100 Yer PM PPM 0006

Yanbu Export Refinery Project
PROJECT PROCEDURE MANUAL (PPM) Project Procedure 304, Process Safety Management (PSM) Program Document No.: 100-YER-PM-PPM-0006 Revision No.: 0 Issue Date: 29 April 2008
PREFACE This procedure is a revision or an overlay to a Saudi Aramco Engineering Procedure, for the scope of the Yanbu Export Refinery Project, YERP, unless specifically defined as a New document. A YERP procedure consists of a revision or an overlay and the Saudi Aramco (SA) document with the same name. An overlay establishes any required changes to the SA document and specifically defines the changes. If the SA document is to be used without any changes the overlay will state there are no changes required. If the document is a new YERP document, with no reference to a SA procedure, the overlay will state it. The YERP Procedure Index identifies which YERP documents are new and the ones that relate to SA documents that are unchanged, changed, or deleted. All references to SA procedures, specifications and standards are to be defined as references to YERP procedures, specifications and standards unless specifically stated otherwise in the overlay. All references to SA organizations are to be defined as the YERP Management Team. Interpret the following as specified: Revise A specific revision to a SA or other Code paragraph or sentence as noted in this specification Add continuation of an SA or other Code paragraph with an overlay requirement Substitute replace the SA or other Code paragraph in entirety by the overlay requirement New New paragraph number in the overlay with no corresponding SA or other Code paragraph Delete SA or other Code paragraph is deleted by the overlay REVISION This is a new YERP document that does not replace any Saudi Aramco Document. ATTACHMENTS None
General / Business Confidential Page 2 of 53

TABLE OF CONTENTS 1.0 2.0 3.0 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5.0 6.0 7.0 7.1 7.2 8.0 8.1 8.2 8.3 8.4 PURPOSE................................................................................................................... 5 SCOPE AND OBJECTIVES ....................................................................................... 5 AFFECTS.................................................................................................................... 5 DEFINITIONS.............................................................................................................. 5 Company Project Management Team (PMT) .......................................................... 5 ConocoPhillips (COP) ............................................................................................... 5 Yanbu Export Refinery Project or YERP ................................................................ 6 Contractor or Contractors ........................................................................................ 6 Process ...................................................................................................................... 6 Facility ........................................................................................................................ 6 Highly Hazardous Chemical ..................................................................................... 6 HAZOP........................................................................................................................ 6 REFERENCES............................................................................................................ 7 CONFLICTS AND DEVIATIONS ................................................................................ 7 RESPONSIBILITIES ................................................................................................... 7 Contractors ................................................................................................................ 7 Company Project Management Team (PMT) .......................................................... 8 PROCEDURE ............................................................................................................. 8 Introduction ............................................................................................................... 8 Chronology Requirements ....................................................................................... 9 Preliminary Process Hazard Review ..................................................................... 10 Consequence Modeling .......................................................................................... 11

8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15
Safety Instrumented System .................................................................................. 11 Process Safety Information (PSI)........................................................................... 11 Process Hazards Analysis (PHA)........................................................................... 13 Process Safety Reviews (PSR) .............................................................................. 15 Management Of Change (MOC) Requirements .................................................... 15 Vendor Operating Procedures ............................................................................... 16 Pre-Start Up Safety Review (PSSR) ....................................................................... 16 Mechanical Integrity (MI) ........................................................................................ 17 Contractor Safety Management ............................................................................. 18 Safety Review Action Item Management Program............................................... 18 Plant Layout............................................................................................................. 19
ATTACHMENTS ATTACHMENT 1 .................................................................................................................. 21 ATTACHMENT 2 .................................................................................................................. 40 ATTACHMENT 3 .................................................................................................................. 51

1.0
PURPOSE The purpose of this procedure is to define the Process Safety Management (PSM) program for the development and execution of the Yanbu Export Refinery Project. The intent of this program is to meet all requirements of OSHA regulation 29 CFR 1910.119, OSHA 3132 and OSHA 3133, even thought all requirement are not specifically mentioned.
2.0
SCOPE AND OBJECTIVES The basis scope covered by this procedures is to established the managerial and engineering requirements and functions to be followed to emphasize the management of hazards and prepare a comprehensive management program that integrates the process design, process technology, process changes, operational and maintenance activities and procedures, non-routine activities and procedures, emergency preparedness plans and procedures, training programs, and other elements that affect the process. The major objective of process safety management (PSM) program is to prevent hazardous situations in the workplace when the Yanbu Export Refinery Project is in the development stages and when the Yanbu Refinery Project is in operation, including hazardous chemicals where unwanted releases of them should be prevented, especially into locations that could expose employees and others to serious hazards. An effective process safety management program requires a systematic approach to evaluating the whole Project and Yanbu Refinery Project operation.
3.0
AFFECTS Applicable to all engineering, design, and construction for the development and execution of the Yanbu Export Refinery Project.
4.0 4.1
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.
4.2
ConocoPhillips (COP) ConocoPhillips as used in this procedure shall mean ConocoPhillips Company and its affiliated companies, including but not limited to ConocoPhillips Yanbu Ltd.

4.3
Yanbu Export Refinery Project or YERP The Yanbu Export Refinery Project (YERP) as used in this procedure, shall also mean the Yanbu Export Refinery Company and its affiliated companies. It is also named as the COMPANY .
4.4
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.
4.5
Process Process means any activity involving a highly hazardous chemical including using, storing, manufacturing, handling, or moving such chemicals at the site, or any combination of these activities. For purposes of this definition, any group of vessels that are interconnected, and separate vessels located in a way that could involve a highly hazardous chemical in a potential release, are considered a single process.
4.6
Facility A facility means buildings, structures, containers or equipment which contains a process.
4.7
Highly Hazardous Chemical A Highly Hazardous Chemical is any substance possessing toxic, reactive, flammable, or explosive properties.
4.8
HAZOP The Hazard and Operability Study (HAZOP) is a formally structured method of systematically investigating each element of a system for all of the ways in which important parameters can deviate from the intended design conditions to create hazards and operability problems. The hazard and operability problems are typically determined by a study of the piping and instrument diagrams by a team of personnel who critically analyze effects of potential problems arising in each pipeline, equipment and in all aspect of the operation. Pertinent parameters are selected, for example, flow, temperature, pressure, levels and time, also evaluation of all rotating equipment, access, confined space. Then the effect of deviations from design conditions of each parameter is examined.

A list of key words, for example, "more of", "less of", "part of", are selected for use in describing each potential deviation. The system is evaluated as designed and with deviations noted. All causes of failure are identified. Existing safeguards and protection are identified. An assessment is made weighing the consequences, causes and protection requirements involved. 5.0 REFERENCES YERP Engineering Reports YERP-SAER-5437 YERP Engineering Procedures YERP-SAEP-302 YERP Project Procedures Project Procedure 305 Project Procedure 327 Project Procedure 1008 Management Of Change (MOC) HAZOP Systems Requirements Engineering Revision Document Preparation and Instructions for Obtaining a Mandatory YERP Requirements Waiver of Guidelines for Conducting HAZOP Studies
6.0
CONFLICTS AND DEVIATIONS Any conflicts between this document and other applicable YERP Engineering Standards (YERP-SAES), YERP Materials System Specifications (YERPSAMSS), YERP-Standard Drawings (YERP-SASD), or Industry Standards, Codes, and Forms shall be resolved by the YERP Management Team. Direct all requests to deviate from this specification in writing to the YERP PMT who shall follow internal project procedure YERP-SAEP-302, Instructions for Obtaining a Waiver of Mandatory YERP Requirements.
7.0 7.1
RESPONSIBILITIES Contractors Contractor is responsible for the performance of the process safety work and completion of the documentation as described in this Procedure and Attachments sections. Contractor is responsible for developing the plans and analysis to meet the PSM requirements. Contractor shall submit the completed documents to PMT for review and approval.

Contractor is responsible for the planning, organizing, conducting, and implementing recommendations of a HAZOP. 7.2 Company Project Management Team (PMT) PMT will conduct Process Safety Reviews (PSR) as the project progresses for the purpose of ensuring that potential health and safety factors are assessed. See section 8.8 Process Safety Reviews (PSR). 8.0 8.1 PROCEDURE Introduction The Process Safety Management (PSM) program includes information on the following: Contractor Requirements Process Safety Information (PSI) Preliminary Process Hazard Review (PHR) Process Safety Reviews (PSR) Consequence Modeling Safety Instrumented System (SIS) Process Hazards Analysis (PHA) Management of Change (MOC) requirements Vendor Operating Procedures Pre-Start Up Safety Reviews (PSSR) Mechanical Integrity Contractor Safety Management Safety Review Action Item Management Program Plant Layout Described herein are elements of OSHA regulation 29 CFR 1910.119 with which Company is required to comply. During the course of the work to be done under this contract, Contractor shall assist PMT to comply with the regulation. Contractor shall work closely with PMT's representative to finalize the agreed-upon scope of the following items of work.

On-going communication between Contractor and PMT's representative shall be established to set benchmarks for the work and assure that work is being done in a timely manner to prevent the need for additional work outside the scope described. 8.2 8.2.1 Chronology Requirements Appraise Phase There were not any Process Safety Management Program deliverables to be accomplished during the Appraise Phase. 8.2.2 Optimize Phase Following activities and/or studies were performed during the Optimize Phase of the Yanbu Export Refinery Project: Preliminary Process Hazard Review (PHR) Safety Review Action Management Program Plant Layout Consequence Modeling Hazard Register Log (HRL) 8.2.3 Define Phase Following activities and/or studies were performed during the Define Phase of the Yanbu Export Refinery Project: Safety Instrumented System (SIS) Preliminary Process Hazard Analysis (PPHA) Safety Review Action Management Program Plant Layout 8.2.4 EPC Phase Following activities and/or studies shall be performed during the EPC Phase of the Yanbu Export Refinery Project: Safety Instrumented System (SIS) Timing: Immediately the P&ID review meeting P&IDs issued for Client Review (ICR) Safety Review Action Management Program Timing: After SIS Detail design Process Hazard Analysis (PHA) Timing: After P&IDs issued Approved for Development (AFD)

Safety Management of Change (MOC) Timing: After detail design PHA Plant Layout Timing: After P&IDs issued Approved for Development (AFD) Process Safety Review (PSR) No. 1 Timing: After detail design PHA Mechanical Integrity (MI) Timing: Before starting procurement program Process Safety Review (PSR) No. 2 Timing: After beginning of the construction phase Contractor Safety Management Timing: During the construction phase Pre-Start Up Safety Review (PSSR) Timing: Thirty (30) days before the Process Unit or System is completed (construction) Process Safety Review (PSR) No. 3 Timing: Before commissioning of the plant. Following support documents or group of documents shall be prepared, to have them available for the activities and/or studies shown above: Process Safety Information (PSI) EPC Issue of the Process Technology Package (PTP) EPC Issue of the Flare Technology Package (FTP) Vendor Operating Procedures 8.3 Preliminary Process Hazard Review The Preliminary Process Hazard Review (PHR) identifies and analyzes possible deviations from the process design intention and thereby identifies potential hazards which may have significant impact on cost and/or schedule. The results of the PHR were addressed by the design team with the goal of eliminating the hazard, reducing its likelihood of occurrence and/or severity of the consequence. The Technical Review of Process Flow Diagrams (PFD) including the licensor information has been used as an introduction (process description and design intent) for the PHR.

The appropriate Project, Technical, Operations, Client and Licensor representatives participated in the PHR immediately following the PFD review. The minimum required documents were the PFDs and the heat and material balance information with expected temperatures, pressures and flow rates. A Process Safety Checklist was used for the purpose of these reviews. The recommendations or Action Items (AI) were entered into the Hazard Register Log (HRL) for that specific unit, and each item was tracked until it was completed with the required documentation. 8.4 Consequence Modeling Consequence modeling (screening level) is a study of selected hazards identified in the PHR to be performed to quantify the severity of the consequences associated with potential releases of process fluids. Consequences of interest are potential exposures to facility personnel (as well as the surrounding public), the environment and property with damage resulting from explosion overpressure, fire radiation and toxic releases. Using the YERP criteria, the results of these studies were used as a basis for the design associated with facility sitting, such as the location of occupied buildings and critical structures. Such criteria and related facility requirements will apply to both permanent and temporary buildings and structures (e.g., construction warehouses and offices, temporary training facilities, etc.). 8.5 Safety Instrumented System After P&ID development to the Issue for Client Review (ICR) in the Optimize Phase, a review was performed to check potential Safety Instrumented System (SIS) requirements and determine the appropriate Safety Integrity Level (SIL) of these systems. The purpose of this review is to ensure that the level of reliability of safety related instrumentation is adequate based on the level of risk associated with credible process hazards. The SIS criteria and the risk ranking procedure to be used in assigning SILs were provided by YERP. Comments and recommendations resulting from the review were incorporated into the report and any required revisions will be made to the documentation. The SIL assignments shall be reevaluated during EPC Phase to determine if they can be reduced based on any new layers of protection or other mitigation features identified immediately after the EPC Phase P&ID review meeting and also during the course of the EPC PHA review. 8.6 Process Safety Information (PSI) Contractor must complete a compilation of written process safety information before conducting any process hazard analysis (PHA) required by this Procedure.

The compilation of written process safety information will help everybody to identify and understand the hazards posed by operating the process involving highly hazardous chemicals. Process safety information must include information on the hazards of the highly hazardous chemicals used or produced by the process, information on the technology of the process, and information on the equipment in the process. Two documents are used to collect the Process Safety Information: Process Technology Package (PTP) Flare Technology Package (FTP) 8.6.1 Process Technology Package (PTP) Contractor shall prepare a Process Technology Package (PTP) for the project per PMT's Process Technology Package Guidelines included in ATTACHMENT 1. The PTP is a collection of process unit or process system based safety information and provides the base information necessary to complete a PHA. A PTP shall be prepared during EPC Phase development two weeks before the Process Hazard Analysis (PHA) meeting. All sections shall be included. Any section to be issued after the PHA should be clearly indicated. EPC Contractor will continue the development of PTP. Final Deliverable of the PTP shall include three (3) hard copies and one (2) electronic copy. The deliverables shall be issued at the completion of design. PTP is considered an Ever Green document and deliverables included therein are to be As Built and shall incorporate all changes from the PHA to PMT's acceptance of the unit. 8.6.2 Flare Technology Package (FTP) Contractor shall prepare flare system documentation for the overall flare system per PMT's Flare Technology Package (FTP) Guidelines included in ATTACHMENT 2. The FTP is a collection of flare system based process safety information and provides the base information necessary to complete a PHA. The FTP shall be prepared during EPC Phase development before the Process Hazard Analysis (PHA). All sections should be included.. EPC Contractor will continue the development of FTP. Final Deliverable of the FTP shall include three (3) hard copies and one (2) electronic copy. The deliverables shall be issued at the completion of design. FTP is considered an Ever Green document and deliverables included therein are to be As Built and shall incorporate all changes from the PHA to PMT's acceptance of the unit.

8.7
Process Hazards Analysis (PHA) The process hazard analysis is a thorough, orderly, systematic approach for identifying, evaluating, and controlling the hazards of processes involving highly hazardous chemicals. The Contractor must perform an initial process hazard analysis (hazard evaluation) on all process units or process systems. The process hazard analysis methodology selected is the Hazard and Operability Study (HAZOP). Contractor shall follow the system requirements and PHA/HAZOP deliverables listed in the Project Procedure 327 HAZOP Systems Requirements. The procedure for conducting the HAZOP study shall be in accordance with the Engineering Report YERP-SAER-5437, Guidelines for Conducting HAZOP Studies. As a minimum scope, a Process Hazard Analysis (PHA) will be performed on only the portions of the design involving hazardous materials and/or operations. A third party facilitator and third part scribe may be utilized in the PHA. Other reviews may be scheduled as part of the overall Process Safety Scope to supplement the PHA. Contractor shall conduct systematic and comprehensive HAZOP studies (per 29 CFR 1910.119) as defined in the Definitions section (4.9) for each process unit or process system. Contractor shall submit a PHA work plan for PMT approval before beginning HAZOPS. The PHA will be performed after the P&IDs are complete and issue Approved for Development. The objective will be to systematically review design documentation in order to identify potential hazards and major operability problems in the plant which could compromise the ability of the systems and equipment to safely handle start-up and credible operating deviations from the design intent (normal and planned operations). The PHA documentation format shall comply with the indications shown in the Engineering Report YERP-SAER-5437, Guidelines for Conducting HAZOP Studies. Extent of documentation of each PHA shall be agreed between Contractor and PMT prior to beginning any PHA. All the recommendations or action Items (AI) will be added to the Hazard Register for each process unit and these AI will require resolution in the EPC phase and also as required by the Pre-startup Safety Review (PSR). For some mature technology where design has been developed and undergone extensive reviews, it may be appropriate to do only a detailed Checklist methodology. The findings of the review team will be by consensus. A Process Hazards Analysis (PHA) has different objectives than a project P&ID review, and thus shall be performed as separate efforts. The PHA shall focus on the process hazards as opposed to the P&ID review that defines the project scope.

