RFQ For Safety Studies OF Dukhan Gas Lift System Upgrade - Phase1 Project
RFQ For Safety Studies OF Dukhan Gas Lift System Upgrade - Phase1 Project
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Table of Contents
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1.0 INTRODUCTION
VENDOR shall carry out the Safety Studies for “Front-End Engineering Design (FEED) for
Dukhan Gas Lift Upgrade Project”.
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field-wide lift gas gathering headers to the centralised lift gas compressors located at
Fahahil North Lift Gas Compressor Station (FNLGCS).
HP Rich Associated Gas (RAG) Dehydration: Balance of Khatiyah sector RAG (after gas lift
supply) is compressed at KN & KM and dehydrated at KS HP Glycol Dehydration Unit (HP
GDU). Similarly, Fahahil sector RAG is compressed and dehydrated through Molecular
Sieve dehydration units and balance of Jaleha sector RAG is compressed and dehydrated
at HP GDU. Dehydrated gas streams are transported to FSP for further processing.
DCS installed in each degassing station are receiving slot level information from SCADA
PLCs (Control Logix, Allen Bradley) of all associated manifold stations through existing STM
Ring network.
Existing control systems at each degassing station are listed in below table.
Each degassing station DCSs are connected to the existing STM Ring through existing
Telecommunication Networks (SDH/PDH). Similarly, each Degassing Station’s DCS is
communicating with FNLGCS DCS and DIC system through the same Telecommunication
Network (SDH/PDH).
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The Degassing stations have existing 110V AC and 240V AC UPS which supply the
instrument and telecom loads.
3.2. FNGLCS:
FNLGCS, located 1km to the south of the FN, supplies gas lift to all the production wells that
cannot sustain natural flow because of low reservoir pressure and/or rising water-cut.
Maintaining optimized, stabilized/constant gas lift injection rates (above a minimum
pressure) for individual wells honouring reservoir management controls is a key for Dukhan
production optimization.
At present FNLGCS has two gas turbine driven gas lift compressors, each having design
capacity of 125 MMSCFD, compressing the gas from approximately 6.9 – 10.55 barg to
127.57 barg. Each compressor has three stages, comprising suction knock-out drum (KOD),
interstage KOD and discharge KOD; interstage and discharge air coolers.
Utility systems e.g. fuel gas, instrument air, nitrogen, auxiliaries, emergency diesel generator
(EDG), electric power, flare and closed drain system are part of FNLGCS plant.
FNLGCS receives power at 33kV from two no. overhead line. 33kV is stepped down to
3.3kV via 2 no. 33/3.3kV, 4MVA transformer. 3.3kV is further reduced to 415V via 2 no.
2MVA transformer. The 415 V Switchboard (15-MCC-1001) feeds all the LV loads at
FNLGCS. The existing AC UPS units (15-UPS0001A/B,15-UPS-1001 & 15-UPS-1004) are
40kVA, 60kVA and 5kVA, which supply the instrument, telecom and vital loads of the
station.
FNLGCS Station houses Process Control System (DCS- Centum), ESD (Prosafe), FGS
(Pro-safe), AMS/PRM, UGS system, Alarm management, Cyber security systems, SOE,
Operator & Engineering stations, printers, servers, Flare package PLC, Nitrogen package
PLC, Instrument Air compressor PLC, Water bath heater PLC etc supplied by the control
system OEM Yokogawa. The FNLGCS data is further transmitted to Dukhan Information
centre through existing telecom networks for monitoring purpose. As a Backup system,
FNLGCS can be controlled and monitored through the servers located at PWI-1 station
equipped with back-up servers.
Gas lift Compressors trains are controlled by SPEEDTRONIC GE Mark VIe, which is a
Triple Modular Redundant (TMR), microprocessor-based control system. Each (R), (S) and
(T) controllers contains its own power supply, processor, communications, and I/O for all of
the critical control, protection and monitoring of the gas turbine and centrifugal compressor,
including all auxiliary. Mark VIe also manages the interfaces with Distributed Control System
(DCS) and receives signals from Bently Nevada Vibration Monitor for unit shutdown.
