Safety

Avoid Natural Gas

Piping Hazards
John R. Puskar, P.E. Repairing natural gas piping is inherently dangerous.
CEC Combustion Safety
Follow these safety protocols to avoid potentially
catastrophic results from improper installation
and repair of natural gas lines.

O
ver the last 10 years, several industrial accidents Many individuals who manage or perform gas piping
related to natural gas piping problems have taken repairs lack the knowledge needed to do so safely. Some
more than a dozen lives, injured hundreds of people, in purchasing or maintenance functions think that all
and cost the companies involved billions of dollars. Many piping is the same; they do not understand that repairing
more significant incidents and fires involved commercial and or installing an air or water line is quite different from
even residential facilities. working on a gas line.
One of the most recent cases described on the U.S. This problem is especially relevant in the current
Chemical Safety and Hazard Investigation Board’s (CSB) economy, with many companies choosing the lowest bidder
website (www.csb.gov) is the June 2009 explosion at a food for repair projects. In the past, contractors apprenticed pipe-
plant in Garner, NC (1). A new piece of equipment was being fitters by directly training them and sharing their experience.
installed and a natural gas line was being re-energized for In addition, many businesses that provided training related to
light-off. Four people were killed and more than 40 others gas piping risks no longer have the resources to do so. Very
were sent to the hospital with injuries when the blast knocked few communities regulate who is qualified to perform gas
down walls and caused the roof to collapse. Investigators piping work, and local building inspectors rarely see projects
concluded that the gas line was purged into the building, and beyond low-pressure residential jobs.
that led to the accident. As a result, the state of North Caro- NFPA 54 explains how to safely perform gas piping
lina now prohibits the purging of gas lines into buildings. repairs, purging, and pressure testing. Unfortunately, many
Another purging incident in February 2010 killed six who should be familiar with NFPA don’t even know that it
workers and injured 50 others at an energy plant under exists, don’t have time to read it, or don’t interpret it cor-
construction in Middletown, CT. The CSB determined that rectly. Another problem is that NFPA 54 does not go into
the explosion was most likely caused during a routine gas detail about the reintroduction of natural gas after repairs.
purging procedure (2). The accumulating gas reached an Even the newest changes require some amount of interpreta-
ignition source, where welding and other work were being tion depending on the project size and scope. In addition,
performed nearby, setting off the blast that leveled much of many nuances of repair can only be learned through experi-
the facility. ence and practical examples.
The National Fire Protection Association (NFPA) has This article fills some of the gaps that are not explicitly
adopted sweeping changes to NFPA 54, the “National Fuel covered in NFPA 54 and summarizes some important les-
Gas Code” (3), to protect against these kinds of incidents. sons learned that can help prevent devastating natural gas
The changes were deemed important enough to be added accidents. It reviews ten common hazards associated with
as a tentative interim amendment (TIA) to the standard (see the installation and repair of natural gas piping and provides
www.nfpa.org for the complete changes). insights on how to avoid them. These tips and techniques

Copyright © 2011 American Institute of Chemical Engineers (AIChE) CEP January 2011 www.aiche.org/cep 45
Safety

