the challenges involved in designing a code compliant …€¦ · reza rasooli – 19 years...
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TheChallengesInvolvedinDesigningaCodeCompliantOverpressure
Protec9on(OPP)SystemRezaRasooli
SolarisManagementConsultants
RezaRasooli– 19yearsexperience– ProcessSafetyExpertwithSolarisManagementConsultantsInc.
– BSc.inElectricalEngineering– MSc.inMechatronicsEngineering– RegisteredProfessionalEngineerinB.C.andAlberta– CerDfiedAutomaDonProfessional– ISA84/IEC61511ProcessSafetySISExpert– ExidaFireandGasPracDDoner– ISA84standardcommiMeemember– MemberoftheStandardsCouncilofCanada(SCC)andrepresenDngSCCinIEC61511standardcommiMee
ObjecDves&Overview
• WhyisOPPimportant?• OPPchallenges• Whichcodeisthegoverningcode?• Reviewofavailablestandards• ReviewofindustrypracDceforwellsites• HIPSdesign• HowtosavecostbyusingHIPS
WhyisOPPimportant?• OverpressureprotecDonisconsideredthelastlineofdefenseagainstpossiblecatastrophicfailureofpressureequipment.ThefuncDonofoverpressureprotecDonisto:– Protectpeople,– PreventunsafeoperaDonofpressureequipment,– Protectequipmentfromfailureduetooverpressure,
– PreventlossofproducDon.
OPPChallenges
• SinceaPSVistheprimarymethodofprovidingOPPforpressureequipment,almostallpressureprotecDonguidelineshavefocusedonprovidingdetailsonhowtoimplementPSVsanddonothelpmuchwhenaPSVcannotbeused.
– Whichcodeisthegoverningcode?– WhyOverpressureRiskAssessment(ORA)isrequired?– WhatisroleofinstrumentaDoninoverpressureprotecDon?
– WhenshouldweuseHIPSinsteadofPSV?
Whichcodeisthegoverningcode?• ThebiggestchallengeinevaluaDngordesigninganoverpressureprotecDon(OPP)systemisfindingtherightguidelinewithinthevarietyofapplicablestandardsandhowtodealwithdifferentinterpretaDonsofavailableresources,including:– ASME(BPVCSecDonI,VIII,B31.1,B31.3,B31.4,B31.8)– APIStd521– CAN/CSA-Z662– ABSAAB-525– IEC61508,IEC61511orANSI/ISA-61511
ASMEBPVC.VIII.1UG-140OPPbysystemdesign• UG-140(a):Apressurevesseldoesnotrequireapressurereliefdeviceifthepressureisself-limiDng(e.g.,themaximumdischargepressureofapumporcompressor),andthispressureislessthanorequaltotheMAWPofthevesselatthecoincidenttemperature…
• UG-140(b):Ifthepressureisnotself-limiDng,apressurevesselmaybeprotectedfromoverpressurebysystemdesignorbyacombinaDonofoverpressurebysystemdesignandpressurereliefdevices…
ASMEBPVC.VIII.1UG-140(b),3• Theusershallconductadetailedanalysistoiden9fyandexamineallscenariosthatcouldresultinanoverpressurecondi9onandmagnitudeoftheoverpressure.The“CausesofOverpressure”asdescribedinANSI/APIStandard521,Pressure-RelievingandDe-pressuringSystems,shallbeconsidered.OtherstandardsorrecommendedpracDcesthataremoreappropriatetothespecificapplicaDonmayalsobeconsidered.AmulDdisciplinaryteamexperiencedinmethodssuchasHAZOP,FMECA,what-ifanalysis,orotherequivalentmethodologyshallconducttheanalysis.
ASMEB31.3K322.6.3OPPforhighpress.pipingsystems• SystemprotecDonmustincludeonereliefdevicesetatorbelowthedesignpressureattheoperaDngtemperaturefortherelievingcondiDon,withnodevicesettooperateatapressuregreaterthan105%ofthedesignpressure…
• ASMEB31.3doesnotprovideanyalternaDveforaPSV.
CAN/CSA-Z662Oilandgaspipelinesystems• Pressure-controlsystemsshallbeinstalledwheresupplyfromanysourcemakesitpossibletopressurizethepipingaboveitsmaximumoperaDngpressure…
• Wherefailureofthepressure-controlsystem,orothercauses,canresultinthemaximumoperaDngpressureofthepipingbeingexceeded,overpressureprotecDonshallbeinstalled…
CAN/CSA-Z662,4.18PCandOPPofpiping• OverpressureprotecDonreferstoasecondlevelofprotecDon(i.e.,beyondthatprovidedbypressurecontrol)thatisrequiredinordertoprotectthepipelinefrombeingoverpressured.
