VECO Doc. No.

20298-00-EJ12-101
Project Title

MEHAR GAS DEVELOPMENT PROJECT

Area Location Discipline Document No. Rev. Page
12 MGDP I 1045 0 2 of 26

TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 4
1.1 General............................................................................................................................................ 4
1.2 Scope............................................................................................................................................... 4
1.3 Definitions....................................................................................................................................... 4
1.4 Abbreviations ................................................................................................................................. 5
1.5 Environmental Conditions ............................................................................................................ 5
2.0 CODES AND STANDARDS ................................................................................. 7
3.0 SCOPE OF SUPPLY............................................................................................. 8
4.0 FUNCTIONAL REQUIREMENTS ......................................................................... 8
4.1 General............................................................................................................................................ 8
4.2 Operating Philosophy.................................................................................................................... 8
4.3 Opening / Closing Times ............................................................................................................... 9
4.4 Opening and Closing Sequence................................................................................................... 9
4.5 Interlock, Shutdown & Override Requirements ........................................................................ 10
4.6 Choke Valve Operation................................................................................................................ 11
4.7 Indications & Controls................................................................................................................. 11
5.0 DESIGN & CONSTRUCTION ............................................................................. 13
5.1 Panel Construction ...................................................................................................................... 13
5.2 Hydraulic System ......................................................................................................................... 15
5.3 Main Reservoir ............................................................................................................................. 16
5.4 Hydraulic Pumps.......................................................................................................................... 17
5.5 Accumulators ...............................................................................................................................18
5.6 SCSSV Return Tank / Hydraulic Quick Exhaust ....................................................................... 19
5.7 Hydraulic Components................................................................................................................ 19
5.8 Instruments & Electrical Components....................................................................................... 20
5.9 Junction Boxes ............................................................................................................................ 21
5.10 Power Supply ...............................................................................................................................22
5.11 Nameplates & Labeling................................................................................................................ 23
6.0 INSPECTION & TESTING .................................................................................. 23
7.0 INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING .................. 24
8.0 DOCUMENTATION............................................................................................. 24
9.0 QUALITY ASSURANCE / QUALITY CONTROL................................................ 25
10.0 SPARE PARTS & SPECIAL TOOLS.................................................................. 25
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Project Title

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Area Location Discipline Document No. Rev. Page
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11.0 GUARANTEE...................................................................................................... 26
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Project Title

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Area Location Discipline Document No. Rev. Page
12 MGDP I 1045 0 4 of 26

1.0 INTRODUCTION

1.1 General
PETRONAS CARIGALI (Pakistan) Ltd. (PCPL) is undertaking the development of Mehar
Gas Field in Mehar Block (Block 2767-1) located in Sindh and Balochistan Provinces of
Pakistan.
Mehar Block is located in the Kirthar Fold belt area, in the Middle Indus Basin. Mehar
field is located about 190 km west of Sukkur and 400 km north of Karachi in Sindh
province (distances by road). The environment is arid and the terrain is mountainous.
Mazarani gas field, operated by PPL is situated about 25 km to the north, while
Zamzama gas field operated by BHP is situated about 70 km to the north of Mehar Field.
Mehar field consists of Pab and Ranikot formations. The wells will be connected to the
new GPF through a Gathering System. There will be a total of 6 wells (3 Wells from the
North and 3 Wells from the South). 3 Wells will be producing in Phase-1 and 3 Wells in
Phase-2 (future). ME-1 well is from PAB reservoir. ME-2 wells is from Ranikot reservoir.
Wells, ME-3, ME-4, ME-5 and ME-6 are dual completion.
PCPL intends to develop the Mehar Field by installing a Gathering System, Gas
Processing Facility (GPF) and Product Storage & Loading Facilities. The field facilities
will be developed in two phases, Phase-I and Phase-2.
Phase-1 development will cater for 55 MMSCFD of gas production and Phase-2 will
cater to 80 MMSCFD of gas production. The expected condensate production rate is
6600 BPD in Phase-I increasing to 7000 BPD in Phase-2.

1.2 Scope
This specification covers the basic minimum requirements for the Wellhead Hydraulic
Control Panel for the Mehar Gas development project.

1.3 Definitions

COMPANY Petronas Carigali Pakistan Limited

(PCPL) or any Third Party assigned by
the COMPANY
ENGINEER Party which carries all or part of the
design, engineering of the PROJECT.
VECO Engineering, Abu Dhabi is the
ENGINEER.

PCC CONTRACTOR The party which carries out all or part of

the design and engineering,
procurement, construction,
commissioning or management of the
PROJECT. PCC CONTRACTOR
includes his approved
MANUFACTURERS, SUPPLIERS,
VENDORS and SUBCONTRACTORS.
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MANUFACTURER/SUPPLIER/VENDOR Party/ies, which manufacture and/or
supply materials, equipment and
services to perform the duties as
specified by the CONTRACTOR in the
scope of supply.

