statoil PROCESS DESIGN HANDBOOK INTENT AND USE Intent The Process Design Handbook is an introduction to the design aspects of offshore facilities for oil and gas production. It is intended to provide sufficient information to prepare a preliminary design. Additionally, it may also be used as a useful checklist for the detailed design. It is not intended to be used as a substitute for other engineering discipline input to the design, but more as an initial guide until specialist information is available. The Handbook is for internal use by Statoil's employees only. It is not to be copied or lent to any third parties. Design The guide is a reddy data source, providing information on estimating procedures, design criteria and design methods. It should be used in conjunction with currently available data and technical reference books. Codes and Standards Where applicable reference is given to appropriate codes and Statoil standards that are required to complete the full and proper detailed engineering design. If any conflict with approved Statoil General Engineering Guides, Design Specifications, standard specifications or other official Gocuments should occur, such documents will always override this handbook. Technical References It is assumed that for the more detailed requirements the engineer has ready access to design and data references regarded as industry standards, and to specialist vendor information.SECTION 1 SECTION 2 SECTION 3 PROCESS DESIGN HANDBOOK GENERAL 1.1 Safety Considerations 1.2. Establishing Design Conditions 1.3. Platform Operations 1.4 Training/Sparing Philosophy 1.5 Process Control/Instrumentation 1.6 Layout Considerations 1.7) P& T.D.'S 1.8 Overall Process Optimisation 1.9 Design Basis Documentation 1.10 Topsides Weight Estimation 1.11 Topsides Capital Cost Estimation PROCESS 2.1 Composition of Wellhead Fluid 2.2 Composition of Products and Bffluents 2.3 Dehydration (Gas) 2.4 Dewpoint Control 2.5 Acid Gas Removal 2.6 Heat and Material Balances 2.7 Crude Oil Processing PROCESS SUPPORT 3.1 3.2 3.3 3.4 www Lau Refrigeration Systems Fuel Gas Systems Heating Systems Cooling Systems Flare and Vent System Oily Water Treatment Chemicals stat. fSECTION 4 SECTION 5 SECTION 6 SECTION 7 statoil UTILITIES 4.2 4.2 Seawater System 041 Storage and Ballast Drainage Freshwater Sewage Treatment Firewater System Instrument and Plant Air 4.8 Accommodation 4.9 Jet Fuel System : 4.10 Diesel System 4.11 Steam Systems 4.12 Inert Gas 4.13 Injection water 4.14 Drilling EQUIPMENT 5.1 Separators 5.2 Compressors - 5.3 Heat Exchangers. 5.4 Heaters 5.5 Pumps 5.6 Drivers 5.7 Piping 5.8 Pipelines 5.9 Valves 5.10 Tanks & Vessels 5.11 ‘Fractionating Columns 5.12 Insulation and Heat Tracing 5.13 Caissons ” DATA 6.1 ..Physical Data 6.2 Conversion Tables REVISION RECORD TL Revision Record& Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table 14.1 1.6.1 1.6.2 1.10.1 1.10.2 2.2.2 2.3.1 2.3.2 2.5.1 3.1.1 List of Tables Training and Sparing Module Type Area Ratios Crane Vessel Capacities and Module Dimensions Typical Density Factor Typical "Percentage Split" Typical Gas Specifications Comparison of Dehydration Methods Comparison of Inhibitors for aydrate Suppressio ~,! Design Data for Various Amine Process Size and Weights for Packaged Refrigeration Units using Freon R-12 Purge Rates (Sm?/day) Tilted Plat Separator Size and Weight Filter/Coalescer Dimensions Chemicals for Crude Oil Streams Chemicals for Water Injection Streams Miscellaneous Chemicals Hypochlorinator Package Units Seawater Lift Pump weights Minimum Firewater Application Rates Diesel Oil Fired Utilities ~ Fuel Gas Fired Utilities PSA Unit Utilities Inert Gas Units - Space and Weight Drilling Options Typical-Overall Heat Transfer Coefficients Tube Count Tables - Typical - Air Cooler Overall Heat Transfer Coefficients Air Cooler Sizing Information Pump Types for Offshore Applications Preferred Motor Outputs (kW)> Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table 5.6.2 5.6.3 5.7.1 5.7.2 5.7.3 5.8.1 5.9.2 5.10.1 5.12.1 5.12.2 5.12.3 6-1-1 6.1.2 6.1.3 statoil Gas Turbine data for Mechanical Drive Application Typical Gas Turbine Gas Specification Requirements Gas Turbine Generator Set Data Gas Turbine Driven - Pump/Compressor Package Data Flange Pressure ~ Temperature Ratings for Normal Grade (1.1) Carbon Steel Equivalent Length of Fittings Multiplying Factor for Piping Length when Fittings and Valves not known Summary of Design Factors Onshore Pipelines Typical Cy Values Cylindrical Vessel Data Thermal Conductivity of Insulation Materials Typical Insulation for Personnel Protection Insulation Thicknesses for Heat Conservation Physical constants of Hydrocarbons Thermal Conductivities of Gases and Vapours Steam TableFigure Figure Pigure Pigure Figure Figure Figure Figure Figure Pigure Pigure Pigure Pigure Pigure Pigure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure ele 14d 1.5.1 1.5.2 1.6.1 1-10-1 Led. 1.11.2 2.2.1 2.3.1 2.3.2 stat~} List of Figures Firewall Requirements Maximum Vessel Diameter Based on 100mm Thickness Simplified PDQ Platform Control Schematic Simplified ESD system Simplified Area Segregation for Platform Layout Weight Contingencies Typical Cash Flow Simple Payback =) Wobbe Index Prediction Water Dew Point of Natural Gas Pressure - Temperature Curves for Predicting Hydrate Formation Ethylene Glycol Injection system Methanol Injection Rates Hydrate Depression and Minimum withdrawal Concentration for Ethylene Glycol Ethylene Glycol Injection Parameters Methanol Vaporisation Losses Glycol Contacting/Regeneration System Tray Requirements = Concentration Requirements 6 Trays = Concentration Requirements 8 Trays Concentration Requirements 10 Trays TEG Regeneration Skid Sizing Molecular Sieve Adsorption System Maximum Superficial Velocity Regeneration Gas Requirements Phase Envelope Terminology Simplified Process Scheme Dewpoint Control Systems Joule Thomson and Expander Paths Typical Turbo Expander Performance CurvesFigure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 2.5.1 2.5.2 2.5.3 2.5.5 3.2.1 3.3.1 3.3.2 3.3.3 3.3.4 3.4.2 3.4.2 3.5.1 3.5.2 3.5.3 statoi Typical Amine Treating Unit Typical Physical Solvent Treating Unit Range of Gas Treating Process Application COD Removal with no BD or other Impurities Present Range of Gas Treating Process Application HS Removal with no CO, or other Impurities Present Range of Gas Treating Process Application Simultaneous HOS and COD Removal with no other Impurities Present Range of Gas Treating Process Application Selective Hydrogen Sulphide Removal Typical Oil Processing System Approximate Column Diameter TDS vs Dilution Water Typical Two-Stage Refrigeration System Vapour Pressure Curves for Freon Refrigerants Ratio of Compressor Power to Refrigeration Duty for Freon R-12 Ratio of Compressor Power to Refrigeration Duty for Freon R-22 Mollier Diagram for Freon-12 showing a Single Stage Compression with Gas Superheat Refrigeration Cycle Typical Fuel Gas Conditioning Scheme Typical Heating System Shell Thermia B Viscosity vs Temperature Shell Thermia B Specific Heat vs Temperature Shell Thermia B Density vs Temperature Typical CCCW System Typical Seawater System Controlled and Uncontrolled Blowdown Flare Size Estimation for Emergency Flare Load Flare Size Estimation for Continuous Flare Loadstat) Figure 3.5.4 Relationship between Flare Boom Length and Weight Figure 3.5.5 Relationship between Flare Tower Height and Weight Pigure 3.6.1 Corrugated Plate Interceptor (CPI) Figure 3.6.2 Gas Floatation Figure 3.6.3 Typical Oily Water Treatment System _ Figure 3.7.1 Chemical Injection System Capacity Figure 3.7.2 Sodium Hypochlorite Dosing Figure 4.1.1 Typical Seawater System Figure 4.1.2 Seawater Coarse Filters - Weights and Dimension. -/ Pigure 4.2.1 Typical Oil Storage System Figure 4.3.1 Typical Offshore Drainage System (GBS) Pigure 4.6.1 Firewater Pump Schematic Figure 4.6.2 Pressure Drop in Kunifer '10' Pigure 4.7.1 Typical Combined Instrument and Plant Air System Figure 4.8.1 Helideck Arrangement for a Chinook 234LR Helicopter . Figure 4.10.1 | Typical Flow Scheme for a Diesel Distribution System for G.B.S. . Figure 4.13.1 | Simplified Injection water System Figure 4.13.2 Deaeration Tower Diameter Figure 4.13.3 Area and Weight Requirements -" Figure 4.14.1 | Simplified Mud system ~ Figure 4.14.2 Typical Platform Stack-up Pigure 4.14.3 Typical Wellhead and xmas Tree Figure 5.1.1 Vertical Vessel Sizing Criteria Figure 5.1.2 Horizontal Separator Sizing Criteria Figure 5.2.1 Specific Heat Capacity Ratio (Reference 1) Figure 5.2.2 Polytopic Efficiency (Reference 2) Figure 5.2.3 Compressor Operation Characteristics Figure 5.2.4 Typical Control System Figure 5.3.1 Shell and Tube Exchanger Size/Weight Correlation Figure 5.3.2 Plate Exchanger Area Figure 5.3.3 Air Temperature Correction FactorFigure Figure Figure 5.4 Figure 5.4 Figure 5.4 Figure 5.4 Figure 5.4 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure statoil MID Crossflow Correction Factor Air Cooler - Fan Power Fired Heater - Typical Diameter and Height Fired Heater - Typical Height and Diameter Typical Fired Heater Controls Waste Heat Availability Waste Heat Recovery from Gas Turbine Exhaust Gas with Supplementary Heater Waste Heat Recovery from Gas Turbine exhaust with Induct Burner Unit, Horizontal End Suction Vertical In Line Heavy Duty Process Horizontal Split Case Multistage Pumps Vertical Pumps Sump Pump Rotary Pumps Metering Pump Centrifugal Pump Applications Calculation of Pump Head Pump Efficiency Typical End Suction Centrifugal Pump Estimating Pump Weights Approximate Performance Boundaries of Drivers for High Powers and Speeds Estimating Weights for Zone 1 Electric Motors Maximum Velocities for Cupro-Nickel Piping Recommended Pressure Drops for Vapour Lines Allowable Gas Velocities for Vapour Lines Optimum Line Size for Minimum Pressure Drop for Upward Vertical Two-Phase Plow Lines Darcy (Moody) Friction Factor Flow Efficiency as a Function of Gas Velocity and Liquid Gas RatioFigure 5.9.1 Figure 5.9.2 Figure 5.9.3 Figure 5.10.1 Pigure 5.11.1 Figure 5.11.2 Figure 5.11.3 Figure 5. Figure S-is2.1 Figure 5.12.2 of 5 Pigure 5.13.1 Figure 5.13.2 Pigure 5.13.3 Figure 6.1.17 Figure 6.1.2 Figure 6.1.3 Figure 6.1.4 Figure 6.1.5 Figure 6.1.6 Figure 6.1.7 Figure 6.1.8 Figure 6.1.9 Figure 6.1.10 Figure 6.1.11 Figure 6.1.12 Figure 6.1.13 Control Valve Major Components Valve Characteristics Approximate Weight of Tanks Tray Efficiency Key Ratio vs Tray Number Key Ratio vs Tray Number Key Ratio vs Tray Number { Key Ratio vs Tray Number Generalised Pressure Drop Correjation Heat Loss Uninsulated Pipe and Equipment Heat Loss from Piping and Equipment Insulated Valve Typés | | with Calcium Silicate Typical Oily/Waste Water Caisson Rising Velocity of Oil Droplets in Waste Water | Waste Water Separator Submerged Caisson . Dimensions } TVP of Gasolines and Finished Petroleum Products Vapour Pressure for Light Hydrocarbons | Hydrocarbon Fluid Densities Compressibility factors for Natural Gas i Specific Heats of Petroleum Fractions Liquid State » Specific Heats of N-Paraffinic Gases v Thermal Conductivity of Normal Paraffinic Hydrocarbon Liquids \ Thermal Conductivity of Gases Hydrocarbon Gas Viscosity | Viscosities of Hydrocarbon Liquids Specific Gravity of Aqueous Ethylene Glycol | Solutions Specific Gravities of Aqueous Triethylene Glycol | Solutions Specific Heats of Aqueous Ethylene Glycol SolutionsFigure Figure Figure Figure Figure Figure 6.1.14 6.1.15 6.1.16 6.1.17 6.1.18 6.1.19 Oo statoil Specific Heats of Aqueous Triethylene Glycol Solutions Viscosities of Aqueous Ethylene Glycol Solutions Viscosities of Aqueous Triethylene Glycol Solutions Seawater Density Seawater Heat Capacity Seawater ViscosityPROCESS DESIGN HANDBOOK ISSUE DAT! 25 MAY 1984 SECTION:1.1 - —™ REV DATE: 1 JUNE 1984 REV:0 PAGE:1 of 17 statu! 