Antisurge System is implemented in Mark VIe and provides protection against centrifugal
compressor surge. It prevents surge, but it also quick open antisurge valve in case the anti-
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surge loop is insufficient to prevent surge. Data and alarm transfer to Customer Distributed
Control System (DCS) will occur through Mark VIe communication gateway. Gas Lift
Compressor trains consists of Integrated Turbine & Compressor Control (ITCC) for control /
monitoring, sequencing and safeguarding function including compressors and its auxiliaries,
GE Mark VIe system for anti-surge controls and Load sharing controls, dedicated Bently
Nevada (BN 3500 series), GE mark VIe servers, GE Operator & Engineering station, GPS &
SNTP server and Historian server. These Compressor control systems are interfaced with
station Yokogawa DCS system for control and monitoring from station control room.
Compressor trains are provided with dedicated CEMS for monitoring the emissions at vent
stack. Compressor trains are provided with common Fire & Gas system (Honeywell FSC)
which is dedicated for the Turbine and Compressor fire & gas detections.
The Bently Nevada System (BN 3500) provides monitoring of bearing radial & axial
displacement of turbine, compressor, monitoring of vibration of turbine casings. Bently
Nevada Vibration Monitor interfaced with Mark VIe and System-1. GE system-1 servers are
provided for machines condition monitoring through interface with the MMS systems of
FNLGCS and other PWI stations. Vibration monitoring data from the FNLGCS is centrally
monitored from DOMB via RG plant using existing STM Link.
Honeywell PHD systems for historization of the data at Dukhan Information centre through
existing telecommunication network.
Existing Control room/Substation building is a blast resistant building.
3.3. GAS LIFT MANIFOLD:
The high-pressure gas lift from FNLGCS is distributed to all production wells through two 18-
inch field-wide distribution headers and 28 number of gas lift manifolds at the North and
South sectors. Each manifold supplies a cluster of wells and is strategically located to
receive utilities and power from the nearby production station. From Jaleha another 12-inch
header is branched off and serves the Diyab area.
There are 28 existing Gas Lift Manifold Stations installed as part of Dukhan Gas Lift Project.
These manifolds provide artificial lift arrangements of Oil Wells in Dukhan Fields by injecting
high pressure gas into the wells. The existing manifold station sites consist of instrument
equipment buildings, steel skids and foundations to support headers, corrosion inhibitor
chemical injection facilities and other associated arrangements.
In Gas Lift Manifold the instrument loads are supplied from 240V AC UPS and 415V loads
from LV distribution board.
Gas lift receiver headers & distribution manifolds are provided with Allen Bradley Control
Logix SCADA PLC system for station control and Honeywell FSC for F&G and safeguarding
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systems at each location. Honeywell F&G FSC system are communicating to the SCADA
PLC system.
The SCADA PLC system of manifold station is connected to existing STM Ring Telecom
Network through the existing hubs and server routers to the respective Degassing station by
redundant Fibre Optic links. For each Slot, instrumentation signals are configured on the
Gas Lift manifold SCADA PLC, Degassing Stations control room, FNLGCS control room and
DIC system.
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4.1. PART 1
4.1.1. FNLGCS 3rd Gas Lift Compressor Train
QatarEnergy shall prepare the tender package/material requisition for Third GL
Compressor Package and issue to BH on a single source basis. QatarEnergy intend
to place Purchase Order directly to the Vendor during FEED execution phase and
novate this compressor package later to the EPIC Contractor.
CONTRACTOR shall be responsible for the incorporation of GL Compressor vendor
data into the FEED Engineering deliverables and EPIC Scope of Work
Installation of a new compressor train in FNLGCS whose process design in terms of
capacity, sizing, suction & discharge conditions shall be like to like to the existing trains.
The 3rd Gas Lift Compressor train shall consist of:
1. Gas turbine driven centrifugal compressor package
2. Suction, interstage, & discharge KOD as applicable
3. Interstage and Discharge air cooled heat exchangers
4. Associated auxiliaries
5. Fuel Gas Package
6. Nitrogen Generator Package
7. All interconnecting pipework for the new compressor train, associated valves, and
utility piping.
