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TECHNICAL SPECIFICATION I-ET-3010.00-1200-940-P7V-002


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PROGRAM:
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TITLE:

SUP/SIA/UAP GENERAL TECHNICAL DESCRIPTION

INDEX OF REVISIONS

REV. DESCRIPTION AND/OR AFFECTED SHEETS


0 FOR BID
A Revised as per Circular #2
B Revised as per Circular #3
C Revised as per Circular #6
D Revised as per Circular #7
E Revised as per Circular #8
F Revised as per Circular #9
G Revised as per Circular #11
H Revised as per Circular #12
G
I #11
Revised as per Circular #13
G
J #11
Revised as per Circular #14
K Revised as per Circular #16
L Revised as per Circular #17
M Revised as per Circular #18
N Revised as per Circular #19
O Revised as per Circular #21
P Revised as per Circular #22
Q Revised as per Circular #32
R Revised as per Circular #34
S Revised as per Circular #35
T Revised as per Circular #37

REV. 0 REV. A REV. B REV. C REV. D REV. E REV. F REV. G REV. H


DATE 2017-12-06 2018-02-28
DESIGN SUP/SIA/UAP SUP/SIA/UAP
EXECUTION CJI8/CLW8 CJI8/CLW8
VERIFICATION W0Z5 W0Z5
APPROVAL CMEP CMEP

THE DATA, OR PARTS THEREOF, ARE PETROBRAS PROPERTY AND SHALL NOT BE USED IN ANY WAY WITHOUT THEIR PERMISSION.
THIS FORM IS IN ACCORDANCE WITH PETROBRAS STANDARD N-381 – REV. F
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I N D E X
1. GENERAL .................................................................................................................................................... 7

1.1. INTRODUCTION ..................................................................................................................................... 7


1.2. GENERAL DESCRIPTION ................................................................................................................... 10
1.2.1. REFERENCE DOCUMENTS ........................................................................................................ 10
1.2.2. GENERAL DESCRIPTION ............................................................................................................ 11
1.3. CLASSIFICATION ............................................................................................................................. 1413
1.4. CERTIFICATES, TERMS AND STATEMENTS.................................................................................... 15
1.5. UNIT ACCEPTANCE ............................................................................................................................ 15
1.5.1 PROVISIONAL ACCEPTANCE ...................................................................................................... 15
1.6. RULES, REGULATIONS, STANDARDS AND CONVENTIONS REQUIREMENTS............................ 16
1.7. DOCUMENTATION, UNITS AND IDENTIFICATION OF EQUIPMENT .............................................. 17
1.8. INSPECTIONS, TESTS AND TRIALS .............................................................................................. 1817
1.9. TRANSPORT AND INSTALLATION ..................................................................................................... 18
1.10. HEALTH SAFETY AND ENVIRONMENTAL CERTIFICATION ..................................................... 2019
1.11. MATERIALS .................................................................................................................................... 2019
1.12 UNIT MODELS ................................................................................................................................. 2322

2. PROCESS .............................................................................................................................................. 2322

2.1. FLUID CHARACTERISTIC ............................................................................................................... 2322


2.1.1. PRODUCED OIL AND RESERVOIR ........................................................................................ 2322
2.1.2. PRODUCED WELLS COMPOSITION ...................................................................................... 2524
2.1.3. WELL TEST CHARACTERISTICS ................................................................................................ 26
2.1.4. PRODUCED GAS...................................................................................................................... 2726
2.1.5. PRODUCED WATER ................................................................................................................ 2726
2.2. PROCESS ............................................................................................................................................. 27
2.2.1. EXPORTED OIL ........................................................................................................................ 2827
2.2.2. PRODUCED WATER DISPOSAL ............................................................................................. 2827
2.2.3. LIFT GAS ....................................................................................................................................... 28
2.2.4 EXPORTED GAS ........................................................................................................................... 28
2.2.5 IMPORTED GAS ............................................................................................................................ 28
2.3. SEAWATER INTAKE ............................................................................................................................ 29
2.3.1. COMPOSITION ............................................................................................................................. 29
2.4. WATER INJECTION ............................................................................................................................. 30
2.4.1 SEA WATER INJECTION............................................................................................................... 31
2.4.2 PRODUCED WATER INJECTION ................................................................................................. 32
2.5. DESIGN SUMMARY ............................................................................................................................. 32
2.5.1. WELL DESIGN SUMMARY ........................................................................................................... 32
2.5.2. PROCESS DESIGN SUMMARY ................................................................................................... 33
2.6. OIL & GAS COLLECT SYSTEM ........................................................................................................... 34
2.6.1. TOPSIDE MANIFOLDS AND FLEXIBILITY .................................................................................. 34
2.6.1.1. COILED TUBING OPERATIONAL DESCRIPTION ........................................................................... 4241
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2.7. PROCESS FACILITIES .................................................................................................................... 4342


2.7.1. SEPARATION AND TREATMENT ............................................................................................ 4342
2.7.1.1 SETTLING TANK ................................................................................................................................ 4443
2.7.2. OIL TRANSFER SYSTEM ......................................................................................................... 4745
2.7.3. GAS PROCESS PLANT ............................................................................................................ 4847
2.7.3.1 OBJECTIVES ...................................................................................................................................... 4847
2.7.3.2 DESIGN CASES ................................................................................................................................. 4847
2.7.3.3 PROCESS CONFIGURATION - BASE CASE .................................................................................... 4947
2.7.3.3.1 H2S REMOVAL UNIT ....................................................................................................................... 4948
2.7.3.3.2 DEHYDRATION UNIT – MOLECULAR SIEVES OR TEG (TRY ETHILENE GLYCOL) .................. 5351
2.7.3.4. GAS COMPRESSORS ........................................................................................................... 5957
2.7.3.4.1 VAPOR RECOVERY UNIT (VRU) ................................................................................................... 6058
2.7.3.4.2 MAIN COMPRESSORS ................................................................................................................... 6059
2.7.3.4.3 GAS LIFT / EXPORT COMPRESSORS .......................................................................................... 6159
2.7.3.4.4 COMPRESSORS DRIVERS ............................................................................................................ 6260
2.7.3.5. OTHER REQUIREMENTS ..................................................................................................... 6261
2.7.3.6 - GAS PIPELINE COMMISSIONING ....................................................................................... 6261
2.7.4. NOT APPLICABLE .................................................................................................................... 6361
2.7.5. FLARE AND VENT SYSTEM .................................................................................................... 6361
2.8. CHEMICAL INJECTION.................................................................................................................... 6462
2.8.1. CHEMICAL INJECTION FLOW CONTROL SYSTEM .............................................................. 7068
2.9. SAMPLE COLLECTORS .................................................................................................................. 7169
2.10. CORROSION MONITORING.......................................................................................................... 7371
2.11. LABORATORY ................................................................................................................................ 7471

3. UTILITIES............................................................................................................................................... 7674

3.1. GENERAL ......................................................................................................................................... 7674


3.2. SEA WATER LIFT SYSTEM ............................................................................................................. 7674
3.3. COOLING WATER SYSTEM ............................................................................................................ 7775
3.4. FRESH AND POTABLE WATER SYSTEM ...................................................................................... 7876
3.5. HEATING MEDIUM SYSTEM ........................................................................................................... 7977
3.6. DIESEL SYSTEM .............................................................................................................................. 7977
3.7. SEWAGE SYSTEM ........................................................................................................................... 7977
3.8. NITROGEN GENERATOR SYSTEM OR CRYOGENIC EXPANSION UNIT .................................. 8077
3.9. COFLEXIP® - FLEXIBLE STEEL PIPE FOR SERVICE APPLICATION ......................................... 8078
3.10. DRAIN SYSTEMS ........................................................................................................................... 8179

4. ARRANGEMENT ................................................................................................................................... 8279

4.1. SUPERSTRUCTURE (ACCOMMODATIONS) ................................................................................. 8381


4.2. PROCESS PLANT ............................................................................................................................ 8381
4.3. UTILITY ROOM (ENGINE ROOM) ................................................................................................... 8481
4.4 DIVING AREAS .................................................................................................................................. 8482
4.5 HELIDECK ......................................................................................................................................... 8582

5. HEATING VENTILATION AND AIR CONDITIONING SYSTEMS (VAC) ............................................. 8583


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5.1. GENERAL ......................................................................................................................................... 8583


5.2. HVAC SYSTEMS .............................................................................................................................. 8683
5.3. REFRIGERATION SYSTEM (PROVISIONS) ................................................................................... 8684
5.4. CONTROL AND OPERATION .......................................................................................................... 8684
5.5. VENTILATION OF THE TURRET AREA (NOT APPLICABLE)........................................................ 8684
5.6. REGULATION ................................................................................................................................... 8684
5.7 ELECTRICAL SWITCHBOARD ROOMS (E-HOUSE) ...................................................................... 8784

6. SAFETY ................................................................................................................................................. 8784

6.1. GENERAL ......................................................................................................................................... 8784


6.2. LIFE SAVING APPLIANCES ............................................................................................................ 8785
6.3. FIRE WATER SUPPLY SYSTEM ..................................................................................................... 8785
6.4. ASBESTOS POLICY......................................................................................................................... 8785
6.5. RISK MANAGEMENT ....................................................................................................................... 8785
6.6 - VENT POST LOCATION ................................................................................................................. 8885

7. AUTOMATION AND CONTROL ........................................................................................................... 8886

7.1. GENERAL ......................................................................................................................................... 8886


7.2. CENTRAL CONTROL ROOM (CCR) ............................................................................................... 8987
7.2.1. CONTROL NETWORK ARCHITECTURE AND STANDARD (PI) ............................................ 9088
7.3. CONTROL/INTERLOCKING SYSTEM (CIS) ................................................................................... 9088
7.4. CARGO MONITORING SYSTEM (CMS) ......................................................................................... 9189
7.5. SUBSEA PRODUCTION CONTROL SYSTEM (SPCS) .................................................................. 9189
7.5.1 TYPES OF CONTROL SYSTEM USED BY THE SUBSEA EQUIPMENT ................................ 9289
7.5.2 SPCS MAIN SPECIFICATIONS ................................................................................................. 9492
7.5.3. SPCS UMBILICALS AND TOPSIDE UMBILICAL INTERFACES ............................................. 9997
7.5.4. SPCS OPERATOR INTERFACES .......................................................................................... 10199
7.5.5. SPCS HYDRAULIC POWER UNIT (HPU) ............................................................................ 103101
7.5.6. WELL CONTROL RACK (WCR) FOR DIRECT HYDRAULIC CONTROL SYSTEM ........... 106104
7.5.7. DOWNHOLE DATA ACQUISITION SYSTEM (SAS PANEL) ............................................... 107105
7.5.8. SPECIAL REQUIREMENTS FOR SINGLE POINT MOORING (TURRET) .......................... 108105
7.5.9. PORTABLE UMBILICAL PRESSURIZATION SYSTEM (PUPS) ......................................... 108106
7.5.10. SUBSEA EMERGENCY SHUTDOWN VALVES CONTROL PANEL ................................. 109106
7.6. NOT APPLICABLE ........................................................................................................................ 109107
7.7. METERING ................................................................................................................................... 109107
7.8. CCTV............................................................................................................................................. 116114
7.9. DPRS - DYNAMIC POSITIONNING REFERENCE SYSTEMS ................................................... 116114
7.10. ENV - METOCEAN DATA GATHERING AND TRANSMISSION SYSTEM ............................... 117114
7.11. RMS - RISER MONITORING SYSTEM ...................................................................................... 117114
7.11.1. NOT APPLICABLE .............................................................................................................. 117114
7.11.2. POSITIONING SYSTEM FOR MOORING OPERATION AND OFFSET DIAGRAM .......... 117115
7.11.3. MODA RISER MONITORING SYSTEM.............................................................................. 118115
7.11.4. ANNULUS PRESSURE MONITORING AND RELIEF SYSTEM ........................................ 118116
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8. ELECTRICAL SYSTEM ..................................................................................................................... 119116

8.1. GENERATORS ............................................................................................................................. 120117


8.1.1. MAIN GENERATORS............................................................................................................ 120117
8.1.2. EMERGENCY GENERATOR ................................................................................................ 121118
8.2. DISTRIBUTION SYSTEM ............................................................................................................. 121119
8.2.1. POWER DISTRIBUTION ....................................................................................................... 121119
8.2.2 POWER TRANSFORMERS ................................................................................................... 122119
8.3. LOW VOLTAGE SYSTEM ............................................................................................................ 122119
8.4. UNINTERRUPTIBLE POWER SUPPLY (UPS) AC AND DC ....................................................... 122120
8.4.1. UPS FOR AUTOMATION/INSTRUMENTATION SYSTEM .................................................. 122120
8.4.2. VDC SYSTEM ....................................................................................................................... 123120
8.5. ELECTRICAL STUDIES ............................................................................................................... 123120

9. EQUIPMENT ...................................................................................................................................... 123121


9.1. NOISE AND VIBRATION.......................................................................................................... 124121
9.1.1. NOISE .................................................................................................................................... 124121
9.1.2. VIBRATION ........................................................................................................................... 124121
9.2. HOISTING AND HANDLING SYSTEMS .................................................................................. 124121
9.2.1. CRANES ................................................................................................................................ 125122

10. TELECOMMUNICATION ................................................................................................................. 125122

11. STRUCTURE AND NAVAL DESIGN .............................................................................................. 125122


11.1. LOAD REQUIREMENTS ........................................................................................................ 125122
11.2. CONVERSION SURVEY (If applicable) ................................................................................. 126123
11.2.1 PLATE REPLACEMENT CRITERIA .................................................................................... 126123
11.3. MATERIALS ........................................................................................................................... 129126
11.4. WEIGHT CONTROL PROCEDURES .................................................................................... 129126
11.5. STABILITY ANALYSIS ........................................................................................................... 129126
11.6. HULL ....................................................................................................................................... 130126
11.6.1. TURRET AND CARGO TANK INTERFACE ....................................................................... 131127
11.6.2. RISERS BALCONY AND CARGO TANK INTERFACE (Spread Mooring Option) ............. 131127
11.6.3. PROCESS PLANT DECK STRUCTURE ............................................................................ 131128
11.6.4. CATHODIC PROTECTION AND PAINTING....................................................................... 131128
11.6.5. CARGO AND BALLAST TANKS STRUCTURAL INSPECTION ........................................ 132128
11.6.6. HULL EXTERNAL INSPECTION ........................................................................................ 132129
11.7. FATIGUE ASSESSMENT REQUIREMENTS ........................................................................ 132129
11.8. MOTION ANALYSIS ............................................................................................................... 132129
11.8.1. GENERAL ............................................................................................................................ 132129
11.8.2. NOT APPLICABLE .............................................................................................................. 133129
11.8.3. RAO – RESPONSE AMPLITUDE OPERATOR .................................................................. 133129
11.8.4. VERTICAL LIMITATION FOR RISERS ............................................................................... 134130
11.8.5. MODEL TESTS ................................................................................................................... 134131
12. OPERATIONAL CONDITIONS ................................................................................................. 134131
12.1. MAXIMUM DESIGN CONDITION .......................................................................................... 134131
12.2. MAXIMUM OFFLOADING DESIGN CONDITION .................................................................. 135132
12.3. BEAM SEA CONDITION ........................................................................................................ 135132
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12.4. MAXIMUM PULL-IN / PULL-OUT ENVIRONMENTAL CONDITION ..................................... 136132


12.5. MOTIONS AND ACCELERATIONS DESIGN CONDITIONS ................................................ 136133
12.5.1. NORMAL OPERATION AND EXTREME CONDITIONS .................................................... 136133
12.5.2. OPERATIONAL CONDITION FOR UTILITIES ................................................................... 137134
12.5.3. FOUNDATIONS AND FASTENINGS STRUCTURAL REQUIREMENTS .......................... 137134

13. MOORING ........................................................................................................................................ 137134

14. FLEXIBLE RISERS .......................................................................................................................... 138134


14.1. RISERS CHARACTERISTICS ............................................................................................... 138134
14.2. RISERS INSTALLATION AND DE-INSTALLATION PROCEDURES ................................... 139136
14.3. RISER HANGOFF AND PULLING SYSTEMS ....................................................................... 140136

15. SOIL DATA ...................................................................................................................................... 140137

16. MARINE SYSTEMS AND PIPING ................................................................................................... 140137

17. ENVIRONMENT IMPACT STUDIES ............................................................................................... 140137


17.1. GENERAL ............................................................................................................................... 141137
17.2. GENERAL DESCRIPTION ..................................................................................................... 141138
17.3. EFFLUENT ............................................................................................................................. 142139
17.4. ATMOSPHERIC EMISSIONS ................................................................................................ 142139
17.5. WASTE MANAGEMENT ........................................................................................................ 143140

18. PETROBRAS LOGOTYPE .............................................................................................................. 143140


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1. GENERAL

1.1. INTRODUCTION

The intent of this specification and documents referenced hereinafter is to provide the
CONTRACTOR with general information of intended service and requirements for the design,
construction, (conversion or re-deployment), assembly, transport, installation and operation of one
Floating Production Storage and Offloading System (FPSO), also called “the Unit” in this
document. The complete outfitted and equipped Unit shall be installed offshore Brazil.
The Unit design life shall be at least 34 years. During the Contract period, the Unit shall be
adequate for uninterrupted operation, without the need of dry-docking. Fatigue life and hull
substantial corrosion criteria used during the design shall comply with the CS (Classification
Society) requirements and Structure and Naval Design requirements (chapter 11), in order to
allow continuous offshore operation during its contract period, with no dry-docking in a shipyard. In
addition, the Unit shall be fitted with facilities that enable any maintenance required during the
operational lifetime as well as the surveys required by the CS, Port Administration or Flag
Statutory requirements without affecting the production/processing capacity of the Unit.
The Unit’s accommodation size shall be compatible with the POB required to accomplish the
CONTRACTOR’s operation, maintenance and asset integrity management plans.
All requirements herein provided must be considered as a minimum, according to the terms
agreed upon in the Contract.
All CS, Brazilian Administration and Flag Administration requirements for the Unit shall be
complied with. These requirements are included in CONTRACTOR’s scope of work and take
precedence over PETROBRAS’ Technical Requirements in case of discrepancies.
The Unit shall enable surface diving, supervised, operated and supplied from the Unit, according
to requirements issued by the Administration and NR-15 (“Norma Regulamentadora”) issued by
the Brazilian Labor and Employment Ministry (“Ministério do Trabalho e Emprego”). Any Unit
related diving operation shall fall under CONTRACTOR’s responsibility.
This document shall be read together with all technical documents. In case of conflicting
information between this GENERAL TECHNICAL DESCRIPTION and other technical document,
this specification shall prevail. In case of conflicts between GTD and SAFETY GUIDELINES FOR
OFFSHORE PRODUCTION UNITS, PETROBRAS shall be consulted.
This GENERAL TECHNICAL DESCRIPTION provides necessary information for the development
of the Basic and Detailed Design. However, they do not exempt CONTRACTOR from contractual
responsibilities during operation lifetime. CONTRACTOR shall be responsible for the provision of
all services and other requirements necessary to deliver one complete functional Production Unit
as described herein. Any calculation presented in this document is preliminary and shall be
reviewed during the Detail Design Phase.
In all documents, the word “shall” and equivalent expressions like “is to”, “is required to”, “has to”,
“must” and “it is necessary” are used to state that a provision is mandatory.
In all documents, the verb “consider” and “foresee” and all their forms (considered, considering,
etc.) are used as “taking into account” and state that a provision must be complied with.
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Unless otherwise expressed, any reference to “CONTRACTOR responsibility” or


“CONTRACTOR’s responsibilities” means that the CONTRACTOR will design, supply, install,
operate and maintain according to the Contract provisions with no commercial interference or
responsibility from PETROBRAS.
PETROBRAS, at their sole discretion, may accept or not any solution that is different from those
herein specified.
In all technical documents provided by PETROBRAS (e.g. GTD and its annexes, technical
clarification) the expression "PETROBRAS approval" implies PETROBRAS intention to technically
interfere in the design development, at their sole discretion.
PETROBRAS “approval” or "comments" on the documents shall not exempt CONTRACTOR from
responsibility to carry out the work in accordance with contractual and legal requirements.
The design of the Unit shall be based on field proven solutions and PETROBRAS, at their sole
discretion, have the right to reject any detail of the Unit’s design.
CONTRACTOR shall address the need of stand-by equipment for systems which requires full
capacity on continuous operation, ready to operate, in order to guarantee no process capacity
reduction or degradation of the oil, gas and water specification. CONTRACTOR shall also comply
with stand-by philosophy for equipment whenever specifically required on this General Technical
Specification.
CONTRACTOR shall develop all necessary Engineering Design work (design details, workshop
drawings, specifications, etc.) in order to deliver the complete Unit, which in all aspects, shall be
ready for the intended service on arrival in Brazil according to the Contract provisions. No type of
completion work offshore shall be accepted, unless it strictly depends on produced gas, according
to the terms of the Contract.
The Unit, as delivered, shall be completed with all its parts and appurtenances proven to be
thoroughly workable as specified. The Unit shall be seaworthy and able to perform its designed
functions as specified.
CONTRACTOR is responsible for any infringement of patents related to its scope of work in Brazil
and in any other countries where work will be carried out.
CONTRACTOR shall promptly inform PETROBRAS about any amendments of rules and
regulations and consequences thereof during the Contract term.
CONTRACTOR shall provide PETROBRAS representative with free access to services in
progress. PETROBRAS shall be allowed to take part in technical discussions with the Consultant
Company at least in the stages of basic assumptions definition, equipment and system modeling,
discussion of results and analysis of proposed corrective actions.
Before construction (conversion) starts, CONTRACTOR shall prepare and issue to PETROBRAS
the construction planning with the schedule, activities and all resources to be utilized.
During the execution phase, CONTRACTOR shall issue monthly reports on planning update with
remarks about delayed activities. The project schedule, with all activities or tasks precedence
links, also shall be sent in editable "Oracle - Primavera P6 Professional Project Management" file
format (.xer). The procurement item list should be sent in editable Microsoft Excel file format.
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The following items shall be included in the monthly report:


 Progress “S” curves (overall, engineering, procurement and construction).
 Description of the main activities performed during the status report period;
 CONTRACTOR’s points of concern with monthly follow up;
 Milestones to be identified under HOA (heads of agreement). Those milestones progress
shall have the planned, forecast and actual dates, as well as any deviation between
planned date and actual date or planned date and forecast date;
 Regulatory Compliance Schedule/Report in other to demonstrate that all aspects related to
Brazilian Authorities and Regulations are being addressed and in compliance;
 HSE Studies/Assessments status: planned activities, follow up and tracking register
regarding action items form HAZID, HAZOP and other studies;
 Procurement status, including items delayed and comments informing the impact of the
delay;
 HSE activities and statistics, areas of concern and look ahead for the next month
activities. HSE statistics should be provided separated by main subcontractors and site,
and one for the overall project. HSE statistics (items to be agreed during Kick-off meeting)
should be provided for the following period: Month under analysis, Year to date, and Total
Cumulative. All rates should be calculated per 1.000.000 men hours. Injuries / Illness
definition. Contractor shall follow classification rules established by OSHA Recording
Keeping Handbook: OSHA 3245-09R 2005;
 During construction, integration and commissioning activities, CONTRACTOR shall apply
good practices related to safety in construction sites. CONTRACTOR shall assess the
status of implementation of such practices. PETROBRAS recommends applying IOGP
Report 577 / 2017 – “Fabrication Site Construction Safety Recommended Practices”.
CONTRACTOR shall inform PETROBRAS assessment schedule 30 days in advance, and
PETROBRAS, at its solely discretion, may participate in the assessments. An initial
assessment shall be carried out at the beginning of construction activities and after that
every 6 months. All assessments shall be submitted to PETROBRAS for
comments/information. Action Plans shall be created by CONTRACTOR based on gaps
assessed as findings and the associated recommendations actions shall be tracked and
reported to PETROBRAS;
During construction-integration-commissioning phases, the report shall include detailed run down
curves of the main activities (piping spools and cables installation, piping hydrostatic tests and
reinstatement, cable termination, loop tests, subsystems mechanical completion and
commissioning etc.) and missing materials/equipment control tables.
An updated mobilization plan for all factory service representatives (FSRs) from equipment
manufacturers (vendors), scheduled during the pre-operation and technical assistance phase for
all operating systems shall be provided.
Additionally, CONTRACTOR shall provide:
 Access to its document filing system;
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 High quality photos of the construction/conversion phase;


 Petrobras shall receive full copies of CAE databases (diagrams, instrumentation design
and 3D model), as well as 3D Model of the whole Unit with accessible format or its proper
viewer software, containing all engineering data as per CONTRACTOR's standard,
updated after final FPSO delivery. In case of any major modification on the FPSO during
operational phase, CAE databases shall be updated.
 Commissioning and preservation philosophy;
 The overall FPSO commissioning schedule and procedures for information. The
commissioning procedures shall be approved by CONTRACTOR’s (pre) operational team.
Operational procedures shall be signed-off before starting the system offshore operations.
 Qualitative and Quantitative Risk Assessment on the FPSO Provisional Acceptance dates
at each 4 (four) month period.

1.2. GENERAL DESCRIPTION

1.2.1. REFERENCE DOCUMENTS

Throughout this document, the following Technical Specifications and drawings are referenced:
Table 1.2.1.1: Referenced documents list.
# Number Rev. Title
01 I-ET-3000.00-1000-941-PPC-001 D METOCEAN DATA - CAMPOS BASIN
POLYESTER ROPE FOR OFFSHORE
02 DR-ENGP-I-1.9_R2 1
STATION KEEPING
SPREAD MOORING & RISER SYSTEMS
03 I-ET-3534.00-1350-274-PLR-002 G
REQUIREMENTS
SAFETY GUIDELINES FOR OFFSHORE
04 I-ET-3010.00-5400-947-P4X-001 D
PRODUCTION UNITS
OFFSHORE LOADING SYSTEM
05 I-ET-005 J
REQUIREMENTS
06 I-ET-007 D TELECOMMUNICATIONS SYSTEM
REQUIREMENTS OF METEOCEAN DATA
07 I-ET-3534.00-5521-931-PEA-002 A
ACQUISITION SYSTEM
08 I-ET-3010.00-1300-279-PPC-203 0 BELL MOUTH SUPPLY SPECIFICATION
09 I-LI-3010.00-1300-279-PPC-003 H BELL MOUTH PART LIST DRAWINGS
ANNULUS PRESSURE MONITORING AND
10 I-ET-3010.00-5529-812-PAZ-001 E
RELIEF SYSTEM
ET RISER TOP INTERFACE LOADS
11 I-ET-3010.00-1500-274-PLR-001 C
ANALYSIS
FPSO MARLIM MOD 1 LOCATION AND
12 SL-M1 0
CORALS
13 I-ET-3558.00-5530-850-PEA-001 A POSITIONING AND NAVIGATION SYSTEMS
14 I-ET-3010.00-5529-854-PAZ-005 A MODA RISER MONITORING SYSTEM
15 I-DE-3534.00-1500-741-P56-002 A RISERS SUPPORTS ARRANGEMENT
COIL TUBING REQUIREMENTS – BLOCK
16 DE-3534.00-1223-941-PQC-001 0
DIAGRAM
PROCESS FLOW DIAGRAM TOPSIDE
17 I-DE-3534.00-1223-941-PP6-002 0
MANIFOLD
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WAVE SPREAD PARAMETER FOR SANTOS


18 I-RL-3A26.00-1000-941-PPC-001 A BASIN (TO BE USED ALSO FOR CAMPOS
BASIN)
UNIDADE HIDRÁULICA (HPU) PARA
EQUIPAMENTOS SUBMARINOS QUE
PODERÃO ESTAR EQUIPADOS
COM SISTEMA DE CONTROLE ELETRO-
HIDRÁULICO MULTIPLEXADO OU SISTEMA
19 ET-3000.00-5139-800-PEK-007 0
DE CONTROLE ELETRO-HIDRÁULICO
DIRETO, EM QUALQUER COMBINAÇÃO, E
QUE REQUEREM ATÉ 5000PSI DE
PRESSÃO MÁXIMA DE ATUAÇÃO (HPU-
FLEX 5000)
DADOS PARA O PROJETO DE HPU DOS
20 FD-3534.00-1500-941-PH8-005 0 EQUIPAMENTOS SUBMARINOS DO FPSO
MÓDULO 2 DE MARLIM”
21 I-ET-3010.1R-5330-940-P4X-001 B PRODUCED WATER SYSTEM
Note 1: Will be confirmed at kick-off meeting;
Note 2: The Subsea Layout will be made available until kick-off meeting.
1.2.2. GENERAL DESCRIPTION

The Unit shall be a vessel provided with a topside crude oil process plant and gas process plant.
The Unit shall be capable to be moored offshore Brazil, at a location with water depth up to 927
meters considering the METEOCEAN DATA (see item 1.2.1). As a brief overview, the Unit will
receive the production from subsea oil wells and shall have production plant facilities to process
fluids, stabilize them and separate produced water and natural gas. Processed liquids will be
metered, stored in the vessel cargo storage tanks and offloaded to shuttle tankers.
Produced gas shall be compressed, dehydrated, treated and used as a fuel gas for the FPSO and
lift gas for the subsea production wells. Surplus gas will be exported through a gas pipeline to
PETROBRAS gas pipeline system.
Produced water will be disposed overboard to comply with CONAMA requirements or will be re-
injected. Please refer to document I-ET-3010.1R-5330-940-P4X-001 (See item 1.2.1)
CONTRACTOR shall consider the SUBSEA LAYOUT documents (see item 1.2.1) for a Spread
Moored FPSO.
The Process Plant shall have the following capacity:
Table 1.2.2.1 Process plant capacities.
Parameter Capacity
Total Maximum Liquids 39,750 Sm3/d
Total Maximum Oil 11,130 Sm3/d
Total Produced Water 32,000 Sm3/d
Total De-Sulphated Sea Water Injection 38,000 Sm3/d
Total Gas Handling, including lift gas, treatment and compression 4,000,000 Sm3/d
The riser balcony of the Unit shall be designed on the Port side, with guide tubes or receptacles
and a support for the upper balcony installed on the Hull upper side.
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PETROBRAS highlights this is a preliminary plan. It can be changed up to Kick-off Meeting.


CONTRACTOR shall consider that risers can come from portside and/or starboard side of Unit
CONTRACTOR shall consider:
The riser balcony of the Unit shall be designed in order to connect the flexible risers listed in table
1.2.2.2:

Table 1.2.2.2 Risers details


Risers Function Total Comments
The production risers will be
6" ID Oil Production 7
flexible, 7 slots required
Satellite Oil
Gas lift risers will be flexible,
Production Wells 4” ID Gas Lift/Service 7
7 slots required
(Total of 7 wells)
Umbilicals will be TPU
UEH Control 7
(Thermoplastic Umbilical)
The production risers will be
9" ID Oil Production 4
flexible
Oil Production 6" ID Gas Lift/Service 4 Gas lift risers will be flexible
Manifolds (Total of 4 The production test risers will
Oil Production 6" ID Oil Production Test 4
be flexible
Manifolds for 16 The gas lift test risers will be
wells) 8" ID Gas Lift Test 4
flexible
Umbilicals will be TPU
UEH Control 4
(Thermoplastic Umbilical)
The water injection risers will
Satellite Water 6" ID Water Injection 1
be flexible
Injection Wells (Total
Umbilicals will be TPU
of 1 wells) UEH Control 1
(Thermoplastic Umbilical)
Water Injection
Manifolds (Total of 3
The water injection risers will
Water Injection 8" ID Water Injection 3
be flexible
Manifolds for 18
wells)
Umbilicals will be TPU
UEH Control 3
(Thermoplastic Umbilical)
Fiber Optic CO Communication 1 For Platform communication
The gas import/export line will
8" ID Gas Import/Export 1
be flexible
The gas import/export line will
Gas Import/Export 9.125" ID Gas Import/Export 1
be flexible
Umbilicals will be TPU
UEH SESDV control 2
(Thermoplastic Umbilical)
TOTAL 54
For riser details please refer also to I-ET-SPREAD MOORING & RISERS SYSTEM
REQUIREMENTS (see item 1.2.1).
CONTRACTOR shall size the topsides manifolds as indicated in I-DE-3534.00-1223-941-PP6-001
(see item 1.2.1).
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In summary, the Unit shall have the following main characteristics:


 Ship shaped or barge shaped unit of Suezmax size or greater, with a minimum storage
capacity of 1,000,000 bbl of crude oil. For this purpose, storage capacity is defined as the
minimum volume of oil available to be offloaded. The amount of oil considered as
permanent ballast, if necessary, shall be added to this value;
 To calculate the "volume of oil available to be offloaded" the Contractor shall proceed as
follows:
1) One condition approved by the Classification Society of maximum loading of oil shall
be included in the "Trim and Stability booklet"
2) One condition of minimum loading safe operational condition approved by the
Classification Society shall be included in the "Trim and Stability booklet".
3) The "volume of oil available to be offloaded" is to be calculated as follows:
(Volume of oil available to be offloaded) = (Oil capacity in the maximum loading
condition - Oil Capacity in the minimum loading safe operational condition)
4) The volume of oil available to be offloaded shall be equal or greater than
1,000,000bbl.
 Offloading system, including hawser and export hose, as specified in the document
OFFSHORE LOADING SYSTEM REQUIREMENTS (see item 1.2.1)
 Process plant, comprising deck structure, safety facilities, steel flare tower or flare boom,
equipment for oil processing, associated gas treatment, gas compression, gas exportation,
water treatment and water injection, etc.;
 Utilities necessary to keep the Unit’s standalone operation capacity, according to Contract
terms;
 Power generation system to meet all the needs of the Unit, based on dual fuel gas turbine-
generators;
 Gas compression plant comprising high-pressure centrifugal compressors driven by gas
turbines or electric motor;
 Accommodation for normal operation crew, maintenance technicians required for
contracted performance and for PETROBRAS representatives;
 Spread Mooring System;
 Facilities to connect risers for oil production, gas-lift, water injection, gas export and control
umbilical;
 Cargo handling systems, including cranes, monorails, rail cars, etc.;
 Helideck, suitable for Sikorsky S-61, S-92, Agusta AW-139 and Eurocopter EC 225
helicopter landing;
 Telecommunication facilities;
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 The Unit shall be designed to withstand the environmental conditions stated in the I-
METOCEAN DATA (see item 1.2.1).
1.3. CLASSIFICATION

CONTRACTOR shall contract a single Classification Society to follow and approve the whole
project from the basic design to the decommissioning. The CS shall also consider all construction
loads and the environmental loads during transportation from construction/conversion shipyard to
Brazil and, after decommissioning, from Brazil to a point outside its territory. The CS shall consider
those conditions for the final approval of the Unit design. CONTRACTOR shall also contract the
same CS for the classification and statutory survey of the Unit. The CS’s Contract shall clearly
specify that the Unit shall comply with all requirements for continuous operation during its
operational lifetime, as stated in item 1.1, at the site without the need to be dry-docked in a
shipyard.
Acceptable CSs are DNV (Det Norske Veritas), BV (Bureau Veritas), ABS (American Bureau of
Shipping), and LRS (Lloyd’s Register of Shipping).
The scope of the work shall be carried out in accordance with the requirements of this document,
CS Rules and Brazilian and Flag Administration requirements. All relevant aspects in design and
construction phases, shall consider the stated operational lifetime.
As stated above, the contract between CONTRACTOR and CS shall comprise the design,
construction, installation on site, operation and decommissioning phases. This CS shall be the
same during all project phases.
The Unit shall obtain Class notation for the following items:
 Vessel structure, equipment and marine systems;
 Permanent mooring system;
 Production facilities and utilities;
 Fuel gas system;
 Oil storage;
 Offloading;
 Inert gas system;
 Automation and control systems;
 Centralized Control Room Operation;
 Lifting Appliances.
Note: Riser system Classification is not part of CONTRACTOR’s scope of work.
PETROBRAS intention is to have the CONTRACTOR assisted by the CS to ensure that the
engineering practice, construction work and operation of the Unit comply with the rules and
regulations.
In the CS contract, CONTRACTOR shall, clearly, establish the following items as minimum
requirements:
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 Permission for the CS to inform PETROBRAS or notify directly, under PETROBRAS’


formal request, the Classification status regarding pending and/or outstanding items and
any other relevant information about the Unit;
 CONTRACTOR shall promptly inform PETROBRAS about all changes in the rules and
regulations that will affect this project;
 CONTRACTOR shall promptly inform PETROBRAS of any CS rule or regulation that have
not been fulfilled by CONTRACTOR, even though the CS has exceptionally waived it;
 CS shall review and approve the Unit Operation Manual issued by CONTRACTOR.

