Specification for

CHEMICAL INJECTION PACKAGE

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REMARKS / REMARQUES :
- CHEMICAL INJECTION PACKAGES

Table of Contents

1. Purpose ........................................................................................................................... 5

2. Scope of supply ................................................................................................................ 6

3. Limit of supply ................................................................................................................. 9

4. General requirements .................................................................................................... 10

5. Particular requirements ................................................................................................. 12

6. Inspection and shop tests .............................................................................................. 16

7. Surface preparation and coating .................................................................................... 18

8. Performance / guarantee ............................................................................................... 19

9. Alternatives and deviations ............................................................................................ 19

10. SELLER’s responsibilities................................................................................................. 19

11. Quality control ............................................................................................................... 20

12. Schedule for BUYER, fabrication and delivery................................................................. 20

13. Field erection and tests .................................................................................................. 21

-
1. Purpose

This specification covers the minimum requirements for the supply of chemical injection
package.

1.1 Basic data and site conditions

1.2 Standards, codes and documents

All local laws, rules and regulations shall be applicable to the design, inspection and test of
the equipment.

It is the SELLER' s responsibility to ensure the compliance with all local laws, rules and
regulations in addition to documents and specifications listed into requisition.

1.3 Document precedence

In the case of conflict between any of the documents referenced in this specification, the
following shall be the order of precedence:

• National, regional or local Algerian laws, regulations and codes,

• The requisition and attached documents,

• This present specification,

• CLIENT’ s specifications,

• Codes & standards.

When code requirements are more stringent they shall prevail over the requisition,
specification and standards. Should any doubt arise regarding the rules, the SELLER shall
submit to the BUYER all requests of deviations and /or clarifications and obtain a written
approval before proceeding.

If during the studies or the fabrication, inconsistencies have been founded in contractual
documents, any delay in good / document delivery or extra price should be applied.

1.3.1 Authority Approval

Algerian laws and regulations apply for this project.

It shall be SELLER's responsibility to ensure that his scope of supply fully meets the
requirements of the Algerian laws and regulations.

SELLER shall include all authority documentation, approvals documentation, etc in the
manufacturing data books. Documentation required for Authority Approval shall be in
both English and French languages.
-2. Scope of supply

2.1 Skid for the chemical injection package

• Fabricated steel baseplate for the chemical injection package, packers and shims,
anchor bolts, jacking plates or positioning device, grouting products.

2.2 Storage tanks

• V-711 Spare storage tank (volume 5 m3),
1 • V-712 scale inhibitor storage tank (volume 1 m3),
• V-713 oxygen scavenger storage tank (volume 1 m3),
• V-714 bactericide storage tank (volume 1 m3),
• V-715 corrosion inhibitor storage tank (volume 2.5 m3),
• V-717 corrosion inhibitor storage tank (volume 1 m3),
• V-718 scale inhibitor storage tank (volume 1 m3),
• V-719 demulsifier storage tank (volume 5 m3),
• V-720 demulsifier storage tank (volume 3.5 m3).

2.2.1 Each storage tank shall be provided with

1 • Filling connection with isolating valve,

• Level gauge,
• Level transmitter,
• Cleaning connection with blind flange,
1 • Over flow (with hydraulic seal for V-711 and V-713) connected to drip tray,
• Connection to injection pumps,
• Vent.

2.2.2 Electric mixers

All storage tanks shall be provided with electric mixer, except V-714 bactericide storage
tank.
• Electric mixer M-711 for V-711 Spare storage tank,
• Electric mixer M-712 for V-712 scale inhibitor storage tank,
• Electric mixer M-713 for V-713 oxygen scavenger storage tank,
• Electric mixer M-715 for V-715 corrosion inhibitor storage tank
1 • Electric mixer M-717 for V-717 corrosion inhibitor storage tank
• Electric mixer M-718 for V-718 scale inhibitor storage tank
• Electric mixer M-719 for V-719 demulsifier storage tank
• Electric mixer M-720 for V-720 demulsifier storage tank
2.2.3 Blanketing device

For V-711 Spare storage tank and V-713 oxygen scavenger storage tank shall be provided
with blanketing device including :
- • Blanketing connection,
• Pressure control valves for fuel gas blanketing,
1 • Pressure safety valve,
• Vent connection to pressure safety valve,

2.2.4 Vent to atmosphere

1 • Vent connection shall be provided for V-712 scale inhibitor storage tank, V-714
bactericide storage tank, V-715 corrosion inhibitor storage tank, V-716 corrosion
inhibitor storage tank, V-718 scale inhibitor storage tank, V-719 demulsifier storage
tank and V-720 demulsifier storage tank.

