HSE Parts Count Guide PDF [PDF]

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FORMAL SAFETY ASSESSMENT PARTS COUNT METHODOLOGY CONTENTS FRONT PAGE CONTENTS ABBREVIATIONS 1.0 INTRODUCTION 1.1 Purpose 1.2 Scope 1.3 Associated Documents 2.0 SYSTEM BOUNDARIES 2.1 Process System 2.2 Grouping by Category 2.3 Other Hydrocarbon Systems 3.0 ISOLATABLE SECTIONS 3.1 Designation 3.2 Boundary Delineation 4.0 PARTS COUNT METHODOLOGY 4.1 General Approach 4.2 Counting Simplifications 4.3 Marking up P&IDs 5.

EQUIPMENT AND PIPING CATEGORIES

6.

PARTS COUNT TABULATION

7.

REFERENCES

APPENDIX A EQUIPMENT GROUPS COUNTED APPENDIX B EXAMPLES OF COUNTING

ABBREVIATIONS 3D Three dimensional BDV Blowdown Valve COPI ConocoPhillips Indonesia ESDV Emergency Shutdown Valve FERA Fire and Explosion Analysis HCR Hydrocarbon Release LPG Liquid Propane Gas NC Normally Closed NLL Normal Liquid Level OIR Offshore Industry Release OTO Offshore Technology Organisation PARLOC Pipeline and Riser Loss of Containment PDMS Process Dimensional Model System PFD Process Flow Diagram PSV Pressure Safety Valve P&ID Piping and Instrumentation Diagram QRA Quantitative Risk Assessment SDV Shutdown Valve SP Sample Point UK HSE United Kingdom Health & Safety Executive

1.0 INTRODUCTION Leaks may occur from various process ‘parts’ such as vessels, pipes, valves, flanges and instruments. It is these leaks that represent the hazardous events that may lead to escalation and possibly catastrophic consequences. The potential for a leak is

dependent on the number of parts physically installed in a process such that a leak is possible. The greater the number of ‘leak sources’, the greater is the chance of there being a leak. The overall leak frequency potential for a process facility is therefore the summation of the number of process parts (determined through a parts count) multiplied by their individual frequency of failure. Over the many years of offshore operations, incidents relating to loss of hydrocarbon containment have been recorded and analysed with respect to individual failures of these process components and as a function of process type/system, fluid type and the size of leak (hole size). The UK HSE OIR12 Offshore Industry Release is one such database from which Hydrocarbon Release (HCR) Statistics have generated generic historical leak frequency per single component, eg a leak frequency per flange-year or per metre of pipe per year. This database is continually updated to include all offshore incidents within the UK waters. As a participant of this venture, ConocoPhillips has membership access to the information contained in the database. The most recent and complete public domain document providing this data is the previous HSE OTO 1999 (Ref 1) that should be used if up to date information is not available. In addition the PARLOC database (Ref 2) is used instead of HCR for riser and pipeline leaks as it is more complete. Other references such as the older E&P Forum (Ref 3) may also be appropriate under certain circumstances. Risk reduction measures to prevent hazardous events through loss of hydrocarbon containment therefore focus on the number reduction of parts or a reduction in the parts leak frequency through welded connections or preventive maintenance. This document focuses on establishing the parts count for a process facility and providing statistical data that contributes to the understanding of the overall risk picture for the facility. 1.1 Purpose The purpose of this document is to standardise the approach by which a Parts Count is conducted such that a consistent, acceptably accurate and verifiable count is achieved, and in so doing potential ‘leak sources’ within a process system are identified and recorded. 1.2 Scope This document and its contained methodology shall be applied to all Fire and Explosion Analyses conducted as part of the Formal Safety Assessment for process facilities associated with the ConocoPhillips Indonesian Business Unit. The data represents the input parameters for the determination of the potential hydrocarbon leak frequency of the process facility. It does not cover the actual determination of leak frequency which is the subject of another technical note. 1.3 Associated Documents Basic spreadsheet for Parts Count

2.0 SYSTEM BOUNDARIES

2.1 Process System The boundaries of the process system will be the location of the first and last potential leak source that could impact the facilities, ie first and last isolation valve at the onshore boundary fence, or the import and export riser valves on an offshore platform. Leak sources are identified and recorded through a systematic count of all equipment and fittings illustrated on the P&IDs and other associated piping information. Consolidation of this information provides a comprehensive count of the number of individual components making up the facilities. This, coupled with generic historical leak frequency data for the components identified, provides the input data for determining the potential release frequency of a hydrocarbon release event that may occur within the process. The parts count will be delineated through a hierarchy of ‘sections’ in order to ensure that all is counted, easily verified and can be adjusted thereafter should changes occur to the process and P&ID. Certain grouping of the sections also provides statistical insight into areas of potential risk. The hierarchy of sections are: Isolatable Section – a subdivision of a larger hydrocarbon fluid stream defined by isolation primarily between in-line emergency shutdown valves (ESDV) or process shutdown valves (SDV) in the main hydrocarbon process stream and other hydrocarbon containing utility streams. Release Section – a specific part within an Isolatable Section relating to a fluid phase and/or a major item of equipment. This is particularly relevant for an Isolatable Section that contains vessels with more than one hydrocarbon phase. Parts Count Section –the smallest part of an Isolatable Section that allows ease of counting and recording; eg a piping line number or major item of equipment. The sum of the parts count sections represents the Isolatable Section. 2.2 Grouping by Category The Parts Count often provides statistical insight into the specific leak potential for a facility when grouped together under certain categories. The potential for loss of containment in the facilities may be identified for a particular fluid, process system or specific location. This may be done within a spreadsheet by providing a designator or colour for certain rows that are similar. 2.2.1 Grouped by P&ID The P&ID on which the recorded line numbers reside is often used as an identification category. Although it serves no statistical purpose, it does provide ease of identification when referring back to P&IDs for updating the parts count information. The P&ID number first associated with the start of the isolatable section shall be used as the designator. In some drawing schedules, particularly those used by COPI, part of the P&ID number will also represent the Process System (see below). 2.2.2 Grouped by Contained Fluid Phase

The actual type of fluid phase contained within the process system shall be recorded against each line number. Specific designators should be used, rather than gas or liquid, in order to better differentiate between the different fluids types of phase and hydrocarbon composition, eg well (production) fluids, process gas, sales gas, fuel gas, condensate, oil, diesel, etc. Release Cases are defined in part by the fluid phase with some Isolatable Sections containing more than one hydrocarbon phase. The resulting consequence of a leak could therefore be different for each phase. It is important to identify the sections containing well fluids as it is a two phase fluid and is handled differently than single phase when performing consequence modelling. 2.2.3 Grouped by Process System A useful grouping is by process system, eg separation, compression as historical data is often categorised in this way to indicate the higher risk contributors. These process systems are often identical to the isolatable sections or delineated by a manifold that represents the start of a new process system. Onshore, it is likely that an isolatable section will be associated with a process system and a specific location due to availability of space. However offshore, an isolatable section may cover one or more process systems and extend over several deck levels. Analysis may show this is not desirable with respect to large inventory volumes and therefore it is important to capture this aspect. The designator for this category may best be a shortened version of the process system description to immediately highlight the section of the facility. 4.

Grouped by Location

The final delineation category for an isolatable section is its physical location, and as mentioned above, could span several deck levels on a platform. Such information, together with fatality estimation, may highlight specific locations where the risk is high and personnel presence should be avoided for continuous periods. Release Cases are also defined by their location as it is possible for a fluid phase withn an isolatable Section to extend over more than one deck or vessel. In this case, the fluid phase will give rise to several Release Cases defined by location. Care should be taken when applying this category offshore as decks may be either plated or grated. No separation is assumed in the vertical plane when the deck is grated. 2.3 Other Hydrocarbon Systems In addition to the main hydrocarbon process streams, other hydrocarbon systems may exist and should be included if such fluids give rise to events that have serious consequences, eg o o o o o o

Fuel Gas System Diesel Fuel System Hot Oil System Methanol System Amine System Lubricating Oil System

The decision to include these systems in any Fire and Explosion Risk Analysis (FERA) or Quantitative Risk Assessment (QRA) depends on whether the inventory temperature exceeds the flash point of the fluid or whether it is a known airborne toxic substance.

