Issued For Implementation

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Process Design Basis (PDB), Part B

TABLE OF CONTENTS

1. INTRODUCTION............................................................................................................... 5

1.1. Project Background ........................................................................................................... 5

1.2. Scope of Document........................................................................................................... 6

1.3. Codes and Standards ....................................................................................................... 6

1.4. CAIRN Standards / Procedures......................................................................................... 8

2. DEFINITIONS & ABBREVIATIONS................................................................................... 8

2.1. Definitions ......................................................................................................................... 8

2.2. Abbreviations .................................................................................................................... 9

3. REFERENCE .................................................................................................................. 12

4. UNITS OF MEASUREMENTS ........................................................................................ 12

5. PLANT LOCATION ......................................................................................................... 14

5.1. MAP ................................................................................................................................ 14

5.2. Raag ............................................................................................................................... 14

5.3. Guda ............................................................................................................................... 15

5.4. Tukaram.......................................................................................................................... 15

5.5. NL ................................................................................................................................... 16

5.6. KW-3 ............................................................................................................................... 16

5.7. KW-6 ............................................................................................................................... 16

5.8. GSV ................................................................................................................................ 16

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5.9. Raag- South .................................................................................................................... 17

5.10. Shakti .............................................................................................................................. 17

5.11. SL-1 ................................................................................................................................ 17

5.12. Saraswati SW-1 .............................................................................................................. 18

5.13. Guda South – 7 ............................................................................................................... 18

5.14. NP ................................................................................................................................... 18

5.15. Kaam-1 ........................................................................................................................... 19

6. METEOROLOGICAL DESIGN DATA.............................................................................. 19

7. PLANT LIFE .................................................................................................................... 20

8. PLANT OPERATION ...................................................................................................... 20

9. DESIGN MARGIN & TURN DOWN CAPABILITY ........................................................... 21

10. EQUIPMENT DESIGN PHILOSOPHY ............................................................................ 21

10.1. Selection of Mechanical Design Conditions ..................................................................... 21

10.2. Vessels ........................................................................................................................... 24

10.3. Pumps............................................................................................................................. 28

10.4. Compressors................................................................................................................... 30

10.5. Fired Heaters .................................................................................................................. 30

10.6. Electric Heaters ............................................................................................................... 31

10.7. Pigging ............................................................................................................................ 31

10.8. Produced Water Treatment Package .............................................................................. 32

11. LINE SIZING ................................................................................................................... 32

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12. PIPE LINE ....................................................................................................................... 34

13. CONTROL VALVE SIZING ............................................................................................. 34

14. DEPRESSURIZATION .................................................................................................... 35

15. SOFTWARES ................................................................................................................. 36

16. UTILITY SPECIFICATIONS ............................................................................................ 36

16.1. Utility Conditions ............................................................................................................. 37

17. INSTRUMENTATION & CONTROL ................................................................................ 40

18. PIPING & INSULATION .................................................................................................. 41

19. ENVIRONMENTAL CONTROL ....................................................................................... 41

20. SAFETY .......................................................................................................................... 41

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1. INTRODUCTION

1.1. Project Background

Cairn Oil & Gas (Vedanta Limited) is India’s largest private upstream O&G company
with operating interests in several producing fields in India contributing ~27% of India’s
domestic crude production. Cairn Oil and Gas (Vedanta Limited) is the operator of the
onshore RJ-ON-90/1 block, on behalf of itself and its Joint Venture (JV) partners Cairn
Energy Hydrocarbons Limited (CEHL) and Oil and Natural Gas Corporation Limited
(ONGC), located in Barmer & Jalore districts, in the state of Rajasthan, India. Cairn Oil
& Gas (Vedanta Limited) holds 70% participating interest in the block which contains
38 major oil and gas discoveries, with significant gas potential in the southern area and
oil in the northern area of the Barmer Basin. Apart from 4 major discoveries in the
basin, viz. MBA (Mangala, Bhagyam & Aishwariya) & RDG (Raageshwari Deep Gas),
remaining 34 discoveries are relatively marginal in nature, and are geographically
widespread across the basin and are under various stages of execution.

Cairn Oil and Gas (Vedanta Limited) intends to fast track the execution of 14 identified
fields in RJ-ON-90/1 block in order to maximize the resource monetization with cost
optimization. To achieve these objectives, Cairn Oil and Gas (Vedanta Limited) intends
to partner with global Oil & Gas Service/EPC companies and/or consortiums, with
capabilities for end to end Integrated Oil well construction (including but not limited to
drilling, completion, frac and associated well services) and development of surface
facilities (including but not limited to well pad, intra-field network and evacuation
facilities / pipeline to designated hook-up point).

Halliburton Offshore Services Inc. (HOSI) has been awarded the Engineering,
Procurement and Construction (EPC) contract for Integrated Field Plan Execution
Services in the identified 14 fields in RJ-ON-90/1 block in Barmer & Jalore Districts of
Rajasthan, India. Sparklet Engineers Private Limited (SEPL) is the subcontractor to
Halliburton Offshore Services Inc. for the development of surface facilities in these
fields and Petrocil Engineers and Consultants is the selected engineering partner of
SEPL. Accordingly PETROCIL will carry out the FEED and Detailed Design &
Engineering services including interfacing of all vendor packages along with
procurement support services like RFQ preparation, Technical Bid Evaluation and
Vendor Document Review of identified packages.

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1.2. Scope of Document

This document describes basis of design and provides the process design data and
criteria including the process design codes and standards that will be used for the
design & engineering of various equipment, process systems, lines etc. The main
objective of the document is to define the basis of design i.e. inlet compositions, design
scenarios & envelop for design of process & utility systems, production rate, product
specification etc. for the “Satellite Field Integrated Project” at each location.

The Process Design Basis (PDB) is prepared in two parts:

Part - A : Process Design Basis, Part-A;

(Applicable to each packages (i.e. Package A, B & C))
Part - B : Process Design Basis & Criteria, Part-B;
(Common, applicable to all Packages)
This document describes the “Process Design Basis, Part-B” and it should be read in
conjunction to Process Design Basis, Part-A for different Packages, i.e. Package A, B
& C.

1.3. Codes and Standards

The following international codes and standards will be referred for the design and
detailed design & engineering services.

Codes & Standards Description

API 14C Basic Surface Safety Systems
Recommended Practice for Design and Installation of
API RP 14E
Offshore Production Platform Piping Systems
Sizing, Selection, and Installation of Pressure-Relieving
API 520 Part I
Devices in Refineries
API 520 Part II Pressure-Relieving Devices Installation
Guide for Pressure-Relieving and Depressurizing
API 521
Systems
API 526 Flanged Steel Pressure Relief Valves
Flare Details for General Refinery and Petrochemical
API 537
Service
API 560 Fire Heater for General Refinery Service
ASME B 31.8 Gas Transmission and Distribution Piping Systems
ASME B 31.3 Process Piping
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Codes & Standards Description

