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Table of contents
Page No.
Mod 14 Equipment Isolation
14.1 Introduction
2
14.3Devices
3
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14.1. Introduction
What is isolation?
It is Company policy that maintenance or modification work to process plant requires that the
plant concerned is effectively isolated from all sources of energy and hazardous materials, and
made safe before work is allowed to proceed. Controls are provided for the purpose of plant
isolation to ensure the safety of personnel and the protection of company assets and
environment.
Scope:
Competency:
The responsible Supervisor must ensure that the person nominated to do
isolation is competent for the task.
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Security:
Each isolation is to be secured in the required position so that the
accidental release of energy source is prevented.
Labeling:
The isolation is to be labeled with a high visibility “Isolation Label” so that
anyone can immediately see why that isolation is in place, and should not
be tempered with.
Recording:
Isolation is to be recorded on the Permit for the work or on the separate
isolation Certificate. For complex isolation, marked-up P&Ids or line
diagrams should be attached to the isolation Certificate. ALL isolation
work SHALL be carried out under the Permit to Work system.
Integrity:
It is essential that Operators and Supervisors being constantly vigilant
during the work or in the case of a long-term isolation maintain the
integrity of isolations for the entire period of any works by formal auditing
of such isolations at pre-defined intervals.
Hazards:
Hazards SHALL be identified, detailed and controlled by proper use of the
Permit to Work system. Isolation of any equipment that may cause a
hazard to personnel, the environment or damage to the Company's
assets SHALL be accomplished to provide the safest environment to carry
out any work on that equipment.
Authority:
All work SHALL be authorised by the Production Co-ordinator or his delegated
representative.
Method of Isolation:
The method of isolation depends on such factors as the type of work involved, e.g. of
major, minor or routine nature, the properties of the process medium and the
temperature and pressure of the process system.
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Minor work:
Such as replacing a faulty instrument on a vessel (subject to the approval
of the site maintenance and production supervisors), the required
isolation on liquid containing systems (not gas) may be affected by
closing valves only
Longer duration:
For work of longer duration or where fittings and accessories remain
removed for an appreciable period, e.g. overnight or longer, spades or
blinds SHALL isolate the equipment.
Electrical Systems:
All electrical isolations are to be done in accordance with the Electrical
Safety Rules (ESRs) and Electrical Safety Operation Procedures (ESOPs)
Spectacle Blind
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Spade
Blind/Blank Flange:
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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 which controls the passage of a liquid through a pipe with the intention that it permits
either full flow or no flow.
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 downside of the block
valve when closed.
B leed V alve
Abbreviations:
CC - Corrosion Coupon
DN - Nominal Diameter
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FB - Full Bore
FIG - Figure
LG - Level Gauge
LO - Locked-Open
NC - Normally Closed.
NO - Normally Open
PG - Pressure Gauge
RO - Restriction Orifice
Typ - Typical
UZ - Emergency Shutdown
XI - Pig Signaler
Suspended flow and gaslift lines, once isolated, SHALL be left with
an inert medium for corrosion prevention purposes.
If the well is to be kept on the ‘swing list’ or closed in for less than
two months the following steps must be followed:
Ø Close gaslift manifold
Ø Close in the well.
Ø Leave gaslift lines/flowline pressurised to station
manifold/separator pressure.
If the well is to be closed in for more than two months but SHALL
have future use, the following steps must be followed:
Tagging of Isolation:
Every valve, spade, switch, breaker etc. used in isolation (except for isolation that does not
require isolation certificate) must be marked with the correct type of tag label. Different tags
are available for the isolation of Valves, Spades, and Electrical Equipment.
All tags have three parts. The first part is to be attached to the isolation point. The other two
parts are to be attached to the permit Issue Point copy of the permit or isolation Certificate
and kept at the issue Point until the isolation is removed.
When the isolation is removed the tags that have been removed must be compared with those
at the Permit Issue Point to confirm that all isolation has been removed. The third part of the
tag (the smallest part) is provided to assist in the removal of complex isolation. This part is
kept attached to the middle part of the tag at the issue point until de-isolation is required. The
third parts can be detached and taken to the site by the de-isolator to ensure he only de-
isolates the correct valves/switches.
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Proving of Isolation:
Whenever isolation is complete, the isolator must prove that the area
within the isolation is fully isolated from pressure/electricity. This can
normally be done by checks at vent valves or by the checks to prove
electrical equipment dead required by ESOPs/ESRs. If it is not possible to
check that a pressure system has been de-pressurised without unbolting
a flange, the work part must be aware of the possible pressure hazard.
The Job Safety plan must include clear instructions on controlling the
unbolting of the first flange to ensure that any pressure is released before
bolts have been removed.
1) Where work has started but will be suspended for a period of short
time. For example, when awaiting spares for repairs.
2) Where equipment becomes redundant and is to be permanently
isolated.
Unrecorded Isolations:
Locked valves are used for safety purposes in process plant, either to ensure that a flow
pathway is maintained (in the case of a relief valve) or a system/vessel is securely isolated from
adjacent processing equipment. Similarly, ‘spectacle’ blinds are used for effecting positive
isolations between vessels and pipe work.
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Procedure Description:
Definitions
Locked Valve:
A locked valve is a valve which is designated on the Process and
Engineering Flow Scheme (PEFS) as being either Locked Open (LO) or
Locked Closed (LC). Locked valves are those valves identified during
the design phase, or in subsequent reviews, as being essential to the
safety and integrity of the plant or facility. The changing of the
normal state of a locked valve must be controlled through the Permit to
Work System according to this procedure to assure the continued safe
operation of the facility.
