FUNCTIONAL SPECIFICATIONS OF EFFLUENT TREATMENT MODULE

06.12.2007

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DATE

PREPARED BY

CHECKED BY APPROVED BY

ONSHORE ENGG SERVICES, New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-O7-001

EFFLUENT TREATMENT MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 1 OF 18

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TABLE OF CONTENTS 1.0 1.1 1.2 1.2.1 1.2.2 1.3 2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.1.1 3.2 4.0 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.6.1 5.6.2 6.0 7.0 7.1 7.2 INTRODUCTION Scope Definitions and Abbreviations Definitions Abbreviations Units of Measurements & Language SCOPE OF SUPPLY Engineering Design Equipment Supply Options Exclusions REFERENCED DOCUMENTS & ATTACHMENTS Acts, Codes, Standards and Regulations Codes and Standards Requirements of Statutory Authorities OPERATING CONDITIONS PROCESS Process Design Cases Process Description Process Design Data Product Specification Measurement and Control Philosophy Process Guarantee Guarantee Guarantee Period MODULE EQUIPMENT Hydro cyclones Low Shear Feed Pumps
ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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7.3 7.3.1 7.3.2 8.0 9.0 10.0 11.0 12.0 13.0 14.0

Piping & Valves Design Installation OPERATION AND CONTROL ELECTRICAL DESIGN MAINTENANCE PAINTING & PRESERVATION QUALITY ASSURANCE, INSPECTION AND TESTING CONTRACTOR DATA REQUIREMENTS SPARE PARTS AND SPECIAL TOOLS

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 3 OF 18

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1.0 1.1

INTRODUCTION Scope
This Functional Specification covers the design, materials, fabrication, testing, painting, inspection and supply of an Effluent Treatment Module for Onshore applications. This Specification is based on Hydro cyclone Water Treatment technology and describes a module where all necessary equipment for effluent treatment is completely confined within the boundaries of a single structural module and mounted on it. The Module shall be equipped with equipment, piping, control devices and all necessary accessories to make a complete and functional unit. The number of modules required to replace the existing ETPs of ONGCs Assam facilities is FOUR (4). This Functional Specification describes a single module. This Specification should be regarded as the Companys minimum requirements for this equipment. Wherever stringent requirements for design, safety and testing are to be met as per Codes and Standards listed below, the same may be notified to the company. Under no circumstances the requirements shall be relaxed to meet this specification without prior written approval / agreement from the company. The effluent treatment module shall be designed in accordance with the process design criteria stipulated in Section 5.0. In addition to the above, contractor shall investigate the proven state of art technology to improve the separation process. Outcome of the study highlighting the process / cost or any tangible / intangible benefits will be provided to the company.

1.2
1.2.1

Definitions and Abbreviations

Definitions Company Contractor Oil and Natural Gas Corporation Limited (ONGC). The party responsible for the design and supply of goods and/or services, for a complete project or installation. The person appointed by the Contractor to carry out engineering inspection in the Suppliers works. Assam Renewal Project

Inspector

Project

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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Supplier

The organisation, company or agency that is contracted to provide goods or services to the Contractor. An impartial body, possessing the necessary competence to verify that designs and/ or manufacture satisfy the specification and purchase order requirements.

Third Party Inspector

1.2.2

Abbreviations BRH CMG CTF DGMS DML ETP GCP GCS GLK GGS KGH LKM LKW LPN ONGC OISD PFD P&ID RDS TPL Borholla (Oil & Gas Field) Chaingmaigaon (oil and gas field) Central Tank Farm Directorate General of Mines Safety Demulgaon (oil and gas field) Effluent Treatment Plant Gas Compressor Plant Gas Collecting Station (in gas fields mainly) Geleki (oil and gas field) Group Gathering Station (for oil) Koraghat ((oil and gas field) Lakwa (oil and gas field) Lakwa (oil and gas field) Laiplingaon (oil and gas field) Oil and Natural Gas Corporation Limited Oil Industry Safety Directorate Process Flow Diagram Piping and Instrumentation Diagram Rudrasagar (oil and gas field) Trunk/Feeder/Collector Pipe Line

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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WIP WHI/EPS

Water Injection Plant Well Head Installation / Early Production System

1.3

Units of Measurements & Language

All values will be in SI Units (according to ISO 1000). Standard conditions at 101.325 kPa and 15.56C. All documents and correspondence shall be in English language.

