Professional Documents
Culture Documents
PROJECT DESCRIPTION
In Bab field around 43,000 BWPD of effluent water is currently being disposed of.
into 05 disposal wells namely Bb-356. Bb- 437. Bb-558. Bb- 657 and Bb-658. A
further increase in ,effluent water- production fro.m its curr.e nt level of 43,000
BWPD to arou'nd 63,000 BWPD is predicted 'during period 2008-2012. Howeve r
the new header should be sized for 97,000 BWPD to cater for the exg:ected
future requirements. This increase in water production is expected due to the
increase in water cut from both Thamama B and oil rim wells and through the
implementation of artjficial lift schemes. Since each disposal well is estimated to
--
---
The associated water is collected from 1st stage, 2nd stage separators and FST's. The
stream then goes through a EWTP to separate the oil before it is recollected into
disposal water tank T-2402. It is then pumped for disposal through 12" header into 5
disposal wells.
Due to the frequent failures in the existing GRE disposal water header and considering
the trend of increasing associated water production, it has become crucial to debottleneck the entire existing disposal water system. This De-bottJenecking would
involve engineering study, techno-economic analysis of different feasible options, etc.
which is being carried out under separate project. However as an interim measure; the
de-bottlenecking shall be implemented by laying another header of suitable size to
handle 97000 BWPD in parallel to the existing header. The arrangement for .the new
header shan be simila-r to the existing .header; however the number of joints shall be
minimized. The new header shall 'be '12", as
minimum; however the size shall be
confirmed during the Detail!ilg Engine!ilriog b): ~he- GO~TRAGTOR. , As a short term
solution, this' shall ensure' sufficient redundancy & shall augment the disposal water
system reliability and prevent total shutdown of BGDS in case of header line failure.
dispes-aT
P11S1B-11 - 70-93-0601-1
Rev. E
Paae 6 of62
I Date:
Mar 2008
, PACKAGE 1:1
Tie-in of two new water disposal wells Bb-744 & 745.
PACKAGE II: /
Installation of New header I branch lines for existing water disposal wells (Bb-657 & Bb-
658)
COMPANY intends to employ an CONTRACT,OR, having single point responsibility to
carry out the above packages [Package I & 11].
4.0
CLIMATIC CONDITION
The construction site is in a desert location with frequent sandstorms. Rainfall is
infrequent but can be very heavy.
Wind:
Prevailing direction
Mean Speed
Maxjmum SpeedlOesign Speed
Particulate borne
Temperature:
Maximum Solar
Maximum Shade
FromNW
8 mI,
44.7m/s .
Sulfurous and dust
85C
58 C
Average Shade:
SUmmer
36 C
Winter
22 C
Yearl y
28C
Maximum Soil at 1m depth
38 C
Minimum Soil af 1m depth
13C
Air temperature for design of various equipment under shade (or indoor)
Air Coolers in main process
Air COQlers - others
Air Coolers, Process design approach to ambient:
Gas Turbines
:
55 C
Electrical generators I motors
Electrical eq uipment
Instrumentation Equipment
Air Compressor
46 C
.58 'C
10 C
55C
52 C
55C
46C
I Date:
Mar 2008
95%
60%
Dew
Mists
.. 40 deg. C
54 deg . C
"
5.0
P&ID
Piping MTO
Piping GA drawings
Valve datasheets
Civil drawings and documents e.g. Pipe Support Foundation and Structural
Steel work "details, Crash Barrier, Plan, Section and Details, etc.
Detailed engineerir:g i~cluding ' design" of fouhdation, supports, structure to
support GRE pipe, etc. which is in GRE pipe Vend6r's scop e. CONTRACTOR
shall co-ordinate with GRE pipe Vendor for the same.
6.0
SCOPE OF WORK
6.1
Package I & II
n e~
Package 1of this project catls for tie-in of two new disposal water wells (Bb-744
and Bb-745) with the existing Bab water dispcisill network.
The CONTRACTOR shall refer Figure
the new wells.