1.4. CERTIFICATES, TERMS AND STATEMENTS

CONTRACTOR shall submit to PETROBRAS whenever required an electronic copy of any FPSO
Terms and Certificates issued by Classification Society and Authorities (included but not limited to
Flag Authority, Brazilian Authority, etc.). The originals shall also be made available or accessible
to PETROBRAS, whenever required during the execution and operational phase.
1.5. UNIT ACCEPTANCE

1.5.1 PROVISIONAL ACCEPTANCE

PETROBRAS will issue the Unit’s Provisional Acceptance Term in Brazil. The Provisional
Acceptance is a PETROBRAS acknowledgement that Unit has the minimum conditions to sail-
away from anchorage (sheltered waters) and proceed on the offshore installation. The provisional
acceptance will be issue as far the following is met:
a) Health Authorities (ANVISA) inspection and clearance;
b) Federal Police inspection and clearance;
c) Customs inspection and clearance
d) CERTIFICATES, TERMS AND STATEMENTS referenced in item 1.4 being issued;
e) Port States Control Inspection report performed without impeditive items for offshore
installation including “AIT” (Atestado de Inscrição Temporária) certificate;
f) PETROBRAS Tests (Note 1) being performed;
g) Mooring System provisionally accepted without critical outstanding item (Note 2);
h) Pull-in System provisionally accepted without critical outstanding item (Note 2);
i) System necessary for the First oil provisionally accepted without critical outstanding (Note 3);
Note 1:
 Outstanding items raised in the PETROBRAS Tests shall be closed-out on due dates
mutually agreed with Contractor.
 All PETROBRAS Tests shall be performed using only facilities installed onboard, with no
external resources. If any specific test could only be conducted using external hardware
resources, for example a pigging simulation, it shall be conducted during the construction
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or conversion phase, at the yard. Sixty days prior to the commissioning phase
PETROBRAS will inform which tests can only be carried out at the shipyard.
 The PETROBRAS Tests will evaluate safety, utilities such as power generation, water
intake, refrigeration, and injection plant, Central Control Room operation as well as some
spot-check of looping-tests and process plant simulations.
 An example of a PETROBRAS Test to be performed is the black start-up test of the whole
system where the time to normalize the operation is checked and shall be less than 20
(twenty) minutes (time required for the Unit to be ready to start operation of the process
plant).
 The scope of PETROBRAS TESTS will be mutually agreed with CONTRACTOR.
CONTRACTOR shall have no commercial complaints regarding the time spent to
implement all tests required by PETROBRAS.
Note 2:
 Critical outstanding item is any condition that will cause a delay in mooring installation and
riser pull-in operation.
Note 3:
 Critical outstanding item is any condition that cannot be closed-out in parallel to the
mooring and pull-in operations, and therefore would delay the first oil milestone.
1.6. RULES, REGULATIONS, STANDARDS AND CONVENTIONS REQUIREMENTS

The Unit shall be designed, built and operated in accordance to the international rules approved
by the International Maritime Organization (IMO). All such CODES and CONVENTIONS are
turned into law in Brazil and in the intended flag country.
RULES shall be complied with where applicable and shall include any amendment and/or revision
in force on the date of SERVICE Contract signature.
The Unit shall be designed to be registered under a convenient flag and it is CONTRACTOR’s
obligation to comply with the rules and regulations stated by Flag and Brazilian Authorities (see
also item 1.8) INSPECTION, TEST AND TRIALS).
The following philosophy shall be used for FPSO design:
 CONTRACTOR shall cope with Classification Society requirements in order to obtain and
keep the FPSO Class Notation as specified in Item 1.3.
 CONTRACTOR shall cope with any codes and/or regulations prescribed within the
Classification Society Rules.
 In case Classification Society has no specific requirements, then CONTRACTOR shall
consider API RP 14C, API 521, ISO 10418, ISO 21457, ISO 13702, and ISO 17776.
In such cases alternative codes will be accepted if applicable.
 CONTRACTOR shall cope with specific design requirements whenever specifically
mentioned on this GTD.
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Piping and valves design, materials fabrication, assembly, erection, inspection and testing shall
fully comply with ASME-B31.3, and CS rules. Piping system layout, design, structural and fatigue
analysis are required. Special attention shall be taken, but not limited to, well production lines,
vents/drains of hydrocarbon system and other lines subjected to vibration (e.g. compression/pump
systems and vibration dead leg), including small line diameters. Regarding such subject, the
compliance to NORSOK L-002 is required. CONTRACTOR shall comply in all stages of the
Contract with applicable rules from Brazilian Labor and Employment Ministry (“Ministério do
Trabalho e Emprego”), specially but not limited to the “Normas Regulamentadoras” NR-3, NR-10,
NR-12, NR-13, NR-15, NR-17, NR-26 and NR-30.
CONTRACTOR shall fully comply with all applicable Brazilian regulation during UNIT construction,
specially but not limited to:
 National Agency of Petroleum, Natural Gas and Biofuels (Agência Nacional do Petróleo,
Gás Natural e Biocombustíveis) (ANP);
 Health Authorities (Agência Nacional de Vigilância Sanitária) (ANVISA);
 Health Ministry (Ministério da Saúde);
 National Council of Environment (Conselho Nacional do Meio Ambiente) (CONAMA);
 Environment Authorities (Instituto Brasileiro do Meio Ambiente e Recursos Naturais
Renováveis) (IBAMA).
 Diretoria de Portos e Costas (DPC);
 Brazilian Navy (Marinha Brasileira);
 Brazilian Labor Ministry (Ministério do Trabalho), including all applicable “Norma
Regulamentadora”.
During contract period, if at any time, CONTRACTOR is submitted to external audits, or
inspections, PETROBRAS shall receive, whenever requested, a copy of the pending list with
action plans to resolve each item.
1.7. DOCUMENTATION, UNITS AND IDENTIFICATION OF EQUIPMENT

The metric system complying with ISO standard, as far as practicable shall be used for equipment,
machinery and fittings identification and data.
Standard conditions are defined as follows:
 Sm3 @ 15.6ºC and 101.3 kPa(a);
 m3 @ 20ºC and 101.325 kPa(a), as per ANP metering regulation requirement.
CONTRACTOR shall issue to PETROBRAS for information the Unit design documentation as well
as the “AS BUILT” documentation.
All Unit identification, signs and documents shall be written according to the Brazilian
Administration and Flag Authorities requirements.
Operation manual and operational procedures shall be available in Portuguese language, updated
considering the latest version of the design and including risk management follow up as per safety
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studies. If required by Regulatory Agencies, the documentation part of Regulatory Compliance


requirements shall be provided in Portuguese language. This documentation shall be kept
updated during all life cycle of the FPSO.
1.8. INSPECTIONS, TESTS AND TRIALS

CONTRACTOR shall carry out inspections, tests and trials during construction of the Unit in
accordance to the latest inspection standards and CS guidelines, technical specifications and test
procedures, which shall be submitted for CS’s approval.
Special attention shall be given to the testing of pressure vessels, heat exchangers, boilers and
piping. Tests shall be carried out in presence of CS’s representatives, which will issue a test
certificate to meet the requirements of NR-13 (“Norma Regulamentadora”) from the Brazilian
Labor Ministry (“Ministério do Trabalho e Emprego”).
1.9. TRANSPORT AND INSTALLATION

CONTRACTOR shall be responsible for the Unit’s transportation to the specified site location,
according to the Contract terms and conditions.
CONTRACTOR shall be responsible for engineering and Marine Warranty Survey activities for
transportation in general.
CONTRACTOR shall be responsible to provide towing bridles whenever necessary as well as
cables/wires/chain to assist FPSO positioning using PETROBRAS towing boats.
In case the FPSO keeps its own propulsion for navigation, after arrival on location rudder shall be
permanently locked or removed.
If CONTRACTOR decides to use the FPSO main engine to move to site location, then the bunker
required for transportation from integration yard or sheltered waters to the final site location will fall
under CONTRACTOR’s scope.
PETROBRAS will provide towing and scout AHTSs from sheltered water (upon arrival in Brazil to
start Contract) to the final offshore site location. These boats will be mobilized by PETROBRAS
upon Unit arrival at anchorage point. Pilots for the PETROBRAS towing and scout boats,
whenever required, falls under PETROBRAS scope of supply.
Harbor tugs and Pilots for the FPSO whenever required to will fall under Contractor’s scope.
The conditions stated in NORMAM-20 (Ballast Water Management and Control) and IMO
Resolution MEPC.207(62) shall apply, if the Unit is transported from a site outside Brazilian waters
using seawater as ballast.
If the Unit is transported from a site outside Brazilian Waters, CONTRACTOR shall ensure the hull
to be free of marine growth/biofouling as follows:
(i) Hull and niche areas cleaning shall be performed and properly reported within 30 days before
sailing to Brazilian Waters. Cleaning reports with cleaning method description and photos after
cleaning shall be submitted to PETROBRAS appraisal, and shall be attested be signed by a
qualified professional, as biologists or oceanographers, capable to state that the hull and all niche
areas are free of macrofouling. CONTRACTOR shall also deliver to PETROBRAS videos and
photos of all the cleaning process in a separate report.
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(ii) Monthly under water hull and niche area cleaning to be performed during the hull stay at
Brazilian yard, or sheltered waters (whenever those areas have proven occurrence of sun coral in
order to prevent any marine growth/biofouling. Cleaning reports as per item (i) shall be performed.
(iii) In any other areas, CONTRACTOR shall evaluate the best way to prevent and ensure the hull
and niche areas will be free of sun coral before sail away to final location or other regions. If the
presence of sun coral is confirmed than hull and niche areas cleaning shall be performed,
following the requirements of the competent environmental agency and the Brazilian legislation.
Cleaning report with cleaning method description and photos after the cleaning shall be submitted
to PETROBRAS appraisal, and shall be attested and signed by a qualified professional, as
biologists or oceanographers, capable to state that the hull and all niche areas are free of sun
coral. CONTRACTOR shall also deliver to PETROBRAS videos and photos of all the cleaning
process in a separate report.
(iv) Within 30 days before sail away to final location or other regions CONTRACTOR shall perform
hull and niche areas inspection in order to confirm that the hull and niche areas are free of sun
coral. Inspection report with inspection method description and photos shall be submitted to
PETROBRAS appraisal, and shall be attested and signed by a qualified professional, as biologists
or oceanographers, capable to state that the hull and all niche areas are free of sun coral.
CONTRACTOR shall also deliver to PETROBRAS videos and photos of all the cleaning process
in a separate report.
Additionally, during operation phase CONTRACTOR shall issue reports to monitor the presence of
sun coral, those reports shall be issued whenever CONTRACTOR performs underwater survey
inspections required by class or other statutory/regulatory agency.
CONTRACTOR shall execute another Hazards Identification (HAZID) study focusing on the risks
associated to the transportation of the Unit from the shipyard to Brazil.
At the end of the Contract, handling and removal of the Mooring System from the specified site will
be performed by PETROBRAS. PETROBRAS will deliver the mooring system at a place that will
be mutually agreed with CONTRACTOR. CONTRACTOR shall dispose/transport the mooring
system according to tax/legal regulation. CONTRACTOR shall transport the mooring system from
this place to outside Brazilian jurisdictional waters (minimum of 200 miles from the Brazilian
coast).
CONTRACTOR shall provide an emergency mooring system in accordance to CS`s and Brazilian
Naval Authorities requirements. This system shall be similar to the mooring system required for a
ship of similar size under the CS’s normal “Steel Vessel Rules” and is intended for use in shallow
coastal waters and harbors.
CONTRACTOR shall answer for all onboard mooring and risers’ installation procedures and shall
supply all devices and facilities onboard to perform mooring and riser pull-in and pull-out
connections. CONTRACTOR shall be able to perform these onboard operations 24 hours a day
with skilled crew working simultaneously at two different mooring clusters. CONTRACTOR shall
provide handling devices which include pull-in winches, mooring winches/chain-jacks, auxiliary
winches, snatch blocks, sheaves, pull-in wires, guide tubes if any, and all devices and facilities for
mooring and risers’ installation as well as accessories to be used in those operations (messenger
lines, etc.). In addition, CONTRACTOR shall answer for any diver assistance during the mooring
and pull-in/out operation as well as during other diving operations required onboard.
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CONTRACTOR is also responsible for the Unit installation at the site, as described in documents
SPREAD MOORING & RISERS SYSTEM REQUIREMENTS (see item 1.2.1).
1.10. HEALTH SAFETY AND ENVIRONMENTAL CERTIFICATION

The Unit shall obtain a certificate of compliance with OHSAS 18001, ISO 14000 and ISM Code,
issued by a Brazilian Certification Society authorized by INMETRO, to ensure health, safety and
environmental appropriate operations.
1.11. MATERIALS

CONTRACTOR shall submit the reasoning and calculations (philosophies) to be considered


during the design to specify the materials, for all piping, valves, fittings and equipment, according
to each type of fluid, considering the corrosion allowance as well as the protection considered.
These selections shall be compatible with the operational lifetime, as stated in item 1.1.
For materials selection purposes, CONTRACTOR shall determine the lower design temperature
(LDT) or alternatively the minimum allowable temperature (MAT) for all unfired pressure vessels,
heat exchangers, piping, piping components and valves (including control valves) or rotating
equipment containing compressed gas (hydrocarbon or CO2) or liquefied gas.
CONTRACTOR shall also take measures to prevent the equipment from being at temperature
below the LDT or alternatively ensure the equipment metal temperature is not below the
appropriate MAT, at any given operating pressure. CONTRACTOR shall consider scenarios in
which equipment temperature can drop such as blowdowns, as well as scenarios of subsequent
repressurization of equipment.
LDT or MAT shall be specified as the lowest of the following values:
- The minimum operating temperature;
- The minimum startup/shutdown, test or upset temperature while at normal operating pressure;
- The minimum temperature during depressurizing or repressurizing.
CONTRACTOR shall also comply with the following minimum materials specification, for the
indicated portions of the topsides process facilities:
1) Materials specification shall be carried out based on the following inlet fluids characteristics
and normal operating conditions:
 Produced gas CO2 content: up to 1 % mol;
 Produced gas H2S content: up to 1,000 ppmv;
 Produced gas H2O content: up to saturated
 BS&W: up to 86 %;
 Chloride (Cl-1): up to 53,500 ppm;
 Minimum pH: 4.5.
Materials for the exported gas and gas lift lines will have to be able to handle 10 ppmv of H2S.
2) Carbon steel and its welds, when used, will have to be in accordance with ISO 15156 for the
lowest anticipated pH and the highest H2S partial pressure.
For the system where H2S is likely to be present, all welding procedures will have to be qualified
including Sulphide Stress Corrosion Cracking required by ISO 15156.
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CONTRACTOR shall consider the following H2S contents for the streams below:
Downstream dehydration system: 60 ppmv;
Gas lift system and exported gas system: 10 ppmv;
Maximum hardness as prescribed by ISO 15156 or construction code for both base material and
welds shall be ensured to all vessels, equipment, piping, fittings and accessories. Dehydration of
gas, use of corrosion inhibitors or even H2S scavengers will not, in any case, be accepted as
measures to relax the requirement to use H2S resistant materials, if the operational conditions are
categorized as sour in accordance with ISO 15156 (all parts). As per ISO 15156, operational
conditions shall include upset conditions such as, but not limited to, dehydration and H2S removal
systems malfunction.
QA procedure shall be implemented on the various fabrication sites to control hardness. Hardness
measurements at fabrication sites are being performed in order to ensure maximum hardness will
not be exceeded.
3) Materials from the top-of-risers up to the Free Water K.O Drum or Degassers (e.g. hard
risers, pipelines, manifold, etc.) shall follow (a) or (b) below: (see Figure 2.7.1.1, item 2.7.1):
a) Carbon steel with INCONEL 625 or 825 cladding (min. cladding thickness 3 mm);
b) Duplex (22Cr) or Super duplex stainless steel (25Cr).
4) Heat exchangers:
 Shell: Carbon steel with INCONEL 625 or 825 cladding (3 mm) or weld overlay. Accepted
alternatives:
 carbon steel with 3 mm corrosion allowance, if the cooling/heating fluid is not corrosive;
 Super duplex 25Cr or duplex 22Cr, when corrosion studies have shown it shall be suitable
for service and there is no risk of crevice corrosion, stress corrosion cracking and/or
corrosion under deposits.
a) Tube: Super duplex 25Cr duplex 22Cr, or Titanium
Accepted alternatives:
 AISI 316L. All limits imposed by ISO 15156 shall be complied (temperature, chlorides
concentration, pH and H2S partial pressure).
 carbon steel. All limits imposed by ISO 15156 shall be complied (temperature, chlorides
concentration, pH and H2S partial pressure) and both fluids (cooling and heating) shall not be
corrosive.
5) Separation (including Free water KO drum) and degassing vessels shall follow (a) or (b) or
(c) below:
a) Carbon steel with Inconel 625 or 825 (min. cladding thickness 3 mm);
b) Carbon steel with 904L clad;
c) Duplex (22Cr) or Super duplex stainless steel (25Cr), when corrosion studies have shown it
shall be suitable for service and there is no risk of crevice corrosion, stress corrosion
cracking and/or corrosion under deposits
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6) Saturated Gas lines shall follow (a), (b) or (c) below:


a) Carbon steel with Inconel 625 or 825 (min. cladding thickness 3 mm);
b) Duplex 22Cr or Super duplex 25Cr;
c) AISI 316L with external coating if temperature greater than 60°C degrees.
7) Suction K.O.Drum & Suction Scrubbers (upstream and including gas dehydration unit):
Carbon steel with AISI 316L, Inconel 625 or 825 cladding (3 mm) or 904L weld overlay;
Suction K.O. Drum & Suction Scrubbers(1) (downstream gas dehydration unit): Carbon Steel
according to item 2 above, with 3mm corrosion allowance; 904L weld overlay is an acceptable
alternate material.
Note 1: for fluids with contaminants.
8) Sea water lines upstream deaerator:

Please refer to document I-ET-3010.1R-5330-940-P4X-001 (See item 1.2.1)


9) For the Main compressors construction materials shall be selected considering the following
contents on the process gas:
 CO2: up to 1 % mol;
 H2S: up to 1,000 ppmv;
 H2O: up to saturated.

10) For the Export/Gas Lift compressors, construction materials shall be selected considering
the following contents on the process gas, in case of design consider the Amine unit upstream
Export/ Gas Lift compressors, otherwise shall be considered the same contents as described in
item 9) above (Main Compressors):
 CO2: To be determined by simulation;
 H2S: To be determined by simulation;

11) For the VRU compressors, construction materials shall be selected considering the following
contents on the process gas:
 CO2: To be determined by simulation;
 H2S: To be determined by simulation;
 H2O: up to saturated.

CONTRACTOR shall take measures to guarantee compressor performance and availability if


wet/contaminated gas is used for commissioning or start-ups.
Note1: Operational conditions shall include upset conditions such as, but not limited to,
dehydration and H2S removal systems malfunction.
Note 2: PETROBRAS may accept deviation from materials specifications whenever asked based
on technical reasons provided by CONTRACTOR, during the design phase.
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Note 3: Contractor shall consider the marine atmosphere C5-M for atmospheric zone and IM-2 for
splash and immersion zone according to ISO 12944-Part 2, for the design of external coating of
piping.
Note 4: For wet gas compressors, free water carryover shall also be considered due to the
scrubbers’ efficiency and water condensation along the piping, both suitable to occur on normal
running, on cold startup and on pressurized stop condition.
Note 5: In case contractor decides to use stainless steel material for Pneumatic and hydraulic
instruments transmission lines, including its connections (junction boxes), contractor shall use
ASTM A269 Gr TP 316L (or EN 1.4435) with minimum molybdenum content of 2.5% Mo or other
stainless steel material with higher galvanic corrosion resistance.
Tubing shall be electrically isolated from carbon steel supports and materials to avoid galvanic
corrosion.
1.12 UNIT MODELS

CONTRACTOR shall supply two (2) models of the UNIT in a 1:300 scale."
2. PROCESS

CONTRACTOR shall also design the topsides facilities according to riser characteristics included
but not limited to item 14.1.
Process Plant and Utilities shall operate normally when subjected to the motions induced by the
environmental conditions (see Section 12).
CONTRACTOR shall bear in mind that, as the design is part of the Contract and falls under
CONTRACTOR’s responsibility, production shutdown or degraded oil, water or gas specification
or any other equipment malfunction due to vessel motions shall not be acceptable.
CONTRACTOR shall minimize vessel motions in all environmental conditions, especially in Beam
Sea Condition, as specified in BEAM SEA CONDITIONS, see item 12.3.
2.1. FLUID CHARACTERISTIC

2.1.1. PRODUCED OIL AND RESERVOIR

The typical range of properties for the oil producing wells to be tested is indicated in the Table
below and shall be taken into account for all design purposes. CONTRACTOR shall design the
Unit to process oil with any blend within these properties. CONTRACTOR shall make simulations
to assess the correct design parameters.
CONTRACTOR shall submit the process simulation to PETROBRAS for comments / information
considering the range of fluid components. This simulation shall clearly show the operating
conditions of process plant equipment.
Table 2.1.1.1 Oil producing wells properties.
MRL -II
Oil API grade 18 - 24
665.3 cSt @ 20 ºC
Viscosity (dry – dead oil from
320.6 cSt @ 30 ºC
Blend) (1)
98.2 cSt @ 50 ºC
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BS&W (blend) 0 a 86%


Initial Paraffin Deposit
19 °C (2nd event)
Temperature (4)
Pour Point -24°C
Oil arrival temperature at the
40 – 70 ºC
Unit (5)
Pressure at top of
20,680 kPa(a)
production riser (shut-in) (3)
Top of production Riser
1,500 to 2,000
pressure range (flowing and
kPa(a)
upstream the choke) (6)
Foam Yes (severe)
No, but small
Sand (2) amounts of solids
are expected
Note 1: Pressure loss due to emulsified oil viscosity shall be considered.
Note 2: The installation of a manual sand-jetting system in the HP and Test Separators is an
acceptable means to remove the solids.
Note 3: CONTRACTOR shall design all production lines for maximum operating pressure equal to
20,680 kPa(a). The service lines connected to the production wells shall be designed to a normal
operating pressure of 18,800 kPa(a) and water injection subsea wells shall be designed to a
normal operating pressure of 18,800 kPa(a).
Note 4: Wax is expected to deposit only in the second event.
Note 5: Operational temperature upstream of production choke valve. During the production field
life, the temperature can vary from 40ºC to 70ºC.
Note 6: CONTRACTOR shall consider the following for protect the risers:
Gas export pipeline:
- Normal Operating Pressure: 16,000 kPa (a);
- Design Pressure: See Table 14.1.1
- Maximum 10 ppmv of H2S;
- Maximum 1 % mol CO2;
- Maximum H2O content: 32 ppmv
- Design Temperature: During execution phase PETROBRAS will provide to
CONTRACTOR the temperature requirement for riser protection.
Gas lift riser:
- Normal Operating Pressure: 18,800 kPa (a);
- Design Pressure: See Table 14.1.1
- Maximum 10 ppmv of H2S;
- Maximum 1 % mol CO2;
- Maximum H2O content: 32 ppmv
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- Design Temperature: During execution phase PETROBRAS will provide to


CONTRACTOR the temperature requirement for riser protection.
Water injection riser
- Normal Operating Pressure: 18,800 kPa (a);
- Design Pressure: See Table 14.1.1
- Maximum 10 ppb (vol) O2;
- Design Temperature: During execution phase PETROBRAS will provide to
CONTRACTOR the temperature requirement for riser protection.

2.1.2. PRODUCED WELLS COMPOSITION

CONTRACTOR shall design the Unit to process oil with the following blends within the
compositions given below.
CONTRACTOR shall submit to PETROBRAS, as part of the technical proposal and also during
execution phase, for comments/information the process simulation considering the range of
reservoir fluid components as follows:
BLEND 1) 70% of Well A and 30% of Well B

BLEND 2) 30% of Well A and 70% of Well B

Viscosity is equal for both wells compositions


For simulations, the process plant scheme is proposed at figure 4 (item 2.7.1) with flip point of
20%, based on settling tank and, at least, the following design cases:

Table 2.1.2.1 Design cases


Arrival Produced Produced Gas lift Produced 1st degass.
Case Temp. Blend Oil Gas(1) flow rate(1) Water(2,3) Pressure
(ºC) (m³/d) (Sm³/d) (Sm³/d) (m³/d) (kPa a)
1 40 Blend 1 11,129 940,000 3,060,000 2,226 900
2 70 Blend 1 11,129 940,000 3,060,000 2,226 900
3 40 Blend 1 11,129 940,000 3,060,000 28,617 900
4 70 Blend 1 11,129 940,000 3,060,000 28,617 900
5 40 Blend 1 7,746 617,082 3,382,918 32,000 900
6 70 Blend 1 7,746 617,082 3,382,918 32,000 900
7 40 Blend 2 11,129 940,000 3,060,000 2,782 900
8 70 Blend 2 11,129 940,000 3,060,000 2,782 900
9 40 Blend 2 11,129 940,000 3,060,000 28,617 900
10 70 Blend 2 11,129 940,000 3,060,000 28,617 900
11 40 Blend 2 7,746 617,082 3,382,918 32,000 900
12 70 Blend 2 7,746 617,082 3,382,918 32,000 900
13 40 Well A 11,129 940,000 3,060,000 0 900
14 70 Well A 11,129 940,000 3,060,000 0 900
15 40 Well B 11,129 940,000 3,060,000 0 900
16 70 Well B 11,129 940,000 3,060,000 0 900
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Note 1: Gas Flow rate at suction of main compressor shall be at least 4,000,000 Sm³/d (Produced
Gas + Gas Lift). Any recycle stream to be also considered.
Note 2: Produced water flow rate upstream first vessel (Degasser).
Note 3: The maximum BSW at the production header is mentioned on item 2.1.1.
These simulations shall consider flip point of 20% of water cut according to configuration
presented on item 2.7.1 for settling tanks and minimum retention time of 08 hours based on liquid
flow rate.
To design settling tanks, the CONTRACTOR shall guarantee the minimum retention time of 08
hours based on total liquid capacity (see item 2.5.2).
During project execution phase PETROBRAS will provide to CONTRACTOR the pressure,
temperature and flow rate conditions to size the gas export control valve and the choke valves to
lift gas, water injection.
These simulations shall show clearly the operating conditions of process plant equipment. In
addition, further simulations as requested in item 2.7.3.2 shall also be submitted to PETROBRAS,
for comments/information during execution phase.
The unit shall be able to import the minimum gas flow rate of 800,000 m³/day from pipeline for
start-up and kick-off operations.
The following tables shall be taken into account for the fluid composition (@ reservoir):
Table 2.1.2.2 Molar well composition.
Component Well A Well B Component Well A Well B
CO2 0.08 0,07 C12+ 28.60 NA
N2 0.20 0.29 C12 NA 1.31
C1 54.53 44.55 C13 NA 1.40
C2 2.83 4.13 C14 NA 1.32
C3 1.26 3.97 C15 NA 1.25
iC4 0.32 0.66 C16 NA 0.93
nC4 0.57 1.76 C17 NA 1.01
iC5 0.27 0.65 C18 NA 0.84
nC5 0.57 0.95 C19 NA 0.52
C6 0.73 1.18 C20+ NA 24.23
C7 1.30 1.89 Mol. Weight C12+ 626 NA
C8 2.18 2.27 Mol. Weight C20+ NA 395
C9 2.18 1.81 Density C12+ (kg/m³) 959 NA
C10 2.25 1.61 Density C20+ (kg/m³) NA 985
C11 2.13 1.40

Note 1: CONTRACTOR to consider following BTEX concentrations.

Included as following
Component Minimum %v/v Maximum %v/v
component

BENZENO C6 0,00217 0,05709

ETILBENZENO C8 0,01473 0,06465


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TOLUENO C7 0,03242 0,20552


XILENO
TOTAL (o.m.p) C8 0,03619 0,21797

BTEX NA 0,08550 0,54522

2.1.3. WELL TEST CHARACTERISTICS

The following table shall be taken into account to define test separator system (test heater, test
separator, pumps and other related items):
Table 2.1.3.1: FPSO capacities
CHARACTERISTICS VALUE
Liquid Flow per test separator (maximum) 4,000 m³/d
(minimum, for accuracy of measurement purpose) 100 m³/d

Gas Flow (minimum / maximum for each vessel) 12,450 / 400,000


Sm³/d
Rate of BS&W (for accuracy of measurement 0 to 97.5%
purpose)
Arrival temperature range 40 to 70 oC

Note 1: Well test separator shall be able to operate from LP separator pressure up to the normal
first stage pressure separation of 8 bar (g). Only for well kick-off purpose the low gas flow rate
may be routed to flare. The minimum operating pressure shall be enough to route the liquid to
further low pressure separation stage.
Any gas excess at LP test separator operating condition shall be routed to VRU.
Note 2: The well test separator normal operating temperature shall be at least 90°C.
Note 3: The test separator will also receive fluids such as wells completion fluids, pigging
procedures and fluids after special operations as described in item 2.6.1.
Note 4: The Unit shall consider test heater bypass.
Note 5: Gas stream outlet in each test separator shall be monitored by a H2S online analyzer, as a
minimum, besides sample points to allow lab analysis.
2.1.4. PRODUCED GAS

The complete description of the gas treatment and compression plant is found on item 2.7.3.
2.1.5. PRODUCED WATER

Reference to produced water composition, please refer to the document I-ET-3010.1R-5330-940-


P4X-001 (see item 1.2.1).
2.2. PROCESS
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2.2.1. EXPORTED OIL

The oil to be exported shall meet the following specification:


 Basic Sediment & Water content (BS&W): lower than 0.5% vol.
 Salt content: less than 285 mg/L- NaCl.
 Maximum RVP: 10 psia at 37.8 ºC.
 Maximum Oil TVP @ 45°C: 70 kPa (a).
 H2S content: lower than 1 mg/kg
2.2.2. PRODUCED WATER DISPOSAL

Please refer to the document I-ET-3010.1R-5330-940-P4X-001 (se item 1.2.1).


2.2.3. LIFT GAS

The lift gas to provide artificial lift shall meet the following specification:
 Operating pressure: 18,800 kPa
 Maximum lift gas temperature at the top of the riser: 55 ºC;
 Maximum H2O content downstream gas dehydration unit: 32 ppmv;
 Lift gas flow rate per satellite well: min. 35,000 to max. 350,000 Sm³/d;
 Lift gas flow rate per manifold: min. 50,000 to max. 1,000,000 Sm³/d;
 Maximum CO2 content: 1% mol;
 Maximum H2S content: 5 ppmv;
2.2.4 EXPORTED GAS

 Maximum exported gas temperature at the top of the riser: 55 ºC;


 Maximum H2O content downstream gas dehydration unit: 32 ppmv

 Operating pressure: 16,000 kPa(a);


 Maximum export gas CO2 content: 1% mol;

 Maximum export gas H2S content: 5 ppmv;

2.2.5 IMPORTED GAS

The following table shall be taken into account for the imported gas composition.
Table 2.2.5.1 Imported Gas composition
Gas Pipeline (1) Gas Pipeline (2)
Molar (%) Molar (%)
Component Minimum Maximum Minimum Maximum
Molecular Molecular Molecular Molecular
Weight Weight Weight Weight
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CO2 0.5 0.8 0.3 0.7


N2 1.2 0.4 0.2 1.4
C1 81.1 71.9 89.9 71.4
C2 7.0 9.1 5.1 10.3
C3 5.7 7.6 2.6 8.5
iC4 1.1 1.3 0.4 1.4
nC4 2.0 3.1 0.7 3.5
iC5 0.5 1.2 0.2 0.8
nC5 0.5 1.8 0.2 1.0
C6 0.3 1.5 0.1 0.5
C7 0.1 1.0 0.1 0.2
C8 0.0 0.3 0.0 0.1
C9 0.0 0.1 0.0 0.1
C10 0.0 0.0 0.0 0.1
The design shall take into account the following contaminants for the imported gas:

 Maximum H2S of 5 ppmv;

 Maximum CO2 of 1% mol.

 Maximum H2O content of 140 ppmv


Imported gas parameters for wells kick-off:

 Pimport = 6,865kPa
 Timport = 3.8 °C
 Qgás = 800,000 m³/d
2.3. SEAWATER INTAKE

2.3.1. COMPOSITION

Table 2.3.1.1: Sea water composition.


SEA WATER ANALYSIS
pH 8.1
Conductivity 5,800 μmho/m
+
K 425 mg/L
Na+ 12, 000 mg/L
++
Ca 512 mg/L
++
Mg 1,418 mg/L
++
Ba <1 mg/L
Sr++ 10 mg/L
Fe total <1 mg/L
CO3-- 6 mg/L
HCO- 137 mg/L
NO3- <1 mg/L
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SEA WATER ANALYSIS


Cl- 21,665 mg/L
SO4-- 2,400 mg/L
Salinity 35,685 mg/L
Total suspended solids 2.0 mg/L
Oxygen content 7 mg/L
Turbidity 0.20 FTU
Silt density index 5.1
m-SRB 25 MPN/mL
Aerobic bacterias 7,500 MPN/mL
Facultative bacterias 44 CFU/mL
MPN – Most Probable Number CFU – Colony Formation Unit
PARTICLE SIZE DISTRIBUTION
SIZE RANGE (μm) NUMBER OF PARTICLES (part./mL)
3 to 5 424.1
5 to 7 151.1
7 to 10 103.4
10 to 15 52.8
15 to 30 30.5
30 to 50 5.8
50 to 100 1.2
100 to 250 0.0
TOTAL 769.2
Note 1: This information does not take into consideration the vessel and UNIT overboard lines
interferences, e.g., temperature, particles and others.

2.4. WATER INJECTION

The Unit shall be able to operate continuously with only one injection well up to 19 (nineteen)
connected wells, in which 1(one) are satellite wells and 18 (eighteen) are manifolded wells (six
wells per manifold)
The water injection system shall be able to inject continuously from 1,500 m³/day up to 38,000
m³/day. at maximum operating pressure of 18,800 kPa(a);
The water injection temperature shall be controlled downstream the injection pump and its set
point shall be up to 60°C.
Installed spare pumps shall be provided for booster and main injection pumps.
With regard to water injection capacity per well, CONTRACTOR shall consider the information
stated on item 2.5.1 (note 2).
The injection pumps may be of two types:
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 High speed, with the main pump and booster pump stages incorporated into a gearbox;
multiple stages, with a separate booster pump.
 Multiple-stage pumps shall conform to the latest edition of API-610.
Contractor shall evaluate Injection pumps control system of the following types: hydraulic, VSD,
minimum flow recycle and others.
The water injection system shall have no stagnation points. If this is impossible, water drainage
points shall be provided.
Contractor shall maintain on board water injection pumps/motor spare kits ready to be used in
case of system failure (e.g seals, sensors, instruments cartridge, filters, etc.) as per vendor
requirement.
The main water injection pump shall be monitored, at least, for vibration, axial displacement,
bearing and motor temperature. All monitored data shall also be available for PI Software, in order
to Contractor monitor the system performance and to prevent failure.
Piping shall be designed according to API-RP-14E, considering maximum erosion velocity.
Acceptable vendor list for injection pumps:
 Sulzer Brasil S.A.;
 Frank Mohn Flatoy AS;
 Flowserve do Brasil LTDA;
 KSB Bombas Hidráulicas S.A.
 Nuovo Pignone SPA Firenze;
2.4.1 SEA WATER INJECTION

The sea water injection system shall have a Sulphate Removal Plant. The Injection water quality
specification is as follows (maximum values):
 Content of suspended solids: 1.5 mg/L;

 Maximum particles/mL greater than 1 m: 5 (five) per milliliter;


 Dissolved oxygen: 10 ppb (vol) O2;
 Soluble sulfide content: 2 ppm (vol);
 Bacteria (SBR planctonic – mesophile): 50 NMP/mL;
 Total anaerobic bacteria (BANHT planctonic): 5,000 NMP/mL;
 Maximum sulphate content: 100 mg/L;
The sea water injection system shall have an online O2 analyzer connected to the process alarm
system, installed downstream of the deaerator system and oxygen scavenger injection point.
The system shall consist of cartridge filters, deaerator system, sulphate removal unit (including
CIP system), chemical injection. Multi-media fine filters can be used upstream of the cartridge
filters to reduce cartridge filter replacement.
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The Sulphate Removal Unit shall be located upstream Deaerator.


Ultrafiltration membranes can also be employed as an alternative to cartridge filters. If
ultrafiltration is the selected alternative, design of the UF recovery shall consider inlet solid content
defined by membrane supplier. This unit shall comply with the following specifications as a
minimum:
 Normal operation permeate flux and maximum permeate flux to maintain the total water
injection flowrate at all times, including backwashing and/or cleaning and routine
maintenance;
 Maximum permeate flux in operation during cleaning: 80 LMH@25ºC;
 Membrane shall be sodium hypochlorite (NaOCl) resistant to a minimum of 500 ppm
during cleaning procedure;
 Membrane absolute pore size: maximum of 0,22 µm.
 Ultrafiltration design specification shall be in accordance to SRU supplier’s requirements.
A full and partial bypass of SRU unit shall be considered. The bypass may be used during SRU
unit cleaning to sustain water injection flow, whenever requested by PETROBRAS.
Acceptable vendor list for Sulphate Removal Membranes:
 Hydranautics;
 Toray Membrane USA, inc.
 DOW Chemical - Filmtec Corporation;
 GE Water & Process Technologies do Brasil LTDA;
 Nltto Denko Corporation Shiga Plant
 Filmtec Corporation
CONTRACTOR shall consider the alternative of produced water reinjection (segregated or
comingled with dessulphated seawater). The specification as stated on this item refers to
dessulphated seawater.
2.4.2 PRODUCED WATER INJECTION

Reference to produced water injection, please refer to the document I-ET-3010.1R-5330-940-P4X-


001 (see item 1.2.1).
2.5. DESIGN SUMMARY

2.5.1. WELL DESIGN SUMMARY

Table 2.5.1.1: Well design summary


Design data
Oil satellite wells 7 (1)(4)
Oil manifolded wells 16(4 wells per manifold) (1)(4)
Water injection satellite wells 1(1)(2)(4)
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Water injection manifolded wells 18 (6 wells per manifold) (1)(2)(4)


Maximum production flow rate per well 4,000 Sm3/d (3)
Maximum gas lift flow rate on subsea manifold 1,000,000Sm³/d (1)(3)

Maximum water injection flow rate per well 5,000 m3/d (2)(3)

Maximum water injection pressure (top of risers) 18,800 kPa (a) (4)

Maximum lift gas flow rate per well 350,000 Sm3/d(1)(3)

Maximum produced gas flow rate per well 200,000 Sm³/d

Total gas flow rate per manifold 1,200,000 Sm³/d

Note 1: All piping, instrumentation, and equipment must be provided for all the producers,
gas and water injection wells, before leaving the conversion/construction shipyard.
Note 2: With regard to water injection wells CONTRACTOR shall design branch piping as follows:
(i) For each satellite well water injection riser from main water injection header to
handle up to 5,000 m³/d of injection water.
(ii) For each manifolded water injection riser from main water injection header to handle
from 1,500 m³/d to 30,000 m³/d of injection water
Note 3: For accuracy of measurement purpose.
Note 4: During project execution phase PETROBRAS will provide to CONTRACTOR the pressure,
temperature and flow rate conditions (steady flow and well start-up) to size production choke
valves.

