Table of Content

Table of Content...................................................................................................................... 1 List of Tables........................................................................................................................... 1 List of Figures.......................................................................................................................... 2 List of Abbreviations................................................................................................................. 3 1.0 INTRODUCTION............................................................................................................... 3 1.1 Project Objective................................................................................................................ 4 1.2 Project Design Overview....................................................................................................4 1.3 Proposed Plant Modification..............................................................................................4 2.0 DESIGN DOCUMENTATION BASIS.................................................................................5 2.1 Numbering System............................................................................................................ 6 2.2 Measurement Units............................................................................................................ 6 2.3 Language........................................................................................................................... 7 2.4 Applicable Laws & Regulations, Codes and Standards......................................................7 3.0 SCOPE OF WORK/DESIGN BASIS..................................................................................8 3.1 Site Visit .......................................................................................................................... 8 3.2 As-Built, Demolition and Scope of Work Drawings...........................................................8 3.3 PFD/P&IDs Development.................................................................................................8 3.4 Equipment/Piping Validation Check...................................................................................9 3.5 Line List Preparation........................................................................................................10 3.6 Equipment List................................................................................................................. 10 3.7 Update SAFE Chart.........................................................................................................10 3.8 Input to Update Control Philosophy..................................................................................11 3.9 Sales Gas Antisurge Equalizing Line Requirement Study................................................11 4.0 PROJECT DESIGN DATA...............................................................................................12 4.1 Site Location.................................................................................................................... 12 4.2 Meteorological Data......................................................................................................... 12 4.3 Sales Gas Composition ..................................................................................................15 4.4 Sales Gas Interstage Cooler (2-E-5795C) Design Data...................................................15 4.5 Sales Gas Aftercooler (2-E-5800C) Design Data.............................................................16 5.0 REFERENCES.................................................................................................................17

List of Tables

Table 1 Equipment Validation Basis Table 2 - Periodic temperatures recorded at Warri and % Relative humidity Table 3 - Gulf of Guinea barometric pressure reading Table 4 Typical rainfall conditions Table 5 - Seasonal Variation in Wind Speed for Offshore Nigeria Table 6 Sales Gas Composition Table 7 Sales Gas Interstage Cooler C (2-E-5795C)

Table 8 Sales Gas Aftercooler C (2-E-5800C)

List of Figures Figure 1 Wind Rosette

List of Abbreviations

Abbrevia tions BoD CAD CES XXX COMPANY CWE DED XXXXXX EPC IDC IFC IFR MDR PFD P&ID PMT SoW Basis of Design Computer Aided Design

Meaning

XXXXXX Engineering Standards XXXXXX Nigeria Limited XXXXXX Nigeria Limited CONTRACTOR Work Estimate Detailed Engineering Design XXXXXX Gas Plant Engineering, Procurement and Construction Inter-Discipline Check Issued for Construction Issued for Review Master Document Register Process Flow Diagram Piping and Instrumentation Diagram Project Management Team Scope of Work

1.0

INTRODUCTION

XXX wishes to have a Detailed Engineering Design performed in support of its plan to increase the existing XXXXXX Gas Plant (XXXXXX) processing capacity. This document describes the basis of all engineering design that shall be used for executing the Detailed Engineering Design (DED) of the XXXXXX 3 Debottlenecking

project. It also make references to the relevant and /or applicable industry Codes and Standards. 1.1 Project Objective

The objective of this Project is to carry out a DED aimed at increasing the existing XXXXXX Gas Plant (XXXXXX) processing capacity of 156 MMscfd to 224 MMscfd sales gas capacity by debottlenecking the existing piping and replacing inter-stage and after-coolers while using the existing sales gas compressors (C-2270A & C-2270B). 1.2 Project Design Overview

Presently, Train 1 of the existing XXXXXX Gas Plant has a sales gas capacity of 156mmscfd. This will be upgraded to 224 MMscfd by debottlenecking the existing piping and replacing inter-stage and after-coolers while using the existing sales gas compressors (C-2270A and C-270B). XXXXXX sales gas compressor is a 2-stage compressor unit with compression trains A, B and C. The first stage of compressors A & B shall handle 112 MMscfd of gas each (without any Inter-Stage Fuel gas take off). 1.3 Proposed Plant Modification

