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Specific
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 DRAFT FOR COMMENT EP1
SYRIA

Deviation Control Procedure Rev 001

Controlled Document No. : Custodian : TED/1

Originated by : Verified by : Approved by : Revision & Date :
TED/1 TED,TES,TEP TEN,TEN/1 Rev 00 10/96

Reason for Revision :

Printed: 10 November, 1996 Page 2 of 15

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TABLE OF CONTENTS

1.0 INTRODUCTION.

1.1 SCOPE
1.2 COMPLIANCE WITH THIS SCHEDULE
1.3 APPLICABLE STANDARDS, REFERENCES AND CODES

1.3.1 AFPC Schedules

1.3.2 International Standards

2.0 DEFINITIONS

2.1 GENERAL
2.2 TECHNICAL
2.3 ABBREVIATIONS

3.0 DRAIN SYSTEMS

3.1 OBJECTIVE OF DRAINAGE SYSTEMS

3.2 CLASSIFICATION OF DRAINAGE SYSTEMS

3.2.1 Open Non-Hazardous Drains

3.2.2 Open Hazardous Drains
3.2.3 Closed Drains
3.2.4 Process Drains

3.3 SOURCES AND DESTINATION OF VARIOUS DRAINS

3.4 DESIGN REQUIREMENTS

3.4.1 Open Drain Systems

3.4.2 Closed Drain Systems
3.4.2.1 Piping
3.4.2.2 Closed drain Vessel
3.4.3 Drains
3.4.3.1 Instrument Drains
3.4.3.2 Sample Drains
3.4.3.3 Tank Drains
3.4.3.4 Equipment Drains
3.4.3.5 Process Drains
3.4.3.6 Laboratory Drains
3.4.3.7 Chemical Drains

FIGURES

Figure 1 - Piping Specification Break for Drains

Figure 2 - Backflush and end header connection for drains
Figure 3 - Drain Hookups for Level Instruments in Sour Service and for Volatile Hydrocarbons
Figure 4 - Drain Hookups for Level Instruments for Non-Volatile Hydrocarbons in sweet service
Figure 5 - Sour Service and Volatile Hydrocarbons Sample Drain Connection
Figure 6 - Sample Drain in Low Pressure, Sweet, Non-Volatile Service System
Figure 7 - Closed Drain Vessel General Arrangement

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USER FEEDBACK PAGE

Any user who identifies an inaccuracy, error, ambiguity or omission is requested to notify the chairman of the
‘Discipline Standard Committee’ which designator is shown below, so that appropriate action can be taken.
The user is requested to return this page fully completed, indicating precisely the amendment(s) proposed.

From :

To : TES (Chairman of the Discipline Standard Committee)

Date :

A - Description of discrepancy detected.

B - Correction Proposed.

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1.0 INTRODUCTION

1.1 SCOPE

Drainage streams are produced from many sources and this Schedule defines the means for the
safe collection and disposal of these streams.

This Schedule defines the Company’s requirements for the design and selection of drainage
systems for on-shore oil and gas facilities. The drainage systems are needed for maintenance of
equipment, piping and instruments and to reduce the risk of fire and environmental pollution.

The importance of well designed and constructed drainage systems cannot be overstressed.
Shortcomings in drainage systems and management of drainage systems can have a significant
impact on safety and the environment (e.g. pollution of soils, ground water, public waters and air)
and can result unnecessary additional expenditure.

This Schedule does not cover domestic wash water or sewage drain systems for accommodation
areas, buildings and control rooms. However, these drain systems shall be completely separated
from plant drain systems.

1.2 COMPLIANCE WITH THIS SCHEDULE

The Contractor shall obtain written approval from the Company for any deviation from the
requirements of this Schedule.

If national and/or local regulations exist in which some of the requirements may be more stringent
than in this Schedule, then the Contractor shall determine by careful scrutiny which of the
requirements are more stringent and which of the combination of requirements will be acceptable
for the Company as regards safety, environmental, economic and legal aspects. In all cases the
Contractor shall inform the Company of any deviation from the requirements of this Schedule
which is considered to be necessary in order to comply with national and/or local regulations.

1.3 APPLICABLE STANDARDS, REFERENCES AND CODES

The following standards are referred to in this Schedule and shall be consulted by Contractor
when applicable. All listed documents shall be the latest issue.

