OSE571 Ocean Plant Design

Safety design and API RP 14C

Korea Advanced Institute ofScience and Technology

Daejun CHANG (djchang@kaist.edu)

Division of Ocean System Engineering

Design Procedure and Key deliverablesDesign Procedure and Key deliverables

Design Basis (Philosophy)

Concept Consolidation

Process Flow DiagramProcess Simulation

Equipment SpecificationEquipment Design

System Description

Production Availability ?

-1- Ocean Systems EngineeringOcean Systems Engineering

Process Operation and Control Philosophy

P&ID

Layout

HAZOPRisk AssessmentSafety Studies

Caution: Not universally applicable

Hazards and Safety SystemsHazards and Safety Systems

Accident Controlling Protection(F&G Detection, ESD, Depressurization, Alarm)

Accident Mitigating Protection(Active/Passive Fire Protection, Fire/Blast Walls)

Emergency Response(Escape Route, TR, Evacuation Means, Rescue Equipment, Emergency Power)

Potential Accident:

Accident:Fire/Explosion

-2- Ocean Systems EngineeringOcean Systems Engineering

Inherent Safety Design(Layout, Inventory, Leak, Ignition)

Basic Process Control(P, T, F, Surge, Back Pressure)

Preventive Protection(Structural & Machinery Integrity, Relief, PSV)

Potential Accident:Gas Leak

Layered Structure of Safety Systems against Fire and Explosion

P&ID (W11)

Process Operation and Control Philosophy (W9)

System Description (W4)

Workflow for Process ControlWorkflow for Process Control

-3- Ocean Systems EngineeringOcean Systems Engineering

Field Implementation

Logic Diagram

Functional Design Specification (W11)

API RP 14CAPI RP 14C

-4- Ocean Systems EngineeringOcean Systems Engineering

Not restricted to platform topside design.

Topside design for floating installations (FPSO, FSRU, FLNG) conforms to this.

API RP 14CAPI RP 14C

-5- Ocean Systems EngineeringOcean Systems Engineering

This document presents recommendations for designing, installing, and testing a basic surface safety system on an offshore production platform.

This recommended practice illustrates how system analysis

1.2 SCOPE1.2 SCOPE

-6- Ocean Systems EngineeringOcean Systems Engineering

methods can be used to determine safety requirements to protect any process component.

Overview of Safety SystemsOverview of Safety Systems

-7- Ocean Systems EngineeringOcean Systems Engineering

2. SAFETY DEVICE SYMBOLS2. SAFETY DEVICE SYMBOLS

-8- Ocean Systems EngineeringOcean Systems Engineering

Safety Device SymbolsSafety Device Symbols

-9- Ocean Systems EngineeringOcean Systems Engineering

3.1 PURPOSE AND OBJECTIVES The technical content of this recommended practice establishes a

firm basis for designing documenting a production platform safety system for a process composed of components and systems normally used offshore.

3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN

-10- Ocean Systems EngineeringOcean Systems Engineering

Moreover, it establishes guidelines for analyzing components or systems that are new or significantly different from those covered in this document.

3.2 SAFETY FLOW CHART Hazards, their propagation, and intervention of safety devices Overall objectives

1. Prevent a release of hydrocarbons2. Shut in the process to stop the flow of hydrocarbons to a leak3. Treat hydrocarbon escaping from the process.

3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN

-11- Ocean Systems EngineeringOcean Systems Engineering

3. Treat hydrocarbon escaping from the process.4. Prevent ignition5. Shut in the process in the event of a fire.6. Prevent undesirable events causing the additional release

3.4 PREMISES FOR BASIC ANALYSIS AND DESIGNa. Accordance with good engineering practicesb. Two levels of protectionc. Activation order of the two: primary and secondaryd. Proven systems analysis techniques to determine the minimum

safety requirements for a process component.e. All process equipment and functions are incorporated into the

3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN

-12- Ocean Systems EngineeringOcean Systems Engineering

e. All process equipment and functions are incorporated into the safety system.

f. Safe components + logical integration the entire facility will be protected.

g. The analysis procedure should provide a standard method to develop a safety system and provide supporting documentation.

