SOW Vol II Part II Engg Package - Marked Up

OIL & NATURAL GAS CORPORATION LTD.
URAN
VOL-II, Part-II
ENGINEERING PACKAGE
FOR
TENEDR No:
BID DOCUMENT
OF
ISBL PIPING SYSTEM & NETWORK

AT ONGC, URAN
FOR & ON BEHALF OF

OIL & NATURAL GAS CORPORATION LTD.
URAN
0 28-Aug-18 Comments Incorporated & Approved for Bid Package
0B 29-Jul-17 Approved for Bid Package PHT AVS REU
0A 30-Jun-17 Draft for Review PHT AVS REU
Rev. Date Description Prep. By Chk. By App. By
PREPARED BY
Process System Engineers (I) Pvt. Ltd.
Doc No: 5602-PE-ST-00-203-00 Rev No: 0 Page 1 of 59
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CONFIDENTIAL : The information contained herein is confidential property of Process System Engineers (India) Pvt. Ltd. & is not for publication. No
part of this document shall be copied or communicated to a third party unless authorized in writing from PSE.
Doc No: 5602-PE-ST-00-203-00; Rev No: 0 Customer: Oil and Natural Gas Corporation Ltd.
Project: ISBL Piping System & Network Plant Location: Uran, Maharashtra
TABLE OF CONTENT
Section No SN Title Page No.
I Introduction 3 of 59
1 Background
2 Objectives
3 Project Description
4 Abbreviation
II Basic Engineering Package 5 of 59
1 Facilities at Uran Terminal

2 Basis For Engineering Package
3 Project Description
4 Condensate Fractionation Unit (CFU) - II
5 CFU-I, GSU-12 & 13 (UNIT 19)
6 CFU-I and GSU - 12 & 13
7 Ethane Propane Recovery Unit (EPRU)
8 LPG recovery unit (LPG) - I
9 LPG recovery unit (LPG) - II
10 AGHAS - Liquid Handling System
11 Basic engineering documents
III Way Forward, Time & schedule 53 of 59
1 Way Forward
2 Time & Schedule
ANNEXURE:
A Basic Engineering Documents B Piping Drawings

A1 Line List B1 Piping Isometrics
A2 P & I Diagrams (Indicating lines to be replaced) B2 BOQ - Valves, Pipe, pipe-fittings
B3 Piping GAD - LPG-I & II CW Network
C Project Schedule
C1 ISBL Project Schedule
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Sec I : INTRODUCTION
1 BACKGROUND
Oil and Natural Gas Corporation Ltd is a public sector petroleum company involved in wide scale
exploitation of oil as well as natural gas from the Indian mainland as well as from Arabian Sea
and Indian Ocean. ONGC is one among the most profit making Indian Government’s
Navarathna Companies operating in India
Oil and Natural Gas Corporation Limited (ONGC) Uran, is located geographically at 18.50 N
Latitude and 72.55 E longitude, near shore line of Arabian Sea and approx. 55 KM from Mumbai,
Maharashtra. The complex is having units like Crude Stabilization Unit (CSU), Condensate
Fractionation Unit, Gas Sweetening Unit (GSU), and C2/C3 Plants etc.
Oil and Natural Gas Corporation Ltd appointed Process System Engineers (India) Pvt. Ltd. for
preparing a Study Report for Piping Systems & Network in order to enable ONGC to replace
existing piping which has lived its life. Accordingly PSE has carried out Site Survey for
performing the Study and the report is presented as in this document.
2 OBJECTIVES
ONGC's onshore gas & oil processing facilities at URAN Terminal has been in operation for
more than 35 years. The facility has already exhausted its design life. In view to extend its
design life further it has been identified by ONGC that certain critical lines shall be replaced.
A study on piping replacement was carried out and established that the subsequent execution
work can be awarded as an EPC contract. The objectives behind Engineering Package are as
under:
1 Based on the study of existing piping system & network, establish a feasible solution for
replacement of piping system and network.
3 Ensure that the selected option of pipe replacement shall be constructible.
4 Estimate cost of the replacement of piping system and network.
5 Establish requirement of shutdown and that the shutdown shall be feasible for the
associated system for line replacement. The shutdown if needed shall be for as minimum
duration as possible.
6 It may be noted here that, it is not intended here to carry out a detailed engineering for
replacement of piping system & network; however, a limited engineering has been carried
out for establishing feasibility & constructability of the replacement solution along with cost
estimation of the same.
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Sec I : INTRODUCTION
3 PROJECT DESCRIPTION
The scope of this tender is to replace the existing corroded piping / piping which has been
identified in the Engineering Package at Uran Complex with new piping having same material
specification as in the existing Piping as per scope of work.
The detailed scope of work under this tender is covered in the subsequent sections of the Bid
Document.
4 ABBREVIATION:
1 B/L : Battery Limit

2 BOQ : Bill of Quantity
3 C2 : Ethane
4 C3 : Propane
5 CFU : Condensate Fractionation Unit
6 D/S : Downstream
7 EPRU : C2-C3 Recovery Unit
8 GAIL : Gas Authority of India Limited
9 GSU : Gas Sweetening Unit
10 HDR : Header
11 I/S : Isolation
12 ISBL : Inside Battery Limits
13 KOD : Knock Out Drum
14 LPG : Liquefied Petroleum Gas
15 LSTK : Lump-Sum Turn Key.
16 MMSCFD : Million Standard Cubic Feet per Day
17 MMSCMD : Million Standard Cubic Meter per Day
18 MMTPA : Million Metric Tonnes per Annum
19 MMTPD : Million Metric Tonnes per Day
20 MTO : Material Take-Off
21 NA : Not Applicable
22 ONGC / Company : Oil and Natural Gas Corporation Limited
23 OSBL : Outside Battery limits
24 OTO : One-To-One
25 SRU : Sulphur Recovery Unit.
26 TPI : Third Party Inspection
27 U/S : Upstream
28 WP : Work packet
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Sec II : BASIC ENGINEERING PACKAGE
1 FACILITIES AT URAN TERMINAL
Facilities at Uran Terminal can broadly be classified in to four distinct areas as under:
1 Process Plant
2 Utilities & Offsite
1 PROCESS PLANT
ONGC Uran plant primarily produces LPG and other value added products and pumps the
stabilized oil to different refineries. Oil & gas received at Uran terminal is processed in following
listed Plants:
a Slug catcher unit

b Condensate fractionation unit
c Gas sweetening unit
d Crude separation unit
e LPG recovery unit
f Ethane propane recovery unit
2 UTILITIES & OFFSITES
In Uran Terminal, utilities & offsite plays very important role similar to in any other process
industry. They provide support to process plant for the smooth running and continuous
production. The basic utilities & offsite are:
1 Effluent treatment
2 Instrument air
3 Air dryer
4 Flare system
5 Blow down system
6 Soft water system
7 Fuel gas
8 Inert gas system
9 Co-generation plant
a Gas Turbine
b Boilers(
c Gas fired boilers
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3 OVERVIEW OF PROCESS FLOW
Following block flow are provided just for understanding overall operations at Uran Terminal.
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2 BASIS FOR ENGINEERING PACKAGE
1 LINE LIST
For ISBL piping system & network project, the scope of work is indicated by line list. Refer to
line list of individual process plants for ISBL system attached as Annexure- A1 Doc. No: 5602-
PS-LI-00-201-00 Lines to be replaced are also indicated in P&IDs attached as Annexure A2.
ISBL lines are classified based on Process Plants and further based on fluid it handles as under.
The same classification is reflected in line list too.
Process Plants CFU - II CFU - I GSU - EPRU LPG - I LPG - II AGHAS

