Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
0
Rev.No. Date Prepared By Checked by Approved by
GENERAL REQUIREMENTS
The sizes, specifications / drawings furnished in this bid package for various
facilities are indicative. It is the Contractor’s responsibility to verify all the design
/ data before proceeding to the detailed design and engineering. Under the
scope of this contract, Contractor shall perform all necessary process &
pipeline simulations, using HYSYS and PIPESIM or equivalent software and
furnish design calculations to the company considering adequate margins as
per relevant code / as specified elsewhere in the bid while specifying
equipments / instrumentations. Contractor’s responsibility also includes review
of safety and operability aspect of the facilities under the scope of this contract.
Contractor shall develop detailed process design basis, process flow diagrams,
material and energy balance data for different cases indicated in this criteria
and design the process and associated utilities systems accordingly. In case,
simulation results show higher flow rates or requirements of other
facilities/equipment to meet the requirements of installations for some
applications, same shall be used for design under the scope of this contract.
The design of process and associated utility systems shall be suitably designed
for these higher flow rates. Accordingly, Contractor shall develop detailed utility
balance and utility flow diagrams.
Contractor shall ensure that design of installations shall meet the requirement
of relevant national & international legislations/ rules &
regulations/codes/standards/ recommended practices/guidelines. A typical list
of applicable legislations/ rules & regulations/codes/standards/ recommended
practices/guidelines is included in this Bid package. This, however, cannot be
taken as an exhaustive list and various codes as mentioned in various other
specifications and standards as well as those applicable as per good
engineering practice shall be followed by the Contractor in consultation with
company / company’s consultant.
Contractor to note that P& IDs shall be approved for Construction (AFC), only
after review and approval of aforesaid calculations / documents/ drawings.
Process calculation report shall include sizing calculations for process / utility
piping, equipments / vessels, safety / relief valves, control valves, choke valves,
orifice plates etc. However, sizing of equipments / instruments for which
vendor’s information are required, preliminary calculations shall be submitted
initially. Subsequently, the same shall be updated by the Contractor based on
vendor’s information and shall be resubmitted for Company’s review and
approval. Also hydraulics calculation shall be updated based on final routing /
layout etc. Contractor to note that based upon review and approval of aforesaid
calculation report / documents / drawings and subject to completion of all safety
studies like HAZOP, HAZID, QRA, ALARP, SIL, ESR, EMERA etc. given in the
functional specifications for safety studies only, P&IDs shall be “Approved for
Construction (AFC)”. Engineering shall also be done for future facilities where
ever required. Adequate care shall be exercised while developing the existing
installation modification requirement with special emphasis toward safety and
operability of the systems at the existing installations.
Block Diagram (Indicative) for GGS is given in the bid document. The surface
facilities shall vary in quantity and capacity from one GGS to other. However
the process shall be the same in all the GGSs. In case of any additional /
specific requirement, the same has been indicated in the GGS special
requirements as mentioned under “installation wise scope of work and design
basis”.
Pig receivers:
The well fluids coming from dedicated field manifold lines of 6” & above sizes
shall have pig receivers with pig indicators in the GGS. All incoming lines shall
have suitable provisions to monitor pressure & temperature in local as well as
in control room. The lines to the inlet manifold shall be branching off before the
pig barrel with all necessary isolation valves, NRV’s etc. The details of pig
receiver are given in the pipeline scope of work.
Pipelines from various Self-flow (SF) wells, isolated wells, High Pressure Gas
Wells, wells nearby to the GGS (other than those connected to the above well
fluid field manifold) will run independently to respective GGSs
The Well Fluid Inlet Manifold (LP/Test) will have connections for Well Fluid
pipelines and provisions for future connections, as tabulated in installation-wise
scope of work. These pipelines shall be connected to inlet manifold consisting
of the following headers:
The well fluid inlet manifold shall be provided with all connections (present +
future) for hook up of incoming pipelines from various field manifolds and
individual wells directly as tabulated in installation-wise scope of work. Each of
these incoming pipelines shall have a battery limit isolation valve, chemistry
sampling points, suitable provisions to monitor pressure and temperature in
local as well as in control room along with suitable venting, draining & flushing
provisions. Each incoming pipeline to the manifold shall be connected to the
headers with NRV and isolation valves. Provision for connecting future
incoming pipelines shall be provided at the well fluid inlet manifold with NRV,
isolation valves and blind flanges.
It shall be noted that the design pressure rating is changing from 96 kg/cm2 g
(incoming well fluid pipelines) to 16 kg/cm2 g (well fluid inlet manifold headers)
downstream of the last isolation valves on the incoming well fluid pipelines
connecting the manifold headers. Accordingly, Pressure Safety Valves (two
numbers designed for block discharge case for three-phase fluid set at 16
kg/cm2 g) to be provided in each of the well fluid inlet manifold headers
(including Test Header) for overpressure relief / safety protection. The well fluid
inlet manifold shall be having headers as mentioned above to divert the well
fluid in either of the separation trains depending upon the process requirement.
All well fluid inlet manifold headers shall have chemistry sampling points,
suitable provisions to monitor pressure and temperature in local as well as in
control room along with suitable chemical (PPD/DMF) injection, isolation,
venting, draining & flushing provisions. Independent Pressure Indications
through transmitter for emergency alarms at high-high/low-low pressure shall
be provided in each of the inlet manifold headers.