1. Safety Considerations Reference Specifications: General Engineering Guides A-SG-006 A-SG-007 "Project Safety Programme Standard” “Guidelines for Planning and Implementation of Hazard and Operability Studies* D Design Specifications $-SD-001 S-SD-002 S-SD-003 S-SD-004 S-SD-005 S-SD-006 S-SD-007 S-SD-008 S-SD-009 S-SD-010 S-SD-011 S-SD-012 S-SD-013 S-SD-014 S-SD-015 LLL “Layout and Arrangement” "Escapeways" "Lifesaving/Evacuation" "Area Classification" "Safety Ventilation" “Passive Fire Protection" "Active Fire Protection" "Drainage Systems" “Relief and Flaring" "Fire and Gas Detection" "Emergency Alarm System(s)” ~ - "Emergency process and utility shutdown - systems" "Noise and Vibrations” "Emergency Control/Emergency Management* "Black Start Philosophy" The safety of an offshore installation and the personnel involved is the prime concern during all phases of the design. Good engineering practice and adherence to the appropriate codes and standards is essential to achieve an acceptable level of safety. The following codes and standards are given as a guide, but the list is not intended to be complete.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 REV DATE: 1 JUNE 1984 REV:0 PAGE:2 of 17 statoil Authorities Regulatory Requirements 5 NPD: The Continental Shelf, Main Acts, Regulations and Guidelines NPD: Guidelines for the Safety Evaluation of Platform Conceptual Design (1.9.81) Recognised standards, codes and practices ‘ API R.P.'5 14C/520/521/2000 . BS 5500/ASME VIII . TBK Company specifications and guidelines . Statoil Safety Manual : Statoil General Engineering Guide . Statoil Design Specifications for Offshore Installations 5 Statoil Standard Specifications The design of an offshore installation incorporates both active and passive safety features to reduce the probability and consequences of an accident. [Link] Active Protection a. Provision of a Pire and Gas detection system b. Provision of an Emergency Shutdown System (ESD System) c. Provision of a Relief/Depressurising system a. Installation of adequate process instrumentation and control; i.e. sufficient to maintain safe operation and to give a true operational picture in the control room e. Provision of Fire Fighting System £. Provision of Ventilation systems [Link] Passive Protection a. Platform layout and configuration, segregation of areas (particularly ignition sources from fuel sources), provision of adequate escape routes, positioning of fire and blast walls, lifeboat locations, provision of suitable muster areas. b. Specification of suitable design conditions for process and utility equipmentPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 — REV DATE: 1 JUNE 1984 REV:0 PAGE:3 of 17 stat 7}, The process engineer is usually responsible for the following | aspects of safety design: a. Development of process safety systems including: 1 specification of relief valves specification of process equipment shutdowns ' provision of depressurising facilities b. Provision of relief/blowdown systems including flare : and/or vent facilities : ; ce. Provision of firewater system a. Specification of suitable design conditions for process | and utility equipment » The process engineer also participates in the following aspects of safety design: a. Specification of functional requirements for the Emergency Shutdown (ESD) system i.e. development of Cause and Effect diagrams b. Development of platform configuration, layout and hazardous area drawings. c. Location of fire and gas detectors ! a. Participate in the Hazard and Operability Review (HAZOP) e. Participation in Safety Evaluation | Each of these safety aspects in which the process engineer is Girectly or indirectly involved are discussed in the following | sub-sections. eld Process Safet: The process safety systems are designed to detect abnormal | process conditions and prevent a dangerous situation resulting. The systems provided should be in accordance with the | requirements of NPD and API RP 14C and be consistent with the requirements of the mechanical equipment involved. ) API RP 14C gives a standardized method for designing and checking ! safety systems for offshore production platforms, which should be used when first developing Piping and Instrument Diagrams, P & |PROCESS DESIGN HANDBOOK YU ISSUE DAT 25 MAY 1984 SECTION: 1.6 REV. DATE: 1 JUNE 1984 REV:0 PAGE:4 of 7 statoil Other documentation, such as Process Flow diagrams and Piping and Instrumentation Diagrams will be required at subsequent stages of the project. The list given is intended to represent the minimum requirements to formulate a layout. 1.6.5 Specific Equipment Considerations Reference is made to Design Specification M-SD-028 “Platform Layout" for specific considerations relating to the following equipment/areas: Unfired Pressure Vessels 7 Fired equipment Hydrocarbon storage . Machinery . Cranes . Life boats . Flare ‘ . Fire Protection : Workshop and Stores 1.6.6 Specific Process Considerations The following process considerations are relevant to the platform layout: a. the layout should reflect a logical progression of the process. This should then minimise major piping requirements. Other equipment with small diameter piping, can be located where necessary e.g. glycol regeneration package. b. related equipment should be modularised to allow maximum hook up and precommissioning to be achieved, e.g. compressor with associated knock out drum and aftercooler. c. requirements for pump NPSH should be established e.g. export pumps.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: ” REV DATE: 1 JUNE 1984 REV:0 PAGE:5 of hy statu 2.1.3 Bmergency Shutdown system Reference Specifications: S-SD-011 "Emergency Alarm Systems" S-SD-012 "Emergency process and utility shutdown systems" The Emergency Shutdown (ESD) System is designed to protect personnel, the installation and environment from unsafe operating conditions and catastrophic situations. It should be capable of shutting down part or all of the installation both rapidly and safely. ~ The main functions of the ESD systems are as follows: a. prevent circumstances which could lead to a release of hydrocarbons b. shut in process system as required to minimise hydrocarbon leak or overflow c. prevent ignition of released hydrocarbons da. shutin and depressure hydrocarbon systems in the event of fire e. limit spread of released hydrocarbon gases. To achieve this, automatic monitoring and initiation of emergency shutdown should be provided through the process safety system, and the fire and gas detection system. Manual initiation of | @~ emergency shutdown should be possible from strategic locations on ~ the platform. e.g. control room, lifeboat muster areas etc. The platform shutdown system should be divided into several levels to cover both emergency shutdown and partial/local process shutdown. The following levels should be provided: ae Level 1 : Total Shutdown of ali systems (ESD 1) by Level 2. : Shutdown of Production Systems (ESD 11) c. Level 3: Partial Shutdown of Production Systems a. Level 4: Shutdown of Individual systems e. Level 5 +: - Shutdown of Individual Components Level 1 (ESD 1) is manually initiated and used in conjunction with an abandon platform. ESD 1 should close down the entire installation, except for the emergency systems. It would normally be preceded by an ESD II.PROCESS DESIGN HANDBOOK Oo ISSUE DATE: 25 MAY 1984 SECTION: 1.1 REV DATE: 1 JUNE 1984 REV:0 PAGE:6 of 17 statoil Level 2 (ESD II) is either manually initiated or automatically initiated in the event of gas or fire detection or failure of operation of one of the critical systems. ESD II should shutdown and secure all major hydrocarbon handling systems. On gas or fire detection, the extent of shutdown depends on the area of occurrence and should be defined by the Fire and Gas Cause and Effects diagrams. If sudden shutdown of drilling or workover equipment could result in increased danger, these can be excluded from the emergency shutdown system and initiated manually. Levels 3, 4, and 5 are used if abnormal operating conditions arise in the process/utility systems, but do not require a total production shutdown. = The process engineer participates in defining the functional requirements for the ESD system. The P & I.D.'S indicate the inputs to and outputs from the ESD System, but they do not show which inputs initiate which outputs. This is usually done by preparing Cause and Effect Diagrams. A Cause and Effect Diagram consists of a matrix with the inputs (causes) to the ESD system listed on one axis and the outputs (effects) listed on the other. The effects initiated by each cause can then be indicated on the matrix. 1.1.4 Flare System The flare and vent system should be designed to provide safe disposal of hydrocarbon vapours during relief and depressurising conditions. The flare should ensure combustion of flammable, poisonous or corrosive gases, without exceeding acceptable radiation levels on the platform. Design requirements for this system are given in Section 3.5, Flare and Vents. 1.1.5 Firewater System The firewater system is designed to reduce the risk of a fire spreading and protect adjacent areas/equipment by cooling exposedPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 =. REV DATE: 1 JUNE 1984 -REV:0 PAGE:7 of 17 statri surfaces. In certain circumstances the firewater may control burning or even extinguish the fire. The design of fire water systems is discussed in Section 4.6. 1.1.6 | Design Conditions The passive protection of the process and utility systems is achieved by specifying suitable design conditions, this is the responsibility of the process engineer. Design conditions for items of equipment are recorded on the process data sheets. For =. the pipework, design conditions are recorded on the Piping Line / List. The specification of design conditions is discussed in Section 1.2. 1.1.7 Platform Layout and Arrangement Many aspects of the platform arrangement are dictated by safety considerations particularly segregation of hazardous and non- hazardous areas. This is discussed fully in Section 1.6, Layout Considerations. Hazardous area classification and escape route requirements are considered in Sections 1.1.8 and 1.1.12 respectively. The process engineers main area of responsibility is to identifum the potential sources of hazard associated with the facilities. This can then be used as a basis for arranging the topside layouts and preparing the hazardous area drawings. 1.1.8 Hazardous Area Classification Reference Specification: S-SD-101 “Area Classification Philosophy" Areas on a platform shall be assigned 'Zone' numbers which correspond to the probability of explosive concentrations of gas or vapour being present at any time. These are designated as follows: a. zone 0 - Area where an explosive gas-air mixture isPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.1 . REV DATE: 1 JUNE 1984 REV:0 PAGE:8 of 17 statoil continuously present or present for a long period. b zone 1 - Area where an explosive gas-air mixture is likely to occur in normal operations. c. Zone 2 - Area where an explosive gas-air mixture is not likely to occur, and if it occurs, it will only exist for a short time. a. Non-hazardous - all other areas of the platform. Reference is made to the Design Specification for detailed requirements. 1.1.9 Fire and Blast Walls Reference Specification: S-SD-006 “Passive Fire Protection" To effectively contribute to the development of layouts and overall platform safety a process engineer must have an appreciation of the application of fire and blast walls. Fire walls are provided between areas of different risk levels to prevent the passage of flame and/or smoke for a minimum specific period, i.e. ‘fire resistance’. Firewalls have three (3) major classifications: a. Class A: 1 hour fire resistance b. Class B: 4 hour fire resistance ce. Class H: 2 hour fire resistance Additionally, the firewall is designed so that the face of the partition remote from the fire is not allowed to exceed a certain maximum temperature. The time lapse during which this temperature can be controlled is dependent on construction, and forms the second part of the firewall classification. As an example the firewall specification for Class A firewalls is as follows: [Link] Class A Firewalls The partitions shall be made of steel or equivalent material. They shall be sufficiently braced and they shall prevent flamesPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 REV DATE: 1 JUNE 1964 REV:0 PAGE:9 of 17 state! and smoke from advancing for a minimum of one hour as per standardized test. The partitions shall be insulated with non-combustible materials so that the average temperature on the side of the wall not being exposed, does not exceed 139°C (250°F) above the initial temperature and the temperature shall not at any place exceed 180°C (3259F) above the initial temperature within the time limit given belo Class A-60 : 60 minutes Class A-30 30 minutes *) Class A-15 15 minutes Class A+0 : 0 minutes The location of firewalls, and the firewall class is in accordance with the NPD's ‘Regulations for Production and Auxiliary Systems on Production Installations’ and the Statoil Design Specification, S-SD-006 "Passive Fire Protection". The minimum requirements for designation of firewalls is given below. These divisions are the minimum required for the separation of adjoining areas. It is however, preferable in some instances to provide more than these minimums either by specifying a higher class of firewall or by locating areas so that they are physically separated one from another. ~ Firewalls are used to divide larger areas of identical risks int. _ smaller ‘fire areas', particularly in production areas. When there is more than one production module, it is often beneficial to use firewalls to separate them, thus reducing the size of the ‘fire area’ and reducing the maximum firewater requirement for the ‘fire area’. This can also benefit the flare system by reducing flare loads, refer to section 3.5. Blastwalls are used in areas where there is a high risk of explosion, and their location depends on the actual topsides configuration. It is common practice to provide a blastwall between the wellhead area and adjacent facilities.PROCESS DESIGN BANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 REV DATE: 1 JUNE 1964 REV:0 pace:10 of 17 StQtoil AREA AREA uri AREA LIVING Notes: B-120 H-0 DRILLING PRODUCTION ry QUARTERS: DRILLING EQUIPMENT AREAS WELLHEAD AREAS PROCESSING AREAS FLAMABLE MATERIAL STORE Figure 1.1.2 Firewall Requirements Areas to be safely separated and have resisting divisions of minimum Class B-120 Areas to be separated by fire resisting divisions of minimum Class B-0 Areas to be separated by fire resisting divisions of minimum Class A-60 Areas to be separated by fire resisting divisions of minimum Class A-0 Areas to be separated by fire resisting divisions of minimum Class B-30 Areas should not be located adjacent to each other.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 ~ REV DATE: 1 JUNE 1984 REV:0 PAGE:11 of 17 stat 1.1.10 Fire and Gas Detection | Reference Specification: S-SD-010 “Fire and Gas Detection" | A process engineer is required to identify potential sources of hazard associated with the process and utility systems and assist | in the location of fire and gas detectors. A fire and gas detection system is provided to continuously monitor all platform areas, and initiate the appropriate fire- fighting/protection system. The primary function of the detection system is to provide an early warning of a fire or hazardous vapours so that action can be initiated to attempt to contain the event to the area of origin. Systems for detection of gas, flame, heat and smoke are provided according to the hazards within each area. The following table gives an indication of the type of detectors that would be expected in a particular fire area. This can be used as a checklist in a safety review of the facilities proposed: | Area Detector Type ' High Risk Areas: ' : Process areas including: -; Wellhead Flane/Heat/Gas ut Manifolds, coolers, etc. Flame/Heat/Gas . Drilling area including : Drill floor, mud processing Flame/Heat/Gas Other Risk Areas: j ; utility areas including: Diesel Oil Area Flame/Heat | Turbine/Generator Area Smoke/Heat Turbine Hood Flame/Heat/Gas ! Diesel Generator Room Flame/Heat/Smoke i Workshop (if applicable) Heat Storage Heat/Smoke |PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.1 REV DATE: 1 JUNE 1984 REV:0 pacE:12 of 17 Statoil Switchgear Roon Smoke . Accommodation areas including: Cabins Smoke/Heat Public Rooms Smoke/Heat Galley Heat Laundry Beat/Smoke Washrooms/W.C. Heat Radio Room Smoke . General areas including: . Staircase Smoke/Beat Ceiling voids smoke Air Intakes (to ventilated areas) Gas . Ventilation Exhaust Ducts Gas . On detection of a fire, audible and visible alarms will be initiated, the dedicated fire-fighting systems will be activated and the emergency shutdown system will stop flow of hydrocarbons to the affected areas. 1.1.11 Ventilation Reference Specification: S-SD-005 "Safety Ventilation" When assessing the feasibility of proposed topsides facilities it may be necessary for the process engineer to estimate the power requirements for module ventilation. Generally the air change rates are as follows: Topsides Air_changes/h Hazardous area 12 Safe area 6 Except: Fire pump rooms, batteries and chargers, emergency & main generation 12 Accommodation - 0.012 m3/sec/personPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 REV DATE: 1 JUNE 1984 REV:0 pace:13 0817 S§tat jl GBs Shaft changes/h , Hydrocarbon equipment area Zone 2 12 } General equipment areas, where normal maintenance work will take place Safe 6 General equipment areas, where little maintenance work is expected to take place Safe 1.5 Stairs/goods lift shaft Safe 12 ~ Escape/personnel lift shaft Safe 12 » , Safe areas should be pressurised to between 0.63 and 1.25 mbar and at least 0.63 mbar higher than connecting hazardous areas. Using the module dimensions and the above table of air changes it is possible to estimate the flowrate of air required. A preliminary estimate of the power consumption can then be made using the following equation. Power 0.143 x Vx aP , kW i volumetric flowrate, m/s where: V ap pressure across fan, assume 20 mbar The equation is based on a fan efficiency of 708. ; 1.1.12 Escape Routes 7 Reference Specification: S-SD-102 "Escape Route Philosophy" 1 The provision of adequate escape routes and normal access ways shall be considered as a major priority in the layout of equipment and platform arrangement. Reference is made to the standard for detailed consideration.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 REV DATE: 1 JUNE 1984 REV:0 PAGE:14 of 17 statoil 2.1.13. Hazard and Operability Study - BAZOP [Link] General A hazard and operability study is a systematic design check on the proposed process scheme to identify possible safety or operations problems, From this, the extent of the problems are assessed and measures implemented to minimise or alleviate the problem. The Hazop study also provides the opportunity to independantly check that the proposed design is in accordance with NPD Regulations and API RP 14C. The study may be carried out on conceptual/pre-engineering phase Piping and Instrument Diagrams, P & 1.D.'s and should be repeated during the final detail design phase. The procedure is based on the premise that’a problem, safety or operations, can only arise when there is a deviation from design or operating conditions. The technique is to search the process design systematically, aided by a check list of guidewords, looking for every process deviation from normal. The procedure is summarised as follows: POSSIBLE CAUSES —= DEVIATION ———————> POSSIBLE CONSEQUENCES HAZARD, OPERATING PROBLEM TRIVIAL INCIDENT LIST OF GUIDE WORDS FOR GENERATION OF DEVIATIONS Typical list of guidewords are: NONE, MORE OF, LESS OF, PART OF, MORE THAN, OTHER This list can be modified/extended for particular reference to individual items of equipment or special processes.PROCESS DESIGN HANDBOOK | | ISSUE DATE: 25 MAY 1984 SECTION:1.1 sy REV DATE: 1 JUNE 1984 REV: pace:15 of 17 Stat | [Link] Study Planning A full set of P & I.D.'s is required. The study team consists of 5 to 8 people as required. The study leader must be well trained in the technique and is responsible for checking that each deviation is considered. The other members of the team should have a wide range of expertise, and should include the design engineer, operations representative, safety engineer, project engineer, and, any other technical people as required. Generally a study > { ) meeting should last 2 to 3 hours, and can be carried out every day until the complete system is evaluated. The time between meetings is used for collecting information and progressing action on points raised. 1.1,13.3 Study Procedure At the first meeting, the team leader outlines the procedure to be followed. The first P & ID is selected, and the study begins by applying the'checklist of guidewords in turn to a selected line entering the first item of equipment. This is repeated for all lines entering the item of equipment. When this is complete, the item of equipment is evaluated, usually only requiring the guideword = ‘other’. This is repeated on a line-by-line, equipment-by- - equipment basis until the whole section has been completed. As each problem is identified, the need for action should be evaluated immediately. Where action is required, and the : solution obvious this should be recorded. Where the solution is { not obvious, the problem is recorded for further evaluation. The Procedure should be recorded in tabular form with the following ‘ headings: [surDe] WORD] DEVIATION [POSSIBLE [CAUSES [CONSEQUENCES [ACTION [REQUIRED]PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.2 REV DATE: 1 JUNE 1984 REV:0 PAGE:16 of 17 StQtoil Recording should be limited to actions agreed on, and points requiring further attention. Copies of the recording sheets should be given to each team member, with ‘action by' designated. Once the study is completed for the entire installation, the follow-up period should evaluate the actions proposed, implement the changes required, and monitor the implementation of the changes. The study should be repeated at suitable phases during the design. 1.1.14 Safety Evaluation When the conceptual design is completed, a safety evaluation of the installation is required, and should be carried out in accordance with the NPD requirements. This evaluation is required as part of the information submitted to the government for development approval. The purpose of the evaluation is to identify ‘accidents’, i.e. unwanted incidents which are assumed not to occur during-normal operation, and which can cause significant damage if not taken into consideration during design. The following types of accidents should be evaluated where relevant: a. blowout b. fire c. explosion and similar incidents a. falling objects e. ship and helicopter collisions £. earthquakes 3. other possible relevant types of accidents he extreme weather conditions i. relevant combinations of these accidents Evaluations of these incidents should verify a suitably low probability of loss of human life, high material damage and unacceptable environmental pollution as a result of the accident. Each possible accident should be reviewed in terms of the safety measures employed to reduce the probability of the accident, andPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.1 Came | REV DATE: 1 JUNE 1984 REV:0 PAGE:17 o£ 17. $tat a) then those provided to reduce the consequences of the accident. This involves checking that the criteria set out earlier in this section, and other relevant sections, for the design safety of the platform have been implemented. Prom this evaluation, the 'Design Accidental Events' should be identified; i.e. those within a defined area of probability which would result in ‘unacceptable consequences’ if special considerations are not carried out. Unacceptable consequences are: 5 death or serious injury to personnel during or outside their working situation » 5 damage to essential parts of the installation or environment, . In selecting design accidental events, the most improbable accidental events may be excluded. The total probability of occurrence of each type of accidental event excluded should not exceed 1074 per year, by the best available estimates. Each event is checked against ‘acceptance criteria’, principally that the accidental event does not impose danger to personnel outside the immediate vicinity. This is satisfied if the following criteria are met: a. at least one escape way from central positions, which may be subjected to an accident, shall normally be intact for at least one hour. b. shelter areas shall be intact until safe evacuation is possible. when exposed to a design accidental event, the main support structure must maintain its load carrying capacity for a specified time. | Establishing and accepting design accidental events shall be 1 based on estimated risk. When this is evaluated, the events may “be considered acceptable in principle, and the design may j proceed. In all phases of the design, measures to reduce the risk should be considered, and evaluated with regard to cost and | efficiency.PROCESS DESIGN HANDBOOK Oo ISSUE DATE: 25 MAY 1984 SECTION: 1.2 REV. DATE: 1 JUNE 1984 REV:0 PAGE:1 of 2 statoil 1.2 Establishing Design Conditions Reference Specification: M-SP-113 "Pressure vessels" 1.2.1 Design Pressure For an equipment item or a series of connected equipment items protected by a common pressure safety (relief) valve or valves, the design pressure of all the items should be not less than the greatest of the following values using the highest operating pressure of the series of itens. a. 0.35 bar above the maximum operating pressure. b. 10% above the maximum operating pressure, up to 70 barg. c. 8 1/2%, but not less than 7.0 bar above the maximum operating pressure exceeding 70 barg. For vessels operating at less than atmospheric pressure the following design pressure shall apply: a. For internal operating pressure equal to or greater than 0.35 bara, the internal design pressure shall be the minimum operating pressure minus 0.1 bar or 0.5 bara whichever is the lower. b. For internal operating pressure less than 0.35 bara, the internal design pressure shall be 0 bara i.e. full vacuum. The maximum operating pressure should be evaluated with regard to the means of pressure control and may exceed the normal operating pressure shown on PFD's. As a minimum use: Maximum operating pressure = Normal operating pressure plus 58. For equipment items piped in the discharge side of a pump the design pressure should be calculated as follows: Design pressure = Normal pump suction operating pressure plus (1.25 x pump differential at design flow) or the design pressure of the vessel from which the pump takes suction plus pump differential at normal flow, whichever is the greater.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.2 REV. DATE: 1 JUNE 1984 REV:0 PAGE:2 of 2 stat}, | 1.2.2 Design Temperature pescaressas! es | The design temperature limits are any max/min temperature that may occur under normal and emergency operating conditions. These 1 limits are stated on the Data sheet. The design temperature shall be as follows: 1 a. At operating temperatures above 15°C the upper design i temperature shall be not less than 30°C above the maximum operating temperature. The lower design temperature shall be equal to or lower than the ambient temperature. b. At operating temperatures between 15°C and minus 30°C the lower design temperature shall be not less than 5°C 1 below the minimum operating temperature or equal to or lower than the ambient temperature whichever gives the lower value. 1 The minimum design temperature shall be 50°C. 7 At operating temperatures below minus 30°C the lower design i temperature shall be equal to or lower than the minimum operating tenperature. i In establishing the design temperature the following considerations should be taken into account: 1 a. Steam out of equipment and piping. Generally dual : operating conditions are specified. =] be Bypassing of upstream exchangers, e.g. if it is possible ~! to bypass an upstream cooler the downstream equipment must be designed for the temperature upstream of the | cooler. c. Depressuring of equipment and piping. This will usually | govern the lower design temperature for high pressure gas/condensate equipment. | a. Joule Thomson effect across relief and blowdown valves. e. For compressor suction drums account should be taken for ! possible failure of recycle cooler and increased suction temperature. |PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.3 REV. DATE: 1 JUNE 1984 = REV:0 PAGE:1 of 4 statoil 1.3 Platform Operations 1.3.1 General Offshore facilities are, for the most part, designed around normal, steady state, operating conditions. However it is also necessary for a process engineer to be aware of the requirements associated with: : Fabrication, installation and hook-up . Testing and commissioning a Start-up and shutdown under normal and emergency conditions 1.3.2 Fabrication/Installation/Hook-Up To reduce or simplify the requirements for fabrication, installation and hook-up, the following considerations should be borne in mind during the design phases of a project: a Equipment should be located to minimise intermodular piping, cabling ané ducting connections. This is of particular importance if firewall or blastwall penetrations are involved. b. Equipment should be located to maximise the degree of onshore testing and precommissioning that can be carried out. Typically work performed onshore is cheaper than if the same work were performed offshore. For example, if a compressor, complete with associated scrubbers, coolers, recycle, control panel etc, is installed within the one module it would be possible to test and precommission the system prior to installation offshore. ce. Modules shoulé preferably be arranged to enable direct placement rather than requiring skidding to their final position, This will minimise crane barge requirements. a In the case of integrated deck designs, the equipment layouts should give maximum flexibility to the deckPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.3 REV. DATE: 1 JUNE 1984 © REV:0 PAGE:2 of 4 stat. construction schedule e.g. design such that late delivery items can be installed last. e. The platform should be designed such that the fire | protection accommodation, life support and drilling facilities are available for use as soon as possible 1 i after installation. 1.3.3. Testing and Precommissioning : Once a system is certified as mechanically complete, usually as a j result of a P & I.D. check, it is then ready for testing and pre- } commissioning. Typically this consists of the following activities: _ flushing and cleaning ' . pressure testing { drying and purging ‘i During the detailed design phase of a project the process i engineer should ensure that adequate high point vents and low point drains are provided to assist these activities. It is a | good idea to prepare pressure testing P & I.D.'s. These are construction issue P & I.D.'s marked up to show each test | system/spool. Having indicated the extent of each system/spool it is then possible to check that sufficient provision has been @ made to isolate, test, vent and drain. | After testing, the systems are dried. This is usually carried out using hot dry air. It may be possible to use the platform | plant/instrument air facilities, if these can be run froma diesel generator, if not temporary facilities will be required. | Purging of process systems is required prior to the introduction of hydrocarbons to prevent the possibility of a fire or explosion | arising from mixtures of natural gas and oxygen. This is preferably carried out using nitrogen or inert gas. Supplies of | 1 purge gas are required for normal operations. However these facilities are usually too small to meet the pre-commissioning | | requirements.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.3 e] REV, DATE: 1 JUNE 1984 REV:0 PAGE:3 of 4 statoil Therefore temporary facilities are usually required for pre- | commissioning purposes. Process systems are normally pressurised to 5 barg 3 to 4 times and tested to ensure oxygen content is below the lower flammability limit. 1.3.4 Commissioning/Start-Up During the pre-engineering phase of a project “Black Start" and “Routine start" philosophies should be prepared. The usual system start-up sequence is: . Safety 0 Life support : Process support/utilities 5 Drilling (if required) . Process Careful analysis and development of these philosophies will identify the procedures and specific requirements associated with commissioning and start-up. e.g. black start heaters, auxillary sea water lift pumps etc. These systems have to be operated from a dedicated black start generator e.g. the diesel driven emergency generator since they may be required to enable a main turbine/generator set to be started. When designing the facilities, the process engineer should ensure that adequate provisions are made to start-up equipment, such as: a. small bore by-passes around block valves for pressurisation b. recycles on pumps and compressors so that the machines can be run up to operating conditions before being brought on line. c. J-T valves bypasses on expanders to enable flow and operating pressures to be established before bringing the expander on line. a. Time éelays and overriders on alarms and switches to enable equipment to be started and normal operating conditions to be established.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.3 ~N, REV. DATE: 1 JUNE 1984 REV:0 PAGE:4 of 4 stat. ] : : ! e. Provisions for the installation of temporary strainers i in the suction line to pumps and compressors. In discussion with vendors specific start-up and shutdown requirements should be established. During the design sufficient chemical injection points should be provided for all foreseeable operations. 1.3.5 Shutdown Shutdowns can be divided into two major catagories: : operational shutdowns, which are necessary for turndown, inspection or maintenance requirements } emergency shutdowns, which are initiated as a result of potential hazardous upset conditions occurring in the 1 facilities. For dperational shutdowns, the main concern of the process : engineer is that equipment can be started up and shutdown with i minimal impact on the remaining processing facilities. Problems can occur if upset in the operating conditions are of such a | magnitude that another shutdown switch is tripped, unintentionally shutting down other items of equipment. This } situation is known as a "knock-on" effect, which could eventually, shutdown all the facilities. Consideration should also be given ! to starting and running-up to speed spare machines before taking 7 the machine to be shutdown off line. 1 Emergency shutdowns are initiated by switches set to protect the i facilities against potentially hazardous conditions. The requirements for Emergency Shutdown (ESD) systems are discussed in Section 1.1. In the case of an emergency shutdown, the facilities, or part of the facilities, are isolated, machinery shutdown and hydrocarbon systems depressurised. Depressurisation of high pressure hydrocarbon systems can result in low temperatures. The process engineer should ensure that such low temperature requirements are adequately catered for in the design 1 of effected equipment and pipework.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.4 REV. DATE 1 JUNE 1984 REV:0 PAGE:1 of 6 statoil 1.4 1.4.1 Training parallel required a. Training/Sparing Philosoph Training of equipment involves the provision of two or more units to achieve the design duty. The number of trains is determined by: Equipment physical size limitations for fabrication and transportation. For vessels increasing wall thickness restricts vendor supply. As a guideline a maximum wall thickness of approximately 100mm is recommended. Note that there is not a definite cut off value. Pigure 1.4.1 gives typical diameter limitations for a standard grade steel. A normal transportation limit of 4m diameter is recommended but local conditions may control. . Equipment/driver availability - the selection of equipment is usually on the basis of proven technology. Bence, only specific frame sizes are available which may necessitate the use of a number of machines. For gas turbine drivers the restriction is on available frame sizes, these are noted in Section 5.6. Por electric motor drivers a maximum size of approximately 5MW is recommended on the basis of increased availability and limiting starting loads. Turndown requirements - these should be reviewed on a case by case basis. A number of trains offer advantages with respect to turndown, however this will not usually be an overriding factor. Flare load requirements - if the flare study for the facility identifies that blowdown is the design case, then decreasing inventories by increasing the number of trains and reviewing the layout may be one possible solution.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 REV. DATE: 1 JUNE 1984 REV:0 stat. *! Within the restrictions imposed above, the optimum design will generally correspond to the minimum number of trains. This gives the minimum equipment requirements, and consequent space, weight and cost implications. It also reduces the piping, hook up and instrument requirements. 1.4.2 Sparing Equipment sparing is determined by: a. Safety requirements - specific systems such as, firewater require installed spare capacity for safety reasons. b. Loss of capacity and line pack. Sparing of equipment may be required to ensure that , sales contracts are met for all operating contingencies. Generally, this is more critical for gas field developments than for oil field developments. For an oil field, the contract usually allows flexibility with respect to supply. Crude storage is available either in GBS cells, pipeline, tanker or at a refinery and thus there is not usually a penalty \ associated with non deliverability. Hence a prolonged shutdown results mainly in loss of revenue. = For a gas field the sales contract is usually based on a _ stated DCQ (Daily Contract Quantity). Penalities will be applicable if the production is less than the required Deg. Generally, no storage is available but the line pack in an export pipeline does provide some storage. Hence loss of production in a gas field development may result in a contractual penalty as well as loss of revenue. For both oil and gas fields, the design flowrates take . into account an annual maintenance period. ce. Requirements for regular maintenance - this will depend on how critical the machinery is to operation of the process.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.4 or REV. DATE: 1 JUNE 1984 = REV:0 PAGE:3 of 6 statoil The requirements for sparing and training are interrelated and should be established in parallel, i.e. 2 x 1008 trains may have greater impact than 3 x 50¢ trains if installed spare capacity is required. Spare equipment can be: a. Installed when immediate replacement is required. b. Platform stored when immediate replacement is not required, but can be reinstalled quickly. Shore Base stored for large items and those not needing to be reinstalled quickly. ami E GY mena: Assine> i asco TE ty BE Lome eases ov a neoness ew E20 Sieis He Ba DesOW eAPSeUMe te ob t : Figure 1.4.1 Maximum Vessel Diameter Based on 100mm ThicknessPROCESS DESIGN HANDBOOK ISSUE DATE: REV. DATE: 1 JUNE 1984 25 MAY 1984 REV:0 SECTION: PAGE:4 of 6 The training and sparing requirements for various types of equipment are summarised below in Table 1.4.1. EQUIPMENT TRAINING SPARING Separators Limit vessel thickness to 100mm for fabrication. Limit vessel diameter to 4m for transportation. Limit vessel size to suit layouts. Not normally spared unless, part of a rotating machinery train i.e. compressor scrubbers. Compressors Select compressor/driver arrangement to give good power match. Consider capacity range requirements, ie. turndown. Normally installed spare machine on critical duty. Include K.0. drums and exchangers in spare train Heat Exchangers Physical size limitations. Tube length less than 7m Tube bundle maintenance weight less than 10 tonnes. Spared when regular maintenance/cleaning required in critical duty. Pumps Available pump and driver size dictates training requirements: If electric motor limit to SMW. Normally installed spare on continuous duties. No spare for intermittent non- critical duty. Drivers To suit driven equipment and availability of machine size. If electric motor limit to 5MW. See driven equipment. stat“ } ) 4 i Table 1.4.1 Training and Sparing| PROCESS DESIGN HANDBOOK Lf ISSUE DATE: 25 MAY 1964 SECTION: 1.4 S REV. DATE: 1 JUNE 1984 REV:0 PAGE:5 of 6 statoil I i EQUIPMENT TRAINING SPARING ! Columns Limit vessel thickness |Not normally spared. to 100mm. Limit vessel diameter : to 4m for transporation. Consider turndown requirements. a Heaters See heat exchangers. Spared in critical duties. Firewater | Two independent 1008 Sparing catered for by Pumps capacity trains must training. be installed. Number of pumps in each train is dictated by available pump and ‘ driver size. Control, |For high rangeability |Control valves can be Valves use control valves in |spared for extra plant parallel. reliability, but not normally done. Usually by-passed by hand control valve. - Relief Where large relief Relief valves spared Valves valves are needed, a where maintenance or multiple arrangement testing would otherwise with different set mean shutdown. pressures can be used |Isolation valves must to avoid valve chatter. |be safely interlocked. Table 1.4.1 Training and Sparing (Continued)PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 REV. DATE: 1 JUNE 1984 REV:0 EQUIPMENT TRAINING SPARING } Power Consider turndown Install spare generator I Generation | requirements for all (Main) operating modes (gas turbines should run as fully loaded as possible, preferably 60-90% full load). Use similar machines throughout platform, where possible, to ease maintenance. e7 Power Depends on emergency No sparing. Generation | power demand and (Emergency) | available unit size. Table 1.4.1 Training and Sparing (Continued) 1PROCESS DESIGN HANDBOOK ~ ISSUE DATE: 25 MAY 1984 SECTION: 1.5 REV. DATE: 1 JUNE 1984 REV:0 PAGE:1 of 5 statoil 1.5 Process Control/Instrumentation Reference Specifications: J-SD-001 “Supervisory Control and Data Acquisition System" J-SD-013 “Shutdown and Alarm Systems" J-SD-021 “Control Centres" 1.5.1 General The main objective of the platform control system is to achieve safe operation and high production availability. Considering a single Production, Drilling and Quarters (PDQ) platform then control of all the platform facilities is usually undertaken from ~ a@ continuously manned Central Control Room (CCR), i.e. a Centralised Operation. In the case of a PDQ Platform this implies that all production process equipment, utilities and safety systems is controlled from the CCR, or instructions are given to personnel who will execute the control functions from the local panels or equipment rooms. The majority of the process control functions are provided from the CCR but specific large package systems such as process gas compressofs, turbogenerators etc., are provided with local, normally unmanned panels. However, monitoring and executive control is available from the CCR. When personnel are allocated to local duties, they will be under the direction of the CCR operator, who will ensure that direct communication between the personnel and CCR is maintained at all times for the duration of the locally manned operation. It is emphasised that the local panels are primarily provided to accommodate equipment interfacing directly with interrelated groups of process plant and equipment, thus achieving savings in cabling costs and hook-up/commissioning effort.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.5 yy REV. DATE: 1 JUNE 1964 REV:0 PAGE:2 of 5 statui w — \k ; ao oar eereearar| (os 3° 8 fe |_ [ha a Es sums swausis BE Bee 33 ee 1 # # ! gs : ‘| ie LE | 7 22 — ere —— | { i « a os a | arom # ess NET TT | Figure 1.5.1 Simplified PDQ Platform Control Schematic |PROCESS DESIGN HANDBOOK = ISSUE DATE: 25 MAY 1984 SECTION: 1.5 REV. DATE: 1 JUNE 1984 REV:0 PAGE:3 of 5 statoil The complexities of multiple remote facilities with multiplexed signal usage and the degree of control and data acquisition on the platform necessitates a combination of microprocessor and computer techniques. The use of a Supervisory Control and Data Acquisition system (SCADA) is appropriate for such a system. This allows the operator the facility to overview all operational parameters in addition to allowing control of the important faciltity systems, from the main CCR. See Figure 1.5.1 for a simplified control schematic. [Link] Supervisory Control and Data Acquisition (SCADA) System The SCADA system collects data from the process and utility systems and also relays control signals to the various systems. The system is computer based and can also be used to store data to utilise for management reports. This could be achieved using the platform SCADA system or link to a similar Shore Based Computer (SBC). The platform SCADA system comprises operator consoles, work stations, computers with data storage facilties and input/output interfaces. 1.5.2 Emergency Shutdown (ESD) System The ESD system is designed to protect personnel and the installation against unsafe operating conditions and catastrophic situations. Unsafe operating conditions could be a fire or gas hazard or an operational malfunction. The ESD system is designed with a failsafe redundant configuration, to ensure maximum system safety, availability and control flexibility. The system is energised in a non-alarm state and will therefore failsafe on power failure. The ESD system provides five shutdown levels as follows: Level 1: Total shutdown of all systems (ESD I) Level 2: Shutdown of production systems (ESD II) Level 3: Partial shutdown of production systems Level 4: Shutdown of individual systems Level 5: Shutdown of individual system componentst PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.5 ~ stated 1 JUNE 1984 0 REV:0 PAGE REV. DATE of 5 The first two levels are classified as Emergency Shutdown (ESD) while the lower levels are referred to as Partial Shutdowns. A simplified ESD system is shown in Pigure 1.5.2. Poo PLATFORM aoz | [Somes] [eee Eo Peas) rrese oe we ane Pigure 1.5.2 Simplified ESD system ESD-1 is manually initiated and will only be used when a decision has been made to prepare to abandon platform. ESD-1 is normally preceeded by ESD-2. However, actuation of ESD-1 will automatically initiate the functions of ESD-2. ESD-2 is normally automatically actuated, however the option for manual activation is retained. Where necessary two out of three voting will be employed, to avoid spurious trips caused by single instruments. The ESD system status is displayed on demand at the SCADA console. 1.5.3 Fire and Gas System The fire and gas system continuously monitors all platform areas and automatically initiates appropriate fire fighting protection system, shutdown system and alarm system in response to the detection of a fire or gas release. The fire and gas display and control is located on a separatePROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.5 . REV. DATE: 1 JUNE 1984 REV PAGE:5 of 5 statoil panel in the CCR. Monitoring equipment is hardwired to the panel from the field devices. The platform is divided into fire areas which are evaluated with respect to area classification, ventilation, occupancy, enclosure, potential fire risk, and the combustable hazards that may be present. Choice of fire and gas detectors is then made on the basis of the anticipated causes of fire in that area. 1.5.4 Process Control Considerations Process control is used to maintain conditions within a process to give steady and continuous production automatically. Instrumentation is necessary to give operators an insight into the actual process conditions within the plant. Alarms can be ~ associated with both controllers and individual instruments to warn of excursions from desirable conditions, and to take remedial action i.e. shutdown of all or part of the process if the excursion is not checked by the operators. To determine the requirements it is best to consider control functions on a simplified process flow diagram, preferably contained on one sheet of paper to facilitate interaction checks and duplication. Determine the main overall parameters of the process, and initially imagine the plant operating under purely manual control. To maintain manual control a variable, e.g. pressure, is shown by an indicating instrument, and the desired value (set point) is maintained by opening or closing a valve or by some other manual operation. Once this manual link has been éetermined, the indicator can be changed to a controller which takes over the manual operation. The controller will maintain the variable about the set point, with the degree of deviation from the set point being a function of the response of the instrument. This can be adjusted to suit upstream or downstream processing. This method can be used to determine all the control loops required on the plant, and also whether it is necessary to have one controller adjusting the set point of another.PROCESS DESIGN HANDBOOK ISSUE_DAT! 25 MAY 1984 REV. DATE: 1 JUNE 1984 REV 1.6 Layout Considerations Reference Specification: M-SD-028 “Platform Layout" 1.6.1 General The layout development for a platform is a multi , 2 SECTION: 1.6 status} PAGE:1 of 7 ! 5 i i discipline activity which is centered on the feasibility and conceptual phases. At the later phases of the project the layout is -~ basically agreed and provides data for the disciplines. This D section gives a review of the layout concepts and details any specific process considerations. Reference is made to the Design Specification M-SD-028 "Platform Layout" for specific considerations. 1.6.2 Field Development Plan Before commencement of a preliminary layout study it is necessary that a design basis for the field development is formulated. This will include both the field related and platform related aspects: The main field related aspects are: Platform support concept Platform service e.g. full production, wellhead. e Number of platforms, interactions and connections. e.g. Steel jacket, concrete gravity base, Tension Leg Platform. t . Deck concept e.g. Module support frame, U Integrated deck. ! The main platform related aspects include: ) : installation method e.g. inshore or offshore. p . drilling/wellhead requirements. i : process and utility requirements. : manning levels. | o safety requirements. With the above data defined the platform layout can commence. |PROCESS DESIGN HANDBOOK oO ISSUE DATE: 25 MAY 1984 SECTION: 1.6 REV. DATE: 1 JUNE 1984 REV:0 PAGE:2 of 7 ey * E statoil 1.6.3 Layout Premis: The aim of the platform design and layout is to minimise the occurance and consequence of accidents and maximise the intrinsic safety of the facility so as to afford the maximum protection to human life and property. Proper segregation of equipment and areas appropriate to hazard, environmental and-operating requirements shall be achieved. This should be by employing adequate allowance for operation, maintenance and emergency escape while at the same time making the most efficient use of space and weight. A simplified block layout for a fully integrated platform concept is shown in Figure 1.6.1. Figure 1.6.1 shows the main areas (depending on service) for the platform. Specific layout considerations applicable to each of these areas are outlined in the Design Specification M-SD-028 "Platform Layout". Hazardous area and escape route requirements are discussed in Section 1.1, Safety Considerations. The general layout philosophy shown in Figure 1.6.1 is to locate the Wellhead area and Accommodation area as remote from each other as possible. The process equipment, hazardous and non- hazardous utilities can then act as a buffer between the above areas with the equipment arranged in order of decreasing potential hazard. 1.6.4 Process Information - The following process related information is required at the feasibility stage to undertake a platform layout: a. Process schematics outlining the basic flows and equipment required. b. Utility schematics. ce Equipment list giving sizes and weights. a. Identification of hazardous/toxic substances and equipment.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.6 REV. DATE: 1 JUNE 1984 © REV:0 PAGE:3 of 7 state! al MEAD AND mun | ag 4 processine oy mt SE VTAL_ sERvices AccOMMODATION WELLHEAD AND ORLLNO. umumes sta € Cr 1h, Stone SS] | La LEE i Figure 1.6.1 | Simplified Area Segregation for Platform LayoutISSUE DATE: 25 MAY 1984 SECTION: 1.6 REV. DATE: 1 JUNE 1984 REV:0 PAGE:4 of 7 statoil Other documentation, such as Process Flow diagrams and Piping and Instrumentation Diagrams will be required at subsequent stages of the project. The list given is intended to represent the minimum requirements to formulate a layout. 1.6.5 Specific Equipment Considerations Reference is made to Design Specification M-SD-028 "Platform Layout" for specific considerations relating to the following equipment/areas: 5 Unfired Pressure Vessels 5 Fired equipment a Byérocarbon storage a Machinery : Cranes - Life boats a Flare ‘i Pire Protection : Workshop and Stores 1.6.6 | Specific Process Considerations The following process considerations are relevant to the platform layout: a. the layout should reflect a logical progression of the process. This should then minimise major piping requirements. Other equipment with small diameter piping, can be located where necessary e.g. glycol regeneration package. b. related equipment should be modularised to allow maximum hook up ané precommissioning to be achieved, e.g. compressor with associated knock out drum and aftercooler. ce. requirements for pump NPSE should be established e.g. export pumps.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.6 REV. DATE: 1 JUNE 1984 REV:0 PAGE:5 of 7 ~ pump suction lines should have no vapour pockets and be | of minimum length. e. systems based on gravity drainage should be identified. } eo requirements for future equipment should be identified a to allow incorporation into the initial layout. } allowances for straight piping runs should be made where appropriate e.g. compressor suction lines, metering , runs. ; he compressor suction lines should have no liquid pockets. i. two phase lines should be of minimum length and with no = } pockets to minimise potential slugging. o) j two phase lines from coolers should free drain to the | knock out drum. ke vapour lines in wet carbon dioxide or corrosive service should have no liquid pockets. 1 filter separator/KO drums located upstream of TEG contacting/acid gas treating units should be located close to the contactor. This minimises the possibility of hydrocarbons or millscale entering thé contactor. a. flare lines shoulé slope to the KO drum with no liquid pockets. j ne locate control valves in bubble point liquid service so that there is no possibility of flashing at the valve ™ | inlet. - 1.6.7 Preliminary Space Estimate On the assumption that a modularised concept is used the following factors can be used to assess deck area requirements for preliminary layout studies:PROCESS DESIGN HANDBOOK BEV. DATE: 1 ONE 1964" REV:0 PRET Of REV. DATE: 1 JUNE : 26 ©: fF statoil Module Type Area Ratio* Wellhead Set by well pattern/ drilling requirements Separation 0.20 = 0.40 Gas Compression 0.15. - 0.20 Water Injection 0.20 - 0.25 Power Generation 0.20 - 0.30 Utilities 0.15 - 0.20 Accommodation 23 to 25m*/bed * Ratio of Major Equipment footprint area to total module area. Table 1.6.1 Module Type Area Ratios Accommodation requirements in Table 1.6.1 are based on single man cabins and a typical 300 man accommodation unit, Note that many small items of equipment require more deck space than fewer larger items of equipment. It is stressed that the above factors are for first pass estimates only, and may be modified by special requirements and considerations. Module sizes will be determined for each platform dependent on the location of the platform, its size and type. Some guidelines based on maximum crane capacities for offshore lifts are given below: Crane Max. Lift Max. Max. Max Vessel Weight Module Module Module Length Width Height Tonne Tonne m m m 2000 1820 34 13 to 15 10 to 12 3000 2720 38 to 44 13 to 15 10 to 12 Table 1.6.2 Crane Vessel Capacities and Module DimensionsPROCESS DESIGN HANDBOOK 25 MAY 1984 SECTION: 1.6 ~ 1 JUNE 1984 REV:0 PAGE:7 of 7 stat™ ISSUE DATE REV. DAT! The use of tandem lifts or inshore lifts may give increased dimensions although these will have to be defined for each case. When the module dimensions have been established, the following allowances can be made for steelwork and cladding to arrive at.a "usable" plot area: : 1.0m from all walls. ‘i 1.0m from horizontal members in the floor and roof. These allowances are given as a starting point and should be reviewed at an early stage.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.7 REV. DATE: 1 JUNE 1984 REV:0 PAGE:1 of 2 statoil rit) Piping and Instrument Diagrams Reference Specification: A-SG-003° “Draughting Standard for Piping, Instrument and Flow Diagrams" 1.7.1 General The piping and Instrument diagram (P & ID) summarises the design intent of the facility and acts as a basic control document between process and other disciplines. The P & ID goes through certain development levels during a project. Five levels are defined in the draughting standard, with level 5 as the approved for detailed engineering drawings. For this guideline, which is intended for preliminary design, the Level 1 data is applicable. The content includes: Level 1 (P& ID) a. All process and utility equipment to be shown and tagged. b. Equipment data summary label to be shown with tag number and service indicated. c. All interconnected main pipework. a. Instrumentation reflecting the control philosophy such as control loops, trips, shutdown valves, PSVs, blowdown and flow measurement. e. valves such as isolation valves in control loops, in connection with PSVs around equipment and pumps to be shown. Operating philosophy with respect to standby/operating equipment. 3. Packages to be identified. he Connections of other systems identified.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.7 ~ REV. DATE: 1 JUNE 1984 © REV:0 PAGE:2 of 2 stat_ i For the requirements of the other levels reference is made to the Design Specification. Other information in the Design Specification A-SG-003, "Draughting Standard for Piping Instrument and Flow Diagram" includes: 5 draughting requirements : symbols for instruments etc. : equipment data summaries : revision codingo PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.8 7 REV. DATE: 1 JUNE 1964 REI PAGE:1 of 4 statoil 1.8 Overall Process Optimisation 1.8.1 | General The steps necessary for an overall process optimisation study are illustrated below: Step 1 Establish Design Requirements Step 2 ->———— Establish/Screen Technically Feasible {__________ processes Step 3 >—————Es tablish ———___ Weight, Space and Utility Consumption For Each Process | Step 4 -———— Perform Preliminary Screening on Basis of Weight, Space, Utility Consumption, Process Operation and Flexibility Step 5 Perform Simple Economic Evaluation of Each System at a Chosen Datum I Select Process Taking Economics, Flexibility Land Suitability into Account Step 6 | For most process optimisation studies it is not necessary to perform a cost comparison. Generally, the preliminary screening in terms of weight, space, utility consumptions, processPROCESS DESIGH HANDBOOK . oO 25 MAY 1984 SECTION: 1.8 ISSUE _DATI REV. DATE: 1 JUNE 1984 REV:0 PAGE:3 of 4 statoil 1.8.4 Weight, Space and Utility Consumptions Weight, space and utility consumptions can be estimated either by reference to the relevant section in the Process Design Handbook or from other design information e.g. computer simulations, vendor data etc. All data should be developed to a similar level and to a consistent set of criteria e.g. it is not realistic to compare a fully developed process design for one system with a preliminary estimate for another. Overall topside space requirements can be estimated from the equipment footprint area and typical module density criteria (listed in Section 1.6). Common items of equipment or systems should be identified and either excluded from all options or the same figures applied to each option. Vendor/licensor data should be checked to ensure - they meet Statoil's criteria for weight, space and operability, e.g. refrigeration packages may not confirm with Statoil's normal spacing criteria, equipment weights may be estimated to different design codes etc. 1.8.5 Preliminary Screening For most process optimisation studies it is possible to select the preferred process scheme without carrying out a detailed cost comparison, The preliminary screening should first consider process operation, flexibility and potential maintenance requirements. Unless the process, which is preferred on this basis, shows a significant penalty in terms of weight, space or utility consumptions, it can be selected with confidence. Generally, this preliminary screening will at least narrow the number of potential options down to two or three which can be subjected to a more detailed cost evaluation. 