OFFSHORE DESIGN SECTION

FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

5903F 0 Mechanical

Page 1 of 18

FUNCTIONAL SPECIFICATION

FOR

INERT GAS GENERATOR PACKAGE

PREPARED REVIEWED / REVISED BY BY

APPROVED BY

TOTAL NO. OF PAGES

DATE

REV.

18 SKT SKG JSS

15-04-05

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CONTENTS 1. INTRODUCTION

1.1 General 1.2 Contractor Responsibilities 1.3 Proven equipment 2. STANDARDS, CODES AND REFERENCED SPECIFICATIONS

2.1 Codes and Standards 2.2 Reference Specifications 3. SCOPE OF SUPPLY 3.1 General 3.2 Scope of Supply 4. ENVIRONMENTAL DESIGN CRITERIA 4.1 Climatic Conditions 4.2 Area Classification 4.3 Design Life, Availability and Reliability 5. DESIGN REQUIREMENTS 5.1 General 5.2 Compressed air system 5.2.1 Air supply from platform source 5.3 Pressure Swing Adsorption towers 5.4 Vessels 5.5 Skid 5.6 Piping 5.7 Electrical 5.8 Instrumentations 5.9 Control System 5.10 Insulation

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6. 6.1 6.2 6.3 6.4 6.5

INSPECTION, TESTING AND CERTIFICATION General Test Requirements Hydrostatic Test Performance Test Reports and Acceptance Certificates

7.

SPARE PARTS AND SPECIAL TOOLS

7.1 Spares parts 7.2 Special Tools 8. PAINTING AND PREPERATION FOR SHIPMENT

8.1 Painting and Protection Coating 8.2 Preparation for Shipment 9. 10. CONTRACT DATA REQUIREMENTS WARRANTY

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1 1.1

INTRODUCTION General This specification describes the minimum requirements for the design, manufacture, supply, inspection and testing of Inert gas generator package to be installed on an offshore platform. The Inert gas generator package shall be complete with all required accessories installed and connected, ready for independent operation upon connecting all needed utility services and piping. The Package based unit shall be installed as per this specification.

1.2

Contractor Responsibilities The contractor shall be responsible for the complete design, manufacture, supply, inspection, testing, preparation for shipment for the Inert gas generator package, including full compliance with all applicable design codes and standards, including those listed in section 2.0 of this specification. The items shall preferably be supplied by the Contractor as a standard package; however those components which are not required shall be identified.

1.3

Proven Equipment The supplier shall have designed, manufactured, tested and supplied two (2) Inert gas generator package sets of similar type, design and of equal or higher rating from the proposed manufacturing plant. Contractor shall provide evidence of satisfactory operation of at least 8000 hours for one of such unit when operating in similar service conditions in offshore areas.

2 2.1

STANDARDS , CODES AND REFERENCED SPECIFICATIONS Codes, Standards The instrument air compressor package shall be designed, manufactured, certified and tested in accordance with the requirements of this specification, reference Specifications and the latest revisions of the following Codes, Standards.

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ASME Section-II, Div-I ASME SectionVIII, Div-I ASME SectionIX ASME B 16.5 ASME B31.3 API RP 14F/14FZ API RP 500 API RP 520 API 661 ASTM NEC NEMA OSHA 2.2 Reference Specifications

: : :

Boilers and Pressure Vessel Code- Materials Boilers and Pressure Vessel Code Boilers and Pressure Vessel Code- welding and Brazing qualification Steel Pipe Flanges and Flanged Fitting Process Piping Design & Installation of Electrical system for offshore production system Electrical Hazardous Area Classification Design and Installation of relieving system in Refineries Air Cooled Heat Exchangers for General Refinery Services. American Society for Testing and Material National Electrical Code National Electrical Manufacturers Association Occupational Safety and Health Act

: : : : : : : :

