PETRONAS TECHNICAL STANDARDS

Design Of Once-Through Seawater Heat Transfer

Systems

PTS 16.51.03
June 2017

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 4
SCOPE .............................................................................................................................. 4
GLOSSARY OF TERM ........................................................................................................ 4
SUMMARY OF CHANGES ................................................................................................. 5
DESIGN OF SEAWATER SYSTEMS – ONSHORE FACILITY ........................................... 6
GENERAL DESIGN REQUIREMENTS ................................................................................. 6
SEAWATER QUALITY........................................................................................................ 6
SEAWATER SYSTEM HYDRAULIC ..................................................................................... 7
SPECIFIC DESIGN REQUIREMENTS .................................................................................. 8
MATERIAL SELECTION ................................................................................................... 15
DESIGN OF SEAWATER SYSTEMS – OFFSHORE FACILITY ........................................ 16
GENERAL DESIGN REQUIREMENTS ............................................................................... 16
SEAWATER QUALITY...................................................................................................... 16
SEGREGATION OF USERS............................................................................................... 17
SPECIFIC DESIGN REQUIREMENTS ................................................................................ 19
MATERIAL SELECTION ................................................................................................... 24
CONTROL AND INSTRUMENTATION ............................................................................. 25
BIBLIOGRAPHY .................................................................................................... 26
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1.0 INTRODUCTION

This PETRONAS Technical Standards (PTS) provides the technical requirements for the design
of seawater heat transfer systems for both onshore and offshore facilities. This PTS was
developed to ensure safe and reliable operations meeting the intended pressure,
temperature, flow and quality to all users.

This PTS adopts PETRONAS lessons learnt and best practices to address environmental impact
and ensure its integrity during its service life.

SCOPE

This PTS specify requirements for the design of once-through seawater heat transfer system
for onshore and offshore facilities including material selection.

GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition

1 Caisson A section of open-ended pipe from the platform

to below sea level which is use to draw in
seawater or dispose used seawater.

2 Diffuser A device to dilute the used seawater before

disposing back into the sea.

3 Froude Number Dimensionless unit used in hydrology which

indicates the influence of gravity on fluid
motion.

4 Sea Water Intake Facility to extract clean seawater with minimum

impact to the surrounding environment.

5 Sea Water Outfall Facility to discharge and disperse return

seawater with minimum impact to the
surrounding environment.

6 Weir Box A device to keep the system completely filled

with water and ensure positive pressure is
achieved all the times at the various pump
operating modes.
Table 1.1: Specific Definition of Terms
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1.2.3 Specific Abbreviations

No Abbreviation Description

1 ALARP As Low as Reasonably Practicable

2 CDBM Corrosion Design Basis Memorandum

3 CFD Computational Fluid Dynamics

4 CMP Corrosion Management Plan

5 CS Carbon Steel

6 DN Diameter Nominal

7 GRP Glass Reinforced Plastic

8 GRE Glass Reinforced Epoxy

9 HVAC Heating, Ventilation and Air Conditioning

10 LAT Lowest Astronomical Tide

11 LNG Liquefied Natural Gas

12 NPS Nominal Pipe Size

13 NPSH Net Positive Suction Head

14 PHE Plate and Frame Heat Exchanger

15 TOC Total Organic Carbon

16 TSS Total Suspended Solids

Table 1.2: Specific Abbreviations

SUMMARY OF CHANGES
PTS 16.51.03 (June 2017) replaces PTS 16.51.03 (July 2014).
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DESIGN OF SEAWATER SYSTEMS – ONSHORE FACILITY

GENERAL DESIGN REQUIREMENTS

2.1.1 The system design shall meet the plant availability throughout its intended design life-time.
This can be achieved via redundant equipment such as bar and band screens, basin (settling
section), pumps, heat exchanger (where applicable), header and outfall which enable online
maintenance of any section of the system. The optimum design shall be based on techno
economic assessment of the design scheme.

2.1.2 The hot seawater shall be returned to sea in such that the seawater should not change more
than 3⁰C after dilution at a 100 meters’ distance from the outfall unless otherwise stated by
the local regulatory requirements.

2.1.3 Residual chlorine at discharge point shall be in accordance to the relevant local regulatory
requirements.

2.1.4 Sufficient design margin shall be added as per project specification taking into account the
design class and fouling tendency of the system.

2.1.5 Sufficient modelling /simulation such as flow dispersion study shall be performed to check the
thermal recirculation risk with respect to the location and distance of intake and outfall
location.

2.1.6 Metocean data shall be obtained from relevant authorities to ensure seawater seasonal
variations are considered.

SEAWATER QUALITY

2.2.1 The quality of seawater shall govern the design of the intake, distribution and outfall systems.

2.2.2 Seawater characterisation study shall be performed at various location (sea surface, mid
depth, bottom) to determine the seawater quality for the basis of design of the onshore
seawater system. As a minimum, the study shall include the following:

i. Level of contaminants and pollutants including pH, turbidity, conductivity, oil and
grease, TOC, chlorine demand, TSS, ammonia.

ii. Temperature profile.

iii. Seasonal and diurnal seawater quality fluctuation e.g. marine life, season jellyfish,
algae bloom/red tide.

iv. One (1) year data.

