207695005 full revised specification for well head control panel

7/25/2019 207695005 Full Revised Specification for Well Head Control Panel

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INTEGRATED WHCP & SAFEGUARDING SYSTEM FOR HPG WELLS

Table of Contents

1. INTRODUCTION .................................................................................................................. 7

1.1 General ............................................................................................................ 7

1.2 Definitions ....................................................................................................... 8

1.3 Proposal structure ......................................................................................... 9

1.3.1 Details of Offer and Variation ...................................................................... 10

1.3.2 Information to be submitted with Offer ...................................................... 10

1.3.3 Information to be submitted after award of Contract ................................ 11

2. ABBREVIATIONS .............................................................................................................. 12

3. CODES, STANDARDS ABD REFERENCE DOCUMENTS ................................................ 13

3.1 PDO Standards ............................................................................................. 13

3.1.1 Engineering Specifications (SP & SPE) ..................................................... 13

3.1.2 Guidelines (GU) ............................................................................................ 13

3.1.3 Design Engineering Practice (DEP) ............................................................ 14

3.2 International Standards: .............................................................................. 14

3.2.1 ANSI (American National Standards Institute) .......................................... 14

3.2.2 API (American Petroleum Institute) ............................................................ 14

3.2.3 ASME (American Society of Mechanical Engineers) ................................. 15

3.2.4 ISA (Instrument Society of America) .......................................................... 15

3.2.5 IEC (International Electro-technical Commission) .................................... 15

3.2.6 European Codes (CENELEC) for Electrical Eqpt. in hazardous area ...... 16

3.2.7 Other international standards ..................................................................... 17

3.3 EMC (Electromagnetic Compatibility) ........................................................ 18

3.4 General .......................................................................................................... 18


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3.4.1 Language and Units of Measurement ......................................................... 18

4. OPERATING CONDITIONS / AREA OF INSTALLATION .................................................. 19

4.1 Relevant Ambient Data ................................................................................ 19

4.1.1 Ambient Temperature .................................................................................. 19

4.1.2 Relative Humidity and Barometric Pressure .............................................. 19

4.1.3 Wind speed ................................................................................................... 19

4.1.4 Rainfall .......................................................................................................... 20

4.1.5 Earthquakes .................................................................................................. 20

4.1.6 Geographical Data ....................................................................................... 20

4.1.7 Sandstorms .................................................................................................. 20

4.1.8 Design Life .................................................................................................... 20

5. WELL HEAD CONTROL PANEL (WHCP) .......................................................... .............. 21

5.1 General .......................................................................................................... 21

5.2 Material of Construction and Fabrication .................................................. 23

5.3

Hydraulic System ......................................................................................... 26

5.3.1 Hydraulic Power Circuits ............................................................................. 27

5.3.1.1VHP (SC- SSV hydraulic circuit) ................................................................. 27

5.3.1.2HP1 (SSV & WV hydraulic circuits) ............................................................ 28

5.3.1.3HP2 (HIPPS Valve & CV) .............................................................................. 29

5.3.1.4MP (Fusible plugs hydraulic circuit) ........................................................... 30

5.3.2 Common hydraulic circuit ........................................................................... 30

5.3.3 Hydraulic Circuit Components .................................................................... 33

5.4 Electric Components ................................................................................... 34

5.5 Well Controls and Shutdown Requirements .............................................. 36

5.5.1 General .......................................................................................................... 36

5.5.2 ESD Section .................................................................................................. 37


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5.5.2.1Manual ESD .................................................................................................. 37

5.5.2.2Fire detected ESD ........................................................................................ 38

5.5.3 Closure of actuated valves .......................................................................... 39

5.5.3.1HIPPS valve closure ..................................................................................... 39

5.5.3.2WV & CV (simultaneous) closure ................................................................ 39

5.5.3.3SSV closure .................................................................................................. 39

5.5.3.4SC-SSV closure ............................................................................................ 39

5.5.4 Hydraulic Logic Control Circuit .................................................................. 40

5.5.4.1SC-SSSV ....................................................................................................... 40

5.5.4.2SSV ................................................................................................................ 40

6. ASSOCIATED INSTRUMENTS AND ACCESSORIES ..................... ........... ........... ............ 42

6.1 Pilots ............................................................................................................. 42

6.2 Extra high pressure switch ......................................................................... 42

6.3 Quick Dump Valve Local Panel with Wire line Connection ...................... 42

6.4

Fusible Plugs ................................................................................................ 42

6.5 SSV/ Wing Valve Limit Switch Assembly ................................................... 43

6.6 First fill Mineral Oil ....................................................................................... 43

7. UTILITY REQUIREMENT ................................................................................................... 44

7.1 Electrical ....................................................................................................... 44

7.2 Hydraulic ....................................................................................................... 44

8. HIPPS VALVE ASSEMBLY................................................................................................ 45

8.1 Technical requirements ............................................................................... 45

8.1.1 Material of Construction .............................................................................. 46

8.1.2 Design Requirement .................................................................................... 46

8.1.3 Electric Components ................................................................................... 47

8.1.4 Hydraulic Power Section ............................................................................. 48


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8.1.6 HIPPS Valve Controls .................................................................................. 48

8.1.7 HIPPS Valve ESD/TRIP Section ................................................................... 49

8.1.8 Mechanical Switches ................................................................................... 49

9. CHOKE VALVE ASSEMBLY ............................................................................................. 50

9.1 Technical details .......................................................................................... 50

9.1.1 Material of Construction .............................................................................. 50

9.1.2 Design Requirement .................................................................................... 51

9.1.3 Electric Components ................................................................................... 52

9.1.4 Hydraulic Power Section ............................................................................. 53


9.1.6 Choke Valve Controls .................................................................................. 54

9.1.7 Choke Valve ESD Section ............................................................................ 54

10. PAINTING ........................................................................................................................... 55

11.

INSPECTION & TESTS ...................................................................................................... 56

11.1 Visual Checks ............................................................................................... 56

11.2 Performance Tests ....................................................................................... 56

11.3 Functional Tests ........................................................................................... 57

11.4 Integrated (FAT) System Test ..................................................................... 57

11.5 Other Requirements ..................................................................................... 57

11.5.1 Body Test ...................................................................................................... 58

11.5.2 Leak Test and Stroke Test for IPF Valves .................................................. 58

11.5.3 Functional Test (Test Medium: Nitrogen) ................................................... 58

11.5.4 Gas Seat Test (Test Medium: Nitrogen) ..................................................... 58

12. CERTIFICATION ................................................................................................................ 60

13. TRANSPORTATION AND STORAGE ............................................................................... 61


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14. PROGRESS OF WORK ..................................................................................................... 62

15. GURANTEE ........................................................................................................................ 63

16. DOCUMENTS REQUIRED FROM VENDOR ...................................................................... 64

17. SPARE PARTS .................................................................................................................. 65

APPENDIX A : ACTUATED VALVES PRESSURE AND TUBING

APPENDIX B : HYDRAULIC POWER SECTION DESIGN CONDITION

APPENDIX C :SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT FOR

API 10,000

APPENDIX D :SCHEMATIC DIAGRAM FOR HYDRAULIC CIRCUIT FOR

ASME 2500#

APPENDIX E : WELL HEAD CONTROL PANEL LAYOUT DRAWINGS

APPELDIX F : LOCAL DUMP VALVE PANEL

APPENDIX G : ARRANGEMENT OF SSV SWITCH ASSEMBLY

APPENDIX H : HIPPS VALVE AND ACTUATOR DATA SHEETS

APPENDIX I : HIPPS PANEL SCHEMATIC DIAGRAM

APPENDIX J : CHOKE VALVE AND ACTUATOR DATA SHEET

APPENDIX K : CHOKE VALVE PROCESS DATA

APPENDIX L : CHOKE VALVE PANEL SCHEMATICAPPENDIX M : WET GAS COMPOSITION

APPENDIX N : RVED

APPENDIX O : AVME LIST

APPENDIX P : TABLE OF COMPLIANCE (TOC)


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1. INTRODUCTION

1.1 General

This specification and accompanying documents referenced herein describes the

minimum requirement for design, engineering, manufacturing, assembly, testing,

inspection, supply and commissioning of Integrated Hydraulic Wellhead Control and

Safeguarding System for High Pressure Gas (HPG) Wells in Saih Rawl, Saih Rawl

Grab, Saih Rawl South, Fahud South West, Mabrouk, Burhaan West, Harmal, Khulud,

Kauther and Fakhar area.