1.3.1 AFPC Schedules

Schedule QQ Pipe, Valves and Fittings for Sour (H2S) Service

Schedule S Standard Design Specification for Oil and Gas Separators
Schedule TT Unfired Pressure Vessels in Sour Service
Schedule V-9 Painting of New Construction Projects
Schedule D-6 Centrifugal Compressors
Schedule D-7 Reciprocating Compressors

1.3.2 International Standard

IP Code Part 3 Refining Safety Code

API 2000 Venting Atmospheric and Low Pressure Storage tanks
API RP 500 A,B,C Hazardous Area Classification
NACE MR-01-75 Standard Material Requirement “Sulphide Stress Cracking Resistant
Material for Oilfield Equipment “
BS 6651 Code of Practice for Protection of Structures against Lightning

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2.0 DEFINITIONS

2.1 GENERAL

For the purposes of this document the following definitions apply:

Shall The word ’shall’ is to be understood as mandatory.
Should The word ‘should’ is to be understood as strongly recommended.
May The word ’may’ is to be understood as indicating a possible course of action.
Company Al Furat Petroleum Company, Damascus, Syria.
Contractor The party to the Contract with the Company who is responsible for the design,
engineering, procurement, construction and other related works specified in the
Contract.

2.2 TECHNICAL

Open Non Hazardous Drain (ONHD) System

This system provides drainage for areas which are ‘non-classified’ according to the guideline
provided in API RP 500 A,B,C.

Open Hazardous Drain (OHD) System

This system provides drainage for areas which are classified as hazardous according to the
guideline provided in API RP 500 A,B,C.

Closed Drains (CD) System

This system provides drainage from closed equipment vessels and pipework.

Process Drains
These drains are continuous discharges from process systems due to normal operation of the
plant.

Sour Service
The environment is considered sour service when:
a) Sour conditions, as defined in NACE MR-01-75, prevail.
b) In liquid full systems, the concentration of H 2S in the aqueous phase is higher than would occur
in equilibrium with a gas containing H2S at a partial pressure of 0.05 psia (0.0035 bar); the
aqueous phase is normally in contact with the steel, and its pH is lower than 7.

Toxic substances
Toxic substances are those which produce serious harm to health as a result of a single or short
term exposure. The following shall be considered very toxic:
a) Levels of H2S > 500 ppm in process streams
b) Levels of H2S > 200 ppm in process streams if, on leaking, the stream may release vapour that
is heavier than air (i.e. if the density is greater than 1.05 times the density of air). For example.
light sour condensate
c) Other substances indicated by the Company as being “toxic”

Primary Treatment.
Primary treatment is water purification based on the difference in density of the polluting
substance and the medium, the former being removed either by rising or settling.

Oil
The word ‘oil’ in this Schedule is synonymous with the word ‘hydrocarbon’.

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2.3 ABBREVIATIONS

H - High - Level (of liquid )

HH - High - High Level (of liquid )
HHH - Extra High - High Level (of liquid )
IP - Institute of Petroleum (UK)
kPa - Kilo - Pascal
L - Low Level (of liquid )
LC - Locked - Closed or Level Controller
LG - Level Gauge
LI - Level Indicator
LL - Low-Low Level (of liquid )
LO - Locked - Open
LS - Level Swirch (+ Alarm)
NC - Normally Closed
ONHD - Open Non-Hazardous Drain
OHD - Open Hazardous Drain
PS - Pressure Switch (+ Alarm)
PG - Pressure Gauge
RO - Restriction Orifice

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3.0 DRAIN SYSTEMS

3.1 OBJECTIVE OF DRAINAGE SYSTEMS

Drain systems are required for the safe and environmental friendly collection and disposal of :

- Contents of process vessels, piping and equipment, prior to inspection and /or maintenance.
- Liquids from knockout vessels for compressors, flares, etc.
- Liquids from instruments, level glasses, etc.
- Liquids from scraper traps.
- Surface liquids (rainwater, washdown water and waste oil ).
- Fire fighting water.
- Liquids from a Laboratory.

