02 Process Description

PROCESS DESCRIPTION

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Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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PROCESS DESCRPTION The Process Description for different type of installations is given as under. The Process Description covers the description of various surface facilities as envisaged in scope of work. Bidder to note that the details brought out in this document are only indicative for having a general idea of the surface facilities at GGS, ETP, WIP, CTF, GCP, CPP etc. to be covered under Assam Renewal Project. The contractor shall be required to carry out Engineering including generation of PFD, P&ID, Data Sheets, Material and Energy balance etc. based on General Scope of Work, Process Description, Design Basis, Scope of Work, Functional Specifications, Standard Specification, Drawing, Pre engineering survey etc.), Procurement, transportation, Installation, Hook up and Commissioning of various facilities described in the bid on turnkey basis.

GENERAL REQUIREMENTS The sizes, specifications / drawings furnished in this bid package for various facilities are indicative. It is the Contractor’s responsibility to verify all the design / data before proceeding to the detailed design and engineering. Under the scope of this contract, Contractor shall perform all necessary process & pipeline simulations, using HYSYS and PIPESIM or equivalent software and furnish design calculations to the company considering adequate margins as per relevant code / as specified elsewhere in the bid while specifying equipments / instrumentations. Contractor’s responsibility also includes review of safety and operability aspect of the facilities under the scope of this contract. Contractor shall develop detailed process design basis, process flow diagrams, material and energy balance data for different cases indicated in this criteria and design the process and associated utilities systems accordingly. In case, simulation results show higher flow rates or requirements of other facilities/equipment to meet the requirements of installations for some applications, same shall be used for design under the scope of this contract. The design of process and associated utility systems shall be suitably designed for these higher flow rates. Accordingly, Contractor shall develop detailed utility balance and utility flow diagrams. Further, Contractor shall develop detailed Piping and Instrumentation Diagrams, Cause & Effect charts, incorporating all suppliers’ information. Contractor shall prepare data sheets / specifications for all the items (equipments / instruments, etc.).Contractor shall develop and finalize during detailed engineering the routing / distribution of various utilities (namely, flare; Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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closed blow-down, oily water, storm water, contaminated rain water & other drainage systems; hot oil; hot water; fuel gas; instrument air; utility air; service water; raw water; utility water; potable water; cooling water; Inert gas; etc.) indicated in this bid. Contractor shall ensure that design of installations shall meet the requirement of relevant national & international legislations/ rules & regulations/codes/standards/ recommended practices/guidelines. A typical list of applicable legislations/ rules & regulations/codes/standards/ recommended practices/guidelines is included in this Bid package. This, however, cannot be taken as an exhaustive list and various codes as mentioned in various other specifications and standards as well as those applicable as per good engineering practice shall be followed by the Contractor in consultation with company / company’s consultant. Adequate care shall be exercised while developing the existing installation modification requirements with special emphasis towards safety, operability and hook ups. It shall be ensured that the modifications to be implemented do not affect the safety and operability of the existing system at the installations and shall require minimum shutdown. The various process and utility system hook ups shown for the existing installations, if any, included in this Bid package are indicative only. Contractor shall visit the installation, carryout preengineering survey of the existing facilities, verify the hook up points / routing of the lines and finalize all essential aspects of works/modifications including Execution Methodology of all installations in a field provided by company, before leaving the installation. Wherever as-built drawings of existing facilities are not available, Contractor shall develop the existing drawings relevant for the intended modifications to an as built status for the detailed engineering. Special attention shall be given to minimize the shut down time required at each installation and safety for executing the modifications. The Contractor shall provide necessary facilities including temporary modification wherever required for carrying out the works/modifications/hook-up works on existing installations. Contractor shall submit calculations reports / documents / drawings as per list given below for Company’s review and approval. The changes arising due to Company’s review / approval shall be carried out by the Contractor in the design of the facilities under the scope of this contact without any cost / schedule impact. - Process Design Basis & All process / Equipment Sizing calculations - Process Simulation report - PFDs / UFDs & Material balance - Process Calculation Report - P&IDs (1st submission & subsequent revisions) - Equipment list and data sheets - Instrument data sheets -Line list and schedule Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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- Cause & Effect chart - SAFE chart Contractor to note that P& IDs shall be approved for Construction (AFC), only after review and approval of aforesaid calculations / documents/ drawings. Process calculation report shall include sizing calculations for process / utility piping, equipments / vessels, safety / relief valves, control valves, choke valves, orifice plates etc. However, sizing of equipments / instruments for which vendor’s information are required, preliminary calculations shall be submitted initially. Subsequently, the same shall be updated by the Contractor based on vendor’s information and shall be resubmitted for Company’s review and approval. Also hydraulics calculation shall be updated based on final routing / layout etc. Contractor to note that based upon review and approval of aforesaid calculation report / documents / drawings and subject to completion of all safety studies like HAZOP, HAZID, QRA, ALARP, SIL, ESR, EMERA etc. given in the functional specifications for safety studies only, P&IDs shall be “Approved for Construction (AFC)”. Engineering shall also be done for future facilities where ever required. Adequate care shall be exercised while developing the existing installation modification requirement with special emphasis toward safety and operability of the systems at the existing installations.

A.

Group Gathering Stations (GGS): Block Diagram (Indicative) for GGS is given in the bid document. The surface facilities shall vary in quantity and capacity from one GGS to other. However the process shall be the same in all the GGSs. In case of any additional / specific requirement, the same has been indicated in the GGS special requirements as mentioned under “installation wise scope of work and design basis”. Surface facilities of GGS broadly comprises of following, however any equipment / system that is required for safe operation shall also be included in the scope: Pig receivers: The well fluids coming from dedicated field manifold lines of 6” & above sizes shall have pig receivers with pig indicators in the GGS. All incoming lines shall have suitable provisions to monitor pressure & temperature in local as well as in control room. The lines to the inlet manifold shall be branching off before the pig barrel with all necessary isolation valves, NRV’s etc. The details of pig receiver are given in the pipeline scope of work.

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WELLFLUID INLET MANIFOLD Wells (generally within a periphery of 1 Km) will be initially connected to identified Well Fluid Field Manifolds at various suitable locations in the field and from there onwards, one group well fluid line and one test line will run up to respective GGSs. Pipelines from various Self-flow (SF) wells, isolated wells, High Pressure Gas Wells, wells nearby to the GGS (other than those connected to the above well fluid field manifold) will run independently to respective GGSs The Well Fluid Inlet Manifold (LP/Test) will have connections for Well Fluid pipelines and provisions for future connections, as tabulated in installation-wise scope of work. These pipelines shall be connected to inlet manifold consisting of the following headers:



One LP header (all GGSs) (except GGS-V Lakhmani, where HP header is also required and Borholla & Koraghat where VHP headers are also required) One Test header (all GGSs except Geleki GGS-II & Lakwa GGS-VIII, where two Test Headers are required )

The well fluid inlet manifold shall be provided with all connections (present + future) for hook up of incoming pipelines from various field manifolds and individual wells directly as tabulated in installation-wise scope of work. Each of these incoming pipelines shall have a battery limit isolation valve, chemistry sampling points, suitable provisions to monitor pressure and temperature in local as well as in control room along with suitable venting, draining & flushing provisions. Each incoming pipeline to the manifold shall be connected to the headers with NRV and isolation valves. Provision for connecting future incoming pipelines shall be provided at the well fluid inlet manifold with NRV, isolation valves and blind flanges. It shall be noted that the design pressure rating is changing from 96 kg/cm2 g (incoming well fluid pipelines) to 16 kg/cm2 g (well fluid inlet manifold headers) downstream of the last isolation valves on the incoming well fluid pipelines connecting the manifold headers. Accordingly, Pressure Safety Valves (two numbers designed for block discharge case for three-phase fluid set at 16 kg/cm2 g) to be provided in each of the well fluid inlet manifold headers (including Test Header) for overpressure relief / safety protection. The well fluid inlet manifold shall be having headers as mentioned above to divert the well fluid in either of the separation trains depending upon the process requirement. All well fluid inlet manifold headers shall have chemistry sampling points, suitable provisions to monitor pressure and temperature in local as well as in control room along with suitable chemical (PPD/DMF) injection, isolation, venting, draining & flushing provisions. Independent Pressure Indications through transmitter for emergency alarms at high-high/low-low pressure shall be provided in each of the inlet manifold headers. Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Pre-Heater: Pre heaters shall be provided to heat up the incoming well fluid before same is sent to bath heaters/separators. Individual pre-heaters shall be provided for Test, LP & HP headers to raise the temperature of well fluid to 40oC. The preheaters shall be shell & tube type exchangers having hot water from the outlet of heater treaters in the shell side & inlet well fluid in the tube side. The maximum pressure drop across Pre-Heater should not be more than 0.5 Kg/cm2 at maximum flow condition. The capacities of the heaters will be as per the design basis provided. The pre-heaters shall be provided with complete instrumentation for pressure and temperature monitoring in local as well as in control room and safety devices for monitoring and smooth operation. Incoming well fluid from wells through pipelines is estimated to arrive at a pressure of 3 -15 kg/cm2g at the inlet manifold. The average well fluid arrival temperature of 15 Deg C (minimum in winter) and 40 Deg C (maximum in summer) is to be considered for the processing facilities design. However, control and shutdown valves should not be present in the well-fluid circuit. Pre-heaters shall have common inlet and outlet manifolds for both tube side fluid and shell side fluid as mentioned above. Each pre-heater shall also have a bypass arrangement for maintenance purpose with suitable isolation, sampling, flushing, venting and draining provisions for both tube side and shell side fluids. Insulation for heat conservation (personal protection if applicable) shall be provided for both tube-side and shell-side fluids for each heat exchanger, as required. Pre-Heaters are to be symmetrically placed to have equal distribution of flow.

