Quick Guide for Nitrogen Generation Package

Process Description Brief

The System is composed of One (1) train of Nitrogen Generator (2 100%) with Eight (8) unit membrane modules for
Produced Nitrogen of 97%; the description below applies to one train.
Compressed Air is supplied to the Nitrogen Generator Package via the tie-in point. After passing through the Pre-Filter
System and Electrical Heater, the Air is separated into Nitrogen product and Oxygen rich permeate by the separation
Membranes.
The Pre-filtration System consists of Two (2) Coarse Coalescer Filters, and Two (2) Particulate Fine Filters. The air will enter
into the Electrical Heater upon leaving the Pre-filtration System. Air will be heated to 52C before entering Nitrogen
Membranes. Four (4) unit membranes are required for the system of the prescribed Flow Rate of 390 Sm3/h at standard
conditions and Nitrogen purity of 97%.
On the other hand, the Oxygen rich waste is vented off to atmosphere in a safe area via the tie-in point on the skid.
Measuring and Control Instrumentation
Measuring and Control Instrumentation within the Nitrogen Generator Package includes:
- Differential Pressure Indicators across each fine filter,
- Differential Pressure Transmitter across the whole filtration train,
- Feed Air Pressure Gauge,
- Feed Air Temperature Gauge,
- Oxygen Analyzer,
- Produced Nitrogen Pressure Transmitter,
- Produced Nitrogen Flow Transmitter.
All the above signals are wired to Junction Boxes for connection to Clients DCS.
The following parameters are continuously controlled by the Local Control Panel:
- Pressure of Generated Nitrogen, with limitation of Flow in case of excessive demand,
- Cascade control of the Set Point of Generated Nitrogen Flow Controller, based on signal from Oxygen Analyzer.
The discharge Pressure (flow of Nitrogen) is controlled by a Pressure Control Valve and monitored by a Pressure Controller
and a Flow Controller. The Control Valve will adjust the Flow of nitrogen to the Receiver according to the control loop that
generates the lower % opening signal.
In case the product Nitrogen falls outside specification (High Oxygen content), the Set Point of the Flow Controller will be
reduced in order to avoid contamination of the Nitrogen in the Receiver. If the Oxygen content exceeds the High-High
threshold, Pneumatic On/Off Valves will divert the Flow of Nitrogen to atmosphere and the Nitrogen Generator will trip. Said
On/Off Valves are controlled via a solenoid valve that receives a signal from DCS. Manual valves are provided for isolation of
the packages instrumentation, filters and membranes.
Posted 25th May 2013 by Danaraj Chandrasegaran
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25
MAY