Pipeline Transportation Systems for Liquid
ASME B 31.4
Hydrocarbons and other Liquids
ASME Sec. II Material Specifications and Properties Parts A,B,C&D
ASME Sec. VIII Div.1 Rules for Construction of Pressure Vessels.
Venting Atmospheric and Low-Pressure Storage Tanks
API 2000
- Non-Refrigerated and Refrigerated
Specification For shop Welded Tanks For Storage Of
API 12 F
Production Liquids.
Report No. 9 – Measurement of Gas by multi path
AGA 9
ultrasonic flow meters
API 660 Heat Exchangers for General Refinery Service
Air-Cooled Heat Exchangers for General Refinery
API 661
Service
Centrifugal Pumps For Petroleum, Heavy Duty
API 610
Chemical and Gas Industry Services
API 12J Oil and Gas Separators
API 12 K Specification for Indirect Type Oilfield Heaters
Heaters Specification for Vertical and Horizontal
API 12 L
Emulsion Treaters
API 676 Positive Displacement Pumps- Rotary
Axial and Centrifugal Compressors and expander –
API 617 compressor for petroleum chemical and gas industry
services
Reciprocating Compressor for Petroleum,
API 618
Petrochemical and Natural gas Industries.
Rotary-type Positive Displacement Compressors for
API 619
petroleum, Petrochemical and Natural Gas Industries
Standard for the Installation of Stationary Pumps for Fire
NFPA 20
Protection
NACE MR 0175/ ISO Petroleum and Natural Gas Industries- Materials for use
15156 in H2S containing environments in Oil& Gas Production
OISD-STD-106 Pressure Relief & Disposal System
OISD-STD-108 Recommended Practices on Oil Storage and Handling
Process design and operating philosophies on fired
OISD-STD-111
process furnace
OISD-STD-118 Layouts for Oil and Gas Installations
OISD-STD-119 Selection, Operation and Maintenance of Pumps
OISD-STD-120 Selection, Operation and Maintenance of Compressors
Selection, Operation and Maintenance of rotary
OISD-RP-123
equipment components
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Codes & Standards Description

OISD-STD-125 Inspection and Maintenance of Mechanical Seals
Selection operation inspection and maintenance of
OISD-STD-127
Diesel Engines
Design and Construction requirements for cross country
OISD-STD-141
hydrocarbon pipelines
Standard On Fire Fighting Equipment For Drilling Rigs,
OISD-STD-189
Work Over Rigs and Production Installations
Corrosion Monitoring Of Offshore & Onshore
OISD-STD-188
Pipelines
Simultaneous Operations in Exploration & Production
OISD-STD-186
industry
Note-1: Relevant OMR and DGMS standards will be applicable.

1.4. CAIRN Standards / Procedures

Standards Description
CAIRN-TSG-J-STD-0001 Units of Measurement
CAIRN-TSG-IM-PRO- Document Numbering Procedure & Requirement for the
0001-B1 Delivery of Supplier Documentation
DECO-RX-J-PRO-2001-
Equipment Numbering System
B2

2. DEFINITIONS & ABBREVIATIONS

2.1. Definitions

NOMENCLATURE DESCRIPTION
Cairn Oil and Gas (Vedanta Limited) or its authorized
Company
representative (CAIRN)
Main Contractor Halliburton Offshore Services Inc. (HOSI)
Sub-contractor Sparklet Engineers Pvt Ltd (SEPL)
Engineering Consultant Petrocil Engineers & Consultants (PETROCIL)
Shall mean the party, who manufactures or supplies
Vendor
the equipment and services specified
Integrated Field Plan Execution Services In Satellite
Project Fields In RJ-ON 90/1 Block-Surface Facilities (Satellite
Project)

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2.2. Abbreviations

Abbreviations Description
API American Petroleum Institute
APH Air Pre Heating
ASME American Society of Mechanical Engineers
BL Battery Limit
BBLD Barrels per Day
BOPD Barrels of Oil per Day
BLPD Barrel of Liquid per Day
BS&W Basic Sediments & Water
CBH Central Basin High
CD Closed Drain
C&E Cause and Effect
CO2 Carbon Dioxide
CTM Custody Transfer Meter.
cP Centi Poise
CPCB Central Pollution Control Board
CPF Central Processing Facility
CR Control Room
CS Carbon Steel
CSS Control and Safety System
DB Design Basis
DCS Distributed Control System
DG Diesel Engine Generator
DGMS Director General of Mines Safety.
EIA Environmental Impact Assessment
ESD Emergency Shutdown
FBE Fusion Bond Epoxy
FFG Flame Front Generator
FGS Fire and Gas System
FG Fuel Gas
F&G Fire & Gas
FV Flow Control Valve
GEG Gas Engine Generator
GLC Ground Level Concentration
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GOR Gas Oil Ratio

HC Hydro Carbon
HHLL High High Liquid Level
HLL High Liquid Level
HMI Human Machine Interface
HP High Pressure
HVAC Heat ventilation and Air Conditioning
H&MB Heat & Mass Balance
H2O Water
H2S Hydrogen Sulfide
IA Instrument Air
IS Indian Standard
IWBH Indirect Water Bath Heater
J-T Joule Thomson
KOD Knock Out Drum
KW Kaameshwari West
LCP Local Control Panel
LC Level Control
LLL Low Liquid Level
LLLL Low Low Liquid Level
LP Low Pressure
LPH Litre Per Hour
LR Long Radius
LTCS Low Temperature Carbon Steel
LV Level Control Valve
MCC Motor Control Centre
MFB Minimum Flow Bypass
MP Medium Pressure
MPT Mangala Process Terminal
MMSCFD Million Standard Cubic Feet per Day
N2 Nitrogen
NFPA National Fire Protection Association
OISD Oil Industry Safety Directorate
OMR Oil Mines Regulations
PA Plant Air

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PFD Process Flow Diagram

PSA Pressure Swing Adsorption
P&ID Piping and Instrumentation Diagram
PCB Pollution Control Board
PCS Process Control System
PCV Self-Regulated Pressure Control Valve
PLC Programmable Logic Controller
PLR Pig Launcher Receiver
PRV Pressure Relief Valve
PVRV Pressure Vacuum Relief Valve
PSV Pressure Safety Valve
PTFE Poly Tetra Flouro Ethylene
PV Pressure Control Valve
QPF Quick Production Facility
RDG Raageshwary Deep Gas
RFQ Request For Quotation
RGT Raageshwary Gas Terminal
SCF Standard Cubic Feet
SDV Shutdown Valve
SEHMS Skin Effect Heat Management System
SIL Safety Integrity Level
STB Stock Tank Barrel
TBA To Be Advised
TBC To Be Confirmed.
TC Temperature Control
TCV Self-Regulated Temperature Control Valve
UPS Uninterruptable Power Supply
UT Upper Thumbli
WAT Wax Appearance Temperature

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3. REFERENCE

Doc. No. Description

PO no.8500002333 - Integrated Field Plan Execution Services in Satellite
Scope of Services (SOS) Fields in RJ-ON-90/1 Block- Scope of services
Raag-Oil-Stage-II Scope of Services RJ-ON-90/1
Chapter 1
Block Rajasthan
Guda Oil Field Scope of Services RJ-ON-90/1 Block
Chapter 2
Rajasthan
Tukaram Scope of Services RJ-ON-90/1 Block
Chapter 3
Rajasthan
Chapter 4 NL Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 5 KW-6 Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 6 KW-3 Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 7 GSV Scope of Services RJ-ON-90/1 Block Rajasthan
Raag-South Scope of Services RJ-ON-90/1 Block
Chapter 8
Rajasthan
Chapter 9 Shakti Scope of Services RJ-ON-90/1 Block Rajasthan
Chapter 10 SL-1 Scope of Services RJ-ON-90/1 Block Rajasthan
Saraswati SW-1 Scope of Services RJ-ON-90/1 Block
Chapter 11
Rajasthan
Guda South 7 Scope of Services RJ-ON-90/1 Block
Chapter 12
Rajasthan
Chapter 13 NP Scope of Services RJ-ON-90/1 Block Rajasthan
Kaam 1 Scope of Services RJ-ON-90/1 Block
Chapter 14
Rajasthan
Appendix 1 Scope of Services for Quick Production Facility (QPF)
S340HAL-SRX-P-SDP-
Isolation & Sparing Philosophy
0001
S340HAL-SRX-P-SDP-
Shutdown Philosophy
0003
S340HAL-SRX-IC-BD-
Instrumentation & Control Design Basis
0001
S340HAL-SRX-L-BD-
Piping Design Basis
0001

4. UNITS OF MEASUREMENTS

All Dimensions & weights measurement shall be expressed in international unit

system.

