PROFESSIONAL EXPERIENCE REPORT
Presented
To
Council for the Regulation of Engineering in Nigeria
(COREN)
By
CHUKS EMU
B.Eng. (Hons) Electrical Engineering
University of Benin, Benin City, Edo State
OF
Makon Engineering and Technical Services Ltd.
IN FULFILMENT OF THE REQUIREMENT FOR
REGISTRATION
Into
Council for the Regulation of Engineering in Nigeria
(COREN)
TABLE OF CONTENTS
ATTESTATION ... 4
1.0 INTRODUCTION ... 5
SUMMARY OF EXPERIENCE... 5
1.1 Abbreviations and Definitions ... 5
CAREER OVERVIEW ... 9
1.2 Makon Engineering & Technical Services Limited, Lagos State ... 9
1.3 China Petroleum Engineering & Construction Company, Khartoum, Sudan ... 12
1.4 FMC Technologies Inc. Houston, Texas ... 15
1.5 Deltaafrik Engineering Limited, Victoria Island, Lagos ... 19
1.6 Cakasa Nigeria Company Limited, Ikoyi, Lagos ... 26
1.7 Software Proficiency ... 29
1.8 Trainings... 29
2.0 ELECTRICAL AND SUBSEA ENGINEERING DESIGN IN OIL AND GAS INDUSTRY ... 30
2.1 Project Design Phases ... 30
2.2 Basic Design Consideration ... 31
2.3 Typical Electrical Deliverables ... 32
2.4 Typical Subsea Controls Engineering Deliverables ... 33
2.5 Interactions Between Disciplines During Project Execution ... 34
2.6 Some Typical Electrical Deliverables ... 36
2.7 Main Topside Electrical Equipment ... 40
2.8 Subsea Control System Equipment ... 44
2.9 Some Typical Subsea Controls Engineering Deliverables... 54
3.0 DETAILED ELECTRICAL ENGINEERING DESIGN FOR AGBADA NAG PROJECT ... 60
3.1 Lighting & Power Design for all Sheds or Shelter ... 61
3.2 Loadlist and UPS System Sizing ... 61
3.3 Electrical Single Line Diagram ... 62
3.4 Cable Sizing ... 63
3.5 Electrical Cable Schedule or List ... 65
3.6 Raceway System Design ... 65
3.7 Earthing Layout ... 65
APPENDIX 1: DETAILED ELECTRICAL ENGINEERING DESIGN FOR SPDC AGBADA NAG
DOMESTIC GAS SUPPLY PROJECT DELIVERABLES ... 67
ATTACHEMENTS: CURRICULUM VITAE, COPIES OF DEGREES AND PROFESSIONAL
ATTESTATION
I certify that the information as contained in this report is to the best of my knowledge, the true practical experience of Mr. Chuks Emu.
NAME: ________________________________________________________________
DESIGNATION: _________________________________________________________
REGISTRATION No: _____________________________________________________
SIGNATURE: ___________________________________________________________
1.0 INTRODUCTION
This report summarizes my professional experience gained from various projects I have worked on after my graduation in April 2004.
The experience covers diverse areas of engineering as the engineering profession involves interactions between various engineering disciplines while working on projects. My experience comprises of work in a multi-discipline environment in oil & gas engineering projects. Specific works include the design of Topside Electrical Engineering and Subsea Control Systems for both downstream and upstream of the oil and gas industry.
Also I have worked with equipment vendors/manufacturers, majorly in evaluating and reviewing the equipment specifications, quotes and other technical submissions in order to meet specific project needs as stated in the project design basis.
Finally, I have also provided technical support to construction works on site for various projects.
SUMMARY OF EXPERIENCE
Over eight (8) years working experience in both Downstream & Upstream sector of the Oil and Gas industry as an Electrical & Subsea Controls Systems design engineer. Familiar with all Subsea & Topside products design.
Knowledgeable in NEC, IEEE, IEC, ISA, API and ISO Standards and Codes related to design and analysis of Topside Electrical and Subsea Controls systems
1.1 Abbreviations and Definitions
AC Alternating Current AG Associated Gas
AGG Associated Gas Gathering
ANSI American National Standards Institute API American Petroleum Institute
BOPP Barrel of oil per day bwpp Barrel of water per day CAPEX Capital Expenditure CP Cathodic Protection
DCC Document Control Centre DCV Directional Control Valve DED Detailed Engineering Design DEP Design Engineering Practice DOMGAS Domestic Gas
DRB Design Review Basis DSC Delta Steel Company EDG Eastern Domestic Gas EDU Electrical Distribution Unit
EFAT Extended Factory Acceptance Test EFL Electrical Flying Lead
EJB Electrical Junction Box
EMC Electro-Magnetic Compatibility E&P Exploration & Production
EPCC Engineering. Procurement, Construction and Commissioning EPCM Engineering, Procurement, Construction and Project Management EPU Electrical Power Unit also called SPCU)
ESD Emergency Shutdown ETU Electronic Test unit
EVDT Enhanced Vertical Deepwater Tree eWOCS Electrical Work-over Control System FAT Factory Acceptance Test
FEED Front End Engineering Design FPF Field Production Facility
FDPSO Floating, Drilling, Production, Storage & Offloading FPSO Floating, Production, Storage & Offloading
FSF Field Surface Facility GA General Arrangement
HDM Hydraulic Distribution Module HFL Hydraulic Flying Lead
HP High Pressure
HPU Hydraulic Power Unit
HSE Health, Safety & Environment
HVAC Heating, Ventilation & Air Conditioning IEC International Electro-technical Commission IEEE Institute of Electrical & Electronic Engineers IES Illuminating Engineering Society
IP Institute of Petroleum IP Ingress Protection
ISO International Organization for Standardization LAN Local Area Network
LP Low Pressure
MCC Motor Control Centre MCS Master Control System
MMscfd Million Standard Cubic feet per Day MPFM Muilti-Phase Flow Meter
MQC Multiple Quick Connect MTO Material Take-off
MUX Multiplex Electro-Hydraulic (E/H) Control System NAG Non-associated Gas
NEC National Electric Commission NFA No Future or Further Action NFPA National Fire Protection Agency NLNG Nigeria Liquefied Natural Gas OGM Oil Gathering Manifold OPEX Operating Expenditure
PCC Procurement, Construction & Commissioning PCS Production Control System
PFD Process Flow Diagram
PHCN Power Holding Company of Nigeria P&ID Piping and Instrumentation Diagram
PLC Programmable Logic Controller PO Purchase Order PSD Process Shutdown PVC Polyvinyl chloride QA Quality Assurance QC Quality Control RMU Ring Main Unit ROW Right of Way
SAFOP Safety and Operability Study Scfd Standard Cubic feet per day SCM Subsea Control Module
SCMMB Subsea Control Module Mounting Base SDS Subsea Distribution System
SPCU Subsea Power and Communication Unit (also EPU) SPM Single Point Mooring
STFL Steel Tube Flying Lead
SUTA Subsea Umbilical Termination TLP Tension Leg Platform
TPU Topside Processing Unit TSCP Touch Screen Control Panel
TUTA Topside Umbilical Termination Assembly ULM Umbilical Line Module
UPS Uninterruptible Power Supply UTA Umbilical Termination Assembly UTH Umbilical Termination Head XLPE Cross Link Polyethylene XT Christmas Tree
CAREER OVERVIEW
1.2 Makon Engineering & Technical Services Limited, Lagos State