Spectacle Blind:
A spectacle blind is designated on the Process and Engineering Flow
Scheme (PEFS) as being either open or close. Spectacle blind positions
are identified during the design phase, or in subsequent reviews, as being
essential for positive isolation purposes and the safety of the
plant or facility. Changing the status of a spectacle blind must be
controlled through the Permit to Work System according to this procedure
to assure the safe operation of the facility.
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ALL deviations from the approved status of locked valves or spectacle blinds
shall be recorded (for audit purposes) and reported to the Production Co-
ordinator and the Area Team Leader.
The Production Supervisor shall audit the status of locked valves
once in every six months, and shall be accountable to ensure
that the status of locked valves are physically checked and recorded
once in every shift change – “shift” being a 2 week tour of duty.
Spectacle blinds shall be audited once every 12 months. The
plant operators shall check both against the latest PEFS/UEFS. A
file shall be kept of all audits for external checking.
The main hazard when working on equipment that has been isolated from live plant is that
isolation from a source of energy or hazardous fluid may be overlooked and the source then
activated. These hazards are identified, detailed and controlled by proper use of the permit to
work system. All isolation shall be authorized by a work permit. The production supervisor
or permit applicant shall write a site specific procedure for every piece of equipment to be
isolated from live plant and it shall be attached to the work permit, describing what
connections shall be disconnected, blocked or tagged before starting to open the equipment. A
spade and blind check list shall be made by the permit applicant and submitted with the work
permit to ensure the correct spades or blinds are closed during isolation and removed upon
completion of the work. This spade list will be signed off by the operator after isolation and
prior to equipment reinstatement after de-isolation.
The procedures for isolation as attached to the work permit can be straightforward when all
valves have a leak tight shut-off. However when valves do not have a tight shut-off, judgment
is required to decide how the work may be continued, and unless the person involved is
qualified to make such a decision, the work (also the installation of blinds) should be stopped.
This should be stated in the work permit.
Supervision of the work by the operator is required, particularly checking all isolation
points before starting, restarting and after finishing the job. The operator will verify spade and
blind positions with the list before the work is commenced and after the work is completed, he
will also supervise gas testing and purging as needed.
Moving machinery is defined here as any equipment using external motive force such as
Electricity, air, steam, or hydraulic fluid.
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The electrical, steam, hydraulic or other source of energy to the moving machinery, both flow
and return circuits, must be isolated from its drive unit and secured immobile before work
commences. For electrical isolation this must be done in accordance with ESOP.
Isolation of Vessels:
Design procedures indicate that normally open spectacle blinds should be installed on the
downstream side of the inlet block valve and the upstream side of the outlet block valve. If
practical these blinds should be mounted directly on the inlet flange. These blinds shall be
swung closed for maintenance work. If a spool piece is present between the blind and the
block valve it should be equipped with a vent or drain valve to allow the bleed off of any
pressure build up between the valve and the blind during maintenance before removing the
blind to reconnect the vessel.
Isolation of Tanks:
Blinds or spades should be inserted on the tank side of all inlet and outlet block valves. These
should be placed as close to the tank as possible. This also applies to blanket / purge gas lines,
tank balancing lines, 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.
Toxic gas is defined for isolation purposes as a gas containing more than 50 ppm of H2S. A
double block and bleed system is the minimum mandatory requirement for systems containing
toxic fluids.
Double block and bleed arrangements will provide a measure of protection when used in conjunction
with spades or blinds, however they should never be considered an acceptable replacement for
mechanical isolation for major work unless physical isolation by removing pipe-work is agreed
to be totally impractical by the Area Coordinator.
When double block and bleed systems are used in toxic service, the bleed connection shall be
hard-piped to a safe disposal location to ensure that the bleed itself does not create a hazard.
Acceptable disposal routes are to a remote vent or to a plant closed drain (or vent) system
provided that no live facilities are connected to the drain system while the double block and
bleed is in use.
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For work on equipment containing toxic gases, wearing positive pressure breathing apparatus
is mandatory when breaking flanges and opening equipment, this should be clearly stated on
the work permit.
Adequate isolation and purging shall be proven by a direct measurement, for both
hydrocarbons and the toxic component concerned (usually H2S), further work such as
opening the equipment for inspection will be carried out wearing a personal H2S monitor and
escape set.
Variation To Procedure:
When the piping and valve arrangement of process equipment does not allow for Double block
and bleed to comply with this procedure, the area coordinator will determine if isolation can
be safely accomplished by an alternate method. In this event the procedure to be followed will
be clearly written on or attached to the Work Permit.
Notes
1. The definition of minor and major work for any specific job will be determined by the
Production Supervisor.
2. Minor work is defined as a job of a routine nature e.g. control valve or pig-trap opening.
3. Major work is defined as a job of a complex nature e.g., inspection, maintenance shutdown
or vessel entry.
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Note 1 A bleed connection should be installed between the valve and the
spade/blind for line sizes 6" and above. The purpose of the bleed is to
establish that positive isolation is achieved and to provide a means of
draining or depressurising the volume between spade/blind and isolation
valve.
Note 2 For the purposes of this requirement, toxic in the case of H2S is defined
as more than 50ppm H2S in the process stream.