PROJECT MEHAR GAS DEVELOPMENT

PROJECT

1.4 Abbreviations

ESD Emergency Shutdown System

FGS Fire and Gas

HP High Pressure

LP Low Pressure

MP Medium Pressure

PLC Programmable Logic Controller

RTU Remote Terminal Unit

WHCP Wellhead Hydraulic Control Panel

SCSSV Surface Controlled Sub-surface Safety Valve

SSV Surface Safety Valve

FAT Factory Acceptance Test

SPIR Spare Part Interchangeability Record

GPF Gas Processing Facility

PMCS Plant Monitoring & Control System

1.5 Environmental Conditions

Wellhead facilities, Gathering stations and Gas Processing Facility (GPF) area has been
tentatively selected at a location about 190 km west of Sukkur and 300 km north of
Karachi in Sindh Province. The environment is arid the terrain is mountain.

The Environmental conditions are:

Maximum Ambient Temperature : 55ºC

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Minimum Ambient Temperature : 0.5ºC

Wet bulb temperature (design) : 30ºC

Relative humidity (max / nor /min ) : 90 / 65 / 20 %

Direction of prevailing wind : From south to north

Wind Velocity (max / normal) : Hold / 2.9 knots

Elevation Above Mean Sea Level (GPF) : 54m (Site-IV) / 56m (Site-l)

Average barometric pressure : 1001.2 mbar (29.56 inches of Mercury)

Ice / Snow : None

Seismic zone : Zone 2B, upper moderate with ground

acceleration of 0.2(Hold)

Annual rainfall min. : 63.3 mm (year 2006)

Annual rainfall max. : 139.9 mm (year 2005)

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2.0 CODES AND STANDARDS

Codes, specifications and standards referred to within this specification, form a part of
the requirements of this specification in a manner and to the extent specified within
those codes and standards.

Unless otherwise specified, the latest edition or revision to these codes specifications,
and standards in force at the time of request for quotation and/or Purchase Order shall
apply.

No deviations from the Codes and Standards listed in this document will be allowed
unless such deviations are clearly identified in the bids, with the reasoning. In addition,
they must be approved in writing by COMPANY.

Where only British standards are quoted, other internationally acceptable codes and
standards may be put forward in lieu for COMPANY approval. All the applicable codes
and standards shall be of the latest edition at the time of order.

API RP 520 Sizing, selection and installation of pressure relieving

devices in refineries.

API RP 551 Recommended practice for process measurement

instrumentation.

API RP-14B Recommended Practice for the Design, installation, repair

and operation of Subsurface safety valve systems

API RP-14C Recommended Practice for Analysis, Design, Installation

and Testing of Basic Surface Safety Systems for Offshore
Production Platforms

API RP-14D Specification for Wellhead Surface Safety Valves and

underwater safety valve for Offshore Service.

API RP-14H Recommended Practice for Installation, Maintenance and

Repair of Surface Safety Valves and underwater safety
valves for offshore service.

IEC 60529 Degree of protection provided by enclosures

IEC 60079 Electrical installations in Hazardous areas (other than

mines)

EN 50018 Electrical Apparatus for Potentially Explosive Atmosphere:

Flame Proof EEx(d)

A 790 Standard specification for Seamless and Welded

Ferritic/Austenitic Stainless Steel Pipe.
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Area Location Discipline Document No. Rev. Page
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ASTM A-269 Standard Specification for Seamless and Austentic stainless

steel tubing for general service.

ANSI B16.5 Steel pipe, Flanges and Flanged fittings

ANSI/AWS D1.1 Structural Welding Code – Steel

3.0 SCOPE OF SUPPLY

Each well head hydraulic control panel package shall include the following as a
minimum:

• Well head hydraulic control panel including all required power, indications,
controls, and protections as detailed in the subsequent sections of this
specification;

• Controller / PLC to incorporate WHCP logic, for design and specification of PLC
PCPL document no. 12-MGDP-I-1046 shall be referred;

• All interconnecting instrument tubing & hydraulic tubing up to the bulkhead;

• RTU interface junction boxes;

• Framework or skid, if required;

• Four (4) field mounted Low-Pressure fusible Plugs through separate headers

• Three (3) ESD push button stations (loose supply);

• All other tools/accessories that are not specifically mentioned, but are required to
deliver a fully operational system.

4.0 FUNCTIONAL REQUIREMENTS

4.1 General

Proposed well head facilities are shown on P&ID drawings and the layout drawings
developed for this project. WHCP will provide for actuation of the following:

• SCSSV;

• SSV-Master Valve.

4.2 Operating Philosophy

The operation of Xmas tree valves shall be by hydraulic power supply. These valves
shall be controlled through electrical solenoid valves installed in the WHCP. WHCP
shall be provided with SIL2 PLC.
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When the wellhead valves are in operation, all devices on flow path (SCSSV and SSV-
Master valve) shall normally be in the energized / open condition and the hydraulic
system shall be in the pressurized state. Loss of hydraulic pressure or electrical
component de-energisation state shall close the respective valve.

Panel shall have in-service / wire line diverter valve and provision for connection of wire
line unit, to operate each of these valves.

Local and remote operations of the valves shall be as indicated below,

SCSSV OPENING: local manual only by the initiation of ‘open’ pushbutton

on the hydraulic control panel.
CLOSING: local manual by the initiation of ‘close’ pushbutton on
hydraulic control panel, remote manual by the initiation of ESD
pushbutton at the PMCS operator console and automatic closure by
the logic in the RTU.

