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Specification For WHCP GPF Osf 9500 Spe Cs 5003 2 0001
Specification For WHCP GPF Osf 9500 Spe Cs 5003 2 0001
Specification For WHCP GPF Osf 9500 Spe Cs 5003 2 0001
DOCUMENT CLASS
2
REJECTED TO BE RESUBMITTED
A
FOR REVIEW
APPROVED/ACCEPTED WITH
B COMMENTS
APPROVED
C
RE-ISSUED AT STATUS C
STATUS CODE : A = Issued for COMPANY Review - B = Issued for COMPANY Approval - C = Approved
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DESCRIPTION OF CHANGES
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CONTENTS
Description Page No
Front Page 1
Tabulation of Revised Pages 2
Description of Changes 3
Table of Contents 4
1.0 SCOPE 5
2.0 TERMS AND ABBREVIATIONS 6
3.0 STANDARDS AND CODES 7
4.0 REFERENCES 8
4.1 PROJECT SPECIFICATION 8
4.2 PROJECT DRAWINGS 8
4.3 BP GUIDELINES 8
5.0 ENVIRONMENTAL CONDITION 9
6.0 AREA CLASSIFICATION 10
7.0 GENERAL 11
8.0 PANEL ENCLOSURE 14
9.0 PANEL INSTRUMENTATION 15
9.1 PANEL DESIGN CRITERIA INTERFACE WITH HYDRAULIC SYSTEM 15
9.2 WHCP ESD SEQUENCE ADDED 16
9.3 WHCP "OFFLINE BYPASS" FEATURE 16
9.4 WHCP "OUT-OF-SEQUENCE" FEATURE 16
10.0 TUBING INSTALLATION 17
11.0 NAMEPLATE AND TAGGING 18
12.0 CLEANLINESS 19
13.0 INSPECTION AND TESTING 20
14.0 FACTORY ACCEPTANCE TEST (FAT) 21
15.0 SITE ACCEPTANCE TEST 22
16.0 PREPARATION FOR SHIPMENT 23
17.0 DOCUMENTATION REQUIREMENT 24
18.0 ATTACHMENT 25
18.1 Attachment-1 : WHCP Schematic Diagram (Control Module Drawer Typical) 25
18.2 Attachment-2 : WHCP Schematic Diagram (Common Module Bypass
Drawer Typical) 26
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18.3 Attachment-3 : Typical WHCP Layout 27
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1.0 SCOPE
WHCP unit shall be combined with HPU, see 9500-SPE-CS-5004 on the same Panel/Skid.
This specification together with approved data sheets and drawings, covers the minimum
requirements for design, fabrication, testing and delivery of Wellhead Control Panels and
Hydraulic Valve Control Panels for the COMPANY for installation on the Vorwata A (VR-A) and
Vorwata B (VR-B) platforms to be located in Berau Bay, Papua - Indonesia.
The selection of all accessories and materials, method of fabrication, and production of detail
drawings shall be the responsibility of the CONTRACTOR / PANEL FABRICATOR and shall be
carried out in accordance with good engineering practices and subject to COMPANY approval.
No deviation from this specification or referenced data sheet or drawing will be permitted without
written COMPANY approval.
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All work performed inside this panel shall comply with applicable sections of the latest edition of
the following standards and codes:
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4.0 REFERENCES
4.3 BP GUIDELINES
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The equipment furnished shall be suitable for the following environmental conditions:
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Wellhead Control Panels will be located at the Mezzanine Deck. Hydraulic control panels are
located in a classified area. All electrical and instrument components of control panels shall be
certified for use in an IEC 60079 Class 1, Zone 1, Gas Group IIA, Temp. class T3 minimum area
classification with IP 65 minimum.
