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杜邦管线开封程序管线的安全开封指引Copyright©2002E.I.duPontdeNemoursandCompany.Allrightsreserved.学习目标在结束之际，你将：了解杜邦S27G内的9个管线开封安全的要素明白管线开封的定义，了解何时需要执行管线开封和执行9个步骤来安全地进行管线开封.为管线开封做安全准备如果你被要求作管线开封，你一定能做好准备工作

管线开封安全的9个关键要素1.新建项目和项目改造2.培训3.工作计划4.系统准备5.上锁/隔离6.作业的移交7.PPE:选择和使用8.执行9.事故调查

管线开封定义:通过下列行动（也许不局限于这些行动）来开启清洁的或还未被清洁的管线或设备：

开启法兰

从法兰上移调一个以上的螺丝

开启放空阀门

移调阀门帽或止逆阀门帽

转动双孔版

断开管线连接点移调盲板，盲法兰，封头、塞子等

断开管线

断开装卸料的工艺管道

使用机械的方法打开管线（湿的或热的分离）

开启观察孔

进行设备的微调(如,更换阀门的填料)

图示管道开封1. 开启法兰2. 从法兰上移调一个以上的螺丝

图示管道开封（续）5. 转动双孔版6. 断开管线连接点

图示管道开封（续）7. 移调盲板，盲法兰，封头、塞子等8. 断开管线U型接口弯头

图示管道开封（续）9. 断开装卸料的工艺管道10. 热分接：一种在现有的管道或设备不中断服务的情况加入连结管或放尽管的机械方法。

图示管道开封（续）11. 开启观察孔12. 进行设备的微调(如,更换阀门的填料)概述所有的管线开封都被视为具有潜在的液体、固体或气体的意外释放的可能。这种意外释放可以是在开封时立即发生的，也可能在开封了一段时间后发生。对密闭管道设备或系统的危害识别和合适的清洁工作是保护作业人员安全基本控制手段

个人防护只是作为第二手段

进行管线开封是上述二个手段是同时需要落实的

管线安全开封的9个关键要素

新建项目和项目改造系统应被设计得和安装得能便于隔离和清除危害。业主管理层应和工程设计团队合作，使得管线安全开封得要求被充分地考虑在新建项目和对已有项目得改造过程中。使得员工远离管线开封工作得危害得管道隔离设计的优先秩序依次是:1.

双重隔断阀门加排尽阀门2.隔断阀门和盲板加盲法兰3.双重隔断阀门4.单一隔断阀门5.工程工艺塞(即凝固化该工艺)

培训工厂应制定符合S27G要求的管道开封程序并向所有从事危害工艺和系统作业的人员（包括计划和执行人员）提供培训。培训应包括杜邦管线开封指引内的内容

培训的对象包括

生产操作人员，包括生产管理层

维修和施工人员,包括管理层

合同工和合同工管理人员

计划制定人员

管线隔离作业的申请人员和批准人员

复训的周期不应大于3年

培训记录应按照杜邦S21A的要求进行保管

现场的第一方审核应作为验证培训效果的手段之一

作业计划一份书面的计划来确保管线隔离作业能被怎样地安全执行，其中包括系统内的危害因素的识别、清扫或控制。这份计划的的制定人应该明白这项具体作业所具有的危害，且这份计划应被每个参与管线隔离作业的人员回顾。首选的管道开封计划请参照杜邦管线隔离手册内的管道隔离许可证。

作业计划，续作业计划的内容包括:危害识别隔离、清洁和冲洗计划关于PPE使用的描述（何时使用PPE和何时去掉PPE）明确监护人的职责如果使用单一的隔离措施或人员没有恰当的保护措施/和环境有可能受到污染，应额外建立应急计划对管道隔离的作业区采取隔离措施

作业计划，续对于一些常规的管道开封作业，书面作业计划可以是书面的、经批准的常规管道开封作业程序，包括对管道开封的安全准备工作。如果使用上述程序,额外作业流程应包括以下要素:

