Nigerian Petroleum Development Company Limited

ANE-SPINMU-PJM-REP-00001

STUDY FOR SITE PREARATION & INTEGRATION OF NPDC LACT UNITS PROJECT SITE VISIT REPORT

JUNE 2013

Rev

Date

Description

Issued by

Checked by

Approved by

A01

25-06-2013

Issued for Inter-Discipline Check

D. Owoseni

C. Ogini

M. Omotoso

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TABLE OF CONTENTS
1.0 INTRODUCTION........................................................................................................2 1.1 General ......................................................................................................2 1.2 Background.......................................................................................................3 2.0 SCOPE OF WORK....................................................................................................4 3.0 REFERENCE DOCUMENT & DRAWINGS...............................................................6 4.0 SITE VISIT FINDINGS ..............................................................................................6 ............................................................................................................................34 4.2.1 Challenges............................................................................................35 4.2.2 Recommendations................................................................................36 4.3.1 Recommendations................................................................................43

1.0
1.1

INTRODUCTION
General

This Site Visit report documents the findings of the site visit to NPDC facilities. The site visit was initiated to access the facilities concerned with a view deriving all necessary information that could be of great assistance during the design and feasibility of installation and construction of new LACT unit and Interim Metering system. CONTRACTOR (IESL) representative conducted the site survey with the assistance of NPDC representatives.
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The exercise was conducted between 15th May and 16th June, 2013 as described in the scope of work, the site visit checklist also hereby attached with this report.

1.2

Background

Nigerian Petroleum Development Company Limited (NPDC), a subsidiary of Nigerian National Petroleum Corporation (NNPC) intends to install twelve (12) Lease Automatic Custody Transfer (LACT) units with capacities ranging from 25,000bpd and 600,000bpd at NPDCs OMLs 30,34,40,42 and 65 assets. NPDCs objective is to conduct a detailed study of the proposed LACT unit installation sites to determine site conditions and extent of work required during the site preparation for the LACT units. The study shall also cover interim metering requirement survey at NPDC Flowstations in these OMLs. The study shall cover the following; Development of Plot Plan Layout for LACT unit installation. Site Survey and Soil tests Basic design of structural foundation, civil works, fencing, LACT unit housing etc Development of an integration solution of the LACT units with the existing pipeline manifold and electrical power system. Basic design Telemetry requirement to link each LACT Unit with NDPC Information Technology network and SPDC network to enable real-time data transfer. Interim metering requirement survey at NPDC Flowstations listed in Table 1.

Table 1: List of NPDC Flow station for Interim Metering Study ASSET FLOWSTATION REMARK YES OML 20 EGBEMA EGBEMA WEST OSIOKA
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NO NO NO NO
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EVWRENI ORONI UZERE OLOMORO OML 30 OLEH OWEH KOKORI ERIEMU AFIESERE UTOROGU OML 34 OML 40 OML 42 UGHELLI EAST UGHELLI WEST OPUAMA JONES CREEK ODIDI 1

YES YES NO NO NO YES YES YES YES YES YES YES NO YES YES

2.0

SCOPE OF WORK

The Scope of works shall include but not limited to the following: 1. Study of Interim Metering for NPDC Flowstations in OMLs 30, 34, 40 And 42 Carryout the Designs, Sizing /Calculations, Drawings and Documents necessary for the definition of Site work scope in line with technical specification attached (Fiscal Liquid Metering Station Interim Metering Sample System Specification). Prepare Scope of work for the Site works. Prepare Schedule of work for the implementation of the Interim Metering works

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Prepare a Cost estimate for the implementation of the Interim Metering works.

Detail all battery limits and interfaces with the existing Facility. Ensure that existing drawings are reviewed to show modifications in the Facilities. Mark all tie-points with the existing facility.

2.

The Study for Site Preparation & Integration of NPDC LACT Units in at Eriemu Manifold station, UPS, Batan Manifold and Warri refinery for OMLs 30, 34, 40 and 42 Assets Carryout the Designs, Sizing /Calculations, Drawings and Documents necessary for the definition of Site work scope. Prepare Scope of work for the Site works. Prepare Schedule of work for the implementation of the Site preparation works Prepare a Cost estimate for the implementation of the site works. Define and prepare all documents required for NPDC to apply for, obtain and comply with all permits and authorizations required for the site preparation works. Detail all battery limits and interfaces with the existing Facility. Ensure that existing drawings are reviewed to show modifications in the Facilities. Mark all tie-points with the existing facility.