1.8.6 | Economic Evaluation For most offshore platforms an overall cost estimate is only required for determining the feasibility of the development as aPROCESS DESIGN HANDBOOK Oo ISSUE DATE: 25 MAY 1964 SECTION: 1.8 REV. DATE: 1 JUNE 1984 REV PAGE:3 of 4 statoil 1.8.4 Weight, Space and Utility Consumptions Weight, space and utility consumptions can be estimated either by reference to the relevant section in the Process Design Handbook or from other design information e.g. computer simulations, vendor data etc. All data should be developed to a similar level and to a consistent set of criteria e.g. it is not realistic to compare a fully developed process design for one system with a preliminary estimate for another. Overall topside space requirements can be estimated from the equipment footprint area and typical module density criteria (listed in Section 1.6). Common items of equipment or systems should be identified and either excluded from all options or the same figures applied to each option. Vendor/licensor data should be checked to ensure .. they meet Statoil's criteria for weight, space and operability, - e.g. refrigeration packages may not confirm with Statoil's normal spacing criteria, equipment weights may be estimated to different design codes etc. 2.8.5 | Preliminary Screening For most process optimisation studies it is possible to select the preferred process scheme without carrying out a detailed cost comparison. The preliminary screening should first consider process operation, flexibility and potential maintenance requirements. Unless the process, which is preferred on this basis, shows a significant penalty in terms of weight, space or utility consumptions, it can be selected with confidence. Generally, this preliminary screening will at least narrow the number of potential options down to two or three which can be subjected to a more detailed cost evaluation. 1.8.6 | Economic Evaluation For most offshore platforms an overall cost estimate is only required for determining the feasibility of the development as aPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.8 ~ REV. DATE: 1 JUNE 1984 REV: PAGE:4 of 4 stal whole. Generally, minor variations in equipment cost will be well within the accuracy of the overall estimate. Hence, for most process optimisation studies, cost differences between options can be compared by applying simple values to the following items: : topsides weight (cost/tonne topsides weight) : topsides space (cost/m? deck area) : utiltiy consumptions (cost/MW power etc.) The above criteria will normally be set at the beginning of the development by the cost and planning group. The figures will only be applicable to evaluating cost differences between proces: _ options and will not represent absolute costs. Most optimisation studies will be comparing similar equipment types and the above figures will give a good basis for comparison without resorting to a full cost evaluation. A detailed cost comparison should be considered for either of the following cases: a. if the options being compared are totally dissimilar e.g. different materials of construction or different equipment types. b. if the options being compared have different effects on the overall project schedule. If the options being considered impact on the overall project schedule then the relative timing of income and expenditure must be taken into account e.g. if the platform throughput increases with time, it may be possible to delay installing equipment until a later date. This may impact significantly on the overall project economics and may substantially favour one option over another. Economic analysis techniques which take into account the relative timing of income and expenditure are based on discounted cash flow techniques, refer to Section 1.11. They are generally performed by the planning group using computer simulation techniques.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.10 s REV. DATE: 1 JUNE 1984 REV:0 PAGE:1 of 4 statoil 1.10 Topsides Weight Estimation 1.10.1 Introduction Weight estimates are produced at each state of a project. The accuracy of these estimates improves during each successive phase of a project as more information becomes available. Weight estimates are usually the responsibility of weight control engineers, however, it is useful for all discipline engineers to have a understanding of weight estimating particularly during the preliminary study phases of a project. 1.10.2 Input Information There are different types of information needed at different stages of the project. Pirst Estimate : - Overall layout drawings of topsides, giving main dimensions of modules and their functions (e.g. Process module, utility module with length, width and height) . Second Estimate + - Equipment lists including net weights (dry and operating) of each specified item. - Preliminary Layouts. Each discipline is responsible for the weights included in the equipment list issued from its department. However, the weight control engineers shall question and compare these estimates with relevant reference data. 1.10.3. Bulk Weights Once the number, type and size of the various modules has been established, bulk material weights can be estimated using the following procedure:PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.9 REV. DATE: 1 JUNE 1984 REV:0 PAGE:2 of 4 stat 7 Molecular Weight heavy fraction * : Density heavy fraction * . Mean average boiling point heavy fraction * . Gas/Oil Ratio, (State Basis) * : Density of Residual Oil, (State Temperature Base) * : Pour Point of Residual Oil * : Oil Volume Factor, at Reservoir Pressure and Temperature 5 Saturation Pressure at Reservoir Temperature . Saturation Pressure at Ambient Temperature (State eS Temperature Base) i) 0 Emulsion Forming Breaking Characterists * : Wax Formation Temperature, if applicable. * [Link] Production Mechanism Describe production method and supply the following for both platform and satellite wells. : Number of Production Wells * 5 *Oil Well Description a Conductor Spacing * : Casing Sizes * . Tubing Sizes (ID) * . Completion Types * ~ 5 Oil Wells Potentials Z 5 Peak Offtime Rate : Surface Shut-In Pressure * . Flowing Tubing Head Pressure * Flowing Tubing Head Temperature * : Oil Bottom Sediment Content 5 Is Gas Lift required during early and/or later Production Period, if so state : Bottom Hole Pressure c Entry Pressure : Surface PressurePROCESS DESIGN HANDBOOK a ISSUE DATE: 25 MAY 1984 SECTION: 1.10 REV. DATE: 1 JUNE 1984 = REV:0 PAGE:3 of 4 statoil 1.10.4 Special Items Two types of modules are of specific importance. The Module Support Frame (MSF) and the Living Quarters. [Link] MSF The first rough estimate of the weight of the MSF can be carried out in the same way as the other modules. However, the shape and type of the structure selected have a large influence. In addition one also has to remember that the weights included in the MSF may add up to as much as 1/3 of the totel topside weight. It is therefore very important to establish a reliable weight calculation for this part of the platform as soon as possible. [Link] Living Quarters Also for the accommodation facilities one can establish preliminary weights based on density factors. However, the different demands and specifications (e.g. number of one-man cabins, daylight, recreation areas etc.) will influence the final weight to a large extent. Bearing in mind that the Living Quarters may make up as much as 10 to 15% of the total weight it is important that the design and layouts are established in an early phase of a project. 1.10.5 Weight Contingencies Contingency can be defined as: "A factor given in per cent of total or item weight to provide for inaccuracies and uncertainties". By this definition it is obvious that the contingency factor will vary through a project's life cycle. At an early stage it may be as high as 30%. As more information is available and more details are clarified, this factor will be reduced. At the final stage, when a module is fabricated and weighed, it will be reduced to 0 to 28%, depending on the accuracy of the weighing equipment. An illustration of this development is given in Figure 1.10.1PROCESS DESIGN HANDBOOK | ISSUE DATE: 25 MAY 1984 SECTION: 1.9 REV. DATE: 1 JUNE 1984 REV:0 PAGE:4 of 4 stat“, , | This should include any other data which is pertinent to the | production facilities. 1 Location . Water Depth | Maximum/minimum ambient temperatures [Link] Other Data Wind rose Wave hieghtPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.9 ° REV. DATE: 1 JUNE 1984 = REV:0 PAGE:1 of 4 statoil 1.9 Design Basis Documentation 1.9.1 | General This section covers the design basis documentation required for a preliminary process design. A comprehensive data list is given below and the minimum data required for process preliminary Gesign identified by an asterisk. 1.9.2 Design Basis Documentation [Link] Reservoir Characteristics : Type of Reservoir - General Description * : Description of Development Method * [Link] Reservoir Date A Area . Gross Sand 6 Net Sand 6 Average Porosity . Formation Volume Factor : 01 in Place : Recoverable Reserves 5 Reservoir Temperature 5 Reservoir Pressure : Depth (State Reference Zero) . Effective Permeability . Production Index . Water Injectivity Index [Link] Reservoir Fluid Analytical Data ; State Type of Sample Analysis [Link] Reservoir Fluid Composition c Composition in Mole percent . State if hydrogen sulphide has been detectedPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.10 ~ REV. DATE: 1 JUNE 1984 REV:0 PAGE:2 of 4 stat 7" a. The volume of each module is calculated. | be The volume is multiplied by a “density factor" which is unique for each type of module for a specified type of ! platform. c. The total weight of each module is then separated into “discipline weights" by a given set of percentages. : These density factors and percentages have been derived by analysing "as-built" data for existing major North Sea developments. Compression Power Generation Process Utilities Wellhead | Table 1.10.1 | Typical Density Factors Disciplines =| Module Types [Steel _| Equipm. | Piping | avac | Arch | £1. | Misc, compression 46.6 29.3 11.6 +6 | 2.3 [2.5 Living Quarters |51.7 +6 sl | 4.1 134.7 | 4.0] 4.8 | Power Generation] 48.3 38.9 1.9 [1.2 | 2.2 [2.9] 4.7 Process 46.2 25.0 16.5 a) +9 [2.2] 9.3 | Utilities 58.8 18.0 7.3, | 3.0 | 2.9 | 1.7] 9.3 Wellhead 64.0 4.8 22.1 2 <5 | 1.0] 7.5 | Table 1.10.2 Typical "Percentage split* |PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.9 REV. DATE: 1 JUNE 1984 REV:0 of 4 statoil [Link] [Link] Production Forecasts Oil Production Water Production Profile Maximum Daily Production Rate Water Injection Water Injection Forecast and Phasing in Relation to Production Water Injection Well Description Number of Water Injection Wells Depth (State Reference Zero) Water Injection Rate per Well Surface Pressure Formation Fracture Pressure Injection Water Oxygen Level Injection Water Maximum Particle Size of Solids Chemical Injection Requirements Sea Water Disolved Oxygen Depth Profile Sea Water Chemical Analysis Any Seasonal Microbiological Growth in the Sea Water that would influence Water Filtration. Production Requirements Describe the marketing strategy for the produced oil and gas including sufficient information to define discharge pressures of product streams. Vapour Pressure Requirement of Tanker Quality Crude Vapour Pressure Limitation, if any, of Pipeline Quality Crude. Maximum Allowable Water Content of Produced Oil Ryérocarbon and Water Dew Point Requirement of Gas Product.PROCESS DESIGN HANDBOOK Oo ISSUE DATE: 25 MAY 1984 SECTION:1.10 REV. DATE: 1 JUNE 1984 REV:0 PAGE:4 of 4 stat 7}, i aa i DESIGNATED WEIOHT CLASSES. Figure 1.10.1 Weight ContingenciesPROCESS DESIGN HANDBOOK = ISSUE DATE: ‘25 MAY 1984 SECTION:1.11 REV DATE: 1 JUNE 1984 RE PAGE:1 of 9 statoil 1.12 Topsides Capital Cost Estimation 1.11.1 Introduction Capital cost estimates are produced at each phase of a project. The accuracy of these estimates improves during each successive phase of a project as more information becomes available. Cost estimating is the responsibility of Statoil's estimators, however, it is useful for process engineers to have an understanding of cost estimating so that they are aware o p how cost estimates are prepared. what engineering information must be produced to support the cost estimates. : Investment analysis techniques. During the pre-feasibility phase of a project where many possible alternatives are being considered, it is useful for a process engineer if he can produce his own cost estimates. 