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EPC FOR ASAB UNIT 6 & 7 PROJECT

Contract no.: 15587.01/EC10867

Project No. P14381

Document No. 14.99.91.1601

DESIGN BASIS MEMORANDUM

FR/SK/FSB/PK/MA/
2 02.02.14 S. NAIR A. BHAYO FINAL ISSUE
SY/SB/SK/SP/AJ
FR/SK/FSB/PK/MA/
1 18.12.13 S. NAIR A. BHAYO FINAL ISSUE
NM/SB/SK/SP/AJ
FR/SK/FSB/PK/MA/
B 10.11.13 S. NAIR A. BHAYO ISSUED FOR APPROVAL
NM/SB/SK/SP/AJ
FR/SK/AR/PK/ ISSUED FOR REVIEW /
A 10.09.13 S. NAIR A. BHAYO
NM/SB/SK/SP/AJ COMMENTS
REV DATE ORIGINATOR REVIEWED APPROVED DESCRIPTION

THIS DOCUMENT IS INTENDED FOR USE BY ADCO AND ITS NOMINATED CONSULTANTS, CONTRACTORS, MANUFACTURERS AND SUPPLIERS .

ENGINEERING CONTRACTOR EPC CONTRACTOR

Internal Ctrl. Doc. No.: 479288-00-50110-0001

CH2M HILL VECO Engineering PROJECT NO: 479288 PAGE 1 OF 91

ADCO DOCUMENT No: 14.99.91.1601 PROJECT No. P14381 REV. 2 DATE : 02/02/14
Class 1
TABLE OF CONTENTS

1.0 INTRODUCTION............................................................................................................... 6

1.1 OVERALL PROJECT REVIEW.........................................................................................6

2.0 SITE CLIMATIC CONDITIONS.........................................................................................7

3.0 KEY STUDY BASIS AND ASSUMPTION.........................................................................8


3.1 Definitions........................................................................................................................ 9
3.2 Abbreviations..................................................................................................................9

4.0 UNITS OF MEASUREMENTS........................................................................................13

5.0 CODES, STANDARDS AND SPECIFICATIONS.............................................................14


5.1 International Codes and Standards.............................................................................14
5.2 Order of Precedence.....................................................................................................23
5.3 Design Capacity and Design Life.................................................................................23

6.0 PROJECT DESCRIPTION..............................................................................................24


6.1 Project Background......................................................................................................24
6.2 Existing Facilities.......................................................................................................... 24

7.0 PROCESS DESIGN BASIS............................................................................................28


7.1 Basis of Design – Oil Production Side........................................................................28
7.2 Design Considerations- Water Injection System........................................................35
7.3 Proposed Facilities – Water Injection Cluster.............................................................35
7.4 Utilities........................................................................................................................... 40
7.5 Simulation Basis........................................................................................................... 42
7.6 Hydraulic Study / Simulation........................................................................................42

8.0 MECHANICAL DESIGN BASIS......................................................................................43


8.1 Scope............................................................................................................................. 43
8.2 General Design Requirements.....................................................................................43
8.3 Surface Water Injection Pumps....................................................................................44
8.4 Chemical Injection Package.........................................................................................44

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8.5 Multiport Selector Manifold (MSM)...............................................................................45
8.6 Manual Hoist.................................................................................................................. 46
8.7 Noise.............................................................................................................................. 47
8.8 Spare Parts Philosophy................................................................................................47
8.9 Shop Testing.................................................................................................................. 47
8.10 Packages........................................................................................................................ 47

9.0 PIPELINE DESIGN BASIS..............................................................................................48


9.1 Design Data................................................................................................................... 48
9.2 Design Pressure............................................................................................................ 50
9.3 Flowline Design Parameters.........................................................................................50
9.4 Flowline Materials......................................................................................................... 51
9.5 Flowline Routing........................................................................................................... 52
9.6 Flowline/Pipeline Design..............................................................................................53
9.7 Valves............................................................................................................................. 58
9.8 External Corrosion Protection.....................................................................................58
9.9 Hydrostatic Test, Pre-commissioning & Commissioning..........................................59

10.0 PIPING DESIGN BASIS..................................................................................................60


10.1 Design Conditions.........................................................................................................60
10.2 Piping Material Specification........................................................................................60
10.3 Plant Layout................................................................................................................... 60
10.4 Piping Size..................................................................................................................... 60
10.5 Underground Piping Systems......................................................................................61
10.6 Painting.......................................................................................................................... 61
10.7 Maintenance.................................................................................................................. 61
10.8 Valve Installation and Operation..................................................................................61
10.9 Valve Access.................................................................................................................. 63
10.10 Instrument Accessibility...............................................................................................63
10.11 Relief Valves.................................................................................................................. 64
10.12 Control Valves............................................................................................................... 65
10.13 Orifice Runs................................................................................................................... 65
10.14 Instrument Connections...............................................................................................66
10.15 Temperature Instruments.............................................................................................66

11.0 CIVIL / STRUCTURAL DESIGN BASIS..........................................................................67

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11.1 General........................................................................................................................... 67
11.2 Scope............................................................................................................................. 67
11.3 Design Data................................................................................................................... 67
11.4 Earthwork, Paving, Grading and Fencing...................................................................67
11.5 Storm Water Drainage...................................................................................................68
11.6 Pipe Supports and Pipe Sleepers................................................................................68
11.7 Equipment Foundations...............................................................................................68
11.8 Sun Shades.................................................................................................................... 69
11.9 Miscellaneous Steel Structures...................................................................................69
11.10 Drawings & Documents................................................................................................69
11.11 Structural Steel Member Connections.........................................................................69
11.12 Structural Steel Deflection Limits................................................................................70
11.13 Fire Protection............................................................................................................... 70
11.14 Crack Width for Concrete Structures..........................................................................70

12.0 ELECTRICAL DESIGN BASIS.......................................................................................70


12.1 General........................................................................................................................... 70
12.2 Project Scope................................................................................................................ 70
12.3 Methodology.................................................................................................................. 71
12.4 General Design Requirements.....................................................................................71
12.5 Reference Documents..................................................................................................72
12.6 Power Supply Arrangement.........................................................................................72
12.7 Utilization Voltages and Frequency.............................................................................73
12.8 Electrical Calculations and Protection Study Report.................................................74
12.9 Electrical Equipment for Hazardous Areas.................................................................75

13.0 INSTRUMENTATION & CONTROL DESIGN BASIS......................................................81


13.1 Field Instruments.......................................................................................................... 82
13.2 Instrument Cables......................................................................................................... 82
13.3 Fire & Gas Instruments.................................................................................................83
13.4 Control Valves............................................................................................................... 83
13.5 Shut Down Valves......................................................................................................... 83
13.6 New Oil Production Well Head.....................................................................................83
13.7 New Water Injection Well Heads..................................................................................84
13.8 New Water Supply Well (Cluster No. 26)......................................................................84

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13.9 New Water Disposal Wells............................................................................................84
13.10 New Multi-Port Selector Manifolds...............................................................................84
13.11 Utilisation of Water Injection (Cluster No. 9)...............................................................84

14.0 TELECOM DESIGN BASIS............................................................................................84

15.0 LOSS PREVENTION DESIGN BASIS............................................................................85


15.1 Facility Layout............................................................................................................... 85
15.2 Safe Distances............................................................................................................... 85
15.3 Emergency Shutdown Design......................................................................................85
15.4 Emergency Depressurization (EDP) – Vent and Flare................................................85
15.5 Drainage Design............................................................................................................ 85
15.6 Fire and Gas Detection.................................................................................................86
15.7 Fire Protection Philosophy...........................................................................................86
15.8 Emergency Evacuation and Escape Routes...............................................................86
15.9 Project Specific HSE Deliverables and Studies..........................................................86
15.10 Safety Equipment Layout.............................................................................................87
15.11 Classification of Hazardous Areas...............................................................................87
15.12 Ignition Control............................................................................................................. 87
15.13 Isolation......................................................................................................................... 88
15.14 Noise and Vibrations.....................................................................................................88

16.0 REFERENCES................................................................................................................88

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1.0 INTRODUCTION

This document identifies the Overall Design Basis for Engineering, Procurement and
Construction (EPC) Services for Asab Units 6 & 7.

The purpose of this document is to define all the input parameters, standards and codes
on which the detail engineering of this project ‘EPC Services for Asab Unit 6 & 7’ shall be
based.

1.1 Overall Project Review

ADCO is planning to develop Asab Unit 6 & 7 (which is a reservoir in the Asab field) to
deliver 15 MBOPD as part of ADCO’s objective of increasing sustainable production
capacity to 1.8 MMBOPD (Millions Barrels of Oil per Day). The Production of Asab Unit 6
& 7 Phase-I will be through tie-in to ASAB FFD facilities.

The PROJECT is titled “Engineering, Procurement and Construction For Asab Unit 6 &
7”. As a part of scope of services CONTRACTOR shall carry out the detailed
engineering, procurement, fabrication, construction, installation, testing, provides pre-
commissioning, commissioning, vendor assistance activities and hand over to ADCO
operations group

The Abu Dhabi Company for Onshore Oil Operations (ADCO) has appointed China
Petroleum Engineering & Construction Corporation (CPECC) as the EPC
CONTRACTOR for Asab Unit 6 & 7 Project. CH2M Hill VECO Engineering, acting as the
Engineering SUBCONTRACTOR, shall carry out the Engineering consultancy services
for Asab Units 6 & 7 for Detailed Engineering.

The proposed facilities shall be having the following:

1. Three Multi Selector Manifolds (MSMs) in RDSs 1, 2 and 6 (One in each RDS);

2. New four (04) natural flowing Oil Producer Wells flowlines. All four natural flowing
Oil Producer Wells shall be Dual Completion wells.

3. New Six (6) Water Injection Wells;

4. Re-instatement of the existing water injection cluster no.9 (i.e. Sb-275) by;

 Demolition of the existing suction piping and pipelines of the existing


surface water injection pump, water supply wells (Sb-275) and water
disposal well (Sb-40);

 Tie-in of new water supply well (Sb-275) to the existing surface water
injection pump of the water injection cluster no.9;

 Tie-in of new water supply (Sb-275) to its water disposal well (Sb-40);

 Installation of power supply cable from the water supply well (Sb-275)
ESP pump’s junction box to the existing power skid at water injection
cluster no.9.

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5. Installation of one new water injection cluster system no. 26 which shall include
but not limited to the following:

 Installation of new surface water injection pump, chemical injection skid,


power skid, OHL, all necessary controls, utilities, auxiliaries, etc.

 Tie-in new water supply well (Sb-587) to the new surface pump of the
water injection cluster no.26;

 Tie-in the new water supply well (Sb-587) to the water disposal flowline
between the existing water injection cluster (WSW-488) and its water
disposal well (Sb-563);

 Interconnecting the new surface pumps discharge to the interconnecting


header between the existing water injection cluster (WSW-488) and
(WSW-32).

6. Installation of interconnecting header between the existing water injection cluster


no.24 (WSW-552) and no.25 (WSW-529).

2.0 SITE CLIMATIC CONDITIONS

Prevailing Direction From NNW

Mean Speed 8.0 m/s


Wind
Maximum Design Speed 44.7 m/s
Saliferous dust & sand with
Airborne Particles
frequent sandstorms
Maximum Solar 85°C

Maximum Shade 58°C

Average Minimum Shade 4°C

Temperature Average Shade Summer 36°C

Average Shade Winter 22°C

Average Shade Yearly 28°C

Max/Min Underground 38/13°C


Maximum air Air coolers (Process) 52°C
temperature for
design of equipment Air coolers (Process) 58°C

Electric Generators / Motors 55°C


Electric Equipment 52°C
(outdoor under shade)

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Electric Equipment 40°C
(indoor with redundant A/C)
Battery Design Temperature 4°C

Air Compressors 51°C

Mean Speed 8 m /sec


Wind (see note-1)
Maximum Speed 45 m /sec (3 sec gust)

Maximum Relative at 45°C 95 %


Relative humidity
(see note-2) Average Relative Maximum at
60 %
54°C
Frequency Infrequent

Maximum 51 mm/year
Rainfall
Minimum Trace
January-April 25 mm in 24
Highest Rate
hrs
Solar radiation - 946 W/m2

Dew - Heavy Dew


Early Morning mists causing
Mists - evaporative cooling loss on
air coolers
Desert, mostly sand which
is loose to medium density.
Fine to medium sand in the
upper 1.5 m followed by
Terrain -
medium dense to dense
sand below.
Subject to sand storms and
sand.
Underground Cable 40°C
Design ambient
In Concrete Trench, In Air & In
temperature for 54°C
Duct
electrical cables
Soil Thermal Resistivity 2.5°C

Notes:

1. Winds are predominantly North westerly, however, between October


and March the wind is interrupted by SE, NE and SW winds. Wind speed of 2
m/sec will be considered as worst case for dispersion.

2. Humidity of 10% will be considered as worst case for dispersion.

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3.0 KEY STUDY BASIS AND ASSUMPTION

ADCO Pipeline Corridor for Pipeline routing:

 Producer Well fluid Composition based Zone-A, Zone-B, Zone-C and Asab-6 & 7
Composition;

 UTM Co-ordinates of Water Supply Wells, Water injectors and Water Disposal
Wells;

 UTM Co-ordinates of Oil Producer Wells;

 Capacities of Gathering Manifolds (MSMs) at RDS-1, 2 and 6;

 New Water Injection Cluster Capacity (WIC-026);

 PIPESIM Software, Version 2011.1 will be used for Steady State Hydraulics;

 HYSYS Simulation Software Version 7.3.

1.2 Definitions

Within this document, the following definitions apply:

OWNER : Abu Dhabi Company for Onshore Oil Operation

PROJECT : Engineering Consultancy Services For Asab Unit 6 & 7

EPC CONTRACTOR : China Petroleum Engineering & Construction


Corporation (CPECC)

Engineering : CH2M HILL VECO Engineering


SUBCONTRACTOR

VENDOR : MANUFACTURER(s)/Supplier(s) of goods/equipments

Shall : Indicates a mandatory requirement

Should : Indicates a strong recommendation to comply with the


requirements of this document

1.3 Abbreviations

The following abbreviations have been used in this document

AC : Alternating current

ADCO : Abu Dhabi Company for Onshore Oil Operation

ADNOC : Abu Dhabi National Oil Company

ASAB : Oil field of ADCO

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ALARP : As Low As Reasonably Practicable

ASME : American Society of Mechanical Engineer

API : American Petroleum Institute

BOPD : Barrels of Oil Per Day

BLPD : Barrel Liquid per Day

BWPD : Barrel Water per Day

CA : Corrosion Allowance

CDS : Central Degassing Station

CCR : Central Control Room

CBCT : Core Balance Current Transformer

CPECC : China Petroleum Engineering & Construction Corp.

CT : Current Transformer

DCS : Distributed Control System

DC : Direct current

DEP : Shell Design Engineering Practice

E/P : Electro / Pneumatic

ESD : Emergency Shut Down

ESP : Electrical Submersible Pump


EPC : Engineering, Procurement and Construction

EOS : Equation of State

FEED : Front End Engineering Design

FO : Fiber Optic

F&G : Fire and Gas

FAT : Factory Acceptance Test

FFD : Full Field Development

GOR : Gas Oil Ratio

GRP : Glass Reinforced Plastic

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HV : High Voltage

FF : Flood Front

HIPPS : High Integrity Pressure Protection System

HSE : Health, Safety and Environment

HAZOP : Hazard and Operability study

HP : High Pressure

IEC : International Electro Technical Commission

ISA : Instrumentation Society of America

ITP : Inspection Test Plan

LV : Low Voltage

LP : Low Pressure

MCC : Motor Control Centre

MCCB : Moulded Case Circuit Breaker

MCSA : Motor Current Signature Analysis

MCU : Motor Control Unit

MDB : Main Distribution Board

MMSCFD : Million Standard Cubic Feet per day

MMBOPD : Million Barrels per day

MSM : Multi Selector Manifold

MPFM : Multi Phase Flow Meter

MAWP : Maximum Allowable Working Pressure

MAOP : Maximum Allowable Operating Pressure

MOV : Motor Operated Valve

MTU : Master Telemetry Unit

MOC : Material of Construction

MV : Medium Voltage

NER : Neutral Earthing Resistor

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PR : Intelligent Protection Relay

PLDS : Pressure Let Down Station

PPM : Parts Per Million

P&IDs : Piping and Instrumentation Diagrams

PFD : Process Flow Diagrams

RDS : Remote Degassing Station

RTU : Remote Terminal Unit

STBOPD : Stock Tank Barrel Oil Per Day

SCADA : Supervisory Control and Data Acquisition

SCF : Standard Cubic Feet

SLD : Single Line Diagram

SSV : Surface Safety Valve

SDV : Shutdown Valve

SP : Surface Pump

SWP : Surface Water Pump

STB : Stock Tank Barrel

THD : Total Harmonic Distortion

TOR : Term of Reference

UPS : Uninterruptible Power Supply

UTM : Universal Transverse Mercator

VCB : Vacuum Circuit Breaker

VT : Voltage Transformer

WHCIP : Well head Close In Pressure

WHCP : Well head Control Panel

WHFP : Well head Flowing Pressure

WHFT : Wellhead Flowing Temperature

WC : Water Cut

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WIC : Water Injection Cluster

WSW : Water Supply Well

WDW : Water Disposal work

WIW : Water Injection Well

WAG : Water Alternating Gas

4.0 UNITS OF MEASUREMENTS

Quantity Units Symbols Notes


Length Meter m 1)
Actual Flow Cubic Meter per hour m3/hr
Litre per hour l/h
Volume Cubic meter /(gallon) m3 /(gal) 5)
Liquid flow(std) Barrel per day BPD 1) 2)
Gas flow (std) Million standard cubic feet per day MMSCFD 1) 2)
Mass flow Tonne per hour t/h
kilogram per hour kg/h
Pressure bar (gauge) barg 1) 3)
bar (absolute) bara
Temperature Degree Celsius C 1)
Density Kilogram per cubic meter Kg/m3 4)
Concentration parts per million by weight ppm (wt)
(pounds per thousand barrels of oil (salt) (PTB)
milligram per litre mg/l
grams per cubic meter g/m3
Kilogram per cubic meter kg/m3
Viscosity(kinematic) Square millimeter per second mm2/s(cst)
Viscosity (dynamic) Milli Pascal –second mPas (cP)
Corrosion rate Millimeter per year mm/yr
Force Kilo Newton KN
Power kilo Watt KW
Mega Watt MW
Heavy duty Million kilocalorie per hour MM kcal/h
Molecular weight Kilogram per mol kg/mol
Velocity meters per second m/s
Bit rate Bite per second bit/s

Notes:

1. Imperial units shall not be used with the following exceptions:

 For nominal bore and rating of piping, flanges and valves.

 Where required, for code calculations

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 SCFD and BPD will be given on PFD

2. Reference conditions are 1.013 bar a, 15° C (stock tank condition).

3. Gauge pressure shall be referenced from 1.013 bar absolute. Always indicate
gauge pressure [bar g, (psig)] or absolute pressure (bar a, psia) except for
pressure difference (bar, psi) e.g. pumps differential pressure.

