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Gas Freeing, Purging and Pressure Testing

MS-SP00041 Rev.03

Metadata

This is a Sub-Procedure under MS-PR00001 Work Permit.

Contents:

Choice of Purging Medium

Gas Freeing with Nitrogen
Gas Purging with Steam
Ventilation for Entry Work
Removal of Oxygen before Start-Up
Pressure Testing

Choice of Purging Medium

The choice of purging medium has a great influence on the other activities in the area. Purging with nitrogen
usually has the least influence and is preferred when many simultaneous activities are ongoing.

Before entering a process system or before carrying out hot work on a pipe or container, the system must be
purged free for hydrocarbons. The following media will normally be relevant for removal of hydrocarbons:

1. Steam
2. Nitrogen gas
3. Filling with water
4. Nitrogen foam
5. Inert Gas

Prior to internal inspection or repair of pipes and containers, consider cleaning using steam. Filling with water
or purging with nitrogen alone may will not be enough to remove hydrocarbons. If nitrogen gas is used to
purge hydrocarbons from the system, it may be followed by steaming to remove the remaining hydrocarbons
in liquid or solid form. When welding on or cutting dry gas pipes, purging with nitrogen is an alternative to
steaming. Pipes which contain oil or wax must be steamed. If this is impractical, nitrogen foam is an
alternative. Before the hot work can start, the following safety measures must be ensured:

1. When purged with steam/water, the hydrocarbon content in the atmosphere must be 0% LEL
measured with an explosimeter.
2. When purged with nitrogen gas the hydrocarbon content in the atmosphere must be max. 2% Vol.
measured with an instrument for inert gases.
3. In the case of nitrogen foam, it must be checked that the foam is in place in accordance with the
approved procedure.
4. Obtained Work Permit for hot work and entry.

Gas Freeing with Nitrogen

All loose equipment (hoses, distribution centres, threaded connections) used to distribute low pressure
nitrogen (below 20 bar) must be tagged and equipped with a connection that can not be mixed up with or
used up to existing compressed utility- or instrument- air systems.

There are two ways of gas release with nitrogen gas; atmospheric purging and pressure setting.

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Atmospheric purging:
This method is most suitable for simple systems with few branches. Due to the difference in density between
nitrogen and natural gas (nitrogen is heaviest), nitrogen must be added to the bottom of the system, with
venting at the top. Some hydrocarbon gases, e.g. pure propane, are heavier than nitrogen. Nitrogen must
therefore be added to the top in this case, while venting should take place at the bottom of the system.

The most effective purging takes place at moderate speeds. The nitrogen gas will then act as a "plug" and
displace the gas. At very low and large flow rates, the nitrogen will mix with the HC gas and make
displacement less effective. Experience must be used for adjustment of flow rates.

Pressure purging:
Pressure purging is suitable if the system to be purged is complicated, with many branches which are difficult
to purge using atmospheric purging.

This method displaces the hydrocarbon gas by pressurising the system with nitrogen to 60 psig (4.1 barg).
This pressure is maintained for at least 30 minutes to mix the gases before the system is depressurised. The
system must be pressurised at 60 psig (4.1 barg) a total of 3 times to come down to 2% HC. Pressurisation
must be repeated if the HC concentration is measured greater than 2%.

Nitrogen Foam
Use of nitrogen foam will not remove all traces of hydrocarbons. Use of nitrogen foam requires special
equipment and the work may only be done by qualified personnel. Before the work, it must be possible to
confirm that there is foam on the cut. The nitrogen foam will be heavier than the gases to be displaced and is
therefore added to the bottom of the equipment with venting at the top.

Inert Gas
Inert Gas is mostly used for purging Cargo tanks. It may also be used for inerting voids and ballast tanks in
case of Hydrocarbon detection. Method of using Inert Gas / purging of cargotanks is mostly based on vessel's
purge line design. Most common, and most effective, is to insert IG at the bottom of the tank, and venting at
top.
Large cargotanks must be gas measured at forward and aft section, as well as all elevations, to make sure no
areas in the tank are within limits.

Gas Purging with Steam

Purging may have to be done by use of steam if the equipment contains oil or wax. Before entering the
containers which have contained oil or wax, the container may have to be purged with steam.

Personal protective equipment must be used. At least hands and face must be protected.

Only threaded union connections designed for steam must be used. Air hose connections are not permitted.
All equipment, hoses and nozzles must be checked before use. The nozzles must be checked now and then
during use to ensure that they close the supply of steam.

Steaming is completed when the entire system has reached an adequate temperature. This must be
assessed according to experience. The pressure during steaming must not exceed 15 psig (1 barg).

When cooling after steaming, there must be adequate venting to avoid under-pressure which may lead to
damage on the equipment.

Steam hoses must be earthed to avoid a build up of static electricity. Steam hoses with a fixed screw
connection to the equipment are regarded as adequate earthing.

Work may start when the temperature is down at a level where the HC concentration may be measured and
this is measured at 0% LEL.

Ventilation for Entry Work

Once the compartment has been thoroughly purged with the appropriate medium, to enable entry to the

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compartment and to ensure that the presence of an explosive or toxic mixture has been eliminated, the
compartment must be thoroughly ventilated with fresh air prior to entry.

The fresh air ventilation could be carried out using fan(s) or by natural ventilation, depending upon
circumstances.

On completion of ventilation and prior to entry of the compartment, gas tests must be carried out to ensure
that there is 21% Oxygen (really 20,946%, reading may be 20,9%) present throughout the compartment and
less than 1% LEL hydrocarbon gases and less than any maximum specified limit of toxic gases (in ppm).