• OverpressureprotecDonisrequiredtobeconDnuousandautomaDcbecauseitisasafety-typesystem,withoutanyrelianceonmanualintervenDon.OverpressureprotecDoncanbeaccomplishedbypressure-limiDngsystemsorpressure-relievingsystems.
CAN/CSA-Z662,4.18.4AddiDonaloverpressure-protecDonrequirements• 4.18.4.1:ForposiDvedisplacementgascompressors,apressure-relievingsystemshallbeinstalledbetweenthegascompressorandthefirstblockvalveonthedischargesideofthecompressor.Therelievingcapacityofthepressure-relievingsystemshallbeequaltoorgreaterthanthecapacityofthecompressor.
• 4.18.4.2:Forcentrifugalgascompressors,apressure-limi9ngorpressure-relievingsystemshallbeinstalledbetweenthecompressorandthefirstblockvalve,orbetweenthefirstandsecondblockvalvesonthedischargesideofthecompressor.
AERReferenceToolforInterpreDngPipelinePCandOPP• ThistoolclarifiestherequirementsofCanadianStandardsAssociaDon(CSA)Z662-03:OilandGasPipelineSystems,Clause4.14.1,…
AERReferenceToolforInterpreDngPipelinePCandOPP• UserNotes– Thesuitablecasesshowninthediagrams…arenotuniversallyacceptable.
– Allsourcesfromwhichoverpressuremayoccurmustbetakenintoaccount.Forthepurposeofthesediagrams,itisassumedthatothersuitableupstreampressurecontrolequipmentisinplace.
– Thesuitableexamplesreflecttypicalsystemsandaretobeusedonlyasaguideline.CertainexcepDonsorrestricDonsmaybewarrantedbasedonthecircumstancesandfacilitylayout.Everysystemshouldbeevaluatedcarefully,consideringallpossiblemodesofoperaDon.
DirecDve077:Pipelines—RequirementsandReferenceTools – Toprotectthewellsitesandtheassociatedgathering
pipelinesystems,thecommonindustrypracDceistouseaback-pressurecontrolvalve(BPCV)locatedonapressurevesselinthebaMeryaspressurecontrolforthepipeline,andtouseapressureswitchlocatedatthewellheadasoverpressureprotecDonthatshutsdownthearDficiallinequipmentatthewell.However,thepipelinesarenotalwaysprovidedwithadedicatedpressurecontrolandoverpressureprotecDonsystem,asrequiredbyCSAZ662-07.
– TheERCBdoesnotconsiderthisdesigntobemeeDngCSArequirements…
ImportantNote
InaccordancewithClause4.18ofCSAZ662,anoverpressureprotecDondevice(e.g.,emergencyshutdownvalve)incombinaDonwithapressurecontroldevice(e.g.,anautomaDcchoke)maybeusedtoprovideprotecDonforCSAZ662pipelinepiping.ThereisnoregulatoryorCSAZ662coderequirementforapressurerelievingsystemnorfortheuseofHIPSratedcontrols/components.WhereASMEcodeequipmentexistsatapointdownstream,ASMECoderequirementsshallprevail.
ThePressureEquipmentSafetyRegulaDon(PESR)• 38(1):AnownerofpressureequipmentmustensureithasoverpressureprotecDonthatis:
(a) apressurereliefvalvethatmeetstherequirementsoftheASMEcode,or,
(b) othermeansofoverpressureprotecDonacceptabletotheAdministrator.
AB-525OverpressureProtecDonRequirementsforPressureVesselsandPressurePiping• AccordingtothePESR,apressurereliefvalvethatmeetstherequirementsoftheASMEcodeisrequiredforprotecDonofallpressureequipmentunlessthepressureequipmentisprotectedbysomeothermeansacceptabletotheAdministrator.
• TheAdministratormayacceptanalternaDvemeansofoverpressureprotecDonthatisnotaPRVinaccordancewithSecDon38(1)(b)ofthePESRandSecDon5.5ofAB-525.
AB-525
• WhenpressurevesselsandpressurepipingareprotectedbyPRVsinaccordancewithSecDon38(1)(a)ofthePESR,thePRVsmust:– provideoverpressureprotecDonforalloverpressureevents(scenarios)validatedwithanORA,and,
– meetalltherequirementsspecifiedinthePESR,thisdocument,AB-524document,andtheapplicableCSAandASMEcode.