SN Fluids 12/13
Process Lines (Gas)
1 Sour Gas 9 9
2 Sweet Gas 9 9 9
3 LP Fuel Gas 9 9 9 9
Process Lines (Liquid)
4 Sour Condensate 9 9 9
5 Produced water from slug liq.sump 9
6 Methanol Injection 9 9 9 9
7 LAN Product 9 9 9
8 LPG Product 9 9 9
9 C2C3 Product 9
10 Propane Make-up 9 9
11 Propane Pump out 9
Utility Lines (Vapor)
10 LP Steam 9 9 9 9 9 9
11 MP Steam 9 9 9 9 9
Utility Lines (Liquid)
12 Steam Condensate 9 9 9
13 Service Water 9 9
14 Drinking Water 9 9
15 Cooling Water (Supply & Return) 9 9 9 9 9 9
Utility Lines (Gas)
16 Instrument Air 9 9 9
17 Plant Air 9 9 9
18 Inert Gas 9 9 9 9 9 9
Note:
All the branches within B/L of each Process Plants are included in scope of work. Refer to Annex-
1 (Line List) for further details of lines under scope of contract.
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2 WORK PACKET CONCEPT
Work packet concept has been followed for implementation of the project. The entire work of
ISBL piping & network has been grouped based on individual Process Plants. Piping inside each
Process Plant is further divided into work-packets based on fluids handled. Refer to work packet
definition given subsequently in this section.
3 LINE REPLACEMENT METHODS:
Broadly the replacement line routing can be categorised in to three main types as under:
1 Replace one-to-one
2 Replace with Parallel Route
3 Replace with Alternate Route
The above three methods may be used in combination for achieving line replacement result.
1 Replace one-to-one
One-to-one replacement method adopts demolition of the old line, followed by installation
of new line exactly same as the one demolished.
With choice of one-to-one replacement, the final routing of the replaced line will be
identical with existing. Though, internationally, this method of replacement has been
choice of first preference by all renowned companies, this method may not be always
feasible.
The salient features of this method of replacement important to our project are as given
below:
1 Original piping design get restored with extended life.
2 No additional space required and hence, there is no further congestion in layout.
3 Major work is carried in-situ. Hence a longer local or global shutdown become
essential.
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Work Flow Diagram:

Following work flow diagram provides a typical execution sequence for OTO route method.
All such work packets are tagged as R*, where * depicts a sequence number.
Fig 2.3.1: Typical Work Flow Diagram for one-to-one Method, tagged in P&ID as 'P*'
START
Local S/D if Needed
Isolate Existing Line
Demolish Existing Line
Construct New Line
END
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2 Replace with Parallel Route
Parallel Route replacement method adopts installation of new line parallel to old line,
followed by demolition of old line.
This is next choice of replacement if one-to-one is not a feasible solution.
below:
1 Many a times, enough free space adjacent to existing line to be replaced is not
available.
2 Since, majority of the work can be done ex-situ, less time is required for local or
global shutdown.
3 This method of replacement may enable line replacement without taking local or
global shutdown.
Work Flow Diagram:

Following work flow diagram provides a typical execution sequence for parallel route
method. All such work packets are tagged as P*, where * depicts a sequence number.
Fig 2.3.2: Typical Work Flow Diagram for Parallel Route Method, tagged in P&ID as 'P*'
START
Hot Tap with Hook-up

Lay Parallel Line Local / Unit S/D
Valve
Cold Tap with Hook-up

Valve
Hooking up Parallel Line to Hot Tap & Cold Tap
END
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3 Replace with Alternate Route
The "Alternate Route" option can compete with "parallel route" option. However, this can
be the next choice of replacement option if one-to-one option is not feasible solution.
1 Many a times, enough free space is not available for alternate route.
2 Maintaining piping aesthetic & operational ergonomics is a big challenge.
3 Since, majority of the work can be done ex-situ, less time is required for local or
global shutdown.
4 This method of replacement may enable line replacement without taking local or
global shutdown.
4 Combination Method
For replacing one line, combination of any two of the above methods or all the three
methods may be adopted.
below:
1 Advantages of available space is taken for laying parallel or alternate route, while
one-to-one replacement is restricted to very specific area.
2 This method may turn out to be most optimal solution.
4 GUIDELINES FOR LINE REPLACEMENT METHOD:
In ISBL areas one feature about routing of existing lines is common and that is, most of the lines
to be replaced travels in form of header throughout the length of plant in central pipe rack. To
this header, tapings are taken at locations where needed for distribution of the fluid it handles.
After thorough site survey it has been observed that, in pipe rack uniform empty space is not
available along the length of the rack for laying new parallel headers / lines. Thus, we do not
have any option for line replacement other than One-To-One method.
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PSE carried out study on feasible options for replacement of each of ISBL Lines and following
general philosophy shall be employed:
1 Lines of size 2" and below:

All lines of size 2" and below can be laid by "Combination Route" method. (Refer to clause
2.3.4) For this purpose new structural supports can be provided. Contractor shall carryout
site survey to study & finalize the routing in form of isometric drawings. Few examples of
such lines are hose stations for Plant Air, Inert Gas, Service Water & Low Pressure Steam.
2 Lines of size 3" and above:

Contractor shall carryout site survey to study & finalize the routing in form of isometric
drawings. Based on isometric drawings the contractor shall develop piping spool
drawings. The spool drawings shall indicate details of pre-fabrication and field weld joints.
Thus during shutdown no or only few weld joints will be performed.
5 SEQUENCING OF LINE REPLACEMENT ACTIVITIES
Sequencing of the line replacement activities is the key behind success of replacement project.
Proper sequencing of the work will enable utilisation of most optimal resources, time of work &
time of shutdown and hence the optimal utilisation of money.
It may be noted that means of creating space for laying new lines is very important. Sequencing
of activities within a work packet plays important role. Few of the activities such as, demolition of
existing line, increasing shoe height of the pipe supports, extending pipe-rack / slippers either
horizontally or vertically can make extra space available depending on how one sequence the
activities.
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3 PROJECT DESCRIPTION
1 Scope of replacement of piping is limited to ISBL lines only. It shall be noted that ISBL Flare lines
are excluded from scope of replacement.
ISBL lines will have interface with OSBL lines. All interfaces will preferably with flange end
connection at battery limit valves.
2 ISBL piping system & network of following Process Plants is to be replaced:
a Condensate Fractionation Unit (CFU) - II

b Condensate Fractionation Unit (CFU) -I
c Gas Sweetening Unit (GSU) - 12 & 13
d Ethane Propane Recovery Unit (EPRU)
e LPG recovery unit (LPG) - I
f LPG recovery unit (LPG) - II
g AGHAS - Liquid Handling System
3 Piping to be replaced in each of the process plant mentioned above, mainly includes utility lines
& few process lines except in AGHAS - Liquid Handling System, where only process lines are to
be replaced. (Refer to line list of individual process plants for ISBL system attached as Annexure-
A1 Doc. No: 5602-PS-LI-00-201-00)
Broadly fluids handled by these ISBL lines are classified as follows:
a Process Lines (Gas) c Utility Lines (Vapor)

- Sour Gas - MP & LP Steam
- Sweet Gas
- LP Fuel Gas d Utility Lines (Liquid)
- Steam Condensate
b Process Lines (Liquid) - Service Water & Drinking Water
- Sour Condensate - Cooling Water (Supply & Return)
- Produced water from slug liq.sump
- Methanol Injection e Utility Lines (Gas)
- LAN Product - Instrument Air
- LPG Product - Plant Air
- Propane Pump out - Inert Gas
- Propane Make-up
- C2C3 Product
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4 Isolation valves are available on all the existing utility lines at battery limit of each process plant
which will enable to isolate ISBL lines from OSBL network for purpose of replacement.
5 Generally, all the ISBL lines from process unit B/L Isolation valve are routed over central main
pipe rack & further distributed by supporting over structural supports.
6 For utility lines all the branches within B/L of process plants mentioned above are to be replaced.
7 Change in Piping Class:
A Referring to P&IDs attached to this report, existing piping class of following listed services
is A3A / J1A. However, while replacing the piping, instead of A3A / J1A, piping class A1A
shall be used.
a Instrument Air
b Plant air
c Service water
d Cooling Water
e Inert Gas
B Referring to P&IDs attached to this report, existing piping class of sour gas and sour
condensate in are not according to NACE requirement. However, while replacing the
corresponding piping, the piping class shall be changed to A16A, B16A & D16A as
applicable. The contractor shall change P&ID accordingly and carry out subsequent
activities.
C The piping standard for LP Steam / Condensate line shall be A2A (IBR Grade), Schedule
80 instead of A1A. The contractor shall change P&ID accordingly and carry out
subsequent activities.
D All utility pipelines less than 3"size shall be of Schedule 80.
E MTO in Isometrics & BOQ were prepared based on existing MOC of Lines. LSTK
contractor to consider changes in MOC as mentioned above and accordingly update MTO
as well as BOQ.
8 Following points shall be taken care during replacement of 1" and below Instrument Air lines:
1 MOC shall be SS-304

2 NPT fittings shall be used.
3 Ball valves shall be used for isolation.
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4 CONDENSATE FRACTIONATION UNIT (CFU-II)
4.1 WORK DESCRIPTION
Line list for CFU-II is divided based on fluids handled as given in below table. For execution of
replacement work also this classification will be of great help. The table provides information on
line sizes involved along with flange ratings associated with the lines.
SN Fluid Line sizes, inch Pipe Class Rating

1 Air - Inst & Plant 1" to 2" A3A 150#
2 Inert Gas (Nitrogen) 1" to 2" A3A 150#
3 Steam & condensate 3/4" to 14" A2A, A3A, B2A 150, 300#
4 Cooling water 1 1/2" to 16" A3A 150#
5 Service Water 2" A3A 150#
6 Fuel Gas 1" to 2" A1A 150#
7 Methanol 1" to 2" D1A 150, 600#
8 Process Lines 3" to 8" A1A, B1A, D6A 150, 300, 600#
Additionally refer "Section-II, clause 3, Note-7 & Note-8".
4.2 LINE LIST
Refer to line list doc no 5602-PS-LI-00-201-00, rev 0 attached as Annexure- A1.
4.3 WORK PACKETS
In order to carry out the replacement work smoothly, the entire work shall be grouped into
individual work-packet so as to complete one work-packet at a time.
4.4 WORK PACKETS & FEASIBLE SOLUTION
Work packet concepts have been used to define various lines to be replaced. Subsequent
section provides work packet definition.
Refer to the piping & instrumentation diagram, attached as Annexure-A2 for understanding exact
extend of the line segment to be replaced.
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1 Work Packet R1: (Instrument Air Lines)
Line From Line To Work Description

CFU-II B/L Instrument Air Header One to one replacement
Instrument Air Header Entire Distribution Network
2 Work Packet R2: (Plant Air Lines)

CFU-II B/L Plant Air Header One to one replacement
Plant Air Header Entire Distribution Network
3 Work Packet R3: (Inert Gas Lines)

CFU-II B/L Inert Gas Header One to one replacement
Inert Gas Header X-2501 A

X-2501 B
K-2501 A/B
TO PCV-302 / 303
Hose Stations
K-2501 A/B
4 Work Packet R4: (Low Pressure Steam Lines)

CFU-II B/L Low Pressure Steam Header One to one replacement
Low Pressure Steam Header Hose Stations

PSV-403 AB
V-2501
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5 Work Packet R5: (Medium Pressure Steam Lines)

CFU-II B/L Medium Pressure Steam Header One to one replacement
Medium Pressure Steam Header PSV-202/VENT

V-2505 / PSV-202/VENT
V-2506
PSV-402/VENT
E-2504 / V-2506
E-2501
6 Work Packet R6: (Steam Condensate Lines)

Steam Condensate Header CFU-II B/L One to one replacement
P-2504 AB Steam Condensate Header

V-2507
7 Work Packet R7: (Cooling Water Supply Lines)

CFU-II B/L Cooling Water Supply Header One to one replacement
Cooling Water Supply Header PUMP SEAL P-2504

E-2502
E-2505
E-2503 A/B
8 Work Packet R8: (Cooling Water Return Lines)

Cooling Water Return Header CFU-II B/L One to one replacement
PUMP SEAL P-2504 Cooling Water Return Header

E-2502
E-2503 A/B
E-2505
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9 Work Packet R9: (Service Water Lines)

CFU-II B/L Service Water Header One to one replacement
Service Water Header Entire Distribution Network
10 Work Packet R10: (Fuel Gas Lines)

CFU-II B/L Fuel Gas Header One to one replacement
Fuel Gas Header Flare Header Purging
11 Work Packet R11: (LPG Product Lines)

P-2503 A/B V-2504 One to one replacement
C-2502
CFU-II B/L
12 Work Packet R12: (LAN Product Lines)

E-2505 CFU-II B/L One to one replacement
13 Work Packet R13: (Sour Condensate Line)

CFU-II BL V-2501 One to one replacement
14 Work Packet R14: (Methanol)

CFU-II BL PV-.301B One to one replacement
PV-101B
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5 CFU-I, GSU-12 & 13 (UNIT 19)
Even though, CFU-I, GSU-12 & 13 are three different units, they are being catered by common
utilities and offsite supplies. Hence, all the three units shall be treated as common (Unit-19) as
well as individual units. As far as shutdown availability is concerned, the three units will be
considered as individual, that is individual unit shutdown one at a time will be available; however,
simultaneous shutdown of all the three units will not be provided.
The common utilities and offsites line list for CFU-I, GSU-12 & 13 are divided based on fluids
handled as given in below table. For execution of replacement work also this classification will
be of great help. The table provides information on line sizes involved along with flange ratings
associated with the lines.

1 Inert Gas (Nitrogen) 3/4" to 2" A3A 150#
2 Steam & condensate 3" to 18" A2A, A3A, B2A 150#, 300#
3 Cooling Water 1" to 20" A3A 150#
4 Drinking Water 1 1/2" to 2" A3A 150#
5 Fuel Gas 3/4" to 2" A1A, B1A 150#, 300#
6 Methanol 1" to 2" A1A, D1A 150, 600#
7 Process Lines 18" to 24" D1A, D6A 600#
5.2 LINE LIST
5.3 WORK PACKETS
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PSE carried out study on feasible options for replacement of CFU-1, GSU-12 & 13 piping system
& network.
Replacement of the common header catering to CFU-1, GSU-12 & 13 is not possible without
shutting down all the three process units. In order to avoid this shutdown, we have planned a
temporary common header of size ---" running along length of all the three process units. Each
of the common header will be replaced one at a time. The teporary common header will provide
teporary connection to individual process unit, whereby existing common header can be isolated
without affecting individual process unit operation. After replacig the common header, the new
header is commissioned and temporary common header is disconnected.
Work packet concepts have been used to define various line segments to be replaced.
Subsequent section provides work packet definition.
Following work packets are related with the commonheader replacement activities.

Unit-19 B/L CFU-I B/L One to one replacement
GSU-12 B/L
GSU-13 B/L
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GSU-12 B/L
GSU-13 B/L

GSU-12 B/L
GSU-13 B/L
4 Work Packet R87: (Drinking Water Lines)

Unit-19 B/L GSU-12 B/L One to one replacement
GSU-13 B/L

GSU-13 B/L
6 Work Packet R89: (Sour Gas Lines)

UNIT-19 B/L V-1202 / 1302
7 Work Packet R810: (Sweet Gas Lines)

V-1201 / 1301 UNIT-19 B/L
8 Work Packet R811: (Methanol Lines)

GSU-13 B/L
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6.1 CONDENSATE FRACTIONATION UNIT (CFU) -I
6.1.1 WORK DESCRIPTION
The entire line list for CFU-I is divided based on fluids handled as given in below table. For
execution of replacement work also this classification will be of great help. The table provides
information on line sizes involved along with flange ratings associated with the lines.