The quantity required in each area is as follows:

a. Saih Rawl type, ASME 2500# 25 sets

b. Burhaan type, API 10,000 30 sets

The Integrated Well Head Control and Safeguarding System shall be supplied complete

with the following:-

1. Well Head Control Panel with hydraulic circuit lines for SC-SSV, SSV, WV,

HIPPS valve and CV

2. HIPPS valve with Hydraulic Control Panel

3. Choke valve with Hydraulic Control Panel

4. Fusible plugs (4 nos.)

5. Associated Instruments and accessories

Vendor shall complete the Table of Compliance at Appendix P and provide all

the necessary technical drawings, documentations or third party certifications to

verify the compliance of each section of this specification.

The documents covered in various parts of this specification are intended to be

complementary to one another and as mutually explanatory of one another, but in the

case of ambiguities or discrepancies the Vendor shall submit to PDO his request for

any clarification. PDOs clarification shall be final.

The Vendor shall be responsible for the design and supply of the Integrated Hydraulic

Wellhead Control and Safeguarding System inclusive of Well Head Control Panel with

hydraulic circuit lines for SC-SSV, SSV, WV, HIPPS Valve and CV, supply of HIPPS

Valve and CV with hydraulic panels, Associated Instruments and accessories based on

the information furnished in this specification.


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Any work shown on the reference drawings or documents and not particularly given in

the specification or vice versa, shall be included by the Vendor. The omission from this

specification of any items essential for the correct functioning of any part of the

specified equipment shall be brought to the attention of PDO. Failure to do this shall not

absolve the Vendor from the supply of any items / services required to achieve the full

functioning of the equipment to the intent of this specification.

Where alternatives are offered, they shall be fully described, and must be accompanied

by all pertinent engineering information to facilitate their evaluation.

It shall be the responsibility of the Vendor to select the peripheral instruments of the

wellhead control system and also to ensure all the interoperability issues. The Vendor

shall use the latest issue of AVME (attached as Appendix - O) for standardization

purpose and also seek the proper PDO (CFDH C&A)approvalif particular make is not

appearing in list before procurement and shall supply only specific wellhead applicationproven items with reference list for approval. The PDO (CFDH C&A) approval or

Consultants recommendation does not absolve the supplier from his responsibility of

interoperability.

Vendor shall not use any failed peripheral instruments which have been delivered under

the previous PDO orders

It is not the intent of this Specification to specify completely the details of design,

manufacture, configuration, inspection and testing. It is the Vendor's responsibility to

ensure that the item is designed, manufactured, configured, installed, tested and

commissioned in accordance with the latest standards, statutory regulations and safety

codes, and is' also consistent with good engineering practice. This requirement shall befully detailed in the Vendor's manufacturing drawings and documentation, which shall

be reviewed by PDO.

1.2 Definitions

For the purpose of this document, the following definitions shall hold:-

The word Principalor Company isPDO and is the party which initiates the project

and ultimately pays for its design and construction. The Principal will generally specify

the technical requirements. The Principal may also include an agent or consultant

authorized to act for, and on behalf of, the Principal.

The word Purchaser is PDO

The word Contractor is the party which carries out all or part of the Design,

Engineering, Procurement, Construction, Commissioning or Management of a Project

or Operation of a facility. The Principal may undertake all or part of the duties of the

Contractor.


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The word Manufactureror Supplieror Vendor is the party which manufactures

or supplies equipment and services to perform the duties specified by the Principal or

the Contractor.

The word shall is to be understood as mandatory.

The word should is to be understood as strongly recommended.

1.3 Proposal structure

The proposal shall include, as a minimum:

a) Project, Administration, Technical and Engineering personnel required to implement

the scope of this specification.

b) Estimated normal and maximum Electric power consumption.

c) Typical panel internal layout drawings and estimated weights.

d) Drawings (Hydraulic & Electrical schematic), details and description of the operation

of the proposed system as well as manufacturer, model no, materials and types of

auxiliary equipment.

e) Completed Table of Compliance (TOC)

f) Pump sizing, Pump running time during initial start-up, normal running time.

g) Tube sizing.

h) Accumulator sizing.

i) Any start-up, shutdown or operating restriction required to protect the integrity of the

system.

j) Preliminary manufacturing / production program

k) Conditions of guarantee.

l) A statement of the extent of any sub-contracted work together with the name of the

proposed sub-contractor, for the Purchaser's approval. The Purchaser reserves the

right to survey any such sub-contractor's place of manufacture prior to giving written

approval.


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1.3.1 Details of Offer and Variation

Vendor shall include 2 years operation spares in the offer for the complete package.

Sufficient numbers of soft goods kits for spares shall be provided.

Vendor shall provide service for pre- commissioning and commissioning assistance at

site for the WHCP package (including valves). The service shall be given as per man

day rate, mobilisation and demobilisation rate as applicable.

The offer shall be accompanied by a tabulation of components, equipment and

documentation forming the system with an itemized list of those items supplied directly

by the Vendor and those supplied by third parties i.e. bought out items.

If the Vendor is unable to undertake the whole of the equipment construction, the extent

of sub-contracted work shall be stated in his quotation, together with the name of the

proposed sub-contractor, for the PDOs approval.

Details and calculations of electrical properties of load 1 (control logic) and load 2

(hydraulic motors) shall be included.

Note: PDO reserves the right to survey any sub-contractors place of manufacture prior

to giving written approval.

The tender shall be accompanied by detailed specifications of the various items of the

equipment being offered. The data supplied shall be complete and comprehensive, no

item shall be omitted and statement like To follow and After Award shall be avoided.

The Vendor shall clearly indicate in the table of compliance either deviation from, or

acceptance of, each and every item of the specification. Failure to clearly identify

specific deviations will lead to PDO assuming that the Vendor is in total compliance with

the specification. No deviation from the specification shall be allowed.

A manufacturing / production program shall be submitted with the tender showing, as a

minimum, the drawing approval dates, order and delivery dates for bought out items,

the manufacturer and assembly periods, system configuration times, inspection and test

dates, packing and shipment dates, unpacking, installation and commissioning times.

1.3.2 Information to be submitted with Offer

The Vendor shall provide all drawings and documents as indicated in the RVED form

(Appendix - N) including the following:

a) Detailed Specification of Well head Control Panel with associated instruments,

wiring, accumulator sizing, external tubing size(return line) and accessories

including dimensions and weights


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b) Estimated normal and maximum Electrical Power consumption

c) Complete Table of Compliance (Refer Attachment A) with all the attachedtechnical drawings/documents

d) Typical panel internal layout drawings

e) Manufacturing / Production Program

f) Project Implementation Plan including Vendor's proposed project team

including the names of the key personnel involved.

g) Vendor Workloads

h) A list of similar system installed and operating a gas processing facilities

i) Any start up, shutdown or operating restriction required to protect the integrity

of the system

j) Maintenance requirements

1.3.3 Information to be submitted after award of Contract

The Vendor shall provide all drawings and documents as indicated in the RVED form

(Appendix - N) and the following drawings within two weeks from the award of

Contract:-

a) Manufacturing Drawings.

b) Schematic and Logic Drawings.

c) Control Logic Narratives.

d) Weekly Progress Report (Update Schedule), In case of delay, the Vendor

shall immediately inform PDO in writing.