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Quick Guide for Pedestal Cranes
Quick Guide for Pedestal Cranes
Pedestal crane is one of the key equipment installed in an offshore platform and other floating units e.g FPSO, FSO, FPU. Other
than that, it represents significant progress achievement visually during the fabrication period once it is erected at the yard.
Pedestal cranes are usually supplied in accordance to API Spec. 2C. This requirement applies to most part of the world. However,
in European and north sea environment EN13852-1 are used. Most vendors (e.g. NOV, Liebherr, Oil States, Favelle Favco) are able
to cater for both requirements. In addition, Civil Aviation Authority Regulation CAP 437 needs to be implemented as well.
22
DEC
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Hydraulic power units for the pedestal crane could be diesel engine driven or electric motor driven. For diesel engine unit, if there is
cranking time requirement e.g. 3 starts in 1.5 mins., an air receiver need to be an integral part of the crane. Cab design and
operator's interface differs according to supplier's standard design and owner's needs. The more sophisticated and elaborate
interfaces are always available at higher cost.
Construction interfaces that are related to pedestal cranes are:
Structural: Pedestal interface with deck structure, ladders, handrails, aircraft obstruction markings
Piping: Instrument air supply and diesel fuel supply
Electrical: Normal power supply and UPS requirement, aircraft warning lights, JBs
Instrumentation: F&G detectors, windsock, JBs
Telecommunication: Radio unit, antennaes, surge arrestors, Jbs
Installation: Installation procedures, slew bearing change procedure
Testing of the crane unit will be done in accordance to the code and regulations. Usually a witnessed shop test on a fully assembled
crane mounted on a test pedestal shall be required. This test will include a mechanical run of all main and auxiliary machinery,
control panels for a minimum 2 hours under full load test. Prior and post test , the crane and its auxiliaries will be visually inspected
as well. Once the crane's test found satisfactory, a certificate will be issued.
Posted 22nd December 2012 by Danaraj Chandrasegaran
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Quick Guide for Pressure Vessel Drawing Review
Quick Guide for Pressure Vessel Drawing Review.
Pressure vessels are among the key items in a mechanical packaged equipment e.g Instrument air package, Nitrogen
generators. Usually, vessel constructions shall comply with ASME Boiler and Pressure Vessel Code (BPVC) Section VIII and
the project specific requirements, including welding specification. For vessel general arrangement drawing review, it should
be completed together with datasheet, calculations and welding document. This would facilitate the consistency check
between documents.
Checklist:
1. Nozzle schedule
2. Design data or equipment data table
3. Bill of material
4. Fabrication (welding) details to be shown:
earthing lugs/ boss
lifting lug
access opening
skirts
nozzles
other attachments
5. Weld details for main circumferential and longitudinal weld line
6. Loading data operating, dry, wind, seismic and transportation
7. Nozzle allowable loads
8. Painting requirements
9. Notes referencing project specifications
References:
ASME codes and standards
A Brief discussion on ASME Section VII Division 1, 2 and the new Division 3
22
OCT
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Posted 22nd October 2012 by Danaraj Chandrasegaran
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Quick Guide for P&ID Review
Quick Guide for P & ID Review.
Piping and Instrumentation Diagram (P&ID) is one of the key documents that will be reviewed during the course of project execution. It will
be the basis of piping and instrumentation design, as the name implies. Once P&ID is firmed up, secondary drawings such as electrical and
control schematics, bill of material and detailed arrangement can be generated by the engineers. Other than that, P&ID needs to be read in
conjunction with the control philosophy to have the operational overview of the system.
Checklist for P&ID review:
1. Tagging this to be referred against the project tagging philosophy
2. Symbology this to be referred against the project symbols. Otherwise, vendor standard symbol to be listed for referencing.
3. Inlet and outlet design parameters design pressure/ temperature; operating pressure/ temperature
4. Key equipment design parameters design/ operating pressure; design/ operating temperature; material of construction,
corrosion allowance; dimensions
5. Material selection of key components - this to be referred against the project material selection report
6. Line sizing this to be referred against the piping class for material and ratings
7. Valve sizes
8. Valves position during operation or failure
9. Instrumentation suitability for the selected parameters; ranges; alarm set points, trip set points
10. Control panel interfaces signals to/ from main control room and field instruments; hardwired signals; serial linked signals
11. Pressure relief valves sizes
12. Control loops between the instruments and equipment
13. Termination points
14. Notes describing project requirements, exceptions or operational points.
15. Consistency between documents such as instrument index, control philosophy, line list sizing calculations to be reviewed as well.
Posted 11th October 2012 by Danaraj Chandrasegaran
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11
OCT

