4.3 Vol II Sec.3.2 - Process Design Criteria

Offshore Design Section Engineering Services ISO 9001:2008

DESIGN CRITERIA

PROCESS AND UTILITIES

Volume No: II

Section No: 3.2

HRD-Process Platform Project No:

Page: 1 OF 34

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE: ODS/SOF/020B ODS/SOP/017 01 00 21.07.2010

PART IV

SECTION - 3.2

PROCESS DESIGN CRITERIA

OIL AND NATURAL GAS CORPORATION LIMITED

INDIA

AB BSW AKR

05.05.12 34 0

PREPARED

BY

CHECKED

BY

APPROVED BY

ISSUED FOR BID

DATE No. of

Pages

REV


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TABLE OF CONTENTS

ANNEXURES

ANNEXURE-I WELL FLUID COMPOSITION (TYPICAL)

HEERA FIELD

ANNEXURE-II PRODUCED WATER ANALYSIS

ANNEXURE-III DIESEL FUEL SPECIFICATIONS

SECTION TITLE

3.2 INTRODUCTION

3.2.1 DESIGN CRITERIA HRD PROCESS PLATFORM

3.2.2 DESIGN CRITERIA FOR MODIFICATIONS ON

EXISTING HEERA COMPLEX (HRC, HRG, WIH)

3.2.3 DESIGN CRITERIA OF PRE-INSTALLED RISERS

3.2.4 DESIGN CRITERIA OF FUTURE EQUIPMENTS

3.2.5 INSTRUMENTATION AND CONTROL

3.2.6 SPARING PHILOSOPHY

3.2.7 UNITS OF MEASUREMENT

3.2.8 NUMBERING PHILOSPHY

3.2.9 CODES AND STANDARDS


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3.2 INTRODUCTION This section of bid package defines design criteria for Process and Utility

systems required for HRD Process Platform (bridge connected to existing HRC

platform) under HRD Re-development (Phase-II) Project. Under this project, the

scope of work includes the following facilities:-

a) HRD Process Platform. Section 3.2.1 covers the design criteria for process

platform. b) Modifications at existing HEERA Process Complex (HRG/ H R C / WIH).

Section 3.2.2 covers the design criteria for various facilities and modifications

envisaged at HEERA HEERA Process Complex including bridge inter-

connection between existing HRC Process Platform and new HRD Process

Platform

GENERAL REQUIREMENTS

Contractor to note that this document provides the design criteria of various

process facilities and utilities envisaged in the project. Contractor to strictly

follow these criteria while designing various systems or units envisaged in the

project. However, the sizes, capacities etc. of various units specified in this

design criteria or specified elsewhere in the bid package shall be followed as

minimum requirement. In case of any discrepancy between various documents,

Contractor shall refer the same to the Company for resolution and proceed wi th

the i r design and engineering only after companys decision with no impact to

cost and schedule of the project.

The sizes, specifications and drawings furnished in bid document for various

facilities at HRD Process Platform and modifications at existing HEERA Process

Complex are indicative & minimum to be provided by the Contractor. It is the

Contractors responsibility to verify all the design/ data before proceeding for the

detailed design and engineering. Under the scope of this contract, Contractor

shall perform all necessary process simulation using HYSYS software (latest

version), design calculations and consider adequate design margins while

specifying equipment /instrumentations. Contractors responsibility also includes

carrying out safety studies and review operability aspects of the facilities and

incorporates findings of the same while designing the facilities. Any deviation

shall require Companys approval.


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The process and utility flow diagrams and indicative P&ID s are enclosed

in the bid document. Contractor shall develop detailed process design basis, process

flow diagrams, material & energy balance, utility flow diagrams etc. for

different cases indicated in this criteria and design the process and utility

systems, accordingly. In case, simulation results show higher flow rates and

varying pressure/ temperature ranges for some applications, the more conservative

figures/ ranges shall be used for design and no. of process vessels/ equipment

required under intended operations shall be so decided within the scope of this

contract. Contractor may seek clarifications, if required any, during detailed

engineering. The design of process and associated utility systems for HRD

process platform and modifications at existing HEERA complex shall be

suitably designed for these higher flow rates/ ranges. Accordingly, Contractor shall

develop detailed utility balance and utility flow diagrams.

Contractor shall develop detailed Piping and Instrumentation Diagrams, Cause &

Effect Diagrams, SAFE charts etc. incorporating all suppliers information.

Contractor shall prepare data sheets and specifications for all the equipment,

instruments etc. Sufficient margins shall be taken on operating parameters viz.

pressure/ pressure drop, temperature, flow, level etc. to take care of complete

operating range and any other unforeseen eventualities. Contractor shall ensure that P&IDs shall include all required instrumentation

for local as well as for remote monitoring and control of critical process

parameters (including but not limited to pressure, temp., flow, level etc.).

Additional instrumentation, if required based upon HAZOP study as well as

operational requirement, shall be provided without any time and cost impact to

the Company.

Contractor shall develop sizes / routing / distribution of various utilities (namely

Vent/ HP flare/ LP flare, Open/ Closed Hydrocarbon Drain, Open Deck Drain,

Diesel, Instrument/ Utility/ Starting Air, Fire water, Utility water, Potable

water, Cooling water, Inert gas, Chemicals etc.) and finalize the same during

detail engineering.

Contractor shall ensure that the design of process platform shall meet the relevant

codes and standards requirements. A typical list of applicable codes is

included in this Bid Package. This, however, cannot be taken as an exhaustive

list and various codes and standards as mentioned in functional

specifications as well as those applicable as per good engineering

practices shall also form the basis and shall have to be followed by the

Contractor in consultation with Company/ Companys engineering consultant.


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The various process and utility system hook-ups indicated under bridge inter-

connections, between existing HRC platform and HRD platform are minimum

indicative. It shall be the Contractors responsibility to get familiar with the

existing process/ utility lines/ headers on HRC/ HRG platform, during pre-

engineering survey (topside modifications) in order to ascertain the extent

and completeness of work to be carried out for hook- up, extension and routing of

such lines/ headers up to new bridge and their further hook-up with corresponding

lines/ headers on HRD platform through bridge inter-connections.