From September 2010 to date I have been working with Makon Engineering and Technical Services (METS) Limited as Senior Electrical and Lead Electrical Design Engineer. METS is an indigenous engineering design and construction company providing Engineering, Procurement, Construction and Project Management (EPCM) services to the Nigerian oil and gas Industry. Capabilities exist in the engineering group for Downstream (Petroleum Products Depot & Process Industry) and Upstream (Onshore and Offshore) in the following areas:
Conceptual Engineering Design
Front End Engineering Design (FEED)
Detailed Engineering Design
As Built Engineering Services
Follow on Engineering Services
Project Management Services
Consultancy Services
Some Project Executed/Work Experience:
Projects: Alakiri, Utorogu & Agbada NAG; Bonny, Adibawa and Egbema West AG Position: Senior and Lead Electrical Engineer
Project Brief:
AG Solutions: Flares review that was initiated in 2004, identified Twenty six (26) flowstations,
which had no AG Solution plans in place, and were considered “Stranded”. A commercial ranking of the opportunities was carried out on the basis of 2008 NFA oil production protection and to secure the reserves, which favoured the idea to harness the AG from these facilities with a view to eliminate gas flaring. Of these twenty six (26) flowstations, six (6) were being matured in AG solution phase 1 which covered Otumara, Opuama and Saghara flowstations in the Western division and Umuechem, Ahia and Adibawa flowstations in the Eastern division. While the Phase II is considered for eleven flowstations, viz. Bonny, Egbema, Egbema West, Oguta, Diebu Creek, Nun River in the Eastern division and Greater Ughelli node (Ughelli East, Ughelli West, Ogini, Oroni and Evwreni flowstations) in the Western Division. However, the Greater
Ughelli node and Egbema flowstation were stalled due to budget constraints, concept change (DRB minutes of meeting of 27th September 2007) and need for further subsurface study. Subsequently, phase II was later divided into two tranches. Tranche 1 is to provide AG facility for Bonny and Egbema West flowstations while Tranche 2 is to provide AG facilities for Oguta, Diebu creek and Nun
river flowstations
NAG Solutions: In support of government’s desire to increase supply of domestic gas
(DOMGAS) to local industries and power plants, SPDC submitted a plan to government in October 2008 detailing out steps to increase its contribution to the DOMGAS market between 2008 and 2013; divided into short-term and medium-term supply targets. The short-term covers a period of 2008 – 2010 and includes refurbishment/expansion of existing plants and completion of on-going projects in selected locations (referred as gas hubs), and AGG nodes. This is aimed at increasing supply to circa 1.3bscfd supply target from the current 900MMscfd supply rate. The medium-term plan from 2011 – 2013 is aimed at further capacity expansion at the identified gas hubs with wellstream supply from immediate and remote fields to achieve a supply target of circa 2bscfd.
As part of plans to achieve the short-term target for SPDC-East, the Agbada Non Associated Gas (NAG) field is being developed to enhance gas supply to the Eastern
Domestic Gas (EDG) network. This will provide an additional 100 MMscf/d gas to the EDG Network.
The capacity of the Utorogu gas hub will be increased from 360 MMscfd to circa 510MMscfd by end - 2010 to urgently address the supply shortfalls in the ELPS/WAGP captive market. Approval has been secured to relocate the 150MMscfd GHF earlier planned for Ughelli-East to Utorogu with the Ughelli-East NAG wells re-routed via a bulk line to Utorogu. A sales gas return line to supply the low-pressure customers in the Ughelli area (e.g. PHCN Delta I - IV, DSC, Beta Glass, etc) will also be constructed. The existing Ughelli-East NAG plant will be subsequently decommissioned
The Aim of the Alakiri NAG refurbishment is to keep the plant running for another 20 years and secure the gas volume of 100MMscf/d – 120MMscf/d to Eastern Domestic Gas Network and allow full swing to NLNG during NGC outage.
These Projects were executed by a multidisciplinary team of engineers which included Process, Piping, Civil, I&C and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Generation and Distribution System
Power and Lighting Systems
Earthing System
Lightning Protection System
Since these projects were both brown and green field project, data gathering was required before the actual project work execution. The approach was to make reference to previous designs and drawings as existing on site, site survey and interviews of relevant personnel on the sites were done to retrieve the needed input for the calculations and production of deliverables. All the relevant files were carefully studied and needed information stored for reference purposes during the actual design. Pictures of all relevant structures and facilities were taken. Measurements were also taken where applicable, existing equipment specifications were taken from the Nameplates. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures. The following are the deliverables I produced on the projects:
Power and Lighting Layouts/Details
Cable Tray Layout/Details
Cable Route Layout
Switchroom General Arrangement
Cable Sizing
Power system studies
Electrical Cable Schedule
Earthing Layout
Electrical Design Basis
Equipment Data Sheets
Single line Diagrams and loadlists
Specifications for Electrical equipment
Detailed installation drawings
SAFOP Reviews
Hazardous Area Classification drawings
Installation Manuals
Construction supports
As-built documentations
1.3 China Petroleum Engineering & Construction Company, Khartoum, Sudan
I joined CPECC as a Senior Electrical Engineer between March - September 2010. CPECC is a Chinese engineering design and construction company providing Engineering, Procurement, Construction and Project Management (EPCM) services to the Sudanese oil and gas Industry. Capabilities exist in the engineering group for Onshore Petroleum Industry in the following areas:
Front End Engineering Design (FEED)
Detailed Engineering Design
As Built Engineering Services
Construction and Commissioning Services
Consultancy Services
Summary of Some Project Executed/Work Experience: Projects:
1. Provision of PCC Services for FSF and Transit Lines for FNE and JAKE Phase III Project for Petro-Energy
2. Upstream Facilities EPCC for Field Surface Facilities – Petrodar Operating Company
3. Palouge Produced Water Reinjection Project - Petrodar Operating Company
Position: Senior Electrical Engineer Project Brief:
Petro-Energy – PCC for FNE and Jake Facilities: Petro-Energy E&P Co., Ltd, hereinafter
referred to as PE, is currently operating oil production facilities in the Fula and Moga Fields, in the Muglad Basin located in South West of Sudan (approximately 760 km from Khartoum at
MSL 550 m). During past four years, PE carried out Fula surface facilities Phase-I and Phase-II project to build Fula FSF, Moga FSF, Fula CPF, Moga FPF, Gas Fired Power Plant and pipeline from Baleela to Khartoum refinery. Now total production has reached 40,000 BOPD.
