NORSOK STANDARD

COMMON REQUIREMENTS

PROCESS DESIGN

P-CR-001 Rev. 2, September 1996

Process Design

P-CR-001 Rev. 2, September 1996

CONTENTS
1 FOREWORD 2 SCOPE 3 NORMATIVE REFERENCES 4 DEFINITIONS AND ABBREVIATIONS 4.1 Definitions 4.2 Abbreviations 5 DESIGN PRESSURE AND TEMPERATURE 5.1 Design Pressure Criteria 5.2 Design Temperature 5.3 Temperature and Pressure Protection 6 LINE SIZING CRITERIA 6.1 Design Basis 6.2 Sizing of Liquid Lines 6.3 Sizing of Gas Lines 6.4 Sizing of Gas/Liquid Two-or Multi-Phase Lines 6.5 Sizing of Gas Relief Lines 6.6 Maximum allowable velocities due to reaction forces 7 SYSTEM AND EQUIPMENT ISOLATION 7.1 System and Equipment Isolation 7.2 Connections to Vents and Drains 7.3 Isolation Devices 8 INSULATION AND HEAT TRACING OF PIPING AND EQUIPMENT 8.1 Insulation and Heat Tracing Requirements ANNEX A: FIGURES (NORMATIVE) 2 2 2 3 3 5 5 5 7 8 8 9 9 13 14 15 16 16 16 17 19 20 20 23

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FOREWORD
NORSOK (The competitive standing of the Norwegian offshore sector) is the industry initiative to add value, reduce cost and lead time and remove unnecessary activities in offshore field developments and operations. The NORSOK standards are developed by the Norwegian petroleum industry as a part of the NORSOK initiative and are jointly issued by OLF (The Norwegian Oil Industry Association) and TBL (Federation of Norwegian Engineering Industries). NORSOK standards are administered by NTS (Norwegian Technology Standards Institution). The purpose of this industry standard is to replace the individual oil company specifications for use in existing and future petroleum industry developments, subject to the individual company's review and application. The NORSOK standards make extensive references to international standards. Where relevant, the contents of this standard will be used to provide input to the international standardization process. Subject to implementation into international standards, this NORSOK standard will be withdrawn. Annex A is normative.

SCOPE
The scope of this standard is to provide requirements for the following aspects of topside process piping and equipment design on offshore production facilities: Design Pressure and Temperature. Line Sizing. System and Equipment Isolation. Insulation and Heat Tracing. These criteria are applicable for all process, process support, utility and drilling systems. The design pressure and temperature criterias are mainly based on API 521 and line sizing criterias on API RP 14E.

NORMATIVE REFERENCES
ANSI B31.3 API RP 14 E Chemical Plant and Petroleum Refinery Piping Recommended Practice for Design and Installation of Offshore Production Platform Piping Systems. (Will be covered in the new ISO standard 13703 which is now in preparation. When issued, the ISO standard will replace API RP 14E as a guideline for calculation methods, etc.) Guide for Pressure-Relieving and Depressuring Systems. Salt water piping systems in ships

API 521 BS MA 18

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P-CR-001 Rev. 2, September 1996 Recommended Practice for Analysis, Design, Installation and Testing of Basic Surface Systems for Offshore Production Platforms. Replaces API RP 14 C Piping and valves Life cycle cost for systems and equipment Piping and equipment insulation Technical safety Working environment Environmental care

ISO 10418

NORSOK L-CR-001 NORSOK O-CR-001 NORSOK R-CR-004 NORSOK S-DP-001 NORSOK S-DP-002 NORSOK S-DP-003

4
4.1

DEFINITIONS AND ABBREVIATIONS

Definitions Operating pressure The pressure in the equipment when the plant operates at steady state condition, subject to normal variation in operating parameters. The maximum pressure predicted for deviations from normal operations, like start-up/shutdown, process flexibility, control requirements and process upsets. The minimum pressure predicted for deviations from normal operations, like process start-up and shutdown. The maximum internal or external pressure to be used in determining the minimum permissible wall thickness of equipment and piping. Note that the minimum permissible wall thickness may be derived from a lower operating pressure, but higher operating temperature. The first relief valve is normally set to open at design pressure. The temperature in the equipment when the plant operates at steady state condition, subject to normal variation in operating parameters.

Maximum operating pressure

Minimum operating pressure Design pressure

Operating temperature

Maximum operating temperature The maximum temperature in the equipment when the plant operate at unstable conditions, like startup/shutdown, control requirements, process flexibility and process upsets. Minimum operating temperature The minimum temperature in the equipment when the plant operate at unstable conditions, like start-up, shutdown and depressurizing. The material temperature representing the most severe condition of coincident pressure and temperature.The Page 3 of 26

Maximum design temperature

NORSOK Standard

Process Design

P-CR-001 Rev. 2, September 1996 design temperature shall encompass the maximum operating temperature.

