FUNCTIONAL SPECIFICATION

FOR

GAS DEHYDRATION MODULE

0 06.12.2007

REV. DATE PREPARED BY CHECKED BY APPROVED BY

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 TABLE OF CONTENTS

1.0 INTRODUCTION
1.1 Scope
1.2 Definitions and Abbreviations
1.2.1 Definitions
1.2.2 Abbreviations

1.3 Units of Measurements & Language

2.0 SCOPE OF SUPPLY
2.1 Engineering Design
2.2 Equipment Supply
2.3 Options
2.4 Exclusions
3.0 REFERENCED DOCUMENTS & ATTACHMENTS
3.1 Acts, Codes, Standards and Regulations
3.1.1 Codes and Standards
3.2 Requirements of Statutory Authorities
4.0 OPERATING CONDITIONS
5.0 PROCESS
5.1 Process Design Cases
5.2 Process Description
5.3 Process Feed Data
5.4 Product Specification
5.5 Process Guarantee
5.5.1 Guarantee
5.5.2 Guarantee Period
6.0 MODULE
7.0 EQUIPMENT
7.1 Inlet Gas Scrubber
7.2 Glycol Contactor

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7.3 Glycol Regeneration Package
7.3.1 Reflux Condenser
7.3.2 Still Column
7.3.3 TEG Flash Tank
7.3.4 Rich-Lean TEG Heat Exchanger
7.3.5 Rich TEG Filter
7.3.6 Glycol Reboiler / Surge Tank
7.3.7 Glycol Ciculation pumps
7.4 Piping & Valves
7.4.1 Design
7.4.2 Installation
7.4.3 Insulation
8.0 OPERATION AND CONTROL
9.0 ELECTRICAL DESIGN
10.0 MAINTENANCE
11.0 PAINTING & PRESERVATION
12.0 QUALITY ASSURANCE, INSPECTION AND TESTING
13.0 CONTRACTOR DATA REQUIREMENTS
14.0 SPARE PARTS AND SPECIAL TOOLS

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1.0 INTRODUCTION

1.1 Scope

This Specification covers the design, materials, construction, testing, preparation,

shipment and quality assurance requirements of a Gas Dehydration Module for
onshore applications. The Gas Dehydration Module shall be based on TEG
(Triethylene Glycol) system with regeneration and shall consist of a structural steel
base onto which will be mounted all the necessary equipment to deliver dry gas
before compression for gas-lift or transport through pipelines. The Module shall
consists of all necessary vessel, piping, valve and instruments mounted on a
module ready for connection in the field.

The optimum number of modules required are to be estimated by the contractor.

This Functional Specification describes Module and the following is the distribution
for each field:

• Lakwa:

GCP NEW : Total HP Gas is 15.0 LSCMD (2 x50%)

• Geleki:

GCP (new) : Total HP Gas is 15.0 LSCMD (2 x50%)

• RDS:

GCP-I & II : Total LP Gas is 5.0 LSCMD (1X100%)

This Specification should be regarded as the Company’s minimum requirements for

this equipment. Any of the requirements defined herein may be amended where the
Codes and Standards have more stringent requirements for design, safety and
testing. Those requirements shall be notified to the Company and shall not be
reduced in order to meet this Specification without the Company’s prior agreement.

The Gas Dehydration Module shall be designed in accordance with the process
design criteria stipulated in Section 5.0. In addition, the Company requests the
Vendor to investigate proven state of the art technology that can improve the gas
dehydration process. The findings should be provided to the Company, highlighting
the process or cost benefits and proven track record of the same.

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1.2 Definitions and Abbreviations

1.2.1 Definitions

Company Oil and Natural Gas Corporation Limited (ONGC).

Contractor The party responsible for the design and supply of goods and/or
services, for a complete project or installation.

Inspector The person appointed by the Contractor to carry out engineering

inspection in the Supplier’s works.

Project Assam Renewal Project (ARP).

Supplier The organisation, company or agency that is contracted to provide

goods or services to the Contractor.

Third Party An impartial body, possessing the necessary competence to verify

Inspector that designs and/ or manufacture satisfy the specification and
purchase order requirements.

