Contents
Paragraph Page
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1 Introduction 1
1.1 Purpose 1
1.2 Scope 1
1.3 Responsibilities 1
1.4 Self-regulation and Audit 2
1.5 Isolating Authority Training and Competency 2
1.6 Modifications and New Facilities 3
Contents (cont’d)
Paragraph Page
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3.6 Boundary Isolations 13
3.7 Long-term Isolations 14
3.8 Locked Open/Locked Closed Valves 15
3.9 Personal Isolations 15
3.10 Testing Isolation Integrity 15
3.11 Monitoring Isolation Integrity 16
Contents (cont’d)
Paragraph Page
Table
1 Minimum Recommended Isolation
Standards for Predetermined Risk Levels 8
2 Permitted Limits for Confined Space Entry and Work 26
Figure
1 Example Tagging Label 12
2 Leak Testing Checklist 33
Contents (cont’d)
Addendum 1 References
Addendum 2 Glossary of Terms
Addendum 3 Typical Valve Isolations Integrity Tests
Addendum 4 Safe Isolation and Reinstatement
of Plant Flowchart
Addendum 5 Workplace Assessment Plan Template
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Issue Authority
Name: Ross Kinnear
Signature: ________________________________________________
Date: ________________________________________________
Technical Authority
Name: Brian Howell
Signature: ________________________________________________
Date: ________________________________________________
Amendment Record
AMOSAF.171
Amendment Summary
Distribution List
01 OIM Andrew
02 OIM Arbroath
03 Terminal Manager Bacton Terminal
04 OIM Bruce
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31 Operations Engineer Wytch Farm
32 Data Control Centre (DCC) ODL, Aberdeen
33 OIM Unity
34 Technical Safety Engineer AMEC
35 Technical Safety Engineer AMEC
36 Wood Group Aberdeen
37 Wood Group Aberdeen
38 OIM Mungo
39 BJ Process and Pipeline Services Ltd Aberdeen
40 BJ Process and Pipeline Services Ltd Aberdeen
41 BJ Process and Pipeline Services Ltd Aberdeen
42 Headley Purvis, c/o BJ Process and
Pipeline Services Ltd Aberdeen
Virtual Copyholders
Copy Copyholder
Preface
All holders of this document are registered so that they can be sent updates and be kept
informed of changes or reviews.
Responsibility of Copyholders
It is the responsibility of the registered copyholder of controlled hard copy versions to
maintain the accuracy of the document by ensuring that all updates are promptly
incorporated and acknowledged.
Furthermore, the registered copyholder of controlled hard copy versions must at all times
maintain custody of this document unless prior approval is given by the relevant
Technical Authority.
The roles and responsibilities of copyholders and ‘virtual’ copyholders are detailed in Section 1
of the Document Control Procedure (UKCS-DCM-001).
List of Abbreviations
1 Introduction
1.1 Purpose
The purpose of this document is to define BP operating policy and procedures for the
safe isolation and reinstatement of plant or equipment from sources of hydrocarbons
and other fluids.
A glossary of the terms used in the document is given in Addendum 2.
1.2 Scope
This document applies to the preparation for isolation, mechanical isolation,
reinstatement and leak testing of process utility and drilling systems. It shall be followed
at all BP UK upstream operated sites, both onshore (excluding Grangemouth) and
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1.3 Responsibilities
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1.4 Self-regulation and Audit
Business Units shall periodically review isolation-related activities including review of
individual isolations and review of overall isolation processes. Such reviews may
also include:
• General compliance with this document and any local procedures
• The assessment of non-compliant isolations and the extent of any approved
deviations
• Registers of competent area and isolating authorities
The competency requirements for process isolations for the key positions within this
document are as follows:
All key participants in the implementation of the BP Isolations Policy shall be trained and
assessed as competent to the appropriate level in the safe isolation and reinstatement
of plant.
An audit programme shall be established at each site to ensure that regular checks are
made on isolations to provide assurance that the isolations policy and standards are
being applied and that lessons learned are communicated effectively.
• Preparation for isolation involving draining, flushing, purging and venting of process
pipework shall be conducted under the Integrated Safe System of Work (ISSOW)
according to the appropriate procedures for the task and including the appropriate
isolation
• Amendments shall not normally be made to isolations in place other than to allow
testing of equipment prior to return to service. Amendments may be made to
improve the integrity of the isolation with the approval of the Area Authority. The
reason for the amendment shall be recorded and the Performing Authority advised of
the change
• Pressure relief valves shall only be isolated following the provision of an alternative
means of pressure relief
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The highest quality of isolation which is reasonably practicable shall be applied to every
individual isolation point. The methods of isolation normally available are detailed in
Paragraphs 2.3.1 to 2.3.4, listed in decreasing order of security and effectiveness.
Conventional mechanical plugs or stopple bags may be used as a vapour or liquid seal to
contain and direct to vent any small amounts of vapour. Flammable vapour monitors
shall be used where the presence of vapour could create a hazard.
In all cases, contingency measures against injury or damage caused by sudden ejection
of the isolation device shall be put in place.
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positive isolation
A Use mandatory safeguards as on List A
B Use mandatory safeguards as on List B
SVI Single valve isolation
DBB Double block and bleed
Mandatory Safeguards Category A Category B
(Low Risk) (High Risk)
Continuous gas monitoring (for hydrocarbon y y
systems only)
Pressure buildup to test valve integrity y y
Regular monitoring of isolation integrity y y
Control and prevent nearby work y y
Operations Technician in attendance y y
Radio link to control room when breaking y
containment
Develop contingency plan against leakage y
Identify backup isolation valves, shutdown y
systems etc
Minimise task time y
Portable firefighting equipment available (for y
hydrocarbon systems only)
Minimise possibility of plant disturbance y
• Identifying additional isolation valves and the expected action if the isolation fails
• Knowing the position of the local ESD facilities
Firefighting equipment shall be readily available and the work party shall be in radio
contact with the control room.