Contractor , during pre-engineering survey (topside modifications) of HEERA

complex, shall also assess/ verify the deck space, hook-up points, routing of the

lines, necessary inter-connections through bridge, integration with existing facilities

etc. and finalize all essential aspects of modifications. Wherever as-built

drawings of e x i s t i n g facilities are n o t a v a i l a b l e , Contractor shall

develop the existing drawings relevant for the intended modifications to an as-built

status for the detailed engineering. Since the existing HEERA complex will be operational, the Contractor shall

develop detailed procedures for carrying out modification works and shall design/

plan his works such that hot work and platform shutdown requirements are

eliminated or reduced to bare minimum. Adequate care shall be exercised while

developing the existing process platforms modification requirements with special

emphasis towards safety, operability and hook-ups. Special attention shall be

given to minimize the shut down time required at existing process platforms and

safety for executing the modifications.

All the process, utility, safety and instrumentation systems shall meet the

requirements of API-RP-14C Recommended Practice for Analysis, Design,

Installation and Testing of Basic Surface Safety Systems on Offshore

Production Platforms Latest Edition.


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Contractor shall submit reports/ documents/ calculations/ drawings as per the list

given below for Companys review and approval. Contractor to note that this is a

typical list and shall be supplemented with additional detail engineering

documents as felt necessary by the Company, during detail engineering:-

- Pre-engineering Survey Report (Topside Modifications)

- Process & utility design basis

- Process & utility description

- Process simulation report

- PFDs / UFDs/ P&IDs (1st submission & subsequent

revisions)

- Process and utility calculation report (*)

- CFD Report of all the major process flows/ vessels

- Process control philosophy

- Black start philosophy

- Isolation philosophy

- Blow down calculation report

- Flare load calculation report

- Vent dispersion analysis report

- Equipment list

- Tie-in schedule

- Alarm & trip schedule

- Process Data Sheets - Equipment

- Process Data Sheets Instruments

- Cause & effect chart

- SAFE chart

- Line list

- Operating manual etc.

(*) Process and utility 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 equipment/ instruments for which vendors

information are required, preliminary calculations shall be

submitted initially. Subsequently, same shall be updated by the

Contractor based upon vendors information and shall be re-

submitted for Companys review and approval. Also, hydraulic

calculations shall be updated based on final routing/ layout etc.

as per actual piping isometrics, and re-submitted for

Companys review and approval.


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Contractor shall submit soft copy (including EXCEL sheets

indicating mathematical correlations) of sizing calculations for

review of results indicated in calculation report.

Detailed CFD analysis shall be carried out for all the Process

vessels, systems and PGCs during the design as well as

manufacturing phase and the due results shall be submitted to

ONGC.

Contractor to note that based upon review and approval of aforesaid

calculations/ documents/ drawings only, P&IDs shall be Approved

For Construction (AFC).

Engineering shall also be done for all specified future facilities

wherever required.

HAZOP STUDY Based upon review and approval of aforesaid reports/ documents/ calculation/

drawings etc., P&IDs shall be issued for HAZOP study. Contractor shall

engage an internationally reputed third party agency for carrying out HAZOP

study. The venue and timing of HAZOP workshop shall be finalized

through mutual consent between Contractor and the Company. The HAZOP

observations/ recommendations shal l be deliberated in presence of/ with

Companys representatives/ Operations representative/ Engineering

consultant. The firmed-up HAZOP recommendations shall be incorporated

in relevant doc./ drgs. and after their approval, P&IDs shall be issued for

Approved for Construction (AFC).

Contractor to note that all changes arising due to HAZOP study shall be

considered and incorporated as part of firm scope of this contract without

any time and cost impact to the Company. Also, any changes arising due to

Companys review / approval, for whatsoever reason shall be

implemented in the design of the facilities under the scope of this contract

without any time and cost impact to the Company.

DOCUMENTATION

The Contractor shall submit all the documentation as per requirements

given elsewhere in the bid document. In addition, Contractor shall prepare

process packages and submit to the Company & their Consultant, within

one month of approval of these documents. The process package shall

consist of the following documents:


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- Design basis (with approved deviations, if any)

- AFC P&IDs /Suppliers P&IDs (A3 size & bound

together)

- AFC Equipment lay-outs (A0 &A3 size & bound

together)

- PFDs & UFDs including Heat and material balance.

- Cause and Effect Diagram

- SAFE Charts

- Data sheet for Equipment

- Data sheet for Instruments

- Line list

- Equipment list

- All process /sizing calculations

- CFD Report of all the major process flows/ vessels

- Operating manual

- Vendor Document/ Literature

3.2.1 DESIGN CRITERIA HRD PROCESS PLATFORM

3.2.1.1 DESIGN LIFE: 25 years

3.2.1.2 PLATFORM LOCATION: Refer Structural Design Criteria Part

- II

3.2.1.3 SOURCE OF WELL FLUID : Additional well fluid from HP,HK

AND HSD well platforms (from

extended production manifold at

HRC through HRC- HRD bridge

inter-connection)

3.2.1.4 DESTINATION OF OIL

(AFTER HP SEPARATOR): HRC Oil manifold (through

HRD-HRC

interconnection)

3.2.1.5 DESTINATION OF GAS

(AFTER COMPRESSION): HRC-HRG net gas header on HRG

(through HRD- HRC inter-

connection

3.2.1.6 DESTINATION OF PDODUCED WATER

(AFTER HP SEPARATION): HRC-HRG produced water header on

HRC platform (through HRD-

HRC inter-connection).

25 years


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3.2.1.7 PROCESS DESCRIPTION

Well fluid from HP,HK and HSD well platforms via existing HRC production

manifold shall be received at HRD plat form through HRC-HRD bridge

interconnection at operating pressure 8 16 kg/cm2g.

The well fluid received at HRD Process Platform shall be first routed

to the three phase cyclone separator with a provision to bypass the same.Then the

WF is diverted to the well fluid heaters using hot oil and shall be heated from 210C

to 600

C and then shall be routed to the new 3 Phase HP separators (with in-built

electrostatic coalescer) maintained at operating pressure range 7.5 -12 kg/cm2g.

