Instrument Design Basis - offshore platform

FRONT-END ENGINEERING DESIGN (FEED) SERVICE FOR BK-TNG WELLHEAD PLATFORM

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INSTRUMENT DESIGN BASIS Page 2 of 32

TABLE OF CONTENTS 1.0

GENERAL

4

1.1

Background

4

1.2

Purpose of document

4

1.3

Definitions and Abbreviations

4

1.4

Reference Documents

7

2.0

CODES & STANDARDS

9

2.1

General

9

2.2

Applicable Vietnam Standards

9

2.3

International Codes & Standards

9

3.0

ENGINEERING DESIGN DATA

13

3.1

Environmental Conditions

13

3.2

Design Life

14

3.3

Utilities

14

3.4

Hazardous Area Classification

14

3.5

Weather Protection

15

3.6

Earthing

16

3.7

Units of Measurement

16

3.8

Electromagnetic Compatibility

16

4.0

MATERIAL REQUIREMENTS

16

5.0

OVERALL INSTRUMENT & CONTROL PHILOSOPHY

17

5.1

General

17

5.2

Shutdown Levels

18

6.0

INTEGRATED CONTROL & SAFETY SYSTEM (ICSS)

19

6.1

Distributed Control System (DCS)

19

6.2

Emergency Shutdown System (ESD)

19

6.3

Fire & Gas System (FGS)

21

6.4

Operator Workstations (OWS)

21

6.5

Engineering Workstations (EWS)

22

6.6

Operator Pushbutton Stations (OPS)

22

6.7

Mimic Panel

22

6.8

Sequence of Events (SOE)

22

6.9

Maintenance Override

23

6.10

Start-up Override

23

6.11

Data Collection & Transfer Server (DCTS)

23

6.12

Asset Management System (AMS)

23

6.13

GPS Timer & Time Synchronization

24

6.14

Spare Capacity

24


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7.0

ADDRESSABLE FIRE DETECTION SYSTEM (AFDS)

24

8.0

WELLHEAD CONTROL PANEL (WHCP)

24

9.0

FUSIBLE PLUG LOOP PANEL

25

10.0

CUSTODY TRANSFER AND ALLOCATION METERING SYSTEMS

25

11.0

SAND MONITORING SYSTEM (SMS)

26

12.0

CENTRALIZED MACHINE MONITORING SYSTEM (CMMS)

26

13.0

MECHANICAL PACKAGE EQUIPMENT

26

14.0

INTERFACE WITH ELECTRICAL SYSTEM

27

15.0

INTERFACE WITH SSIV HYDRAULIC POWER UNIT (HPU)

28

16.0

INTERFACE WITH PA/GA SYSTEMS

28

17.0

INTERFACE WITH TELECOMUNICATION SYSTEM

28

18.0

FIELD INSTRUMENTATION

29

19.0

INSTRUMENT TUBINGS AND FITTINGS

30

20.0

CABLING

30

21.0

CABLE TRAYS / LADDERS

30

22.0

ELECTRICAL HEAT TRACING

31

23.0

SIL CLASSIFICATION & VERIFICATION STUDY

31

24.0

FIRE & GAS MAPPING STUDY

31

APPENDIX A – INSTRUMENT CONNECTION DETAILS

32


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1.0

GENERAL

1.1

Background Thien Ung field is located in the middle part of Block 04-3 in the Nam Con Son Basin, offshore the Socialist Republic of Vietnam, approximately 15 km of Dai Hung field, and approximately 270 km southeast of Vung Tau. The Block 04-3 covers an area of approximately 2600 km2. The Thien Ung field is including its 2 structural parts. Thien Ung structure discovery was made in 2004 with the 04-3-TU-1X well. Two subsequent appraisal wells (04.3-TU-2X and 04.3-TU-3X), drilled and tested respectively, delineated the field. Location of Thien Ung field is shown in Figure 1.1 below.

Figure 1.1: Thien Ung Reservoir Location 1.2

Purpose of document This document defines the Instrumentation and Control design basis for BK-TNG Wellhead Platform. It also describes the overall process control and safeguarding systems of the facilities for BK-TNG.

1.3

Definitions and Abbreviations

1.3.1

Definitions PROJECT

FEED service for BK-TNG Wellhead Platform

COMPANY

The party, which initiates the project and ultimately pays for its design and construction and owns the facilities. Here the COMPANY is Vietsovpetro (Referred to as VSP)

CONTRACTOR

The party which carries out all or part of the design, engineering, procurement, construction and commissioning of the project


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1.3.2

VENDOR

The party on which the order or contract for supply of the equipment / package or services is placed

Shall

Refers to mandatory requirement

Should

Refers to a recommendation

WILL

Refers to mandatory requirement

CONSIDER

Is a mandatory requirement unless a technical justification exists for not implementing and an equivalent solution is implemented

MAY

Indicates an acceptable course of action

MIGHT


CAN


“Fit for Purpose”

A standard of work or design which has no specified design parameters but which is generally accepted will meet the performance requirements required of it over its intended life of service, specifically including but not limited to safety, operability and maintainability.

Abbreviations AFDS

Addressable Fire Detection System

AMS

Asset Management System

API

American Petroleum Institute

APS

Abandon Platform Shutdown

AWG

American Wire Gauge

BK-TNG

Thien Ung Wellhead Platform

CCR

Central Control Room

CMMS

Centralized Machine Monitoring System

CPP

Central Processing Platform

CPU

Central Processing Unit

DCS

Distributed Control System

DCTS

Data Collection & Transfer Server

EMC

Electromagnetic Compatible

EMI

Electromagnetic Interference

EPR

Ethylene-Propylene Rubber

ESD

Emergency Shutdown System

ESDV

Emergency Shutdown with Blowdown

EWS

Engineering Workstation

F&G

Fire and Gas

FEED

Front - End Engineering Design

FGS

Fire and Gas System


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GPS

Global Positioning System

HART

Highway Addressable Remote Transducer

HF-EPR

Halogen Free Ethylene-Propylene Rubber

HMI

Human Machine Interface

HPU

Hydraulic Power Unit

HVAC

Heating Ventilation and Air Conditioning

ICSS

Integrated Control & Safety System

IEC

International Electrotechnical Commission

IER

Instrument Equipment Room

IGF

Induced Gas Floatation

IMCS

Integrated Motor Control System

IR

InfraRed

IS

Intrinsically Safe

ISA

Instrument Society of America

I/O

Input/Output

JB

Junction Box

LAN

Local Area Network

LCP

Local Control Panel

LED

Light Emitting Diode

LQ

Living Quarters

LCD

Liquid Crystal Display

LSZH

Low Smoke Zero Halogen

MCC

Motor Control Centre

MCT

Multi Cable Transits

MCP

Manual Call Point

MDR

Modular Drilling Rig

MODBUS

Serial Communication Protocol by Modicon

MOS

Maintenance Override Switch

MOS-ENB

Maintenance Override Switch Enable

MOS-IND

Maintenance Override Switch Individual

OPS

Operator Pushbutton Station

OWS

Operator Workstation

PA/GA

Public Address And General Alarm System

PAPA

Prepare to Abandon Platform

PLC

Programmable Logic Controller

PC

Personal Computer

PSD

Process Shutdown

PSMCS

Power Supply Monitoring and Control System


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1.4

PVE

Petrovietnam Engineering Consultancy Joint Stock Corporation

RFI

Radio Frequency Interference

RTU

Remote Terminal Unit

SCSSV

Surface Controlled Subsurface Safety Valve

SIL

Safety Integrity Level

SMS

Sand Monitoring System

SOE

Sequence of Events

SS

Stainless Steel

SOS

Start-up Override Switch

SOS-ENB

Start-up Override Switch Enable

SOS-IND

Start-up Override Switch Individual

SSV

Surface Safety Valve

SSIV

Sub-Surface Isolation Valve

TCP/IP

Transmission Control Protocal/ Internet Protocal

TEG

Triethylene Glycol

TPGM

Technip Geoproduction (M) Sdn Bhd

UCP

Unit Control Panel

UPS

Un-interruptible Power Supply

USD

Unit Shutdown

UV

UltraViolet

VAC

Volts Alternating Current

VDC

Volts Direct Current

VSD

Variable Speed Drive

VSP

Vietsovpetro

WCM

Wellhead Control Module

WHCP

Wellhead Control Panel

WV

Wing Valve

Reference Documents DRAWING/DOCUMENT NO.