2: (Attachment-6) for
Project No .: P11518
Pao. 9 0162
- A new 6" GRE pipeline (approx. 225 m) to tie-in the new well Bb-744 to the
12" GRE headers from BCDS as shown in Figure 1 (Attachment-6).
- GRE piping engineering by GRE vendor.
- The flow meters, field instruments, hand control valves (to adjust flow to the
disposal wells), .etc.
:.
- GRE vendor's supervision (full time) during ~R~ piping installation.
6.3
Package II: EPC f or Inst allat ion of New header I branch lines
For Package II, the new Pipin~ for lbfLdisposal-water_Iir.l6-sbaILfolklw the route
of the existing disposal wate~The header shall be sized by the Contractor du ring'thEf"d~tmlifd-erfgineenng stage. The routing of the new ,6" GRE lines (for
Bq-657 & Bb-658) shall follow the eXisting routes. The existing master drawing
shall be used to mark up the routing of the new head.er I. .branch lines. The
CONTRACTOR shall develop all the necessary additional drawings/documents,
etc as required for implementation of the project.
The outline of Package II is as follows:
a
The new GRE header shall be tied to the existing discharge header down
stream the thermal relief valve TSV-2403-01 as shown on the marked-up
P&ID No. 11-01-08-0165, RevA (Attachment-6).
P11S18-11-70-93-0601 -1
Rev. E
r----------L----------1
Poo. 10 of 62
Replacement of the existing carbon steel lines with 6 GRE lines for Bb-657
and Bb-658.
The scope also includes the demolition of existing Carbon Steel (CS) lines
which are being replaced with GRE as mentioned above. It is to be noted that
most of the CS line shall be demolished after the installation of new lines as
the system will remain in operation during the installation of new lines .
6.4
Construction Scope
The CONTRACTOR shall take utmost care', mark all exposed obstacles to avoid
any possible damage throughout the perfonna'nce of the work and restore them
to their previous state if damage occurs.
~!Dln-::2:::meJ~rs ~Qf a[ly~dergrp!lnd ::.serYice- and transfer- lines , -trenching or
other-excavations-_shall
be~done . manuCl!ly .
. )
All field instruments shall be calibrated before installation. New tag plates
shall be installed with each field instruments being installed as a part of this
project.
All piping shall be fabricated and installed to the configuration as shown in the
relevant approved documents. No changes shall be made without p"rior approval
of the COMPANY.
The Construction Scope shall include but not be limited to the following:
The CONTRACTOR shall prepare the following documents as relevant &
applicable for Package I & II:
a)
b)
Spool Numbers
Field Welds
Weld numbers
o .Inspection/NDE requirements
0 '"
P11518-11709306011
Rev.E
Pace 11 of 62
I Date:
Mar 2008
c)
d)
>
instrum~nts.
--;;
-0
Visual Inspection.
o
e)
1)
"
Functional
testi~g and commissioning.
g)
Checking and ensuring that the foundations are properly located, checking _
of the Elevations etc., erection of the equipment and final alignment, as',.
applicable .
h)
i)
Preparation _and
COMPANY
approval.
j)
submission
p re~
Tie-ins:
Tie-ins shall be as shown on the relevant P&IDs, listed in the Tie-in
schedule, and t~eir. locations . shall, be reflected in the General
ArrangemenUPiping Layout Drawings.
It is to be noted that the existing operation outages are to be kept t'o
the minimum possible. Therefore the CONTRACTOR shall consider
that all activities, actions, materials procurement, and requirements for the
tle:ins completion are planned in detail and in a timely manner.
Possible System outage and tie~ in availability times as defined by
COMPANY are to be strictly adhered to by the CONTRACTOR and that tieTERMS OF REFERENCE FOR
P11518-11-70-93-0601-1
Rev. E
Paoe 12 of 62
I Date:
Mar 2008
ins shall be periormed in the shortest possible time and that all required
resources will be continuous throughout these tie-in activities.
k)
I)
m)
Mechanical Completion.
n)
0)
p)
q)
r)
-,I
Joints in GRE piping, welds in other piping material and ,wells flowlines
shall be subjected t6 NDE iri accordance with t~e specifications. The .extent
of such test and the acceptability of any joints or weld shall be ' solely the
discretion of COMPANY.