参照S27G的标准，定期回顾已经制定的程序对那些参与从事常规管道隔离作业人员进行培训和复训，定期复核他们的培训记录无论使用何种书面的作业准备，其目的是要保证管道开封工作获得了合适的安全准备并得到授权人的批准在开始管道开封前，对开启点所在系统的安全准备必须已经完成

系统准备的关键要素包括:

系统准备化学品的危害应被彻底排除。如果系统内的化学危害不能被证实已经获得清理，应准备额外的化学危害排除或控制程序。如果清理工作无法达到期望的结果，作业计划应被中止并执行以下步骤：重新计划、记录、授权和沟通。系统的清洁程度应被确定和验证.注意: 能冷凝成固体的热液体会产生特殊的问题,如果气体和热液体截留在固化了的两段塞子之间,那末它们可能会"流出"来。

管道隔离的陷阱1.Pockets2.Slopes3.Plug(pipesorvalves)

管道隔离的陷阱（续）4.Backfeed(heatexchangers,jacketedlines,etc.)5.Threadfailures(pipe,flange,bolts,plugs,etc.)6.Potentialenergy管道的状态示例1: 隔离,泄压,放空和排尽示例2: 隔离,泄压,排尽，但没有放空

注意:系统内没有放空点，所以很难排尽.ClosedClosedOpenOpenClosedOpenClosed管道的状态示例3: 隔离、泄压、放空，但没有排尽点示例4: 隔离，没有排尽和放空ClosedClosedOpenClosedClosed上锁/隔离所有的管道开封作业都应按照S14G的要求进行隔离

合适的系统隔离包括以下要素:

在现场有一套文件(如:上锁清单,P&ID图)来用于识别和说明作业范围内的阀门、法兰、盲法兰位置.法兰和盲法兰应被挂牌所有在隔离系统内的阀门应被保持在开启状态，管道应被清理，以避免出现物料积聚在管线或设备内部将辨识隔离所有初级和次级（蒸汽伴随和电热伴随）能源的特定步骤。这对于用冻结(即凝固)来隔离它们的聚合物和熔融系统，以及对于那些如果先冷却然后再加热可能蒸发的酸类是尤为重要的。

上锁/隔离（续）有很多隔离系统或设备内危害因素的方法，优先秩序依次为：

1.

双重隔断阀门加排尽阀门2.隔断阀门和盲板加盲法兰3.双重隔断阀门4.单一隔断阀门5.工程工艺塞(如：固化工艺介质)示例：管道隔离示例隔离的程度取决于要隔离的物料的危险性、管道系统的结构、管道启封的频率、由于另加的隔离阀的泄漏而増加的危险以及从过去的管道启封得到的经验。

1.我们应优先考虑以下的隔离形式隔离阀–排尽控制阀门–隔离阀门FlowClosedClosedOpenanddrainedsafelyWorkarea

管道隔离示例（续）如果我们不能采用第一种隔离方法，我们应采用关闭隔离阀门再加盲板的做法

注意:隔离的盲板或盲法兰的使用必须符合管道原有设计的规格（温度压力），具体参照P9E和ANSI/ASMEStandardB16.5.

设置盲板和盲法兰可以被视为管道隔离.

移调上述隔离措施应被视为管道开封.

SlipblankBlindflangeBlindflangewithaventvalve/drainFlowLocked/ClosedSlip-BlankBlockandBlankWorkarea不锈钢盲板的厚度注意: Iftemperaturesexceedthe100F(38C)maximumtemperature,contactsiteengineeringforthecorrectthicknessblankstobeused.Theseblanksshouldbemarkedwiththepressureandtemperatureforwhichtheyaredesigned.Linesize

(inches)Flangeclas81/81/81-1/21/83/163/1621/83/161/433/161/43/841/45/167/1665/161/211/1683/85/87/8101/23/41-1/16129/167/81-1/4145/811-3/81611/161-1/81-9/161813/161-1/41-3/4207/81-3/82241-1/161-11/162-3/8