TITLES

1014-BKTNG-PR-RPT-0001

Process and Utilities Design Basis

1014-BKTNG-PR-RPT-1003

Start-up and Shutdown Philosophy

1014-BKTNG-EL-RPT-0001

Electrical Design Basis

1014-BKTNG-ME-RPT-0001

Mechanical Design Basis

1014-BKTNG-SA-RPT-0002

HSE Design Basis

1014-BKTNG-SA-RPT-0003

Safety and Loss Prevention Philosophy


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1014-BKTNG-IN-SP-0001

Specification for Distributed Control System (DCS)


Specification for Emergency Shutdown System (ESD)


Specification for Fire and Gas System (FGS)


General Specification for Instruments


Specification for Package Equipment Instrumentation


Specification for Fire & Gas Detectors


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2.0

CODES & STANDARDS

2.1

General The equipment shall be designed, fabricated and tested in accordance with the latest revision of all relevant international Codes and Standards including but not limited to the standards listed below. In the event of conflict between codes and standards and/or this specification, the matter shall be highlighted for COMPANY’s attention/approval.

2.2

Applicable Vietnam Standards CODES & STANDARDS

2.3

TITLES

TCVN 6171 - 2005

Fixed Offshore Regulation – The Technical Supervision and Classification

TCVN 6767 – 2000

Fixed Offshore Platform

International Codes & Standards CODES & STANDARDS

TITLES

AGA Report No.9

Measurement of Gas by Multi-path Ultrasonic Meters

API RP 14C

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

API RP 14E

Design and Installation of Offshore Production Platform Piping Systems

API RP 14J

Design and Hazards Analysis for Offshore Production Facilities

API RP 14FZ

Recommended Practice for Design, Installation and Maintenance of Electrical Systems for Fixed and Floating Offshore Petroleum Facilities for Unclassified and Class 1, Zone 0, Zone 1 and Zone 2 Locations

API RP-505

Recommended Practice for Classification of Locations for Electrical Installations at Petroleum Facilities Classified as Class I, Zone 0, and Zone 2

API Spec 6D

Pipeline Valves (Gate, Plug, Ball and Check Valves)

API Spec 6FA

Fire Test for Valves

API STD 520 Part 1

Sizing, Selection and Installation of Pressure-relieving Devices in Refineries – Part I Sizing & Selection

API RP 520 Part 2

Sizing, Selection and Installation of Pressure-relieving Devices in Refineries – Part II Installation

API STD 521

Guide for Pressure Relieving and De-pressurizing Systems

API STD 526

Flanged Steel Pressure Relief Valves


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CODES & STANDARDS

TITLES

API RP 551

Process Measurement Instrumentation

API RP 552

Transmission Systems

API RP 553

Refinery Control Valves

API RP 554 Part 1

Process Control Systems Part 1 - Process Control Systems Functions and Functional Specification Development

API RP 554 Part 2

Process Control Systems - Process Control System Design

API RP 555

Process Analyzers

API STD 598

Valve Inspection and Testing

API STD 607

Fire Test for Quarter Turn Valves and Valves equipped with Non-Metallic seats

API MPMS 21.1

Flow Measurement Using Electronic Metering Systems Section 1 - Electronic Gas Measurement

ASME B 1.20.1

Pipe Threads, General Purpose (Inch)

ASME B16.5

Pipe Flanges and Flanged Fittings

ASME B16.10

Face-to-face and end-to-end dimensions of valves

ASME B16.11

Forged fitting, Socket welding and threaded

ASME B16.25

Butt welded ends for pipe, valves, flanges and fittings

ASME B16.34

Valves Flanged, Threaded and Welding End

ASME B16.36

Orifice Flanges

ASME PTC 19.3

Temperature Measurements

ASME PTC 19.3 TW

Thermowells Performance Test Codes

ASME MFC–4M

Measurement of Gas Flow by Turbine Meters

ASME MFC–5.1

Measurement of Liquid flow in Closed conduits using TransitTime Ultrasonic Flow meters

ASME MFC–6M

Measurement of Fluid Flow in Pipes Using Vortex Flow meters

ASME MFC–14M

Measurement of Fluid Flow using Small Bore Precision Orifice Meters

ASME MFC–16

Measurement of Fluid Flow in Closed conduits by means of Electromagnetic Flow meters

ASTM A123 / A123M

Standard Specification for Zinc (Hot Dip Galvanized) Coatings on Iron and Steel Products


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CODES & STANDARDS

TITLES

ASTM A269

Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

FCI 70-2

Control Valve Seat Leakage

BS EN 50262

Cable Glands for Electrical Installations

BS ISO 5208

Industrial Valves – Pressure Testing of metallic valves

BS 6739

Code of practice for instrumentation in process control systems: installation, design and practice.

BS EN12266-1

Industrial Valves – Testing of Valves, Part 1: Pressure tests, test procedures and acceptance criteria mandatory requirements

BS EN12266-2

Industrial Valves – Testing of Valves, Part 2: Pressure tests, test procedures and acceptance criteria supplementary requirements Testing of valves - Fire type-Testing requirements

BS EN ISO 10497 BS 6883

Elastomer insulated cables for fixed wiring in ships and on mobile and fixed offshore units. Requirements and test methods

BS EN 60812

Analysis Techniques for System Reliability - Procedure for Failure Mode and Effects Analysis (FMEA)

BS EN837-1

Pressure gauges. Bourdon tube pressure gauges. Dimensions, metrology, requirements and testing

BS EN 10204

Metallic Products - Types of Inspection Documents.

BS 4368

Metallic Tube Connectors for Fluid Power and General Use

BS-7917

Elastomer insulated fire resistant (limited circuit integrity) cables for fixed wiring in ships and on mobile and fixed offshore units Requirements and test methods Specification for dimensions of temperature detecting elements and corresponding pockets

BS 2765 EN 54-2

Fire Alarm Control Panel

IEC 60079

Electrical Apparatus for Explosive Gas Atmospheres

IEC 60092-350

Electrical Installation in Ships – Part 350: Shipboard Power Cables – General Construction and Test Requirements

IEC 60092-351

Electrical Installation in Ships – Part 351: Insulating Materials for Shipboard and Offshore units, Power, Control, Instrumentation, Telecommunication and Data Cables

IEC 60092-353

Electrical Installation in Ships – Part 353: Single and Multicore non-radial Field Power Cables with extruded solid insulation for rated voltages 1 kV and 3 kV

IEC 60092-359

Electrical Installation in Ships – Part 359: Sheathing materials for Shipboard Power and Telecommunication Cables


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CODES & STANDARDS

TITLES

IEC 60092-376

Electrical Installation in Ships – Part 376: Cables for Control and Instrumentation circuits 150/250 V (300 V)

IEC 60331

Tests for Electric Cables under Fire Conditions

IEC 60332

Tests on Electric and Optical Fiber Cables under Fire Conditions

IEC 60529

Degrees of Protection Provided by Enclosures (IP Code)

IEC 61000

Electromagnetic Compatibility (EMC)

IEC 61131

Programmable Controllers

IEC 61508

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

IEC 61511

Functional Safety - Safety Instrumented Systems for the Process Industry Sector

IEC 60751

Industrial Platinum Resistance Thermometer Sensors

IEC 61537

Cable tray systems and cable ladder systems

IEC 60534-Part 2-1

Sizing Equations For Fluid Flow Under Installation Conditions

IEC 60534- Part 4

Inspection and Routine Testing

IEC 60534- Part 8-1

Noise Considerations - Laboratory Measurement of Noise Generated by Aerodynamic Flow through Control Valves

IEC 60534- Part 8-2

Noise Considerations Section Two: Laboratory Measurement Of Noise Generated by Hydrodynamic Flow through Control Valves

IEC 61000 6-2

Electromagnetic Compatibility (EMC) – General Standard – Immunity for industrial environments

