Kamose Wellhead Control Panel Specification PDF

North Sinai Petroleum Company Kamose Wellhead Wellhead Control Pa Panel nel Specification Minimal Topside Kamose Study - Phase II

TABLE TAB LE OF CONTENTS CONTENTS GLOSSARY ............................................................................................................................ 5 1

INTRODUCTION............................. ............................. .............................. .............. 7

1.1

Project Description ................................................................................................... 7

1.2

Minimal Topside Study Kamose Study Phase II Scope .............................. ............. 7

1.3

Objective .................................................................................................................. 7

2

SCOPE ..................................................................................................................... 8

3

CODES AND STANDARDS .................................................................................... 9

4

ENVIRONMENTAL DATA ..................................................................................... 12

4.1

Meteorological Data ............................................................................................... 12

4.1.1

Air .............................. ............................. .............................. ............................. ..... 12 12

4.1.2

Sea Water Temperature.............................. ............................. .............................. 12

4.1.3

Rainfall. .................................................................................................................. 12

4.1.4

Wind Data .............................................................................................................. 13

4.2

Hazardous Area ..................................................................................................... 14

4.3

Electro-Magnetic Electro-Magnetic Compatibility Compatibility .......................... ............................. ........................ 14

5

DESIGN ................................................................................................................. 15

5.1

General .................................................................................................................. 15

5.2

Maintenance.......................... .............................. ............................. ...................... 15

5.3

Hydraulic Power Unit........................... ............................. .............................. ........ 15

5.4

Structural Design......................... .............................. ............................. ................ 15

5.5

Standardisation Standardisation of Sub-suppliers .......................... ............................ ..................... 16

5.6

System Design ....................................................................................................... 16

5.6.1

System Capacity .................................................................................................... 16

5.6.2

Reservoir ................................................................................................................ 16

5.6.3

Hydraulic System Supply Pumps ........................... ............................... ................. 17

5.6.4

Clean-up Loop............................. ............................. .............................. ................ 17

5.6.5

Filters ..................................................................................................................... 17

5.6.6

Accumulation.......................... ............................. .............................. ..................... 18

5.6.7

Panel Instruments & Controls................................................................................. Controls ................................................................................. 18

5.6.8

Valve Connections ................................................................................................. 19

5.7

Wellhead Control Modules Modules ......................... ............................. ............................ ... 19

5.7.1

Front of Module Equipment ............................ ............................. ........................... 19

5.7.2

Back of Module Equipment Equipment ................................................. ............................. ...... 19

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J08617A-J-SP-13482 Rev D1 Kamose Wellhead Control Panel Specification

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TABLE TAB LE OF CONTENTS CONTENTS GLOSSARY ............................................................................................................................ 5 1

INTRODUCTION............................. ............................. .............................. .............. 7

1.1

Project Description ................................................................................................... 7

1.2

Minimal Topside Study Kamose Study Phase II Scope .............................. ............. 7

1.3

Objective .................................................................................................................. 7

2

SCOPE ..................................................................................................................... 8

3

CODES AND STANDARDS .................................................................................... 9

4

ENVIRONMENTAL DATA ..................................................................................... 12

4.1

Meteorological Data ............................................................................................... 12

4.1.1

Air .............................. ............................. .............................. ............................. ..... 12 12

4.1.2

Sea Water Temperature.............................. ............................. .............................. 12

4.1.3

Rainfall. .................................................................................................................. 12

4.1.4

Wind Data .............................................................................................................. 13

4.2

Hazardous Area ..................................................................................................... 14

4.3

Electro-Magnetic Electro-Magnetic Compatibility Compatibility .......................... ............................. ........................ 14

5

DESIGN ................................................................................................................. 15

5.1

General .................................................................................................................. 15

5.2

Maintenance.......................... .............................. ............................. ...................... 15

5.3

Hydraulic Power Unit........................... ............................. .............................. ........ 15

5.4

Structural Design......................... .............................. ............................. ................ 15

5.5

Standardisation Standardisation of Sub-suppliers .......................... ............................ ..................... 16

5.6

System Design ....................................................................................................... 16

5.6.1

System Capacity .................................................................................................... 16

5.6.2

Reservoir ................................................................................................................ 16

5.6.3

Hydraulic System Supply Pumps ........................... ............................... ................. 17

5.6.4

Clean-up Loop............................. ............................. .............................. ................ 17

5.6.5

Filters ..................................................................................................................... 17

5.6.6

Accumulation.......................... ............................. .............................. ..................... 18

5.6.7

Panel Instruments & Controls................................................................................. Controls ................................................................................. 18

5.6.8

Valve Connections ................................................................................................. 19

5.7

Wellhead Control Modules Modules ......................... ............................. ............................ ... 19

5.7.1

Front of Module Equipment ............................ ............................. ........................... 19

5.7.2

Back of Module Equipment Equipment ................................................. ............................. ...... 19

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5.7.3

Sequence of operation ............................ ............................. .............................. .... 20

5.7.4

Wireline Valves....................................................................................................... 20