Other precautions that should be considered when breaking containment are as follows:
• Consideration should be given to hot bolting flanges prior to the operation and all
materials for the job shall be available at the job site
• Bolts are to be slackened off in the correct sequence. No bolts shall be removed until
they have all been slackened and the joint cracked, and until it has been confirmed
that the line contents will not be released in an uncontrolled manner and any
appropriate gas testing has been carried out
• Particular care shall be taken with clamp lock type fittings. With nuts slackened, the
fitting should be physically dislodged to confirm there is no residual pressure, before
final disassembly
• The person who opens the flange shall do so in such a way as to minimise the
possibility of contact with the contained fluids and of sudden escape of large
quantities. Suitable Personal Protection Equipment (PPE) shall be worn
• Where there is a danger of H2S being present, full H2S procedures covered in the BP
Hydrogen Sulphide Procedures shall be followed
• The Area Classification procedure used for the selection of electrical equipment in
hazardous areas does not consider abnormal operations when breaking containment.
Consideration shall be given to restricting the use of electrical (and other) equipment
during breaking containment due to the risk of releasing flammable gas
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man, development of a contingency plan for isolation failure
• Full consideration shall be given to the alternatives including partial or full production
shutdown or deferral of the work
• The recommendations from the Level 2 Risk Assessment shall be approved by the
OIM/Site Controller who may also recommend further review by technical specialists
or management before taking the decision on whether to proceed with the work
Certain routine operational tasks such as Duplex filter changeouts may not fully comply
with the minimum recommended isolation standard. These tasks shall be conducted in
accordance with a local operating procedure which has been developed based on an
isolation risk assessment.
from the locked position. Where this method is used, padlock keys shall be held by
the Area Authority
• The use of specifically designed tamper-proof valve interlocks. The activation of the
interlock shall be controlled by the Area Authority utilising the master key held at
the site
When isolating any valve that cannot be locked and may inadvertently be opened by
accidental contact, the valve handle shall be removed where practicable.
Electrically operated valves shall have the power supply positively isolated and any
handjack shall be manually locked. If the valve cannot be physically immobilised it should
not normally be used for isolation purposes.
Pneumatically and hydraulically operated valves which fail closed shall have their control
lines isolated and physically disconnected.
Pneumatically and hydraulically operated valves which fail open should not normally be
used for isolation purposes. If no other alternative is reasonably practicable, the valve
shall be prevented from moving. Under this situation the isolation shall be considered as
non-compliant with SIRP and a Level 2 Isolation Risk Assessment carried out under
ISSOW.
It is not necessary to lock bleed valves in a DBB arrangement as they are required to be
opened periodically to check the integrity of the isolation.
Personal isolations (refer to Paragraph 3.9) shall be secured to the same standard to
prevent unauthorised operation of the valves.
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master key cabinet or individual key safes.
Where there are overlapping isolations where some of the isolation points are common
to more than one isolation then these points shall have a separate locking device and tag
from each isolation. Each isolation shall be registered and controlled by its own
individual ICC.
BREAKING CONTAINMENT
SIGN:
DATE:
NO: 467
BREAKING CONTAINMENT
SIGN:
DATE:
NO: 467
UKCSSSW001_002.fh8
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Certificates to be raised, and the implementation of additional security measures.
Boundary Isolations shall not be removed until all applicable Work Control Certificates
have been cancelled.
If for any reason work on a particular piece of plant within the Boundary needs to be
suspended (eg whilst awaiting spares) then a separate isolation shall be implemented
and an ICC raised before the Boundary Isolation can be cancelled.
Where the de-isolation of boundary isolations is proposed, an isolation review team that
includes an Area Authority shall ensure that all associated Work Control Certificates have
been cancelled. They should also ensure that equipment within the boundary is in a safe
condition.
example replacing pressure gauges, filters or small valves, or other such tasks where the
completion of an ICC is considered to add no significant value in terms of risk reduction.
The rules for approval of a personal isolation are as follows:
• The task and isolation are performed by one person within one shift; the person may
receive assistance from others but he shall be present at all times when work is in
progress
• Before approval, the Area Authority must be satisfied with the competence of the
Performing Authority to both carry out the isolation and execute the work. Personal
isolations shall only be carried out by those deemed to be a competent Isolating
Authority. Where an isolation involves competency in more than one discipline eg
electrical, mechanical, instrument or process, personal isolation is only permissible if
the Performing Authority has all the appropriate isolating competencies
• The same isolation standards apply to personal isolations other than the completion of
the ICC
• The isolation points shall be labelled with a personal isolation label and locked
• If the worksite is left unattended, the plant shall be left safe, including capping or
plugging of any open ends
An ICC shall be raised whenever these conditions are broken.
On completion of checking valve integrity, a bleed valve shall be left in the closed
position, unlocked to allow regular monitoring. A pressure gauge may be fitted to the
bleed valve to monitor for pressure buildup.
An isolation can only be considered to be of DBB standard if the integrity of both valves
has been proven.
If zero pressure buildup is not achievable when checking integrity of a valved isolation,
consideration should be given to either including additional isolation valves, installing
positive isolation or carrying out an assessment of risk to determine whether it is
acceptable to proceed.
Alternative methods of valve integrity testing may be considered where there are
practical difficulties in using the conventional method, providing that they have been
endorsed by the relevant Technical Authority.
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Once the Area Authority is satisfied with the integrity of the valved isolation and that the
system is depressurised and drained, containment may be carefully broken either to
effect positive isolation or to perform the required task (taking into account all
precautions regarding H2S, pyrophoric scale, Low Specific Activity (LSA) scale, Naturally
Occurring Radioactive Material (NORM) or hydrates).
The extra security of untested but witnessed positive isolation, in addition to the valved
isolation used to effect it, is normally acceptable for most confined space entry tasks.