2.0

SCOPE OF SUPPLY
The Effluent Treatment Module (the Module) shall include all the equipment identified within this Functional Specification. The Module shall be completely packaged with the related components and accessories and delivered ready for operation. No fabrication shall commence till the Company, or their designated representative, has approved the approval drawings for construction / fabrication. Approval of construction drawings does not relieve the Contractor of his responsibility for compliance with process performance and following of relevant codes, standards, specifications, safety design and meeting the requirements of governmental agencies and boards. The final sizing and design of the Module, including all internal and external components, shall be the responsibility of the Contractor. Proven new technology options and developments are acceptable provided they give equivalent or better process performance. The alternative options must be proven and tested in field conditionsand submitted with relevant justification. Contractor to list techno-economic advantages of new technology proposed.

2.1

Engineering Design
The effluent treatment module shall be designed in accordance with the process design criteria stipulated in Section 5.0. The Contractor shall be responsible for the detailed design of the Effluent Treatment Module as detailed in Section 5.0. Module should include two distinct parts namely fixed submodule and customisable submodule. The fixed submodule shall consists of the following:
ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 6 OF 18

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Item Hydrocyclones Filter Feed Pump Filtration System

Qty tba tba tba

Notes Indicated in Scope of work of ETP

Fine and coarse system to be provided. With auto backwash and air scouring system. 100% Duty each Module only Module only Module only Module only Module only Vessels, pipes and structures. To conform with process and safety standards. As required to meet process requirements.

Low Shear Feed Pumps Base Assembly Piping Electrical Control valves & Instrumentation Controls & Safety System Insulation

Heat Tracing

The customisable sub module shall consists of the following: Item Wash Tanks Effluent Transfer pump Qty Notes One day storage. Refer details elsewhere in the document 2x100% pump capacity covering total requirement. Refer details elsewhere in the document One day Storage. Refer details elsewhere in the document 20% of module capacity. Refer details elsewhere in the document 2x100% pump capacity covering total requirement. Refer details elsewhere in the document

Holding tank Slop Oil tank Slop Oil Transfer Pump

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 7 OF 18

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OWS Pit

For holding backwash water. Backwash water will be further pumped in the inlet of wash tank. One day storage. Refer details elsewhere in the document Capacity 3 m3 per tank. Refer details elsewhere in the document pumps Metering pumps of 0-100 LPM capacity. 2x100% pumps per chemical tank. Dosing pump outlet to be connected to holding tank as well as to outlet of the filter package. Refer details elsewhere in the document 2x100% pump capacity covering total requirement. Refer details elsewhere in the document Measurement of influent and treated effluent quantity at the inlet and outlet of ETP 2x100% pump capacity covering total requirement. Refer details elsewhere in the document

Treated Effluent Storage Tank Chemical Storage tanks Chemical dosing (metering pumps)

Backwash Pump

Measurement System

OWS Pump

The Module, and internal equipment, shall be constructed of materials appropriate for the installation (operating and design conditions) and long-term operation in the area with ambient conditions as identified in Section 4.0. Materials and components for this unit shall be new and unused. The Module design shall be based on the process information provided within this document. However vendor to simulate and consider the particle size distribution at the outlet of low shear pump which shall feed the emulsion to Hydro cyclones. The Module shall be supplied based on a 25 year design life.

2.2

Equipment Supply
The equipment supply shall include design, fabrication and supply of the items as detailed in 2.1 (Engineering Design):

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 8 OF 18

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2.3

Exclusions
Supply and installation of equipment, piping, electrical, instrumentation, structural and civil installations outside the module boundaries. Fire & Gas detection and suppression systems.

3.0

REFERENCED DOCUMENTS & ATTACHMENTS

Equipment, materials, design, construction and testing shall be in accordance with this Specification and with the applicable parts of the documentation listed below. Latest editions of standards, codes etc. as on Purchase Order date shall apply unless otherwise specified.

3.1

Acts, Codes, Standards and Regulations

As a minimum, all equipment supplied should be designed, manufactured and delivered in accordance with the requirements of the latest editions of the following Codes, Standards and Regulations:

3.1.1

Codes and Standards

3.1.1.1 Indian OISD-STD-106 Process Design and Operating Philosophies on Pressure Relief and Disposal System Recommended Practices on Static Electricity Classification of Area for electrical installations at Hydrocarbon processing and handling facilities Layouts For Oil & Gas Installations Inspection of Unfired Pressure Vessels.