A new project “PHASE III UPSTREAM SURFACE FACILITIES PROJECT” for Block 6 was initiated by Petro-Energy to develop three new oilfields, Keyi, Jake and FNE, and to identify the bottlenecks and carry out the modifications in Fula CPF. This will enable the CPF to process crude oil from the new identified wells in Fula, Moga, Keyi and Jake fields to achieve the production rate of 60,000 BOPD.
As part of the FSF Phase III project, Service Order No. 1 contains the following scope of work:
18 light crude wells, 4 water injection wells and 4 gas injection wells at Jake field
15 heavy crude wells at FNE field
Crude/Gas transit line from Jake FPF to Fula CPF
Crude/Gas transit line from FNE FPF to Fula CPF
PDOC – Palouge Water Re-injection Project: PDOC is currently carrying out exploration,
development and production of oil in Block 3 & 7 of Melut Basin, south-west Sudan. The Palouge FPF is designed to perfume bulk removal of water to an acceptable maximum of 10% bulk water cut from the crude oil. The produced water from Palouge FPF is expected to reach 1,180,000bwpd by year 2018. With the expected increase in produced water, PDOC has commenced the upgrade of the produced water disposal system. Presently the bulk of the produced water is treated by existing skim tanks and sent a pilot scale water to injection plant. The aim of the project is to design and install a new water treatment and injection facilities at Palouge FPF in ordet to improve production recovery. The new plant capacity shall be designed to facilitate the treatment and injection of 300,000bwpd of produced water with discharge quality of 10ppm oil-in-water into the oil bearing reservoir.
PDOC – EPCC for Field Surface Facilities: Petrodar Operating Company Ltd. (PDOC)
(hereinafter referred to as PDOC) holds the right for exploration and development of the contract areas Block 3 & 7 located in the Southeast of the Republic of the Sudan. PDOC is developing the oil reserves in Block 3 & 7 that hereinafter shall be referred to Gumry Field Surface Facility Project, consisting of the development of oil production from several existing identified fields. Teng and Mishmish are the new discovered oilfields. Teng & Mishmish oilfield is located 24 km
north-west of Gumry oil field. The crude oil produced from each production well will be collected to OGMs, and then go into the Gumry FPF.
The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical, I&C and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Distribution Facilities
System Studies
Lighting System
Earthing System
Cathodic Protection System for Pipelines
Since the project was a brown field project, data gathering was required before the actual project work execution. The approach was to make reference to previous designs and drawings as existing on site, site survey and interviews of relevant personnel on the sites were done to retrieve the needed input for the calculations and production of deliverables. All the relevant files were carefully studied and needed information stored for reference purposes during the actual design. Pictures of all relevant structures and facilities were taken. Measurements were also taken where applicable, existing equipment specifications were taken from the Nameplates. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures.
The following are the deliverables I produced on the project:
Electrical Design Basis
MCC Single Line Diagram
MCC elevation drawing
Cable Route Layout
Cable Sizing and Voltage Drop Calculations
Outdoor lighting Layout
Lighting Distribution Board Schedule
Lighting Calculation
Hazardous Area Classification drawings
CP layouts and details drawings
Datasheets – Transformers, MCC, Panel Board
MTO, Technical Bid Evaluation and Material Requisition
1.4 FMC Technologies Inc. Houston, Texas
For two years (2007 – 2008), I was seconded to FMC Technologies Inc, Houston as a Subsea Controls System Engineer. FMC Energy Production Systems and Energy Processing Systems businesses are global technology leaders providing solutions for customers engaged in petroleum exploration, production, measurement and transportation. Capabilities exist in the engineering group for Downstream and Upstream (Subsea Engineering) in the following areas:
Conceptual Engineering Design
Front End Engineering Design (FEED)
Detailed Engineering Design
Subsea Processing
Light Well Intervention
Deepwater Subsea Production Systems
Flow measurement (metering) and assurance
Floating System
Fluid Controls
After Market Services
Project Management Services
Summary of Some Project Executed/Work Experience:
Projects: Conceptual, FEED and Detailed Design for Agbami FPSO, Llog, Helix Noonan,
Nexen, Murphy Azurite, Callon Entrada, Blind Faith, Cascade and Chinook and eWOCS for various Clients – Chevron, Murphy West Africa, Helix, Callon Petroleum and Petrobras.
Project Brief:
Agbami FPSO: The Agbami field will be developed by subsea completed production and
injection wells connected to a Floating Production, Storage and Offloading (FPSO) Facility through a system of subsea manifolds, flowlines and risers. Treated and stabilized crude oil will be periodically offloaded from the FPSO through multiple, mid-water offloading lines
connected from the stern of the FPSO to a Single Point Mooring (SPM) offloading buoy and multiple offloading hoses connected from the offloadingbuoy to a tanker moored to the buoy. Produced gas is re-injected into the reservoir.
Murphy Azurite: Murphy West Africa, Ltd. is planning the development of its Azurite oil
discovery offshore Republic of Congo. The Azurite oilfield is located in the Mer Profonde Sud block in approximately 1400 m water depth.
The field development consists of a spread moored FDPSO tied to a subsea drill center. The subsea drill center utilizes a ten slot cluster manifold, six slots for production and four slots for water injection. The subsea manifold is tied to the FDPSO using three flexible risers, two for production and one for water injection. The trees are tied to the subsea manifold using flexible well jumpers. The Azurite Development will be drilled and produced from a centrally located drilling center. The produced oil will be offloaded to tankers of opportunity for transportation. The relatively small amount of gas that is produced will be flared.
Callon Entrada: The Callon Entrada Field Development Project is a subsea tieback
development that is located approximately 230 miles offshore in the Garden Banks (GB) area of the Gulf of Mexico. The Magnolia Tension Leg Platform (TLP) will be the host facility and is located in Garden Banks Block 783 at a water depth of 4675 feet. The subsea development area lies to the west of the Magnolia TLP in water depth variations ranging from 4481 feet to 4663 feet and approximately a 5.5 mile maximum offset from the TLP.