Minimum design temperature

The minimum temperature which serves as a base for specifying the low temperature characteristics of the material. The design temperature shall encompass the minimum operating temperature. Use of a material with a low conductivity applied to equipment and piping in order to prevent energy flow (i.e. heat, noise). Use of heat from electrical cables for heat conservation or frost protection. Use of insulation and heat tracing, or insulation only, for frost protection. Isolation means a physical barrier (blind) or a tested barrier Two barriers with a bleed between the barriers. Typical arrangement is two block valves with a bleed valve in the middle. One isolation and a bleed. The point to be isolated can be bled down by the bleeder, but there is only one barrier against the pressure side (e.g. a valve). Shall is an absolute requirement which shall be followed strictly in order to conform with the standard. Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable. May indicates a course of action that is permissible within the limits of the standard (a permission). Can requirements are conditional and indicates a possibility open to the user of the standard.

Insulation

Heat tracing Winterization Isolation Double Block & Bleed

Single Block & Bleed

Shall Should

May Can

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4.2

Abbreviations HP LC LO LP NPSH PSV High Pressure Locked Closed Locked Open Low Pressure Net Positive Suction Head Pressure Safety Valve

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5.1 5.1.1

DESIGN PRESSURE AND TEMPERATURE

Design Pressure Criteria Design Pressure The design pressure shall be calculated using the following procedures: For pressurised equipment, the criteria in table 1 shall be applied. Table 1 Design pressure criteria. Maximum operating pressure (barg) 0-35 35-70 70-200 200 Design pressure (barg) Maximum operating pressure +3.5 bar Maximum operating pressure +10% Maximum operating pressure +8.5% but minimum 7 bar and maximum 10 bar Maximum operating pressure + 5%

Consider whether the design pressure as calculated according to table 1, may be set equal the nearest piping specification limit. To minimise the requirements for process relief (full flow), the design pressure should be kept identical for systems with almost identical operating pressures. The design pressure at the discharge of positive displacement pumps shall be calculated in accordance with table 1. Equipment not protected by PSV or rupture disc and located downstream of a pump or a compressor shall be designed for the shut-in pressure. The design pressure for an injection pump shall, as a minimum, be the same as for the system into which it injects. For flare knock out drums, it is acceptable that the design pressure is equal to the maximum operating pressure.

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Square or rectangular storage tanks operating at atmospheric pressure, shall be designed for an over-pressure of 0.07 bar. To give mechanical strength to the side and bottom plates, the liquid static pressure of a liquid filled vessel shall be added to the quoted pressure of 0.07 bar. Equipment where condensing vapours (e.g. after steamout of vessels), drainage or pump out may lead to less than atmospheric pressure, shall be designed for full vacuum or protected by vacuum relief, except for vessels where the design requirements for equipment operating below atmospheric pressure shall be used. Table 2 Design pressure for equipment operating below atmospheric pressure. Minimum operating pressure 0.35 bara and below 0.35 - 1.00 bara Design pressure full vacuum(FV) the minimum operating pressure minus 0.1 bar, but maximum 0.5 bara

Equipment operating below atmospheric pressure shall also withstand an over-pressure of 3.5 bar (3.5 barg). 5.1.2 Maximum operating pressure Maximum operating pressure for vessels is defined as follows: Separators; the highest pressure resulting in a trip. Compression suction scrubber and coolers; settle-out pressure. The maximum operating pressure may be limited by installation of full flow pressure safety valves (PSVs). When full flow pressure safety valves (PSVs) are not installed, then: The maximum operating pressure (shut-in pressure) for compressors should, when accurate information is unavailable, be determined as: Maximum operating suction pressure +1.3 times the normal differential pressure developed by the compressor. For multi-stage compressors, the maximum operating pressure (shut-in pressure) for each stage should be calculated for the worst operating condition, i.e. all upstream stages at minimum flow and maximum operating pressure (shut-in pressure). The pressure rise at minimum flow is set at 1.3 times the normal differential pressure developed by the compressor, when accurate information is unavailable. The maximum operating pressure (shut-in pressure) for centrifugal pumps should, when accurate information is unavailable, be determined by choosing the greater of the two following criteria: Operating suction pressure +1.25 times the normal differential pressure developed by the pump. Maximum suction pressure at relieving conditions plus the normal differential pressure developed by the pump. NORSOK Standard Page 6 of 26