OISD-STD-110 OISD-STD-113

OISD-STD-118 OISD-STD-128

OISD-STD-132

Inspection of Pressure relieving Devices

OISD-RP-149 OISD-STD-152

Design Aspects for Safety in Electrical Systems Safety Instrumentation for Process System in Hydrocarbon Industry

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

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OISD-STD-180 OISD-GDN-192 OISD-GDN-201

Lightning Protection Safety Practices During Construction Recommended Practices for Environmental Protection in Upstream Petroleum Sector. Guidelines on Safety Petroleum Industry Management System in

OISD-GDN-206

3.1.1.2 ANSI/API/NACE Standards API RP 520 Sizing, Selection and Installation of Pressure-Relieving Devices in Refineries Guide for Systems Pressure-Relieving and Depressurising

API RP 521

API RP 550

Manual on Installation of Refinery Instruments and Control Systems Boiler & Pressure Vessel Code Chemical Plant and Petroleum Refinery Piping Pipe Flanges and Flanged Fittings Structural Welding Code-Steel Methods and Controls to Prevent In-Service Environmental Cracking of Carbon Steel Weldments in Corrosive Petroleum Refining Environments

ASME VIII Div 1 ANSI / ASME B31.3 ANSI / ASME B16.5 ANSI / AWS D1.1 NACE-RP-0472

3.2

Requirements of Statutory Authorities

The Assam onshore facilities operate within the legal domain of India. The Contractor, and sub-Contractors, must comply with the Regulations of India. These include, but are not limited to: Equipment and Materials in accordance with Directorate General of Mines Safety India DGMS, Oil Mines Regulations, 1984 Assam Pollution Control Board/ Central Pollution Control Board

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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4.0

OPERATING CONDITIONS
The Module will be designed, fabricated and installed to accommodate the local environmental conditions of Assam statet in India.

4.1 4.2 5.0

Local and Environmental Conditions are given in Appendix C Utilities are given in Appendix C PROCESS
The Modules main function is to receive water from the effluent water tanks at GGS and remove any remaining oil, suspended solids and other impurities from water prior to re-injection into water injection wells/disposal wells or for surface disposal..

5.1

Process Design Cases

Design case summary with respect to fixed module as follows: Lakwa throughput Lakmani throughput Geleki throughput Rudrasagar throughput/numbers: 10000 m3/day 2000 m3/day/ 3500 m3/day 2,100 m3/day

Units should be able to operate efficiently at 20% turn down ratio of design rate. No of Sub Modules required: Lakwa Lakhmani: Geleki: 4 (2500 m3/d) 2(1000 m3/d) 1x2500 +1x1000

Rudrasagar: 2 (1000m3/d)

5.2

Process Description
Produced water recovered from the GGS is first sent through a wash tank where oil / emulsions separate out on top. Water separated goes to holding tank and then to hydrocyclone by a low shear pump Oil is sent to a recovery / slop tank and pumped back to the heater treater. This system exists at each Module. The equipment required for the Module will consist of the following

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 11 OF 18

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Low-shear pumps Hydro-cyclones Filtration system (fine and coarse) contractor to advise on the latest technology for this application to meet the required specifications. Additional equipment to meet the specifications detailed below.

Treated water is sent to the water injection plant for disposal into water injection / disposal wells. Recovered oil / fluids are transferred to slop oil tanks where it is sent to a GGS for treatment in the heater treater.

5.3

Process Design Data

PARAMETERS Design Flow Density Molecular Weight Viscosity Cp/Cv kg/m3 g/mol cP UNITS DATA 1000/2500 m3/day 968 18 0.0124 1.124

Typical parameters of the untreated effluent - based on Lakwa ETP (also refer design basis) PARAMETERS
Oil & Grease Total Suspended Solids pH

UNITS

INLET
As per ETP DB As per ETP DB As per ETP DB

OUTLET SPEC
< 10 mg/l < 100 mg/l 5.5 9.0

Low-Shear Pumps

PARAMETERS Design Flow

UNITS m3/day 1000/2500

VALUE

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 12 OF 18

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Effluent Parameters Suction Pressure Discharge Pressure kg/cm g kg/cm2g

2

as above Vendor to work out 7 contractor to advise pressure required for optimum hydro cyclone performance.