Note 3 The definition of flashing liquids for the purposes of this Table is that given for
Cat. A fluids in Appendix B of the IP Code Part 15.
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 pipe work 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
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spectacle blinds are more convenient and impose less strain on the pipe work during the
isolation operation.
For the isolation of vessels and tanks where nozzle inspection is required, isolation may also
be provided by complete removal of an upstream piping spool with the resultant free end of
the potentially live pipe work being closed with a blind flange.
Details of the correct dimensions of spades and spectacle blinds for ANSI pressure ratings are
given respectively in SIPM Standard Drawings S38.042 and S38.011 (see DEP 00.00.06.06-
Gen).
Double Block And Bleed:
Any process stream which is considered sour in accordance with PDO-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 600# and higher rated gas or
liquid systems, which may involve maintenance/inspection activities which use the block valves
for isolation against the upstream or downstream system.
C C
Spool Removal
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The actual location of spectacle blinds will normally be determined during detailed design of
the Facilities based upon 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 installation of the spectacle blinds.
Below figure shows the isolation requirements at wellhead.
Swab Valve
Wing Valve
Location Valve
SSV
Master Valve
NC FB
NC FB
Note -1 INLET OR OUTLET
NC
NC NC NC
TO CLOSED DRAIN
NC
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NOTE - 1 : DOUBLE BLOCK AND BLEED REQUIRED FOR SOUR SERVICE AND 600# AND ABOVE RATED SYSTEM
NOTE - 2 : REFER ERD 08-11 (LATES VERSION ON WALLCHART) FOR THE LATEST UPDATE OF THIS DIAGRAM
Petroleum Development Oman HLD OTTP handout
Refer to Fig. 3 and Fig. 4 for general requirements of isolation for vessels.
TO VENT HEADER
NC C
C
LG
LIC
MANUAL
NC DRAIN NC NC NC
C
C NC
DEPRESSURISATION TO FLARE
N.C
XX UZ XXX
VAPOUR OUTLET
XX PIC XXX
INLET
H
LG LIC LZA
TO CLOSED DRAIN
N.C NC NC NC NC
LIQUID OUTLET
Figure - 4
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Fig. 5 represents the isolation requirements for tanks. If a spool is used for isolation at tank
inlet nozzle, the spool shall be straight and its length shall not exceed I meter.
Automatic depressurising lines shall not have any block valves upstream or downstream.
Manual depressurising lines should be equipped with normally closed block valves having the
open spectacle blinds upstream; the spectacle blind should preferably be located at the
equipment flange.
For isolation of electrical equipment and moving machineries the electrical, steam, hydraulic,
fuel or other source of energy to the moving machinery, both flow and return circuit, must be
isolated. Alternatively the moving machinery must be isolated from its drive and secured
immobile.
HEADER
C C
Rotating equipment shall be provided with spectacle blinds at equipment side of inlet and
outlet isolation valves as each may be subjected to maintenance while the surrounding facilities
remain live.
There shall be no isolation valve at the inlet and outlet of safety relief valves.
For all cases in 600# and above and in sour service the double block and bleed requirement
shall be followed.
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Gas-Barrier Plugs:
The gas barrier plugging technique involves cutting and parting the line before installing one of
a variety of plugging materials or devices into the open ends of the pipeline. Most of the work
is done manually so little specialised equipment is needed. This is a fast and practical plugging
method which is most often used in the repair of short run, small diameter and low vapor
pressure liquid pipelines.
- gas barrier plugs will not retain liquids or pressure exerted by vapor or gas. Venting,
blinding and other precautions are necessary to minimize the possibility of liquid or gas
bypassing or ejecting the plug from the line,
- any debris (grass, sticks, rocks, etc.) in mud or clay plugs may be harmful to meters,
seals and other pipeline components.
Pressure-retaining plugs:
The pressure-retaining plugging method involves setting one or more plugs in the line by
mechanical means through connections hot-tapped onto the pipeline. These plugs will retain
pressure and will allow continued operations through bypasses at the work site. Preliminary
preparations can be made with little or no disruption of operations. The length of the line to
be isolated and drained is largely optional and minimizes drainage volumes and product losses.
Venting and clean up requirements are minimal. This can be the most practical method for
repairing LP-gas pipelines.
Equipment Isolation:
A) Well-head Isolation: (PR 1037)
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Requirement to carry out work on the wellhead (i.e. Christmas Tree) or at the down hole, it is
necessary to isolate the wellhead from the downstream as well as from the upstream.
Sometime wellhead can be found on the ground or below the ground level in the Cellar. While
isolating wellhead with the Cellar, precaution should be taken as confine space entry to
minimise the hazards.
Well head flowline that is taken out of service for maintenance or isolated long term for other
reasons, is always subject to the insertion of spectacle blinds and tagging of valves which
ensures the safety integrity of isolation
W ell C ontrol
Swab Valve
W ing Valve
SSV
M aster Valve
Control Line for SSV
Control L ine for
SC SSV
Control Line
C asing
Tubing
SCSSV
Isolation of Well-Head:
Obtain a Well Location Custodian ship Transfer Form to carry out the
work.
A gas test shall be carried out on arrival at the wellsite.
Oxygen levels in the well cellar shall also be checked if work is to be
done in this area and on H 2S designated locations, a test shall also
be conducted to ensure that the H2S level is below 10 PPM
Note: If either test is outside acceptable limits, BA sets shall be worn whilst working
in the areas concerned. Refer to:
PR-1042 “General Operational Safety”;
PR-1044 “H2S Environment”.