2.5.2. PROCESS DESIGN SUMMARY

Table 2.5.2.1: Process design summary


Design data
Total liquids processing capacity (Sm3/day) 39,750 (250,000 bpd)
Total oil processing capacity (Sm3/day) 11,130 (70,000 bpd)
Produced water capacity (m3/d) 32,000 (201,280 bpd)
Gas treatment & compression system (Sm3/d) 4,000,000 (1)
Injection gas pressure (kPa (a)) Not applicable
Maximum gas-lift pressure (kPa (a)) 18,800 (2) (3)
Maximum lift-gas capacity (Sm3/d) 4,000,000(1)(2)
Maximum exported gas pressure (kPa (a)) 16,000 (2)(3)
Export gas capacity (Sm3/d) 940,000(1)(2)
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Design data
Water injection capacity (m3/d) 38,000 (240,000 bpd) (2)
Maximum water injection pressure (kPa (a)) 18,800(2)
Note 1: The design shall consider, additionally, the fuel gas requirement for the unit. See item
2.7.3
Note 2: During project execution phase PETROBRAS will provide to CONTRACTOR the pressure,
temperature and flow rate conditions to size gas export control valve, lift gas and water injection
choke valves.
Note 3: CONTRACTOR shall take into account the maximum design pressure for gas export riser.
2.6. OIL & GAS COLLECT SYSTEM

2.6.1. TOPSIDE MANIFOLDS AND FLEXIBILITY

Oil stream:
All the oil production satellite wells and manifolded wells shall be connected to oil production
header and to oil test header.
A service header to allow flexibility to access each well with no disturbance to the others shall also
be provided as indicated in I-DE-3534.00-1223-941-PP6-001 (see item 1.2.1).This service header
may be used to perform diesel injection (pigging operations, diesel circulation, bullhead operation,
etc.) and well stimulation through Chicksan Connection on Topside Pump Discharge and water
cleaning of subsea system. Pigging operations through gas lift should be done by the dedicated
gas lift header branch.
A dedicated atmospheric diesel /oil service tank shall be installed at topsides for well service
system operations (including diesel and oil mixture) in order to avoid the return of reservoir
fluid/gas to hull, protecting the unit in case of gas return during well service operations. The
minimum volume required for atmospheric diesel /oil service tank shall be 30m³.
Contractor shall provide the Flowline circulation pumps to inject diesel or mixture of diesel/crude
(in any proportion) into production risers and gas lift risers as per I-DE-3534.00-1223-941-PP6-
001 (see item 1.2.1). The flow rate required is 360 m³/h at maximum discharge pressure up to
20,680 kPa(a). It shall be considered that each pump can operate in a range of flowrate from 24 to
180 m3/h. A minimum arrangement of 3 x 50% to the service pump is required.
Flow control shall be obtained by variation in pump speed with a variable speed drive, with or
without supplemental bypass. If supplemental bypass is needed, the recycle shall return to a the
dedicated atmospheric tank installed at topsides, recirculation to hull is not allowed. In case of
recirculation is necessary, besides variable control, the necessity of recycle cooling shall be
evaluated. A spare connection from laydown area to downstream of well service pump shall be
available to allow connection (chicksan) of a diesel motor driven rented service pump (including
connections for supply to rented pump tank).
The system shall allow crude oil flow in any rate from 'only diesel' to 'only crude oil', contractor is
responsible to provide a way to measure and control the mixture. The fluid to be injected (diesel,
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crude oil or a mixture of diesel/oil) shall be measured with dedicated fiscal metering (see item
7.7_note 11).
It shall be provided means to perform the system flowrate test during commissioning.
Additionally, the unit shall be able to inject hot diesel or mixture of crude and diesel at 80ºC only
into production riser at maximum flowrate of 180 m³/h, return through gas riser and aligned to
production test header at minimum pressure of 5 bar g.
Whenever necessary, the well service system shall be prompt to be used.
The minimum storage capacity required for all operations to prevent hydrate is 5,000 m³ of crude
oil and 5,000 m³ of diesel.
The Well service pumps provided by contractor shall comply with API 674.
All oil production risers will be connected to the test header. Problems on the test train shall not
affect the main process train. The same philosophy applies to the production well producing to the
test header. CONTRACTOR shall provide pressure and temperature transmitter upstream each
choke valve and also pressure and temperature transmitters downstream each choke valve in
order to track fluid arriving temperature and wax deposition.
The Test Header and the Test Separator shall be able to perform periodical production test for
each well, according to ANP requirements, as well as pigging operations, production subsea
manifold test (to check H2S content on blend, etc.), receiving fluids during special operations, like
squeeze (see item 3.9) and coiled tubing operations.
Production and test headers shall be provided with chemical injection to enhance the separation
and/or protect the facilities (anti-foaming, demulsifier, scale inhibitor, etc.).
In addition, CONTRACTOR shall provide facilities to inject Nitrogen into production, services lines
and gas pipeline in accordance to item 3.8 below.
Contractor shall provide facilities to inject Nitrogen during coil tubing operations in any position of
topside manifold, according to I-DE-3534.00-1223-941-PP6-001 in item 1.2.1.
Contractor shall provide facilities to installation Coflexip® Support in accordance with 3.9 below.
Each production well shall have adjustable chokes at both lines (production and service/gas-lift).
The production choke shall have a minimum opening range of 0 (zero) to the internal piping
diameter. Opening accuracy/precision on the valve stroke shall be 0.2%, and shall be remotely
actuated from the Central Control Room. The choke valve shall also be able to be manually
operated.
Gas stream:
The unit shall be prepared to import / export gas from both PETROBRAS gas pipelines system.
The 8” and 9.13” gas pipelines shall be connected to the gas export header.
The 4” gas lift line for satellite wells, 6” gas lift line and 8” gas lift test line to manifolded wells shall
be connected to a gas lift header through individual chokes.
The design shall take into account the requirements to control the flow rate at normal well
production and during pigging operations, considering not only satellite wells, but also manifolded
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wells. An individual flow meter shall be installed for each gas riser. For pigging purposes
(pipeline), gas flow rate shall be controlled and totalized.
Topsides arrangement shall allow temporary injection of hydrate inhibitor individually in any of the
gas risers.
Water injection stream:
The 6” water injection risers for satellite wells and 8” manifolded wells shall be connected to a
water injection header through individual chokes. An individual flow meter shall be installed for
each water injection riser.
The design shall take into account the requirements to control the flow rate considering not only
satellite wells, but also manifolded wells. In addition, each water injection lines shall have
individual choke.
General:
Shut down valves (SDV) shall be installed in all satellite and manifolded well lines including
production, water injection and gas lift. Also SDV shall be installed in the gas export / import line.
Pressure transmitters shall be installed upstream production SDV and downstream water and gas
lines SDV to allow monitoring the pressure of the risers with SDV closed.
PETROBRAS will supply all chemicals to be injected for subsea use and the amount of chemicals
mentioned on the table in item 2.8 for oil production, oil and gas treatment, water treatment for
injection and discharge and marine use.

One pig launcher shall be provided for each one gas lift / service riser.

Pig receivers shall be provided for the whole set of production risers, with each serving up to 5
risers, as a reference see I-DE-3534.00-1223-941-PP6-001 (item 1.2.1). The topside pig
arrangement shall be compatible with the use of foam pig.

The gas export / import line must have a pig launcher / receiver which shall be compatible with
intelligent / instrumented pigs.

All pig receivers, except gas export pig receiver, shall be aligned to test separator and production
header in order to allow receiving fluids from risers after flushing during commissioning and
operations.
Wye, can be either symmetric or no, but shall be 30º and convergent type, 2 pipeline arriving in
one, in accordance with figure 2.6.1.1.
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Figure 2.6.1.1: Wye

The topside pig arrangement shall be compatible with the use of foam and rigid pigs (conventional
scrapping pigs) as well as intelligent / instrumented pigs. CONTRACTOR shall comply with the
following requirements for “Intelligent / instrumented” pigging for all wells and gas export.
a) Requirements for Launcher and Receivers

Figure 2.6.1.2: Pig receiver


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Figure 2.6.1.3: Pig launcher

Figure 2.6.1.4: Pig launcher / receiver.

Table 2.6.1.1: Access area sizing for launchers and receivers.

Requirements for "Intelligent/Instrumented" Pig

Nominal L1 STRAIGHT PIPE X


L1 (BARREL)
Diameter of (BARREL) LENGTH - L2
Free Access
Receivers
Hard-Piping Launchers only for Receivers Area behind
Gas Export (8”) 3050 mm 3050 mm 3000 mm 4050 mm
Gas Export and
2900 mm 2900 mm 2750 mm 3900 mm
9.13”)
Notes:
 The inside diameter of the barrel of launchers and receivers shall be at least 89 mm (3 ½
inch) larger than the inside diameter of the pipeline;
 Y-=1000 mm;

 Barrel reducer for launcher and launcher-receiver traps shall be eccentric, and shall be
concentric for receiver trap. The maximum slope angle of the reducers shall be 11° (Figure
2.6.1.5).
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Figure 2.6.1.5: Maximum Slope of Reducers.

 For intelligent pig launcher/receiver the access area dimension Y shall be Y= 1.0 meters
for 4 to 12 inch;
 For sizing the access area for launchers and receivers that operate only with non-
intelligent pigs, dimension “X” shall be 1500 mm for nominal diameters up to 12” and 2000
mm for nominal diameters of 14” and 16”, and dimension “Y” shall be 750 mm.
 Position required for the pig sensor on the receiver: between L1 and L2;
 Position required for the pig sensor for launching operation: minimum length equivalent to
L2 (does not need to be straight pipe) measured downstream the trap valve.
 The access area between the bottom of the barrel and the operation floor shall be
sufficient for the installation of the fittings for drainage connections, basins and other
possible accessories. The elevation between the operation floor and the bottom of the
barrel shall be 1,000mm.
 The pig receivers shall be installed in horizontal direction.
 The pig launcher/receiver of the gas export shall be installed on the horizontal position.
 Launchers for pipelines designed for intelligent pig passage with nominal diameter of 150
mm (6”) and larger shall have a flanged outlet with nominal diameter of 50 mm (2”) to help
loading the pig into the barrel, using a pulling cable (see Figure 2.6.1.6: Figure 2.6.1.6: ).
This outlet shall be installed horizontal (3 h or 9 h positions), inclined at 45° and without
interference with the trap block valve;
 The pig passage indicators shall be installed at a minimum distance as dimension L2 from
the trap valve. They shall allow the detection of all types of pigs to be used.
A system for collecting drainage from receivers/launchers shall be provided. Drainage shall be in
accordance with the same philosophies of the process plant.
 All pig receivers shall have adequate basket inside for proper pigging operation.
NOTE: Trolleys, carts or any device suitable for PIG handling shall be part of the scope.
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Figure 2.6.1.6: Illustration of flanged outlet


b) Piping Requirements
b.1) With regard to production wells, topsides piping for the 4”/6”/8” I.D service risers and 6”/9.125”
I.D production risers, including pig launcher and receiver, shall have their internal diameter
minimum 4.0 inch to maximum 9.125 inch. All bend radius shall be 3xD minimum, where D is
the nominal diameter, referenced to the piping centerline. Adjoining bends or any two
components or features like Tees, Wyes shall be separated by straight spool pieces of pipe
with the same O.D and I.D and at least 3xD long each. The transitions between topside
pipes/subsea pipelines/components with different internal diameter shall be made with
chamfer of maximum angle of 15º with the centerline of the pipe. The spool piece that will be
connected to the riser shall have the same I.D. of the riser end fitting or a 1:5 slope at the
end.
b.2) Not applicable.
b.3) Not applicable.
b.4) Piping for the gas export pipeline systems, including pig launcher/receiver, shall have their
internal diameter in the range of 8 inch to maximum 9.13”. All bend radiuses shall be 5xD
where D is the nominal diameter, referenced to the piping centerline. Adjoining bends shall
be separated by straight spool pieces of pipe with the same OD and ID and at least 5xD
long each. The transitions between pipes/components with different wall thicknesses shall
be made with chamfer of maximum angle of 15º with the centerline of the pipe. For internal
diameter changes the maximum slope allowed shall be 1:5. The spool piece that will be
connected to the riser shall have the same I.D. of the riser end fitting or a 1:5 slope at the
end.
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b.5) All topsides piping, launcher and receiver nominal/internal diameter and length shall be
submitted to PETROBRAS comments/information. Preliminary GAs indicating compliance
with required free access areas shall be also submitted to PETROBRAS
comments/information.
b.6) In addition, CONTRACTOR shall perform a pig test in the yard to demonstrate that the pig
can freely (without any damage) pass through each piping of the service and production
pipeline systems. PETROBRAS will supply such a pig, including those to be used during
the operation lifetime.
The installation of pig launcher and receiver implies in providing facilities to inject lift-gas and/or
circulating diesel to push the pigs, as well as other fluids required. The Unit shall also have
facilities to inject an ethanol or MEG bed during pigging operations.
All of those subsea service operations (diesel circulation, leak test, pigging, etc.) shall be done
using facilities onboard. CONTRACTOR shall take into account the requirements of those
operations, for example, volume control, pressure control, etc.).
The topside shall have facilities to allow the leak test of the risers with water, using rented service
pumps that shall be provided. The table 14.1.1 shows the leak test pressure requirements.
The unit shall have facilities and space to allow the commissioning of gas pipeline with nitrogen.
The NGU (Nitrogen Generator Unit) will be supplied by PETROBRAS.
CONTRACTOR shall guarantee the performance of pigging operation regarding pig velocity.
PETROBRAS is responsible to supply those pigs during operational lifetime.
Facilities shall be provided to allow the depressurization of any riser, including production, gas lift,
gas injection and gas exportation with no production disturbance. The following requirements shall
be fulfilled:
a) All production riser depressurization must occur within 1,5 (one and a half) hours (considering
the proposed subsea arrangement issued by PETROBRAS) in order to avoid hydrates blockage.

b) Each gas lift, and gas exportation riser shall be able to be depressurized on a rate not greater
than 3.5 bar/min. For the gas lift riser, pressure at the flare tip, shall be 5 psig or less, within no
more than 3 hours of depressurization. For the gas export riser there is no time constraint.

Note 1: CONTRACTOR shall submit to PETROBRAS for comments / information the


documentation that shows that both (a) and (b) requirements were fulfilled.
Note 2: The design may consider the depressurization through the pig receiver.
Exported and imported gas shall be pressure controlled and measured. CONTRACTOR shall
foresee provisions to send / receive foam and intelligent pigs to the gas export / import riser. The
expected diameter for pipeline will be between 8 to 11.13 inches internal diameter.
CONTRACTOR shall take care during the design and construction phase to avoid any pigging
problems such as protruding welds inside piping or other arrangement that cause risk to the
pigging operation. Barred tees shall be provided on branch connections where the I.D is greater
than 2 inches.
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All satellite and manifolded wells (oil production, gas production and water injection) shall be
controlled and monitored through the Central Control Room Workstations, as described in Section
7. FPSO shall have manifolds with well piping flexibility.
Hard-piping, instrumentation, valves, etc. shall be fitted before FPSO sails away from shipyard.
2.6.1.1. COILED TUBING OPERATIONAL DESCRIPTION

This operation is one of the alternatives considered to remove possible plugs inside the oil
production lines or gas injection/service lines during operation of the Unit.
Contractor shall provide facilities to inject Nitrogen during coil tubing operations in any position of
the riser balcony.
CONTRACTOR shall include on the Unit’s arrangement a lay-down area for the coiled tubing
operations, designed to accommodate the coiled tubing equipment and accessories. See DE-
3534.00-1223-941-PQC-001 for dimensions and weights (see item 1.2.1. REFERENCE
DOCUMENTS1.2.1. REFERENCE DOCUMENTS).
The coiled tubing spread will be supplied by PETROBRAS and the Unit’s crane shall be able to lift
all equipment from a supply-boat and temporarily set them down at a convenient lay-down area,
whenever required by PETROBRAS.
CONTRACTOR shall provide means for deployment of the coiled tubing equipment from laydown
area to riser balcony according to the proposed layout to be submitted to PETROBRAS during
detailing phase. CONTRACTOR shall also guarantee facilities and personnel support to assemble
the Coiled Tubing Well Head Assembly (BOP + PUP JOINT (for height adjustment) + Quick
Connector + Stuffing Box + Injector + Goose Neck) as well as other CT equipment for each
production, service, gas pipeline risers.
CONTRACTOR shall guarantee enough head-room above all production risers end fittings to
assemble the Coiled Tubing Well Head Assembly. This means a vertical free space to assemble
all the components. These components will be assembled just above the derivation valve on the
special coiled tubing pipe spool.
CONTRACTOR shall supply the special coiled tubing pipe spools with a 3” derivation for each oil
production or service riser. The derivation shall be supplied with a full bore blocking valve and
blind flange. Contractor shall take into account load requirements related to the coil tubing
assembly when designing the spools.
CONTRACTOR shall guarantee free access of each part of the BOP set, with no disturbance of
normal production operation on the other wells and risers.
CONTRACTOR shall guarantee no interference between the coiled tubing and any other
structure, piping, deck, etc.
CONTRACTOR shall clearly show the possibility to move the coiled tubing reel and BOP
Assembly along the riser balcony area so that access to all production well risers is achieved.
CONTRACTOR shall submit the proposed layout for the coiled tubing operations during detailing
phase.
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PETROBRAS shall only perform this operation in good weather conditions, such as those
specified for pull-in / pull-out of risers.
2.7. PROCESS FACILITIES

2.7.1. SEPARATION AND TREATMENT

The oil processing will be carried through a train of degassers (see figure 2.7.1.1), with total liquid
capacity of 39,750 m3/d (250,000 bbl/d) and maximum oil production of 11,130 m³/d (70,000 bpd),
constituted of a first and second degasser, 2 (two) settling tanks, and (1) one electrostatic treater.
Gasket Plate Heat Exchangers, if considered by Contractor, shall be designed as per API STD
662 - Part 1. Equipment shall be designed as "severe service". They shall be able to stand
dynamics pressure variations resulting from fluid flow and process control. For cyclic services,
fatigue design shall be in accordance with ASME BPVC Section VIII, Division 2.
This configuration could be modified in function of detailed studies to be developed during the bid
phase of the Unit if provided the same final specification and presented to PETROBRAS for
evaluation
The producing oil wells will flow to the test or production headers. From there oil is sent directly to
first and second degasser in sequence.
The oil stream from the settling tank is sent to the heating system, pre-heaters and oil heater. The
oil stream from the settling tank is heated to fit the treatment temperature, being this final
temperature obtained through the use of heat from the treated oil and complemented by the hot
water system.
The heated oil at the treatment temperature (105 ºC), is sent to an electrostatic treater.
In the electrostatic treaters, the oil shall be specified with the desired quality (less than 285 mg/L
salt, BS&W< 0.5% and H2S < 1 mg/kg). It is not expected that there will need to be additional
crude processing to meet this H2S specification.

The design shall include ability to inject H2S scavenger into the suction of the offloading pumps
header.
The treated oil from the electrostatic treater is cooled in the oil/oil pre-heater and in the crude
cooler to reach the maximum temperature of 55ºC and sent to the cargo tanks, after fiscal
metering system.
In case of off-spec oil and/or off-spec water the Unit shall be able to route these fluids to an off-
spec tank (see 11.6) and also send these fluids back to the oil and/or water treatment plant to be
reprocessed. Off-spec oil can only be sent to the off-spec tank before fiscal metering. The return
to oil treatment plant shall be upstream pre-heater.
CONTRACTOR shall provide pumping system from test separator to upstream second degasser,
in order to allow receiving low pressure fluids.
CONTRACTOR shall consider slug volume (NLL to LAH of the vessel) in the 1st degasser and
Test Separator design (20.0 m3 for 1st degasser and 10.0 m3 for Test separator
The following figure presents a simplified proposed flow diagram of the Oil Processing.
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Optimizations on the Process described in item 2.7.1 or different solutions can be proposed by
Contractor and submitted to PETROBRAS approval, during the bidding phase.

Main
Compression Storage
tanks
Fiscal
metering
VRU
CMS
A
Test
Separator

8 bar g
90 °C
Electrostatic
Treater

3,5 bar g
C 98 °C

Choke

8 bar g HMS
40 °C B

1st
DEGASSER 0,5 bar g
70 °C
Topside
HMS 2 nd
C
DEGASSER

B Oil offspec tk A

Water Treatment
Water offspec tk C
Plant

Discharge

Produced Water Water Injection


adjustment System

Settling Tk

2 x 100%

Figure 1.7.1.1. – Simplified Process Scheme

2.7.1.1 SETTLING TANK

The settling separator is the third separation stage of the oil processing system. The first two
stages are high and low pressure degassers. Each tank contains three compartments; one large
tank where separation takes place and two collection sections (caissons) for the crude oil and
produced water.
At the interface level the crude will rise and the water will settle. To transport the produced water
and crude oil to downstream processes underflow and overflow connections shall be provided to
respectively the produced water and crude oil compartments.
The main separation will take place in the settling separator tank. These compartments are just
used to displace the liquids from the tank to downstream processes.
Contractor shall consider that vapor from settling tanks shall return to process plant for treatment,
upstream the VRU.
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The tank pressure control is done by an eductor or similar device. If the eductor (or similar device)
fails, the pressure control shall be done by a HV vent valve (or similar device). The Settling
Separator shall be protected against overpressure and underpressure by means of P/V breakers.
The Liquids sent to the settling tanks shall meet the following specifications:
 Maximum RVP: 10 psia at 37.8 ºC.
 Maximum Oil TVP @ Rundown Temperature to Settling tanks: 1.0 bar (a).
Liquids from the LP Degasser shall be introduced below the oil/water interface level in order to
maximize the fluids separation (location to be defined by Contractor) and shall be distributed
evenly via a sparged pipe type inlet device.
Liquid inlet in settling tank shall guarantee no disturbance in oil_water interface and a good
distribution for oil and water separation. The sparged pipe shall have a minimum length, to limit
support requirements. To ensure even distribution, the pipe shall be designed with holes taking
the bulk of the total pressure drop over the inlet device; the maximum allowable pressure drop
shall be 0.2 bar.
Any settling tanks fluids operations (transfers, crude oil washing (COW), sea water washing
(SWW) and stripping), shall not be performed through pump room.
The submerged crude oil pump shall be located in the crude oil compartment/caissons, inside the
settling tank. The oil compartments shall have the following connections for the various modes of
operation.
 Crude Oil Overflow
 Crude Oil Underflow
 Vapour Outlet
 Stripping
 Submergible Pump (crude outlet)
 Standpipes connections for level measurement
 Breather valve return
The base of this compartment/caisson shall be defined by CONTRACTOR during design phase
based on the selected liquid levels (interface, oil/water).
The submerged produced water pump shall be located in the produced water
compartment/caisson. The following connections shall be provided on produced water
compartment for various modes of operation:
 Produced water underflow
 Vapour Outlet
 Stripping
 Submergible Pump (produced water outlet)
 Standpipes connections for level measurement
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 Breather valve return


The underflow shall be located at the bottom of the produced water compartment/caisson and
shall be located above the bottom of the compartment to avoid potential sand build up in the
compartment.
Compartment/caisson for oil and water installation shall be provided with facilities to allow pumps
maintenance with no impact in operation.
For pump maintenance no man entry is required in the crude oil/produced water compartments
considering that the pump shall be pulled out of it. Contractor shall evaluate the necessity of
cleaning the pump system prior of removal for maintenance/replacement.
Single valve isolation between the underflow connection of the pump oil compartment/caisson with
the Settling Tank is acceptable.
Compartment/caisson shall have means to allow inspection from the outside according to class
requirements Furthermore, the compartment shall not be attached to a bulkhead so it can be
inspected from the outside.
Minimum of 2 settlings tanks shall be considered. Those tanks shall not be adjacent or shall have
a cofferdam between each other in order to not have a common bulkhead..
Only one tank is inspected at the time, in order to not stop the production. At least double valve
isolation is provided on the cross connections between the two tanks, for safety reason.
Furthermore, it shall be possible to operate a pump in one compartment/tank while the other tank
is under inspection.
All tanks and compartments are connected to one main vent header. Therefore, the tanks are
communicating through the overflow and underflow connections.
Due to gas flashing off from the liquids in the separator, pressure control is required to prevent
overpressure. A back up protection shall be provided (e.g. HV vent). This vent shall also be used
during start up when the tank shall be liquid filled and displaces the inert gas, start-up operation
shall not be done by educator.
It is recommended to use the vent instead of the eductor to prevent inert gas in the booster
compressor, because it is not designed for such high molecular weights.
The Settling Separator is a Cargo Tank converted into a process vessel. However, it still contains
the required connections as for a cargo tank, which are:
 Stripping Connection
 Inert gas connections
 Crude Oil Washing (COW) machines.
As per the other Cargo Tanks the settling separator tank shall be provided with a Crude Oil
Washing system
The fuel gas back-up (utility) shall be used if the level in the settling separator drops and the
eductor (or similar device) is not able to control the pressure.
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For the compartments/caisson CONTRACTOR shall evaluate the wash/cleaning system to be


provided.
As per the other Cargo Tanks the settling separator tank shall be provided with inert gas
connections; 1 supply line and 1 return line for each tank.
Contractor shall evaluate at design phase the tank and caisson level control system to be used in
order to not stop the production.
Contractor may propose different solutions, however, shall be subjected to PETROBRAS
approval at his sole discretion.2.7.2. OIL TRANSFER SYSTEM

The oil from the storage tanks will be exported to a shuttle tanker, according to the document
OFFSHORE LOADING SYSTEM REQUIREMENTS (see item 1.2.1).
The Unit shall be equipped to transfer 159,000 m3 of oil to the shuttle tanker in no more than
24(twenty-four) hours. The total discharge of 159,000 m3 of oil shall be made considering the Unit
at all operational draught variations. Attention must be paid to the oil physical properties,
particularly to the viscosity and temperature, and for the losses through the offloading system
(valves, hose reel, offloading hose etc.).
The unit shall be able to perform any step of oil transfer operation during any time, meaning that
operations such as, shuttle tanker connection and disconnection, oil transfer shall be performed
daily or night time. The Unit cargo transfer system, besides the offloading hose reel, shall have
one stand-by pump, ready to operate in substitution for any other cargo pump set to allow
maintenance with no impact to the offloading operation and without affecting the
production/processing capacity of the Unit. If the cargo pumps are steam driven, boiler
redundancy is also required. Individual submerged pumps (deep-well) in each tank are acceptable
if CONTRACTOR decides to replace the original cargo transfer system with the following
requirements:
 A longitudinal header shall be installed on the main deck and branches provided with
manual valves and blind flanges for the connection of the portable cargo pump to every
and each tank. For further details, cargo portable pumps supplier standards shall be used.
 Each cargo tank and each slop tank shall have cargo pumps complying with the following
requirements: (a) submerged hydraulic driven pumps or Deep-Well Pumps with electrical
drives on main deck.
CONTRACTOR shall limit exported oil temperature through export hoses, from a minimum of 35ºC
to a maximum of 55ºC, to comply with shuttle tankers requirements.
CONTRACTOR shall provide arrangements and facilities to allow proper cleaning of the offloading
system (including the offloading hose), which will be performed immediately after every cargo
transfer (offloading) as follows:
 The Unit shall allow pumping water through the offloading hose from the Unit to the shuttle
tanker.
 After the oil offloading being performed, the shuttle tanker will pump the water back to the
Unit. Therefore, the Unit shall not have any constraint, such as non-return valves at the
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hose reel that may jeopardize the seawater pump-back operation from shuttle tanker to
FPSO.
 Additionally, Unit shall be capable to perform final flushing (cleaning) of the offloading hose
on a “closed circuit mode”. The close circuit mode means the offloading hose will be reeled
and stored onboard the Unit.
 The arrangements for connecting water lines to cargo system slop tank or dedicated return
tank shall be submitted to PETROBRAS for comments / information.
The inspection and maintenance of the offloading hose shall fall under CONTRACTOR’s
responsibility.
The offloading system, including the hose reel, shall be designed considering the operation with
Suezmax shuttle tankers, as described in document I-ET-005 OFFSHORE LOADING SYSTEM
REQUIREMENTS (see item 1.2.1).
CONTRACTOR shall provide means to store the NSV (North Sea Valve) within FPSO boundaries
in order to avoid possibility of oil spills overboard.
CONTRACTOR is responsible for the operation and the maintenance of the system during
operational lifetime.
As the Unit will have a Spread Mooring System, CONTRACTOR shall provide 2 (two) offloading
systems, each complete with its own hose and hawser, one at the stern another at the bow, in
order to allow the offloading operation in a broader range of weather conditions.
2.7.3. GAS PROCESS PLANT

2.7.3.1 OBJECTIVES

The gas shall be gathered, treated and compressed, to comply with four main applications:
 Transport to shore, through a gas pipeline;
 Import gas during part of field production life;
 Fuel gas;
 Lift gas for the producing wells.
The gas pipeline operating pressure range is from 4,000kPa(a) to 16,000kPa(a).
Proper device Control shall be installed at the export gas compressors discharge header to
guarantee the required lift gas pressure level of 18,600 kPa(a), and send the excess gas to the
export pipeline at maximum pressure of 16,000 kPa(a).
2.7.3.2 DESIGN CASES

Main Compressors downstream equipment capacities shall be determined by simulation modeling


the design cases mentioned above (see item 2.1.2), considering the maximum fuel gas required
for the unit.
The fuel gas required for the unit shall be gathered after the gas treatment system (dehydration
unit and H2S removal unit), complying with the gas turbine vendor requirements.
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The gas treatment plant shall be designed according to Figure 2.7.3.3


2.7.3.3 PROCESS CONFIGURATION - BASE CASE

The gas treatment plant shall consist of different units, in order to attain the contaminants removal
according to Figure 2.7.3.3 which represents a gas system simplified flow diagram.

VRUs
2 x 115%

~8 bara Main Compression Gas treatment Export / Lift Gas


Compression
H2S
Removal

~ HVSD ~ HVSD

3 x 50% Dehydration
or
2 x 100% 2 x 100 %

~191 bara Gas lift

Fuel Gas
System

Gas Pipeline 1

40 - 160 Bar a

Gas Pipeline 2
Process Plant

Figure 2.7.3.3 – typical gas treatment plant scheme

The Process described in item 2.7.3 shall be considered as a Base Case and is considered
PETROBRAS preference, nevertheless, other gas processing schemes that satisfy the same
functional requirements and final specifications are acceptable but shall be presented to
PETROBRAS for approval during the bid phase.
Bidder shall present the API datasheet for all the gas compressors and drivers during the bid
phase.
The gas treatment module comprises 2(two) main units:
 H2S removal unit; and
 Dehydration unit.
2.7.3.3.1 H2S REMOVAL UNIT

The H2S removal Unit shall be designed according to the following:


 Minimum design Capacity = 4,000,000 Sm³/d;
 Inlet pressure: to be simulated
 Inlet H2S: up to 1,000 ppmv
 Inlet CO2: up to 1% mol
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 Turndown: the unit shall be designed to continuous operation for any flow rate between 5%
and 100% of the design capacity, considering all design cases.
 Maximum outlet gas H2S content = 5 ppmv.
An Amine Unit is acceptable and CONTRACTOR shall submit to PETROBRAS for comments and
information.
The Unit shall have an online H2S content analyzer upstream and downstream unit connected to
the process interlock system.
The H2S removal Unit shall comply with the following requirements:
The H2S removal Unit shall be designed in accordance with API RP 945 – Avoiding Environmental
Cracking in Amine Units.
The gas stream from the common discharge of compression units shall be directed to the H2S
removal unit.
A scrubber vessel (1 x 100%), to minimize carry-over of heavy hydrocarbons, and coalescer filters
(2 x 100%) shall be installed upstream the gas-amine contactor(s).
For the scrubber vessel design, as a minimum, CONTRACTOR shall consider:
 three individual separation stages to ensure the required gas-liquid separation:
o Inlet device to receive the incoming process stream and evenly distribute the flow
to improve gravitational liquid separation in the vessel inlet zone
o Mesh or Vane device to separate large liquid droplets, drain it without re-
entrainment;
o Demisting cyclones to ensure high efficiency of droplet removal.

 The maximum simulated condensate liquid increased of 5% of gas mass flow;


The coalescer filters shall have quick open device and differential pressure transmitter (PDT).
The scrubber vessel and the coalescer filter shall have independent level control loops (LIT, LIC
and LV).
The level meters shall have several side connections to avoid measurement errors in case of two
liquid phases.
The amine contactor(s) and amine stripper towers shall use packing. The liquid distributor shall be
tubular type or similar. The packing height and dimensions shall be defined considered the vessel
motion of 1 year waves return period (DOC: Design Operational Conditions). PDTs shall be
installed around the packings.
The amine contactor shall have a bucket to eventually separate condensed hydrocarbons.
A by-pass around the amine contactor(s) shall be provided for lean amine to allow circulation
during start-up.
Temperature of lean amine entering the top of the amine contactor(s) shall be controlled at a
higher temperature than the gas entering the contactor.
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All coolers shall use cooling water as cooling medium.


All heaters shall use hot water as heating medium.
The amine flash drum shall be a three-phase horizontal separator, to separate amine,
hydrocarbon and gas, with dedicated level control loops (LIT, LIC, LV) for each liquid phase.
Cartridge filters (2 x 100%) shall be provided for 100% of lean amine flow. Activated carbon filter
and a secondary cartridge filter, with a by-pass, shall be provided for 20% of lean amine flow.
Facilities (tanks, pump, instrumentation, etc.) for chemicals injection (anti-foam, etc.) shall be
provided.
The regeneration system shall be design in order to avoid oxygen entrance during a
shutdown/cooling-condensation of the steam inside de tower.
The H2S removal unit shall also be designed taking into account the minimum temperature that
occurs during the depressurizing condition of H2S removal unit to the flare system.
For plate heat exchangers, consider hydrocarbon presence in order to specify the equipment, a
spare equipment or spare plates and gaskets on board are required.
SPARE PHILOSOPHY
H2S Removal unit equipment shall comply with the following minimum requirements as spare
philosophy:
 Contactor towers minimum of 2 x 50%;
 Pumps: N+1 (one stand-by);
 Filters: N+1 (one stand-by); except Amine Carbon Filter and its associated cartridge
downstream filter which shall be 1 x 100%;
 Lean/Rich Amine Exchanger (2 x 100%);
 Amine Stripper Reboiler (2 x 50%).
SAMPLING
Manual sampling points shall be provided, at least, as follow:
Sour gas - at gas inlet of amine contactor (s)
Sweet gas - at gas outlet of amine contactor
Lean amine - at inlet of amine contactor(s)
Rich amine - downstream of amine flash vessel level control valve
Rich amine - downstream of activated carbon filter
Sour gas - upstream scrubber vessel
Sweet gas - downstream of KO drum in the outlet of amine contactor(s)
Reflux water to the stripper tower
Make-up water
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The Amine System Flue Gas can be vented or flared, this vent shall be unique to the H2S
Removal Unit (Amine System Flue Gas); dispersion study shall be provided evaluating safety risks
related to gas release to Unit surroundings atmosphere.
The vent line cannot have low points to avoid vent trap installation.
The gas dispersion study shall determine the final height of the vent to ensure that:
 The vent end point shall be located in a safe place, considering good practices and
techniques to carry it out, as well as, the worst atmospheric conditions (eg: calm; plumes
directed into the Unit);
 Exhausted gases cannot reach workplaces and expose workers to their incidence, or
classify unclassified areas, except the venting itself;
 Exhausted gases shall not interfere with the Unit detection system avoiding spurious
emergency shut down.
Amine tank or vessels with connections to atmospheric vent shall be equipped with nitrogen or
other inert gas blanketing system.
H2S detector distribution in the UNIT plant shall be defined based on H2S dispersion study and
considering any leak possibility from H2S contaminated streams
A proper amine shall be selected taking into account the inlet composition and required
specification for CO2 and H2S in the outlet gas.
The CONTRACTOR shall provide an online flow meter (transmitter) in the lean amine inlet of each
contactor Tower.
The performance of the treatment shall be monitored by a CO 2 and H2S online analyzer at the
contactor tower inlet, outlet and export gas stream, as a minimum, besides sample points to allow
lab analysis.
CONTRACTOR shall provide the amine for the first fill-up of H2S removal system
Additional requirements:
 Facilities for chemicals injection (anti-foam) shall be provided;
 KO drum at the gas outlet of the absorber shall be provided to prevent amine loss and
damage to dehydration unit, with recycle of the recovered liquid to the surge drum;
 In case of electrical resistors at reboiler heating system, instead of heating water,
contractor shall consider minimum of (2x120%) electrical resistors and a jacket system
provided with standby resistors, allowing the resistors to be changed without the need of
draining the amine system. Energy demand calculation shall consider the loss of thermal
conductivity caused by this jacket;
 In case of Unit malfunction, the off-spec treated gas shall be deviated to flare, through the
scrubber pressure control valve.
 The make-up water shall have the following quality parameters, as a minimum, or more
restrictive according to the amine plant designer specification.
o Total Hardness (Ca & Mg) < 50 ppmw max
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o Chlorides < 2 ppmw max


o Sodium < 3 ppmw max
o Potassium < 3 ppmw max
o Iron < 10 ppmw max

2.7.3.3.2 DEHYDRATION UNIT – MOLECULAR SIEVES OR TEG (TRY ETHILENE


GLYCOL)

Contractor has the option to use Molecular Sieves or TEG for dehydration unit system complying
with the minimum requirements as per described ahead:
a) Molecular Sieves
The Molecular Sieves Unit shall be designed according to the following:
 Minimum design capacity = 4,000,000 Sm³/d;
 Maximum capacity = depends on previous capacities and condensation;
 Outlet gas specification = 32 ppmv H2O
 A spare vessel is required (recommended arrangement of 4 x 50%) meaning 2 vessels
under operation, 1 vessel under regeneration and 1 as spare ready to operate.
 Inlet gas H2S content = 10 ppmv

The Molecular Sieve shall not adsorb H2S.


All molecular sieves manufacturer recommendations shall be followed, including design
parameters, monitoring instruments, subsystems and facilities for bed discharge and replacement.
For Molecular Sieve design and specification purposes, maximum H2S content (10 ppmv) shall be
considered and heat and mass balance for the unit shall include concentration on regeneration
gas and recirculating H2S destiny after regeneration cycle.
A scrubber (1 x 100%) and a coalescer filter (2 x 100%) upstream the Molecular Sieve unit shall
be installed to avoid liquid carry over. A combined scrubber/filter configuration is acceptable. In
this case a spare set (scrubber/filter) shall be considered (2 X 100%). Layout and piping
arrangement of the unit shall minimize risk of liquid condensation downstream coalescer filter, by
avoiding liquid pocket points, using thermal insulation, minimizing piping length and height
difference. A heater shall be installed upstream, as near as possible of the molecular sieve vessel,
in order to guarantee superheating of at least 5°C and avoid condensation in the molecular sieve
bed.
For the scrubber vessel design, as a minimum, CONTRACTOR shall consider:
 three individual separation stages to ensure the required gas-liquid separation:
o Inlet device to receive the incoming process stream and evenly distribute the flow to
improve gravitational liquid separation in the vessel inlet zone

o Mesh or Vane device to separate large liquid droplets, drain it without re-
entrainment;

o Demisting cyclones to ensure high efficiency of droplet removal.


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 The maximum simulated condensate liquid increased of 5% of gas mass flow;


The scrubber vessel and the coalescer filter shall have independent level control loops (LIT, LIC
and LV).
The level meters shall have several side connections to avoid measurement errors in case of two
liquid phases.
CONTRACTOR to evaluate potential of hydrate formation on condensate/liquid return lines of the
scrubber and coalescer filter and forecast a mitigation solution, if required.
The molecular sieves regeneration gas shall be indirectly heated (electrical, steam or hot water).
Thermal oil fluid and directly heating by turbine exhaust gases will not be allowed. A standby
heater system shall be provided ready to operate.
If electrical heating is used, system shall have appropriate redundancy to assure high reliability:
 Redundant feeding transformers, each one capable of supplying 100% load. Transformers
shall be suitable for low power factor and high harmonic content, with provisions for forced
ventilation installation.
 SCRs shall have (n-1) configuration, with one standby unit.
 FPSO shall have one spare resistance bundle in its warehouse for prompt replacement of
faulty resistance bundle.
 Electrical heater system shall be fully redundant (2 x 100%), considering (transformers,
electrical panels, SCRs and heaters). Electrical heater shall be arranged in independent
and separated vessel, in order to allow maintenance and replacement of bundles in a way
not to impact heating system availability. Disconnecting switch or circuit breakers shall be
provided for quick change over of bundles.
A proper outlet gas filter (2X100%) shall be provided in the Molecular Sieves Unit to avoid fine
particles carry-over. During design, the possibility of gas hydrate formation must be checked on
condensate lines from scrubbers and avoided.
For the regeneration gas recycle, a specific blower shall be used (2x100%). If CONTRACTOR
decides to send regeneration gas back to Main Compressor, this machine capacity shall be
increased to accommodate this additional flow.
Contractor shall provide means of isolating and depressurizing each vessel, so that they can be
operated separately, enabling bed exchange operation, without stopping the system.
CONTRACTOR shall design unit considering procedure for change out of molecular sieve bed,
including support structure for the new and spent molecular sieves, facilities to remove solids from
the vessel, required purge gas (N2), among others. A material handling plan shall be provided
evidencing that the arrangement of the process plant equipment complies with the requirements
above. A dump to flare valve shall be provided downstream the unit.
CONTRACTOR shall consider the following requirements regarding each molecular sieve vessel
bed support, as minimum:
 Support ring welded to the vessel wall;
 Support grid above the support ring;
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 Coarse mesh screen above the support grid (structural function);


 Fine mesh screen above the coarse mesh screen (sealing function).
Note 1: CONTRACTOR shall ensure that there are no gaps between: (i) grid and vessel wall; (ii)
grids; (iii) grid and internal thermal insulation, if applicable. The gaps shall be properly sealed by
using a ceramic fiber rope.
Note 2: CONTRACTOR shall use a ring fixed by bolts to the support ring in order to hold both
screens in between.
Note 3: CONTRACTOR shall consider that all gaskets materials must be suitable for design
operating conditions.
Note 4: Any different solution shall be presented to PETROBRAS during project execution phase.
Vendors for Molecular Sieves:
 CECA;
 UOP a Honeywell Company;
 ZEOCHEM L.L.C.
 Axens;
 Grace / W.R. Grace Brasil Industria e Comercio
Automatic valves to switch over from dehydration to regeneration mode shall be supplied by:
 Cameron International Corporation;
 Control Seal B.V.
CONTRACTOR shall install proper online instrumentation and analysis devices to determine H2O
content in the outlet gas stream. This online instrumentation shall be connected to the process
system.
Instrument Vendor:
 AMETEK
 SPECTRASENSORS, INC
 MICHELL INSTRUMENTS
b) TEG UNIT
The gas dehydration unit by TEG absorption shall be designed to a maximum inlet gas operational
temperature of 40°C. Contractor shall install a shell and tube heat exchanger for this purpose.
Contractor may consider design alternatives to achieve lower inlet gas temperatures. Only shell
and tube heat exchangers are acceptable to TEG unit inlet gas.
A scrubber (1 x 100%) and a coalescer filter (2 x 100%) upstream the TEG unit shall be installed
to avoid liquid carry over and condensate removal. A combined scrubber/filter configuration is
acceptable. In this case a spare set (scrubber/filter) shall be considered (2 X 100%).
For the scrubber vessel design, as a minimum, CONTRACTOR shall consider:
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 Three individual separation stages to ensure the required gas-liquid separation:


o Inlet device to receive the incoming process stream and evenly distribute the flow to
improve gravitational liquid separation in the vessel inlet zone
o Mesh or Vane device to separate large liquid droplets, drain it without re-
entrainment;
o Demisting cyclones to ensure high efficiency of droplet removal.

