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Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3506 1 Instt. 1 of 11

FUNCTIONAL SPECIFICATION FOR HYDRAULIC POWER UNIT CUM CONTROL PANEL

PREPARED REVISED BY

REVIEWED BY

APPROVED BY

TOTAL No. OF PAGES

DATE

REV. No.

VS AK
FORMAT No. DD/SOF/004A/B

SSK MC
Ref. PROCEDURE No. DD/SOP/008 TO 015

GRP RK
ISSUE No. 02

11 11

16.06.08 10.02.06
REV. No. 01

1 0
REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3506 1 Instt. 2 of 11

CONTENTS

Clause No. 1.0 2.0 3.0

ITEM Scope of This Document Scope of Supply Hydraulic Power Unit Cum Control Panel 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Design Criteria Inspection & testing Warranty Spares Tools Packing & transport Documentation Operation & Maintenance Manual

Page No. 3 3 5 5 8 9 9 9 10 10 10

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REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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1.0 SCOPE OF THIS DOCUMENT: 1.1 This functional specification describes the essential design considerations for the selection of Hydraulic power Unit Cum Control Panel for the intended service. 2.0 SCOPE OF SUPPLY: 2.1 The quantity to be supplied and installed shall be as per the requirements indicated in the Basic Bid Work, Design Criteria and the P & IDs. 2.2 The vendor shall be responsible for the selection of the Hydraulic Power Unit Cum Control Panel suitable for its intended application, its procurement, tagging, packing, testing & calibration, preparation for shipment, along with accessories, spares, and assistance where required for its installation & commissioning at site. This FS shall be read in conjunction with:1. Instrumentation Design Criteria 2. Basic Bid Work 3. Project P & IDs 4. Process Design Criteria 5. Electrical Design Criteria 6. Mechanical Design Criteria 7. Piping Design Criteria 8. Environmental condition of the project 2.3 The following codes and standards (latest edition) as applicable to be referred ASME, Sec.VIII, Div.1 API RP 2A API-RP-14C API 17A API 17D API 17E Boiler and Pressure Vessel Code

Recommended Practice for Planning, Designing and Construction of Fixed Offshore Platforms Analysis, Design, Installation and Testing of Surface Safety System on Offshore Production Platforms. Recommended practice for design and operation of subsea production systems Specifications for sub-sea wellhead and Christmas tree equipment. Sub-sea Production Control Umbilical

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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NAS 1638 SAE J 343 NEC NEMA IEC ASTM API-610 API-674 API-676

Cleanliness Requirements of parts used in Hydraulic system Specifications for tests and procedures for hose and hose assemblies National Electrical Code National Electrical Manufacturers Association International Electro technical Commission American Society for Testing and Material Centrifugal Pumps for General Refinery Services Positive Displacement Reciprocating Pumps Positive Displacement Pumps- Rotary

2.4 Vendor shall supply all necessary equipment including major items as specified below but not limited to the following Hydraulic pump driven by electric motor Hand hydraulic pump as back-up facility Hydraulic fluid reservoir with filter, breather etc. Hydraulic accumulators with instrumentation Solenoid operated control valves Manual control valves Interconnected piping, electrical, instrumentation and controls Necessary connectors, tubing for connecting HPU with Hydraulic umbilical Pressure relief valves, pressure switches, pressure indicators, SS 316 tubing, valves and fittings.

All above equipments, units and components shall be skid mounted on a common structural skid, fully assembled, piped with inlet and outlet piping terminated at skid edge with appropriately rated flanges, wired, tested and painted for manned environment. Umbilical hoses shall connect HPU to the sub surface intervention valve actuators through quick disconnect couplings for hydraulic supply to and return from actuators

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3506 1 Instt. 5 of 11

3.0 HYDRAULIC POWER UNIT CUM CONTROL PANEL: 3.1 DESIGN CRITERIA: 3.1.1 The control system shall consist of the following major components in a single skid mounted unit. Hydraulic power unit Control panel with all control and display instruments. 3.1.2 It shall be possible for the operator to actuate the subsea valves from the panel (HPU) and to observe the status of the valves. Valve status shall be electrically or electro-hydraulically transmitted by a separate pair of cable/umbilical chords. The panel should have provision to accept and respond to ESD & FSD signal commands from the existing platform ESD/FSD loop. An ESD /FSD signal from the platform should cause a closure of the subsea shut down valve. Vendor shall also supply the initial charge of hydraulic control fluid for the entire system (up to the sub-sea valve) as well as nitrogen cylinders. An integrated test of the HPU cum control panel, subsea shutdown valve and the Umbilical shall be carried out by the contractor/vendors The equipment shall be designed for outdoor location on an offshore platform with site conditions as detailed in BID package. The equipment shall be selected as per the area classification requirement. Hydraulic Power Unit shall be designed for a complete life of 25 years minimum of the platform as specified elsewhere in the BID. The Hydraulic Power Units shall operate sub-surface intervention valves located at a distance from platform as per the enclosed P&IDs and data sheet The following shall be given due consideration in sizing, selection and design of various components forming a part of the electric motor driven Hydraulic Power Unit: Working pressure requirement Pressure drops in umbilical Ease of operation and maintenance Overall compactness Reliability of Operation