Pre heaters shall be provided to heat up the incoming well fluid before same is
sent to bath heaters/separators. Individual pre-heaters shall be provided for
Test, LP & HP headers to raise the temperature of well fluid to 40oC. The pre-
heaters shall be shell & tube type exchangers having hot water from the outlet
of heater treaters in the shell side & inlet well fluid in the tube side. The
maximum pressure drop across Pre-Heater should not be more than 0.5
Kg/cm2 at maximum flow condition. The capacities of the heaters will be as per
the design basis provided. The pre-heaters shall be provided with complete
instrumentation for pressure and temperature monitoring in local as well as in
control room and safety devices for monitoring and smooth operation.
However, control and shutdown valves should not be present in the well-fluid
circuit. Pre-heaters shall have common inlet and outlet manifolds for both tube
side fluid and shell side fluid as mentioned above. Each pre-heater shall also
have a bypass arrangement for maintenance purpose with suitable isolation,
sampling, flushing, venting and draining provisions for both tube side and shell
side fluids. Insulation for heat conservation (personal protection if applicable)
shall be provided for both tube-side and shell-side fluids for each heat
exchanger, as required. Pre-Heaters are to be symmetrically placed to have
equal distribution of flow.
Individual IDBH shall be provided for LP and HP headers for heating well Fluids
up to 60o C for better separation of well fluid in the separators. The Indirect
water bath heaters shall be as per the functional specifications enclosed with
this document. The maximum pressure drop across Bath-Heater should not be
more than 0.5 Kg/cm2 at maximum flow condition. Bypass arrangement shall
be provided across IDBH so that the well fluid from pre-heaters can be routed
directly to production separators in case of process requirement. Provisions to
monitor inlet and outlet pressure, temperatures shall be provided in both local &
remote modes. Suitable meters shall be provided for measuring fuel gas
consumption.
The required nos. of IDBH modules for individual GGSs are given in the
respective Scope of Work.
Production Separators shall be two phase Vertical vessel. The well fluid from
VHP / HP headers shall be taken into VHP / HP Separators (wherever
provided) after heating the well fluid in Preheater/ Preheater & indirect water
bath heaters respectively. The LP separation train shall be receiving well fluid
from LP header via Pre-heater and IDBH. At location where VHP / HP
separator is provided, LP separator shall also receive liquid from VHP / HP
separator. The Liquid from LP Separation trains shall be routed to heater
treater. The gas from VHP Separation module shall be routed to Gas Lift
network and HP separation module shall be routed to the Sales Grid. The LP
gas from LP separation module shall be routed to suction of LP compression
module which are located either within the same premises or GCP in field.
Suitable measurement system for Liquid & gas from separators shall be
provided.
The VHP / HP & LP separation trains shall be as per functional specs enclosed
with this document. The required nos. of Production Separation modules for
individual GGSs are given in the respective Design basis.
The maximum pressure drop across Separators (LP/Test taken together) shall
not be more than 0.5 Kg/cm2g at maximum flow condition. The LP separators
shall be provided with complete instrumentation for pressure & level monitoring
& control (split-range between main & flare for pressure control) along with
temperature & flow monitoring in local as well as in control room. The
separators shall also be provided with complete instrumentation for emergency
alarms (high-high pressure, low-low pressure, high-high / low-low level) and
safety valves (fire case) for safe and smooth operation. Each separator shall
also have arrangement for suitable isolation, sampling, flushing, venting and
draining provisions. LP Separators are to be symmetrically placed to have
equal distribution of flow Pressure & level gauges (local indication) should
cover the entire range (high-high to low-low).
Test separator:
Heater treater:
Heater treaters modules shall be provided to separate out gas, oil & water from
the emulsion received from LP & Test separator modules by thermo-chemical-
electrical process.
Treated Crude oil from Heater Treater shall go to Oil storage tanks. Oil
separated at the HT should have BS & W less than 0.2% w/w and separated
Water should have oil content less than 125 ppm.
The outlet gas shall be routed to fuel gas system of respective GGS [except,
GGS-II, Geleki; where it will be directly fed to LP compressor for further
utilsation.
Heating requirement for heater treaters shall be met by burning fuel gas
sourced from FG system of respective GGS [except, GGS-II, Geleki; where it
will be met by hot oil based heat exchanger system]. Heater portion is required
for heating emulsion from up to 75 degree C for better separation of oil & water
in the heater treaters. The maximum heater treater operating temperature shall
be 75 degree C.
Demulsifier (presently @50 -120 ppmv) will be dosed in the inlet to the heater
treaters for emulsion breaking. Pour point depressant i.e. PPD (presently @
200 ppm) will be dosed in the outlet to the heater treaters for preventing
congealing in crude oil storage tanks. Suitable dosing facility shall be provided
for proper mixing of Demulsifier / PPD.
In addition to liquid from each LP separator , Heater Treater shall also receive
liquid from Crude Oil (Tank Bottom) Re-circulation Pump, Skimmed Oil Return
Pump (effluent tank), Oil from Slop Oil Tank Pump of ETP, Flare KOD Pump,
CBD Pump, Compressor KODs, other KODs/Scrubbers at GGS, Condensate
Return Pump of GCP.
.