5.8

Fusible Loop........................... ............................ ............................ ........................ 20

6

REMOTE TERMINAL UNIT & RADIO ................................................................... 22

6.1

Remote Terminal Unit (RTU).................................................................................. (RTU) .................................................................................. 22

6.2

Radio ...................................................................................................................... 23

6.3

Antenna ........................... .............................. ............................. ............................ 24

6.4

Antenna Cable Cable ................................ .............................. ............................. ............ 25

7

INSTRUMENT & ELECTRICAL REQUIREMENTS .............................................. 26

7.1

General .................................................................................................................. 26

7.2

Materials.......................... .............................. ............................. ............................ 27

8

TESTING ................................................................................................................ 28

8.1

General .................................................................................................................. 28

8.2

Factory Acceptance Test........................................................................................ 28

8.3

Combined System Test ............................. .............................. ............................. .. 29

8.4

Site Acceptance Test (SAT) ........................ ........................... ........................... ..... 29

9

PRESERVATION ................................................................................................... 30

10

DOCUMENTATION ............................................................................................... 31

11

PACKAGING ......................................................................................................... 32

12

REFERENCES............................ .............................. ............................. ................ 33

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North Sinai Petroleum Company Kamose Wellhead Control Panel Specification Minimal Topside Kamose Study - Phase II

HOLDS LIST

HOLD

Descript ion

Section

1

Confirmation of valve actuator operating pressures & capacities

2

Frequency range to be determined during detail design

5.6.1 6.2 & 6.3

REVISION HISTORY

REV.

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Descript ion

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GLOSSARY AES

Advanced Encryption Standard

AISI

American Iron & Steel Institute

API

American Petroleum Institute

ATEX

Atmosphere EXplosibles

BS

British Standard

DIN

Deutsches Institut für Normung eV (German Institute for Standardisation)

EGPC

Egyptian General Petroleum Corporation

EIA

Electronics Industries Alliance

EMC

Electro Magnetic Compatibility

EN

European Norm

ESD

Emergency Shutdown

FAT

Factory Acceptance Test

FEED

Front End Engineering & Design

F&G

Fire & Gas

HP

High Pressure

HPU

Hydraulic Power Unit

ICSS

Integrated Control & Safety System

IEC

International Electro-Technical Commissiom

IEEE

Institute of Electrical & Electonics Engineers

I/O

Input/Output

ISO

International Standards Organisation

LP

Low Pressure

MV

Master Valve

NAS

National Aerospace Standard

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NOSPCO

North Sinai Petroleum Company

ONS

Offshore North Sinai

PoE

Power over Ethernet

PUWER

Provision and Use of Work Equipment Regulations

QA

Quality Assurance

RTU

Remote Terminal Unit

Rx

Reciever

SAT

Site Acceptance Test

SDRL

Supplier Data Requirements List

SOV

Solenoid Valve

SSSV

Sub Surface Safety Valve

TCP

Transmission Control Protocol

Tx

Transmitter

TIA

Telecommunications Industries Association

VHF

Very High Frequency

VSAT

Very Small Aperture Terminal

WCP

Wellhead Control Panel

WV

Wing Valve

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1 1.1

INTRODUCTION Project Descr ipt ion

NOSPCO, a Joint Venture Company involving Perenco and EGPC, is progressing with the development of the Offshore North Sinai (ONS) leases. The Offshore North Sinai (ONS) concession lies just offshore on the eastern flank of the Nile Delta. The concession is comprised of three separate areas. Each of the three areas has a gas discovery making three proven accumulations. The discoveries: Tao-1, Kamose-1 and Seti Plio-1, were all made in 1997 in high porosity Plio/Pleistocene sandstones. The focused reservoirs are located at depths ranging from 600 to 2300 meters. The gas fields contain lean natural gas. The ONS Phase II project aims at the further development and exploitation of the natural gas from Tao and Kamose leases, which are located offshore respectively at about 60 km and 50 km north of Rommana, North western Sinai, Egypt, in order to maintain the production plateau at an average rate of 180 mmscfd as long as possible, ensuring the highest reserves are achieved for each reservoir. The ONS Phase II project consists of: 2 wells (TAO SW) drilled from TAO existing platform 2 subsea wells (Wastani reservoir) connected to TAO existing platform The development of the Kamose Field includes a new infrastructure comprising an offshore ‘not normally manned’ platform, and a submarine pipeline tied back to the existing sea line through a hot tap connection. The Kamose Phase II FEED includes the FEED design for all topsides equipment and instrumentation, controls as well as the Detailed Design of the jacket and topsides structure. 1.2

Minimal Topsi de Study Kamose Study Phase II Scope

This project covers the topside design of the Kamose platform from the tie-in to the Christmas tree at the wellhead to the cottom of the export riser, as well as the design of the platform itself. The rest of the ONS phase II project is outside of this project Scope. 1.3

Objective

This document defines the minimum requirements for the design, fabrication, inspection and testing of an electro / hydraulic wellhead control system designed for two topside wells. Wellhead Control Panel (WCP) shall also contain a programmable Remote Terminal Unit (RTU) and radio for transmitting signals between Tao & Kamose platforms. Genesis File name:

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2

SCOPE

The Supplier’s scope of work shall include the design, supply, inspection, Q.A., system testing, certification and documentation, including operational handbooks necessary for good operation and maintenance of the specified system. The Supplier will assume full responsibility; this means the Supplier shall guarantee operability, quality of all components inclusive of all sub-suppliers and conformance to authority and code requirements. The unit design shall be based on a fit for purpose philosophy and shall utilise, as far as possible, tried and tested designs, previously implemented in the European offshore environment. Supplier scope of work shall include design, fabrication, testing, calibration and packing for shipment and supply of all materials and documentation necessary for good operation and maintenance for the system. Supplier shall provide nameplates for all instruments and equipment.

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3

CODES AND STANDARDS

The manufacture and supply of the system shall be carried out in accordance with the latest revision of all applicable Egyptian Standards and Codes. Where these do not exist, internationally recognized Standards and Codes shall be applied. Reference

Title Am eri can Petr ol eum Ins ti tu te (A PI)

API Spec 6A

Specification for well head and Christmas Tree Equipment

API RP 14C

Analysis, Design, Installation and Testing of Basic Surface Safety Systems for Offshore Production Platforms

API RP 500

Instrumentation

API RP 520

Recommended practice for sizing, selection and installation of pressure relieving (parts I and II).

API RP 521

Guide for pressure devices in refineries relieving and depressurising systems.

API RP 550

Manual on installation of refinery instruments and control systems. Part I : Process instrumentation and control Part II: Process stream analysers. British Standards Institute

BS 5760

Reliability of Systems, Equipment and Components

BS 6174

Specification for Differential Pressure Transmitters with Electrical Outputs

BS 6447

Specification for Absolute and Gauge Pressure Transmitters with Electrical Outputs Electronics Industries Alliance/Telecommunication Industries As so ci ati on

EIA/TIA (RS) 232

Data Communication Interface Standard

EIA/TIA (RS) 422


EIA/TIA (RS) 485


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Reference

Title International Electro-Technical Commissio n

IEC 60529

Specification for classification of degrees of protection provided by enclosures (IP Code)

IEC 60079

Electrical Apparatus for Explosive Gas Atmospheres Part 0: General requirements Part 1: Flameproof enclosures “d” Part 4: Method of test for ignition temperature Part 7: Increased safety "e" Part 10: Classification of hazardous areas Part 11: Intrinsic safety “i” Part 12: Classification of mixtures of gases or vapours with air according to their maximum experimental safe gaps and minimum igniting currents Part 14: Electrical installations in hazardous areas (other than mines)

IEC 60096-2

Radio Frequency Cables: Relevant Cable Specifications

IEC 60227

Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V

IEC 60331

Fire Resistant Cables

IEC 60332

Flame Retardant Cables

IEC 60439

Low Voltage Switch Gear and Control Gear Assemblies

IEC 60584

Thermocouples

IEC 60751

Resistance Temperature Detectors

IEC 60947

Low Voltage Switchgear and Control Gear

IEC 61131-1

Programmable Controllers –Part 1 General Information

IEC 61131-2

Programmable Controllers –Part 2 Equipment Requirements

IEC 61131-3

Programmable Controllers –Part 3 Programming Languages

IEC 61508

Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems.

IEC 61511

Functional Safety – Safety Instrumented Systems for the Process Industry Sector

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Reference

Title Institut e of Electrical & Electonics Engineers

IEEE 802

LAN Interfaces and Protocols

IEEE C37.1

Specification used for Supervisory Control, Data Acquisition and Control

International Standards Organisation (ISO) ISO 9000

Quality Management & Quality Assurance Standards

ISO 9001

Quality Systems – Model for Quality Assurance in Design, Development, Production, Installation and Servicing Institut e of Petroleum

EI 15

Institute of Petroleum, Model Code of Safe Practice, Part 15: Area Classification Code for Installations Handling Flammable Fluids, 2005

EN 61000-6-1: 2007

Electromagnetic Compatibility Generic Emission Standard, Part 1, Residential, Commercial & Light Industry Environment.

EN 61000-6-2: 2005

Electromagnetic Compatability Generic Immunity Standard, Part 2, Industrial Environment.

Miscellaneous ATEX Directive 94/9/EC

Equipment and Protective Systems intended for use in Potentially Explosive Atmospheres

73/23/EEC

CE Directive for low voltage

89/336/EEC

CE Directive for Electromagnetic Compatibility

NAS 1638 SNT-TC-1 A

Cleanliness Standard for Hydraulic Fluid

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4

ENVIRONMENTAL DATA

The following data shall be used for design purposes. Should the Supplier consider that other data is required for the design or supply of the equipment, or that the omission of certain data could either affect the cost or compromise any safety aspect of the design, this should be requested in writing prior to submission of the bid. The equipment will be located on an offshore production platform in the Mediterranean Sea, 50 km offshore from the North coast of Sinai and consequently will be subjected to the effects of a highly saliferous atmosphere coupled with high temperature and humidity. All components and accessories inside the well head control package shall be suitable for continuous operation under the outside environmental conditions stated below. 4.1

Meteorol ogi cal Data

4.1.1

Ai r

The air quality should be considered to be a highly corrosive marine climate with high moisture and salt levels. The dry bulb temperatures, for the design of offshore facilities above the splash zone, are as follows: Average

Design

Summer:

27 to 31°C

40°C

Winter:

11 to 24°C

5°C

4.1.2

Sea Water Temper ature.