2.2.3 The results of the characterization study shall also be used together with flow dispersion study
for identification of the right location of both seawater intake and outfall.
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SEAWATER SYSTEM HYDRAULIC

2.3.1 System hydraulic study shall be conducted to determine the design of intake pipeline,
seawater supply pumps, heat exchangers, distribution piping and outfall system covering the
various modes of operations i.e. normal, maximum, turndown and maintenance.

2.3.2 As a minimum, the studies shall determine the following:

Pump pit water level to ensure adequate NPSH for pump operation and avoidance
of cavitation.

Number of pump stations, weir and main headers (return and supply) line sizing
and routing.

Flow distribution including determination of preferential flow during turndown

and maintenance operation considering that the sea water system is not
controlled.

Prevention of water hammer through a specific surge / water hammer study to

ensure control of the cooling water pumps and valves in the distribution system
is adequate to handle water hammer occurrence.

Requirement of booster pump to supply to elevated consumers and balancing

lines.

2.3.3 Specialized test and modelling shall be undertaken for the following:

Pump station and sea water intake sizing – This is to confirm the flow in the pump
basin under various operating conditions (effects of pump stops and start) meets
the design requirements for satisfactory pump operations. The model shall
include the effects of the different flow paths, through the inlet screens up to and
including the pump suction with water swirl breakers under the pump inlets. This
physical model test shall also be based on the hydraulics study.

Weir Box - Physical model and simulation model (e.g. CFD) is required to confirm
the effects of the operation modes to match with the dissipation device and
deaeration chamber design.

2.3.4 The number and diameter of intake pipes for the range of design flow shall consider a balance
between high velocities which cause head losses, tube erosion and avoiding low velocities
which could lead to sedimentation problems. Refer to PTS 12.30.02.

2.3.5 The seawater flow shall be designed to minimise throttling and low flow condition and also to
enable regulation of heat transfer duty from process side. Normally, the flow to each user is
fixed via trim valve during early stage of operation and to be checked regularly to ensure
uniform distribution. Cooling or heating duty control to be regulated on the process side.
Fouling due to biological growth shall be mitigated by injecting biocide at certain
recommended dosage.
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2.3.6 A minimum and maximum seawater flow rate at all-time shall be determined in the design to
prevent potential overheating or overcooling.

2.3.7 Monitoring instrumentations for flow, level, differential level, temperature, differential
temperature, pressure, differential pressure and residual chlorine should be made available
in the system design.

2.3.8 Sampling points shall be made available at intake and outfall to collect representative sample
to allow for operational monitoring and trouble shooting.

SPECIFIC DESIGN REQUIREMENTS

The following should be provided with seawater system onshore facility:

i. Intake Systems
a) Structure
b) Intake Pipelines
c) Mechanical Filtration
d) Basin
e) Chemical Dosing

ii. Distribution Systems

a) Supply Pumps
b) Heat Exchangers
c) Distribution Piping Networks

iii. Outfall System

Refer to Figure 2.1 below for general illustration of the system.

Figure 2.1: Onshore Once-Through Seawater Heat Transfer System

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2.4.1 Intake System - Structure

A seawater intake system shall be designed to deliver a reliable supply of clean

seawater with minimum impact to the surrounding ecological system and in
compliance to Environmental Impact Assessment study in accordance to specific
company, regional and local regulatory requirement.

The intake water system shall be designed taking into consideration the
characteristic of the seawater to minimize carryover of suspended material and
to achieve the specified sea water supply temperature.

Location of the intake shall be selected conforming to the following

considerations:
a) Sufficient distance from the shore to ensure uniform water temperature
and the absence of localize temperature fluctuations.
b) Sufficient depth below the water surface with a minimum of 20 m to avoid
vortex action and wave slam.
c) Sufficient depth above the seabed with a minimum of 2 m to prevent fine
sandy sediment be entrained into the water during storms from being
drawn into the intake in any significant quantity.
d) Avoid designing seawater intake near the outfall system to minimize risk
of recirculation of hot water.
e) Sufficient distance from jetty to minimize intake of silt stirred up by ship
movement.
f) Adequate water depth to accommodate the required intake dimensions
and minimizing draw in of silt.
g) Avoiding location downstream of a hot or polluted outfall or jetty or other
area of ship movement.

Seawater velocity at the point of intake is limited to 0.3 m/s at which marine life
will be avoided from being drawn into the intake station.

The transition zones seawater velocity i.e. before the screen channel and pump
chamber shall also be limited to 0.3 m/s to avoid surface vortices formation.

The hydraulics and layout of the intake system and pump suction pit shall be
designed as follows:
a) The lowest recorded seawater level shall be taken into account in
calculating the total system head loss. During pump switch over scenario,
the impact of sudden increased in flow rate to the pump pit level shall be
considered.
b) Calculations shall consider mechanical head loss, 30% mesh blockage of
bar screens and 75% mesh blockage of band/rotating drum screens.

For the actual screens dimensions, the design shall incorporate all Manufacturer’s
information, system frictional loss, intake pipe size, pump suction pit dimension,
and overall intake station dimension.

The pump shaft length shall be optimized to meet the required NPSH as well as
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meeting the low tide level scenario in the pump pit.

The pump intake shall have the following:

a) Adequate depth of flow to limit velocities in the pump bays and minimizes
the occurrence of surface vortices
b) Adequate pump bay width to limit pump approach velocities to 0.5 m/s
but yet narrow and long to enable channel flow uniformly towards the
pumps

The adequacy of pump basin arrangement shall be confirmed by a physical flow

model to ensure that the pump flow meets design requirements in various
operating conditions.

The design of concrete structure shall be in accordance with the requirements of

PTS 11.10.01

2.4.2 Intake System – Intake Pipelines

The intake pipelines sizing shall be based on NPSH for maximum pumping rate
from the pump pit.

To avoid any potential of sediment ingress and floating object, the design of intake
level shall at least 2 m above seabed and a minimum of 20 m below the surface
level respectively. The design shall also avoid hot seawater intrusion into the
intake station.

Under normal operating condition, the seawater velocity via the intake station
shall not be more than 0.3 m/s to avoid potential marine life entrance. Prevention
of marine growth should be aided by the injection of hypochlorite inside the
intake line.

For process plant with multiple process trains e.g. LNG plant or Regasification
plant, the design shall also take into consideration the requirement for inspection
or maintenance of one of the intake lines during the shutdown of any trains
without impacting other trains. The specific inspection and maintenance
requirement shall be detailed out by respective O&M team at site.
Requirement for the additional flow margin shall be considered and indicated in
datasheet to cater for fouling due to marine growth on top of the normal design
margin.

Non-fouling material or anti fouling coating may be utilized for the design of metal
structure and intake coarse bar screens.

Pipeline design shall follow PTS 11.30.07.

2.4.3 Intake System – Mechanical Filtration

The mechanical filtration sizing shall comprise of:

a) A coarse bar filter equipped with automatic scraping system
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b) A rotating drum screen installed in between the course bar filter and sea
water pump.

Sparing and N+1 redundancy shall be considered to ensure continuous operation

while another unit is on maintenance work.

This unit shall be designed with minimum human intervention. The rotating drum
screen shall include automatic spray water system, automatic collection, removal
and dewatering of debris from the drum. Collection sump debris removal shall be
made available for both coarse bar and rotating drum filter and accessible by the
truck. For maintenance of the unit, lifting equipment shall be used to lift out the
drum.

The mesh size for the rotating drum shall be sized to prevent marine life from
passing through.

2.4.4 Intake System – Basin

The basin shall be designed with minimum ingress of silt and dirt. A settling
section with common basin or dedicated basin shall be provided to assist the
removal of silt and dirt that accumulates over time.

The pump basin shall be located onshore close to the shoreline to minimize the
length of intake pipelines passing through and as necessary a shore protection to
be provided against wave’s action.

A physical model shall be undertaken to confirm the adequacy of the pump basin
arrangement so that flow in the pump basin under various conditions meets
pump operation performance.

The actual dimensions of the pump basin shall be determined by hydraulics

calculations and equipment requirements.

2.4.5 Intake System - Chemical Dosing

For macro biological control, chemical dosing system shall be designed to deliver
sufficient biocide level for total seawater flow rate on a continuous basis.

Oxidizing biocide such as chlorine shall be used. Additional injection using non-
oxidizing biocide on intermittent basis such as glutaraldehyde can be considered
but this needs further analysis due to high cost impact and tight discharge
requirement.

Chlorine requirement can be supplied by sodium hypochlorite generator via

electrolysis of seawater slipstream taken from supply pump discharge. As a
minimum, the unit shall consist of electrolytic generator, transformer/rectifier
unit, hydrogen cyclone separator, acid cleaning system (tank and pump),
wastewater neutralization system, chemical dosing pumps, residual chlorine
analyser, hydrogen detectors, ventilation fan (2 X 100%) and local control panel.
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The design capacity of the chemical dosing system shall be based on normal
continuous dosage of 2 ppm equivalent chlorine with a flexibility to conduct shock
dosing up to 5 ppm with the operation of spare hypochlorite generator unit during
abnormal situation.

The actual operating rate shall be set to meet the specified free chlorine residual
of 0.2 to 0.5 ppm or below depending on local regulatory discharge requirement
at the seawater outfall, having regard to the chlorine demand of the seawater.
The chlorine demand of the incoming seawater is based on the requirement to
protect the whole system from biological fouling. The location of injection points
shall be selected to meet the chlorine dosage requirement.

The material for piping including distribution pipes shall be corrosion resistant.
The velocity and residence time of sodium hypochlorite or other oxidizing biocide
in the pipeline shall be optimized to mitigate any degradation of the biocide
chemicals.

Since sodium hypochlorite is a hazardous chemical and the hypochlorite

generators produce hydrogen as by-product, the system design shall [PSR] ensure
the safety of personnel handling and operating the generator unit.

2.4.6 Distribution Systems – Supply Pumps

Design capacity shall be based on the cooling demand with a temperature rise of
not more than 10⁰C and at the same time meets the discharge local regulatory
limit.

Hydraulic analysis will determine the required pump head taking into
consideration 10% margin on the flow rate and surface roughness factor.

For material selection of the centrifugal pump component, PTS 12.11.02 shall be
referred to.

There should be easy access for maintenance vehicles for maintenance,

inspection and replacement of pumps and various pump components.

Lifting devices shall be provided to assist in maintenance activities of various

equipment i.e. water supply pumps, drum filters, etc. In the event that pump
house is necessary, the roof should be able to cater for maximum crane loading
which is required during maintenance.

Sparing and pump redundancy shall be provided to ensure continuous operations

and reliable supply of sea water systems considering the maintenance and pump
reliability.

A minimum seawater flow rate via pump minimum flow shall be ensured to
prevent potential overheating.
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2.4.7 Distribution Systems – Heat Exchangers

For a closed loop system where seawater is used as cooling medium, N + 1 sparing
shall be provided for critical service which requires continuous operations. The
titanium plate and frame heat exchanger (PHE) design shall comply with PTS
12.21.03.

A dedicated fine mesh auto backwash screen shall be provided at the inlet
seawater supply line for the removal of fine material such as silts prior to entering
each of the PHE.

Refer to PTS 12.21.01 for applicable velocity criteria and PTS 12.21.03 for shear
stress criteria.

The design and layout of the piping and manifold between heat exchangers shall
be limited to a maximum of 10% of uneven flow distribution.

A bypass around the plate hex shall also be provided for commissioning/start-up
of the seawater system.

If necessary, future provision for additional plate heat exchanger and additional
plates should be included in the design.

For system with shell and tube heat exchangers, PTS 12.21.01 shall be referred to.

2.4.8 Distribution Systems – Distribution Piping Network

The robustness of the distribution network shall take into consideration the
hydraulics, piping distribution network design, material selection and overall
construction, testing and commissioning of the system.

The loop serving the largest user in the distribution network shall be designed to
minimize the head requirement. For the other loops, their head requirement
should not exceed the head of the largest user in the distribution network.

A seawater distribution study shall be performed to confirm equal distributions

of seawater to the parallel heat exchanger. Flow balancing shall be controlled
using valves located downstream of a group or individual heat exchanger.
Alternatively, restriction orifice can be used for cases of high pressure drop across
the valve.

Where valves are used in parallel heat exchangers application, locked open
provisions shall be made to ensure that the system is always open to protect the
low pressure side of the heat exchangers.

For a once through design approach, open ended stand-pipes shall be installed to:
a) Protect against overpressure of line
b) Prevent excessive pressure surges during pump start-up / shutdown
c) Displacement of air during initial filling of line after maintenance
d) Prevent vacuum in lines during draining
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The sea water return and supply lines shall be designed to both positive and
negative pressure associated with surge conditions resulting from reversal of
water flow when the sea water pump trips or closure of any shutdown valves.

Sufficient access manholes shall be installed at strategic location for inspection

and maintenance work.

Constructability of large on-shore pipelines shall be taken into consideration in

the design stage e.g. large diameter pipeline to be prefabricated pipes to ease
pipe length and bend adjustments bend on site.

The main headers and distribution network shall be designed with optimum
velocity which is high enough to prevent any potential silt or debris settlement
resulting to under deposit corrosion in the pipelines.

Upon completion of construction stage, distribution network shall be pressure

tested. Provision shall be made to enable pressure testing of piping section with
various mechanical design conditions.

2.4.9 Sea Water Outfall

Seawater outfall systems comprise of:

a) Upstream weir box or siphonic recovery
b) Energy dissipation device or step type weir
c) Degassing chamber
d) Outfall lines with diffusers at the end

Spares shall be provided to enable maintenance on one side while maintaining

the operation of the alternate line.

As a minimum, each outfall system shall be sized for 75% of the total duty.

Returned seawater shall pass to a single compartment weir box which shall have
sufficient height to ensure that the system is completely water filled and positive
pressure is maintained. This back pressure is such that enough head is available
to send the water to the outfall.

Sea water return to outfall using a gooseneck in return pipeline with restriction
orifice shall not be used unless the weir box design is not feasible.

From the weir compartment, seawater return will overflow to the step type weir
to regulate down flow velocity and minimize air bubble generation. Typical height
for the step type weir is 4 m.

Following the step type weir, seawater shall enter the open type degassing
chamber for efficient air removal under maximum water flow conditions.

After the degassing chamber, seawater should be directed to the diffusers at the
end of outfall line. The diffusers shall ensure that hot seawater be distributed
evenly over a wide area to meet the discharge temperature limit.
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Air venting devices shall be installed at the outfall lines to prevent accumulation
of air under various flow condition.

Hydraulic study shall be conducted to determine the optimum option between

weir box and alternate siphonic recovery system.

MATERIAL SELECTION

2.5.1 Corrosion Design Basis Memorandum (CDBM) and Corrosion Management Plan (CMP) shall
address the material selection, corrosion control and monitoring requirements for equipment
included in the seawater heat transfer system based on the specific design basis, in
accordance to PTS 15.04.01.

2.5.2 Glass-Reinforced Plastic (GRP)

GRP pipe systems if chosen shall comply with PTS 12.34.02.

2.5.3 Carbon Steel (CS)

i. Carbon steel may be used for pipelines, piping and heat exchangers. This material
is to be used in conjunction with adequate cathodic protection and internal
coating systems.

ii. Application of internal Thermal spray aluminium coating, if specified, shall comply
with PTS 15.20.05. Qualification of thermal sprayer shall comply with ISO 14918.

iii. The application of sacrificial anode cathodic protection can be considered. It is

recommended that a regular visual inspection of the anode to be included as part
of the maintenance and inspection program.

iv. The application of internal cathodic protection for carbon steel equipment and
piping shall take into consideration the anode configuration on flow dynamics,
anchor method for anodes, coating degradation factor and accessibility for
maintenance and inspection of coating
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DESIGN OF SEAWATER SYSTEMS – OFFSHORE FACILITY

GENERAL DESIGN REQUIREMENTS

3.1.1 An offshore seawater system shall be sized based on inventory of seawaters users and
demands of the facility. The seawater inventory of a facility shall be determined considering
the following factors:

Minimum/normal/maximum flow, duty and temperature ranges for all the

seawater users

Demand pattern for each user whether continuous or intermittent

The demand loads which is supplied from the return header such as water
injection, may be excluded from the system capacity calculations

Provision for filter backwashing capacity should be reserved

Other than meeting the thermal demand, seawater flow to coolers shall be
supplied above the minimum velocity to prevent precipitation of solids

Provision for future demand, if any

Designs should comply with the environmental constraints of the locality such as
the allowable discharge seawater temperature

3.1.2 The optimum design shall be based on techno economic assessment of the design scheme.

SEAWATER QUALITY

3.2.1 The quality of seawater shall govern the design of the intake, distribution and outfall systems.

3.2.2 Seawater characterisation study should be performed at various location (sea surface, mid
depth, bottom) to check for the seawater quality for the basis of designing the offshore
seawater system. Typically, the study may include the following:

Level of contaminants and pollutants including pH, turbidity, conductivity, oil and
grease, TOC, chlorine demand, total suspended solids.

Temperature profile

Seasonal and diurnal seawater quality fluctuation e.g. marine life, season jellyfish,
algae bloom/red tide.

3.2.3 Water intake shall be located such that the quality is not impacted by interference with other
discharge or intake points.

3.2.4 For other than “once-through” users, a detail seawater characteristic study shall be
considered. The minimum requirement shall be as per clause 3.2.2.
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SEGREGATION OF USERS

3.3.1 Hazardous and non-hazardous users shall [PSR] be segregated to eliminate the possibility of
hazardous substance migration into a non-hazardous area.

3.3.2 A hazardous user is one where, if the equipment fails, the seawater can be contaminated with
hydrocarbon, flammable or toxic substance. Hazardous users typically include process heat
exchangers, such as crude oil cooler and gas coolers.

3.3.3 Equipment failure in an unsegregated seawater system may results in the ingress of a
hazardous substance such as hydrocarbons or hydrogen sulphide into an unprotected non-
hazardous area through the seawater system which subsequently may cause explosion, fire,
poisoning or asphyxiation.

3.3.4 For new installation, the seawater system shall be designed as follows:

A separate and dedicated utility system for each cluster of users in hazardous and
non-hazardous area as per Figure 3.1; OR

An inherently safe system e.g. a common seawater system supplies seawater to

non-hazardous users and cools a closed circuit heat transfer system for hazardous
users as per Figure 3.2.

Hazardous users Non-hazardous users

Vent

Water Break Potable Domestic Dump

injection tank/vessel water users caisson (2)
Dump
maker
caisson (1)

HVAC
Drilling package Process
coolers coolers

Seawater
Chlorination Filter(s)
pumps

Fire main
Seawater
Filters pressurisation
pumps

Figure 3.1: Seawater system where hazardous users and non-hazardous users are segregated
completely
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Hazardous users Non - hazardous users

Figure 3.2: Inherently safe seawater system where closed loop cooling water system is provided to
segregate the hazardous and non-hazardous users.

