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BCP-B2 PLATFORM PROJECT FUEL GAS CONDITIONING PACKAGE SPECIFICATION

OIL AND NATURAL GAS CORPORATION LIMITED INDIA

ISSUED FOR BID PACKAGE

47
NO. OF PAGE S

19.04.2005

0

BY

APPROVED

REMARKS

DATE

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CONTENTS 1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.2 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 INTRODUCTION Scope/ General Application of this Document Contractor Responsibilities Sub-Contractors/ Sub Vendors STANDARDS, CODES AND REFERENCE DOCUMENTS Codes, Standards and Regulations Reference Specifications and Drawings SCOPE OF SUPPLY General Scope of Supply Acceptance Criteria ENVIRONMENTAL DESIGN CRITERIA AND UTILITIES Climatic Conditions Design Life, Availability and Reliability Area Classification SYSTEM DESIGN CRITERIA General Safety General Plant Process Design Chlorinator Performance Mechanical Requirements Materials Welding Piping Electrical

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5.10 5.11 5.12 5.13 6.0 7.0 8.0 8.1 8.2 8.3 8.4 8.5 9.0 10.0 10.1 10.2 11.0 12.0 12.1 12.2 13.0

Instrumentation and Controls Insulation Fire Protection Utilities DESIGN AND CONSTRUCTION F.G.CONDITIONAR - PACKAGE DESIGN INSPECTION, TESTING AND CERTIFICATION General Quality Assurance Shop Inspection and Testing Hydrostatic tests Material and Welding Inspection Warranty SPARE PARTS & TOOLS Spare Parts Special Tools CONTRACTOR DATA REQUIREMENTS CORROSION PROTECTION AND PREPARATION FOR SHIPMENT Painting and Protective Coatings Preparation for Shipments ATTACHMENTS

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1.0 1.1

INTRODUICTION Scope/General This specification together with P&IDs, other specifications, codes & standards describes the minimum requirements for the design, manufacture, inspection & testing, supply and commissioning of Fuel Gas Conditioning Package including skid based Conditioning package and any other off skid items, complete with all associated auxiliaries and control systems for the BCPB-II Platform Project.

1.2

Application of this Document This document applies specifically to the portion of the EPC contract to develop BCPB-II Platform for the Company The scope of this document is limited to the new BCPB-II Platform Project. This document shall not be used for any other purpose.

1.3

Contractor Responsibilities The Contractor shall be responsible for the complete engineering and coordination, design, manufacture, supply, installation and commissioning, inspection, testing, preparation for shipment of the Fuel Gas Conditioning Package, including full compliance with all applicable design codes and standards, including those listed in Section 2.0 of this specification. The items shall preferably be supplied by the Contractor as a standard package.

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Contractor shall comply with all the requirements of this Specification and its attachments, and no deviation / exceptions will be acceptable in their Tender.
1.4

Sub-Contractors / Sub Vendors Approval shall be obtained from the Company before any work is subcontracted or material is purchased from any sub vendor whose name does not appear in Suggested Vendor list of this Tender

2.0 2.1

CODE, STANDARDS AND REFERRENCE DOCUMENTS Codes and Standards The Fuel Gas Conditioning Package shall be designed, manufactured, certified and tested in accordance with the requirements of this specification, the data sheets, referenced Project Specifications and the latest revisions of the following codes, standards and statutory regulations: • • • • • • • • • NEC NEMA IEC NFPA ASME VIII Div. 1 ASME IX ASME B16.5 ASME B31.3 National Electrical Code National Electrical Manufacturers Association International Electromechanical Commission National Fire Protection Association Pressure Vessels and Boiler Code Welding and Brazing Qualifications Steel Piping Flange and Flanged Fittings Codes for Chemical Plant and Petroleum Refinery Piping. Analysis, Design, Installation and Testing of Basic Surface Safety Systems on Offshore Production Platforms.
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API RP 14C

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• • •

API RP 14F

Electrical Systems for Offshore Production Platforms Fire Prevention and Control Open Type Offshore Production Platforms. Classification of Areas for Electrical Installations at Drilling rigs and Production Platforms on Land and on Marine Fixed or Mobile Platforms. Tubular Exchangers manufacturer’s Association National Association of corrosion Engineers Standard

API RP 14G

API RP 500

• •

TEMA NACE MR-01-75

2.2

Reference Specifications and Drawings. The Fuel Gas Conditioning Package covered by this Specification shall be designed, manufactured and tested in accordance with the requirements of the following Project Specifications: • • • • • • • • • Process Data Sheet for Fuel Gas Conditioning Package Basis of Design Material Requirement Report Specification for Instrumentation General Instrumentation Specification for Packaged Equipment Specification for Electrical Equipment with Packaged Plant Specification for Piping Materials and Design Spec. No. 2004/A Specification for Piping Fabrication and Installation Spec. No. 2004/B Specification for Insulation of Piping and Equipment Spec. No. 2006

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• • • •

Specification for Pressure Vessels Spec. No. 5601F Specification for Packaged Equipment Spec. No. 5100P Specification for Structural Welding and Inspection for Offshore Platform Spec. No. 2009F Protective Coatings for Offshore Structures and Facilities Spec. No. 2005

To minimize conflict, other documents listed herein, the following order of precedence will govern: -Data sheets. -This specification. -P&ID -General Specification. -Code and standards.

3.0 3.1

SCOPE OF SUPPLY General This specification, with attachments and referenced specifications, outlines the minimum requirements for one complete Fuel Gas Conditioning System. This specification does not dictate detailed design of the equipment or assembly of component or assembly of components. It is intended that those responsibilities be retained fully by the Contractor so that all equipment and process warranties remain unmitigated.

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The Contractor shall have single point responsibility for the entire Fuel Gas Conditioning system which shall include the complete design, engineering, coordination, manufacture, testing, delivery and proper functioning of the equipment, not withstanding any omissions from this specification.