4. Specific gravity shall not be used.

5. Gallon to be read as US gallon (0.0037854 m3) unless otherwise specified

5.0 CODES, STANDARDS AND SPECIFICATIONS

1.4 International Codes and Standards

The engineering/design shall be in accordance with the latest edition and /or
amendments of the Codes of Practice, Standards and Specifications as indicated
below and the Codes, Standards and Specification referenced therein.

ADCO
ES 30.99.37.904 Engineering Specification Cathodic Protection Using
Sacrificial Anodes
ES 30.99.90.0035 QC Requirement for Wellhead Tie-ins and Flowline
Construction
ES 30.99.12.0023 Engineering Specification for Plant Layout and Piping
Basis of Design
ES 30.99.037.002 Standard specification for painting and coating of metal
surfaces
EP 30.99.90.0001 Drawing Design and Numbering Systems
ES 30.99.12.017 Protecting Existing ADCO Services During Construction
Work
ES 30.99.37.902 Guide for material selection in sour services
ES 30.99.00.0103-1 Pipeline Launcher and Receiver System
EP 30.99.95.0004 ADCO CAD Manual for Consultants
EM 30.99.95.0006 ADCO Guidelines for Submission of Electronic
Documentation
ES 30.99.00.0102 Engineering specification – Corrosion & Material Selection
Philosophy
ES 30.99.37.0013 Engineering specification – Painting & coating of
production & processing facilities.
ES 30.99.00.001 Engineering Specification Tag Plates for Field and Indoor
Equipment
ES 30.99.90.0024 Procedure for Preparation of Supplier’s/ Vendor’s

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Engineering Drawings and Documents
ES 30.99.00.0107 Engineering Specification for Chemical Injection Skid
ES 30.99.37.0001 Engineering Specification Cathodic Protection Design
ES 30.99.37.0003 ADCO Engineering Specification for Cathodic Protection
Materials and Equipment
ES 30.99.37.0005 ADCO Engineering Specification for Cathodic Protection,
Construction, Installation, Testing and Commissioning
EP 30.99.90.0279 ADCO Engineering Specification for Site applied coating
and CP for pipelines at road / track crossings
ES 30.99.37.0017.1 ADCO Engineering Specification for External Pipeline
Coatings
ES 30.99.75.0067 Structural Design Basis Specification
ES 30.99.75.0066 Specification for Concrete
ES 30.48.00.31 Painting and Coating of New Equipment
Preparation of Project Drawings, As-built Drawings and
30.99.90.002
Documents
Applicable Shell DEP’s, EP’s, and Safety Standards
30.10.02.15-Gen Materials for Use in H2S Containing Environments in Oil &
Gas Production
30.10.73.33-Gen Pipeline Transportation System – Pipeline Valves
(Amendments / Suppliments to ISO 143131
31.38.01.11-Gen Piping – General Requirement
61.40.20.30 Gen Welding of Pipeline and Related Facilities (amendments /
suppliment to ANSI/API STD 1104)
30.10.60.18 Welding of Metals (amendments/supplements to API RP
582)
31.01.10.10 Chemical injection systems for upstream production
facilities
31.10.00.31 Noise control (amendments/supplements to ISO 15664)
31.22.20.31 Pressure Vessels (Amendments/Supplements to ASME
Section VIII Div 1 & 2) and ADCO Amendments to DEP
31.22.05.12 Liquid/Liquid and Gas/Liquid/Liquid Separators-Type
Selection and Design Rules
31.29.00.10 Installation of rotating equipment (amendments /
supplements to API RP 686)
31.29.00.33 Shaft sealing systems for centrifugal and rotary pumps
(amendments / supplements to ISO 21049 : 2004)
31.29.02.11 Pumps - Selection, testing and installation
31.29.02.30 Centrifugal Pumps (Amendments/Supplements to ISO
13709:2003)

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31.29.60.32 Lubrication, shaft-sealing and oil-control systems and
auxiliaries (amendments/supplements to ISO 10438)
31.37.00.11 Instrument Air Supply
33.64.10.10 Electrical Engineering Design.
33.65.11.31 Synchronous AC machines (amendments/supplements to
IEC 60034-1 and IEC 60034-14)
33.67.01.31 Low voltage Switchboard and Control gear assemblies
(amendments / supplements to TEC 439-1)
33.67.51.31 High-voltage switchgear and control gear assemblies for
rated voltages between 1 kV and 52 kV
(amendments/supplements to IEC 62271-200)
33.65.50.32 Static A.C. uninterruptible power supply unit (static A.C.
UPS unit)
33.65.40.31 Power transformers (amendments/supplements to IEC
60076-1 and IEC 60076-11)
33.65.60.30 Solar power systems
30.10.73.10-Gen Cathodic Protection
30.10.73.31 Design of Cathodic Protection Systems for Onshore
Buried Pipelines
63.10.08.11-Gen Field commissioning and maintenance of electrical
installations and equipments
80.00.10.10-Gen Area Classification
30.99.53.0001 Amendments / Supplements to DEP No. 33.64.10.10-Gen
Electrical Engineering Design
61.10.08.11 Field Inspection Prior to Commissioning of Mechanical
Equipment
70.10.80.11 Cleaning of Equipment
70.10.90.11 Spare Parts
80.45.10.12 Design of Pressure Relief, Flare and Vent Systems
80.45.10.12 Emergency Depressuring and Sectionalizing
31.29.00.39-Gen Shaft Sealing Systems for Centrifugal and Rotary Pumps
– Selection, Testing And Installation
31.29.00.11-Gen Condition Monitoring of Rotating Equipment
31.29.00.36-Gen Flexible Couplings for Mechanical Power Transmission –
Special Purpose Applications (amendments / supplements
to ISO 10441)
31.21.70.31-Gen Air Cooled Heat Exchangers (amendments / supplements
to ISO 13706)
30.48.00.31-Gen Painting and Coating of New Equipment
31.25.00.10-Gen Hoisting Facilities and Weather Protection for Rotating

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Equipment
70.10.70.11-Gen Preservation of Old and New Equipment and Piping
Standing Idle
31.29.12.30-Gen Reciprocating Positive Displacement Pumps and Metering
Pumps (amendments / supplements to API 674 & API
675)
ADCO Modified SHELL DEPs
31.38.60.10A Rev 1 Hot Tapping on Pipelines, Piping and Equipments (DEP
31.38.60.10 Gen)
31.40.40.38A Rev 1 Hydrostatic Pressure Testing of new Pipelines (DEP
31.40.40.38 Gen)
31.38.01.31A Rev B Shop and Field Fabrication of Steel Piping (DEP
31.38.01.31 Gen)
WS-1 Rev 2 Welding and welding inspection of shop and field
fabricated carbon steel process and utility piping.
34.11.00.11 Site Preparation & Earthworks
34.13.20.31 Roads, Paving, Surfacing, Slope protection and Fencing
34.14.20.31 Drainage and Primary Treatment Facilities
34.19.20.11 Fireproofing of Steel Structures
34.28.00.31 Steel Structures
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)
NFPA 70 National Electrical Code®
NATIONAL ASSOCIATION OF CORROSION ENGINEERS (NACE)
NACE MR-01-75 Sulphide Stress Cracking Resistant Metallic Material for
Oilfield Equipment
NACE RP 0169 Control of External Corrosion on Underground or
Submerged Metallic Piping Systems
NACE RP 0575 Design, Installation, Operation and Maintenance of
Internal Cathodic Protection System in Oil Treating
Vessels
NACE SP-05-72-85 Design, Installation, Operation and Maintenance of
Impressed Current Deep Ground beds
NACE SP-01-77-83 Recommended Practice of Alternating Current and
Lightening Effects on Metallic Structures and Corrosion
Control systems
NACE SP-02-86-86 Cathodic protection Code of Practice for Land and Marine
Applications
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
ASME Code ASME Boiler and Pressure Vessel Code Accreditation and
Code Symbol Stamps

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ASME B16.10 Face-to-face and End-to-end Dimensions of Valves
ASME B16.36 Orifice Flanges
ASME B46.1 Surface Texture (Surface Roughness, Waviness, and Lay)
ASME B1.20.1 Pipe Threads, General Purpose (Inch)
ASME B31.3 Process Piping
ASME B16.5 Steel Pipe Flanges & Flanged Fittings
ASME B16.20 Metallic Gasket for Pipe Flanges
ASME B16.21 Non-Metallic Flat Gaskets for Pipe Flanges
ASME B16.34 Valves Flanged Threaded and Welding End
ASME B16.9 Factory Made Wrought Steel Butt Welding Fitting
ASME B18.2.2 Nuts for General Applications: Machine Screw Nuts, Hex,
Square, Hex Flange, and Coupling Nuts (Inch Series)
ASME B1.1 Unified Inch Screw Threads, UN and UNR Thread Form
ASME B36.10M Welded and Seamless Wrought Steel Pipe
ASME B36.19 Stainless Steel Pipe
ASME Section V Non Destructive Examination
ASME Section VIII Rules of construction for Pressure Vessel
ASME Section IX Welding and Brazing Qualification
ASME Section II Material Specifications
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbon
and Other Liquids
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)
ASTM A53/A53M-07 Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-
Coated, Welded and Seamless
ASTM A490-09 Specification for Structural Bolts, Alloy Steel, Heat treated,
150 ksi, Minimum Tensile Strength
ASTM A320/A320M-08 Standard Specification for Alloy-Steel and Stainless Steel
Bolting materials for Low-temperature service
AMERICAN PETROLEUM INSTITUTE (API)
API STD 598 Valve Inspection and Testing
API STD 607 Fire Test for Soft Seated Ball Valves
API 5L Specification for Line Pipe
Recommended Practice for Classification of Locations for
API RP 500 Electrical Installations at Petroleum Facilities Classified as
Class 1, Division – 1 & 2
Sizing, Selection and Installation of Pressure-relieving
API 520
Devices in Refineries

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API 521 Pressure-Relieving and Depressuring Systems
API 551 Process Measurement Instrumentation
API 614 Lubrication, shaft sealing and oil control systems and
auxiliaries
Centrifugal Pumps for Petroleum, Petrochemical and
API 610
Natural Gas Industries
API 670 Machinery Protection Systems
API 671 Special Purpose Couplings for Petroleum, Chemical and
Gas Industry Services
API 675 Positive Displacement Pumps-Controlled Volume
API 676 Positive Displacement Pumps-Rotary
Pumps Shaft Sealing Systems for Centrifugal and Rotary
API 682
Pumps
API RP535 Burners for Fired Heaters in General Refinery Services
TEMA Tubular Exchanger MANUFACTURERs Association
BRITISH STANDARD (BS)
BS 1677-5 Components for slings. Safety Forged steel lifting hooks
with latch. Grade 4
BS 13157 Cranes. Safety. Hand powered cranes
BS7361: Pt 1 Cathodic protection Code of Practice for Land and Marine
Applications
BS EN ISO 1461: 2009 Hot Dip Galvanized Coating on Fabricated Iron and Steel
Articles – Specifications and Test Methods”.
CENELEC
EN 50018 Electrical Apparatus for Potentially Explosive Atmosphere:
Flame Proof EEx(d)
EN 50020 Electrical Apparatus for Potentially Explosive Atmosphere:
Intrinsically safe EEx(i)
INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC)
IEC 60529 Degree of protection provided by enclosures
IEC 60073 Coding of indicating devices and actuators by colours and
supplementary means
IEC 60079 Electrical installations in Hazardous areas (other than
mines)
IEC 60227 PVC insulated cables and conductors of rated voltage up
to and including 450 / 750 V.
IEC 60228 Conductors of insulated cables
IEC 60269 Low voltage fuses
IEC 60331 Tests for Electrical Cables Under Fire Conditions – Circuit

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Integrity
IEC 60332 Tests on electric cables under fire conditions.
IEC 60364 Earthing Standard
IEC 60445 Identification of equipment terminals and terminations of
certain designated conductors including general rules for
alphanumerical system
IEC 60478 Stabilized power supplies DC output
IEC 60865 Short Circuit currents – Calculation of effects
IEC 60896 Stationary Lead Acid Batteries, general Requirements and
Methods of Test
IEC 60904 PhotoVoltaic devices
IEC 60947 Low Voltage switchgear and control gear assembly
IEC 60265 High Voltage Switches
IEC 60282 High Voltage Fuses
IEC 60271 High Voltage switchgear and control gear
IEC 62040 Uninterrupted Power system (UPS)
IEC 60470 High-Voltage Alternating Current Contactors and
Contactor-Based Motor Starters
IEC 61000 Electromagnetic Compatibility (EMC)
IEC 60038 IEC Standard Voltages
IEC 60050 International Electro technical Vocabulary
IEC 60051 Direct Acting Indicating Analogue Electrical Measuring
Instruments and their Accessories
IEC 60060 High-Voltage Test Techniques
IEC 60071 Insulation Co-ordination
IEC 60072 Dimensions and Output Series for Rotating Electrical
Machines
IEC 60073 Basic and Safety Principles for Man-Machine Interface,
Marking and Identification-Coding Principles for Indicators
and Actuators
IEC 60079 Electrical Apparatus for Explosive Gas Atmospheres
IEC 60083 Plugs and Socket outlets for domestic and similar general
use
IEC 60085 Electrical Insulations - Thermal Classification
IEC 60112 Method for the Determination of the Proof and the
Comparative Tracking Indices of Solid Insulating Materials
IEC 60137 Insulated Bushings for Alternating Voltages above 1000 V
IEC 60227 Polyvinyl Chloride Insulated Cables of Rated Voltages up

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to and Including 450/750 V
IEC 60228 Conductors of Insulated Cables
IEC 60255 Electrical Relays
IEC 60076-1 Power transformers, Part 1: General
IEC 60076-2 Power transformers, Part 2: Temperature Rise
IEC 60076-3 Power transformers, Part 3: Insulation levels, dielectric
tests & external clearances in air
IEC 60076-4 Power transformers, Part 4: Guide to Lighting Impulse &
Switching Impulse testing- Power Transformers and
Reactors
IEC 60076-5 Power transformers, Part 5: Ability to withstand Short
Circuit.
IEC 60044-1 Instrument TransformerPart-1
Current Transformer
IEC 60044-2 Instrument Transformer Part-2
Inductive Voltage Transformer
IEC 60085 Thermal evaluation & Classification of Electrical Insulation
IEC 60137 Bushings for Alternating Voltages above 1000 V
IEC 60185 Current Transformers
IEC 60296 New insulating oil
IEC 60076-7 Loading guide for oil-immersed transformers
IEC 60529 Classification of degrees of protection provided by
enclosures (IP code)
IEC 60076-10-1 Determination of sound levels
IEC 60606 Application guide for power transformers
IEC 60616 Terminals and tapping markings for power transformers
Low-Voltage Switchgear and Controlgear Assemblies Part
IEC 61439-1
-1 : General Rules
Low-Voltage Switchgear and Controlgear Assemblies Part
IEC 61439-2
-2 : Power Switchgear and Control assemblies
IEC 60034 Rotating Electrical Machines
IEC 60034-1 Rating and Performance
IEC 60034-2 Methods of Determining losses and Efficiency from tests.
IEC 60034-5 Degrees of protection provided by enclosures
IEC 60034-6 Methods of Cooling (IC code)
IEC 60034-7 Symbols for types of construction and mounting
arrangements
IEC 60034-8 Terminal markings and direction of rotation

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IEC 60034-9 Noise limits
IEC 60034-12 Starting performance of single speed three phase cage
induction motors for voltage up to and including 660V.
IEC 60072 Dimensions and output ratings for rotating electrical
machines. Frame numbers 56 to 400 and flange numbers
FFS5 to FF1080 and FTSS to FT1080.
IEC 60085 Recommendations for the classification of materials for
the insulation of electrical machinery and apparatus in
relation to their thermal stability in service.
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
IEC 60721 Classification of Environmental Conditions
IEC 60851 Methods of Test for Winding Wires
IEC 60894 Guide for Test Procedures
IEC 60502 Power cables with extruded insulation and their
accessories.
IEC 60811 Common Test Methods for Insulating and Sheathing
Materials of Electric Cables and Optical cables.
IEC 60885 Electrical Test Method for Electrical cables
IEC 61173 Over-voltage protection for Photovoltaic (PV) Power
generating System
IEC 61194 Characteristic parameters of standalone Photovoltaic (PV)
system
IEC 61215 Crystalline Silicon Terrestrial Photovoltaic (PV) modules –
Design Qualification and Type Approval
IEC 61277 Terrestrial Photovoltaic Power Generating systems
IEC 61345 UV Test for Photovoltaic (PV) modules
IEC 61427 Secondary cells and batteries for solar photovoltaic
energy systems
IEC 61646 Thin-Film Terrestrial Photovoltaic (PV) Modules - Design
Qualification and Type Approval
IEC 61683 Photovoltaic Systems – Power Conditioners - Procedure
for measuring efficiency
IEC 61701 Salt Mist Corrosion Testing of Photovoltaic (PV) Modules
IEC 61721 Susceptibility of a Photovoltaic (PV) Module to Accidental
Impact Damage (Resistance to Impact Test)
IEC 61829 Crystalline Silicon Photovoltaic (PV) Array – On site
measurement of I-V Characteristics

IEC 62271-100 Specification for HV circuit breaker from above 1000V up


to 56kV rated equipment.

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IEC 62271-200 Specification for HV controlgear from above 1000V up to
56kV rated equipment.
IP Part 15 Area Classification Code
ISO STANDARD
IS0 9001:2008 Quality Management Systems - Requirements
ISO 4301-- Part 1 Cranes and lifting appliances -- Classification
ISO 10474 Steel and steel products -- Inspection documents
ISO 15156 Petroleum and natural gas industries -- Materials for use
in H2S-containing environments in oil and gas production
ISO 1940 Mechanical Vibration

1.5 Order of Precedence

The order of precedence shall be as follows, unless otherwise directed by ADCO:

1. UAE local codes & regulations

2. ADNOC COPs

3. ADCO specific codes & standards

4. ADCO amendments to Shell DEPs

5. Shell DEPs

6. International codes & standard

The VENDOR shall obtain a written approval from the OWNER, in case of any deviations
proposed to be taken to the OWNER’s Specifications/ Data Sheets/Codes and
Standards.

1.6 Design Capacity and Design Life

The design capacity of the Asab Unit 6 & 7 shall be 15 MBOPD. The Production of Asab
Unit 6 & 7 Phase-I will be through tie-in to Asab FFD facilities.

The design life of Asab Unit 6 & 7 shall be 30 years.

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6.0 PROJECT DESCRIPTION

1.7 Project Background

The south east (SE) fields consist of Sahil, Asab, Shah, Quashwira, Mendor and other
satellite fields. The Asab, Sahil and Shah (SAS) fields are located in a desert area
approximately 100, 160 and 200 km respectively south of Abu Dhabi city. Asab started
production in 1973, Sahil and Shah little later. Sahil and Shah are essentially satellite
fields to Asab. All are sour to some extent.

Asab reservoir fluids including ASAB Unit 6 & 7, together with Shah, Sahil, Quashwira
and SE field fluids, is dehydrated, desalted, and stabilized at Asab before being exported
to Bab and then to Jebel Dhanna. Associated gas at Asab, including Shah’s and some of
Sahil’s, is sent to the nearby GASCO NGL plant. Gas re-injection at Asab uses lean gas
provided by GASCO.