IEC 61000-6-3

Electromagnetic Compatibility (EMC) – Part 6 Generic Standards -Section 3 : Emission Standard for residential, commercial and light industrial environments

IEC 61892

Mobile and fixed offshore units - Electrical installations

ISA 5.1

Instrumentation Symbols Identification

ISA 5.3

Graphic Symbols for Distributed Control/Shared Instrumentation, Logic, and Computer Systems

ISA 5.4

Instrument Loop Diagrams

ISA 5.5

Graphic Symbols for Process Displays

ISA 20

Specification Forms for Process Measurement and Control Instruments, Primary Elements, and Control Valves

ISA RP 60 Series

Control Center

Display


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CODES & STANDARDS ISA TR 84.00.01 P3 ISA 75.08.01

TITLES Functional Safety: Safety Instrumented Systems for the Process Industry Sector - Part 3: Guidance for the Determination of the Required Safety Integrity Levels - Informative Face-to-Face Dimensions for Integral Flanged Globe-Style Control Valve Bodies (ANSI Classes 125, 150, 250, 300, AND 600)

ISA 75.17

Control Valve Aerodynamic Noise Prediction

ISA 75.01.01

Flow Equations for Sizing Control Valves

ISA 75.19.01

Hydro Testing of Control Valves

ISA 71.04

Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants (Downloadable)

ANSI/ISA 12.13.01

Performance Requirements for Combustible Gas Detectors

ANSI/ISA 12.13.04

Performance Requirements for Open Path Combustible Gas Detectors

ANSI/ISA TR12.21.01

Use of Fibre Optic Systems in Class 1 Hazardous (Classified) Locations

NFPA 72 Edition 10

National Fire Alarm and Signalling code

NFPA 101

Life Safety Code

SOLAS

International Convention for Safety Of Life at Sea

EU 94/9/EC

ATEX GUIDELINES Approximation of the Laws of the Member States Concerning Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres

DNV-OS-A101

Safety principles and Arrangements

DNV-OS-D201

Electrical Installations

DNV-OS-D202

Automation, Safety and Telecommunication Systems

IP 15

Area Classification Code for Installations

3.0

ENGINEERING DESIGN DATA

3.1

Environmental Conditions All Instrument and Control equipment shall be suitable for operation on offshore platform. The equipment shall be suitable for continuous and short time duty, in the environmental conditions prevailing at site. The environmental and climatic data are summarized below: Atmosphere:

Offshore, dusty, salt laden, marine air condition, expose to monsoon storm and winter depression

Ambient Temperature:

39°C (Max) 21°C (Min)


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3.2

Relative Humidity:

98% (max) 62% (min)

Wind Velocity:

18.8 m/s

Rainfall:

50 mm/hr

Design Life All new equipment shall be designed for a service life of 25 years and shall have minimum 2 years proven use in offshore environment condition.

3.3

Utilities

3.3.1

Electrical Power Power supply to Instrument and Control systems shall be as follows: ·

230 VAC, 50 Hz, 1-phase, UPS

·

230 VAC, 50 Hz, 1-phase, Non-UPS

·

400 VAC, 50 Hz, 3-phase

24 VDC power supplies, if required, shall be derived from the respective power supply unit within the systems. Note 1: For UPS backup time definition, reference shall be made to Electrical Basis of Design. 3.3.2

Instrument Air The facilities will be equipped with instrument air system. Oil free, water free, dry and clean instrument air system shall be made available with header pressure maintained at 7~9 barg. However, all valve actuators shall be sized for a minimum instrument air supply pressure of 4 barg and shall withstand maximum design instrument air pressure of 13 barg. Design Instrument Air pressure

: 13 barg

Normal Instrument Air pressure

: 7~9 barg

Minimum Instrument Air pressure

: 4 barg

Each instrument/valve requiring air supply shall be provided with individual air filter regulator and isolation valve. Where valves require high torque, which cannot be met by pneumatic actuator, hydraulic actuator may be considered. 3.3.3

Hydraulic System The hydraulic power unit shall be located as part of the Well head control panel and shall derive the following pressures for the wellhead valves. The Hydraulic pump shall be power driven backed up by pneumatic driven pump. The hydraulic system shall be sized based on the worst case figures below but sizing calculation shall be carried out during detailed design by vendor for each individual application and worst case figures will be revisited where necessary. SSV (Wing and Master) supply pressure : 415 Barg (Maximum) SCSSV Supply Pressure

3.4

: 420 Barg (Maximum)

Hazardous Area Classification All instruments shall be certified suitable for the hazardous area classification in which they are located. The selection of type of protection for instrumentations shall be in accordance with IEC 60079


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and ỊP 15. In general, EEx”d” protection shall be used for field devices. Where EEx”d” protection is not available for the particular devices, other type of protection e.g. EEx”i” can be used with approval by COMPANY. Junction boxes shall be EEx”e” type for IS and non IS circuits. Enclosures (LCP) shall be EEx’e’/EEx’d’ type, where installed in hazardous are. All applicable instruments shall be provided with hazardous area certification IEC / CENELEC standards. All certificates shall be issued by an Approved national authority (e.g. UL, BASEEFA, etc.) and shall be in English. All instrument equipment to be installed in a hazardous area meets all the relevant requirements of the ATEX Directive (94/9/EC) and shall have the symbol clearly fixed to indicate compliance. In addition, all equipment and protective systems must be marked legibly and indelibly with the following minimum particulars: ·

Name and Address of the Manufacturer

·

Type of device

·

Designation of Series or Type

·

Serial Number

·

Year of Construction

·

The specific marking of explosion protection (e.g. Ex ‘d’) followed by the symbol of the equipment group and category

·

Maximum voltage for instrument.

·

Frequency of the connected voltage.

·

IP- classification.

·

The letter G (denoting explosive atmospheres caused by gases, vapours or mists)

·

All information essential to their safe use

3.5

Weather Protection

3.5.1

Ingress Protection Ingress protection for instruments / equipment shall be in accordance with IEC 60529 and as follows:

3.5.2

·

Minimum IP 56 for outdoor installations

·

Minimum IP 44 for installations inside enclosed rooms without air-conditioner

·

Minimum IP 22 for installations inside enclosed rooms with air-conditioner

Lightning Protection All instruments & controls are inherently protected against lightning due to the welded / bolted steel construction of the facilities. Hence separate surge protection devices are not required.

3.5.3

Painting All field instruments in carbon steel, frame works and supports shall be painted to suit the marine saliferous tropical environment as indicated in section 3.0. Stainless steel instruments/equipment shall not be painted.


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3.5.4

Tropicalization All field mounted electrical/electronic instruments/equipment shall be tropicalized in accordance with manufacturer’s standard procedure. All electronic printed circuit boards shall be conformal coated or equal, to protect against humidity, corrosion and heat (i.e. tropical ambience).

3.6

Earthing All equipment shall be connected to the suitable earth as follows: ·

Instrument Earth

·

Instrument IS Earth (if required)

·

Protective Earth

All panels, junction boxes, frames, etc. shall be equipped with 10 mm diameter earth studs and all metal work shall be earth bonded. All outdoor equipment shall have external earth studs. All Instrument signal cable screens shall be earthed at one point only. This shall be at the equipment panels. All screens shall be continued through junction boxes and insulated from earth at the field side. Cable armours shall be earthed at both ends with continuity through junction boxes. All electronics field instrument housings shall be separately grounded by connecting the external studs to the platform ground. For Offshore all the earth points converge to a single earthing boss, however the safety and Instrument earths will remain segregated at the enclosure end. In general, the IEEE guidelines as per IEEE std. 1050 and IEC 61000-5-2 may be followed. Earthing cables used shall be Cu, EPR stranded and insulated, 600/1000 Volt grade to BS 6883 and shall have green / yellow colored outer sheaths. 3.7

Units of Measurement Units of measurement shall in general be in accordance with the International System of Units (SI Units), IS0 80000-1.