This project is intended towards upgrading the sales gas compressor trains A & B by replacing the inter-stage coolers (E-5795A & E5795B) and gas after-coolers (E-5800A & E-5800B) with new coolers which will be the same size as the existing coolers for sales gas compressor train C, however, the compressor pipings shall be upsized. XXXXXX Train 1 Compressors A & B facility modification shall be carried out in the following three (3) stages: Stage 1 - Shut-Down Tie-in Scope : consists of the verification of replacement piping and equipment sizes and the design and installation of all necessary piping,

electrical and I&C tie-ins to the existing facilities which will be performed during the 30 day shut down starting in September 2009. Stage 2 - Parallel Piping & Coolers Scope: consists of the design and installation of all new parallel piping, equipment and accessories to be hooked up

to the tie-ins, elevated equipment support structure and pipe rack (if needed), i.e. all that is required to achieve the project goals. Stage 3 - Demolition Scope: consists of the demolition of the existing piping and equipment that will be made redundant by the new installations. This document describes the basis of design for stage 2 and 3 of the debottlenecking project.

2.0

DESIGN DOCUMENTATION BASIS

This section gives a description of the Numbering System, Measurement Units, Language and the Codes and Standards to be used in project design documentation.

2.1

Numbering System

Refer to the XXX Design, Drafting & Documentation Manual (55-001.MST.ST.00-0001) for information on the numbering system used. 2.2 Measurement Units

SI units shall be used for the project. SI units include the following: Description Temperature Pressure ~ for gases and liquids ~ for structural loading Pressure difference Mass Length Area Volume ~ for gases and solids ~ for liquids Flow rate ~ for gases ~ for liquids Heat transfer rate Velocity Thermal Conductivity Thermal Resistance / Fouling factor Specific heat Mass Density Molar Density Viscosity Time sec. Angle radian (rad), degree () Unit C bara MPa bar kg m m2 m3 m3 SCMH m3/hr W m/s, km/hr W/m2K m2K/W J/kgK kg/m3 kgmol/m3 cP year, month, day, hour, min,

Frequency Revolution Stress Energy Power

per min 1/s, 1/min, 1/h kg/m2 kJ kW

It is acceptable to provide a given value in US industry units in parenthesis after the value in SI units. measurement. 2.3 Language Refer to XXXXXX300.23 for more information on units of

All drawings and documents shall be prepared in English. 2.4 Applicable Laws & Regulations, Codes and Standards

The DED shall comply with the following design rules and guidelines: (a) (b) XXX XXXXXX 3 Project Specifications These are the XXXXXX 3 project design specifications provided by XXX Laws and Regulations This refers to the laws and regulation acceptable in Nigeria. These are: Department of Petroleum Resources (DPR) Environmental Guidelines and Standards for the Petroleum Industry in Nigeria (EGASPIN) (c) Applicable Codes and Standards These are international Codes and Standards such as follows: ASCE API American Society of Civil Engineers American Petroleum Institute American Society of Mechanical Engineers American National Standards Institute Instrumentation, Systems and Automation Society

ASME ANSI ISA -

3.0

SCOPE OF WORK/DESIGN BASIS

This section describes the design activities required in achieving the objective of this project. 3.1 Site Visit

The Process Group shall participate in the field survey/site visit to be carried out on this project based on a detailed site visit checklist which will be prepared by the Process group. The check list will cover all as-built P&IDs and all necessary information/data that will be needed to finalize the work. Efforts will be made to obtain necessary information required to perform process simulations of the proposed system. 3.2 As-Built, Demolition and Scope of Work Drawings

During site visit, existing as-built P&IDs of the areas covered by the project scope will be marked up to reflect the as-built status of the facilities. These mark ups will be incorporated into the existing P&IDs and the CADDED version will go through the P&ID review and approval cycle within Cakasa / Fluor and with XXX. Also, the areas to be demolished, according to the project scope, will be shown on the Demo-P&ID that will also pass the approval cycle within Cakasa / Fluor and with XXX. The P&IDs will be saved in AUTOCAD Version 2004 as required by XXX. Basis: 3.3 Field Survey/Site Visit Findings Existing Gas Plant Sales Gas P&IDs.