3.0 ISOLATABLE SECTIONS 3.1 Designation A discrete reference number shall be provided for each isolatable section in order that traceability is achieved during subsequent risk analysis and consequence modelling. The following represents a commonsense approach to designating the isolatable sections but may not be suitable for all situations and therefore should be used as a guideline only. As there will be a number of isolatable sections within any given process facilities, then an ascending two digit code shall be used, eg 04. The fluid phase should be identified and shall be represented by a two letter code that is a short descriptor of the fluid phase, eg PG (process gas). The code used in the piping specification may be appropriate, or it may be extended if more definition, is required, eg SG (sales gas). The location of an isolatable section should be known within the process and therefore the first P&ID number (or part representation of it), on which the isolatable section began, shall be used, eg 3126. It may also represent the Process System, eg 26 - Compression. No set number of digits is stipulated here. As several release cases (potential points of hydrocarbon release) may exist within an isolatable section, then a further ascending two digit code shall be used, eg 01 etc. The location of the release case may be useful and this shall be represented by a two letter code that is a short descriptor of the location, eg MD (Main Deck). Thereafter additional sub-codes may be used depending on how descriptive the designation is required to be. For example, if the P&ID code does not contain the Process System or Process Module, then a two digit code may be used to locate the isolatable section, eg 26 (optional). The actual consequence to be modelled as a result of a hydrocarbon release is also important. This shall be represented by a two letter code that is a short descriptor for the consequence, eg JF (jet fire). A discrete designation is therefore established on a hierarchy basis of the form: [Isolatable Section] – [Release Section] – [Consequence] For example:

[04 – PG – 3126] – [01MD] – [JF]

Other two letter codes that may be used are: PF Production Fluid TD Top Deck PF Pool Fire PG Process Gas MD Main Deck JF Jet Fire PG Process Liquid CD Cellar Deck FF Flash Fire GF Fuel Gas SC Sub Cellar Deck GC Gas Cloud DF Diesel Fuel BL Boat Landing EX Explosion

3.2 Boundary Delineation As mentioned above, the Isolatable Sections are a subdivision of the larger hydrocarbon fluid stream and are defined by points of positive isolation using the following acceptable means: Emergency Shutdown Valve, ESDV Process Shutdown Valve, SDV Blowdown Valve, BDV Pressure Safety (Relief) Valve, PSV Manual Valve, Normally Closed, NC (drain valve) Blind Flanges Instrument fittings Other valves such as choke valves, check valves or control valves do not provide positive isolation as it is not their designated safety function and are therefore not considered. However, actuated control valves may achieve acceptable isolation provided they are specified as fail close, fire resistant with gas tight seals and have additional solenoid valve isolation in the control line. It is important before commencing a parts count that the number of Isolatable Sections is approximately known in order to determine the optimum approach to data recording. Complex facilities may require subdivision of the parts count in order to address the quantity of information. For a quick appraisal, the Process Flow Diagram (PFD) may be used to identify isolatable sections as it highlights only the relevant components such as vessels, ESDVs, SDVs and fluid types. This diagram however is not of sufficient detail to provide a parts count. Once the isolatable sections have been identified from the PFDs (or P&IDs), it will be necessary to conduct a parts count from the P&IDs for each isolatable section. This will include all in-line equipment and any associated branches for process splits, PSVs, blowdowns, sampling points, drains and chemical injection. It is recognised the P&IDs do not necessarily capture all equipment parts, e.g. hookup flanges, some instrument connections, but the P&IDs provide sufficient detail for the purposes of risk modelling.

In the majority of cases, an isolatable section will consist of major equipment and several piping runs that represent changes in piping material (spec breaks), inlet and outlet lines of vessels, and branches for pressure relief valves and blowdown valves. Each piping line number and major equipment item shall be recorded separately as a Parts Count Section in order to simplify updating of the Parts Count should P&IDs be revised.

4.

PARTS COUNT METHODOLOGY 4.1 General Approach The UK HSE database is annually updated and provides leak frequency data for the list of generic process equipment and piping fixtures as given in Appendix A. This list represents the groups in which parts are to be counted. In most cases, the equipment will be pressure vessels, compressors, pumps and heat exchangers and the interconnecting piping, flanges, valves, and instruments. All equipment items on the P&IDs shall be counted in accordance with the list in Appendix A but the grouping with regard to size shall be ignored. Pipelines, risers and process piping shall be counted in sizes as shown on the P&ID in order that hydrocarbon inventory may be calculated. This also applies to flanges, valves and pig launchers/receivers. Where equipment on a P&ID does not correspond to a particular group, then it should be recorded as an additional group and highlighted for further review. It is recommended that the parts count is recorded in a simple spreadsheet format, with Rows as piping line numbers and major equipment, and Columns as equipment and piping/fixture sizes. This will then be in the correct layout to continue with the determination of leak frequency data. The following approach will be employed to define what shall be counted within an Isolatable Section: o o o o o o