3.1.3

3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

3.1.9

3.1.10 HYDRAULIC RESERVOIR LINE FITTINGS 3.1.10.1 Hydraulic reservoir shall be of SS 316 construction provided with the following accessories and fittings as a minimum:-

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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Drain point Breather screen with desiccant type air filters cum particulate filters Level gauge Necessary pipe/tubing connections

Hydraulic accumulators shall be in stainless steel 316 constructions with ASME code stamp and shall be provided with 100% standby capacity. The Vendor in bid shall describe the make and design and operating conditions of hydraulic accumulators along with typical drawing. The Vendor shall also specify the make and material of accumulator bladder and other accessories suitable for the service and application in bid and describe the operation of accumulators 3.1.10.2 Pumps shall be driven by electric motor and the Vendor shall furnish full details of pumps with bid for the technical evaluation. 3.1.10.3 Pump discharge pressure and flow rates shall be decided by the vendor based on the design and operating conditions required for the operation of sub-sea valves as per process design criteria and basic scope of work. 3.1.10.4 Hydraulic pipe work in the system shall be done with soft annealed seamless SS 316 tubes and SS 316 fittings. 3.1.11 FILTERS Filters at suction to pump shall be provided to provide 5 microns degree or better of filtration for the safety of the pump. Filter housing shall be in stainless steel construction with suitable vent and drain connections. 3.1.12 HYDRAULLIC CONTROL FLUID Hydraulic control fluid shall be Marston Bentley (HW560, Isaac Bentley make or equivalent and shall meet the following requirements as a minimum. The fluid shall be water based, consisting of de-ionized water, biocide and water-soluble lubricant. Viscosity shall be less than 4 Centistokes at +200 C The fluid shall contain a corrosion inhibitor and shall be compatible with the material and seals used in the system. The fluid shall be free from foaming. The fluid shall be thermally stable (i.e. stratification or precipitation shall not occur over a temperature range of -50 C to +650 C at pressure of 0-5000 psi. The fluid shall not form harmful products when exposed to oil, gas, water, completion fluid and greases or thread sealants employed in equipment

FORMAT No. DD/SOF/004A/B

Ref. PROCEDURE No. DD/SOP/008 TO 015

ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3506 1 Instt. 7 of 11

manufacture. The fluid should be miscible with unto a minimum of 10% sea-water. The fluid shall be resistant to deterioration by oxidation. The fluid shall include biocide to control any biological growth. Vendor shall state any limitations on its useful life and recommended action to maintain the required protection. The fluid shall meet NAS 1638 Class 6 standard of cleanliness. Vendor shall provide procedures for laboratory tests for fluid quality. Vendor shall furnish the Test data for fluid pH, viscosity, specific gravity, water content, pour point and cleanliness. The fluid shall not cause deterioration of the materials and seals in the system.

3.1.13 SPECIAL REQUIREMENTS: 3.1.13.1 Vendor shall furnish with the bid detailed P&ID, system description and bill of material for the Hydraulic Power Unit. 3.1.13.2 HPU requirement shall be compatible with overall operation and control philosophy of platform. However, following facilities shall be necessarily included. 3.1.13.3 Reservoir capacity shall take into account the distances traversed by umbilical and the type of actuator. Reservoir should have at least 30% reserve capacity for leakages etc, capacity calculations shall be as per design criteria and company approval shall be obtained. 3.1.13.4 Hydraulic system shall be capable of withstanding a proof test pressure that is 1.5 times the operating pressure. 3.1.13.5 Hydraulic reservoir shall be complete with breather valve, level gauge, level switch, drain connection and access opening for inspection and cleaning of reservoir.. 3.1.13.6 The selection, fabrication and installation of piping work shall meet the minimum requirements defined in the piping specification. 3.1.13.7 Electrical equipment and materials shall be in accordance with the attached electrical functional specification and electrical design criteria. 3.1.13.8 All equipment selected for hazardous area shall be certified by BASEEFA, UL or equivalent international testing, agency for the service and area in which it is to be used

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3.1.13.9 The selection and installation of instrumentation works shall meet the minimum requirements defined in the instrument design criteria and functional specification. The material exposed to the sour service shall meet the NACEMR-01-75 standard (latest edition). 3.1.14 SKID 3.1.14.1 The skid shall be designed and built to ensure that all the equipment along with accessories, panel and piping are mounted suitably for convenient operation. 3.1.14.2 A canopy shall be provided above the skid for protection against rain and direct sun light. 3.1.14.3 The skid mounted unit will be equipped with lifts slots in the slid base. And the upper from will be equipped with a lifting eye on each of the top four corners. 3.1.14.4 The lift points and skid structures will be designed to withstand four times the units static weight, in the event of snatch lifts. The skid structure shall be sandblasted, primed and painted as per the bid requirements. 3.2 INSPECTION AND TESTING: 3.2.1 Vendor shall carryout various tests as per applicable Codes/Standards. certificates shall be submitted for Companys approval. Test

