Professional Documents
Culture Documents
A Systems Approach To Offshore Facility Design PDF
A Systems Approach To Offshore Facility Design PDF
K.E. Arnold*
ABSTRACT
The "typical facility1'concept employed by Shell Oil is described
and the guidelines included in the system design are discussed. While the
process concepts of an offshore facility are relatively simple, the space
restrictions of an offshore platform require that consideration be given
to the interdependent nature of the various components to assure safety.
This is best accomplished by establishing procedures and guidelines for
design and analyzing in detail a lltypicalfacility" which is used as the
basis for all new facility designs.
INTRODUCTION
In orfer to minimize the effort involved in assuring an adequate
system analysis which would consider the interaction between the various
components, Shell in 1967 designed a standard oil treating facility. The
same basic detailed flowsheet and system analysis was used for six almost
identical facilities. The basic flow scheme and philosophy of design of
the standard facilities have been proven sound. However, experience indicated
several areas where improvements could be made to the concept of a standard
facility and in 1971 work was begun on developing the typical facility concept described herein.
DISCUSSION
PROCESS
now
The f i r s t s t e p i n e s t a b l i s h i n g a t y p i c a l f a c i l i t y is t o design
process flowsheete such a s those shown i n Figures 1 and 2. These port r a y t h e b a s i c interdependence of t h e v a r i o u s equipment components. Spaces
a r e provided f o r t h e p r o j e c t engineer t o f i l l i n t h e design parameters . ( e . g.
flow r a t e s , g r a v i t i e s , temperatures) t h a t a r e needed t o s i z e t h e equipment.
B a s i c a l l y , t h e process flow chosen f o r t h e S h e l l t y p i c a l f a c i l i t y can be
described a s follows:
2.
O i l Dehydration and S
3.
5.
6.
a.
Normal f l a s h gas.
b.
c.
F a i l u r e of t h e b l a n k e t gas r e g u l a t o r i n t h e open p o s i t i o n .
d.
3.
4.
E l e v a t i o n d i f f e r e n c e s i n t h e v e n t and r e l i e f headers t o a s s u r e l i q u i d s
(The c o n f i g u r a t i o n and l e n g t h of t h e headers is
needed t o adequately s i z e them).
w i l l n o t accumulate.
5.
6.
E l e c t r i c a l c l a s s i f i c a t i o n a r e a s must be considered.
1. General F a i l u r e of a Control
The most important s i n g l e concept i s t o assume t h a t each back p r e s s u r e
o r dump v a l v e w i l l e i t h e r f a i l open o r c l o s e d , and t o determine t h e
p o s s i b l e consequences. I f an unsafe c o n d i t i o n could p o s s i b l y develop
from such a f a i l u r e , i t i s r e q u i r e d t h a t a t l e a s t one s h u t - i n s e n s o r
(e.g., high l e v e l shutdown, h i g h p r e s s u r e shutdoyn) should b e a c t i v a t e d
and c o n t r o l t h e process. F u r t h e r , i n t h e a n a l y s i s i t is assumed t h a t t h i s
device w i l l a l s o f a i l and a backup device, which is more r e l i a b l e than a
shut-in s e n s o r , such as a r e l i e f v a l v e o r f l a r e s c r u b b e r , w i l l b e capable
of s a f e l y handling t h e f a i l e d c o n d i t i o n . For example, i n Figure 8 assume
t h e dump v a l v e on t h e high p r e s s u r e (HP) s e p a r a t o r f a i l s open. This would
cause t h e l e v e l t o drop and e v e n t u a l l y gas would flow through t h i s l i n e t o
t h e i n t e r m e d i a t e p r e s s u r e (IP) s e p a r a t o r . I f t h i s causes t o o g r e a t a
p r e s s u r e s u r g e i n t h e IP s e p a r a t o r , i t w i l l a c t i v a t e t h e h i g h p r e s s u r e
shutdown (HPSD). F u r t h e r , assume t h e HPSD f a i l s . I n t h i s c a s e t h e
r e l i e f v a l v e must be designed t o handle t h i s flow ( i . e . , HP ao w e l l as
IP g a s ) .
2.
Pipe P r e s s u r e R a t i n g
Using t h e above technique, shutdown s e n s o r s , r e l i e f v a l v e s , e t c . , a r e
added t o t h e mechanical flowsheets t o p r o t e c t a g a i n s t c o n t r o l v a l v e
f a i l u r e s . P r o t e c t i o n a g a i n s t improper opening o r c l o s i n g of a v a l v e
is obtained by a v i s u a l p r e s s u r e r a t i n g check. That i s , s t a r t i n g w i t h
t h e h i g h e s t p r e s s u r e system, any v a l v e which could i s o l a t e t h e p r e s s u r e
3.
