11 Engineering Management Scope of Work
11.3 Process Engineering & Flow Assurance
Contractor shall carry out all process discipline design and engineering associated with the South Belut production facility and its integration and impact to the existing North Belut production facility
The subsea and topsides Process and Flow Assurance design shall be based on the Basis of Design, PFDs, preliminary P&IDs, specifications and studies developed previously during FEED as provided in Company Supplied Data as set out in Exhibit G. The Contractor shall immediately notify Company if Contractor determines that the process design will result in any product(s) not complying with the export specifications; and must do so before any detailed study or implementation of changes to achieve compliance. Contractor shall update the process engineering package during detailed engineering to incorporate information developed during the design and as Supplier information is obtained.
Contractor shall revalidate and update all Process simulations, and Heat & Material Balance calculations. Process simulation shall be prepared using HYSYS, OLGA, PIPESIM, FLARENET or other Company approved simulation programs. Simulation runs and updates shall be made at anytime a change occurs or a modification is proposed and approved by Company during the detailed design that may affect the design basis.
Table 11.3 below provides a list of non prioritized studies and engineering tasks to be performed in a logical sequence such that rework is minimized and important studies are completed first.
Process Simulation
• Contractor shall develop simulation model(s) in order to review and validate the heat and material balances in the Company Supplied Data. Contractor shall complete and update the South Belut subsea and topsides steady-state and dynamic simulations based on Company provided well test data, in order to update the Basis of Design, PFD’s and P&ID’s, and other supporting documentation.
• Simulations shall include all existing North Belut CPP equipment that will be affected by the new South Belut facilities.
• Data for actual purchased equipment shall be used for the model updates and final sizing.
• PFDs provided by Company shall be reviewed and revised based on the results of the process simulations. PFD's shall be updated as required to incorporate any design changes, or as Company Furnished Material design information is received.
• Contractor shall maintain the process simulations, progressively incorporating the latest Supplier and piping information, and updating the process design to accurately reflect the process simulation results. Contractor shall document the process simulation basis and results for Company’s review and acceptance.
Requirements requirements. This summary shall include, but not be limited to the following:
o Fuel and Purge gas;
o Fresh water;
o Potable water;
o Fire water;
o Utility and Instrument air;
o Electrical power;
o Chemical injection;
o Nitrogen (bottles)
• Contractor shall include in the utility requirements, the demand associated with the existing NBCPP processing facilities and the additional South Belut production facility. Contractor shall review and update the utility requirements throughout the performance of the Work.
Process Flow Diagrams
(PFDs)
• Contractor shall review, validate, and update Company supplied South Belut PFDs based on the results of the process simulations and heat and material balance validation. These drawings shall show all relevant details that include, but are not limited to:
o process and utility equipment, tag numbers, and interconnecting pipe work;
o shutdown valves and location of blow down valves;
o manual isolation valves (only if required to differentiate between operating modes);
o check valves;
o NC (normally closed) and NO (normally opened) valves where required;
o major process control systems;
o heat and material balances;
o process equipment operating and design temperatures and pressures;
o process equipment design capacity;
o vessel diameter and tan-to-tan length;
o pump fluid rate and pump driver brake horsepower;
o pig receiver size;
o special considerations such as insulation and heat tracing if critical to system performance
• Contractor shall modify existing or generate new PFDs as required.
• Contractor shall update all PFDs to “as-built” status based on marked-up drawings provided by Company’s construction/installation contractors.
Piping and Instruments
Diagrams (P&IDs)
• Contractor shall review, validate, and update the Company Supplied South Belut P&IDs to AFD status in accordance with the specifications provided in the Company Supplied Design Basis.
