Vent Nozzle Design Criteria

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PART IV

SECTION 3

DESCRIPTION OF WORKS AND SPECIFICATIONS

DESIGN CRITERIA

FOR

9 WELL PLATFORMS PROJECT

OFFSHORE DESIGN OIL AND NATURAL GAS CORPORATION LIMITED

MUMBAI REGION, MUMBAI INDIA

ISSUED FOR BID 45 0

PREPARED BY

APPROVEDBY

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SECTION - 3

TABLE OF CONTENTS SUB-SECTION TITLE 3.0 DESIGN CRITERIA

3.1 GENERAL

3.2 PROCESS

3.3 PIPING

3.4 STRUCTURAL

3.5 ELECTRICAL

3.6 INSTRUMENTATION

3.7 MECHANICAL, SAFETY &

LIFE SAVING QUIPEMENT

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PART-IV

SECTION 3.1

DESIGN CRITERIA

GENERAL

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3.0 DESIGN CRITERIA

3.1 GENERAL

This bid document include design parameters, P & IDs, electrical schematics, specifications and drawings for piping and submarine pipelines, mechanical, electrical, instrumentation and equipment items to convey the concept of ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-4, RS-8 and RS-11 well platform facilities.,

The final design of the facilities is the ultimate responsibility of the Contractor. In doing this, the Contractor is expected to follow the guidelines of the preliminary design as presented herein for the works to be performed to ensure that its intent is fulfilled. The Contractor shall also ensure that his final design complies fully with the design philosophy and criteria as furnished herein.

3.1.1 Objectives

The Contractors design must be done in a manner to assure that the

following objectives will be met -

- Provide a safe and well protected facility that meets the requirement as detailed herein and consistent with industry accepted and good engineering practices.

- Provide facility that complies with the design parameters and

International Codes and Standards but incorporating changes/ revisions which are not adequately covered and reflected, considering that bid document is solely based on functional specifications .

- Install the most appropriate equipment that will allow

optimum operation of the facility for the given design conditions which will require a minimum of supervisory, operating and maintenance personnel.

- Provide maximum protection to prevent environmental

pollution.

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- Provide optimum use of platform space yet allow sufficient space for operation and maintenance functions, and future expansions.

- Provide shutdown system dedicated to a failsafe design.

- Provide convenient and safe escape route through pathway,

walkway, ladders, staircases etc.

3.1.2 Basic Environmental Conditions

3.1.2.1 The wind, tidal, wave and current parameters are defined in report by

A.H.Glenn & Associates (relevant parameters based on this report are included in Appendix 3.2.1). The complete report will be given to the contractor to be used in his final design.

3.1.2.2 The minimum seabed temperature is 22.8 C (73 F).

3.1.2.3 The ambient temperature varies from a minimum of 16 C (60 F) to a maximum of 40 C (104 F).

3.1.3 Deck Equipment Layouts

For new well platforms, Contractor shall develop deck equipment layout keeping in view operational, maintenance and future expansion requirement. Besides, safety and environment protection conforming to international standards shall be adhered to. Contractor shall ensure that all the facilities are adequately covered to prevent damage due to dropped objects. Further, Contractor shall ensure that the facilities (including space for future facilities) on cellar deck shall be covered with main deck. Deck equipment layouts contained in layout drawings represent the desired layouts of facilities to be installed on the existing platforms. However, Contractor is encouraged to offer alternate / optimum deck equipment layout which will result in the optimum use of deck space. Effects of suggested layouts on the overall structural components shall be taken into consideration by Contractor and shall be subject to review and approval by the Company.

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3.1.4 Noise and Vibration

The Contractor shall follow Part II, Section 5.9 of the document -

"Offshore Installation Guidance on Design and Construction", Department of Energy, U.K. (Latest Edition) in general and the following specifically

- Recommended noise limits for specific work areas. - Vibration limits for human exposure. - Guidelines to minimize noise and vibration problems.

3.1.5 Material of Construction

The Contractor shall note that in this bid document, wherever NACE

Carbon Steel or Carbon Steel with MR-01-75 is specified, it shall mean NACE Carbon Steel meeting the requirement of NACE MR-01-75 specification. This requirement shall be applicable to risers and submarine pipelines, piping components, vessels, instruments and other related facilities. The Contractor shall clearly specify this requirement while procuring the necessary equipment / piping.

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PART-IV

SECTION 3.2

DESIGN CRITERIA

PROCESS

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3.2 PROCESS

This section of the bid document outlines design criteria for

Process and utility systems on ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11 RS-4 and RS-8 well platforms.

In addition to above contractor shall supply loose material for the following

- Well/string hook-up (9 well platforms) in well head area for well fluid, lift gas system and water injection. The respective hook-up material required for well head area shall also be handed over as loose supply material.

= - ONE NO. MPFM as per detail mention in instrumentation specification no 3209. The details of loose supply material are indicated in clause 2.5 of Basic Bid Work.

General Requirements

The description, sizes, specifications, drawings furnished in this bid document for various facilities on ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11, RS-4 and RS-8 well platforms, are indicative & minimum requirements to be provided by the Contractor. Also, it is the Contractor's responsibility under this contract to perform all necessary process simulations, using preferably PROVISION or HYSIM software, and design calculations considering adequate margins when specifying equipment. Any deviation shall require companys approval . Contractor shall prepare process design basis for ZB, RS-1, RS-2, RS-3 RS-5, RS-7, RS-11, RS-4 and RS-8 well platforms, (based on the design criteria indicated in this section. On its review and approval, for ZB. RS-1,RS-2, RS-3 ,RS-5, RS-7, RS-11, RS-4 and RS-8 well platforms, the Contractor shall carry out simulation for different cases indicated in this criteria and develop detailed Process Flow Diagrams In case, simulation results show higher rates for some applications, same (higher rates) shall be used for design

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within the scope of this tender. The design of process and associated utility systems for ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11, RS-4 and RS-8 well Platforms shall be suitable for these rates. Contractor shall also develop detailed Piping and Instrumentation Diagrams and SAFE charts, incorporating all suppliers information..

For ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11, RS-4 and RS-8 well

platforms, the routing / distribution of various utilities (namely Vent/ CD/ OHD/ ODD headers, instrument gas, utility gas, fire water etc.) shown in the bid P & IDs are indicative. The Contractor shall complete these as per final engineering requirements.

Placed below, is the list of sizing calculations/ documents/ drawings which shall be submitted by Contractor, for review and approval

- Process Design Basis - Process Simulation Report - PFDs - P&IDs (1st submission & subsequent revisions) - Process Calculation Report

NOTE Contractor shall necessarily include sizing calculations

in respect of process/ utility piping, equipment/ vessels, safety/ relief valves, control valves, choke valves, orifice plates etc, in above report. However, the sizing of test separator, valves and orifice plates shall be preliminary & subject to review and approval of calculations received from vendors/ suppliers.

- SAFE charts - Cause & Effect Diagram - Process Data Sheets for Instruments - Process Data Sheets for Equipments - Line List - Equipment List - Pressure & Temperature Profiles (for pipelines) - Fire Water Hydraulic calculations ( RS-7,ZB ) - Vent Dispersion Calculations Contractor to note that based upon review and approval of aforesaid calculations/ documents/ drawings only, P&IDs shall be Approved For Construction (AFC).

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On ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11, RS-4 and RS-8 well

platforms. space provision shall be kept for installation of future facilities as shown in P & IDs, layouts and elsewhere in the bid document. It shall be ensured that these future facilities can be installed and operated with ease. Engineering shall be done to take care of future facilities. The built-up of future facilities requirement in local and main shutdown panels are in firm scope of supply of the Contractor. Adequate care shall be exercised when developing the existing platforms modification requirement with special emphasis towards safety, operability and hook up with the existing system with minimum shutdown time requirements. It shall be ensured that modifications to be implemented, do not affect the safety and operability of the systems at the existing platforms.

The following sections outline the design criteria for ZB, RS-1,

RS-2, RS-3 RS-5, RS-7, RS-11, RS-4 and RS-8 well platforms. Also, the size of topside piping, riser and pipeline from barrel to barrel to be maintained same to ensure smooth piggability.

Documentation

The Contractor shall submit all documentation as per the requirements given elsewhere in the bid document. In addition, Contractor shall prepare 8 Nos. process packages and submit to the Company & their Consultants, within one month of approval of all these documents. The process package shall consist of the following documents: - Design basis (with approved deviations, if any) - AFC P & IDs/ Suppliers P & IDs ) - AFC Equipment Layouts ) (A0 & A3 size & bound ) together) - PFDs & Material Balance ) - Data Sheets for Equipments - Data Sheets for Instruments - SAFE Charts - Logic Diagram - Line List - Equipment List - All process / sizing calculations

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3.2.1 WELL PLATFORM FACILITIES

This sub-section of the bid document defines the design criteria for the process and utility systems required on ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11, RS-4 and RS-8 well platforms. Design of these new platforms shall be done as per the data given in this sub-section. All the process, utility, safety and instrumentation systems must meet the requirement of API-RP-14C Recommended Practice for Analysis, Design, Installation and Testing of Basic surface safety systems on offshore production platforms- Latest Edition.

The complete platform system design shall be based on unmanned operation requiring minimum attention for routine maintenance and check-ups.

The process and utility systems required on each platform are discussed in greater detail in the following clauses -

3.2.1.1 NAME OF PLATFORMS : ZB, RS-1, RS-2, RS-3 RS-5, RS-7,

RS-11, RS-4 and RS-8 (Total 9)

3.2.1.2 DESIGN LIFE : 25 years

3.2.1.3 PLATFORM LOCATION :

LOCATION WGS-84 EVEREST-1830 Bombay High Datum

(EVEREST 1830) 732625mE 732603.358mE 732778.358mE

UTM 2145375mN 2145123.510mN

2145128.510mN

19 23 20.77 19 23 18.255N

19 2318.345NZB GEOGRAPHIC

AL 7112 53.939 71 12 54.264E

71 13 00.263E

750413mE 750391.263mE 750566.263mE

UTM 2147021mN 2146769.469mN

2146774.469mNRS1 (FJ1)

GEOGRAPHICAL

1924 6.566 19 24 04.054N

19 24 04.138N

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71 23 4.079 71 23 04.482E

71 23 10.481E

736875mE 736853.337mE 737028.337mE

UTM 2146625mN 2146373.496mN

2146378.496mN

19 23 59.616

19 23 57.104N

19 23 57.192NRS2 (P02) GEOGRAPHIC

AL 71 15 20.098

71 15 20.442E

71 15 26.441E

744934.789mE 744913.079mE 745088.079mE

UTM 2145186.803mN 2144935.292mN

2144940.292mN

19 23 9.378 19 23 06.862N

19 23 06.947NRS3 (P06) GEOGRAPHIC

AL 71 19 55.555

71 19 55.934E

71 20 01.932E

2136 875 mN 2136 623.512

mN 2136 628.512

mNUTM

758 375 mE 758 353.201 mE

758 528.201 mE

19o 18 33.141 N

19o 18 30.601 N

19o 18 30.683 N

RS7 (P-17)

