1 Twelve Steps to Engineering Safe Oil and Gas Facilities Based on SPE 141974 By: Jim Johnstone and...
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Transcript of 1 Twelve Steps to Engineering Safe Oil and Gas Facilities Based on SPE 141974 By: Jim Johnstone and...
1
Twelve Steps to Engineering Safe Oil and Gas Facilities
Based on SPE 141974 By: Jim Johnstone and Jim Curfew – Contek Solutions LLC
Presenter: Mike Leonard – VP of Special Projects – Contek Solutions LLC
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
2
Twelve Steps to Engineering Safe Oil and Gas Facilities
1.Set a Design Standards Policy2.Lay Out the Site for Safety3.Personnel Safety4.Design Piping Properly5.Select the Proper Pressure Vessel6.Picking the Right Tank7.Specifying Rotating Equipment for Safety8.Relief-System Design is Critical9.Determining the Right Electrical-Area Classification10.Design the Instrumentation and Control System for Safety11.Conduct a Process Hazard Analysis12.Design Verification and Commissioning
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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Get Management On Board
• Are you following the “High Road”?• Does the company have personnel with facility safety
engineering experience? • Is cost a barrier to safety?
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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1. Set a Design Standards Policy
• What Standards to Follow?• Communicate to ALL
Example Statement: “All facilities will be designed in accordance with good industry design practices and codes, and to also meet all regulatory requirements.”
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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2. Lay out the Site for Safety
• Vents, Flares, Fired Equipment, Engines, Vessels, Tanks, Offices and Control Equipment
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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Spacing Guidelines
Reference: PIP PNE 00003 “Process Units and Offsite Layout Guide
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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3. Personnel Safety• Exit Routes• Stairs• Platforms• Guarding
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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4. Design Piping Properly
• B31.3 – Process Piping• B31.4 – Liquid Pipelines• B31.8 – Gas Pipelines
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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5. Select the Proper Pressure Vessel
• ASME Section VIII Division 1
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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6. Picking the Right Tank
• Fiberglass or Steel? • Atmospheric or Low Pressure?
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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7. Specifying Rotating Equipment for Safety
• Pumps• IC Engines• Compressors• Electric Motors
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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8. Relief System Design is Critical
• Capacity
• Types
• Sizing
• System Design
• Vent or Flared
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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9. Determining the Right Electrical Area Classification
• API RP 500• NFPA 497
Vent
Division 1: 5' RDivision 2: 10' R
Separator
Division 2: 10' R
Oil Tank
Division 1: Inside of TankDivision 2: Inside of Berm
Division 2: 5' R
Wellhead
Compressor
Division 2: 10' R
Division 1
Division 2
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
16
10. Design the Instrumentation and Control System for Safety
• Levels of Protection
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
17
Safe Alarm and Control SystemsCondition Cause Effect Primary Protection Secondary Protection Location of
Safety Devices
Overpressure High inflow pressure; thermal expansion
Sudden rupture or leak PSH PSV Gas vapor section
Leak Corrosion, erosion, mechanical failure, rupture, external damage
Release of hydrocarbons to the atmosphere
PSL to shut off inflow; Check Valve to prevent backflow; LSL on an atmospheric tank or vessel
Sump/drain system; LSH on sump system
PSL in vapor section; LSL at lowest point in atmospheric tank
Liquid Overflow High liquid inflow; Upstream failure of a device; Blockage of liquid outflow
Overpressure or excess liquids in downstream devices; Release of hydrocarbons to atmosphere
LSH Sump/drain system; LSH on sump system
LSH at high point in vessel or tank
Gas Blowby Failure of liquid level system; opening of bypass
Overpressure of downstream components
LSL Safety devices on downstream component
LSL at lowest point in vessel or tank
Underpressure Withdrawal in excess of inflow; thermal contraction when blocked in
Collapse of the component; leak
Atmospheric vessels: vent; Pressurized vessels: gas makeup system
Atmospheric vessels: second vent or PSV; Pressurized vessels: PSL to shut off inflow and outflow
PSL at highest practical point; PSVs and Vents in accordance with good Eng. Practices
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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11. Conducting a Process Hazard Analysis
• Obtain Drawings• Select type of PHA • Incorporate results into final design
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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12. Design Verification and Commissioning
• Pre-Startup Safety Review (PSSR)• Site Punch List
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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Conclusions and Recommendations
Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS