Training Course Packet - Kenexis€¦ · · 2018-03-30Training Course Packet Gas Production...

Training Course Packet

Gas Production Facility

General Oil and Gas Operating Company Chemical City, TX

Kenexis

Kenexis Client:

General Oil and Gas Operating CO.

Consultant:

Kenexis Consulting Corporation 3366 Riverside Drive Suite 200 Columbus, OH 43221 Ph: (614) 451-7031 Fax: (614) 451-2643 E-Mail: [email protected] http://www.kenexis.com

Project Number: Internal Report Number: XXX.XXX-01:0

Release Date: June 2011

Report Type: Training Course Packet

Process Area: Gas Production Facility

Revision History: Revision Release Date Primary Author Review Approval

0 1 Jun 2011 SA Gray B Buckeye B Buckeye

Responsible Staff: Signature Date

Project Manager:

B Buckeye 1 Jun 2011

Authors:

SA Gray 1 Jun 2011

Disclaimer:

This document was prepared using best effort. The authors make no warranty of any kind and shall not be liable in any event for incidental or consequential damages in connection with the application of the document.

This report contains information, including equipment failure characteristics, and discussion of typical analysis techniques, which are the intellectual property of Kenexis – pre-existing this work made for hire. This report of copyright 2011, Kenexis Consulting Corporation. No part of this document may be circulated, quoted, or reproduced for distribution to other than the above named client without prior written approval from Kenexis Consulting Corporation.

Kenexis XXX-XXX-01:0 June 2011 CONFIDENTIAL INFORMATION Page 1

Background Information

This booklet contains background information on a sample facility that is used as a basis for discussion for seminars and training classes. The sample facility is intended to present typical equipment utilized in the process industries in order to provide a realistic training environment, while keeping the process very small in order for an entire facility to be analyzed during a single seminar or class.

The sample facility contains equipment similar to that which would be used for a natural gas production process and also a high-head pumping system that would be similar to charge systems in some high pressure refining units such as hydrotreaters and hydrocrackers.

It is important to note that this type of facility would not serve a real process purpose in isolation, and is thus not entirely genuine. It is important for attendees at the training classes and seminars that use this sample plant to focus on the principles and techniques that are being discussed, and not to dwell on perceived inconsistencies or process engineering related issues related to the sample plant. This will ensure a beneficial training experience.


Contents

Background Information ....................................................................................................... 1

Contents .............................................................................................................................. ii

1 Process Description ................................................................................................... 4

1.1 Overview ........................................................................................................... 4

1.2 High Pressure Separator (V-101) ......................................................................... 4

1.3 Low Pressure Separator (V-102) ......................................................................... 4

1.4 Export Pump (P-103) .......................................................................................... 5

1.5 Gas Compressor (C-104) .................................................................................... 5

1.6 Support Facilities................................................................................................ 5

2 Process Flow Diagram (PFD) ...................................................................................... 6

3 Piping & Instrumentation Diagram (P&ID) .................................................................. 8

4 Plot Plan - Equipment Layout ................................................................................... 15

5 PHA Risk Ranking Matrix and Tables ......................................................................... 17

5.1 Risk Matrix ...................................................................................................... 17

5.2 Severity ........................................................................................................... 17

5.3 Likelihood ........................................................................................................ 18

5.4 Risk Ranking .................................................................................................... 18

6 SIL Selection Risk Ranking Matrix and Tables ............................................................ 19

6.1 Risk Matrix - Safety .......................................................................................... 19

6.2 Severity - Safety .............................................................................................. 19

6.3 Likelihood ........................................................................................................ 20

6.4 Risk Matrix - Environment ................................................................................. 20

6.5 Risk Matrix - Commercial .................................................................................. 20

7 Alarm Rationalization Matrix and Tables .................................................................... 21


7.1 Risk Matrix ...................................................................................................... 21

7.2 Severity ........................................................................................................... 21

7.3 Response Time ................................................................................................ 22

7.4 Priority ............................................................................................................ 22

8 Safety Analysis Functional Evaluation (SAFE) Chart ................................................... 23


1 Process Description

1.1 Overview The General Oil & Gas Operating Company’s production facility located in Chemical City, TX processes hydrocarbon fluids coming out of natural gas wells located in production platforms. The wells discharge the production fluids into a main production header, which in turn supplies the facility with feedstock. In the first stage of the separation process (high pressure stage), the production fluids enter a high pressure separator where the liquid and gas components are separated at a specific temperature and pressure. The gas leaving the high pressure separator is predominantly composed of lighter hydrocarbons and does not need any additional treatment. The gas leaves the facility via the export gas pipeline to neighboring gas processing companies. In the second stage of the separation process (low pressure stage), the liquid from the first stage enters the low pressure separator and flashes at a specific temperature and pressure. The gas stream from the low pressure separator is compressed and the compressed gas combines with the gas leaving the high pressure separator. The liquid from the low pressure separator is considered to be stabilized for processing purposes and it is pumped into the high pressure export liquid pipeline. The major equipment used in this process, includes a High Pressure Separator, Low Pressure Separator, Export Pump and Gas Compressor are described in the following sections.