AB-525ORA• ORAmeansOverpressureRiskAssessment.ThisisariskassessmenttodeterminethesourcesofoverpressureandtheMaximumUpsetPressure….TheORAmustuseanorganized,systemaDcanddocumentedapproachconductedbyqualifiedpersonnelthroughamulD-disciplinaryteam.TheprocessusedforORAmustbebasedonrecognizedstandardsandgoodengineeringpracDces(WRC-498,ANSI/API521,ANSI/API-520,etc.).TheORAshallincludealistofSafetyCriDcalElementsuDlizedinthedeterminaDonoftheMaximumUpsetPressure.
AB-525,5.5OtherMeansofOverpressureProtecDon• ThefollowingaresomeexamplesofothermeansofoverpressureprotecDonthatrequireindividualcase-by-caseconsideraDon:– HighIntegrityProtecDonSystem(HIPS)providingoverpressureprotecDonofsystems(FurtherinformaDononHIPScanbefoundinAnnexEofANSI/API521),
– …,– OtheroverpressureprotecDoncasesthatarenotincludedinSecDons5.1,5.2,5.3or5.4ofthisdocument,
– …,
APISTANDARD5214.2.6RoleofInstrumentaDoninOPP• Fail-safedevices,automaDcstart-upequipment,andotherconven9onalinstrumenta9onshouldnotbeasubs9tuteforproperlysizedPRDsasprotecDonagainstsinglejeopardyoverpressurescenarios.Therecanbecircumstances,however,wheretheuseofPRDsisimpracDcalandrelianceoninstrumentedsafeguardsisneeded.Wherethisisthecase,ifpermiMedbylocalregulaDons,aPRDmightnotberequired.
ImpracDcalPRDs• ExtraordinaryreliefloadthatresultsinunrealisDc
knockoutdrumandflaresystem• Sand,waxorothermaterialsthatcanblockthePSV• PSVsthatcancausenewhazards• Atmosphericvent:areaclassificaDonandfacilitysiDng
issues• Hotprocessortwo-phaseflow• Environmentaldamage• WheremulDple,full-sizePSVsarerequiredtofuncDon
simultaneously• PSVreliefratecancausetemperatureslowerthan
systemMDMT(MinimumDesignMetalTemperature)
APISTANDARD5214.2.6RoleofInstrumentaDoninOPP• ThedesignshallcomplywiththelocalregulaDonsandtheowner’srisktolerancecriteria,whicheverismorerestricDve.IftheserisktolerancecriteriaarenotavailabletoperformanalysespertheguidanceinAnnexE,thenasaminimum,theoverallsystemperformanceincludinginstrumentedsafeguardsshouldprovidesafetyintegritylevel3(SIL-3)performanceinaccordancewithISAS84.01.
APISTANDARD521AnnexE(HIPS)• High-integrityProtecDonSystems(HIPS)– AdifferentapproachtooverpressureprotecDonistheuseofaninstrumentedsystem.HIPStypicallyinvolveanarrangementofinstruments,finalcontrolelements(e.g.,valves,switches,etc.),andlogicsolversconfiguredinamannerdesignedtoavoidoverpressureincidentsbyremovingthesourceofoverpressureorbyreducingtheprobabilityofanoverpressureconDngencytosuchalowlevelthatitisnolongerconsideredtobeacrediblecase.
APISTANDARD521AnnexE(HIPS)• TherearefiveprincipalusesofaHIPS:– toeliminateaparDcularoverpressurescenariofromthedesignbasis
– toeliminatetheneedforaparDcularreliefdevice– toprovidesystemoverpressureprotecDonwhereareliefdeviceisineffecDve
– toreducetheprobabilitythatseveralreliefdeviceswillhavetooperatesimultaneously,therebyallowingforareducDoninthesizeofthedisposalsystem
– toreducethedemandrateonareliefdeviceconsequentlyreducingtherisk
TypicalWellsiteforpressures≤5000psig
TypicalWellsiteforpressures≥15000psig
Costofflaresystem$700,000to$4000,000dependingonflowrates
PSVchallenges– Two-phaseflowwithlargeamountofliquids– Six,full-flowPSVsarerequiredtofuncDonsimultaneously
– largeamountofsandisflowingfromthewell– HighH2Scontent– ExtraordinarybigFKODrequired– Extraordinarytallflarestackrequired– Highcostofflaresystem(makingprojecteconomicallynotfeasible)
– Costofflaresystem$700,000to$4,000,000dependingonflowrates
HIPSDesignpressures≥15000psig
CostofHIPS$300,000regardlessofflowrates
HybridDesignHIPS+PSVs
QuesDons