The design seabed temperatures are as follows: Summer:

25°C

Winter:

15°C

The seawater density is taken as 1027 kg/m3. 4.1.3

Rainfall.

The following offshore rainfall data shall be used for design: Maximum (winter):

50-100 mm/h, brief and severe

Maximum (summer):

zero rainfall for long periods

Annual average:

40 mm/year

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4.1.4

Wind Data

The mean hourly wind speeds at 10m above sea level, indicating the directions from, are shown below: Table 3-1 Mean Hourl y Wind Speeds Direction

1 Year

10 Year

100 Year

from North

m/sec

m/sec

m/sec

0°

9.2

10.8

12.3

30°

9.6

11.7

13.5

60°

10.2

13.1

15.6

90°

8.6

11.5

14.2

120°

8.0

11.0

13.8

150°

7.1

9.6

11.9

180°

7.9

10.7

13.2

210°

12.1

16.9

21.3

240°

14.3

18.4

22.1

270°

14.1

17.2

20.0

300°

12.1

14.0

15.8

330°

12.0

14.2

16.1

OMNI

14.3

18.4

22.1

The omni-directional wind speeds in m/sec for other sample intervals are shown below. Table 3-2 Omni Directi onal Win d Speed Omni directional

1 Year

10 Year

100 Year

m/sec

m/sec

m/sec

1 hour mean

14.3

18.4

22.1

10 minute mean

15.3

19.9

24.0

1 minute mean

16.6

21.7

26.4

3 second gust

18.3

24.1

29.6

Reference: Basis of Design J08617A-P-RD-15000

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4.2

Hazardous Area

All equipment located in the wellhead hydraulic unit shall be suitable for the following hazardous area:Zone 1 Gas Group IIA Temperature Class T3. All instrumentation shall be EEx(d) Solenoid valves shall be EEx(d) and protected to IP65 minimum. Pump motors shall be EEx(de), protected to IP56 minimum, without anticondensation heaters. All equipment to be ATEX approved The minimum degree of protection for the housings, field panels & enclosures when containing electrical components, shall be IP65. 4.3

Electro-Magnetic Compatibi lit y

All equipment or systems containing electrical or electronic apparatus shall satisfy the requirements of electromagnetic compatibility legislation, e.g. S. I. 1992 No. 2372 (1992). The Electromagnetic Compatibility Regulations, as amended by S. I. 1994 No. 3080; S. I. 1992 No. 2932 The Provision And Use Of Work Equipment Regulations (PUWER). Relevant apparatus should satisfy the following EMC performance requirements. Emissions Emissions performance shall be in accordance with EN 61000-6-1: 2007 Electromagnetic Compatibility Generic Emission Standard, Part 1, Residential, Commercial & Light Industry Environment. Immunity Immunity performance shall be in accordance with EN 61000-6-2: 2005 Electromagnetic Compatibility Generic Immunity Standard, Part 2, Industrial Environment. Perfo rmance Criteria Performance Criterion A as applied to immunity of measuring instruments to radiated interference is hereby defined as allowing a degradation in performance not exceeding +/- 0.1% of the output span with the instrument enclosures (covers) in place and not exceeding +/- 0.5% of the output span with the instrument enclosures (covers) removed.

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5 5.1

DESIGN General

The WCP shall consist of an integral skid mounted Hydraulic Power Unit (HPU), Remote Terminal Unit (RTU), radio/modem and operator controls for two topside wells. The Hydraulic Power Unit shall provide hydraulic power for the well valves and additional topsides ESD and HIPPS valves as defined in Section 5.6.1 of this specification. The hydraulic fluid shall be Castrol Transaqua HT, cleaned to NAS1638 class 6. The programmable Remote Terminal Unit shall provide the required minimum automatic control and ESD/F&G shutdown functions required for the safe shutdown of the platform. The Platform power supply will be derived from a solar power package. The design of the WCP shall minimize its electrical power usage whilst ensuring that the overall system can be safely operated. The design and controls must be kept as simple as possible, consistent with safe and reliable operation. Failure of any part of the system / package shall be to the safe or isolated condition. The WCP shall be of the fully ‘enclosed’ type and is to be lockable. There is no instrument /plant air supply available on the platform. An overview of the system is shown on Wellhead Typical Detail P&ID -Drawing No: J08617A-P-DW-15420 / 15421. 5.2

Maintenance

The platform will be designed for infrequent maintenance visits. The WCP shall be designed to ensure that the interval between periodic maintenance visits is maximised. The Supplier shall advise, in his bid, the expected maintenance interval. 5.3

Hydraulic Power Unit

The HPU shall consist of hydraulic reservoirs, pumps, accumulators, filtration, intensifiers and other equipment and instruments required to produce the required hydraulic pressures. It shall be located integrally within the Wellhead Control Panel. 5.4

Struct ural Desig n

The structural design of the WCP shall, in addition to the normal static loads, take account of transportation loads and include for acceleration to 1 g in any direction and roll motions of 20 with a 10 Sec period. 