3. 4.

Packaged Invitation to Bid (ITB) for Interim Metering works. Make a site visit to NPDC proposed Interim Metering Location to: Sight the Proposed location of the Facilities and make the necessary measurements.

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Package a Status report on the existing facilities. This report should highlight all equipments which are not fit for purpose (down-graded) for the project (PD Meters, Counters, etc).

3.0

REFERENCE DOCUMENT & DRAWINGS

Request for quotation

NPDC/MD/05.11

4.0 4.1

SITE VISIT FINDINGS Process

ERIEMU FLOWSTATION
The metering skid at the flowstation is shown as below and with 3 runs. One out of the 3 runs is working and one on standby while the third run is not in operation because there is no PD meter installed on any of the runs.

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Eriemu Flowstation Metering Skid The spool downstream the third run of the metering skid will be removed so as to be able to install a new pressure indicating transmitter (PIT) and a temperature indicating transmitter (TIT) and to also install an auto sampler (interim metering).

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Spool length for Autosampler & other fittings

At the Eriemu manifold 3 LACT units will be installed, these LACT units are One for the 16 incoming line from Ogini to eriemu (not part of A & N scope) One for kokori and afiesere 12 lines ( common header to the LACT) One for 16 line from uzere to eriemu manifold

A common header will be provided for the 12 kokori and 12 afiesere line which will be connected to the LACT unit and the line downstream the kokori/afiesere LACT will be routed to the 24 line from eriemu to UPS.

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Kokori 12 Pipe

Showing elbow that will be rerouted to a common header

Afiesere 12 Pipe

Showing elbow that will be rerouted to a common header

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Tie-in point for uzere LACT to 24 line to UPS

Spare Tie-in on 24 pipeline to UPS

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24 Eriemu line to UPS AFIESERE FLOWSTATION The metering skid at Afiesere flowstation is shown below with 3 runs, one working and 2 others on stand-by. Each of the line consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e outgoing line from the metering skid. The spool upstream the check valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.

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Afiesere Flowstation Metering Skid

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Spool length for Autosampler & other fittings

Showing the outgoing line from the metering skid

EVWRENI FLOWSTATION The metering skid at evwreni flowstation is shown below with 3 runs, one working, one on stand-by and the third run has its strainer and PD meter removed (not working). Each of the line consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e outgoing line from the metering skid. The spool downstream the check valve up to the shutdown valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.
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Evwreni Flowstation Metering Skid

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Spool length for Autosampler & other fittings

Showing the outgoing line from the metering skid

OWEH FLOWSTATION The metering skid at oweh flowstation is shown below with 3 runs, one working and 2 others on stand-by. Each of the line consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e outgoing line from the metering skid. The spool downstream the shutdown valve (100-XZV-150) and the 6 gate valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.
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Oweh Flowstation Metering Skid

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Spool length for Autosampler & other fittings

Showing the outgoing line from the metering skid

KOKORI FLOWSTATION There are two metering skids at Kokori flowstation and these are shown below. The first metering skid has a working single run with 2 spare tie ins for future runs. The second metering skid has 3 runs, two working and one on stand-by. Each of the runs consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e outgoing line from the second metering skid. The spool downstream the check valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.
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Kokori metering skid with one run

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Kokori metering skid with three runs The meeting point of the outlets of the two metering skids is shown below.

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Meeting point of the 2 kokori metering skids

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Spool length for Autosampler & other fittings

UGHELLI WEST FLOWSTATION The existing metering skid at ughelli west flowstation is shown below with 2 runs. Each of the lines consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e outgoing line from the metering skid. The spool downstream the check valve up to the shutdown valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.

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Ughelli West Flowstation Metering Skid

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Spool length for Autosampler & other fittings

Outgoing line from the metering skid

UTOROGU FLOWSTATION The metering skid at Utorogu flow station is shown below with 3 runs, 2 working and one on standby. Each of the lines consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e. outgoing line from the metering skid.

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Utorogu Flowstation Metering Skid The spool downstream the check valve will is too short to accommodate the pressure indicating transmitter (PIT), temperature indicating transmitter (TIT) and the auto sampler. The new spool that will be installed will be long enough to accommodate the auto sampler, PIT and TIT. The demolition/installation of spools will involve digging/excavation.