2 Steam & condensate 3/4" to 8" A2A, A3A, B2A 150#, 300#
3 Cooling Water 3/4" to 10" A3A 150#
4 Methanol 1" to 2" A1A, D1A 150, 600#
5 Process Lines 6" D6A 600#
6.1.2 LINE LIST
6.1.3 WORK PACKETS
6.1.4 WORK PACKETS & FEASIBLE SOLUTION
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CFU-I B/L Inert Gas Header One to one replacement
Inert Gas Header 11 AT 102

K-1101 A/B
Hose Stations
C-1102

CFU-I B/L Low Pressure Steam Header One to one replacement
Low Pressure Steam Header SP- 1126

Steam Press PSV 101
C-1102
Hose Stations

CFU-II B/L Medium Pressure Steam Header One to one replacement
Medium Pressure Steam Header Steam Condensate Header

Steam Straps
V-1103
E-1101
V-1103 PSV-203
PSV-203 ATM.

Steam Condensate Header CFU-I B/L One to one replacement
V-1103 CONDENSATE HDR
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CFU-I B/L Cooling Water Supply Header One to one replacement
Cooling Water Supply Header P-1101 A/B

K-1101A/B
E-1103
E- 1102

Cooling Water Return Header CFU-I B/L One to one replacement
P-1101 A/B Cooling Water Return Header

K-1101A/B
E-1103
E-1102
7 Work Packet R1110: (Sour Condensate Line)

CFU-I B/L X-1101 One to one replacement
8 Work Packet R1111: (Methanol Line)

CFU-I Methanol Header 11 PV 101A One to one replacement
11 PV 201
11 FV 101
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6.2 GAS SWEETENING UNIT (GSU) - 12 & 13
6.2.1 WORK DESCRIPTION
GSU 12 & 13 are two separate units but are identical to each other in terms of locations of all the
equipments & piping routing. Only the location headers on pipe rack is different.
The entire line list for GSU-12 / 13 is divided based on fluids handled as given in below table.
For execution of replacement work also this classification will be of great help. The table
provides information on line sizes involved along with flange ratings associated with the lines.
GSU-12 / 13
2 Steam & condensate 3/4" to 18" A2A, A3A 150#
3 Cooling Water 1" to 20" A2A, A3A 150#
4 Drinking Water 3/4" to 1 1/2" A3A 150#
5 Fuel Gas 3/4" to 2" A1A, B1A 150#, 300#
6 Methanol 1" to 2" A1A, D1A 150, 600#
7 Process Lines 18" to 24" D1A, D6A 600#
6.2.2 LINE LIST
6.2.3 WORK PACKETS
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6.2.4 WORK PACKETS & FEASIBLE SOLUTION

GSU-12 B/L Inert Gas Header One to one replacement
Inert Gas Header J-1201

V-1209
Hose Stations
C-1202

GSU-12 B/L Low Pressure Steam Header One to one replacement
Low Pressure Steam Header P-1902

X-1205 A/B
X-1203
OWS PIT
T-1901
T-1902
T-1202
Hose Station
C-1201
T-1201 / X-1204, X-1201 A/B

GSU-12 B/L Medium Pressure Steam Header One to one replacement
Medium Pressure Steam Header OWS PIT
J-1201
E-1205 B
E-1205 A
Page 27 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

Steam Condensate Header GSU-12 B/L One to one replacement
E-1211 Steam Condensate Header

X-120A/B

GSU-12 B/L Cooling Water Supply Header One to one replacement

P-1203 A/B
J-1201
E-1208
E-1211
E-1206 A
E-1210
E-1206 C
E-1204
E-1203 B

Cooling Water Return Header GSU-12 B/L One to one replacement

P-1203 AB
J-1201
E-1211
E-1208
E-1206 A
E-1210
E-1204
E-1203 A
Page 28 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

GSU-12 B/L Drinking Water Header One to one replacement
Drinking Water Header Eye Wash

GSU-12 B/L Fuel Gas Header One to one replacement
Fuel Gas Header T-1901

T-1902
T-1202
V-1203
T-1201
Flare Header
C-1202

GSU-12 B/L 12 FV 301 One to one replacement
V-1201

GSU-13 B/L Instrument Air Header One to one replacement

GSU-13 B/L Plant Air Header One to one replacement
Plant Air Header Hose Stations

Entire Distribution Network
Page 29 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

GSU-13 B/L Inert Gas Header One to one replacement
Inert Gas Header J-1301

V-1309
Hose Stations
C-1302

GSU-13 B/L Low Pressure Steam Header One to one replacement
Low Pressure Steam Header X-1305 A/B

X-1303
OWS PIT
T-1302
Hose Station
C-1301
T-1301 / X-1304, X-1301 A/B

GSU-13 B/L Medium Pressure Steam Header One to one replacement
Medium Pressure Steam Header OWS PIT

J-1201
E-1205 B
E-1205 A

Steam Condensate Header GSU-13 B/L One to one replacement
E-1311 Steam Condensate Header

X-120A/B
Page 30 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

GSU-13 B/L Cooling Water Supply Header One to one replacement

P-1303 A/B
J-1301
E-1308
E-1311
E-1306 A
E-1310
E-1306 C
E-1304
E-1303 B

Cooling Water Return Header GSU-13 B/L One to one replacement

P-1203 AB
J-1201
E-1211
E-1208
E-1206 A
E-1210
E-1204
E-1203 A

GSU-13 B/L Service Water Header One to one replacement
Service Water Header 13-SL-601/602

13-SL-301
13-HC-501
J-1301 SEAL POTS
HS-13-02
13-SL-302-306
Page 31 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

GSU-13 B/L Service Water Header One to one replacement

GSU-13 B/L Fuel Gas Header One to one replacement
Fuel Gas Header T-1901

T-1902
T-1302
V-1303
T-1301
Flare Header
C-1302

GSU-12 B/L 13 FV 301 One to one replacement
V-1301
Page 32 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
7 ETHANE PROPANE RECOVERY UNIT (EPRU)
The entire line list for EPRU is divided based on fluids handled as given in below table. For

1 Inert Gas (Nitrogen) 1" to 2" A3A 150#
2 Steam & condensate 3/4" to 8" A3A 150#
4 Drinking Water 1/2" to 3" A3A 150#
5 Fuel Gas 1" to 2" B1A 300#
7.2 LINE LIST
7.3 WORK PACKETS
Page 33 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

EPRU B/L Inert Gas Header One to one replacement
Inert Gas Header Hose Station

PSV-501 A/B

EPRU B/L Inert Gas Header One to one replacement
Low Pressure Steam Header Hose Station

Steam Traps

EPRU B/L Cooling Water Supply Header One to one replacement
Cooling Water Supply Header EK-1501 A/B

EK-1502 A/B

Cooling Water Return Header EPRU B/L One to one replacement
EK-1501 A/B Cooling Water Return Header

EK-1502 A/B

EPRU B/L Drinking Water Header One to one replacement
Page 34 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

EPRU B/L Fuel Gas Header One to one replacement
Fuel Gas Header V-1513

Flare Header
Blow Down Header
7 Work Packet R410: (Propane Make-up)

EPRU B/L 15 LV 701 One to one replacement
8 Work Packet R412: (C2C3 Product)

EPRU B/L E-1515 One to one replacement
E-1515 EPRU B/L
Page 35 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
8 LPG RECOVERY UNIT (LPG) - I
The entire line list for LPG-I is divided based on fluids handled as given in below table. For

