13. Shut-in condition A condition resulting from the shutting-in of the facility which is caused by the occurrence of one or more undesirable events.

14. Upsteam process Process that draws up and transfer produced fluid to process equipment on the unit. Such process are generally from wellhead to inlet of the first process equipment on the unit.

15. Downstream process Process that purifies produced fluid by separating them into crude oil, water and gas on the unit.

16. Pipeline Piping that directs fluids between platforms or between a platform and a shore facility.

17. Flowline Piping that directs well stream from the well head to the frist downstream process component.

18. Production deck A deck that production facilities are installed on.

105. Design conditions

The production and process systems are to be designed to account for all applicable operational, and test loads, or combination thereof. These include the following:

1. Environmental Conditions

(1) Earthquake

(2) Wind Ice

(3) Ice

(4) Temperature

(5) Current, waves

(6) 1, 10, 50, 100 year storm event, as applicable

2. Operational

(1) Static pressure

(2) Vibration

(3) Transient pressure excursion

(4) Acceleration loads due to movement of installation

(5) Temperature excursion

(6) Fluid static head and properties

(7) Tension

(8) Bending

3. Transportation

4. Installation

5. Commissioning

6. Test loads

environmental,

106. Classification survey during construction

1. Plans and documents to be submitted

(1) The following plans and documents are to be submitted for the approval of sification survey during construction before the work is commenced.

(A) General arrangement of production and process systems

(B) Hazardous area classification plans and ventilation arrangement

(C) Piping & instruments diagrams

(D) Pressure relief and depressurization vent systems arrangement

(E) Flare/gas release systems arrangements

(F) Spill containment, closed and open drain systems arrangements

the Society at clas-

(2) The following plans and documents are to be submitted for the reference of the Society at classification survey during construction before the work is commenced.

(A) Process flow sheets showing major process equipment components, process piping, material balance, normal pressures and temperatures at the inlet and outlet of each major component.

(B) Safety Analysis Function Evaluation Chart.

(C) Installation, hook-up and commissioning procedures of production and process systems.

2. Certification of equipment

(1) The manufactured equipment and components are to be verified for satisfactory compliance with the recognized codes and standards, and the requirements of this Chapter.

(2) Equipment and components of production and

according to importance for safety.

process systems are categorized as Table 11.1

Table 11.1 Categorization of process equipment

(3) Category 1 equipment is to comply with the followings.

(A) Plans and documents are to be submitted for the approval of the Society before the work is commenced. However, equipment design-approved in accordance with Ch 4 of Guidance for Approval of Manufacturing Process and Type Approval, Etc. are not required drawing approval.

(B) Tests required in (5) are to be carried out at the plant of manufacturer.

(C) Prior to commencement of surveys, the Society is to discuss with the manufacturer at a kick off meeting the items listed as the followings.

(a)

Confirmation of the main point of contacts for the manufacturer and the Society

(b) Review the project quality plans

(c)

Review proposed manufacturing specification

(d) Review project manufacturing and delivery schedules

(e)

(f)

Review and confirm project "hold-points"

Review any proposed sub-contractor lists and qualifications

(g) Confirm specification, drawings and/or documentation associated with the manufacturing process

(D) The attending Surveyor is to perform or verify the followings.

(a)

To confirm that the facilities to manufacture, fabricate or repair process systems and equipment have and maintain an effective quality control program effectively covering design, procurement, manufacturing and testing, and meeting the requirements of a rec- ognized standard applied to their product

(b) Welder’s qualifications

(c)

Welding procedure specifications and corresponding weld procedure qualification records

(d) To verify material certificates

(e)

(f)

To survey fit-up prior to major weldments To survey final weldments

(g) To witness, as far as deemed necessary, nondestructive examination tests of welds and to review records of nondestructive examinations.

(h) To review records of post-weld heat treatment, in particular for piping subjected to pres- surized sour service and subject to NACE MR0175/ISO 15156 requirements

(i)

(j)

To verify dimensions are as shown on approved drawings

To check dimensional tolerances and alignment of mating surfaces

(k) To witness pressure and proof-load testing of equipment and unit as specified in the fabrication procedures.

(l)

To witness final testing and functional testing of subassemblies and completed units, as specified in the fabrication procedures.

(m) To verify all purged and pressurized systems, motor controllers, SCR banks, consoles

and instrumentation and control panels are in compliance with approved drawings.

(n) To carry out other inspections as agreed upon during prefabrication meeting

(o) To review and approval final manufacturing Data Book and issue final survey report or certificate and confirm compliance with approved drawings.

(4) For category 2 equipment, manufacturers' certificate containing the following data is to be

submitted.

(A) Equipment specification

(B) statement to confirm that their products are designed, manufactured and tested in accordance with the recognized codes and standards, and the requirements of this Chapter

(C) Operating limitation of the equipment

(D) Test record

(5) Equipment of production and process systems are to be tested in accordance with the following.

