Utilities (CoE)

Engineering Guideline
Double Block and Bleed for
Steam Process Isolation

Reference ENG-UTI-STE-ISO

Version 1.0

Date 10.09.2018

Mars Global Petcare

Notice of Confidentiality

This document and the information contained in it are confidential and are the property of
Mars Incorporated. They may not in any way be disclosed, copied or used by anyone except as
expressly authorized by Mars. This document should always be kept in a secure place and
should be destroyed or returned to Mars when it is no longer needed.
 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

1 Table of contents

1 Table of contents ................................................................................................................... 2

2 This Document ....................................................................................................................... 3

2.1 Version History ................................................................................................................ 3
2.2 Contributors .................................................................................................................... 3
3 Scope of the document.......................................................................................................... 4
3.1 Summary ......................................................................................................................... 4
3.2 Steam Isolation systems .................................................................................................. 5
4 DBB Process Equipment Isolation (Executive Summary)....................................................... 6

5 Isolation Categories ............................................................................................................... 8

5.1 Positive Isolation ............................................................................................................. 8
5.2 Proved Isolation............................................................................................................... 8
5.3 Non-Proved Isolation....................................................................................................... 9
6 Isolation method for steam isolation selection ................................................................... 10

7 MARS GLOBAL HSE STANDARD FOR STEAM ISOLATION ..................................................... 12

8 Double Block and Bleed valve system. Requirements at MARS .......................................... 13

8.1 Isolation Valves.............................................................................................................. 15
8.2 Bleed Valve .................................................................................................................... 16
8.3 Pressure indicator ......................................................................................................... 16
8.4 Safe Verification point ................................................................................................... 18
8.5 New Isolation systems. Double block and bleed (all in one) ........................................ 19
9 Isolation procedure .............................................................................................................. 20

10 Special cases: Steam Traps .................................................................................................. 22

10.1 The steam trap belongs to an equipement (like heat exchangers…) ........................... 22
10.2 The steam trap works separately (directly connected to the steam net work) ........... 26
11 Associated Documents ........................................................................................................ 28

Confidential – for Internal use only 2

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

2 This Document

2.1 Version History

Version Date Author Position Modification

1.0 10/09/18 M.Romero Regional Utilities Eng (Europe) First Issue

2.2 Contributors

Name Position Date signed

Guenther Muller-Roehlk Global Utilities Leader

Sergey Illyin Regional Utilities Eng (CIS)
Eric Lortie Regional Utilities Eng (N.A.)
Francois Mele Regional Utilities Eng (R.C.)
Alejandro Sanchez Regional Utilities Eng (LATAM)
Neeraj Trevedi Regional Utilities Eng (ASIA)
Philippe Frickert Global WET Eng (Royal Canin)
Jerome Huez Regional SES leader (Europe)

Confidential – for Internal use only 3

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

3 Scope of the document

3.1 Summary
The aim of this document is to give a clear indication to Project Engineers and technicians in
order to help to them to make safe and efficient designs for installing Double block and bleeds
(DBB) for the Steam Isolation of Process equipment and therefore it describes the
requirements and the recommendations for designing the installation of a new steam line and
or for the retrofit of existing systems to meet with Mars Petcare requirements.
This document provides the guidance for the design and application of a safe and effective
process equipment isolation where DBB is valid.
This document doesn’t cover the cases for lines isolation like:
• Isolation process where DBB is not enough and Positive Isolation is required see chapter
5.
• Access to confined spaces.
• Breaking of the envelope (Major interventions, like piping modifications)
For these process isolation, it should be necessary to conduct a risk assestment and most
probably to use Positive Isolation procedures (see chapter 5)

Confidential – for Internal use only 4

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

3.2 Steam Isolation systems

Mars Petcare factories, like most of the food processing companies, are characterised by long
pipelines connecting processes, pumps, vessels, installations. Some of these pipes content
hazardous sustances like steam which operates at high temperatures and pressure.
Any intrusive activity could allow the escape of hazardous substances. The implementation of
adequate isolation practices is critical for avoiding loss of containment. You should minimise
isolation requirements, wherever practicable, by planning intrusive maintenance for shutdown
periods. However when maintenance work has to be carried out on live plant, LOTO principles
has to be applied for a good isolation activity.

The Mars Petcare safety rules obligues, as a base standard, to apply for any steam process
equipment isolation, the Double Block and Bleed methodology.

Minimum requirement Best Practice Configuration

The next chapters describe the different isolation methodologies, the Double block and bleed
isolation way of working and recommended design, and some special cases.