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Quantity or Variable Metric Units Imperial / Field Units

Capacity m3 BBL
Liquid Flow by Volume m3/hr or L/H BOPD/BLPD
Gas Flow by Volume kgmol/h or Nm3/h MMSCFD
Liquid / Gas Flow by Weight kg/h or kg/s
Length mm or m
Pipe Diameter mm N.B.
Surface Area m2
Volume m3 BBL
Pressure kPa, bara or mmWG
Design Pressure kPa, barg or mmWG
Differential Pressure kPa, bar or mmWG
Pressure Losses kPa/km or bar/km
Power kW
Heat Duty 106 kcal/h or kJ/h
Temperature oC , oK

Viscosity Pa.s (Pascal-second)

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5. PLANT LOCATION

5.1. MAP

5.2. Raag

Raageshwari Oil Field, a horst block structure is located on the Central Basin High
(CBH), situated in the southern part of Barmer Basin. This was discovered in February
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2003. The field was put on production in March 2012 and the field is currently producing
from 7 wells in Raag-3 and Raag-3ST fault blocks at ~850 BOPD with a GOR of ~4000
SCF/BBL.

Raageshwari execution plan is focused on the oil bearing Upper Thumbli reservoir
units of Thumbli Formation which has been subdivided into Basal Thumbli, Middle
Thumbli and Upper Thumbli. The Upper Thumbli is further subdivided into 5 sub-units,
UT5 to UT1, wherein UT1 is the deepest unit and UT5 is the shallowest. UT4, UT3 and
UT1 units are hydrocarbon bearing whereas UT2 and UT5 are non-reservoir
mudstones.

5.3. Guda

Guda field was discovered in 1999 through Guda-2 well. The Guda field targets two
reservoirs, Upper Thumbli (UT) & Giral which are geologically dissected into multiple
fault compartments.

Guda field demonstrates the horst block morphology and is situated in the
southernmost culmination of the main Central Basin High (CBH) structure. The Guda
structure is governed by multiple phases of deformation which has resulted in separate
fault patterns across Thumbli and Giral reservoirs. Hydrocarbon pools have been
discovered across Upper Thumbli and Giral formations. Upper Thumbli (UT) is
subdivided into 5 sub-units, UT1 to UT5; UT4, UT3 and UT1 sub-units are hydrocarbon
bearing whereas UT2 and UT5 are non-reservoir mudstones. The deeper Giral
Formation is sub divided into 3 zones (Giral-1 to 3). The present focus on further growth
is only for Giral-1 zone which has tested oil.

5.4. Tukaram

Tukaram-Oil Field, located on eastern flank of the producing Raageshwari Field was
discovered in February, 2008 through the discovery well Tukaram-1Z.

The Tukaram field is situated on the eastern hanging wall of the Central Basin High
(CBH) horst structure which also comprises of the Raageshwari oil field. Tukaram plan
is focused on the oil bearing Upper Thumbli reservoir units of Thumbli Formation. The
Upper Thumbli is further subdivided into 5 sub-units, UT5 to UT1, wherein UT1 is the
deepest unit and UT5 is the shallowest. UT4, UT3 and UT1 units are hydrocarbon
bearing whereas UT2 and UT5 are non-reservoir mudstones.

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5.5. NL

The NL-NE Barmer Hill Field is located stratigraphically above the NE Fatehgarh Field
and the two fields overlap spatially.

The NL-NE Barmer Hill Field is on an east-dipping tilted fault block west of the Mangala
Field in DA2 area of RJ-ON-90/1 block. The NL-NE Barmer Hill Field is a three-way
structural trap, formed by a NNW / SSE trending normal fault. During the Miocene
inversion, strike-slip movement along the main bounding fault caused local
compression, resulting in formation of localized reverse faults along the main fault.

5.6. KW-3

The Kaameshwari West fields are located in the RJ-ON-90/1 Block in the Barmer Basin
of western Rajasthan, India. The discoveries lie within the approved DA-3 of the block.
Kaameshwari-West-3 discovery well targeted Barmer Hill Formation. The field was
subsequently appraised by drilling of Kaameshwari-West-3ST well.

Kaameshwari West-3 structures, a tilted fault block, lie in the DA-3 block. Hydrocarbon
accumulation occur in the reservoirs of Barmer Hill Formation.

5.7. KW-6

The Kaameshwari West fields are located in the RJ-ON-90/1 Block in the Barmer Basin
of western Rajasthan, India. The discoveries lie within the approved DA 3 of the block.
Kaameshwari West-6 discovery well targets the Thumbli sands.

The two Kaameshwari West structures lie in the DA-3 block. Hydrocarbon occur in the
Thumbli reservoir sand.

5.8. GSV

The GSV-1 Field lies ~10 km to the north-west of the Saraswati field, within a smaller,
terrace downthrown from the Saraswati Field.

In GSV, the volcanic rocks constitute the primary hydrocarbon bearing reservoir. The
volcanic interval constitutes Basalt and Felsic rocks. The characteristics of the volcanic
rocks are similar to the volcanic in Raageshwari Deep gas field. The GSV-1 structure
is a three-way dip closure at the Pre-Rift (Volcanic level) level. Significant losses were

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recorded over this section suggesting presence of an effective natural fracture system
within the felsic. The open-hole image interpretation suggests the presence of fractures
in the drilled volcanic reservoir section.

5.9. Raag- South

Raageshwari-South field, discovered through Raageshwari-South-1 (Raag-S-1) well is

located in CBH (Central Basin High) structure.

The Raageshwari South field is a horst block structure which is located on the Central
Basin High (CBH), Barmer Basin. Raageshwari-south plan is focused on the oil bearing
Giral reservoir units of Dharvi Dungar Formation. Giral Formation is having different
sands namely G1 Sand, G2a Sand and G2b Sand.

5.10. Shakti

Shakti field, located within the north eastern part of RJ-ON-90/1 block of Barmer Basin,
comprises of two closely spaced hydrocarbon closures, namely, Shakti North & Shakti
South.

Shakti field, comprising two closely spaced 3-way structural closures (Shakti North and
Shakti South), is situated on the uplifted north eastern terrace of Barmer Basin. Shakti
North is about 180m shallower than Shakti South and the structures are approximately
5km apart. Major hydrocarbon bearing interval in Shakti field is the fluvial clastics of
Fatehgarh Formation which is a moderate net-to-gross (NTG) sandstone package with
good porosity and permeability.

