Recommended Practice for Design and Hazards Analysis for Offshore Production Facilities

API RECOMMENDED PRACTICE 14J SECOND EDITION, MAY 2001

REAFFIRMED, SEPTEMBER 2019

Recommended Practice for Design and Hazards Analysis for Offshore Production Facilities

Upstream Segment

API RECOMMENDED PRACTICE 14J SECOND EDITION, MAY 2001

REAFFIRMED, SEPTEMBER 2019

SPECIAL NOTES

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Copyright © 2001 American Petroleum Institute

FOREWORD

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict.

Suggested revisions are invited and should be submitted to the standardization manager, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.

iii

CONTENTS

Page

1. GENERAL 1

   1. Purpose 1

   2. Scope 1

   3. Industry Codes, Practices, and Standards 1

   4. Government Codes, Rules, and Regulations 1

   5. Organization of Technical Content 1

2. INTRODUCTION 2

   1. General 2

   2. Containing Hydrocarbons 2

   3. Preventing Hydrocarbon Ignition 5

   4. Preventing Fire Escalation 6

   5. Personnel Protection and Escape 7

   6. Hazards Analysis 7

3. BASIC FACILITIES DESIGN CONCEPTS 8

   1. General 8

   2. Applicable Codes, Regulations, Standards, and Recommended Practices 8

   3. Mechanical Design Considerations 8

   4. Special Safety Considerations 22

4. HAZARD MITIGATION AND PERSONNEL EVACUATION 23

   1. General 23

   2. Fire and Gas Detection, Alarm/Communication Systems 23

   3. Escape Paths 24

   4. Fire-Fighting and Evacuating Procedures 24

   5. Passive Fire Mitigation 24

   6. Active Fire Mitigation 24

   7. Hydrocarbon Inventory Reduction 25

5. PLATFORM EQUIPMENT ARRANGEMENTS 25

   1. General 25

   2. Wellhead Areas 28

   3. Unfired Process Areas 28

   4. Hydrocarbon Storage Tanks 28

   5. Fired Process Area 29

   6. Machinery Areas 29

   7. Living Quarters Area 29

   8. Pipelines and Risers 29

   9. Flares and Vents 30

   10. Practical Limitations 31

6. DOCUMENTATION 31

   1. General 31

   2. Safety and Environmental Information 31

   3. Documentation for Hazards Analysis 32

   4. Design Documentation for New Facilities 32

   5. Pre-Start-up Review 34

   6. Operating Procedures 34

      v

      Page

7. HAZARDS ANALYSIS 35

   1. General 35

   2. Introduction 35

   3. Application 36

   4. Hazards Analysis Concepts 36

   5. Hazards Analysis Methods 38

   6. Review Procedures 39

   7. Guidelines For Selecting An Analysis Method 40

APPENDIX A.1 EXAMPLE SIMPLIFIED CHECKLIST 41

APPENDIX A.2 EXAMPLE DETAILED CHECKLIST 43

APPENDIX B ANALYSIS OF EXAMPLE LAYOUTS 63

APPENDIX C INDUSTRY CODES, GUIDES, AND STANDARDS 69

APPENDIX D GOVERNMENT CODES, RULES AND REGULATIONS 75

Figures

1. Hazard Tree for Production Facility 3

2. Matrix of Safe Facilities Design Principles 4

3. Determining Pressure Breaks 19

4. Determining Pressure Breaks 19

5. Determining Pressure Breaks 20

6. Determining Pressure Breaks 20

A-1 Hazards Analysis Worksheet 61

1. Oil Production Facility, 2-Level Platform 64

2. Oil Production Facility, 2-Level Platform 66

3. Oil Production Facility, 2-Level Platform 68

Tables

1. Design Aids for Process Facilities Systems 9

2. Design Aids for Facilities Components 10

3. Fuel and Ignition Sources 27

4. Equipment Categories 27

vi

Abbreviations

AGA American Gas Association

ANSI American National Standards Institute API American Petroleum Institute

ASME American Society of Mechanical Engineers AWWA American Water Works Association

CAA Clean Air Act

Chapt Chapter

CFR Code of Federal Regulations

DOT Department of Transportation EPA Environmental Protection Agency ESD Emergency Shutdown

FAR Federal Aviation Regulation

FCC Federal Communications Commission HA Hazards Analysis

IEEE Institute of Electrical and Electronics Engineers ISA Instrument Society of America