Confidential – for Internal use only 5

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

4 DBB Process Equipment Isolation (Executive Summary)

The Double block and bleed isolation system consist of:

2 Flanged isolation Valves, same size as steam
pipe

1 Flanged bleed valve to depressure the line and

to confirm the isolation valve doesn’t leak.
Optionally 1 additional bleed valve after second
valve.
1 Pressure gauge to monitor and verify the
pressure after the isolation block. Optionally 1
additional pressure gauge between the two
isolation valves.
1 open and safe bleed confirmation point

Isolation Valves for steam applications (block and bleed valve units)

Bellow sealed stop Piston Valves

Gate Valves Butterfly Valves Ball Valve
Valves
RECOMMENDED RECOMMENDED ACCEPTABLE LESS NOT ACCEPTABLE NOT ACCEPTABLE, (except
RECOMMENDED for steam traps cases)

Valve material
Spheroidal Graphite Iron
Cast steel (Also called: Ductil Iron Cast Iron
or SG IRON)
RECOMMENDED ACCEPTABLE NOT ACCEPTABLE

Confidential – for Internal use only 6

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

Bleed Valve Sizing

Main Pipe D<DN65 Bleed valve: DN15 Main Pipe D>DN65 Bleed valve: DN32

Pressure Indicator
Gauge Cock
Gauge Valve
Install with Syphon Acceptable Pressure Range
Best Practice
Less recommended

[0--1,5xSetup pressure]
bar and psi

Safe Verification Point

Open connection Closed connection

RECOMMENDED NOT ACCEPTABLE

Confidential – for Internal use only 7

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

5 Isolation Categories

The possible isolation methods are classified in three categories:

5.1 Positive Isolation

There is a complete separation of the equipment to be worked on from other parts of the
system. As well a positive isolation is achieved inserting a spade.
It’s the most safe way to operate, because there is a physical disconnection between the hazard
source and the equipment.

Physical disconnection

Spade Insertion

However this kind of methods don’t permit to conduct efficiently some of the normal
interventions and obligue to make a shutdown or to use a proved isolation before in order to
apply safely this isolation method.
This kind of isolation are out of the scope of this document.

5.2 Proved Isolation

This kind of isolation methods are done with valves, the effectiveness of valve closure can be
confirmed at any time via vent/bleed points before and during the intrusive work commences.

Confidential – for Internal use only 8

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

There are several methods within this category:

SBB Single Block and bleed

DBB Double Block and Bleed

As a general rule, SBB should not be used for harzardous substances like steam.

5.3 Non-Proved Isolation

These kind of isolation methods are done with valves, however there is not any provision to
confirm effectiveness of valve closure prior to breaking into system.

Double valves

Single Valve

Confidential – for Internal use only 9

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

6 Isolation method for steam isolation selection

The best way to choose the best isolation method is to use the tool provided by the British
Health and Safety Executive in the HSG253 Document: The safe isolation of plant and
equipment.

Where:
• R: Consider whether the associated risk is acceptable or whether there is a need to
further reduce risk by eg risk reduction measures, extending the isolation envelope,
plant shutdown.
• I: Positive Isolation
• II: Proved Isolation
• III: Non-Proved Isolation
The steam is category 2, therefore the minimum Isolation method to be applied is Proved
Isolation.
The reasons to applied a Positive isolation or Shutdown factory depends on the outcome factor,
which determines by: Pressure, pipe size, and severity of damages (potential number of
casualties, fires…)

Confidential – for Internal use only 10

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

Let’s see one example:

One of the most common isolation need at Mars is the isolation of a machine to perform
an intervention:
The steam pressure in the line is <10bar(g), the pipe diameter is <200mm.
The machine is the factory hall and the maximum amount of people affected by an isolation fail is
10 people.
There is not any risk to trigger a fire/explosion in case of isolation failure.

1. Subtance Category for steam is number: 2

2. Outcome Factor: The outcome factor is a combination of two factors:
The location factor which determines the severity of the potential damages, basically
the number of people could be affected by an incident.
And the release factor, which depends on pipe size and pressure:

As it was explained, this is the baseline isolation method. It’s necessary to evaluate every
isolation need by separate, to determine if it’s necessary to apply a higher protection.