The Package covered by this Specification shall be designed, manufactured and tested in accordance with the requirements of these Project Specifications: SPEC NO 5002 5004 5100P 5601 5701F 5102 FS 4017 FS 4008 2004-A 2004-B DESCRIPTION Specification for noise limit Specification for equipment vibration Specification for packaged equipment- Process plat form Functional specification for unfired pressure vessel Functional specification for air cooled exchanger Functional Safety Specification Functional specification for Electrical Equipment of Packaged Plant Functional specification for Electrical Motors. Functional specification for Piping Design Functional specification for piping fabrication and installation

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

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2006 2009F 1060 2005 Vol IISect 2.3.6 3 3.1

Functional specification for Insulation of Piping and Equipment Insulation Functional specification for Welding And NDT Vendor Data Requirement Specification For Protective Coating Basic bid work -for Instrumentation

SCOPE OF SUPPLY General The Contractor shall be responsible for the design, preparation of drawings and data sheets, production of materials, manufacture, assembly, all sub-contractors, testing and guarantees, shipment, plus the provision of skilled personnel for the testing and commissioning of the complete package. The Contractor shall not commence manufacturing and/or purchasing of required equipment or material until required Contractor drawings and data sheets have been submitted to, and approved by the Company.

3.2

Scope of Supply The scope of supply shall include all the items of equipment and instrumentation necessary for a complete and safe operational unit. The Package unit shall include the items that are shown with in the Package limits detailed on the P&ID drawing or as specifically identified with this Specification and shall include, but may not be limited to, the following: Pressure Control Valve (compressed air supply is made available from the platform source) PSA Towers Inert gas Receiver Interconnecting Piping, Valves and Instrumentation Local Control Panel including PLC All necessary instrumentation controls panels, including automatic regeneration / change over sequence control and protection facilities All necessary spare parts for start up and commissioning A list of spare parts recommended for one years operation Initial desiccant charges.

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

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Two sets of any special tools required for maintenance of the package All documentation as requested in this specification . Inspection and testing as called for in this specification. All necessary items not listed here but required for a complete unattended safe operational unit. All the above components shall be mounted on a common structural skid, fully assembled, piped with inlet and outlet piping terminated at the skid edge with appropriately rated flanges, wired, tested and painted for marine environment. 4 4.1 ENVIRONMENTAL DESIGN CRITERIA Climatic Conditions The climatic conditions under which the Equipment will operate are detailed in section 3.1 of Design Criteria- General in the bid document (Vol.II) . The equipment shall be designed for outdoor location on an offshore platform. The contractor is responsible for ensuring that all equipment and components provided are suitable for the utility and environmental conditions as specified during the entire design life. 4.2 Area Classification Electrical and instrumentation equipment will be suitable for the applicable Hazardous Area classification according to Electrical design criteria enclosed in the bid. 4.3 Design Life, Availability and Reliability Equipment shall be designed and constructed for a minimum service life equal to the platform life. The contractor shall specify the estimated availability figure for this package. In addition, the contractor shall furnish their best estimates of Mean Time Between Failures (MTBF) and Mean Time to Repair (MTTR) for the equipment concerned.

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SPEC. No. Rev. No. Discipline

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In making assessments of the availability and reliability, the contractor will need to estimate maintenance and repair times. For the purpose of making such estimates, the contractor may assume that the spares holding is in accordance with their submitted recommendations unless otherwise stated. The contractor may also neglect any delay caused by factors not directly related to the package in question, unless a basis for estimating such delays is provided by the company. In the case of failure modes which make a significant contribution to the overall unavailability, the contractor may be required to demonstrate that their assumed repair times can be achieved. 5 5.1 DESIGN REQUIREMENTS General It is the intent of the Company that operational hazards be reduced to a minimum. Vendor shall use sound engineering judgment to complete an installation that will perform the required process function without compromising this aim. All controls shall operate in a fail safe mode. All couplings, gears, and exposed rotating parts shall be provided with adequate guards of non sparking type. Drive belts, if used, shall be antistatic type. Piping shall be arranged in a manner so as to avoid tripping or headroom problems. Piping or tubing of insufficient mechanical strength for standing or hanging shall be protected from personnel traffic. The requirements of Noise Limits and Equipment vibrations as defined in the attached Functional Specifications 5004 and 5002 shall be met. 5.2 Compressed Air system Compressed air shall be made available from the platform source, in accordance with the details attached in the bid. 5.2.1 Air Supply from the Platform source