5.11. SL-1

The SL field situated in the central part DA-3 of Barmer Basin, was discovered in April,
2014 through drilling of SL-1 well. The well has been perforated in Basal Thumbli @
982-987 m MD (DD-3) and hydraulic fracture stimulation carried out and activated
through N2 lift through CTU and produced oil of 42 API.

The field is located in the central part of Barmer basin, South of Airfield high within the
DA-3, Barmer Basin. SL-1 plan is focused on the oil bearing Basal Thumbli reservoir
units. The SL-1 is a strati-structural trap closing against N-S trending fault in west and
faces change on the eastern side. The reservoir is inter bedded clay stone and sand
stone. Intra-formational shales act as the top and lateral seal.
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5.12. Saraswati SW-1

The Saraswati-SW fault block is located on a hanging wall structure 2.6 Km WSW of
Saraswati-2 well (foot wall of the main Kaameshwari fault).

The Saraswati-SW fault block lies on the hanging wall of the main Saraswati field and
footwall of the Kaameshwari field. The structural trap is provided by N-S and E-W
trending normal faults. E-W trending fault in the north of the Saraswati-SW-1 well has
very little mapped throw at the Mesozoic level. Saraswati-SW fault block primarily
targets the upper member of pre-rift Mesozoic channel sands of fluvial environment
which is co-relatable to the Upper Fatehgarh sands in producing Saraswati field at
Saraswati-6. The petrographic studies of the core show that due to digenesis, the
reservoir properties are very poor due to digenetic quartz overgrowth cement.
Reservoir quality in Saraswati-SW-1 well is similar to the main Saraswati field.

5.13. Guda South – 7

Guda-South-7 field discovered through Guda-South-7 well in April 2014, is situated at

the southern tip of Guda / Guda South culmination.

The Guda South-7 field is situated on the southern-most culmination of N-S plan is
focused on the oil bearing Thumbli reservoir units within the Upper Thumbli

5.14. NP2

N-P field is located 6.4 km southeast of the N-E-1 discovery well, in the northern
Barmer Basin, Rajasthan.

N-P field, a tilted fault bounded structure by two 1st order trending N-S trending reverse
fault in East and West in Western part of the Barmer Basin. NP field is overlain by the
Air field. In N-P field, Fatehgarh Formation has an average porosity of 20%, water
saturation of 19% and average permeability of 500 md. Overlying Barmer Hill in this
area is interpreted to be a lacustrine deposit, with a switch back to fine clastic sediment
from suspension with possible seasonal control of lamination.

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5.15. Kaam-1

The Kaameshwari field situated within the south-central part of DA-1 of Barmer Basin,
was discovered through Kaameshwari -1 exploration well with primary targets as
Fatehgarh and Barmer Hill sands.

The Kaameshwari structure is primarily a structural trap with three-way dipping closure
against the main NNW-SSE trending fault to the west. This fault provides the lateral
seal to the hydrocarbon column in the reservoir sections. Fatehgarh is the main
reservoir in this structure, as proven in the drilled wells. Wire line image data
interpretation and core data suggests the presence of major and minor fractures, both
open and partially closed in the drilled Fatehgarh section.

6. METEOROLOGICAL DESIGN DATA

The following data is common for all locations in RJ field.

Site Environment
170 meters above MSL (shall vary from
Site elevation
location to location)
Environment Typical desert climate
Soil Temperature @ 1 m Burial Depth 37 °C (Max) / 22 °C (Min)
Ambient Conditions
Black Body Temperature 80°C
Design maximum temperature 50°C
Design minimum temperature -2°C
Coldest month normal minimum
10.6°C
temperature
Hottest month normal maximum
42°C
temperature
Solar Radiation Level 1.04 kW/m2
Relative Humidity
 Post monsoon 31% to 74%
 Winter 27% to 53%
 Summer 23% to 67%
Wind
47 m/s at 10 m above mean ground
 Basic Wind Speed(Vb)
level
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Site Environment
 Risk Coefficient Factor (K1) 1
 Terrain Category 1
 Topography Factor (K3) 1
The predominant wind direction
switches over from N-W/N-E sector in
Prevailing direction
winter season to S-W sector in summer
season.
10.60%
1 – 5 km/hr : 7.1%
N-E
5 – 11 km/hr : 3.2%
11 – 19 km/hr : 0.3%
13.50%
1 – 5 km/hr : 8.8%
S-W
5 – 11 km/hr : 3.3%
11 – 19 km/hr : 1.0%
Dust storms or Thunderstorms
accompanied by squalls occur during
Dust Storms
April-June, and also during monsoon
months.
Rainfall
 Annual average rainfall in 30
262.9
years - mm/year
 Maximum rainfall in 24 hour – mm 240
 Maximum rainfall Monthly – mm 664
 Maximum rainfall hourly- mm 89
Rainy season months June to September
Seismic Conditions
 Seismic Zone
(For seismic design, refer to IS Zone- III
1893 Part 1 and 4)

7. PLANT LIFE

The plant life for the surface facilities at all locations shall be 10 years.

8. PLANT OPERATION

All QPF (except RS1 & RS4) & CPF facilities shall be designed for manned operation.
However for satellite fields Company Philosophy shall be applicable.

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9. DESIGN MARGIN & TURN DOWN CAPABILITY

The design margin for all the equipments shall be 10%, as applicable. For details of
design margin, refer Design Basis Part - A, package wise.

Turn down capability shall be 30%.

10. EQUIPMENT DESIGN PHILOSOPHY

10.1. Selection of Mechanical Design Conditions

Equipment and piping systems shall be designed for the most stringent coincident
temperature and pressure conditions, accommodating the maximum expected working
pressure and temperature without causing a relieving condition. The design shall be
such that instrument safeguarding systems or availability of emergency power are not
relied upon for overpressure protection. Abnormal conditions shall be evaluated
considering a single contingency. A double or multiple contingency shall not be
considered, but if one failure is a result of another failure, both failures are to be
considered as one contingency. Guide for "Pressure Relieving and Depressurizing
Systems", API RP 521 (latest edition) “Pressure Relief & Disposal System”, OISD-
STD-106 shall be followed for evaluating failures. All pressure vessels should be
designed based on ASME / ASTM and ANSI codes.

Mechanical design pressure for pressure systems

The Design pressure shall normally be as per SOS document, however the same shall
be verified by the CONTRACTOR and following criteria also shall be followed and
higher of the both shall be selected.

A pressure system, protected by a pressure relief device connected to the flare system,
shall have a mechanical design pressure, calculated at the location of the relieving
device, as the higher of the following:

 If system is protected by relief valves,

for OP < 350 kPag, DP = MOP + 200; min 350 kPag

for OP between 350 to 6900 kPag (both values included), DP = MOP x 1.1; min
550 kPag
for OP > 6900 kPag, DP = MOP x 1.07
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 if system is protected by relief device other than relief valve,

DP = MOP x 1.1 or 70 kPag whichever is higher.

The design pressure calculated as per above is at the location of the relieving device
such as the top of a vertical vessel. The design pressure at the bottom of the vessel
and of associated pieces of equipment shall be determined by adding applicable
maximum operating liquid heads and pressure gradients.

Vessels operating under vacuum shall be, in general, designed for an external
pressure of 100 kPaa and full internal vacuum, unless otherwise specified.