2.2.5 Dilution injection

• Water dilution injection manifold for V-711, V-712, V-713, V-715, V-717, V-718 and
1 V-720,

• Diesel injection for V711 and V-719.

2.3 Injection pumps

P-711 A/B spare injection pumps, with two heads
P-712 A/B scale inhibitor pumps, with two heads
1
P-713 A/B oxygen scavenger pumps, with one head
P-714 A/B bactericide pumps, with two heads
P-715 A/B corrosion inhibitor pumps, with one head
P-716 A/B corrosion inhibitor pumps, with one head
P-717 A/B corrosion inhibitor pumps, with four heads
P-718 A/B scale inhibitor pumps, with one head
P-719 A/B demulsifier pumps, with two heads
P-720 A/B demulsifier pumps, with two head
1
Each pump is provided with a spare pump (consider sparing identical pump with combined
spare parts).

2.3.1 Each injection pump shall be provided with

• Local Injection rate control per head,

• Local injection rate readout per head,
• Calibration pot per head, common to main and spare pumps,
1 • Pressure indicator on discharge injection line,
• Filter and isolating valves for each pump,
• Integrated relief valves.
-
2.4 Electricity
• Electric motor for injection pumps and mixers
• Cable glands of electric motors
• Earthing of components and base plate

2.5 Injection devices

1 SELLER shall supply 20 injection devices consisting of injection pipe with flange connection
for process line piping and chemical injection line (see tabulation and sketch in document
N° 5037-SK-PD-00-001).

2.6 Miscellaneous

• Piping/Tubing manifolds in base plate,

• Inspection and tests of the equipment as specified in paragraph 6 of this
1 specification,
• Testing devices,
• Internal & external cleaning after fabrication and tests,
• Bolts, nuts, gaskets necessary for erection,
• Name plate,
• Bolts, nuts, gaskets for each piping connection to BUYER’s connecting flanges,
• Preparation and painting of the equipment,
• Anchor bolts,
• Preparation for shipment, packing and transportation in accordance with the
specification N° XXXXXXXX,
• All special devices necessary for shipping and erection,
• Special tools required per installation, commissioning and maintenance, including
alignment tools and instrument calibration kits,
• All contractual documentation and drawings as specified in the requisition.

2.7 Services
The scope of services of the SELLER shall include the following:

2.7.1 SELLER / sub-SELLER services

• Co-ordination meetings in SELLER or representative offices,

• Setting up of all documents and fabrication drawings necessary for purchasing of all
materials and equipment,
• Inspection of equipment and materials manufactured by sub-SELLERS,
• Progress reporting,
• Third party certification for all pressure apparatus of the supply.
-
2.7.2 SELLER / CONTRACTOR and CLIENT services

a. Co-ordination meetings in BUYER or SELLER offices,

b. Technical assistance at site.

SELLER technical assistance shall concern his assistance during erection, commissioning
1 and start-up. This request is clearly shown in the purchase order terms. All services shall
be supervised by BUYER.

2.8 Spare parts

SELLER shall supply the following spare parts:

a. Spare parts for field installation, start-up and commissioning.

b. Capital spare parts.SELLER to advise which capital spares could be considered being
recommended for the quoted scope of supply.
1 Based on this list the required spares will be ordered.

c. Spare parts required for two years operation.

This type of spares will be purchased in parallel to the main order. The two years
spares will be based on SELLER's detailed list of recommended spares for two years
of operation.
Based on this list the required spares will be ordered.

