PROFESSIONAL / POST GRADUATION WORK EXPERIENCE REPORT
BY
OKOLI, TOCHUKWU CHINEDU
B.Engr. MECHANICAL ENGINEERING
UNIVERSITY OF NIGERIA, NSUKKA,
ENUGU-STATE,
MSC. ROTATING MACHINERY ENGINEERING AND MANAGEMENT
CRANFIELD UNIVERSITY,
UNITED KINGDOM
SUBMITTED TO
NIGERIAN SOCIETY OF ENGINEERS (NSE)
IN PARTIAL FULFILMENT OF A REQUIREMENT FOR CORPORATE
MEMBERSHIP OF NIGERIAN SOCIETY OF ENGINEERS (NSE)
SEPTEMBER, 2014
ATTESTATION
I certify that the information as contained in this report is to the best of
my knowledge, the true practical experience of OKOLI TOCHUKWU
CHINEDU.
Engr. Bright Udi (MNSE, COREN)
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page I of IX
DEDICATION
This piece of work is dedicated to Almighty God for strength and inspiration to put this
piece of work together.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page II of IX
ACKNOWLEDGEMENT
I would like to appreciate my lovely wife Kate and Daughter Emmanuella for their
encouragement
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page III of IX
Abstract
This report presents eight years of post-graduation experience acquired from working at
WELTEK limited as mechanical engineer, studying Rotating Machinery Engineering and
Management at Cranfield University, United Kingdom and now working at Saipem
Contracting Nigeria Limited as Rotating Equipment Engineer. In these establishments I
was involved in several EPC projects. The key skills acquired from working in these
establishments are the use of API, ASME, international and Company standards for
mechanical equipment selection and sizing, line sizing and use of engineering software
such as AutoCAD for Engineering Drawing and GasTURB for Gas turbine design and off
design analysis.
As a fresh graduate my greatest passion was to find practical application of the theory I
was taught in the classroom in solving real life challenges. The first discovery was in the
design of Lease Automatic Custody Transfer (LACT) Unit where Bernoulli’s equation was
applied in flow measurement.
There are two major project discussed in this piece of work. The Southern Swamp
Associated Gas Solution (SSAGS) Project. The aim of this project is to stop routine gas
flaring in the flow stations. And the Cawthorne Channel Further Oil Development
(CCFOD) Project of which at the present time, the associated gas is separated and
flared at the flow stations.
The major activities as reported in this piece of work are sizing and selection of
centrifugal pumps for the export of crude oil from Cawthorne Channel flow station
3(CAWF3) to Nembe Creek Trunk line (NCTL). For SSAGS project the report was on the
preparation of Pump Data sheet, Inspection Data Sheet, Technical Supply specification
and Supplier Document Requirement Listing. These documents define the minimum
requirement for the supply of self-priming centrifugal pumps for the open drain system.
After preparing these documents they are submitted to procurement department. This
department returned lists of interested vendors with their respective bid proposals.
Technical bid evaluation, tabulation and clarification through emails was then carried out
to select a vendor for the supply of the self-priming centrifugal pump used to return
recovered oil from oil saver pit to the surge vessel. The selected vendor was followed up
during the manufacturing to ensure that the equipment performed according to
guarantee process duties as described in datasheets issued for order placement.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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NOMENCLATURE
AG
Associated Gas
API
American Petroleum Institute
ASME American Society of Mechanical Engineers
AutoCAD
Auto Computer Aided Design
BEME Bill of Engineering Material and Evaluation
BfD
Basis for Design
CAPEX
Capital Expenditure
CCFOD
Cawthorne Channel Further Oil Develepoment
CPF
Central Processing Facility
DC
Direct Current
DCS
Distributed Control System
DEP
Design & Engineering Practices
EGASPIN
Environmental Guidelines and Standards for the Petroleum Industry in
Nigeria
EPC
Engineering, Procurement and Construction
ESD
Emergency Shutdown
E-SPIR
Electronic Spare Parts Interchange ability Record
FAT
Factory Acceptance Test
GAs
General Arrangements
HFE
Human Factors Engineering
HSE
Health, Safety & Environment
HMI
Human Machine Interface
IASS
Integrated Automation Safety System
IDS
Inspection Data Sheet
IEC
International Electrotechnical Commission
IFAT
Integrated Factory Acceptance Tests
I/O
Input/Output
IOM
Installation, Operation and Maintenance
ISO
International Standards Organisation
ITP
Inspection and Test Plan
MAWP
Maximum Allowable Working Pressure
MMSCFD
Million Standard Cubic Feet per Day
MOP
Maximum Operating Pressure
NAG
Non Associated Gas
NCTL Nembe Creek Trunk Line
NPSHA
Net Positive Suction Head Available
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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NPSHR
Net Positive Suction Head Required
NYSC
Nigeria Youth Service Corps
NFA
No Further Activity
NDE
Non Destructive Examination
NSE
Nigeria Society of Engineer
OSD
Operational Shutdown
PEFS
Process Engineering Flow Scheme
PFS
Process Flow Scheme
ppmw
Part per million weight
QA/QC
Quality Assurance / Quality Control
QMS
Quality Management System
RPM
Revolutions Per Minute
SDRL
Supplier Document Requirements Listing
SIL
Safety Integrity Level
SIS
Safety Instrumented System
SNEPCO
Shell Nigeria Exploration Company
SPDC
Shell Petroleum Development Company of Nigeria
TAMAP
Technically Accepted Manufactures And Products
TEFC
Totally Enclosed, Fan Cooled
UCP
Unit Control Panel
UEFS
Utility And Engineering Flow Scheme
UHF
Ultra High Frequency
UPS
Uninterruptible Power Supply
USD
United State Dollars
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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Table of Contents
ATTESTATION
DEDICATION
ACKNOWLEDGEMENT
ABSTRACT
NOMENCLATURE
TABLE OF CONTENTS
1.
INTRODUCTION
1.1. Career Summary
1.1.1.
1.1.2.
1.1.3.
2.
3.
I
II
III
IV
V
VII
1
1
Cawthorne Channel Further Oil Development Project
Pipeline Conceptual Design on OPL277
Industrial Gas Turbine Creep Life Analysis using Creep Factor
Approach.
1.1.4. Engineering, Procurement and Installation of Topsides Facilities
Bonga North West
1.1.5. Southern Swamp Associated Gas Solution Project
1.1.6. Northern Option Gas Pipeline Project
CAWTHORNE CHANNEL FURTHER OIL DEVELOPMENT PROJECT
2.1. Introduction
1
2
2
3
4
4
6
6
2.2. Project Overview
6
2.3. Project Contribution: Crude Oil Export Centrifugal Pump
7
2.3.1. Subject Matter Discussion
2.4. Line Sizing
7
9
2.4.1. Lines to be investigated
2.4.2. General Criteria
2.4.3. Results
2.5. Export Pump Sizing
9
9
10
11
2.5.1. Calculation & Results
2.5.2. Shaft Power Calculation
2.5.3. Net Positive Suction Head Available
2.6. Pump Data Sheet for Export Pump
12
15
17
18
2.6.1. Issued for firm proposal
2.6.2. Issued for order Placement
2.6.3. Pump Curves
SOUTHERN SWAMP ASSOCIATED GAS SOLUTION PROJECT
3.1. Introduction
19
23
25
27
27
3.2. Project Overview
27
3.3. Project Contribution-New Open Drain Pumps
29
3.3.1. Subject Matter Discussion
3.3.2. Open Drain system
3.3.3. Verification of Process Data Sheet
3.3.4. Mechanical Data Sheet for Open Drain Pumps
3.3.5. Supply Specification for New Open Drain Pumps
1.1. 72
29
36
36
40
40
1.1. 72
3.3.6.
3.3.7.
Inspection Data Sheet for Open Drain Pumps
Supplier Document Requirement listing
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77
Page VII of IX
4.
5.
3.3.8. Technical Bid Tabulation and Evaluation
3.3.9. Problems encountered
3.3.10. Solution proffered
ATTACHMENTS
4.1. ATTACHMENT A: Shop Fabrication Drawing with BEME
87
91
92
93
94
4.2. ATTACHMENT B: LACT Unit Line Size Verification
95
4.3. ATTACHMENT C: P & ID for Crude oil Export Pump
96
4.4. ATTACHMENT 1 – Technical tabulation BENF1-P-5701 AB
97
4.5. ATTACHMENT 2 – Technical tabulation OPUF1-P-5701 AB
98
4.6. ATTACHMENT 3 – Technical tabulation TUNF1-P-5701 AB
99
4.7. ATTACHMENT 4 – Commented SDRL by Flowserve
100
4.8. ATTACHMENT 5 – Clarification form Flowserve
101
4.9. ATTACHMENT 6 – Scope of Supply form Flowserve
102
4.10. ATTACHMENT 7 – Deviation List by Flowserve
103
4.11. ATTACHMENT 8 – Sub-Vendor List
104
4.12. ATTACHMENT 9. – Reference List
105
REFERNCE
106
List of Tables
Table 2.1: Line Size Verification
Table 2.2:Power rating for motor drives
Table 2.3: Standard Rating for electric Motor
Table 2.4: Data Sheet Issued for Firm Proposal and Order Placement
10
17
17
19
List of Figures
Figure 2.1: Pump and Piping System
Figure 2.2: Oil Export Scheme
Figure 2.3: Pressure at discharge Header for CAWC3
Figure 2.4: Pump Data Sheet Issued for firm proposal (Sheet 1)
Figure 2.5: Pump Data Sheet Issued for firm Proposal (Sheet 2)
Figure 2.6 Data sheet Returned by Vendor
Figure 2.7: Issued for Order Placement (sheet 1)
Figure 2.8: Issued for Order Placement (sheet 2)
Figure 2.9 Pump Performance Curve
Figure 3.1 Major Component of Centrifugal Pump
Figure 3.2: Centrifugal Pump Operating Principle
Figure 3.3: Centrifugal Pump with Mechanical Seal
Figure 3.4 Cartridge Mechanical seal
Figure 3.5: Pump Stopped before Priming
Figure 3.6: Initial fill
Figure 3.7: Pump Priming Cycle
Figure 3.8: Pump Primed and Running
Figure 3.9: Pump remained Primed after Stopping
Figure 3.10: Oil Saver Pit
Figure 3.11: ‘Suction Tank below Pump suction Nozzle
Figure 3.12 Open Drain Pump Data Sheet issued for firm proposal
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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11
11
20
21
22
24
25
26
29
30
30
31
32
32
33
33
34
36
37
40
Page VIII of IX
List of Equations
Equation 2.1
Equation 2.2
Equation 2.3
Equation 2.4
Equation 3.1
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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8
9
13
92
Page IX of IX
1.
INTRODUCTION
1.1. Career Summary
This chapter summarises all the projects that I took part in. I was involved in different
projects at different design stage. For some I was involved in the conceptual or basic
design, for some other Detail Engineering Design and then a few others detailed
engineering design during fabrication.
I began my engineering experience by producing shop fabrication drawings and Bill of
Engineering material and Evaluation (BEME) from an Approved for construction drawing
(see Attachment A). Whenever a drawing gets to this revision what follows is the detailed
engineering design during fabrication. The basic skills required to carry out this project
are ability to interpret an Approved for Construction drawing, the use of AutoCAD to
produce shop fabrication drawing, and then measuring the pipe spool for dimensional
check.
My eight years of post-graduation experience was acquired by participating in the
following projects:
1. Cawthorne Channel Further Oil Development Project (CCFOD)
2. Pipeline Conceptual Design on OPL277
3. Engineering, Procurement and Installation of Topsides Facilities Bonga North
West (BMIP)
4. Industrial Gas Turbine Creep Life Analysis using Creep Factor Approach
5. Southern Swamp Associated Gas Solution Project (SSAGS)
6. Northern Option Gas Pipeline Project (NOPL)
1.1.1.Cawthorne Channel Further Oil Development Project
Date: Nov 2006 to Mar 2008
Contractor: WELTEK LIMTED
Client: Shell Petroleum Development Company Nigeria
The main project objectives of the Cawthorne Channel Further Oil Development (FOD)
Project are:
•
Expansions of Cawthorne channel 3 flowstation production capacity from a single
train (30Mbd) to double train flowstation (2 x 30Mbd).
•
Upgrade of flowstation instrumentation and control from pneumatic to electronic
using the foundation field bus technology in the five flowstations (CawC 1, 2, 3,
Awoba
and
Krakama).
All
redundant
pneumatic
equipment
will
be
decommissioned and returned to SHELL warehouse in Kidney Island.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 1 of 106
•
Change out of the existing gas engine driven reciprocating crude oil pumps, to
electric motor driven centrifugal pumps in CawC 1, 2, 3 and Awoba flowstations,
with the associated electrical upgrade works.
I carried out the following activity
•
Line Verification of :
-
Crude Oil Pump Suction Header
-
Crude Oil Pump Discharge Header
-
Suction line of each Crude Oil Pump
-
Discharge Line of each Crude Oil Pump
•
Equipment Sizing and Selection of Centrifugal Pump for crude oil export.
1.1.2.Pipeline Conceptual Design on OPL277
Date: Mar 2008 to October 2009
Contractor: WELTEK LIMTED
Client: Sterling Global Oil Resources Limited
The main project objectives of Pipeline Conceptual Design on OPL277 are:
•
Conceptual Design of 6” X 18km OPL 277 F/S to Addax FS Oil Pipeline
•
Conceptual Design of 6” X 17km OPL 277 F/S to Shell Egbema FS Gas Pipeline
•
Conceptual Design of 2 (two) 4” X 2.5km Well Flow lines
•
Conceptual Design of Lease Automatic Custody Transfer (LACT)
I carried out the following activities:
•
Using API 14e RP to size the pipes in the LACT unit. This unit measure the
quantity of Crude oil produced and their physical properties such as density see
Attachment B
•
Pipeline wall thickness calculation
•
3D Model of the LACT Unit
1.1.3.Industrial Gas Turbine Creep Life Analysis using Creep Factor
Approach.
Date: October 2009 to April 2011
Client: Petroleum Technology Development Fund
Contractor: Cranfield University, united Kingdom
Gas turbine hot section components can fail due to creep, low cycle fatigue, hot
corrosion or any combinations of these failure modes. The service life of aircraft engine
is limited by the low cycle fatigue life while industrial engine service life is fixed by the
creep life.
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This project presents a method of predicting the remnant creep life of high pressure
turbine (HPT) blade of aero-derivative gas turbine based on analysis of engine
performance at various ambient and engine health operating conditions. HPT blades
suffer permanent deformation due to application of mechanical and thermal loads held,
over a time at high temperature. This component is a critical component and can
significantly affect the life cycle cost of the overall engine.
Creep life at a design point is given by the engine manufacturer. This creep life defers at
off design conditions, so the users of gas turbine need to know the creep life available at
the conditions which the gas turbine will be operating.
To study the remnant creep life at various off design and deteriorated conditions, a case
engine similar to RB211 aero-derivative gas turbine is to be modelled using Pythia. The
engine is used for electric generation and so the engine handle for the simulation is
constant output power. Part load performance simulation, ranging from 82% part load to
full load is to be carried out. A simple creep model based on Physics law, Larson-Miller
relationship and Miners law is developed. The result of performance simulation is
imported into the creep model, for creep life analysis.
The concept of Creep Factor is used to reveal the magnitude of the impact of operating
an engine in conditions other than the user defined normal condition. In applying this
concept the reference creep life is the remnant creep life when operating the engine at
90% part load in clean condition, with varying ambient temperature of a hot climate
country.
1.1.4.Engineering, Procurement and Installation of Topsides Facilities
Bonga North West
Date: April 2011 –April 2013
Contractor: WELTEK LIMTED
Client: Shell Petroleum Development Company Nigeria
The Project comprises the fabrication engineering, procurement, fabrication and the
provision of support for SNEPCO during the offshore installation; hook-up, precommission, commissioning and start-up phases of the facilities.
Mechanical Scope of Work is the production of shop and other related drawings from
SNEPCO supplied drawings, onshore fabrication and the provision of support
facilities/services for the offshore hook up, pre-commissioning, commissioning and startup of the topsides mechanical infrastructure which includes:
•
Methanol Injection Skid
•
Hydraulic Control Unit and Hydraulic Power Unit Skid
•
Corrosion Inhibition Skid
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 3 of 106
•
Switchgear subsea control building (SSCB)
I carried out the following activity:
•
Generate Material Take off from the supplied AFC Drawing
•
To review the approved for construction drawings (AFC) sent to us by our client,
Then generate a fabrication drawing from the AFC
•
Produce a 3D Model for this structural skids with AutoCAD 2011
•
Supervise the fabrication of steel structures and pipe spools
•
Attend weekly project meeting
1.1.5.Southern Swamp Associated Gas Solution Project
Date: January 2013 till date
Client: Shell Petroleum Development Company
Contractor: Saipem Contracting Nigeria Limited
This is an EPC project involving the modification of existing facilities in four site locations
(flow stations) and the engineering designs and construction of a new gas Central
Production Facilities (CPF) in order to gather all Associated Gas (AG), which is flared till
now, and to export the Non-AG / AG to the domestic market at the required specification.
I carried out the following activity:
Preparation of Technical specification, Datasheet, supplier Document Requirement
listing (SDRL) and inspection datasheet for industrial Gas Turbine, Pumps, Centrifugal
Compressors, Bridge crane and Filters. Pump types include: Centrifugal API pumps (VS,
OH and BB); ASME Pumps (Horizontal End suction and Vertical In-Line). Other
responsibilities include Technical bid evaluations and vendor document review,
clarifications and follow-up.
1.1.6.Northern Option Gas Pipeline Project
Date: February 2014 till date
Client: Shell Petroleum Development Company
Contractor: Saipem Contracting Nigeria Limited
NOPL comprises about 52 kilometers of 24” pipeline with Above Ground Installations
(AGI) at RUMUJI (adjacent to the NLNG facilities) and at IMO RIVER (adjacent to the
NGC facilities).
NOPL will follow partially the route of the existing SPDC pipelines
between RUMUJI and IMO RIVER.
NOPL is expected to source its gas mainly from the 42” OUR Gas Pipeline with
(optional) provisions for additional tie-ins to 36” GST1 and 36” GTS4 at RUMUJI NODE.
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The scope of work includes but not limited to design, procurement, fabrication and
installation of 24’ X 52 km API 5L X65 pipeline and fiber optic cable between RUMUJI
and IMO RIVER, pig launcher and receiver at each extremity, sludge catcher at IMO
RIVER, and associated AGI (piping, SCADA, Fiscal Metering, firewater systems,
cathodic protection, electrical, instrumentation, etc.)
I carried out the following activity:
-
Vendor follow-up for Close Drain Pumps
-
Vendor follow-up for Condensate Pump:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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2.
CAWTHORNE CHANNEL FURTHER OIL DEVELOPMENT PROJECT
2.1. Introduction
Cawthorne Channel Further Oil Development Project (CCFOD) is an EPC Project. This
project was awarded to WELTEK Limited Port-Harcourt Nigeria at a contract sum of
40million USD. As the Mechanical engineer my contribution reported in this section is
detailed sizing and selection of the Crude Oil Export Pump and verification of the line
sizing. The crude oil export pump is changed from reciprocating to centrifugal pump as
demanded by client. Since this is a brown field the Piping system already exists. I
verified this line size. I also calculated for frictional losses along the suction piping,
frictional losses along the discharge piping, differential head, Shaft Power and electric
motor sizing.
2.2. Project Overview
Shell Production Development Company, SPDC operates the fields Cawthorne Channel,
Awoba and Krakama. These fields produce high yields of light crude oil. The facilities
associated with these fields comprise five flowstations: Cawthorne Channel 1 (CAWC1),
Cawthorne Channel 2 (CAWC2), Cawthorne Channel 3 (CAWC3), Awoba and Krakama.
At these flowstations the well-stream fluids are stabilised and the resulting crude oil is
transported to the oil terminal at Bonny. At the present time, the associated gas is
separated and flared at the flowstations.
The main project objectives of the Cawthorne Channel Further Oil Development (FOD)
Project are:
1. Expansions of Cawthorne channel 3 flowstation production capacity from a single
train (30Mbd) to double train flowstation (2 x 30Mbd).
2. Upgrade of flowstation instrumentation and control from pneumatic to electronic using
the foundation field bus technology in the five flowstations (CawC 1, 2, 3, Awoba and
Krakama). All redundant pneumatic equipment will be decommissioned and returned
to SHELL warehouse in Kidney Island.
3. Change out of the existing gas engine driven reciprocating crude oil pumps, to
electric motor driven centrifugal pumps in CawC 1, 2, 3 and Awoba flowstations, with
the associated electrical upgrade works.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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2.3. Project Contribution: Crude Oil Export Centrifugal Pump
2.3.1.Subject Matter Discussion
Centrifugal pump operating principle and terminologies used in this technical report are
discussed in this section
2.3.1.1.
Process for Selecting Ideal Pump
In pump selection there is a saying that the bitterness of poor selection is felt long after
the sweetness of low cost is forgotten.
The choice of pump depends mainly on the operating pressure, differential head,
operating temperature, volumetric flow rate, physical characteristics of the pumped
liquid, suction specific speed and NPSHA (net positive suction head available).
If more than one pump type is considered technically suitable, the final selection should
be based on a life cycle cost evaluation, taking into account standardization, efficiency,
suction specific speed, NPSH margin and minimum flow.
The followings steps are adopted in selecting the ideal pump:
•
Understand the Pump circuit particularly what determines the pressure in the
system.
•
Establish sparing criteria and hence pump flow
•
Estimate Suction and discharge system losses and hence pressures
•
Calculate the required pump head & NPSHA and NPSHR
•
Select an appropriate pump curve
•
Select the pump materials
•
Select seal, bearings and couplings
•
Select the ideal pump for the duty
•
Select the driver.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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2.3.1.2.