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2. ABBREVIATIONS

AVME Approved Vendors of Materials and Equipment document

CITHP Closed In Tubing Head Pressure

CV Choke Valve

DSS Duplex Stainless Steel

ESD Emergency Shut Down

FF Foundation Fieldbus

FTHP Flowing Tubing Head Pressure( for wellhead)

HP High Pressure

HIPPS High Integrity Pressure Protection System

IPF Instrumented Protective Function

MP Medium Pressure

PDO Petroleum Development Oman

PSD Process Shut Down

RVED Request for Vendor Engineering Documents

SC-SSSV Surface Controlled Sub Surface Safety Valve

SSV Surface Safety Valve

VHP Very High Pressure

WHCP Wellhead Control Panel

WHCS Well Head Control System

WT Wall Thickness

WV Wing Valve


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3. CODES, STANDARDS ABD REFERENCE DOCUMENTSThe latest versions of the following standards shall be applicable for the specified

equipment.

It is assumed that the standards listed below are in the Vendors possession. If not,

then the Vendor is requested to obtain the same from the Purchasers Procurement

Office.

3.1 PDO Standards

3.1.1 Engineering Specifications (SP & SPE)

SP-1084 (Dec. 2006) :Standard Specification for Fire, Gas and

Smoke detection systems

SP-1089 (Jan-2001) :Instrument Impulse lines

SP-1090 (Dec. 2005) :Instrument Signal Lines

SP-1099 (Dec. 2006) :Electrical Installation Practice

SP-1171 (Dec. 2007) :Spec. for Quality assurance of Design,

Const. & Engineering works

SP-1189 (Dec. 2000) :Specification for Duplex Stainless Steel

Pipe

SP-1245 (Nov. 2006) :Standard Specification for Fieldbus

Control System

SPE 77/302 :Valves general requirements

SPE 77/312 :Fugitive emission leak detection of

valves

3.1.2 Guidelines (GU)

GU-556 (Feb 2007) : Project Engineering Guideline for

Vendor Project Document Deliverables


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3.1.3 Design Engineering Practice (DEP)

DEP 00.00.20.10 (Feb -2011) :The Use of SI Quantities and Units

DEP 02.00.00.10 (Oct. 1995) :Preparation and microfilming of technical

drawings.

DEP 31.40.70.30 (Feb-2011): Quarter Turn Actuators for On/Off Valves

DEP 32.31.00.32 (Feb-2011) :Instruments for Measurements & Control.

DEP 32.31.09.31 (Sep-2011) :Instrumentation for Equipment Packages

DEP 32.31.00.34 (Sep-2011) :Instrumentation Documents and

Drawings DEP 31.22.10.35 (Aug. 2005) :Manufacturing report for pressure

vessels.

DEP 32.36.01.17 (Feb-2011):Control Valves Selection, Sizing &

Specifications

DEP 33.66.05.31 (Feb-2012) :Electric machines.

DEP 62.10.08.11 (Feb-2011) :Inspection & Functional Testing of

Instruments

DEP 70.10.90.11 (Feb-2012) :Spare Parts

3.2 International Standards:

3.2.1 ANSI (American National Standards Institute)

ANSI B1.20.1 : Specification for taper pipe threads.

ANSI/ISA S.75.01 : Flow Equations for Sizing Control Valves

ANSI B 16.34 : Valves-Flanged , Threaded and Welded end

ANSI / FCI 70-2 : Control Valve Seat Leakage

3.2.2 API (American Petroleum Institute)

API RP 551 : Process measurement instrumentation

API 607 : Fire test of Soft Seated Quarter turn Valves


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API 6FA : Specification for Fire Test for Valves

API 6D : Specification for Pipeline Valves ANSI/API RP 14B :Recommended Practice for Design, Installation

and Operation of Sub-surface Safety Valves

Systems

API 598 : Valve Inspection and Testing

API 6A :Specification for Well head & Christmas Tree

Equipment

3.2.3 ASME (American Society of Mechanical Engineers)

ASME Section IX :B & PV Code Welding and Brazing

Qualifications.

ASME Section VIII Div.1/2: B & PV Code Section VIII including A98, A99

and A00, Rules for Construction of Pressure

Vessels.

ASME B16.5 : Pipe flanges and flanged fittings

ASME B16.34 : Steel valves flanged and butt welding ends

3.2.4 ISA (Instrument Society of America)

ISA S75.01 : Flow Equations for Sizing Control Valves

3.2.5 IEC (International Electro-technical Commission)

DIN EN 60654-1 :Industrial-process measurement and control

equipment Operating conditions Part 1:Climatic conditions.

DIN EN 60529 :Degrees of protection provided by enclosures

(IP Code).

DIN EN 60079-14 :Electrical apparatus for explosive gas

atmosphere Part 14:Electrical installations in


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hazardous area.

IEC 60534-4 :Industrial Process control valves- Inspection &Routine Testing

IEC 61508 :Functional Safety of Electrical/ Electronics/

Programmable Electronic Safety Related

Systems

IEC 61511 :Functional Safety Safety Instrumented

Systems For the Process Industry Sector

3.2.6 European Codes (CENELEC) for Electrical Eqpt. in hazardous area

CENELEC EN 50.014 :General Requirements Electrical Apparatus for

Potentially Explosive Atmosphere

BS EN 50.018 :Electrical Apparatus for Potentially Explosive

Atmospheres Flameproof Enclosure D

BS EN 50020 :Electrical Apparatus for Potentially Explosive

AtmosphereIS

BS EN 10204 :Metallic Products Types of Inspection

Documents.

CENELEC EN 50081 :Electromagnetic Compatibility Generic Emission

Standard Part 2 (Emission regulations applies to

position sensors and solenoid valves).

CENELEC EN 50082 :Electromagnetic Compatibility Generic Emission

Standard Part 2 (Immunity regulations applies to

position sensors and solenoid valves)

CENELEC EN 60.801 :Electromagnetic Compatibility for process

measurement & control Equipment Electrostatic

Discharge Requirements-(Immunity test applies

to position sensors and sol. valves).


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3.2.7 Other international standards

ISO 1219 : Fluid Power Systems and Components-Graphic

Symbols and Circuit Diagrams

ISO 10432 :Petroleum and natural gas industries Down

hole equipment-Subsurface safety valve

equipment

BS PD 5500 : Rules for the Construction of Pressure Vessels

ISO 15156 :Metals for sulphide stress cracking and stress

corrosion cracking resistance in sour oil fieldenvironments

ASTM A269 :Standard Specification for Seamless and welded

Austenitic Stainless Steel Tubing for General

Service

EN 61000-4-5 : EMC Testing and Measurement Techniques.

(electrical surges due to lightning and/or

switching

The Vendor shall have a QA/QC system, based on ISO 9001, controlling the quality of

their design and manufacturing during all stages of the production process and be ableto demonstrate its implementation to the Purchase.

Should any conflict occur as a result of complying with referenced standard and this

specification, the order of preference shall be as follows:

1. Local laws, Decrees & statutory requirements

2. P.D.O. management policies

3. This specification

4. Codes of Practice (CP)

5. Procedures (PRs)

6. Engineering Specifications (SP)

7. Guidelines (GU)

8. Design & Engineering Practice (DEP - Version as applicable in a project)

9. National Standards

10. International Standards.


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3.3 EMC (Electromagnetic Compatibility)

For Electromagnetic Immunity of the equipment following standard is applicable:

CENLEC EN 50081 (1993 Jan 01): Electromagnetic Compatibility Generic Immunity

Standard part 2, Industrial Environment.

CENLEC EN 50082 (1995 Jan 01): Electromagnetic Compatibility Generic Immunity

Standard part 2, Industrial Environment

Equipment shall comply with surge test according to EN 61000-4-5 (1995 March 01)

EMC Testing and Measurement Techniques (Electrical surges due to lightning and/or

switching).

Pulse shape is 1.2/50 S (8/20 S current).

Where a relevant dedicated product or product family EMC standard exists, it shall take

precedence over all aspects of above generic standards. Manufacturer shall indicate

the difference with above-mentioned standard.

