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Page 1 of 19 ABU DHABI GAS INDUSTRIES LTD. (GASCO) P & ID DEVELOPMENT

DESIGN GENERAL SPECIFICATION

P & ID’s DEVELOPMENT

4 3 2 1 0

01/07/01

A.KARA

ABDUL AZIZ AL AMERI

ISSUED FOR IMPLEMENTATION

A

01/06/01

A.KARA

ABDUL AZIZ AL AMERI

ISSUED FOR COMMENTS

Rev

Date DD/MM/YY

WRITTEN BY

APPROVED BY

STATUS

CHECKED BY

DOCUMENT REVISIONS Sections changed in last revision are identified by a vertical line in the left margin

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1.

INTRODUCTION .................................................................................................................................................................3

2.

GENERAL NETWORKS .....................................................................................................................................................3 2.1 FLARE NETWORK .................................................................................................................................................................3 2.2 DRAIN SYSTEMS ...................................................................................................................................................................3

3.

GUIDELINES FOR P&ID'S DEVELOPMENT ................................................................................................................4 3.1 3.2 3.3 3.4 3.5 3.6

4.

GENERAL..............................................................................................................................................................................4 INSTRUMENTATION ..............................................................................................................................................................5 PIPING ..................................................................................................................................................................................7 PUMPS INSTALLATION ..........................................................................................................................................................7 SLOPING REQUIREMENTS ......................................................................................................................................................8 VENTS AND DRAINS .............................................................................................................................................................8

TYPICAL REPRESENTATION DETAILS .......................................................................................................................9 4.1 4.2 4.3 4.4 4.5

APPENDIX 1: BATTERY LIMIT ARRANGEMENTS ..................................................................................................10 APPENDIX 2: REPRESENTATION OF DRAIN CONNECTIONS...............................................................................15 APPENDIX 3: SUGGESTED CONTROL VALVES MANIFOLD SIZE ...........................................................................................16 APPENDIX 4: SUGGESTED DOUBLE VALVING REQUIREMENTS ...........................................................................................17 APPENDIX 5: PURGE FOR FILTERS AND PUMPS SUCTION..................................................................................18

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1.

INTRODUCTION The purpose of this document is to define and possibly standardize the design and representations philosophies to be used during P&ID's development. This document is intended to be a continually developing document and to be updated based on ENGINEER and COMPANY discipline specialists experience. All updates shall be submitted to the COMPANY for review and approval prior to implementation in accordance with COMPANY procedure. It does not intend to supersede such documents as "Instrument Design Specification", or "Piping Design Specification", but to synthesized information from said documents which may prove to be helpful when developing P&ID's. ENGINEER shall review this document and highlight any conflicting requirements documented elsewhere.

2. 2.1

GENERAL NETWORKS Flare Networks The following flare networks are anticipated for OGD-III /AGD-II facilities Low Pressure Acid Gas Flare (FAG) High Pressure Hydrocarbon Flare (FL) Low Temperature Flare (LTF)

2.2

Drain Systems The following closed drain systems will be provided: An amine closed drain system (SDM) in each of the Gas Treatment areas. Drains will be collected in dedicated surge drums for future recovery. This drain network should be able to handle sour fluids and the sump drum will be in equilibrium with the FAG header. A separate CD network will also be installed to collect Hydrocarbons drains in the Amine treating area. If required, a glycol closed drain system (GD) drains will collect drains from TEG units in dedicated surge drums for future recovery. This drain network shall be able to handle sour fluids and the sump drum will be in equilibrium with the FL header. Hydrocarbon closed drain system (CD) for the Inlet Separation and Stabilization area, and in the Sour Water Stripper area and for each of the Dewpointing areas. Drains will be collected in dedicated surge drums and pumped back for future reprocessing or disposal to the Hydrocarbon Flare Knock-Out Drum. This drain

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network shall be able handle sour fluids and the sump drum will be in equilibrium with the FL header. A Low Temperature Drain Network (CDC) will be implemented in the NGL recovery and fractionation areas. Hydrocarbon skimming facilities will be provided from each of the Gas Treating areas (HR network). 3.

