Full Revised Specification for Well Head Control Panel

Table of Contents 1.

INTRODUCTION .................................................................................................................. 7 1.1

General ............................................................................................................ 7

1.2

Definitions ....................................................................................................... 8

1.3

Proposal structure ......................................................................................... 9

1.3.1

Details of Offer and Variation ...................................................................... 10

1.3.2

Information to be submitted with Offer ...................................................... 10

1.3.3

Information to be submitted after award of Contract ................................ 11

2.

ABBREVIATIONS .............................................................................................................. 12

3.

CODES, STANDARDS ABD REFERENCE DOCUMENTS ................................................ 13 3.1

PDO Standards ............................................................................................. 13

3.1.1

Engineering Specifications (SP & SPE) ..................................................... 13

3.1.2

Guidelines (GU) ............................................................................................ 13

3.1.3

Design Engineering Practice (DEP) ............................................................ 14

3.2

International Standards: .............................................................................. 14

3.2.1

ANSI (American National Standards Institute) .......................................... 14

3.2.2

API (American Petroleum Institute) ............................................................ 14

3.2.3

ASME (American Society of Mechanical Engineers) ................................. 15

3.2.4

ISA (Instrument Society of America) .......................................................... 15

3.2.5

IEC (International Electro-technical Commission) .................................... 15

3.2.6

European Codes (CENELEC) for Electrical Eqpt. in hazardous area ...... 16

3.2.7

Other international standards ..................................................................... 17

3.3

EMC (Electromagnetic Compatibility) ........................................................ 18

3.4

General .......................................................................................................... 18 Page 2 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

3.4.1 4.

5.

Language and Units of Measurement ......................................................... 18

OPERATING CONDITIONS / AREA OF INSTALLATION .................................................. 19 4.1

Relevant Ambient Data ................................................................................ 19

4.1.1

Ambient Temperature .................................................................................. 19

4.1.2

Relative Humidity and Barometric Pressure .............................................. 19

4.1.3

Wind speed ................................................................................................... 19

4.1.4

Rainfall .......................................................................................................... 20

4.1.5

Earthquakes .................................................................................................. 20

4.1.6

Geographical Data ....................................................................................... 20

4.1.7

Sandstorms .................................................................................................. 20

4.1.8

Design Life .................................................................................................... 20

WELL HEAD CONTROL PANEL (WHCP) ........................................................................ 21 5.1

General .......................................................................................................... 21

5.2

Material of Construction and Fabrication .................................................. 23

5.3

Hydraulic System ......................................................................................... 26

5.3.1

Hydraulic Power Circuits ............................................................................. 27

5.3.1.1 VHP (SC- SSV hydraulic circuit) ................................................................. 27 5.3.1.2 HP1 (SSV & WV hydraulic circuits) ............................................................ 28 5.3.1.3 HP2 (HIPPS Valve & CV) .............................................................................. 29 5.3.1.4 MP (Fusible plugs hydraulic circuit) ........................................................... 30 5.3.2

Common hydraulic circuit ........................................................................... 30

5.3.3

Hydraulic Circuit Components .................................................................... 33

5.4

Electric Components ................................................................................... 34

5.5

Well Controls and Shutdown Requirements .............................................. 36

5.5.1

General .......................................................................................................... 36

5.5.2

ESD Section .................................................................................................. 37 Page 3 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

5.5.2.1 Manual ESD .................................................................................................. 37 5.5.2.2 Fire detected ESD ........................................................................................ 38 5.5.3

Closure of actuated valves .......................................................................... 39

5.5.3.1 HIPPS valve closure ..................................................................................... 39 5.5.3.2 WV & CV (simultaneous) closure ................................................................ 39 5.5.3.3 SSV closure .................................................................................................. 39 5.5.3.4 SC-SSV closure ............................................................................................ 39 5.5.4

Hydraulic Logic Control Circuit .................................................................. 40

5.5.4.1 SC-SSSV ....................................................................................................... 40 5.5.4.2 SSV ................................................................................................................ 40 6.

7.

8.

ASSOCIATED INSTRUMENTS AND ACCESSORIES....................................................... 42 6.1

Pilots ............................................................................................................. 42

6.2

Extra high pressure switch ......................................................................... 42

6.3

Quick Dump Valve Local Panel with Wire line Connection ...................... 42

6.4

Fusible Plugs ................................................................................................ 42

6.5

SSV/ Wing Valve Limit Switch Assembly ................................................... 43

6.6

First fill Mineral Oil ....................................................................................... 43

UTILITY REQUIREMENT ................................................................................................... 44 7.1

Electrical ....................................................................................................... 44

7.2

Hydraulic ....................................................................................................... 44

HIPPS VALVE ASSEMBLY................................................................................................ 45 8.1

Technical requirements ............................................................................... 45

8.1.1

Material of Construction .............................................................................. 46

8.1.2

Design Requirement .................................................................................... 46

8.1.3


8.1.4

Hydraulic Power Section ............................................................................. 48 Page 4 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

9.

8.1.5


8.1.6

HIPPS Valve Controls .................................................................................. 48

8.1.7

HIPPS Valve ESD/TRIP Section ................................................................... 49

8.1.8

Mechanical Switches ................................................................................... 49

CHOKE VALVE ASSEMBLY ............................................................................................. 50 9.1

Technical details .......................................................................................... 50

9.1.1

Material of Construction .............................................................................. 50

9.1.2

Design Requirement .................................................................................... 51

9.1.3


9.1.4

Hydraulic Power Section ............................................................................. 53

9.1.5


9.1.6

Choke Valve Controls .................................................................................. 54

9.1.7

Choke Valve ESD Section............................................................................ 54

10. PAINTING........................................................................................................................... 55 11. INSPECTION & TESTS ...................................................................................................... 56 11.1

Visual Checks ............................................................................................... 56

11.2

Performance Tests ....................................................................................... 56

11.3

Functional Tests ........................................................................................... 57

11.4

Integrated (FAT) System Test ..................................................................... 57

11.5

Other Requirements ..................................................................................... 57

11.5.1 Body Test ...................................................................................................... 58 11.5.2 Leak Test and Stroke Test for IPF Valves .................................................. 58 11.5.3 Functional Test (Test Medium: Nitrogen) ................................................... 58 11.5.4 Gas Seat Test (Test Medium: Nitrogen) ..................................................... 58 12. CERTIFICATION ................................................................................................................ 60 13. TRANSPORTATION AND STORAGE ............................................................................... 61 Page 5 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

14. PROGRESS OF WORK ..................................................................................................... 62 15. GURANTEE ........................................................................................................................ 63 16. DOCUMENTS REQUIRED FROM VENDOR ...................................................................... 64 17. SPARE PARTS .................................................................................................................. 65 APPENDIX A

: ACTUATED VALVES PRESSURE AND TUBING

APPENDIX B

: HYDRAULIC POWER SECTION DESIGN CONDITION

APPENDIX C

:SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT FOR API 10,000

APPENDIX D

:SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT FOR ASME 2500#

APPENDIX E

: WELL HEAD CONTROL PANEL LAYOUT DRAWINGS

APPELDIX F

: LOCAL DUMP VALVE PANEL

APPENDIX G

: ARRANGEMENT OF SSV SWITCH ASSEMBLY

APPENDIX H

: HIPPS VALVE AND ACTUATOR DATA SHEETS

APPENDIX I

: HIPPS PANEL SCHEMATIC DIAGRAM

APPENDIX J

: CHOKE VALVE AND ACTUATOR DATA SHEET

APPENDIX K

: CHOKE VALVE PROCESS DATA

APPENDIX L

: CHOKE VALVE PANEL SCHEMATIC

APPENDIX M

: WET GAS COMPOSITION

APPENDIX N

: RVED

APPENDIX O

: AVME LIST

APPENDIX P

: TABLE OF COMPLIANCE (TOC)

Page 6 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

1.

INTRODUCTION

1.1

General This specification and accompanying documents referenced herein describes the minimum requirement for design, engineering, manufacturing, assembly, testing, inspection, supply and commissioning of Integrated Hydraulic Wellhead Control and Safeguarding System for High Pressure Gas (HPG) Wells in Saih Rawl, Saih Rawl Grab, Saih Rawl South, Fahud South West, Mabrouk, Burhaan West, Harmal, Khulud, Kauther and Fakhar area.

The quantity required in each area is as follows: a. Saih Rawl type, ASME 2500# – 25 sets b. Burhaan type, API 10,000 – 30 sets

The Integrated Well Head Control and Safeguarding System shall be supplied complete with the following:1. Well Head Control Panel with hydraulic circuit lines for SC-SSV, SSV, WV, HIPPS valve and CV 2. HIPPS valve with Hydraulic Control Panel 3. Choke valve with Hydraulic Control Panel 4. Fusible plugs (4 nos.) 5. Associated Instruments and accessories Vendor shall complete the “Table of Compliance at Appendix – P and provide all the necessary technical drawings, documentations or third party certifications to verify the compliance of each section of this specification. The documents covered in various parts of this specification are intended to be complementary to one another and as mutually explanatory of one another, but in the case of ambiguities or discrepancies the Vendor shall submit to PDO his request for any clarification. PDO’s clarification shall be final. The Vendor shall be responsible for the design and supply of the Integrated Hydraulic Wellhead Control and Safeguarding System inclusive of Well Head Control Panel with hydraulic circuit lines for SC-SSV, SSV, WV, HIPPS Valve and CV, supply of HIPPS Valve and CV with hydraulic panels, Associated Instruments and accessories based on the information furnished in this specification. Page 7 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

Any work shown on the reference drawings or documents and not particularly given in the specification or vice versa, shall be included by the Vendor. The omission from this specification of any items essential for the correct functioning of any part of the specified equipment shall be brought to the attention of PDO. Failure to do this shall not absolve the Vendor from the supply of any items / services required to achieve the full functioning of the equipment to the intent of this specification. Where alternatives are offered, they shall be fully described, and must be accompanied by all pertinent engineering information to facilitate their evaluation. It shall be the responsibility of the Vendor to select the peripheral instruments of the wellhead control system and also to ensure all the interoperability issues. The Vendor shall use the latest issue of AVME (attached as Appendix - O) for standardization purpose and also seek the proper PDO (CFDH C&A) approval if particular make is not appearing in list before procurement and shall supply only specific wellhead application proven items with reference list for approval. The PDO (CFDH C&A) approval or Consultant’s recommendation does not absolve the supplier from his responsibility of interoperability. Vendor shall not use any failed peripheral instruments which have been delivered under the previous PDO orders It is not the intent of this Specification to specify completely the details of design, manufacture, configuration, inspection and testing. It is the Vendor's responsibility to ensure that the item is designed, manufactured, configured, installed, tested and commissioned in accordance with the latest standards, statutory regulations and safety codes, and is' also consistent with good engineering practice. This requirement shall be fully detailed in the Vendor's manufacturing drawings and documentation, which shall be reviewed by PDO.

1.2

Definitions For the purpose of this document, the following definitions shall hold:The word “Principal” or “Company” is PDO and is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant authorized to act for, and on behalf of, the Principal. The word ‘Purchaser” is PDO The word “Contractor” is the party which carries out all or part of the Design, Engineering, Procurement, Construction, Commissioning or Management of a Project or Operation of a facility. The Principal may undertake all or part of the duties of the Contractor. Page 8 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

The word “Manufacturer” or “Supplier” or “Vendor” is the party which manufactures or supplies equipment and services to perform the duties specified by the Principal or the Contractor. The word “shall” is to be understood as mandatory. The word “should” is to be understood as strongly recommended.

1.3

Proposal structure The proposal shall include, as a minimum:

a) Project, Administration, Technical and Engineering personnel required to implement the scope of this specification. b) Estimated normal and maximum Electric power consumption. c) Typical panel internal layout drawings and estimated weights. d) Drawings (Hydraulic & Electrical schematic), details and description of the operation of the proposed system as well as manufacturer, model no, materials and types of auxiliary equipment. e) Completed Table of Compliance (TOC) f) Pump sizing, Pump running time during initial start-up, normal running time. g) Tube sizing. h) Accumulator sizing. i) Any start-up, shutdown or operating restriction required to protect the integrity of the system. j) Preliminary manufacturing / production program k) Conditions of guarantee. l)

A statement of the extent of any sub-contracted work together with the name of the proposed sub-contractor, for the Purchaser's approval. The Purchaser reserves the right to survey any such sub-contractor's place of manufacture prior to giving written approval.


1.3.1

Details of Offer and Variation

Vendor shall include 2 years operation spares in the offer for the complete package. Sufficient numbers of soft goods kits for spares shall be provided. Vendor shall provide service for pre- commissioning and commissioning assistance at site for the WHCP package (including valves). The service shall be given as per man day rate, mobilisation and demobilisation rate as applicable. The offer shall be accompanied by a tabulation of components, equipment and documentation forming the system with an itemized list of those items supplied directly by the Vendor and those supplied by third parties i.e. ‘bought out’ items. If the Vendor is unable to undertake the whole of the equipment construction, the extent of sub-contracted work shall be stated in his quotation, together with the name of the proposed sub-contractor, for the PDO’s approval. Details and calculations of electrical properties of load 1 (control logic) and load 2 (hydraulic motors) shall be included. Note: PDO reserves the right to survey any sub-contractor’s place of manufacture prior to giving written approval. The tender shall be accompanied by detailed specifications of the various items of the equipment being offered. The data supplied shall be complete and comprehensive, no item shall be omitted and statement like ‘To follow’ and ‘After Award’ shall be avoided. The Vendor shall clearly indicate in the table of compliance either deviation from, or acceptance of, each and every item of the specification. Failure to clearly identify specific deviations will lead to PDO assuming that the Vendor is in total compliance with the specification. No deviation from the specification shall be allowed. A manufacturing / production program shall be submitted with the tender showing, as a minimum, the drawing approval dates, order and delivery dates for bought out items, the manufacturer and assembly periods, system configuration times, inspection and test dates, packing and shipment dates, unpacking, installation and commissioning times.

1.3.2

Information to be submitted with Offer

The Vendor shall provide all drawings and documents as indicated in the RVED form (Appendix - N) including the following: a) Detailed Specification of Well head Control Panel with associated instruments, wiring, accumulator sizing, external tubing size(return line) and accessories including dimensions and weights Page 10 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

b) Estimated normal and maximum Electrical Power consumption c) Complete Table of Compliance (Refer Attachment A) with all the attached technical drawings/documents d) Typical panel internal layout drawings e) Manufacturing / Production Program f)

Project Implementation Plan including Vendor's proposed project team including the names of the key personnel involved.

g) Vendor Workloads h) A list of similar system installed and operating a gas processing facilities

1.3.3

i)

Any start up, shutdown or operating restriction required to protect the integrity of the system

j)

Maintenance requirements

Information to be submitted after award of Contract

The Vendor shall provide all drawings and documents as indicated in the RVED form (Appendix - N) and the following drawings within two weeks from the award of Contract:a) Manufacturing Drawings. b) Schematic and Logic Drawings. c) Control Logic Narratives. d) Weekly Progress Report (Update Schedule), In case of delay, the Vendor shall immediately inform PDO in writing.


2.

ABBREVIATIONS AVME

Approved Vendors of Materials and Equipment document

CITHP

Closed In Tubing Head Pressure

CV

Choke Valve

DSS

Duplex Stainless Steel

ESD

Emergency Shut Down

FF

Foundation Fieldbus

FTHP

Flowing Tubing Head Pressure( for wellhead)

HP

High Pressure

HIPPS

High Integrity Pressure Protection System

IPF

Instrumented Protective Function

MP

Medium Pressure

PDO

Petroleum Development Oman

PSD

Process Shut Down

RVED

Request for Vendor Engineering Documents

SC-SSSV

Surface Controlled Sub Surface Safety Valve

SSV

Surface Safety Valve

VHP

Very High Pressure

WHCP

Wellhead Control Panel

WHCS

Well Head Control System

WT

Wall Thickness

WV

Wing Valve


3.

CODES, STANDARDS ABD REFERENCE DOCUMENTS The latest versions of the following standards shall be applicable for the specified equipment. It is assumed that the standards listed below are in the Vendor’s possession. If not, then the Vendor is requested to obtain the same from the Purchaser’s Procurement Office.

3.1

PDO Standards

3.1.1

Engineering Specifications (SP & SPE)

•

SP-1084 (Dec. 2006)

:Standard Specification for Fire, Gas and Smoke detection systems

•

SP-1089 (Jan-2001)

:Instrument Impulse lines

•

SP-1090 (Dec. 2005)

:Instrument Signal Lines

•

SP-1099 (Dec. 2006)

:Electrical Installation Practice

•

SP-1171 (Dec. 2007)

:Spec. for Quality assurance of Design, Const. & Engineering works

•

SP-1189 (Dec. 2000)

:Specification for Duplex Stainless Steel Pipe

•

SP-1245 (Nov. 2006)

:Standard

Specification

for

Fieldbus

Control System •

SPE 77/302

:Valves general requirements

•

SPE 77/312

:Fugitive

emission

leak

detection

of

valves

3.1.2

Guidelines (GU)

•

GU-556 (Feb 2007)

:

Project

Engineering

Guideline

for

Vendor Project Document Deliverables


3.1.3

Design Engineering Practice (DEP)

•

DEP 00.00.20.10 (Feb -2011) :The Use of SI Quantities and Units

•

DEP 02.00.00.10 (Oct. 1995) :Preparation and microfilming of technical drawings.

•

DEP 31.40.70.30 (Feb-2011): Quarter Turn Actuators for On/Off Valves

•

DEP 32.31.00.32 (Feb-2011)

•

DEP 32.31.09.31 (Sep-2011) :Instrumentation for Equipment Packages

•

DEP 32.31.00.34 (Sep-2011) :Instrumentation

:Instruments for Measurements & Control.

Documents

and

Drawings •

DEP 31.22.10.35 (Aug. 2005) :Manufacturing

report

for

pressure

vessels. •

DEP 32.36.01.17 (Feb-2011):Control Valves – Selection, Sizing & Specifications

•

DEP 33.66.05.31 (Feb-2012) :Electric machines.

•

DEP 62.10.08.11 (Feb-2011) :Inspection

&

Functional

Testing

of

Instruments •

DEP 70.10.90.11 (Feb-2012)

:Spare Parts

3.2

International Standards:

3.2.1

ANSI (American National Standards Institute)

3.2.2

•

ANSI B1.20.1

: Specification for taper pipe threads.

•

ANSI/ISA S.75.01

: Flow Equations for Sizing Control Valves

•

ANSI B 16.34

: Valves-Flanged , Threaded and Welded end

•

ANSI / FCI 70-2

: Control Valve Seat Leakage

API (American Petroleum Institute)

•

API RP 551

: Process measurement instrumentation

•

API 607

: Fire test of Soft Seated Quarter turn Valves


•

API 6FA

: Specification for Fire Test for Valves

•

API 6D

: Specification for Pipeline Valves

•

ANSI/API RP 14B

:Recommended Practice for Design, Installation and Operation of Sub-surface Safety Valves Systems

•

API 598

: Valve Inspection and Testing

•

API 6A

:Specification for Well head & Christmas Tree Equipment

3.2.3

ASME (American Society of Mechanical Engineers)

•

ASME Section IX

:B

&

PV

Code

Welding

and

Brazing

Qualifications. •

ASME Section VIII Div.1/2: B & PV Code Section VIII including A98, A99 and A00, Rules for Construction of Pressure Vessels.

3.2.4

•

ASME B16.5

: Pipe flanges and flanged fittings

•

ASME B16.34

: Steel valves flanged and butt welding ends

ISA (Instrument Society of America)

•

3.2.5

ISA S75.01

: Flow Equations for Sizing Control Valves

IEC (International Electro-technical Commission)

•

DIN EN 60654-1

:Industrial-process equipment –

measurement

and

control

Operating conditions – Part 1:

Climatic conditions. •

DIN EN 60529

:Degrees of protection provided by enclosures (IP Code).

•

DIN EN 60079-14

:Electrical

apparatus

for

explosive

gas

atmosphere –Part 14:Electrical installations in


hazardous area. •

IEC 60534-4

:Industrial Process control valves- Inspection & Routine Testing

•

IEC 61508

:Functional

Safety

Programmable

of

Electrical/

Electronic

Electronics/

Safety

–

Related

Systems •

IEC 61511

:Functional

Safety

–

Safety

Instrumented

Systems –For the Process Industry Sector

3.2.6

European Codes (CENELEC) for Electrical Eqpt. in hazardous area

•

CENELEC EN 50.014

:General Requirements – Electrical Apparatus for Potentially Explosive Atmosphere

•

BS EN 50.018

:Electrical Apparatus for Potentially Explosive Atmospheres – Flameproof Enclosure “D”

•

BS EN 50020

:Electrical Apparatus for Potentially Explosive Atmosphere–IS

•

BS EN 10204

:Metallic

Products

–

Types

of

Inspection

Documents. •

CENELEC EN 50081

:Electromagnetic Compatibility Generic Emission Standard Part 2 (Emission regulations applies to position sensors and solenoid valves).

