4.3 Vol II Sec.3.2 - Process Design Criteria

Offshore Design Section Engineering Services ISO – 9001:2008

DESIGN CRITERIA PROCESS AND UTILITIES “HRD-Process Platform”

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Project No: Page: 1 OF 34

PART – IV

SECTION - 3.2

PROCESS DESIGN CRITERIA

OIL AND NATURAL GAS CORPORATION LIMITED INDIA

AB

BSW

AKR

05.05.12

34

0

PREPARED BY

CHECKED BY

APPROVED BY

DATE

No. of Pages

REV

ISSUED FOR BID

FORMAT No. ODS/SOF/020B

Ref. PROCEDURE No. ODS/SOP/017

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TABLE OF CONTENTS SECTION TITLE 3.2 INTRODUCTION 3.2.1 DESIGN CRITERIA – HRD PROCESS PLATFORM 3.2.2 DESIGN CRITERIA FOR MODIFICATIONS ON EXISTING HEERA COMPLEX (HRC, HRG, WIH) 3.2.3 DESIGN CRITERIA OF PRE-INSTALLED RISERS 3.2.4 DESIGN CRITERIA OF FUTURE EQUIPMENTS 3.2.5 INSTRUMENTATION AND CONTROL 3.2.6 SPARING PHILOSOPHY 3.2.7 UNITS OF MEASUREMENT 3.2.8 NUMBERING PHILOSPHY 3.2.9 CODES AND STANDARDS

ANNEXURES ANNEXURE-I

WELL FLUID COMPOSITION (TYPICAL) – HEERA FIELD ANNEXURE-II PRODUCED WATER ANALYSIS ANNEXURE-III DIESEL FUEL SPECIFICATIONS



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3.2


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INTRODUCTION This section of bid package defines design criteria for Process and Utility systems required for HRD Process Platform (bridge connected to existing HRC platform) under HRD Re-development (Phase-II) Project. Under this project, the scope of work includes the following facilities:-

a)

HRD Process Platform. Section 3.2.1 covers the design criteria for process platform.

b)

Modifications at existing HEERA Process Complex (HRG/ H R C / WIH). Section 3.2.2 covers the design criteria for various facilities and modifications envisaged at HEERA HEERA Process Complex including bridge interconnection between existing HRC Process Platform and new HRD Process Platform

GENERAL REQUIREMENTS Contractor to note that this document provides the design criteria of various process facilities and utilities envisaged in the project. Contractor to strictly follow these criteria while designing various systems or units envisaged in the project. However, th e sizes, capacities etc. of various units specified in this design criteria or specified elsewhere in the bid package shall be followed as minimum requirement. In case of any discrepancy between various documents, Contractor shall refer the same to the Company for resolution and proceed w i t h t h e i r d es i gn a n d engineering only after company’s decision with no impact to cost and schedule of the project. The sizes, specifications and drawings furnished in bid document for various facilities at HRD Process Platform and modifications at existing HEERA Process Complex are indicative & minimum to be provided by the Contractor. It is the Contractor’s responsibility to verify all the design/ data before proceeding for the detailed design and engineering. Under the scope of this contract, Contractor shall perform all necessary process simulation using HYSYS software (latest version), design calculations and consider adequate design margins while specifying equipment /instrumentations. Contractor’s responsibility also includes carrying out safety studies and review operability aspects of the facilities and incorporates findings of the same while designing the facilities. Any deviation shall require Company’s approval.



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The process and utility flow diagrams and indicative P&ID s are enclosed in the bid document. Contractor shall develop detailed process design basis, process flow diagrams, material & energy balance, utility flow diagrams etc. for different cases indicated in this criteria and design the process and utility systems, accordingly. In case, simulation results show higher flow rates and varying pressure/ temperature ranges for some applications, the more conservative figures/ ranges shall be used for design and no. of process vessels/ equipment required under intended operations shall be so decided within the scope of this contract. Contractor may seek clarifications, if required any, during detailed engineering. The design of process and associated utility systems for HRD process platform and modifications at existing HEERA complex shall be suitably designed for these higher flow rates/ ranges. Accordingly, Contractor shall develop detailed utility balance and utility flow diagrams. Contractor shall develop detailed Piping and Instrumentation Diagrams, Cause & Effect Diagrams, SAFE charts etc. incorporating all suppliers’ information. Contractor shall prepare data sheets and specifications for all the equipment, instruments etc. Sufficient margins shall be taken on operating parameters viz. pressure/ pressure drop, temperature, flow, level etc. to take care of complete operating range and any other unforeseen eventualities. Contractor shall ensure that P&IDs shall include all required instrumentation for local as well as for remote monitoring and control of critical process parameters (including but not limited to pressure, temp., flow, level etc.). Additional instrumentation, if required based upon HAZOP study as well as operational requirement, shall be provided without any time and cost impact to the Company. Contractor shall develop sizes / routing / distribution of various utilities (namely Vent/ HP flare/ LP flare, Open/ Closed Hydrocarbon Drain, Open Deck Drain, Diesel, Instrument/ Utility/ Starting Air, Fire water, Utility water, Potable water, Cooling water, Inert gas, Chemicals etc.) and finalize the same during detail engineering. Contractor shall ensure that the design of process platform shall meet the relevant codes and standards requirements. A typical list of applicable codes is included in this Bid Package. This, however, cannot be taken as an exhaustive list and various codes and standards as mentioned in functional specifications as well as those applicable as per good engineering practices shall also form the basis and shall have to be followed by the Contractor in consultation with Company/ Company’s engineering consultant.



