Mechanical Safe Working Procedure

Table of Contents
1 Introduction ............................................................................................................. 2
1.1 Background............................................................................................................. 2
1.2 Purpose .................................................................................................................. 2
1.3 Scope ..................................................................................................................... 3
2 Reference Documentation ....................................................................................... 3
3 Abbreviations .......................................................................................................... 4
4 Roles and Responsibilities ...................................................................................... 5
5 DEFINITIONS ......................................................................................................... 8
6 General requirements for isolation ........................................................................... 9
7 Precautionary Considerations for Isolation ............................................................ 10
8 Isolation of Process Equipment ............................................................................. 12
8.1.1 Issue of PTW to Permit Holder/ Performing Authority..................................... 12
8.1.2 Positive Isolation of Equipment for Maintenance ............................................ 12
8.1.3 Removal and Replacement of Relief Valves on 'Live' Systems ...................... 12
8.1.4 Isolation of Moving Machinery ........................................................................ 13
8.1.5 Isolation of Vessels ........................................................................................ 13
8.1.6 Isolation of Tanks ........................................................................................... 13
8.1.7 Isolation of Equipment Containing H2S .......................................................... 13
8.1.8 Use of Breathing Apparatus ........................................................................... 13
8.1.9 Exceptions to this Procedure ......................................................................... 14
8.2 Typical Isolation and De-isolation Process ............................................................ 15
Figure 1 – Process Equipment Isolation Process ............................................................ 15
9 Spectacle Blinds, Spades, or Spools for Isolation .................................................. 18
10 Dimensions of Spades and Spectacle Blinds......................................................... 18
11 Double Block and Bleed ........................................................................................ 18
12 Location of Spectacle Blinds ................................................................................. 19
POSITIVE ISOLATION ARRANGEMENTS ................................................................... 20
13 Breaking Containment ........................................................................................... 27
13.1.1 Hazards...................................................................................................... 28
13.1.2 Prework ...................................................................................................... 28
13.1.3 Defenses .................................................................................................... 29
13.1.4 Respiratory protective requirements ........................................................... 30
13.1.5 Prepare for First Break ............................................................................... 33
13.1.6 First break on Flanges Procedure .............................................................. 34
13.1.7 First Break on Vents or Drains Procedure .................................................. 35

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 Mechanical Safe Working Procedure

1 INTRODUCTION
1.1 Background
Whenever a process plant, equipment, or systems require to be taken out of Service
for major Maintenance, repair or modification, positive mechanical isolations shall be
provided between the process plant, equipment, or system and any potential
hazardous energy source.
Positive Mechanical Isolation requires the insertion of a spade / blind in the line or the
removal of a spool (whichever is applicable), 'downstream' of the last tight isolation
valve, to physically isolate the potential energy source.'

IMPORTANT: A 'double block and bleed' arrangement on its own is not

considered 'positive mechanical Isolation without the insertion of a spade /
blind.

1.2 Purpose
The purpose of this Procedure is to provide a safe and consistent method for the
Isolation of process equipment prior to and during maintenance/modification / repair.
This specification is primarily intended for use by plant designers but it may also be
used by operations Personnel as a general guide for checking the appropriate
positioning of spectacle blinds and spades.
This specification primarily describes the correct positioning of spectacle blinds,
spades, and double block and bleed requirements in facility pipework. While typical
example applications are described, it is stressed that these are not necessarily
specific. It is the responsibility of the user to assess the actual requirements based on
the maintenance/inspection philosophy agreed during the conceptual design of the
facility.

The purpose of this standard is to set the minimum requirements of when and under
what conditions respiratory protection is required when breaking into process
systems.

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 Mechanical Safe Working Procedure

1.3 Scope
This Procedure covers the mandatory administration and mechanical Isolation of
process equipment prior to maintenance/inspection/modification work.

For major Maintenance or engineering work, the minimum requirement for process
equipment shall be;

• shut down;

• depressurized to atmospheric pressure;

• drained and flushed (if required);

• freed of flammable or toxic gases

Positive Isolation shall be applied once the above have been completed between any
adjacent systems that may, or may not, remain live during the work.

2 REFERENCE DOCUMENTATION
KR-HSE-003-24 Karbala Refinery HSE Policy and HSE Manual
KKR-HSE-004-24 Permit To Work Procedure
Manual EI 15 – Model Code of Safe Practice - Area Classification Code for Installations
Handling Flammable Fluids. Energy Institute 2005.
Operations Procedure Temporary Variance
Gas freeing and Purging of Process Equipment (excluding tanks)
Preparation of Tanks and Vessels for Internal Work
Locked Valve and Spectacle Blind Control
Entry into a Confined Space
Gas Testing Procedure Permit to Work

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 Mechanical Safe Working Procedure

3 ABBREVIATIONS
The following abbreviations are used in this Procedure.
ANSI American National Standards Institute

API American Petroleum Institute

DN Nominal Diameter

DFT De-isolated for Test

ESD Emergency Shutdown

FB Full Bore

LC Locked Closed

LG Level Gauge

LO Locked Open

NC Normally Closed

NO Normally Open

PdS Pressure Differential Switch

PFD Process Flow Diagram

PG Pressure Gauge

PR Procedure

PTW Permit to Work

RAM Risk Assessment Matrix

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 Mechanical Safe Working Procedure

