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REVISION TABLE
REVISION PAGE
Page

Description

Revision

Date

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TABLE OF CONTENT
PAGE
COVER

REVISION TABLE

TABLE OF CONTENT

1.

PURPOSE

2.

DUTY AND RESPONSIBILITY

2.1 Construction Manager


2.2 Construction Supervisor
2.3 Safety Officer

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3 DEFINITION

Isolation

4 REFERENCE

5 ISOLATION

5.1
5.2

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General Principles
Isolation Techniques
5.2.1 Single Valve Isolations
5.2.2 Double Block Isolation Principle
5.2.3 Double Block and Bleed

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6 DETAIL PROCEDURES
6.1
6.2
6.3
6.4
6.5
6.6

General
Working on lines
Isolating/Opening lines
Coupling and Flanges
Insertion of Spades
Pipeline Marking

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7. SPECIFIC PROCEDURES
7.1 Isolation for entry into vessel or confined spaces
7.2 Isolation for Naked flame
7.3 Isolation for Cold Work
7.4 Electrical Isolation
7.5 Padlocks
8. ATTACHMENT

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1. PURPOSE
To provide the standards for various aspects of isolating pressure systems and
machinery.
2. DUTY AND RESPONSIBILITY
2.1
Construction Manager
Ensuring that isolations are carried out by authorized responsible
persons and in accordance with this procedure.
2.2

Construction Supervisor
Informing the relevant personnel of intended isolations
In case of Process Mechanical Isolations, authorizing the isolation/deisolation and specifying the methods used, but remains responsibility
for ensuring that correct procedures are used throughout.
In case of Electrical Isolations, delegating responsibility to Authorized
Electrical Person for the actual isolation/de-isolation, but remains
responsibility for ensuring that the correct administrative Work Permit
procedures are used.

2.3

Safety Officer
Conducting periodic checks for the status of isolations and conformance
with this procedure.
Providing advice/or assistance requested.

3. DEFINITION
Isolation means separate or keep apart the area from others in securing the
health and safety environment.
4. REFERENCES
XXXX/8AHSE-SFT/P-001 Work Permit Procedure
XXXX/8AHSE-SFT/P-003
Entry into Vessel and Confined
Procedure
XXXX/8AHSE-SFT/P-004
Pressure Testing Procedure

Spaces

5. ISOLATION
5.1 General Principles
The degree of physical isolation required prior to work on any flow line,
process system or pressure vessel will depend on the particular
circumstances of each job. Ensuring that a checklist is developed indicating
the appropriate positions for isolation, de-pressurization and venting. This list
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is to be recorded on the isolation certificate. A mark-up P&ID is to be attached


to the isolation certificate.
Any deviation from the method of isolation described in these procedures that
may be required in unusual circumstances, must have prior approval of the
Construction Manager. Non standard isolations must also be brought to the
attention of the personnel carrying out work and the potential hazards
explained.
All valves, switches etc. that are involved in isolations are to be locked in
position and clear signs posted such as :
LOCKED OPEN DO NOT CLOSE
LOCKED CLOSE DO NOT OPEN
All signs are to be in English and Bahasa Indonesia.
If any valve or switch to be involved in more than one isolation, then the
number of work Permits shall equal the number of padlocks required.
5.2 Isolation Techniques
5.2.1

5.2.2

Single Valve Isolations


A single valve isolation should only be used when there is no
alternative and never as a convenience. It is never to be used for
pressure > 70 bar or where the H 2S partial pressure is > 1 bar.
Special considerations are to give to the situation where a potentially
large inventory is involved e.g. on a pipeline/flow line.
It is important that when work is to be performed downstream of
single valve isolation, the effects of the work and other operations on
the isolation must be duly considered and adequate precautions
taken. For example, even though positive shut-off is initially
demonstrated, the results of vibration, temperature changes etc.
must also be considered.
Prior to work commences, a single isolation valve should be
subjected to a pressure test in order to determine flow passing or
not.
Once work has started single valve isolations should not be
subjected to higher pressures than can reasonably be avoided i.e.
the loading on a single valve isolating valve should be kept to a
minimum. When considering this effect of non-routine loading on
valves should be remembered e.g. higher pressures in the flare
system created by plant blow down.
Double Block Isolation Principle
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Double Block isolation (Preferably with bleed) is the preferred


isolation arrangement except in the case of vessel entry & hot work .
The principle of never relying on single valve isolation from process
to atmosphere also has wider application. Nipples, nozzles, vents,
drains that are not used for routine operations should be capped or
blanked off (Caps are preferred to plugs, because female threads
cannot be inspected). Nipples and connections needed for frequent
routine operations or sampling should have double-valve isolation.
The only exception to this is for non-hazardous systems such as
domestic water.
For pressures > 70 bar or where the H2S partial pressure > 1 bar,
double block & bleed should considered as the minimum isolation
standard. Ideally double block & bleed should be used initially to
allow safe insertion of spades, blinds, etc.
5.2.3

