‘Sarawak Shell Berhad Sabah Shell Petroleum Company Limited STANDARD ENGINEERING SPECIFICATION HAZARDOUS. AREA. GLASSIEIGATION. SES 65.1 REV, 4 AAA10 worsenCONTENTS 1.0 scoPE 2.0 ABBREVIATIONS 3.0 REFERENCES 4.0 DEFINITIONS 5.0 PROCEDURES FOR AREA CLASSIFICATIONS 6.0 CLARIFICATIONS 6.1 Threaded Connections 6.2 Pressurised Areas 6.3 Ventilation Levels 6.4 Hot Work 6.5 Non Routine Situations 6.6 Furnace: 6.7 Dispersion Calculations 6.8 Gas Density APPENDICES APPENDIX 1: CODE APPLICATION FLOWCHART APPENDIX 2: VENTILATION CHECK FLOWSHEET Sarawak Shell Berhad Sabah Shell Petrolaum Company Limited STANDARD ENGINEERING SPECIFICATION SES 65.1 Rev. 4 Page i BAGE 1 Sheet 1 Sheet ens aoeSarawak Shell Berhad Sabah Shell Petroleum Company Limited SES 65.1 Rev. & Page ii STANDARD ENGINEERING SPECIFICATION Revision Register Revision No. Details of Revision Entire SES Entire SES Part 15 of the IP Model Code of Safe Practice in the Petroleum Industry; Area Classification Code for Petroleum Installation (March 1990), 1s adopted as the base document for this SES, eS TOE2.0 3.0 Sarawak Shell Berhad Sabah Shell Petroleum Company Limited SES 65.1 Rev. 4 Page 1 STANDARD ENGINEERING SPECIFICATION SCOPE This Specification adopts Part 15 of the IP Model Code of Safe Practice in the Petroleum Industry "Area Classification Code for Petroleum Installations" as a base document and presents clarifications and supplementary details applicable to SSB/SSPC facilities. ‘This Specification shall be used for the determination of hazardous area classification of all SSB/SSPC facilities both Onshore and Offshore. ABBREVIATIONS DEP - Design and Engineering Practice (SIPM) Pr - Exploration and Production (SIPM)) IP - Institute of Petroleum MF - Manufacturing (SIPM) SIPM - Shell International Petroleum Maatschappij B.V ‘The Hague SSB/SSPC - Sarawak Shell Berhad/Sabah Shell Petroleum Company Ltd. USD - Unit Shutdown REFERENCES 3.1 Group Reference Documenta DEP 31.38.01.12-GEN. Piping Classes M.F. DEP 31.38.01,15-GEN, Piping Classes E.P. EP-55000-21 - Safety Engineering in Facilities Design MF Newsletter - Manufacturing Oil and Gas Safety newsletter 85-0010 November 19844.0 ‘Sarawak Shell Berhad Sabah Shell Petroleum Company Limited SES 65.1 Rev. & Page 2 STANDARD ENGINEERING SPECIFICATION International/National Codes and S\ ds IP - Area Classification code for Petroleum Installations, March 1990 being Part 15 of the IP Model Code of Safe Practice, (Hereinafter referred to as "the Code") and all publications referenced in Appendix J of the Code. ANSI/NFPA-496 - Purged and Pressurised Enclosures for Electrical Equipment In the event of conflict between the above referenced standards the order of precedence shall be taken as : 1, This Standard Engineering Specification 2. Group Reference Documents 3. International Codes and Standards DEFINITIONS MANNED A facility which is bridge linked to _a living quarters. The facility nay consist of several bridge inked Hise platforms such as drilling jackets or platforms, production stations, compression platforms and gas processing platforms. No specific level of attendance is implied by this term. MAY Indicates one possible course of action ‘SHOULD Indicates a course of action which is strongly preferred. SHALL Indicates a mandatory course of action, THE COMPANY Sarawak Shell Berhad/Sabah Shell Petroleum Company Limited (SsB/SSPC) ‘UNMANNED A facility which 1s not bridge linked to a living quarters. The facility may consist of several bridge Linked platforms such as drilling jackets or platforms, production stations, compression platforms and gas processing platforms. No specific level of attendance is implied by this term.Sarawak Shell Berhad Sabah Shell Petroleum Company Limited SES 65.1 Rev. 4 Page 3 STANDARD ENGINEERING SPECIFICATION 5.0 PROCEDURES FOR AREA CLASSIFICATION Area classification plans and elevations shall be prepared for all Company facilities which contain point release sources of flammable fluids as defined by the Code. The area classification drawings shall be prepared strictly in accordance with the Code. Particular emphasis is placed on the concepts outlined in para 1.4, "THE MANAGEMENT OF AREA CLASSIFICATION", and para 5.1 "SCOPE FOR POINT SOURCE METHOD". Selection of electrical equipment shall be in accordance with section 7.0 of the Code and section 8.0 of the Code shall be used as a guideline for the control and location of ignition sources other than electrical. Appendix 1 presents a flow chart which indicates general guidelines to be followed during application of the Code. Appendix 2 presents a flow chart which may be utilised when determining the ventilation level classification for any given situation. 