GUIDELINES FOR P&ID'S DEVELOPMENT

3.1

General 1.

All isolation valves will be single block valves, except: •

ANSI Class 600# for fluids in sour service where frequent use is expected,

•

ANSI Class 900# and higher for all services, except PSV's downstream block valves.

Double valving shall be in accordance with Appendix 4. 2.

Battery Limits will be defined based on Plot Plan considerations. Each unit or processing area will be a distinct battery limit.

3.

Aircoolers: Air coolers fans motors shall be remotely controlled and shall be shown as such on P&ID's. Aircoolers will be stopped from NMCR.

4.

Pumps: All pumps can be stopped from control room and locally. Pump status will be displayed on the DCS for main pumps Pumps could be started locally and/or from control room after operator has checked pump status. As a guideline, pumps with automatic start-up shall be able to be started from control room. Other pumps will be considered on a case-by-case basis with prior consultation with OPERATOR depending on process considerations.

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3.2

Instrumentation 1.

Safety/Relief Valves: PSV's will be spared on the n+1 basis (n required for the service + 1 identical spare), except for those PSV's mounted on equipment which can be taken out of service for PSV maintenance (typical example: 3 50% filters with fire case PSV's will be equipped with one PSV per filter). Thermal expansion relief valves will not be spared. Such non spared PSV's will not be equipped with an inlet block valve. All inlet and outlet block valves to PSV's will be full port valves (type in accordance with the service). Inlet and outlet block valves of PSV's in service will be locked open. Inlet block valve of spare PSV will be locked closed, outlet block valve will be locked opened. Blinding provision will be included for each set of PSV's including the by-pass. This will be in the form of a spacer ring on the nozzle of the protected equipment when the set of PSV's is directly mounted on equipment. A note will be added on P&ID in such case. Each set of PSV's will be equipped with a 2" by-pass with single globe valve for low-pressure service and gate + globe valve for high-pressure services. The bypass valve(s) will not be locked. PSV's will be fitted with a vent between block valve and inlet flange. To the maximum possible extent, downstream block valves and PSV's will be installed flange to flange (in that case without vent). Block valves downstream PSV's will be gate valves.

2.

ESD valves will be tagged XV, while sequence valves (if any) will be tagged KV. Critical valves positions (XV/KV) will be performed through position switches. No use of position transmitter will be done.

3.

ESD valves: ESD valves will be specified bubble-tight as per API 598. Wherever applicable they will be provided with a pressurization by-pass. The by-pass will be an XV, working automatically with the ESD valve status signal (ESD valve limit switch open signal will close the XV bypass valve). If the XV is fitted with a spectacle blind or spacer ring, then by-pass line will be equipped with a spectacle blind (irrespective of line size). A differential pressure transmitter will be used as a permissive to open the ESD valve on high pressure services. Under NO circumstances shall control valves be used as ESD valves. Where ESD valves are deemed necessary, they shall be independent on/off type initiated by the operator via the ESD system.

4.

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Shut down systems will be equipped with dedicated field sensors.

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5.

2 out of 3 voting logic shall be based on the recommendations of the Safety Integrity Level Studies which shall be completed for the project.

6.

Control Valves: Control valves will be equipped with a by-pass manifold as dictated by Process reasons. Block and by-pass valves, by-pass lines will be sized following the guide lines included in Appendix 3. Except for specific cases, the following drains/vents will be provided : • for FO valves on both liquid and gas services, one vent/drain upstream valve, • for FC valves on both liquid and gas services, one vent/drain on each side of the valve. Vents and drains will be connected to relevant networks where appropriate.

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7.

Control valves with by-pass will not be equipped with handwheels, unless it is required for process reasons.

8.

All flow measurement irrespective of single gas or liquid phase shall be performed by orifice plates with the exception of flow measurement in flare headers, which shall be by use of ultrasonic meters.

9.

Gauge glasses will cover the full range of level transmitters and alarm switches. Standpipes should not be specified in dirty services and for interface measurement.

10.

In general, all drain connections from level measuring instruments will be connected to closed drain system for good housekeeping and when in sour service to the flare for environment protection requirement. Details showing the possible arrangements will be prepared by the Engineer for COMPANY review and approval.

11.

Except for specific locations (columns for instance), all TW's will be fitted with TI's.

12.

Lines smaller than 4" will be locally enlarged to 4" if a TW installation is required.

13.

All Battery Limit Process and main Utilities flow measurement will be pressure and temperature compensated. Pressure and temperature compensation for some other flow measurements will be evaluated and added as required or if instructed by COMPANY.

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3.3

Piping 1.

Ball valve should be used for shut-off services in gas and light hydrocarbon systems.

2.

Butterfly valves shall not be used for isolation of equipment irrespective of leakage class.

2.

Full port valves (type in accordance with the service) should be used at compressors and turbine inlet. Use of pipe reducers should be avoided for the same services.

3.

Block valves will be motorised for sizes greater or equal to 16" where frequent use is expected.

4.

No globe valves larger than 6" will be used. Reduced port ball valves will be used instead, except for specific Process requirements.

5.

Steam out connection will not be, in principle, hard pipe, except for large capacities requiring more than the flow supplied by one or two steam hoses. When hard pipe connection is provided, it will be fitted with double block valve, bleed and blinding provision.

6.

Battery Limit valves will be manual valves. When an ESD valve is supplied at plant inlet and/or outlet Battery Limit, it will be supplemented by a manual BL valve. Refer to Appendix 1 for details.

7.

The following guidelines will be used for specifying blinds for equipment isolation: • less than 12": spectacle blinds • above 12": spacer rings Drain lines may not be fitted with spectacle blinds at equipment flange provided that the drain lines are equipped with spectacle blinds. Safety valves nozzle when installed on the equipment will be fitted with spacer ring, irrespective of the nozzle diameter. A specific note will be added on the P&ID's.

8.

The following minimum guidelines will be followed for pressurization by-pass sizes: • 1 “ by-pass for valves below and including 14" • 1.5” above 14"

9.

3.4

Minimum pipe size for steam and Nitrogen from distribution headers to utility station and connectors shall be 2”

Pumps installation 1.

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Pumps will be equipped with suction and discharge pressure gages. Suction gage to be installed downstream the suction strainer.

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Suction piping will of the same rating than discharge piping up to and including the suction block valves. 2.

Pumps discharging in a common network will be equipped with a recalculation by-pass on the discharge check-valve for •

viscous fluids, or fluids which may solidify at minimum ambient temperature,

•

cryogenic fluids, or considerably below ambient temperature,

•

high temperature services (over 230°C).

Check valve bypass will be in 1" for valves below or equal to 14" and 1.5" for larger sizes. 3. Block valves diameters for suction and discharge lines are defined below, in function of pumps nozzles diameters: •

Suction line : in all case, valve size is equal to suction line diameter.

•

Discharge line : line size is one diameter higher than nozzle, check valve and block valve will have the same size than the pump nozzle. If difference between line size and nozzle size is greater than one diameter, check valve and block valve will be of the lowest possible intermediate size (e.g.: nozzle 4", line 10", check and block valves: 6").

3.5

Sloping requirements 1. Sloping requirements shall be indicated on P&ID's. 2. Flare headers shall slope towards the flare drum. Except for specific cases, PSV's discharge should slope to the flare headers/subheaders. Connection to the header should preferably be at 45° angle for lines greater or equal to 2". 3. Compressors suction lines should preferably slope to the suction KO drum. Compressors anti-surge lines should preferably slope to suction and discharge drums with anti-surge valve at high point.

3.6

Vents and Drains

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In addition to drainage to dedicated drain network, when applicable, all drains are to be equipped with a drain to the water drain through an open cup.

2.

Depending on line size, utilities header will be equipped, either with a blind flange or with a cap fitted with a 3" valve and blind flange.

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2" valves with blind flanges will be installed at the end of flare headers and subheaders for Nitrogen purging. 3.

Steam vents, which may be used, for long duration during start-up phases will be equipped with silencers. Individual vents will be connected to its dedicated single silencer, grouping of vents to a single silencer is not permitted. PSV's on steam system will not be equipped with silencers.

4.

For steam turbines, open drain traps and vents will be provides for draining of steam condensate during start-up phases (until quality is achieved).

5.

3/4" vents and drains will be differentiated. The following is suggested: •

V1: vent, 3/4", gate valve (1)

•

V2: vent, 3/4", globe valve (1)

•

V3: vent, 3/4", ball valve (1)

•

D1: drain, 3/4", gate valve (1)

•

D2: drain, 3/4", globe valve (1)

•

D3: drain, 3/4", ball valve (1)

(1) with plug or blind flange, according to piping class. 3.7

Miscellaneous Sample connection will shown as simplified on the P&ID's. Specific P&ID's will be develop to show sample connection details (line size and numbers, valve types, etc). The minimum connection size is 3/4".

4.

TYPICAL REPRESENTATION DETAILS Typical representation will be developed on P&ID's and will be shown on the symbol P&ID's for the following items: Standpipes, showing drains and valving as required, Valves such as XV, KV and MOV's, showing the instrument loop details. In addition, the following Appendixes provide typical guidelines. 1. Typical Battery Limit Arrangement is shown in Appendix 1. 2. Drains representation for various systems are shown in Appendix 2. 3. Control valves manifolds are defined in Appendix 3. 4. Double valving philosophy is defined in Appendix 4.

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4.1 APPENDIX 1: BATTERY LIMIT ARRANGEMENTS a. General The simplest battery limit arrangement is shown below for process gases and liquids. It includes block valve, spectacle blind and vent and/or drain. When the outcoming line is connected to a common header (e.g. Sales Gas), a check valve will be added to prevent backflow in case of a single train shut down. Mini

LIQUID LINES Note 1 B/L OR

3/4"

GAS LINES (General case)

B/L Mini

Note 1 :

∅ = 1" for line < 4" ∅ = 2" for line 4" to 8" ∅ = 3" for line > 8"

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b. Specific Cases 1.

HP Sour Gas

For HP Sour Gas with XV valve at the Battery Limit, refer to the following schemes for incoming and outgoing lines. FL

Mini

Mini B/L

HP Sour Gas inlet

CD

FL

Mini

Mini B/L

HP Sour Gas outlet

CD

2.

HP Sweet Gas

For HP Sweet Gas with XV valve at the Battery Limit, refer to the following schemes for incoming and outgoing lines.

3/4"

Mini

Mini B/L

HP Sweet Gas inlet

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Page 12 of 19 ABU DHABI GAS INDUSTRIES LTD. (GASCO) P & ID DEVELOPMENT 3/4"

Mini

Mini B/L

HP Sweet Gas outlet

3.

LP Sour Gas/Acid Gas

For LP Sour Gas and Acid Gas with XV valve at the Battery Limit, refer to the following schemes for incoming and outgoing lines. FL or FAG

Mini

Mini B/L

LP Sour Gas & Acid Gas inlet

CD

FL or FAG

Mini

Mini B/L

LP Sour Gas & Acid Gas outlet

CD

4.

LP Sweet Gas

For LP Sweet Gas with XV valve at the Battery Limit, refer to the following schemes for incoming and outgoing lines.

