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Hengam Offshore Development Project EPCI For

Topsides and Infield Pipelines and Subsea Cables


Contract No. 4405-90-2FG
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SPECIFICATION FOR CHEMICAL


INJECTION PACKAGES

B4

08.Dec.2013 Re-Issue as AFD

J. Patel

Tushar

Arun

B3

12.Mar.2013 Re-Issue as AFD

J.W.Jung

Y.H. Park

Jitendra Patel

B2

15.Jan.2013

J.W.Jung

Y.H. Park

B1

21 Sep.2012

J.W.Jung

Y.H. Park

B0

24 Aug.2012

J.W.Jung

Y.H. Park

Rev.

Date

Approved for
Design
Issued for
Approval
Issued for
Comment
Purpose of Issue

Prep.

Checked/Approved
Approve
ISI / Ocean Development

H. Karimi

Approve
IOOC

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Document Number

INPUTS
Title

REVISONS & HOLDS


Revision

Rev. B4

Description of Changes & Holds

Status

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TABULATION OF REVISED PAGES


Sheet

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Table of Contents
1.

INTRODUCTION .................................................................................................................... 7

1.1

Definition ........................................................................................................................................................7

1.2

Reference Documents ..................................................................................................................................8

1.3

Applicable Codes, General Specifications and Standards .....................................................................9

1.4

Units of Measurement .............................................................................................................................. 10

1.5

Ambient Conditions ................................................................................................................................... 10

1.6

Utility supply condition............................................................................................................................. 10

2.

SCOPE OF SUPPLY .............................................................................................................. 11

2.1

SUPPLIERS Overall Responsibility and Supplied Items ...................................................................... 11

2.2

Exclusions from Supplier's Scope of Supply ......................................................................................... 12

2.3

Termination / Boundary Conditions ....................................................................................................... 13

2.4

Interfaces ..................................................................................................................................................... 13

3.

TECHNICAL DESCRIPTION ................................................................................................ 13

3.1

General Requirements ............................................................................................................................... 13

3.2

Technical Requirements ............................................................................................................................ 14

3.2.1 Process Description ................................................................................................................................... 14


3.2.2 Mechanical Design ..................................................................................................................................... 14
3.2.2.1

Pumps ................................................................................................................................................... 14

3.2.2.2

Chemical Tanks ................................................................................................................................... 16

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Driver .................................................................................................................................................... 16

3.2.3 Material Requirements .............................................................................................................................. 16


3.2.4 Piping ........................................................................................................................................................... 17
3.2.5 Structural ..................................................................................................................................................... 18
3.2.6 Instrumentation Requirements ................................................................................................................ 19
3.2.7 Electrical Requirements ............................................................................................................................. 20

4.

PACKAGE DESIGN ............................................................................................................... 21

5.

ACCEPTANCE CRITERIA ..................................................................................................... 21

6.

INSPECTION AND TESTING REQUIREMENT ................................................................. 22

6.1

Scope of Testing and Inspection ............................................................................................................ 22

6.2

Completion of Test and Release for Shipment .................................................................................... 24

7.

SPARE PARTS....................................................................................................................... 24

8.

WEIGHT CONTROL ............................................................................................................. 24

9.

MAINTENANCE REQUIREMENTS ..................................................................................... 24

10.

PRESERVATION AND PACKING ....................................................................................... 25

11.

STORAGE .............................................................................................................................. 25

12.

TRANSPORTATION AND WIND LOADING ................................................................... 26

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DOCUMENTATIONS ........................................................................................................... 27

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1. INTRODUCTION
The Hengam Field is located in the Persian Gulf at approximately 45 km south of Qeshm Island. Iranian
Offshore Oil Company (IOOC) has awarded HENGAM offshore development EPCI project to Intelligent
Solutions Inc. and Ocean development LLC. Joint Venture to perform Basic & Detailed Engineering, as
well as procurement, fabrication, installation, pre-commissioning & commissioning for:

Topside facilities of three offshore wellhead platforms

Infield pipe lines

Submarine composite Cable (Power, Control, Fiber optic) from offshore to onshore facilities.

1.1
B4

Definition

Wherever the word "shall" has been used, its meaning is to be understood as mandatory.
Wherever the word "should" has been used, its meaning is to be understood as strongly recommended
or advised.
Wherever the wording "may be" has been used, its meaning is to be understood as a freedom of choice.
The following words and expressions shall have the meanings hereby assigned to them except where
the context of this document otherwise requires:

OWNER
Shall mean Iranian Oil and Offshore Oil Company (IOOC)

EPCI CONTRACTOR
Means Company mentioned in the Contract as part of the "other part" and includes its
successors and permitted assignees. (ISI/ODCO)

CONTRACT
Shall mean the Agreement between the COMPANY and the CONTRACTOR and includes
documents referred therein.

PLANT
Shall mean the permanent offshore facilities designed, constructed and completed under the
CONTRACT.

SITE
Shall mean the premises and places on, under, in, over or through which the WORK is to be
executed or carried out including CONTRACTORs engineering office and the PLANT.

WORK
Shall mean all and any of the works and/ or services and/ or materials required to be provided
by the CONTRACTOR under the CONTRACT with COMPANY.

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APPROVED, APPROVE, APPROVAL


Means approved, approve, approval in writing by PURCHASER.

PURCHASE ORDER
Shall mean the written Purchase Order agreed between PURCHASER and VENDOR together
with any appendices or attachments thereto.

GOODS
Shall mean any and all of the design, engineering, services, warranty related services, labor,
assistance, articles, materials, equipment, spare parts, other supplies including but not limited
to manuals, operating instructions, reports and drawings and all other documents to be supplied
or performed by VENDOR as described in (or to be inferred from) the PURCHASE ORDER.