Spare parts shall be preserved for long time storage.

2.9 Exclusions

• Civil works,
• Instrument wiring connection between junction boxes and Control building,
• All electrical power to motors and power cables,
• Washing oil and first filling of oil
• Site erection and commissioning.

3. Limit of supply

The SELLER shall supply all the equipment and accessories with the following limits:

3.1 Piping
At connecting piping flanges located at limit of the skid,

All nozzles will be blanked off with ANSI blind flanges, bolts (or stud bolts) and gaskets.

At vents and drains in base limit, blanked off with flanges.

-3.2 Instrumentation / Electrical equipment
At cable glands of junction boxes of electric motors,

At cable glands on terminal connections of junction boxes.

3.3 Earthing bosses

Earthing connections.

4. General requirements

4.1 Installation
The chemical injection package and auxiliaries will be installed outdoors, in an hazardous
classified area : Zone 2.

4.2 Units
S.I. system of measurement shall be used for all calculation, documentation, drawings,
instrument calibration and equipment name plates.

4.3 Documents & drawings

According to requisition N° 5037-PD-00-02.

4.4 Numbering
Numbering of documents and drawings issued by SELLER shall be performed in
accordance with SELLER’ standard.

4.5 Location of connections

(To be confirm, if any)

4.6 Nozzle loads and moments

The SELLER shall indicate the maximum allowable moments & forces on nozzles.

4.7 Materials
The material selection of all major components shall be in accordance with those shown
on relevant BUYER ’s data-sheets and/or specifications and drawings attached to the
requisition.

Materials shall be identified by reference to the norms listed to the requisition N° 5037-
PD-00-02.

Where such appropriate designation are not available, the steel mills' code or brand name
or references may be used. In such cases, the steel mills shall be identified and the
- chemical composition and the significant physical properties of the materials shall be
submitted to BUYER approval.

A full tracibility of the fabrication materials will be provided by SELLER.

4.8 Noise level

Noise level shall be limited to 85 dBA at 1 m from the package.

4.9 Name plate

All name plates and inscriptions attached to the equipment and instruments will be in
both English and French languages.

Name plates made of stainless steel shall be securely attached to the equipment and
located on easily accessible position.

SELLER' s standard name plate shall be used, the following information has to be provided
as a minimum.
• SELLER name and / or supplier if SELLER and supplier are not the same,
• Equipment type,
• Equipment serial number / item number,
• Equipment design conditions,
• Unit weight,
• Date of fabrication,
• BUYER order number,
• Third party certifying authority stamp.

4.10 Sub-contractors selection

Sub-contractor selection shall be made according to the list previously agreed by the
BUYER.

4.11 Materials selection

Electrical and instrument components shall be selected according to BUYER list.

4.12 Miscellaneous

• Maximum parts shall be interchangeable, easily removable and provided from

SELLER’s standard.

• All elements will be suitably marked, in order to enable their easy identification on
site.

• All piping connections shall be protected from damage during shipping, storage and
installation by means of wood, heavy duty plastic or metal covers or counter flanges
(ANSI type) as required.
- • Machined flange surface shall be coated with an easily removable rust preventive
grease or strippable protection coating.

• Standard replacement parts shall be readily available.

• The chemical injection package shall be supplied with all auxiliary elements
necessary for erection and start-up.

• The chemical injection package shall be installed by others according to the

instruction manual supplied by SELLER and assistance of SELLER supervisor on site.

5. Particular requirements

5.1 Introduction
In the MLN Development Project, the streams of number of oil wells are combined. The
gas is separated off, from the oil in the high and medium pressure separators,
compressed, dried and re-injected into the wells.

The oil from the wells, also contains some salt water. The water is separated off from the
oil, the oil is washed with dilution water and desalted, and the oil is stabilized, stored and
exported. The produced water, together with additional aquifer water is stored and
injected into the wells.

The Chemical Injection Package will be designed to control :

Corrosion in the gas /oil separation equipment, the gas compressors, and the injection
water system,

Oxygen in the injection water system,

Bacteria in the injection water system, and the firewater system,

Scaling in the reboiler of the stabilizer, injection water system, wash water (also called
dilution water with deep aquifer water quality),

Demulsifier control in the oil/water separators.