 The maximum simulated condensate liquid increased of 5% of gas mass flow.


Some operational parameters shall be monitored in order to define when the hydrate inhibitor
injection is required. These parameters are shown below and shall be ratified in later phases of
the project.

Parameter Export Gas Export Gas with hydrate inhibitor


Online Dew point Analyzer ≤ 32 ppmv >32 ppmv
Chanscope ≤ 32 ppmv >32 ppmv
Lean Glycol > 99,75 % ≤ 99,75 %
Reboiler Temperature > 195 °C ≤ 195 °C
Contactor Temperature ≤ 40 °C > 40°C
Glycol Flow to be defined to be defined
Stripping gas to be defined to be defined
Layout and piping arrangement of the unit shall minimize risk of liquid condensation downstream
coalescer filter, by avoiding liquid pocket points, using thermal insulation, minimizing piping length
and height difference. Contractor shall provide an additional gas-liquid separation step, built into
the TEG absorber column.
The scrubber vessel and the coalescer filter shall have independent level control loops (LIT, LIC
and LV).
The level meters shall have several side connections to avoid measurement errors in case of two
liquid phases.
CONTRACTOR to evaluate potential of hydrate formation on condensate/liquid return lines of the
scrubber and coalescer filter and forecast a mitigation solution, if required.
TEG unit shall meet the following specification:
 TEG unit turndown: from 5% to 100% of nominal design gas flow;
 Lean TEG specification: minimum 99,95% (mass %);
 Rich TEG specification: minimum 95% (mass %).
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TEG absorber column shall be fitted with proper packing and liquid distributor in order to achieve a
high efficiency. Means for minimizing TEG carry over shall also be provided in the form of column
internals or a separate K.O. drum. PDT shall be provided to monitor differential pressure across
the packing.
Temperature of lean TEG entering the top of the absorber shall be controlled at 5ºC higher than
inlet gas temperature.
A by-pass around the absorber column shall be provided for lean TEG as to allow startup of the
unit.
Consider 10ºC of approach between the desired water dew point and equilibrium theoretical water
dew point to design the number of equilibrium stages of absorber tower.
TEG Flash drum shall be designed considering 15 minutes of residence time for Rich TEG.
Cartridge filters (2x100%) shall be provided for 100% of rich TEG flow. Activated carbon filter and
a secondary cartridge filter, with a by-pass, shall be provided for 20% of rich TEG flow.
A flow meter shall be provided to deviated rich TEG flow.
The TEG circulation pump shall meet the following specifications:
 Configuration: N+1 (one stand-by);
 Reciprocating pump diaphragm type;
 Pumps shall be designed according to API 674 or 675;
 PSV and recycle valve shall return to surge vessel;
 Pulsation damper in discharge pump is required;
 Flow control with Variable Speed Driver (VSD);
 Glycol flow rate: minimum 1m³/h/m² of dehydration column area section to ensure
sufficient wetting of the structured packing.
A Coriolis flow meter shall be provided to measure the lean TEG flow. This equipment shall be
installed as close as possible the absorber, downstream of any by-pass line to measure the TEG
flow through the absorber.
The Reboiler shall operate as close as possible to atmospheric pressure. The backpressure shall
not exceed 0.2 barg.
For TEG design and specification purposes, maximum H2S content (10 ppmv) shall be considered
and heat and mass balance for the unit shall include concentration on regeneration gas and
recirculating H2S destiny.
TEG Regeneration Reboiler shall be electrical heating in stages (not on-off) and shall have
appropriate redundancy to assure high reliability:
 Redundant feeding transformers, each one capable of supplying 100% load. Transformers
shall be suitable for low power factor and high harmonic content, with provisions for forced
ventilation installation;
 SCRs shall have (N+1) configuration (with one standby unit);
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 FPSO shall have one spare resistance bundle in its warehouse for prompt replacement of
faulty resistance bundle;
 Resistance bundle maintenance shall be done in a way not to impact heating system
availability;
 It shall be considered a 10% additional margin in the maximum estimated heating demand;
 The maximum heat flux to be considered for electrical heating design shall be 1.25 W/cm².
 The Reboiler shall control the glycol temperature in 204ºC.
CONTRACTOR shall provide a stripping gas distribution system in the bottom of the reboiler.
Automated gas stripping flow control shall be provided using Cone flowmeter.
CONTRACTOR shall provide Stahl Column with stripping gas injection, containing a minimum of 3
equilibrium stages, at a lower level than the reboiler. Automated gas stripping flow control shall be
provided using Cone flowmeter.
Flash vapor from Flash drum and Exhaust gas from Stahl column shall be sent to VRU, using a
boosting device if necessary
Surge Vessel shall be designed to store the entire TEG inventory during maintenance shutdowns.
Sampling points shall be provided in the following points:

Stream Manual Sampling Points


Lean TEG Inlet of absorber
Rich TEG Upstream of absorber level control valve
Downstream of activated carbon filter
Upstream of absorber, downstream of
Wet gas
coalesce filter
Dry gas Fuel Gas Distribution
CONTRACTOR shall install proper online instrumentation and analysis devices to determine H2O
content in the gas dehydration outlet stream, downstream of absorber.
The analyzer shall be adjusted to execute gas water content validation by internal permeation tube
(at least weekly check).
CONTRACTOR to provide calibration of gas water content analyzer according to supplier
recommendation or when it occurs some divergence during periodical check.
At any time, analyzer measurement will be compared to most recent version of GPSA Equilibrium
Chart “Equilibrium H2O Dew point vs. Temperature at Various TEG Concentrations”. These results
will be used to mediate divergences about measured values. CONTRACTOR to consider McKetta
Method (GPSA chart: “Water Content of Hydrocarbon Gas”) to convert equilibrium dew point to
lb/MMscf.
At any time, PETROBRAS can ask gas water content analyses by manual chilled mirror according
to ASTM D-1142 to mediate divergences about measured values. CONTRACTOR to consider
“GPSA + Wichert (acid gases correction)” to convert equilibrium dew point to lb/MMscf.
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The offspec treated gas shall be deviated to flare, through a pressure control valve installed on
downstream TEG contactor.
Instrument Vendors:
 AMETEK
 SPECTRASENSORS, INC
 MICHELL INSTRUMENTS
Minimum Requirements for TEG Units Suppliers:
 Proven experience on offshore TEG Units design with 5 MM Sm³/d gas capacity;

2.7.3.4. GAS COMPRESSORS

The main compressors and export/gas lift compressors shall comply with API-617 centrifugal
compressor type.
Dry Gas Seal (DGS) System:
 The shaft seals shall be of self-acting tandem dry gas seals (DGS) type with intermediate
labyrinth seal;
 Primary seal gas shall be the treated and conditioned discharge process gas sufficiently
clean to avoid particulate and at the suitable dew point to avoid liquids condensation
(considering hydrocarbon and water) and at the required pressure to fit all the operational
conditions. For the VRUs fuel gas shall be used as the primary seal gas
 Nitrogen shall be injected in the intermediate labyrinth seal and in the oil separation seal.
Alternatively, the oil separation seal gas may be air, once nitrogen is used for the
intermediate labyrinth seal;
 O-rings and any other polymer-based sealing element in contact with process gas shall be
strongly resistant to explosive decompression taking into account a large number of
compressor starts/stops;
 The compressor packages shall include a seal gas treatment system per package
consisting, as a minimum, of: separator/coalescer duplex filter, one electric heater with
spare heater element installed or, alternatively, a duplex electric heater, and a booster
compressor to provide the required positive feed pressure to the seals on any
operating/stop condition. This system shall be supplied by the DGS manufacturer.
The condensate from inlet, inter stage and final compressor stage collected on the scrubber
vessels shall be routed to the oil plant or to the previous gas scrubbers. They shall not be sent to
slop or drain system.
Recycle system for anti-surge control shall be preferably “hot recycle”, meaning that there is no
cooler or scrubber vessel installed in between the compressor discharge and the related recycle
valve. Compression with wet gas shall be checked to prevent hydrate formation due to recycle of
antisurge valve.
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The compressor packages supplier shall be the compressor OEM (original equipment
manufacturer).
Contractor shall consider utilities to start-up the stand by compressor without turning off the
running gas compressor during units change over.
For hood protection specification shall be considered additional requirements in SAFETY
GUIDELINES FOR OFFSHORE PRODUCTION UNITS document.
CONTRACTOR shall perform coupled test run in all topsides gas compressors/drivers as part of
FPSO´s commissioning and Provisional Acceptance Tests prior sail-away from shipyard to final
offshore location. Any deviation due to a mandatory and reasonable motivation on this
requirement shall be mutually agreed between PETROBRAS and Contractor at early stage of
execution phase.
2.7.3.4.1 VAPOR RECOVERY UNIT (VRU)

The Vapor Recovery Units (VRU) shall be API-619 dry-screw compressor type.
The VRU package supplier shall be the compressor OEM (original equipment manufacturer).
The VRUs configuration shall be 2 Units x 100%. The VRU compressor capacity shall be designed
considering 115% of the maximum flow rate, as defined by the cases stated on table 2.1.2 design
cases.
Note 1: CONTRACTOR shall consider Unit as compressor machine, scrubber, coolers etc.
Its capacity shall be defined by CONTRACTOR, in accordance with all design cases simulations
and considering all recycles.
 test separator
 second degasser
The compressor shall be designed for continuous operation at any flow rate between zero and
100% of the design capacity, considering all design cases (refer to item 2.1.2).
The driver shall be electric motor. The capacity control may be performed either by Electric
Variable Frequency Drive (VFD) or recycling.
Dry-Screw Compressor Vendors list:
 MAN DIESEL & TURBO
 KOBELCO Compressors America INC;
 HOWDEN
2.7.3.4.2 MAIN COMPRESSORS

The first step compressors shall be designed according to the following:


 Nominal minimum capacity = 4,000,000 Sm³/d, for inlet pressure resulted from normal
operating 1st degasser pressure and molecular weight range correspondent to all design
cases;
 inlet pressure range = depends on previous simulations and pressure drop;
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The compressors shall be designed to continuous operation/start up for any gas flow rate up to
100% of the design capacity, considering all design cases (refer to items 2.7.3.2 and 2.1.2) and all
compressor derating. A spare unit is required. The following configurations are accepted:
2 X 100% or 3 X 50%.
A Safety K.O. drum shall be installed upstream the Main Compressors, in order to separate the
condensate formed due to inlet gas cooling and carried droplets, as well as to avoid any liquid
carry-over. This condensate shall return to the second stage oil separation system. Under no
circumstances it shall be sent to the slop or drain system.
For the Safety design, as a minimum, CONTRACTOR shall consider:
 three devices (three individual separation stages) to ensure the required gas-liquid
separation:
o Inlet device to receive the incoming process stream and improve gravitational liquid
separation in the vessel inlet zone (the current device designed to perform this
function will not be accepted)
o Mesh or Vane device to separate large liquid droplets, drain it the liquid without risk
of entrainment;
o Demisting cyclones to ensure high droplet removal efficiency;
 The maximum simulated condensate liquid increased of 5% of gas mass flow."
2.7.3.4.3 GAS LIFT / EXPORT COMPRESSORS

The second step compressors shall be designed according to the following:


 maximum capacity = 4,000,000 Sm³/d;
 Inlet pressure = depends on previous simulations, gas compositions and pressure drop;
The compressors shall be designed to continuous operation/start-up for any gas flow rate up to
100% of the design capacity, considering all design cases (refer to items 2.2 and 2.1.2) and all
compressor derating. A spare unit is required. The following configurations are accepted:
2 X 100% or 3 X 50%.
Compressors Vendors list:
 Siemens/Dresser-Rand Company;
 Elliot Turbo;
 BHGE – Baker Hughes -GE
 Hitachi;
 MAN Diesel & Turbo;
 MCO (Mitsubishi Compressors).
For gas export/import
 A Safety K.O. drum (or a slug catcher for both stream directions) shall be installed for
import gas from pipeline, in order to separate any liquid carry-over. For this purpose, shall
be the maximum liquid capacity to the flow of 240 m³/day. This condensate shall return to
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the second stage oil separation system and under no circumstances it shall be sent to the
slop or drain system. Additionally, CONTRACTOR shall consider slug volume (NLL to LAH
of the vessel) of 26.0 m3.
 In case of import gas heating systems with electrical resistors, a jacket system provided
with standby resistors shall be used, allowing the resistors to be changed. Energy demand
calculation shall consider the loss of thermal conductivity caused by this jacket;
2.7.3.4.4 COMPRESSORS DRIVERS

Induction electric motors or gas turbines are the only acceptable drivers for the compressors and
they shall include speed variation capability.
In case the selected driver is electric motor, Hydraulic Variable Speed Driver shall be applied as
power transmission.
Electric Variable Frequency Drive (VFD) is not acceptable, except for the VRUs
If Gas Turbine is selected, all trains associated with the fuel gas production shall be dual fuel, in
order to allow initial operation of the fuel gas system.
In addition, the equipment shall be selected complying with one of the following requirements:
 ISO Power - At least 33% higher than compressor greatest power required (including gear
and coupling losses) indicated in the supplier data sheet, considering fuel gas operation or;
In case of Electric Motor driver, the available power shall be at least 10 % higher than compressor
greatest power required (including gear and coupling losses) indicated in the supplier data sheet.
Gas Turbine:
 GENERAL ELECTRIC: LM2500, LM2500+, LM2500+G4;
 SIEMENS: SGT-100, SGT-200, SGT-600, RR501, RB211G/GT;
 SOLAR: SATURN, CENTAUR, TAURUS 60, MARS, TITAN 130, TITAN 250
Hydraulic Variable Speed Driver:
 VOITH VORECON
2.7.3.5. OTHER REQUIREMENTS

Utilities (including power generation system) shall be designed considering at least the capacity of
4,000,000 Sm3/d for the compression system.
The gas inventory inside the gas export line should be able to be used as fuel gas in case of
availability of gas export pipeline with unavailability of fuel gas.
2.7.3.6 - GAS PIPELINE COMMISSIONING

Commissioning of the gas export pipeline shall occur after pull-in the gas export riser and will be
PETROBRAS scope of work. The Unit shall provide device to vent the residual inert gas and drain
from the gas pipeline during commissioning
CONTRACTOR shall be responsible only for the part of the commissioning procedure that
requires operations and support personnel onboard the FPSO. This procedure shall consider that
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the pipeline will not be pressurized with hydrocarbons (pressure = zero). The procedure will be
issued by PETROBRAS.
The Ethanol and MEG pumps (5 m³/h each one) shall be used in the commissioning of all gas lift
risers and gas export lines (refer to Note 1, item 2.8).
2.7.4. NOT APPLICABLE

2.7.5. FLARE AND VENT SYSTEM

The Unit shall be equipped with 2 (two) independent flare systems, one operating at high pressure
(HP) and the other at low pressure (LP), to collect and burn residual gases released from safety
valves, pressure control valves, blow down valves, pipelines, etc. The system shall be designed
for emergency burning and also shall have a backup of the ignition system. The systems shall be
designed to operate simultaneously.
CONTRACTOR shall consider/evaluate a low temperature flare header and scrubber.
CONTRACTOR shall consider the use of an independent pressure safety piping relief from the
normal operation gas piping.
CONTRACTOR shall also take into account the need to periodically test the PSVs, according to
NR-13. The allowed radiation levels shall not be exceeded in any weather condition and in any
continuous or emergency gas flow range at any point over the Unit where human presence is a
possibility during operation and maintenance, or when equipment manufacturers requires specific
radiation level limits.
The flare stack height shall be designed considering that radiation levels fall within ISO-23251
limits during emergency flaring. Once the stack height is calculated, the maximum continuous HP
Flare flow rate shall be subsequently determined, based on same allowable thermal radiation
levels. Also for the determination of the flare stack height, CONTRACTOR shall consider the
dispersion analysis of the flare snuffing.
Guide Codes and Standards to be fulfilled:
 ISO-23251;
 API-STD-521;
 CS Requirements and Guidelines.
During the design of the tower or boom CONTRACTOR shall also take into account, the possibility
of igniting venting gas devices by the flare and the possibility of gas leakage at the production
plant. The tower length shall be designed to guarantee 20% (maximum) of the L.E.L. (lower
explosive limit) on the flare tip due to gas dispersion after a leakage in the production plant.
CONTRACTOR shall guarantee a maximum noise level exposition according to NR-15,
considering the offshore work cycle, for continuous gas burning at any point in the Unit where
human presence is possible during operation and maintenance.
CONTRACTOR shall guarantee smokeless burning, in accordance with Level 1 of the
RINGLEMANN Scale for operational condition.
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Flare model shall be a non-pollutant type, with low NOx emissions. Burning efficiency shall be high
enough to guarantee low HC emissions to the atmosphere.
Three independent vent systems shall be provided to collect low pressure (around atmospheric
pressure) gases and vent them safely:
 For process plant;
 To collect vent gases from cargo tanks;
 For risers
OBS: Contractor shall consider the presence of H2S for venting system.
CONTRACTOR shall create an inventory of all atmospheric vents, assess the risks, document and
implement remedial steps in design.
The flare shall be located in a way that avoids any interference with offloading, supply boat, pull-in
and helideck operations.
CONTRACTOR shall guarantee that flare system have suitable supports in order to avoid transfer
vibration to the flare piping system.
2.8. CHEMICAL INJECTION

The Unit shall be equipped with a chemical injection system, which shall be used to improve and
enhance the operating conditions of equipment, lines and pipelines. The oil, gas, water treatment
and water injection systems shall be designed to inject the following main products:
 H2S scavenger for subsea and gas system (topside and subsea gas line)
 H2S scavenger for offloading system;
 Gas hydrate inhibitor for topside and subsea;
 Scale inhibitor for topside;
 Scale inhibitor for subsea;
 Water-in-oil demulsifier (topside)
 Water-in-oil demulsifier (subsea);
 Oil defoamer;
 Gas corrosion inhibitor;
 Polyeletrolyte (inverted emulsion inhibitor);
 Biocides for Slop Tank, Settling Tanks, Water/Oil Off-spec Tank;
 Amine for H2S removal unit
 TEG (in case TEG unit application)
Facilities for additional chemical injection points shall be provided as per I-ET-3010.1R-5330-940-
P4X-001 (see item 1.2.1).
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The entire manufacturer recommended chemicals for the Sulphate Removal Unit and Ultrafiltration
Unit. As a minimum CONTRACTOR shall consider:
 Membrane biocide and/or shock biocide;
 Chlorine scavenger and/or oxygen scavenger;
 Scale inhibitor for SRU;
 Acid cleaning;
 Alkaline cleaning.
Whenever necessary, the Unit shall have facilities, via the well service system, to inject other
products also including diesel, water and nitrogen.
CONTRACTOR shall provide facilities to keep the cleanliness of chemicals injection system on
topsides in order to avoid particles to be sent to umbilical’s.
Where not specifically mentioned, storage tanks for chemicals shall have enough capacity for 7
days of normal consumption, calculated by using 80% of the maximum injection rate indicated in
the Table 2.8.1.
The Unit shall be able to inject hydrate/scale inhibitors/demulsifier into subsea Christmas trees
and at topside facilities. For umbilical (subsea) injection, filters (2x100%, 400 mesh stainless steel)
on pump discharges shall be added. These filters shall have remote differential pressure alarm for
replacement.
Systems for subsea injection shall be flushed during commissioning to prevent umbilicals from
clogging.
The Unit lay-down area shall be equivalent to the space needed for storing the amount of 5000 L
tote tanks for 7 days consumption, considering 50% of the maximum injection rate indicated in the
first Table of this item at maximum gas, oil, produced water and injection water flow rates.
Products of non-continuous use shall not be considered in this calculation. No stacking of tote
tanks is allowed. For H2S Scavenger storage capacity see table 2.8.1.
Chemical tanks shall have outlet nozzle with at least 150 mm distance from the bottom. Also,
bottom shall be slopped toward to drain nozzle in order to facilitate tank cleaning operations.
CONTRACTOR shall install stand-by pumps at all chemical units to guarantee continuous
performance, even high-volume pumps as ethanol/MEG and oxygen scavenger.
Each injection point shall have an online flow meter (transmitter) and a calibration gauge glass in
order to measure the injection rate.
Each injection point shall be in the center of pipe.
Concentration ranges for each chemical to be complied with when designing the chemical
injection system are:
Table 2.8.1: Chemical injection list
PRODUCT INJECTION RATE
H2S scavenger for subsea Each well will have individual pump (or multi head pump).
(oil or Gas Stream) and Each scavenger line will pass through X-tree and TH down to
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PRODUCT INJECTION RATE


offloading system the well bottom to allow H2S scavenger to react with H2S in the
tubing;
The subsea injection system provided shall operate in the
range of 20 to 200l/h per well;
CONTRACTOR Shall provide an injection point at each topside
gas lift line;
In case of injection into manifolded gas lift line, the flow rate
shall be between 80 and 800 l/h;
There shall be a total storage tank of 285 m3 and additional
area for 285m³ considering tote tank of 5000 liters each (total
storage capacity of 570m ³).
An injection point upstream each offloading pumps shall be
provided. (11) (13)
Topside (to each gas lift line) and by umbilical:
The subsea injection system provided shall operate in the
Gas hydrate inhibitor range of 20 to 200 l/h per well; (1)
(ethanol) In case of injection into each manifolded gas lift line, the flow
rate shall be between 80 and 800 l/h;
There shall be a total storage of 60 m3
Gas hydrate inhibitor By service line: 5,000 l/h 1 (one) pump for injection when
(MEG/Ethanol bed) requested by PETROBRAS. (1)
Each well will have individual pump (or multi head pump).
Each scale inhibitor line will pass through X-tree and to be
hanger (TH) down to the well bottom.
The injection system provided shall operate in the range of 20
Scale inhibitor for subsea
to 200 L/day per well;
There shall be a total storage of 35 m3 (2).
One of the H2S scavenger tanks shall be able to be used for
Scale inhibitor (11).
Wax inhibitor Not applicable.
Asphaltene inhibitor Not applicable.
Batch use
The use of xylene will be done through service boats and
Xylene there is no need of xylene storage.
Injection rate will be informed during the engineering detailing
phase (see item 3.9)
Topside: from 0 to 50 ppm
Scale inhibitor for topside
Minimum tank capacity: 15 m3 (2)
Each well will have individual pump or 1 (one) multi head
pump.
Each demulsifier line will pass through X-tree and to be
Demulsifier hanger (TH) down to the well bottom.
From 0 to 100 ppm
Minimum tank capacity: 30 m3 (3)(4)
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PRODUCT INJECTION RATE


Minimum Tank Capacity: 45 m³
Acid See I-ET-3010.1R-5330-940-P4X-001 for additional
information.
From 5 to 80 ppm
Oil defoamer
Minimum tank capacity: 17 m3 (4) (5)(6)
export gas pipeline;
Consider an inhibitor dosage of 1.0 liter/MMscf. (7)
Gas corrosion inhibitor
 Minimum tank capacity: 2 m3

Polyelectrolyte
 from 0 to 50ppm
(inverted emulsion
 Minimum tank capacity: 15 m3 (8)
inhibitor)
(SRU) Acid cleaning  Batch use (9)
(SRU) Alkaline cleaning  Batch use (9)
Biocide  Batch use (14)
For Deaerator located downstream of SRU
From 100 to 1000 ppm twice a week during one hour, before
Shock Biocide: DBNPA SRU (10). Under PETROBRAS approval, other frequency
strategies may be proposed.
Water injection shock
biocide: THPS (tetrakis from 100 to 1000 ppm twice a week during one hour, before and
hydroxymethyl phosphonium after the deaerator.
sulfate)
from 1 to 10 ppm before SRU
Scale inhibitor for SRU
 Minimum tank capacity: 8 m3
Chlorine scavenger from 0 to 20 ppm before SRU
from 5 to 20 ppm (operational deaerator)
Oxygen scavenger from 100 to 200 ppm (non-operational deaerator)
 Minimum tank capacity: 8 m3
Biofouling disperser from 5 to 20 ppm after deaerator

Notes:
(1) To inhibit hydrate formation, an independent system of ethanol / MEG shall be injected into the
producing Wells Wet Christmas Trees. CONTRACTOR shall provide the required flow rate and
pressure at the top connection of each control umbilical at the FPSO.
To design this Unit, CONTRACTOR shall consider that the hydrate formation temperature, will, at
least, be kept 5oC below the stream temperature. A safety margin of 15% shall be considered. The
minimum flow rate for each injection point shall be 1.0 (one) L/h. An injection point shall also be
provided for the exported gas pipeline.
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Minimum ETHANOL storage capacity: 60 m3 built-in tanks. Additional injection points are required
at the topside facilities in case of gas dehydration treatment malfunction. Those additional points
shall be installed with spray nozzle devices to accelerate the mixing of inhibitor and gas.
CONTRACTOR shall consider the simultaneous ethanol injection to the all “firm” production wells
and also the additional spare production wells.
To summarize, separate MEG pumps with maximum flow rate of 5,000 l/h (each one) will be
provided to use in the following services:
Minimum MEG storage capacity: 20.0 m3 built-in tanks and the necessary storage area for the
extra 20.0 m3.
One connection from discharge of MEG pump (5,000 l/h) to each service line shall be installed.
a) Injection into the producing wells Wet Christmas Trees at the top connection of each
control umbilical (Not continuous, but design should include injection into all points at the same
time)

b) Injection into all Service or Gas Lift Risers (Not continuous, but design should include
injection into 2 points at the same time); (Hydrate prevention and commissioning). Those
additional points shall be installed with spray nozzle devices to accelerate the mixing of inhibitor
and gas.

c) Injection into gas export line (hydrate prevention and commissioning);

In addition, ETHANOL pumps will be provided to use in the following services:

a) Injection into the producing wells at topside (each gas lift line) or Wet Christmas Trees /
manifold at the top connection of each control umbilical. Design should include injection into all
wells at the same time);

b) Additional injection points at the topside facilities in case of gas dehydration treatment
malfunction (these injection points to include spray nozzle devices).

(2) The Unit shall be prepared to inject the scale inhibitor continuously at the well down hole (in
all production wells at the same time) and at the topside facilities (production header, test
header, upstream of treaters and/or heat exchangers, upstream and downstream of
hydrocyclones and others) whenever required by PETROBRAS. Separate systems shall be
provided, as different products are injected topsides and subsea. PETROBRAS informs that
there is a high potential of scaling at topside.

(3) This chemical uses Xylene as solvent. Products that are injected subsea have no monthly
allowance; they shall be supplied by PETROBRAS on an "as needed" basis.

(4) The Unit shall be prepared to inject this product continuously topsides.
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(5) Points of injection: production and test headers and at the upstream of the oil level control
valve of the first stage separator.

(6) Injection rate shall not exceed 20 ppm, unless expressly authorized by PETROBRAS

(7) The Unit shall be prepared to inject continuously, topsides, the corrosion inhibitor into the gas
export pipeline.

(8) The dilution system of polyelectrolyte shall be used with fresh water on line and adjust the
dilution range from 0.5% to 20% of polyelectrolyte.

Polymaster type pump (or similar) is acceptable. Injection point shall be downstream of
hidrocyclones.
(9) SRU chemicals disposal shall be neutralized before being sent to the FPSO slop tanks.

(10) PETROBRAS states that DBNPA is a corrosive product so its injection system should not
be metallic.

(11) During execution phase PETROBRAS will provide to CONTRACTOR the pressure and flow
rate requirements to size the subsea chemical injection system. The topsides requested
pressure and flow rate are different for the early, medium and late field life.

(12) Not applicable.

(13) CONTRACTOR shall provide a dedicated system to inject H2S scavenger upstream each
offloading pump. There shall be a total storage of 10 m3. The injection system provided shall
operate in the range of 200 to 1,000 l/h.

(14) CONTRACTOR shall provide means to inject biocide into settling tank (water phase), Slop
Tank and water/oil off-spec tank in the water phase. It shall be considered the dosage from
10 to 1000 ppm, twice a week, during one hour, into the liquid outlet line of 2nd Degasser.

PETROBRAS will define the supplier of the chemicals based on their proposals and previous
agreement with the CONTRACTOR. As a rule, PETROBRAS shall always be able to receive
proposals from, at least, 2 (two) chemical suppliers.
PETROBRAS will provide the following chemicals up to the limit mentioned in the table 2.8.2
below, measured monthly. These quantities are referred to the maximum flow rate (Refer to item
2.5.2) or storage capacity mentioned in the table 2.8.1. For flow rates smaller than the maximum,
a proportional amount will be considered.
Table 2.8.2: Maximum limits for Chemical
PRODUCT Quantities (Maximum limits / month)
Scale inhibitor for subsea 100 m3
Scale inhibitor for topside 40 m3
Demulsifier 100 m3
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PRODUCT Quantities (Maximum limits / month)


Oil defoamer 40 m3
Polyeletrolyte (inverted
40 m3
emulsion inhibitor)
Biocide disperser – 248m3
Biocides to water injection
Shock biocide – 20m3
Hydrate inhibitor See remark below
Wax inhibitor Not applicable.
Asphaltene inhibitor Not applicable.
Corrosion inhibitor 5 m3
H2S scavenger for
subsea, gas system and 2500 m³
offloading
Acid 191 m³

Remarks:
1. The necessary amount of hydrate inhibitor for cleaning the flowlines will be provided by
PETROBRAS at no cost.
2. Subsea chemicals will be provided by PETROBRAS at no cost.
3. The quantities above may be revised during the operation, if CONTRACTOR presents
technical evidence that supports such need and is accepted by PETROBRAS.
4. As chemical injection facilities may contain low flashpoint, flammable and/or toxic substances,
these risks shall be used in development of the appropriate protection requirements.
5. Due to potential hazards, the location of chemical injections packages shall not obstruct
escape and evacuation routes by any very toxic substances that might result from an incident.
2.8.1. CHEMICAL INJECTION FLOW CONTROL SYSTEM

The chemical injection flow control system shall be automatic and multi-dosing, ensuring the
injection rate accuracy of each individual injection point, through a dedicated panel with a PLC and
a Human Machine Interface (HMI). Differential Pressure Control (IRCD or similar) is not
acceptable.
The systems shall follow the minimum requirements:
a) Flow Meters:

 The flow meters shall have flow and totalizing indication in the field.
 Accuracy shall be +/- 0,5%.
 Meters electrical enclosures shall be 316 SST.
 Meters output shall be 4 to 20 mA + Hart, 24V, two wires
b) Control Valves:

 The control valves shall be pneumatically actuated or electrically actuated, a turn


down ratio of 50:1, keep the last position in case of power failure and All explosion
proof housings or wetted parts shall be made of 316 SST.
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c) Control Panel:

 "The control panel shall be independent from other systems and allow the flow
control of each metering run of the chemical injection system, consisting of Cabinet,
PLC/ IO’s, HMI".

d) Operation

Communication driver between HMI and PLC by TCP/IP and the software shall provide the
following operation modes and functions:
 Manual operation shall allow the operator to set the valve position through the flow
controller.
 Automatic operation: Dose a pre-established injection rate; Allow shock dosing with pre-set
function; Start and Stop of each metering line; Alarm the maximum and minimum flow rate
of each flow meter; Allow the meter factor correction after calibration.
 Reports: the system shall be capable to generate the following reports: Chemical
consumption per day/month, Historical data on flow rates and valve position.
The chemical injection system shall foresee individual trip per well. The trips will be defined by
PETROBRAS and CONTRACTOR and shall be included in the Process Cause and Effect Matrix.
The information from the system shall also be available for PI Software.
2.9. SAMPLE COLLECTORS

Provisions to collect samples shall be designed in such a way as to guarantee correct sample
accuracy. Each collecting point shall be in accordance with regulations and shall allow safe
operation with no environmental impact. Therefore, CONTRACTOR shall install an adequate drain
system, for each of the collecting points listed below:
Additionally to this item, please refer to I-ET-3010.1R-5330-940-P4X-001 (see item 1.2.1)
regarding sampling collection facilities to be provided.
Table 2.9.1: Sample collectors list.

POINTS SAMPLE COLLECTION


 Test and Production headers (upstream from the
chemical injection points)
 Upstream and Downstream of process vessels
 Try-cocks on 1st degasser, 2nd degasser and
electrostatic treater
Produced oil (1,2)
 Transference pump discharge (from the process plant
to the cargo tanks);
 All production lines
 Offloading line
 Slop, off-spec tank, Settling tanks and Cargo Tanks
Gas (3,4,5)  Upstream and Downstream of process vessels
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 Gas import;
 Gas export (upstream of pig launcher)
 Fuel Gas;
 High Pressure Flare gas;
 Low pressure Flare gas;
 Gas lift header
 Production line from each well / manifold
 Downstream from the scrubber
 Service header
 Slop, settling tanks and Cargo Tanks
 Upstream and downstream of process vessels
Condensate
(Scrubbers)
 Downstream of process vessels
 Slop, Off-spec tank and settling tanks
Produced water (6)  Water discharge piping to overboard (located near
to the oil and water online analyzer)
 Downstream of each treatment water equipment.
 Upstream and downstream of deaerator (if any)
 Seawater intake, upstream of water lift pumps
Injection water  Sulfate removal membrane unit: inlet, treated water
and Sulfate stream (in each vessel)
 Injection header and risers

Hydraulic control  High pressure header for DHSVs


fluid  Low pressure header for WCTs
 Upstream and downstream of the sewage treatment
Sewage
unit.

Note 1: CONTRACTOR shall provide means to collect samples and to determine BTEX content in
produced oil according to EPA 3585/ EPA 8260C and produced water according to EPA 5021/
EPA 8260C.
Note 2: CONTRACTOR must provide facilities to collect samples of oil in vessels of 0,25L up to
1000 L (container). Sampling condition must be at atmospheric pressure. All the gas released in
this process must be sent to a safe place.
Note 3: All gas sampling points shall follow the standards referenced in Technical Regulation
Measurement of Oil and Natural Gas, approved by Resolução Conjunta ANP/Inmetro nº1 de
10/06/2013.
Note 4: CONTRACTOR shall also provide sample collection in every online analyzer (gas
chromatographer, moisture analyzer, oil in water content, etc.) and meter.
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Note 5: CONTRACTOR shall provide means to collect and to determine BTEX content in
produced gas according to GPA 2286.
Note 6: CONTRACTOR shall provide sample collection at produce water discharge pipe,
according to regulation EPA 1664/SM5520B and F and API RP 45. TOG shall be analyzed in a
laboratory certified by INMETRO.

2.10. CORROSION MONITORING

Due to the presence of contaminants in the oil, CONTRACTOR shall take special care with the
material selection for the process plant and also provide means to monitor the corrosion on piping
and equipment.
As a minimum, electrical resistance corrosion or Linear Polarization monitors and corrosion
coupons shall be provided in the following points along the produced oil, gas and water streams:
a) corrosion monitoring (coupons and electric resistance) probes installed:

 Upstream the export gas pipeline;


b) Connection and display for the high sensitivity electric resistance probe installed subsea at the
PLET/PLEM;

c) Corrosion monitoring system, Linear Polarization Resistance, LPR, and coupon on water
injection lines. The probes should be installed downstream of the injection pumps;

d) Downstream of the production chokes;

 For each monitoring location shall be installed at least two points of access, one for
coupon and one for probes, spaced at least 500 mm.
 The places for installing the monitors SHALL be downstream of corrosion inhibitors
injection.
PETROBRAS recommends:
 Main line in horizontal section with the lower generatrix (6 o'clock position) and optionally
the upper generatrix (12 o'clock position);
 The bottom generatrix be installed on a minimum stature of 2 m from the floor, and a
minimum space of 1 m in each side, in order to enable the coupons exchange. If required,
a box access need to be installed.
The coupons, ER/LPR probes shall be tangential type if they will be installed in the “PIG” path.
All ER and LPR probes shall be provided with automated transmission of corrosion data to the
supervisory system unit. The range data acquisition probe shall be at most 6 hours.
All coupons and probes access fitting bodies shall be high pressure type, regardless of the
operating pressure, welded to the pipe.
PETROBRAS will not provide chemicals for corrosion protection of topsides equipment.
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2.11. LABORATORY

CONTRACTOR shall provide onboard a Laboratory equipped to perform, as a minimum, the


following analysis onboard:
Additionally to this item please refer to I-ET-3010.1R-5330-940-P4X-001 (see item 1.2.1)
regarding laboratory requirements.
Table 2.11.1: Required chemical analysis
SYSTEMS ANALYSIS
BS&W (1);
Salinity (5);
Sand content (ASTM 4381-06 - Standard Test Method for
Produced oil Sand Content by Volume of Bentonitic Slurries);
Density.
PVR (ASTM D 323 or 6377)

Cargo, settling, off- BS&W (1);


spec tanks and Slop
tanks H2S content (oil (4), water (7), vapor phases (3))
Oil content (molecular absorption spectrophotometry and
infrared spectroscopy) at all points of discharge to
overboard;
Hardness.
Oil content
Chloride content;
Produced and
Magnesium content;
Discharged water
Calcium content;
PH;
Composition (Salinity, organic acids, bicarbonates,
Calcium, Magnesium, Bromide, Barium, Strontium, Iron,
Manganese, Potassium, Lithium, Boron, Sulfates); (6)
TOG.
O2 content (measurement range shall be from 0 to 1000
ppb);
SDI (Silt Density Index);
Bacteria SBR planctonic – mesophylic and thermophilic)
(6);
Injection water Total anaerobic bacteria (BANHT planctonic) (6);
Number of particles;
Sulfate Content (Ion Chromatographic – For reference IC
861 Metrohm or Photometry – Standard Methods 4500E);
Chlorine content (8);
Soluble sulfide content (7);
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Total suspended solids (TSS) (6);


pH.
H2S content by iodometry (GPA STD 2265);
H2S and CO2 content by length of stain tubes (GPA STD
Produced gas 2377-14 or ASTM D4810-06); Hydrocarbons and CO2
content by chromatographic analysis (ASTM D1945 or
ISO 6974-2-).
H2O content (2);
H2S content by Potentiometry by ISO 6326-3;
Treated gas
Hydrocarbons and CO2 content by chromatographic analysis
(ASTM D1945 or ISO 6974-2-2001).

Hydraulic control fluid Cleanliness according to (ISO 4406 and ISO 11500);
Sea water lift system Chlorine content in inlet filter.(8)
pH;
Cooling and Heating Chloride Content;
medium system Corrosion inhibitor content;
Iron content.
Chlorine content;(8)
Chloride content;
Utility water make up
pH;
Iron content.
Potable Water As per Ordinance MS 2914/2011 and its Annexes
Glycol concentration (9);
Lean and Rich TEG
pH;

Analysis in natural gas by gas chromatography (including


H2S and CO2) (10)
Lean and rich amine concentration
H2S Removal Unit Amine acid gas loading
Nitrite ion in the reflux water to the stripper tower
Oxygen content, pH, free chlorine, total hardness, total
iron and alkalinity in the make-up water.

