OFFSHORE PROCESS DESIGN (PROJECT STANDARDS AND …

1 KLM TechnologyGroupProject :1of28 Rev: 01 April2011 KLM Technology Group#03-12 Block Aronia,Jalan Sri Perkasa 2 Taman Tampoi Utama81200 Johor BahruMalaysiaOFFSHOREPROCESS DESIGN (PROJECT STANDARDS AND SPECIFICATIONS)TABLE OF CONTENTSCOPE2 REFERENCES2 DEFINITIONS AND TERMINOLOGY3 SYMBOLS AND ABBREVIATIONS4 DESIGN PRESSURE AND TEMPERATURE4 General4 DESIGN Pressure4 DESIGN Temperature6 safety INSTRUMENTED SECONDARY PRESSURE PROTECTION SYSTEMS8 General8 Testing9 LINE SIZING CRITERIA10 General10 Sizing of liquid lines11 Sizing of Gas Lines14 Sizing of Gas/Liquid Two-/Multiphase Lines15 Sizing of Flare and Vent Lines16 DETAILED REQUIREMENTS FOR SYSTEMS AND EQUIPMENT18 System and Equipment Isolation18 Connections to Flare, Vents and Closed Drains20 INSULATION AND HEAT TRACING OF PIPING AND EQUIPMENT21 General21 Heat Conservation and Frost Protection21 APPENDIX A23 KLM TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page2of28 Rev.

2 01 April2011 SCOPEThis Project Standard and Specificationprovides requirements for the followingaspects of topside PROCESS piping and equipment DESIGN on OFFSHORE productionfacilities:- DESIGN pressure and temperature;- safety instrumented secondary pressure protection systems;-line sizing;-system and equipment isolation;-insulation and heat criteria are applicable for all processes, PROCESS support and this Standard the following dated and undated STANDARDS /codes arereferred to. These referenced documents shall, to the extent specified herein,form a part of this standard. For dated references, the edition cited applies. Theapplicability of changes in dated references that occur after the cited date shallbe mutually agreed upon by the Company and the Vendor. For undatedreferences, the latest edition of the referenced documents (including anysupplements and amendments) (American Petroleum Institute)API RP 14 CAnalysis, DESIGN , Installation and Testing of Basic SurfaceSafety Systems on OFFSHORE Production PlatformsAPI RP 520 Sizing, Selection and Installation of Pressure-RelievingSystems in RefineriesAPI RP 521 GuideforPressure-RelievingandDepressurin gSystemsBS MA-18, Salt water piping systems in shipsAPI Std 2000 Venting Atmospheric and Low-Pressure Storage (International Electro Technical Commission)

3 IEC 61508 Functional safety of electrical/electronic/programmableelectr onic safety related systemsIEC 61511 Functional safety safety instrumented systems for theprocess industry sectorOLF GL 070 Recommended guidelines for the application of IEC 61508and IEC 61511 KLM TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page3of28 Rev: (International Organization for Standardization)ISO 10418 Petroleum and Natural Gas Industries OffshoreProduction Installations Basic Surface PROCESS SafetySystemsISO 13703 Petroleum and natural gas industries DESIGN andinstallation of piping system on OFFSHORE productionplatformsDEFINITIONS AND TERMINOLOGYD esign pressure-pressure, together with the DESIGN temperature, used todetermine the minimum permissible thickness or physical characteristic of eachcomponent as determined by the DESIGN rules of the pressure DESIGN : The DESIGN pressure is selected by the user to provide a suitable marginabove the most severe pressure expected during normal operation operating pressure-maximum pressure including plant operation atunstable.

4 Unstable conditions include start-up/shutdown, control requirements andprocess operating temperature-maximumtemperature including plantoperation at unstable : Unstable conditions include start-up/shutdown, control requirements andprocess operating temperature-minimum temperature including plantoperation at unstable : Unstable conditions include start-up, shutdown and pressure-pressure during normal operation, including temperature-temperature during normal operation, including out pressure-pressure equilibrium after a compressor pressure-pressure for pumps and compressors determined by thecurves for a no flow situation, blocked TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page4of28 Rev: 01 April2011 SYMBOLSANDABBREVIATIONSSYMBOL/ABBREVIATI ONDESCRIPTIONCS carbon steelFBfull boreGRPglass fibre reinforced polyesterIDinternal diameterLOlocked openNPSHnet positive suction headPSVpressure safety valveSSstainless steelDESIGN PRESSURE AND TEMPERATUREG eneralWhere pressure relief devices are used, set points for these shall be inaccordance with the DESIGN code applied for the components in the DESIGN pressureFor systems protected by a PSV, the criteria in Table 1 shall be appliedunless the PSV manufacturer guarantees that use of other margins isacceptable.