VENDOR
Shall mean the person or Company identified on the Purchase Order as the VENDOR of the
GOODS

SUB VENDOR
Shall mean any person or Company (other than PURCHASER) having a contract with
VENDOR for the manufacture and/or supply of the GOODS or a part of the GOODS.

PURCHASER
Means EPCI Contractor

INSPECTOR
Means the CONTRACTORS REPRESENTATIVE or THIRD PARTY INSPECTION AGENCY or
CERTIFYING AUTHORITY as specified in Purchase Order.

1.2

Reference Documents

HEN-WHP1-PI-LY-0001

Platform Equipment Layout

HEN-0000-SA-PH-0001

HSE Philosophy

HEN-0000-PR-PH-0003

Shutdown Philosophy

HEN-0000-PR-PH-0000

Isolation Philosophy

HEN-000-PR-DB-0001

Process basis of design

HEN-000-SA-CE-0002

F&G and ESD cause & effect chart

P&ID of Chemical Injection System for WHP1, 2, and 3

HEN-0000-ME-SP-0009

Specification For Pressure Vessels & Columns

HEN-0000-ME-SP-0008

Specification for Welded Steel Tanks

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HEN-0000-ME-SP-0003
HEN-0000-ME-SP-0005

B4

Rev. B4

Specification For Nozzle Loadings Of Equipments


Specification For Centrifugal and Reciprocating pumps

HEN-0000-ME-DB-0001

Mechanical Design Basis.

HEN-000-MP-SP-0005

Specification for package equipment (General)

HEN-0000-EL-DB-0001

Electrical Design Basis

HEN-0000-EL-SP-0011

Specification For Electrical Components For Package Units

HEN-0000-EL-SP-0008

Specification For Low Voltage Electric Motors

HEN-0000-IN-SP-0015

Specification For Package Control And Instrumentation

HEN-0000-PI-DB-0001

Piping Design Criteria

HEN-0000-PI-SP-0001

Specification For Piping Materials

HEN-0000-ST-DB-0001

Structural Design Basis

Besides above documents, following drawing and documents shall be referred and considered integral part of
this technical specification:

Data Sheet - Corrosion Inhibitor Injection Pumps.

Data Sheet - Corrosion Inhibitor Storage Tank.

Data Sheet Demulsifier Tank.

Data Sheet Demulsifier Injection Pumps.

Any further Code, General Specification and Standard referenced in any of the above listed documents
shall be considered to be applied, unless explicitly otherwise indicated, even if not included in above list.
The compliance of design, material and fabrication with the regulations in force in the Country where the
equipment is to be installed is the full and exclusive responsibility of Supplier. Supplier shall obtain the
necessary approval and execute the required tests and certificates.
After issuing all above reference drawing and documents, this specification shall be revised according
to relevant drawings and documents, if required.
1.3

Applicable Codes, General Specifications and Standards

The following Codes, General Specifications and Standards form a part of this specification. When an
edition date is not indicated for a Code or Standard, the latest edition in force at the time of the contract
award shall apply.
Note: Edition year for all standards shall be latest edition at the time of order placement of
B4

equipments/packages.

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API 5L

Specification for line pipe.

ANSI B31.3

Process piping.

ANSI B16.5

Pipe flanges and flanged fittings.

ANSI B1.20.1

Pipe threads, general purpose.

API RP 520

Sizing, selection and installation of pressure-relieving devices in Refineries.

API RP 521

Guide for Pressure Relieving and De-pressurizing Systems.

API RP 550

Manual on installation of refinery instruments and control systems.

API 650

Welded Steel Tanks for Oil Storage

API 675

Positive Displacement Pumps Controlled Volume.

API 14C

Basic Surface Safety System for Offshore.

ASME VIII Div.1

Rules for construction of pressure vessels.

ASME B31.3

Process piping

SAME B16.5

Pipe flanges and flanged fittings

IP Code 15

IP Area Classification Code for Installations Handling Flammable Fluids.

1.4

Units of Measurement
The units of measurement on all documentation and all equipment shall be in accordance with Project
Codes, Standards and Definitions including following units, unless otherwise specified.
Temperature

Pressure

Bar

Vacuum

mmHG

General Length

Millimeter or meter

Pipe outline dimension

inch

Weight

Kg or ton

In general, the equipment shall be installed on offshore facilities, in open sided process modules,
subjected to high humidity, saline environment.
1.5

Ambient Conditions
For ambient condition refer to Process Design Basis HEN-0000-PR-DB-0001 and Structural Design

B4

Basis HEN-0000-ST-DB-0001.
1.6

Utility supply condition


For utility supply condition refer to Process Design Basis HEN-0000-PR-DB-0001 and Electrical
Design Basis HEN-0000-EL-DB-0001

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2. SCOPE OF SUPPLY
2.1

SUPPLIERS Overall Responsibility and Supplied Items


This Technical Specification defines the minimum requirements for the design, fabrication, inspection
and testing of Demulsifier injection Skid and Corrosion Inhibitor Skid that to be installed in each well
head platform. The contractual production life time is 25 years.
This specification shall be read in conjunction with all referenced documentation. Any conflicts between
this specification and any other project documents, codes, standards, etc. shall be brought to the
attention in writing for clarification prior to any further action. The more stringent requirements shall
govern until written clarification is provided. In addition, attention shall be immediately called to any error
or omission in this specification.

SUPPLIER shall be responsible for all equipment and auxiliary systems included in the scope of supply.
SUPPLIER shall be responsible for the design, manufacture, inspection, testing, surface preparation
and painting, shipment and delivery of the pump with drive motor, mixer with driver motor, storage tank,
auxiliary piping, instrumentation, electrical and skid; all in accordance with this specification,
attachments, and applicable codes and standards.
Scope of supply and work for Chemical Injection System Package shall be, but not limited to, the
following:
a) Engineering activities for the design of the packaged Units, installed on a single skid, to meet
the process requirements as specified on process and equipment Data Sheets and Piping &
Instrumentation Diagrams.
b) Documentation for information and/or approval as required. Detailed requirements like
commissioning spares, operation spares, consumables, special tools, equipment weight control
summary and deviations (if any) will be listed on dedicated forms available at the detailed
engineering stage.
c) Data Book containing final technical documentation for all equipment within the scope of supply,
including brochures, operating and maintenance manuals.
d) Supply of the Demulsifier Injection System Package and Corrosion Inhibitor Injection System
Package, each skid complete of:
-

One (1) no. of Corrosion Inhibitor Tank.