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

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No of Pages: 9 of 18

Instrument / Utility air shall be made available from the platform source at the package battery limit by the contractor, at conditions defined in the Process design criteria. Necessary Pressure Control Valve (PCV) suitable for the supply line shall be provided by the vendor, to obtain desired pressure for operation of PSA Towers. Vendor shall precisely define the quantity of compressed air required in his bid proposal, to enable the contractor to size the Instrument / Utility Air System accordingly. 5.3 Pressure Swing Absorption (PSA) Towers Two identical PSA towers, packed with special molecular sieves (carbon sieves) shall be provided to remove oxygen from compressed air supply leaving nitrogen in the product stream. Adsorber loaded with air shall predominantly absorb oxygen while nitrogen shall pass through. Air loading shall be stopped, by time cycle / automatic sequential valve operations, at the precise moment when oxygen concentration in the product gas stream reaches designed limit. Oxygen adsorbed by the molecular sieve shall then be desorbed by depressurization while the other adsorber is being loaded with compressed air supply. Loading and desorption shall be designed to have near identical periods to ensure continuous plant operation. 5.4 Vessels All pressure vessels shall be designed fabricated and tested in accordance with the attached Functional specification for unfired pressure vessel 5601 and ASME, Section-VIII, Div.1. Welding shall meet the requirements of the attached Functional Specification for Welding And NDT 2009F. ASME code stamp shall be provided for all pressure vessels. The materials of all pressure vessels shall meet the following requirements, as a minimum: a) All boiler quality plates for shell, head etc., shall be supplied in Normalised condition.

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b) All boiler quality plates over 15mm design thickness shall be ultrasonically examined as per ASTM A 435. c) Materials specifications: Shell, Head Reinforcement Pads Nozzles Nozzle Flanges : : : SA 516 Gr 60 SA-10G Gr.B SA-105

d) The vessel shall be designed for spot radiography and dish ends to shell circumferential joints as partially radiographed. 5.5 Skid The skid shall be designed and built to ensure that all the equipment along with accessories, panel and piping are mounted suitably for convenient operation. The skid shall be designed and built in accordance with the attached Functional Specification for packaged equipment 5100P. 5.6 Piping The selection, fabrication and installation of piping works shall meet the minimum requirements defined in the attached Functional Specifications 2004 A, 2004-B and 2009-F. Resonance in air piping shall be avoided by use of a pulsation dampener or selecting the appropriate pipe lengths. Piping shall be arranged, adequately supported and connected in such a manner that a minimum number of fittings must be disconnected to remove the Units. Flexible connection shall be used where applicable. Accessory items, including drain traps, check valves control and safety devices shall be installed and connected in such a manner that they can be readily removed, replaced or maintained. 5.7 Electrical

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

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Electrical equipment and materials shall be in accordance with the attached Functional Specifications for Electrical Equipment of Packaged Plant FS 4017. 5.8 Instrumentation The selection and installation of instrumentation works shall meet the minimum requirements defined in the basic bid work of Instrumentation. The controls / indications which are required to be connected to Companys remote control room (e.g. start/shutdown switches, indication lamps RTU etc.) shall be terminated in junction boxes located at the edge of the skid. Separate junction boxes shall be provided for different type of signals. Connections from these junction boxes to the central control panel shall be taken by the contractor. Instrumentation shall be as a minimum, in accordance with the P&ID. Any other instrumentation required for proper operation and safety shall be furnished by the vendor. The instrumentation installation shall be as per instrument data sheet and instrument hook up drawing appearing elsewhere in the bid package. All instrumentation and controls shall be provided for fully automatic as well as manual operation. Necessary safety devices shall be provided as per applicable code requirements. 5.9 Control System A local control panel for the complete package, covering the following instruments and controls, as a minimum, shall be mounted on the skid. The panel shall accommodate the controls, local ammeters, indicating lamps, alarms and shutdowns. The front of the panel shall be furnished with the following indicator lights: o Instrument/Utility air supply available o Instrument/Utility air supply-not available The panel shall contain the following alarms and shut down devices: o Low system Pressure alarm o High pressure drop across system alarm o High system Pressure alarm and shutting off of pressure control valve