Gas from 3-Phase Cyclone separator shall be routed to compressor inlet manifold

and liquid shall be routed for further processing at existing platform of HRC and

HRG.

Oil s t r e am from 3-Phase HP separator shall be sent to a location o n H R C

p l a t f o r m a n d b e h o o k e d u p t o t h e o i l o u t l e t l i n e a t t h e

d o w n s t r e a m o f H P s e p a r a t o r o n H R C p l a t f o r m . (through HRC-

HRD bridge inter- connections). This partially stabilized oil shall combine with

the crude oil from other sources and flow to the surge tanks at HRG and HRA for

further separation and stabilization and subsequent pumping.

Separated water (from HP Separator) shall be routed to the HRC platform and shall

be connected to the produced water line at the outlet of the HP separator located at

HRC platform via HRD-HRC Bridge,which shall be transported ultimately to HRG

platform via HRC-HRG bridge up to the HRG produced water treatment system.

The interconnection with produced water header is to be provided at HRC platform.

A typical heat and mass balance is enclosed in bidding documents. Contractor

shall, however, review the operating pressure range for w e l l fluid heater and

HP separator based upon vendor data and carry out heat and mass balance for all

the possible cases.

The operation of PG compressors shall be facilitated through load sharing and

capacity controls incorporated into the compressor skid control system. The new

PG compressor shall be linked to the existing PG compressors on HRC as well

as HRG platform via suction and discharge header. In normal operation, 6 nos.

compressors (2 at HRC and 3 at HRG and 1 at HRD) will run in parallel

maintaining 6 operating and one standby philosophy. If required, all 6 nos.

compressors (including the new two at HRD) may also run in parallel.


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Gas will be compressed by the process gas compressor (PGC) up to 95 kg/cm2g

followed with processing by the dehydration unit in HRG. A scrubber shall be

provided on the discharge of PGC (after 3rd

stage cooler) to prevent hydrocarbon

liquid carryover from the compression train o n H R D to dehydration unit on

HRG platforms respectively. G a s from HRD shall then be routed across the

HRD-HRC and HRC-HRG bridge to mix with the compressed gas from the

existing facility and then to the dehydration system of the exist ing platform

- HRG. The outlet l ine of the compressors shall be routed up to the

HRG platform and shall be connected to the outlet manifold of the

compressors on the HRG platform.

All necessary process and utility inter-connections shall be made through HRC-

HRD bridge. Provision shall also be made to use gas separation, compression

facilities of existing HEERA complex and HRD Process Platform from

either of the platforms. The process inter-connections between HRD and HRC

shall include but not be limited to hook-up of production manifolds,

separated oil and produced water, compressor suction headers, compressor

discharge headers . For utility inter-connections, refer Design Criteria Utilities.

3.2.1.7 DESIGN CRITERIA PROCESS EQIPMENTS AND SYSTEM

3.2.1.7.1 PRODUCTION H E A D E R / MANIFOLD

No Production manifold has been envisaged at HRD platform. However, the

production manifold of HRC platform shall be extended through the bridge of

HRC-HRD and shall be routed up to the inlet of the De-sander and the

wellfluid heater and then the HP separator. There shall be a flushing

connection on extended inlet line. Also the line should hot insulated.

The extended production header will be designed based on the following:-

Operating pressure, kg/cm2g : 8 16

Design pressure, kg/cm2g : 94.0

Operating temperature, 0C : 21 60.

Design temperature, 0C : 75.

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3.2.1.7.2 THREE PHASE CYCLONE SEPARATOR

One no. Three Phase Cyclone Separator shall be provided in the upstream of

W.F. heater. The well fluid shall be de-gassed in a centrifugal type 3-Ph.

Cyclone Separator.

The 3-Phase Cyclone Separator will be designed based on the following:-

Operating pressure, kg/cm2g : 8 16

Design pressure, kg/cm2g : 94.0

Operating temperature, 0C : 21 60.

Design temperature, 0C : 75.

The provision shall also be kept for bypassing it, if required .

The cyclone separators are vertical vessels designed for 3 phase separation,

primarily meant to knock-out gas from liquid and to drain the free water

present in the fluid. This will be designed based on

the following

a) Operating conditions :

- Pressure, kg/cm2g : 8.0 (Min.)

: 16.0 (Max.).

- Temperature, 0C : 21 - 60

b) Design conditions :

- Pressure, kg/cm2g : 94.0

- Temperature, 0C : 75.0

c) Flow rates (per unit)

- Liquid, BLPD : 55000

- Gas, MMSCMD : 2.0

d) Surge factor : 25% of the maximum well fluid

e) Swell factor : 15 % Minimum

f) Maximum allowable : 13.4 Lit/MMSCM. Liquid Particle size in gas

carry over liquid in gas shall not be more than 10 microns.

g) Well fluid composition : Refer ANNEXURE

centrifugal type 3-Ph.

Cyclone Separator.


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3.2.1.7.3 WELL FLUID HEATERS

The well fluid heaters are shell and tube type heat exchangers. The crude oil/

water emulsion is passed through the tube side and heated by hot oil on the

shell side. This temperature increase of the process fluid promotes the break

down of the emulsion, thereby permitting downstream separation of the water

phase.

The well fluid heater will be designed based on the following:

Heating medium: Hot oil

Heating requirement: To heat well fluid from 210C (MIN) to 60

0C(MAX.)

Max. temp. heating medium(Hot oil ): 2500C .

Min. temp. heating medium(Hot oil ): 1500C.

3.2.1.7.4 HP SEPARATORS

The HP Separators are horizontal vessels (with in-built electrostatic

coalescer) designed for 3 phase separation of oil-gas-water by static

electricity induced gravity settling. These will be designed based on the

following:-

a) Operating conditions :

- Pressure, kg/cm2g : 7.5 (Normal)

: 12 (Max.).