I)
The CONTRACTOR shall allow ample time in his program for inspection.
No claim for additional cost arising from delays due to weld I joint
inspection will be entertained.
u)
Construction Scope of work for GRE pipe work shan include all activities
required for proper installation and functioning of GRE pipe work. However,
handling, fabrication, installation, testing and commissioning shan be as per
GRE vendor instructions, who , slJali be responsible for designing,
engineering and supplying of the GRE system. GRE vendor's supervision
is mandatory during the GRE piping ill~taltation, repair works.
v)
Piping MTO summary shall cover the material requirement for the project.
All materials shall be procured by the CONTRACTOR. The GRE material
procured by CONTRACTOR shalt be as per the Scope of Work for GRE
Vendor, to be developed during the Engineering phase.
6.4.1
Civil
6.4.1.1
Earth works:
Excavation, filling and compaction shall be strictly in accordance
with relevant drawings and DEP standard: 'Site preparation and
Earthworks': 34.11 .00.11-Gen Rev. 1 dated November 1983
along with COMPANY amendment 'Site preparation and
Earthworks': 34.11.00 .11A-Gen Rev. 1 date~ September 1983.
6.4.1.2
Setting out:
Location of all the foundations shall be set out by the
CONTRACTOR and be approved by the site ergineer of
COMPANY before excavation.
6.4.1.4
The reinforcing bars, ties, links, stirrups and all other reinforcing
shall be positioned and rigidly fixed exactly as shown on the
Drawings. Corner bars in columns and beams ~hall be cranked
from the entire length "of the lap such that the minimum cover
requirements are .achieved and the lrue alignment ' of the
reinforcement is maintained. Splices in reinforcements shall be
made at design locations as shown on the drawing. Lap lengths
for splices shall be in accordance with BS 8110.
If necessary, and only if approved by COMPANY, a naphthalene
sulphonate retarding superplasticizer shall be used to increase
workability of the concrete and retard the initial set. It shall
comply with ASTM C-494 Type G. Acceptable Manufacturers
are ~ Fosroc", "Master Builders "Grace", OSika", or equal
approved.
ft
P11S18-11-70-93-0601-1
Rev. E
Page 16 of 62
I Date:
Mar 2008
PRECAST CONCRETE:
Pre-cast concrete shall be any concrete that is not cast and
cured in its final position: p-re-cast concrete whether cast at the
job site or at a designate.d _facility shall be deslgn.ed in
accordance with BS 6073 . . ,
6.4.1.5
c1
~
Sieve Size
Passing
Percentage
3 in (75 mm)
100
1 / 2 in (38.1 mm)
85 to 100
3 / 8 in (9.52 mm)
40 to 90
P11518-11-70-93-0601-1
Rev. E
Page 17 of 62
I Date:
Mar 2008
25 to 85
30 to 50
10 to 30
Not
less
than
1.6
2.5 g/litre
50% by weight
.
Site preparations and
DEP.34.11.00.11-Gen
earth works
6.4.1.6
Painting:
All painting, all structural steel works like pipe supports, etc. as
applicable shall be in accordance with applicable COMPANY
specification.
6.4.1.8
ErQ~ection
wQrk:
All existing COMPANY services shall be protect~d from damage
Material Supply
The CONTRACTOR shall supply all materiali, The malerials
supplied shall include but not limited 10 the following.
Plain and reinforced concrete, polythene sheet, foundation
Pl1518-11709306011
Rev. E
Page 18 of 62
I Date:
Mar 2008
Welding procedures
.. <
'.
Welder qualification
,, .
NDT procedures
Procedures for cold field bending of pipes
Hydrotesting and dewatering procedures
Pre-commissioning procedures and ITP's
All welds shall be 100% visually inspected and 100% radiography shall be
done using X-ray.
6.4.3 Testing
~nd Pre.com~issioning
The CONTRACTOR shall test the entire he'aders /piping including all
associated works. This shall indude instrument calibration, fu nctional,
integrity and leak testing, and pre-commissioning. The CONTRACTOR
shall provide and install all facilities required for testing.