Indirect Water Bath Heater (IDBH): Individual IDBH shall be provided for LP and HP headers for heating well Fluids up to 60o C for better separation of well fluid in the separators. The Indirect water bath heaters shall be as per the functional specifications enclosed with this document. The maximum pressure drop across Bath-Heater should not be more than 0.5 Kg/cm2 at maximum flow condition. Bypass arrangement shall be provided across IDBH so that the well fluid from pre-heaters can be routed directly to production separators in case of process requirement. Provisions to monitor inlet and outlet pressure, temperatures shall be provided in both local & remote modes. Suitable meters shall be provided for measuring fuel gas consumption. The required nos. of IDBH modules for individual GGSs are given in the respective Scope of Work.

Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Production Separators (HP/LP/TEST): Production Separators shall be two phase Vertical vessel. The well fluid from VHP / HP headers shall be taken into VHP / HP Separators (wherever provided) after heating the well fluid in Preheater/ Preheater & indirect water bath heaters respectively. The LP separation train shall be receiving well fluid from LP header via Pre-heater and IDBH. At location where VHP / HP separator is provided, LP separator shall also receive liquid from VHP / HP separator. The Liquid from LP Separation trains shall be routed to heater treater. The gas from VHP Separation module shall be routed to Gas Lift network and HP separation module shall be routed to the Sales Grid. The LP gas from LP separation module shall be routed to suction of LP compression module which are located either within the same premises or GCP in field. Suitable measurement system for Liquid & gas from separators shall be provided. The VHP / HP & LP separation trains shall be as per functional specs enclosed with this document. The required nos. of Production Separation modules for individual GGSs are given in the respective Design basis. The maximum pressure drop across Separators (LP/Test taken together) shall not be more than 0.5 Kg/cm2g at maximum flow condition. The LP separators shall be provided with complete instrumentation for pressure & level monitoring & control (split-range between main & flare for pressure control) along with temperature & flow monitoring in local as well as in control room. The separators shall also be provided with complete instrumentation for emergency alarms (high-high pressure, low-low pressure, high-high / low-low level) and safety valves (fire case) for safe and smooth operation. Each separator shall also have arrangement for suitable isolation, sampling, flushing, venting and draining provisions. LP Separators are to be symmetrically placed to have equal distribution of flow Pressure & level gauges (local indication) should cover the entire range (high-high to low-low). Test separator: Generally One no of test separation module shall be provided as detailed in the Scope of Work of GGS, However in GGS-VIII, Lakwa and GGS-II, Geleki , two trains of LP Separator shall be provided. The well fluid from Test headers shall be taken into Test Separators after heating the well fluid in pre heater. The oil from Test separation module shall be routed to heater treater module and the gas shall be sent to the suction header of LP compressor. However for cases where Test separator is operated in HP mode, liquid shall go to LP separator and gas shall go to the sales grid. Liquid Dispatch quantity along with Water Cut is required to be measured with Coriolis Mass Flow Meter. Suitable sampling provision shall be provided for water cut analysis in the liquid.

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Water cut meter shall measure total mass flow as well as water percent (volume %) and emulsion density such that total water flow rate can be established in the well fluid flow. The Test separation train shall be as per functional specs enclosed with this document. The required nos. of Test Separation modules for individual GGS’s are given in the respective Design basis /Scope of Work. Heater treater: Heater treaters modules shall be provided to separate out gas, oil & water from the emulsion received from LP & Test separator modules by thermo-chemicalelectrical process. The Produced Water separated in the Heater-Treater shall be routed through pre heater to effluent/produced water/wash tanks. Treated Crude oil from Heater Treater shall go to Oil storage tanks. Oil separated at the HT should have BS & W less than 0.2% w/w and separated Water should have oil content less than 125 ppm. The outlet gas shall be routed to fuel gas system of respective GGS [except, GGS-II, Geleki; where it will be directly fed to LP compressor for further utilsation. Heater treaters are to be symmetrically placed to have equal distribution of flow. Heater Treater shall have suitable bypass arrangement with common inlet & outlet manifolds as described above. Heating requirement for heater treaters shall be met by burning fuel gas sourced from FG system of respective GGS [except, GGS-II, Geleki; where it will be met by hot oil based heat exchanger system]. Heater portion is required for heating emulsion from up to 75 degree C for better separation of oil & water in the heater treaters. The maximum heater treater operating temperature shall be 75 degree C. Demulsifier (presently @50 -120 ppmv) will be dosed in the inlet to the heater treaters for emulsion breaking. Pour point depressant i.e. PPD (presently @ 200 ppm) will be dosed in the outlet to the heater treaters for preventing congealing in crude oil storage tanks. Suitable dosing facility shall be provided for proper mixing of Demulsifier / PPD. In addition to liquid from each LP separator , Heater Treater shall also receive liquid from Crude Oil (Tank Bottom) Re-circulation Pump, Skimmed Oil Return Pump (effluent tank), Oil from Slop Oil Tank Pump of ETP, Flare KOD Pump, CBD Pump, Compressor KODs, other KODs/Scrubbers at GGS, Condensate Return Pump of GCP. . Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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The Heater treater module shall be designed as per functional specs enclosed with this document. The required no of Heater treaters modules for individual GGSs shall be as per the respective Scope of work Storage tanks: Existing Storage Tanks for Emulsion, Treated Crude Oil and Effluent are to be retained with following philosophy & Activity: •

• • • • •

Electronic FMCW Radar Type Tank Gauging System is to be Installed & Commissioned on Crude Oil Storage Tanks and Guide Wave Radar Type on Effluent Storage Tanks. Local Mechanical Level Indicator is to be provided and same to be calibrated. Breather Valves and required safety Devices are to be replaced . Dykes of Tank farm are to be developed as per latest codes & practices. Fire fighting facilities along with foam system, sprinkler system is to be provided as per fire fighting scope of work Painting of all the existing storage tanks

The total storage capacity envisaged for a typical GGS is for 3 days of oil production and one day effluent production. In order to meet this requirement additional storage tanks shall be provided, equipped with all the safety & monitoring facilities including proper dykes where ever required as per the GGS Scope of Work. The tanks for additional storage capacity(to meet three days storage) shall be in Turnkey EPC Contractor’s scope. CRUDE OIL/ EFFLUENT STORAGE TANKS Existing crude oil/effluent storage tanks shall be retained and utilized for storing crude oil/ effluent as per the status given elsewhere in the bid document. It shall be noted that the existing 90 m3 capacity oil tanks shall be dedicated for storing test liquids. In addition to the existing tanks mentioned above, additional crude oil/effluent storage tanks shall be provided as per installation-wise scope of work/design basis so as to store oil production for three days and effluent production for one day. This storage tanks consisting of existing tanks and new tanks will be equally distributed between Production, Settling and Dispatch tanks. The following works shall be carried out for existing oil / effluent storage tanks: 1. Replacement of all safety valves, breather valves; isolation valves/flanges/piping etc. for inlet/outlet/drain; man-hole covers, gauging & sampling hatch, etc. & any other items, as required. 2. Provision for monitoring pressure, level and temperature (multi-point for average temp.) in local as well as in control room shall be installed.

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3.

4. 5. 6. 7. 8.

Electronic FMCW radar type tank gauging system on Crude Oil Storage Tanks and guide wave radar type tank gauging system on Effluent Storage Tanks. Independent provision for emergency alarm on high-high & low-low level shall also be installed. Dykes of tank area is to be developed as per latest codes & practices Fire fighting facilities along with foam system, sprinkler system is to be provided as per fire fighting scope of work External Painting of all the existing storage tanks Any other works to make it compatible with new crude oil/effluent storage tanks.

New crude oil/effluent storage tanks shall be constructed as per installationwise scope of work/design basis. Tanks shall have safety valves, breather valves and vents for over-pressure/under-pressure (vacuum) protection and overflow line for preventing over-filling. Provision for monitoring pressure, level and temperature (multi-point for average temp.) in local as well as in control room shall be installed. Independent provision for emergency alarm on highhigh & low-low level shall also be installed. Suitable provisions for inlet, outlet, isolation, draining, flushing, bypass, re-circulation, man-holes (at least two), gauging & sampling hatch, prevention of flash-back/bird nest in atmospheric connections, lightning arrester etc. shall be installed. Common inlet & outlet manifolds as described above shall be provided.

Tanks shall conform to DGMS/OISD/API/ASME/ASTM and other national/international codes/standards/ recommended practices/guidelines. Contractor shall design the entire system accordingly. Crude Oil recirculation pumps: Oil recirculation pumps shall be provided to re-cycle the off - spec crude back to heater treaters for further improvement in quality. These pumps shall be of centrifugal type. The nos. of pumps shall be two (1 no. in operation + 1 no. standby). Crude oil dispatch pumps: Pumps shall be provided to dispatch entire treated daily oil production to the field CTF. The pumps shall be suitable to pump out single day’s production in 20 hours as given in the installation-wise scope of work/design basis. Common inlet & outlet manifolds as described above shall be provided. Two no.s centrifugal type pump as API 610 latest edition (One operating and one installed spare) shall be provided.