1.2 High Pressure Separator (V-101) Hydrocarbon fluids enter the high pressure separator (V-101) through a pressure reducing valve (PRV-101A) which reduces the pressure from approx.700 psig (production header pressure) to 350 psig (first stage operating pressure). The pressure in the separator is maintained by the pressure control valve PV-101B. Flashing occurs in the vessel causing separation of gas and liquid components. Reduction in flow velocity causes the liquid droplets to drop out of the gas stream. The separator vessel provides the retention time needed for effective gas-liquid separation and also provides a surge volume necessary to handle intermittent surges of liquid. The liquid level in the vessel is maintained by the level control valve LV-101A.

As the hydrocarbon fluids come into contact with the inlet diverter, most of the liquid falls into the liquid section and the gas flows over the inlet diverter. The gas stream continues to flow horizontally above the liquid section and small drops of liquid not separated by the inlet diverter are separated out by gravity. Drops of liquid that are too small to be separated by gravitational force are removed from the gas stream by a de-mister pad.

The gas leaves the high pressure separator and enters the export gas pipeline to neighboring gas processing facilities. Over pressure protection of the high pressure separator is provided by relief valve PSV-101.

1.3 Low Pressure Separator (V-102) The liquid from the high pressure separator enters the low pressure separator through the level control valve LV-101A. The operating pressure in the low pressure separator is maintained at 50 psig to flash off the lighter hydrocarbons into the gas phase and partially stabilize the liquid phase. The vapor and liquid disengage similar to V-101. The gas is sent to compressor C-104


and the partially stabilized liquid is pumped out using pump P-103. Over pressure protection of the low pressure separator is provided by relief valve PSV-102.

1.4 Export Pump (P-103) The partially stabilized hydrocarbon liquid from V-102 is pumped using high pressure pump P-103 to the export liquid pipeline. P-103 is a multistage pump that discharges the liquid at a pressure of 2200 psig needed to transport the hydrocarbon liquid several miles before it can be further processed. A pressure relief valve PSV-103 protects the pump from damage in case of a blocked flow in the export liquid pipeline.

1.5 Gas Compressor (C-104) The gas stream leaving the low pressure separator V-102 at a pressure of 50 psig enters compressor C-104 where its pressure is increased to 350 psig to match the gas pressure leaving the high pressure separator. The pressure controller PIC-104A controls pressure from the compressor to the export gas pipeline. The pressure controller senses changes in separator pressure and sends a signal to either open or close the control valve PV-104A accordingly. Controller FIC-104 provides anti-surge control by “spilling back” sufficient material through FV-104 to the low pressure separator and prevents surging. Over pressure protection of the suction and discharge sides of the compressor are provided by pressure relief valves PSV-104A and PSV-104B respectively.

1.6 Support Facilities The support efforts include:

1. A site with roads

2. Security with perimeter chain link fencing a guard house and an entry gate

3. Utilities to enable the process to work: electricity; fuel oil or diesel; instrument air and water

4. Safety systems include fire water deluge, personnel protection, and escape

5. Vent systems which discharge to a flare header and flare


2 Process Flow Diagram (PFD)

The process flow diagrams begin on the following page.

OF 11SHEET

B A

SDV104

PSV104B

SDV106

F A

PSV103

SDV102B

D B

A D

PV101A

SDV103

F A

TO EXPORT LIQUID PIPELINE

4"-F

FT103C

FV103C

P-103(Trim: F)

A F

4"-A

B A

PSV102 TO FLARE SYSTEM

12"-A

SDV102A

D ALV101

4"-D

PV101B

TO FLARE SYSTEM14"-A

AD

D A

PSV101

SDV101

FROM PRODUCTION HEADER (NOTE 1)

C-104(Trim: B)

1ST STAGE

C-104GAS COMPRESSOR

CAPACITY: 0.50 MMSCFD (14160 SCMD)SUCTION: 50 PSIG (3.4 BAR) AT 70°F (21°C)

DISCHARGE: 350 PSIG (24.1 BAR) AT 279.1°F (137.3°C)MOTOR: 73 HP

TO EXPORT GAS PIPELINE

10"-B

6"-B6"-D

V-101HIGH PRESSURE SEPARATOR

SIZE: 60" I.D. (1.52 M) X 18'-6" S/S (5.64 M)DESIGN: 1200 PSIG (82.7 BAR)/FV AT 300°F (149°C)

OPERATING: 350 PSIG (24.2 BAR) AT 70°F (21°C)LIQUID RESIDENCE TIME: 3 MIN.

TO FLARE SYSTEM8"-A

PSHH101D

PSLL101D

V-102

LSHH102B

LSLL102B

PSHH102B

PSLL102B

6"-D

V-102LOW PRESSURE SEPARATOR



P-103EXPORT PUMP

CAPACITY: 100 GPM (0.38 SCM) @ 2200 PSIG (151.7 BAR)DIFFERENTIAL PRESSURE: 2100 PSIG (144.8 BAR)

MOTOR: 200 HP

FT103B

FV103A

FV104

FT104

PV106

LSLL101B

V-101

LSHH101B

4"-A

10"-A

LSLL101B

FT103A

PSHH103A

PSLL103A

PSLL103C

PSLL106

TO FLARE SYSTEM

10"-A

PSHH104C

PSLL104C

PSV104A

H-105(Trim: B)