The CONTRACTOR shall prove to the satisfaction of the COM PANY that
the completed pipeline is free of any defects such as buckles or dents.
The CONTRACTOR shall carry out a calliper survey, the results of which
shall be submitted to the COMPANY for approval.
AI! materials and equipment used for testing shall be in good condition
and of the correct rating.
All temporary materials, such as test spades and supports shall be
suitably identified to . ensure that they are removed . prior to
commissioning. Hydrotest gaskets shall not be r~- used.
The CONTRACTOR shall maintain complete documentation of all tests
carried out and this documentation shall be submitted to the COM PANY
upon completion of pre-commissioning activities. The format of the test
packages shall be submitted to the COMPANY for approval.
P11 518-11-70-93-06011
Rev. E
Page 19 of 62
I Date:
Mar 2008
:.
1.
Contacior shall perform all mechanical tests. Thi s will include water
flushing and hydrostatic t~sting :
.,
ii. CONTACTOR shall clean, flush and hydratest all pipe work in
accordance with COMPANY specification. All flange joints shall be
tested for leaks during pre-commissioning.
iii. CONTRACTOR shall be responsible for provision of all materials
required for testing (e.g. Test blinds, gaskets, bolts, strainers, etc.)
All such supplied materials shall be in accordance with the
specifications.
Hydrostatic testing
Hydrostatic testing shall be carried out in accordance with the SHELL
DEP 31.40.40.38 and COMPANY amendment to SHELL DEP
31.40.40.38 A. The entire pipeline system shall be hydrostatically tested ..
The CONTRACTOR shall produce - a complete hydrostatic test plan
covering all required activities, test acceptance criteria and water
treatment chemicals. The CONTRACTOR shall submit the hydrostatic
test plan and method statement (includi ng the hydrotest water disposal)
to the COM PANY for approval within 30 days of the contract award.
The CONTRACTOR shall be responsible for the sourcing, handling,
treatment, transportation and disposal of water for hydrotesting. The
CONTRACTOR shall arrange for all necessary approvals for obtaining
the water and its subsequent disposal from the appropriate authority.
Details Qf all sources shall be submitted for COMPANY approval together
with a sample of the proposed water a minimum of 30 days before
commencement of hydrostatic testing . .use of water shall be optimised. '
Prior to commencement of hydrostatic test the CONTRACTOR shall
demonstrate to the COMPANY that the interior of the header/piping are
free of debris and sand.
P11S18-11-70-93-0601-1
Rev. E
Date: Mar 2008
~---------L----------1
Paqe 20 of 62
All hydrotest will be held at full test pressure as per specification . Any fall
in pressure in this period wi!! require a re-test after correction.
..
The .CONr RACTOR shall not commence . ~ydrostatic . testing "of any
pipeline s~ctio"n unless the jointing , welding an"d NDT records for that
section have "been approved by the "COMPANY. After completio"n of
hydrotest, the CONTRACTOR shall depressurise the line and leave the
water inside the pipeline prior to commissioning.
All valves and other equipment removed or disconnected for the purpose
of hydrotesting shall be reinstated by the CONTRACTOR.
Pressure gauges on hydrostatic test equipment shall be calibrated at
regular intervals to be agreed with the COMPANY site representative.
7.0
B.O
8.2
8.3
8.4
following:
8.4.1
HSE Meetings
The Plan shall include requirements for HSE meetings to be held with ,the .
8.4.3
HSE Inspections/Audits
The Plan shall include any requirements for HSE inspections and audits
to ensure that the CONTRACTOR is fulfilling their HSE plans agreed at
the commencement of their contracts.
COMPANY will audit the CONTRACTOR HSE performance
accordance to HSE Rules and Conditions of the CONTRACTOR.
)
8.4.4
in
8.4.5
PHSER
The Plan shall define any requirements for a Project HSE Review to be
conducted during the construction stage.
COMPANY may conduct PHSER, with Construction CONTRACTOR
participation.