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Dispatch rate along with water cut is required to be measured with Coriolis Mass Flow Meter. Water cut meter shall measure total mass flow as well as water percent (volume %) and liquid density such that total water flow rate can be established in the liquid flow. Contractor shall have complete responsibility for water cut meter and their integration with other facilities on respective installations. NRV at outlet with local & remote discharge pressure/ start/ stop/ running indication shall be provided. Suitable provisions should exist for isolation, draining, flushing, sampling, bypass and pump starting/stopping from control room/locally. The provision for monitoring of Pump “On/Off” Status in control room is required to be provided Pumps shall conform to DGMS/OISD/API/ASME/ASTM and other national/international codes/standards/ recommended practices/guidelines. Contractor shall design the entire system accordingly. CRUDE OIL START- UP (MAIN OIL LINE RESTART) PUMPS One reciprocating / positive displacement type start up pump shall be provided for re-start (start-up) of pumping considering congealing of oil pipeline. Common inlet & outlet manifolds as described above shall be provided. Suitable provisions for isolation, sampling, flushing, venting and draining shall also be provided. Numbers: One (One operating and no spare) Drive: Flame-proof Electric Motor Type: Reciprocating/ positive displacement Code : API 674 Rated Capacity: 10 m3/hr (Minimum) Differential Pressure: To suit pipeline pressure requirement for de-choking/ decongealing (rated at 60 kg/cm2g) Pumping Temperature, 0C: 50 Design Temperature, 0C: 65 Pump shall be complete with suction Strainer, pressure indication, NRV at outlet, safety valve, pulsation dampeners at suction & discharge, local & remote discharge pressure/ start/ stop/ running indication shall be provided. Suitable provisions should exist for isolation, draining, flushing, bypass and pump starting/stopping from control room/locally. Pumps shall conform to DGMS/OISD/API/ASME/ASTM and other national/international codes/standards/ recommended practices/guidelines. Contractor shall design the entire system accordingly.

Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Effluent dispatch pumps: Pumps shall be provided to dispatch entire daily effluent production to the ETP. The pumps shall be suitable to pump out single day production in 12 hours as given in the design basis. • • •

No. of Pumps shall be 02 nos. (01 no. in operation+01 no. stand by). The provision for monitoring of Pump “On/Off” Status in control room is required to be provided. Dispatch quantity is required to be measured with Magnetic Flow Meter.

The following will be the outgoing fluid lines from GGS: • • • • •

Treated Crude Oil to CTF. Effluent to ETP. Gas from LP Gas Feeder Lines to GCP or LP Compressor Discharge to GCP (where ever LP Compressors are located at GGS) Gas Lift lines to the intermediate Gas Lift field manifolds. Storm Water Drainage Line Pig launching facilities for outgoing lines: Design Basis for GGS shall be followed for pig launching facilities given in bid document. Pig launching facility shall be provided in each outgoing Oil line having diameter 6” and above. Pig launching facility shall be located within GGS premises. Interconnecting lines between all the facilities in integrated complexes shall be in the scope of Turnkey EPC Contractor

Pig receiving facilities for incoming lines: The following shall be the incoming lines to the GGS: •

The incoming well fluid lines from well manifolds to GGS as mentioned in the pipeline scope. Design Basis for GGS shall be followed for pig receiving facilities and specifications of pig receiver facilities are given in bid document. Pig receiver facility shall be provided in each incoming Oil/ well fluid line, having diameter 6” and above. Pig receiving facility shall be located within GGS premises Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Gas lift system Gas lift manifold shall be provided in GGS to collect high pressure gas received from field GCP thru’ a dedicated pipeline (size as per installation-wise scope of work) and send it to either gas lift field manifolds or to individual wells thru’ pipelines as per installation-wise & pipeline scope of work/design basis. Each gas pipeline outgoing from GGS to gas lift Field Manifolds or to individual wells shall be provided with orifice metering system within the GGS premises for both continuous as well as intermittent gas lift systems within the battery limit of GGS. Well Injection Cycle is to be mapped in the DCS. Further, DCS shall monitor online flow rates of individual gas injection stream and should perform comparison of online flow rates vis-à-vis mapped injection cycles in real time mode. Gas lift manifold as well as all outgoing lines shall have suitable provisions for pressure & temperature monitoring in local as well as in control room along with suitable provisions for isolation, venting, draining, flushing, sampling etc. No. & size of lift gas : As per pipeline scope of work/ design basis injectors No. & size of lift gas 2 (two), As per pipeline scope of work/ design headers basis Operating Pressure : 80 kg/cm2g (max) Design Pressure 96 kg/cm2 g : (ANSI 600 Class pressure rating) Operating Temperature : 45-55 Design temperature : 65 0C

Box Flare system: New flare system (ground flare) including sub & main flare headers, flare KOD, flare KOD pumps (for transferring liquid to heater treater inlet), water seal drum, FG purging, remote- main & pilot-igniters, box flare, on-line monitoring of flare emissions etc. shall be provided. Hydrocarbon discharge from flare control valves, blow-down valves, safety valves shall be received in the flare system. New flare system shall be designed for the total gas capacity of the plant. One common flare system shall be provided for integrated complexes. Flare Measurement System – Thermal Mass Flow Type / Ultrasonic Type is to be installed & commissioned. Box flare modules shall be designed as per functional specifications. The maximum backpressure shall not be more than 0.2 kg/cm2g in the flare system. The overall design criteria for Flare KOD & its Pumps are illustrated below (other components of flare system are as per DGMS/CPCB/OISD/API/ASME/ASTM and other national/international codes/standards/ recommended practices/guidelines): Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Process Utilities The utilities are described in details in the utilities section. However some specific utilities applicable for the group gathering stations are as follows: FUEL GAS SYSTEM Fuel Gas conditioning skid for CPP and integrated complex having GGS Fuel Gas conditioning skid consisting of Preheater, Scrubber, Super heater, associated instruments, Filter etc shall be provided for fuel gas requirement of CPP. Dehydrated gas from Gas dehydration unit at outlet of HP compressors at GCP shall be source of fuel gas system at respective location. Fuel gas header will be electrically traced and insulated if required to prevent liquid condensation. For black start, a separate line shall be connected with all the outgoing gas lift pipelines from GCP to GGS/GL manifold at field in such a way that gas can be drawn from the gas lift network. It is therefore imperative that no NRVs are present in the GL network except at the well head. In view of the case when gas lift network pressure falls below 40 kg/cm2g at any point of time , a provision to be made by contractor to source LP gas from separators at 3.5-5 Kg/cm2 and feed the gas to existing gas driven HP compressors through bypass line and run the same for meeting the fuel gas requirement . Once the CPP is started, the new electrical motor driven compressors shall be run to restore normal mode.

Fuel gas conditioning system as a minimum, shall comprise of the following: a) Fuel gas KOD b) Fuel gas pre heaters (Electrical) c) Fuel gas scrubber d) Fuel gas filter-coalescer and e) Fuel gas super heaters (Electrical) Super heater shall be designed for 20 °C super heat of fuel gas. Instrumentation control for for level, temperature and pressure control to be provided . Preheater and superheaters shall be provided with Temperature switches for trip at higher temperature. PCV in the skid shall control the output gas pressure to fuel gas header. Fuel Gas Conditioning system for GGS / CTF Fuel Gas Conditioning system for GGS / CTF consisting of filters , scrubbers ,volume bottle etc. shall be provided for each GGS to meet the entire fuel gas requirement of the installation as described above. Source of fuel gas system will be from the heater treater gas outlet with back-up from LP gas separator/scrubber outlet..

Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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For black start at GGS , a separate line shall be connected with all the outgoing gas pipelines from GGS to GCP in such a way that gas can be drawn from the feeder/collector pipeline. It is therefore imperative that no NRVs are present in the pipeline except at the GCP manifold. Also, it has to be ensured that gas pipeline pressure does not fall below 1.5 kg/cm2g at any point of time. Fuel gas composition shall be taken same as LP gas composition given in design basis. Liquid carryover during sourcing the low temperature gas shall be taken care in design basis.

Fuel gas system shall conform to DGMS/OISD/API/ASME/ASTM and other national/international codes/standards/ recommended practices/guidelines. Contractor shall design the entire system accordingly.

Blow down An underground Closed Blow Down (CBD) system with blow down vessel is provided to collect all hydrocarbon liquid drains. CBD pumps are provided to pump out CBD liquid. Liquid from Flare CBD is normally routed to Heater Treater or to the existing crude oil storage tanks. Chemical Dosing System Demulsifier Demulsifier dosing tanks and dosing pumps shall be provided to inject demulsifier into the well fluid at the inlet of LP / Test Separators and liquid at the inlet of Heater Treater. Dedicated demulsifier dosing pumps shall be provided for LP well fluid / Test fluid and at Heater treater inlet to meet the requirement as mentioned in bid document. No. of Pumps shall be 02 nos. for each i.e. LP well fluid / Test fluid and Heater treater inlet (01 no. in operation + 01 no. stand by). PPD PPD storage tank, dosing vessel and dosing pumps alongwith heating arrangement shall be provided to inject PPD into the oil outlet of Heater Treater. Dedicated PPD dosing pump shall be provided for Heater treater Oil outlet. No. of Pumps shall be 02 nos. for Heater treater outlet (01 no. in operation + 01 no. stand by).

Hot Oil system A new dedicated hot oil system shall be provided for GGS-II, Geleki to recover waste heat of flue Gas of Turbines at CPP, Geleki and same shall be used for Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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heating requirement of IDBH / Heater Treater and Reboiler of GDUs. Contractor shall firm up the heat load requirement and design the entire system accordingly considering CPP-Geleki Gas Turbine Exhausts for Waste Heat Recovery. The new hot oil system (1+1) basis, as a minimum, shall comprise the following: a) Hot oil expansion vessel b) Hot oil transfer pump c) Hot oil circulating pumps d) Hot oil filters e) Waste heat exchangers (at CPP) f) Hot oil dump cooler PCVs,TCvs and flow switches shall ensure that required heat is available to the units and minimum flow is maintained through the WHRU Hot oil system shall conform to DGMS/OISD/API/ASME/ASTM and other national/international codes/standards/ recommended practices/guidelines. Contractor shall design the entire system accordingly.