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7.0 GENERAL
The following is a list of panel (2100-V-1001A1002A) and associated valves for VR-A (typical for
6 flowlines & 2 spare flowlines) :
The following is a list of panels and associated valves for VR-B typical for 6 flowlines installed
and 2 flowlines spare to be associated by 2200-V-1001A 1002A and typical for 3 flowlines
installed and 5 flowlines spare to be associated by 2200-V-1001B 1002B :
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2205-XV-1005 SCSSV Wellhead #5
2205-XV-1008 SMV Wellhead #5
2205-XV-1009 SWV Wellhead #5
The panels shall be completely factory assembled with all instruments mounted, all tubing installed
to bulkhead points, all wiring installed to terminal blocks, tested and ready for field installation by
others.
All material furnished shall be new, unused and free from all defects.
Panel design shall be developed based on hydraulic and electric/electronic control systems only.
All hydraulic bulkhead connections shall be on top of panel with a stainless steel bulkhead crossing
fitting. Bulkhead shall be tagged inside/outside panel.
The general principle to be implemented for shutdown shall be fail-safe, i.e., de-energize / de-
pressurize/contacts open to trip. Actuated valves will be spring action to close.
• Remote signal (manual close) from SIS to Master and Wing Valves and indication
open/close status to SIS of SCSSV, Master and Wing Valves,
• Remote pressure signal for control indication of SCSSV, Master and Wing Valves to SIS,
• Medium Pressure hydraulic supply and return for Master and Wing Valves,
• High Pressure hydraulic supply and return for Surface Controlled Subsurface Safety Valves
(SCSSV),
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• Common Module Bypass
Local common module bypass facility shall be provided for any well control module which
is removed for service maintenance.
• Automatic Shutdown (ESD, WSD & TWSD) of each Master and Wing Valve on loss of
individual control signal.
• All cabling should be Flame Retardant, detail see cable specification (9500-SPE-CS-5009).
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Panel shall be free standing, two a front face, a top face, a bottom face. Panel enclosure shall be
IP66 minimum, 3 mm thickness 316 stainless steel plate from prime stock, free of tool and clamp
marks, brushed finished.
Panel shall have sufficient internal braces and supports to prevent bulging or bulking from
excessive overhang and/or equipment weight and sufficient to withstand handling during
transportation.
All braces and supports shall be fabricated from 316 stainless steel.
316 stainless steel lifting padeyes shall be provided on the top of panel enclosure for handling
operations fixed on the panel frame to avoid distortion when lifting.
Panel shall have removable full length opening doors on the rear side with heavy duty 316 SS
hinges and lock. If center posts are required, they shall be removable for unobstructed access to
Panel internals.
All hardware such as bolts, nuts, screws, etc shall be 316 stainless steel.
• Number of Wellheads
• Valves
• Control Local/Remote
• Shutdown Level
• Stroke volume
• Closing Time
• Sequence Time
• Back face including fully gasketted locking access doors to the inside
• Canopy of 40cm above the instruments to facilitate the reading in day light and to provide
protection against rain in any direction
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All indicators, relay valves and block valves shall be 316 stainless steel.
All Medium Pressure hydraulic equipment shall be suitable for use with minimum design pressure
of 340 bar g at 40ºC.
All High Pressure hydraulic equipment shall be suitable for use with minimum design pressure of
690 bar g at 40ºC.
PANEL MANUFACTURER shall ensure that seal material of all manual valves, solenoid valves,
regulators, etc. shall be compatible with the characteristics of the specified hydraulic fluid. This
will be castrol Transqua HT a water-based fluid. .
The well head control panel shall contain all parts necessary for proper and safe operation,
installed, pretubed and prewired including the following:
• Hydraulic system shall be via hydraulic pilot valves and hydraulic solenoid valves with single
acting spring return. The hydraulic pilot and solenoid valves shall be compatible with hydraulic
fluid.
• Hydraulic push button shall be mounted on the front face of modules : push to shutdown, pull
to reset of pilot valve for each SCSSV, Master & Wing valves.
• Hydraulic logic of sequence for interlock between SCSSV, Master & Wing valves.