4 ROLES AND RESPONSIBILITIES

The IA shall be competent in understanding the activity being
Isolation performed, its intrinsic hazards, and how to control them safely with
Authority suitable isolations. They shall be responsible for the following:
o Supply isolation LOTO Plan certificate before PTW is issued
o Ensuring all suitable isolations are in place
o The equipment being worked on is de-energized,
depressurized, drained, and vented, with no hazard
o Suitable locks are used and or locking devices, and all
isolations are tagged out and cross-referenced to the PTW
number
o Worker(s) have put their lock on the device before work
commences
o Tested for dead and crew briefed on the isolations
o Maintain an isolations log to be passed to the next shift
The Isolation authority cannot be the issuing Authority or the
permit receiver. They have to prove to the issuing Authority all
isolations are in place before the permit is issued.
Permit The KR-appointed permit issuer is responsible for:
Issuer
o Ensuring that they have the correct level of Authority for
authorizing the work controlled by the permit to work, unit
operations supervisor, not unit operator;
o Ensuring activity-relevant task risk assessment (TRA)and work
methods are suitable
o Work method statements (WMS) and or RAMS have been
prepared by the Performing Authority and reviewed by the Issuing
Authority and are adequately safe for the work permitted;
o Liaising with MCB operations to control simultaneous operations
(SIMOPS), including the impact of the work scope on the site
operations or the impact that site operations will have on the work;
o Ensure that all work permits that are issued are prepared and
executed in full compliance with this Procedure;
o Detail the work to be undertaken and the tools and equipment to
be used, in writing and verbally, to the crew;
o Details specific actions to be taken to make safe hazards of the
work in the unit;
o Specify with the crew and the permit receive the monitoring
requirements,
o including frequency of inspections and permit control measures
such as gas testing, verifying the integrity of isolations;
o Ensure that the work area and relevant equipment are made safe

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 Mechanical Safe Working Procedure

before handover to the permit receiver;

o For confined space entry, determining that the emergency
response and rescue plan proposed by the permit receiver is
adequate for the safe and timely
o extraction of workers for the identified work scope
o Ensure that the permit receiver and workers are made aware of
all hazards
o Ensure operations in process units issue maintenance permits;
maintenance permit issuers can issue permits in non-process
areas
o Ensure all permits are issued as close to the work location and
never from the office
o The Permit Issuer shall not be the same person as the Permit
Receiver
o Permit o The permit receiver shall be competent in understanding the
Receiver activity being performed, its intrinsic hazards, and how to control
Performing them safely. The permit receiver is responsible for compiling the
Authority documents needed to get a permit to work, such as RAMS,
including a TRA that reduces the risk to ALARP.
o The permit receiver is responsible for the following:
o Ensure that tools and equipment to be used are fit for purpose,
non-sparking, and intrinsically safe and inspected;
o Be aware of the hazards at the location that could exist and have
suitable precautions put in place to mitigate them;
o Receive the Work Permit document at the work location from the
Permit Issuer and check and indicate to the Permit Issuer if any of
the requirements are not understood or unclear;
o Sign the Work Permit before work commences, thereby accepting
any conditions or controls stipulated in the work permit and
referenced in the RAMS/TRA/WMS;
o Ensure a pre-start meeting with the work crew on the Permit and
TRA controls.
o Ensure that all workforce members read and understand the risk
assessment and Work Permit and acknowledge this by signing the
Work Permit Acknowledgment Form (See appendices for the
form)
o Ensure that skilled, qualified, trained, and competent Personnel
perform the work, adhering to the conditions of the Work Permit
and the TRA.'
o Ensure that the job is performed in a safe manner within the
conditions prescribed for the work on the permit or work clearance,
and be responsible for the work and for the people on the job.;
o Make equipment and the work area safe before handover or return
to Service; this also includes waste management, housekeeping;
o The permit receiver must have attended a Karabala Refinery
permit to work training before being allowed to receive permits and

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 Mechanical Safe Working Procedure

conduct any work

o The Permit Receiver shall NOT be the same person as the Permit
Issuer for a Permit and not the Isolation Authority.

Maintenance o Be accountable for the COW process within the

Manager refinery
o Ensure conformance with this Procedure and the
OHSE system
o Ensure that COW – PTW training is provided at KR.
o Ensure that maintenance permit issuers are
supported for all shifts
o Ensure SIMOPs are in place and communicated.
o Ensure operations in process areas/units authorize
maintenance PTW
o Maintenance permits can be issued by the
maintenance supervisors in non-process areas.
Workers The people doing the work must read and understand
the permit and TRA, then sign that they accept the
safe system of work. They must follow the permit and
• the TRA information or stop and speak to the IA and
Area HSE.
AREA HSE • The appointed HSE person shall review the permit,
TRA, and WMS before the permit is given to the
permit issuer. They will jointly inspect the work area
location to determine that all hazards have been
suitably controlled as described in the task risk
assessment (TRA). They will monitor the work
throughout their shift.

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 Mechanical Safe Working Procedure

5 DEFINITIONS
ALARP : 'As Low As Reasonably Practicable', which is simplified means' reducing the
risk to a level at which the cost and effort (time and trouble) of further risk reduction
are grossly disproportionate to the risk reduction achieved'.
Bleed Valve A small vent valve, usually immediately downstream of a block valve,
which can be opened to release the pressure and to ascertain whether there is
pressure on the downstream side of the block valve when closed.

Blind /Blank : Flange A solid flange, which can be bolted to a flanged connection on
pipes or equivalent to block off flow from it. The flange shall be of the same rating.

Block Valve : A valve that controls the passage of a liquid through a pipe with the
intention that it permits either full flow or no flow.

Spectacle Blind : A solid circular plate connected to a circular plate with a hole in
it by a straight handle. The plates are designed to be bolted between flanges on piping
and equipment. The first will block off flow, and the second will pass normal flow. The
plate shall be thick enough to withstand the anticipated maximum differential pressure.
The advantage of this device is that no additional mechanical stress is applied to the
equipment when it is changed between the open and closed position.