Head Provided by Pump and NPSH
Figure 2.1: Pump and Piping System
The total head, H. which must be provided by the pump in the arrangement shown in
Figure 2.1 above is:
H = hd − hs = H st + (h fd + h fs ) + (Pd − Ps )
Equation 2.1
Heads may be expressed either all in absolute units or all in gauge units, but not in
mixed units. The various head terms in this equation are, with reference to the
illustration:
hd = total discharge head
hs = total suction head
Hst = static head (differential) = D - S
hfd
= friction head loss in discharge piping, including exit loss (as liquid discharges
into vessel)
hfs = friction head loss in suction piping, including entrance loss (as liquid enters line
from header) and loss at reducer located at pump inlet
Pd
= Pressure head above liquid level in discharge vessel or header
Ps = Pressure head above liquid level in suction header
Net Positive Suction Head is defined by the equation below:
NPSH = S − h fs + Ps − Pvp
Equation 2.2
Where:
Pvp = vapour pressure of liquid at temperature of liquid at suction header. Vapour
pressure are given in absolute unit
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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2.3.1.3.
Cavitation and NPSHA
Net Positive Suction Head Available (NPSHA) is the difference between the total suction
system head and the fluid vapor pressure at the suction flange in absolute terms.
NPSHA depends on the suction piping system layout and must always be greater than
NPSHR to ensure proper pump operation and eliminate cavitation.
2.3.1.4.
Low recirculation and Suction Specific Speed
Suction-specific speed, S, an index number relating to a pump's suction performance, is
calculated at best efficiency point flow rate with the maximum diameter impeller at a
given rotational speed and provides an assessment of a pump's susceptibility to internal
recirculation. It is defined by Equation 2.3:
nq 0,5
Equation 2.3
S=
NPSH 30.75
Where:
n = the rotational speed, expressed in revolutions per minute
q = flowrate per impeller eye, expressed in cubic metres per second (US
gallons per minute),
Equal to one of the following:
• total flowrate for single-suction impellers,
• one-half the total flowrate for double-suction impellers
(NPSH3) = the net positive suction head required, expressed in metres (feet).
The suction specific speed (S) shall be calculated by the Manufacturer in accordance
with clause 6.1.9 of DEP 31.29.02.30-Gen. and shall be stated in the proposal. Suction
specific speeds shall be no greater than 12 800 unless approved by the client.
2.4. Line Sizing
2.4.1.Lines to be investigated
1. Crude Oil Pump Suction Header
2. Crude Oil Pump Discharge Header
3. Suction line of each Crude Oil Pump
4. Discharge Line of each Crude Oil Pump
2.4.2.General Criteria
According DEP 31.38.01.11 “Piping - General Requirements” the velocity should be in
the following range in order to size the lines:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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Water and other liquids: min. 0.5
to
max. 5 m/s
Air and other gases: min. 10
to
max. 20 m/s
Suction and Discharge Lines of Pumps: acc. Appendix 1 of DEP 31.38.01.11GEN
If multiphase flow exists, for each phase (gas/liquid) the individual phase velocities were
calculated.
2.4.3.Results
The following results have been achieved:
Table 2.1: Line Size Verification
Name
P&ID
pOp
[bar
TOp
Max. Flow
4)
[°C]
g]
To be
review
ed:
Line
Size
[inche
s]
Revie
Velocit
wed
y
Line
(revie
Size
wed
[inche
line)
s]
[m/s]
≈1
30
437 m³/h
18 3)
18 3)
0.9
Crude Oil Pump Attachmen
≈
30
437 m³/h
8 1)
8 1)
4.2
Discharge Header t C
35
Suction
≈1
30
110 m³/h
8
8
0.9
Attachmen
≈
30
110 m³/h
4
4
3.9 2)
tC
35
Crude Oil Pump Attachmen
Suction Header
Line
tC
of Attachmen
each Crude Oil t C
Pump
Discharge Line of
each Crude Oil
Pump
• Notes:
1) Same size as downstream oil delivery line
2) Due to short line length from the pumps to the discharge header and
existing space limitation the discharge line has been sized to 4”.
3) Extension of existing 18” crude oil suction header
4) From Process simulation report
The discharge header of export pumps is equally to the size of the pipeline. The length of
discharge header compared with the pipeline length regarding pressure drop can be
neglected. Therefore a 8”-size is verified.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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2.5. Export Pump Sizing
The oil export scheme is shown in the figure below. Pump is selected to transport the
crude oil from Cawthorne Channel3 flow station to the Nembe Creek Terminal Load
which is a distance of 2.5km
Figure 2.2: Oil Export Scheme
The crude oil will be exported by the crude oil export pumps by the existing 8” 2.5 km
delivery line. At its end the delivery line is tied-in into the NCTL system. The required
pressure in order to be able to enter the NCTL system and to export the fluid to its
destination is given by SPDC in the contract document as 34.3barg (see Figure 2.3).
Figure 2.3: Pressure at discharge Header for CAWC3
As the required pressure at the tie-in point is given by SPDC, the pressure drop from the
pump’s discharge flange until the tie-in point has been calculated. The required
discharge pressure of the crude oil export pumps has been calculated as the sum of
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 11 of 106
required tie-in pressure and pressure drop from the pump’s discharge flange until the tiein point.
2.5.1.Calculation & Results
The input data, calculation and results are given in this section
The required differential pressure of the pump shall be
P Differential at rated capacity = 34.3 bar (g)
V rated = 4 x 99.4 m³/h (4x15, 000 bpd)
Input Data:
Fluid: Crude oil and saline water
Capacity: Q: = 4 x 99.4 m3/h (4x15,000 bpd = 60,000 bpd) (Ref. 9, item 5.3)
Fluid density: ρ := 890 kg/m3 (Ref. 3)
Temperature: T: = 30 degree C
Fluid dynamic viscosity: H: = 0.003 kg/m/s (@30°C)
Plant Pressure Drop from Pump Discharge until Discharge Header
Calculation of static head:
Elevation at Pump:
Elevation
at
H0 = 0
m
Discharge H1= 0
m
Header:
∆HST = H1 - H0
Static Head:
m
∆HST = 0
Pressure losses between pump and discharge header
Pressure losses in fittings and valves:
Material
of
line Carbon Steel
pipes:
Volumetric flow:
Length of
Q1 := 99.4
straight L1 := 15
m3/h
m
line:
(estimated before
finalization of pump skid
detail design)
Inside diameter of di1 := 0.1
m
acc. Piping Class 61410
line:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 12 of 106
Roughness
k := 0.15
mm
coefficient:
4
πd i21
V1 = Q1 .
3600
Equation 2.4
V1 = 3.52m / s
Pressure losses in straight line sections:
Pressure losses in straight line sections,
∆PSL1 = 0.2bar
∆PSL1
Head losses in straight line sections, ∆HSL1
∆H SL1 = Q1 .
∆PSL1
.10 5
ρ .9.81
∆H SL1 = 2.29m
Pressure losses in fittings and valves:
No. of 90 degree elbows:
x := 6
Resistance coefficient of elbows:
ζE 90 = x * 0.25
ζE 90 = 1.5
No. of ball valves (full open):
y := 2
Resistance coefficient of ball valves:
ζBV = y * 0.1
ζBV = 0.2
No. of tees (inlet 4"/8"):
z := 1
Resistance coefficient of tees:
ζTees = z * 0.4
ζTees = 0.4
No. of non-return butterfly valves:
V := 1
Resistance coefficient of NR-valve:
ζNRV = v * 0.5 (full open)
ζNRV = 0.5
Total Resistance
ζ 1 = ζE 90 + ζBV + ζNRV + ζTees
Pressure losses in fittings and valves, ∆P
 Q
4 1
∆P1 = ζ 1.ρ . 1 . 2 .
 3600 πdi1  2
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 13 of 106
P 1 1.43 104 N/m2
∆H ζ 1 = Q1.
∆P1
ρ .9.81
∆H ζ 1 = 1.64
Control Valve:
∆H PCV = 0.5bar before final selection of
vendor
∆PCV
.10 5
ρ .9.81
∆H CV =
∆H CV = 5.73m
Flow Measurement:
∆pORI = 0.4bar
∆H ORI =
∆PORI
.105
ρ .9.81
∆H ORI = 4.58m
Total sectional dynamic pressure losses:
∆H1 = ∆H SL1 + ∆H ζ 1 + ∆H CV + ∆H Ori
∆H1 = 2.29 + 1.64 + 5.73 + 4.58
∆H ORI = 14.24m
Total pressure losses from Pump Discharge until Discharge Header:
∆H Plant = ∆H ST + ∆H1
∆H Plant = 0 + 14.24
∆H Plant = 14.24m
Considering a safety factor of 5%:
∆H PlantSF = ∆H Plant *1.05
∆H PlantSF = 14.24 *1.05
∆H Plant = 14.95m
Required pressure at Discharge Header:
require pressure at tie in point
∆PTP = 33bar
∆H TP =
∆PTP
.10 5
ρ .9.81
∆H TP =
33
.10 5
890 * 9.81
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 14 of 106
∆H TP = 377.97m
Required pressure of Crude Oil Export Pump:
∆H D = ∆H PlantSF + ∆H TP
∆H D = 14.95 + 377.97
∆H D = 392.92m( g )
∆PD =
∆H D * ( ρ * 9.81)
10 5
∆PD =
392.92 * (890 * 9.81)
10 5
∆PD = 34.31bar ( g )
∆PDa = ∆PD + 1.01325
pressure in discharge vessel,
∆PDa = 35.32bar (a)
Head at discharge Vessel
∆H Da =
∆PDa
*10 5
ρ * 9.81
∆H Da = 404.52m(a)
Note that the Value of differential head at discharge vessel changed from 404.52m
(a) to 247.5m (a) as shown in Figure 2.7 below. This is due to the fact that the
required tie-in pressure has been decreased by SPDC
2.5.2. Shaft Power Calculation
Total minimum suction head,
H ST = H SV + hmin S − H SL
(m)
HST
Pressure in Suction Vessel, 111
kPA (abs)
PSV
Head in Suction Vessel, HSV
Total head loss in suction line
H SV =
PSV *1000
ρ * 9.80665
H SV =
111 * 1000
= 12.72
890 * 9.80665
H SL = 0.5m
m.liq (abs)
(Provided by
between suction vessel and
process
pump, HSL
Department)
Minimum Height of liquid in
hmin S = 5.2m
(Provided by
suction vessel above pump
process
centreline, hminS
Department)
Total minimum suction head,
H ST = H SV + hmin S − H SL
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 15 of 106
HST
Total minimum suction head,
H ST = 12.72 + 5.2 − 0.5
HST
Total minimum suction head,
H ST = 17.42
m.liq (abs)
HST
Differential Head at Rated
∆H DS = H DT − H ST
flow
Total
maximum
discharge
H DT = H DV + hmin D + H DL
head (HDT)
Pressure in discharge vessel 201.30kPa (abs)
Provided by
PDV
SPDC
Head in discharge vessel, HDV
H DV =
PDV * 1000
ρ * 9.80665
H DV =
2160 * 1000
890 * 9.80665
H DV = 247.5m
Max.
liquid
height
in
Not
discharge vessel, hminD
Available
Friction loss in Discharge line,
Not
HDL
Available
Total
maximum
head (HDT)
discharge
H DT = H DV + hmin D + H DL
H DT = 247.5 + 0 + 0
H DT = 247.5m
∆H DS = H DT − H ST
∆H DS = 247.5 − 17.42 = 230m
Prated =
Power, Prated (kw)
Qrated * ρ * ∆H D * g

3600 *1000 * η
100


Where: Qrated = Process rated flow, m3/h
r = density at pumping temperature, kg/m3
ΔHDS = Differential Head at rated flow rate,
m
η = estimated efficiency
g = acceleration due to gravity
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 16 of 106
Prated =
99.4 * 890 * 230 * 9.81
3600 * 1000 * .52
Prated = 106.6kw
Table 2.2:Power rating for motor drives
Considering the API margin in the above table:
Motor name plating rate = 106.6*1.1=117kW
Table 2.3: Standard Rating for electric Motor
From Table 2.3 above 1 choose 132kW. 110kW is less than 117kW from the above
calculation hence was not selected.
2.5.3.Net Positive Suction Head Available
The NPSHA is calculated manually as shown below. However the equations used in this
calculation are entered in Microsoft Excel and result is as shown in the data sheet issued
to vendor for quotation see Figure 2.4 below.
Input Data
Volumetric flow, Q
99.4m3/h
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 17 of 106
Pump suction area, amp
0.029m2
Operating pressure, Pa
1.113bar
Vapor pressure, PV
1.113bar
Fluid density, ρ
890kg/m3
Minimum operating liquid level, H1min
6.2m
Maximum operating liquid level,H1max
7.5m
Pump suction level, H2
1.0m
Pressure losses in suction line, HV
0.5m
Temperature, T
300C
Calculation
Velocity at suction basin entry, Ve
Velocity Head, VH
Pressure Head less vapour pressure, PH
Ve =
Q
amp * 3600
Ve =
99.4
= 0.95m / s
0.029 * 3600
VH =
Ve2
0.95 2
=
= 0.05m
2 g 2 * 9.81
(
Pa − Pv ) *10 5 (1.113 − 1.113) *10 5
P =
=
= 0.00m
H
Geodetic Height,
ρg
890 * 9.81
∆H min = H 1 min − H 2 = 6.2 − 1.0 = 5.2m
∆H max = H 1 max − H 2 = 7.5 − 1.0 = 6.5m
NPSHA minimum
NPSHAmin =
(Pa − Pv )*105 + Ve2 − H + ∆H
ρg
2g
V
min
NPSHAmin = 0 + 0.05 − 0.5 + 5.2 = 4.75m
NPSHA maximum
NPSHAmax =
(Pa − Pv )*105 + Ve2 − H + ∆H
ρg
2g
V
max
NPSHAmax = 0 + 0.05 − 0.5 + 6.5 = 6.05m
2.6. Pump Data Sheet for Export Pump
Centrifugal pump and mechanical seal datasheets are designed to record requisition as
well as proposals data. For each application, the centrifugal pump and mechanical seal
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 18 of 106
datasheets shall be issued several times, electronically in Excel format, with the issue
status as below:
Table 2.4: Data Sheet Issued for Firm Proposal and Order Placement
Issue
Firm
Proposals
#
Purpose
To enquire for technical and commercial proposals, which shall
be used to nominate pump and mechanical Seal Vendors for
each application. Nomination of Seal Vendor(s) shall be
undertaken during the Project Definition phase of the project.
Nomination of Pump Vendor(s) shall be undertaken during the
Project Implementation phase of the project.
Requisition data to support the purchase order, which will be
Order
placed on Nominated Pump Vendor and the sub-order, which
Placement will be placed by Nominated Pump Vendor on Nominated Seal
Vendor.
2.6.1.Issued for firm proposal
Contractor revised the Pump datasheets and marked it ‘Issued for Firm Proposal’.
Contractor passed pump datasheet and seal datasheet from Nominated Seal Vendor to
Selected Pump Vendor(s) and invites submission of Firm Proposal(s).
Pump Vendor(s) shall select pump type and size, based on the requisition data and shall
enter all information requested on the datasheet under columns headed ‘Firm Proposal’
(see Figure 2.4 below)
Pump Vendor(s) shall provide a Firm Proposal including the following information:
•
Firm price for standard pump scope of supply;
•
Firm price for standard seal scope of supply;
•
Separate prices for each additional requirement as requested in the enquiry;
•
Completed datasheets (see Figure 2.6 below), drawings and production, testing
and delivery schedule;
Full details of materials of construction, design and reference lists to facilitate approval
and acceptance of products classified as ‘Engineered Solution”
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 19 of 106
1
2
D a ta / re q uis itio n s he e t fo r
CENTRIFUGAL PUMP NUMBER(S)
P -2390 A / B / C/ D / E
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Issued for Quotation
( based on preliminary process data )
3
Pump manufacturer :
:
Pump type/size
Manufacturers ref. # :
OPERATING DATA
31 deg.C
:
: Crude Oil and saline water
Pumped Liquid
Pumping temperature ( Normal )
:
18 deg.C
mg/kg Pumping temperature ( Minimum )
:
H2 S content
42 deg.C
:
:
Liquid Type
Abrasive
Corrosive
Pumping temperature ( Maximum )
: 890.00 kg/m3
:
Hazardous Category
Non-hazardous
Density at pumping temperature
:
3.6 mm2 /s
Normal process Flow
:
4 x 27.6 dm3 /s Viscosity at pumping temperature
:
Rated process Flow
4 x 27.6 dm3 /s Vapour pressue at pumping temperature
1.11 bara
:
1.11 bara
:
:
Minimum process flow
By Supplier dm3 /s Pressure in suction vessel
Single / Parallel Operation:
:
35.3 bara
Parallel
Pressure in discharge vessel
2.1 bara
Continuous / Intermittent :
Continuous
Highest possible pressure in suction vessel :
:
Remote starting
No
Specific process conditions during start/stop/transients :
:
Service category
Essential
see notes 8) , 9) and 10)
: Clockwise ( facing pump drive end )
Direction of rotation
PUMPING DATA
12.8 m liq.abs. Head in discharge vessel
:
404.4 m liq. abs.
:
Head in suction vessel
Min. height of liquid level in suction vessel
Max. height of liquid level in discharge
:
:
5.2
m
above pump centre line (minus if below)
vessel above pump centre line(minus if
Total head loss in suction line between
Total head loss in discharge line
:
:
0.5 m liq.
suction vessel and pump
between pump and discharge vessel
:
404.4 m liq. abs.
17.5 m liq.abs. Total maximum discharge head
:
Total minimum suction head
387.0 m liq.
:
:
12.8 m liq.abs. Differential head at normal flow
Head of vapour pressure
4.7 m liq.
:
%
:
Estimated efficiency
Minimum available NPSH
kW
:
SITE CONDITIONS
Power at estimated efficiency
:
Ambient temperature ( minimum )
PUMP DRIVER
18 deg.C
:
42 deg.C Type
:
Ambient temperature ( maximum )
Electric Motor
:
: Tropicalisation Fixed / Variable Speed
Winterisation / Tropicalisation required
Fixed speed
Area classification
:
:
Zone 2 ExnAII T3
Transmission
Direct drive
kW
Estimated installed power
:
Local Authority requirements :
Customer's reference
Location
Number required
:
: CAWC-3
: 5 = 4 + 1 Spare
33
34
35
36
37
38
39
40
COOLING WATER
Chlorine content
Maximum inlet temperature
Maximum allowable outlet temperature
Supply pressure
Return pressure
Fouling coefficient
:
:
:
:
:
STEAM HEATING
ppm
deg.C
deg.C
ELECTRICAL SUPPLIES
bara
:
Electrical frequency
Voltage
Motors : 6,6 k V
bara
Heaters :
Motors : 3 Phases
Heaters :
W/m2 .K Phase
50
Hz
Volts
Figure 2.4: Pump Data Sheet Issued for firm proposal (Sheet 1)
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 20 of 106
Figure 2.5: Pump Data Sheet Issued for firm Proposal (Sheet 2)
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 21 of 106
Figure 2.6 Data sheet Returned by Vendor
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 22 of 106
2.6.2.Issued for order Placement
Contractor shall revise datasheets to reflect the agreement and shall mark them ‘Issued
for Order Placement’ (See Figure 2.7 below)
Contractor shall re-issue datasheets
together with purchase order to the Nominated Pump Vendor for the full agreed scope of
supply. Pump Vendor shall issue a purchase order for the Nominated Seal Vendor’s
agreed scope of supply.
As it can be seen from the data sheet below the required export pressure is lower as
specified in the contract documents. This is due to the fact that the required tie-in
pressure has been decreased by SPDC. Thus a lower pump discharge pressure is
required. The pressure in Discharge Vessel is 21.6bara and not 35.3bar.a
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 23 of 106
Figure 2.7: Issued for Order Placement (sheet 1)
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 24 of 106
1
2
CENTRIFUGAL PUMP NUMBER(S)
P-2390 A/B/C
Issued for Order Placement
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Customer's ref
: E-13597
Manufacturer's ref. : 266Q4140470
GENERAL INFORMATION
REQUISITION
FIRM SPEC.
Compliance with Procurement Initiative Manual
Specification dated
DESIGN OPERATING CONDITIONS
REQUISITION
FIRM SPEC.
rpm
/
/
Pump speed (single/double suction impeller)
Min. continuous flow (stable / thermal)
by vendor
dm3 /s
Rated Capacity
2 x 27.6
dm3 /s
Differential head at rated capacity
m liq.
230.0
Efficiency at rated capacity
%
Power absorbed at rated capacity
kW
Capacity at BEP (actual impeller size)
by vendor
dm3 /s
Power absorbed at 120 % BEP
kW
by vendor
Recommended driver power
kW
by vendor
Viscous correction factors
CQ/CH/CE
/
/
/
/
m H2 O
#REF! Max.
NPSH required from Minimum to Rated capacity
m H2 O
4.7
Max.
NPSH required from Rated to 125% BEP capacity
PUMP DESIGN
REQUISITION
FIRM SPEC.
Pump model / frame / size :
by vendor
oh
= API 610 Basic Type ( Rotor )
= API 610 configuration code
= Single / Double volute / Diffuser
DEP 31.29.02.11
= Single / Double suction (first stage)
Single suction
Number of stages
Minimum
Max. / Actual / Min. impeller diameter
mm
/
/
by vendor
Max. allowable casing working pressure
bara
DEP 31.29.02.30
Max. allowable jacket / C.W. piping pressure
bara
DEP 31.29.02.30
Suction specific speed with max. impeller
Less than 6,730
3
diameter at BEP (dm /s - m - rpm )
MECHANICAL SEAL & SEALING SYSTEM
Seals and Sealing System shall be in accordance with requisition number :
MATERIALS OF CONSTRUCTION
REQUISITION
FIRM SPEC.
