Kamose Wellhead Control Panel Specification PDF

North Sinai Petroleum Company
Kamose Wellhead Control Panel Specification

Minimal Topside Kamose Study - Phase II
TABLE OF CONTENTS
GLOSSARY ............................................................................................................................ 5
1
INTRODUCTION ...................................................................................................... 7
1.1
Project Description ................................................................................................... 7
1.2
Minimal Topside Study Kamose Study Phase II Scope ........................................... 7
1.3
Objective .................................................................................................................. 7
SCOPE ..................................................................................................................... 8
CODES AND STANDARDS .................................................................................... 9
ENVIRONMENTAL DATA ..................................................................................... 12
4.1
Meteorological Data ............................................................................................... 12
4.1.1
Air ........................................................................................................................... 12
4.1.2
Sea Water Temperature. ........................................................................................ 12
4.1.3
Rainfall. .................................................................................................................. 12
4.1.4
Wind Data .............................................................................................................. 13
4.2
Hazardous Area ..................................................................................................... 14
4.3
Electro-Magnetic Compatibility ............................................................................... 14
DESIGN ................................................................................................................. 15
5.1
General .................................................................................................................. 15
5.2
Maintenance ........................................................................................................... 15
5.3
Hydraulic Power Unit .............................................................................................. 15
5.4
Structural Design .................................................................................................... 15
5.5
Standardisation of Sub-suppliers ........................................................................... 16
5.6
System Design ....................................................................................................... 16
5.6.1
System Capacity .................................................................................................... 16
5.6.2
Reservoir ................................................................................................................ 16
5.6.3
Hydraulic System Supply Pumps ........................................................................... 17
5.6.4
Clean-up Loop ........................................................................................................ 17
5.6.5
Filters ..................................................................................................................... 17
5.6.6
Accumulation .......................................................................................................... 18
5.6.7
Panel Instruments & Controls................................................................................. 18
5.6.8
Valve Connections ................................................................................................. 19
5.7
Wellhead Control Modules ..................................................................................... 19
5.7.1
Front of Module Equipment .................................................................................... 19
5.7.2
Back of Module Equipment .................................................................................... 19
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J08617A-J-SP-13482 Rev D1 Kamose Wellhead Control Panel Specification
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5.7.3
Sequence of operation ........................................................................................... 20
5.7.4
Wireline Valves....................................................................................................... 20
5.8
Fusible Loop ........................................................................................................... 20
REMOTE TERMINAL UNIT & RADIO ................................................................... 22
6.1
Remote Terminal Unit (RTU).................................................................................. 22
6.2
Radio ...................................................................................................................... 23
6.3
Antenna .................................................................................................................. 24
6.4
Antenna Cable ....................................................................................................... 25
INSTRUMENT & ELECTRICAL REQUIREMENTS .............................................. 26
7.1
General .................................................................................................................. 26
7.2
Materials ................................................................................................................. 27
TESTING ................................................................................................................ 28
8.1
General .................................................................................................................. 28
8.2
Factory Acceptance Test........................................................................................ 28
8.3
Combined System Test .......................................................................................... 29
8.4
Site Acceptance Test (SAT) ................................................................................... 29
PRESERVATION ................................................................................................... 30
10
DOCUMENTATION ............................................................................................... 31
11
PACKAGING ......................................................................................................... 32
12
REFERENCES ....................................................................................................... 33
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HOLDS LIST
HOLD
Description
Confirmation of valve actuator operating pressures & capacities
Frequency range to be determined during detail design
Section
5.6.1
6.2 & 6.3
REVISION HISTORY
REV.
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GLOSSARY
AES
Advanced Encryption Standard
AISI
American Iron & Steel Institute
API
American Petroleum Institute
ATEX
Atmosphere EXplosibles
BS
British Standard
DIN
Deutsches Institut fr Normung eV (German Institute for

Standardisation)
EGPC
Egyptian General Petroleum Corporation
EIA
Electronics Industries Alliance
EMC
Electro Magnetic Compatibility
EN
European Norm
ESD
Emergency Shutdown
FAT
Factory Acceptance Test
FEED
Front End Engineering & Design
F&G
Fire & Gas
HP
High Pressure
HPU
Hydraulic Power Unit
ICSS
Integrated Control & Safety System
IEC
International Electro-Technical Commissiom
IEEE
Institute of Electrical & Electonics Engineers
I/O
Input/Output
ISO
International Standards Organisation
LP
Low Pressure
MV
Master Valve
NAS
National Aerospace Standard
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NOSPCO
ONS
Offshore North Sinai
PoE
Power over Ethernet
PUWER
Provision and Use of Work Equipment Regulations
QA
Quality Assurance
RTU
Remote Terminal Unit
Rx
Reciever
SAT
Site Acceptance Test
SDRL
Supplier Data Requirements List
SOV
Solenoid Valve
SSSV
Sub Surface Safety Valve
TCP
Transmission Control Protocol
Tx
Transmitter
TIA
Telecommunications Industries Association
VHF
Very High Frequency
VSAT
Very Small Aperture Terminal
WCP
Wellhead Control Panel
WV
Wing Valve
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1 INTRODUCTION
1.1
Project Description
NOSPCO, a Joint Venture Company involving Perenco and EGPC, is progressing