Storage tanks:
Existing Storage Tanks for Emulsion, Treated Crude Oil and Effluent are to be
retained with following philosophy & Activity:
The total storage capacity envisaged for a typical GGS is for 3 days of oil
production and one day effluent production. In order to meet this requirement
additional storage tanks shall be provided, equipped with all the safety &
monitoring facilities including proper dykes where ever required as per the GGS
Scope of Work. The tanks for additional storage capacity(to meet three days
storage) shall be in Turnkey EPC Contractor’s scope.
Existing crude oil/effluent storage tanks shall be retained and utilized for
storing crude oil/ effluent as per the status given elsewhere in the bid
document. It shall be noted that the existing 90 m3 capacity oil tanks shall be
dedicated for storing test liquids. In addition to the existing tanks mentioned
above, additional crude oil/effluent storage tanks shall be provided as per
installation-wise scope of work/design basis so as to store oil production for
three days and effluent production for one day. This storage tanks consisting of
existing tanks and new tanks will be equally distributed between Production,
Settling and Dispatch tanks.
The following works shall be carried out for existing oil / effluent storage tanks:
1. Replacement of all safety valves, breather valves; isolation
valves/flanges/piping etc. for inlet/outlet/drain; man-hole covers, gauging &
sampling hatch, etc. & any other items, as required.
2. Provision for monitoring pressure, level and temperature (multi-point for
average temp.) in local as well as in control room shall be installed.
Oil recirculation pumps shall be provided to re-cycle the off - spec crude back
to heater treaters for further improvement in quality. These pumps shall be of
centrifugal type. The nos. of pumps shall be two (1 no. in operation + 1 no.
standby).
Pumps shall be provided to dispatch entire treated daily oil production to the
field CTF. The pumps shall be suitable to pump out single day’s production in
20 hours as given in the installation-wise scope of work/design basis. Common
inlet & outlet manifolds as described above shall be provided.
Two no.s centrifugal type pump as API 610 latest edition (One operating and
one installed spare) shall be provided.
Pumps shall be provided to dispatch entire daily effluent production to the ETP.
The pumps shall be suitable to pump out single day production in 12 hours as
given in the design basis.
• No. of Pumps shall be 02 nos. (01 no. in operation+01 no. stand by).
• The provision for monitoring of Pump “On/Off” Status in control room is
required to be provided.
• Dispatch quantity is required to be measured with Magnetic Flow Meter.
Design Basis for GGS shall be followed for pig launching facilities given in bid
document.
Pig launching facility shall be provided in each outgoing Oil line having
diameter 6” and above.
• The incoming well fluid lines from well manifolds to GGS as mentioned in the
pipeline scope.
Design Basis for GGS shall be followed for pig receiving facilities and
specifications of pig receiver facilities are given in bid document.
Pig receiver facility shall be provided in each incoming Oil/ well fluid line, having
diameter 6” and above. Pig receiving facility shall be located within GGS
premises
Gas lift manifold shall be provided in GGS to collect high pressure gas received
from field GCP thru’ a dedicated pipeline (size as per installation-wise scope of
work) and send it to either gas lift field manifolds or to individual wells thru’
pipelines as per installation-wise & pipeline scope of work/design basis. Each
gas pipeline outgoing from GGS to gas lift Field Manifolds or to individual wells
shall be provided with orifice metering system within the GGS premises for both
continuous as well as intermittent gas lift systems within the battery limit of
GGS. Well Injection Cycle is to be mapped in the DCS. Further, DCS shall
monitor online flow rates of individual gas injection stream and should perform
comparison of online flow rates vis-à-vis mapped injection cycles in real time
mode. Gas lift manifold as well as all outgoing lines shall have suitable
provisions for pressure & temperature monitoring in local as well as in control
room along with suitable provisions for isolation, venting, draining, flushing,
sampling etc.
No. & size of lift gas : As per pipeline scope of work/ design basis
injectors
No. & size of lift gas 2 (two), As per pipeline scope of work/ design
headers basis
Operating Pressure : 80 kg/cm2g (max)
Design Pressure 96 kg/cm2 g
:
(ANSI 600 Class pressure rating)
Operating Temperature : 45-55
Design temperature : 65 0C
New flare system (ground flare) including sub & main flare headers, flare KOD,
flare KOD pumps (for transferring liquid to heater treater inlet), water seal drum,
FG purging, remote- main & pilot-igniters, box flare, on-line monitoring of flare
emissions etc. shall be provided. Hydrocarbon discharge from flare control
valves, blow-down valves, safety valves shall be received in the flare system.
New flare system shall be designed for the total gas capacity of the plant. One
common flare system shall be provided for integrated complexes. Flare
Measurement System – Thermal Mass Flow Type / Ultrasonic Type is to be
installed & commissioned.
The utilities are described in details in the utilities section. However some
specific utilities applicable for the group gathering stations are as follows:
Fuel Gas conditioning skid for CPP and integrated complex having GGS
Fuel Gas conditioning skid consisting of Preheater, Scrubber, Super heater,
associated instruments, Filter etc shall be provided for fuel gas requirement of
CPP. Dehydrated gas from Gas dehydration unit at outlet of HP compressors at
GCP shall be source of fuel gas system at respective location. Fuel gas header
will be electrically traced and insulated if required to prevent liquid
condensation.