S6
Service Group / Material Group:
Casing
Inner casing or volutes
Casing studs
Min. wall thickness
mm
Cover
Casing gaskets
Wet bolting
Bearing bracket
Impeller
Impeller wear ring hardness
HB
Casing wear ring hardness
HB
Wear ring coating
Diffuser
Shaft
Interstage shaft sleeve
Interstage bushing
Balance drum
Balance ring
Throat bushing
PRESSURE CONTAINING PARTS
REQUISITION
FIRM SPEC.
Pump casing manufacturer
by vendor
Pump covers manufacturer
by vendor
ORDER SPEC.
15-Sep-2005
ORDER SPEC.
/
3000
9.7
2 x 27.6
230
52.4
105
34.4
124
132
1.0 / 1.0 / 0.99
2.4
ORDER SPEC.
3 HED 16 DS
Double volute
Double suction
2
410 / 318 / 300
80
5076
ORDER SPEC.
A216 WCB
A193 B7
A216 WCB
A193B7/194 2H
A216WCB
A487 CA6NM
A426 CPcA15
A426 CPcA15
A434 4140/A276-410
ORDER SPEC.
Figure 2.8: Issued for Order Placement (sheet 2)
2.6.3.Pump Curves
This pump curve was submitted by the Vendor based on the above data sheet. This
Pump curve was analysed against the following API 610 requirement:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 25 of 106
•
Rated flow shall be selected between 80 % and 110 % of best efficiency point
(BEP) for the rated impeller.
•
Pumps shall be capable of at least a 5 % head increase at rated conditions by
replacement of the impeller(s) with one(s) of larger diameter. This requirement is
intended to prevent a different pump having to be purchased due to a refinement
of hydraulic requirements after the original pump has been purchased.
•
The value of Suction Specific Speed shall be 12,800 (11,000 in USC units) or less
Figure 2.9 Pump Performance Curve
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 26 of 106
3.
SOUTHERN SWAMP ASSOCIATED GAS SOLUTION PROJECT
3.1. Introduction
This project was awarded to saipem Contracting Nigeria Limited at a contract sum of
1billion USD.
I was employed as a rotating equipment engineer and contributed in the sizing selection
and procurement of the following equipment:
•
Air Driven Pumps
•
ASME Centrifugal Pumps for Potable, Service and Heating medium pump
•
Vessel with Bladder
•
Self-priming pump for open drain system
However due to similarity of approach in sizing and selection of these equipment, this
section focused on the self-priming pump for open drain system.
The activities carried out include developing an equipment pump data sheet, supplier
document requirement listing, (SDRL), Inspection Data sheet and Technical supply
specification.
Afterward technical tabulation, clarification and Bid Evaluation were carried out for the
selection of this equipment vendor.
3.2. Project Overview
The Southern Swamp area comprises 16 fields (12 producing and 4 partially appraised
fields (PAFs) with Scope for Recovery (SFR) volumes in the order of 858 MMboe. The
fields are situated in OMLs 35, 36 and 46 in the coastal swamp area, 65km South of
Warri. All existing production in the area is gathered into a total of four flow stations
located at Tunu, Ogbotobo, Benisede and Opukushi. The produced oil in the area is
evacuated via the Trans Ramos pipeline to the Forcados Terminal whilst the associated
gas is currently flared.
The Southern Swamp Integrated Oil & Gas Project (SSIOGP) was initiated in October
1999 with a mandate for further oil development and ending routine flaring at the flow
stations. Between 1999 and 2008 the project passed through a number of re-framing
efforts which considered different development concepts.
The concept of AGG and new oil development was matured in 2005 was progressed to
EPC tendering stage in 2005 before the project stalled due to unfavourable business
environments. However, the current concept has incorporated NAG opportunities in the
area to improve the gas supply to the domestic market.
The project intent is to utilise ullage in the existing surface facilities and infrastructure
without adversely impacting surface facility capacities.
The overall project scope is summarised below:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 27 of 106
•
Construct a new Central Processing Facilities (CPF) at Tunu comprising but not
limited to:
- 2 x 50% associated gas compression system (gas turbine driven centrifugal
compressors)
- Twister hydrocarbon dew pointing and dehydration facilities
- 2 x 50% export compression system (gas turbine driven centrifugal
compressors)
- Main (3x50%) and 1x100% blackstart/emergency (essential loads) Electrical
power generation system
- Electrical Power distribution System
- AC and DC UPS Systems complete with battery banks.
- Cathodic Protection System
- Earthing and Lighting Protection System
- Lighting and small power distribution system
- Allocation gas metering system
- CDM Ultrasonic meters.
- Instrument Air package
- Process, drain and utility pumps
• Refurbish Tunu, Benisede, Opukushi and Ogbotobo flow stations through
Brownfield upgrade with the following scope:
- Install a gas engine driven booster compressor package in each of the flow
stations:
at Tunu No. 3 5MMSCFD (3 x 33%)
at Benisede No. 2 10MMSCFD (2 x 50%)
at Opukushi No. 3 10MMSCFD (3 x 33%)
at Ogbotobo No. 2 5MMSCFD (2 x 50%), together with minor flowstation
upgrades.
- Install a (2 x 100%) fixed speed electric motor driven surge vessel gas booster
compressor at Tunu flow station
- Install a (1 x 100%) fixed speed electric motor driven surge vessel gas booster
compressor at Ogbotobo, Benisede and Opukushi flow stations
- Install main (4 x 33%) and blackstart/emergency (1x100%) Electrical power
generation systems at Benisede and Opukushi flow stations
- Install main (3 x 50%) and blackstart/emergency (1x100%) Electrical power
generation systems at Ogbotobo flow station
- Decommission existing Electrical Power generation systems at Tunu, Ogbotobo,
Benisede and Opukushi flow stations
- Install Electrical Power Distribution Systems at Ogbotobo, Benisede and
Opukushi flow stations
- Decommission existing 3.3 kV HV Switchgear at Ogbotogbo flow station
- Install A.C and D.C UPS Systems complete with battery banks, at Ogbotobo,
Benisede and Opukushi flow stations
- Install Cathodic Protection System at Tunu, Ogbotobo, Benisede and Opukushi
flow stations
- Install Earthing and lightning protection system at Ogbotobo, Benisede and
Opukushi flow stations for the AG Handling facilities
- Tie-in of the Tunu, Ogbotogbo, Benisede and Opukushi flow stations existing
Earthing system to the new Earthing and Lightning protection systems
- Install Lighting and small power distribution system at Ogbotobo, Benisede and
Opukushi flow stations for the AG handling facilities
- Install process, drain and utility pumps (various) at Tunu, Benisede, Opukushi
and Ogbotobo flow stations
- Install instrument air compression packages at Benisede, Opukushi and
Ogbotobo flow stations
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 28 of 106
3.3. Project Contribution-New Open Drain Pumps
3.3.1.Subject Matter Discussion
The type of pump selected for the open Drain system is the self-priming centrifugal
pump. This pump is used to pass recovered oil back to the surge vessel. To prevent
leakage every pump makes use of mechanical seal. The principle of operation of selfpriming pump, mechanical seal and other terminologies used in its design and
procurement are discussed in this section:
3.3.1.1.
Centrifugal Pump and Mechanical Seal
A centrifugal pump is simply a shaft, suspended on bearings with an impeller attached to
one end. The impeller is encased in a housing that is filled with a liquid. As the shaft is
rotated, centrifugal force expels the liquid out through an orifice, where it is typically
piped into a process or another collection point.
Figure 3.1 Major Component of Centrifugal Pump
As the expelled liquid exits the case, additional liquid is added to the case so that a flow
develops. That is basically how a centrifugal pump works.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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Figure 3.2: Centrifugal Pump Operating Principle
The force of the expelled liquid creates pressure. This liquid under pressure will seek
areas of lower pressure. This is a known physical principle of hydraulics. Some form of
seal must be applied to keep liquid from leaking around the shaft at the point where it
enters the case to drive the impeller. This is where our mechanical seal comes into play.
Take a look at the same pump again. The mechanical seal is behind the impeller: within
the yellow rectangular box in Figure 3.3 below:
Figure 3.3: Centrifugal Pump with Mechanical Seal
A cartridge type mechanical seal is a pre-assembled package of seal components
making installation much easier with fewer points for potential installation errors to occur.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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Figure 3.4 Cartridge Mechanical seal
3.3.1.2.
Self-Priming Principle
3.3.1.2.1. Pump Stopped Before Priming
Avoid foot valves or suction strainers as they can restrict the priming and pumping
process. The suction line must not be excessively large- the inlet pipe should be as short
as possible and have the smallest practical volume. It is recommended that the inlet pipe
should be no larger than the Pump inlet bore. The suction line must be airtight to achieve
the optimum priming time. If there is a delivery valve it will need to be at least partially
open. If there is a non-return valve then a bleed pipe will be required to allow venting
during the priming cycle.
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Figure 3.5: Pump Stopped before Priming
3.3.1.2.2. Initial Fill
The pump casing must be filled with liquid before the first start up. The casing should be
filled to the level mark with process compatible liquid. The liquid to be pumped should
have the characteristic that entrained air will be released without generating excessive
foam
Figure 3.6: Initial fill
3.3.1.2.3. Pump Priming Cycle
The air from the suction line is mixed with liquid in the impeller. The liquid/ air mixture is
centrifuged into the upper chamber of the casing where the velocity is lower allowing air
to escape through the discharge. The de-aerated liquid, having a higher density, flows
back into the volute where it is again aerated. The cycle continues until all the air in the
suction line has been evacuated.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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Figure 3.7: Pump Priming Cycle
3.3.1.2.4. Pump Primed and Running
When all the air has been evacuated from the suction pipe the pump operates as a
normal centrifugal pump.
Figure 3.8: Pump Primed and Running
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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3.3.1.2.5. Pump Remain Primed after Stopping
When the pump is stopped the liquid from the discharge pipework flows back through the
pump and into the sump. The casing is designed to retain sufficient liquid to start the
priming cycle when required.
Figure 3.9: Pump remained Primed after Stopping
3.3.1.3.
Procurement Process for Centrifugal Pumps
For procurement of centrifugal pumps accurately and completely tell the supplier:
•
The scope of his supply
•
All the machine design and operating cases
•
All the design specifications and standards with which the machine must comply
•
What are the site conditions
•
What utility system are available
•
Use an API 610 data sheet to transmit process and mechanical data
3.3.1.4.
•
Golden rule for Centrifugal Pump Procurement
Ask the supplier for all the data you need to fully appraise his bid and complete a
bid comparison
•
Do not send the bid request to suppliers you will not order from
•
Obtain a statement of compliance
•
Carry out a detailed bid analysis
•
Meet with chosen supplier prior to order placement
•
Review the need for installation and/or commissioning engineer
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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•
Ensure that supplier has a local base
•
Consider limiting the number of suppliers
•
Consider that the initial Pump cost is only 20% to 30% of its life cycle cost.
3.3.1.5.
Bid Tabulation
For proper bid tabulation list all this Engineering variables:
•
Design data: NPSHR, design pressure, head, flow, best efficiency point and
number of stages
•
Pump speed, critical speed and Shaft stiffness
•
Utility requirement and Drivers details.
•
Seal, coupling and Bearing Design
•
Material of construction
•
Compliance with standard and specifications
•
Supplier experience
•
Size weight and nozzle size
•
Painting
Also list the entire important commercial variable
•
Cost, delivery, warranty details
•
Difference from scope of supply
•
Non-compliance data
•
Extent of equipment testing offered
•
Commissioning engineer costs
•
Cost of spares and possible optional extras
•
Vendor drawing schedule
•
Life cycle costs
•
Payment schedule and currency
•
Transport cost and method
It is important to have a non-compliance list from the supplier since it will alert the
purchaser to any requirements, which will not be met, without having to search for them
in the bid documents. It may also mean, that a decision whether one of those
requirement was ‘a must have’ and hence may invalidate one potential suppliers bid.
Vendor drawings are essential to ensure that other parts of the project team can carry
out their work, e.g. electrical load list, pipe routing foundation design etc.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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3.3.2.Open Drain system
The existing open drains system enables liquids from existing process vessels to be
drained via the open drain header to the oil saver tank. The oil saver pit is an API
separator with separate compartments for skimmed oil and water. Oil from the saver pit
is pumped back into the process via the surge vessel where it is combined with the
process stream and exported to Bonny Terminal. The water flows under gravity to the
waste pit where it overflows into the creek.
Figure 3.10: Oil Saver Pit
Pumping temperature ( Normal )
Pumping temperature ( Minimum )
Pumping temperature ( Maximum )
Density at normal pumping temperature , r
Kinematic Viscosity at normal pumping temperature
AMB
1000.00
0.62
Vapour pressure at normal pumping temperature
30.00
Pressure in suction vessel
101.30
Pressure in discharge vessel
201.30
Highest possible pressure in suction vessel
101.30
Rated process Flow
15.00
deg C
deg C
deg C
kg/m3
mm2/s
kPa
(abs)
kPa
(abs)
kPa
(abs)
kPa
(abs)
m3/h
3.3.3.Verification of Process Data Sheet
Process department prepares data sheet based on process simulation. The information
in this data is verified by applicable equation. Figure 3.11 below shows that the liquid is
below the pump suction and hence the need to use self-priming pump: connection betw
The parameters to be verified are:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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•
Net Positive Suction Head Available
•
Differential Head at Rated flow
•
Power absorbed at rated capacity
Figure 3.11: ‘Suction Tank below Pump suction Nozzle
3.3.3.1.
Net
NPSHA Verification
Positive
Suction
NPSHA = H ST − H VP
(m)
H ST = H SV + hmin S − H SL
(m)
Head Available
Total minimum suction
head, HST
Pressure
in
Suction 101.3
kPa (abs)
Vessel, PSV
Head in Suction Vessel,
HSV
Total
head
loss
suction
line
suction
vessel
in
H SV =
PSV *1000
ρ * 9.80665
H SV =
101.3 *1000
= 10.33
1000 * 9.80665
H SL = 1.13m
between
m.liq (abs)
(Provided by process
Department)
and
pump, HSL
Minimum Height of liquid
hmin S = −3.55m
in suction vessel above
(Provided by process
Department)
pump centreline, hminS
Total minimum suction
H ST = H SV + hmin S − H SL
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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head, HST
Total minimum suction
H ST = 10.33 − 3.55 − 1.13
head, HST
H ST = 5.65
m.liq (abs)
Vapour pressure, PVP
30
kPa (abs)
Head
H VP =
PVP *1000
ρ * 9.80665
30 X 1000
H VP =
= 3.06
1000 X 9.80665
m.liq (abs)
Total minimum suction
head, HST
of
Vapour
Pressure, HVP
NPSHA = H ST − H VP
NPSHA = 5.65 − 3.06 = 2.59
NPSHA calculated same as shown in the process data sheet. (See Figure 3.12 below)
Differential Head Verification
Differential Head at rated flow is the difference between the Total maximum discharge
head (HDT) and Total minimum suction head (HST)
Differential
Head
at
∆H DS = H DT − H ST
Rated flow
Total
maximum
H DT = H DV + hmin D + H DL
discharge head (HDT)
Pressure in discharge 201.30kPa (abs)
Provided by process
vessel PDV
Department
Head
in
discharge
vessel, HDV
H DV =
PDV .1000
ρ .9.80665
H DV =
201.30 X 1000
1000 X 9.80665
H DV = 20.53m
Max. liquid height in 7.00
Provided by process
discharge vessel, hminD
Department
Friction
Provided by process
loss
in 21.7m.liq
Discharge line, HDL
Department
H DT = H DV + hmin D + H DL
H DT = 20.53 + 7.00 + 21.7
H DT = 49.23m
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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∆H DS = H DT − H ST
∆H DS = 49.23 − 5.65 = 43.58m
Differential Head at rated flow calculated is as shown in process data sheet.
3.3.3.2.
Power absorbed verification
The power absorbed by the process liquid is given by the equation below:
Note that the efficiency used in this equation is estimated. Vendor efficiency as seen
from the tabulation sheet is different from this estimated value
Prated =
Power, Prated (kw)
Qrated * ρ * ∆H DS * g

3600 *1000 * η
 100 
Where: Qrated = Process rated flow, m3/h
r = density at pumping temperature, kg/m3
ΔHDS = Differential Head at rated flow rate,
m
η = estimated efficiency
g = acceleration due to gravity
Prated =
15 *1000 * 43.58 * 9.81
3600 *1000 * .5
Prated = 3.56kw
Absorbed power at rated flow is same as shown in the process data sheet.
Now we proceeded to mechanisation of process data sheet. The major concern of the
rotating equipment engineer is the mechanical seal,
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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3.3.4.Mechanical Data Sheet for Open Drain Pumps
Figure 3.12 Open Drain Pump Data Sheet issued for firm proposal
3.3.5.Supply Specification for New Open Drain Pumps
Supply Specification, along with the datasheets, IDS (Inspection Datasheets) and SDRL
(Supplier Document Requirements Lists) defines the requirements for the supply of the
New open drain pumps. It covers minimum technical requirements for mechanical,
electrical, instrumentation and structural design together with fabrication, shop
inspection, testing, preservation, packaging and transportation.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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The outline of a supply specification is as follows:
1.
INTRODUCTION
1.1.
Project Overview
1.2.
Scope
1.3.
Definitions
1.4.
Abbreviations
1.5.
Language
1.6.
Units of Measurements
2.
UNIT RESPONSIBILITY
3.
APPLICABLE CODES, STANDARDS AND SPECIFICATIONS
3.1.
Project Specifications
3.2.
Project Datasheet
3.3.
Shell DEPs (Design Engineering Practice)
3.4.
Shell Standard Drawings
3.5.
National and International Codes and Standards
3.6.
Conflicting Requirements
3.7.
Deviations/Exceptions to Specifications
4.
ENVIRONMENTAL DESIGN CRITERIA
4.1.
General
4.2.
Area Classification
4.3.
Site Environmental Data
5.
SCOPE OF SUPPLY
5.1.
Vendor Scope
5.2.
Sub-supplier List
5.3.
Spare Parts
5.4.
Special Tools
5.5.
Training
5.6.
Documentation/Certification
5.7.
Exclusions
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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5.8.
Name plates
6.
TECHNICAL REQUIREMENTS
6.1.
General
6.2.
Pumps
6.3.
Main Drivers
6.4.
Couplings
6.5.
Mechanical Seals
6.6.
Piping, Valves and Tubing
6.7.
Baseplate
6.8.
Instrumentation and Controls
6.9.
Noise limits
6.10. Operating and Maintenance Requirements
6.11. Materials and Certification
7.
INSPECTION AND TESTING
8.
PAINTING, PRESERVATION, PREPARATION AND SHIPMENT
8.1.
PAINTING AND PROTECTIVE COATING
8.2.
TRANSPORTATION
8.3.
PREPARATION FOR SHIPMENT
9.
INSTALLATION
10.
QUALITY ASSURANCE
11.
SUB-CONTRACTS
12.
GUARANTEES
13.
WARRANTY
14.
ATTACHMENTS
3.3.5.1.
INTRODUCTION
3.3.5.1.1. Project Overview
Same as in Paragraph 3.2above
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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3.3.5.1.2. Scope
This Specification, along with the datasheets, IDS (Inspection Datasheets) and SDRL
(Supplier Document Requirements Lists) defines the requirements for the supply of
ASME B73.1 Horizontal end suction Self-Priming Pumps for Tunu, Benisede, and
Opukushi flowstations, for the Southern Swamp Associated Gas Solutions (SSAGS)
project.
It
covers
minimum
technical requirements for mechanical,
electrical,
instrumentation and structural design together with fabrication, shop inspection, testing,
preservation, packaging and transportation.
Objects of this specification are the following items:
No. of
Unit
Item
pump
s
Tunu
Flowstatio
Saver Pit Pumps TUNF1-P-5701 A/B
2
Saver Pit Pumps BENF1-P-5701 A/B
2
n
Pump
Typology
Self Priming
Overhung
Benisede
Flowstatio
Overhung
n
Opukushi
flowstation
Self Priming
Saver Pit Pumps OPUF1-P-5701 A/B
2
Self Priming
Overhung
The pumps are to be installed in a swamp area, located some 65 km South of Warri in
the Niger Delta area. All pumps at Tunu, Benisede and Opukushi AG Booster stations
shall be installed on concrete foundations.
Pumps shall come complete with fixed speed electric motor driver, self contained seal
system, fully assembled and wired, instrumented, tested and pre-commissioned in
accordance with datasheets, this specification and applicable standards and DEPs in
section 3.
All equipment shall be supplied complete, single Baseplate mounted and require
minimum site work to bring it into operation.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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3.3.5.1.3. Definitions
For the purpose of this specification, the following definitions shall have the meanings
stated:
SHALL - Indicates a mandatory requirement
SHOULD - Indicates a preferred course of action or strongly recommended to comply
with the requirements of this specification.
MAY - Indicates an acceptable course of action
PRINCIPAL - The party who initiates the project and ultimately specifies the technical
requirements, which is Shell. The PRINCIPAL may also include an agent or
consultant, authorised to act for the PRINCIPAL e.g. EP Projects & Engineering.
CONTRACTOR - The party who carries out all or part of the engineering,
procurement, construction and commissioning of a project. For SSAGS Project
SAIPEM CONTRACTING NIGERIA LIMITED (SCNL) shall be the CONTRACTOR to
carry out all EPC Activities. The PRINCIPAL may sometimes undertake all or part of
the duties of the CONTRACTOR.
VENDOR - The party who manufactures the equipment to perform the duties specified
by the CONTRACTOR.