8.7.1
Contractor Responsibility Contractor shall establish a system to: Address promptly the teams findings and recommendations Ensure that the recommendations are resolved in a timely manner and that the resolutions are documented Document what actions are to be taken Develop a written schedule of when these actions are to be completed Complete actions as soon as possible
8.7.2
Detailed PHA HAZOP Contractor shall conduct this review when the P&ID's have been approved for development (AFD) that include the detailed piping design and the major equipment approval drawings that have been reviewed and returned to the vendor. All hazards are identified and their controls thoroughly analyzed. Management of Change will begin with the documents used for this review. Action items from this PHA will be documented and resolved to the satisfaction of PMT. Impact of any change to documents issued for fabrication or construction shall be brought to PMT's attention before implementation (refer to procedure 305 Management of Change MOC).
8.7.3
PHA Team The PHA team shall be subject to PMT's approval. Participants and their source for PHA Reviews shall be as a minimum: PHA Facilitator (one familiar with the HAZOP technique) by Contractor. Lead Engineer (or equivalent familiar with area) by Contractor. Project Engineer by PMT Mechanical Engineer by PMT Instrument Engineer by Contractor Automation Engineer by Contractor Operations Specialist by PMT PHA scribe by Contractor Contractor shall make project team specialists available as needed for periodic consultation, if required, during the course of the HAZOP review. PMT will inform if additional support is required from the Company for the HAZOP review meetings.

Copies of the PTP and the FTF shall be available to each participant in advance (at least two working days before meeting). Contractor shall prepare a total of 10 hard copies of these documents. 8.8 Process Safety Reviews (PSR) PMTs Process Safety Review (PSR) team will at its discretion conduct up to three (3) process safety reviews of the project during the EPC design stages. The purpose of these reviews is to ensure that potential health and safety factors are fully assessed. Each review will be for a period of one week and will be conducted in a conference room at the Contractors Offices. Contractor to ensure that the room and the facilities for the meeting will be in place. The PSR team is composed of up to six members, all of which will be supplied by the PMT. An independent member could be selected to be part of this group, to lead the review and improve the objectivity of these PSR meetings. For each PSR review, Contractor will make the appropriate personnel available to clarify any data provided and to provide answers regarding the design which arise during the course of the review. Contractor will respond to the findings of the PSR team in a timely manner on forms to be provided following each PSR review. PMT will give one month's notice of the dates for each review to the Contractor to allow time for preparation of the required data. PMT will conduct the PSR No. 1 review following the detailed design PHA. PMT will conduct the PSR No. 2 review early in the beginning of the construction phase of the project. PMT will conduct the PSR No. 3 review just prior to commissioning of the plant. Contractor will supply the information indicated in Attachment 3 to the PSR team. 8.9 Management Of Change (MOC) Requirements Contractor shall follow the comprehensive Management of Change (MOC) system for design and construction changes as set forth in Project Procedure 305, "Management of Change (MOC)". The system shall track all changes that occur while the subject contract is in effect. MOC for each unit shall be implemented following the EPC detail design PHA noted in the Process Hazard Analysis Section 8.7 as applicable. All changes shall be provided to PMT Representative who will decide whether the item is a MOC item or shall be reviewed by the PHA team. The latest PHA report shall be modified to include any of the changes requiring consideration by the PHA team.

Change Approval Forms (CAF) shall be utilized to obtain approvals for changes. CAF's should be defined with assistance from PMT representative. Appropriate documentation attached to the CAF will be required to represent changes made. Contractor shall maintain files for all changes and the basis for the changes for the duration of this contract. Contractor shall audit the MOC effort to ensure compliance. Contractor's PSM activities. 8.9.1 Log of Change (LOC) Log of Changes (LOC) is the process of identifying, tracking and keeping appropriate documentation of changes that occur after the pre-authorization PHA during the Design Phase. Contractor shall follow the indication included in the Project Procedure 305, "Management of Change (MOC)". Optimize and Define Phase Contractor shall initiate a LOC beginning with the PHA revision set of P&IDs. After the Detail PHA (HAZOP) is conducted, all project changes that affect P&IDs (i.e. pressure, flow rate, temperature, metallurgy of equipment or piping, etc.) must be identified as requiring a HAZOP review to ensure that the PSM integrity established is maintained. 8.10 Vendor Operating Procedures Contractor shall provide Operating Procedures available from applicable vendor and/or licensor supplied literature for mechanical, rotating or packaged equipment. Any applicable Material Safety Data Sheets (MSDS) for the chemicals, lube oils, desiccants, protective coatings, grease, solvents or other material required for storage, preservation, start up and normal operation should be included. 8.10.1 Contractor Requirements Contractor shall perform all work in accordance with Contractors written plan which meets or exceed OSHA 29 CFR 1910.119, and as approved by PMT. Contractor shall submit final contract documentation as outlined herein for PSM. It shall be the responsibility of Contractor to ensure that any sub-contracted work is in full compliance with OSHA 29 CFR 1910.119 and PMT requirements. 8.11 Pre-Start Up Safety Review (PSSR) EPC Contractor shall initiate/conduct a Pre-Startup Safety Review (PSSR), thirty (30) days before the Process Unit or System is completed (construction). The PSSR will confirm the finished project unit has been completed per the "As-Built" specifications and design philosophy (confirmed through MOC) and that all final documentation is complete. The PSSR shall be conducted in accordance with Contractors plan, approved by the PMT.
PMT will monitor

Contractor's plan shall include, but not be limited to, the following: Agree with PMT that all Process Technology Packages are complete and have been delivered to PMT. Contractor shall commit to delivery of any documentation required for any late changes to the process technology not included in the packages. Agree with PMT that information required from licensors for startup, emergency procedures, and normal operation has been delivered to PMT. Present documents to PMT, which confirm that, all construction, equipment, and piping is in accordance with the design specifications. Confirm that unit operating manual and mechanical procedures for all equipment are complete and have been delivered to PMT. Confirm that all PHA items have been resolved by presenting written statements to PMT describing the resolution (if not previously presented). Confirm that all approved changes are complete by presenting written evidence to PMT describing the implementation of each change (completed summary of changes during contract). 8.12 Mechanical Integrity (MI) The Mechanical Integrity (MI) program ensures that the facility is specified in accordance with recognized standards, and that proper testing and inspections are done and documentation provided for all process-related equipment. The Facilities segment of OSHA regulations includes Mechanical Integrity verification of the physical components of an operating unit (i.e., vessels, exchangers, pumps, piping - including components, relief and vent systems and devices, emergency shutdown systems, controls, HVAC, etc.). The goals will include, but not be limited to, proper specification of materials, correct fabrication procedures, proper installation, and accurate documentation. The following components are involved: 8.12.1 Quality Assurance (QA) Contractor shall be responsible to manage QA as defined in Scope of Work, Project Quality Assurance/Quality Control Plan. Any equipment with deficiencies that are outside acceptable limits shall be corrected before being placed in service. Contractor shall assure that equipment as fabricated meets design specifications and that all inspections and tests required have been performed and documented. Contractor shall ensure that equipment is installed properly and consistent with design specifications and manufacturer's instructions.

8.12.2 Maintenance Procedures Contractor shall provide Equipment Maintenance Procedures available from applicable vendor and/ or licensor supplied literature for mechanical, rotating or packaged equipment. 8.13 Contractor Safety Management Contractor shall assure that subcontractors are informed of the known fire, explosion, or toxic release hazards related to their work. They shall also be trained in the work practices necessary to safely perform their job, and to be aware of any applicable site safety rules and site's emergency action plans. 8.14 Safety Review Action Item Management Program A Safety Review Action Item Management Program will be implemented throughout the project to track all safety review action items during all phases of the project. The program will consist of two basics features: Safety Review Action Item Form Hazard Register Tracking Log 8.14.1 Safety Review Action Item Form A separate Safety Review Action Item Form will be completed for each safety review action item. As a minimum, the form will contain a description of the hazard, the review teams recommendation for resolving the hazard and the final design action taken to resolve the concern. Upon completion of each action item, copies of the documents (P&ID, data sheets, etc.) that implemented the action item will be attached to the Action Item Form. The form will be signed by the responsible parties with the date the Action Item Form is completed. All safety review Action Item Forms (and associated documentation) will be maintained (in a single source) as proof that appropriate actions were taken to resolve all safety review action items. 8.14.2 Safety Review Action Items in the Hazards Register This register will be in a spreadsheet format that contains specific summary information for each safety review action item and appropriate cross references to other documents such as the PFDs, P&IDs, Plot Plan, etc. as may be appropriate. The tracking will be continuous during the course of the resolution of the item until it has been implemented and signed off as completed on the Action Item Form. When an action item has been verified as being complete, its status will be updated to reflect completion of the item. A file of the completed Action Item Forms and supporting documentation will be included in the final project documentation file records.