SSV-Master OPENING: local manual by the initiation of ‘open’ pushbutton on the

Valve hydraulic control panel or RTU panel front & remote manual by the
initiation of ‘open’ pushbutton at the PMCS operator console.
CLOSING: local manual by the initiation of ‘close’ pushbutton on
hydraulic control panel or RTU panel front or push button at
Wellhead gate, remote manual by the initiation of ’close’ or ESD
pushbutton at the PMCS operator console and automatic closure by
the logic in the RTU.
Provision shall be made for closing the SSV when the signal from
one of the wellhead Pressure Transmitter (PT) deviates (high and
low) from the set point. The pressure transmitters shall have their
alarm status displayed on the WHCP along with reset push button.

4.3 Opening / Closing Times

The overall well shutdown time is within 45 seconds from the activation of the trip device.
Each hydraulic supply line to these valves shall include throttling valves for adjusting the
actuation time. VENDOR shall provide provision to adjust opening / closing time from
panel.

The actuator shall be spring to close type. Typical actuator volume is 1500cc (HOLD).
The control system shall be designed by the VENDOR to comply with the timing
indicated above.

4.4 Opening and Closing Sequence

Opening sequence shall be LOCAL MANUAL only (by initiation of panel push buttons).
Valves shall open in the following sequence with adjustable time delays:
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12 MGDP I 1045 0 10 of 26
• Surface Controlled Sub-surface Safety Valve (SCSSV can be opened
immediately after charging the low pressure fusible plug loops);

• Hydraulic SSV-Master Valve (typically after 10 sec of SCSSV opening).

It shall not be possible to open valve when the respective ESD situation is not healthy.

Closing sequence for total well shutdown shall be automatic in the following order with
adjustable time delay:

• Hydraulic operated SSV-Master valve (typically after 30 sec of wing valve closing)

• Hydraulic surface controlled sub-surface safety valve (typically after 30 sec of

SSV closing)

4.5 Interlock, Shutdown & Override Requirements

Interlock, shutdown and override requirements shall be as indicated below:

Initiator / Cause Action / Effect

ESD Pushbutton Total well shutdown (SCSSV + SSV)

Fire / Gas detection Total well shutdown (SCSSV + SSV)
SSV closes immediately. & SCSSV remain
Flow line pressure disturbance or remote
open (SCSSV closes only on low
well closing signal
pressure)
Close the SCSSV, closing of the SCSSV
High-pressure fusible plug in Hydraulic
shall result in closing of SSV from the RTU
supply line of SCSSV.
logic.
HP header pressure low Start duty hydraulic pump
HP header pressure high Stop duty hydraulic pump

A facility shall be provided to allow “out of sequence closing & opening” of the SSV and
SCSSV and shall be tagged Rigless Operation ON/OFF. When selected ON, the valve
shall be able to operate from the Wellhead hydraulic control panel only. This shall
incorporate a key locked mechanical local command override to prevent remote
operation of the SCSSV and SSV during wireline operation. This override shall prevent
any remote operation (i.e. well ESD) in order to avoid cutting of wireline. The key locked
wireline overrides shall be provided with a proximity switch and wired to RTU interface
junction boxes to indicate the override position. A common alarm will be sent to PMCS
from RTU. The following only shall be capable of overriding the wire–line lockout.
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• ESD at wellhead, Pig launcher and Wellhead;

• Fire at wellhead.

In addition to ESD push button on the panel, three (3) ESD push button stations shall be
installed at main gate, Xmas tree and launcher. The hand stations shall be supplied by
VENDOR & mounted on stand pipe by CONTRACTOR.

Hydraulic pumps shall be operated automatically based on header pressure transmitter

signal. Standby pump shall start if header pressure does not reach to PSH setting within
specified time. Starting of the pump shall be inhibited based on Low-Low level signal
from the main reservoir level transmitter. Duty & Stand-by pump shall operate
alternately.

4.6 Choke Valve Operation

Panel shall control wellhead choke valve using stepping action. For this hydraulic oil
distribution to the choke valve shall be provided. Pulsed output signal from RTU shall be
interfaced with the panel. The choke valve shall also be able to be controlled remote
from PMCS console by pulsed signal. This pulsed signal shall control the stepping
function with sufficient dwell time between each step to ensure full cylinder retraction.
Choke Valve position indicator (a 4-20 mA position feedback) shall be interfaced with the
hydraulic panel. Choke valve position shall also be interfaced with RTU. Hydraulic
supply pressure to choke valve shall meet the choke valve actuator output torque
requirement.

4.7 Indications & Controls

Panel shall control SCSSV and SSV-Master valve. Panel shall control the 2 valves, with
normally pressurized hydraulic signals through hydraulic tubing. The regulator knob for
all pressure regulators shall be located on the faceplate of the Panel.

Following parameters shall be indicated locally on the panel front, using local gauges (as
a minimum):
• Hydraulic Pump A discharge pressure;
• Hydraulic Pump B discharge Pressure;
• HP Hydraulic Header Pressure (HP);
• MP Hydraulic Header Pressure (MP);
• LP Hydraulic Header Pressure (LP);
• Fusible Plugs Loop Pressure;
• Hydraulic Pressure to SCSSV;
• Hydraulic Pressure to SSV-Master valve;
• Hydraulic Pressure to SSV-Wing valve;
• Main Hydraulic Reservoir Level;
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• Return Reservoir Level;
• Rigless Operation ON / OFF (mechanical override with castle key).