3.2

Scope of Supply The Contractor shall supply the following equipment and auxiliary systems and all other requirements in accordance with this specification. Any

equipment that is required for safe operation and shutdown of the Fuel Gas Conditioning System as determined by the Company but not specifically identified herein shall also be included in the Contractor's Scope of Supply.

The Fuel Gas Conditioning System shall condition the Fuel Gas for making it suitable for combustion in the Gas Turbines of Booster Compressors.

The Contractor shall be responsible for the complete design, engineering, co-ordination, manufacture, inspection and testing, delivery and precommissioning and commissioning of the equipment, not withstanding any omissions from this specification.

The Contractor shall supply all the items shown with in the battery limit of Fuel Gas system on the enclosed P&ID, as a minimum, and other items considered necessary to meet the performance guarantees detailed in the EPC Contract. It is envisaged that the system will include, but may not be limited to the following list of items.
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Fuel gas heater (Pre Heater) Fuel gas scrubber Fuel gas filter Fuel gas heater (Super Heater ) Interconnecting piping, fittings and valves, including drain connections Access ladders and maintenance platforms required for normal operational and maintenance. Necessary electrical, instrumentation and control system Any other item, not shown on the P&ID but required to make the system complete and efficiently operable.

-

All the above components shall be mounted on one structural skid fully assembled, piped with inlet and outlet appropriately rated flanges, wired tested and painted for marine environment. 3.3 Acceptance Criteria As a minimum requirement, the offered equipment or the equipment of similar design manufactured by the same supplier: shall have been type tested; and shall have been in continuous satisfactory service on offshore for a minimum period of two (2) years.

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4.0 4.1

ENVIRONMENTAL DESIGN CRITERIA AND UTILITIES Climatic Conditions The Climatic and other conditions under which the Equipment will operate are detailed elsewhere in the Bid Package. The Equipment will be operated on an offshore platform located in the Arabian Sea. The Contractor is responsible for ensuring that all equipment and components provided are suitable for the utility and environmental conditions as specified in the EPC Contract.

4.2

Design Life, Availability and Reliability The Design Life of the process facilities is 25 years. Equipment shall be designed and constructed for a minimum service life of 25 years. Uninterrupted periods of operation shall be detailed in specific equipment specifications.

The Contractor shall be required to meet a specific minimum availability figure, either to enable particular equipment or package configurations to be practicable or for operating reasons. The Contractor shall specify the

estimated availability figure for this package. In addition, the Contractor shall furnish their best estimates of Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) for the equipment concerned.

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In making assessments of the availability and reliability, the Contractor will need to estimate maintenance and repair times. For the purpose of making such estimates, the Contractor may assume that the spares holding is in accordance with their submitted recommendations unless otherwise stated. The Contractor may also neglect any delay caused by factors not directly related to the package in question, unless a basis for estimating such delays is provided by the Company. In the case of failure modes which make a significant contribution to the overall unavailability, the Contractor may be required to demonstrate that their assumed repair times can be achieved. 4.3 Area Classification Electrical and instrumentation will be rated for the applicable Hazardous Area Classification nominated in the Equipment Data Sheets according to API RP500 definitions.

5.0 5.1

SYSTEM DESIGN CRITERIA General These requirements apply to all Equipment listed in the Scope of Supply Section 3.2. Specific Equipment requirements are detailed in Section 6 & 7.

The Equipment's standard designs that meet the performance requirements and that will operate in the marine environment documented in Section 4.0 for a period of 25 years are preferred. The Contractor shall identify any aspects of the standard components or packages that do not meet this Specification and submit descriptions to the Company during the tendering process.

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The Contractor shall be responsible for the process, mechanical, structural, piping, instrumentation and electrical design, sizing, material and equipment procurement and coordination for fabrication, insulation, inspection and testing and protective coating in accordance with this specification. The Contractor's Tender shall include any equipment necessary to make a complete, operable, safe and dependable system including all the equipment and instrumentation necessary to make the unit operational. Instrumentation for the Fuel Gas Conditioning System shall be wired to package edge mounted junction boxes for connection to the Company's Control and shutdown Systems. Instruments for the Fuel Gas Conditioning Skid shall be shipped lose for final installation at site. The Contractor shall prepare equipment data sheets for each item in the Package and include them in its Tender.

The noise emissions of the packages shall not exceed the limits defined elsewhere in the Contract.

The Contractor shall submit detailed calculations for the design of Fuel Gas Conditioning System prior to fabrication, including all components and appurtenances etc., Fuel Gas Pre Heater, Super Heater, Filter, Scrubber, control panel, power requirement, piping, lifting loads, reinforcement requirement for nozzles, man ways, saddle supports, base plates, lifting lugs, platform and ladder clips, normal and surge operating weights, test weights etc. Other specific calculations submittal requirements are stated elsewhere in this specification and attachments. The Contractor shall obtain drawing approval from the Company for all fabricated equipment and Package assemblies prior to fabrication.

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The Contractor data shall include detail design drawings of the vessels, heaters and appurtenances. provided include: • • • • • • • • The drawings that shall as a minimum be

Fuel Gas Scrubber Assembly details Fuel Gas Filter details Power Supply details Fuel Gas Pre Heater details Fuel Gas Super Heater details Control System details Access Platform complete with Ladder Package Drawings & Documentation

All detail design drawing shall be fully dimensioned and complete with a bill of materials. All dimensions shall be in Metric units. The Contractor shall supply suitably rated blank flanges for all blanked off vessel nozzles.

Spectacle blinds where specified at the Package edge tie in points shall be supplied by the contractor.

5.2

Safety

It is the intent of the Company that operational hazards be reduced to a minimum. Contractor shall use sound engineering judgment to complete an installation that will perform the required process function without compromising this aim. The packages shall be designed in accordance with

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API RP 14C, "Recommended Practice for Analysis, Design, Installation and Testing of Basic Safety Systems on Offshore Production Platforms."