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Care should be taken not to define higher pressure than required when it affects the selection of material and pressure class rating. 5.1.3 Piping The design pressure of a piping system comprising pipes, fittings, flanges and valves shall be according to NORSOK Standard L-CR-001. Static head, friction loss and surge pressures shall be taken into consideration. Occational variation above design according to ASME B 31.3 should be evaluated where total cost can be significantly reduced. 5.2 5.2.1 Design Temperature Maximum design temperature Where the maximum operating temperature can be calculated accurately, this temperature shall be used as design temperature, without adding a safety margin. Where the maximum operating temperature can not be calculated accurately, the design temperature is normally determined by adding 30C to the operating temperature. For equipment operating at ambient conditions, the maximum design temperature is 50C. For seawater supply systems where the maximum operating temperature is defined by the seawater yearly variations, the maximum operating temperature is defined as 10 above the seawater supply operating temperature chosen for design. For maximum operating temperature of seawater discharge to sea, reference is made to NORSOK Standard S-DP-003. The operating temperature on a compressor discharge is defined as 15C above the predicted design point temperature to allow for lower efficiency at compressor minimum flow conditions. Compressor suction scrubber maximum design temperatures are defined as the higher of the following: Maximum operating temperature at the compressor suction in the event of cooling medium failure. Maximum operating temperature can be limited by a high temperature shutdown function. Maximum recycle temperature (maximum discharge minus Joule Thompson drop across anti-surge valve) in the event of cooling medium failure. Maximum temperature due to settle out conditions. Operating temperature plus 30C. For all heat exchangers, both sides shall have a maximum design temperature determined by the hottest fluid.

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Vessels and instruments subject to steam-out shall be designed to meet pressure and temperature during steam-out operation. 5.2.2 Minimum design temperature The minimum design temperature shall be the more stringent of the following: Operating temperature (obtained during normal operation, start-up, shutdown or process upsets) with a margin of 5C. Minimum ambient temperature. Minimum temperature occurring during depressurizing from settle-out pressure and subsequent cooling to ambient temperature. Pressure reduction due to cooling before depressurisation shall be included. If calculations results in unacceptable values, operational procedures may be included for only partial depressurisation of equipments or start of depressurization at higher temperature. Minimum temperature occuring during depressurising from settle-out pressure and temperature with a margin of 5C. The depressurisation calculations shall as a minimum include heat transfer between fluid and vessel. 5.3 Temperature and Pressure Protection Protection of equipment and piping against pressure and temperature beyond those values designed for, shall for hydrocarbon systems be according to ISO 10418.

LINE SIZING CRITERIA

Before final linesizing, the system shall be evaluated with the objective of resulting in a total cost effective design. This may include evaluation of functional requirements, cost of equipment and piping, space requirements and weight, CO 2-tax and energy costs, mechanical and process limitations etc. In general, when sizing of pipes are to be performed, different criteria are to be addressed, such as : 1. Required capacity / available driving pressure 2. Flow induced forces 3. Noise / vibration 4. Pressure surges 5. Material degradation - erosion, corrosion, cavitation 6. Liquid accumulation / slug flow 7. Sand accumulation Minimum pipe diameter will be determined by point 1 - 5 above, while eventually maximum pipe diameter will be determined from point 6 and 7. Which of the above criteria will be limiting may vary from one situation to the other. The sizing criteria may also be influenced by the surroundings - noise need not be critical in certain areas, high flow induced forces may be accomplished with better supports, pressure drop may not be critical for short pipes or at high pressure conditions, material degradation will depend on

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pipe material, chemistry of liquid, pressure and temperature and content of particles, corrosion / erosion allowance, time for operation, criticality of systems etc. 6.1 6.1.1 Design Basis Permissable pipe sizes A minimum size of DN50 (2") should in general be used for all process, process support and utility piping to ensure adequate mechanical integrity. Piping of diameter DN25 (1") can be used, where protection and/or support is provided for the following services: Instrument air. Chemical injection. Auxiliary services such as pump cooling. Services where a minimum velocity is required. Internal piping on equipment skids. Sample connections. Instrument connections. Minimum size for the sewage and open drain header shall be DN100 (4") and sub-headers DN80 (3"). Overflow from atmospheric tanks shall as a minimum be equal to the largest inlet pipe. Tubing may be used for air, hydraulic oil and other non-combustible / non- hazardous fluids. 6.1.2 Pipe roughness For all calculations of pressure drop, the following pipe roughness values should be used: Carbon Steel (CS) non-corroded: Carbon Steel (CS) corroded: Stainless Steel (SS): Titanium and Cu-Ni: Glassfiber Reinforced Pipe (GRP): Polyethylene, PVC: 0.05mm 0.5mm 0.05mm 0.05mm 0.02mm 0.005mm

Flexible hose: Vendor to be consulted. (As a rough estimation, ID/20mm can be used (ID in inch) for steel carcass and 0.005mm for plastic coating.) 6.2 6.2.1 Sizing of Liquid Lines Velocity limitations The velocities shall in general be kept low enough to prevent problems with erosion, waterhammer pressure surges, noise, vibration and reaction forces. In some cases a minimum velocity is required. The acceptable pressure drop will in general be the governing criterion when: Flashing of liquid has to be avoided, eg. upstream control valves and in pump suction lines. NORSOK Standard Page 9 of 26