Hydrocyclones PARAMETERS Design Flow Effluent Parameters Inlet Pressure Required kg/cm g
2

UNITS m3/day 1000/2500 as above

VALUE

7 contractor to advise on hydro cyclone inlet pressure required and finally be able to transfer oil and water to designated tanks

Filter-feed Pumps PARAMETERS Design Flow Effluent Parameters Suction Pressure Discharge Pressure kg/cm2g kg/cm g
2

UNITS m3/day 1000/2500 as above 1

VALUE

6 contractor to advise required for optimum performance.

pressure filtration

Filtration System PARAMETERS Design Flow Effluent Parameters Inlet Pressure Required kg/cm2g UNITS m3/day 1000/2500 as above 6 contractor to advise on filtration system inlet pressure required. VALUE

Presently Effluent are treated with chemicals as detailed below for meeting the output quality requirement. However the list is neither exhaustive nor mutually exclusive. Contractor may suggest a better chemical injection scheme based on latest available technology, non-proprietary chemicals and trends.

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 13 OF 18

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Deoiler removal of residual oil Alum coagulant Hydrated Lime - For maintaining pH Polyelectrolyte - coagulant Ammonium bi-sulphite - Oxygen Scavenger Corrosion and scale inhibitor dosed in ppm Biocide for removal of inorganic bacteria Bactericide dosed in ppm CaSO4, MgSO4, DAP for growth of oil scavenging bacteria

5.4

Product Specification
Treated water from each Module should meet the specification detailed in the design basis of ETP.

5.5

Measurement and Control Philosophy

The hydrocyclone unit takes feed from the low-shear pumps to separate oil from produced water. PITs provide differential pressure across the Hydrocyclone (feed to overflow as well as feed to underflow DPs are measured). The Hydrocyclone is essentially controlled on pressure drop across the unit, set at a level which is known to achieve the required oil-water separation. A PCV is installed in the overflow line. The underflow pressure is controlled as a ratio between the feed-overflow pressure drop and feed underflow pressure drop. A PCV is installed on the underflow line to achieve this. The contractor should suggest a control philosophy for the rest of the package that best serves the system in meeting the specifications. The control system should be able to offer advantages in terms of process performance and cost savings as far as possible. Provision to be kept for sampling and measurement of Hydro cyclone output (oil/water quality )to check the performance as per design basis.

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

DOCUMENT NO. : OESG/ARP/ETM/M0008 PAGE NO. : 14 OF 18

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5.6
5.6.1

Process Guarantee
Guarantee The subcontractor guarantees and warrants for the duration of the Guarantee Period described below that the Process System will be: a) manufactured and commissioned in accordance with and will meet or exceed the Specifications; and b) free from all defect in design and workmanship; and c) operable in accordance with, and based on the design data contained in the Specifications; and d) suitable for its intended purpose as per the Specifications.

5.6.2

Guarantee Period The Guarantee Period will be for a period of twenty four (24) months from the date of Delivery, or twelve (12) months from the date of completion of installation and commissioning of the Process System at the Companys Production Site, whichever is less. During the Guarantee Period, Subcontractor at his cost, risk and expense, will repair, redo or replace any part of the Process System which fails to meet the above warranty or guarantee which manifests itself during the Guarantee Period. The Guarantee Period for any executed repairs and replacement shall be eighteen (18) months from the completed repair or replacement. Any repairs should be carried out on-site if at all possible, so as to minimise any disruption to the working of the Process System and any other parts of the Installation/Plant to the greatest possible extent.

6.0

MODULE
Refer to Appendix C: Module.

7.0

EQUIPMENT
All rotating exposed components shall have suitable non-sparking guard covers designed to prevent accidental contact. These guards shall be solidly constructed, securely fastened in place using 316 SS bolting, but easily removable for maintenance. Guards must comply with OISD standards.

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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Adequate sampling connections and future connections for chemical additives shall be provided and appropriately located. Adequate means shall be provided by Contractor to control the reject rate under varying conditions of flow and pressure. Where automatic control is proposed, the reject control device and the main control valve shall operate in unison.