should be incorporated into a comprehensive documented is much more effective to find and repair leaks in reasonably
procedure for natural-gas piping purging, piping system sectionalized piping, possibly hundreds of feet at a time.
design, and equipment start-up. Other important considerations during the planning pro-
cess include:
Inadequate design and planning • Where are isolation points and how will isolation be
A safe gas piping installation or repair job involves six safely achieved?
basic steps: • Will the utility be involved? What will be required of
Pre-repair the utility? What does the utility require of the facility?
1. Planning • Is there an overall plan and does everyone involved
2. Isolation understand it?
3. Pre-repair purging • Is there enough nitrogen to handle the purging require-
Making the repair ments? Does everyone involved understand nitrogen hazards?
4. Pressure testing • Where will the purge stream be sent?
5. Post-repair purging • Have reintroduction and start-up been discussed,
6. Reintroduction and light-off including their unique hazards?
Before any work can be performed, significant planning
is needed to ensure the job is completed safely. Proper plan- Improper isolation (an often-tragic mistake)
ning includes: The U.S. Occupational Safety and Health Administra-
• procedures: What specific written procedures of the tion’s (OSHA) lockout/tagout standard (OSHA 1910.147)
work to be done and processes to be used will provide a (4) governs the isolation of hazardous energy sources. Much
step-by-step understanding for everyone involved? has been written about this issue, and most facilities comply
• people: What is the knowledge and skill level of the with it when isolating electrical equipment. For gas piping,
staff to be involved? Is training needed? however, proper isolation is much less common. Even some
• design: Has a thorough review of the design been sites that place locks on all electrical disconnects may close
completed to ensure that everything to be installed meets a gas valve, but not lock it.
applicable codes and best practices? The isolation of lubricated plug valves, which account for
• resources: What resources will be required? When will 60–80% of the manual shut-off valves in natural-gas piping
they be needed? systems, requires special attention. These valves have a small
• hazards: What possible hazard assessments and abate- gap between the plug and the valve body. If a sealant is not
ment steps need to be performed at this stage? applied annually, as required by code and the manufacturer,
Planning also needs to include a review of isolation gas will leak past the plug even when the valve is in the
points, including existing valves and flanges, the pos- closed position. Many facilities have never sealed their lubri-
sible need to install flanges, and areas where blanks can be cated plug valves. Hence, closing or locking out a valve in
installed. According to NFPA 54, pressure testing cannot be this condition does not necessarily isolate the energy source.
carried out against valves if there is a pressurized substance Isolation must ensure that all active gas-filled parts of
on the other side of the valve. The engineer will need to the system are safely separated from open sections of pipe
evaluate the entire gas piping system to determine where the and/or the areas to be repaired. Most people think of isola-
system can be sectionalized for proper testing. tion as valves. However, even when they are in the closed
It is helpful to have (at a minimum) a schematic repre- position, valves may leak, especially if they have not been
sentation of the facility’s gas piping systems on hand during serviced properly. Because of this, the safest approach is to
planning. A schematic typically shows major line sizes, use blinds or double-block-and-bleed valves for isolation.
valves, and equipment. A detailed natural gas piping draw- A double-block-and-bleed system consists of three valves
ing depicts much more detail and may include isometric in series — the two end valves are closed and the middle
representations of some of the piping. If neither is available valve is open and vented to a safe place. If a valve leaks, the
for use during the planning stage, a schematic representation leaked gas can exit through the vent rather than pressurize the
will need to be prepared (detailed piping drawings for a large downstream valve and create a more serious hazard.
facility could take weeks to make). Effective isolation protects not only personnel from the
Planning is vital because it allows piping sections to be hazard of natural gas, but it also protects components in fuel
designed to be somewhat reasonable in length for testing trains from the elevated pressures that may be encountered
and evaluation. For example, if the system does not hold during pressure tests. Valves that are left open or leak in the
pressure during pressure testing of all of the plant piping, the closed position can overpressure and permanently damage
entire plant will need to be searched to locate a small leak. It delicate components such as regulators and pressure switches.

46 www.aiche.org/cep January 2011 CEP Copyright © 2011 American Institute of Chemical Engineers (AIChE)
Improper purge points
Purge points are pipe nipples installed at strategic loca- Purge Endpoint Vent
(<1% LEL, <1% O2) reached to a
tions in the piping system for the purpose of introducing or safe
removing nitrogen and natural gas at various stages of the Purge location
process. These are generally 1-in. Sch. 80 nipples (which Closed
Inlet Valve Closed
are thicker and stronger than common Sch. 40 pipes) with PV1

natural-gas-rated ball valves on the ends. It is important to 100% Nitrogen

select locations and orientations that minimize their suscepti- Vent
Valve
bility to damage from things like vehicle traffic. VV1
For effective purging, the nipples must be installed in
the piping system and the workers must know how to use <1% LEL
them. The facility should have a purge plan that details <1% O2