Following electric devices shall be installed on the panel front for local control, as a
minimum. These signals shall be wired to RTU interface junction boxes:

• OPEN & CLOSE Pushbuttons, one set each for SCSSV & SSV;
• Start & Stop push button, one set each for Hydraulic Pumps A & B;
• ESD pushbutton;
• Lamp for ESD station activation with reset PB;
• Local / Remote selector switch to allow remote operation from the RTU panel;

• Override Switch, one each for SCSSV and SSV (for in-service / wire line
diverter valve);

• Hydraulic Pump A&B Normal / Maintenance Switch;

• Open & Close Lamp one set each for SCSSV, SSV & Wing Valve;
• Start & Stop Lamp, one set each for Hydraulic Pumps A&B;
• Hydraulic Pump Fault indication;
• Lamp for indication of FP loop activation with reset PB;
• Lamp for ESD station, activation with reset PB;
• Flowline pressure high status lamp;
• Flowline pressure low status lamp;
• Reset pushbutton for flowline high/low pressure trip;
• Remote ESD Trip status lamp;
• Remote ESD Trip Reset pushbutton;
• Lamp Test pushbutton;
• Lamp Enable switch;
• Power ON & OFF lamps.
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In addition to above following analog signals / potential free contact shall be wired to RTU
interface junction boxes. Use of switches for status purposes shall be avoided; instead a
transmitter shall be used.

• OPEN and CLOSE indication for SCSSV (by monitoring the hydraulic control line
using a pressure transmitter);

• OPEN and CLOSE limit switches for SSV (supplied by others);

• Fusible plug low pressure (fire);

• Well ESD status;

• Hydraulic pump running status;

• Hydraulic Pump fault indication;

• Hydraulic oil reservoir level transmitter;

• Power ON & OFF status.

5.0 DESIGN & CONSTRUCTION

5.1 Panel Construction

a. The panel shall be complete with isolation valves, relief valves, check valves,
hydraulic control valves, pilot valves, lubricators, filters, pumps, pressure
regulators, ESD push buttons, tubing, fittings, pressure gauges, etc as required for
smooth trouble free and safe operation of the well.

b. Panel shall have SS316L cabinet weatherproof to IP-65 as a minimum with front &
rear access doors. Panel may be of welded construction with proper considerations
for the environment corrosion where it is to be installed.

c. Panel shall be suitable for Area Classification Zone 2 Gr IIA / IIB, T3 and
approved.

d. Panel shall be constructed using 316L SS sheets with minimum thickness of 12

gauges (14 gauges for doors). The supporting framework shall be using angles or
channels with 10-gauge thickness as a minimum.

e. Panel shall be provided with a perplex glass window on the front. All the doors and
windows shall be provided with mechanical door stoppers, pad-lockable handle
arrangement with three-point locking mechanism as a minimum. Door shall have
pocket for holding drawings. The panel rear door shall be designed with allowable
clearance 700 mm at the back of the opening.

f. Imperial tube sizes and double compression ferrule fittings with NPT threads in
316L SS shall be used for all panel tube work. Liquid sealant shall be applied to all
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threaded connections. All tubing fittings shall be installed with due consideration for
maintenance access. Tubing shall be supported, clipped to framework or spaced
by means of Imperial Eastman 'Poly-tube' brackets or similar.

g. All tubing, fittings and other components shall be designed for pressure rating of
10,000 psi;

h. The base of the panel shall be fitted with an enclosed drip tray to collect any
spillage of oil. The tray shall be sloped and fitted with 1”, ANSI 150#, RF flange
connection to facilitate draining from one corner.

i. The panels shall have proper lighting arrangement and auxiliary power socket. The
supply voltage for auxiliary socket shall be 24 VDC.

j. A rain canopy shall be provided over the panel for access under adverse weather
conditions. A sunshade shall be provided such that the panel is shaded for most of
the day. Canopy shall have a minimum extension of 18” from the panel edge to
provide shade to the operator.

k. Panel shall be provided with adequate corner supporting legs of 250 mm height,
suitable for installation and bolting on concrete foundation.

l. Lifting “Pad Eyes” fabricated of 316 SS, shall be provided at the ends of the panel.
Each pad eye shall be capable of lifting the entire weight of the fully assembled
panel. Special lifting arrangement if any shall be foreseen by the VENDOR and
provided accordingly.

m. A minimum of two numbers of external earthing bosses shall be provided for the
panel.

n. PLC controller shall meet ambient temperature requirement;

o. Well head hydraulic control panel and all field mounted equipment shall be painted
suitable to environment condition.

p. Panel, junction boxes and hydraulic reservoir shall be painted suitable for the
environmental conditions.

q. Each hydraulic line on the bulkhead shall have isolation valve accessible from
outside. All the bulkheads shall be tagged.
r. Components inside the panel shall be suitable for the continuous operating
temperature that may arise due to heat generated within and also ambient
conditions.

s. Panel shall have an inside lamp suitable for hazardous area. It shall not be
interlocked with the door switch; instead manual switch shall be provided.
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5.2 Hydraulic System

a. Hydraulic system shall consist of following as a minimum

• Two Hydraulic driven pump (One duty and one Standby)

