Quick Guide for Nitrogen Generation Package

Process Description Brief

The System is composed of One (1) train of Nitrogen Generator (2 × 100%) with Eight (8) unit membrane modules forProduced Nitrogen of 97%; the description below applies to one train. Compressed Air is supplied to the Nitrogen Generator Package via the tie-in point. After passing through the Pre-FilterSystem and Electrical Heater, the Air is separated into Nitrogen product and Oxygen rich permeate by the separationMembranes. The Pre-filtration System consists of Two (2) Coarse Coalescer Filters, and Two (2) Particulate Fine Filters. The air will enterinto the Electrical Heater upon leaving the Pre-filtration System. Air will be heated to 52°C before entering NitrogenMembranes. Four (4) unit membranes are required for the system of the prescribed Flow Rate of 390 Sm3/h at standardconditions and Nitrogen purity of 97%. On the other hand, the Oxygen rich waste is vented off to atmosphere in a safe area via the tie-in point on the skid.

Measuring and Control Instrumentation Measuring and Control Instrumentation within the Nitrogen Generator Package includes: - Differential Pressure Indicators across each fine filter, - Differential Pressure Transmitter across the whole filtration train, - Feed Air Pressure Gauge, - Feed Air Temperature Gauge, - Oxygen Analyzer, - Produced Nitrogen Pressure Transmitter, - Produced Nitrogen Flow Transmitter.

All the above signals are wired to Junction Boxes for connection to Client’s DCS. The following parameters are continuously controlled by the Local Control Panel: - Pressure of Generated Nitrogen, with limitation of Flow in case of excessive demand, - Cascade control of the Set Point of Generated Nitrogen Flow Controller, based on signal from Oxygen Analyzer.

The discharge Pressure (flow of Nitrogen) is controlled by a Pressure Control Valve and monitored by a Pressure Controllerand a Flow Controller. The Control Valve will adjust the Flow of nitrogen to the Receiver according to the control loop thatgenerates the lower % opening signal. In case the product Nitrogen falls outside specification (High Oxygen content), the Set Point of the Flow Controller will bereduced in order to avoid contamination of the Nitrogen in the Receiver. If the Oxygen content exceeds the High-Highthreshold, Pneumatic On/Off Valves will divert the Flow of Nitrogen to atmosphere and the Nitrogen Generator will trip. SaidOn/Off Valves are controlled via a solenoid valve that receives a signal from DCS. Manual valves are provided for isolation ofthe package’s instrumentation, filters and membranes.

Posted 25th May 2013 by Danaraj Chandrasegaran

Labels: Equipment, Quick Guide

25

MAY

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Quick Guide for Pedestal Cranes

Quick Guide for Pedestal Cranes

Pedestal crane is one of the key equipment installed in an offshore platform and other floating units e.g FPSO, FSO, FPU. Otherthan that, it represents significant progress achievement visually during the fabrication period once it is erected at the yard.

Pedestal cranes are usually supplied in accordance to API Spec. 2C. This requirement applies to most part of the world. However,in European and north sea environment EN13852-1 are used. Most vendors (e.g. NOV, Liebherr, Oil States, Favelle Favco) are ableto cater for both requirements. In addition, Civil Aviation Authority Regulation CAP 437 needs to be implemented as well.

22

DEC

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Hydraulic power units for the pedestal crane could be diesel engine driven or electric motor driven. For diesel engine unit, if there iscranking time requirement e.g. 3 starts in 1.5 mins., an air receiver need to be an integral part of the crane. Cab design andoperator's interface differs according to supplier's standard design and owner's needs. The more sophisticated and elaborateinterfaces are always available at higher cost.

Construction interfaces that are related to pedestal cranes are:

Structural: Pedestal interface with deck structure, ladders, handrails, aircraft obstruction markingsPiping: Instrument air supply and diesel fuel supplyElectrical: Normal power supply and UPS requirement, aircraft warning lights, JBsInstrumentation: F&G detectors, windsock, JBsTelecommunication: Radio unit, antennaes, surge arrestors, JbsInstallation: Installation procedures, slew bearing change procedure

Testing of the crane unit will be done in accordance to the code and regulations. Usually a witnessed shop test on a fully assembledcrane mounted on a test pedestal shall be required. This test will include a mechanical run of all main and auxiliary machinery,control panels for a minimum 2 hours under full load test. Prior and post test , the crane and its auxiliaries will be visually inspectedas well. Once the crane's test found satisfactory, a certificate will be issued.

