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CC ENERGY DEVELOPMENT S.A.L

(Oman Branch)

PROJECT

Farha & Saiwan AdequacyChecks

JOB NR. DOCUMENT NR. REV. DATE SHEET

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Adequacy Check Report

JS1034-XX-F06-0001.A1

SHEET REVISIONS SHEET REVISIONS

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CONTENTS

ABBREVIATIONS ..............................................................................................................................6

1 EXECUTIVE SUMMARY ...................................................................................................9

2 INTRODUCTION ............................................................................................................ 12

2.1 Reservoir Description & Production Background ........................................................ 12

2.2 Facilities Description ................................................................................................. 13

2.2.1 Farha Crude Treatment Facility..................................................................................................... 13

2.2.2 Saiwan Crude Treatment Facility .................................................................................................. 16

2.3 Station Production Capacities – Phase 2B ................................................................... 18

3 OBJECTIVE ................................................................................................................... 19

4 SCOPE OF WORK .......................................................................................................... 19

5 FARHA & SAIWAN PLANT PROCESS SIMULATIONS ........................................................ 19

5.1 Objective of Simulation ............................................................................................. 19

5.2 Farha Simulation Description ..................................................................................... 19

5.3 Saiwan Simulation Description .................................................................................. 22

5.4 Base Data and Assumptions ...................................................................................... 24

5.4.1 Compositions ................................................................................................................................ 24

5.4.2 Key Component Conditions .......................................................................................................... 28

5.5 Simulation Cases & Production Profile Scenarios ........................................................ 28

5.5.1 Simulation Cases ........................................................................................................................... 28

5.5.2 Production Profile Scenarios and Simulation Comparison ........................................................... 29

6 FARHA PROCESS EQUIPMENT ....................................................................................... 32

6.1 Inlet Manifold (201-XY-001B) .................................................................................... 32

6.2 Production Separators (201-VS-001A/B/C) ................................................................. 32

6.3 Dehydration (Heater Treaters 201-FY-001A/B/C)........................................................ 33

6.4 Oil Storage ................................................................................................................ 34

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6.5 Oil Export (Export Pumps & Pipeline) ......................................................................... 34

6.5.1 10” Pipeline Farha to Saiwan ........................................................................................................ 34

6.5.2 Oil Transfer Booster Pumps (221-PA-002A/B/C) & Oil Transfer Pumps (221-PA-001A/B/C) ....... 35

7 SAIWAN PROCESS EQUIPMENT ..................................................................................... 35

7.1 Inlet Manifold .......................................................................................................... 35

7.2 Production Separators (200-VS-001A/B) .................................................................... 36

7.3 Dehydration (Heater Treaters 200-FY-001A/B) ........................................................... 37

7.4 Oil Storage ................................................................................................................ 37

7.5 Oil Export (Export Pumps & Pipeline) ......................................................................... 38

7.5.1 16” Pipeline Saiwan to Alam ......................................................................................................... 38

7.5.2 Oil Transfer Booster Pumps (220-PA-002A/B/C) & Oil Transfer Pumps (220-PA-001A/B/C) ....... 38

8 FARHA UTILITIES (Excluding Electrical) .......................................................................... 39

8.1 Instrument Air System ............................................................................................... 39

8.2 Chemical Dosing Packages ......................................................................................... 39

8.3 Diesel Storage System ............................................................................................... 40

8.4 Flaring System........................................................................................................... 42

8.5 Nitrogen ................................................................................................................... 44

8.6 Utility Water ............................................................................................................. 45

8.7 Closed Drain System .................................................................................................. 45

9 SAIWAN UTILITIES (Excluding Electrical) ........................................................................ 46

9.1 Instrument Air System ............................................................................................... 46

9.2 Chemical Dosing Packages ......................................................................................... 46

9.3 Diesel Storage System ............................................................................................... 47

9.4 Flaring System........................................................................................................... 48

9.5 Nitrogen ................................................................................................................... 51

9.6 Utility Water ............................................................................................................. 52

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9.7 Closed Drain.............................................................................................................. 52

10 FARHA MAIN HEADERS................................................................................................. 53

11 SAIWAN MAIN HEADERS .............................................................................................. 53

12 FARHA & SAIWAN OVERALL PLOT PLAN (Mechanical) ................................................... 54

13 FARHA AND SAIWAN - C&A ADEQUACY CHECKS ........................................................... 60

13.1 Control and ESD System at Farha South Station.......................................................... 60

13.1.1 Existing DCS System at Farha South Station ................................................................................. 60

13.1.2 Existing ESD System at Farha South Station ................................................................................. 61

13.2 Adequacy Evaluation at Farha South Station .............................................................. 63

13.2.1 Existing DCS System at Farha South Station ................................................................................. 63

13.2.2 Existing ESD System at Farha South Station ................................................................................. 68

13.3 Available Space in FES Control Room for System Cabinet and HMI .............................. 77

13.4 Control and ESD System at Saiwan East Station .......................................................... 78

13.4.1 Existing DCS System at Saiwan East Station .................................................................................. 78