1.2.2 Abbreviations

BRH Borholla (oil and gas field)

CMG Changmaigaon (oil and gas field)

CTF Central Tank Farm

DGMS Directorate General of Mines Safety

DML Demulgaon (oil and gas field)

ETP Effluent Treatment Plant

GLK Geleki (oil and gas field)

GCP Gas Compressor Plant

GCS Gas Collecting Station (in gas fields mainly)

GGS Group Gathering Station (for oil)

LKW Lakwa (oil and gas field)

LPN Laiplingaon (oil and gas field)

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 ONGC Oil and Natural Gas Corporation Limited

OISD Oil Industry Safety Directorate

PFD Process Flow Diagram

P&ID Piping and Instrumentation Diagram

RDS Rudrasagar (oil and gas field)

TPL Trunk/Feeder/Collector Pipe Line

WIP Water Injection Plant

WHI/EPS Well Head Installation / Early Production System

1.3 Units of Measurements & Language

All values will be in SI Units (according to ISO 1000).

Standard conditions at 101.325 kPaa and 15.56°C.

All documents to be in the English language.

2.0 SCOPE OF SUPPLY

The Contractor shall be responsible for the detailed design of the Gas Dehydration
Module (“the Module”) - based on TEG (Triethylene Glycol) system with
regeneration, including structural and associated pipe work within the limits of the
module to meet the specified mechanical and process conditions as specified in
Section 5.0. All interconnecting piping/ tubing, valve, pipe, control and
instrumentation, and system components are to be supplied complete on the
Module to ensure safe, efficient, operable and maintainable system. The final
sizing and design of the Module, including all internal components, shall be the
responsibility of the Contractor.

The layout of the components and piping within the Module is subject to the
approval of Company before commencement of any fabrication. In addition,
detailed calculations, and mechanical and instrumentation data sheets for the
design of the gas dehydration package shall be submitted to the Company for
approval.

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 Approval of construction drawings does not relieve the Contractor of compliance
with process performance, codes, standards, specifications, safety design or
meeting the requirements of governmental agencies.

Proven new technology options and developments are acceptable provided they
give equivalent or better process performance. The alternative options must be
proven and tested in field condition. Vendor to list advantages of new technology
proposed.

2.1 Engineering Design

The Module shall be designed for an overall working life of at least 25 years.
Equipment used on this unit shall be capable of meeting this overall life.

Materials and components selection for this unit shall be appropriate with the
ambient conditions as identified in Section 4.0.

The Gas Dehydration system design shall be based on the process information
provided within this document.

Components used shall be in accordance with the country’s local applicable

standards.

The Contractor shall be responsible for the detailed design of each type of Module
as detailed in Section 5.0, for the total number of units which will be optimally
decided by the LSTK contractor. Module should include the following;

Item Qty Notes

Gas Scrubber Including internals for suction and

2
discharge

Glycol Contactor tower 1 Including internals

Glycol Regeneration Package 1
Base Assembly Module only
Piping Module only
Electrical & Instrumentation Module only
Controls Module only

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2.2 Equipment Supply

The equipment supply shall include design, fabrication and supply of the following
main items:

Item Qty Notes

Gas Scrubber Including internals for suction and

2
discharge
Glycol Contactor tower 1 Including internals,
Glycol Regeneration Package 1
Base Assembly Module only
Piping Module only
Electrical & Instrumentation Module only
Controls Module only

2.3 Options

The Contractor may provide options to the scope detailed in this Specification.

2.4 Exclusions

Supply of interconnecting pipe, pipe fittings, fastening hardware, gaskets, electrical

hardware, instrumentation, and structural and civil installations outside of the
Module boundaries shall be provided by others.

Metering equipment for gas.

3.0 REFERENCED DOCUMENTS & ATTACHMENTS

Equipment, materials, design, construction and testing shall be in accordance with

this Specification and with the applicable parts of the documentation listed below.
Latest editions of standards, codes etc. at Purchase Order date shall apply unless
otherwise noted.