with the development of the Offshore North Sinai (ONS) leases.
The Offshore North Sinai (ONS) concession lies just offshore on the eastern flank of
the Nile Delta. The concession is comprised of three separate areas. Each of the
three areas has a gas discovery making three proven accumulations. The
discoveries: Tao-1, Kamose-1 and Seti Plio-1, were all made in 1997 in high porosity
Plio/Pleistocene sandstones.
The focused reservoirs are located at depths ranging from 600 to 2300 meters. The
gas fields contain lean natural gas.
The ONS Phase II project aims at the further development and exploitation of the
natural gas from Tao and Kamose leases, which are located offshore respectively at
about 60 km and 50 km north of Rommana, North western Sinai, Egypt, in order to
maintain the production plateau at an average rate of 180 mmscfd as long as
possible, ensuring the highest reserves are achieved for each reservoir.
The ONS Phase II project consists of:
2 wells (TAO SW) drilled from TAO existing platform
2 subsea wells (Wastani reservoir) connected to TAO existing platform
The development of the Kamose Field includes a new infrastructure comprising an

offshore not normally manned platform, and a submarine pipeline tied back to the
existing sea line through a hot tap connection. The Kamose Phase II FEED includes
the FEED design for all topsides equipment and instrumentation, controls as well as
the Detailed Design of the jacket and topsides structure.
1.2
Minimal Topside Study Kamose Study Phase II Scope
This project covers the topside design of the Kamose platform from the tie-in to the
Christmas tree at the wellhead to the cottom of the export riser, as well as the design
of the platform itself. The rest of the ONS phase II project is outside of this project
Scope.
1.3
Objective
This document defines the minimum requirements for the design, fabrication,
inspection and testing of an electro / hydraulic wellhead control system designed for
two topside wells. Wellhead Control Panel (WCP) shall also contain a programmable
Remote Terminal Unit (RTU) and radio for transmitting signals between Tao &
Kamose platforms.
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2 SCOPE
The Suppliers scope of work shall include the design, supply, inspection, Q.A.,
system testing, certification and documentation, including operational handbooks
necessary for good operation and maintenance of the specified system.
The Supplier will assume full responsibility; this means the Supplier shall guarantee
operability, quality of all components inclusive of all sub-suppliers and conformance
to authority and code requirements.
The unit design shall be based on a fit for purpose philosophy and shall utilise, as far
as possible, tried and tested designs, previously implemented in the European
offshore environment.
Supplier scope of work shall include design, fabrication, testing, calibration and
packing for shipment and supply of all materials and documentation necessary for
good operation and maintenance for the system.
Supplier shall provide nameplates for all instruments and equipment.
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3 CODES AND STANDARDS

The manufacture and supply of the system shall be carried out in accordance with
the latest revision of all applicable Egyptian Standards and Codes. Where these do
not exist, internationally recognized Standards and Codes shall be applied.
Reference
Title
American Petroleum Institute (API)
API Spec 6A
Specification for well head and Christmas Tree Equipment
API RP 14C
Analysis, Design, Installation and Testing of Basic Surface Safety

Systems for Offshore Production Platforms
API RP 500
Instrumentation
API RP 520
Recommended practice for sizing, selection and installation of

pressure relieving (parts I and II).
API RP 521
Guide for pressure devices in refineries relieving and depressurising

systems.
API RP 550
Manual on installation of refinery instruments and control systems.

Part I : Process instrumentation and control
Part II: Process stream analysers.
British Standards Institute
BS 5760
Reliability of Systems, Equipment and Components
BS 6174
Specification for Differential Pressure Transmitters with Electrical

Outputs
BS 6447
Specification for Absolute and Gauge Pressure Transmitters with

Electrical Outputs
Electronics Industries Alliance/Telecommunication Industries
Association
EIA/TIA (RS)
232
Data Communication Interface Standard
EIA/TIA (RS)
422
EIA/TIA (RS)
485
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Reference
Title
International Electro-Technical Commission
IEC 60529
Specification for classification of degrees of protection provided by

enclosures (IP Code)
IEC 60079
Electrical Apparatus for Explosive Gas Atmospheres