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FTHP H2S
(kPa) Concentration
(PPM by
weight)
300 – 500 > 20,000
500 – 2000 > 5,000
2000 – 5000 > 2,000
5000 - > 800
10000
Note: Sour wells with FTHP < 300 kPa do not require an SCSSSV.
all exploration wells completed with a packer where there is the
possibility of H2S or CO2 being present;
all free flowing, or having the ability to free flow, oil wells located
along areas of major surface water flow
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Types of SSV
Surface safety valves (SSV’s) normally take the form of
hydraulically operated upper master gate valves (UMGV's) installed
in the Xmas trees of wells.
Install a pressure recorder/gauge on the Xmas tree cap, ensuring
that the swab valve is close.
Close the location valve and check for leaking by listening for noise
of fluids passing.
Close in the well on the wing valve.
Depressurise the flowline between the wing valve and the location
valve.
Check leak rate across wing valve by monitoring the flowline
pressure builds up for 15 minutes.
Close the lower master valves
Close the Gas lift line location valve
Close the casing wing valve
Depressurise the gas lift line between location valve and casing
wing valve by connecting tubing between gas lift line to flow line.
Once the line is fully depressurise reverse the spectacle blind to
close position at the up stream of flow line location valve and down
stream of gas lift location valve.
Complete the PTW system.
The purpose of this procedure is to ensure that any interruption in the operation of a well, and
its associated flow and gaslift lines, is performed in a controlled and safe manner.
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Procedure Description:
If there is no future use for the well, the well is suspended from use
by following WSP-71 ‘Suspension of Wells and Completion
Operations’, Manual 2350.
Suspended flow and gaslift lines, once isolated, SHALL be left with
an inert medium for corrosion prevention purposes.
If the well is to be kept on the ‘swing list’ or closed in for less than
two months the following steps must be followed:
If the well is to be closed in for more than two months but SHALL
have future use, the following steps must be followed:
Ø Isolate gas lift from manifold side
Ø Close in all wellhead valves
Ø Depressurise gas lift line to flow line from wellhead end to
station.
Ø Close the location valves of both gaslift and flow line.
Ø Disconnect Gaslift / flowline from Xmas tree.
Ø Install blank flange on Xmas tree.
Ø Flush flowline with potable water (1.5 x line volume).
Ø Purge the flowline with nitrogen until free of liquid.
Ø Install blind flanges on both end of flowline.
Ø Leave 150-kPa nitrogen pressure in flowline.
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Procedure
The power switch near the pump motor shall be switched off and
locked ensuring that the pump is stopped with the counterweights
at their lowest position. The electrical supply shall be isolated and
locked off the at the control panel by the Competent Electrical
Person who will sign the Isolation Certificate to that effect.
Ensure that the master and swab valves are locked open to prevent
fouling of the pump rods. Also, one of the 'A' annulus valves may
be the exit point for a stainless steel PTS line, this should not be
closed either.
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D) Shipping Pump Isolation:The power switch near the pump motor shall be switched
off and locked ensuring that the pump is stopped. The electrical supply shall be
isolated and locked off the at the control panel by the Competent Electrical Person
who will sign the Isolation Certificate to that effect.
Once the pump is stopped it’s suction valve and Discharge valve gets
close if it is motor driven operated. Otherwise close the manual suction
valve and discharge valve.
Motor driven suction /discharge MOV electrical supply should be isolated
by CEP
with the isolation of main motor of the pump.
Drain the suction/discharge line and pump casing through manual drain
valves to the drain vessel.
Once it is ensure that complete content from the system has been
drained than isolate all drain valves.
Reverse the spectacle blind at:
Suction Header
Discharge Header
M
M
M
To Drain
supply shall be isolated and locked off the at the control panel by
the Competent Electrical Person who will sign the Isolation
Certificate to that effect.
Close the master valve and check the THP
Close tubing wing valve
Let the line get depressurise and then close the flowline location
valve.
Isolate all installed safe guarding instruments on the flow line.
Isolation of ESP
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To Stn.
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Note: The nature of the nitrogen supply will depend on the size of
the equipment. Cylinders of gaseous nitrogen may be used in most
cases, with liquid nitrogen being required for larger volumes.
Once it is ensure that system is free of Hydrocarbon and H2S, work can
be started.
Isolation of Compressor
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Strict controls are necessary to ensure that PRV isolation valves are only
closed under specific circumstances and that they are securely set in the
OPEN position during normal operations.
Procedure Description:
Each PRV isolation SHALL be judged at local level to consider if any deviation from
the accepted isolation procedure is acceptable, and whether or not plant
modifications are justified (cost and time) to achieve the objectives of Method I.
above.
In cases where toxic fluid or gas are contained in the vessel (i.e.
H2S) and the vessel has to be temporarily isolated from a vent
header, double block and bleed isolation is the minimum
requirement if depressurisation, degassing, and disconnection of a
vessel is impractical.
PRV De-Isolation:
Note 1 Any alternative method for locking SHALL ensure a positive foolproof
arrangement for isolation valves such that any chains or wire strops which may
be used, cannot be inadvertently removed from the handwheel /operating lever.
Note 2 If padlocks are used for securing chains, a different key for each padlock SHALL
be the accepted practice, the keys being kept on the station control room keyboard.
