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PR-1073 - Gas Freeing, Purging and Leak Testing of Process Equipment (Excluding Tanks)
PR-1073 - Gas Freeing, Purging and Leak Testing of Process Equipment (Excluding Tanks)
L.L.C.
Document ID PR-1073
Security Unrestricted
Revision 4.1
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i Document Authorisation
Authorised For Issue April 2010
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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.
See Appendix 4
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TABLE OF CONTENTS
1 Introduction........................................................................................................................... 7
1.1 Background..................................................................................................................... 7
1.2 Purpose........................................................................................................................... 7
1.3 Scope.............................................................................................................................. 7
1.4 Distribution / Target Audience.......................................................................................... 7
1.5 Changes to the Document............................................................................................... 8
1.6 Step-out Approval............................................................................................................ 8
1.7 ALARP............................................................................................................................. 8
2 Roles and Responsibilities.................................................................................................... 9
3 Gas-Freeing, Purging Process Equipment..........................................................................10
3.1 General.......................................................................................................................... 10
3.2 Draining of Vessels and Pipework to Open Pits............................................................10
3.2.1 Considerations When Draining Vessels and Pipework...........................................10
3.2.2 Criteria for Using an Open Pit.................................................................................11
3.2.3 Control Required for using Open Pits......................................................................11
3.3 Gas-Freeing and Purging.............................................................................................. 12
3.3.1 Preparation and Precautions..................................................................................12
3.3.2 Gas Freeing............................................................................................................ 14
3.3.3 Atmospheric Pressure Method.............................................................................14
3.3.4 Cyclic Pressure Purge Method.............................................................................14
3.3.5 Water Displacement Method...................................................................................15
3.3.6 Series Purging........................................................................................................ 15
3.3.7 Displacing To Air..................................................................................................... 15
3.4 Purging Following Inspection or Maintenance...............................................................15
3.5 Sampling....................................................................................................................... 16
4 Leak Testing........................................................................................................................ 17
4.1 Objective....................................................................................................................... 17
4.2 Definitions for Leak Testing...........................................................................................17
4.3 Reinstatement Policy..................................................................................................... 18
4.3.1 Method Options in Order of Consideration.............................................................18
4.4 Planning Reinstatement Leak Test................................................................................19
4.5 Nitrogen Leak Testing of Systems.................................................................................21
4.5.1 Bubble Forming Solution........................................................................................ 22
4.5.2 Acceptance Criteria for N2 Leak Testing (Bubble Test)............................................22
4.6 Performing the In-Service Reinstatement Test..............................................................22
4.7 Vacuum Testing............................................................................................................. 23
4.8 Reinstatement Testing of Relief Valves Connected to the Flare or Relief Headers......23
5 Hazards............................................................................................................................... 24
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1 Introduction
1.1 Background
Process equipment in hydrocarbon services shall be subjected to periodic inspections
and maintenance which may result in the pressure containment being broken. Such
breaks in the pressure containment can result in explosive mixtures of air and
hydrocarbon vapour being present. Therefore whenever pressure containment is
broken measure must be taken to ensure that:
An explosive atmosphere is not present during such times that work is being
undertaken
An explosive atmosphere is not present in the equipment prior to its return to
hydrocarbon service
Pressure containment is tested and confirmed before the equipment is returned
to hydrocarbon service
IMPORTANT: This procedure will be used for gas freeing, purging and leak testing
process system and equipment that has been commissioned and is being operated
as a production unit.
1.2 Purpose
The purpose of this procedure is to detail the steps necessary to ensure that
hydrocarbon process equipment is correctly gas-freed before the pressure containment
is broken; purged of any explosive mixtures before being returned to hydrocarbon
process service; and leak tested to ensure pressure containment is confirmed.
This procedure may be used in conjunction with PR-1077 - Preparation of Static
Equipment for Internal Maintenance and Inspection.
1.3 Scope
This scope of this procedure1 covers gas-freeing, purging and leak testing of
hydrocarbon process equipment and pipework.
Specific plant / equipment level Work Instructions / Method Statements shall be
developed prior to the work being undertaken. These shall form part of the Scope of
Work.
1
The procedure shall not detail removal of instrumentation lines where the volume of
hydrocarbon vapour / gas / liquid is small and will therefore not present an explosion hazard.
However safe working practice shall still be observed when undertaking this work.
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1.7 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
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3.1 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
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NOTE: Consideration should be given to installing permanent supply and vent lines
for activities that are carried out regularly.
Prior to starting the purging operation, with the exception of the flare system
which may be required to complete the purge activity, the equipment being
purged shall be isolated from all other equipment.
If venting is into a common flare system, Operations staff should be aware of
the possibilities of gas being vented, or leaking across PCV's from another
system and thus recontamination the purged vessel.
When discharging nitrogen to the flare system, considerations shall be given to
the possibility of extinguishing a lit flare.