-All electrical devices shall meet the requirements for the area classification in which they are installed.

-All controls shall operate in a fail-safe mode. Sparking type drive belts, if used, shall be antistatic type.

-Piping shall be arranged in a manner so as to avoid tripping or headroom problems. Piping or tubing of insufficient mechanical strength for standing or hanging shall be protected from personal traffic.

-The unit shall be suitably earthed to prevent stray currents causing corrosion to external equipment.

-The Contractor shall conduct a HAZOP study on the complete Fuel Gas Conditioning System.

5.3

General Plant Process Design The Fuel Gas Conditioning System equipment shall meet the process performance requirements detailed in the EPC Contract documents. Refer also Process Data sheet for the Fuel Gas Conditioning Package.

Sufficient descriptive information including a process flow-sheet with heat and material balances and piping and instrument drawings (P&ID's) shall be furnished with the Equipment Vendor's quotation to enable equipment size,

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weight, performance, quality, capacity and specification adherence to be determined. The Process Flow Diagram shall include all gas and liquid flows, compositions, temperatures, pressures, power consumption and other relevant physical properties to enable full evaluation of the proposed system. The P&IDs shall provide details of line sizes, control valve sizes, control logic, process and safety set-points.

The Contractor shall furnish all calculations and/or design criteria necessary to confirm Fuel Gas processing rate, power requirement and all other process criteria.

5.4

Performance The Fuel Gas Conditioning System shall be designed to supply Fuel Gas of required quality to all prime movers at minimum 20 Deg C super heat and at an operating pressure of 29 kg / cm2. The Fuel Gas Conditioning System shall be sized to meet fuel gas requirement of all the consumers installed on BCPB-II Platform like drivers of process gas compressors and purge gas requirements of flare headers.

The Contractor shall guarantee the process performance of all the Equipment in the Fuel Gas Conditioning system. The guarantee shall

extend to the design parameters specified on the Process Data Sheets for the following. • • • Supply of fuel gas to meet the quality, quantity & pressure requirements of Turbine vendor at maximum load. Power consumption of Pre & Super Heaters Guaranteed design life of each unit

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A performance test on the F G conditioning package shall be conducted, with in one year from initial on stream date. If the system has been in operation for a period of more than ninety days, and the vendor believes that certain equipment require maintenance prior to the performance test, such maintenance will be performed by the company. This condition shall not be interpreted as to relieve the vendor from his responsibilities for modifications or replacement of equipment elements in accordance with the warranted guarantees. Performance test duration shall be 24 hours of continuous run at the design conditions and performance requirements specified in attached data sheets. Results of the performance test evaluation, including test samples and operational data along with necessary engineering calculation shall be used to determine if the system meets guarantee requirements as specified in attached data sheet. Vendor shall supply or otherwise arrange for all apparatus required for performance test. The skid piping, instruments, electrical and structural items shall be tested and inspected as per Spec no. 5100p ‘Skid Mounted Assemblies’. Any or all of the above tests, may at the Company’s option be witnessed by the Company or its representative and its certification agency.

5.5

Mechanical Requirements

Pressure vessels shall be designed, fabricated, tested and ASME code stamped if applicable in accordance with the ASME Pressure Vessel Code, Section VIII, Division 1 and project specification for Pressure Vessels and

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respective data sheets.

Corrosion allowances for carbon steel pressure

vessels and internals shall be stated on the respective Data Sheets.

Man ways, hand holes, inspection openings, instrumentation, valves, etc., shall be located for ease of operation and maintenance. The Contractor's design shall provide access ladders, walkways, and platforms to service and maintain equipment that cannot be reached from the Package deck level.

Access to all equipment on the Packages for operation, maintenance, etc. is of utmost importance. All equipment, such as filters and other components that require on-line maintenance shall be clearly identified and located in accessible positions. Removal of other piping or equipment to provide access to maintain equipment is not acceptable.

The minimum overhead clearance for piping shall be 2.1 m (including any insulation).

5.6

Materials Materials of construction shall be selected to suit the fluid medium in which it is in contact and shall be suitable for offshore service for the process and Equipment design life of 25 years. The Contractor shall identify each component part and the proposed material, including minimum corrosion allowances, etc. Consideration shall be given to the selection of corrosion resistant materials or internal cladding for the construction of vessels. The Contractor shall provide material

selection in their Tender and shall base their selection on economically

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meeting the life and process requirements of this specification. Refer to Materials requirement Report.

All materials shall be new and in accordance with the manufacturing requirements of API RP14E. Actual ASTM numbers and grades for all materials shall be specified on Contractor's data sheets.

All carbon and low-alloy steel equipment in these services shall be post weld heat-treated.

No asbestos or asbestos-based products shall be used.

5.7

Welding

All welding shall be the responsibility of the Contractor and shall be in accordance the appropriate Codes and Specifications as follows: • • • •

Piping ASME B31.3 Packaged equipment/Exchangers ASME VIII Div. 1 and ASME IX. American Welding Society Code. Project specification for Structural Welding and inspection for Offshore Platforms.

Each weld procedure shall be covered by a suitable procedure qualification tested in accordance with the requirements of ASME IX.

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5.8

Piping All inlet and outlet piping shall terminate at the edge of Fuel Gas Conditioning Skid with an appropriately rated flange and Tie in pipe support. All piping shall be in accordance with the following project specifications for design, material selection, fabrication and installation: • • •

Specification for Piping Materials Specification for Piping Design-2004A Specification for Piping Fabrication- 2004B

Piping shall be arranged in such a manner as to avoid tripping or overhead problems. Piping or tubing of insufficient mechanical strength for standing on or hanging from shall be protected from personnel traffic. All piping and tubing shall be adequately supported.

Valves shall be installed as necessary to bypass and allow removal of duplicated components for maintenance without shutting down or draining the complete system.