1 Air - Inst & Plant 2" & Below A3A 150#
2 Inert Gas (Nitrogen) 2" & Below A3A 150#
3 Steam & condensate 1" to 10" A2A, A3A 150#
5 Service Water 2" & Below A3A 150#
6 Process Lines 1 1/2" to 18" A1A, B1A, B4A, D1A 150, 300, 600#
Existing cooling water network in LPG-I is routed below ground. Now ONGC intends to route
new cooling water lines above ground, for which site survey was carried out by PSE & feasible
route was finalized. Existing cooling water network shall now to be replaced with two networks
one on west side (20" Header) & second on east side (32" Header) of plant. Routing for these
new cooling water lines is shown in Piping GAD, doc no 5602-PE-DR-GA-201-00, rev 0A
attached as 'Annexure B3' to this report.
8.2 LINE LIST
8.3 WORK PACKETS
Page 36 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

LPG-I B/L Instrument Air Header One to one replacement

LPG-I B/L Plant Air Header One to one replacement

LPG-I B/L Inert Gas Header One to one replacement
Inert Gas Header Entire Distribution Network

LPG-I B/L Low Pressure Steam Header One to one replacement
Low Pressure Steam Header F-101

V-117
E-117
V-119
F-101
Steam Strap
Hose Stations
Page 37 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

LPG-I B/L Medium Pressure Steam Header One to one replacement
Medium Pressure Steam Header E-115

E-108
E-106

LPG-I B/L Cooling Water Supply Header One to one replacement
(West Side - 20" Header)
LPG-I B/L Cooling Water Supply Header

(East Side - 32" Header)
Cooling Water Supply Header E-107

(West Side - 20" Header) E-109
E-114
E-116
Cooling Water Supply Header E-112 A/B/C/D

(East Side - 32" Header) E-110
E-111
K-102A/B
NEW PROPANE COMP.
P-102/103/105
Page 38 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

Cooling Water Return Header LPG-I B/L One to one replacement
(West Side - 20" Header)
Cooling Water Return Header LPG-I B/L

(East Side - 32" Header)
E-107 Cooling Water Return Header

E-109 (West Side - 20" Header)
E-114
E-116
E-112 A/B/C/D Cooling Water Return Header

E-110 (East Side - 32" Header)
E-111
K-102A/B
NEW PROPANE COMP.
P-102/103/105

LPG-I B/L Service Water Header One to one replacement
Service Water Header Entire Distribution Network
9 Work Packet R59: (Propane Lines)

C- 103 E-116 One to one replacement
E-116 LPG PRODUCT LINE
P-103A/B C-103
LPG PRODUCT LINE
V-107
P-104 A/B LPG-1 B/L
P-105 A/B LPG PRODUCT LINE

LPG-1 B/L
V-107
Page 39 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

P-102 A/B V-106 One to one replacement
C-102
LPG-1 B/L

E-109 LPG-1 B/L

LPG-1 B/L V-101
Page 40 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
9 LPG RECOVERY UNIT (LPG) - II
The entire line list for LPG-II is divided based on fluids handled as given in below table. For

1 Air - Inst & Plant 2" & Below A3A 150#
2 Inert Gas (Nitrogen) 2" & Below A3A 150#
3 Steam & condensate 1' to 10" A2A, A3A 150#
4 Cooling Water 1 1/2" to 22" A1A, A3A 150#
5 Process Lines 2" to 18" A1A, B1A, D4A 150, 300, 600#
Existing Cooling water network in LPG-II is routed below ground. ONGC intends to lay new
cooling water network above ground, for which site survey was carried out by PSE & feasible
route was finalized. New 26" isolation valves shall be located at north side of LPG-II & further
shall be routed over central rack. Routing for these new cooling water lines is shown in Piping
GAD, doc no 5602-PE-DR-GA-201-00, rev 0A attached as 'Annexure B3' to this report.
9.2 LINE LIST
9.3 WORK PACKETS
Page 41 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

LPG-II B/L Instrument Air Header One to one replacement

LPG-II B/L Plant Air Header One to one replacement

LPG-II B/L Inert Gas Header One to one replacement
Inert Gas Header Entire Distribution Network

K-502 A/B
E-501

LPG-II B/L Low Pressure Steam Header One to one replacement
Low Pressure Steam Header Water Tank

V-517
Hose Stations
F-501
Page 42 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

LPG-II B/L Medium Pressure Steam Header One to one replacement
Medium Pressure Steam Header E-509

E-508
E-506

LPG-II B/L Cooling Water Supply Header One to one replacement
Cooling Water Supply Header E-507

E-509
E-510
E-511
E-512 A
FRAME OIL COOLER
K-501
K-502 A/B
P-502 A
WATER COOLER

Cooling Water Return Header LPG-II B/L One to one replacement
E-507 Cooling Water Return Header

E-509
E-510
E-511
E-512 A
FRAME OIL COOLER
K-501
K-502 A/B
P-502 B
WATER COOLER
Page 43 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
8 Work Packet R69: (Propane Lines)

LPG-II B/L V- 508 TO V-509
LPG-II B/L E-512 A/B/C 12" DIS. HDR

V-506 P-502 A/B One to one replacement
P-502 A/B V-506

C-502
LPG-II B/L
C-502 LPG-II B/L

E-109 LPG-II B/L One to one replacement

LPG-II South B/L V-501
Page 44 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
10 AGHAS - LIQUID HANDLING SYSTEM
The entire line list for AGHAS is divided based on fluids handled as given in below table. For

1 Fuel Gas 1" A1A 150
2 Methanol 1" & 2" A4A, E1A 150, 900#
3 Process Lines 1" to 24" A1A, A13A, D1A, D4A, D6A 150, 600#
10.2 LINE LIST
10.3 WORK PACKETS
Page 45 of 59
VOL-II, Part-II
ENGINEERING PACKAGE

Distribution Flare Header One to one replacement
2 Work Packet R72: (Methanol Lines)

Distribution 03 PSV 101 A/B/C/D DISCHARGE One to one replacement
PV-201
02-PV-101A/B
3 Work Packet R73: (Process Lines PH-III)

Slug cather Fingers PH-III 03-V-102 SUMP One to one replacement
03-V-102 SUMP 03-V-201
03-V-201 SUMP E-201
03-V-201 PV-201
PSV-201
03-P-201 B
03-P-201 B
03-P-201 A/B 03-V-201

03-V-201
03-X-201 A/B
03-X-201 A/B
03-X-201 B
03-X-201 A/B B/L AGHAS

03-V-201
SEAL DRUM
PSV-202
PSV-203
HDR (INLET 02 PSV 03 A/B/C/D 03-PSV-A/B/C/D
PH-III SLUG CATCHER RISERS LPG - II & GSU
Slug Catcher PH-III Slug Catcher PH-II
Page 46 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
4 Work Packet R74: (Process Lines PH-II)

48" Sump PH-II 03-X-201 A/B One to one replacement
02-X-201 A/B
02-V-201
Slug Catchers 02-V-201
02-V-201 02-X-201 A/B

PH-III System
SUMP
02-PV-201
PSV-201
P-201 A/B/C
02-P-201 A/B/C 02-V-201

02-X-200 A/B
02-X-200 A/B PSV-108

PSV-109
02-X-201 A/B
02-X-201 A/B VAP. ELIMNATOR

TO 48" SUMP PH II
PSV-202
PSV-203
OWS
02-V-202 02-P-201A/B/C & 02-X-201A/B
5 Work Packet R75: (Produced Water Lines)

03-V-102 Sump Seal Drum One to one replacement
03-V-201
Page 47 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
11 BASIC ENGINEERING DOCUMENTS
In order to work out the scheme of replacement of piping system & network alongwith cost, following
listed specifications and drawings are prepared as a part of basic engineering documentation.
1 Line List
2 Piping & Instrumentation Diagrams
3 Piping Isometrics
4 Piping GAD - Cooling Water - LPG-I & II
5 BOQ - Valves, Pipe, pipe-fittings
Since there are no equipments involved in the project, plot plan / equipment layout drawings are not
required.
1 Piping & Instrumentation Diagrams
Piping & Instrumentation Diagrams are developed for ISBL Piping System, a part of piping
system & network replacement project. Refer to Annexure - A2, P&IDs (indicating piping to be
replaced)
SN Drawing No Rev No Title