GEOGRAPHICAL 71o 27

31.883 E71o 27 32.320

E 71o 27 38.315 E

2148 625 mN 2148 373.473 mN

2148 378.473 mN

UTM 743 625 mE 743 603.303

mE 743 778.303 mE

19o 25 01.719 N

19o 24 59.212 N

19o 24 59.298 N

RS-4 (P-04)

GEOGRAPHICAL 71o 19

12.272 E71o 19 12.646

E 71o 19 18.645 E

2138 500 mN 2138 248.537

mN 2138 253.537

mNRS-11 ( FJ-7)

UTM 739 125 mE 739 103.310

mE 739 278.31 mN

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19o 19 34.522 N

19o 19 31.989 N

19o 19 32.076 N

GEOGRAPHICAL 71o 16

33.515 E71o 16 33.868

E 71o 16 39.864 E

2135 375 mN 2135 123.548

mN 2135 128.548

mNUTM

742 625 mE 742 603.285 mE

742 778.285 mE

19o 17 51.427 N

19o 17 48.885 N

19o 17 48.972 N

RS-8 (FJ-2)

GEOGRAPHICAL 71o 18

31.943 E71o 18 32.310

E 71o 18 38.305 E

2151 875 mN 2151 623.466

mN 2151 628.466

mNUTM

737 125 mE 737 103.345 mE

737 278.345 mE

19o 26 50.180 N

19o 26 47.683 N

19o 26 47.771 N

RS-5 ( P-01)

GEOGRAPHICAL 71o 15

31.022 E71o 15 31.368

E 71o 15 37.368 E

3.2.1.4 DESTINATION OF WELL FLUID : BHN (from RS-5)

SA/BHS (from RS-1,RS-3, RS-4)

SH Complex (from RS-7)

ID (from RS-8 )

IC (from ZB,RS-2, RS-11)

3.2.1.5 FIELD MAP : REFER DRAWING VOLUME - IV

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3.2.1.6 PLATFORM CAPACITY (STOCK TANK CONDITION)

Platformwise, production rates for ZB, RS-1, RS-2, RS-3, RS-5,

RS-7, RS-11, RS-4 and RS-8 well platforms are placed below :-

ZB PLATFORM MAX.OIL/ GAS/ MAX.WATER MAX.

CASE CASE LIQUID

OIL, BOPD 13667 997 1 1734

WATER, 3778 16615 7765 BWPD LIQUID, 17445 17612 19499

BLPD TOTAL GAS 0.746 0.462 0.677

MMSCMD

RS-1 PLATFORM MAX.OIL/ MAX.WATER MAX.

CASE CASE LIQ/GAS

OIL, BOPD 3791 1202 4927

WATER, 4210 9560 6543

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BWPD LIQUID, 8001 10762 11471

BLPD TOTAL GAS 0.228 0.305 0.402 MMSCMD

RS-2 PLATFORM MAX.OIL/ GAS/ MAX.WATER MAX.

CASE CASE LIQUID

OIL, BOPD 3019 807 2421

WATER, 12579 14999 13501

BWPD LIQUID, 15598 15805 15922 BLPD TOTAL GAS 0.320 0.282 0.302 MMSCMD RS-3 PLATFORM MAX.OIL/ GAS/ MAX.WATER MAX.

CASE CASE LIQUID

OIL, BOPD 4032 2909 3185

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WATER, 10944 12082 12125 BWPD LIQUID, 14976 14991 15310 BLPD TOTAL GAS 0.516 0.476 0.486 MMSCMD

RS-4 PLATFORM MAX.OIL/ GAS/ MAX.WATER LIQUID CASE CASE

OIL, BOPD 3951 743

WATER, 6096 7975

BWPD LIQUID, 10047 8718

BLPD TOTAL GAS 0.406 0.30 MMSCMD

RS-5 PLATFORM MAX.OIL/GAS MAX.WATER . LIQUID CASE CASE

OIL, BOPD 5865 1641 WATER, 6734 9446 BWPD

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LIQUID, 12599 11088 BLPD TOTAL GAS 0.594 0.508 MMSCMD

RS-7 PLATFORM MAX.OIL/ GAS MAX.WATER

LIQUID CASE CASE

OIL, BOPD 2201 780

WATER, 702 1030 BWPD LIQUID, 2904 1810 BLPD TOTAL GAS, 0.383 0.374 MMSCMD

RS-8 PLATFORM MAX.OIL/GAS MAX.WATER

. LIQUID CASE CASE

OIL, BOPD 2527 478 WATER, 6871 7671 BWPD LIQUID, 9398 8149 BLPD TOTAL GAS, 0.253 0.221 MMSCMD

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RS-11 PLATFORM MAX.OIL MAX.WATER MAX. LIQUID/

. CASE CASE GAS

CASE OIL, BOPD 3908 857 3616

WATER, 4928 9152 7684 BWPD LIQUID, 8836 10009 11300 BLPD TOTAL GAS, 0.427 0.362 0.431 MMSCMD Additionally, surge factor of 25% on max. well fluid flow rates and

swell factor of min. 15% on oil flow rates shall be considered for the design of topside facilities.

3.2.1.7 WELL DATA

3.2.1.7.1 WELL CONFIGURATION

ZB WELL PLATFORM

No. of Wells to be drilled : 12 (twelve) nos. No. of Producers : 11 (eleven) nos. (single completion) No .of injector : One no.

(Single completion)

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No.of free slots : Nill

RS-1 WELL PLATFORM

No. of Wells to be drilled : 6 (six) nos. No. of Producers : 6 (six) nos. (5 nos. single completion & 1 nos. duel completion)

No .of free slots : Nil

RS-2 WELL PLATFORM

No. of Wells to be drilled : 5 (five) nos. No. of Producers : 5(five nos single completion) No .of free slots : 1 (one ) nos.