However, for longer term positive isolations (eg a week or more), or where the valved
isolation used to effect the positive isolation needs to be removed for operational
reasons, then integrity testing of the positive isolation is required. This shall be done by
service leak testing or formal leak testing of the joint, depending on the level of risk.
Where a single flare or vent valve forms part of an isolation it may not be possible to fully
test integrity. In this situation the valve cannot be considered as a reliable barrier and
therefore an isolation risk assessment shall be carried out to determine whether the task
should proceed.
NUIs
It is recognised on NUIs that there may not be a permanent presence on the Installation
whilst an isolation is in place and that it may not be practicable to monitor on a shift
basis. In this case on first return to the NUI the isolation integrity shall be confirmed
before continuing work on the isolated equipment.
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(5) Gas systems shall only be depressurised to the atmosphere under strictly
controlled conditions. Persons working downwind of any drainage/venting
operation shall be warned by the Area Authority or his nominee and, if instructed,
shall vacate the area. All hot work shall cease within the affected area.
(6) Where suitable facilities exist, liquid residues shall be drained to a closed system.
Where this is not possible, an estimate should be made of the quantity of liquid
remaining in the system. Catchment facilities should then be provided sufficient for
at least this quantity. Liquid can then be drained by carefully opening a flange at a
low point in the system. Precautions should also be taken to prevent the spread of
any accidental spillage.
(7) The existence of possible ‘dead-legs’ in the system must be borne in mind. Such
traps may have to be flushed with water to remove residual liquids if there are no
flanges or connections.
(8) Oil contaminated/soaked lagging material shall be removed from hot equipment as
it is prone to spontaneous ignition.
(3) When emptying and draining, care shall be taken to avoid pulling a vacuum. This
may occur if the atmospheric or vacuum vents are blocked, or by excessive
lowering rates through large diameter lines.
(4) Once suction is lost through the normal offtake it may be necessary to remove
residual liquid contents by means of either a portable pump operating through
an open manhole (by the use of the tank water drain valve) or possibly by
water-flotation, taking appropriate precautions against spillage.
(5) The hazards of using portable pumps in an area likely to be contaminated with
flammable vapour must be taken into account. Appropriately sited, air-powered
pumps should be used where possible.
(6) Residual liquids and sludge must be disposed of in the correct manner according to
the requirements of pollution-control legislation.
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reasonably high velocity is also helpful in ensuring good mixing. Purge with inert gas until
concentration of flammable vapour is less than 4% in emerging mixture of
flammable/inert gas.
Normal flammable vapour monitoring devices will not work accurately in atmospheres
which are deficient in oxygen, therefore it is necessary to use specialised equipment to
determine the effectiveness of an inert gas purge.
Following the displacement of hydrocarbon vapour with inert gas, the vessel or tank
should normally be purged again with air to displace the inert gas in its turn. This shall
always be done in cases where man-entry is planned, regardless of any intended use
of PPE.
4.3.3 Steam
At onshore sites, steam may be available in sufficient quantities to permit its use for
purging and cleaning vessels, tanks and pipework. Steam is the most effective of the
common media for this purpose. It should be used at low pressure, not exceeding 1bar
maximum.
Two methods of steaming may be employed; open or closed steaming:
• Open steaming is used where the tank, vessel and its associated system is fully open
to the atmosphere
• Closed steaming is used for closed vessels and their associated equipment. During
this operation, the temperature is raised allowing volatile liquids to vaporise and
disperse together with the bulk of the steam via a condensing system. The heavy
constituents can flow freely and be drained off with the condensed steam from the
base of the system
For all but the largest vessels and tanks, sufficient steam should be available to raise the
external surface temperature to at least 95°C. Steaming should be continued until the
condensate flowing from the vessel is substantially free of hydrocarbon.
Steam may be used in the case of process vessels, small storage tanks and medium
sized insulated tanks. It is essential that following a period of closed steaming, adequate
provision is made to prevent damage due to a vacuum being drawn by condensation of
steam. In large tanks, the rate of condensation of steam is such that adequate purging is
not possible.
After steaming, it is normal practice to cool down the equipment with copious quantities
of water, this gives an additional wash to help remove residual hydrocarbons.
Where residual material is left on the tank or vessel surface after prolonged steaming,
such residual material may still evolve vapour on application of heat, eg burning or
welding. In such cases, cold cutting may be employed or the internal surface kept
thoroughly wet during the heating operation.
All temporary steam hoses used shall be electrically bonded and earthed.
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4.3.4 Air
Where it is not possible or practicable to use any of the foregoing methods, it may be
necessary to use air directly to ventilate equipment and remove hydrocarbon vapour.
When a decision is made to use this technique, every effort shall be made to pump out
as much oil and sludge as possible before opening the tank or vessel. Where practicable,
forced ventilation shall be used so that flammable vapour is cleared in the shortest
possible time. During this purging operation, the flammable range will be passed
through, presenting an explosion hazard if an ignition source is nearby. All electrical
equipment used shall therefore be suitable for use in a Zone 1 Hazardous Area.
Other equipment within the hazard range of flammable vapour shall be effectively
isolated.
Air movers shall be fitted at the roof or top manhole so as to pull air in at low level.
Temporary trunking may be needed to achieve high-level disposal. In order to minimise
the emission of gas/vapour when the lower manhole door is opened, the air movers shall
be started up first to obtain a slightly negative pressure before the lower manhole is
opened.
Vapour issuing from shell manholes may give rise to a dangerous concentration in a
bunded or confined area and, under such conditions, no kind of ignition source is
allowed. Removal of vapour by air movers attached to the roof manhole is the
recommended safe practice.
Care shall be taken when using natural draught ventilation during periods of calm
weather at onshore sites, since vapour released from tanks can travel considerable
distances without being dispersed. Due regard shall be taken of wind direction and the
risk to adjacent premises or to the public.