3.8

Electromagnetic Compatibility The Instrumentation systems and associated equipment shall be supplied with provisions for protecting against system errors and hardware damage resulting from electrical transients on power or signal wiring. These transients include those generated by switching large electrical loads, by power line faults and due to lightning strikes which induce surges on power or signal cables. The most common sources of electromagnetic radiation are portable hand-held radio transceivers. Other sources are fixed radio stations, commutator type electrical devices and spurious sources such as from welders, variable speed drives and contactors. The above systems shall be immune from these EMI/RFI interferences. For details on application of EMI/RFI protection, reference shall be made to the System specifications.

4.0

MATERIAL REQUIREMENTS In general material selection shall be in accordance with Valve Specification and Piping Specification. The selection of wetted parts material for in-line and on-line instrumentation and valves for control applications shall be according to the Instrument datasheets, which will reflect the material in accordance with the piping material specification. Materials composition certification and testing class shall be to Class specified in the datasheets referenced to BS EN 10204, 3.1 or 3.2.


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Use of SS 304 is strictly prohibited in offshore platforms for any support items. SS316 shall be the minimum material for hydrocarbon service. Monel shall be used for Sea water service and Hastelloy C shall be used for corrosive applications, as indicated in the relevant Instrument datasheets. All materials (including gaskets and sealants) shall be free from the following hazardous substances: ·

Asbestos

·

Ceramic Fibre

·

Chlorofluorocarbons

·

Polychlorobiphenyls (PCB) and their isomers

·

Radioactive Materials

·

Mercury

·

Halogen

Dangerous goods shall be labelled and identified properly. All hazardous materials shall be supplied with a material safety data sheet (MSDS). The use of brass or copper bearing alloys shall not be permitted. Aluminium shall not be used for any part of the equipment that may come into contact with the process fluid. Generally, instruments and their accessories shall be 316 SS as a minimum. Metallurgy of in-line instruments (e.g. valves, thermowells, level instruments, etc.) including the wetted parts of instruments shall meet or exceed that of the associated piping class to which there are connected. As a minimum, they shall be 316 stainless steel with a minimum of 2.5% Molybdenum. Other grades of stainless steel e.g. 302, 303, 304, 305 are forbidden. Transmitter diaphragms, bourdon tubes and other thin walled items will typically be Monel, Hastelloy C-276, Duplex SS, Incoloy 825 or Inconel 625 where applicable and specified in the datasheets . For in-line instruments in salt water services including remote mounted instruments (typically stand-pipe mounted transmitters etc.), body and trim materials shall meet or exceed those called for by the piping specifications and shall typically be Monel. All Internal trim materials shall be resistant to attack by chlorides. Thermoplastics such as Teflon, PEEK or Nylon shall be specified where available in preference to elastomers. Where elastomers must be used for hydrocarbon services, In general Viton shall be used as a minimum. Kalrez or equal elastomers shall be considered if the service temperature is too high (see manufacturer literature) for Viton. Buna -N and neoprene may only be used in air or water services 5.0

OVERALL INSTRUMENT & CONTROL PHILOSOPHY

5.1

General The Instrumentation and Controls provided for the facility shall have the following objectives: ·

To provide a level of control, automation and monitoring that will meet the process requirements

·

To provide instrumentation and controls for highly reliable and safe operation of the facility

·

To comply with local statutory legislation and high standard of oil and gas industry working practices.

·

To provide safeguarding function (emergency shutdown system and fire & gas detection and protection system) for the safety of the personnel, equipment and environment that will meet COMPANY and international guidelines and requirements


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·

To transfer information and data to COMPANY’s onshore facility in Vung Tau, via satellite communication

·

To standardize the instrument equipment as far as practical for rapid troubleshooting through self-diagnostics and other manufacturer’s recommended techniques

BK-TNG Wellhead Platform will be a manned facility. It shall be equipped with a Central Control Room (CCR) for monitoring and controlling the process and utility plant equipment. CCR shall be the center for operation personnel to continuously monitor and control all plant functions, in a safe and efficient manner under normal and abnormal situations. It is important that sufficient, but not excessive information is transmitted to the CCR to achieve visibility of the plant without any obstruction caused by overloading of the operators’ attention. Control principles will be kept as simple as possible consistent with a high degree of availability and safety using equipment that will require minimum maintenance and off-line proof test. Manning levels in the field are assumed to be kept to a minimum therefore actions required to start and operate the plant should largely be achievable from the CCR. All control system panels will be housed in an Instrument Equipment Room (IER) located adjacent to the CCR with door access between the two rooms. The facility shall be provided with Integrated Control and Safety System (ICSS) consisting of: ·

Distributed Control System (DCS)

·

Emergency Shutdown System (ESD)

·

Fire & Gas System (FGS)

ICSS shall be a fully integrated system, thus allowing common “window” to the facility. The DCS, ESD and FGS will be dedicated to their main task and will continue to operate in the event of an inter-system communication failure. Besides ICSS, the other major Instrument and Control systems shall consist of the followings: ·

Addressable Fire Detection System (AFDS)

·

Wellhead Control Panel (WHCP)

·

Metering Systems

·

Sand Monitoring System (SMS)

·

Centralized Machine Monitoring System (CMMS)

·

Control and Safeguarding systems for Mechanical Package Equipment

·

Integrated Motor Control System

·

PA/GA Systems

·

Telecommunication System for platform communication and transferring information to onshore facility in Vung Tau via DCTS

The following hardwired interface signals between ICSS and other control/ safeguarding systems shall be implemented as a standard as far as possible: ·

Volt-free contact: Input signals from other systems to ICSS

·

24 VDC power: Output signals from ICSS to other systems

All electronic equipment and instruments shall be immune from RFI/EMI in accordance with IEC 61000. 5.2

Shutdown Levels The emergency shutdown is carried out on a 4 level basis:


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·

Prepare to Abandon Platform (PAPA) (Manual initiation by operator)

·

Emergency Shutdown with Blowdown (ESDV)

·

Emergency Shutdown (ESD)

·

Process Shutdown and Unit Shutdown (PSD & USD)

For details of shutdown levels definition, refer to 1014-BKTNG-PR-RPT-1003 Start-up and Shutdown Philosophy. Any higher order shutdown level shall automatically initiate any lower levels of shutdown. 6.0

INTEGRATED CONTROL & SAFETY SYSTEM (ICSS)

6.1

Distributed Control System (DCS) The primary function of the DCS is to provide process control, alarm annunciation, alarm logging, production report generation, and operator interface for production operations. DCS shall provide enough information and control actions for the facilities to be controlled from CCR with minimum operator intervention. The DCS shall be microprocessor based “off the shelf” distributed control architecture, utilizing proven industry standard hardware and software connectivity. The DCS shall also be TCP/IP compliant, integrates continuous process control and monitoring functionality with sequence logic capabilities and easy to use object based graphical user interface. The DCS shall be of high reliability and maximum availability. The overall DCS availability shall be better than 99.95%. The DCS shall be robust to suit the environment and application. The DCS shall be designed such that a single failure shall not cause system malfunction and shutdown. As a minimum, the DCS shall employ dual redundancy techniques for the following items: ·

Controller modules

·

Power supply modules

·

Communication module

·

I/O modules for regulatory control

·

Subsystem Interface Modules (Modbus), unless otherwise stated

·

Process Control Network

DCS shall consist of marshalling cabinets for the termination of field incoming/outgoing signals, system cabinets for input/output modules, controllers, communication modules, network switches, converters and other electronic modules specific to the system architecture and the selected DCS supplier. DCS system and marshalling cabinets shall be installed in IER. DCS I/Os shall be wired to junction boxes. From these junction boxes, multi-pair/multi-core cables shall be connected directly to DCS marshalling cabinets in IER. The DCS shall be provided with Operator Workstations (OWS) for operators to control and monitor the plant. Redundant communication bus shall link DCS system cabinets and OWS. Communication between DCS and package control systems can be via serial link and/or hardwired connections. For serial communication, RS-485 Modbus RTU protocol shall be considered as first priority. Redundant serial link shall be provided for systems that require regular monitoring and control from DCS. Non-redundant serial link connection shall be considered for systems that only require data monitoring from DCS. 6.2