RS-3 WELL PLATFORM

No. of Wells to be drilled : 6 (six) nos. No. of Producers : 6 (4 nos. single completion& 2 nos. Duel completion) No .of free slots : Nil

RS-5 WELL PLATFORM

No. of Wells to be drilled : 6 (six) nos. No. of Producers : 6 (six) nos. 4 nos. (single completion) 2 nos. (Duel completion) No .of free slots : 3 (three ) nos.

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RS-7 WELL PLATFORM

No. of Wells to be drilled : 7 (seven) nos. No. of Producers : 5 (five) nos. 5 nos. (single completion )

No. of water injector : 2 (two) nos. 2 nos. (single completion) No. of free slots : .

RS-11 WELL PLATFORM

No. of Wells to be drilled : 5 (five) nos. No. of Producers : 5 (five) nos. 2 nos. (single completion) 3 nos.(Duel completion) No. of free slot(s) : 4 (four) nos. RS-4 WELL PLATFORM

No. of Wells to be drilled : 5 (five) nos. No. of Producers : 5 (five) nos. 4 nos.( single completion) one(dual ompletion wells) No. of free slots : 1 (one)

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RS-8 WELL PLATFORM

No. of Wells to be drilled : 4 (four) nos. No. of Producers : 4 (four) nos. 3 nos. single completion 1 no. dual completion No. of free slots : 2 (two ) 3.2.1.7.2 PRODUCER WELL CAPACITY PER STRING (STOCK

TANK CONDITION) FOR ZB, RS-1, RS-2, RS-3, RS-5, RS-11, RS-4, RS-8 PLATFORM

LIQUID (BLPD) : 4000

OIL PERCENTAGE : UPTO 100 (OF TOTAL LIQUID) WATER PERCENTAGE : UPTO 94

(OF TOTAL LIQUID) GLR (SM/M) : 250

3.2.1.7.3 PRODUCER WELL CAPACITY PER STRING (STOCK TANK CONDITION) FOR RS-7 PLATFORM

LIQUID (BLPD) : 4000

OIL PERCENTAGE : UPTO 100 (OF TOTAL LIQUID) WATER PERCENTAGE : UPTO 75

(OF TOTAL LIQUID) GLR (SM/M) : 1150

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3.2.1.7.4 WELL FLUID CHARACTERISTICS : As per ANNEXURE-1

3.2.1.8 WELL HEAD CONDITIONS AFTER CHOKE

Pressure, kg/cm (g) : 15-21

Temp. degree C : 60 - 93

3.2.1.9 BASIS FOR DESIGN OF TOPSIDE FACILITIES (WELL FLUID)

All topside facilities shall be designed for a design pressure and

design temperature of 93.7 kg/cm(g) and 104 degree Centigrade, respectively, unless indicated otherwise.

3.2.1.10 CHEMICAL INJECTION SYSTEM

Oil Corrosion Inhibitor (OCI) injection shall be carried out using

associated gas pressure and max. possible gravity head. For separating associated gas from well fluid, a pipe separator shall be installed. Contractor shall ensure that the pipe separator size shall be adequate to fulfill gas requirement of OCI storage vessel and IUG System.

3.2.1.10.1 OIL CORROSION INHIBITOR SYSTEM

Service : Production / test header and departing

well fluid pipeline Associated gas source : Pipe Separator

Chemical : COREXIT-7730 or equivalent Dosage rate : 60 ppm (wt) of max. well fluid flow rate @ 30 ppm (wt) of max flow at each, prod/

test header and departing well fluid pipeline

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Storage capacity : 15 days Dilutant : Nil

Mode of Injection : Associated gas pressure and gravity head

3.2.1.10.2 BACTERICIDE AND OXYGEN SCAVENGER

No permanent facilities shall be provided for injecting the above

chemicals. Bactericide and oxygen scavenger shall be injected through the connection provided for this purpose into the departing well fluid line using portable pump. Provision for hooking up of portable pump to the well fluid departing line shall be provided.

3.2.1.11 WELL TESTING

Platform shall be provided with adequate facilities for well testing

which shall include the following:

3.2.1.11.1 PRODUCTION MANIFOLD The wellhead producer well strings (flow arms) shall be connected to

test and production headers. 3.2.1.11.2 TWO-PHASE TEST SEPARATOR & CORIOLIS BASE MASS FLOW METER

Well/strings testing facility shall include two-phase test separator complete with shut-down panel, safety and control system etc. along with coriolis based mass flow meters (latest generation) in its gas & liquid outlet piping to measure gas, oil & water flow rates produced from selected individual wells/strings .

Quantity : One

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Capacity : As described in Clause 3.2.1.7.2 (producer well string capacity)

Type : 2- phase, Horizontal Separator

Surge factor : 25% on maximum well fluid

flow

Swell factor : 15% minimum

Liquid Residence Time : 3 minutes (min.) on maximum liquid flow including surge and swell

Design Basis : International Codes & Standards

Operating Pressure, Kg(Cmg) : 15-21

Operating Temperature, C : 60-93

Design Pressure, Kg(Cmg) : 47.0

Design Temperature C : 104.0

Max. Liquid Level : Centre line of horizontal vessel (including surge)

Liquid carryover in gas : Max. 13.4 Litres/ MMSCM of gas. Liquid particle size should not be more than 10 micron

Minimum nozzle size for the vessel shall be fixed by vendor depending upon requirement for glass flake filled vinyl ester lining. The system shall be designed for the following components in gas phase - CO2 : 3% H2S : 230 ppm

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Water : Saturated Mol. Wt. : 21-24

Testing facilities shall conform to API-RP-14C and other international standards.