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The various process and utility system hook-ups indicated under bridge interconnections, between existing HRC platform and HRD platform are minimum indicative. It shall be the Contractor’s responsibility to get familiar with the existing process/ utility lines/ headers on HRC/ HRG platform, during preengineering survey (topside modifications) in order to ascertain the extent and completeness of work to be carried out for hook- up, extension and routing of such lines/ headers up to new bridge and their further hook-up with corresponding lines/ headers on HRD platform through bridge inter-connections. Contractor , during pre-engineering survey (topside modifications) of HEERA complex, shall also assess/ verify the deck space, hook-up points, routing of the lines, necessary inter-connections through bridge, integration with existing facilities etc. and finalize all essential aspects of modifications. Wherever as-built drawings of e x i s t i n g facilities are n o t a v a i l a b l e , Contractor shall develop the existing drawings relevant for the intended modifications to an as-built status for the detailed engineering. Since the existing HEERA complex will be operational, the Contractor shall develop detailed procedures for carrying out modification works and shall design/ plan his works such that hot work and platform shutdown requirements are eliminated or reduced to bare minimum. Adequate care shall be exercised while developing the existing process platforms’ modification requirements with special emphasis towards safety, operability and hook-ups. Special attention shall be given to minimize the shut down time required at existing process platforms and safety for executing the modifications. All the process, utility, safety and instrumentation systems shall meet the requirements of API-RP-14C “Recommended Practice for Analysis, Design, Installation and Testing of Basic Surface Safety Systems on Offshore Production Platforms – Latest Edition”.



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Contractor shall submit reports/ documents/ calculations/ drawings as per the list given below for Company’s review and approval. Contractor to note that this is a typical list and shall be supplemented with additional detail engineering documents as felt necessary by the Company, during detail engineering:- Pre-engineering Survey Report (Topside Modifications) - Process & utility design basis - Process & utility description - Process simulation report - PFDs / UFDs/ P&IDs (1st submission & subsequent revisions) - Process and utility calculation report (*) - CFD Report of all the major process flows/ vessels - Process control philosophy - Black start philosophy - Isolation philosophy - Blow down calculation report - Flare load calculation report - Vent dispersion analysis report - Equipment list - Tie-in schedule - Alarm & trip schedule - Process Data Sheets - Equipment - Process Data Sheets – Instruments - Cause & effect chart - SAFE chart - Line list - Operating manual etc. (*)

Process and utility calculation report shall include sizing calculations for process/ utility piping, equipments/ vessels, safety/ relief valves, control valves, choke valves, orifice plates etc.

However, sizing of equipment/ instruments for which vendor’s information are required, preliminary calculations shall be submitted initially. Subsequently, same shall be updated by the Contractor based upon vendor’s information and shall be resubmitted for Company’s review and approval. Also, hydraulic calculations shall be updated based on final routing/ layout etc. as per actual piping isometrics, and re-submitted for Company’s review and approval.



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Contractor shall submit soft copy (including EXCEL sheets indicating mathematical correlations) of sizing calculations for review of results indicated in calculation report. Detailed CFD analysis shall be carried out for all the Process vessels, systems and PGCs during the design as well as manufacturing phase and the due results shall be submitted to ONGC. Contractor to note that based upon review and approval of aforesaid calculations/ documents/ drawings only, P&IDs shall be Approved For Construction (AFC). Engineering shall also be done for all specified future facilities wherever required. HAZOP STUDY Based upon review and approval of aforesaid reports/ documents/ calculation/ drawings etc., P&IDs shall be issued for HAZOP study. Contractor shall engage an internationally reputed third party agency for carrying out HAZOP study. The venue and timing of HAZOP workshop shall be finalized through mutual consent between Contractor and the Company. The HAZOP observations/ recommendations s h a l l be deliberated in presence of/ with Company’s representatives/ Operations representative/ Engineering consultant. The firmed-up HAZOP recommendations shall be incorporated in relevant doc./ drgs. and after their approval, P&IDs shall be issued for “Approved for Construction (AFC)”. Contractor to note that all changes arising due to HAZOP study shall be considered and incorporated as part of firm scope of t h i s contract without any time and cost impact to the Company. Also, any changes arising due to Company’s review / approval, for whatsoever reason shall be implemented in the design of the facilities under the scope of this contract without any time and cost impact to the Company. DOCUMENTATION The Contractor shall submit all the documentation as per requirements given elsewhere in the bid document. In addition, Contractor shall prepare process packages and submit to the Company & their Consultant, within one month of approval of these documents. The process package shall consist of the following documents:



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Design basis (with approved deviations, if any) AFC P&IDs /Suppliers’ P&IDs (A3 size & bound together) AFC Equipment lay-outs (A0 &A3 size & bound together) PFDs & UFDs including Heat and material balance. Cause and Effect Diagram SAFE Charts Data sheet for Equipment Data sheet for Instruments Line list Equipment list All process /sizing calculations CFD Report of all the major process flows/ vessels Operating manual Vendor Document/ Literature

3.2.1 DESIGN CRITERIA – HRD PROCESS PLATFORM 3.2.1.1 DESIGN LIFE:

25 years

3.2.1.2 PLATFORM LOCATION:

Refer Structural Design Criteria Part - II

3.2.1.3 SOURCE OF WELL FLUID :

3.2.1.4 DESTINATION OF OIL (AFTER HP SEPARATOR):

3.2.1.5 DESTINATION OF GAS (AFTER COMPRESSION):

Additional well fluid from HP,HK AND HSD well platforms (from extended production manifold at HRC through HRC- HRD bridge inter-connection) HRC Oil manifold (through HRD-HRC interconnection) HRC-HRG net gas header on HRG (through HRD- HRC interconnection

3.2.1.6 DESTINATION OF PDODUCED WATER (AFTER HP SEPARATION): HRC-HRG produced water header on HRC platform (through HRDHRC inter-connection).



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3.2.1.7 PROCESS DESCRIPTION Well fluid from HP,HK and HSD well platforms via existing HRC production manifold shall be received at HR D p l at f o rm through HRC-HRD bridge interconnection at operating pressure 8 –16 kg/cm2g. The well fluid received at HRD P rocess Platform shall be first routed to the three phase cyclone separator with a provision to bypass the same.Then the WF is diverted to the well fluid heaters using hot oil and shall be heated from 210C to 600 C and then shall be routed to the new 3 Phase HP separators (with in-built electrostatic coalescer) maintained at operating pressure range 7.5 -12 kg/cm2g. Gas from 3-Phase Cyclone separator shall be routed to compressor inlet manifold and liquid shall be routed for further processing at existing platform of HRC and HRG.

