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Eni - IRAQ ZUBAIR OIL FIELD DEVELOPMENT PROJECT Hammar DGS

COMPRESSED AIR PACKAGE PACKAGE PROCESS DUTY SPECIFICATION 002511104600XX001

CD-FE

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Issue for Tender Final Issue

00 25/01/2011 CD-FE Validity Rev. Description Status number Date Revision Index Company logo and business name

F. Rossi

M. Talucci

T. Veccia

R. Chiorrini

F. Rossi Prepared by

M. Talucci

T. Veccia

R. Chiorrini

Checked by

Approved by

Contractor Approval

Exploration & Production Division

Project name ZUBAIR OIL FIELD DEVELOPMENT PROJECT

Company Approval

Company Document ID

00251100BPST86205 Job N.

Contractor logo and business name

Contractor Document ID

2511-ZA-E-86205 Contract N. 022026 Vendor Document ID

Vendor logo and business name

Facility Name ZUBAIR FIELD HAMMAR DEGASSING STATION Document Title

Location ONSHORE

COMPRESSED AIR PACKAGE - 002511104600XX001PROCESS DUTY SPE CIFICATION

Software: Microsoft Word 97-2003

Scale N/A

Order N. Sheet of Sheets 1 of 15 Supersedes N. XXX

Superseded by N. Plant Area Plant Unit N/A 460 File No. 00251100BPST86205_CDFE01_15.doc

This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

Logo and business name of Document owner

Company Document Identification

Owner Document Identification

00251100BPST86205

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Revision Index Validity Status

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Description

00 01

25/01/2011 10/02/2011

15 15

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INDEX 1 2 3 4 5 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.1.1 7.1.2 7.1.3 8 8.1 8.2 8.3

INTRODUCTION ................................................................................................................... 4 DOCUMENT SCOPE ............................................................................................................ 5 ACRONYMS, DEFINITIONS AND ABBREVATIONS ........................................................... 6 REFERENCE DOCUMENTS ................................................................................................ 7 ENVIRONMENTAL CONDITION .......................................................................................... 8 Utilities ................................................................................................................................... 9 Electric Power ........................................................................................................................ 9 Utility Air................................................................................................................................. 9 Instrument Air ........................................................................................................................ 9 Nitrogen ............................................................................................................................... 10 Blanketing Gas .................................................................................................................... 10 PROCESS DESCRIPTION ................................................................................................. 11 Compressed Air Package: 002511104600XX001 ............................................................... 11 Air Compressors 002511104600KC001A/B ........................................................................ 11 Emergency Air Compressors 002511104600KC002A/B..................................................... 11 Air Compressors Control Panel ........................................................................................... 12 SCOPE OF SUPPLY ........................................................................................................... 13 Detailed Scope of Supply .................................................................................................... 13 Supplier Documentation ...................................................................................................... 14 Process Guarantee.............................................................................................................. 15



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INTRODUCTION ENI has been awarded the Zubair project for the development of an oil field (ZUBAIR FIELD) in joint venture with Occidental, Korea Gas and Missan Oil COMPANY (as state partner), with Eni as operator. The Zubair Field is located in the southern area of Iraq, 20 km from Basra city. The structure of the Zubair Field is a relatively gentle anticline oriented NNW - SSE, approximately 60 km long and 10-15 km wide. The Zubair project is a “brown field project” in which two main phases can be defined: o

o

Rehabilitation phase (or RP) in which includes the revamping of existing facilities to maximise production capacity of the existing treatment plants in order to achieve an oil production rate of 700 KBOPD at Q3 2013, after rehabilitation of wells, gathering network and overall facilities, plus installation of new facilities as required. These activities should be concluded within 36 month starting from the Contractual Effective Date (CED). Enhanced Re-Development (or EP). During this phase the installation of new permanent production facilities to achieve the plateau rate of 1200 KBOPD of oil production has been foreseen. The oil will be produced from reservoir with natural flowing and artificial lift systems requiring also water injection to support reservoir pressure and maintain it above saturation pressure. This second phase should be finished within 6 years from the CED.





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DOCUMENT SCOPE Scope of present document is to provide process technical requirements for the supply of 1 package for Compressed air system to the Hammar Degassing Station in accordance with the documents and the process data of Zubair Oil Fi eld Development Project.





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ACRONYMS, DEFINITIONS AND ABBREVATIONS API BOPD BS&W CAPEX CED CPI DGS EPF EP ESP FEED GOR GTP H HIPPS HM kBOPD kBWPD kBLPD MDMT MMSCFD MTA PPM PPB PWT R RAM RP RVP S SCF SCFD SOW TDS TSS TWP WC WHFT WHFP Z ZM

