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876C-04-00-B-RP-006_K1
876C-04-00-B-RP-006_K1
PDVSA PETROCEDEÑO
Ingeniería de Detalle para las Interconexiones de los Sistemas de la Planta de Compresión y
Acondicionamiento de Gas con la Estación Principal y la Estación de Recepción de Gas de PDVSA
“Safety Philosophy”
ADDENDUM
REVISION INDEX:
This Document Consists of 35 Pages
(Addition) Indicates the following statement(s) is/are added to the document referenced text
(Deletion) Indicates the following statement(s) is/are deleted to the document referenced text
(Modification) Indicates the following statement(s) is/are revision(s) to the document referenced text.
The modification(s) is/are indicated with bold the letters.
Aprobación
Proyecto
Preparado por / Revisado PDVSA Razón para la
Rev. Aprobado por /
Fecha por / Fecha PETROCEDEÑO Revisión
Fecha
/ Fecha
H. López P. Gentile F. Salazar F. Malpica Issued for
M0
July 06, 2009 July 06, 2009 July 06, 2009 July 06, 2009 Approval
H. López P. Gentile F. Salazar F. Malpica
Issued for
M1 August 04, August 04, August 04, August 04,
Approval
2009 2009 2009 2009
H. López P. Gentile F. Salazar F. Malpica Issued for
K0 August 12, August 12, August 12, August 12,
2009 2009 2009 2009 Construction
H. López P. Gentile F. Salazar F. Malpica Issued for
K1 August 26, August 26, August 26, August 26,
2009 2009 2009 2009 Construction
PETROCEDEÑO Documento No: 876C-04-00-B-RP-006
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Rev./ Fecha: K1/ August 26, 2009
TABLE OF CONTENTS
SECTION Nº PAGE
1. INTRODUCTION................................................................................................................ 4
1.1 Purpose and Scope................................................................................................................ 4
1.2 Objectives............................................................................................................................... 4
1.3 Main Principles........................................................................................................................ 4
1.4 Developing the SAFETY CONCEPT at Project Stages..........................................................5
1.5 Handing-over the SAFETY CONCEPT at the End of the Project...........................................5
2. SAFETY ASSURANCE......................................................................................................5
2.1 Scope of SAFETY CONCEPT................................................................................................5
3. APPLICABLE DOCUMENTS.............................................................................................8
3.1 List of Applicable Documents..................................................................................................8
3.2 Prevailing Order, Scope and Deviations of/from Applicable Documents................................8
4. RISK ASSESSMENT..........................................................................................................8
4.1 List of Reference and Applicable Documents to Risk Assessment.........................................8
4.2 Description of the risk Assessment Studies............................................................................9
5. LAYOUT........................................................................................................................... 15
5.1 Applicable Documents to Layout..........................................................................................15
5.2 Particular Requirements and Description of the Layout........................................................15
6. HAZARDOUS AREAS CLASSIFICATION AND EXTENT..............................................20
6.1 Applicable Documents to Hazardous Areas..........................................................................20
6.2 Particular Requirements and Description of the Hazardous Areas.......................................21
7. ELECTRICAL POWER.....................................................................................................21
7.1 Applicable Documents to Electrical Power............................................................................21
7.2 Particular Requirements and Description of Safety to Electrical Power................................21
8. FIRE AND GAS................................................................................................................ 22
8.1 Applicable Documents to Fire and Gas.................................................................................22
8.2 General Requirements of Fire and Gas................................................................................22
9. PRESSURE PROTECTION AND RELIEF, SHUT-DOWN AND BLOW-DOWN..............25
9.1 Applicable Documents to PPR, SD and BD..........................................................................25
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1. INTRODUCTION
(Addition)
The purpose of this document is to define the basic SAFETY CONCEPT for the SINCOR
Upstream Surface Facilities which concern mainly:
Clusters,
Main Station,
1.2 Objectives
The present document is the up dated of the original SAFETY CONCEPT from the pre-basic
engineering and was developed during the basic engineering phase by OTEPI-FOSTER
WHEELER; rev. 2 is an update which includes some minor modifications and “Short term
Water Upgrade Project”
This document was updated during detail engineering phase of water upgrade project by
JANTESA-PROYCCA Consortium and issued as revisions X1 approved by Sincor.
Any issue or modification to the SAFETY CONCEPT shall be either prepared by, or formally
approved by SINCOR.
(Addition)
This document was updated by PDI / EXTERRAN during the basic/detail engineering
phase for “Main Station Gas Delivery Facilities Project”.
This document is intended to list-out the requirements of SINCOR regarding, Safety concerns
for the whole life cycle of the installation, and to define which options have been selected at
the basic-project stage. The Health and Environmental concern are included in the document
CA04-04-00-B-RP-008 (Replaced old Sincor Doc. No. 1020-13-00-2210-IN-002) “Health and
environmental philosophy”.
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At each engineering phase, the SAFETY CONCEPT shall be developed, by engineer and
SINCOR, explaining how safety is taken into account in all areas according to the risks
inherent to the project and shall state in writing the safety principles adopted.
As a consequence, the SAFETY CONCEPT naturally evolves in the course of the project.
In any phase it shall serve as the prevailing support document in matters of the requirements
and the principles applied, dealing with Safety.
At the end of the project, the SAFETY CONCEPT shall constitute the key document in the
safety dossier that shall be handed-over to the operator for the rest of the life cycle of the
installation.
2. SAFETY ASSURANCE
(Addition)
Main Station.
Main Station.
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Main Station Process Operating and Control Philosophy Doc. No. CA04-04-00-B-DC-004 has
been issued by CPO as per Sincor letter No. SPUC/CA004-4/L/MSCR/CPO/111 dated May
26, 1999. This document was update by CJP to include the facilities associated with Main
Station Upgrade Project.
(Addition)
Operating Philosophy for Short term Water Upgrade Project was issued as a separate
document and included in the Design Basis Specification, which is:
The Operating Philosophy for Gas Delivery Facilities was issued as a separate
document N° 876C-04-18-B-DC-003.
2.1.3 HAZID
2.1.4 HAZAN
2.1.5 HAZOP
Hazards and Operability (HAZOP) studies were carried-out by COMPANY during Upstream
Surface Facilities basic and detailed engineering projects, also during Short term Water
Upgrade Project and some modifications such as Mod 055 (Pressurization Console for P-
3001´s), recirculation lines to slug catchers, etc.
During Main Station Water Upgrade Project a HAZOP for the new Production Water
Treatment Plant and oil treatment plant modification, were developed during basic and
detailed engineering phases.
(Addition)
During the Basic Engineering for Gas Delivery Facilities Project was carried out a
Hazards and Operability Study (HAZOP). The report of this study is available in
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2.1.6 QRA
According to the Safety concepts and the Statements of Requirements issued during the pre
basic engineering phase “No Quantitative Risk Assessment (QRA) study is required for this
project”.
(Addition)
For Gas Delivery Facilities Project a Quantitative Risk Assessment (QRA) was
developed During Basic Engineering Phase (See Document N° 209001-R-ACT-ACR-
PETROCEDEÑO-EXTERRAN “Análisis cuantitativo de Riesgos Interconexión de
Paquetes de Compresión y Acondicionamiento de Gas”). 1
2.1.7 WHAT IF
(Addition)
2.1.8 PTR
3. APPLICABLE DOCUMENTS
1
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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4. RISK ASSESSMENT
The applicable document to Risk Assessment is PDVSA IR-S-02 “Criterios para el análisis
cuantitativo de riesgos”.
A Consequence Analysis study has been carried out during “Upstream Surface Facilities
Project” basic engineering and Main Station Water Upgrade Project (MSWUP) Detail
Engineering. The report regarding Upstream Surface Facilities project is provided in
Attachment 2 and the main assumptions, criteria and results are summarized in next section,
including results associated with MSWUP. For more detail regarding consequence analysis
and calculation for MSWUP see document nº CA04-00-13-K-RP-113.
(Addition)
During the Basic Engineering for Gas Delivery Facilities Project was carried out a Risk,
Assessment and Consequence Analysis. The main assumptions, criteria and results
are summarized in the next section. A report of this study was provided in document
N° 209001-R-ACT-ACR-PETROCEDEÑO-EXTERRAN “Análisis Cuantitativo de Riesgos-
Interconexión de Paquetes de Compresión y Acondicionamiento de Gas”. 1
4.2.1 Scenarios
Ambient Conditions: Pasquill Stability Class D (neutral), wind speed
5 m/s or 20 m/s.
1
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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(Addition)
Gas Delivery Facilities
4.2.3 Criteria
Toxic gas: 10 ppm H2S for restricted area.
Flammable gas: 100 % LFL
Radiation levels, inclusive about 1 kW/m2 (300 BTU/hft2) for sun radiation:
The criteria of 13.5 KW/m2 for equipment and tanks spacing has been taken
from PDVSA IR-S-02 “Criterios para el analisis cuantitativo de riesgos”, the
others criteria come from the original safety concepts.
- In Main Station:
- The criteria assumed for tank spacing is a pool fire in the tank
surface. This is the criteria used by PDVSA. IR-S-02
- The safety distance between tanks is:
56 m for Offspec Storage tank
66 m for diluent tank.
- The safety distance between tanks and process is same
In the rest of the areas have been taken in account the results of the
dispersion analysis from the assessment studies were:
Clusters vents:
Vent 10 ppm H2S 0.4 m
Vent 100 % LFL 2.1 m
Vent 50 % LFL 4.1 m
Main Station:
Offspec Storage Tank pool fire 13.5 56 m
kW/m2
Offspec Storage Tank pool fire 4.73 106 m
kW/m2
Offspec Storage Tank pool fire 3.15 133 m
kW/m2
Diluent Tank pool fire 13.5 kW/m2 66 m
Diluent Tank pool fire 4.73 kW/m2 122 m
Diluent Tank pool fire 3.15 kW/m2 151 m
Pump P-3001 pool fire 13.5 Kw/m2 26 m
Pump P-3001 pool fire 4.73 Kw/m2 41 m
Pump P-3001 pool fire 3.15 Kw/m2 47 m
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In Main Station:
The impacted area extends 133 m from the tank for Offspec storage.
151 m from the tank for diluent storage.
The restricted area extends 106 m from the tank for Offspec storage.
122 m from the tank for diluent storage.
The safety distance between tanks and process is
56 m for oil export tank.
66 m for diluent tank.
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(Addition)
Gas Delivery Facilities:
5. LAYOUT
Main principles:
The restricted area is defined as the area where, in the event of a major gas
leak, gas may be present at a concentration up to 100 % LFL and/or the
distance limit of 4.73 kW/m2 (1500 BTU/h.ft2). All potential ignition sources
located in a restricted area shall be suppressed if this event occurs.
The restricted area concept is used to define the ignition prevention measures
to be taken for an equipment, located inside the restricted area, which can be a
potential source of ignition. For instance, particular attention shall be given to
the shut-down control facilities of electrical equipment, open fire
furnaces/heaters and engines not suitable for use in explosive atmosphere.
It will not be noted that the restricted area generated by an hydrocarbon unit is,
generally, far greater than the hazardous area defined by the Codes.
Description:
For the clusters, the restricted area around well has been estimated as 30 m.
For the Main Station, the restricted areas around the installations are defined
by the preliminary Consequence Analysis study, the basic and detailed
engineering calculations whose report is provided in Attachment 2 and 4, and
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(Addition)
For the Gas Delivery Facilities the restricted area around its installations
were defined by the Consequence Analysis study from the basic
engineering project, whose report is provided in document N° 209001-R-
ACT-ACR-PETROCEDEÑO-EXTERRAN: “Análisis Cuantitativo de
Riesgos- Interconexión de Paquetes de Compresión y Acondicionamiento
de Gas” 1 the main assumptions, criteria and results are summarized in
previous section 4.
Property limits shall be materialized by security fences and shall include the
restricted area limit drawn all around any process equipment including the
open drain or API basins. Distances to heat radiation limit to 4.73 kW/m 2 (1
500 BTU/h.ft2) shall also apply to flare when emergency flaring, and to tanks in
case of fire.
Main principles:
Installations are split into fire zones in order to separate risks and limit the
probability of escalation.
Distances used between separate fire zones are based on a credible leak
ignition and explosion consequence limits of:
1
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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a) Clusters:
Z1: Wells.
Z2: Vent.
b) Main Station:
Main Station split into fire zones consists in (New equipment for MSWUP-
Basic Engineering are included):
Z9: Flare.
Z14: Deleted
(Addition)
The Zone 16 was divided in Zone 16A and 16B in order to optimize the
use of Main Station fire water system. The thermal radiation effects inside
of zone 16A (Gas Conditioning Skids) during a fire event will not affect the
zone 16B (Gas Compression Skids).
5.2.4 Spacing
The safety distances required here-after do not induce separate fire zones but
however improve the overall safety of the plant:
a) ESDV location:
(Modification)
Fire resistance and the effects of blast over-pressure has been considered
when locating the ESDVs and BDVs, associated cabling, piping, valves and
actuators. The location of the ESDVs shall be carefully studied to find a
compromise between the hydrocarbon inventory between valves and the
remote location to avoid any damage to the valves in case of fire and/or
explosion as well as a possible passive fire and blast protection. ESDVs and
BDVs location shall afford maximum mechanical protection. Trunk-lines and
export line ESDVs shall be at 30 m minimum distance from any other process
equipment. ESDV`s installed on Inlet line and outlet line of Delivery Gas
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b) Oil heaters:
c) Process units:
d) Special provisions:
(Addition)
f) Gas Delivery Facilities
Clusters:
The local unmanned electrical building of each cluster has been located at 30
m minimum distance from the wells.
Main Station:
1
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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The main control room of Main Station has been located at:
(Addition)
Gas Delivery Facilities:
The classification of locations with regard to hazard of explosion or fire and selection
of suitable type installation must be in accordance with IEC 79-10 Electrical Apparatus
for Explosive Gas Atmosphere. Definition of degree of mechanical protection shall be
in accordance with IEC recommendation (see document CA04-04-33-P-DC-001
instead of Sincor Doc. No. 1020-13-00-1602-ET-001,”Electrical system design”).
Wet oil and diluted crude were considered as stabilized crude oil (Cat. C).
(Addition)
The maximum identified temperature in the Gas Delivery Facilities is 160 °C,
under normal operating conditions. The attachment “D” of document N° 209001-
R-ACT-ACR-PETROCEDEÑO-EXTERRAN “Análisis Cuantitativo de Riesgos-
1
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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The battery used for the project are sealed type. No special room ventilation is
required.
7. ELECTRICAL POWER
Inside the Gas Delivery Facilities the emergency electrical loads will be
supplied from rechargeable batteries (UPS systems), with 1-hour of
autonomy. These UPS System is fed from the electrical substation TS-03.
For Gas Delivery Facilities the following are typical emergency loads:
2
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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Fire and gas detection shall be installed in the vicinity of the following locations:
CLUSTERS:
MAIN STATION:
Fire Detection
Z9: flare
Flammable gas detection shall be installed in the vicinity of the following locations:
Smoke Detection:
(Addition)
Z16: Gas Delivery Facilities
For Gas Delivery Facilities, the ESD system must include the following
functions:
10. DRAINAGE
Closed drainage:
All the process effluents from the process equipment and from the Fuel Gas Drum are
drained by means of a closed drain system to a Closed Drain Drum.
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Additionally, the thermal relief valves located in the diluent trunklines in Main Station
discharge to this system. This slop is used for feed the Oil Heaters Feed Pumps by
routing back to slug catchers.
(Addition)
For Gas Delivery Facilities, all the process effluents from the process equipment
are drained to a Closed Drain Drum D-3301.
Open drainage:
Adequate containment and drainage has been provided around each equipment
involving hydrocarbon. Appropriate provision has been made for draining rain water
from those parts of the installation. First 10 min rain water from any area where liquid
hydrocarbon may be present will be drained into API feed sump via open drain system
and sent to an API Separator. After that the treated water are conduced to a Trim Oil
Separator and finally to an Observation Pond before the final disposal to the storm
basin. Any rain water more than first 10 min will bypass the API Separator direct into
the observation pond and storm basin.
For Producction Water Treatment plant, the contaminated rain water drainage is sent
toward the Diversion Manhole at existing open drain system. But all process efluents
from the process equipment of Producction Water Treatment plant are drained by
means of a Open Drain system to a Open Drain Sump T-3940 and then recycling to
Skimmer tank T-3900
(Addition)
All process effluents from Gas Delivery Facilities plant will be drained on the
way to the Open Drain Sump T-3940 and then recycled to Skimmer tank T-3900.
system to a Treatment Plant of domestic effluent (Sewage Treatment plant) before the
final disposal to the ditch.