One (1) no. of Corrosion Inhibitor Tank Mixer, complete of Electric Motors

Two (2) no. of Corrosion Inhibitor Pumps, complete of Electric Motors and Flexible type
Spacer Couplings.

One (1) no. of Demulsifier Tank.

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One (1) no. of Demulsifier Electrical Heater, if required.

Two (2) no. of Demulsifier Pumps, complete of Electric Motors and Flexible type Spacer
Couplings.

Pulsation Dampeners on each Injection pumps discharge lines.

Interconnecting Piping and Valves, strainers, hoses with relevant connections and quick
connect / disconnect couplings and insulation.

B4

Local power / control panel including the glands, as specified in datasheet.

Push Button Stations to locally control (start/stop) for the Electric Motors other than the
ones connected to the Local Power / Control Panel.

Necessary instrumentation with in the skid.

Pressure Safety Valve (PSV) at each pump discharge.

Calibration Gauge at pump suction.

Cables, cable trays, junction boxes, fittings, support, etc. for electrical and
instrumentation power/control, including erection and connection.

Structural skid and supports complete of service walkways and ladders (if required).

Earthing system and related connections.

Items not explicitly identified, but required for a proper and safe operation of all the
systems.

B4

B4

Spare parts for pre-commissioning (if any).

Spare parts for commissioning and start-up.

Special tools, if required.

Performance Guarantee.

Painting of equipment, piping, skid and auxiliary equipment except 316L stainless steel
material as per manufacturer's standard suitable for offshore environment.

e) Necessary accessories like suction strainer, pressure safety valve, pulsation dampeners on
suction side (if needed) and discharge side, discharge pressure gauge, stroke counter, Nitrogen
pressure gauge for pulsation dampeners and pulsation dampener charging unit.
f)

The Supplier is responsible for ensuring that all equipment and components provided are
suitable for the operating conditions stated and utilities.

2.2

Exclusions from Supplier's Scope of Supply


a) All off-skid piping;
b) Foundation for mounting of skid;
c) Switchgear;
d) All off-skid cabling and wiring.

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Termination / Boundary Conditions


The termination of piping shall be located conveniently at skid edge with suitably rated flange.
Electrical motor feeder cables shall be terminated at the motor terminal boxes for power, space heater
and RTD as per motor data sheet.
The SUPPLIER shall submit a detailed schedule of all terminal points for each Chemical
Injection Package, including as a minimum:
a) Fill connection to tank;
b) Flanged outlet to vents;
c) Flanged outlet to drains;
d) Flanged drip pan connection(s);
e) Earthing bosses, two (2) per skid, located diametrically opposite;
f)

Lifting pad eyes; and

g) Foundation details for mounting.


2.4

Interfaces
SUPPLIER shall take note of the following critical interfaces that apply to the Chemical Injection
Package. SUPPLIER is expected to provide sufficient detail design information soon after order
placement to enable the topsides design to proceed. This shall include the following data:
a) Interface of the Chemical Injection Packages with the platform structure, support details,
locations and loads.
b) Interface of the Chemical Injection Packages with the platform piping.
c) Interface of the Chemical Injection Packages with the platform electrical power supply and utility
systems.
d) Interface of the Chemical Injection Packages with the platform control systems.

3. TECHNICAL DESCRIPTION
3.1

General Requirements
The package shall be designed for outdoor covered installation, in Zone 2 Classified Area, Gas Group
IIA & IIB, Temperature ClassT3, according to IP Code15.
The Units shall be structural supported/ completely packaged and shall include equipment, instruments,
interconnecting piping and valves as required for proper operation as stipulated in P&ID. The Units shall
be designed to fully adhere to process and construction requirements stated on each individual item
Data Sheets.
The Supplier shall take single point responsibility for the complete scope of this package.

Hengam Offshore Development Project EPCI For


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Technical Requirements
3.2.1

Process Description

A chemical injection facility including Corrosion inhibitor and demulsifier shall be provided on each
wellhead platforms.
Corrosion inhibitor will be injected into the each production manifold inlet line on the continuous basis to
protect wellhead topside piping and export pipeline against corrosion.
Corrosion inhibitor injection facilities will consist of storage, handling and injection. Corrosion inhibitor
tank will be refilled from the boat / tote-tank. The capacity of corrosion inhibitor storage tank will be
based on 14 days requirement of corrosion inhibitor at the normal injection rate. Corrosion inhibitor
injection will be by reciprocating type motor driven pumps. The injection rate will be set by manual
adjustment of the stroke of the injection pumps. The storage tank will be provided with level transmitter
to monitor the level in the tank. Low level on the chemical storage tank will stop the chemical injection
pump.
The effectiveness of the corrosion inhibitor chemical will be monitored using corrosion probes and
coupons on the flow lines and export pipelines.
SUPPLIER shall provide suitable control system to maintain proper condition of demulsifier and
corrosion inhibitor.
Emergency shower and eye wash facilities will be located adjacent to chemical injection skids for safety.
Demulsifier will be injected only to Test Separator Inlet and MEG is injected to Production Well and to
the downstream of blow down valve. The demulsifier and MEG injection system are under intermittent
services.
3.2.2

Mechanical Design

3.2.2.1

Pumps

Each Corrosion Inhibitor Injection System and Demulsifier Injection System shall have two (2) nos. of
chemical injection pumps, one operating and one stand-by. Standby pump shall start automatically in
case main pump malfunctioning for the Corrosion Inhibitor System and Demulsifier Injection System.
B4