3.2.2 Company/its authorized representative or certifying agency shall have access to inspect the equipment at any stage during manufacture. Company shall specify hold points/witness points while approving purchase specification during project execution. During inspection, material certificates, shop test data, certificates for bought out components and other relevant information shall be furnished for companys perusal so as to ascertain that the specifications and quality are complied with. 3.2.3 In case Vendor/their sub vendors of equipments/packages have in-house elaborate Quality/Assurance Systems (operating in their shop) for Inspection & Testing of equipments/packages shall obtain approval of their Quality Assurance System from the Company prior to commencement of manufacturing activities. Where such Quality Assurance System is not in operation with the manufacturer/their sub-vendors, the Tests specified as witnessed in the Specification shall be carried out in presence of the Company/as authorized representative or certifying agency. The cost of preparation for shop testing of equipments/packages including inspection fee etc. shall be borne by the Contractor. Vendor/Contractor shall give minimum 15 days prior intimation to the Company regarding testing schedules. Company/its authorized representative or certifying agency shall have access to inspect the equipment at any stage during manufacturer. During inspection,

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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material certificates, shop test data, certificates for bought out components and other relevant information shall be furnished for companys perusal so as to ascertain that the specifications and quality are complied with. Company shall specify hold points/witness points while approving purchase specification during project execution 3.3 WARRANTY Vendor shall have final and total responsibility for the design and mechanical performance of all equipment supplied under this specification. Vendor shall warrant the equipment furnished by him and the performance of the said equipment in accordance with this specification. Also refer to Warranty clause as given in bidding documents (Volume I). 3.4 SPARES

3.4.1 Vendor shall recommend and provide list of spare parts needed for startup and commissioning in purchase specification. In addition, vendor shall also furnish a separate itemized priced list of recommended spares for one (1) year normal operation and maintenance. Recommended spares should take into account related factors of equipment reliability, effect of downtime upon production or safety, cost of parts and availability of equipment service facilities. 3.4.2 All spare parts furnished by Vendor should be wrapped and packaged so that they will be preserved in original as-new condition under the normal conditions of storage to be anticipated in India and shall be properly tagged and codes so that later identification as to intended equipment usage will be facilitated. They shall be packaged separately clearly marked as Spare Parts and shipped at the same time as the equipment. Packing lists shall be furnished so that the parts can be handled without uncrating, if desired start-up spares shall be packed and identified separately 3.5 TOOLS Vendor shall provide two sets of special tools, if not stated elsewhere, for operation and maintenance of the furnished equipment.

3.6

PACKING AND TRANSPORT The offered equipment along with their accessories shall be shipped packed in wooden crates. They shall be wrapped with polythene sheets, before being placed in the crates to prevent damage to finish. Crates shall have skid bottom for handling.

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3.7

DOCUMENTATION Installation and commissioning procedures for HPU unit and control system. These shall be submitted to the company for review at least 60 days before the start of said activities. These shall include, but not necessarily be limited to the following. Procedure for installation and interconnection of surface elements of the system. Final cleaning and flushing procedures for control system components. Pressure leak test procedures for the hydraulic circuit Final check out of the surface equipment prior to connection to the umbilical. Check out of the subsea and surface electrical system Procedure for tie-up procedure of umbilical to surface equipments. Sequence and functional testing of entire subsea system Procedure for removal and reinstallation of subsea connection before and after work over and wire line jobs, including safety procedures. Procedures should also include (where-ever applicable) The required test sheets indicating clearly the activities /tests tube carried out and acceptance criteria for each of the tests conducted during installation. Pre-commission ing and commissioning.

3.8

OPERATION AND MAINTENANCE MANUAL

3.8.1 The contractor shall prepare on operation and maintenance manual for all the equipment (provided by contractor) and submit to company representative within 10 days subsequent to fabrication completion. This manual shall systematically include all information on the system equipment. Its installation, operation and maintenance. In particular, the following information shall be covered where- ever applicable: Component / equipment system description should explain the design criteria, functional description and mode of operation and start-up and shut down procedures including logic flow charts Checks and test program and procedure for individual sub assembly level tests and for final tests upon completion. Operating instructions during normal operations Operating instructions during failure conditions Description of monitoring control and safety system Fault finding procedures Procedure for periodic performance tests Maintenance and repair procedures Safety precautions and safe practices Drawings and equipment schedules

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ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HYDRAULIC POWER UNIT CUM CONTROL PANEL

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3.8.2 The maintenance manual shall include the following attachment where applicable: Drawings showing supporting structure, pressure drawing(s) showing piping system, value and instrumentation (P&IDs). Drawing showing individual component details. Drawing showing the de tails of each subassembly and assembly. Drawing showing controls and safety systems. Flow diagrams and schematics. Equipment vendor data. Instrument list. Blank test sheets for all the tests. Drawings for electrical system. Drawings and description of test equipment and tools Recommended parameters for routine system monitoring Equipment and instruments parts list. List of tools and test equipments. As built drawings, inspection and test reports, operation manual and other relevant documents shall be submitted to the company in hard copies and as well as in CD ROM.

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REV. No. 01

REV. DATE: 01/08/2006