Part 0: General requirements
Part 1: Flameproof enclosures d
Part 4: Method of test for ignition temperature
Part 7: Increased safety "e"
Part 10: Classification of hazardous areas
Part 11: Intrinsic safety i
Part 12: Classification of mixtures of gases or vapours with air
according to their maximum experimental safe gaps and minimum
igniting currents
Part 14: Electrical installations in hazardous areas (other than mines)
IEC 60096-2
Radio Frequency Cables: Relevant Cable Specifications
IEC 60227
Polyvinyl chloride insulated cables of rated voltages up to and

including 450/750 V
IEC 60331
Fire Resistant Cables
IEC 60332
Flame Retardant Cables
IEC 60439
Low Voltage Switch Gear and Control Gear Assemblies
IEC 60584
Thermocouples
IEC 60751
Resistance Temperature Detectors
IEC 60947
Low Voltage Switchgear and Control Gear
IEC 61131-1
Programmable Controllers Part 1 General Information
IEC 61131-2
Programmable Controllers Part 2 Equipment Requirements
IEC 61131-3
Programmable Controllers Part 3 Programming Languages
IEC 61508
Functional Safety of Electrical/Electronic/Programmable Electronic

Safety-related Systems.
IEC 61511
Functional Safety Safety Instrumented Systems for the Process

Industry Sector
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Reference
Title
Institute of Electrical & Electonics Engineers
IEEE 802
LAN Interfaces and Protocols
IEEE C37.1
Specification used for Supervisory Control, Data Acquisition

and Control
International Standards Organisation (ISO)

ISO 9000
Quality Management & Quality Assurance Standards
ISO 9001
Quality Systems Model for Quality Assurance in Design,

Development, Production, Installation and Servicing
Institute of Petroleum
EI 15
Institute of Petroleum, Model Code of Safe Practice, Part 15: Area

Classification Code for Installations Handling Flammable Fluids,
2005
EN 61000-6-1:
2007
Electromagnetic Compatibility Generic Emission Standard, Part 1,

Residential, Commercial & Light Industry Environment.
EN 61000-6-2:
2005
Electromagnetic Compatability Generic Immunity Standard, Part 2,

Industrial Environment.
Miscellaneous
ATEX
Directive
94/9/EC
Equipment and Protective Systems intended for use in

Potentially Explosive Atmospheres
73/23/EEC
CE Directive for low voltage
89/336/EEC
CE Directive for Electromagnetic Compatibility
NAS 1638
SNT-TC-1 A
Cleanliness Standard for Hydraulic Fluid
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4 ENVIRONMENTAL DATA
The following data shall be used for design purposes. Should the Supplier consider
that other data is required for the design or supply of the equipment, or that the
omission of certain data could either affect the cost or compromise any safety aspect
of the design, this should be requested in writing prior to submission of the bid.
The equipment will be located on an offshore production platform in the
Mediterranean Sea, 50 km offshore from the North coast of Sinai and consequently
will be subjected to the effects of a highly saliferous atmosphere coupled with high
temperature and humidity.
All components and accessories inside the well head control package shall be
suitable for continuous operation under the outside environmental conditions stated
below.
4.1
Meteorological Data
4.1.1
Air
The air quality should be considered to be a highly corrosive marine climate with
high moisture and salt levels.
The dry bulb temperatures, for the design of offshore facilities above the splash
zone, are as follows:
Average
Design
Summer:
27 to 31C
40C
Winter:
11 to 24C
5C
4.1.2
Sea Water Temperature.
The design seabed temperatures are as follows:
Summer:
25C
Winter:
15C
The seawater density is taken as 1027 kg/m3.
4.1.3
Rainfall.
The following offshore rainfall data shall be used for design:
Maximum (winter):
50-100 mm/h, brief and severe
Maximum (summer):
zero rainfall for long periods
Annual average:
40 mm/year
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4.1.4
Wind Data
The mean hourly wind speeds at 10m above sea level, indicating the directions from,
are shown below:
Table 3-1 Mean Hourly Wind Speeds
Direction
from North
1 Year
m/sec
10 Year
m/sec
100 Year
m/sec
9.2
10.8
12.3
30
9.6
11.7
13.5
60
10.2
13.1
15.6
90
8.6
11.5
14.2
120
8.0
11.0
13.8
150
7.1
9.6
11.9
180
7.9
10.7
13.2
210
12.1
16.9
21.3
240
14.3
18.4
22.1
270
14.1
17.2
20.0
300
12.1
14.0
15.8
330
12.0
14.2
16.1
OMNI
14.3
18.4
22.1
The omni-directional wind speeds in m/sec for other sample intervals are shown
below.
Table 3-2 Omni Directional Wind Speed
Omni directional
1 Year
m/sec
10 Year
m/sec
100 Year
m/sec
1 hour mean
14.3
18.4
22.1
10 minute mean
15.3
19.9
24.0
1 minute mean
16.6
21.7
26.4
3 second gust
18.3
24.1
29.6
Reference: Basis of Design J08617A-P-RD-15000
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4.2
Hazardous Area
All equipment located in the wellhead hydraulic unit shall be suitable for the following
hazardous area:
Zone 1 Gas Group IIA Temperature Class T3.
All instrumentation shall be EEx(d)