3.1 Acts, Codes, Standards and Regulations

As a minimum, all equipment supplied should be designed, manufactured and

delivered in accordance with the requirements of the latest editions of the following
Codes, Standards and Regulations:

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3.1.1 Codes and Standards

American National Standards Institute (ANSI)

ANSI/ASME B16.5: Pipe Flanges and Flanged Fittings

ANSI/ASME B31.3: Code for Pressure Piping

ANSI/ASME B31.8: Gas Transmission and Distribution Piping Systems

American Petroleum Institute

API Spec 12GDU: Glycol-Type Gas Dehydration Units

API Std 674: Positive Displacement Pump - Reciprocating

API Std 676: Positive Displacement Pump – Rotary

API STD 610: Centrifugal Pumps

American Welding Society

AWS D1.1: Structural Welding Code

American Society of Mechanical Engineers

ASME VIII Div 1: Boiler and Pressure Vessel Code

Tubular Exchanger Manufacturer’s Association

Oil Industry Safety Directorate

OISD-STD-106: Process Design and Operating Philosophies on Pressure Relief &

Disposal System

OISD-STD-113: Classification of Area for electrical installations at Hydrocarbon

processing and handling facilities

OISD-STD-119: Inspection of Pumps

OISD-STD-128: Inspection of Unfired Vessels

OISD-STD-132: Inspection of pressure relieving devices

OISD-STD-134: Inspection of Heat Exchangers

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 OISD-STD-152: Safety Instrumentation For Process System in Hydrocarbon
Industry

OISD-STD-180: Lightning Protection

OISD-GDN-192: Safety practices during construction

OISD-GDN-201: Recommended practices for environmental protection in upstream

petroleum sector

OISD-GDN-206: Guidelines on safety management system in in petroleum industry

3.2 Requirements of Statutory Authorities

The Assam onshore facilities operate within the legal domain of India. The
Contractor, and sub-Contractors, must comply with the Regulations of India. This
includes, but is not limited to;

• Equipment and Materials in accordance with Directorate General of Mines

Safety – India

• DGMS, Oil Mines Regulations, 1984

• Central Pollution Control Board(CPCB) & Assam Pollution Control

Board(APCB)

4.0 OPERATING CONDITIONS

The Module will be designed, fabricated and installed to accommodate the local
environmental conditions of the Assam state of India.

4.1 Local and Environmental Conditions are given in Appendix C

4.2 Utilities available are given in Appendix C

5.0 PROCESS

The Gas Dehydration Module’s main function is to remove water from Compressed
HP Gas for gas lift or transport through pipeline. TEG Contactor will be used for
stripping water from the gas stream. The location of dehydration is envisaged at the
downstream of HP compressors . Dehydrated gas is meant for gas lift and fuel gas
requirement .

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5.1 Process Design Cases

Design case summary as follows:

Number of modules required:

• Lakwa:

GCP-new 2 X 50%

• Geleki:

GCP- (new) 2 X 50%

• RDS:

GCP-new 1x 100%
The supplier is to provide a design and cost for each of the different sized modules.
The gas composition and other design parameters are given in the design Basis.

5.2 Process Description

Separator off-gas from first-stage separation and LP gas after compression is

routed to GCP for compression prior to gas lift ,FG skid or export through pipeline.
The gas dehydration is envisaged for the total gas used for gas lift purposes, fuel
gas and for the export gas through pipeline. So, the dehydration plants are
envisaged for the entire gas from HP compressor discharge for Lakwa, Geleki and
Rudrasagar field.

The Process feed data are to be arrived based on the design basis provided for the
HP compressor at GCPs
The supplier is to provide a design for the specific module above. The total number
of modules will be based on and validation of process data arrived from the design
basis as provided for GCP s.

5.3 Product Specification

The maximum allowable water content is specified as 0°C water dew point at the
highest MAOP (Maximum Allowable Working Pressure) of the connected pipeline
system with an absolute upper limit of 7 lb/MMSCF.

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5.4 Process Guarantee

5.4.1 Guarantee

The subcontractor guarantees and warrants for the duration of the Guarantee
Period described below that the Process System will be:

(a) manufactured and commissioned in accordance with and will meet or

exceed the Specifications; and

(b) free from all defect in design and workmanship; and

(c) operable in accordance with, and based on the design data contained in
the Specifications; and

(d) suitable for its intended purpose as per the Specifications.

5.4.2 Guarantee Period

The Guarantee Period will be for a period of twenty four (24) months from the date
of Delivery, or twelve (12) months from the date of completion of installation and
commissioning of the Process System at the Company’s Production Site, whichever
is the less. During the Guarantee Period, Subcontractor at its cost, risk and
expense, will repair, redo or replace any part of the Process System which fails to
meet the above warranty or guarantee which manifests itself during the Guarantee
Period.

The Guarantee Period for any executed repairs and replacement shall be eighteen
(18) months from the completed repair or replacement.