Slip Blind / Spade - A circular flat plate with a handle, which can be bolted between
two flanges to block off the flow. The handle should extend outside the flanges. The
plate shall be thick enough to withstand the anticipated differential pressure, which
need not be the flange rating pressure.

Major Work: Any intervention that results in spools or equipment being removed from
a process line (including non-hydrocarbons), Confined Space entry, or Hot Work
(including cold cutting) being carried out.

Minor Work: Valved Isolation shall be required for all Minor Work. Any intervention
that does not require spools or equipment to be removed from a process line (including
non-hydrocarbons) or where there is no Hot Work.

Battery Limits:A battery limit is an agreed boundary surrounding a processing unit or

battery of units, along with related utilities and services. The perimeter of a 'Battery
Limit' can form a single boundary isolation or a number of boundary isolations within
the defined limit.
Baseline Isolation Standard : The Baseline Isolation Standard is the minimum
acceptable standard of final Isolation for intrusive and non-intrusive Maintenance
against live plants under normal circumstances as per the HSE guidelines (UK HSE
Publication Issue 2006 ISBN 0-7176-6171-7 The Safe Isolation of Plant and
Equipment) This standard is based upon risk assessment. The Baseline Isolation
Standard shall be one of the following two isolation methods:

Positive Isolation: is the removal of a spool and fitting of blinds, or fitting of a spade
or spectacle blind to allow complete separation of the plant/ equipment to be worked
on from other parts of the system
Proved Isolation: is a valved isolation where effectiveness of the Isolation can be
confirmed via vent/bleed points before breaking into the system, and for the duration
of the Isolation

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 Mechanical Safe Working Procedure

Boundary Isolation: An isolation at any location where the defined Baseline Isolation
Standard is met.
Hydrocarbon Services. All systems that contain hydrocarbons.
Hazardous Service. A substance containing a substance that can cause harm or
damage if containment is lost.
Non-Hazardous Service. Any service not classified as hazardous.
H2S / Toxic System
High concentrations of H2S in the process fluid, require a high degree of protection
against leakage. For the purpose of this Procedure, an H2S / Toxic System is defined
as having >500ppm in the process stream.
Moving machinery: Any equipment using external motive force such as electricity, air,
steam, or hydraulic fluid.

6 GENERAL REQUIREMENTS FOR ISOLATION

The maintenance/inspection activities should be implemented only on plant, units or
systems which have been shut down, depressurized to atmospheric pressure, cooled,
drained, purged free of flammable or toxic gases, and isolated.

It may be impractical or uneconomic to shut down the complete facilities or systems

for Maintenance or inspection. Equipment could remain connected to live facilities or
systems during inspection or Maintenance, with the consequent potential for hazards
to Personnel and plants. In such cases, the design of the facilities shall incorporate
means of positive Isolation of the individual piece of equipment undergoing inspection
or Maintenance from remaining live facilities to protect Personnel from hazards of
flammable and/or toxic liquids and gases.

The method of Isolation is dependent on such factors as the type of maintenance

and/or inspection work involved, i.e. of a major, routine or minor nature, the
properties of the process fluid in the live plant connected to the equipment being
maintained and the pressure and temperature of those fluids. These factors
determine whether Isolation should consist of single or double block valves, together
with bleeds and inserted spades or closed spectacle blinds.

Inserted spades or closed spectacle blinds should always be used during Maintenance
since they provide the most positive means of Isolation.

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7 PRECAUTIONARY CONSIDERATIONS FOR ISOLATION

1) The main hazard when working on equipment that has been isolated from live
plant is that positive Isolation from a source of energy or hazardous fluid/gas
may be overlooked or the Isolation compromised, and the source then released
with serious consequences.

2) Positive Isolation of equipment shall be accomplished to provide the safest

environment to carry out any Major Work on that equipment to reduce the risk
of injury to Personnel and damage to the Company's assets or the
environment.

3) Operation Supervisors and Operators shall ensure that the integrity of isolations
be maintained for the entire period of any work being carried out. The Isolation
(s) and the EPI register shall be included in the shift change handover.

Long-term positive Isolation shall be audited as part of the Level 2 Audit

conducted at 3-6 monthly intervals.

4) ALL isolation work shall be carried out under the Permit to Work system.

5) Hazards shall be identified, detailed, and controlled by proper use of the Permit
to Work system.

6) All work shall be authorized by the Operations Supervisor.

7) All approved blinds that are fitted shall have all of their bolts set to correct torque
in accordance with the approved Bolt Torquing procedure.

8) Actuated valves shall only be used as part of the positive Isolation if the "fail
safe" condition is closed and all motive power to the valve has been physically
disconnected from the actuator.

9) WARNING: Reliance on switches shall not be acceptable under any

circumstances.

10) Double block and bleed arrangements provide positive Isolation when used in
conjunction with spades or blinds.

11) Where the insertion of spades and blinds in conjunction with double block and
bleed is considered impractical, i.e., not possible to break containment or
suitable spading and blinding locations not available, the use of the double

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block and bleed may be authorized by the Operations Coordinator provided a

variance is raised in accordance deviation request procedure

12) For minor work, such as replacing a faulty instrument on a vessel a single
'demonstrated' tight valve may be allowed if authorized by the Production
Coordinator. For toxic and high-pressure applications, double block and bleed
shall be considered a minimum requirement. Where the piping and valve
arrangement of process equipment does not allow this to be met a variance
shall be raised in accordance deviation request procedure In addition the work
shall be completed during a working shift, and all valves employed for Isolation
shall be 'demonstrated tight' and the work site shall not be left unattended while
the work is in progress.

13) 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 be
employed to provide positive Isolation.