5.2 General
The chemical injection package and auxiliary elements shall be designed for continuous
operation.

The equipment shall be delivered pre-assembled to the maximum extent possible on

skids, ready for transport and installation on its foundations.

SELLER shall review its equipment design with regard to the discovery and elimination of
any safety hazards. This review shall cover amongst others:

• Safeguarding of personnel against hazards of machinery in operation.

- • Ergonomics (operability, maintainability).
• Falling objects.
• Tripping.
• Leaking of hazardous liquids and gasses.
• Fire and explosion.
All elements of the chemical injection package shall be of proven design and shall be well
within manufacturer’s actual experience.

Equipment shall be suitable for operation in Zone 2, gas group IIB, temperature class T3.

English language shall be used for all design and engineering documents, for drawings and
for communication with BUYER. For authority approvals refer to paragraph 1.4.

1 Operating and Maintenance manuals shall be in English and French.

5.3 Design rules

The equipment shall be designed, constructed and tested in accordance with the
specifications, codes and standards and documents listed in the requisition.

5.3.1 Construction

The unit shall be skid mounted for ease of construction and shipping. The materials to be
used shall ensure a service life of 20 years. The unit will be mounted outside in a desert
environment. Outer surface should be prepared and protected against external corrosion,
including the effects of sand.

• The material of construction to be used are SS 316, but alternatives can be

proposed by the SELLER.
• The injection pump discharge must be protected with a relief valve against
overpressure at the design value given in the data sheet. (The pump must be able to
supply the chemical product up to this pressure design value).
• Availability : SELLER shall indicate any preventive maintenance requirements to
1 guarantee the unit reliability.

5.3.2 Connections

All connections shall be flanged unless otherwise specified on individual item data sheet.

5.3.3 Water & Oil characteristics

See the ‘ WATER & OIL CHARACTERISTICS’ extract of document 5037-00-101 ‘BASIS OF
DESIGN’ (pages 31 to 33/49).

5.3.4 Atmospheric conditions

See the ‘ ENVIRONMENTAL CONDITIONS’ extract of document 5037-00-101 ‘BASIS OF

DESIGN’ (pages 34 to 37/49).
-
5.3.5 Utility conditions

See the ‘ UTILITY CONDITIONS’ extract of document 5037-00-101 ‘BASIS OF DESIGN’

(pages 45 to 49/49).

5.4 Design conditions

Design conditions for the equipment are stated in the data sheets.

The pumps are not located immediately next to the equipment where the injection takes
place.

1 Storage volume : one week based on diluted chemical (1 m3 mini), refer to paragraph 2.2.

5.5 Electrical
The electrical materials, equipment and installation shall comply with the requirements of
Electrical Specification for Package Units n° 5037-SP-UE 341.

Special consideration shall be given to the design with respect to the mechanical integrity
that will be governed by the severe conditions of the road transport through the desert.

5.5.1 Emergency power

Control equipment that requires emergency power will be connected to the plants
redundant AC UPS system (230 V, 50Hz).

5.5.2 Electric Motors

All motors shall be in accordance with IEC 60034 and shall be suitable for direct on-line
starting. Motors below 200 kW shall be 400 V, 3ph, 50Hz, motors above 200 kW rating
shall be supplied from 5.5 kV. See ‘Electrical specification for Package units’ N° 5037-SP-
UE341.

The degree of protection afforded by the motor enclosure shall be IP 55 minimum. The
motor shall be 400 V.

Windings shall be provided with Class F (temperature rise limited to class B) type of
insulating materials, as defined in IEC Standards.

Motors shall be standardized on make, type and execution to the maximum extent.

Motors shall be supplied together with the driven equipment whereby the supplier of the
driven equipment will be responsible for compliance with the project requirements.

5.5.3 Earthing

All major components of equipment shall be properly earthed by SELLER. Each base plate
shall be provided with two (2) earthing lugs diagonal opposite of each other.
-
5.5.4 Miscellaneous

All electrical devices shall be supplied complete with cable glands, metallic glands for
metallic enclosures and plastic glands for plastic enclosures.