3.2 CLASSIFICATION OF DRAINAGE SYSTEMS

The drainage system of AFPC on-shore oil and gas facilities can be classified as follows :

3.2.1 Open Non-Hazardous Drain System

This system provides drainage for areas which are designated Non-Hazardous.
Non-Hazardous areas generally include storage vessel areas for utility materials such as
lubricating oil, diesel fuel, etc. The drain systems from these areas, referred to as the Open Non-
Hazardous Drain (ONHD), handle fluids collected from open drip pans, tundishes and floors in
Non-Hazardous areas. This system shall be entirely segregated from all other open or closed
drain systems.

3.2.2 Open Hazardous Drain System

This system provides drainage for areas which are designated as Hazardous. These generally
include all process areas and locations where hydrocarbons are present in significant quantities.
The drain system from these areas, referred to as the Open Hazardous Drain (OHD), handles
fluids collected from open drip pans, tundishes and floors in hazardous areas. Open drainage
systems must only by used for draining hydrocarbon fluids from process vessels (via tundishes )
when such vessels have undergone a maintenance preparation procedure, as described in
Section 3.4.2.1.

3.2.3 Closed Drain System

The Closed Drain (CD) System, handles hazardous fluids from process vessels, keeping them out
of contact with the atmosphere. The Closed Drain System consists of permanent pipework
connections which route the fluids via a collection header into a drain vessel for the safe removal
of generated vapour and liquids.
Many process vessels contain fluids which, even after depressuring to the blowdown system,
would release significant quantities of hazardous vapours if they were discharged via open
drainage systems.

This system should also be used where toxic materials are likely to by present. Sour liquid drains
(other than Process Drain ) from any source shall be routed to Closed Drain System .

Hydrocarbon fluids shall be routed to a Closed Drain system from process vessels and pipe works
only after depressurisation to atmospheric pressure.

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3.2.4 Process Drains

Some continuously produced liquids, which are not further needed in the process system e.g.,
liquids from gas compressor knock-out drums are often discarded as drains.
These drains are generally discharged on level control from the source vessels. The process
drains shall be flashed into an atmospheric flash vessel for degassing (e.g. flare knock-out vessel)
before routing to a closed drain system. The drained hydrocarbons shall be recovered and routed
back into the process.

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3.3 SOURCES AND DESTINATION OF VARIOUS DRAINS

Table - 1 lists the major sources of drain fluids, their contents and destination.

TABLE -1
FLUID SOURCE AND DRAINAGE SYSTEM
SOURCE EXPECTED NON HAZARDOUS HAZARDOUS CLOSED DRAIN
COMPONENTS OPEN DRAIN OPEN DRAIN
1 Process equipment and lines Oil, Condensate, Water, X
containing hydrocarbons for Sand, Gas, thermal oil
maintenance purpose
2 Turbine and compressor lube Lube oil X (3)
oil tank
3 Pump seal drain Oil, Gas X
4 Bunded areas containing fuel Spilt fuel / chemicals , wash X
& chemical storage water , drain water .
5 Atmospheric oil Oil, water X (6) X
storage tanks
6 Floor drains in hazardous Oil, water X
area
7 Centrifigal Compressor Lube oil, gas, condensate X
barrel
Reciprocating compressor
distance piece
8 Fire /Deluge water Contaminated water X
9 Scraper barrel Oil , Condensate X X
via tundish (1), (2)
10 Sample drains Oil , water , Condensate X X
via tundish (1), (2)
11 Instrument drains Oil , Condensate X X
via tundish (1),(2)
12 Floating roof tank, roof drains Oil , Oily water X
13 Flare knock -out drum Oil , Oily water X`
14 Atmospheric thermal relief Oil X
valve in oil system
15 Discharge from thermal relief Oil X X(1)
valve in oil system
16 Laboratory drains Oil, Chermicals X (4)
17 Other process Chemicals See Note (5) See Note (5) See Note (5)
chemicals systems
X- Drain System to be used .

NOTES TO TABLE -1

1. Sour liquid shall be routed to closed drain.

2. Volatile hydrocarbons shall be routed to closed drain.
3. Large quantities may be reclaimed into barrels.
4. Laboratory drains shall have local facilities to drain various chemicals. Only oily -water drain can be connected to OHD via a water
sealed pipe discharging into the OHD gully outside the laboratory wall.
5. Drains for different types of chemicals shall be independent . Disposal of the contents of such drains shall depend on type of
chemicals handled. Some types of chemicals may need to be neutralized prior to discharge e.g. sulphuric acid, caustic soda etc.
6. For washing operation discharge only.