how the system will be sectionalized, where each section’s

Nitrogen Endpoint
nitrogen will enter, and where purge products and/or natural
gas will go.
S Figure 1. Before natural gas enters a pipe, air needs to be removed to
Remember that (as required by code) purged products prevent the formation of a flammable mixture.
must go to a safe place. This is usually outside, away from
air intakes and ignition points. These materials are often defects. Check all the fittings in advance to make sure they
routed with a garden hose, although in practice only hoses are free from casting defects, thread damage, and thread
rated for natural-gas piping should be used. Caution tape misalignment.
should be erected around the perimeter (at least 25 ft from
the purge point) and an employee should monitor the area Nitrogen hazards
with flammability meters. Even though the air we breathe is 78% nitrogen, two
Monitoring is especially important if the purge point full breaths of pure nitrogen can kill a person. Make sure
or equipment is within a building. Although it may require everyone involved and in the vicinity understands this haz-
a long line to reach outside, this is vital because the lower ard. Purge points should be located in well-ventilated areas
explosive limit (LEL) of natural gas is only 4.3% by volume, and be well-marked. Verify the pressure ratings of hoses and
and it does not take much gas to reach this point in a small regulators because large liquid nitrogen tanks can produce
enclosed area. high discharge pressures. When discharging nitrogen, the
purge discharge areas need to be monitored. All person-
Improper piping repairs nel involved in the purging and pressure testing need to be
Proper repairs start with the right materials. Gas lines are trained on the safe handling of nitrogen.
usually Sch. 40 ASTM A53B piping. If welding is needed, Nitrogen is used during the pre-repair purge to push
ensure that the welders have the proper credentials. In addi- the natural gas out of the line (Figure 1); then it is used to
tion, make certain that fittings and tees are used instead of perform a pressure test before the repair; and finally after
fish-mouth joints. Threaded connections must be done with the repair, nitrogen is used again to remove the air from
tapered threads. the pipe before gas is reintroduced. If this last step is not
Hangers and supports must be carefully planned. It done properly, the air in the pipe can mix with the natural
is important to ensure that pipe supports are adequate to gas and create a flammable mixture. If this gets to a burner
prevent sections of pipe from falling when they are discon- under the right conditions, the flame can travel backward
nected. It is also important that hangers do not put stress and cause the pipe to explode. These three uses need to
on joints or flanges. In some cases, special supports will be be considered when estimating the amount of nitrogen
required, such as for large, very heavy plug valves. required.
NFPA 54 does not allow the reuse of flange gaskets even
if they appear to be in good condition. To ensure leakfree Improper endpoint monitoring
joints, it is important to use new gaskets and correctly rated Verify that purge endpoints where natural gas may be
bolts for the flanges. When mating up flanges, place one released are outside and at least 25 ft from any ignition
raised face adjacent to another raised face and a flat face source. Cordon off these areas to keep ignition sources,
adjacent to a flat face. vehicles, and people away.
Only pipe and fittings with the proper rating should Do not use a combustion fluegas analyzer. Instead,
be used. Verify that all suppliers are reputable and that use a good quality, recently calibrated LEL meter during
all materials are free from manufacturing and installation natural gas introduction and removal. A four-gas meter

Copyright © 2011 American Institute of Chemical Engineers (AIChE) CEP January 2011 www.aiche.org/cep 47
Safety

