OIL & GAS DEVELOPMENT COMPANY LIMITED ‘T DEPARTMENT, ISLAMABAD. tn tin on FOREIGN SECTION B ol sat PROCUREMENT O° WELLHEAD CONTROL PANEL. ANNEXURE A" ‘SCHEDULE OF REQUIREMENT SER ra a ea i ac ne moe Pose 1Pogestota2 | ANNEX-2 SPECIFICATIONS FOR PNEUMATIC DRIVEN WELLHEAD CONTROL PANEL Project: Wellhead Control Panels for Various Production Fields. Oil & Gas Development Co. Ltd. otCONTENTS PANEL & INSTRUMENTATION, DESCRIPTION Pact NO, 10 _ | mwrRODUCTION 3 2.0 | REFERENCE DOCUMENTS 5 30 | SERVICE CONDITIONS 6 40_| SCOPE OF WORK o 5.0 | FUNCTIONAL DESCRIPTION 08 60. | DESIGN AND CONSTRUCTION B 70 | HYDRAULIC CONTROL SYSTEMS 5 80 | OTHER VITAL COMPONENTS » 90 | LOOSE ITEMS - 20 10.0 _| PAINTING AND PREPARATION FOR SHIPMENT 24 BILL OF MATERIAL — 25 FUNCTIONAL & PERFORMANCE TESTS 29 13.0 | THIRD PARTY INSPECTION 29 140 | VENDOR DOCUMENTATION REQUIREMENTS. 30 15.0 | TERMS & CONDITIONS 30 160 | ANNEXY 3 17.0 | GENERAL DIAGRAM FOR WELLHEAD CONTROL, Fry use?12 INTRODUCTION Desi Oil & Gas Development Company Lil. (OGDCL is operating OiVGas Feds in various pats of Islamic Republic of Pakistan, OGDCL has planned to purchase Wellhead Control Panels for monitoring & contol of ‘producing wells, The Wellhead Control Panel (WHCP) shall be used to operate hydraulically ‘uated Sub Surface Safety Valve (SSSV) and Surface Safety Valve (SSV). Both SSV & SSSV te already installed and hydraulic operated and not in vendor's scope, The WHCP should be ‘capable of automatically shutting down the SSSV as well asthe SSV in response to various ‘alarm constions requiring shutdown either through pneumatic logie Fasble plug oop, ESD loop, Pressure Pilots et.) or through RTU using solenoid valve, ‘Vendor Responsibility ‘The Vendor shall be responsible forthe complete design, manufacturing and testing of the Instrumentation equipment in the package unit in accordance with this specification and the compliance with applicable codes, standards, specifications and regulations issued by the “organizations listed in Section 2 ‘The Vendor shall coatinn/do the following + Define all instrumentation systems and cons required to ensue satsfctory continuous ‘operation This shall include all instrumentation systems required for sitisfactory start-up and shut-down ofthe equipment, + Ensure that adequate instrumentation is provided for demonstrating the guaranteed performance ofthe packaged equipment. ‘Ensure that all instrumentation within his cope i suitable for the service conditions, Inorder to achieve standardization with the project instrumentation, OGD, reserves the right, Itoecessary to; ‘+ Prescribe o proseribe the use of particular makes, models and types of instrumentation. ‘+ Free issue specific pans ofthe proposed instrumentation for installation by the Vendo. ‘+ Prescribe the use of sandardized instrument process connections. + Suggest changes tthe proposed instrumentation and contol systems. ‘Notes Changes shall only be made with fll co-operation and agreement of the Vendor who shall remain aly responsible for the setsfactony operation ofthe package All nformation, manuals, certificates dat, and inscriptions shall be in the English language. age At13 Deviation All deviations from the technical requirements of this dacument or any ofthe listed Codes, ‘Standard, Regulations, Guidance Note, et, shall be as state inthe Supplies proposal and subsequent comespondence (On acceptance ofthe onder, it understood that al listed requirements are accepted, without exception. Any cost for engineering and materia subsequent identified shal be wholly bore by the Supplier and the changes incorporated without slippage to schedule or delivery and Without farther charge othe company.20 a REFERENCE DOCUMENTS Design Codes and landard Pakistan Codes and Standards as covered by Pakistan Standards and Quality Control Authority (PSQCA) shal be used where applicable, Where there is no applicable Pakistan Code oe Standard, codes or standards published by the following organizations wil be used American Gas Association (AGA) + International Standards Organization (ISO) ‘+ American Nationa Standards Institute (ANSI) ‘+ American Petoleum Insitute (API) ‘American Society of Mechanical Engineers (ASME) ‘American Society of Material Testing (ASTM) Brish Standards (BS) Institute of Electrical & Electronic Engineers (IEEE) Instrument Society of America (ISA) International Electrotechnical Comission (IEC) International Standard Organisation (ISO) International Telecommuniatins Union (ITU) ‘+ National Fite Protection Association (NFPA) ‘+ National Association of Comoson Engineers (NACE) + Scientific Apparatus Manufacturers Association (SAMA) aes ea3.0. SERVICE CONDITIONS 34 Environmental Conditions ‘Care should be taken during the selection ofthe instrament, so thatthe seleted item can ‘withstand the effects of moderate ambient temperatures coupled with high humiciy + Ambient Temperature Range 0-60 °C /32-131* © Relative Humigity 20.65% ‘+ Maximum Rainfall (Annual) 175mm + Wind Velocity 10 100 Kenar ‘+ Barth Quake Zone Zone2A of uniform building code 1997 32 Design Lite ‘The equipment and accessories sal be suitable for @ minimum period of 15 years ‘operation. Bidders to provide writen confirmation in thee technical bids. 33° ity design criteria 334 Electrical Supplies ‘An cletrzal supply of24V DC will be available from the solar power pack at sit, 332 PacumaticSupplics Pncurnatc supply at sit shall be raw as from instrument gas scrubber at normal pressure 100-150 psig40 SCOPE OF WORK ‘Scope of work for Suppl stall include design, tion, supply, testing and shipment of Pneumatic hydraulic wellhead control panels and assocated equipment, The scope of sippy work / Services shall include Design fabrication, consrston & supply of Wellhead Control Panel in accordance with echnical specifications mentioned in his document Supply of Fusile ples (lose shipped items). Supply of