ISOLATION,GAS FREEING &

REINSTATE PROCEDURES
(PTP-8)

Training Package PTP 8.1

Isolation -General

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Table of contents

Page No.

8.1. Introduction 03

8.1.1. Isolation 03

8.1.2. General Requirements 03

8.1.3. Different purpose of Isolation 05

8.1.4. General Procedure 07

8.1.4.1. Tagging of Isolation 07

8.1.4.2. Securing Isolation 07

8.1.4.3. Providing Isolation 07

8.1.4.4 Extended period of Isolation 08

8.1.4.5 Unrecorded Isolation 08

8.1.4.6 Locked valves & Spectacle Blinds 08

8.1.4.7 Minimum Isolation Requirements 10

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8.1. INTRODUCTION:

8.1.1 What is isolation?

It is Company policy that maintenance or modification work to process plant

requires that the plant concerned is effectively isolated from all sources of
energy and hazardous materials, and made safe before work is allowed to
proceed. Controls are provided for the purpose of plant isolation to ensure
the safety of personnel and the protection of company assets and
environment

Purpose:

The purpose of this procedure is to specify and describe in detail the steps
necessary for the isolation.

Scope:

To isolate process plant prior to maintenance or engineering work. Under

normal circumstances, this requires that a process unit is shut down,
depressurised to atmospheric pressure, drained, purged free of flammable or
toxic gases, and then effectively isolated from any adjacent systems that may,
or may not, remain live during the work.

8.1.2 General Requirements for Isolation(s)

The following requirements apply to all isolation.

Competency:
The responsible Supervisor must ensure that the person nominated to do
isolation is competent for the task.

Security:
Each isolation is to be secured in the required position so that the accidental
release of energy source is prevented.

Labelling:
The isolation is to be labelled with a high visibility “Isolation Label” so that
anyone can immediately see why that an isolation is in place, and should not be
tempered with.

Recording:
Isolation is to be recorded on the Permit for the work or on the separate
isolation Certificate. For complex isolation, marked-up P&Ids or line diagrams
should be attached to the isolation Certificate. ALL isolation work SHALL be
carried out under the Permit to Work system.

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Integrity:
It is essential that Operators and Supervisors being constantly vigilant during
the work or in the case of a long-term isolation maintain the integrity of
isolations for the entire period of any works by formal auditing of such
isolations at pre-defined intervals.

Hazards:
Hazards SHALL be identified, detailed and controlled by proper use of the
Permit to Work system. Isolation of any equipment that may cause a hazard to
personnel, the environment or damage to the Company's assets SHALL be
accomplished to provide the safest environment to carry out any work on that
equipment.

Authority:
All work SHALL be authorised by the Area Co-ordinator or his delegated
representative.

Method of Isolation:
The method of isolation depends on such factors as the type of work involved,
e.g. of major, minor or routine nature, the properties of the process medium
and the temperature and pressure of the process system. To provide the most
positive means of isolation, disconnection of lines, blind flanges, inserted
spades, and closed spectacle blinds SHALL be used wherever possible. The use
of ‘home made’ spades or blinds is forbidden.
Actuated valves can only be used for isolation if all motive power to the valve
has been physically disconnected from the actuator. Relying on a switch is
not adequate.

Block and Bleed:

Double block and bleed arrangements will provide a measure of protection
when used in conjunction with spades or blinds. However, they should never
be considered as an acceptable replacement for mechanical isolation for major
work, unless physical isolation (by removing pipework) is agreed.
When the piping and valve arrangement of process equipment does not allow
for double block and bleed, the Area Co-ordinator will determine if isolation
can be safely accomplished by an alternative method. In this event, the
procedure to be followed will be clearly illustrated and written on or attached
to the Work Permit.

Minor work:
Such as replacing a faulty instrument on a vessel (subject to the approval of
the site maintenance and production supervisors), the required isolation on
liquid containing systems (not gas) may be effected by closing valves only

Longer duration:
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 isolate the equipment.

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 Long term isolations:
For long term 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. Such isolations SHALL be audited and checked for integrity at a
frequency defined by the Area Co-ordinator.

Electrical Systems:
All electrical isolations are to be done in accordance with the Electrical Safety
Rules (ESRs) and Electrical Safety Operation Procedures (ESOPs)

8.1.3 Different Purpose of Isolation:

Isolation of Equipment for Maintenance:

 The most important rule for isolation of equipment is ‘Stick to the

Procedures’. For guidance, the schematic diagrams attached to this
procedure show typical isolation arrangements.

