(4 f. &) L # s J l

KUWAIT OIL COMPANY (K.S.C.)

Engineering Group

Specifics tion Number

0 15-AH- 1003

S ys tems /sola tion

1

0

Rev

23 MAY 94

7 MAR 94

Date

ISSUED AS KOC ENG. GROUP SPEC.

ISSUED FOR INVITATION TO BID

Revision BY Chkd Section PE Client

CONTENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCOPE 3

STANDARD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

BASIC ENGINEERING INFORMATION . . . . . . . . . . . . . . . . . . . . . 4

SYSTEM DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SYSTEMISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

RELIEF AND BLOWDOWN VALVING . . . . . . . . . . . . . . . . . . . . . 7

DRAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

INSTRUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Englneedng Gmup SpeMcatbn

VALVE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

. . . . . . . . . . . . . . . . . . . . . ISOLATION. PURGING AND FLUSHING 9 11.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1 1.2 Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Specification Number

01 5-AH-1 003

ATTACHMENT 1 : ISOLATION AREAS PLANT CATEGORISATION . . . . . . . . . . . . . . . . . . . . 11

ATTACHMENT 2: RELIEF VALVE ISOLATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 2

ATTACHMENT 3: BLOWDOWN LINES . ISOLATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 3

ATTACHMENT 4: TYPICAL VESSEL ISOLATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1 4

Rev

1

Date

23-5-94

Sheet

2 of 14

This specification covers the design of the facilities required for the isolation of systems and equipment items in the process and utility units to be installed in the Facility in Kuwait,

Englnedng Group Specricic%i&n

The Systems Isolation Specification shall fully comply with all the relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract.

It is intended to interface with other discipline proceduresand, therefore, only criteria required for the following activities are described in this document:

Specification Number

01 5-AH-1 003

1.3.1 P&ID Development.

1.3.2 SAFE Chart Production.

1.3.3 Piping, Equipment and Instrumentation Isolation.

Rev

1

1.3.4 Shutdown Logic Diagrams Development.

Implementation of this specification by the Contractor shall be by means of isolation symbology in the P&IDs, supplemented by appropriate notes.

Date

23-5-94

Reference shall also be made to the Process Safeguarding Flowsheets (PSFS).

Sheet

3of 14

1.0 SCOPE

2.0 STANDARD SPECIFICATIONS

2.1 Systems isolation shall conform in design, materials and performance, except where otherwise specified, with the current issue of the following prevailing on the effective date of the Contract, and as amended by this specification:

2.1.1 International Standards

API RP520 Sizing, Selection, and Installation of Pressure- Relieving Devices in Refineries - Parts I and II

API RP521 Guide for Pressure-Relieving and Depressuring Systems

2.1.2 Engineering Group Specifications

All the designs covered by this specification shall comply with all relevant Engineering Group specifications and standard Drawings

of which the following are specifically referenced in this specification:

Englnedng Gmup SpeMcatbn

01 5-AH-1 001 Basic Design Criteria

01 5-AH- 1 002 International Codes and Standards

Specification Number

01 5-AH-1 003

01 5-LH-1001 Piping Material Classes

0 1 5-LH- 1 002 Piping Design

Rev

1

2.2 Compliance with this specification shall not relieve the Contractor of its responsibility to supply equipment suited to meet the specified service conditions and applicable regulations.

2.3 Where conflicts exist between this specification and other Drawings, standards, codes and specifications, the most stringent shall be applied.

Date

23-5-94

3.0 SERVICE CONDITIONS

Sheet

4 of 14

3.1 The equipment shall be suitable for continuous operation at a desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces of hydrogen sulphide.

3.2 Systems isolation shall in all respects be suitable against continuous operation in the service conditions stated in the Engineering Group Specification entitled "Basic Design Criteria" (Number 01 5-AH-1 001 ).

4.0 BASIC ENGINEERING INFORMATION

Prior to opening for access or maintenance, any item of the Facility shall be positively isolated from all sources of hydrocarbons, toxicity or pressure and flushed out with water or purged with nitrogen. Any electrical equipment should be isolated accordingly under the permits to work required for the Site.

5.0 SYSTEM DEFINITION

5.1 Before any work for access maintenance on process or utility equipment is carried out, the relevant segment shall be completely depressurised. The design shall permit discrete areas of the Facility to be mechanically isolated so that spades, spectacle blinds, etc. can be installed to make them safe for opening, without the need to purge connected plant. Upon completion of isolation works, the system shall be flushed with water and/or purged with nitrogen prior to carrying out work on equipment.