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Symbols:
nel
s
nel ion
son
r
Return from/forward
son erat
ato
Activity
Per
to another activity
din
Per O p
oor
ce
Decision MA Meeting Attendee
n
ctio
nan
aC
int e
du
Are
ST
E Start/End Continuation Pro
ST
1 Identify equipment to be isolated.
2 Identify hazards.
Major
3 Is the work major or minor?
Minor
Specify isolation by valves (if
4
appropriate).
7 Authorise permits.
12 _________________________________________________________________________________________
De-isolate when required.
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13 Sign off permit. E E E
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Process vessels and related equipment (vessel tower skirts and flare stacks), boilers, water
storage tanks, other tanks (including pontoons on floating roof tanks), bunds, tank cars and
trucks;
Spaces located below ground or deck level, nominally deeper than 1.5 m, such as drain pits,
sewage pits and associated tunnels, ducts, trenches, wells, shafts, cellars, vaults and
unventilated rooms which may be considered confined spaces under specific circumstances;
The same type of risk may exist in close proximity to equipment which has already been
opened up, in which case some of the precautions which apply to entry would also apply. The
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assessment of this situation will be made by the Responsible Person. (e.g. Production
Supervisor.
Entry should only be considered when all specified safety precautions have been fully
observed. Where specific area or equipment conditions dictate, further additional regulations
and procedure will be supplied by the Responsible Person involved.
Principles Of Control:
General:
Entry into a confined space, for whatever purpose, shall only be contemplated after all
practical steps have failed to deal with the problem in a less hazardous way.
There are three key areas of control as indicated below, from which cascade the appropriate
company Procedures/Systems which shall be complied with:
All personnel who are required to issue/supervise the above documents, as well as those who
are required to enter confined spaces as defined in this procedure are required to fully
understand and comply with the following codes and procedures:
Supervisory Responsibilities
Responsible Person/Representative
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A Site Representative (approved Work Permit holder) fully authorised by the Responsible
Person (e.g. Tank and Vessel Supervisor) is to be present on the site at all times for any work
covered by this procedure, and he is responsible for:
- Ensuring that all "vessels" are checked for pressure prior to opening, and for all the
subsequent tasks to be performed.
- Arranging for preparation of the area for safe entry (refer section 1. 1 of this
procedure).
- The issuing and control of all permits, check lists, pre-entry conditions, and isolations
for all facilities within the work area (GU 258 Permit to Work Systems).
- To ensure that personnel are fully trained in how to apply the appropriate safeguards in
controlling the hazards, and in the use of the test equipment for monitoring the hazards.
Ensuring that the confined space has been safely isolated, and that he clearly
understands what tasks are done.
Safety of the men entering the confined space (Refer to detailed check list in
"Guidelines for entry into Confined Spaces" Shell Safety and Health Committee
1992).(Custodian:- T.S.E. Department)
Briefing and testing (either as a group or individually) his men to ensure the
whole squad know and clearly understand the methods and plans for
entering or leaving the Confined Space - and appreciate the safety regulations
being undertaken for means of escape, should an emergency arise.
Obtaining “ Confined Space Entry Certificates” and complying with the specified
precaution on the permit.
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Maintaining a record of all persons and tools equipment inside the vessel and
for the removal of all fittings, scrap, waste at the end of the job, so as to leave the
area in a clean condition ready for re-commissioning.
The duties of the Attendant(s) or Stand-by Person(s) (e.g. Foreman) outside the
Confined Space are specifically related to the safety of those inside the enclosed space
and include:
If at any time whilst inside a vessel the contact with the Stand by man outside fails, the vessel
must be vacated immediately and may only be re-entered if this contact has been restored.
- To agree with those inside on signals for immediately leaving the confined space.
- Know who to summon and get the necessary help if anyone inside gets into
difficulties, e.g. via radio communications to a control room. This communication
link shall be actively tested at the commencement of each shift.
To alert the men inside the vessel or Confined Space of hazards that may cause air and life
lines to foul; give normal assistance in the handling of materials, tools, messages etc.
Note: 1.
A Stand-by man will not leave his post at the point of entry, or enter the vessel himself,
for any purpose whatever, without properly handing over to another Stand-by man,
except for emergency rescue after first calling for and receiving aid.
Note:2
On no account must the attendant / Stand-by person attempt to enter the space before
additional help has arrived.
If any person considers that there is a hazard present or the conditions set up for a particular
job change for any reason, the work must stop and the men must leave the Confined Space
until such conditions have been re-appraised by the Supervisor or his Representative.
After each change of shift, or a break in the operation of more than thirty minutes the
Supervisor has to ensure himself that conditions are still safe before allowing re-entry.
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Before entering confined spaces, the following particular hazards may need to be considered
and safeguard against:
- Chemical hazards.
- Physical hazards.
- Other hazards, e.g. poor visibility, persons becoming trapped in the event of
an accident etc.
A complete schedule of all blanks/spades used shall be made to ensure isolation, and the same
schedule used to ensure reinstatement of the plant at the end of the work.
Flammable Substances:
Where there is any possibility of the existence of flammable liquids or vapours, a competent
operator, authorised by the Responsible Person must test the area with an explosimeter,
witnessed by the representative and the work supervisor. A full record of these results must be
recorded on the Work Permit. This competent gas tester operator remains responsible for
continued testing and recording as specified on the Work Permit.