All pumps shall be Diaphragm Type Metering motor driven pump and shall be designed, fabricated,
inspected and tested in accordance API 675 latest edition, as specified in the mechanical data sheet
and this specification.
Pumps shall be designed for the chemical flow rates and discharge pressures throughout the entire
operational range.
All pumps shall be selected with variable stroke control with a turn down of 1:10 as a minimum with

B4

local and manual stroke adjustment. The pump shall have a positive return stroke mechanism and not

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the spring return motion. The pump shall be designed so as to cushion the piston at the end of the
stroke.
The injection pumps shall be capable of starting with full discharge back pressure. Each pump unit on
standby shall be capable of isolation and safe removal with the operating pump running. Pulsation
dampeners shall be provided to limit pulsation within 3%. The pulsation dampener shall be designed
as per ASME Section VIII Div. I and full radiography shall be done. The details of pulsation dampener
shall be given by Supplier.
Supplier shall provide the suitable calibration system. Pump bearings shall be oil lubricated.
A calibration pot to set the injection flow rate shall be also provided in the pump suction line.
Pump direct drive by a 50 Hz electric motor is preferred without use of speed increaser/ reducer. Local
start/stop provisions shall be provided. Pump shall also trip on low level of the chemical tanks.
A safety relief valve shall be provided in each pump discharge line to prevent over pressurization of the
discharge lines. The safety relief valve shall relieve back to the chemical injection tank. Local pressure
gauges shall be provided at locations where the pressure is required to be monitored.
B4

Y strainers shall be installed on the pump suction line.


Manual isolation valves shall be provided on pumps suction and discharge lines and check valves on
the pumps discharge side, to prevent back flow. All double diaphragm pumps shall be equipped with
individual drip trays under pump and motor.
Pulsation dampeners and pressure indicators are required on the pumps discharge lines, ahead of the

B4

relevant isolation and non-return valves. Dampeners shall be gas filled bladder type.

All shafts shall be protected by renewable shaft sleeves at all vulnerable areas, including labyrinths and
centre bushes. Shaft coupling shall meet the requirements of API 675. Coupling guards shall be nonsparking type in brass sheet or plate material.
Pumps and its accessories shall be suitable for sour service conditions. Detail shall be furnished along
with proposal.
Performance test shall be carried out with the pump running at 25%, 75% and 100% and 125% of the
rated speed. During testing the capacity shall be within +3% and no negative tolerance of rated capacity.
NPSH test is required where difference between NPSH required and NPSH available is 1 meter or less.

Positive displacement pumps with double diaphragm should be designed in order to provide suitability
of stroke: length, volume for required resulting pumping pressure + gas/liquid volume (also speed).
Hydrodynamic considerations should regard pressure-volume due to stroke length and longitudinal (and
also rotational) speed of shafts. Stroke adjustment should be according to given stroke frequency.
Adjustability & control devices over pressure-volume control should be available.

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Diaphragm material hardness certification and strength due to available pumped pressure/head,
dynamic of gas/liquid and also corrosion resistance due to process fluid should be regarded.
Requirements due to NPSHA should be met with appropriate design and also be proved at performance
test.
3.2.2.2

Chemical Tanks

Each Corrosion Inhibitor Injection System and Demulsifier Injection System shall have one (1) nos. of
chemical injection tank.
The tanks shall be designed, fabricated, inspected, and tested in accordance with this specification,
data sheets, Specification for Storage Tank.
The acceptance test criteria shall comply with API 650 - Welded Steel Tank for Oil Storage.
Tank shall be tested for full of water only. It shall be equipped with a level gauge and level transmitter.
Tank liquid level shall be monitored through level transmitter. The Injection Pumps will be tripped in
case of low tank liquid level condition.
All openings in Tanks shall be reinforced, the size of which shall be in accordance with API 650.
Reinforcement plate shall be of the same thickness and material as the tank plate. External attachment
pads if required shall have round corners. All lugs (if required) shall be secured to on attachment pad.
The Supplier shall ensure that all attachments, pads, lugs (if any), etc. are properly welded and
complete before testing. All welds attaching lifting lugs (if any) shall be full-penetration type.
The structure of the storage tanks shall be provided with suitable ladders, an access for operation and
B4

maintenance by the PURCHASER/COMPANY.


3.2.2.3

Driver

The driver shall be sized to meet the maximum specified operating conditions, including external gear
and/ or coupling losses, and shall be in accordance with applicable specifications. The driver shall be
suitable for satisfactory operation under the utility and site conditions specified. The motor nameplate
rating shall be as per API 675.

B4

3.2.3

Material Requirements

Materials selection should be based on working conditions: available pressure-flow rate (speed-volume),
chemical properties and corrosion behavior of process fluid.

Material hardness certifications for pressure containing parts and sufficient strength due to available
loads and working conditions of pressure-flow rate should be available. Calculations should consider
requirements for lifetime and corrosion. Pump inlet/outlet and corresponding piping and auxiliaries

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should be designed according to relevant available pressure/speed/volume with appropriate class and
material.

All piping and valves shall be suitable for carrying process gas/liquid and thereby appropriate corrosion
considerations should be undertaken. Class and sizing should be according to available working
conditions: pressure/head, volume and speed (dynamic of gas/liquid).

Considerations due to temperature variations for material strength of different parts subjected to
temperature variations should also be performed.

In addition check valves and process relief valves selection should be according to requirements due to
available working conditions pressure/speed/volume. Pressure relieving calculations and considerations
due to pressure control should also be available. Material hardness test, performance test and function
test should have appropriate results.

The base-plate stiffness shall be sufficient for withstanding all loads: statics due to weights and
dynamics in full operations. Also thermal tensions resulting in base plate should be resisted with
adequate stiffness.

