Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

TABLE OF CONTENTS 1.0 2.0 3.0 4.0 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 PURPOSE................................................................................................................... 3 SCOPE........................................................................................................................ 3 AFFECTS .................................................................................................................... 3 DEFINITIONS.............................................................................................................. 3 FEED ACTIVITIES ...................................................................................................... 4 Administrative.............................................................................................................. 4 Process Hazards Reviews .......................................................................................... 5 Preliminary Process Hazards Analyses ...................................................................... 5 SIL Determination Reviews ......................................................................................... 6 Safety Review Action Item Management .................................................................... 6 Toxic Consequence Modeling ..................................................................................... 6 Blast Overpressure Monitoring.................................................................................... 7 SCOPE OF EPC ACTIVITIES..................................................................................... 7 Administrative.............................................................................................................. 7 Process Hazards Reviews .......................................................................................... 8 Process Hazards Analyses ......................................................................................... 8 SIL Determination Reviews ......................................................................................... 8 Safety Review Action Item Management .................................................................... 8 Toxic Consequence Modeling ..................................................................................... 9 Blast Overpressure Modeling ...................................................................................... 9 Quantitative Risk Assessment..................................................................................... 9 Flare Radiation Modeling ............................................................................................ 9 Management of Change.............................................................................................. 9 Pre-Start-up Safety Review....................................................................................... 10
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

1.0

PURPOSE The purpose of this Design Basis is to provide the Engineering, Procurement and Construction (EPC) Contractor(s) with information specific to a given discipline to achieve a better overall understanding of the work scope and provide additional detailed engineering and construction requirements. This Design Basis illustrates how the elements of Process Safety Management were employed during the FEED phase of the Yanbu Export Refinery Project and how those elements should be employed during the EPC phase of the project. This basis is meant to be a quick reference to, but does not supersede, the Project Procedure Manuals (PPM), 304 - Process Safety Management (PSM) Program [100-YERPM-PPM-0006], and 305 - Management of Change [100-YER-PM-PPM-0007]. The Project Procedure Manuals contain the detailed requirements for the Project.

2.0

SCOPE This document is intended to highlight specific procedures, specifications, standards and/or other documents which are to be adhered to during the detailed engineering and construction phase of the project.

3.0

AFFECTS This affects all Contractors executing engineering and construction for the Yanbu Export Refinery Project.

4.0

DEFINITIONS Company Project Management Team (PMT) The Company Project Management Team (PMT) is the group responsible for the management of the entire project and is dedicated to the overall success, development and execution of the work and to ensure alignment across the numerous project interfaces. The PMT consists of Aramco Services Company and ConocoPhillips team members, partner(s), agency personnel, and Contractors. These project management resources will form a cohesive, seamless team responsible for the project execution. Saudi Aramco (SA) Saudi Aramco as used in this document shall mean Saudi Arabian Oil Company and its affiliated companies including, but not limited to, Aramco Services Company.
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

ConocoPhillips (COP) ConocoPhillips as used in this document shall mean ConocoPhillips Company and its affiliated companies including, but not limited to, ConocoPhillips Yanbu Ltd. Yanbu Export Refinery Project (YERP) The Yanbu Export Refinery Project (YERP) as used in this document shall also mean the Yanbu Export Refinery Company and its affiliated companies. It is also named as the COMPANY. Contractor or Contractors Any design, construction or service Contractor(s), manufacturer(s), vendor(s), government agencies, and other similar organization(s) having a contractual relationship or a prospective contractual relationship with the COMPANY. Process Technology Package (PTP) A collection of process unit or process system based safety information that provides the base information necessary to complete a Process Hazards Analysis. 5.0 5.1 FEED ACTIVITIES Administrative Prepared work plans for the following Process Safety activities during FEED: Process Hazards Reviews, PHR Preliminary Process Hazards Analyses, PPHA SIL Determination Reviews Preliminary Process Hazards Register Safety Review Action Item Management Toxic consequence modeling Blast overpressure modeling

Updated work plans as project needs evolved and kept current version on hand for review by project personnel and any other interested parties. Provided Process Safety consultation for the various disciplines during the life of the FEED.

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

5.2

Process Hazards Reviews For each required* unit, obtained Process Flow Diagrams (PFDs, from Process Systems that reflected at least one round of client review. Ensured that drawings were ready for a high-level review by a multi-discipline team consisting of representatives from client, company, and licensor (where applicable). Obtained Material Safety Data Sheets, MSDS, for substances affecting the units being reviewed. Obtained plot plans for units and the overall facility. Reviewed applicability of standard PHR questions with Process Design and the Licensor prior to review sessions. Tailored PHR questions according to consultation with Process and Licensor. Ensured that team members were provided a personal copy of the PFDs, plot plans, and review questions. Facilitated review sessions and recorded team discussions. Issued minutes of review sessions for quick review/approval by team members. Issued PHR Action Items once approved by team members. Issued report for PHR. Updated PHR Report as needed. Tracked PHR Action resolution and updated the Process Hazards Tracking Register as warranted. Process Hazard Review Reports can be examined by accessing the document numbered XXX-YER-HS-PSM-0001 (where XXX represents the WBS number).