Solenoid valves shall be EEx(d) and protected to IP65 minimum.
Pump motors shall be EEx(de), protected to IP56 minimum, without anticondensation heaters.
All equipment to be ATEX approved
The minimum degree of protection for the housings, field panels & enclosures when
containing electrical components, shall be IP65.
4.3
Electro-Magnetic Compatibility
All equipment or systems containing electrical or electronic apparatus shall satisfy

the requirements of electromagnetic compatibility legislation, e.g. S. I. 1992 No. 2372
(1992). The Electromagnetic Compatibility Regulations, as amended by S. I. 1994
No. 3080; S. I. 1992 No. 2932 The Provision And Use Of Work Equipment
Regulations (PUWER).
Relevant apparatus should satisfy the following EMC performance requirements.
Emissions
Emissions performance shall be in accordance with EN 61000-6-1: 2007 Electromagnetic Compatibility Generic Emission Standard, Part 1, Residential,
Commercial & Light Industry Environment.
Immunity
Immunity performance shall be in accordance with EN 61000-6-2: 2005 Electromagnetic Compatibility Generic Immunity Standard, Part 2, Industrial
Environment.
Performance Criteria
Performance Criterion A as applied to immunity of measuring instruments to radiated
interference is hereby defined as allowing a degradation in performance not
exceeding +/- 0.1% of the output span with the instrument enclosures (covers) in
place and not exceeding +/- 0.5% of the output span with the instrument enclosures
(covers) removed.
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5 DESIGN
5.1
General
The WCP shall consist of an integral skid mounted Hydraulic Power Unit (HPU),
Remote Terminal Unit (RTU), radio/modem and operator controls for two topside
wells.
The Hydraulic Power Unit shall provide hydraulic power for the well valves and
additional topsides ESD and HIPPS valves as defined in Section 5.6.1 of this
specification. The hydraulic fluid shall be Castrol Transaqua HT, cleaned to
NAS1638 class 6.
The programmable Remote Terminal Unit shall provide the required minimum
automatic control and ESD/F&G shutdown functions required for the safe shutdown
of the platform.
The Platform power supply will be derived from a solar power package. The design
of the WCP shall minimize its electrical power usage whilst ensuring that the overall
system can be safely operated.
The design and controls must be kept as simple as possible, consistent with safe
and reliable operation. Failure of any part of the system / package shall be to the
safe or isolated condition.
The WCP shall be of the fully enclosed type and is to be lockable.
There is no instrument /plant air supply available on the platform.
An overview of the system is shown on Wellhead Typical Detail P&ID -Drawing No:
J08617A-P-DW-15420 / 15421.
5.2
Maintenance
The platform will be designed for infrequent maintenance visits. The WCP shall be
designed to ensure that the interval between periodic maintenance visits is
maximised. The Supplier shall advise, in his bid, the expected maintenance interval.
5.3
Hydraulic Power Unit
The HPU shall consist of hydraulic reservoirs, pumps, accumulators, filtration,

intensifiers and other equipment and instruments required to produce the required
hydraulic pressures. It shall be located integrally within the Wellhead Control Panel.
5.4
Structural Design
The structural design of the WCP shall, in addition to the normal static loads, take
account of transportation loads and include for acceleration to 1 g in any direction
and roll motions of 20 with a 10 Sec period.
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The layout of equipment and instrument items shall allow ease of access for
maintenance.
The layout of equipment and instrument items shall be determined by supplier
subject to purchaser approval.
5.5
Standardisation of Sub-suppliers
The Purchaser will select the project supplier for electric motors, mechanical seals,
mechanical couplings, and general instrumentation and instrument fittings. Suppliers
shall define the manufacturers offered as sub-suppliers in these categories, in their
bids.
5.6
5.6.1
System Design
System Capacity
The system shall be sized to operate valves at capacities and pressures stated
below (HOLD 1)
Valve Type
Quantity
Min Op.
Press
(Barg)
Norm Op.
Press
(Barg)
Max Op.
Press
(Barg)
Approx.
Swept
Volume
(Litres)
Platform Well Master Valves