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

FS 5903F 0 Mechanical

No of Pages: 12 of 18

Inert Gas Generation The unit shall have an automatic control system with necessary instrumentation. In addition, it shall meet the following requirements as a minimum: o Safety Valves on Feed Air Line, Inert Gas Line and Pressure Vessels. o Visual indication for vessels to indicate whether under adsorption or desorption. o Audio-visual alarm to indicate failure of sequential control valve. o Oxygen analyzer and unit shut down controls with alarm in case of high oxygen analysis. Additional contact, wired to terminal, shall be provided for single remote indication of unit alarm or unit shut down condition. All control sequences shall be accomplished within the control panel. One normally open (closed for operation) contact shall be provided, wired to terminal blocks, for each motor for control of contractor furnished motor starter. Vendor shall provide contacts for running indication of the compressor for remote indication. Local pressure gauges, temperature gauges etc., shall be housed in local gauge board mounted at the skid edge at suitable location. 5.10 Insulation Insulation shall be applied to all relevant piping and in the area of Instrumentation if required for personnel protection as per the attached Functional Specification for Insulation , Piping and Equipment -2006 . 6 6.1 INSPECTION, TESTING AND CERTIFICATION General The responsibility for inspection and testing rests with the contractor. The Company reserves the right to inspect at any time during fabrication of the equipment and to witness all hydrostatic, mechanical and performance tests.

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Inspection will be carried out by the Company or their authorized representative. They shall have at any time, entry to plants, including sub contractors plants, to inspect the on going work or to witness testing of equipment. The contractor shall submit a detailed proposed inspection and testing schedule to the Company 6 weeks prior to the commencement of the test program. All stages of design, material purchase, fabrication and assembly shall be controlled by the contractor in accordance with the requirements of his Companys approved Quality Assurance Manual. The Quality Assurance manual shall contain detailed inspection and non destructive testing (NDT) procedures and the relevant qualifications of all NDT operators. The extent of NDT and acceptance tests shall be approved by Company. Should these test requirements be below that required in manufacturers standard test, manufacturers standard test will then be the requirement. All facilities materials, tools, labour and expendables required to run the tests shall be supplied by Contractor and shall be included in his bid. 6.2 Test Requirements Vendor shall carryout various tests as per applicable codes / standards. Test Certificates shall be submitted for Companys approval. During inspection, materials certificates, shop test data, certificates for bought out components, shop test data, certificates for bought out components and other relevant information shall be furnished so as to ascertain that the specifications and quality are complied with. Tests specified as Witnessed shall be at companys option carried out in presence of the Company, its authorised representative or certifying agency. Vendor shall give minimum 15 days prior intimation regarding testing schedules. 6.3 Hydrostatic Test All pressure containing parts shall be hydrostatically tested to 1.5 times their respective design pressures. The duration of tests shall be long enough to permit

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complete inspection but not less than a period of one (1) hour of leak free testing. Pressure vessels shall be inspected and tested in accordance with the requirements of the Functional Specification for unfired Pressure Vessels, 5601 and ASME VIII, Division-I 6.4 Performance Tests Performance test for inert gas generator shall be carried out at manufacturers works. This shall include functional tests of instrumentation, controls and / or equipment within the package. All performance running tests shall use the package components 6.5 Reports and Acceptance Certificates The Contractor shall prepare a full report on all tests and their results noting any discrepancies observed, including those by Companys inspectors. Should any test is found to be unacceptable corrections shall be made and the test repeated. 7 7.1 SPARE PARTS AND SPECIAL TOOLS Spare Parts The contractor shall submit a recommended parts list for initial commissioning and start up. A recommended priced parts list for one year operation shall also be included. Recommended spares should take into account related factors of equipment reliability, effect of equipment down time upon production or safety, cost of parts, and availability of equipment service facilities. Lists shall include part number, part description, serial number and normal delivery lead time. All spare parts furnished by Contractor shall be wrapped and packaged so that they will be preserved in original as new condition under normal conditions of storage. Spare parts shall be properly tagged and coded. They shall be packaged separately, clearly marked as Spare Parts and shipped at the same time as the equipment. Package lists shall be furnished so that the parts can be handled without removing from crates if required.