Equipment shall be oriented on the Package to allow as much space as possible between pieces of equipment to facilitate maintenance. Adequate space shall be allowed for access to and maintenance of package components without removing any major assembly.

The pipe stress analysis shall be carried out by the Contractor for piping within Conditioning Package, utilizing proven software package.

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The Contractor shall be responsible for meeting flexibility criteria specified in ANSI B31.3 and design of pipe supports. Contractor shall also be

responsible for co-ordination with vessel/exchanger sub-contractors, to ensure that local stress at nozzle junctions are within code acceptable limits. The Contractor shall furnish proposed Pipe Stress Analysis Program with the Tender. The Contractor shall submit pipe stress analysis calculations and report for the Company's approval.

5.9 5.9.1

Electrical All electrical devices and equipment shall meet the requirements for the area classification detailed on respective Data Sheets.

5.9.2

All electrical work on the Conditioning Package shall conform to the project specification for Electrical Equipment of Packaged Plant (FS-4017).

5.9.3

The electrical heater and controls shall be in accordance with enclosed specifications and data sheet.

5.9.4

A Thyristorised/IGBT (Insulated Gate BipolarTransistor) Heater Control Panel shall be provided for heater power supply control. The control panel shall be free standing, metal enclosed compartmentalised ( for separation between power & control circuits) dust and vermin proof, suitable for indoor floor mounting. The control panel shall be located in switchgear room.

5.9.5

The main contactor and all power components in the thyristorised/IGBT (Insulated Gate BipolarTransistor) heater control panel shall be suitable for the thyristorised/IGBT (Insulated Gate BipolarTransistor) power control circuit

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application. The contractor shall have minimum AC-3 duty rating for the full heater load, with adequate margin.

5.9.6

The compatibility of the thyristor panel input signal requirements with the instrumentation/PLC signal shall be ensured. The controller shall be suitable for the input signal received from temperature monitoring device. The system shall be designed to obtain heater power control over the complete range to meet the process requirements from minimum to maximum flow of fuel gas and minimum to maximum inlet temperature. The thyristor circuit shall be able to achieve the control in this range without the switching ON/OFF of the contactor. Contactor shall be kept as a back up to cut off the supply should the thyristor fail resulting in excessive heating. Necessary controls/interlocks shall be provided as per process

requirements/P&Ids.

5.9.7

The control circuit shall be designed so that in case of gas output/supply shutdown the thyristor power circuit output shall be zero. Additionally, in such a case, the heater supply shall be cut off by switching off the main contactor.

5.9.8

The main incoming MCCB of thyristor panel shall be provided with shunt tripping facility with provision of remote tripping. One stop P.B. shall be located in CCP to enable the operator to trip the main incoming MCCB from remote control panel also.

5.9.9

Electrical heat tracing shall be provided for pipelines/equipment within the skid as per P&ID/process requirements. The same shall comply with Spec. No. 4016. for Heat Tracing.

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5.9.10 All equipment selected for hazardous area shall be certified by BASEEFA, UL, FM, CMRI or an internationally recognized certification agency for the service and area in which it is to be used.

5.10

Instrumentation and Controls The Contractor shall design and provide the regime for control and monitoring of the Fuel Gas Conditioning System to assure effective, smooth and safe operation.

Instrumentation shall be in accordance with Project Specifications: • • Basic bid work / Description of works & Design Criteria, Instrumentation, Cl.no.2.3.6. Instrumentation Specification for Packaged Equipment

The panel shall be weather proof to NEMA-4 & explosion proof to NEMA-7. Contractor shall provide interlock logic schemes for the Conditioning Package for the safe operation of the unit. The logic shall be represented by a Cause and Effect Matrix as per API RP 14C, Safe Charts.

The Fuel Gas Conditioning System shall be supplied with its own dedicated Unit control system that shall include ESD/FSD functions.

The Unit Control System shall interface with the platform DCS via serial and / or hardwired interfaces. These interfaces shall provide full operator access to Fuel Gas Conditioning System for monitoring, control and alarms and be capable of receiving and responding to Platform ESD/FSD and Safety Shutdown Signals.

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The Fuel Gas Conditioning System ESD/FSD functions shall be independent of the process control functions and shall have separate field instruments, cabling and terminations. No part of the process control system shall be used for ESD/FSD functions.

The Unit Control Panel (UCP) will be located in Electrical Switchgear room of the BCP-B2 Platform.

The fuel gas conditioning system shall have a local control panel for heater. The Local Control Panel shall send control signals to Thyristorised/IGBT (Insulated Gate BipolarTransistor) Heater Control Panel for heater power supply control. Push button and indication shall be provided in local control panel for tripping & indication of heater power supply. All shutdown/interlocking sequential start/stop and other auxiliary equipment shall be located within the Local Control Panel. In this panel, interface shall be provided to accept the signals from DCS/ESD/FSD to take local action and shall send signals to DCS/ESD/FSD in case action is required by Central Control room.

Contractor shall coordinate with vendor for interface. Auxiliary contacts required for closing/tripping of Remote breaker/contactor shall be rated for 06 Amp at 240 V A.C. Ac-11 duty and 4.0 Amp at 110V D.C–11 duty.

Important parameters indication, recording, alarm etc. shall be repeated in Central Control Room. Vendor shall provide these signals through a skid mounted junction box.

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First out sequence type alarm cabinet shall be provided on local panel.

The Contractor shall include all instrumentation necessary for the safe and effective control and operation of the F.G. Conditioning Skid. The

Contractor shall provide full details of all instrumentation included and shall complete the Instrument data sheets where indicated and submit with their Tender.

Instrumentation and associated equipment shall be suitable for use in a Class 1, Group B & D, Division 1, hazardous area.

Instruments shall be wired to Package edge mounted junction boxes identified and terminated strictly in accordance with Project specifications. Cables from instruments to junction boxes shall be armored type in compliance with FS-4011. Junction boxes shall be suitable for use in a Class 1, Div 1, GR B & D hazardous area.