Contractor shall have complete responsibility for process guarantee

of test separator and coriolis based mass flow meters and their integration with other facilities on ZB, RS-1, RS-2, RS-3, RS-5, RS-7, RS-11, RS-4 and RS-8 well platforms for well testing requirement and not limited to design criteria, specification, data sheet etc. included in bid document.

Further, the specifications in respect of two-phase test separator and water cut meter, though, included in the bid document, yet Contractor shall have the liberty to suggest modifications in the same and put-up for companys approval, to achieve the intent of scope of work. Contractor shall also develop specification for coriolis based mass flow meter (for gas outlet) and submit to Company for review and approval.

3.2.1.12 CRUDE CONDENSATE VESSEL

3.2.1.12.1 PURPOSE : To collect liquid from Closed Drain

Headers (CDH) and Open Hydrocarbon Drain (OHD) Headers

3.2.1.12.2 HOLD-UP : 2 M (Minimum)

3.2.1.12.3. LIQUID DISPOSAL : To departing well fluid pipeline based upon blow-case design & utilizing lift gas/ instrument & utility gas for blow down of liquid into the departing pipeline

Contractor shall review the blow-case design indicated in bid P & IDs and incorporate necessary changes for automatic blow down (without any manual intervention) of crude/ condensate into well fluid pipeline, within the scope of this tender. Further, Contractor

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shall demonstrate that the final blow-case design adopted shall remain operational under all operating conditions and meet safety requirements.

3.2.1.14 SAFETY AND RELIEF SYSTEM

Platform Safety Relief System including ESD & FSD shall be

designed as per API-RP-14C. All vents shall be discharged to a relief (vent) header which shall be connected to a vent boom located at a safe distance from platform. Vent boom shall be at such an angle, height and distance from the main deck so that H2S and HC gas concentration, on the platforms shall remain within acceptable limits for personnel safety under worst conditions.

Contractor shall carry out dispersion analysis considering all production scenario and worst environmental conditions based on which the vent boom extension / elevation shall be decided.

3.2.1.15 FIRE AND GAS DETECTION & FIRE SUPPRESSION

Various fire and gas detection and fire suppression facilities shall be

provided to ensure safe operation of the platform. These shall include:-

- Fixed HC Gas Detection, Alarm and Shutdown System - Portable HC Gas Detectors (2 nos. for each platform) - Portable CO2 & DCP Fire Extinguisher

- ESD and FSD provisions Relevant codes e.g. API-RP-14C & NFPA shall be followed. (A list

of codes is attached as APPENDIX 3.2.1).

3.2.1.15.1 Dry Chemical System

Dry chemical system shall comprise of a minimum 3 no. skids of

350 lb. each, one each on cellar deck, main deck and helideck.

3.2.1.16 DIESEL STORAGE

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Diesel shall be stored in the deck crane pedestal. The size shall be sufficient to cater for 48 hrs. continuous operation of the deck crane.

3.2.1.17 LAUNCHERS/ RECEIVERS

PLATFORM LAUNCHERS/ RECEIVERS

ZB i) 16 WF launcher (to ICD)

ii) 6 LG Receiver (from IB) iii) 6 WI Receiver (from IQ) iv) 2 Nos.12 Launcher/Receiver (Space only)

RS-1 i) 10 WF launcher (to SA)

ii) 6 LG Receiver (from SC1) iii) 2 Nos.12 Launcher/Receiver (Space only)

RS-2 i) 12 WF launcher (to ICD)

ii) 6 LG Receiver (from NM) iii) 2 Nos. 12 Launcher/Receiver (Space only)

RS-3 i) 12 WF launcher (to BHS)

ii) 6 LG Receiver (from SA/BHS) iii) 2 Nos. 12 Launcher & Receiver (Space only)

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RS-5 i) 12 WF launcher (to BHN)

ii) 6 LG Receiver (from NM) iii) 2 Nos.12 Launcher/ Receiver (Space only)

RS-4 i) 12 WF launcher (to BHS)

ii) 6 LG Receiver (from SB) iii) 2 Nos.12 Launcher/Receiver (Space only)

RS-8 i)10 WF launcher (to ID)

ii) 4 LG Receiver (from ID) iii) 2 Nos.12 Launcher/Receiver (Space only)

RS-7 i) 12 WF launcher (to SH Complex)

ii) 6 LG Receiver (from SH

Complex)

iii) 6 Receiver for water injection (from ED)

iv) 2 Nos. 12 Launcher/ Receiver (Space only)

RS-11 i) 12 WF launcher (to ICD)

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ii) 4 LG Receiver (from ICP) iii) 2 Nos. 12 Launcher & Receiver (Space only)

3.2.1.18 INSTRUMENT AND UTILITY GAS SYSTEM

Lift gas will be used as the primary source of Instrument and Utility

Gas. During start-up and failure of lift gas, associated gas separated from well fluid in pipe separator shall be used for meeting instrument and utility requirements. The instrument and utility gas system shall primarily consist of utility gas cooler/ air cooled finned pipe heat exchanger, pressure reduction system, filter separator, instrument gas receiver and hairpin type double pipe heat exchanger alongwith piping, safety and instrumentation items.

.

3.2.1.18.1 Purpose

The system shall be provided to cater to the requirement of instrumentation, blowing down crude / condensate to departing well fluid pipeline and pneumatic supply to OCI transfer pump.

3.2.1.18.2 Operation and Philosophy

The pipe separator shall be operated continuously for OCI Injection system and also, as fall back arrangement for inst./ utility gas.