Owing to the possible presence of pyrophoric scale within tanks or vessels which have
contained sour crude or products, provision shall be made for continuous wetting of the
internal surfaces by means of water from one or more water fog nozzles inserted into
the roof opening. The nozzles shall be turned on first and the air movers opened
immediately afterwards. A shell manhole shall be opened after approximately 5 minutes
operation, when the internals are thoroughly wet. With the air movers still in operation,
the fog nozzles should then be removed and loose scale dislodged with high-pressure
water streams.
CAUTION: WHEN THIS METHOD IS EMPLOYED, THE WATER NOZZLES SHALL BE
EARTHED.
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5.2 Planning
5.2.1 Introduction
Prior to planning any confined space entry all alternatives to avoid entry shall be
considered.
Planning for confined space entry shall include the following:
• Confined space hazard identification and Level 2 Risk Assessment (mandatory)
• Gas testing and confined space inspection
• Entry Certificate issue and validity
• Procedures for control of work and non-compliance
• Procedures for any non-compliance based on Level 2 Risk Assessment
• Emergency response arrangements
Emergency response arrangements shall cover rescue, resuscitation and treatment
of casualties.
Entry into confined spaces shall be strictly controlled to prevent persons being exposed
to risks associated with toxic and/or flammable fumes and vapours in the atmosphere,
and with atmospheres which may be deficient (or enriched) in oxygen.
The number of personnel entering a combined space shall be limited by the resources
available to deal with any potential emergency that may arise.
Prior to any entry into a confined space, the atmosphere shall be tested to determine the
precautions necessary, and an Entry Certificate issued. An Entry Certificate is not a work
permit and for all work a relevant Work Control Certificate is required.
Gas tests required for hot work shall be carried out separately (ie the tests done for entry
are not valid for the Work Control Certificate).
Access and egress should be considered in the event that a casualty may need to be
evacuated in an emergency. It would require a winch to vertically hoist an average
person from a space below. Wearing a harness and lifeline shall only be considered
practicable if the nature of the confined space is such that the attendant could hoist or
drag out the person from the space if the latter were immobilised, and if the rope would
not impede an unassisted exit. Wearing only the harness should also be considered.
A rescuer could attach the lifeline to effect evacuation of the person.
Procedures for entering confined spaces with and without Breathing Apparatus (BA) are
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described in Paragraphs 5.3 and 5.4.
• Slippery surfaces
• Sources of ionising radiation (eg level gauges, sludge and LSA scale or NORM)
• The relevant procedures shall be followed for disarming or retracting radioactive
sources, for removal of LSA scale or NORM etc
• Vessel boots and sumps full of liquid which could be fallen into
• Pyrophoric scale formed in systems which may contain H2S
• Excessive noise
• Inadequate visibility
• Excessive temperature in the confined space (causing heat stress to personnel)
• Possible ingress of fumes from drain systems etc
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Also, the Authorised Gas Tester (AGT) shall confirm that there are no materials left inside
which in his opinion may give off sufficient quantities of vapour and fumes if disturbed,
such that the atmosphere would cease to be classed as fit for entry without BA.
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Limit – measured on a Permitted) 1 to 4% LEL Permitted) (Note 4)
combustible gas indicator) (Inspection and Cold Work
(Note 3) Permitted)
Notes: (1) Occupational exposure limits for various toxic substances are defined
in HSE Guidance Document EH40.
(2) If longer work shifts ie 12 hours (offshore), LTMEL must be
extrapolated to give 12-hour Time Weighted Average (TWA).
(3) Lower Explosive Limit (LEL) synonymous with Lower Flammable Limit
(LFL).
(4) Continuous gas monitoring must be performed throughout confined
space occupancy.
A minimum requirement would be the provision of an air bottle and mask which
provided a constant air supply. Further reviving equipment may be supplied
providing that relevant personnel are competent in its use.
(6) Facilities for the rescue of the AGT should be considered.
(7) The appropriate emergency response personnel shall be advised of the nature and
the location of the work to be undertaken.
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space whenever possible
• Awareness of the site layout and the site emergency procedures
• An understanding of the work to be undertaken, the hazards and the necessary
precautions of the WCC and associated paperwork. Where practicable all personnel
involved in the work should take part in the Level 2 Risk Assessment
• Familiarisation with the site emergency procedures for the rescue and recovery
of Entrants
• Instruction in the communication methods to be used between the Attendant and
Entrant working in the confined space
The Area Authority must ensure that the Entry Attendant understands his duties and is
competent to perform them.
Entrants shall be briefed by the Performing Authority, Supervisor or Entry Attendant to
ensure that they understand the hazards of the task in hand, the signs, symptoms and
consequences of exposure to those hazards, and are aware of the emergency signal to
be used by the attendant if evacuation becomes necessary.
The Rescue Team Members shall receive approved Personal Protective Equipment (PPE)
and rescue equipment (including BA sets) and be trained in its use. They should be
trained fire team members.
New personnel shall not be assigned to the above tasks, unless under training and
accompanied by a competent person who is familiar with the hazards of confined
space entry.
5.3.2 Entrants
Entrants to the confined space shall:
• Wear suitable PPE
• Wear a harness and lifeline, if specified on the Work Control Certificate
• According to the type of work and the risk, take adequate rest periods out in the
open air
• Continuously monitor for oxygen, hydrocarbons and H2S
This may be achieved by one of the Entrants wearing a Crowcon Triple meter (or
similar) to warn of hazardous conditions. If this should occur, the space should be
vacated, ventilated and re-tested until conditions have improved to within the limits
set out on the Entry Certificate.
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his face and BA are submerged, he shall be assisted by a rescue person who shall be
stationed at the opening, equipped to make an entry wearing BA so as to give
immediate help, if he considers it safe to do so.