3.3.5 For existing installations where the seawater supply is a common and unsegregated system,
it shall be demonstrated that associated risks are reduced to ALARP level. The following
method in order of preference shall be employed;

Installation of a dedicated system for a non-hazardous user;

Insertion of elevated break tanks (refer to Figure 3.3), with water flow inlet
should enter the tank above the water level. The break tank shall [PSR] also
equipped with a continuous vent which has self-draining with no low points and
has sufficient capacity to handle maximum rate of gas produced in the event of a
leak or failure of the hazardous users e.g. failure of one tube in shell and tube
heat exchanger.

The break tank also shall be sized to ensure full degassing. If toxic gas may be
present, the gas shall [PSR] be routed to a relief system instead of venting. In-depth
analysis should be conducted to ensure that it is not possible for the gas to pass
through the break tank. There shall be suitable protection to maintain the
integrity of the liquid seal.

Installation of a detection system which will automatically actuate the valve to

prevent migration from hazardous to non-hazardous system.
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Hazardous users Non - hazardous users

Vent

Water Break Dump

injection tank/vessel

Firemain pressurisation
Dump caisson

Potable water maker

caisson

Domestic users
Process Drilling package
coolers coolers

HVAC
Chlorination

Seawater Filters
pump(s) Vent

Break
tank

Figure 3.3: Seawater system where hazardous users and non-hazardous users are segregated by a
break tank.

SPECIFIC DESIGN REQUIREMENTS

Intake System
a) Seawater Lift Caissons, Pumps and Rising Main
b) Mechanical Filtration
c) Chemical Dosing

Distribution System
a) Heat exchangers
b) Distribution network

Outfall System
a) Overboard Discharge Caisson

3.4.1 Intake System - Seawater Lift Caissons, Pumps and Rising Main

To avoid recirculation of effluent from seawater discharge, drilling cuttings, spent

mud or sewage discharge, the locations of seawater intake and discharge shall be
determined based on the following:
a) Tidal currents
b) Wind direction and conditions
c) Type of platform substructure design
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Marine ecological impact shall be minimized by drawing seawater lower than the
sea thermocline depth where there is less marine life population. The seawater
intake should normally be located above the drilling cuttings chute, and below the
seawater discharge.

To ensure that the pump inlet conditions remain stable in all sea states, the
seawater lift caissons should be located at a sufficient depth below the lowest
astronomical tide (LAT). Caissons may be mounted vertically or at an angle; as
long as the pump operation and maintainability are unaffected. The increased
possibility of pump wear and handling difficulties should be accounted if lift
pumps are to be installed at an angle.

The caisson should be sized based on the following:

a) To accommodate the largest diameter of pump set plus a radial clearance
to allow unrestricted suction flow and allowance for marine growth
b) A minimum radial clearance of 50 mm should be provided; for pump sets
with a diameter of 500 mm and above, the radial clearance should be
increased to 75 mm
c) The fitting of cables
d) Ease of maintenance during pump installation/removal
e) Requirement to maintain a minimum flow velocity around the pump
motor casing for cooling purposes

Seawater lift pump shall be positioned at a sufficient depth which provides

enough NPSH required for the system at all operating modes (including start-up).
Waves and tidal effect towards the pump suction head should be also taken into
account.

To prevent ingress of marine life to the seawater system, a mesh should be

installed at the caisson inlet. The caisson shall have a reinforced grid or any other
means to prevent the pump from accidentally falling to the seabed. The seawater
lift pump shall be equipped with a strainer at the pump suction inlet; where the
strainer can be cleaned or replaced when the pump is lifted up.

The pump and its associated rising main should be installed in such a way so that
the pump can be lifted up by the platform crane and laid down for dismantling.
The rising main should be constructed of rigid pipes and sectionalized to 3 m per
section for easy removal during maintenance.

For seawater lift pump installed within caisson inlets, seawater lift pumps should
be submersible, suspended in the seawater lift caissons, and driven by a
submersible electric motor. The pump electric cable terminal box should be
located close to the top of each pump caisson to facilitate disconnecting and cable
storage. Pump shut-off pressure shall (PSR) not exceed design pressure of discharge
piping.

Each pump shall be equipped with a non-return valve to prevent backflow in the
event of a sudden pump trip. A power actuated isolation valve shall be located
adjacent to the system header at the top of each pump rising main to allow
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operation of the system when one or more pumps are not running.

An air vent line fitted with a float type air valve with a restriction orifice should be
installed at a high point of the rising main (upstream of the non-return valve).
During pump start up, air should be vented prior to opening the discharge
isolation valve. The float type air valve prevents seawater leakage as the rise of
the water column is controlled by the restriction orifice located downstream the
air valve.