- Temperature, 0C : 30-60

b) Design conditions :

- Pressure, kg/cm2g : 21.1

- Temperature, 0

C :104.0

c) Flow rates:

Oil (BOPD) Water

(BWPD)

Liquid (BLPD) Gas

(MMSCMD)

Maximum oil

case

20000 35000 55000 2.0

Maximum

water case

5000 50000 55000 2.0


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d) Residence time : Min 5 minutes for oil and water

phase on maximum flow including

surge & swell factor

e) Maximum allowable : Centre line of vessel liquid level

f) Allowable quantity of : 200 ppm ( V/V) max. oil in water

g) Allowable quantity of : 1% ( V/V) max. water in oil

h) Maximum allowable : 13.4 Lit/MMSCM.

carry over liquid in gas Liquid Particle size in gas

shall not be more than 10

microns i) Well fluid composition : Refer ANNEXURE-I

3.2.1.7.5 PROCESS GAS COMPRESSOR

The process gas compressor takes suction from compressor Inlet

Manifold on HRD platform and which is also interconnected to the

compressor inlet manifold at HRC platform through HRD-HRC bridge

inter-connection and delivers compressed gas to Discharge Manifold which

is connected to compressed gas manifold at HRC through HRD-HRC

bridge inter-connection. The process gas compressor will be designed based on the following

i) No. of trains: 2 no. (1W+1S)

ii) Flow:

- Max. : 1.6 MMSCMD (dry basis)

- Rated : 1.6 MMSCMD (dry basis)

iii) Molecular Weight (*):

- Max. : 23.5 (dry basis)

- Min. : 20.5 (dry basis)

(*) In case, simulation results show wider range, highest

and lowest out of above and simulation results whichever

are governing, shall be considered.


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iv) Pressure (at module battery limit):

- Suction, kg/cm2g : 6.0 8.0

- Discharge, kg/cm2g : 95.0

v) Temperature (at module battery limit)

- Suction, 0C : 30 - 60

- Discharge, 0C :54

vi) Type : Centrifugal (Dry gas seal type)

vii) Driver : Gas turbine

The gas shall be considered as saturated with water vapour at

operating conditions of HP separator.

Compressor package vendors scope shall include self-contained compressor

skid having 1st stage, 2nd stage and 3rd stage compressor suction

scrubber, inter- coolers, after-cooler, 3rd stage discharge scrubber, dedicated fuel gas conditioning unit, metering system, surge and speed

controls, lube and seal oil system, local panel, unit control panels (located in central control room) and other utility and auxiliary systems. The fuel

gas conditioning skid will consist as a minimum, suitable filters (specification to be decided by turbine vendor) and electric super heater designed to give a

minimum super heat of 20 0C.

Pressure and temperature at intermediate compressor stages indicated in the

heat and mass balance is indicative. Contractor shall finalize the same in

consultation with compressor vendor.

The design pressure of suction side of compressor shall be maximum of the

followings:

i) Bid package specification

ii) 110% of highest operating pressure

iii) 1 kg/cm2 above the settle-out pressure.

Compressor package vendors scope shall include self-contained compressor

skid having 1st stage, 2nd stage and 3rd stage compressor suction

scrubber, inter- coolers, after-cooler, 3rd stage discharge scrubber, dedicated fuel gas conditioning unit, metering system, surge and speed

controls, lube and seal oil system, local panel, unit control panels (locatedin central control room) and other utility and auxiliary systems. The fuel

gas conditioning skid will consist as a minimum, suitable filters (specificationto be decided by turbine vendor) and electric super heater designed to give a

minimum super heat of 20 0C.


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The facilities of HP gas compressor system shall be designed for the performance under all environmental conditions as given in the enclosed environmental data. The air cooler shall be designed for cooling gas for 14 0C approach to maximum ambient temperature of 40 0C.

The FG Skid as well as the L/O Cooler for individual compressors shall be

considered to be the part of compressor module.

Equipments exposed to process fluids shall be designed conforming to

NACE MR-01-75.

3.2.1.7.6 GAS DEHYDRATION & GLYCOL RE-GENERATION SYSTEM

The dehydration and glycol regeneration system is not part of the present scope

of this tender. However, for dehydrating the compressed gas from the new

compressors at HRD, the feed from compressor discharge header shall be

merged with the common discharge header on HRG. This shall be done

through the extension of the discharge header on HRD platform up to HRC

and then up to HRG platform through bridge inter-connections respectively.

Equipments exposed to process fluids shall be designed conforming to

NACE MR-01-75.

3.2.1.7.7 PRODUCED WATER CONDITIONING SYSTEM

Produced conditioning system is not part of the scope of present tender.

However, for processing, the 35000 BWPD of Produced water from the new

separator it has to be sent to PWC s -1 unit at HRC and 2 units of HRG

platforms. The produced water outlet line from the outlet of the new separator

on HRD platform, shall be extended and hooked up to the produced water line

at HRC, outlet line of the PW of HP separator on HRC. The related piping,

instrumentation modifications are also included along with in the tie ins.

However the future space shall be provided on HRD platform for a new future

PWC of 100, 000 BWPD Capacity, as shown in the EQ. Layout diagram as

well as mentioned in other parts of the bid package.


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3.2.1.8 DESIGN CRITERIA UTILITIES

3.2.1.8.1 ELECTRICAL GENERATION FACILITIES

Main power generation unit (TG) not envisaged at HRD Process Platform .

However, all electrical power requirements for auxiliaries as well as prime

movers and lighting loads at HRD shall be met from the excess power available

in the HEERA Complex which shall be brought via cables (HT and LT) via

HRC-HRD interconnection bridge.

An Emergency Gener a to r of 1.2 MW capacity shall be provided on HRD.

The capacity is based on the load and governed by the electr ical

scope of work and design cri teria.

3.2.1.8.2 FLARE AND VENT SYSTEM

The HEERA Process Complex has three waste gas collection systems.

These are HP flare system, LP flare system and vent collection system.

The HP, LP of the new HRD Process Platform shall be integrated with

existing complex . The main header of the HP and LP flare header shall be

extended up to the main complex via HRD-HRC bridge and shall be

connected to the main header at an appropriate point in the upstream of the

respective Flare KODs. The HP flare system at HRD w i l l collect high pressure flare gas which

i s to r o u t e t o HP Flare header on HRC platform. HP flare gas header

shall be hooked up with HP flare H e a d e r o n H R C p l a t f o r m . T h e

H P f l a r e l i n e i s t o p a s s through HRD-HRC bridge inter-connection.

The LP flare system collects low pressure gas which flows to LP K.O.

