Makaraba Gas Development Project

Specification for Control and Safety

Philosophy
DOCUMENT NO. MGD-M022-ICS-SPC-ARS-0000-00701-00

E01

18-Aug-2016

Issued for Review

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HNG

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11-Aug-2016

Issued for Interdisciplinary Check

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DATE:

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ICS

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TABLE OF CONTENTS
ABBREVATIONS AND DEFINITIONS............................................................................ 5
1.

2.

3.

4.

5.

INTRODUCTION.............................................................................................. 6
1.1

Project Overview.................................................................................... 6

1.2

Purpose................................................................................................ 6

1.3

Scope................................................................................................... 6

REFERENCES................................................................................................ 6
2.1

Industrial Codes and Standards...............................................................7

2.2

Company Standards............................................................................... 7

2.3

Project Documents.................................................................................7

OVERVIEW OF FACILITIES.............................................................................. 7
3.1

General Overview.................................................................................. 7

3.2

Offshore Wellhead Jacket........................................................................8

3.3

Interconnecting Flowline..........................................................................8

3.4

Makaraba Production Facilities.................................................................8

3.5

Liquid Handling Facility...........................................................................8

3.6

Gas Compression System.......................................................................9

MAKARABA CONTROL AND SAFETY SYSTEM..................................................9

4.1

Existing Control and Safety System..........................................................9

4.2

New Control and Safety System...............................................................9

4.3

Modification to Existing Control System.....................................................10

CONTROL AND SAFETY PHILOSOPHY.............................................................10

5.1

Offshore Wellhead Jacket........................................................................10

5.1.1

Safety Control of Wellhead......................................................................10

5.1.2

Pressure of Wellhead..............................................................................11

5.1.3

Temperature of Wellhead........................................................................11

5.2

Offshore Wellhead Flowline.....................................................................11

5.2.1

Safety Control of Flowline........................................................................11

5.2.2

Pressure of Flowline...............................................................................11

5.2.3

Temperature of Flowline..........................................................................12

5.3

Makaraba Bulk Manifold..........................................................................12

5.3.1

Safety Control of Manifold.......................................................................12

5.3.2

Pressure of Manifold............................................................................... 12

5.3.3

Temperature of Manifold..........................................................................12

5.4

Makaraba NAG HP Separator..................................................................12

5.4.1

Safety Control of Separator.....................................................................13

5.4.2

Pressure of Separator............................................................................. 13

5.4.3

Level of Separator.................................................................................. 13

5.4.4

Temperature of Separator........................................................................14

ABBREVATIONS AND DEFINITIONS

AG

Associated Gas

CNL

Chevron Nigeria Limited

ESD

Emergency Shutdown

ESDV

Emergency Shutdown Valve

HP

High Pressure

IA

Instrument Air

LAL

Level Alarm Low

LAH

Level Alarm High

LSL

Level Switch Low

LSH

Level Switch High

LP

Low Pressure

LCP

Local Control Panel

MCP

Master Control Panel

NAG

Non Associated Gas

NGC

Nigerian Gas Company

PAHL

Pressure Alarm High-Low

PSHL

Pressure Switch High-Low

PP

Production Platform

RP

Riser Platform

SDV

Shutdown Valve

WHCP

Wellhead Control Panel

WHJ

Wellhead Jacket

WSITP

Wellhead Shut-In Pressure

1.

INTRODUCTION

1.1

Project Overview
Chevron Nigeria Limited (CNL) wishes to undertake, FEED and DED in support of her plan
to stop flaring Associated Gas (AG) from Makaraba Production Facility and Develop the Gas
reserves. Prior to 2003 Swamp crisis, CNL was sending Associated Gas (AG) to NGCs
Compression Station for processing and delivery into ELPS via Jones Creek pipeline. The
NGC compression station was vandalized during the 2003 Swamp crisis and remains in that
state till date. In 2004, during the Swamp Re-Entry Program, CNL recommenced production
operation at Makaraba but has been unable to recommence the processing of Associated
Gas at the Nigerian Gas Company (NGC) Makaraba Compressor Station.
In response to Federal Government of Nigeria (FGN) request for increased gas supply to the
domestic market, CNL plans to accelerate Makaraba gas development which was originally
scheduled to backfill Abiteye Gas decline. There has been preliminary engagement with
NGC to fast track the repairs of their Makaraba Compression station and associated export
pipelines as an integral part of this accelerated plan for the Makaraba Gas development.
Several alternatives were evaluated in early phase 2. The current selected alternative is a
commercial solution which is to install HP Separator on Makaraba production facility and
have Nigerian Gas Company (NGC) install Glycol dehydration unit on their facility. Chevron
will separate the condensate from the gas and send the wet gas to NGC for further
dehydration process.