•

CENELEC EN 50082

:Electromagnetic Compatibility Generic Emission Standard Part 2 (Immunity regulations applies to position sensors and solenoid valves)

•

CENELEC EN 60.801

:Electromagnetic

Compatibility

for

process

measurement & control Equipment Electrostatic Discharge Requirements-(Immunity test applies to position sensors and sol. valves).


3.2.7

Other international standards

•

ISO 1219

: Fluid Power Systems and Components-Graphic Symbols and Circuit Diagrams

•

ISO 10432

:Petroleum and natural gas industries – Down hole

equipment-Subsurface

safety

valve

equipment •

BS PD 5500

: Rules for the Construction of Pressure Vessels

•

ISO 15156

:Metals for sulphide stress cracking and stress corrosion cracking resistance in sour oil field environments

•

ASTM A269

:Standard Specification for Seamless and welded Austenitic Stainless Steel Tubing for General Service

•

EN 61000-4-5

: EMC Testing and Measurement Techniques. (electrical

surges

due

to

lightning

and/or

switching The Vendor shall have a QA/QC system, based on ISO 9001, controlling the quality of their design and manufacturing during all stages of the production process and be able to demonstrate its implementation to the Purchase. Should any conflict occur as a result of complying with referenced standard and this specification, the order of preference shall be as follows: 1.

Local laws, Decrees & statutory requirements

2.

P.D.O. management policies

3.

This specification

4.

Codes of Practice (CP)

5.

Procedures (PRs)

6.

Engineering Specifications (SP)

7.

Guidelines (GU)

8.

Design & Engineering Practice (DEP - Version as applicable in a project)

9.

National Standards

10. International Standards.


3.3

EMC (Electromagnetic Compatibility)

For Electromagnetic Immunity of the equipment following standard is applicable: CENLEC EN 50081 (1993 Jan 01):Electromagnetic Compatibility Generic Immunity Standard part 2, Industrial Environment. CENLEC EN 50082 (1995 Jan 01):Electromagnetic Compatibility Generic Immunity Standard part 2, Industrial Environment Equipment shall comply with surge test according to EN 61000-4-5 (1995 March 01) – EMC Testing and Measurement Techniques (Electrical surges due to lightning and/or switching). Pulse shape is 1.2/50 µS (8/20 µS current). Where a relevant dedicated product or product family EMC standard exists, it shall take precedence over all aspects of above generic standards. Manufacturer shall indicate the difference with above-mentioned standard.

3.4

General

3.4.1

Language and Units of Measurement

All documentation, drawings, correspondence, operating, maintenance and installation manuals shall be in English. English Language shall be used for tags, labels etc. which shall be available to the operators. All measurement units shall be in accordance with DEP 00.00.20.10, The Use of SI Quantities and units and DEP 32.31.00.32, Instruments for Measurement and Control.


4.

OPERATING CONDITIONS / AREA OF INSTALLATION All the WHCP’s and the accessories shall be suitable for outdoor installation in the desert at a remote wellhead area. The local environmental conditions are severe. There are frequent sand storms and the atmosphere can be heavily laden with airborne dust particles, some as small as 2 micrometers. It rains infrequently but, when it does, it is often combined with hail and sand storms.

4.1

Relevant Ambient Data

4.1.1

Ambient Temperature

The conditions are severe; the climate is mainly hot and humid. Summer runs from April to October with June and July being the hottest period. Maximum/Minimum shade temperature

: 60 °C

Black bulb temperature maximum

: 82 °C

Electrical equipment and systems shall be designed in accordance with the relevant PDO and project standards. Maximum/Minimum ground temperature Min)

4.1.2

4.1.3

: 30 °C (Summer Max)/ 22 °C (Winter

Relative Humidity and Barometric Pressure

Maximum/Minimum relative humidity

: 98%

Average barometric pressure

: 97.7 to 98.9 kPa (a)

Wind speed

Maximum wind speed (1 hour duration)

: 26 m/s

Maximum gust (3 second duration)

: 39 m/s

Wind speeds are at a height of 10 metres above ground level. The prevailing wind direction is southeast, south and southwest.


4.1.4

Rainfall

Rainfall is infrequent but may be heavy though brief and is often combined with hail and sandstorms.

4.1.5

Rainfall design

: 25 mm/h

Average annual

: Negligible

Earthquakes

No allowance is to be made for earthquakes.

4.1.6

Geographical Data

Location

4.1.7

: To be announced, Oman

Sandstorms

Sandstorms are frequent and severe and can continue for days with the atmosphere heavily laden with dust particles. Fine dust in these sandstorms can be as small as 2 microns.

4.1.8

Design Life

All equipment and facilities shall be designed for a minimum operational life of 25 years.


5.

WELL HEAD CONTROL PANEL (WHCP)

5.1

General The Well Head Control Panel is required to control manually and automatically both the closing & opening sequence of operation and the individual operation of SC-SSSV, SSV, WV & CV and HIPPS valve installed in HPG wellhead. These valves are designed to shut the production and isolate the production facilities from the wells in response to different shutdown requirements. In addition to the above, WHCP shall charge hydraulic power to 4 nos. Fusible plugs The following functions shall be considered as minimum design requirement of Integrated Well Head Control Panel & Safeguarding System:-

Item

Functions

Flow line pressure high high (1 out of 2)

Fire detection ESD by Fusible plugs (4 nos.) on field

Remote CPSD

Remote open well head valves Remote open WV / CV Remote close WV / CV Manual ESD pushbutton on WHCP (Push for ESD & Pull for reset) Manual push button on WHCP for open close SCSSV

1. Close HIPPS valve (immediate) 2. Close CV and WV (immediate simultaneous) 3. Close SSV (delay 2 sec.) 4. Signals to RTU from HIPPS 1. Close CV and WV (immediate simultaneous) 2. Close SSV (delay 2 sec.) 3. Close SC-SSV (delay 9 sec.) 1. Close CV and WV (immediate simultaneous) 2. Close SSV (delay 2 sec.) 1. Open SSV 2. Open CV and WV simultaneously Open WV and CV simultaneously Close WV and CV (immediate simultaneous) 1. Close CV and WV (immediate & simultaneous) 2. Close SSV (delay 2 sec.) 3. Close SC-SSV (delay 9 sec.) Open / Close SC-SSV, SSV , WV and CV per the closing and opening sequence

&

&

&

&

as


Manual push button on WHCP for SSV Manual push button on WHCP for WV Manual push button on WHCP for HIPPS Manual push button on WHCP for fusible plug to charge Hydraulic reservoir level low WHCP common alarm Selector switch on WHCP Indicating lamp on WHCP Selector switch on WHCP Selector switch on WHCP Selector switch on WHCP Indicating lamp on WHCP Indicating lamp on WHCP Remote start / stop Pump-1 in WHCP Remote start / stop Pump-2 in WHCP Pump-1 running / close status Pump-2 running / close status Panel mounted Pressure Gauges Local Pressure Gauges

Open / Close SSV, WV and CV as per the closing and opening sequence Open / Close WV and CV simultaneously Open / Close HIPPS, SSV, WV and CV as per the closing and opening sequence For charging fusible plug loop

1. Trip 2 pumps 2. Signal to RTU Signal to RTU Pump Duty selection (Pump-1 or Pump-2) Pump selection indication Pump-1 Start/Stop/Auto Pump-2 Start/Stop/Auto Bypass Choke valve switch Pump-1 running / close status Pump-2 running / close status Signal from RTU Signal from RTU Signal to RTU Signal to RTU To monitor hydraulic control circuits pressure To monitor hydraulic control circuits pressure

Notes 1. The maximum pressure and tubing size for SC-SSV, SSV, WV, CV and HIPPS are attached at Appendix - A 2. HIPPS valve shall be closed first and opened last 3. WV & CV shall be closed / opened simultaneously 4. HIPPS panel shall be hydraulically interlocked with local CV panel to close CV after HIPPS trip or manual close 5. HIPPS panel shall be hydraulically interlocked with WHCP panel to initiate WHCP CPSD after HIPPS trip or manual close 6. Delay means time counted from signal given


The WHCP shall be installed in an open safe area. However all instruments shall be explosion proof type (EExd) and Junction box shall be EExe type (suitable for Zone 2, Gr IIB, T4). The Junction box enclosing motor soft starter, relays shall be EExd type. The UL certified components are acceptable if the components are same as that certified to the equivalent CENELEC / ATEX. The minimum design of WHCP shall include 2 nos. motor driven hydraulic pumps (1W + 1S), & a manual pump, accumulators, common hydraulic control logic, hydraulic headers, internal wiring up to electrical terminal strips, internal tubing, tank and bulkheads with isolation valves for external connections etc.. Panel design shall have all necessary devices and equipments to cater for operation of SC-SSV, SSV, WV, HIPPS valve, CV and Fusible plug loop. The schematic diagram for the Hydraulic circuit for the WHCP is attached as Appendix - C (for API 10,000) and Appendix - D (for ASME 2500#). The ingress protection for enclosures shall be IP65 minimum for electronics and IP 55 minimum for terminal boxes. The 24 VDC motor driven hydraulic pump power consumption shall be maximum 550 W The solenoid valve shall be of low power, hydraulically latched & fail to close on loss of power. The components shall withstand shaded temperature of 70 degrees Celsius. 2 nos. drain valves shall be installed in the supply compartment and return compartment of the tank for sampling purpose. The level gauge and level transmitters shall be mounted outside the reservoir tank. The Electrical Push button shall be mushroom type. The WHCP’s basic design shall be fail-safe. Pilot valves and solenoid valves shall be energized during normal operating conditions and de-energized during shutdown conditions. 3 nos. 3/8” and 1 no. ½” bulk head plates shall be supplied as spares Rubber shall be provided as insulation between SS and CS components.

5.2

Material of Construction and Fabrication The WHCP shall be heavy duty construction having environmental protection classification IP55 as a minimum and both the enclosure and internal components shall be suitable for long term service in a desert atmosphere. The ingress protection for enclosures shall be IP65 minimum for electronics and IP 55 minimum for terminal boxes.


The WHCP shall be stand alone structure manufactured from 316 L stainless steel sheet of minimum 3 mm. thickness, with internal stiffening and support structures as required. Access to the internals (accumulators, pumps, motors etc.) shall be via a single rear lockable door on lift-off hinges. Stainless Steel shall be used for all valves, fittings, tubing, accumulators, pipe and pipe fittings, panel, reservoir fabrication, internal components etc. All panel tube work shall be 316 L stainless steel, rated according to each system pressure. All hydraulic connections for SC-SSV in Khulud area shall be with very high pressure (> 20,000 psi) and shall be executed with PDO approved make All hydraulic connections for SC-SSV in other area shall be with high pressure (> 15,000 psi) and shall be executed with PDO approved make All hydraulic connections for SC-SSV, SSV, WV, HIPPS valve and CV circuits shall be for high pressure fittings and tubing and shall be executed with PDO approved make All hydraulic connections for SC-SSSV, SSV, WV, HIPPS valve and CV shall be suitable for the pressure indicated above and shall be with AISI 316 L and compression fittings of imperial type. The WHCP dimension shall be minimum 1500 mm. (W) x 1800 mm. (H) x 800 mm. (D). The panels shall be self-supported and suitable for raising by means of lifting eyes. The panel face shall be fastened to the back framing from the rear. High integrity "C" channel foundation shall be provided. High integrity “C” channel cabinet panel base shall be provided All materials used in fabrication of the WHCP shall be new and of the highest quality. Only qualified and experienced tradesman shall be employed in fabrication of the panels in order to achieve the highest standard of workmanship.. Vendor shall ensure that maintenance access to all the instruments, valves, regulators, relief valves, fittings, tubes, accumulators’ pumps, motors etc is properly given without obstruction of other equipments or instruments. All components inside the WHCP shall be freely accessible from rear for maintenance purpose without disturbing any other component or equipment. The panel shall be of rigid construction with lifting lugs and shall have adequate internal stiffening to prevent buckling during shipment or lifting operations at site. Stainless steel plate materials used shall be free from surface defects such as scoring and tool or clamp marks. All sharp edges and burrs must be removed. A polished finish is required on all exterior panel surfaces. Bolting through panel face is not allowed and no evidence of component supporting studs shall be visible on panel face. Page 24 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

Flame cutting tools shall not be used to cut any holes for the mounting of instruments. Door seals and any sealing between panel sections when finally assembled as a single panel unit must be adequate to maintain an IP55 environmental protection rating. The layout of internal panel, tubing and cables shall be neat and must be designed to give maximum ease of access for dismantling trouble shooting and maintenance operations at site. Instruments shall be located such that normal adjustments may be made by hand or with standard tools without removal of any panel-mounted hardware. Panel shall be provided complete with all internal tubing and wiring requiring only connection to the external tubing and wiring circuits. All tubing runs within the panel shall be either horizontal or vertical plane, carefully grouped for accessibility and ease in tracing lines and clamped for rigidity. Hydraulic lines shall be fixed by adequate soft seated clamps. All bending shall be made by standard bending tools of correct size and minimum allowed bending radii shall be observed. Bright, annealed seamless 316, stainless steel tubing to ASTM A 269 shall be used for all tubing connections. All hydraulic and electrical components shall withstand the environmental conditions as specified in Clause 4. If required Purchaser will ask the WHCP supplier to furnish supporting documents \ compliance documents in this regard. Junction boxes shall be provided for interfaces with external cabling (from field), segregated according to service and signal type, connected to each internal device by a signal pair cable. Junction box shall be mounted inside the WHCP. Junction box shall be suitable for a Zone 1 hazardous area and protected to IP55. Proper draining mechanism for the panel shall be provided in case of leaks inside the panel. The panel shall be provided with sufficient louvers and of sufficient sizes for ventilation keeping in mind the extreme desert conditions as per Clause 4 Panel door hinges and the door open stoppers shall be strong enough to withstand high wind velocity of the region. Panel shall be provided with minimum 3 hinges and two door stoppers per door. Pumps shall be located at a minimum of 250 mm height from the panel bottom to avoid contact with liquid( due to leakage from the fittings). Bolting through the panel face is not allowed and no evidence of component supporting studs shall be visible on panel face. Electric cables and hydraulic tubing entries shall be from the side of the cabinet. To avoid cables damage the cable entries shall be located at higher level than of hydraulic


tubing. The exact number of cable entries, sizes and which side shall be approved by the Company. Each cabinet shall be fitted with an AISI 316 nameplate mounted on the front of the panel indicating the following information. •

Manufacturer.

•

A unique Serial Number.

•

Purchase Order Number.

•

Equipment Number

•

Min. & Max Supply Pressure

•

Well Number

•

Date of Manufacture.

Inside the WHCP, a laminated Overall Schematic drawing with Cause & Effect drawing and Bill of Material identifying make and model no of all items shall be placed. All documentation referring to the equipment shall identify the manufacturer’s serial number and Principal’s requisition number. Tag plates shall be fixed as follows, as per Drg. No. S37.601.D. Panel Designation

Type – A.

Equipment Number Type – B. Identification of components inside panel Type – C. Identification of gauges and controls in front of panel Type – D1.

5.3

Hydraulic System

The Well Head Control Panel is required to control manually and automatically both the closing & opening sequence of operation and the individual operation of SC-SSSV, SSV, WV & CV and HIPPS Valve installed in HPG wellhead. These valves are designed to shut the production and isolate the production facilities from the wells in response to different shutdown requirements. In addition to the above, WHCP shall charge hydraulic power to 4 nos. Fusible plugs The maximum pressure and tubing size for SC-SSV, SSV, WV, CV and HIPPS valve are attached at Appendix - A


5.3.1

Hydraulic Power Circuits

The system shall be engineered by incorporating two redundant hydraulic system circuits for hydraulic power for the following: 1. VHP (for SC-SSV), 2. HP1 (for SSV & WV), 3. HP2 (for HIPPS & CV) 4. MP (for Fusible plugs) 5. Common hydraulic circuit The above hydraulic circuits shall be designed as per the hydraulic power section design given at Appendix - B. It is vendor’s responsibility to cross check the adequacy of given values based on the given CITHP value & required strokes of the valves without pump running. Vendor shall submit the calculations for review. Vendor shall guarantee enough swept volume and no pressure drop during operation of any of the above valves either individual or in combination. Vendor shall submit with the technical bid documents volume and pressure calculations to verify the compliance of this requirement. The hydraulic oil shall be supplied from the supply compartment of a common supply tank. All hydraulic return headers common or individual shall return to the return compartment of the supply tank (Degassing section). Tubing shall be AISI 316 L, and fittings shall be AISI 316, imperial type Hydraulic system tubing shall be sized and selected by vendor in order to minimize pressure and power losses and to meet with PDO external tubing rating and sizes as given below.

5.3.1.1 VHP (SC- SSV hydraulic circuit)

WHCP shall have SC–SSV hydraulic circuit with all the necessary devices required to operate SC-SSV. The SC– SSV operating circuit shall be designed for: • Very High pressure as per the design criteria mentioned at table in Appendix B • All necessary fittings / tubing, pressure gauges, regulators. • All components of SC-SSV circuit shall be rated for a minimum of 15000# rating.

The maximum pressure and tubing size for SC-SSV are attached at Appendix - A Page 27 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

All hydraulic connections for SC-SSV in Khulud area shall be with very high pressure (20,000 psi) All hydraulic connections for SC-SSV in other pressure (15,000 psi)

area shall be with

high

The Vendor shall submit a simplified schematic and control logic narrative, which includes sufficient information for PDO to evaluate the Vendor’s proposal for very high pressure SC-SSV hydraulic circuit. For SC-SSV, vendor shall provide a system to open and close the valve from the panel. For sizing purpose, the following average distance shall be considered: From WHCP to SC-SSV = 150 m. Note: The above distance will be firmed up after layout finalization. The hydraulic bulkhead fittings and internal tubing of the WHCP should be the type and rating as the PDO external tubing and rating used outside the WHCP, as listed below: SC-SSV supply line (Khulud area) Pressure)

: 3/8” OD x 0.086” WT, 20,000 PSI (Very High

SC-SSV supply line (Other area) : 3/8” OD x 0.086” WT, Pressure)

15,000 PSI (Very High

However, Vendor shall reconfirm the above tubing OD and ratings based on his system design and calculations and if required may suggest suitable changes.

5.3.1.2 HP1 (SSV & WV hydraulic circuits)

WHCP shall have SSV & WV hydraulic circuits with all the necessary devices required to operate SSV & WV. The SSV & WV operating circuits shall be designed for:•

High pressure as per the design criteria mentioned at table in Appendix-B

•

All necessary fittings/tubing, pressure gauges, regulators.

The maximum pressure and tubing size for SSV & WV are attached at Appendix - A The Vendor shall submit a simplified schematic and control logic narrative, which includes sufficient information for PDO to evaluate the Vendor’s proposal for high pressure SSV hydraulic circuit. For sizing purpose the following average distance shall be considered: From WHCP to SSV

= 100 m.

From WHCP to WV

= 100 m.

Note: The above distance will be firmed up after layout finalization. Page 28 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

The hydraulic bulkhead fittings and internal tubing of the WHCP should be the type and rating as the PDO external tubing and rating used outside the WHCP, as listed below: SSV supply line SSV return line

: 1/2” OD x 0.083” Wall Thickness, 10,000 PSI Medium Pressure : 3/4" OD x 0.049” Wall Thickness

WV supply line WV return line

: 1/2” OD x 0.083” Wall Thickness, 10,000 PSI Medium Pressure : 3/4" OD x 0.049” Wall Thickness

However, Vendor shall reconfirm the above tubing OD and ratings based on his system design and calculations and if required may suggest suitable changes.

5.3.1.3 HP2 (HIPPS Valve & CV)

WHCP shall have hydraulic circuit with all the necessary devices required to supply hydraulic power to HIPPS Valve & CV. •

High pressure as per the design criteria mentioned at table in Appendix -B

•

All necessary fittings/tubing, pressure gauges, regulators.

The max. pressure and tubing size for HIPPS Valve & CV are attached at Appendix - A For sizing purpose the following average distance shall be considered: From WHCP to CV

= 80 m.

From WHCP to HIPPS Valve

= 60 m.

Note: The above distance will be firmed up after layout finalization. The Hydraulic Bulkhead fittings and internal tubing of the WHCP should be the type and rating as the PDO external tubing and rating used outside the WHCP, as listed below: Choke supply line : 3/8" OD x 0.065” Wall Thickness, 10,000 PSI Medium Press Choke return line : 3/4" OD x 0.049” Wall Thickness HIPPS valve supply line : 3/8” OD x 0.065” Wall Thickness, 10,000 PSI Medium Press HIPPS valve return line : 3/4" OD x 0.049” Wall Thickness However, Vendor shall reconfirm the above tubing OD and ratings based on his system design and calculations and if required may suggest suitable changes.


5.3.1.4 MP (Fusible plugs hydraulic circuit)

WHCP shall have hydraulic circuit with all the necessary devices required to supply hydraulic pressure to 4 nos. Fusible plugs For sizing purpose the following average distance shall be considered: From WHCP to Fusible plugs

= 200 m.

