OSE571 Ocean Plant Design

Safety Design Philosophy

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
-1- 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:
Preventive Protection Gas Leak
(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

-2- Ocean Systems Engineering
 Principles of Safety Design

Ø Segmentation

Ø Depressurization (Blowdown)

Ø Pressure Protection

Ø Preventive Measures

Ø Mitigating Measures

Ø Shutdown Logic

-3- Ocean Systems Engineering

 Segmentation

Ø What if there is a leak?

§ All the inventory (gas) will get out of the process!

§ Segmentation

- Divide the whole plant into several segments

(Divide and defeat!)

- Boundary of the segments: block valves

- The valves are closed if there is a leak.

è The inventory within the segment will get out.

-4- Ocean Systems Engineering

 Depressurization (Blowdown
(Blowdown))

Ø Do we have to wait until all the inventory gets out.

§ Venting of the inventory into a safe area. How?

§ Depressurization (Blowdown)

- Install a vent line from each segment.

- The vent line is normally blocked by blowdown valves.

- In case of fire, the valve is open to guide the inventory to the

flare stack.

è Reduce the leaked inventory by the amount vented to flare

-5- Ocean Systems Engineering

 Pressure Protection

Ø What if the internal pressure of a segment increases?

§ Cause

- Too much incoming feed flow

- Outlets blocked

- Fire à thermal explosion

- Leak due to internal rupture (tube rupture of exchanger)

§ Double-layer pressure protection

- Layer 1: PSV, rupture disc

- Layer 2: depressurization

-6- Ocean Systems Engineering

 Pressure Protection

PSV

Flare
Open

BDV

Closed Closed

ESDV ESDV

PSV: Pressure Safety Valve PSDV Open

BDV: Blowdown Valve
ESDV: Emergency Shutdown Valve Closed Drain
PSDV: Pressure Shutdown Valve

-7- Ocean Systems Engineering

 Preventive Measures

Ø Prevent an accident from happening

(or to decrease the frequency)

§ Detection: Fire and Gas (F&G System)

§ Ventilation

-8- Ocean Systems Engineering

 Mitigating Measures

Ø Once an accident happens, mitigate the consequence.

§ Water spray (deluge)

§ Fire and blast walls

-9- Ocean Systems Engineering

Overview of Safety Systems

-10- Ocean Systems Engineering

An Real Example: ESDV & PSDV

-11- Ocean Systems Engineering

An Real Example: PSV and BDV

-12- Ocean Systems Engineering

 Shutdown Logic

Ø Shut down the system partially or entirely.

Ø To what degree è depending on the seriousness

§ Low seriousness è partial shutdown

§ High seriousness è total shutdown

§ Extreme seriousness è Just escape and abandon the facility

-13- Ocean Systems Engineering

 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)

-14- Ocean Systems Engineering

 Input
APS

Shut DHSV
Manual Auto Depressurisation

Gas detection Timer-based disconnection

Non hazardous area Fire&gas detection
PA, ESD/PSD, radio
Emergency generator/UPS
ESD I

Manual Disconnection
Main generator
Standardizing Fire&gas detection Non-critical non-EX
equipment
Hazardous area
Tube rupture Start Emergency generator
in cooler
ESD II

Manual Activation of
DHSV (fire in riser
High lev flare k.o drum / well area)
Riser ESDV
Low pressure Depressurisation
Instrument air
Low pressure
hydraulic system Shut fuel gas supply
PSD
-15- Ocean Systems Engineering
 Cause and Effect Chart

Effect

Cause

-16- Ocean Systems Engineering

-17- Ocean Systems Engineering
 Design and Maximum Operating Pressure

Ø Design Pressure
§ The maximum allowable pressure for equipment and piping
under pressure
§ Used for equipment design (with some margin)

Ø Maximum Operating Pressure

(or Maximum Allowable Working Pressure)
§ The maximum of all the pressure fluctuations over the all the
conceivable operation mode.
§ start-up/shutdown, process flexibility, control requirements and
process upsets
§ Shut-off (discharge blocked) cases for rotating machineries
§ For unknown cases, the rules of thumbs are
- Pump: 1.25 times the discharge pressure

- Compressor: 1.3 times the discharge pressure

-18- Ocean Systems Engineering

 Design Pressure

Ø PSV (pressure safety valve) to vent out the internal gas

Ø Segment with a PSV

Maximum operating pressure Design pressure, barg

(MOP), barg

0 – 23 MOP + 3.5 bar

35 – 70 1.1 MOP

70 – 200 Max (1.085 MOP, MOP + 7 bar)

200 + 1.05 MOP

-19- Ocean Systems Engineering

 Design Temperature

Ø Maximum design temperature

§ When the maximum operating temperature is clear, take it for the
design temperature
§ Otherwise, design temperature = MOT + 30 oC

Ø Minimum design temperature

§ Material selection may be affected.
§ The minimum operating temperature – 5 oC
§ Operating conditions considered
- Air temperature (winter condition)

- Normal

- start-up, shutdown, process upsets

- Cooldown due to depressuriization

-20- Ocean Systems Engineering