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The layout of equipment and instrument items shall allow ease of access for maintenance. The layout of equipment and instrument items shall be determined by supplier subject to purchaser approval. 5.5

Standardisatio n of Sub-suppli ers

The Purchaser will select the project supplier for electric motors, mechanical seals, mechanical couplings, and general instrumentation and instrument fittings. Suppliers shall define the manufacturers offered as sub-suppliers in these categories, in their bids. 5.6

System Design

5.6.1 System Capacity The system shall be sized to operate valves at capacities and pressures stated below (HOLD 1) Valve Type

Quantity

Min Op. Press (Barg)

Norm Op. Press (Barg)

Max Op. Press (Barg)

Approx. Swept Volume (Litres)

Platform Well Master Valves MVs.

2

150

200

207

1.6

Platform Well Wing Valves WVs.

2

150

200

207

0.4

Platform Well Sub Surface Safety Valves SSSVs

2

250

310

345

0.1

Platfor m Well Completions

At start up or after a shutdown it shall be possible to recharge the hydraulic system via the electrically driven pump or a hydraulic hand pump. Pumps and accumulation shall be sized to suit. 5.6.2

Reservoir

A reservoir shall be provided for the supply and return fluid from the well valves. The reservoir shall have sufficient capacity to supply and operate the maximum system configuration referred to in this specification, including hydraulic accumulator volume. Genesis File name:

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The supply reservoir shall be provided complete with drain valve, level gauge, & two level transmitters (1 for ESD, 1 for monitoring) covering the full range of the reservoir with isolation valves, clean out bulkhead plate, tank breather and magnetic particle collector & sample points. Fresh fill fluid shall be filtered before use. 5.6.3

Hydraulic System Supply Pumps

Pumps shall generate one level of hydraulic pressure (LP), with intensifiers to generate the HP supply: LP

200 Barg for MV’s, WV’s and other platform valves. (HOLD 1)

HP

310 Barg for SSSV’s (HOLD 1)

One electric driven pump shall be provided to deliver hydraulic fluid at the lower pressure level. Dual (duty/standby) pressure intensifiers shall be provided to supply fluid at the higher pressure level. The pump shall be installed complete with suction block valve, discharge check valve, discharge relief valve, discharge double block and bleed valve. Pump shall have a discharge pressure gauge, a discharge pressure transmitter, inlet & outlet filters as required. Supplier to advise method of control & pressure settings for the pump start/stop within the installation and operation manual. Pump motor shall be provided with an emergency stop latching pushbutton unit. A manually operated pump shall also be provided, in parallel with the above electric pump, this pump shall also be supplied with suction block valve, discharge block valve, discharge relief valve, discharge double block and bleed valve and discharge pressure gauge. 5.6.4 Clean-up Loo p The system shall be provided with a clean up pump and filter system for cleaning of the reservoir contents, the pump shall be manually operated. The clean up system shall include valves to allow replacement of the filter elements before recirculation of fluid from and to the storage reservoir. Valving shall also allow pump to be used to fill/top-up supply reservoir using a quick connect coupling and barrel lance assembly. 5.6.5 Filters Filters shall be provided with a differential pressure transmitter to monitor for cleanliness and replacement interval.

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5.6.6 Ac cu mu lat io n Nitrogen charged, bottle type bladder accumulators shall be connected by tubing to the system for pressurising the HP and LP hydraulic manifolds. Accumulators shall be sized for the full system configuration. Accumulators shall be sized for the following actions:One opening stroke of two platform SSSV One opening stroke of two platform MV One opening stroke of two platform WV Once a well has been opened, the system shall replenish the accumulators to their normal pressures within 30 minutes. 5.6.7 Panel Instruments & Controls The panel shall have the following front of panel controls and indications: LP header, HP header and Fusible loop header pressure gauges LP pump, Recirc pump and Manual pump discharge pressure gauges LP pump start pushbutton LP pump stop pushbutton ESD pushbutton Open / Close pushbuttons for all SSSVs, Master and Wing valves Nitrogen pressure indications shall be as per accumulator Suppliers standard. LP header shall have two transmitters: One transmitter will provide local control of LP hydraulic pumps and low/high pressure alarms. Second transmitter will provide low low pressure ESD signal. HP header shall have two pressure transmitters: One transmitter will provide low/high pressure alarms. Second transmitter will provide low low pressure ESD signal.