13.4.2 Existing ESD System at Saiwan East Station .................................................................................. 79

13.5 Adequacy Evaluation at Saiwan East Station .............................................................. 80

13.5.1 Existing DCS System at Saiwan East Station .................................................................................. 80

13.5.2 Existing ESD System at Saiwan East Station .................................................................................. 88

13.6 Available Space in SES Control Room for System Cabinet ........................................... 95

13.7 Control Valve Adequacy Check .................................................................................. 96

14 ELECTRICAL ADEQUACY CHECKS ................................................................................... 98

15 RECOMMENDATIONS & CONCLUSIONS (Process) ........................................................ 103

16 REFERENCES ............................................................................................................... 105

17 APPENDICES ............................................................................................................... 106

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ABBREVIATIONS

2oo3 2 out of 3

AP Atmospheric Pressure

BMS Burner Management System

BOPD Barrels of Oil per Day

BS&W Basic Sediment and WaterBVS Block Valve Station

BWPD Barrels of Water per Day

C&E Cause & Effects

CCED Consolidated Contractors Energy Division S.A.L (Oman Branch)

CCC Consolidated Contractor Group of Companies

DB Distribution Board

DCS Distributive Control System

DEP Design Engineering Practice

DG Diesel Generator

EPF Early Production Facility

ESD Emergency Shutdown

ESDV Emergency Shutdown Valve

FEED Front End Engineering Design

FG Fuel Gas

F&G Fire and Gas

FV Full Vacuum

GU Guideline

HAC Hazardous Area Classification

HMI Human Machine Interface

HP High Pressure

HV High Voltage

IA Instrument Air

ICS Integrated Control System

ISO International Standards Organisation

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JB Junction Box

KOD Knock Out Drum

LP Low Pressure

LPG Liquefied Petroleum Gas

LT Level Transmitter

LV Low Voltage

MCC Motor Control Centre

MMSCFD Millions of Standard Cubic Feet per Day

MOV Motor Operated Valve

MV Medium Voltage

MVA Mega Volt Ampere

NPSH Net Positive Suction Head

OCSP Operating Control and Safeguarding Philosophy

OHL Over Head LinePCV Pressure Control Valve

PDO Petroleum Development Oman

PESD Process Emergency Shut Down

PLC Programmable Logic Controller

PSV Pressure Safety Valve

P&ID Piping and Instrumentation Diagram

PT Pressure Transmitter

RO Restricted Orifice

RTU Remote Transmission Unit

RV Relief Valve

SCADA Supervisory Control and Data Acquisition

SDV Shut Down Valve

SP Specification

SR Switch Rack

TCV Temperature Control Valve

TP Tie-in Point

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TRV Thermal Relief Valve

TSV Thermal Safety Valve

TT Temperature Transmitter

UCP Unit Control Panel

UG Underground

UPS Uninterrupted Power Supply

WC Water Cut

VEC Value Engineering Centre

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1 EXECUTIVE SUMMARY

Adequacy checks were carried out by VEC at the order of CCED for the Phase 2B expansion of

Farha and Saiwan Crude Treatment Facilities.

The facilities at Farha and Saiwan each consist of one Separation Train (each Separation Train

consists of one Separator and one Heater Treater). Under Phase 2B, two additional Separation

Trains are to be added to the existing Farha Facilities and one additional Separation Train is to

be added to the existing Saiwan Facilities. Each additional train is to be a replica of the pre-

existing Separation Trains at Farha and Saiwan.

Majority of the items are found to be adequate however, some of the equipment was found

not to be adequate and require replacement or additional equipment in order to successfully

increase the production and satisfy Phase 2B of the expansion project. It is recommended that

the replacement/new equipment be designed and catered for during the detailed design of

Farha and Saiwan Phase 2B Expansion Project.

The tables on the following two pages show an overview of the items/equipment that was

considered as part of the scope of work under this adequacy study and found to be

inadequate.

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Farha Plant

Description Remarks

Storage Tanks

Inadequate based upon a 48 hour

production philosophy butadequate based on a 24 hr

retention of product.

Off-Spec Tank

Inadequate based on 24 hours

product retention.

Flare System

LP Flare Knockout Drum Inadequate

based on momentum criteria at

inlet nozzle.

Vessel Relief Valves

Heater Treater Relief Valves are

inadequate based on fire case

scenario.

Instrument Air System 1 more package is required

Chemical Dosing Packages Demulsifier Package is inadequate

Diesel Storage System

Diesel Storage Tank Capacity is

inadequate based on 15 days

consumption

Nitrogen

Inadequate based on worst case

scenario i.e. No Fuel Gas Available.

Plot Plan Spacing

Distance between 3rd

Train Heater

Treater and Separator is

inadequate.

Electrical InadequacyExpansion of switchgear room is not

possible.

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Saiwan Plant

Description Remarks

Separators

Operating outside of Operating

Envelope.

Storage Tanks Please see section 7.4 of Report

Export Pumps

Export Booster Pumps

Flare System



inlet nozzle. Also, Production

Separator Train 1 Tailpipe Mach

Number is too high.