The field development comprises two (2) production wells with the option to add two (2) production wells.
The existing appraisal subsea wells (GB782 #4 in the Southeast area of Block GB782 and GB782 #3 in the Northwest area of Block GB782) will be evaluated and re-used. All wells are initially oil producing; with well GB782 #3 switching over to gas production after approximately two (2) years.
The subsea production wells will be controlled from the Magnolia TLP by means of electro-hydraulic umbilicals. The main umbilical will be suspended from the TLP and will be connected to the subsea umbilical termination assembly (SUTA), located near the Entrada #4 well. A Steel Tube Flying Lead (STFL) with cobra-head connections and Electrical Flying Leads (EFL) will connect the SUTA to an Umbilical Termination Head (UTH), which is bolted to an in-field umbilical. A UTH at the far end of the in-field umbilical near Well #3 will be connected to the Well #3 tree via an STFL with cobra-head connections and EFLs. Two hydraulically actuated valves on each PLEM will be functioned via a thermoplastic HFL using head bracket connections to stab plates on the tree and manifold.
The eWOCS: eWOCs development is to integrate several components and functions, normally
done at the surface, onto the spanner joint. The components being moved are the HPU including reservoir, control valves and electronic controllers and batteries. This allows the typical thermoplastic multi-line electro-hydraulic umbilical to be replaced with a simple electrical cable to supply power and communications to the eWOCs unit. The components required in the topside MCS are the system controller, power supply and communication units.
While the eWOCs system will be developed using several building block components, the system described in this document is to be developed for use with the EVDT slimbore completion system. The core building blocks shall maintain the ability to be used in other applications like external eWOCs for use in open water mode and other systems as needed for other system applications
Blind Faith: The Blind Faith field of Chevron is located in the Mississippi Canyon Blocks 695
and 696. The field is situated 162 miles south of New Orleans in a water depth of approximately 7000 feet. The MCS will be designed for the initial 3 production trees and a possible 4th production tree, located on Drill Center #1, up to two future production trees located on Drill Center #2, and two Subsea Gas Distribution Manifold for both mudline and downhole gas lift. The 3 initial production trees located at drill center 1 will be connected to one 4 slot manifold. The future production trees located at drill center 2 will be connected to a future 2 slot manifold. All future facilities will be programmed in the MCS initially, but disabled until the future equipment is installed.
Helix Noonan: Helix Energy Solutions wishes to provide subsea tie-back development for its
scope will cover the provision of Topside Control systems – MCS, SPCU, UPS and HPU; while the Subsea systems will cover provisions for umbilical systems, foundations structures, steel and electrical flying leads.
Cascade and Chinook: The Petrobras America Inc. Cascade & Chinook drill centers are
located in 8,100ft and 8,800ft water depth, respectively, in the Gulf of Mexico. The current development plan assumes a phased development incorporating an initial Phase I production for about one year, followed by Phase II production of an additional four years and then subsequent full field development. The full field development includes up to 24 production trees, 4 production manifolds and 2 subsea boosting pumps. In Phases I and II the wells will be tied back to a floating production, storage and offloading (FPSO) facility, for Phase III a production platform should replace the FPSO
. The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Structures, Mechanical and Control (E&I) System Engineers. The Subsea Engineering team had the responsibility of providing the following services:
Subsea Structures
Signal, Power and Hydraulic Analysis
Umbilical System
Christmas Trees and Manifold & tie-in Systems
Subsea Electrical Distribution and Subsea Control Systems
Topside Equipment - Hydraulic Power Unit, UPS, Electrical Power Unit and Master Control Station
Cathodic Protection System
Since these projects were green field projects, data required was basically the environmental conditions and the site survey plan of the proposed facility. The actual project execution work was carried out based on clients’ specifications, international standards and company procedures. The following are some of the deliverables produced by Subsea Control team on the project:
Functional Design Basis
Functional Specifications for MCS, SPCU, ULM, UPS and SCM
Schematic diagrams, GA and assembly drawings for Subsea Products
Electrical block diagrams and schematics
Subsea Distribution schematics
FAT, EFAT, Operation & Maintenance Manuals
Cable Sizing and Voltage Drop Calculations
1.5 Deltaafrik Engineering Limited, Victoria Island, Lagos
I joined Deltaafrik Engineering Limited as an Electrical Design Engineer in September 2006. Deltaafrik Engineering Limited is an indigenous engineering design company incorporated in 2002 to provide Engineering, Procurement and Project Management services to the Nigerian oil and gas Industry. Following the alliance with Worley Parsons, US the Deltaafrik/Worley Parsons alliance is a strategic relationship between two firms specializing in the rendering of engineering services to the oil and gas industry. Capabilities exist in the engineering for Downstream (Petroleum Products Depot & Process Industry) and Upstream (Onshore and Offshore) in the following areas:
Conceptual Engineering Design
Front End Engineering Design (FEED)
Detailed Engineering Design
As Built Engineering Services
Follow on Engineering Services
Project Management Services
Consultancy Services
Summary of Some Project Executed/Work Experience:
Project: Amenam Kpono Oily Water Treatement Upgrade Project for Total ELF Nigeria
Limited
Position: Senior Electrical Engineer
Project Brief: FSO UNITY receives crude oil and its associated water from OML 99, 100 &
102. Presently, the FSO treats 45,000 bwpd compared to the design capacity of 36,000 bwpd. In the future with the arrival of Nkarika, Ofon Phase II production and the aging of the present
OML 100 & 102 fields, the amount of produced water that would be treated at the FSO is expected to increase significantly with a peak of 60,000 bwpd in 2014. In addition to the large amount of produced water required to be treated, the diverse nature of the different crudes also presents a challenge to meet the DPR limit of 40 ppm (TOG) of discharge water quality.
As a result of the above situation, the FSO Unity Oily Water Treatment (FSO-OWT) Upgrade Project was conceived to upgrade the present water treatment process. The ultimate objective is to provide water treatment capacity of 75000bwpd and achieve water quality of better than 40ppm TOG. This will be achieved by the installation of a new OWT module (module 14) comprising principally a Coalescer, a Flotation unit and a Polishing unit
The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical, I&C and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Distribution System to OWT Facilities
Lighting System
Earthing System
Cabling system
Since the project was a brown field project, data gathering was required before the actual project work execution. The approach was to make reference to previous designs and drawings as existing on site, site survey and interviews of relevant personnel on the sites were done to retrieve the needed input for the calculations and production of deliverables. All the relevant files were carefully studied and needed information stored for reference purposes during the actual design. Pictures of all relevant structures and facilities were taken. Measurements were also taken where applicable, existing equipment specifications were taken from the Nameplates. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures.