Note 1: With regard to produced oil BS&W analysis CONTRACTOR shall be able to perform the
lab analysis according to ASTM D 4007 (BS&W higher than 5%) and Karl Fisher (BS&W lower
than 5%).
Note 2: With regard to dehydrated gas, CONTRACTOR shall be able to perform the primary
standard lab analysis according to ASTM 1142/95 (Chandler Chanscope Digital Dew Point Meter),
including provision for the low temperature needed for the analysis, such as a liquid nitrogen
generator. The analyses must be able to measure with accuracy H2O content below 32 ppmv.
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Note 3: Dragger test tube (ASTM D 4810). Analyses method should be able to measure H 2S
content.
Note 4: Potentiometry: UOP 163.
Note 5: Salt-in-Crude analyzer (ASTM D 3230) and Potentiometric method (ASTM D 6470).
Note 6: These analyses shall not be performed onboard. CONTRACTOR shall provide means to
provide these analyses onshore. Note 7: Sulfide in water: Standard Methods 4500.
Note 8: Laboratory analyses should be able to measure from 0,1 to 2 ppm of chlorine content.
Note 9: ASTM E 1064-12: Standard Test Method for Water in Organic Liquids by Coulometric Karl
Fischer Titration or ABNT-NBR 5758: Líquidos e sólidos orgânicos e inorgânicos — Determinação
do teor de água — Método geral por reagente Karl Fischer.
Note 10: For H2S content, alternatively to gas chromatography, it might be used methods of
colorimetric tubes or iodometry (GPA STD 2265) or Potentiometry by (ISO 6326-3).
All the Laboratory equipment and analysis methodology shall provide reliable results and shall be
approved by PETROBRAS during the engineering design phase. PETROBRAS at their own
discretion will collect samples for further comparison with the measured results obtained in the
Unit.
All glasses and equipment should be calibrated with certified standards of RBC/INMETRO.
Laboratory shall preferably be located at a non-classified area. If it is not possible, devices (like air
lock, fire damper) should be installed to guarantee the lab technician safety.
Laboratory drain system shall prevent the possibility of back-flow of flammable vapors.
Air conditioning should be exclusive for laboratory facilities.
Separates sinks shall be installed. One sink dedicated to inorganics (e.g water) and other sink
dedicated to organics (e.g kerosene).
An eye-washer and shower shall be provided inside the laboratory.
Each equipment should have its own socket.
3. UTILITIES

3.1. GENERAL

This item describes the minimum requirements and specifications that shall be applied to utility
systems and equipment of the Unit.
3.2. SEA WATER LIFT SYSTEM

A Sea Water Lift System shall be installed to supply seawater to the deaerated water injection
system, to the firefighting system, to the production plant cooling water system and to meet other
Unit’s needs. For sea water characteristics contractor shall consider item 2.3.1 of this GTD and
METOCEAN DATA. For sea water temperature, CONTRACTOR to consider the maximum
temperature (see METOCEAN DATA on item 1.2.1) at each water depth.
For installation/maintenance purposes, the Unit shall be designed to install and repair the intake
water pipe in the final location offshore preferably with no need of diving operations
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Chlorine shall be injected at the inlet of the seawater lift system, to avoid fouling or marine growth.
CONTRACTOR is responsible to supply the chlorine to be used onboard. To control the injection,
according to demand, the residual chlorine content shall be monitored through the redox potential,
which shall be between 0.5 and 1 ppm. The design shall define the monitoring point to assure the
entire system protection.
The sea water lift system shall be designed in order to supply, besides all other consumption
requirements, water to fill the service and production lines before service and production lines
pressurization and leak test.
3.3. COOLING WATER SYSTEM

A closed fresh water cooling system shall be provided to supply cooling medium to the Unit
systems, including the process plant. Two independent cooling systems shall be provided, one to
cool hydrocarbon (gas-cooling water or oil-cooling water heat exchangers) and the other one to
supply cooling medium to the other systems (accommodation, marine and etc.). However, direct
sea water cooling is acceptable for steam generator cooling or other auxiliary systems within
Contractor experience. Contractor shall give special attention to appropriate material selection for
seawater service, according to required operational lifetime.
If CONTRACTOR decides to use PCHE (Printed Circuit Heat Exchanger) the commissioning,
operation and maintenance procedure shall be defined by PCHE vendor. PCHE will only be
accepted for gas coolers in gas compression systems.
An integral T-type (or similar) strainer shall be supplied on the gas inlet and a separate Duplex in
line cleanable strainer shall be supplied for the coolant side, and the strainer aperture for both
cases shall be advised by manufacturer.
All the cooling medium control valves shall guarantee the minimum flow rate to the PCHE
(typically around 20%) rudder stop valves are recommended. In addition, the pressure drop across
the PCHE and also the pressure drop across the strainers shall be individually and remotely
monitored for both streams. A side stream filtration (polishing) system shall be included and all
measures necessary to guarantee the high quality and cleanliness of the cooling water, as
recommended by PCHE manufacturer. The coolant operating pressure shall be higher than its
vapor pressure at the maximum exchanger process inlet temperature, to prevent boiling in low
flow or turndown conditions, and higher than the sea water pressure, to prevent sea water ingress
to the closed loop in case of any leaks in the sea water cooler.
Additional spare PCHEs, subject to PETROBRAS appraisal, shall be provided and made available
at CONTRACTOR onshore warehouse.
CONTRACTOR shall design heat exchangers and pressure protection systems according to the
rupture scenarios as per API 521, especially where large pressure difference is observed.
Gasket Plate Heat Exchangers, if considered by Contractor, shall be designed as per API STD
662 - Part 1. Equipment shall be designed as "severe service". They shall be able to stand
dynamics pressure variations resulting from fluid flow and process control. For cyclic services,
fatigue design shall be in accordance with ASME BPVC Section VIII, Division 2.
The design shall not use sea water as the cooling medium in hydrocarbon heat exchangers.
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CONTRACTOR shall fulfill all Brazilian Administration regulations issued by Environment Ministry
(“Ministério do Meio Ambiente”), through its CONAMA Resolução Nº357/2005 and CONAMA
Resolução Nº430/2011.
CONTRACTOR shall provide a temperature transmitter to monitor cooling water discharge
temperature.
During project execution phase, CONTRACTOR shall provide cooling water system design basis,
such as system inlet and outlet temperature.
3.4. FRESH AND POTABLE WATER SYSTEM

Water maker units shall be installed to generate sufficient fresh and potable water for the Unit’s
consumption.
The fresh and potable water aboard shall comply with Ordinance MS Nº 2914/2011 and ANVISA
RDC 72/2009. Chlorination of potable water is mandatory. Special attention shall be given to the
quality parameters as well as cleanness requirements, tanks and distribution lines disinfection,
analysis routine and the separate storage of water for human consumption of distinct sources.
Material selection for potable water piping system (upstream and within accommodation) shall
avoid corrosion particles and contaminants.
Despite the Unit being prepared to generate fresh and potable water, a minimum of 2 (two) filling
connections (one for water and another for diesel) shall be installed at each bunkering station. The
bunkering stations to be located at Starboard side of the Unit near each aft and forward cranes
respectively. The bunkering stations shall be located as close as possible to the supply boat
mooring area and allow quick operation. Piping shall be at least 4” diameter.
The bunkering stations shall be provided with separate hoses, connections and valves for diesel
(see item 3.6) and fresh water, as follows:
Connections:

 Type EVERTIGHT quick connect-disconnect couplers for diesel and fresh water hoses;
 Filling station end: swaged-on male NPT carbon steel nipple + female thread/male adapter
+ female coupler/female straight pipe thread (connected to the filling station piping);
 Supply-boat end: swaged-on male NPT carbon steel nipple + female straight pipe
thread/female coupler.
Hoses:

 120 m (3 x 40 m) for all hoses;


 The 3 x 40 m sections of 4” hoses shall be connected by WECO wing union type SHU;
 150 psi working pressure;
 Cover: black, weather, ozone and oil resistant high quality chloroprene rubber;
 Reinforcement layers: synthetic textile yarns;
 Tube: black, smooth fuel/oil resistant high quality nitrile rubber;
 Temperature range: -30°C to +80 ºC.
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Remarks: 1. Lifting clamps shall be provided at hose ends;

2. Hoses shall float (self-floating hoses or with floating devices)

3.5. HEATING MEDIUM SYSTEM

A Heating Medium System shall be provided to recover the heat from the turbines exhaust gas
and from other systems. Preferably, each gas turbine shall have its waste heat recovery unit
(WHRU) or alternatively, if the number of WHRU is less than the number of turbines, each turbine
shall have the capability to operate with one WHRU at least.
A Heating Medium System shall be provided to recover the heat from the exhaust gas and from
other systems.
CONTRACTOR shall design heat exchangers and pressure protection systems according to the
rupture scenarios as per API 521, especially where large pressure difference is observed.
3.6. DIESEL SYSTEM

The diesel system shall be designed in order to supply, besides all other consumption
requirements, the service pump to push pigs and clean flowlines (see item 2.6.1).
For details of bunkering station connections see item 3.4.
Diesel hoses shall have a stop-check valve at the supply-boat end in order to prevent pollution
environmental damage. A drip-pan shall be installed to collect any leakage from all bunkering
station connections with manually operated drainage valve located at the pan bottom.
Diesel shall be filtered and on-line metered before being sent to the storage tank.
A minimum configuration of 2 x 100% configuration is required for diesel lift pump and oil lift
pumps for well service which shall be designed in order to guarantee the required flow rate of the
well service pump (as per item 2.6.1).
The diesel lift pumps and oil lift pumps shall be dedicated to each fluid (segregated), and they
shall have filter upstream, and recycle for flow control to avoid frequent start/stop and guarantee
the required mixture of diesel/crude oil.
The diesel tank volume shall have enough capacity to provide diesel to be used as fuel for 7
(seven) days continuously and to flush the production lines (as per item 2.6.1).
PETROBRAS will provide diesel in accordance with ANP standard. DMA (Diesel Marítimo TIPO
A) shall be considered for turbo generator projects.
3.7. SEWAGE SYSTEM

Unit shall have a sewage treatment Unit in compliance with MARPOLand IBAMA requirements
specially but not limited to the “Resoluções” CONAMA and the NOTA TÉCNICA
CGPEG/DILIC/IBAMA Nº 01/11. Sampling point shall be provided upstream and downstream.
Sewage overboard shall be metered.
Note 1: Both grey and black waters shall be previously treated and metered before discharged to
sea.
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3.8. NITROGEN GENERATOR SYSTEM OR CRYOGENIC EXPANSION UNIT

CONTRACTOR shall provide facilities to receive an independent Nitrogen Generation Unit (NGU)
or a Cryogenic Expansion Unit (CEU - N2 Cylinders), supplied by PETROBRAS, whenever
necessary as per PETROBRAS request. Typical operations will be hydrate prevention on
production risers, service risers, gas injection risers, and gas pipeline; and Coil Tubing operations.
For this purpose, during execution phase PETROBRAS will provide detailed information about
Nitrogen Generation Unit according to CONTRACTOR request. As reference the following
interfaces shall be considered:
Maximum Pressure: 5500 psi

Maximum Flow: 1500 SCFM

Dimensional and Weights: NGU arrangement is composed of up to 8(eight) modules of 6.5 x 3.0 x
2.7 m (L x W x H) each, with a maximum weight of 16 Tons each. Modules could be stacked up to
2 (two) modules. Ancillary components are the Fuel Skid (1.2 x 1.2 x 1.6 m) and the Tool Box (4.5
x 3,0 x 2.7 m).
Necessary facilities to the NGU operation are: Compressed air (120 psi); Filtered Diesel (refueling
supply point with nozzle); Industrial Water supply point; Electrical Power supply (440V 3 pins and
220V 3 pins).
Connections to Service Header: WECO type connection.

PETROBRAS will decide during execution phase the use of NGU or CEU.
3.9. COFLEXIP® - FLEXIBLE STEEL PIPE FOR SERVICE APPLICATION

The Unit shall also be prepared to perform remote operations using pumps from Special Purpose
Boats (squeeze, etc.) to operate alongside of the FPSO. Therefore, CONTRACTOR shall provide
one permanent and dedicated line from the bunkering station to be tied into to the discharge of the
service pump. This line shall be designed considering the pressure rate of the well service pump.
The CONTRACTOR shall provide facilities to isolate and drain service line and also flush topsides
piping (using inert fluid) after the remote operation.
The Unit shall have a special permanent support with access and railing located at the side shell
to fit the flexible lines coming from the special boat. The place where the platform will install the
special permanent support shall have structural capacity to support 18,000 kg. The flexible line
shall be fitted using the FPSO crane. The flexible line weight will be 12,000 kg.
For special operations, attended by a special purpose service boat operating alongside of the
FPSO, a flexible line support (“COFLEXIP® - flexible steel pipe for service application”) shall be
installed. It shall be provided at least, but not limited to, a support with a suitable and accessible
platform in order to receive and accommodate the line and structural reinforcements, as required.
The platform and support shall be located in the surroundings of a crane, so that the flexible line
shall be fitted using the FPSO crane. There shall also be foreseen a way to connect it to the
topsides pipelines, allowing fluids injection from a special boat to the production wells of the
FPSO. The empty flexible line weight is approximately 12 tons.
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The following operations made by boat can be considered:


A – Squeeze:

A1 - Calcium Carbonate (CaCO3) anti-scaling products injection

 Aqueous solution of acid salt of EDTA or similar

A2 – Scale inhibitor injection: carbonate and sulfate

 Aqueous solution of scale inhibitors

B – Asphaltene deposit removal using solvents

 Xylene

During the operation, when the line is flooded with fluids (which are pumped during the operation)
the dynamic forces from the special boat and the vessel motions must be considered. The weight,
in this case, is approximately 18 tons. This line shall be designed considering the pressure rate of
the flowline circulation pump. CONTRTACTOR shall evaluate the use of same connection on riser
balcony for coiled tubing operations.
The flexible line has also a support that will be connected to the fixed support. A simplified sketch
of this support are presented below:

3.10. DRAIN SYSTEMS

Contractor shall design drain system to collect and convey unit drained liquids to an appropriate
treating and/or disposal system in such a way as to protect personnel, equipment and to avoid
environmental pollution. Drainage system shall comply with NOTA TÉCNICA
CGPEG/DILIC/IBAMA Nº 01/11 and MARPOL requirements. The effluents shall be segregated,
treated (oil and greases less than 15 ppm) and monitored through dedicated TOG analyzer(s),
previously to being discharged overboard
Drain systems shall be segregated into specific systems, each designed for a particular type of
stream, with no interconnection between the systems. Further to this, when appropriate, features
such as seal loops and air gaps shall be used to segregate areas served for the same drain
system.
Process vessels, piping or other sources containing hazardous liquids which need to be drained
for interventions/maintenance/inspection reasons, and may not be drained directly to atmosphere
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without undue risk to personnel, environment or assets from release of flammable or toxic
vapours, shall be connected to a contained drain system (e.g closed drain). By toxic vapours
CONTRACTOR shall consider streams containing poisonous substances at critical
concentrations, such as, but not limited to H2S (special attention for Gas Sweetening Unit). Critical
concentrations shall be discussed on a case by case analysis during detail design phase and
submitted to PETROBRAS’ appraisal.
Instrument drains shall be accounted for in hazardous area classification. The handling of
instrument drains shall be on a case by case analysis (special attention for poisonous substances
at critical concentrations, e.g., sour gas containing H2S ≥10 ppmv), however in all cases, the
instrument drain piping or tubing shall be arranged so that the draining liquid is visible to the
operator when the instrument is being drained.
4. ARRANGEMENT

The Unit arrangement shall be consistent with the Hazard Management Program (See SAFETY
GUIDELINES FOR OFFSHORE PRODUCTION UNITS in item 1.2.1) proposed by
CONTRACTOR outputs of risk assessments shall be incorporated into the layout development
and optimization.
The concept of Risk Tolerability Criteria in comparing alternative layout design shall be considered
valuable as part of the decision-making process, and will support in the demonstration of the risk
criteria have been achieved considering ALARP (As Low As Reasonable As Possible).
In the developing the facility layout, the following HSE points shall be considered, as a minimum:
 Maximize natural ventilation
 Minimize escalation of ignited flammable or toxic release, therefore, arrangement, facilities
and equipment shall prevent the possibility of propagation of any potential risk from one
area to another. For this purpose, equipment malfunction as well as operational error shall
be considered.
 Minimize probability of ignition
 Continuous permanent ignition sources shall always be installed in non-classified areas
 Layout shall provide the maximum practical separation between: Classified Areas vs. Non
Classified Areas, Systems with hydrocarbon-containing inventory vs. potential sources of
ignition
 The risk of loss of containment should be minimized by minimizing the possibility of
mechanical damage. Protecting hydrocarbon equipment and piping from dropped objects
should be a main consideration. Special attention for the amine regeneration vent line,
since it has the highest H2S content at the Unit. In case CONTRACTOR decides to use
Molecular Sieve as the Dehydration method, dropped object studies shall assess the cargo
handling during the replacement of molecular sieves. Provision of suitable means for
escape (whether or not these are regularly manned), temporary refuge and evacuation.
 Proper implementation of working environment (Human Factors) guidelines, tools and
techniques into the design (e.g Proper and safe access for valves and equipment
operation according to critically analysis). All equipment associated with emergency power
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(Emergency generator, emergency switchboard, storage batteries and inverters, etc.) shall
be situated in non-hazardous areas, with adequate protection against fire and explosion.
CONTRACTOR shall carry out Layout Reviews considering HSE aspects.
The objective of these Layout Reviews is to identify any issues associated with the overall planned
layout of the topsides, utilities, and marine systems.
Layout review activities to assure that the layout is ALARP shall take place at various distinct
stages during the project development cycle including all changes during the course of the project.
These reviews shall be conducted with a multidisciplinary team to ensure that the requirements of
all disciplines have been incorporated in the layout design to eliminate possible clashes and to
ensure the design is ALARP.
The offloading station shall be located at stern and bow (see the OFFSHORE LOADING SYSTEM
REQUIREMENTS document, as indicated in item 1.2.1).
The use of long-bolt (wafer) type valves for services which contains flammable or combustible
fluids shall not be acceptable. As the only exception, LUG type valves with threaded holes would
be acceptable.
4.1. SUPERSTRUCTURE (ACCOMMODATIONS)

Concepts for living quarters and storage areas shall comply with the CS Rules, OHSAS 18001,
Brazilian Regulations (NRs, especially NR 30 and its annex II) and safety requirements of SOLAS.
In addition, CONTRACTOR shall provide accommodations for PETROBRAS / partners
representatives onboard in 4 (four) cabins for 2 (two) persons each with bunk bed. 1 (one) single
bed cabin, equivalent to the Offshore Installation Manager’s or the Chief Unit Superintendent’s. An
office and a meeting / video-conference room shall also be provided for PETROBRAS
representatives onboard. Both PETROBRAS office and PETROBRAS main Fiscal cabin shall be
fitted with windows at front wall of the accommodation Block.
Galley, mess room and storage area – Comply to RDC 216/2004 and RDC 72/2009, ANVISA, with
emphasis on the separation between vegetables, meat (poultry, fish and red meat), pasta and
storage areas, and waste disposal.
The infirmary installations shall comply with NORMAN 01 CHAPTER 9, SECTION V; ANVISA
RDC 50/2002 and ANVISA Resolution RDC 306/2004.
The smoking area shall be provided in the outer area with natural ventilation and protected from
the weather and shall comply with Civil law 12.546/2011 and Decree 8262/2014.
4.2. PROCESS PLANT

CONTRACTOR shall submit a maintenance plan and load handling plan evidencing that the
arrangement of the process plant equipment, skids and accessories allows maintenance at site
without affecting the production/processing capacity of the Unit according to the technical
specification hereinafter considered.
Enough space for operational maintenance of production plant equipment shall be provided,
taking into account the personnel circulation, safety and CS requirements.
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Human Factor Engineering shall be considered as part of this assessment (OGP Report 454:2011
as a reference).
CONTRACTOR shall define the height of the main process plant deck level as well as its layout.
For the spread mooring option, CONTRACTOR shall take into account the effects of green water,
according to item 11.6.3, with the vessel in a maximum draft condition.
Areas of the UNIT reserved for storage of chemicals and gas cylinders shall include requirements
for safety, health and environment, including the criteria for separating chemical compatibility.

4.3. UTILITY ROOM (ENGINE ROOM)

CONTRACTOR shall submit a maintenance procedure plan evidencing that the Unit arrangement
for utility systems, skids and accessories allows maintenance with a minimum disturbance of the
Unit’s performance.
4.4 DIVING AREAS

CONTRACTOR shall provide diving stations at main deck level of the Unit to be used during CS
underwater surveys, pull-in/pull-out operations, etc. During operational phase, these stations may
be used by PETROBRAS for riser inspections.
The number and location of diving stations shall be defined in accordance with NR-15 and
NORMAM 15, considering the maximum allowable outreach of 33 m measured from the diving
bell. The stations shall not interfere with the Unit facilities and operations (cargo transfers, etc.).
The following requirements shall also be fulfilled:
 Proper means (cranes, mono-rails, skidding, crawlers, slings, rigging, etc.) for the
installation/de-installation of diving equipment on the stations shall be available. The
heaviest piece of equipment to be handled is 5 t.
 Gas discharges near the stations is not acceptable.
 Each station shall be provided with the utilities listed below:
o Compressed air - two outlets for diving bell and ballast winches:
- Required pressure: 7 kg/cm²
- Required Outflow: 20 Nm³/min (Approximately 2,85 m³/min, at constant
pressure of 7 kgf/cm²), allowing ± 10% of tolerance.
o Electric power - two outlets for diving equipment (from different essential
circuits):
- 440V/60Hz/max 100 A
o Fresh water supply – one outlet for cleaning diving equipment and
clothes:
- Required pressure: 1 kg/cm²
- Required outflow: 20 l/min
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o Communication:
- One telephone connection for internal and external calls
The diving stations location and handling plan shall be submitted to PETROBRAS for
comments/information. See also reference document I-ET-SPREAD MOORING AND RISER
SYSTEM REQUIREMENTS for additional provisions.
Access to the diving stations shall not be dependent on vertical ladders, which may require
specific training for work at height or hinder evacuation of injured personnel.
4.5 HELIDECK

The helideck shall be located and designed according to Brazilian Navy Regulations (NORMAM)
and CAP 437 requirements, disconsidering the Helicopter refueling devices that are not required.
In addition, the following international/national standards shall also be complied (latest editions):
 ICA 63-10 Estações Prestadoras de Serviços de Telecomunicações e de Tráfego Aéreo –
EPTA. DECEA.
 “Standard Measuring Equipment for Helideck Monitoring System (HMS) and Weather
Data", HCA, Bristow Group, Bond Offshore, CHC;
 MCA 105-2/2013 Manual de Estações Meteorológicas de Superfície - DECEA.
Meteorological and ship motion data shall be transmitted to HMS (Helideck Monitoring System) in
real time, through analogic or digital applicable interface.
CONTRACTOR shall ensure remotely access to HMS, at any time, through internet. Such access
shall be available in real time to PETROBRAS and Helicopter Operator Company through the
same screen/system used by radio-operator of FPU. The Internet access shall be compatible with
standard softwares, e.g., Microsoft Internet Explorer, Mozilla Firefox or Google Chrome.
HMS and all related systems/sensors shall be considered essential loads and shall operate even
in case of loss of power in the main generators.
In addition, CONTRACTOR shall present evidence that there is no interference between Unit’s
normal operation and helicopter operations.
CONTRACTOR shall paint in the helideck a codification (to be informed during execution phase)
as per NORMAN 27.

5. HEATING VENTILATION AND AIR CONDITIONING SYSTEMS (VAC)

5.1. GENERAL

The Air Conditioning and Ventilation Systems shall be designed to suit the following conditions:

SUMMER

- Dry Bulb Temperature (TBS): 32°C

- Relative Humidity: 61%

- Daily Temperature Range: 3,6°C


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5.2. HVAC SYSTEMS

"In general, the minimum air change required due to safety and hygienists requirements for
ventilated rooms is 6Ch/h. For compartments where the inside equipment handle hydrocarbons,
the minimum air change/h shall be 12, as required in safety guidelines."
There shall be an independent system of air conditioning for sealed batteries room.
Cooling fluids with HCFC and CFC are not acceptable. Only cooling fluids with HFC are
acceptable.
Insulation shall be provided with CFC-free polyurethane foam injected under pressure for uniform
thermal efficiency and strength.
The air intakes, whenever possible, shall be placed in a safe area and where the prevailing winds
are favorable.
It shall be guaranteed that HVAC equipment selected shall be capable of operating under
conditions described in item 12.5.2.
For rooms where any unit fed by emergency generator is installed, the HVAC equipment
configuration 2 x 50% (MINIMUM) shall be used.
It shall be provided means for manual opening of the dampers in rooms that have internal
combustion engines, when they inspire the combustion air from the room.
5.3. REFRIGERATION SYSTEM (PROVISIONS)

Cooling fluids with HCFC and CFC are not acceptable. Only cooling fluids with HFC are
acceptable.
Insulation shall be provided with CFC-free polyurethane foam injected under pressure for uniform
thermal efficiency and strength.
5.4. CONTROL AND OPERATION

Pneumatic and electrical fire dampers actuators are acceptable. In case the pneumatic actuator is
chosen an independent air supply systems, with their own air reservoirs, shall be provided for fire
dampers and pressurization of instrumentation panels located in hazardous areas. This shall be
provided in order to avoid any further consequence caused by a fault in the air supply. All the fire
dampers shall be CS type approval. Application and installation of fire damper shall be based on
the recommendations of SOLAS and Classification Society requirements.
5.5. VENTILATION OF THE TURRET AREA (NOT APPLICABLE)

Not applicable.

5.6. REGULATION

CONTRACTOR shall comply with all applicable Brazilian Regulations and ISO 15138.
The minimum outside airflow per person is 27 m3/h, in order to comply with Brazilian Legislation
for Conditioned Rooms (“Portarias do Ministério da Saúde MS 3523/1998” and MS 9/2003,
ANVISA "Resolução-Re Nº 9, de 16 de Janeiro de 2003 and Resolução CONAMA 267). Ducts
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shall be designed and assembled taking into consideration the requirements for inspection and
maintenance established by Health Ministry.
5.7 ELECTRICAL SWITCHBOARD ROOMS (E-HOUSE)

E-House (Electrical Switchboard Room) shall be pressurized and air-conditioned inside


temperature (<24oC), 2 x 100% or 3 x 50% machines. Variable Speed Drive, if used, shall be
installed in air-conditioned rooms.
Sealed type or VRLA type batteries shall be installed in air-conditioned rooms inside temperature
(<25oC); UPS and battery chargers shall be installed in air-conditioned rooms.
Chilled Water Pipes and/or Cooling Water shall not be installed inside panels rooms, electrical
equipment, transformers rooms, control rooms, radio room and telecom. Exception to condensed
water piping from Air Cooled HVAC machines coil if there is any. In this case equipment and
piping shall be installed at floor level, closed to a wall, contained by physical barrier and with a
drain directly to outside.

6. SAFETY

6.1. GENERAL

The Unit’s safety philosophy shall comply with all safety aspects/orientations foreseen at the
SAFETY GUIDELINES FOR OFFSHORE PRODUCTION UNITS document (see item 1.2.1).

6.2. LIFE SAVING APPLIANCES

CONTRACTOR shall take into consideration Brazilian Navy requirement and Statutory Rules /
Legislations (LSA Code) not allowing anymore the inflatable rafts increase as a mean to allow
more POB after first oil during gas commissioning phase. PETROBRAS recommends providing
Life Boats to maximum foreseen POB including hook-up phase, first oil and gas commissioning
scenario.
6.3. FIRE WATER SUPPLY SYSTEM

The design shall cover the total firewater demand considering at least one pump set in stand-by
(2 x 100% or 3 x 50%). These pump sets shall be dedicated to firefighting service. Fire pump room
arrangement shall comply with SOLAS, Chapter II-2, Regulation 10, FSS Code Chapter 6, the
Classification Society and SAFETY GUIDELINES FOR OFFSHORE PRODUCTION UNITS. The
pump sets with their respective power sources, fuel supplies, electrical and control cables, lighting,
piping and control valves shall be located in such a way that a fire in any location will not render
more than one fire water pump set inoperable.
Chlorine shall be injected at the inlet of the system intake, to avoid fouling or marine growth.
6.4. ASBESTOS POLICY

CONTRACTOR shall remove all materials containing asbestos from the Unit and assure that the
materials are disposed of properly. No new materials containing asbestos shall be used.
6.5. RISK MANAGEMENT
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A Risk Management Program shall be implemented, to continuously monitor and control the risks
identified by the Risk Analysis and Evaluation studies during the operational lifetime, as defined in
SAFETY GUIDELINES FOR OFFSHORE PRODUCTION UNITS see item 1.2.1.
PETROBRAS at their sole discretion shall take part in any Risk Assessment or workshop, for
example: Layout Reviews, HAZOPs, HAZIDs.
An independent Consultant Company shall be hired to perform the risk assessment studies
established in the scope of the project. This Consultant Company shall have proven previous
experience in this type of studies.
At early stage of the project, CONTRACTOR shall provide a HSE Plan for the all life cycle phases
of the project. This HSE Plan shall be updated as required and according project phase. As
reference, HSE plan can follow the "OGP report 423 - Appendix 3: Guidelines for Working in a
Contract Environment". The HSE Plan shall include a description of the scope and methodologies
that will be followed.
The Qualitative Risk Assessments, Consequence Analyses, Safety Report and the Risk
Management Program, as defined in Item 5 of the SAFETY GUIDELINES FOR OFFSHORE
PRODUCTION UNITS, shall be submitted to PETROBRAS for comments / information.
6.6 - VENT POST LOCATION

In addition to the requirements presented at SAFETY GUIDELINES FOR OFFSHORE


PRODUCTION UNITS (I-ET-3010.00-5400-947-P4X-001), item 5.4.8 GAS DISPERSION STUDY
FOR VENT POST LOCATION, in respect of risks for people, CONTRACTOR shall develop the
study considering different oil composition that results in each one of these worst gas discharge
composition cases: inflammability; toxicity and asphyxiation, taking into account normal and
abnormal operational conditions.
The study shall consider the interference on the platform fire and gas detection system in order to
avoid undesired shut downs of the Unit. The results of the study shall indicate the safe location
and the height of the vent post discharge considering the aspects above mentioned.
7. AUTOMATION AND CONTROL

7.1. GENERAL

Contractor shall develop an automation and control system security program for the unit, in
accordance with IEC 62443 and submit to PETROBRAS.
The Instrumentation/Automation design is to be mainly based on an integrated operation and
supervision system of the Unit as a whole, using CIM - Computer Integrated Manufacturing
technologies.
The Unit shall be supplied with an overall Automation and Control (A&C) Architecture composed
by field instruments and control/automation systems. The unique characteristic of the Architecture
is the integration promoted among these systems by means of redundant digital communications
channels that includes optical and electrical networks, switches, hubs modems etc.
The AC and DC power supply for all components of the A&C Architecture shall be redundant, fed
from duplicated and redundant UPS. Common failure mode shall be avoided.
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The systems of the A&C Architecture, which shall be supplied with the Unit, are:

 CCR: Central Control Room


 CIS: Control & Interlocking System;
 CMS: Cargo Monitoring System;
 SPCS: Subsea Production Control System;
 FMS: Flow Metering System
 ESD: Emergency Shutdown;
 CCTV: Closed Circuit TV monitoring;
 DPRS: Dynamic Positioning Reference System (DPRS);
 ENV: Metocean Data Gathering and Transmission System;
 POS: Positioning System for Mooring Operation and Offset Diagram;
 MODA Moda Riser Monitoring System;
 RIMS: Riser Monitoring System;
Contractor shall prepare and submit to PETROBRAS, for approval an Interface (FPU-Subsea)
Operating Manual, based on interface procedures (well start-up procedure, gas export line
commissioning procedure, etc.) to be provided by PETROBRAS 4-5 month prior to starting
operations, with the aim of guiding the relation between PETROBRAS’ and CONTRACTOR’s
operation team.
7.2. CENTRAL CONTROL ROOM (CCR)

The Unit shall have a CCR with an integrated working area from which the Topside process and
utilities plant, subsea production/injection systems and Hull/Marine systems shall be continuously
monitored, operated and controlled, enabling the proper operation of the Unit as a whole.
The supervision and monitoring shall be done by navigating through HMI (human machine
interface) screens showing the Topside and Hull/Marine diagrams and other fixed structures. The
main components of this hardware (such as equipment, valves, detectors, process analyzers and
instruments) are animated by displaying changes to their status, such as the opening of a valve,
start-up of a pump, indication of a process variable etc.
The term HMI refers to the displays, computers and software that serve as an interface with CIS,
specialized in processing/displaying the field data in a suitable format, leaving the tasks of data
gathering to the other systems.
The HMI has three primary functions: (i) provide visualization of process parameters and methods
with which to control the process; (ii) provide alarms and indications to the operator that the
process is outside limits or behaving abnormally or that the CIS has detected faults or failures;
(iii) provide a method to allow the operator to understand where the process is going and how fast
(trending functionality). HMIs shall be supplied with all necessary graphic screens and windows to
allow adequate Unit operation.
The CONTRACTOR shall mirror all CCR HMIs (and ECR HMIs, if applicable) at the PETROBRAS
Office (according to item 4.1) in order to allow PETROBRAS to monitor the Unit.
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If the Unit is provided with a permanently manned engine control room (ECR), the engine room
equipment can be controlled from the ECR and only the critical alarms and status signals repeated
back to the CCR.
A “black box” capability shall be foreseen into the CCR, so that all Topsides, subsea and
Hull/Marine systems monitored data events, audit trails and alarms of the last 30 (thirty) days can
be recorded in an easily removable data storage unit which can be carried off the Unit in case of
abandonment.
CONTRACTOR shall design and operate an Alarm Management System according to the
standard IEC 62682, in order to ensure that:
 Unit shall have an alarm management system that provides the operator with an adequate
set of warnings against excursions beyond its safe operating limits both during normal
operation and during abnormal situations (startups, shutdowns and upsets);
 Actions necessary to bring the process back to its normal state shall be defined for every
safe operating limit and details shall be available to the operator. The operator shall be
made responsible to execute such actions.
 The alarm management system shall also minimize and where necessary suppress
standing alarms, nuisance alarms, repeating alarms and alarm floods.

7.2.1. CONTROL NETWORK ARCHITECTURE AND STANDARD (PI)

During the operation phase, all Topsides, subsea and Hull/Marine shall be available online via
OPC (OLE for Process Control) protocol at PETROBRAS’ PI server offshore, located in
PETROBRAS’ telecommunications room see (I-ET-007 TELECOMMUNICATIONS SYSTEMS see
item 1.2.1.) Those data are to be defined by PETROBRAS during the detail design. Its OPC
Server shall be installed in a dedicated machine.
7.3. CONTROL/INTERLOCKING SYSTEM (CIS)

The Unit shall be equipped with fully automated control system, named Control & Interlocking
System (CIS), to provide both control and safeguarding functions according to SAFETY
GUIDELINES FOR OFFSHORE PRODUCTION UNITS.
A number of dedicated CIS controllers (redundant CPUs/processor modules in a fully hot stand-by
scheme), preferentially designed to be independent systems, shall be foreseen for the following
functions:
a) Process Control System (PCS), for Unit systems remote controlling and monitoring.
Regulatory control (PID), monitoring, remote actuation, control transmitters data acquisition
and process alarms shall be carried out by this system;

b) Process Shutdown System (PSD), for carrying out overall Unit safety and safeguarding
preventive automatic and manual actions. The purpose of this system is to prevent
escalation of abnormal conditions into a major hazardous event and to limit the extent and
duration of any such events that do occur;
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c) Fire & Gas/ESD System (FGS/ESD), for carrying out overall Unit safety mitigation
automatic actions mainly due to fire, flammable and toxic gas releases/leaks and explosion
events. This system shall monitor continuously for the presence of a fire or gas leakage to
alert personnel and allow control actions to be initiated manually or automatically to
minimize the likelihood of fire or gas escalation and probability of personnel exposure.