3.2.1.18.3 Gas Conditioning System

Inlet Gas Conditions

Pressure, kg/cmg - Normal/minimum/Design : 8/7.5/10.6

Temperature, Deg. C - Normal/minimum/Design : 60/40/75

3.2.1.18.4 The Gas Conditioning System (including Instrument Gas System and

Utility Gas System) and Instrument Gas System shall be designed for minimum 80 NM/hr. and 25 NM/hr., respectively. However, the Contractor shall consider higher of the utility gas requirement

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(OCI transfer pump and blow down requirement for crude/ condenste vessel) plus Instrument Gas Requirement (Max.) for deciding the total capacity of Gas Conditioning System.

Gas conditioning system consists of the following equipment -

ITEM CAPACITY NUMBER TYPE

i) Utility Gas To meet the requirement One Finned Pipe Cooler Cooler/ Air of inst. & utility gas (*)_ Cooled Finned Pipe Heat Exchanger

(*) Shall be manifolded with multiple smaller bore pipes having extended surfaces.

ii) IG/UG Filter To meet the requirement One -

Separator of inst.& utility gas

iii) Hairpin type To meet the requirement One Based on heat double pipe of instrument gas transfer from

prod. heat exchanger header to inst.

gas 3.2.1.18.5 HAIRPIN TYPE DOUBLE PIPE HEAT EXCHANGER

The Instrument / Utility gas downstream of filter separator remain

saturated and not having required dew point for proper functioning of the instruments as well as OCI transfer pump.

In view of above, a hairpin type double pipe heat exchanger is

envisaged downstream of instrument gas receiver. It is anticipated that the Instrument / Utility gas will get heat from the well fluid flowing in the production header.

The design of hairpin type double pipe heat exchanger shall be based

on providing 10 degree superheat to Instrument / Utility gas. This

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heat exchanger may preferably be kept in the scope of Instrument / Utility gas System vendor who shall demonstrate and provide all necessary back-up calculations to prove that the system being supplied is capable enough to fulfill the design criteria and also, even after pressure reduction, the instrument gas shall remain condensate free for smooth operation of instruments.

3.2.1.18.6 INSTRUMENT GAS RECEIVER Number : One Capacity : 15 minutes requirement between

normal and minimum pressure Pressure, kg/cm(g) Normal/min./Design : 7.5/5.5/10.6 Temperature, deg. C Normal/Min./Design : 55/30/10

3.2.1.19 WATER INJECTION FACILITIES FOR ZB

Water injection facilities shall be provided on ZB well platform only, as per following details:-

Source of injection water : IQ well platform No. of wells on water injection : 3 nos. (*) (all single completion)

Injection Pressure (at well head) : 95.0 kg/cm2g

* Well ZB#JH is an injector well. ZB#CH & #EH shall be converted from producer to injector subsequently.

Departing and arrival pressure and temperature for IQ - ZB water

injection pipeline are given below

Sl.No. Pipeline Departing Arrival

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Pres.,kg/cm2g Temp.,deg c Pres.,kg/cm2g Temp.,deg c IQ ZB 1 IQ-ZB

103.0 28 96.0 28 Injection Water shall be hooked up with fire water header after

pressure reduction and serve as source of water for fire suppression in case of FSD on ZB well platform.

Water injection facilities shall be designed for the following flow

rates

SM3/day Sl.No. Max. Nor. Min.

1 ZB Platform - Wellwise 1600 1000 500 - Total 3000 2400 500

3.2.1.20 WATER INECTION FOR RS-7

Water injection facilitiesbe provided on RS-7 well platform , as per following details:-

Source of injection water : ED well Platform No. of wells on water injection : 2 nos. (*) (all single completion)

Injection Pressure (at well head) : 95.0 kg/cm2g Departing and arrival pressure and temperature for ED- RS-7 water

injection pipeline are given below

Departing Arrival Sl.No. Pipeline Pres.,kg/cm2g Temp.,deg c Pres.,kg/cm2g Temp.,deg c

1 ED-RS-7 ED RS-7

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133.14 27.47 133 36.98 Injection Water shall be hooked up with fire water header after

pressure reduction and serve as source of water for fire suppression in case of FSD on RS-7 well platform.

Water injection facilities shall be designed for the following flow

rates

SM3/day Sl.No. Max. Nor. Min.

1 RS-7 Platform - RS-7 BH 1000 750 350 RS-7 CH 400 250 150 Total 1400 1000 500

3.2.1.21 BASIS FOR DESIGN OF TOPSIDE FACILTIES (INJECTION

WATER) All topside facilities shall be designed for a design pressure and

design temperature of 151.6 kg/cm (g) and 55 deg Centigrade, respectively.

3.2.1.22 LIFT GAS FACILITIES FOR ZB,RS-1,RS-2,RS-3

Lift gas facilities shall be provided as per following details:

Source Lift gas facilities : IB platform (for ZB) SC1 platform (for RS1) NM platform (for RS2) SA/BHS platform (for RS3) No. of producer wells on gas lift :

- 11 nos. (all single compl.) on ZB platform - 6 nos. (5 nos. single compl. & one dual compl.) on RS1 platform - 5 nos. (all single compl.) on RS2 platform

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- 6 nos. (4 nos. single compl. & 2 nos. dual compl.) on RS3 platform

Injection Pressure (at well head) : 80.0 kg/cm2g Departing and arrival pressure and temperature for lift gas pipelines

are given below


IB ZB 1 IB-ZB 88.0 27 83.0 25

SC1 RS1 2 SC1-RS1 86.7 29 84.8 28

NM RS2 3 NM-RS2 85.0 28 83.8 26

SA RS3 4 BHS-RS3 87.1 36 85.3 27

Lift gas facilities shall be designed for the following flow rates

MMSCMD Sl.No. Max. Nor. Min.