The following are the deliverables I produced on the project:
Electrical Design Basis
As-built drawings
Cable Tray and Routing Layout
Cable Sizing and Voltage Drop Calculations
OWT module lighting Layout
Lighting Distribution Board Schedule
Lighting Calculation
Power and Earthing Layouts
Hazardous Area Classification drawings
Cable schedule
Datasheet for motors
Project: New 16” Abiteye - Escravos Pipeline Project for Chevron Nigeria Limited (CNL) Position: Senior Electrical Engineer
Project Brief: Chevron Nigeria Limited wishes to carry out a Detailed Engineering Design
(DED) for the Abiteye Escravos Pipeline Project. This is to support its plan to construct a new 16” Abiteye – Escravos Pipeline and provide a new 12” Oil Pig Launcher at Abiteye and Cathodic protection for its Abiteye – Escravos 12”, 26” and 18” Pipelines along its ROW.
The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical, I&C and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Distribution System to Pigging Facilities
System Studies
Lighting System
Earthing System
Cathodic Protection System for 12”, 16” and 26” Pipelines
Since the project was a brown field project, data gathering was required before the actual project work execution. The approach was to make reference to previous designs and drawings as existing on site, site survey and interviews of relevant personnel on the sites were done to retrieve the needed input for the calculations and production of deliverables. All the relevant files were carefully studied and needed information stored for reference purposes during the actual
design. Pictures of all relevant structures and facilities were taken. Measurements were also taken where applicable, existing equipment specifications were taken from the Nameplates. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures.
The following are the deliverables I produced on the project:
Electrical Design Basis
MCC Single Line Diagram and Loadlist
MCC elevation drawing
Cable Route Layout
Cable Sizing and Voltage Drop Calculations
Outdoor lighting Layout
Lighting Distribution Board Schedule
Lighting Calculation
Earthing Layout
Hzardous Area Classification drawings
CP layouts and details drawings
Datasheets – Transformers, Panel Board
MTO
Project: Escravos Terminal Diesel Storage Project for Chevron Nigeria Limited (CNL) Position: Senior Electrical Engineer
Project Brief: Chevron Nigeria Limited wishes to carry out a Detailed Engineering Design
(DED) for the Escravos Terminal Diesel Storage Project. This is to support its plan to construct a new diesel storage facility, a new filling station and to demolish the existing diesel storage facility including the existing filling station at the Escravos Terminal. A Front End Engineering Design (FEED) was carried out to define the project. The new diesel storage facility shall have three tanks with a total storage capacity of 5 million litres and shall be located beside the drum road.
The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
System Studies
Lighting System
Earthing System
Lightning Protection System
Diesel Pumping System
Since the project was a brown field project, data gathering was required before the actual project work execution. The approach was to make reference to previous designs and drawings as existing on site, site survey and interviews of relevant personnel on the sites were done to retrieve the needed input for the calculations and production of deliverables. All the relevant files were carefully studied and needed information stored for reference purposes during the actual design. Pictures of all relevant structures and facilities were taken. Measurements were also taken where applicable, existing equipment specifications were taken from the Nameplates. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures.
The following are the deliverables I produced on the project:
Electrical Design Basis
Single Line Diagram
Switchroom General Arrangement
Cable Route Layout
Cable Sizing and Voltage Drop Calculations
Indoor and outdoor lighting Layout
Lighting Distribution Board Schedule
Lighting Calculation
Earthing Layout
Hazardous Area Classification drawings
Datasheets – RMU, Transformers, MCC and Motors
Project: Post IFC Verification of Asasa Uplift Pipelines and Etim Asasa Uplift Development
Projects for Mobil Producing Nigeria Unlimited (MPN)
Position: Electrical Engineer
Project Brief: Rapidly declining pressure in the Etim and Asasa fields from the original
discovery pressures of about 2500-2900 psi to the current pressure in the range of 1500 - 2000 psi has resulted in a production decline from the former level of 120 KBD to current 72KBD. Pressure maintenance via gas injection has been identified to mitigate this 15% - 24% per annum production decline.
The EAPM project is designed to transport compressed associated gas via a new pipeline network from the Edop gas compression platform for injection into the Etim and Asasa B reservoirs. High-pressure gas shall be routed via a common manifold on Etim PP to wellhead platforms in Etim and Asasa fields. The gas shall be dehydrated by the existing Edop Dehydration Unit, which is to be restored to operation by another project.
In the future, there will be provisions to divert the gas off the Edop compression platform to the planned EAP NGL plant around Ubit area, to return lean, dry gas for injection via the same network. Consequently, the Edop gas compressors shall supply 175 Mscfd of gas at 2100 psi, while in the future EAP is expected to deliver 241 Mscfd of gas at 2800psi for pressure maintenance of targeted Etim and Asasa B reservoirs. Platform modifications on EADP are required for Etim LA, LB, LC, LD and LP Platforms and on AUP, modifications are required for Asasa VB and EDOP QI Platforms.
