Line Walk Meaning

Line walk
Line walks are a visual check of process plant, designed to identify hazards which may lead to a loss of
containment. They are often carried out as part of plant reinstatement checks, both before a leak test,
and prior to reintroduction of hazardous substances.
Line walks can be a very useful tool to reduce risk, but as with any operational control it is important that
the arrangements are formalised. Appropriate training and supervision need to be in place to ensure
that staff perform them consistently and effectively, and regular auditing is essential.
When to line walk
Some companies only require line walking following major maintenance, overhauls or project work.
Good practice however is for line walking to take place after every maintenance task which has involved
breaking of containment.
How to line walk
Line walks should be performed by one (or preferably two) technicians who walk alongside the plant
equipment that is being reinstated and noting any issues that they find.
The scope of the line walk should be well defined. A combination of a marked-up P&ID showing the
extent of the process lines and equipment to be checked, and a plot plan (or description) of the general
area in which the equipment is located is typically used for this, and should be prepared in advance. The
latter helps ensure that ancillary issues such as housekeeping, lighting etc are also addressed.
What to check for
Anything that could give rise to a risk on re-start! Non-exhaustively this includes issues such as:-
 Open ends on pipework (e.g. blanks missing from drain lines, caps/plugs missing from vent
connections)
 Discrepancies between the installed plant and the P&ID, perhaps as a result of modifications or
incomplete work
 Incorrect valve alignments (including for locked open/locked closed valves) e.g. isolation valves
in line with blowdown valves or pressure safety valves being closed, bypass valves being open, or
instruments with an operational or safety function being isolated, counter to requirements
 Level bridle or sight glass tappings not being in the open position, or water being present within
dry-legs of differential pressure/level transmitters
 Interlocks and keys not being in the correct position
 Motors/drives not being electrically de-isolated
 Analyser systems not being re-instated correctly
 Critical heat tracing being offline (typically on impulse lines and level bridles)
 Temporary equipment not having been removed (e.g. leak testing equipment, drain hoses)
 Local isolations and tags remaining in place
 Accessibility issues, such as ability to operate plant equipment, blockage of emergency escape
routes, access to firefighting or safety equipment and lighting.
It is common for pre- leak test line walks to have a different (reduced) scope to that of final pre-
reintroduction of hazardous fluids line walks. The former are typically limited to ensuring that the
mechanical scope of work has been completed, and there are no open ends, such that the leak test may
be performed safely.
How to record findings
Technicians carrying out a line walk should mark the P&ID and plot plan as they go with a highlighter pen
to show the extent of the check so far performed. Any issues identified can be marked with a unique
reference number on the drawings, as well as a tag on the equipment, linked back to a register (or
'punch list') explaining what is wrong.
The rigour of the process is likely to be higher when the technicians responsible (as well as their
supervisor) are required to sign the marked-up drawings and register, and to confirm that each of the
potential types of risk issue have been checked. The written records should be retained for follow-up and
audit.
How to manage actions
Each item on the register should be risk assessed, and acted upon as required as reinstatement is
progressed. Some actions need to be completed before leak test (e.g drain point needs blind flange
fitting), some before introduction of hazardous substances (e.g. critical insulation not in place), and some
can wait until the plant is back in service (e.g light fitting needs replacement). Post start-up actions that
are not immediately addressed need to be transferred into the asset's maintenance management
system.
What is the difference between hydrotesting and tightness
testing?
Pipelines are a critical component of many industrial processes, used to transport liquids and gases from
one location to another. It is important to verify that these pipelines are capable of handling the
intended flow and pressure without leaking. This is why two common tests are conducted to measure
the integrity of the piping system: hydrotesting and tightness testing.
Hydrotesting, also known as hydrostatic testing, is a method of testing the pipes by filling them with
water and pressurizing them. This test is performed to ensure that the piping system is capable of
withstanding the maximum operating pressure without leaking. During the hydrotest, water is pumped
into the piping system to a predetermined pressure, usually between 1.5 and 2 times the system’s
maximum operating pressure. The pressure is maintained for a specified duration, typically several
hours, while the pipes are closely monitored for any leaks.
Tightness testing, on the other hand, involves testing the piping system for leaks using gas or air. This test
is performed to ensure that the piping system is capable of maintaining a specific pressure without losing
or leaking any gas or air.
The primary difference between these two tests is the media used to pressurize the system.
Hydrotesting uses water, while tightness testing uses gas or air. Additionally, hydrotesting primarily
checks for the structural integrity of the pipe, while tightness testing primarily checks for leaks in the
system.
Hydrotesting uses the maximum design pressure to check the integrity of the weld, leak testing uses
the maximum working pressure to make sure the line will not leak during operation loaded with
product.
In conclusion, while both methods serve similar purposes, hydrotesting and tightness testing are two
different approaches to verifying the integrity of piping systems. Hydrotesting is a more reliable but time-
consuming method that is better suited to testing larger systems. Tightness testing, while less accurate,
is better suited to smaller systems and is a faster and less expensive alternative. Ultimately, which test is
used depends on the nature of the piping system and the specific requirements of the industry in
question.

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Line Walk Meaning

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Line walk

When to line walk

How to line walk

What to check for

 Interlocks and keys not being in the correct position

 Motors/drives not being electrically de-isolated

 Analyser systems not being re-instated correctly

 Local isolations and tags remaining in place

How to record findings

How to manage actions

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