Figure 1: Project Location Map

1.8 Existing Facilities

6.1 Remote Degassing stations (RDS’s)

The following is a brief description of the Asab FFD project facilities at Asab fields which
Asab Units 6 & 7 will be tied-in to:

The RDSs receive well production fluids and provide manifolding and well testing
facilities and act as field control points. In the ADCO Asab FFD Project, the five existing
RDS 1 to 5 are retained and the number of producing wells connected to each RDS shall
be increased. The existing CDS which receives some local well fluids will be re-designed
as RDS-6.

The RDSs provide testing gathering and distribution nodes within the field. New
production manifolds are to be installed at the existing RDS(s) to account for an increase
in the overall number of producing wells.

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All new production gathering manifolds are to be Multi Selector manifolds (MSM).
Typically these manifolds will connect seven well flowlines in to single production line
and has the provision to route the flow from any one of the flowlines to a separate
header.

The increased number of wells and gas lifting frequency necessitates installing new
testing facilities to augment the existing test separators. Multiphase flow meter (MPFM)
will be used for well testing. At all RDSs a crossover is provided such that wells can be
routed from new MPFM to a test separator. In addition, all of the MPFM’s can be
interchanged with one another. This ensures that the accuracy and repeatability of each
of the MPFMs can be verified.

The gathered production flow is combined with fluids from testing and routed via a
transfer line to CDS. All transfer lines are equipped with permanent facilities for intelligent
pigging.

Lift gas from CDS is routed to each RDS. The lift gas pipe line is equipped with
launching/receiving facilities for intelligent pigs. Lift gas is received at each RDS in a
knock out drum, to remove condensed liquids before being distributed by manifold to the
wells requiring lift gas assistance. List gas is injected at 104 bar g. Liquid accumulating in
the knock out drum is routed under level control into the production transfer line for
return to CDS.

The produced water from CDS is routed to RDS - 2, 3 & 4 from where it is distributed via
manifolds to the water reinjection wells for reinjection into the reservoir for the pressure
maintenance. The control and metering for individual wells is located at the respective
RDS. The water is pumped from the CDS at the sufficient pressure to enter the re-
injection well at 104 barg without the need for further pressure boosting at the RDS.
Each produced water line to the RDSs is equipped with connections for temporary
intelligent pigging facilities.

Other facilities at the respective Remote Degassing Stations includes:

 Closed Drain System;


 Flare System;
 Launcher & Receiver Pig Traps;
 Chemical Injection System;
 Instrument Air and Nitrogen System;
 Diesel Driven Emergency Generator;
 Potable Water System.

6.2 Central Degassing station (CDS)

The Asab field transfer lines from each RDS are routed to the new CDS and all are
equipped with permanent facilities for intelligent pigging. A fully flexible conventional
manifold is provided, such that fluids from any of the source RDSs can be routed to any
of the four production trains. The inlet manifold at new Asab CDS is expanded to
accommodate future RDS as they are installed.

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The crude oil stabilization is carried out at Asab CDS. The Asab separation and
stabilization process comprises

 Four separation trains each consists of :


- Slug Catcher;
- 1st Stage Separator;
- Crude Heater;
- 2nd Stage Separator Desalter Pumps;
- 1st and 2nd Stage Desalter;
- LP Stripper;
- LP Stripper Pumps.
 Three Flow Suction Tanks;
 Export Pumping and Metering.

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Figure 2: Block Flow Diagram for ASAB FFD CDS

6.3 Water Injection System

Peripheral water injection is the main source to support the reservoir pressure at the
optimum level for maximizing ultimate oil recovery. Further, water Alternative Gas (WAG)
injection is also being developed in Asab. Injection water supply is from Dammam
(relatively shallow), Umm Er Radhuma and Simsima where more of supply wells are
perforated in Umm Er Radhuma and Open-hole is completed in Simsima.

The existing water injection system in Asab filed consists of 23 water clusters with a total
of 127 injection wells. In addition, two additional water injection clusters (clusters no. 24
& 25) are planned to be installed under ongoing Asab FFD project. The water injection
cluster no. 24 will be a peripheral water supply well which will augment the existing water
injection clusters. The water injection cluster no. 25 will be the WAG Water Supply well
(WAG_WSW) to provide the entire aquifer water supply to WAG Wells.

Water is supplied to each cluster through single water supply wells (WSW) which is
equipped with a down hole electrical submersible pump (ESP) that feeds the water
injection surface pump (SP). The surface pump boosts the water pressure to the
required injection pressure into a surface laid distribution header which feeds the surface
flowline to water injection wells. The 23 clusters are all interlinked through pipeline
headers with isolation valves at appropriate locations in order to provide a ring main that
enhance sharing of water capacity between clusters.

Figure 3: Water Injection Cluster System

A chemical injection skid is provided at each water supply well to inject corrosion
inhibitors into the annulus of the water supply well and downstream of the submersible
pump.

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Power to each water cluster is provided from the 33 KV overhead power line which form
a ring around the field. A top off from overhead line provides power to a power skid
located in the vicinity of each cluster. The power skid includes transformers, Starter
panels and all necessary electrical equipment for the pumps, auxiliaries and control.

The water clusters are deigned to run unmanned during normal operation after local
start-up. SCADA systems are provided to transmit water injection data back to the main
Asab control room.

7.0 PROCESS DESIGN BASIS

1.9 Basis of Design – Oil Production Side

7.1 Producer Fluid Composition


The Proposed one new Multi-Port Selector Manifold at RDS-1, RDS-2 and RDS-6
receives the well fluid from the following zones and each zone well fluid has different fluid
densities as given below:
Unit -6 Oil : 817 Kg /m3

Unit-7 Oil : 815 Kg/m3

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The well fluid (Unit-6) composition is indicated in Table PROCESS DESIGN BASIS-1 below:

Table PROCESS DESIGN BASIS-1: Composition Data & Properties for Well Fluid – Unit-6

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The well fluid (Unit-7) composition is indicated in Table PROCESS DESIGN BASIS-2 below:

Table PROCESS DESIGN BASIS-2: Composition Data & Properties for Well Fluid – Unit-7

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7.2 Oil Producer Well Data

Table PROCESS DESIGN BASIS-3 below provides the new well coordinates, tie in
location and flow line lengths and well target rates for the oil producer wells. All the
Producer wells are Dual Completion.

Table PROCESS DESIGN BASIS-3: Oil Producer Wells Data


Well Flow WHFT Min. Max. Co-ordinates Min. Tie-in Flow
rate point line
WHFP WHFP WHCIP
Length
BPD Deg F Psia Psia East North Psia meter
Sb-553 3000 200 450 2000 213721 2579759 3800 RDS- 4500
6
Sb-611 3000 200 450 2000 215427 2581232 3800 RDS- 2000
4
Sb-609 3000 200 450 2000 217167 2582118 3800 RDS- 2500
5
Sb-599 3000 200 450 2000 211675 2576947 3800 RDS- 2000
1
Note-1: WHFP provided is downstream of Production Choke.
Note-2 Flow lines sizes shall be 6 inch and 2500# rating with wellhead facility.

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Note-3: 2oo3 voting by Pressure transmitters with shutdown valve on operating
through hydraulic fluid in WHCP.
Note-4: Flowline sizing is based on GOR = 832 (scf/bbl).

7.3 New Three (3) MSM at RDS -1, 2 & 6

The number of producing wells connected to RDS needs to be increased as part of Asab
Units 6 & 7 Project. Three (3) new production manifolds (i.e-MSM) to be installed at the
existing RDS- 1, 2 & 6 (one in each RDS) to account for an increase in the overall
number of producing wells.

Each of Multi Selector Manifold shall be provided with 7 nos of inlet and additional one
inlet port to be used for inspection.

Each Multi-port Manifold shall combine fluid from seven wells. Any combination of Zone
A, B and C is possible and thus the MSM must be capable of handling fluid from seven of
the worst case scenario

MSM is intended to be used as motorized actuated switching valve unit at remote


degassing stations namely RDS-1,2 & 6. Monitoring of MSM shall be from the operator
console at the control room of the respective RDS.

MSM (3 nos) will be designed for following conditions:

Location : MSM at RDS-1, 2 and 6


Quantity : 3 Nos
Design Pressure : 93 bar g
Design Temperature : 93o C
Production header : 63,635 Nm3/hr Gas + 174.13 m3/hr Liquid
Test Header : 7273 Nm3/hr Gas + 33.5 m3/hr Liquid
Water cut : 0 - 95%
No of slots in Manifold : 7 Slots
Rating : 600 # rating
MOC : CS with 3 mm Alloy 625 cladding
Trim : 061441-Y

7.4 Test Separator / MPFM at RDS -1, 2 & 6


No new Test Separator or MPFM is envisaged for Asab Unit 6 & 7 Project. The existing
Test Separator or MPFM at RDS-1, 2 & 6 shall be used for testing of new wells at each
respective RDS.
The 6” test header of the proposed new MSM at RDS 1, 2 & 6 shall be integrated with
the existing 6” test header to facilitate the testing of new wells associated with Asab Unit
6 & 7 Project.

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7.5 Chemical Injection Facility at RDS-1, 2 & 6

No Chemical Injection System is envisaged at the well head facility. Only provision for
chemical injection dosing shall be considered downstream of choke valve on wellhead
piping.

Tie-in of Chemical Injection from existing chemical injection distribution header at


respective RDS-1, 2 & 6 shall be provided for 16 inch production header and 6 inch test
header of Multi Selector Manifold (MSM).

7.6 Closed Drain Drum at RDS-1, 2 & 6

The following drains associated with each new Multi Selector Manifold at the RDS-1, 2 &
6 shall be tie-in to the existing drain header connected to the respective closed drain
drum.

(a) Drains from each flow line at well head fence battery limit of the respective
remote gathering station (RDS-1, 2 & 6)
(b) Drains from 16 inch Production header (i.e- outlet of Multi Selector Manifold)

(c) Drain from 6 inch test header of Multi Selector Manifold.

7.7 Oil Flow Line

The design considerations for oil flow line shall be as follows:

(i) Flow line size of 6 inch and maximum flow line length limited to 10 kilometers will
be considered.

(ii) Sizing of flow lines will be done based on the worst scenarios of the Maximum oil,
Maximum Water, Maximum Liquid and Maximum Gas.

(iii) Irrespective of WHCIP, the flow line shall be designed for 2500# rating within well
head facility upto and including the midway valve which is 100 m away from X-
mas tree.

(iv) Flow line Sizing shall consider the following factors:

 Allowable Erosion ratio of 0.7 for sizing of new flow lines;

 Back Pressure at well head (d/s of choke) not to exceed 450 psia;

 Respective RDS-Manifold Pressure (17 barg – 25 barg).

(v) Steady State Hydraulics for Oil flow line from each Producer to the respective
RDS will be performed using PIPESIM Software, Version 2011.1 to establish the
flow line size for each Producer well head.

(vi) Length of flow line from the producing wells to manifold of respective oil gathering
station (RDS) will be estimated based on ADCO pipeline corridor drawing. To
account for inaccuracies in the estimation of pipeline length, design margin of
10% will be considered in the hydraulic simulation.

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(vii) Minimum expected flow temperature (rather than average temperature) will be
considered for sizing of flow lines since this will have impact on the viscosity and
hence pressure-drop in the flow line. Minimum flow temperature 4oC (winter) and
58oC (summer) for surface laid well flowline.

1.10 Design Considerations- Water Injection System

Water Injection Clusters

Currently there are 23 Water injection Clusters (WIC-1 to WIC-23). Two additional water
injection clusters (WIC-24 and WIC-25) are currently being installed as part of ongoing
Asab FFD Project.

Water Injection Cluster no.24 (WSW-552) supplement water to peripheral injection


network.

Water injection Cluster no.25 (WSW-529) supplement water to WAG Injection network.

1.11 Proposed Facilities – Water Injection Cluster

To augment the water injection capacity of Asab field, the following additional facilities
and modifications to the existing facilities has been proposed:

(a) Utililize the existing Water Injection Cluster no. 9 with the current location being
retained.

(b) Tie-in six (6) new water injection wells to the nearby existing clusters.

(c) Install one new Water Injection Cluster with interconnecting headers to water
injection network.

(d) Installing interconnecting headers between Water Injection Cluster no. 24 and
Water Injection Cluster no. 25.

(e) Tie-in to two (2) Water Supply Wells (i.e. one new water supply well for WIC-26
and one existing water supply well Sb-275 reinstated for tie-in to Water Injection
Cluster no. 9).

(f) Tie-in to two (2) disposal well (i.e. disposal well flowline tie-in to existing disposal
well network for WIC-26 and one existing water disposal well Sb-40 reinstated for
tie-in to Water Injection Cluster no. 9).

7.8 Utilizing Existing Water Injection Cluster No-9

The existing Water Injection Cluster no.9 is being utilized for produced water re-injection
pilot project. Accordingly, the existing Water Supply Well (Sb-275) which is part of Cluster
no.9 is stripped off the ESP pump and abandoned. Even, the existing Water Disposal
Well (Sb-40) which is originally part of WIC No.9 is abandoned since the water supply
well (Sb-275) is abandoned.

However, as part of Asab Unit 6 & 7 Project, it has been decided that the existing water
injection Cluster no.9 will be retained in the current location and shall be utilized as a part
of the overall Asab field water injection system.

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The existing Water Supply Well (Sb-275) integrity has been checked by ADCO and
informed that Water Supply Well (Sb-275) to be reinstated as WSW for Water Injection
Cluster No.9.

Similarly, the existing Water Disposal Well (Sb-40) integrity also has been checked by
ADCO and informed that water disposal well (Sb-40) to be re-instated as WDW for Water
Injection Cluster No.9.

Accordingly, Sb-275 is the WSW and Sb-40 is the disposal well to be considered for
WIC-9.

7.9 Tie-In Of New Six Asab Unit 6 & 7 Water Injection Wells

The below Table PROCESS DESIGN BASIS-4 provides the tie-in location for water
injection wells which are required to be tie-in to the nearby Water Injection Clusters.

Table PROCESS DESIGN BASIS-4: Tie-in point of Water Injection Wells


Co-ordinates Flowline Tie-in Co-ordinates
Tie-in
Well East North length East
point North
(Km)
Sb-607 218009 2581375 WSW-035 3.2 220514.5 2581381.58
Sb-588 214611 2576847 WSW-033 5.8 218461.41 2578397.16
Sb-612 212334 2574816 WSW-066 4.5 216519.66 2574286.38
Sb-603 210061 2577835 WSW-055 1.3 209279.69 2578865.08
Sb-602 212395 2580557 WSW-488 2.0 210984.84 2581611.5
Sb-595 214778 2583231 WSW-032 2.8 212248.42 2583424.23

 Water injection flow rate = 5000 BWPD

 Water injection pressure = 104 barg.

 Water injection temperature = 50-80ºC

7.10 New Water Injection Cluster (WIC- 26)

Install a new Water Injection Cluster System with a new Water Supply Well for WIC-26.
This WSW will be located between the existing Cluster WSW-488 and the existing
Cluster WSW-032 (Base Scope).

Engineering design for the new Water Injection Cluster System (WIC-26) and networks
that shall include WSW, Surface Pump, chemical injection system, power skids, WDW,
WIWs, and all piping and pipeline (i.e. Water injection header, flow lines, well heads
piping’s, etc). Design shall follow ADCO standards and Engineering Packages.

Install Interconnecting headers from the new Water Injection Cluster Header to the
existing Water Injection Cluster no.2 (WSW-488) and Water Injection Cluster no.4
(WSW-032).

Tie-in of the new Water Injection Cluster System with a new Water Supply Well to the
existing GRE pipeline running between WSW-488 and its dedicated Water Disposal Well
(Sb-563). The tie-in flowline length will be around 1.5km.

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Electrical Submersible Pump

Tag No P-2126-01
Number of pumps One
Operation/Stand by One (1) / -
Flow rate (Normal/Design) 30000 BWPD (199 m3/hr)
Discharge Pressure (Min / Normal /Max) 120 psig (8.3 bar g) / 150 psig (10
barg) / 1500 psig (102 bar g)
Temperature (Normal/Max) 50oC / 80oC
Note: 1500 psig is Shut-off pressure of ESP and 1200 psig at surface water pump

Water Injection Surface Pumps

Tag No P-2126-02
Number of pumps / Type One / Centrifugal
Operation/Stand by One (1) / -
Flow rate (Normal/Design) 30000 BWPD (199 m3/hr)
Inlet Pressure (Normal /Max) 120 psig (8.3 bar g) /
1200 psig (82.76 bar g)
Discharge Pressure (Normal /Max) 2534 psig (172.4 bar g) / 3629 psig
(246.86 barg)
Temperature (Normal/Max) 50ºC / 80ºC

Chemical Injection Tank (i.e-Corrosion Inhibitor Storage Tank)

Tag No T-6226-11
Design Capacity 3.3 m3
Dimensions Diameter -1450 mm
Height – 2100 mm T-T
No of Tanks One (1)
MOC SS316L
Design Pressure 0.056 bar g + water column
Design Temperature 4 / 85ºC
Storage Time 28 days

Chemical Injection Pump (i.e-Corrosion Inhibitor Pump)

Tag No P-6226-11/12
Number of pumps Two
Type Diaphragm Reciprocating
Operation/Stand by One (1) / One (1)
MOC - Casing / Internals SS316
Flow rate 4.9 Liters / hr
Discharge Pressure 18.3 bar g

7.11 Interconnection Header for WIC-09

The existing water supply well (Sb-275) is currently interconnected to nearby Water
Injection Clusters (WSW-66 and WSW-33) via existing interconnecting headers to
enhance the operating flexibility in terms of availability of injection water between
adjacent water injection clusters. The interconnection header of Sb-275 with nearby
water injection clusters to be reinstated by operations.

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7.12 Interconnection Header for WIC-24 & WIC-25

In order to enhance the operating flexibility between Water Injection Cluster no. 24 and
Cluster no. 25, an interconnection header (approximately 5 KM) is proposed to be
installed between Water Injection Cluster no. 24 (WSW-552) and Cluster no. 25 (WSW-
529) as part of this project.

The co-ordinates of the water supply wells WSW-552 and WSW-529 are as follows:

Well East North


WSW-552 220223.00 2589318.00

WSW-529 215093.00 2581181.99

7.13 Interconnection Header for Proposed New WIC-026

In order to enhance the operating flexibility, an interconnection header is proposed to be


installed between existing Water Injection Cluster no. 2 (WSW-488) and Water Injection
Cluster no. 4 (WSW-032) as part of this project.

The tentative co-ordinates of the proposed new Water Supply Well for Water Injection
Cluster no. 26 (WSW-587) are as follows:

Well East North


WSW-587 209599.74 2580888.40

7.14 Water Supply Wells

Water is supplied to the respective Water Injection Cluster through single Water Supply
Well (WSW) which is equipped with a down hole electrical submersible pump (ESP) that
feeds the water injection surface pump. The surface pump boosts the pressure to the
required injection pressure into a surface laid distribution header which feeds the surface
flow lines to the water injection wells.

