1

1.1

Gas-Freeing, Purging Process Equipment

General
Gas-freeing This is the process whereby a safe atmosphere is established within the process equipment / pipework prior to opening. Gas-freeing will normally be undertaken in conjunction with the draining and flushing processes. Purging This is the process whereby the atmosphere within the process equipment / pipework is purged of air by an inert gas i.e. nitrogen prior to final leak testing and reinstatement.

The following procedures shall be referenced in conjunction with this Section and Section 3. PR-1076 - Isolation of Process Equipment PR-1077 - Preparation of Tanks and Vessels for Internal Work Procedure PR-1086 - Locked Valve Control PR-1148 - Confined Space Entry PR-1154 - Gas Testing PR-1172 - Permit to Work 1.2 Draining of Vessels and Pipework to Open Pits Before vessels and pipework can be gas freed they require to be drained and flushed / cleaned of hydrocarbons. The preferred method for draining and flushing of vessels and pipework is via a closed drain system to a sealed drain tank. On a large number of facilities in PDO this means of safely draining hydrocarbons liquids was not provided in the design. Because of this draining and flushing in some instances is carried out to open pits. 1.2.1 Considerations When Draining Vessels and Pipework The following will be considered when draining vessels and pipework; NOTE: The list is not limited to, there could be more Volume of liquid; Size of pipework and flanged sections etc.; Type of medium i.e. hydrocarbon; hydrocarbon / water; oily water; H 2S content etc.; Pressure; Location; Concurrent activities; Type of work to be undertaken; Hazard and Associated Risks of the operation identified (Risk Assessment required)

NOTE: When draining and flushing to an Open Pit a Risk Assessment reviewed and signed by the appropriate authority shall be required. 1.2.2 Criteria for Using an Open Pit It shall be a mandatory requirement to ensure that the following criteria are met before draining or flushing operations can be carried out to an Open Pit. The liquids to be drained shall not contain NORM, H2S, or Mercury

The Residual Risks associated with the draining / flushing operations are LOW (after putting controls in place as part of the Risk Assessment) All hazards identified can be managed safely The systems, equipment, vessels or pipe work is depressurised to atmospheric A detailed Job Safety Plan has been developed and approved A TRIC Discussion is held and a TRIC Card completed before the operation is commenced Hydrocarbon monitoring instruments are within calibration and certification The operation is continuously supervised by the appropriate Area Authority

Failure to meet the above criteria shall require a Variance to be raised in accordance with PR-1001e Operations Procedure Temporary Variance. 1.2.3 Control Required for using Open Pits Draining / flushing to Open Pits in the most part will have common risks attached to it and therefore the following require to be adhered to Open Pits Open pits shall be no larger than 3m x 3m x 1m (deep). Liquid levels in the open pit shall be maintained as low as possible. Open pits shall be lined with thick gauge PVC covered with firefighting foam to reduce evaporation of hydrocarbon to atmosphere.

Hazardous Areas A hazardous Zone 1 will be established 1m above the pit and 3m around the pit. The pit itself shall be Zone 0 All electrical equipment that does not meet the specification for operation within these Zone ratings shall be isolated Vacuum tankers shall meet PDO Specification SP-1207 Specification for Vacuum Tankers.

Vacuum Tankers

Vehicle Access and Control General When breaking flanges sufficient bolts will be retained to enable the flanges to be closed in the event of uncontrolled draining. Vehicles shall be not be allowed to within 5m of the pit. Continuous gas testing will be required if vehicles such as mobile cranes and vacuum tankers are required to be run in the vicinity of the pit. Local gas testing shall be required before other vehicles are allowed to enter or are restarted in the vicinity of the pit.