5.4.2 Entrants
Entrants shall perform the duties listed in Paragraph 5.3.2. In addition, they shall wear
approved positive pressure BA and be trained in its use.
Notes: (1) Canister respirators shall not be used in any circumstances. Air-supplied
apparatus shall be used.
(2) All personnel expected to wear BA and carry out work at the same time
are recommended to be clean shaven.
Where high-pressure water jets are used in the removal of sludge and scale, only
specifically trained operators should be used. Where standard water hose and nozzles
are used to wash out, the nozzles shall be earthed.
When chemical cleaning takes place there is a possibility of toxic gases, including H2S,
being evolved. Therefore a closed drain system shall be used for the disposal of effluent
from these operations. Personnel engaged in these operations shall wear suitable
chemical protective clothing/equipment and suitable toxic gas monitoring/warning
devices shall be provided.
point to detect the presence of oil. If it is found, the hollow member must be purged by
one of the methods discussed above before work on the tank or vessel is allowed
to proceed.
Any linings or wear plates attached to the shell of a tank or vessel may trap liquid
hydrocarbons behind them. This liquid can percolate into the vessel or tank by way of
minute cracks. Therefore, the vessel or tank shall frequently be tested to ensure that it
remains gas free.
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Test Plan/Programme
Maximum Allowable Working Pressure (MAWP) defined
Test pressure defined
Marked up P&IDs produced showing test boundaries
Written test procedure developed
Test medium selected (hydraulic considered rather than pneumatic)
If pneumatic test planned, consider reducing the volume by water filling vessels
Emergency depressurisation route identified
Pressurisation/depressurisation procedures take account of the position of non-return valves
Pressurisation procedure specifies hold points (25%, 50%, 75% of test pressure)
Post-test Checks
Vents to be opened at high points during liquid depressurisation
Pressure to be released gradually
Inert gases vented to flare or alternatively to a safe area
Confirm that there is no trapped pressure within test envelope
UKCSSSW001_006.fh8
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valves, just the removal of locking devices and/or other immobilising equipment.
Particular care should be taken with regard to electrically, pneumatically or hydraulically
operated valves, which may open or close on reinstatement of the operating
source/medium.
The volume of the pressure envelope under test shall be kept as small as reasonably
practicable to minimise the amount of stored energy in the envelope.
When defining the pressure envelope, consideration should be given to interfaces with
lower pressure systems or equipment (including exchangers etc) – provision must be
made to ensure that adjacent systems cannot be overpressured.
The leak paths to be tested shall include, but not be limited to, flanged joints; other
proprietary joints including clamp-type connectors (ie Grayloc-type) and hammer-lugged
unions; threaded joints; valve body/bonnet joints; valve stem glands; valve body vent and
drains; pig receiver/launcher door seals; and all piping connections to instrumentation.
The envelope shall include adequate means for the venting of air or process gas from
high spots and dead legs during filling with a liquid pressuring medium.
The envelope shall contain adequate means for draining liquids after the test and for
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Inert gas mixtures such as nitrogen or a nitrogen/helium mix can also be used for
leak testing. This may be the preferred method for large testing or where the use of
water could be detrimental to the process. Gross (preliminary) air leak tests, using
instrument air up to a maximum of 8barg, are often used at an early stage of
hook-up/commissioning as a means of identifying large leaks, prior to performing the
standard pressure tests.
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Every effort should be made to conserve nitrogen by decanting to pressurise or partially
pressurise other systems.
To avoid background helium readings and to assist in leak detection, flanged joints shall
be taped for nitrogen leak tests. All other joints and valve stems should only be taped as
required for identification numbering, identification on as-built drawings and reference
back to the testing database. The tape shall be removed once testing is complete.
Introducing nitrogen to a system introduces a large energy source, far greater than the
energy stored in an equivalent liquid leak test. To minimise this stored energy, vessels
which normally operate with a liquid level should be water filled (ensure water filling of
the vessel is acceptable with respect to corrosion and scaling) prior to pressurising with
nitrogen.
When a specialist contractor is contracted to carry out nitrogen leak testing rather than
leak testing with nitrogen quads or low volume pumps the following additional
measures apply:
• There will be a Pump Operator who will be in radio contact with the Leak Test
Supervisor who will monitor system pressure. The pumping unit will be manually shut
down on the instruction of the Leak Test Supervisor. The leak test crew should have a
written procedure for radio protocol
• There will be an automatic pump trip (Overpressure Protection Device (OPPD)) that
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will shut down the pumping unit. The OPPD will be located close to the injection point
so that it can monitor the highest pressure that will be seen in the Installation system
• Full flow pressure relief will be available via Pressure Safety Valves (PSVs). It is
acceptable and appropriate for the PSVs on the Installation system/plant to be used
for this purpose. However, if full flow pressure relief is not available via a plant
system, then consideration should be given to the use of temporary PSVs supplied by
the leak test contractor. If full flow pressure relief is not provided, then a Level 2 Risk
Assessment should be completed and assurance gained that there is sufficient
control in place to manage the HP/LP interface
• If it has been identified that the leak test contractor will have to supply PSVs,
consideration should be given to the location that these PSVs would vent to in an
emergency. The vent location should be surveyed and approved by the Installation
Area Authority with guidance from the leak test contractor on expected
nitrogen plume
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Method 1 involves the application of a No presence of continuous bubble growth
soap solution to the joint and monitoring detected in 60 seconds for flanges up to
for surface bubbles. and including 4in NB and 90 seconds for
flanges above 4in NB.
Method 2 involves taping the joint and 5 bubbles/min.
inserting a 1/4in diameter tube from the
flange into a water bucket and monitoring
the number of bubbles released.
Target Maximum
Acceptance of leak rates in the range between target and maximum allowable leakage is
by exception only and review by the appropriate Technical Authority. The review shall
take into account fluid type, location of joint and ventilation and subsequent monitoring
programme.
capacity to relieve the volume supplied by the pressuring source to a safe area.
