguity.
6 Section 1.3 Distribution and Target Audience
Added Well Services, EMC and ODC
8 Section 2 Roles and Responsibilities
Made additions and changes to Production Coordinator, Production Supervisor, Operator
and Area Authority, and Permit Holder
10 Removed the word Procedure from Section 3 heading
Revised extensively the whole section and re-organised the order.
Inclusion of more specific text to cover H2S operations
Typical Isolation and De-isolation Process moved to Section 3.4. Process flow chart
revised
18 Appendix 1 all illustrations revised to show isolation requirement updates.
24 Appendix 3 Changes made to enhance safety when undertaking the procedure.

Revision: 6.0
Addendum 8 Interim Amendment May 2011

13 Added Section 3.3 General Exceptions
Any proprietary insertion or extraction device e.g. Welker/ COSASCO retrievable
probes, Daniel Orifice Carriers etc, used on sweet systems up to, and inclusive of,
900# rating shall be allowed exception to the isolation requirements of this procedure.
NOTE: This exception shall be allowed provided the design of the fittings is not
modified or changed and that regular maintenance and inspection is carried out.

Revision: 6.0
Addendum 9 Interim Amendment September 2011

10 & 11 Added Section 3.1.1 Major Work & 3.1.2 Minor Work
Positive isolation shall be required for all Major Work. For the purpose of this
procedure major work will be considered as any intervention that results in spools or
equipment being removed from a process line (including non-hydrocarbons),
Confined Space entry, or Hot Work (including cold cutting) being carried out.
Examples:
Valve removal / replacement (including RV changeout);
Spool removal / replacement;
Equipment i.e. pump, changeout;
Vessels / tank inspections:
IMPORTANT NOTE: There may be exceptions to the above e.g. relief valves
changeout, and these shall be addressed on an individual basis after risk
assessment.
Valved isolation shall be required for all Minor Work. For the purpose of this
procedure minor work will be considered as any intervention that does not require
spools or equipment being removed from a process line (including non-
hydrocarbons), or where there no Hot Work.
Examples:
As a re-cusor for major work;
Breaking flanges for draining of depressurised systems;
Insertion of blinds between flanges on depressurised systems;
Working on instrumentation lines.
NOTE: For Minor work the valve isolation will require to be appropriate to address the
risk i.e. double block and bleed for H2S or pressurised lines, and demonstrated tight.

Revision: 6.0

Added Section 3.2 Terminology. All subsequent Sections renumbered accordingly.
Revised Table 1 Minimum Isolation Requirements in line with Sour Projects Isolation
Philosophy


PR-1076 - Isolation of Process Equipment Procedure

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PR-1076 - Isolation of Process Equipment Procedure

Uploaded by

Copyright:

Available Formats

Petroleum Development Oman L.L.C.

Isolation of Process Equipment

Document Type Procedure

Discipline Engineering and Operations

Owner UOP Functional Production Manager

Issue Date May 2012

This page was intentionally left blank

Page 2 PR-1076 - Isolation of Process Equipment Printed 14/07/17

Page 3 PR-1076 - Isolation of Process Equipment Printed 14/07/17

Revision No. Date Author Scope / Remarks

iii Related Business Processes

iv Related Corporate Management Frame Work (CMF)

CP-115 Operate Surface Product Flow Assets CoP

Reference are included in Appendix 4

Page 4 PR-1076 - Isolation of Process Equipment Printed 14/07/17

Appendix 5 - User Feedback Page............................................................................................. 31

Page 6 PR-1076 - Isolation of Process Equipment Printed 14/07/17

1.3 Distribution / Target Audience

1.4 Changes to the Document

1.5 Step-out Approval

Page 7 PR-1076 - Isolation of Process Equipment Printed 14/07/17

2 Roles and Responsibilities

Specifying frequency of isolation integrity checks (if

Page 8 PR-1076 - Isolation of Process Equipment Printed 14/07/17

Permit Holder Conducting TRIC discussions and completing TRIC

Page 9 PR-1076 - Isolation of Process Equipment Printed 14/07/17

3 Isolation of Process Equipment

3.2.1 Major Work

Page 10 PR-1076 - Isolation of Process Equipment Printed 14/07/17

Table 1 Minimum Isolation Requirements

I System in service, of ANSI Positive isolation by a single proven

II System in service, of ANSI Double block and bleed plus a

All systems containing

NOTE 1 Provided the line upstream of the required isolation is depressurised,

Page 11 PR-1076 - Isolation of Process Equipment Printed 14/07/17

3.2.2 Minor Work

3.2.3 Battery Limits

3.2.4 Baseline Isolation Standard

3.2.5 Boundary Isolation

3.2.6 Hydrocarbon Services

3.2.7 Hazardous Substance / Service

3.2.8 Non-Hazardous Service

Page 12 PR-1076 - Isolation of Process Equipment Printed 14/07/17

3.2.9 H2S / Toxic System

3.3 Guidance Notes for Isolation

3.3.1 Issue of PTW to Permit Holder

3.3.2 Positive Isolation of Equipment for Maintenance

3.3.3 Removal and Replacement of Relief Valves on Live Systems

3.3.4 Isolation of Moving Machinery

Page 13 PR-1076 - Isolation of Process Equipment Printed 14/07/17

3.3.5 Isolation of Vessels

3.3.6 Isolation of Tanks

3.3.7 Isolation of Equipment Containing H2S

3.3.8 Use of Breathing Apparatus

Page 14 PR-1076 - Isolation of Process Equipment Printed 14/07/17

3.3.9 Immobilising Devices

3.4 General Exceptions

3.5 Precautionary Considerations for Isolation

Page 15 PR-1076 - Isolation of Process Equipment Printed 14/07/17

3.6 Typical Isolation and De-isolation Process

Figure 1 Process Equipment Isolation Process

Page 17 PR-1076 - Isolation of Process Equipment Printed 14/07/17

Appendix 1 Positive Isolation Arrangements