7.1

Hydrocyclones
Hydrocyclones shall be designed to properly operate for the flow conditions specified in Section 4.0. Hydrocyclones shall be designed to adequately separate fluids to the efficiencies specified in Section 4.0. The quantity and size of Hydrocyclones shall be suitable for 40% turndown on feed, and, provide a suitable level of sparing for in-service maintenance without loss in productivity. All elastomers internal to the Hydrocyclones shall be Viton unless specifically approved by the Company. Hydrocyclone liners shall be constructed of Stellite and stainless steel, unless another material is found technically more suitable for long term uninterrupted operation based on the process operating conditions.

7.2

Low Shear Feed Pumps

Low shear feed pumps provided shall be module mounted, unless specified otherwise, for pumping effluent feed to the pressure required for efficient operation of the Hydrocyclones. The flow rate shall be as per process conditions, see Section 4.0. The Contractor shall evaluate shearing action on the process fluid and ensure that the ability of the Hydrocyclones to meet effluent specifications is not undermined by pump operation and sharing of particles during pumping . Pump selection shall not adversely affect overall performance of the system. It should be noted that any pumps if used they shall be of the lowest possible speed to have low shear to match the required flow / pressure characteristics and must also be reviewed to ensure optimum Hydrocyclone performance with the selected pumps. However contractor to ensure selection of suitable pumps to meet the specific requirement of the process guarantee of Hydrocyclone .

ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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The low shear feed pumps shall be 100% spared. Piping and valves shall be designed / installed to ensure rapid pump change-over in case of failure / tripping, or for maintenance purpose.

7.3
7.3.1

Piping & Valves

Design All piping shall be designed in accordance with ANSI / ASME B31.3 and this Specification unless otherwise noted. Process liquid lines shall be sized for fluid velocities in accordance with industry standards. The minimum required pipe wall thickness for any service shall be calculated in accordance with ANSI / ASME B31.3. Unless otherwise specified, all pressure piping shall have a minimum corrosion allowance of 1.6mm. This is in addition to mechanical allowances.

7.3.2

Installation Stub-in branch connections shall not be permitted. A sufficient number of flanges or unions shall be provided in all piping to allow disconnection of valves and equipment for maintenance. Piping shall be arranged in a neat and simple manner. Piping, including supports, valves and controls, shall be located so as not to present obstructions or stumbling hazards nor interfere with equipment operation and maintenance. At least 600 mm clear space shall be provided for access to equipment. The minimum overhead clearance for piping or walkways shall be 2 metres. Piping installed in pipe racks shall be grouped to have common bottom pipe elevations. Piping headers shall generally be terminated with flanges and shall be installed to allow for future expansion of the header. Pipe systems shall have block valves, by-passes and cleanouts to provide convenient access and repair. Piping shall be designed to minimise pockets and low points. Drain and vent connections as required for testing, maintenance and operation shall be provided on piping. As a minimum, lines shall have vent connections at high
ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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points and shall have drain connections at low points. Connections only for hydrotest do not require valves. Valve drains shall be installed on equipment that is not self draining. Pipe elbows shall be long radius bends unless approved otherwise. Where threaded pipe or fittings are used in hydrocarbon service, the piping between any vessel or bridle and the first valve shall be a minimum of schedule 160. Piping at equipment shall be supported in such a manner that the equipment may be removed without effecting the piping and shall be supported to prevent transmission of excessive moments and forces to equipments. Adequate provisions shall be made in piping systems for thermal expansion and contraction in accordance with ANSI / ASME B31.3. Eccentric reducers with flat side up shall be used in pump suction connections.

8.0

OPERATION AND CONTROL

Refer to Appendix A, Instrumentation and Control Guidelines.

9.0

ELECTRICAL DESIGN
Refer to Appendix B, Electrical Guidelines.

10.0

MAINTENANCE
Refer to Appendix C: Maintenance.

11.0

PAINTING AND PRESERVATION

Refer to Appendix C: Quality Assurance , inspection and testing

12.0

QUALITY ASSURANCE, INSPECTION AND TESTING

Refer to Appendix C: Quality Assurance , inspection and testing.

13.0

CONTRACTOR DATA REQUIREMENTS

Refer to Appendix C: Contractor data requirement .

14.0

SPARE PARTS AND SPECIAL TOOLS

Refer to Appendix C: Spare parts and special tools.
ONSHORE ENGG SERVICES , New DELHI PROJ.: ASSAM RENEWAL PROJECT JOB NO.: OESG- AA-07-001

EFFLUENT TREATMEN T MODULE

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