PCS shall be an independent system from PSD and FGS/ESD. It is recommended that PCS, PSD
and FGS/ESD be from the same vendor.
CONTRACTOR shall update all control loops tuning during plant start-up. CONTRACTOR shall
also present control strategies to minimize oil slug flow instabilities in separator vessels.
The decision of using Safety Instrumented Systems (SIS), in accordance with IEC 61508/61511,
for the CIS systems should be evaluated by CONTRACTOR taking into account the associated
risks, the risk tolerability criteria, proper risk tool analysis and Classification Society requirements.
In case of using SIS (which shall be integrated to the Risk Management Program - see Item 6.5),
a Safety Integrity Level (SIL) determination review shall be carried out to define the integrity levels
required of the system(s) taking into account the Unit safety life-cycle, according to IEC 61511- 1.
All necessary documents and studies, such as the ones for determination of the required SIL for
all Safety Instrumented Functions (SIFs) using Layer of Protection Analysis (LOPA) methodology,
shall be issued for comments/information during the design.
7.4. CARGO MONITORING SYSTEM (CMS)

The Cargo Monitoring System shall provide reliable, fast and highly accurate information on tank
level and related variables (draft, pressure, etc.).
The CMS comprises, at least, the following main subsystems:
 Cargo tanks level measurement, high level independent interlocking;
 Cargo tanks inert gas pressure measurement;
 Draft electronic based level measurement;
 Loading calculator (hardware and software);
 Online oxygen content in produced inert gas.
CONTRACTOR shall create an inventory of all storage tanks containing fluids that have the
potential to overfill resulting in a vapour cloud explosion, assess the risks, document and
implement remedial steps. This also refers to topside storage tanks.
7.5. SUBSEA PRODUCTION CONTROL SYSTEM (SPCS)

 The SPCS comprises the integration between the Floating Production Unit (FPU) Central
Control Room (CCR) and Control & Interlocking System (CIS) equipment and the following
types of subsea control systems:
 Electrohydraulic Multiplex (EHMUX) for the total number of subsea production manifold
and subsea water injection manifold connected to FPU. Each subsea production manifold
will group four (4) production wells and each subsea water injection manifold will group six
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(6) water injection wells. Four (4) subsea production manifolds and two (2) subsea water
injection manifolds will be connected to FPU.
 Direct Hydraulic (DH) for Seven (7) production wells connected directly to FPU and for one
(1) water injection well satellite to FPU. Direct Hydraulic (DH) must be used to control the
two (2) of FPU’s subsea emergency shutdown valves (SESDV).
7.5.1 TYPES OF CONTROL SYSTEM USED BY THE SUBSEA EQUIPMENT

7.5.1.1 Electrohydraulic Multiplex Subsea Control System (EHMUXSCS):


This type of subsea control system combines two fundamental characteristics at the same time:
 It allows the use of a small number of common hydraulic supplies from topside to actuate
all subsea valves. This is accomplished locally subsea by opening or closing an
electrohydraulic valve that provides hydraulic pressure from a common supply header from
topside to the subsea equipment valve actuator.
 It allows the use of a small number of common electrical supplies and a communication
link from topside with a “Subsea Electronics Module (SEM)” to select electrohydraulic
valve that provides hydraulic pressure from a common supply header from topside to the
subsea equipment valve actuator to open or close it according to the Operator command
selected topside.
The electrohydraulic valve is typically a three-way, two position, solenoid operated Directional
Control Valve (DCV) or “Solenoid Valve”. The DCV pressurize or depressurize the hydraulic
control line to the subsea valve actuator whenever commanded to open or close by the SEM after
this one receives the respective command from the SPCS. A given number of DCV are housed
together with two SEM inside a retrievable Subsea Control Module (SCM) installed in subsea
manifold. A typical gate valve counts as one SCM Function, while manifold choke valves and
some types of downhole valves with two actuators requires two SCM Functions.
The EHMUXSCS used by PETROBRAS is an open-type system. When the hydraulic pressure
from the SCM common supply header for the subsea actuators is removed by its respective DCV
in the SCM, a given volume of hydraulic fluid between the DCV and valve actuator and is expelled
(vented) to seawater by the SCM. The EHMUXSCS will use water-based hydraulic fluid that needs
to be maintained according to ISO 4406 Class 17/15/12 cleanliness standard by the
CONTRACTOR at all times.
Each subsea equipment with EHMUXSCS will be provided with two sets of dual redundant
hydraulic supplies from the SPCS HPU topside:
 The “Low Pressure” set with two individual supplies referred as LP1 & LP2 providing
between 1,500 psi and 3,000 psi operating pressure range for subsea gate valves;
 The “High Pressure” set with two individual supplies referred as HP1 & HP2 providing
between 3,000 psi and to 5,000 psi for the WCT´s downhole valve(s), operating pressure
range for subsea downhole safety valves.
Data acquisition from subsea sensors is provided by the SCM. The SCM also provides its own
internal “housekeeping” data for periodic record and display by the SPCS. The open or closed
status of a subsea valve is provided by indirect means using the fast scan monitoring of the
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pressure in the respective control function DCV outlet, together with other measurements such
pressure or flow rates in the SCM hydraulic headers and fluid vent.
Electrical power and communication for the SCM is provided from topside by a pair of
EHMUXSCS Control Cabinets. Power and communication are combined in a same pair of wires of
the umbilical electrical cable. This combination is referred as a “Channel or Line”. A topside
EHMUXSCS Control Cabinet pair provides two Channels for the SCM. The Channels are referred
as “Channel A” or “Line A” and “Channel B” or “Line B. Each Channel will use one twisted pair
among the four (4) provided in the manifold umbilical electrical cable. Two other pairs are a back-
up against umbilical cable or electrical connector failures.
Each topside EHMUXSCS Control Cabinet pair is composed by two identical Control Cabinet
racks, with each rack dedicated to a SCM Channel. An EHMUXSCS Control Cabinet rack typically
houses the Channel A or B electrical modem, power supply, and data servers. Each EHMUXSCS
Control Cabinet rack also have a Programmable Logic Controller (PLC) or industrial grade
computer with the logic memory map of all subsea valves, sensors, housekeeping data and status
functions that the SPCS will access to send valve commands and read all EHMUXSCS data
relevant to SPCS operation.
Both EHMUXSCS Control Cabinet racks belonging to the same pair will normally operate in “hot
stand-by” redundancy mode, with periodic update of their memory map variables. One of the two
SCM Channels will be always the “active” or “master”, with automatic or manual change over to
the other (“stand-by”) Channel in case of communication loss or failure. Each EHMUXSCS Control
Cabinet rack has network communication and hardwired I/O interface with the CCR and CIS
Systems in the FPU.
Although the SPCS operation shall be fully integrated in the CCR, a limited degree of stand-alone
EHMUXSCS operation will be possible from a dedicated Operator Work Station (OWS) to be
supplied by PETROBRAS. The OWS is intended to offer temporary operation back-up capability
during CONTRACTOR integration work for EHMUXSCS Control Cabinet racks. The OWS
software and display graphics may not allow the same flexibility and resources available in the
CCR System. A pair of OWS will be provided for use in a network with all EHMUXSCS Control
Cabinet pairs from the same Supplier (up to 4 suppliers).
7.5.1.2 Direct Hydraulic Control System (DHCS):
This type of control system is defined here as the one which each valve actuator of a Wet
Christmas Tree (WCT), downhole valve, or SESDV valves is directly connected to topside
electrohydraulic “switch” valve through a dedicated umbilical line (thermoplastic hose or tube) in
the control umbilical. The electrohydraulic valve, also referred as solenoid operated Directional
Control Valve (DCV) or “Solenoid Valve”, pressurizes or depressurizes the umbilical control line
directly to the subsea valve actuator.
A given number of DCV are housed together topside in a Well Control Rack (WCR), with electrical
power provided from the FPU CIS and the pressurized hydraulic fluid supplied by the SPCS HPU.
Except in the case of actuation of SESDV, the Direct Hydraulic control system used by
PETROBRAS is a closed type system where the control fluid depressurized from an umbilical line
by a DCV returns to the SPCS HPU return reservoir. The SESDV will be actuated by a dedicated
control panel. The return fluid from SESDV will not be allowed to return to the SPCS HPU.
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The WCR and the SESDV Control Panel will provide the following operating pressures according
to type of equipment used:
a) 5k-Type DHCS-WCT:

 Between 1,500 psi and 3,000 psi for all WCT gate valves;
 Between 3,000 and 5,000 psi for the WCT’s well downhole safety valve(s).
b) Subsea Emergency Shutdown Valve (SESDV):

 Between 1,350 psi and 3,300 psi.


The open or closed status of a given subsea equipment gate valve is provided by indirect means
by monitoring the pressure in the respective control function DCV valve outlet in the WCR or
SESDV’s Control Panel for display in the respective well P&ID on the CCR. For SESDV the open
or closed status will be provided also by 4-20mA pressure and temperature sensor installed in the
subsea valve and connected directly to the CIS by two electrical pair in the umbilical. The others
three 4-20mA analog sensors of typical PETROBRAS 5k or 10k Direct Hydraulic WCT (production
pressure; production temperature and annulus or gas injection pressure) are typically connected
directly to the CIS by two electrical pairs in the umbilical. The exact configuration will be provided
by PETROBRAS during the detail design phase.
The downhole pressure and temperature gauge will be connected directly to the topside Signal
Acquisition System (SAS) Panel (see item 7.5.7).
7.5.2 SPCS MAIN SPECIFICATIONS

The SPCS includes (but it is not limited to) the following types of subsea and topside equipment
listed below:
The equipment listed below, from the seabed to the Unit, comprises the SPCS:
 Wet Christmas Tree for direct hydraulic control system (DHCS-WCT)– Supplied by
PETROBRAS;
 Subsea production manifold fitted with electrohydraulic multiplex subsea control system
(MSP) – Supplied by PETROBRAS;
 Subsea Water injection manifold fitted with electrohydraulic multiplex subsea control
system (MSIA) – Supplied by PETROBRAS;
 Downhole valves: DHSV (safety) Supplied by PETROBRAS;
 Downhole pressure & temperature transmitter (PDG) – Supplied by PETROBRAS;
 Subsea Emergency Shut Down Valve (SESDV) in each Gas Export Line – Supplied by
PETROBRAS;
 Subsea Umbilical – Supplied by PETROBRAS;
 Topside EHMUXSCS Control Cabinet pair for each one of five (4 + 1) subsea production
manifolds and three (3) subsea water injection manifolds – Supplied by PETROBRAS;
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 Topside stand-alone Operator Workstation (OWS) pair for all EHMUXSCS Control Cabinet
pairs from the same EHMUXSCS Supplier (up to 4 suppliers) – Supplied by PETROBRAS;
 Topside Signal Acquisition System (SAS) for downhole pressure & temperature transmitter
(PDG) used for each well with DHCS – Supplied by PETROBRAS;
 Topside SAS Panel to install SAS equipment – Supplied by CONTRACTOR;
 Topside SPCS Hydraulic Power Unit (HPU) – Supplied by CONTRACTOR;
 Topside Well Control Rack (WCR) for WCT fitted with Direct Hydraulic control system –
Supplied by CONTRACTOR;
 Topside SESDV control panels – Supplied by CONTRACTOR;
 Topside Portable Umbilical Pressurization System (PUPS) – Supplied by CONTRACTOR;
The SPCS shall provide operation control and monitoring of the following subsea equipment from
the CCR:
 Eight (7+1) DHCS-WCT, a set of downhole valves (DHSV), PDG and TPT for eight (7+1)
satellite wells, seven (7) of which are production wells and one (1) is injection well;
 Four (4) subsea production manifolds (MSP) and three (3) subsea water injection manifold
– (MSIA) connected directly to the FPU by its own control umbilical. The subsea
production manifold can be connected to a maximum of four (4) wells and subsea water
injection manifold can be connected to a maximum of six (6) wells.
 Two (2) Subsea Emergency Shutdown Valves (SESDV)
Note: The number of WCT and SESDV will be confirmed by PETROBRAS during the detail
design phase.

Normal operation shall be performed from CCR screens selected by the Operator.
PETROBRAS will provide P&ID’s for each subsea equipment according to their respective type of
control system, for CONTRACTOR to include in the SPCS CCR screens. The P&ID’s will include
a selection of the most important EHMUXSCS and DHCS parameters that shall be displayed.
The SPCS HPU shall provide hydraulic supplies for EHMUXSCS and DHCS. CONTRACTOR
shall provide the SPCS HPU, the WCR, the SESDV control panel and the PUPS according to the
specifications 7.5.5, 7.5.6 and 7.5.9.
The SPCS hydraulic system shall be fully compatible with the following water-based control fluids:
MacDermid HW443, MacDermid HW525P and Castrol Transaqua DW. PETROBRAS will select
the fluid during execution phase.
CONTRACTOR shall provide the whole SPCS hydraulic system topside flushed to ISO 4406 class
17/15/12 cleanliness standard (former standard NAS1638 Class 6), using either MacDermid
HW443, MacDermid HW525P or Castrol Transaqua DW fluids (to be defined by PETROBRAS).
CONTRACTOR shall maintain the SPCS fluid cleanliness on all SPCS topside equipment
according to ISO 4406 Class 17/15/12 specification at all times. Fluid cleanliness shall be
analyzed and recorded by the CONTRACTOR at least on a weekly basis and that information
shall be available to PETROBRAS at any time.
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CONTRACTOR is required to always recirculate the SPCS hydraulic fluid transferred from fluid
manufacture’s barrels to the SPCS HPU until achieving the required ISO 4406 Class 17/15/12
cleanliness specification.
The umbilical hang off position for the spare manifold shall allow the operation of a Manifold
(EHMUXSCS) or DHCS-WTC (dual control system capability).
Each umbilical slot hang off position (except for SESDV) shall be provided also with four hydraulic
supplies LP1, LP2, HP1 and HP2 directly from the SPCS HPU.
CONTRACTOR shall provide the topside hydraulic distribution for all EHMUXSCS and DHCS
supplies with ½” Internal Diameter (ID) thermoplastic hoses or Stainless Steel Tubes suitable
rated for continuous operation with 5,000psi (maximum) internal pressure.
SESDV umbilical slot hang off position shall be provided with ½” ID control lines rated for 5,000psi
maximum operating pressure from the SESDV Control Panel. The number of control lines will be
provided by PETROBRAS during the detail design phase.
CONTRACTOR shall provide the integration (see below the definition for “integration”) of Third
Party SPCS equipment supplied by PETROBRAS. The main types of such equipment are:
a) Topside Control Cabinets for EHMUXSCS;

b) SAS Panels.

Note: Topside Control Cabinets for EHMUXSCS application is herein referred only as “SPCS
Control Cabinets”, except when each specific type is identified.
For the “Integration” specified above, CONTRACTOR shall provide the complete installation and
commissioning of all SPCS Control Cabinets’ racks and their OWS to be supplied by
PETROBRAS. CONTRACTOR scope of supply shall also include (but it is not limited to): All
cables (power; signal; instrumentation) with suitable connectors and terminations required;
CIS/CCR hardware and software; configuration of CIS/CCR for communication with SPCS Control
Cabinets; configuration of CIS/CCR for SPCS cause and effect chart; configuration of SPCS
operation screens in the CCR.
PETROBRAS will provide the dimension drawings and interface documentation for each type of
topside SPCS Control Cabinet and SAS Panels. PETROBRAS will also provide Third Party
technical assistance to CONTRACTOR’s integration work.
PETROBRAS will provide the topside SPCS Control Cabinets according to the Table 7.5.2.1.1
below:
Table 7.5.2.1.1: SPCS Topside Control Cabinets
SPCS Topside Control Cabinets
Individual Cabinet
Control Pair Channel
Preliminary assignment for Marlim
Cabinet Type or Line
Number (note 1)
1 A MSIA or MSP (note 2)
Type 1
2 B MSIA or MSP (note 2)
3 A MSIA or MSP (note 2)
Type 1
4 B MSIA or MSP (note 2)
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5 A MSIA or MSP (note 2)


Type 1
6 B MSIA or MSP (note 2)
7 A MSIA or MSP (note 2)
Type 1
8 B MSIA or MSP (note 2)
9 A MSIA or MSP (note 2)
Type 1
10 B MSIA or MSP (note 2)
11 A MSIA or MSP (note 2)
Type 1
12 B MSIA or MSP (note 2)
13 A MSIA or MSP (note 2)
Type 1
14 B MSIA or MSP (note 2)
15 A Spare MSP (note 2)
Type 1
16 B Spare MSP (note 2)
Notes and abbreviations:
Note 1 Type 1 is for PETROBRAS standard EHMUXSCS Cabinet pair Types
Note 2 Includes the WCT connected to each manifold
MSIA Subsea water injection manifold for up to six (6) wells
MSP Subsea production manifold for up to four (4) wells
Quantity of SPCS Control Cabinet racks per FPU: eight (8).
MOST IMPORTANT: The assignment of each well or manifold to specific SPCS Control Cabinets
is preliminary. PETROBRAS will provide the first assignment configuration of at least one
EHMUXSCS Cabinet pair up to three months in advance of the scheduled start of operation
offshore Brazil for CONTRACTOR make the interconnections in the Control Cabinet room.
CONTRACTOR shall provide installation, integration and commissioning for topside EHMUXSCS
Control Cabinets manufactured by three (3) different subsea control system suppliers. At least two
EHMUXSCS Control Cabinets (one pair) will be delivered at the CONTRACTOR shipyard.
PETROBRAS is going to provide 60 man-days of technical assistance to the CONTRACTOR for
this first integration.
CONTRATOR shall take into account that not all topside SPCS Control Cabinets will be available
for shipyard installation before the FPU starts production.
CONTRACTOR shall provide at any time with no cost to PETROBRAS the installation, integration
and commissioning of any quantity of SPCS Control Cabinets up to the total specified by Table
7.5.2.1.1, whenever requested by PETROBRAS, including while the FPU is offshore.
PETROBRAS will request to CONTRACTOR this offshore installation and integration work with at
least three months in advance. CONTRACTOR shall plan and carry out this work with minimum or
no impact for the FPU’s operation.
The layout of the SPCS Control Cabinet room shall allow the easy installation and removal of each
SPCS Control Cabinet rack, including while the FPU is offshore. Special attention shall be given to
position cable trays and junction boxes in order to cope with installing and removing cable
interconnections. Cable entries to each SPCS Control Cabinet shall be from the bottom of each
Cabinet rack.
CONTRACTOR shall provide the cabling between each umbilical slot hang off electrical junction
box and the SPCS Control Cabinet room with at least four (4) high grade 0.6/1.0kV class 6.0mm²
twisted pairs with individual shield per pair with PE (Protection Earth) to be dedicated to
EHMUXSCS use.
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CONTRACTOR shall provide at any time with no cost to PETROBRAS the reassignment of the
electrical connections between the four (4) twisted pairs from each EHMUXSCS umbilical to any
individual topside SPCS Control Cabinet.
For this purpose, CONTRACTOR shall provide two (2) TOPSIDE ELECTRICAL ASSIGNMENT
PANELS (TEAP-A and TEAP-B). Each TEAP (A or B) will be connected to all EHMUXSCS control
cabinets, respective A or B channels, i.e., TEAP-A to all EHMUXSCS Channel A control cabinets
and TEAP-B to all EHMUXSCS Channel B control cabinet.
Each TOPSIDE ELECTRICAL ASSIGNMENT PANEL shall be in the form of a single, enclosed
type rack with front and rear doors that allows the electrical connection of the two (2) of the four
(4) twisted pairs from each EHMUXSCS umbilical to any individual topside EHMUXSCS Control
Cabinet of the same Channel. The TEAP shall allow changing the connections very easily
whenever required, without the need to reposition the cables arriving to the panel itself. The use of
wire jumpers between the TEAP cable termination blocks or something similar for this purpose
may be considered. The final configuration assignment between wells, manifolds and their
respective control cabinets will be confirmed by PETROBRAS up to 90 days before the FPU
leaves the integration shipyard.
CONTRACTOR shall consider housing all Control Cabinets, TEAP-A, TEAP-Band SAS Panels in
the same room to facilitate cable routing among them.
CONTRACTOR shall submit to PETROBRAS for approval the design documents for the complete
installation and commissioning of SPCS Control Cabinets, TEAP-A, TEAP-B and SAS Panels.
CONTRACTOR shall also submit to PETROBRAS for approval the SPCS cause and effect chart.
CONTRACTOR shall guarantee the SPCS Control Cabinet room ambient temperature to be kept
lower than 35ºC at all times, taking as a premise that all SPCS Control Cabinets listed in Table
7.5.2.1.1 will be in full operation. The room temperature shall be monitored and recorded at all
times by the CCR.
Each EHMUXSCS Control Cabinet will be based on 19” type rack with preliminary dimensions of:
900 mm (W) x 1400 mm (D) x 2500 mm (H). The exact dimensions will be confirmed by
PETROBRAS during the detail design phase.
CONTRACTOR shall provide permanent front and rear accesses for each SPCS Control Cabinet
rack. The access shall allow both front and rear doors to fully open when necessary.
PETROBRAS will provide to CONTRACTOR two (2) desktop Operator Work Stations for all of
EHMUXSCS Control Cabinets from the same supplier. The Operator Work Stations can be used
as a local Master Control Station (MCS) with limited operator interface capabilities, allowing some
back-up to the full operation of the EHMUXSCS from the CCR.
CONTRACTOR shall provide room and desktop facilities in the CCR or nearby room for the
Operator Work Stations. Specifications of the cables and connectors between the EHMUXSCS
Control Cabinets and the Operator Work Stations will be provided by PETROBRAS during the
detail design.
CONTRACTOR shall request PETROBRAS to specify the communication network and protocol
interface between the following topside equipment:
a) CIS/CCR with each EHMUXSCS Control Cabinet rack
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b) Each EHMUXSCS Control Cabinet rack from the same subsea control system supplier and
their pair of OWS (three (3) such networks shall be implemented, being one for each
subsea control system supplier equipment);

CONTRACTOR shall provide all necessary switches to connect the equipment as above.
Each network above shall have its own and exclusive cable network. For each one,
CONTRACTOR shall provide PETROBRAS’s choice among the two following options:
i. Ethernet TCP/IP with OPC protocol;

ii. MODBUS/TCP;

Each network cable interface shall be 100-BASE-T or 100-BASE-FX type optical connection, also
to be defined by PETROBRAS together with the interface protocol.
CONTRACTOR shall provide the following digital hardwire shutdown signals from CIS to each
individual EHMUXSCS Control Cabinet rack:
 ASD (Abandon Ship and Total FPU Shutdown): 1-off signal activated by the CIS to
perform the shutdown sequence in all wells and the respective DHSV;
 ESD (Emergency Shutdown): 1-off signal activated by the CIS to perform the shutdown
sequence in all wells without closing the respective DHSV;
 PSD (Process FPU Shutdown): 1-off signal activated by the CIS to close the WCT
Crossover and Pig Crossover valves;
 USD (Well Shutdown): 1-off digital signal per well, activated by the CIS to perform the
shutdown sequence in each well individually except for the DHSV. The number of signals
shall be according to the number of wells controlled from the respective EHMUXSCS
Control Cabinet. Each subsea manifold requires 1-off USD signal per well. The exact
configuration will be provided by PETROBRAS during the detail design phase.
For each shutdown signal above, CONTRACTOR shall provide a CIS-powered 24VDC two wire
signal, hardwired to a relay type Digital Input interface on each EHMUXSCS Control Cabinet rack.
PETROBRAS will inform the maximum current drawn by each coil during the detail design phase.
For further information about ASD, ESD, PSD, and USD, see SAFETY GUIDELINES FOR
OFFSHORE PRODUCTION UNITS.
Each SPCS Control Cabinet rack shall be powered by 220V AC @ 60 Hz from the FPU
Uninterruptable Power Supply, allowing 15 minutes of full power operation after an electrical
shutdown. Power consumption of each EHMUXSCS Control Cabinet rack will be 6.0 kVA and heat
dissipation of each Control Cabinet will be 3.5 kW.
CONTRACTOR shall provide the interface between the SAS Panel and the CCR. All DHCS-WCT
sensors shall be displayed in the respective well P&ID screen, as well as the SESDV sensor shall
be displayed in the SESDV P&ID screen.
7.5.3. SPCS UMBILICALS AND TOPSIDE UMBILICAL INTERFACES

The SPCS shall be designed for operation with the following types of control umbilicals:
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a) 5,000psi Standard TPU (Thermoplastic Umbilical) for Production Wells with 5k DHCS-
WCT:

 9 x 3/8" x 5,000 psi – Thermoplastic hoses for direct hydraulic control of the WCT and
downhole valves;
 3 x 1/2" x 5,000 psi – High Collapse Resistant (HCR) hoses for chemical injection;
 1 x Electrical cable with three twisted pairs of 2.5mm2 conductors with Voltage Class
0.6/1.0 (1.2) kV, according with IEC 60502-1 (Power cables with extruded insulation and
their accessories for rated voltages from 1 kV (Um = 1.2 kV) up to 3 kV (Um = 3.6 kV)) for
the WCT pressure and temperature transmitters, and the PDG for the respective well.
b) 5,000psi Standard TPU (Thermoplastic Umbilical) for SESDV and Water Injection Wells
with 5k DHCS-WCT:

 5 x 3/8" x 5,000 psi – Thermoplastic hoses for direct hydraulic control of the WCT and
downhole valves;
 1 x Electrical cable with three twisted pairs of 2.5mm2 conductors with Voltage Class
0.6/1.0 (1.2) kV, according with IEC 60502-1 (Power cables with extruded insulation and
their accessories for rated voltages from 1 kV (Um = 1.2 kV) up to 3 kV (Um = 3.6 kV)) for
the WCT pressure and temperature transmitters, and the PDG for the respective well.
c) 5,000psi Standard TPU (Thermoplastic Umbilical) for Subsea Production Manifolds:

 4 x 1/2" x 5,000 psi – Thermoplastic hoses for direct hydraulic control of the WCT and
downhole valves;
 9 x 1/2" x 5,000 psi – High Collapse Resistant (HCR) hoses for chemical injection;
 1 x Electrical cable with four twisted pairs of 10 mm2 conductors with Voltage Class 0.6/1.0
(1.2) kV, according with IEC 60502-1 (Power cables with extruded insulation and their
accessories for rated voltages from 1 kV (Um = 1.2 kV) up to 3 kV (Um = 3.6 kV)) for the
SCM installed in subsea manifold.
d) 5,000psi Standard TPU (Thermoplastic Umbilical) for Subsea Water Injection Manifolds:

 4 x 1/2" x 5,000 psi – Thermoplastic hoses for direct hydraulic control of the WCT and
downhole valves;
 6 x 1/2" x 5,000 psi – High Collapse Resistant (HCR) hoses for chemical injection;
 1x Electrical cable with four twisted pairs of 4 mm2 conductors with Voltage Class 0.6/1.0
(1.2) kV, according with IEC 60502-1 (Power cables with extruded insulation and their
accessories for rated voltages from 1 kV (Um = 1.2 kV) up to 3 kV (Um = 3.6 kV)) for SCM
installed in subsea manifold.
Hydraulic connections for umbilical hoses shall be provided by their respective fittings grouped in
a plate herein referred as “Topside Umbilical Termination Unit” Plate (TUTU Plate). Umbilical
hydraulic hose pig-tails are typically 600mm long and will be provided with the following fittings, to
be confirmed by PETROBRAS during the detail design phase:
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 HCR ½” 5000 psi: 1/2 " – Female JIC 37° 3/4" - 16UNF, AISI 316L
 Thermoplastic Hose 3/8” 5000 psi: 3/8 " – Female JIC 37° 9/16" - 18UNF, AISI 316L
The TUTU Plates shall be equipped with male JIC connector according to the umbilical tail
connector.
SESDV umbilical slot hang off position shall be provided with a TUTU Plate for 5,000psi TPU.
TUTU Plates shall be positioned in order to not block or interfere with pull-in/pull-out operations.
Where this cannot be fully guaranteed, they shall be made removable.
CONTRACTOR shall present each TUTU Plate design for PETROBRAS approval.
Each umbilical hang off position shall be provided with an Electrical Junction Box (EJB) for the
termination of the umbilical electrical cable.
For the umbilical hang off positions where PETROBRAS specified the capability to use umbilicals
with different electrical cable configurations, the EJB shall have one cable entry specific for each
type of umbilical cable or a single cable entry adaptable according to the type of umbilical
installed.
The subsea umbilical’s electrical pig-tails are typically 600mm long.
Each EJB shall have terminal blocks capable to accept any conductor size between 2,5mm² and
10mm². Terminal blocks shall be dimensioned with individual ground connections for every pair of
umbilical conductors.
Each EJB shall be positioned in order to not block or interfere with pull-in/pull-out operations.
Where this cannot be fully guaranteed, they shall be made removable.
CONTRACTOR shall present EJB design for PETROBRAS approval.
The electrical cable pig-tails preparation and connection inside the EJB is CONTRACTOR’s scope
of work. Details on the cables nominal diameters will be provided by PETROBRAS during the
design phase.
7.5.4. SPCS OPERATOR INTERFACES

The SPCS shall be operated from the CCR using dedicated screens and pop-up menus according
to the particular CCR system used.
As a preliminary requirement, the following screens shall be implemented as an intuitive way of
navigating through the system in a logical manner as the main building blocks are connected:
a) Well type, according to respective P&IDs;

b) Subsea manifolds and associated wells, according to their respective P&IDs;

c) Assignment of individual wells to a manifold;

d) SPCS HPU monitoring;

e) SCM monitoring;

f) SESDV
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CONTRACTOR shall implement without cost to PETROBRAS all CCR screen reconfigurations
needed by future changes in the SPCS subsea layout. The reconfiguration shall be easily
accomplished by the use of simple pop-up menus on the CCR screen under password protected
supervisor level. PETROBRAS will request such reconfigurations at least three months in advance
with the new subsea P&IDs for configuration of the HMI screens.
The following minimum information shall be displayed on the CCR screens for each well P&ID:
a) Downhole valve status (opened or closed);

b) Downhole pressures and temperatures;

c) WCT valve status (opened or closed);

d) WCT pressures and temperatures;

e) Pig detection;

f) Corrosion monitoring of pipeline (to be confirmed by PETROBRAS during the detail design
phase);

g) ESD status;

The following minimum information shall be displayed on the CCR screens for each manifold
respective P&ID:

a) The respective manifold well’s P&ID;

b) Valve status (opened or closed);

c) Pressure and temperatures;

d) Injection flow rates (measured and calculated);

e) Choke position (measured by position sensor and calculated by control steps given);

f) Pig detection;

g) Corrosion monitoring of pipeline (to be confirmed by PETROBRAS during the detail design
phase);

h) ESD status;

The SPCS HPU shall be monitored from the CCR using dedicated screens and pop-up menus
according to the particular CCR system used. At least the following data monitored from the SPCS
HPU shall be displayed on the CCR screens:

a) Reservoirs levels;

b) Unregulated header pressure (both headers);

c) Regulated header pressure (both headers);


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d) Pump status;

e) Individual supply pressures LP1, LP2, HP1 and HP2 for each EHMUXSCS umbilical;

f) Individual supply pressures for the WCR and the SESDV Control Panel;

The hydraulic pressure of each umbilical line (control and chemical injection) shall also be
monitored as close as possible of their respective hang off connection plate. Pressures shall be
displayed on the CCR.

The following minimum information specific for the subsea equipment provided with EHMUXSCS
shall be displayed on the CCR screens:

a) Hydraulic supply pressures monitored by each Subsea Control Module;

b) Active Line or Channel providing communication and power to each SCM;

c) Subsea electronic module (two for each SCM) health status and internal temperature;

d) Individual Control Cabinet statuses (to be confirmed by PETROBRAS during the detail design
phase);

e) ESD status;

The following minimum information shall be displayed on the CCR screens for each SESDV:

a) Valve status (opened or closed) for SESDV;

b) Pressure and Temperature for SESDV;

c) Pig detection.

7.5.4.1. Time delay for subsea valve command operations


It shall be possible to configure a time delay for the SPCS initiate a subsea valve operation after
the command is issued by the Operator. This configuration shall be available for each subsea
valve tag and be easily accomplished by simple pop-up menus on the CCR screens at password
protected supervisor level. Default values for time delays will be informed by PETROBRAS during
the detail design phase.
7.5.4.2. Subsea valve open and close sequences
It shall be possible to configure open and close sequences for all valves of each subsea
equipment and SESDV. It shall also be possible to configure open and close sequences among
the subsea equipment installed. Such configurations shall be easily accomplished by calling
special CCR screens under password protected supervisor level. Default sequences will be
informed by PETROBRAS during the detail design phase.
7.5.5. SPCS HYDRAULIC POWER UNIT (HPU)

CONTRACTOR shall provide SPCS HPU according to PETROBRAS specification number:


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 ET-3000.00-5139-800-PEK-007 (Unidade Hidráulica (HPU) para equipamentos


submarinos que poderão estar equipados com Sistema de Controle Eletro-Hidráulico
Multiplexado ou Sistema de Controle Eletro-Hidráulico Direto, em qualquer combinação, e
que requerem até 5000 psi de pressão máxima de atuação (HPU-FLEX 5000) – see item
1.2.1.
In case of conflicting information between item 7.5.5 and ET-3000.00-5139-800-PEK-007
PETROBRAS shall be consulted.
7.5.5.1. Manifolded wells
The SPCS HPU specification above is in Brazilian Portuguese language. All translations to other
languages required by CONTRACTOR or by other third parties, such vendors, and suppliers (just
to name a few), shall be CONTRACTOR’s responsibility and shall be part of CONTRACTOR’s
scope of supply.
The SPCS HPU shall be dimensioned in terms of reservoirs, accumulator bank and pumps
capacities according to the criteria specified by the SPCS HPU specification referred above and
the DADOS PARA O PROJETO DE HPU DOS EQUIPAMENTOS SUBMARINOS DO FPSO
MÓDULO 2 DE MARLIM” (FD-3534.00-1500-941-PH8-005) provided as a reference document
mentioned on item 1.2.1 of this GTD or as a separate document. The “Datasheet of HPU
Consumers” for a given FPU specifies the quantities of subsea equipment according to each type.
The first filling of the HPU fluid tanks falls under CONTRACTOR´s scope. During operations
PETROBRAS will provide the fluid make-up whenever necessary, if the HPU is operating properly
and without leakages.
The SPCS HPU will provide the following pressure regulated supplies for each EHMUXSCS
subsea equipment:
 LP1: Operation between 1,500 psi and 3,000 psi;
 LP2: Operation between 1,500 psi and 3,000 psi;
 HP1: Operation between 3,000 psi and 5,000 psi;
 HP2: Operation between 3,000 psi and 5,000 psi.
The SPCS HPU will provide two unregulated hydraulic supplies outlets for the WCR operate the
following subsea valves (according to WCT Type used):
 WCT gate valves requiring between 1,500 psi and 3,000 psi;
 Downhole valves requiring between 3,000 psi and 5,000 psi;
The SPCS HPU will provide two hydraulic supplies for the SESDV Control Panel. Both will allow
the operation of the SESDV between 1,350 psi and 3,300 psi.
MOST IMPORTANT: Fluid depressurized from SESDV shall NOT be allowed to return to the
SPCS HPU reservoirs. This fluid shall be disposed by the CONTRACTOR whenever necessary.
All SPCS HPU supplies shall have individual pressure transmitters downstream of the HPU for
Operator’s monitoring on the CCR screens.

7.5.5.2. Satellite wells


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The Vendor list shall be composed by: AKER SOLUTIONS, COOPER-CAMERON, FMC,
ANZZET, FRAMES, W-INDUSTRIES HITEC and CONTROLS ELECTRIC PTE LTD.
The HPU and all associated hydraulic equipment shall be designed to maintain the cleanliness of
control fluid according to NAS 1638 Class 6. In order to meet this requirement, the HPU shall have
a supply reservoir and a return reservoir, connected by circulation pump and filters.
Fluid cleanliness shall be analyzed and recorded by the CONTRACTOR on a weekly basis and
that information shall be available to PETROBRAS at any time.
The hydraulic control fluid will be water-based MacDermid Canning HW443, MacDermid HW525P,
Castrol Transaqua DW. PETROBRAS will define the fluid during execution phase.
The hydraulic supply and return headers between the HPU and the WCRs shall be sized
(minimum) according to the Hydraulic analysis, in order to avoid flow restrictions.
The hydraulic power for the Christmas Trees and ESDVs shall be provided by the HPU through
pressure regulator valves, set up at pressure levels, according to requirements of the consumers
defined by the SUBSEA LAYOUT see item 1.2.1.
HIGHER LEVEL (Typical): pressure of 5,000 psi for the actuation of the Downhole Safety Valve
(DHSV), adjustable by a pressure regulator between 3,000 psi and 5,000 psi).
LOWER LEVEL (Typical): pressure of 3,000 psi for the actuation of the other valves, adjustable by
a pressure regulator between 1,500 psi) and 3,000 psi).
SESDV operation pressure (Typical): pressure of 1350 to 3300 psi adjustable by a pressure
regulator.
Note: PCVs shall be able to operate at any specific set within pressure ranges listed above.
The HPU shall be designed considering the following:
1. Accumulators shall be designed to open the farthest well, from the maximum pressure (High)
to minimum pressure (Low), with no need of hydraulic pump;

2. Pumps shall be designed to replenish the whole hydraulic system (accumulators), from the
minimum pressure (Low) to the maximum pressure (High), within 5 minutes. In addition, the
minimum HPU flow rate to the WCR, shall be 50 litres per minute;

3. The hydraulic fluid reservoir shall be split into two totally segregated reservoirs - the supply
reservoir and the return reservoir;

4. A hydraulic pump shall be installed to recirculate the hydraulic fluid from the return reservoir
to the supply reservoir. Filtering and sample collectors shall be installed to allow
commissioning of the fluid to guarantee the required cleanness class and to enable
hydraulic fluid analysis. Minimum circulating pump flow rate shall be 20 litres per minute;

5. The net internal volume of the supply reservoir shall be sufficient to pressurize the whole
subsea system (all hydraulic lines from the Unit to the wells and Sub- Surface Safety
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Valve). For the design, the pressurization from zero to maximum working pressure shall be
considered;

6. The return reservoir shall be sized to receive twice the internal volume of all subsea system
(during an ESD 3 or 4);

7. Two independent pressure headers shall be segregated with the use of independent
pressure regulators. The first, to be distributed and used at the WCR for WCT valves
actuation. The second to be distributed and used at the WCR for DHSV actuation.

8. The hydraulic tubings in the umbilicals are pre-filled with hydraulic fluid before launching.

In addition, materials of tanks, accumulators, pumps, tubing, valves, etc. shall be specified to meet
the hydraulic fluid and cleanness (NAS class 6 or better) requirements.
For the design of the hydraulic system, CONTRACTOR shall consider the subsea lay-out for a
Spread Moored FPSO.
The HPU shall have stand-by equipment (filters, pumps, accumulators) to allow an adequate
maintenance during all operational lifetime, with no influence on the hydraulic system
performance.
All pressure switches, manometers and level switches shall have shutoff and draining valves so
that any of these instruments from the pneumatic or hydraulic circuits can be removed without
affecting the operation of the HPU. These valves shall be positioned so as to prevent accidental
closure due to vibration. The pressure switches, transmitters and manometers shutoffs will be
effected by means of manifold valves.
The HPU shall be designed to operate even in case of a continuous subsea hydraulic fluid
leakage, that causes a fluid loss smaller than the HPU design flowrate capacity.
The HPU shall be provide with local control and monitoring as well as remote control from the
CCR.
MOST IMPORTANT: The return fluid from the ESDV Panel shall not be allowed to the HPU
reservoirs. This fluid shall be always disposed by the CONTRACTOR.
7.5.6. WELL CONTROL RACK (WCR) FOR DIRECT HYDRAULIC CONTROL SYSTEM

CONTRACTOR shall provide the WCR for the number of wells that may be equipped with DHCS-
WCT according with specifications 7.5.2 above.
CONTRACTOR shall provide the WCR capable of controlling the 5k DHCS-WCT types and the
well’s downhole valves. A total of ten (10) control functions for production wells and four (4)
functions for injection wells (see below), each with a Directional Control Valve (DCV), shall be
provided for each well. The P&ID for each DHCS-WCT type will be provided by PETROBRAS
during the detail design phase.
The WCR shall be provided with two (2) unregulated pressure supplies from the HPU for this
purpose:
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1. One to allow the operation of subsea valves with pressures between 1,500 psi and 3,000
psi;

2. One to allow the operation of downhole valves with pressures between 3,000 psi and
5,000 psi;

The WCR shall provide a set of two separate headers for each well, derived from the two DHCS
supplies from the SPCS HPU. Each set of headers shall be provided with manually adjusted
pressure regulators upstream of the respective well’s Directional Control Valves (DCV) in order to
allow the individual control of the 5 kpsi WCT and downhole valves. The two headers shall be
divided according to:
1. One header to allow the operation of DHCS-WCT gate valves (1,500 - 3,000 psi range
when used for a 5kpsi type WCT). This header will supply eight (8) WCT valve functions
for the production wells and two (2) WCT valve functions for the injection wells;

2. One header to allow the operation of downhole valves typically used with 5kpsi type
DHCS-WCT (3,000 - 5,000 psi range). This header will supply two (2) downhole valve
functions for production and injection wells.

The WCR shall be designed to avoid back pressures in the umbilical control lines, considering the
worst case depressurization of all control lines at the same time to the SPCS HPU. Return fluid
lines from the WCR to the SPCS HPU shall be sized with sufficient flow capacity for this purpose.
The WCR shall allow all WCT and downhole valves to close in less than 10 minutes.
The Directional Control Valves for the WCR shall be spring return fail-close solenoid valve type
energized from the CCR/CIS. They shall bleed the pressure when the electrical power for the
solenoid is removed. The DCV shall be specified to avoid any pressure drop during subsea
hydraulic lines pressurization and depressurization. Their minimum internal passages shall be
equivalent in area to a 6mm² bore. It is important to take into account the pressure drop during the
pressurization of the subsea system. This shall not cause any malfunction to the solenoid valves.
It is recommended that the DCV and most hydraulic components be installed in stainless steel
manifold blocks. The same recommendation applies for the WCR itself to be made in stainless
steel.
Individual pressure transmitters shall be provided downstream of each WCR DCV for Operator’s
monitoring on the CCR screens.
Umbilical hang off for the spare manifold shall allow dual control system capability. In addition to
four (4) hydraulic supplies LP1, LP2, HP1 and HP2 for umbilical hang off position of the spare
manifold CONTRACTOR shall provide hydraulic supplies at TUTU Plate for a DHCS-WCT
operation as described above, that is, eight (8) supplies for WCT gate valves (1,500 - 3,000psi
range) and two (2) supplies for the downhole safety valve (3,000 - 5,000psi range).
7.5.7. DOWNHOLE DATA ACQUISITION SYSTEM (SAS PANEL)
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The SAS equipment is topside data acquisition for the satellite wells. SAS acquires the signals
from Permanent Downhole Gauges (PDG) installed in wells and the pressure and temperature
(TPT) digitally transmitted from the production WCT.
The SAS equipment provide RS-232, RS-485 and Ethernet network interfaces with MODBUS
RTU protocol. Power can be supplied from 85-240VAC @ 60Hz or 24VDC options. Each SAS
equipment requires standard 19” & 3U rack space.
CONTRACTOR shall install the SAS Equipment(s) in 19” type standard rack(s), herein referred as
SAS Cabinet, with a height of 2500mm. Front and rear accesses shall be provided.
PT & TPT 4-20mA transmitters from each DHCS-WCT shall be read by the FPSO CIS/CCR
system PLC and displayed in the CCR. The DHCS-WCT electrical system schematic will be
provided by PETROBRAS during the execution phase.
CONTRACTOR shall provide to PETROBRAS no longer than 60 days after the contract award the
preliminary drawings showing the space available in the SAS Panel to be used.
The installation, integration, commissioning and operation of these panels, onboard, are
CONTRACTOR’s Scope of work.
7.5.8. SPECIAL REQUIREMENTS FOR SINGLE POINT MOORING (TURRET)

Not applicable.