Drum for separation of liquid carry over. LP flare gas h e a d e r is t o b e

h o o k e d u p w i t h t h e L P f l a r e h e a d e r a t H R C , through HRC

HRD bridge inter-connection.

The vent collection system collects vent gas which is routed to the vent

scrubber followed by a glycol seal drum before flowing into atmosphere via

the independent vent line on the new HRD platform. The vent boom shall be

located at a suitable position and safe location.

Main power generation unit (TG) not envisaged at HRD Process Platform .

An Emergency Gener a to r of 1.2 MW capacity shall be provided on HRD.


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The HP and LP flare systems are t o b e continuously purged with fuel

gas at each dead end to assure a continuous flow through all headers.

Further, the HP and LP flare headers to respective flare headers shall be

provided with ultrasonic flow meters covering overall flare gas flow rates

based on simulation and including design margins.

The flare and vent system will be designed based on the following

HP Flare:

i) Header pipe dia.,inch : 20 (Min.) .

ii) Max. back pressure, : 3.5 (NOTE-1) Kg/cm2.

LP Flare


ii) Max. back pressure, : 0.2 (NOTE-1) kg/cm2g

Vent Header


NOTE-1 Max. back-pressure for flare at existing HRC

platform. However, new flare system at HRD shall be

designed for back pressure considering its integration with

existing flare system at HEERA complex.

Flare system shall be designed for the following radiation level at the

nearest process platform including HRD platform including solar radiation

of 250 Btu/hr ft2

Continuous (Normal ) : 400 Btu/hr ft2

Emergency (Peak) : 1500 Btu/hr ft2

The Flare piping network (piping including the header) on HRD shall be

designed for new facilities only, However as the flare system shall be

integrated with Heera complex as a whole. Thus, the changing the existing

flare tip to the sonic tip will form the scope of present tender. The flare system

and the Sonic flare Tip shall be designed for minimum load (purging),

continuous load (compressor not available i.e. associated gas loads-

Maximum up to 7.5 MMSCMD) and peak load (i.e. 5/6 nos. operating

compressors capacity + blow down requirements).


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3.2.1.8.3 FUELGAS SYSTEM

The fuel gas conditioning system is designed to meet requirements of the

following as a minimum Process gas compressor, HP and LP flare header

purge. The fuel gas header shall be hooked up with existing fuel gas

header at HRC platform through HRC-HRD bridge inter- connection.

Dehydrated gas from HRC platform shall be used as source of fuel gas

conditioning system.

Operating pressure : 30.0 Kg/cm2g

The Fuel gas shall be re-conditioned f o r the gas turbines of p r o c e s s gas

compressor in accordance with the recommendations of the compressor

manufacturer.

FG skids for individual compressors shall be considered as a part of

compressor modules.

3.2.1.8.4 DIESEL FUEL SYSTEM

The diesel fuel system is designed to meet requirements of the following as

a minimum Pedestal cranes ; Start-up air compressor ; Fire water pump ;

Emergency generator. The diesel fuel header shall also be hooked up with

existing diesel fuel header at HRC platform through HRCHRD bridge

inter- connection.

The diesel fuel system shall consists of the following Diesel inlet filter,

Diesel centrifuge, Diesel storage tank and Diesel transfer pumps.

Diesel inlet filter (one no.)

Particle removal size, : 99.99% removal of 0.8 micron and larger microns

Pressure drop, kg/cm2g : 0.3 (dirty)

Diesel Centrifuge (one no.)

Water in diesel, : 50ppm by wt.

The fuel gas conditioning system is designed to meet requirements of the

following as a minimum Process gas compressor, HP and LP flare header

purge.

3.2.1.8.4 DIESEL FUEL SYSTEM


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Diesel transfer

pumps

Nos. : 2 nos. (1 operating +1 standby)

Pump Capacity : 10 M3/ hr.

Diesel quality : Refer ANNEXURE-II

Diesel storage shall be provided in crane pedestal. Storage volume is

intended to meet the requirement of the following:-

24 hours supply for running fire water pump and emergency

generator plus 48 hours running of one deck crane.

Additional day-tanks for diesel storage shall also be provided for fire

water pump, emergency generator, deck cranes etc.

3.2.1.8.5 INSTRUMENT AND UTILITY AIR SYSTEM

The instrument and utility air system is designed to meet requirements of

the following as a minimum Pedestal cranes ; Starting air receivers,

Hypochlorite generator , instrument air etc.

The instrument and utility air shall consists of 2 nos. Air compressors.

The air stream from the compressors is scrubbed in the Utility air receiver

and then split into two streams one, to utility air header for onward

distribution and other, to air dryers (consisting of pre-filters, dryers and

after filters) followed with instrument air header for onward distribution.

The instrument and utility air system will be designed based on the

following:

Air compressors

Nos.: 2 nos. (1 operating +1 standby)

Air capacity (Dry): 700 (min.) Nm3/hr.

Discharge pressure: 11.4 Kg/cm2g

Type: Motor driven non-lubricating type screw

compressor.

INSTRUMENT AND UTILITY AIR SYSTEM


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Instrument air dryers

These shall consists of pre-filters, dryers and after filters.

Nos.: 2 nos. (1 operating + 1 standby)

Instrument air dew point: (-) 40 0C

Operating pressure: 11.4 Kg/cm2g

Utility air receiver

Capacity: 30 minutes operation

Operating Pressure: 10.0 Kg/cm2g

Instrument air receiver

Capacity: 30 minutes operation of all air consuming

instruments

Instrument air header: To supply instrument gas to all consumers

Operating Pressure: 7.5 8.2 Kg/cm2g

The instrument and utility air headers shall also be hooked up

with respective headers at HRC platform through HRD-HRC bridge

inter- connection.

3.2.1.8.6 STARTING AIR SYSTEM

The starting air system is designed to meet starting requirement of fire

water pump and emergency generator. It consists of start-up air

compressor, fire water pump starting air receiver and

emergency generator starting air receiver.

The starting air system will be designed based on the following:

Start-up air compressor:

Nos.: One no.

Air capacity (Dry): 35 (min.) Nm3/hr.

Discharge pressure: 17.6 Kg/cm2g

Type: Diesel engine driven reciprocating compressor.

