Upgrading Fine Filters at CC Water Injection Plant

CLIENT: ZAKUM DEVELOPMENT COMPANY
CC WATER INJECTION PLANT

PROJECT/JOB TITLE: UPGRADE (PACKAGE 1) FINE
FILTERS MODIFICATIONS FEED
ZADCO PROJECT NUMBER: P8341
DOCUMENT TYPE: TECHNICAL SPECIFICATION
MECHANICAL EQUIPMENT
DOCUMENT TITLE:
SPECIFICATION
ZADCO DOCUMENT NUMBER: P8341-TS-260-M-0003
GENESIS JOB NUMBER: J18001
GENESIS DOCUMENT NUMBER: J18001-J02-001
D 26/09/12 Issued for EPC GS AMH AMH
C 04/07/12 Issued for Approval GS AW AMH
B 13/04/12 Re-issued for Review GS IWH AMH
A 17/02/12 Issued for Review GS IWH AMH

Rev Date Description Issued By Checked Approved Client
By By Approval
ZADCO – Upper Zakum Facilities
CC Water Injection Plant Upgrade
(Package 1) Fine Filters Modifications FEED Project
Mechanical Equipment Specifications
HOLDS LIST
HOLD Description Section
REVISION HISTORY
Rev. Description Section
B Content and format rewritten as an amendment to All

relevant ZADCO mechanical specifications Z0-TS-M-
02010 & 02020, in line with Client comments
C Client comments incorporated 2.3, 2.5, 2.6,

3.3 & 3.6
D Issued for EPC, no change to content -
Genesis Page 2 of 18 Date: Sep 2012

File name: P8341-TS-260-M-0003 Rev D Mechanical Equipment Specification Rev: D
ABBREVIATIONS
ADNOC Abu Dhabi National Oil Company
AISC American Institute of Steel Construction
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing of Materials
AWS American Welding Society
BS British Standard
CC Central Complex
CRA Corrosion Resistant Alloy
CS Carbon Steel
DPI Dye Penetrant Inspection
EEMUA Engineering Equipment and Materials Users Association
EN Euronorm
EPC Engineering, Procurement, Construction.
FEED Front End Engineering Design
GTAW Gas Tungsten Arc Welding
ISO International Standards Organisation
ITP Inspection and Test Plan
IVB Independent Verification Body
LPI Liquid Penetrant Inspection
MAWP Maximum allowable working pressure
MDMT Minimum Design Metal Temperature
MPI Magnetic Particle Inspection

MRB Manufacturing Record Book
MSDS Material Safety Data Sheet
MTO Material Take Off
NACE National Association of Corrosion Engineers
NB Nominal Bore
NDE Non-Destructive Examination
NPT National Pipe Thread
PIM Pre-Inspection Meeting
PMI Positive Materials Identification
ppm Parts Per Million
PWHT Post-Weld Heat Treatment
QA / QC Quality Assurance / Quality Control
RT Radiographic Testing
SDRL SUPPLIER Document Requirements List
SI Système International d’Unités (metric system)
SS Stainless Steel
SWL Safe Working Load
TEMA Tubular Exchanger Manufacturers Association
TDFT Total Dry Film Thickness
UT Ultrasonic Testing
VI Visual Inspection
WFT Wet Film Thickness
WPQR Weld Procedure Qualification Records
WPS Weld Procedure Specifications
ZADCO Zakum Development Company