Posted 22nd December 2012 by Danaraj Chandrasegaran

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Quick Guide for Pressure Vessel Drawing Review

Quick Guide for Pressure Vessel Drawing Review.

Pressure vessels are among the key items in a mechanical packaged equipment e.g Instrument air package, Nitrogengenerators. Usually, vessel constructions shall comply with ASME Boiler and Pressure Vessel Code (BPVC) Section VIII andthe project specific requirements, including welding specification. For vessel general arrangement drawing review, it shouldbe completed together with datasheet, calculations and welding document. This would facilitate the consistency checkbetween documents.

Checklist:

1. Nozzle schedule2. Design data or equipment data table3. Bill of material4. Fabrication (welding) details to be shown:

earthing lugs/ bosslifting lugaccess openingskirtsnozzlesother attachments

5. Weld details for main circumferential and longitudinal weld line6. Loading data – operating, dry, wind, seismic and transportation7. Nozzle allowable loads8. Painting requirements9. Notes referencing project specifications

References:ASME codes and standards A Brief discussion on ASME Section VII Division 1, 2 and the new Division 3

22

OCT

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Posted 22nd October 2012 by Danaraj Chandrasegaran

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Quick Guide for P&ID Review

Quick Guide for P & ID Review.

Piping and Instrumentation Diagram (P&ID) is one of the key documents that will be reviewed during the course of project execution. It willbe the basis of piping and instrumentation design, as the name implies. Once P&ID is firmed up, secondary drawings such as electrical andcontrol schematics, bill of material and detailed arrangement can be generated by the engineers. Other than that, P&ID needs to be read inconjunction with the control philosophy to have the operational overview of the system.

Checklist for P&ID review:

1. Tagging – this to be referred against the project tagging philosophy2. Symbology – this to be referred against the project symbols. Otherwise, vendor standard symbol to be listed for referencing.3. Inlet and outlet design parameters – design pressure/ temperature; operating pressure/ temperature4. Key equipment design parameters – design/ operating pressure; design/ operating temperature; material of construction,

corrosion allowance; dimensions5. Material selection of key components - this to be referred against the project material selection report6. Line sizing – this to be referred against the piping class for material and ratings7. Valve sizes8. Valves position during operation or failure9. Instrumentation– suitability for the selected parameters; ranges; alarm set points, trip set points

10. Control panel interfaces – signals to/ from main control room and field instruments; hardwired signals; serial linked signals11. Pressure relief valves sizes12. Control loops between the instruments and equipment13. Termination points14. Notes describing project requirements, exceptions or operational points.15. Consistency between documents such as instrument index, control philosophy, line list sizing calculations to be reviewed as well.

Posted 11th October 2012 by Danaraj Chandrasegaran

Labels: Equipment, General, Quick Guide

11

OCT

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Quick Guide for General Arrangement Drawing Review.

Quick Guide for General Arrangement Drawing Review.

General arrangement drawings usually would be the earliest submission by Vendors to the Purchaser ( e.g. EPCcontractor). Since, the GA submission schedule more often than not occurs within 4 weeks from purchase orderplacement; Vendor would provide typical arrangement followed up by more details on subsequent revisions.

Checklist for GA design review:

1. Footprint dimensions2. Interface points for piping and structural3. Interface points for electrical and instrumentation4. Maintenance access requirements and lifting arrangements

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OCT

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5. Special protections6. Human factors requirements7. Bill of material8. Weight and load information (dry, operating, seismic and transport)9. Painting requirements

10. Notes referencing project specifications.

Posted 9th October 2012 by Danaraj Chandrasegaran

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Wellhead Platform (WHP)

WHP

A wellhead platform includes an integrated deck, utility systems, wellhead systems, living quarters, a helideck and drilling facilities. At times, it could be linkedto Floating, Production, Storage and Offloading (FPSO) vessel or central production platforms. WHPs are normally unmanned. They are designed to beoperated remotely and visited during routine inspection and maintenance activities.