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NOTE: To reduce number of signals sent to the Onshore Control room, low/high pressure alarms shall be combined with the reservoir low/high level alarms to provide a common status alarm signal. Fusible loop header shall have one pressure transmitter for low low pressure F&G/ESD function. Transmitters shall be SMART type with integral indicators. All process pressure gauges shall be fitted with snubbers. Supplier shall provide sizing calculations for each relief valve. 5.6.8 Valve Connection s All external WHU connections to well valves shall be terminated on 12 mm bulkhead compression fittings. Spare bulkhead connections for well valves to be supplied. 5.7

Wellh ead Contro l Modules

The Wellhead Hydraulic Unit shall be sized to accommodate a maximum of 2 platform well control modules. It shall be supplied with 2 platform well control modules installed. Internal panel cabling and tubing shall be designed for easy change out of well modules via removable drawers. Hydraulic connections to each drawer shall be via a double block and bleed arrangement. The controls for each wellhead shall be clearly separated on the front of the hydraulic unit. Each Platform well control module shall control the SSSV, MV and WV for one platform well. Control modules shall be of a failsafe design. 5.7.1 Front of Module Equipment Each platform well control module shall have the following front of panel indication: Pressure gauge for hydraulic supply to each of SSSV, MV & WV. 5.7.2 Back of Module Equipment Equipment mounted back of panel on each topsides well control module shall include:Pressure transmitters for remote indication of each SSSV position. One solenoid valve for each MV, SSSV and WV (controlled by the RTU/ESD system) Wireline key lockable 2 position selector valves Genesis File name:

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Position 1 - Normal operation. Position 2 - Wireline control. 5.7.3 Sequence of operatio n Sequencing of well valve operation will be carried out by the RTU/ESD. Sequence and time delay requirements are to be defined by Purchaser. The hydraulic system shall include adjustable flow control valves to delay closure of the SSSV until after the master and wing valves have closed. This is to prevent premature SSSV closure in the event of loss of electrical power to the system solenoid valves, or loss of hydraulic pressure. Well Shutdown: The well valves will be closed in the following sequence wing, master and then SSSV. There will be a 5 second delay between wing and master closure initiation this will be implemented in the RTU/ESD. There will be a 15 second delay between master and SSSV closure initiation this will be implemented in the WHU. Signal Failure or Hydraulic Loss: On loss of signal or hydraulic pressure there will be a 15 second delay between master and SSSV closure initiation this will be achieved by a hydraulic timer in the WHU. System shall be designed to ensure closure of platform well valves within 30 seconds of demand. 5.7.4 Wireline Valves During wire lining workover operations the MV & SSSV of the selected well shall be under the control of the wireline or workover crew. A well will be placed in wireline control by using the lockable valves on the appropriate well control module. The wireline connection from each of these valves shall be tubed to 12mm bulkhead connectors on the exterior of the WHU. 5.8

Fusibl e Loop

The WCP shall be connected to a common process area hydraulic fusible loop system with frangible bulbs and supply/return tubing. The unit shall include a pressure transmitter which will be connected to the RTU/F&G system. Supplier shall provide a pressure letdown system within the WHU to operate and monitor the loop system at 6 barg. Supplier shall provide 30 off suitable frangible bulb change-over valves for site installation by others.

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All tubing, fittings, cables, junction box and hook-up material for complete installation to be in Suppliers scope of work.

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6

REMOTE TERMINAL UNIT & RADIO

The Kamose platform is intended to be of a ‘minimal’ design and to operate with minimal facilities. Instead of an Integrated Control & Safety System (ICSS) located in a Local Equipment Room (LER) the platform will have a programmable, SIL 2, Remote Terminal Unit (RTU) located in the Wellhead Control Panel (WCP). This will provide the required minimum automatic control and ESD/F&G shutdown functions required for the safe shutdown of the platform. 6.1

Remote Termin al Unit (RTU)

RTU shall comply with, but not be limited to t he following: SIL 2 (Certified by third party, such as TUV) Suitable for use in a Zone 2 Gas Group IIA Temperature Class T3 hazardous area. Compliance with IEC 61508 and IEC 61511 Programmable using IEC 61131-3 automation languages. Redundant controllers for increased availability. Inherent reliability Data logging Time stamping Extensive diagnostics Non volatile memory, data to be retained in event of loss of power Hot replacement of I/O modules Automatic configuration of replacement I/O modules Low cost of ownership Low power, suitable for solar power Dual redundant power supplies RTU to continue to operate for a defined period on loss of communication RTU to be shock & vibration resistant. The RTU will be programmed to provide the following: Automatic start/stop control of LP hydraulic pump to maintain hydraulic fluid at correct pressure. Group selected pre-alarms to provide ‘common’ alarms for display on the onshore remote terminal. Refer to J08617A-J-AE-13470 Kamose Offshore Instrument Index.