Oil s t r e a m from 3-Phase HP separator shall be sent to a location o n H R C platform and be hooked up to the oil outlet line at the d o w n s t r e a m o f H P s e p a r a t o r o n H R C p l a t f o r m . (through HRCHRD bridge inter- connections). This partially stabilized oil shall combine with the crude oil from other sources and flow to the surge tanks at HRG and HRA for further separation and stabilization and subsequent pumping.

Separated water (from HP Separator) shall be routed to the HRC platform and shall be connected to the produced water line at the outlet of the HP separator located at HRC platform via HRD-HRC Bridge,which shall be transported ultimately to HRG platform via HRC-HRG bridge up to the HRG produced water treatment system. The interconnection with produced water header is to be provided at HRC platform. A typical heat and mass balance is enclosed in bidding documents. Contractor shall, however, review the operating pressure range for w e l l fluid heater and HP separator based upon vendor data and carry out heat and mass balance for all the possible cases. The operation of PG compressors shall be facilitated through load sharing and capacity controls incorporated into the compressor skid control system. The new PG compressor shall be linked to the existing PG compressors on HRC as well as HRG platform via suction and discharge header. In normal operation, 6 nos. compressors (2 at HRC and 3 at HRG and 1 at HRD) will run in parallel maintaining 6 operating and one standby philosophy. If required, all 6 nos. compressors (including the new two at HRD) may also run in parallel.



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Gas will be compressed by the process gas compressor (PGC) up to 95 kg/cm2g followed with processing by the dehydration unit in HRG. A scrubber shall be provided on the discharge of PGC (after 3rd stage cooler) to prevent hydrocarbon liquid carryover from the compression train o n H R D to dehydration unit on HRG platforms respectively. G a s from HRD shall then be routed across the HRD-HRC and HRC-HRG bridge to mix with the compressed gas from the existing facility and then to the dehydration s ystem of th e ex istin g platfo rm - HRG. The outlet li ne o f th e compresso rs sh all be ro uted u p to the HRG platform and s hall be co nnected to the outlet manifold of the compresso rs on t he HRG pl atfo rm. All necessary process and utility inter-connections shall be made through HRCHRD bridge. Provision shall also be made to use gas separation, compression facilities of existing HEERA complex and HRD Process Platform from either of the platforms. The process inter-connections between HRD and HRC shall include but not be limited to hook-up of production manifolds, separated oil and produced water, compressor suction headers, compressor discharge headers . For utility inter-connections, refer Design Criteria – Utilities.

3.2.1.7 DESIGN CRITERIA – PROCESS EQIPMENTS AND SYSTEM 3.2.1.7.1

PRODUCTION H E A D E R / MANIFOLD No Production manifold has been envisaged at HRD platform. However, the production manifold of HRC platform shall be extended through the bridge of HRC-HRD and shall be routed up to the inlet of the De-sander and the wellfluid heater and then the HP separator. There shall be a flushing connection on extended inlet line. Also the line should hot insulated. The extended production header will be designed based on the following:Operating pressure, kg/cm2g Design pressure, kg/cm2g Operating temperature, 0C

: 8 – 16 : 94.0 : 21 – 60.

Design temperature, 0C



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3.2.1.7.2


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THREE PHASE CYCLONE SEPARATOR One no. Three Phase Cyclone Separator shall be provided in the upstream of W.F. heater. The well fluid shall be de-gassed in a centrifugal type 3-Ph. Cyclone Separator. The 3-Phase Cyclone Separator will be designed based on the following:Operating pressure, kg/cm2g Design pressure, kg/cm2g Operating temperature, 0C Design temperature, 0C

: 8 – 16 : 94.0 : 21 – 60. : 75.

The provision shall also be kept for bypassing it, if required . The cyclone separators are vertical vessels designed for 3 phase separation, primarily meant to knock-out gas from liquid and to drain the free water present in the fluid. This will be designed based on the following – a) Operating conditions : - Pressure, kg/cm2g : 8.0 (Min.) : 16.0 (Max.). - Temperature, 0C : 21 - 60 b) Design conditions : - Pressure, kg/cm2g : 94.0 - Temperature, 0C : 75.0

c) Flow rates (per unit) - Liquid, BLPD : 55000 - Gas, MMSCMD : 2.0 d) Surge factor e) Swell factor

: 25% of the maximum well fluid : 15 % Minimum

f) Maximum allowable : 13.4 Lit/MMSCM. Liquid Particle size in gas carry over liquid in gas shall not be more than 10 microns. g) Well fluid composition : Refer ANNEXURE



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WELL FLUID HEATERS

3.2.1.7.3

The well fluid heaters are shell and tube type heat exchangers. The crude oil/ water emulsion is passed through the tube side and heated by hot oil on the shell side. This temperature increase of the process fluid promotes the break down of the emulsion, thereby permitting downstream separation of the water phase. The well fluid heater will be designed based on the following:– • • • •

3.2.1.7.4

Heating medium: Hot oil Heating requirement: To heat well fluid from 210C (MIN) to 600C(MAX.) Max. temp. heating medium(Hot oil ): 2500C . Min. temp. heating medium(Hot oil ): 1500C.

HP SEPARATORS The HP Separators are horizontal vessels (with in-built electrostatic coalescer) designed for 3 phase separation of oil-gas-water by static electricity induced gravity settling. These will be designed based on the following:a) Operating conditions : - Pressure, kg/cm2g

: 7.5 (Normal) : 12 (Max.).