The P&IDs shall show all relevant details that include, but are not limited to:
o sizing of all piping based on detailed hydraulic calculations and in accordance with the Process Piping Design document and Equipment Design Philosophy document;
o piping numbering, material specification, service, and insulation thickness in accordance with the piping numbering and material requirements specification;
o specific piping layout requirement i.e. slope, no pockets etc;
o valve and piping arrangements in accordance with the Isolation and Valve Configuration Philosophy;
o chemical injection and sampling point locations to meet the corrosion and flow assurance design requirements;
o set points on all switches, shutdowns, and controllers;
o instrumentation and control loops
o signals to/from the PCS and SIS and between package units o instrumentation type and control loop(s) and connection(s) o sand monitoring equipment locations;
o corrosion monitoring equipment location;
o equipment design information, including:
Drivers Brake horsepower
Pumps Flow rate, US gpm
Differential pressure, psi
Brake horsepower
Materials
Vessels Design pressure and temperature Operating pressure and temperature
Diameter, inches Seam to seam length, feet
Level information (NLL, HLL, etc.)
Material trim
Pig Receiver Design pressure and temperature Operating pressure and temperature
Diameter, inch
Length, ft (F/F)
Material
Tanks Design pressure and temperature Operating pressure and temperature Size LxWxH, ft
Material
Gas Metering Design pressure and temperature Operating pressure and temperature
Capacity, MMSCFD
o confirmed Supplier information;
o details required by technical specifications;
o relief valve set pressure, sizes and controlling relief scenario;
o closed drain and open drain connections;
o extent of heat tracing and insulation as per the equipment and piping insulation specification;
o control valve, shutdown valve and blowdown valve size, failure position, and tag number;
o manual valve size, interlocking requirements, full bore or reduced bore type and tag number as per piping numbering and material requirements specification;
o material and pressure rating specification limit boundaries;
o skid boundary limits;
o unique tag numbers, including specialty piping items;
o All process flanges shall be indicated to help future projects
identify possible tie-in points;
o main process piping shall be indicated by heavier lines.
• Contractor shall redraft all Supplier P&IDs, utility flow diagrams and such data utilizing the Company standard format.
• Contractor shall modify existing or generate new P&IDs as required
• Contractor shall update all P&IDs to “as-built” status based on marked-up drawings provided by Company’s construction/installation contractors.
• Contractor shall ensure all HAZOP action items are incorporated into the P&IDs.
Pressure Vessels and
Tanks
• Contractor shall review all equipment data sheets in the Company Supplied Data. Contractor shall prepare detailed equipment data sheets suitable for fabrication. Contractor shall design vessel internals for effective gas, liquid and solid separation and removal.
• Contractor shall perform a specialist study to optimize the Slug Catcher dimensions to finalize the installation method. The optimization and offshore installation method selection shall be based on minimizing offshore pre-installation scope associated with the slug catcher installation.
• A CFD analysis will be required for the Slug Catcher to validate the design of vessel internals.
• Contractor shall validate and confirm size of Inlet Gas Metering Scrubber to ensure it meets design requirements.
Data Sheets
• Contractor shall review and verify data sheets in the Company Supplied Data, and assume responsibility for ensuring data sheets are accurate. Contractor shall update the data sheets to reflect actual design conditions, equipment information provided by Suppliers, and any other design developments. Contractor shall develop data sheets for all equipment for which data sheets are not provided in the Company Supplied Data.
Other Equipment
• Contractor shall perform sizing validation to comply with design requirements.
System Design and Operating
Manuals
• Contractor shall prepare system design manuals for all process and utility systems. The system design manuals shall include, but not be limited to, the following:
o system description;
o normal and alternative mode of operation (heat and material balances);
o utility consumption;
o shutdown and start-up procedures (including black start);
o pigging requirements and procedures o equipment list and Supplier specific data;
o line sizing basis;
o instrument data including control, alarm and trip settings;
o general start-up and shut-down operating guidelines;
o relevant PFDs and P&IDs (A3 size);
o document references.
• Contractor shall utilize design manuals to develop Operating Manuals for the South Belut Production facility and affected North Belut facilities. Operating Manuals Requirements are described in Exhibit K of this Contract.