STARTING AIR SYSTEM


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3.2.1.8.7 INERT GAS SYSTEM

The inert gas is primarily required for providing dry gas seal as well as

use in purging and blanketing of various systems and other

miscellaneous requirements, if any. The system shall have its own air

compressor to meet its input air requirement.

The inert gas system will be designed based on the following:

Nos.: 1 no (1X100 %)

Gas generated: Nitrogen

Capacity per unit: 150 (min.) Nm3/hr.

Dew point, C: (-) 40

Discharge Pressure 4.0 - 7.0 kg/cm2g

Discharge Temp, C: 43

Purity, %: 99 (min.)

Type of Adsorber : Membrane type

The inert gas header at HRD platform shall be extended to HRC and

HRG platform through HRC-HRD and HRC-HRG bridge inter-

connections for meeting the inert gas requirement. Isolation valves

along with blind flange, shall be provided at HRC and HRG platforms

for necessary hook-ups.

The N2 system shall also include N2 filter, N2 receiver and N2 cylinder

cubicle separately.

3.2.1.8.8 CHEMICAL STORAGE AND INJECTION SYSTEM

There are three chemical systems for HRD platform. These

systems include oil corrosion inhibitor (OCI) and gas corrosion

inhibitor (GCI) shall be dosed at the new platform of HRD, and

demulsifier shall be dosed at HRC platform.

INERT GAS SYSTEM

CHEMICAL STORAGE AND INJECTION SYSTEM


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As a minimum chemical storage and injection facility shall consist

the following:

Facilities shall be suitable for chemicals available from at least two

manufacturers for each type of chemical.

Mixing, heating & blanketing facilities etc shall be provided as per

chemical manufacturers specification/ Operational requirement.

Chemicals chosen shall be compatible with each other and with well

fluids / process stream / formation water as applicable.

All chemicals will be stored in full strength in storage tanks based on 15

days requirement at normal rates.

Drums equivalent to 15 days normal consumption of each chemical

shall be stored in the open. A suitable shelter shall be provided over the

drum storage area as required to protect the chemicals from direct

exposure to sun light (As per manufacturers recommendation).

Two drum racks, each for 4 drums (min.) shall be provided for

unloading of chemicals into respective tanks. All drum handling

will be mechanized. Portable pneumatic pumps (one for each chemical)

shall be provided for unloading drums into respective tanks.

Eye wash plus safety shower shall be provided near the storage tanks

and drum handling area (one each).

Suitable dosing pumps - one operating and one standby as minimum

shall be provided for each chemical. Dosing Pumps shall be sized to

meet required dosing rates .

Dosing rates and chemical type are tentative and shall be confirmed

during detailed engineering as per chemical manufacturers

recommendation. Chemical treatment package design shall take care

of this requirement.

CHEMICAL DOSING RATES

Following indicative dosing rates for various chemicals are given

below. These rates are to be confirmed during detailed engineering

as per chemical manufacturers recommendation

1) OCI 60 ppm at each injection point.

2) GCI 16.7 L/ MMSCM at each injection point

3) DEMULSIFIER 300 ppm based on maximum incoming

fluid flow

Eye wash plus safety shower shall be provided near the storage tanks

and drum handling area (one each).


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LOCATION OF CHEMICAL INJECTION

Oil Corrosion Inhibitor

It shall be injected in the oil header upstream and/ or downstream of the

HP separator as is appropriate to the inhibitor system selected. Hence it

is to be dosed on at new HRD platform

Gas Corrosion Inhibitor

It shall be injected upstream of the 1st, 2nd and 3rd stage coolers on

the process gas compression system.

Demulsifier

It shall be injected to the production headers upstream of the respective

well fluid heaters. Hence it is to be injected at HRC platform.

CHEMICAL NAMES

1) OCI Corexit 7730 or equivalent

2). GCI Corexit 7730 or equivalent

3) DEMULSIFIER Diatrolite DE 220 or equivalent .

3.2.1.8.10 UTILITY WATER SYSTEM

The utility water system is designed to meet requirements of

hypochlorite generation, potable water, cooling water, fire water header

(for pressurization) as a minimum. The utility water header shall also

be hooked up with respective header at HRC platform through HRC-

HRD bridge inter-connection.

The utility water system will consist of 2 nos of submersible utility

water pumps. Pump discharge pressure shall be 10.6 kg/cm2g.

The potable water system consists of potable water tank and potable

water pump and it shall be hooked-up with HRC platform through

HRC-HRD bridge inter-connection. The potable water shall be

supplied from HRC potable water header through HRC-HRD bridge

inter-connection.


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The cooling water system consists of cooling water tank, cooling water

circulation pumps and cooling water cooler. It shall include an on-

line filter, chemical injection facilities for maintaining pH of the water,

and an injection system for scale inhibitor. The cooling water header

shall also be hooked up with respective header at HRC PLATFORM

through HRD-HRC bridge inter-connection.

The cooling water system will be designed based on the following:

Cooling water circulation pumps:

Nos.: 2 nos. (One operating + one standby)

Pump diff. pressure: 5.0 Kg/cm2g

Cooling water inlet supply temp. : 50.0 0C

Cooling water outlet temp. : 60.0 0C

3.2.1.8.11 DRAIN SYSTEM

The drain system consists of open deck drain (ODD), open hydrocarbon

drain (OHD) and closed hydrocarbon drain (CHD) for collection of

hydrocarbon, chemicals and water.

Open deck drain (ODD) is meant for collection of the following:-

a) Storm water not in contact with hydrocarbon

b) Deluge and fire water

c) Utility water, potable water etc. spilled during cleaning

and maintenance.

Open deck drain system shall be designed for collection of rainwater

considering heaviest monsoon rain fall and deluge. The rainfall for

facilities design shall be taken as 100 mm rain in 2 hrs and this intensity

to last over a period of 20 minutes. Water entering the open deck

drain system shall be routed to sea through sump caisson.

Open hydrocarbon drain (OHD) is meant for collection of the

following:-

a) Oil, oily water and chemicals from platform piping /equipment/

storage tanks, spillage etc.

b) Oily water from vessel cleanout and other operations and

maintenance activities.