14) For long-term isolations where a piece of equipment, or a system, is taken out
of Service for a considerable period, whereas an adjacent plant remains live, it
is essential that proper records are kept. (e.g. spade / blind / valve checklist)
and a record of the status of the Isolation and its continuing integrity is kept.
This should be carried out during an extended period isolation and verified
regularly.

15) Such isolations shall be audited and checked for integrity at a frequency
defined by the Production Coordinator.

16) All process isolations shall be recorded on the Process Isolation Logbook.

17) All electrical isolations must be done in accordance with xxxxx - Electrical
Safety Operational Procedures.

18) The most important rule for the Isolation of equipment is to 'Follow the
procedures.' For guidance, the schematic diagrams in Appendix 1 should be
used for reference to typical isolation arrangements.

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8 ISOLATION OF PROCESS EQUIPMENT

8.1.1 Issue of PTW to Permit Holder/ Performing Authority
The Issuing Authority shall not release the PTW to the Permit Holder (authorization to
commence work) until all isolation processes have been completed and verified.
8.1.2 Positive Isolation of Equipment for Maintenance
A spade and blind checklist, marked-up copies of the As-Built drawings etc, shall be
made by the Permit Applicant and submitted to the PTW to ensure the correct spades
or blinds are closed during Isolation and removed upon completion of the work.
NOTE: This spade list will be signed off by the Operator / Issuing Authority after
Isolation and prior to equipment reinstatement after de-isolation.
The positive Isolation shall be reviewed and approved by the Responsible Supervisor.
The Area Authority shall
a) apply or oversee the positive Isolation for every piece of equipment, identifying the
connections that will be isolated, disconnected, and tagged before starting to open
the equipment.
b) 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 gas
freeing/purging as required.
Locked Open / Locked Closed valves that are operated during Isolation shall be
recorded on the Lock Open / Locked Closed Register.
Valves used as part of Isolation shall be 'tight' when shut off.
NOTE: Butterfly valves shall not to be considered as 'tight shut-off' valves.
8.1.3 Removal and Replacement of Relief Valves on 'Live' Systems
The permit applicant shall write a site-specific procedure for the removal and
replacement of Relief valves) and attach a Task Risk Assessment (TRA) signed by the
appropriate Authority. The Procedure shall be reviewed and approved by the
Responsible Supervisor and shall be attached to the PTW.
PTW shall be in accordance with the KKR-HSE-004-24 Permit To Work Procedure
No authorization for the work shall be given if:
• The system that the relief valve it is protecting does not have 100%
redundancy;
• The relief valve does not have, at a minimum, a 'double block and bleed'
arrangement upstream. This includes interlock systems;
• The relief valve is connected to a live vent and flare system that cannot be
isolated by one 'demonstrated' tight valve

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8.1.4 Isolation of Moving Machinery

The electrical, air, steam, hydraulic or other energy source to the moving machinery,
both flow and return circuits, shall be isolated from the drive unit, and the drive unit is
secured immobile before work commences.
Isolation of moving machinery from process fluids shall be accomplished by tight
valves and spades or blinds on the equipment side of inlet and outlet lines so that
Maintenance may be carried out while the surrounding facilities remain live. Where
H2S is present in the process stream, double block and bleed and swung blind is the
minimum mandatory requirement.
Machinery brakes and brake locks are to be applied, and the clutch (if applicable) is to
be disengaged.
8.1.5 Isolation of Vessels
Spades/blinds shall be installed on the downstream side of the inlet block valve
and the upstream side of the outlet block valve. Where practical these
spades/blinds should be mounted directly on the flange. Where H2S is present
in the process stream, double block and bleed and swung blind is the minimum
mandatory requirement.

NOTE: Refer to Table 1 for recommendations regarding isolation requirements.

8.1.6 Isolation of Tanks
Blinds/spades shall be inserted on the tank side of all inlet and outlet block valves.
These shall 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, collection tank or suitable
open pit
8.1.7 Isolation of Equipment Containing H2S
For isolations on equipment containing H2S, a double block and bleed system and
swung blind is the minimum mandatory requirement.
For double block and bleed systems used on H2S service, the bleed shall be hard-
piped to a safe disposal location to ensure that it does not create a hazard. Acceptable
disposal routes are to a remote vent or to a plant-closed drain system. When using
closed drains systems, checks shall be made to ensure that reverse flow does not
occur in the system.
8.1.8 Use of Breathing Apparatus
It is mandatory to wear positive pressure breathing apparatus when breaking flanges
and opening equipment containing toxics. This shall be clearly stated on the Work
Permit.

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Adequate Isolation and purging shall be proven by a direct measurement (using gas
detector) for both hydrocarbons and the toxic component concerned (usually H2S).
Further work such as opening the equipment for inspection, will be carried out wearing
a personal H2S monitor and escape set. Refer to entry into a confined space. The
Procedure for conditions allowing entry into a confined space is as follows:

8.1.9 Exceptions to this Procedure

Any proprietary insertion or extraction device e.g. COSASCO retrievable probes can
be used up to the rating of the tool as dispensation of the isolation requirements of
this Procedure, as long as it can be demonstrated that the tool was properly
maintained and inspected previously to usage.

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8.2 Typical Isolation and De-isolation Process

Typical Isolation and De-isolation Process

Issuing Operations
Responsible Production
Permit Applicant Area Authority
Authority & Permit Holder Manager /Delivery
Supervisor Isolating Authority Coordinator
Team Leader
PREPARE THE PTW
AND DEFINE THE
POSITIVE ISOLATION
REQUIREMENTS
REVIEW PTW WITH
PERMIT APPLICANT AND
AGREE POSITIVE
ISOLATION
REQUIREMENTS

YES DO ISOLATIONS
COMPLY TO PR-1076?

