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NAO-SPC-D-PF-002
APPROVALS:
Tech Auth:
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Note: This is an existing specification currently being used by Talisman and has not been
technically reviewed or signed off by the Technical Authority at this time. Over time, these specifications will be rebuilt and validated through a specification review process. Please ensure that you use the most current copy of the specs listed on the NAO Portal under Engineering Specifications. The Technical Authority identified on the cover sheet is the point of contact for this specification.
Attention: Paper copies are uncontrolled. This copy is valid only at time of printing, 12/15/2010. The controlled document is available on the Talisman NAO Portal.
Attention: Paper copies are uncontrolled. This copy is valid only at time of printing, 12/15/2010. The controlled document is available on the Talisman NAO Portal.
WorleyParsons
resources & energy
TALISMAN
ENE R G Y
TABLE OF CONTENTS
TABLE OF CONTENTS ...............................................................................................................................111
LIST OF FIGURES .......................................................................................................................................111
1.
INTRODUCTION............................................................................................................................1
ESD VALVES.................................................................................................................................2
2.1
2.
2.2
2.3 2.4
3.
BLOWDOWN VALVES.................................................................................................................. 7
3.1
3.2
LIST OF FIGURES
Figure 1: SCHEMATIC FOR BETTIS PRESSUREGUARD HYDRAULIC ESD SYSTEM ...........................5
EcoNomics
Page iii
1.
INTRODUCTION
This document describes the recommended design standards for emergency shutdown (ESD) valves and blowdown valves for the design of Talisman wellsites and facilities. The section on ESD valves is limited to hydraulic and pneumatic types, as these comprise the vast majority of those used in the Talisman
system.
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2. ESD VALVES
An ESD (emergency shutdown) valve is a valve equipped with a spring return actuator, such that when the actuator pressure signal is released the valve is forced closed by the actuator spring. Generally speaking, ESD valves are quarter turn actuated ball valves, but they can also be sliding stem gate valves or other types, although these are less common. The actuator types considered in this document are hydraulic or pneumatic. The actuator pressure signal can be tripped by a mechanical pilot assembly, a solenoid valve, or a combination of the two.
ESD valves are used to isolate the facilities in emergency situations. For single well tie-ins, a wellhead
ESD valve is usually suffcient. If the well is sour and fed with fuel gas for a line heater, then there should
also be a fuel gas ESD valve to shut off the fuel supply in the event of a line heater building fire. On single well tie-ins, there is generally no need for an outlet ESD valve, as these installations usually are not equipped with auto blowdown valves. Whenever an auto blowdown valve is added to a system, the outlet check valve should be accompanied by an outlet ESD valve.
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The one advantage of hydraulic actuators is that they do not require an instrument operating medium, and can therefore be used at sites that do not have instrument air or fuel gas. Also, the hydraulic fluid is totally impervious to cold temperature. The disadvantage of hydraulic systems is that they are reliant on a perfect seal in the actuator, leak free check valves on the hydraulic pump, and leak-free tubing from the hydraulic pump to the actuator. If a leak develops in a hydraulic system, the actuator spring will push the hydraulic fluid out of the leak, and this leaking hydraulic fluid will cause the valve to "creep" closed. This leak may also be a clean-up issue. Small hydraulic leaks can be managed by having the operators regularly pump the actuator back up to keep the valve open, and mopping up as needed with rags. In a pneumatic system, small leaks are replenished by the pneumatic supply on a continual basis, and the leak does not spill material on the ground. From this standpoint the pneumatic system is superior.
Another advantage of hydraulic systems is that each stroke of the pump handle will move the valve a predictable few degrees, and on smaller systems the hydraulic ESD valve would not require a car sealed closed bypass. The same can not be said of pneumatic ESD valves. Generally speaking, pneumatic ESD valve's should have a bypass to equalize the pressure across the valve prior to opening, unless the system is small and there is a means of throttling flow elsewhere on the piping system.
Page 3
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these types would be less prone to erosion damage from sand that may come up hole. Port sizes on
other ESD valves would match what one would use on manual isolation valves on the same line. For example, if it is acceptable to use a reduced port ball valve for a manual isolation valve on a line, then the ESD valve would also be a regular port valve. In some cases, such as larger piping systems, it may be acceptable to reduce down to the next line size for the valve, but in this case the process engineer should check flowing fluid velocities and ensure that a reduced size will be acceptable.
The pressure rating of the valve matches the highest line classification that the valve is connected to. The actuator sizing is done by Instrumentation, but the process engineer should check to ensure that the maximum differential pressure used for sizing the actuator matches the full cold flange rating of the highest pipe classification. This ensures that the ESD valve can be re-used for any application that matches the pipe classification when the facility is abandoned or modified.
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3.
