Energy Isolation Process

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Superseded: None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.

Page 1 of 8
ATTENTION: Printed copies should be used with caution. The user of this document must ensure the current approved version of
the document is being used. This copy was printed on 10/18/2010 1:50:00 PM TNL-SFT-00062-KNO.
Energy Isolation Process Liquid &

Vapor
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).
Page 2 of 8
the document is being used. This copy was printed on 10/18/2010 1:50:00 PM TNL-SFT-00062-KNO..

Vapor
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.
Page 3 of 8

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
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
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
Manager
Operations
backer and 2
backer.
vents
space.
ISOLATION.
2nd Optional Mud Plug with Install mud plug. Vent required on pipeline side of
VP
VP
Method
vent behind
plug.
Operations
Operations
to 9 cubic feet).
Page 4 of 8

Vapor
Alternate
Method
Alternate
Isolation Plan

PLUG.
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
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
VP
VP
Method
vent behind
plug.
Operations
Operations
to 9 cubic feet).
PLUG.
Alternate
Alternate
VP
VP
Method
Isolation Plan
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
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
Manager
Operations
backer and 2
backer.
vents
space.
ISOLATION.
VP
VP
Method
vent behind
plug.
Operations
Operations
Page 5 of 8

Vapor
Alternate
Method
to 9 cubic feet).
PLUG.
Alternate
Isolation Plan
NOTES:
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
Page 6 of 8
End

Vapor
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
Page 7 of 8

Vapor
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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Marathon Petroleum Company LLC

Energy Isolation Process Liquid & Vapor

Document No.: TNL-SFT-00062-KNO

Region Operations Superintendents are responsible for reviewing and approving

Invasive Hot Work

Isolation blinds/skillets or physical disconnection

Isolation blinds/skillets or physical disconnections are recommended. The

Blinds or skillets may be installed against a single valve.

Energy Isolation Process Liquid &

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

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

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

Invasive Cold Work

Double block and bleed

Energy Isolation Process Liquid &

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

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

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

PLANNED MAINLINE WORK

Energy Isolation Process Liquid &

Dual foam pig

Mud Plug with

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

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

UNPLANNED WORK PIPELINE RUPTURE

Energy Isolation Process Liquid &

Document No.: TNL-SFT-00062-KNO

DO NOT WORK IN FRONT OF THE MUD

Effective Date: 09/01/2010

STATION PIPING INCLUDING DRAIN PIPING

Energy Isolation Process Liquid &

Effective Date: 09/01/2010

Document No.: TNL-SFT-00062-KNO

Isolation Process Flow

Document No.: TNL-SFT-00062-KNO

Energy Isolation Process Liquid &

Effective Date: 09/01/2010

Energy Isolation Process Liquid &

Document No.: TNL-SFT-00062-KNO

Effective Date: 09/01/2010

pump rotor change out

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