If a reading greater than 0% is indicated the Responsible Person or his representative must be
notified who will specify any restrictions or precautions to be taken on the "Confined Space
Entry Certificates".
Toxic Substances:
Where toxic liquids or vapours or other dangerous substances may be present, positive
pressure respiratory protection must be worn by each man in the tank or vessel, or the
equipment must be well ventilated by use of an air diffuser or blower-exhausted system, until it
is certified as safe for personnel to enter without breathing apparatus.
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Atmosphere-Oxygen Level:
Tanks, vessels and confined spaces may only be entered when the atmosphere inside has been
certified as having a safe oxygen content as indicated by recognised PDO detection apparatus.
This test will be conducted only by a competent gas tester permit holder who has been
formally instructed in the use of oxygen detectors.
If the oxygen content is sufficient this must be noted on the "Confined Space Entry
Certificates". If the oxygen content is less than 20% the vessel must not be entered.
Respiratory Protection
Respiratory protection for each man in the confined space, and for the Stand-by man must be
provided where the representative/work supervisor consider it necessary, and recorded on the
Work Permit. At least one properly connected air mask shall be available on the outside, for
rescue purposes.
Protective Clothing:
Goggles, gloves, rubber/safety boots, safety helmet and special clothing shall be worn as
directed by the Responsible Person on the Work Permit.
Closure Of Vessel:
The operations representative will not authorise the closure of the vessel until he has received
a copy of the permit signed by the Work Supervisor that the work is complete and that all men
and equipment are out of the vessel.
The representative should make a final check inside the vessel prior to closure and acceptance
of the vessel back for service.
Electrical Equipment:
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(i) Extension cords and portable electric hand tools/equipment must not exceed
50 volts and must be explosion proof rated for use in potentially hazardous
hydrocarbon environments.
(ii) Temporary lighting facilities will normally be provided by hand held battery
units and shall be intrinsically safe.
(iii) Pneumatic equipment shall be used instead of low voltage equipment, where
this is a practical alternative.
(iv) Any special electrical equipment rated above the voltage requirements of this
section including:
Spark testers, magnetic drill holder, etc. may only be used if it is done under
close supervisory control, and be authorised by a "Hot Work Permit".
It is frequently a requirement to carry out work inside a tank or vessel, whether it is for
routine scheduled inspection or for repair to known defects. As entry into enclosed spaces is a
potentially hazardous activity careful preparation of the tank/vessel and application of entry
controls are required to minimise the hazards.
Purpose:
The purpose of this procedure is to specify and describe the steps necessary for the
preparation of a vessel/tank for internal work or inspection, and the controls that must be
exercised during cleaning.
Procedure Description:
General Preparation/Isolation:
Insert a suitably rated blind between two flanges (i.e. same class
as the flange).
Removal of Hydrocarbons:
Wash out, flush out, steam out, ventilate and, in general, use the
most effective method in the circumstances to remove
hydrocarbons from the vessel/tank.
Keep vessel/tank internals wet in case pyrophoric ferrous sulphide (FeS) is present.
Prepare work/entry permit specify precautions and allow work to commence for
sludge removal.
Sludge Removal:
Before maintenance/inspection work can be carried out there will almost certainly be
the need to remove sludge and solid deposits from within the vessel/tank. Sludge
containing hydrocarbons shall be removed using spark-proof tools.
CAUTION: When sludge is disturbed, the atmospheres above the sludge will
become contaminated with hydrocarbon vapour and quickly become
unsuitable for working without breathing apparatus. In some tanks
H2S may be released at hazardous levels. Personnel removing sludge
deposits from vessels/tanks must wear breathing apparatus at all
times while inside the vessel/tank. Sludge containing lead is subject
to additional, special precautions. A proper suit, rubber gloves and
boots are to be worn in all cases of sludge removal.
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LO
BALANCE LINE
NOTE -1
LG
OIL OUT
TANK
INLET
WATER OUT
NC
SUMP
NC DRAIN NC
NC
NC
TO CLOSED
NOTE - 1 : ENSURE DOUBLE BLOCK AND BLEED ON THIS LINE FOR TANK ISOLATION DRAIN HEADER
NOTE - 2 : REFER TO ERD 08-11(LATEST VERSION ON WALL CHART) FOR THE LATEST UPDATE
OF THIS DIAGRAM
Introduction:
Purging and Flushing of piping and equipment are most important as they used in oil
and gas industry for the processing of hydrocarbons. When they need to take out of
service for the maintenance purpose or for the annual service, it is require to make sure it
is gas free before carrying out any type of jobs. As hydrocarbons are handle by these
equipments and pipeline, when they are open to atmosphere, air is getting mixed with the
hydrocarbon gas and make the explosive mixture which is very danger and thing can explode if
there is a presence of ignition. To avoid this potential risk, purging or flushing operation need
to carry out with the help of WATER or NITROGEN gas.
Background
Piping and equipment used in Oil and Gas industry for the processing of
hydrocarbons are routinely taken in and out of service due to
maintenance work or annual inspection of the vessels. During which time
there is a possibility of an explosive mixture of gas and air forming within
the equipment. To remove this potential risk, the equipment is subject to
make gas free prior to removal or open and make air free prior to return
to service. To avoid this potential risk, purging or flushing operation need
to carry out with the help of WATER or NITROGEN gas.