Two Water Supply wells are required to be considered as part of Project Scope and the
considerations for the same are as follows:

(i) Existing water supply well (Sb-275) was a part of Water Injection Cluster no.9.
Currently, Sb-275 is disconnected from the Water Injection Cluster no.9 in the
field as the existing Water Injection Cluster no.9 is utilized for Produced Water re-
injection Pilot Project. However, as part of Asab Unit 6 & 7 Project, integrity of
water supply well (Sb-275) needs to be studied in case of restoration of Sb-275
as water supply well for Water Injection Cluster no.9. This integrity study was
performed by ADCO and water supply well (Sb-275) was found to be acceptable
for supplying water to water injection cluster no.9.

Hence no New Water Supply Well needs to be drilled for supplying water to water
injection cluster no.9.

(ii) New Water Supply Well will be drilled to supply water to proposed new Water
Injection Cluster no.26 (WIC-026) (i.e. Sb-587)

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7.15 Disposal Wells

ADNOC Zero Dumping policy restricts dumping of sub-standard quality water to the
desert. As a mitigation, substandard water or brackish water occurring during restart of
Water Supply Wells needs to be disposed off into shallow aquifer Umm er radhuma via
disposal wells.

The location of disposal well shall be within radius of 1 to 2km from the WSW’s clusters
considering the capital cost of GRE flowline.

Two disposal wells are required to be considered as part of this Project and the
considerations for the same are as follows:

(i) The existing disposal well Sb-40 is part of Water Injection Cluster No.9. Currently,
disposal well is disconnected from the Water Injection Cluster no.9 in the field as
the existing Water Injection Cluster no.9 is utilized for Produced Water Re-
injection Pilot Project. However, as part of Asab Unit 6 & 7 Project, integrity of
disposal well Sb-40 in case of reinstatement for usage as disposal well for Water
Injection No.9 was done by ADCO and found to be acceptable.

Hence no new disposal well needs to be drilled for water injection cluster no.9.

(ii) Existing New Disposal well WDW-563 currently is receiving disposal water from
WSW-488. The WSW associated with WIC-26 shall be connected to WSW-488
as close as distance of 120 m. With this philosophy, disposal water from WIC-26
shall also be disposed to disposal well WDW-563.

The following are the design considerations related to water disposal wells:

 Disposal Well will be tie-in into the respective WSW piping upstream of
the Surface pump;

 Material of Construction for Disposal Well flow line will be GRE;

 Piping within 120 m from the WSW are designed to be removable type to
allow rig access or movement during work-over;

 Down hole completion and the X-mas tree of the disposal well are
designed for maximum injection rates of 20,000 BWPD and WHIP
pressure of 300 psig.

7.16 Injection Water Reservoir Composition:

There are three large aquifers namely Dammam, Umm Er Radhuma and Simsima which
are used to supply aquifer water. The aquifer water obtained is highly alkaline and
contains dissolved gases including hydrogen sulphide and carbon dioxide.

7.17 Water Injection Line Sizing Criteria

The following line sizing criteria shall be used for water injection line sizing:

(i) The Criteria given in Table PROCESS DESIGN BASIS-5 shall be used as
guideline for sizing single phase lines. The criteria are appropriate to metallic and

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non-metallic piping material unless otherwise stated. Velocities checked to meet
the criteria as mentioned in Table PROCESS DESIGN BASIS-5 below.

Table PROCESS DESIGN BASIS-5: Guidelines for sizing Liquid Lines

Recommended High Limits


Description
DP (Bar/100 m) Velocity (m / sec)

Pump Suction Lines (Sub cooled 0.45 2.4


liquid for < or =8”)
Pump Discharge Lines (CS/GRE) 0.45 3.7
Liquid Transfer Lines 0.34 3.7

(ii) Water Injection lines shall have a minimum velocity of 0.9 m/sec.

(iii) Beggs & Brills Revised correlation will be used for water injection hydraulics.

(iv) Pipe roughness of 0.0018 inch will be used in hydraulic calculation for water
lines.

(v) The smallest pipe diameter to be considered for pipelines is 4 inch.

(vi) Velocities for preliminary line sizing is given in table below

Fluid Velocity (m/sec)


Water and other liquids 0.5 – 5.0

Source: Shell DEP 31.38.01.11

(viii) Preliminary disposal line sizing will be performed by considering 2 m/sec velocity
as a basis

1.12 Utilities

No new additional utilities are envisaged for development of Asab Unit 6 & 7 to deliver 15
MBOPD. The tie-in from the existing utilities shall be considered.

The purpose and operating conditions of various utilities associated with Asab Unit 6 & 7
are as provided below:

a. Instrument Air

Instrument Air will be made available from the nearest tie-ins connection in the
existing manifold location.

Operating conditions at tie-ins:

Normal Operating Pressure : 7 barg

Normal Operating Temperature : 60oC

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Design Pressure : 12 barg

Design Temperature : 85oC

Dew Point : -30oC @ atm

b. Nitrogen

Nitrogen is used for purging of piping, drains and inertization of equipment (e.g.
MSM) prior to maintenance. Nitrogen for the proposed facilities is provided by tie-
ins to nitrogen line available to the existing drain pit of existing conventional
Manifolds. Nitrogen is used as medium to support rodding and flushing of
hydrocarbons at the drain pit.

Operating conditions at tie-ins:

Min / Normal Operating Pressure : 4.5 / 7.6 barg

Maximum Temperature : 60ºC

Design Pressure : 12 barg

Design Temperature : 85ºC

Purity of N2 : 98%

c. Chemical Injection (i.e.-Corrosion inhibition)

No Chemical Injection System is envisaged at the well head facility. Only


provision for chemical injection dosing shall be considered upstream of choke
valve on wellhead piping.

Tie-in of Chemical Injection from existing chemical injection distribution header at


respective RDS-1, 2 & 6 shall be provided for 16 inch production header and 6
inch test header of Multi-Port Selector Manifold (MSM).

Injection rate shall be 5-10 ppm and location of chemical injection shall be
provided at the 16 inch production header and 6 inch test header of Multiport Slot
Manifold (MSM at RDS-1, 2 & 6).

Further, Corrosion inhibitor skid package shall also be provided for new water
injection cluster No -26 (Sb-587) for pipe work and equipment protection against
sour aquifer and high salt levels. The corrosion inhibitor shall be injected into the
annulus of the water supply well and also downstream of the submersible pump.
The dosing rate and final concentration to be confirmed by chemical package
vendor based on selected chemical.

d. Flare header and Flare System

Vents from the proposed MSMs to be installed each at RDS-1, 2 and 6 shall be
tie-in to the existing flare header at respective RDS.

e. Closed Drain Drum

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The drains from the following areas shall be connected to the existing drain
header which is turn is connected to the Closed Drain Drum at RDS-1, 2 & 6.

(a) Drains from the proposed six (6) new flowlines

(b) Drains associated with 16 inch Production header of MSM at RDS-1, 2


and 6

(c) Drains associated with 6 inch Test header of proposed MSM at RDS-1, 2
and 6

1.13 Simulation Basis

Process Simulation and Properties estimation will be carried out using Aspen HYSYS 7.3
Version with “Peng Robinson” fluid package.

HYSYS simulator will be used for estimation of fluid properties to be used for sizing of
instruments, line sizing, etc.

1.14 Hydraulic Study / Simulation

Basis for hydraulics simulation is as provided below:

Software PIPESIM 2011.1


Flow rate, Composition & Op. Conditions Refer Section 2.0 and 7.0
Thermodynamic Model – EOS Peng Robinson
Flow Correlation (Oil Flowline) Beggs & Brills Revised
Flow Correlation (Water injection) Darcy’s equation

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8.0 MECHANICAL DESIGN BASIS

1.15 Scope

The ENGINEERING, PROCUREMENT AND CONSTRUCTION OF ASAB UNIT 6 & 7


PROJECT shall consist of the following major Mechanical equipment / packages:
 Surface Water Injection Pump package with auxiliaries;
 Chemical Injection Skid;
 Multiport Selector Manifold Skids;
 Manual Hoists.
The following subsections cover the design basis for mechanical equipment and
packaged items to be engineered in this Project.

All other design requirements shall be as specified in PROJECT specifications and


datasheets.

1.16 General Design Requirements

Mechanical equipments and auxiliaries shall be suitable for the specified operating
conditions and shall be designed and constructed for a minimum design life of 30 years.

Design of equipments and its components shall aim to achieve highest standards of
safety, reliability, operability and maintainability.

All equipment shall be field proven design only. Prototypes, unproven equipment are not
acceptable.

The design shall ensure safety of personnel and equipment during standby, operation
(includes safe starting, operation and shutdown of the plant under all conditions) and
maintenance.

The material of construction for all equipment shall be suitable for the service fluid
specified in the data sheets.

Plot area will be efficiently utilized with provision of adequate space for operation,
Inspection for maintenance requirement.

All equipment skids shall be designed to allow ease of lifting.

Material handling facility shall be provided as required for maintenance & material
handling of major mechanical equipment.

Painting requirements for all equipment shall be as per ADCO Specification ES


30.99.37.0013 (Amendments / Supplements to Shell DEP 38.40.00.31 – Gen.)

Environmental design conditions, Wind conditions, Seismic design shall be considered in


accordance with this document.

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1.17 Surface Water Injection Pumps

New Pump shall be of Horizontal Centrifugal Multistage BB5 type, designed based on
API 610, Shell DEP standard 31.29.02.30-Gen and PROJECT specifications. The
Surface Water Injection Pump package shall consist of Surface Pump, Motor, Coupling,
Lube Oil System, Mechanical Seal Flushing System, Barrier Fluid Make-up / Refill Unit,
Control System and Instruments terminated at local junction box on the skid.

Lube Oil System shall be supplied as per requirements of API 614, Ch. 3, as modified in
Shell DEP 31.29.60.32-Gen.

Seal Plan / Seal Flushing System shall be in accordance with API 682 as modified in
Shell DEP 31.29.00.33-Gen.

The Seal Barrier Fluid Make-up System shall comprise of a pressurized closed circuit
using fresh water. Barrier pressure shall be maintained at a sufficiently high pressure to
ensure that no process fluid can leak out under any operating condition, including closed
valve. Material of construction for the complete system (Reservoir, Accumulator, Pumps,
Piping / Valves etc.) shall be type 316L Stainless Steel.

Removable internals shall be bolted type and bolting shall be of SS 316L.

Rotary pumps shall be used in the Seal Supply Make-up System and shall be in
accordance with API 676. Two pumps, one working and one standby shall be provided
for seal system in the skid.

All piping system component materials for the wetted parts shall be SS 316L as a
minimum unless otherwise stated.

Instruments shall be provided as per P&ID. All instruments (apart from local gauges)
shall be wired up to skid mounted junction boxes.

Fragile components (if any) shall have mechanical guard / protection against damage
during shipment / handling.

The electrical and instrumentation required for package equipment shall be suitable for
the specified hazardous area classification and weather conditions as well.

Extensive inspection and tests shall be specified to be carried out at MANUFACTURER’s


shop to avoid any delay in erection and commissioning at site.

Adequate material handling facilities shall be provided.

1.18 Chemical Injection Package

The system shall be skid mounted and designed for continuous duty. Each chemical
injection skid (package) shall consist of chemical injection pumps, tank, piping, valves,
accessories, instruments and cables terminated at junction box on the skid.

The package shall comply with the requirements of Shell DEP 31.01.10.10.

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Chemical Storage Tank shall be sized to provide useful volume as specified in process
datasheet. Unless otherwise specified, tank material shall be SS 316L and mechanical
design shall be in accordance with good engineering practice.

All nozzles on the tank shall be flanged type with minimum size NPS 2. All nozzles and
manway shall be ‘set in’ type attached to vessel with full penetration weld.

The minimum diameter of inspection openings (hand holes) shall be 200mm (NPS 8)
nominal. Hand hole covers shall be provided with hinges.

As a minimum, tanks shall be spot examined by radiography. Minimum of 10% of each


weld process and all T-joints shall be examined. Additional radiography may be required
by code. Requirements shall be shown on datasheets as a minimum.

Removable internals shall be bolted type and bolting shall be of SS 316L.

Chemical Injection Pumps shall be positive displacement (controlled volume type) double
diaphragm (hydraulically actuated) and shall be in accordance with API 675 and DEP
31.29.12.30. Two pumps, one working and one standby shall be provided in the skid.

The diaphragm shall be provided with rupture detection system. The pump stroke
adjustment, either manual or remote shall be possible during pump operation.

Pumps shall comply with API 675 and Shell DEP 31.29.12.30 for design and testing
requirements.

All piping system component materials for wetted parts shall be SS 316L as a minimum
unless otherwise specified.

Instruments shall be provided as per P&ID. All instruments (apart from local gauges)
shall be wired up to skid mounted junction boxes.

Fragile components e.g. calibration pot etc. shall have mechanical guard / protection
against damage during shipment / handling.

All tie-in flanges shall be terminated at the edge of the skid boundary for easy hook up.

The electrical and instrumentation required for package equipment shall be suitable for
the specified hazardous area classification mentioned in the specification / data sheet
and weather conditions as well.

Extensive inspection and tests shall be specified to be carried out MANUFACTURER’s


shop to avoid any delay in erection and commissioning at site.

Adequate material handling facilities shall be provided in accordance with material


handling study outcome.

1.19 Multiport Selector Manifold (MSM)

The MSM skids shall be completely assembled, wired and piped with all relevant
interface terminations at the skid edge i.e. Process inlet and outlet flanges, junction
boxes, drain and vents. Maintenance platform with handrails, cage ladders etc. Shall be

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provided on the skid for the instrument / valves / pushbutton stations shall be mounted at
accessible locations.

MSM material of construction shall be in accordance with the “Piping Material


Specification, Doc No. 14.99.12.0601 and MSM Valve Datasheet Doc No.14.99.18.0602.
All material in contact with the process fluid shall be designed for sour service. Vendor
shall certify that the MSM skid is fully in accordance with the ISO15156 / NACE MR 0175
and ES 30.99.00.0102-1 requirements.

The design of equipment should be of an adequate standard to maintain its performance


during its operational life in its installed environment. For the purpose of EMC, the
performance of apparatus, which must comply, is taken to be degraded if permanent or
temporary loss of function occurs, or an error of 0.1% is observed.

All complete systems and individually supplied instruments should conform to the intent
of IEC 60801 and IEC 61000.

All electrical equipment located on the MSM skid shall be certified by a recognized
certifying authority as suitable for use in Zone 1, Gas Group II A/ II B, Temp Class T3
hazardous area.

1.20 Manual Hoist

Design and manufacture of hoist shall be consistent with capacity, lift, head room and
other parameters.

In design of hoist, care shall be taken for following features:

 Minimum effort to lift a specified load;

 Self-braking system for holding the load in any position, using self actuated clutch in
lifted position;

 Even loading of bearings;

 Minimum effort to move the loaded hoist along the monorail using motorized geared
trolley;

 Ease of installation and maintenance;

 Compact design;

 Spark proof construction.

All associated parts to enable the Chain Pulley Block to be a fully operational package
shall be included.

The hoist shall be provided with Load Brakes, Hooks, Load Chain, Hand Chain and Hoist
Control as specified in the PROJECT specification (Doc. No. 14.99.24.1605) and
datasheets.

The hoist shall be rated for the Safe Working Load (SWL) as specified in the Hoist data
sheet.

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All machinery parts shall be designed in accordance with BS 1677-5 and BS 13157.

1.21 Noise

Noise control shall be in accordance with Shell DEP 31.10.00.31.

Equipment design shall meet the noise level (85 dBA @ 1m in free field conditions). It is
the VENDOR/EPC Contractor’s full responsibility to ensure that noise level of supplied
equipment will not exceed the maximum allowable as specified in HSE philosophy.

1.22 Spare Parts Philosophy

Design and manufacture of hoist shall be consistent with capacity, lift, head room and
other parameters.

All spares requirement shall be submitted through ADCO SPIR procedure.

Spares shall be considered as follows:

 Start-up & Commissioning spares (Supplier’ scope);

 Spare parts for 1 year operation (Provisional for ADCO review/approval);

 Recommended spares for two years of normal operation (For ADCO review /
Approval);

 Insurance Spares as recommended by Vendor (For ADCO review / approval).

1.23 Shop Testing

Major equipment under each package shall be tested at the manufacturer facilities in-
line with the design codes & Standards applicable for the equipment. For main
equipment the testing procedures will follow applicable international standards as a
minimum; however additional requirements may be specified in the material requisition /
inspection test plan if required.

Critical tests shall be witnessed by ADCO / Purchaser’s representatives. Extent of


ADCO / Purchaser intervention shall be as per Inspection and test plan to be developed
during FEED/Detailed design.

1.24 Packages

Packages shall be assembled to the maximum extent possible at manufacturers shop.

Individual equipment shall be tested as per codes/standards /specifications applicable


to that equipment. Dimensional check, accessibility, pressure tests of complete
package shall be carried out.

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9.0 PIPELINE DESIGN BASIS

1.25 Design Data

9.1 General & Environmental Data

The design data includes data generally applicable to the flowline on the project and
also data for specific applications. Where data or properties are not provided, then
the properties shall be taken from the base design documents referenced in Section
2.0.

Table PIPELINE DESIGN BASIS-6: Environmental Data

 Prevailing Direction From NW


Mean Speed 8.0 m/s
Wind Maximum Design Speed 44.7 m/s
Saliferous dust & sand with frequent
Airborne Particles
sandstorms
Maximum Solar 85°C
Maximum Shade 58°C
Average Minimum Shade 4°C
Temperature Average Shade Summer 36°C
Average Shade Winter 22°C
Average Shade Yearly 28°C
Max/Min Underground 38/13°C
Maximum air Air coolers (Process) 52°C
temperature for
design of equipment Air coolers (Process) 58°C
Mean Speed 8 m /sec
Wind (see note-1)
Maximum Speed 45 m /sec (3 sec gust)
Maximum Relative at 45°C 95 %
Relative humidity
(see note-2) Average Relative
60 %
Maximum at 54°C
Frequency Infrequent
Maximum 51 mm/year
Rainfall
Minimum Trace
Highest Rate January-April, 25 mm in 24 hrs
Solar radiation - 946 W/m2
Dew - Heavy Dew
Early Morning mists causing
Mists - evaporative cooling loss on air
coolers

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Desert, mostly sand which is loose to
medium density. Fine to medium
Terrain sand in the upper 1.5 m followed by
medium dense to dense sand below.
Subject to sand storms and sand.
Underground Cable 40 °C
Design ambient
temperature for In Concrete Trench 54 °C
electrical cables
Soil Thermal Resistance 2.5 °C

Notes:

1) Winds are predominantly North westerly, however, between October and March the
wind is interrupted by SE, NE and SW winds.

2) Wind speed of 2 m/sec will be considered as worst case for dispersion.

3) Humidity of 10% will be considered as worst case for dispersion

9.2 Design Life

The design life for the proposed pipelines will be 30 years.

9.3 Pipeline Categories

The pipeline categories shall comply with the requirements as shown in DEP
31.40.00.10-Gen Section 2.0, which has been reproduced in Table PIPELINE DESIGN
BASIS-7, for design purposes.

