NORSOK STANDARD
P-002
Edition 1, August 2014
Process system design
This NORSOK standard is developed with broad petroleum industry participation by interested parties in the
Norwegian petroleum industry and is owned by the Norwegian petroleum industry represented by the Norwegian Oil
and Gas Association and The Federation of Norwegian Industries. Please note that whilst every effort has been
made to ensure the accuracy of this NORSOK standard, neither the Norwegian Oil and Gas Association nor The
Federation of Norwegian Industries or any of their members will assume liability for any use thereof. Standards
Norway is responsible for the administration and publication of this NORSOK standard.
Standards Norway
Strandveien 18, P.O. Box 242
N-1326 Lysaker
NORWAY
Copyrights reserved
Telephone: + 47 67 83 86 00
Fax: + 47 67 83 86 01
Email: petroleum@standard.no
Website: www.standard.no/petroleum
NORSOK standard P-002
Edition 1, August 2014
Foreword
6
Introduction
6
1 Scope
7
2 Normative and informative references
2.1 Normative references
2.2 Informative references
7
7
8
3 Terms, definitions and abbreviations
3.1 Terms and definitions
3.2 Abbreviations
8
8
9
PART [I] – GENERAL PROCESS SECTION
10
4 Design pressure and temperature
4.1 General
4.2 Design pressure
4.3 Design temperature
10
10
10
11
5 General system design
5.1 Design for minimum impact of facility movement
5.2 Material selection
5.3 Maintenance and isolation
12
12
12
12
6 Safety requirements
6.1 Objectives
6.2 Safety analysis
6.3 Hazard and operability
6.4 Overpressure protection
6.5 Check valves
6.6 Piping
13
13
13
13
14
15
15
7 Line sizing criteria
7.1 General
7.2 Sizing of liquid lines
7.3 Sizing of gas lines
7.4 Sizing of gas/liquid two phase / multiphase lines
7.5 Sizing of flare and vent lines
15
15
16
18
19
20
8 General process equipment design
8.1 Horizontal separator design
8.2 Vertical separator design
8.3 Scrubber design
8.4 Atmospheric tank design
8.5 Heat exchanger design
8.6 Pig launcher/receiver design
8.7 Filters
21
21
23
23
25
25
29
29
9 Detailed requirements for system and equipment isolation
9.1 General
9.2 Physical separation
9.3 Level of isolation
9.4 Connections to flare, vents and closed drains
9.5 Operational drain, vent and flushing requirements
29
29
29
30
33
35
10
35
35
36
Insulation and heat tracing of piping and equipment
10.1 General
10.2 Heat conservation and frost protection
PART [II] – SYSTEM DESIGN SECTION
37
11
37
37
37
37
37
11.1
11.2
11.3
11.4
Topside flow lines and manifolds (system 13)
General
System design
Monitoring
Safety
NORSOK © 2014
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NORSOK standard P-002
12
12.1
12.2
12.3
12.4
12.5
13
Separation and stabilisation (system 20)
General
Pressure and level control
Test separator
Layout
Injection of chemicals
Crude handling (system 21)
13.1 General
13.2 Design requirements
13.3 Safety
14
Edition 1, August 2014
37
37
37
37
38
38
38
38
38
38
14.1
14.2
14.3
14.4
14.5
Gas compression (systems 23, 26 and 27)
General
System design
Compressors
Safety
Layout
39
39
39
39
40
40
15.1
15.2
15.3
15.4
15.5
15.6
15.7
Gas treatment (system 24)
General
Glycol contactors
Regeneration unit and storage
Wet gas inlet coolers
Safety
Layout
Environmental requirements
40
40
40
41
42
42
42
42
16.1
16.2
16.3
16.4
16.5
Gas conditioning (system 25)
General
Heat exchangers and scrubbers
Turbo expander and recompressor unit
Design pressure and temperature
Layout
42
42
43
43
43
43
17.1
17.2
17.3
17.4
17.5
17.6
17.7
Water injection (system 29)
General
Filtration
Disinfection
Deoxygenation
Pumps
Chemical injection
Monitoring
43
43
44
44
44
44
44
44
18.1
18.2
18.3
18.4
18.5
Cooling medium (system 40)
General
Filtration
System operating pressure
Expansion tank
Layout
44
44
45
45
45
45
19.1
19.2
19.3
19.4
19.5
19.6
Heating medium (system 41)
General
Pumps
Waste heat recovery units
Filter
Expansion tank