Pneumatic ESD sation as loose shipped items) Supply of Instrument Tubing / fitings within WHCP and outside fr instment conestions ‘Supply of High Low Pilots lose shipped item) Supply of Space pas fr two year operations. ‘Documentation including those elated to engineering / design as well a ‘manual, operation and maintenance manuals > par ‘Thinl Party Inspection50 SA FUNCTIONAL DESCRIPTION ‘The wellhead contol panel (WHCP) will bused to operate the Surface Safty Valve (SSV) and Sub Surface Safety Valve (SSSV) va to hydraulic headers; HP header sssv: (Operating pressure (10000 psi) Detail at Section 7.1.6 MP header ssvi Operating pressure (4000 psi) Detail at Section 7.1.6 ‘The WHCP willbe designed based on pneumatic hydraulic system, The sequc Shutdown loge of WHICP will be done pneumatically ‘The WHCP shall be capable ofauromatically shutting down the SSSV as well asthe SSV in response to various alarm conditions requiring shutdown either trough pneumatic loge (sible Plug lop, ESD loop, pressure pilots et) or through solenoid valves from RTU, ly contol and ‘The WHCP logic shall be designed tbe usaf, For instrament supply, regulated raw wellhead ‘fs shall be used fom Gas Scrubbers (notin vendors seope) rn comprescrs (notin vendor's scope). "Note thatthe distance between wellhead panel andthe Xmas tee nearly SO meters, It shal also contain means of overriding low pressure and esting of he high and low-pressure pilot uring operation, Vital Components of WHCP ‘Wellhead Control panel shall be fished with the following vi omponents:- |. Prcumatc driven Hydraulic pump for SSV, Supplier to design the pumps as per max ratings provided in section 71.6. Discharge hydraulic pressure shale adjustable with panel mounted pneumatic supply regulator. 2 Pneumatic driven Hydraulic pump for SSSV, Supplier to design the pumps as pee imax ratings provided in section 71.6. Discharge hydraulic presse shall be adjustable wih panel mounted peumatic supply regulator. 3. Manual Hydraulic pump of 10,000 ps rating. 4 Scrubberiiltration assembly for panel supply. S Adequate sized hydraulic ol ites with built-in differential pressure gauges and Y- {ype sirainers for hydraulic ouput ines from reservoir tank to pumps. 6 Flow contol valve 1. Adequatlysizod dels 3 way valve % Panel mounted First Out Indicators for providing satus of ESD station lop, Fusible ‘plug loop and Hi-Lo Pilots loop. 9 Panel mounted pressure gauges for monitoring of ll he erica pressures inthe ‘ime volame bot For pneumatic supply othe plo operat32 peumatie and hydraulic loops. Hydraulic’ pneumatic pilot operated interface Sway valves with manual bypass ‘option. Hydraulic release by these valves wll turn to the reservoir tough return ines, 11. Hydraulic pressure reli valve on SSV & SSSV fines, Adjustable pressure rane. 12 Pheumatic pressure reli valve. Adjustable pressure range 1. Preumatic pressure regulators, HL Ball valves, Needle and check valves 1. The hydeaulc reli system shouldbe configured so that it relieves the sytem pressure ino the hydraulic ol chambertank. 16 Pilot Operated pneumatic valves 1. Pressure switches on ESD loop, Fusibe plug loop and Hi-Lo pilots loop for remote monitoring oF Loop stats 18 Hydraulic Accumulators on both hydraulic ins of SV and SSSV. 18. Pullpush contrl knots: to open/close SSV and SSSV. ‘ML Push to charge valve: to charge ESD loop, fusible plug loops. 21, 45 Lite Reservoir’ Hydraulic Oil Tank/chamber with breather and level gauge. 2 Expl. prof Level switch forthe fo level status indicator of hydraulic reservoir. a Provision for emote shut-down (through RTU) for SSV shutdown & SSSV shutdown trough solenoid valves, A Remote Opening of SSV agains SSV shutdown only 25. _Presuretransmiters on SSV & SSSV lines ControlsIndicators All operated interface controls shall be on the ont of panel The following control unstions ‘nd indications on the front ofthe WHCP shall be provided (as minimum) ‘+ Push buton (5 fo charge the ESD station & fusible loop. ‘+ Knob to be pulled pushed to open clase both SSV & SSSV. *+ Knob to be pulled pushed 1 open clase SSV, Pressure gauges for pneumatic system (gas supply Reader, regulated pressure, ESD Stion fusible plug holding pressure & Hi-Lo Pilot Loop ete) 4 Pressure gauges for hydraulic sytem + First out Status Indicators (Det st Section 8.3) + Reservoir level Indicator (Gass yp). + Pneumatic Pressure Regulaorsicontrollrs for adjusting output pressures of Pheamatic ‘riven hydraulic pumps to SSSV & SSV (Detail at section 8.10), Pees yoNote: i Knobs shal be mushroom head. Raised guards shall be provided to prevent the accidental 53 4 ss ‘operation. Knob colors are described in setion 6.8. The controls and indicators shal be labeled and color coded na clear and consent manner. 4. Plot operated pneumatic valve relays with manual actuation facility (Knobs) shall be wsed 4 open the SSSV and SSV valves or 10 activate the fusible loop oF ESD function. These ‘pneumatic relays shall be locked in the open postion by use of lock open device. The lock ‘open function will automaticaly disengage as soon as the plot instrament pressure gets cctvaed. Critical Features of WHCP “Manual / Adjustable time delay for Well losing sequence ‘Sequential valve opening and closing for both valves ic. SSSV and SSV. “Manual bypass for abnormal process inputs sent shutdown opions- ‘Remote shutdowns (ESD) (by deenergzing 28V DC solenoid valves via TU). Two ‘options of ESD (Emergency Shutdown) must be in place for shutdown of either SSV ‘only or complete shutdown of hath SSV & SSSV. Fusibe plug loop (Low presse). . {© High / ow pressure relative tothe pilot stings. <4. Manual ESD button a pane {Manual BSD station, near escape gate. Opening of SSSV Valve “The wel is equipped with a down-hole Sub-Surface Safety Valve (SSSV). ‘A contol line fom the valve will be connected toa bulkhead atthe wellhead pant Opening of the SSSV shall be by regulating the hydeaulie pressure fam pump 2to the actuator of SSSV. Sequence ofthe well opening 1. SSS will open first. 