Table PIPELINE DESIGN BASIS-7: Pipeline Categories

Fluid Relevant Applicable Project


Product Type
Category Code Pipelines
Non-flammable stable and non-toxic fluids which
are liquid at prevailing ambient temperature and Water Injection
A atmospheric pressure plus 0.5 bar,i.e.the vapour ASME B31.4 Lines/Inter connecting
pressure is lower then 1.5 bar(abs) at ambient headers
temperature. Example: water, slurries

Flammable or unstable or toxic fluids which are


liquid at prevailing ambient temperature and
B atmospheric pressure plus 0.5 bar,i.e the vapour ASME B31.4 Oil Flowlines
pressure is lower than 1.5 bar(abs) at ambient
temperature. Example: stabilised crude, gas oil

1.26 Design Pressure

Refer to Table PIPELINE DESIGN BASIS-8 Flowline design parameters for the
specific flowlines design pressures.

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9.4 Maximum Allowable Incidental Pressure (MAIP)

The MAIP is the pressure which shall not be exceeded at any point along the Flowline
during upset conditions, i.e. conditions of limited frequency. Upset conditions include
relief valve lifting (i.e. pressure increase between relief valve set pressure and full
relief) and surge pressure in liquid Flowlines. The MAIP for all flowlines shall be 110%
of design pressure.

9.5 Test Pressure

The test pressure for flowlines shall not be less than 1.25 times the design pressure
as defined in DEP 31.40.40.38-Gen “Hydrostatic pressure testing of Pipelines” and as
amended by ADCO document No.31.40.40.38A, Rev.1.

9.6 Flowline Flange Rating Philosophy


For the selected material class, the flange rating shall be selected by applying the
chosen design pressure and temperature in the appropriate rating table in the piping
specification.

1.27 Flowline Design Parameters

Table PIPELINE DESIGN BASIS-8: Flowline Design Parameters - Asab Unit 6 & 7
Oil Water Disposa Water Chemical
Disposal
Description Producer Injection l Water Interconne- Injection
Water Line
Flowline Flowline Line cting Line Line
NPS (inch) 6” 6” 6” 6” 8” 2”
API 5L Gr. B API 5L Gr. B API 5L Gr. B API 5L Gr. B
Material GRE TP 316L
PSL 2 PSL 2 PSL 2 PSL 2
As per Wall Thickness Pipeline Calculation and Crossing Report
Thickness
(Doc. No. 14-99-23-1602)
Transported Multiphase Chemical
Water Water Water Water
Fluid Oil Oil
Design 102
93 barg 222.3 barg 102 barg 219.5 93 barg
Pressure barg
Design Temp 93oC 85oC 85oC 85oC 85oC 85oC
Installation
21 oC 21 oC 21 oC 21 oC 21 oC 21 oC
Temp
Min.Design
4 oC 4 oC 4 oC 4 oC 4 oC 4 oC
Temp
Corrosion
6 mm 3 mm 0 mm 6 mm 3 mm 0 mm
Allowance
ASME Class
600 # 1500 # 600 # 600 # 1500# 600 #
Rating
ASME API ASME
Design Code ASME B31.4 ASME B31.4 ASME B31.4
B31.4 15HR B31.4
0.72 0.72 0.72 0.72 0.72
(General) (General) By (General) (General) (General).
Design Factor
0.6 0.6 Vendor 0.6 0.6 0.6
(Crossing) (Crossing) (Crossing) (Crossing) (Crossing)
H2S Sour & HIC Sour & HIC Sour Sour & HIC Sour & HIC Non-Sour

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Designation
Internal
Nil Nil Nil Nil Nil Nil
Coating
Glass Flake Glass Flake Glass Flake Glass
Reinforced Reinforced Reinforced Flake
External Vinyl ester Vinyl ester at Vinyl ester at Reinforced
Nil Nil
Coating at Buried Buried Buried Vinyl ester
Rig/Road Rig/Road Rig/Road for buried
Crossings Crossings Crossings section
Design Life 30 years 30 years 30 years 30 years 30 years 30 years

1.28 Flowline Materials

9.7 General

Carbon Steel to API 5L/ISO 3183 Grade (PSL2) shall be used as the Flowline MOC,
except for water disposal wells which shall be used GRE. Flowlines shall be of seamless
carbon steel type of line pipe. Size of any branch or instrument connections shall not be
less than 2 inches for mechanical strength reasons.

9.8 GRE Flowline Design Properties

Glass Reinforced Epoxy (GRE) pipeline routing confirmation, crossing calculations and
stress analysis shall be performed by GRE vendor. As part of scope of work for these
lines, GRE vendor shall prepare all stress analysis calculations. The GRE pipeline shall
comply with requirement of ISO 14692-3/ Shell DEP 31.40.10.19 – Gen.

9.9 GRE Vendor Responsibilities

The GRE Vendor shall be responsible for GRE pipelines system design - with detailed
calculations and analysis of suitable supports and casings protection, and all related
drawings for GRE pipelines systems:

 All GRE pipeline for this project will be designed to contain a UV radiation barrier;

 Wall thickness calculations;

 Road crossings;

 Drawings – including overall route layout, alignment sheets, crossing drawings


including cased crossings;

 Pipeline stress analysis;

 Thrust Block designs;

 Stress Analysis with Caesar II software.

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9.10 The engineering of GRE pipeline shall be subcontracted to GRE Vendor. Buried pipeline
analysis shall use soil friction, soil stiffness and backfill density appropriate for the
location. The model shall accurately reflect the geometry of the pipeline system. Buried
analysis shall include for full pipeline length. Thrust Blocks will be provided based on
stress analysis.

9.11 Computer Generated Analysis

Stress Analysis for GRE pipelines shall be carried out by computer software program
using CAESAR-II, latest version. This will be in the scope of the GRE Vendor.

The analysis shall model the route profile and soil conditions and the following load
combinations shall as a minimum be considered:

a) Hydrostatic test load

b) Internal Pressure

c) Functional Loads (effect of pressure, temperature and thermal resistance).

d) Live loads arising from the weight of transported fluids.

e) Dead loads from the self-weight of the pipeline, coating and appurtenances.

f) Environmental loads.

g) Transient loads (where applicable)

h) Fatigue load (where applicable)

1.29 Flowline Routing

All the flowline shall be routed to satisfy the requirements of COMPANY’s corridor
guidelines (Doc.No:30.99.91.604). The ROW of the Flowlines shall pass through the
existing corridors in the field. Before proceeding with any design or construction
activity, contractor shall take approval from COMPANY for the proposed flowline
routing.

9.12 Flowline Separation Distance within Corridors & Other Features

Within corridors where Flowline are laid parallel to one another in a trench or on the
surface alongside/across existing services the Flowlines are required to be laid at a
minimum distance as required in COMPANY Corridor Guidelines Doc No:
30.99.91.604 and as given in Table 9-4 below.

The flowlines shall be laid at a minimum distance of 75 m apart from the wellhead CP
Ground beds as a safe distance in order to avoid any interference.

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Table PIPELINE DESIGN BASIS-9: Flowline Separation within Corridors

Minimum Separation
Flowline Condition
Vertical Horizontal Reference
Flowlines laid in same trench or
ADCO
surface laid Flowlines (alongside - 1.0 m
Doc.No:30.99.91.1604
each another)
Flowlines installed in separate
Drg No. 30.78.23.1601
trenches (new or existing lines) - 10 m
(Note- 1)
except at plant approaches
Flowlines that run parallel with power Drg No.30.78.23.1601
- 150 m
lines (Note 1)
Flowline or existing service crossing Drg No.30.78.23.1605
0.3 m -
(existing laid on the ground surface). (Note 1)

Note-1: These drawings are part of ADCO Corridor Guidelines Doc No: 30.99.91.0603
Rev. B.

9.13 Burial Depth


All CS flowlines shall be surface laid. GRE water disposal flowlines shall be buried and
will have minimum burial depth from ground surface to top of pipe based on DEP
31.40.00.10, as given in Table PIPELINE DESIGN BASIS-10.

Table PIPELINE DESIGN BASIS-10: Flowline Burial Depth


Location Class Minimum Cover References
General Terrain 1.0 m Drg No.14.78.23.20.34 Rev1
Govt. & PWD Roads 2.0 m Drg No.14.78.23.20.34 Rev1
Gatch Tracks 2.0 m Drg No.14.78.23.20.34 Rev1
Asphalt Roads 2.0 m Drg No.14.78.23.20.34 Rev1
Sand Tracks 1.5 m Drg No.14.78.23.20.34 Rev1

1.30 Flowline/Pipeline Design

9.14 General

Flowline Wall thicknesses are to be based on pressure containment and corrosion


allowance according to shell DEP 31.40.00.10-Gen.

The minimum selected wall thickness shall be based on the following:

Minimum wall Thickness: 4.8 mm (Category-For All Flowlines) (Section 3.4.3, DEP
31.40.00.10-Gen)

OD/WT ratio maximum ≤ 96 (land installation) (Section 3.4.3, DEP 31.40.00.10-


Gen)

The flowline are not required to be designed as piggable.

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9.15 Wall Thickness Calculation

Wall thickness shall be calculated as per Para 403.2.1of ASME B31.4 for Oil
Flowlines, Water Injection Lines, Water Disposal Lines, Water Interconnecting Lines
and Chemical Injection Lines. The nominal wall thickness is calculated in accordance
with the following equations:

tn = P*D/ (2*S)

t = tn + A
Where,
t : Nominal wall thickness satisfying requirements for pressure and allowance
tn : Pressure design wall thickness
P : Internal design gauge pressure
D : Outside diameter of pipe
S : applicable allowable stress value, psi (MPa), as determined by the following
equation
S = F x E x SMYS
specified Minimum Yield Strength (SMYS) of pipe material
F : Design factor
E : Weld Joint factor
A : Sum of allowances for corrosion
While setting design factor, due consideration has been given to and allowance has
been made for the under thickness tolerance and maximum allowable depth of
imperfections provided for in the specifications approved by code.

9.16 Design Factor


Design factors to be used for calculating wall thickness shall be as per
recommendations of shell DEP 31.40.00.10-Gen.and are given in following Table
PIPELINE DESIGN BASIS-11.

Table PIPELINE DESIGN BASIS-11: Design Factor

Fluid Category A and B


Applicable Code ASME B31.4
Pipelines General Route 0.72
Crossings 0.6
Private roads 0.6
Unimproved public Road 0.6
Roads,Highways,Streets and railways 0.6
Rivers, dunes and beaches 0.6
Parallel encroachments (Note 1) 0.72
Fabricated assemblies (Note 2) 0.60
Pipelines on bridges 0.60

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Near concentration of people 0.5
Pipelines, within plant fences, block valve
0.60
stations and pig trap stations

Notes:

1) Parallel encroachments are defined as those sections of a Flowline running


parallel to existing roads, at a distance of less than 50 meters but exclude
Flowline access roads.

2) Fabricated assemblies include pig traps, valve stations, headers etc.

9.17 Calculation of Flowline Stresses and Minimum Elastic Bend Radius

The stresses in Flowline shall be calculated as per B31.4 (for Oil Flowlines, water
disposal lines, water injection lines, water interconnecting lines.

The entire surface laid Flowlines/ Pipelines shall be considered as fully unrestrained
pipeline and calculation shall be done accordingly. Flowlines shall be routed
considering sufficient flexibility and avoiding long straight section before buried
crossings. Further, additional 6o(minimum) horizontal deflection bends after every 150
meters shall be provided as per ADCO specification for installation of water injection &
oil piping and Flowlines Doc No. ES 30.99.12.0005 Rev.7.

Compliance with ASME Codes

As per code ASME B31.4 (for oil flowlines, water Injection lines, water Disposal lines and
water interconnecting line) the following equation shall be satisfied.

Equivalent combined stress,Seq1

2   S L  S H  / 2 2  S t 2 ≤ 0.90 x SMYS of pipe Cl. No. 402.7 of ASME 31.4

Equivalent combined stress,Seq2

2 2 2
S H  S L S H  S L  3S t
≤ 0.90 x SMYS of pipe Cl. No. 402.7 of ASME 31.4
Where,
PiD iM Fa
SL, Longitudinal stress =  
4t Z A
Pi * D
SH, Hoop stress = 2 * (t  CA)

St, Torsional stress (Assuming there is no torsional stress in the pipeline considered)
E = Young’s modulus for steel = 3.05 x 107 psi
α= 11.7 x 10-6 mm/mm x oC
T2 = Maximum operating (Design) temperature, oC
T1 = Installation temp, oC

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v = Poisson’s Ratio
P = Design pressure, bar
D = Pipe outside diameter, Inch
t = Pipe Nominal wall thickness, Inch
CA = corrosion allowance, Inch
M= Bending moment across the nominal pipe cross section due to weight or seismic
inertia
Loading, in-lb
A= Metal area of nominal pipe cross section, in2
Z = section modulus of the pipe or of the fitting outlet, as applicable, in3

The following will be the limits of calculated stress due to sustained loads and thermal
expansion:

a) Internal Pressure Stresses: The calculated stresses due to internal pressure shall
not exceed the value F x S, where S = SMYS of pipe and F = appropriate design
factor, as per Table PIPELINE DESIGN BASIS-11 of this design basis.

b) External Pressure Stress: Stresses due to external pressure shall be considered


safe when the pipe wall thickness is calculated using formula given in section
9.6.2 of this design basis with appropriate design factor.

c) Allowable Expansion Stresses: The equivalent tensile stress for restrained lines
shall not exceed 90% of SMYS and for unrestrained lines stress value shall not
exceed SA (SA as per ASME B31.4 para 403.3.2).

d) Additive Longitudinal Stresses: The sum of the longitudinal stresses due to


pressure, weight and other sustained external loadings shall not exceed 90% of
SMYS in case of restrained pipelines and 75% of SMYS for unrestrained pipeline.

9.18 Road and Track Crossings

The design calculations shall be performed using the format from API 1102 as per DEP
31.40.00.10-Gen.A design factor 0.6 has been adopted for the design as the roads/tracks
are considered to be minor and are located within a restricted area.

The pipe hoop stress design factors for the various flowline group categories shall be
based on Table PIPELINE DESIGN BASIS-11 of design basis and table 1 of DEP
31.40.00.10 –Gen.

The location of flowline road crossings will need to be identified and designed to
establish the requirement for thick walled pipe. The minimum Flowline burial depths at
road and track crossings are given in Table PIPELINE DESIGN BASIS-10 of design
basis.

Flowline road and track crossings shall be in accordance with COMPANY requirement.

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As recommended by API 1102, the total wheel load of 448 kN with wheel contact area of
0.093 m2 to be considered for road crossing stress calculations. For rig crossings the
total wheel load of 2200 kN with wheel contact area of 0.403 m2 shall be considered.

The number of crossings of roads, tracks, Flowlines, and other services by new
replacement Flowlines and their right-of-way access tracks shall be minimised. Access
across the new and replacement Flowlines shall be by existing roads and tracks. Where
no suitable road or track exists, crossing point at intervals not greater than 2 km shall be
provided. For flowlines running alongside other (existing) flowlines, crossing points shall
be at the location of existing crossings.

Number of crossings and locations shall be reviewed and approved by COMPANY


operations.

9.19 Stress Calculations at Road Crossings

Stresses in flowlines at road crossing shall be checked using methods specified in API
RP 1102.

Stresses will be checked for fully corroded flowline i.e.; after deducting corrosion
allowance from the Flowline Crossing Railroads and Highways.

The following are considered as acceptable levels of stress:


p*D
S Hi ( Barlow)   F * E * T * SMYS
2 * tw

Seff ≤ F’ x SMYS
Where,
p = Flowline Design Pressure
D = Pipe Outside Diameter
tw = Flowline corroded wall thickness
F=Design factor road crossings
F’ = Design factor for effective allowable stress = 0.90
E = Longitudinal weld joint factor = 1.00
T = Temperature derating factor = 1.00

Seff = Total effective stress in flowline, given by the following equation

S eff 
1
2

 S1  S 2  2   S 2  S 3  2   S 3  S1  2 
[Equation 12 of API RP 1102]
S1 = Maximum circumferential stress
S2 = Maximum Longitudinal Stress
S3 = Maximum radial Stress

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Effective stress: The sum of the circumferential, longitudinal and radial stresses from
internal design pressure and external loads in pipe installed under road/highway/rig
crossings as combined in accordance with API RP 1102 shall not exceed F’ x SMYS
(Specified Minimum Yield Strength). The surface laid flowlines shall be considered fully
unrestrained pipeline and effective stress calculated accordingly.

To satisfy the above criteria, some flowline wall thickness may have to be increased at
the crossings while majority of specified wall thickness will satisfy the above
requirements.

The design factor of 0.6 is used for road/rig crossings.

9.20 Minimum Cold Field bend Radius and Elastic Bend Radius

Pipeline change in direction shall be achieved by using cold field bends. The minimum
radius of cold field bend shall not be less than 40 times nominal diameter of the pipe.
Calculations shall be done to establish the maximum allowable cold bend angle
achievable from one 12 m pipe length. Factory manufactured hot induction bends may
be permitted where there is a limitation of space for using cold field bends. Factory made
induction bends are permitted up to minimum bend radius of 5 time’s nominal pipe
diameter.

Elastic bending shall only be utilized for gradual changes in elevation achieved by
profiling the trench and laying the pipeline to fit the contour without cold bending. The
minimum elastic bend radius shall be 500 times (Shell DEP 31.40.00.10-Gen) the outer
diameter of pipe or the calculated radius derived from the margin between the equivalent
stress and 85% SMYS, whichever is greater. No tie-ins shall be made within any section
of bend.

9.21 Branch Connections

Slip-on flanges, mitred connections and threaded connections (pipe to pipe fittings) shall
not be used in any part of the pipeline system. All pup pieces shall be minimum 500 mm
long.

All branch pipelines shall be designed with a valve to permit isolation of branch from the
pipeline. For mechanical strength, there shall be no branch or instrument connection
smaller than 2” on any section of the pipeline.

Gaskets for flanged connections shall be as per project specifications for the relevant
pressure class. The number of flanged connections in Flowline shall be minimized.

1.31 Valves

The type of valves to be provided shall be in accordance with P&IDs. Valve design shall
be as per API 6D, DEP 30.10.73.33-Gen, and relevant COMPANY specification.

1.32 External Corrosion Protection

The buried section at the crossings shall be externally coated with Glass Flake
Reinforced Vinyl Ester. The above ground surface laid flowline is not required to be
painted and not required to be coated. The underground chemical injection line for

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Cluster-09 (from chemical injection skid to WSW-275) is also to be coated with Glass
Flake Reinforced Vinyl Ester.

Against external corrosion, only buried parts of carbon steel pipelines (at any crossing
such as rig crossing or road crossing section) shall be protected with sacrificial anode
type cathodic protection. Cathodic protection shall not be provided for buried GRE
pipelines.

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Table PIPELINE DESIGN BASIS-12: External Coating for Buried Sections of
Flowlines at Crossings

Pipe No of Coat Coat Total Film


Max
Diameter Coating System Thickness Thickness Thickness
Temp oC
(inch) (Micron) (micron) (micron)

Glass Flake
All Sizes Reinforced Vinyl 120 2 750-800 1500-1600
Easter

1.33 Hydrostatic Test, Pre-commissioning & Commissioning

9.22 Flowline Cleaning and Hydro Testing

The new flowline shall be hydrostatically pressure tested after construction to prove the
strength and leak tightness.

The pressure test of Flowline test section should commence as soon as practicable after
construction of Flowline has been completed.