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The available pressure drop is limited. A compromise between line size and pump power has to be taken. Table 3 Maximum velocities for sizing of liquid lines. Fluid Liquids Liquids with sand 3) Liquids with large quantities of mud or silt 3) Untreated Seawater 1) Deoxyginated Seawater 2)
2)

Maximum velocities (m/s) CS SS CuNi 4) 6 7 3 5 7 N.A. 4 4 N.A. 3 6 7 7 3 3

GRP 6 6 N.A. 6 6

Notes: 1) For pipe less than DN200 (8", see BS MA-18 for maximum velocity limitations. 2) For Stainless Steels and Titanium the maximum velocities is limited by system design (available pressure drop/reaction forces). 3) Minimum velocity shall normally be 0.8 m/s 4) Minimum velocity for CuNi is 1.0 m/s. When the service is intermittent, the velocity can be increased to 10 m/s, except for CuNi material. With corrosion inhibited fluids in carbon steel piping, the velocity shall be limited by a wall shear stress of 40 N/m, with the corresponding maximum velocity: Vmax = (80/(f x ))1/2 (m/s) f = Fanning's friction factor = fluid density (kg/m) With f = 0.005 6.2.2 Vmax = 126/1/2 (m/s)

Centrifugal pump suction and discharge lines The suction piping shall be sized based on NPSH requirements. Maximum velocity from Table 3 and the following maximum pressure drops shall in general be used: Subcooled liquids: Boiling liquids: 0.25 bar/100 m 0.05 bar/100 m

The fluid temperature shall be at least 15C below the fluid boiling point temperature to allow sizing based on the criterion for subcooled liquids. The discharge piping shall be sized using the governing criterion of maximum velocity from Table 3. The pressure drop shall normally not be higher than 0.9bar /100m, except

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when economical evaluation, including installation cost, energy cost and CO2 taxes demonstrate a higher optimal pressure loss. (Ref. NORSOK Standard O-CR-001) 6.2.3 Reciprocation pump suction and discharge lines For reciprocating pumps, the suction piping shall be sized based on NPSH requirements. Table 4: Recommended maximum velocity in reciprocating pump piping. Maximum velocity (m/s) Suction 0.6 0.5 0.3 Discharge 1.8 1.4 0.9

Speed (RPM) < 250 250-300 > 300

The limits are for a single plunger pump and the velocity is the average during several strokes. The discharge velocities can be increased if the number of plungers are increased, and/or if dampers are installed (ref. API RP 14E). 6.2.4 6.2.5 Control valve suction lines Control valve inlet lines shall be sized such that single phase liquid is maintained. Liquid flowing by gravity Lines flowing by gravity includes tank overflows, drains (sanitary, closed and open drains), and other lines where the liquid flows due to gravity forces instead of pressure difference. Generally, for fixed installations, a minimum downward slope of 1:100 shall be used. However, with mud and/or sand, the slope shall be at least 1:50. On floating installations the slopes must be evaluated according to planned installation trim. Pipes that are running full, and do not require a minimum downward slope to avoid particle deposition, shall be sized according to the total available static pressure head, and the maximum allowable velocities for liquid lines. Near horizonal pipes not running full shall be sized based on the maximum flow as given in Table 5.

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Table 5: Flow Capacity - near horizontal pipes. Diameter (mm (inch)) Entrance to pipe (m3/h) 1.8 8 20 50 80 130 200 280 Liquid flow capacity Slope 1:50 (m3/h) 3.0 20 60 240 440 620 710 890 Slope 1:100 (m3/h) 2.5 15 35 170 310 440 500 630

50 (2) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) 400 (16)

Vertical gravity lines (such as liquids from sea water returns and produced water discharge) shall be designed such that the Froude number is less than 0.3 to avoid air entrainment and ensure undisturbed flow without pulsations. ___ Froude number = V/ Dg V = Velocity assuming full pipe (m/s) D = pipe inner diameter (m) g = gravity constant (m/s2) Drainage of deluge water from drain boxes through vertical lines shall be sized on basis of 50% of the available head (assuming the pipe running full of liquid) and not Froude number. For sea water and produced water discharge lines to sea, a vent line is normally included from top of the vertical gravity line from platform topside to sea. The vent line should be designed for an air volumetric flowrate equal to the liquid volumetric flow through the vertical line and a pressure loss of maximum 0.02bar/100m. 6.2.6 Fire water The line sizing of fire water lines shall be based on available system pressure and allowable flow velocities. The pressure drop to the large deluge systems shall be calculated on basis of the most unfavourable pipe routing to those systems. In the ring main pipework the flow velocity shall in general not exceed the velocity as given in Table 3. Upstream the deluge skids, the flow velocities shall normally not exceed 10m/s. Some areas may require velocities higher than 10m/s in order to hydraulically balance the systems, which is acceptable provided the reaction force within the system does not cause excessive stress in the pipe work or the supports. NORSOK Standard Page 12 of 26

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6.2.7

Oily water systems The lines for oily water to water treatment facilities, shall be sized in order to retain the size of oil droplets in the water. This can be achieved by providing low flow velocities. Typically the velocity should not exceed 3m/s. This should also be considered in selection of fittings and instruments in these lines to avoid shearing of oil droplets.