The Conditioning Package instrumentation and any local instrument panels shall be installed so that indicators and controls are readily visible or accessible from the Package edge.

5.11

Insulation

The respective P&ID drawings provide only the minimum requirements for equipment and piping insulation.

The Contractor shall provide insulation for personnel protection for those

Format No ODS/SOF/004B

Ref. Proc. No ODS/SOP/008 to 015

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SPEC. No. Rev. No. Discipline Page: 25

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parts on external equipment surfaces that can reach temperature more than 60OC and for heat conservation, in accordance with attached Specification No.2006.

5.12

Fire Protection

Passive fire protection measures shall be as per the requirements of project specification and shall be incorporated in to the Fuel Gas Conditioning Package design.

5.13

Utilities Utilities available are indicated in the attached data sheet. The contractor shall specify the utilities required along with their rate of consumption in his bid.

6.0

DESIGN AND CONSTRUCTION

6.1

Fuel Gas Scrubber

Scrubber vessel, its internals and other accessories shall be designed for design condition and shall meet the performance requirement, as detailed here and in data sheet(s).

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 26

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i)

Contractor shall size the vessel based on the governing capacities of finally approved process flow sheets and material/utility balance sheets, as applicable and shall submit all calculations to the company.

ii)

Gas stream into vessel shall be scrubbed for removal of 99.9% of all liquid droplets of size 10 micron and larger.

iii)

As a minimum, vessel shall be sized for liquid residence time of 5 minutes.

iv)

To prevent re-entertainment of liquid into gas stream, feed point shall be higher than maximum liquid level, as indicated below:

Feed Nozzle Size (NB)

Min. distance from Max. liquid level

Up to 6” 8”, 10” 12”, 14” 16”

300 mm 400 mm 500 mm 600 mm

v)

The primary separator assembly shall be designed to separate the bulk of liquid from gas stream using mechanism of impingement, change in direction, centrifuge force. This may consist of a simple device as “Fluid deflector” or a special device developed by vendor for the specific application.

vi)

Vane type mist eliminator

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 27

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Vane mist eliminator assembly shall consist of suitably boxed vane type elements which coalesce finer liquid droplets and separate the same from gas stream, by mechanism of impingement, change in direction, centrifugal force etc. This shall be located below the gas outlet nozzle and shall serve to remove the finer droplets of liquid in the gas stream. The assembly shall be located sufficiently above in the vessel to prevent re-entrainment of liquid in outgoing gas stream. Sufficient space between the exit from this assembly to gas exit nozzle shall be provided to prevent larger liquid droplets formed in the mist extractor from being carried away by gas. Wire mesh type demister shall not be used. In order to achieve performance specified, vendor shall use special internals, developed by him, as an alternate or supplement to above defined internals, with company’s approval.

vii)

The vessel shall be designed, fabricated and tested as per ASME section VIII division 1.

6.2

Fuel Gas Pre heater and Super heater

Fuel gas pre heater and super heater shall be designed to meet the thermal and mechanical requirements given in the attached specification and data sheet. The pre heater & super heater shall be complete with all instrumentation and controls required as per P&ID enclosed. Designing of the vessel shall be as per attached specifications, ASME Sec VIII, Div 1. Fuel gas pre heater & super heater shall be designed for gas flow rate variation from minimum flow (idle run of Turbine ) to maximum flow (under full load) as

Format No ODS/SOF/004B

Ref. Proc. No ODS/SOP/008 to 015

Issue No 01

Rev No 01

Rev. Date 15/10/2003

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SPEC. No. Rev. No. Discipline Page: 28

FS 5095 0 Elect

mentioned in data sheet. Bidder to note that the turbine of compressors may run in idle condition for prolonged durations up to 2-3 hours. Heating element shall be designed accordingly to meet both idle & full load conditions. 6.3 Fuel Gas Filter Bidder shall provide two fuel gas filters (each of 100% capacity) to separate out any solids and liquids from fuel gas. Coalescing filter element extractor shall be of high efficiency for removal of 95% of particles (entrained liquid & solids) of 5 microns and above size (to be confirmed by Gas Turbine vendors for Compressors ). Filter vessels shall be designed in accordance with the attached Data Sheet and ASME Section VIII Division 1.

6.4 i)

Vessels The vessel shall be designed to meet the requirements specified in the attached data sheet(s).

ii)

The vessel shall be designed, fabricated and tested in accordance with ASME, Section-VIII, Div-1. All welding shall be in accordance with the attached Specification No. 2009F.

iii)

The vessel shall be ASME Code stamped.

iv)

As a minimum, the vessel shall be designed for spot radiography. The circumferential joint of dished ends to shell, shall be as a minimum, partially radio graphed. The vessel intended to be used in sour services shall have welds 100% radio graphed. The carbon steel vessel intended to be used in sour service shall be given P.W.H.T.

Format No ODS/SOF/004B

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v)

All nozzles of size 2” NB and less shall be adequately stiffened by gussets to prevent damage during transportation.

vi)

Vessel shall be adequately supported in a manner that there is a clear gap between vessel and platform deck to avoid accumulation of rain water in saliferous marine environment.

vii)

Scrubber vessel shall be heat treated wherever it is required due to service requirements or due to code requirements. It shall be post weld heat-treated as a complete unit and no welding is permitted once post weld heat treatment is done.

viii)

Plates shall be supplied in normalised condition and free from any injurious defects. No repair welding is permissible.

Boiler quality plates over 15 mm thickness shall be examined ultrasonically as per ASTM-A-435.

ix)

Carbon steel plates 50 mm and above in thickness shall meet the following additional requirements.

a)

Charpy ‘V’ notch impact test as per the supplementary requirements S-5 of specification SA 20 at (-)260C.

b)

Vacuum treatment as per supplementary requirement of S-1 of specification SA-20.