Scope
The procedure covers the purging and leak testing of the following
equipment types:
Separators
Scrubbers
Tanks
Filters and other vessels of a similar size and nature
Pumps of all types
Gas compressors of all types
On-plot pipe work and all associated valves and fittings.
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Procedure Description:
Differences in elevation.
Whether the displaced oil will contain high levels of H 2S. If so,
observe H2S procedures for handling sour crude.
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C o n tr o l P r o c e d u r e - A c tiv ity M a tr ix
B u s in e s s P r o c e s s : F lo w lin e F lu s h in g F ig . 1
S y m b o ls :
ons
R e tu rn fr o m /fo r w a r d
A c t iv it y
tor
son rati
t o a n o th e r a c tiv ity
ina
Per Ope
nel
d
D e c is io n M A M e e tin g A tte n d e e
oor
tion
aC
duc
Are
ST
E S ta r t/E n d C o n t in u a t io n
Pro
No. A b b r e v ia t e d A c t iv it y D e s c r ip t io n 1 2 3 4 5 6 7 8 9 10 11
R e q u ir e m e n t f o r f lo w lin e f lu s h in g ST
1
id e n tif ie d .
2 D e c id e o n d ir e c t io n o f f lu s h .
3 C h e c k f lu s h in g w a t e r a v a ila b ilit y .
A r r a n g e f o r e n v ir o n m e n t a lly s a f e
4
d is p o s a l/c o n t a in m e n t o f f lu s h in g s .
C h e c k f o r d if f e r e n c e s in e le v a tio n
5 b e t w e e n w e llh e a d s it e a n d d is p o s a l
p o in t.
No
6 W ill o il c o n t a in h ig h le v e ls o f H 2 S ?
Yes
I m p le m e n t H 2 S p r o c e d u r e s f o r
7
h a n d lin g o f s o u r c r u d e .
8 F lu s h f lo w lin e .
C h e c k f lo w lin e f o r r e s id u a l
9
h yd ro c a rb o n s .
F lo w lin e r e a d y t o h a n d o v e r t o
10 E
M a in t e n a n c e / E n g in e e r in g D e p t s .
11
12
13
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De-commissioning:
De-commissioning is the process of removing equipment from service,
draining all hydrocarbons and purging with an inert gas (nitrogen) prior to
allowing air to enter. The following procedure prevents the occurrence of
an explosive mixture of gas and air.
Ensure that all Permit to Work formalities have been completed, and that a Job
Safety Plan is in place.
Drain as much liquid from the equipment as possible to the drains system, using
any residual pressure to assist the process. If internal jetting systems are installed
(as is the case with some separators) use these to loosen and remove any sludge.
Drain the resulting slurry.
Once draining is complete, fully depressurise the equipment to the vent header.
Isolate the main process lines of the equipment (excluding the vent line) in
accordance with PR-1076 and any conditions stipulated on the Work Permit.
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Blow approximately three times the total volume of the equipment through with
nitrogen, as quickly as the source will allow. The more rapid the sweep, the better
the purge. Where possible, the mixture of gas and nitrogen should be routed to a
remote vent system (particularly in sour installations). In the case of rotating
equipment, bar the rotor over where feasible during the purging.
Isolate the remaining vent lines of the equipment in accordance with procedure PR-
1076 and any conditions stipulated on the Work Permit.
CAUTION: The equipment is now depressurised and purged with inert gas. However, the
equipment may still contain some residual liquid and/or pyrophoric iron deposits. Due
caution SHALL be exercised when opening the equipment. Where it is known that
pyrophoric iron deposits exist, the equipment SHALL be flooded with water to ensure
that any such deposits are wetted to prevent combustion. Until the deposits have been
removed or the equipment has been returned to service, the deposits SHALL be kept
wet.
The isolation details SHALL be logged and filed by the Area Co-ordinator, until
the equipment is returned to service.
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C o n tr o l P r o c e d u r e - A c tiv ity M a tr ix
B u s in e s s P r o c e s s : G a s F r e e in g , P u r g in g & L e a k T e s tin g : D e c o m m is s io n in g
S y m b o ls :
nel
tors
R e tu rn fro m /fo rw a rd
son
tors
A c tiv ity
era
to a n o th e r a c tiv ity
Pe r
a
din
Op
D e c is io n M e e tin g A tte n d e e
ce
M A
oor
tion
nan
aC
duc
inte
Are
ST
C o n tin u a tio n
Pro
E S ta rt/E n d
Ma
No. A b b r e v ia te d A c tiv ity D e s c r ip tio n 1 2 3 4 5 6 7 8 9 10 11
S e le c t e q u ip m e n t to b e ST
1
d e c o m m is s io n e d .
2 C o m p le te P e r m it to W o r k f o r m a litie s .
3 S h u t th e e q u ip m e n t d o w n .
4 D ra in e q u ip m e n t c o m p le te ly .
D e p r e s s u ris e e q u ip m e n t to v e n t
5
h e a d e r.
6 Is o la te th e e q u ip m e n t.
7 C o n n e c t n itro g e n s u p p ly .
P u r g e e q u ip m e n t th o r o u g h ly w ith
8
n itr o g e n .
Y es
9 G a s d e te c te d b y te s tin g ?
N o
10 Is o la te r e m a in in g v e n t lin e s .
12 E q u ip m e n t re a d y f o r m a in te n a n c e . E
13
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Re-commissioning:
Re-commissioning is the process of purging (air filled) equipment with an inert gas (nitrogen)
and leak testing it in readiness to accept hydrocarbons. The following procedure prevents the
occurrence of an explosive mixture of gas and air.