3.4 General

3.4.1 Language and Units of Measurement

All documentation, drawings, correspondence, operating, maintenance and installation

manuals shall be in English.

English Language shall be used for tags, labels etc. which shall be available to the

operators. All measurement units shall be in accordance with DEP 00.00.20.10, The

Use of SI Quantities and units and DEP 32.31.00.32, Instruments for Measurement and

Control.


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4. OPERATING CONDITIONS / AREA OF INSTALLATION

All the WHCPs and the accessories shall be suitable for outdoor installation in the

desert at a remote wellhead area.

The local environmental conditions are severe. There are frequent sand storms and the

atmosphere can be heavily laden with airborne dust particles, some as small as 2

micrometers. It rains infrequently but, when it does, it is often combined with hail and

sand storms.

4.1 Relevant Ambient Data

4.1.1 Ambient Temperature

The conditions are severe; the climate is mainly hot and humid. Summer runs from April

to October with June and July being the hottest period.

Maximum/Minimum shade temperature : 60 C

Black bulb temperature maximum : 82 C

Electrical equipment and systems shall be designed in accordance with the relevant

PDO and project standards.

Maximum/Minimum ground temperature : 30 C (Summer Max)/ 22 C (Winter

Min)

4.1.2 Relative Humidity and Barometric Pressure

Maximum/Minimum relative humidity : 98%

Average barometric pressure : 97.7 to 98.9 kPa (a)

4.1.3 Wind speed

Maximum wind speed (1 hour duration) : 26 m/s

Maximum gust (3 second duration) : 39 m/s

Wind speeds are at a height of 10 metres above ground level. The prevailing wind

direction is southeast, south and southwest.


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4.1.4 Rainfall

Rainfall is infrequent but may be heavy though brief and is often combined with hail and

sandstorms.

Rainfall design : 25 mm/h

Average annual : Negligible

4.1.5 Earthquakes

No allowance is to be made for earthquakes.

4.1.6 Geographical Data

Location : To be announced, Oman

4.1.7 Sandstorms

Sandstorms are frequent and severe and can continue for days with the atmosphere

heavily laden with dust particles. Fine dust in these sandstorms can be as small as 2

microns.

4.1.8 Design Life

All equipment and facilities shall be designed for a minimum operational life of 25 years.


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5. WELL HEAD CONTROL PANEL (WHCP)5.1 General

The Well Head Control Panel is required to control manually and automatically both the

closing & opening sequence of operation and the individual operation of SC-SSSV,

SSV, WV & CV and HIPPS valve installed in HPG wellhead. These valves are

designed to shut the production and isolate the production facilities from the wells in

response to different shutdown requirements.

In addition to the above, WHCP shall charge hydraulic power to 4 nos. Fusible plugs

The following functions shall be considered as minimum design requirement ofIntegrated Well Head Control Panel & Safeguarding System:-

Flow line pressure high high

(1 out of 2)

1. Close HIPPS valve (immediate)

2. Close CV and WV (immediate &

simultaneous)

3. Close SSV (delay 2 sec.)

4. Signals to RTU from HIPPS

Fire detection ESD byFusible plugs (4 nos.) on field

1. Close CV and WV (immediate &simultaneous)


3. Close SC-SSV (delay 9 sec.)

Remote CPSD 1. Close CV and WV (immediate &

simultaneous)


Remote open well head

valves

1. Open SSV

2. Open CV and WV simultaneously

Remote open WV / CV Open WV and CV simultaneously

Remote close WV / CV Close WV and CV (immediate &

simultaneous)Manual ESD pushbutton on

WHCP

(Push for ESD & Pull for

reset)

1. Close CV and WV (immediate &

simultaneous)


3. Close SC-SSV (delay 9 sec.)

Manual push button on

WHCP for open close SC-

SSV

Open / Close SC-SSV, SSV , WV and CV as

per the closing and opening sequence


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WHCP for SSV

Open / Close SSV, WV and CV as per the

closing and opening sequence


WHCP for WV

Open / Close WV and CV simultaneously


WHCP for HIPPS

Open / Close HIPPS, SSV, WV and CV as

per the closing and opening sequence


WHCP for fusible plug to

charge

For charging fusible plug loop

Hydraulic reservoir level low 1. Trip 2 pumps

2. Signal to RTU

WHCP common alarm Signal to RTU

Selector switch on WHCP Pump Duty selection (Pump-1 or Pump-2)Indicating lamp on WHCP Pump selection indication

Selector switch on WHCP Pump-1 Start/Stop/Auto

Selector switch on WHCP Pump-2 Start/Stop/Auto

Selector switch on WHCP Bypass Choke valve switch

Indicating lamp on WHCP Pump-1 running / close status

Indicating lamp on WHCP Pump-2 running / close status

Remote start / stop Pump-1

in WHCP

Signal from RTU

Remote start / stop Pump-2

in WHCP

Signal from RTU

Pump-1 running / close status Signal to RTUPump-2 running / close status Signal to RTU

Panel mounted Pressure

Gauges

To monitor hydraulic control circuits pressure

Local Pressure Gauges To monitor hydraulic control circuits pressure

1. The maximum pressure and tubing size for SC-SSV, SSV, WV, CV and

HIPPS are attached at Appendix - A

2. HIPPS valve shall be closed first and opened last

3. WV & CV shall be closed / opened simultaneously

4. HIPPS panel shall be hydraulically interlocked with local CV panel to close CV

after HIPPS trip or manual close

5. HIPPS panel shall be hydraulically interlocked with WHCP panel to initiate

WHCP CPSD after HIPPS trip or manual close

6. Delay means time counted from signal given


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The WHCP shall be installed in an open safe area. However all instruments shall be

explosion proof type (EExd) and Junction box shall be EExe type (suitable for Zone 2,

Gr IIB, T4). The Junction box enclosing motor soft starter, relays shall be EExd type.

The UL certified components are acceptable if the components are same as that

certified to the equivalent CENELEC / ATEX.

The minimum design of WHCP shall include 2 nos. motor driven hydraulic pumps (1W

+ 1S), & a manual pump, accumulators, common hydraulic control logic, hydraulic

headers, internal wiring up to electrical terminal strips, internal tubing, tank and

bulkheads with isolation valves for external connections etc.. Panel design shall have all

necessary devices and equipments to cater for operation of SC-SSV, SSV, WV, HIPPS

valve, CV and Fusible plug loop. The schematic diagram for the Hydraulic circuit for the

WHCP is attached as Appendix - C (for API 10,000) and Appendix - D (for ASME

2500#).The ingress protection for enclosures shall be IP65 minimum for electronics and IP 55

minimum for terminal boxes.

The 24 VDC motor driven hydraulic pump power consumption shall be maximum 550 W

The solenoid valve shall be of low power, hydraulically latched & fail to close on loss of

power.

The components shall withstand shaded temperature of 70 degrees Celsius.

2 nos. drain valves shall be installed in the supply compartment and return

compartment of the tank for sampling purpose.

The level gauge and level transmitters shall be mounted outside the reservoir tank.

The Electrical Push button shall be mushroom type.

The WHCPs basic design shall be fail-safe. Pilot valves and solenoid valves shall be

energized during normal operating conditions and de-energized during shutdown

conditions.

3 nos. 3/8 and 1 no. bulk head plates shall be supplied as spares

Rubber shall be provided as insulation between SS and CS components.

5.2 Material of Construction and Fabrication

The WHCP shall be heavy duty construction having environmental protection

classification IP55 as a minimum and both the enclosure and internal components shall

be suitable for long term service in a desert atmosphere. The ingress protection for

enclosures shall be IP65 minimum for electronics and IP 55 minimum for terminal

boxes.


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The WHCP shall be stand alone structure manufactured from 316 L stainless steel

sheet of minimum 3 mm. thickness, with internal stiffening and support structures as

required. Access to the internals (accumulators, pumps, motors etc.) shall be via a

single rear lockable door on lift-off hinges.