Confidential – for Internal use only 11

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

7 MARS GLOBAL HSE STANDARD FOR STEAM ISOLATION

As a general rule the HSE toolbox provides examples for isolation procedures in individual
cases:
Pipework Isolation
Pressure Design 'Best Practice' Standard Minimum isolation Standard Detail Comments/ Advice
Diameter Method
(a) When installed to equipment with 'interlock guarding' the valving
Double block, bleed and must be installed external to guarding, but as close to the plant as
spade. (a) Complete separation of the plant/
possible.
equipment to be worked on from other parts
> 200mm (8") Positive Isolation (b) The bleed pipework outlet should go to a safe place away from the
E of the system.(use of flange, or spade)
Fluid Fluid E (b) See note (d) below
work activity.
(c) The work activity risk assessment must cover hot surfaces and the
potential for a cooling down period.
> 10 Bar
Double block, and bleed (a) When installed to equipment with 'interlock guarding' the valving
(DBB). must be installed external to guarding, but as close to the plant as
DBB - Valve Isolation with effectiveness of
Proved Isolation - possible.
valve closure(s) confirmed via vent/ bleed
<= 200mm (8") (Double Block Fluid E Fluid E points and pressure gauges, before
(b) The bleed pipework outlet should go to a safe place away from the
and Bleed) work activity.
intrusive work commences.
(c) The work activity risk assessment must cover hot surfaces and the
potential for a cooling down period.

Double block, and bleed

(DBB). (a) When installed to equipment with 'interlock guarding' the valving
must be installed external to guarding, but as close to the plant as
DBB - Valve Isolation with effectiveness of
Proved Isolation - possible.
< 10 Bar All (Double Block
Fluid E Fluid E valve closure(s) confirmed via vent/ bleed
(b) The bleed pipework outlet should go to a safe place away from the
points and pressure gauges, before
and Bleed) work activity.
intrusive work commences.
(c) The work activity risk assessment must cover hot surfaces and the
potential for a cooling down period.

The whole document, could be found in the next sharepoint location:

https://team.effem.com/sites/globalses/HSE/Forms/AllItems.aspx?RootFolder=%2Fsites%2Fglo
balses%2FHSE%2FMHSEMS%2FHSE%20Management%20System%20Training%20and%20other
%20materials%20Library%2FLock%20Out%20Tag%28Test%29%20Out%2FTools&FolderCTID=0x
012000F244A038DE95A4459508CD380FBBE9F0&View=%7B7E260582%2DA387%2D46A8%2D9
B50%2D756DE10785F4%7D

Confidential – for Internal use only 12

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

8 Double Block and Bleed valve system. Requirements at MARS

Every equipment/device that consumes steam and is intended to be isolated has to be

equipped with a Proved Isolation device, consisting of a Double Block and Bleed Valves.
The minimum recommended configuration for any steam Double Block and Bleed Valve is:

Minimum DBB configuration

The system consist of:

• Two Isolation valves that fit to the Pipe diameter.
• One Bleed port in between with a size that depends on the main pipe diameter:
o DN15 bleed valve for main pipe D<DN65.
o DN32 bleed valve for main pipe D>DN65.
• One pressure indicator, to monitor the pressure in the pipe and monitor what happens
while the DBB is manipulated.
• A safe bleed confirmation point, to verify that the energy has been released.
• All the components are in the same area and visible from the equipment to be isolated.
(example: if one of the isolation valves is placed in a different room, far away from the
equipment, the block is not considered a DBB).

Confidential – for Internal use only 13

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

Double Block and Bleed Valves

In order to permit an easy purge of the energy before to break into the envelope the best
practice configuration for a steam Double block and bleed is the same as the minimum plus a
bleeding valve after the second block valve and a pressure gauge between isolation valves,
which permits to purge easily the steam and fluid between Valve 2 and the equipment:

Best Practice DBB configuration

Confidential – for Internal use only 14

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

8.1 Isolation Valves

The Isolation Valves types to be used are:
• Bellow-sealed stop valve type
• Piston valve type
• Gate valves are also acceptable but less recommendable because they tend to leak.
Ball valves and butterfly valves should not be used for this application because the operation
of this kind of valves tends to cause waterhammer and butterfly valves tend to leak.

