SOUTH PARS GAS FIELD DEVELOPMENT PHASE - 1 SADRA-SAMSUNG CONSORTIUM

CONSTRUCTION OF OFFSHORE PLATFORM

TOPSIDES & FACILITIES
N.I.O.C. Petropars Ltd Heavy industries SADRA

DOCUMENT TITLE DOCUMENT NO.

Proj. Fac. Area Dis. Doc. Seq. Rev.
HAZOP REPORT
SP1-220 0000 00 SA RT 106 D1 Page: 1

HAZOP REPORT

RUNNY
D1 26.07.00 T.G.ONG K.S. HOE ISSUED FOR APPROVAL
POH
RUNNY
D0 02.06.00 SREDHARAN K.S. HOE ISSUED FOR IFR
POH
Prepared Checked Approved Approved Approved
Rev. Date DESCRIPTION
TECHNIP SADRA/SAMSUNG COMPANY

507329026.doc
1.0 MANAGEMENT SUMMARY

This Hazard and Operability study (HAZOP) conducted during the period April
24 – May 12, 2000 on the proposed South Pars Gas Platform was for the purpose
of identifying any safety and operability issues that may arise. The HAZOP was
carried out with representation from the project team viz., Technip Geoproduction
(TPGM), Sadra–Samsung (SSC) and Petropars (PPL) for the system process.

No major issues were encountered. Most of the findings were basically for
improvement of operations. Redundant equipment/valves were proposed for
deletion.

Overall the facilities have been designed to meet the specification and should be
operable subject to the proper implementation in fabrication and commissioning.

Other systems that were not available will be studied at a later date. These are
mainly the vendor supplied items/systems.

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2.0 INTRODUCTION

The new installation is for the production of gas from the South Pars Gas Field
Development Phase 1 which is to be supplied to the onshore gas processing plant.

The gas platform is part of the total development of the South Pars Gas field.

This Hazard and Operability (HAZOP) study is commissioned by Technip

Geoproduction as part of the design for the platform facilities. Through the
rigorous process, it :

- identifies potential hazards related to the system,

- determines the operability of each facility as designed and
- makes recommendations to eliminate or mitigate the hazards and where
appropriate simplify or improve design and the operations.

Whilst the experiences of the study team will, in most instances, be adequate for a
pragmatic and appropriate response to an identified concern, the decision to
implement requires confirmation and acceptance by the project’s design team with
endorsement from Company. However, any decision to the contrary must be
recorded to enable the establishment of an audit trail on the decision process and
also in the final hand-over to the operator of the facility.

The worksheets in APPENDIX I is a record of the process.

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3.0 PROJECT OUTLINE

The South Pars Gas Field Development Phase 1 Project has been identified for the
exploitation of a gas and condensate reservoir located in the Persian Gulf. The
scope of the project includes both offshore and onshore installations. This
philosophy concerns only the offshore facilities, which will be capable of
producing, processing and transporting to the mainland 1000 MMSCFD of dry
reservoir fluid.

The offshore complex will be located at approximately 100 km from the Iranian
coast, in water depths ranging from 60m to 70m. The purpose of the offshore
facilities is to produce and process the reservoir fluids to enable their
transportation by a single pipeline.

Design Basis

The key process design parameters are as follows:

Satellite and Wellhead Platform Max. Flowrate 600 MMSCFD(each)

Production Platform Max. Flowrate 1000 MMSCFD
Maximum Flowrate for each Slug Catcher, and 600 MMSCFD
Condensate Train.
Maximum flowrate for Each Gas Train 500 MMSCFD
Turndown for normal operation 200 MMSCFD (based on
40% turndown from 500
MMSCFD)
Maximum Formation Water Flowrate per 1000 BPD
Wellhead Platform
(Maximum flowrate for each Produced Water Train
will include associated condensed saturation water and 0.2% volume oil max.)

Capacity of each Test Separator Max.: 120 MMSCFD (gas)

1000 BPD (water)
Min.: 30 MMSCFD

Overview of Process Platforms

The complex consists of five platforms as described below:

 A Wellhead Platform (SPD-1) located adjacent to the Central Production

Platform with 16 well slots, producing up to 600 MMSCFD.
 A Satellite Platform (SPD2) located 5 km from the Central Production
Platform and connected to it via an infield pipeline. It has 16 well slots and
produces up to 600 MMSCFD.
 A Central Production Platform (SPP-1) accommodating the equipment
required to process the reservoir fluids coming from the Wellhead and
Satellite Platforms.
 An Accommodation Platform (SPQ-1).