Note: The above distance will be firmed up after layout finalization. The Hydraulic Bulkhead fittings and internal tubing of the WHCP should be the type and rating as the PDO external tubing and rating used outside the WHCP, as listed below: Fusible Plug supply line : 3/8" OD x 0.065 Wall Thickness, However, Vendor shall reconfirm the above tubing OD and ratings based on his system design and calculations and if required may suggest suitable changes.

5.3.2

Common hydraulic circuit

The hydraulic system shall be engineered for two redundant hydraulic circuits with 2 electric motor (24 VDC, 550 W max.) operated hydraulic pumps (1W + 1S) to supply hydraulic power to VHP (SC-SSV), HP1 (SSV & WV), HP2 (HIPPS valve & CV) & MP (Fusible plugs) as per Appendix - B (Design conditions / Criteria) Under normal operation one pump shall operate. However if one pump fails to generate enough pressure within 10 seconds, the second pump shall start automatically. Both pumps shall have sufficient capacity to charge all accumulators from the empty to the full condition within 30 minutes. A back-up manual hand pump shall be provided and sufficiently rated to allow charging of the headers in the event of the loss of electric supply to the motors. The hand pump shall be provided with block valves, check valve, safety relief valve, output pressure gauge and individual header isolations valves. Hydraulic Low Level protection shall be provided to protect the Hydraulic pumps. The system shall not allow the running of the pumps when the oil in the tank is less than the minimum acceptable level.

The common supply tank shall be fitted with the following equipment: •

Volume tank with internal baffle (Volume - 250 liters. Vendor to size and confirm the adequacy of volume).

•

Level Gauge. Page 30 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

•

Drain Valve.

•

Internal Baffle.

•

Smart type Pressure Transmitters

•

Level transmitter (Smart type with HART Protocol in SR, SRS, SR Grab &

Mabrouk and Foundation Fieldbus type in other area) with a Trip

amplifier shall be provided to trip the hydraulic pump on low hydraulic level in the reservoir and also wired to Junction Box for remote indication purpose. Magnetic type level transmitter is preferred. •

Removable Bolted Inspection Cover.

•

Breather/Accessibly Filler Nozzle/Cap.

•

Hydroscopic breather.

•

Magnetic Catcher.

•

Individual Pump suction strainer.

•

Temperature Gauge (with Thermo well).

Hydraulic fluid shall be taken from the non return side of the internal baffle in the supply tank to each of the pump suctions via block valves through suction strainers with 20 micron filter element. Filter element shall be of spin on removable type. Strainers shall be provided with block valves and by-pass valve so that they may be isolated and replaced for maintenance purpose with the system on line. Each pump discharge shall be provided with a safety relief valve, check valve, a block valve and an output pressure gauge. Each of the pump discharge headers shall be connected to a common duty standby configuration filters, fitted with two 100% rated hydraulic bucket type filters with 3 micron exchangeable filter element and complete with block valves, local clogging indicators and drain plug. Full flow pressure filters with minimum element dimensions of 30 mm. diameters and 90 mm. length shall be provided. The clean element pressure drop across the filter shall not exceed 500 kPa (g) at specified viscosity, temperature range and throughput of hydraulic fluid. The filters shall be fitted with a by-pass valve so that they may be isolated for maintenance purposes with the system on line. The common header shall be fitted with pressure switch with block and bleed manifold for pump control purposes (cut-in & cut-out), and a panel mounted pressure gauge. Vendors shall utilize integrated manifold block for the pump discharge and high pressure sections to minimize the use of tubing / fittings, reduce leakage and optimize the layout within the panel.


The discharge header shall be provided with a safety relief valve. The main pump / hand pump should be provided with block valves so that they may be isolated and replaced for maintenance purpose with the system on line. Separate valve shall be provided downstream of discharge filter allowing for hydraulic fluid sampling. The main supply header shall be fitted with Pressure Transmitter (Smart type with HART Protocol in SR, SRS, SR Grab & Mabrouk and Foundation Fieldbus type in other area) and Trip amplifier for pump control purposes and panel mounted Pressure Gauges. The pump / motor circuit shall be supplied with local on / off / auto motor control circuits / starters and local push buttons and lamp indicators on WHCP front face. Also provision shall be made for remote pump running indication. Regulators on the hydraulic circuits shall be of bleed back type. Regulators shall be with AISI 316 construction, self relieving, designed for hydraulic applications and vent connection routed to reservoir. Regulator seals shall be suitable for the design temperature specified. Downstream fluid can be vented through a segregated vent system for easy pressure adjustment in either direction.

The required closing and opening times of the process valves shall be guaranteed by the panel manufacturer, based on the following: •

Volume and working pressure of actuator.

•

Diameter of hydraulic lines.

•

Length of hydraulic lines.

•

Viscosity of hydraulic fluid.

•

Volume and pre-charge of hydraulic accumulator.

•

Any resistance in pilots, filters and any other hydraulic component in the panel.

Each hydraulic pressure system shall be equipped with bladder type / piston type accumulators. All accumulators shall be designed as per BS 5500. Each accumulator shall be provided with pressure gauge with proper isolation facility. A suitable arrangement (i.e. plug) shall also be provided on these accumulators by the Vendor, so that these Pressure Gauges can be removed at later stage if required. Accumulators shall have sufficient capacity for emergency operation of all valves, which means three full cycles, (a cycle is defined as one stroke) i.e., one closing cycle, one opening cycle and another closing cycle. The required capacity shall be determined by the change in volume of fluid contained in the accumulator between the main pump start position (with the pump switched off) and the minimum system pressure to finish the last cycle of all valves properly. The Vendor shall furnish the accumulator sizing calculation along with the tender. Page 32 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

Accumulators shall be placed in a separate compartment within the WHCP, suitable door shall be provided to access these accumulators from outside. To avoid accumulation of spilled oil inside the WHCP during routine maintenance etc. the bottom plate of the WHCP shall be either: •

Sloped to one side of WHCP with a drain opening at the lowest end.

•

Be such that the lowest point is in the middle of the floor plate and provided with a drain opening.

The drain openings shall be provided with drain valve.

5.3.3

Hydraulic Circuit Components

a)

All components used for hydraulic circuits including `O' rings shall be suitable for outside/desert applications.

b) All valve bodies including manual valves, pilot valves and solenoid valves shall be manufactured in AISI 316 stainless steel. c) All pressure gauges shall be 63mm size, AISI 316 stainless steel construction, and glycerin filled. d) All gauges and switches shall be provided with block and bleed valves, or quick opening devices (with check valves), to allow for removal and maintenance during operation without the need of removing other devices or tubing. The Hydraulic Bulkhead fittings and internal tubing of the WHCP should be the type and rating as the PDO external tubing and rating used outside the WHCP, as listed below: Common return : 3/4" OD x 0.049” Wall Thickness However, vendor shall reconfirm the above tubing OD and ratings based on his system design and calculations and if required may suggest suitable changes. Hydraulic connections shall use bulkhead unions or bulkhead connectors mounted on the side of the panel. All tubing shall be neatly laid out and adequately supported by tubing saddles to prevent kicking, facilitate trouble shooting and present a neat appearance. The internal arrangement of the panel shall be such to minimize the length of tubing runs. Vendor shall look into the possibility of using a common return instead of individual lines to minimize the numbers of return lines, fittings /tubing etc. Vendor shall confirm that it will not have any adverse effect on the system design or operation. Each hydraulic pressure system shall be equipped with the following accumulators: VHP -

for SC-SSV, one piston type / bladder type accumulator.


HP1 -

for SSV and WV, one piston type / bladder type accumulator.

HP2 -

for IPF and CV, one piston type / bladder type accumulator.

LP

Hydraulic Logic with one bladder type accumulator.

-

Vendor shall confirm volume for each accumulator and also furnish the accumulator sizing calculations with the technical bid documents. A minimum accumulator shall be sized for 3 strokes of the SC-SSV (one stroke = opening and closing of the valve). Hydraulic low level protection shall be provided to protect the hydraulic pumps. The system shall not allow the running of the pumps when the oil in the tank is less than the minimum acceptable level. The Hydraulic Bulkhead fittings and internal tubing of the WHCP should be the type and rating as the PDO external tubing and rating used outside the WHCP, as listed below: •

Low pressure pilot inlet, outlet and drain : suitable for 3/8" OD X 0.049” WT

5.4

Electric Components

All Electrical devices to be installed within the panel shall be suitable for Zone1, IIB, T4 and EEXd certified to CENELEC / ATEX. The UL certified components are acceptable if the components are same as that certified to the equivalent CENELEC / ATEX All Transmitters shall be Smart type with HART Protocol in SR, SRS, SR Grab & Mabrouk and Foundation Fieldbus type in other area All Electric components shall be suitable for 24 V DC All internal wiring shall be provided with a cross-sectional area of at least 1 mm2 and for Solenoid valves with diameter of 2.5 mm2. Electrical connection shall be by means of cables and certified cable glands. Each cable shall be tagged at both ends with an appropriate marker. All internal cable numbers for the cables shall within WHCP and cables to & from WHCP Junction Boxes shall be tagged by the Vendor. Tagging shall be done at both ends. Cables shall be tagged with terminal block reference and terminal number so as to be easily terminated again when loosened. All Electrical devices installed in the panel shall be wired to their respective terminals. Separate terminals shall be provided for power and signals. All terminals shall be properly identified and 20% terminals as spare capacity in each terminal / Junction Box. Cable trays shall be used for cable supports.


An external ground terminal shall be provided, suitable for a 16 mm2 ground cable as per Std. Drg. S 68.004. Threaded, M20 size, plugged holes, shall be provided for the external electric connections. The number will be advised during Detailed Engineering. Electrical enclosure weather protection shall be at least IP 65. All electrical equipment shall be tropicalised. Each wire shall be tagged at both ends with an appropriate marker. Electrical connections shall be by means of cables and certified cable glands. Junction boxes shall be CENELEC EExe and cable glands shall be certified to CENELEC EExd. However Junction box housing soft starters, relays etc shall be EExd design and certified. Junction boxes shall be provided for interfaces with external cabling, segregated according to service and signal type, connected to each internal device by a single pair cable. Junction boxes shall be easily accessible and located not more than 1.5 meters in height. The Electric Components shall conform to the following: 1. Electrical enclosure weather protection shall be at least IP 65. 2. All electrical equipment shall be tropicalised. 3. All wiring shall be provided with a cross-sectional area of 1mm2, while for solenoid valves a cross-sectional area of 2.5mm2 wire shall be used. 4. Each wire shall be tagged at both ends with an appropriate marker. 5. Electrical connections shall be by means of cables and certified cable glands. Junction boxes and cable glands shall be certified to CENELEC EExe. 6. All electrical components installed in panels shall be wired to their respective terminal points. Separate terminals shall be provided for power and signals. Cable trays shall be use for cabling. Stuff block c/w EVA covered stainless steel "BAND-IT R" cable ties, shall be used to hold instrument tubing in place. 7. All terminals shall be permanently identified with 20% spare terminals provided in each terminal box. 8. An external ground terminal shall be provided, suitable for a 16 mm2 ground cable. 9. Vendor shall provide for each pump, individual power connection terminals suitable for 2C x 6.0 mm2 cable. Pumps shall not share a common power supply connection. 10. Threaded, M20 size, plugged holes, shall be provided for the external electric Connections. The number will be advised during detailed engineering. Page 35 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

11. Each pump/motor circuit shall be supplied with local/auto motor control circuits with soft starter, local push buttons and lamp indicators on the panel front face.

WHCP shall be provided with two 100% capacity 24V DC motor driven hydraulic fluids pumps. Under normal operation one pump shall operate. However if one pump fails to generate enough pressure, the second pump shall start automatically. Both pumps shall have sufficient capacity to charge all accumulators from the empty to the full condition within 120 seconds. The starting current of each motor shall be maximum 60A for 3 seconds. The running current of each motor shall be 35A. Each motor shall operate for continuous duration of 20 minutes per 24 hours. Both the motors shall not start simultaneously. Vendor shall crosscheck and confirm the adequacy of the above current ratings. Each pump/motor circuit shall be supplied with local / auto motor control circuits with soft starter, local push buttons and lamp indicators on the panel front face. In addition a Duty / Standby pump selector switch shall be provided. Vendor shall provide for each pump, individual power connection terminals suitable for 2 core x 6.0 mm2 cable. Pumps shall not share a common power supply connection. Vendor shall ensure that overload protection for the hydraulic pump motors are connected prior to start-up for new equipment

5.5

Well Controls and Shutdown Requirements

5.5.1

General

•

HIPPS valve shall be closed first and opened first

•

WV & CV shall be closed / opened simultaneously

•

HIPPS panel shall be hydraulically interlocked with local CV panel to close CV after HIPPS trip or manual close

•

HIPPS panel shall be hydraulically interlocked with WHCP panel to initiate WHCP CPSD after HIPPS trip or manual close

There are two types of production facility shutdowns activating wellhead valves / surface valves. Logic for this is performed in the WHCP: •

Emergency Shut Down (ESD) 1. Manual ESD 2. Fire detection by Fusible plugs Page 36 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

An ESD is initiated by an emergency pushbutton on the WHCP or in response to fire detection (by Fusible plugs). This requires the closure of all the actuated valves CV & WV, SSV and SC-SSSV. •

Remote Process Shut Down (PSD)

This will initiate closure of CV, WV and SSV by remote shut down signal.

5.5.2

ESD Section

5.5.2.1 Manual ESD

An ESD is initiated by manual operation of local ESD push button (push for ESD & pull to reset) at the WHCP. This push button on pushing (ESD) shall de-energize solenoid valve fitted on the hydraulic circuit to close CV,WV and SSV in the following sequence. This push button on pulling (reset) shall energize the solenoid valve and reset hydraulic interface valves to open the SSV, WV and CV in the following sequence. Activation of this local ESD reset switch shall not affect other circuit hydraulic pressure. An ESD shall cause the wellhead and surface valves to close as per sequence indicated below:Normal Closing Sequence CV and WV (simultaneous)

First

SSV (with 2 sec. delay)

Second

SC-SSV (with 9 sec. delay)

Third

An ESD re-set shall cause the wellhead and surface valves to open as per sequence indicated below:Normal Opening Sequence SC-SSV

First

SSV

Second

WV and CV (simultaneous)

Third

The panel shall operate with delayed opening and closing of Wing Valve, SSV in order to protect the SC-SSV. The vendor shall provide adjustable hydraulic delay mechanism within the SC-SSV circuit.


5.5.2.2 Fire detected ESD

Fire at wellhead shall be detected by 4 nos. Fusible plugs. A fire at the wellhead causes the eutectic material in the fusible plugs to melt and vent the supply line pressure and initiates a well head shutdown. These fusible plugs shall activate to de-energize solenoid valve fitted on the hydraulic circuits to close CV & WV, SSV and SC-SSSV. Fire detection shall cause the wellhead and surface valves to close as per the sequence indicated below. Normal Closing Sequence CV and WV (simultaneous)

First

SSV (with 2 sec. delay)

Second

SC-SSV (with 9 sec. delay)

Third

An ESD re-set shall cause the wellhead and surface valves to open as per sequence indicated below:Normal Opening Sequence SC-SSV

First

SSV

Second

WV and CV (simultaneous)

Third

The panel shall operate with delayed opening and closing of Wing Valve, SSV in order to protect the SC-SSV. The vendor shall provide adjustable hydraulic delay mechanism within the SC-SSV circuit.

As the local ESD push button will close in the event of a Fusible Loop shutdown, the. Fusible Plug Loop re-charged after fitting of replacement plugs and well head control system shall be reset locally. Vendor shall develop a logic that in case of Fusible Plug Shutdown the loop will remain isolated without dispersing oil of the circuit outside. A common logic shall be made in such a way that after local ESD or Fire ESD activation, SC-SSSV, SSV & WV shall open only after the local reset pushbutton is activated. The above ESD Shutdown header and the logic supply header shall be provided with a pressure gauge and a pressure switch.


5.5.3

Closure of actuated valves

5.5.3.1 HIPPS valve closure

1. Flow line High High pressure 2. Manual push button on WHCP

5.5.3.2 WV & CV (simultaneous) closure

1. Flow line High High pressure 2. Fire detection by fusible plugs 3. Manual ESD push button on WHCP 4. WHCP mounted push button for WV & CV close 5. Remote PSD 6. Remote close WV / CV 7. Local Close/Open HIPPS 8. Local Close/Open SSV 9. Local Close/Open SC-SSV 10. Remote Close Wellhead

5.5.3.3 SSV closure

1. 2. 3. 4. 5. 6.

Flow line High High pressure Fire detection by fusible plugs Manual ESD push button on WHCP Remote PSD Remote Close Wellhead Local Close/Open SSV 7. Local Close/Open SC-SSV

5.5.3.4 SC-SSV closure

1. Fire detection by fusible plugs 2. Manual ESD push button on WHCP 3. Local Close/Open SC-SSV.


5.5.4

Hydraulic Logic Control Circuit

5.5.4.1 SC-SSSV

The SC-SSSV is controlled with pushbuttons for open / close control. The logic for the SC-SSSV is derived from the ESD logic and so the SC-SSSV will be closed manually or by an ESD detected by the Fusible plugs. A flow control valve would be provided in the logic to enable the required closing sequence after an ESD. The actuator hydraulic supply pressure is indicated by a local pressure gauge. As solenoid valve fitted on the hydraulic circuit, de-energizes on ESD, this will require resetting after an ESD. The SC-SSSV is flapper type which will require manual pressure equalization across the SC-SSSV prior to being opened. (i.e. not self-equalizing). The Vendor shall provide a system to open the SC-SSSV from the panel.

The SC-SSV shall close on the conditions indicated in 5.5.3.4

5.5.4.2 SSV The SSV are controlled with pushbuttons for open / close. The SSV & WV shall be interlocked so that it can only be opened if the SC-SSSV is open. The actuator hydraulic supply pressure is indicated by a local pressure gauge. The SSV shall close on the conditions indicated in 5.5.3

The logic for the SSV is derived from the ESD logic and as solenoid valve fitted on the hydraulic circuit de-energies on any of the above conditions, this will require resetting after an ESD. The logic shall also include remote open / close operation of these SSV. Upon closing of SC-SSV, SSV & WV on Fire / ESD, an automatic opening or remote opening shall not be possible. The SSV shall be interlocked so that it can only be opened if the SC-SSV is open. The actuator hydraulic supply pressure is indicated by a local pressure gauge. The logic for the SSV is derived from the ESD logic header and, as the manual latching valve resets on loss of pressure, this will require resetting after an ESD. The manual pull & pin valve allows the opening of SSV without the flow line pressure. The initiation of low sense pressure from the flow line will cause the choke valve to start closing followed by the SSV. A solenoid valve shall be provided in the control logic for remote open and close of the SSV. Page 40 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

A solenoid valve will also be provided to close the SSV / WV based on the HIPPS valve signal. The manual valve will have to be reset locally following an IPF close signal. The SSV / WV and CV can also be initiated to close from a remote signal (CPSD) and also opened from remote with remote reset facility. The opening and closing of WV shall be done remotely, the dump valve shall be provided to speed up the closing time for the valve. Provision shall also be provided on the WHCP for local close and open operation for the wing valve. The SC-SSV shall close on the conditions indicated in 5.5.3.3


6.

ASSOCIATED INSTRUMENTS AND ACCESSORIES (to be supplied as loose Items)

6.1

Pilots Low pressure pilot switches shall be supplied as loose items to be installed on production lines of SR, SRS and SR Grab and shall have the following characteristics: 1. Direct acting pilot relay, piston type 2. AISI 316 stainless steel body 3. Wetted parts material Alloy-C 4. ½” NPT M process connections 5. NPT F hydraulic connections 6. IP 65 degree of weather mechanical protection 7. Process fluid: Hydrocarbon gas 8. One mechanical on-off switch set within the following ranges: Design Pressure 12,000 kPa(g) ( set at 3000 kPa(g) falling).

6.2

Extra high pressure switch Third pressure switch) to be installed in flow lines in Mabrouk area

6.3

Quick Dump Valve Local Panel with Wire line Connection 5-10 seconds, restriction orifice and isolation valves(2 Sets per panel)

1. Quick dump valve assembly shall be supplied as loose complete with all accessories as listed below. The quantity referred below is for 1 no set only. Refer to PDO drawing Appendix – F for further details. 2. ½” NPT(F) 316SS, Full Ball valve, make & model: Oliver BIOFX25S- Qty 2 nos 3. 1/2” 3166SS, Quick dump valve, Make & model : SIGMA 13-QS-40- Qty 1 nos 4. ½” OD TEE, 5. Other accessories as applicable

6.4

Fusible Plugs

Fusible plugs shall be supplied as loose items complete with "T" compression fittings for installation in a fusible plug circuit, having the following characteristics: Page 42 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

4 nos, Fusible Plug 3/8" NPT-M, Eutectic Material Melting Temperature: 120° C. Make & Model: SWAGELOK CAJON SS-6FTA-255DEG "T" Compression fittings 3/8" OD tube St. Steel suitable for MP.