6.2.8

Drilling fluid systems The minimum flowing velocity of drilling fluid shall not be lower than 0.8m/s in order to avoid sand settling in pipes. The maximum velocity in carbon steel should not exceed 4m/s to avoid problems such as cavitation/erosion on bends and damage to inline equipment / vessels internals. Line sizing criteria for drilling fluids are summarized in Table 6. Table 6 Allowable pressure drop and velocity in drilling fluid systems. Line Service Pump Suction (and Gravity) flow (Carbon Steel pipes) Max pressure drop [bar/100 m] 0.3 Velocity limits [m/s] Min Max 0.8 4.0

6.3 6.3.1

Sizing of Gas Lines General Gas lines shall generally be sized in order to not exceed the acceptable noise level at the platform. Piping with gas at the dewpoint and/or with some droplets shall be designed as gas lines.

6.3.2

Maximum velocities In lines where pressure drop does not have a cost penalty, gas velocity shall not exceed limits which may create noise or vibrations problems. As a rule of thumb the following velocity shall not be exceeded : V = 175 * ( 1/ ) 0.43 or 60 m/s where : V = max. velocity of gas to avoid noise (m/s) = density of gas (kg/m) For installations where high noise levels are not considered as a problem or if the noise level is reduced by insulation or other means, maximum velocity to be 60m/s.

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For sizing and arrangement connected to and adjacent to pressure control valves in order to avoid excessive dispersion of noise, the valve manufacturer shall be considered. Antisurge recycle lines can be designed to a maximum velocity of 76 m/s during process upsets, if the noise level is acceptable. However, during normal recycle, the velocity shall be limited to the velocity as given by the equation above. If solid particles exist, special attention shall be given to particle erosion. 6.3.3 Recommended pressure drops Pressure drop in gas lines shall be considered in order to minimize the compression power. Table 7. lists recommended pressure drops in gas lines. For lines where pressure drop is not considered critical for compression power, the lines should be sized based on maximum velocity only. Table 7 : Recommended pressure drop for single phase gas process lines. Operating pressure (Barg) 0 - 35 35 - 138 Over 138 Note 1: P is operating pressure in bara. 6.4 Sizing of Gas/Liquid Two-or Multi-Phase Lines Wellhead flowlines, production manifolds, process headers and other lines transporting gas and liquid in two- or multi- phase flow, shall be sized on the basis of flowing velocity. The maximum velocity shall not exceed the lowest of 183/(mix) and maximum velocity for single gas flow (mix = mixture density in kg/m). The maximum velocity criterias does not apply for well flowlines (with only small amounts of sand) or separator drain lines where higher velocity (maximum 25 m/s) is acceptable for duplex stainless steel pipelines If the available pressure drop allows, the velocity shall in general be sufficiently high to ensure homogeneous flow. This prevents unstabilities due to liquid accumulations, and it allows simple pressure drop calculations. If lower velocities are required due to limited available pressure drop, problems with slugging and/or liquid accumulation in the lines shall be considered. Pressure drop (Bar/100 m) 0.001 - 0.11 0.11 - 0.27 P/500 1)

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6.5 6.5.1

Sizing of Gas Relief Lines Flare headers and subheaders The maximum velocity for flare headers and subheaders shall not exceed 0.6 Mach and the value of V2 should not exceed 200 000 kg/ms2 ( is the fluid density kg/m3).

6.5.2

Pressure safety valve lines The upstream line shall be sized so that the pressure loss is below 3% of valve set pressure to avoid valve chattering. The value of V2 shall be below 200 000 kg/ms2. In any case the upstream line size should be at least equal to the PSV inlet nozzle size. Maximum back pressure shall be less than 10% of the set pressure for conventional (spring loaded) and less than 30 to 50% for balanced (pilot operated and ballanced bellows) safety relief valves (PSVs). Maximum flowing velocity in the lines downstream of the PSVs shall in general be less than 0.7 Mach. For the PSVs where the outlet velocity is higher, a reducer shall be installed adjacent to the PSV to increase line size and hence limit the velocity to max 0.7 Mach downstream of the reducer. Nevertheless, the actual back pressure at the PSV outlet and in the block valve shall be checked to be consistent with back pressure limitations.

6.5.3

Controlled flaring lines Flaring lines downstream of control valves shall be designed for a maximum velocity of 0.5 Mach and a maximum value of V2 = 200 000 kg/ms2, in order to prevent acoustic fatigue.