can be used to monitor oxygen levels during post-repair

nitrogen purging.
Before you begin, make sure that two LEL meters are
available. Stopping the process due to an instrumentation
error can create a hazard. One LEL meter can be positioned
at the barrier protecting employees near the purging area;
the other should have a sensor with tubing at least 6 ft long
so it can monitor conditions at the actual discharge point.
No one should stand in harm’s way at the discharge point.
Perform a timed and measured discharge, and then —
after carefully stopping the flow — approach to take an
LEL reading at the end of the purge hose. This may need to
be done repeatedly. It should be done by two people who
are in radio contact with everyone on the team, including S Figure 2. Before pressure testing, make sure that all equipment is
properly isolated. Verify that all main equipment shut-off valves are closed
those introducing the nitrogen or gas some distance away.
and are able to hold pressure. Otherwise, regulators and other sensitive fuel
In some cases, the best approach is for those doing the end- train components could blow out.
point monitoring to be equipped with breathing air. (Note
that the TIA from the NFPA states, “Persons not involved source should be continuously maintained. If a problem is
in the purging operations shall be evacuated from all areas detected, the supply of natural gas will need to be imme-
within 10 ft (3 m) of the point of discharge.” We recom- diately isolated. In addition, valves should be serviced,
mend a 25-ft barrier around the purge zone.) handles installed, and valve function verified before the
repair process begins.
Pressure-testing errors During reintroduction, nitrogen is pushed outside with
All new or repaired gas piping must be pressure-tested. the gas behind it, and the process is periodically stopped so
NFPA 54 provides information on what pressure needs to the endpoint can be tested. When the LEL meter indicates
be held and for how long. Some states require pressures or 100%, the lower explosive limit has been reached — which
timing that is more stringent than required by NFPA 54. In is just 4.3% gas by volume. Sometimes this is not sufficient
addition, if the natural gas is shut off, the local utility may to light a burner. Depending on the equipment to be lit, it is
impose special requirements before it will turn the gas back a good idea to continue past this point for a short period of
on. Each facility needs to determine which standards apply time to increase the gas concentration slightly.
to it.
NFPA 54 also requires documentation of pressure- Equipment light-off hazards
testing for new or repaired piping systems prior to intro- Once the gas is at the proper concentration, complete
ducing natural gas. The results of these tests should be several dry light-offs — that is, attempt to start the equip-
retained for the life of the piping system. A best practice is ment with the gas completely turned off and locked out and
the use of pressure chart recorders. These battery-powered the combustion chamber purged of fuel. It will not light,
paper-and-pen recorders have very small pressure incre- but this will provide an opportunity to check the movement
ments (1 psig) and provide an excellent record of pressure of linkages and gas pressures. Gas regulators (main and
and hold times. pilot) could have been compromised during pressure test-
It may also be necessary to install blinds for the pressure- ing and debris could have entered orifices or control points.
testing. NFPA 54 prohibits pressure-testing against closed If possible, light only a pilot while the main fuel supply
valves. Temporary low-pressure blinds can usually be made remains off. When the pilot is lit, verify that the gas pres-
from sheet metal of the appropriate thickness for a short- sure is stable and that there are no damaged components.
term, one-time use. Permanent blinds, such as spectacle Then light the main flame, and observe it after light-off for
blinds, may require piping modifications, but are beneficial stability and proper flame strength.
in the long run should more work need to be done. It should take only 2–3 s for the pilot to light and
another 2–3 s for the main flame to light. The light-offs
Gas reintroduction problems should not be accompanied by loud banging or popping
After the post-repair purge, it is imperative that the noises. Never put your face near an observation port during
natural-gas source valve (at the inlet from the utility) be light-off — look at the flame only after a flame meter or
continuously attended during the reintroduction of natural other control indicates that the flame is lit.
gas. Communication with the individual observing the Light-off should not be attempted repeatedly. If ignition

48 www.aiche.org/cep January 2011 CEP Copyright © 2011 American Institute of Chemical Engineers (AIChE)
does not occur after three light-off attempts, stop the pro- require the installation of a blind on equipment that will
cess. Shut off all the gas and perform a dry light-off purge be out of service for months to avoid the possibility of gas
to move any accumulated flammables out of the firebox. leaks through valves.
If light-off is still not achieved after six or more attempts, This is a compliance issue. NFPA 54 is a code — not a
verify the level of gas entering the fuel train to see what standard — and it has the force of law in many jurisidic-
concentration was reached. If it is too low, more purging tions. The newest changes state that any natural-gas piping
is needed. system larger than 2 in. in diameter or operating at pres-
Automatic fuel valves should be leak-checked within sures over 2 psig needs to follow the directives of the code.
30 days of major gas piping repairs. Considerable slag and In many cases, this is a game changer and the maintenance
debris in piping systems can be found after major repairs and plant service people must be aware of this.
and construction. This is also a time to clean strainers and
sediment traps. Taking lessons learned to heart
You should now have a heightened awareness of the
Human error — the greatest risk of all issues involved in gas piping repairs and equipment com-
The most important factor in avoiding gas piping and missioning. If you are involved in this activity on a regular
equipment recommissioning issues is human error. Human basis, you may be able to put some of the advice presented
error can be minimized by changing cultures — that is, here into practice immediately. If you have only casual
through training and discipline. contact with gas piping repair, please share what you have
Training includes reaching out to maintenance depart- learned with those who routinely service or maintain gas-
ments and anyone involved in this process and teaching fired equipment. This is a very specialized area that many
them how to correctly perform gas piping repairs. The take for granted and that has proven to be anything but
trade unions that provide training for pipefitters do not nec- straightforward and simple. CEP