5.2 For isolation purposes, the Facility shall be categorised into the following discrete areas:

Specification Number Rev Date Sh9.t Ehg/neerlng Omup SpeM%atkn 01 5-AH-1 003 1 23-5-94 5 of 14

5.2.1 Oil Production

Flowlines (each individual flowline).

Manifolds (each individual manifold connection).

Separators (each individual separator or buffer vessel or connections to high or medium pressure systems).

Test separators.

Desalters, including fired water bath heaters.

Import lines from other gathering centres.

Export lines to external facilities, e.g., pipeline.

Storage tanks (wet, dry and test tanks).

Pumps (transit, circulation pumps).

Interconnecting pipelines within the gathering centre between the oil facilities.

5.2.2 Gas and Condensate Production (After Separation)

High-pressure (HP) gas collection system and knockout (KO) drum.

Medium-pressure (MP) gas collection system and KO drum.

Low-pressure (LP) gas collection system and crude oil accumulator.

TV gas collection header system.

Tank vapour compressor stage, including recycle cooler, suction scrubber and seal drum.

LP gas compressor stage, including suction scrubber and TV compressor discharge cooler.

MP gas compressor stage, including suction scrubber and LP compressor discharge cooler.

MP compressor discharge cooler and discharge scrubber.

HP gas connections to gas pipeline including fuel gas system.

6.4 For LP systems (defined as below 10 barg (145 psig) design pressure), the following isolation methods shall apply:

6.4.1 Single block valve isolation for short-term isolation of process or utility systems.

6.4.2 Spool removal or spectacle blind to disconnect an LP system from the closed drains system.

6.4.3 Spectacle blind, blank flange or caps for positive isolation of a system.

7.0 RELIEF AND BLOWDOWN VALVING

7.1 See Attachment 2, Relief Valve Isolation System.

7.2 The valving on inlet and outlet lines to relief and blowdown systems shall be governed by the following rules:

7.2.1 Where there is a relief case, key items of equipment (which are unspared) and critical to production shall be equipped with dual relief valves (one on line with the second on standby). However, all separators, desalters, compressors and dehydration unit vessels (if applicable) shall be equipped with dual relief valves.

7.2.2 In cases where relief valves are 100% spared, the inlet and outlet lines shall be provided with mechanically interlocked block valves to ensure that one valve is online with the other offline.

7.2.3 In cases where equipment is 100% spared, or not critical to production, then a single relief valve shall be used with upstream and downstream locked open block valves with a bleed connection between the relief valve and the block valve. Bleed connections shall be vented to a safe location.

7.2.4 In the event of the relief valve requiring maintenance or re- certification, the isolation area to which it is attached shall be isolated and made safe prior to the valve's removal.

7.2.5 In cases where a single relief valve is provided for blocked-in thermal protection and where during normal operation the equipment is otherwise protected, the relief valve shall be fitted with up and downstream locked open valves.

7.2.6 No isolating valves are required for relief valves venting to atmosphere.

7.2.7 Blowdown lines shall be designed as shown in Attachment 3, Blowdown Lines - Isolation System:

a. Automatic blowdown facilities shall consist of an automatically operated blowdown valve with a restriction orifice in a line to flare. There shall be upstream and downstream locked open isolation valves and a manual by- pass facility round the automatic valve.

0 KOC EMneerfng Gmup SpaMcatrion

b. Manual blowdown lines shall consist of a double valve system, a restriction orifice in between the two valves, and a bleed valve downstream of the RO.

8.0 DRAINS

Specificstion Number

01 5-AH-1 003

Refer to Attachment 4, Typical Vessel Isolation System,

8.1 All HP and MP vessel maintenance connections to the closed drain system shall be in accordance with paragraph 6.0. Attachment 4 shows the preferred method of isolation for HP/MP vessels.

Rev

1

8.2 This system is designed to provide drains segregation and to avoid overpressuring the closed drains system by ensuring that any vessel is depressurised before being connected.

8.3 All drain lines and blowdown lines shall be generously sized and be provided with a utility connection to clear the line of any blockage.

Date

23-5-94

9.0 INSTRUMENTATION

Sheet

8 o f 14

9.1 All instrumentation standpipe nozzles shall have a single block valve. All vent lines from instrument standpipes shall be valved and plugged, and drain lines shall be routed to the open oily drains system.

9.2 Drain lines from instruments in condensate service shall be connected to the pressurised drains and a flash drum.

10.0 VALVE SELECTION

10.1 All block valves and bleed valves shall be in accordance with the Engineering Group Specification entitled "Piping Material Classesn (Number 01 5-LH-1001). Double-seated valves with internal bleed fittings shall not be used for isolation duty where double block and bleed is specified.

