Procedure for Use of High Pressure Mechanical Plugs on Piping in Hydrocarbon Service

Note: High pressure mechanical plugs allow for the safe isolation of piping where flange blind locations are remote from the work area, and it is not possible to completely gas free the piping. Use of this procedure requires the development of a specific work procedure and the approval of the Terminal Superintendent and Distribution Engineer.

Allowed Uses Of Plugs 1. High pressure mechanical plugs may be used for isolation and purging of piping in utility and hydrocarbon services at distribution terminals. High pressure mechanical plugs are also allowed in hydro-test procedures. High pressure mechanical plugs may not be used as the sole barrier between the process (eg. liquid hydrocarbons contained in a tank) and the work. The installation of blinds/block plates is mandatory. High pressure mechanical plugs may be used to hydro-test new piping or tie-in welds only when the test media is either glycol or water. The use of any type of plug is not allowed in any pneumatic pressure test.

2.

3. 4.

Types Of Plugs 1. High Pressure Mechanical Plugs High pressure mechanical plugs are designed to withstand a given pressure and temperature. Ensure the manufacturer of the plug will certify the plug for use within the stated pressure and temperature ranges. One style of high pressure mechanical plug has a design feature (serrated teeth) which mechanically prevents the plug from moving after it has been installed in the pipe.

Procedure for Use of High Pressure Mechanical Plugs on Piping in Hydrocarbon Service
1. High Pressure Mechanical Plugs (contd) These plugs can also be used in hydro-test procedures because they are designed to withstand full hydro-test differential pressure across the plug. This style of plug is also direction dependent. That is, the serrations hold in one direction only. The plug must be installed in one direction for welding, then removed and reversed for the hydro-test. Plugs meeting the above description are also known as engineered plugs, hydro-test plugs or by various brand names such as Thaxton or Proline. Bi-directional High Pressure Mechanical Plugs are available from some manufacturers. These plugs can be used without having to change their orientation. Another type of high pressure mechanical plug is a double plug design which maintains a positive pressure between two adjacent plugs. Car-Ber plugs are of this type. This style of plug can contain the positive barrier pressure but it is not capable of withstanding a large differential pressure across the plug. Car-Ber plugs should not typically be used for hydro-testing. The user of a high pressure mechanical plug must have in his possession the plug manufacturers data sheet verifying design temperature and pressure. 2. Low Pressure Plugs Note: Low pressure plugs are not to be used for piping that has been in hydrocarbon service. Low pressure plugs (also known as plumbers plugs) typically consist of a rubber donut that is compressed between two steel plates. When compressed, the donut expands to seal against the pipe. The friction created by the rubber-to-pipe contact holds the plug in place. The only approved application of Low Pressure Plugs would be in utility, sewer, sanitation systems. 3. Special Plugging Operations There are a variety of special plugging operations offered by contractors. These include, but are not limited to the use of mechanical plugs as positive pressure barriers, freeze plugs, mud plugs, ice plugs, and Stopple plugs. None of these special plugging operations are covered in this procedure. Use of these special plugging operations requires the completion of a Plant Change form, critical task analysis and Head Office Distribution Specialist approval.

Procedure for Use of High Pressure Mechanical Plugs on Piping in Hydrocarbon Service
Instructions For Using Plugs Action Planning and Documentation Proper planning is required to use a high pressure mechanical plug prior to performing hot work. Information Identify the service of the piping to be isolated and define the limits of equipment to be isolated or purged. Identify the location of all plugs to be installed. Select the appropriate plug. Review the need for special procedures. Write specific procedures for the job (written procedure must identify isolation/blinding points, venting and drain locations, test hole and cold cut locations. Consider distillate flush in gasoline piping systems to reduce LELs prior to blinding. The design pressure of the selected plug must be at least 110% of the hydro-test pressure. Ensure that the seal material of the plug is compatible with the product or test media in the pipeline. Consider the direction of hydro-test pressure against the plug and ensure that the plug is installed as designed to withstand maximum pressure forces. Inspect and verify that the plug is properly positioned in the piping. High pressure mechanical plugs typically have a chain or other restraining device. How this device will be secured must be considered when selecting the plug. Use of any high pressure mechanical plug in hydrocarbon service requires the completion of a Plant Change form and the approval of the Terminal Superintendent and the Distribution Engineer.

1.

2.