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Mini

Mini B/L

LP Sweet Gas inlet

3/4"

Mini

Mini B/L

LP Sweet Gas outlet

c. Flare Headers Battery Limit 1" 1/2 Upper Tangent Line

Note 1

LO

B/L

Offsite

Mini

Note 1 :

HC Flare: valve to be installed wheel down locked open with position indicator. For acid flare : valve to be installed wheel horizontal locked open with position indication.

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d. Utilities Battery Limit

Steam condens. HP Steam (STH, STS) LP Steam (STL, SLH) Fuel gas Nitrogen Instrum./Plant air BFW Utility water Cooling water Potable water Demin. water

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Double block-valve No No No No No No No No No No No

Vent No Yes Yes Yes Yes Yes No No No No No

Drain Yes No No No No No Yes Yes Yes Yes Yes

B/L valve by-pass No Yes No No No No No No No No No

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4.2 APPENDIX 2: REPRESENTATION OF DRAIN CONNECTIONS Multiple drains arrangement

Valve(s) type according to piping class

Second Piping Class break (if applicable)

Valve type according to piping class

Globe Valve Piping Class break (if applicable)

CD

(or GD, SDM, ....)

OD 1. A note on P&ID's will indicate that drains could be tie-in. " Drains to closed drain systems (CD, SDM, .....) may be grouped according to piping arrangement" 2. Drains to closed systems are not intended to be operated when the line / equipment is in service. The normal procedure is to empty the line/vessel to the maximum possible extent to capacities where liquids can be easily recovered, isolate line/vessel and reduce pressure before draining to the closed drain network. Therefore double valving upstream spectacle blind is not foreseen.

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4.3 Appendix 3: Suggested Control Valves Manifold Size Line size (inches) Control valve size (inches) 3/4" 1" 1.5" 2" 3" 4" 6" 8" 10" 12" 14"

Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass Block Bypass

1.5"

2"

1.5" 1.5" 1.5" 1.5" 1.5" 1.5"

2" 2" 2" 2" 2" 2" 2" 2"

3"

2" 2" 2" 2" 3" 2" 3" 3"

4"

3" 3" 3" 3" 4" 3" 4" 4"

6"

8"

4" 4" 4" 4" 6" 4" 6" 6"

10"

6" 6" 6" 6" 8" 6" 8" 8"

8" 8" 8" 8" 10" 8" 10" 10"

12"

10" 10" 10" 10" 12" 10" 12" 12"

14"

12" 12" 12" 12" 14" 12" 14" 14"

1.

Other configurations to be studied on a case by case basis, using the same approach.

2.

Reducers to be installed according to the above table.

3.

For flashing services, the line downstream the block valve will of a size equal to the main line size and equipped with the corresponding reducer. In all other cases, by-pass line and valve will be of identical size.

4.

By-pass valves will normally be globe valves if smaller or equal to 6".

5.

By-pass valve size may be reduced if they impair downstream safety relief system.

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4.4 Appendix 4: Suggested Double Valving Requirements Service Control valves block valves Control valves by-pass valves PSV's inlet block valves PSV's outlet block valves PSV's bypass valves Battery limit valves Pumps suction/discharge block valves Itemized filters

900 # doubled doubled (2) doubled not doubled doubled (2) doubled (1) not applicable doubled (1)

600# in sour service doubled doubled (2) not doubled not doubled doubled (2) doubled (1) doubled (1) doubled (1)

(1) ESD valve may be used as second block valve (2) one valve is used for throttling purposes (usually a globe valve)

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4.5 APPENDIX 5: PURGE FOR FILTERS AND PUMPS SUCTION DETAIL "A" T filter in vertical position

Note 1 P 3/4"

LPT

3/4"

3/4"

DETAIL "B" T filter in horizontal position

Note 1

3/4" 3/4"

DETAIL "C" Y filter in vertical position

Note 1

LPT 3/4" P

3/4"

3/4"

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DETAIL "D" Y filter in horizontal position

Note 1

3/4" 3/4"

Notes : 1. Excentric reducer 2. Use Y type filters up to pipe size 2", T type filter above

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