MVs.
150
200
207
1.6
Platform Well Wing Valves

WVs.
150
200
207
0.4
Platform Well Sub Surface

Safety Valves SSSVs
250
310
345
0.1
Platform Well Completions
At start up or after a shutdown it shall be possible to recharge the hydraulic system

via the electrically driven pump or a hydraulic hand pump. Pumps and accumulation
shall be sized to suit.
5.6.2
Reservoir
A reservoir shall be provided for the supply and return fluid from the well valves.
The reservoir shall have sufficient capacity to supply and operate the maximum
system configuration referred to in this specification, including hydraulic accumulator
volume.
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The supply reservoir shall be provided complete with drain valve, level gauge, & two
level transmitters (1 for ESD, 1 for monitoring) covering the full range of the reservoir
with isolation valves, clean out bulkhead plate, tank breather and magnetic particle
collector & sample points.
Fresh fill fluid shall be filtered before use.
5.6.3
Hydraulic System Supply Pumps
Pumps shall generate one level of hydraulic pressure (LP), with intensifiers to
generate the HP supply:
LP
200 Barg for MVs, WVs and other platform valves. (HOLD 1)
HP
310 Barg for SSSVs (HOLD 1)
One electric driven pump shall be provided to deliver hydraulic fluid at the lower
pressure level. Dual (duty/standby) pressure intensifiers shall be provided to supply
fluid at the higher pressure level.
The pump shall be installed complete with suction block valve, discharge check
valve, discharge relief valve, discharge double block and bleed valve. Pump shall
have a discharge pressure gauge, a discharge pressure transmitter, inlet & outlet
filters as required.
Supplier to advise method of control & pressure settings for the pump start/stop
within the installation and operation manual.
Pump motor shall be provided with an emergency stop latching pushbutton unit.
A manually operated pump shall also be provided, in parallel with the above electric
pump, this pump shall also be supplied with suction block valve, discharge block
valve, discharge relief valve, discharge double block and bleed valve and discharge
pressure gauge.
5.6.4
Clean-up Loop
The system shall be provided with a clean up pump and filter system for cleaning of
the reservoir contents, the pump shall be manually operated. The clean up system
shall include valves to allow replacement of the filter elements before recirculation of
fluid from and to the storage reservoir. Valving shall also allow pump to be used to
fill/top-up supply reservoir using a quick connect coupling and barrel lance assembly.
5.6.5
Filters
Filters shall be provided with a differential pressure transmitter to monitor for

cleanliness and replacement interval.
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5.6.6
Accumulation
Nitrogen charged, bottle type bladder accumulators shall be connected by tubing to

the system for pressurising the HP and LP hydraulic manifolds. Accumulators shall
be sized for the full system configuration.
Accumulators shall be sized for the following actions:
One opening stroke of two platform SSSV
One opening stroke of two platform MV
One opening stroke of two platform WV
Once a well has been opened, the system shall replenish the accumulators to their
normal pressures within 30 minutes.
5.6.7
Panel Instruments & Controls
The panel shall have the following front of panel controls and indications:
LP header, HP header and Fusible loop header pressure gauges
LP pump, Recirc pump and Manual pump discharge pressure

gauges
LP pump start pushbutton
LP pump stop pushbutton
ESD pushbutton
Open / Close pushbuttons for all SSSVs, Master and Wing valves
Nitrogen pressure indications shall be as per accumulator Suppliers standard.

LP header shall have two transmitters:
One transmitter will provide local control of LP hydraulic pumps and low/high
pressure alarms.
Second transmitter will provide low low pressure ESD signal.
HP header shall have two pressure transmitters:
One transmitter will provide low/high pressure alarms.
Second transmitter will provide low low pressure ESD signal.
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NOTE:
To reduce number of signals sent to the Onshore Control room, low/high pressure
alarms shall be combined with the reservoir low/high level alarms to provide a
common status alarm signal.
Fusible loop header shall have one pressure transmitter for low low pressure
F&G/ESD function.
Transmitters shall be SMART type with integral indicators.
All process pressure gauges shall be fitted with snubbers.
Supplier shall provide sizing calculations for each relief valve.
5.6.8
Valve Connections
All external WHU connections to well valves shall be terminated on 12 mm bulkhead

compression fittings. Spare bulkhead connections for well valves to be supplied.
5.7
Wellhead Control Modules
The Wellhead Hydraulic Unit shall be sized to accommodate a maximum of 2

platform well control modules. It shall be supplied with 2 platform well control
modules installed. Internal panel cabling and tubing shall be designed for easy
change out of well modules via removable drawers. Hydraulic connections to each
drawer shall be via a double block and bleed arrangement. The controls for each
wellhead shall be clearly separated on the front of the hydraulic unit.
Each Platform well control module shall control the SSSV, MV and WV for one
platform well. Control modules shall be of a failsafe design.
5.7.1
Front of Module Equipment
Each platform well control module shall have the following front of panel indication:
Pressure gauge for hydraulic supply to each of SSSV, MV & WV.
5.7.2
Back of Module Equipment
Equipment mounted back of panel on each topsides well control module shall
include:Pressure transmitters for remote indication of each SSSV position.
One solenoid valve for each MV, SSSV and WV (controlled by the RTU/ESD
system)
Wireline key lockable 2 position selector valves
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Position 1 - Normal operation.