The system design, the system layout and panel design shall be approved by the COMPANY prior
to fabrication. WHCP Schematic Diagram (Control Module Drawer Typical & Common Module
Bypass) and detail layout of panel see attachment.
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The valve operating sequence shall be arranged via the WHCP interlock such that the wellhead
valves close in the following order when ESD occurs :
then
Master valve
then
- SCSSV first
then
Master valve
then
Wing valve
Timers shall be provided on the to logic provide delay between valve operations.
The delay will be adjustable 0 ~ 60 seconds for SCSSV and 0~30 seconds for Maser Valve at the
WHCP by operations personnel. Position of timing device to be located as to allow easy access.
The closing time for full shutdown for SCSSV shall be 20 seconds.
The closing time for full shutdown for Master and Wing valves shall not be more than 10 seconds
as per API RP 14C
The offline bypass system provide alternative power via three (3) headers and front mounted local
3/2 selector valves and allows the well module to be shutdown, isolated and removed without loss
of well production.
The out of sequence shall be initiated by local front mounted selector, allows random opening or
closing of the wellhead safety valves from inside the normal well control modules.
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Tubing installation shall be neat, plumb, parallel, rigidly supported and exhibit professional
workmanship.
Tubing shall be routed so as to allow easy accessibility to panel mounted instruments for routine
maintenance with minimum tubing removal.
All tubing shall be seamless 316L stainless steel, ASTM-A-269/213 316/316L (for high
temperature service such as tubing to downhole valve).
All tubing fittings shall use 316 stainless steel, and shall be SWAGELOK double ferrule type. The
supplier to ensure that fittings are suitable for the temperature conditions when the HP circuits trips
(the return fluid to reach 131 deg.c)
Tubing wall thickness shall be sized to be suitable for the operating pressure. Refer to 9500-SPE-
CS-5004 “Hydraulic Power Unit Specification“.All bulkhead are tube O.D connections and shall
be provided with female bulkhead fittings.
Block valves on bulkhead lines to and from well control modules shall be located as close to the
module to panel connection points as possible.
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Nameplates shall be phenolic, laminated and engraved type. Text and character size and color shall
be accordance with the referenced drawings.
1. 2100-V-1001A1002A VR-A
3. 2200-V-1001A1002A VR-B
4. 2200-V-1001B1002B VR-B
Nameplate shall be fastened to the panel with 18-8 stainless steel screws.
All bulkhead connectors shall have nameplates both inside and outside panel enclosure.
All instruments shall be provided with a permanently attached nameplate with tag numbers as
shown in the reference drawings.
A plastic coated stainless steel plate showing panel control schematic etched on the plate shall be
provided by the SUPPLIER. This plate shall be attached to the internal face of the enclosure door.
SUPPLIER name, serial number and purchase order number shall be indicated on panel enclosure
and well control module. This SUPPLIER nameplate shall be permanently attached to inside of the
panel enclosure.
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12.0 CLEANLINESS
For reference hydraulic fluid shall be “Castrol Transaqua” HT , it will be water base fluid and
environmentally benign.
All WHCP components receiving hydraulic fluid shall be suitably flushed in order to obtain a final
ex works particle pollution ≤ level 17/15/12 as stated in ISO 4406 “Hydraulic fluid power –
Method for encoding level of contamination by solid particles”, and class 6 as stated in NAS 1638
“Cleanliness Requirements of Parts used in Hydraulic System”.
Procedure for determination of particle contamination shall conform with ARP 598-&-598A
(Aerospace Recommended Practice) “Procedure of the determination of particle count method”.
After cleaning operation of WHCP at the SUPPLIER premises, the tubing at the bulkhead side
shall be suitably plugged to avoid any contamination before being connected on site.
Cleaning and checking operations WHCP shall be included in the SUPPLIER scope of work, and
be performed by a specialised Subcontractor.