1.11.2 Input Information The following sets of input information are required to produce a preliminary cost estimate: 5 Mechanical Equipment List, including weights of equipment Topside Structural Steel Weight Estimates subdivided into 'Primary' and 'Secondary' steel. Bulk Materials Weight Estimates 5 Manhours Estimates for Engineering and the various construction phases of the project 1.11.3 Summary of Cost Centres The topside cost estimate can be divided into the following cost centres: c Engineering : Materials PurchasePROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTIO? REV DATE: 1 JUNE 1984 REV:0 PAGE:2 of 9 5 Onshore Fabrication : Atshore Installation 7 Inshore Installation Offshore Hook-up and commissioning Certification and Insurances : Management 1.11.4 Engineering Engineering includes pre-engineering, detailed engineering and construction engineering services. Engineering cost = manhours x manhour rate 1.11.5 Materials Purchase [Link] General Materials purchase is sub-divided into five sections: Process and Utility Equipment : Process and Utility Bulks . Structural Steel . Specialist Packages : Transportation to Site [Link] Process and Utility Equipment Process and utility equipment is identified on the Mechanical Equipment List. Costs for these items are based on: budget quotations from vendors. historical cost data collected on previous projects. Costs for these items will have to be adjusted to the cost basis for the project using escalation factors for the intervening years. These factors are obtainable from cost engineers. i)PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.11 REV DATE: 1 JUNE 1964 REV:0 PAGE:3 of 9 statoil [Link] Process and Utility Bulks Process and Utility bulk material costs are calculated by applying factors to the process and utility equipment costs. These factors are based on an analysis of data collected fron North Sea production platform projects. [Link] Structural Steel Steel weights for the topsides i.e. decks, modules, module support frames, integrated decks etc., have to be estimated by a structural engineer. A158 allowance for cutting and wastage is applied. The purchase costs are estimated by applying costs/tonne to the weights. [Link] Specialist Packages Specialist packages include living quarters, helidecks, flare structures, telecommunications etc. Costs are based on: : budget quotations from vendors : historical cost date collected on previous projects. As with historical equipment costs these costs will have to be escalated to current costs. 1.11.6. Onshore Fabrication [Link] Introduction Onshore fabrication includes all labour, consumables, construction plant, temporary construction services and site facilities required up to and including load out and sea fastening. [Link] Process and Utility Equipment and Bulk Fabrication Costs Process and utility equipment and bulk material fabrication costs are calculated by applying factors to the process and utilities equipment and bulk costs. These factors are based on an analysisPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION: 1.11 | REV DATE: 1 JUNE 1984 REV:0 PAGE:4 of 9 stat i! of the data collected from North Sea production platform projects. [Link] Structural Steel Fabrication Costs Structural steel fabrication costs are calculated from the structural steel weight estimates utilising manhour/tonne rates. [Link] Loadout and Seafastening Costs Load out and seafastening costs are calculated using a rate per tonne lift weight of completed deck and/or modules. Weights of completed deck and/or modules can be calculated by adding the equipment, special package, bulk materials, and structural steel weights and applying the appropriate contingencies. 1.11.7 | Atshore Installation Atshore installation includes the transportation of the deck and/or modules (including drilling packages, living quarters, helideck etc) from the various onshore fabrication sites to the atshore installation site, where the modules and decks will be assembled. Also included is the necessary hook-up and preparatory work prior to tow-out to the inshore installation site. Transportation and lifting costs are calculated by applying appropriate day rates to the marine equipment involved for the duration of the work. Marine equipment includes crane barge spreads, tugs, barges and supply boats. The hire rates include for mobilisation, demobilisation, labour, special equipment rental, fuel, port costs and other marine charges, anchor handling vessels when required and all consumables. Assumptions will have to be made about the number of days required for transportation lifting etc. On the basis that atshore installation takes place somewhere in south west Norway the following are typical transportation times: oD i | | =| 1 | |PROCESS DESIGN HANDBOOK ~ ISSUE DATE: 25 MAY 1984 SECTION:1.11 REV DATE: 1 JUNE 1984 REV:0 PAGE:5 of 9 statoil Days Elsewhere in Norway to atshore site 3 Denmark to atshore site 4 United Kingdon to atshore site 4 The Netherlands to atshore site 6 Atshore hook-up includes all labour, construction plant, consumables, temporary construction services and support costs. 1.11.8 Inshore Installation : Inshore installation includes the transportation of the deck assembly to deep water location for mating with the concrete gravity base structure (GBS) and for the installation of the Mechanical Outfitting in shafts. Marine equipment usually includes two large barges to support the deck assembly ané four tugs to tow the barges. The day hire rates quoted below are inclusive of fuel, port charges, maintenance costs and consumables. Costs relative to the transportation, ballasting and deballasting of the gravity base are NOT included in this estimate as they are assumed to be included in the sub-structure cost estimate. Inshore hook-up includes all labour, construction plant, consumables, temporary construction services and support costs required to bring the platform to as complete a state as possible prior to tow-out and installation offshore. 1.11.9 Offshore Hook-up and Commissioning Offshore hook-up and commissioning includes all labour, construction plant, consumables, temporary construction services and support for the work force employed on hook-up work to bring the platform to the state where all systems have been tested, commissioned and handed over to the operating staff.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.11 —~y REV DATE: 1 JUNE 1984 REV:0 PAGE:6 of 9 stat If the estimated size of the work force exceeds the available accommodation then the additional cost of a hotel/construction support vessel should be taken into account. 1.11.10 Certification and Insurances Certification and insurance costs are calculated as a percentage of the total cost of engineering, materials purchase, onshore fabrication, atshore construction, inshore construction and offshore construction. 1.11.11 Management Management costs are calculated as a percentage of the total cost of engineering, materials purchase, onshore fabrication, atshore construction, inshore construction and offshore construction. 1.11.12 Investment Analysis Three simple methods are available for undertaking this type of analysis. 1,11.12.1 Return on Investment A simple method which may be sub-divided into: = a Return on original investment ad = average yearly profit x 100 Original investment + working capital b. Return on average investment = average yearl: rofit x 100 average investment + working capital Where: average investment is either one half the original investment or the average between the original investment and the salvage valve. working capital is the sum of cash plus goods/inventories needed for the day to day functioning of the company or project. “) i| PROCESS DESIGN HANDBOOK . ISSUE DATE: 25 MAY 1984 SECTION:1.11 [s REV DATE: 1 JUNE 1984 REV:0 PAGE:7 of 9 statoil + POSITIVE ORIGINAL NVESTMENT CASH POSITION (PROFIT) “AVERAGE ANNUAL PROFIT ° TIME (YEARS) NEGATIVE CASH ORIGINAL INVESTMENT — SALVAGE VALUE | AVERAGE POSITION 2 INVESTMENT = ; ‘starts propucins AT THIS POINT CONSTRUCTION / S (INSTALLATION / HOOK-UP + PERIOD 5 Figure 1.11.1 Typical Cash Flow Each company must decide what is an acceptable minimum rate of return which may be adjusted in line with worldwide and company - economic conditions. - The major disadvantages of these methods are: a Cannot consider construction/installation/hook-up period. b. Considers only an average profit over the project life. Cannot make allowance for variations in project income with time. 2.12,12.2 Payback Period The simplest of the four methods, payback period is the time necessary, usually in years, to recover the original investment. Payback period is calculated by adding together the net profit per year until the total sum equals the original depreciable investment.PROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.11 > REV DATE: 1 JUNE 1984 REV:0 PAGE:8 of 9 statuil 9 | e.g. Original investment = 9 x 10° NOK j Net profit/year = 3 x 109 NOK (assumed constant per year) Payback period = 9x109 = 3 Years 3.x 10° ‘ In the form given above payback period is essentially the reciprocal of return on investment. However, some companies prefer to add the yearly depreciation to the net profit/year thus reducing the payback period. In this case payback period is not the simple reciprocal of return on investment. + POSITIVE CASH POSTION (PROFIT) 0. NEGATIVE CASH POSITION PAYBACK PERIOD. eee TIME (YEARS) ORIGINAL INVESTMENT STARTS PRODUCING ‘AT THIS POINT CONSTRUCTION / INSTALLATION / HOOK-UP PERIOD Figure 1.11.2 Simple PaybackPROCESS DESIGN HANDBOOK ISSUE DATE: 25 MAY 1984 SECTION:1.11 REV DATE: 1 JUNE 1984 REV:0 PAGE:9 of 9 statoil Each company must decide what is an acceptable payback period and this value may be adjusted from time to time to reflect both worldwide and company economic conditions. For example, in times when general interest rates are low and the company is performing well, a longer acceptable payback period may be justifiable as compared to more stringent economic conditions. The disadvantages of such a simple criterion are: a. only shows how quickly money will be returned but gives no indication of profitability of the investment. b. cannot consider investment in land or working capital. e. usually does not consider construction/installation/hook-up period (but could if necessary). a. considers income only up to end of payback period. [Link] Discounted Cash Flow (DCF) This is a method for estimating what one unit of currency received or expended in N years time, at a rate of interest R, is worth today. 1 unit currency in N years time = 1/(1 + R/100)% (the present value) All expenditure and income is phased over the life of the project and the net cash flow for each year is discounted back to present day value at a Company accepted rate of interest. Alternatively, and more commonly, the rate of interest is varied until the present day value is zero, by a trial and error method. e.g. 1 x 10° NOK income in 5 years time at an interest rate of 128 is worth today: ax 10° x 1/1 + 12/100)> © 567,427 NOK The net present value or rates of interest to give zero NPV are then compared for each scheme to determine the most economically attractive one. This method is suitable for investigating advantages gained by phasing installation of equipment.