Most times, WHPs would be four legged platforms; consisting of 4 decks. The decks would be spider deck, cellar deck, main deck and heli deck. It may have 3 to32 well, depending on the size of WHPs. These wells are usually drilled by jack-up rigs that docks with the WHPs.

Currently market is moving towards minimum facilities installation, whereby minimal engineering activities envisaged and standardization between fields.Schedule and cost savings can be anticipated by decreasing manhours, fabrication time, streamlining designs and equipment selections. Also, expandableplatforms helps on future field development strategies. Facilities could also be designed to accommodate wider design needs. Standardization and streamliningof design also offers improved operational requirements e.g. better spare parts management and decrease manned intervention.

Therefore, WHPs design and technology development should be interesting to watch in coming years.

16

SEP

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RasGas Al Khaleej Gas Project - WHP (By McDermott-Photos)

Posted 16th September 2012 by Danaraj Chandrasegaran

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Quick Guide for Flare Ignition System

Overview: Flare Ignition System

Ignition Method Flame Front Generators(FFG)

Electronic Ignition Ballistic

Brief FFG creates a mixture off u e l gas and air in theignition line. Subsequently,this is ignited. The meteringand mixing process isaccomplished through theuse of small valve trainsplaced on the FFG controlpanel.

This ignition system uses afuel gas line much like otherignition systems. However,utilizing the “exciter” whichproduces a high voltagespark directly in the pilotnozzle, compared toconventional FFGs.

Installed at a safe distancefrom the flare stack and aguide lead to the flare tip.The system is suitable forall flare tips and may igniteseveral flares on one flaredeck. It is easily retrofittedinto existing installations.

Interface Electrical, Fuel, Air Electrical Compressed air

Installation limits <1600m <2000m

Advantages Reliable conventionalsystem

Instaneous reignition if thepilot should ever lose itsflame.

No electronic parts orm o v a b l e parts withinsystem. Does not need any pilotb u r n e r s , and has noequipment on the flare deckthat is sensitive to heat,such as cables,instrumentation orelectrodes.

Disadvantages Components may requirereplacement over its life.

Cabling for electronicignition line required.Ignition detection systemrequired.Components may requirereplacement over its life.

Only single vendor able tosupply this type i.e.Hamworthy.Require guide pipe for theignition pellet.

Posted 2nd September 2012 by Danaraj Chandrasegaran

Labels: Equipment, WHP

2

SEP

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Talent Development: Malaysian Oil & Gas Industries19

AUG

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TalentDevelopment: Malaysian Oil & Gas Industries

Introduction

Recentannouncement by PETRONAS on several major oil and gas project such asRAPID project in Pengerang and North Malay Basin Developmenthavecertainly created much excitement in our industry. Other notableoffshore field development within Malaysia that are in thelimelight are Malikai, Rotan andKanowit. Also, marginal fields arebeing developed and existing fields will be rejuvenated with enhancedoil recovery system to boost our oil production forcoming years. Allthese developments in our local oil and gas industries are forecastto create thousands of skilled jobs comprising of different level ofeducation,trainings and skill sets. For example, for RAPID project,it is envisaged 40,000 to 50,000 workforce would be needed duringconstruction period (Bernama news,12 May 2012).

Thequestion that comes to our mind that where do we source all thetechnical personnel and skilled workers that are much needed toexecute and ensure thesuccess and continuity for all theseprojects. In other words, if the projects concerned do not create themultiplier effect that is needed to boost our overalleconomy, itwould be no good at all to all of us, in a nutshell so to speak.

News,opinions have been generated and discussed regarding the talentissues lately. Here is to focus to a particular industry, which arehigh worth and where wehave the capability to be front runners aswell and may in fact are leading the region at the moment.Nevertheless, considering the significance of oil and gasindustry toour nation's economy. It would be prudent to have holistic and longterm approach to address the talent issue here, while being cautiouswith externalpull factors.