A cable/cable gland schedule shall be provided by SELLER in the early stage of the project.

All electrical equipment and installation components other than electric motors are to be
labeled and certified according to the prescriptions of the authorities.

SELLER shall indicate on P&ID’s any piping, instrument process lines and / or instruments
which require electrical tracing.

All major components of equipment shall be properly grounded by SELLER. Each base-
plate shall be provided with two grounding lugs.

BUYER will supply and install all interconnecting power and control cables between the
substation and the electrical consumers that form part of the package.

Electrical equipment data shall be filled in on the attached data sheets. Power
consumption data of auxiliary equipment shall be provided in tabular format showing the
actual consumed loads, the load patterns and duration of load requirements

5.6 Instrumentation

General

SELLER shall provide all instrumentation and associated equipment for a safe, fully
1 operational and maintainable unit as specified by BUYER and required by SELLER. This
shall include all skid-mounted instruments wired to skid-mounted junction boxes, located
at limit of the skid, local instrumentation, local gauge board(s).

All in accordance with the specification “Instrumentation for Package units”:N° 5037-SP-
UE 351, category option A.

Instrument tag numbers, cable numbers, Local panel numbers, Junction box numbers, etc.
will be advised to the SELLER during the project execution.

SELLER shall furnish a detailed functional analysis with regard to control, monitoring,
interlocks and safe shutdown of the package; clearly indicating which parts (if applicable)
need to be incorporated into the overall plant DCS, MCC, ESD, CCC, and Fire & Gas
1 systems.

5.7 Piping
Piping shall be in accordance with specification 5037-SP-UE302 piping class, the Nuts and
Bolts will be executed in compliance with ISO standards (see pages 4/7 of requisition N°
5037-PD-00-02.
-5.8 Injection devices
Injection device will consist of an injection pipe welded on blind flange in Stainless Steel
material, inserted between 2 process flanges.

Injection device shall be as per document N° 5037-SK-PD-00-001 and associated PID.

Injection device shall be in accordance with specification 5037-SP-UE302 piping class

6. Inspection and shop tests

Inspection and tests shall performed by the SELLER according to codes, local rules and the
documents listed in the requisition:

6.1 General
The BUYER, its designated representative, or both, reserve the right to inspect all
components and their assembled units to ensure that materials and workmanship are in
accordance with applicable standards, specifications, codes and drawings.

Inspection of BUYER and/or the CLIENT will be based on the applicable scope of inspection
attached to the requisition and shall never release the SELLER of the fulfilment of all his
duties related to quality control and certification of his supply.

The SELLER shall inspect all individual components and their shop assembled units to
ensure that materials and workmanship are in accordance with applicable standards,
specifications, codes and drawings.

6.2 Material inspection and tests

All major parts shall receive a material test as specified in the following paragraphs in
accordance with the requirements of the applicable material specification as follow:

6.2.1 Chemical analysis

SELLER shall supply certificate of material chemical analysis as follow:

• 3.1 b for all process wetted and pressure retaining parts.

• 2.2 for all others.

6.2.2 Destructive & non destructive tests

The SELLER shall perform the shop inspection in accordance with the applicable standards
listed in the requisition and in the individual data sheets.

Standards tests of unit shall be proposed by SELLER. The SELLER shall include a description
of tests in his proposal and will clearly indicate the means used.

Quality control in SELLER's workshop with Organism of control if required and tests for
pressure vessel (test certificates).
- A certifying authority will be appointed by SELLER for all vessel/shell pressure tests.
SELLER will make sure that the third party can deliver a certification which is valid in
Algeria.
-6.2.3 Chemical injection package

The minimum test requirements are:

• Hydrostatic test of storage vessels.

• Hydrostatic test of piping and pumps.
• Functional and performance test of pumps according to API 675, 2nd edition.
• Full assembly of the package.

6.2.4 Instrumentation

The minimum test requirements are as required by specifications listed in the requisition.