1.2

Purpose
This purpose of this document is to define the philosophy to be used as guidelines in the
design of process control and safety systems in Makaraba Non-Associated Gas
Development Project. By following this philosophy, it is intended that the design of all
required control and safety instrumentation systems deployed for this project will adequately
provide means of controlling, monitoring, shutdown and alarms for effective operation and
safety of the process facilities.

1.3

Scope
The scope of this document shall be limited as guidance to the engineering design of
facilities related to Makaraba Non-Associated Gas Development Project which comprises of
wellhead platform, interconnecting flow-line, bulk manifold, NAG HP Separator and provision
for a temporary pig receiver including all required controls and utilities for safe, efficient,
maintainable and reliable operations. Some modifications on the existing control and safety
systems may also be included, as they will be related to the integration of the new
instrumentations into the existing systems.

2.

REFERENCES
This document shall be read in conjunction with all the relevant sections of the standards,
codes, specifications and project documents referenced herein.

2.1

Industrial Codes and Standards

API RP 14C

Recommended Practice for Analysis, Design, Installation, and Testing

of of Basic Surface Safety System for Offshore production platforms

2.2

2.3

API RP 551

Process Measurement Instrumentation

API RP 554 Part 2

Process Control - Process Control System Design

ASTM A269

Standard Specification for Seamless and Welded Austenitic Stainless

Steel Tubing for General Service

ASTM A213

Standard Specification for Seamless Ferritic and Austenitic Alloy-Steel

Boiler, Superheater, and Heat-Exchanger Tubes

IEC 60529

Specification for the Degrees of Protection Provided by Enclosures (IP

Code)

NEMA 4/12

Industrial Electrical Enclosures

Company Standards
ICMDU11.01

Instrument Installations Offshore

ICMSU11.06

Instrument Control Panels

SIDSU5106

Safety in Designs

Project Documents
MGD-M022-TEC-SOW-CNL-0000-00001-00

Scope of Work

MGD-M022-TEC-BOD-CNL-0000-00001-00

Basis of Design

MGD-M022-TEC-RPT-CNL-0000-00104-00

PreFEED Report

MGD-M022-PRO-PID-ARS-0000-00211-00

P&ID Wellhead Jacket

MGD-M022-PRO-PID-ARS-0000-00214-00

P&ID NAG Bulk Manifold

MGD-M022-PRO-PID-ARS-0000-00215-00

P&ID NAG HP Separator

3.

OVERVIEW OF FACILITIES

3.1

General Overview
Makaraba field is located in the swamps of the western Niger Delta near Alajiko creek in
OML 49. Makaraba NAG Development Project shall involve the development of a Wellhead
Jackets (WHJ), modification to the Makaraba flare scrubber by deck extension to
accommodate bulk manifold, NAG HP Separator, pig receiver provision, piping
system/manifold and provision for future tie-ins.

3.2

Offshore Wellhead Jacket

The wellhead jacket will be designed as un-manned with no permanent living
accommodation provided.
Makaraba NAG design covers only one flow line and the facilities will be designed
accordingly. Therefore, only space for future risers, tie-ins for the future pipelines and
footprint for the pigging facilities will be provided.
The primary wellhead jacket will have the following facilities:

Well bay / Wellheads

3.3

Subsurface or Wellhead Control Panel to act as Emergency Shutdown System and

Hydraulic Power Unit (HPU)

Piping Systems including provision for Pig Launcher

Departing Pipeline including Pig Launcher and Riser

Chemical Injection System (Corrosion Inhibitors)

Gas conditioning unit for Instrument Gas supply

Passive fire protection systems

Other utilities as required by safe operation (e.g.: Nitrogen)

Interconnecting Flowline
The interconnecting flowline is a multiphase well flowline which is connected to a production
manifold on Makaraba Production Platform. The flowline will transport the well fluids from
the remote Wellhead Jacket to the Makaraba Production Platform.
Facilities will also be provided to allow venting/ depressurization of the flow line to allow for
maintenance.