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South Pars Gas Platform - HAZOP Study 5

 A Flare Platform (SPF-1).

3.1 Process Description

Overall Flow Scheme

The facilities are designed to allow free flow of well fluids from the wellheads to
the Refinery without any requirement for compression or pumping. Most of the
pressure reduction from wellhead flowing pressure to the export pipeline
operating pressure will be taken across the wellhead choke valves. Additional
pressure drops will be taken across the pressure control valves on the Central
Production Platform as well as frictional losses through the system.

The Central Production Platform will dehydrate the gas and dewater the
condensate such that the amount of water vapour in the mixture is sufficiently
below the saturation point at pipeline conditions to allow the use of carbon steel
export pipeline.

Wellhead Platform (SPD-1)

The Wellhead Platform will have sixteen slots and it is currently envisaged to
have five wellheads installed. The wellheads have an initial flowing pressure of
207 barg which will reduce to approximately 110 barg over the 25 years design
life. The pressure of the well fluids will be dropped across the choke valves to the
system pressure of 110.4 to 97.4 barg.

The wells are located in two well bays. Each well bay will have separate Test and
Production Manifolds.

The well fluids can be directed either to the dedicated Production or Test
Manifolds by motorised valves. The production manifolds route the well fluids to
the Slug Catcher in either train with or without being mixed with the Satellite
Platform fluids. The test manifolds route fluids to the Test Separator. These
separator vessels are located on the Central Production Platform.

Facilities are provided to inject methanol upstream of the choke valves during
well start-up, to prevent hydrate formation. The space between the surface
controlled sub-surface safety valve (SCSSV) and choke valve will be depressured
and filled with methanol for SCSSV pressure equalisation prior to well start up.

The Satellite Platform (SPD-2) has similar facilities as SPD-1 with exception of
the test separator, vent /flare boom and the Pig Launcher, which is required for
well testing and intelligent pigging of the infield pipeline.

Central Production Platform (SPP-1)

The fluids from the Wellhead Platform and Satellite Platform are routed to a
manifold, which enables production from either platform to be routed to each

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processing train. The processing trains are identical and interchangeable. Each
train consists of:

Primary Separation/Cooling
Gas Dehydration
Condensate Dewatering

Primary Separation/Cooling

Well fluids from the Wellhead Platform (SPD-1) are piped to the Slug Catcher,
which separates the produced water and condensate from the gas and provides a
hold-up volume for slugs. Condensate is removed from the Slug Catcher under
level control and flows via Condensate Cooler to the Condensate Dewatering
System. The Condensate Cooler is designed to cool the production from the
wellhead Platform to 45 oC in Summer. A temperature control valve located at the
condensate bypass across the Condensate Cooler operates under temperature
control to ensure that the temperature of the condensate flowing forward for
treatment is maintained above a minimum of 25 C. This provides a margin of 8
C above the hydrate formation temperature. On failing to do so due to low well
fluid flowrate, the exchanger can be isolated for full bypass.

Produced water from Slug Catcher is removed under interface level control and
routed to the Produced Water Treatment System for de-oiling.

Vapour from the Slug Catcher is routed to the Gas Cooler. A crossover between
the two trains is provided upstream of the coolers to allow flow-balancing
between the trains. The parallel Gas Coolers are sized to cool the production from
the Wellhead Platform to 45 C in Summer. Lower seawater temperatures in
winter or operation on satellite well fluids will allow lower temperatures to be
achieved which will minimise the load on the dehydration unit. A temperature
control valve located at the gas bypass across the Gas Coolers operates under
temperature control to ensure that the temperature of the gas is maintained above a
minimum of 25 C. This provides a margin of 5 C above the hydrate formation
temperature. During low seawater temperature in winter and low gas production,
one or both of the parallel exchangers can be bypassed.