6.5.4

Depressurisation lines In the lines, upstream or downstream of the blowdown valve, the value of V2 should not exceed 200000 kg/ms2. The maximum flowing velocity in the lines downstream the reducer shall be 0.7 Mach. The pressure loss shall be so as to not impose any restrictions on the depressurisation objectives.

6.5.5

Two/multiphase relief lines Two/multi phase relief lines shall be sized based on the following criteria: Potential slug/plug flow:V < 50m/s(branch lines only) Homogenous flow: V2 < 200,000kg/ms

6.5.6

Vent lines Maximum backpressure shall be 0.07barg .

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6.6

Maximum allowable velocities due to reaction forces If V2 > 200,000 the piping discipline shall be consulted in order to consider reaction forces. ( is fluid density in kg/m and V is velocity in m/s) This applies to all fluid services (gas, liquid, two-phase).

7
7.1 7.1.1

SYSTEM AND EQUIPMENT ISOLATION

System and Equipment Isolation General Requirements for isolation shall be implemented based on an assessment of safety, system availability, and frequency of regular production and maintenance operations. In general single block and bleed shall be used on all systems. Double block and bleed shall only be used for safety reasons i.e. on hazardous systems with pressure rating 600 lbs and above, systems/equipment critical for the overall reliability and systems/equipment with high maintenance frequency, such as: Pig launchers and receivers. Process compressors and crude oil pumps which are maintained when the process system is pressurized. Illustrations of different isolation arrangements are given in Annex A figures 1 and 2.

7.1.2

Isolation of pressure vessels All vessel nozzles shall be equipped with spectacle blinds, or blinds/spacers, except for small vessels that cannot be entered. See Annex A, figure 3. Vessel isolation shall be located as close to the vessel as practical, normally directly on the nozzle. Purge and steam valves shall be provided with blind flanges. Connections to vent/drain systems from instruments shall be isolated on the instrument.

7.1.3

Isolation of Equipment being Removed for Maintenance Spool pieces shall be used when necessary for maintenance purposes. This type of isolation requirement is generally used for pumps, compressors and heat exchangers.

7.1.4

Isolation of control valves Control valves shall be equipped with isolation and bleed valves. See Annex A, figure 4. If tight shut-off is required, an isolation valve shall be installed upstream the bypass throttling valve. See Annex A, figure 5.

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On non essential equipment, single control valve is acceptable. See Annex A figure 6. 7.1.5 Isolation of pressure and level instruments, chemical injection and sample points Generally, the same requirements applies to instruments as to system and equipment isolation. All pressure instruments shall have a flanged isolation valve at the point where pressure is tapped off on a process line, vessel, etc. In addition, chemical injection points shall have a check valve. 7.1.6 System Isolation In general, hydrocarbon fluid and hazardous utilities with system design pressure corresponding to 600 lbs flange rating and above, shall be isolated using double block and bleed valves if the system is to be maintained while the rest of the systems are in operation. The blind flange or spool piece shall be placed in the flange closest to the required isolation point. For 300 lbs flange rating and below, single block valve is sufficient. A single valve is acceptable as double block and bleed only if the force acting on the seal faces is independant of system pressure, except around pig launchers and receivers. 7.2 7.2.1 Connections to Vents and Drains General The philosophy for connections to flare, vents and drains is described in this section: 1. Closed drain system Intended for draining of liquid after depressurisation from vessels, piping and other equipment due to maintenance work etc. All pressure drain connections shall be equipped with a blind to avoid accidental draining of pressurized liquids/gas. 2. Flare system Process relief system. Also used to blow down equipment to flare header pressure. 3. Vent system System for venting of hydrocarbon gas to an atmospheric vent at a safe location. Used during maintenance before equipment is opened and normally done after blowdown of equipment to flare system. If a vent system is not present, alternatively a blinded nozzle is acceptable for connections of high pressure hoses to a safe location.

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7.2.2

Detailed requirements All equipment and piping shall be provided with highpoint vents and lowpoint drains. All pressure vessels shall be provided with a vent valve and blind, venting to atmosphere during maintenance. All vessel or tower drains discharging into the oily water drain system shall have permanent piping arranged with visual observation of flow. Drains used only during major shut-down shall be fitted with blanks or plugs. Vent and drain connections shall be fitted with block valves for all heat exchangers. On stacked exchangers operating in series, drain valves with plugs shall be installed on the lower exchanger only. Where provisions shall be made for chemical cleaning with the tube bundle in place, blind flange connections shall be provided for chemical hose attachments. The connections shall preferably be 3 NPS, but not exceeding line size, and shall be located between the exchanger nozzles and the block valves. All pump casing vents and drains not permanently connected to the flare/drain system shall be blinded off downstream of the valves. Connections to the closed drain system from equipment and piping shall have two valves, one block and one throttling valve, and single blinded bleed valve arrangement. A spectacle blind shall be located between the upstream block valve and the bleed valve. See Annex A, figure 7. The drain pipe down to the T-piece connection on the header, should be designed for the same pressure as the system to be drained. The last drain valve should be a slow opening valve or alternatively an orifice to prevent too high pressure ratio/flow. A single block valve with blind flange/plug shall be used for level transmitters and level gauges for connections to closed drain and flare systems. If permanently connected to the flare or closed drain system, the blind is not necessary. Connections to the atmospheric vent system from pressurised vessels require single isolation, valve and blind. Connections to the atmospheric vent system from atmospheric vessels require a blind Atmospheric vents discharging from hazardous sources including tanks shall be routed to the atmospheric vent system. However, tanks vents from non-hazardous tanks may be routed individually to atmosphere. Vents and drains(and bleeds) in hydrocarbon service not permanently hooked up to flare or closed drain systems shall be provided with double block valve and blind for pressure ratings 600 lbs (ANSI class) and above. Pressure ratings 300 lbs and below shall be equipped with single block valve and blind.