3.4

Makaraba Production Facilities

Facilities to be located at Makaraba Production Platform shall include:

NAG HP Separator

Bulk Manifold

Pig Receiver (provision only - HOLD)

Associated piping and instrumentation

Chemical Injection Pumps

Replacement of the existing flare tip

These facilities are to be designed according to CES specifications.

3.5

Liquid Handling Facility

The liquids (Condensate + Water) from the NAG HP Separator will be commingled with the
existing oil production flow rate and sent to the Abiteye facilities for further treatment.

3.6

Gas Compression System

Gas compression is not required at the early life of the fields as the well pressure is
sufficient to drive the well resources to EGP. However, during late field life, booster
compression may be required to sustain required production and transportation pressure
and increase the ultimate recovery from the reservoirs. Gas compression and its associated
utilities are not part of the Makaraba Gas Development project and will be a separate
project. Moreover they will be part of the NGC scope for future development.

4.

MAKARABA CONTROL AND SAFETY SYSTEM

The overall process control and safety system for the Makaraba Production Platform is
designed based on pneumatic system. The new process control and safety functions of the
Makaraba Gas Development Project shall be integrated into the existing process control and
safety systems.

4.1

Existing Control and Safety System

The existing control and safety system in Makaraba Production Platform is based on a
pneumatic Master Control Panel (MCP) which monitors and controls several unit control
panels for specific systems.
Unit control panels connected to the MCP include:

West Separator Local Control Panel (LCP-200)

East Separator Local Control Panel (LCP-210)

Gas Lift Separator Local Control Panel (LCP-220)

Incoming Flowline SDV Selector Panel West Manifold (LCP-100)

Incoming Flowline SDV Selector Panel East Manifold (LCP-120)

Gas Lift Manifold SDV Reset Panel (LCP-130)

Fuel Gas Control Panel (LCP-400)

Pipeline Pump SDV Control Panel (LCP-500)

Platform ESD and TSE fusible loop are inputs to the MCP which initiates total platform
shutdown as an output to all local control panels. All process monitoring, control and
shutdown operations are implemented via the respective local control panels.
4.2

New Control and Safety System

The new control and safety system in this Makaraba Gas Development Project shall be
designed to handle facilities of the following:

Offshore Wellhead Jacket

Makaraba Production Facilities

The control and safety operation in offshore wellhead jacket area shall fully be controlled by
Wellhead Control Panel which acts as both Emergency Shutdown System and Hydraulic
Power Unit (HPU). This platform shall be operated as un-manned platform.
As similar to the existing ones, all new instrumentation in Makaraba Production Facilities
shall be of pneumatic type. The control and safety instrumentation shall also interface with
the existing MCP pneumatically but will be relayed to their respective systems for shutdown
and alarming requirements. A new local control panel (LCP-230) shall be installed mainly to
control the Makaraba NAG HP Separator. The safety shutdown of the bulk manifold shall
also be controlled by this new LCP-230.
4.3

Modification to Existing Control System

The overall existing control and safety system of Makaraba Production Platform will not be
significantly altered as a result of the additional facilities to the platform. However, due to the
requirements to integrate the new control and safety system into the existing one, some
modifications shall be made on the existing MCP to facilitate the tie-ins to the new NAG HP
Separator Local Control Panel (LCP-230).

5.

CONTROL AND SAFETY PHILOSOPHY

The control and safety philosophy for the Makaraba Gas Development Project is intended to
ensure that the design of all required instrumentation for process control and safety system

complies with the requirements of the specifications and is adequately applied to provide
means of control, monitoring, shutdown and alarms for effective operation and safety of the
process facilities on the platform.
5.1

Offshore Wellhead Jacket

As an un-manned platform, the operations at the wellhead jacket will not normally be
attended by operators. The attendance of operators will be required in certain conditions
only, such as well start-up and routine maintenances.
The control and safety operation at the wellhead jacket shall mainly be handled by the
Wellhead Control Panel (WHCP), which shall act both as Emergency Shutdown (ESD)
System and Hydraulic Power Unit (HPU). All safety functions performed by the WHCP shall
be designed based on fail-safe concept with minimize human error and unexpected
operation.