碳钢盲板厚度管道隔离示例（续）如果具有危害的系统只能提供单一隔离的机会，那么管道开封程序或管道开封许可证上应注明危害减轻的方法，包括最坏的可能以及对应措施。FlowSingleBlockWorkarea能否在单一隔离点前寻找管道断开点在单一隔离点和作业位置间是否有排尽或放空点管道隔离示例（续）以下的信息可以作为制定只能进行单一隔离的管道系统的作业准备参考注意: 记住,对采用单一隔离措施的管道进行明火作业时，每个班次必须进行爆炸性气体测试工作。

管道隔离示例（续）4.当启封涉及危险工艺的系统和/或设备时,如要脱下PPE，在初始管道启封已完成后的全部工作应当在双倍隔离后进行。5.如果采用自动控制阀门进行管道隔离，工厂必须制定特殊的程序来确保隔离的效果

作业的移交对于有危害物质的管道作业的准备、开封和移交给业主的过程进行作业范围和计划的回顾。回顾工作应在作业开始前或作业结束后进行，并且，参与工作准备的人员、维修的人员或设备的操作人员应共同进行回顾。回顾工作应包涵安全、健康和环保的内容.

作业移交的关键回顾要素包括:

提供管道隔离位置、清洁和效果验证的方法、设备的状态的信息在作业开始前，与维修人员或合同作业人员进行作业状态的沟通，沟通并明了残留在设备物质的危害特性如果作业的延续已经超过一个班次，提供交接班的记录在开始作业前，验证系统或设备是可以继续安全地作业的所有涉及作业的人员应在交接班的文件上进行确认PPE对每件有可能暴露于某种危险的工作任务,无论系统已为管道启封作好如何彻底的准备，都将基于正常系统的操作条件，指定和准备好以及使用PPE。

每个工厂将有一个系统,准备好适用而干净的PPE供随时使用。人员将就该如何使用特定的PPE及其有何使用限制接受培训。

PPE的选择对于工厂中每个潜在的暴露，将选择工作时既给予保护又方便实用的PPE。

选择PPE的关键要素包括下列各项:

应有跨部门知识广博的人员，包括使用PPE的人员参与选择。任何一种PPE，在采用前，应当由使用它的人员在现场测试其实用性。

工厂已批准使用的PPE清单，按危险分类别，将对所有员工是现成可取的。

PPE的使用PPE使用的要点使用那种PPE何时使用PPE.何时去掉PPE作业的执行管道开封工作应严格按照S27G的要求进行关键点：明确地知道断开点的位置现场采取隔离措施，避免应突然泄放的危害物质而造成对周边的人员的伤害。作业的执行（续）当作业不能象期望的SHE条件进行（如，排尽阀门堵塞或管线不能被清理干净），作业应被中止。重新进行作业安全评估或制定新的作业计划。处理意外情况的关键要素将包括下列各项:

任务将以与评估初始工作计划相同深度进行再评估。

批准新的工作计划至少要与批准初始工作计划相同级别。

进行工作任务的人员将了解工作计划和予料情况以使他们能认识到何时会出现意外情况。

事故调查所有管道开封的事故应按照S3Y标准进行调查.使用事故原因树来分析

SupplementalInformation

GeneralSafePracticesShieldingshouldbeconsideredonlinebreaksifandwhenpractical.

Employeesperforminglinebreaksshouldpositionthemselvesontheupwindsideof—andasfarawayaspossiblefrom—anypotentialmaterialrelease.

Whenbreakingintolineswithoutanexistingbreakapparatus(e.g.,vent,drain,flange,tubingfitting),makethebreakusingacuttingordrillingdevice.

Thisdevicemustbenonelectricalandproducenosparks(e.g.,anair-operateddrillmotororhacksaw).D. Whenbreakingintoaflange,loosentheboltnutsontheloweroppositesideawayfromtheworkerfirst,keepingtheboltnutsnearesttheworkerundercontrol.Thisallowsthelinetoseparateinawaythatcausesanymaterialreleasedtobeawayfromtheworker.