SUB-VENDOR - The party who supplies services and/or the equipment to perform the
duties specified by the VENDOR.
INSPECTING AUTHORITY - The body or organization, appointed to carry out an
independent design review, and ensure compliance to Quality Assurance processes,
as required by the Codes and Specifications.
3.3.5.1.4. Abbreviations
AG
Associated Gas
API
American Petroleum Institute
ASME
American Society of Mechanical Engineers
BfD
Basis for Design
CAPEX
Capital Expenditure
CPF
Central Processing Facility
DC
Direct Current
DCS
Distributed Control System
DEP
Design & Engineering Practices
EGASPIN
Environmental Guidelines and Standards for the Petroleum Industry
in Nigeria
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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EPIC
Engineering, Procurement, Installation and Commissioning
ESD
Emergency Shutdown
E-SPIR
Electronic Spare Parts Interchange ability Record
FAT
Factory Acceptance Test
GAs
General Arrangements
HFE
Human Factors Engineering
HSE
Health, Safety & Environment
HMI
Human Machine Interface
IASS
Integrated Automation Safety System
IDS
Inspection Data Sheet
IEC
International Electrotechnical Commission
IFAT
Integrated Factory Acceptance Tests
I/O
Input/Output
IOM
Installation, Operation and Maintenance
ISO
International Standards Organisation
ITP
Inspection and Test Plan
MAWP
Maximum Allowable Working Pressure
MMSCFD
Million Standard Cubic Feet per Day
MOP
Maximum Operating Pressure
NAG
Non Associated Gas
NFA
No Further Activity
NDE
Non Destructive Examination
OSD
Operational Shutdown
PEFS
Process Engineering Flow Scheme
PFS
Process Flow Scheme
ppmw
Part per million weight
QA/QC
Quality Assurance / Quality Control
QMS
Quality Management System
RPM
Revolutions Per Minute
SDRL
Supplier Document Requirements Listing
SIL
Safety Integrity Level
SIS
Safety Instrumented System
SPDC
Shell Petroleum Development Company of Nigeria
TAMAP
Technically Accepted Manufactures And Products
TEFC
Totally Enclosed, Fan Cooled
UCP
Unit Control Panel
UEFS
Utility And Engineering Flow Scheme
UHF
Ultra High Frequency
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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UPS
Uninterruptible Power Supply
3.3.5.1.5. Language
Unless otherwise agreed in writing, the language of written and spoken communication
between the parties to this scope of supply shall be English. Translation to English of
communications in other languages shall be provided.
English language shall be used for all documents, drawings and manuals.
3.3.5.1.6. Units of Measurements
Units shall be in accordance with the system international (SI) form of units unless
otherwise stated
3.3.5.2.
UNIT RESPONSIBILITY
VENDOR shall be responsible for all aspects of the work performed by VENDOR and his
SUB-VENDORs covered by assigned Order; this shall include, but not limited to,
responsibility for management and design development, quality, costs and scheduled
performance.
VENDOR shall ensure the satisfactory mechanical, acoustic, and
thermodynamic performance of the complete supply.
VENDOR shall assure responsibility for the entire train, including driver, seal system and
all auxiliary equipments and components included in the scope of supply.
VENDOR’s responsibilities shall include, but not be limited to the followings:
Furnish all components required for the entire train (except what specifically listed being
outside scope of supply)
Connect to single INLET/OUTLET connections all piping entering and leaving the
baseplate for internal distribution (drain, vent, water, N2, air, etc…)
Resolving all engineering question or problems related to the supply rating
Selecting and rating all components in the supply, ensuring applicable operating
experience
Furnish all drawings including mechanical, Instrument, electrical, etc…drawings as per
this requisition
Testing the equipment and resolving all problems revealed during tests, prior to shipment
Provide lubricants and hydraulic fluid consumption, filling the Lubricants Data Sheets.
Type and physical properties of oils or other fluids and greases shall be specified in
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 46 of 106
sufficient detail to permit a proper selection and procurement. lubricants shall be
selected within Shell range of products
Co-ordinating all instruments and auxiliary items such as vibration detection devices,
thermocouples, etc…(if any) in order to maintain interchangeability of parts furnished by
the VENDOR and Sub-suppliers, and to minimise varieties of parts needed for
maintenance and replacement
Assure proper alignment of the entire train, including supply of proper stainless steel
shims under all equipment
Provide expediting and inspection service on train components purchased and /or
supplied by VENDOR
Review all train component drawing and data to ensure acceptability in accordance with
applicable specifications
Assure all relevant testing, including mechanical and performance testing of pump and
auxiliary system in accordance with applicable specifications
Assure preparation for shipment of entire train in accordance with applicable
specifications
VENDOR shall define components that will be supplied by 3rd party and ensure that only
components with demonstrated experience are applied
Main components and instruments shall be selected according to project vendor list
Take responsibility for co-ordination and costs associated with all correspondence and
activities required by 3rd party or independent inspection authority for pressure vessels
(if any) and any other Certifying Authorities
Participation at any clarification meeting, SIL review or HAZOP, SAFOP meeting as
required by Purchaser in Purchaser’s office
Supervision of field service activities for Installation, Commissioning and start-up by
suitably qualified and experienced personnel
Whole Guarantee and responsibility for assembling and good operation of the complete
unit, under normal and transient conditions as specified in equipment data sheets
Take responsibility for the co-ordination with driver Sub-supplier to ensure satisfactory
installation and alignment of the motor driver on common baseplate and good operation
of combined unit under normal operating conditions and transient conditions such as
start-up and shutdown
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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Carry out any work not specified in the assigned Order, which is necessary for the
completion of the package; this shall include all integration and interfacing of facilities
and service provided under the assigned contract of this supply
Contractor may audit the VENDOR performance, during all stage of the project, to
ensure compliance with requirements of the Order.
Any Contractor approval of documents and technical solutions shall in no way relieve
VENDOR of his overall responsibilities and obligation for the work under the Order.
Any variation that occurs for a complete and safe operability of the train during detailed
engineering in the supply phase shall be at VENDOR responsibility and cost
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
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3.3.5.3.
APPLICABLE CODES, STANDARDS AND SPECIFICATIONS
The pumps covered by this specification shall be designed, manufactured, inspected,
tested, painted, prepared for shipment, and delivered in accordance with the
requirements of the codes, standards and specifications listed here. Unless otherwise
specified, the latest standards referred to in this specification at the time of issue or
subsequent specific revision shall be used.
3.3.5.3.1. Project Specifications
SCNL Document
Description
Doc. number
Rev
Doc. number
Rev
SSG-NG01012401-GEN-MR-7771-00019
D01
GEN-MA-E-30016
D01
This specification
SSG-NG01012401-GEN-MR-5510-00001
A01
GEN-MA-E-30049
A01
Rotating Equipment Design Philosophy
SSG-NG01012401-GEN-MP-7880-00022
C01
GEN-GA-E-60808
C01
Piping Design Philosophy
SSG-NG01012401-GEN-MP-7737-00001
D01
GEN-GA-E-60001
D01
Piping Classes
SSG-NG01012401-GEN-VA-6180-00009
A01
GEN-ZX-E-09310
A01
Instructions for Spare Parts Management
SSG-NG01012401-GEN-VA-6180-00008
A01
GEN-ZX-E-09300
A01
Inspection Procedure
SSG-NG01012401-GEN-VA-6042-00001
A01
GEN-ZX-E-09303
A01
Tagging, Marking, Packing and Shipping
SSG-NG01012401-GEN-HX-5680-00001
C01
GEN-ZA-E-09710
C01
HSE design philosophy
SSG-NG01012401-GEN-HX-5680-00002
C01
GEN-ZA-E-09711
C01
Project HSE Requirements for Vendors
SSG-NG01012401-GEN-AA-6180-00001
A02
GEN-ZA-E-09020
A02
Equipment and Material Numbering Procedure
SSG-NG01012401-GEN-IN-7771-00002
C01
GEN-SA-E-50001
C01
SSG-NG01012401-GEN-IN-7771-00001
C01
GEN-SA-E-50000
C01
General Specification for Instruments
SSG-NG01012401-GEN-EA-7880-00001
C01
GEN-EA-E-40001
C01
Electrical requirement in Package Unit
SSG-NG01012401-GEN-MR-7880-00038
D01
GEN-MA-E-30091
D01
SDRL for Self Priming ASME Pumps
SSG-NG01012401-GEN-MR-7880-00037
D01
GEN-MA-E-30066
D01
IDS for Self Priming ASME Pumps
SSG-NG01012401-GEN-PX-1924-00001
R02
GEN-ZA-E-86000
R02
Utility Information
SSG-NG01012401-GEN-EA-5733-00012
C02
GEN-EA-E-40660
C02
IDS for LV induction electric motors
SSG-NG01012401-GEN-MP-7880-00017
C01
GEN-GA-E-60701
C01
Specification for painting
SSG-NG01012401-GEN-JA-6017-00001
C01
GEN-ZX-E-09024
C01
Document Numbering Procedure
SSG-NG01012401-GEN-AA-6180-00011
A01
GEN-ZA-E-09027
A01
Supplier Documents Requirements
SSG-NG01012401-GEN-QA-6050-00002
C01
GEN-ZA-E-09604
C01
Quality requirements for Vendors and Subcontractors
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
General Specification for Instrumentation
Systems
Supplied with Packages
Page 49 of 106
SSG-NG01012401-GEN-QA-6050-00007
C01
GEN-ZA-E-06901
C01
SSG-NG01012401-GEN-CS-7880-00006
C02
GEN-CA-E-11040
C02
QC requirements for supplier of material, equipments
and services
Design specifications for anchor bolts
3.3.5.3.2. Project Datasheet
SPDC Document
SCNL Document
Description
Doc. number
Rev
Doc. number
Rev
SSG-NG01012401-TUNF1-MR-2105-00001
D01
TUNF1-MA-E-30250
D01
NEW OIL SAVER PIT PUMPS TUNF1-P-5701 A/B
SSG-NG01012401-TUNF1- MR-2105-00002
D01
TUNF1-MA-E-30251
D01
NEW CLOSED DRAIN PUMPS TUNF1-P-5702 A/B
SSG-NG01012401-BENF1-MR-2105-00001
D01
BENF1-MA-E-30255
D01
NEW OIL SAVER PIT PUMPS BENF1-P-5701 A/B
SSG-NG01012401-OPUC1- MR-2105-00001
D01
OPUF1-MA-E-30260
D01
NEW OIL SAVER PIT PUMPS OPUF1-P-5701 A/B
3.3.5.3.3. Shell DEPs (Design Engineering Practice)
The following list contains the main DEP standards applicable to this scope of supply.
Vendor has to note that all the all the DEPs and relevant standard drawings included in
the DEP DVD ed. 32 shall apply to this package.
Refer to DEP DVD-ROM (version 32) for copies of all DEPs. The Supplier shall use
these versions of the DEPs to maintain design consistency.
DEP 30.10.02.11-Gen
Metallic materials - Selected standards
DEP 30.48.00.31-Gen
Protective coatings for onshore facilities
DEP 31.10.00.31-Gen
Noise control (amendments/supplements to ISO 15664)
DEP 31.22.20.31-Gen
Pressure vessels (based on ASME Section VIII)
DEP 31.29.00.10-Gen
Installation of rotating equipment (amendments/supplements
to API RP 686)
DEP 31.29.00.33-Gen
Shaft sealing systems for centrifugal and rotary pumps
(amendments/supplements to ISO 21049:2004)
DEP 31.29.00.39-Gen
Shaft sealing systems for centrifugal and rotary pumps -
Selection, testing and installation
DEP 31.29.02.11-Gen
Pumps - Selection, testing and installation
DEP 31.38.01.10-Gen
Piping class - Basis of design
DEP 31.38.01.11-Gen
Piping - General requirements
DEP 31.38.01.15-Gen
Piping classes - Exploration and production
DEP 32.31.09.31-Gen
Instrumentation for equipment packages
DEP 32.37.10.11-Gen
Installation of on-line instruments
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DEP 32.37.20.10-Gen
Instrument signal lines
DEP 33.64.10.33-Gen
Electromagnetic compatibility (EMC)
DEP 33.66.05.31-Gen
Electrical
machines
-
Cage-induction
types
(amendments/supplements to IEC 60034-1 and IEC 60034-14)
DEP 70.10.70.11-Gen
Preservation of new and old equipment standing idle
DEP 70.10.90.11-Gen
Spare parts
3.3.5.3.4. Shell Standard Drawings
S68.004H
2002 Earthing boss for steel structures, tanks, vessels, etc.
S68.003
2009 Typical Mounting Details for Earthing Connection
3.3.5.3.5. National and International Codes and Standards
The following international codes and standards (as listed edition):
ASME B73.1 2001
Specification for Horizontal End Suction Centrifugal Pumps for
Chemical Process
ISO 15664
2001 Acoustic – Noise control design procedures for open plant
ISO 21049
2004 Pumps – Shaft sealing systems for Centrifugal and Rotary Pumps
API RP 500 2002 Recommended Practice for Classification of locations for Electrical
Installations at Petroleum Facilities Classified as Class I, Division I and Division II
API RP 686 2009 Recommended Practices for Machinery Installation and Installation
Design
ASME B 16.5
2009 Pipe Flanges and Flanged Fittings NPS ½ through NPS 24
ASME B 31.3
2010 Process Piping
ASME VIII
2010 Boiler and Pressure Vessels
ASME IX
2011 Qualification Standard for Welding and Brazing Procedures
BS EN 10204
2004 Certificate on Material Testing
EEMUA 140 1985 Noise Procedure Specification
IEC 60034
2010 Rotating Electrical Machines
IEC 60079
2011 Electrical apparatus for explosives gas atmospheres
EGASPIN
Environmental Guidelines and Standards for Petroleum Industry in Nigeria
ISA
Instrumentation
ASTM last ed.
Materials
3.3.5.3.6. Conflicting Requirements
In the event of any conflict between this specification and other referenced or subreferenced documents forming the Contract Documents, SCNL shall be informed in
writing. Written approval from SCNL must be given before proceeding with any work.
Unless otherwise agreed, the following order of precedence shall apply:
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•
Statutory Nigerian Regulations.
•
Equipment Datasheets and this Specification.
•
The Contract documents, other referenced Project Specifications and any notes,
drawings or schedules attached thereto this specification.
•
Shell DEP or Standard Specifications.
•
International Codes and Standards
•
Other Industry or National Codes or Standards, whether or not referenced in this
Specification
3.3.5.3.7. Deviations/Exceptions to Specifications
VENDOR’s proposal shall either state the complete compliance to requirements of this
Specifications listed in section 3 or identify and duly list, in a dedicated section of the
proposal using the “Deviations List Form” (please, refer to Section 3.3.5.14below,
ATTACHMENT 2) all the exceptions and comments to the above, for SCNL review.
This is a mandatory requirement for bid evaluation.
Deviations not identified and listed using the “Deviation List” form shall be rejected.
Even if not explicitly mentioned, VENDOR is responsible for compliance to all applicable
Nigerian laws and codes.
In the event of a deviation from the requirements of this Specification and/or
Specifications, listed in section 3.3.5.3 during supply follow-up, a written application shall
be made to SCNL. The written application on a Concession Request Form (section
3.3.5.14, ATTACHMENT 3) shall identify the document affected, details of the deviation
and the reason for it, the proposed alternative and the cost and delivery implications.
The deviation request shall be submitted to SCNL for review. Approval of the Deviation
Request Form shall be required before work affected by the deviation can proceed.
Where no deviations from this Specification or Data Sheets are stated, it shall be
assumed that the equipment complies with this Specification in all respects
3.3.5.4.
ENVIRONMENTAL DESIGN CRITERIA
3.3.5.4.1. General
Unless otherwise stated in dedicated datasheets, pumps shall be suitable to operate in
an open , exposed area. All equipments and components in the scope of supply shall be
suitable for the design and operating conditions given in this specification and the
accompanying datasheet.
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3.3.5.4.2. Area Classification
All electrical equipment, unless otherwise stated on the datasheets, shall be suitable for
Zone 2 and be rated for gas subdivision IIB and temperature T3.
3.3.5.4.3. Site Environmental Data
Ambient Temperature
Mean minimum temperature:
Minimum temperature:
23°C
18°C
Mean maximum temperature:
Maximum temperature:
38°C
43°C
Swamp temperature:
20°C
Black-bulb temperature:
80°C
Humidity:
100% condensing
Rainfall
Heavy rainfall can be expected in the wet season during months of April through
October.
Average annual rainfall
3800 mm
Mean max. hourly rainfall
100 mm
Wind Speed
Design wind speed
35.6 m/s
Entomology and Vermin
Prevalent in the Niger Delta area due to thick forest and swamp habitat.
Fungi and Growths
Prevalent in the Niger Delta area due to thick forest and swamp habitat
Lightning
Severe & frequent in the rainy season. (6 months per year)
Site Altitude
Sea level.
Dust
During November/December of every year, in the Harmattan season, the atmosphere is
laden with extremely fine dust (particle size of 5 microns or less), which can penetrate
equipment, block air filters, etc.
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3.3.5.5.
SCOPE OF SUPPLY
3.3.5.5.1. Vendor Scope
The following scope of supply shall be considered applicable for each flowstation Tunu,
Benisede and Opukushi for horizontal end suction Self-Priming pumps (designed
according to ASME B73.1 and DEP 31.29.02.11-Gen.). Below scope shall be considered
a minimum requirement, and VENDOR shall provide any other items for a safe and
correct operation of pumps, ensuring complete installation and the proper fulfilment of
the function:
• Self-Priming pump (refer to para. 1.2 for configuration for CPF and flowstations)
• LV 400V 50 Hz Fixed Speed Electric Motor Driver
• Dry flexible spacer type coupling with non-sparking guard
• Mechanical Seal
• Seal System
• Bearing Isolator (INPRO-SEAL)
• Flanged and valved casing vents and drains.
• Field instrumentation as per datasheets
• Painting
• Common baseplate for horizontal pump, driver and seal system with drip pan and
single drain connection, designed for sea and road transportation to site
• Packing suitable for 12 months of outdoor storage
• Preservation procedure to cover 24 months in outdoor tropical environment
• Inspections and testings
• Documentation
• Instruction, operation and maintenance manual
• Commissioning & start-up spares
• 2 Years Operational Spares (VENDOR to recommend, quoted separately as
option)
• Ex-work delivery
• Training of SPDC operations personnel
• Participating at Kick-off meetings in Port Harcourt
• Participation at HAZOP, SIL, HFE (Human Factors Engineering), Maintenance
review meeting and technical clarifications meetings in Port Harcourt (daily rates)
• Support during installation, pre-commissioning and start-up (daily rates)
All other equipments not listed on ATTACHMENT 1, but necessary for good design,
correct and safe operation of the train, shall be included in VENDOR scope of supply
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3.3.5.5.2. Sub-supplier List
Deviation requests shall include SUB-VENDOR reference list and experience on similar
application.
Sub-orders for main items such as plate, forgings and pipe shall be accompanied with a
detailed material specification which specifies the requirements for heat treatment,
chemical composition constraints, impact testing, certification, NDE and hardness
limitations, etc. SCNL shall be provided with ‘un-priced’ copies of all major sub-orders
together with the material specification (see SDRLs)
3.3.5.5.3. Spare Parts
The scope of supply shall include list of commissioning/start-up spares and 2 years
operations spares shall be provided with the tender. The scope of supply shall include
commissioning/start-up spares, while 2 years operations spares shall be quoted
separately as optional.
All required equipment, tools and spares list, shall be available prior to any precommissioning activities. Spare parts for all critical equipment shall be identified and
made stock items. Such spares shall be specified in the Electronic Spare Parts Interchangeability Record (e-S.P.I.R. to be downloaded from www.e-spir.com website) and
shall include the appropriate MESC numbers for parts already included in COMPANY’s
MESC system.
Quotation for 2 years operatons spares (as stated above) shall be submitted, including
the completed e-SPIR forms.
The spares quotation should cover all the equipment within the package, including but
not limited to Mechanical, Electrical, Instrumentation and Electronic components.
3.3.5.5.4. Special Tools
All special tools and fixtures that are required for the installation, removal, adjustment,
commissioning, operation and maintenance of the equipments supplied shall be provided
by the VENDOR. A complete list shall be provided with the VENDOR’s quotation.
3.3.5.5.5. Training
Training shall be provided to Shell Operations/Maintenance personnel. The objective is
to develop their competence to such a level required to successfully operate and
maintain the equipment items in the package.
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Training courses shall be focused on the equipments included in the pump package and
should cover functional characteristics, assembly/disassembly procedures and operating
procedures.
Specific instruction courses and training manuals shall be provided i.e. computer based
training (CBT) package.
As a general guideline for courses, number of participants and duration, please make
reference to the table below:
Duration
Session x
Venue
Course
participant
(days)
ELV
Pump course
3
Edjeba
2 x 10
(Nigeria)
The duration, venue, date and number of participants are subject to changes.
Detailed training programmes, course contents and all other training requirements shall
be agreed with SPDC/SCNL three months prior to commencement of training.
3.3.5.5.6. Documentation/Certification
All documents shall be provided as specified in the SDRL. These shall be supplied in
both hard copies and electronic format.
During technical evaluation the SDRL shall be reviewed, and advise of any documents
which are not appropriate to the Scope of supply or which can be combined with other
documents in the SDRL. Also the timetable for submission of documents shall be
finalized by review of the SDRL at the clarification meeting during technical evaluation.
All documentation/certification shall be written in English.
In addition to the SDRL, the VENDOR shall supply an IOM manual for each pump and it
shall include but not limited to the following:
• General description of the equipment including nameplate data, total weight, center
of gravity, capacity, power and operating instructions.