2. Then SSV will open ater some delay ‘Opening of SSV Valve In case of opening of SSV, it should only be opened afer opening of SSSV & after certain tne ela, this time delay should be adjustable Opening of the SSV shall be by regulating the hydraulic pressure from pump 1 to the SSV actuator.56 80 58 \ulomatic Shutdown Following means shall be incorporated to achieve automate shutdown, 4) By means of Block and Bleed HI-LO Pressure Piles. i) By means of Fusible plugs on detection of ire on wellhead, Manual Shutdown, Following means shall be incorporated to achieve manual shutdown, 4) By "BSD Station’ near wellbead area via open/close ball valve fi) By remote pushbutton (at CCR) which actuate the solenoid valve ie. ‘electial ESD’ through RTUIPLC (PLC/RTU is notin vendors scope), ii) By pushing the red knob of pneumatic relay given onthe front of wellhead contol panel i8) SV valve shall be operated independently fom SSSV valve by switching the ‘Pneumatic relay knob given on the wellbea panel Font side (pl to open and push to lose). ¥) _SSSV vale shall not be operated independently from the SSV vale, so as to avid losing of SSSV valve when well is Nowing, If SSSV valve is manually closed ‘erroneously, the SSV also closes in sequence, uence (Timed lode) Surface safety valve (SSV) and the subsurface safety valve (SSSV) will closes in the following sequence. |) SSV valve closes without anytime delay, ii) SSSV valve closes 20-30 seconds later afer SSV valve Time delay circuits consisting of low control devices, Volume botlstiming device and 3- ‘way valve shal be provided to fulfil the requirements Seq. | Shutdown Source ssv_ | scssv 1_ | fig a Welhend (rile Pat Loop Awomat | coe Tian ame [2 | Hibh Pessre at Howie. (igh Paot Automate] a one Frstclose | Not Closed 3 | low Pesure stow ne (Low pot Automate | le sag [a | Manual tin to open 50 station Fistclose | ast cose [5 Fmanual push to close ssv of WHE? close__[ Not Closed | {5 | Manual push o close SSSV of WHER Fist close |Last close Remote close SSV of WHCP by de-energizng 28 V : 7 | dc solenoid valves via RTU oe | Remote close S55V of WHCP hy de-enerating4V| 5 ose | a cose 8 | oe solenoid waives via ATU. cee aa Pre aS10 ‘Startup Over-ride ‘A start-up bypass shall be installed to override the low presute shutdown signals from Now= line, The bypass will automatically reset when pest process pressures reached. ‘Closing of SSSV and SSV remotely he logc shall be so arranged that either SSV or both SSSV and SSV can be remotely closed ‘through solenoid valves SI and 82. Opening of SV remotely a Afshuts v. neruzing of solenoid valve SL “The logic shall be so arangod that SSV can be remotely opened through utilization of solenoid valve 83 to provide air pressure tthe POV3 valve & energize the SRV2. However SI valve will iniially be reset remotely in this scenario. However if suitable soltion is not provided, then OGDCL reserves the right to remove this loi feture tan time.60 6a DESIGN AND CONSTRUCTION Panel Construction ‘The skid mounted WHCP shall be made of stainless steel and painted to finished coat. Pane! shall be suitable for zone 2 hazardous ara installation with: Framework Botom plate and plinth ii, Roof with sunshade iv, Front & Back doors ‘The skid shall be designed with consideration to wind, looting transportation and panel izing. ‘The strcture shall be designed with dimensions large enough 10 contain all equipment, Instrumentation and piping including adequate space for operational and maintenance sees. [General Matera oF —] Comal wm 12 gauge oF Sam 316 sanless ses! materials Veldng shall be continuous and spot welding shal ot be acceptable [gh stan loti | [Degree af rowction | At east IP-4 1 IBC 529 ‘Sun Protetion ‘Sun shields shall be proved for optimal shade fom the san during the hotest periods oF hed Panel Ceriictions62 Panel shall be lockable by key-lck. Skid 10 be lied shall be supplied with our pad eyes adequately designed and propery spaced ro ensure safe lit without easing any dstrton in panel. Where a spreader bar or spreader frame is required, the Vendor shall include, is fabrication and supply in ther design and seope of work, including any required shackles and slings. {A drainable rip tay must be provided under the non-slip grating Rao, The drinable display shal be sized to hold the contents ofthe reservar Please no that H2S & CO2 may increase uplo 13% and 15% with some water contents inthe insrumeat gas supply. ‘Component Mentifcation Al components and equipment inside the panel shall be clearly identified witha ue-ply \hitetblac/white laminated plastic lab! displaying tag number, service and working pressure. All labels on te outside of the panel sall be stainless sel, The hydraulic bulkhead fiings shall be identified with a fed tag number, Different working pressures shall be clearly identified at entry and ext points Following knobs colors shall be prefered, + Openistat Green + Close’Stop Red + ESD Red © ESDRest Black Air Filtration for Panel Supply Fier with 25 um iter clement and auto drain fility Foe panel supply’ shall be installed. “Material shall be SS 316 (Body & bowl) and NACE compliant. It wil ensue removal of guid and solid particles. Bow capacity shall be minimum 8 lid ounce (0.28 lie) Service lif indicator tums from green to red when the fier element needs to be replaced, ‘Other detail & quantity are mentioned i the BOM under section 11.0. Internal Tubing and Compression Fittings 4) Internal Tubing All tubing stall be aecording to ASTM A269, 31685 seamless, Tubing must be suitable forthe operating pressures & temperatures required bythe specifications. ll ting inside ‘ofthe panel should be 3/8 size, ) Instrument Tubing Fitings “Tube tings shall be twin ferrule compression type 316 stainless steel