6.5

SSV/ Wing Valve Limit Switch Assembly SSV limit switch / junction box assembly shall be supplied as loose items complete with accessories as listed below. (Refer Appendix G for typical type A & B arrangement). 1. Proximity Switch Make / Model No. P & F / NJ4-12-GK-6N, weather proof to IP-67 and EEx-ia-IIC-T6 conforming to NAMUR (DIN 19234). EEx PTB Ex-96 D2023X – 2 nos. per assembly. 2.

Junction Box – STAHL 8118/22 – 1 no. per assembly, each having 6 terminals and 3 cable entries. 2 entries for ½” connection of conduit fittings and 1 entry with M20 cable gland.

3. Proximeter conduit along with cable – 2 nos. per assembly each of 1.8 m. length with suitable end connectors.

6.6

First fill Mineral Oil Shell Tellus 32 (200 liters per panel)


7.

UTILITY REQUIREMENT

7.1

Electrical All electrical items shall operate on the following voltage. Power Supply shall be provided by PDO. However bidder shall provide the details of total power supply requirement during starting and running of the Hydraulic Pump Motors.

Electric motor

: 24 V DC, 550 W (max.)

Solenoid valves

: 24 V DC. (Low power, hydraulically latched & Fail to close)).

Pressure transmitters : 24 V DC. Level transmitter Trip Amplifiers

7.2

: :

24 V DC. 24 V DC. (Low power)

Hydraulic Mineral Oil

SHELL TELLUS 32 - 200 litres (approx.).


8.

HIPPS VALVE ASSEMBLY

8.1

Technical requirements Each HIPPS valve shall be designed and sized for over pressure protection of each wellhead flow line and fully equipped with the relevant line control module and include the following: •

Hydraulic spring return actuator shall be mounted on top of the valve. The power shall be provided from the well head control panel hydraulic unit.

•

Control unit equipped with internal wiring and tubing up to electrical terminal strips.

•

Proximity type Limit Switches for open and close position for each valve.

•

Hydraulic Mechanical Pressure Switches, 2 nos. for each valve inside the HIPPS panel. The pressure switches shall have facility to adjust the set point at field. Pressure switches are for protecting the process pipeline against High pressure.

•

Pressure Switches inside Local HIPPS Panel for remote indication of High Pressure trips.

•

Hydraulic Reset push button to reset valve after trip.

•

Quick dump valve as loose supply( Make and Model No: SIGMA 13-QS40)

•

Hydraulic shutdown signal interlock to Choke Valve

Note: 1. The reference schematic diagram for the HIPPS valve assembly is attached as Appendix - I. 2. Based on HIPPS classification there can be a requirement of additional HIPPS valve assembly. Hence, vendor to quote as optional additional HIPPS valve assembly as per clause 4.2 above. The price shall include the modification to be done in WHCP panel as well.


8.1.1

Material of Construction

Duplex Stainless Steel shall be used for the valve body installed on well head flow line as specified inside the relevant data sheet (Appendix - I). The hardness of material, Charpy Impact test, Corrosion test, Ferrite content shall be as per SP 1189 For all fittings, tubing, valves, panels and other hydraulic components stainless steel (AISI 316L) shall be used and shall be executed with PDO approved make for high pressure fittings and tubing’s. Junction boxes shall be provided for interface with external cabling segregated according to service and signal type, coupled to the actuator. All soft materials like O rings, to be Viton 90. NBR is not acceptable. The cylinder seal upgrade (Viton 90 o ring + backup ring) is to be applied. Actuator material for the case or housing shall be of carbon steel. The purchaser shall approve other metallic material. Aluminium shall not be used. Actuator spring shall be of a multi type enclosed in a metal housing and permanently treated to resist atmospheric corrosion. Actuator action shall be oil to open and spring to close.

8.1.2

Design Requirement

1. The HIPPS Valve Safety System shall be as a fully stand alone system. Each valve shall be equipped with a hydraulic actuator (multi spring type), limit switches, control module, pressure sensing instruments (mechanical switches). 2. For quantification of the risk reduction as per IEC 61508 and IEC 61511, the HIPPS valve and the actuator shall have certified / validated failure rate in accordance to IEC 61508 to meet the target SIL level for the application. In other words the combination of the HIPPS valve and the actuator should be certified by TUV for appropriate SIL level (SIL 3). 3. The failure rate should be validated for the HIPPS valve design, size, rating, the stroking time requirement and service conditions under consideration in accordance to prior to use clause in IEC 61511. The requirement for full closure of HIPPS valve is < 2seconds, hence the TUV certification should validate the failure rate for stroking speed of less than 2 seconds. Proof test time interval for the valve shall not be less than one year, Vendor to provide PFD calculation which indicate test interval of one year while maintaining SIL 3 level.


4. The HIPPS valve should be certified for the leakage class requirements of the Class V leakage IEC 60634-4 (Metal to metal seated). 5. Overall dimensions shall be kept to a minimum, compatible with easy accessibility for maintenance purpose. 6. Due to safety requirement, a bypass arrangement across HIPPS valve is not acceptable. 7. The control system shall be inside one AISI 316 stainless steel cabinet, suitable for the specified hazardous area classification. 8. Limit switches are mounted inside the actuator pedestal 9. Ingress protection shall be to IP65 as a minimum. 10. The hydraulic system shall be inside one AISI 316 stainless steel cabinet with mechanical protection of IP65 as minimum. 11. Bolting through cabinet faces is not allowed and no evidence of component supporting shall be visible on cabinet face. 12. Electric cable and hydraulic tubing entries shall be from the bottom of the cabinet/junction box. Each cabinet shall have one lockable front door with minimum of 3 nos. hinges and 2 nos. door stoppers ( to hold in open position).

8.1.3

Electric Components

1. The electrical enclosure shall have weather protection of at least IP65. 2. All electrical equipment shall be tropicalised. 3. Each wire shall be tagged at both ends with an appropriate marker. 4. The electrical connections shall be suitable for Zone 2 hazardous area. 5. All components installed in the panels shall be completely wired to their respective terminal points. Separate terminals shall be provided for power and signals. 6. All terminals shall be permanently identified, 20% spare terminals shall be provided in each terminal box. 7. An external ground terminal shall be provided, suitable for a 16 mm2 ground cable. 8. 2 nos. of threaded holes, M20 size, shall be provided for the external electric connections. 9. Limit switches shall be of the proximity type according with NAMUR (DIN 19234). 10. Limit switches shall be adjustable and autonomous to their function, one for the "fully open" position and one for the "fully closed" position. 11. Dedicated limit switches shall also be used to detect the movement of the mechanical pressure switch, when it reaches the set point. Page 47 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

12. All proximity switches shall be mechanically protected. The flying leads of the proximity shall be terminated in a junction box suitable for the specified hazardous area classification.

8.1.4

Hydraulic Power Section

The system shall receive hydraulic power supply from a single hydraulic circuit line powered from a well head control panel. The supply pressure shall be 200 bar maximum, 185 bar minimum. The supply pressure requirement to be re confirmed by HIPPS / HIPPS valve vendor. The circuit shall be provided with relief valve with properly designed set point for protecting the Choke valve and HIPPS valve. Vendor to provide the necessary calculations for approval. •

The tubing size of the hydraulic power supply shall be 3/8 "inch.

•

The preliminary distance between the Well Head Control Panel and the HIPPS Valve is 60 m.

•

Hydraulic system tubing shall be sized and selected by Vendor in order to minimize pressure and power losses. Material for tubing shall be AISI 316L according to ASTM A 269. Maximum working pressure for fittings shall be 500 bar (g) at 38°C. All hydraulic circuit s shall be tested at 1.5 times the working pressure.

•

8.1.5

All tubing shall be neatly laid out and adequately supported.


1. All components used for hydraulic /pneumatic circuits shall be suitable for outside/desert application. 2.

All valve bodies shall be AISI 316 except for the valve on mechanical switch that shall be manufacturer std. certified.

3. Hydraulic Low Level protection shall be provided for the Hydraulic system.

8.1.6

HIPPS Valve Controls


Each HIPPS Valve Control System shall consist of following:

8.1.7

•

Two number of mechanical Pressure Switches

•

Two number Pressure switches for remote indication and closure of SSV

•

One number of Control Module

•

Four numbers of Limit Switches

•

One number of control panel

•

One number mechanical reset push button.

HIPPS Valve ESD/TRIP Section

An HIPPS trip is initiated by a remote signal from the two pressure sensing points (voting 1oo2) installed on the flow line downstream the HIPPS Valve. On initiation of shutdown signal the valve shall close in a time period of 2 (two) seconds, including any response time in the sensing and controlling part of the system. In the event of a trip the HIPPS valve control module, installed on the valve, shall send a signal to the Well Head Control Panel by means of proximity switch. The control module shall also send an extra hydraulic pressure signal to initiate the closing of the CHOKE valve.

8.1.8

Mechanical Switches

Mechanical pressure switches shall have the following characteristics as minimum: •

Pressure sensing point.-Mechanical Type.

•

Body material: Stainless Steel.

•

Wetted parts: Inconel 600.

•

1/4 " NPT-M process connection.

•

IP 65 degree of weather protection.

•

Accuracy shall be +/- 1% of range.

•

Externally adjustable set point initially set at 130 bar g rising. (Hold to be confirmed during Engineering).

•

Certification for the appropriate SIL classification (SIL 3) including fault tree analysis for the required SIL3 PFD.


9.

CHOKE VALVE ASSEMBLY

9.1

Technical details Each Choke valve shall be designed and sized for controlling pressure and flow on each wellhead flow line and fully equipped with the relevant accessories as below: •

Hydraulic spring actuator mounted on top of the valve powered from a hydraulic line of the well head control panel hydraulic power unit.

•

Hydraulic Control Choke panel.

•

Solenoid Valves (3 no’s on each Local Choke Panel, one for opening, one for closing and one for choke valve shutdown). Solenoid valves for opening and closing shall be suitable for operating with variable width pulse commands from remote system.

•

PSV downstream of the SOV for protection of Choke vale actuator against overpressure during hydraulic supply blocked in condition and high ambient temperature.

•

Conventional (4-20 mA) or Foundation Field bus compatible Valve Position Transmitter as per the attached Choke Valve data sheet.

•

Hydraulic shutdown signal interlock from HIPPS panel.

Note: 1.

Angle type of actuator is not acceptable as this will lead to higher dead band between actuator movement and valve stem movement.

2. The reference schematic diagram for Choke Valve assembly is attached as Appendix - L.

9.1.1

Material of Construction

Duplex Stainless Steel shall be use for the valve body installed on wellhead flow line as specified inside the relevant data sheets (Appendix - J).

The hardness of material, Charpy Impact test, Corrosion test, Ferrite content shall be as per SP 1189


For all fittings, tubing, valves, panels and other hydraulic components stainless steel (AISI 316L) shall be used and shall be executed with PDO approved make for high pressure fittings and tubing’s. Junction boxes shall be provided for interface with external cabling segregated according to service and signal type, coupled to the actuator. All soft materials like O rings shall be Viton 90. NBR is not acceptable. The cylinder seal upgrade (Viton 90 O ring + backup ring) shall to be applied. Seal materials shall be of PTFE or PEEK. No elastomeric material is acceptable. Actuator material for the case or housing shall be of steel. The purchaser shall approve other metallic material. Aluminium shall not be used. Actuator spring shall be of a multi type enclosed in a metal housing and permanently treated to resist atmospheric corrosion. Actuator action shall be oil to open and spring to close. The trim of the valve shall be with highly erosion resistance as sands and propane presence are expected in the fluids. Vendor shall submit the mechanical properties of trim material (tungsten carbide) for PDO review and approval prior to manufacture. This design of trim has to be independently tested and proved that proposed trims are compatible for most erosive services.

9.1.2

Design Requirement

1. Choke Valves shall be sized according to the formulae and calculation methods as defined by ANSI/ISA S.75.01 STD., Latest Revision. The Vendor shall check the valves with reference to the operating data contained in the Process Data Sheets Attached (See Appendix - K). In particular the Vendor shall check range, fluid velocity and noise level. 2. The valve shall fully comply with SPE 77/302 and SPE 77/312. 3. The valve body shall be preferably of the same size that of pipe line size, but in any case body size reduction shall not be more than one size down from the pipe line size. 4. The design shall be suitable for safe depressurisation of the bonnet as per section 10.9.3.5 of the API 6A and ISO 10432 section 10.9.3.6 by means of an intrinsically safe solution. 5. Based on the flow condition and fluid properties, vendor shall confirm if multistage trim design is required. 6. The installed CV shall be at least 10% more than the maximum calculated CV, but not more than 15 % of the maximum calculated CV to ensure good controllability. Valve shall be designed such that no cavitations and choke occurs during operation. Page 51 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

7.

Admissible noise level shall not exceed to 85 dBA at 1 meter from the valve. Noise calculation for two phase flow is Mandatory.

8. During initial opening of choke valve from fully closed position, it experiences high differential pressure and very high fluid velocities due to which temperature of choke valve reduces drastically and due to this it gets frozen and can not be operated. Vendor to give details of his valve design and performance for this condition and minimum opening of the valve possible for this condition. 9. Valve shall be able to withstand very high pressure, up to the maximum closed-in well pressure and shall be capable of delivering the desired maximum and minimum flow rates. 10. Valve shall be balanced trim angle body with cage type internal trim of Tungsten carbide material. The cage shall be supported at both the sides and supported elements shall be fixed to the body. The piston shall be guided over the full stroke. 11. Actuator shall be directly connected to the valve stem. Angle coupling between Actuator and valve is not acceptable 12. Valve internal shall be removable, by using special tools, without disconnecting re-adjusting or removing the actuator from the valve or removing the valve from the process line. Vendor to include in his scope of supply all the special tools as required. 13. Each valve shall be TSO, Class V as per IEC 60534-4.

9.1.3

Electric Components

1. Solenoid valves and relevant Junction box shall be explosion-proof type according to hazardous area classification zone 2, IIB, T4 as per IEC Code. All Solenoid Valves shall be connected to a single junction box. Junction box shall be EExe design. 2. Electrical enclosure weather protection degree shall be at least IP 65. 3. All electrical equipment shall be tropicalised. 4. The wiring shall be provided for Solenoid Valve and Foundation Fieldbus or SMART 4-20mA Analogue Valve position transmitter. 5. Each wire shall be tagged at both ends with an appropriate marker. 6. The electrical connections shall be suitable for Zone 2 hazardous area. 7. All components shall be completely wired to their respective terminal points. Separate terminals shall be provided for power and signals. 8. All terminals shall be permanently identified, 20% spare terminals shall be provided in each terminal box. 9. An external ground terminal shall be provided, suitable for a 16 mm2 ground cable. Page 52 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

10. 3 Off Threaded holes. M20 size shall be provided for the external electric connections. 11. Valve position transmitter shall be a potentiometer type device, and will provide an output electric signal either Foundation Fieldbus or SMART 420mA Analogue type as required. The potentiometer shall be connected to the valve stem, mounted within the pedestal.

9.1.4

Hydraulic Power Section

The system shall receive hydraulic power supply from one hydraulic circuit line powered by one Well Head Control Panel. The supply pressure to be 200 bar maximum. 185 bar minimum. To be re confirmed by Choke Valve vendor. The hydraulic circuit inside the Choke panel shall be provided with relief valve with properly designed set point for protecting the Choke valve actuator from over pressurisation due to extreme temperature variations. Vendor to provide the necessary calculations/details for approval. The tubing size of the hydraulic power supply shall be 3/8 inch OD and return line shall be 3/4 inch OD. The preliminary distance between the Well Head Control Panel and the CHOKE Valve is 50 m. 1. Hydraulic system tubing shall be sized and selected by Vendor in order to minimize pressure and power losses. Material for tubing shall be AISI 316L according to ASTM A 269. Maximum working pressure for fittings shall be 500 bar (g) at temperature of 38°C. All hydraulic circu it shall be tested at 1.5 times of working pressure. 2. All tubing shall be neatly laid out and adequately supported and present a neat appearance. 3. One hydraulic control cabinet shall be supplied for each valve. It shall receive a hydraulic supply from a remote hydraulic power supply and two remote 24V open / close control signals (see Appendix - L). Control cabinet location shall be design to be fixed in either side of the Choke actuator and without the need of any special tools. 4. The remote control signals shall be from a Wellhead Control System and shall be digital type mode. The control cabinet shall be capable of converting the pulse inlet signal at different width length into a Hydraulic Output Signal to the valve actuator without any delay. Valve physical position (measuring value) shall always be equal to the remote control signal (Set point). 5. The solenoid valve installed on the Hydraulic Power Line to the actuator shall close the valve via a remote emergency shutdown signal from the wellhead control panel. Page 53 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

9.1.5


1. All components used for hydraulic circuits shall be suitable for outside/desert application. 2.

9.1.6

All valve bodies, including that of the solenoid valves shall be AISI 316

Choke Valve Controls

Each Choke Valve Control System shall consist as follows: •

One Foundation Fieldbus or 4-20mA SMART Position Transmitter as required.

9.1.7

•

Three Solenoid Valves

•

One Hydraulic Control Cabinet

•

One Hydraulic Actuator

•

One Hydraulic operated 2/2 - way valve

Choke Valve ESD Section

An ESD is initiated by a remote signal from the Wellhead Control Panel (WHCP) to the ESD solenoid valve. On initiation of shutdown signal the valve shall close in a time period of 5 (five) seconds.


10.

PAINTING The treatment and protection of valve body and actuator shall be according to Manufacturer's standard but shall include cleaning, degreasing, rust resisting primers and paint finishing and provide effective protection against corrosion under the functional and climatic conditions described in this specification.


11.

INSPECTION & TESTS All the WHCPs and the wellhead safety system shall be subject to but not limited to the test and checks specified according to the following specifications. • DEP. 62.10.08.11 Factory Inspection and Testing of Instrument. •

SP - 1087 Control Valve-Selection, Sizing and Specification.

The above specifications do not relieve the Vendor to proceed with the following test and check as minimum.

11.1

Visual Checks The visual check shall be carried out in order to verify: • Overall dimensions and components location according to the approved Vendor construction drawings. •

Labelling and marking of front panel devices, internal components and wiring.

•

Materials and degree of protection of the whole system and individual components.

11.2

•

Range of pressure gauges.

•

Range of Low pressure pilots.

Performance Tests

These tests shall be carried out in order to verify the electromechanical performances of the components and shall include: • Insulation resistance tests of electric components and wiring (500 V ac shall be used). •

The solenoid valves shall be energized at maximum operating voltage for at least 12 hours before the insulation test.

•

Hydrostatic test for the hydraulic circuit accumulators according to BS 5500

•

Hydraulic circuit pressure test performed with hydraulic oil to 1.5 times the design pressure for at least 5 min.

•

Calibration of Low pressure pilots

•

Check of fusible plugs Page 56 of 65 DOC No:-LGF-15-101983-IN-7880-00001-0000-XX-01 INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

11.3

Functional Tests

The functional tests shall be carried out in order to check the following functions: • Remote shutdown (through the solenoid valve actuation) of SSV & Choke Valve. •

Manual shutdown and reset of SSV and Sc-SSV valves through the command on the front panel.

•

Manual shutdown of IPF valves through local push button.

•

Shutdown of IPF valves by the actuation of pressure switches.

•

Remote shutdown of IPF valves (loss of hydraulic supply).

•

Opening/Closing of Choke valve (through the pulse signal).

•

Automatic shutdown of SSV and CHOKE valves by the Low pressure pilots and test of by-pass function.

•

Automatic shutdown of SSV, SC-SSSV and CHOKE valves through the fusible plug.

11.4

•

Actuation of the alarms for any abnormal condition envisaged on design.

•

Wellhead Control System Functional Tests.

Integrated (FAT) System Test The Integrated Factory Acceptance Test for PDO consisting of Wellhead Control Panel, Sc-SSV hydraulic circuit, Choke Valve and Control Panel and associated Instruments and Accessories. The Primary Purpose of the integrated FAT is to functionally test the workings of the WHCP's, Valves Actuators, Panels and associated Instruments and accessories, such that it meets PDO Codes, Standards and Specifications.

11.5

Other Requirements Vendors are expected to suggest any other tests that, according to their experience, are recommended in order to qualify the product. Vendors shall submit to the purchaser, for approval, testing and planning procedure for the functional tests.


11.5.1 Body Test

All IPF and Choke Valves shall be subject but not limited to the test and checks specified according to the following international standards. Non Destructive Test as per ANSI B 16.34 Special Class. Hydraulic test as per API 598 and ANSI B 16.34 and ANSI/FCI 70.2 class V.

11.5.2 Leak Test and Stroke Test for IPF Valves

Vendors shall conduct the test described below for all IPF valves which will be witnessed by PDO personnel.