7.5.9. PORTABLE UMBILICAL PRESSURIZATION SYSTEM (PUPS)

PUPS is a topside portable device to allow the CONTRACTOR to safely pressurize each control
line of an umbilical during installation, from any LP or HP pressure supply from the SPCS HPU.
The PUPS device shall allow for quick air removal and safe pressurization and depressurization of
up to twelve (12) umbilical tubings or thermoplastic hoses from one or two hydraulic supplies at
any TUTU Plate.
The PUPS device shall be composed of two identical hydraulic headers, each one with a common
pressure inlet port, a pressure regulator, manometer, 6 (six) function branch outlet ports and one
drain port to drain/bleed any of the 6 outlets. Each drain and outlet port, as well as each
manometer shall have their own isolating valve. All components shall be stainless steel type with
at least ½” O.D suitable for the above said control fluid and fluid cleanliness. The drain/bleed ports
shall be used also to take fluid sampling when necessary.
JIC fittings mentioned below in this chapter are just for reference. CONTRACTOR shall provide
the PUPS with the matching hydraulic terminations for umbilical hose and Steel Tube fittings to be
informed by PETROBRAS during the detail design phase.
The PUPS device shall be able to pressurize each umbilical line with a regulated pressure
between 1,350 psi and 3,000 psi, from any supply between 3,000 and 5,000 psi. However, all
PUPS hydraulic components shall be rated to 5,000 psi operation. Each of the 12 (twelve)
pressurization outlets shall be terminated with a quick connector adapter to allow the fitting of a ½”
or 3/8” male JIC 37° termination prior the pressurization. Each PUPS device shall be provided with
sets of at least 13x 3/8” and 5x ½” male JIC 37° fittings. CONTRACTOR shall consider provide
each PUPS with its own storage box for those fittings when not in use.
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CONTRACTOR shall provide and maintain at least two identical PUPS devices always ready for
use when asked so by PETROBRAS.
The PUPS device shall be used for CONTROL LINES only with water-based control fluids
MacDermid HW443, MacDermid HW525P or Castrol Transaqua DW.
CONTRACTOR shall maintain the PUPS devices always flushed to ISO 4406 Class 17/15/12
cleanliness.
7.5.10. SUBSEA EMERGENCY SHUTDOWN VALVES CONTROL PANEL

CONTRACTOR shall provide the SESDV control panel for the number of SESDV according with
specifications 7.5.2 above.
 The SESDV control panel shall be provided with two (2) regulated pressure supplies from
the HPU for actuation of two (2) SESDV valves with pressures between 1,350psi and
3,300 psi;
The SESDV control panel shall be designed to avoid back pressures in the umbilical control lines,
considering the worst case depressurization of all control lines at the same time to the SPCS
HPU. Return fluid lines from the SESDV control panel shall be sized with sufficient flow capacity
for this purpose. The return fluid from SESDV control panel shall not be allowed to return to the
SPCS HPU.
The SESDV control panel shall allow SESDV to close in less than two (2) minutes.
The Directional Control Valves for the SESDV control panel shall be spring return fail-close
solenoid valve type energized from the CCR/CIS. They shall bleed the pressure when the
electrical power for the solenoid is removed. The DCV shall be specified to avoid any pressure
drop during subsea hydraulic lines pressurization and depressurization. Their minimum internal
passages shall be equivalent in area to a 6mm² bore. It is important to take into account the
pressure drop during the pressurization of the subsea system. This shall not cause any
malfunction to the solenoid valves.
It is recommended that all DCVs and hydraulic components be installed in stainless steel manifold
blocks. It is also recommended that SESDV control panel itself to be made in stainless steel.
Individual pressure transmitters shall be provided downstream of each SESDV control panel DCV
for Operator’s monitoring on the CCR screens.
TPT 4-20mA transmitter from SESDV shall be read by the FPSO CIS/CCR system PLC and
displayed in the CCR. The SESDV electrical system schematic will be provided by PETROBRAS
during the execution phase
7.6. NOT APPLICABLE

7.7. METERING

The flow measurement system (FMS) shall comply with Brazilian legislation, including National
Agency of Petroleum, Natural Gas and Biofuels (ANP) and Brazilian National Institute of
Metrology, Quality and Technology (INMETRO) regulations.
The FMS shall be designed, selected, installed, commissioned and tested in order to comply with
all technical requirements mentioned in the Technical Regulation Measurement of Oil and Natural
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Gas, or just RTM, approved by Resolução Conjunta ANP/INMETRO nº1 de 10/06/2013 (or other
updated document which substitutes it), in other supplementary regulations issued by
ANP/INMETRO and in manufacturer’s recommendations, including all applicable standards and
reference technical documents.
Standards, codes and recommendations that shall be followed in the design of the FMS are listed
in RTM-Appendix D or explicitly referenced in this document.
The following requirements for the FMS shall be interpreted as minimum and are in accordance to
the RTM. Other metering points may be necessary depending on the topside process philosophy
adopted and should not be omitted.
Table 7.7.1_Points of Measurement
Metering Accuracy
Item Fluids Duty Type of meter
points (note 1)

Ultrasonic or Coriolis 0.3%


Cargo pump Custody (system)
1 Oil (note 2) or turbine
discharge transfer 0.2%
meters; flow computer.
metering (sensor)
Minimum 1 spare meter

Cargo pump Calibration of


Custody
Master meter and Prover  0.1%
2 Oil discharge (note 2), or only Prover;
transfer (system)
(offloading) flow computer
metering
Transference
pump
 0.3%
discharge Fiscal metering Ultrasonic or Coriolis
(system)
3 Oil (from the (oil and (note 2) or turbine
 0.2%
process plant condensate) meters; flow computer
to the cargo (sensor)
tanks)
Transference
pump
discharge Master meter and Prover
Calibration of  0.1%
4 Oil (from the (note 2), or only Prover;
fiscal metering (system)
process plant flow computer
to the cargo
tanks)
Positive Displacement,
Well injection  0.3%
Coriolis (with volume
operations (system)
5 Oil Fiscal Metering indication) or helical
(Diesel and/or  0.2%
turbine meter (note 3);
Treated Oil) (sensor)
flow computer (note 11)
Positive Displacement,
 1.0%
Coriolis (with volume
Allocation (system)
6 Oil Test separator indication) or helical
metering  0.6%
turbine meter (note 3);
flow computer (sensor)
Positive Displacement,
Production Operational Coriolis (with volume 1%
7 Oil
separators metering indication) or turbine meter (system)
with flow computer
Transference
pump
discharge Online transmitter
8 BSW (from the Online (Microwave, RF) with static
process plant mixer (note 4)
to the cargo
tanks)
Transference Automatic and manual
9 BSW pump Sampler (installed downstream of
discharge the static mixer) (note 5)
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Metering Accuracy
Item Fluids Duty Type of meter
points (note 1)
(from the
process plant
to the cargo
tanks)
Well injection
operations Automatic and Manual
10 BSW Sampler
(Diesel and/or (note 11)
Treated Oil)
Well injection
Online transmitter
operations
11 BSW Online (Microwave) with static
(Diesel and/or
mixer (note 11)
Treated Oil)
Online transmitter
12 BSW Test separator Online (Microwave) with static
mixer
Manual
(installed downstream of
13 BSW Test separator Sampler
the static mixer). Provision
to pressurized cylinder.
Cargo pump Online transmitter
14 BSW Online
discharge (Microwave, RF) (note 4)
Automatic and manual
Cargo pump (installed downstream of
15 BSW Sampler
discharge the static mixer)
(note 5)
Orifice plate meter with
Gas Lift flow computer; Senior
Allocation
16 Gas individual per orifice fittings and 2%
metering
slot removable straight pipe
sections to be provided.
Operational Cone or Orifice Plate with
17 Gas Gas Lift Total  3.0 %
metering flow computer
Orifice plate meter
(Senior orifice fittings and
Production Operational removable straight pipe
18 Gas 3%
separators metering sections to be provided)
or cone meter with flow
computer.
Fuel Gas
Orifice plate meter or
19 Consumers Operational
Gas Cone meter with flow  3.0 %
(notes 8, 8.1 Metering
computer
and 8.2)
Orifice plate meter with
flow computer; Senior
Fuel Gas Fiscal  1.5 %
20 Gas orifice fittings and
Total (note 8) metering
removable straight pipe
sections to be provided.
Orifice plate meter with
Operational
21 Gas Flare Pilot flow computer  3.0 %
metering
Note(8.1)
Orifice plate meter with
flow computer; Senior
Export line Fiscal
22 Gas orifice fittings and  1.5 %
(Note 9) metering
removable straight pipe
sections to be provided.
Orifice plate meter with
flow computer; Senior
Import line Fiscal
23 Gas orifice fittings and  1.5 %
(Note 9) metering
removable straight pipe
sections to be provided.
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Metering Accuracy
Item Fluids Duty Type of meter
points (note 1)
Ultrasonic flare meter
Fiscal 5%
24 Gas Flare LP (FLUENTA or GE type)
metering (note 6)
with flow computer.
Ultrasonic flare meter
Fiscal 5%
25 Gas Flares HP (FLUENTA or GE type),
metering (note 6)
with flow computer.
Orifice plate meter with
flow computer; Senior
Allocation orifice fittings and
26 Gas Test separator 2%
metering removable straight pipe
sections are to be
provided (note 12)
Orifice plate meter,
magnetic meter (spool
Allocation
27 Water Test separator type) or Coriolis meter; 1.0%
metering
pressure and temperature
transmitter; flow computer
Orifice plate meter, Cone
meter, magnetic meter
Individual Operational
28 Water (spool type), temperature 1.0%
Injection metering
transmitter (note 10) with
flow computer
Orifice plate meter, Cone
Operational meter, magnetic meter 1.0%
29 Water Produced
metering (spool type) with flow (note 7)
computer
Orifice plate meter, Cone
Operational meter, magnetic meter 1.0%
30 Water Disposal
metering (spool type) with flow (note 7)
computer

NOTES:
(1) Maximum allowable errors for liquid metering; uncertainty for gas metering;
(2) Ultrasonic meters shall have 4 (four) channels as minimum. In case of using ultrasonic or
coriolis meters as duty meter, a master meter and a Prover are required and the master meter
shall be a helical turbine meter;
(3) The duty meter shall be calibrated against a master meter or a prover at the FPSO facilities. If
a master meter is used, it shall be proved against a prover at the FPSO facilities. If a turbine
master meter is used, it shall be of helical type;
(4) The transmitter shall be able to be disassembled without interruption of the whole metering
system operation;
(5) 2 (two) samplers shall be available, one manual and other automatic.
(6) Although classified as fiscal measurement, the meter technologies and process conditions do
not allow better uncertainties than the one specified; each flow loop shall be composed by: flow
meter (FE), electronic unit (manufacturer’s "flow computer”) (FT), pressure (PT) and temperature
(TT) transmitters and flow computer (FQl); the FT, PT and TT shall be linked to the FQI (control
room); this kind of arrangement is acceptable by ANP-INMETRO once they are characterized as
fiscal points (even at a 5.0% uncertainty level); all flow computation and data storage shall be
done at FQI (INMETRO approved flow computer); sensors shall be removable in order to enable
the dry calibration procedure; Flow meter shall be supplied in a spool; Electronic unit shall
communicate with flow computer using field network (MODBUS RTU protocol).
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(7) One temperature transmitter shall be provided in order to comply with API MPMS 20.1.
(8) CONTRACTOR shall provide means to measure separately the gas flow rates of the following
fuel gas consumers (if applicable): e.g.: gas-turbines, turbo-generators and boilers, flare purge;
inert gas. Flow meters as part of those equipment packages are acceptable.
(8.1) Flare pilot or any other flow which is flared without being previously measured by LP Flare
Meter or HP Flare Meter shall automatically generate Daily Metering Reports in “.XML” files
containing production, configuration and log data extracted from flow computers according to ANP
specifications (Resolução ANP 65/2014 and other supplementary regulations issued by
ANP/INMETRO)
(8.2) In case of a process unity that uses fuel gas and return it to process or flare it: this fuel gas
shall be derived upstream the fuel gas total fiscal meter;
(9) CONTRACTOR shall install one online CGA – Gas Chromatographic Analyzer for hydrocarbon
composition (until C6+), CO2 and N2 in the gas import and export lines and linked to the flow
computer, which shall inform daily:
a) Gas composition;
b) Total Gas flow rate;
c) Gas flow rate per compound;
d) Gas Higher Heating Value.
(10) The water injection metering shall be designed to allow the water injection flow rate
measurement of each well separately. One temperature transmitter and one pressure transmitter
shall be provided. Shared temperature and pressure transmitters for injected water points are
acceptable depending on the design.
(11) When using Diesel or Treated Oil on well operations such as hydrate prevention on flow lines,
a fiscal metering system shall be provided to measure injected volumes. Meter calibration shall be
done with fluid similar to operational conditions. In case of using diesel the calibration may happen
outside FPSO facility.
(12) There shall be provided means to avoid condensate on gas test separator meter, such as
piping thermal coating, meter location as close as possible to the test separator and piping
downstream of flowmeter with no upward slope.
Additional requirements:
 It is not allowed any kind of by pass at fiscal metering points;
 All fiscal, allocation, operational control (as defined at ANP metering regulation) and
custody transfer flow meters and flow computers shall have valid Model / Type Approvals
by INMETRO (except orifice plates) by the time of the FPSO design phase (procurement).
All the technical requirements and constraints inside each of INMETRO Approval
Document shall be complied. For all flow computers, INMETRO requirements shall be
complied, including those listed on Portaria INMETRO 499/15 from 02/October/2015;
 All fiscal, allocation, operational and custody transfer meters shall be connected to flow
computers.
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 The oil fiscal metering system shall be provided with 3 meter runs, each one at 50% of
maximum total flow rate, one acting as stand-by meter installed; each meter shall be able
to comply with nominal flow rates specified at the INMETRO Model Approval; the metering
systems shall cover the rangeability since the Unit start-up when low flows will be present;
 Routing hydrocarbon volumes directly to cargo tanks without fiscal metering is not
acceptable; this requirement also includes any recovered oil volume and condensate
streams from H.P Flare K.O Drum, L.P Flare K.O Drum, Closed Drain (if applicable),
overflow (oil stream) from hydrocyclone, overflow (oil stream) from the flotation unit,
overflow (oil stream) from slop tanks and others; the Unit shall be also capable to collect
and treat these streams and route them back to the process plant upstream oil fiscal
metering system;
 Off-spec/Settling tanks (and any other tanks that may have crude oil not fiscal metered)
alignments that do not return the oil to process plant shall have valves sealed controlled
with open/close register on unit supervisory system (PI included). Unit shall have
operational procedure to guarantee that the above mentioned alignments are used only in
special circumstances and crude oil not fiscal metered is not routed to cargo tanks.
 The gas fiscal meter systems with senior orifice fittings shall allow the change and/or
retrieving of the orifice plates during normal operation under pressure;
 Technical design and certifications of all orifice plate metering points shall comply with ISO
5167 standards; Zanker flow conditioner shall be used as a mean to shorten the upstream
straight run;
 Secondary tapings such as pressure and temperature tapings shall be installed in piping or
straight run at same diameter as primary meter. Meter flange diameter shall be considered
as meter reference diameter;
 The use of V-Cone meters shall include means of dimensional verification and/or
calibration. A verification procedure shall be presented for PETROBRAS comments /
information during the basic design; this procedure shall have INMETRO and/or ANP
approval. For each metering point, one spare V-Cone shall be available;
 Each gas metering points shall be provided with representative manual sampler devices
(flare included) as close as possible to its respective metering point and easily accessible
by the operator. These sample points shall be provided with sampling panels which shall
have bottle/cylinder support and means for gas purge before handling collection. Flare
sampling system shall be able to collect representative samples even with the low
pressure, so devices such as vacuum pump may be required.
 Regarding periodicity and procedures for results achievement and implementation for
physical-chemical analysis for oil and gas, in complement with Resolução Conjunta
ANP/Inmetro nº1/2013, Resolução ANP 52/2013 details what shall be complied.
 The lift gas metering shall be designed to allow the gas lift flow rate measurement of each
well separately and the total gas lift flow rate measurement;
 Contractor may consider the option to use a gas lift test header for allocation purposes. In
this case, one test gas lift meter shall be included and classified as allocation. Project shall
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consider that this meter shall be able to be aligned to each individual well (for well testing
purposes) and this alignment valves shall be leak tested according to ANP regulation. The
individual gas lift meters per well may be classified as operational.
 Calibration and inspection procedures as required by ANP and maintenance of the
metering systems shall not cause any impact (decrease and/or shutdown) on the Unit’s
production;
 In the beginning of the Unit design, within 3 months time, CONTRACTOR shall provide to
PETROBRAS the following documents (in Portuguese language) to be submitted to ANP
for approval, according to Resolução Conjunta ANP/INMETRO nº1 de 10/06/2013: (1)
“Schematic Diagram for Metering System/Diagrama Esquemático das Instalações”; and
(2) “Technical description of the production unit metering system /Memorial Descritivo dos
Sistemas de Medição”;
 Before production system start-up, in due time (four months before), CONTRACTOR shall
provide to PETROBRAS the documentation (in Portuguese language) of the metering
system (design and operating description reports, diagrams and other related documents)
to be submitted to ANP for approval, according to Resolução Conjunta ANP/INMETRO nº1
de 10/06/2013;
 Metering reports (daily, monthly, calibration and audit trail) shall be readily available for
ANP and/or PETROBRAS Representatives on board, as well as recorded for further
internal or authority audit. The measurement data shall also be available at the workstation
in PETROBRAS Office onboard.
 Flow & Supervisory Computers - All log files shall be created based at the actual data from
the flow computers simply by uploading, keeping their inviolability. The files shall be kept at
the FMS Workstation non-volatile memory / dedicated directory and shall be recorded at
the DVD recorder in a monthly basis.
o General log files to be generated by Flow Metering System:

o Daily Configuration Data Log (for each flow computer);

o Daily Input and Output Data Log (for each flow computer);

o Daily Audit Trail Log (for each flow computer);

o Daily Alarm Log (for each flow computer);

 All log files shall be generated according to the formats defined in (last editions):
API/MPMS 21.1, Electronic Gas Measurement; API/MPMS 21.2, Flow Measurement-
Electronic Liquid Measurement.
 In order to set up the better synchronicity between all Flow Computers and the FMS
Workstation clocks, there shall be a means of synchronization of the flow computers with
the FMS, consider the FMS clock as reference.
 Daily Metering Reports in “.XML” files containing production, configuration and log data
extracted from flow computers shall be automatically generated according ANP
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specifications (Resolução ANP 65/2014 and other supplementary regulations issued by


ANP/INMETRO);
 Fidelity between flow computers, FMS workstation and other automation systems - All
production volumes at the FMS workstation shall be based on the variable “Previous Day
Net (NSV) Totalizer” of each flow loop.
 Note: NSV is an acronym to “Net Standard Volume” which means: The total volume of all
petroleum liquids, excluding sediment and water and free water, corrected by the
appropriate volume correction factor (CTL) for the observed temperature and specific
gravity to a standard temperature and also corrected by the applicable pressure correction
factor (CPL) and meter factor.
 A measurement management system shall be included and applied on the FPSO
according to ISO 10012 “Measurement management systems — Requirements for
measurement processes and measuring equipment” in order to assure the effectiveness
and adequacy to the intended use, besides managing the risk of incorrect metering results.
This system shall be implemented according to PETROBRAS Standards and
recommendations. Contractor shall submit to PETROBRAS comments/information a plan
on implementing that system. During operation, a monthly report shall be issued by
Contractor.
 Calibration and dimensional requirements (after dec/2015): flow (when onshore), pressure,
temperature and dimensional inspections (including flare ultrasonic meters) shall be made
through accredited laboratories (Inmetro or ILAC or IAAC)
 Control valves shall be used on oil calibration systems so that it is possible to calibrate the
flow meters on different flow rates along the extense of all of its flow range.
 Double block and bleed valves with drain shall be installed where tightness is required and
to guarantee compliance with ANP/Inmetro requirement of periodically check valves for
leaks.
7.8. CCTV

CONTRACTOR shall install a Closed Circuit TV system to monitor the Unit. The riser connection
deck shall be monitored by dedicated TV cameras. A dedicated TV camera with a recording
device shall also be provided for the helideck area and operations. The recording shall cover at
least the last 24 hours of helicopter operations. NORMAM 27 requirements shall be followed.
Recording device to cover at least the last 24 hours shall be provided to all remaining CCTV
system as well.
A specific Infra-red Closed Circuit TV system shall be provided to monitor possible oil spills to the
sea. The signal must be provided in the CCR. Monitoring shall be based on cameras with infrared
(IR) vision capacity in the 7-14 m range, definition of 160x240 pixels. At least one camera shall
be provided to monitor the offloading operation (oil transfer to shuttle tankers) at each offloading
station.
7.9. DPRS - DYNAMIC POSITIONNING REFERENCE SYSTEMS
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CONTRACTOR shall provide and install the three reference systems according to the
requirements mentioned on the Technical Specification OFFSHORE LOADING SYSTEM
REQUIREMENTS I-ET-005 included in the documentation (see item 1.2.1).
 DARPS 900B - Differential Absolute and Relative Positioning System (DARPS).

 Artemis - a microwave radio positioning system of “range-bearing” type, ARTEMIS Mark V


version, fixed station.

 Fan-beam - an optical laser positioning system target.

7.10. ENV - METOCEAN DATA GATHERING AND TRANSMISSION SYSTEM

This system shall be supplied and installed by the CONTRACTOR according to the specific
document I-ET-3534.00-5521-931-PEA-002 - Requirements of Meteocean Data Acquisition
System _ mentioned in Item 1.2.1.
7.11. RMS - RISER MONITORING SYSTEM

The riser monitoring system is composed by sub-systems:


 Offset Diagram;
 Annulus Pressure Monitoring;
 MODA Optical Monitoring Direct on the Wire (Flexible Risers)
7.11.1. NOT APPLICABLE

7.11.2. POSITIONING SYSTEM FOR MOORING OPERATION AND OFFSET DIAGRAM

The Technical Specification "I-ET-3534.00-5530-850-PEA-001 – POSITIONING AND


NAVIGATION SYSTEMS FOR FLOATING PRODUCTION UNIT (see item 1.2.1)" describes the
requirements for the POS - Positioning System (positioning, navigation and monitoring activities)
of the Unit.
Through the DOF (Diagram of Offset), this position monitoring allows faster assessment of
possible damage to the mooring system. The content of this document is to allow the FPU control
during critical operations as towing, entrance on location (hook-up), connection and
disconnections of risers (pull in / pull out), tensioning mooring lines, mooring lines maintenance,
supplying and off-loading operations. This document will also allow monitoring FPU ride to
calculate the stresses of risers and alarm in the event of disruption of a tie, as well as monitoring
boats around.
The Contractor shall provide to PETROBRAS a document containing the maximum offset for
intact condition in 16 directions considering the environmental conditions: 100-year and 1-year.
Those 16 directions determine a polygon with includes all the offsets environmental cases
analyzed. For that, the table below can be used as an example:
Table 7.11.1.1: Maximum Offset for intact condition (example).
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100 year (Intact)

Offset
Point Offset (%) Angle (deg) UTM E UTM N
(m)

Offset- Direction “going to” related to Coordinate Coordinate


1-16 %WD
meters North, positive clockwise UTM East UTM North

7.11.3. MODA RISER MONITORING SYSTEM

The tensile armor wires of every flexible risers shall be monitored by the MODA System. This
system shall be applied to all flexible risers (gas exportation riser, production risers, injection risers
(gas and water) and service risers (gas lift) of all wells).
The CONTRACTOR shall provide the infrastructure for the MODA System including:
 2 (two) cabinets with at least 1,000 mm deep, 800 mm wide and 42 U (approximately
2,000 mm) height, with front and rear access (for equipment installation), installed in
Control Cabinet Room. Each cabinet shall be connected to PETROBRAS cabinet where is
placed PETROBRAS Firewall and shall have AC wall outlets in 127 V or 220 V in 50/60 Hz
with at least 3 kW of power available;
 10 (ten) rack mounted Fiber Bragg Grating (FBG) interrogators for all monitored risers.
CONTRACTOR shall request PETROBRAS approval of the interrogator model selected;
 3 (three) rack mounted servers (1U each);
 1 (one) rack mounted ethernet switch (1U). CONTRACTOR shall request PETROBRAS
approval of the switch model selected;
 1 (one) rack mounted LCD console integrated with KVM (Keyboard, Video, Mouse) switch
(1U);
 Fiber patch panels for optical cable termination in the MODA cabinet;
 Optical fiber splice boxes near each flexible riser;
 Optical cables (laid in cable trays) interconnecting the MODA cabinet to the splice boxes
near each flexible riser;
 Cable trays for the optical cable interconnecting the splice boxes to the risers connectors;
MODA software, full system commissioning (with MODA software and risers) and the optical
cables between the riser and the splice boxes are not included in the scope of supply of the
CONTRACTOR.

Additional information on the MODA System is presented in the Technical Specification I-ET-
3010.00-5529-854-PAZ-005.
7.11.4. ANNULUS PRESSURE MONITORING AND RELIEF SYSTEM
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CONTRACTOR shall provide the annulus pressure monitoring and relief system to guarantee a
safe release for the gas permeated in the annulus space of flexible risers and to detect any
pressure build up that may damage the risers.
CONTRACTOR shall perform detailed engineering of this system (including piping, valves,
pressure sensors, supervisory integration, etc.).
This system shall be applied to all flexible risers, except for umbilical’s and water injection risers
(gas exportation riser(s), production risers, injection risers (water) and service risers (gas lift) of all
wells), in the continuous vented configuration.
Additional information is presented This system is detailed in the Technical Specification (I-ET-
3010.00-5529-812-PAZ-001) Annulus Pressure Monitoring and Relief System - (see item 1.2.16.2
of referred specification).
Each riser (except for umbilicals and water injection risers) shall be equipped with a Local
Continuous Vented System. This system is detailed in I-ET-3010.00-5529-812-PAZ-001 item 6.2.
Gas dispersion study shall be performed by Contractor in the discharge area due to H2S content in
the gas.
8. ELECTRICAL SYSTEM

The electrical system design and installation shall comply with latest version IEC 61892 series and
IMO MODU CODE.
Bidder shall present the API datasheet for the turbo-generators and emergency/essential
generators during the bid phase.
A power management system (pms) shall be provided, including functions of main generation
voltage control, main generation frequency control, load shedding, load sharing and permission of
starting for high demand loads:
 The load shedding shall command fast selective tripping of pre-determined HV consumers,
in the event of main generation overload (sudden or gradual) and main generation under
frequency, to prevent total loss of power;
 The load shedding function and priorities shall be selectable by operator according to the
operation mode; each load or group of loads shall be arranged according to priority in the
shedding sequence;
 The load shedding function shall allow temporary overload of main generation due to
starting of big motors and transformers;
 The load sharing function shall be capable to share active power demand evenly (in
proportion of their capacities) among the main generators running, or to set adjustable
fixed active power to n-1 (n = quantity of generators running), keeping one generator with
variable active power, according to the demand variation;
 The load sharing function shall be capable to share reactive power demand evenly (in
proportion of their capacities) among the main generators running, or to set adjustable
fixed power factor to n-1 (n = quantity of generators running), keeping one generator with
variable reactive power, according to demand variation;
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8.1. GENERATORS

8.1.1. MAIN GENERATORS

The power generation system shall be designed considering the following cases:
 100% of the treated gas shall be exported simultaneously with 100% water injection
capacity.
 The generators packages on duty shall be designed to supply the maximum electrical load
at maximum ambient temperatures (30 degrees Celsius).
Essential generator(s) shall consist of new diesel generator package(s)."
Produced gas shall be treated as necessary to be used as fuel for the gas turbines, boilers, flare
pilot and flare purge according to each vendors specifications.
In any case, either with low or high CO2 content (high or low NHV), the fuel gas shall be properly
treated to comply with the gas turbines manufacturer requirements.
The configuration of the main generator packages shall consider one generator in stand-by
condition, for all operational case above, with [n-1] generators running.
CONTRACTOR is requested to present the following on the technical proposal submission in
order to evidence power generation compliance to GTD:
X(kW) = [Turbine ISO output power at 15ºC (kW)] * [N-1] generators

Y(kW) = [maximum electrical demand from electrical load balance calculation report] (kW) * 1.33

X(kW) shall be greater or equal than Y (kW)

[N] = total number of main turbo-generators sets installed.

Note: PETROBRAS considers that Bidder will build in design contingencies into the maximum
expected electrical demand. However, PETROBRAS consider those contingencies (margins) as a
bidder internal issue.
For starting the largest electric motor, it shall be considered [N-1] main generators running,
keeping transient voltage drop within tolerable limit for the electrical system, according to
IEC61892-2.
Contractor shall consider stand-by gas compressor start without turning off the running gas
compressor during units load transfer.
Each power generation set shall consist of a synchronous alternator driven by dual fuel gas
turbine, designed to operate on fuel gas (normal) or on diesel fuel (no fuel gas available).
The main generators shall be capable of immediately restart at any time after a shutdown event.
The fuel gas and liquid fuel for the gas turbines shall be properly treated to comply with the gas
turbine manufacturer requirements. The turbine ISO Power shall be at least 33% over the
maximum expected demand considering [N-1] generators on duty.
For main power generation based on gas turbines, the essential and the emergency generator
shall be capable to start-up the main generator, assuming dead-ship condition. Independent
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means for starting the essential generator shall be provided apart from the operation of the
emergency generator.
Power generation packages shall include all required auxiliary systems and controls, i.e.,
voltage/reactive power control, speed/active power control synchronization, load shedding, load
sharing, etc.
To increase operational performance, it is recommended that the Main Generators auxiliary loads
MCCs control voltage circuits shall be fed by redundant online UPS, with automatic changeover of
these redundant power supplies, without power interruption.
Accepted vendors list for Gas Turbines for Main Generators:
 GENERAL ELECTRIC: LM2500, LM2500+, LM2500+G4;
 SIEMENS: SGT-100, SGT-200, SGT-600, RR501, RB211G/GT;
 SOLAR: SATURN, CENTAUR, TAURUS 60, MARS, TITAN 130, TITAN 250

8.1.2. EMERGENCY GENERATOR

Emergency generator shall be dimensioned to feed simultaneously all loads indicated in the
SAFETY GUIDELINES FOR OFFSHORE PRODUCTION UNITS, IMO MODU CODE and
required by C.S., for at least 18 hours.
Emergency generator system shall not be composed by grouping small existing units from ship to
be converted and shall consist of a single new package.
The emergency generator system should be tested in accordance with item 5.4.16 from IMO
MODU CODE. It is suggested that the Emergency generator protection degree shall be at least
IP54, according to IEC 60529.Testing at regular intervals shall also cover load operation without
interruption of connected loads.

8.2. DISTRIBUTION SYSTEM

8.2.1. POWER DISTRIBUTION

The HV, LV and UPS distribution systems shall be designed with required redundancy, so that a
single failure in any equipment, circuit or bus section does not impair the whole system and
neither reduces the production/processing capacity of the Unit.
For main generation systems, the main bus bar shall be subdivided into at least two parts, which
shall be normally connected by a tie circuit breaker.
The earthing and detection methods shall comply with IEC 61892-2 requirements and the
Classification Societies’ rules, as applicable
The Low Voltage power distribution system shall be of secondary-selective type, with main buses
subdivided in at least two parts, which shall be normally connected by tie circuit breakers; each
bus part shall normally be fed from secondary of duplicated and fully redundant HV/LV
transformers with tie circuit breakers open.
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For Medium Voltage generation and distribution systems, the high resistance earthing, with
instantaneous selective tripping in the event of earth fault shall be adopted.
Electric panels shall have the front and rear floor covered by insulating rubber matting complying
with ASTM D-178-01 requirements for Type II – ABC (ozone, fire and oil resistant) and minimum
Class 0 (tested for 5kV) for panels with rated voltage up to 690V and minimum Class 1 (tested for
10kV) for panels with rated voltage above 690V.
In case of conversion, where CONTRACTOR intend to reuse electric panels, special attention
shall be given to guarantee that all panels are certified and have appropriate incident energy level
and short-circuit levels.
8.2.2 POWER TRANSFORMERS

Each power transformer shall be dimensioned to feed 100% of the maximum switchboard load
demand, with no forced ventilation, on a contingency condition with the duplicated redundant unit
out of service.
Transformers dedicated for LCI (line commutated) convertors shall comply with IEC 60146.
Transformers dedicated for other kind of non-linear loads shall comply with IEC 61378-1.
Transformers for both, linear and non-linear loads, shall comply with requirements of
IEC 60076-12 and IEEE C57.110.

8.3. LOW VOLTAGE SYSTEM

Low voltage distribution system shall be divided into different groups and switchboards:
 Normal Process Plant loads;
 Normal Utilities/Ship Service loads;
 Essential loads

8.4. UNINTERRUPTIBLE POWER SUPPLY (UPS) AC AND DC

UPS shall be arranged and dimensioned to feed simultaneously all loads indicated in the SAFETY
GUIDELINES FOR OFFSHORE PRODUCTION UNITS (see item 1.2.1), IEC 6189-2, IMO MODU
CODE and required by C.S., and corresponding autonomy time.
Provisions should be made for the periodic testing of the complete UPS and DC system. Testing
at regular intervals shall also cover load operation and battery discharge test, without interrupting
connected loads.
UPS log report shall be recordable, retrievable and available for PETROBRAS as requested,
providing comprehensive information on the equipment status and diagnostic information.

8.4.1. UPS FOR AUTOMATION/INSTRUMENTATION SYSTEM


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The UPS system for Automation shall comprise two redundant units (2 x 100%), operating
isolated. Each UPS shall be provided with dedicated by-pass transformer, with automatic transfer
through static switches.
Each UPS shall feed one distribution switchgear. The distribution switchgears shall have full
capacity interconnecting circuit breakers for transfer all connected loads to and from redundant
UPS keeping the loads operating (without temporary black-out).
UPS output voltage shall be isolated from earth. Ground fault detection with local and remote
alarm at CCR shall be provided; Means for troubleshooting and locating ground fault as portable
clamp meter should be provided without interrupting services.
Instantaneous ground fault trip and alarm shall be provided for loads installed in hazardous areas
Zone 0 (if any) and Zone 1, and for loads which cables cross hazardous areas Zone 0 (if any) and
Zone 1.
The AC and DC power supply for all components of the A&C Architecture shall be redundant, fed
from duplicated and redundant UPS. Common failure mode shall be avoided.
8.4.2. VDC SYSTEM

The VDC system shall comprise:


 Emergency Generator Starting and Control;
 Auxiliary (Essential) Generator Starting and Control
 Fire Water Pumps Starting and Control.
8.5. ELECTRICAL STUDIES

Contractor shall present to PETROBRAS, whenever required, electrical studies, such as:
 Main and Emergency Generation electrical load balance;
 Load Flow calculation report;
 Short-circuit calculation report;
 Voltage drop due to motor starting calculation report;
 Transient stability calculation report;
 Harmonic analysis calculation report;
 Protection coordination and selectivity calculation report;
 Arc fault incident energy calculation report;
 UPS and battery bank sizing report;
 Cable sizing report;
 Grounding Fault Analysis.

8.6. LIGHTING SYSTEM


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The lighting system of the Unit shall comply with requirements of IEC 61892 and with regulations
from Brazilian Labor and Employment Ministry (Ministério do Trabalho e Emprego), Brazilian Navy
(Marinha Brasileira) and Diretoria de Portos e Costas (DPC) regulations and any mandatory
international regulations.
Design of external lighting and illumination system shall avoid the disturbance on seawater,
meaning that contractor shall avoid directing the lighting to the sea. Outdoors lighting fixtures shall
be preferentially directed to internal areas of the Unit, in order to not affect/impact marine life.
Contractor shall consider that only specific lighting systems required by Brazilian and international
regulations, Class and Flag requirements and Unit safe operation shall be directed to overboard in
direction to seawater area.