• Instructions for troubleshooting including corrective action
• Procedures for equipment shipment and up to two years storage at VENDORs
factory and long term storage at Purchaser’s site.
• Instructions for installation, checkout,
inspection,
service,
lubrication and
maintenance requirements.
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• Disassembly, re-assembly, special tools, repairs, replacement instructions,
cleaning procedures and routine, inspection records and testing procedures.
• Schematic and wiring diagrams of electrical circuits and instrumentation, including
earthing and bonding diagrams (if any).
• Inspection schedule and parts list.
• Overhaul schedule and parts list for full replacement including part number,
nomenclature and quantity.
• E-SPIRS for all components in the pump package.
3.3.5.5.7. Exclusions
The following items are excluded from the Scope of supply:
• First fill of Lube oil
• All civil works
• Electric cables off skid
• Bleed Line (However, vendor shall state required connection on discharge Piping)
• Control and instrumentation cables off skid
• Supply of other utilities, such as Air, however VENDOR shall state consumption
and pressures required
• Off skid piping
• LV AC switchgear
• Gaskets for bolting to CONTRACTOR’s interface connections.
• Anchor bolts
• Transportation of equipment from delivery sea port to site
• Custom Clearing
3.3.5.5.8. Name plates
All nameplates shall be made from stainless steel or other corrosion resistant material.
They shall show as a minimum:
• Manufacturers’ name
• Equipment name
• Equipment type and Tag number
• Pump and Driver duty in kW
• Model and Serial number
• Inspection date
• Design Pressure & Temperature (barg and °C)
• Rated Capacity
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• Year of manufacture
• Test pressure (barg)
All wording shall be in English language and data shall be in SI units, unless agreed
otherwise
3.3.5.6.
TECHNICAL REQUIREMENTS
3.3.5.6.1. General
Mechanical equipments shall be designed and constructed in accordance with the
requirements of the codes specified in both this section and Section 3.3.5.3.
Pump packages shall be suitable for continuous operation over the full range of
operational and environmental conditions as specified on the relevant applicable
datasheets and in this specification. Packages shall be designed for at least 25 years.
Adequate access shall be provided among the various main components to permit
routine maintenance to be carried out.
Equipment and components shall be selected from the manufacturer’s standard range
and the equipment shall be, in all respects, within the range of the manufacturer's proven
experience, and shall not involve the use or application of any prototype in design or
components.
The pump packages shall be furnished self-contained, instrumented, tested and precommissioned. Each package shall be provided with all necessary accessory equipment
and materials for safe and satisfactory operation and maintenance. All equipment shall
be supplied complete and requiring minimum site work to bring into operation.
Only equipment that has proved its reliability shall be selected. In this respect, proven
equipment is defined as equipment of which at least three units of similar type, size and
specific loading have each accumulated a minimum of 24000 hour of uninterrupted
operating time in comparable service. The manufacturer shall provide the necessary
evidence in his proposal.
Package design shall comply with requirements specified in spec. SSG-NG01012401GEN-MR-5510-00001 “Rotating Equipment Design Philosophy”.
3.3.5.6.2. Pumps
Each pump described in this specification shall be designed, manufactured and tested in
accordance to ASME B73.1 for Horizontal end suction centrifugal pumps and DEP
31.29.02.11-Gen. Testing of pump packages shall also be carried out in accordance to
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issued IDS SSG-NG01012401-GEN-MR-7880-00037, as per section Error! Reference
source not found..
Pumps with driver power up to a maximum of 40 kW shall be greased lubrified, whilst the
estimated grease life shall be 25000 hour as minimum.
3.3.5.6.3. Main Drivers
Pumps shall be driven by fixed speed electric motor in accordance with applicable
datasheets.
Electric motor shall be designed in accordance with IEC 60034, DEP 33.66.05.31-Gen,
and shall be suitable for installation in hazardous area Zone 2 IIB T3. The motor shall
also be suitable for the environmental conditions stated in section 3.3.5.4.
All electric motors with nominal power < 185 kW shall be feeded by LV supply (400V, 50
Hz, 3 phase).
No winding temperature detectors shall be foreseen for LV electric motors.
Instrumentation on motors, if any, shall be according to dedicated datasheets.
All electric motors shall be tropicalized.
IP54 (as minimum) is requested for motors, while terminal boxes and bearing housings
shall have an ingress protection at least equal to IP55.
LV machines equipped with rolling element bearings, with rated outputs up to and
including 37 kW may be equipped with sealed-for-life bearings pre-charged with Shell
Nerita HV or comparable grease. The Manufacturer shall ensure that such bearings are
selected to meet L10 lifetime (bearings shall have a rated L10 lifetime in excess of
50,000 h under the worst case operating conditions as specified in the requisition and in
DEP 33.66.05.31-Gen). The lifetime shall be calculated in accordance with ISO 281.
All motors shall be provided with locally mounted control units complete with stop / start
push buttons (supplied by others).
Motor cabling (supplied by others) shall be direct to the terminal box on the equipment.
Terminal boxes and Junction boxes shall have cable entries suitable for metric threated
cable glands (supplied by others) and shall be provided with temporary plugs.
3.3.5.6.4. Couplings
ASME B73.1 (Horizontal end suction centrifugal pumps) flexible dry coupling, spacer
type, with non-sparking coupling guard shall be installed on each pump package.
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Each coupling shall be designed to retain the spacer in the event of failure of the
coupling flexible elements and shall be protected by coupling guard that shall be
designed to contain any material released from the coupling.
Spacer lengths shall be selected to permit removal of coupling hubs, pump bearings and
mechanical seal without moving the motor or pump.
3.3.5.6.5. Mechanical Seals
Mechanical seal and seal system shall comply with ISO 21049 amended and
supplemented by DEP 31.29.00.33-Gen.
For Mechanical seals, unless otherwise specified on data sheet, the following Vendor list
shall be applied:
•
•
•
•
Flowserve FSD
Eagle Burgmann
John Crane
Fluiten
Plan 53B, where specified, shall be provided in accordane with clause 8.7.3 and figure
G16 of DEP 31.29.00.33.
Accumulator for plan 53B shall be SS made and its volume shall be sized for a manual
refill interval time of
at least 25 days based on the normal seal leakage rate specified by the seal Vendor
without compromising the specified seal life time.
All plan 53B shall be provided with a ½” quick connection for manual refilling. The
position of the quick connection shall make it possible to fill the system from grade level.
Seal barrier fluid shall be cooled down by an air-cooler heat exchanger.
All piping relevant to seal API plan 53B shall be stainless steel and shall be provided in
accordance to project piping class. Screwed connections are not acceptable
Seal API plan 53B shall be supplied with pump installed on a common skid. Vendor
scope of supply shall include also seal oil interconnecting piping supplied in commercial
bar length and with relevant fittings (1 couple of flanges and 4 90° elbows for each line,
as minimum)
Following special tools for mechanical seal system have been quoted as option:
•
•
n° 1 nitrogen recharge kit for plan 53B
n° 1 portable re-filling unit for plan 53B System using barrier fluid that is
compactible with process fluid.
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3.3.5.6.6. Piping, Valves and Tubing
Piping and valves comply with requirements given in the Piping Design Philosophy SSGNG01012401-GEN-MP-7880-00022 and DEP 31.38.01.11-Gen.
All piping included in vendor scope of supply shall be in accordance with project piping
Class here below listed:
Item
Service
Piping
Classes
Rating
Base material
TUNF1-P-5701 A/B
Discharge/Suction lines
11432
150
Carbon steel
TUNF1-P-5702 A/B
Discharge/Suction lines
11432
150
Carbon steel
BENF1-P-5701 A/B
Discharge/Suction lines
11432
150
Carbon steel
OPUF1-P-5701 A/B
Discharge/Suction lines
11432
150
Carbon steel
Piping and valves comply with requirements given in the Piping Design Philosophy SSGNG01012401-GEN-MP-7880-00022 and DEP 31.38.01.11-Gen.
Utility piping (if any) shall be manifolded to single flanged connections at the baseplate /
soleplate edge, where possible.
3.3.5.6.7. Baseplate
For overhung typology, pump, motor, seal system, piping, instrumentation and all the
ancillary equipment shall be packaged on a common baseplate.
VENDOR shall optimise the pump skid layout to achieve an arrangement with good
access for operation, inspection and maintenance of all equipment, valves and
instruments.
The arrangement drawings shall show maintenance spaces and all interface
terminations.
The Baseplate shall be fitted with drain pan(s) sloped to drain points. Drain connection
shall be a minimum of 50 mm flanged ANSI 150 lb. At least 2 earth connections at
diagonally opposite corners of the base plate shall be supplied. For details of earthing
boss, reference should be made to Shell Standard Drawing S68.004H. The top of base
plate shall be fully grated.
No equipments or piping shall protrude beyond edge of the base frame.
All equipment packages supplied shall have provision for lifting the skid-mounted
packages safely from a minimum of four points.
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All Pumps shall be installed on concrete foundation. Vendor shall provide full details of
foundation bolts (size and required number). Bolts shall be selected from “Design
Specification for Anchor Bolts” SSG-NG01012401-GEN-CS-7880-00006.
VENDOR shall provide the overall weight, height, width, length and centre of gravity of
the module and also include the complete skid layout drawing, including the terminal
points and details of the skid/structure.
3.3.5.6.8. Instrumentation and Controls
The instrumentation and controls shall comply with the requirements of specification
SSG-NG01012401-GEN-IN-7771-00002 “Specification for Instrumentation for Package
Equipment”.
Effective lightning protection shall be included for all electronic instrumentation. The
lightning protection shall be capable of operation in tropical environments.
Minimum IP rating for field instrumentation shall be IP 65 (as per DEP 32.31.00.32Gen.).
For field instruments, locally mounted surge protection devices shall be used depending
on their criticality and consequences of failure of the particular instrument.
Field instrumentation (where applicable), i.e. pressure, temperature, flow, vibration etc,
shall preferably be transmitted with local readout, where available.
As long as for any process reason (special service) or other technical reasons which
require the application of particular devices, equipment and components of similar type
should be purchased from the same manufacturer.
In order to minimise spare parts required for the facilities, all instruments, by type, shall
be of the same manufacturer and model series for process control and SIS applications
individually.
3.3.5.6.9. Noise limits
VENDOR shall design and manufacture the pump package (including auxiliaries)
ensuring that noise emissions are reduced to bearest minimum considering all updated
technology.
Sound pressure levels (SPL – Maximum and average) in octave band levels for each
center frequency (spectrum) shall be submitted by VENDOR, filling noise data sheet.
Maximum allowable noise level shall be 85 dB(A) ± 0 dB(A) for the complete package at
a distance of 1 m from each machine.
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3.3.5.6.10. Operating and Maintenance Requirements
Maintenance requirements shall be as simple as practicable. All equipment components
requiring regular monitoring or maintenance shall be easily and safely accessible by
operations and maintenance personnel without use of ladders or any form of temporary
aids to access.
All heavy items shall be fitted with lifting eyes and if appropriate, davits to ease their
handling.
A handling arrangement shall be planned and documented in the manuals for all
package items that may be required to be removed.
A maintainability review shall be held between SCNL, VENDOR and Operations
personnel at an early stage of the Contract.
Equipments within the pump package shall be designed for high reliability and
availability. VENDOR shall specify the overall system uptime achieved by similar supply.
3.3.5.6.11. Materials and Certification
Based on the fluid characteristics and impurities specified on the pump datasheet,
VENDOR is requested to advise on material selection given in the datasheet for his
equipment and requirement (or otherwise) for corrosion allowances.
The Supplier shall provide a full Certification manual on completion of the works.
Material certificates, manufacturer’s certificates and test documentation shall be required
for all tests whether witnessed or not.
3.3.5.7.
INSPECTION AND TESTING
The package equipment material, inspection and testing requirements will be as per
relevant IDS and applicable codes and DEPs. The equipment shall be subject to
inspection and witnessing of tests by the PRINCIPAL and/or authorised representatives.
Access to VENDOR and SUB-VENDORs premises during all stages of manufacturing
and testing is a mandatory requirement. All critical equipment tests, e.g. performance,
mechanical and string tests shall be witnessed by the PRINCIPAL.
The VENDOR shall provide (prior arrangement) free access to his works and that of
SUB-VENDORs for the authorised representative of SCNL and the certifying authority (if
required). All necessary certification of materials, shop test data, etc. shall be made
available to verify that the requirements of the Contract are being met.
Inspection of the pump package and its components shall include but not be limited to
the following:
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• Check (against outline drawings which have been approved by the Purchaser) of all
main dimensions, location of foundation bolt holes, piping and instrumentation;
• Size/position/rating of flanges and coupling guard arrangement;
• Inspection of flange face finish;
• Verification that the Manufacturer has performed the specified inspections and tests
with satisfactory results;
• Verification of the required material certificates and (to the extent specified) their
traceability to the respective components;
• Check of casing wall thickness;
• Measurement of the running clearances;
• Visual check for good workmanship and finish of internals;
• Verification of taper fits with matched plug and ring set;
• Verification of machinery alignment and operability of contract special tools;
The extent of inspection and testing of welds shall be specified on the QC Inspection
Plan.
All welding shall be in accordance with ASME IX and the VENDOR shall submit
proposed weld procedures, weld details and welding procedure qualification records for
the Purchaser's review and approval prior to commencing any welding activity.
Radiographic, ultrasonic, magnetic particle and dye penetrant inspection shall be
performed by operators having an internationally recognised qualification.
Material analysis and/or Test certificates shall contain both Chemical and Mechanical
properties for all main components in accordance with referenced standard as
supplemented by DEP requirements. Material traceability records shall be maintained for
all material/parts incorporated into the equipment.
The method of inspection for individual weld types shall be agreed between
FLOWSERVE and SCNL.
Inspection shall be performed after any post weld heat treatment.
Testing of the package and its components shall be as follows and shall be in
accordance with listed codes:
• Hydrotest of the pumps, vessels and piping, etc…
• Performance test as per ASME B73.1:2001 for horizontal end suction centrifugal
pumps. The test will be done on one pump for each item. Job mechanical seals
shall be used during test.
• NPSH test if required by DEP 31.29.02.11. The test will be done on one pump for
each item.
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In case of positive results of performance tests, the disassembly and inspection of
mechanical seals and bearings shall not be done as per clause 4.1.9 of DEP
31.29.02.11.
Instrumentation shall be in accordance to SSG-NG0101240-GEN-IN-7771-00002;
3.3.5.8.
PAINTING,
PRESERVATION,
PREPARATION
AND
SHIPMENT
3.3.5.8.1. PAINTING AND PROTECTIVE COATING
Surface preparation, painting and coating shall be in accordance with Project
specification for paiting SSG-NG01012401-GEN-MP-7880-00017 and DEP 30.48.00.31Gen.
Where painting is specified, the complete equipment shall be painted. Nozzles shall be
painted to the flange edges, inside boltholes, and up to the gasket surface. Insulated
surfaces shall be shot blasted and given one coat or primer only. VENDORs shall submit
proposals for repair of painting/coating at site.
No fireproofing for structures and/or equipments is required.
3.3.5.8.2. TRANSPORTATION
The Package supplied will be transported by sea from the VENDOR’s Works/Test
Facility to Nigeria. The VENDOR shall ensure that the Packaging shall be suitable for
export and transportation by sea and/or barge.
3.3.5.8.3. PREPARATION FOR SHIPMENT
VENDOR shall provide packing suitable for a 12 months storage period in outdoor
tropical environment and shall state in the quotation his recommendations for long-term
storage (24 months) for both indoor and open-air storage in a tropical environment.
As a guide the standard procedures should be at least equivalent to the procedures for
long term preservation set out in Shell DEP 70.10.70.11.
Following testing, the equipment shall be cleaned thoroughly and dried. All equipment
shall be shipped fully assembled, where practicable, provided that no damage can be
caused due to shipment forces or lifting. When bearings, seals and instrument devices
could be vulnerable to damage during transportation, they should be removed and
separately packed.
All delicate equipment shall be removed before shipment.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 65 of 106
All terminal flanges to be sealed and fitted with steel blanking plates bolted to the flange
with a minimum of 4 bolts, while small pipes shall be provided with plastic caps and
sealed with tape.
All items shall be properly packed/crated and protected from damage during shipment.
Each crate, bag or package shall be clearly identified with the item number and purchase
order number to facilitate installation in the field, and shall be securely fastened to the
item. Tags and wire shall be stainless steel.
All instruments, and any equipment which extends beyond the baseplate edge, shall be
removed, tagged and crated in waterproof boxes. The contents of each box shall be
clearly stated on the outside of the box.
3.3.5.9.
INSTALLATION
VENDOR, in collaboration with SCNL, shall ensure that the arrangement of the pump
packages follows requirements given in DEP 31.29.00.10-Gen. “Installation of Rotating
Equipment (Amendments/Supplements to API RP 686)”.
3.3.5.10.
QUALITY ASSURANCE
The VENDOR and any SUB-VENDOR shall show that an effective system of Quality
Assurance is in operation, for both products and services, which complies with ISO
9001:2008. The VENDORs and SUB-VENDOR(s) shall be ISO 9001:2008 certified.
The VENDOR shall provide according to agreed SDRL his Quality Manual for review by
Purchaser. The Quality Manual should contain but not be limited to the following:
• A signed policy statement on commitment to quality by the head of the VENDOR
company.
• An
organisation
matrix
of
the
VENDOR
Company
indicating
reporting
responsibilities.
• An index of the VENDOR company quality procedures.
• A brief outline of each procedure indicating individual responsibilities for
maintaining quality.
The VENDOR and SUB-VENDORs shall submit also Quality Execution Plan (QEP) and
Quality Control Plan (QCP) and as proof that the Sub-contractor/Manufacturer are able
to
operate
within
the
guidelines
of
ISO
9001:2008
QMS,
the
Sub-
contractor/Manufacturer shall submit with his quotation a copy of their ISO 9001:2008
QMS registration certificates endorsed by an accredited certified body.
VENDOR shall also provide a preliminary Inspection and Test Plan, which shall be
revised for the contract.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 66 of 106
Activity and intervention activities at the equipment WORKSITE shall be based on
Inspection and Test
Plans (ITPs) or Quality Control Plans.
Inspection and test plans shall be made available to Principal/Contractor thirty (30)
working days before any fabrication and assembly operation commences.
Company shall review Inspection and Test Plans, to ascertain that they meet Company
intervention requirements and to indicate appropriate Company inspection points.
Each Inspection and Test Plan shall detail the following:
• A brief activity description following the Process/production time Sequence for each
of the Key activities
• Applicable Specification, Codes or Standards (with section references) for each
identified Activity
• Inspection Frequency for each activity
• Inspection/Test requirements
• Activity Number
• Activity Inspection - Approval record type
• Reference Documents
• Points for witness testing and verifications by the VENDOR, Sub-contractors,
Contractor and Company
• Points for witness, testing and verifications by Third Party and regulatory authorities
(if any)
The following codes shall be used to describe the intervention points on Inspection Test
Plans (ITPs).
Review (R): Appraisal for appropriateness and conformity to specifications of
materials and equipment via review of the documents referenced and
pertinent to a process.
Monitor (M): A continuous surveillance and verification of status of a process and / or
products and the review and analysis of records to ensure that specified
requirements are being met.
Witness (W): A point defined as when the customer shall be informed to come and
observe an activity in order to attest to compliance of a process or product
to specified requirement(s).
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 67 of 106
Hold Point (H): A predefined point in a process beyond which the process/production
must not advance without the approval of the customer or the customer’s
representative. Hold points must be respected at all times.
Company reserves the right to have resident Quality inspectors (PQMS Contractor) at
the equipment fabrication and assembly WORKSITEs who shall report all findings, nonconformances and corrective actions to PRINCIPAL.
The resident inspector shall be responsible for liaison with the Contractor’s Quality
Manager and his delegated site representatives to monitor the implementation of the
Inspection and Test Plan. The resident inspector shall procure engineering discipline
intervention support from his office, for key witness and hold points on the Inspection and
Test Plans as and when required.
If the PRINCIPAL or Contractor consider necessary, the Sub-contractor/Manufacturer
shall agree for the Purchaser to carry out a Quality Systems Audit of the Subcontractor/Manufacturer’s Quality System against ISO 9001:2008 QMS.
Quality related documentation required after award of Contract is detailed in the SDRL.
Shop inspection records for a period of 5 years shall be kept complete and available for
the PRINCIPAL’S inspection upon request. All defects having no bearing on
performance but which are considered departures from good workmanship shall be
noted on inspection records. The PRINCIPAL shall have free entry during normal
working hours while work is being performed on or related to the equipment module.
Special arrangement shall be made by the VENDORs if visitation is required out of
normal working hours. The VENDORs shall afford the PRINCIPAL, without charge, all
reasonable facilities to confirm the units are being furnished in accordance with the
specified requirements.
3.3.5.11.
SUB-CONTRACTS
The VENDOR must manage any SUB-CONTRACTOR to ensure that their product
meets the required quality, traceability and delivery in accordance with the overall project
delivery and QA requirements.
The SUB-CONTRACTOR scope of supply must be
integrated into the VENDOR’s delivery and QA plan.
The VENDOR may only subcontract items to SUB-CONTRACTORs that have a
recognized quality system and auditable industry track record in their field of expertise
and, in any case, according to project vendor list SSG-NG01012401-GEN-VA-430500001.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 68 of 106
3.3.5.12.
GUARANTEES
The VENDOR shall guarantee the Performance of the packages supplied for the process
requirements stated in the Data Sheets.
If pump does not achieve performance guarantees, VENDOR has to analize causes of
the failure and take all the necessary actions in order to reach guarantee values at its
care and costs.
The VENDOR shall guarantee that the equipment and component parts shall be free of
defects as specified in the relevant specifications and Terms and Conditions of Purchase
pertaining to the Purchase Order.
3.3.5.13.