11.5.3 Functional Test (Test Medium: Nitrogen)

1. Operate the valve actuator unit through one (1) complete open/close cycle without differential pressure applied to the valve.

2. Verify manoeuvrability of the valve actuator unit. 3. With the valve in the fully open position apply to the valve port the maximum pressure used for sizing the actuator with the drain of body cavity in closed position. 4. Release quickly the actuator supply pressure and measure the operating time to close the valve. 5. Depressurize the valve 6. Carry out the operation described from par point no. 3 to 5 twenty (20) times. 11.5.4 Gas Seat Test (Test Medium: Nitrogen)

1. Place the valve in the bunker and connect the nitrogen pressure source 2. Operate the valve to the fully closed position 3. Apply to side A of the valve the maximum test pressure used for sizing the actuator for duration of 5 minutes, with side B and valve body cavity vented to atmosphere 4. Measure any leakage at the valve downstream side with a calibrated flow meter (rota-meter)


5. Depressurize the valve 6. Repeat the operation described from point no. 3 to 5 on the side B and measure side A 7. The acceptance criteria are maximum 36 cc/min.


12.

CERTIFICATION In addition to the required "Test and Inspection documents", the Vendor shall supply a certificate of compliance with the applicable MESC description, the requisition/ indent and the purchase order, including the test requirements.


13.

TRANSPORTATION AND STORAGE Transport and Storage requirements shall be as applicable to PDO Standards and as per the the following: • The items shall be shipped and transported to PDO - Majan • All threaded holes shall be plugged with screw-in plastic caps. • The Vendor shall provide adequate packing to alleviate damage in storage and transit. • The unit shall be packed as assembled and tested, and not dismantled.


14.

PROGRESS OF WORK At the time of placing the order, the following dates will be agreed and confirmed: •

The earliest integrated date of starting the work.

•

The date for integrated FAT inspection for one complete system, WHCP, SC-SSV hydraulic circuit, choke & IPF valve and associated instruments and accessories.

•

The date for FAT inspection WHCP, Sc-SSV hydraulic circuit and associated instruments and accessories.

•

The date for the FAT inspection Choke valves and associated panels instruments and accessories.

•

The date for the FAT inspection IPF valves and associated panels instruments and accessories.

•

The Vendor shall issue actual project planning schedule.

In the case of delay, the Vendor shall immediately inform PDO in writing.


15.

GURANTEE The Vendor shall guarantee all work and materials in his supply against defective material, poor workmanship, improper design, improper packaging and/or failure in normal use for 12 months after the system has been placed in service but not exceeding 18 months after date of dispatch. The Vendor shall repair or replace within one week, without any charge to PDO, the parts found defective within the guarantee period.


16.

DOCUMENTS REQUIRED FROM VENDOR Documentation requirements are as per RED form (Appendix - N) Operation and Maintenance manuals will be split into a minimum of two (2) volumes and shall be in an electronic format (CD). Volume 1: Wellhead Control Panel (WHCP). A.

All drawings, logic diagrams, control narratives, trouble shooting guide lines etc.

B.

Instruments, accessories and

C.

Vendor data.

A.

IPF valve and associated instruments, drawings, control panel

Volume 2: and vendor data. B.

Choke valve and associated instruments, drawings, control panel and Vendor data.

C.

Test, Testing certificates.

D.

Hazardous area electrical certification.


17.

SPARE PARTS E-SPIR Form shall be completed by the Vendor in accordance with the instructions for use of SPIR Forms (refer note 2 of the RED Form) and submitted to PDO not later than 6 weeks after PDO Order date.


APPENDIX-A

ACTUATED VALVES PRESSURE AND TUBINGS Actuated valve

SC-SSV

SSV

WV HIPPS CV ASME 2500# API 10,000

ASME 2500 # (25 sets)

API 10,000 (30 sets)

PRESSURE

69000 kPa

86000 kPa

TUBING

3/8" OD x 0.086" THK.

3/8" OD x 0.086" THK.

PRESSURE

35000 kPa

35000 kPa

TUBING

1/2" OD x 0.083" THK.

1/2" OD x 0.083" THK.

PRESSURE TUBING PRESSURE TUBING PRESSURE TUBING

35000 kPa 1/2" OD x 0.083" THK. 20000 kPa 3/8" OD x 0.049" THK. 20000 kPa 3/8" OD x 0.049" THK.

35000 kPa 1/2" OD x 0.083" THK. 20000 kPa 3/8" OD x 0.049" THK. 20000 kPa 3/8" OD x 0.049" THK.

SR, SR GRAB, MABROUK, HARMAL, KAUTHER, FAKHR SRS, BRNW,

APPENDIX - B Hydraulic Power Section Design Condition

SC-SSV Supply Line SSV Supply Line Choke Valve Supply Line HIPPS Valve supply Line WHCP control supply line WHCP common retrun lines

SC-SSV Supply Line SSV Supply Line WV Supply Line Choke Valve Supply Line HIPPS Valve supply Line WHCP control supply line WHCP common retrun lines

Hydraulic Supply Line Design for Wells (ASME 2500 #) No of Max Press. Min Press. Valve Actuator strokes Bar(g) Bar(g) Swept Vol. ( Note 3) 0.025 Litres 690 450 3 (1.53 Cu Inch) 4.34 Litres 350 200 1 ( 265 Cu Inch) * * * 1 * * * 1 * * * 1 Hydraulic Supply Line design for Wells ( API 10,000) No of Max Press. Min Press. Valve Actuator strokes Bar(g) Bar(g) Swept Vol. ( Note 3) 0.025 Litres 860 600 3 (1.53 Cu Inch) 4.34 Litres 350 200 1 ( 265 Cu Inch) 4.34 Litres 350 200 1 ( 265 Cu Inch) * * * 1 * * * 1 * * * 1 -

Line size

Accumalator capacity ( Note 3,6) Remarks

3/8"

Note 2

1/2"

Note 2

3/8" 3/8" 3/8" 3/4"

Line size

Accumalator capacity ( Note 3,6)

Remarks

3/8"

Note 2

1/2"

Note 2

1/2"

Note 2,8

3/8" 3/8" 3/8" 3/4"

Note: * Data to be provided by vendor 1. Vendor to consider a design margin of 20% above the actual required capacity for accumulator sizing 2. To be reconfirmed the SC SSV, SSV and WV max supply pressure requirement based on Christmus Tree design. 3. The accumulator shall be designed for the mentioned minimum no of strokes without pump operation. 4. Vendor shall provide the precharge pressure for all the accumulators. 5. Vendor to provide a detailed sizing for the pumps capacity, accumulators capacity, accumulator pre charge pressure, relief valves set points & Pressure switch set points for approval. 6. The Process trip set point for High High pressure and Low Low pressure will be provided later during Engineering.

Description WHCP Hdr Pressure( L) WHCP Hdr Pressure( H)

Trip and Alarm set points Set point Remarks * Pump Auto start * Pump Auto stop

Process P/L High High Pressure Trip

Note 9

Process P/L Low Low Pressure Trip Hydraulic control loop press ( L) Hydraulic pressure to SC SSV( L)

Note 9,10 * *

Set pt for HIPPS Switches Set pt for Low press. Switch Set pt for low press. Switch on WHCP control supply line Set pt for Low press. Switch on SC SSV Hydr. Supply line

SHEET 1 OF 2

Notes: 7. The Process trip set point for High High pressure and Low Low pressure will be provided later during Engineering. 8. P/L low low pilot pressure trip is applicable only for ASME 2500 PSI rated, Well delivery 2014/2015 project. Remote Indications required from WHCP Description of Signal Hydraulic supply tank level indication Pumps Running indication Hydraulic supply pressure low SC SSV close indication

Description of Signal Wellhead Close command Wing Valve close command Choke Valve Shutdown command

Type of signal FF/HART type transmitter with local and remote indication Potential free contacts Pressure switch with potential free contacts Pressure switch with potential free contacts

Remote commands to WHCP Type of signal DO( Potfree) DO( Potfree) DO( Potfree)

SHEET 2 OF 2

Remarks Closes Choke Valve, WV & SSV Closes Choke Valve & WV Choke Valve Shutdown only

APPENDIX-C SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT TYPICAL (API 10000)

APPENDIX-D SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT TYPICAL (ASME #2500)

APPENDIX-D SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT TYPICAL (ASME #2500)

APPENDIX - E WHCP Lay out drawing -1

APPENDIX - E WHCP Lay out drawing -2

APPENDIX F : LOCAL DUMP VALVE PANEL (WITH WIRELINE CONNECTION)

APPENDIX G : TYP. ARRANGEMENT-SSV LIMIT SWITCH ASSEMBLY ‘TYPE A”

SSV LIMIT SWITCH ASSEMBLY “TYPE B”

Sht no. 2 OF 2

APPENDIX - H

REQN. NO.

Rev. O

PROJECT CLIENT

PETROLEUM DEVELOPMENT OMAN, LLC

ENGG. BY

GALFAR ENGG AND CONTACTING

DATA SHEET FOR ACTUATOR FOR HIPPS TAG No. O

ISSUED FOR ENQUIRY

REV

DESCRIPTION

IJ

HKW

DS

31.03.'13

PREP

CHK

APP

DATE

MESC. No.

----

MANUFACTURER

AS PER AVME CODE 36.605

MODEL No.

*

DESCRIPTION

SPECIFIED

AS OFFERED BY VENDOR

1

QUANTITY

25 NOS. FOR ASME 2500# VALVES AND 30 NOS. FOR API 10,000 VALVES

2

ACTUATOR TYPE

SPRING RETURN, PISTON TYPE

3

ACTUATOR MECHANISM

SCOTCH YOKE

4

ACTION ON FAILURE

HYDRAULIC FAIL CLOSE / SPRING TO CLOSE

5

ACTUATING MEDIUM

HYDRAULIC OIL

6

FIRE SAFE CONSTRUCTION

YES

7

MOUNTING POSITION

TOP MOUNTED ALONG PIPE AXIS

8

POSITION INDICATOR (LOCAL)

REQUIRED

9

CYCLE FREQUENCY

LONG STAND STILL

10

VALVE CLOSING TIME

LESS THAN 2 SECONDS

11

VALVE OPENING TIME

< 45 SECONDS

12

SUPPLY PRESSURE MIN / MAX

185/200 BAR (G)

13

ACTUATOR COLOUR

RED

14

AREA CLASSIFICATION

EEXd.

15

BODY

BY VENDOR

16

PNEUMATIC CYLINDER

BY VENDOR

17

CYLINDER BARREL

BY VENDOR

18

YOKE HOUSING

BY VENDOR

19

YOKE

BY VENDOR

20

YOKE PIN

BY VENDOR

21

YOKE PIN ROLLER

BY VENDOR

22

YOKE PIN NUT

BY VENDOR

23

END CAPS

BY VENDOR

24

PISTON RODS

BY VENDOR

25

CONNECTING RODS

BY VENDOR

26

THRUST BLOCK

BY VENDOR

27

THRUST PIN

BY VENDOR

28

THRUST PLATE

BY VENDOR

29

TIE BARS

BY VENDOR

30

BOLTS

BY VENDOR

31

NUTS

BY VENDOR

32

SPRING

BY VENDOR

33

SPRING CARTRIDGE

BY VENDOR

ACTUATOR & VALVE TORQUE DETAILS

( ALL VALUES SHALL BE IN Nm )

34

VSOT (VALVE START TO OPEN TORQUE)

BY VENDOR

35

VROT (VALVE RUNNING TO OPEN TORQUE)

BY VENDOR

36

VEOT (VALVE END TO OPEN TORQUE)

BY VENDOR

37

VSCT (VALVE START TO CLOSE TORQUE)

BY VENDOR

38

VRCT (VALVE RUNNING TO CLOSE TORQUE)

BY VENDOR

39

VRST (VALVE CLOSING/RESEATING TORQUE)

BY VENDOR

40

VSST (VALVE STEM SHEAR TORQUE)

BY VENDOR

41

SST (SPRING START TORQUE)

BY VENDOR

42

SRT (SPRING RUNNING TORQUE)

BY VENDOR

43

SET (SPRING END TORQUE)

BY VENDOR

44

MBST (MAXIMUM SPRING BREAKAWAY TORQUE)

BY VENDOR

45

HST (HYDRAULIC START TORQUE)

BY VENDOR

46

HRT (HYDRAULIC RUNNING TORQUE)

BY VENDOR

47

HET (HYDRAULIC END TORQUE)

BY VENDOR

48

MAOT (MAX. AIR OUTPUT TORQUE)

BY VENDOR

49

SST / VSCT ( > = 2.0 )

BY VENDOR

50

SRT / VRCT (> = 1.5)

BY VENDOR

51

SET / VRST ( > = 1.25 )

BY VENDOR

52

MBST / VSST (< 0.95 )

BY VENDOR

53

SST / SET ( BET 1.5 & 2.0 )

BY VENDOR

54 55 56 57 58 59 60

SRT / SET ( > 0.75 ) HST / VSOT ( > = 2.0 ) HRT / VROT ( > = 1.5 ) HET / VEOT ( > = 1.25 ) MAOT / VSST ( < 0.95 ) HST / HET ( BET 1.5 & 2.0 ) HRT / HET ( > 0.75 )

BY VENDOR BY VENDOR BY VENDOR BY VENDOR BY VENDOR BY VENDOR BY VENDOR

MATERIALS

SALALAH GAS PIPELINE

Sht no. 2 OF 2

APPENDIX - H

REQN. NO.

Rev. O

PROJECT CLIENT


ENGG. BY


DATA SHEET FOR ACTUATOR FOR HIPPS TAG No. O

ISSUED FOR ENQUIRY

REV

DESCRIPTION

IJ

HKW

DS

31.03.'13

PREP

CHK

APP

DATE

MESC. No.

----

MANUFACTURER


MODEL No.

*

DESCRIPTION ANCILLARIES

SPECIFIED


61

LIMIT SWITCHES , MICRO SWITCH TYPE QUANTITY MANUFACTURER MODEL NO

24 VDC EEXd. SOV, PROXIMITY SWITCHES, QUICK EXHAUST VALVE, JUNCTION BOX, FILTERS, PILOT VALVE, HIGH HIGH PRESSURE SWITCHES ETC. ( ALL ANCILLARIES SHALL BE AS PER PDO APPROVED VENDOR LIST , APPENDIX - IV) EEx(d) 1 NO, OPEN & CLOSE POSITION AS AVME CODE 36.521 *

62

HYDRAULIC REGULATOR MANUFACTURER MODEL NO

TO BE PROVIDED WITH PRESSURE GAUGE AS PER AVME CODE 37.210 VTA

63

TUBE & FITTINGS MANUFACTURER

SS 316 AS PER AVME CODE 37.310 & 37.320

64

PAINTING

REQUIRED

65

ELECTRICAL AREA CLASSIFICATION

ZONE - 2, GAS GR. IIB, T4

66

TAG NUMBER

Stamped on S.S.tag screwed to body

67

INGRESS PROTECTION

IP 66 AS PER IEC 529

68

TOTAL ACTUATOR SUPPLY

AS PER DEP 31.40.70.30-PDO

69

MATERIAL CERTIFICATE

AS PER RED FORM

70

ELECTRICAL CERTIFICATION

REQUIRED

SUPPLEMENTRY REQUIREMENTS

CERTIFICATION

NOTES :

1) VENDOR TO SUBMIT THE ABOVE SHEET COMPLETELY FILLED IN AND DULY STAMPED , ALONG WITH THE QUOTATION 2) CYLINDER PART COVERED BY THE PISTON STROKE SHALL BE INTERNALLY NICKEL PLATED TO PREVENT CORROSION. 3) ALL ACCESSORIES AS REQUIRED SHALL BE PROVIDED AND MENTIONED IN THE DATA SHEET BY VENDOR 4) ALL SOFT GOODS (O RINGS) SHALL BE VITON 90. NBR IS NOT ACCEPTABLE * - VENDOR TO FURNISH

APPENDIX- H

HIPPS Valve Data Sheet (API 10,000) SL NO. DESCRIPTION

REQUIREMENT

1

Valve qty./ tag nos

30 NOS./ TO BE ADVISED LATER

2

Medium

WET HC GAS

3

Valve manufacturer / model no / serial no

*

4

Valve type

HYDRAULIC ACTUATED PISTON TYPE-SPRING TO CLOSE

5

Design temperature ( deg c)

-20/120

6

Nominal size

5 1/8”

7

Pressure Rating

API 10000#

8

Face of flange

RTJ, FINISH AS PER API 6A

9

Ring No.

BX-169

10

Design spec

API SPEC 6A (LATEST VERSION)

11

Length, Face to Face

AS PER API SPEC 6A

12

Type of end connection

FLANGED

13

Type of closure member

TRUNNION MOUNTED BALL

14

Type of bore/bore size

FULL BORE

15

Type of construction

TWO/ THREE PIECE

16

Type of bonnet / cover

BOLTED (NON-EXTENDED)

17

Type of seat

METAL TO METAL

18

Type of seat piston

SINGLE PISTON EFFECT SEAT IN UPSTREAM AND DOUBLE PISTON EFFECT SEAT IN DOWNSTREAM

19

UNI/BI Directional

UNI DIRECTIONAL

20

Service(s)

SOUR

21

Fugitive Emmission class

A(HS)

22

Material requirement, sour service NACE MR-01-75/ ISO 15156 & SP 2041

23

Mat, body

DUPLEX STAINLESS STEEL( DSS)

24

Mat, trim

DUPLEX STAINLESS STEEL

25

Mat, seals

GRAPHITE/THERMO PLASTIC

26

Mat spec, body

ASTM A182 GRADE F 51

27

Mat spec, bonnet


28

Mat spec, cover


29

Mat spec, gland flange


30

Mat spec, gland ring

ASTM A276 UNS31803/ASTM A182 GRADE F 51

31

Mat spec, Ball


32

Mat spec, stem

API 6A 718

33

Mat spec, trunnion

ASTM A182 GRADE F51

Mat spec, seat

ASTM A 182 GRADE F 51 /TUNGSTEN CARBIDE ( NOTE 6)

34

ASTM A276 UNS S31803

35

Mat spec, spring(s)

ASTM B637 UNS N07718

36

Mat spec, static primary seal

VIRGIN/FILLED/MODIFIED PTFE

37

Mat spec, static sec seal

GRAPHITE

38

Mat spec, dynamic primary seal


39

Mat spec, dynamic sec seal(s)

BRAIDED GRAPHITE + PTFE LUB

Mat spec, bolts/studs

ASTM A193 GRADE B7M

41

Mat spec, nuts

ASTM A194 GRADE 2HM

42

Valve test and Inspection Standard API 6A, PSL3G AND PR2 FOR ALL VALVES( NOTE 2,3)

43

Seat tightness leakage

TSO AS PER API 6A

44

Seals

RPTFE / PEEK ( NOTE 4)

45

Valve material class

NACE MR-01-75 ( SOUR SERVICE)/ SP 2041

40

DIE FORMED GRAPHITE + PTFE LUB

Page 1 of 4

APPENDIX- H Test & inspection certification & material certificate

ISO 10474 3.2

47

Mounting position

HORIZONTAL

48

Additional mandatory requirements

46

MESC SPE 77/300A (LATEST VERSION) MESC SPE 77/302 (LATEST VERSION) MESC SPE 85/203 (LATEST VERSION) MESC SPE 85/204 (LATEST VERSION) MESC SPE 85/301 (LATEST VERSION) PREN > 34 49

Inspection category

IC IV

50

Tests required

AS PER API 6A PSL 3G

NOTE: 1. * Vendor to provide. 2. All the valve shall be as per tested as per PSL3G and PR2. Vendor shall produce valve performance qualification certificate as per PR2. If the valve has not yet qualified with PR2, vendor has to carryout PR2 test which shall be witnessed /qualified by PDO. 3. All the valves shall be tested with high pressure gas seat test as per API-PSL3G. 4. The seal material shall be of PTFE or PEEK. No elastomeric material is acceptable. 5. The material shall be suitable for fluid with sand and highly erosive service. 6. The seat facing shall be coated / cladded with Tungsten carbide. 7. No sealant / grease point required. 8. Valves shall be provided with lip seal design 9. Valves shall be fire safe as per API 6FA

Page 2 of 4

APPENDIX- H

HIPPS Valve Data Sheet (ASME 2500#) SL NO.