Hydraulic fluid necessary for cleaning operation shall be part of the SUPPLIER scope of supply.
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The responsibility for inspection and testing rests with the CONTRACTOR. However, the
COMPANY reserves the right to inspect equipment at any time during fabrication to assure the
materials and workmanship are in accordance with this specification, referenced data sheets and
drawings.
Supplier shall provide FAT procedure for CONTRACTOR/COMPANY approval prior to
submitting for FAT.
The CONTRACTOR shall notify COMPANY or its authorized representative of its intention of
carrying out factory tests at least two (2) weeks prior to commencement of such tests in order that
the COMPANY may witness the test.
The CONTRACTOR/SUPPLIER shall supply the services of a competent technician who shall be
responsible for carrying out shop performance tests to the satisfaction of the COMPANY or its
authorized representative.
The SUPPLIER shall provide all necessary test certificates to be signed by CONTRACTOR during
the Factory Acceptance Tests. These certificates shall be part of the “Functional test procedure”
The CONTRACTOR shall submit test and commissioning data to the COMPANY or its authorized
representative within two (2) weeks of the completion of the above tests.
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14.0 FACTORY ACCEPTANCE TEST (FAT)
Before the system is delivered to the site, satisfactory performance of the entire system shall be
demonstrated to the project’s designated representative. The system shall simulate the final onsite
configuration as closely as possible.
The following test are recommended. They shall be developed in detail during preparation test
procedures. The vendor shall have technician and test equipment available full time during testing
• Inspection of equipment
• Functional test, including operator control panel functions and failures and interaction between
different part of the system
• Grounding test
Vendor shall follow the FAT procedure in accordance with document no. 9000-DBS-MM-0001,
“Source and Factory Inspection Basis of Design”.
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Site acceptance will involve two stages; checkout in the fabrication yard prior to load out and in-
situ at the Job Site
The SUPPLIER shall provide qualified engineering assistance in the fabrication yard to assure that
the equipment has been received and installed without damage, and that it is ready for
commissioning.
The SUPPLIER shall then perform site acceptance tests (SAT) to prove satisfactory system
performance at Job Site. SUPPLIER shall commission the WHCP and demonstrate the
performance of the system to the satisfaction of the COMPANY. All deficiencies, errors, action
items, etc. shall be corrected and or completed prior to final acceptance of the system.
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SUPPLIER shall prepare the Panel for export shipment. Panel shall be crated in a manner to
provide maximum protection during shipment and storage.
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Operating and Maintenance Manual shall be written specifically for the particular system.
Installation manual section shall contain all information necessary for site preparation, powering,
grounding, installation procedure, commissioning, start up, etc. All auxiliary equipment supplied
shall be provided with manufacturer’s installation, operating and maintenance manual specific to
the equipment.
Operating manual shall completely describe the theory, configuration and overall operation of
WHCP.
Maintenance manual shall contain all necessary information to maintain WHCP. The manual shall
have instructions for trouble shooting, routine maintenance, preventive maintenance, assembly and
disassembly, etc.
The SUPPLIER shall be responsible for producing an ‘as-built’ set of documents reflecting all
modifications made during testing and commissioning. Operation and maintenance manuals shall
be provided in editable format to aid preparation of the COMPANY documentation.
Refer to Appendix-1 of Requisition for WHCP (9500-REQ-CS-5020).
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18.0 ATTACHMENT
18.1 ATTACHMENT
-1 : WHCP SCHEMATIC DIAGRAM
( CONTROL MODULE DRAWER TYPICAL
)
H
L
HYDRAULIC SUPPLY
FROM HPU HP LP HEADER
5 bar g
HYDRAULIC SUPPLY
FROM HPU HP HEADER
590 bar g
H
L
H
L
311 bar g
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18.2 ATTACHMENT-2 : WHCP SCHEMATIC DIAGRAM (CONTROL MODULE BYPASS DRAWER TYPICAL)
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