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THESIS
FOR HØGSKOLEN I OSLO (Oslo University College)
DEPARTMENT OF ENGINEERING
Spring 2013
Piping Arrangement, Steel Construction, Instrumentation, Process- & Mechanical
design.
Ekofisk
Ekofisk was Norway's first producing field and is also one of the largest on the Norwegian
continental shelf. Production started in 1971. With the projects now under development, the
lifetime of the field is prepared for production towards 2050.
THE EKOFISK COMPLEX
The Ekofisk Complex comprises all installations which are connected with bridges on the central
Ekofisk field. As of 2011, this includes seven platforms plus bridge supports. In 2013/2014, a
new accommodation and field center platform, Ekofisk 2/4 L, is planned to start operation at the
Ekofisk Complex. In addition, a new wellhead platform, Ekofisk 2/4 Z, and a new seabed unit
for water injection (Ekofisk 2/4 VB) are planned.
Since the development started early in the 1970s, the Complex has been a field centre and hub
for the production from the Ekofisk field itself, and from the other fields in the Greater Ekofisk
Area. In addition, production from other fields in the area has been - and is - transported via the
Ekofisk Complex to the receiving terminals in Emden, Germany (gas) and Teesside, UK (oil).
The Ekofisk Complex was developed in stages, and has been upgraded and modernised several
times. The Ekofisk Complex was given a major boost from 1998, when the ’new’ Ekofisk
facility came on stream. This was a huge transition with new and modern platforms, at the same
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time as unprofitable fields were closed down and several old platforms were taken out of
service.
Greater Ekofisk Area
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This year’s thesis will be based on the Ekofisk 2/4 Z platform located in the Greater
Ekofisk Area.:
2/4 Z
Ekofisk Complex Lay-out included the new coming platforms
Modifications to existing platforms
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Ekofisk 2/4Z Wellhead Platform – Topside and Bridge
Approx. 75 m long, 43 m wide and 30 m high
Approx. 8 500 Tonnes Topside weight
36 wellhead slots (Drilling from Jack-up)
Well intervention deck arrangement to facilitate for simultaneous drilling, well
intervention and production
Test separator
Emergency power generator
Normal power from Complex
Production lines tied in to platform 2/4J via 2/4M
Gas lift supply from Complex
Platform control from Complex
Central Control Room at Ekofisk 2/4J
Equipment rooms, administration area and work shops
(LQ elsewhere)
Future tie-back functionality, including structural capacity and space
Main Task for students:
Module 20m x 9m
2 levels with 6,5 meters deck height (from lower deck ”top of steel” to highest point ”top of
steel”).
The module will include a test separator with multiphase test meters, liquid holding tanks
with pumps and filters as well as other equipment.
Students to arrange and place equipment on each level.
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The following tasks shall be solved:
1. Multidiscipline coordination and planning:
The assignments described in Chapters 1-6 are of a multidisciplinary character where each task
is depending on the others to be solved. It is therefore important for the students to identify
dependencies between the different assignments and to find their connection. We will focus on
teamwork and planning so that the students find what will be the right activity at the right time
and what is important to start with.
Students will be asked to define Milestones, attaching descriptions, at important stages in their
work to make sure the project can be executed within the given time frame. The number of
Milestones will be decided between the students, in collaboration with the supervisors. At each
Milestone the students (each group) will present the project status at Aker Hus. The students
should be aware that the final evaluations will be based on the finished project thesis and that the
Milestone reviews are only meant to support the students and to verify that they are on the right
track.
The Thesis will be based on:
• Process engineering diagram
• Process simulation data
• P&ID's (except system 21 to be produced by Process group).
• Data sheets for pipes
• Standards and codes (Norsok etc.)
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2.
Piping & Layout
Piping arrangement
A piping arrangement between different mechanical equipment (i.e. pumps, vessels/separators,
coolers etc.) shall be designed. The piping arrangement shall be based on information given on
Process- and Instrument diagrams, P&ID’s. Equipment shall be located within the defined
module.
Maintenance, access and COG (Centre of Gravity) for the module shall be considered. The
piping arrangement shall be developed in accordance with project requirements, specifications
and process P&ID’s.
Maintenance and access to valves, instrumentation and total pipe system area utilization shall be
considered together with locations of required pipe supports for pipe stress calculations.