Gas Dehydration Trains

Cooled gas from the Gas Coolers flows to the Dehydration Inlet Separator where
any liquid droplets produced by cooling the gas are removed. The Dehydration
Inlet Separator is fitted with proprietary internals to ensure a high efficiency of
liquid disentrainment from the gas, which then flows to the Glycol Contactor. The
Glycol Contactor includes an integral separator to reduce liquid carry-over into
the contactor section. This also minimises salt contamination of the glycol from
the produced water. Liquids are removed from the separators under level control
and are routed to the Condensate Dewatering System. Dehydration is
accomplished by contacting the gas with lean Triethylene Glycol (TEG). The lean
TEG entering the top of the contactor will be maintained at a temperature above
that of the gas to prevent hydrocarbon condensation in the contactor. The water

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rich TEG is collected on the chimney tray and is sent to the Glycol Regeneration
Package where the water is stripped from the TEG so it can be reused.

The column operates at a pressure of approximately 109 barg (year 1 condition).

The pressure in the contactor is controlled by a pressure controller on a pressure
control valve downstream of the contactor. Downstream of the pressure control
valve the gas is combined with the offgas from the Condensate Processing Train
and metered. The metering is used for flow control of the wells. Downstream of
the gas metering, the gas streams from trains 1 and 2 are combined with the
dewatered condensate streams from trains 1 and 2.

A connection from the contactor to flare is located upstream of the pressure

control valve to allow venting to the HP flare during start-up. Start-up flaring will
be at a rate of up to 200 MMSCFD per train, however the total start-up flaring rate
to the HP flare must not exceed 200 MMSCFD. A methanol injection point will
be located upstream of the flare valve for hydrate inhibition.

Liquid Handling Facilities

Condensate from the Slug Catcher and liquids from the separators in each gas
train are discharged under level control to the Condensate Dewatering Train.
Recovered oil from the drains system may also be pumped to the inlet of either
Condensate Dewatering Train. The Condensate Dewatering Train consists of a
Condensate Dewatering Vessel and a Condensate Coalescer. The Dewatering
Vessel provides bulk dewatering of the condensate and separates off any flash gas.
The flash gas is combined with dried gas upstream of gas metering. The water
content of the gas is sufficiently small not to require dehydrating. Dry gas off the
Contactor Tower is routed to the Condensate Dewatering Vessel as blanket gas.
Overcooling of the condensate in the Condensate Cooler will depress the liquid
vapour pressure below that of the required pipeline export pressure.

In order to achieve dewatering down to 40 ppm water in the condensate, the

Condensate Coalescer operates as a two phase separator. To achieve two phase
operation i.e. prevent formation of gas, the vessel is located beneath the
Condensate Dewatering Vessel and pressure drop across the coalescing media is
restricted to 0.1 bar. Water removed in the Condensate Dewatering Trains flows
under level control to the Produced Water Treatment packages. The dewatered
condensate flows to the export pipeline and is combined with the gas. The need
for pumps in this system is obviated by choking the gas flow.

Corrosion Inhibitor Injection

Corrosion inhibitor is injected by the Corrosion Inhibitor Pumps into the

condensate upstream of the export pipeline to protect against corrosion in the
condensate line due to the possibility of water dropout when the line is stagnant.
The corrosion inhibitor will also protect the export pipeline should any free water
collected as a result of inadequate mixing with the dehydrated gas or upset
conditions in the gas dehydration and condensate separation.

Export Facilities

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The Export Pig Launcher enables pigging of the export pipeline. The launcher is
to be sized for either intelligent pigs or spheres. The facilities for receiving pigs
and spheres and liquid slugs will be provided at the Refinery. Pigging is not
proposed for dispersal of corrosion inhibitor, or for routine removal of liquids
from the pipeline.

Produced Water System

Design Basis

No. of Trains 2 x 50% Capacity

Inlet Flowrate Normal 9.1 m3/hr per Produced Water Train
Max. 10.2 m3/hr per Produced Water Train
Inlet Oil in Water 0.2 % vol.
Inlet CO2 concentration 830 ppm (mol)
Inlet H2S concentration 775 ppm (mol)
Outlet Oil in Water 15 ppm excluding dissolved hydrocarbons
Outlet H2S in Water 400 ppm

Process Description

Two 50 % trains of Produced Water Treatment are provided. The produced water
from each Process Train will flow to a dedicated water treatment train. The
following system description gives an overview of the system.

