ATTACHMENT No. E.1 Emissions to Atmosphere
Contents Attachment E.1.1 Drawing Showing Location of Emission Points to
Atmosphere (IPPCL-011) Attachment E.1.2 Overview of Low Emission Technology in Design
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E.1.2 Overview of Low Emission Technology used in Design The principal sources of emissions from equipment and fittings in the terminal are pumps, compressors, flanges and valves. All items are subject to leak tightness checks with the aim of minimising unplanned emissions. The design, construction/fabrication methods and testing of equipment and piping systems all have their emphasis on eliminating potential hydrocarbon emissions. Piping Systems The design of piping systems is in accordance with established industry standard codes of practice, in particular ASME B31.3 Process Piping. This sets out requirements for the design of individual components, including criteria for selection of appropriate material and calculations to ensure sufficient wall thickness for pressure containment. Piping design has sought to minimise the number of non-welded joints in hydrocarbon containing systems. Requirements for flexibility analysis of piping systems are covered in ASME B31.3, with analyses having been carried out for all critical piping systems on the project. This ensures that the piping system design is suitable for all modes of operation and all appropriate loading combinations, e.g. wind loading, ground settlement etc. Forces and moments at equipment connections and at flanged joints are examined as part of the flexibility analysis, to ensure these are within allowable limits (usually to a code of practice, e.g. API 610 for pumps, API 617 for compressors). This will ensure that emissions from joints are minimised. Any piping systems with the potential for opening to atmosphere, e.g. vents and drains are designed in accordance with the project isolation philosophy, and require at least two means of isolation (e.g. valve and blind flange). Construction/Fabrication Piping systems are fabricated in accordance with ASME IX Welding and Brazing Qualification (and other standards.) Weld Procedure Qualifications and Procedure Qualification Records are required for all welding. Welders are required to be qualified to the appropriate parts of ASME IX. Welding is subject to non-destructive testing and inspection as appropriate. Hydrocarbon gas systems are all subject to visual inspection, radiography, magnetic particle inspection and dye penetrant inspection of all welds. Hydrocarbon containment welding wil be subject to 100% inspection and NDT. Bolted joints in piping systems are minimised, with welded connections used wherever practical, in order to minimise the number of potential leak paths. Piping systems with design pressure above 425 barg use ‘ring type joints’ at bolted connections, utilising ‘pressure energised’ solid metal gaskets. Trained personnel assemble any bolted joints, with detailed records kept of every joint made. Specialist equipment and materials are used, such as hydraulic tensioning tools on large diameter bolts to maintain specified bolt stress levels. Even tensioning improves the quality of seal achieved between flanges. Valves The project philosophy is to minimise the use of rising stem valve types in hydrocarbon service. Quarter turn valves (e.g. ball valves) have been specified where appropriate.
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Valves in piping systems are also required to comply with applicable codes of practice for their design, e.g. API 6D. Valves with rising stems incorporate a live loading gland design to maintain packing integrity. Piping valves are subject to stringent pressure testing by the manufacturer. This is generally to BS 6755 “Testing of Valves”, with any additional requirements over and above this specified in the purchase order. Valves are subject to assembled hydrostatic body tests at 150% of the design pressure, as well as internal seat leakage tests. Block valves are subject to high pressure gas testing on 10% of all valves by type. Testing After installation, and prior to operation, the complete piping system is subject to pressure testing in accordance with ASME B31.3. A hydrostatic test at a pressure equal to 150% of the highest design pressure (highest possible operating pressure) is performed on all hydrocarbon pipe-work. A Leak test is performed on all systems, once fully assembled. This involves pressurising the system with a Nitrogen-Helium mix, and using gas detection equipment to identify any leakage at flanged joints. Pumps & Compressors The process pumps have been designed to international recognised standards (e.g. API etc) for the process fluid being handled. International standards are based on the accumulated knowledge and experience of manufactures and users of equipment in the petroleum, natural gas and chemical industries. International standards define requirements for materials of construction, pressure & temperature rating, sealing systems and hydrostatic & performance testing to ensure maximum mechanical integrity & safe operation of the equipment with minimal environmental impact. The process pumps were originally designed and manufactured four years ago to api 610 centrifugal pumps, with API 682 Pump Sealing Systems. Since that time API 682 has been revised and, to enhance the pump sealing systems for the pumps handling flammable fluids (hydrocarbon condensate, methanol, etc), the relevant pumps will have their sealing systems upgraded to a double seal arrangement incorporating the latest API 682 Plan 53b Sealing Arrangement. This will improve the pump sealing system safety standard, and reduce potential emissions. Centrifugal compressors are provided with tandem dry gas seals. Degradation in primary seal performance is monitored by trending the pressure drop across the restriction orifice in the inter-seal bleed line to flare. Reciprocating compressors each have two rod seals. The inter seal cavity is purged with inert gas and alarms in the event of seal degradation. Operational Surveillance A formal Leak Detection and Repair (LDAR) programme will be developed which will incorporate the checks identified above, in addition to periodic monitoring by an intrinsically safe, hand held analyzer to detect any hydrocarbon loss from valves, flanges and pump seals. The LDAR programme will include the determination of the type of measurement, frequency, type of components to be checked, what leaks should be repaired and how fast action should take place (as per BREF note). Internal leakages across passing critical valves will be noticed via the increased rate above background (e.g. nitrogen purge) levels.
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ATTACHMENT No. E.2 Emissions to Surface Waters
Contents Attachment E.2.1 Treated Water Discharge Locations Attachment E.2.2 Emission Points to local Surface Waters (Dwg: IPPCL-012)
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Legend - Main Pipeline and Umbilical Route
As built location of outfall shown complies with condition 5.4 of IPPC licence (P073841)
MOTE: Onshore pipeline route under revision
Shell Explwation 8 Production in Europe Shell E & P Ireland {SEPIL)
CORRIB BELLANABOY BRIDGE
GAS TERMINAL TREATED WATER
DISCHARGE LOCATIONS
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ATTACHMENT No. E.2 (ctd) Emissions to Surface Waters
Contents Attachment E.2.3 Terminal Drainage Plan (Dwg: IPPCL-013/014) Attachment E.2.4 Perimeter Drainage Layout - Surface Water (Dwg: IPPCL-015) Attachment E.2.5 Perimeter Drainage Layout - Groundwater (Dwg: IPPCL-016) Attachment E.2.6 Settlement Ponds (Dwg: IPPCL-017) Attachment E.2.7 Planned Catchments (Dwg: IPPCL-018)
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ATTACHMENT No. E.5 Noise Emissions
Contents Attachment E.5 Drawing showing Location of Noise Sources (Dwg: IPPCL-019)
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