Close out Action for HAZOP review point no: H-17

The HAZOP action was recorded as given under:

Pressure will increase, flow will decrease

Low flow alarm is
leading to the minimum recycle line
provided in the pump
opening for both the pumps. No Surge upstream of the
discharge to be
hazardous consequence. Deep water disposal
DWD pumps enabled when
Pressure More In-efficient operation leading to increase pumps in case of they are TRE 1
trip. minimum recycle line
level in CPI’s as no flow will be send to tripping & booster pumps
will open.
DWD system. Level in the CPI will are still on to be checked.
HH level trip in the
increase very fast leading to overflow.
CPI.
Production deferment.

To enable closure of the action, the following was made available from PDO.

 Latest TLNET files (Cases 1A/B, 2A/B 3A/B 4A/B & DWD1234trip) on the same system worked by WPAI. As
the TLNET model carried by WPAI is latest, the same will be followed for the current surge analysis.
 Surge analysis report Nimr- DWD pipeline Replacement (off – plot), Doc.no.3112505 Rev A (dt: 18/04/2010)
carried out by Tebodin is only be referred.

1) Based on the WPAI TLNET model the following is summarized:

a) Simulation Scenarios

There are 5 operating Simulation cases considered for Surge analysis. Out of 5 operating cases, the governing
case is when all the DWD pumps in all sites tripped with no flow to NWTP. The matching TLNET file is:
DWD1234trip. The table below show the same which has been considered in the Transient Scenario.
 b) A snap shot of the TLNET model for DWD1234trip (All DWD pumps trip) is provided in fig 1.1 below.

From the above sketch, it is seen that three numbers of water disposal booster pumps (north train Bank-D) have
been considered for the surge analysis during DWD PUMP trip scenarios. The pump tag numbers are P-48148,
48159 & 48160 with each pump delivering flow of 20000m3/d.

2) Modifications in north train Bank-D pumps based on Nimr-G project.

 As part of this project, the existing pumps P-48159 /160 will be made redundant and new three water
disposal booster pumps P-48354/55/56 (2 working + 1standby) will be installed in the North train bank-D.
 The TLNET model for North train bank-D is updated for the same by changing with respective tag
numbers.

And based on the latest As-built PEFS (NIM-1-5407-001.Rev.F & NIM-1-5325-001.Rev. K), the existing
pump P-48148 from North train bank-D is relocated to North train Bank- C pumps as working pump. The
subsequent changes for pump P-48148 is updated in the TLNET model.

 The three new water disposal booster pumps with tag numbers P-48354/55/56(2 working + 1 standby)
will be installed in north train (Bank-D) connecting to the same 36” DWD header. Refer to PEFS NIM-48-
000000-PX-2365-93609-0001-KP.Rev.03 for more details.

In addition to above modifications, the below provided changes are also updated in the North train
bank-D based on Nimr-G project inputs:

Pump Capacity: 20000 m3/d (each) – No change

Pump curve: Same as already available in Model – No Change
Discharge piping design pressure: 47.5 barg (for information)
Maximum allowable incidental pressure: 47.5 (design pressure) x 1.1= 52.25 barg (for information)

Parameters Segments Original software Changes to be made for North

file(version 2.6) inputs for train Bank-D water disposal
north train Bank -D water pumps as per Nimr-G project
disposal pumps inputs

Internal Dia.(ID) & Pipe segments 303.3mm(ID), 381 mm(ID)

thickness(t),mm
(P-090/091/092/093/094/095) 10.3 mm(t) 12.7 mm(t)

Internal Dia. (ID) & Pipe segments 736.6 mm(ID), 727 mm(ID)
thickness(t),mm
(P-096/097/098/099) 12.7 mm(t) 17.5 mm(t)

Tag, number Pump P-48148(*)/159/160 P-48354/55/56 (Two working

change with 1 stand by) of 20,000 m3/d
each.
Control valve FCV-153
FCV-3520

Control valve(FCV- CV & Size change CV=9340 Max CV=4550 (Based on the
153) characteristics control valve data of one vendor)

Size=355.6mm
Size=457.2mm
  The transient model of case DWD1234trip was re-run with the settings of the given base model. Available
TLNET Version is 3.2.7.

3) Results

All the above changes mentioned in the section 2) are updated in the WPAI provided TLNET model for case
DWD1234trip. It has been identified from the model/reports, that the highest surge pressure will be occurred at
the existing DWD pump (P-9510) suction side. The surge pressure arrived at this location is provided below
(refer fig 3.1) along with trend plots.

Fig 3.1: Transient Trend curve

4) Conclusions

 The surge pressure in the new piping i.e. from the new water disposal booster pump discharge joining to
the DWD header is well within the MAIP (52.25) of the system.

 The highest surge pressure achieved on the suction of the existing DWD pump (P-9510) located at the
DWD site-3. From the fig 3.1, it is seen that the surge pressure achieved is 51 barg which is well within
the MAIP (52.25=47.5*1.1) of the system.