WARRANTY
VENDOR’s shall warranty the design/workmanship/performance of material/equipment
for a period of 12 months from first placing in service on site, eighteen (18) months from
shipment or six (6) months after plant start-up whichever comes first.
3.3.5.14.
ATTACHMENTS
ATTACHMENT I.
SCOPE OF SUPPLY FORM
N°
Q.TY
Total
1
2
Self-Priming ASME Pumps Complete with:
1.1
2
Single Mechanical Seals
Y
1.2
2
Seal Flushing system Plan 11
Y
1.3
2
Flexible coupling (with Spacer) with no sparking guard
between Pump and Main Motor
Y
1.4
2
Main electric motor induction type
Y
1.5
2
Single baseplate common for Pump, Motor and seal
system
Y
2
2
Self Priming ASME Pumps Complete with:
2.1
2
Single Mechanical Seals
Y
2.2
2
Seal Flushing system Plan 11
Y
2.3
2
Flexible coupling with no sparking guard between
Pump and Main Motor
Y
2.4
2
Main electric motor induction type
Y
2.5
2
Single baseplate common for Pump, Motor and seal
system
Y
3
2
Self Priming ASME Pumps Complete with:
2
Single Mechanical Seals
Y
2
Seal Flushing system Plan 11
Y
3.1
3.2
3.3
2
3.4
2
Description
3.5
2
4
2
4.1
2
4.2
2
Seal system Plan 11/53B
2
4.4
2
Required
TUNF1-P-5701 A/B
Y
BENF1-P-5701 A/B
OPUF1-P-5701 A/B
Flexible coupling with no sparking guard between
Pump and Main Motor
Main electric motor induction type
Single baseplate common for Pump, Motor and seal
system
Self Priming ASME Pumps Complete with:
Double pressurised Mechanical Seals
4.3
Item
Included
Notes
Y
Y
Y
Y
Y
TUNF1-P-5702 A/B
Flexible coupling with no sparking guard between
Pump and Main Motor
Main electric motor induction type
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Y
Y
Y
Y
Y
Page 69 of 106
N°
Q.TY
Total
4.5
2
Description
Single baseplate common for Pump, Motor and seal
system
For all pumps:
5
Bearing isolators
6
Interconnecting piping on skid terminating at skid
edge with flanged connections according to
datasheets specified materials
2 set
Item
Required
Notes
Y
Y
Y
7
Commissioning and Start-up Spare Parts.
Y
8
Two years spareparts
Y
9
Technical documentation as specified in the
Supplier Document Requirement Listing (SDRL)
Y
10
Inspection and Tests as per Inspection Data Sheets.
Y
11
Painting
Y
12
Special tools (where applicable)
13
Packing suitable for 12 months of outdoor storage
Y
14
Preservation procedure to cover 24 months in outdoor
tropical environment
Y
15
Ex-work delivery
Y
16
Instruction, Operation and Maintenance Manual
Y
17
Vendor attendance to Kick-off meeting in Port
Harcourt
Y
18
Vendor assistance to supervise site activities for
erection, pre-commissioning, commissioning.
Y
19
Training course at Vendor Facilities
Y
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Included
Separate
Quotation
(Daily rates)
Separate
Quotation
(Daily rates)
Separate
Quotation
(Daily rates)
Page 70 of 106
ATTACHMENT II“DEVIATION LIST” FORM
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 71 of 106
ATTACHMENT III CONCESSION REQUEST FORM
TECHNICAL DEVIATION REQUEST
Contract Number:
TITLE:
Date: DD-MMMYYYY
NG01012401
(Ex: 28-AUG-2012)
tdr No.:
Contractor:
SSG-NG01012401(FAC-CODE)(DISCIPLINE)-7205(SQ No-To be given
by DCC)
SAIPEM CONTRACTING NIGERIA LTD.
Page: 1 OF 2
rev:
PART A – ORIGINATOR
CLASSIFICATION
CRITICALITY
REQUIREMENT
Essential

Urgent
Query / Clarification
Non-essential


Routine

Information Request

Documentation Involved:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014

Page 72 of 106
Nature of Query:
Submitted by: Name and signature of Lead Approved by: Name and signature of Engineering
Discipline
Name:
Manager
Signature: Date:
Name:
Signature:
Date:
TECHNICAL DEVIATION REQUEST
Contract Number:
TITLE:
NG01012401
Date: DD-MMMYYYY
(Ex: 28-AUG-2012)
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 73 of 106
tdr No.:
Contractor:
SSG-NG01012401(FAC-CODE)(DISCIPLINE)-7205(SQ No-To be given
by DCC)
SAIPEM CONTRACTING NIGERIA LTD.
Page: 2 OF 2
PART B – OUTCOME
Received by:
Name:
Signature:
Date:
Response:
CHANGE PROPOSAL APPLICABLE
YES
NO
Response By: Discipline Engineer (TA2 of applicable Discipline)
Name:
Signature:
Date:
Approved By: (Lead Discipline Engineer/Project Team Leader)
Name:
Signature:
Date:
Signature:
Date:
PART B – ORIGINATOR
Received by :
Name:
THIS DOCUMENT DOES NOT CONSTITUTE A VARIATION
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 74 of 106
3.3.6.Inspection Data Sheet for Open Drain Pumps
This Inspection Data Sheet (IDS) indicates the minimum inspection and
tests for which Saipem requires certification and/or witnessing.
The Supplier shall in any case conduct all the tests required by the
contractual documents, Specifications, Codes and Standards, and keep
the relevant documentation.
Where required, this Inspection Data Sheet (IDS) shall be used as a
basis for the definition of the material inspection plan during the Preinspection meeting.
3.3.6.1.
LEGEND OF THE TECHNICAL SURVEILLANCE
1 = 100% WITNESSED. Action performed for all materials or equipment,
which is witnessed by saipem and, where indicated, by the Client and/or
Third Parties.
2 = % OF TYPE/LOT WITNESSED. Action performed only on a certain
number of pieces. The number (n) or percentage (%) of pieces to
submit to witness inspection is defined in the Order Specifications.
3 = TYPE UNIT WITNESSED. Action performed on one spot-sampled
piece. Type unit is used to denote all the pieces of the same type that
are identical.
4 = WITNESSING NOT MANDATORY. The Supplier shall inform saipem of
the date of the activity and saipem reserves the right to witness the test.
If the test is conducted at the notified date, the Supplier may proceed
with the subsequent phase, even if saipem did not witness the test.
C = REVIEW
OF
TECHNICAL
DOCUMENTS
BEFORE
COMMENCEMENT OF CONSTRUCTION. The technical documents
shall be reviewed before the commencement of construction.
V = REVIEW OF DOCUMENTS. Materials certificates, statement of
compliance and reports of inspection and tests conducted by the
Supplier shall be revised to assess their conformance with the
requirements specified in the Code and Standards, Specifications
and/or Purchase Order.
Documentation
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 75 of 106
5 = MILL CERTIFICATE/SOURCE CERTIFICATE. Document quoting
numerical data from the results of tests, conducted on raw materials.
6 = INSPECTION AND TEST CERTIFICATE. Document issued by Supplier
quoting numerical data from the results of the activity performed.
7 = STATEMENT OF COMPLIANCE. Document issued by the Supplier
certifying that the product supplied meets the requirements of
contractual and non-contractual Codes and Standards, without quoting
numerical data from the results of the inspections and tests conducted.
8 = CERTIFICATE OF APPROVAL. Document issued by the Testing
Authorities certifying, with numerical data from the results of inspections
and tests that the materials and/or equipment comply with the Codes
and Standards.
9 = PROTOTYPE TEST CERTIFICATE. Document issued by the Supplier
certifying, with numerical data from the results of inspections and tests,
that the materials and/or equipment comply with the Codes and
Standards.
MATERIAL:
SELF PRIMING ASME PUMPS FOR PROCESS SERVICE
(NON API)
OF M0100501E
CLASS
PRODUCT:
CODE:
3/N
PARTIES:
SA Contractor (SCNL)
A Principal (SPDC)
B
S Supplier
REFERENCED STANDARD, CODES, SPECIFICATION DRAWINGS:
SSG-NG01012401-GEN-MR-7771-00019
Priming ASME Pumps
Supply Specification for Self
BS EN 10204 (2004) Metallic product – Type of Inspection documentation
ASME B73.1:200
DEP 30.48.00.31
Specification for Horizontal End Suction Centrifugal Pumps for
Chemical Process
Protective Coatings for Onshore Facilities
DEP 31.29.02.11
Pumps - Selection, Testing and Installation
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 76 of 106
No.
PARTIES
INSPECTION AND TESTS
SA A
B
NOTES
S
CHECKS AND TESTS ON UNFINISHED MATERIALS
1
verification of chemical analysis certificate of main components
V
V
5
2
verification of mechanical test certificates of main components
V
V
5
CHECKS AND TESTS DURING FABRICATION
3
UT on pump shaft
V
V
6
4
MT on casing / cover
V
V
6
5
MT or PT on impeller (machned surface)
V
V
6
6
Hardness test of wear rings
V
V
6
7
NDE on interconnecting lines / vents & drains (as per applicable code)
V
V
6
8
casing thickness check
V
V
6
9
hydrostatic pressure test of pumps casing
V
V
6
10
NDE of mechanical seal vessel (as applicable)
6
11
Hydrostatic pressure test of mechanical seal vessel (as applicable)
6
FINAL CHECKS AND TESTS
8
verification of gauging and calibration of instruments used for checks and tests
V V
Functional checks and tests
9
Performance Test (with job driver and job mechancial seals)
3
4
6
10
NPSH test (when required by DEP 31.29.02.11)
3
4
6
11
Vibration & noise level check
3
4
6
Visual and dimensional checks
12
Wear rings clearances check
3
V
6
13
Dimensional check of assembled unit / check of instruments of seal system
1
4
6
14
Check of correct rotation of driven equipment and driver
1
4
7
15
1
4
7
16
check of general compliance of supply with specifications, data sheets, manufacturer's
documentation (technical data)
spare parts check
1
4
17
supply limits check
1
4
Painting
18
thickness check
2
V
19
Check of colour
1
V
V
V
6
FINAL INSPECTION CERTIFICATION
19
The manufacturer shall furnish the whole documentation concerning verifications, checks
and tests above mentioned (collected in sets), in the number of copies and in the
language required in the purchase order
review of manufacturer's data book
3.3.7.Supplier Document Requirement listing
SDRL is the list of all documentation submitted by the Vendor or the Pump manufacturer
This was accompanied with NOTES as follows:
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 77 of 106
•
All documents must be prepared and submitted in accordance with the following
specification: SSG-NG010112401-GEN-AA-6180-00011 "SUPPLIER
DOCUMENTS REQUIREMENTS"
•
The first issue date specified in the latest that is considered acceptable. The
Bidder/Supplier is to complete the Supplier Document Schedule (SDS - Code
A01) with the agreed issue dates.
•
The quantity of documents required with the BID, at first and final issue are
indicated by the numbers within the ‘with Bid’, ‘first issue’, ‘final issue’ and 'asbuilt' columns adjacent to the document. The specified number of copies of the
Certification Data Book (K01) is inclusive of 1 (one) original, i.e. "red stamped"
copy
•
An ‘x’ within the ‘within manuals’ column indicates those documents (Certified
Final issue) that are required to be
included within the Certification Data
Book and/or Installation, Operating and Maintenance Manuals.
•
All documents shall be submitted in pdf or tif format. Each document shall be
delivered as "single file" without any reference attached. Supplier shall advise any
non-compliance.
•
An 'X' in the column "with Bid", "first issue", "final issues" and "As built" indicates
that an Electronic Copy is required.
•
An (*) in the column First issue required date indicates documents subjected to
liquidated damages for late delivery.
•
Turnaround time for documents is 15 working days. Any delay in return of
commented drawing shall not be in any case cause of delay in the supply of the
package. If after 30 calendar days from the Contractor receipt of one document no
comment has been received by Vendor, he shall advise Contractor about his
matter and proceed with the package construction in full accordance with the
requirement of the Contract.
•
This document list is relevant to 1 set of document only. Each item included in the
supply shall be provided with a dedicated set of documentation.
•
Document size A0 shall be avoided; the maximum size shall be limited to A1.
•
All documents shall be supplied in English and free of coprights prohibiting use
within project.
•
All units of measure shall be in SI.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 78 of 106
3.3.7.1.
SDRL Matrix
SUPPLIER DOCUMENT REQUIREMENT LISTING (SDRL)
CODE
DOCUMENT DESCRIPTION
WITH
FIRST
BID
ISSUE
DOCUMENT
COPIES REQUIRED
FIRST
ISSUE
REQD
1+X
P+4
FINAL
ASISSUE
BUILT
DOCUMENT
COPIES REQUIRED
REVIEW
CLASS
WITHIN
MANUAL
J01
K01
A-
CONTROL DOCUMENTS
A01
Suppliers Document Schedule (SDS)
A02
Fabrication/Production Schedule
A03
Progress Reports (Weekly / Monthly)
A04
Sub-order Schedule
B-
GENERAL ARRANGEMENT DRAWINGS
B01
General Arrangements
X (*)
P+6
1+X
B02
Acceptable Nozzle Loads
X
P+8
1+X
O
X
B03
Interface and Connection Schedule
X
P+8
1+X
O
X
B04
Foundation Loading Diag. & Support Details
X
P+8
1+X
O
X
C-
SYSTEM DIAGRAMS & DATA SHEETS
C04
Bill of Materials
X
P + 12
1+X
O
X
C06
Utilities Schedule
1+X
X
P + 10
1+X
O
X
C07
Weight Data Sheet
1+X
X
P+8
1+X
O
X
C08
Equipment Data Sheet
1+X
X (*)
P+8
1+X
O
X
C09
Noise Level Data Sheet
1+X
X
P + 10
1+X
O
X
C10
Schedule of Elec. Equipment in Haz. Area
X
P+8
1+X
O
X
D-
DETAIL DRAWINGS
Cross Sectional Drawing or Exploded View Diagram
with Parts List
X
P + 14
1+X
1+X
O
X
X
P + 14
1+X
1+X
O
X
O
X
D01
X
X
X
1+X
1+X
O
1+X
O
1+X
O
1+X
1+X
X
X
O
X
X
O
X
D02
Mechanical Seal Details
D03
Shaft Alignment Drawings
D04
Name Plate Format Drawings
X
P + 14
1+X
1+X
O
X
D05
D07
Sub Assembly Drawings
Detail Drawing
X
P + 14
1+X
1+X
O
X
X
P + 14
1+X
1+X
O
X
E-
INSTRUMENT & ELECTRICAL DRAWINGS
E01
Interconnection Diagrams
X
P + 12
1+X
1+X
O
X
E06
Instrument Termination and Hook up Details
X
P + 12
1+X
1+X
O
X
E08
Instrument Index
X
P + 12
1+X
O
X
E09
Instrument Data Sheets
X (*)
P + 12
1+X
O
X
E10
Instrument Layout Drawings
X
P + 12
1+X
O
X
FF28
CALCULATIONS
Motor Performance Curves
X
P + 12
1+X
O
X
F30
Centrifugal Pump Performance Curves
X
P+6
1+X
O
X
F36
Speed / Torque Starting Curves
X
P+8
1+X
O
X
G-
HANDLING, INSTALL. & SITE PRESERVATION
G01
Erection and Installation Procedure
X
D-8
1+X
O
X
G02
Unpacking and Preservation Procedure
X
D-8
1+X
O
X
G03
Handling and Shipping Procedure
X
D-8
1+X
O
X
G04
Weight Control / Weighing Procedure
X
D-8
1+X
O
X
H-
MANUFACTURING, QUALITY PROCEDURES
H01
Quality Manual
H02
Quality Plan
Weld Procedure Specification (WPS) and Qualification
(WPQ) Records
H04
1+X
1+X
1+X
X
P+6
1+X
O
X (*)
P+6
1+X
O
X
X
X
U-4
1+X
O
X
H05
Non-destructive Examination Procedure (NDE)
X
T-4
1+X
O
X
H07
Hydrostat/Flushing/Pneumatic Test Procedure
X
T-8
1+X
O
X
H08
Performance Testing & Acceptance Test Proc.
1+X
X
T-8
1+X
O
X
H09
Surface Preparation & Painting Procedure
COMMISSIONING, OPERATING, MAINTENANCE
AND SPARES
1+X
X
Q-8
1+X
O
X
JJ01
D-6
10 + X
O
P + 14
1+X
O
X
X
P + 14
1+X
O
X
X
X
D-6
1+X
O
X
X
X
P + 10
1+X
O
X
D-2
1+X
O
Operating and Maintenance Manual
Recommended Start-up and Commissioning Spares
List
X
X
J04
Recommended Spares For 2 Years Operation
X
J06
Pre-commissioning / Commissioning Proc.
J07
Special Tools List
K-
CERTIFICATION
K01
Certification Data Book
K02
Equip. Haz. Area Certificate and Schedule
P + 12
O
X
K04
Performance Test Results
T+2
O
X
J03
1 + X (*)
1+X
K05
Factory Acceptance Test Report (FAT)
T+2
O
X
K06
Vibration Report
T+2
O
X
K07
Noise Report
D+2
O
X
K08
Weight Report
D
O
X
D - 10
O
1 + X (*)
X
X
K10
Indices for Manuals J01 / K01
L-
TEST & INSPECTION REPORTS
L01
Material Test Certificate
S
X
L02
Welder Performance Qualification Cert.
S
X
L03
NDE Operator Qualifications
S
X
L04
Production Test Results (inc Welding)
S
X
L05
NDE Records
S
X
L07
Material Traceability Records
S
X
L09
Pressure Test Certificate
S
X
L10
Instrument Test / Calibration Certificate
X
L11
Dimensional Report
S
S
L14
Certificate Of Compliance
S
X
L15
Electrical Equipment Type Tests
X
L16
Routine Test Certificate - Electrical Equipment
S
S
L20
Purchaser's Release Note / Waiver
S
X
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
X
X
Page 79 of 106
3.3.7.2.
Description of SDRL Code
A01
Suppliers Document Schedule
(SDS)
FORMAT/TYPE: Initial issue by completion of Purchaser's format. Updates by mark-up of Purchaser's computerised
register.
PURPOSE: To establish and update Purchaser's register.
INFORMATION TO BE SHOWN ON DOCUMENT
- Listing by category and title of all Supplier's documents to be issued per SDRL.
- Date of first submission of each document to Purchaser.
- Listing to contain both Purchaser's and Supplier's document numbers.
- Refer to Purchaser's specification 'Drawing and Data Requirements - Instructions to Suppliers' included in the purchase
order documentation.
WHERE PURCHASE ORDER REQUIRES THE ISSUE OF A MONTHLY REPORT THIS SCHEDULE SHALL BE
INCLUDED UNDER DATA CODE A03 AFTER FIRST SUBMISSION.
A02
Fabrication/Production Schedule
FORMAT/TYPE: Bar Chart (A3 size maximum)
PURPOSE: Control document
INFORMATION TO BE SHOWN ON DOCUMENT
- Schedule to barchart form , showing design, manufacture, inspection, testing and delivery of all equipment, materials and
components to be delivered by Supplier and his sub-suppliers.
- Earliest and latest completion dates shall be entered alongside each activity with float indicated.
- Once agreed with Purchaser, the "planned" dates shall not change without prior approval by purchaser.
- Progress to date shall be clearly shown against each activity.
- Procurement and delivery of sub-supplier items with names and references to be included.
- Summary schedule of issue dates required for all documents in Data Code A01 above grouped by prime category, in bar
chart format to show relationship with the Fabrication/Production Schedule.
- Schedule to show calendar dates.
WHERE PURCHASE ORDER REQUIRES THE ISSUE OF A MONTHLY REPORT THIS DOCUMENT SHALL BE
INCLUDED UNDER DATA CODE A03 AFTER FIRST SUBMISSION.
FORMAT/TYPE: Telex/Fax/A4 document.
PURPOSE: Control document.
INFORMATION TO BE SHOWN ON DOCUMENT
Telex or fax reports to be submitted on the Friday of each week giving:
- activities completed this week and % complete.
- activities planned for the next week.
- any problems encountered, with corrective actions proposed.
- identification of areas in which Purchaser is delaying Supplier's progress.
- confirmation that contracted delivery date(s) will be maintained.
A03
A04
Progress Reports (Weekly /
Monthly)
Sub-order Schedule
Monthly report to be submitted three working days after the last Friday in each calendar month. Report to contain the
following information as a minimum:a) Narrative explaining salient features of work carried out during the month, problems encountered of both an engineering
and programme nature, steps being taken to overcome them, and confirmation that contracted delivery date(s) will be
achieved.
b) Running log of all commercial changes or requests made (whether or not approved by Purchaser) together with status.
c) Running log of all design concessions requested by Supplier (whether or not approved by Purchaser) together with
current status.
d) Updated fabrication/production schedule 'front-lined' to shown actual progress at cut-off (Ref Data Code A02).
e) Updated sub-order schedule indicating all sub-orders to be placed by Supplier (Ref Data Code A03).
f) Updated Supplier Document Schedule showing status of all drawings to be produced against the order (Ref Data Code
A01).
g) If purchase order is subject to IVB appraisal prior to delivery, certification status report identifying documentation
submitted to and approvals received from CA together with any details of any concerns highlighted by the IVB.
FORMAT/TYPE: Purchasers forms.
PURPOSE: Control document.
INFORMATION TO BE SHOWN ON DOCUMENT
Schedule shall show all sub-orders to be placed by Supplier. Against each entry Supplier shall indicate anticipated award
date and the latest data by which sub-order must be placed to meet the overall schedule. Supplier shall submit unpriced
copies of sub-orders at the time of order placement.