Emergency vacuum pressure of 100 kPaa can be considered by engineer based on

the process requirements and assessment of transient operations.

For a full liquid system at the discharge of a centrifugal pump, the mechanical design
pressure shall be as under:

P des = P max suction + Del P max

Where,
P max suction = Maximum pressure at suction vessel bottom during suction
system relieving conditions
Del P max = Pump differential pressure at pump shutoff head with maximum
operating density or 125% of operating differential head,
whichever is higher
For a full liquid system at the discharge of a positive displacement pump, the
mechanical design pressure shall be the higher of:

P des = P rated discharge + 200 kPa

P des = 1.1 x P rated discharge
Mechanical Design Pressure for Storage Tanks and Atmospheric Vessels are as
follows.

Design pressure of storage tanks shall be in accordance with API-620, API-650 and
API-2000, as appropriate.

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Blanketed storage vessels shall have a blanketing pressure of 150 mm WC, unless a
higher pressure is deemed necessary from process considerations. The design
pressure of blanketed storage vessels shall be determined to allow adequate
overpressure for out breathing and emergency relief devices. The blanketed tanks
shall also be designed for 25 mm vacuum.

Mechanical Design Temperature

For systems operating at or above 0 oC, the mechanical design temperature shall be
the higher of the following:

T des = 80 °C (black body temperature)

T des = T max + 30 °C (for heated lines)
= T max + 20 °C (for non-heated lines)
T des = T relief (excluding fire relief temperatures)
Where,
T max = Maximum operating temperature expected considering different
possible operating scenarios for the equipment or system,
including air drying or gas drying conditions.
T relief = Temperature corresponding to pressure relief conditions for an
operational failure case (excluding fire relief temperatures).
For systems operating below 0 oC, the mechanical design temperature shall be equal
to the lowest anticipated operating temperature with (-) 5 °C margin

For pressure vessels storing refrigerants or liquefied hydrocarbons at ambient

temperature, the design temperature (based on depressurization) shall correspond to
the coincident design pressure when this lowest temperature is reached. The
coincident design pressure can be different from the maximum design pressure
specified for the vessel depending upon the system under consideration. However, if
this calls for a change in metallurgy, then other strategies to avoid this situation shall
be evaluated.

Minimum Design Metal Temperature (MDMT)

MDMT shall be specified wherever required. The depressurization shall be done for
the relevant cases as per section 12 and the MDMT shall be identified and reported
with (-) 5 degree margin.

Corrosion Allowance
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The Corrosion allowances for the equipment shall be based on the corrosion study.
The allowances shall be in the range of 1.6 mm, 3.2 mm, and 6.4 mm as per the
requirement.

10.2. Vessels

All pressure vessels shall be designed as per ASME Sec VIII, Div. I and sour service
material shall conform to NACE requirements with respect to material composition.

10.2.1 Hold-Up Criteria

As a general practice, following criteria for hold-up in process vessels is followed:

Criteria that call for higher hold-up volumes, if warranted from a design point of view
may be adopted. The working hold up volumes are expressed as minutes of liquid
residence time / pump out time between Low Liquid Level (LLL) and High Liquid Level
(HLL). The residence time for each vessel shall be identified on case to case basis.
Any additional hold ups shall apply between the operating levels and corresponding
trip levels (LLLL / HHLL), when a shutdown is stipulated. The maximum fill level of a
vessel (HHLL) shall be 85% of the vessel diameter. Between LLLL & LLL/ HLL & HHLL
the minimum residence time shall be 10 minutes. The Distance criteria shall be 150
mm minimum between Bottom Line to LLLL, LLLL & LLL/ HLL & HHLL. The distance
between HLL & LLL shall be minimum 350 mm (shall be validated during design on
case to case basis). Allowances for dirt / sand, vortex breaker, sand jetting
arrangement, heating coils etc. also to be considered while fixing the levels. This shall
be done on case to case basis.

For cases where submersible pumps are used, like closed drain vessels, boot shall be
provided and the philosophy shall be same as the process vessels.

For horizontal vessels, the normal liquid level shall be set at halfway between HLL and
LLL. For Vertical Vessels, normal liquid level shall be fixed based on the liquid level in
the vessel.

The slug criteria shall be considering the slug volume corresponding to 5 sec flow
based on the slug flow rate and this shall be accommodated between LLL & HLL.

For fuel gas scrubber / KOD hold–up to be calculated considering the liquid in inlet
stream as 2% (by Volume) of total plant liquid capacity.
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Flare K. O. Drum and Water Seal Drum shall be designed to remove liquid droplets
with diameter 400 micron and greater. The vapor space above high liquid level or high
high liquid level (HLL or HHLL) shall be sufficient to allow the maximum gas relief rate.
Liquid hold up volume for Flare KODs shall be corresponding to the worst case of relief/
depressurization cases. The volume occupied by the liquid should be based on a
release that lasts minimum of 25 minutes.

Drain pit capacity is designed for draining of largest vessel / equipment in the well pad
upto LALL during maintenance / shutdown.

Process Vessel- 2 Phase separator

Storage Vessel

Process Vessel- 3 Phase separator

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10.2.2 Vessel Dimensions

Vessel and tower diameters shall be reported based on inside diameter (ID). Tori
spherical heads will be normally specified. Hemispherical heads will be considered,
when relevant.

Maximum gas superficial velocity VGmax through the vessel is determined by the
following equation,
𝐿 − 𝐺
𝑉𝐺𝑚𝑎𝑥 = 𝐾𝑠√( )
𝐺
Where,
L and G is the liquid and gas phase densities respectively and,
Ks is the sizing parameter. The API 12J recommends ranges of Ks –values for vertical
and horizontal gas-liquid separators as given below,
Type Height or Length, Typical KS range, ft/sec Typical KS range, m/s
ft (m)
Vertical 5 (1.52) 0.12 to 0.24 0.037 – 0.073
10 (3.05) 0.18 to 0.35 0.055 – 0.107
Horizontal 10 (3.05) 0.40 to 0.50 0.122 to 0.152
Other Lengths 0.40 to 0.50 (L/10)0.56 0.122 to 0.152 (L/3.05)0.56

Once the maximum gas velocity, VGmax, through the vessel is determined, the
minimum vessel diameter, Dmin is calculated using the below equation,
4
√ () 𝑞𝑎
𝐷𝑚𝑖𝑛 =
𝐹𝐺 𝑉𝐺𝑚𝑎𝑥
Where,
𝐹𝐺 = Fraction of cross section area available for gas flow (𝐹𝐺 = 1 for vertical separators
and is a function of liquid height for horizontal separators)
𝑞𝑎 = Gas flow rate at the actual flowing condition

Retention Time
The liquid capacity of a separator is primarily dependent upon the retention time of the
liquid in the vessel. Good separation requires sufficient time to obtain an equilibrium
condition between the liquid and gas phase at the separator operating conditions.

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The liquid retention time, t of a separator can be determined from the following
equation:
1400(𝑉)
𝑡=
𝑊
Where,
W is the liquid capacity, BBL/day at flowing conditions
V is the liquid settling volume, BBL
t is the retention time, minutes.