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Process Design

P-CR-001 Rev. 2, September 1996

Single relief valves can be equipped with a block valve upstream and downstream and a single blinded bleed valve upstream of the relief valve. See Annex A, figure 8. Relief valves or rupture disc with spare shall be equipped with single selector valves or mechanically interlocked block valves upstream and downstream and a single blinded bleed valve, upstream of each relief valve. See Annex A, figure 9. The pressure relief valves shall be located at high points in the piping system. Piping to pressure relief valve inlet shall be as short as possible. All branch connections on relief and blowdown system will enter the header at 90 unless otherwise highlighted on the P&IDs. Blow down shall be arranged with one blow down valve, orifice and a block valve. See Annex A, figure 10. The P&IDs shall show all process drains, vents and sample points required for commissioning and operation. Vents and drains exclusively used for hydrostatic pressure testing will be added by piping layout and design. 7.3 7.3.1 Isolation Devices General It shall be possible to isolate equipment or process sections during maintenance work to obtain safe working conditions for the maintenance personnel. Process sections will also be isolated for leak testing before commissioning or after a maintenance operation. Provisions necessary to facilitate isolation are: shut off valves or manual block valves on all connections to equipment or the process section to be isolated. Vent/drain (bleed) between isolation valves, or between a valve and a blind. Flange pair with blind at the point of isolation. The actual blinding is accomplished through one of the following arrangements: Spectacle blind. Spade and spacer. Spool piece and blind flange. When sandwich type butterfly valves are used, an additional flange must be provided between the valve and the spool piece to allow for spool removal without disturbing the butterfly valve. The location of line blinds and insulation spools shall be shown on the P&IDs

NORSOK Standard

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Process Design

P-CR-001 Rev. 2, September 1996

8
8.1 8.1.1

INSULATION AND HEAT TRACING OF PIPING AND EQUIPMENT

Insulation and Heat Tracing Requirements General Due to corrosion under insulation being a general problem on insulated equipment, the philosophy shall be to avoid insulation where possible. Appropriate coating systems shall be selected to minimize the above problem when insulation is required. The insulation and heat tracing requirements shall be determined with due consideration to safety aspects as well as to process aspects and with the objective to minimize Life cycle cost. All operating modes shall be considered. Insulation and heat tracing shall be avoided on spectacle blinds and flanges. The insulation classes are designated as follows: Code 0. 1. 2. 3. 4. 5. 6. 7. 8. 9. Description No Insulation Heat Conservation Cold Medium Conservation Personnel Protection Frost Proofing Fire Proofing (Insulation) Acoustic 10 d Acoustic 20 d Acoustic 30 d External Condensation and Icing Protection Abbreviation NI HC CC PP FP FI AI AI AI EP

Design requirements and criteria for the respective insulation classes are specified in the following sections. 8.1.2 Heat conservation Insulation/Heat tracing for this purpose shall be used where heat losses from the piping and equipment to the surroundings are to be minimized for the following reasons: Maintain a proper heat balance for optimum operation of the process and utility systems. Limit heat losses in heat exchangers and heater systems to minimize required heat input and thereby reduce equipment size and weight. To avoid internal condensation in gas systems (e.g. fuel gas system). To maintain sufficient liquid temperature and avoid increased liquid viscosities. If sufficient (waste) heat is available, consideration shall be given to possibly avoid insulation.

NORSOK Standard

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Process Design

P-CR-001 Rev. 2, September 1996

8.1.3

Cold medium conservation This insulation type shall be used for piping and equipment including valves and instruments which normally operate below ambient temperature and where heat transfer from the surroundings shall be minimized for the following reason: Maintain a proper heat balance and low temperature in the process system. Limit heat input to piping, and thereby reduce equipment size and weight.

8.1.4

Personnel protection Shields are the preferred option for personnel protection against hot and cold surfaces, unless insulation is required for other purposes. Where shields are not a practical solution, insulation for personnell protection shall be considered on surfaces that can be reached from workareas, walkways, ladders, stairs or other passageways and where the surface temperature exceed 70C or is below -10C (see NORSOK S-DP-002 and NORSOK R-CR-004).