Any repairs should be carried out on-site if at all possible, and so as to minimise
any disruption to the working of the Process System and any other parts of the
Installation/Plant to the greatest possible extent.

6.0 MODULE

Refer to Appendix C: “Module”.

7.0 INDICATIVE EQUIPMENTS

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7.1 Inlet Gas Scrubber

The purpose of the gas scrubber is to remove condensate from wet gas. The
condensate that is removed from the gas collects at the bottom of the scrubber and
drains into a tank provided by others off-base of the Module.

The scrubber will be an industrial type, designed to meet the requirements of the
appropriate regulatory bodies.

Scrubber shall be designed to properly operate for the process conditions identified
in Section 5.0.

Scrubber shall also be designed to properly operate under the ambient conditions
as specified in Section 4.0.

The scrubber shall be a vertical type vessel. The scrubber vessel shall be of
carbon steel construction, designed as per Section VIII of the ASME Boiler and
Pressure Vessel Code. The Contractor shall be responsible for mounting all
externally mounted components, control and instruments at the factory.

Internal corrosion allowance of 3.0mm is to be used in the vessel design.

7.2 Glycol Contactor

The function of a Glycol Contactor is to remove residual condensate from the gas
stream that is received from the Discharge KOD of the HP Compressors. The dry
Gas after GDU module is sent into Gas lift network.

The Contactor shall be designed to properly operate for the process conditions
identified in Section 5.0

Glycol Contactor shall also be designed to properly operate under the ambient
conditions as specified in Section 4.0

The Contactor shall be a vertical tower with structural packing. The height and
number of packing shall be designed by the Contractor. The Contactor shall be of
carbon steel construction, designed as per Section VIII Div I of the ASME Boiler and
Pressure Vessel Code. The Contractor shall be responsible for mounting all
externally mounted components, control and instruments at the factory.

Internal material for packing and support shall be 316 stainless steel.

Internal corrosion allowance of 3.0mm is to be used in the vessel design.

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7.3 Glycol Regeneration Package

7.3.1 Reflux Condenser

Condensed vapour off the reflux condenser shall be piped to the drip pan on the
structural base.

7.3.2 Still Column

The still column shall be of vertical design. The packing and, the top and bottom
support grids shall be 316 stainless steel. The still column shall have flanged
connections to the reboiler and the vent outlet.

7.3.3 TEG Flash Vessel

The TEG Flash Vessel is required to remove gas and condensate from rich glycol.
The flash tank shall be a Vertical vessel and constructed from carbon steel material
designed per Section VIII of the ASME Boiler and Pressure Vessel Code. The
Contractor shall be responsible for mounting all externally mounted components,
control and instruments at the factory.

7.3.4 Rich-Lean TEG Heat Exchanger

The lean glycol from the reboiler and the rich glycol from the flash drum forms the
lean-rich heat exchanger. The heat exchanger may be shell and tube or finned
tube hairpin type. Plate type heat exchangers are not allowed. Piping connections
to the heat exchangers shall be flanged type. The heat exchangers shall be
designed to the appropriate TEMA standard.

7.3.5 Rich TEG Filter

The filter vessel shall be carbon steel construction and designed to ASME VIII
standard.

A hinged top cover, with an air vent valve, shall be provided for removal of
elements. A differential pressure gauge shall be provided to allow the operator to
know when to change out the element.

Filter shall be located with clear access to allow ease of changing the filter
elements.

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7.3.6 Glycol Reboiler / Surge Tank

The glycol reboiler / surge tank shall be designed as a single vessel or in a separate
vessel configuration. A separate surge tank is required where the use of stripping
gas with an external stripping column is essential. The separate surge /storage
tank shall be located underneath the reboiler under gravity flow.

At RDS the reboiler shall use a burner and fire tube to heat the fluid by fuel gas .At
Geleki Hot oil system shall be used for reboiler.

The reboiler shall be designed to ensure that the fire tube is always immersed. The
reboiler shall be horizontal, direct fired/hot oil based , with provision to remove the
firetube/tube bundle and stack. Excess flash gas shall be vented to a relief
header.

At Geleki , Hot oil system based reboiler shall be used . Temperature selection shall
be based on the thermal fluid properties and heating requirement for regeneration
of Glycol. Reboiler shall be horizontal shell and tube type heat exchanger with
instrument control for temperature.

The reboiler shall be carbon steel construction with minimum corrosion allowance of
3.0mm.