The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Verification of IFC packages to applicable codes, standards and specifications
Confirm accuracy and completeness of MTO
Compare MTO with issued PO and material receiving and inspection reports
Prepare TSD for the procurement of identified shortfalls
Revise any document deviations from specifications and standards
Since the project was a brown field project, data gathering was required before the actual project work execution. The approach was to make reference to previous designs and drawings as
existing on site, site survey and interviews of relevant personnel on the sites were done to retrieve the needed input for the calculations and production of deliverables. All the relevant files were carefully studied and needed information stored for reference purposes during the actual design. Pictures of all relevant structures and facilities were taken. Measurements were also taken where applicable, existing equipment specifications were taken from the Nameplates. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures
The Electrical team had the responsibility of reviewing the deliverables produced by the sub-contractor. The following are the activities I carried out on the project:
QA/QC reviews and checks on Hazardous Area Classification
QA/QC reviews and checks on Electrical Lighting Layout
QA/QC reviews and checks on Earthing System Layout
QA/QC reviews and checks on Single Line Diagram
QA/QC reviews and checks on Cable Tray Layout
QA/QC reviews and checks on Power & Control Schematics
Revised Single Line Diagrams, Lighting Panel schedule, Hazardous Area Classification Drawings, lighting layouts and installation details
Prepared MTO and TSD for identified shortfall
Project: Conceptual and FEED of Eastern Area Gas Utilization and Produced Water Disposal
Project for Chevron Nigeria Limited (CNL)
Position: Intermediate Electrical Engineer
Project Brief: Chevron Nigeria Limited (CNL) intends to have a Conceptual Engineering
Design (CED) and a Front End Engineering Design (FEED) performed in support of its plan to execute the Gas Utilization and Produced Water Disposal (EAGU) Projects in its Eastern Area of operations. The project objectives are the elimination of routine gas flaring and the compliance with legislations related with produced water disposal. The locations to be covered in the Conceptual Engineering Design and FEED include Idama, Inda and Robertkiri producing fields. The production from Idama (and thereby from Jokka) is to be routed as a multiphase flow to SPDC owned Ekulama flow station, for processing at Ekulama, The HP gas collection at Robertkiri is to be gathered, and sent to Santa Barbara gas facility operated by SPDC
. The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical, I&C and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Generation and Distribution System
System Studies
Lighting System
Earthing System
Lightning Protection System
Produced Water Disposal System
Since the project was a green field project, data required was basically the environmental conditions and the site survey plan of the proposed facility. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures. The following are the deliverables produced on the project:
Electrical Design Basis
Single Line Diagram
Cable Route Layout
Cable Sizing and Voltage Drop Calculations
Perimeter lighting Layout
Lighting Distribution Board Schedule
Lighting Calculation
Earthing Layout
Datasheets – MCC, Motors, Generators
1.6 Cakasa Nigeria Company Limited, Ikoyi, Lagos
Immediately after the NYSC, I joined Cakasa Nigeria Company Limited as an Electrical Design Engineer in November 2005. Cakasa Nigeria Company Limited is an indigenous engineering design company incorporated in 1974 to provide Engineering, Procurement, Construction and Project Management (EPCM) services to the Nigerian oil and gas Industry. The engineering arm of Cakasa was set up in Lagos in 2002 following an alliance with Fluor Incorporated, US. Cakasa/Fluor alliance is a strategic relationship between two firms specializing in the
engineering, construction operations and maintenance of oil and gas services. Capabilities exist in the engineering group for Downstream (Petroleum Products Depot & Process Industry) and Upstream (Onshore and Offshore) in the following areas:
Conceptual Engineering Design
Front End Engineering Design (FEED)
Detailed Engineering Design
As Built Engineering Services
Follow on Engineering Services
Project Management Services
Consultancy Services
Summary of Some Project Executed/Work Experience:
Project: Detailed Engineering: Sahara Energy Petroleum Product Storage Depot Position: Junior Electrical Engineer
Project Brief: Sahara Energy intends to build a new facility for the storage of Petroleum
Products. The main objective of the project is to transfer Petroleum Products from storage vessels on a ship into the storage tanks on the facility and unload from the storage tanks into tankers via a loading gantry which are installed on the facility. The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Generation and Distribution System
Lighting System
Earthing System
Lightning Protection System
Product Loading and Offloading System
Fire Fighting and Protection System
Since the project was a green field project, data required was basically the environmental conditions and the site survey plan of the proposed facility. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures. The following are the deliverables produced on the project:
Design of Lightning Protection System
Perimeter Lighting Layout
Cable route Layout
Equipment Sizing e.g. generator, switchboard, cables
Earthing Layout and detail drawings
Datasheets for UPS, MCC, Motors and Generators
Cable Schedules
Bulk MTO
Hazardous Area Classification
Project: Sigmund Petroleum Products Depot Position: Junior Electrical Engineer
Project Brief: Sigmund Petroleum intends to build a new facility for the storage of Petroleum
Products. The main objective of the project is to transfer Petroleum Products from storage vessels on a ship into the storage tanks on the facility and unload from the storage tanks into tankers via a loading gantry which are installed on the facility. The Project was executed by a multidisciplinary team of engineers which included Process, Piping, Civil, Mechanical and Electrical Engineers. The Electrical team had the responsibility of providing the following services:
Power Generation and Distribution System
Lighting System
Earthing System
Lightning Protection System
Product Loading and Offloading System
Fire Fighting and Protection System
Since the project was a green field project, data required was basically the environmental conditions and the site survey plan of the proposed facility. The actual project execution work was carried out based on clients’ specifications, Nigerian standards, international standards and company procedures. The following are some of the deliverables I produced on the project:
Lighting Layouts
Power Layouts
Earthing Layouts
Electrical load list
Cable Schedules
Bulk MTO
Hazardous Area Classification
1.7 Software Proficiency
AutoCAD
SKM Power Tool for Windows
Chalmlite
Micro-station
ORCAD Capture
PSPICE
Electronic Test Unit (ETU)
Team Centre Engineering (iMAN), CITADON and EDMS (Laserfische)
Microsoft Office Suite
1.8 Trainings
SKM Power Tools for Windows, Lagos (2011)
Helicopter Underwater Escape and Offshore Survival (HUET), Port Harcourt (2011)
Electrical Control and Programmable Logic Control, Houston (2008)
Ethernet and IP Technology, Houston (2008)
ETU Topside Communication and SCM Data Allocation, Houston (2007)
FMC Engineering Boot Camp – Subsea Engineering, Houston (2007)
Total Quality Management - Trithel International Consulting, Lagos (2006)
Project Management, QA/QC, DCC, HSE - Design Team Limited, Lagos (2005)
2.0 ELECTRICAL AND SUBSEA ENGINEERING DESIGN IN OIL AND GAS INDUSTRY
Before a project kicks off, an agreement has to be signed by both the client and the contractor. Usually the client will make available the Invitation To Bid (ITB) document to the prospective contractors to study. The ITB document clearly defines the scope of work, proposed duration and methodology for the execution of the project among other things. The contractor then responds by putting together their own submission which will indicate to the client how the contract will be executed, the strategies, man-hours, manning, schedule for the project, project organogram, execution plan, hourly rate of personnel, list of projects executed in the past. Most of this information is made available from disciplines to the nominated Proposal Manager who coordinates, compiles and forwards to the proposed client in conjunction with the Business Development Manager of the company (Contractor). Upon award of the contract, after all formalities between the two parties, the company can then mobilize their personnel for the commencement of the project.
Brown Field Project: This is a type of project that deal with an existing facilities, which are to
be upgraded to meet legislation, or life span of the facilities has been reached, and needed to be upgraded.
Green Field Project: This is a new project that is being design from scratch, it does not have
existing facilities and go-by.
2.1 Project Design Phases
The overall system design is divided into two stages: conceptual design and detailed design.
Conceptual design begins at the inception of a project and includes:
Gathering process and load data.
Choosing the most suitable system configuration and bus arrangements for the particular application.
Selecting a power source.
Detailed design comes after the conceptual design and involves:
Developing the one-line diagram.
Performing system studies.
Sizing equipment and feeder systems.
Designing grounding and lighting systems.
Designing system protection
2.2 Basic Design Consideration
The following basic design considerations must be included in the design of all electrical systems.