6.8 Planning
A checklist summarising the key steps in planning and implementing a test is shown in
Figure 2.
When risk assessing the leak testing activity, as a minimum the following should be
considered:
• Any parts inside the proposed envelope which may be adversely affected by the test
pressure (eg the maximum static pressure on a balanced pump seal)
• Any interfaces with lower pressure systems or equipment (positive or double blocks
and bleed isolation shall be used with consideration given to locking open a vent path
to prevent overpressurisation)
• The location and condition of screwed fittings within the test envelope
• The stability of components such as expansion joints and spring hangers
• The ability to control the rate of pressure rise and the ability to depressurise quickly
• Connected high-pressure equipment such as accumulators or pulsation dampers
• Need for additional piping support (and its subsequent removal after reinstatement)
when items are removed
• The implications of Non-return Valves (NRVs) in the system in relation to
pressurisation and depressurisation
• The provision of an emergency depressurisation route for large volume tests. This will
ideally be a remote operated blowdown valve which is an integral part of the leak test
envelope and which will operate automatically on an Installation trip and blowdown
event. If this is not possible, a manual blowdown route should be identified and both
the BP Isolating Authority and the leak test contractor should be aware of its location
Whenever the test envelope extends beyond one site (eg pipelines), effective
communication including formal procedures must be established between each site.
During turnarounds where a boundary isolation provides the isolation from the process
(eg reservoir and export line) the isolation standard used to carry out nitrogen leak
testing within the boundary may be relaxed to single valve isolation, subject to Level 2
Risk Assessment of the hazards to work on the adjacent systems.
6.9 Preparation
The site shall be inspected by the Performing Authority to confirm that:
• The equipment to be tested is free from any obvious flaws
• All low-pressure attachments have been removed or effectively isolated
• Pressure-indicating and pressure relief devices are secure and online, calibrated and
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set to the appropriate pressure as necessary
• Any temporary restraints are in place and sufficient to restrain movement on
system failure
• Vent and drain valves are in the correct position
• The pressuring equipment and all associated fittings and connections are secure, in
sound condition and free from contaminants (eg diesel oil)
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integrity. Once system integrity is established then pressurisation will recommence and
continue in 25% increments of the final test pressure, with all checks carried out as
previously stated until the acceptable leak criteria has been met at 100% system test
pressure.
If any leakage is detected whilst a system is being pressurised, pressurisation must
cease immediately and that system must be totally depressurised via the approved
venting point and left open to atmosphere. Confirmation that the system pressure is at
0barg must be confirmed by the BP Area Authority or their delegate prior to any remedial
works commencing.
Prior to returning equipment to service, the hazards of any residual pressuring fluids shall
be assessed and actions taken to eliminate them, eg:
• In the case of water, its effects on products on high or low temperature service may
require the use of special drying methods, such as hot, dry air
• The need to inert (remove oxygen) prior to introducing process fluids
Consideration should be given to the normal operating temperature of the process.
Where practicable, the operating temperature should be increased slowly and all broken
connections monitored until a stable operating temperature is maintained.
NUIs
It is recognised that for NUIs where a permanent presence does not exist, the ability to
monitor will depend on the length of stay and timing of subsequent visits. The flange
tagging process (refer to Paragraph 3.3) should still be applied and the monitoring
process followed as far as is practicable, with a final check and removal of the flange
tags being made at least on the next return visit to the site.
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6.16 Records (Certification)
All leak tests and service tests shall be formally certificated and recorded, and all
certificates included with the relevant equipment records within the BU/Installation
management system.
For leak tests Form SL1 from GOC should be used.
Service tests and the critical joint installation should be recorded using Form JI1 from the
GOC guidelines.
Form JI1 from GOC should be used for recording post integrity checks.
Addendum 1
References
References
June 2002 Issue 2 Add 1-1/2
Safe Isolation and Reinstatement of Plant UKCS-SSW-001
Addendum 2
Glossary of Terms
Glossary of Terms
June 2002 Issue 2 Add 2-1
UKCS-SSW-001 Safe Isolation and Reinstatement of Plant
Flash Point The lowest temperature to which a liquid must be heated to give
off sufficient vapour to form a mixture with air that can be ignited
momentarily in prescribed laboratory apparatus.
Gas Free A tank is considered to be gas free when the concentration of
flammable gases is within safe prescribed limits. The term gas
free does not imply absence of toxic gases or sufficiency of
oxygen for vessel entry.
Hazardous Area An area in which there exists, or may exist, a hazardous
atmosphere.
Hazardous Atmosphere An atmosphere containing flammable gas or vapour in a
concentration capable of ignition. (The term refers exclusively to
hazards arising from ignition. Where there is hazard from other
causes such as toxicity, asphyxiation or radioactivity, this is
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specifically mentioned.)
Hazardous Utility Corrosive, toxic or irritant chemical fluid, nitrogen, steam or hot
water, drilling mud, diesel oil, Aviation Turbine Kerosene (ATK) and
other fluids that could have an environmental impact.
Hot Work This includes welding or the use of any flame or electric arc or the
use of any equipment likely to cause heat, flame or spark. It also
includes caulking, chipping, drilling, riveting and any other
heat-producing operation, unless it is carried out in such a way as
to keep the temperature below 100°C (refer to Cold Work).
Incendive Spark A spark of sufficient temperature and energy to ignite a
flammable gas.
Isolation A method of preventing the passage of fluids through connecting
pipework in order to allow safe access to vessels or other intrusive
equipment maintenance.
Leak Testing The application of a pressure differential to detect leakage paths or
leakage rates. The pressure applied, liquid or gaseous, may be
much less than the maximum service pressure eg vacuum tests,
search gas tests, air tests, and water or service fluid tests.
Local Procedures Site-specific or BU-specific procedures which address the
arrangements in place for the implementation of HSE Practices,
TIPS or other Federal documents.