8. Tie-ins with existing piping system
9. Extension of compressor suction and discharge headers, flare piping, closed drain
header, fuel gas header, instrument air piping and other utilities.
10. All the associated Instrumentation, F&G Devices, Integrated Turbine and
Compressor control panels, Anti-surge controls, Load sharing controls, and Machine
Monitoring system.
11. For compressor package, required Fire and gas detection system, and automated
fire protection system shall be designed inline to QatarEnergy fire and safety
philosophy and Shell DEP for the compressor/ turbine package.
12. Design related to upgrade and modifications to the electrical system in FNLGCS for
power supply to the new loads added in the project. No existing Gaseous based fire
suppression system is installed for the substation, if modification of the existing
substation (to be confirmed as part of FEED) required, a new Gaseous based fire
suppression system to cover existing substation and new extension shall be
designed.
13. All required modification/upgrades required for the existing facilities to make the
design safe during operations and maintenance activities.
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14. All the upgrades/facilities modifications required as a result of the adequacy checks
of existing systems at FNLGCS.
15. The 240V AC 15-UPS-1001 must be upgraded to dual redundant UPS.
4.2. PART 2
4.2.1. FNLGCS
Replacement of the 3 existing Instrument Air Compressors (IACs) package in FNLGCS.
Modification of existing compressed air receiver vessels and air buffer vessels for new
requirement if required.
4.2.2. RG PRODUCER WELLS
1. Replacement of manual choke valves with automated valves for six numbers of RG
producer with associated piping modification.
2. Modifications of the existing control systems.
3. Modifications of the existing Wellhead control panel.
4. Power supply to the instrument loads and required upgrades to the UPS and electrical
system.
4.2.3. DEGASSING STATIONS
1. Replacement of existing internals of the Wet Gas Lift KOD at KSDS (23-V-4701), KNDS
(22-V-4601), FMDS (14-V-4621) with Schoepentoeter Mistmat Swirldeck Mistmat
(SMSM) or equivalent mist extraction system and the demister.
2. Replacement of existing TEG contactor internals with structured packing and other
Internals as required for the following columns:
a) LP GDU (gas lift)
i. KN (22-C-4602)
ii. KS (23-C-4702)
iii. FM (14-C-4602)
iv. JDS (31-C-4902)
b) HP GDU (RAG)
i. KS (23-C-4602)
ii. KS (23-C-4622)
iii. JDS (31-C-4802).
3. Installation of new F&G detectors at the gas lift header (high pressure) receivers at
KNDS, JMDS and Diyab.
4. All the required upgrades/facilities modification as a result of adequacy checks of
existing systems at Degassing Stations.
5. Provide normal and UPS supply to the instrument loads and required upgrades and
modifications to the UPS and electrical systems.
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6. Modifications of the existing control systems for the additional F&G signals.
4.2.4. GAS LIFT MANIFOLDS & GAS LIFT NETWORKS-
1. Modification to the existing F&G detection system including detectors in the gas lift
manifolds (including Arab-D back up manifold).
2. Installation of downstream pressure control valve (8”) in each of the 28 gas lift manifolds
with associated piping modification.
3. Provide normal and UPS supply to the instrument loads. Upgrade and modifications to
the UPS and electrical systems.
4. Modifications of the existing control systems for the additional F&G signals and pressure
control valves.
5. All the required upgrades/facilities modification as a result of adequacy checks of
existing systems at Arab D backup manifold.
5.0 DEFINITIONS
PURCHASER/ CONTRACTOR
CONSULTANT/ The party that supplies all the items and services as per
VENDOR this Requisition/ scope of work
OWNER QatarEnergy
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Deliverables:
Vendor
Scope/P&IDs Modification New Tie In Typical Total
Package
2 (28 are
Process 32 30 8 18 90
typical)
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The Project HAZOP workshop will be held at COMPANY’s Location (i.e., Doha, Qatar) OR
on Microsoft’s Team as applicable.