P1151S-11-70-93-0601-1
WELLS AND INSTALLATION OF GRE
LINES FOR EFFLUENT WATER SYSTEM LR"e"v:...
. E=--_ _ "iLD"a::te::'...:M::a::.r-=
2o"o:..:8-l
AT BAB CDS
,
Page 22 0162
8.4.7
Note:
P1151S-11-70-93-0601-1
Rev.
PaQe 23 of 62
I Date:
Mar 2008
8.5
Vehicle Safety
CONTRACTOR vehicle' operations shall comply with 'COM PANY HSE manual
10/3.
CONTRACTOR shall ensure that all vehicles used in COMPANY premises are
provided with Safety Belts and ensure that an drivers are complying with the
rules to wear the safety belt.
- CONTRACTOR's equipment used on site shall be equipped with reversing alarm
device.
CONTRACTOR shall not use pick-up trucks for personnel transportation.
8.6
Environmental Protection
COMPANY is committed to maintaining the environment and accordingly the
CONTRACTOR shalt maintain the emissions and effluents within limits set by the
StatutOf)' Govemment Authorities, Attachment-1.
The CONTRACTOR shalt comply with the ADNOC Codes of Practice for
environmental protection, Attachment-1, including applicable air emission,
ambient air q,uality and effluent discharges.
Stringent requirements regarding airfwater/soil pollution 'and -noise production
exist for the Project Site and its surroundings. CONTRACTOR shall comply with
all statutory requirements for both noise abatement and the avoidance of
pollution during the performance of the Contract.
Permanent drainage systems shalt not be used for the disposal of any waste
materials other than those for which they are designed. No wastes shall be
disposed of into any natural drainage system.
The burning of refuse, scrap and waste in the open ai r is not permitted. The
CONTRACTOR shall submit. its waste disposal arrangements to COMPANY for
approval. No pollutants including domestic and industrial waste, oil, bilge water,
toxic or hazardous materials shall be discharged or allowed to escape from the
CONTRACTOR's Equipment or containment vessel or from its Sub-contractor's
Equipment or vessels .
The CONTRACTOR shall take aU reasonable measures to instruct hi!;> personnel
and personnel of Sub-contractor'in such matters to prevent pollution.
The CONTRACTOR shall at his own expense clean up, to the satisfaction of
COMPANY, any pollution caused by him or by his Sub-contractor's in the course
of performing the Works.
I Date:
Mar 2008
The CONTRACTOR shall accept full responsibility for all loss, damage or injury
of any nature due to failure of CONTRACTOR to strictly observe these
requirements.
Th.e CONTRACTOR shall immediately notify COMPANY of any spillage of oil or
grease, or any other material , which CQuid have a harmful effect on the
environment. CONTRACTOR shall agree : with COMPANY on the required
method for clean up and disposal to the satisfaction of COMPANY.
P11518-11 -70-93-0601-1
Rev. E
Date: Mar 2008
________- L________~
PaQ9 25 of 62
9.0
INTERFACES
T he Wo.r~s to be perfqrmed under the project will be executed within the confines of
COMPANY's Operational facilities. CONTRACTOR shall ..liaise with COMPANY's
Operating perSonflel tci obtain required Work Permit prior to cahy out. any work . .All
work shall be planned and carried out in such a manner as to minimise intelierence
with on going field operations. CONTRACTOR shall comply strictly with work, safety,
and
health rules
governing the
conduct
of the
CONTRACTOR
and
the
GENERAL REQUIREMENTS
10.1
General
In addition to the Specific Requirements listed elsewhere,
CONTRACTOR's work shall incl!Jde but not be limited to the following:
~)
b)
the'
c)
d)
e)
f)
g)
h)
i)
j)
k)
I)
m)
n)
0)
p)
q)
10.2
r)
AI! trenching and grading work required for. installation of the buried.
pip~lines- (if any) in undulated C!nd stiff sand dune terrain.
s)
I)
Mark up the drawings in red for As-built status and carry out the
physical tagging as per COMPANY specification. COMPANY will
prepare/update master drawings from these As-built mark ups through
the draughting consultant. CONTRACTOR shall contact COMPANY
Drawing office representative at Bab construction office for As-built and
physical tagging through SPC (Bab).
b)
c)
. d)
e)
inspection
10.3
g)
h)
10.4
Supply of Material
10.4.1 Procurement Policy statement and Procedures
CONTRACTOR shall submit his policy statement and procedure for
compliance by CONTRACTOR with the applicable export I import rules
and regulations, understanding that the work is going to be carried out
in the United Arab Emirates.