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Pipelines and risers shall be recorded separately under their own Parts Count Section and pipeline category. Only the downstream isolation valve of an Isolatable Section is counted rather than counting half a valve at each end of the section Each isolation point is inclusive of the upstream flange and valve, but excludes the downstream flange. All internal boundaries such as drain lines, flare lines and blowdown lines are taken to the first positive pressure isolation. Normally Closed valves (e.g. usually marked NC) are assumed to provide isolation with the valve and upstream flange included in the upstream section; Spectacle Blind in closed position, or Spade is assumed to provide isolation. The count for the upstream section is taken up to and including the flange connection that contains the spectacle blind or spade, but no further components downstream; If a cap or blind flange is shown against a valve, it is to be assumed that the valve is in the Normally Closed position, even if no NC is shown; Chemical Injection and Inert Gas connections are to be counted for the hydrocarbon section back to the first Closed valve encountered by hydrocarbon flowing back into the injection system. Where Special Connection (SP) injection connections are shown (temporary or manual injection connection), all valves in the connection are assumed closed. Check valves are NOT to be included as isolation boundaries, but are assumed to function as normal valves.

In counting only the downstream isolation valve of an Isolatable Section ensures that a whole valve of a single size is counted instead of perhaps two half valves of dissimilar sizes. The only difference between the two methods is when the process stream splits into two or more streams when the parts count would be overestimated by half a valve in each stream. However, the effect on the overall leak frequencies for each section is considered negligible. Each equipment item comprises the item of equipment itself, excluding all valves, piping, flanges, instruments and fittings beyond the first flange. 4.2 Counting Simplifications There are certain simplifications that are made when dealing with multiple equipment as follows: o

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Only one flowline need be counted for a multi-flowline production system with other flowlines assumed to be of equivalent lent and parts count. (The total Parts Count will be calculated based upon the number of flowlines in each production header). Only one process train need be counted with other trains assumed to be of an equivalent parts count. (The total Parts Count will then be calculated based upon the number of trains). Standby duty equipment shall be treated as if isolated by the first isolation valves installed in the inlet and the last isolation valve installed in the outlet line, unless otherwise advised. Equipment shall be counted to ensure 100% duty, ie 3 x 50% pumps – two operating, one on standby.

In establishing Release Sections, two-phase flowlines, such as those containing well fluids, will be counted as a separate Release Case from gas and liquid sections. The boundary for a two-phase section will be the flange that connects the two-phase flowline to a vessel where separation of the fluid into gas and liquid occurs. The vessel and other components downstream of that flange shall be classed liquid or gas and counted as separate Release Sections appropriately. See Figures in Appendix II for two-phase inlet examples. 4.3 Marking up P&IDs Each equipment item, valve, flange, piping run and branches, instrument and fittings on the P&ID shall be marked in highlighter or felt tip pen, once it has been counted. This will identify those items that have been missed and also assist in the revision of the parts count at a later stage. The parts count is usually prepared at an early stage of design and the P&IDs may go through several revisions before being approved for construction. Although it is likely that the changes will not significantly affect the final outcome of the analyses, the parts count does require to be accurate at the end of detailed design and therefore some adjustment will be necessary. The following method of marking up shall be adopted: o

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Equipment Item: The illustrated outline of the equipment on the P&ID shall be traced with an coloured felt tip pen, preferable Red and the type, as listed in Appendix A, written either inside the outline or alongside it, eg pressure vessel, vertical, scrubber. The tag number of the equipment shall be highlighted in Yellow. Isolation Valves shall be highlighted in Pink. Moreover, for automated shutdown valves, the circular symbol for SDV shall also be shaded in Pink.

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Boundary Valves (on drain lines, pressure relief, blowdown and pressure isolation) shall be highlighted in Orange. Moreover, for automated blowdown valves, the circular symbol for BDV shall also be shaded in Orange. Other valves, required to be counted, shall be highlighted in Blue. Flanges, required to be counted, shall be highlighted in Green. Lines belonging to an isolatable section shall be traced in a Single Colour and varied for each isolatable section. Care shall be taken not to overlap other highlighted items.

•

Instruments shall be circled in Red felt tip pen.

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Each Release Section shall be clearly marked on the P&ID with a dotted line in Blue felt tip pen and the section ID annotated.

All marked up P&IDs shall be retained for reference purposes.

