10 1.

PREPARATION FOR MAINTENANCE

1.1.6 Some Miscellaneous Incidents Involving Isolation for

Maintenance
(a) A slip-plate that had been in position for many months, perhaps
years, was relied on to isolate equipment. It had corroded right
through (Figure 1-5). Slip-plates in position for a long time should
be removed and inspected before being used as maintenance isola-
tions. (Such slip-plates should be registered for inspection every few
years.)
(b) A slip-plate with a short tag was overlooked and left in position
when maintenance was complete. Tags should be at least 130 mm
long on lines up to and including 6 in. diameter and at least 150 mm
long on larger lines. Figure-8 plates are better than slip-plates, as
their position can be seen at a glance; figure-8 plates should be used
on lines that have to be slip-plated regularly. Although the initial cost
is higher, they are always available on the job, while slip-plates tend
to disappear and have to be replaced.
(c) On several occasions, small bore branches have been covered by
insulation, overlooked, and not isolated.
(d) On several occasions, thin slip-plates have been used and have
become bowed; they are then difficult to remove. Figure 1-6 shows a
thin slip-plate that has been subjected to a gauge pressure of 470 psi
(32 bar).
Slip-plates should normally be designed to withstand the same
pressure as the piping. However, in some older plants that have not
been designed to take full-thickness slip-plates, it may be impossible
to insert them. A compromise will be necessary.
(e) A butane pump was isolated for repair by valves only. When it was
opened up, the pump and adjoining lines were found to be full of
hydrate, a compound of water and butane that stays solid at a higher
temperature than ice. A steam hose was used to clear the choke. Soon
afterward there was a leak of butane, which was ignited by a furnace
40 m away, and exploded. The suction valve was also blocked by ice
and was one turn open [22].
If you are not convinced that all isolation valves should be backed up
by slip-plates before maintenance takes place, at least back up valves on
lines containing materials that might turn solid and then melt.

1.1.7 Electrical Isolation

When an electrical supply has been isolated, it is normal practice to
check that the right switches have been locked or fuses removed by try-
ing to start the equipment that has been isolated. However, this system is
not foolproof, as the following incidents illustrate.