- Temperature, 0C : 30-60 b) Design conditions : - Pressure, kg/cm2g - Temperature, 0C

: 21.1 :104.0

c) Flow rates:

Oil (BOPD) Maximum case Maximum water case


oil 20000 5000


Water (BWPD) 35000

Liquid (BLPD) Gas (MMSCMD) 55000 2.0

50000

55000

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d) Residence time

e) Maximum allowable liquid level

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: Min 5 minutes for oil and water phase on maximum flow including surge & swell factor : Centre line of vessel

f) Allowable quantity of

: 200 ppm ( V/V) max. oil in water

g) Allowable quantity of

: 1% ( V/V) max. water in oil

h) Maximum allowable carry over liquid in gas

:

13.4 Lit/MMSCM. Liquid Particle size in gas shall not be more than 10 microns

i) Well fluid composition

: Refer ANNEXURE-I

PROCESS GAS COMPRESSOR The process gas compressor takes suction from compressor Inlet Manifold on HRD platform and which is also interconnected to the compressor inlet manifold at HRC platform through HRD-HRC bridge inter-connection and delivers compressed gas to Discharge Manifold which is connected to compressed gas manifold at HRC through HRD-HRC bridge inter-connection. The process gas compressor will be designed based on the following – i)

No. of trains: 2 no. (1W+1S)

ii)

Flow: - Max. - Rated

iii)

: 1.6 MMSCMD (dry basis) : 1.6 MMSCMD (dry basis)

Molecular Weight (*): - Max. - Min.

: 23.5 (dry basis) : 20.5 (dry basis)

(*) In case, simulation results show wider range, highest and lowest out of above and simulation results whichever are governing, shall be considered.



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iv) Pressure (at module battery limit): - Suction, kg/cm2g : 6.0 – 8.0 - Discharge, kg/cm2g : 95.0 v) Temperature (at module battery limit) - Suction, 0C - Discharge, 0C vi) Type vii) Driver

: 30 - 60 :54 : Centrifugal (Dry gas seal type) : Gas turbine

The gas shall be considered as saturated operating conditions of HP separator.

with water vapour at

Compressor package vendor’s scope shall include self-contained compressor skid having 1st stage, 2nd stage and 3rd stage compressor suction scrubber, inter- coolers, after-cooler, 3rd stage discharge scrubber, dedicated fuel gas conditioning unit, metering system, surge and speed controls, lube and seal oil system, local panel, unit control panels (located in central control room) and other utility and auxiliary systems. The fuel gas conditioning skid will consist as a minimum, suitable filters (specification to be decided by turbine vendor) and electric super heater designed to give a minimum super heat of 20 0C. Pressure and temperature at intermediate compressor stages indicated in the heat and mass balance is indicative. Contractor shall finalize the same in consultation with compressor vendor. The design pressure of suction side of compressor shall be maximum of the followings: i) ii) iii)


Bid package specification 110% of highest operating pressure 1 kg/cm2 above the settle-out pressure.


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The facilities of HP gas compressor system shall be designed for the performance under all environmental conditions as given in the enclosed environmental data. The air cooler shall be designed for cooling gas for 14 0C approach to maximum ambient temperature of 40 0C. The FG Skid as well as the L/O Cooler for individual compressors shall be considered to be the part of compressor module. Equipments exposed to process fluids shall be designed conforming to NACE MR-01-75. 3.2.1.7.6

GAS DEHYDRATION & GLYCOL RE-GENERATION SYSTEM The dehydration and glycol regeneration system is not part of the present scope of this tender. However, for dehydrating the compressed gas from the new compressors at HRD, the feed from compressor discharge header shall be merged with the common discharge header on HRG. This shall be done through the extension of the discharge header on HRD platform up to HRC and then up to HRG platform through bridge inter-connections respectively. Equipments exposed to process fluids shall be designed conforming to NACE MR-01-75.

3.2.1.7.7

PRODUCED WATER CONDITIONING SYSTEM Produced conditioning system is not part of the scope of present tender. However, for processing, the 35000 BWPD of Produced water from the new separator – it has to be sent to PWC s -1 unit at HRC and 2 units of HRG platforms. The produced water outlet line from the outlet of the new separator on HRD platform, shall be extended and hooked up to the produced water line at HRC, outlet line of the PW of HP separator on HRC. The related piping, instrumentation modifications are also included along with in the tie –ins. However the future space shall be provided on HRD platform for a new future PWC of 100, 000 BWPD Capacity, as shown in the EQ. Layout diagram as well as mentioned in other parts of the bid package.



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3.2.1.8

DESIGN CRITERIA – UTILITIES

3.2.1.8.1

ELECTRICAL GENERATION FACILITIES

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Main power generation unit (TG) not envisaged at HRD Process Platform . However, all electrical power requirements for auxiliaries as well as prime movers and lighting loads at HRD shall be met from the excess power available in the HEERA Complex which shall be brought via cables (HT and LT) via HRC-HRD interconnection bridge. An Emergency G e n e r a t o r of 1.2 MW capacity shall be provided on HRD. The cap acit y is b as ed on the lo ad an d go vern ed b y th e el ectrical scop e of wo rk and d esi gn crit eri a. 3.2.1.8.2

FLARE AND VENT SYSTEM The HEERA Process Complex has three waste gas collection systems. These are – HP flare system, LP flare system and vent collection system. The HP, LP of the new HRD Process Platform shall be integrated with existing complex . The main header of the HP and LP flare header shall be extended up to the main complex via HRD-HRC bridge and shall be connected to the main header at an appropriate point in the upstream of the respective Flare KODs. The HP flare system at HRD w i l l collect high pressure flare gas which i s to r o u t e t o HP Flare header on HRC platform. HP flare gas header shall be hooked up with HP flare H e a d e r o n H R C p l a t f o r m . T h e H P f l a r e l i n e i s t o p a s s through HRD-HRC bridge inter-connection. The LP flare system collects low pressure gas which flows to LP K.O. Drum for separation of liquid carry over. LP flare gas h e a d e r is t o b e h o o k e d u p w i t h t h e L P f l a r e h e a d e r a t H R C , through HRC– HRD bridge inter-connection. The vent collection system collects vent gas which is routed to the vent scrubber followed by a glycol seal drum before flowing into atmosphere via the independent vent line on the new HRD platform. The vent boom shall be located at a suitable position and safe location.