Produced water is removed from the Slug Catcher, Test Separator, Condensate
De-watering Vessel and Condensate Coalescer under level control and flows to
the Produced Water Collection Drum. The Collection Drum operates at
approximately 1 bar below the Condensate Coalescer pressure. The operating
pressure of the Collection Drum pressure is maximised in order to avoid shearing
of droplets in the level control valves and reduce the potential for the formation of
stable emulsions. Any flash gas from the high-pressure drum is routed to the HP
flare system. The drum acts as a three phase separator to i) remove bulk
condensate and ii) protect the hydrocyclones from slugs of condensate in the event
of level control upsets in the process separators. The condensate is routed to the
Oily Water Degassing Vessel. The water is routed to the Hydrocyclone vessel.

The Hydrocyclone Vessel is a pressure vessel which contains a number of

hydrocyclone bundles. The hydrocyclones are shaped so as to form a vortex with a
reverse flowing core. The denser fluid (produced water) moves to the walls of the
hydrocyclone and is removed at the downstream fluid outlet (underflow). The less
dense fluid (hydrocarbon) is drawn into the low pressure core and is removed at
the upstream outlet orifice (overflow). The underflow is expected to contain
approximately 40 ppm oil in water. The overflow is expected to contain
approximately 7 % oil in water.

The underflow is let down in pressure and flows to the Produced Water Flash
Drum where the water is degassed. The gas is routed to the LP flare. The flash
drum will be fitted with a weir to allow three-phase separation, although little

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condensate is expected to be removed from this vessel. The water will be passed
under level control through the Produced Water Filter Coalescer to ensure
removal of oil to less than 15 ppm, before discharge to the Produced Water
Caisson. Separated oil will be removed from the Filter Coalescer under on/off
level control and will flow to the Oily Water Separator.

The overflow from the Hydrocyclone Vessel is passed to the Oily Water
Degassing Vessel for degassing of the oil/water before it flows to the Oily Water
Separator. The flash gas is sent to the LP flare.

The produced water contains 400 ppm of dissolved H2S. As the pressure is
reduced through the hydrocyclone package part of the H2S flashes out of solution,
leaving dissolved H2S concentration of approximately 300 ppm. However, the
proposed design is based on disposal of H2S by dispersal from the Produced
Water Caisson. The produced water caisson will discharge at a depth of 32.5m
below LAT. The Produced Water Flash Drum is provided with a nitrogen sparge
pipe to enable reduction of H2S content in the produced water by stripping with
nitrogen if necessary.

The produced water leaving the Filter Coalescer (last stage of treatment) will be
discharged into the Produced Water Caisson via a submerged dip pipe and will
exit the pipe through a reduced bore outlet to increase the discharge velocity and
aid dispersion. Produced Water Flash Drum will be operated at an adequate
pressure to provide sufficient driving force for the required discharge conditions
from the submerged dip pipe.

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4.0 HAZOP STUDY SCOPE AND METHODOLOGY

4.1 Scope of Study

The objectives of the HAZOP study were to:

1. Review the process design for the various facilities consisting of the
wellhead platform facilities, well test separators, slug catcher, gas coolers,
condensate coolers, glycol contactor towers, glycol regenerators, produced
water treatment facilities, seawater intake system, diesel system, fuel gas
system, methanol injection system, pressurised air system, nitrogen system
and firewater system to identify potential hazards and operability problems.

2. Offer recommendations to eliminate or mitigate the identified problems, and

to identify areas that need to be investigated further.

4.2 Methodology

A hazard and operability study (HAZOP) is a formal systematic procedure used to

review the design and operation of potential hazardous process systems. It is used to
identify deviations from the design intent that could lead to hazards or operability
problems, and to define any actions necessary to eliminate or mitigate these.

The study is conducted through a detailed line by line review of the Piping and
Instrumentation Diagrams. Supplementary documentation, such as cause and effect
matrix, layout drawing, etc. are used for reference where available.

The study is performed by a team of people who are familiar with the design and
operation of the proposed actual facility, or similar facilities. The team worked
under the guidance of a leader who is experienced in the use of the HAZOP
methodology.

The method involves several repetitive steps:

1. Identify a section of the process on the P&ID, typically a line.

2. Define the design intent and normal operating conditions of this section.

3. Identify a deviation from design intent or operating conditions by applying

guidewords (see below).

4. Identify possible causes for, and consequences of, the deviation. A deviation
can be considered "meaningful" if it has a credible cause and can result in
harmful consequences.