AGHAS
1 02-03-A1-101A 0 ADDITIONAL GAS HANDLING FACALITIES AT URAN
PROCESS AND INSTRUMENTATION DIAGRAM PHASE-III
SLUG CATCHER AND INTERCONNECTION WITH PHASE-
II SLUG CATCHER.
2 02-03-A1-101B 0 ADDITIONAL GAS HANDLING FACILITIES AT URAN
PIPING & INSTRUMENTATION DIAGRAM SAFETY VALVE
MODIFICATION
3 02-03-A1-102 0 ADDITIONAL GAS HANDLING FACILITIES AT URAN
PIPING & INSTRUMENTATION DIAGRAM SOUR SLUG
LIQUID HANDLING SYSTEM
4 10-0200-E-201 0 PIPING AND INSTRUMENTATION D1AGRAM NEW SLUG
CATCHER
5 10-0200-E-202 0 PIPING AND INSTRUMENTATION D1AGRAM SLUG LIQUID
HANDLING UNIT
6 10-0200-E-203 0 PIPING & INSTRUMENTATION DIAGRAM SLUG LIQUID
STABILIZATION UNIT
CFU-I
7 02-11-E-101A 0 PIPING & INSTRUMENTATION DIAGRAM CONDENSATE
FRACTIONATION UNIT CONDENSATE COALESCER AND
OFF GAS COMPRESSOR
8 02-11-E-101B 0 PIPING & INSTRUMENTATION DIAGRAM CONDENSATE
FRACTIONATION UNIT OFF-GAS COMPRESSION
FRACTIONATION UNIT CONDENSATE STRIPPING
Page 48 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
CFU-I
10 02-11-E-103A 0 PIPING AND INSTRUMENTATION DIAGRAM UTILITY
DISTRIBUTION FOR CONDENSATE FRACTIONATION &
SWEETENING UNITS
11 02-11-E-103B 0 PIPING AND INSTRUMENTATION DIAGRAM UTILITY
DITRIBUTION FOR CONDENSATE FRACTIONNATION UNIT
12 02-11-E-103C 0 PIPING AND INSTRUMENTATION DIAGRAM UTILITY

DISTRIBUTION FOR CONDENSATE FRACTIONATION UNIT
CFU-II
13 02-25-E-101 0 PIPING & INSTRUMENTATION DIAGRAM CONDENSATE
FRACTIONATION UNIT-II CONDENSATE RECEIVING
SYSTEM
FRACTIONATION UNIT-II STRIPPER COLUMN
FRACTIONATION UNIT-II OFF GAS COMPRESSOR
FRACTIONATION UNIT-II LPG COLUMN
(FUEL GAS, SOFT WATER, COOLING WATER, METHAOL,
LP STEAM, MP STEAM, LPCONDENSATE)
18 02-25-E-106B 0 PIPING & INSTRUMENTATION DIAGRAM CONDENSATE
FRACTIONATION UNIT-II IG, SERVICE WATER, INST. AIR
PLANT AIR AND FLARE DISTRIBUTION SYSTEM
EPRU
19 02-15-E-102A 0 PIPING AND INSTRUMENTATION DIAGRAM C2/C3
RECOVERY UNIT FEED GAS PRE-COMPRESSION-II
20 02-15-E-106A 0 PIPING & INSTRUMENTATION DIAGRAM C2/C3
RECOVERY UNIT LEAN GAS COMPRESSION
21 02-15-E-107B 0 PIPING AND INSTRUMENTATION DIAGRAM C2/C3
RECOVERY UNIT PROPANE REFRIGERATION SYSTEM
22 02-15-E-108C 0 PIPING AND INSTRUMENTATION DIAGRAM C2/C3
RECOVERY UNIT FLARE, BLOWDOWN & FUEL GAS
SYSTEM
23 02-15-E-108E 0 PIPING AND INSTRUMENTATION DIAGRAM C2/C3
RECOVERY UNIT UTILITY DISTRIBUTION SYSTEMS
GSU 12/13
24 2335-02-12-A-101 0 P & I DIAGRAM GAS SWEETENING UNIT (UNIT 12)
30 2335-02-12-A-107 0 P & I DIAGRAM P&I DIAGRAM FOR CBD & CS GAS
SWEETENING UNIT (UNIT 12)
31 2335-02-19-A-101 0 P & I DIAGRAM FOR GAS SWEETENING UNIT (UNIT 12)
32 2335-02-19-A-102 0 PIPING AND INSTRUMENTATION DIAGRAM GAS
SWEETENING UNIT
33 2335-02-19-A-109A 0 UTILITY HEADER DIAGRAM FOR MP STEAM LP STEAM
AND LP CONDENSATE GAS SWEETENING UNIT
Page 49 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
34 2335-02-19-A-109B 0 UTILITY HEADER DIAGRAM FOR COOLING WATER, SOFT

WATER, SERVICE WATER AND DRINKING WATER GAS
SWEETENING UNIT
35 2335-02-19-A-109C 0 UTILITY HEADER DIAGRAM FOR FUEL GAS, INERT GAS,
INSTRUMENT AIR AND PLANT AIR GAS SWEETENING
UNIT
36 2335-02-19-A-109D 0 UTILITY HEADER DIAGRAM FOR SULFOLANE DIPA
CORROSION INHIBITOR AND METHANOL GAS
SWEETENING UNIT
LPG-I
37 10-1000-E-101A 0 INTEGRATED PIPING AND INSRUMENTATION DIAGRAM
FEED GAS PRECOOLING
38 10-1000-E-101B 0 INTEGRATED PIPING AND INSTRUMENTION DIAGRAM
DRYING-REGENERATION
39 10-1000-E-101C 0 PIPING AND INSTRUMENTATION DIAGRAM GAS DRYER
40 10-1000-E-103 0 PIPING & INSTRUMENTATION DIAGRAM LIGHT ENDS
FRACTIONATOR AND RESIDUE GAS COMPRESSOR
41 10-1000-E-104 0 PIPING & INSTRUMENTATION DIAGRAM LPG AND
PROPANE COLUMN
42 10-1000-E-105A 0 PIPING & INSTRUMENTATION DIAGRAM PROPANE
REFRIGERATION SYSTEM
43 10-1000-E-105B 0 INTEGRATED PIPING AND INSTRUMENTATION DIAGRAM
PROPANE REFRIGERATION SYSTEM
LPG-I
44 10-1000-E-106 0 PIPING & INSTRUMENTATION DIAGRAM FLARE AND
BLOW DOWN SYSTEM
45 10-1000-E-107 0 PIPING & INSTRUMENTATION DIAGRAM FUEL GAS,
METHANOL, NITROGEN/IG INSTRUMENT AIR PLANT AIR
SYSTEM
46 10-1000-E-108 0 PIPING & INSTRUMENTATION DIAGRAM COOLING
WATER SYSTEM, CONDENSATE SERVICE
WATER/STEAM SYSTEM
47 10-1000-E-108A 0 PIPING & INSTRUMENTATION DIAGRAM COOLING
WATER
LPG-II
48 10-5000-E-501A 0 PIPING & INSTRUMENTATION DIAGRAM FEED GAS
RECEIVING & DRYING.
49 10-5000-E-501B 0 PIPING & INSTRUMENTATION DIAGRAM LIQUID DRYER &
REGENERATION HEATER
50 10-5000-E-503 0 PIPING & INSTRUMENTATION DIAGRAM LIGHT ENDS
FRACTIONATOR AND RESIDUE GAS COMPRESSORS.
51 10-5000-E-503B 0 PIPING & INSTRUMENTATION DIAGRAM CLOSED
CIRCUIT COOLING WATER SYSTEM FOR CYLINDERS
52 10-5000-E-504 0 PIPING & INSTRUMENTATION DIAGRAM LPG COLUMN
53 10-5000-E-505A 0 PIPING & INSTRUMENTATION DIAGRAM PROPANE
REFRIGERATION SYSTEM
54 10-5000-E-507 0 PIPING & INSTRUMENTATION DIAGRAM FUEL GAS,
METHANOL, INERT GAS INSTRUMENT AIR PLANT AIR
SYSTEM
55 10-5000-E-508 0 PIPING & INSTRUMENTATION DIAGRAM COOLING,
WATER, STEAM, CONDENSATE. SERVICE
WATER/STEAM SYSTEM
56 10-5000-E-508A 0 PIPING & INST. DIAGRAM COOLING WATER
Page 50 of 59
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ENGINEERING PACKAGE
2 Piping Isometrics
For knowing actual routing of lines to be replaced and working out precisely piping BOQ, piping
Isometric drawings have been prepared.
Following listed Isometrics are for ISBL piping system & network. Refer to Annexure - B1.