UTILITIES (Common to all installations) o

Raw & Service (Utility) Water storage & distribution system consisting of bore-wells, bore-well pumps, raw water storage tanks, service water pumps, water softener package etc. Except, hose stations (utility water for cleaning/washing), all other water requirement/systems like potable water, hot water, cooling water, flare (seal drum), safety shower & eyewash etc. will be fed by soft water. One common raw & service water system for integrated complexes.

o

Potable (drinking) water storage & distribution system consisting of R.O. plant fed by softened water, potable water storage tanks, potable water pumps etc. One common potable water system for integrated complexes.

o

Gas-fired Waste Incineration system (hazardous as well as non-hazardous)

o

Diesel storage & transfer facilities for fire water pump and emergency generator (DG set) consisting of diesel storage tanks for receipt from tankers, diesel transfer pumps (1+1), diesel filters (if required) etc.

o

Safety shower & eyewash systems

o

POL storage & handling systems as per Mechanical Scope of Work & Design Basis

o

Oily Water Sewerage (OWS) system consisting of sub & main OWS headers, OWS pit/ sump, Oily Water Separator, OWS-oil transfer pumps (for transferring liquid to CBD vessel), OWS-water pumps (for transferring water to storm water drainage) etc. as per Civil Scope of Work & Design Basis.

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o

Contaminated Rain Water Sewerage (CRWS) system consisting of sub & main CRWS headers, CRWS pit/ sump, Oily Water Separator, OWS-oil transfer pumps (for transferring liquid to CBD vessel), OWS-water pumps (for transferring water to storm water drainage) etc. as per Civil Scope of Work & Design Basis.

o

Storm Water Drainage (SWD) system consisting of drain channels, SWD pit for collection, SWD pumps for discharging clean water outside the installation into nearby river thru’ SWD pipelines etc. as per Civil Scope of Work & Design Basis.

o

Fire and Gas detection system consisting of IR-point type HC gas detectors, UV-IR combination fire detectors, smoke detectors, fusible plugs, manual call points, etc. along with PLC based F&G panel and portable HC gas detectors, portable oxygen monitors etc. as per Instrumentation Scope of Work & Design Basis

o

Instrumentation, control & monitoring systems, including all field instruments and separate high integrity programmable systems for process Control (DCS/ PCS {PC-based PLC system}) and Safety shutdowns (SD-PLC) as per Instrumentation Scope of Work & Design Basis

o

Fire Fighting system consisting of Fire Water System – FW tanks, pumps, network, hydrants, monitors, fixed water spray system (deluge, sprinklers) etc.; Fixed Foam System – Foam Concentrate Tanks, Fixed Piping system, Foam Pourers, Foam Monitors etc.; Fixed Clean Agent Fire Extinguishing Systems; First Aid Fire Fighting Equipment etc. as per Fire Fighting Scope of Work & Design Basis

o

Electrical systems consisting of electric motors for pumps & compressors etc.; emergency power generation (DG set); normal & emergency power transmission and distribution systems; un-interrupted power supply (UPS);capacitor banks; high mast & plant lighting; communication & paging system; lightning arrester; air conditioners &fire alarm system as per Electrical Scope of Work & Design Basis

o

Material handling systems consisting of chain pulley blocks, monorails, hoists, battery operated fork lift, hand operated material carrying cart etc. as per Mechanical Scope of Work & Design Basis

o

All associated Civil Works like jungle clearance, earth-filling, site-grading & land-scaping; construction of security gates, watch towers, internal roads, buildings, sheds, laboratory and testing equipment etc. as per Civil Scope of Work & Design Basis B.

EFFLUENT TREATMENT PLANT (ETP):

Block Diagram for typical ETP is given in the bid document. The surface facilities shall vary in quantity and capacity from one ETP to other. In case of any additional / specific requirement, the same has been indicated in the ETP

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special requirements as mentioned under “installation wise scope of work and design basis”. Surface facilities of ETP broadly comprises of following, however any equipment / system that is required for safe shall also be included in the scope: 1.0

Inlet Manifold: The inlet manifold shall be having suitable connections from various GGS/CTF .The produced water / effluent from inlet manifold shall be routed to Wash Tanks of ETP. The header shall be provided with isolation valves and injection point for De-oiler.

2.0

Wash Tank: The produced water / effluent shall be collected in Wash Tanks from where the free floating oil shall be recovered by proper skimming facility / suitable oil recovery system and routed to the Slop Oil Tank. Guided Wave Radar Type Tank gauging and safety system shall be provided. Sludge from wash tanks shall be routed to sludge drying bed by sludge transfer system.

3.0

Effluent transfer pump: The effluent from wash tanks shall be transferred to Holding Tank by suitable Effluent transfer pumps.

4.0

Effluent holding tank: The effluent water shall be collected in effluent holding tanks from where effluent water shall be routed to Hydro-cyclone module via low shear feed pump.

5.0

Low Shear Feed Pump: The effluent from Holding Tank shall be routed to Hydro-cyclone via Low Shear Feed Pumps. The Low Shear Feed Pump shall be as per functional specs for Effluent Treatment module enclosed with this document

6.0

Hydro-cyclone: Hydro-cyclones shall be provided to separate out oil from the effluent received through Low Shear Feed Pumps. Treated effluent from Hydrocyclone shall be routed to filtration system via filter feed pump. The recovered Oil from Hydro-cyclone shall be routed to Slop Oil Tank. The Effluent treatment module shall be as per functional specs enclosed with this document. The Hydro-cyclones shall have proper back wash arrangement to achieve the desired parameters as a part of Effluent treatment module.

7.0

Filtration System: The effluent from Hydro cyclones shall be routed to Filtration system. The filtered effluent shall be routed to treated effluent water tanks. Suitable backwash system shall be provided in the filtration system and backwash dirty water shall be routed to OWS pit. The Filter Feed Pump shall be as per functional specs for Effluent Treatment module enclosed with this document.

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8.0

Treated Effluent Tank: Treated effluent shall be stored in this tank for onward transfer to WIP or Disposal well.

9.0

Effluent Transfer/ Disposal Pumps: Effluent transfer pumps shall be provided to transfer treated effluent to remote WIP and Effluent Disposal pumps shall be provided to transfer treated effluent to Effluent disposal wells as described in the Scope of Work. These pumps shall be provided for continuous operations. • No. of Pumps should be minimum 02 nos.( 01 no. in operation + 01 no. stand by). • The provision for monitoring of Pump “On/Off” Status in control room is required to be provided. • Dispatch quantity shall be measured through suitable Flow Meters

10.0

Chemical Treatment: Facility to be provided for storage, dosing and pumping and handling of chemicals such as De-oiler , Alum, Polyelectrolyte ,Corrosion Inhibitor,Bactericide,Sodium Hypo chloride and Oxygen Scavenger that are commonly used for treatment of effluent before subsurface disposal and any other chemical that is included to meet process requirement .

11.0

Slop Oil Tank: The recovered oil from Hydro-cyclone shall be collected in a Slop Oil Tank along with recovered oil from wash tank, indirect heating coil in each tank shall be provided to avoid congealing of the recovered oil. The slop oil tanks shall be provided with all safety system. Portable Boiler shall also be additionally provided for heating as specified in ETP Scope of Work.

12.0

Slop Oil Transfer Pumps: The recovered oil shall be routed to the inlet of Heater-Treater / the nearest GGS oil tank via Slop Oil Transfer pumps. • No. of Pumps should be 02 nos. (01 no. in operation +01 no. standby). • Dispatch quantity shall be measured through suitable flow meter.

13.0

Sludge Drying Bed : Wet Sludge from slop oil tanks / wash tanks drain, sludge pit of OWS system and other recovered sludge shall be collected in sludge drying beds of adequate sizes. Total 3 no. of sludge drying beds shall be provided. Sludge from sludge drying bed shall be transferred to Sludge Lagoon of adequate sizes. The collected sludge shall be allowed to dry in the natural process in Sludge Lagoon. The sludge cake will then be removed and disposed off for land filling etc. Provision shall be kept for draining liquid from sludge drying bed to OWS pit. All tank drains i.e. Wash Tank, Treated Effluent Storage Tank etc. shall be routed to Sludge Drying Bed. Proper flushing arrangement shall be provided in all out let lines from Tanks to Sludge drying pit.

14.0

OWS System: Oily Water Sewer system with OWS Pit shall be provided. The skimmed residual foreign materials shall be transferred to the Sludge pit .The effluent / drain water shall be recycled back to Wash tank via pumps (1 no. in operation + 1 no. stand by)

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15.0

Utilities: Service Water System, Drinking Water System, Plant & instrument Air system and all other utilities shall be as defined else were in the bid document

C.