• One Hydraulic Hand Pump

• One hydraulic Main reservoir (tank);

• One SCSSV return tank;

• All instruments and accessories such as regulators, check valves,

transmitters, gauges, relief valves, filters, flame arrestor etc.;

• Internal interconnection tubing and manifolds;

• Hydraulic accumulators;

• Quick-opening exhaust valves for all Xmas tree valves.

b. Hydraulic system shall be designed to provide power for the SCSSV and for SSV-
Master. VENDOR shall provide details of hydraulic thrust required for SCSSV &
SSV according to well shut in pressure i.e. 370 barg (5400 Psig). A pressure
reducing valve shall supply the lower pressure system from the pump discharge
and shall be protected by a relief valve;

c. Separate hydraulic headers shall be provided for the following:

• Operation of SCSSV;

• Operation of SSV-Master valve;

• Pilot control of Fusible plugs.

d. An additional inlet connection shall be provided for connecting external hydraulic

power source;

e. Each hydraulic output line (SCSSV and SSV) shall be provided with pressure
regulator and pressure relief valve;

f. Four (4) low-pressure fusible plugs shall be installed around well head. Fusible
plugs shall have a melting point of 255°F;

g. Each hydraulic supply line to two (2) valves and fusible plugs shall have its own
pressure regulator, knob of which shall be located on the faceplate of the panel
front. Vendor shall also provide adjustable regulation range;
h. All regulators shall have auto drain (bleeding) facility and drain line shall be routed
back to the hydraulic reservoir;
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i. There shall be a “in sequence and out of sequence” switch on the panel. Logic
shall be such that, in out-of-sequence mode only panel ESD push button shall be
active bypassing all other ESD;

j. Panel shall also have well start & stop push button. This push button will operate
the logic in sequence when “Local-Remote” switch is in “Local” position;

k. All three (3) valves shall have open/close indication lamps on the panel front;

l. Hydraulic system startup from zero pressure to operating pressure shall be within
10 minutes. Pump capacity shall be selected based on this;

m. Accessibility of the components inside the panel is very important and vendor shall
ensure that good accessibility for maintenance and operations;

n. The type of hydraulic fluid will be decided later. All WHCP hydraulic components
and tubing shall be suitable for the service. VENDOR shall include for the supply of
the first fill quantity of hydraulic oil in suitable containers for transportation to the
construction site. VENDOR shall supervise the partial filling of the system, with
sufficient hydraulic fluid retained in secure containers for shipping with the modules
for replenishment of the system following the hook-up of the wells.

The system cleanliness shall be:

SCSSV NAS - 1638 Class 6

SSV-Master valve NAS - 1638 Class 8
SSV-Wing valve NAS - 1638 Class 8

5.3 Main Reservoir

a. The main hydraulic reservoir shall have a capacity of 100 liters, minimum.
VENDOR shall calculate and design adequate capacity of the main reservoir,
based on the actual swept volume of the valves actuators and the requirements of
operation. The VENDOR is solely responsible for co-ordination with the
CONTRACTOR for obtaining actual actuator swept volumes for all valves;

b. The main reservoir shall be fabricated from AISI 316 SS and shall be equipped
with the following:
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• Liquid level sight glass indicator;

• Level transmitter for pump protection;

• Filler / breather and vent with flame arrestor;

• Magnetic plug located in the base of the reservoir to trap iron and steel
particles;

c. The level transmitter shall be D/P type. The level transmitter body, internal and
enclosure shall be in 316 SS. Level gauges shall be fitted with automatic and
manual shut-off valves to prevent loss of fluid due to accidental gauge glass
breakage. Also it should be possible to change the gauge glass without draining
the reservoir;

d. The main reservoir shall be engraved or labeled with the following level marks
adjacent to the level gauges:

• Max fill level (system de-pressurized);

• Min fill level (system in full operation);

• LSH alarm point;

• LSL alarm point;

• LSLL trip point (for both pumps run inhibit);

e. The LSH, LSL and LSLL shall be set accordingly in RTU logic, for alarming and
interlock functions. The low-level switch shall be activated (set point) when the
level is approximately 100 mm above the section line. Switch functions shall be
derived from transmitter;

f. The MP return lines from the Xmas tree quick opening valves shall have ¾”
connections and are piped with ¾” OD tube to the main reservoir;

g. Hydraulic reservoir shall have filling, drain and level gauge located outside the
panel;

h. Breather vent of the hydraulic reservoir shall be extended outside away from the
panel and shall not be kept below the canopy.

5.4 Hydraulic Pumps

Hydraulic pumps shall meet the following requirements:

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• Pumps shall be pneumatically driven. Regulators may be used to supply low
pressure gas for pneumatic control circuits.

• The hydraulic pump shall operate automatically. The pump run / stop status shall
be made available to RTU. Running hours of each pump shall also be recorded.

• Hydraulic Hand Pump shall be used to manually pump up the hydraulic system to
put the safety in service. This hand pump shall be used to re-open the valve
following a trip.

• It should be possible to isolate, reset, repair and test each pump independently.
Hydraulic pump suction pipe work shall have an OD of 10 mm, minimum.