For Flowlines, minimum hydrostatic pressure shall be 1.25 x design pressure. Design
calculations shall assume a density of hydrostatic test water of 1025 kg/m 3.These shall
be duly adjusted for the Flowline profile. Hydrostatic testing diagram for a test section
and hydrostatic testing plan shall be developed for approval by company prior to
commencement of testing.

These activities shall be carried out as per Company specifications and industry
accepted practice.

Table PIPELINE DESIGN BASIS-13: Flowline Cleaning and Hydrostatic testing

Spec. No Title
Doc.No. 31.40.40.38
ADCO Amendments/Supplements to DEP 31.40.40.38-Gen
Rev.A, April 2001

ES 30.99.12.0005 Installation of Water Injection & Oil Piping and Flowlines

9.23 Pipeline Dewatering, Drying & Purging

Flowline dewatering and drying shall be carried out in accordance with Company
approved Project Specifications and Industry accepted Practices.

During the pre-commissioning stage, the complete flowline shall be thoroughly


dewatered, cleaned and dried and preserved by Dry Air or Nitrogen for commissioning
and operation of the flowline. Commissioning commence when the complete system has
been successfully hydrostatically pressure tested, pre-commissioning is completed and
is ready for operational duty.

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Flowline pre-commissioning and commissioning shall be carried out in accordance with
Company approved Project Specifications, Method Statement and Industry accepted
Practices.

10.0 PIPING DESIGN BASIS

This section covers the piping design basis for process and utility piping systems,
equipment / piping layouts, pipe routing and drawing procedures for this Project. Piping
system shall be designed based on the minimum requirements stated hereunder.
Apparent conflicts between the information contained in this specification and the
codes/specifications mentioned shall be referred to and resolved by ADCO. No
requirement of this specification shall have the effect of waiving the applicable code,
unless it is more stringent than the code.

1.34 Design Conditions

Design pressure and temperature of piping are according to the line list. Calculation of
pipe wall thickness and the test pressure shall be based on the design pressure and
temperature given in the piping class.

Pipe sizes are determined by process design with due consideration to flow, velocity and
corrosion aspects, and are indicated on PIDs. The type of the valves shall be as
indicated on the PIDs.

1.35 Piping Material Specification

Piping Material shall be in accordance with the Technical Specification for Piping System
(Piping Material Classes) Document No: 14.99.12.1606

Piping special items (such as special valves, liquid traps, strainers, flexible hoses, flame
arrestors etc.) shall be subject to datasheet showing actual line design conditions and
requirements.

1.36 Plant Layout

Layout of piping shall comply with the requirements of:

a. ADCO Spec ES.30.99.12.0023

b. SHELL DEP 31.38.01.11

c. ASME B31.3

1.37 Piping Size

 The minimum sizes of branch connections on piping are limited to 1” NPS for
150# to 900# and 2” NPS for 1500# and above;

 Pipe sizes 1-1/4” NPS, 2-1/2” NPS, 3-1/2NPS, 5”NPS, and 22”NPS shall not be
used except for connections to equipment;

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 In on-site areas, the minimum pipe size in pipe racks and main pipe bridges
shall be 1-1/2” NPS. A minimum of 2” NPS is required in off-site pipe racks and
tracks;

 Pipe size callouts will be in inches (e.g. 1-1/2”, 3”, and 6”);

 Pipe size will be as indicated on P&ID’s;

 No threaded or socket welded connections are allowed in process piping.

1.38 Underground Piping Systems

 Underground gravity drains, sewers, and firewater collection systems shall be


designed in accordance with civil design basis;

 Minimum clear distance between buried piping and electric and instrument
cables shall be 300mm.

1.39 Painting

For painting, project specification for painting and coating Doc No. 14-99-12-1602 along
with ADCO specification 30.99.37.0013 Amendments/Supplements to Shell DEP no
30.48.00.31 shall be followed.

1.40 Maintenance

Equipment, structures and piping shall be arranged to permit maintenance and service
by means of mobile equipment. Permanent facilities, as indicated in the plot plan, shall
be provided where maintenance by mobile equipment is impractical.

Access around machine operating positions shall be adequate for safety, operating and
maintenance purposes. Flooring shall be adequate for safety, operating and
maintenance purposes. Flooring shall be capable of withstanding loads and forces
imposed during maintenance work. There shall be no un-collared floor openings around
the machines.

Equipment or components, which are to be maintained in a workshop, and which are


inaccessible to mobile equipment, for such items lifting beams shall be provided. All
access ways and lay-down areas shall be paved and shall be capable of withstanding
the axle loads of vehicular traffic expected.

Platforms shall be provided as required by operational necessity and where maintenance


or inspection is expected

Gauges, instrumentation, cable trays, small bore equipment, underground and above
ground piping shall not interfere with access for routine maintenance. Portable platforms
shall be provided to maintain instruments not accessible from grade level.

All equipment or part of plant that requires periodic removal shall be without structural or
piping alterations. Wherever possible, derrick or pulley block arrangements shall be
provided. Necessary ladders and platforms shall be provided in order to minimize
scaffolding requirements.

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1.41 Valve Installation and Operation

Valves above roads shall be avoided. In-line valves in overhead pipe racks should be
avoided, but if valves are required, platform and ladder shall be provided for access.

Valves should be positioned with their stems pointing upwards; however, horizontally
pointing stems and intermediate positions are acceptable. For operating valve
accessibility, see Section 10.10.

For ergonomics aspect SHELL DEP 30.00.60.13-Gen (Human Factors Engineering -


Valve Analysis) shall be followed.

The following are exceptions:

 No horizontally positioned stems in low temperature service;

 Butterfly valves in services where collection of dirt in the lower shaft bearing
could occur shall have the stem horizontal;

 To avoid accidental blocking due to a loosened wedge, gate valves installed


around safety/relief valves in wet sour service and in flare lines shall be
positioned with the stem pointing horizontally;

 Gate valves in a fouling service shall be positioned with the stem horizontal. This
is to mitigate closing difficulties when bottom cavities become filled with
solids/dirt;

 Valves with an extended bonnet, in liquid service with design temperature from
-46ºC to -80ºC shall be installed with the stem vertical or with a maximum
inclination of 60º from the vertical;

 Valves with an extended bonnet, in liquid service below -80ºC, shall be installed
with the stem vertical or with a maximum inclination of 30º from the vertical;

 Valves in no flow connections (such as vents and pressure gauges) where the
trapped gas bubble protects the valve packing from too low temperatures, may
be installed with the stem in the horizontal position;

 Valves with extended bonnets are required in systems with design temperature
below -46ºC. Systems, which operate above -46ºC, but have (due to de-
pressuring conditions) a minimum design temperature below -46ºC, do not
require extended bonnets;

 Since drain valves in liquid service with design temperature below -46ºC shall be
installed with the stem in the vertical position, the drain connections require a
support / bracing. The drain connection should be braced to the process line.

In general, the location of valve hand wheels, handles and stems shall not obstruct
operating aisles, walkways or platforms. Valves shall be easily accessible for operation
and maintenance.

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Valves for normal and emergency operations shall be operable from grade or platform.
The bottom of the operating valve hand wheel shall not be higher than 1.8m above the
high point of finish surface or operating platform.

Emergency shutdown and major isolation valves are to be preferably located at grade
level or shall be provided with good and safe access. For valves provided with fire
protection boxes, sufficient clear space shall be provided around the valve for removal of
the valve or box, when required.

1.42 Valve Access

Allowable access depends on valve type and shall be as per the following:

Grade/Fixed Portable Fixed Portable


Platform Platform or Ladder Ladder
Scaffold
Operating Valves(a) Yes No No No
Operating Valves, Yes Yes Yes No
Small (a,c)
Non-Operating Valves Yes No No No
(b)
Non-Operating Yes Yes Yes Yes
Valves, Small (b,c)

a) Operating valves are valves that are essential for plant operation.

b) Non-operating valves are the valves used only during maintenance.

c) Small valves are defined as valves that can be easily operated with one hand and
normally 1-1/2” and smaller.

d) The placement of chain-operators on valves shall be minimized and will require


COMPANY’s approval.

1.43 Instrument Accessibility

Allowable access depends upon instrument type and shall be as per the following:

Table PIPING DESIGN BASIS-14: Instrument Access and Visibility


Portable
Process
Platform Grade
Connection Fixed Instrument
Instrument Type or Ladder or Fixed
First Valve Ladder Visibility
From Platform
Access
Grade
Thermocouples & (TE)
(1) (1) Yes Yes -
Resistance Bulbs
Test Thermo Wells (TW) (1) (1) Yes Yes -
Dial Thermometers (TG) (1) Yes Yes Yes Yes
Pressure Gauges (PG) Yes (1) Yes Yes Yes

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Portable
Process
Platform Grade
Connection Fixed Instrument
Instrument Type or Ladder or Fixed
First Valve Ladder Visibility
From Platform
Access
Grade
Level Gauges (LG) Yes No Yes Yes Yes
Orifice Plates (FE) (2) (2) Yes Yes -
Level Displacement (LT/LC) Yes No No Yes Yes
Level Switches (LS) Yes No No Yes -
Transmitters - No No Yes -
Indicators Inline (FI) - No Yes Yes Yes
Control Valves - No No Yes -
Analysis Tap (Sample
Yes (1) No Yes -
connection tap)

Notes:

1) Permanent accessibility – All plant instruments, their measuring elements, such


as orifice plates and thermocouples, and their process connections as well as
sampling points for taking laboratory samples should be safely and permanently
accessible. To attain this, they shall be located not more than 0.5m horizontally
away from and not more than 1.7m vertically above grade, platform or walkway.

2) Limited Accessibility – When the realization of the permanent accessibility, as


defined in (1) is not feasible, the process connections for pressure instruments
and differential pressure, flow, or level instruments, may be located not more than
4m vertically above grade level or 2m vertically above walkways or platforms,
provided that such locations are accessible by means of a mobile platform or
ladder. The limited accessibility defined above is also acceptable for those
analyzer sample take-off and return points having a valve only. Where retractable
probes or flue gas probes are specified, these shall be permanently accessible,
see (1). For dial thermometers, permanent accessibility shall be provided when
the instrument mounted directly on the process connection. All other cases where
limited accessibility is considered, such as for thermocouples and resistance
thermometers or displacer level instruments, will require COMPANY’s approval.
Where limited accessibility cannot be accepted, platforms shall be extended or
additional platforms shall be provided to attain the permanent accessibility as
defined in (1).

1.44 Relief Valves

Inlet lines to relief valves and de-pressuring valves shall be self-draining to the process
equipment.

Relief valves shall be accessible by either from grade or a fixed platform.

Spring-loaded and pilot-operated or assisted safety / relief valves as well as thermal


expansion valves shall always be installed in the upright position. Liquid shall be drained
from the valve both at the valve inlet and outlet.

When indicated on the P&ID’s relief valves discharging to atmosphere shall comply with
the following requirements to protect personnel and equipment:

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a) The discharge pipe shall be vertical.

b) The vent pipe at least 2m long.

c) Terminate at least 5m above grade.

d) 3m above the tallest accessible structure within 8m radius.

e) 30m horizontally from furnaces, boilers, air intakes, etc.

f) The end of the vent pipe shall be cut off 45º down direction, with a ¼ inch drain
hole at the lowest point.

Closed relief systems shall slope towards a knock-out vessel near the flare stack or to an
intermediate liquid / solids knock-out vessel.

The discharge line from this K.O. vessel should then slope towards the K.O. vessel of the
flare.

a) The outlet line from a relief valve shall be self-draining into the flare header.

b) Connecting branches shall, if possible, connect to the top header, or, in any case,
drain into the headers. The branches must be connected in such a way that there
are no welds in the lower third of the circumference of the header. The branches
shall be connected at 45º into the header to promote one directional flow in the
header in the direction of the slope.

c) The flare header shall be self-draining towards a knockout drum. Minimum slope
for unit branch headers shall be 1:200, for main headers 1:500 or as indicated in
P&IDs.

1.45 Control Valves

Control valve, block valve and bypass valve sizes shall be indicated on the P&ID’s.
Control valves shall be located at grade or first level platform unless otherwise required
for process or operational reasons. In general, the instruments or indicators showing the
process variables shall be visible from the control valve.

Control valves shall be installed with clearance available to remove the actuator, stem
and plug as a single unit.

1.46 Orifice Runs

Orifice runs should be located in the horizontal piping. Vertical orifice runs may be used
with approval of COMPANY. Permanent access shall be required for all the orifice
meters.

Orifice plate accessibility shall be as noted in Section 10.10.

The location of measuring elements and the orientation of pressure taps for differential –
pressure flow meters shall comply with the following requirements:

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a) For vertical piping, the taps shall point in the direction from which they are
accessible.

b) For normal applications on average size piping, the angle between the taps
should be approximately 90º. For large-size piping a somewhat smaller angle
may be more practicable and is therefore acceptable.

c) For horizontal pipes, the orientation shall be such that the taps are self-draining
on gas service or steam service and are self-venting on liquid service, but in
locations where sub-zero temperatures may occur the taps for liquid service shall
be self-draining.

d) For horizontal piping, bolts shall not obstruct the vertical position of the tap on the
orifice plate (upwards on gas and steam service, downwards on liquid service).

Note: This is to ensure that the bleed hole in the orifice plate is in the correct
position. In pre-fabricated meter runs of size ½”, the tap can be in any
position from the vertical, which is acceptable in this case because these
orifice plates do not have a bleed hole.

1.47 Instrument Connections

In general the following shall be taken into consideration while providing instrument
connections:

 Instruments in liquid service shall be mounted below the tapping point on the
piping;

 Instruments in gas service shall be mounted above the tapping point on the
piping;

 Instrument process piping / tubing shall slope up or down towards the


instruments at least 1:12.

1.48 Temperature Instruments

Temperature test well locations and accessibility shall be as noted in Section 9.10

Temperature indicators shall be visible from grade, ladder or platform.

The accessibility and location of thermocouple and temperature indicators shall be as


noted in Section 9.10

Run pipe diameters shall not be less than 4 inches.

Local Temperature indicators shall be visible from grade, permanent ladder, or platform.
Accessibility shall be as noted in Table PIPING DESIGN BASIS-14.

Connections on horizontal piping shall not be located below the horizontal centre line of
the pipe. Preferred location is on top of the horizontal pipe.

For remote temperature indicator thermocouple shall be used if accuracy requirements


are met otherwise used Resistance Temperature Detector (RTD).

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Mercury filled system shall not be used. Filled thermal systems, such as those with
alcohol, shall only be used on Company’s approva

11.0 CIVIL / STRUCTURAL DESIGN BASIS

1.49 General

This document describes the basic specifications that are adopted in the design of Civil /
Structural works and general notes to be followed in this discipline deliverables.

This document shall be read in conjunction with specification no. 30.99.75.0067 titled
“Structural Design Basis Specification”. All related design philosophies, as stated in
ADCO specification shall be applicable for this Project. In case of any conflict, the ADCO
standard specification prevails.

1.50 Scope

The purpose of this document is for the following:

 To ensure consistency and compatibility between of all design aspects of the


Project;

 To ensure all necessary input, understanding and commitment to the design by the
client and consultant/contractor is incorporated in the engineering design
deliverables satisfying multidisciplinary requirements.

1.51 Design Data

11.1 Loading Data

The loads and load combinations shall be as per ADCO Standard No. 30.99.75.0067
“Structural Design Basis Specification”.

11.2 Design Considerations

The design and calculations shall be as per ADCO Standard No. 30.99.75.0067
“Structural Design Basis Specification”.

11.3 Steel Structures

The Design of Steel Structures shall be as per ADCO Document No. 30.99.75.0067
‘’Structural Design Basis Specification’’, relevant Shell DEP and relevant ADCO EP
standards.

11.4 Reinforced Concrete Foundations and Structures

The Design of Reinforced Concrete Foundations and structures shall be as per ADCO
Standard No. 30.99.75.0066 “Specification for Concrete Construction”, ADCO document
No. 30.99.75.0067 “Structural Design Basis Specification” and relevant Shell DEP.

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1.52 Earthwork, Paving, Grading and Fencing

The site preparation and earthwork shall be as per ADCO Document


“Amendments/Supplements to DEP 34.11.00.11” and DEP 34.11.00.11-Gen. “Site
Preparation and Earthwork”.

The oil well areas shall be fenced and gates shall be provided where required.

Equipment areas shall be paved with 80mm concrete pavement interlocking tiles.
Walkways shall be minimum 1.0m wide and shall provide access to shelters,
equipments, gates, etc. Walkways shall be paved with 60mm thick interlocking tiles.

Instrument cable shall be laid in trenches as per the relevant SHELL DEP requirements.

Electrical and instrumentation cables outside station area will be laid in trenches and
marking tiles, tape and cable markers shall be provided.

All foundations will be of shallow type, in areas where top soil is not stabilized,
foundations shall be founded at a minimum of 1.0m below the final finished grade level to
prevent undermining of the foundations by wind or water post construction.

Sand/ bituminous mix/ bitumen/ cement mix shall not be used for stabilizing earthworks.

A security fence of 3.0m height in which, one minimum 4.0m wide double leaf gate and
one 1.00m wide personal gate shall be installed all around the oil well location. Sufficient
access for sand clearance equipment shall be provided within the fence line. Security
fence shall be as per Critical National Infrastructure Authority (CNIA) perimeter fencing
security standards.

11.5 Stabilization

A minimum 2.00m wide, 300mm thick compacted gatch stabilization shall be provided
around the perimeter of fencing. The area inside the perimeter fence of wellhead
facilities shall be stabilized with 300mm thick compacted gatch.

1.53 Storm Water Drainage

Storm water drainage shall conform to DEP 34.14.20.31-Gen “Drainage and Primary
Treatment Facilities”.

Contaminated Water Drainage from Process shall be routed as an underground system


in accordance with DEP 34.14.20.31-Gen “Drainage and Primary Treatment Facilities”.

1.54 Pipe Supports and Pipe Sleepers

Pipe supports/ racks and sleepers shall be designed for the critical piping loads, wind
loads and self– weight of the structure in line with ADCO amendment on minimum
requirement of structural design and engineering guidelines/basis. The locations of the
pipe supports and sleepers shall be as per piping general arrangement drawings.

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1.55 Equipment Foundations

All equipment supporting structures and foundations shall be designed considering the
following equipment load conditions:

 Erection;

 Operating;

 Testing;

 Shutdown.

Piping loads in general shall be considered as equipment loads.

Vertical loads from pipes during erection, operation and testing shall be considered.
Horizontal loads caused due to pipe expansion and anchor shall be considered as
operating loads.
For rotating equipment, foundation design shall be based on equivalent/quasi static
analysis and dynamic analysis using manufactures loading data.

1.56 Sun Shades

In general, sunshades shall be provided for the pumps, chemical injection skids and
utility packages.
Where found necessary, sunshades shall be provided with adequate lifting facilities and
laydown areas.
Roof connections shall be bolted type unless noted otherwise.

1.57 Miscellaneous Steel Structures

Besides the pipe supports and the sunshades the following steel structures shall be
installed where found necessary:
Walk-overs, Platforms, Stairs and Ladders.

1.58 Drawings & Documents

All the drawings shall have the new ADCO Project specific drawing numbers and be
prepared as per ADCO drafting standards and procedures.