The piping arrangement shall be presented on drawings and shall give a good picture of the
arrangement including all pipe lengths and elevations. Lines including 4” and above shall be
included in design.
Stress analysis
It shall be documented that the piping system is in line with requirements given in ASME B31.3.
Stress isometric drawings with required information for stress analysis of the piping system shall
be provided.
The following shall be evaluated for the piping systems:
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Temperature
Weight
Pressure
Explosion
Earth quake
Support loads, spring sizes and largest tensions shall be reported on the stress isometrics if
selected.
Loads and moments on equipment nozzles shall be controlled with respect to allowable nozzle
loads given on equipment drawing and in accordance with Norsok R-001.
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3. Structural
The module shall be designed and dimensioned according to the structural design brief.
In order to dimension the module a structural analysis is required. The module shall be
dimensioned with regards to the ultimate and serviceability limit states according to current
standards and regulations (Norsok, Eurocode). Loads from equipment and piping shall be
estimated/calculated and be implemented in the analysis. General deck live loads are defined in
Norsok.
Selection of flexible and fabrication friendly solutions is important when designing the module.
Solutions for a safe and efficient material handling during maintenance and repair of valves and
equipment shall be assessed.
Evaluations of different structural arrangement concepts shall be documented. The final structure
shall be shown on an arrangement drawing and the results from the structural analysis shall be
documented and discussed.
The structural design brief and figures showing overall module size and support points are
attached.
4. Process Design
Process design
The task for the Process discipline is design of a system comprising a Test Separator and two
multiphase test meters, including headers and piping. The purpose with the Test Separator is to
test production performance from one well at the time and to measure gas/oil ratio and water cut.
The Test Separator inlet is connected to the Test Header North and Test Header South to allow
for any of the production wells from each header to be connected to the Test Separator for
testing.
In addition each test header is connected to a multiphase test meter. One multiphase test meter is
dedicated to each header. No crossover line is included. Production via both multiphase test
meters can either be routed to the Test Separator, HP (high pressure) production line or LP (low
pressure) production line. Well stream from both test headers can bypass the multiphase test
meters when fed to the Test Separator.
The Test Separator is a three phase separator and shall be able to operate in both low pressure
and high pressure mode. In both modes the Test Separator outlets are routed to the LP production
line. Each outlet from the Test Separator is provided with flow meters and control valves for
level control (liquid outlets) and pressure control (gas outlet).
Well production design data and sizing criteria for the Test Separator will be provided by Aker
Solutions.
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Main challenges for design of the Test Separator and multiphase test meter system:
• Design of piping and required bypass arrangements to facilitate the different production
scenarios.
• Pressure protection of the Test Separator
• Blow down arrangement
• Control system.
• Isolation valve arrangement
The group work shall include the following:
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Determine size and weight of the Test Separator and multiphase flow meters.
Size relief lines and valves (Required relief capacity will be provided)
Blow down calculation (HYSYS)
Size the pipes based on process requirements, requirements in relevant codes and standards,
(A tool for pressure drop calculations will be available.)
Process datasheet for Test Separator and all instruments required on the Test Separator
Process datasheet for the multiphase test meters.
Process datasheet for control valves
Process datasheet for flow meters.
Include control system on P&ID.
Make P&IDs
Ensure that the system design is in compliance with requirements in NORSOK P-001,
NORSOK P-100 and ISO 10418
5. Mechanical Design
The task for the mechanical group will be to:
1. Design and select a High Pressure (HP) pump which will serve the required operating
conditions along with the controls for its proper operation.
2. Size a suction strainer for protection of the HP pump.
3. Size the test separator based on holding time and available process data.
The HP Injection Pump shall be suitable for injection of hydrocarbons and hot fluids from 4
degC and up to 80 degC with a working pressure of 340 barg. The design flow is 95 m3/h.
The suction strainer shall be sized using the process data available. The shell thickness shall be
calculated using simplified calculations based on EN13345.
A GA drawing shall be produced for the strainer, showing CoG and nozzles positions. In
addition the strainer hole size and material quality shall be suggested.
Allowable nozzle loads according to NORSOK R-001 shall be calculated and presented on the
GA drawing.
The Test separator shall be sized using the process data available. The shell thickness shall be
calculated using simplified calculations based on EN13345. The dry and operating weight of the
separator shall be calculated along with the dry CoG.