Double Block and Bleed


A typical assembly is vented spool piece section of line between two
block valves. The bleed vent is blanked or capped off when not in use
i.e. when in use as a vent it must be kept open. It is of an adequate
diameter to reduce the danger of plugging and to pass any leakage
through the block valves. Obviously higher-pressure gas systems
need larger diameter bleed vents.
Methods of use
Before the assembly is used, the bleed is tested and shown to be
clear by removing the blank or cap and allowing a small amount of
fluid or gas to escape before closing the block valves (This must be
done while wearing goggles/face plus any further protection
depending on the nature of the anticipated contents).
Both block valves to be closed and locked. Where the block valve is
power-operated, the power source shall also be isolated to prevent
operation of valve when closed.
The bleed valves are carefully opened and the pressure is relieved. If
a hose is temporarily attached for routing the line contents to the
appropriate drain, the hose should be firmly attached and secured
throughout its length to prevent any movement in the event of
subsequent pressure. Alternatively if the hose is used to vent directly
to atmosphere this must be in a safe location.
The flow through the hose should be confirmed by observing the end,
and non-plugging of the bleed confined by removing the hose
connection (temporarily if necessary).
When the bleed valve is in use it must be locked open and checked
on a regular basis for leakage.
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Line plugs, sewer plugs, stopples, freeze plugs, hydro plugs may be
used as a last resort because of the lack of any other means of
system isolation but then only under a specific written procedure or
vendor documentation.
The use of these devices requires experienced personnel and must
be the subject of a pre-planning meeting.
In a double block and bleed system, a pressure gauge can be fitted
to the bleed line to give additional information in case of the bleed
line blockage.
6. DETAIL PROCEDURES
6.1

General
The decision to isolate is made by the Client Site Superintendent when
completing the Work Permit.
All Isolation is to be Locked, listed on the isolation certificate and have an
isolation tag fixed (refer also to the Work Permit Procedure No.
XXXX/HSE-SFT/P-001).

6.2

Working on lines
Observing general safety precautions when working on lines :
Obtaining a Work Permit before commencing any operation.
Ensuring lines are marked to indicate the contents.
Note the type of fluid or gas that is, or was contained in the line.
Obtaining the Material Safety Data Sheets.
Checking the location of all top valves and the direction of flow of the
line contents.
Tightening the flange, as soon as possible to stop the leak when
unbolting a flange a leak begins to occur.
Ensuring all lines are adequately supported, allowing for movement due
to pressure and temperature variations.
Wearing correct personal protective clothing as dictated by the present
or previous contents of the line.
Ensuring that the line to be unbolted has been depressurized by
opening a drain valve and observing the pressure gauge (the drain
valve may be plugged).

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Isolating/opening lines
Prior working on lines, the lines containing hydrocarbons or chemicals
must be isolated by one or more the following methods:
Physical disconnection or a spool piece removed and sealing off the live
section with blank flanges.
Inserting spades, etc.
Locking isolation valves in the shut position such as for double block
and bleed. A notice to the valve is not sufficient.
Caution : lines must be closed or disconnected until all pressures
have been released. Every line to be considered LIVE
until proved otherwise.
Before any operation commences to break into any line, which has been at
anytime filled with flammable gas or liquid, the appropriate Construction
Superintendent must give clearance under the Work Permit System. All
work must be carried out strictly in compliance with the conditions laid
down in the work Permit. The Construction Superintendent together with
the Safety Supervisor shall be in attendance at all times when breaking
into a line which has contained flammable gas or fluids.
Lines that have contained flammable gasses, must be positively isolated,
depressurized, and, if practicable, flooded with water before being purged
with an inert gas. Simple purging with an inert gas is acceptable if flooding
is impracticable. Lines that have contained hydrocarbon liquids, require
draining and flushing with water prior to inerting. Before any hot cutting,
the line must be drilled, gas tested and proved to be safe.
Persons breaking flanges must wear protective clothing appropriate to the
contents of the pipe. Eye protection must be worn. Flanges must be
cracked open slowly so that any hydrocarbon incompletely purged from
the system can be safely controlled. Where difficulty occurred in either
loosening or re-tightening the bolts, each bolt must be replaced with a new
one after the flange is reinstalled.
The bolts on the flange side facing-away from the fitter must be loosened
first and opened with a wedge or a flange spreader to vent any material
away from the fitter. No bolts should be completely withdrawn before it is
confirmed that no pressure remains inside the system.
If there is any possibility that oil, hot liquids or acids or may escape :
Wear rubber gloves and goggles.
Position a drip tray under the joint to be broken.
Cover the joint with a sheet of lead or rubber.
Crack the joint by driving a chisel through the sheet, this will help to
prevent personal contamination by the liquid.
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Coupling and Flanges