4.2.1 Undesirable Events4.2.1.1 Overpressure4.2.1.2 Leak4.2.1.3 Liquid Overflow4.2.1.4 Gas Blowby: gas flow through the liquid line

4. PROTECTION CONCEPTS AND SAFETY ANALYSIS4. PROTECTION CONCEPTS AND SAFETY ANALYSIS

Protection Concept

1. Cause

2. Effect and Detectable Abnormal Condition

3. Primary Protection

-13- Ocean Systems EngineeringOcean Systems Engineering

4.2.1.5 Under Pressure4.2.1.6 Excess Temperature4.2.1.7 Direct Ignition Sources4.2.1.8 Excess Combustible Vapors in the Firing Chambers

3. Primary Protection

4. Secondary Protection

5. Location of Safety Devices

Example: Undesirable Events - Overpressure Cause

- Inlet: input source, overflow, gas blow-by- Outlet: flow rate control failure, restrictions, blockage- Body: thermal expansion

Effect

4. PROTECTION CONCEPTS AND SAFETY ANALYSIS4. PROTECTION CONCEPTS AND SAFETY ANALYSIS

-14- Ocean Systems EngineeringOcean Systems Engineering

Effect- High pressure- Hydrocarbons leak- Rupture

Protection 1: PSH - inflow, heat, fuel shut off

Protection 2: PSV

4.3 SAFETY ANALYSIS Analyzing the process and establishing design criteria for an

integrated safety system covering the entire platform process SAT: Safety Analysis Table SFC: Safety Analysis Checklist

4. PROTECTION CONCEPTS AND SAFETY ANALYSIS4. PROTECTION CONCEPTS AND SAFETY ANALYSIS

-15- Ocean Systems EngineeringOcean Systems Engineering

SAFE: Safety Analysis Function Evaluation Chart Completion of the SAFE chart provides a means of verifying the

design logic of the basic safety system. Implemented into the shutdown logic (Cause and Effect Chart)

Level 1 APS Abandon platform

Level 2 ESD I Emergency shutdown (total)

Level 3 ESD II Emergency shutdown (partial)

Shutdown LogicShutdown Logic

-16- Ocean Systems Engineering

Level 3 ESD II Emergency shutdown (partial)

Level 4 PSD Process shutdown (total)

Level 5 PSD Process shutdown (partial)

Shut DHSVAuto Depressurisation

Timer-based disconnectionFire&gas detectionPA, ESD/PSD, radioEmergency generator/UPS

DisconnectionMain generatorNon-critical non-EXequipment

APS

ESD I

Manual

Manual

Input

Gas detection Non hazardous area

Fire&gas detectionHazardous area

Standardizing

-17- Ocean Systems Engineering

Start Emergency generator

equipment

Shut fuel gas supply

Activation of DHSV (fire in riser/ well area)Riser ESDVDepressurisation

ESD II

PSD

Manual

Low pressurehydraulic system

Low pressure Instrument air

High lev flare k.o drum

Tube rupture in cooler

Hazardous area

Recommended Safety DevicesRecommended Safety DevicesA.1 Wellheads and Flow Lines

-18- Ocean Systems Engineering

UndesirableEvent

Cause Detectable Abnormal Condition at Component

Overpressure Blocked or restricted lineDownstream choke pluggedHydrate plugUpstream flow control failureChanging well conditions

High pressure

A.1 Wellheads and Flow Lines

Safety Analysis Table (SAT)Safety Analysis Table (SAT)

-19- Ocean Systems Engineering

Changing well conditionsClosed outlet valve

Leak DeteriorationErosionCorrosionImpact damageVibration

Low pressure

a. High Pressure Sensor (PSH)1. PSH installed.2. Flow line segment has a maximum allowable working pressure greater than maximum

shut in pressure and is protected by a PSH on a downstream flow line segment.

b. Low Pressure Sensor (PSL)1. PSL installed.2. Flow line segment is between the well and the first choking device and is less than 10

feet(3m) in length or in the case of an underwater installation, reasonably close to that

Safety Analysis Checklist (SAC)Safety Analysis Checklist (SAC)A.1 Wellheads and Flow Lines

-20- Ocean Systems Engineering

distance.

c. Pressure Safety Valve (PSV)1. PSV installed.2. . . .

d. Flow Safety Valve (FSV)1. FSV installed.2. . . ..

Wellheads and Flow lines Wellhead Injection line Header Pressure vessel Atmospheric vessel Fired and Exhaust heated component

More Examples in Appendix AMore Examples in Appendix A

-21- Ocean Systems Engineering

Fired and Exhaust heated component Pump Compressor Pipeline Heat exchanger(Shell-Tube)

Check the examples before drawing your P&ID

Safety Analysis Function Evaluation Chart (SAFE)Safety Analysis Function Evaluation Chart (SAFE)

-22- Ocean Systems Engineering

Cause

Effect

Cause and Effect ChartCause and Effect Chart

-23- Ocean Systems Engineering

X