1.59 Structural Steel Member Connections

All structural steel member connections shall be designed for the following minimum
forces:

 Moment Connection: 60% of bending capacity together with 30% of shear capacity
of the member;

 Shear connection: 40% of shear capacity of the member;

 Bracing connection: 30% of the tensile capacity of the member.

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However in no case shall the minimum force calculated for the connections design be
less than 50kN for shear/axial case. Bolted connection shall not have less than two bolts.
At all the splice locations, the joint shall be designed for 100% capacity of the member
cross section (in the respective force/moment direction) at that location.

1.60 Structural Steel Deflection Limits

The following deflection limits shall be used for structural steel design:

 Horizontal deflection for steel structures = Height/200;

 Vertical deflection for Grating/ Checkered Plate = Span/250 or 6mm whichever is


less;

 Vertical deflection for Roof/Cladding sheet = as per manufacturer’s


recommendation.

1.61 Fire Protection

Fire protection shall conform to Fireproofing of Steel structures, DEP 34.19.20.11-Gen


and 34.19.20.11-A Fireproofing of steel structures, and Design Standard for Fire
Protection Systems including fire water flow rates in section 8.7 of Drainage and primary
treatment facilities DEP 34.14.20.31-Gen.
Fireproofing shall conform to Application Criteria and Installation. Specification for
Fireproofing, DEP 34.19.20.11-Gen and 34.19.20.11-A Fireproofing of steel structures.

1.62 Crack Width for Concrete Structures

Crack width for the concrete members shall be limited to:

 0.1mm for liquid retaining structures;

 0.2mm for other structure.

12.0 ELECTRICAL DESIGN BASIS

1.63 General

This section of the document is to outline the general electrical requirements for the
electrical design, engineering, selection, inspection and testing, installation and pre-
commissioning and commissioning of electrical facilities for the ‘EPC Services for Asab
Unit 6&7’ Project.

This section shall be read in conjunction with project specifications, data sheets,
drawings, schedules, SHELL DEP and their amendments defines the minimum
requirements for carrying out work or services to the Project.

1.64 Project Scope

The electrical scope of work for the ‘EPC Services for Asab Unit 6&7’ Project facilities
shall comprise of following:

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 Provide power supply for the three (3) Multi selector Manifolds (MSM’s) at RDS’s
1, 2 and 6 (One in each RDS);

 Provide area lighting for MSM’s area at all the RDS’s;

 Provide power supply skid (PSS) to new Water Injection Cluster 26 (WIC – 26)
from existing 33KV over head line;

 Provide power supply for Cathodic Protection System for the buried pipelines;

 Provide solar power supply to new oil producer wells (as required);

 Provide earthing to new oil producer wells and water injection wells;

 Electrical cables routing, lighting and earthing system;

 Preparation of MTO’s;

 Preparation of detail design drawings and documents;

 Preparation of MR’s for all Long lead items;

 Technical Bid Evaluation of all long lead Items;

 Vendor Drawings/Documents review;

 FAT and SAT activities and pre-commissioning and commissioning procedures.

For RDS’s, spare feeders in the existing switchboard shall be verified and utilized with
necessary modifications (if required), provided they are found to be adequate. Spare
feeders from existing Switchboard shall be identified / verified during site visit.

1.65 Methodology

In order to provide power supply to new MSM’s, availability of spare feeders from near-
by Switchboards from where similar types of loads are fed will be checked during site
visits at each RDS’s. Power adequacy check will be done to use the existing spare
feeders.

For the new Water Injection Cluster (WIC-26), location of nearest 33KV Overhead line
will be checked and the tap-off point will be identified during site visit. Routing from 33KV
OHL tap-off point to new WIC-26 location will also be identified.

For new water injection wells, solar power will be provided to supply power for instrument
and telecommunication loads. Solar panels will be sized accordingly by Vendor.

Earthing will be provided for new six (6) nos. of water injection wells and four (4) nos. of
normal flow oil producer wells.

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1.66 General Design Requirements

The design of electrical facilities and systems shall be based on the following:

a. 30 years minimum design Life for new / upgraded systems


b. Safety to personnel, equipment and Plant during operation and maintenance
c. Reliability and continuity of service under all working conditions at site
d. Ease of inspection, maintenance and repairs
e. Full inter-changeability of corresponding parts of similar equipment
f. Convenience of operation
g. Ease of future addition of loads/ facilities
h. Compatibility of all power supply extension to the existing system.

1.67 Reference Documents

The design and installation of electrical system shall be in accordance with the following
Codes and Standards

a. SHELL DEP33.64.10.10 – Gen: Electrical Engineering Design (Version 32)

b. Other design codes and standards listed in section 5.0

In case of conflict between documents the following priority of documents shall apply.

a. The laws, standards and regulations of the United Arab Emirates

b. ADNOC Codes of Practice

c. Project equipment Data Sheets /SLD Drawings

d. Project Specifications.

e. ADCO Procedures and Codes / Standards

f. ADCO Specifications and Engineering Practices

g. ADCO supplements/amendments to shell DEP’s

h. Shell DEPs

i. International oil and gas Industry Codes, Standards and Recommended


Practices

j. IEC and International applicable standards

1.68 Power Supply Arrangement

The power supply for the new Multi selector manifolds at RDS-1, RDS-2 and RDS-6
(CDS) shall be taken from the available spare feeders of existing substation LV
switchboards. Suitable modifications at existing switchboards shall be done, if required.

If the existing area lighting for the new MSM’s area is found to be inadequate, then new
lighting shall be provided. Power supply for lighting at new MSM’s skid / shelter shall be
provided. Power for both area lighting and MSM’s skid / shelter lighting shall be taken

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from available spare feeders of existing Lighting distribution boards. Utilizing the existing
spare feeders of existing switchboards shall be confirmed based on the outcome of the
power adequacy check report.

Power supply input for the new power supply skid (PSS) at new Water Injection Cluster –
26 (WIC-26) in Asab shall be sourced from the existing 33kV overhead line. Existing OHL
is currently feeding 25 nos. of existing water injection clusters (WIC) at Asab field. Power
tapping tie-in point at existing OHL shall be identified and the overhead line shall be
extended up to the new power supply skid location at WIC-26.

The power supply (if required) for the new 6 no. of water injection wells shall be provided
from solar panels (by Vendor).

1.69 Utilization Voltages and Frequency

Following power supply voltage levels shall be considered unless specified, otherwise:

Consumer Utilization Voltages

Above 200KW up to 1100KW Motors 3.3KV-AC Resistance earthed system

Motors greater than 1100KW 11KV-AC Resistance earthed system


Motors above 0.18KW up to and
415V-AC, 3 Phase, Solidly earthed system
including 200KW
Fractional horse power non- process
240V-AC, 1 phase or 415V-AC, 3 phase
motors upto 0.18kW
Fractional horse power process
415V-AC, 3 Phase, Solidly earthed system
motors upto 0.18kW
33KV-AC, 3 Phase tapped through fused
isolator switch from OHL, 33KV OHL is fed
Supply to WI Cluster
through buffer transformer, the secondary of
which is solidly earthed
Surface water injection pump motors
3.3KV-AC, 3 Phase, earthed system
at water supply wells
Electrical submersible pump motors at
3.3KV-AC, 3 Phase, Unearthed system
water supply wells
Welding receptacles 415V-AC, 3 Phase, 4 Wire
240V-AC, 1 Phase, 2 wire derived from 415V
Lighting and receptacle supply
3 Phase 4 wire system
Switchgear anti condensation Heater 240V-AC, 1 Phase
Instrument loads at water injection
240V- AC
well heads
Tele communication panels at water
240V- AC
injection well heads
Cathodic Protection power at water
240V- AC
injection well heads
Control Supply Voltage:
3.3KV & 415V Switchgears 110V- DC
ACB Spring charging, closing coil 110V- DC
3.3KVMotor feeder 110V- DC
415V Motor feeder 240V- AC
Instrumentation 240V- AC

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Telecommunication 240V- AC

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The transient limits and steady state limits for voltage & frequency variation shall be as
follows:

Voltage variation Frequency variation


Normal Conditions Normal voltage +/- 5 % *** 50 Hz +/- 2 % ***
Transient Conditions -10% at Switchgear Busbars 50 Hz +/- 2 %
+10% and -20% at Motor
Terminals

*** The electrical equipment including motors shall be designed suitable for voltage
variation of +/-10% and frequency variation of +/- 5%.

1.70 Electrical Calculations and Protection Study Report

The following shall be performed in the design of the electrical distribution system:

12.1 Electrical Calculations

The electrical design calculations shall cover for the following requirements:

13.0 Proper sizing of the MV and LV electrical feeder cable sizes for each equipment
taking into consideration the % V.D. allowed during motor starting and steady
state condition.

14.0 Proper sizing of the electrical feeder cable sizes for each equipment taking into
consideration its short circuit withstand capability based on the fault clearing time
of the equipment protection device during fault condition.

15.0 Lighting illumination level calculation shall be performed for the design of the
lighting system installation inside the PSS package substation, surface water
pump shed and chemical injection package shed to determine the required
illumination levels.

16.0 Earthing system sizing design for the PSS substation and WIC area shall be
performed to determine the required minimum resistance to earth for proper
operation of the protection relay during earth fault.

16.1 Protection Study Report

The protection study report shall be restricted to all equipment in the power supply skid
(PSS) and it’s immediate upstream 33kV fuse at the tap-off point on the existing 33kV
overhead line pole.

As a part of the final protection study report, a comprehensive protection schedules


covering every circuit in Asab field (including all main HV and LV switchboards/MCCs)
shall be furnished. The protection schedule shall include as a minimum the following
information:

i) Switchgear Reference

ii) Circuit Reference

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iii) Single Line Diagram Drawing

iv) Protection type (O/C, E/F, etc.)

v) Relay make

vi) Relay type

vii) Relay setting ranges and calculations

viii) CT ratio

ix) Recommended relay settings (from final study)

x) Protection device operating curve / coordination curve reference

xi) Remarks

In addition to the above study, the insulation coordination for surge arresters and RC
dampers connected for the surface water pump and submersible pump transformers
primary and secondary side, respectively, shall be included in the report.

1.71 Electrical Equipment for Hazardous Areas

The electrical equipment for hazardous areas shall be suitable for Zone 2, Group IIA /
IIB, and Temperature Class T3. The basic philosophy with the minimum requirements is
summarized below.

Zone 1 areas

HV motors Flame proof type Ex (d) type.

LV motors Flame proof type Ex (d) type.

Junction boxes, etc. Flame proof type Ex (d) type.

Light fittings Flame proof type Ex (d) type.

Zone 2 areas

HV motors Flame proof type Ex (d) type.

LV motors Non sparking Ex(n) type.

Junction boxes, etc. Increased safety Ex(e) type.

Light fittings Flame proof type Ex (d).

16.2 MV Switchgears

The MV Switchgears shall be designed and manufactured and tested in compliance with
Project specification. All MV switchgears shall be metal enclosed construction (as per
IEC 62271) and extendable from both ends. The 3.3KV switchgear protection circuit
breakers shall all be VCB drawout type for the incoming feeders and the respective

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outgoing transformer feeders and motor feeders. The minimum degree of protection for
Switchgears external housing shall be IP42. Suitably sized surge arresters shall be
provided on the downstream motor circuit feeders load terminal side.

The earthing switches shall be provided to earth the incoming and outgoing circuits.
Suitable mechanical key interlocks shall be provided to ensure that circuits are isolated
before earthing switches can be closed and earthing switches are open before
energizing the circuits. Additionally, the MV upstream and LV downstream circuit breaker
shall be provided with mechanical interlocking (Castell key interlock) for safety to
personnel during switching operation sequence.

All circuit breakers in the 3.3KV switchgear assembly shall be installed in single tier
formation. Number of equipped and unequipped shall be as shown in Project’s single line
diagrams.

The MV Switchgear assemblies shall comply with IEC 62271-200 and with IEC 62271-
100 for circuit breaker design.

Intelligent Protection Relays (IPR’s) shall be used for main incomer feeders and outgoing
MV feeder and MV motor feeder circuits rated 160KW & above with serial data
communication link capability with RTU (by instrument).

16.3 LV Switchboard

The LV Switchboard shall be complying with project specification and SHELL DEP
33.67.51.31-Gen. The LV switchgear assemblies shall be type tested, metal clad fully
withdrawable, form 4b, Type-5 constructions and extendable at both ends. The HVAC
power panels shall be form-2b construction with plug-in type MCCB’s. The switchgear
and control gear shall be accessible from the front.

The minimum degree of protection for external housing shall be IP42. The circuit breaker
protection for main incomer feeder shall be MCCB with suitable rated current and shall
be drawout type and with serial data communication link with the RTU.

Intelligent Protection Relays (IPR’s) shall be used for LV motors rated 160KW & above
and Motor Control Unit (MCU) for LV motors less than 160KW or as shown in the
approved SLD.

LV distribution boards located in plant area (if required) shall be of either frame mounted
or free standing types. The enclosures shall have a minimum degree of protection of
IP55, corrosion resistant suitable for use in area classification as Zone 1 or Zone 2, gas
group IIB, temperature class T3.

LV distribution boards located inside the new PSS substation shall be free standing type.
The enclosures shall have a minimum degree of protection of IP42.

LV distribution boards shall be fitted with 240V-AC, single line anti-condensation heaters.
They shall be controlled automatically by adjustable hygrostats, setting range 50-100%
relative humidity.

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16.4 Power and Auxiliary Service Transformers

The surface water pump and submersible power transformers and auxiliary service
transformer shall comply with project specifications and data sheets. Transformers rated
up to and including 2500KVA shall be hermetically sealed, non-breathing type. At rated
3150KVA and above power transformers shall be of the oil-filled conservator type. All
hermetically sealed transformers shall be provided with pressure relief device, oil
temperature indicator, winding temperature indicator, etc.

For all outdoor type transformers, a fire wall between the transformer bays shall be
provided.

16.5 AC UPS system & Batteries

The AC UPS system shall comply with project specification and data sheet. AC UPS
shall be of the static type, PWM switching topology. The UPS configuration shall consist
of 1 x 100% Charger, 1 x 100% Inverter and 1 x 100% Batteries (For the autonomy time
of 30 Minutes), static switches with one make-before-break maintenance by-bass switch,
Battery Isolation MCCB with EE”xd” box if in hazardous area classified location (i.e.
inside battery closet) or IP55 box, if in safe area only. The AC & DC-Distribution Boards
for downstream loads shall be provided as well.

The rectifier/charger shall be solid state technology and inverters shall be transistorized
using pulse width modulation (PWM) switching type with minimal allowable amount of
THD with microprocessor control. Microprocessor based protection, control and metering
system with serial data communication link capability with the RTU shall be provided on
the AC-UPS.

While sizing the AC-UPS systems, a margin of 25% shall be allowed for future load
growth.

Vented Ni-Cd batteries shall be used for AC UPS systems. Autonomy of battery sizing
shall be for instrumentation system and analyzers is 30 minutes.

For power supply skid, Battery cells shall be of the nickel cadmium, gas recombination
(restricted breathing) type, maintenance free (or ultra low maintenance type). Cells shall
be fitted with flame-arresting vent plugs and provided with cell tag no. on each cell.

16.6 Motors

The electric motors shall comply with project specification. Motors shall generally be 3
phase squirrel cage induction type totally enclosed, adequately rated for their duty and
suitable for direct on line starting. Motors shall be suitable for direct on line starting.
Motors shall be suitable to start and accelerate the load at 80% nameplate voltage at its
terminals. In addition, it shall also be suitable for re-acceleration with 100% voltage in
phase opposition.

All Motors shall be designed for continuous duty (S1) except shown otherwise in data
sheet and preferably with service factor of 1. The operating duties of motors that are
paired for ‘’duty’’ or ‘’stand-by’’ operation shall be interchangeable and shall be fed from
bus bars separated by a sectionalized unit to optimize supply continuity.

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All MV motors shall be star-connected and all LV motors above 1.5KW rating shall be
delta–connected.

Motor enclosure minimum protection shall be IP54 (indoor) and IP55 (outdoor).

The electric motors shall be selected to suit the conditions as follows:

 Site ambient, voltage deviation and corrosive conditions;

 Actual location ambient conditions;

 Classification of area in which the motor is required to operate.

Motor insulation class shall be class F with temperature rise to class B limits.

All 415V-AC motors less than 160KW rating shall be supplied through MCCB’s suitable
for motor circuit protection controlled via starters/contactors and/or MCU’s. LV motors
rated 160KW and above shall be switched through air circuit breakers and protected by
IPR’s.

All 3.3KV-AC motors shall be switched through drawout type VCB suitable for motors
circuits and protected by IPR’s devices with serial data communication link with RTU.

The surface water pump motors rated greater than 3 MW shall be provided with motor
differential protection (87M) within the IPR or through separate multifunction numerical
relay, complete with sensing CTs.

Motors with rating of above 1.1KW located outdoors shall be fitted with anti-condensation
heaters.

The earth fault protection relay shall also be provided for MV motor feeder’s with suitable
CBCT and LV motors of 30KW rating and above, with suitably rated zero sequence CT
(i.e. CBCT).

16.7 33KV Over Head line

The 33KV Overhead line design and materials shall comply with Project specification and
data sheets.

16.8 MV Power Cables

The MV power cables and termination kits shall comply with Project specification and
data sheets.

16.9 LV Power, Control and Earthing Cables

The LV power, control and earthing cables shall comply with Project specification and
data sheets.

16.10 Lighting System

The lighting system design shall be in accordance with DEP 33.64.10.10. Industrial
fluorescent lighting in ‘white’ shall be used in general.

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Lighting fixtures shall be suitable for the area in which they are located and designed for
an ambient temperature of 52 deg C. Fixtures in Zone 2 shall generally be EE”x(d)” type.

Plant lighting circuits shall be single phase and neutral or three phase and neutral.
Protected with maximum 16A MCB’s, but not loaded higher than 12A. Plant lighting
distribution boards shall include a minimum of 25% spare outgoing circuits.

Area lighting shall be provided by flood lighting columns 20 meters high with a number of
high pressure sodium vapour lights. Additional EE”x(d)” fluorescent type lighting shall be
provided near equipment where necessary and near package units for operation and
maintenance.

Security fence lighting shall be provided by 70Watts HP sodium vapour lamps on


standard 8 meters poles at typically 50 meters spacing.

Indoor lighting shall be provided by 2 x 40W, 2 x 20W fluorescent lamps, suitable for
suspension mounting or ceiling mounting.

The main distribution board provided for the lighting system shall be for a 3 phase
415/240V-AC volts, 4 wire supply and shall be located in a substation. This switchboard
shall incorporate the photocell control equipment. Lighting panels, if required in
hazardous areas shall be EE”x(d)” type.

Adjacent luminaries in plant lighting shall be on separate phase as far as practical. All
outgoing circuits in panels shall be controlled by double pole MCB’s.

The emergency luminaries shall have self-contained rechargeable battery packed. The
autonomy hours for MSM shelters in RDS area is 2 hours and 3 hours for new
switchgear in WIC-26.

16.11 Power and Welding Outlets

The location of the outlets shall be throughout the process and utility plants. All units in
Zone1 and Zone 2 areas shall be with EE”x(d)” execution. For safe areas, industrial type
weather proof type outlets shall be used.