For black start, a separate line shall be connected with all the outgoing gas lift
pipelines from GCP to GGS/GL manifold at field in such a way that gas can be
drawn from the gas lift network. It is therefore imperative that no NRVs are
present in the GL network except at the well head. In view of the case when
gas lift network pressure falls below 40 kg/cm2g at any point of time , a
provision to be made by contractor to source LP gas from separators at 3.5-5
Kg/cm2 and feed the gas to existing gas driven HP compressors through
bypass line and run the same for meeting the fuel gas requirement . Once the
CPP is started, the new electrical motor driven compressors shall be run to
restore normal mode.
Blow down
An underground Closed Blow Down (CBD) system with blow down vessel is
provided to collect all hydrocarbon liquid drains. CBD pumps are provided to
pump out CBD liquid. Liquid from Flare CBD is normally routed to Heater
Treater or to the existing crude oil storage tanks.
Demulsifier
PPD
PPD storage tank, dosing vessel and dosing pumps alongwith heating
arrangement shall be provided to inject PPD into the oil outlet of Heater
Treater. Dedicated PPD dosing pump shall be provided for Heater treater Oil
outlet. No. of Pumps shall be 02 nos. for Heater treater outlet (01 no. in
operation + 01 no. stand by).
The new hot oil system (1+1) basis, as a minimum, shall comprise the
following:
a) Hot oil expansion vessel
b) Hot oil transfer pump
c) Hot oil circulating pumps
d) Hot oil filters
e) Waste heat exchangers (at CPP)
f) Hot oil dump cooler
PCVs,TCvs and flow switches shall ensure that required heat is available to the
units and minimum flow is maintained through the WHRU Hot oil system shall
conform to DGMS/OISD/API/ASME/ASTM and other national/international
codes/standards/ recommended practices/guidelines. Contractor shall design
the entire system accordingly.
Block Diagram for typical ETP is given in the bid document. The surface
facilities shall vary in quantity and capacity from one ETP to other. In case of
any additional / specific requirement, the same has been indicated in the ETP
1.0 Inlet Manifold: The inlet manifold shall be having suitable connections from
various GGS/CTF .The produced water / effluent from inlet manifold shall be
routed to Wash Tanks of ETP. The header shall be provided with isolation
valves and injection point for De-oiler.
2.0 Wash Tank: The produced water / effluent shall be collected in Wash Tanks
from where the free floating oil shall be recovered by proper skimming facility /
suitable oil recovery system and routed to the Slop Oil Tank. Guided Wave
Radar Type Tank gauging and safety system shall be provided. Sludge from
wash tanks shall be routed to sludge drying bed by sludge transfer system.
3.0 Effluent transfer pump: The effluent from wash tanks shall be transferred to
Holding Tank by suitable Effluent transfer pumps.
4.0 Effluent holding tank: The effluent water shall be collected in effluent holding
tanks from where effluent water shall be routed to Hydro-cyclone module via
low shear feed pump.
5.0 Low Shear Feed Pump: The effluent from Holding Tank shall be routed to
Hydro-cyclone via Low Shear Feed Pumps. The Low Shear Feed Pump shall
be as per functional specs for Effluent Treatment module enclosed with this
document
6.0 Hydro-cyclone: Hydro-cyclones shall be provided to separate out oil from the
effluent received through Low Shear Feed Pumps. Treated effluent from Hydro-
cyclone shall be routed to filtration system via filter feed pump. The recovered
Oil from Hydro-cyclone shall be routed to Slop Oil Tank.
The Effluent treatment module shall be as per functional specs enclosed with
this document. The Hydro-cyclones shall have proper back wash arrangement
to achieve the desired parameters as a part of Effluent treatment module.
7.0 Filtration System: The effluent from Hydro cyclones shall be routed to
Filtration system. The filtered effluent shall be routed to treated effluent water
tanks. Suitable backwash system shall be provided in the filtration system and
backwash dirty water shall be routed to OWS pit. The Filter Feed Pump shall
be as per functional specs for Effluent Treatment module enclosed with this
document.
9.0 Effluent Transfer/ Disposal Pumps: Effluent transfer pumps shall be provided
to transfer treated effluent to remote WIP and Effluent Disposal pumps shall be
provided to transfer treated effluent to Effluent disposal wells as described in
the Scope of Work. These pumps shall be provided for continuous operations.
• No. of Pumps should be minimum 02 nos.( 01 no. in operation + 01 no.
stand by).
• The provision for monitoring of Pump “On/Off” Status in control room is
required to be provided.
• Dispatch quantity shall be measured through suitable Flow Meters
11.0 Slop Oil Tank: The recovered oil from Hydro-cyclone shall be collected in a
Slop Oil Tank along with recovered oil from wash tank, indirect heating coil in
each tank shall be provided to avoid congealing of the recovered oil. The slop
oil tanks shall be provided with all safety system. Portable Boiler shall also be
additionally provided for heating as specified in ETP Scope of Work.
12.0 Slop Oil Transfer Pumps: The recovered oil shall be routed to the inlet of
Heater-Treater / the nearest GGS oil tank via Slop Oil Transfer pumps.
• No. of Pumps should be 02 nos. (01 no. in operation +01 no. standby).
• Dispatch quantity shall be measured through suitable flow meter.