Select The High Pressure Mechanical Plug

3.

Approvals

Procedure for Use of High Pressure Mechanical Plugs on Piping in Hydrocarbon Service
Execution of a High Pressure Mechanical Plug Operation The safe execution of a high pressure mechanical plug operation depends on the proper use of plugs and the execution of any special procedures. The following steps are required to properly execute a high pressure mechanical plug operation: Action Inspect plugs prior to use Information Ensure that seal material is compatible with process fluids. Obtain manufacturers specifications, inspection procedures and operating procedures and review them prior to commencing the operation. Outline specific safety issues pertinent to the job. Inspect the area where work will be performed. All contractor personnel must be familiar with Shells Worksite Health and Safety Rules and sign the acknowledgement form. A safe evacuation route must be mapped out and posted. Complete the Terminal safe Work Permit form. Develop step by step job procedures, review them in detail, and initial. Close tank valve, any upstream valves, load rack valves and any isolation valves as appropriate. Use double lockout procedure for all valves and pumps that require isolation. Drain as much product as possible from the line. Contractor to use a respirator during this procedure. Vacuum trucks and drain pans are to be properly bonded during draining procedure. Vacuum truck to be vented down wind and away from the work area. Refer to the Distribution Safe Work Practice For The Use of Vacuum Trucks.

1.

2.

Conduct pre-job safety meeting with contractor and operating staff

3.

Isolate the piping system

4.

Drain product from the piping

Procedure for Use of High Pressure Mechanical Plugs on Piping in Hydrocarbon Service
Action Install blinds at isolation locations Information Steam cleaning the piping is an acceptable procedure to remove hydrocarbon liquids and vapours. For pipelines in gasoline service, flushing the pipeline with diesel is an acceptable procedure to reduce flammable vapours. 2. Install vent piping Ensure that a high point vent is used to vent the pipeline. Vent piping to be located away from the work area. Use an air drill to drill a small hole in the top of the pipeline. The hole is used as a vapour test port near the cold cutting location. Vapour must be less than 20% LEL. (For vapour concentrations > 20% LEL, additional ventilation is required; before cold work can be initiated.) Note: If a high point vent or low point drain is available at the work area, the test hole can be eliminated. 4. Cold cut the pipe Cold cut the piping at two locations. Ensure there is enough room in the cut-out section to allow the plugs to be inserted. Clean the interior wall surface of the pipe to ensure a good seal between the plug and the pipe. Ensure that the plug is properly installed (i.e., at least 300 mm from the proposed welded joint) Use a gas detector to sniff the inside of the pipe around the sealing surface of the plug to ensure that positive isolation has been achieved.

1.

3.

Drill test hole in top of pipe

5.

Install the high pressure mechanical plug

6.

Gas test plug seal area

Procedure for Use of High Pressure Mechanical Plugs on Piping in Hydrocarbon Service
Action Vent the contained piping area between the high pressure mechanical plugs and the isolation point Information Vent the plug downwind to a remote location at least 10 metres away from the hot work location. Alternatively, the plug vent can be capped and the other end of the pipeline can be used to vent. Ensure that the work area is suitable for welding. An area free of combustible material with a radius of 15 m is recommended. Weld new flanges on the pipeline. Constant hydrocarbon vapour monitoring must be performed throughout the welding procedure. Contractor to monitor wind direction and vapour levels throughout the welding operation. To avoid contact between the welding rod and the vent pipe, install insulating material around the vent pipe. Provide fire fighting equipment in the direct vicinity of the welding operation (minimum of 2 20 lb Class BC fire extinguishers) Ensure that the area directly in front of the open pipe is clear. Equipment and personnel should not be placed in line with the end of the pipe. Once the weld area has completely cooled, perform hydro-test on the new flange. The high pressure mechanical plug must be chained to prevent loosing the plug into the pipe during the hydro-test. Following completion of the work and any testing required, remove the plug from the piping as per the manufacturers instructions. Install spool piece in piping. Write a re-commissioning procedure for the system. Remove all lockouts (i.e., blinds, chains, locks, etc.). Close all drains and control the closure of all high point vents according to the pipeline filling procedure. Install bull plugs in drains and vents. Flood/refill the piping to remove all air from the system.

1.

2.

Perform hot work (welding)

3.

Hydro-test the flange

4.

Plug removal and spool installation

5.

Re-commissioning the system.