Emergency Shutdown System (ESD) The ESD primary function is to bring the facility to a safe state in case of emergency situation, thus protecting the personnel, equipment and environment. It shall carry out the shutdown


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and depressurization functions of the facility according to the defined safety and process philosophies. The ESD shall be completely independent of the measurement and control schemes implemented in the DCS. ESD shall be provided with dedicated measurement sensors and final elements. ESD shall continuously monitor all associated process and utility systems including those derived from equipment packages, MDR status and manual field inputs. The ESD system shall be a Programmable Electronic Safety-related System certified by TUV to class AK-6 and conform to SIL 3 requirements in accordance with IEC 61508. The ESD shall be of high reliability and maximum availability. The ESD availability shall be better than 99.999%. The ESD shall be robust to suit the environment and application. The ESD shall be designed such that a single failure shall not cause system malfunction and shutdown. As a minimum, the ESD shall employ fault tolerant, minimum dual redundancy configuration for the following items: ·

Controller modules

·

Power supply modules

·

Communication modules

·

I/O modules

·

Safety Network

For Controller modules and I/O modules, ESD shall provide one fault tolerant for undetected failure and two faults tolerant for detected failures or two faults tolerant for both. In order to maximize the availability of the ESD, it shall not have time restraint imposed as part of SIL3 certification for the time taken to replace a faulty module. The compliance with this requirement shall be verified by TUV Rheinland and/or stated in the Safety Manual (or the same), which has been verified by TUV Rheinland. All IO modules shall be capable of Open and Short Circuit and wire break (where possible) monitoring for both digital and analogue I/O. ESD input and output signals shall be hardwired. All safeguarding execution signals to other systems shall be hardwired. The ESD shall be designed “fail-safe”, utilizing de-energize to trip principles. The information transfer between ESD and DCS shall be via dual redundant communication link. The communication protocol for this link shall be TUV Rheinland certified. Communication between ESD and DCS using DCS communication bus may be considered if ESD and DCS are from the same manufacturer. ESD shall consist of marshalling cabinets for the termination of field incoming/outgoing signals, system cabinets for input/output modules, controllers, communication modules, network switches, converters and other electronic modules specific to the system architecture and the selected ESD supplier. ESD system and marshalling cabinets shall be installed in IER. ESD I/Os shall be wired to junction boxes. From these junction boxes, multi-pair/multi-core cables shall be connected to ESD marshalling cabinets in IER. On-line removal and/or replacement of modules shall be possible without affecting the existing wiring system, reconfiguration of system software, de-energizing of modules or system re-boot.


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6.3

Fire & Gas System (FGS) The FGS primary function is to mitigate against the effects of any fire and/or gas releases, thus protecting the personnel, equipment and environment. FGS shall be independent of the DCS and ESD with regard to detecting fire or gas incidents and initiating protective actions as defined in the safety philosophies. Hardwired outputs shall be provided to ESD to initiate shutdowns. FGS shall be a Programmable Electronic Safety-related System certified to NFPA 72 and EN 54-2 for fire and gas detection. FGS shall be certified by TUV Rheinland to class AK-6 and conform to SIL 3 requirements in accordance with IEC 61508. The FGS shall be of high reliability and maximum availability. The FGS availability shall be better than 99.999%. The FGS shall be robust to suit the environment and application. The FGS shall be designed such that a single failure shall not cause system malfunction and shutdown. FGS shall employ fault tolerant, with configuration similar to ESD. FGS shall be of the same manufacturer as ESD, therefore can share the same Safety Network. The information transfer between FGS and DCS shall be via dual redundant communication link. Communication between FGS and DCS using DCS communication bus may be considered if FGS and DCS are from the same make. Fire and gas detection on the platforms will consist of the following types of devices. These devices shall be hardwired directly to FGS. ·

Combustible Gas Detectors (point and open path type)

·

Triple IR Flame Detectors

·

UV/IR Flame Detectors (for restricted high temperature application)

·

Smoke Detectors

·

Heat Detectors

·

Hydrogen Gas Detectors

·

Manual Call Points (MCP)

Suitable fire and gas detection for the respective areas / sections of BK-TNG will be recommended by Safety. In general, the FGS shall be designed based on “energize to trip” principles. The requirements for line monitoring shall be similar to ESD. FGS system and marshalling cabinets shall be installed in IER. FGS I/Os shall be wired to the respective junction boxes. From these junction boxes, multi-pair/multi-core cables shall be connected to FGS marshalling cabinets in IER. 6.4

Operator Workstations (OWS) The OWS shall be provided in CCR complete with 21” LCD displays, keyboards and pointing devices. The ICSS operator interface shall be implemented in OWS. All shutdown and common system alarms, analogue field device values and override/status indications from the ESD and FGS shall be displayed / annunciated in the OWS. F&G overviews, zones, detectors layouts, etc. shall also be displayed on the OWS. OWS shall be the primary operator “window” for BK-TNG Wellhead Platform.


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Configurable graphics shall be used to represent the status of the process, utilities and safeguarding of the plant. The operator shall control the plant by interfacing with the graphical displays of OWS. OWS shall provide audible and visual alarms when process variables fall outside the acceptable operating limits. Annunciation of emergency conditions from ESD and FGS shall also be presented in the same manner in OWS. Alarm management functions shall also be provided in OWS, which shall include the followings but not limited to:

6.5

·

Segregation of alarms by priorities

·

Automatic / Manual suppression of alarms

·

Sorting of alarms by date, time and type

·

Different tones for audible alarms based on the type, etc.

Engineering Workstations (EWS) The EWS for DCS and ESD/FGS shall be provided with complete set of system development, application development and system maintenance software tools. EWS shall have the capability for on-line software downloads to the respective systems without shutdown of the process. Live download shall require security password to avoid unauthorized access. EWS should be workstation type with 21” monitors similar to the operator work stations.

6.6

Operator Pushbutton Stations (OPS) Two (2) separate OPS for ESD and FGS shall be provided. The OPS shall be located in CCR and shall be ergonomically fit alongside the OWS. OPS for ESD shall be used for manual shutdown actions, blowdown/depressurization initiations, unit shutdown for major equipment/packages, override, reset, etc. OPS for FGS shall be used for firewater pump start/stop and selections, extinguishing systems (deluge, etc.) remote release, override, reset, etc. Abandon Platform pushbutton shall also be provided here. The OPS shall contain all required switches, lamps and pushbuttons, hardwired directly to ESD and FGS. Indicating lamps shall be provided for major alarms. Common test lamp switch shall be provided for each OPS.

6.7

Mimic Panel Mimic Panel shall be provided for FGS to indicate fire and gas detection for each fire zone in BK-TNG. The Mimic Panel shall also indicate the status of fire suppression system. All the lamps on the Mimic Panel shall be hardwired from the FGS. The Mimic Panel shall be located in CCR. An additional Mimic Panel shall be provided for general alarm & status to indicate for each main power system and LQ HVAC in BK-TNG. All the lamps on the additional Mimic Panel shall be hardwired from the DCS, and shall be located in LQ Radio Room.

6.8

Sequence of Events (SOE) The ESD and FGS shall have a centralized SOE facility that collects all events. The event data can be used for preventive maintenance and to help identify the causes of shutdowns. In order to determine the precise order of sequence of event leading to an incident, the systems shall stamp all events.


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The SOE shall provide true time-stamping resolution less than 10 ms at the I/O level and available for all types of I/O modules. SOE time stamping shall be independent of system scan time. The SOE database shall be readily and easily accessible by operators and engineers using a set of software tools to quickly and effectively view, analyze and prepare report on the plant. 6.9

Maintenance Override Maintenance Override shall be provided for initiating devices that have executive function (e.g. trip transmitters, F&G detectors, etc.), so that they can be tested online without causing a shutdown. A hard-wired Maintenance Override Enable key switch (MOS-ENA) shall be provided on the OPS for each protection group. When this switch is in the enable position (closed contact), the individual MOS (MOS-IND) signal can be accepted by the protection logic in the ESD / FGS. As this switch is hardwired, the operator can de-activate any override when the communication link with DCS fails. The MOS-IND shall be activated from the soft-key function in OWS. Activation of MOS-IND function requires log-on password security via OWS. A maximum of one trip initiator may be overridden per protection group at any one time. In case the DCS to ESD / FGS communication link fails, the overrides shall remain as they were before the failure. It shall be possible to remove the Maintenance Override by deactivating either the MOS-ENA or MOS-IND. All Maintenance Override related events shall be logged with time stamped in the SOE.

