Marathon Petroleum Company LLC

Energy Isolation Process Liquid & Vapor

Owning Organization: T&L

Document No.: TNL-SFT-00062-KNO

Document Owner: D. J. Foulke, T&L Standards & Practices
Effective Date: 09/01/2010
Advanced Sr. HES Professional

Superseded: None

Energy
Isolation
Plans

The Area (Owning Department) is responsible for assembling energy isolation plans
and Lockout/Tagout LOTO lists for work activities requiring energy isolation. The
isolation plan for invasive work is part of the CDR. Area Project Coordinators or
M&TE Project Leaders can assist with the development.
Plans should be complete two weeks in advance of the work, per CDR requirements.
Plans for emergency repairs will be completed on an expedited basis. Discussions
may be required with Stakeholders on isolation techniques and options to safely isolate
work sites. An approved isolation plan is required before field work can begin.

Approvers

Region Operations Superintendents are responsible for reviewing and approving

Energy Isolation Plans.
Region Managers should also approve invasive hot work plans.

Variances

Energy
Isolation

Deviations to isolation methods defined require a deviation form with approval by the
Region Manager or the VP Operations depending on the method.

Invasive Hot Work

ISOLATION METHOD
Preferred
Method
Alternate
Method

Isolation blinds/skillets or physical disconnection

Alternate Isolation Plan (thinner skillets, double
block & bleed, product evacuation, inert system, etc.)

Initial
Approval
Region
Manager
VP
Operations

Deviation
of Original
Method
VP
Operations
VP
Operations

Isolation blinds/skillets or physical disconnections are recommended. The

equipment or piping between the isolation and workspace must be liquid and gas
free. If not, additional measures must be taken to ensure 0 LEL. A vapor
isolation device may be required.

Blinds or skillets may be installed against a single valve.

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Energy Isolation Process Liquid &

Vapor

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

Deviations to blinding/skilleting or disconnection require a deviation form and

approval by the VP Operations.

If blinding/skilleting or disconnection cannot be performed, an alternate isolation

plan must be developed by the Area and approved by the Region Manager with
final approval by the VP Operations. Once an alternate plan is approved,
deviations to it require a deviation form and approval by the VP Operations.

Invasive Cold Work

ISOLATION METHOD
Preferred
Method
Alternate
Method

Double block and bleed

Alternate Isolation Plan (blinding/skilleting, product
evacuation, inert system, etc.)

Initial
Approval
Ops
Superintendent
Region
Manager

Deviation
of Original
Method
Region
Manager
Region
Manager

Double block and bleed is designed to provide a verifiable means of safe isolation
and is the preferred method as long as all requirements are met.
Double Block and Bleed (DBB) 2 methods available:
Double Block and Bleed Valve:
close and lock a designed double block and bleed valve,
open the double block & bleed valves drain valve,
drain the double block & bleed valve body of product, and
continuous visual monitoring of the valve drain throughout the work to verify
no leakage.
NOTE: Engineered double block and bleed valves are:
Expanding Gate (M&J EG, T3 T1, WKM Pow-R-Seal)
Compact Expanding Gate (M&J CEG)
Expanding Plug (General Twin Seal, Orbit TruSeal)
2 Independent Valves
close and lock the two independent valves,
PIPING WITH DRAIN: drain product between the two valves,
PIPING WITH VENT ONLY: leave product between the two valves but
reduce to zero pressure,
open the drain or vent valve between the 2 valves,
place a Lockout/Tagout tag on the drain or vent valve, and
continuous visual monitoring of the drain or vent throughout the work to verify
no leakage (pressure gauges are not acceptable).
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Energy Isolation Process Liquid &

Vapor

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

Deviations to double block and bleed require a deviation form and approval by the
Region Manager.

If double block and bleed cannot be performed, an alternate isolation plan must be
developed by the Area and approved by the Region Manager. Once an alternate
plan is approved, deviations to it require a deviation form and approval by the
Region Manager.

Vapor Isolation
Additional energy isolation may be required closer to the worksite for vapor isolation.
Tables for planned mainline work, pipeline rupture, station piping including drain
piping and hydrotest repairs are below.
Hot Tap
Isolation requirements are defined in TNLMNT001 Hot Tapping.

Vapor
Isolation

Vapor isolation methods are shown in the tables below for planned mainline work,
unplanned work, station/drain piping work and hydrotest repairs.

Deviations to preferred methods require a deviation form and approval by the

Region Manager.

Deviations to optional methods require a deviation form and approval by the VP

Operations.

In the event a method other than the ones in the tables is desired for work, an
alternate isolation plan must be assembled by the Area and approved by the
Region Manager with final approval by the VP Operations. Once an alternate
plan is approved, deviations to it require a deviation form and approval by the VP
Operations.