Ensure that all Permit to Work formalities have been completed, and
that a Job Safety Plan is in place.
De-spade the equipment but keep all lines isolated by means of closed valves (or
seated relief valves).
Close the vent and pressurise the equipment to its normal working
pressure or to the highest pressure attainable with the Nitrogen
source (whichever is the LOWER). Check the equipment for leaks.
If any are found, depressurise, repair the leaks and repeat the
pressure test.
De-isolate all lines by means of opening valves and carry out a final
visual check to ensure that all spades and blinds have been
removed.
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C o n tr o l P r o c e d u r e - A c tiv ity M a tr ix
B u s in e s s P r o c e s s : G a s F r e e in g , P u r g in g & L e a k T e s tin g : R e c o m m is s io n in g
S y m b o ls :
R e tu rn fro m /fo rw a rd
rs
A c tiv ity
ors
ato
to a n o th e r a c tiv ity
per
dina
D e c is io n M e e tin g A tte n d e e
nO
M A
oor
tio
aC
duc
Are
ST
E S ta rt/E n d C o n tin u a tio n
Pro
N o. A b b r e v ia te d A c tiv ity D e s c r ip tio n 1 2 3 4 5 6 7 8 9 10 11
S e le c t e q u ip m e n t to b e ST
1
r e c o m m is s io n e d .
2 C o m p le te P e r m it to W o r k f o r m a litie s .
3 B o x u p e q u ip m e n t f u lly .
D e s p a d e e q u ip m e n t. K e e p v a lv e s
4
c lo s e d .
5 C o n n e c t n itro g e n s u p p ly .
P u r g e e q u ip m e n t th o r o u g h ly w ith
6
n itr o g e n .
7 P r e s s u r is e e q u ip m e n t u s in g n itr o g e n .
No
8 D o a n y g a s k e ts le a k ?
Yes
R e p la c e a n y le a k in g g a s k e ts a n d
9
r e p r e s s u r is e w ith n itr o g e n .
10 D e - is o la te a ll lin e s .
11 S ig n o f f P e r m it to W o r k .
12 R e tu r n e q u ip m e n t to s e r v ic e . E
13
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De-commissioning:
Ensure that all Permit to Work formalities have been completed, and
that a Job.
Isolate the main process lines of the equipment (excluding the vent
line) in accordance with PR-1076, Isolation of Process Equipment,
and any conditions stipulated on the Work Permit.
Fill up the tank with water by using the minimum flow line of a
water booster or water injection pump.
Pump down the liquid to the minimum level and shut the tank
down.
Drain as much liquid from the tank as possible to the drains system.
Draining of the tank(s) should be done in accordance with the Plant
Operating Manual(s).
Note 1:Take care when draining to a closed drain system so that no overfilling of the drain
vessel takes place (pump capacity may be exceeded by draining too quickly, resulting in the
system backing up).
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Isolate the vent line and blanket gas line of the tank in accordance
with PR-1076 and any conditions stipulated on the Work Permit and
spade all the lines as per the check list.
Once full, isolate the vent line and blanket gas line of the tank in
accordance with PR-1076 and any conditions stipulated on the Work
Permit
Remove the top covers on the tank, open any hatches and install an
air mover on one of the open top covers. Use the air mover to
circulate fresh air through the tank to disperse the blanket gas.
Fogging nozzles should be used where pyrophoric deposits are
known to exist.
Note: If the air supply into the tank becomes blocked during draining,
there is a danger of the tank collapsing.
Prior to tank entry, test for combustible gas, H 2S (if relevant) and
oxygen levels in accordance with the stipulations made on the
Vessel Entry Certificate (see PR-1154, Gas Testing).
Re-commissioning:
Ensure that all Permit to Work formalities have been completed, and
that a Job Safety Plan is in place.
Ensure that the tank is fully boxed up, all instruments and switches
are re-connected and that the tank is ready to be re-commissioned.
De-spade the tank but keep all lines isolated by means of closed
valves (or seated relief valves - although these should not be relied
upon as isolation valves).
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Open the blanket gas supply and, if previously filled with water,
drain the tank.
CAUTION: If the blanket gas supply into the tank becomes blocked during draining, there
is a danger of air being drawn into the tank, or of the tank collapsing.
The tank is now filled with blanket gas, and may be returned to
service.
Check that fire detection and alarm system for the gas compressor
area is operational.
Before the initial start-up, Flushing must be carried out and the
initial lube oil charge introduced to the system.
Run the lube oil pump on circulation till the require temperature of
lube oil achieved.
Put the main oil pump into operation, set the auxiliary pump on
automatic control.
Make sure oil cooler and oil filter air lock has been removed by
venting.
Switch off auxiliary oil pump and set pump start to “Automatic”
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Verify that:
Flare system ready for operation.
Drain system ready for operation.
Gas system ready for operation.
Manual gate valves up stream of compressor, down stream
of blow down, intermediate block valves in common drain
header of scrubbers in open position.
Initiate ESD at local panel (then twist ESD button to reset it)
Discharge valve closes.
Isolation valve closes.
HP section blows down valve opens to HP flare.
Suction valve closes.
LP section blows down valve opens to LP flare.
Set the Suction and Discharge pressure set point to require value.
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After reaching load set point, ADJUST load to required flow and
discharge in accordance with compressor curves.
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