1 ZB Platform - Wellwise 0.06 0.03 - 0.045 0.01 - Total 0.506 0.405 0.02 2 RS1 Platform - Wellwise 0.075 0.03 0.06 0.01 - Total 0.300 0.240 0.02 3 RS2 Platform - Wellwise 0.06 0.03 0.045 0.01 - Total 0.338 0.270 0.02 4 RS3 Platform - Wellwise 0.1125 0.045 0.090 0.01 - Total 0.413 0.330 0.02

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Lift gas pipelines shall be designed for a design pressure and design temperature of 105.0 kg/cmg and 75 deg. centigrade, respectively.

Lift Gas composition : As per

ANNEXURE-2 Lift gas facilities shall include Lift Gas Manifold, lift gas flow arm

piping, instrumentation, safety system and etc.

3.2.1.23 LIFT IES FOR RS-5,RS-7,RS-11,RS-4,RS-8 ` Lift gas facilities shall be provided as per following details:

Source : NM Platform for RS-5 : SH Complex for RS-7 : IC complex for RS-11 : SB Platform for RS-4 : ID Platform for RS-8 No. of producer wells on gas lift :

- 6 nos. ( 4 nos.single compl & 2 nos. dual compl..) on RS-5 platform

- 5 nos. (5 nos. single compl. ) on RS-7 platform - 5 nos. (2 nos. single compl& 3 nos. dual compl..) on RS-11

platform - 5 nos. (4 nos. single compl. & 1 no. dual compl.) on RS-4

platform - 4 nos. (3 nos. single compl. & 1 no. dual compl.) RS-8 platform

Injection Pressure (at well heads) : 80.0 kg/cm2g

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Departing and arrival pressure and temperature for lift gas pipelines are given below


NM RS-5 1 NM RS-5 - - 84.47 30.00

SHP RS-7 2 SHP-RS-7 95.0 58 94.09 21.32

IC RS-11 3 IC-RS-11 89.0 55 87.10 29.80

SB RS-43 4 SB-RS-4 83.0 24 83.013 22.72

ID RS-8 5. ID- RS-8 84.4 24 81.55 27.30

Lift gas facilities shall be designed for the following flow rates

MMSCMD Sl.No. Max. Nor. Min.

1 RS-5 Platform - Wellwise 0.075 0.03 - 0.06 0.01 - Total 0.60 0.36 0.02 2 RS-7 Platform - Wellwise 0.075 0.03 0.06 0.01 - Total 0.325 0.225 0.02 3 RS-11 Platform - Wellwise 0.06 0.03 0.045 0.01 - Total 0.48 0.30 0.02 4 RS4 Platform - Wellwise 0.105 0.045 0.090 0.01 - Total 0.63 0.405 0.02 5 RS-8 Platform - Wellwise 0.06 0.03-0.06 0.01 - Total 0.30 0.225 0.02

Lift gas pipelines shall be designed for a design pressure and design

temperature of 105.0 kg/cmg and 75 deg. centigrade, respectively.

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Lift Gas composition : As per

ANNEXURE-2 Lift gas facilities shall include KO Drum, lift gas manifold, lift gas

flow arm piping, instrumentation, safety system and etc. 3.2.1.24 KO Drum

3 KO Drum is proposed to be installed downstream of scrapper tee for removal of liquid condensed in lift gas pipeline. Contractor shall size KO Drum considering separation of 15 lb/ MMSCF liquid. However, size of KO Drum shall be maintained same on all 5 nos. well platforms. The P&ID and process data sheets are placed elsewhere in the bid document. Bidder shall review the P&ID and process data sheets and suggest necessary changes for automatic drainage (no manual drainage envisaged) of liquid into well fluid pipeline, within the scope of this tender.

3.2.1.25 BASIS FOR DESIGN OF TOPSIDE FACILTIIES (LIFT GAS)

All topside facilities shall be designed for a design pressure and

design temperature of 105.0 kg/cm (g) and 75 deg Centigrade, respectively.

3.2.1.26 MATERIAL OF CONSTRUCTION (Topside Facilities)

Material of Corrosion

Construction Allowance

WELL FLUID : CS-NACE 6 MM

LIFT GAS : CS-NACE 6 MM

INJECTION WATER : CS 3 MM

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3.2.1.27 RTU PARAMETERS

In general, RTU parameters required to be monitored are shown in P&IDs. However, these are indicative and minimum and Contractor is required to supplement the same, based on the list placed at ANNEXURE-4.

.

3.2.1.28 FLOW METER SPECIFICATIONS

Contractor shall develop specifications in respect of coriolis based mass flow meter (latest generation) and multi beam (online) ultrasonic flowmeter (latest generation) and submit to company for review and approval. The observations made by Company shall be duly considered and incorporated for final approval before placement of the order for the these items.

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ANNEXURE-1

(Sheet 1 of 4) WELL FLUID COMPOSITION (TYPICAL) MUMBAI HIGH FIELD

COMPONENT FOR GOR-703 MOL PERCENT (ON DRY BASIS)* N2 1.16 CO2 3.00 H2S 0.023 C1 69.994 C2 5.866 C3 4.409 IC4 0.879 NC4 1.064 IC5 0.197 NC5 0.169 C6 0.089 CUT-1 2.093 CUT-2 0.639 CUT-3 1.873 CUT-4 1.086 CUT-5 1.174 CUT-6 0.973 CUT-7 0.657 CUT-8 0.968 CUT-9 0.773 CUT-10 0.633 CUT-11 0.401 CUT-12 1.880 ------------- 100.0000 --------------

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PSEUDO-CUT DETAILS

CUT ABP (DEG C) SP GR CUT-1 40 0.645 CUT-2 65 0.702 CUT-3 95 0.767 CUT-4 125 0.778 CUT-5 155 0.796 CUT-6 185 0.799 CUT-7 215 0.801 CUT-8 245 0.840 CUT-9 275 0.848 CUT-10 305 0.862 CUT-11 335 0.863 CUT-12 465 0.888 * THIS IS A TYPICAL WELL FLUID COMPOSITION.