8.15
Plant Layout
8.15.1 General The YERP facility will handle hydrocarbon vapors and liquids which if ignited following a release, have the potential to cause a major fire or explosion. It is essential that the Yanbu Export Refinery Project plant layout is configured to minimize the possibility of an undesired event occurring. Careful attention to equipment location improves the safety, accessibility and efficiency of a plant. The first approach to layout is to grade each system according to the nature of the hazard and then categorize the systems of similar grading as follows: Systems which have the potential to emit flammable materials. Systems which must be located in a non-hazardous area. Systems which are considered safe. The layout of the plant or installation shall be developed to achieve the following safety features: Maximum separation between flammable hydrocarbon and ignition sources. Maximum separation between hydrocarbon and hazardous material handling areas and emergency services, main safety equipment, and means of escape. Sufficient means of escape to enable efficient and protected evacuation from all areas to designated muster stations, under a hazard condition. Maximum availability of essential services and the main safety equipment under all foreseeable hazardous conditions. Minimal risk to third parties. Minimal risk of fire spread between plots, so that a fire or other emergency will be contained in the plot of origin. This will also allow for the safe and effective isolation of a unit from its operating neighbors when shut down for maintenance. Division into plots will also optimize on the need for protection systems because the possibility of fire spread is less. Separation between hazardous and non-hazardous areas, for hazardous area classification purposes and control of potential ignition sources. Appropriate and safe access for construction, operations and maintenance. Adequate access during emergency for means of escape, for emergency vehicles and for the fire fighting. The location of roads that carry general traffic in non-hazardous areas, so that vehicles are unlikely to ignite a potential hydrocarbon leak. Fencing requirements and control of visitors.

Consideration shall be given to drainage from all areas taking into account the fire water discharge rates that would be encountered. Large vessels may contain high inventories of flammable material which pose a hazard to the plant. Where possible, the capability shall be minimized and the vessels segregated from non-hazardous areas. Consideration shall be given to the location and height of flares and cold vent stacks which discharge flammable and toxic hydrocarbon materials and combustion products to the atmosphere. Arrangement of flares, vents, drains and exhaust shall be in accordance with applicable environmental standards. 8.15.2 Roads, Access and Escape Dedicated access ways within each plant unit will be provided for operations, escape and fire fighting. These access ways will run to the plant roads. Roads and access ways will be arranged so as to avoid dead ends. To allow for the possibility of one road or access way being blocked e.g., by an accident there will generally be at least two separate routes to any location on the site. The site will itself be accessed by a normal and an emergency road. Roads will as far as practicable be located in non-hazardous areas so that vehicles are unlikely to be a source of ignition. The minimum width of roads will allow for access by plant vehicles such as cranes, and emergency vehicles such as fire trucks. The width of major roads will allow two vehicles to pass each other. All areas of the plant where emergency vehicles may require access shall be provided with roadways of 6.1 meters width minimum. This is to permit two large vehicles to pass each other safely and to deploy to affected areas. There will be two means of escape to safety from any normal working area of the site, except for small platforms or rooms where the distance of a single means of escape is less than 5 meters (to be verified) nominal. Consideration will be given to the escape requirements from any platforms on process columns and structures. Escape routes will be directly away from possible hazards and will terminate at a designated muster area that will be in a safe location by the site entrance. Where practical, two or more means of escape from raised platforms shall be provided. Interconnections between overhead platforms shall be provided where reasonable. The primary means of access to overhead platforms shall be stairway in all cases where frequent access is required or where access is required for operator or maintenance work other than infrequent data collection. Escape route philosophy for buildings shall be in accordance with NFPA-101, Safety to Life from Fire in Buildings and Structures.

ATTACHMENT 1 PROCESS TECHNOLOGY PACKAGE (PTP) DEVELOPMENT GUIDELINES PURPOSE The Process Technology Package (PTP) Development Guideline is a general listing of the requirements for the development of Process Safety Information (PSI). The Process Technology Package (PTP) is the UNIT or SYSTEM based process safety information and serves the following purposes: It will satisfy the OSHA (Occupational Safety, and Health Administration) regulation CFR 1910.119 requirement for process technology and safety information. Provide the base information necessary to complete a PHA (Process Hazard Analysis). Following PTP development, a PHA will be conducted that will identify any deficiencies in the process and recommend remediation steps or procedural changes. The personnel will draw heavily on the information contained in the PTP. Provide basic process safety information to personnel operating the process and maintaining the equipment. The PTP should complement and be consistent with operating manuals. The PTP is intended to be a quick reference for personnel to answer questions on capacity and safe operation. STRUCTURE The PTP is divided into five major sections to help understanding and information retrieval: Section 1.0 Section 2.0 Process Description Piping and Instrument Diagrams is intended to provide overall process understanding. are key to doing practically anything around a UNIT or SYSTEM, so to emphasize their importance and help retrieval they are in a dedicated section. Section 3.0 Hazards of Material is intended to explain chemical hazards from reactions which could occur due to inadvertent mixing of unit chemicals. Work will be done on updating the SHEA MSDS database.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES Section 4.0 Section 5.0 Design Basis Information Protective Safety Systems
is intended to describe basic design information for the process. is intended to provide information on all safety systems in the unit. The PTP should be placed in a three ring binder to expedite updating and information retrieval, with tabs for the major sections mentioned above. The lettering should be black on white. Behind each tab should be a red tab with the subsection number. The lettering should be black on red. This guideline is arranged in the same order as a PTP should be put together. A tag summary is provided and how a table of contents for a PTP should look. Section 1.0 Process Description Process Steps Process Chemistry Process Flow Diagrams Safe Operating Limits Maximum Intended Inventory
Section 1.1 Section 1.2 Section 1.3 Section 1.4 Section 1.5 Section 2.0 Section 3.0
Piping and Instrument Diagrams Hazards of Materials Inadvertent Mixing Table Reaction Explanation MSDS Heat and Material Balance Process Safeguarding Memorandum
Section 3.1 Section 3.2 Section 3.3 Section 4.0 Section 4.1 Section 4.2
Design Basis Information