DESCRIPTION

REQUIREMENT

1

Valve qty. / tag nos

25 NOS. / TO BE ADVISED LATER

2

Medium

WET HC GAS

3

Valve manufacturer/model no/serial no

*

4

Valve type

HYDRAULIC ACTUATED PISTON TYPE-SPRING TO CLOSE

5

Design temperature ( deg c)

-20/120

6

Nominal size

DN 150

7

Design spec, pressure rating

ASME CL 2500

8

Design spec

ISO 14313, API SPEC 6D

9

Dimensional Spec

ISO 14313

10

Length, face to face

914 MM

11

Type of end connection

FLANGED

12

Type of face

RF, SMOOTH FINISH

13

Type of pattern

STANDARD

14

Type of closure member

TRUNNION MOUNTED BALL

15

Type of bore/bore size

FULL BORE

16

Type of construction

TWO/ THREE PIECE

17

Type of bonnet / cover

BOLTED (NON-EXTENDED)

18

Type of seat

METAL TO METAL

19

Type of seat piston

SINGLE PISTON UPSTREAM NAD DOUBLE PISTON DOWN STREAM

20

Uni/bi directional

UNI DIRECTIONAL

21

Service(s)

SOUR

22

Material requirement, sour service

NACE MR-01-75/ ISO 15156 & SP 2041

23

Emission class

A (HS)

24

Mat, body

DUPLEX STAINLESS STEEL( DSS)

25

Mat, trim

DUPLEX STAINLESS STEEL

26

Mat, seals

GRAPHITE / THERMO PLASTIC

27

Mat spec, body

ASTM A890 GRADE 4A/ASTM A182 GRADE F 51

28

Mat spec, bonnet


29

Mat spec, cover


30

Mat spec, gland flange


31

Mat spec, gland ring

ASTM A276 UNS31803/ASTM A182 GRADE F 51

32

Mat spec, ball


33

Mat spec, stem

API 6A 718

34

Mat spec, trunnion

ASTM A182 GRADE F51 ASTM A276 UNS S31803

35

Mat spec, seat

36

Mat spec, spring(s)

ASTM A182 F 51 /TUNGSTEN CARBIDE ( NOTE 3) ASTM B637 UNS N07718

37

Mat spec, static primary seal

VIRGIN / FILLED / MODIFIED PTFE

38

Mat spec, static sec seal

GRAPHITE

39

Mat spec, dynamic primary seal


40

Mat spec, dynamic sec seal(s)

BRAIDED GRAPHITE + PTFE LUB

41

Mat spec, bolts/studs

ASTM A193 GRADE B7M

42

Mat spec, nuts

ASTM A194 GRADE 2HM

43

Seat tightness leakage

CLASS V – AS PER IEC 60534-4 ( METAL SEATED)

44

Seals

RPTFE / PEEK ( NOTE 4)

45

Valve material class

NACE MR-01-75 ( SOUR SERVICE)

DIE FORMED GRAPHITE + PTFE LUB

Page 3 of 4

APPENDIX- H 46

Test & inspection certification & material certificate

ISO 10474 3.2

47

Mounting position

HORIZONTAL

48

Inspection category

IC - IV

49

Additional mandatory requirements MESC SPE 77/130 (LATEST VERSION) MESC SPE 77/300A (LATEST VERSION) MESC SPE 77/302 (LATEST VERSION) MESC SPE 77/312 (LATEST VERSION) MESC SPE 85/203 (LATEST VERSION) MESC SPE 85/204 (LATEST VERSION) MESC SPE 85/301 (LATEST VERSION) PREN > 34 NOTE: 1. * Vendor to provide. 2. If the proposed valve has not yet been qualified by TAT as per 77/300A, vendor has to perform Prototype test as per SPE 300Awhich shall be qualified/witnessed by PDO. 3. The seat facing shall be coated / cladded with tungsten carbide. 4. The seal material shall be of PTFE or PEEK. No elastomer material is acceptable. 5. The material shall be suitable for fluid with sand and highly erosive service. 6. No sealant/grease point is required. 7. Valves shall be provided with LIP seal design 8. Valve shall be of FIRE safe design as per API 6FA

Page 4 of 4

APPENDIX - I HIPPS Panel Schematic diagram

Sht no. 2 OF 2

APPENDIX - J

REQN. NO.

Rev. O

PROJECT CLIENT


ENGG. BY


DATA SHEET FOR ACTUATOR FOR CHOKE VALVE TAG No. O

ISSUED FOR ENQUIRY

REV

DESCRIPTION

IJ

HKW

DS

31.03.'13

PREP

CHK

APP

DATE

MESC. No.

----

MANUFACTURER


MODEL No.

*

DESCRIPTION

SPECIFIED


1

QUANTITY

30 NOS. FOR API 10,000 VALVES AND 25 NOS. FOR ASME 2500# VALVES

2

ACTUATOR TYPE

SPRING RETURN, PISTON TYPE

3

ACTUATOR MECHANISM

SCOTCH YOKE

4

ACTION ON FAILURE

HYDRAULIC FAIL CLOSE / SPRING TO CLOSE

5

ACTUATING MEDIUM

HYDRAULIC OIL

6

FIRE SAFE CONSTRUCTION

YES

7

MOUNTING POSITION

TOP MOUNTED ALONG PIPE AXIS

8

POSITION INDICATOR (LOCAL)

REQUIRED

9

CYCLE FREQUENCY

LONG STAND STILL

10

VALVE CLOSING TIME

LESS THAN 6 SECONDS

11

VALVE OPENING TIME

< 45 SECONDS

12

SUPPLY PRESSURE MIN / MAX

185/200 BAR (G)

13

ACTUATOR COLOUR

RED

14

AREA CLASSIFICATION

EEXd.

15

BODY

BY VENDOR

16

PNEUMATIC CYLINDER

BY VENDOR

17

CYLINDER BARREL

BY VENDOR

18

YOKE HOUSING

BY VENDOR

19

YOKE

BY VENDOR

20

YOKE PIN

BY VENDOR

21

YOKE PIN ROLLER

BY VENDOR

22

YOKE PIN NUT

BY VENDOR

23

END CAPS

BY VENDOR

24

PISTON RODS

BY VENDOR

25

CONNECTING RODS

BY VENDOR

26

THRUST BLOCK

BY VENDOR

27

THRUST PIN

BY VENDOR

28

THRUST PLATE

BY VENDOR

29

TIE BARS

BY VENDOR

30

BOLTS

BY VENDOR

31

NUTS

BY VENDOR

32

SPRING

BY VENDOR

33

SPRING CARTRIDGE

BY VENDOR

ACTUATOR & VALVE TORQUE DETAILS

( ALL VALUES SHALL BE IN Nm )

34

VSOT (VALVE START TO OPEN TORQUE)

BY VENDOR

35

VROT (VALVE RUNNING TO OPEN TORQUE)

BY VENDOR

36

VEOT (VALVE END TO OPEN TORQUE)

BY VENDOR

37

VSCT (VALVE START TO CLOSE TORQUE)

BY VENDOR

38

VRCT (VALVE RUNNING TO CLOSE TORQUE)

BY VENDOR

39

VRST (VALVE CLOSING/RESEATING TORQUE)

BY VENDOR

40

VSST (VALVE STEM SHEAR TORQUE)

BY VENDOR

41

SST (SPRING START TORQUE)

BY VENDOR

42

SRT (SPRING RUNNING TORQUE)

BY VENDOR

43

SET (SPRING END TORQUE)

BY VENDOR

44

MBST (MAXIMUM SPRING BREAKAWAY TORQUE)

BY VENDOR

45

HST (HYDRAULIC START TORQUE)

BY VENDOR

46

HRT (HYDRAULIC RUNNING TORQUE)

BY VENDOR

47

HET (HYDRAULIC END TORQUE)

BY VENDOR

48

MAOT (MAX. AIR OUTPUT TORQUE)

BY VENDOR

49

SST / VSCT ( > = 2.0 )

BY VENDOR

50

SRT / VRCT (> = 1.5)

BY VENDOR

51

SET / VRST ( > = 1.25 )

BY VENDOR

52

MBST / VSST (< 0.95 )

BY VENDOR

53

SST / SET ( BET 1.5 & 2.0 )

BY VENDOR

54 55 56 57 58 59 60

SRT / SET ( > 0.75 ) HST / VSOT ( > = 2.0 ) HRT / VROT ( > = 1.5 ) HET / VEOT ( > = 1.25 ) MAOT / VSST ( < 0.95 ) HST / HET ( BET 1.5 & 2.0 ) HRT / HET ( > 0.75 )

BY VENDOR BY VENDOR BY VENDOR BY VENDOR BY VENDOR BY VENDOR BY VENDOR

MATERIALS

SALALAH GAS PIPELINE

Sht no. 2 OF 2

APPENDIX - J

REQN. NO.

Rev. O

PROJECT CLIENT


ENGG. BY


DATA SHEET FOR ACTUATOR FOR CHOKE VALVE TAG No. O

ISSUED FOR ENQUIRY

REV

DESCRIPTION

IJ

HKW

DS

31.03.'13

PREP

CHK

APP

DATE

MESC. No.

----

MANUFACTURER


MODEL No.

*

DESCRIPTION ANCILLARIES

SPECIFIED


61

LIMIT SWITCHES , MICRO SWITCH TYPE QUANTITY MANUFACTURER MODEL NO

24 VDC EEXd. SOV, PROXIMITY SWITCHES, QUICK EXHAUST VALVE, JUNCTION BOX, FILTERS, PILOT VALVE, HIGH HIGH PRESSURE SWITCHES ETC. ( ALL ANCILLARIES SHALL BE AS PER PDO APPROVED VENDOR LIST , APPENDIX - IV) EEx(d) 1 NO, OPEN & CLOSE POSITION AS AVME CODE 36.521 *

62

HYDRAULIC REGULATOR MANUFACTURER MODEL NO

TO BE PROVIDED WITH PRESSURE GAUGE AS PER AVME CODE 37.210 VTA

63

TUBE & FITTINGS MANUFACTURER

SS 316 AS PER AVME CODE 37.310 & 37.320

64

PAINTING

REQUIRED

65

ELECTRICAL AREA CLASSIFICATION

ZONE - 2, GAS GR. IIB, T4

66

TAG NUMBER

Stamped on S.S.tag screwed to body

67

INGRESS PROTECTION

IP 66 AS PER IEC 529

68

TOTAL ACTUATOR SUPPLY

AS PER DEP 31.40.70.30-PDO

69

MATERIAL CERTIFICATE

AS PER RED FORM

70

ELECTRICAL CERTIFICATION

REQUIRED

SUPPLEMENTRY REQUIREMENTS

CERTIFICATION

NOTES :

1) VENDOR TO SUBMIT THE ABOVE SHEET COMPLETELY FILLED IN AND DULY STAMPED , ALONG WITH THE QUOTATION 2) CYLINDER PART COVERED BY THE PISTON STROKE SHALL BE INTERNALLY NICKEL PLATED TO PREVENT CORROSION. 3) ALL ACCESSORIES AS REQUIRED SHALL BE PROVIDED AND MENTIONED IN THE DATA SHEET BY VENDOR 4) ALL SOFT GOODS (O RINGS) SHALL BE VITON 90. NBR IS NOT ACCEPTABLE * - VENDOR TO FURNISH

APPENDIX- J

CHOKE VALVE DATA SHEET FOR API 10000 RATING VALVE TAG NOS

TBA

MEDIUM

NATURAL GAS *

VALVE MANUFACTURER, MODEL NO & SERIAL NO VALVE TYPE CONNECTION SIZE, RATING, RING NO. & QUANTITY END CONNECTIONS

HYDRAULIC ACTUATED CHOKE VALVE - ANGLE TYPE Inlet

Outlet

Quantity(Nos.)

5 1/8”-API 10000# RTJ, BX169 RING.

7 1/16”-API 10000# RTJ, BX-156 RING.

30

Flanged, smooth finish. The flange dimension and flange face finish shall be as per API 6A

BODY & BONNET MATERIAL

DUPLEX ST. ST. ( ASTM A 182 F51/UNS S31803) Note-8

VALVE DESIGN STANDARD

API 6A ( latest edition)

DESIGN PRESSURE & TEMPERATURE

SEE PROCESS DATA SHEET

DESIGN TEMPERATURE

-20/120 deg C

TRIM TYPE

EXTERNAL SLEEVE AND CAGE

SEAT TIGHTNESS LEAKAGE

AS PER API 6A ( METAL TO METAL SEAT)

MATERIAL NOZZLE

TUNGSTEN CARBIDE

MATERIAL RETAINING SLEEVE

INCONEL 625

MATERIAL FLOW RING

TUNGSTEN CARBIDE

MATERIALBODY & BONNET

DUPLEX ST. ST. ( ASTM A182 F51/UNS S31803)

MATERIAL STEM

API 6A 718

MATERIAL PISTON GUIDE

DUPLEX ST. ST. ( ASTM A 182 F51/UNS S31803)

MATERIAL BOLTING

ASTM A193-B7M/A194-2HM

MATERIAL SPRINGS

INCONEL X 718

MATERIAL SEAT

TUNGSTEN CARBIDE

SEALS

RPTFE/PEEK ( Note 6)

MOUNTING POSITION

HORIZONTAL

TEST & INSPECTION STANDARD

API 6A, PSL3G AND PR2 ( Note 2,3)

TEST & INSPECTION CERTIFICATION & MATERIAL CERTIFICATE MATERIAL REQUIREMENT, SOUR SERVICE

NACE MR-01-75/ISO 15156 & SP 2041

POSITION INDICATOR CV CALCULATED(MIN/NOR/MAX)

REQUIRED *

ISO 10474 3.2

CV SELECTED (100% OPENING)

*

TRIM % OPEN (MIN/NOR/MAX) VALVE CHARACTERISTICS

* EQUAL %

NOTES: * Vendor to provide completed data sheet. All valves shall be as tested as per API PSL3G and PR2. Vendor shall produce valve performance qualification certificate as per PR2. 3. All valves shall be tested with high pressure gas seat test as API-PSL3G. 4. The Choke valve trim shall be designed such that no cavitations and Choke occurred. 5. The trim of the valve shall be with highly erosion resistance as sands and propane presence are expected in the fluids. Vendor shall submit the mechanical properties of trim material (tungsten carbide) for PDO review and approval prior to manufacture. This design of trim has to be independently tested and proved that proposed trims are compatible for most erosive services. 6. The seal material shall be of PTFE or PEEK. No elastomer material is acceptable. 7. Based on the flow condition and fluid properties, vendor shall confirm if multistage trim design is required. 8. Valve material shall fully comply with latest version of SPE 77/302 and API 6A requirements. 9. The fugitive emission test shall comply with SPE 77/312(Latest). 10. The actuator shall be direct connected to Choke Valve. 11. The API 10000# and above rated valve shall be forged material. 12. Vendor to provide Cv calculations for all flow & pressure combinations. 13. Minimum flow shall be 25% of maximum flow or flow corresponding to 10% valve opening whichever is lower. Vendor to confirm this figure to be within normal turndown ratio without causing damage of ports due to erosion / cavitation during normal operation.

1. 2.

Page 1 of 2

APPENDIX- J

CHOKE VALVE DATA SHEET FOR ASME 2500# VALVE TAG NOS

TBA

MEDIUM

NATURAL GAS *

VALVE MANUFACTURER, MODEL NO & SERIAL NO VALVE TYPE CONNECTION SIZE, RATING & QUANTITY

HYDRAULIC ACTUATED CHOKE VALVE - ANGLE TYPE Inlet

Outlet

Quantity(Nos.)

6”-2500# RF

6”-2500# RF

25

END CONNECTIONS

Flanged, smooth finish. The flange dimension and flange face finish shall be as per ASME B16.5

BODY & BONNET MATERIAL

DUPLEX ST. ST. ( ASTM A 182 F51/UNS S31803) Note-8

VALVE DESIGN STANDARD

API 6A ( latest edition)

DESIGN PRESSURE & TEMPERATURE

SEE PROCESS DATA SHEET

DESIGN TEMPERATURE

-20/120 deg C

TRIM TYPE SEAT TIGHTNESS LEAKAGE

AS PER API 6A ( METAL TO METAL SEAT)

MATERIAL NOZZLE

TUNGSTEN CARBIDE

MATERIAL RETAINING SLEEVE

INCONEL 625

MATERIAL FLOW RING

TUNGSTEN CARBIDE

MATERIAL BODY & BONNET

DUPLEX ST. ST. ( ASTM A182 F51/UNS S31803) API 6A 718

MATERIAL STEM MATERIAL PISTON GUIDE

EXTERNAL SLEEVE AND CAGE

DUPLEX ST. ST. ( ASTM A 182 F51/UNS S31803)

MATERIAL BOLTING

ASTM A193-B7M/A194-2HM

MAETRIAL SPRINGS

INCONEL X718

MATERIAL SEAT

TUNGSTEN CARBIDE

SEALS

RPTFE/PEEK ( Note 6)

MOUNTING POSITION

HORIZONTAL

TEST & INSPECTION STANDARD

API 6A, PSL3G AND PR2 ( Note 2,3)

TEST & INSPECTION CERTIFICATION & MATERIAL CERTIFICATE MATERIAL REQUIREMENT, SOUR SERVICE

NACE MR-01-75/ISO 15156 & SP 2041

POSITION INDICATOR CV CALCULATED(MIN/NOR/MAX)

REQUIRED *

ISO 10474 3.2

CV SELECTED (100% OPENING)

*

TRIM % OPEN (MIN/NOR/MAX) VALVE CHARACTERISTICS

* EQUAL %

NOTES: * Vendor to provide completed data sheet. All valves shall be as tested as per API PSL3G and PR2. Vendor shall produce valve performance qualification certificate as per PR2. 3. All valves shall be tested with high pressure gas seat test as API-PSL3G. 4. The Choke valve trim shall be designed such that no cavitations and Choke occurred. 5. The trim of the valve shall be with highly erosion resistance as sands and propane presence are expected in the fluids. Vendor shall submit the mechanical properties of trim material (tungsten carbide) for PDO review and approval prior to manufacture. This design of trim has to be independently tested and proved that proposed trims are compatible for most erosive services. 6. The seal material shall be of PTFE or PEEK. No elastomeric material is acceptable. 7. Based on the flow condition and fluid properties, vendor shall confirm if multistage trim design is required. 8. Valve material shall fully comply with latest version of SPE 77/302 and API 6A requirements. 9. The fugitive emission test shall comply with SPE 77/312(Latest). 10. The actuator shall be direct connected to Choke Valve. 11. The API 10000# and above rated valve shall be forged material. 12. Vendor to provide Cv calculations for all flow & pressure combinations. 13. Minimum flow shall be 25% of maximum flow or flow corresponding to 10% valve opening whichever is lower. Vendor to confirm this figure to be within normal turndown ratio without causing damage of ports due to erosion / cavitation during normal operation.

1. 2.

Page 2 of 2

APPENDIX - K

APPENDIX - K PROCESS DATA FOR CHOKE VALVE SIZING – ASME 2500#

SERVICE

PROCESS DATA RUN NUMBER FLUID TYPE TEMPERATURE °C

HP GAS FLOW LINE INLET

OUTLET

Year 2014

Year 2014

Depletion Year HYDROCARBON

Depletion Year HYDROCARBON

70 -90

70 -90

70 -90

70 -90

0

0

0

0

48.2

48.2

48.2

48.2

VAPOR PRESSURE Bar (a)

95

95

95

95

(liquid) DENSITY OP. COND. Kg/m3 (liq/vap)

663.9/81.5 3

669/70.44

703.1/32.81

735.8/17.48

COMPRESS. FACTOR

0.9

0.91

0.95

0.97

MOLECULAR WEIGHT

21.88

21.88

21.88

21.88

VISCOSITY CP (liq/vap)

0.29/0.016

0.29/0.016

0.33/0.014

0.42/0.014

FLOW MAX Kg/Hr

23925.66

17127.53

23925.66

17127.53

(MMscmd) FLOW MIN Kg/Hr

(0.7) 685.10

(0.5) 685.10

(0.7) 685.10

(0.5) 685.10

(MMscmd)

(0.02)

(0.02)

(0.02)

(0.02)

% GAS (Wt%)

CRITICAL PRESS. Bar (a)

PRESS. AT FLOW MAX Bar (a)

70

30

70

30

PRESS. AT FLOW MIN. Bar (a)

70

30

70

30

DP MAX CLOSED VALVE Bar (g)

300

300

300

300

Notes : 1) CITHP of the well taken as 300 barg as per the data given by the reservoir engineers 2) Each well is designed for 0.7 mmscmd hydrocarbon flow rate 3) The design temperature of the choke Valve -20˚C / 120 ˚C. 4) All compositions include free water. For composition see Appendix M

Sheet 1 of 2

APPENDIX - K

PROCESS DATA FOR CHOKE VALVE SIZING – API 10,000

TAG No.