5. EQUIPMENT AND PIPING CATEGORIES The following categories represent the Columns of the spreadsheet. As mentioned before the actual sizes of the equipment is retained in the Parts Count and not consolidated as given in the list of Appendix A. 5.1 Pipelines and Risers Pipelines and risers shall be recorded as separate Parts Count sections from other process piping and their diameter and length given in metres or kilometres. This will enable leak frequencies from a pipeline database (PARLOC) to be applied. Subsea isolation valves or valves relating to any subsea manifold shall be counted and recorded on the same pipeline number or riser designator. 5.2 Pig Receivers/Launchers For the purpose of the parts count, differentiation is made between pig launchers and receivers as the activity is seen to be different. However, unless influenced by adverse process conditions, a pig receiver/launcher is generally used infrequently, normally isolated and left de-pressurised. Pig receivers/launchers shall therefore not be counted unless known to be in regular use (once a month or more frequent). 5.3 Wells Each well bore represents an isolatable section with length determined by the depth of the installed downhole safety valve to the surface xmas tree. The completion string will denote the diameter of the well. For analysis purposes, it will be assumed that all wells are identical. Care should be taken to identify dual completion wells as this will increase the number of producing wells beyond that associated with the well template. 5.4 Wellheads/Xmas trees

A wellhead is defined as the joint between the xmas tree and the well itself. A xmas tree is a single component comprising a series of manual and remotely operated flanged valves that secures the well contents under shutdown conditions. It can be viewed as one manual master valve, one actuated master valve and an actuated wing valve excluding all piping, valves and instruments branching off it. However, leak frequency data is available for it as a single component. The wellhead and xmas tree are counted separately in accordance with their design pressure. 5.5 Process Piping Each piping line number will be entered on the parts count worksheet and the diameter and length of pipe in linear metres recorded. Depending on the level of design, piping lengths may be approximated from the equipment layouts using the X, Y, Z, coordinates. Alternatively, the following estimates may be used where drawings are not available: Process lines 25m for each line number Manifolds 12m Pressure relief 10m Blowdown 10m Instruments 1m However for more accurate work, other sources should be considered: - blowdown and relief study - piping isometrics where available - direct interpolation from a 3D PDMS model from which the isometrics are derived. All piping and valves of nominal bore 2 inch and over shall be assumed to have flanged connection. Reference should be made to the schedule for piping less than 2 inch. Flanges, valves and instrument fittings shall be captured in their appropriate equipment group and recorded against the piping line number. Pipe fittings such as reducers, tee-pieces etc. are assumed welded and not counted unless otherwise advised as flanged on the P&ID. PIPING, STEEL PIPING, FLEXIBLE 5.6 Flanges Flange size is associated with the line size or vessel nozzle, are counted separately with respect to size and recorded against the piping line number. Access entrances to vessels will be counted as shown on the P&ID, or if not, as one 24 inch flange.

Parts count is often discussed in the context of flange counting but in actual fact, it is the counting of ‘leak sources’ that is carried out. In applying flange counting, it is necessary to exclude flanges that are manufactured as part of other equipment such as valves and vessels. In most cases, one flange represents one leak source. For example: • •

An orifice plate between two flanges results in two leak sources, A flanged valve between two flanges results in two leak sources at the flanges.

However, there are times when this is not so. For example: • •

Two mating flanges or a blind flange results in one leak source A flange connected to a flanged vessel nozzle results in one leak source.

Therefore care must be taken in defining what flanges are counted and where they are recorded on the parts count spreadsheet. 5.7 Valves A valve consists of a valve body, stem and packer, but excludes flanges, controls and instrumentation. Valves are classified in the HCR database according to: SIZE : NOMINAL BORE (INCH) FUNCTION : BLOCK, BLOWDOWN, ESD, CONTROL, RELIEF, CHOKE, CHECK, BLEED ACTUATION : MANUAL OR ACTUATED The number and size of each valve are counted and recorded against the piping line number. Generally valves with a nominal bore of 2 inch and larger will be flanged unless otherwise denoted on the piping specification or P&ID as a fully welded section where the valves are assumed to be flange-less. As mentioned in an earlier section, isolatable section boundaries are usually identified by isolation valves. The parts count shall only record one valve, that being the downstream valve. The flange associated with the downstream section of the valve shall be counted in the next isolatable section. One exception exists that requires to be noted. When a valve is connected directly to a vessel nozzle, the potential ‘leak source’ upstream of the valve shall be recorded as a flange on the downstream piping line number. 5.8 Vessels Vessels are classified within the HCR database in accordance with: ORIENTATION : VERTICAL OR HORIZONTAL FUNCTION : ADSORBER, KNOCKOUT DRUM, REBOILER, SCRUBBER, SEPARATOR

