Contract

Number:P1007

File Reference
1007-DISQ-0-P-PH-48071

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RWE Dea

Disouq Field Development

FEED

Shutdown Philosophy

Document number
1007-DISQ-0-P-PH-48071-Rev.0

12.12.11

Issued for Client comment

Rev

Date

Description

S.Morsi

A.Fawzi

A.Hamdan

Issued By Checked By Approved

By

RWE
Client
Approval

Onspec Engineering Solutions

Disouq Field Development Project
Shutdown Philosophy

Changes List
Rev.

Date
prepared

Prepared by

Description

(dd.MM.yyyy)

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Onspec Engineering Solutions

Disouq Field Development Project
Shutdown Philosophy
Table of Contents
1

Introduction ...................................................................................................................... 4

1.1

Objectives & Scope ...................................................................................................... 5

1.2

Abbreviations ............................................................................................................... 6

Safety Shutdown Philosophy and Principles .................................................................... 7

2.1.

Application ................................................................................................................... 7

2.2.

Principles ..................................................................................................................... 7

2.3.

Applicable Code ........................................................................................................... 7

2.4.

Safety Integrity Level .................................................................................................... 7

3
3.1.

Logic Hierarchy ................................................................................................................ 8

Shutdown Levels .......................................................................................................... 9

Process & Utilities Shutdown Events ............................................................................. 11

Shut Down Valves design Criteria .................................................................................. 12

5.1

ESD valves ................................................................................................................ 12

5.2

Position Status & Resetting ........................................................................................ 12

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Onspec Engineering Solutions

Disouq Field Development Project
Shutdown Philosophy

1 Introduction
RWE Dea Egypt has discovered seven natural gas reserves in the Disouq Concession within
the onshore Nile Delta, starting in 2008, as shown on the concession map below. Further
exploration in the concession is ongoing. RWE Dea Egypt is the operator of the Concession
with EGAS as a partner.

The objective of this project is to carry out front end engineering design (FEED) services and
prepare a scope of work for Engineering, Installation and Construction tenders (procurement will
be undertaken by RWE Dea) to finally install a natural gas trunk line system to be gathered, led
to a central gas treatment plant where the gas shall be treated to achieve sales gas quality and
send to the gas pipeline infrastructure at the boundaries of the Disouq Concession.
The selected development comprises a central gas treatment site near NSG-1x, where the gas
is collected, treated by means of Low Temperature Separation utilizing the Joule Thomson
effect, and compressed for export. Treated gas is exported via a 16 export pipeline directly into
the GASCO NTS pipeline.
The well fluids from the directly routed wells and the trunk line are fed to a common inlet
separator at the central plant. All gases and liquids will be separated and processed on the
central treatment site into sales gas, stabilized condensate, and free production water.
Treatment of gas is carried out in two trains, while treatment of condensate is in a single train.
Three trains of sales gas compression are installed. During FEED investigation shall clarify, if
the installation of front end booster compressors is more advantageous compared to this
concept.
Fuel gas for the gas engine drives is taken from the suction of the sales gas compressors.

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Shutdown Philosophy
To allow further increase of the production additional tailings and all necessary equipment like
valves and flanges shall foresee to allow a simple tie in of future treatment trains.

1.1

Objectives & Scope

This document defines the safety shutdown philosophy and the basis of design for the Safety
System for Disouq Gas Plant Facility.
The principal objectives of the safety system are:
Ensure personal protection
Minimization of hazards to the environment
Plant and equipment protection
The safety system will provide the safe isolation and depressurization of the total facility or
critical sections of the process and utilities in the event of an emergency condition when the
safety of personnel or equipment is threatened. The safety system is divided into two subsystems; Fire and Gas detection and protection system (F&G) and Emergency Shutdown
System (ESD).
This document primarily defines the Process Shutdown philosophy.
Protective systems will provide the protection of personnel, environment, and equipment by
providing the safe shutdown of plant and/or process equipment during an event that may
include hazards such as loss of containment or fire, a process upset, or when the primary
control system fails to keep the process within specified operating limits.
Shutdown, isolation of process inventories into manageable volumes and depressurizing are
used to manage and limit escalation of any event.
Protective systems will include dedicated process sensors and final elements and will not rely
upon functions controlled by the process control system. Except where required by the project
design specifications, protective system outputs will be designed as Fail-Action, that is, loss of
output signal will cause the associated field device to move to its shutdown state.
The Shutdown Philosophy includes systems that respond to different types of events. These
systems are the Emergency Shutdown System (ESD) that includes fire and gas detection, fire
suppression, and emergency depressurizing, Total Plant Shutdown, Process Shutdown, and
Equipment Shutdown.
Electrical protection, including manual emergency switchgear trip, manual emergency generator
trips, and electrical protective relay functions is separate to and independent of the Safety
Instrumented System.
The Shutdown System for each facility will be a self-contained stand-alone system that is not
dependent upon inter-location communications.
The Shutdown System will operate
independently of the Plant Control System, but communicate with the Plant Control System for
data to be available at the operator interface.