Table of Contents
HOLDS LIST .............................................................................................................. 2
REVISION HISTORY ................................................................................................. 2
ABBREVIATIONS...................................................................................................... 3
1 INTRODUCTION ............................................................................................... 7
1.1 BACKGROUND ........................................................................................................... 7
1.2 PROJECT DESCRIPTION ............................................................................................. 8
1.3 PURPOSE OF THE DOCUMENT.................................................................................... 8
1.4 GENERAL DESIGN OBJECTIVES.................................................................................. 8
2 AMENDMENTS TO Z0-TS-M-02010 UNFIRED PRESSURE VESSEL:
DESIGN CRITERIA ......................................................................................... 10
2.1 SECTION 5 REFERENCE STANDARDS, CODES, SPECIFICATIONS AND
REGULATIONS .................................................................................................... 10
2.2 SECTION 6 GENERAL REQUIREMENTS ............................................................. 10
2.3 SECTION 10 DESIGN REQUIREMENTS ............................................................... 10
2.4 SECTION 12 NOZZLE CONNECTIONS ................................................................. 11
2.5 SECTION 14 DESIGN OF VESSEL SUPPORTS ................................................... 11
2.6 APPENDIX B LOCAL LOADS FOR VESSELS......................................................... 12
3 AMENDMENTS TO Z0-TS-M-02020 MATERIALS, FABRICATION &
TESTING OF UNFIRED PRESSURE VESSELS FOR GENERAL SERVICE. 13
3.1 SECTION 2 REFERENCE STANDARDS, CODES, SPECIFICATIONS AND
REGULATIONS .................................................................................................... 13
3.2 SECTION 4 VENDOR’S DOCUMENTS .................................................................. 13
3.3 SECTION 5..VENDOR RESPONSIBILITIES ........................................................... 13
3.4 SECTION 6 DESIGN VERIFICATION..................................................................... 13
3.5 SECTION 7 MATERIALS ........................................................................................ 13
3.6 SECTION 8 NOZZLE CONNECTIONS ................................................................... 14
3.7 SECTION 25 SHOP PAINTING ............................................................................... 14
3.8 SECTION 29 VENDOR DOCUMENT AND DATA REQUIREMENTS ..................... 14
3.9 SECTION 30 VENDOR’S DATA REPORT.............................................................. 14
3.10 INSULATION AND PERSONNEL PROTECTION.............................................................. 14
APPENDIX – A ........................................................................................................ 15
1. DESIGN AND REFERENCE STANDARDS,SPECIFICATIONS AND
REGULATIONS .................................................................................................... 15
2. COMPANY'S SPECIFICATIONS .......................................................................... 15
3. PROJECT DOCUMENTS...................................................................................... 15
APPENDIX – B ........................................................................................................ 17
Z0-TS-M-02010 REV 2 UNFIRED PRESSURE VESSELS: DESIGN CRITERIA ............ 17
APPENDIX – C ........................................................................................................ 18

Z0-TS-M-02020 REV 1 MATERIALS, FABRICATION AND TESTING OF UNFIRED

PRESSURE VESSELS FOR GENERAL SERVICE .............................................. 18

1 INTRODUCTION
1.1 Background
The Zakum offshore field is located 84km from Abu Dhabi, with the Upper Zakum
portion of the field being operated by the Zakum Development Company (ZADCO), a
company in the Abu Dhabi National Oil Company Group (ADNOC), and the Lower
Zakum Field being operated by Abu Dhabi Marine Operating Company (ADMA), a
sister company in the ADNOC Group.
Upper Zakum is divided into four geographical producing areas: Central, North,
South and West. The processing facilities are located on the Central Complex (CC)
which is the focal point of the field with production being received from the three
satellite platforms situated in the North, South and West of the field. The satellite
platforms are fed by flowlines from over 90 Wellhead Platform Towers (WHPT’s).
The Central Complex houses the water injection facilities which treat and feed
injection quality seawater to the WHPT’s via the satellite platforms for reservoir
pressure maintenance.
ZADCO has initiated the Upper Zakum Full Field Development (UZFFD) project
aimed at increasing the target crude oil production rate to 750 MOBPD by the end of
2015, and sustaining this production plateau for at least 25 years.
For this increased production rate, the water injection rate will need to be increased
in order to maintain reservoir pressure. This injection water will be delivered both to
the existing WHPT’s as well as to new facilities located on a number of artificial
islands which are currently being constructed. Any shortfall in the water injection
capacity on Central Complex will be installed at the new Central Island facility.
The CC facilities will be upgraded to enable continuous injection water delivery of

900,000 BWPD, and a 400,000 BWPD injection water treatment plant installed on
the planned Central Island. Until the CI facility is operational it is necessary to
increase the capacity of the CC Water Injection Plant (WIP). The upgraded CC
facilities will be operated to produce up to approximately 1,200,000 BWPD in a
temporary “stretched” operating mode during an interim period between 2013 and
2015 to support the initial oil production expansion of the 750,000 BOPD until the
Central Island facilities are available.
ZADCO has appointed Genesis to carry out a FEED for the selected option of
upgrade of the Fine Filters 260-F-001B/C/D/E and PLC on the Zakum CC. This
follows a Conceptual Design Study also carried out by Genesis during 2009/10.