Aftertheflangeisopenedawayfromtheworker—ensuringnomaterialisreleased—loosentheremainingboltsandspreadtheflangesapart.Removethegasket,positionitthroughtheflangeboltcircle,orpositionitinawaytovisuallydetectalinebreakhasbeenmade.(Ensurethegasketisnotblockingthecreatedopening.)

GeneralSafePractices,continuedNote: Ifflangeboltsareseverelycorroded,theymayneedtobereplacedbeforeproceeding!Looseningand/orremovalofcorrodedboltsshouldbeconsideredalinebreak,necessitatingfollowingofthelinebreakprocedureandwearingtheproperPPEfortheservice.

GeneralSafePractices,continuedE. Whenavalvebonnetmustberemoved,thepipelinemustbedrainedandthevalveplacedintheopenpositionbeforethebonnetboltsareloosened.

Ballandplugvalvesmayhaveliquidsorpressureinthecavityunderthestempackingandbonnetregardlessofthevalvepositionorpressureinadjacentlines.

Ballandplugvalvesthataretoberemovedmustbeopened,closed,andreopenedafterthesystemisdrained,toensuretrappedliquidorpressurehasbeenrelieved.GeneralSafePractices,continuedF. Whenbreakingapipeunion,loosenithalfwayandcheckfortrappedpressureorliquidbypushingthepipeawayfromtheworker.

G. Whenbreakingatubingfitting,loosenitaquartertohalfwayandcheckfortrappedpressureorliquidbygentlypullingitapartandflexingthefitting.

SpecialprecautionmustbeexercisedwhenbreakingaGrayloc*-typefitting,becauseofthedifficultyincontrollingaleak.Ifthisbecomestheonlypossiblebreakpoint,shieldingmustbeconsidered.*GraylocisaregisteredtrademarkofYellowstoneEnergyProducts.GeneralSafePractices,continuedI. Abarricadeorproperlycordoned-offareashouldbeconsideredtoadequatelyprotectpeoplenotinvolvedinthelinebreakfromasuddenunexpectedreleaseofthehazardousmaterial.

J. Whenthelinebreakconsistsofremovingavesselflangeorhead,alwaysbackalltheboltsoffthreeorfourturns,inanormalpattern,beforeremovinganybolts.Thiswillallowtheflange/coverorheadtobackoffthegasketandallowanycontainedpressure(gas/liquid)toleakoutofthejoint,indicatingthepotentialpresenceofpressure.Thistechniquewillensurethattheflange/coverorheadremainscaptiveinplaceuntilanypressurehasventedoff.HazardsPipingsystemcomplexities(e.g.,multi-floorroutes,loops,pockets,turns)cancreateaninabilitytoensureasystemisemptyandpressure-freeevenafterlinebreaksarecompleted.Thevolume,pressure,andtemperatureofthematerialthatcouldbereleasedfromalinebreakshouldbeconsideredpriortomakinganybreaks.Addedhazardsexistwhenvacuumsarecreatedduringcooling.Vacuumscanholdliquidsthatunexpectedlyreleasewhenthetemperatureequalizesandcausespressurization.ExamplesofliquidsthatcreatevacuumduringcoolingareDP:DPO(Dowtherm),steam,andsteamcondensate.Hazards,continued4. Hotliquidsthatcooltosolidcancreatespecialproblemsofgasesandhotliquidsbeingtrappedbetweensolidifiedplugsthatcanblowout.Examplesofhotliquidsthatcooltoasolidinclude:polymer,prepolymer,TPAresidue,DMTsludge,DMT,monomer,oligomer,ICLorTCL,andothers.Examplesofheatsourcesthatcreatehotmoltenproductsinclude:steamtracing,DP:DPO(Dowtherm)jacketing,steamjacketing,hotoiljacketing,electrictracing,andothers.5. Chemicalreactionscanoccurthatareuniqueforgivensituations.Theseconditionsmaycausethereleasetobeflammableortoxic,thusrequiringspecialplanning.6. Thespecificstepsforisolatingallprimaryandsecondary(e.g.,steamtracingandelectrictracing)energysourcesshallbeidentified.Thisisespeciallyimportantinpolymerandmeltsystemsthatare“frozen”(i.e.,solidified)toisolatethemandforacidsthatcanvaporizeifcooledandthenreheated.OtherDefinitionsWet/hottapInitialbreakControlledbleedDoubleisolationFlushingPurgingDepressurizationVentingDrainingIsolationProprietorWorkgroupSecondaryenergysourceStandbyRoutinetaskBlindflangeLineblankHazardousprocessorsystemQualifiedpersonnel