10.2 The use of shutdown valves as isolation valves shall be assessed on a case-by-case basis and shall be subject to approval by the Company.

11.0 ISOLATION, PURGING AND FLUSHING

Engineering Gtvup SpeMmtrion

The following isolation procedure serves as a typical example. It is essential that the valve line-up and the ability of drums and vents to take fluids have been checked before isolation is commenced:

11.1.1 Prior to taking a system out of operation, the hydrocarbon inventory shall be minimised by reducing all vessel liquid levels to Low Low Liquid Level (LLLL).

Specification Number

01 6-AH-1 003

11 .I .2 System isolation valves are now closed and after depressuring to flare, the system/vessel is connected to the drain system. The balance of liquid inventories is drained by gravity through a dedicated drain header to the drain sump.

The system (or vessel) is still close to atmospheric pressure through the flare system.

Rev

1

Crude oil systems are now flushed with water and the water finally blown out with a nitrogen purge.

Gas and condensate systems are purged with nitrogen, and any residual liquids are drained through the dedicated drain header.

Date

23-5-94

Vents and drains are now closed and isolating blinds are inserted at system extremities and/or all vessel process connections under a small positive pressure of nitrogen. Low-range compound pressure gauges 3t 1 bar are used to check the purge pressure.

Sheet

9 0 f 14

The system or vessel is now finally nitrogen purged, checking for any liquid at low point drains and when the outlet vent has tested hydrocarbon gas-free, the system/vessel is ready for opening and further gas checks.

Entry to vessels without breathing apparatus is only allowable after air purging and testing for normal levels of oxygen.

11.2 Facilities

The following facilities are required to enable the isolation and purging procedures to be successfully performed:

I 11.2.1 System isolation facilities: see sections 5.0 and 6.0 above.

Maintenance drains: see section 8.0 above.

Purge and flush connections at the upstream isolation point of each system or vessel (inside the isolating blinds positions).

High point vents and low point drains at the extremities of any isolatable system or vessel (inside the isolating blinds).

Suitable connections for low-range pressure gauges.

Specification Number Rev Date Sheet Engindng Group spedkethn 01 5-AH-1003 1 23-5-94 11 of 14

Speclflcation Number Englnedng Group

Rev Date Sheet

S p ~ c d t h 01 5-AH-1 003 1 23-5-94 12 of 14

ATTACHMENT 2

RELIEF VALVE ISOLATION SYSTEM

FRW PROCESS EOUIPUENT

POX SPARED OR CRITIC& TO PROMICTW

BLOCKED-IN T HERW PROTECTION

\

INTERLOCK

tUb@mo I T N CRITICAL TO PRODUCTJON REOWZES SECOND RELEF VALVE) NOTES: tTYPE OF VMVE IS DEPfND€NT ON PIPING SPECIFICATION FOR PIPING MATERlAL CLASSES.

2.SYUBOLOGY AS PER L E W D SHEETS "0%-K-lOO1 AND 0%-K-1002."

K0.C UAKIR PROJECTS PROXCT 2906.201 .

SYSTEMS MKATlQN SPf CWATK)N

F I U H 2 REtff VMVE

W.ATlON SYSTEM P f M C T SPEWCAT1ON No

0151AH-YK)3

ATTACHMENT 3

Englneerlng Group S ' c a t i o n

BLOWDOWN LINES - ISOLATION SYSTEM UAMAL BLommJ

NOTES: tTYPC OF VALVE IS MPENOENT ON PlQlNC SPECnCAflON

FOR PIPING MATERN CLASSES. 2.SYMSOtOCY AS PER LEGEND S E T S " 015-Mot001 &J@ 015-AF-1002."

Specification Number

01 5-AH-1 003

K.O.C. UAJOR PROJECTS PROgCT 21206.201

SYSTEMS lSaATsON SPECFEATON

Rev

1

Date

23-5-94

Sheet

13 of 14

ATTACHMENT 4

Englnedng Gmup SpeMc%tbn

TYPICAL VESSEL ISOLATION SYSTEM

m s s OUTLET % ?&Sd%-~M~~ wceq 2.4, ,, ', ,I,, mo€w L

" k!! T . ~ ppP : ' o ' ~g~+~~~~&r&~~$9~ r r ~ ~ SYSTEM.

Specification Number

01 ~-AH-IOO~

Rev

1

K0.C W Pf?oxcTs PROJECT 21206.201

SYSTEMS ' ISOLATW . SPECFLCATW

FlCUK 4 TYPW WIMP SSSU

ISOLATION SYSTEM PROSCT SPECIFICATON ho

015-WW03

Date

23-5-94

Sheet

14 of 14