Format No ODS/SOF/004B

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c)

Bend test as per supplementary requirement of S-14 of specification SA-20.

d)

Ultrasonic examination as per ASTM-A578 with acceptance standards of level-1.

x)

Cladded plates shall have the cladding of minimum 3 mm thick. Cladded plates shall be as per SA263/SA264/SA265 as per applicability in vessel data sheet, and SA-20 and shall also meet the following requirements.

a)

Shear test: Min. shear strength of cladding and base metal shall be 14 Kgf/min.

b)

The alloy steel surface shall be blast cleaned after heat treatment to No. 1 finish as specified in ASTM-A-480. Repair of cladding by welding is not allowed.

c)

After heat treatment, each plate shall be 100% ultrasonically tested in accordance with ASTM-A-578.

xi)

Material of Construction Material of construction shall be as follows, unless specified otherwise in the attached data sheet. Shell, Dished ends Nozzles Flanges Bolting SA-516, Gr. 60 SA-106, Gr. B SA-105 SA-193, Gr B 7M SA-194, Gr 2HM Hot Dip Galvanised

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 31

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xii)

Self Reinforced Nozzles

SA-105

In case vessel is required for sour service (see attached data sheet), additional requirement of NACE, MR-01-75 and Annexure-1 of Spec. No. 2004 attached elsewhere in the bid package shall also be met.

xiii)

Nozzles shall be self reinforced type for vessel where shell thickness is 50 mm or above.

6.5

Skid The skid shall be designed and built to ensure that all the equipment along with accessories, panel and piping are mounted suitably for convenient operation. The skid shall be designed and built in accordance with the attached Specification 5100P. All welding shall be in accordance with the attached Specification No. 2009F.

7.0

F G CONDITIONER PACKAGE DESIGN A Base plate shall be provided for the F G Conditioner Package. The minimum design and structural requirements for package shall be in accordance with the Project Specification for Packaged Equipment. The Contractor shall be responsible for the design of the Base Plate to ensure it does not wrap during lifting operations. The Package shall be mounted flush on the deck and be designed to be seal welded to the Platform deck. The Contractor shall provide drains both open and closed, within the Package base and these shall be piped to the Package edge. Open drains shall be covered with a removable grating.

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 32

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The Package shall be designed for a single-point lift. The Contractor shall supply one set of certified lifting slings and spreader bars suitable for lifting Base-plates. Design details for a spreader bars or frames for lifting the Package shall be supplied. The Package shall support all the equipment and instrumentation necessary to make the F G Conditioner Equipment operational. The Contractor shall provide the necessary data required for structural dynamic and static analysis of the deck support steel. This information shall include but not be limited to the following: Package weights and center of gravity at dry operating condition Operating speeds for all rotating pieces of equipment. The Contractor shall submit a set of dimensional general arrangement drawings of their proposed Package with the Tender. The drawings shall display anticipated Package dimensions, weights, general item layouts and interconnection orientations. 8.0 8.1 INSPECTION, TESTING AND CERTIFICATION General The responsibility for inspection and testing rests with the Contractor. The Company reserves the right to inspect at any reasonable time during fabrication of the equipment and to witness all hydrostatic, mechanical and performance tests. Contractor shall give minimum 15 days prior intimation regarding test schedule.

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 33

FS 5095 0 Elect

-Tests shall be carried out as per applicable codes and standards. Test certificates shall be submitted for company’s approval. -During inspection by company’s authorized representative, material certificates, shop test data, certification for bought out components and other relevant information shall be furnished so as to ascertain that the specifications and quality are complied with. 8.2 Quality Assurance The Contractor shall demonstrate that they operate a quality system in accordance with an acceptable international standard.

The Contractor shall submit a quality control plan for the review of company at the time of tender. The Contractor shall provide necessary facilities and cooperate with Company and statutory authority inspectors during manufacturing, assembly and testing.

8.3

Shop Inspection and Testing All the F G Conditioning System equipment required to meet the design conditions as stated herein shall be completely assembled and "function tested" at the Contractor's shop in accordance with these specifications. The Contractor shall submit for review and approval by the purchaser an Inspection and test Plan (ITP) covering all relevant components, completed equipment and systems.

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 34

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For the purpose of testing, the F G Conditioner System shall be tested at the point of manufacture and the complete packages shall be supplied under the Contract. The entire F G Conditioner System shall be tested functionally (no load) in the completed assembled configuration. A dimensional check of the Package assembly and components shall be performed for compliance with approved drawings. A detailed test procedure of shop tests shall be submitted at least one (1) month in advance of any testing and shall be approved by the Company. The Company's final acceptance of the equipment will be subject to a performance test once the equipment has been installed and commissioned offshore. 8.4 Hydrostatic tests All Pressure Vessels shall be tested as described in the Project Specification for Pressure Vessels. All the pressure containing parts shall be hydrostatically tested to 1.3 times the respective design pressure for a minimum period of one (1) hour. Chloride ion content in water during hydro testing shall not exceed 50 ppm by volume and the water temperature shall be maintained between 16 and 25OC. Vessels shall be drained and thoroughly dried after hydrostatic tests have been completed.