American Petroleum Institute Barrels of Oil per Day Basic Sediment and Water Capital Expenses Contractual Effective Date Corrugate Plate Interceptor Degassing Station Early Production Facilities Enhanced Re-development Electrical Submersible Pump Front End Engineering Design Gas / Oil Ratio Gas Treatment Plant Hammar High Integrity Pressure Protection System Hammar Mishrif Kilo (10^3) Barrels of Oil per Day Kilo (10^3) Barrels of Water per Day Kilo (10^3) Barrels of Liquid per Day Minimum Design Metal Temperature Million Standard Cubic Feet Per Day (at 1.01325 bara and 60°F) Millions metric ton / year Part per Million Part per Billion Produced Water Treatment Rafidiya Reliability Availability and Maintainability Rehabilitation Phase Reid Vapour Pressure Safwan Standard Cubic Feet (at 1.01325 bara and 60°F ) Standard Cubic Feet per Day Scope of Work Total Dissolved Solids Total Suspended Solids True Vapour Pressure Water Cut Well Head Flowing Temperature Well Head Flowing Pressure Zubair Zubair-Mishrif


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REFERENCE DOCUMENTS Reference

Title Hammar DGS – New Facilities – Compressed Air System Utility Flow Diagram Hammar DGS – New Facilities – Air compressors and Plant Air Receiver P&ID Hammar DGS – New Facilities – Dryers and Instrument Air – P&ID

1

002511-00-FP-FQ-03134

2

002511-10-BP-FM-86646

3

002511-10-BP-FM-86647

4

002506-00-BG-SG-09005

Site & Climatic Conditions

5

10007.HTP.PRC.PRG

Best Practice – Compressed Air System

6

002506-00-FP-RB-08007

Recommended actions for concept selection





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ENVIRONMENTAL CONDITION All the equipments supplied must be suitable for outside installation, because the location is an arid zone subject to sandstorms. Their operation shall be guaranteed at the environmental conditions of doc. Site & Climatic Conditions, Ref. [4].





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UTILITIES The following utilities are available.

6.1

Electric Power Voltage Level

6.2

Description

MV Motors above 200 kW

6 kV, 3 Phase, 3W

LV Motors =<200 kW

400 V, 3 Phase + PE, Solidly Grounded, TN-S distribution system;

Distribution & Utilities

400 V, 3 Phase (+N), 3 or 4 Wire+PE, Solidly Grounded, TN-S distribution system; 230 V, 1 Phase + N, 2 Wire+PE, Solidly Grounded, TN-S distribution system.

LV Motor Control Control Centre – Control Voltage

230 VAC, 1 Phase + N, 2 Wire, IT system with insulation fault monitoring system, internally created voltage from main bus bars voltage.

Instrumentation, essential, telecom, system.

230 VAC, 1 Phase+N, 2 Wire from AC UPS, IT system with insulation fault m onitoring system; 110 VDC “floating” 2 Wire not grounded with insulation fault monitoring system, from DC UPS.

Vital, F&G

Utility Air OPERATING Min. Temperature (°C) Pressure (barg)

6.3

Norm.

5 7.0

8

DESIGN Max

Design

60

120

9.5

11.0

Instrument Air OPERATING Min. Temperature (°C) Pressure (barg)

Norm.

5 5.0

7.0

DESIGN Max

Design

60

120

8.5

11.0


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Min. Temperature (°C)

Norm.

DESIGN Max

Design

60

90

7.5

11.0

5

Pressure (barg)

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Nitrogen OPERATING

6.0

7.0

Blanketing Gas OPERATING Min. Temperature (°C)

50

Pressure (barg)

1.0

Norm.

DESIGN Max

Design

75

105

2.0

3.5

1.5

Component

Mol Weight

mol%

Water

18.015

0.79

Nitrogen

28.013

0.92

Carbon Dioxide

44.010

1.38

Methane

16.043

68.33

Ethane

28.013

14.63

Propane

44.097

7.42

I-Butane

58.123

3.62

n-Butane

58.123

1.01

I-Pentane

72.150

0.82

n-Pentane

72.150

0.52

n-Exane

86.300

0.37

C7

100.00

0.11

C8

114.00

0.05

C9

128.00

0.02

C 10 plus

165.70

0.01

(1)

1

Blanketing Gas Composition is preliminary. This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

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PROCESS DESCRIPTION Wet atmospheric air is compressed by 100% oil free rotating air compressors driven by electric motor and working in parallel. Each compressor is equipped with a dust air filter to remove the coarse atmospheric particles. The compressed air is sent to the Plant Air Receiver in order to remove liquid droplets as well as to act as hold up buffer for the entire air system. Compressed Air system will follow a phasing approach to take into account the phasing of new oil processing trains. o

RP phase: two (2) Air Compressors 002511104600KC001A/B (each one rated for 3 2300 Nm /h), fed by Medium Voltage main power circuit, plus two (2) Emergency Air 3 Compressors 002511104600KC002A/B (each one rated for 1150 Nm /h), fed by Low Voltage emergency power circuit. 3

EP phase: one (1) Air Compressor 002511104600KC001C rated for 2300 Nm /h), fed by Medium Voltage main power circuit. This compressor is outside of Package Scope of Supply. Refer to ref. [1], “Hammar Degassing Station: “New Facilities - Compressed Air System Utility Flow Diagram” and Refer to ref. [5] , “Best Practice – Compressed Air System”. o

7.1

Compressed Air Package: 002511104600XX001 The compression unit shall be supplied as a package able to take air from atmosphere and discharge it at the required value of pressure and temperature, free of oil entrainment. Air Compressors 002511104600KC001A/B and Emergency Air Compressors 002511104600KC002A/B (00251110460KC001C in the future EP phase) shall be provide with auxiliaries: air filters, silencers, condensate draining facilities and coolers; the cooling system shall be by air. Design ambient air temperature for air coolers is 50°C [Ref.4]. The aftercooler shall ensure the discharge temperature is low enough to avoid damage to the solid desiccant air dryers, maximum 65°C. A non ret urn valve is installed upstream of instrument air receiver to avoid back-flow from piping to air supply under all circumstances. The Compressed Air Package will be installed in a non-hazardous area.

