Field-Based Bonding Solutions for Insulated Stainless-Steel Piping in Hazardous Oil & Gas Installations

Field-based grounding methods for safety in oil & gas operations

Abstract

This article presents a field-validated method for achieving reliable electrical continuity across insulated stainless-steel flanged joints in hazardous-area chemical injection systems, mitigating the risk of electrostatic discharge ignition. The proposed solution employs 35 mm² PVC-insulated copper bonding jumpers and was implemented in accordance with IEC 60079-14, IEC 60364-5-54, IEEE Std 142, and NFPA 77.

Field testing confirmed bonding resistance values consistently below 0.05 Ω, ensuring compliance with international safety standards. The system was specifically engineered to address practical challenges, including mechanical congestion, material compatibility with stainless steel, and coexistence with electric heat-tracing systems.

This work provides a structured engineering framework for enhancing equipotential bonding in hazardous environments - minimizing electrostatic ignition risks, mitigating stray voltage hazards, and improving grounding integrity across isolated pipeline sections. The approach has been proven in remote oil and gas field conditions and demonstrates strong reliability, maintainability, and economic justification aligned with ALARP principles.