Stainless Steel shall be used for all valves, fittings, tubing, accumulators, pipe and pipe

fittings, panel, reservoir fabrication, internal components etc.

All panel tube work shall be 316 L stainless steel, rated according to each system

pressure.

All hydraulic connections for SC-SSV in Khulud area shall be with very high

pressure (> 20,000 psi) and shall be executed with PDO approved make

All hydraulic connections for SC-SSV in other area shall be with high pressure

(> 15,000 psi) and shall be executed with PDO approved make

All hydraulic connections for SC-SSV, SSV, WV, HIPPS valve and CV circuits shall be

for high pressure fittings and tubing and shall be executed with PDO approved make

All hydraulic connections for SC-SSSV, SSV, WV, HIPPS valve and CV shall be

suitable for the pressure indicated above and shall be with AISI 316 L and compression

fittings of imperial type.

The WHCP dimension shall be minimum 1500 mm. (W) x 1800 mm. (H) x 800 mm. (D).

The panels shall be self-supported and suitable for raising by means of lifting eyes. The

panel face shall be fastened to the back framing from the rear. High integrity "C"

channel foundation shall be provided. High integrity C channel cabinet panel base

shall be provided

All materials used in fabrication of the WHCP shall be new and of the highest quality.

Only qualified and experienced tradesman shall be employed in fabrication of the

panels in order to achieve the highest standard of workmanship..

Vendor shall ensure that maintenance access to all the instruments, valves, regulators,

relief valves, fittings, tubes, accumulators pumps, motors etc is properly given without

obstruction of other equipments or instruments.

All components inside the WHCP shall be freely accessible from rear for maintenance

purpose without disturbing any other component or equipment.

The panel shall be of r igid construction with lifting lugs and shall have adequate internal

stiffening to prevent buckling during shipment or lifting operations at site.

Stainless steel plate materials used shall be free from surface defects such as scoring

and tool or clamp marks. All sharp edges and burrs must be removed.

A polished finish is required on all exterior panel surfaces. Bolting through panel face is

not allowed and no evidence of component supporting studs shall be visible on panel

face.


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Flame cutting tools shall not be used to cut any holes for the mounting of instruments.

Door seals and any sealing between panel sections when finally assembled as a single

panel unit must be adequate to maintain an IP55 environmental protection rating.

The layout of internal panel, tubing and cables shall be neat and must be designed to

give maximum ease of access for dismantling trouble shooting and maintenance

operations at site.

Instruments shall be located such that normal adjustments may be made by hand or

with standard tools without removal of any panel-mounted hardware.

Panel shall be provided complete with all internal tubing and wiring requiring only

connection to the external tubing and wiring circuits.

All tubing runs within the panel shall be either horizontal or vertical plane, carefully

grouped for accessibility and ease in tracing lines and clamped for rigidity. Hydrauliclines shall be fixed by adequate soft seated clamps. All bending shall be made by

standard bending tools of correct size and minimum allowed bending radii shall be

observed.

Bright, annealed seamless 316, stainless steel tubing to ASTM A 269 shall be used for

all tubing connections.

All hydraulic and electrical components shall withstand the environmental conditions as

specified in Clause 4. If required Purchaser will ask the WHCP supplier to furnish

supporting documents \ compliance documents in this regard.

Junction boxes shall be provided for interfaces with external cabling (from field),

segregated according to service and signal type, connected to each internal device by asignal pair cable. Junction box shall be mounted inside the WHCP. Junction box shall

be suitable for a Zone 1 hazardous area and protected to IP55.

Proper draining mechanism for the panel shall be provided in case of leaks inside the

panel.

The panel shall be provided with sufficient louvers and of sufficient sizes for ventilation

keeping in mind the extreme desert conditions as per Clause 4

Panel door hinges and the door open stoppers shall be strong enough to withstand high

wind velocity of the region. Panel shall be provided with minimum 3 hinges and two

door stoppers per door.

Pumps shall be located at a minimum of 250 mm height from the panel bottom to avoid

contact with liquid( due to leakage from the fittings).

Bolting through the panel face is not allowed and no evidence of component supporting

studs shall be visible on panel face.

Electric cables and hydraulic tubing entries shall be from the side of the cabinet. To

avoid cables damage the cable entries shall be located at higher level than of hydraulic


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tubing. The exact number of cable entries, sizes and which side shall be approved by

the Company.

Each cabinet shall be fitted with an AISI 316 nameplate mounted on the front of the

panel indicating the following information.

Manufacturer.

A unique Serial Number.

Purchase Order Number.

Equipment Number

Min. & Max Supply Pressure

Well Number

Date of Manufacture.

Inside the WHCP, a laminated Overall Schematic drawing with Cause & Effect drawing

and Bill of Material identifying make and model no of all items shall be placed.

All documentation referring to the equipment shall identify the manufacturers serial

number and Principals requisition number.

Tag plates shall be fixed as follows, as per Drg. No. S37.601.D.

Panel Designation Type A.

Equipment Number Type B.

Identification of components inside panel Type C.

Identification of gauges and controls in front of panel Type D1.

5.3 Hydraulic System

The Well Head Control Panel is required to control manually and automatically both the

closing & opening sequence of operation and the individual operation of SC-SSSV,

SSV, WV & CV and HIPPS Valve installed in HPG wellhead. These valves are

designed to shut the production and isolate the production facilities from the wells in

response to different shutdown requirements.

In addition to the above, WHCP shall charge hydraulic power to 4 nos. Fusible plugs

The maximum pressure and tubing size for SC-SSV, SSV, WV, CV and HIPPS valve

are attached at Appendix - A


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5.3.1 Hydraulic Power Circuits

The system shall be engineered by incorporating two redundant hydraulic system

circuits for hydraulic power for the following:

1. VHP (for SC-SSV),

2. HP1 (for SSV & WV),

3. HP2 (for HIPPS & CV)

4. MP (for Fusible plugs)

5. Common hydraulic circuit

The above hydraulic circuits shall be designed as per the hydraulic power sectiondesign given at Appendix - B. It is vendors responsibility to cross check the adequacy

of given values based on the given CITHP value & required strokes of the valves

without pump running. Vendor shall submit the calculations for review.

Vendor shall guarantee enough swept volume and no pressure drop during operation of

any of the above valves either individual or in combination. Vendor shall submit with the

technical bid documents volume and pressure calculations to verify the compliance of

this requirement.

The hydraulic oil shall be supplied from the supply compartment of a common supply

tank. All hydraulic return headers common or individual shall return to the return

compartment of the supply tank (Degassing section).

Tubing shall be AISI 316 L, and fittings shall be AISI 316, imperial type

Hydraulic system tubing shall be sized and selected by vendor in order to minimize

pressure and power losses and to meet with PDO external tubing rating and sizes as

given below.

5.3.1.1 VHP (SC- SSV hydraulic circuit)

WHCP shall have SCSSV hydraulic circuit with all the necessary devices required to

operate SC-SSV. The SC SSV operating circuit shall be designed for: Very High pressure as per the design criteria mentioned at table in Appendix B

All necessary fittings / tubing, pressure gauges, regulators.

All components of SC-SSV circuit shall be rated for a minimum of 15000# rating.

The maximum pressure and tubing size for SC-SSV are attached at Appendix - A


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All hydraulic connections for SC-SSV in Khulud area shall be with very high

pressure (20,000 psi)

All hydraulic connections for SC-SSV in other area shall be with high

pressure (15,000 psi)

The Vendor shall submit a simplified schematic and control logic narrative, which

includes sufficient information for PDO to evaluate the Vendors proposal for very high

pressure SC-SSV hydraulic circuit.

For SC-SSV, vendor shall provide a system to open and close the valve from the panel.

For sizing purpose, the following average distance shall be considered:

From WHCP to SC-SSV = 150 m.