The restriction orifice should be sized so that air in the rising main is displaced in
approximately 30 s. The duration of the pump running dead-headed against the
discharge isolation valve should be minimized as short as possible via installing a
timer linked to the pump starter to control the opening of the discharge valve.

Reverse rotation due to draining of the rising main shall be prevented by installing
either a latch or brake, or a non-return valve with a hole to allow controlled
draining of the rising main.

If an anti-reverse rotation device is used, then either a timeout relay shall be

installed to prevent the start of the pump while water is drained, or the pump
motor shall be designed for the high torque required to start against the reverse
flow.

The seawater lift pump should be protected against dead-heading if there is a

drop in seawater demand. For manned installations, the pump should be
protected through pressure regulation at the system return header, via a split
range controller which maintains the header pressure constant by regulating the
overboard dump line control valve and seawater supply header control valve. For
normally unmanned installations, a minimum flow line with restriction orifice
should be installed from overboard seawater discharge line back to the seawater
supply header to secure the minimum flow required by the pump.

3.4.2 Intake System - Mechanical Filtration

Seawater shall be filtered to match the end user’s seawater specification. Typical
mechanical filtration system should be designed to remove particulates above
than 1000 μm size.

Back-washable type filter is preferable than cartridge type for high seawater
demand application.

The design capacity of seawater lift pump shall also cover the backwash water
filter requirement.

Filters shall be automatically backwash based on the differential pressure or by

the timer. Provision for manual backwashing shall also be included.

Typical mechanical filters design should include all the necessary

instrumentations and control i.e. differential pressure gauge complete with alarm
indicator for inlet and outlet headers, etc.
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During emergency case, unfiltered seawater can be supplied via a bypass line
across the filter. However, this bypass line shall always be isolated during normal
operation.

3.4.3 Intake System - Chemical Dosing

The seawater system fouling due to macro-biological growth i.e. mussels,

barnacles and clams should be controlled via continuous sodium hypochlorite or
other oxidizing biocide injection.

Typically, oxidizing biocide such as chlorine (supplied by sodium hypochlorite

generator) is used.

Non-oxidizing biocide such as glutaraldehyde can also be injected as supplement

on intermittent basis. However, this needs further analysis due to high cost
impact and tight discharge regulatory requirement.

2 x 100% sodium hypochlorite generator should be provided together with its

dosing pumps.

Since sodium hypochlorite is a hazardous chemical and the hypochlorite

generators produce hydrogen as by-product, the system design shall [PSR] ensure
the safety of personnel handling and operating the generator unit. Adequate
ventilation fans shall be provided at the sodium hypochlorite storage tank for
hydrogen dilution below the explosive limit.

The design capacity of the chemical dosing system shall be based on normal
continuous dosage of 2 ppm equivalent chlorine with a flexibility to conduct shock
dosing up to 5 ppm with the operation of spare hypochlorite generator unit during
abnormal situation.

The actual operating rate shall be set to meet the specified free chlorine residual
of 0.2 to 0.5 ppm or below depending on local regulatory discharge requirement
at the seawater outfall, having regard to the chlorine demand of the seawater.

Automatic interlocking system shall be provided for prevention of chemical dosing

when seawater intake pumps are not in operation. Nevertheless, provision for
manual chemical injection into the caisson should be made during abnormal
situation i.e. extended pump shutdown.

Sodium hypochlorite flow velocities should be greater than 0.5 m/s to protect the
line from suspended solids deposition. All associated instrumentation and fittings
such as needle valves, rotameters and shut down valves should be installed in the
short section of upwards vertical line to prevent solids deposition during stagnant
condition.

3.4.4 Distribution System - Heat exchangers

i. For a closed loop system where seawater is used as cooling medium, N + 1 sparing
shall be provided for critical service which requires continuous operations.
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ii. The titanium plate and frame heat exchanger (PHE) design shall comply with PTS
12.21.03.

iii. For system with shell and tube heat exchangers, PTS 12.21.01 shall be referred to.

iv. Printed circuit heat exchangers may be considered due to its smaller in size and
lighter in weight. Nevertheless, such heat exchanger is not suitable for fouling
and thermal cycling services which requires good seawater quality.

3.4.5 Distribution System - Distribution network

i. Distribution network design should be as simple as possible and make reference

to both PTS 12.30.02 and PTS 12.31.02.

ii. Adequate extra tie-in points should be made available for future expansion.

iii. Flow balancing should be conducted at the header supplying to various users via
balancing and regulating valve.

iv. A non-slam type check valve is preferred to minimize damage due to pressure
surge. Method to control pressure surge during start-up should also be
incorporated.

v. Prevention of water hammer through a specific surge / water hammer study shall
be conducted to ensure control of the cooling water pumps and valves in the
distribution system is adequate to handle water hammer occurrence.

vi. The network design should also consider adequate isolation valves and spectacle
blinds for maintenance purposes without impacting service or production.

vii. The seawater flow shall not be throttled to avoid low flow, sedimentation, fouling
and potential under deposit corrosion. Normally, the flow to each user is fixed via
trim valve during early stage of operation and to be checked regularly to ensure
uniform distribution. Any further flow regulation should be conducted at process
side.

viii. A minimum seawater flow rate shall be ensured to prevent potential overheating
via pump minimum flow.