Lower Flammable The lowest concentration of flammable gas in air at atmospheric
Limit (LFL) pressure capable of being ignited. The figure is expressed as
percentage by volume.
Glossary of Terms
Add 2-2 June 2002 Issue 2
Safe Isolation and Reinstatement of Plant UKCS-SSW-001
Pyrophoric Scale or Usually finely divided ferrous sulphide formed inside a tank,
Deposits pipeline or equipment, in the presence of mercaptans or hydrogen
sulphide. It is capable of such rapid oxidation on exposure to air
that heating to incandescence can occur.
Reasonably Practicable This term implies that an evaluation of costs versus benefits must
be made. Where the cost or difficulty of a precaution is grossly out
of proportion to the reduction in risk likely to be achieved by
implementing the precaution, the precaution can be considered
not reasonably practicable.
Any additional risks which may arise while installing or removing
the precaution must also be taken into consideration in
determining what is reasonably practicable.
Source of Ignition Naked lights, fires, certain electrical equipment, hot surfaces
above ignition temperature or a spark or flame produced by any
other means.
Tanks Within the context of this document, the majority of the tanks
referred to are located onshore and consist of the following types:
(a) Atmospheric fixed roof, normally used for the storage of
water, chemical or heavy oils, ie materials that do not give
off vapour at normal ambient temperature.
(b) Atmospheric floating roof, where the floating roof can be of
the pan, pontoon or double deck design. The roof floats on
the tank contents. These tanks are mainly used for the
storage of materials which have a flashpoint at or below
normal atmospheric temperatures.
Glossary of Terms
June 2002 Issue 2 Add 2-3
UKCS-SSW-001 Safe Isolation and Reinstatement of Plant
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a percentage by volume.
Glossary of Terms
Add 2-4 June 2002 Issue 2
Safe Isolation and Reinstatement of Plant UKCS-SSW-001
Addendum 3
Typical Valve Isolations Integrity Tests
Paragraph Page
Vent/Drain Vent/Drain
M1 M2
Break
Point
V1 V2
UKCSSSW001_003.fh8
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Key
V1 First (upstream) isolation valve from live system.
M1 Live side monitoring point (pressure gauge or vent/drain).
V2 Second (downstream) isolation valve from live system.
M2 Monitoring point between valves and break point (pressure gauge or vent/drain).
B Bleed point between the isolation valves.
(1) If possible, ensure that tappings at M1, M2 and B are not blocked and that
pressure gauges, where installed, are operating.
(2) Close downstream valve V2 and secure in closed position.
(3) Note pressure at monitoring points M1 and M2.
(4) Vent/drain section of line to be broken into and monitor at M2 until the pressure is
near zero.
(5) Close vent/drain at break point and monitor at M2 for a minimum of 10 minutes.
No pressure buildup at M2 indicates the integrity of the downstream valve V2.
(6) Close upstream valve V1 and secure in closed position.
(7) Note pressure at M1 and B.
(8) Vent/drain between V1 and V2 (B) and monitor at B until pressure is near zero.
(9) Close vent/drain (B) and monitor at M1 and B for a minimum of 10 minutes.
(No pressure buildup at B indicates integrity of upstream valve V1.)
(10) Leave vent/drain (B) in closed position to allow further monitoring.
Note: The two block valves are now closed and secured. The bleed valve is closed but
not locked. It is possible for pressure to build up between the two block valves
therefore regular monitoring of the isolation is essential; a suitable pressure
gauge may be fitted to the vent to monitor the pressure.
Vent/Drain Vent/Drain
M1 M2
Break
Point
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UKCSSSW001_004.fh8
Key
M1 Live (upstream) side monitoring point.
M2 Monitoring point between valve and break point (downstream).
C Cavity drain (between seals).
(1) If possible, ensure that tappings at M1, M2 and C are not blocked and that
pressure gauges, where installed, are operating.
(2) Close isolation valve and secure in closed position.
(3) Note pressure at M1, C (in cavity) and M2.
(4) Vent/drain downstream section of line to be broken into and monitor pressure at
M2 until pressure is near zero.
(5) Close vent/drain at break point and monitor at M2 and C for a minimum of
10 minutes. (No pressure buildup at M2 and no pressure fall-off at C indicates
integrity of downstream seal.)
(6) Note pressure at M1 and C.
(7) Vent/drain off fluid in cavity (between seals) and monitor at C until the pressure is
near zero.
(8) Close cavity vent/drain (C) and monitor at M1 and C for a minimum of 10 minutes.
(No pressure buildup at C indicates integrity of upstream seal.)
(9) Leave vent/drain (C) in closed position to allow further monitoring.
Note: The double sealed, single block valve is now closed and secured. The bleed valve
is closed but not locked. Any fluid passing through the upstream seal will be
detected at the cavity drain (C). Regular monitoring of the isolation is therefore
essential and a suitable pressure gauge may be fitted to the vent to monitor
the pressure.
Vent/Drain Vent/Drain
M1 M2
Break
Point
SVI
UKCSSSW001_005.fh8
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Key
M1 Live (upstream) side monitoring point.
M2 Monitoring point between valve and break point (downstream).
(1) Ensure that tappings at M1 and M2 are not blocked and that pressure gauges,
where installed, are operating.
(2) Close isolation valve and secure in closed position.
(3) Note pressure at M1 and M2.
(4) Vent/drain downstream section of line to be broken into and monitor at M2 until
pressure is near zero.
(5) Close downstream vent/drain and monitor at M2 for a minimum of 10 minutes.
(No pressure buildup at M2 indicates integrity of single valve.)
(6) Leave downstream vent/drain at break point in closed position to allow further
monitoring.
Note: The single isolation valve is now closed and secured, and the downstream
vent/drain is closed. Any fluid passing through the single valve seal would be
monitored by means of the mandatory additional safeguards listed in Table 1.