WATER INJECTION PLANT (WIP): Block Diagram for WIP is given in the bid document. The surface facilities shall vary in quantity and capacity from one WIP to other. In case of any additional / specific requirement, the same has been indicated in the WIP special requirements as mentioned under “installation wise scope of work and design basis”. Surface facilities of WIP broadly comprises of following, however any equipment / system that is required for safe operation and shutdown but not specifically identified here shall also be included in the scope: Incoming lines: The treated effluent water from ETP(s) and Raw water from River/ Bore well shall be coming by lines of different sizes as per details mentioned in the pipeline scope of work. Inlet Manifold: The inlet manifold shall be having suitable connections to receive fluid from different ETPs. Separate train will be provided for River / Bore well water. The raw water / treated effluent from inlet manifold shall be routed to respective raw water / treated effluent storage tanks. The Inlet manifold shall be provided with isolation valves and spare connections (min. 02 nos.) for future provision. Raw Water Treatment Facility: - Suitable treatment facility will be provided for treatment of raw water received from River / borewell before it is fed to Raw Water Storage Tank. Raw water/Treated Effluent Storage Tank: The raw water / treated effluent shall be collected in respective Raw water / Treated effluent Storage Tanks. Construction of new Treated effluent storage tanks are covered in the scope of work for ETP. Filter Feed Pumps: Raw water / treated effluent shall be routed to Pressure Sand Filters via Filter Feed Pumps. These pumps shall be provided for continuous operations. The Filter Feed Pump module shall be as per functional specs enclosed with this document. The provision for monitoring of Pump On/off Status in control room is required to be provided. Pumps shall be kept in shed. Pressure Sand Filters: The raw water/treated effluent shall be routed to Pressure Sand Filters via Filter Feed Pumps. The outlet of Pressure Sand Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Filters shall be routed to Dual Media Filters. PLC based Auto back wash system on filter differential pressure high shall be provided along with air scouring system. The Pressure Sand Filters module shall be as per functional specs enclosed with this document Dual Media Filters: Filtered water from Pressure Sand filter shall be routed to Dual Media Filter modules to meet the desired outlet parameters. The outlet from Dual Media Filter Module shall be routed to Treated Water Storage Tank for injection purpose. PLC based Auto back wash system on filter differential pressure high shall be provided along with air scouring system. The Dual Media Filter module shall be as per functional specs enclosed with this document. Filter Back Wash Pump: The water from treated water storage tank shall be used for back washing of Pressure sand and Dual Media filters. The Filter Back Wash Pump module shall be as per functional specs enclosed with this document The provision for monitoring of Pump On/off Status in control room is required to be provided. Chemical Treatment: Injection of chemicals in a WIP would depend upon the process finalized. Indicated injection point is mentioned here but actual injection point to be finalized during Detailed Engineering. Sodium Hypo chlorite solution shall be dosed at the inlet of Raw water/Treated Effluent Storage Tanks. Bactericide, Sodium Sulphite, Scale Inhibitor, KCl & Corrosion Inhibitor solution shall be dosed at the suction manifold of Booster pumps. Chemical dosing system which shall be located inside shed comprises of chemical dosing tanks , chemical store room and dosing pumps as detailed elsewhere in the bid document. The system shall be equipped with EOT for lifting and shifting of the chemicals from chemical store room to the individual dosing tanks for dosing solution preparation. Chemical storage area shall be provided with adequate protection to guard against damage to the chemicals from the surroundings. Provision for Rota-meters shall be provided for each of the chemicals at their respective injection points for measurement of dosing rates. The Chemical Tanks & Dosing Pump Module shall be as per functional specs enclosed with this document Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Treated Water Storage Tanks: The outlet of Dual Media Filter modules shall be routed to Treated water Storage Tanks Booster Pumps: The treated water from Treated Water Storage Tanks shall be routed to the suction manifold of Booster Pump Module where different chemical treatment prior to injection shall be carried out. The discharge of Booster Pump Module shall be routed to suction manifold of Main Injection Pump module. The Booster Pump module shall be as per functional specs enclosed with this document. The provision for monitoring of Pump On/off Status in control room is required to be provided. Main Water Injection Pumps: Main Water Injection pump Module shall receive treated water from outlet of Booster Pump Module. The discharge of Main Water Injection pump Module shall be routed to water Injection manifold for further injection into the respective injectors. These pumps shall be provided for continuous operations. • No. of Pumps should be as per Design data Basis for WIP • The provision for monitoring of Pump “On/Off” Status in control room is required to be provided. • Adequate Shed is to be provided • Pump tripping for low level in treated water tank and high vibration . Suitable EOT is to be provided for removal/ reinstallation of pumps/motors for maintenance. Injection Manifolds: The discharge of Main Water Injection Pump shall be routed to Water Injection Manifolds located at WIP end. From Water Injection Manifolds, Water will be routed through feeder lines to wells or group of wells at cluster by branching out as per the pipeline architecture attached in the Pipeline Scope of work. Manifolds for Cluster wells shall be as per pipeline scope of work. The following are water injection metering requirements: 1. Orifice Meter / Ventury Meter at Water Injection Main line at the Manifold located in the WIP Battery Limit 2. Orifice Meter / Ventury Meter at Individual lines from the injection header located in the WIP Battery Limit. 3. Clamp on type ultrasonic flow meter to test individual wells. Vendor will provide three sets of Clamp on type ultrasonic flow meter per WIP. Utilities: Various utilities viz. Instrument Air, Plant Air, potable water, service water etc. required shall be provided for plant operation as detailed else were in the bid document. Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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D.

Central Tank Farm (CTF): Block Diagram for CTF is given in the bid document. The surface facilities shall vary in quantity and capacity from one CTF to other. However the process shall be the same in all the CTFs. In case of any additional /specific requirement, the same has been indicated in the CTF special requirements as mentioned under “installation wise scope of work and design basis”. Surface facilities of CTF broadly comprises of following, however any equipment / system that is required for safe operation and shutdown but not specifically identified here shall also be included in the scope: Pig receivers: The treated crude oil coming from various GGSs through pipelines of 6” & above shall have pig receivers with Pig Indicators in the CTF. The lines to the incoming manifold shall be branching off before the pig barrel with all necessary isolation valves, NRVs, pig indicator, etc. Provisions for pressure and temperature monitoring (Local & Control Room) shall be made. The details of pig receiver are given in the pipeline scope of work Incoming Manifold: The existing incoming manifold shall be dismantled and a new manifold shall be constructed. The incoming manifold shall be having suitable connections from various pipelines coming from GGSs .The incoming manifold shall be having different headers to divert the crude oil in the available tanks of CTF depending upon the process requirement. Each line to the manifold shall be connected to these headers with isolation valves and spare connections (min. 03 nos.) for future provision etc. All incoming lines shall be having provisions for pressure and temperature monitoring through local as well as remote instruments. All incoming lines shall be having Chemistry Sampling points as per relevant standards. Coriolis type mass Flow Meter shall be provided in all inlet lines coming to the incoming manifold. Intermediate Manifold: This manifold is meant for interconnecting the tanks for crude transfer from one tank to another, connecting the tank to Polishing heater treater for processing off-spec crude oil at CTF etc. The existing Intermediate Manifold shall be dismantled and a new one shall be constructed. This new manifold shall be provided with remote operated valves with manual override system, and spare connections (min. 03 nos.) for future provision etc. and provision for pressure and temperature monitoring through local as well as remote instruments. Dispatch Manifold: This manifold is meant for connecting the ready for dispatch tank to Pump House for final dispatch to CTF/Oil India etc. The existing dispatch manifold shall be dismantled and a new one shall be constructed. This new manifold shall be provided with remote operated valves Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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with manual override system, and spare connections (min. 03 nos.) for future provision etc. and provision for pressure and temperature monitoring through local as well as remote instruments. Storage Tanks: Existing Storage Tanks shall be retained. All the pipelines and valves from manifold to tanks and vice versa shall be replaced with new ones. •

• • • • •

Electronic FMCW Radar Type Tank Gauging System is to be Installed & Commissioned on Treated Crude Oil Storage Tanks and Guide Wave Radar Type on Effluent Storage Tanks. Local Mechanical Level Indicator is to be provided. Breather Valves and required safety Devices are to be replaced and latest safety devices required for Storage tanks are to be installed. Dykes of Tank farm are to be developed as per latest codes & practices of OISD and other relevant standards. Fire fighting facilities along with foam system, sprinkler system is to be provided as per fire fighting scope of work Painting of all the existing storage tanks

The dyke of each tank shall be provided with suitable OWS/SWD system. Fire fighting facilities along with foam system/ sprinkler system is to be provided as per OISD standards. The details are mentioned in scope of Fire Fighting as given else were in the bid document. Polishing Heater-Treater: Polishing Heater treaters shall be provided at Lakwa CTF to separate out oil & water from the off-spec crude oil. Treated oil shall be routed to storage tank in CTF and Effluent shall be routed to Effluent tank in nearby installation. Two nos. of heater treater from Lakwa GGS-IX shall be removed and refurbished by contractor in all respect to make it functional for it’s intended purpose and shall be installed at Lakwa CTF with control system, electrical system, Burner management system with remote ignition system, internal fuel gas consumption meter, safety devices, internals, as specific. The contractor shall be required to fully overhaul the company supplied Heater Treaters to make them fully functional for intended application. Heat recovery is not envisaged from polishing heater treaters. The contractor may take a stock of status by fully acquainting themselves about the condition and extent of revamping work required for these units during pre-bid site survey.

Hot Oil Based Heat Exchanger for CTF, Geleki Hot Oil Based Heat Exchanger for CTF, Geleki shall be provided for supply of hot water to various storage tanks for heating of crude oil.