H-105COMPRESSOR DISCHARGE COOLER

DUTY: 0.12 MMBTU/HR (35.2 KW)DESIGN: 500 PSIG (34.4 BAR) AT 350°F (177°C)

OPERATING: 350 PSIG (24.1 BAR) AT 279.1°F (137.3°C)

2

3

1

6

4

7

8

5

OBL

OBL

OBL

OBL

OBL

OBL

OBL

TSHH104

Parameter USC Units 1 2 3 4 5 6 7 8

Temperature oF 70.00 70.00 70.00 38.00 38.00 279.08 70.00 38.00Pressure PSIA 714.69 364.69 364.69 64.69 64.69 364.69 364.69 2114.69Molecular Wt. LB/LB-MOL 20.25 18.63 67.99 21.69 74.25 21.69 18.64 74.25Density LB/FT3 1.43 1.28 38.46 0.27 40.50 1.00 1.19 40.50Compressibility Factor (Z) UNITLESS 0.91 0.94 n/a 0.98 n/a 0.98 0.93 n/aHeat Value BTU/LB 23168 23311 21125 22951 21072 22951 23295 21072

Rate MOL/DAY 263512 254842 8670 1033 7637 1033 255875 7637LB/HR 222338 197789 24549 933 23615 933 198722 23615LB/MIN 3706 3296 409 16 394 16 3312 394

Energy Rate MMBTU/HR 5151 4611 541 21 519 21 4632 519

Std. Liq. Rate GAL/HR n/a n/a 4774 n/a 4362 n/a n/a 4362GAL/MIN n/a n/a 80 n/a 73 n/a n/a 73BOPD n/a n/a 2728 n/a 2492 n/a n/a 2492

Std. Vapor Rate MMSCFD 100 97 n/a 0 n/a 0 97 n/aSCFM 69444 67160 n/a 272 n/a 272 67432 n/a

Stream Number

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-01

Process Flow DiagramGas Production Facility

Kenexis3366 Riverside Drive, Suite 200, Columbus OH 43221

This drawing, © 2011 Kenexis Consulting Corporation is business confidential. No part of this document may be circulated, quoted, or reproduced for distribution other than by the above named client without prior written approval from Kenexis Consulting Corporation.

The Design Basis for this facility is 100 MMSCFD of natural gas at a pressure of 700 psig and a temperature of 70oF. The incoming production header pressure is assumed to be 700 psig in normal operation. The molar composition of the natural gas stream is: Methane – 90%, Ethane – 2%, Propane – 2%, N-Butane – 2%, N-Pentane – 2%, and N-Hexane – 2%.

CLIENTNOTES REV DESCRIPTION DATE BY APP DRAWN S. A. Gray 9 Jun 09CHECKED B. Buck 23 Jun 09

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0 As Built 9 Jun 09 SAG BB1 Revision 23 Jun 09 SAG BB

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K:\Training Courses\Sample Process for Training\DWG-PFD_PIDs.vsd



3 Piping & Instrumentation Diagram (P&ID)

The Piping and Instrumentation Diagrams begin on the following page.

OF 61SHEET

Analysis

Burner, Combustion

Blowdown

Choice (Conductivity)

Choice (Density)

Voltage

Flow/Flowrate

Flow Ratio

User’s Choice

Hand

Process Variable

A

B

BD

C

D

E

F

FF

G

H

AAL

BAL

BDAHH

CAL

DAL

EAL

FAL

FFAL

AAH

BAH

CAH

DAH

EAH

FAH

FFAH

AE

BE

FE FG

AI

BI

CI

DI

EI

FI

FFI

AT

BT

CT

DT

ET

FT

FFT

AIC

BIC

CIC

DIC

FIC

FFIC

HIC

AV

BV

BDV

FV

FFV

HV

FCV

ASL

BSL

CSL

DSL

ESL

FSL

FFSL

ASH

BSH

CSH

DSH

ESH

FSH

FFSH

AY

BY

BDY

CY

DY

EY

FY

FFY

HY

Alar

m L

ow,

Low

-Low

AL(L) AH(H) E G I L CV SL(L) SH(H) Y

Alar

m H

igh,

Hig

h-H

igh

Alar

m H

igh/

Low

Elem

ent

Gau

ge/G

lass

(Dire

ct)

Indi

cate

Ligh

t(S

tatu

sIn

dica

tion)

Tran

smitt

er(N

ote

1)

Con

trolle

r(N

ote

2)

Valv

e,D

ampe

r,Lo

uver

Valv

e,Se

lf-R

estra

inin

g

Switc

h Lo

w

Switc

h H

igh

Switc

h H

igh/

Low

Com

pute

,C

onve

rt,R

elay

ProcessLegendSheet

Inst

rum

ent

Func

tion

T CI V

Current (Electric)

Power

Time

Level

Level, Safety

User’s Choice (Moisture)