Layout
45
45
46
46
46
46
46
20.1
20.2
20.3
20.4
20.5
20.6
Chemical injection (system 42)
General
Storage tanks
Drip trays and drainage
Injection points
Safety
Maintenance
46
46
47
47
47
47
47
15
16
17
18
19
20
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NORSOK standard P-002
21
21.1
21.2
21.3
21.4
21.5
21.6
Flare and vent (system 43)
General
Knock-out drum
Thermal radiation
Flare gas recovery systems
Layout
FPSO Considerations
48
48
48
48
48
49
49
22.1
22.2
22.3
22.4
Oily water treatment (system 44)
General
Produced water treatment
Flash drum
Layout
49
49
49
50
50
22
23
Fuel gas (system 45)
23.1 General
23.2 System design
23.3 Fuel gas heating
24
24.1
24.2
24.3
24.4
25
26.1
26.2
26.3
26.4
26.5
Sea water (system 50)
General
Pumps
Filters
Prevention of marine growth
Layout
Fresh water (system 53)
27.1 General
27.2 Fresh water treatment
27.3 Maintenance
28
50
50
50
50
50
50
50
51
51
51
51
51
52
52
52
52
53
53
53
53
53
53
53
28.1
28.2
28.3
28.4
28.5
28.6
28.7
Open drain (system 56)
General
System capacity
Drain tanks
Drilling drain
Maintenance
Layout
Safety
54
54
54
54
54
54
54
55
29.1
29.2
29.3
29.4
29.5
29.6
Closed drain (system 57)
General
Closed drain flash drum
Design temperature
Reclaimed oil sump
Reclaimed oil sump pump
Safety
55
55
55
55
55
55
56
30.1
30.2
30.3
30.4
30.5
Diesel oil (system 62)
General
Storage tanks
Hose loading stations
Day tanks
Maintenance
56
56
56
56
56
56
Compressed air (system 63)
56
29
30
31
Methanol injection (system 46)
General
System design
Storage tank
Injection
Chlorination (system 47)
25.1 General
25.2 System design
25.3 Electrolysis cells
26
27
Edition 1, August 2014
NORSOK © 2014
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NORSOK standard P-002
Edition 1, August 2014
31.1
31.2
31.3
31.4
31.5
31.6
31.7
General
Dehydration
Filtration
Air receiver
Sparing
Safety
Layout
56
57
57
57
57
57
57
32.1
32.2
32.3
32.4
Inert gas (system 64)
General
System design
Sparing
Operational requirements
58
58
58
58
58
33.1
33.2
33.3
33.4
33.5
33.6
33.7
Hydraulic power (system 65)
General
Reservoir
Pumps
Filters
Accumulator capacity
Safety
Maintenance
58
58
58
59
59
59
59
59
34.1
34.2
34.3
34.4
Sewage (system 66)
General
System capacity
Operating temperature
Layout
59
59
60
60
60
32
33
34
NORSOK © 2014
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NORSOK standard P-002
Edition 1, August 2014
Foreword
The NORSOK standards are developed by the Norwegian petroleum industry to ensure adequate safety,
value adding and cost effectiveness for petroleum industry developments and operations. Furthermore,
NORSOK standards are, as far as possible, intended to replace oil company specifications and serve as
references in the authorities’ regulations.
The NORSOK standards are normally based on recognised international standards, adding the provisions
deemed necessary to fill the broad needs of the Norwegian petroleum industry. Where relevant, NORSOK
standards will be used to provide the Norwegian industry input to the international standardisation process.
Subject to development and publication of international standards, the relevant NORSOK standard will be
withdrawn.
The NORSOK standards are developed according to the consensus principle generally applicable for most
standards work and according to established procedures defined in NORSOK A-001.
The NORSOK standards are prepared and published with support by the Norwegian Oil and Gas
Association, The Federation of Norwegian Industries, Norwegian Shipowners’ Association and The
Petroleum Safety Authority Norway.
NORSOK standards are administered and published by Standards Norway.
Reprint January 2015
In the first print, shadow elements were displayed with some of the figures in Clause 9. They have been
removed. Print format was checked and some sections were numbered due to inconsistency in the first print.
No words have been changed.