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 35

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8.5

Material and Welding Inspection Non-destructive materials tests and pressure testing shall be in accordance with the ASME Section VIII, Division 1 and project specification for Pressure Vessels and for Piping Fabrication. The tests shall be witnessed and approved by an inspector representing the Purchaser. All but welds shall be 100% examined by radiography and pressure retaining fillet welds shall be 100% examined by magnetic particle. Should radiography prove impractical, 100% ultrasonic inspection shall be permitted with the approval of the Company. The final non-destructive examination of welds for acceptance purposes shall be carried out after completion of PWHT, where applicable. At the manufacturer's option, radiography may be performed before PWHT, in which case an ultrasonic examination shall be performed after PWHT for acceptance purposes. All structural welds shall be tested in accordance with GS for Structural Welding and Inspection for Offshore Platforms. All Package and vessel pad eyes shall require 100% NDT. Radiographic, ultrasonic, magnetic particle or liquid penetrant inspection of welds shall be in accordance with the ASME/ASTM specification listed in the Table below: Material Inspection Methods & Acceptance Criteria Examination Type Ultrasonic Method of Examination ASME
Ref. Proc. No ODS/SOP/008 to 015

Acceptance Criteria ASME Code Section VIII
Rev No 01 Rev. Date 15/10/2003

Code
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Section V Article 5 Radiography ASME Section V Article 2 Magnetic Particle Inspection Liquid Penetrant ASME E709 Code

Division 1 Appendix 12 ASME Code Section VIII Division 1 UW 51

ASME Code Section VIII Division 1 Appendix 6 Code ASME Code Section VIII Division 1 Appendix 8

ASME Section V Article 6

All non-destructive testing shall be performed by a third party approved and accredited Non-Destructive Testing (NDT) inspection organization. Full traceability of all material components (to material certificates) is required. Full traceability of all welds is required. The contractor shall provide a weld map with full traceability to individual weld numbers. The traceable data shall include NDT reports, welding procedure and welder number. All vessels shall be ASME code stamped. The heat exchangers shall be listed as per TEMA-R Spec. No. 5003 API-661, ASME Sec VIII, Div.1 and attached specifications. All heat exchangers shall be ASME code stamped.

9.0

warranty Vendor shall have final and total responsibility for the design and mechanical performance of all equipment supplied under this specification. Vendor shall

Format No ODS/SOF/004B

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warrant the equipment furnished by him and the performance of the said equipment in accordance with this specification.

10.0 10.1

SPARE PARTS & TOOLS Spare Parts The Contractor shall provide with their Tender a recommended spare parts list to cover the commissioning and start-up, and the first year's operation and maintenance for all the Equipment that comprises the F G Conditioning System. When preparing recommended spare parts lists the Contractor shall follow the Equipment manufacturer's recommendations. The contractor shall provide these spares. All spare parts furnished by the Contractor shall be wrapped and packaged to preserve original as new condition under normal conditions of storage anticipated in India. The same parts shall be appropriately tagged using stainless steel tags and coded so that later identification as to their intended equipment usage will be facilitated. All items supplied shall be packaged separately and clearly marked as "Spare Parts" and shipped along with the equipment in accordance with the instructions from the Company. Packing lists shall be furnished complete and in detail so that parts can be handled without uncrating, should this be required. Start up spares shall be packed and identified separately. Recommended spare should take into account related factors of equipment reliability, effect of equipment downtime upon production and safety, cost of parts and availability of equipment Facilities.

Format No ODS/SOF/004B

Ref. Proc. No ODS/SOP/008 to 015

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SPEC. No. Rev. No. Discipline Page: 38

FS 5095 0 Elect

10.2

Special Tools The Contractor shall provide a list of any special tools required for the erection, operation and maintenance of the equipment with their Tender. The Contractor shall furnish two (2) sets of special tools. Prior to shipment each special tool shall be tagged with stainless steel tag detailing its description and where it is to be used.

11.0

CONTRACTOR DATA REQUIREMENT The Contractor shall furnish data for review and approval in accordance with this specification. In addition to providing completed data Sheets the Contractor shall also provide the following data with their Tender: • • • • • • • • • • • • Preliminary Package Layout Drawings Utility Requirements Availability and Reliability Estimates Data Sheets for all major items of Equipment Sizing Variables/ Process design calculations Details of Thyristor Control System for heaters Descriptive process Information Process Flow Diagram/P&IDs/Heat and Material Balance(s) Proposed Pipe Stress Analysis Computer program Quality Assurance Program Special Tools List Recommended Spare Parts List
Ref. Proc. No ODS/SOP/008 to 015 Issue No 01 Rev No 01 Rev. Date 15/10/2003

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• •

Compliance with Process Guarantee Reference list of previous installations

In addition Contractor shall submit detailed design information including design details for the following items as part of its proposal. This information will be used as part of the proposal evaluation. • • • • • • • • • • • • Mass and Energy Balances Instrument Index Deck space requirement for each separably installed component Weight and Centre of Gravities for each separably installed component Maintenance access space required around each such separable portion of the work. Package hard point positions and design criteria, including all alternatives acceptable to Contractor Vessel nozzle sizes, orientations and locations Locations and sizes of all electrical, control and piping connections to the package and each separately mounted portion Detailed power requirements specification with heat output Approximate number of spare I/O. Quantitative list of consumables and components required for normal operation per annum. Quantity, specification and indicative pricing of the consumables required for the first fill and also for the second fill of all fluids which are required to be changed out following commissioning. As built drawings, inspection and test reports, operation manual and other relevant documents, shall be submitted as a part of Equipment Data Book.

Format No ODS/SOF/004B

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12.0 12.1

CORROSION PROTECTION AND PREPARATION FOR SHIPMENT Painting and Protective Coating Painting and protective coating and the procedures for preparation for painting shall be as specified in the project specification for Protective Coating for Offshore Structure and facilities.

12.2

Preparation for Shipment Prior to shipment, all instrumentation and other equipment vulnerable to damage shall be disassembled and boxed separately for shipment.

All items shall be adequately packed and protected against damage during shipment. Each crate, bag or packages shall be clearly identified with the purchase order number and identification symbol, and shall be securely fastened to the Package Base. Exposed machined surfaces shall be coated with an easily removable rust preventative. All flanged openings shall be protected with steel plate covers attached by proper bolting and sealed with plastic compound. All electrical control enclosures shall be appropriately plugged at entries and loaded with silica gel bags. Screwed connections shall be protected with threaded forged steel plugs.