Hazard I s o l a t i o n
A review of t h e mechanical flowsheets should trssure t h a t a p o t e n t i a l
hazard can be i s o l a t e d . For t h e most p a r t thjls i s accomplished by t h e
i s o l a t i n g v a l v e s provided around c o n t r o l and check v a l v e s t o allow
proper maintenance. However, t h e flowsheets crnd l a y o u t should be
checked t o a s s u r e t h a t a l l process v e s s e l s car1 indeed be i s o l a t e d and
t h a t t h e d i s t a n c e between t h e v e s s e l and i t s i s o l a t i n g v a l v e s i s n o t
too g r e a t .
4.
Leak Detection
Perhaps t h e most d i f f i c u l t hazard t o d e t e c t a u t o m a t i c a l l y i s a s m a l l
l e a k . P r o t e c t i o n i s provided t o some e x t e n t t ~ ylow p r e s s u r e and low
l e v e l shutdown s e n s o r s on v e s s e l s . Most l e a k s which occur i n a c t u a l
process w i l l be too small t o be d e t e c t e d . The number of l e a k s can be
minimized by using a p p r o p r i a t e p i p i n g and vess:el design codes, s p e c i f y i n g adequate s e a l s f o r pumps, u s i n g t e e s i n s t e a d of e l l s i n p i p i n g where
e r o s i o n may be a problem, e t c . However, i t must s t i l l be assumed t h a t
l e a k s w i l l develop which w i l l n o t be immediate!ly d e t e c t e d .
The process a r e a s of a Gulf of Mexico offshore: p l a t f o r m a r e w e l l v e n t i l a t e d and hydrocarbon vapors a r e r a p i d l y diepersed. I n a d d i t i o n , t h e
following a r e included i n t h e t y p i c a l f a c i l i t y concept ' t o minimize
t h e hazard:
a,
b.
Carefully defined e l e c t r i c a l c l a s s i f i c a t i o n s .
Gas d e t e c t o r s i n i n a d e q u a t e l y v e n t i l a t e d a r e a s .
,d.
Adequately i n s u l a t e d e x h a u s t s t a c k s , h e a t medium p i p i n g , e t c .
e.
Fusible plug f i r e d e t e c t o r s .
f.
No open flames a r e p e r m i t t e d on t h e p r o c e s s p l a t f o r m s ,
'
TABLE I
FACILITIES ENGINEERING GUIDELINES AND DESIGN PROCEDURES
SHELL OIL COMPANY - SOUTHERN E&P REGION - OFFSHORE DIVISION
I
SUBJECT
" .
COMPRESSION
CORROSION PREVENTION
DRAIN SYSTEMS AND SUMPS
ELECTRIC POWER GENERATION
ELECTRIFICATION
- GENERAL
TABLE
- I1
-GUIDELINES FOR-IGN
OF PLATFORM
P.IPING SYSTEMS
SCOPE
CODE COMPLIANCE
P I P E SELECTION
SIZING CRITERIA
P I P E WALL THICKNESSES
JOINT CONNECTIONS
VALVE SELECT1 ON
VALVE SIZING
VALVE PRESSURE AND TEMPERATURE RATINGS
VALVE MATE RIALS
FITTINGS AND FLANGES
GASKETS, BOLTS AND NUTS
rc
Q)
d 1
garcP
Q)
Q)
Q)
u P
a
rl
-. .
TI .
't'
--.
-I .
I
~
.
., .
-..,
I,.
.,
.<::
2) <
C'..
V)
13
.,*
c.
Tr
s.2
lIi.,
.
i...
2'
rbL'
..,8
...
i 3 i
.i
L'
(.:
-.
_. .
a .s.:
a-
'
.-
.-
..
- ,.
.I...
A
.'
c:\
-,
-,
:..-.
,, ;
L
_
--
..,J
C I
w-
,/
>.
'5'
'.
.- 9 <-::,
20
CJ
,>.
-.\
-,A
m
.
in
..
b
4
.
3,
-a
72
.-$d
.;b
?-
..G
a*';
%..;
mz- ;.
V);P
:<..
t*
:a1
-x
1, d
-13
'
. .--$--.r ^ S .
'-2
,
I
-!A
.>Q
,. .,
:,..
:*
i.4
p.
:;
-..
w; >
3,-:! ,,L;
Ch
b.
-..
>
a
><Q
CU
->
w%
>LT-' S$,
4k.i
22
'A:
Y,".~
'ri
'Z
{I?
>
,: '6I
s
:?
b.1-
&W
XV)
* c6
if\ :.,
*I
. a
--
7-
P
.
a.2
L-
Lu
3
..L
".
.f
<
$L",
..*
..-.
.: 2
.-
.,
db
:'y:
,A
-+,2
1-
:c
iP-'
_D
",
: 9,
A?
FROM LOW
PRESSURE
MANIFOLD
FROM HlGH
PRESSURE
MANIFOLD
HP
SEP
11.0
--A
L0 -*J
FWKO
'T
SET @
2 0I0 psi
TO RELIEF
HEADER
FIGURE 9
ANSI
ANSI 150
ANSI 6 0 0
TO RELIEF HEADER
PRESSURE R A T I N G
PIPE