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3.4 DESIGN REQUIREMENTS

3.4.1 OPEN DRAIN SYSTEMS

In case open systems are unavoidable (i.e. drip pan), then the catchment area’s shall be kept to
an absolute minimum and consideration shall be given to the installation of a local drainage sump
with oil separation capabilities rather then installation of a open channel network terminating in a
large catch basin.

The size of open drain channels shall be determined by hydraulic calculations for the actual design
condition applicable.
Open drain channels designed for transporting hydrocarbon contaminated effluents shall ‘run dry’
after a rain or fire condition.
The cross sectional profile of open drain channels may be rectangular or hydraulically shaped. A
slope of 1:300 shall be used. However, for oil free networks slopes as small as 1:1000 may be
used if construction methods can be executed which avoid low spots and possible ponding. The
minimum width of rectangular channels shall be 300 mm, and the minimum depth for all channels
shall be 150 mm.
Open channels shall be covered with galvanized grating only at those places where
operator/maintenance access is required.

3.4.2 CLOSED DRAIN SYSTEM

The CD system shall be used only to empty equipment containing hydrocarbon liquids
prior to equipment maintenance. Liquid levels in equipment are lowered to the minimum
practical level using the normal process connections and it is essential that the equipment is fully
depressurised before draining via the CD system.

Depressurising may lead to cooling of the vessel contents which should be allowed to regain
ambient temperature before being admitted to the drain system. Only after this procedure has
been completed will the equipment be emptied to drain. To reinforce this procedure, all closed
drain lines must be isolated from equipment by double block valves and intervening spade or
spectacle blind. A removable spool may be used where draining is infrequent.

To avoid the possibility of heating up and flashing of hydrocarbon contained inside the drain
headers, hot oil/fluid drains shall be routed separately to the Closed Drain Vessel .
Spent hot oil (dead oil) may be drained into OHD after it is allowed to cool down to the ambient
temperature or 50 degree Celsius, whichever is higher.

3.4.2.1 PIPING

Design
(see figures 1 & 2)
Discharge to the closed drain system shall be by hard-piped connections, minimum size 2”, which
shall be positively isolated from the process during normal operation by means of spectacle blind.
The drain connection shall be positioned at the bottom of the process vessel, ensuring that the
complete inventory can be drained. This may require more than one drainage point i.e.
compartmentalised vessels. In addition a back flushing connection on the drain line underneath
the vessel shall be installed.

The main drainage header shall be fabricated from ANSI 150 # rated piping class. The main header
size shall be designed based on a realistic time (approximately 10 minutes) of draining the
residual system hold up, but shall be minimum 4”. The underground main drain header shall be at
least one size larger than the maximum drain connection sizes routed into it from the process
side of equipment/piping.

The branch connections from the vessels to the main header or up to the first pipe diameter
increase shall be rated for the same pressure as the vessel itself. The need for hydrotesting the
CD system means that a flange must be installed at the spec break, so that the two pipe classes

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can be isolated from one another. This specification break shall be recognized as demarcation of
process and drain system. (see Figure -1).

There shall be no drain valve or any other means of isolation downstream of a

specification break, which could cause the drain system to be overpressurised. The
single exception is the isolation valve installed at the drain header for drain vessel
maintenance, which shall be kept locked open during normal operation.

Drain piping shall be adequately and continuously sloped at 1:200 minimum to eliminate the
possibility of creating liquid pockets. Elbows, bends and flanges should be avoided as much as
possible.
Possibility of blockage by sludge/sand shall be assessed and appropriate measures such as 45 o
bends, larger diameter pipe etc. should be taken.
Sufficient rodding - points shall be installed if sand, solids or sludge are expected. Water hose
connections may be fitted at the rodding - points . (See Figure -2) .

Material
Drain piping design and installation shall comply with Company’s Schedule QQ and Q-CP
The piping shall be carbon steel with a 3 mm corrosion allowance. Alternatives such as Glasfibre
Reinforced Epoxy (GRE) may be specified, subject to Company approval. All piping materials
shall be suitable for sour service and shall be Hydrogen Induced Cracking (HIC) resistant.