Note: The above distance will be firmed up after layout finalization.The hydraulic bulkhead fittings and internal tubing of the WHCP should be the type and

rating as the PDO external tubing and rating used outside the WHCP, as listed below:

SC-SSV supply line (Khulud area) : 3/8 OD x 0.086 WT, 20,000 PSI (Very High

Pressure)

SC-SSV supply line (Other area) : 3/8 OD x 0.086 WT, 15,000 PSI (Very High

Pressure)

However, Vendor shall reconfirm the above tubing OD and ratings based on his system

design and calculations and if required may suggest suitable changes.5.3.1.2 HP1 (SSV & WV hydraulic circuits)

WHCP shall have SSV & WV hydraulic circuits with all the necessary devices required

to operate SSV & WV. The SSV & WV operating circuits shall be designed for:-

High pressure as per the design criteria mentioned at table in Appendix-B

All necessary fittings/tubing, pressure gauges, regulators.

The maximum pressure and tubing size for SSV & WV are attached at Appendix - A

The Vendor shall submit a simplified schematic and control logic narrative, which

includes sufficient information for PDO to evaluate the Vendors proposal for highpressure SSV hydraulic circuit.

For sizing purpose the following average distance shall be considered:

From WHCP to SSV = 100 m.

From WHCP to WV = 100 m.

Note: The above distance will be firmed up after layout finalization.


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The hydraulic bulkhead fittings and internal tubing of the WHCP should be the type and


SSV supply line : 1/2 OD x 0.083 Wall Thickness, 10,000 PSI Medium Pressure

SSV return line : 3/4" OD x 0.049 Wall Thickness

WV supply line : 1/2 OD x 0.083 Wall Thickness, 10,000 PSI Medium Pressure

WV return line : 3/4" OD x 0.049 Wall Thickness


design and calculations and if required may suggest suitable changes.

5.3.1.3 HP2 (HIPPS Valve & CV)

WHCP shall have hydraulic circuit with all the necessary devices required to supply

hydraulic power to HIPPS Valve & CV.

High pressure as per the design criteria mentioned at table in Appendix

- B

All necessary fittings/tubing, pressure gauges, regulators.

The max. pressure and tubing size for HIPPS Valve & CV are attached at Appendix - A


From WHCP to CV = 80 m.From WHCP to HIPPS Valve = 60 m.


The Hydraulic Bulkhead fittings and internal tubing of the WHCP should be the type and


Choke supply line : 3/8" OD x 0.065 Wall Thickness, 10,000 PSI Medium Press

Choke return line : 3/4" OD x 0.049 Wall Thickness

HIPPS valve supply line : 3/8 OD x 0.065 Wall Thickness, 10,000 PSI Medium Press

HIPPS valve return line : 3/4" OD x 0.049 Wall Thickness




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5.3.1.4 MP (Fusible plugs hydraulic circuit)

WHCP shall have hydraulic circuit with all the necessary devices required to supply

hydraulic pressure to 4 nos. Fusible plugs


From WHCP to Fusible plugs = 200 m.




Fusible Plug supply line : 3/8" OD x 0.065 Wall Thickness,



5.3.2 Common hydraulic circuit

The hydraulic system shall be engineered for two redundant hydraulic circuits with 2

electric motor (24 VDC, 550 W max.) operated hydraulic pumps (1W + 1S) to supply

hydraulic power to VHP (SC-SSV), HP1 (SSV & WV), HP2 (HIPPS valve & CV) & MP

(Fusible plugs) as per Appendix - B (Design conditions / Criteria)

Under normal operation one pump shall operate. However if one pump fails to generate

enough pressure within 10 seconds, the second pump shall start automatically. Both

pumps shall have sufficient capacity to charge all accumulators from the empty to the

full condition within 30 minutes.

A back-up manual hand pump shall be provided and sufficiently rated to allow charging

of the headers in the event of the loss of electric supply to the motors. The hand pump

shall be provided with block valves, check valve, safety relief valve, output pressure

gauge and individual header isolations valves.

Hydraulic Low Level protection shall be provided to protect the Hydraulic pumps. The

system shall not allow the running of the pumps when the oil in the tank is less than the

minimum acceptable level.

The common supply tank shall be fitted with the following equipment:

Volume tank with internal baffle (Volume - 250 liters. Vendor to size and

confirm the adequacy of volume).

Level Gauge.


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Drain Valve.

Internal Baffle. Smart type Pressure Transmitters

Level transmitter (Smart type with HART Protocol in SR, SRS, SR Grab

& Mabrouk and Foundation Fieldbus type in other area) with a Trip

amplifier shall be provided to trip the hydraulic pump on low hydraulic

level in the reservoir and also wired to Junction Box for remote indication

purpose. Magnetic type level transmitter is preferred.

Removable Bolted Inspection Cover.

Breather/Accessibly Filler Nozzle/Cap.

Hydroscopic breather.

Magnetic Catcher.

Individual Pump suction strainer.

Temperature Gauge (with Thermo well).

Hydraulic fluid shall be taken from the non return side of the internal baffle in the supply

tank to each of the pump suctions via block valves through suction strainers with 20

micron filter element. Filter element shall be of spin on removable type. Strainers shall

be provided with block valves and by-pass valve so that they may be isolated and

replaced for maintenance purpose with the system on line. Each pump discharge shall

be provided with a safety relief valve, check valve, a block valve and an output pressure

gauge.

Each of the pump discharge headers shall be connected to a common duty standby

configuration filters, fitted with two 100% rated hydraulic bucket type filters with 3

micron exchangeable filter element and complete with block valves, local clogging

indicators and drain plug. Full flow pressure filters with minimum element dimensions of

30 mm. diameters and 90 mm. length shall be provided. The clean element pressure

drop across the filter shall not exceed 500 kPa (g) at specified viscosity, temperature

range and throughput of hydraulic fluid. The filters shall be fitted with a by-pass valve so

that they may be isolated for maintenance purposes with the system on line. Thecommon header shall be fitted with pressure switch with block and bleed manifold for

pump control purposes (cut-in & cut-out), and a panel mounted pressure gauge.

Vendors shall utilize integrated manifold block for the pump discharge and high

pressure sections to minimize the use of tubing / fittings, reduce leakage and optimize

the layout within the panel.


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The discharge header shall be provided with a safety relief valve. The main pump /

hand pump should be provided with block valves so that they may be isolated and

replaced for maintenance purpose with the system on line.

Separate valve shall be provided downstream of discharge filter allowing for hydraulic

fluid sampling.

The main supply header shall be fitted with Pressure Transmitter (Smart type with

HART Protocol in SR, SRS, SR Grab & Mabrouk and Foundation Fieldbus type in other

area) and Trip amplifier for pump control purposes and panel mounted Pressure

Gauges. The pump / motor circuit shall be supplied with local on / off / auto motor

control circuits / starters and local push buttons and lamp indicators on WHCP front

face. Also provision shall be made for remote pump running indication.

Regulators on the hydraulic circuits shall be of bleed back type. Regulators shall be with

AISI 316 construction, self relieving, designed for hydraulic applications and vent

connection routed to reservoir. Regulator seals shall be suitable for the design

temperature specified. Downstream fluid can be vented through a segregated vent

system for easy pressure adjustment in either direction.

The required closing and opening times of the process valves shall be guaranteed by

the panel manufacturer, based on the following:

Volume and working pressure of actuator.

Diameter of hydraulic lines.

Length of hydraulic lines.

Viscosity of hydraulic fluid.

Volume and pre-charge of hydraulic accumulator.

Any resistance in pilots, filters and any other hydraulic component in the

panel.

Each hydraulic pressure system shall be equipped with bladder type / piston type

accumulators. All accumulators shall be designed as per BS 5500. Each accumulator

shall be provided with pressure gauge with proper isolation facility. A suitable

arrangement (i.e. plug) shall also be provided on these accumulators by the Vendor, so

that these Pressure Gauges can be removed at later stage if required.Accumulators shall have sufficient capacity for emergency operation of all valves, which

means three full cycles, (a cycle is defined as one stroke) i.e., one closing cycle, one

opening cycle and another closing cycle. The required capacity shall be determined by

the change in volume of fluid contained in the accumulator between the main pump

start position (with the pump switched off) and the minimum system pressure to finish

the last cycle of all valves properly. The Vendor shall furnish the accumulator sizing

calculation along with the tender.