BLOWDOWN VALVES
Blowdown valves are fail-open valves that allow the piping system to be de-pressured in an emergency condition. The actuator on the valve is usually a pneumatic actuator, tripped by either a pneumatic pilot or a solenoid valve. The trip device (pneumatic pilot or solenoid valve) is configured such that loss of signal to the device will vent the blowdown valve actuator, causing the valve to go to its fail position.
The valve is usually a control valve, although an actuated ball valve can be used. The advantage of using a control valve is that the blowdown rate can be accurately predicted based on the wide open flow coefficients as published by the valve manufacturer. If a ball valve is used as a blowdown valve, a
restriction orifice should be installed between the downstream valve flange and the pipe flange to
create a predictable flow through the valve.
For example, consider a simple compressor installation consisting of an inlet ESD valve, an inlet control valve, a separator, a compressor package, and an outlet ESD valve. Let's say that the compressor package is equipped with an auto blowdown valve. However, it is located upstream of the unit check valve, and would therefore not serve to de-pressure the piping from the unit check valve to the outlet ESD valve. This would mean it would be necessary to add an auto blowdown valve to the piping between the unit check valve and the outlet ESD valve. Under normal operation, when the compressor is running, these two blowdown valves would serve to depressure all piping between the inlet and outlet ESD valve's. However, let's say the compressor package can be double block and bleed isolated from the separator in order to perform maintenance. (The idea is to save the gas in the separator, so it is not blown down during maintenance.) Now if an ESD condition arose during the time when the compressor was isolated for maintenance, the two blowdown valves mentioned above (one in the compressor package, the other on the outlet line upstream of the outlet ESD valve) would not be able to blow down the site as needed, so another blowdown valve would be added to the separator package to blow it down.
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3.2.1
During an ESD event, one assumes that all of the blowdown valves open at the same instant in time. The peak flow to flare can be modeled using Aspen Flare System Analizer (formerly Flarenet), and the flow specified for each blowdown valve would correspond to the wide open flow capacity of the blowdown valve at the maximum system operating pressure. This creates a large initial peak flow rate to flare, which must be within the allowable flow capacity of the flare system. In some cases, with existing flare systems, it may be necessary to stage the opening of blowdown valves or installing travels stops to limit the maximum opening of the blowdown valve in order to limit the instantaneous rate such that the peak capacity of the existing flare system capacity is not exceeded. Another consideration is that the blowdown valve on a separator or other vessel should not exceed the maximum gas capacity of the
separator or vesseL.
Most of Talisman's newer compressor packages are equipped with electronic control panels that automatically open the compressor recycle valve on unit shut down. This creates a condition where the pressure in the compressor system settles out to an average pressure that is higher than normal suction pressure, but substantially lower than the normal discharge pressure. This would in turn result in much lower pressure at the inlet of the compressor blowdown valve, and hence much less flow. However, for the purposes of calculating the initial peak flow rate to flare, this settle-out phenomenon should be ignored, as we can't guarantee that the recycle valve opens quicker than the blowdown valve.
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3.2.2
Time to Blowdown
The other design parameter regarding blowdown valve sizing is time to blowdown. The standard for blowdown time is to follow API STD521, which indicates "de-pressured rate to achieve 100 psig or 50 percent of vessel design pressure, whichever is lower, in 15 minutes or less".
The time to blowdown from a given pressure can be estimated using the spreadsheet "IBU-TLM-CLCEM-PE-003 Depressuring Time.xls located at SharePoint\Prime Operating Manual\Standard Calculations\Engineering Management - Process. Note that this spreadsheet includes a feature whereby the valve percent open can be specified. In most cases this would be 100 percent. In some cases, the blowdown rate must be limited by the use of actuator travel stops, which limit the opening of the valve by the setting of the stop. If possible, the system should be designed without travel stops. Travel stops introduce a possibility of operator intervention such that the capacity of the system would be exceeded, and also add cost. A valve with a certain orifice size is much more difficult to tamper with and from this standpoint is more desirable in order to ensure that we don't exceed flare capacity.
For purposes of estimating the blowdown time (NOT FOR DETERMINING THE PEAK RATE OF THE VALVE), the settle out pressure should be used as valve inlet pressure in a compressor situation
(provided it is certain that the recycle valve opens on compressor shut down). This is because the time required to open both the blowdown valve and the recycle valve is small in relation to the time needed to
de-pressure.
The other pertinent parameter to specify for using this spread sheet is the system volume. For purposes of estimating blowdown times, assume that any separators or scrubbers are empty. This would give a conservative blowdown time, as any liquid would reduce the volume of gas present. Piping volumes can be estimated by estimating total length from the piping GA's or plot plan. If the project is being done in Autoplant, the piping designer can provide an accurate estimate of piping lengths by line number. Useful spreadsheets for determining the vessel volumes are:
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