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Crude Oil Dispatch Pumps: Crude oil dispatch pumps shall be provided to dispatch entire oil production to the next CTF i.e. from Lakwa CTF and Geleki CTF to Moran CTF and Jorhat CTF respectively. No. of Pumps shall be maximum 02 nos. (01 no. in operation + 01 no. standby) as Main Pumps and 02 nos. Restart pumps (Reciprocating type) to keep Flow line alive when main pumps are not pumping. The provision for monitoring of Pump “On/Off” Status in control room is required to be provided. Dispatch quantity along with Water Cut is required to be measured with Coriolis Mass Flow Meter At Lakwa & Geleki CTF and Ultrasonic Flow Meter with Meter Prover at Moran & Jorhat CTF. Auto Sampling System as per API Chapter 8.2 and Sample Chemistry checking system as per API Chapter 10. In addition to this, system for proving Auto Sampler shall also be provided. Effluent Dispatch Pumps: Effluent dispatch pumps of adjacent GGS i.e. Lakwa GGS I and Geleki GGS II respectively shall be used for transfer of effluent of Lakwa and Geleki CTF to respective ETP’s. No. of Pumps should be 02 nos. (01 no. in operation + 01 no. standby). The provision for monitoring of Pump On off Status in control room is required to be provided. Dispatch quantity is required to be measured with Magnetic Flow Meter

Pig launching facilities for outlet lines : The following shall be the treated crude oil outgoing lines from Lakwa & Moran CTF: • The treated crude oil from oil storage tanks of Lakwa and Geleki CTF shall be sent to respective Moran& Jorhat CTF. • The effluent from effluent storage tank shall be sent to respective installation by pipeline. Design Basis for CTF shall be followed for pig launching facilities and specifications of pig launching facilities are given in bid document. Pig launching facility shall be provided in each Oil outgoing line having diameter 6” or more. Pig Launching facility shall be located with in CTF premises. The interconnecting lines between two facilities in integrated complexes shall be in the scope of Turnkey EPC Contractor. Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Utilities Service Water System, Drinking Water System, Plant & Instrument Air system shall be as defined in the bid document E.

GAS COMPRESSION PLANT (GCP) The following shall be the typical surface facilities in a Gas Compressor Plant. The surface facilities shall vary in quantity and capacity from one GCP to other. In case any additional /specific requirement, the same has been indicated in the GCP special requirements. Surface facilities of GCP broadly comprises of following, however any equipment / system that is required for safe operation and shutdown but not specifically identified here shall also be included in the scope: Pig receivers: The LP / MP / Sales gas coming from GGSs having lines of above 6” & 8” sizes shall have pig receivers with Pig Indicators in the GCP. The lines to the inlet manifold shall be branching off before the pig barrel with all necessary isolation valves, NRV’s etc. The details of pig receiver are given in the pipeline scope of work Inlet Manifold: The inlet manifold shall be having suitable connections for the lines coming from various GGSs. The inlet manifold shall be having LP, MP & HP headers to divert the gas to LP, MP, HP Compressors depending upon the process requirement .Each line to the manifold shall be connected to these headers with isolation valves and spare connections (min. 03 nos.) for future provision etc. All incoming lines shall be having provisions for pressure and temperature monitoring through local as well remote instruments. LP / MP Compressor Module: LP Gas from various GGS received at GCP shall be compressed by LP compressors modules, details for which are given in Scope of Work and Design Basis. MP Compression Module shall be installed for Sales Gas Supply lines or Gas transportation from one field to another field. HP Compressor Module: Compressed Gas from LP Compressor as well as return lean gas from sales grid shall be routed to HP Compressor modules, details of which are given in scope of work and design basis of GCP. Compressed HP gas will be sent to Gas dehydration Unit before sending the gas to Gas Lift / Injection Network.

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Gas Dehydration units: The Compressed HP gas from the outlet of Gas Lift Compressor shall be routed to Gas Dehydration Module prior to sending it to Gas Lift Network and fuel gas conditioning skid so as to remove water from the Gas to prevent corrosion ,hydrate formation and condensation of water in the line . Dehydrated gas shall be designed accordingly to meet the Outlet Gas Specifications as mentioned in Design Basis. The required nos. of TEG based Gas Dehydration modules for individual GCPs are given in the respective Design basis. Inlet and outlet Manifolds for GDU are also required with isolation valves and spare connections (min. 02 nos.) for future provision etc. TEG (tri-ethylene glycol) shall be used as dehydration media. Gas shall flow from the bottom upward and the glycol falls from the top. The gas and glycol comes in intimate contact. The lean glycol introduced from the top shall fall gradually on the packing and the gas bubbles through the glycol on the packing wherein the lean glycol absorbs water. The dry gas shall come out of the contractor. Thereafter it shall pass through a gas/glycol exchanger where the high temperature of glycol aids in increasing gas temperature. Thereafter the gas shall go to the reflux condenser which is also an exchanger and the water vapor from the glycol still again increases the temperature of the gas and the water thus condensed is sent to the reflux drum and to the still as a reflux. The gas thereafter shall pass through an overhead scrubber where the liquid droplets shall be scrubbed and the dry gas is dispatched to the trunk line. The pressure in the contractor shall be controlled through a PCV located downstream of the overhead scrubber. The rich glycol that comes out of the contactor shall go to the glycol flash drum to remove dissolved hydrocarbon. The gas thus released is sent to flare KOD. To remove any solid particles and liquid hydrocarbon, the rich glycol is thereafter passed through the cartridge and active carbon filters. Thereafter the temperature of the rich glycol shall be increased by passing it through a glycol/glycol exchanger, wherein the hot lean glycol helps in increasing the temperatures of the rich glycol.

Glycol Regeneration Thereafter the rich glycol enters the still of the reboiler. The reboiler is an atmospheric vessel and operates at about 200 0C. The glycol is heated with the help of hot oil. The hot water vapor leaves the top of the still and is sent to the reflux condenser. A part of the condensed water is sent to the still as a reflux from the reflux drum. The lean glycol overflows a weir and drops to the storage tank through a packed column.

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In order to achieve higher glycol concentration (98.5%) stripping gas may be used in the storage tank.. The regenerated glycol shall be stored in the storage tank and shall be pumped to the glycol/glycol exchanger to reduce temperature through a booster pump. Thereafter the re-circulation pump shall increase the pressure and the lean glycol shall be sent to the dehydration tower. Before entering the tower it shall pass through a gas/glycol exchanger wherein the temperature of the lean glycol further drops and the temperature of the sales gas increase. The dryness of the gas shall be measured. Dehydrated gas shall supply gas to fuel gas conditioning skid and the Gas lift network. Separate meters shall be provided for measuring the gas inlet to Fuel gas skid and Gas lift network. Gas dehydration unit shall be as per functional specification provided in the bid. Gas Lift Manifold: The HP (Gas Lift) compressor outlet gas shall be routed to Gas Lift Manifold. The branch lines from this manifold shall be routed to respective GGS’s to cater to the gas lift requirement of wells surrounding those GGS’s. Metering facility shall be provided in each finger of the manifold. Gas Lift Manifold shall also be provided with isolation valves and spare connections (min. 03 nos.) for future provision etc. Gas Grid Manifold: The existing Gas Grid Manifold located at GCP shall be dismantled and new manifold shall be constructed. This manifold shall receive gas from MP compressor discharge header of GCP and MP Gas feeder lines coming from various GGS/fields. The outlet from this manifold shall be routed to GAIL / other installations. Metering facilities shall be provided in each inlet lines of manifold and custody meter shall be provided in outlet header of manifold. The following shall be the outgoing pipelines from GCP: The MP gas from outlet of Gas Grid Manifold to GAIL. The HP gas from outlet of HP compressors shall be sent to respective GGS’s through Injection Manifold at GCP. Design Basis for GCP shall be followed for pig launching facilities and drawing of pig launching facilities are given in bid document. Pig Launching facility shall be provided in each outgoing line having diameter 6” or more. Pig Launching facility shall be located within GCP premises.

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F.

CAPTIVE POWER PLANT: Captive Power Plant shall have heavy duty industrial open cycle gas turbine/ Generator Sets to generate electrical power at 11KV and the same is distributed to various installations in Assam Oil & Gas Field. At CPP, Geleki, an exhaust mounted Waste Heat Recovery Exchanger to be provided with necessary bypass diverter valves, actuators and control system. On the basis of process requirement the sizing of the exchangers to be finalized during detailed engineering. Waste Heat recovery Units are required for CPP at Geleki only. The power requirement shall be finalized after the detailed engineering. Basis of the number and capacities of Gas turbine / generators is provided in the detailed scope of work of Captive Power Plant. The combination and size of the turbine generator sets shall be worked out on the basis of capacity of industrial type gas turbine/generator sets available worldwide with proven track record. The power to be distributed to various installations is through new underground cables and existing / new overhead lines as detailed in the scope of work of CPP. Provision of minimum two spare feeders to be kept for future expansion at each CPP in addition to the feeders as brought out in Scope of Work. The tentative location of new CPPs have been identified at GGS-IX, Lakwa, Integrated Complex, Geleki and existing location of CPP, Rudrasagar. The new CPP will be commissioned first and then the existing CPP’s shall be dismantled. CPP shall comprise of the following equipment/ system. However any equipment / system that is required for safe operation & shut down but not specifically identified here shall also be included in the scope. Gas Turbine The gas turbines are required for power generation. Turbines shall be industrial type. The combination and size of the turbine generator sets shall be worked out on the basis of capacity availability of industrial type gas turbine/generator sets worldwide with proven track record. Fuel Gas System for CPP Fuel Gas shall be available from Gas Lift Network at Pressure 40 – 80 Kg/cm2. It is the responsibility of Contractor to provide the Fuel Gas Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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Conditioning Skid meeting Quality, and Quantity requirement for all the Turbine Packages in the CPP as per the OEM guidelines. Individual isolation valves to be provided in case more than one turbine is to be fed from fuel gas header. The fuel gas shall also be made available from Gas lift Network at pressure 40-80 kg/cm2 during power shutdown conditions (when the gas turbines are not running). This is to enable starting of the turbine/generator set after plant power shutdown. Waste Heat Recovery Unit As part of the Plant waste heat recovery system, a Waste Heat Exchanger(WHE) will be fitted into the exhaust of each Turbine Exhaust System. The sizing of the exchanger shall be finalized during detailed engineering.The flue gas from power generators shall be used to heat the thermal fluid.The flue gas can be released directly to atmosphere or through waste heat exchanger. Even if diverter valves are closed , flue gas can pass and therefore minimum flow of oil is maintained through WHE to avoid charring of Hot Oil The Exchanger shall be designed to meet TEMA, ASME and API standards. The tube bundle shall be designed to avoid any dead areas or areas where tubes are partially filled and ensure the WHRE tubes are capable of running dry in the event of a malfunction, whilst still operating at full exhaust flow. Provisions shall be made in the Exchanger to facilitate ease of cleaning. Electrical Generator Generating units shall be suitable for continuous operation at rated output. The rated output of the generator shall exceed the rated output of the gas turbine prime mover over the ambient temperature range as specified in the project documents. Reduction Gear Box A suitable heavy duty multi shaft skid mounted load gear box between GT and the alternator. Black Start DG Set of suitable capacity for Black start system is to be provided. It should be capable of handling all Gas turbine auxiliary loads, Instrument air, water lifting, cooling and indoor/outdoor Lighting system. The DG Set power will be fed to MCC/PMCC and back-fed to 11KV bus where it will be synchronized with GT power. DG breakers with battery back up, battery charger, Diesel storage tanks of suitable capacity, pipeline, filters and pumps are to be provided.