Tag numbers to be provided later

QUANTITY: SERVICE

HP GAS FLOW LINE WELLS

PROCESS DATA

INLET

RUN NUMBER Composition Note 1

year 2012 Barik

Amin

FLUID TYPE Operating temperature °C (Note 3) % GAS (Wt %) CRITICAL PRESS. bara

Commi ngled

year 2013 Comm ingled

OUTLET year 2014 Commin gled

Year 2015 Commi ngled

Amin

HYDROCARBON + WATER

year 2013 Barik

Comm ingled

year 2013 Commin gled

year 2014 Commin gled

Year 2015 Comm ingled

HYDROCARBON + WATER

90

90

90

90

90

90

72

81

80

84

84

84

95

45

63

59

58

59

95

45

57

59

59

59

63.6

324

52

52

52

52

63.6

324

52

52

52

52

-66.8

83.7

-5.8

-5.8

-5.8

-5.8

-66.8

83.7

-5.8

-5.8

-5.8

-5.8

229.9 (Note 4)

199@ 37.8˚C

198@ 37.8 ˚C

106 @ 37.8 ˚C

92 @ 37.8 ˚C

83 @ 37.8 ˚C

112.9 (Note 4)

95 @ 37.8 ˚C

95 @ 37.8 ˚C

72 @ 37.8 ˚C

63 @ 37.8 ˚C

53 @ 37.8 ˚C

Critical Temperature, ˚C VAPOR PRESSURE bara (liquid) DENSITY OP. COND. Kg/m3 (liq/vap) COMPRESS. FACTOR

965/ 150

528/ 236

577/ 219

625/ 111

636/95

643/86

960/74.87

618/101

637.6/ 97.94

657/72

665/63

674/ 53.5

0.9093

0.88

0.8332

0.8422

0.8525

0.8601

0.9037

0.8353

0.8427

0.8661

0.8797

0.8922

MOLECULAR WEIGHT

18.09

35.91

30.14

30.14

30.14

30.14

18.09

35.91

30.14

30.14

30.14

30.14

0.3113/ 0.002

0.4404/ 0.002

0.4889/ 0.0027

0.5515/ 0.0018

0.5659/ 0.0017

0.5758/ 0.0016

0.3113/ 0.001

0.5876/ 0.0017

0.6118/ 0.0017

0.6048/ 0.0015

0.5357/ 0.0016

0.3290/ 0.0015

15940 (0.5)

53111 (1)

53111 (1)

53111 (1)

53111 (1)

53111 (1)

15940 (0.5)

53111 (1)

53111 (1)

53111 (1)

53111 (1)

53111 (1)

9562 (0.3)

26555 (0.5)

26555 (0.5)

26555 (0.5)

26555 (0.5)

26555 (0.5)

9562 (0.3)

26555 (0.5)

26555 (0.5)

26555 (0.5)

26555 (0.5)

26555 (0.5)

229.9

229.9

229.9

129

113

103

112.9

112.8

113.4

87.4

77.3

66.2

229.9

229.9

229.9

129

113

103

112.7

112.5

113.2

72.7

59.6

43.6

500

500

500

500

500

500

500

500

500

500

500

500

VISCOSITY CP (liq/vap) FLOW MAX Kg/h (mmscmd) FLOW MIN Kg/h (mmscmd) PRESS. AT FLOW MAX, bara PRESS. AT FLOW MIN. bara DP MAX CLOSED VALVE Bar (g) (Note 2) Notes :

1) All compositions include free water. For composition see Appendix D 2) CITHP of the wells is 500 bara 3) The design temperature of the choke valve is 120 ˚ C/ -20˚C 4) FTHP/back pr is reported as vapour pressure since the fluid has got 95% vapour.

Sheet 2 of 2

APPENDIX - L Choke Valve Panel Schematic diagram

APPENDIX – M

WET GAS COMPOSITION

Table 1: ASME 2,500 PSI rating, Area compositions

Components Nitrogen Carbon dioxide Methane Ethane Propane I Butane N Butane I pentane N Pentane Hexanes Heptanes Octants Nonanes Decanes Undecanes Water Total

Mole % 8.21 0.31 83.63 3.84 1.76 0.49 0.57 0.23 0.21 0.22 0.14 0.05 0.02 0.019 0.01 0.3 100

Sheet 1 of 3

APPENDIX – M

WET GAS COMPOSITION

Table 2: API 10,000 PSI Rating, Components

Units

Composition

NBP

MW

Liq Density

C

kg/kmol

kg/m3

1.5613

82.3

89.07

726.8

1.6288

132.63

113.5

767.1

179.61

145

799.1

227.29

185.3

829

289.45

236.5

858.7

357.31

301.7

889.4

433.4

384.4

921.5

540.6

512.2

962.6

o

H2O

mol%

H2S

mol%

CO2

mol%

Nitrogen

mol%

Methane

mol%

Ethane

mol%

Propane

mol%

i-butane

mol%

n-butane

mol%

i-pentane

mol%

n-pentane

mol%

n-hexane

mol%

PC6

mol%

PC7

mol%

PC8

mol%

PC9

mol%

1.4347 1.0972

PC10

mol%

0.709

PC11

mol%

0.3798

mol%

0.1520

mol%

0.0590

PC12 PC13

8.58 0 0.98 3.81 59.67 6.38 3.012 0.911 1.308 0.5908 0.692 7.0216

Note: See next sheet for commingled composition.

Sheet 2 of 3

APPENDIX – M

WET GAS COMPOSITION

Table 2C: Commingled

Components

Units

Composition

NBP

MW

Liq Density

C

kg/kmol

kg/m3

1.0996

82.3

89.07

726.8

1.1471

132.63

113.5

767.1

179.61

145

799.1

227.29

185.3

829

289.45

236.5

858.7

357.31

301.7

889.4

433.4

384.4

921.5

540.6

512.2

962.6

o

H2O

mol%

H2S

mol%

CO2

mol%

Nitrogen

mol%

Methane

mol%

Ethane

mol%

Propane

mol%

i-butane

mol%

n-butane

mol%

i-pentane

mol%

n-pentane

mol%

n-hexane

mol%

PC6

mol%

PC7

mol%

PC8

mol%

PC9

mol%

1.0105 0.7727

PC10

mol%

0.4993

PC11

mol%

0.2675

mol%

0.1070

mol%

0.0416

PC12 PC13

4.817 0 1.1212 3.5496 69.86 5.4637 2.4793 0.759 1.0230 0.4623 0.5182 4.9975

Sheet 3 of 3

REQUISITION FOR VENDOR ENGINEERING DOCUMENTS Project Description Integrated Hydraulic Wellhead Control Panel

PO / Enquiry No. APPENDIX - N

LATER

Principal

Contractor

Address Attn: Petroleum Development Oman LLC. P.O.BOX 81 POSTAL CODE 113 Muscat, Sultanate of Oman

Address LATER

Review Codes R-1 Documents to be Reviewed by Principals Project Engineer before Final Issue R-2 Documents to be Reviewed by Contractors Project Engineer before Final Issue R-3 Documents to be Reviewed at Vendors Office / Works by Auditor / Inspector approved by Contractor before Final Issue

Approval and Final Issue Approval Approval - Two (2) Copies Copies to to the the Principals Principals Project Project Engineer // Two Two (2) (2) Copies to to the the Contractors Contractors Project Project Engineer

Final Final Issue - One (1) (1) Copy Copy Principals Project Project Engineer Engineer / One One (1) (1) Copy Copy Contractors Project Engineer / One Operations & Maintenance Maintenance // One (1) (1) Copy Copy Principals Document Document Control / One One (1) (1) Copy Principals Operations One One (1) (1) Copy Copy Principals Principals Commissioning / One One (1) (1) Copy Copy Principals Principals Engineering Support Support + + Five (5) (5) Data to Principals Principals Project Project Engineer Engineer / Operations Operations & Data CD's containing all all document files files distributed distributed to Maintenance Maintenance // Commissioning // Document Control and and the the Contractor Contractor Project Project Engineer

Manuals Vendor shall provide the following Manuals as required: Design Book O&M Manual Certification & Manufacturing Data Book Where indicated the appropriate information shall be included within these documents.

General Remarks Invoice Invoice must must certify that that the following drawings drawings and and engineering documents documents have been been dispatched dispatched to to all all parties concerned. concerned. Any Any deviation deviation from from the timing for submittal of documents must must be be notified notified and approved by the the Contractors Contractors Project Project Engineer. Fabrication Fabrication shall shall not commence until Approved Approved drawings have have been Issued Issued for for Construction. Construction. each each document document shall bear bear the the Item // Tag and and Reference Reference Number Number and shall be dispatched by the approved approved method. method. Units Units / Dimension Dimension used on Engineering Engineering Documents Documents shall be be SI, SI, with the the exception of standardixed imperial imperial nominal siases siases of pipe, valve valve flanges, bolting, bolting, etc. etc. Documents Documents shall shall be in in the the English English language. The The following following standard standard sizes shall shall be use A4 A4 / A3 A3 / A2 A2 / A1

PDO Form GU-556_01

Sheet 1 of 4

21140-00, 4397010 Rev -A Appendix L -RVED

REQUISITION FOR VENDOR ENGINEERING DOCUMENTS Issued with BID

Review Code

Required in Manual

Date Required

CONTROL DOCUMENTS 1

Vendor Document Schedule Fabrication / Production / Delivery Schedule

R1, R2, R3

YES

2

R1, R2, R3

YES

3

Table of Contents for Manuals (Design Book, Data Book, O&M)

R1, R2, R3

YES

4

Project Management Organisation

R1, R2, R3

YES

5

Progress Reports

R1, R2, R3

YES

6

Variance Proposal (as required)

YES

7

List of Sub-Suppliers

YES

8

Major Sub-Order Schedule

R1, R2 R1, R2 R1, R2, R3

YES

R1, R2, R3

YES

R1, R2, R3

YES

YES

R1, R2, R3

YES

YES

R1, R2, R3

YES

ARRANGEMENTS DRAWINGS 1

General Arrangement Drawings (including Interface Details)

2

Foundation Loading Diag, & Support Details

YES

SYSTEM DIAGRAMS & DATA SHEETS 1

PEF/UEF

2

PEFS/UEFS

3

C&E diagrams

4

Alarm & Trip Settings

5

Heat & Mass Balance Sheets

6

Key SLD's

7 8

Schematics Bill of Materials

9

Utilities Schedule

10

Weight Data Sheet

R1, R2, R3

YES

11

Equipment Data Sheets

YES

R1, R2, R3

YES

12

Elec. Power Supply Requirements Data Sheets

YES

R1, R2, R3

YES

13

Schedule of Elec / Instr Equipment in Hazard Areas YES

R1, R2, R3

YES

R1, R2, R3

YES

14

Detailed Description of Operation

15

Noise Level Data Sheets

16

Enclosure Ventilation Requirements

17

Piping Isometrics

18

Allowable Nozzle Loads

19

Material Safety Data Sheet

20

Piping Line List / Tie-in Schedule

DETAILED DRAWINGS 1

Cross Section Drawing/Exploded View Diagram/Assembly Drawing w/BOM

2

Mechanical Seal Drawings

3

Shaft Alignment Drawings

4

Name Plate Format Drawings

5

Vessel Fabrication Drawings

ELECTRICAL & INSTRUMENTATION DRAWINGS 1

Electrical/Instrument/Communication Power Supply & Earthing Diagrams

R1, R2, R3 YES

2

Inst/Electrical Panel Detail Drawing

R1, R2, R3 YES

3

Instrument/Electrical Logic Diagram

4

Cable Block Diagrams

5

Cable Schedule

6

Instrument Termination & Hook Up Details

7

Loop Diagrams

8

Software System Diagrams (Configuration & Displays)

9

Instrument Data Sheets

10

Electrical Interconnection Diagrams

11

Functional Design Specification

12

Instrument index

13

I/O Allocation

14

Electric Motor General Arrangement Drawings

15

Instrumentation Outline / Arrangement Drawings

PDO Form GU-556_01

R1, R2, R3 YES

YES

Sheet 2 of 4

R1, R2, R3 YES



Review Code

Required in Manual

Date Required

CALCULATIONS & PERFORMANCE DATA 1

Design Book

2

Pressure Vessel/Tank Mech Calcs

3

Safety, Control and Metering Calcs( Control Valve calculations)

YES

R1, R2, R3 YES

4

Miscellaneous Calculations( Hydraulic Pressure, Volume required, Motor ratings etc)

YES

R1, R2, R3 YES

5

Structural Calculations

6

Lateral/torsional Critical Speed Analysis Reports

7

Performance & Rating Calculations

8

Rotating Equipment Performance Curve

9

Motor Performance Curve

10

Superimposed Torque/Speed Curve for Driver/Driven Equipment

HANDLING, INSTALLATION AND SITE PRESERVATION 1

Site Planning, Erection & Installation Procedures

R1, R2, R3 YES

2

Handling & Shipping Procedure

R1, R2, R3 YES

3

Unpacking and Preservation Procedure

R1, R2, R3 YES

MANUFACTURING / QUALITY PROCEDURES 1

Contract Quality Plan

R1, R2, R3 YES

2

Contract Inspection & Test Plan

R1, R2, R3 YES

3

Quality Manual

4

Detailed Fabrication Drawings

5

Weld Proc Specs (WPS) & Qual Records (WPQR)

6

Non Destructive Examination Procedure

R1, R2, R3 YES

7

Manuf. Procedures Including Heat Treatment

R1, R2, R3 YES

8

Pressure Test Procedures

R1, R2, R3 YES

9

Performance and Acceptance Test Procedures

R1, R2, R3 YES

10

Surface Prep and Painting Procedure / Specification

11

Weighing Procedure

12

Repair Instructions / Procedures

R2, R3

YES

COMMISSIONING, OPERATING, MAINTENANCE & SPARES 1

Installation, Operating & Maintenance (IOM) Manual

2

Lube Oil & Operating Fluid Schedules

3

Recommended Start-Up & Commissioning Spares List

YES

R1, R2, R3 YES

4

Recommended Spares - 2 years Operating

YES

R1, R2, R3 YES

5

Pre Commissioning/Commissioning Procedures

R1, R2, R3 YES

6

Vendor Catalogues / Product Information

R1, R2, R3 YES

7

List of Special Tools & Tackles

R1, R2, R3 YES

R1, R2, R3 YES

CERTIFICATION 1

Certification and Manufacturing Data Book

R1, R2, R3 YES

2

Equipment Haz Area Certificates & Schedule

R1, R2, R3 YES

3

Manufacturing Procedure Qualification Test

4

Performance Test Report / Results

R1, R2, R3 YES

5

Factory Acceptance Test Report

R1, R2, R3 YES

6

Vibration Report

7

Noise Report

8

Weight Report (for equipment > 50 kg)

PDO Form GU-556_01

Sheet 3 of 4



Review Code

Required in Manual

Date Required

TEST & INSPECTION REPORTS 1

Material Test Certificates

2

Welder Performance Qual Certificates

3

NDE Operator Qualifications & Certificates

4

Production Test Results (Including welding)

R1, R2, R3 YES

5

NDE Records

R1, R2, R3 YES

6

Heat Treatment Records

R1, R2, R3 YES

7

Material Traceability Records (Location Drwg)

8

Pressure Test Certificate

R1, R2, R3 YES

9

Instrument Test/Calibration Certificate

R1, R2, R3 YES

10

Dimensional Report

R1, R2, R3 YES

11

Lifting Equipment Test Certificates

12

Certificate of Compliance to Code

13

Electrical Type Tests / Ingress Protection

R1, R2, R3 YES

14

Painting/Insulation Inspection Reports

R1, R2, R3 YES

15

Fire Test Reports/Certificates

R1, R2, R3 YES

16

Hardness Test Reports

R1, R2, R3 YES

17

Corrosion Test Results

18

Inspection Release Certificate

19

Baseline Thickness Measurement Schedules

20

Visual Inspection Reports

R1, R2, R3 YES

R1, R2, R3 YES R1, R2, R3 YES

SHIPPING & PACKING DOCUMENTS 1

Shipping & Packing Documents

2

Hazardous Material Shipping Certificates

3

Special Lifting and Handling Procedures

R2, R3

YES

4

Dims, Weights and CofG on Packing List

R2, R3

YES

5

Special Export Packing

R2, R3

YES

6

Export Certificates

R2, R3

YES

R2, R3

YES

Note: 1. All the document as mentioned here in to the reviewed by vendor and exemptions to be taken in case which are deemed as not applicable for this project. 2. Vendor to ensure the following: a. All the manufacturing drawings, calculations and sizing as listed above shall be submitted within 3 weeks of award of contract. b. All the Schematics, Logic Drawings Control Logic Narratives shall be submitted within 8 weeks of award of contract. 3. Weekly Progress Report ( Update Schedule), In case of delay, the Vendor shall immediately inform PDO in writing. 4. Details of Inspection by 3rd party & or client will be decided during Engineering.

PDO Form GU-556_01

Sheet 4 of 4


Project No: 21140 Document No: 4397010 Rev No: A Title: Wellhead Control Panel

APPENDIX-M

PDO APPROVED VENDOR LIST FOR WHCP ( EXTRACT OF AVME LIST) ITEM DESCRIPTION

ORIGINAL EQUIPMENT MANUFACTURER

AVME 30.320 - INTEGRATED HYDRAULIC WELL HEAD CONTROL & SAFEGUARDING SYSTEM - SSI 60SDGB 40 14 16 9 ACTUATORS, HYDRAULIC, CV Frames stated that for any engineered products not interested to go for OLB FRAMES ENERGY SYSTEMS BV REV APRIL 02. WILMAX CONTROL SYSTEMS CONSULT CFDH PETRICO PTE LTD USE IPF VALVES FROM VAC MSP/DRILEX SHANGHAI CO LTD SULAIMAN PETROTECH ME FZE INNOVATIVE TECHNOLOGIES (SYNTECH) MOKVELD

COUNTRY OF MANUFACTURE

HOLLAND SINGAPORE SINGAPORE CHINA UAE

AVME 31.111 - PUSHBUTTON / SWITCH EX - SSI 60CAAA 41 11 INSTRUMENT SYSTEMS 8040 INSTALLATION SWITCH EX38, EX42, EX28P. REV JUNE 99.

STAHL ABB

AVME 31.112 - INDICATOR LIGHT EX - SSI 60CAAA 41 11 INSTRUMENT SYSTEMS 8013 DIODE INDICATING LAMP

STAHL TOP WORX BEKA ASSOCIATES LTD

USA UK / IRELAND

AVME 31.242 - FUSIBLE PLUG HEAT DETECTION - SSI 60PACA 46 19 15 2 DETECTORS, HEAT, THERMAL 100 & 140 DEG. C. ALSO THROUGH PETROTECH SIGMA 71, 124 & 138 DEG. C (100 C TANKROOF). FP, FTA, FSC, FSP CAJON

AVME 33.211 - LEVEL FLOAT (WITH SWITCHING FUNCTION) EEX D - SSI 60GAAB 41 11 37 10 LEVEL INSTRUM.FLOAT LOCAL INDICATION, MAGNETIC COUPLING. SIMCO KSR H&H MEASUREMENT BV LOCAL INDICATION, MAGNETIC COUPLING. MAGNETEL MAGNETROL INTERNATIONAL N.V LOCAL INDICATION, MAGNETIC COUPLING. MS30 K-TEK

HOLLAND BELGIUM

AVME 34.041 - TRANSMITTER DP, GP, AP- SMART -EEX D - SSI 60JDAA 41 11 24 TRANSMITTERS, PRESSURE DP-HARP EJAXXXA SERIES

YOKOGAWA MIDDLE EAST B.S.C

BAHRAIN

MODEL LD 301 FOR MONITORING PURPOSE ONLY

SMAR EQUIPAMENTOS INDUSTRIAIS LTDA

BRAZIL

ST3000 HART. REV NOV. 97. ST3000 100 / 900 SERIES. REV JUN. 99

HONEYWELL ABB INDUSTRIES LLC

UAE

YAMATAKE CORPORATION

JAPAN

IGP10/20/25/50; IAP10/20; IDP10/25/50; 143DP; 141 GP

THE FOXBORO COMPANY

USA

143 DP SERIES (BIA 408). REV NOV. 97

FOXBORO-ECKARDT AG YAMATAKE CORPORATION

JAPAN

GP DIRECT MOUNTED SUPPLIED WITH 1/2" NPT MALE ADOPTER, 2088 IND ICA ONLY

EMERSON FZE

UAE

3051C. 3051C WITH HJ ADAPTOR

EMERSON FZE

UAE ENDRESS + HAUSER GMBH + CO KG INSTRUMENTS INTERNATIONALGERMANY

AVME 34.051 - TRANSMITTER DP, GP, AP - FIELDBUS - EEX D - SSI 60JDAA 41 11 24 TRANSMITTERS, PRESSURE DP-HARP EJAXXXA SERIES MODEL LD 302 FOR MONITORING PURPOSE ONLY ST3000

3051C WITH HJ ADAPTOR. REV JUN. 99

YOKOGAWA MIDDLE EAST B.S.C SMAR EQUIPAMENTOS INDUSTRIAIS LTDA YAMATAKE CORPORATION HONEYWELL EMERSON FZE

BAHRAIN BRAZIL JAPAN

UAE ENDRESS + HAUSER GMBH + CO KG INSTRUMENTS INTERNATIONAL GERMANY

AVME 34.090 - PRESSURE SWITCH, IPF CLASS I AND II ONLY - SSI 60JDCA 30 21 19 07 SWITCHES, PRESSURE HYDRAULIC PILOT APPROVED BY SERIES ONLY