WHERE PURCHASE ORDER REQUIRES THE ISSUE OF A MONTHLY REPORT THIS SCHEDULE TO BE INCLUDED
UNDER DATA CODE A03 AFTER FIRST SUBMISSION
B-
GENERAL ARRANGEMENT DRAWINGS
FORMAT/TYPE: Maximum size A1. Scale drawing.
PURPOSE: Interface liaison. Design review.
B01
General Arrangements
INFORMATION TO BE SHOWN ON DOCUMENT.
- Envelope and dimensions relative to unit datum.
- Access, withdrawal and laydown requirements for maintenance to be shown.
- Location and numbering of all piping and tubing terminations for Purchaser connection to process and utilities,
including size, rating and type.
- Location of all skid edge junction boxes requiring Purchaser connections.
- Identification and location of all major on skid components with Purchaser's tag numbers added.
- Where a package consists of more than one skid, separate drawings shall be provided for each skid.
- Overall weights and maintenance weights for major components.
- Spreader beam, lifting points and C of G to be shown.
- Where appropriate, an equipment list is also to be submitted.
FORMAT/TYPE: A4 document.
PURPOSE: Interface liaison. Design review.
B02
Acceptable Nozzle Loads
INFORMATION TO BE SHOWN ON DOCUMENT.
- Drawing to indicate acceptable loads, forces and moments on flanges to which Purchaser connects, together with
loads during normal and maximum operating conditions - if not covered by applicable specifications. Calculations
to be included.
FORMAT/TYPE: A4 listing.
PURPOSE: Interface liaison.
INFORMATION TO BE SHOWN ON DOCUMENT
B03
- Listing by number of all Supplier termination points, including electrical and instrument cable terminations and
all junction boxes cross referenced to the relevant drawings.
- Size, rating and specification of all piping and tubing termination points requiring purchaser connection.
Interface and Connection Schedule
- Identification of corresponding connection point on another skid or system to which each point shall be
connected.
- Identification of fluids at each connection point including pressure and temperature conditions. For each vent
and drain, fluids under normal and abnormal operating conditions shall be stated, and system to which each must
be connected (ie, Purchaser's vent or drain - safe, open or closed).
- This document shall always be submitted together with Data Code B01 - General Arrangement Drawings.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 80 of 106
FORMAT/TYPE: Maximum drawing size A1.
PURPOSE: Interface liaison.
INFORMATION TO BE SHOWN ON DOCUMENT.
B04
Foundation Loading Diag. &
Support Details
- Floor fixing details.
- Including all static and dynamic forces or movements acting on foundations or other load bearing supports during
start-up, shut-down, normal and maximum operation conditions and test conditions (eg. motor/generator short
circuit).
- Also including Supplier's recommended anchor bolt details with sizes and grades and locations (including
tolerances) relative to equipment centre lines in all three planes, also recommended lengths and pre-tensioning.
- Anchor bolt details show chock block and shimming arrangements.
- Temporary fixing details for barge transportation to be shown.
- For equipment which is welded, skirt weld preparation is to be detailed.
- Operating frequencies for vibrating equipment.
- Drawing may be combined with Data Code B01 - General Arrangement Drawings.
C-
SYSTEM DIAGRAMS & DATA SHEETS
FORMAT/TYPE: A4 listing.
PURPOSE: Design and review and operation and maintenance.
INFORMATION TO BE SHOWN ON DOCUMENT
C04
Bill of Materials
Each tagged item on the P&ID (SDRL Code C01) shall be identified and the following information shall be given (as
appropriate):
- Purchaser's tag number of Supplier's tag number (as applicable).
- Service description.
- Rating or range of operation.
- Materials of construction.
- Signal output.
- Manufacturer and model number.
- Contacts for switches.
- Shipped loose items required for offshore installation and assembly shall clearly highlighted.
This document shall always be submitted together with drawing/P&ID/ HVAC flow diagrams to which it refers.
C06
C07
Utilities Schedule
Weight Data Sheet
FORMAT/TYPE: A4 listing.
PURPOSE: Interface liaison.
INFORMATION TO BE SHOWN ON DOCUMENT
Schedule to indicate types, quantities, pressure, temperature, voltage, KW, KVA, of all utilities required to start and
operate the equipment under start-up normal operation and shutdown conditions.
FORMAT/TYPE: Purchaser's A4 sheet completed by Supplier.
PURPOSE: Interface liaison.
INFORMATION TO BE SHOWN ON DOCUMENT
Supplier shall complete weight data sheets for each separately installed item of equipment or skid in accordance with
weight data and instructions. Information shall be submitted for each design change affecting weight data and at the
following stages during the contract.
- with enquiry
- 6 weeks after order
- where there is any change to the weight identified by Supplier
- as weighed, endorsed as such by Purchaser
The following information shall be updated: empty (dry), operating, test (full), shipping weight, C of G.
Heaviest lift during maintenance to be defined.
C08
C09
Equipment Data Sheet
FORMAT/TYPE: Purchaser's A4 sheets completed by Supplier.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Where Equipment Data Sheets are issued by Purchaser as part of purchase order, Supplier to fully complete. Data
sheets are to be completed for each and every instrument.
Noise Level Data Sheet
FORMAT/TYPE: Purchaser's A4 sheets completed by Supplier.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Purchaser will define sound power and sound pressure level limitation. Supplier will complete and return these sheets with
anticipated, and if requested, guaranteed data, for the Octave mid band frequencies corresponding to these limitations.
FORMAT/TYPE: A4 Listing
PURPOSE: Certification Date Box
INFORMATION TO BE SHOWN ON DOCUMENT
All equipment and electrically operated instrumentation equipment to be listed in a tabular form with information presented
under the following column headings:
- Equipment type
i.e. “Junction Box”, “Motor”, “Pressure Transmitter”. Etc
- Tag Number(s)
Quantity fitted (only for identical items fitted in same Zone. All other equipment must be listed individually)
- Manufacturer
- Manufacturer’s Type Number
- Zone in which fitted
i.e. Zone 0, Zone 1, Zone 2 or Safe area
- Approval Body
e.g. BASEEFA, PTA, INTEX etc.
- Type of protection
e.g. Flameproof, Increased Safety, Intrinsically Safe etc.
- Type of protection code
e.g. eeXD: eXD: eeXE, eeXIA: etc.
- Apparatus Group (sometimes call “Gas Group”)
e.g. IIA: IIB: IIC.
- Temperature Classifications
e.g. T3, T6 etc.
- Hazardous Area Certificate Number
Date of expiry of current BASEEFA LICENCE (not certificate)
- Standard to which the equipment is certified
e.g. BS5501 Parts 1 & 6
- Entry Protection ie the IP rating
e.g. IP56, IP67 etc
C10
Schedule of Elec. Equipment in
Haz. Area
C11
FORMAT/TYPE: Schematic diagram.
PURPOSE: Interface liaison and design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Electric / Electronic / Pneuamtic /
Diagrams shall indicate the schematic arrangement of all component parts. The format shall be such that an
Hydraulic Schematics
understanding of the function shall be readily gained with accompanying notes, if needed. Relays shall be shown in a deenergised state, with their contacts open or closed accordingly.
Interface terminals shall be uniquely identified by both symbol, type and number and their physical location identified.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 81 of 106
D-
10-Sept.-2013
FORMAT/TYPE: Scale Drawings
PURPOSE: Design Review
INFORMATION TO BE SHOWN ON DOCUMENT
D01
Scale drawings of component parts shall be shown in cross section or, if required, by exploded view representative
Cross Sectional Drawing or
Exploded View Diagram with Parts where the various parts of the assembly are separated, but in proper position relative to each other. All parts to
List
be identified by the parts list, which shall give full details of:
- Material of Construction
- Thickness
- Manufacturer and references No
FORMAT/TYPE: Scale drawing.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
D02
Mechanical Seal Details
- Dimensions including clearances.
- Parts list, defining materials,
- Identification of fluid connection points.
- Seal system description (if required).
- Description of operation (if required).
- Piping system indicating all components and materials.
FORMAT/TYPE: Scale drawing.
PURPOSE: Design review.
D03
Shaft Alignment Drawings
INFORMATION TO BE SHOWN ON DOCUMENT
Scale drawings showing design/actual alignment with thermal growths and tolerances both angular and
displacement together with alignment procedures.
Name Plate Format Drawings
FORMAT/TYPE: Scale drawing.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Drawings for Coded Vessel and equipment name plates, which shall include all details to satisfy Code and Purchaser’s
requirements.
Sub Assembly Drawings
FORMAT/TYPE: Scale drawing.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Details of sub assemblies which form part of the Suppliers package and which may be required for Purchaser’s review and
approval or for information, but which are not shown to be adequate detail on the General arrangement drawing. Information
shall be shown in accordance with the requirements for the GA.
D07
Detail Drawing
FORMAT/TYPE: Scale drawing.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Detail drawings to indicate method of construction, plus all features which are omitted from the GA drawing for clarity.
Drawings will contain the following information where appropriate:
- Manufacturer
- Tag Number
- Process connection size(s) and ratings
- Inlet and outlet configuration
- Face-to-face dimensions
- Overall height, width and depth
- Electrical connection size(s)
- Instrument mounting details
- Instrument accessories (positioner, handwheel, air set, etc)
- Weight
E-
INSTRUMENT & ELECTRICAL DRAWINGS
D04
D05
FORMAT/TYPE: Detailed Diagrams
PURPOSE: Interface liaison
INFORMATION TO BE SHOWN ON DOCUMENT
E01
Interconnection Diagram
1. Diagrams shall display, in block form, the items of electrical and instrument equipment and the cables
connecting them to panel or UCP. The terminal block reference for each item shall be stated, along with the
number and size of the conductors and cables. Cable NOT in the Supplier’s Scope of Supply shall be clearly
identified.
Diagrams shall show each terminal block with the terminals numbered and the cores of the connecting cables
identified. The core identifiers given shall be those ferruled onto the conductors and shall follow any numbering
system advised by Purchaser. Terminal block diagrams may be incorporated with interconnection diagrams - if the
complexity of the system permits.
Drawings must show AC/DC segregation, IS and non-IS segregation (where applicable) and cable screen
terminations, together with duty description/tag against input and output. For ease of identification, destination
'to and from' is to be shown, with cross-referenced drawing numbers and earthing requirements clearly shown.
FORMAT/TYPE: Diagramatic drawing, one sheet for each hook-up.
PURPOSE: Interface liaison, design review, maintenance, installation and commissioning.
INFORMATION TO BE SHOWN ON DOCUMENT
E06
Instrument Termination and Hook
up Details
Instrument cable termination details shall show junction box gland plate drilling sizes to suit external cabling
to/from the package, and all glanding information. All cable indicated on these drawings must be terminated at
both ends. Process hook-up drawings shall be prepared for each tagged instrument that requires a process
impulse line for sensing purposes. Similarly, a pneumatic hook-up drawing shall be prepared for each tagged
instrument air transmission/control signal. Both types of drawings shall include all the necessary mounting details
and a schedule of all installation materials used.
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 82 of 106
FORMAT/TYPE: A3 listing on Purchaser's format.
PURPOSE: Installation and commissioning and maintenance.
INFORMATION TO BE SHOWN ON THE DOCUMENT
E08
Instrument Index
The following minimum information must be presented in a format advised by the Purchaser:
- Tag number (in alpha-numeric sequence).
- Purchasers Works Identification Number (WI Number).
- Instrument description (pressure switch, control valve, level gauge, etc).
- Service description (eg, pump P3102 discharge, etc).
- Location of line (size/number/spec)
- P&ID number.
- Data sheet number.
- Hook-up drawing reference.
FORMAT/TYPE: Purchaser's A4 sheets completed by Supplier.
PURPOSE: Design, review, inspection and testing and operating and maintenance.
E09
Instrument Data Sheets
INFORMATION TO BE SHOWN ON DOCUMENT
Each and every instrument shall have a data sheet completed to the project format provided by the Purchaser for
the Supplier to complete.
FORMAT/TYPE: Scale Drawing.
PURPOSE: Interface liaison and design review.
INFORMATION TO BE SHOWN ON DOCUMENT
E10
Instrument Layout Drawings
F-
CALCULATIONS
F28
Motor Performance Curves
F30
Centrifugal Pump Performance
Curves
Layout drawings will show the location and elevation of all instruments, control valves, control panels etc, and
Purchaser free issued equipment where applicable. In addition, the drawing will show the routing of all
instrument air distribution, pneumatic tubing, signal/power supply cables, and the location of all instrument
junction boxes. Layout drawings will also be required to show fire detection instrumentation.
FORMAT/TYPE: A4 graphs.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Curves to indicate torque and current against speed for 80% and 100% voltage conditions and at 80% frequency. Driven
equipment torque shall also be plotted to confirm that there is adequate nett torque for acceleration.
FORMAT/TYPE: A4 graphs.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Curves to indicate differential head developed, efficiency, and absorption power, versus flow with any velocity corrections for
rated impeller. Units driven by variable speed drivers shall indicate four performance curves to indicate performance from
minimum to maximum operating speeds. Curves shall indicate performance from zero to 120% rated flow, with minimum
continuous flow clearly indicated. For firepumps a shop test curve identified by pump serial number is required showing
head to rated and 150% capacities. NPSHR shall be plotted for the full range of flow and for each speed line as
appropriate.
Guarantee points shall be clearly identified.
FORMAT/TYPE: A4 graphs.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Curves shall indicate torque speed characteristics of both driver and driven equipment from zero to rated speed, and a
statement as to the process condition prevailing at the driven equipment for the curve shown.
F36
Speed / Torque Starting Curves
G-
HANDLING, INSTALL. & SITE PRESERVATION
FORMAT/TYPE: A4 manuals and drawings.
PURPOSE: Installation.
INFORMATION TO BE SHOWN ON DOCUMENT
G01
- lifting points
- lifting weights
- shipping break points for panels and switchboard assemblies
Erection and Installation Procedure
- erection match markings
- fixing points
- levelling procedures
- alignment procedures
- erection fasteners summary list
- details of any special unpacking/handling requirements shall be stated
FORMAT/TYPE: A4 procedure.
G02
Unpacking and Preservation
Procedure
PURPOSE: Traffic and design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Detail preservation procedure detailing inspection periods, materials required, for both onshore and offshore
requirements and materials needing disposal. Any special unpacking/handling requirements shall be stated.
FORMAT/TYPE: A4 procedure.
G03
Handling and Shipping Procedure
PURPOSE: Traffic and design review.
INFORMATION TO BE SHOWN ON DOCUMENT
Supplier to propose techniques. Indicate size of container, number off weight, identification and contents.
FORMAT/TYPE: A4 procedure.
PURPOSE: Design review.
INFORMATION TO BE SHOWN ON DOCUMENT
G04
Weight Control / Weighing
Procedure
To detail method recording weights during design and manufacture and method of weighing equipment prior to
shipment. The weighing procedure shall include:
- A description of the weight measuring and recording devices giving capacity and accuracy. Accuracy to be within
+1%.
- Description of calibration methods. The Supplier shall provide a current valid calibration certificate (calibrated
within the last six months) for each of the measuring/recording devices to be used for the weighing.
- Methods to be used for weighing and measuring/calculating centre of gravity including temporary
lifting/supporting equipment used.
- Weight recording data sheets to document weighing, eg. measuring equipment serial number, all measured data.
- Verifying actual weight against estimated weight.
The Supplier shall, within ten (10) days of the weighing, submit the original of the records and related data
together with a Weight and Centre of Gravity Datasheet summarising the results. The weighing results shall define
the state of completion of equipment (listing as appropriate the weight of those items that were missing).
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 83 of 106
H-
MANUFACTURING, QUALITY PROCEDURES
FORMAT/TYPE: A4 bound volume.
PURPOSE: QA/QC.
INFORMATION TO BE SHOWN ON DOCUMENT
H01
Quality Manual
Where the Supplier has a quality system approved in accordance with ISO 9000: 2000, only a copy of the approval
certificate and the index of the Quality Manual is to be submitted to the Purchaser unless specifically requested.
Purchaser reserves the right to request a copy of the complete Quality Manual at any time during the life of the
purchase order.
FORMAT/TYPE: A4 sheets.
PURPOSE: QA/QC.
H02
Quality Plan
INFORMATION TO BE SHOWN ON DOCUMENT
The Quality Plan shall be job specific and shall clearly identify all Quality Control activities performed by the
Supplier including all hold and witness points for Purchaser to comment and indicate those activities to be
witnessed by Purchaser; third party inspectorate and IVB as appropriate
FORMAT/TYPE: Supplier's standard forms in accordance with Purchaser's requirements.
PURPOSE: Materials Engineering review and QA/QC.
INFORMATION TO BE SHOWN ON DOCUMENT
H04
Weld Procedure Specification
(WPS) and Qualification (WPQ)
Records
Define all shop, field and repair welding procedures in accordance with Purchaser's requirements. The Welding
Procedure Specification (WPS) shall be cross referenced to the applicable weld location plan (Data Code J01) and
Weld Procedure Qualification (WPQ). All WPS documents shall be issued in a single submission, together with the
WPQ and a listing register to show status of approval. Qualification records describe parameters used in
qualification of WPS's together with mechanical testing and results in accordance with Purchaser's requirements.
WPQ test records are to be cross referenced to the WPS's and when applicable stamped by the third party
inspection authority. Fabrication shall not commence before the appropriate weld procedure has been approved
by Purchaser unless notified otherwise in writing.
FORMAT/TYPE: Supplier's procedures.
PURPOSE: Materials Engineering review and QA/QC.
INFORMATION TO BE SHOWN ON DOCUMENT
H05
Non-destructive Examination
Procedure (NDE)
Define method, extent and acceptance levels of all NDE used to verify that materials and/or formed or welded
fabrications comply with Purchaser's requirements. To include as applicable visual, radiographic, ultrasonic,
magnetic particle, dye penetrant, hardness tests and other techniques.
When applicable, procedures shall comply with the requirements of the third party inspection authority.
Procedures shall also be cross referenced to the weld location plan (SDRL Code ).
FORMAT/TYPE: Supplier's procedures.
PURPOSE: QA/QC, materials engineering review.
H07
Hydrostat/Flushing/Pneumatic
Test Procedure
H08
Performance Testing &
Acceptance Test Proc.
INFORMATION TO BE SHOWN ON DOCUMENT
Detailed procedures for compliance with Purchaser's specifications including duration of test, quality of test
medium, confirmation of no leakage. Methods of flushing pipework systems at works and site (eg, lube, seal and
hydraulic oil systems) including acceptance criteria.
FORMAT/TYPE: Supplier's procedures.
PURPOSE: QA/QC, materials engineering review.
INFORMATION TO BE SHOWN ON DOCUMENT
Suppliers procedures detailing all tests which will be carried out to demonstrate that the equipment fulfils the
Purchaser’s requirements and meets process guarantees. A procedure is required to cover all factory acceptance
test reports (ref SDRL code K05)
FORMAT/TYPE: A4 procedure.
PURPOSE: Design review and QA/QC.
INFORMATION TO BE SHOWN ON DOCUMENT
This shall be supplied for equipment, especially where exception to Purchaser specification has been agreed (in
writing), and shall include:
- surface cleaning
- preparation
- shop or field painting
- linings (where applicable)
- repairs to damaged finishes
H09
Surface Preparation & Painting
Procedure
J-
COMMISSIONING, OPERATING, MAINTENANCE AND SPARES
FORMAT/TYPE: A4 bound volumes to Purchaser's specifications.
PURPOSE: Installation, commissioning and maintenance.
J01
Operating and Maintenance
Manual
INFORMATION TO BE INCLUDED IN MANUAL
Manual shall include description of equipment, operating procedures for start-up, steady state, shutdown,
emergency and fault conditions, operating parameters, function of protective devices and controls, maintenance
data copies of all relevant cause and effect charts and block diagrams, and fault finding guidelines.
FORMAT/TYPE: A4 typed listing.
PURPOSE: Commissioning and maintenance.
INFORMATION TO BE SHOWN ON DOCUMENT
J03
Recommended Start-up and
Commissioning Spares List
List shall indicate spare parts and special maintenance/handling tools recommended by Supplier, and be defined
by reference to cross-sectional drawings and relevant parts list. These shall include wearing parts such as bushes,
seals, gaskets which need replacement after start-up, test and shutdown prior to production start. Against each
entry, price and delivery shall be indicated.
J04
Recommended Spares For 2
Years Operation
FORMAT/TYPE: A4 typed listing.
PURPOSE: Maintenance.
INFORMATION TO BE SHOWN ON DOCUMENT
List shall indicate spare parts recommended by Supplier, and be defined by reference to cross-sectional drawings and
relevant parts list. Each item shall be referenced by its original manufacturers name and part number. Against each entry,
number of parts in operation, price and delivery shall be indicated. Format shall be as supplied by Purchaser.
J06
Pre-commissioning /
Commissioning Proc.
FORMAT/TYPE: A4 procedure.
PURPOSE: Commissioning.
INFORMATION TO BE SHOWN ON DOCUMENT
Procedure shall include list of spare parts, special tools and utilities required, pre-commissioning checks to be performed,
sequenced procedure for start-up, and fault finding guidelines. Copies of all relevant drawings shall also be included.
Special Tools List
FORMAT/TYPE: A4 listing.
PURPOSE: Maintenance and installation and commissioning.
INFORMATION TO BE SHOWN ON DOCUMENT
List shall indicate those tools necessary for removing equipment from transport at site, plus those necessary for
installation and maintenance equipment. Against each entry, a brief description shall be given and where necessary for
clarity, a drawing shall be provided.
J07
T.C. Okoli Nigeria Society of Engineer Technical Report Sept. 2014
Page 84 of 106
K-
CERTIFICATION
FORMAT/TYPE: A4 bound volumes to Purchaser's specifications.