1.2 Project Description

The project involves the following upgrades:
• Modification of four out of the ten existing fine filters 260-F-001A to K to

become high capacity dual media filters in order to increase capacity for
seawater injection to 1,200,000 BPD treated water
• Modification of WIP sequence control system to allow two independent back

wash cycles, ie one for modified fine filters and one for the remaining fine
filters. The WIP sequence control will be built into the new DCS system.
• Addition of temperature compensation to the fine filter backwash process.
• Allowance for all five HP injection pumps to be operated at the same time.
The current logic only allows four HP pumps to be started under automatic
control.
1.3 Purpose of the Document
The purpose of this document is to specify the recommended mechanical design

practices for changes associated with upgrading Fine Filters 260-F-001B/C/D/E.
The document supplements the general requirements of ZADCO vessel
specifications Z0-TS-M-02010 and Z0-TS-M-02020 with project-specific
requirements.
1.4 General Design Objectives

The mechanical design philosophy for the project shall be to produce Fine Filter
modifications designed to achieve the following objectives:-
 Safe to operate
 Non-hazardous to the health of site personnel
 Best available proven technology
 Equipment shall be designed for ease and simplicity of operation
 Equipment shall be designed to minimise the need for maintenance
 Design shall ensure that the layout and configuration of equipment allows
isolation of equipment and systems for safe maintenance
 The design shall ensure that maintenance, can be accomplished with
minimum impact on production and with minimum exposure of personnel to
health and safety hazards
 Equipment design based on similar field-proven technology used in off-shore
or similar locations

 Equipment supplied, as far as possible, complete and ready for installation at

site with minimum site-fabrication and hook-up by others
 Equipment designed to permit sequential modification of the filters, to
minimise down-time during installation
 Mechanical design of new process drain-down nozzles on Filter vessels in
accordance with ASME VIII Div 1

2 AMENDMENTS TO Z0-TS-M-02010 UNFIRED PRESSURE VESSEL: DESIGN

CRITERIA
2.1 Section 5 REFERENCE STANDARDS, CODES, SPECIFICATIONS AND

REGULATIONS
Add the following:
5.5 The edition or revision, including addenda, of the referenced Codes,

Standards & Specifications governing, shall be the latest ruling on the
date of order, unless noted otherwise.
2.2 Section 6 GENERAL REQUIREMENTS

Section 6.5.6 Design Life
Add the following:
This is interpreted as requiring the materials selected for all major items
of piping and equipment items to be resistant to the anticipated
degradation mechanisms and remain fit-for-service for 30 years,
providing routine maintenance and inspection is carried out in
accordance with suppliers’ instructions.
It is acceptable to replace consumables during planned maintenance

interventions, such as wear parts, seals, gaskets and any other
components that cannot achieve the full service life.
2.3 Section 10 DESIGN REQUIREMENTS

10.1.9 Delete clause, since flange rigidity calculations are now mandatory
(ASME VIII Div 1 Appendix 2, section 2,14; ASME VIII Div 2 section
4.16)
Add the following:

10.3.9 The provision of suitable mechanical handling facilities shall be made in
the detail design for any component requiring removal or handling that
exceeds 25kg in weight.
Refer to Lifting & Handling Study P8341-SR-260-M-0008 for project-

specific, handling-related design requirements.
10.6 Weight Control

A Weight Control Report shall be compiled as part of the design
process, to include weight data sheets that indicate empty, hydrotest
and operational weights of the existing and modified Fine Filters 260-F-

001B/C/D/E together with position of centre of gravity. Ref Weight

Control Report P8341-TR-260-S-0003.
10.7 Sparing & Spare Parts

10.7.1 Sparing of Critical Equipment
Current operating mode of existing Fine Filters is eight filters operating,
one in backwash plus one on standby.
For the modified Fine Filters, this shall be revised to nine filters on duty
plus one on backwash, so no Fine Filters will be on standby during the
interim “stretch period” of operations.
10.7.2 Spare Parts
Refer to Spare Parts Philosophy P8341-BD-260-M-0009 for project
specific, spares related design requirements for the modified Fine
Filters
10.8 Insulation and Personnel Protection
The Fine Filter vessel modifications do not give rise to any requirement
for insulation or additional personnel protection equipment.
2.4 Section 12 NOZZLE CONNECTIONS

Add the following:
12.1.40 The new process drain-down nozzles P1/P2/P3 on upgraded Fine

Filters F-260-001B/C/D/E shall be designed for loads specified in
Appendix B of Z0-TS-M-02010.
2.5 Section 14 DESIGN OF VESSEL SUPPORTS

Add the following:
14.19 Design of existing Filter vessel saddle supports and vessel internal
supports shall be carried out for modified Filters 260-F-001B/C/D/E in
accordance with Client approved procedure P8341-PB-260-M-0001
Procedure for Design of Vessel Supports.