The SUPPLIER remains responsible of the final selection of the materials for the specified service.
Material certification requirement in accordance with BS EN 10204 shall be submitted as follows:
- For pressure retaining parts of pump and piping
- For other non-pressure parts
The relevant certificates shall be included in the Manufacturer's Data Report (MDR)
3.2.4
B4

Piping

AII piping within the skid limits shall comply with piping classes stated on the P&IDs and with HEN0000-PI-DB-0001, Piping Design Criteria.
AII process and utility piping shall terminate at the skid edge in ASME flanges with size as per the
project P&IDs.
AII piping shall be properly supported within the skid limits and anchored at skid limits.
AII interconnecting piping between equipment shall be arranged so that all maintainable items of
equipment are accessible and capable of removal, preferably without dismantling the piping.
AII drains and vents which represent an interface between SUPPLIER and PURCHASER, shall be
routed to the edge of base frame/base plate, and shall be terminated by a flange and blinded.

Hengam Offshore Development Project EPCI For


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Contract No. 4405-90-2FG
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Permissible nozzle loads at skid edge shall follow HEN-0000-ME-SP-0003, Specification for Nozzle
Loadings Of Equipments.
Piping at equipment and vessels shall be adequately supported to ensure that under no circumstances
will the nozzle of equipment be subject to any stress that could cause distortion in alignment or internal
clearance, thus jeopardizing the operation of the equipment.
SUPPLIER shall be responsible for pipe stress analysis and provide all necessary piping supports
within his scope of supply.

3.2.5
B4

Structural

No part of equipment shall protrude beyond the skid edge. The skid shall be of carbon steel, fulIy
welded steel construction with no intermittent welding. Fabrication and welding shall be in accordance
with the requirements of AISC Manual of Steel Construction and AWS D1.1 codes. AII fillet welds shall
be continuous.
The skid shall be shown by calculation to be suitable as per HEN-0000-ME-SP-0005, Specification for
Package Equipment(General) and for two primary conditions:
-

Support of equipment during all conditions of operation (including flushing and testing)

Support of equipment (empty) during lifting and handling in delivery / sea transport and at the
fabrication site.

The following calculation notes shall be supplied:


-

Max allowable loads on piping connections and nozzle flanges at limit of supply

Static and dynamic calculation of the compressor unit skid.

In the operating condition, unless otherwise specified, the skid shall be assumed (for design purpose) to
have simple supports at the extreme ends and at the midpoint of the longitudinal base members.
Each skid shall be lifted using four padeyes and designed to working stress with enough safety factor.
In both the operating condition and lifting condition, the skid shall be shown by calculations to be
capable of supporting all equipment without deflections that would result in permanent deformation or
transfer of unacceptable loads into the operating equipment. Calculations for the design of the skid shall
be submitted for PURCHASER approval.
Areas that may contain spills or may require draining shall have a drip pan built into the skid by
SUPPLIER. Drip pans shall be sloped at 1:50 to a low point drain (min. 2" NB, 150# flanged connection)
and shall be covered with a galvanized grating.
Skids shall be fixed to the platform structure by bolting. Fixing bolts, nuts, washers shall be supplied by
PURCHASER. Leveling bolts with lock nuts shall be provided by SUPPLIER.

Hengam Offshore Development Project EPCI For


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The SUPPLIER shall provide the necessary data required for structural dynamic and static analysis of
the deck support steel. This information shall include but not be limited to the following:
-

Skid weight, support points and center of gravity

Operating speeds for all rotating pieces of equipment

Operating rotational imbalance forces

Maximum allowable displacements along the skid

Necessary platforms and access ways shall be provided to all major components and instruments.
Platforms and relevant ladders shall be furnished only if strictly necessary to provide access for
operation, inspection and maintenance requirements.
Sufficient access shall be provided to areas requiring regular maintenance such as filters and drains
without the need to remove other equipment. Instruments shall be oriented to allow monitoring from the
edge of the skid
Lifting devices will be provided by PURCHASER. Lifting diagram & method shall be provided by
SUPPLIER.
Transport forces and Ship motions should be according to Structural Design Basis HEN-0000-ST-DB0001.
The SUPPLIER shall submit a set of preliminary sketches of his proposed skid with his bid in
accordance with the Project weight control data sheet. The sketches shall display skid dimensions,
weights, centre of gravity, general item layouts and interconnection orientations.

3.2.6

Instrumentation Requirements

The instruments installation shall generally be according to Recommended Practice API RP 550
"Manual on installation of refinery instruments and control systems". All instruments will be connected to
process through manual isolating valves, on both sides (process and instrument sides). Should the
process connection be rated ANSI 900 # and above, the use of double block and bleed process
connections is mandatory. The instruments shall be easily accessible and removable to allow calibration
and maintenance operations. Instruments connections towards process shall be provided with manual
isolation valves, process and instrumentation sides.
All instruments and relevant connections shall be suitable for installation in Zone 1
Classified Area, Gas Group IIA & IIB, Temperature ClassT3, according to IP Code 15.
Safety execution and degree of protection shall be Eex-d - IP 65. Materials for potentially hazardous
area shall be supplied complete of certification issued by an internationally recognized Authority.
Armored multicore cables shall be used mechanically protected in cable trays. Conduit is not generally
allowed.