A GA drawing shall be produced for the separator, showing CoG and nozzles positions.
Allowable nozzle loads according to NORSOK R-001 shall be calculated and presented on the
GA drawing.
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The task will include the following activities:
• Based on the pump process datasheet evaluate different type of pumps and select the best
suited type for the task
• Evaluate the need for a booster pump.
• Evaluate type of configuration to use (2X 50%, 2X100% or 1X100%) based on operation
criticality, cost of equipment and maintenance cost.
• Decide pump control based on the type of pump and required functionality.
• Collect weight, dimensions and interface information to be used by layout for the pump.
• Ensure that the pump requirement related to pipe arrangement is incorporated by layout
discipline
• Ensure that the pumps requirement for maintenance and handling is incorporated in the
layout.
6. Technical Safety
An offshore installation must consist of both passive and active safety barriers. This thesis will
consider two such barriers, one passive and one active. The safety barriers are put in place to
reduce the risk for accidents that will affect personnel, the environment, and/or assets. This part
of the thesis consists of the following subtasks:
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The installation shall be reviewed with regard to area classification. NORSOK S-001,
IP15, and ISO10418 can be of assistance here. Hence, the end result shall be an area
classification sketch of the module . The sketch shall further act as basis for an evaluation
of the need to implement any fire and explosion sized barriers in the areas. Thus, type of
wall, roof etc. shall be defined and included in the respective plot plan.
An active fire fighting system shall be sized with regards to the necessary firewater
demand. This includes the following subtasks:
o Total firewater demand, based on area and equipment, per area shall be estimated
o Dimensioning firewater demand shall be established
o Firewater pump configuration shall be selected and explained. Pump capacity
with regards to quantity and pressure shall be determined (routing of piping not
part of scope)
7. Instrumentation
The process, piping arrangement and equipment as described in the previous chapters shall be
instrumented. The thesis will be to design an instrumentation system based on basis
documentation delivered at start of the thesis and to design on a general basis a metering system
suitable for measurement of the gas and liquid outlets of the test separator. Although the outlet
measurements from the test separator are not normally regarded as fiscal metering, the
requirements for fiscal measurement of gas and oil shall be evaluated and the relevant
requirements shall be covered by the measurement system design.
The thesis shall include a proposal for how the multiphase meter measurements can be verified
using the test separator measurements.
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The final paper shall describe the complete system, giving an overview over the thesis and how it
was solved, about technical solutions and equipment to be used. The paper shall include which
possible solutions are evaluated and argument for the selections been made.
Particularly different communication and instrumentation solutions shall be evaluated and
discussed.
Topics to be discussed but not limited to:
• Communication between the instrument items
• Hardwiring
• Equipment for Ex-protection
• Integrated Operations (IO)
• Measurement and detection principles including multiphase meters
• Instrument datasheets for some of the chosen instruments and valves
In addition to the system description the following shall be included in the paper:
• Instrument system topology / Block diagram
• Instrument index
• System Control Diagram (SCD)
• Instrument datasheets for some of the chosen instruments and valves
• Metering Block diagram
NORSOK I-001, Field Instrumentation, NORSOK -104 Fiscal Measurement System for
hydrocarbon Gas, NORSOK -105 Fiscal Measurement System for hydrocarbon Liquid and other
relevant standards will the basis for the thesis.
It is important that the thesis is solved in coordination with the other disciplines represented in
the thesis. The final solution shall be incorporated with the other disciplines.
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8. Attachments:
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List of groups and Supervisors
Other attachments (if needed) will be given to you by your Supervisor or be put on the HiO
Intranet page.
Mechanical:
• API 610 (Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries)
• API 674 (Positive Displacement Pumps – Reciprocating)
• API 676 (Positive Displacement Pumps – Rotary)
• API 682 (Pumps Shaft Sealing Systems for Centrifugal and Rotary Pumps)
• API 685 (Seal-less Centrifugal Pumps for Petroleum, Heavy Duty Chemical, and Gas Industry
Services)
Piping:
• Master Equipment List
Structural:
• Structural design brief
Process:
• P & ID’s (except P&IDs of multiphase meters and Test Separator)
Safety:
• IP15-rev03
• ISO 10418
• ISO 13702
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