• A selector switch tagged, “Normal/Maintenance” shall be provided. When

selected “Maintenance”, the pumps shall be able to operate independently of the
logic;

5.5 Accumulators

The accumulator size shall be optimized to act as a buffer and to cater for temperature
variation during day and night.

The accumulator shall be provided with the following minimum features:

a. Accumulator shall be designed to ASME section VIII, DIV-1 or BS5500 with the
design pressure identical to the hydraulic pressure circuits and temperature at
149°F. It shall be provided with pressure vessel code stamps;

b. Accumulator shall be bladder type, painted Stainless Steel. It shall be provided with
316 SS isolation valve and shall be mounted in the vertical position, on separate
skid to allow easy handling and maintenance;

c. Each accumulator shall be provided with a pressure gauge to indicate the pre-
charge pressure;

d. Each hydraulic header shall be provided with nitrogen pre-charge accumulators of

sufficient capacity for opening of wellhead SCSSV and SSV within 15 minutes
period, while the hydraulic pumps are not running, without dropping the hydraulic
pressure below pump start pressure set point (PSL);

e. Nitrogen pre-charge facility shall be designed by the VENDOR. A pressure gauge

to check the accumulator pre-charge shall be provided along with a charging kit.
Also, burst disc shall be provided to protect from overpressure;

f. VENDOR to provide the calculations for the accumulator capacity;

g. Accumulators shall be located outside the panel for easy lifting and charging;

h. Accumulator must be provided with pressure gauge.

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5.6 SCSSV Return Tank / Hydraulic Quick Exhaust

There is a risk of the hydraulic fluid being contaminated by the process fluid, in the
SCSSV circuit. Hence, the fluid from the SCSSV pilot solenoids shall be returned to a
dedicated SCSSV return tank. (The fluid return from the quick dump valve of the
SCSSV, installed at Xmas tree actuator shall be returned to a vent pipe located close to
the Xmas tree).

a. The minimum capacity of the SCSSV return tank shall be 10 liters minimum.
During detailed engineering VENDOR shall calculate exactly the required tank
capacity and design accordingly;
b. This return tank shall be equipped with a level gauge. This tank shall be fitted with
an overflow connection. This tank shall not vent within the control panel, but vent
outside and a flame arrestor shall be installed;

c. Provision shall be made to permit the SCSSV return tank contents to be drained to
the main reservoir after examination for contamination. In an event of
contamination of this return tank, it shall be possible to flush / drain the tank and
tubing for the same with isolation valve shall be provided, up to the main reservoir.
A tank top mounted duplex filter with visual indication for clogging shall be provided
on the return line to the main reservoir;

d. A hydraulic, quick-exhaust valve shall be supplied for SCSSV and SSV-Master

valve. The quick-exhaust will be loose supplied and will be installed on the valve
actuator by CONTRACTOR;

e. The hydraulic fluid return from quick-exhaust valve on SSV actuators shall be
individually piped back to the main reservoir on the wellhead panel.

The hydraulic fluid return from quick exhaust valve on SCSSV actuator shall be
terminated near the wellhead and be connected to a 4”x 12’, 316 SS vent pipe with an oil
collection facility. The height of the pipe shall be at least 10 ft above the Xmas tree and
be equipped with flame arrestor. VENDOR shall design the vent pipe and shall supply it
loose for installation by CONTRACTOR

5.7 Hydraulic Components

a. The wellhead hydraulic control system shall utilise suitable components, which are
field proven for hydraulic service in identical application. All components shall be of
AISI 316 SS, suitably rated for the service pressure;

b. Pumps, flow control valves, accumulators, solenoid valves, pressure relief valves,
regulators, gauges, transmitters and switches, shall be from client approved Sub-
VENDOR List;

c. The hydraulic equipment shall be designed and constructed to prevent entrapped

air in tubing or components and allow proper and complete expurgation of air;
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d. All hydraulic interface valves shall be block before bleed design. Generally the
valves shall be ¼” or ½” NPT type only. Where the pressure rating permits,
ball/needle and check valves with integral fitting connection shall be used to
minimise NPT connections to reduce leaks;

e. All tubing within panel and modules shall be of annealed seamless 316L SS, with
sizes of, ½" and wall thickness 0.083”. Tubing wall thickness shall be suitable for
the maximum hydraulic pressure i.e. PSV setting on the main supply header.

f. All external tubing shall be same as of internal tubing with 2 mm thick UV resistant
PVC coating. All tubes run under-ground shall be single piece and joint free for its
entire length.

g. Tubing size, pilots, quick exhaust valve etc., shall be designed to meet the closing
time for the distance (minimum 246 ft) between the well head hydraulic control
panel & the master/wing/sub-surface safety valves as per the layouts;

h. All tube fittings shall be of SWAGELOK, 316 stainless steel, double ferrule, and
double compression type;

i. All input/output connections (signal & supply) to modules or panel shall be by

bulkhead union fittings and bulkhead shall be of 316 SS. Connections which are
external to the panel shall be provided on the sides of panel.