Nozzle Sizing (Reference: Shell DEP 31.22.05.11)

Diameter of the inlet nozzle is a function of the feed flow rate, fluid properties and
pressure. The criterion for nozzle sizing is that the momentum of the feed should not
exceed an allowable limit. The following table shows the allowable V2 criterion for
different inlet devices.

Inlet No Inlet Device Deflector baffle Half open pipe Schoepentoeter

Device
mVm2, 1400 1400 2100 8000
kg/ms (Pa)

Where,
m is the average density of mixture in the feed pipe in kg/m 3
Vm is the velocity of the mixture in the inlet nozzle in m/s
Gas outlet nozzle sizing, criteria taken into consideration is,
GVG2 ≤ 4500 Pa
Where,
G is the density of gas at outlet conditions in kg/m3
VG is the velocity of gas in the gas outlet pipe nozzle in m/s
Liquid outlet nozzle size is checked such that for the given size of the liquid outlet
nozzle the liquid velocity does not exceed 1 m/s (3.3 f/s).

L/D Ratio
Normally the L/D ratio for horizontal vessels shall be between 2.5 to 3.5.

10.2.3 Nozzle requirements for vessels

Recommended minimum sizes of vessel nozzles shall be as per below:

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Process or instrument nozzle in unclad vessel : 2” NB

Process or instrument nozzle in internally lined vessel : 2" NB
Vent & Drain Nozzles : 2” NB
Utility Connection (UC) : 2” NB
For nozzle sizing for process vessels, the momentum criteria shall be envisaged.
10.3. Pumps

10.3.1 Selection Of Type Of Pumps

All Centrifugal pumps within process battery limits for hydrocarbon service shall be
specified to conform to API Standard 610 (Latest Edition). API/ ANSI/ ISO pumps shall
be employed for the facility.

Design of progressive cavity pump shall confirm to API 676, latest edition.
Manufacturer standard may be considered where no API pumps are required.

Fire water pumps and jockey pumps along with drivers (motors, diesel engines etc.)
and auxiliaries shall be in accordance with NFPA 20.

Pump specifications shall assume unsheltered outdoor location.

Pump NPSHa shall be 1m greater than the NPSHr.

Suction strainers either Y / T - type or basket type shall be considered for each pump.

Discharge relief requirements shall be considered where ever required for pump
protection in the blocked discharge case.

10.3.2 Sparing Of Pumps

Process pump services in continuous service will, in general, be provided with installed
spare. Intermittent pump services such as chemical unloading, batch make-up etc.,
shall not be provided with installed spare. These shall be decided on a case-to-case
basis and possibility of common spares shall be examined.

Where more than one operating pump is found necessary for a service or when defined
by owner, pump capacity and spare shall be as follows:

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No of Operating
Rated capacity per pump Spare pumps
pumps Remarks

1 100% of total normal flow 1

2 50% of total normal flow 1
3 33% of total normal flow 1
4 25% of total normal flow 2

Company may exercise the option of specifying at least 2 operating pumps for specific
services as an operational strategy.

10.3.3 Specification Of Pump Seals

Single mechanical seals shall normally be specified for centrifugal pumps unless other
considerations prevail. Seal flushing where necessary, shall preferably be with the
process fluid itself through an appropriate API seal plan for all clean liquids.

External seal flushing oil shall be made a requirement only when a self-flushing plan is
infeasible. Pumps shall be specified such that pump vendor is completely liable for
proper seal fluid selection and supply.

10.3.4 Minimum Flow Bypass (MFB) Provisions & Controls

Requirement of MFB for centrifugal pumps is usually determined in the course of

detailed design & engineering. Preferences for the MFB shall be as follows:

 High pressure, multistage pumps: ■ yes

 Pumps with source vessel / temperature control valve at discharge ■ yes
 Pumps with FC type control valve in
Discharge line & single destination: ■ yes no
The scheme for an MFB will usually be a spillback line with constant bypass flow
through a restriction orifice and a globe valve.
For large capacity pumps, except recirculating service pumps, an automatic MFB with
a protective minimum flow control shall be provided to save the pumping energy.

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For low capacity pumps (Capacity < 10 m3/hr), minimum flow circulation requirements
shall be confirmed based on Vendor recommendation. For pumps with greater than
one working option, individual minimum flow bypass shall be provided.

10.4. Compressors

10.4.1 Selection Of Type Of Compressors

Oil Free IA Compressor (Motor Driven Screw Type) shall be selected based on the
capacity conforming to the standards as per zone criteria where the equipment is
located.

Screw compressors can be specified in special cases where found to have an

operating, economic or maintenance advantage over other choices. Drivers shall be
motor driven.

10.4.2 Compressor Controls

PLC based control system shall be envisaged. Compressor shut down and interlock
shall be implemented in unit PLC.

10.5. Fired Heaters

Applicable Standards: API-12K, API 12L, API-560 latest editions, OISD Standard-111

The major equipment included in the facility are Heater Treater and IWBH (Indirect
Water Bath Heater).

10.5.1 Selection of fuel

Fired heaters shall be designed for continuous operation with 100% firing on either
diesel or fuel gas.

10.5.2 Target Thermal efficiency

The targeted Thermal efficiency shall be 70%.

Achievable thermal efficiency depends on service, process temperatures, heat duty

and quality of fuel. Target efficiency shall be maximized and options for heat recovery
such as air preheater, steam generation/ superheat etc., shall be adopted as per
requirement.

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10.5.3 Fouling factor

Fouling factor for clean process fluid shall be considered as 0.0002 (Hr-m2-oC/ Kcal);
for other services it will be decided case to case basis.

10.5.4 Heater stack

Stacks shall be individually mounted on each heater unless there are considerations
such as combined APH system for a group of heaters. Minimum fired heater stack
heights shall be calculated from the formula below:

H = 14 (Q) 0.3
Where, H: Stack height, meters
Q: Total SO2 emission, kg/hr
Owner/ Environmental group to furnish minimum stack heights based on EIA study/
PCB norms for different units.

10.6. Electric Heaters

Electric heaters shall be envisaged where the heating of the process fluid is required.
Electric heaters are used for raising the temperature of the process fluid above the wax
appearance temperature.

Package vendor shall design the equipment in such a way that all the equipment
performance parameters are meeting the design intent and shall be suitable for the
design life (10 years).

10.7. Pigging

Well fluid from the fields is highly viscous and is waxy in nature, therefore it is
necessary to clean the crude transporting pipelines, to avoid deposition of wax. One of
the recommend practice to remove the deposited wax in the pipeline is pigging.

The interconnecting field pipelines are having 5D bends to navigate all variety of pigs.
Normally, it is a practice to use standard 2 Cup or 4 Cup Scrapper pig. The Scrapper
Foam pig can also be used for the purpose (SCC- WB) (Scarlet Criss Cross with Wire
Brush) having density of 80 kg/cm2. Velocity of the pig to be maintained within 1- 2
m/s.

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The provision for connecting portable Pig Launcher/ receiver shall be provided at
relevant locations i.e, at the beginning and at end of the pipelines. The provision of
kicker and bypass arrangement is also provided. Operation and Maintenance manual
shall cover the pigging procedure in detail.

For location wise details regarding requirement of temporary or permanent pigging,

Refer Design Basis Part B.

10.8. Produced Water Treatment Package

Separated water is routed to a Degassing Vessel to remove the gases (if any) prior to
entering the Effluent Water treatment system. The Effluent Water Treatment System
consists of Settling Buffer Tank, Corrugated Plate Interceptor, Multimedia Filter,
storage and Transfer pumps. After meeting the required TSS and oil-in-water
specification and taken to Treated Effluent water storage tank and trucked out.