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The fuel gas for starting the Gas turbines during black start shall be made available from the Gas lift network at pressure 40-80 kg/cm2 to meet the total gas turbine/generator load. Plant Fire and Gas system The plant fire and gas system shall consist of all the relevant detection and protection systems as per current standard. Adequate number of Gas, Flame and Thermal detectors shall be provided. Control Room /Switchgear Room An air conditioned control room will be constructed to accommodate 1. Unit(Turbine) Control Panel 2. Generator Control Panel including MAVR, Synchronizer and protection relays 3. Plant Fire & Gas panel 4. Instrumentation and control system for WHRU system. 5. Load shedding panel 6. Parallel redundant UPS along with servo regulated bypass 7. Battery Chargers for Control and as well as for critical lighting 8. Display & control system for SCADA (Electrical System) A separate Air conditioned Switch Gear room will be constructed to accommodate power control center, motor control center and 11kv indoor switch gears ,UPS distribution boards, DC Distribution boards etc. Suitable fire detection, alarm and suppression systems for control room and switchgear rooms will be provided and to be integrated with the plant fire and gas system. Air Compressor/Dryer Air compressor with suitable air dryer to be provided to meet the air requirements of the plant such as Gas Turbine skid, WHRU,DG set, HVAC system of Control Room and Switchgear Room etc. Air Conditioning System Air Conditioning system with humidity control of suitable capacity is to be provided to meet the requirements of the plant for Control Room, Switchgear Room, and Stores etc. G.

UTILITIES : The following shall be the typical utilities for an installation/complex. In case any additional /specific requirements, the same will be indicated in the installation’s special requirements

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PROCESS UTILITIES & OTHERS IN TURNKEY EPC CONTRACTOR’s SCOPE: 1.0

Utility Specifications: The plant shall have dedicated utility systems as required. The battery limit operating and design conditions of the utilities in the unit shall be as under and as defined in the bid package. The source / system of utilities are as indicated below: Power

: CAPTIVE Power Plant / ASEB/D.G/G.G

Emergency Power

: Emergency Power:

Water

: Tube Well (2 nos.) for service water (40 M3/Hr each). Typical water analysis for surrounding water is given in the bid package.

Steam

: Not required.

Instrument Air

: Electric Motor driven Air Compressors of air/water cooled type with air drier (heatless type). ( 1W+1S ) If required for compressor jacket cooling, vendor to provide cooling water system .

UPS System

: Separate for instrumentation control system & SCADA system.

1 no. DG Set

Plant Air

:

Inert Gas

: In cylinders for purging.

Fuel Gas

: Associated gas at 1.0-2.0 Kg/cm2 from fuel from gas header.

Fire system

fighting : As per relevant OISD standards, TAC manual and other applicable safety standards / statutory guidelines.

Potable water Diesel system

2.0

Compressors shall be common for instrument and plant air. Requirement shall be met from instrument air compressor discharge line.

:

Bore well water shall be used after processing in R.O. Plant. Drinking water shall be taken from R.O. Plant.

: Diesel storage tanks and diesel transfer pumps.

FLARE, BLOWDOWN & DRAINS: Chemical disposal

water : Common sewer water drain pit.

Flare system

: As per Central, State

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guidelines such as DGMS / OISD 106, 118 / CPCB / API 521 etc. Vent system from : As per requirement. tank / separators Blow system 3.0

down : There shall be one closed blow down vessel. All process drains shall be routed to blow down vessel.

FLARE SYSTEM: Box flare system shall be provided for safe disposal of flammable toxic or corrosive vapors discharged by pressure relief system of various units. Various safety valve / blow down valve discharges/ excess gas from production & test separators/ gas scrubber/, knock out drums etc are connected to two phase flare header. In case pressure exceeds set safety valve pressure in any process vessel, the escaped gas/ oil water emulsion from the vessels shall go to flare header. In case any liquid particles are carried over or any condensation of gas takes place, liquid shall get collected in the flare gas knock out drum. The gas shall flow to box flare and shall be flared there. All discharges to flare header are to be kept sloping towards the flare gas knock out drum. The liquid collected in the KOD shall be pumped to crude oil storage tanks by 2 nos of KOD pumps.(1 working + 1 standby) Flame front generator, pilot burner, etc are envisaged as part of the box flare system package. Gases from fuel gas header shall also be used as fuel in the pilot burner. The Flare header shall be taken on trestles which shall be suitably spaced. The quantity of gas flared shall be metered using suitable flow meter like ultrasonic flow meter / thermal mass flow meter in control room. Contractor to carryout flare load calculations for all cases covering blocked discharge, fire case and depressurization / blow down. All calculations including flare header sizing is to be submitted for company review and approval. Flare system design shall be as per latest API RP 521. Turnkey EPC Contractor shall also comply to other latest applicable statutory/central/state guidelines such as OMR-1984/CPCB/OISD-106,118 etc on environmental standards. In case of any conflict the more stringent requirement shall be followed.

4.0

CLOSED BLOWDOWN SYSTEM: Adequate Closed Blow Down system based on the design basis of the proposed installation is to be provided. Liquid from gas scrubber, flare KOD, main oil storage tanks, effluent tanks also shall be drained here The closed blow down facility shall include blow down vessel with vent to atmosphere, Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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transfer pumps , removable steam coil etc as a minimum. The instrumentation required for smooth operation of the blow down system is to be provided. 5.0

CHEMICAL WATER COLLECTION AND DISPOSAL SYSTEM: An underground closed drain header is envisaged for receiving chemical water discharges from various safety valves, chemical dosing tanks, raw and treated water tanks etc. as indicated in the bid document for further disposal to the storm water drainage system.

6.0

STORM WATER DRAINAGE SYSTEM: Suitable storm water drainage system to be designed by Turnkey EPC Contractor after carrying out contour survey etc. Direction of storm water discharge shall be as per natural drainage of the GGS plot. To prevent water logging of the surrounding areas of the plant, cross drainage shall be provided to allow water to drain off as per natural drainage of the site based on overall topography of the area. At all point of time i.e. at the time of landfilling, Construction or post construction, natural drainage shall be obtained. Two (2) nos. suitable storm water disposal pumps along with associated piping, fitting, strainer etc. shall be provided to dispose the collected storm water meeting statutory requirement. The discharge of the pump shall be hooked up with the storm water drainage pipeline, (Details provided elsewhere in the bid). Contractor is advised to select disposal point in a way to avoid back flow to installation.

7.0

POL Storage & Handling System POL storage & handling system consisting of : a) One no. of diesel storage tank of 5 days plant requirement storage capacity, diesel transfer pumps with its associated instrumentation, piping and valves shall be provided. Diesel shall be supplied from diesel storage tank to emergency generator, Fire water pump etc. b) Storage space and material handling facilities for lubricant barrels.

8.0

SERVICE WATER SYSTEM: Two numbers of dedicated bore well of 40 M3/hr capacity each shall be the source of service water. The water softener shall be supplied to treat raw water for meeting service water requirements of process units and water supply for buildings. Provision of one number of over ground service water storage tank with suitable pumps has been kept to meet plant requirements as indicated in the bid document. For drinking purpose, one reverse osmosis plant (R.O Plant) shall be provided to purify the service water to potable water. The potable water shall be stored in an over ground drinking water storage tank with suitable pumps to meet the Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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potable water requirement of the plant. Provision shall also be provided to fill the potable water storage tank through road tankers. 9.0

ELECTRICAL SYSTEM: Power supply is to be taken either directly or through overhead lines coming from Captive Power Plant wherever feasible. At other remote locations, power shall be drawn from ASEB network or Gas Generators. Charali GGS will be equipped with Diesel Genarator set to take care of peak load inplace of emergency load. One number emergency diesel generator set, as detailed in the bid document is to be provided by the contractor to meet power requirement during normal operation / power failure. The emergency DG set shall provide power for the minimum load of Process & Control Systems, lighting, air compressors, UPS and DC critical supply, Communication System, instrumentation, etc. Details of power supply scheme are provided in the bid document. Provision for momentary running of emergency generator set with grid supply and automatic change over from Gen set supply to grid supply shall be provided to avoid interruption of power during switching over from Generator sets supply to grid supply. •

10.0

The Emergency Generator sets should be self contained full fledged package with all the accessories required for their smooth operation and control. SCADA SYSTEM: SCADA system shall be provided for remote monitoring of critical process parameters of the plant. The detailed list of process parameters to be monitored is mentioned elsewhere in the bid document. The SCADA system will be operated from the control room. However the scope of Turnkey EPC Contractor shall be limited to providing isolated signals in RTU cabinets to be placed in control room. The uninterrupted power required for SCADA shall be met through a dedicated UPS for SCADA system. The Scope of contractor shall also include interfacing with SCADA contractor in this regard.