User’s Choice

User’s Choice

Pressure

Pressure Differential

I

J

K

L

LX

M

N

O

P

PD

IAL

JAL

LAL

LXALL

PAL

PDAL

IAH

JAH

LAH

LXAHH

PAH

PDAH

LALH LG

II

JI

LI

PI

PDI

IT

JT

LT

LXT

PT

PDT

IIC

JIC

LIC

PIC

PDIC

LV

PV

PDV

LCV

PCV

PDCV

ISL

JSL

LSL

PSL

PDSL

ISH

JSH

LSH

PSH

PDSH

IY

JY

LY

PY

PDY

LSLH

Pressure Ratio

Pressure, Safety

Quantity

Radiation

Speed

Shutdown

Temperature

Temperature Differential

Temperature, Safety

Multi-Variable

PF

PX

Q

R

S

SD

T

TD

TX

U

PFAL

PXALL

SAL

TAL

TDAL

TXALL

UAL

PFAH

PXAHH

SAH

TAH

TDAH

TXAHH

UAH

PSE

TE TG

PFI

SI

TI

TDI

PXT

ST

TT

TXT

UT

PFIC

SIC

TIC

TDIC

UIC

PFV

PSV

SV

SDV

TV

TDV

UV

TCV

PFSL

SSL

TSL

TDSL

USL

PFSH

SSH

TSH

TDSH

USH

PFY

SY

SDY

TY

TDY

UY

Vibration

Weight

Unclassified

Event, State, Presence

Position

V

W

X

Y

Z

VAL

WAL

ZAL

VAH

WAH

ZAH

VE

WE

VI

WI

XI

YI

ZI

YL

ZL

VT

WT

XT

ZT

WIC

XIC

ZIC

XV XCV

VSL

WSL

XSL

ZSL

VSH

WSH

XSH

ZSH

VY

WY

YY

ZY

ANSI Piping Pressure Specifications at 300°F (149°C)

Maximum Design Pressure

230 psi (15.9 bar)

655 psi (45.2 bar)

1315 psi (90.7 bar)

1970 psi (135.8 bar)

3280 psi (226.2 bar)

ANSI Class Rating

150#

300#

600#

900#

1500#

Piping Class

A

B

D

E

F

Instrument Symbols

Lines

Instrument ImpulseLines from ProcessPneumatic Signal

Electrical Signal

Hydraulic Signal

Capillary Tube

Fiber Optic“Soft Link” Communication“Serial Link” Communication

Control Valve/Relief Device

Flow Symbols

Miscellaneous

Diaphragm Spring Return

Piston Spring Return

Self-Actuated

Motor Operated

Solenoid Operated

Buckling Pin

Relief Valve (Spring)

Pressure/VacuumSafety Valve

Pilot Operated

Fixed Choke

Adjustable Choke

Actuated Choke

Rupture Disk

Deluge

Diaphragm with Positioner

Piston with Positioner

Double Acting Piston with Positioner

Orifice

Quick Change Orifice Meter (SR/JR Optional)

Venturi Meter

Averaging Pilot Meter

Turbine Meter

Vortex Meter

Magnetic Flowmeter

Positive Displacement Flow Meter

In-Line Flow Glass

Rotameter

Cone Meter

Coriolis Meter

Ultrasonic Flowmeter

Flow Conditioner

M

S

(SR/JR)

M

FG

FG

DiaphragmSeal

S3 Way Solenoid

3 Way Solenoid with Manual Reset

S

Motor Control Center

R

MCC

Detail “A” - SIS Inputs

XIXXX

XTXXX

HAXXX

XAHHLLXXX

XAHLXXX

HSXXX

XDAXXX

Detail “B” - SIS Outputs

USCXXX Indicator

Bypass Switch

Trip Alarm

Pre-Alarm

Bypass Alarm

Deviation Alarm

XIXXX

XVXXX

HSXXX

XAXXX

USCXXX

OutputCommandStatus

Output Activated

Reset

Material of Construction

Carbon Steel

Carbon Steel

Carbon Steel

Carbon Steel

Carbon Steel

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-02

Legend SheetGas Production Facility



NOTES:1. All electronic transmitters are indicating transmitters.2. If an “I” is omitted, the device is a non-indication controller.


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OF 62SHEET

C101

D A

LV101A

V-101

PT101B

PV101B

PSV101

PT101D

SDV101

OBL

OBL

OBL

SHT 5

LT101A

TO GAS COMPRESSOR

TO FLARE SYSTEM

TO FLARE SYSTEM

TO L.P. SEPARATOR

FROM PRODUCTION HEADER

IASS

LT101B

PI101C

LIC101A

PIC101B

H

L

H

L

SHT 3

6"-D

4"-D

8"-D

14"-A

8"-A

A

D

PT101C

PV101A

PIC101A

PT101A

USC101

USC101

USC101

LG101A

LG101B

H

H

L

V-101HIGH PRESSURE SEPARATOR



USC100

FT101

FQI101

Detail “A”

Detail “A”

Detail “A”

C100

Detail “B”

HS100

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-02

High Pressure SeparatorGas Production Facility




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OF 63SHEET

SHT 44"-A

FROM PSV-103

SDV102B

IASS

USC102

B A

SHT 5GAS COMPRESSOR SPILLBACK

6"-A

SHT 4

V-102

PSV102

SDV102A

SHT 2

OBL

SHT 5

LG102A

LT102A

TO GAS COMPRESSORS

TO FLARE SYSTEM

TO EXPORT PUMP

FROM HP SEPARATOR

IASS

BLOCKED FLOW8"FB12"SET AT75 PSIG

LG102B

LT102B

PI102A

SHT 4

I

4"-D

4"-A

D A

6"-B

12"-A

LIC102A4"-A

PIPELINE PUMP SPILLBACK

PT102A

PT102B

USC102

USC102

H

L

USC102

H

SHT 4TO FIC-103C

V-102LOW PRESSURE SEPARATOR



Detail “A”