STABILISER OR OTHER The vessel comprises the vessel itself, its nozzles and manways only and all piping, valves and associated instrumentation shall be counted and recorded separately on the equipment vessel line number. Where a vessel contains more than one phase (gas and liquid), the vessel shall, for the purpose of the parts count, be split in accordance with the associated volume occupied by each phase. The P&ID may indicate the normal liquid level (NLL) and this shall be used to determine if the vessel is either 1, ¾, ½, or ¼ full of liquid, which ever is the nearest. For example, an LPG column that has a nominal 20% liquid level should be counted as ¼ of a liquid vessel and ¾ of a gaseous vessel. Where no normal liquid level is given on the P&ID, the vessel shall be assumed to be half filled with liquid and recorded as ½ a liquid vessel and ½ a gaseous vessel. The parts count shall roughly differentiate from the P&ID illustration of the vessel which nozzles and instruments are above (gas) or below (liquid) the normal liquid level, so that they may be counted and recorded appropriately. For the sake of the parts count, each phase in the vessel shall be recorded as a ‘line number’ and the respective nozzles, manways and installed instruments counted as part of the line number. Although this method is seen to remove one flange count from each process line, it allows the parts count to accurately represent the vessel data sheet in terms of nozzles. Because the line numbers are eventually combined, there is no overall loss of count for the section. For two-phase lines within a process section (but excluding incoming well-fluid lines), the parts count shall be divided equally between the downstream liquid and gas release cases. This is a simplification in making the release analysis manageable, and is not considered critical to the outcome. The same approach shall be used for atmospheric storage tanks. 5.9 Pumps Pumps are classified according to: PUMPS, CENTRIFUGAL, DOUBLE SEAL PUMPS, RECIPROCATING, DOUBLE SEAL PUMPS, CENTRIFUGAL, SINGLE SEAL PUMPS, RECIPROCATING, SINGLE SEAL PUMPS SEAL-LESS MAG DRIVE The type of pump is usually identified from the symbol used on the P&ID but process assistance will be required to determine the type of seal integrity The number of pumps to provide 100% duty shall be counted and remaining pumps assumed isolated as from the last upstream isolation valves installed in the inlet line and the first downstream isolation valve installed in the outlet line. However, isolation of standby equipment should be confirmed as this will affect the parts count in this section by increasing the equipment count and inventory. 5.10 Compressors

Compressors are classified according to: COMPRESSORS, CENTRIFUGAL COMPRESSORS, RECIPROCATING TURBO-EXPANDERS RE-COMPRESSORS It is often the case that more than one compression stage is needed to achieve the desired pressure, and this is done using a single turbine with a common shaft. In keeping with the compressors being individual and separate on the shaft, each stage is counted. Therefore a three stage compressor represents a count of three. However this is not in line with the method used by the UK HSE to collect leak frequency data which only registers the incidents occurring on a single shaft regardless of the number of compressors. 5.11 Turbines Turbines shall be recorded in accordance with the type of fuel used as determined from the P&ID: TURBINES, DUAL FUEL TURBINES, GAS 5.12 Heat Exchangers A heat exchanger comprises the compartment of the exchanger in which hydorcarbons are contained, the nozzles and/or the bonnets but excludes all piping, valves and instrumentation associated with it. Heat exchangers shall be counted only with respect to their hydrocarbon duty and their containment, either shell or tube side recorded in accordance with: HEAT EXCHANGERS, HC IN SHELL HEAT EXCHANGERS, HC IN TUBE HEAT EXCHANGERS, PLATE FEED GAS EXCHANGER Where both sides of a shell and tube exchanger contain hazardous inventories, one tube side and one shell side heat exchanger shall be counted. WHAT ABOUT FLANGED BONNETS 5.13 Fin Fan Cooler A Fin Fan Cooler is generally a heat exchanger using forced draft air as a cooling medium. It may be a single unit or multiples arranged in banks. It is likely that only one cooler will be illustrated on the P&ID but with the actual number either noted or displayed in the tag number as A/B/C (for 3 units). The parts count shall record the total number of units.