Wet/HotTapAmechanicalmethodofaddinganewtie-inordrainpointtoexistingserviceorequipmentwithoutinterruptingtheexistingservice.Note: Awet/hottapisconsideredalinebreak,butrequiresspecialprocedures.

AsareferenceseeFacilitiesConstructionSafetyManualB-20.1(/sheprocs/word/b-20-1.doc).InitialBreakThefirstopeningofdrainedandundrainedlinesorequipmentbydisconnectingflanges;breakingpipeortubingjoints;removingblinds,blanks,andplugs;orpenetratingalinebymechanicalmeans.OpenClosedInitialbreakControlledBleedAvalvedopening(bleed)locatedbetweentwoblockvalves.Thebleedconsistsofanopenblockvalveandterminateswithanopenendorpressuregauge.Thebleedservesasanindicatoroftheintegrityoftheupstreamblockvalve.Selectionandpositioningofthebleedterminationpointaredependentonthehazardsassociatedwiththeprocessmaterialandlocalconditionsatthetimeofthelinebreak.ControlledbleedClosedClosedVentDoubleIsolationDoubleblockvalveandcontrolledbleed(i.e.,blockvalve/controlledbleed/blockvalve)orblockvalveandblank/blindflange.FlowDoubleblockvalveandcontrolledbleedFlowBlockvalveandblank/blindflangeWorkareaWorkareaFlushingTheremovalofhazardouschemicals(vapororliquid)byflushingtheline/equipment.LiquidforflushingDrainvalveopenforflushingfluidFlowClosedOpenOpenPurgingTheremovalofhazardouschemicals(vapor)bypurgingtheline/equipmentwithagas.GasforpurgingDrainvalveopenforpurgingfluidClosedOpenFlowOpenDepressurizationTheloweringofpressureintheline/equipmentbyreleasingthepressuretootherline/equipmentandventsystemspriortoventingordraining.VentsystemPressuredroppingtozeroVentingThecontrolledreleaseofremainingpressurethroughavent.PressuredroppingtozeroOpenClosedDrainingThecontrolledremovalofliquidremaininginthelineorequipmentbyopeningadrain,bleed,orblowoutvalveatthelowestpossiblepointontheline.Thedrainpointmustbeverifiedtobeclear.LowpointdrainvalveOpen

IsolationTheclosingofvalvesandde-energizingofotherenergysourcestopreventprocessflowentryintotheline/equipment.Thehierarchyforisolatinghazardousprocessesstartingwiththemostprotectivelevelis: 1.Doubleblockvalveandcontrolledbleed 2.Blockvalveandblank/blindflange 3.Doubleblockvalve 4.Singleblockvalve 5.EngineeredprocessplugProprietorThepersonorgroupwhohasprimaryoperatingresponsibilityfortheequipmenttobeopened.WorkGroupPersonnelperformingtheactualline/equipmentbreak.SecondaryEnergySourceSourcesofenergythatcanposeahazardtothoseperformingaline/equipmentbreak(e.g.,steamtracing,electrictracing,springs,andgravity).StandbyAqualifiedpersonwhoseresponsibilitiesincludebeingphysicallycapableofperformingtherequireddutiesandassistinginthecontrolofreleasesorhazards.