Parker “AI, ‘Swagelok or HOKE Gyrolck (or equivalent) and shall be installed in accordance with ‘manufacturer’ instretons.0 mM maa HYDRAULIC CONTROL SYSTEMS Hydraulic Power Units (HPUs) ydraulic Power Units are required forthe Welthead Control Panels. The Hydraulic Power Units shall be designed withthe general considerations as outlined below. Minimization of Contamination Contamination ofthe hydraulic system shall be minimized by giving consideration tothe following:- ‘+ Components shall be selected which can be easly cleaned and do not generate ‘contaminants. ‘+ Fitration provision shall be adequate and shall be situited fo give the most effective Protection, dein points or means of flushing ol circulation shall be provided through dead sections ‘Sampling connections shall be fited at required points around the sytem. Hydraulic reservoir salle filled via filtration unis + Packing shall be ofa non-fbreus material, Cold couplings shall be use. ‘Sample points shall be provided for regular monitoring of contamination levels and system Arsinin, Sampling procedures sal be provided bythe Vendor. Semple points shal ake the form of a capped isolation ball valve installed at suitable points around the compete Hydraulic system, (Consideration shal be given to possible contamination caused by dus reve side sand ‘Materials and Coatings {Care shal stake in the seletion of materials used within the Hy draulc Control Sytem to Iinimize conosion effects induced by process conditions, environmental conditions and ‘combinations of dissimilar metals, Allitems onthe Hydraulic Conta System that are expose to the environment shall be ofa nomcorroding material. Where aluminum is proposed, the Vendor shall submit to the Purchaser for approval of protective finishes that provide lng term corrosion prevention ‘This sll include all threaded pats, packing glands and materials required for the mounting of accessories ‘+ Cadmium plating or galvanizing shall not be use for any component. Hydraulic Faia Vendor shal specify hydraulic uid suitable for the application.744 Reservoir Tank ‘The resevoit tank shall be Fabricated fom type BL stainless stel to reduce the rsk of ‘uid contamination. The reservoir shal be designed to prevent any build-up on the bottom and shall include a lage acess covert facilitate cleaning and inspection, Reservoir volume capacity “4S Lite ‘Level gauge shall be provided with markings indicating: ‘Mas fil evel (system de-pressurzed) + Low level alarm point Allrequired instrumentation shal be adequately provided with fsolaton valves and drains to allow removal without draining the reser ‘The reservoir shall be adequately vented to allow unrestricted level variation due to secumulatr and actuator volume changes, ‘The breathers shall have a flow eating large enough to prevent presse rise inthe reservoir during an ESD and have adequate micron rating to prevent the ingress of contaminants fom the envionment “The reservoir retur lines shall be long enough 1 extend to below the reservoir Mud 19 prevent foaming. The retum lines installation shall be provided with an ant-spho hole 19 ‘prevent he reservoir draining through siphon action when the retum lines are disconnected a either the skid limit ora the wellhead actuators Allreservoir drain and fil lines shall be piped tothe imi ofthe skid and be clearly identified. ALA ines shall have stainers ited to prevent contamination Level sith shall be installed for the level status of hydraulic reservoir. 4. Hydraulic tank consist of Reservoirs supply turn Reservoir Total Volume aS ites Bale Level switch ves No evel Gauge ves No Outlet point ves No Return point No ves Drain valve ves No Flame Arrestor ves No Air Breather ves No 745 Di tra V ‘Two irectional High Pressure Contol Valves (POV | and POV 2) sal be installed on both hydraulic lines to SSV and SSSV. These valves wil be ir pilot operated These valves shall ‘be configured in the fllowing manner= we 16|. On supplying sic supply, these high pressure dection contol valves will pass the hydaulie oil fom respective pumps to SSV and SSSV. 2 On sirsupply cutcf, these high pressure diction control valves will ret the hydraulic il released by SSV and SSSV to the reservoir tank through retuen fines, Vendor ean also quote quik exhaust valves forthe retum of hydraulic il released by SSV and SSSV to the reservoir tank through retum ines. Type Tigh Pressure Dirstonal Control Valve 3 ort 2 postion, Normally closed Wated Pars ‘SS Material Taput Pr Pressure Peumatic Air Supply (10 bar) Tiydraule Tnpuoutpu presse | 0 bar Cetfction NACE Bidder can provide similar solution but OGDCL reserves the ight fo ascept or eect the solution without assigning any reasons Pacumatic Driven Hydraulic Pumps & Hs Hand Pus ‘Wellhead Control Panel shall have fllowing pumps 1. Preumatic driven Hydeaule Pump for SSV 2, Preumatc driven Hydraulic Pap for SSSV 3. Manual Hydraulic Hand pump ‘wo pneumatic driven (gas powered) hydraulic pumps shall be NACE compliant. Pane ‘mounted ar regulators will control the pump discharges at the desired operating pressures ‘The capacity of the pumps shall enable the whole system tobe lly charged within minimum time, when re-commisscning following a shutdown, A manual hydaulc hand pup sal be connected othe hydraulic ystems fr test purposes, Priming and system purging. In case of malfunction or maintenance of any pneumatic riven !nydauli pump, this manual hydraulic pump will be used to maintain the desired hydraulic pressure to SSV or SV. Pressure Rating of Hydraulie Pamp for SSSV ~ 10,000 pst Hydraulic Pamp for SSV_= 4000 psi Discharge pressures shall be in adjustable range in accordance with the SSV & SSSV Pressures, Data set of pneumatic diven hydraulic pumps sas fallows= Type Pheumatc Driven Rydaule Pump [ Wetted Paris [8 Materiat Tape Preumati Ate Sopp Ourpar Hiydraulie OT (Cenfcaion | ATEX & NACE Pg? yt‘Manual Hydraulic Hand Pomp, Data sheet of manual hand pump ia follows Tre Tiaraule toagh Rand par Pressre Rating 10,000 ps Piston diameter T2 inch Volume per stroke (039 Cu-Trsh Handle Lever Lad Per 100 pat [123 Lbs Output Hydraulic O1 7.1.7 Separate Hydraulic Lines to SSV and SSSV. ‘Separate hydraulic ouput ines from Pacumatic driven Hydraulic pumps for SSV and SSSV is mandatory 7418 Hudraulic Accumulators ‘Two Hydraulic accumltors inthe SSV and SSSV loops will compensate changed system pressure tht made by micro leakage and expands wih het and contacts with cold. At the same time, they can reduce impact influence that caused by hydraulic pump operation and reduce the tar-up of hydraulic pumps. Other dtl qusntity are mentioned inthe BOM under section 11.0. 