6.2.5 Electrical

• For LV motors : routine test and noise test.

6.2.6 Site acceptance test

1
The Site Acceptance Test will be carried out at the construction site when all appropriate
parts of the systems have been installed and powered-up. SAT will be a repeat of the FAT,
but actual source inputs and final actuation elements are included. All special features
such as control interlocks, start-up after power failure etc. shall also be tested.

7. Surface preparation and coating

7.1 General
The painting shall be applied following the SELLER' s standard specification in accordance
with the contract specification N° 5037-SP-001.

The SELLER's painting specification shall be included in the proposal.

Stainless steel parts are not painted.

7.2 Minimum requirements

• Preparation : Power tool cleaned to SA 2½

• Priming : HOLD
Proposed by SELLER
• Finishing : HOLD

• Colour : RAL 7035

Machined parts shall be protected with STD SELLER.

The required film thickness shall be the minimum dry thickness to be guaranteed by the
SELLER.
- Painting shall be done after all other inspections are completed.

8. Performance / guarantee

8.1 Performance guarantees

In addition to the warranty and guarantees required in BUYER general conditions of
purchase the SELLER shall provide performance guarantee based on the process data
given in the data sheets and documents attached to the requisition.

It is understood and agreed that if the stated performance is not achieved the SELLER shall
at this own expense make the necessary modifications to the equipment to enable the
guaranteed performance to be reached and shall agree the repair, modify, or replace free
of charge any part which proves defective or operates unsatisfactorily.

8.2 Mechanical guaranties

According to the general conditions of purchase, the SELLER shall guarantee that all
materials shall be new and free from vices and defects.

9. Alternatives and deviations

Without a clear agreement in writing from the BUYER, it shall be mutually agreed that the
1
SELLER complies with the requisition and attached documents.

The SELLER shall be responsible in obtaining the conformity of equipment supplied by sub-
SELLERS.

Any deviation from Sub-SELLERS has to be incorporated into the agreed "deviations" to be
considered acceptable.

10. SELLER’s responsibilities

The chemical injection package supplier shall be the "SELLER" and will be responsible for
the design, the co-ordination and the guarantee of the complete unit including the
equipment manufactured by others, it shall guarantee the good compatibility for
dimensions, lubrication, vibration, control and performances of the different components
of the supply.

All equipment and component parts shall be guaranteed by the SELLER against defective
materials, design and workmanship for the duration specified in the conditions of
purchase.

All inspection costs shall be at the charge of the SELLER, including inspections from official
authority.
-11. Quality control

The SELLER shall apply a quality control plan in accordance with ISO 9001.

The SELLER shall give a quality control plan which will describe the main control and
manufacturing processes operations

This quality plan shall cover the following topics :

11.1 Hold points

The SELLER shall provide a plan identifying proposed hold points in the production process
or witness or approval of particular activities by the BUYER or its appointed agents. In
particular:

11.2 Procedures
The SELLER shall provide details of procedures and standards by which it is proposed to
control. In particular:
• Quality relating manufacturing processes,
• Methods of qualification of work, inspection and test procedures,
• Welding procedures specifications & qualification,
• Heat treatment procedure & diagram,
• Non destructive examination procedure,
• The calibration and maintenance of inspection and test equipment,
• Surface preparation & painting specifications,
• Packing and shipping of finished products.

11.3 Production schedule

The SELLER shall provide a production schedule indicating the key points where quality-
related manufacturing processes, inspection and tests will occur.

12. Schedule for BUYER, fabrication and delivery

12.1 Workshop
A planning of design, fabrication, mounting, testing and preparation for shipment shall be
1
submitted to BUYER every month.

12.2 Erection on site

A detailed erection schedule shall be given to the BUYER 2 months after the purchase
order.
1
- This schedule shall indicate the number of supervisors, specialists, … required.

Erection manuals will be provided two months after the purchase order.

12.3 Commissioning (option)

A detailed commissioning and start-up schedule shall be submitted to the BUYER
1
2 months at the latest before shipment at site.

13. Field erection and tests

1 See purchase order for detail.