Deliverables:
Functional Safety Expert according to QP-GDL-S-030, SHELL DEPs, IEC 61508 and
61511 using the generic data and failure data provided by equipment vendors. If vendor is
not selected yet, failure data from ExSILentia database shall be used. Utilization of failure
data from other sources shall be subject to approval from QatarEnergy. Testing frequency
shall be agreed with QatarEnergy prior to verification. SIL verification report with
supporting documentation shall be submitted to QatarEnergy for approval.
ExSILentia (by Exida) shall be used to record SIL selection, and to build database for SIL
verification. Native ExSILentia file to be provided and report shall be submitted in MS
words / pdf version to QatarEnergy for approval.
Deliverables:
QRA shall include Building Risk Assessment for new and existing building impacted by the
FACILITIES.
Cost benefit analysis and ALARP demonstration shall be performed to justify the
implementation of further risk reduction measures in line with QatarEnergy ALARP
Demonstration Standard (QP-MAH-STD-040)
VENDOR shall carry out site visit to develop QRA Assumptions register.
CONTRACTOR shall organize all critical workshop such as Assumptions Register
workshop, study modelling, ALARP demonstration workshops.
CONTRACTOR shall utilize the results of QRA to locate FACILITIES, determine
requirements for process safeguarding, personal safety systems, fire & gas detection and
fire protection systems.
CONTRACTOR shall carry out sensitivity analysis for all important assumption and risk
reduction measures.
The result shall be plotted in GIS map and plot plans. QatarEnergy will provide the existing
QRA model for the Fahahil North Lift Gas Compression Station (FNLGCS) for
CONTRACTOR updates.
Deliverables
VENDOR shall be required to execute / submit the following activities/deliverables
• Site Visit
• QRA Study Assumption Register
• QRA Study Assumption Register Workshop
• Initial QRA Study Report
• Incorporation of Company Comments
• Final QRA Study report (Minimum 2 revisions)
• Presentation of QRA Study Modelling, Findings & Recommendations
• ALARP Demonstration Workshops
• ALARP Study Report (minimum 2 revisions)
• Final Study Outcome Presentation to all stakeholders
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The VENDOR shall provide experienced Chairman and a technical Scribe for Bow-tie
analysis study. The workshop shall be undertaken with KEI’s design team consisting of
process, instrument, mechanical, and loss prevention / safety engineers and COMPANY’s
engineering team representatives from safety, end users and asset holders. The Chairman
for Bow-tie study shall be approved by COMPANY / KEI.
Deliverables:
6.10. HSE CRITICAL ELEMENT (SCE) AND SAFETY CRITICAL TASK (SCT)
IDENTIFICATION STUDY
VENDOR shall carry out HSE Critical task as per QP MAH Critical Element and Task
Identification and Management Requirements standards (QP-MAH-STD-030).
Performance standard shall be developed for all HSE critical elements and tasks which
can be expressed in qualitative and quantitative terms for design verification such as
functionality, availability, reliability, survivability and dependencies in any emergency
conditions.
CONTRACTOR shall set performance standard functional criteria for each HSE critical
element and task and that must be met to achieve the HSE Critical Element and Task goal.
Compliance on performance standards functional criteria shall be signoff by all discipline
engineers.
Deliverables:
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6.12. SIMOPS
The purpose of the SIMOPS was to:
• Identify the simultaneous / concurrent activities
• Identify constraints and hazards during simultaneous operation
• Analysis of identified hazards
• Draw a check list of Risk Management for identified hazards i.e., prevention measures
and mitigation measures
• Define the responsibilities and nominate a responsible person and the hierarchy of the
control established for each work specific SIMOPS activity
The results of the SIMOPS exercise shall be recorded on the PHA PRO Software or
COMPANY approved Software. The VENDOR shall provide experienced SIMOPS
chairman and a technical scribe. The SIMOPS workshop shall be undertaken with
CONSULTANT’s design team consisting of process, instrument, mechanical, and loss
prevention / safety engineers, construction & operation engineers, maintenance, engineer,
commissioning engineer and COMPANY’s engineering team representatives from safety,
end users and asset holders. The Chairman for SIMOPS study shall be approved by
COMPANY / CONSULTANT.