11. LINE SIZING

The hydraulic study and line sizing shall be performed with ASPEN HYSYS (Version
10.0) software.
Velocity Criteria.
The criteria for sizing of multiphase piping shall be the erosional velocity i.e. actual fluid
velocity shall be maintained below the erosional velocity.
For gas piping, generally the velocity shall be limited to 20 m/s. Lower velocity shall be
considered where pressure drop limitations exists or due to other process
considerations. Higher velocity can be considered for low pressure systems.
For flare header piping the Mach number shall be limited to 0.5 (max) for headers and
0.7 (max) for branch lines subject to back pressure limitations.
For liquid piping, velocity shall be limited to < 1 m/s for pump suction and 2-3 m/s for
pump discharge lines.
Pressure Drop Criteria
For liquid lines, in general the following allowable pressure drop guidelines will be used
to determine acceptable line sizes for pump circuit:

Allowable Pressure Drop Maximum Velocity

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bar/100m (psi/100ft) m/s (ft/sec)

Nomin
al Line Pump Suction
Pump Pump Pump
Size Sub-Cooled Discharge Suction Discharge
Boiling Fluid
Fluid
0.011-0.045 0.045-0.136 0.226-0.339 1.1 1.8
1"-3"
(0.05-0.20) (0.20-0.60) (1.0-1.5) (3.5) (6.0)

0.011-0.045 0.045-0.136 0.226-0.339 1.4 2.4

4”
(0.05-0.20) (0.20-0.60) (1.0-1.5) (4.5) (8.0)

0.011-0.045 0.045-0.136 0.226-0.339 1.5 3.0

6”
(0.05-0.20) (0.20-0.60) (1.0-1.5) (5.0) (10.0)

0.023-0.05 0.113-0.26 0.339-0.453 1.8 4.3

8"
(0.10-0.25) (0.50-1.00) (1.5-2.0) (6.0) (14.0)

10" 0.023-0.07 0.113-0.226 0.339-0.453 1.8 4.3

and
Larger (0.10-0.30) (0.50-1.00) (1.5-2.0) (6.0) (14.0)

For Gas lines the criteria shall be as follows,

Pressure Drop Maximum

Service bar/100m Velocity m/sec
(psi/100ft) (ft/sec)
Less than atmospheric 0.01-0.06 60
pressure (vacuum) (0.05-0.25) (200)
Up to 7 bar 0.06-0.12 40
(100 psig) (0.25-0.5) (130)
7 to 70 bar 0.12-0.45 30
(100 to 1000 psig) (0.5-2.0) (100)
Over 70 bar 0.6% x OP 30
(over 1000 psig) (0.2% x OP) (100)

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For flare lines the criteria shall be as follows,

12. PIPE LINE

Soil Temperature @ 1 m Burial Depth

 Max: 37 °C

 Min: 22 °C

13. CONTROL VALVE SIZING

Based on project requirements Control valves are provided with bypass line, isolation
valves, Drain valves (as required) & fail safe positions always shown for control valves.
In general, system considerations dictate the required control valve pressure drop, if
this is not the case, normally 0.7 bar (liquid control valve) & 0.3 bar (gas control valve)
or 30% of the total system friction losses including the control valve shall be
considered.

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14. DEPRESSURIZATION

Depressurizing systems are principally required to reduce the risk of loss of equipment
integrity during a fire or to reduce a local loss of containment arising from a leak which
may otherwise lead to escalation and the risk of catastrophic structural failure.
Emergency blow down during a fire must minimize the risk that the pressure within the
system exceeds the rupture pressure at any point of the system at any time during
blow down, causing reduction of yield strength with increasing temperature. Equipment
particularly at risk includes pressurized equipment with thin walls (especially piping),
equipment with a low liquid inventory and equipment without fire proof insulation. It
should be noted that a relief valve does not provide the same level of protection as
depressurization during a fire since the pressure in the vessel would remain the same
as the temperature increases (and the vessel strength is reduced).
Depressurizing should be achieved solely by the release of vapors and not liquids. The
maximum amount of liquid will then be retained in order to slow down the temperature
rise of the system exposed to fire and hence to delay the reduction in material strength.
Depressurizing shall be carried out within 15 minutes from maximum operating
pressure to 50% of the vessel design pressure or to 100 psig whichever is applicable
as per the below criteria.

 For vessels with wall thickness 25.4 mm (1 in.) or higher, depressuring upto
50% of design pressure in 15 minutes

 For thinner wall vessels (thickness less than 25.4 mm), faster depressurization
is required hence system depressuring upto either 50% of vessel design
pressure or any other criterion may be used (API recommends that
depressuring upto 50% of design pressure can be used in such case, however
depressuring to 100 psig in 15 minutes is normally used as a most conservative
approach)

 When system is designed to mitigate the consequences due to vessel leak or

failure, depressuring to 100 psig in 15 minutes is commonly considered.
Operating temperature is used as initial temperature for fire case. Winter and summer
case shall be considered for fire case and select the orifice based on maximum
depressurizing peak flow rate.
The depressurizing orifice must dispose of vapor due to:

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 Initial vapor inventory

 Liquid flashing due to the reduction in pressure

 Vapor generated from liquid by heat input from a fire.

To determine the vapor quantities contributed by the factors mentioned above, it is
necessary to establish a liquid inventory and a vapor volume of the system. Subject to
corrections made necessary by the final plant design, the following initial assumptions
should be used: Initial pressure equal to maximum operating pressure.
To determine the liquid inventory and the vapor volume of the system, all the facilities
located in the fire zone and all equipment outside the fire area which, under operating
conditions, are in open connection with the facilities located within the fire area must
be considered.
The liquid inventory of separators, knock-out drums etc., shall be based on normal
operating levels. The sizing of depressurizing systems shall be based on the
assumption that during a fire, all feed and output streams to and from the equipment
are stopped and all internal heat sources within the process have ceased.
Overall peak blow downs load shall be calculated on the basis that the whole
installation is depressurized simultaneously. The peak load will occur at the beginning
of the event. Heat input from fire (if any) should be considered only for equipment in
the most significant fire zone. It is recognized that during a fire incident, it is unlikely
that the fire will simultaneously impinge on all vessels/equipment within a manageable
area.
The rate of depressurizing of relevant equipment / unit / system shall be estimated
based on API STD 521 Edition 2014.

15. SOFTWARES

Hysys version 10.0 shall be used for the simulation and Line sizing. Thermodynamic
model shall be Peng Robinson. PREDICT version 6.1 & SOCRATES version 9.1 shall
be used for corrosion study & material selection.

16. UTILITY SPECIFICATIONS

Following utilities shall be supplied to all locations and the B/L conditions of the same
are mentioned below.

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16.1. Utility Conditions

Sl. Item

1 Utility Water

Utility water shall be supplied by company and shall be stored in storage tanks
above ground at sufficient height for utility water distribution (design & engineered
by Civil).

2 Plant Air

Plant Air is required for maintenance activities in CPFs, QPFs and Gas Well Pads.
A tapping with valve for Plant Air shall be provided before the Air Dryer within
Instrument Air Package.