Safety: Safety of life and preservation of property are the most critical factors that must be
considered when designing an electrical system. Established codes and standards must be followed in the selection of material and equipment to ensure a safe system design. Petroleum production and processing involve flammable liquids and gasses, often at elevated temperatures and pressures. Electrical systems must be designed to prevent accidental ignition of these flammable liquids and gases.
Reliability: The degree of continuity of service required is dependent on the type of process or
operation of the facility. Some facilities can tolerate interruptions, while others cannot. The power source, the electrical equipment, and the protection system should provide the maximum dependability consistent with the facility requirements and justifiable costs.
Maintenance: Maintenance requirements should be considered when designing electrical
systems. A well-maintained system is safer and more reliable. Systems general One-Line Diagram for Electrical Distribution System should be designed to allow maintenance without major interruptions to the process. It is important to consider accessibility and availability (for inspection and repair) when selecting and locating equipment.
Flexibility: Flexibility of the electrical system determines the adaptability to meet varied
requirements during the life of the facility. Voltage levels, equipment ratings, space for additional equipment, and capacity for increased load should be considered.
Simplicity of Operation: Operation should be as simple as possible to meet system
Voltage Regulation: Utilization voltage must be maintained within equipment tolerance limits
under all load conditions. Poor voltage regulation is detrimental to the life and operation of electric equipment.
Cost: While initial costs (CAPEX) are important, the lifetime cost (OPEX) also should be
considered.
Thus the design of the electrical system is executed in line with the scope of work and the design criteria are governed by the following principles:
Persons and plant safety
Environmental conditions of the site
Reliability of supply depending on the importance of service and on the unmanned operations
Reduction of spaces, weights and cost
Ease of management and maintenance
Possibility of future extensions
Standardization and availability of components
2.3 Typical Electrical Deliverables
Typical deliverable prepared for electrical project depending on the scope of work (Conceptual, Basic or FEED and Detail Engineering) are as follows:
Electrical Design Basis
Hazardous Area Classification
Interconnection Diagrams
Schematic/ Wiring Diagrams
Electrical Load List / Load Balance
Electrical Equipment List
Lighting/Power/ Earthing Philosophy and Layout Diagram
AC and DC UPS Specification/Sizing/Datasheet
Single Line Diagrams / Protection & Metering SLD
Electrical Equipment Room Layout
Cable/Cable Tray Routing Layout
Lighting/Power/ Earthing Installation Details
Equipment Data Sheets
Equipment Specifications
Control System Block Diagram
Electrical System Block Diagram
Earthing/ Grounding System/Layout
Package Unit Electrical Specification
Electrical Installation Specification
Cathodic Protection System
Lightning Protection System
Construction Details
Material Take-Off.
2.4 Typical Subsea Controls Engineering Deliverables
Typical deliverables prepared for Subsea Controls project depending on the scope of work (Conceptual, FEED and Detail Engineering) are as follows:
Subsea Controls Facilities Design Basis
Topside Controls Design Basis
Functional Specifications for Subsea Control Products – MCS, SPCU/EPU, ULM, SCM, HPU, UPS, Umbilical etc
HPU Reservoir and accumulator Sizing Calculation
Subsea Umbilical System Arrangement
Subsea and Topside Control System Interface diagram and details
Hydraulic and Electrical schematic subsea control
General Arrangement MCS, HPU, TUTA, SCM, EPU
SCM and SCMMB General arrangement
SCM Sensor schematics
Electrical single line diagram and schematic wiring diagrams – MCS, EPU, ULM, HPU
Umbilical cross section drawing
FAT and EFAT Procedure; Operational Manuals
Hazardous Area Classification among others
Deliverables are generated in accordance with international codes and standards such as IEE, IEEE, IEC, IES, API, NFPA/ANSI (NEC), ISO etc. and Companies design standards such as SHELL DEP, ELF, Mobil, Agip, Chevron specifications etc. depending on the client and project specification. Considering a project with Detailed Engineering Design as the scope of work, the initial phase of the project will be the review of the Electrical Basic Engineering/FEED documents, in particular the electrical design philosophy and the configuration of the electrical power generation and distribution system. The evaluation shall be based on both the economic considerations and potential saving, using the confirmed loads and power system contingencies. Also the skill of operating and maintenance, personnel operational flexibility, unmanned operations, extension possibility and noise limitations are taken into consideration in arriving at a suitable design. Electrical deliverables are generated by using the following software:
Microsoft Office (Word, Excel, Power Point)
AutoCAD
SKM Power Tools for Windows, EDSA or ETAP Software
Micro-Station
PDMS/PDS
Chalmlite
PSPICE
Luxicon
2.5 Interactions Between Disciplines During Project Execution
In view of the peculiar nature of engineering design firms in the oil and gas sector, a similar organization structure is always set up for any project being handled or executed by the company. The Project Team is usually constituted immediately after a project has been awarded to the company and a Project Manager, who in turn reports to the company’s Manager, leads each project. The Project Team usually comprises all of the engineering discipline groups. Each
group produces working documents called deliverables. These deliverables are a product of each group’s specialty; the disciplines that constitute a design team are as follows:
The Process Group would run simulations to obtain working material if the client brought new data. Their results come out in form of deliverables like Line Designation Table (LDT), Process Flow Diagrams (PFD), Piping and Instrument Diagrams, etc. They also size pipes, valves and vessels and determine optimal operating conditions. All information generated is passed on to downstream disciplines. The process group has to liaise with all other groups, who consult it from time-to-time throughout the project. In effect, the process group stays with the project from inception to completion.
The Pipeline group generates alignment sheets, which show how the terrain would affect the pipelines. They settle right-of-way (ROW) matters, conduct test on the soil e.g. soil resistivity tests, acidity tests, and tests to determine the depth of the water table. They also determine when and where supports are necessary along the whole length of the pipelines. The Piping group receives skeletal piping and instrumentation diagrams and line designation tables from the process group. It uses these to produce more detailed piping diagrams like the plot plan. They write pipe specifications i.e. size of pipes.
The Civil/Structural Group determines whether loads need support, to balance them in order to avoid collapse, dampen vibrations, or ensure proper drainage by utilizing the effects of gravity. It also defines the foundation requirements for every structural member.
The Electrical Group sets up the lighting systems, specifies power ratings for motor driven pumps, determines the capacities of generators, etc. The results come out in form of single line diagrams and cable layout diagrams.
The Control Systems group produces the logic diagrams, which provide a readily understood representation of the operation is an extension of the P&ID and will provide added insight and will help define the requirements for safe operation and start-up/shutdown sequencing. Logic diagrams are only produced for complex systems. Cause and effect diagrams and safety charts are all valid alternative formats.