7.19 Hydraulic Oi! Filters and Suetion Strainers Hydraulic Oil Filters with builtin differential pressure gauges shall be installed at the Hydraulic output lines coming from Hydraulic reservoir tank before etch pump. To isiltate ‘one mainienance, the fier shall be capable of being isolated and replaced without Shutting dvin the complete system, ‘The fer shal be manufactured in stanless stot 05 hydraulic ol filters shall be require forthe hydraulic ilration process & monitering. Complete etal (Make, Mode, Partnumber with supporting literature) shal be provided in the technical bid, wetlon Strainers Suction strainers (¥ type, $8316) sal be il ters atthe ‘Hydraulic output ines coming from Hydraulic reserve tank, nd each shal be capable of being sot and drained without shutting down the complete sytem. (03 Yaaype suetion strainers shal be required before esch pump forthe hydraulic ftration process80 at 83 OTHER VITAL COMPONENTS Control Valves ‘These valves can be actuated bya pilot signal or manually by pling the knob when there is no pilot signal 3 way or 4-way type can be used for creating the required logic of netionality. Other details & quantity are mentioned in the BOM under seton 11.0 ‘solation and Non-return Valves 2) Isolation Valves All equipment installed on headers operating at pressures greater than 290 psig shall be installed as follows (Must be showa on P&ID):- ‘+ Instrument & Pressure Gauges Double Block and bled valves 4 Allsher Servioeble tems Double isolation valves >) Common Mode Failure ‘The failure of any common component shall not cause the flue of any other hydraulic circ. Examples of such tems include, but are not limited tothe allowing: + Fillers Regulators ‘+ Non-retuen valves Indications (First Ou “First Out” status indications on any shutdown condition shall be provided locally on main contol pane o guide the operator to know the reason ofthe shutdown, Spectieations ae as fallows:- ‘Construction: | Body: 316 sajalow wel, Seals FRM (Foweaibony ‘Lens: Polycarbonate (sealed to prevent moisture inrusion) NACE Compliant Aetwation | Pilot Functions | Status Tear Servee: toa manimom 200 pa CS har) Tndicators Mowat Panel mount Indicator displays a greenfield when a minimum of 8 psi to a max of 200 psi is present. ‘Complete os of pressure causes the indicator wo dsplay a refed, mated with recognition character “R. Minimum of Fusible Loop, ESD Loop, Flaw-line Pre Low & Flow-line Pre ih Indicators must be available on the font panel. Other details & quantity are mentioned inthe BOM under section 1.0, wtry as 86 7 Solenoid Valve EEX‘U' type, 3-way Solenoid valve with terminal box should be used. Body should be suitable for Zone 1 and gas group IA and temperature lass T3, Solenoid vent should be extended vertically up oa safe distance. Solenoid valves shall operate at 24 VDC soppy nd shall below power type, For Remote shutdown, solenoid valve shall be utilized, Data shoei as fllows “Type ‘Explosion Proof 3way solenoid valve Material Suitable forZone 1 & Group HA Power Supply 24 voe ‘Other dtl & quantity are mentioned in the BOM under section 11.0. ‘Bleed and Drain Connections Bleed connections shall be installed atthe highest points within the panel to ensure that ‘entaned ar canbe vented. A drain connection shal he installed atthe lowest point within ‘the panel. Vents and din shall have valve and plug Ball Valves Alltall valves to ensue quick ction and a positive leak proof shut-off. The complete valve consruction shall be 316 stainless tee. Al valves getting pneumatic supply must be NACE compliant, Other dtl & quantity are mentioned inthe BOM under sei 11.0. Pressure Gauges Indicating pressure gauges shall be of heavy duty, guid filled and precision ype. All gauges shallbe equipped wit ablow-out salt 18x psig). They shall beso nstaled hat mounting arrangements d not prevent the fanetoning ofthese blowout devices, Cubicles mounted gauges shall have 2-1 numerals als minimum, Dials sal be white with Back The blowout features described above are requir. Material for bourdon tubes shall be sulle for wet sour gas services. Pressure gauges for pulsing services shal havea hela srless type movement with micro range ajustment and dampener. Dial Sze 3-12 inch wih shaierprooF alas Pressure Range Varies depending on pressure loop. ‘Material 316 Stainless steel wetted parts & 304 wanes Stee case and bayonet ing. All gauges on | pneumatic ines must be NACE Compliant. races Conneston ‘Gauges mounted on the pane! front shall have back Tiguid Filed Yer ‘Aceuraey = Por span a) age205 89 810 sat Bidder to provide complete details of pressure gauges with make, model, part number, specifications & supporting literature inthe technical bid Pressure Relief Valve Pressure relie'valves shal be installed & configured in aeessible locations to relieve excess pressure in the hydraulic ines ino the hydraulic ol tank, To allow a controlled build-up of Pressure for normal opening of the subsurfice safety vale and the surface safety valve, ‘manually adjusted pressure eyultors and pressure gauges shal be installed in the hydraulic supply ines tothe SSSV and SSV. Valve constuction