5.8 Instruments & Electrical Components

a. All the instruments shall be weatherproof to IP65 as per IEC 60529 and per IEC
60079. For the purpose of standardization following philosophy shall be followed:

• Solenoid valves: EEx’d’ certified, Gr IIA / IIB, T3;

• Junction boxes, pushbuttons, selector switches: EEx’e’, Gr IIA / IIB, T3;

• Electronic Transmitters: EEx ‘i’, Gr IIA / IIB, T3;

b. All transmitters shall be 2 wires, 4~20 mA DC HART transmitters. Body & wetted
parts material shall be 316L SS as a minimum;

c. All the solenoids shall be spring return type. The solenoid valves and pilot valves
shall be of auto reset type. Solenoid coils shall be LOW POWER, high temperature
(class H insulation) moulded and encapsulated type suitable for continuous duty at
rated voltage (24V DC +10, -15%). Solenoids shall have suitably rated suppression
diodes connected across the coil.

Body and enclosure material, shall be 316 SS with suitably sized NPT connections
for tubing and ISO M20 entry for cabling;

d. Solenoid valve must be high-pressure direct acting. Pilot solenoids are not
acceptable;
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e. The pressure gauge shall be full safety pattern, incorporating blowout and safety
glass. The casing, wetted parts material shall be SS316L as a minimum;

f. Emergency Stop push buttons shall be stay-put type with RED actuator provided
with a shroud to avoid accidental actuation. It shall comply with requirements of
IEC & EN standards. Normally Closed contact (open on actuation) shall be wired to
the junction box;

g. START / STOP, OPEN / CLOSE push button shall be momentary type. Colour of
the actuator shall be GREEN for START / OPEN and RED for STOP / CLOSE
push button. Normally Open contact (close on actuation) for start and normally
closed contact for stop shall be wired to the junction box for these push buttons;

h. Color of the indicating lamps shall be GREEN for RUN / OPEN status and RED for
TRIP / CLOSE / POWER ON status indication.

i. Contact rating of switches shall be 24V DC, 2Amp as a minimum.

j. All supply/installation of interconnecting cables from the power supply input within
the system shall be by VENDOR.

k. Cable glands associated with the internal junction boxes shall be EEx’d’
compression type (inner, outer sheaths & armour clamp) manufactured from brass
with nickel plating. Cable glands shall be supplied in metric (ISO) thread and
complete with PVC shroud/sleeve, earth tag and lock nuts.

5.9 Junction Boxes

a. All signals to / from Wellhead hydraulic control panel to RTU shall be wired to the
junction boxes located at one side of the panel. Junction boxes shall be accessible
from outside the panel. All internal wiring / cabling to these junction boxes shall be
done at factory;

b. Junction boxes shall be made of corrosion resistant 316L SS provided with

removable cover, breather drain, and external earthing connection. All junction
boxes shall be Ex’e’ certified and ingress protection shall be IP 65. Proper sealing
shall be provided for internal wiring / cabling to it;

c. Separate junction boxes shall be provided for analog (4~20 mADC) signals, digital
signals (contacts, limit switches, pushbuttons, selector switches), FGS signals and
solenoid valves. If signals are combined in one junction box, signals shall be
segregated based on separate terminal strips;

d. Junction box shall be provided with removable gland plate at the bottom with
proper sealing at the cable entries. Sufficient free space shall be made available
for easy wiring & maintenance;
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e. Terminal arrangements shall be such that all cores, including spares, of the
multicore cables can be connected in the same sequential order as the pattern and
layout of the cores in the cable;

f. Terminals shall be DIN rail-mounted, non-hygroscopic, screw type spring loaded.

Make shall be Weidmuller or equivalent. Terminals shall be suitable for 2.5mm2
conductor. Fused terminals shall be equipped with ‘blown’ fuse indicator;

g. No more than two conductors shall be connected to any one terminal. If more than
two conductors must be terminated at the same point, terminations shall be made
on as many terminals as necessary and terminals interconnected with special
jumpers specially designed for this purpose;

h. All terminals shall be marked i.e. provided with suitable markers for identification.
Terminal markers shall be pre-printed from manufacturer and not hand written;

i. All internal cabling / wiring shall below smoke zero halogen type with suitable cross
section (not less than 0.5 mm2). If stranded copper wire is applied, wire ends at
terminal points shall be provided with suitable type wire crimp pins/lugs and
markers;

j. Colour code and marking of wires shall be as per VENDOR’S standards. All power
wiring shall be clearly marked with reference codes and/or tag numbers with
permanent wire marker;

k. Junction boxes shall be located completely outside the panel without any cutout on
the panel i.e. no portion of junction box shall be inside the panel.

5.10 Power Supply

The power supply for the wellhead control panel shall be 24 VDC, -10%, +15%, negative
earthed. This will be fed from the SOLAR array power system, supplied by others.

a. External power supply terminals shall generally be suitable for 2C x 95 mm2 cable
(to be confirmed by VENDOR). VENDOR shall provide separate terminal box to
terminate large size cable.

b. Panel shall be provided with isolators for each individual incoming power feeder.
The isolators shall be installed in the terminal boxes. The terminal boxes shall be
provided with a single switch for isolating the incoming power of both pumps. This
switch shall be accessible externally, without opening the terminal box. The
terminal box shall be supplied with un-drilled plate for cable glands.

c. The power supply to the solenoids shall be 24 VDC and will be provided from the
RTU.

d. VENDOR shall provide detailed power consumption calculation and submit it to the
CONTRACTOR for approval, stating all assumptions made concerning leakage
rates both internal and external to his scope of supply.
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e. There are two types of calculations involved. The first one is for the power
consumption of cold start or after a power shutdown. The second is the daily
consumption to account for leakages.

f. Since the solar power generation is critical, it is important that the hydraulic safety
system employs low power consumption design. Hence, due consideration shall be
given to avoid over sizing.