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Spool to be extended for Autosampler & other fittings

Outgoing line from the metering skid

UGHELLI EAST FLOWSTATION The metering skid at ughelli east flow station has 2 meter runs. Each of the lines consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e. outgoing line from the metering skid. The spool downstream the check valve up to the shutdown valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.

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Spool to be extended for Autosampler & other fittings

Outgoing line from the metering skid The new spool that will be installed will be long enough to accommodate the auto sampler, PIT and TIT. The demolition/installation of spools will involve digging/excavation.

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ODIDI FLOWSTATION The metering skid at odidi flowstation has 3 meter runs and none is working at the moment since the station has been shutdown since 2010. There is no pulse/mechanical transmitter and no inner mechanism in meter C, meters A & B have inner mechanism but the functionality cannot be confirmed.

Odidi Flowstation Metering Skid An interim metering (auto sampler) will be installed downstream the metering run i.e. outgoing line from the metering skid. The spool upstream the ball valve will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed
..

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Spool length for Autosampler & other fittings

Outgoing line from the metering skid BATAN FLOWSTATION The metering skid at oroni flowstation is shown below with 3 meter runs, two working and the other on stand-by. Each of the line consists of a strainer and PD meter. An interim metering (auto sampler) will be installed downstream the metering run i.e. outgoing line from the metering skid. The spool will be demolished and a new spool with pressure indicating transmitter (PIT) and temperature indicating transmitter (TIT) with the auto sampler will be installed.

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Batan Flowstation Metering Skid

Spool length for Autosampler & other fittings

Outgoing line from the metering skid

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At the Batan manifold, a LACT unit will be installed on the line to UPS, the flange downstream the check valve will be demolished and a tee will be introduced to tie-in to the LACT. There will be hot work on the pipeline.

Flange to be demolished

Batan Manifold KEREMU MANIFOLD The keremu pigging manifold is shown below. The incoming line has been vandalized and also the pig receiver. The LACT unit will be installed downstream the pig receiver and tie-in to the blind flange shown.

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Keremu Manifold

Blind Flange as tie-in

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Process Site visit Checklist Status / Note # Description

Confirm the location of the Manifold. Identify and confirm possible Tie-in point locations. Discuss philosophy operations. current operating of facility with

Item # 1 2 3 4 5 6 7

OK NOK x x x x x x x

N/A

Mark up Drawing Number

Findings/ Recommendations

Operators on site were unable to discuss the operating philosophy of the facility.

Confirm the location proposed Metering unit. Take relevant photographs.

of

the

Obtain existing drawings of the facility. Confirm location of LACT unit

Location of LACT unit were identified in Eriemu Manifold station, UPS, Warri refinery

Eriemu Flowstation Metering Skid Area

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Spool length Autosampler & fittings

for other

Outgoing spool tied to the existing facilities. New Cable tray of size 300mm wide will be installed to route power and control cable for the new Sampling system. The Existing tray and Junction box will be used for new PIT and TIT instrument to be installed at the down stream of the outgoing Line since there are available spares on them.

New two LACT units at Eriemu and four at UPS are to be installed: Common Gas and diesel generator set with a larger capacity will be installed at Eriemu manifold and UPS manifold for power supply to all the instrument equipment, illumination, motors and Normal Power Distribution Panel and UPS power Supply will be considered in the design. Voltage Levels are 400VAC for 3-Phase supply and 230VAC for 1-Phase supply and 24Vdc for Controls at frequency 50Hz. New MCC room for motor control, instrument Air system and control room will also be installed.

Earthing System Design:

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New Earthing system is required for new LACT unit skid within OML 30 Field and items on the LACT system including the fence and some Electrical Equipment At the Manifold station. For Interim metering system, earthing to be tied to the existing earthing system.