NO

RAISE VARIANCE (STEP-

REVIEW VARIANCE & REVIEW VARIANCE,
OUT) IN ACCORDANCE
RAM RAM & AUTHORISE
WITH PR-1001E

VARIANCE NO
AUTHORISED?

YES
RECEIVE PERMIT FROM
PA / RESP. SUPRV.
AUTHORISE THE PTW
SUBMIT FOR
VALIDATION

PERFORM / OVERSEE
POSITIVE ISOLATION AS
DEFINED ON
MECHANICAL ISOLATION
CERTIFICATE AND SIGN

VALIDATE PTW AND

UNDERTAKE WORK IN
AUTHORISE PERMIT
ACCORDANCE WITH
HOLDER TO START
PTW
WORK

CARRYOUT PERIODIC CARRYOUT PERIODIC

SITE INSPECTIONS TO SITE INSPECTIONS TO
ENSURE POSITVE ENSURE POSITVE
ISOLATION AS DEFINED ISOLATION AS DEFINED
BY PTW BY PTW

ON COMPLETION OF
WORK DE-ISOLATE.
CHECK THAT DE-
ISOLATION AGAINST
MECHANICAL ISOLATION
CERTIFICATE / MARKED
UP PEFS

CLOSE-OUT PTW

Figure 1 – Process Equipment Isolation Process

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The following process shall be followed to isolate and de-isolate process equipment prior to
and on completion of maintenance/repair/modification work.
[Link] Performing Authority Shall complete the relevant sections of the PTW and define the
isolation requirements on an As-Built drawing (PEFS).
The marked-up As Built drawing and the PTW shall be submitted to the Isolating Authority.
[Link] Isolating Authority shall review and discuss the PTW and isolation requirements with the
Performing Authority/ Supervisor. The positive Isolation proposed on the marked-up As-Built
drawing shall comply with this Procedure. Where compliance has been demonstrated, a LOTO
plan attached to the PTW shall then be authorized by the Issuing Authority Unit Operations
Supervisor.
[Link] that do not comply with this Procedure shall require to have a variance raised
against them following the deviation request procedure. The Operations Supervisor and the
Permit Applicant shall agree with the minimum Isolation that can be used to address the risks.
The Task Risk Assessment and the variance shall be reviewed, endorsed and authorized by
the Operations Manager before further work can be planned.
4. The authorized PTW with the marked-up As-built drawing shall be handed to the Permit
Holder/performing Authority, who shall give them to the Isolating Authority.
The Isolating Authority shall complete the Mechanical Isolation Certificate from the approved
positive Isolation on the As-Built drawing. Isolation as detailed on the Mechanical / Electrical
Isolation Certificate authorized by the responsible Supervisor.
IMPORTANT NOTE: No PTW shall be validated by the Issuing Authority until the required
isolation process is completed.
Mechanical isolations that are to be put in place shall be listed on the Mechanical Isolation
LOTO Plan Certificate and attached to the PTW. These LOTO certificates shall be used to
verify that all mechanical isolations have been safely removed.
Positive Isolation shall require spades or blinds/spectacle blinds placed into the lines. This shall
involve breaking pipework at flanges and shall be recorded in a specific procedure/method
study for the work.
All precautions and safety points shall be recorded in the Safety Plan before any breaks are
made to the system/equipment integrity.
[Link] work required to be undertaken can proceed as soon as the Isolation has been
established and checked and the PTW is issued.
The Issuing Authority shall validate the PTW and hand it to the Permit Holder to undertake the
work; if hot work is involved, the Area Authority Will do this.
[Link] the equipment is required to be test run, this should be carried out under a 'De-Isolation for
Test (DFT) procedure' using the reverse side of the Mechanical Isolation Certificates
Depending on the length of time that the isolations will be applied, integrity checks shall be
defined. The integrity checks shall be carried out by the Area Authority and Operations
Supervisor who will ensure that the isolations are correct and intact.
7. Depending on the length that the isolations will be applied, integrity checks shall be defined.
The integrity checks shall be carried out by the Area Authority and Operations Supervisor who
will ensure that the isolations are correct and intact.
8. On completion of all works, commissioning, and testing the process equipment can be de-
isolated. The de-isolation should be checked off against the Mechanical Isolation Certificate
and the marked-up As-Built drawings.
When the de-isolation is completed by the Isolating Authority, the PTW can be closed out by
the Permit Holder and returned back to the PTW office.

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Minimum Isolation Requirements

Table 1 below shows the recommended minimum isolation requirements.

System System Description Major Work

Class

A A shutdown Positive Isolation by a spade or remove spool

depressurized and and install blind.
hydrocarbon-free
system.

B System in Service, of Single leak-tight valve plus spade/blind (Note 1).

ANSI class 600# and
below.
For flashing liquids
and toxic see C
below.

Double block and bleed plus a spade/blind.

C System in Service, of
ANSI class 900# and
above.
All systems contain
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
When the volume of liquids to be drained is significant (e.g., for line sizes of 6" and
above).
Note 2 For the purposes of this requirement, toxic in the case of H2S is defined as
more than 500 ppm H2S in the process stream.

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9 SPECTACLE BLINDS, SPADES, OR SPOOLS FOR ISOLATION

Wherever routine Isolation of equipment is foreseen for Maintenance or inspection,

spectacle blinds shall be installed irrespective of pipe diameter and rating as swinging
a spectacle blind is an easier operation than installing a spade. Furthermore, the
isolation status is visually apparent with a spectacle blind.
For substantial runs of smaller diameter piping (DN 150 and below) of lower pressure
classes (ANSI 300 and below) where there is sufficient flexibility in the pipework for
easy flange spreading, then spades are an acceptable and convenient isolation
method. For larger diameter and higher rated piping or for cases of more rigid piping
systems, permanently installed spectacle blinds are more convenient and impose less
strain on the pipework during the isolation operation.