1 5602-PE-DR-IS-201-00 ISOMETRIC DRAWING
Sht 301 to Sht 309 0B CFU-1

Sht 310 0B GSU 12/13
Sht 325 to Sht 360 0B GSU 12/13
Sht 369 0B GSU 12/13
Sht 371 to Sht 390 0B LPG-1
Sht 436 to Sht 457 0B EPRU
Sht 463 to Sht 474 0B EPRU
Sht 504 to Sht 509 0B AGHAS
Sht 532, 535 0B AGHAS
Sht 536, 537 0A EPRU
Sht 538 0A CFU-1
Sht 538 to 540 0A GSU 12/13
Sht 541 0A CFU-2
Sht 542 & 543 0A EPRU
Sht 302, 303, 308, 309 & 315

Sht 319 to Sht 324 -
Sht 326, 327, 332 & 333 -
Sht 336, 337, 342, 343, 351 & 352 -
Sht 361 to 370 & Sht 391 to 400 -
Sht 419 to 425 & Sht 427 & 431 - Please note that these isometric sheets are discarded
Sht 441 to Sht 450 -
Sht 454 & 455 & Sht 458 to 462 -
Sht 469 to 474 & Sht 491 to 497 -
Sht 510, 518, 525, 526, 530, 531 -
Sht 533, Sht 534 -
Page 51 of 59
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ENGINEERING PACKAGE
Note:
In case of ISBL piping system & network, the piping isometric drawings will give much clearer
picture for pipe routing and MTO / BOQ calculations. Hence, we have chosen to make Isometric
drawings over piping GADs.
3 Piping GAD
Existing cooling water supply and return headers originating from LPG-2 CW pumps &
terminating in to LPG-2 cooling tower are partially laid underground. The underground segment
of the headers are now planned for above ground routing. For this new route a piping General
Arrangement drawing has been prepared and attached as Annexure-B3.

1 5602-PE-DR-GA-201-00 0B Piping GAD - Cooling Water - LPG-I & II
Sht 1 of 1
4 BOQ - Valve, Pipe, Pipefittings:
Following is BOQ - valve, Pipe & Pipefittings prepared for ISBL piping system & network. Refer
to Annexure - B2

1 5602-PE-BQ-00-201-00 0 BOQ Pipes
2 5602-PE-BQ-00-202-00 0 BOQ Flanges & Fittings
3 5602-PE-BQ-00-203-00 0 BOQ Valves
Page 52 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
ISBL PIPING SYSTEM & NETWORK REPLACEMENT
Project: Engineering Package - Piping System & Network Plant Location: Uran, Maharashtra
Sec III : WAY FORWARD, TIME & SCHEDULE
1 WAY FORWARD
Quality engineering, well-planned specific procedures, skilled & trained personnel for execution are key
factors in minimizing risk associated with time, schedule and cost for "Piping system & Network
replacement" project.
The consequence analysis of way forward will lead to estimated time, project schedule and cost
associated with the project. It is very important to understand the considerations or basis applied for
the way forward. If the considerations i.e. way forward is changed, the time & cost estimation will
change. Following are the primary considerations.
1 SHUTDOWN TIME
In accordance with the objectives of this study, the basis for piping system & network
replacement shall focus on shutdown time as prime criteria for selection of the replacement
process.
It is required to understand that every minute saved on shutdown time is directly proportional to
reducing cost of line replacement. Also, it may be noted that the cost of physical material (BOQ)
when weighed against the cost of shutdown, reducing cost of shutdown (time of shutdown) shall
be given preference. Thus, between two options for execution, lower time of shutdown shall be
given preference.
2 AVAILABILITY OF SHUT-DOWN:
As a general rule, fluid wise local shutdown by means of isolating and handing over the relevant
line segment can be given. All such local shutdown will be pre-planned.
3 MANPOWER RESOURCES
Piping system & network replacement work demands a skill work output. Appointing a
contractor having excellent skill sets and capabilities of working under scenario of following is
essence:
a Working at elevations
b Working in hydrocarbon environment especially when hydrocarbon is present
c Working under strict and short period schedule
d Ability for micro level planning and capability of executing the same
e Established track record of working with all portable modern automatic hand tools /
Page 53 of 59
VOL-II, Part-II
ENGINEERING PACKAGE
machines for cutting, shaping, facing and welding or any other operation that may be
needed along with modern equipments for lifting & shifting.
A bad quality contractor can not only ruin the entire project; but will delay the schedule and
customer will incur a lot of indirect cost.
4 PIPE STANDS / PIPE JACKS
Pipe stands / pipe jacks shall be extensively used so as to be able to construct new pipe at
temporary location adjacent to pipe to be replaced. As required temporary secondary support in
form of heavy bottom plate / foundation shall be considered.
5 SHOP FABRICATION & EX-SITU PREFABRICATION:
Shop fabrication and Ex-situ prefabrication shall be considered to the extend possible; while in-
situ fabrication shall be as minimum as possible. This is in view to minimise the shutdown time.
Adequate lifting and shifting equipments shall be used.
The shop fabricated & ex-site prefabricated parts shall be pre-tested so that only the tie-in welds
are inspected and the pipeline can be returned to normal service quickly.
6 EXECUTION PLAN FOR LINE REPLACEMENT:
During actual execution, Contractor shall make a micro level plan for executing each activity of
line replacement. Each activity planned shall be supported with adequate documentations as
listed below. Each of such plan shall be discussed & brain-stormed by expert team of
construction work and the plan shall be approved. The execution shall be carried as per the
approved plan.
1 Execution Engineering Drawings: Accurate piping GADs, Isometrics, pipe spool drawings,
drawings indicating field joints etc shall be developed based on final physical
measurements at site. The drawings shall be of high accuracy and fit for shop fabrication.
2 Resources: A detailed method statement of level of SOP (Standard Operating Procedure)

for employing man & machine shall be prepared. The method statement shall be well
supported with work execution sketches / plan / elevation drawings that shall indicate
l ti t hi h th h ll b d l dd i ti
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locations at which the resources shall be deployed during execution.
3 Check List: A check list for execution based on above referred method statement shall be
developed by contractor for purpose of actual execution
4 Log Sheet: A log sheet shall be prepared for actual execution of each line segment
replacement work. The log sheet shall list all micro level activities along with planned time
and against that actual time.
5 Physical verification at site: Complete plan based on above listed points shall be physically
verified at site in presence of customer representative by the contractor before starting the
work of actual replacement.
7 PRIMARY & SECONDARY SUPPORTS:
1 The logic that, "lines have exhausted its design life" is applicable to all primary supports
also. Hence, as a part of line replacement requirements all primary supports such as
guide, anchor, rest .. Etc shall be replaced.
2 All secondary supports, if made of structural steel shall be verified for stability and shall be
strengthen as required, unless otherwise specified separately.
3 Activities related to secondary supports shall be completed before commencing piping