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Shutdown Philosophy
1.2

Abbreviations

Blowdown valve

: BDV

Central treatment Plant

: CTP

Emergency Shutdown

: ESD

Emergency Shutdown Valve

: ESDV

Fire and Gas

: F&G

General Process Shutdown

: GPSD

Safety Instrumented System

: SIS

Safety Instrumented Function

: SIF

Process Shutdown

: PSD

Safety Integrity Level

: SIL

Safety System

: SS

Unit Shutdown

: USD

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Shutdown Philosophy

2 Safety Shutdown Philosophy and Principles

2.1.

Application

A common safety shutdown system is provided for the entire facility. The shutdown hierarchy
applies across all plant areas.

2.2.

Principles

The overall safety shutdown philosophy is based on the principle of maintaining the facility at an
acceptable level of safety for personnel; equipment and the environment whilst initiating the
lowest shutdown level possible to allow for efficient re-start.
The following principles shall apply to the achievement of an acceptable level of safety:

Personnel safety.

Protect the environment, plant and equipment

Prevent escalation and minimize the consequences of a hazardous event.

Minimize the requirement for manual operations during and after a hazardous event.

Where appropriate, limit cascaded process trips to allow easier identification of the trip
cause and make use of operator intervention.

Provide a system that is simple to implement, test / verify and operate thereby achieving
high availability.

2.3.

Applicable Code
API RP 500

Classification of Locations for Electrical Installations

API RP 520

Recommended practice for sizing, selection and installation of

pressure relieving (parts I and II).
Guide for pressure devices in refineries relieving and
depressurizing systems.

API RP 521

2.4.

Safety Integrity Level

Safety Instrumented Functions (SIF) within the Protective System will be analyzed to ensure
compliance with the required Safety Integrity Level (SIL) and will be designed to meet the target
SILs of the project.

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Shutdown Philosophy

3 Logic Hierarchy
The shutdown system logic is structured in a hierarchical form ensuring that an orderly
shutdown of systems can be accomplished. The structure includes:

An Emergency Shutdown System (Level 4) that includes fire or gas detection that initiates
the site emergency alarm isolates the electrical systems and following either confirmed fire
or confirmed gas detection in the processing area initiates a Total Plant Shutdown with
depressurization.

A General Process Shutdown (Level 3) that isolates the site from external sources of
hydrocarbons by closing the facility import and export pipeline valves and inter-facility tie
line valves, isolates large volume inventory, and initiates a process shutdown for train, unit
or process station shutdown.

A Process Shutdown (Level 2) stops a whole process train, closes inventory isolation
valves and initiates Process Equipment Shutdown for the train.

An Equipment (Unit) Shutdown (Level 1) that stops a single equipment item (process
component) and closes its inventory isolating valves.

Figure 1 - Shutdown system logic hierarchy

Total Plant Shutdown, Process Shutdown, and Equipment Shutdown respond to both manually
initiated shutdowns from shutdown hand switches, and automatically initiated shutdown from
process sensors.

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Shutdown Philosophy

3.1.

Shutdown Levels

The safety shutdown system for the facility is arranged in a hierarchical manner, with each
shutdown level automatically initiating the level below.
The shutdown levels are divided into four (4) main groups, ESD, GPSD, PSD and USD as
follows:
3.1.1 Emergency Shutdown (ESD)
ESD is a high emergency shutdown which will be initiated under extreme circumstances when
normal operations cannot be resumed in the foreseeable future.
ESD shutdown will be initiated by the following conditions:
I.

Explosion identified by operator.

II.

Manual fire call point activation.

III.

Major plant fire, confirmed fire (by at least two detectors) in more than one fire
zone at CTP

The ESD is aimed at isolating hydrocarbon feeds and outlets, reducing hydrocarbon inventory
and limiting ignition sources and will be automatically activate in the following;

Activate the facility emergency alarm

Start fire pumps (where installed)

Activate fire water monitors (where installed)

Initiate fire suppression (where applicable)

De-energize electrical systems

Initiate a Total Plant Shutdown; by closing all SDVs

Initiate emergency depressurizing at CTP facilities (except well area).