5.1.1

Safety Control of Wellhead

The Wellhead Control Panel (WHCP-0035) is designed for wellhead control and safety
through Wellhead Shutdown Valves. There 3 (three) shutdown valves installed at the
wellhead:

Wing shutdown valve (SDV-0301),

Surface Safety Valve (SSV-0301), and

Sub-Surface Safety Valve (SCSSV-0301).

These shutdown valves shall be controlled by shutdown signals, which are triggered by:

WHCP Emergency Shutdown button

Fire detection of fusible plug loop

Flowline pressure low-low.

Flowline pressure high-high

Failure of pneumatic power supply

The WHCP uses instrument gas as the primary source of energy to generate the hydraulic
system power source and for interfacing between low-pressure pneumatic system and highpressure hydraulic system. All logics and components in WHCP shall be designed using failsafe operating concept.
Due to environmental condition enclosure type and material selection are considered.
Minimum gas consumption shall also be considered.
5.1.2

Pressure of Wellhead
The shut-in pressure of wellhead (022-G-03A) will be of 3796 psig. A pressure gauge (PG0301) is installed at the wellhead to indicate its operating pressure. The well production is
handled by a choke valve (XVC-03A).

5.1.3

Temperature of Wellhead
Wellhead flowing temperature will be 172 deg F. A temperature gauge (TI-0301) is installed
at the downstream of choke valve to provide indication of the well flowing temperature. The
WHCP is designed for wellhead control and safety through Wellhead Shutdown Valve
(SDV), Surface Safety Valve (SSV).

5.2

Offshore Wellhead Flowline

One bulk flowline will be fabricated and installed to transport the well fluids from the
wellhead to Makaraba Production Platform. The flowline will has approximate length of 0.6
km. It will be designed for delivery of 50 MMSCFD (+10%) of gas and associated
condensate flowrate.
The size of the flow line will be of 8, as per latest calculation. The flowline is fully rated to
the wellhead shut-in tubing pressure (WSITP), to ensure it is not over pressurized by the
production well due to potential blocked outlet case.

5.2.1

Safety Control of Flowline

To provide safety protection on the flowline, there are 2 (two) shutdown valves installed at
downstream of the flowline (ESDV-1001A and SDV-1001B), located at Makaraba production
platform. In the case of proses shutdown, only the SDV-1001B shall be closed by the
process shutdown logic of the local control panel (LCP-230). While in the case of emergency
shutdown, both the valve shall be closed by the logic of emergency shutdown, and the fluids
in between the valves shall be relieved.

5.2.2

Pressure of Flowline
The flow line with a design pressure of the wellhead shut-in tubing pressure is intrinsically
safe against the blocked outlet overpressure scenario. The pressure is indicated by pressure
gauges (PI-0035B and PI-0035B).
The abnormal pressure at inlet of the flowline shall be detected by pneumatic pressure
switches (PSH-0301 and PSL-0301) to initiate wellhead shutdown by Wellhead Control
Panel.
Facilities will also be provided to allow venting/depressurization of the flow line to allow for
maintenance.

5.2.3

Temperature of Flowline
The temperature of the flowline could be monitored by reading the indication of temperature
gauge (TG-0035) located at the wellhead jacket, and temperature gauge (TI-1001) located
at makaraba production platform.
5.3

Makaraba Bulk Manifold

A new bulk manifold (022-GAY-0610) will be installed at the Makaraba Flow Station. The
manifold is designed to host three (3) wells. The two (2) spares will be used for future wells
to compensate for production depletion from the initial well. There is one flowline for each
well, extending from the wellhead jacket to the Makaraba flow station. Size of each flow line
is 8, as per preliminary calculation. The flowline is fully rated to the Wellhead Shut-In Tubing
Pressure, to ensure it is not over pressurized by the production well due to potential blocked
outlet case. Flowlines are individually routed to the manifold location.

5.3.1

Safety Control of Manifold

Safety shutdown valves (ESDV-1001A and SDV-1001B) are installed for the flowline, and no
shutdown valves installed for future provision flowlines. The shutdown valves shall be closed
when shutdown command is activated from the local control panel of NAG HP Separator.
The emergency shutdown shall be triggered by:

Emergency shutdown command from control panel.