PURPOSE: Purchaser order, design documentation and Quality Assurance documentation tracing manufacturing
K01
Certification Data Book
history. Retained by Purchaser for record purposes, and reference by the Certifying Authority.
INFORMATION TO BE INCLUDED IN MANUAL CONTENTS: Comprehensive indexed volume of purchase order,
design documentation, and manufacturing records.
FORMAT/TYPE: A4 document.
PURPOSE: Certification.
K02
Equip. Haz. Area Certificate and
Schedule
INFORMATION TO BE SHOWN ON DOCUMENT
Certificate issued by a recognised independents authority indicating that a type test has satisfied the specified
standards, eg, BASEEFA, INTRINSIC SAFETY, FIRESAFE. Certification not in the English language shall be supplied
with a verified translation.
FORMAT/TYPE: A4 report.
PURPOSE: QC.
INFORMATION TO BE SHOWN ON DOCUMENT
K04
Performance Test Results
Report shall include the following:
- Description of how test was conducted, including all pertinent items of Data Code L01 below.
- Method of calculating results.
- Acceptance criteria.
- Log of test readings, signed by Purchaser's representative and third party inspection authority (when applicable).
- Calculations of results, taking into account the accuracy of the results.
- Problems encountered during the test, and corrective actions taken
FORMAT/TYPE: A4 report.
PURPOSE: QC.
K05
Factory Acceptance Test Report
(FAT)
INFORMATION TO BE SHOWN ON DOCUMENT
Report on performance/functional tests carried out in the factory to demonstrate the equipment suitability to
fulfil the duty specified. This report to include certificates as appropriate, tests for overspeed, balancing, shaft
mechanical and electrical run out, and vibration. FAT reports on electrical and instrument control equipment shall
include high voltage pressure tests and insulation resistance certificates
FORMAT/TYPE: A4 report.
PURPOSE: QC.
K06
Vibration Report
INFORMATION TO BE SHOWN ON DOCUMENT
Test report of vibration performance during factory acceptance testing, including mechanical and electrical run out
for displacement measuring systems during mechanical and performance testing of machinery.
FORMAT/TYPE: A4 report.
PURPOSE: QC.
K07
Noise Report
INFORMATION TO BE SHOWN ON DOCUMENT
Report to compare actual noise sound pressure and sound power level output with predictions stated in noise
level data sheets (SDRL Code C09).
FORMAT/TYPE: A4.report
K08
Weight Report
PURPOSE: Input to Weight Monitoring System.
INFORMATION TO BE SHOWN ON DOCUMENT
FORMAT/TYPE: A4 documents
PURPOSE: Each index shall contain sufficient information to facilitate ease of accessibility to all sections
K10
Indices for Manuals J01 / K01
contained within the manual. Each section shall be systematically compiled.
INFORMATION TO BE SHOWN ON DOCUMENT
L-
TEST & INSPECTION REPORTS
FORMAT/TYPE: A4 certificate.
PURPOSE: Certification.
INFORMATION TO BE SHOWN ON DOCUMENT
L01
Material Test Certificate
L02
Welder Performance Qualification
Cert.
Certificates in compliance with E.N. 10204 3.1.C. 3.1.B. or otherwise as required by PO Documentation shall include
as a minimum chemical analysis, specification range analysis, mechanical test results, heat treated condition for
the product supplied to the Purchaser. Unless otherwise requested in Design Specification and Quality
Requirements Specification included in the Purchase documentation. Certificates must be fully traceable to each
component by means of a unique numbering system, together with supplementary material placement drawings
when necessary. Certificates and material placement drawings (when required) shall be verified by inspection
authority. Each certificate shall state that it is to E.N. 10204 3.1.C. 3.1.B.
FORMAT/TYPE: Supplier's format A4 report.
PURPOSE: QA/QC and to be approved by Purchaser prior to start of manufacture.
INFORMATION TO BE SHOWN ON DOCUMENT
Welders name, identification and positions to be recorded to code requirements with approval by third party
inspection authority when applicable, using approved weld procedure.
INFORMATION TO BE SHOWN ON DOCUMENT
L03
NDE Operator Qualifications
Copies of Qualification Certificates for the technicians/operators signing certificates within Data Code L09.
Certificates to state Purchaser's purchase order number.
FORMAT/TYPE: A4 certificates.
PURPOSE: Certification.
INFORMATION TO BE SHOWN ON DOCUMENT
L04
Production Test Results (inc
Welding)
Results of tensile, ductility hardness and impact tests carried out on production tests.
- Includes production weld test results.
- Certificates to state Purchaser's purchase order number, tag number (of other unique identification) to permit
traceability of tested equipment, item or piping system. Supplementary marked-up piping isometrics shall be
included when necessary to define extent of testing, those being verified by the Purchaser, when required.
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FORMAT/TYPE: A4 certificates.
PURPOSE: QC.
INFORMATION TO BE SHOWN ON DOCUMENT
A) Radiography
Results of radiography tests carried out and signed by a qualified technician. Detailed reports are to state
Purchaser's order number, and to include the procedure used, acceptance level and results obtained in accordance
with Purchaser's specified standard. Reference shall be made to applicable operator qualification certificates, and
approvals by third party inspection authority shall be gained when necessary.
L05
NDE Records
B) Ultrasonic Examination
Certificate confirming that acceptable results have been obtained on examinations carried out to the specified
standard and stating the equipment used, calibration standard and procedure adopted. The certificate shall be
signed by a qualified operator. Reference shall be made to applicable NDT operation qualification certificates, and
approvals by third party inspection authority shall be gained when necessary.
C) Crack Detection, covering Magnetic Particle Inspection (MPI) and DYE Penetrant Inspection (DPI)
Details as in (B) above.
Note: When applicable, NDE Records shall be supplemented with weld history drawings verified by Purchaser (and
the third party inspection authority, when necessary).
FORMAT/TYPE: Suppliers format, Maximum drawing size A1.
PURPOSE: QC.
INFORMATION TO BE SHOWN ON DOCUMENT
L07
Material Traceability Records
Location plans/records with an identification system cross-referring to the individual material certificates.
When applicable, material placement drawings shall be verified by the Purchaser and/or third party inspection
authority.
FORMAT/TYPE: A4 certificate.
L09
Pressure Test Certificate
PURPOSE: Certification.
INFORMATION TO BE SHOWN ON DOCUMENT
Certificate of hydrostatic and/or pneumatic tests carried out.
FORMAT/TYPE: A4 certification.
PURPOSE: QC.
L10
Instrument Test / Calibration
Certificate
INFORMATION TO BE SHOWN ON DOCUMENT
Calibration certificate for measuring with calibration standard compared with stated.
Test/calibration certificates required for all items of instrumentation. Each certificate to state Purchaser's
purchase order number, and Purchaser's tag number.
FORMAT/TYPE: A4 report.
PURPOSE: QC.
L11
Dimensional Report
INFORMATION TO BE SHOWN ON DOCUMENT
Report to verify all critical dimensions, including Purchaser inter-connection points are in accordance with
Supplier's approved drawings.
Certificate Of Compliance
FORMAT/TYPE: A4 document.
PURPOSE: Certification.
INFORMATION TO BE SHOWN ON DOCUMENT
Certificate issued by the manufacturer confirming that the product complies with the purchase order requirements and
current EC legislation.
L15
Electrical Equipment Type Tests
FORMAT/TYPE: A4 report.
PURPOSE: QC.
INFORMATION TO BE SHOWN ON DOCUMENT
Test report to include temperature rise on full rated load, resistance of windings, no load losses, locked rotor current/torque
momentary overload, high voltage tests, power factor and any tests to establish efficiency. Alternator reports will include
wave form and magnetisation curves. Results of all Type Tests carried out in accordance with the relevant
National/International Standards referenced in the approved Suppliers Technical Specification.
L16
FORMAT/TYPE: Certificate.
PURPOSE: QC.
Routine Test Certificate - Electrical
INFORMATION TO BE SHOWN ON DOCUMENT
Equipment
Certificate of routine tests carried out, eg, no load losses. High voltage, insulation resistance etc, when type tests have
been carried out.
L20
FORMAT/TYPE: Issued by Purchaser.
PURPOSE: QC.
Purchaser's Release Note / Waiver INFORMATION TO BE SHOWN ON DOCUMENT
Purchaser's Release Notes/Waivers to state Purchaser's purchase order number, item number, and other unique
identification when necessary (eg, cast numbers, serial numbers etc).
L14
L21
Code / Standard / Compliance
Certificate
FORMAT/TYPE: A4 document.
PURPOSE: Certification.
INFORMATION TO BE SHOWN ON DOCUMENT
Certificate issued by a recognised independent authority indicating the equipment has been manufactured in accordance
with code/standard. For fire test certification the certificates are to be complete and as issued by the testing authority.
Certificates are to state Purchaser's purchase order number, item number and identification to permit traceability to the fire
tested item or material. Certificates not in the English language shall be supplied with a verified translation. Type approval
certificates are normally acceptable for proprietary items.
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FORMAT/TYPE: A4 documents.
PURPOSE: Certification.
Painting / Insulation Inspection
Report
L22
INFORMATION TO BE SHOWN ON DOCUMENT
Inspection Report issued by Inspecting Authority to confirm Paint/Insulation specification and results.
L23
FORMAT/TYPE: A4 document.
PURPOSE: QC.
INFORMATION TO BE SHOWN ON DOCUMENT
The index of concessions to list those approved by Purchaser, those awaiting Purchaser approval, and those not accepted
by Purchaser.
Concession Records
Supplier shall comply with Purchaser’s procedures for Concession Requests as included in the Purchase Order
documentation. The copy included in the Certification Data Book (SDRL Code K01) shall be complete with all
attachments.
M-
PACKING AND SHIPPING DOCUMENTS
FORMAT/TYPE: A4 listing.
PURPOSE: Traffic.
Packing and Shipping Schedule
M01
INFORMATION TO BE SHOWN ON DOCUMENT
For equipment shipped in more that one piece, a schedule is to be submitted which identifies all the major
components of the package for use as a Check List at the receiving point to ensure all items have been received.
Copy of document to accompany shipment.
3.3.8.Technical Bid Tabulation and Evaluation
3.3.8.1.
SUMMARY
Purpose of this technical bid evaluation is to provide an overview on tender received for
“Closed drain and open drain Pumps”, involving no. 4 Items to be installed on Tunu,
Benisede, and Opukushi Existing flowstations for Southern Swamp Associated Gas
Solutions (SSAGS) Project.
3.3.8.2.
SCOPE OF SUPPLY
3.3.8.2.1. EQUIPMENT
Object of this document are the following items:
Unit
Pump datasheets
Item
pumps
Tunu
Saver
Flowstation
TUNF1-P-5701 A/B
2105-00001_D01 (*)
Benisede
Saver
SSG-NG01012401-BENF1-MR-
Flowstation
BENF1-P-5701 A/B
2105-00001_D01(*)
Opukushi
Saver
SSG-NG01012401-OPUF1-MR-
flowstation
Pit
Pit
Pit
No. of
Pumps
Pumps
Pumps
OPUF1-P-5701 A/B
SSG-NG01012401-TUNF1-MR-
2105-00001_D01(*)
2
2
Pump Typology
Self
Priming
Overhung
Self
Priming
Overhung
2
Self
Priming
Overhung
(*) with comments included in mark-up datasheets.
Closed Drain Pumps, TUNF1-P-5702 A/B have been removed from the scope of work
due to vapour pressure issue, contractor suggests changing pumps typology to Vertical
screw pumps.
The scope of supply of each Pumps consists mainly of:
-
Centrifugal Self-Priming pump
-
LV 400V 50 Hz Fixed Speed Electric Motor Driver
-
Dry flexible spacer type coupling with non-sparking guard
-
Mechanical Seal
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-
Common baseplate for horizontal pump and driver with drip pan and single drain
and all necessary auxiliaries as detalied in ATTACHMENT 6 for Flowserve.
A brief summary of proposed selections is listed below:
SELF PRIMING PUMP VENDOR
ITEM
Flowserve
BENF1-P-5701 A/B
1K1.5x1.5US82RV M3(*)
OPUF1-P-5701 A/B
1K1.5x1.5US82RV M3(*)
TUNF1-P-5701 A/B
1K1.5x1.5US82RV M3(**)
(*) The selected pumps have the rated flow at the 58.7% of BEP.
(**) The selected pump has the rated flow at the 57.9% of BEP
Technical bid evaluation has been performed on machinery required to guarantee
process duties as described in reference datasheets with mark-ups:
SPDC Document
SCNL Document
Description
Doc. number
Rev
Doc. number
Rev
SSG-NG01012401-TUNF1-MR-2105-00001
D01
TUNF1-MA-E-30250
D01
NEW OIL SAVER PIT PUMPS TUNF1-P-5701 A/B
SSG-NG01012401-BENF1-MR-2105-00001
D01
BENF1-MA-E-30255
D01
NEW OIL SAVER PIT PUMPS BENF1-P-5701 A/B
SSG-NG01012401-OPUF1- MR-2105-00001
D01
OPUF1-MA-E-30260
D01
NEW OIL SAVER PIT PUMPS OPUF1-P-5701 A/B
3.3.8.2.2. ACCESSORIES and OPTIONS
Below listed accessories and options have been quoted separately and have been
object of technical alignment between Contractor and Vendors:
a) 2 Years Operational Spares (VENDOR to recommend)
b) Vendor attendance to engineering meetings (Vendor acknowledgs to be
discussed)
c) Site assistance by Vendor (daily rates -Vendor acknowledged to be discussed)
d) Training of SPDC personnel (Vendor acknowledgs to be discussed)
3.3.8.2.3. SPARE PARTS
Commissioning and start-up spare parts for Open Drain Pumps are included in the base
scope of supply.
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3.3.8.2.4. COMMENTS/DEVIATIONS
TO
DEPs,
PROJECT
SPECIFICATIONS AND CODES
Flowserve agreed to design their pumps in accordance with contractual version of Shell
DEP and the project specs stated in the Supply Specification SSG-NG01012401-GENMR-7771-00019, Nigeria regulations and attached clarification form.
Relevant deviations of Flowserve are specified in ATTACHMENT 7 for Company
perusal.
Contractor carefully analysed and took positions on listed comments/deviations.
Final acceptance to above shall be communicated by Company.
Company’s decision shall impact on technical and commercial aspects, as well as
technical acceptability of Vendors.
3.3.8.2.5. NOTES ON OPEN DRAIN PUMPS CONFIGURATION
For Items BENF1-P-5701 A/B, OPUF1-P-5701 A/B and TUNF1-P-5701 A/B, Flowserve
provide a selection of pumps that does not satisfy clause 3.4.3 of DEP 31.29.02.11. The
flow declared by Flowserve is 58.7% of BEP for BENF1-P-5701 A/B, OPUF1-P-5701 A/B
and 57.9% for TUNF1-P-5701 A/B.
Flowserve noted that these selections are the best to achieve a compromise between
NPSH, priming time and BEP operating point.
Open drain pumps operate intermittently. Items BENF1-P-5701 A/B, OPUF1-P-5701 A/B
start operating at NPSH margin of 2.39 or greater and stop at NPSH margin of 1.1m.
TUNF1-P-5701 A/B start operating at NPSH margin of 3.21m or greater and stop at
NPSH margin of 2.27m. Contractor recommends NPSH test shall be witnessed.
During priming the liquid temperature rises. Consequently the vapour pressure rises and
this reduces the NPSH margin. However Vendor confirmed that the Pumps will not
cavitate during priming. Vendor equally confirmed that the vapour pressure returns to
normal value of 30kPa.a after priming.
Flowserve observed that when the lead or duty pump is priming the tendency is that it
will evacuate the lag pump casing of its initial fill and the lag pump could therefore run
dry when it starts. Vendor recommended having 2 independent suction lines for the selfpriming pumps to prevent this from happening.
However contractor due to the already existing common nozzle from the sump
suggested the provision of a bypass line with a flow orifice for each check valve in the
discharge side of the pumps. This shall ensure the replacement of the initial fill.
Flowserve rather insisted that without dedicated suction for each pump they cannot
guarantee satisfactory operation of the pumps. Hence contractor after internal review
resolved to adopt dedicated suction for each pump and discarded the option of bypass
with flow orifice at the downstream of the pump.
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Flowserve confirmed that based on the approximate piping layout provided by contractor
the items have acceptable Priming time and NPSHA after priming.
This selection proposed by Flowserve is considered technically acceptable by
Contractor but is subject to Company approval.
As per Datasheet SSG-NG01012401-TUNF1-MR-2105-00001, SSG-NG01012401BENF1-MR-2105-00001, SSG-NG01012401-OPUF1- MR-2105-00001 for items TUNF1P-5701 A/B,
BENF1-P-5701A/B,
OPUF1-P-5701A/B respectively, 12% chromium
stainless steel material is specified for impeller. Flowserve provides an upgrade on
impeller material (Duplex Stainless Steel).
3.3.8.2.6. INSPECTION AND TESTS
Regarding main components, inspection and tests shall be carried out based on issued
inspection datasheet SSG-NG01012401-GEN-MR-7880-00037 Rev.D01 and relevant
codes/DEPs. Vendor provided some minor comments to this document which is shown
in attachment 5:
3.3.8.2.7. PAINTING
External surfaces preparation and painting shall be in accordance with specification
SSG-NG01012401-GEN-MP-7880-00017.
Contractor has informed Vendor that painting procedure shall be in accordance to
environment condition C5-M and shall be quoted as base case.
3.3.8.2.8. ADDITIONAL REQUIREMENTS
Vendor provided their compliance to scope of supply listed in supply specification (by
providing back “Scope of Supply” form duly flagged), with comments/deviations which
have been discussed and agreed during technical evaluation stage.
Clarification forms and deviations to codes, project specs. and international codes are
attached to this technical bid evaluation.
3.3.8.2.9. SUB VENDOR LIST
Standard Manufacturer Sub Vendors have been analysed and deemed accepted by
Contractor (Refer to ATTACHMENT 8). Final acceptance shall be communicated by
Company.
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3.3.8.3.
VENDORS
3.3.8.3.1. BIDDER LIST
Below is the vendor that provided a bid for this tender:
Bidder
Country
Flowserve
UK
“Flowserve” is a well known pump manufacturer.(Refer to ATTACHMENT 9-“Reference
List”)
3.3.8.3.2. .HIGHLIGHTS ON DEVIATIONS/ALTERNATIVES
“Flowserve” is considered technically acceptable by Contractor.
Deviations proposed by vendor have been discussed and accepted by Contractor.
For further details, reference to be done to ATTACHMENTS.
3.3.8.4.
ATTACHMENTS
ATTACHMENT 1 – Technical tabulation BENF1-P-5701 AB
ATTACHMENT 2 – Technical tabulation OPUF1-P-5701 AB
ATTACHMENT 3 – Technical tabulation TUNF1-P-5701 AB
ATTACHMENT 4 – Commented SDRL by Flowserve
ATTACHMENT 5 – Clarification form Flowserve
ATTACHMENT 6 – Scope of Supply form Flowserve
ATTACHMENT 7 – Deviation List by Flowserve
ATTACHMENT 8 – Sub-Vendor List
ATTACHMENT 9. – Reference List
3.3.9.Problems encountered
The vendor offered a pump with NPSH margin below project requirement which is 1m.
NPSH Margin is the difference between NPSHA and NPSHR. For this item Flowserve
pumps is a sole vendor not because it was single sourced but they are the only bidder
that submitted a proposal.
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3.3.10.
Solution proffered
At first I suggested to the vendor to reduce the rotational speed from 2900rpm for 2-pole
motor to 1450rpm for 4-pole motor in other to decrease the NPSHR and hence improve
on the NPSH margin.
S=
nq 0,5
NPSHR 0.75
Equation 3.1
From Equation 3.1 above for a constant suction specific speed to improve on the NPSH
margin decrease the rotational speed to decrease the NPSHR. However the Vendor
pointed out that If they offer an alternative 4 pole selections for the 3 applications the
NPSHR reduces to 1.0m but the pumps are operating at approx. 47% of BEP (does not
comply with 80-110% BEP requirement). In addition the impeller is close to minimum
diameter which increases the priming time considerably. The solution finally adopted was
to modify the existing suction system and moved the pump as closely as possible to the
oil savers pit. This increased the NPSH margin above 1.0.
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4. ATTACHMENTS
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4.1. ATTACHMENT A: Shop Fabrication Drawing with BEME
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4.2. ATTACHMENT B: LACT Unit Line Size Verification
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4.3. ATTACHMENT C: P & ID for Crude oil Export Pump
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4.4. ATTACHMENT 1 – Technical tabulation BENF1-P-5701 AB
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4.5. ATTACHMENT 2 – Technical tabulation OPUF1-P-5701 AB
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4.6. ATTACHMENT 3 – Technical tabulation TUNF1-P-5701 AB
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4.7. ATTACHMENT 4 – Commented SDRL by Flowserve
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4.8. ATTACHMENT 5 – Clarification form Flowserve
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4.9. ATTACHMENT 6 – Scope of Supply form Flowserve
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4.10. ATTACHMENT 7 – Deviation List by Flowserve
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4.11. ATTACHMENT 8 – Sub-Vendor List
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4.12. ATTACHMENT 9. – Reference List
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5. REFERNCE
1. DEP 31290211 Pumps - Selection, testing and installation
2. DEP 31290230 Centrifugal pumps (amendments-supplements to ISO
13709)
3. DEP 31.38.01.11 “Piping - General Requirements
4. API 610 Centrifugal Pumps for Petroleum. Petrochemical and Natural
Gas Industries
5. Cranfield University Pump lecture note
6. CCFOD contract Document
7. Ingersoll-Dresser Pumps
8. Users Instructions Durco Mark3 Sealed Metallic Pump
9. The Piping Guide for the design and drafting of industrial piping
systems by David R Sherwood et al
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