CONTRACTOR shall prepare procurement procedure and submit to
COMPANY for approval 4 weeks prior to placement of the first
purchase order. The procedure shall describe procu rement process
from inquiry through technical bid evaluation to delivery of materials to
site & subsequent storage and obtain COMPANY approval. The
request for COMPANY approval shall include . selected vendor's
technical bid evaluation, clearly identifying the deviations f rom the
project specifications and COMPANY standards.
All materials shall be new and of the best quality suitable for
working under the specified site and climatic conditions. All
materials shall conform to the ~pproved standards and codes as
specified and be approved by COMPANY.
b)
c)
'.
Material Control
The CONTRACTOR shall implement strict material control
. throughout all pha:ses of construction and installation by
utilisation of a proven Material Control System. This .will be
reflected in CONTRACTOR's Quality Plan.
The CONTRACTOR shall:
Pao. 310(62
10.4.6.2
Material Handling
The CONTRACTOR shan be responsible for receiving
handling and issuing of all material (both COMPANY and
CONTRACTOR supplied).
Preparation of material receiving formalities;
-
fonowing
P11518-11709306011
Rev. E
Page 32 of62
I Date:
Mar 2008
10.4.6.3
Material Storage
The CONTRACTOR shall be responsible to store, protect
and maintain all material and equipment (both COMPANY
and CONTRACTOR supplied).
The CONTRACTOR shall submit detailed drawings within 1
(one) month of award of Contract showing the layout of his
storage area including the warehouse and open storage
areas.
10.4.9 Traceability
CONTRACTOR shall submit to GOMPANY for approval his proposed
method of
achieving a full materia! traceability system on this
Contract. This procedure shall b~ submitted for approval within 14
days of Contract award.
10.5
10.6
P11518-11-70-93-0601-1
Rev. E
I Date: Mar2008
r-----__
---L----------1
Paae 34 of 62
10.7
Subcontracting strategy
Before the start of construction activities, the CONTRACTOR shall furnish the
fonowing documents for COMPANY review and approval:
The final issues of the material requisitions and data sheets for the items to
be purchased .
TERMS OF REFERENCE FOR
P11518-11-70-93-0601-1
Rev. E
Page 35 of 62
I Date:
Mar 2008
Inspection plan for all bought out materials, Material Traceability and
Storage Procedure.
Construction Engineering Procedures.
TiE;l-ins and Changeover Procedures.
Detailed Acceptance and Handover Procedures.
~As- Bu ilt"
Drawing Procedure.
~pplicable.
Traceability records
Hydrotest , NOT records
10.7.2 Drafting and Tagging Requirements
The Contractor shall refer to Attachment-8 for the drafting & tagging
requirements that are typical for EPC ,cQntract (COMPANY Doc. No. 30- .
99-11-0149, Hev. 2, June 2007).
.
.
10.8
Progress Reporting
COMPANY standard planning and scheduling requirement for EPC shall be
adhered to. Attachment-II of Appendix-I. Instructions to tenders.
10.9
P11518-11-70-93-0601-1
Rev. E
f-------'------'-"--1
Paae 36 of62
Ao CO DOC. NO.
TIE-IN OFlWO NEW DISPOSAL WATER
P11518-11-70-93-0601 -1
WELLS AND INSTALLATION OF GRE
LINES FOR EFFLUENT WATER SYSTEM LR:.ev"..::
E'--_ _.L.:
10.::8.::
18,,:..:M
.::8::.'.::2:.
00:.8'-1
AT BAB CDS
,
Page 37 of 62
11 .0
Quality Manual
An updated copy of the Quality Manual showing any revisions to the
Manual since submitting the Tender (if applicable).