6.0 CLARIFICATIONS This section clarifies areas of the Code which have historically been subject to misinterpretation or confusion. 6.1 Threaded Connections In accordance with EP-55000 Section 2136 and the DEP 31.38.01,12/15-GEN. piping classes, screwed fittings shall not be utilised for piping systems on any new facility in flammable or toxic service. In certain cases however a single threaded connection to vendor supplied equipment may be unavoidable. Examples of this are manifold connections downstream of the carburretor on the fuel gas supply to gas engine driven equipment or fuel gas connections to direct fired burners. In such cases the fuel gas supply pressure to the equipment shall be reduced to the minimum acceptable pressure as far as practicable from the equipment concerned. A block and bleed valve shall be provided to isolate the fuel gas supply and to vent the fuel gas inventory between the equipment and the valve on any equipment USD. This block and bleed valve shall be located as close to the engine as practicable. In such high integrity systems the final threaded connection, provided that it is not subjected to high Erequency/high amplitude vibration and is regularly inspected, shall not be considered to pose any greater leakage risk than a flanged connection.‘Sarawak Shell Berhad Sabah Shell Petroleum Company Limited STANDARD ENGINEERING SPECIFICATION For the purpose of hazardous area classification using section 5.0 of the code, such screwed connections shall be treated as flanged connections. The hazardous radius around the equipment concerned shall be determined from all such point sources on both the driving and driven equipment. See also Para. 6.6 ‘Furnaces’, SES 65.1 Rev. 4 Page 4 Guidelines are available in MF Oi1 and Gas Safety Newsletter 85-0010 dated November 1984 defining acceptable frequencies/ amplitudes of vibration and potential causes of, and solutions to, typical vibration problens. If on review it is considered that any such threaded connections in WC service may be at risk of failure under normal operating conditions then they shall be designed out and flanged connections utilised in their place. When upgrading hazardous area classification drawings for existing platforms, subject to their satisfying the criteria of acceptably low vibration and regular inspection, the hazardous radius around existing screwed connections may be determined as for a flanged connection under the Code. Note It is not acceptable to utilise threaded connections in hydrocarbon service, where vibration or other considerations indicate such connections may be vunerable to failure. The application of hazardous area calculations based on the total failure of such a connection should not be used to justify its use as catastrophic failures are outside the scope of the code. 6.2 Pressuri: Ar Section 6.5 of the Code covers ventilation/pressurisation and area classification requirements for enclosed rooms. These requirements are considered fully applicable for continuously manned platforms. However, for stations which are classified as unmanned, on loss of ventilation all electrical equipment inside the room which is not suitable for operation in a zone 1 area shall be isolated. For enclosed rooms on unmanned stations, a 15 minute tine delay shall be built in to the shutdown system to allow for transient losses of pressurisation ventilation such as auto/standby fan changeover or door opening/closing. As electrical power is normally available on unmanned platforms with pressurised areas an audible alarm shall be provided to indicate loss of pressurisation ventilation to enable remedial action to be taken by any operators present on the platform. Tuna6.3 Sarawak Shell Berhad SES 65.1 ‘Sabah Sheil Petroleum Company Limited Rev. & Page 5 STANDARD ENGINEERING SPECIFICATION Visual indication of room pressure shall be provided inside all pressurised areas. This should take the forn of a simple sloping tube manometer. For detection of loss of pressurisation ventilation, velocity pressure switches located at the discharge of the pressurisation ventilation fans shall be the preferred device, ‘Running’ signals fron the fan motors shall not be considered acceptable. Written procedures shall always be prepared for Ye-establishing power supplies to pressurised roons following platform shutdown or any shutdown initiated by loss of room pressurisation. When optimising layouts for new projects, enclosed areas containing non