The precautions to be used when breaking open unbolt Couplings and
Flanges are as follows:
A. Unbolt coupling
Back off the nuts until the faces are level with the ends of the bolts.
Strike the coupling housing on the edge of the mating surfaces to
release the friction mechanism.
Remove the nuts completely and dismantle coupling.
Use anti sparking tools e.g. brass wedges brass headed hammers.
B. Flanges
Where there is no likelihood of oil, hot liquids, or acids in the pipes:
Back off nuts
Separate the flanges using a screw safety spreader
Remove nuts and bolts
Small amounts of materials can be vented or drained harmlessly while
taking care not to contaminate or endanger the immediate area. If large
amounts of materials are present, the flanges must be closed quickly
for further purging of equipment or controlled release elsewhere. New
gaskets shall always be installed on all broken flanges.

6.5

Insertion of Spades (blind, spectacles, blanks , etc)


Opening lines to install spades must only be done when the responsible
operator in charge of the equipment is in attendance.
The torquing, design and strength of the spade or blank must be such as
to withstand the full line pressure, which may, over a period of time, leak
through adjacent valves.

6.6

Pipeline Marking
The color and scheme for pipeline marking is according to the specification
available from the client.

7. SPECIFIC PROCEDURES
7.1

Isolation for entry into vessel or confined spaces


Isolation requirements for entry into vessels or confined spaces are by
physical disconnection. If this is not practical then spading is acceptable.
In all cases the following apply :
If spading is used, then full consideration must be given to upstream
conditions that prevail, e.g. pressure fluctuation, temperature, vibration
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and regular checks to ensure the integrity of the spade. Spades must be
fitted at the nozzle closest to the vessel. A spading/disconnection
diagram must be made to identify the points at which spades are fitted
and points at which disconnection has been made. A copy of the
diagram must be attached to the isolation certificate.
All spades must be designed to take withstand the maximum possible
pressure in case of the upstream valve(s) passing
Isolation by physical disconnection requires the live side of the
disconnection to be spaded, plugged, capped or blanked off. The device
used must be rated to withstand the maximum pressure rating of the
system.
Closed valves of any description must not be considered as a means of
isolation for vessel entry.
7.2

Isolation for Naked Flame


The isolation requirement for Hot Work is one or a combination of the
following:
Physical disconnection
Spading

7.3

Isolation for Cold Work


The degree of isolation for cold work normally would be double block and
bleed for volatile, inflammable or toxic fluids. If double block and bleed
facility is used, the block valves must be locked closed and the bleed valve
must be locked open.
However, if the design of the pipe work is such that it is impractical to
achieve double isolation under normal operating conditions then normal
alternative arrangements can be considered. Aspects to be considered are
the duration of the work, the nature of the work and the facility to prove
that the designed isolations are not passing.
The Site Superintendent and the Operating Authority must establish that
the alternative method of isolation is satisfactory.
Caution : When single valve isolation is utilized for cold work
purposes associated with hydrocarbon systems, then all
hot work, in the area of the work, must be suspended.

7.4

Electrical Isolation
When preparing electrical plant and equipment for maintenance work,
specific reference should be made.
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Padlocks
All isolations (whether process or electrical) are to be locked using a
padlock and key. Some of the principles, which must be adhered to, are:
Each padlock must have a key
Each padlock must be clearly marked
When padlocking valves, switches, etc. the chain must not allow any
movement of the valve or switch hand etc.
If one isolation is being used on two different jobs i.e. with two permits,
then two padlocks must be used.
Each isolation device shall be clearly labeled. Labels are to be in
English and Bahasa Indonesia.
While the padlock is attached to the isolation device, the key shall be
locked away in a safe secure place e.g. Superintendents Office.
If a common key is used for many padlocks then only one key of this type
shall be available on site.

8. ATTACHMENT
Checklist No. SFT-002/ATC-001 : Isolation Checklist

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