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Initiate shutdown actions in response to specific inputs from field devices, F&G logic, manual ESD pushbuttons (Both offshore and onshore). The ESD status will be communicated to the onshore remote terminal The F&G logic will interface directly with the platform ESD logic to initiate local executive actions and activate audible and visual alarms. The F&G status will be communicated to the onshore remote terminal Inputs to the ESD logic will be from both analogue and digital devices with outputs generally being fail safe, de-energise to trip. The ESD status will be displayed in the jack-up drilling rig, when it is on-station. The ESD system will be programmed in accordance with the requirements of the Kamose platform F&G and ESD Cause & Effect Diagrams J08617A-J-CF-13460 The safety systems for Kamose will be configured as ‘fail safe’. Loss of power or utilities or open circuit on inputs and/or outputs will r esult in external equipment going to a safe condition. The F&G logic will interface with various types of field devices used for F&G detection, the F&G element of the RTU shall have standard interfaces for all commonly used detector systems. Fire and Gas detectors that require occasional maintenance will be provided with an override function accessed via the RTU interface, these provide inhibit and enabling functions thus permitting routine work. The F&G system will be programmed in accordance with the requirements of the Kamose platform F&G and ESD Cause & Effect Diagrams J08617A-J-CF-13460. Selected data shall be transmitted to the onshore remote terminal via a VHF radio link between Kamose and Tao platforms and a ‘line of sight’ microwave radio system and VSAT between Tao platform and onshore. For details of data to be transmitted between Kamose platform and onshore refer to J08617A-J-AE-13470 Kamose Offshore Instrument Index. A laptop shall be provided loaded with all the relevant software to enable operator to interface with the RTU. Laptop will allow operator to connect to the RTU to setup/configure controllers and display data during a platform visit. 6.2

Radio

A high speed digital data VHF radio shall be mounted in the WCP and shall be connected to the RTU using an Ethernet link. Radio requirements to be, but not limited to the following: Genesis File name:

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Frequency range:

HOLD 2 (To be determined during detail design)

Operational modes:

Simplex, Half Duplex, Full Duplex options

Configuration:

Via Windows based software.

Diagnostics:

Full diagnostic capability

Transmission:

Data & Voice

Ethernet Protocol:

Modbus/TCP

Encryption:

WPA2 – 802.11i - 128 bit AES encryption

Connections:

Ethernet port (IEEE 802.3) RJ45 Power Separate N(Tx) and SMA(Rx) connectors for full duplex mode. Handset

Power supply:

24VDC

Housing:

Rugged enclosure

Mounting:

DIN rail

Handset:

Yes

Hazardous Area Certification:

Suitable for use in a Zone 2 Gas Group IIA Temperature Class T3 hazardous area.

Vendor to ensure that selected frequency channels comply with Egyptian regulatory standards. 6.3

Antenna

Antenna shall be a Yagi type with a narrow beam width suitable for point to point communication. It shall have a high front to back ratio to help minimize potential interference to and from other radio systems. Antenna shall be constructed of heavy duty stainless steel and be suitable for use in an offshore environment as stated in Section 3.1. Antenna requirements to be, but not limited to the following: Frequency range:

HOLD 2 (To be determined during detail design)

Polarisation:

Vertical or Horizontal. (Antenna on Tao & Kamose platform to have same polarization)

Number of elements:

To be decided during detail design.

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Construction:

Stainless steel.

Mounting:

Heavy duty mounting hardware

Antenna shall be mounted at the correct height to achieve the required communication performance with Tao platform. Antenna shall be suitable for wind conditions as stated in Section 4.1.4. 6.4

Ant enna Cable

Vendor to supply suitable antenna cable complete with connectors. Cable will be required to have galvanized steel wire braid and flame retardant outer sheath. Cable run will be approximately 50m, Vendor to confirm that this cable length is acceptable and will not have a detrimental effect on the radio performance. If cable run is to long consider Power over Ethernet (PoE) as this enables radio placement near antenna to improve wireless network performance.

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7

INSTRUMENT & ELECTRICA L REQUIREMENTS

7.1

General

The electrical supplies available are:Motor drives 24 V dc. Solenoid Valves 24V dc - Negative pole earthed Solenoid valves shall consume low power, be continuously powered and fail safe. All WCP instrumentation and pushbuttons that interface with the RTU shall be cabled directly to the RTU I/O terminals via a gland plate in the RTU enclosure. Field cables (by others) carrying signals between the RTU and field devices shall enter the WCP via a gland plate in the side of the panel, glands shall be through type to provide environmental seal. Cables shall enter RTU enclosure via a gland plate, glands shall be Ex type suitable for use in specified hazardous area. Motor start, stop and emergency stop pushbuttons and motors will be cabled, by supplier, directly to the motor starters. Motor starters will be by supplier and located in the WHU. All instruments shall be tagged with stainless steel labels bearing Purchaser’s tag numbers (to be advised later). All unit cabling shall be flame retardant in accordance with lEC 332 part 1 & 3 Standard ships wiring cable to BS6883 with braid wire armour shall be used for routes external to the cabinet, with unarmoured cable within cabinet. Nylon sealing washers shall be used on glands to maintain enclosure IP ratings where applicable. Junction boxes etc. shall be earthed to skid by means of star washers. WHU shall be fitted with M10 earth bosses on diagonally opposite corners of the skid. There will be no power available for internal cabinet lighting. The design of the cabinet shall make provision for ambient light to be available for maintenance purposes (removable panel/window). If this is not possible, Supplier shall state this in his bid so that Client can ensure maintenance crews visit the platform with necessary portable lighting. All DC motors shall be standard products in accordance with IEC. DC motors shall be 24 VDC. Motor datasheets are to be submitted with bidder’s offer. The electrical installation shall meet IEC requirements. A single, 4 x 50mm2, cable (by others) shall supply the 24vdc power to the WHU for the RTU.