2.6 Appendix B LOCAL LOADS FOR VESSELS

Section 1. General
1.6 Revise the clause, to read:
Load combinations shall be in accordance with ASME VIII Div 2,

section 4.1.5.3. Calculations for local loads shall be carried out
according to WRC 107 and WRC 297 or FE analysis.

3 AMENDMENTS TO Z0-TS-M-02020 MATERIALS, FABRICATION & TESTING

OF UNFIRED PRESSURE VESSELS FOR GENERAL SERVICE
3.1 Section 2 REFERENCE STANDARDS, CODES, SPECIFICATIONS AND

REGULATIONS
Add the following:
2.5 The edition or revision of the referenced Codes, Standards &

Specifications governing, shall be that ruling on the date of order,
unless noted otherwise.
3.2 Section 4 VENDOR’S DOCUMENTS

Amend opening sentence to read:
Vendor shall furnish the following documents where applicable to the

Filter vessel modification, for review and approval.
3.3 Section 5 VENDOR RESPONSIBILITIES

Add the following:
5.3 R stamping of the vessel nameplates is not a requirement for

modifications to the non-U-stamped Filter vessels 260-F-001B/C/D/E.
3.4 Section 6 DESIGN VERIFICATION

Add the following:
6.4 EPC Contractor shall be responsible for obtaining third party approval
of design and fabrication survey of modifications to Fine Filters 260-F-
001B/C/D/E.
3.5 Section 7 MATERIALS

7.7 Replace paragraph with:
Coating of new carbon steel bolting and threaded fasteners for

upgraded Fine Filters 260-F-001B/C/D/E shall be in accordance with
OS-FI memo #OS-FI/M.229/11 and appendices 1 & 2 attached.
Add the following
7.16 Refer to Materials Design Basis Memorandum P8341-BD-260-W-0002

for further project-specific, materials-related design requirements.

3.6 Section 8 NOZZLE CONNECTIONS
8.10 Revise the clause to read:
Details (a1), (a2), (a3), (b-2), (c), (j), (k), (l), (m), (n), and (o) of FIG UG-
40 of ASME Section VIII division 1 or details (3), (4) and (5) of Table 4.2.11,
details (1), (2), (3) and (4) of Table 4.2.12 and details (1), (2), (3) and (4) of
Table 4.2.14 of ASME Section VIII division 2 shall not be used.
3.7 Section 25 SHOP PAINTING

Change section heading to SHOP AND FIELD COATING
Change section content to:

All external and internal surfaces for the Fine Filters modifications shall be
prepared, painted, coated and lined in accordance with ZADCO Manual of
Protective Coatings Specifications for Corrosion Control, Z0-TS-Y-02010.
3.8 Section 29 VENDOR DOCUMENT AND DATA REQUIREMENTS

Add the following to the end of the clause:
,where applicable to modification of Fine Filters 260-F-001B/C/D/E
3.9 Section 30 VENDOR’S DATA REPORT

Replace the opening clause with:
Vendors data report shall be complete with the following, where applicable to
modification of Fine Filters 260-F-001B/C/D/E.
3.10 Insulation and Personnel Protection

The Fine Filter modifications do not give rise to any requirement for insulation or
personnel protection equipment.