Hengam Offshore Development Project EPCI For


Topsides and Infield Pipelines and Subsea Cables
Contract No. 4405-90-2FG
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Alarms and digital status signals shall be through voltage-free contacts, 24 V dc, 2A rating. All the
electrical connections of Instrumentation with the platform control and safety systems shall terminate at
a dedicated terminal strip within the Local Control Panels or at the skid interface junction boxes. For
control system type refer to Specification For Package Control And Instrumentation HEN-0000-IN-SP0015.
3.2.7

Electrical Requirements

Electrical motors shall comply with project specifications Specification for Electrical Requirements for
B4

Packages HEN-0000-EL-SP-0011 and Specification For Low Voltage Electric Motors HEN-0000-ELSP-0008.
The Chemical Injection Pump electric motor shall be fed through the power / control local panel, located
on the Chemical Injection Skid. The power cable shall be in the scope of supply and will be connected
by Supplier to the electric motor junction box terminals.
Push button stations for locally control requirements (start / stop) shall be provided for each motor by
Supplier.
The Power / Control local Panels will be individually fed from the platform Electrical Room by dedicated
feeders at 400V / 3ph+N / 50Hz. Other voltages for auxiliaries, instrumentation and controls
requirements shall be obtained by the internal installation of a proper step-down transformer by
SUPPLIER.
The panel shall be equipped as a minimum with the following:
a) Electrical main circuit breaker.
b) Line contactor and thermal relays (for electrical motor starters).
c) Selector switches, start/stop pushbuttons with integral signaling lamps.
d) Indicating lamps for process alarms.
e) Lamps test and alarms reset pushbutton.
f)

Relays.

g) Terminal strips.
B4

All electrical equipment shall be as a minimum suitable for installation in Zone 2 Classified Area, Gas
Group IIA & IIB, Temperature Class T3 according to IP Code 15. Safety execution and degree of
protection shall be IP56 . Materials for potentially hazardous area shall be supplied complete of
certification issued by an internationally recognized Authority. Cable glands shall be EExd, double
sealing brass type, nickel plated including earth tag and shroud.
All the wiring inside the package (cables, cable trays, glands, fittings, etc.) shall be in scope of supply.

Hengam Offshore Development Project EPCI For


Topsides and Infield Pipelines and Subsea Cables
Contract No. 4405-90-2FG
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4. PACKAGE DESIGN
The Chemical Injection System Package shall be designed as a base load machine capable of running
continuously all year round planned maintenance shall be allowed for, but the package shall be capable
of running for at least 12 months without unplanned shutdowns. Mechanical handling equipment over
the Chemical Injection System Package will be provided as part of module structure. For routine
maintenance and breakdown, the Supplier shall provide a mechanical handling plan. This may be part
of the general arrangement drawing. It shall be applied on the basis that all components greater than
25kg in weight for single man lift or 50 kg for two-man lift shall require a mechanical lifting aid. The plan
shall show the routing of runway beams, the location of pad-eyes etc, to be provided by Purchaser.
All piping connections shall be terminated at skid edge flange compliance with ASME B16.5. Flange bolt
holes shall be straddle centerlines. Minimum connection size shall be DN 20. Piping termination nozzle
connections shall be anchored at the skid, the supplier shall define the allowable forces and moments
on these terminations. All external bolting shall be PTFE Teflon coated (or equivalent) and internal
bolting shall be Stainless Steel type, with Double Nut system.
The Supplier shall ensure that all pressure containing components, including equipment and piping are
protected as per requirement of API RP 520 and 521. The Supplier shall provide holding down details
and bolting designs, suitable for all conditions. The Supplier shall include provision for attachment of
sea fastenings. The Supplier shall provide the reaction schedule in his skid drawings for the dry
conditions, operating conditions, hydrostatic testing conditions and transportation conditions.
The Chemical Injection System package shall meet the requirement of Specification for Requirement
for Skid-Mounted Packages and Technical Specification for Minimum Criteria for Nozzle Loading on
Vessels and Skid Connections.
All the couplings, gears and exposed rotating parts shall be provided with adequate guards of non
sparking type. All electrical devices shall meet the requirement of area classification in which they are
installed.

5. ACCEPTANCE CRITERIA
The Supplier shall guarantee that the pump shall meet the various performance guarantees as required
by API 675 and detailed elsewhere in this specification and on the pump data sheet.
The supplier shall guarantee the mechanical design and the suitability of the material to be used.
However, if the Purchaser has so defined the materials, the Supplier shall be responsible for the
corrosion characteristic of the material with regard to the process fluid.

Hengam Offshore Development Project EPCI For


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Contract No. 4405-90-2FG
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6. INSPECTION AND TESTING REQUIREMENT


Supplier shall carryout various tests as per API 675 requirement and pump data sheet. Test Certificates
shall be submitted for Purchasers review. Purchasers inspection representative shall have normal
access to Suppliers manufacturing facilities and those of Sub-Suppliers for the purpose of confirming
that quality assurance procedures and equipment manufacture and testing are satisfactory. Supplier
shall make available all relevant quality assurance procedures and records for review.
In case Manufacturer / their Sub-Supplier of equipments / packages have in-house elaborate Quality
Assurance Systems (operating in their shop) for Inspection and Testing equipment / packages, the
witnessing of inspection and testing by Purchaser may not be necessary provided such Manufacturer /
Sub- Supplier of equipment / packages obtain approval of their Quality Assurance System from
Purchaser prior to commencement of manufacturing activities. However, witnessing of Inspection and
Testing by Third Party Inspector of Contractor shall be necessary as per approved Quality Assurance
System.
6.1

Scope of Testing and Inspection

NDE testing

Factory acceptance test and procedure includes component information: pump, vessels
visual examination and inspection, and testing of different parts: gears, couplings mechanical
runs. Also subject of inspection should include: dimensional check, installations according to
layout and instructions, constructional inspection, inlet/outlet connections

Performance, function and mechanical running test should be performed according to predefined criteria and procedures and eventually with determining best working pressure under
operating conditions as practical results. Adequacy of pressure control and functionality, and
also considering start-up, shut down, overpressure and failure occurrences should be regarded.

Pressure / pneumatic tests and leakage test.