If nitrogen is being supplied by cylinders, a two-gauge regulator control, which
indicates cylinder and flowing pressure, shall be used, fitted directly onto the
manifold.
CAUTION: At no time, irrespective of the relative volumes of the operation
and the cylinder(s), shall nitrogen be used without a regulator.
If the nitrogen is being supplied by `quads', the cylinders shall not be removed
from the frame and the lifting slings shall not be altered in any way.
To avoid reverse flow of product into the nitrogen supply, the line up shall be
equipped with check valves.
CAUTION: Where temporary hoses are used for purging and re-pressurisation
these should be secured in position at 3m intervals to prevent whipping.
Where temporary hoses are fitted with crows foot type connections these
must be fitted with R clips and whip checks.
Temporary hose connections and tie-in points shall be blanked off when not in
use and for all tie-in points an isolation valve shall be fitted. Where the
connection is envisaged as being required to operate against a pressure
in the vessel, the connection to the vessel shall comprise a hose
connection coupling, a bleed valve, a check valve and a block valve.
All temporary connections and vent points shall be controlled under the PTW
system. Labels should be fitted to identify all nitrogen purge points and
regular checks carried out to identify the valve status. This status should be
recorded on an Isolation Certificate (IC).
During periods when large numbers of temporary connections are in use (i.e.
during shutdown or startup) regular checks shall be carried out, referring to a
checklist, on all nitrogen utility points in service, in order to identify their
status.
PVC or leather gloves must always be worn when handling anything that
contains, or has been in contact with, cryogenic liquids. These gloves should be
loose fitting so that they may be easily removed if liquid is splashed onto or into
them.
Where spraying or splashing may occur, a face visor must be worn to protect
the face and eyes.
Before the arrival of any temporary nitrogen equipment on site, the dangers of
nitrogen in both liquid and gaseous form should be discussed at a safety
meeting. Refer to Appendix 1.
It is very difficult to totally gas free a hydrocarbon vessel by nitrogen
purging, even if flushing with water is part of the procedure. It is therefore
most important that any hotwork in the vicinity of the vessel to be opened up is
stopped prior to the removal of any manway doors, access hatches etc.
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Gas Freeing
Before starting the purging operation, the nature and the properties of the substances
to be purged must be taken into account.
a. Where practicable, liquid hydrocarbons must be cleared prior to purging.
Relatively small quantities of hydrocarbon liquid will produce significant
volumes of gas if vaporised.
b. Where recontamination by solids or sludge is likely, the purge procedure,
where possible, should be preceded by a water flushing operation if purging
efficiency is not to be impaired.
c. The relative densities of the gases to be purged must be considered.
Where possible, propane or heavier gases should be displaced by
downflow purging, and ethane or lighter gases should be displaced by
upflow purging.
NOTE: Certain equipment, particularly filter beds, may require to be purged in one
direction only. Generally this will be in a direction toward the support structure, but at all
times the manufacturer's instructions should be followed.
Several methods of nitrogen purge are available which are described briefly below.
Under normal conditions, a combination of these methods is generally used.
Four times one bar cycles require four volumes of nitrogen and results in
6.25% hydrocarbons, whereas a single purge to nine bars will require nine
volumes of nitrogen and results in 10% hydrocarbons.
Care must be taken that low-pressure instrumentation is not damaged by the purge.
In a typical case, the required purge will be obtained by use of successive purges, the
number required being based upon experience of the operation but governed at all
times by the sampling procedure.
Series Purging
Where vessels or plant can be pressure purged in series, significant economies in time
and nitrogen can be made by passing each cycle purge forward to the next vessel
before releasing to the vent or flare. Can be used in conjunction with 2.3.5.
Displacing To Air
Following purging, it is normal to displace the nitrogen in the vessel or system with air
to ensure that it is safe to work on. Care must be taken, as with the nitrogen, that the
purge method used is appropriate to the conditions and to the system.
WARNING: AT NO TIME SHALL AIR BE PURGED INTO A LIVE FLARE OR VENT
SYSTEM.
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3.5 Sampling
When purging hydrocarbons using nitrogen, it should be noted that the detector used
must be capable of measuring a hydrocarbon gas in an inert atmosphere. The MSA
Tankscope and Neotronics Digiflamm are examples of detectors that can be used.
For both flowing and cyclic purges the checks should be made at not only the
recognised vents but also at any dead legs in the system.
When purging the nitrogen out of the system with air, it is equally important that
representative checks are carried out. If the vessel or system is going to be entered,
conditions for the entry are as defined in PR-1148 Confined Space Entry.
The recommended criteria to give safe conditions when purging a mixture of
hydrocarbon gases with nitrogen are shown in Table 1.
For specific criteria when purging individual hydrocarbon components with nitrogen,
refer to Table2.
Table 2 - Inert Gas End Points for Purging Equipment Out of Service
Combustible Percentage Inert Gas Purging end points Percent of Purging end points
required to render with 20% Safety Combustible below with 20% Safety
mixtures non- Factor which no mixture is Factor
flammable when air is flammable when air is
added in any amount added in any amount
Hydrogen 95 96 5 4
Carbon 81 85 19 15
Monoxide
Methane 86 89 14 11
Ethane 93 95 7 5
Propane 94 95 6 5
Butane 95 96 5 4
Iso-butane 95 96 5 4
Pentane 97 98 3 2
Hexane 97 98 3 2
Gasoline 96 97 4 3
Ethylene 94 95 6 5
Propylene 96 97 4 3
Benzene 96 97 4 3
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4 Leak Testing
4.1 Objective
The objective of this section is to guarantee the integrity of process equipment and
/ or pipework that has been reassembled after inspection, maintenance, repairs,
modifications or replacement, prior to it being returned to operation. This is required in
order to eliminate the loss of containment of process fluids, thereby protecting the safety
of all personnel either involved with, or in the vicinity of, the plant and maintaining the
integrity of the Installation.
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Design pressure (DP) The DP (sometimes referred to as the upper design pressure,
UDP) is the gauge pressure at the top of the equipment in its
operating position that is taken to determine the minimum
thickness of equipment parts at the DT.
The DP is initially selected by the process engineer and
finally determined in close consultation with the mechanical
design engineer.
Since the DP is related to the top of the equipment, for other
parts or elements of the equipment the designer shall
establish the associated design pressures taking into account
the maximum pressure drop caused by flow through the
equipment, plus the fluid static head.
NOTE: The definitions for pressure were taken from DEP 01.00.01.30-GEN Definitions
of Temperature, Pressure and Toxicity Levels - December 2008 (DEP Circular 14/09 has
been incorporated)
2
On facilities where High H2S levels are encountered i.e. Harweel, Sensitive Leak testing shall
be enforced.
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1. Prior to the reinstatement of items of plant, all connections that have been
disturbed (flanges, clamps etc) shall have been reinstated in accordance
with SP-2020 Flange Connection Bolt Torquing.
Any replaced or modified item of equipment, which forms part of the pressure
envelope, must have previously undergone a successful strength pressure test
prior to installation. Also, any repairs to equipment shall have been carried
out in accordance with the design specification and in its original location.
2. If the above cannot be satisfied, a hydrostatic or pneumatic strength test
must be carried out using a safe medium. The boundaries of this test shall
ensure that all previously untested items of equipment have been
incorporated.
3. The PDO Standards for reinstatement leak testing are;
For Sour Service - N2 / He at a pressure equal to 95% of the RV
setpoint for the system or equipment being tested
For Sweet Service N2 at a pressure equal to 95% of the RV setpoint
for the system or equipment being tested
Where it can be clearly demonstrated that achieving the Standards above are
not reasonably practicable inservice leak testing using the service medium
will be considered. A Risk Assessment requires to be completed and control
put in place to mitigate any risks that could be encountered by stepping out of
the Standard.
4. Is the Process Medium Sour or Sweet Service?
5. Sour service shall require that all reinstatement leak testing on process
systems containing or exposed to H 2S or Toxics be carried out using a nitrogen
with a helium trace to a pressure equal to 95% of the RV setpoint for the
system or equipment.
6. This method of testing also referred to as sensitive. Reinstatement leak
testing of this kind requires specialist equipment and shall normally be carried
out by a contract company.
7. Operations shall obtain quotations for the work from an approved contractor,
based on the scope of work. The quotation should also have a method
statement detailing how the work shall be undertaken and all safety
considerations. Operations shall agree Terms and Conditions and authorise the
work.
8. Sweet service shall require that all reinstatement leak testing on process
systems containing hydrocarbons be carried out using nitrogen to a pressure
equal to 95% of the RV setpoint for the system or equipment.
9. If it is demonstrated that testing using N2 is not practicable and that the
potential for an uncontrolled leak after a Risk Assessment is Low the leak
testing shall be considered as detailed in 13.
10. If it cannot be demonstrated then reinstatement testing shall continue using N2
to a pressure equal to 95% of the RV setpoint for the system or equipment.
11. The volume and pressure of N2 required to undertake the testing will be
dependant on the system or equipment. Large volums of N2 can be supplied
as liquid and then vaporised. This method is ideal for gas freeing and purging
and can also achieve reinstatement testing requirements at the lower
pressures. For small volume, higher pressure testing N2 quads can be used.
Where large volume and high pressure is required this will require putting the
work out to a specialist contractor equipped with equipment to pump-up the
system. For this work refer to the 6 and 7 above.
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3
N2 leak testing shall be performed by trained and experienced technicians.
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4
Items for vacuum service should be tested with a vacuum. The reason for this is that applying
a pressure test to vacuum equipment does not necessarily detect places where there can be
leakage in the opposite direction, e.g. a gasket fault.
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5 Hazards
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Appendix 3 - Abbreviations
The following abbreviations are used in this Procedure.
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UOP7
Custodian of Document Date:
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