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES Section 4.3 Section 4.4 Section 4.5 Section 5.0 Area Electrical Classification Equipment Summary Tables Piping Schedule
Protective Safety Systems Plot Plan and Fire Protection Equipment Ventilation Systems Mechanical Safety Systems Safety Instrumented Systems
Section 5.1 Section 5.2 Section 5.3 Section 5.4 APPEARANCE
The white three ring binder should have a slip-in cover with the identification of the Yanbu Export Refinery Project, and the words PROCESS TECHNOLOGY PACKAGE below. The page should be in Yellow color and title in black letters centered on the cover should be the UNIT or SYSTEM name in black lettering. The spine slip should contain the same information. ASSOCIATED DOCUMENTATION During PTP development, several items may be uncovered for consideration by the PHA team. These items should be included in a separate document called the Observations Letter. Generally, these items are logged during PTP development and included in one letter. If an item is deemed serious, the PHA facilitator should be informed.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT 1.0 Process Description 1.1 Process Steps
Process Steps is a basic process description that contains two parts. The first part will be a description of the unit purpose (i.e., convert H2S to sulfur for a sulfur recovery unit) and major processing steps. It also will describe how the unit fits into the overall plant operation. A Block Flow Diagram (BFD) may be included where it helps understanding. For small or somewhat simple units (e.g., Amine Regenerator, Cryo, Sour Water Stripper), the PFD and P&IDs provide sufficiently simple explanation for understanding. The second part will describe the "how and why" the process works in more specific terms. This description allows the reader to follow the process flow diagrams. All major equipment will be shown with its function and how it interacts with other equipment. General control will be described here (e.g., Tower X overhead flows to tower Y on pressure control). Also included in this section is a description of the major process streams entering the unit.
1.2
Process Chemistry
Process Chemistry is a general description of the chemicals and products to be handle in the Unit or System and the reactions that occur in the process. The process chemistry description also should be divided by major section as discussed in the Process Steps. This section should include only those reactions that are integral to the process (i.e., Claus reaction for a sulfur recovery unit) and any important side reactions that affect safety or product quality. The explanation, to aid in clarity, should include the chemical formula and common name of each product and reactant. Sometimes, operating parameters such as pressure, temperature and reactant concentration should be discussed. In particular, any variable the operator can control which could affect the reaction and would have any safety implications also should be included. Reactions that normally do not occur and can only occur if the current piping is changed (tubing from one location to another) will be included in the Reaction Explanation - Section 3.2.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT 1.3 Process Flow Diagrams Process flow diagrams (PFD) should provide enough information so the reader can quickly understand the process basics. The major equipment should be shown with important operating variables. Specifically, the following parameters should be included: Temperatures Pressures Heat Exchanger and Furnace Duties Heat of reaction Compositions should be shown in a separate table in the Heat and Material Balance (HMB) - Section 4.1. Vessel dimensions may be shown on the PFD's and will be consistent with the information in Section 4.4, Equipment Summary Table. The PFD information will be consistent with the HMB data found in Section 4.1. The PFD also should include important control schemes and use the appropriate control Symbology.
1.4
Safe Operating Limits (SOL) The Safe Operating Limits (SOL) are intended to define the unit's ultimate safe operating envelope based on the most constraining of either physical equipment limits or process limits. SOL are process parameter limits beyond which the process is unsafe to operate. Additional SOL may be required to prevent unsafe operation in downstream units. Unsafe operation is defined by those situations that may lead to catastrophic equipment failure, reaction runaway, release of flammable material, release of toxic material, or emergency unit shutdown. Catastrophic equipment failure includes immediate damage, as well as accelerated corrosion or erosion which could occur before it would be anticipated based on historical data. Examples of equipment damage that result in personnel injury are compressor destruction leading to flying debris. Flow to prevent an air compressor from surging fits this category. An example of equipment damage due to corrosion is in a sulfuric acid alkylation unit. Accelerated corrosion can cause personnel exposure to sulfuric acid very quickly.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT The items listed on the table should have the following criteria: Each SOL parameter must be monitorable. There is little value in specifying a parameter limit for which there is no means of verifying a deviation. There should be a temperature indicator, for example, if there is an equipment temperature limit. Examples of monitored variables should include, but not be limited to, any of the following:
Temperature Speed Composition related properties Pressure Level Flow Current Vibration Position Each SOL parameter must be controllable. The Operator must be able to correct a deviation. Examples include: Adjusting the set point on a pressure, temperature, or flow controller Opening or closing a manual valve Shutting the unit down Safety device set pressures or corresponding design pressures if repeated will be consistent with the data in Section 4.2. Any contingency that allows the pressure above the set pressure/design pressure (plus allowed accumulated over pressure) is a deficiency that should be corrected. Safety device set pressures must be included where they prevent any unsafe conditions other than vessel rupture. For example, a high fuel gas pressure trip may be installed to prevent unsafe furnace operation. Another example is the pressure setting on a sulfur recovery unit to prevent atmospheric H2S release by blowing the sulfur seals.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT
Some SOL are protected by safety instrumented systems (SIS). Safety systems are outlined in Section 5.4. The SOL table must be consistent with Section 5.4. Unlike safety valves (passive devices), instrument trip systems (active systems) do not have any codified standard and can be bypassed. They should therefore be included in the SOL table. Although this duplicates information, adding these will define the unit's ultimate safe operating envelope. Strictly environmental emission limits will not be listed on the SOL table. Only potential emissions that could result in short term health risk will be included. Examples of SOL are deviations that could result in large quantities of SO2 / SO3 or NH3 that would cause immediate health problems. The normal environmental limit would not be listed. A statement should be included at the beginning of the SOL table that explains the following are also safe operating limits: Mechanical limits listed in the Equipment Summary Table - Section 4.4 Piping specification (e.g., A2-1) limits outlined in the Piping Material Specifications & Valve Catalog (see Piping Schedule - Section 4.5 - for piping specifications.) Following is a suggested statement: Consult Equipment Summary Table - Section 4.4 - for equipment temperature and pressure limits. Consult the Piping Schedule - Section 4.5 - for piping specifications. Piping specification pressure and temperature limits are found in the Piping Material Specifications & Valve Catalog. Temperature limits from the Equipment Summary Table or piping specifications limits should be included in the SOL table where they can be exceeded. A deficiency is in the process if there is an Operating Limit indication required, but there is neither indication nor control. This deficiency should be noted in the Observations Letter.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT SOL Table Description: The SOL table is divided into six columns. The first column describes the Process Step. The second column describes the Parameter being monitored. The third and fourth columns show the parameter minimum or maximum. The fifth column is a text description of the Consequences of Deviation. The sixth column describes the Steps to Correct or Avoid Deviations. Process Steps are identifiable equipment groups (or single pieces of equipment) to which the SOL apply. A tower, its condenser and reboiler could represent a process step. There should be a step showing the relief evaluation (Section 4.2) rating basis. An example of the rating basis is unit charge rate or another unit operating rate. Each Process Step will be numbered. A letter designation will be assigned to each Parameter associated with the process step. The Parameter is that parameter being limited (see list above in first bullet on monitorable parameters). This parameter may be a direct limit reading or an indication of the actual limit. Low temperature is an example of an indirect reading on a water blow down (to sewer) to show a loss of water level when light hydrocarbon is separated from water. Auto-refrigeration occurs (i.e., temperature decreases) across the valve, thus showing the water level has been lost. The Consequences of Deviation is the deviation end result. Examples of these are possible equipment failure, reaction runaway, release of flammable material, release of toxic material, or emergency unit shutdown. There should be a brief description of how the end result is achieved. There should be a brief description how the two parameters are related (e.g., temperature and corrosion rates) if there is an indirect relationship between the measurement parameter and the limited parameter. The immediacy of the correction needed will be listed in the Consequences of Deviation. A low flow that will cause a compressor to surge, for example, is an item requiring immediate action. A temperature limit to prevent accelerated corrosion may not require immediate action, but nonetheless requires action to prevent unacceptable equipment damage. The limit probably does not need to be included on the SOL table if the immediacy is longer than within one shift.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT The Steps to Correct or Avoid Deviations is the direct action Operations must take to bring the unit back to a safe operation or avoid an unsafe operation. This is where control information is placed (see comment above on SOL being controllable). This description is not meant to recreate the operating procedures, but is meant to present concise steps to secure the unit. Operating procedures may be referred to when detailed troubleshooting is required following securing the unit. These steps should be consistent with the Operating Procedures. A footnote should be employed to emphasize the SOL table must be used with the operating procedures. A suggested footnote is as follows: These steps to correct or avoid deviation are the primary actions required to ensure safe operation. The Operating Procedures should be consulted for complete explanation of the action required. 1.5 Maximum Intended Inventory The Maximum Intended Inventories (MII) are the normal inventories (e.g., 50% instrument span) inside unit battery limits and maximum working capacity for storage vessels and tanks. The maximum inventory will include all chemicals used or manufactured in the unit. Hydrocarbons will be broken down into Flammable Liquids and Flammable Gases. This simplification eliminates the need to break the hydrocarbon streams into their various components. Examples of other chemicals include; sour water, catalyst and support material, hydrofluoric acid, molten sulfur, potassium hydroxide, lime, hydrogen sulfide, etc. Equipment volumes will be based on vessel dimensions in Section 4.4 or on specific documents such as catalyst loading diagrams. Fluid densities, where required, should be on the same basis as the PFD. 2.0 Piping and Instrument Diagrams (P&IDs) The purpose of the P&IDs in the PTP is to show how the process works and how alternate line-ups and operation can be made so that a thorough evaluation of process hazards can be performed.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT 3.0 3.1 Hazards of Materials Inadvertent Mixing Table The Inadvertent Mixing Table shows reaction possibilities between binary mixtures of unit chemicals. A square matrix is created where all the chemicals are listed on both axes. A Y (meaning a reaction may occur) or an N (a reaction does not occur) is used to show whether a reaction is possible. Operating manuals, back ground reading, and technology experts are all possible sources of information for this section. There should be a one-to-one correspondence for the "Y" on the table and the explanations in Section 3.2 Reaction Explanation. Chemicals with similar chemical reactions can be grouped together in the Reaction Explanation. For example, light hydrocarbons such as fuel gas and propane can be grouped together. 3.2 Reaction Explanation The Reaction Explanation is a structured method to explain every reaction that was positive ("Y") in the Inadvertent Mixing Table - Section 3.1. The reaction explanation includes: Unit in which the reaction occurs. Reactant One Reactant Two - Chemicals with similar chemical reactions can be grouped together in the Reaction Explanation. Conditions Of Reaction. This includes means by which the reaction is started. Examples include the contact or ignition source Result Of The Reaction. An example of this is an explosion or toxic gases evolved from the solution, etc. Most Likely Circumstance. This explains how the two reactants would get together and how the conditions would occur. It is acceptable to place "unlikely" in this field if mixing the two reactants require extremely difficult routes. Steps For Handling The Reaction. This outlines the steps that need to be followed should the reaction occur. For example, cut off the hydrocarbon flow to put out the fire or extinguish with chemical extinguisher, etc.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT Safeguards This field explains any safeguards in place either to prevent, control or mitigate the reaction. Examples are equipment and piping design to mitigate the situation, operating procedures, instrumentation that mitigates the reaction occurrence. Additional Information. This field has been provided to give the reader any additional reaction information if it is particularly noxious or substantial information is required for safe unit operation. Typically, this will not be needed. 3.3 MSDS Reference Table This section is intended to show the MSDS references for a unit and the relationship between the MSDS's and equipment. Chemical hazard information contained in the MSDS will be provided. Information relating the MSDS to the equipment is required under the Hazards Communication regulation 29 CFR 1910.1200. Copies of the MSDS should be provided in this section. 4.0 4.1 Design Basis Information Heat and Material Balance The HMB included in the PTP is an overall unit balance. The HMB can be (but need not be) broken down by equipment. Compositions and flows for feed, product and important intermediate streams should be shown here (when available). Molar or Volume percent is preferred for compositions. Mass or molar flow rates are acceptable if existing compositions do not use percentages (Use the most convenient information). The streams will have labels corresponding to labels on the PFDs.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT 4.2 Process Safeguarding Memorandum Here is the Table of Contents for the Safeguarding Memorandum: 1.0 1.1 1.2 2.0 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.2 2.2.1 2.2.2 2.2.3 3.0 4.0 Introduction Process Safeguarding Flow Scheme Safeguarding Intent and Design Practices Process Safeguards Final Elements Equipment Protection Summary Pressure Relief Devices Relief Device Selection Lockable Valves Emergency Depressuring Valves Protective Instrumentation Limiting Elements Emergency Isolation Valves Pump Check Valves Automatic Valve Failure Analysis Interfaces with Other Systems Miscellaneous
NOTE: Section 2.1.2 consists of a table that lists all relief devices in a unit. The information required is the relief device number, relief device location description (e.g., vessel, exchanger or line number), where the device relieves to (e.g., flare, acid relief, atmosphere or process), set pressure, required/maximum relief rates, the design basis (i.e., fire, blocked liquid outlet or steam failure), and relief device size will be listed.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT Relief devices not included may be located in the mechanical catalogs. Typically these are reliefs to the atmosphere (e.g., steam reliefs) or reliefs to a dedicated disposal system (e.g., Sulfur Recovery Unit incineration). The unit rate basis should be footnoted. The information source for the required and maximum relief rates should be shown. 4.3 Area Electrical Classification The purpose of the Electrical Area Classification drawing is to show the unit electrical classification(s) so that a thorough evaluation of the sources of process hazards can be performed. 4.4 Equipment Summary Table The Equipment Summary Table provides supplemental information which may NOT be included on the Equipment List. Equipment Summary Tables will be by type of equipment ( i.e., pressure vessels, exchangers, pumps etc ) by project unit. All equipment information should reside in a single Equipment List/ Summary Table spreadsheet or database electronic program file. The purpose of the Equipment Summary Table is to have all of the equipment design conditions and data available in a summary format so that a thorough evaluation of process hazards can be performed. The information in this "database" must be consistent with the "as-built/ as- purchased" equipment item as well as the final equipment specifications and datasheets. The following information is to be provided in the Equipment Summary Tables. PRESSURE VESSELS DESIGN CONDITIONS Equipment Number/ Name Configuration/ Section Inside Diameter Tangent - Tangent Length Operating Pressure and Temperature Metal Design: Pressure, Temperature, Minimum Design Metal Temperature (MDMT), and Vacuum Metallurgy Notes ( include design code if NOT ASME Section VIII, Div. 1 )