Eventually repeat NDE after pressure tests

Positive displacement pumps tests include testing of providing requirements due to


pressure/head-flow (volume-speed) at different operating conditions: from start-up to rating
point, also appropriate behavior during shut down and failure occurrence, and comparison of
head-flow characteristic curves with given ones. Considerations should be done regarding
efficiency and finding optimized working conditions: pressure-flow (volume-speed). During
performance and functional test, flow rate and available pressure at discharge should also be
measured and considered as test parameters and additionally pressure-flow curve should be
acquired and considered for optimized rating conditions and best efficiency.

Hengam Offshore Development Project EPCI For


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Contract No. 4405-90-2FG
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Also stroke control should be performed due to requirements stated before. Performance test
should achieve requirements due to finding appropriate stroke and adjustment for best
efficiency due to design (available) pressure/head-flow and determining the rating point: manual
stroke adjustment.

Pulsation suppression construction inspection and function testing should also be performed.
For discharge pulsation dampeners: pressure tests, appropriate pressure and pressure setting
should be done. Performance and function test should prove appropriate damping under
operating conditions. Proper construction and adjustments should met requirements due to
proper working conditions with adjusting pulsation level. Performance test include also testing
of dampeners during working situations and assuring of satisfiable performance in pre-defined
working pressure-flow (volume-speed) conditions.

Performance test of each pump train should be performed according to data given regarding
pump fluid characteristics: specific gravity, density, viscosity and also design flow-pressure:
discharge and suction pressures, flow constructions

Alignment and vibration tests should be performed according to pre-given procedures and
requirements. Vibration amplitudes should be less than max permissible value (from start-up to
rating point, also during conditions related to max operating loads and shut down).

For coupling, bearings and gear box, mechanical running test should be done regarding
transmitted power and speed-load test. Material hardness tests should also be performed.

Piping, valves, fittings and also bolting should appropriate material and class. Pressure,
function and leakage tests should be done according to pre-defined instructions. Nozzles and
connections load calculations, material certifications, and corrosion considerations with
appropriate material are also important. Design of piping and valves placement is also subject
of inspection and should be reviewed. Inspection check of required and determined connections
and accessories for pump and other parts should be done. Especial connections should be
provided for injection points. Also input/output connections

from

pump,

valves

and

connection should be inspected.

LV Motor routine test shall be carried out on each motor .

Noise test should show acceptable sound level.

Factory Acceptance Test / Industrial test / Assembled skid testing should be done according to
API standard. Mechanical running of whole system should be tested and results be compared

B4

with requirements.

Functional acceptance test for each cabinet (All alarms & safety device) including interface shall
be done.

B4

Hengam Offshore Development Project EPCI For


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Contract No. 4405-90-2FG
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Completion of Test and Release for Shipment

All discrepancies, damaged or missing equipment, malfunctions, missing documents, if not


corrected immediately, shall be recorded within a Punch List. A level of priority shall be
assigned to each punch item and SUPPLIER shall clear all items deemed mandatory by
PURCHASER/COMPANY/TPA.

Final acceptance of shop tests shall be made by PURCHASER/TPA after complete test
sequence has been performed and mandatory punch items solved, but shall not constitute a
waiver of SUPPLIER/TPA obligation to provide a complete package unit which meet all
performance requirements.

On completion and acceptance by PURCHASER/TPA of all shop acceptance tests, complete


unit test, load out procedures approved and provided that all required documentation has been
submitted to PURCHASER/COMPANY/TPA. PURCHASER/TPA shall release a "READY FOR
SHIPMENT CERTIFICATE" prior shipment of the package.

7. SPARE PARTS
SUPPLIER shall furnish list for following categories:
a) Spares for Commissioning and start-up.
b) Spares for 2 years of normal operation.
c) Special Tools, if required

8. WEIGHT CONTROL
Weight and COG data shall be provided for the dry, operating and test conditions. The basis for the
weights provided shall be clearly indicated (i.e. whether based on weight estimates, calculated weights,
weighed weights etc.), and shall include all equipment items, structural items including base plates and
skids, bulks, etc. SUPPLIER shall list any allowances included in the weight data to cover items or bulks
not readily quantifiable and contingency factor shall not be applied to the weight data provided.

9. MAINTENANCE REQUIREMENTS
Supplier shall highlight and supply special tools required for routine and major maintenance work for the
package.
Full details of the designs of all major equipment components that will be subject to planned
maintenance / replacement during the life of the equipment, shall be provided by Supplier.
The supplier shall work closely with the Purchaser to ensure that the most effective layout for
maintenance is achieved around the package.

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Contract No. 4405-90-2FG
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10. PRESERVATION AND PACKING


All items shall be tagged. All boxes, crates and containers shall be properly labeled in accordance with
Purchasers instructions. All packing shall be clearly marked for shipping, including crate dimensions,
gross weight and net weight lifting points, and COG. This information shall be stenciled in black print, in
at least two locations on the crate.
Sufficient number of certified lifting eye bolts shall be provided at appropriate places for handling,
marked clearly with Safe Working Load (SWL).
Supplier shall apply preservation to and pack the equipment and materials for transportation as sea
freight and outdoor storage for 12 months in a tropical, marine environment. For items which require
preservation during transportation from yard to offshore site Supplier shall advise Purchaser of the
requirements.
All flammable or toxic liquids shall be drained before packing. Any water based fluids left in any
equipment shall be chloride free.
Small parts that are easily damaged or lost shall be separately packed, suitably protected and marked,
and shipped with the related equipment. All loose supplied items shall be specifically tagged and shall
be accompanied by instruction for site/offshore assembly. A list of loose supplied items shall be
furnished to check completeness and as reference.
Spare parts and special tools shall be separately packed complete with inventory for long duration
storage in a tropical saliferous atmosphere, and suitably marked so as to be recognized as insurance
spares, commissioning spares parts, operating spare parts, or special tools, etc.
Flanges and other end connections shall be properly capped or protected with metallic blind flanges,
secured by bolts and nuts. Threaded connections shall be protected by metal plugs or caps. For
stainless steel items these caps shall be of stainless steel.
Instrumentation equipment shall have its terminals adequately protected to prevent damage due to
moisture ingress.
Hazardous fluids used for preservation to be clearly identified on equipment and packing.