CONTRACTOR SHALL GENERATE THE COMPOSITION OF WELL FLUID FOR OTHER GORs AND ALSO, FOR LIFT GAS BASED ON INFORMATION FURNISHED IN THIS DATA SHEET.

CRUDE OIL PROPERTIES API GRAVITY AT 60 degree F : 38-40 B.S. & W, % VOL. : TRACES POUR POINT, degree C : 27.0 WAX CONTENT, % WT : 14-15% w/w RVP OF STABILISED CRUDE : 0.7 kg/cmA(Max.)

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VISCOSITY : AS PER TABLE BELOW

TYPICAL CRUDE OIL VISCOSITY (CP) DATA AT DIFFERENT TEMPERATURES

1st Stage Separator Sample

(Collected at 14 kg/cmg & 85C)

2nd Stage Separator Sample (Collected at 3.5 kg/cmg & 85C)

3rd Stage Separator Oil Sample

(Collected at Atmospheric

Temp. & Pressure)

Oil Sample from Storage Tanker (Temp. 18C)

Temp Increas-ing

Temp.

Decreas-ing

Temp.

Reheat-ing

Cooling

Increas-ing

Temp/

Decreas-ing

Temp.

Increas-ing

Temp/

Decreas-ing

Temp.

Increas-ing

Temp/

Decreas-ing

Temp.

24C Ball does not roll

Ball does not roll

Ball does not roll

- - - - - -

26C 4.9827 -do- -do- - Ball does not roll

18.2242*

- - -

28C 3.9370 -do- -do- Ball does not roll

2.7762 - - Ball does not roll

Ball does not roll

29C - 2.8903 -do- 3.5561 - - - - -

30C 3.5936 2.4961 2.4746 3.5136 1.4455 4.5309 Ball does not roll

5.4875 3.2371

35C 2.8276 2.2177 2.2249 3.0789 1.2244 See Note

4

4.4834 -do- 4.9931 3.0115

40C 2.5279 1.9677 2.0396 2.7728 1.0891 4.2723 2.9075 4.7326 2.8282

50C 2.1858 1.8047 1.7688 2.0455 0.9613 2.6399 2.1525 2.5252 2.1624

80C - - - - - 1.3316 1.2488 - -

* Repeat experiments at 28C showed inconsistent roll timings.

1) Viscosity of 1st Stage Separator sample was determined at 14 kg/cmg. 2) Viscosity of 2nd Stage Separator sample was determined at 3.5 kg/cmg.

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3) Viscosity of 3rd Stage Separator Oil and Storage tanker oil sample was determined at atmospheric pressure.

4) Viscosity of 2nd Stage Separator sample with decreasing Temperature

are not as they are expected to be.

AVERAGE FORMATION WATER ANALYSIS

COMPONENT mg/l Ca++ 290

Mg++ 36

Na+ and K+ as Na+ 9483

Cl- 14200

SO4= 230

CO3= 120

HCO3= 1281

TDS 25640

Salinity AS Nacl 23400

TSS 40

pH 8.3

Sp. Gr.@ 30C 1.018

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ANNEXURE-2

LIFT GAS COMPOSITION - MUMBAI HIGH FIELD COMPONENT MOL%

N2 1.365 CO2 3.475 C1 81.613 C2 6.505 C3 4.314 IC4 0.706 NC4 0.764 IC5 0.094 NC5 0.068 C6 1.070 H2S 0.026

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APPENDIX- 3.2.1 List of applicable codes for Fire Suppression System and design of other well platform facilities as applicable- - National Fire protection Association (NFPA)

- American Petroleum Institute (API) RP 55

- American Petroleum Institute RP 14 C

- American Petroleum Institute RP 14 G

- American Petroleum Institute RP 2 G

- American Petroleum Institute RP 14 E

- American Petroleum Institute RP 500

- National Electric Code (NEC)

- National Electrical Manufacturer's Association (NEMA)

- UK Department of Energy (DOE)

- Offshore Installations : Guidelines on Design and Construction.

- Under writers Laboratory Inc, PTB, BASSEEFA or equivalent Testing

Institution

- Instrument Society of America (ISA)

- Recommended Practices

- Other relevant Codes and good engineering practices followed in the industry.

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ANNEXURE-3

LIST OF RTU PARAMETERS

I. WELL PLATFORM - Well head pressure - Flow arm temperature - SSSV status - SSV status - Main well fluid line pressure - Main well fluid line temperature - Main gas lift injection line pressure - Main gas lift injection line temperature - Gas lift injection pressure (well wise) - Gas lift injection differential pressure (well wise) - Water injection pressure at well head - Instrument gas header pressure - Battery charging current - Battery voltage - Annulus pressure A section - Annulus pressure B section - Annulus pressure C section II. PROCESS PLATFORM (for monitoring at Control Room / elsewhere) - Well platform flow line pressure (Incoming) - Well platform flow line temperature (Incoming) - Gas lift line flow rate (outgoing) - Gas lift line pressure (outgoing) - Gas lift line temperature (outgoing) - Water injection line pressure (Outgoing) - Water injection line flow rate (Outgoing)

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