Position 2 - Wireline control.
5.7.3
Sequence of operation
Sequencing of well valve operation will be carried out by the RTU/ESD. Sequence
and time delay requirements are to be defined by Purchaser.
The hydraulic system shall include adjustable flow control valves to delay closure of
the SSSV until after the master and wing valves have closed. This is to prevent
premature SSSV closure in the event of loss of electrical power to the system
solenoid valves, or loss of hydraulic pressure.
Well Shutdown: The well valves will be closed in the following sequence wing,
master and then SSSV. There will be a 5 second delay between wing and master
closure initiation this will be implemented in the RTU/ESD. There will be a 15 second
delay between master and SSSV closure initiation this will be implemented in the
WHU.
Signal Failure or Hydraulic Loss: On loss of signal or hydraulic pressure there will be
a 15 second delay between master and SSSV closure initiation this will be achieved
by a hydraulic timer in the WHU.
System shall be designed to ensure closure of platform well valves within 30
seconds of demand.
5.7.4
Wireline Valves
During wire lining workover operations the MV & SSSV of the selected well shall be
under the control of the wireline or workover crew.
A well will be placed in wireline control by using the lockable valves on the
appropriate well control module.
The wireline connection from each of these valves shall be tubed to 12mm bulkhead
connectors on the exterior of the WHU.
5.8
Fusible Loop
The WCP shall be connected to a common process area hydraulic fusible loop
system with frangible bulbs and supply/return tubing. The unit shall include a
pressure transmitter which will be connected to the RTU/F&G system.
Supplier shall provide a pressure letdown system within the WHU to operate and
monitor the loop system at 6 barg. Supplier shall provide 30 off suitable frangible
bulb change-over valves for site installation by others.
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All tubing, fittings, cables, junction box and hook-up material for complete installation
to be in Suppliers scope of work.
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REMOTE TERMINAL UNIT & RADIO
The Kamose platform is intended to be of a minimal design and to operate with

minimal facilities. Instead of an Integrated Control & Safety System (ICSS) located in
a Local Equipment Room (LER) the platform will have a programmable, SIL 2,
Remote Terminal Unit (RTU) located in the Wellhead Control Panel (WCP). This will
provide the required minimum automatic control and ESD/F&G shutdown functions
required for the safe shutdown of the platform.
6.1
Remote Terminal Unit (RTU)
RTU shall comply with, but not be limited to the following:
SIL 2 (Certified by third party, such as TUV)
Suitable for use in a Zone 2 Gas Group IIA Temperature Class T3 hazardous
area.
Compliance with IEC 61508 and IEC 61511
Programmable using IEC 61131-3 automation languages.
Redundant controllers for increased availability.
Inherent reliability
Data logging
Time stamping
Extensive diagnostics
Non volatile memory, data to be retained in event of loss of power
Hot replacement of I/O modules
Automatic configuration of replacement I/O modules
Low cost of ownership
Low power, suitable for solar power
Dual redundant power supplies
RTU to continue to operate for a defined period on loss of communication
RTU to be shock & vibration resistant.
The RTU will be programmed to provide the following:
Automatic start/stop control of LP hydraulic pump to maintain hydraulic fluid at

correct pressure.
Group selected pre-alarms to provide common alarms for display on the

onshore remote terminal. Refer to J08617A-J-AE-13470 Kamose Offshore
Instrument Index.
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Initiate shutdown actions in response to specific inputs from field devices,

F&G logic, manual ESD pushbuttons (Both offshore and onshore). The ESD
status will be communicated to the onshore remote terminal
The F&G logic will interface directly with the platform ESD logic to initiate local
executive actions and activate audible and visual alarms. The F&G status will
be communicated to the onshore remote terminal
Inputs to the ESD logic will be from both analogue and digital devices with outputs
generally being fail safe, de-energise to trip.
The ESD status will be displayed in the jack-up drilling rig, when it is on-station.
The ESD system will be programmed in accordance with the requirements of the
Kamose platform F&G and ESD Cause & Effect Diagrams J08617A-J-CF-13460
The safety systems for Kamose will be configured as fail safe. Loss of power or
utilities or open circuit on inputs and/or outputs will result in external equipment going
to a safe condition.
The F&G logic will interface with various types of field devices used for F&G
detection, the F&G element of the RTU shall have standard interfaces for all
commonly used detector systems.
Fire and Gas detectors that require occasional maintenance will be provided with an
override function accessed via the RTU interface, these provide inhibit and enabling
functions thus permitting routine work.
The F&G system will be programmed in accordance with the requirements of the
Kamose platform F&G and ESD Cause & Effect Diagrams J08617A-J-CF-13460.
Selected data shall be transmitted to the onshore remote terminal via a VHF radio
link between Kamose and Tao platforms and a line of sight microwave radio system
and VSAT between Tao platform and onshore. For details of data to be transmitted
between Kamose platform and onshore refer to J08617A-J-AE-13470 Kamose
Offshore Instrument Index.
A laptop shall be provided loaded with all the relevant software to enable operator to
interface with the RTU. Laptop will allow operator to connect to the RTU to setup/configure controllers and display data during a platform visit.
6.2
Radio
A high speed digital data VHF radio shall be mounted in the WCP and shall be
connected to the RTU using an Ethernet link.
Radio requirements to be, but not limited to the following:
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Frequency range:
HOLD 2 (To be determined during detail

design)
Operational modes:
Simplex, Half Duplex, Full Duplex options
Configuration:
Via Windows based software.
Diagnostics:
Full diagnostic capability
Transmission:
Data & Voice
Ethernet Protocol:
Modbus/TCP
Encryption:
WPA2 802.11i - 128 bit AES encryption
Connections:
Ethernet port (IEEE 802.3)