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OML 42: Jones Creek, Odidi, Batan & Rapele Observations / Findings
The Auto Sampler (Interim metering) will be installed in Batan, and Rapele: Power supply shall be tied to the existing facilities. Jones Creek and Odidi are not in operational for now, NPDC to advice. New Cable tray of size 300mm wide will be installed to route power and control cable for the new Sampling system. The Existing tray and Junction box will be used for new PIT and TIT instrument to be installed at the down stream of the outgoing Line since there are available spares on them. New LACT units are to be installed: Gas and diesel generator set will be installed for power supply to all the instrument equipment, illumination, motors and Normal Power Distribution Panel and UPS power Supply will be considered in the design. Voltage Levels are 400VAC for 3-Phase supply and 230VAC for 1-Phase supply and 24Vdc for Controls at frequency 50Hz. New MCC room for motor control, instrument Air system and control room will also be installed.

Earthing System Design:

New Earthing system is required for new LACT unit skid within OML 30 Field and items on the LACT system including the fence and some Electrical Equipment at the Manifold station. For Interim metering system, earthing to be tied to the existing earthing system.

4.2.1 Challenges
NPDC Electrical and Instrument Engineer were not available on site as at the time of visit, so some Electrical Panels and Control Room were not inspected.

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4.2.2 Recommendations
Company to provide existing electrical drawings of NPDC Flow stations and Manifolds under OMLs 30, 34, 40 and 45. Standby generator set is required for perfect operation. It will be good that SCADA system be install at Evwreni flow station for perfect operation. Some Cable ties are loosed and the cables are out of the tray, new cable ties and tray cover should be provided to keep the cable firm in the cable tray.

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APPENDIX
Electrical Checklist Item # Status / Note # NO OK N/A K Ok Mark up Drawing Number

Description
Verify existing equipments (HV, LV Switchboard and UPS) condition, dimension and Location. Check the Tie-in point between the existing facilities with the proposed Metering and LACT units. Verify the existing UPS Power consumption, if the capacity can power the new Metering and LACT unit. Verify the existing electrical one line diagram. Verify available spare terminals in the LV switchboard drawer (new trip signal for motors), Verify the Existing cable Tray/routing condition and space.

Findings/ Recommendations
HV, LV switchboard and UPS condition and ratings was confirmed for all the flow stations visited but for LACT unit new one will be installed. Confirmed.

Ok

Ok

For Autosampler yes but for LACT unit new UPS is required. The existing single line diagram for all the flow stations visited are yet to be received from NPDC. Confirmed. See photos below. New cable tray are required For Autosampler and LACT unit, but for the new PIT and TIT instrument to be install, available space in the existing instrument cable tray will be used. No available spare cable at the flow stations to wire the sampling system, therefore, new cables are required both for sampling system and LACT unit. Done Done for interim, existing will be reused while for LACT, new cabinet will be installed. The photograph of all the checked items at the flow stations and manifold was taken and some are attached in this report.
OKOPORO/UBALEME SITE VISIT REPORT

Ok

Ok

Ok

Check if Existing cables have enough spare length for the new unit. Check Existing MCT type and spare/space to accommodate new cables from metering and LACT units. Verify spare/space to install the new Electrical power distribution cabinet or to use the existing for the new Unit. Take photograph of all above checked items
IES-OPE-OKOUB-B04-00002

Ok

Ok

Ok

10

Ok
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11

Verify the existence of Instrument Air at the proposed LACT Units location

Ok

Instrument Air is available in all the flow stations but for LACT unit, new Instrument Air system will be required.

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SITE VISIT PICTURES

Cables falling off the tray. Recommendation: Cable tie required here to tie the cables back in the tray.

Fig.1. Existing Cable Tray with available space that will accommodate new instruments (PIT and TIT).

Existing 2x36W fluorescent lighting fixtures. Observation: one Tube is damaged and need to be replaced. Fig.2 Existing 2x36W fluorescent lighting fixtures located in Afiesere SCADA room
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Tags required for proper identification and perfect operation.

Fig.3. Existing spare breakers to be re-used for power supply to the new system

Fig.4. Existing Electrical Panels Located in the Power house.

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Battery box housing the Battery

Fig.5. Existing Battery house in a battery box Located in the power house

Fig.6. Existing UPS located in the SCADA rooms.

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4.3

Instrument/ Control:

OML 30- Interim Metering/ Autosampler (Eriemu, Evwreni, Afiesere, Kokori, Oweh and Oroni) Observations/Findings
The visit shows that there are existing Instrument Junction box on these metering skids at the flow stations in which the existing instruments are connected, with available spare to accommodate new Instruments, such as new Pressure Indicating transmitter (PIT) and Temperature indicating transmitter (TIT). Also it was observed that the existing System/Panel in the Control room have enough spare terminals, hence no need to expand the cabinet.

