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.

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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

Contek Solutions LLC

ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS

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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



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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

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



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10. Design the Instrumentation and Control System for Safety

• Levels of Protection



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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



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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?



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.

Documents

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