PLANNED MAINLINE WORK

(Mainline system isolated to comply with hot work requirements & initial cuts to remove line section are to be cold
cuts.)
Deviation
Initial
of Original
VAPOR ISOLATION METHOD
Approval
Method
Preferred
Nitrogen
Displace product in line by pig, followed by
Ops
Region
Method
nitrogen to create inert atmosphere. Special
Superintendent
Manager
testing required for nitrogen atmosphere. If 0
LEL, no vent required. If LEL is >0, use optional
methods below.
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Energy Isolation Process Liquid &

Vapor

Preferred
Method

Stopple with
vent behind

1st Optional
Method

Dual foam pig

with mud
backer and 2
vents

2nd Optional
Method

Mud Plug with

vent behind

Alternate
Method

Alternate
Isolation Plan

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

Weld stopple fitting and vent (on line side), tap

vent.
Stopple, drainup, clean and gas free isolated
section.
High density foam pigs insert foam pig, leave
interstitial space, insert 2nd foam pig with mud
backer.
2 vents required: pipeline side of pig & interstitial
space.
Interstitial space to be filled with water or dry ice.
DO NOT WORK IN FRONT OF THE
ISOLATION.
Install mud plug. Vent required on pipeline side of
plug.
Dry ice may be installed behind the mud plug to
act as an inert agent (1 pound of dry ice sublimes
to 9 cubic feet).
DO NOT WORK IN FRONT OF THE MUD
PLUG.
Detailed plan (procedure, isolation list, and
monitoring plan) including drawings.

Ops
Superintendent

Region
Manager

Region
Manager

VP
Operations

VP
Operations

VP
Operations

VP
Operations

VP
Operations

UNPLANNED WORK PIPELINE RUPTURE

(Mainline system isolated to comply with hot work requirements & initial cuts to remove line section are to be cold
cuts.)
Deviation
Initial
of
Original
VAPOR ISOLATION METHOD
Approval
Method
Preferred
Stopple with
Weld on stopple fitting and vent (on line side), tap
Ops
Region
Method
vent behind
vent.
Superintendent
Manager
Stopple close to ruptured area, clean and gas free
isolated section.
Preferred
Engineered
Clean line & install engineered isolation plug
Ops
Region
Method
Isolation Plug
system (CAR-BER Isolation Tools or equivalent). Superintendent
Manager
(plumbers
Weld on flange, remove plug & install a flanged
plugs are not
spool piece.
NOTE: IMP to define risk with a flanged section
acceptable)
and timeframe to replace if necessary. (IDP&R
Mgr to review for Integrity issues)
1st Optional Dual foam pig
High density foam pigs insert foam pig, leave
Region
VP
Method
with mud
interstitial space, insert 2nd foam pig with mud
Manager
Operations
backer and 2
backer.
2 vents required: pipeline side of pig & interstitial
vents
space.
Interstitial space to be filled with water or dry ice.
DO NOT WORK IN FRONT OF THE
ISOLATION.
2nd Optional Mud Plug with Install mud plug. Vent required on pipeline side of
VP
VP
Method
vent behind
plug.
Operations
Operations
Dry ice may be installed behind the mud plug to
act as an inert agent (1 pound of dry ice sublimes
to 9 cubic feet).
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Energy Isolation Process Liquid &

Vapor

Alternate
Method

Alternate
Isolation Plan

Document No.: TNL-SFT-00062-KNO

DO NOT WORK IN FRONT OF THE MUD

PLUG.
Detailed plan (procedure, isolation list, and
monitoring plan) including drawings.

Effective Date: 09/01/2010

VP
Operations

VP
Operations

STATION PIPING INCLUDING DRAIN PIPING

(Piping isolated to comply with hot work requirements & initial cuts to remove line section are to be cold cuts.)
Deviation
Initial
of
Original
VAPOR ISOLATION METHOD
Approval
Method
Preferred
Clean piping
Water wash, chemical clean, etc. to remove
Ops
Region
Method
system
residual liquid and vapor.
Superintendent
Manager
Preferred
Engineered
Clean line & install engineered isolation plug
Ops
Region
Method
Isolation Plug
system (CAR-BER Isolation Tools or equivalent). Superintendent
Manager
(plumbers
Weld on a flange, remove isolation plug & install
plugs are not
a flanged spool piece.
acceptable)
1st Optional Remove piping Remove piping section, gas free and work on in
Region
VP
Method
shop.
Manager
Operations
2nd Optional Mud Plug with Install mud plug. Vent required on pipeline side of
VP
VP
Method
vent behind
plug.
Operations
Operations
Dry ice may be installed behind the mud plug to
act as an inert agent (1 pound of dry ice sublimes
to 9 cubic feet).
DO NOT WORK IN FRONT OF THE MUD
PLUG.
Alternate
Alternate
Detailed plan (procedure, isolation list, and
VP
VP
Method
Isolation Plan
monitoring plan) including drawings.
Operations
Operations