shall be 316 sinless tel & NACE ‘compliant. Other details & quantity are mention inthe BOM under section 110. Check Valves Chock valves shal be installed in the hydaulic/pocumatc loge supply ines to contol the leakage of hydraulic ui/pneumatc signal in the event ofa pilot ine break. The complete valve construction shall be 316 stainless steel. All valves on the instrument fines shall be [NACE compliant. Other deals & quantity ae mentioned inthe BOM under setion 11.0. el Mounted Pressure Regulators Four Panel mounted pneumatic pressure regulators with control knob shall be insalled on the font panel to control the input ar supply of Pneumatic driven hydraulic pumps for & desired output pressures to SSSV and SSV, One forthe main supply and one forthe complete Pocumatic loops. Body material & range spring shall be SS-316, Pressure range skal be upto 200 psi. These stall be NACE compliant. Explosion proof Junction Explosion proof juneton box (SS-316) shall be installed on the side of WHCP for the ‘omections of switches & transmiters. I shall be Suitable for operation in Class I I Divison 2. Cable entries, cable gland types & other accessories will be vendor recommended according to the zone classifications. Degree of protection shill be 1P654 Quantity is ‘mention in BOM under section 11.0 wv90 94 92 Loose Items Fusible Plugs ‘The wellhead shall have dual fusible plugs, strategically located in parallel, o form a common ‘contol pressure in. Fusible lugs act as fire sensors and sensing ofa fie will melt the fusible lug. Venting of the conto pressure shall shut the well. Quantity is mention in BOM under section 11.0. Spees are as under= Constustion AISTST6SS ‘Maximum Ambient Temp. | 60 Deg ‘Maximum Thread size Ta NPP only Material 36S Maximum Presure 300 pat Adjustable | Rieing Point ~~ 90 deg I High Low Pilots ‘The SSSV and SSV shall be controlled by a block and bleed HILO ples. The two pilots shall ‘be mounted ona manifold block, to sense a common pressure (pipeline pressure). One is se to ‘monitor low pressure & other high pressure. Under normal cantons these plot valves shall ret the control pressure othe interface valve to allow passage of hydaulic power tothe valve Actuators, thus causing ito open. IF either a high or low limit i reached, the respective pilot blocks te inet side and bleeds the control pressure, thus allowing the hydraulic id pressre ‘0 relieve to the return header; esl in oss of both valve actuator pressures thus provide a failsafe shutdown ofthe system. On los of hydraulic pump pneumatic soppy or on loss ofthe hydraulic supply Hine pressure tothe actuators the valves shall move tothe close position, Some specification areas under { Gonsinction ~~) 316 $$ wth NACE Compliant] “Temperature Range ~3D TO F350 deg. F Design Pressure ( manifeld assmBly | 5000 pat 4 ‘Operating Pressure Range 200-2500 pat 4 Pressre Range of Lo Plot T00= 1000 pa Adjustable ‘Pressure Range of Fi Pile 1500 = 3000 pat Adjustable ‘SetPoint Repeaiabiliy FoF Set presure Quantity is mentioned in BOM under seston 11.0,93 94 os Instrument Fitting “ube fitngs shall be win ferule compression type 316 stainless steel Parker “AVlok, ‘Swagelok or HOKE Gyrolock (or equivalent) and shall be installed in accordance with ‘manufacturers instructions, All instrument ting & iting insidelon the panel ae inthe vendor's scope of supply. Supplier shall slso provide instrument fitings as loose for external use between WHCP and SSSVISSVIESDIMi:Lo Pilot et ‘Quantity 1s mentioned in BOM under section 11.0 External Instrument Tubing All external tubing shall be according to ASTM A260, 3168S seamless. Tubing must be stable for the operating pressures & temperatures required by the specifications ‘endar shall provide loose tubing (1/4" x 0.065 wall thickness Tubing 3168S) for each ‘wellhead contr! panel for conneston between WHCP, SSVSSSVIESD (Qty mentioned BOM under setion 11.0, ‘Spare Parts for 02 year Operation ‘Vendor shall prove & quote spares [5 ses of seals for pneumatic driven hydraulic pump for ‘S8SV, 5 sets of seals ar pneumatic driven hydraulic pump for SSV, 5 sets of seas for hydraulic V, 1 Panel mounted pressure gauge for SSV] agus each WHCP, required fortwo years of operation. and pump, 20 pes of ol ters 01 Panel mounted pressure gauge for All spare parts furnished by the vendor shall be wrapped and packaged so that they willbe preserve in original in new condition under normal storage conditions for min 03 years and shall be propery tagged and coed so that later dentiiatons as to intended equipment usage wil be faite, They shall be pocked separately clearly marked as “spare pars’ and shipped along withthe other equipment, Bidder shall provide itemized peices ofall spars in ts financial bid with male, most, part number & specifications. Cost of Spares stall not be the part of financial evaluation; however OGDCL wil reserve the right to drop all spares without assigning any reasons, pt100 PAINTING AND PREPARATION FOR SHIPMENT. ta PAINTING Supplier standard procedure in accordance withthe relevant industy standards for suitable protection and paint shall be followed 102 PREPARATION FOR SHIPMENT ‘The Supplier and any: sub-Supplie shall comply with standard procedures for preservation and packaging and will dispatch with proper marking and documentation. “The Supplier shall take al precaution deemed necessary for protection during shipment and additionally during storage in a marine envionment including the Following A A desiccant shall be provided inside all enclosures 1 prevent damage by high humidity. The Supplier shall supply a recommended procedure for longterm storage (up 1 36 mont), Equipment shal be suitably picked in a wooden crate such that damage during Shipment due to distortion canbe avoided Bach individual carton or box shall be marked the top and side ofthe arto. the instrument tag No. on All ports and openings