RoutineTaskAtaskthatisperformedbyasingleworkgrouponaperiodicbasisthatisbasedonannuallyreviewedwrittenprocedures.TheproceduremustclearlyoutlinethestepsandcontrolsnecessaryandspecifyrequiredPPEforthetask,consistentwithsitesafetyprocedures.Trainingonthis“RoutineTask”shallbedocumentedandcurrent.BlindFlangeAsolidflangemanufacturedaccordingtoANSI/ASMEStandardB16.5.Blindflangesmayrequirematerialmatchingthepipingsystemorequivalentbasematerial.Insomecases,carbonsteelblindflangesmaybecladwiththepipeorequipmentbasematerial.LineBlank

(Alsocalledaskilletblankandfryingpan)Aslipblankinstalledbetweentwoflanges,fabricatedinaccordancewiththecurrentissueofDuPontEngineeringStandardP9E*.Whenselectingalllineblanks,thefollowingmustbeconsidered:thebasematerialofthepipeorequipment,theserviceorprocess,the

operatingpressureandtemperature,andthelengthoftimetheisolationblankwillberequiredinservice.Insomecases,carbonsteelblanksmaybecladwiththepipeorequipmentbasematerial;requirementsofthelineblankdirectthisdecision.*P9Eisdesignedforpressuretestingonly.ContacttheTechnicalAssistanceGroupfortemporaryblankingunderoperatingconditions.HazardousProcessorSystemAprocessorsystemthatcontainsanymaterialatanypressurethatcouldcauseariskofinjurytoanindividual(s),ariskoffireorexplosion,anenvironmentalrisk,oranoff-siterisk.Examplesofhazardousprocessesorsystemsinclude,butarenotlimitedto,compressedfluids,especiallygasesinpipesandvessels;corrosiveand/orflammablesubstances;andtoxicprocesslinesandanyotherlinesthatcouldcontainmaterialthatishazardousoncontactorinhalation,includingfluidwhosetemperatureishigherthan140F(60C)orlowerthan14F(-10C).Example:3to15psiairinanimpulselinemightnotbehazardous,but3to15psiairinalargetankcouldbeveryhazardous!QualifiedPersonnelThosewhobyextensiveknowledge,training,andexperiencehavesuccessfullydemonstratedtheirabilitytosolveorresolveproblemsrelatedtolinebreaksinaccordancewithDuPontSHEStandardS27G.LineBreakFAQsQ: Whyisitnecessaryforastand-bypersonfromOperationstobepresentwhenhotsuitsarerequiredwhenmakingalinebreak?A: TheOperationspersoncanrenderassistanceinanemergencyandisthemostknowledgeablepersontofindanotherisolationpointifneeded.

Q: Iamusingahotsuitwhilemakingalinebreak,thelineisopen,andnothingisdraining.CanIremovemyhotsuitbeforeinstallingaslipblankorablindflange?A: Youcanonlyremoveyourhotsuitbeforeinstallingaslipblankorblindflangeaftertheinitiallinebreakwhentheworkisbeingperformedbehindadoubleblockvalveandcontrolledbleedisolation.Ifyouareworkingbehindasingleblockvalve,potentialleaksposearealdangeruntilaslipblankorblindflangeisinstalled.

LineBreakFAQs,continuedQ: WhyshouldIsuitupbeforeremovingablankorblind?ThevalvewasnotleakingwhenIinstalledtheblind/blank.A: Noonecanpossiblyknowifthevalveleakedthroughornot.Theblind/blankmaybeholdingbackafluid/gasandmaycontainpressure.Q: Inahot-suitsituation,whyshouldastand-bymechanicbeinahotsuitwhilealinebreakisbeingperformed?A: Thestand-bymechanicistheretoaidtheworkingmechanic(s),ifneeded.Ifanemergencysituationarose,itwouldbeimpossibleforthestand-bymechanictogetintoahotsuitquicklyenoughtohelp.LineBreakFAQs,continuedQ: Howbigshouldabarricadebeforalinebreak?A: Ataminimum,thebarricadeshouldbeaslargeastheareatheline