5.3

Preliminary Process Hazards Analyses For each unit, obtained Piping and Instrument Diagrams (P&IDs), from Process Systems that reflect at least one round of client review. Ensured that drawings were ready for a What If? process hazards analysis by a multi-discipline team consisting of representatives from client, company, and licensor (where applicable/available). When warranted by the size and complexity of the unit, separated the process into distinct nodes to enhance the teams focus during the review. Prepared What If? questions based on P&IDs and nodes. Ensured that team members were provided a personal copy of the P&IDs and other information needed during the review. Facilitated review sessions and recorded team discussions. Issued minutes of review sessions periodically for quick review/approval of team members. Issued PPHA Action Items to assigned personnel once approved by team members. Issued all PPHA action items after conclusion of review sessions once team members had reviewed and approved. Issued report for PPHA. Updated PPHA Report as needed. Tracked PPHA Action resolution and updated the Process Hazards Tracking Register as warranted. Preliminary Process Hazard Analysis Reports can be examined by accessing the document numbered XXX-YER-HS-PSM-0101 (where XXX represents the WBS number).

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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

5.4

SIL Determination Reviews For each unit, obtained P&IDs from Process Systems that reflected at least one round of client review. Obtained unit cause and effect diagrams. Ensured that drawings and diagrams were ready for a Safety Integrity Level, SIL Determination Review by a multi-discipline team consisting of representatives from client, company, and licensor (where applicable/available). When warranted by the size and complexity of the unit, separated the process into distinct nodes to enhance the teams focus during the review (nodes may have been the same as were used during the PPHA). Ensured that team members were provided a personal copy of the P&IDs, plot plans, and cause and effect charts. Using information from PPHA, documented the initiating event(s) and consequences of a safety instrumented system failing to respond upon demand. Using information from PPHA, documented the independent protection layers present in the design. Using the methodology approved by the project, assigned safety integrity levels for each safety instrumented function (SIF) in the design and each safety instrumented function proposed by the PPHA team. Issued minutes of review sessions periodically for quick review/approval of team members. Issued assigned SILs to Control Systems personnel once approved by team members. Issued all SILs after conclusion of review sessions once the team members had reviewed and approved them. Issued report for SIL Determination Review. Updated report as needed. Tracked SIL assignment resolution and updated the Process Hazards Tracking Register as warranted. Prepared SIL Listing once safety integrity levels had been established. SIL Determination Review Reports can be examined by accessing the document numbered XXX-YER-HS-PSM-0103 (where XXX represents the WBS number).

5.5

Safety Review Action Item Management Developed and implemented a management system to capture all of the action items resulting from the PPR, PPHR, and SIL reviews. This system documented the action items and closure responsibilities. The system will facilitate client approval of the proposed resolution and document closure of the resolution and the individuals that closed the action item.

5.6

Toxic Consequence Modeling Limited Toxic Consequence Modeling was performed during the YERP FEED design phase. Selected process streams with high concentrations of H2S were the bases for modeling a series of two-inch hole releases to the atmosphere. These releases were modeled to a dispersion endpoint matching the concentration immediately dangerous to life and health (100 ppm) for hydrogen sulfide. The modeling was conducted to ascertain the suspected impact of a release of toxic gas from the facility upon any neighboring, occupied areas. Toxic modeling was conducted by a third party consultant with support from the YERP FEED project team.
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

5.7

Blast Overpressure Monitoring Preliminary blast modeling was carried out for YERP to provide guidance as to the development of the overall layout plan for the main process units as well as the design and location for normally occupied buildings and buildings that house critical equipment. PHAST v6.5 software (Baker-Strehlow blast model) was used for simulating the blast overpressure isopleths. The blast modeling was carried out in two steps: Dispersion modeling was carried out to determine the extent of a flammable cloud mass within Lower Flammability Limit (LFL) concentration limit. Blast modeling was carried out to determine overpressure contours based on the flammable cloud mass determined in step one.