3.4.2.2 CLOSED DRAIN VESSEL

Sizing
The Closed Drain Vessel shall be sized to accommodate the largest expected volume of liquid
which remains in any process vessel (excluding tanks) after it has been emptied to its lowest liquid
level prior to draining for maintenance.

The hold up volume of liquid in the Closed Drain Vessel shall be considered to be the volume
between high and low liquid level alarm settings. The Hi-Hi-liquid level shall be set at 80% of
vessel diameter. Figure-7 represents the general arrangement/requirement of a Closed Drain
Vessel.

Design Pressure
The Closed Drain Vessel shall have a design pressure of at least 350 kPa(g) in order to withstand
possible flame flashback from the vent.

Material
The Closed Drain vessels shall comply with Company’s Schedules TT and S. The material of
construction shall be carbon steel with a 3 mm corrosion allowance which shall be suitable for sour
service and shall be Hydrogen Induced Cracking (HIC) resistant. The vessel shall be internally and
externally coated. Painting/coating of the vessel and drain system piping shall comply with
Company’s Schedule V-9.

Internals and Associated Connections

The Closed Drain Vessels shall have a weir to separate sludge and solids. The weir height shall
be kept at about 40 percent of the vessel diameter. Length of sludge catch area may be kept
about 40 percent of the vessel tangent to tangent length.

A pump-out connection at pump side with an isolation valve shall be provided to facilitate removal
of the liquid. A dump connection with a valve can be provided at the oil inlet side of the weir for
dumping oil from external source and also to pump-out weir side oil before maintenance.

A closed drain inlet header shall be provided with a locked open isolation valve and a spectacle
blind on the downstream side to isolate the drain vessel for maintenance. A pit shall be provided
for access to valve and blind.
Operating procedures should take care of the possibility of over-pressurisation of the drain header
due to inadvertent opening of a drain valve in the plant system while the spectacle blind is closed.

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Vent System
Gas from the Closed Drain Vessel should pass to lowest pressure flare system if a flare system
exists in the plant or otherwise to a vent.

Due to the possibility of air ingress into the closed drain system a closed drain vessel shall be
purged continuously by inert or blanketing gas. The purge gas requirement shall be calculated
using the method described in API-2000 considering simultaneous running of both the pumps in
the drain vessel. The flow of purge gas shall be through a restriction orifice which shall be
proceeded by a locked open isolation valve.

The vent shall be sized to discharge safely the greatest vapour flow that could enter the Closed
Drain Vessel if a single source is allowed to pass to the closed drain system without proper
degassing .
Vent pipe size should be checked for the vapour disengaged in the Closed Drain Vessel due to
draining of hot oil to the drain vessel .

Provision of lightning protection shall be assessed as per BS 6651. Where required, lightning
protection schemes shall be designed in accordance with the aforementioned standard. A
minimum of two local earth rod assemblies and connection to facility earth ring/system via 20 mm 2
PVC insulated earth cable shall be installed. The combined resistance to the general mass of
earth of the electrodes shall not exceed 10 Ohms isolated from the plant earth ring.

Instrumentation, Control And Shut-Down.

The following instrumentation shall be used for the Closed Drain Vessel.

Level Indicator controller (Local ) If Transfer Pumps are installed (ON-OFF control of Pump
with High -Low switch ).

Low - Low Level Trip Additional Safety for Pump protection if level controller fails
to stop the pump.

High-High Level Alarm Operator attention and stand - by pump starts.

Hi-Hi-Hi Level Trip and Alarm Station Emergency Shutdown (ESD).

Pressure Gauge Local Pressure indicator on vessel .

High Pressure Alarm When Blanket gas is used, a high pressure alarm at 50
kPa(g) may indicate process upset in the Drain system .

Cathodic Protection.
Cathodic protection by means of sacrificial anodes shall be provided for the buried Closed Drain
Vessel.

Insulating flanges shall be installed at vessel and piping connected to above ground systems.
Insulating spool pieces are not required where a continuous water phase is not present.

Hazardous Area Classification.

Hazardous area classification applicable to the closed drain vessel pump motors and vents shall
be as per API RP500 A,B,C.