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The HP and LP flare systems are t o b e continuously purged with fuel gas at each dead end to assure a continuous flow through all headers. Further, the HP and LP flare headers to respective flare headers shall be provided with ultrasonic flow meters covering overall flare gas flow rates based on simulation and including design margins. The flare and vent system will be designed based on the following – HP Flare: i)

Header pipe dia.,inch

ii)

Max. back pressure,

: 20 (Min.) . : 3.5 (NOTE-1) Kg/cm2.

LP Flare i)


: 16 (Min.) .

ii)

Max. back pressure,

: 0.2 (NOTE-1) kg/cm2g


: 10 (Min.) .

Vent Header i)

NOTE-1 – Max. back-pressure for flare at existing HRC platform. However, new flare system at HRD shall be designed for back pressure considering its integration with existing flare system at HEERA complex. Flare system shall be designed for the following radiation level at the nearest process platform including HR D platform including solar radiation of 250 Btu/hr ft2 – Continuous (Normal ) Emergency (Peak)

: 400 Btu/hr ft2 : 1500 Btu/hr ft2

The Flare piping network (piping including the header) on HRD shall be designed for new facilities only, However as the flare system shall be integrated with Heera complex as a whole. Thus, the changing the existing flare tip to the sonic tip will form the scope of present tender. The flare system and the Sonic flare Tip shall be designed for minimum load (purging), continuous load (compressor not available i.e. associated gas loadsMaximum up to 7.5 MMSCMD) and peak load (i.e. 5/6 nos. operating compressors capacity + blow down requirements).



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3.2.1.8.3 FUELGAS SYSTEM The fuel gas conditioning system is designed to meet requirements of the following as a minimum – Process gas compressor, HP and LP flare header purge. The fuel gas header shall be hooked up with existing fuel gas header at HRC platform through HRC-HRD bridge inter- connection. Dehydrated gas from HRC platform shall be used as source of fuel gas conditioning system. Operating pressure : 30.0 Kg/cm2g The Fuel gas shall be re-conditioned f o r the gas turbines of p r o c e s s gas compressor in accordance with the recommendations of the compressor manufacturer. FG skids for individual compressors shall be considered as a part of compressor modules.

3.2.1.8.4

DIESEL FUEL SYSTEM The diesel fuel system is designed to meet requirements of the following as a minimum – Pedestal cranes ; Start-up air compressor ; Fire water pump ; Emergency generator. The diesel fuel header shall also be hooked up with existing diesel fuel header at HRC platform through HRC–HRD bridge inter- connection. The diesel fuel system shall consists of the following – Diesel inlet filter, Diesel centrifuge, Diesel storage tank and Diesel transfer pumps. Diesel inlet filter (one no.) Particle removal size, : 99.99% removal of 0.8 micron and larger microns Pressure drop, kg/cm2g : 0.3 (dirty) Diesel Centrifuge (one no.) Water in diesel, : 50ppm by wt.



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Diesel pumps


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transfer Nos.

: 2 nos. (1 operating +1 standby)

Pump Capacity

: 10 M3/ hr.

Diesel quality

: Refer ANNEXURE-II

Diesel storage shall be provided in crane pedestal. Storage volume is intended to meet the requirement of the following:24 hours supply for running fire water pump and emergency generator plus 48 hours running of one deck crane. Additional day-tanks for diesel storage shall also be provided for fire water pump, emergency generator, deck cranes etc. 3.2.1.8.5

INSTRUMENT AND UTILITY AIR SYSTEM The instrument and utility air system is designed to meet requirements of the following as a minimum – Pedestal cranes ; Starting air receivers, Hypochlorite generator , instrument air etc. The instrument and utility air shall consists of 2 nos. Air compressors. The air stream from the compressors is scrubbed in the Utility air receiver and then split into two streams – one, to utility air header for onward distribution and other, to air dryers (consisting of pre-filters, dryers and after filters) followed with instrument air header for onward distribution. The instrument and utility air system will be designed based on the following:– Air compressors


Nos.:

2 nos. (1 operating +1 standby)

Air capacity (Dry):

700 (min.) Nm3/hr.

Discharge pressure: Type:

11.4 Kg/cm2g Motor driven non-lubricating type screw compressor.


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Instrument air dryers These shall consists of pre-filters, dryers and after filters. Nos.:

2 nos. (1 operating + 1 standby)

Instrument air dew point: (-) 40 0C Operating pressure:

11.4 Kg/cm2g

Utility air receiver Capacity:

30 minutes operation

Operating Pressure:

10.0 Kg/cm2g

Instrument air receiver Capacity:

30 minutes operation of all air consuming instruments

Instrument air header:

To supply instrument gas to all consumers

Operating Pressure:

7.5 – 8.2 Kg/cm2g

The instrument and utility air headers shall also be hooked up with respective headers at HRC platform through HRD-HRC bridge inter- connection.

3.2.1.8.6

STARTING AIR SYSTEM The starting air system is designed to meet starting requirement of fire water pump and emergency generator. It consists of start-up air compressor, fire water pump starting air receiver and emergency generator starting air receiver. The starting air system will be designed based on the following:– Start-up air compressor: Nos.: One no. Air capacity (Dry): Discharge pressure: Type:



35 (min.) Nm3/hr. 17.6 Kg/cm2g

Diesel engine driven reciprocating compressor.

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REV. DATE: 21.07.2010


3.2.1.8.7


Volume No:

II

Section No:

3.2


INERT GAS SYSTEM The inert gas is primarily required for providing dry gas seal as well as use in purging and blanketing of various systems and other miscellaneous requirements, if any. The system shall have its own air compressor to meet its input air requirement. The inert gas system will be designed based on the following:– Nos.:

1 no (1X100 %)

Gas generated:

Nitrogen

Capacity per unit:

150 (min.) Nm3/hr.