APPENDIX – A
REFERENCE STANDARDS, CODES & SPECIFICATIONS
1. DESIGN AND REFERENCE STANDARDS,SPECIFICATIONS AND

REGULATIONS
Add the following:

ASME B1.1 Unified Inch Screw Threads
ASTM A153 Specification for Zinc (Hot-Dip Galvanised) Coating
of Iron and Steel Products
ASTM A193 Alloy Steel and Stainless Steel Bolting for High
Temperature
2. COMPANY'S SPECIFICATIONS
Delete the following:
Z0-TS-Y- 02020 Specification for Fluoropolymer Coated Bolting and

Threaded Fasteners
Add the following:

OS-FI/M-229/11 Technical Review and Coating Specification
dated 8 December, 2011 Update for ZADCO Paint Specification NC 21 and
Z0-TS-Y-02020 Rev A, with Appendices 1 & 2
3. PROJECT DOCUMENTS
Add the following
P8341-MR-260-V-0004 Site Survey Report
P8341-TM-260-G-0035 Basis of Design
P8341-BD-260-W-0002 Materials Design Basis Memorandum
A3-260-M-0004-001 GA’s of modified Fine Filters incl. Internals
A3-260-M-0005-001 Vessel Internal Details
P8341-DS-260-M-0002 Vessel Mechanical Data Sheet
P8341-PB-260-M-0001 Procedure for Design of Vessel Supports

P8341-BD-260-M-0007 Maintenance Philosophy
P8341-SR-260-M-0008 Lifting & Handling Study

APPENDIX – B
Z0-TS-M-02010 Rev 2 UNFIRED PRESSURE VESSELS: DESIGN CRITERIA
Z0-TS-M-02010 Rev
2-Unfired Press Vesse

APPENDIX – C
Z0-TS-M-02020 Rev 1 MATERIALS, FABRICATION AND TESTING OF

UNFIRED PRESSURE VESSELS FOR GENERAL
SERVICE
Z0-TS-M-02020_Rev
_1 Mat, Fab & Test of


Upgrading Fine Filters at CC Water Injection Plant

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CLIENT: ZAKUM DEVELOPMENT COMPANY

CC WATER INJECTION PLANT

ZADCO PROJECT NUMBER: P8341

DOCUMENT TYPE: TECHNICAL SPECIFICATION

ZADCO DOCUMENT NUMBER: P8341-TS-260-M-0003

GENESIS JOB NUMBER: J18001

GENESIS DOCUMENT NUMBER: J18001-J02-001

D 26/09/12 Issued for EPC GS AMH AMH

C 04/07/12 Issued for Approval GS AW AMH

B 13/04/12 Re-issued for Review GS IWH AMH

A 17/02/12 Issued for Review GS IWH AMH

HOLD Description Section

Rev. Description Section

B Content and format rewritten as an amendment to All

C Client comments incorporated 2.3, 2.5, 2.6,

D Issued for EPC, no change to content -

Genesis Page 2 of 18 Date: Sep 2012

ADNOC Abu Dhabi National Oil Company

AISC American Institute of Steel Construction

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Society for Testing of Materials

AWS American Welding Society

CRA Corrosion Resistant Alloy

DPI Dye Penetrant Inspection

EEMUA Engineering Equipment and Materials Users Association

EPC Engineering, Procurement, Construction.

FEED Front End Engineering Design

GTAW Gas Tungsten Arc Welding

ISO International Standards Organisation

ITP Inspection and Test Plan

IVB Independent Verification Body

LPI Liquid Penetrant Inspection

MAWP Maximum allowable working pressure

MDMT Minimum Design Metal Temperature

MPI Magnetic Particle Inspection

Genesis Page 3 of 18 Date: Sep 2012

MRB Manufacturing Record Book

MSDS Material Safety Data Sheet

MTO Material Take Off

NACE National Association of Corrosion Engineers

NDE Non-Destructive Examination

NPT National Pipe Thread

PIM Pre-Inspection Meeting

PMI Positive Materials Identification

ppm Parts Per Million

PWHT Post-Weld Heat Treatment

QA / QC Quality Assurance / Quality Control

SDRL SUPPLIER Document Requirements List

SI Système International d’Unités (metric system)

SWL Safe Working Load

TEMA Tubular Exchanger Manufacturers Association

TDFT Total Dry Film Thickness

WFT Wet Film Thickness

WPQR Weld Procedure Qualification Records

WPS Weld Procedure Specifications

ZADCO Zakum Development Company

Genesis Page 4 of 18 Date: Sep 2012

HOLDS LIST .............................................................................................................. 2

REVISION HISTORY ................................................................................................. 2

Genesis Page 5 of 18 Date: Sep 2012

Z0-TS-M-02020 REV 1 MATERIALS, FABRICATION AND TESTING OF UNFIRED