7.3.7 Glycol Circulation Pumps

The pumps are 2 x 100% duty and standby to allow the process to continue during
pump maintenance. Pumps shall be reciprocating plunger type designed as per
API 674 unless specified otherwise, and shall be suitable for continuous glycol
service.

Pumps shall be provided with packing/seal leakage containment pans piped to the
drip pan on the structural base.

Pumps shall have suction strainers. Mesh size and flow area shall be in
accordance with the pump manufacturer’s recommendation. Pulsation dampers
shall be provided and located as close to the pump discharge connections as
practical.

The flow rate shall be as per process conditions in Section 5.0. Flow meter shall be
provided for monitoring and adjusting the glycol flow rate to glycol contactor. Flow
rate adjustment by adjustment of suitable control valves shall be provided.

7.3.8 Any other item/equipment not listed but required for the intent of this Functional
specification shall also be part of the scope.

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7.4 Piping & Valves

7.4.1 Design

All gas piping shall be designed in accordance with ANSI / ASME B31.8 and this
Specification unless otherwise noted.

All liquid piping shall be designed in accordance with ANSI / ASME B31.3 and this
Specification unless otherwise noted.

Process liquid lines shall be sized for fluid velocities in accordance with industry
standards.

The minimum required pipe wall thickness for any service shall be calculated in
accordance with ANSI / ASME B31.3 and ANSI / ASME B31.8.

Unless otherwise specified, all pressure piping shall have a minimum corrosion
allowance of 1.6mm. This is in addition to mechanical allowances.

The Contractor shall pre-size the valves and piping within the Module based on the
process design conditions as specified on Section 5.0

7.4.2 Installation

“Stub-in” branch connections shall not be permitted.

A sufficient number of flanges or unions shall be provided in all piping to allow

disconnection of valves and equipment for maintenance.

Piping shall be arranged in a neat and simple manner. Piping, including supports,
valves and controls, shall be located so as not to present obstructions or stumbling
hazards nor interfere with equipment operation and maintenance. At least 600 mm
clear space shall be provided for access to equipment.

The minimum overhead clearance for piping or walkways shall be 2 metres. Piping
installed in pipe racks shall be grouped to have common bottom pipe elevations.

Piping headers shall generally be terminated with flanges and shall be installed to
allow for future expansion of the header.

Pipe systems shall have block valves, by-passes and cleanouts to provide
convenient access and repair.

Piping shall be designed to minimise pockets and low points.

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 Drain and vent connections as required for testing, maintenance and operation shall
be provided on piping. As a minimum, lines shall have ½ “ vent connections at high
points and shall have ½ “ drain connections at low points. Connections only for
hydro test do not require valves.

Valve drains shall be installed on equipment that is not self draining.

Pipe elbows shall be long radius bends unless approved otherwise.

Where threaded pipe or fittings are used in hydrocarbon service, the piping between
any vessel or bridle and the first valve shall be a minimum of schedule 160.

Piping at equipment shall be supported in such a manner that the equipment may
be removed without effecting the piping and shall be supported to prevent
transmission of excessive moments and forces to equipments.

Adequate provisions shall be made in piping systems for thermal expansion and
contraction in accordance with ANSI / ASME B31.8.

Eccentric reducers with flat side up shall be used in pump suction connections.

7.4.3 Insulation

Piping and components that contain fluid above 60oC shall be insulated such that
the temperature of the outer surface of the insulation is below 60oC. Removable
insulating blankets shall be provided over valves, and flanges. The insulation
materials and blanket shall be resistant to the fluids. Pipe insulation shall only be
placed directly on piping.

8.0 OPERATION AND CONTROL

Refer to Appendix A, “Instrumentation and Control Guidelines”..

9.0 ELECTRICAL DESIGN

Refer to Appendix B, “Electrical Guidelines”.

10.0 MAINTENANCE

Refer to Appendix C: “Maintenance”.

11.0 PAINTING AND PRESERVATION

Refer to Appendix C: “Quality Assurance , inspection and testing

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12.0 QUALITY ASSURANCE, INSPECTION AND TESTING

Refer to Appendix C: “Quality Assurance , inspection and testing”.

13.0 CONTRACTOR DATA REQUIREMENTS

Refer to Appendix C: “Contractor data requirement ”.

14.0 SPARE PARTS AND SPECIAL TOOLS

Refer to Appendix C: “Spare parts and special tools”.

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