API 14C SAFE Charts and
Cause and Effects
• Contractor shall design the safety instrumented system as per API 14C. Contractor shall review and update the South Belut API 14C SAFE chart in conjunction with the existing North Belut API 14C SAFE chart
• Contractor shall review and update South Belut Cause and Effect Chart in conjunction with the existing North Belut Cause and Effect Chart in accordance with API 14C requirements consistent with other engineering and safety reviews/studies
Process Philosophies,
Studies, Reports
• Contractor shall develop and update documentation of overall process design conditions; and
• Contractor shall prepare reports as required for securing approval by Governmental Authorities for relief and vent systems.
Flare
• Contractor shall review and update blowdown and relief rates based on final equipment selection. Contractor shall update the Relief System Design Summary Report as required and develop a flare network model to confirm flare system back pressure calculations.
• Contractor shall update the existing North Belut radiation study.
The updated radiation study shall include a prediction of flare radiation at all locations on and near the NBCPP and WHP-D to demonstrate safe levels of radiation conforming to the Flare Relief and Blowdown Philosophy. Contractor shall consider the interface with all the associated equipment and vessels that will be mobilized during the execution of this work. Contractor shall develop the appropriate design basis, for review and acceptance by Company, regarding such matters as the relief scenarios, modeling technique, and environmental conditions to be considered in the study.
Design of Chemical Injection
Systems
• Contractor shall review and update the Chemical Requirements Study Reports provided by Company and design chemical injection and sampling point locations to meet the design requirements.
Flexibility to meet changing chemical injection requirements during the life cycle of the facilities shall be incorporated into the design.
Flow Assurance
• Contractor shall review all flow assurance work provided in Company Supplied Data and validate or advise of any issues arising from the review. Wherever necessary, the steady state and transient analysis shall be updated and re-evaluated by Contractor based on fluid properties, operating parameters, varying water cuts, chemical selection and any additional vendor updates.
• Contractor shall provide pipeline temperature profiles to support Cathodic Protection design.
• Contractor shall provide transient analysis and procedures for pipeline start-up, shut down, de-pressuring and re-pressurising, pigging and all required surge control. Analysis shall include but not be limited to, maximum liquid hold up, pigging strategy, start up and shutdown sequence, maximum flowrate, minimum temperature and hydrate formation during pipeline depressurization.
• Transient analysis, utilizing OLGA software, shall be performed by Company approved qualified personnel.
Environmental Impact Study
• Contractor is responsible for preparing a report which identifies and quantifies the South Belut contributions to NB CPP emissions and discharges to the environment. The report shall address atmospheric emissions from compression gas turbines and power generation facilities as well as an estimate of flare emissions, discharges to the sea, and waste transported to shore.
Pipeline Settle-Out Pressure
Study
• Contractor shall establish the settle-out pressure the pipeline systems once the subsea layouts and sizes are confirmed.
Control Philosophy
Report
• Contractor shall develop detailed control system descriptions.
Contractor shall review, update and finalize the Operating and Control Philosophy Report supplied by Company to reflect any changes due to design development or issues identified as a result of the dynamic modeling studies.
Start-up, Operating and
Shutdown Procedures
• Contractor shall develop detailed Black Start-Up, start-up, operating, and shut-down procedures for the South Belut Production Facility. Contractor shall review impacts of South Belut to the existing North Belut Start-up, Operating and Shutdown Philosophies. Procedures shall be developed for all operating
Belut and South Belut Production.
• Pipeline start up, ramp up and ramp down procedures shall also be developed based on the transient analysis.
Low Temperature
Study
• Contractor shall review and update the minimum design temperatures for equipment and piping systems. In particular, Contractor shall identify any South Belut and existing NBCPP design which is overly conservative, resulting in unnecessarily higher grade materials. Contractor shall reconfirm MDMT of Flare KO Drums for all blowdown and high-pressure flare cases. This study shall also confirm material selection.
Table 11.3: Process Studies and Engineering Tasks