essarily provide training about gas. It cannot be assumed

that if someone does piping work, he/she has been taught
Literature Cited
about gas. In some facilities and locales, gas piping work
1. U.S. Chemical Safety and Hazard Investigation Board,
is done by plumbers, not by pipefitters. The best approach “ConAgra Natural Gas Explosion and Ammonia Release,”
is to conduct a simple knowledge assessment for everyone www.csb.gov/investigations/detail.aspx?SID=74, CSB,
involved that can reveal whether they understand the basics Washington, DC (2010).
and the nuances of safe gas piping installation and repair. 2. U.S. Chemical Safety and Hazard Investigation Board,
Reinforcement with regular training is also a must. “Kleen Energy Natural Gas Explosion,” http://www.csb.gov/
investigations/detail.aspx?SID=91, CSB, Washington, DC
Special policies need to be in place and enforced to (2010).
change culture and build discipline. The following types of 3. National Fire Protection Association, “NFPA 54: National Fuel
activities and authorizations can make a difference in gas Gas Code,” NFPA, Quincy, MA (2009).
piping safety. 4. U.S. Occupational Safety and Health Administration, “The
Gas leak surveys and work plans involve regular inspec- Control of Hazardous Energy (Lockout/Tagout),” OSHA 1910.147,
www.osha.gov/pls/oshaweb/owadisp.show_document?p_
tions for gas leaks, which are then identified and prioritized. id=9804&p_table=STANDARDS, OSHA, Washington, DC.
Leaks in areas where concentrations can easily build up to
flammable levels, such as small or poorly ventilated rooms,
become a higher priority than those outside or in open areas. JOHN R. PUSKAR, P.E., serves as Principal of CEC Combustion Services
An immediate repair is recommended if an LEL meter mea- Group in Cleveland, OH, which he founded in 1984 as an engineering
consulting firm specializing in utility systems and energy conserva-
sures 10% LEL or more within 6 in. of a leak. tion. After witnessing the devastation that can be caused by fuel-fired
Line breaking permits require development of a plan equipment when it is not properly operated or maintained, he focused
the company’s growth toward the field of combustion safety. He made it
before lines (pipes) that may have natural gas in them are the mission of his company and his life to help save lives worldwide by
opened. This provides an opportunity to discuss the haz- preventing explosions and industrial fires. He is a licensed mechanical
engineer and electrical contractor in several states, and also holds a
ards and plan for making this a safe activity. Master Plumber license. He has published more than 50 papers, includ-
Gas purging, blanking, and isolation permits are spe- ing many in peer-reviewed journals, and has presented at more than
20 technical conferences. He has chaired the local American Society of
cial permits that allow for a more-thorough review before Mechanical Engineers chapter and the Cleveland Technical Societies
gas piping repairs occur. These may require precautions, Council. He is also part of two National Fire Protection Association code
committees and serves on the American Society of Mechanical Engi-
such as the insertion of blanks instead of just closing neers code committee. He received a Bachelor’s degree in mechanical
valves whenever a person is entering a firebox or gas- engineering from Youngstown State Univ. in 1981 and a Master’s degree
in business in 1985 from the Weatherhead School of Management at
fired device. They might also call for two knowledgeable Case Western Reserve Univ.
individuals to review the proposed methods of lockout, or

Copyright © 2011 American Institute of Chemical Engineers (AIChE) CEP January 2011 www.aiche.org/cep 49