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT HEAT EXCHANGER DESIGN CONDITIONS Equipment Number/ Name Service - Shell and Tube sides Normal Operating Pressure and Temperature - Shell and Tubes Metal Design (Shell and Tubes): Pressure, Temperature, Vacuum and MDMT Metallurgy - Shell and Tubes Notes ( Include design code if NOT ASME Section VIII, Div. 1 ) PUMPS AND COMPRESSORS DESIGN CONDITIONS Equipment Number / Service Suction Pressure - Rated and Maximum Design: Rated Flow, Discharge Pressure, Suction Temperature Shut-In Pressure Nominal Flange Rating - Suction, Discharge Case Material Notes FIRED HEATERS DESIGN CONDITIONS Equipment Number / Name Normal Pressure and Temperature Coil Design: Pressure - Elastic, Pressure - Rupture,- Temperature Maximum Allowable Skin Temperature Tube Metallurgy Design Basis Notes

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT STORAGE TANKS DESIGN CONDITIONS Equipment Number / Name Inside Diameter Height Capacity ( based upon strapping tables ) Maximum Filling/Emptying Rates Specific Gravity Maximum Fill Height Operating Temperature Design Temperature Design MDMT Material of Construction Roof Type Notes (include API code, if other than welded, etc.) 4.5 Piping Schedule (Line Table, etc.) The Piping Schedule is a list of unit process and utility piping and describes base information about each line. Information typically provided: line number, size, fluid phase, pipe material class, normal and/ or design conditions, special design conditions, insulation type and thickness, special requirements, etc. 5.0 5.1 Protective Safety Systems Safety Plot Plan and Fire Protection A Safety Plot Plan with all of the safety equipment located within the unit as identified by standard symbols is included in this section. A list of fire and safety equipment available shall be included in the Plot Plan, with location in coordinates indicated.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT 5.2 Ventilation System A description of format and content for HVAC REPORT FOR PSM PROCESS TECHNOLOGY PACKAGES, is outlined below. The PTP will include the ventilation system summary. Subsequent units sharing the same control room will be referenced to the PTP containing that information. HVAC System Description General description of the HVAC system installed in the building. The description includes: if the system is a heating only system, or cooling is provided and the system provides for building pressurization. Equipment Installed List all of the HVAC equipment, by model number, installed in the building. Basis of Design - Codes and Standards List all applicable codes and standards used in the design of the building. Date of Project Design or Construction Show the date the project was designed or constructed. 5.3 Mechanical Safety Systems Section 5.3 includes mechanical devices installed to prevent personnel injury or equipment damage. Design parameters will be supplied, if applicable. Text, explaining the device/system function is provided in this section. The standards will not be repeated, if the design parameters are included in the Engineering Practices, Safety Practices or Design Basis, Philosophies or Guidelines. The following are examples of mechanical safety devices: Mechanical safety devices: Centrifugal Compressors Low lube oil pressure switch Axial vibration probes Low seal oil differential pressure switch or low level oil switch on elevated seal tanks

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT High liquid level shutdown switch in suction drums (not always used) High temperature discharge shutdown switch Reciprocating Compressors Low lube oil pressure switch High liquid level shutdown switch in suction drums Frame vibration switch Cylinder lubricating system low oil level switch (more likely to be in older/smaller units) Crankcase blowout doors Steam Turbines Overspeed trip device associated with the governor Sentinel valve (safety relief) for turbine exhaust Axial vibration probes (larger steam turbines) Low lube oil pressure (larger steam turbines) Electric Motors (Approximately 750 - 1000 HP + RTD's in motor core/stator Large Pumps - 500 HP + Low lube oil pressure switch Positive Displacement Pumps Relief valve before first block valve after discharge flange Fin - Fan Exchangers Vibration switch Cooling Towers Vibration switch

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT Sumps Explosion Doors Heaters Flame Arrestors Conveyor Systems Flow Controllers Metal Detectors Belt Mis-Alignment Switches Tilt Switches Limit Switches The list of safety equipment is not limited to the above devices. 5.4 Safety Instrumented Systems This section is broken into two parts. The first section includes a detailed written description of these trips/interlocks requiring description for understanding. Text describes the safety system purpose and function. A cause/effect system description is included. Alarm or switch activation points are also included. Examples of systems requiring explanation are shutdowns or autostarts. Examples of systems that do not require explanation are simple alarm circuits. The second part is an Safety Instrumented System table showing safety systems/shutdown alarms. Every safety system described in the first part is included on the summary table. There also should be a corresponding SOL (Section 1.4) for Safety Instrumented Systems meeting the SOL criteria. The Safety Instrumented System table includes only devices that protect equipment or personnel. This list would not include alarms relating to controls or unit optimization. External sensing devices such as H2S and hydrocarbon alarms may not be included here. They are included on the plot plan.