Mechanical Group sizes the vessels and determines the best kinds of material to be used for the vessel and pipes. They also have specialties on pump sizing.
Project Controls Department monitors the progress of the project. They determine the sequence in which activities should be performed in order to identify the critical paths and know which
area to focus greater attention on. They also ensure, to the best of their ability that these time schedules are kept because there could be a slippage and the project would not be finished in the planned time and the risk of being termed inefficient arises. Therefore, a lot of importance is placed on each group finishing their task within the allotted time as this has a lot to do with company reputation.
2.6 Some Typical Electrical Deliverables
Hazardous Area Classification Drawing
Hazardous locations are those locations where fire or explosion hazards may exist due to the presence of flammable gases or vapors, flammable liquids, combustible dust, or ignitible fibers or flyings. Locations within a facility are classified according to the presence of flammable gases or vapors, combustible dusts, or easily ignitable fibers or fittings. Hazardous locations must be identified in order to select proper electrical equipment for these areas. The Procedures are:
Designate the type (Class) of hazard which may be present i.e. gas, dust or fiber.
Class I: If the hazardous material is flammable gas or vapor is present.
Class II: If the hazardous material is combustible dust.
Class III: If easily ignitable fibers of flying are present.
Designate the specific “Group” of the hazardous substance. To do this, references should be made to either National Electrical Code (NEC) or National Fire Protection Association. (NFPA)
Group A- Acetylene
Group B- Hydrogen All in Class I Group C- Ethylene
Group D- Methane Group E- Metal dust
Group F- Coal dust All in Class II Group G- Grain dust
No sub-groups – Fibers Class III
To permit the proper selection of electrical apparatus for areas where flammable gas or vapour risks may arise, area classification drawing(s) are prepared by safety department based on the API RP 500, Classification of locations for electrical installations at Petroleum Facilities, IEC 60079-10 and/or IP Part 15. For the installation of electrical equipment in hazardous areas, IEC
60079-14 is complied with. The process group providing hazardous area data sheets will initiate area classification review activities. Safety and Electrical Group will take ownership of these documents and based on the plot plans and elevations provided by Piping Group, develop the hazardous area layouts and elevation drawings. Electrical equipments are, as far as is reasonably practicable located in the least hazardous area. Control rooms and switch houses are situated in non-hazardous areas. Where electrical equipment has to be installed in hazardous areas, equipment with a type of protection suitable for the relevant zones are selected and specified in accordance with IEC 60079-14. Certification of equipment and materials for duty, rating, hazardous area use, etc. are obtained from recognized National or International testing authorities. Evidence of the appropriate certifications is obtained prior to commitment to purchase.
In Europe, the zone system is used and the classification is in accordance with IEC 60079-10 and IP Part 15. A comparison between the zone and Class systems is depicted below.
FREQUENCY OF
OCCURRENCE DIVISION ZONE SYSTEM Continuous Class I, Div. 1 Zone 0
Intermittent Periodically Class I, Div. 1 Zone 1 Abnormal Conditions Class I, Div. 2 Zone 2
Electrical Cable Schedule
Cable schedule is a spread sheet showing the tag number, number of core, material code, description, length of run and sequential link between one cable to the other etc.
Electrical Load List/ Summary
A load summary is a detailed listing of all loads to be served by the electrical distribution system. It is used to determine the power requirements of a system—in order to properly size power sources, distribution equipment, and feeder systems. The load summary also aids in determining system. Generally, industrial facility loads are a function of the process equipment. A list of loads must be obtained from the process and Mechanical/equipment Engineers and designers
The Electrical Load List is developed based on Electrical Load for Motors and details of other electrical loads, i.e. non-rotating process loads; electrical heaters, instrument, lighting / small power etc. are included on the load list. The Electrical Load List is prepared to determine the total load on each switchboard and is used to determine the rating of generators, transformers, bus-bars, circuit breakers, and other elements of the electrical distribution system. As design evolves Electrical Load List should be updated constantly. It is important to coordinate with other design disciplines to ensure that up-to- date data are used.
Single line Diagram
The Single Line Diagram is produced, from information contained on the P&ID, Plot Plan and Load list, to show overall electrical schematic and configuration of the electrical distribution network. It is used during commissioning and plant operation to show switching and isolation position on the network.
The drawing shall include the following information:
All bus bars with details of the continuous current rating, voltage, frequency, number of phases, switchgear tag number and description
All main switching devices connected to the bus bar with details of their continuous current rating, showing inter trips, interlocks and changeover system as relevant.
A list, by tag number, of all users of electrical power connected to each bus bar, identifying the individual load and circuit type
Representation of each circuit type showing the particular control facilities
Distribution transformer with details of their power and voltage ratings
All main supply cables
All emergency supply facilities
All generation facilities with details of their power and voltage ratings
Power Layouts
Power layouts are produced to show the location of all electrically powered process equipment items, associated auxiliaries and the main cable routing. The drawings uses the plot plan as a background if this is suitable, modified to suit the power layout by removing unnecessary detail. The preferred scale shall be adopted as appropriate but will be subject to the scale of the plot plans and the detail of the work to be carried out. The drawings include the following as a minimum:
A symbol/legend sheet
Location of all electrically driven process equipment items, which will be identified by their Tag numbers
Location of all field mounted electrical power equipment e.g. pushbutton stations, control panels, distribution boards etc.
Provision of cable routes, including main tray and rack runs
Identification of the standard drawing and installation details to be used
Cross reference list to other relevant documents
Lighting Layouts
Lighting Layouts are produced to show the preliminary and indicative location of the luminaries. Lighting study/design is performed using software such as Chalmlite or manual calculation to determine the number of luminaries required to meet the illumination requirement. The drawings shall use the plot plan as backgrounds where possible and if not suitable Electrical Department will develop their own.
The drawings include the following as a minimum:
A symbol/legend sheet
Location of all luminaries together with tag numbers and circuit references.
Location of main junction boxes, distribution boards, and specific items of equipment to be illuminated
Identification of the standard drawings and installation details to be used
Earthing Layouts
The term Earth is defined as the conductive mass of the earth whose potential at any point is conventionally taken as zero. Earthing is essential for personnel safety, prolong insulation, life and for selective isolation of earth faults. The Earthing layout shows the connection of specific equipments and structures to the earth.
Material Take Off (MTO)
Material Take Off can be best defined as the list of materials by quantity and based on a particular design. Taking into consideration the lighting requirement of an area, different types of lighting fittings can be used for illuminating such area. Such fitting may include flood lights fluorescent fittings and decorative fittings. During MTO preparation for such layout are listed to enable purchase of adequate number of fittings for such design.