shall be sealed. Threaded connections shal be protected ‘with metalic caps o plugs. Line connections shall be covered with wooden, plastic o metal fiction plugs, ‘aps or anges to exclude foreign material rom the interior of the valve and 0 Tully protect the fees of te Nanged valves from damage during shipping, Machine surfices which may be exposed to the atmosphere in transit and subsequent storage shal be protected with an easily emovable ust preventative coating applied by the manufacturer, but not wntl inspection, if equied, has been completed. Handling ofthe equipments shall be cated outwith bes industrial practices, t0 avid damage due to rough handling. age 2410 BILL OF MATERIAL FOR WHCP Detals of fllowing minimum BOM is under- SNe. | Tem Tait | Ow T Details of following minimum inside BOM for each WGP I as under equiite minimum of folowing | Weiiead Contra Pane witha equ Internal accessories: 1. Pneumatic driven hydraulic pump for SSSV, NACE compliant, ydraulic 0/? Pressure mentioned in section 7.2.6, Qty: 01 2. Pneumatic driven hydraulic pump for SSW, NACE compliant, Hydraulic 0/? Pressure mentioned in section 7.2.6, Qty: OL "Manual Hydraulic pump, Pressure 10,000 psi, ty: 02 4, Static Pressure gauges for pneumatic systom, 2-1/2 inch dat size, Panel mounted, Lguld lle, 1% Accuracy, $5216, Pressure 250/300 pl, NACE compliant, ty (010) [Distribution Main ‘uoply, Supply pressure of Pump 1 (03), Supply pressure of Pump 2 (01), Complete ESD Loop (03), ESD Staton loop (01), Fusble plug loop (01), HiLo Plots in and Out (02), Supply ressue to Pilot Operated valve POVI (01), Supply pressure to Pilot Operated valve POV2 (01), 5. Static Pressure gauges for hydraulic line system on SSV & SSSV ‘ine (1, 42}, 2-1/2 inch ial sie, Panel mount, igi filed, 1% Accuracy, $5316, Pressure: 6,000 psi, ty (02)~ Distbutlon Immediate Outlet of Preumatic driven Hydraulic Pump 1 (ty: 03), Immediate Outlet of Plot Operated valve on hydraulic tine to SV aty (02) 6. Static Pressure gauges for hydraulic ine system on SSSV tne (H3,H4), 24/2 inch dal siz, Panel mounted, Liquid filed, 1% Accuracy, $5316, Pressure: 10,000 psi, ty (02) ~[Distiution= Immediate Outlet of Pneumatic driven Hydraulic Pump 2 (Qty 1), immediate Outlet of Plt Operated valve on hydraulic line to sssvaty (03)} 7. Hydraulic Oi iter with bulin Differential pressure gauge, Qty: 3 ‘8. Instrument After with automatic drain, 3165S, Nominal bow! size:8 uid ounce 0.24 ier), 25 ym filtration, NACE compliant, any: 02 9. Instrument Air Pressure Regulator (PRI, PR2, PRS, PRA), Pane ‘mounted, $5336, NACE compliant, Supply Max: 250 psi, Output: (0-150 ps, Adjusting knob has snap ation lack, Qty: 04 30. V-4pe Staines Stel Suction Strainer with end cap plug. Qty: 03 we | age 2si wv. 23 4 15. 16. 18. 19. 20. 21. 22 23 24, 25. 26. 2. 2, a1 Double block & Bleed valves for pneumatic gauges S36, Pressure rating: S00 ps, Qty 01 Double block & bleed valves fr Hydraulic gauges on SSV line, 55316, Pressure: 8,000 ps, aty 02 ‘Double block & bled valves fr Hydraulic gauges on SSSV line & ‘manval pump line, $8316, Pressure: 10,000 ps, Qty 02 Solenoid valve (53,24 VOC, Normally closed, NACE, I energized, cutoff the st supply, Qty O2 Solenoid valve, 24 VOC, Normally Open, NACE, If enerized, pass the ar supply, Qty 02 ‘Check valve for pneumatic loops (C3), min. 500 ps $5316, NACE compliant, Qty: 03 ‘Check valve for hydraulic loops after pump (C2), $5316, pressure rating: vendor recommended according to max pressure of respective pumps, Qty: 03 ‘Check valve for hydraulic loops before pump (2), $-236, pressure rating: vendor recommended according to max Pressure of respective pumps, Qty: 03, Ball valve in pneumatic loops (81), 2-way, S636, $00 pl, NACE, ‘ay: 25 Ball valve at reservoir tank on return input in (22), Pressure: according to the loop pressures from SSSV/SSV, 55-316, Qty: O1 Ball valve on SSV,SSSV hydraulic loop after pumps (83), 32,000 sl, Qty: 06 Ball valve before hydraulic pumps & on reservoir tank, pressure: according to the lop pressures (output oops), $8316, Qty: 15, "Needle valve on pneumatic loops (NI), WACE, 500 ps, Qty: 07 "Needle valve on SSV line (N2}, 6,000 psi, Qty: 02 "Needle valve on SSSV tine (N3}, 12,000 psi, ty: 02 Inernal /5-326 Instrument Tubing with connectors, ty: 3 Lot Reservoir tank 45 l, $S.316 materi with S/S breathe, Fl cap and Stainless tee level gouge, Qty: 02. Level switch for eservoir tank, side mounted float type, Stainless ste! sensor, explosion proof, Qty: 01 Pilot/Manual Operated spring return valve, 300 psi, NACE, (SRVL & SAV2), Knob color One Red & One black, Qty: 02 Pilot Operated Directional Contra valve, 3 port 2 position, 300 si, NACE, [POV3, POV, POVS, POVS, POV?) ty Os Pilot operated High Pressure Diectional Control valve for SSV line (POV), with manual bypass, Plot supply 10 bar, 10,000 pst hydraulic inputvoutpu pressure, 3 port2 position, narmally closed. aty:01432. Pilot operated High Pressure Directional Conta valve for S850 Fine (POV2), with manual bypass, lot supply 10 bar, 15,000 psi hydraulic input/output pressure, 3 port? position, normally Closed. ay: 02 33. Flow Control Valve on pneumatic tine for $V closure delay, ‘5326, Max working pressure: 150 ps, Set @ 30 seconds, ty: a 34. Air Reservoir Volume bottle, O.3+Litre capacity, 200 psi, $5216, ays 01 35. Pheumatic elie valve, NACE, Adjustable, $0-300 psi, aty 02 36. Hydraulic el value, Adjstabe setting according to output pressure rating of pumps in their respective loop, vendor recommended, Qty 02 37. Hydraulic Accumulator for SSV line, pressure rating 10,000 ps, capacity: 316 Staines steel body, other details: vendor recommended, Qty 01 38, Hydraulic Accumulator for SSSV line, pressure rating! 