13.0 Sludge Drying Bed : Wet Sludge from slop oil tanks / wash tanks drain, sludge
pit of OWS system and other recovered sludge shall be collected in sludge
drying beds of adequate sizes. Total 3 no. of sludge drying beds shall be
provided. Sludge from sludge drying bed shall be transferred to Sludge Lagoon
of adequate sizes. The collected sludge shall be allowed to dry in the natural
process in Sludge Lagoon. The sludge cake will then be removed and disposed
off for land filling etc. Provision shall be kept for draining liquid from sludge
drying bed to OWS pit. All tank drains i.e. Wash Tank, Treated Effluent Storage
Tank etc. shall be routed to Sludge Drying Bed. Proper flushing arrangement
shall be provided in all out let lines from Tanks to Sludge drying pit.
14.0 OWS System: Oily Water Sewer system with OWS Pit shall be provided. The
skimmed residual foreign materials shall be transferred to the Sludge pit .The
effluent / drain water shall be recycled back to Wash tank via pumps (1 no. in
operation + 1 no. stand by)
Block Diagram for WIP is given in the bid document. The surface facilities shall
vary in quantity and capacity from one WIP to other. In case of any additional /
specific requirement, the same has been indicated in the WIP special
requirements as mentioned under “installation wise scope of work and design
basis”.
Incoming lines: The treated effluent water from ETP(s) and Raw water from
River/ Bore well shall be coming by lines of different sizes as per details
mentioned in the pipeline scope of work.
Raw Water Treatment Facility: - Suitable treatment facility will be provided for
treatment of raw water received from River / borewell before it is fed to Raw
Water Storage Tank.
Raw water/Treated Effluent Storage Tank: The raw water / treated effluent
shall be collected in respective Raw water / Treated effluent Storage Tanks.
Construction of new Treated effluent storage tanks are covered in the scope
of work for ETP.
Filter Feed Pumps: Raw water / treated effluent shall be routed to Pressure
Sand Filters via Filter Feed Pumps. These pumps shall be provided for
continuous operations.
The Filter Feed Pump module shall be as per functional specs enclosed with
this document. The provision for monitoring of Pump On/off Status in control
room is required to be provided. Pumps shall be kept in shed.
The Pressure Sand Filters module shall be as per functional specs enclosed
with this document
Dual Media Filters: Filtered water from Pressure Sand filter shall be routed to
Dual Media Filter modules to meet the desired outlet parameters. The outlet
from Dual Media Filter Module shall be routed to Treated Water Storage Tank
for injection purpose. PLC based Auto back wash system on filter differential
pressure high shall be provided along with air scouring system.
The Dual Media Filter module shall be as per functional specs enclosed with
this document.
Filter Back Wash Pump: The water from treated water storage tank shall be
used for back washing of Pressure sand and Dual Media filters.
The Filter Back Wash Pump module shall be as per functional specs enclosed
with this document
The provision for monitoring of Pump On/off Status in control room is required
to be provided.
Sodium Hypo chlorite solution shall be dosed at the inlet of Raw water/Treated
Effluent Storage Tanks.
Bactericide, Sodium Sulphite, Scale Inhibitor, KCl & Corrosion Inhibitor solution
shall be dosed at the suction manifold of Booster pumps.
The Chemical Tanks & Dosing Pump Module shall be as per functional specs
enclosed with this document
Booster Pumps: The treated water from Treated Water Storage Tanks shall
be routed to the suction manifold of Booster Pump Module where different
chemical treatment prior to injection shall be carried out. The discharge of
Booster Pump Module shall be routed to suction manifold of Main Injection
Pump module.
The Booster Pump module shall be as per functional specs enclosed with this
document. The provision for monitoring of Pump On/off Status in control room
is required to be provided.
Main Water Injection Pumps: Main Water Injection pump Module shall
receive treated water from outlet of Booster Pump Module. The discharge of
Main Water Injection pump Module shall be routed to water Injection manifold
for further injection into the respective injectors. These pumps shall be provided
for continuous operations.
• No. of Pumps should be as per Design data Basis for WIP
• The provision for monitoring of Pump “On/Off” Status in control room is
required to be provided.
• Adequate Shed is to be provided
• Pump tripping for low level in treated water tank and high vibration .
Utilities: Various utilities viz. Instrument Air, Plant Air, potable water, service
water etc. required shall be provided for plant operation as detailed else were in
the bid document.
Block Diagram for CTF is given in the bid document. The surface facilities
shall vary in quantity and capacity from one CTF to other. However the process
shall be the same in all the CTFs. In case of any additional /specific
requirement, the same has been indicated in the CTF special requirements as
mentioned under “installation wise scope of work and design basis”.
Pig receivers:
The treated crude oil coming from various GGSs through pipelines of 6” &
above shall have pig receivers with Pig Indicators in the CTF. The lines to the
incoming manifold shall be branching off before the pig barrel with all
necessary isolation valves, NRVs, pig indicator, etc. Provisions for pressure
and temperature monitoring (Local & Control Room) shall be made. The details
of pig receiver are given in the pipeline scope of work
Dispatch Manifold: This manifold is meant for connecting the ready for
dispatch tank to Pump House for final dispatch to CTF/Oil India etc. The
existing dispatch manifold shall be dismantled and a new one shall be
constructed. This new manifold shall be provided with remote operated valves
Storage Tanks: Existing Storage Tanks shall be retained. All the pipelines and
valves from manifold to tanks and vice versa shall be replaced with new ones.