5.14 Instrumentation and Small Bore Fittings Instruments shall be to be counted and recorded individually in the following groups: • • • • • •

Pressure tapping points Differential pressure tapping points (including orifice flow meters) Temperature tapping points Level tapping points (including sight glasses) Flow tapping points Sample and other small bore connections (chemical injection, corrosion coupons)

The OIR12 reporting system has stated that an instrument plus up to two valves, four flanges and small bore piping shall be counted as one instrument. As a simplification this will be extended to all instruments even if the flange/valve count per instrument exceeds the criteria specified above. This is considered a reasonable assumption with minor impact on the overall leak frequency analysis. The exception here is that the valves, flanges and small bore piping shall be counted as separate items and not included as part of the instrument.

6.0 PARTS COUNT TABULATION Once the P&IDs are annotated, the count shall be tabulated in a spreadsheet with the Parts Count Section as row headings, equipment groups as column headings, and the count contained within. An example of the parts count spreadsheet is given in Appendix C although non used equipment groups have been removed in order to conveniently fit the landscape page. o o

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To the left of the table are the categories that group the various line numbers. To the left of the table are the various line numbers and major equipment items recorded sequentially as they approximately appear in each isolatable section. At the top of the table is the categories as given in Appendix A, subdivided into the sizes corresponding to the facilities. At the bottom of the table for each equipment and piping group are the total number of items contained in each equipment and piping group

The spreadsheet may contain all the isolatable sections, or only those isolatable sections for a particular fluid, or represent only one isolatable section. The amount of information on each spreadsheet depends on the complexity and extent of the process. Dividing it into manageable sections may be advantageous but eventually a single spreadsheet consolidating the data will be required. The spreadsheet is also used to determine the potential hydrocarbon leak frequency associated with the design of the process facilities. This is not shown in Appendix C and will be the subject of another document. The spreadsheet may also be used to calculate the individual hydrocarbon inventories associated with each line number and thereby derive a total inventory for the isolatable section when later combined with equipment volumes. 7.0 REFERENCES

1. HSE Offshore Hydrocarbon Releases Statistics 1999. UK HSE. OTO 1999 079, Jan 2000 2. PARLOC Pipeline and Riser Loss of Containment, published in 1996, 1998, 2003, 2005. 3. Exploration & Production (E&P) Forum, Quantitative Risk Assessment Data Directory, Report No. 11.8/250, 1996. 4. DNV Technica, Offshore Reliability Database (OREDA), 2004

APPENDIX A EQUIPMENT GROUPS COUNTED WELLHEADS XMAS TREES PIPELINES, STEEL, D < = 4" RISERS, FLEXIBLE, D < =4" PIPELINES, STEEL, 4" < D < = 8" RISERS, FLEXIBLE, 4" < D < = 8" PIPELINES, STEEL, 8" < D < = 12" RISERS, FLEXIBLE, 8" < D < = 12" PIPELINES, STEEL, 12" < D < = 16" RISERS, FLEXIBLE, 12" < D 16" RISERS, FLEXIBLE, D > 16" PIG LAUNCHERS, D < = 8" PIG RECEIVERS, D < = 8" PIG LAUNCHERS, 8" < D < = 12" PIG RECEIVERS, 8" < D < = 12 PIG LAUNCHERS, 12" < D < =16" PIG RECEIVERS, 12" < D 16" PIPING, STEEL, D < 3" PIPING, FLEXIBLE, D < 3" PIPING, STEEL, 3" < D < = 11" PIPING, FLEXIBLE, 3" < D < =11" PIPING, STEEL, D > 11" PIPING, FLEXIBLE, D > 11" PRESSURE VESSEL, HORIZONTAL, ADSORBER PRESSURE VESSEL, VERTICAL, ADSORBER PRESSURE VESSEL, HORIZONTAL, K.O. DRUM PRESSURE VESSEL, VERTICAL, K.O.DRUM PRESSURE VESSEL, HORIZONTAL, REBOILER PRESSURE VESSEL, VERTICAL, REBOILER PRESSURE VESSEL, HORIZONTAL, SCRUBBER PRESSURE VESSEL,VERTICAL SCRUBBER PRESSURE VESSEL, HORIZONTAL, SEPARATOR PRESSURE VESSEL, VERTICAL, SEPARATOR PRESSURE VESSEL, HORIZONTAL, STABILISER PRESSURE VESSEL, VERTICAL, STABILISER PRESSURE VESSEL, OTHER HEAT EXCHANGERS, HC IN SHELL FILTERS