8.1.5

Frost protection Insulation/Heat tracing for external low temperature protection shall only be used for safety reasons or where a positive effect on regularity can be demonstrated. Equipment and piping should be protected for purposes such as: Prevention of hydrate formation. Heat tracing specified to maintain minimum fluid temperature required. Protection of standby pumps in unheated areas to avoid the pumping medium to freeze or become too viscous to pump. Heat tracing to maintain operating temperature may be required for operational reasons, e.g. instrument connections and impulse lines. In this service, thermostat controlled heat tracing is preferred. Frost protection of equipment, piping and instrumentation in systems carrying fluids which in a stagnant flow and low ambient temperature condition may be subject to solidification. This may be applicable to liquid-filled small bore lines carrying fresh water, sea water or pure glycol. Heat tracing shall be specified to maintain minimum temperature above 5C, however, for pure glycol, the temperature shall be maintained above 20C to reduce viscosity. No winterization is required for water lines (sea water, fresh water, produced water and completion fluid) where continuous flow is assured or the system is self draining when shutdown. The piping shall be arranged to minimize the part of the system containing stagnant or slow moving fluids. Stagnant conditions shall be avoided by design, but where this cannot be done, provisions must be made to drain or flush out the system (i.e. winterization bleeds). Adequate protection may sometimes be obtained by increasing the velocity in a line. Maintaining the flows listed below is generally sufficient to avoid freezing in lines up to 50m length. The flowrate should be increased pro rata with the exposed length for lengths over 50m. The table below can be used for sea water and, if applicable, fresh water.

NORSOK Standard

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Process Design

P-CR-001 Rev. 2, September 1996

Line Size below 3" 3 and above

Minimum Volumetric Flowrate 0.02 m/h 0.10 m/h

Where such provisions can not be made, heat tracing and/or insulation shall only be applied based on a critical evaluation of: Location/Environmental conditions. Ambient conditions. System criticality. For lines where intermittent flow and stagnant conditions cannot be avoided, the following guidelines shall apply: Line size < 3" 3"-10" >10" 8.1.6 Fire proofing Fireproofing insulation shall be applied on equipment and piping where passive protection against a hydrocarbon fire is required, and on equipment which is required to be operable during a fire. The philosophy and criteria for application of passive fire protection are detailed in NORSOK S-DP-001. 8.1.7 Acoustic insulation Acoustic insulation comprise Insulation Classes 6, 7 and 8.The respective requirements for these classes are 10, 20 and 30dB linear average attenuation between 500 and 2000Hz. The philosophy and criteria for application of such insulation are detailed in NORSOK Standard S-DP-002. 8.1.8 External condensation and icing protection This type of insulation shall be used to prevent external condensation and icing on piping and equipment in order to protect personnel and equipment. Normally, insulation for external condensation and icing protection shall not be installed. Action Heat trace and insulate Insulate No winterization

NORSOK Standard

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Process Design Annex A

P-CR-001 Rev. 2, September 1996

ANNEX A: FIGURES (NORMATIVE)

Legend:
GENERAL BLOCK VALVE OPEN GENERAL BLOCK VALVE CLOSED CONTROL VALVE THROTTLE VALVE, NORMALLY CLOSED PRESSURE SAFETY VALVE ORIFICE SPECTACLE BLIND

POINT TO BE ISOLATED

BLEED

Figure 1: Double block and bleed for process systems

POINT TO BE ISOLATED

BLEED

Figure 2: Single block and bleed for process systems

NORSOK Standard

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Process Design Annex A

P-CR-001 Rev. 2, September 1996

POINT TO BE ISOLATED

Figure 3: Single block for pressure vessel isolation.

SPEC BREAK

HP SPEC BREAK

LP

Figure 4: Isolation of control valve having bypass.

SPEC BREAK

HP SPEC BREAK

LP

Figure 5: Isolation of control valve having bypass with tight shut off.

NORSOK Standard

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Process Design Annex A

P-CR-001 Rev. 2, September 1996

HP SPEC BREAK

LP

Figure 6: Single control valve on non essential systems (no isolation).

POINT TO BE ISOLATED

SPEC BREAK

Figure 7: Double block for connection to closed drains.

SPEC BREAK FLARE LO LO SYSTEM TO BE PROTECTED

Figure 8: Arrangement for single relief valve (PSV).

NORSOK Standard

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Process Design Annex A

P-CR-001 Rev. 2, September 1996

FLARE SPEC BREAK LO LO

LC

LO SYSTEM TO BE PROTECTED

Figure 9: Arrangement for interlocked relief valves (PSV's).

BLOW DOWN VALVE

SPEC BREAK FLARE LO

SYSTEM TO BE BLOWN DOWN

Figure 10: Blow down valve.

NORSOK Standard

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