HIGH PRESSURE (700 BAR). PRISCO SWITCH

HALLIBURTON ASHCROFT INSTRUMENTS BARKSDALE CONTROL PRODUCTS BOURDON HAENNI BARBER INDUSTRIES SOR INC

AVME 34.095 - PRESSURE SWITCH, EEX, IPF CLASS III AND ABOVE - SSI 60JDCA 30 21 19 07 SWITCHES, PRESSURE PISTON. 6905PE-XX-7042 CCS BARKSDALE CONTROL PRODUCTS APPROVED BY SERIES ONLY ASHCROFT INSTRUMENTS PISTON. SPECTRA 12. REV NOV. 97 UNITED ELECTRIC SOR INC

GERMANY GERMANY FRANCE CANADA USA

GERMANY GERMANY USA

AVME 34.110 - BOURDON - SSI 60JGAA 41 11 24 03 GAUGES, PRESSURE

REV JAN'01

REV MARCH '02

STEWART - BUCHANAN GAUGES LIMITED OBSERVATOR RUEGER BOURDON HAENNI ABB INDUSTRIES LLC PURO ELECTTIC GOA INSTRUMENTS GOA BUDENBERG GAUGE CO LTD WIKA ALEXANDER WIEGAND THE BRITISH ROTOTHERM COMPANY LTD ASHCROFT INSTRUMENTS NUOVA FIMA S.P.A PLC WAAREE INSTRUMENTS LTD EERSTE NEDERLANDSE (ENFM) BADOTHERM HOLLAND

UK

FRANCE UAE INDIA UK GERMANY UK GERMANY UK INDIA HOLLAND

AVME 36.250 - CONTROL VALVE - SEVERE SERVICE - CHOKE VALVE - SSI 60SAWB 40 14 16 VALVE, CONTROL, CHOKE, ANSI 900 - 2500 CHOKE. REV JUNE 99. DRAG CHOKE VALVE RZD - RVX CONSULT CFDH (UES) FOR MODEL

VONK VALVES CONTROL COMPONENTS INC (CCI) NIHON KOSO CO. LTD MOKVELD MASTER FLO

Pg 1 of 4

USA JAPAN


APPENDIX-M




AVME 36.290 - CONTROL VALVE - SEVERE SERVICE - ANTI-SURGE - SSI 60SAAA 40 14 16 9 CONTR.VALVE/CHOKE, ACTUATORS & ACCESSORIES CONTROL VALVE ACTUATOR (ASC) SERIES 41000

RZD

DRESSER INC CONTROL COMPONENTS INC NIHON KOSO CO. LTD SEVERN GLOCOM LIMITED MOKVELD

AVME 36.5 - VALVE ACCESSORIES - SSI 60SAAA 40 14 16 9 CONTR.VALVE/CHOKE, ACTUATORS & ACCESSORIES AVME 36.52 - LIMIT SWITCH - SSI 60APBC 30 21 19 28 SWITCH, PROXIMITY, LIMIT AVME 36.521 - LIMIT SWITCH EEX D - SSI 60APBC 30 21 19 28 SWITCH, PROXIMITY, LIMIT ROTARY SWITCH. 496 SERIES DRESSER - MASONEILAN TOP WORX ROTEX AUTOMATION LIMITED YAMATAKE CORPORATION ROTARY SWITCH. WESTLOCK

USA USA JAPAN UK

USA INDIA JAPAN

AVME 36.522 - LIMIT SWITCH EEX I - SSI 60APBC 30 21 19 28 SWITCH, PROXIMITY, LIMIT INDUCTIVE PROXIMITOR. NJ-XX-XX-GK/SN SERIES (FAIL SAFE)

PEPPERL & FUCHS TOP WORX ROTEX AUTOMATION LIMITED ROTARY SWITCH. 496 SERIES. REV SEP.00 DRESSER - MASONEILAN BIFFI ITALIA S.R.L AVME - 36.530 - SOLENOID VALVE- DIRECT ACTING- EEX D - SSI 60SDKA 40 14 16 09 VALVE, SOLENOID OPERATED 3 - WAY 24VDC. NBXB307 (24 V 10 W) ASCO ROTEX AUTOMATION LIMITED 3 - WAY 24VDC. 2401191 / 3960 COIL. HERION 3 - WAY 24VDC. ICO4BBV1SASN (8 W) MAXSEAL LIMITED

USA INDIA

INDIA

AVME 36.532 - SOLENOID - SMART - SSI 60SDKA 40 14 16 09 VALVE, SOLENOID OPERATED ROTEX AUTOMATION LIMITED

INDIA

AVME 36.540 - QUICK EXHAUST VALVE - SSI 60SAAA 40 14 16 9 CONTR.VALVE/CHOKE, ACTUATORS & ACCESSORIES S-XX-QEV. REV MAY 01. EV 250

ITALY USA

BIFFI ITALIA SRL SWAGELOK COMPANY

AVME 36.550 - VOLUME BOOSTING RELAY - SSI 60SAAA 40 14 16 9 CONTR.VALVE/CHOKE, ACTUATORS & ACCESSORIES 3/4 NPT. REV JUNE 99.

FLOWSERVE INC YAMATAKE CORPORATION

USA/INDIA JAPAN

AVME 36.560 - PORT PROTECTOR - SSI 60SAAA 40 14 16 9 CONTR.VALVE/CHOKE, ACTUATORS & ACCESSORIES DE-4. REV NOV 97.

VERSA VALVES BIFFI ITALIA SRL

ITALY

AVME 36.572 - VALVE POSITIONER - SMART - SSI 60SDAA 40 14 16 09 POSITIONERS, CV LOGIX SERIES 1000 12XX-13 VP200. REV MAY 98

ND800/B1 SRD991 (BIA 637). REV MAY 98 SVI. REV JUN. 99 DVC 5000 SERIES (FIELDVUE). REV MAY 98

FLOWSERVE INC YOKOGAWA MIDDLE EAST B.S.C ARCA - REGLER YAMATAKE CORPORATION SAMSON AG NELES - JAMESBURY THE FOXBORO COMPANY DRESSER - MASONEILAN Emerson Process Management

USA/INDIA BAHRAIN GERMANY JAPAN GERMANY

FLOWSERVE INC YAMATAKE CORPORATION SAMSON AG YOKOGAWA MIDDLE EAST B.S.C DRESSER - MASONEILAN Emerson Process Management

USA/INDIA JAPAN GERMANY BAHRAIN

USA

AVME 36.573 - VALVE POSITIONER - FIELDBUS - SSI 60SDAA 40 14 16 09 POSITIONERS, CV LOGIX 1400

YVP. REV JUN. 99 FVP. REV SEP.00 DVC 5000F-SC. REV SEP.00

AVME 36.6 - IPF FINAL ELEMENTS AVME 36.60 - VAC CONSULT CFDH (UES). - 77MAAA 31 25 15 5 VALVE ACTUATORS, GENERAL AVME 36.600 - IPF FINAL ELEMENT ASSEMBLY, CLASSII TO VI (SIL A2 TO 3) - VAC - SSI 77MDCA 31 25 15 5 "VAC CENTRE" WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 (Frames stated that for any engineeredFRAMES productsENERGY not interested SYSTEM to goB.V OLB) VALBART SRL WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 BIFFI ITALIA SRL VAC CENTER, DUBAI WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 DRESSER INC WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 PIBIVIESSE SRL WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 MATCO ASIA PTE LTD WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 MOKVELD WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 POWER MECHANICAL WITH VALVE AVME 36.602 & ACTUATORS AVME 36.604 or AVME 36.605 WILMAX CONTROL SYSTEMS

HOLLAND ITALY ITALY USA ITALY SINGAPORE UK SINGAPORE

AVME 36.601 - IPF FINAL ELEMENT ASSEMBLY CLASS II TO VI (SIL A2 TO 3) - SSI 77MAAA 31 25 15 5 VALVE ACTUATORS (FAST ACTING, LESS THAN 2 SECONDS)

AVME 36.602 - IPF VALVE - SSI 77MAAA 31 25 15 5 "IPF VALVES" TO BE SUPPLIED THROUGH VAC CENTRE ONLY TO BE SUPPLIED THROUGH VAC CENTRE ONLY TO BE SUPPLIED THROUGH VAC CENTRE ONLY TO BE SUPPLIED THROUGH VAC CENTRE ONLY TO BE SUPPLIED THROUGH VAC CENTRE ONLY

BIFFI ITALIA SRL

ITALY

PIBIVIESSE SRL VIRGO VALVES & CONTROLS LIMITED POWER MECHANICAL TYCO VALVES & CONTROLS MIDDLE EAST GROOVE VALBART SRL DAFRAM SPA

ITALY INDIA UK UAE

AVME 36.604 - IPF ACTUATOR PNEUMATIC QUARTER TURN - VAC - SSI 60SDGA 40 14 16 09 ACTUATORS, PNEUMATIC, CV TO BE SUPPLIED THROUGH VAC CENTRE ONLY LEEDEN TO BE SUPPLIED THROUGH VAC CENTRE ONLY (BIFFI) POWER MECHANICAL TYPE G (EMERSON FZE) TO BE SUPPLIED THROUGH VAC CENTRE ONLY BETTIS UK LTD

ITALY ITALY

UK UAE

AVME 36.605 IPF ACTUATOR HYDRAULIC - VAC - SSI 60SDGB 40 14 16 09 ACTUATORS, HYDRAULIC, CV TYPE G (EMERSON FZE) TO BE SUPPLIED THROUGH VAC CENTRE ONLY TO BE SUPPLIED THROUGH VAC CENTRE ONLY (BIFFI)

UAE

BETTIS UK LTD LEEDEN POWER MECHANICAL

UK

Pg 2 of 4


APPENDIX-M




AVME 37.022 - CABLE, XX2.5 MM2, BS-5308 WITH PE OUTER SHEATH, MESC 68.44.14.X03.9 - SSI 68AANA 26 12 16 CABLE, INSTRUMENT/COMMUNICATION REV MAY 98. FORMELY ABERDARE TELECOM NETWORKS / ATC REV MAY 98.

REV MAY 98. Former Company name GORSE

AVME - 37.060 - CABLE XLPE - SSI 68AANA 26 12 16 CABLE, INSTRUMENT/COMMUNICATION REV MAY 98. FORMELY ABERDARE TELECOM NETWORKS / ATC REV MAY 98.

REV MAY 98. Former Company name GORSE REV MAY 98.

AVME 37.153 -JUNCTION BOXES EEX E - SSI 68APAB 30 21 17 9 CABLE, TERMINAL, JUCTION BOXES ACC TO STD DRAWINGS, SS & GRP SERIES 8125. REV JUN. 99 ACC TO STD DRAWINGS, SS. TNUP 343412. REV AUG'01 ACC TO STD DRAWINGS, SS. 07-5106. REV JAN'01 ACC TO STD DRAWINGS. KE06.08.08.06 / 06.41.40.12 SERIES. REV NOV. 97 ACC TO STD DRAWINGS, SS. KEL92XX SERIES. & KEL94XX SERIES ACC TO STD DRAWINGS, GRP. BJE SERIES (LEGRAND). REV SEP.00 ACC TO STD DRAWINGS,GRP TBF3/TBF4A/KESTROL - SS TB10 TO TB14 GRP & SS

THERMO ELECTRIC CBI ELECTRIC ABERDARE ATC TELECOM CABLES TWENTSE KABEL FABRIEK TEKAB CO LTD GRUPO GENERAL CABLE SISTEMAS S.A KEI INDUSTRIES LTD POLYCAB WIRES PVT LTD CORDS CABLE INDUSTRIES LTD KERPEN GMBH & CO. KG INCORE CABLES B.V TC LTD CAVICEL spa FURUKAWA NEXANS FRANCE OMAN CABLES INDUSTRY EHLERS MIDDLE EAST SPECIALIZED CABLES

THERMO ELECTRIC CBI ELECTRIC ABERDARE ATC TELECOM CABLES TWENTSE KABEL FABRIEK KEI INDUSTRIES LTD CORDS CABLE INDUSTRIES LTD POLYCAB WIRES PVT LTD INCORE CABLES B.V GRUPO GENERAL CABLE SISTEMAS S.A TC LTD CAVICEL S.P.A FURUKAWA NEXANS FRANCE OMAN CABLES INDUSTRY EHLERS MIDDLE EAST SPECIALIZED CABLES

STAHL TECHNO (check if active) BAR-TEC (check if active) ROSE SYSTEMTECHNIK MIDDLE EAST RITTAL SKIL CONTROLS (check if active) RTK ENGINEERING GOVAN INDUSTRIES PTY LTD WALSALL Ltd

AVME 37.160 - TERMINALS, FIELD MOUNTED EEX E - SSI 68ASCA 30 21 18 1 TERMINALS, RAIL MOUNTED POWER. GSK-S1-KRI PHOENIX CONTACT GLAZED CERAMIC. SSK/0525-KER EX PHOENIX CONTACT FUSED (POLYAMIDE). SAK RTK ENGINEERING SAK 2.5 RTK ENGINEERING

SOUTH AFRICA UAE SPAIN INDIA INDIA INDIA GERMANY HOLLAND UK ITALY FRANCE OMAN KSA

SOUTH AFRICA INDIA INDIA INDIA HOLLAND SPAIN UK ITALY FRANCE OMAN KSA

UAE

UK AUSTRALIA UK

UK UK

AVME 37.240 - NON RETURN VALVE - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS SERIES IR 4000/5000/6000, XPR, APR66, MIR700 & NPR4100

AVME 37.310 - INSTRUMENT TUBING - SSI 60TJAC 41 11 INSTRUMENT MOUNTING ASSEMBLIES STAINLESS STEEL ASTM A269-TP 316L. 3/8 IN., 1/4 IN., 1/2IN OD

PARKER HANNIFIN plc (PARKER)

UK

SWAGELOK COMPANY SAFELOK COMPONENTS LIMITED MAXIMATOR GMBH

USA UK GERMANY

SWAGELOK COMPANY

USA

AVME 37.320 COMPRESSION FITTINGS - SSI 60TJAC 41 11 INSTRUMENT MOUNTING ASSEMBLIES STAINLESS STEEL ASTM A269-TP 316L

AVME 37.321 - SUPER PRESSURE FITTINGS (> 10.000 PSI) - SSI 60TJAC 41 11 INSTRUMENT MOUNTING ASSEMBLIES GLAND AND COLLAR, CONED AND LEFT-HANDED THREADED. REV AUG 00.

GLAND AND COLLAR, CONED AND LEFT-HANDED THREADED GLAND AND COLLAR, CONED AND LEFT-HANDED THREADED. UP TO 60.000 PSI. REV MAY 98. GLAND AND COLLAR, CONED AND LEFT-HANDED THREADED. REV MAY 98.

BUTECH PARKER HANNIFIN plc (PARKER) HASKEL ENERGY SYSTEMS LIMITED AUTOCLAV SNO-TRIK SWAGELOK COMPANY

UK UK

USA

AVME 37.410 - HIGH PRESSURE REGULATORS - SSI 60SAMA 40 14 16 09 REGULATORS, PRESSURE, REDUCING C AND CO SERIES

PARKER HANNIFIN plc (PARKER) Tescom

UK

PARKER HANNIFIN PLC

UK

AVME 37.430 - INSTRUMENT VALVES - NEEDLE - SSI 60SATA 40 14 16 9 VALVE, NEEDLE

REV JUNE 99. KENMAC

OLIVER VALVES LIMITED

UK & IRELAND

SAFELOK COMPONENTS LIMITED SABRE WHITEY SWAGELOK COMPANY

UK

USA

AVME 37.431 - INSTRUMENT VALVES - BALL - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS UK

PARKER HANNIFIN PLC

40, 83 SERIES


UK & IRELAND

SAFELOK COMPONENTS LIMITED SABRE WHITEY

UK

Pg 3 of 4


APPENDIX-M




AVME 37.432 - INSTRUMENT VALVES - CHECK - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS UK

PARKER HANNIFIN PLC

AVME 37.433 - INSTRUMENT VALVES - GAUGE / ROOT - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS 108-06. REV MAY 98. REV MAY 98. SS-6PNXGM8-F8. REV JUNE 99. VX4L-44-NT-611-10HT

ASTAVA


UK & IRELAND

WHITEY SABRE

AVME 37.7 - INSTRUMENT MANIFOLD BLOCKS / VALVES AVME 37.71 - 60.98.56.207.9 1/4" NPTF>3/8"OD AVME 37.710 - MANIFOLD - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS SABC1HZB87AS. REV MAY 98. M-927SCT-EZ-1 (AF73,AF93,G2,G3,GB,WL,TH,VSH,W9). REV MAY 98. 492-06/SL38+906/P NUMBER 1.24.62 REV A. Y43S/FV/1V/25F/25F/AT-EV/MTG/NA/SSB/BKTC85. REV MAY 98. F48BOA7A15T0200 + 5A11-PH-069. REV MAY 98. MX10-2-NT-611-6HT-3S-SG RMP(OMAN). ERV MAY 98.

PARKER HANNIFIN PLC PGI ASTAVA

UK HOLLAND


UK & IRELAND

THOMPSON VALVES SABRE THE BRITISH ROTOTHERM COMPANY LIMITED MULTI INSTRUMENTS B.V TYCON

UK HOLLAND

PARKER HANNIFIN PLC ASTAVA

UK HOLLAND


UK & IRELAND

THOMPSON VALVES SABRE THE BRITISH ROTOTHERM COMPANY LIMITED MULTI INSTRUMENTS B.V TYCON

UK HOLLAND

PARKER HANNIFIN PLC ASTAVA

UK HOLLAND


UK & IRELAND

HOLLAND UK

A26TVIS-2/A-SG-SK-I-MB6.S.SP. REV MARCH 02.

THOMPSON VALVES SABRE MULTI INSTRUMENTS B.V THE BRITISH ROTOTHERM COMPANY LIMITED TYCON

AVME 37.780 - MANIFOLD 2003 - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS DN50 3 X 1/4" NPTF > 3/8" VENT 1/4 > 3/8". 6-F-12-660-00-SV. REV JUNE 99.

ASTAVA

HOLLAND


AVME 37.72 - 60.98.56.217.9 1/4" NPTF>3/8"OD AVME 37.720 - MANIFOLD - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS SBBC1HZB87AS. ERV MAY 98. 494-06/SL38+906/P NUMBER 1.24.63 REV 0. YDV44S/FV/25F/25F/AT-V/MTG/NA/SSB/BKTC85. REV MAY 98. F49BOA7A15T0200 + 5A11-PH-069. REV MAY 98. MX11-2-NT-611-6HT-3S-SG RMP(OMAN). REV MAT 98.


AVME 37.75 60.98.56.315.9 1/4" NPTF>3/8"OD 1/2" NPTF AVME 37.750 - MANIFOLD - SSI 60TAAA 41 11 INSTRUMENT INSTALLATION MATERIALS SFBCDC1B87AS. REV MAY 98. 298-06/SL38+906/P NUMBER 1.24.64 REV 0. G12AFS/25F/50F/25F/AT-V/MTG/NA/SSB/BKTC F20BOA7A302AL + 5A11-PH-070. REV MAY 98. MX26-42-NT-611-6HT-3S-SG RMP(OMAN). REV MAY 98.

Pg 4 of 4

APPENDIX P : TABLE OF COMPLIANCE (TOC)

The Vendor shall complete the following Table Of Compliance:

Date

:

Project

:

Indent Number

:

Supplier

:

PARAGRAPH NUMBER

1 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 2 3 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.3 3.4 3.4.1 4 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5

ENHANCMENT

CINFORMS YES / NO

VARIATION (IF ANY)

ALTERNATIVE

EXCEPTION

NOTED

4.1.6 4.1.7 4.1.8 5 5.1 5.2 5.3 5.3.1 5.3.1.1 5.3.1.2 5.3.1.3 5.3.1.4 5.3.2 5.3.3 5.4 5.5 5.5.1 5.5.2 5.5.2.1 5.5.2.2 5.5.3 5.5.3.1 5.5.3.2 5.5.3.3 5.5.3.4 5.5.4 5.5.4.1 5.5.4.2 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 7.2 8 8.1 8.1.1 8.1.2 8.1.3

8.1.4 8.1.5 8.1.6 8.1.7 8.1.8 9 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7 10 11 11.1 11.2 11.3 11.4 11.5 11.5.1 11.5.2 11.5.3 11.5.4 12 13 14 15 16 17 Appendix - A Appendix - B Appendix - C Appendix - D Appendix - E Appendix - F Appendix - G Appendix - H Appendix - I Appendix - J Appendix - K Appendix - L

Appendix - M Appendix - N Appendix - O Appendix - P

Definition of the Column headings is as follows: Enhancement: Feature fully complies with the specification and offers more functionality. The supplier shall give full description supported by technical drawings. Conforms: Feature fully complies to the specification supported by technical drawings/third part certifications. Variation: Feature offers the same functionality in a different execution. The supplier shall give a full description supported by technical drawings. Alternative: Feature does not meet the specification but functional requirements can be met in a different way. The Vendor shall give full description supported by technical drawings. Exception: The supplier cannot meet the specification. Noted: The relevant paragraph in the specification does not contain any requirements.

Full Revised Specification for Well Head Control Panel

Recommend Documents