3 Instrument Air

Instrument Air shall be supplied from Instrument Air Package. Buffer hold-up for
IA receiver shall be 30 minutes.
Quantity of instrument air requirement shall be estimated based on the following
consumptions:

 Control valve consumes air at 2 Nm3/hr. (To be confirmed by vendor during

detailed engineering.)
 Shutdown valve consumes air at 4 Nm3/hr. (To be confirmed by vendor
during detailed engineering.)
10% of shutdown valves IA requirement shall be considered to estimate the peak
/ intermittent requirement.

Parameter Minimum Normal Maximum Mech. Design

Pressure, kPag 400 800 850 1050

Temperature, oC Amb. Amb. 50 Refer Section 10.1

Dew Point (-) 40 deg C @ ATM. Pressure)

Oil content Nil

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4 Fuel Gas

Fuel Gas required for the facilities are sourced from the facility itself (wherever
required). The gas stream coming out of the heater treater (and from the Annulus
Vent, where applicable) shall be routed to the Fuel Gas scrubber and the liquid
shall be removed from the stream. The gas stream from the FG scrubber shall be
used as Fuel Gas for the facility.
Industrial LPG Bottles shall be provided as start-up FG for the Flare Stack and
Heater wherever required.
For requirements of Fuel gas at various well pads, refer Design Basis Part - A,
location wise.

Parameter Minimum Normal Maximum Mechanical Design

As per
Pressure, kPag 140 - Refer section 10.1
design
Temperature, oC - 70 - 90 - Refer section 10.1
5 Diesel

Diesel shall be supplied tanker and shall be stored in above ground storage
vessels and shall be dispensed through transfer pumps.

6 Nitrogen (Dew Point (-) 100 deg C @ Atm. Pressure)

Wherever, IA Package is not supplied, Bottled Nitrogen shall be used for

Instrument functioning / actuation of valves. If there are more than two instruments
in the field that require nitrogen, then a nitrogen bank (N working + 1spare bottles)
shall be provided.
Also nitrogen shall be made available by Contractor during the commissioning and
the startup stage. Industrial Nitrogen Bottles shall be supplied by Company and
shall be let down to required operating pressure. Typical Industrial Nitrogen quality
is indicated below.
Nitrogen required for maintenance shall be supplied by company (on temporary
basis) as & when required at suitable operating conditions.

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For requirements of Nitrogen at various well pads, refer Design Basis Part - A,
location wise.
Mech.
Parameter Minimum Normal Maximum
Design
Pressure, kPag 400 800 850 1050
Refer
Temperature, oC Amb. Amb. 50
section 10.1
Dew Point at atmospheric pressure (-) 100oC
Oil Content, ppm Nil
Nitrogen purity, Vol% 98 - 99 min
Oxygen content, vol ppm < 2 max
CO + CO2 content, vol ppm 0.5
7 Power
At Raag WP-01 & Tukaram-2, GEGs shall be provided for power generation. At
other locations, DG set of suitable capacity shall be provided for the Power
generation. DG Set shall also be provided as back-up power wherever required.

8. Fire Water
Fire water shall be supplied by company & shall be filled in the corresponding pits
/ tanks at the respective locations and shall be used based on requirement.

9 Drinking Water

Drinking water shall be supplied by Company through packaged bottles.

10 Flushing Oil System

Flushing Oil systems are not envisaged for the project. However provision for
flushing connection shall be provided for the flushing of piping & equipment at
various locations including Heavy Oil treating locations.

11 Chemical Injection

Chemical Injection quills shall be provided at locations where Chemical Injection

is envisaged. For Corrosion coupon only provision (2” tie-in with BF) shall be made
and same shall be used by company.

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For Oxygen scavenger injection, a tapping with blind flange shall be provided at
downstream of the choke valve.
For details regarding the requirement of Chemical Injection and Injection
provisions at various well pads, refer Design Basis Part - A, location wise.

17. INSTRUMENTATION & CONTROL

PLC based Plant Control System shall be provided to perform the following Functions

 Control and Monitoring

 Fire and Gas Monitoring and Shutdown

 Emergency shutdown

 Data Record
An integrated PLC based system consisting of Process Control System (PCS),
Emergency Shutdown System (ESD) and Fire and Gas System (FGS) shall be used
for the Plant Control and Shutdown. Local Control Panels (LCP) shall be provided for
package units. Push Button console (not envisaged in QPFs) shall be provided. In
QPF, a combined PLC based control system shall be considered taking into account
of the lesser number of I / O’s.
For more details refer Shutdown Philosophy (S340HAL-SRX-P-SDP-0003)

The system shall perform all the necessary functions to monitor and control the
facilities.
Fire & Gas Monitoring and shutdown functions shall be implemented in SIL-3 certified
PLC.
The Packages shall be provided with dedicated PLC for operation and control if
necessary. Alternatively the package shall be interfaced with facility PLC system for
control and monitoring. The package PLC, if applicable, shall be interfaced with facility
PLC system through communication for remote monitoring.
The Facility PLC system shall be located in control building / porta cabin with suitable
operator interface.
For more details refer Instrumentation Design Basis (S340HAL-SRX-IC-BD-0001).

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18. PIPING & INSULATION

Detailed Engineering Piping Design Basis shall define the detailed design
requirements for overall piping, insulation, and painting and corrosion protection
standards.

Insulation thicknesses to be adopted as per Insulation Specification

It is mandatory to adhere to stipulations of OISD standard # 118 for minimum inter-

equipment spacing and inter-distance between process unit and offsets.

For details about piping system, refer Piping Design Basis S340HAL-SRX-L-BD-0001

19. ENVIRONMENTAL CONTROL

1. Emission norms as stipulated by CPCB and other mandatory regulations like

RSPCB, shall be satisfied for the project.
2. SO2 ground level concentration contribution of the project shall be less than the
allowable limit.
3. Noise level :
i) 85 dB (A) at 1 meter from source
ii) 70 dB (A) at the fence
4. No effluent discharge from the complex is envisaged.100% re-use is to be
planned and facilities are to be designed accordingly.
5. Flare stack height shall be 30 (max) meter.
6. Total complex emissions (gaseous SO2, Nox etc. and liquid and solid if any) to
meet ENVIRONMENTAL CLEARANCE stipulations and other applicable
regulations.

20. SAFETY

1. This section presents a short list of safety aspects that will be reflected, as
appropriate, in the basic engineering design or in the detailed design &
engineering stages. This list is not intended to be a complete enumeration of
safety features for a project. For more details refer HSE Philosophy (S340HAL-
SRX-R-SDP-0001)
2. Push buttons for stopping critical motors, if identified, shall be provided at a safe
location, away from the fire-zone of the respective motors. This is in addition to
usual start / stop push buttons provided for such motors.
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3. Gas detectors shall be provided in the critical process and utilities area.
4. Suction / discharge valves of suction filter should be close to the pump in order
to avoid hydrocarbon wastage during filter cleaning and pump maintenance.
5. Flare line isolation valve at unit battery limits should be installed only in the
horizontal line with stem in horizontal position to avoid free fall of gate and
blockage of flare system.
6. It is mandatory to adhere to stipulations of OISD standards for minimum inter-
equipment spacing and inter-distance between process unit and utilities.
7. For selection of Gear Operated valves & MOV. Refer Piping Design Basis
S340HAL-SRX-L-BD-0001

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