6.0 6.1

SCOPE OF EPC ACTIVITIES Administrative Prepare work plans and execute them for the following Process Safety activities during EPC: Update and validate Process Hazards Reviews Conduct and document Process Hazards Analyses utilizing hazard and operability, HAZOP, review technique Update and validate SIL Determination Reviews Safety review action item management Support third party Toxic Consequence Modeling efforts Support third party updating and validating of Blast overpressure modeling Support third party Quantitative Risk Assessment, QRA Support Interconnecting Systems (SP-6) Flare radiation modeling Management of Change

Update work plans as project needs evolve and keep current version on hand for review by project personnel and any other interested parties. Provide Process Safety consultation for the various disciplines during the life of the EPC. Note that the activities described in detail during FEED will be similar to those during EPC. YERP reserves the right to attend and participate in all process safety reviews.
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

6.1.1

Documentation The EPC Contractor shall provide a report of all process safety hazards identified and the engineering and administrative controls employed to eliminate and/or mitigate the hazards identified. Studies performed in FEED shall be updated as the design becomes more detailed and any additional studies shall be documented in individual reports. The EPC Contractor shall assemble and make available to the review teams all of the required process safety information to effectively conduct the process safety studies.

6.2

Process Hazards Reviews The PHR conducted in FEED will be reviewed and revalidated during detailed engineering, paying particular attention to identified action items and any changes to the Process Technology Package (PTP).

6.3

Process Hazards Analyses The EPC Contractor will review and validate the What If type PHA conducted in FEED, paying particular attention to identified action items. Once P&IDs are finalized, the EPC Contractor shall develop the PTP in accordance with the project procedure and conduct an additional PHA utilizing the hazard and operability, HAZOP, guide word method. The EPC Contractor will document the HAZOP study and update it based on changes made after the study.

6.4

SIL Determination Reviews During detailed engineering the EPC Contractor shall review, revalidate and update the SILs for the safety instrumented functions as determined during FEED. If EPC SIL Determination Reviews recommend a deviation in SIL (from the FEED study), the Management of Change (MOC) procedure must be implemented. Similarly, removal of a SIF from the Safety Instrumented System (SIS) will require an MOC if the FEED study recommended keeping it as an SIF. Any new SIFs should have their integrity levels established in a manner consistent with that which was used during the FEED phase of the project.

6.5

Safety Review Action Item Management Develop and implement a management system to capture all of the action items resulting from all of the above safety review activities. This system will document the action items and closure responsibilities. The system will facilitate YERP
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

approval of the proposed resolutions and document closure of the resolutions and the individuals that closed the action items. The additional engineering or administrative controls resulting from these actions shall be documented in association with the hazards eliminated or mitigated. 6.6 Toxic Consequence Modeling During detailed engineering the EPC Contractor shall support third party update and/or revalidation of toxic consequence modeling conducted in FEED and apply any recommended mitigation measures as required. 6.7 Blast Overpressure Modeling During detailed engineering the EPC Contractor shall support third party update and/or revalidation of the blast overpressure modeling conducted in FEED and apply any recommended mitigation measures as required. 6.8 Quantitative Risk Assessment During detailed engineering, the EPC Contractor shall support and exchange information with a specialized third party contracted to perform a quantitative risk assessment for the facility including pipelines entering and exiting the facility. The third party should be asked to provide an example study with appropriate documentation prior to being approved to conduct the assessment. The third party shall provide a full list of releases evaluated, models employed and a list of assumptions used. The risk contours that are produced shall conform to acceptability standards established by the Kingdom of Saudi Arabia and YERP. The EPC Contractor shall coordinate with third party contractor to provide the risk analysis along with the risk assessment as part of the documentation for the QRA studies. 6.9 Flare Radiation Modeling The Interconnecting Systems (SP-6) Contractor shall perform flare radiation modeling to establish safety design parameters for the flares such as height, location, ground exposure levels and appropriate safety zones. The Interconnecting Systems (SP-6) Contractor is to document the modeling in accordance with YERP standards. 6.10 Management of Change The EPC Contractor will implement a management of change system that will review the design changes for process safety impact and update the associated
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Yanbu Export Refinery Project

PROJECT DESIGN BASIS 000B.3.1.13 PROCESS SAFETY Design Basis Document No.: 100-YER-PE-PDB-0113 Revision No.: FF Issue Date: 09 May 2008

process safety documentation and studies to maintain a current listing of all hazards and associated engineering and administrative controls. All items identified as MOC will be tracked to completion. The management of change system shall cover all phases of the work through construction and the mechanical completion and acceptance process. 6.11 Pre-Start-up Safety Review The EPC Contractor will conduct a Pre-Start-up Safety Review prior to commissioning. The scope of this review may include, but is not limited to, the following: Closeout of Hazard Analyses actions Confirmation of equipment design Confirmation of Safety Integrity Levels Confirmation of Pressure Safety Valves (set pressures and relief capacities) Confirmation of control valve failure positions Confirmation of critical check valves

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