SIMOPS workshop shall comply with QatarEnergy Guideline for SIMOPS study
Document No. QP-GDL-S-069.
The Project SIMOPS workshop will be held at COMPANY’s Location (i.e., Doha, Qatar) or
on Microsoft’s Team as applicable
Deliverables
VENDOR shall be required to execute / submit the following activities / deliverables.
• SIMOPS TOR
• SIMOPS Study Workshop
• Initial SIMOPS Report
• Incorporation of Company Comments
• Final SIMOPS report (minimum 2 revisions)
Noise study methodology shall be developed by CONSULTANT /VENDOR in-line with ISO
15664 and DEP 31.10.00.31-Gen requirements during FEED and reviewed / approved by
QatarEnergy. These reports shall be developed as per timeline indicated in ISO 15664.
Being existing facility, baseline noise survey shall be performed before development of
Noise allocation report. Noise measurements shall be taken in a 72 hours period at site,
with sufficient measurement points to cover the compressor shelter, discharge piping, and
discharge air cooler area. This shall constitute as the base line noise for the existing
facility. Noise datasheet shall be prepared for each equipment in accordance with Shell
DEP format 31.10.00.94.
Noise Allocation Report
Noise allocation report shall be prepared based on above noise for expected noise level
from new compressor package and baseline noise survey. Noise allocation report shall
define how sound power levels are allocated to various equipment items. The report
serves to set equipment noise limits and to anticipate noise control & mitigation measures.
Noise datasheet shall be prepared for each equipment in accordance with Shell DEP
format 31.10.00.94.
Noise Control Report
CONTRACTOR shall prepare a noise control report for approval by the QatarEnergy after
the major part of the equipment selection has taken place. The report shall give sufficient
data and calculations to demonstrate to the satisfaction of the QatarEnergy that the
acoustic design of the plant will meet the requirements stipulated in Shell DEP 31.10.00.31
In case, any working area needs to be designated as “Restricted area” as per Shell DEP
31.10.00.31, following shall be considered:
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1. A study into the expected level of attenuation that is achieved by wearing ear
protectors.
2. Various ear protection should be studied, i.e., over-ear, in-ear & combination of both.
3. For areas that are deemed “Restricted Areas” due to the high noise level, study should
recommend what ear protection is required for personnel to work safely for a
continuous period.
4. Study shall determine if normal working hours per day can be achieved safely or if
there needs to be a restriction placed on the number of hours that personnel can work
in the area.
5. Scope of Study shall also include the initial period of brownfield works. Since there will
always be compressors running during the upgrade works.
A determination of the noise levels and the subsequent safety measures and/or restricted
working hours shall be made to ensure personnel carrying out the upgrade works are not
subjected to damaging noise levels.
Deliverables
1. Noise Study – Method Statement
2. Noise Allocation report.
3. Noise datasheets
4. Noise Control Report.
VENDOR shall develop method statement and obtain approval on it prior to performing
HFE assessment. VENDOR shall submit the HFE review report with findings and close out
report to CONTRACTOR / QatarEnergy.
Valve Criticality Analysis shall be carried out in accordance with Shell DEP 30.00.60.10
and 30.00.60.20. Valve criticality shall be shown in P&ID as part of Valve Criticality
Analysis Report. CONTRACTOR shall ensure accessibility to each valve based on the
valve category
Deliverables
VENDOR shall be required to execute / submit the following activities/deliverables
• Human Factor Engineering study Method Statement
• Human Factor Engineering Workshop
• Human Factor Engineering Study Report
• Incorporation of Company Comments
• Final Human Factor Engineering Study report (minimum 2 revision).
