OSE571 Ocean Plant Design

Safety design and API RP 14C

Daejun CHANG (djchang@kaist.edu)

Division of Ocean System Engineering

Korea Advanced Institute of

Science and Technology

Design Procedure and Key deliverables

Concept Consolidation
Production Availability

Design Basis (Philosophy)

System Description
Process Flow Diagram

Equipment Specification

Process Simulation

Equipment Design

Process Operation and

Control Philosophy
P&ID
Layout
Safety Studies

Risk Assessment
HAZOP
Caution: Not universally applicable
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Ocean Systems Engineering

Hazards and Safety Systems

Emergency Response
(Escape Route, TR, Evacuation Means,
Rescue Equipment, Emergency Power)
Accident Mitigating Protection
(Active/Passive Fire Protection, Fire/Blast Walls)

Accident:
Fire/Explosion

Accident Controlling Protection

(F&G Detection, ESD, Depressurization, Alarm)

Potential Accident:
Gas Leak

Preventive Protection
(Structural & Machinery Integrity, Relief, PSV)
Basic Process Control
(P, T, F, Surge, Back Pressure)
Inherent Safety Design
(Layout, Inventory, Leak, Ignition)

Layered Structure of Safety Systems against Fire and Explosion

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Workflow for Process Control

System Description (W4)
Process Operation and Control Philosophy (W9)

P&ID (W11)
Functional Design Specification (W11)
Logic Diagram
Field Implementation
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API RP 14C

Not restricted to platform topside design.

Topside design for floating installations (FPSO, FSRU, FLNG) conforms to this.

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API RP 14C

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1.2 SCOPE
This document presents recommendations for designing, installing,
and testing a basic surface safety system on an offshore
production platform.

This recommended practice illustrates how system analysis

methods can be used to determine safety requirements to protect
any process component.

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Overview of Safety Systems

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2. SAFETY DEVICE SYMBOLS

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Safety Device Symbols

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3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN

3.1 PURPOSE AND OBJECTIVES

The technical content of this recommended practice establishes a
firm basis for designing documenting a production platform safety
system for a process composed of components and systems
normally used offshore.
Moreover, it establishes guidelines for analyzing components or
systems that are new or significantly different from those covered in
this document.

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3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN

3.2 SAFETY FLOW CHART

Hazards, their propagation, and intervention of safety devices
Overall objectives
1.
2.
3.
4.
5.
6.

Prevent a release of hydrocarbons

Shut in the process to stop the flow of hydrocarbons to a leak
Treat hydrocarbon escaping from the process.
Prevent ignition
Shut in the process in the event of a fire.
Prevent undesirable events causing the additional release

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3. INTRODUCTION TO SAFETY ANALYSIS AND SYSTEM DESIGN

3.4 PREMISES FOR BASIC ANALYSIS AND DESIGN
a. Accordance with good engineering practices
b. Two levels of protection
c. Activation order of the two: primary and secondary
d. Proven systems analysis techniques to determine the minimum
safety requirements for a process component.
e. All process equipment and functions are incorporated into the
safety system.
f. Safe components + logical integration the entire facility will be
protected.
g. The analysis procedure should provide a standard method to
develop a safety system and provide supporting documentation.

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4. PROTECTION CONCEPTS AND SAFETY ANALYSIS

4.2.1 Undesirable Events
4.2.1.1 Overpressure
4.2.1.2 Leak

Protection Concept

4.2.1.3 Liquid Overflow 1.

Cause

2.

Effect and Detectable Abnormal Condition

3.

Primary Protection

4.

Secondary Protection

4.2.1.4 Gas Blowby: gas flow through the liquid line

4.2.1.5 Under Pressure

4.2.1.6 Excess Temperature

5. Location of Safety Devices
4.2.1.7 Direct Ignition Sources
4.2.1.8 Excess Combustible Vapors in the Firing Chambers

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4. PROTECTION CONCEPTS AND SAFETY ANALYSIS

Example: Undesirable Events - Overpressure
Cause
- Inlet: input source, overflow, gas blow-by
- Outlet: flow rate control failure, restrictions, blockage
- Body: thermal expansion
Effect
- High pressure
- Hydrocarbons leak
- Rupture
Protection 1: PSH - inflow, heat, fuel shut off
Protection 2: PSV
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4. PROTECTION CONCEPTS AND SAFETY ANALYSIS

4.3 SAFETY ANALYSIS

Analyzing the process and establishing design criteria for an
integrated safety system covering the entire platform process

SAT: Safety Analysis Table

SFC: Safety Analysis Checklist

SAFE: Safety Analysis Function Evaluation Chart

Completion of the SAFE chart provides a means of verifying the

design logic of the basic safety system.
Implemented into the shutdown logic (Cause and Effect Chart)

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Shutdown Logic

Level 1 APS Abandon platform

Level 2 ESD I Emergency shutdown (total)
Level 3 ESD II Emergency shutdown (partial)
Level 4 PSD Process shutdown (total)
Level 5 PSD Process shutdown (partial)

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Input
APS

Manual
Gas detection
Non hazardous area

Shut DHSV
Auto Depressurisation
Timer-based disconnection
Fire&gas detection
PA, ESD/PSD, radio
Emergency generator/UPS

ESD I
Manual

Standardizing

Fire&gas detection
Hazardous area
Tube rupture
in cooler
ESD II
Manual
High lev flare k.o drum
Low pressure
Instrument air
Low pressure
hydraulic system
PSD
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Disconnection
Main generator
Non-critical non-EX
equipment
Start Emergency generator

Activation of
DHSV (fire in riser
/ well area)
Riser ESDV
Depressurisation
Shut fuel gas supply
Ocean Systems Engineering

Recommended Safety Devices

A.1 Wellheads and Flow Lines

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Safety Analysis Table (SAT)

A.1 Wellheads and Flow Lines
Undesirable
Event

Cause

Detectable Abnormal
Condition at Component

Overpressure Blocked or restricted line

Downstream choke plugged
Hydrate plug
Upstream flow control failure
Changing well conditions
Closed outlet valve
Leak

Deterioration
Erosion
Corrosion
Impact damage
Vibration

High pressure

Low pressure

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Safety Analysis Checklist (SAC)

A.1 Wellheads and Flow Lines
a. High Pressure Sensor (PSH)
1. PSH installed.
2. Flow line segment has a maximum allowable working pressure greater than maximum
shut in pressure and is protected by a PSH on a downstream flow line segment.
b. Low Pressure Sensor (PSL)
1. PSL installed.
2. Flow line segment is between the well and the first choking device and is less than 10
feet(3m) in length or in the case of an underwater installation, reasonably close to that
distance.
c. Pressure Safety Valve (PSV)
1. PSV installed.
2. . . .
d. Flow Safety Valve (FSV)
1. FSV installed.
2. . . ..

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More Examples in Appendix A

Wellheads and Flow lines

Wellhead Injection line
Header
Pressure vessel
Atmospheric vessel
Fired and Exhaust heated component
Pump
Compressor
Pipeline
Heat exchanger(Shell-Tube)

Check the examples before drawing your P&ID

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Safety Analysis Function Evaluation Chart (SAFE)

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Cause and Effect Chart

Effect
Cause

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