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Quick Guide for General Arrangement Drawing Review.
Quick Guide for General Arrangement Drawing Review.
General arrangement drawings usually would be the earliest submission by Vendors to the Purchaser ( e.g. EPC
contractor). Since, the GA submission schedule more often than not occurs within 4 weeks from purchase order
placement; Vendor would provide typical arrangement followed up by more details on subsequent revisions.
Checklist for GA design review:
1. Footprint dimensions
2. Interface points for piping and structural
3. Interface points for electrical and instrumentation
4. Maintenance access requirements and lifting arrangements
9
OCT
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5. Special protections
6. Human factors requirements
7. Bill of material
8. Weight and load information (dry, operating, seismic and transport)
9. Painting requirements
10. Notes referencing project specifications.
Posted 9th October 2012 by Danaraj Chandrasegaran
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Wellhead Platform (WHP)
WHP
Awellhead platform includesan integrated deck, utility systems, wellhead systems, living quarters, a helideckand drilling facilities. At times, it could be linked
to Floating, Production, Storage and Offloading (FPSO) vessel or central production platforms. WHPs are normally unmanned. They are designed to be
operated remotely and visited during routine inspection and maintenance activities.
Most times, WHPswould be four legged platforms; consisting of 4 decks. The deckswould be spider deck, cellar deck, main deckand heli deck. It may have 3 to
32 well, depending on the size of WHPs. These wellsare usually drilled by jack-up rigsthat dockswith the WHPs.
Currently market is moving towards minimum facilities installation, whereby minimal engineering activities envisaged and standardization between fields.
Schedule and cost savings can be anticipated by decreasing manhours, fabrication time, streamlining designs and equipment selections. Also, expandable
platformshelpson future field development strategies. Facilitiescould also be designed to accommodate wider design needs. Standardization and streamlining
of design also offersimproved operational requirementse.g. better spare partsmanagement and decrease manned intervention.
Therefore, WHPsdesign and technology development should be interesting to watch in coming years.
16
SEP
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RasGasAl Khaleej GasProject - WHP (By McDermott-Photos)
Posted 16th September 2012 by Danaraj Chandrasegaran
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Quick Guide for Flare Ignition System
Overview: Flare Ignition System
Ignition Method Flame Front Generators
(FFG)
Electronic Ignition Ballistic
Brief FFG creates a mixture of
f u e l gas and air in the
ignition line. Subsequently,
this is ignited. The metering
and mixing process is
accomplished through the
use of small valve trains
placed on the FFG control
panel.
This ignition system uses a
fuel gas line much like other
ignition systems. However,
utilizing the exciter which
produces a high voltage
spark directly in the pilot
nozzle, compared to
conventional FFGs.
Installed at a safe distance
from the flare stack and a
guide lead to the flare tip.
The system is suitable for
all flare tips and may ignite
several flares on one flare
deck. It is easily retrofitted
into existing installations.
Interface Electrical, Fuel, Air Electrical Compressed air
Installation limits <1600m <2000m
Advantages Reliable conventional
system
Instaneous reignition if the
pilot should ever lose its
flame.
No electronic parts or
mo v a b l e parts within
system.
Does not need any pilot
bur ner s, and has no
equipment on the flare deck
that is sensitive to heat,
such as cables,
instrumentation or
electrodes.
Disadvantages Components may require
replacement over its life.
Cabling for electronic
ignition line required.
Ignition detection system
required.
Components may require
replacement over its life.
Only single vendor able to
supply this type i.e.
Hamworthy.
Require guide pipe for the
ignition pellet.
Posted 2nd September 2012 by Danaraj Chandrasegaran
Labels: Equipment, WHP