ATTACHMENT 1 (Cont.) PROCESS TECHNOLOGY PACKAGE ( PTP ) DEVELOPMENT GUIDELINES PTP STANDARD SUBSECTIONS CONTENT The Safety Instrumented System table consists of six columns. Column content is as follows: The Tag is the alarm, instrument or switch destination. Description is the parameter being monitored by the alarm or switch. Equipment is the designation for related equipment described in the description column. Activation Point is the process variable measurement at which the control circuit becomes active (or inactive for a deactivation circuit). A high pressure, for example, shuts off the oxygen flow to the reactor. The activation point is the pressure at which the shutdown circuit activates the valve to shut down oxygen flow. Activation Type is a description of the action that occurs. The terms used in this column, for example, are alarm, shutdown, start-up, and interlock. Activation Equipment is the equipment that is shutdown, started, or interlocked. Examples are compressors, heaters, control valves, and pumps. This column is not intended to include solenoid valves, switches, or other control loop devices.

ATTACHMENT 2 FLARE TECHNOLOGY PACKAGE (FTP) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES PURPOSE The Flare Technology Package (FTP) Development Guideline is a general listing of the requirements for the development of Process Safety Information (PSI). This document provides guidelines for assembling and maintaining the Flare Design Document at each plant. The objective of the Flare Design Document is to: Operate a safe flare system and be able to keep it safe in the future. Have an all-inclusive source of flare system information Have an easily used, maintained, and updated "living" flare system model Satisfy the OSHA requirements Produce required information cost effectively The two documents (FDD and FTP) are intended to complement each other. Generally, the FTP will contain the flare system design. FTP is focused on ensuring operations and maintenance have the necessary information at their disposal to ensure safe flare operation. The FDD contains the flare system design basis. It is focused on maintaining data and simulations so that future inputs to the flare can be managed and designed safely. The FDD also complies with the OSHA requirement to document the flare system design basis. STANDARD SECTION CONTENT The general requirements for the Flare Technology Package (FTP) are very similar to those for a unit Process Technology Package (PTP). The (FTP) is the base flare process safety information and serves the following purposes: Satisfy the Occupational Safety and Health Administration (OSHA) regulation CFR 1910.119 requirement for process technology and safety information. Provide the base information necessary to complete a PHA (Process Hazard Analysis). A PHA will be conducted, following FTP development, that will identify any deficiencies in the process and recommend remediation steps or procedural changes. The personnel will draw heavily on the information contained in the FTP. Provide basic process safety information to personnel operating the process and maintaining the equipment. The FTP should complement and be consistent with operating manuals. The FTP is intended to be a quick reference for personnel to answer questions on capacity and safe operation.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES STRUCTURE The FTP is divided into five major sections to assist in understanding and information retrieval: Section 1.0 Process Description
is intended to provide general understanding of the flare system. Section 2.0 Piping and Instrument Diagrams are key to doing practically anything around a UNIT or SYSTEM, so to emphasize their importance and help retrieval they are in a dedicated section. Section 3.0 Chemical Hazard is intended to explain chemical hazards. This will be an abbreviated description of the hazard particular to the flare system. Most chemical hazards are handled by the unit PTP. Section 4.0 Design Basis Information is intended to describe basic design information for equipment and piping. More general design basis information included in Heat and Material Balance, Relief System Design, and Area Electrical Classification will be handled by unit PTP. Section 5.0 Protective Safety Systems is intended to provide information on all safety systems in the flare system. To ease updating and information retrieval, the FTP should be placed in a three-ring binder with tabs for the major sections mentioned above. The lettering should be black on white. Behind each tab should be a red tab with the subsection number. Lettering should be black on red. This guideline is arranged to show how an FTP should be put together.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES Below is a tag summary and how a table of contents for a FTP should look. Section 1.0 Section 1.1 Section 1.2 Section 1.3 Section 1.4 Section 2.0 Section 3.0 Section 3.1 Section 3.2 Section 3.3 Section 4.0 Section 4.1 Section 4.2 Section 5.0 Section 5.1 Section 5.2 Section 5.3 Process Description Process Steps Process Flow Diagrams Safe Operation Limits Maximum Intended Inventory Piping and Instrument Diagrams Chemical Hazard Inadvertent Mixing Table Reaction Explanation MSDS Reference Table Design Information Equipment Summary Tables Piping Schedule Protective Safety Systems Safety Plot Plan and Fire Protection Equipment Mechanical Safety Systems Safety Instrumented Systems
Guidelines for content of each subsection are included in Appendixes 1.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES APPEARANCE The white three ring binder should have a slip-in cover with the identification of the Yanbu Export Refinery Project, and the words FLARE TECHNOLOGY PACKAGE below. The page should be in Yellow color with a center red band and title in black letters centered on the cover should be the UNIT or SYSTEM name in black lettering. The spine slip should contain the same information.
ASSOCIATED DOCUMENTS During FTP development, several items may be uncovered for consideration by the PHA team. These items should be included in a separate document called the Flare Technology Package Observations Letter. Generally, these items are logged during FTP development and included in one letter. If an item is deemed serious, the PHA facilitator should be informed.
FLARE DESIGN DOCUMENT (FDD) The Flare Design Document (FDD) is a companion document to the Flare Technology Package and has the following purposes: Provides a structure by which the flare system design basis is easily understood. Specifically, the document shows the flare system in relation to design parameters. Provides a platform for future changes that can be safely made. The document shall be consulted each time a change is made to the flare system. Provide the design basis information necessary to complete a Process Hazard Analysis (PHA ). A PHA will be conducted, following FTP and FDD development, that will identify any deficiencies in the process and recommend remediation steps or procedural changes. The personnel will draw heavily on the information contained in the FDD.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES FDD STRUCTURE The FDD is divided into five major sections: Section 1.0 Process Description is intended to give an overview of the flare system. Section 2.0 Flare Model
describes the flare model. Section 3.0 Rationale
describes the basis for calculation of relief loads in text format. Section 4.0 Relief Device Calculations
collects the individual relief device calculation sheets for each contingency. Section 5.0 Hand Calculations
collects the hand calculations that result from the rationale. These hand calculations and the simulations (Section 2.2) should be consistent. Any critical mechanical design calculations should also be included here. Below is a tag summary and how a table of contents for a FDD should look. Section 1.0 Process Description
Section 1.1 Introduction - Document Overview Section 1.2 Flow Diagrams - Contingency Section 1.3 Design Parameters Section 1.4 Flow Rate Basis - Unit Charge Rate Section 1.5 Relief Device Load Summary

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES Section 2.0 Flare Model
Section 2.1 Flare System Code Section 2.2 Contingency Simulation Code Files Section 2.3 Node Diagrams Section 3.0 Rationale Section 3.1 Individual Relief Device Rationale Section 3.2 Trip Philosophy Section 4.0 Section 5.0 Relief Device Calculations Hand Calculations
APPEARANCE The appearance should be similar to the FTP/PTP. The general standards should be followed. If the FDD spans more than one volume, then an additional descriptor on the cover slip should be included to identify the contents of the volume. FTP PACKAGE STANDARD SUBSECTIONS CONTENT 1.0 1.1 Process Description Process Steps Process Steps portion of the FTP is a brief description of the flare system. FTP includes the major components and units served by the flare system. Major component description will focus on the function served in the flare's system (e.g., molecular seal, prevent ingress of air) This section should be consistent with the PFDs (Section 1.3). This section, for people seeking information not covered in this document on the flare system, should direct them either to the Flare Design Document (FDD), or unit Process Technology Package (PTP).