5 The minimum margin is defined to avoid unintentional PSVopening. The relation between high trip pressure and maximum operatingpressure is given in Figure 1-Pressure relationsKLM TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page5of28 Rev: 01 April2011 Table1- DESIGN pressure criteria for pressurised systemsHigh trip pressure 1),2)bargMinimum margin between high trip pressure1),2) and PSV set pressurebar0 to 353,5over 3510 % of PSV set pressureNote:1)For systems without a high pressure trip, the minimum margin shall beapplied between the maximum operating pressure and the PSV )Maximum operating pressure for compressor suction scrubbers andcoolers shall be the maximum settle-out pressure, calculated fromcoincident high trip pressures on both suction and discharge sides of thecompressor, and the minimum margin shall be applied between themaximum operating pressure and the PSV set rupture disks are applied, sufficient margin shall be included to-prevent unintentional disk ruptures, margin between the disk setpressure and the operating pressure,-ensure system pressure protection, margin between the disk setpressure and the maximum accumulated is made to relevant pressure relieving DESIGN codes for accurate information is unavailable, the shut-in pressure for centrifugalcompressors should be determined as the maximum operating suctionpressure +1.

6 3 times the normal differential pressure developed by thecompressor, to include for pressure rise at surge condition and maximumspeed. The maximum operating suction pressure for a compressor shall inthis case be determined by the high trip pressure from upstream separatorsor accurate information isunavailable, the maximum operating pressure(shut-in pressure) for centrifugal pumps should be determined as the suctionpressure at relieving conditions +1,25 times the normal differential pressuredeveloped by the should be taken not to define higher DESIGN pressure than requiredwhen it affects the selection of material and pressure class minimise the requirements for PROCESS relief (full flow) the DESIGN pressureshould be kept identical for systems with almost identical piping, occasional variations in the pressure above the DESIGN pressure ispermissible in some DESIGN codes.

7 This shall be subject to due considerationof all aspects in the relevant piping DESIGN code. If such variations areKLM TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page6of28 Rev: 01 April2011permitted by the project owner, the duration and extent of overpressure thatthe piping is subjected to, shall be logged. Logging is not considered requiredwhen it is evident that overpressure will not occur more frequently thanallowed by the piping shall as a minimum be designed to be liquid filled to thehighest point of the overflow line, and with an overpressure of 0,07 bar. If theoverflow line can be blocked or have reversed flow ( during loading) theatmospheric tank shall be designedfor a liquid filled vent line up to the gooseneck. Reference is made to API Std 2000 for further flare knock out drums, it is acceptable that the DESIGN pressure is equal tothe maximum operating pressure.

8 A safety margin shall be added tothemaximum operating pressure in the DESIGN phase to account for increase dueto uncertainties in the calculations. When accurate information is unavailable,Table 1 shall be used to set the safety DESIGN pressureFor equipment where cooling or condensing vapours ( after steam-out ofvessels), drainage or pump out may lead to less than atmospheric pressure,the equipment shall be designed for full vacuum or protected by vacuumrelief. Reference is made to API RP 521 for further DESIGN the maximum operating temperature can be determinedaccurately, this temperature should be used as maximum designtemperature, without adding a safety margin. As an example, this canapply to the use of reservoir temperature as maximum DESIGN temperaturefor platform inlet the maximum operating temperature can not be calculatedaccurately, the maximum DESIGN temperature should be determined byadding 30 C to the operating temperature.

9 For equipment operating atambient conditions, the maximum DESIGN temperature should be 50 C forthe North high temperature shut down function, in accordance with ISO 10418 orAPI RP 14C, can limit the maximum operating temperature. A marginshould be included to determine the DESIGN should be taken not to define higher DESIGN temperature thanrequired when it affects the selection of material and pressure class and instruments subject to steam-out shall bedesigned fortemperature during steam-out TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page7of28 Rev: water systemsFor sea water supply systems a maximum DESIGN temperature less than50 C can be accepted if documented by seawater return systems the maximum operating temperature shall becalculated at the minimum seawater flow. Minimum seawater flow iscalculated at lowest seawater supply temperature and heat exchangerwithout systemsThe maximum operating temperature on a compressor discharge shall bedetermined as follows:-when a compressor curve is not available: as 15 C above thepredicted DESIGN point temperature to allow for lower efficiency andhigher pressure ratio at compressor surge conditions;-when compressor curves are available: as the temperature at surgeconditions and maximum compressor speed for normal and start following shall be used to determine the maximum designtemperature:-add 15 C to the maximum operating temperature to allow for marginsin the compressor curves, and for wear and tear giving lower efficiencyover time.

10 -add 10 C as an additional suction scrubberCompressor suction scrubber maximum DESIGN temperatures shall be thehigher of the following:-maximum operating temperature at the compressor suction in theevent of cooling medium failure, the maximum operating temperaturecan be limited by a high temperature shutdown function on thecompressor suction or discharge;-maximum recycle temperature (maximum discharge (temperature trip)minus temperaturedrop across anti-surge valve) in the event ofcooling medium failure;-maximum temperature due to settle out conditions;-operating temperature plus a margin as defined exchangersFor all heat exchangers, both sides shall have the same maximum designtemperature determined by the hottest of the fluids on either side. Forupset conditions, overpressure of connected piping at resulting upsettemperature may be acceptable if permitted by relevant piping TechnologyGroupProject Engineering StandardOFFSHOREPROCESS DESIGN (PROJECT STANDARDS ANDSPECIFICATIONS)Page8of28 Rev: DESIGN temperatureThe minimum DESIGN temperature determines the requirements to the lowtemperature characteristics of the material, and shall be the more stringent ofthe operating temperature (obtained during normal operation, start-up, shutdown or PROCESS upsets) with a margin of 5 C; ambient temperature, the lowest temperature should be basedon available weather data, and safety factors should be selected based onthe quality of such weather data.