MAWP Maximum Allowable Working Pressure MMS Minerals Management Service

MSDS Material Safety Data Sheet NEC National Electric Code

NFC National Fire Code

NEMA National Equipment Manufacturers Association MPMS Manual of Petroleum Measurement Standards NFPA National Fire Protection Association

OSHA Occupational Safety and Health Administration PES Programmable Electronic Systems

PLC Programmable Logic Controller P&ID Process and Instrument Diagram PFD Process Flow Diagram

PSV Pressure Safety Valve

PTC Power Test Code (ASME)

Publ Publication

RP Recommended Practice

SAFE Chart Safety Analysis Function Evaluation Chart SCADA Supervisory Control and Data Acquisition

Systems

SEMP Safety and Environmental Management Plan SOLAS International Convention of the Safety of Life

at Sea

Std, S Standard

TEMA Tubular Exchanger Manufacturers’ Association USCG United States Coast Guard

vii

Recommended Practice for Design and Hazards Analysis for Offshore Production Facilities

1. General

   1. PURPOSE

      The purpose of this recommended practice is to assemble into one document useful procedures and guidelines for plan- ning, designing and arranging offshore production facilities, and performing a hazards analysis on open-type offshore pro- duction facilities. This will promote safe, pollution free and efficient production of oil and gas. This publication is only a guide and requires the application of sound engineering judg- ment. Furthermore, it is not intended to override or otherwise supersede any existing code or governmental rule or regula- tion, nor is it intended as a comprehensive document contain- ing all useful and appropriate information.

      
      

   2. SCOPE

      This document recommends minimum requirements and guidelines for the design and layout of production facilities on open-type offshore platforms, and it is intended to bring together in one place a brief description of basic hazards anal- ysis procedures for offshore production facilities. This recom- mended practice discusses several procedures that could be used to perform a hazards analysis, and it presents minimum requirements for process safety information and hazards anal- ysis that can be used for satisfying the requirements of API RP 75.

      The concepts contained herein recognize that special haz- ard considerations exist for offshore production facilities. As a minimum, these include:

      1. Spatial limitations that may cause potential ignition sources being installed in or near production equipment.

      2. Spatial limitations that may result in quarters being installed near production equipment, pipeline/flow line risers, fuel storage tanks, or other major fuel sources.

      3. The inherent fire hazard presented by the release of flammable liquids or vapors, whether during normal oper- ations or as a result of any unusual or abnormal condition.

      4. The severe marine environment, including corrosion, remoteness/isolation, and weather (i.e., wind, wave and current, ice).

      5. High-temperature and high-pressure fluids, hot sur- faces, and rotating equipment located in or near operating areas.

      6. The handling of hydrocarbons over water.

         1

      7. Large inventories of hydrocarbons from wells/reser- voirs and pipelines connected to or crossing a producing platform.

      8. Storage and handling of hazardous chemicals.

      9. Potential H2S releases.

         
         

         This recommended practice is directed to those permanent and temporary installations associated with routine produc- tion operations. The guidelines presented herein should pro- vide an acceptable level of safety when used in conjunction with referenced industry codes, practices and standards.

         
         

   3. INDUSTRY CODES, PRACTICES, AND STANDARDS

      Various organizations have developed numerous codes, practices and standards that have substantial acceptance by industry and governmental bodies. Codes, practices, and stan- dards useful in the design, fabrication, installation, layout, and operation of offshore production facilities are listed in Appendix C. These references are not to be considered a part of this recommended practice except for those specific sec- tions of documents referenced elsewhere in this recom- mended practice.

      
      

   4. GOVERNMENT CODES, RULES, AND REGULATIONS

      Government regulatory agencies have established certain requirements for the design, fabrication, installation, layout and operation of facilities on offshore production platforms. These requirements may supersede the recommendations of this document. Refer to Appendix D for applicable govern- ment codes, rules and regulations related to the outer conti- nental shelf of the United States.

      
      

   5. ORGANIZATION OF TECHNICAL CONTENT

The technical content of this recommended practice is arranged as follows:

Section 2?Introduction. Presents an overview of the gen- eral principles of safe facilities design. It addresses the importance of containing flammable hydrocarbons, mini- mizing the chances of hydrocarbon ignition, preventing fire escalation, and providing personnel escape routes.

Section 3?Basic Facilities Design Concepts. Presents a detailed discussion on basic facilities design. It addresses both general and special safety considerations as well as operational and maintenance considerations.