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c) Run-off water from process areas which may be contaminated

accidentally with oil (e.g. water from around rotating

equipment/skid mounted process equipment which may be

contaminated with oil).

Open hydrocarbon drain system shall be designed to accept minor

volumes of hydrocarbons drained intermittently from equipment and

instruments and chemical spillage/ leakages during handling of

chemicals/ hydrocarbon. It is routed to sump caisson from where the oil

is routed to closed drain drum. Recovered oil from closed drain drum is

pumped to condensate header/ HP separator outlet and water to sump

caisson for disposal into sea.

Closed hydrocarbon drain (CHD) is meant for collection of

hydrocarbon/ oily water from the pressurized vessel/ equipment/ pumps/

compressors etc. which are required to be drained under pressure as a

part of normal operational requirement.

The condensate header shall also be hooked up with respective header at

HRC platform through HRC-HRD bridge inter-connection. The drain

system will be designed based on the following:

Closed Drain Drum:

The closed Drain Drum shall be utilized for receiving the all closed

drain liquids from new HRD platform. 2 nos. of closed drain pumps

shall also be used for transferring the crude. The required refurbishment

shall be carried out for the existing pumps.

The drain system will be designed based on the following Closed

Drain Drum

Storage Capacity : 10 M3

(min.)

Design pressure, : 3.5 Kg./cm2g

Closed Drain Pumps:

Nos. : 2 (One operating + one standby)

Capacity, m3/hr. : 10 (min.)

Diff. pressure, kg/cm2 : 10 (min.)

Type : Electrical motor driven reciprocating

Also, at HRC platform the same capacity and type of closed drain drum

and pumps are to be provided.

Closed Drain Drum:


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Sump caisson with blow case

The Sump Caisson shall be utilized for receiving all open, closed drain

fluids separately from HRD Process Platform as well as from the

PWCs on HRC and HRG platforms respectively. Sump caisson is to be

provided with blow case for lifting skimmed oil to Closed Drain Drum.

Sump Caisson shall be a vertical, partially submerged stand pipe with an

open bottom (Min.length-30M, Min.dia.-60). Separation of oil

from water is accomplished by differences in specific gravities. Sump

caisson shall have gas sparger for separation of oil. Baffle arrangement

inside the caisson enhances the separation of the entrained oil particles

and water thus separated is discharged to the ocean. The oil collects

inside the blow case (Min.length-3M, Min.dia.-12) is removed

periodically by pressurizing the blow case with fuel gas to the closed

drain drum. The caisson is vented to LP flare header.

The oil content in sump caisson water outlet shall be less than 25 ppm.

Sampling facility for collecting water sample from the outlet of

sump caisson shall be provided.

3.2.1.8.12 WASTE HEAT RECOVERY AND HOT OIL SYSTEM

The waste heat recovery and hot oil system is designed to meet the

heating requirements of well fluid heater (HRD), Heating of Closed

drain drum at HRD and also the hot oil line to be extended upto HRC

platform to meet the additional heat requirement of HRC. Waste heat

recovery units (WHRUs) shall be installed in the exhaust of turbines of

process gas compressors (PGC).

The hot oil supply and return headers shall be hooked up with respective

inlet and outlet hot oil header of new well fluid heater at HRC platform

through HRD-HRC bridge inter-connections.

The waste heat recovery and hot oil system shall consists of - hot oil

expansion tank, hot oil circulation pumps, hot oil make-up pump, hot

oil filter, gas compressors WHRU and hot oil dump cooler.

Sump caisson is to be

provided with blow case for lifting skimmed oil to Closed Drain Drum.

Sump caisson with blow case


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The waste heat recovery and hot oil system will be designed based on

the following

- Heating oil medium : Hytherm 500

- Hot oil supply pressure : 5.0 kg/cm2g

- Hot oil operating temp. : 250 oC

Hot oil dump cooler is provided to remove excess heat to avoid damage

to the WHRUs and to avoid degradation of the hot oil medium

(Hytherm- 500). Its duty is based on 5% (indicative, to be confirmed

by system vendor) of the total heat generated in the exhaust gases.

3.2.1.8.13 FIRE WATER SYSTEM

The fire water system is designed to primarily meet fire water

requirement of HRD as per relevant codes and standards and

good offshore engineering practices. However, Minimum capacity of

1200 M3/ hr needs to be provided. Fire water deluge systems shall be

provided on all decks and around all equipments containing

hydrocarbons. Fire fighting equipment including hose reels, foam

generators, fire monitors etc. shall be provided at locations determined

by the safety studies. The fire water headers shall be hooked up with

respective headers at HRC platform through HRC-HRD bridge inter-

connection.

The HRC and HRD fire water systems shall provide back-up to

each other. In case of failure of start of FWP at HRC, HRD fire water

pump to start automatically and also in case of HRD pump fails to start,

HRC FWP to start automatically. Logic sequence is to be developed

accordingly. Contractor shall ensure that the HRD fire pumps and

ring main (including the bridge link to HRC) are capable of supplying

the required flow rates and pressures of fire water to HRC in the event

of failure of HRC fire water pump and ensure that there is mutual back-

up.

A chlorination system based on parallel plate electrolytic principle

shall be provided to prevent fouling. Contractor shall design this

system in a manner that ensures that contamination of the potable water

system does not occur.


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The fire water system shall consists of fire water pump, FW pump

caisson, deluge valves, fire water ring main, hose reels, foam

generators, fire monitors, spray network etc.

The fire water system will be designed based on the following:

The fire water pump shall be capable of supplying total

water requirements for the greatest single fire occurrence plus a

minimum of two firewater hose reels maintained at main deck as a

minimum.

No.: One

Capacity, m3/hr.: 1200 (min.)

Discharge Pressure: Adequate to maintain fire water header

pressure at 7 kg/cm2g

Type: Diesel engine driven

3.2.1.8.14 FIRE PROTECTION AND SAFETY SYSTEM

The shutdown system for HRD shall be inter-connected with the

corresponding HEERA complex systems.

2 nos. of Survival Craft of 50 persons capacity shall be provided one

at cellar deck and one at main deck.

Clean Agent unit shall also be provided.