The dyke of each tank shall be provided with suitable OWS/SWD system.
The contractor shall be required to fully overhaul the company supplied Heater
Treaters to make them fully functional for intended application. Heat recovery is
not envisaged from polishing heater treaters. The contractor may take a stock
of status by fully acquainting themselves about the condition and extent of
revamping work required for these units during pre-bid site survey.
Hot Oil Based Heat Exchanger for CTF, Geleki shall be provided for supply of
hot water to various storage tanks for heating of crude oil.
Dispatch quantity along with Water Cut is required to be measured with Coriolis
Mass Flow Meter At Lakwa & Geleki CTF and Ultrasonic Flow Meter with
Meter Prover at Moran & Jorhat CTF.
Auto Sampling System as per API Chapter 8.2 and Sample Chemistry
checking system as per API Chapter 10. In addition to this, system for
proving Auto Sampler shall also be provided.
Pig launching facilities for outlet lines : The following shall be the treated
crude oil outgoing lines from Lakwa & Moran CTF:
• The treated crude oil from oil storage tanks of Lakwa and Geleki CTF shall be
sent to respective Moran& Jorhat CTF.
• The effluent from effluent storage tank shall be sent to respective installation
by pipeline.
Design Basis for CTF shall be followed for pig launching facilities and
specifications of pig launching facilities are given in bid document.
Pig launching facility shall be provided in each Oil outgoing line having
diameter 6” or more.
Service Water System, Drinking Water System, Plant & Instrument Air
system shall be as defined in the bid document
The following shall be the typical surface facilities in a Gas Compressor Plant.
The surface facilities shall vary in quantity and capacity from one GCP to other.
In case any additional /specific requirement, the same has been indicated in the
GCP special requirements.
Pig receivers:
The LP / MP / Sales gas coming from GGSs having lines of above 6” & 8” sizes
shall have pig receivers with Pig Indicators in the GCP. The lines to the inlet
manifold shall be branching off before the pig barrel with all necessary isolation
valves, NRV’s etc. The details of pig receiver are given in the pipeline scope of
work
Inlet Manifold: The inlet manifold shall be having suitable connections for the
lines coming from various GGSs. The inlet manifold shall be having LP, MP &
HP headers to divert the gas to LP, MP, HP Compressors depending upon the
process requirement .Each line to the manifold shall be connected to these
headers with isolation valves and spare connections (min. 03 nos.) for future
provision etc. All incoming lines shall be having provisions for pressure and
temperature monitoring through local as well remote instruments.
LP / MP Compressor Module:
HP Compressor Module:
Compressed Gas from LP Compressor as well as return lean gas from sales
grid shall be routed to HP Compressor modules, details of which are given in
scope of work and design basis of GCP. Compressed HP gas will be sent to
Gas dehydration Unit before sending the gas to Gas Lift / Injection Network.
The required nos. of TEG based Gas Dehydration modules for individual GCPs
are given in the respective Design basis. Inlet and outlet Manifolds for GDU are
also required with isolation valves and spare connections (min. 02 nos.) for
future provision etc.
TEG (tri-ethylene glycol) shall be used as dehydration media. Gas shall flow
from the bottom upward and the glycol falls from the top. The gas and glycol
comes in intimate contact. The lean glycol introduced from the top shall fall
gradually on the packing and the gas bubbles through the glycol on the packing
wherein the lean glycol absorbs water. The dry gas shall come out of the
contractor. Thereafter it shall pass through a gas/glycol exchanger where the
high temperature of glycol aids in increasing gas temperature. Thereafter the
gas shall go to the reflux condenser which is also an exchanger and the water
vapor from the glycol still again increases the temperature of the gas and the
water thus condensed is sent to the reflux drum and to the still as a reflux. The
gas thereafter shall pass through an overhead scrubber where the liquid
droplets shall be scrubbed and the dry gas is dispatched to the trunk line. The
pressure in the contractor shall be controlled through a PCV located
downstream of the overhead scrubber.
The rich glycol that comes out of the contactor shall go to the glycol flash drum
to remove dissolved hydrocarbon. The gas thus released is sent to flare KOD.
To remove any solid particles and liquid hydrocarbon, the rich glycol is
thereafter passed through the cartridge and active carbon filters. Thereafter the
temperature of the rich glycol shall be increased by passing it through a
glycol/glycol exchanger, wherein the hot lean glycol helps in increasing the
temperatures of the rich glycol.
Glycol Regeneration
Thereafter the rich glycol enters the still of the reboiler. The reboiler is an
atmospheric vessel and operates at about 200 0C. The glycol is heated with the
help of hot oil. The hot water vapor leaves the top of the still and is sent to the
reflux condenser. A part of the condensed water is sent to the still as a reflux
from the reflux drum. The lean glycol overflows a weir and drops to the storage
tank through a packed column.
Gas dehydration unit shall be as per functional specification provided in the bid.
Gas Lift Manifold: The HP (Gas Lift) compressor outlet gas shall be routed to
Gas Lift Manifold. The branch lines from this manifold shall be routed to
respective GGS’s to cater to the gas lift requirement of wells surrounding those
GGS’s. Metering facility shall be provided in each finger of the manifold. Gas
Lift Manifold shall also be provided with isolation valves and spare connections
(min. 03 nos.) for future provision etc.
