Production Facilities Design Philosophy

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CLIENT:

SBM OPERATIONS PROJECT:

GROUP TECHNICAL STANDARDS ES45000

PECEPRPF999003

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DOCUMENT TITLE:

PROCESS PRODUCTION FACILITIES SPARING AND LOAD SHARING DESIGN PHILOSOPHY

TECHNICAL AUTHORITY:

V. Alary

SBM Monaco Technical Expert

SBM Schiedam Technical Expert

SBM Houston Technical Expert

SBM Kuala Lumpur Technical Expert

SBM Operations Technical Expert

A Gerritse

F Westerbeek-Bontje

S Renner

P. Campbell / G. Westwood

W Goodfellow

PURPOSE OF THE DOCUMENT:

This document was previously referenced STT92007.

To define the philosophy for sparing of equipment and instruments on offshore production units. o

Status/ Revision

(DD-MMM-YYYY)

N of Pages

Written by

Reviewed by

Checked by

Approved by

C1

18-Jan-2003

17

B. Axford

Technical Experts

J. Bronneberg

F. Marchais

V1

24-Sep-2003

17

B. Axford

Technical Experts

J. Bronneberg

F. Marchais

A1

08-Mar-2004

19

B. Axford

Technical Experts

J. Bronneberg

F. Marchais

A2

28-Jun-2011

13

M. McAreavey

Technical Experts

M. McAreavey

J-L. Isnard

A3

19-Dec2014

9

V. Alary

Technical Experts

R. Boiton

J-L. Isnard

Date

INFORMATION ON STATUS: P I C V A D

Preliminary for Information Inter Discipline Checking For Comments and Approval Valid for Construction Approved for Construction Deleted

© Copyright SBM Offshore N.V. 2014 Copyright by SBM Offshore N.V. or any of its subsidiaries. This document is the property of SBM Offshore N.V. or any of its subsidiaries. This document or any part thereof is CONFIDENTIAL and may not be made known, copied, multiplied, or used in any other way without the permission of SBM Offshore N.V. or any of its subsidiaries

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REVISION STATUS / SUMMARY OF CHANGES

REVISION

REVISED CHAPTERS

C1 V1

REVISION DESCRIPTION

REASON FOR REVISION

For Comments and Approval 1, 2, 5 & A

A1

Valid for Construction

To incorporate comments from C1 revision

Approved for Construction

ABS Approval

A2

ALL

Approved for Construction

General update

A3

As marked in left margin

Approved for Construction

Specific sparing requirements moved to Systems GTS.

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TABLE OF CONTENTS 1.

SCOPE .............................................................................................................................. 5

2.

REFERENCES .................................................................................................................. 5

3.

DEFINITIONS AND ABBREVATIONS .............................................................................. 6 3.1 3.2

4.

SPARING AND LOAD SHARING CRITERIA.................................................................... 7 4.1 4.2

5.

DEFINITIONS ...................................................................................................... 6 ABBREVIATIONS ................................................................................................ 6 SPARING CRITERIA ........................................................................................... 7 LOAD SHARING CRITERIA ................................................................................ 7

SPARING PHILOSOPHY .................................................................................................. 8 5.1

GENERAL ............................................................................................................ 8 5.1.1 Equipment .............................................................................................. 8 5.1.2 Instrumentation and Instrumented Valves ............................................... 9

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FOREWORD

This document forms part of the suite of SBM Offshore Group Technical Standards (GTS). The use of GTS is mandatory on all SBM leased Production Unit projects, and on projects for other Clients where they have been accepted. As such, all Execution Centres within the SBM Offshore Group, and their nominated subcontractors, shall use them. The management of the GTS documents is governed by the Group Management System (GMS) Working Procedure (WP) PE – 202. The objective of the GTS is to provide a fit-for-purpose set of minimum design philosophies, design standards and standard specifications, which incorporate project execution feedback from recent SBM projects as well as the operational experience from the SBM Operations’ fleet of production units. The GTS are intended to be general, not project specific, they will have a lower order of precedence than Client Specifications, Class Rules, Flag State Regulations and Local Legislation. It is therefore intended that when GTS have been selected for use on a project, they are supplemented by a project specification that clarifies their use, identifies changes needed to comply with project requirements and defines any higher precedence specifications, codes, standards or regulations. In any case, deviations to the GTS have to be raised and submitted to the approval of the relevant Group Technical Authorities, or their substitutes, duly mandated. This GTS has been reviewed and found compliant with the requirements of the applicable ABS Rules, Guides and IMO Code listed below: • • • • •