6.10

Start-up Override Start-up Override facility shall be provided for initiating devices that have executive function (e.g. trip transmitters, etc.), so that the plant start-up can be achieved whilst process conditions are off specification. A hard-wired Start-up Override Enable key switch (SOS-ENA) shall be provided on the OPS for each protection group. When this switch is in the enable position (closed contact), the individual SOS (SOS-IND) signal can be accepted by the protection logic in the ESD / FGS The SOS-IND for selected individual inputs to the ESD shall be activated from the soft-key function in OWS. Activation of SOS-IND function requires log-on password security via OWS. The Start-up Override shall be automatically deactivated by the ESD after a preset period or when the initiating device becomes healthy, whichever comes first. All Start-up Override related events shall be logged with time stamp in the SOE.

6.11

Data Collection & Transfer Server (DCTS) A Data Collection & Transfer Server (DCTS) shall be provided. DCS shall act as the data collection interface for DCTS. DCTS shall provide central data acquisition and archiving of all systems / units on BK-TNG. The DCTS shall transmit the data via satellite communication to COMPANY’s onshore network in Vung Tau. The DCTS shall be compatible with existing COMPANY’s communication network. DCTS shall also provide the interface point to the platform’s Local Area Network (LAN) DCTS shall provide database of historical data for post event analysis, records of test, etc. The DCTS shall be able to store real time data for long duration (minimum 4 years).

6.12

Asset Management System (AMS) Asset Management System (AMS) shall be provided. AMS shall record data and shall include facilities to enable online diagnostic, maintenance, fault finding and provide historical data regarding the health and status of DCS and ESD Smart instrumentation, e.g. positioners, transmitters, etc.


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The DCS and ESD I/O modules should have HART pass through capability to send noncritical data of the Smart field devices for AMS application. For ESD, HART multiplexer connection can be considered if HART pass through capability is not possible. 6.13

GPS Timer & Time Synchronization All system clocks shall be synchronized to precision, sufficient to obtain the specified time discrimination between alarms and events originating from the different systems. GPS Timer shall be provided and connected to DCS. GPS Timer shall function as the master reference clock for DCS. DCS shall send hardwired signals (volt-free contact) to other systems for time synchronization.

6.14

Spare Capacity ICSS design shall allow for the following minimum spare capacities: ·

The systems shall have a minimum 20% installed spare input/output capacity and at least 20% spare space for future expansion.

·

20% wired spare installed system I/O of each I/O type

·

20% installed spare multi-pair / multi triad cables

·

20% installed spare terminals and gland plate space in field junction boxes and panels

·

Each controller and OWS shall be sized not to exceed its 50% of full capacity regarding both execution time and memory occupation (including all installed spares).

·

All power supplies shall be sized and dimensioned to take the above requirement into consideration.

Wired, installed spare I/O’s shall be complete with I/O boards, signal conditioning units, wiring, terminals and isolators (where applicable) up to and including field terminals in the cabinet. 7.0

ADDRESSABLE FIRE DETECTION SYSTEM (AFDS) A separate Addressable Fire Detection System (AFDS) will be used for the detection of fire in LQ. All heat detectors, smoke detectors, MCPs, alarm bells and other F&G devices inside LQ shall be connected to the AFDS in addressable loops. The design and installation of AFDS and its components shall be in accordance with NFPA 72 and EN 54-2. AFDS shall be certified by TUV Rheinland for SIL 2 applications. The AFDS shall have hardwired interface to FGS for signals requiring executive action (e.g. confirmed fire) and to DCS for time synchronization. The individual detector’s alarm, trouble and bypass status shall be sent from AFDS to DCS through redundant serial link via RS-485 Modbus RTU protocol. In case of activation of any of the devices in the addressable loops, AFDS shall identify the exact location of the device and alert the operator via OWS. The AFDS shall be site configurable and provided with the configuration tools, software and software licenses.

8.0

WELLHEAD CONTROL PANEL (WHCP) A Wellhead Control Panel (WHCP) shall be provided for the safe operation and control of SCSSV, SSV and WV. The WHCP shall be located close to the wellheads area. The Wellhead Control Panel (WHCP) shall be constructed from heavy duty 316L stainless steel sheet suitable for the Zone 1, Group IIA, Temp, Class T3 applications. The panel will


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have lockable rear access doors, top side or side entry bulkhead connections for tubing and cables and front mounted pushbuttons, status indicators, gauges, override switches, etc. The WHCP design and construction will be modular form, with the control components for each wellhead contained in a slide-in front access module. Modules shall be identical, and shall include key operated facilities to protect against unauthorized removal. Each wellhead string shall have a dedicated wellhead control module (WCM) which can be isolated, depressurised, removed and reinstated without affecting the operation of the other WCMs. Each WCM will be hydraulic connected to each well’s SCSSV and SSV. Hydraulic fluid used shall be Oceanic HW 510 or equivalent environmental friendly fluid. The WHCP shall be hydraulic type. A Hydraulic Power Unit (HPU) located in WHCP shall provide hydraulic power at suitable pressures for the operation of SCSSV, MSSV and WSSV. All the instruments used in the WHCP (except local gauges) shall be electronic type and shall interface with platform DCS and ESD directly. The logic for opening, closing and shutdown of the SCSSV, SSV and WV shall be implemented by the ESD. Any out of sequence valve opening or positioning of the well valves shall give a common alarm to DCS. The position of each SCSSV shall be provided to DCS using limit switches of the respective valves. The hydraulic output signal to each SCSSV and SSV/WV shall include a nitrogen accumulator to allow for pulsation when pump is running. Opening and closing of the SCSSV, SSV and WV shall be sequentially operated i.e. while opening, SCSSV to open first, then SSV, followed by WV. While closing, WV to close first, then SSV, followed by SCSSV. However, password protected sequence override facility shall be provided in the OWS to open/close wellhead valves without any sequence. WHCP shall be provided with panel-mounted pushbuttons and indications for local operator interface. WHCP shall interface with DCS for transferring wellhead status signals and for controlling hydraulic pumps in WHCP. Automatic closing of SCSSV, SSV and WV due to Emergency Shutdown or Process Shutdown shall be as per Process Cause & Effect Matrix. 9.0

FUSIBLE PLUG LOOP PANEL Fusible loop panel will be installed at various location of BK-TNG platform. Detection of fire by a fusible plug will bleed off the fusible loop air pressure and activate the low pressure alarm via the 2oo3 pressure transmitter, located as part of each fusible loop panel. Under normal, non-fire conditions the fusible loop will be held at 2.75 barg pressure by air supply through a restrictor. The restrictor is to be sized such that the maximum flow rate (corresponding to a single fusible plug at a location most distant from the panel), results in a pressure drop sufficient to reduce the pressure measured at in above pressure transmitter is less than 2 barg. During normal conditions it shall supply sufficient flow to make up for losses due to fitting leakage.

10.0

CUSTODY TRANSFER AND ALLOCATION METERING SYSTEMS Allocation gas metering system shall be provided on BK-TNG to cater for Dai Hung 02 associated gas pipeline. Export custody gas metering system to be provided to cater for total gas flow from BK-TNG and Dai Hung 02 associated gas, before offloading to export pipeline.