Format No ODS/SOF/004B

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SPEC. No. Rev. No. Discipline Page: 41

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Contractor shall state in the proposals his recommendations for long term storage (up to 12 months) for both indoor and open air storage in a marine environment. Each item of equipment shall be checked for its suitability to resist a horizontal force of 0.7 g (6.9 m./s2), in any direction and vertical force of 1.0 + 0.2 g (9.8 m/s2) during sea transportation. Where equipment is not adequate, brackets for attaching sea fastenings shall be provided by the Contractor. The Contractor shall include these loads as an occasional load case in all calculations for, but not limited to, Vessels, Vessel supports, Bases, Piping stress analysis. Where specific calculations are required for transport cradles etc., the Contractor shall submit to the Company for approval. The offered equipment along with their accessories shall be shipped packed in wooden crates. They shall be wrapped with polyethylene sheets, before being placed in the crates to prevent damage to finish. Crates shall have skid bottom for handling.

Format No ODS/SOF/004B

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13.0

ATTACHMENTS The following attachments form part of this specification :

13.1 13.2 13.2.1 13.2.2 13.3

General Specifications DATA SHEETS Fuel Gas Conditioning Unit Process Data (4 shts) Fuel gas Composition (1 sht)

DRAWINGS P & I Diagram : 7036-ODS-A1-119

13.1

Specifications : 5100P 2004A 2004B 4017 2005 Skid Mounted Assemblies Piping Materials and Design Piping Fabrication and Installation Electrical for Skid-Mounted Equipment Protective Coating for Offshore Structures and Facilities

Format No ODS/SOF/004B

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13.2.1 1

F G CONDITIONER PROCESS DATA SHEET Skid located on : BCP-B Platform (Cellar deck level)

2

Nos. Reqd. Inlet Conditions

:

One unit

3

Capacity

:

Minimum 16500 kg/hr of fuel gas & shall meet the requirements of gas turbine vendors and purge gas. i) From Dehydration outlet of BPB ii) From new Booster Comp. discharge header

4

Feed to Fuel gas Conditioning : Unit

Outlet Conditions 5 Fuel gas Pressure and temperature : Operating pressure 29 to 31 Kg/cm2 g required at the Skid battery limit and 45 Deg C or 20 Deg super heat whichever is controlling

6

Quality Requirement

:

i) Scrubber shall remove 99.9% of all liquid droplets of 10 micron and higher size

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ii) Filter shall remove 95% of particles of 5 micron and above 7.0 Design Conditions Pressure Temperature 8.0 Major Equipment involved : : 35 Kg/cm2g : 150 Deg C i) Scrubber (V-51000) ii) Filters (F-51100 A/B)

iii)

Super A/B)

heater(E-51200

iv) 9.0 Reference P&ID Drg. No. :

Pre heater ( E-51300) 7036-ODS-A1-119

10.0

Area Classification

: The equipment will be located within Class-1, Group-D, temperature Class-T3, Division-2, hazardous area classified as per API-RP500B.

11.0 i) ii) iii)

Utilities Available : Instrument air Utility air Electric power : : : 5.5 to 9.0 Kg/cm2g (clean and dry) 6 to 9 Kg/cm2g 415V a 5%, 3 phase, 50 Hz A 3% 240v A5%, 1 phase, 50 Hz A3% 110V ±5%, 1 phase, 50 Hz ± 3% 24V A5%, D.C. for instruments.

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iv) 12.0 13.0

Utility Water Guaranteed design life Material of construction -

: : :

8 to 10 Kg/cm2g Shall be 25 years

Shell, Dished ends Nozzles

SA-516, Gr. 60 (Incolloy cladding) SA-106, Gr. B (Incolloy cladding)

-

Flanges

SA-105

-

Bolting

ASTM

A

453

GR

660

CL

A

-

Self Reinforced Nozzles

SA-105 (Incolloy cladding)

14.0

Mat. of const of internals

:

Shall be DSS complying with NACEMR-01-75 (latest edition). 0.35 kg/cm2

15.0

Allowable pressure drop in filter is

:

Notes: 1. For typical fuel gas composition, refer to the composition given below. However, gas M.W. may vary from 20 to 23. Vendor shall provide skin temperature thermo couples for cut off of electrical heating element. The skin temperature of heating element shall not exceed 80% of the ignition temperature of fuel gas being heated.

2.

3.

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4.

Material of construction of shell shall be NACE carbon steel with Incolloy cladding complying with the requirements of latest revision of Spec. NACE-MR-01-75. MOC for vessel internal shall be of DSS. Actual requirement of degree of superheat shall be based on vendor (fuel gas consumers) information. Same shall be met by contractor. Sizings of all equipment shall be firmed-up by the Contractor based on his process/system design, subject to the approval of the Company. Vendor shall furnish with his proposal sufficient descriptive information and proposed skid layout to enable the Company to evaluate equipment sizes, performance, capacity, specification and quality adherence. In view of sour gas service, all carbon steel materials shall meet the requirements on NACE, MR-01-75 and Annexure I to Specification No. 2004. Heat tracing shall be provided as per P&ID/Process requirement. All level instruments connections & tubing on F.G. scrubber shall be electrically traced and insulated. Vendor shall carryout the process simulations for establishing the followings : a) Weighted properties (heat transfer properties) at inlet to fuel gas superheater and preheater. Gas quality requirements such as i) ii) Dew point at various operating condition. Hydrate formation and Condensate at filter and Scrubber.

5.

6

7

8

9

10

b)

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13.2.2

TYPICAL DEHYDRATED GAS COMPOSITION (FEED TO FGC) COMPONENT C1 C2 C3 I-C4 N-C4 I-C5 N-C5 N-C6 CO2 N2 H2S MOLF % 77.263 7.526 5.419 0.904 1.178 0.288 0.288 0.062

6.822 0.135 0.115

Calorific Value of feed gas ( CVN : 9262 kcal/SM3

Format No ODS/SOF/004B

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