Dew point, ºC:

(-) 40

Discharge Pressure

4.0 - 7.0 kg/cm2g

Discharge Temp, ºC:

43

Purity, %:

99 (min.)

Type of Adsorber

: Membrane type

The inert gas header at HRD platform shall be extended to HRC and HRG platform through HRC-HRD and HRC-HRG bridge interconnections for meeting the inert gas requirement. Isolation valves along with blind flange, shall be provided at HRC and HRG platforms for necessary hook-ups. The N2 system shall also include N2 filter, N2 receiver and N2 cylinder cubicle separately.

3.2.1.8.8

CHEMICAL STORAGE AND INJECTION SYSTEM There are three chemical systems for HRD platform. These systems include – oil corrosion inhibitor (OCI) and gas corrosion inhibitor (GCI) shall be dosed at the new platform of HRD, and demulsifier shall be dosed at HRC platform.



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As a minimum chemical storage and injection facility shall consist the following:– Facilities shall be suitable for chemicals available from at least two manufacturers for each type of chemical. Mixing, heating & blanketing facilities etc shall be provided as per chemical manufacturer’s specification/ Operational requirement. Chemicals chosen shall be compatible with each other and with well fluids / process stream / formation water as applicable. All chemicals will be stored in full strength in storage tanks based on 15 days requirement at normal rates. Drums equivalent to 15 days normal consumption of each chemical shall be stored in the open. A suitable shelter shall be provided over the drum storage area as required to protect the chemicals from direct exposure to sun light (As per manufacturer’s recommendation). Two drum racks, each for 4 drums (min.) shall be provided for unloading of chemicals into respective tanks. All drum handling will be mechanized. Portable pneumatic pumps (one for each chemical) shall be provided for unloading drums into respective tanks. Eye wash plus safety shower shall be provided near the storage tanks and drum handling area (one each). Suitable dosing pumps - one operating and one standby as minimum shall be provided for each chemical. Dosing Pumps shall be sized to meet required dosing rates . Dosing rates and chemical type are tentative and shall be confirmed during detailed engineering as per chemical manufacturer’s recommendation. Chemical treatment package design shall take care of this requirement. CHEMICAL DOSING RATES Following indicative dosing rates for various chemicals are given below. These rates are to be confirmed during detailed engineering as per chemical manufacturer’s recommendation


1) OCI

60 ppm at each injection point.

2) GCI

16.7 L/ MMSCM at each injection point

3) DEMULSIFIER

300 ppm based on maximum incoming fluid flow


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Section No:

3.2


LOCATION OF CHEMICAL INJECTION Oil Corrosion Inhibitor It shall be injected in the oil header upstream and/ or downstream of the HP separator as is appropriate to the inhibitor system selected. Hence it is to be dosed on at new HRD platform Gas Corrosion Inhibitor It shall be injected upstream of the 1st, 2nd and 3rd stage coolers on the process gas compression system. Demulsifier It shall be injected to the production headers upstream of the respective well fluid heaters. Hence it is to be injected at HRC platform. CHEMICAL NAMES

3.2.1.8.10

1)

OCI

Corexit 7730 or equivalent

2).

GCI

Corexit 7730 or equivalent

3)

DEMULSIFIER

Diatrolite DE 220 or equivalent .

UTILITY WATER SYSTEM The utility water system is designed to meet requirements of hypochlorite generation, potable water, cooling water, fire water header (for pressurization) as a minimum. The utility water header shall also be hooked up with respective header at HRC platform through HRCHRD bridge inter-connection. The utility water system will consist of 2 nos of submersible utility water pumps. Pump discharge pressure shall be 10.6 kg/cm2g. The potable water system consists of potable water tank and potable water pump and it shall be hooked-up with HRC platform through HRC-HRD bridge inter-connection. The potable water shall be supplied from HRC potable water header through HRC-HRD bridge inter-connection.



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II

Section No:

3.2


The cooling water system consists of cooling water tank, cooling water circulation pumps and cooling water cooler. It shall include an online filter, chemical injection facilities for maintaining pH of the water, and an injection system for scale inhibitor. The cooling water header shall also be hooked up with respective header at HRC PLATFORM through HRD-HRC bridge inter-connection. The cooling water system will be designed based on the following:– Cooling water circulation pumps: Nos.:

2 nos. (One operating + one standby)

Pump diff. pressure:

5.0 Kg/cm2g

Cooling water inlet supply temp. Cooling water outlet temp.

3.2.1.8.11

: 50.0 0C

: 60.0 0C

DRAIN SYSTEM The drain system consists of open deck drain (ODD), open hydrocarbon drain (OHD) and closed hydrocarbon drain (CHD) for collection of hydrocarbon, chemicals and water. Open deck drain (ODD) is meant for collection of the following:a) Storm water not in contact with hydrocarbon b) Deluge and fire water c) Utility water, potable water etc. spilled during cleaning and maintenance. Open deck drain system shall be designed for collection of rainwater considering heaviest monsoon rain fall and deluge. The rainfall for facilities design shall be taken as 100 mm rain in 2 hrs and this intensity to last over a period of 20 minutes. Water entering the open deck drain system shall be routed to sea through sump caisson. Open hydrocarbon drain (OHD) is meant for collection of the following:a) Oil, oily water and chemicals from platform piping /equipment/ storage tanks, spillage etc. b) Oily water from vessel cleanout and other operations and maintenance activities.



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c)


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Section No:

3.2


Run-off water from process areas which may be contaminated accidentally with oil (e.g. water from around rotating equipment/skid mounted process equipment which may be contaminated with oil).