15,000 psi, 316 Stainless steel body, ther detals: vendor recommended, yor 39, Fist Out Loop Status indeator, Red/Green, Sody: $5316, Panel ‘mount, NACE compliant, Indiestoresplays.a green leld when a ‘minimum of psi toa max of 200 pis presen. , Complete loss ‘of pressure causes the indicator ta display a red fed, Cty 04 40. Pressure Transmitter, Explosion proof, Wetted parts $5336, Pressure equivalent tothe max output pressure of pneumatic riven hydraulic pumps, 20VDC, Body & wetted parts: 316 stale see, IP6S+, NEMA AX enclosure, Qty 02 41, Adjustable Pressure Suitch, Explosion prof, P65, 316 S/S. Body, 326 Stainless ste! wetted materials, NACE compliant, pressure range: 250 150 psig, Qty: 03 422, 2 WAY Manual Pushbutton vale to charge, $5316, NACE, Pressure rating: 230 psi, Qty 0% Plugs! High Low Pi 8) Fisible Pgs, SS3T6, Melting point 90 degC, Max pressure: 300 pst | No. | 30 Paeumaic ESD Siaton, S316, Valve We. | 1 ”) High Low Pos, Two biosk and Died FI-LO pilots, 31688 with | Na.) 13 NACE Compliant, Design Pressure (manifold assembly: $000 pi, Operating Pressure Range: 200-2500 psi Tasturnent Tubing, SS-3T6, Size WA", 065 wall kes ‘eis | 3000 (Required between WHCP and SSVISSSV/ESD Staton Fusible 8 Paget ZeTnstrument Frings & Valves #14" LH" Male Elbow, $8316 Qy.10 #14" 1" Male Connector, $8316 Quy. 10 + 1/4 Mate Run Toe, 8-316 Qy. 05 + VA" Union, 85-316, Qy. 10 #1 Front Ferme, 8-316 Qy.20 + U4" Rear Ferule 85-316 Qy.20 Ball Vale for connection to Hi-Lo Piloe from Well pipeine, Pressure Rating: 3000 psi NACE compliant, $S- 316 99.01 ‘Explosion proof Tuneton Bax (placed in SIS box as mentioned Ta DWG in section 6.1), IPOS, for al electrical connections Two Yeas Operational Spare Parts [5 sts of eal for peutic ‘riven hydrauic pump for SSSY, 5 ses of seals fr pneumatic driven hydraulic pump for SSV, 5 sets of seals fr hydraulic hand pump, $ pes ofl fiers}12.0 FUNCTIONAL AND PERFORMANCE TESTS Functional & performance tet ofthe WHCP sal be carried out a vendor's facilites with input and output simulation. Maximum period for Functional & performance tests shall not exceed 08 working days. he complete panel with al equipment installed and connected shall be pressute tested for {any leak inthe system. The hydraulic lines shal be pressure tested for 24 ours a maximum ‘operating pressure using the specified hydraulic Mud, The pneumatic ines shal be leaked- {ested o 220 psig sing SNOOP quid o equal ‘The complet system shal be tested in two sages: i. Assembly level checks in acordance with the vendor's QA/QC plans and procedures. i. Functional & performance tes onthe completed system: Functional & performance tests shall include but mo be lined to i Visual inspection ii, Hydrostatic ests ii Hardware tests iv, Funetonal tests The offered system shal be visually inspected by vo OGDCL officials o ensure that it has ‘been constructed to the specications and othe approved drawings. However OGDCL. will Intate separate case for inspection of Functional & Performance Tests at OGDCL's own ‘envdoe wil submit the dese report of Functional & Performance Tess to OGDCL before shipment 13.0 ‘THIRD PARTY INSPECTION cTPh OGDCL will iniiate separate case for earying out Third party inspection of Wellhead ‘Control Panels at vendors site before shipment. The cost ofthe PI shall be borne by OGDCL. In this regard, bidder will confirm to cooperate and fciltate for carrying out TPL at vendor's ites. a140 VENDOR DOCUMENTATION REQUIREMENTS ‘Vendor shal provide 02 sets ofeach, both soft and hard copies, as under 150 Operation and maintenance manuals. Product catalogs. Installation Drawings. Panel Layout Drawings. Inspection and Test Certfcates. P&ID's ee i Pheumatc-hydraulic-lectrc schematic drawing (ta be submitted with he bid) vil. Complete component ist along with make and country of origin (tobe submited with eI 9 » ° » eo » » the bid, Dimensional drawings and weight information (tobe submited with the big). Product catalog including components details (o be submitted with the bi). A soft copy of, documentation shoul also be provide by the Supplier. TIONS. Packager Manufacturer must have a proven track manufacturing record of Wellhead Control Panels overa minimum period of ten (10) years. Package Manufacturer must have also a proven tack sale record of over 500 similar wellhead control panels, Bidder is requized to submit documentary evidence (purchase orders) inthis regard, otherwise bid willbe rejected Packager ‘Manafactarer shall provide warantessuarantees regarding the performance of |WHICP acconding tothe tender specications Packager! Manufacturer shall be responsible to ensue the delivery of complete material ‘within O4 Months after the establishment of LIC. Pockager/Manfictrer shall be responsible to provide Original Testing and Calibration Centfcates ofthe equipment. Package/Manufacturer shall provide Certificate of Origin, “The Packager! Manufacturer shall ensure that all maeralbeing used inthe WHCP shall be new and ee of defets in any way. For specications, most stringent clause shall preva “The Packager! Manufacturer shall submit complete P&ID ofthe process i technical bid {epiting pumps, instrument & hydraulic tines, Hydraulic reservoir, suction strainer, ers, bull valve, solenoid valves, Plot operated valves, Relief valve, check valve, pressure uees, First out stauis indicators, HsLo Pilos, Fusible plugs, aecumlator, Interface ‘vale, pressure regulators, time delay crit, First ou indicators ee Bidder shall submit complete details of all items with make, model, part number, specifications & supporting literature in the technical bi. Non-provision of desired Information may lead to disqualification ofthe bi,* ANNEXURE-Y, se Na -& Description of Suppl Name Address guint Country “nn email of Bayer o Year OF | Contract fay | Sinn | ate Details & Desrition ‘of Scope of Supply & Responsibites (7) Please st eum frig hme cor) order firs flowed by Pakistan ad other counties ore: ‘Please as provide Uist ofeurrem onder for Supply, Installation & Commissioning of Wellhead Conirl Panel on the above pater