Twelve Steps to Engineering Safe Oil and Gas Facilities

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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
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• Twelve Steps to Engineering Safe Oil and Gas
  Facilities
• Set a Design Standards Policy
• Lay Out the Site for Safety
• Personnel Safety
• Design Piping Properly
• Select the Proper Pressure Vessel
• Picking the Right Tank
• Specifying Rotating Equipment for Safety
• Relief-System Design is Critical
• Determining the Right Electrical-Area
  Classification
• Design the Instrumentation and Control System for
  Safety
• Conduct a Process Hazard Analysis
• Design Verification and Commissioning

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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?

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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.
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2. Lay out the Site for Safety

• Vents, Flares, Fired Equipment, Engines, Vessels,
  Tanks, Offices and Control Equipment

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Spacing Guidelines
Reference PIP PNE 00003 Process Units and
Offsite Layout Guide
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3. Personnel Safety

• Exit Routes
• Stairs
• Platforms
• Guarding

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4. Design Piping Properly

• B31.3 Process Piping
• B31.4 Liquid Pipelines
• B31.8 Gas Pipelines

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5. Select the Proper Pressure Vessel

• ASME Section VIII Division 1

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6. Picking the Right Tank

• Fiberglass or Steel?
• Atmospheric or Low Pressure?

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7. Specifying Rotating Equipment for Safety

• Pumps
• IC Engines
• Compressors
• Electric Motors

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8. Relief System Design is Critical

• Capacity
• Types
• Sizing
• System Design
• Vent or Flared

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9. Determining the Right Electrical Area
Classification

• API RP 500
• NFPA 497

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10. Design the Instrumentation and Control System
for Safety

• Levels of Protection

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Safe Alarm and Control Systems
Condition 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
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11. Conducting a Process Hazard Analysis

• Obtain Drawings
• Select type of PHA
• Incorporate results into final design

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12. Design Verification and Commissioning

• Pre-Startup Safety Review (PSSR)
• Site Punch List

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Conclusions and Recommendations
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Questions?