 The Production Supervisor or permit applicant SHALL write a site specific

procedure for every piece of equipment to be isolated from live plant and it
SHALL be attached to the Work Permit, describing what connections
SHALL be disconnected, blocked or tagged before starting to open the
equipment.

 A spade and blind check list SHALL be made by the permit applicant and
submitted with the Work Permit to ensure the correct spades or blinds are
closed during isolation and removed upon completion of the work. The
Operator will sign off this spade list after isolation and prior to equipment
reinstatement after de-isolation.

 If valves do not have a leak tight shut-off, the Production Foreman must be
consulted to advise on how the work can be progressed safely. If the
situation is deemed unsafe, the work, including the installation of blinds,
should be stopped. This should be stated in the Work Permit.

 Supervision of the work by the Operator is required, particularly

checking all isolation points before starting, restarting, during and after
finishing the job. The Operator 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 purging as
needed.

Isolation of Moving Machinery:

 Moving machinery is defined here as any equipment using external motive

force such as electricity, air, steam or hydraulic fluid.

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 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 as per
ESOP (Electrical Safety Operational Procedures - ERD 64-07).

 Isolation of moving machinery from process fluids SHALL be accomplished

by physical disconnection of the machinery and the use of spades or blinds on
the equipment side of inlet and outlet block valves in order that maintenance
may be carried out while the surrounding facilities remain live.

 Moving machinery brakes and brake locks are to be applied and the clutch (if
applicable) is to be disengaged.

Isolation of Vessels:

 Design procedures indicate that normally open spectacle blinds should

be installed on the downstream side of the inlet block valve and the
upstream side of the outlet block valve. If practical these blinds should
be mounted directly on the inlet flange.

 Spectacle blinds SHALL be swung closed for maintenance work. If a spool

piece is present between the blind and the block valve it should be equipped
with a vent or drain valve to allow the bleed off of any pressure build up
between the valve and the blind during maintenance before removing the
blind to reconnect the vessel.

Isolation of Tanks:

 Blinds or spades should be inserted on the tank side of all inlet and
outlet block valves. These should 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.

Isolation of Equipment Containing H2S Gas:

 Toxic gas is defined, for isolation purposes, as a gas containing more than
50ppm of H2S in the gas phase of the process stream. A double block and
bleed system is the minimum mandatory requirement for systems.

 When double block and bleed systems are used in toxic service, the bleed
connection SHALL be hard-piped to a safe disposal location to ensure that the
bleed itself does not create a hazard. Acceptable disposal routes are to a
remote vent or to a plant closed drain (or vent) system, provided that no live
facilities are connected to the drain system while the double block and bleed is
in use.

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Use of Breathing Apparatus:

 It is mandatory to wear positive pressure breathing apparatus when

breaking flanges and opening equipment during work on equipment
containing toxic gases. This should be clearly stated on the Work Permit.

 Adequate isolation and purging SHALL be proven by a direct measurement

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.

8.1.4 GENERAL PROCEDURE:

8.1.4.1 Tagging of Isolation:

Every valve, spade, switch, breaker etc. used in isolation (except for isolation that
does not require isolation certificate) must be marked with the correct type of tag
label. Different tags are available for the isolation of Valves, Spades, and Electrical
Equipment.

All tags have three parts. The first part is to be attached to the isolation point. The
other two parts are to be attached to the permit Issue Point copy of the permit or
isolation Certificate and kept at the issue Point until the isolation is removed.

When the isolation is removed the tags that have been removed must be compared
with those at the Permit Issue Point to confirm that all isolation have been removed.
The third part of the tag (the smallest part) is provided to assist in the removal of
complex isolation. This part is kept attached to the middle part of the tag at the issue
point until de-isolation is required. The third parts can be detached and taken to the
site by the de-isolator to ensure he only de-isolates the correct valves/switches.

8.1.4.2 Securing of Isolation:

MECHANICAL:
All valves etc. used as part of an isolation boundary are to be secured in the required
position using a high visibility-securing device, e.g. red/white plastic chains. The
purpose of securing the isolation is to prevent valves from being moved accidentally,
and to show everyone in the area that the valve is being used as part of isolation.

ELECTRICAL:
All electrical isolation is to be done in accordance with the Electrical Safety Rules and
Electrical Safety Operation Procedures.

8.1.4.3 Proving of Isolation:

Whenever isolation is complete, the isolator must prove that the area within the
isolation is fully isolated from pressure/electricity. This can normally be done by
checks at vent valves or by the checks to prove electrical equipment dead required by
ESOPs/ESRs. If it is not possible to check that a pressure system has been de-

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pressurised without unbolting a flange, the work part must be aware of the possible
pressure hazard. The Job Safety plan must include clear instructions on controlling the
unbolting of the first flange to ensure that any pressure is released before bolts have
been removed.