For the Isolation of vessels and tanks where nozzle inspection is required, Isolation
may also be provided by the complete removal of an upstream piping spool with the
resultant free end of the potentially live pipework being closed with a blind flange.

10 DIMENSIONS OF SPADES AND SPECTACLE BLINDS

The spade or spectacle blind shall be of sufficient thickness to provide pressure
containment capability equivalent to the piping class in which it is installed. If there is
a specification break at the spectacle blind, then the blind shall be rated for the higher
piping class.

11 DOUBLE BLOCK AND BLEED

Any process stream which is considered sour in accordance with ERD-08-04 shall be
provided with a double block and bleed system for Isolation. The bleed system shall
be connected to a closed drain/flare system.

Double block and bleed shall be provided for Isolation in all 900# and higher rated gas
or liquid systems and for sour systems with H2S >500 ppm, which may involve
maintenance/inspection activities that use the block valves for Isolation against the
upstream or downstream system. The recommended isolation requirements are given
in section 3.

18
 Mechanical Safe Working Procedure

12 LOCATION OF SPECTACLE BLINDS

The actual location of spectacle blinds will usually be determined during the detailed
design of the facilities based on the agreed maintenance philosophy. This should
consider whether periodic maintenance/inspection will be implemented on individual
equipment items, trains, units, or the plant as a whole. Consideration of these factors
will indicate the required number and best locations for the installation of the spectacle
blinds.

Fig. 1 shows the typical isolation requirements of a pig launcher/receiver. If the piping
specification calls for welded valves, separate flanges shall be provided to
accommodate the spectacle blind.

Fig. 2 and 3 show the general requirements of Isolation for tanks and vessels in sour
Service.

Fig. 4 and Fig. 5 represent the isolation requirements for tanks. If a spool is used for
Isolation at the tank inlet nozzle, the spool shall be straight, and its length shall not
exceed 1 meter. 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.

Fig. 6 shows a typical pump isolation arrangement. Rotating equipment shall be

provided with spectacle blinds on the equipment side of the inlet and outlet isolation
valves, as each may be subjected to Maintenance while the surrounding facilities
remain live. The pressure rating of the suction valve and piping between the valve and
the suction nozzle shall be equal to the rating of the pump's suction piping.

Fig. 7 shows Isolation of sweet service tanks

Fig. 8 shows the isolation requirements for vent and flare headers.
Fig. 9 and 10 show the general requirements for the isolation and pressure
equalization of ESD and PSD valves, respectively.

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 Mechanical Safe Working Procedure

POSITIVE ISOLATION ARRANGEMENTS

PIG LAUNCHER
Vent & Flare System

Vent & Flare System

or Atmosphere at

or Atmosphere at

Vent & Flare System

Safe Location

Safe Location

Vent & Flare System

or Atmosphere at

or Atmosphere at
Safe Location

Safe Location
PG NC
NC
PG PG
Pig Indicator NC Pig Indicator

INLET OR
OUTLET
NC

NC

NC NC NC NO

DRAINS
SYSTEM

(Balance Line)

NC

NC

NC FROM / TO
MAIN LINE

Normal Operation
Vent & Flare System

Vent & Flare System

WARNING. Where a
Vent & Flare System
or Atmosphere at

or Atmosphere at

Pressure Safety Relief valve

Vent & Flare System
or Atmosphere at
Safe Location

is provided on the Launcher

Safe Location

or Atmosphere at
Safe Location

that is tied into a Vent and

Safe Location

Flare System then a full

Shutdown is required
unless isolation is provided
upstream of the Relief Valve

LC
NC
Pig Indicator LC Pig Indicator

INLET OR
LC OUTLET
LC

NC

LC LC LC NO

DRAINS
SYSTEM

(Balance Line)

LC C

LC

LC
FROM / TO
MAIN LINE

Isolation

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 Mechanical Safe Working Procedure

TANK ISOLATION (SOUR SERVICE)

TO FLARE
HEADER

BLANKET GAS LO
LO

BALANCE LINE
OIL OUTLET

OIL INLET
WATER OUTLET
Breakout
Spool

NC NC

NC
CLOSED DRAIN
HEADER
Normal Operation

TO FLARE
HEADER

WARNING. The ‘Blind’ on the tank vent line to Flare can only be
BLANKET GAS LC swung if the station / facility is Shutdown or an isolation valve
LC is provided on the line upstream of the spade location.

BALANCE LINE
OIL OUTLET
LC
LC
Flange
Blinded

LC LC
OIL INLET
WATER OUTLET
LO
NOTE. The Bleed Valve LC
will be locked open to
relieve any pressure build Breakout
up to the closed drains. Spool LC
Provision should be made
Removed
to provide a means of LC LC
monitoring the bleed line
from the ‘double block
and bleed’

LO
SPADE CLOSED DRAIN
HEADER
Isolated

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 Mechanical Safe Working Procedure

VESSEL (SOUR SERVICES)

To Vent / Flare

Blowdown
to Flare

LO LO
Gas
Outlet

Inlet
H
LG LG LA
NC
L

NC

Closed Drains
NC NC
NC NC NC Liquid
Outlet

NC

NC

To Closed Drains
Header

Normal Operation

To Vent / Flare

WARNING. The ‘Blinds’ on the

Pressure Safety Relief and Blowdown
lines can only be swung if the vent
and flare systems are shutdown or Blowdown
isolation valves are provided to Flare
upstream of the Relief and Blowdown
valves. LC LC
Gas
Outlet