7.1.1

Air Compressors 002511104600KC001A/B The following data, for one compressor, will be used to design the air compressors 002511104600KC001A/B: Compressor type Screw Compressor 3 Design Air Flow rate 2300 Nm /h Discharge Pressure 9.5 barg Inlet Air Condition Atmospheric Design Pressure 11 barg Design temperature -5/120°C

7.1.2

Emergency Air Compressors 002511104600KC002A/B The following data, for one compressor, will be used to design the Emergency Air Compressors 002511104600KC002A/B: This document is property of Eni S.p.A. Exploration & Production Division. It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.




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Compressor type Design Air Flow rate Discharge Pressure Inlet Air condition Design Pressure Design Temperature

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Screw Compressor 3 1150 Nm /h 9.5 bar g Atmospheric 11 bar g -5/120°C

Air Compressors Control Panel The package is inclusive of all the control panel and safety instruments for the right and safety operation of compressors, including start-up and shut-down, and the instruments and control devices suitable to maintain the required air pressure in the discharge header. Instrument must be connected to the control and safety system, provided with an operator interface suitable to read inform ation and manage operating variables. The control system will fit to manage the fifth compressor installed in the EP phase. Free contacts are required to transfer the following information to an external D.C.S. •

Indication of run/stop of the unit

•

General alarm for unit malfunction

•

Interlock for external causes





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SCOPE OF SUPPLY

8.1

Detailed Scope of Supply


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The following PACKAGE shall be supplied: Tag: 002511104600XX001 Compressed Air Package •

•

•

• •

•

•

•

The SUPPLIER shall provide a complete detailed design package for the unit and shall provide sizing and operating conditions for all the equipment The design package shall include all items within the battery limits shown on the attached PFD and P&IDs The SUPPLIER responsibility for the process design and guarantee shall start at the process inlet flange(s), as shown in the P&IDs SUPPLIER shall be responsible for the equipment layout. SUPPLIER shall perform all calculations required as part of the design. The calculations will require approval by the CONTRACTOR. SUPPLIER shall be responsible for verification of pressure and temperature design condition for both piping and equipment and relevant rating. Information included in the P&IDs are to be considered as preliminary. SUPPLIER shall evaluate and then submit for CONTRACTOR approval, the corrosion protection system for the carbon steel interiors. The equipment supplied shall be designed to have a service life of at least 25 years and at least 3 years of uninterrupted operation. It is acceptable to replace consumables (such as seals, gaskets) and any components that cannot achieve the full service life during planned maintenance interventions.

The SUPPLIER has the overall responsibility for process and hydraulic design. It is understood that all the process guarantees of the overall package is under the Supplier responsibility and Contractor approval of Vendor design will not release Supplier from his responsibility. •

The supplier shall provide one COMPRESSED AIR PACKAGE (002511104600XX001) which shall be prefabricated and shop assembled to the maximum possible extent according to the limitations in dimensions and weight due to transport reasons. The package shall include, but not be limited to, the following: 1. Air intake filters 2. High efficiency screw compressor 3. Cooler 4. Electric motors 5. Instrument for unit control 6. Instrument and devices for safety unit running 7. Control system 8. Structure for skid 9. Spare parts Material selection defined by vendor. •





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Supplier Documentation DESIGN DOCUMENTATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Specifications Data sheets Procedures Equipment list Electrical equipment list Instrument list Line list Electrical load list Cause & Effect Diagrams Lubricant and utility consumption list Safety valves calibration certificates Pre-commissioning/commissioning spare parts SPIR forms Calculations Miscellaneous

DESIGN DRAWING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Assembly/overall layouts PFDs/P&IDs Heat & Material balance Piping, valves and fittings Mechanical Electrical Instrumentation Controls and automation Installation/dismantling drawings Brochures Miscellaneous

OPERATING AND MAINTENANCE MANUAL DESCRIPTION OPERATION

MAINTENANCE

Information on identification, sizes, weights, performance, etc. To enable rapid familiarization with equipment operation. To include functional description, operating controls and procedures, start-up and shut-down requirements, trouble shooting checklists, operational limits and precautions, etc. To enable the development of a planned maintenance system covering all preventative and corrective activities. To include maintenance schedules, routine, text procedures, calibration, tools, safety requirements, access and lifting requirements, etc.





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Process Guarantee SUPPLIER shall warrant that the Supply performs according to the process conditions required in this specification and approved Data Sheets including also transient and turndown conditions.


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