Open hydrocarbon drain system shall be designed to accept minor volumes of hydrocarbons drained intermittently from equipment and instruments and chemical spillage/ leakages during handling of chemicals/ hydrocarbon. It is routed to sump caisson from where the oil is routed to closed drain drum. Recovered oil from closed drain drum is pumped to condensate header/ HP separator outlet and water to sump caisson for disposal into sea. Closed hydrocarbon drain (CHD) is meant for collection of hydrocarbon/ oily water from the pressurized vessel/ equipment/ pumps/ compressors etc. which are required to be drained under pressure as a part of normal operational requirement. The condensate header shall also be hooked up with respective header at HRC platform through HRC-HRD bridge inter-connection. The drain system will be designed based on the following: Closed Drain Drum: The closed Drain Drum shall be utilized for receiving the all closed drain liquids from new HRD platform. 2 nos. of closed drain pumps shall also be used for transferring the crude. The required refurbishment shall be carried out for the existing pumps. The drain system will be designed based on the following – Closed Drain Drum Storage Capacity : 10 M3 (min.) Design pressure,

: 3.5 Kg./cm2g

Closed Drain Pumps: Nos. : 2 (One operating + one standby) Capacity, m3/hr. : 10 (min.) Diff. pressure, kg/cm2 : 10 (min.) Type : Electrical motor driven reciprocating Also, at HRC platform the same capacity and type of closed drain drum and pumps are to be provided.



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Section No:

3.2


Sump caisson with blow case The Sump Caisson shall be utilized for receiving all open, closed drain fluids separately from HRD Process Platform as well as from the PWCs on HRC and HRG platforms respectively. Sump caisson is to be provided with blow case for lifting skimmed oil to Closed Drain Drum. Sump Caisson shall be a vertical, partially submerged stand pipe with an open bottom (Min.length-30M, Min.dia.-60”). Separation of oil from water is accomplished by differences in specific gravities. Sump caisson shall have gas sparger for separation of oil. Baffle arrangement inside the caisson enhances the separation of the entrained oil particles and water thus separated is discharged to the ocean. The oil collects inside the blow case (Min.length-3M, Min.dia.-12”) is removed periodically by pressurizing the blow case with fuel gas to the closed drain drum. The caisson is vented to LP flare header. The oil content in sump caisson water outlet shall be less than 25 ppm. Sampling facility for collecting water sample from the outlet of sump caisson shall be provided.

3.2.1.8.12

WASTE HEAT RECOVERY AND HOT OIL SYSTEM The waste heat recovery and hot oil system is designed to meet the heating requirements of well fluid heater (HRD), Heating of Closed drain drum at HRD and also the hot oil line to be extended upto HRC platform to meet the additional heat requirement of HRC. Waste heat recovery units (WHRUs) shall be installed in the exhaust of turbines of process gas compressors (PGC). The hot oil supply and return headers shall be hooked up with respective inlet and outlet hot oil header of new well fluid heater at HRC platform through HRD-HRC bridge inter-connections. The waste heat recovery and hot oil system shall consists of - hot oil expansion tank, hot oil circulation pumps, hot oil make-up pump, hot oil filter, gas compressors WHRU and hot oil dump cooler.



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REV. No. 00

REV. DATE: 21.07.2010



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Section No:

3.2


The waste heat recovery and hot oil system will be designed based on the following – - Heating oil medium - Hot oil supply pressure - Hot oil operating temp.

: Hytherm 500 : 5.0 kg/cm2g : 250 oC

Hot oil dump cooler is provided to remove excess heat to avoid damage to the WHRUs and to avoid degradation of the hot oil medium (Hytherm- 500). Its duty is based on 5% (indicative, to be confirmed by system vendor) of the total heat generated in the exhaust gases.

3.2.1.8.13

FIRE WATER SYSTEM The fire water system is designed to primarily meet fire water requirement of HRD as per relevant codes and standards and good offshore engineering practices. However, Minimum capacity of 1200 M3/ hr needs to be provided. Fire water deluge systems shall be provided on all decks and around all equipments containing hydrocarbons. Fire fighting equipment including hose reels, foam generators, fire monitors etc. shall be provided at locations determined by the safety studies. The fire water headers shall be hooked up with respective headers at HRC platform through HRC-HRD bridge interconnection. The HRC and HRD fire water systems shall provide back-up to each other. In case of failure of start of FWP at HRC, HRD fire water pump to start automatically and also in case of HRD pump fails to start, HRC FWP to start automatically. Logic sequence is to be developed accordingly. Contractor shall ensure that the HRD fire pumps and ring main (including the bridge link to HRC) are capable of supplying the required flow rates and pressures of fire water to HRC in the event of failure of HRC fire water pump and ensure that there is mutual backup. A chlorination system based on parallel plate electrolytic principle shall be provided to prevent fouling. Contractor shall design this system in a manner that ensures that contamination of the potable water system does not occur.



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Section No:

3.2


The fire water system shall consists of – fire water pump, FW pump caisson, deluge valves, fire water ring main, hose reels, foam generators, fire monitors, spray network etc. The fire water system will be designed based on the following: The fire water pump shall be capable of supplying total water requirements for the greatest single fire occurrence plus a minimum of two firewater hose reels maintained at main deck as a minimum. No.:

One

Capacity, m3/hr.: Discharge Pressure:

Type: 3.2.1.8.14

1200 (min.) Adequate to maintain fire water header pressure at 7 kg/cm2g Diesel engine driven

FIRE PROTECTION AND SAFETY SYSTEM The shutdown system for HRD shall be inter-connected with the corresponding HEERA complex systems. 2 nos. of Survival Craft of 50 persons capacity shall be provided – one at cellar deck and one at main deck. Clean Agent unit shall also be provided. The ESD and F&G systems shall be based on a high reliability, high availability type PLC, certified to TUV level AK6. The Contractor shall conduct a risk assessment of the ESD and F&T systems requirements prior to detailed design to assess the required Safety Integrity Level (SIL) in accordance with IEC-61508, and shall specify the associated equipment accordingly. For details on fire protection & safety system, refer Scope of Work – Instrumentation.

3.2.1.8.15

FIRE SUPPRESSION SYSTEM For details on fire suppression system, Mechanical.