Detail “A”

Detail “B”

Detail “B”

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-02

Low Pressure SeparatorGas Production Facility




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OF 64SHEET

F A

PSV103

BLOCKED FLOW8"FB10"SET AT2200 PSIG

F A

SHT 3

A F

SDV103

IAS

S

MCC

STOP

SIS

FT103C

FIC103C

FV103C

OBL

SHT 3

TO EXPORT LIQUID PIPELINE

FROM LP SEPARATOR

P-103(Trim: F)

4"-A

4"-F

PT103B

PI103B

PIPELINE PUMP SPILLBACK TO LP SEPARATOR

4"-A

FT103A

FIC103A

FV103A

P-103EXPORT PUMP

CAPACITY: 100 GPM (0.38 SCM) @ 2200 PSIG (151.7 BAR)DIFFERENTIAL PRESSURE: 2100 PSIG (144.8 BAR)

MOTOR: 200 HP

SHT 3FROM LIC-102A

USC103

USC103

H

FT103B

TO LP SEPARATOR4"-A

USC103

C103B

PT103A

USC103TT

103TI

103

H

Detail “A”

C103A

PT103C

Detail “A”

Detail “A” Detail “B”

SHT 3

Detail “B”

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-02

Pipeline PumpGas Production Facility




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OF 65SHEET

B A

IASS USC

106

SDV106

SDV104

IASS

D B

SHT 2

D A

SHT 3

MCC

STOP

C-104(Trim: B)

1ST STAGE

VENDOR FURNISHEDUNIT CONTROL

PANEL

SHT 3FROM LP SEPARATOR

OBLTO EXPORT GAS PIPELINE

XL104A

XL104B

XL104C

SY104D

RUN STATUS

IR1RUN

STATUS

ELSKW

ELSRUN

STATUS

6"-B

10"-B

10"-A

GAS COMPRESSOR SPILLBACK TO LP SEPARATORFV

104FT104

FIC104

ANTI-SURGE

PT106

PI106

C106

6"-DFROM HP SEPARATOR

PT106ATT

105

TI105

HH

PIC106A

PV106

USC104

H

L

C-104GAS COMPRESSOR



C102

USC104

USC106

PT106B

H-105COMPRESSOR DISCHARGE COOLER

DUTY: 0.12 MMBTU/HR (35.2 KW)DESIGN: 500 PSIG (34.4 BAR) AT 350°F (177°C)

OPERATING: 350 PSIG (24.1 BAR) AT 279.1°F (137.3°C)

OBL10"-A

TO FLARE SYSTEMPSV104B

RUPTURE8"FB10"SET AT250 PSIG

PT104C

USC104

BACKFLOW6"FB10"SET AT640 PSIG

PSV104A

H-105(Trim: B)

C104

USC104

TT104

Detail “A”

Detail “B”

Detail “A”

Detail “A”

Detail “B”

Detail “B”

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-02

Gas CompressorGas Production Facility




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OF 66SHEET

IASS

5"

HV105

1"

3"3"

PCV105C

4"

PCV105B

LT110

1"

1"1"

PDV105A

3/4"

1"

1"1"3/4"3/4"

C-104GAS COMPRESSOR



C-104

1"-D1"

F-104ASEAL GAS

FILTER

PIC105A

H

L

PCV105A

PT105A

1"1" 1" 1" 1"

PDT105A

PDI105A

H

1"

1"1"

TO DRAIN

F-104B&CLUBE OIL FILTERS

T-110OIL TANK

H-110OIL TANKHEATER

LG110

USC104

TO DRAINM

P-104BAUX. LUBE OIL

PUMP

4"-D

4"-D

PSV105

PSV106

4"-D4"

4"

SET PRESSURE450 PSIG

SET PRESSURE450 PSIG

M

P-104AMAIN OIL PUMP

4"-D

8"-D

4"-D

1"-D1"-D

3" x 1”

3" x 1”

3" x 1”

1"-D

2"

GT105A

USC104

TT105A

TI105A

H

TT105B

USC104 TT

105C

TI105C

HTT

105DUSC104

XT105B

XT105AUSC

104

USC104

TT105F

TT105E

TI105E

H

MONITORING TRAPS

LG106A

LG106B

M-104

1 / 2”

PRV105A PRV

105CPRV105B

PDT105C

USC104

TT105G

TI105G

H

TT105H

USC104

XT105C

XT105D

USC104

PT105B

USC104

TT105I

TI105I

H

TT105J

USC104

XT105E

XT105F

USC104

TT105P

TI105P

H

TT105O

TI105O

H

TT105N

TI105N

H

TT105K

TI105K

H

TT105L

TI105L

H

TT105M

TI105M

H

5"-D

FROM COMPRESSOR PANEL

HY105FT

105FI

105L

FLAMEARRESTOR

1"

3" x 1” 3" x 1”

3"

4" x 3”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

Detail “A”

REVDRAWING NUMBER

DRAWING TITLE

1DXXX.XXX-02

Gas Compressor Utility DetailsGas Production Facility




APPROVED

APPROVED


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4 Plot Plan - Equipment Layout

The equipment layout plot plans begin on the following page.

