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ISSUE RECORD
DISTRIBUTION
Mr J Brown OMV Petrom, Romania
File Risktec Solutions Limited, Glasgow.
CONTENTS
Issue Record ........................................................................................................................... 1
Distribution ............................................................................................................................. 1
1 INTRODUCTION ............................................................................................. 3
1.1 Background................................................................................................................ 3
1.2 Scope and Methodology .............................................................................................. 3
2 REVIEW AGAINST SAFETY CRITICAL ELEMENTS ........................................... 4
2.1 Methodology .............................................................................................................. 4
2.2 Gap Analysis .............................................................................................................. 4
2.3 Conclusion ................................................................................................................. 9
3 COMPRESSOR PERFORMANCE STANDARD .................................................. 10
3.1 Methodology ............................................................................................................ 10
4 OTHER REQUIREMENTS FROM EXISTING PERFORMANCE STANDARDS ...... 15
4.1 Methodology ............................................................................................................ 15
5 CONCLUSION AND RECOMMENDATIONS ..................................................... 21
6 REFERENCES ................................................................................................ 22
Tables
Table 1: FRD Lebada East NAG & LP Brownfield Upgrade Safety Critical Elements .......................... 5
Table 2: PS06–P - Compressors............................................................................................... 11
1 INTRODUCTION
1.1 Background
To optimise gas and condensate recovery from the Asset X facility, OMV Petrom plan to upgrade the
current compression capability available from the Central Production Facility (PFCP).
The PFCP-A platform was originally designed with six produced gas compressors:
• 1 x LP gas compressor (420-K-01) for the 2nd stage flash gas from the oil production
separators;
• 2 x HP gas compressors (421-K-01A/B) for the 1st stage flash gas from the oil production
separators plus the compressed gas from the 2nd stage separator;
• 3 x NAG compressors (450-K-01A/B/C) for non-associated or “free” gas.
The HP gas compressors and the NAG compressors were designed to be identical and
interchangeable to an extent. Over the years following the start-up of PFCP-A, the need for non-
associated gas compression never eventuated and two of the NAG compressors were utilised in HP
gas compression service and the remaining NAG compressor was utilised in LP gas compression
service.
Production rates of non-associated gas are declining rapidly and, in 2014, NAG compression is likely
to be required. This project will bring the NAG compressors into their original intended service. The
pressure and flow rate requirements for the NAG compressors are quite different to those
considered in the original design of the facility and the existing NAG compression packages must be
modified for the new service requirements.
In addition, the LP gas compression requirements have increased since the original design of the
PFCP-A facility and the LP gas compression capacity is to be increased.
1.2 Scope and Methodology
The scope of this document is to review the current Performance Standards for the PFCP-A platform
to ensure that they are applicable for the FRD Lebada East NAG & LP Brownfield Upgrade project
(LENAG).
This was carried out by firstly reviewing the Safety Critical Elements (SCE) that were identified for
the project and ensuring that each SCE is adequately covered by the Performance Standards. A
review is then carried out on all other Performance Standards to identify any additional shortfalls
that are outside the scope of the SCE’s. Any shortfalls in the existing Performance Standards are
identified.
TABLE 1: FRD LEBADA EAST NAG & LP BROWNFIELD UPGRADE SAFETY CRITICAL ELEMENTS
Safety Critical Element Relevance to Project Performance Standard Review Adequate coverage of SCE
within Performance
Standard?
PS06 – Compressors
Gas compressor system equipped with Compressor upgrade is within scope of Section F1.2 details the specific trip Yes, see Section 3 for detailed
overpressurisation protection (trips via project functions that are required on the breakdown of requirements.
SCADA) compressors.
Safety Critical Element Relevance to Project Performance Standard Review Adequate coverage of SCE
within Performance
Standard?
Emergency brakes are applied to hold load Mechanical handling and dropped Section F1.2 addresses gross overload Yes, covered by standard
and crane motion is stopped. Crane operator objects hazards identify lifting plans as protection systems lifting procedures
is able to lower the load by manual means. a preventative control in the project
HAZID Section F7.6 addresses brake systems
but not emergency brakes or mechanism
to manually lower loads
Load indicator installed in cranes Mechanical handling and dropped Section F6 addresses capacity indicator Yes, covered by standard
objects hazards identify lifting plans as function lifting procedures
a preventative control in the project
HAZID
Hooks have safety flaps to prevent slipping Mechanical handling and dropped Section F4 addresses hook blocks, Yes, covered by standard
of loads objects hazards identify lifting plans as although safety flaps are not specified lifting procedures
a preventative control in the project
HAZID
Wind speed indicator interlocked with crane Mechanical handling and dropped Wind speed indicators are not covered in Yes, covered by standard
control system objects hazards identify lifting plans as the Performance Standard lifting procedures
a preventative control in the project
HAZID
Fire Fighting Systems
Initiate Emergency Fire-fighting Response Emergency response plans identified PS22 covers fire water distribution for the Yes, potential impact on fire
Procedures. All systems tested, inspected as a recovery control in the project fire fighting systems fighting systems during
and maintained. HAZID following loss of containment / construction
fire / explosion PS23 covers the deluge, sprinkler and
mist systems
Safety Critical Element Relevance to Project Performance Standard Review Adequate coverage of SCE
within Performance
Standard?