Removal of Oxygen before Start-Up

General
Two different types of media are relevant for this operation, nitrogen gas and process gas (hydrocarbon gas).
If available, use of nitrogen gas is preferable, both for safety and practical reasons.

It is important to be aware that the choice of purging medium has a great effect on other activities in the area.
Purging with nitrogen usually has least effect and is preferred when many simultaneous activities are ongoing.

Purging with Nitrogen Gas

Removal of oxygen using nitrogen as a preparation for start-up does not require that the displaced mixture
must be lead to a safe area free of spark sources. It is important to be aware of the risk of suffocation if the
nitrogen is vented to an enclosed area.

Systems to be purged with nitrogen will be ready for start up when the concentration of oxygen is measured at
less than 4% vol.

The atmosphere in a system may be replaced with nitrogen in two ways, atmospheric purging or
pressurisation.

Purging
Nitrogen is blown through the system at almost atmospheric pressure. Ideally, nitrogen will act as a plug
which will displace the air with one volume purge. This assumes that the nitrogen and air mix insignificantly.
The number of volumes will however depend on the number/length of the branches in the system and on the
rate. This method is therefore mainly suitable for purging simple systems. The most effective purging, i.e.
least use of nitrogen, is achieved during moderate rate. At faster rates, there will be too much turbulence so
that the purge gas and air mix. The displacement will therefore be less effective. The nitrogen and air also mix
at lower rates. The most favourable purge rate must be stipulated based on experience.

Pressurisation
The system may be pressurised with nitrogen to remove the oxygen. When the necessary pressure has been
reached, this is maintained for at least 30 minutes. After depressurisation and measurement of adequately
low oxygen concentrations, the system has been purged. It is assumed that the equipment to be purged has
been designed for the necessary pressure. Repeated pressurisation with bleeding between each
pressurisation is carried out until the oxygen concentration is lower than 4%. The flanges are also checked at
the same time for leaks, etc.

Purging with process gas

NOTE: No purging with process gas must take place until and unless the system has first been inerted
with nitrogen. Purge pressure can be controlled using a suitable reducing valve.

Electrical heating on systems/containers must be disconnected. Purging must not be started until all the hot
spots have had time to cool.
The pressure must not exceed 15 psig measured on the system during purging. There must be enough
adequately sized venting to safe area.

If the purge gas is available from several different sources, the system to be purged must be connected to the
source which has the lowest pressure and highest temperature. This will limit cooling of the equipment as a
result of a pressure drop.

When purging and pressuring before start-up, all flanges, manholes, etc. must be checked for leaks. All

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broken flanges must be taped.

Blind Flanges / Blinds

The following regulations apply to blind flanges/blinds, venting and control of purging to remove oxygen
before start-up.

Blinds are removed when purging is complete. This is because an explosive mixture must not migrate to the
connected pipe-works through leaky valves.

After the blinds have been removed, the valves are kept closed while the oxygen concentration is checked. If
this is greater than 4%, purging will continue until the concentration is less than 4%. After this limit has been
reached the valves may be opened.

When removing the blinds it is important to reduce the time that several flange pairs are out. Several openings
in the system create a risk of "draughts" and thus the possibility to form an explosive mixture.

The technicians who install or remove blinds, register this on the blind list section in the Isolation Statement.
The supervisor for the area checks the blind list to ensure that all blinds have been removed and that all
gaskets have been checked/replaced.

Venting
Venting must be done via a suitable hose to a safe area free of ignition sources.

The necessary measures must be taken to vent parts of the system which have little purging.

Purging should be carried out in one operation when several containers or systems are linked together. This
means that the gas may be supplied in one and vented out the other.

The purged system is ready for start-up when the concentration of oxygen is measured to be less than 4%
vol.

Monitoring
The pressure must be monitored and must not exceed 15 psig measured inside the container or pipe.

Pressure Testing

Preparation
The equipment to be tested must be checked visually for soundness and that it is in accordance with the
drawings.

Pumps which supply pressure and all fittings, couplings and flexible hoses connected to these, must be in
good order and rated for the job in hand. The container/pipe's metallurgy should be compatible with the test
fluid, e.g. salt water not to be used on austenitic steels, etc.

Where large volumes of water are involved, the foundations and supports must be rated for the additional load
to be carried to avoid overloading.

Fittings, instruments, gauges, glasses not rated for the test pressure must be removed or isolated to prevent
rupture.

The test pressure requested must be confirmed so that the vessel/pipe-work's test pressure rating is not
exceeded.

Operation
Unauthorised personnel must keep clear of any pressure test area. The area must be roped off and a look-out
posted.

When a container/pipe is under pressure, neither it nor the testing appliance must be left unattended.

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When a container/pipe is under pressure for detection of pressure decay or leaks, consideration must be
given to day/night temperature changes, particularly with respect to expansion (pressure rise) or freezing
(when water is the test medium).

Completion
When emptying a container, a system high vent must be opened to avoid pulling a vacuum and risking
collapse.

All water must be drained completely to avoid freezing (in cold weather) and process fluid contamination.

Document links

Reference documents
MS-PR00001 Work Permit
MS-SP00055 Hot Work Procedure
MS-SP00040 Isolation

Attachments

Gas Freeing, Purging and Pressure Testing

. . Re: Gas Freeing, Purging and Pressure Testing (Pavel Reznikov, 10.05.2009 12:23:57)

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