Valves activated upon ESD are identified in the C&E Diagram.

3.1.2 General Process Shutdown (GPSD)
GPSD shutdowns shall be initiated under emergency conditions due to abnormal process
conditions not within the limits of process control system, where it is possible that normal
operation could be resumed in the foreseeable future. These conditions are process upset
circumstances.
Utilities will be kept running as long as possible to enable recovery from the shutdown trip
situation.
The GPSD will be automatically initiated in the following circumstances;

Manual activated switch in the control room or remotely in the CTP.

Shut down of un spared main equipment (such as slug catcher)

Total power failure.

Loss of instrument air pressure.

Loss of fuel gas pressure.

High high level in the flare K.O drum.

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Shutdown Philosophy
This level of shutdown will:

Isolate a site from external hydrocarbon sources by closing the site or facility import and
export pipeline (S) valves that are located at or near the plant area boundary

Isolate a site or facility from external hydrocarbon sources by closing valves on interfacility.

Isolate large volume inventory by closing inventory isolation valves

Initiate a Process Shutdown

Initiate Process Equipment Shutdown that is not shutdown by a Process Shutdown

GPSD comprises the activation of all SDVs only. These are identified in the C&E
Diagram.

3.1.3 Process Shutdown (PSD)

PSD is Lower level shutdowns resulting from abnormal process conditions within a defined
process system.
Shutdown is aimed at avoiding escalation to an emergency condition. Only the train with the
abnormality is isolated as well as the electrical system connected to it.
The Process Shutdown provides protection of process units and/or equipment and will
shutdown rotating equipment and close equipment shutdown valves. The Process Shutdown
minimizes the potential for equipment damage or process excursions.
A Process Shutdown is initiated by:

A manually activated switch in the control room, or field

Automatically by process sensors (pressure, level, temperature)

A Process Shutdown will:

Isolate all trains or units by closing the train or unit isolation valves

Isolate large inventory within trains or units by closing inventory isolation valves

Initiate Process Equipment Shutdown

3.1.4 Equipment/Unit Shutdown (USD)

This level of shutdown is the lowest shutdown level. It results from abnormal process conditions
for a single equipment/unit only.
Unit shutdown is initiated by:

A Process Equipment Shutdown switch in the control room, or process area

Automatically by process sensors (pressure, level, temperature)

Unit shutdown will activate the followings:

Stop/shutdown a single equipment item or rotating equipment.

Close the process equipment or rotating equipment isolation valves.

Inventory blow down is initiated manually except for incidents for which blow down is
automatic.

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Shutdown Philosophy

4 Process & Utilities Shutdown Events

The plant flare systems will be designed to handle the plant capacity of 165 MMSCFD based on
blocked outlet case resulting from process upset conditions. The flare header is designed for
275 MMSCFD to accommodate future expansion expected.
The action of GPSD will reduce the quantity of flared hydrocarbon due to process upset
conditions.
4.1.

Abnormal flow
Low flow shutdown inputs should be used for centrifugal pumps to prevent cavitation and
subsequent pump damage from operating at flow rates less than the required minimum
flow. These are not required where pump minimum flow protection is provided.

4.2.

Abnormal level
Low low level shutdown inputs are recommended for any vessel where loss of level would
result in damage to process pumps or significant gas blow-by and overpressure of
downstream equipment.

4.3.

Abnormal Pressure

Low pressure shutdown inputs should be considered for:

Process equipment that is susceptible to damage in the event of low inlet pressure and no
other adequate protection exists, e.g. compressors.

Fuel/pilot gas pressure to shutdown gas engine.

High pressure shutdown inputs and alarms should be considered for compressor
discharge and seal leakage detection systems for pumps.

4.4.

Abnormal Temperature

High temperature shutdown inputs and alarms are required for:

Compressor, cooling system, diesel engines and pump lube-oil systems.

Rotating equipment, bearing temperatures.

4.5.

Abnormal Vibration

Rotating equipment will be provided with the appropriate vibration protection.

4.6.

Utilities Shutdown

All utilities shall be shut down only in case of ESD (level 4) except fire fighting system.
All essential utilities listed below will normally remain in operation.

Instrument Air

Fuel gas system

Fire fighting and deluge systems

Flare System

Open drain & closed drain

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Shutdown Philosophy

5 Shut Down Valves design Criteria

5.1

ESD valves
Please refer to Valves Specifications 1007-DISQ-0-J-SS-33033

5.2

Position Status & Resetting

Please refer to Control Philosophy Specifications 1007-DISQ-0-G-MA-30092

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