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Deliverables
VENDOR shall be required to execute / submit the following activities/deliverables
• MAHM Study TOR
• MAHM Study Report
• Incorporation of Company Comments
• Final MAHM Study report. (Minimum 2 revisions)
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The SAFOP Study during FEED shall be carried out for the Project Scope presented in
Attachment-1, of this document.
The SAFOP study shall be performed to provide a formal framework for a searching and
systematic examination of engineering design in terms of effective operation and safety of
personnel, using information provided by Engineering and project staff, VENDOR, plant
Manufacturers and relevant Government agencies.
Analyze tasks set for operators in both normal and abnormal condition, assess facilities
and instructions provided to undertake these tasks and recommend measures to avoid
operator error and, therefore; avoid operator error through implementing the strategies
including training, competency procedures, authorities, and work systems. The SAFOP
Study includes
• Safety Analysis
• System Security and Operability Analysis
• Operator Task Analysis.
In case the VENDOR finds any conflicts or discrepancies between the requirements of this
requisition and reference documents, or among the reference documents, the VENDOR
shall notify the PURCHASER in writing for making decision and the PURCHASER will
reply to the VENDOR in writing.
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Conflicting or inadequate information in this requisition shall not relieve VENDOR from
supplying equipment / package of satisfactory design, material, and workmanship based
on his experience for the intended service.
In the event of any discrepancies of technical or engineering nature between local
laws/regulations and the documents listed above, the more stringent requirement shall
govern.
In addition, supplier shall submit those items and submit to Purchaser with quotation.
8.0 QUALITY ASSURANCE & QUALITY CONTROL
SUBCONTRACTOR shall plan, establish, implement and maintain a certified quality
management system in compliance with ISO 9001-2015 and the requirements of
Contractor PQP to be issued post award.
SUBCONTRACTOR shall comply with all the quality requirements as specified in Appendix
A scope of services, contractor issued PQP and associated Quality elements as pertinent
to Scope of services and ad-hoc Quality requirements (if any) and shall submit a formal
PQP for Contractor review and approval prior to start of execution.
Any subcontracted service shall be subject to CONTRACTOR and OWNER’s approval.
Contractor reserves the right and shall either schedule an audit at the subcontractor’s
execution office and/or may witness the Internal Audit performed by Subcontractor for the
specific scope of service.
9.0 HEALTH, SAFETY & ENVIRONMENT (HSE) & PERMITRY
VENDOR shall follow applicable Qatar Energy safety, security and work permit regulations.
The Subcontractor is responsible for complying with all applicable local and national
legislation governing the works. The Subcontractor shall confirm compliance with the
above in their bid and detail the requirements for obtaining the necessary authorizations
and Permits to Works.
10.0 VENDOR’S DOCUMENTATION
All correspondences with CONTRACTOR shall be in English language.
All engineering documentation shall be in accordance with the formats, title blocks and
drafting standards for the project. These will be supplied to CONSULTANT in native format
by CONTRACTOR / COMPANY. CONSULTANT shall complete and submit the software
verification and validation form (Attachment-5) along with the bid submission.
CONSULTANT shall submit the following documents with technical offer but not limited to:
• Execution Methodology of each study
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• Lump sum prices (Both Face to Face (F2F) and Virtual (online) workshops) as per
price schedule
• Organization chart with CV’s of key personnel.
• Software Verification & validation form (duly filled and signed)
• Reference list of similar projects executed.
• Schedule and time duration.
• Any Deviations from the listed scope of work.
• Inputs required from KEIL
• Participation of Consultant for various activities (demonstration of inputs, assumption
register, simulation models, results and recommendations) for following safety studies:
i. QRA Study
ii. FERA and Toxic Gas Dispersion Study
iii. EERA
iv. ESSA
v. Flare and Vent Radiation Dispersion Study
vi. Noise Study
vii. RAM Study
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11.0 ATTACHMENTS
CONSULTANT shall utilize the following documents for Safety Studies estimation purpose.
Sr. Price
Description Qty Remarks
No. (QAR)
Hazard & Operability (HAZOP) Study which
1. includes all the items mentioned under the
Lot
deliverable head of each study (Refer. Section
6.1)
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