Piping dead-legs remain a persistent source of plant maintenance and safety incidents. Not a year passes without a major fire or process fluid release due to dead-legs. These problems have been long known. Thirty years ago, as a beginning engineer, I prepared a rough sketch to explain required modifications to a piping layout. This drawing caused much excitement — not because of the changes needed but because of the existing dead-legs shown. After years of hunting and removing dead-legs, the plant still had many waiting to be found.
Dead-legs merit special attention to maintain asset integrity and prevent incidents. Well-run plants will have dead-leg elimination, special inspection, and preventive maintenance programs. However, different plants may classify different things as dead-legs.
So, what qualifies as a dead-leg? Piping segments continuously exposed to the process but without normal flow or provision for flow, including lines closed by flanges, welded caps or other fittings, nearly always are considered dead-legs. However, other situations are trickier to classify. Two particular issues that perplex the most are dealing with intermittent flow lines and defining how much line is required for something to be classified as a dead-leg.
Commonly, batch-system piping used on an intermittent but reasonably frequent scheduled basis isn't considered a dead-leg. This seems simple but leaves a lot of room for honest disagreement. Most would agree that a pipe regularly used once a day isn't a dead-leg. Many would treat a pipe used roughly once a year and only for a few minutes as a dead-leg. But what about the intermediate situations? For instance, does a pipe used once a month on a scheduled basis for several hours count as a dead-leg?
The decision should rest on the likely problems that may occur in a specific process and piping segment. Incident reviews show that two major events cause the vast majority of dead-leg problems: water freezing and localized corrosion.
The volume expansion as water turns into ice may rupture a piping system. This can lead to immediate process fluid escape if the system pressure can push the ice plug out. At other times, the ice plug can keep a crack sealed until the system starts to warm. Then, once the ice melts, process fluid escapes.
Unusually cold weather most commonly causes ice plugs. However, freezing also can result from autorefrigeration from process pressure drops. Any piping can crack. Plastic piping is especially vulnerable because at low temperatures many common polymers become brittle.