certified electrical equipment should be located outside of any external hazardous areas. Where this is not possible means of access to the enclosed area should be from a non hazardous area For enclosed areas located outside of a hazardous are: overpressure ventilation is not a mandatory requirement. Overpressure ventilation systems shall however be installed for enclosed areas which are overlapped by external hazardous areas even should they be considered as normally vapour tight. For additional guidelines on pressurisation ventilation systems for rooms and enclosures in hazardous areas, in particular those associated with control and switchgear rooms, reference is made to NFPA-496 "Purged and pressurised enclosures for electrical equipment". This standard is quoted for reference only and shall not be considered mandatory, the requirements of the Code shall always take precedence. Ventilation Levels Para 6.2 of the code defines open areas as those areas which are basically fully open and where typical air velocities are rarely less than 0.5 m/s and are frequently above 2,0 m/s. As adequacy of ventilation of any facility is dependent on its physical form and the prevailing winds in the area, this section of the code is one in which informed engineering judgement must be used. Typical wind data available for SSB/SSPC operational areas indicates that the wind speed is above 0.5 m/s for approximately 90% of the time and above 2.0 m/s for approximately 65% of the time. It can be seen that the rarely below 0.5 m/s and frequently above 2.0 u/s criteria is satisfied and, in the absence of significant obstructions to airflow, an installation would be classed as ‘open’ in accordance with the Code, under these conditions. ENSoaS AT6.4 Sarawak Shell Berhad Sabah Shell Petroleum Company Limited STANDARD ENGINEERING SPECIFICATION In accordance with the Code and referenced publications, facilities typically encountered in the Chemical and Petroleum industries generally constitute open areas. Offshore and onshore plant consisting of normally spaced vessels, rotating equipment, Pipeways and generally open structures would typically be classified as ‘open’ areas for hazardous area classification purposes. SES 65.1 Rev. & Page 6 Situations may be encountered where significant obstructions to free ventilation exist in areas which would otherwise be classed as open areas. Examples of this are buildings, modules, walls or congested areas of plant which restrict the flow of afr to any given area from two directions. Such obstructions may result in areas of the facility being classified as ‘sheltered’ or ‘enclosed’, with the potential for localised zone 1 and zone 0 areas. Adequacy of ventilation shall be considered at the conceptual stage of any project when layouts are being developed. Areas of potentially inadequate ventilation should be designed out at this stage when layout changes may be effected with minimal cost impact. Should it not be possible to design out such areas, the location of gas release sources in these areas shall be avoided. Adjacent release sources should be located such that their hazardous radius does not overlap the sheltered/enclosed area. The practice of blanket classification of platforms or onshore plants as inadequately ventilated as a conservative measure shall be avoided. Hot Work It 1s permissible under the Code (ref. para 8.4.1) to temporarily reduce the extent and zonal classification of areas normally classified as hazardous for the purpose of carrying out hot work in areas adjacent to live plant which cannot be shut down for the duration of the vork. This temporary reduction in classification is effected by eliminating all primary release sources, providing facilities to rapidly detect secondary releases, avoiding unnecessary ignition sources and being prepared to halt all work on detection of release. It can be seen that whilst hot work would be permissible in the vicinity of launcher/receiver barrels it would not be allowed on the roof area of a floating roof tank or adjacent to an operational vent although the hazardous area classification may be zone 1 in each area.6.5 ‘Sarawak Shell Berhad Sabah Shell Petroleum Company Limited STANDARD ENGINEERING SPECIFICATION The reason for this is that in the case of the launcher/receiver barrels the primary release source can be eliminated by ensuring that no pigging operations are carried out during the hot work and that the barrel is suitably isolated from the process pressure, In the case of an operational vent or the roof area of a floating roof tank this isolation