5.11 Nameplates & Labeling

Well head hydraulic control panel and all field mounted equipment shall be tagged with a
stainless steel tag. Nameplate shall be provided under each item on the front and major
components inside the panel.

Nameplate shall be laminated plastic, engraved in English with black lettering on a white
background. Nameplate shall be secured with self-tapping screws or adhesive.
Nameplate size on the panel front shall be uniform and letter height shall be such that
service description can be read from the distance.

6.0 INSPECTION & TESTING

The well head hydraulic control panel shall be subjected to inspection by COMPANY. It
is a prior requirement to any final inspection that the drawings/relevant documents be
certified/ approved in advance by COMPANY where appropriate.

The inspection & testing shall be in accordance with the approved “Inspection & test
plan”. It shall cover the following as a minimum.

• Physical / dimensional checks (general panel layouts and dimensions);

• Bill of material check including spare parts;

• Inspection of test records performed by the VENDOR prior to FAT;

• Inspection of material reports;

• 100% functional checks;

• Calibration checks.
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After inspection tests, all pipes and tubing shall be dried, thoroughly cleaned and free
from dirt, loose foreign material and water.

The FAT shall be as per the procedure approved by COMPANY.

VENDOR shall conduct integrated FAT (panel & RTU system) for both wells. COMPANY
will witness one of them.

VENDOR shall notify COMPANY/CONTRACTOR at least fifteen (15) calendar days in

advance for each schedule witnessed inspection.

Acceptance of shop test shall not constitute a waiver of requirements to meet this field
test under specified conditions and final guarantee for material design, workmanship and
performance.

7.0 INSTALLATION, PRE-COMMISSIONING AND COMMISSIONING

The installation and pre-commissioning of the WHCP shall be done by the

CONTRACTOR. VENDOR shall provide the services of qualified Personnel to assist the
EPC CONTRACTOR with pre-commissioning and commissioning.

Flushing of hydraulic lines from WHCP to well head valves shall be part of VENDOR’S
scope. As the RTU is being supplied by others, Integrated Testing at site (100%
functional testing) shall be part of VENDOR’S scope.

8.0 DOCUMENTATION

The documentation shall be in accordance with project documentation requirement and

as per the requisition. The following shall be included as a minimum with the BID:

• Project Schedule;

• Bill of material, specifications, data sheets & catalogs for all the components;

• Well head control schematic;

• Panel general arrangement & installation details;

• Equipment weight & dimensional drawings;

• Hydraulic leakage, power consumption calculations;

• Equipment sizing calculations;

• Single line diagram for power distribution;

• Pneumatic Pump control schematic.

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Apart from above following drawings / documents shall be provided by VENDOR after
placement of Order, as a minimum:

• Functional design specifications;

• Panel internal layout with part numbers;

• Panel, JB wiring diagrams;

• Inspection & Test Plan;

• FAT / SAT Procedure;

• Operating, Installation and Maintenance Manuals;

• Final Dossier;

• Spare parts list in COMPANY format.

All drawings, documents, operating/ maintenance and installation manuals shall be in

English. AS BUILT drawings & documentation shall be in VENDOR’S scope. Number of
hard copies and soft copies shall be as per the Material Requisition.

9.0 QUALITY ASSURANCE / QUALITY CONTROL

Vendor proposed quality system shall fully satisfy ISO 9001/2000 QMS Requirements.
The VENDOR and the Sub-vendors shall be ISO certified. VENDOR shall provide a
specific Quality Plan (QP) within 2 weeks of order award for COMPANY review and
approval. VENDOR shall provide the following to COMPANY for approval:

• Coordination procedure to coordinate the manufacturing of all materials, parts and

components in different places;

• The source of material supply for all parts and components including the country
of origin and place of manufacturing, assembly and testing;

• Material certificates for all parts and components before assembly;

• Sub-vendors and contractors list and these shall be from COMPANY approved
list.

10.0 SPARE PARTS & SPECIAL TOOLS

VENDOR shall include with the bid the recommended spare parts for start-up,
commissioning and two (2) years of operation.
VENDOR shall also provide special tools and tackles, if any, for operation and
maintenance of the WHCP.
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Vendor shall include all tools and tackles required for commissioning. All tools and
tackles used for commissioning, including pumps, shall be handed over to COMPANY
after commissioning.

Vendor shall provide additional equipment, if any, to boost the pressure available from
nitrogen cylinders, which is in the range of 2000-3000 psig (VENDOR to confirm the
requirment).

11.0 GUARANTEE

The VENDOR shall ensure that the material and accessories provided is his standard
product regularly manufactured, tested and serviced in accordance with the Codes and
Standards, defined in this document.

Any material or part thereof covered by this specification that shows evidence of
deterioration, contamination or corrosion within the guarantee period shall be considered
the result of failure to comply with the requirements and the intent of this specification
and shall be replaced on site at no extra cost to the Owner.