Is this a
No Yes
confined space entry?
(Paragraph 5.1)
Complete draining/flushing/
Isolation
purging of equipment where
Confirmation
necessary (Paragraph 4)
Certificate
Addendum 4
No STOP
Reassess and consider
production shutdown,
Safe Isolation and Reinstatement
No Is
leak test covered by No Prepare specific
existing procedure leak test procedure
(Paragraph 6.2)
Yes
Service test for
Service test for process hydrocarbons Carry out appropriate level
non-hazardous Carry out leak test
Mandatory Level 2 Risk of risk assessment within
utilities and record test result
Assessment required ISSOW of leak test operation
UKCSSSW001_001.fh8
Add 4-1/2
UKCS-SSW-001
Addendum 5
Workplace Assessment Plan Template
Paragraph Page
1 Introduction 1
2 Objectives 1
3 Underpinning Knowledge 1
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4 Assessment Methodology 2
4.1 Field Assessment Requirements 2
4.2 Observation, Demonstration and Questioning 3
4.3 Simulation 3
4.4 Guidance on the Assessment Process 3
1 Introduction
The following assessment plan consists of four components which make up the unit
Safe Isolations and Reinstatement of Plant:
• Process isolations
• Breaking containment
• Confined space entry
• Pressure/leak testing
It provides the framework for the workplace D32/33 Assessor to carry out
the assessment.
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2 Objectives
This assessment plan sets a common standard for assessing an individual as a
competent BP process isolator. It should be applied to all candidates, however, the
extent of the assessment process will depend on the previous experience of the
individual (refer to Paragraph 4.4).
Successful assessments will be recorded within the CMAS system by a D32/33
Assessor with the appropriate comments.
3 Underpinning Knowledge
Prior to the workplace assessment the candidate must have completed the following
training.
• SIRP Training Course (either classroom or CBT)
• Permit to Work or ISSOW training to Performing Authority level
4 Assessment Methodology
Assessing competence will be carried out by observation, practical demonstration and
questioning. Plant availability and practicality may dictate an element of simulation.
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For consistency each site/Installation should decide which six field assessments will be
applied and ensure that the CMAS database is edited to reflect that. Guidance on editing
the CMAS database is available from the CMAS Team if required.
4.3 Simulation
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Where the opportunity does not exist to assess the candidate either by observation or
demonstration on complex isolations, the competence can be assessed by the use of
simulated scenarios.
Simulation can involve:
• Detailed description of all aspects of applying isolations to a specific system or
section of plant and equipment. The exercise should include all documentation
required, marked up diagrams and the application of locks and tags
• Answering questions or participating in desktop scenarios, which show the depth of
knowledge gained
Note: Complex isolations which cannot be readily applied and therefore lend
themselves to simulated exercises may include such topics as:
• Confined space and vessel entry
• Actions on not being able to obtain integrity of isolation
• Breaking containment, drain flush and purge
• Leak test and reinstate plant and equipment
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credit can be given for this.
The D32/33 Assessor will still be required to register the candidate as satisfactory
against six field assessments within the CMAS database adding appropriate comments
to substantiate the assessment judgement.
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register updated – appropriate signatories in place.
Section 3 Application of Install isolations – locking of valves – physical
Isolations disconnection – tagging – integrity checks –
record status on ICC.
Section 4 Breaking Flushing and purging method followed. Safeguards
Containment for breaking containment in place (Table 1 –
Category A + B). Potential hazards understood –
additional precautions in place.
Section 5 De-isolate and Confirm isolation integrity prior to de-isolation –
Reinstate Plant and lock/tag removal – ICC and associated
Equipment documentation update – removal of equipment and
return of area to satisfactory level of housekeeping
– final onsite checks.
Overrides/inhibits removed – register updated.
Other associated registers updated (eg LO/LC
register).
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ICC – cross-reference to associated
documentation – overrides/inhibits register
updated – appropriate signatories in place.
Section 3 Application of Install isolations – locking of valves – physical
Isolations disconnection – tagging – integrity checks –
record status on ICC.
Section 4 Breaking Containment Flushing and purging method followed.
Safeguards for breaking containment in place
(Table 1 – Category A + B). Potential hazards
understood – additional precautions in place.
Section 5 De-isolate and Confirm isolation integrity prior to de-isolation –
Reinstate Plant and lock/tag removal – ICC and associated
Equipment documentation update – removal of equipment
and return of area to satisfactory level of
housekeeping – final onsite checks.
Overrides/inhibits removed – register updated.
Other associated registers updated (eg LO/LC
register).
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register updated – appropriate signatories in place.
Section 3 Application of Install isolations – locking of valves – physical
Isolations disconnection – tagging – integrity checks – record
status on ICC.
Section 4 Breaking Flushing and purging method followed. Safeguards
Containment for breaking containment in place (Table 1 –
Category A + B). Potential hazards understood –
additional precautions in place.
Section 5 De-isolate and Confirm isolation integrity prior to de-isolation –
Reinstate Plant and lock/tag removal – ICC and associated
Equipment documentation update – removal of equipment and
return of area to satisfactory level of housekeeping
– final onsite checks.
Overrides/inhibits removed – register updated.
Other associated registers updated (eg LO/LC
register).
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document.
Section 3 Performance of All safety measures undertaken – site patrolled –
Test recording of pressure of system during test at
suitable intervals – monitoring of system and
adjacent system.
Section 4 Depressuring and Recording of test pressure and any pressure fall-off
Return to Service after it is locked in and isolated – gradual and
controlled pressure reduction – correct use of
vents and drains – correct reinstatement of
worksite.
Section 5 Completion of Sign off relevant Work Control Certificates –
Documentation ensure test is formally certificated and recorded –
and Post Test carry out visual checks as per the SIRP document
Integrity Checks Paragraph 6.15.