HYDROTEST REPAIRS
(Hydrotest blinds installed to comply with isolation requirements. Product in line has been displaced and line is full
of water. Initial cuts to remove line section are to be cold cuts).
Deviation
Initial
of
Original
VAPOR ISOLATION METHOD
Approval
Method
Preferred
Water
Line full of water from hydrotest. If 0 LEL, no
Ops
Region
Method
vent required. If LEL is >0, use optional methods
Superintendent
Manager
below.
1st Optional Dual foam pig High density foam pigs insert foam pig, leave
Region
VP
Method
with mud
interstitial space, insert 2nd foam pig with mud
Manager
Operations
backer and 2
backer.
2 vents required: pipeline side of pig & interstitial
vents
space.
Interstitial space to be filled with water or dry ice.
DO NOT WORK IN FRONT OF THE
ISOLATION.
2nd Optional Mud Plug with Install mud plug. Vent required on pipeline side of
VP
VP
Method
vent behind
plug.
Operations
Operations
Dry ice may be installed behind the mud plug to
act as an inert agent (1 pound of dry ice sublimes
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Energy Isolation Process Liquid &

Vapor

Alternate
Method

Effective Date: 09/01/2010

to 9 cubic feet).
DO NOT WORK IN FRONT OF THE MUD
PLUG.
Detailed plan (procedure, isolation list, and
monitoring plan) including drawings.

Alternate
Isolation Plan

NOTES:

Document No.: TNL-SFT-00062-KNO

VP
Operations

VP
Operations

Foam pigs and mud plugs MUST NOT be relied on to retain pressure or free
liquid.
Vent lines should be extended to a safe location downwind from the work site
and monitored to verify pressure is not increasing during the work activity.
Atmospheric testing must be performed to ensure a proper vapor seal has been
established before work proceeds and throughout the work activity. Special
testing is required for nitrogen.

Isolation Process Flow

Initial Plan
no

Ops
Superintendant

yes

Approve
Preferred
Plan?

yes

Area
(Owning
Department)

Develop/Update
Energy Isolation
Plan

Choose
Preferred
Method?

Execute Plan

Conduct
Monitoring
per Plan

yes
Zero (0) LEL?

no

Plan Approver

no

no

Approve
Alternate Plan?

Option #1 Approver:
Option #2 Approver:
Alternate Plan Approver:

Continue
Executing
Plan

yes
A

Region Manager
VP Operations
VP Operations

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End

Document No.: TNL-SFT-00062-KNO

Energy Isolation Process Liquid &

Vapor

Effective Date: 09/01/2010

LEL Present
A

Area
(Owning
Department)

LEL > 0

no

Plan Approver

Execute
Optional
Method or
Alternate
Isolation Plan

Propose:
Option #1
Option #2
Alternate Plan

Develop/Update
Optional Method

Approve
Plan

Conduct
Monitoring
per Plan

yes
End

Option #1 Approver:
Region Manager
Option #2 Approver:
VP Operations
Alternate Plan Approver: VP Operations

Definitions

Alternate Isolation Plan A written plan to deviate from the preferred isolation
method which provides additional or alternative ways to safely isolate the worksite.
(Ex: double block and bleed for mainline repairs, skillets for invasive cold work,
thinner isolation skillets, evacuating product between two valves, water washing,
chemical cleaning, purging, inerting, etc.)
The alternate isolation plan should include:
detailed procedure for alternate isolation,
isolation list,
monitoring plan and
drawings.
Blind/Skillet Temporary or permanent blank to positively isolate systems for
maintenance activities. Thickness is specified in TNLDGN004 Skillet/Blank Design,
Section 12. Blinds/skillets can be installed against a single isolation valve.
Invasive Cold Work Maintenance, repair, cleaning, or construction activity, which
does not produce fire, hot surfaces, sparking, etc. or does not otherwise provide an
ignition source.
Examples (not all inclusive)
strainer cleaning
filter change out
pump seal replacement
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Energy Isolation Process Liquid &

Vapor

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

pump rotor change out

prover ball replacement
meter intermech replacement
bonnet removal on a valve for internal work
instrument replacement where the instrument is an integral part of the line or
screwed into the line
unbolting piping, bolting piping into existing systems

Invasive Hot Work Any activity which could produce an ignition source (Ex:
welding, cutting, grinding, or burning. Use of mobile equipment such as trucks,
cranes, welding machines, etc.).
Invasive Work Work that involves exposure to residual liquids or vapors when
working on piping or equipment that is open to the atmosphere.

Page 8 of 8
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