3.4.6 Outfall System – Overboard Discharge Caisson

The position of overboard discharge caisson should ensure the safe disposal of
used seawater and at the same time prevent intrusion of warm seawater into the
inlet.

Overboard dump control valve cavitation and loss of system contents due to
pump shutdown can be eliminated via direct seawater return line into the caisson
located above the supply and return headers including all major equipment.

The caisson design shall (PSR) include a venting system to prevent vacuum, flashing
and pulsations. The vent line should be designed for an air/ vapour volumetric
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flow-rate equal to the liquid volumetric flow through the vertical line, and a
pressure loss of maximum 0.005 bar. The vent line shall also be designed for the
wave motion inside caisson.

Froude number should be used to determine the optimum caisson diameter to

minimize any potential gas entrainment and ensure undisturbed flow without
pulsations.

As general rule, use a Froude number of 0.3 for caisson sizes below DN 300 (NPS
12), 0.5 from DN 300 (NPS 6) to DN 600 (NPS 24), and 0.7 above DN 600 (NPS 24).

MATERIAL SELECTION

3.5.1 Corrosion Design Basis Memorandum (CDBM) and Corrosion Management Plan (CMP) shall
address the material selection, corrosion control and monitoring requirements for equipment
included in the seawater heat transfer system based on the specific design basis, in
accordance to PTS 15.04.01.

3.5.2 Corrosion control of facilities in seawater service shall be through careful selection of
corrosion resistant materials or application of internal coatings. Allocation of internal
corrosion allowance and corrosion inhibitors is not an acceptable practice.

3.5.3 Material selection shall be performed after making the following considerations:

Service conditions, i.e. operating temperature, chlorine dosage, presence of other

contaminants

Design conditions, i.e. existing piping classes, allowable velocity which influences
size of piping

Capital expenses

Location and extent of pipework and accessibility for maintenance and repairs

3.5.4 Preferred gasket materials for seawater systems include mineral-filled gaskets, GRE laminated
gaskets and spiral wound gaskets with non-graphite fillers, in order of preference.

3.5.5 To prevent galvanic corrosion, the following guidelines shall be observed:

The inner ring of the spiral wound gasket shall be more cathodic than the
adjacent piping.

Plain graphite gaskets shall not be used with corrosion resistance alloys

Materials of construction for piping should be homogenous as far as possible, or

well-isolated electrically if any change in material of construction is unavoidable.
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CONTROL AND INSTRUMENTATION

3.6.1 Typical alarms and shutdowns for a seawater system are given in table below.

Location Instrument Action

Seawater Lift Caisson On-line monitoring tools for
macro organism infestation
Seawater lift pump Temperature indicator
discharge
Seawater lift pump Pressure indicator Low pressure alarm in control
discharge room with start of stand-by
pump (if fitted)
Seawater lift pump Flow rate indicator
discharge
Seawater lift pump Pressure High-High and
discharge Low-low Trip
Pump instrumentation Refer to PTS 14.10.03
Seawater filtration Differential pressure High alarm in control room.
indicator
Seawater header Flow rate indicator Low flow alarm in control room
Seawater outfall Temperature indicator High temperature alarm in
control room
Seawater outfall Hydrocarbon detector and Alarm in control room
sample point on top of
pipework.
Table 3.1: Seawater system instrumentation

3.6.2 Sampling points shall be made available to collect representative sample to allow for
operational monitoring and trouble shooting.
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BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS STANDARDS
Index to PTS PTS 00.01.01
Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide

Minimum Loadings And Load Combinations For Onshore Structural PTS 11.10.01
Design
Pipeline & Riser Engineering Design PTS 11.30.07
Centrifugal pumps (amendments/supplements to ISO 13709:2003) PTS 12.11.02
Shell and tube heat exchangers (amendments/supplements to ISO PTS 12.21.01
16812)
Plate and frame heat exchangers (amendments/supplements to ISO PTS 12.21.03
15547-1)
Piping - general requirements PTS 12.30.02

Piping classes - exploration and production (Offshore) PTS 12.31.02

Glass-Fiber Reinforced Plastic Pipeline and Piping Systems PTS 12.34.02
Instrumentation for equipment packages PTS 14.10.03
On-line Process Analyser Sampling System PTS 14.30.01
Corrosion Management PTS 15.04.01
Thermal Spray Coatings of Aluminum and 85/15 Zinc / Aluminium PTS 15.20.05
Alloy

INTERNATIONAL STANDARD
Thermal Spraying – Approval Testing for Thermal Sprays ISO 14918