11.0

COMMUNICATION SYSTEM: As per scope of work and design basis of communication in Vol II.

12.0

BUILDING: A double storied building consisting of Administrative block, Control block & electrical substation shall be provided. The Control room shall be on ground floor. The toughened glass windows shall be provided on three sides of the control room. The access to the control room is to be of double door type to avoid dust particles inside the control room The Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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block shall have aesthetic look with proper ventilation. For control room suitable Air Conditioners are to be provided, details for which are indicated in the bid document. The administrative block shall consist of Installation In-charge’s Room, Mechanical In-charge’s room, Electrical In-charge’s room ,Staff room, Store cum tool room, Chemistry lab, Instrumentation lab, Conference room, dining hall cum pantry room, Bath/Toilet on individual floors shall be provided. The block shall have aesthetic look with proper ventilation. Air conditioners are to be provided for all the rooms of In-charges & conference room, details for which are indicated in the bid document. All the rooms shall be suitably furnished with furniture & fixtures as detailed in the document. 13.0

ACCOMMODATION Suitable accommodation shall be provided for personnel of CISF and ONGC. The accommodation for CISF shall consist of dormitory, pantry, toilet & bath rooms. The accommodation for ONGC persons shall be having four bedded two bedded rooms and single bedded room with attached toilet/bathrooms, one dining/pantry room besides common toilet and bath rooms as per civil scope of work for GGS. All the rooms shall be suitably furnished with furniture & fixtures as detailed in the document. Both the accommodations shall be independent buildings, adequately spaced and close to the entry gate for ease of operations.

14.0

INSTRUMENTATION SYSTEM: General Control : Mode of plant operation

:

Control Room

Type of control

:

DCS System / PLC system

Final control elements

:

Control Valve (pneumatic)

Instrument power source (For Final control element) Power source for Instrumentation

:

Dry Instrument air.

:

110V AC UPS /24 V DC.

Control room location with UPS : system located near Control room. Flow integrators/ totalizers / recorders : on Process streams.

Control room on Ground Floor As per Functional Specs.

DCS / PLC system shall be provided for alarm monitoring, data acquisition and controlling facilities for the plant long with operating work stations. The details control system has been defined in the bid document Onshore Engineering Services, New Delhi Project : Assam Renewal Project Job No.: OESG-AA-07-001

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The design and installation of instruments shall be generally in accordance with ISI/API recommended practices and other applicable standards like ISI, IBR etc. The material specifications and practices shall, in general, confirm to appropriate ASTM or equivalent standards. All standards, code of practices to be followed up shall be of the latest edition. 15.0

INSTRUMENT / Plant AIR SYSTEM: Min. Two reciprocating air compressors (One operating + one standby) are required for meeting instrument air and plant air (process and utility) requirements. The system shall also include instrument air receiver, utility air receiver, pre-filters ,dryers and After filters. The compressor air shall be stored in Utility air receiver. From there a part of air shall go to air dryer, where drying shall take place. There shall be two dryer ,one shall be in operation and other one standby and it shall changeover after certain no of hours. There after air shall be stored in a instrument air receiver vessel. The flow and pressure of this receiver shall be maintained by a PCV. In case of low pressure alarm the standby compressor shall be started. Instrument air receiver of five cubic meters capacity (minimum) / back up of 30 minutes which ever is more shall be provided.

16.0

GAS DETECTION SYSTEM: LEL gas detection system shall be provided in this plant and for that suitable IR type fixed gas detectors shall be installed at various critical locations including separator area, Oil storage tanks area, effluent storage area ,OWS pit, Flare area etc. The gas detection panel shall be provided in control room. The Turnkey EPC Contractor shall design and implement Hydrocarbon gas detection system as per existing OISD-189, TAC guidelines and other applicable standards indicated in the bid document. The exact no. of detectors and locations shall be decided during detailed engineering. The F&G panel (completely wired) for housing the monitor/controller for gas detectors with relays, hooters, and annunciation with location indication shall be provided in the control room. The 02 spare channels per module to be provided. The gas detection system shall give low gas alarm and High gas alarms in the gas detectors monitor . Minimum 3 Nos. of DGMS approved portable hydrocarbon gas detectors with recharging facility / system of power supply 220 V AC & calibration kit shall also be provided. One no. of calibration kit complete with calibration gas cylinders for gas detector calibration is to be provided. All equipment should be DGMS approved.

17.0

FIRE & SMOKE DETECTION SYSTEM:

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Suitable fire and smoke detection system for control room and field area are to be provided with receiver instruments in control room with separate alarm and plant FSD linking facility as per norms. The Turnkey EPC Contractor shall design and implement fire & smoke detection system as per OISD, TAC guidelines and other applicable standards indicated in the bid document. The location and type of fire detection system to be provided is as follows:Smoke detectors Fixed type Thermal detector Infrared type fire detection system Fusible plug loop Manual call points

Control room , MCC room /switchgear room and in all closed rooms Control room , MCC room /switchgear room and in all closed rooms Separator area, Oil storage & transfer area. Oil Storage tanks Exit doors of the buildings, Gas Compressor area, separator area , oil storage tank area.

The fire, gas and smoke detector layout shall cover the entire plant area following NFPA-72 standards. The contractor will develop the detailed layout and same will be finalized during detailed engineering. All the alarms for fire/gas/smoke detection system will lead to the annunciation in the Fire & gas panel to be placed in Control room. The receiver instruments will be placed in the control room. The annunciation system will have an interfacing with the paging system of the plant with different tone for various detections as detailed in the bid document. The fire signal/alarm shall also be provided in fire water pump house and fire station. All equipment shall be DGMS approved.

18.0

EMERGENCY SHUT DOWN SYSTEM (ESD) ESD shall be provided to take immediate action on account of serious abnormality in the plant. ESD switches shall be provided at control room, Gas compressor area, Separator area and oil storage area. ESD switches will activate the alarm at the Central Control room, MCC / switch gear room, In-charge room / office, Control room, fire fighting pump house and fire station. On receiving the alarm control room will operate the emergency shut down system.

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It will close the SDV at the inlet of the separators, knock out drums, trip all rotating equipments including gas compressors. It will also open the flare PCV at the discharge of the Gas compressor suction KOD and discharge KOD. ESD will be activated manually from specified locations. 19.0

FIRE SHUT DOWN SYSTEM (FSD) Fire shut down system (FSD) shall have linking with fire detection and alarm system. FSD switches shall be provided at Central Control room, office, Gas compressor area, Separator area and oil storage tank area. On activation, FSD shall close SDV at the inlet of Separators. It will trip all rotating equipments including gas compressors. It will also open the flare PCV at the Gas compressor suction KOD and discharge KOD. For protecting the control room provision of discharging of clean agents in the control room to be kept with prior alarm, flash beacon at the entry. Suitable storage area for fire retarding /extinguishing agent (clean type) shall be provided. In addition to above, fusible plug loop is also to be provided in the oil storage tank area for auto start of water sprinklers on the storage tanks. FSD shall get activated automatically by the fire detector and also manually by operating the switches from the specified point mentioned above.

20.0

FIRE FIGHTING FACILITIES: The Turnkey EPC Contractor shall design and implement fire fighting system as per existing OISD standards, TAC guidelines and other applicable standards indicated in the bid document. The details of fire fighting system are given in the bid document.

21.0

INCINERATOR: Electrical Type / Gas Fired Type Incinerator for handing oily solid waste at the rate of 10 Kg/hr is to be provided in proposed installation.

22.0

LIGHTNING ARRESTOR: Suitable lightning arrestor shall be provided at a suitable location in the installation as per relevant standards & codes. Details are provided in electrical scope of work and Design Basis.

23.0

HIGH MAST LIGHTING SYSTEM:

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High mast lighting system shall be provided for entire complex. The details are given in the Electrical scope of work. The number and locations of the high mast lighting system for each installation shall be finalized during detailed engineering. 24.0

SIGN/DISPLAY BOARDS: Necessary sign/display boards shall be provided in all installations to meet statutory requirement. Display board shall include PFD, Layout and display of environment & safety parameters

25.0 All pumps, compressors and heavy equipment to be placed in such a way that they are accessible by crane for shifting / repairs

.

26.0 Chemical Transfer Pump: One no. of Barrel mounted Pneumatic driven Chemical Transfer Pump for each chemical shall be provided, to transfer Chemicals from standard Barrels to Chemical Tanks in 10 mins.

27.0 Chemical Storage & Handling System: Chemical Storage facility for 10 days storage shall be provided. Mechanized chemical handling system (like EOT, SILO etc.) for loading & unloading of chemicals with minimum manual interface shall be provided. 28.0 CCTV Closed circuit TV (CCTV) shall be provided in process and strategic areas for montoring and surveillance at all GGS. Display monitor of CCTV cameras shall be made available in security room and Control rooms

29.0 Electrically operated Security barrier Electrically operated security bar shall be provided at the entry of installations. These gates shall be operated from inside the gate

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