These outlets shall be 415V-AC, 3 phase, 4 wire, 5 pin switched socket units. Not more
than 2 outlets shall be connected per circuit, which shall be fed from 30mA earth leakage
circuit breaker on the MCC. The outlets shall be provided such that the maximum length
of extension lead is 50meter.

16.12 Convenience socket outlet

The convenience outlets shall be 240V-AC, 1 phase, 3 poles (Phase, Neutral and Earth)
switched socket units. Not more than 8 outlets shall be connected per circuit. The outlets
shall be provided such that the maximum length of extension lead is 25 meter. For
industrial areas, twin 240V-AC, 13A, switched socket outlets to BS1363 shall be provided
in non-plant buildings like substation, control room, etc.

All indoor convenience outlet circuits shall be fitted with 30mA RCD.

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16.13 Solar Power System

The entire power requirement for the well site facility including instruments, various
control and communication system, WHCP and cathodic protection system shall be
provided from a Solar Power System which is a self-contained unit capable of delivering
the required 24V DC power within the limitations of the available solar radiation and
storage battery bank capacity. The system shall be designed so as to be capable of
providing a minimum of three days (72 hours) uninterrupted power back-up under no sun
condition.

The system shall be a standalone 24V DC power source consisting of an array of


photovoltaic panels, charging regulator, storage battery, output control centre and all
required enclosures and supporting structures. The solar array may be arranged in
several modules to be interconnected in parallel-series combination. The systems and
individual components shall be designed for minimal maintenance and for an operational
life of 30 years in a harsh, unattended, remote desert environment.

Solar power system shall comply with project specification and data sheets.

16.14 Earthing System

Earthing shall generally be done in accordance with DEP 33.64.10.10.

A general earthing system shall be provided within the fence limits. The general system
shall be designed in such a way that any electrical equipment shall be connected to the
earthing grid by at least two connections. The earth ring shall extend throughout the new
facilities with branch interconnections to the equipments to be earthed. All joints and taps
in the earthing conductor shall be made using thermoweld connections. Earthing
connection to equipment / structures shall be made with bolted connections.

The main grid conductor shall have a cross section of 70 mm 2. The potential of the
earthing system of the areas shall be fixed by earth connections consisting of one or
more electrodes driven into the ground. In areas of high soil resistivity, deep well
electrodes shall be installed. Earth electrode sections are coupled together such that the
electrode penetrates summer water table by at least two metres. The resistance to earth
shall not exceed 1 Ohm.

The earth grid shall be connected to at least two (2) earth electrodes.

The minimum size of earth wire conductors shall be:

a) Metallic enclosures of LV electrical equipment , having a supply cable


70mm2
cross-sectional area ≥ 35mm2
b) Metallic enclosures of LV electrical equipment , having a supply cable
25mm2
cross-sectional area ≤ 35mm2
c) To Control Panels 25mm2

d) Non-electrical equipment 25mm2

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One (1) deep well earth electrode shall be provided at each normal flow oil producer
wells and each water injection wells.

At the 33kV overhead lines, surge arrester earthing and structural gantry steel work
earthing wherever employed shall be separated by at least 5 meters.

The PSS packaged substation earthing ring conductor shall have a minimum cross
sectional area of 185 sq.mm where it shall be sized based on the maximum fault current
(Switchgear rating) and the fault clearing time of 1 second. All the major electrical
equipment in substation shall be connected to the main earth grid with two (2)
conductors having the same cross section as the earth grid conductor.

Buried earth conductors shall be run 500mm minimum below finished grade.

Flanges of metallic pipelines that have insulated linings shall be bonded to ensure
electrical continuity. A bond shall also be applied at the equipment connection. Flanged
joints in other metallic pipelines shall be considered inherently continuous. Where driven
equipment is not mounted on a bed plate common with the driver, it shall be
independently earthed.

16.15 Lightning and static electricity

Lightning protection shall be provided for equipment and structures taller than 20m
including telecom towers, substation and control room. Lightning protection networks
shall be independent and dedicated earth electrodes shall be installed, but bonded to the
main earthing network at the buried earth electrode.

Down conductors of lightning protection system shall not be used for earthing electrical
equipment.

16.16 Electrical Bulk Materials

The required earthing materials and wires, lighting fixtures, lighting poles, junction boxes,
fittings, cable trays, u.g. cable markers, cable tags and installation support structures,
etc. shall be design, provided and installed in accordance with the Project specification
for bulk materials.

17.0 INSTRUMENTATION & CONTROL DESIGN BASIS

Instrument Design Basis briefs the basic design requirement which will be followed and
implemented in this project for following facilities as below.

(i) 4 Nos. New Oil Production Wellhead


(ii) 6 Nos. New Water Injection Wells
(iii) 2 Nos. New Water Supply Wells
(iv) 2 Nos. Water Disposal Wells
(v) 3 Nos. New Multi-Port Selector Manifolds in RDSs 1, 2 and 6 (One in each
RDS).
(vi) Utilisation of Water Injection Cluster-9.

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1.72 Field Instruments

Units of measurement for all the documents will be as per section 4.0.

All instruments shall be in accordance with the relevant part of latest version of DEP
32.31.00.32-GEN. “Instrument for measurement and control”.

Enclosures protection for instruments located outdoor shall be as per IP65 to IEC 60529.

Instruments shall be intrinsically safe Ex-‘ia’/’ib’ as per IEC-60079. Solenoid valves shall
be Ex-’d’ ex-proof type and shall not have flying leads. Instruments located in hazardous
area shall be certified intrinsic safe/Ex-’d’ (ex-proof) to Zone 2, Gas group IIA, Temp
class T3.

All instrument and control equipment wetted parts material shall be suitable for the
process media. Particularly materials of construction for instruments in contact with fluids
shall be compliant in accordance with “Standard material requirements – sulphide stress
cracking resistant metallic materials for oil filled equipment” NACE MR 01-75 (latest
edition).

All pressure (transmitters and pressure gauge) instruments shall have ½ “NPT (M)
process connection.

Transmitters shall be based on industrially proven sensing element technology.


Transmitters shall be 2-wire, 24V DC loop powered type. It shall have digital
communication signal superimposed (HART) on the standard 4-20 mA DC signal through
600 ohms load.
Impulse tubes shall be of AISI SS316L material. Tube fittings shall be double
compression type in AISI 316 SS material.

Impulse tube fittings shall comply with NACE MR-01-75 requirements.

Pressure gauges shall be designed to BS-EN-837-1. Differential pressure gauge shall be


balanced bellow type.

Bimetal thermometer shall be every angle type and with AISI SS316 stem.

All field instrumentation shall be provided with double block and bleed valves for
isolation.

Operating voltage of field instruments and solenoids shall be 24VDC.

1.73 Instrument Cables

Cables shall comply with IEC standards. All Instrument, fire and gas detector cables shall
be flame retardant to IEC-60332. Cables shall be armoured type. Signal cable shall have
individual and overall screen and shall be suitable for direct burial in trench.

Junction box shall be of SS316 material. It shall be weather proof to IP-65. Separate
junction boxes shall be provided for IS and ex-proof circuits. Similarly separate JB’s shall
be provided for analogue and digital signals.

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1.74 Fire & Gas Instruments

HC gas open path detectors will be provided as per HSE requirement at multi-port
selector manifold and same shall be connected to their nearest RDS Fire and Gas
Control System.

1.75 Control Valves

Control Valves shall be selected in accordance with DEP 32.36.01.17-Gen "Control


Valves: Selection, Sizing and Specification".

Control Valve Sizing and Characteristics shall be performed and selected in accordance
with DEP 32.36.01.17-Gen "Control Valves: Selection, Sizing and Specification". Valve
noise level shall be equal to or less then 85db A.

1.76 Shut Down Valves

Shut down valves shall normally be Ball Valves and line size with reduced port. Ball
Valve shall be designed as per API-6D and shall be fire safe to API-6F. All shut down
valves shall use fail-safe spring return actuators.

Where double acting actuators are unavoidable a secured instrument air buffer vessel
shall be provided in accordance with section 9.6 of DEP 32.36.01.17-Gen "Control
Valves: Selection, Sizing and Specification".

Proximity type Limit switches shall be provided for open/close status of the valve.

1.77 New Oil Production Well Head

Each Oil Well Heads will have standalone local hydraulic based Well Head Control Panel
for Control & Safety critical trips.

Choke valves will be manually operated.

New oil producing well have a New hydraulically wellhead control panel (WHCP) will be
provided for each of the wellhead control. WHCP will be self contained hydraulic based
panel for safety critical trips.

Each of the WHCP will control/monitor following valves based on the high/low pilots &
ESD inputs to WHCP.
SCSSV (Sub Control Sub-surface Safety Valve)
SSV (Surface Safety Salve on the oil line)
SSV/HIPPS Shutdown Valve (upstream of choke valve in each oil production line)

All the shut down logics related to the above valves will be implemented in the wellhead
panel. No remote control/monitoring is envisaged from the CDS.

Power supply to well head panel, associated push buttons & other utilities will be
provided from solar panel unit.

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The hydraulic system shall be designed to provide power at 5000 psig for SCSSV and at
3000 psig for SSV.

1.78 New Water Injection Well Heads

Each New water injection wells will have local control, flow monitors and mechanical
totaliser. Flow control shall be through manually operated valve, similar to existing water
injection skid of Sb 438.

No remote control & monitoring is envisaged from the CDS.

1.79 New Water Supply Well (Cluster No. 26)

New Water Supply Well shall be control and monitored by RTU/PLC. The RTU/PLC and
Telecom Panel shall be installed in Power Supply Skid. New WSW RTU/PLC shall be
connected through fibre optic cable to existing Siemens SCADA network at Asab CDS
for remote control and monitoring.

1.80 New Water Disposal Wells

Each New Water Disposal Wells will have local control, flow monitors and mechanical
totaliser. Flow control shall be through manually operated valve, similar to existing water
disposal wells.

No remote control & monitoring is envisaged.

1.81 New Multi-Port Selector Manifolds

Three Nos. Multi-Port Selector Manifolds shall be installed in RDS-1, RDS-2 & RDS-6
respectively. These multi-port selector manifolds shall be controlled and monitored
through existing Yokogawa DCS and Pro-Safe ESD & Fire and Gas Systems.

1.82 Utilisation of Water Injection (Cluster No. 9)

Existing Water Injection Cluster -9 is controlled through RTU/PLC, which is connected to


existing SCADA network. No additional Instrument activities are envisaged.

18.0 TELECOM DESIGN BASIS


Telecommunication scope involves interfacing the new RTU/PLC in WIC-26 with the
existing Siemens PCS7 SCADA Server in Asab CDS via the Fibre Optic Network. Fibre
Optic connection to Asab CDS shall be established through the existing North
communication fibre optic ring network. New Siemens Switch (Scalance X204-2LD
make) along with Optical Distribution Frame (ODF), patch cords and related accessories
shall be provided in WIC-26 Power skid active shelter room so as to facilitate the fibre
optic link connectivity for the transmission of the new PROJECT control signals.

32 Core buried Single mode FOC (300 meters) shall be laid along with the electrical
cable from WIC-26 Power skid active shelter room to the nearest electrical pole
(identified as number OHTL-01-00-019) and terminated to a new 3-way junction box.
This new 3-way junction box for integrating the UGFO - OPGW cable as well as OPGW
cable connectivity from the nearest Northern ring pole number OHTL-01-03-031 to

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electrical pole number OHTL-01-00-019 (adjacent to WIC-26) shall be under the scope
of OHL CONTRACTOR. The new Siemens switch shall utilize the same fibre optic cores
(in OPGW) as WSW-1, WSW-2, SB-031 and WSW-048 as these clusters are part of the
latest upgraded Siemens S-7 PLC SCADA Network.
CONTRACTOR shall use the existing 48 core buried Single mode FOC link connection
between RDS-6 and Asab CDS for transmitting the new PROJECT control signals to
Asab CDS.

19.0 LOSS PREVENTION DESIGN BASIS


Project shall aim at minimising the exposure of people to hazards. Project shall not
increase the risks on existing installations beyond the acceptance levels. The design
team shall strive to deliver to ADCO a safer design where:

1.83 Facility Layout

The design of the facility layout for safety shall consider the safety criteria developed in
Design General Specification General Piping - Process and Utility Design, Layout and
Drawings. Units, which contain large quantities of flammable fluids, shall be located such
that the prevailing wind will blow any vapor from an accidental spill away from the units
and facility.

For Plant Layout and accessibility ADCO Engineering Specification # 30.99.12.0023 shall
be considered along with HSE ADCO HSE Philosophy and Shell Standards.

1.84 Safe Distances

Plot Plan layout and safe distances, eliminating the possibilities of escalation shall be
finalised after conducting a gas dispersion study. Finally, QRA study shall confirm that
all escalation probabilities are within the acceptable ALARP region, as defined by the
ADNOC Risk Management matrix. COMPANY standards, showing the minimum
distances to be maintained between the various types of plant equipment, shall be used
during the engineering phase.

1.85 Emergency Shutdown Design

As the project will be part to the on going ASAB FFD Phase 1 project, the system shall
be designed inline with the existing shutdown Philosophy.

1.86 Emergency Depressurization (EDP) – Vent and Flare

As the project will be part of on going Asab FFD Phase 1 project, the system shall be
designed inline with the existing Vent and Flare Philosophy.

All equipment and pipelines shall be protected against loss of containment or rupture.
The process safeguarding system shall ensure that suitable protection is provided
against the maximum pressure and other operating parameters that can be generated
by the worst credible malfunction.

1.87 Drainage Design

Closed drain systems shall be provided to prevent any discharges of hydrocarbon or


hazardous materials into the environment, air and land. Drains shall not be located

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directly beneath, but adjacent to vessels because any blockage could create pooling,
which could lead to rapid fire escalation. The design shall cater for sloped foundations
beneath flow control channels, drain manifolds and maintenance requirements. This will
avert sand ingress into drainage systems. Shell DEP 34.14.20.31-Gen “Drainage and
Primary Treatment facilities” shall be referred to during the design works. The method
and design of the collection systems shall be defined on the respective unit P&ID’s.

1.88 Fire and Gas Detection

As the project will be part to the ongoing Asab FFD Phase 1 project, the system shall be
connected to the existing Fire and Gas detection system. The details of Fire and Gas
Detection shall be coved under Fire Detection & Protection Philosophy Doc No.
14.99.89.1603.

Fire and gas detection systems shall, depending on the type of the event, automatically
initiate control actions and/ or audio-visual alarms.
The types of manual call point, smoke and heat detectors to be provided shall be
reviewed.

1.89 Fire Protection Philosophy

The basis of the ADCO fire protection philosophy is the rapid process ESD and blow-
down, combined with rapid removal of any hydrocarbon spillage from process areas. Fire
Protection shall be risk based upon requirements as identified in the Fire Safety
Assessment study. Fire protection within process plants shall be automated as far as
practical, or manually activated from the Control Room, or on site from safe areas.
Manual intervention shall only be considered as an initial response or for small to
medium sized fires.

Structural steel that supports equipment or piping in hydrocarbon service and vessels
supports such as skirts for vessel in hydrocarbon service shall be fireproofed according
to the Provisions of API 2218.

1.90 Emergency Evacuation and Escape Routes

Escape/access routes leading to main escape routes shall have a minimum width of
1.2m and have a clear headroom of 2.1m. Consideration shall be given to the evacuation
of injured personnel on stretchers.

1.91 Project Specific HSE Deliverables and Studies

The following HSE deliverables are applicable on this project.


 Project HSE Plan
 Project HSE Philosophy
 PSA Workshop Report
 PSA Closeout Report
 HAZOP Study Report
 HAZOP Closeout Report
 SIMOPs Study Report

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 SIL Study Report
 FSA Study Report
 QRA Study Report
 HSEIA Report
 PHSER Report
 Hazard and Effect Register
 HSE Action Tracking Register
 Fire Detection and Protection Philosophy
 Safety & Fire Fighting Equipment Specifications
 Safety & Fire Fighting Equipment Layout
 Fire & Gas Cause and Effect Diagrams
 Fire & Gas detector Layouts
 Hazadous Area Classification Schedule
 Hazardous area classification Drawings
 Escape Route Layout

1.92 Safety Equipment Layout

Personal protective equipment (PPE), Safety Showers, eye wash stations, wind socks,
Safety signs and notices shall be provided wherever necessary for the modified and
new facilities in accordance with ADCO requirement and standards. Safety shower shall
be in line with the requirement of ANSI Z358.1. The type of new safety equipment
installed shall be the same as that already available on existing facility to ensure
standardisation.

1.93 Classification of Hazardous Areas

The classification of hazardous areas for the Project facilities shall be accordance with
IP Code Part 15, 3rd edition 2005 and Shell DEP 80.00.10.10. Electrical equipment
installed in a hazardous area shall be certified for use in the appropriate zone
classification and comply with the requirement of IEC 60079. Any electrical field
equipment that is required to operate under emergency conditions shall be suitable for
use within a hazardous area. Electrical Substations, combustion equipment and engines
shall be installed in safe areas. Due attention shall also be given to the location of
sample points, cold vents, chemical storage and handling areas. Areas to be considered
non-hazardous include control rooms, accommodation modules, radio rooms, fire pump
rooms, muster areas and laboratories.

1.94 Ignition Control

Ignition control will be achieved by consideration of the following:


 Using electrical equipment and instrumentation classified for the zone in which it is
located;
 Earthing of all equipment, as required;

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 Elimination of surfaces above auto-ignition temperatures of flammable materials
being handled.

1.95 Isolation

The basis of isolation to be followed in the design of this Project shall be such that it
shall be possible that any part of the facility (equipment or unit) that might have to be
shutdown for inspection or maintenance during operation can be safely and positively
isolated from the remaining facilities. Inventory isolation valves shall be located in areas
where they will not be affected by mechanical damage from fires and explosions or
projectiles.

1.96 Noise and Vibrations

ADNOC noise exposure limits are 85 dB(A) for 8 hours and/or 83 dB(A) for 12 hours at
1m from the source. These limits shall be considered in the design.

20.0 REFERENCES
 Process Flow Diagram for WIC Doc No. 14.20.08.1601;
 Terms of Reference for Engineering Consultancy Services for Asab Units 6 &
7 Doc No. 14.99.92.0601;
 Utility Basis of Design for ASAB doc no. 14.99.91.1620 Rev1 (Project no. P-
14333);
 Specification for Piping design and Plant layout Doc No. 14.99.12.1607;
 Specification for Painting & Coating Doc No. 14.99.12.1602;
 Abu Dhabi Emirate Law No. 8, year 1978, “Conservation of Petroleum
Resources”;
 UAE Federal Law No. 8, year 1980, “Labor and Social Affairs”, Part V, “Industrial
Safety, preventive Measures, Health and Social care for Workers”;
 Ministry of Labour and Social Affairs, Ministerial Order no. 32, year 1982,
“Determination of the Ways and Means to Protect Employees against
Occupational Hazards”;
 UAE Federal Law No. 24, year 1999, “Protection and Development of the
Environment”;
 Regulation for the Protection of Air from Pollution developed by Federal
Environment Authority based on The Executive Act of federal Law No 24, year
1999, “Protection and Development of the Environment”.
 ADNOC Health, Safety and Environmental Management Codes of Practice.
 ADCO Safety Manual Vol. 10.
 IP Part 15 Area Classification Code
 MSS SP 44 Steel Pipeline Flanges

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