The ESD and F&G systems shall be based on a high reliability, high

availability type PLC, certified to TUV level AK6. The Contractor shall

conduct a risk assessment of the ESD and F&T systems requirements

prior to detailed design to assess the required Safety Integrity Level

(SIL) in accordance with IEC-61508, and shall specify the associated

equipment accordingly.

For details on fire protection & safety system, refer Scope of Work

Instrumentation.

3.2.1.8.15 FIRE SUPPRESSION SYSTEM

For details on fire suppression system, refer Scope of Work

Mechanical.


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3.2.1.8.16 LAUNCHERS/ RECEIVERS

On HRD platform, space provision shall be kept for installation of

two nos. 12 and one no. 16 well fluid receivers.

3.2.2 DESIGN CRITERIA FOR MODIFICATIONS ON

EXISTING HEERA COMPLEX (HRC/ HRG/ WIH)

For detailed scope of work for modifications envisaged on existing

HEERA Complex (HRC/HRG/WIH platform), refer Clause - Section

2.0 - Description of Work (Basic Bid Work).

3.2.3 DESIGN CRITERIA FOR PRE-INSTALLED RISERS:

Two numbers 12 and one number 16 pre-installed risers are to be

provided with jacket. The design pressure and temperature for the same

will be 93.7 Kg/Cm2g and 93 oC

3.2.4 DESIGN CRITERIA FOR FUTURE EQUIPMENT:

The Provision of space, access, process and utility tie-in locations

for the equipment that has been identified as future requirement in

Basic Bid work are to be provided.

Provision for isolation valves to allow future tie-in without any

requirement for hot work or shutdown.

Provision for layouts and preliminary design and engineering so

that the future equipment can be incorporated, supported and

installed into the operating facility without the requirement for hot

work.

3.2.5 INSTRUMENTATION & CONTROL

For instrumentation and control, refer Clause 2.3.6 Description of

Work (Basic Bid work) and Section 3.6 - Instrumentation Design

basis.

3.2.6 SPARING PHILOSOPHY

Sparing philosophy for unit, equipment etc. shall be as per

bid documents. In general, all rotating equipment (pumps, compressors

etc.) shall have one stand-by of same capacity.


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3.2.7 UNITS OF MEASUREMENT

Metric system of units shall be followed.

3.2.8 NUMBERING PHILOSOPHY

Tag numbering philosophy for equipment and instruments shall be

adopted as per industry accepted practice, preferably 4 digits for process

platform. Instrument and piping symbols shall be as per legend sheets.

3.2.9 CODES AND STANDARDS

The following are the minimum applicable Codes and Standards /

relevant API Recommended Practices that shall be followed:-

API 14C

API 14E

API 520

API 521

API 14G

API 14J

NFPA 15 & 20


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ANNEXURE-I

(SHT. 1 OF 2)

WELL FLUID COMPOSITION (TYPICAL) HEERA FIELD

COMPONENT MOL PERCENT

(ON DRY

BASIS)*(FOR GOR-

275)

N2 0.50

CO2 0.940

H2S 0.023

C1 52.97

C2 8.00

C3 5.41

IC4 0.99

NC4 1.37

IC5 0.43

NC5 0.39

C6 0.25

NC7 0.05

CUT-1 4.84

CUT-2 6.63

CUT-3 4.07

CUT-4 2.39

CUT-5 2.46

CUT-6 2.66

CUT-7 2.89

CUT-8 1.16

CUT-9 0.52

CUT-10 0.36

CUT-11 0.32

CUT-12 0.39

TOTAL 100.00


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ANNEXURE-I

(Sheet 2 of 2) PSEUDO-CUT DETAILS

CUT ABP (DEG C) SP GR CUT-1 89.57 0.7219 CUT-2 110.10 0.7539 CUT-3 132.50 0.7781 CUT-4 160.80 0.8030 CUT-5 192.10 0.8254 CUT-6 228.90 0.8471 CUT-7 268.80 0.8670 CUT-8 307.70 0.8845 CUT-9 351.80 0.9030 CUT-10 402.50 0.9144 CUT-11 455.20 0.9362 CUT-12 524.00 0.9572 * THIS IS A TYPICAL WELL FLUID COMPOSITION. CONTRACTOR SHALL GENERATE

THE COMPOSITION OF WELL FLUID FOR OTHER GORs.

Characteristics of Crude oil of Heera Platform

S.N. Parameter Result

1 Density at 15C 0.8397

2 Sp.gravity at 60/60F 0.8397

3 API Gravity (60F) 36.93

4 Pour Point C 33

5 Water Content (% by vol.) -

6 B.S.&W (% by vol.) -

7 Kinematic Viscosity at 37.8 C

(cst)

4.44

8 Asphaltene content (% w/w) 1.15

9 Resin content (% w/w) 9.4

10 Wax content (% w/w) 16.67

11 KUOP 11.80

12 Molecular weight 230


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ANNEXURE-II

PRODUCED WATER ANALYSIS

Component mg/l

Ca++ 290

Mg++ 36

Na+ & K+ as Na+ 9483

Cl 14200

SO4 230

CO3 120

HCO3 1281

TDS 25640

Salinity (as NaCl) 23400

TSS 40

pH 8.3

Sp. Gr. at 30C 1.018


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ANNEXURE-III

DIESEL FUEL SPECIFICATION

Sl.

No.

Property Unit Range of Value

1 Distillation % recovery at 366

deg C

90 (min.)

2 Specific Gravity @ 15/15 deg C 0.84 0.88

(approx.)

3 Copper strip corrosion @ 100 deg C for 3 hrs. No worse than

No.1

4 Kinematic viscosity cSt at 38 deg C 2 7.5

5 Cetane Number - 41

6 Flash Point deg C >50

7 Sulphur Wt % 1.0 max.

8 Water Ppmw 50 max.

9 Sediment Wt% Nil

10 Acidity inorganic - Nil

11 Acidity total Mg KOH/g 0.05 0.5 max).

12 Carbon Residue Wt % 0.2 max.

13 Ash content Wt % 0.01 0.02 max.

14 Lower heating value

(approx.)

Kcal/kg 9600 - 10000

Documents

4.3 Vol II Sec.3.2 - Process Design Criteria