Gas Grid Manifold: The existing Gas Grid Manifold located at GCP shall be
dismantled and new manifold shall be constructed. This manifold shall receive
gas from MP compressor discharge header of GCP and MP Gas feeder lines
coming from various GGS/fields. The outlet from this manifold shall be routed to
GAIL / other installations. Metering facilities shall be provided in each inlet lines
of manifold and custody meter shall be provided in outlet header of manifold.
Design Basis for GCP shall be followed for pig launching facilities and drawing
of pig launching facilities are given in bid document.
Pig Launching facility shall be provided in each outgoing line having diameter
6” or more.
Captive Power Plant shall have heavy duty industrial open cycle gas turbine/
Generator Sets to generate electrical power at 11KV and the same is
distributed to various installations in Assam Oil & Gas Field.
The power requirement shall be finalized after the detailed engineering. Basis
of the number and capacities of Gas turbine / generators is provided in the
detailed scope of work of Captive Power Plant.
The combination and size of the turbine generator sets shall be worked out on
the basis of capacity of industrial type gas turbine/generator sets available
worldwide with proven track record.
Provision of minimum two spare feeders to be kept for future expansion at each
CPP in addition to the feeders as brought out in Scope of Work.
The tentative location of new CPPs have been identified at GGS-IX, Lakwa,
Integrated Complex, Geleki and existing location of CPP, Rudrasagar.
The new CPP will be commissioned first and then the existing CPP’s shall be
dismantled.
Gas Turbine
The gas turbines are required for power generation. Turbines shall be
industrial type. The combination and size of the turbine generator sets shall be
worked out on the basis of capacity availability of industrial type gas
turbine/generator sets worldwide with proven track record.
The fuel gas shall also be made available from Gas lift Network at pressure
40-80 kg/cm2 during power shutdown conditions (when the gas turbines
are not running). This is to enable starting of the turbine/generator set after
plant power shutdown.
The Exchanger shall be designed to meet TEMA, ASME and API standards.
The tube bundle shall be designed to avoid any dead areas or areas where
tubes are partially filled and ensure the WHRE tubes are capable of running dry
in the event of a malfunction, whilst still operating at full exhaust flow.
Electrical Generator
Generating units shall be suitable for continuous operation at rated output. The
rated output of the generator shall exceed the rated output of the gas turbine
prime mover over the ambient temperature range as specified in the project
documents.
Black Start
DG Set of suitable capacity for Black start system is to be provided. It should be
capable of handling all Gas turbine auxiliary loads, Instrument air, water lifting,
cooling and indoor/outdoor Lighting system. The DG Set power will be fed to
MCC/PMCC and back-fed to 11KV bus where it will be synchronized with GT
power. DG breakers with battery back up, battery charger, Diesel storage tanks
of suitable capacity, pipeline, filters and pumps are to be provided.
The plant fire and gas system shall consist of all the relevant detection and
protection systems as per current standard. Adequate number of Gas, Flame
and Thermal detectors shall be provided.
Suitable fire detection, alarm and suppression systems for control room and
switchgear rooms will be provided and to be integrated with the plant fire and
gas system.
Air Compressor/Dryer
Air compressor with suitable air dryer to be provided to meet the air
requirements of the plant such as Gas Turbine skid, WHRU,DG set, HVAC
system of Control Room and Switchgear Room etc.
G. UTILITIES :
Box flare system shall be provided for safe disposal of flammable toxic or
corrosive vapors discharged by pressure relief system of various units.
Various safety valve / blow down valve discharges/ excess gas from production
& test separators/ gas scrubber/, knock out drums etc are connected to two
phase flare header. In case pressure exceeds set safety valve pressure in any
process vessel, the escaped gas/ oil water emulsion from the vessels shall go
to flare header. In case any liquid particles are carried over or any
condensation of gas takes place, liquid shall get collected in the flare gas knock
out drum. The gas shall flow to box flare and shall be flared there. All
discharges to flare header are to be kept sloping towards the flare gas knock
out drum. The liquid collected in the KOD shall be pumped to crude oil storage
tanks by 2 nos of KOD pumps.(1 working + 1 standby)
Flame front generator, pilot burner, etc are envisaged as part of the box flare
system package. Gases from fuel gas header shall also be used as fuel in the
pilot burner. The Flare header shall be taken on trestles which shall be suitably
spaced. The quantity of gas flared shall be metered using suitable flow meter
like ultrasonic flow meter / thermal mass flow meter in control room.
Contractor to carryout flare load calculations for all cases covering blocked
discharge, fire case and depressurization / blow down. All calculations including
flare header sizing is to be submitted for company review and approval.
Flare system design shall be as per latest API RP 521. Turnkey EPC
Contractor shall also comply to other latest applicable statutory/central/state
guidelines such as OMR-1984/CPCB/OISD-106,118 etc on environmental
standards. In case of any conflict the more stringent requirement shall be
followed.
Adequate Closed Blow Down system based on the design basis of the
proposed installation is to be provided. Liquid from gas scrubber, flare KOD,
main oil storage tanks, effluent tanks also shall be drained here The closed
blow down facility shall include blow down vessel with vent to atmosphere,
Provision of one number of over ground service water storage tank with
suitable pumps has been kept to meet plant requirements as indicated in the
bid document.
