Engineering Safe Oil and Gas Facilities

*Twelve Steps to Engineering Safe Oil and Gas FacilitiesBased on SPE 141974 By: Jim Johnstone and Jim Curfew Contek Solutions LLC Presenter: Mike Leonard VP of Special Projects Contek Solutions LLC

*Twelve Steps to Engineering Safe Oil and Gas Facilities

Set a Design Standards PolicyLay Out the Site for SafetyPersonnel SafetyDesign Piping ProperlySelect the Proper Pressure VesselPicking the Right TankSpecifying Rotating Equipment for SafetyRelief-System Design is CriticalDetermining the Right Electrical-Area ClassificationDesign the Instrumentation and Control System for SafetyConduct a Process Hazard AnalysisDesign Verification and Commissioning

*Get Management On BoardAre you following the High Road?Does the company have personnel with facility safety engineering experience? Is cost a barrier to safety?

*1. Set a Design Standards PolicyWhat 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.

*2. Lay out the Site for SafetyVents, Flares, Fired Equipment, Engines, Vessels, Tanks, Offices and Control Equipment

*Spacing GuidelinesReference: PIP PNE 00003 Process Units and Offsite Layout Guide

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*3. Personnel SafetyExit RoutesStairsPlatformsGuarding

*4. Design Piping ProperlyB31.3 Process PipingB31.4 Liquid PipelinesB31.8 Gas Pipelines

*5. Select the Proper Pressure VesselASME Section VIII Division 1

*6. Picking the Right TankFiberglass or Steel? Atmospheric or Low Pressure?

*7. Specifying Rotating Equipment for SafetyPumpsIC EnginesCompressorsElectric Motors

*8. Relief System Design is Critical Capacity Types Sizing System Design Vent or Flared

*9. Determining the Right Electrical Area Classification

API RP 500NFPA 497

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*10. Design the Instrumentation and Control System for Safety Levels of Protection

*Safe Alarm and Control Systems

ConditionCauseEffectPrimary ProtectionSecondary ProtectionLocation of Safety DevicesOverpressure High inflow pressure; thermal expansionSudden rupture or leakPSHPSV Gas vapor sectionLeak Corrosion, erosion, mechanical failure, rupture, external damageRelease of hydrocarbons to the atmospherePSL to shut off inflow; Check Valve to prevent backflow; LSL on an atmospheric tank or vesselSump/drain system; LSH on sump system PSL in vapor section; LSL at lowest point in atmospheric tankLiquid Overflow High liquid inflow; Upstream failure of a device; Blockage of liquid outflowOverpressure or excess liquids in downstream devices; Release of hydrocarbons to atmosphereLSHSump/drain system; LSH on sump systemLSH at high point in vessel or tankGas BlowbyFailure of liquid level system; opening of bypassOverpressure of downstream componentsLSLSafety devices on downstream componentLSL at lowest point in vessel or tankUnderpressureWithdrawal in excess of inflow; thermal contraction when blocked inCollapse of the component; leakAtmospheric vessels: vent; Pressurized vessels: gas makeup systemAtmospheric vessels: second vent or PSV; Pressurized vessels: PSL to shut off inflow and outflowPSL at highest practical point; PSVs and Vents in accordance with good Eng. Practices

*11. Conducting a Process Hazard AnalysisObtain DrawingsSelect type of PHA Incorporate results into final design

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*12. Design Verification and CommissioningPre-Startup Safety Review (PSSR)Site Punch List

*Conclusions and Recommendations

*Questions?