LC LC
Inlet
H
LG LG LA
LO
L

LO

Closed Drains
NOTE. The Bleed Valve NC NC
will be locked open to
relieve any pressure build NC NC NC Liquid
up to the closed drains. Outlet
Provision should be made
to provide a means of
monitoring the bleed line
from the ‘double block NC
and bleed’
NC

SPADE To Closed Drains

Header

Isolation

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 Mechanical Safe Working Procedure

CENTRIFUGAL PUMP

Casing Vent to
Safe Area
Pump Discharge

NC
Pump Suction

PG
PG

Vent/Local/
Atmos Flare

Motor

Seal Drain Pot

NC NC

NC Drain/Local Drain
Collection Tank

To Closed Drains
Header

Normal Operation

CENTRIFUGAL PUMP
Casing Vent to
Safe Area

Pump Discharge

LC
NO
Pump Suction

LC

PG
PG Electric motor
NC
isolated at the
Vent/Local/
main breaker Atmos Flare

Motor

Seal Drain Pot

NC NC

NC
Drain/Local Drain
Collection Tank

NC
To Closed Drains
Header

Isolation

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 Mechanical Safe Working Procedure

VENT & FLARE HEADER

Header
TO FLARE

LO LO

Vessel 2

Vessel 1 Vessel 3

Normal Operation

Header
TO FLARE

WARNING: In this case ‘blinds’ can

LC LC
only be swung if the Vessel
connected to the flare line is
shutdown, isolated and
depressurised.

Where relief lines combine then all

associated vessels and equipment
shall require to be shutdown, isolated
and depressurised.

Vessel 2

Vessel 1 Vessel 3

Isolated

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 Mechanical Safe Working Procedure

FIGURE 6.0 – TANK ISOLATION, SWEET SERVICE

25
 Mechanical Safe Working Procedure

FIGURE 9.0 – ISOLATION AND PRESSURE EQUALISATION FOR INLET ESD VALVE

FIGURE 10.0 – ISOLATION AND PRESSURE EQUALISATION FOR INLET PSD VALVE

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 Mechanical Safe Working Procedure

13 BREAKING CONTAINMENT
First break is used in combination with the Respiratory Protection Standard and ensures:
• Reducing exposure to hazardous fluids, gases, or vapors during the initial opening of
piping, equipment, or vessels that have been removed from Service.
Sources of sour gas or other toxic substances are identified, and defenses are implemented
to reduce exposure risk.
First Break is First break is the act of breaking the integrity
of process piping or equipment that may
contain toxic or hazardous products. It is a
planned loss of containment where there is
potential for trapped pressure or exposure to
a toxic commodity or unknown material.
Completed by First break is typically completed by:
Operations –drain/depressurize equipment
prior to LOTO.
Maintenance and Construction – break a
flange or open a valve on a line containing
H2S, Benzene or other toxic substances.

First break procedure applies. First break procedure applies to the following
conditions:
Toxic piping, process equipment and /or
other equipment with toxic or noxious
products, e.g., H2S, acid, caustic, benzenes,
etc., Refer to Respiratory Protective
Requirements for guidance.
Equipment/piping with unknown
concentrations of toxic or noxious materials.
When removing a blank or a blind, if the
absence of trapped pressure or atmospheric
hazards cannot be proven, the First Break
Procedure must be followed.
When removing a cap or plug from an
engineered vent or drain where the process
stream contains acid, caustic, and or
mercaptan.

First break procedure does not apply. First break procedure does not apply when:
Sampling
When removing a cap or plug from an
engineered vent or drain, where the cap or
plug is isolated from the process stream by a
manual valve.

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 Mechanical Safe Working Procedure

13.1.1 Hazards
Potential hazards The following hazards should be considered, and
defenses implemented for:
• • Fires associated with flammable gases,
liquids, or vapors
• • Source of ignition, e.g., sparking or static
electricity, open flame, iron sulfide
• • Toxic vapours or corrosive substances
e.g., H2S, acid, caustic, benzene
• • High temperature, high-pressure fluids,
gases or vapors
• • Static electric charges.

Hazardous pressures or fumes A vent or drain can be the first break into a system.
If a vent or drain valve test has proven that the first
break is free of hazardous pressures or fumes, then
any flange following is considered a second break. A
second break can be done, provided a proper hazard
assessment has been performed.
13.1.2 Prework
Prior to conducting first break Confirm the following prerequisites prior to
conducting the first break:
Ensure positive or proven Isolation is in place before
breaking containment of a system. This includes
opening a drain/vent valve or breaking a flange
(LSR: Verify Isolations).
Implement defenses against Line of Fire hazards
Apply personal locks to the isolation lockbox.
Obtain a Safe Work Permit if needed (LSR: Work
with a valid permit when required).
Use spill containment under every flange to be
broken or drain to be opened.

Tools and equipment required The following tools and equipment may be required
for first break work:
Spill containment
Portable eye wash and safety shower
Proper wrenches (no crescent wrenches)
Flange spreaders
Pipe supports
Respiratory protective equipment

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 Mechanical Safe Working Procedure

13.1.3 Defenses

Defenses including the following examples should be considered for first break:

Defense Consideration
• Worker performing the first break will conduct
a work permit, field-level hazard assessment
(FLHA) or local process.
• Consider how long the system has been
isolated, as this may increase the potential for
exposure to trapped fluids or hazardous
atmospheres.
• Completed Safe Work Permit listing all
Safe Work hazards and defenses for Maintenance and
Practices construction personnel.
• Work activity is to ensure that line of fire,
and product temperature hazards are
considered and mitigated before any work
starts.
• A Standby Person with a SCBA or SABA must
be present during the first break. A Standby
Person must be ready to go under-air. e.g., if
monitoring from a safe location, they should be
packed up and ready to go but does not need
to have the mask on.
• Two-way (IS) radio communication must be
Communication established.
• Operations must be notified of all first
breaks before performing.
• SABA or SCBA must be worn at first break –
Most work is completed using SABA. SCBA is
only used in emergency situations when SABA
PPE is not practical.
• Chemical proof rain suit, gloves, face
shield (hot sampling PPE) if the product
is >55°C.
• Any other specialized PPE required by
Safety Data Sheets (SDS).
• Gas monitors must be bumped and calibrated
Atmospheric within the specified time (bumped every 24
testing hours, calibrated as per manufacturer guide).
• Spill containment must be placed under all
Spill prevention
flanges, drains, and equipment to be
broken.