For drinking purpose, one reverse osmosis plant (R.O Plant) shall be provided
to purify the service water to potable water. The potable water shall be stored in
an over ground drinking water storage tank with suitable pumps to meet the
One number emergency diesel generator set, as detailed in the bid document is
to be provided by the contractor to meet power requirement during normal
operation / power failure. The emergency DG set shall provide power for the
minimum load of Process & Control Systems, lighting, air compressors, UPS
and DC critical supply, Communication System, instrumentation, etc. Details of
power supply scheme are provided in the bid document. Provision for
momentary running of emergency generator set with grid supply and automatic
change over from Gen set supply to grid supply shall be provided to avoid
interruption of power during switching over from Generator sets supply to grid
supply.
• The Emergency Generator sets should be self contained full fledged package
with all the accessories required for their smooth operation and control.
12.0 BUILDING:
The Control room shall be on ground floor. The toughened glass windows shall
be provided on three sides of the control room. The access to the control room
is to be of double door type to avoid dust particles inside the control room The
All the rooms shall be suitably furnished with furniture & fixtures as detailed in
the document.
13.0 ACCOMMODATION
General Control :
Mode of plant operation : Control Room
Type of control : DCS System / PLC system
Final control elements : Control Valve (pneumatic)
Instrument power source : Dry Instrument air.
(For Final control element)
Power source for Instrumentation : 110V AC UPS /24 V DC.
Control room location with UPS : Control room on Ground Floor
system located near Control room.
Flow integrators/ totalizers / recorders : As per Functional Specs.
on Process streams.
DCS / PLC system shall be provided for alarm monitoring, data acquisition and
controlling facilities for the plant long with operating work stations. The details
control system has been defined in the bid document
LEL gas detection system shall be provided in this plant and for that suitable IR
type fixed gas detectors shall be installed at various critical locations including
separator area, Oil storage tanks area, effluent storage area ,OWS pit, Flare
area etc. The gas detection panel shall be provided in control room. The
Turnkey EPC Contractor shall design and implement Hydrocarbon gas
detection system as per existing OISD-189, TAC guidelines and other
applicable standards indicated in the bid document.
The exact no. of detectors and locations shall be decided during detailed
engineering. The F&G panel (completely wired) for housing the
monitor/controller for gas detectors with relays, hooters, and annunciation with
location indication shall be provided in the control room. The 02 spare channels
per module to be provided. The gas detection system shall give low gas alarm
and High gas alarms in the gas detectors monitor .
The Turnkey EPC Contractor shall design and implement fire & smoke
detection system as per OISD, TAC guidelines and other applicable standards
indicated in the bid document. The location and type of fire detection system to
be provided is as follows:-
The fire, gas and smoke detector layout shall cover the entire plant area
following NFPA-72 standards. The contractor will develop the detailed layout
and same will be finalized during detailed engineering.
All the alarms for fire/gas/smoke detection system will lead to the annunciation
in the Fire & gas panel to be placed in Control room. The receiver instruments
will be placed in the control room.
The annunciation system will have an interfacing with the paging system of the
plant with different tone for various detections as detailed in the bid document.
The fire signal/alarm shall also be provided in fire water pump house and fire
station. All equipment shall be DGMS approved.
ESD switches will activate the alarm at the Central Control room, MCC / switch
gear room, In-charge room / office, Control room, fire fighting pump house and
fire station. On receiving the alarm control room will operate the emergency
shut down system.
Fire shut down system (FSD) shall have linking with fire detection and alarm
system. FSD switches shall be provided at Central Control room, office, Gas
compressor area, Separator area and oil storage tank area.
On activation, FSD shall close SDV at the inlet of Separators. It will trip all
rotating equipments including gas compressors. It will also open the flare PCV
at the Gas compressor suction KOD and discharge KOD.
For protecting the control room provision of discharging of clean agents in the
control room to be kept with prior alarm, flash beacon at the entry. Suitable
storage area for fire retarding /extinguishing agent (clean type) shall be
provided.
In addition to above, fusible plug loop is also to be provided in the oil storage
tank area for auto start of water sprinklers on the storage tanks.
FSD shall get activated automatically by the fire detector and also manually by
operating the switches from the specified point mentioned above.
The Turnkey EPC Contractor shall design and implement fire fighting system as
per existing OISD standards, TAC guidelines and other applicable standards
indicated in the bid document. The details of fire fighting system are given in
the bid document.
21.0 INCINERATOR:
Electrical Type / Gas Fired Type Incinerator for handing oily solid waste at the
rate of 10 Kg/hr is to be provided in proposed installation.
25.0 All pumps, compressors and heavy equipment to be placed in such a way that
they are accessible by crane for shifting / repairs .
26.0 Chemical Transfer Pump: One no. of Barrel mounted Pneumatic driven
Chemical Transfer Pump for each chemical shall be provided, to transfer
Chemicals from standard Barrels to Chemical Tanks in 10 mins.
27.0 Chemical Storage & Handling System: Chemical Storage facility for 10 days
storage shall be provided. Mechanized chemical handling system (like EOT,
SILO etc.) for loading & unloading of chemicals with minimum manual interface
shall be provided.
28.0 CCTV
Closed circuit TV (CCTV) shall be provided in process and strategic areas for
montoring and surveillance at all GGS. Display monitor of CCTV cameras shall
be made available in security room and Control rooms