8.1.4.4 Extended Period Isolation:

Extended period isolation (EPIs) are isolations, which must remain although no work
is being done within their boundary. They may be required for two main reasons:

1) Where work has started but will be suspended for a period of short time. For
example, when awaiting spares for repairs.
2) Where equipment becomes redundant and is to be permanently isolated.

8.1.4.5 Unrecorded Isolations:

It is not necessary to record mechanical isolations if BOTH of the following

conditions are met.

1) The isolation is to be done by a competent person from Operation Department,

nominated by the Responsible Supervisor, for the purpose of calibration or minor
repair/replacement work that he will do himself, and
2) The isolation will be removed before the end of the working period.

Minor repair/replacement work is work that can be done without the person leaving
the worksite. Examples are pressure gauge replacement, isolation for fault-finding etc.

8.1.4.6 Use of Locked Valves and Spectacle Blinds for Isolation:

Locked valves are used for safety purposes in process plant, either to ensure that a
flow pathway is maintained (in the case of a relief valve) or a system/vessel is
securely isolated from adjacent processing equipment. Similarly, ‘spectacle’ blinds
are used for effecting positive isolations between vessels and pipe work.

Process plant that is taken out of service for maintenance, or isolated long term for
other reasons, is always subject to the insertion of spectacle blinds and the locking of
key valves which ensures the safety integrity of the isolation.

The incorrect or unauthorised use of these isolation techniques, or a change in their

ongoing status, can compromise the safety of a facility. To prevent this, and to ensure
that these techniques are used correctly, controls are provided for their authorisation
and audit.

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Procedure Description
Definitions
Locked Valve:
A locked valve is a valve which is designated on the Process and Engineering Flow
Scheme (PEFS) as being either Locked Open (LO) or Locked Closed (LC). Locked
valves are those valves identified during the design phase, or in subsequent reviews,
as being essential to the safety and integrity of the plant or facility. The changing
of the normal state of a locked valve must be controlled through the Permit to Work
System according to this procedure to assure the continued safe operation of the
facility.

Where valve is not required to be opened frequently then the recommended method of
locking is by the crimped wire system; else chain and padlock shall be applied.

Spectacle Blind:
A spectacle blind is designated on the Process and Engineering Flow Scheme (PEFS)
as being either open or close. Spectacle blind positions are identified during the
design phase, or in subsequent reviews, as being essential for positive isolation
purposes and the safety of the plant or facility. Changing the status of a spectacle
blind must be controlled through the Permit to Work System according to this
procedure to assure the safe operation of the facility.

Locked Valve Register and Spectacle Blind Status:

 A register of the change in position of all locked valves (as defined above)
shall be maintained on site, and shall be called the Locked Valve Register.
 All temporary changes to the normal status of locked valves are to be
authorised by the Production Supervisor prior to the change being made.
Permanent changes must be handled through the Facility Change Proposal
(FCP) procedure.
 Any change to the normal status of a valve or spectacle blind shall be recorded
in the Locked Valve together with the reason for the change and the number of
the permit (if applicable) that authorises the change.
 ALL deviations from the approved status of locked valves or spectacle blinds
shall be recorded (for audit purposes) and reported to the Area Co-ordinator
and the Area Team Leader.
 The Production Supervisor shall audit the status of locked valves once in
every six months, and shall be accountable to ensure that the status of locked
valves are physically checked and recorded once in every shift change –
“shift” being a 2 week tour of duty. Spectacle blinds shall be audited once
every 12 months. The plant operators shall check both against the latest
PEFS/UEFS. A file shall be kept of all audits for external checking.

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8.1.4.7 Minimum Isolation Requirements:
Table shows the recommended minimum isolation requirements.
System System Description Major Work
Class

A A shutdown, depressurised Positive isolation by a spade or

and hydrocarbon free remove spool and install blind.
system.

B System in service, of ANSI Single leak tight valve plus

class 600 and below. spade/blind (Note 1).
For flashing liquids and
toxic see C below.

Double block and bleed plus a

C System in service, of ANSI
spade/blind.
class 900 and above.
All systems containing toxic
fluids (Note 2).
Systems containing
flashing liquids above
ANSI 300, (Note 3) i.e.
ANSI 600 and above.

Note 1 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 spade/blind and isolation
valve.
Note 2 For the purposes of this requirement, toxic in the case of H 2S is defined as
more than 50ppm H2S in the process stream.

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Note 3 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.

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