2
SEP

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Talent Development: Malaysian Oil & Gas Industries
19
AUG
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TalentDevelopment: Malaysian Oil & Gas Industries
Introduction
Recentannouncement by PETRONAS on several major oil and gas project such asRAPID project in Pengerang and North Malay Basin Development
havecertainly created much excitement in our industry. Other notableoffshore field development within Malaysia that are in thelimelight are Malikai, Rotan and
Kanowit. Also, marginal fields arebeing developed and existing fields will be rejuvenated with enhancedoil recovery system to boost our oil production for
coming years. Allthese developmentsin our local oil and gasindustriesare forecastto create thousandsof skilled jobscomprising of different level ofeducation,
trainings and skill sets. For example, for RAPID project,it is envisaged 40,000 to 50,000 workforce would be needed duringconstruction period (Bernama news,
12 May 2012).
Thequestion that comes to our mind that where do we source all thetechnical personnel and skilled workers that are much needed toexecute and ensure the
successand continuity for all theseprojects. In other words, if the projects concerned do not create themultiplier effect that is needed to boost our overall
economy, itwould be no good at all to all of us, in a nutshell so to speak.
News,opinionshave been generated and discussed regarding the talentissueslately. Here is to focusto a particular industry, which arehigh worth and where we
have the capability to be front runners aswell and may in fact are leading the region at the moment.Nevertheless, considering the significance of oil and gas
industry toour nation'seconomy. It would be prudent to have holistic and longterm approach to addressthe talent issue here, while being cautiouswith external
pull factors.
TalentDevelopment Needsfor Oil & GasIndustry.
Oiland gas industry talent needs differs on a wide magnitude compared toour local manufacturing and construction industry requirements.Equipment
technologiesand safety requirementsdiffersthroughout theworld and dictated by processlicensorsaswell asoil majors. InMalaysian context, the industry iswell
developed to cater for theregional needs. Local vendors has established themselves throughPETRONAS vendor development programme and large
engineeringconsulting group hastheir presence here aswell.
Inorder to move towards wider global audience, much need to be done.Our local engineers need to be well versed with wider technical skillsets in terms of
familiarizing with standardsand other regulatoryrequirementsin other countries. More over, projectsall over theworld are being completed in shorter period and
involving satelliteoffices around the world engaging with multicultural work force,which would require higher degree of English language proficiency andIT
skills.
Alsothe markets are looking for well rounded talents, meaning technicalskills which are complimented with field experience such asfabrication, testing and
commissioning works. Though, this may becommon requirement for most employers. The ground reality is most ofthe workforce are not trained to be well
rounded. Thiswould be apoint that could be taken up by the industry itself.
Talentdevelopment solutions must also cater beyond the engineeringcommunity, such as government officials, logistics service provider,inspection service
providersand procurement personnel. Theadvancement of the industry very much dependsall these partsof theprivate sector and public sector catering to our
oil and gasindustry.
RaisingStandardsof Training & Education
EnsuringMalaysians are capable of meeting the oil and gas industry needs andmarket demands, our workforce needs to be equipped with rightknowledge and
tools. Workforce, not just fresh graduatesneed to befostered to meet market demandsand keep abreast with current marketdevelopments.
Atpresent, there seemsto be a expectationsgap between the industryand educational institutional graduates. Asthe industry wantstheworkforce entrantsto be
job ready but thisnot alwaysthecase. However, stepsare being taken to addressthisissued by boththe private and public sector.
ThoughIEM and BEM hasprescribed path to attain professional qualificationfor engineer, most graduate engineersare either not aware of theprocessor having
lackadaisical attitude towards it. Emphasizingprofessional development for workforce entrant as well as existingshould be the case. Structured learning process
which suitstheindustry, particularly employersmust be part of the workforcedevelopment plan throughout their career with measurable indicators.
Internshipplans such as spearheaded by MOGEC, whereby linking Malaysianresearch universities and major engineering consultancy companiesbased in
Malaysia must be applauded. Solutionssimilar to thisprovideuniversity studentsan early exposure in building oil &gas
industrycapability. Thisisto ensure a smoother transition upon thecompletion of their undergraduate degree in pursuit of a career inthe oil & gasindustry.
Meanwhile,our academic institutions curriculum should be reflective of thespecializations available in the market. Key ideas and industryterminologies should
be familiarized at tertiary education level,which would enhance the confidence level of workforce entrants. Forexamples, subjectsrelated to safety, technology,
industries' codes&standardsor software toolsshould me available to final yearstudentshere.
Boththe industry and academia need to strengthen the collaboration toalign talent development to match the oil and gasindustriesrequirements. Involvement
by industry personnels in designing theacademic curriculum and providing real field or business exposurethrough the sharing of experiences, must be
encouraged and rewarded. More structured learning programme are also needed for existingindustry practitioners to improve themselves. This could be
arrangedvia partnership between industry and academia.
Conclusion
Whiletalent will be a constant issue for the next decade, there is alreadya talent pool in Malaysia that needs to be developed and refined.This may involve a
long term commitmentsfrom both public sector andindustry players. But the benefitsthat could be reaped far outweighsthe effortsthat are needed.
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Posted 19th August 2012 by Danaraj Chandrasegaran
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Intro
Am currently based in Ulsan, South Korea. Working at the largest shipyard in the world. Doing my bit here to share the
knowledge I have accrued all these years. I find that general literature describing the equipment used in the oil & gas
industry etc. lacking on the web. Hence, my effort here to be a starting point the least.
Posted 6th August 2012 by Danaraj Chandrasegaran
Labels: General

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AUG

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