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 Mechanical Safe Working Procedure

13.1.4 Respiratory protective requirements

Categories (red, yellow, green) are based on the Isolation Standard, SDS, and
likelihood of trapped pressure testing by Industrial Hygiene.
Respiratory protective requirements are as follows:

Commodity Respiratory Protection Requirements

Produced emulsion Operations and Maintenance must pack up when
breaking equipment integrity
Produced gas • Operations will pack-up and remain
Mixed fuel gas protected until atmospheric testing has
confirmed the absence of hazardous
Recycle slop oil substances.
• Maintenance personnel are required to
Sulfite / O2 Scavenger
pack-up and remain protected when
Flare Header / HP Flare breaking into the same system until
additional testing has confirmed the absence
of hazardous substances.
Diluent* • *Diluent applies to condensate or others
known to have high Benzene.
Hydrochloric Acid Operations must pack up when breaking
equipment integrity.
Mercaptan (gas odorant)
• Operations will pack-up and remain
Produced Water protected until atmospheric testing has
confirmed the absence of hazardous
Sodium Hydroxide (Caustic Soda) substances.
Sulfur Dioxide (SO2) Amine • Maintenance personnel are not required to
pack-up and remain protected when
Produced / Sales Oil breaking into the same system.

Synthetic Crude Oil

SABA / SCBA is generally not required for breaking
Hydrated Lime / Lime Slurry
equipment integrity:
Natural Gas (TCPL) • SDS and RPE Selection Chart must be
consulted to ensure workers are
Lift/Fuel/Blanket/Purge Gas protected against exposure.
Methanol • Diluent, Synthetic Crude Oil, and other
Benzene containing commodities may
Soda Ash / Soda Ash Slurry require SABA / SCBA based on
concentrations outlined in the Benzene
Steam Code of Practice.
Steam Condensate
Boiler Feed Water/Backwash
water
De-mulsifier (Emulsion Breaker)
Glycol

30
 Mechanical Safe Working Procedure

Varsol
Potable Water
Instrument Air
Utility Air
Utility Water / Fire Water
Saline Water
Magnesium Oxide (MagOx)
Reverse Demulsifier (REB)
Floculant SABA / SCBA is not required for breaking
equipment integrity:
Coagulant
• Packing-up is not required for first break.
Polymer • SDS and RPE Selection Chart must be
consulted to ensure workers are protected
Chelant / Scale Inhibitor
against unwanted exposure.
Blowdown (Disposal)
Raw Water
Brine
Nitrogen (N2)
Hypochlorite
Filming Agent (Filming Amine)
Carbon Dioxide (CO2)

31
 Mechanical Safe Working Procedure

13.1.5 Prepare for First Break

Pre-job activities Pre-job activities are as follows:

33
 Mechanical Safe Working Procedure

13.1.6 First break on Flanges Procedure

Perform first break Perform first break as follows:

Step Action

Don SABA or SCBA.

Position yourself upwind with a clear evacuation route.

Loosen nuts until flange is proven to

be open.
CAUTION: Always assume the line is
charged unless proven otherwise. Always
loosen nuts on the opposite side of the flange
that you are positioned on.

Confirm nuts remain on flange bolts until zero energy is proven.

Complete based on the

following:
If Then
Fluid or gas is encountered and Tighten flange back up and re-
does not dissipate quickly assess the situation
Fluid or gas is encountered
and dissipates quickly or not Capture all fluids
fluid or gas is encountered

Test atmosphere with 4-head continuous gas monitor and

benzene

NOTE: Do not use your personal gas monitor

as it is not continuous.

Complete based on the following test

result:
If Then
Atmosphere is proven safe SABA / SCBA can be removed
Refer to the RPE selection
If atmosphere is not at safe chart for ongoing respiratory
levels requirements (Benzene)

First Break on Flanges Procedure is complete.

34
 Mechanical Safe Working Procedure

13.1.7 First Break on Vents or Drains Procedure

Perform first break Perform first break as follows:
Step Action

Don SABA or SCBA.

Position yourself upwind and out of the line of fire with a clear
evacuation route.

Open the drain valve

slowly.
CAUTION: Always assume the line is
charged until proven otherwise. Stay clear of
the line of fire.

Confirm all liquids are captured in spill containment.

Open drain valve fully to remove all fluids and pressure if

conditions permit.

Capture all
fluids.
If Then
Fluid or gas is encountered and Close valve and re-assess the
does not dissipate quickly situation
Control the potential release of
Fluid is encountered
fluid and prevent a spill

Utilize rodding tool to confirm valve is clear of obstructions.

Test atmosphere and complete based on

the result:
If Then
Atmosphere is proven safe SABA / SCBA can be removed
Refer to RPE selection chart
If atmosphere is not at safe for ongoing respiratory
levels requirements (Benzene)

First Break on Vents and Drain Procedure is complete.

35
Mechanical Safe Working Procedure

36