ABS Rules for Building and Classing Steel Vessels (SV Rules), publ. 2, 2014 ABS Rules for Building and Classing Mobile Offshore Drilling Units (MODU Rules), publ. 6, 2014 ABS Rules for Building and Classing Facilities on Offshore Installations, publ. 63, 2014 ABS Rules for Building and Classing Floating Production Installations (FPI Rules), pub 82, 2014 IMO Code for the Construction and Equipment of Mobile Offshore Drilling Units (IMO MODU Code), 2010.

ABS Approval for revision A2 (STT92007): letter number 799822 dated 19/09/2011. Revision A3 of this document is issued, pending ABS approval.

- SBM Offshore Asbestos Policy – It is SBM Offshore policy not to use asbestos in any form, or materials containing asbestos, in its working environments or products. For more details, reference can be made to the SBM Offshore Group Asbestos Policy.

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SCOPE This philosophy defines the basis and criteria for the sparing and the load sharing of production related equipment (process and Utility systems), including packages and equipment auxiliaries’ systems on SBM Offshore production units. This philosophy covers generic rules applicable to all equipment of a similar type. For system specific sparing or load sharing requirements refer to the relevant sections in the Process System GTS (ref. [1]). This philosophy covers systems installed on topsides, inclusive of turret manifolds area, and systems within the hull whenever they are required for production. For systems covered refer to list in Process Systems Design Standard GTS [1].

2.

REFERENCES The latest revision of the referenced standards should be consulted. [1]

ES45000 – PECEPRPF999005

Process Systems – Design Standard

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DEFINITIONS AND ABBREVATIONS

3.1

DEFINITIONS

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Brownfield project

Project consisting in adding additional equipment to an existing unit while on location, e.g. debottlenecking, tieback of additional risers…

Can

Can requirements are conditional and indicates a possibility open to the user of the standard.

May

May indicates a course of action that is permissible within the limits of the standard.

Shall

Shall is an absolute requirement that shall be followed strictly in order to conform to the standard.

Should

Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable.

Strainer

A special type of filter installed to protect equipment from large particulates associated to not-normal operating conditions (e.g. commissioning or start-up).

In this document “n” relates to the number of parallel units required to achieve 100% capacity. “n+1”, e.g. 2 x 100% or 3 x 50%, relates to one spare parallel unit.

3.2

ABBREVIATIONS CAPEX

Capital Expenditure (cost of procuring, installing and commissioning equipment)

OPEX

Operating expenditure (cost of operating, maintaining and repairing equipment)

PCHE

Printed Circuit Heat Exchanger

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SPARING AND LOAD SHARING CRITERIA

4.1

SPARING CRITERIA

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Sparing of equipment means the installation of an extra piece of equipment in parallel that is on standby during normal operation. Sparing of equipment is determined by the following general criteria. •

Sparing of equipment may be required to ensure that contractual requirements (i.e. availability targets) are met under all operating contingencies.

•

The actual sparing shall result in the lowest Life Cycle Cost (LCC) of the unit. This is the optimum balance between the additional CAPEX of installing additional equipment and the expected savings in OPEX and fines and the additional income from uptime bonuses.

Some of these parameters are project specific and may justify deviating from the base case philosophy presented in this GTS.

4.2

LOAD SHARING CRITERIA Load sharing between equipment means the provision of two or more parallel units to achieve the design duty (100% capacity). The number of parallel units “n” is determined by the following criteria: •

Equipment physical size limitations for fabrication, layout and transportation.