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES This section also should briefly describe any instrumentation trip philosophy that accompanies the flare system and describe the trip locations. Some sites may use heat input trips to mitigate the flow rate to the flare system in utility failures. This section should briefly and simply describe that philosophy and which trips affect the flaring rate. 1.2 Process Chemistry The only reaction normally occurring in the flare system is combustion at the flare tip. 1.3 Process Flow Diagrams The Process Flow Diagrams (PFD) should only show the major flare system inputs and any equipment associated. Additionally, the PFD should be arranged similarly to the pipe rack layout in the plant. The PFD also should include important control schemes and use the appropriate control symbology. 1.4 Safe Operating Limits (SOL) The Safe Operating Limits (SOL) section should follow the PTP guidelines section 1.4. Typically, parameters included in this section will be levels on flare gas knockout drums, purge gas rates, etc. These parameters must be controllable by operations personnel. 1.5 Maximum Intended Inventories This section should be the same as the PTP guidelines section 1.5. 2.0 Piping and Instrument Diagrams (P&IDs) The general requirements laid down in the Process Technology Package Development Guidelines still apply. Relief Devices: Relief devices, unless they are specific to the flare system, will not be shown on the flare P&ID. Relief devices specific to units will be shown only on that unit's P&IDs. This will eliminate duplication of information on P&IDs.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES 3.0 Chemical Hazard This section contains the same information as Section 3.1 through 3.3 in the PTP. The content of these sections is greatly abbreviated. Specifically, the inadvertent mixing table should generalize components generally found in the plant. Label hydrocarbon streams, as such, is an example. The major emphasis in creation of the table is searching out reactions with possible hazards. Nitrates and ammonia, for example, may have a greater chance of commingling in the flare system than they do from one unit to another. 4.0 4.1 Design Basis Information Equipment Summary Table This section follows the standards set out in the PTP guideline, Section 4.4. 4.2 Piping Schedule This section will have the same standards as the PTP guidelines. 5.0 5.1 Protective Safety Systems Safety Plot Plan And Fire Protection This section has the same standards as those developed for the PTP guidelines, Section 5.1. The plot plan will be included only if there has not been an evaluation done as part of a unit PTP. Direct reference should be made, if the plot plan is part of another unit, to that PTP in the FTP. 5.2 5.3 Mechanical Safety Systems This section shall be the same standards developed for the PTP guidelines. Safety Instrumented Systems This section shall be the same standards developed for the PTP guidelines.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES FLARE DESIGN DOCUMENT (FDD) SUBSECTIONS CONTENTS 1.1 Introduction-Document Overview This section is a document overview and introduction. It explains how to use the document and where things can be found. 1.2 Flow Diagrams - Contingency This section would contain the major utility failure (cooling water, power, instrument air, etc.) flow diagrams with velocities, pressures, temperatures, and mass flow rates. 1.3 Design Parameters This section outlines the design parameters used in flare design. The design parameters should be for the existing design and current design practice. For example, flare knockout drums are typically designed to separate 300 micron particles for effective knockout for new designs or 600 micron particles for existing systems. This section would delineate the design used for the particular flare. See API RP-521 for calculation procedure. 1.4 Flow Rate Basis - Unit Charge Rate This section summarizes each unit charge rate basis that was used to calculate the flare loads. 1.5 Relief Device Load Summary This is a table listing the relief loads and conditions for each relief device under all the major relieving contingencies.
2.1
Flare System Code This is both paper and electronic versions of the flare simulation code. The desired tool to perform the calculations is Visual Flare (VSI). Contractor shall obtain written approval for using different simulation software.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES
2.2
Contingency Simulation Code Files These are the contingency simulations on each equipment. These should be delivered entirely electronically. There should be a list describing each file and the contingency it simulates. Ideally, these files should be in one simulation package; however, there may be a mixture of PRO/II and HYSIM files.
2.3
Node Diagrams This is a paper diagram representing the equivalent line lengths and nodes used to represent the flare system.
3.1
Individual Relief Device Rationale This section is the rationale used to calculate the rates to each relief device. these are divided by unit. This should be placed as-is in the FDD from the flare study. Updates can be made as needed to the flare study.
3.2
Trip Philosophy This section describes any Flare Flow mitigating trip philosophy and how it is applied.

ATTACHMENT 2 (Cont.) FLARE TECHNOLOGY PACKAGE ( FTP ) FLARE DESIGN DOCUMENT (FDD) DEVELOPMENT GUIDELINES TABLE A-1 Content Comparison Flare Design Document Section 1.0 Process Description 1.1 1.2 1.3 1.4 1.5 Introduction-Document Overview Flow Diagrams Contingency Design Parameters RV Load Summary Section 2.0 P&IDs Section 2.0 Flare Model 2.1 2.2 2.3 Flare System Code Contingency Simulation Code Files Node Diagrams Section 4.0 Design Information 4.1 Section 3.0 Rationale Table 3.1 3.2 Individual Relief Device Rationale Trip Philosophy Section 5.0 Protective Safety System 5.1 Section 4.0 Relief Device Calculations 5.2 Section 5.0 Hand Calculations 5.4 Safety Plot Plan & Fire Protection Equipment Mechanical Safety Systems Safety Instrumented Systems 4.2 Equipment Summary Tables Piping Schedule Section 3.0 Chemical Hazards Flare PT Package Section 1.0 Process Description 1.1 1.2 1.3 Process Steps Flow Diagram Block Safe Operating Limits (SOL) Maximum Intended Inventories
Flow Rate Basis Unit Charge Rate 1.4

ATTACHMENT 3 PROCESS SAFETY REVIEW (PSR) INFORMATION REQUIRED PSR 1
Copy of PFDs issued Approved for Development (AFD). Results of the Preliminary Process Hazard Reviews (PHR), the Safety Review Action Management Program and Consequence Modeling. Copy of the Hazard Register Log (HRL) Copy of the Preliminary PTP book and Table of Contents. Complete preliminary recommendations. PHA report for HAZOP with completed
Copy of P&IDs issued Approved for Development (AFD). Any special safety evaluation studies plus a list of agreed upon action items. Results of the Safety Instrumented System (SIS), the Safety Review Action Management Program and Consequence Modeling. Design of the Plant and equipment specifications including description of each process unit and auxiliary facility. Matrix showing all relief valves and all relief scenarios including rates, temperatures and stream molecular weights. Individual process diagrams of relief system for each individual failure of one of the general utilities, showing results of the simulation of the failure ( steam, power, cooling water, instrument air, etc ) with flow rates, temperatures, and back pressure at the outlet of each relief valve required to operate during the utility failure. Plant layout drawings, computer graphics, and scale model (if available). Area Classification drawings. Drawing and specifications for all plant buildings. Final copy of the PTP book, the FTP book and the FDD book.

ATTACHMENT 3 Cont PROCESS SAFETY REVIEW ( PSR ) INFORMATION REQUIRED PSR 2
Copy of completed responses to PSR 1. Any special safety evaluation studies plus a list of agreed upon action items. Complete detail design recommendations. PHA report for HAZOP with completed
Plant and equipment specifications including description of each process unit and auxiliary facility. Matrix showing all relief valves and all relief scenarios including rates, temperatures and stream molecular weights. Individual process diagrams of relief system for each individual failure of one of the general utilities, showing results of the simulation of the failure ( steam, power, cooling water, instrument air, etc ) with flow rates, temperatures, and back pressure at the outlet of each relief valve required to operate during the utility failure. Drawing and specifications for all plant buildings. All data requested, but not available, for the PSR 1 review. Copies of all CAF's (change approval form) done for changes since the completion of the detail design PHA - HAZOP. Documentation of results of all reviews of changes by PHA team when required. Site inspection and test dossier. Equipment manufacturers and independent authorities test certificates. Plant layout drawings, computer graphics, and scale model (if available). Hazardous area classification drawings. Copy of the PTP book, the FTP book and the FDD book.

ATTACHMENT 3 Cont PROCESS SAFETY REVIEW ( PSR ) INFORMATION REQUIRED PSR 3
Copy of completed reports for PSR's 1 and 2. Copy of completed reports for the Pre-Start Up Safety Review for each Unit. Documentation listing all MOC items which records that they have been completed. Copies of all Process Hazard Analyses. Copies of all Process Technology Packages (PTP). Copies of all Flare documentation (FDD). Technology Package (FTP) and Flare Design
Process Flow Diagrams (diagrams not included in PTP or FPT). Piping and Instrument Diagrams (diagrams not included in PTP or FPT). Schedule of relief and protection devices Site inspection and test dossier. Equipment manufacturers and independent authorities test certificates. Plant organization and manning. Pre-commissioning test dossier. Commissioning plan Operating instructions Maintenance instructions Plant inspection schedules Emergency procedures including the works emergency plan. Health requirements Training program.

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