Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
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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Contek Solutions LLC
ENGINEERING • ENVIRONMENT • SAFETY • MANAGEMENT SYSTEMS
Twelve Steps to Engineering Safe Oil and
Gas Facilities
1.
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3.
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12.
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
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•
•
•
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
Oil Tank
Vent
Wellhead
Division 2: 5' R
Separator
Division 1: Inside of Tank
Division 2: Inside of Berm
Division 1: 5' R
Division 2: 10' R
Compressor
Division 2: 10' R
Division 1
Division 2
Division 2: 10' R
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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?
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