RJ45
Power
Separate N(Tx) and SMA(Rx) connectors
for full duplex mode.
Handset
Power supply:
24VDC
Housing:
Rugged enclosure
Mounting:
DIN rail
Handset:
Yes
Hazardous Area Certification:
Suitable for use in a Zone 2 Gas Group IIA

Temperature Class T3 hazardous area.
Vendor to ensure that selected frequency channels comply with Egyptian regulatory
standards.
6.3
Antenna
Antenna shall be a Yagi type with a narrow beam width suitable for point to point
communication. It shall have a high front to back ratio to help minimize potential
interference to and from other radio systems.
Antenna shall be constructed of heavy duty stainless steel and be suitable for use in
an offshore environment as stated in Section 3.1.
Antenna requirements to be, but not limited to the following:
Frequency range:
HOLD 2 (To be determined during detail design)
Polarisation:
Vertical or Horizontal. (Antenna on Tao & Kamose

platform to have same polarization)
Number of elements:
To be decided during detail design.
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Construction:
Stainless steel.
Mounting:
Heavy duty mounting hardware
Antenna shall be mounted at the correct height to achieve the required

communication performance with Tao platform. Antenna shall be suitable for wind
conditions as stated in Section 4.1.4.
6.4
Antenna Cable
Vendor to supply suitable antenna cable complete with connectors. Cable will be
required to have galvanized steel wire braid and flame retardant outer sheath.
Cable run will be approximately 50m, Vendor to confirm that this cable length is
acceptable and will not have a detrimental effect on the radio performance.
If cable run is to long consider Power over Ethernet (PoE) as this enables radio
placement near antenna to improve wireless network performance.
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INSTRUMENT & ELECTRICAL REQUIREMENTS
7.1
General
The electrical supplies available are:
Motor drives 24 V dc.
Solenoid Valves 24V dc - Negative pole earthed
Solenoid valves shall consume low power, be continuously powered and fail safe.
All WCP instrumentation and pushbuttons that interface with the RTU shall be cabled
directly to the RTU I/O terminals via a gland plate in the RTU enclosure.
Field cables (by others) carrying signals between the RTU and field devices shall
enter the WCP via a gland plate in the side of the panel, glands shall be through type
to provide environmental seal. Cables shall enter RTU enclosure via a gland plate,
glands shall be Ex type suitable for use in specified hazardous area.
Motor start, stop and emergency stop pushbuttons and motors will be cabled, by
supplier, directly to the motor starters. Motor starters will be by supplier and located
in the WHU.
All instruments shall be tagged with stainless steel labels bearing Purchasers tag
numbers (to be advised later).
All unit cabling shall be flame retardant in accordance with lEC 332 part 1 & 3
Standard ships wiring cable to BS6883 with braid wire armour shall be used for
routes external to the cabinet, with unarmoured cable within cabinet. Nylon sealing
washers shall be used on glands to maintain enclosure IP ratings where applicable.
Junction boxes etc. shall be earthed to skid by means of star washers. WHU shall be
fitted with M10 earth bosses on diagonally opposite corners of the skid.
There will be no power available for internal cabinet lighting. The design of the
cabinet shall make provision for ambient light to be available for maintenance
purposes (removable panel/window). If this is not possible, Supplier shall state this in
his bid so that Client can ensure maintenance crews visit the platform with necessary
portable lighting.
All DC motors shall be standard products in accordance with IEC. DC motors shall
be 24 VDC. Motor datasheets are to be submitted with bidders offer. The electrical
installation shall meet IEC requirements.
A single, 4 x 50mm2, cable (by others) shall supply the 24vdc power to the WHU for
the RTU.
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A single, 4 x 120mm2, cable (by others) shall supply the 24vdc power to the WHU for
the pump.
The RTU on the Kamose platform shall be supplied from a dedicated power supply
with 96 hour battery backup (By others). This shall be fed from the general platform
electrical supply in normal operation.
7.2
Materials
Base frame, panel and wellhead control modules shall be 316 SS, as a minimum.
Tubing shall be metric AISI 316L stainless steel, as a minimum.
Tube fittings shall be Parker Hannifin metric double ferrule type, AISI 316 stainless
steel, as a minimum.
Cable tray/supports shall be 316L SS
System shall be supplied complete with sufficient hydraulic fluid for topsides system
first fill.
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8 TESTING
8.1
General
The system shall be subject to several levels of testing throughout manufacturing