Introduction
The development of this NORSOK standard is primarily based on proven technology, but it does not
preclude the use of new technology. The system design sections are based on the most frequently used
systems, but this does not imply that alternatives may not be used (for example dehydration by use of glycol
is covered, but not the use of molecular sieves or other means).
The following changes have been made to this NORSOK standard:
x
x
x
x
x
x
x
P-001 and P-100 have been combined into a single document to improve accessibility and remove
redundancy.
Content has been simplified and some superfluous text has been deleted.
The document has been updated to reflect current industry practice and relevant international standards.
In clause 21.2, the sizing of knock out drum with respect to liquid accumulation, has been made more
consistent with international standards. The use of instrumented protection functions to allow for reduced
liquid accumulation capacity requires more stringent documentation.
API Std 521, sixth edition issued January 2014 covers acoustic fatigue in piping, sizing of flare knock-out
drums, choke valve failure, water hammer and allowance for non-return valves in some depth, so these
sections have been removed or edited.
ISO 23251 and ISO 28300 have been classed as Informative in this document as they are similar to
API Std 521 and API Std 2000, which have been recently updated and better reflect current thinking.
For HAZOP studies, the recommendation to use full reporting has been removed. This is seen as being
up to the individual company’s standards.
The system numbers used in this NORSOK standard are those defined in NORSOK Z-DP-002.
NORSOK © 2014
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NORSOK standard P-002
1
Edition 1, August 2014
Scope
This NORSOK standard provides requirements for the following aspects of topside process piping and
equipment design on offshore production facilities:
x
x
x
x
x
design pressure and temperature;
safety instrumented secondary pressure protection systems;
line sizing;
system and equipment isolation;
insulation and heat tracing.
These criteria are applicable for all processes, process support and utility systems.
Additionally this NORSOK standard defines the minimum functional requirements for process systems on an
offshore installation. The standard includes a number of recommendations to give additional guidance for the
system design.
2
Normative and informative references
The following standards include provisions and guidelines which, through reference in this text, constitute
provisions and guidelines of this NORSOK standard. Latest issue of the references shall be used unless
otherwise agreed. Other recognized standards may be used provided it can be shown that they meet the
requirements of the referenced standards.
2.1
Normative references
API 2000,
API RP 14C
API RP 17O
API Std 520
API Std 521
API Std 537
BS MA-18
DNV-OS-E201
EN 1473
FOR-1994-02-10-123,
IEC 61508,
IEC 61882
IEC 61511 (All parts)
ISO 4126
ISO 10418 (All parts)
ISO 12241
ISO 13628-6
ISO 13702
ISO 13703
ISO 25457
Venting Atmospheric and Low-pressure Storage Tanks
Analysis, Design, Installation and Testing of Basic Surface Safety Systems on
Offshore Production Platforms
Recommended Practice for Subsea High Integrity Pressure Protection Systems
Sizing, Selection and Installation of Pressure-relieving Devices in Refineries
Pressure-relieving and Depressuring Systems
Flare Details for General Refinery and Petrochemical Service, Second Edition
Salt water piping systems in ships
Oil and Gas Processing Systems
Installation and equipment for liquefied natural gas – Design of onshore
installations
Norwegian Maritime Directorate (NMD): Forskrift for flyttbare innretninger med
produksjonstekniske installasjoner og utstyr
Functional safety of electrical/electronic/programmable electronic safety related
systems
Hazard and operability studies (HAZOP studies) – Application guide
Functional safety – Safety instrumented systems for the process industry sector
Safety devices for protection against excessive pressure
Petroleum and natural gas industries – Offshore production installations – Basic
surface process safety systems
Thermal insulation for building equipment and industrial installations – Calculation
rules
Petroleum and natural gas industries – Design and operation of subsea production
systems – Part 6: Subsea production control systems
Petroleum and natural gas industries – Control and migration of fires and
explosions on offshore production installations – Requirements and guidelines.
Petroleum and natural gas industries – Design and installation of piping systems on
offshore production platforms
Petroleum, petrochemical and natural gas industries – Flare details for general
refinery and petrochemical service.
NOTE This standard is similar to API Std 537.
NORSOK I-104
NORSOK I-105
NORSOK M-001
NORSOK R-001
NORSOK R-004
NORSOK © 2014
Fiscal measurement system for hydrocarbon gas
Fiscal measurement systems for hydrocarbon liquid
Materials selection
Mechanical equipment
Piping and equipment insulation
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