Bellow sealed stop valve

General requirements:
1) Supplier:
There are a very large number of suppliers for this kind of valves, like Spirax-Sarco,
Gestra, ARI, Klinger, Babcock…. There is not any preference supplier of these valves.
2) Materials:
a) Cast Iron valves should not be used anymore, because they are very fragile and they
are exposed to internal corrosion. In these corrosion cases, the crack is coming from
inside to outside and it’s impossible to detect in advance. The streng to withstand
the waterhammer is significantly lower than the SG iron or cast steel valves.
b) SG Iron valves (spheroidal graphite iron) also called Ductile Iron and cast steel
valves are the most recommended for the Isolation application. They are more
expensive than Cast iron valves but they are definitely safer and more robust.
3) Pressure Rating: The pressure rating should be selected according with the max steam
pressure in the factory.
4) Connection: Flanged connection or Welded connection

Confidential – for Internal use only 15

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

8.2 Bleed Valve

The bleed valve is also a Bellow-sealed stop valve type, however the size of this valve should be
choose depending on the main pipe diameter:
Steam pipe Diam<DN65 Bleed valve Diam DN15
Steam pipe Diam>DN65 Bleed valve Diam DN32
General requirements:
1) Supplier:
There are a very large number of suppliers for this kind of valves, like Spirax-Sarco,
Gestra, Babcock…. There is not any preference supplier of these valves.
2) Materials:
a) Cast Iron valves should not be used anymore, as it was explained in last point.
b) SG Iron valves (spheroidal graphite iron) and cast steel valves are the most
recommended for the Isolation application. They are more expensive than Cast iron
valves but they are definitely safer and more robust.
3) Pressure Rating: The pressure rating should be selected according with the max steam
pressure in the factory.
4) Connection: Flanged connection
5) Locking device: There are some valve manufacturers which offer the possibility to lock
the valve with a screw. In order to minimize the likelihood to open accidentaly the bleed
valve, it’s strongly recommended to use this device:

Locking device

8.3 Pressure indicator

In order to monitor the closure/opening of the vlaves, it’s necessary to have two pressure
indicator.
If the equipement is an open system (steam injector, steam oven, retort direct steam injector),
one pressure indictator is enough. However when the equipment to be isolated is a closed
system (basically heat exchangers) two pressure indicators will help to identify a wrong
isolation process.
There are many pressure indicator in the market valid for this application, it’s only necessary to
choose the right pressure range. For choosing the range, use the next formule:

Confidential – for Internal use only 16

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

Multiply 1,5 x Set pressure to get the maximum.

The pressure indicator has to be installed in combination with a “U” or ring syphon in order to
prevent damages to the indicator due the heat.

Pressure gauge with "U" and ring syphon

Aswell it’s necessary to install a valve which provides the opportunity to vent the pressure
measuring instrument under pressure in order to permit the evaluation of Zero pressure
measurement.
The most recommended is to use a shut-off Gauge valve with vent screw (to evaluate of zero
pressure) like this:

Shut-off Gauge Valve

A pressure gauge cock is a more simple device for doing it, it’s acceptable but less
recommeded:

Pressure Gauge Cock

IMPORTANT: Remember to prim the syphon with water before fitting the gauge.

Confidential – for Internal use only 17

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

8.4 Safe Verification point

It’s very important to drive the bleed port to an visible and safe place.
The bleed port shouldn’t be driven to a closed collector or condensate return pipeline, because:
• It’s difficult to verify that the bleed valve has released the pressure, as it’s not visible.
• In the case of a block valve failure during the intervention, there is not possibility to
detect the leak.
• In case of a bleed valve failure during running conditions, it’s not possible to detect the
leak and therefore steam is wasted with no notice.
Recommended solutions for this kind of safe verification points:

Confidential – for Internal use only 18

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

8.5 New Isolation systems. Double block and bleed (all in one)
ACEPTABLE BUT NOT RECOMMENDED
Some suppliers have introduced in the market some isolation valves which integrate the two
block valve and bleed port in one single block. Like Spirax Sraco Safe Block®.

After some evaluation trials in some Mars factories, this system is not recommended, because
it’s complex for operators to visualize which are the isolation valves and the bleed valve.
Only it could be interesting to apply the solution on those retrofit installations where the gap to
replace an existing block valve by two valves was too small, and therefore it was not possible to
install them.
On top of it the extra cost (35% more in medium size and 75% more in big sizes), comparing this
solution with the standard one (two independent valves plus a bleed valve, including
installation cost) doesn’t invite to go for this solution.