9. EQUIPMENT

9.1. NOISE AND VIBRATION

CONTRACTOR shall conduct Noise and Vibration Study including process areas, marine areas
and accommodations to evaluate working environment and implement mitigating measures
whenever required.
9.1.1. NOISE

Noise limits shall be in accordance with the Brazilian Safety and Heath at Work Regulations
(NRs), CS rules and guidelines requirements for FPSO and / or MODU where applicable.
Additionally, noise limits of living quarters and closed areas shall comply with Annex A of
NORSOK S-002 – Working Environment.
Equipment operating at high noise levels shall be acoustically treated using hoods, silencers,
filters or other noise control system to meet the requirements.
After completion of services, if noise levels exceed the specified limits, CONTRACTOR may be
required to carry out additional improvements in order to insulate individual noise sources. Such
remedial measures can be, for example, the installation of AVMs (Anti-Vibration Mounts),
foundations for smaller equipment and additional insulation for limited areas.
9.1.2. VIBRATION

CONTRACTOR shall carry out structural and main equipment vibration measurements during
commissioning and sea trials in order to verify acceptable levels of vibration, according to NRs,
CS rules and guidelines requirements for FPSO and / or MODU where applicable. Additionally,
acceptable levels of vibration for living quarters and closed areas shall be verified according to
clause 8, table 3 of NORSOK S-002 - Working Environment.
CONTRACTOR shall rectify the stiffening of equipment and/or the equipment itself, if vibrations
are clearly in excess of the recommendations of the above mentioned standards.
9.2. HOISTING AND HANDLING SYSTEMS

CONTRACTOR shall submit to PETROBRAS for comments / information a detailed procedure for
equipment maintenance that should include their removal/disassembly from any part of the Unit to
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allow the installation of a new one. The procedure shall include facilities to allow offshore
maintenance of the Unit, without affecting the production/processing capacity of the Unit.
Special attention shall be given to the main generators, gas compressors and diving equipment
that are composed by large pieces with large weights.
9.2.1. CRANES

All cranes shall be certified for “man-riding” by Classification Society, i.e., transportation of
personnel to/from the supply vessels and shall comply with requirements of NRs and API 2C.
Crane capacities shall be compatible with equipment parts to be removed/disassembled (e.g.
main generator rotor, heat exchanger tube bundles, diving equipment, etc.) and to transfer
material/equipment to/from supply vessels to the Unit. Crane outreaches are measured outboard
from the Unit’s side shell.
In this option, as the risers shall come up on the Unit’s Portside, this side shall not be used for any
supply boat operations. All cranes shall be located on the Starboard side.
The Afterward (AFT) Starboard crane shall be of knuckle boom or lattice type and built to operate
under the following conditions:
 Loading/unloading 35,000 kg from/to a supply vessel with an outreach of 29.0 m;
 The whip hoisting system shall be able to lift 7,500 kg (minimum) with any boom angle;
 Transportation of personnel to/from the supply vessels.
The Forward (FWD) Starboard crane shall be located to operate mainly related to the risers pull-in
operations and other special subsea operations like coil tubing operations. This crane shall be
designed and built to operate under the following conditions:
 Loading/unloading 35,000 kg from/to a supply vessel with an outreach of 29.0 m;
 The whip hoisting system shall be able to lift 7,500 kg (minimum) with any boom angle;
 Transportation of personnel to/from the supply vessels.
CONTRACTOR shall provide means of transporting supplies/goods/spares from a lay-down area
to the galley store, machineries spaces, ware-houses, etc. (i.e., aft spaces/compartments).
Note: All above mentioned capacities are net lift capacities. Vessel motions and dynamic loads
shall also be considered to properly design each crane.
10. TELECOMMUNICATION

The Unit’s telecommunications shall comply with the TELECOMMUNICATION SYSTEM


document (see item 1.2.1).
11. STRUCTURE AND NAVAL DESIGN

Hull Assessment, Motion Analysis and Mooring Design shall not be performed by the CS that will
classify and certify the design, conversion and operation of the Unit.
11.1. LOAD REQUIREMENTS
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Besides the CS load requirements for the operation of the Unit at the site, CONTRACTOR shall
also design the Unit to withstand all construction loads and the environmental loads during
transportation from construction/conversion shipyard to Brazil and, after the decommissioning,
from Brazil to a site outside its territory.
Item 12.5.3 – FOUNDATIONS AND FASTENINGS STRUCTURAL REQUIREMENTS shall be
also considered.
CS requirements latest revision for FPSO shall be used to check the structural parts and for the
design of reinforcements and complementary structures. CONTRACTOR shall use net scantlings
that are obtained deducting corrosion margins (an example of corrosion margins is presented in
item 11.2.1) from final scantlings. “Final scantlings” means the plate thickness measured at the
beginning of the conversion or after plate replacement.
Both ultrasonic gauging report and the reassessment study shall be submitted to CS for approval
and to PETROBRAS for information.
11.2. CONVERSION SURVEY (If applicable)

The hull shall be fully inspected according to CS requirements. Regardless of those CS


requirements, as the Unit must maintain continuous offshore operation during its operational
lifetime with no dry-docking, all damaged areas, including cracks of any nature, and all defective
structural pieces, including welds and all warped areas, shall be replaced or restored to fit
conversion specifications.
The Unit shall be surveyed prior to the installation of any new structure. The survey report shall
inform all items that do not match the original design. Special attention shall be paid to the
following items:
 Structure - girders, beams, stiffeners and plates - dimensions;
 Out of tolerance imperfections of structural elements;
 Changes in the material specifications;
 Corrosion of structural elements.
Hull areas with defect history or which during the former and/or future operational life were and/or
will be overstressed, based on the hull structural reassessment, must be extensively NDT
inspected. This also applies to areas with critical fatigue predicted life that may have its design
modified to the satisfaction of the CS in order to meet the survey requirements of a new Unit.
Ships that have been involved in explosion, grounding damage, lay-up and/or collision relevant
incident during their operational life since the last class survey shall not be utilized for conversion.
However, further inspections (to be made by a third party) may be required by PETROBRAS
during the engineering design phase, as part of the Survey Report.
The hull assessment shall be submitted to a third party for reviewing and validation. This third
party shall be a CS, other than the one that is classing the Unit, or a recognized consultant
previously approved by PETROBRAS.
11.2.1 PLATE REPLACEMENT CRITERIA
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The design philosophy shall take into consideration that no hot work should be done due to
plating/structural replacement during the Unit’s operational lifetime.
Specification of hull steel renewal at conversion is based on the requirement that no part of the
hull will encounter substantial corrosion during the contract period.
Hull steel renewal shall take into account both local corrosion (pitting and grooving) and overall
corrosion.
For overall corrosion of plating and stiffeners, renewal thickness at conversion is defined such that
the substantial corrosion margin will not be reached within the FPSO life, taking into account
anticipated corrosion losses during the FPSO life. The substantial corrosion margin is defined as
75% of the allowable corrosion margin as specified in the inspection criteria of the rules.
When re-assessment is performed, the FPSO required gross thickness (TR) is the required
thickness for use as FPSO without reduction for corrosion, based on site specific gross rule
thickness, even when this is lower than the “as-built” thickness.
As a minimum, the following procedure shall be adopted to determine the steel renewal thickness
at conversion:
Tmeasured < TR * (1 – 0.75 * RL) + M25 Element must be renewed

Tmeasured – Structural element thickness – based on the Thickness Reading Report

M25 –25 years corrosion margin for uncoated steel.

TR – rule required gross thickness – to be defined by the Reassessment Study.

RL – rule allowed corrosion percentage according to Classification Society rules

The plate replacement criteria shall consider that no part of the hull will encounter substantial
corrosion during the contractual period (25 years), as per item 11.2.1.
The following table shows the corrosion margin values (M25) to be used for 25 years of operation
(Contract period) for different uncoated structural elements:
Table 11.2.1.1: Corrosion margin values.

CORROSION MARGIN
(mm)
LOCATION ITEM Slop
Cargo Tanks Tanks/Ballast
(Note 1) Tank
(Note 1)
Deck plating 1.3 x 1.25 2.0 x 1.25

Deck longitudinals 1.3 x 1.25 2.0 x 1.25


LONGITUDINAL Side shell plating 1.0 x 1.25 1.5 x 1.25
ELEMENTS Side shell longitudinals 1.0 x 1.25 2.0 x 1.25
Longitudinal bulkheads plating 1.0 x 1.25 1.5 x 1.25
Longitudinal bulkheads longitudinals 1.0 x 1.25 2.0 x 1.25
Bottom shell plating 1.4 x 1.25 1.5 x 1.25
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Bottom shell longitudinals 1.0 x 1.25 2.0 x 1.25


Deck transverse web plating 1.5 x 1.25 2.0 x 1.25
TRANSVERSE Bottom transverse web plating 1.0 x 1.25 2.0 x 1.25
WEB FRAMES Side shell transverse web plating 1.0 x 1.25 2.0 x 1.25
Long. bhd. transverse web plating 1.0 x 1.25 2.0 x 1.25
Plating 1.0 x 1.25 1.5 x 1.25
TRANSVERSE Vertical stiffener (web) 1.0 x 1.25 1.5 x 1.25
BULKHEADS Horizontal stringer web plating 1.6 x 1.25 2.0 x 1.25
Vertical girder plating 1.0 x 1.25 1.5 x 1.25
Web plating 1.0 x 1.25 1.5 x 1.25
SWASH
Horizontal stringer web plating 1.6 x 1.25 1.6 x 1.25
BULKHEADS
Vertical girder plating 1.0 x 1.25 1.5 x 1.25
By means of coating, the start of corrosion will be postponed. Therefore, a corrosion
postponement can be considered, if CONTRACTOR ensures application of high quality epoxy
painting scheme with guarantee not lesser than 10 years. As so, the corrosion margins given in
the table above can be de-rated, due to the referred corrosion postponement effect, for structural
elements that are fully painted with the high quality performance epoxy scheme. The reduction on
the required corrosion margins in case of coated steel structural elements can be 5 years/25 years
(20% reduction) on the corrosion margins given in the table above.
For pitting inspection/acceptance bottom plating shall be fully inspected after being sand blasted.
The following plating renewal criteria shall be considered:

Figure 11.2.1.1: Plating renewal criteria.

1 - If in the inspected region d < 0,15. TR Plate to be treated and painted


2 - If in the inspected region 0,15. TR < d < TR /3 See note below
3 - If in the inspected region d > TR /3 Plate to be renewed
NOTE:
Additional criteria to be considered for those regions related to item 2 above:

 If pd > 200 mm  plate renewing

 If pd  200 mm and either:


 dbp < 75 mm  plate renewing
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 dbp  75 mm and cpfd  80 mm  plate renewing


 dbp  75 mm and cpfd > 80 mm and tr < 6 mm or to /3  plate renewing
where : pd - pitting diameter
dbp - distance between pittings
cpfd - continuous pitting weld filling distance
tr - residual plate thickness below pitting
to - original plate thickness

Remark: Cpfd is the minimum continuous weld bead necessary to fill up a pit.
11.3. MATERIALS

All materials used for the Unit shall meet the specifications of CS latest revision requirements for
construction of a FPSO. Topsides materials shall also comply with the specifications of item 1.11
CONTRACTOR shall submit to PETROBRAS comments/information the design philosophy to
specify materials to be used with each type of fluid and the corrosion allowance and protection
considered. These choices shall be compatible with the specified operational lifetime defined in
item 1.1.
To prevent the lamellar tearing effect, steel with Z quality (strength through the thickness) shall be
used in places where plate stress occurs in the transversal direction, such as fairlead connections.
Special details may be adopted to avoid stress in the transversal direction of steel plate.
11.4. WEIGHT CONTROL PROCEDURES

It is CONTRACTOR’s responsibility to evaluate the Unit’s weight and Center of Gravity during the
design, installation and operation phases, according to the design and CS requirements.
11.5. STABILITY ANALYSIS

The Unit shall comply with the latest CS - Rules for Building and Classing Mobile Offshore Drilling
Units and correlated rules, MODU Code and MARPOL, regarding intact and damage stability.
Intact and damage stability analysis shall be performed for all load conditions as per CS
requirements, including at least the loading conditions specified in item 11.8.3 for RAO.
For wind heeling levers, in intact stability, the 100-year return period, 1-minute sustained wind
shall be considered.
Wind forces and moments can be estimated according to the following criteria and shall be
submitted to CS for approval and to PETROBRAS for information:
 Ship hull and deckhouse - OCIMF - Oil Companies International Marine Forum, 1994 -
Prediction of Wind and Current Loads on VLCC’s;
 Process plant equipment and deck, flare boom, cranes, helideck, etc. - According to CS
methodology for wind forces and moments calculation.
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The distribution of weights and vertical reactions imposed by the spread mooring and riser system
on the Unit shall be calculated for the purpose of evaluating trim and stability conditions.
11.6. HULL

Only the following alternatives shall be considered for new building or converted FPSO hull:
 Double side, with, at least, three longitudinal bulkheads;
 Single hull, with two longitudinal bulkheads
 Double hull, without any hydrocarbon piping system routed inside the double bottom
and/or void spaces.
(*) Note: any alternative is acceptable but no. 1 shall be prioritized if possible.
The existing bilge keels, if any, shall be enlarged in order to improve roll motion. If such devices
are not present, appropriate bilge keels shall be installed.
Side shell structure, in supply vessel mooring area, shall withstand an impact energy (collision
accidental load) imposed by 5,000 dwt supply vessel, plus added mass, with speed of 2m/s
without causing the rupture of FPSO-s cargo tank inner bulkhead.
Side shell structure shall be designed to withstand an impact energy imposed by the same
5,000-MT supply vessel at 0.5 m/s for the side way impact, plus added mass, associated with
normal operational conditions, without any rupture to the side shell structure.
Additionally, the supply vessel mooring area shall have fenders to prevent contact between supply
boat and the Unit. In case of using floating fenders, at least 3 (three) shall be considered in each
supply vessel mooring area.
Tank arrangement shall meet the requirement that hull compartments adjacent to the supply
vessel mooring area shall be ballast tanks or void spaces on a length of 60m (30 meters forward
and aft of each crane pedestal).
The Unit shall have designated cargo tank to operate as off-spec tank in order to receive the
minimum volume of 10.000 m³ of off-spec oil.
For water off-spec tanks requirements please refer to document I-ET-3010.1R-5330-940-P4X-001
(see item 1.2.1)
Oil and Water off-spec tanks shall also have facilities to send these fluids back to the oil and water
process plant to be reprocessed (see item 2.7.1).
PETROBRAS will accept SPS Overlay System in lieu of voids spaces only in way of supply vessel
mooring area (starboard side). In this case, CONTRACTOR shall comply with MARPOL
recommendation for low energy impact.
To complement gravitational separation in the slop tanks, the Unit shall have a separate water
treatment system in order to treat the oily water prior to discharge. Water discharge from slop
tanks shall be measured and monitored for TOG.
Gas Sampling System shall be provided in ballast tanks and void spaces adjacent to cargo/slop
tanks, according to the requirements of FSS Code (chapter 16).
A contingency hose connection of inert gas shall also be provided for each tank.
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11.6.1. TURRET AND CARGO TANK INTERFACE

Not applicable.
11.6.2. RISERS BALCONY AND CARGO TANK INTERFACE (Spread Mooring Option)

If any existing tank is used to place the balcony structure, it shall be modified in accordance to the
balcony installation requirements and shall be cleaned, painted and maintained as a void space or
segregated ballast tank.
CONTRACTOR shall perform a finite element analysis, at the balcony/hull interface region, in
order to achieve an adequate load transfer path and to verify structural strength and fatigue life.
This analysis shall be submitted to CS for approval.
SPS Overlay will not be accepted in lieu of providing a cofferdam for the side shell in way of cargo
tanks behind risers/riser balcony.

11.6.3. PROCESS PLANT DECK STRUCTURE

Green Water occurrence on deck of FPSO shall be checked.


11.6.4. CATHODIC PROTECTION AND PAINTING

The cathodic protection system, painting specification and corrosion protection shall be part of the
philosophy to allow the Unit to operate continuously during its operational lifetime without any
production interruption. Therefore, design shall clearly identify those requirements.
Galvanic anode CP system is the preferred solution and should be used. Impressed current
cathodic protection systems may be accepted provided that the potential control is assured in a
way that the potential imposed by system will never be lower than -1100mV. Special attention
shall be given to chain pipes and other similar underwater structures to allow maintenance,
inspection and replacement with no dry docking / shutdown and to avoid problems caused by
corrosion and marine growth.
Bottom tank plating and structures shall be fully painted up to 2.0 meters of vertical structures or
maximum water level, whichever is greater. Painting specification shall consider the design life as
stated in item 1.1 herein.
Top tank plating and structures shall be fully painted at least 2.0 meters from top. Alternatively,
Contractor may provide extra corrosion margin for the top tank plating and structures including at
least 2.0 meters from the top.
Zinc anodes shall be adopted in ballast tanks if the “anode installation height X anode gross
weight” is greater than 28 kgf x m and the maximum operation temperature is less or equal to
50ºC.
Off-Spec Tanks, Settling tanks and Slop Tanks shall be entirely painted with a high performance
epoxy scheme considering design life as stared in item 1.1 herein. Bottom anodes shall also be
provided. The paint system should be an anti-corrosive polymeric coating having as basis an
epoxy resin, cored with polyamine, and incorporated, preferably, only with fillers of ceramic type."
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CONTRACTOR shall provide an anti-fouling painting scheme for the external hull, encompassing
bottom plate and side shell plate up to transit draft (maximum foreseen draft during transit phase
from conversion yard to Brazil). The anti-fouling painting scheme shall not contain organotin
compound tributylin (TBT) component in its formulation.
11.6.5. CARGO AND BALLAST TANKS STRUCTURAL INSPECTION

All cargo/ballast/slop tanks access arrangements shall comply with IMO Recommendations A 272
(VIII) and A 330 (IX).
CONTRACTOR shall submit to PETROBRAS and CS an inspection plan of the cargo, ballast
tanks or any other structural compartments evidencing that the Unit enables safe inspection inside
all tanks. This plan shall be based on the Fatigue Analysis and shall consider the continuous
operation during operational lifetime with no drydocking and shall not affect the production
capacity of the Unit.
Means shall be provided to allow a safe “free-for-fire” certificate with minimum disturbance of the
Unit’s operation. In addition, cargo piping shall be installed with devices to reduce the risk of any
accidents during inspection and “hot” services (e.g.: devices to avoid valves or expansion joints
leakage).
11.6.6. HULL EXTERNAL INSPECTION

CONTRACTOR shall provide facilities for the installation of the temporary diving support
equipment and for the diving operation itself, considering that the entire hull must be visually
inspected, as required by CS, twice every 5 (five) years.
11.7. FATIGUE ASSESSMENT REQUIREMENTS

Contractor shall obtain Class Certificate considering 34 years’ fatigue design life for the Unit.
The fatigue analysis shall be submitted to a third party for reviewing and validation. This third party
shall be a CS, other than the one that is classifying the Unit, or a recognized consultant previously
approved by PETROBRAS.
Fatigue Damage calculation for the support structures, foundations, etc., shall be carried out in
accordance with the CS rules and requirements.
CONTRACTOR shall use the fatigue wave data given in the METOCEAN DATA document (see
item 1.2.1), as mentioned in Section 12.
11.8. MOTION ANALYSIS

11.8.1. GENERAL

Motion analysis results, regarding motions and accelerations, shall be used for the analysis of the
following items:
 Process plant structural design;
 Fairlead and riser support structure/hull interface design (Spread-Mooring);
 Flare boom / tower structural design;
 Helideck structural design;
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 Crane foundation structural design;


 Equipment operational limit assessment;
 Offloading operational limit assessment;
 Pull-in / out operational limit assessment.
11.8.2. NOT APPLICABLE

11.8.3. RAO – RESPONSE AMPLITUDE OPERATOR

CONTRACTOR shall issue to PETROBRAS the RAO (Response Amplitude Operator) curves with
their corresponding phase, for the Unit’s 6 (six) degrees of freedom.
The RAO curves shall be informed with the motions natural periods and linear equivalent viscous
damping considered. The viscous damping coefficients shall be submitted to PETROBRAS for
comments / information. Model tests shall be used to validate the CONTRACTOR proposal.
The roll RAO curves shall be computed based on proven software, considering linear roll damping
varying according to the significant wave height level:
1) Table 1 → Hs < 2.5m (irregular waves contour curves)
2) Table 2 → 2.5 < Hs < 4 (irregular waves contour curves)
3) Table 3 → Hs > 4 (irregular waves contour curves).
The RAO curves shall be computed also considering the following:
 The RAO analysis shall be performed for at least five loading conditions: minimum loaded,
40% loaded, 60% loaded, 80% loaded and fully loaded. If applicable, the percentage of
time associated with these drafts shall be 5% (minimum draft), 25%, 40%, 25% and 5%
(maximum draft), respectively.
 The roll viscous damping shall be derived for each draught.
 The mooring lines and risers shall be considered only as weight items to compose the
loading condition and no dynamic effect shall be included in the RAO analysis.
 Excitation frequencies ranging from 0,2 to 3,0 rad/sec.
 The number of calculated frequency components shall be at least 60.
 Around the peaks presented in the Roll and Heave RAO amplitude curves, the frequency
discretization shall be improved.
 Wave incidences ranging from 0 up to 360 degrees with 7,5 degrees increments. being 0
degree value the “aft”, 90 degrees value the “Starboard”, 180 degrees the “bow”.
 These curves shall be referred to the C.O.G. (Center of Gravity of the Unit). Thus, the
C.O.G shall be informed with the RAO curves.
 The waves considered for the roll damping estimation shall be the beam sea condition
(irregular waves) that causes the higher motions (higher Hs or wave peak period: Tp equal
to the natural period of the roll motion for each specific draft).
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The reference system and direction conventions shall be included in the report. The expression
that needs to be employed to generate motion time series shall be also published by
CONTRACTOR.
The RAO curves will be used on the analysis of the stresses acting on the risers, mooring lines
and secondary structures. The reference system and direction conventions shall be included in the
report. The expression that needs to be employed to generate motion time series shall be also
published by CONTRACTOR.
Numerical output data (RAO, added mass coeficients, potential damping coeficients, wave
exciting forces and quadratic transfer functions) shall be released in Microsoft Excel file by
CONTRACTOR. The RAO shall be released to PETROBRAS up to 9 months after kick-off.
11.8.4. VERTICAL LIMITATION FOR RISERS

The FPSO shall have a limited vertical motion, in order to allow the safe operation of the risers
that will be connected to it. A bilge-keel shall be designed and installed in order to keep a limited
roll motion, which contributes to the vertical motion at the riser top connections, below the herein
established limits.
The vertical motion limitation is conceived to be shown by the short term response of the FPSO
under a specific wave condition.
The requirement shall be demonstrated by the CONTRACTOR through calculations including the
wave data and the calibrated RAO tables, considering the FPSO at the free floating condition (with
no lines in terms of stiffness and damping).
The basic hypotheses that shall be considered are:
The maximum ship motion for any riser support point location, considering all the 100yr wave Hs-
Tp pairs in 16 directions, contained in reference document Metocean Data document (see 1.2.1),
shall not exceed the following values:
 Most probable maximum vertical motion single amplitude: 10.5 m;
 Most probable maximum vertical acceleration single amplitude: 3.0 m/s².
11.8.5. MODEL TESTS

In order to verify the predicted FPSO motions, the roll viscous damping level in the presence of the
bilge keel, greenwater (occurrence and mitigation options) and induced loads, CONTRACTOR shall
carry out a Model Test program based on the comments issued by PETROBRAS during the
engineering design phase. Actual dimensions shall not be reduced by a factor more than one
hundred (100), in order to obtain adequate model dimensions.
Only Sea-Keeping model tests (FPSO motions) are required
12. OPERATIONAL CONDITIONS

The Unit shall be designed to operate and withstand environmental conditions, described in the
METOCEAN DATA document (see item 1.2.1).
12.1. MAXIMUM DESIGN CONDITION
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The Unit shall be designed to operate normally (as defined in item 12.5.1) in an extreme storm
condition with 3 (three) hour duration and only the Unit moored (no shuttle tanker in tandem), at any
draft ranging from fully loaded to minimum loaded condition, in accordance with CS requirements,
and varying from no riser connected to all risers connected. Under these conditions, the Unit shall
maintain its offset within the limits stated in the document SPREAD MOORING & RISER
SYSTEMS REQUIREMENTS” I-ET- see item 1.2.1). The most unfavorable of the following
environmental combinations shall be adopted for the Maximum Design Condition:
1) 1-hour average wind speed and wind spectra described in the specific metocean data combined
with a sea state corresponding to 100 (one hundred)-year-return period and a 10 (ten)-year-return
period current. NPD (Norwegian Petroleum Directory) wind spectra shall be used if no data is
available.
2) 1-hour average wind speed and wind spectra described in the specific metocean data combined
with a sea state corresponding to 10 (ten)-year-return period and a 100 (one hundred)-year-return
period current. NPD (Norwegian Petroleum Directory) wind spectra shall be used if no data is
available.
Note: design wind speed should refer to an elevation of 10 m above still water level.
Regarding the incoming directions for the environmental parameters, the most critical approach
shall be adopted as follows:
 A collinear approach, considering wind, waves and current coming from the same
direction;
 Wind and waves coming from the same direction but the current direction may be up to 45°
out of alignment with chosen wind/waves direction.
12.2. MAXIMUM OFFLOADING DESIGN CONDITION

The Unit shall be designed to operate normally with a Suezmax sized shuttle tanker (up to 150,000
dwt), moored in tandem. The design shall ensure that the Unit can withstand any range of draft
conditions for the Unit itself and the shuttle tanker in tandem, and varying from only 3 (three) risers
connected (production, gas-lift and umbilical control risers for one production well) to all risers
connected.
Maximum mooring design conditions to be considered are:
 Winds - 1 (one)-year return period, 10-minute average wind speed, 10 m above sea level;
 Waves - The waves shall be considered as being aligned with the wind and limited to:
HS = 3.5m and TZ = 8.0 sec;

 Current - 1 (one)-year return period. The current shall be considered in any direction, up to
45° out of alignment with the wind and waves. The worst case shall be accounted for.
The incidences to be considered are from 0o to 360o, with increments of 22.5o. The shuttle may be
moored to the Unit bow-to-bow or bow-to-stern for offloading.
12.3. BEAM SEA CONDITION
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In this condition, the Unit finds itself beam on to the seas (90 or 270 degrees incidence), with the
following characteristics:
 Significant wave height and peak period: CONTRACTOR shall use the appropriate beam
(Starboard or Port side) wave height obtained from the METOCEAN DATA document ( see
item 1.2.1) for the 100 (one hundred)-year return period;
 Wave spectra: JONSWAP wave spectrum according to the formulation presented into the
METOCEAN DATA document (see item 1.2.1).
12.4. MAXIMUM PULL-IN / PULL-OUT ENVIRONMENTAL CONDITION

All equipment, component and/or accessory that will be part of the risers pull-in/pull-out operations
shall be designed or specified to perform these operations. CONTRACTOR shall refer to I-
ET_RISER INTERFACE LOAD ANALYSIS document (see item 1.2.1) for the limiting
environmental conditions and additional pull-in requirements.
The Unit shall be considered in a FAR position, with respect to the riser being pulled-in.
12.5. MOTIONS AND ACCELERATIONS DESIGN CONDITIONS

12.5.1. NORMAL OPERATION AND EXTREME CONDITIONS

For motions and accelerations responses, short term statistics shall be evaluated for the DEC
(design extreme conditions – 100 year return period seas) and DOC (design operational condition –
1year return period seas) waves from METOCEAN DATA. These responses shall be appraised on
the COG of the FPSO and on as many points as needed for the right structural sizing as well. The
distribution of the points to be evaluated in this analysis shall be in accordance with CS
requirements.
Sea states (Hs x Tp) in motion analysis for the site location shall consider METOCEAN DATA,
specifically extreme distribution contour curves with range of periods, for all specified directions.
The Unit shall also be able to operate normally for DOC conditions, at any draft from fully loaded to
20% loaded/ballasted condition.
Under DOC conditions, the Unit’s single-amplitude roll motion shall not exceed 10 degrees, while
under DEC conditions the Unit’s single-amplitude roll motion shall not exceed 15 degrees The roll
angle single-amplitude values shall be demonstrated during the model tests to be carried out by
CONTRACTOR. If any conflict appears between this requirement and the requirement stated in
item 11.8.3, motion limitation requirement stated in item 11.8.3 shall prevail.
CONTRACTOR shall design and install a bilge keel in the hull as following:
(i) CONTRACTOR shall present calculations in order to back-up the bilge keel width and length
definition. This shall be submitted to PETROBRAS for comments/information.

(ii) Regardless the calculations in item (i), the minimum width of the bilge-keel shall be 1,5m.

REMARKS:

1. To operate normally means a state in which all systems and processes on the Unit can be
started or kept running without tripping alarms or safety shut-down devices or endangering
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equipment and personnel involved. This includes the oil collecting system, oil offloading
system, utility systems, vessel systems, oil transfer to/from cargo tanks, and other handling
devices operation as well as the maintenance processes of any systems. In addition, process
facilities shall be designed to ensure the efficiency of separation and treatment and transfer of
oil, gas and water;

2. The 20% loaded/ballasted condition refers to a condition corresponding to the Unit’s


lightweight plus 20% of the Unit’s deadweight.

12.5.2. OPERATIONAL CONDITION FOR UTILITIES

The Unit’s utility systems shall operate normally when subjected to the worst of the following
conditions:
 The motions and accelerations associated with the design extreme condition (item 12.5.1);
 All CS requirements, including towing condition;
 At least 15° single-amplitude roll, with a 10-s period and pitch motions taken as the worst
obtained from the application of the conditions stated in item 12.1.
REMARK:

Utility systems are any facilities employed to provide power generation, water for cooling,
compressed air, HVAC to keep the vessel operating while the offloading or pull-in/pull-out
operations cannot proceed due to the weather conditions.
12.5.3. FOUNDATIONS AND FASTENINGS STRUCTURAL REQUIREMENTS

The foundations and fastenings shall be designed according to CS requirements in order to


withstand the worst of the following:
1. Motions and accelerations associated with the DOC and DEC design condition (item 12.5.1);
2. Motions and accelerations calculated from the beam sea condition (item 12.3), considering the
vessel at any draft from fully loaded down to light/ballasted condition (minimum draft);
3. All CS requirements, including towing condition;
REMARKS:

Only in the towing condition no live weights can be considered present in the cargo piping. This
consideration must be checked against CS requirements.
All safety systems and life-saving systems, including emergency equipment and vessel
abandonment equipment, shall continue to operate while under the worst of the conditions listed
above in this item.
13. MOORING
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CONTRACTOR (or respective SUBCONTRACTOR) shall demonstrate previous experience in


mooring design, i.e. in similar projects with at least 1500m water depth and VLCC or larger hulls,
and submit to PETROBRAS approval.
For detailed information of mooring analysis and equipment, see the document I-ET-SPREAD
MOORING & RISERS SYSTEMS REQUIREMENTS mentioned in item 1.2.1
14. FLEXIBLE RISERS

14.1. RISERS CHARACTERISTICS

PETROBRAS will tie-in flexible risers in a coupled scenario, therefore CONTRACTOR shall provide
supports for flexible risers that will be connected to the Unit in accordance with I-ET-SPREAD
MOORING & RISERS SYSTEMS REQUIREMENTS (see item 1.2.1).
The riser balcony of the Unit will have conventional I-Tubes supports with bellmouth locking system
that will be used for flexible risers (coupled system). The bellmouth will lock the riser bend-stiffener
at the lower I-tube, while top end of the riser will be hanged-off on to the upper I-tube using split
collar plates. After the pull-in operations, the spool pieces will be fitted to the riser top end in the
riser balcony area (dry-mounted).
Remarks
 Hard pipes and spools pieces will fall under Contractor's scope of work;
 Spool pieces end flanges shall enable local leak-test before overall pressure test of the
system.

 The CONTRACTOR shall provide pad-eyes that must be welded to the hull at the top
between I-Tubes. These pad-eyes must be provided in order to facilitate the execution of
inspection of risers by climbers;
CONTRACTOR shall consider the following for protect the risers regarding pressure:
Table 14.1.1: Pressure for risers protection.
Maximum
Design
Leak Test
Subsea Line Pressure
Pressure
(kPa(a))
(kPa(a))
Production Flexible Line 20,685 22,754
Gas Lift/Service flexible Line 20,685 22,754
Gas Export Line 20,685 22,754
Water Injection flexible Line 20,685 22,754
Note 1: During the leak test an overpressure of 4% above the leak test pressure (table 14.1.1) for
all risers may be requested by PETROBRAS.
Note 2: A separate low capacity (fresh water, 2.5 m3/h with 100% re-circulation), high pressure
pump shall also be provided to achieve the required pressure up 22,754 kPa(g) for leak test all
risers: production, water injection, lift gas and gas injection risers after hook-up. The service tank
shall be connected to the production and service header. A portable and/or movable skid pump is
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acceptable. Leak-test pump outlet shall have connection to risers to allow open DHSV valve. Piping
and accessories design shall consider the presence of sea water.
Note 3: Facilities to monitor the pressure and depressurize risers during leak test operation shall be
provided.
Note 4: The leak test for rigid lines shall obey the maximum pressures from table 14.1.1.
Note 5: Facilities to allow the leak test of the risers using rented service pumps shall be provided.
Note 6: During execution phase PETROBRAS will provide to CONTRACTOR the temperature
requirement for riser protection.
Note 7: The selection of relief devices to protect the risers against overpressure during service
pump operation shall take into consideration: (i) operating conditions defined on item 2.6.1; (ii) each
riser required design pressure as per Table 14.1.1.; (iii) maximum overpressure (full open
condition) of 10% of relief device set pressure.
Note 8: The selection of relief devices on the discharge of Main Compressors, and Water Injection
Pumps shall also take into consideration each riser required design pressure as per Table 14.1.1.
Note 9: CONTRACTOR shall provide means to protect risers against overpressure during leak test
pump operation. Refer to riser characteristics information on Table 14.1.1.
14.2. RISERS INSTALLATION AND DE-INSTALLATION PROCEDURES

CONTRACTOR shall supply man-power as well as all devices and facilities onboard to perform the
riser pull-in and pull-out connections. CONTRACTOR shall provide handling devices which include
a main chain-jack, fairleads, chains, chain locker, auxiliary winches, sheaves, pull-in wires, guide
tubes if any, hangers and all devices and facilities for mooring and risers installation as well as
accessories to be used in these operations (messenger lines, etc.).
CONTRACTOR shall prepare and submit to CS and PETROBRAS for approval a detailed
installation and de-installation procedure for the risers.
These procedures shall cover, as a minimum, the following:
 Step-by-step pull-in, pull-out and hook-up of risers;
 Special assemblies of sheaves and steel wire paths required for all riser positions;
 Requirements for tug assistance during pull-in/pull-out operations.
The Unit shall be able to perform, onboard, continuous Pull-in and Pull-out operations. Therefore,
CONTRACTOR shall have onboard a skilled crew to operate continuously, 24 hours a day.
Before each pull-in/out operation, within the first oil campaign, CONTRACTOR shall carry out an
underwater survey in order to inspect the bell mouths and to guarantee that the Unit is properly
prepared to start the required operations. CONTRACTOR shall keep spare parts for bell-mouth on
board in case of necessity to replace any loosed piece of the bell-mouth during voyage to the site.
CONTRACTOR will be responsible to supply the riser rigging team and mooring rigging team with
necessary equipment (including bolt tensioner) for any pull-in/pull-out operation as well as for the
mooring hook-up operation.
CONTRACTOR will also be responsible to supply the diving team with necessary equipment.
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CONTRACTOR shall consider also the information expressed in Annex documents (see item 1.2.1:
 SPREAD MOORING & RISER SYSTEMS REQUIREMENTS;
 RISERS TOP INTERFACE LOADS ANALYSIS
 BELL MOUTH SUPPLY SPECIFICATION;
 BELL MOUTH PART LIST DRAWINGS
14.3. RISER HANGOFF AND PULLING SYSTEMS

See the document I-ET-SPREAD MOORING & RISERS SYSTEMS REQUIREMENTS (Spread
Mooring option, item see item 1.2.1) and I-ET-RISERS TOP INTERFACE LOADS ANALYSIS.
15. SOIL DATA

PETROBRAS will be responsible for design, installation of the mooring fixed points (torpedo piles).
CONTRACTOR shall assume that the anchor points will support the maximum loads mentioned in
I-ET-SPREAD MOORING & RISER SYSTEMS REQUIREMENTS.
Mooring system design shall comply with bathymetry chart (stratigraphy and soil profile) of the
Unit’s installation site.
During the detail design phase, PETROBRAS will inform the “fine bathymetry map” for the intended
location of the Unit´s mooring fixed points.
CONTRACTOR shall refer to I-ET- SPREAD MOORING & RISER SYSTEMS REQUIREMENTS for
the mooring materials scope of supply.
16. MARINE SYSTEMS AND PIPING

The Cargo Oil System, Crude Oil Washing System, Sea Water Washing, Ballast System and Inert
Gas System shall follow the requirements of SOLAS and CS rules, guidelines and requirements.
The Inert Gas System and Venting System for cargo tanks shall have piping, control valves and
safety devices for each cargo tank. The cargo tanks shall have an independent cargo header for
exhaust system.
CONTRACTOR shall submit the above arrangement and design to CS for approval and
PETROBRAS for comments / information.
If the Inert gas generator system is exclusive (i.e., apart from the exhaust of either auxiliary or main
boiler equipment), it shall be fed by a dual fuel system, burning preferably fuel gas and alternatively
marine diesel oil.
In case CONTRACTOR decides not to replace the original tanker cargo piping the following
procedure shall be provided: piping shall be 100% de-assembled and 100% internally inspected
(visual and ultra-sonic gauging). Inspection reports shall be submitted to PETROBRAS for
comments / information.
The Ballast system shall fulfill all Brazilian Administration requirements and shall have its inspection
report submitted to PETROBRAS for comments / information.
17. ENVIRONMENT IMPACT STUDIES
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17.1. GENERAL

PETROBRAS will engage third party for Environmental Risk Assessment, in which case
CONTRACTOR shall take part in the assessment, provide all necessary information and comply
with recommendations.
CONTRATOR shall provide a report with information requested by the document called
"Environmental Impact Studies and Report" (Estudos de Impactos ambientais e Relatório de
Impactos Ambientais – EIA-RIMA).
This report shall include the following items.
17.2. GENERAL DESCRIPTION

a) Table with the FPSO characteristics including FPSO name, mooring type, length, molded
breadth, depth, molded depth, light weight, maximum draft, flare height, total cargo oil tanks
storage capacity, fuel gas and diesel consumption list, crane capacities, power generation
(main, auxiliary, emergency) rating, sewage treatment system capacity and technology,
quarters capacity, helideck specification, saving equipment;

b) Hull description;

c) Tank capacity plan including each tank material specification and specifics requirements e.g.
painting;

d) Inert gas system description;

e) Ballast system description;

f) Description of the fluid processing plant (oil, gas, produced water and injected water);

g) Simplified scheme containing both produced oil, produced water, gas and sea water treatment
and injection process;

h) Scheme (for each process: oil treatment, gas treatment, produced water treatment and sea
water treatment and injection) containing main equipment as separators, scrubbers, heat
exchangers, compressors and pumps;

i) Table with pressure, temperature, flow rate and contaminant content (watercut for liquid
streams, CO2, H2S and H2O for gas streams) for inlet and outlets of each main process
equipment as separators, heat exchangers, compressors and pumps;

j) Cooling sea water overboard characteristics as discharge maximum flow rate, temperature,
internal diameter, direction and position in relationship to sea water surface. The draught
variation due to FPSO load shall be informed;

k) Cooling water closed loop system description, including pumping configuration and flow rate;
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l) Industrial water supply system description including type of treatment, suction depth, flow rate
and consumers list;

m) Potable water system description including type of treatment and flow rate;

n) Simplified scheme of industrial and potable water treatment;

o) Power generation description including capacities of main, auxiliary, uninterruptible and


emergency systems. Fuel consumption for each generator considering all fuel sources;

p) Cranes description including length and capacity;

q) Flare and vent systems description including flow rate capacities and stack height;

r) Topsides and Subsea Chemical injection system description including a table expected
chemical, dosage rate, injection points and storage capacity.

17.3. EFFLUENT

Details about effluent discharge on sea are being requested to support plume dispersion included
in environmental studies.
a) Sulphate removal reject flow rate, composition, discharge temperature, pipe internal diameter,
direction and position in relationship to sea water surface. The draught variation due to
FPSO load shall be informed;

b) Sulphate removal membranes cleaning procedure description including expected frequency


and the duration of each cleaning step, waste water overboard description containing
composition, pH, discharge volume and duration, density, salinity, chemical concentration, flow
rate, pipe internal diameter, direction and position in relationship to sea water surface. The
draught variation due to FPSO load shall be informed;

c) Produced water system description, oil content, measurement points, interlock between
measurement and discharge, reprocessing philosophy description, discharge flow rate, pipe
internal diameter, direction and position in relationship to sea water surface. The draught
variation due to FPSO load shall be informed;

d) Drainage, bilge and sewage system description, estimate of volume generated annually,
composition, oil content, measurement points, interlock between measurement and discharge,
reprocessing philosophy description, discharge flow rate, pipe internal diameter, direction and
position in relationship to sea water surface. The draught variation due to FPSO load shall be
informed;

e) Simplified scheme containing all drainage systems (topsides and marine);

17.4. ATMOSPHERIC EMISSIONS


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a) Annually quantification (for commissioning and operation phase) of gas pollutants


concentration and mass flow rate of each source as turbines, boilers, flare, vent, etc. It shall be
quantified at least the following pollutants: NOx, SOx, CO, CO 2, CH4, NMHC, N2O, particulate
matter and total hydrocarbons. In case of a gas with a range of CO2 content, some cases with
different CO2 content shall be used. For power generators with more than one fuel, the
quantification shall be done for each fuel. A table containing all these information shall be
provided;

b) A preliminary description of UNIT commissioning shall also be provided including expected


atmosphere emissions as per item 17.3.a.

17.5. WASTE MANAGEMENT

Solid residues characterization, residue class, disposal destination, annually mass generation
including change out process materials (molecular sieve, CO2 membranes cartridges, sulphate
removal membranes cartridges, H2S removal fixed bed, etc), sewage sludge, oil tank sludge, slop
tank sludge, flotation cell unit sludge, ordinary garbage, nursery garbage, dangerous residues, food
debris, oily residues, chemicals, sewage sludge, etc.
18. PETROBRAS LOGOTYPE

CONTRACTOR shall paint PETROBRAS logo type in the following Unit places:

 Funnel (both sides);

 Port side and Starboard side in visible area.

 Front wall of the accommodation block


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