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Export custody condensate metering system to be provided to measure export condensate for BK-TNG. The gas shall be metered with ultrasonic meters. Custody gas metering shall conform to fiscal standard. The condensate shall be metered with coriolis or turbine meters to fiscal standard for custody transfer. Each metering system (allocation gas, export custody gas and condensate) shall be provided with dedicated flow computers. The flow computers will be installed in IER. High accuracy meters for the condensate will be required on each production platform which consists of field flow computer and associated field instruments; pay and check turbine / coriolis meters; temperature sensors for flow compensation, density measurement at the downstream piping configuration. A serial link will be provided between flow computer and DCS. For further details on liquid metering, reference shall be made to the equipment specification. A dedicated metering system supervisory workstation shall be provided for each metering system for system monitoring and maintenance. The metering systems shall interface with the DCS via redundant RS 485 Modbus RTU / Modbus TCP communication link. 11.0

SAND MONITORING SYSTEM (SMS) Sand Monitoring System (SMS) utilizing acoustic non-intrusive sand probes shall be provided. The sand probes shall be installed near each wellhead. In general, the sand probes will be connected to a Calculation Interface Unit located in CCR. The SMS shall interface with the DCS through the Calculation Interface Unit via RS 485 Modbus RTU communication link. Typical data to be transmitted from the SMS to DCS are sand production rate, detector fault, system alarm and any other VENDOR’s standard signals.

12.0

CENTRALIZED MACHINE MONITORING SYSTEM (CMMS) The primary function of the CMMS is to gather all the vibration sensors and machine monitoring system data from individual rotating equipment Unit Control Panel (UCP) for performance monitoring and preventive maintenance purposes. The rotating equipment may include turbines, generators, etc. The CMMS shall operate using standard PC platforms. The CMMS software and database will reside on a CMMS workstation located in the CCR. The CMMS data review will be available at the CMMS workstation. For performance monitoring, selected process data shall be transmitted from DCS to CMMS via RS 485 Modbus RTU communication link.

13.0

MECHANICAL PACKAGE EQUIPMENT In general, the Mechanical Package Equipment may be designed and supplied in one of the following configurations: ·

Instruments located in the package, connected to DCS, monitored and controlled from DCS.

·

Instruments located in the package, connected, monitored and controlled by dedicated control system in a central location (e.g. turbine generator control panel which will be located in IER). The control panel is called Unit Control Panel (UCP). For some packages, a local gauge panel is also provided at the skid for local operation.


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·

Instruments located in the package, connected, monitored and controlled from dedicated control system integral to the package skid (e.g. sewage treatment system). The control panel is called Local Control Panel (LCP).

Similarly the safeguarding for Mechanical Package Equipment shall be implemented as either ·

Implemented in respective package control system (e.g. turbine generator), or

·

Safeguarding systems initiating devices and final elements located in the respective packages are connected to & the logic implemented in the platform ESD and FGS.

In all cases the relevant package information shall be available in OWS for monitoring purpose. Package control and safeguarding systems shall receive and transmit relevant signals from/to ICSS for safe operation and shutdown of the facility. Communication with DCS will be via serial link or hardwired links or combination of both. However, in case where only small amount of data is required to be transferred, hardwired links are preferred. All safety related signals to/from package control systems shall be hardwired to platform ESD and / or FGS. RS-485 Modbus RTU protocol shall be used for serial communication with DCS as first priority. Other serial communication may be considered upon approval from COMPANY. The mechanical packages and their interfaces with DCS are as follows:

14.0

·

Gas Turbine Generator Package

:

Redundant serial and hardwired

·

Dai Hung Booster Compression System

:


·

Emergency Diesel Generator Package

:


·

HVAC System

:

Single serial and hardwired

·

TEG Regeneration Package

:

Hardwired

·

Hydrocyclone and IGF Package

:

Hardwired

·

Hypochlorite Package

:

Hardwired

·

Potable Water System

:

Hardwired

·

Instrument Air Compressor/Dryer Package

:

Hardwired

·

Flare Ignition Package

:

Hardwired

·

Fuel Gas Package

:

Hardwired

·

Aviation Fuel Package

:

Hardwired

·

Chemical Injection Package

:

Hardwired

·

Firewater Pumps

:

Hardwired

·

Nitrogen Generator Package

:

Hardwired

INTERFACE WITH ELECTRICAL SYSTEM DCS control of low and medium voltage motors shall be via redundant serial link RS 485 Modbus RTU communication to Integrated Motor Control System (IMCS). Remote start and stop of motors from DCS shall be provided as required. Controls of high voltage motors may be via hardwired interface if serial interface is not possible.


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DCS shall also receive status for each motor from the IMCS through serial link. The motor status shall be displayed on OWS. Motor trip command from the ESD shall be hardwired to the MCC cabinets directly. The trip relays required for the ESD signals shall be available in the MCC. When the trip command is active it shall not be possible to start the motor either from DCS or from local field mounted hand switch until the trip is cleared. DCS control and monitoring of Variable Speed Drives (VSD) shall be via hardwired interface. Electrical main circuit breakers’ open/close status shall be available in the DCS through serial link from IMCS. Other miscellaneous electrical system signals, which are not available from IMCS such as battery and charger alarms, UPS common alarms, etc., shall be hardwired to the DCS. DCS shall also have interface with Power Supply Monitoring and Control System (PSMCS) via redundant serial link RS 485 Modbus RTU, for monitoring purpose. 15.0

INTERFACE WITH SSIV HYDRAULIC POWER UNIT (HPU) Control and monitoring of SSIV operation shall be done via SSIV HPU located in BK-TNG platform. SSIV HPU will be controlled and monitored by the platform control systems via hardwire interface for safe operation of SSIV. Open / close actions and logic control of SSIV shall be implemented by ESD. SSIV open / close monitoring and HPU status will be handled by DCS.

16.0

INTERFACE WITH PA/GA SYSTEMS Platform audio/visual alarms shall be generated by PA/GA systems. Audible alarms shall be provided in all platform areas. Visual alarms shall be located in areas of high ambient noise levels e.g. turbine generator areas, etc. and near escape routes. Audible and visual alarms shall be as follows: Alarm:

Tone:

Message:

Beacon Colour:

PAPA

Siren

“ABANDON PLATFORM”

Blue

Confirmed Fire

Warble

“FIRE & GAS ALARM”

Red

Confirmed Gas

Warble

“FIRE & GAS ALARM”

Amber

Emergency Shutdown

Warble

“EMERGENCY SHUTDOWN”

Red

Emergency Shutdown with Blowdown

Warble

“EMERGENCY SHUTDOWN & BLOWDOWN”

Red

The ESD and FGS shall interface with PA/GA systems (both A and B) through hardwired signals for the activation of the audio/visual alarms. The signals shall be directly wired to the PA/GA cabinets. PA/GA systems shall also have hardwired interface with DCS for “common fault” signal. 17.0

INTERFACE WITH TELECOMUNICATION SYSTEM A redundant communication link shall be provided between DCTS and telecommunication system. Information and data as required from ICSS and other systems shall be transferred through


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DCTS for onward transmission to COMPANY’s onshore facility in Vung Tau via satellite communication. Communication link with Dai Hung Field (Platform / Oil Tank Cargo) via Digital Microwave Radio System shall be provided for transferring required information and data for BK-TNG. 18.0

FIELD INSTRUMENTATION Field instrumentation provides the interface between the actual processes and the control and safety systems. The integrity and reliability of the overall control and safeguarding systems, which in turn affect plant availability and safety, are dependent on the use of the correct type and quality of the field instrumentation. Therefore, proper selection of the instrumentation types, manufacturers of devices and proper installation practices shall be paramount considerations throughout design of the facility. All field instruments shall be tropicalized and suitable for continuous operation in offshore marine environment. In general field Instrumentation shall be designed and selected in accordance with API RP 551. All electronic transmitters shall be Smart type with “HART protocol” electronic 4-20mA 2-wire loop powered at 24V DC and connected to the associated control/Safety system. Where both process measurement and safeguarding functions are required, the ESD system and DCS transmitters shall be completely independent and shall cover the same process range. Switch devices shall have a minimum rating of 24V dc, 1A, unless specified otherwise on the relevant datasheets. In general, transmitters are preferred instead of process switches. Process Switches (level, pressure, flow) shall be avoided as far as possible since they are less reliable than transmitters due to their un-revealed failure mode. Electronic components of all instrumentation shall be tropicalised. Appropriate measures will be taken in housings and enclosures to deal with condensation arising from daily temperature fluctuations. All transmitters housing shall be SS316 c/w SS316 mounting accessories as minimum. All electronic field transmitters shall have cable gland entries of ISO M20x1.5 and have an integral LCD Digital indicator scaled in engineering units. The Instrument ranges shall be selected such that the normal value is between 50% and 75 % of span for linear scale and 60% to 80% of span for square root input scales. Electronic transmitter shall provide EMI / RFI immunity by means of the circuit as per the most stringent requirements of IEEE and IEC. The EMI / RFI effect shall be less than 0.1% of span when the instrument is subjected to electromagnetic field strength of 30 V/m for frequency range 20 to 1000 MHz. 3-wire or 4-wire, 4-20mA dc Electronic transmitters shall be acceptable only for special measurements such as machinery monitors/ detectors, analyzers, storage tank level etc. with prior approval, and where a 2-wire transmitter may not be commercially available. All instrumentation shall be in accordance with the Instrument datasheets and General Specification for Instruments 1014-BKTNG-IN-SP-0006. Instrument housing material shall be 316 SS as a minimum. Instrument wetted part materials shall be consistent with the process fluids and 316 SS shall be the minimum selected material. All field transmitters and valve electro-positioners shall be electronic microprocessor based “Smart” type, with HART communication protocol. All field transmitters shall have local indication. Threshold function shall be based on analogue 4-20 mA signals. Therefore, transmitters shall be used instead of switches.