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A single, 4 x 120mm2, cable (by others) shall supply the 24vdc power to the WHU for the pump. The RTU on the Kamose platform shall be supplied from a dedicated power supply with 96 hour battery backup (By others). This shall be fed from the general platform electrical supply in normal operation. 7.2

Materials

Base frame, panel and wellhead control modules shall be 316 SS, as a minimum. Tubing shall be metric AISI 316L stainless steel, as a minimum. Tube fittings shall be Parker Hannifin metric double ferrule type, AISI 316 stainless steel, as a minimum. Cable tray/supports shall be 316L SS System shall be supplied complete with sufficient hydraulic fluid for topsides system first fill.

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8

TESTING

8.1

General

The system shall be subject to several levels of testing throughout manufacturing and installation phases of the project. Prior to shipment the complete system shall be subject to a witnessed Factory acceptance test (FAT) during which the system will be fully functionally tested at normal operating pressures including all pumps, solenoid valves and instrumentation. Prior to testing system shall be flushed to NAS Class 6 or better and a fluid sample taken to confirm this has been achieved. A cleanliness certificate shall be available for review. The Purchaser reserves the right to be present and to participate in any or all the tests conducted. All of the witnessed tests will be scheduled by the Supplier in accordance with the overall project schedule. Written test procedures shall be submitted to the Purchaser for approval prior to testing. The Purchaser shall be notified in writing at least two weeks prior to start of all witnessed tests. The major witness tests which require the Purchaser’s approval include: Factory Acceptance Test (FAT) Site Acceptance Test (SAT) 8.2

Facto ry Accept ance Test

The Factory Acceptance Test shall include the Combined System Test. This will incorporate the WCP, RTU, radio link and field I/O. This test will be carried out at the WCP Suppliers works. Field I/O shall be achieved using a test simulator. The test shall be designed to demonstrate that the WCP & RTU will perform their specified functions. The test shall demonstrate the performance and accuracy required. Vendor shall be responsible for providing a test simulator and all temporary hardware to allow for full function testing. Witness testing shall only be carried out after the Test Procedure has been submitted and approved by the Purchaser. Test procedure to be detailed and include all components to be used for the Test rig. Genesis File name:

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The software configuration and any hardware being supplied shall be fully tested. The Supplier shall demonstrate the operation of all diagnostic and maintenance tests provided with the system. Errors shall be simulated to demonstrate the capability of the system to detect and report errors. 8.3

Combin ed System Test

Included as part of the FAT. 8.4

Site Acc eptance Test (SAT)

The Seller shall provide commissioning support during a full functional test.

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9

PRESERVATION

After successful testing and approval received for shipping, Wellhead Control Panel preservation should be, as a minimum, carried out as follows: Drain down all hydraulic fluid from accumulators, reservoirs, filters etc. Discharge all nitrogen from accumulators. Place silica gel sacks within all junction boxes and electrical enclosures to prevent condensation forming. Cap external tube and pipework connections, using approved blanking / capping devices. Pre-set all valves as per panel schematic drawing. Secure loose items within the panel.

A written Preservation Procedure shall be submitted to the Purchaser for approval prior to packing. Preservation shall only be carried out after the Preservation Procedure has been submitted and approved by the Purchaser.

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10 DOCUMENTATION The wellhead control and hydraulic power documentation shall be developed and be user friendly with respect to design, installation, operational and maintenance requirements. The Purchaser shall initially develop a Supplier’s Document Requirements List (SDRL) and SDRL Instruction Specification that shall accompany the Enquiry Material Requisition. The SDRL instructions shall define precise document requirements, the means of document approval, the quantity of soft/hard copies required from initial enquiry through to final issue, and the dates by which documents should be transferred back and forth throughout documentation development. Prior to commitment of Purchase Order the selected Supplier shall complete the SDRL with additional documentation pertaining to the wellhead control and hydraulic power that enhanced design, installation, operational and maintenance requirements developed during the enquiry.

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11 PACKAGING The Supplier shall be responsible for ensuring that the Wellhead control panel is packed securely, and in such a manner as to prevent damage and dirt ingress whilst being transported, or stored, under the most severe environmental conditions likely to be encountered throughout the entire route from source to construction yard. The WHU shall be accompanied by a Packing List that shall include the following information as a minimum: Project and Purchase Order Numbers; Supplier’s Name and Trademark; Address of destination via interim ports of call; Package sequence number (n of N if one of a sequence of packages); Itemised Material List with equipment identification and serial numbers including descriptions, model numbers etc. Handling and unpacking instructions.

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Kamose Wellhead Control Panel Specification PDF

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