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Accumulators shall be placed in a separate compartment within the WHCP, suitable

door shall be provided to access these accumulators from outside.

To avoid accumulation of spilled oil inside the WHCP during routine maintenance etc.

the bottom plate of the WHCP shall be either:

Sloped to one side of WHCP with a drain opening at the lowest end.

Be such that the lowest point is in the middle of the floor plate and

provided with a drain opening.

The drain openings shall be provided with drain valve.5.3.3 Hydraulic Circuit Components

a) All components used for hydraulic circuits including `O' rings shall be suitable for

outside/desert applications.

b) All valve bodies including manual valves, pilot valves and solenoid valves shall be

manufactured in AISI 316 stainless steel.

c) All pressure gauges shall be 63mm size, AISI 316 stainless steel construction, and

glycerin filled.

d) All gauges and switches shall be provided with block and bleed valves, or quick

opening devices (with check valves), to allow for removal and maintenance during

operation without the need of removing other devices or tubing.



Common return : 3/4" OD x 0.049 Wall Thickness

However, vendor shall reconfirm the above tubing OD and ratings based on his system


Hydraulic connections shall use bulkhead unions or bulkhead connectors mounted on

the side of the panel. All tubing shall be neatly laid out and adequately supported by

tubing saddles to prevent kicking, facilitate trouble shooting and present a neat

appearance. The internal arrangement of the panel shall be such to minimize the length

of tubing runs.

Vendor shall look into the possibility of using a common return instead of individual lines

to minimize the numbers of return lines, fittings /tubing etc. Vendor shall confirm that it

will not have any adverse effect on the system design or operation.

Each hydraulic pressure system shall be equipped with the following accumulators:

VHP - for SC-SSV, one piston type / bladder type accumulator.


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HP1 - for SSV and WV, one piston type / bladder type accumulator.

HP2 - for IPF and CV, one piston type / bladder type accumulator.

LP - Hydraulic Logic with one bladder type accumulator.

Vendor shall confirm volume for each accumulator and also furnish the accumulator

sizing calculations with the technical bid documents. A minimum accumulator shall be

sized for 3 strokes of the SC-SSV (one stroke = opening and closing of the valve).

Hydraulic low level protection shall be provided to protect the hydraulic pumps. The

system shall not allow the running of the pumps when the oil in the tank is less than the

minimum acceptable level.

The Hydraulic Bulkhead fittings and internal tubing of the WHCP should be the type andrating as the PDO external tubing and rating used outside the WHCP, as listed below:

Low pressure pilot inlet, outlet and drain : suitable for 3/8" OD X 0.049

WT

5.4 Electric Components

All Electrical devices to be installed within the panel shall be suitable for Zone1, IIB, T4

and EEXd certified to CENELEC / ATEX. The UL certified components are acceptable

if the components are same as that certified to the equivalent CENELEC / ATEX

All Transmitters shall be Smart type with HART Protocol in SR, SRS, SR Grab &

Mabrouk and Foundation Fieldbus type in other area

All Electric components shall be suitable for 24 V DC

All internal wiring shall be provided with a cross-sectional area of at least 1 mm2 and for

Solenoid valves with diameter of 2.5 mm2.

Electrical connection shall be by means of cables and certified cable glands.

Each cable shall be tagged at both ends with an appropriate marker. All internal cable

numbers for the cables shall within WHCP and cables to & from WHCP Junction Boxes

shall be tagged by the Vendor. Tagging shall be done at both ends. Cables shall be

tagged with terminal block reference and terminal number so as to be easily terminatedagain when loosened.

All Electrical devices installed in the panel shall be wired to their respective terminals.

Separate terminals shall be provided for power and signals. All terminals shall be

properly identified and 20% terminals as spare capacity in each terminal / Junction Box.

Cable trays shall be used for cable supports.


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An external ground terminal shall be provided, suitable for a 16 mm2 ground cable as

per Std. Drg. S 68.004.

Threaded, M20 size, plugged holes, shall be provided for the external electric

connections. The number will be advised during Detailed Engineering.

Electrical enclosure weather protection shall be at least IP 65. All electrical equipment

shall be tropicalised.

Each wire shall be tagged at both ends with an appropriate marker.

Electrical connections shall be by means of cables and certified cable glands. Junction

boxes shall be CENELEC EExe and cable glands shall be certified to CENELEC EExd.

However Junction box housing soft starters, relays etc shall be EExd design and

certified.

Junction boxes shall be provided for interfaces with external cabling, segregated

according to service and signal type, connected to each internal device by a single pair

cable. Junction boxes shall be easily accessible and located not more than 1.5 meters

in height.

The Electric Components shall conform to the following:

1. Electrical enclosure weather protection shall be at least IP 65.

2. All electrical equipment shall be tropicalised.

3. All wiring shall be provided with a cross-sectional area of 1mm2, while for

solenoid valves a cross-sectional area of 2.5mm2 wire shall be used.

4. Each wire shall be tagged at both ends with an appropriate marker.

5. Electrical connections shall be by means of cables and certified cable glands.

Junction boxes and cable glands shall be certified to CENELEC EExe.

6. All electrical components installed in panels shall be wired to their respective

terminal points. Separate terminals shall be provided for power and signals.

Cable trays shall be use for cabling. Stuff block c/w EVA covered stainless

steel "BAND-IT R" cable ties, shall be used to hold instrument tubing in place.

7. All terminals shall be permanently identified with 20% spare terminals

provided in each terminal box.

8. An external ground terminal shall be provided, suitable for a 16 mm2 groundcable.

9. Vendor shall provide for each pump, individual power connection terminals

suitable for 2C x 6.0 mm2 cable. Pumps shall not share a common power

supply connection.

10. Threaded, M20 size, plugged holes, shall be provided for the external electric

Connections. The number will be advised during detailed engineering.


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11. Each pump/motor circuit shall be supplied with local/auto motor control circuits

with soft starter, local push buttons and lamp indicators on the panel front

face.

WHCP shall be provided with two 100% capacity 24V DC motor driven hydraulic fluids

pumps. Under normal operation one pump shall operate. However if one pump fails to

generate enough pressure, the second pump shall start automatically. Both pumps shall

have sufficient capacity to charge all accumulators from the empty to the full condition

within 120 seconds.

The starting current of each motor shall be maximum 60A for 3 seconds. The running

current of each motor shall be 35A. Each motor shall operate for continuous duration of

20 minutes per 24 hours. Both the motors shall not start simultaneously. Vendor shallcrosscheck and confirm the adequacy of the above current ratings.

Each pump/motor circuit shall be supplied with local / auto motor control circuits with

soft starter, local push buttons and lamp indicators on the panel front face. In addition a

Duty / Standby pump selector switch shall be provided.

Vendor shall provide for each pump, individual power connection terminals suitable for

2 core x 6.0 mm2 cable. Pumps shall not share a common power supply connection.

Vendor shall ensure that overload protection for the hydraulic pump motors are

connected prior to start-up for new equipment

5.5 Well Controls and Shutdown Requirements

5.5.1 General

HIPPS valve shall be closed first and opened first

WV & CV shall be closed / opened simultaneously

HIPPS panel shall be hydraulically interlocked with local CV panel to

close CV after HIPPS trip or manual close

HIPPS panel shall be hydraulically interlocked with WHCP panel to

initiate WHCP CPSD after HIPPS trip or manual close

There are two types of production facility shutdowns activating wellhead valves /

surface valves. Logic for this is performed in the WHCP:

Emergency Shut Down (ESD)

1. Manual ESD

2. Fire detection by Fusible plugs


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An ESD is initiated by an emergency pushbutton on the WHCP or in response to fire

detection (by Fusible plugs). This requires the closure of all the actuated valves CV &

WV, SSV and SC-SSSV.