5. For a meaningful deviation, decide what action, if any is necessary.

6. Record the discussion and recommendation.

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Steps 3 to 6 are repeated until all the guidewords have been exhausted and the team
is satisfied that all significant deviations have been considered. The team then goes
back to Step 1 and repeats the procedure for the next section of the process.

4.3 Guide Words

As mentioned in the previous section, a system of guidewords is normally used to

prompt creative thinking and assist the team in identifying possible deviation. The
guidewords used for this study are listed below.

NO/REVERSE/MORE/LESS FLOW
MORE/LESS PRESSURE
MORE/LESS TEMPERATURE
MORE/LESS LEVEL
OPERABILITY
RELIEF
INSTRUMENTATION
SAMPLING
CORROSION/EROSION
SERVICE FAILURE
MAINTENANCE
SAFETY
ENVIRONMENT

4.4 Documents Studied

The study was conducted by detailed line by line and vessel/tankage review as
shown in the P&IDs. The P&IDs HAZOP'd are those relating to the South Pars Gas
processing facilities to be installed at the offshore platform. The Rev. D2 P&ID's are
attached in Appendix 2.

4.5 Records and Follow-up

Recording was basically "by exception"; i.e. only those issues that the team decided
require action were recorded. In instances where the team lacked the necessary
knowledge or information to make a recommendation, a request was made for
further study/investigation.

The records were entered directly into a computer using the HAZOP recording
programme.

A complete set of logsheets describing all identified problems and corresponding

recommendations are included in Appendix I.

After the formal Hazop, members of the Hazop team representing PPL, SSC and
TPGM met and agreed on a classification system shown in Attachment A.

The primary responsibility for the follow-up rests with SSC who will prioritize and
delegate actions as required. It is recommended that the blank "STATUS" column

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on the log sheets or a separate "action sheet" be used to document the outcome of
each recommendation, with references to supplementary documents as required.
Action review meetings should be held to ensure that each concern is resolved
satisfactorily.

4.6 The Team

The team members were:

Sredharan Snr. Project Engineer (TPGM)

A. K. Sharma Snr. Process Engineer (TPGM)
Azhar Hamzah Snr. Process Engineer (TPGM)
Phil Conroy Safety Engineer (Petropars)
Wong Mee Sing Snr. Process Engineer (Petropars)
J. U. Yeo Engineering Manager (Sadra-Samsung)
M. Ghazizadeh Piping Engineer (Sadra-Samsung)
K. P. Singh Piping Engineer (Sadra-Samsung)
A. K. Koushanfar Process Engineer (Sadra-Samsung)
P. Bala Brahmam Process Engineer (Sadra-Samsung)
Chow Yan Ping Deputy Project Manager (TPGM)
K. P. Loo Process Engineer (TPGM)
M. Kasaeian Deputy Engineering Manager (Sadra-Samsung)
Yohan Rew Mechanical Engineer (Sadra-Samsung)
T. Monzavi Mechanical/Fire & Safety Engineer (Sadra-Samsung)
Shahbazi-Karim Process Engineer (Sadra-Samsung)
Runny Poh Hazop Leader (Rayvonne)
Zuraida Wong Scribe (TPGM)

5.0 RESULTS

The results are presented in tabulation form in Appendix II.

6.0 CONCLUSION

The findings are those of the team members and are meant for the improvement of
safety and or operability

The HAZOP study was conducted based on the drawings provided and findings
were based on the design as is. A number of changes have been identified for the
improvement of the system and these needs to be incorporated in the revised
drawings. The safe operation of the facilities will depend on the final design and a
review of the revised system would be required in order to ascertain that the
changes are in order.

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The vendor supplied facilities were not HAZOPed at this session as the drawings
were not available as yet. These will be done at a later stage when the vendor
drawings are available. The facilities for the gas processing were found to be
adequate to meet the intended design with certain improvements mentioned in the
main report either to improve on the safety or operability of the facilities.

Some control systems were considered for removal to ensure that the operators do
not over look the facility as it is intended for manual operation.

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ATTACHMENT A

RECOMMENDATION TABULATION

Classification Legend:

Category S = Safety
O = Operability
M = Maintenance

Implementation Y = Yes
N = No
H = Hold
L = Later

Ranking R1 = Highest Priority

R2 = Lower Priority

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