HEAT EXCHANGERS, HC IN TUBE FIN FAN COOLERS HEAT EXCHANGERS, PLATE STATIC MIXER FEED GAS EXCHANGER STORAGE TANKS PUMPS, CENTRIFUGAL, DOUBLE SEAL PUMPS, RECIPROCATING, DOUBLE SEAL PUMPS, CENTRIFUGAL, SINGLE SEAL PUMPS, RECIPROCATING, SINGLE SEAL PUMPS SEAL-LESS MAG DRIVE COMPRESSORS, CENTRIFUGAL TURBINES, DUAL FUEL COMPRESSORS, RECIPROCATING TURBINES, GAS TURBO-EXPANDERS RE-COMPRESOR VALVE ACTUATED, BLOCK, D < = 3" VALVE ACTUATED, BLOWDOWN, D < = 3" VALVE ACTUATED, BLOCK, 3" < D < = 11" VALVE ACTUATED, BLOWDOWN, 3" < D < = 11" VALVE ACTUATED, BLOCK, D > 11" VALVE ACTUATED, BLOWDOWN, D > 11" VALVE ACTUATED, ESDV, D < = 3" VALVE ACTUATED, CONTROL, D < = 3" VALVE ACTUATED, ESDV, 3" < D < = 11" VALVE ACTUATED, CONTROL, 3" < D < = 11" VALVE ACTUATED, ESDV, D > 11" VALVE ACTUATED, CONTROL, D > 11" VALVE ACTUATED, RELIEF, D < = 3" VALVE ACTUATED, CHOKE, D < = 3" VALVE ACTUATED, RELIEF, 3" < D < = 11" VALVE ACTUATED, CHOKE, 3" < D < = 11" VALVE ACTUATED, RELIEF, D > 11" VALVE ACTUATED, CHOKE, D > 11" VALVE ACTUATED, P/L ESDV, D < = 4" VALVE ACTUATED, P/L SSIV ASSEMBLY, D < 4" VALVE ACTUATED, P/L ESDV, 4" < D < = 8" VALVE ACTUATED, P/L SSIV ASSEMBLY, 4" < D < = 8" VALVE ACTUATED, P/L ESDV, 8" < D < = 12" VALVE ACTUATED, P/L SSIV ASSEMBLY, 8" < D < = 12" VALVE ACTUATED, P/L ESDV, 12" < D < = 16" VALVE ACTUATED, P/L SSIV ASSEMBLY, 12" < D < = 16" VALVE ACTUATED, P/L ESDV, D > 16" VALVE ACTUATED, P/L SSIV ASSEMBLY, D > 16" VALVE MANUAL, BLOCK, D < = 3" VALVE MANUAL, CHECK, D < = 3" VALVE MANUAL, BLOCK, 3" < D < = 11" VALVE MANUAL, CHECK, 3" < D < = 11" VALVE MANUAL, BLOCK, D > 11" VALVE MANUAL, CHECK, D > 11" VALVE MANUAL, CHOKE, D < = 3" VALVE MANUAL, BLEED VALVE MANUAL, CHOKE, 3" < D < = 11" VALVE MANUAL, CHOKE, D > 11"

FLANGES, D < = 3" FLANGES, 3" < D < = 11" FLANGES, D > 11" INSTRUMENTS

APPENDIX B – EXAMPLES OF COUNTING

SUBSEA 12 14 RISER 12 14 PIPING 2 3 4 8 INSTRUMENT PRESSURE TEMPERATURE FLOW LEVEL HORIZONTAL VESSEL PIPELINE

BELIDA PIPELINE, km

32

34KAQ001 BELIDA RISER, m BELIDA PIPELINE/RISER KEONG PIPELINE, km

100 32 0

100 0

0

0

0

0

00 00

0

0

0

0

4

34KAQ004 KEONG RISER, m KEONG PIPELINE/RISER

00 00

100 0 4

0

100

12"-PG-D1-34-003 34KPT001 PIG RECEIVER

1

12"-PG-D1-22-003

1

2

14"-PG-E1-22-002

1

1

24"-PG-D1-22-005

4

14"-PG-E1-34-002

22MBF001 SLUG CATCHER

2

24"-PG-D1-22-008

2

1

4"-PG-D1-22-018 8"-PG-D1-22-277 24"-PG-D1-22-671 22MPF002 SLUG CATCHER

2

24"-PG-D1-22-673

1

2

14"-PG-D1-22-676 8"-PG-D1-22-009 20"-PG-D1-22-010 to SDV-0051/0052

2

20"-PG-D1-22-011 to SDV-0061/0062

2

GAS CONDITIONING

0 0

0

0

00 00

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