Confidential – for Internal use only 19

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

9 Isolation procedure

One critical topic is to have a right isolation and restart procedure in place. The people who has
to do a Isolation activity has to be trained on it.
The isolation valves have to be correctly identified and an information plate to explain how to
conduct an isolation procedure should be fixed near the isolation system.
To have a common isolation procedure is not possible, as each situation will be diferent and will
require a an independent risk analysis.
The common points in every Isolation procedure are:
• It drives to operator to follow LOTO instructions, internal procedures and get proper
permisions.
• It shows the required personal protection equipment, like gloves, glasss….
• It indicates the sequence for opening valves and what are the expected results in
pressure indicator.
• The procedure has to be able to ensure and confirm that the two isolation valves close
correctly (tightness) and they do individually.
• It shows what is necessary to check in order to validate the tightness of the valves.
• It indicates how to lock the valves (chains, special device, lock box….)
• It indicates how to tag the isolation block.
• It indicated also, how to re start the system, once the intervention has finished.
In the next page, you will find an example for a DBB (best practice configuration). It’s only an
example.

Confidential – for Internal use only 20

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

This is only an example.

Each isolation procedure has to be elaborated individually
(Risk assessment).

It’s a good practice (and also a matter of courtesy), once you have completely open
the valve, to turn back the handwheel one quarter. Later for anyone who tries to close
the valve It’s easy to identify if the valve is open or closed and also easier to operate
it. Otherwise the valve is jammed in open position and it’s harder to close.

Confidential – for Internal use only 21

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

10 Special cases: Steam Traps

Steam traps are a special case to be discussed separately, and we can find two different
scenarios:

10.1 The steam trap belongs to an equipement (like heat exchangers…)

There are cases that the equipment gives back the condensates to a condensate return line
(Heat exchangers, Coils, AMMP skids). In these cases the equipment has to be isolated from the
steam energy system at least in two different points: steam supply side and condensate outlet
point.

In this case, for a safe access to the equipment (Heat exchanger) a second isolation device has
to be installed after the heat exchanger, and we can leverage the configuration of the steam
trap station to isolate both systems to permit a safe acces to the heat exchanger and the steam
trap.

Confidential – for Internal use only 22

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

The best option for a safe isolation of the equipment is:

The configuration is:

Two Isolation valves after the steam trap, one bleed valve.
An aditional bleed valve will help to empty all the hot liquid inside the heat exchanger and
minimize the risk of burns.
For the condensate line side, the isolation valves type could be:
• Piston valve. All diameters
• Bellow sealed valve. Diameter size >DN25
• Gate valve. Diameter size >DN25
• Ball valve. Diameter size <DN25 To allow a smooth opening and therefore to avoid
waterhammer, in the steam pressure side of the steam trap (Before the equipment) the
valves must be bellow sealed valve, piston or gate to permit a smooth start up of the
installation after an intervention.

Confidential – for Internal use only 23

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

There is a possibility to use steam trap stations, which includes isolation valves and bleed ports.
This kind of station facilitates the replacement of the steam trap and also the installation works,
as most of the elements are included in a single pack.
The steam trap station consist in a block equiped with a common body (isolation valves, filters
and bleed ports are usually in this body) and a connection port where the specific steam trap
can be attached (therefore for the same body different traps can be fixed to it).
The maximum size is usually 1”, therefore for bigger diameter, we should use the conventional
solution that was shown before.

Some steam trap stations

For these case a common solution is to have the next configuration:

The steam trap station is equipped with two isolation valves (one before and one after steam
trap) and a blowdown port to release pressure. On top of it, one more isolation valve is added

Confidential – for Internal use only 24

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

after the trap to get a right isolation from the condensate line and a bleed valve after the heat
exchanger to empty the hot condensate inside.
There are several suppliers that offers this kind of steam trap station: Spirax Sarco,
Armstromng, TLV:
• Spirax Sarco STS 17.2 equipped with blowdown valve.
• Spirax Sarco PC40
• TLV V2P series
• Armstrong International series tvs 4000
• Gestra TS 36

Confidential – for Internal use only 25

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

10.2 The steam trap works separately (directly connected to the steam net work)
When the element to be isolated is a stem trap that is place to remove the condensate form
the distribution line, we should isolate the system in both sides of the steam trap. High
pressure side and low pressure side.

For this kind of steam traps we should consider to apply the same methodology, double block
and bleed. For Diameter bigger than 1” will be the best solution.

Steam trap configuration for big diameter

However for small diameter traps (D<1”) the most recommended is to use a steam trap station
in order to minimize the number of elements and simplify the configuration.

Confidential – for Internal use only 26

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

Steam trap station equipped with a double valve and also a blowdown valve.

Confidential – for Internal use only 27

 ENG-UTI-STE-ISO. Engineering Guideline
Petcare Engineering

11 Associated Documents

Document Status
Equipment Specifications + Drawings
HSG253: The safe Isolation of plant and Author: British Health and Safety Executive
equipment document.

Further documentation

Confidential – for Internal use only 28