(Addition)
For Gas Delivery Facilities, the condensates liquids are coming from the
Scrubber D-2710 A/B, Skid Compressor Inter-stages Scrubber (X-2710 A/B/C),
and inlet Gas Scrubber of the Exchanger Skid X-2713. These liquids are
collected through Drain Header to finally flow to the Water Treatment Plant
(Skimmer Tank T-3900 A/B).
At the basic phase some gas dispersion calculations and heat radiation
scenarios has been reviewed and recalculated.
Studies has been carried out for the maximum release rate (blocked outlet) and
for not ignited release (dispersion) and for ignited release (radiation).
The dispersion and heat radiation calculations has been performed using the
least favorable wind speed and direction.
Flares:
Process Venting:
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During “Short term Water Upgrade Project” a Gas dispersion and area
classification study associated with the venting system of the produced water
tank T-3802 and the frac tank was performed. The attachment 5 includes the
report.
During “Main Station Water Upgrade Project an Air Dispersion Modeling Report
(see document CA04-00-13-K-RP-104), a Quantitative Risk Analysis Report
(see document CA04-00-13-K-RP-113) and H 2S dispersion modelling report
(see document CA04-00-13-K-RP-107) were performed for venting system
associated with production water treatment plant.
(Addition)
The Main Station relief header is capable to handle the relief loads caused
by a fire inside of Zone 16A, that is 48.222 Kg/h (all flow handled for Gas
Compression Skids plus depressurization of Gas Conditioning Skids and
evaporation of liquid contained in the three phase separator). Under relief
conditions (pressure, temperature and flow), the velocity of the Main
Station Relief Header is below the established critical velocity.
The dimensions of the K.O. Drum D-3501, as well as the liquid levels
established, satisfy the conditions of Gas Delivery Facilities relief,
assuming that at the moment of the contingency the level of liquid within
the drum is 30% of its total level.
The Flare FL-3501 is capable to handle the relief flow when a fire is
present in Zone 16A (48.222 Kg/h), due to the flare design capacity is
54.080 Kg/h.
The radiation generated by the Flare FL-3501 for the Gas Delivery
Facilities relief (48.222 Kg/h) is below the maximum level of 4,73 kW/m2,
calculated with the design capacity (54.080 Kg/h) and same composition
gas.
Fire water monitor flow rate shall be included if required simultaneously with
the deluge system.
(Addition)
12.2.3 Fire and Gas Detection and Protection for Technical Building
For detail see document no. CA04-04-35-J-SP-032, Fire and Gas Detection
and Protection Philosophy for Technical Building
For detail for Produced Water Treatment plant, see document Nº CA04-04-
35-J-SP-005 Fire And Gas Detection And Protection Philosophy For
Technical Buildings
The fire and gas detection system for the telecommunication building,
Instrument Satellite House (ISH), TS-01, TS-02 Electrical Substation and the
Main Station Control Room (MSCR) will detect fire by use of smoke detection
and automatic initiation of fire extinguishing system (FM-200). Offices and
Battery Rooms within these buildings do not require an automatic fire
suppression system, only portable extinguishers are used. None of these
buildings will have fixed firewater system installed.
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(Addition)
Concrete
Ceramic wool
1
The find issue of quantitative risk assessment is by others. PDVSA PETROCEDEÑO trust that results
shown in this addendum are obtained from the last issued updated of this assessment.
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The Main Station has been equipped with an alert system including:
General Alarms will be activated from a panel located in the control room of the
Main Station.
The fire alarm will be initiated manually and automatically from the Fire and
Gas system.
Public Address and General Alarm system has not been supplied on clusters.
(Addition)
The fire alarm will be initiated manually and automatically from the Fire
and Gas system. The escape and muster alarm will be initiated only
manually.
(Addition)
Escape, Evacuation and Rescue from the installations (Clusters, Main Station
and Gas Delivery Facilities) is an essential safety to life feature that shall be
made possible for any possible combination of:
weather conditions
Hazardous material data sheets has been prepared for all materials used in the
processing. These include, but not limited to:
corrosion inhibitors
de-foamer
Diesel oil
(Addition)
For Gas Delivery Facilities, hazardous material data sheets have been
prepared for all materials used in the processing. These include, but not
limited to:
- Glycol
- Corrosion Inhibitor
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15.4.4 Acids
17. PIPELINES
18. STORAGE