TalentDevelopment Needs for Oil & Gas Industry.

Oiland gas industry talent needs differs on a wide magnitude compared toour local manufacturing and construction industry requirements.Equipmenttechnologies and safety requirements differs throughout theworld and dictated by process licensors as well as oil majors. InMalaysian context, the industry is welldeveloped to cater for theregional needs. Local vendors has established themselves throughPETRONAS vendor development programme and largeengineeringconsulting group has their presence here as well.

Inorder to move towards wider global audience, much need to be done.Our local engineers need to be well versed with wider technical skillsets in terms offamiliarizing with standards and other regulatoryrequirements in other countries. More over, projects all over theworld are being completed in shorter period andinvolving satelliteoffices around the world engaging with multicultural work force,which would require higher degree of English language proficiency andITskills.

Alsothe markets are looking for well rounded talents, meaning technicalskills which are complimented with field experience such asfabrication, testing andcommissioning works. Though, this may becommon requirement for most employers. The ground reality is most ofthe workforce are not trained to be wellrounded. This would be apoint that could be taken up by the industry itself.

Talentdevelopment solutions must also cater beyond the engineeringcommunity, such as government officials, logistics service provider,inspection serviceproviders and procurement personnel. Theadvancement of the industry very much depends all these parts of theprivate sector and public sector catering to ouroil and gasindustry.

RaisingStandards of Training & Education

EnsuringMalaysians are capable of meeting the oil and gas industry needs andmarket demands, our workforce needs to be equipped with rightknowledge andtools. Workforce, not just fresh graduates need to befostered to meet market demands and keep abreast with current marketdevelopments.

Atpresent, there seems to be a expectations gap between the industryand educational institutional graduates. As the industry wants theworkforce entrants to be“job ready “but this not always thecase. However, steps are being taken to address this issued by boththe private and public sector.ThoughIEM and BEM has prescribed path to attain professional qualificationfor engineer, most graduate engineers are either not aware of theprocess or havinglackadaisical attitude towards it. Emphasizingprofessional development for workforce entrant as well as existingshould be the case. Structured learning processwhich suits theindustry, particularly employers must be part of the workforcedevelopment plan throughout their career with measurable indicators.

Internshipplans such as spearheaded by MOGEC, whereby linking Malaysianresearch universities and major engineering consultancy companiesbased inMalaysia must be applauded. Solutions similar to thisprovideuniversity students an early exposure in building oil &gasindustrycapability. This is to ensure a smoother transition upon thecompletion of their undergraduate degree in pursuit of a career inthe oil & gas industry.

Meanwhile,our academic institutions curriculum should be reflective of thespecializations available in the market. Key ideas and industryterminologies shouldbe familiarized at tertiary education level,which would enhance the confidence level of workforce entrants. Forexamples, subjects related to safety, technology,industries' codes &standards or software tools should me available to final yearstudents here.

Boththe industry and academia need to strengthen the collaboration toalign talent development to match the oil and gas industriesrequirements. Involvementby industry personnels in designing theacademic curriculum and providing real field or business exposurethrough the sharing of experiences, must beencouraged and rewarded. More structured learning programme are also needed for existingindustry practitioners to improve themselves. This could bearrangedvia partnership between industry and academia.

ConclusionWhiletalent will be a constant issue for the next decade, there is alreadya talent pool in Malaysia that needs to be developed and refined.This may involve along term commitments from both public sector andindustry players. But the benefits that could be reaped far outweighsthe efforts that are needed.

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Posted 19th August 2012 by Danaraj Chandrasegaran

Labels: General

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Intro

Am currently based in Ulsan, South Korea. Working at the largest shipyard in the world. Doing my bit here to share theknowledge I have accrued all these years. I find that general literature describing the equipment used in the oil & gasindustry etc. lacking on the web. Hence, my effort here to be a starting point the least.

Posted 6th August 2012 by Danaraj Chandrasegaran

Labels: General

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AUG

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