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19.0

INSTRUMENT TUBINGS AND FITTINGS Instrument process impulse lines and pneumatic tubing shall be in general 316L SS with minimum content of 2.5% Molybdenum, conforming to ASTM A269 Instrument fittings shall be 316 SS material, double ferule compression type and suitable for the pressure and temperature rating of the process fluids. Other superior tubing/fitting materials such as Super Duplex SS, Monel and Hastelloy will be used, if dictated by the process fluids and piping specifications.

20.0

CABLING All cables shall be of tinned stranded copper conductors with EPR or HF-EPR insulation and LSHF inner sheath, Steel Wire Braided (SWB) armoured (for outdoor) and LSHF outer sheath, thermosetting compound to SHF2. All cables shall be flame retardant as per IEC 60332. Cables for FGS and ESD signals and other signals relating to emergency/essential services shall also be fire resistant as per IEC 60331 and shall have a fire resistant layer between the tinned copper conductor and extruded insulation of MICA glass tape material. Cables for analogue signals shall be individually and overall shielded for signal noise reduction. Cables for discrete volt-free contacts shall be overall shielded only. Discrete 24 VDC power signals shall be without shield (screen). All cables shall be manufactured in accordance with IEC 60092-350, 60092-351, 60092-353, 60092-359 and 60092-376. All cables shall be type tested and certified by an independent testing authority. Cross section for copper conductors shall be as follows: ·

Power cables (i.e. for solenoids, lamps, 24VDC interface signals, etc.): 2.5 mm²

·

Control cables (i.e. for transmitters, positioners, limit switches): 1.5 mm²

All cable glands and plugs/stoppers (for unused cable entry holes) shall be of stainless steel or marine electro-nickel plated brass. Cable glands shall be certified EEx”d” with ingress protection IP 56 according to IEC 61892. All junction boxes shall be of 316 SS construction with bottom entries. Separate junction boxes shall be provided for DCS, ESD and FGS signals. Junction boxes shall also be segregated for IS and Non-IS signals, analogue, digital and powered digital signals for these systems. The IS and non-IS cables shall be routed separately. Cable entry shall be from the bottom (or side) of outdoor instrument and junction box according to IEC 61892. All outdoor cable trays/ladders shall be made from 316 SS. Vertical distance between tray/ladder tiers shall not be less than 300 mm. Multi Cable Transits (MCT) shall be used for cable penetration in order to maintain hermetic levels and zone classification e.g. from hazardous area to non-hazardous area. 21.0

CABLE TRAYS / LADDERS Main Cable Ladders and perforated Cable trays shall be of heavy duty type SS 316L with 1.5 mm thickness as a minimum. Tray / Ladder size shall be selected based on the number of cables and shall have enough strength to bear the cable load. The thickness of cable tray / ladders shall be selected depending on the load on the tray.


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Internal widths of ladders shall be 150, 300, 450, 600 or 900mm unless specified otherwise. For perforated cable trays the widths shall range from 50 to 300 mm. All Cable trays shall be with cover and fastened by suitable nuts and bolts. All cable trays/ ladders shall be treated for Humidity and test shall be as specified in IEC 61537. Electromagnetic Compatibility (EMC) shall be such that in normal use all items shall be passive with respect to electromagnetic immunity and emission. The cable tray/ ladder interior and exterior surfaces shall be free from sharp edges and other projections, which could cause damage to cables. Perforation base area classification for trays shall be Class B as per IEC 61537), unless specified otherwise. All sections of metallic cable runway shall be bonded together between sections and have equipotential bonding. Bonding jumpers shall be stranded insulated copper wire of 6 sq. mm minimum (or 14 AWG), unless otherwise specified. All end sections of metallic cable runway shall be connected to Platform Safety earth at either ends (by 25sq. mm earth wires). 22.0

ELECTRICAL HEAT TRACING When required by process conditions or as indicated in the P&ID, field instruments and instrument impulse lines shall be suitably protected against freezing by electrical heat tracing. The source of electrical heat tracing will be provided by Electrical. For details refer to 1014BKTNG-EL-SP-0013 Specification for Electrical Heat Tracing.

23.0

SIL CLASSIFICATION & VERIFICATION STUDY CONTRACTOR shall carry out safety Integrity Level (SIL) Classification & Verification Study during detailed engineering stage, to determine the SIL of safety loops. SIL Classification & Verification methodology shall be as per IEC 61508 and IEC 61511. SIL Classification & Verification for F&G loops is generally not required. However it will be confirmed as part of classification study. CONTRACTOR shall engage a third party consultant, who is an expert in the SIL Classification & Verification methodology, as the facilitator. COMPANY shall approve the selection of third party consultant. The SIL Classification & Verification Study team shall be formed from competent personnel responsible for process technology, process safety, operations and process control, from COMPANY and CONTRACTOR. Ideally, the SIL Classification & Verification Study should be conducted after HAZOP findings have been incorporated to minimize re-work. CONTRACTOR in detailed engineering P&IDS, as per SIL Classification & Verification, shall indicate the SIL for initiators and final elements.

24.0

FIRE & GAS MAPPING STUDY CONTRACTOR shall carry out Fire & Gas Mapping Study during detailed engineering phase of the project, to determine the location, quantities and coverage of fire and gas detectors in process and utility areas. CONTRACTOR shall engage a third party consultant with mapping software for Fire & Gas Mapping Study. COMPANY shall approve the selection of third party consultant.


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APPENDIX A – INSTRUMENT CONNECTION DETAILS Sl. #

Instrument Type

Process connection

Pneumatic connection

1

Electronic Transmitters

2

Pneumatic Positioners

¼” NPTF or ½” NPTF

3

Valve actuators

3/8” NPTF or ½” NPTF

4

Air Filter regulators

¼” NPTF or ½” NPTF

5

Pressure Gauges

½” NPTM

Pressure Gauges ( Sealed)

DN 50 Flanged

6

Temperature instruments (on Thermo well)

½” NPTM

7

Thermo well

DN 40 Flanged, DN 50 flanged on vessel

8

Level InstrumentsDisplacer

DN 50 Flanged

ISO M20

Rating, Facing and finish as per Datasheet.

Radar Level Instruments

DN 50- DN 100 Flanged ( Based on Vessel nozzle )

ISO M20

Rating, Facing and finish as per Datasheet

9

Level Gauges

DN 50 or DN 25 Flanged on Vessels,

ISO M20– for gauge illumination


10

Flow orifice & Venturi tap

½” NPTF

11

Diaphragm seal Instruments

DN25- DN 80 Flanged

ISO M20


Manifolds (refer datasheets)

Electrical Connection

Remarks

ISO M20

ISO M20 Rating, Facing and finish as per Datasheet.

Notes: 1. For any other instruments not referred above, connection shall be as per individual requirement specified in the data sheets. 2. All flanged connections shall be to ASME.

Instrument Design Basis - offshore platform

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