of the primary release source would be impossible whilst the item is in service. Hot work in general shall always be carried out in accordance with the requirements of Company Operating Procedures but for hot work in the vicinity of launchers and receivers the following additional precautions shall be taken to effect a suitable reduction in area classification for the duration of the hotwork. SES 65.1 Rev. 4 Page 7 a. The closure gasket shall be inspected and replaced as necessary and the barrel door closed. All isolation valves on all pressurised lines to the barrel and on the barrel drains shall be closed. If spec. blinds are available on pressurised lines these shall be swung to the closed position. c. If spec. blinds or double block end bleed are not available on pressurised lines the barrel shall be filled with fresh water and pressure tested to a pressure of at least | barg above the pipeline operating pressure to prove the integrity of the barrel door under operating conditions. On satisfactory completion of the pressure test the barrel pressure shall be reduced to atmospheric pressure and any subsequent increases in barrel pressure which may indicate isolation valve leakage shall be carefully monitored. Non Routine Operations It should be noted that under section 4.0 of the code no increase in hazardous radius or zonal classification is deemed necessary for carefully controlled, non routine operations such as drilling, workover and wirelining even when these operations are carried out adjacent to producing wellheads.Sarawak Shell Berhad Sabah Shell Petroleum Company Limited SES 65.1 Rev. & Page 8 STANDARD ENGINEERING SPECIFICATION Furnaces Furnaces and botlers represent a unique situation in that they are at once a primary release source and a continuous source of ignition and yet must be classified as generally non hazardous. Regardless of the fact that any released vapour may be ignited by the burner flame, in order to absolutely minimise the chances of leakage and ignition, the fuel gas supply to the burners shall meet the requirements of para 6.1 of this document. All electrical equipment within the hazardous radius of any flanges or threaded connections in the fuel gas supply shall be suitable for use in the applicable hazardous zone. Should this type of equipment be located in a sheltered area, such as a boiler house, gas detectors shall be provided at suitable locations inside the building. ‘These shall initiate shutdown of all burners and isolate the fuel gas supply at a location outside of the building on high level gas detection. 6.7 Dispersion Calculations It may be necessary for certain non standard situations to determine a hazardous radius by dispersion calculations. This situation may arise should a conservative hazardous radius be required as would be the case, for example, in determining the extent of flammable vapours around a vent stack in the vicinity of helicopter flight paths. In these situations a formal analysis shall be effected using an approved propietary programe such as ‘Plume Path' or 'TECJET’. The horizontal distance to achieve a mixture concentration of 50% LEL maximum shall be used as the basis for the determination of the dous radius to allow for potential inaccuracies inherent in the programmes and input data. For the particular case of hazardous radii on helicopter approach paths determination of the hazardous radius to 20% LEL is recommended. 6.8 Gas Density Code Appendix C discusses the effects of gas buoyancy on the hazardous area around a point source. Whilst the great majority of gases handled within SSB/SSPC are lighter than air (SG below 0.75) this should be carefully checked in all cases. Should there be any doubt then the gas shall be treated as being both heavier and lighter than air. The hazardous area shall be determined by superimposing both the heavier and lighter than air hazardous areas around the point source and basing the final hazardous area on the extremities of the superimposed areas. Bsaoe si‘Sabah Shell Petroleum Company Limited STANDARD ENGINEERING SPECIFICATION ‘Sarawak Shell Berhad DETERMINE FLUID APPENDIX A) NOTE: eraizeonge iwrasciia) ‘CLASS: (2.12.1 10 2.12.5 & CRITERIA EX CHAP. 6 Reterences in parenthesis indicate applicable code clauses API A’ Wi EvenHH Sarawak Shell Berhad ses65.1 ‘Sabah Shell Petroleum Company Limited APPENDIX 2 ‘SHEET 1 OF 1 STANDARD ENGINEERING SPECIFICATION pene WINDSPEED RARELY 0.5 8 FREQUENTLY 22m. NOTE: References in parenthesis indicate applicable code clauses FLOWSHEET FOR VENTILATION CHECK ens aoea evaizenas eran)