Remote Process Shut Down (PSD)

This will initiate closure of CV, WV and SSV by remote shut down signal.

5.5.2 ESD Section

5.5.2.1 Manual ESD

An ESD is initiated by manual operation of local ESD push button (push for ESD & pullto reset) at the WHCP. This push button on pushing (ESD) shall de-energize solenoid

valve fitted on the hydraulic circuit to close CV,WV and SSV in the following sequence.

This push button on pulling (reset) shall energize the solenoid valve and reset hydraulic

interface valves to open the SSV, WV and CV in the following sequence. Activation of

this local ESD reset switch shall not affect other circuit hydraulic pressure.

An ESD shall cause the wellhead and surface valves to close as per sequence

indicated below:-

Normal Closing Sequence

CV and WV (simultaneous) First

SSV (with 2 sec. delay) Second

SC-SSV (with 9 sec. delay) Third

An ESD re-set shall cause the wellhead and surface valves to open as per sequence

indicated below:-

Normal Opening SequenceSC-SSV First

SSV Second

WV and CV (simultaneous) Third

The panel shall operate with delayed opening and closing of Wing Valve, SSV in orderto protect the SC-SSV. The vendor shall provide adjustable hydraulic delay mechanism

within the SC-SSV circuit.


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5.5.2.2 Fire detected ESD

Fire at wellhead shall be detected by 4 nos. Fusible plugs. A fire at the wellhead causes

the eutectic material in the fusible plugs to melt and vent the supply line pressure and

initiates a well head shutdown. These fusible plugs shall activate to de-energize

solenoid valve fitted on the hydraulic circuits to close CV & WV, SSV and SC-SSSV.

Fire detection shall cause the wellhead and surface valves to close as per the

sequence indicated below.

Normal Closing Sequence

CV and WV (simultaneous) First

SSV (with 2 sec. delay) Second

SC-SSV (with 9 sec. delay) Third

An ESD re-set shall cause the wellhead and surface valves to open as per sequence

indicated below:-

Normal Opening Sequence

SC-SSV First

SSV Second

WV and CV (simultaneous) Third

The panel shall operate with delayed opening and closing of Wing Valve, SSV in order

to protect the SC-SSV. The vendor shall provide adjustable hydraulic delay mechanismwithin the SC-SSV circuit.

As the local ESD push button will close in the event of a Fusible Loop shutdown, the.

Fusible Plug Loop re-charged after fitting of replacement plugs and well head control

system shall be reset locally. Vendor shall develop a logic that in case of Fusible Plug

Shutdown the loop will remain isolated without dispersing oil of the circuit outside.

A common logic shall be made in such a way that after local ESD or Fire ESD

activation, SC-SSSV, SSV & WV shall open only after the local reset pushbutton is

activated.

The above ESD Shutdown header and the logic supply header shall be provided with a

pressure gauge and a pressure switch.


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5.5.3 Closure of actuated valves

5.5.3.1 HIPPS valve closure

1. Flow line High High pressure

2. Manual push button on WHCP

5.5.3.2 WV & CV (simultaneous) closure


2. Fire detection by fusible plugs3. Manual ESD push button on WHCP

4. WHCP mounted push button for WV & CV close

5. Remote PSD

6. Remote close WV / CV

7. Local Close/Open HIPPS

8. Local Close/Open SSV

9. Local Close/Open SC-SSV

10. Remote Close Wellhead

5.5.3.3 SSV closure


2. Fire detection by fusible plugs

3. Manual ESD push button on WHCP

4. Remote PSD

5. Remote Close Wellhead

6. Local Close/Open SSV

Local Close/Open SC-SSV

5.5.3.4 SC-SSV closure

1. Fire detection by fusible plugs

2. Manual ESD push button on WHCP

3. Local Close/Open SC-SSV.


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5.5.4 Hydraulic Logic Control Circuit

5.5.4.1 SC-SSSV

The SC-SSSV is controlled with pushbuttons for open / close control. The logic for the

SC-SSSV is derived from the ESD logic and so the SC-SSSV will be closed manually or

by an ESD detected by the Fusible plugs. A flow control valve would be provided in the

logic to enable the required closing sequence after an ESD. The actuator hydraulic

supply pressure is indicated by a local pressure gauge. As solenoid valve fitted on the

hydraulic circuit, de-energizes on ESD, this will require resetting after an ESD.

The SC-SSSV is flapper type which will require manual pressure equalization across

the SC-SSSV prior to being opened. (i.e. not self-equalizing). The Vendor shall providea system to open the SC-SSSV from the panel.

The SC-SSV shall close on the conditions indicated in 5.5.3.4

5.5.4.2 SSV

The SSV are controlled with pushbuttons for open / close. The SSV & WV shall be

interlocked so that it can only be opened if the SC-SSSV is open. The actuator

hydraulic supply pressure is indicated by a local pressure gauge.

The SSV shall close on the conditions indicated in 5.5.3

The logic for the SSV is derived from the ESD logic and as solenoid valve fitted on the

hydraulic circuit de-energies on any of the above conditions, this will require resetting

after an ESD.

The logic shall also include remote open / close operation of these SSV.

Upon closing of SC-SSV, SSV & WV on Fire / ESD, an automatic opening or remote

opening shall not be possible.

The SSV shall be interlocked so that it can only be opened if the SC-SSV is open.

The actuator hydraulic supply pressure is indicated by a local pressure gauge. Thelogic for the SSV is derived from the ESD logic header and, as the manual latching

valve resets on loss of pressure, this will require resetting after an ESD.

The manual pull & pin valve allows the opening of SSV without the flow line pressure.

The initiation of low sense pressure from the flow line will cause the choke valve to start

closing followed by the SSV. A solenoid valve shall be provided in the control logic for

remote open and close of the SSV.


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A solenoid valve will also be provided to close the SSV / WV based on the HIPPS

valve signal. The manual valve will have to be reset locally following an IPF close

signal.

The SSV / WV and CV can also be initiated to close from a remote signal (CPSD) and

also opened from remote with remote reset facility.

The opening and closing of WV shall be done remotely, the dump valve shall be

provided to speed up the closing time for the valve. Provision shall also be provided on

the WHCP for local close and open operation for the wing valve.

The SC-SSV shall close on the conditions indicated in 5.5.3.3


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6. ASSOCIATED INSTRUMENTS AND ACCESSORIES

(to be supplied as loose Items)

6.1 Pilots

Low pressure pilot switches shall be supplied as loose items to be installed on

production lines of SR, SRS and SR Grab and shall have the following characteristics:

1. Direct acting pilot relay, piston type

2. AISI 316 stainless steel body

3. Wetted parts material Alloy-C

4. NPT M process connections5. NPT F hydraulic connections

6. IP 65 degree of weather mechanical protection

7. Process fluid: Hydrocarbon gas

8. One mechanical on-off switch set within the following ranges: Design

Pressure 12,000 kPa(g) ( set at 3000 kPa(g) falling).

6.2 Extra high pressure switch

Third pressure switch) to be installed in flow lines in Mabrouk area6.3 Quick Dump Valve Local Panel with Wire line Connection

5-10 seconds, restriction orifice and isolation valves(2 Sets per panel)

1. Quick dump valve assembly shall be supplied as loose complete with all

accessories as listed below. The quantity referred below is for 1 no set only.

Refer to PDO drawing Appendix F for further details.

2. NPT(F) 316SS, Full Ball valve, make & model: Oliver BIOFX25S- Qty 2

nos

3. 1/2 3166SS, Quick dump valve, Make & model : SIGMA 13-QS-40- Qty 1 nos

4. OD TEE,5. Other accessories as applicable

6.4 Fusible Plugs

Fusible plugs shall be supplied as loose items complete with "T" compression fittings for

installation in a fusible plug circuit, having the following characteristics:


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