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3.4.3 DRAINS

3.4.3.1 Instrument Drains

Instrument drains are necessary for instruments like level gauges and level instruments which
need draining either for taking readings or for maintenance.

If the drained liquid is sweet and non-volatile then the instrument drains shall be drained to the
open hazardous drain system via tundishes. The drained liquid should be visible when the drain
valve is opened (See Figure 4 ). The valve downstream the tundish shall be manual spring to
close to ensure that these valves are normally closed.

If the drained liquid is sour and/or volatile, then the instrument drain shall be hard piped to the
closed drain system. (See Figure 3 ).

3.4.3.2 Sample Drains

Sampling required initially draining and flushing of the sample equipment. Figure 6 indicates the
required hookup for sampling of low pressure, sweet and non-volatile process liquids to the OHD
in case the sample flushing requirement is small.
Where drainage quantities are high, sample flushing lines, shall be connected to a closed drain
system. A sample draw-off point which is over a tundish shall be connected to the OHD System.

Sample flushing lines for Sour Service and Volatile Hydrocarbons processes shall be directly
connected to closed drain system (see Figure -5 )

3.4.3.3 Tank Drains

Tank bottoms shall be drained via a closed drain system to recover larger quantity of oil .

Any water drained from the roof of a crude oil product storage tank inside the bunded area shall
be treated as contaminated and shall be taken to OHD. Floating Roof Tank drains shall be piped
into the OHD system and a sight glass shall be installed in the drain line to allow checks to be
made for any hydrocarbon contamination due to leakage.

3.4.3.4 Equipment Drains (Pumps, Compressors)

Condensate and oil pumps shall be drained via a tundish to the OHD.
Reciprocating compressor casings shall be drained as per schedule D7 to the CD system.
Water pumps shall be drained via a tundish to OD system.

3.4.3.5 Process Drains

Process drains shall not be connected to a closed drain system, but shall be routed via a flash
vessel or via the flare K.O vessel.

If the process drain contains hydrocarbon and condensate, but does not contain undesirable toxic
chemicals or materials e.g. drains from compressor knock - out vessels, then it can be routed to
the closed drain system provided the following steps are taken :

- Process drain shall first be flashed to an intermediate flash vessel where depressurising to
atmospheric pressure should take place.

- Process drain is checked for flash temperature and the draining liquid temperature to closed
drain system is acceptable for the closed drain system material .

- Process drain is checked for hydrate formation and adequately sized and protected.

- Drain pipe to intermediate flash vessel is checked for breakthrough for process level control
valve failure in an open position and the vessel vent line is adequately sized to restrict
overpressure in flash vessel.

- Gas outlet from intermediate flash vessel shall be connected to flare or vent header at such a
point that overpressuring due to any reason can not occur.

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- Drain from the intermediate flash vessel to the closed drain system is adequately protected
for gas breakthrough.

3.4.3.6 Laboratory Drains

Laboratory drains are used for the disposal of samples, chemical solutions, solvents and
chemicals.

Laboratory drains shall be independent drain systems. Only oil/water drain from the laboratory
may be connected via water sealed pipe into OHD gully outside the laboratory wall.

All other drains shall be collected in drums. For various chemicals separate collecting
systems/drums may need to be considered depending on compatibility of the chemicals mixed.
Some types of chemicals may need to be neutralised prior to discharge e.g. sulphuric acid, caustic
soda etc.

3.4.3.7 Chemical Drains

Separate drains and disposal systems shall be considered for chemicals used in process systems.
The type of drain system shall depend on the properties of the chemicals, compatibility with
other chemicals, need for reclamation etc.

Within the gas and oil processing environment, water treatment is an area where chemical drains
are to be expected. Acid and caustic soda drains from water softening plants requires to be routed
to a neutralizing pit. Neutralizing of acid or caustic solutions creates violet reactions and develop
heat, which shall be considered in the design phase. Vapours from the pit shall be vented at safe
location. The neutralized water can only be routed into the ONHD in case the pH of the water is in
the range of 5 - 8.
Drains from hypo-chlorine facilities shall be routed to a collecting pit. The pit shall have a vent to
safe location. Neutralizing of hypo-chlorine solutions can be done with either a diluted caustic
soda solution, by dilution with water or by time (degradation of the hypo-chlorine). The selected
neutralizing method depends on the expected drain volumes.

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