(A) Pressure vessel

(a) Each vessel is to be subjected to a hydrostatic test which at every point in the vessel is at least equal to 1.3 times the maximum allowable working pressure.

(b) For pressure vessels that cannot be hydraulically tested, a pneumatic test equal to 1.1

times the maximum allowable working pressure is to be performed.

(B) Pump

(a) A hydrostatic test is to be performed at a minimum of 1.5 times the design pressure.

(b) An performance test of the pump is to be performed.

(C) Compressor

(a)

A hydrostatic test is to be performed at a minimum of 1.5 times the design pressure.

(b) An performance test of the pump is to be performed.

(c)

A leakage test is to be performed. Each compressor intended for toxic or flammable gas service is to be pressurized with an inert gas.

(D) Gas turbine

(a) A hydrostatic test is to be performed at a minimum of 1.5 times the design pressure.

(b) An performance test of the pump is to be performed.

(E) Piping systems

(a) A hydrostatic test is to be performed at 1.5 times the design pressure or 3.5 kg/cm2 (50 psig), whichever is greater.

(b) For all joints including welds, a leakage test is to be performed with uninsulated and exposed

(c)

Where it is necessary to perform a pneumatic leak test, the test pressure is to be 1.1

times the design pressure.

(F) Generators and motors

(a) Check windings for dryness. It is recommended that space heating be operated for a sufficient time prior to start-up to assure dryness.

(b) Measurement of stator insulation resistance to the motor or generator frame is to be made with an instrument applying a minimum of 600 V across the insulation. The sug- gested minimum insulation resistance is 2 MŌ and new or rebuilt machines are to pro- vide at least 10 MŌ in insulation resistance readings.

(c)

If generators are to be operated in parallel, check their phase rotation and the synchro-

nizing circuits for proper operation.

(d) Check motor starter overload relay heater elements for proper sizing.

(e)

(f)

Check circuit breaker trip settings and fuse sizes.

Jog motors to check for proper direction of rotation, but only after uncoupling any loads which might be damaged by reverse rotation.

(g) Check motor-to-load and generator-to-prime mover alignments.

(h) Perform an insulation test of all electrical circuits to verify that cables are not damaged during installation.

(i)

(j)

Verify all components are properly grounded.

After motors and generators are started, check for abnormal line currents, vibration, and

high bearing temperatures.

(k) Witness full-load heat run and saturation curve tests for the first unit of a particular design.

(G) Switchboards

(a)

Check all bus-bars for correct sizing and spacing.

(b) Check all components for correct voltage and current rating.

(c)

Verify all components are properly grounded.

(d) The various circuits of switchboard and panelboard assemblies are to be tested by con- ducting dielectric strength test and insulation resistance measurements.

(e)

Satisfactory tripping and operation of all relays, contactors and various safety devices is to be demonstrated.

(H) Instrument and control system

(a) Witness calibration of all pressure, level and temperature switches necessary for func- tioning of controls in accordance with safety analysis function evaluation charts.

(b) Review calibration records of all other instruments.

(c)

Verify all instruments used as pressure-retaining parts have correct pressure ratings.

(d) Verify all electrical/electronic instruments to be installed in a hazardous location are suitable for that environment.

(e)

(f)

Verify all electrical/electronic instruments are properly grounded.

Verify all electrical circuits are installed in a fail safe type, that is, all circuits in nor- mal working state are to be electrically continuous, and non-continuous when in an ab- normal state.

(g) Check logic functions with normal voltage applied to the control circuits, but preferably

with the power circuits not energized.

(h) Check each sensor and end device individually for proper operation before incorporating them into the system.

(6) The following codes may be adequately referred for the testing methods.

3. Onboard test

(1) Onboard installation tests of all production and process systems are to be verified by the Surveyor and are to be in accordance with the Society agreed test procedures. The following surveys are to be carried out in attendance of the Surveyor.

(A) Pressure and leak tests for piping systems and equipment

(B) Functional tests for purging systems

(C) Functional tests for utility systems such as strument air systems, cooling water systems,

(D) Functional tests for fire fighting and safety

power generators, process support facilities, in- etc.

systems such as fire pumps, fixed fire fighting

systems, portable fire extinguishers, lifesaving equipment, etc.

(E) Functional tests for detection and alarm such as fire detection systems, gas detection sys- tems, fire and gas panel, ESD systems, etc.

(F) Functional tests for process systems such as flare systems, instrumentation and control sys- tems, safety shutdown valves, process components, etc.

4. Start-up procedure

Air or other fluid is to be displaced from the process systems prior to start-up. The Surveyor is to be permitted access to suitable vantage points to verify that the startup procedures are satisfactorily accomplished. The Surveyor is to observe the facilities operating at the initial production capacity for at least a 12 hour period. As applicable, the Surveyor is also to observe the facilities operating at various capacities under various conditions.