PFD/P&IDs Development

The PFD/P&IDs will be developed starting from the existing PFD and P&IDs with the site visit mark ups incorporated. These P&IDs shall be marked up according to the project scope of work and CADDED accordingly. When necessary, extra P&IDs shall be generated for the new process lines and equipment in order to avoid cluttering existing drawings. Comments from design review shall be incorporated and the final P&IDs will then be issued for Issue for Design, after which the Process group shall

transfer control of P&IDs to the Piping group prior to HAZOP/IFC. The P&IDs will be saved in AUTOCAD Version 2004 as required by XXX.

Basis: 3.4 Field Survey/Site Visit Findings Existing Gas Plant Sales Gas PFDs. Existing Gas Plant Sales Gas P&IDs.

Equipment/Piping Validation Check

Capacity check shall be performed on the existing sales gas compressor suction and discharge scrubbers, and pressure relief valves. Capacity checks will be performed on the interconnecting process pipings based on the incremental flow from the discharge of the sales gas compressors. Line sizing calculations for the single phase fuel gas lines shall be in accordance with the method presented in API RP 14E which is based on velocity criteria of 18 m/s (60 ft/s) maximum. The compressor scrubbers shall be sized based on API SPEC 12J calculation procedure while the PSVs shall be sized using API RP 520 based on the controlling scenario. Basis: The capacity basis for validation check shall be as follows: Table 1 Equipment Validation Basis Equipment Sales Gas Suction Scrubber (2-V-8005 A/B) 10" Scrubber Inlet Line 16" Scrubber Outlet Line Scrubber Capacity Suction Scrubber PSV Sales Gas Compressor (C-2770A/B) Compressor Duty 14" Compressor Discharge Line - 1st stage 12" Compressor Suction Line - 2nd stage 10" Compressor Discharge Line - 2nd stage Sales Gas Interstage Cooler (2-E-5795A/B) Cooler Duty Sales Gas Interstage Scrubber (2-V-8030A/B) 14" Srcubber Inlet Line 12" Scrubber Outlet Line Scrubber Capacity Interstage Scrubber PSV Sales Gas Interstage Cooler (2-E-5800A/B) 112 MMSCFD 112 MMSCFD 112 MMSCFD Fire Scenario Cooler C (E-5795C) Duty Installed Compressor Duty 112 MMSCFD 112 MMSCFD 112 MMSCFD 112 MMSCFD 112 MMSCFD 112 MMSCFD Fire Scenario Validation Basis

Equipment Cooler Duty 10" Cooler Outlet line to the Sales Gas Header

Validation Basis Cooler C (E-5800C) Duty 112 MMSCFD

3.5

Line List Preparation

Line list shall be developed by listing all the process lines covered by the SoW as shown on the P&IDs. The new process lines shall retain the existing line identity but shall reflect the new line sizes. Inputs will be required from piping group in providing the pressure rating of the listed lines and the numbering of the lines will be in accordance with XXXXXX3-00.06. Basis: 3.6 Existing Gas Plant Sales Gas P&IDs. Updated Gas Plant Sales Gas P&IDs.

Equipment List

A list containing information about the equipments covered by the debottlenecking project shall be initiated by the process group. Inputs will be required from other disciplines like piping and mechanical group in providing other details required to populate the equipment List. The Equipment List shall be prepared in accordance with XXXXXX3-00.06. Basis: 3.7 Existing Gas Plant Sales Gas P&IDs. Updated Gas Plant Sales Gas P&IDs.

Update SAFE Chart

Existing SAFE chart shall be updated to reflect changes made on debottlenecking project. It is however expected that the existing document will be provided by XXX for update.

Basis:

Existing Gas Plant Sales Gas SAFE Chart Existing Gas Plant Sales Gas P&IDs. Updated Gas Plant Sales Gas P&IDs.

3.8

Input to Update Control Philosophy

Process group shall provide required input for Instrument group to update the existing Control Philosophy. This shall include the control philosophy of the new equipment installed as part of the project. Basis: 3.9 Existing Gas Plant Sales Gas SAFE Chart Existing Gas Plant Sales Gas P&IDs. Updated Gas Plant Sales Gas P&IDs.