OML 34- Interim Metering/Autosampler (Ugehelli East and West) Observations/Findings

Ugehelli West flowstation metering skid has existing instrument junction box with spare terminal in to accommodate new instruments, Pressure Indicating transmitter (PIT) and Temperature indicating transmitter (TIT). But for Ugehelli East flowstation, there is no available spare in the junction box on the metering skid. Also it was observed that the existing System/Panel in the Control room have enough spare terminals, hence no need to expand the cabinet.

OML 42 - Interim Metering/Autosampler (Batan, Odidi and Jones Creek) Observations/Findings

Batan flowstation, Metering skid has existing Instrument Junction box with available spares to accommodate new Instruments, Also the System/panel in the control room has spare terminals to take field connection. But it was observed at (Odidi flowstation) that
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there was no existing Instrument Junction box and no instrument was identified on this skid, except for the instrument cables without any connection and no access to the control room. Jones creek, no existing Junction box and Instruments on this metering skid, the only thing that was observed were instruments tapping points. Also, there was no access to the control room.

LACTS UNITS ERIEMU, UPS, BATAN, RAPELE, FORCADOES, KEREMO AND WARRI REFINERY MANIFOLDS
Observations/Findings The site visit reveals that there was an existing LACT Unit in Rapele manifold, but there was no access to it. But from the findings there is enough space for installation of the new LACTS system on these manifolds and the telemetry system that will convey signal to the SCADA room.

4.3.1 Recommendations INTERIM METERING/ AUTOSAMPLER

The proposed Interim metering (Autosampler) for the Metering Skid shall take up part of spare terminals in the Metering Panel in the control room. Instrument Junction boxes is required is some metering skids such as Ugehelli east, Odidi and Jones creek flowstations e.t.c.

LACTS UNITS
The proposed LACTS unit has enough space for installation in these said manifolds. Therefore, space is not a constraint.

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APPENDIX
Instrumentation Checklist
Item # Status / Note # Description OK NOK N/A Mark Drawing Number up Findings/ Recommendations

FLOWSTATIONS
1 Evaluate Equipment standardization Opportunities( Note Manufacturer of similar Instrument) OK The existing equipment standardization was evaluated and Manufacturer information was noted. The were existing Instruments on the metering skid in other flow stations except for Odidi and JONES CREEK flowstations Confirmed System cabinets were identified with available spares. Locations of the Junction boxes were verified, with available spare, except for Ugelli East which has no spare. Odidi and Jones Creek have no JB at all on the skid. New junction box is required for Ugelli East, Odidi and Jones Creek to accommodate new Instruments. Not all is wired through. No JB in Jones Creek and Odidi metering Skids. Confirmed The location for control tieIns was identified The possible tie in points was identified.
OKOPORO/UBALEME SITE VISIT REPORT

Check the existing Instruments locations / layouts Confirm the type Control system of existing

OK

3 4

OK OK

Check the existing system cabinet

Check for available spares for the Instrument Junction box and location

OK

Verify if new junction boxes are required Equipment room termination cabinet(verify all available Junction boxes are wired through) Check to verify that signal and power cables are not in the same tray. Verify physical location for the control system tie-Ins ( Junction box DCS) Check for possible tie in point for auto sampler system
IES-OPE-OKOUB-B04-00002

OK

OK

8 9 10

OK OK OK
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11

Check and review the existing drawings and documents

N/A

There were neither documents nor drawings available.

LACTS UNIT
13 14 Check available space for the LACT Unit Control panel (UCP) Check if there is any SCADA System available at the flow station Confirm existing Lacts System in the Manifold OK OK There are available space to Install LACT system Confirmed No existing LACT system in the manifolds except Rapele manifold and no access.

15

OK

SITE VISIT PICTURES

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Spare terminal in the JB

Existing Instrument Junction Box showing spare terminal on the metering skid

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System Cabinet showing spare terminals

Instrument Cable

This Image showing Instrument cable without connection on the metering Skid at Odidi flowstation

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Instrument connection point

Image on this skid showing tapping points without Instrument connection at Jones creek flowstation

Cable tray conveying instrument cables

Image showing cable tray conveying instrument cable to Junction Box at Afiesere flows station
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