OF 11SHEET

Control Room

ElectricalSwitch-Room

BatteryRoom Air Lock

Tag No. DescriptionV-101 High Pressure SeparatorV-102 Low Pressure SeparatorP-103 Export PumpC-104 Gas Compressor

Equipment List

V-101C-104

P-103

V-102

REVDRAWING NUMBER

DRAWING TITLE

3DXXX.XXX-03

Plot PlanGas Production Facility



1. All dimensions are in inches.CLIENTNOTES REV DESCRIPTION DATE BY APP DRAWN S. A. Gray 09 Jun 09

CHECKED B. Buck 1 Jun 11APPROVED

APPROVED

0 As Built 9 Jun 09 SAG BB1 Revision 23 Jun 09 SAG BB2 Revision 7 Jan 11 SAG BB3 Revision 1 Jun 11 SAG BB

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K:\Training Courses\Sample Process for Training\DWG-Plot Plan.vsd


HVAC


5 PHA Risk Ranking Matrix and Tables

5.1 Risk Matrix

I

I

I

I

I

I

III

III

II

I

I

I

IV

III

III

II

I

I

IV

IV

III

III

II

I

V

IV

IV

III

III

I

V

V

IV

IV

III

I

0 1 2 3 4 5

5

4

3

2

1

0

LIKELIHOOD

SEVE

RIT

Y

5.2 Severity S Category Safety Description Environmental Description Commercial Description 0 None No significant safety

consequence None None

1 Very Low Minor injury - first aid Small release with minimal clean up requirements

Less than $50,000

2 Low Lost time injury not requiring extended hospitalization

Moderate release limited to onsite damage with moedrate clean up effort

$50,000 to $500,000

3 Moderate Severe injury (extended hospitalization, dismemberment)

Large release with limited offsite impact, requires significant onsite clean up

$500,000 to $5,000,000

4 High Single fatality Large release offsite with extensive clean up and damage to sensitive areas

$5,000,000 to $50,000,000

5 Very High Multiple fatalities Very large release offsite with extensive clean up and permanent damage to several sensitive areas

Greater than $50,000,000


5.3 Likelihood L Category Description Recurrence 0 None Not expected to occur N/A 1 Very Low Possible to occur, but not expected to occur in the lifetime of the plant, either at

the plant or at a similar facility in industry 1,000 years

2 Low Not expected to occur in the lifetime of the plant, but expected to occur within the lifetime of the plant at a similar facility in industry

100 years

3 Moderate Expected to occur within the lifetime of the plant 10 years 4 High Expected to occur about once per year 1 year 5 Very High Expected to occur mant times per year 0.1 years

5.4 Risk Ranking Risk

Ranking Category Description

I Low Risk is low and/or sufficiently controlled - no additional risk reduction measures are required II Moderate Risk is moderate - additional controls could be considered, but are not required III High Risk is high and may not be sufficiently controlled - additional risk reduction measures should

be considered IV Very High Risk is high and is not be sufficiently controlled - additional risk reduction measures are

requried and additional operations vigilance measures are required in order to operate the plant in the interim prior to implementing risk reduction measures

V Intolerable Risk is intolerably high - the facility cannot operate in this state. Additional risk reduction measures or process redesign to reduce risk shall be performed prior to allowing the plant to operate


6 SIL Selection Risk Ranking Matrix and Tables

6.1 Risk Matrix - Safety

0

0

0

0

0

0

3

2

1

0

0

0

4

3

2

1

0

0

5

4

3

2

1

0

6

5

4

3

2

0

7

6

5

4

3

0

0 1 2 3 4 5

5

4

3

2

1

0

LIKELIHOOD

SEVE

RIT

Y - S

AFE

TY

6.2 Severity - Safety Severity - S Category Description TMEL-S

0 None No significant safety consequence 1 Very Low Minor injury - First Aid 1E-02 2 Low Lost time injury not requiring extended hospitalization 1E-03 3 Moderate Severe injury (extended hospitalization, dismemberment) 1E-04 4 High Single fatality 1E-05 5 Very High Multiple fatalities 1E-06


6.3 Likelihood Likelihood Category Description Recurrence

0 None Not expected to occur N/A 1 Very Unlikely Possible to occur, but not expected to occur in the lifetime of the plant,

either at the plant or at a similar facility in industry 1,000 years

2 Unlikely Not expected to occur in the lifetime of the plant, but expected to occur within the lifetime of the plant at a similar facility in industry

100 years

3 Occasional Expected to occur within the lifetime of the plant 10 years 4 Frequent Expected to occur about once per year 1 year 5 Very Frequent Expected to occur many times per year 0.1 year