replacement activity.
8 TREES & BUSHES:
1 For execution of piping replacement work, branches of trees and bushes may come
across as hurdles. Only branches that come in way of work shall be trimmed carefully.
9 SEQUENCE OF EXECUTION
The project time and schedule is based on specific plan of replacement depicted in work flow
diagram given subsequently. It is expected that the project shall be implemented in the
sequence given in the work flow diagrams (WFD).
It may be noted that any change in plan of replacement will change the project time and
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schedule and the work flow diagram shall be revised at that point of time.
10 CLEAR WORK-FRONT
It is understood that the work will be carried out when entire Uran facility is in operation; hence
clear wok-front will not be available as and when required. However, it is expected that the
contractor shall make sure that clear work-front AS PLANNED is available to avoid any delay in
schedule.
11 WORK PACKET CONCEPT
Work packet concept shall be followed for implementation of the project. Each work packet shall
be planned by contractor at micro level detailing out sequence of work, resources required for
each activity, execution drawings, time needed for each activity. The resource and time shall
match with each other.
The contractor shall demonstrate physically the work packet execution plan and get it verified
from customer for resources to be deployed, methodology of replacement, in-situ & ex-situ
fabrication details, sequence of activities along with associated time required. The plan for each
work packet shall be approved from customer. Time and schedule shall be declared in advance
and the work packet shall be executed within the planned time.
12 DETAILED ENGINEERING
The contractor appointed for execution, must have in his team a strong detailed engineering task-
force who understand well the criticality of pipe replacement. Inaccurate execution drawings will
lead to site problems, delayed schedule, huge indirect cost to customer. In order to complete
the project within minimum shutdown period, it is very important to have quality execution
drawings.
Throughout the execution period, the contractor shall be accompanied by engineering team at
site. This will enable to resolve on the spot any error, minor changes, last minute findings during
execution.
13 CONTRACTOR’S SCOPE OF WORK:
The contractor’s Scope of Work shall include all necessary integration, modification, addition to
existing piping, instrumentation and control system, safety and shut down of system etc. The
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drawings / documents included in the bid package for the modification works are indicative only
and it shall be contractor’s responsibility to assess the total quantum of work, verify the details
given in the bid package, identify the space, routing etc. and get familiar with the existing details
and type of work to be carried out on existing facilities. Since all the existing facilities where
modifications/ integration are to be carried out are in operational area, the contractor shall
endeavour to design his work in such a manner that hot work and complex / system shutdown
requirements are kept to the minimum.The contractor shall develop and execute the modification
works by using prefabricated piping spools to the maximum extent possible to keep the
shutdown to absolute minimum.
The lines that are required to be replaced are marked on respective P &ID of each unit. All the
manual valves including vent valves, drain valves and strainers installed shall be replaced with
new ones. Tappings for the instruments, flushing connections, vent connections, drain
connections etc. on the piping shall be done by the contractor as per the P & ID / Site condition.
Contractor shall replace piping such that all the existing items which are not required to be
replaced under this tender are to be installed in the new replaced piping. No other items such as
control valves, Actuated valves, Pressure safety valves and instruments etc. are considered for
replacement.It is necessary to commission the parallel pipeline complete dismantling of the old
is taken up. This means that all instrumentation installed in the old line under replacement, shall
be replicated in the parallel newly laid line. Shifting of instruments from old line to new line is in
the contractor scope.
2 TIME & SCHEDULE
1 PROJECT SCHEDULE
Based on methods of replacement discussed in this package, a project schedule in the form of
bar chart has been made. The same is attached as Annexure-C1.
It may be noted here that, the project schedule is a function of availability of shutdown of process
units. As a part periodic maintenance requirements, turn-around jobs are undertaken once in 4
years. Thus, each process unit will have one definite shutdown available at least once in 4
years. At this stage it is very difficult to estimate the shutdown plan of all the process units.
Hence, we have made a fair assumption that once every six months, one process unit will be
available for turn-around jobs and during this period, piping system & network replacement of the
respective unit will be completed.
Based on above assumption, the project will be completed in 4 years 10 months.
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2 ESTIMATED TIME
Project Time period has been worked out based on project schedule. Major milestones are as
under:
SN Milestones Months
CFU-II
1 Engineering completion 8 mo
2 Procurement - piping 9 mo
3 Procurement - structural 3 mo
4 Planning of Execution 4 mo
5 Execution at site 1 mo
CFU-I
GSU-12
GSU-13
EPRU
LPG-1
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LPG-2
AGHAS
Overall time period 4 years 10 months
Page 59 of 59

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OIL & NATURAL GAS CORPORATION LTD.

ISBL PIPING SYSTEM & NETWORK

FOR & ON BEHALF OF

0 28-Aug-18 Comments Incorporated & Approved for Bid Package

0B 29-Jul-17 Approved for Bid Package PHT AVS REU

0A 30-Jun-17 Draft for Review PHT AVS REU

Rev. Date Description Prep. By Chk. By App. By

Section No SN Title Page No.

II Basic Engineering Package 5 of 59

1 Facilities at Uran Terminal

III Way Forward, Time & schedule 53 of 59

A Basic Engineering Documents B Piping Drawings

3 Ensure that the selected option of pipe replacement shall be constructible.

4 Estimate cost of the replacement of piping system and network.

1 B/L : Battery Limit

Sec II : BASIC ENGINEERING PACKAGE

1 FACILITIES AT URAN TERMINAL

a Slug catcher unit

2 UTILITIES & OFFSITES

Sec II : BASIC ENGINEERING PACKAGE

3 OVERVIEW OF PROCESS FLOW

Sec II : BASIC ENGINEERING PACKAGE

2 BASIS FOR ENGINEERING PACKAGE

Process Plants CFU - II CFU - I GSU - EPRU LPG - I LPG - II AGHAS

Sec II : BASIC ENGINEERING PACKAGE

2 WORK PACKET CONCEPT

3 LINE REPLACEMENT METHODS:

1 Original piping design get restored with extended life.

2 No additional space required and hence, there is no further congestion in layout.

Sec II : BASIC ENGINEERING PACKAGE

Work Flow Diagram:

Local S/D if Needed

Isolate Existing Line

Demolish Existing Line

Construct New Line

Sec II : BASIC ENGINEERING PACKAGE

2 Replace with Parallel Route

This is next choice of replacement if one-to-one is not a feasible solution.

Work Flow Diagram:

Hot Tap with Hook-up

Cold Tap with Hook-up

Hooking up Parallel Line to Hot Tap & Cold Tap

Sec II : BASIC ENGINEERING PACKAGE

3 Replace with Alternate Route

2 Maintaining piping aesthetic & operational ergonomics is a big challenge.

2 This method may turn out to be most optimal solution.

4 GUIDELINES FOR LINE REPLACEMENT METHOD:

Sec II : BASIC ENGINEERING PACKAGE

1 Lines of size 2" and below:

2 Lines of size 3" and above:

5 SEQUENCING OF LINE REPLACEMENT ACTIVITIES

Sec II : BASIC ENGINEERING PACKAGE

2 ISBL piping system & network of following Process Plants is to be replaced:

a Condensate Fractionation Unit (CFU) - II

Broadly fluids handled by these ISBL lines are classified as follows:

a Process Lines (Gas) c Utility Lines (Vapor)

Sec II : BASIC ENGINEERING PACKAGE

7 Change in Piping Class:

D All utility pipelines less than 3"size shall be of Schedule 80.

1 MOC shall be SS-304

Sec II : BASIC ENGINEERING PACKAGE

Sec II : BASIC ENGINEERING PACKAGE