11. STORAGE
Unless otherwise specified, equipment shall be protected for storage of 12 months at fabrication yard /
offshore platform. If any extra precaution is to be taken by PURCHASER for storage beyond 12 months
the same shall be explicitly indicated in the operation and maintenance manuals.
All nozzle flange faces and / or machined surfaces shall be coated with easily removable rust
preventative / grease, and shall be further protected with wooden or metal covers bolted in place.
Screwed connections shall be protected with suitable thread protectors.

Hengam Offshore Development Project EPCI For


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12. TRANSPORTATION AND WIND LOADING


B4

The following applies to all equipment located on Wellhead Platforms WHP1, WHP2 and WHP3.
Equipment shall be installed on a deck that will be fabricated in a fabrication yard. The fabricated deck
will then be transported by sea route to the designated location offshore. Equipment supports shall be
suitable to withstand the forces and moments.
Maximum Wind load and duration will be informed to VENDOR from PURCHASER. And seismic load
on site shall be checked by PURCHASER and informed to VENDOR as soon as possible.
Required data should be extracted from Structural Design Basis HEN-0000-ST-DB-0001.

Hengam Offshore Development Project EPCI For


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Contract No. 4405-90-2FG
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13. DOCUMENTATIONS
The supplier shall include but not limited to the following documents and information
No.

A.

Document Title

During Bid

During
Review
Stag
e

Interface Information
Drawings and documents within this clause shall comprise all information which may interface with other
facilities of purchaser, and which are of major importance for platform facilities design and project
schedule.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Outline and Foundation Loading Diagrams


General Arrangement Drawings
Electrical/Instrumentation Layout Drawings
Utility Flow Diagrams
Performance Curves
Piping and Instrumentation Diagrams & Schematics
Instrumentation List
P&ID Bill of Material
Junction Box Termination Drawings
Cable Schedules
Logic Diagrams
Utility Consumption List
Equipment Data Sheets
Weight Data Sheets
Instrument and Process Data Sheets
Instrument/Equipment-Site Mounted (List)
Equipment Terminal Drawing
Performance Guarantee Statement
Design, Manufacturing and Delivery Plan
List of Proposed SUB-SUPPLIERS
Reference List of Previous Supply
Noise Data Sheet
SUPPLIER Document Schedule
MANUFACTURER Catalogue/Literature

B.

1.
2.
3.
4.
5.
6.

Design Information
Drawings and documents within this clause shall provide detail design allow verification of overall compliance with
Purchaser's specification.
X
X
Assembly Drawings
X
Cross-Section Drawings or Views
X
Detail Drawings
X
X
Parts Lists (Technical specification of materials)
Control/Relief Valve Sizing Calculations
X
Flow Element Calculations
X

7.

Schedule of Routine Maintenance Requirement

8.

Control Panel Component List

9.

Tank Calculations

X
X
X
X

X
X
X

X
X
X
X

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

X
X

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10.

General Structural, Deflection and Stress Analysis

11.

Critical Speed Analysis and/or Rotor Response Calculations

12.

Schedule of Manufacturer Recommended Spares for Commissioning/Start-Up and Two


years

X
X

13.

Operation
Weight Calculation Back-Up Sheet

14.

Instrument Hook-Ups

15.

Wiring Diagrams

16.

17.

Spare Parts List and Interchangeability Record (SPIR) and Associated Spare Part
Drawings.
Special Tools, if any

18.

Inspection and Test Plan

19.

Quality Plan

C.

Manufacturing and Testing Procedures

1.
2.
3.
4.
5.
6.
7.
8.

These documents shall demonstrate to Purchaser that manufacturing and testing methods are acceptable.
Surface Cleaning and Painting Procedures
X
Mechanical Run Test Procedures
X
Functional Test/String Test Procedures
X
Performance Test Procedures
X
X
Initial Preservation and Preparation for Shipment/Transport Procedures
Noise Test/Survey Procedure
Vibration Test/Survey Procedures
Hydrostatic Pressure/Leak Test Procedures
X

D.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
E.

Reports Record and Certificates


These documents are required in order to demonstrate that material and equipment comply with specification,
Material (Mill) Certificates
X
Mechanical Run Test Reports
X
Functional Test/String Test Reports
X
Performance Test Reports
X
Certificate of Compliance
X
Noise Test/Survey/Reports
Hydrostatic Pressure/Leak Test Reports
X
Vibration Test Certificates
Ingress Protection Certificates
X
X
Ex. Equipment Hazardous Area Certificates, Electrical and Instrument
Weighing Certificates
Control Panel Test Reports
X
Bought Out Items List
X
X
Shipment Release Note
X
Third Party Certification, Certifying Agency Certification
X
Shipping and Packing Documents
X
Progress Reports
X
List of Contents for Final As-Built Documentation
X
Final As-Built Documentation
X
Instructions for Installations, Operation and Maintenance

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Contract No. 4405-90-2FG
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7.
8.
9.
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These documents shall comprehensively cover the delivered equipment, and shall give personnel at all levels
necessary and sufficient information for safe, correct and efficient installation, operation and maintenance of the
equipment, system and/or plant.
X
Instruction for Lifting and Transport to Fabrication Yard and during Loadout
Instruction for Unpacking, Inspection and Storage
X
Instruction for Installation (Onshore and Offshore)
X
X
Instruction for Preservation during Transport and Storage Before and After Installation
Instruction for Commissioning/Start-Up
X
Instruction for Operation
X
Instruction for Maintenance
X
Lubrication Charts
X
User/Operating Manuals
X
Local Certification Requirements, if required
These documents shall cover all necessary certification requirements as laid down by Local Authority.
Local Certification Requirements for Pressure Vessels
Local Certification Requirements for Lifting Equipment

X
X