6.4 Risk Matrix - Environment

Severity - E Category Description TMEL-E

Risk Matrix Likelihood

0 1 2 3 4 5 Risk

RankingRisk

RankingRisk

Ranking Risk

Ranking Risk

RankingRisk

Ranking0 None None 1E+00 0 0 0 0 0 0 1 Very Low Small release with minimal

clean up requirements 1E-02 0 0 0 1 2 3

2 Low Moderate release limited to onsite damage with moderate clean up effort

1E-030 0 1 2 3 4

3 Moderate Large release with limited offsite impact requires significant onsite clean up

1E-040 1 2 3 4 5

4 High Large release offsite with extensive clean up and damage to sensitive areas

1E-050 2 3 4 5 6

5 Very High Very large release offsite with extensive clean up and permanent damage to several sensitive areas

1E-06

0 3 4 5 6 7

6.5 Risk Matrix - Commercial

Severity - C Category Description TMEL-C

Risk Matrix Likelihood

0 1 2 3 4 5 Risk

RankingRisk

RankingRisk

Ranking Risk

Ranking Risk

RankingRisk

Ranking0 None None 0 0 0 0 0 0 1 Very Low Less than $50,000 1E-02 0 0 0 1 2 3 2 Low $50,000 to $500,000 1E-03 0 0 1 2 3 4 3 Moderate $500,000 to $5,000,000 1E-04 0 1 2 3 4 5 4 High $5,000,000 to $50,000,000 1E-05 0 2 3 4 5 6 5 Very High More than $50,000,000 1E-06 0 3 4 5 6 7


7 Alarm Rationalization Matrix and Tables

7.1 Risk Matrix

Critical

Emergen

High

Emergen

High

Low

High

High

Low

High

Low

Low

Low

Low

Low

Low

Low

Low

5 4 3 2 1 0

3

2

1

SEVERITY

RES

PON

SE T

IME

7.2 Severity Code Category Safety Description Environmental Description Commercial Description

0 None No significant safety consequence None None 1 Very Low Minor Injury - first aid Small release with minimal

cleanup requirements Less than $50,000

2 Low Lost time injury not requiring extended hospitalization

Moderate release limited to onsite damage with moderate cleanup effort

$50,000 to $500,000

3 Moderate Severe injury (extended hospitalization, dismemberment)

Large release with limited offsite impact, requires significant onsite cleanup

$500,000 to $5,000,000

4 High Single Fatality Large release offsite with extensive cleanup and damage to sensitive areas

$5,000,000 to $50,000,000

5 Very High Multiple fatalities Very large release offsite with extensive cleanup and permanent damage to several sensitive areas

Greater than $50,000,000


7.3 Response Time Code Description

1 10-30 Minutes 2 3 to 10 Minutes 3 < 3 Minutes

7.4 Priority Code Description

Critical Critical Emergency Emergency High High Priority Low Low Priority Journal Journal No Alarm No Alarm


8 Safety Analysis Functional Evaluation (SAFE) Chart

The Safety Analysis Functional Evaluation Chart begins on the following page.

C37

C38

C39

C40

C41

C42

C31

C32

C33

C34

C35

C36

C29

C30

C20

C21

C28

C14

C15

C16

C17

C18

C19C8

C9

C10

C11

C12

C13

SAFETY ANALYSIS FUNCTIONALEVALUATION CHART

C4

C5

C6

C7

NU

M

C1

C2

C3

CLIENT LOGO

General Oil and Gas Operating Company

C27

C25

C22

C23

C24

C26

CLIENT NAME

DW

GFU

NC

TIO

N P

ERFO

RM

ED

Clo

se In

let V

alve

Fro

m F

low

line

Clo

se In

let V

alve

Fro

m M

-101

Clo

se M

-102

Out

let V

alve

to P

-103

Com

pres

sor S

hutd

own

Clo

se C

ompr

esso

r Iso

latio

n Va

lve

xpor

t Pum

p Sh

utdo

wn

Clo

se E

xpor

t Pum

p D

isch

arge

Val

ve

Clo

se D

epar

ting

Gas

Shu

toff

Valv

e

nitia

te F

acilit

y Ev

acua

tion

Alar

m

Alar

m

reve

nt F

lam

e Em

issi

on

reve

nt S

park

Em

issi

on

acuu

m R

elie

f

ress

ure

Rel

ief

Min

imiz

e Ba

ckflo

w

002

003

003

004

004

3

(SAFE)BY

KenexisPROCESS COMPONENT

1 Jun 2011REV DATE

This drawing, (C) 2011 Kenexis Consulting Corporation, is business confidential. No part of this document may be circulated, quoted, or reproduced for distribution other than by the above named client without prior written approval from Kenexis Consulting Corporation.