•

Equipment/driver selection.

•

Turndown requirements.

•

LCC, considering flexibility and uptime, planned/unplanned maintenance...

Within the restrictions imposed above, the optimum design will generally correspond to a minimum number of parallel units. This gives the minimum equipment requirements and consequent weight, space and cost. It also reduces the piping, hook-up and instrument requirements. Load sharing shall take into account equipment maintenance requirements and the likelihood of complete downtime or reduced production during maintenance.

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SPARING PHILOSOPHY This section defines the sparing that shall be applied to all projects. For brownfield projects it applies only to the additional/impacted systems. Subject to deviation to this GTS, additional sparing or different load sharing arrangement may be required to satisfy specific availability requirements from Client.

5.1

GENERAL Unless stated otherwise in this GTS or in the Process Systems – Design Standard GTS (ref. [1]) the following general requirements apply: •

Sparing shall be no more than “n+1”

•

Equipment / system which can be bypassed without impacting production shall not be spared.

•

Spared equipment shall be installed, i.e. not just made available in store or warehouse.

•

Spared equipment shall not be needed for the normal (even transient) operation of the plant, e.g. a spare power generator shall not be accounted for starting a large motor.

•

Spared equipment shall be allowed to start in parallel to the running one to allow change-over without production interruption (note 1).

•

Equipment and instrumentation (including valves) that are part of a spared package, auxiliary’s sub-system or train shall not be spared (i.e. no equipment/instrumentation sparing in 2 x 100% compression trains).

•

Sparing may be provided from a different system (e.g. vent mast can be used as backup for non-spared cargo vent recovery compressor).

Note 1: This requirement shall be satisfied using “normal” plant operating conditions, i.e. average sea water and air temperature, 50% fouled heat exchanger and using available margins. This shall not result in higher utility balance or increased equipment size.

5.1.1

Equipment Equipment, including in packages or part of auxiliaries shall be spared as per Table 1 below except where stated otherwise in this GTS or in the relevant sections of the Process Systems – Design Standard GTS (ref. [1]). Table 1 - Equipment Sparing Equipment Sparing Pressure Vessels Not spared, except for pressure vessel loaded with reactive (including swivels and media (e.g. adsorber, absorber) with no bypass hydro cyclones) Eductors Not spared. Compressors (air/gas) Spared. Blowers (air/gas) Spared. Membranes Not spared assuming they can operate in “n-1”configuration during change-out, otherwise spared. Heat Exchangers Not spared unless PCHE type which are spared. Pumps Spared. Filters Spared unless installed on a side stream.

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PROCESS PRODUCTION FACILITIES SPARING AND LOAD SHARING DESIGN PHILOSOPHY

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Air coolers Tanks

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Sparing Not spared. Shall match the driven equipment sparing. Spared. Sparing may be achieved within a single heater body provided spared bundles and thyristor are provided. Not spared. Not spared.

Table 1 equipment sparing applies to all Production related systems with the exception of the following equipment, which shall not be spared: - Turret drain pump, - Swivel Leak Recuperation System (LRS) pump - Pneumatic/hand driven Make-up, transfer or filling pumps - Chemical tank mixer - Sand-jetting/cleaning pump

5.1.2

Instrumentation and Instrumented Valves Instrumentation and instrumented valves shall be spared as per Table 2 below except where stated otherwise in the relevant sections of the Process Systems – Design Standard GTS (ref. [1]). Table 2 – Instrumentation and Instrumented Valves Sparing Equipment Sparing Relief Valves (incl. Spared. Fire Case ones). Thermal Expansion Not spared. Relief Valves Control Valves Not spared. Control / Monitoring Not spared. Instrumentation Shutdown Not spared unless part of an IEC61511 based design which Instrumentation requires considering for hardware fault tolerance. Shutdown Valves Not spared unless part of an IEC61511 based design which requires considering for hardware fault tolerance.