Fire detection by fusible loop (TSE)

The process shutdown shall be triggered by:

High pressure or low pressure of the manifold. (PSHL-1002)

5.3.2

Pressure of Manifold
Pressure indicator (PG-0610) is installed to enable operator to monitor the pressure of the
manifold. The pressure of any future connection of flowlines shall also be indicated by
means of pressure indicators installed locally.

5.3.3

Temperature of Manifold
The temperature of the manifold is indicated by a temperature gauge (TG-0610) installed
locally at the manifold,
.
5.4

Makaraba NAG HP Separator

A high-pressure separator will be installed in Makaraba Production Platform. The separator
is a three-phase production separator which separates well fluid into gas, hydrocarbon liquid
and water streams. The gas is wet gas, and will be sent to the Glycol Dehydration package
at NGC for further separation and dehydration process, while the hydrocarbon liquid and
water are spiked together into the Makaraba oil stream. The NAG HP Separator is designed
to have sufficient capacity to handle 50 MMSCFD of gas plus 10% of design margin.
The process variables shall be considered for control and safety of the NAG HP Separator
are pressure, level and temperature. A safety shutdown valve will be installed at the inlet of
separator for safety purpose.

5.4.1

Safety Control of Separator

As safety means, a shutdown valve (SDV-230A) is installed at the inlet of separator. In the
case of separator shutdown, the SDV will be closed by pneumatic signal from separator
local control panel (LCP-0230).
The local control panel (LCP-0230) will be installed on the production platform and shall
control and monitor the new NAG HP Separator (MBD-0230) and take action if any of the
process parameters go outside pre-defined limits.

5.4.2

The Local Control Panel receives the following command from MCP:
-

Emergency Shutdown command from MCP to LCP-0230.

Production Shut-In command from MCP to LCP-0230.

The Local Control Panel send the following inputs to MCP:

-

Shutdown Alarm from LCP-0230 to MCP.

Unit Alarm from LCP-0230 to MCP.

Pressure of Separator

The makaraba NAG HP Separator is designed to have maximum allowable working

pressure of capable to handle the gas pressure from bulk manifold. The pressure of the
separator will be handle as follows:

The separators pressure is regulated at 1500 psig by pressure controller PC-0230A and
control valve PV-0230E.

Pressure gauges shall be installed to indicate the pressure of the separator locally.

High-low pressure switches shall be installed for high and low pressure monitoring.
These pressure switches, whenever activated, shall trigger the local control panel to
alarm and activate shutdown for the separator.

Pressure safety valve (PSV-0230A)) will be installed for over-pressure protection of the
vessel.

The blowdown valve BDV-0230 is used for pressure blowdown in the case of emergency
shutdown. The blowdown pressure is controlled by pressure controller PC-0230B and
control valve PV-230G

5.4.3

Level of Separator
As a three-phase separator, the liquids phase will be of hydrocarbon liquid and water. The
level of the liquids will be controlled by these means:

Level controllers and the respective control valves shall be provided for regulating the
liquid level as follows:
-

Level controller LC-0230A and control valve LV-0230A are designed to control the
condensate level, while

Level controller LC-0230B and control valve LV-0230B are dedicated of the
separator.

Level gauge(s) shall be installed for local indication of liquid levels:

-

LG-0230E is dedicated for indicating the condensate level.

LG-0230D is dedicated for indicating the water level.

High-low level switch(es) shall be installed for high-low level monitoring. The switch(es)
will send signal to the local control panel for alarming purpose and activate shutdown for
the separator.
-

LSL-0230F is dedicated for low-low interface level. This will trigger logic shutdown of
the separator.

LAL-0230G is dedicated for alarm low of interface level.

LAH-0230G is dedicated for alarm high of interface level.

LAL-0230H is dedicated for alarm low of condensate level.

LAH-0230H is dedicated for alarm high of condensate level.

LSL-0230E is dedicated for low-low level of condensate.

LSH-0230E is dedicated for high-high level of condensate. This LSH-0230E along

with LSL-0230E will trigger logic shutdown of the separator.

5.4.4

Temperature of Separator
As the temperature of the separator is not required to be controlled, there is no instruments
installed to control the temperature of separator. Temperature gauge (TI-0230) is provided
for purpose of local indication only.