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

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7.2

Special Tools Any tools or fixtures not readily available commercially, shall be furnished by the Contractor. Two sets of such tools shall be supplied. Tools shall be permanently tagged with information pertaining to their use. Any special drawings or instructions pertaining to the use of such tools shall be included in the instruction manual. A list shall be established by contractor and included in the contractors tender.

8 8.1

PAINTING AND PREPARATION FOR SHIPMENT Painting and Protective Coating After all shop tests are completed, all exterior parts of the compressor packages, except machined surfaces, shall be painted. Exposed machined surfaces shall be coated with a heavy duty rust preventative. Painting and protective coatings and the procedures for preparation for painting shall be as specified in the Functional specification for Protective Coatings 2005.

8.2

PREPARATION FOR SHIPMENT After final testing and approval, the assembly shall be drained of water and dried. All items shall be properly packed and protected against damage during shipment. Each crate, bag or package shall be clearly identified with the purchase order number and identification symbol, and shall be securely fastened to the Package. Exposed surfaces shall be coated with an easily removable rust preventative All flanged openings shall be protected with steel plate covers attached by proper bolting and sealed with plastic compound. All electrical control enclosures shall be properly plugged at entries and loaded with silica gel bags where necessary.

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

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Screwed connections shall be protected with threaded forged steel plugs. The contractor shall state in their proposal their recommendations for long term storage (up to 12 months) for both indoor and outdoor storage in a marine environment. The package shall be prepared for shipment with packaging and any necessary bracing in accordance with Functional Specification for Packaged Equipment 5100P/W. 9 CONTRACT DATA REQUIREMENTS The contractor shall provide all information as specified in the companys procurement documentation. This shall include, as a minimum, the following: All drawings, calculations and data sheets will require review and approval by Company and will require the issue of as-built documents, should final product differ from those shown on previously issued construction documents. Contractor shall provide a complete document package for unit components and specific for protection of the equipment if taken out of service for finite periods (week) Vendor Data Requirements With Proposal For Company Evaluation And X X X X X After Order Placement For Company Approval / Review X X X X With Eqpt. Data Book

Sl. No.

Description

1 2 3 4 5

Filled in Data sheets Calculations. Catalogues / Leaflets Utility requirements

X X X

Dimensional outline of complete unit G A drawing of Major equipment and package

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FUNCTIONAL SPECIFICATION FOR INERT GAS GENERATOR PACKAGE

SPEC. No. Rev. No. Discipline

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6 7 8 9 10 11 12 13 14 15 16 17 18 19

Skid piping layout G A drawing of control panel and logic diagram Specification valves etc Test procedure Interlocking circuit diagram with control logic Maintenance clearance diagram One year spares list List of sub vendors for major components and instruments Material certificates as applicable Test records Installation operating maintenance manual Deviation list Special tools list Itemised weights maintenance weights WARRANTY including and for instruments,

X X X X X

X X X X X X

X X

X X -

X X X X X

X X X

* -

10

Vendor shall have final and total responsibility for the design and performance of all equipment furnished by him. Vendor shall warrant that the equipment furnished by him and the performance of the said equipment is in accordance with this specification and general codes. Vendor shall warrant and guarantee that all the materials and equipments incorporated in the entire equipment under his Scope shall be new, and all work shall be of good quality.

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Vendor shall also be responsible for all system and detailed designing, the aspects of which may not have been covered in this specification as regards the workmanship, performance etc., of the equipment supplied by him. Vendor shall, upon notice from Company, make good at his own expense all defects found during the warranty period expeditiously. Vendor shall, if required, supply the services of an experienced engineer supervise the correction of any defects found during the warranty period. to

Vendor shall also warrant and guarantee all work, materials and equipment furnished by any Sub-Vendor and which is incorporated in the Package.

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