Contek Solutions LLC

ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Twelve Steps to Engineering Safe Oil and

Gas Facilities
Based on SPE 141974
By: Jim Johnstone and Jim Curfew Contek Solutions LLC
Presenter: Mike Leonard VP of Special Projects Contek Solutions LLC

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Twelve Steps to Engineering Safe Oil and

Gas Facilities
1.Set a Design Standards Policy
2.Lay Out the Site for Safety
3.Personnel Safety
4.Design Piping Properly
5.Select the Proper Pressure Vessel
6.Picking the Right Tank
7.Specifying Rotating Equipment for Safety
8.Relief-System Design is Critical
9.Determining the Right Electrical-Area Classification
10.Design the Instrumentation and Control System for Safety
11.Conduct a Process Hazard Analysis
12.Design Verification and Commissioning
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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Get Management On Board

Are you following the High Road?
Does the company have personnel with facility safety
engineering experience?
Is cost a barrier to safety?

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

1. Set a Design Standards Policy

What Standards to Follow?
Communicate to ALL
Example Statement: All facilities will be
designed in accordance with good industry
design practices and codes, and to also meet all
regulatory requirements.

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

2. Lay out the Site for Safety

Vents, Flares, Fired
Equipment, Engines,
Vessels, Tanks, Offices
and Control Equipment

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Spacing Guidelines

Reference: PIP PNE 00003 Process Units and Offsite Layout

Guide
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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

3. Personnel Safety

Exit Routes
Stairs
Platforms
Guarding

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

4. Design Piping Properly

B31.3 Process Piping
B31.4 Liquid Pipelines
B31.8 Gas Pipelines

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

5. Select the Proper Pressure Vessel

ASME Section VIII Division 1

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

6. Picking the Right Tank

Fiberglass or Steel?
Atmospheric or Low Pressure?

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

7. Specifying Rotating Equipment for Safety

Pumps
IC Engines
Compressors
Electric Motors

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

8. Relief System Design is Critical

Capacity
Types
Sizing
System Design
Vent or Flared

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

9. Determining the Right Electrical Area

Classification
API RP 500
NFPA 497

Oil Tank
Vent
Wellhead

Division 2: 5' R

Separator

Division 1: Inside of Tank

Division 2: Inside of Berm

Division 1: 5' R
Division 2: 10' R

Compressor
Division 2: 10' R

Division 1
Division 2

Division 2: 10' R

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

10. Design the Instrumentation and Control

System for Safety
Levels of Protection

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Safe Alarm and Control Systems

Condition

Cause

Effect

Primary Protection

Secondary Protection

Location of
Safety Devices

Overpressure

High inflow pressure;

thermal expansion

Sudden rupture or leak

PSH

PSV

Gas vapor section

Leak

Corrosion, erosion,
mechanical failure,
rupture, external
damage

Release of
hydrocarbons to the
atmosphere

PSL to shut off inflow;

Check Valve to prevent
backflow; LSL on an
atmospheric tank or
vessel

Sump/drain system;
LSH on sump system

PSL in vapor
section; LSL at
lowest point in
atmospheric tank

Liquid Overflow

High liquid inflow;

Upstream failure of a
device; Blockage of
liquid outflow

Overpressure or excess
liquids in downstream
devices; Release of
hydrocarbons to
atmosphere

LSH

Sump/drain system;
LSH on sump system

LSH at high point

in vessel or tank

Gas Blowby

Failure of liquid level

system; opening of
bypass

Overpressure of
downstream
components

LSL

Safety devices on
downstream component

LSL at lowest
point in vessel or
tank

Underpressure

Withdrawal in excess of
inflow; thermal
contraction when
blocked in

Collapse of the
component; leak

Atmospheric vessels:
vent; Pressurized
vessels: gas makeup
system

Atmospheric vessels:
second vent or PSV;
Pressurized vessels:
PSL to shut off inflow
and outflow

PSL at highest
practical point;
PSVs and Vents in
accordance with
good Eng.
Practices

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11. Conducting a Process Hazard Analysis

Obtain Drawings
Select type of PHA
Incorporate results into final design

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

12. Design Verification and Commissioning

Pre-Startup Safety Review (PSSR)
Site Punch List

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Conclusions and Recommendations

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ENGINEERING ENVIRONMENT SAFETY MANAGEMENT SYSTEMS

Questions?

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