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refer Scope of Work

REV. DATE: 21.07.2010

–


3.2.1.8.16


Volume No:

II

Section No:

3.2


LAUNCHERS/ RECEIVERS On HRD platform, space provision shall be kept for installation of two nos. 12” and one no. 16” well fluid receivers.

3.2.2

DESIGN CRITERIA FOR MODIFICATIONS ON EXISTING HEERA COMPLEX (HRC/ HRG/ WIH) For detailed scope of work for modifications envisaged on existing HEERA Complex (HRC/HRG/WIH platform), refer Clause - Section 2.0 - Description of Work (Basic Bid Work).

3.2.3

DESIGN CRITERIA FOR PRE-INSTALLED RISERS: Two numbers 12” and one number 16” pre-installed risers are to be provided with jacket. The design pressure and temperature for the same will be 93.7 Kg/Cm2g and 93 oC

3.2.4

DESIGN CRITERIA FOR FUTURE EQUIPMENT: • • •

3.2.5

The Provision of space, access, process and utility tie-in locations for the equipment that has been identified as future requirement in Basic Bid work are to be provided. Provision for isolation valves to allow future tie-in without any requirement for hot work or shutdown. Provision for layouts and preliminary design and engineering so that the future equipment can be incorporated, supported and installed into the operating facility without the requirement for hot work.

INSTRUMENTATION & CONTROL For instrumentation and control, refer Clause 2.3.6 – Description of Work (Basic Bid work) and Section – 3.6 - Instrumentation Design basis.

3.2.6

SPARING PHILOSOPHY Sparing philosophy for unit, equipment etc. shall be as per bid documents. In general, all rotating equipment (pumps, compressors etc.) shall have one stand-by of same capacity.



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3.2.7


Volume No:

II

Section No:

3.2


UNITS OF MEASUREMENT Metric system of units shall be followed.

3.2.8

NUMBERING PHILOSOPHY Tag numbering philosophy for equipment and instruments shall be adopted as per industry accepted practice, preferably 4 digits for process platform. Instrument and piping symbols shall be as per legend sheets.

3.2.9

CODES AND STANDARDS The following are the minimum applicable Codes and Standards / relevant API Recommended Practices that shall be followed:• API – 14C • API – 14E • API – 520 • API – 521 • API – 14G • API – 14J • NFPA – 15 & 20



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3.2


ANNEXURE-I

TOTAL


(SHT. 1 OF 2) WELL FLUID COMPOSITION (TYPICAL) – HEERA FIELD COMPONENT MOL PERCENT (ON DRY BASIS)*(FOR GOR275) N2 0.50 CO2 0.940 H2S 0.023 C1 52.97 C2 8.00 C3 5.41 IC4 0.99 NC4 1.37 IC5 0.43 NC5 0.39 C6 0.25 NC7 0.05 CUT-1 4.84 CUT-2 6.63 CUT-3 4.07 CUT-4 2.39 CUT-5 2.46 CUT-6 2.66 CUT-7 2.89 CUT-8 1.16 CUT-9 0.52 CUT-10 0.36 CUT-11 0.32 CUT-12 0.39 100.00


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ANNEXURE-I (Sheet 2 of 2) PSEUDO-CUT DETAILS CUT ABP (DEG C) SP GR CUT-1 89.57 0.7219 CUT-2 110.10 0.7539 CUT-3 132.50 0.7781 CUT-4 160.80 0.8030 CUT-5 192.10 0.8254 CUT-6 228.90 0.8471 CUT-7 268.80 0.8670 CUT-8 307.70 0.8845 CUT-9 351.80 0.9030 CUT-10 402.50 0.9144 CUT-11 455.20 0.9362 CUT-12 524.00 0.9572 * THIS IS A TYPICAL WELL FLUID COMPOSITION. CONTRACTOR SHALL GENERATE THE COMPOSITION OF WELL FLUID FOR OTHER GORs.

Characteristics of Crude oil of Heera Platform


S.N.

Parameter

Result

1

Density at 15°C

0.8397

2

Sp.gravity at 60/60°F

0.8397

3

API Gravity (60°F)

36.93

4

Pour Point °C

33

5

Water Content (% by vol.)

-

6

B.S.&W (% by vol.)

-

7

Kinematic Viscosity at 37.8 °C (cst)

4.44

8

Asphaltene content (% w/w)

1.15

9

Resin content (% w/w)

9.4

10

Wax content (% w/w)

16.67

11

KUOP

11.80

12

Molecular weight

230


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ANNEXURE-II

PRODUCED WATER ANALYSIS Component Ca++ Mg++ Na+ & K+ as Na+ Cl SO4 CO3 HCO3 TDS Salinity (as NaCl) TSS pH Sp. Gr. at 30°C



ISSUE No. 01

mg/l 290 36 9483 14200 230 120 1281 25640 23400 40 8.3 1.018

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3.2


ANNEXURE-III

DIESEL FUEL SPECIFICATION Sl. No. 1


Property Distillation

Unit

Range of Value

% recovery at 366 deg C @ 15/15 deg C

90 (min.)

2

Specific Gravity

3

Copper strip corrosion

@ 100 deg C for 3 hrs.

4 5 6 7 8 9 10 11 12 13 14

Kinematic viscosity Cetane Number Flash Point Sulphur Water Sediment Acidity inorganic Acidity total Carbon Residue Ash content Lower heating value (approx.)

cSt at 38 deg C deg C Wt % Ppmw Wt% Mg KOH/g Wt % Wt % Kcal/kg


ISSUE No. 01

REV. No. 00

0.84 – 0.88 (approx.) No worse than No.1 2 – 7.5 41 >50 1.0 max. 50 max. Nil Nil 0.05 – 0.5 max). 0.2 max. 0.01 – 0.02 max. 9600 - 10000

REV. DATE: 21.07.2010

4.3 Vol II Sec.3.2 - Process Design Criteria

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