PS20 - ATEX Equipment
All third party equipment comply with proper Contractors working on the project Section F1 defines how the integrity of all Yes, all new equipment must
hazardous area ratings must use ATEX rated equipment certified electrical equipment in be suitably ATEX rated
hazardous areas is maintained
Safety Critical Element Relevance to Project Performance Standard Review Adequate coverage of SCE
within Performance
Standard?
Closure of SSIV on gas risers Plant shutdown identified as recovery SSIV’s final elements are not specified as Yes, design and construction
control in project HAZID following part of the Performance Standard, work must ensure that SSIV
damage to equipment/loss of however this should be included on the on oil riser remains fully
containment Cause and Effects Charts and the operational at all times
Performance Standard does not require
update
New
Condensate Drain: Level Control Valve (LCV) Required to reduce back pressure at No applicable Performance Standard No, new Performance
with a restrictive Cv on the NAG suction the NAG suction scrubber liquid outlets identified Standard to be produced as
scrubber liquid outlets (identified in to prevent overpressure in a gas part of the Execute phase.
Reference 2) blowby scenario
2.3 Conclusion
All project SCE’s were found to be addressed in existing Performance Standards, with the following
exceptions:
• The new Condensate Drain SCE, Level Control Valve (LCV) on the NAG suction scrubber
liquid outlets, is not addressed by any of the existing Performance Standards.
F1.2 The following systems Calibrate & test the following F1.2.1 Review CMMS records Complete/update trip logic documents and datasheets on
(trip function) are calibrated & systems to ensure the correct – 12 months project completion
function at the correct set set points are implemented
F1.2.2 Witness function Ensure compressor trip system assurance and verification
points as per Trip logic and alarms (Audible &
testing of the safety systems activities are included in PMS
documents and data sheets. visual)/actions initiated as per
trips and alarms – 12 months
the trip logic / Cause & effects
• Seal protection
charts:
• Over-speed protection
• Seal protection
• Vibration monitoring
• Over-speed protection
• Temperature monitoring
• Vibration monitoring
• Low lube oil pressure
• Temperature monitoring
• Over-pressure protection
• Low lube oil pressure
• Over- axial displacement
• Over-pressure
protection
• Over- axial displacement
protection
F4.1 All predicted failure modes Initial assurance by design. F4.1.1 Review inspection A HAZOP (or other hazard identification process) should
are identified and suitable Ongoing operational assurance program to confirm all failure be undertaken on the detailed design to identify all failure
control, mitigation & monitoring by management of change modes are mitigated – 12 modes and establish suitable controls
measures have been provided. months
Ensure control measure assurance and verification
activities are included in PMS
F5.1 Equipment is inspected, Equipment inspection, testing F5.1.1 - Confirm for a sample Ensure all equipment is inspected, function tested and
function tested and maintained and maintenance are of equipment, including any maintained in line with the Safety Critical Elements–
in accordance with Integrity scheduled through the new equipment, that Integrity Management Guideline (EP-HQ-GDL-008-00)
Management maintenance management inspection, testing and
Ensure compressor equipment assurance and verification
system (CMMS). maintenance is scheduled in
activities are included in PMS
accordance with relevant
Assignment of inspection,
strategy – 12 months
testing & maintenance for new
equipment governed by
management of change
process.
6 REFERENCES
1. Risktec. Review of Safety Critical Elements for the FRD Lebada East NAG & LP Brownfield
Upgrade Project. PTRM-25-R-01 (PE-D-A1011330019-HS-ANL-001-01-E). Issue 1. May 2013
2. FRD Lebada East NAG & LP Brownfield Upgrade Project, Closed and Open Drains Impact
Assessment, NAG-BFFEED-Z-001-00
3. FRD Lebada East NAG & LP Brownfield Upgrade Project, Dropped Object Assessment
Report, PE-D-A1011330019-HS-REP-012-02-E.
4. FRD Lebada East NAG & LP Brownfield Upgrade Project, Escape, Evacuation and Rescue
Assessment Report, PE-D-A1011330019-HS-REP-026-03-E