SHU

TDO

WN

/CN

TL D

EV ID

ALT DEVICE IF APPLICABLESACREFNUM

ALTERNATE PROTECTION

1

NOTES 1 1 1 1

SDV

SDV

SDV

USC

SDV

SA VAC

UU

M

USC

SDV

SDV

PSV

FSV

103

103

ALAR

M

ALAR

M

FA

104

104A

101

102A

102B

104B

M M M G P P

101

101

102

104

103

103

C C C C C E C C In A P P V P M

• •• • • • •• • • •

R1

R2

R3

NUM PID DEV ID

PROCESS COMPONENT

DEVICE ID

High Pressure Separator


M101D

101D

101B

PT

PT

LI

ID SERVICE EQUIP IDDEVICE ID

101 PSHH

PSLL

LSHH

101D

101D

101B

1

NOTES 1 1 1 1

• ••

•

• •• • • • •• • • •

• • • ••

•• • • •• • • •

••

R16

R17

R12

R13

R14

R15

R6

R7

R8

R9

R10

R4

R5

R11

M 102 Low Pressure Separator PSHH

Liquid Line

102D

102D

102B

102B

101B

PSV

FSV

PT

FSV

FSV

PT

PT

LI

LI

PSV

LI

PSV

FSV

PT P 103

Gas Line

Liquid Line at Pump Discharge

Pipeline Pump

LSLL

PSV

FSV

PSLL

LSHH

LSLL

PSV

PSHH

PSLL

PSV

FSV

101B

101

101

102D

102D

102B

102B

102

103C

103C

103

A.4.f.2

A.4.2.2.4

A.7.e.2

FSV 103

• • • •• • • •

••

•• • •

1 OF 3

R21

R22

R23

R24

R25

R27

R26

R18

R19

R20

DXXX.XXX-04DWG

PT

PSV

PSV

FSV

TX

PT

PT

PT

SHT

Gas Compressor Discharge


Gas Compressor Suction






PSHH

PSLL

PSV

PSV

FSV

TSH

104C

104C

104A

105

104A

A.8.f.3

PSHH

PSLL

102B

102B

C37

C38

C39

C40

C41

C42

C31

C32

C33

C34

C35

C36

C29

C30

C20

C21

C28

C14

C15

C16

C17

C18

C19C8

C9

C10

C11

C12

C13


C4

C5

C6

C7

NU

M

C1

C2

C3

CLIENT LOGO


C27

C25

C22

C23

C24

C26

CLIENT NAME

DW

GFU

NC

TIO

N P

ERFO

RM

ED

Clo

se In

let V

alve

Fro

m F

low

line

Clo

se In

let V

alve

Fro

m M

-101

Clo

se M

-102

Out

let V

alve

to P

-103

Com

pres

sor S

hutd

own

Clo

se C

ompr

esso

r Iso

latio

n Va

lve

xpor

t Pum

p Sh

utdo

wn

Clo

se E

xpor

t Pum

p D

isch

arge

Val

ve

Clo

se D

epar

ting

Gas

Shu

toff

Valv

e

nitia

te F

acilit

y Ev

acua

tion

Alar

m

Alar

m

reve

nt F

lam

e Em

issi

on

reve

nt S

park

Em

issi

on

acuu

m R

elie

f

ress

ure

Rel

ief

Min

imiz

e Ba

ckflo

w

002

003

003

004

004

3

(SAFE)BY

KenexisPROCESS COMPONENT

1 Jun 2011REV DATE

This drawing, (C) 2011 Kenexis Consulting Corporation, is business confidential. No part of this document may be circulated, quoted, or reproduced for distribution other than by the above named client without prior written approval from Kenexis Consulting Corporation.

SHU

TDO

WN

/CN

TL D

EV ID


ALTERNATE PROTECTION

1

NOTES 1 1 1 1

SDV

SDV

SDV

USC

SDV

SA VAC

UU

M

USC

SDV

SDV

PSV

FSV

103

103

ALAR

M

ALAR

M

FA

104

104A

101

102A

102B

104B

M M M G P P

101

101

102

104

103

103

C C C C C E C C In A P P V P M

NUM PID DEV ID

PROCESS COMPONENT

DEVICE ID

ALT DEVICE IF APPLICABLESACREFNUMID SERVICE EQUIP IDDEVICE ID

1

NOTES 1 1 1 1

••

•

R28

R29

R30 PSV A.3.c.2

A.3.b.2PT PSLL

PT

PSV

Incoming Gas Production Header PSHH A.3.a.3

• • • • •• • • • •

•• • •• • •

•

• • • •• • • • •

•• • • • • • • • •• • • • • • • • •• • • • • • • • •• • • • • • • • •

R41

R42

R43

R44

R36

R37

R38

R39

R40

R31

R32

R33

R34

R35

PT

PT

PSV

104D

103D

103D

104DPT

PSV

Comb. Gas Det. (2nd 50% LEL)

ASH Process Areas (50% LEL)

TSE Fire Det in Fire Zones 1 through X

ESD Manual ESD Station (Typical)

PSV PSV 104B

104DPT PSLL

PT Compressor Discharge Cooler PSHH 104D

PSV 103

103D

103D

PSLL

Export Liquid Pipeline PSHH

PSV 104C

104E

104E

PSLL

Departing Gas Production Header PSHHPT

••••

• • • • • • • ••••

• • • • • • • •

2 OF 3

R50

R51

R52

R53

R46

R47

R48

R49

R45 Comb. Gas Det. (20% LEL)

SHTDWG DXXX.XXX-04

MCC Build. 1 Gas Leak (20% LEL)

MCC Build. 1 Gas Leak (50% LEL)

ASH

YSH MCC Building 1 Fire

TSH MCC Building 1 Fire

Control Room Gas Leak (50% LEL)

ASH Control Room Gas Leak (20% LEL)

YSH Control Room Fire

TSH Control Room Fire

CLIENT LOGO CLIENT NAME



1

(SAFE) - NOTES

PLACES USED

C1, C3, C4, C9, C10

NOTE

1

DESCRIPTION

Drawing referrences should be prefixed with "D-254-001-".

BY REV DATE 1 Jun 2011

Kenexis This drawing, (C) 2011 Kenexis Consulting Corporation, is business confidential. No part of this document may be circulated, quoted, or reproduced for distribution other than by the above named client without prior written approval from Kenexis Consulting Corporation.

3 OF 3DWG DXXX.XXX-04 SHT

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