and installation phases of the project.
Prior to shipment the complete system shall be subject to a witnessed Factory
acceptance test (FAT) during which the system will be fully functionally tested at
normal operating pressures including all pumps, solenoid valves and
instrumentation.
Prior to testing system shall be flushed to NAS Class 6 or better and a fluid sample
taken to confirm this has been achieved. A cleanliness certificate shall be available
for review.
The Purchaser reserves the right to be present and to participate in any or all the
tests conducted. All of the witnessed tests will be scheduled by the Supplier in
accordance with the overall project schedule.
Written test procedures shall be submitted to the Purchaser for approval prior to
testing.
The Purchaser shall be notified in writing at least two weeks prior to start of all
witnessed tests.
The major witness tests which require the Purchasers approval include:
8.2
Factory Acceptance Test (FAT)
Site Acceptance Test (SAT)

Factory Acceptance Test
The Factory Acceptance Test shall include the Combined System Test. This will
incorporate the WCP, RTU, radio link and field I/O. This test will be carried out at the
WCP Suppliers works. Field I/O shall be achieved using a test simulator.
The test shall be designed to demonstrate that the WCP & RTU will perform their
specified functions. The test shall demonstrate the performance and accuracy
required.
Vendor shall be responsible for providing a test simulator and all temporary
hardware to allow for full function testing.
Witness testing shall only be carried out after the Test Procedure has been
submitted and approved by the Purchaser.
Test procedure to be detailed and include all components to be used for the Test rig.
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The software configuration and any hardware being supplied shall be fully tested.
The Supplier shall demonstrate the operation of all diagnostic and maintenance tests
provided with the system. Errors shall be simulated to demonstrate the capability of
the system to detect and report errors.
8.3
Combined System Test
Included as part of the FAT.

8.4
Site Acceptance Test (SAT)
The Seller shall provide commissioning support during a full functional test.
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9 PRESERVATION
After successful testing and approval received for shipping, Wellhead Control Panel
preservation should be, as a minimum, carried out as follows:
Drain down all hydraulic fluid from accumulators, reservoirs, filters etc.
Discharge all nitrogen from accumulators.
Place silica gel sacks within all junction boxes and electrical enclosures to
prevent condensation forming.
Cap external tube and pipework connections, using approved blanking /

capping devices.
Pre-set all valves as per panel schematic drawing.
Secure loose items within the panel.
A written Preservation Procedure shall be submitted to the Purchaser for approval

prior to packing.
Preservation shall only be carried out after the Preservation Procedure has been
submitted and approved by the Purchaser.
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10 DOCUMENTATION
The wellhead control and hydraulic power documentation shall be developed and be
user friendly with respect to design, installation, operational and maintenance
requirements.
The Purchaser shall initially develop a Suppliers Document Requirements List
(SDRL) and SDRL Instruction Specification that shall accompany the Enquiry
Material Requisition. The SDRL instructions shall define precise document
requirements, the means of document approval, the quantity of soft/hard copies
required from initial enquiry through to final issue, and the dates by which documents
should be transferred back and forth throughout documentation development. Prior
to commitment of Purchase Order the selected Supplier shall complete the SDRL
with additional documentation pertaining to the wellhead control and hydraulic power
that enhanced design, installation, operational and maintenance requirements
developed during the enquiry.
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11 PACKAGING
The Supplier shall be responsible for ensuring that the Wellhead control panel is
packed securely, and in such a manner as to prevent damage and dirt ingress whilst
being transported, or stored, under the most severe environmental conditions likely
to be encountered throughout the entire route from source to construction yard.
The WHU shall be accompanied by a Packing List that shall include the following
information as a minimum:
Project and Purchase Order Numbers;
Suppliers Name and Trademark;
Address of destination via interim ports of call;
Package sequence number (n of N if one of a sequence of packages);
Itemised Material List with equipment identification and serial numbers

including descriptions, model numbers etc.
Handling and unpacking instructions.
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12 REFERENCES
J08617A-J-SP-13000
Kamose Control Philosophy
J08617A-J-BD-13093
Telecommunication Block Diagram
J08617A-J-BD-13402
Kamose Control System Block Diagram
J08617A-J-BD-13451
Kamose Platform Instrument Cable Block Diagram
J08617A-J-CF-13460
Kamose F&G and ESD System Cause & Effect Diagrams
J08617A-J-PH-13465
Kamose Offshore Shutdown Hierarchy
J08617A-J-AE-13470
Kamose Instrument Index
J08617A-P-RD-15000
Minimal Topside Kamose Study - Phase II Project Basis

of Design
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Kamose Wellhead Control Panel Specification PDF

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North Sinai Petroleum Company