Sales Gas Antisurge Equalizing Line Requirement Study

A study shall be performed to determine the requirements for an equalizing line on the compressor A&B in addition to the anti-surge line. The study shall take into account the distance of the new air coolers to the sales gas compressor and the interconnecting piping volume to confirm the need for installing an equalizing line in addition to the anti-surge recycle line. The control system response requirement shall also be considered in determining the need for this line. Basis: Site Survey Data Sales Gas Compressor and Air Cooler Piping Layout. Sales Gas Compressor Control Philosophy Sales Gas Compressor Vendor Data Existing Gas Plant Sales Gas P&IDs. Updated Gas Plant Sales Gas P&IDs

4.0

PROJECT DESIGN DATA

This section provides design input to all design activities. All information documented herein is provided by XXX. XXXXXX3-00.01 4.1 Site Location

XXXXXX3 Onshore activities are located near the mouth of the XXXXXX River and adjacent to the XXXXXX Nigeria Oil Terminal. The XXXXXX Nigeria Ltd. Oil Terminal located onshore near 50 37N and 5011E is in an estuary area, approximately 60 km west of Warri, Nigeria. 4.2 (a) Meteorological Data Temperature and Humidity

The black bulb temperature for the XXXXXX area is 60oC. The Temperatures and Humiditys recorded at Warri are included and profile the day to night and morning to afternoon fluctuations in temperature and humidity. This data is considered representative of the coastal conditions of the onshore facilities area. Table 2 - Periodic temperatures recorded at Warri and % Relative humidity

(b)

Pressure Table 3 below shows the barometric pressure reading of Gulf of Guinea Offshore Nigeria Asabo Platform. This is located near 407'N, 748'E in a water depth of 43 m. Data is applicable for use both on and offshore XXXXXX area. Table 3 - Gulf of Guinea barometric pressure reading

(c)

Rainfall The following values represent typical rainfall conditions for both on and offshore conditions, as measured over a three year period: Max Intensity 102 mm/h Dry Season (October to April) monthly average 142mm Wet Season (May to September) monthly average 320mm Table 4 Typical rainfall conditions

(d)

Wind Data Local winds are dominated by the trade winds, 5 to 15 knot winds from the southerly quadrant. Thunderstorms create the largest local winds with wind gusts ranging from 40 to 60 knots for the 100-year event. Quantified wind gust data of frequency and duration is not currently available. A tabulation of the joint frequency of occurrence of wind speed and direction, offshore Nigeria, is shown in the wind rosette in figure 1 below. This information is applicable to onshore conditions. The dominant wind direction is southwest. The seasonal variation in wind speed is tabulated in Table 5. Figure 1 Wind Rosette

Table 5 - Seasonal Variation in Wind Speed for Offshore Nigeria

Design Condition (100-year return period): 40m/s (3-sec gust @ 33 feet).

4.3

Sales Gas Composition

Table 6 below shows the compositional analysis of the XXXXXX Sales Gas. This shall be the fluid composition basis in the process simulation of the XXXXXX Sales Gas compression system. Table 6 Sales Gas Composition Component CO2 Nitrogen Methane Ethane Propane i-Butane n-Butane i-Pentane n-Pentane C6+ Total Mol% 1.2300 0.0340 84.292 6.830 3.491 0.714 1.167 0.437 0.389 1.415 100

4.4

Sales Gas Interstage Cooler (2-E-5795C) Design Data

The existing Sales Gas Interstage coolers A&B (2-E-5795A/B) shall be replaced with a larger cooler that has the same capacity as Interstage cooler C (2-E-5795C). Interstage cooler C design information is shown in Table 7 below.

Table 7 Sales Gas Interstage Cooler C (2-E-5795C) 2-E-57965C Duty Driver No. Driver Rating k W k W
o

5,020 2 29

Design Temperature

C B a r g

232

Design Pressure

60

4.5

Sales Gas Aftercooler (2-E-5800C) Design Data

The existing Sales Gas Aftercoolers A&B (2-E-5800A/B) shall be replaced with a larger cooler that has the same capacity as Aftercooler C (2-E-5800C). Aftercooler C design information is shown in Table 8 below. Table 8 Sales Gas Aftercooler C (2-E-5800C) 2-E-5800C k W k W
o

Duty Driver No.

7,250 4

Driver Rating

18.6

Design Temperature

C B a r g

343

Design Pressure

105

5.0

REFERENCES 1. 2. 3. XXXXXX Train 1 Compressors A & B Debottlenecking Project Stages - 2 & 3 Detailed Engineering Design Scope of Work - (RWE-118 SoW). XXXXXX3 Debottlenecking of Compressors A & B - Stages 2 & 3 Basis of Design (RWE-118 BoD). XXX XXXXXX3 Project Specifications - XXXXXX3-00.01 - XXXXXX3-22.15