1st Train Production Separator and

2nd Train Heater Treater Relief

Valves are inadequate for the firecase scenario.


Heater Treater Diesel Day Tank is

not adequate based on a 24 hours

supply

Nitrogen



Plot Plan Spacing

Distance between Diesel Unloading

Pump and Diesel Storage Tank is in

adequate. Spacing between the

new 2nd

Train Separator and Heater

Treater is not adequate.

For details, please reference the relevant sections of this Study Report alongside appendices.

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2 INTRODUCTION

2.1 Reservoir Description & Production Background

Consolidated Contractors Energy Division S.A.L. (CCED) is an upstream oil and gas exploration

and production company with operations in the Sultanate of Oman. CCED is part of the larger

Consolidated Contractors Group of Companies (CCC), a world-class engineering and

contracting conglomerate specialized in the construction of upstream oil and gas processing

facilities, refineries and petrochemical plants. It established its operation in Oman in October

2007 with the acquisition of 50 % interest in Blocks 3 and 4, situated in the south eastern belt

in Oman and covers an area of approximately 29,000 square kilometres.

Currently, there are treatment facilities for well-produced fluids at Farha and Saiwan locations

and a crude storage and custody metering arrangement at Alam Station (CCED) from where

the crude is transported to PDO Qarn Alam Station via an 8” PDO oil pipeline. Farha Crude

Treatment Facility is served by Farha South Wells and stabilised crude from Farha EPF is

transferred directly to the Farha Crude Oil Storage Tanks (221-TA-001A/B) from where the

stabilised Farha & Farha EPF crude is exported to Saiwan Crude Oil Storage Tanks (220-TA-

001A/B) via a 10” Export Pipeline. The Saiwan Crude Treatment Facility is served by Saiwan

East Wells and the Saiwan stabilised crude is exported from the Saiwan Crude Oil Storage

Tanks (220-TA-001A/B) along with the Farha stabilised crude to Alam Station which is

approximately 67 kms away from Saiwan East via a 16” Export Pipeline. Custody metering

takes place at Alam Station from where the crude is sent to PDO Qarn Alam Station via an 8”

PDO oil pipeline. Farha and Saiwan fields are approximately 50 kms apart from one another.

The above facilities were developed as part of Phase 2A of the reservoir exploitation program

and the facilities were designed for a maximum oil flow of 5,000 BOPD from Farha wells and a

maximum oil flow of 5,000 BOPD from Saiwan East wells. It was expected that for the future,

the maximum oil production from both Farha and Saiwan wells was to be 10,000 BOPD each.

The increased capacity of each treatment facility is covered under Phase 2B of the reservoir

exploitation program which is currently being carried out. Phase 2B will see additional process

units and utilities to handle the increased production which CCED wishes to achieve from both

Farha and Saiwan East wells. As part of Phase 2B, well produced fluids being treated at Farha

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EPF will be re-routed for treatment at Farha Crude Treatment Facility along with Farha South

Wells Produced Fluids.

In addition to the increased production from Farha and Saiwan wells, CCED wishes to utilise

the crude storage and export facilities at Saiwan Plant to handle stabilised crude from EPFs of

a third newly developed reservoir by the name of SHAHD. The maximum crude production for

all SHAHD EPFs excluding EPF locations “H” and “I” is 30,000 BOPD. Produced well fluids fromEPF locations “H” and “I” will be processed using the second Saiwan Separation Train which is

part of the additional units envisaged for Phase 2B of the reservoir exploitation program. In

the future, further wells are expected to be drilled and brought online for the SHAHD reservoir

and processed using the second Saiwan Separation Train up to a maximum oil flow of 10,000

BOPD.

The facilities at Farha and Saiwan each consist of one Separation Train (each Separation Train

consists of one Separator and one Heater Treater). Under Phase 2B, two additional Separation

Trains are to be added to the existing Farha Facilities and one additional Separation Train is to

be added to the existing Saiwan Facilities. Each additional Train is to be a replica of the pre-

existing Separation Trains at Farha and Saiwan.

2.2 Facilities Description

2.2.1 Farha Crude Treatment Facility

The Farha Plant is a sweet facility and has two Inlet Manifolds 201-XY-001A and 201-XY-001B.

Inlet Manifold (201-XY-001A) currently serves Farha EPF but has a provision for routing the

produced well fluids to the Inlet Manifold (201-XY-001B) which serves the main Farha Plant.

This arrangement is necessary as the produced well fluids being treated at Farha EPF will be

required to be re-routed to the main Farha Plant under Phase 2B.

Under Phase 2B, the produced well fluids are to be routed to the Production Separators (201-

VS-001A/B/C) (Trains 1, 2 and 3) where separation takes place. The separator produced water

is routed to the Evaporation Pond (591-TM-001/002) and the produced crude oil is routed to

the relevant Heater Treater (201-FY-001A/B/C) for dehydration via heat treatment and further

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separation. Each separation train is served by a dedicated Heater Treater unit. The produced

gas from the Production Separators (201-VS-001A/B/C) and Heater Treaters (201-FY-

001A/B/C) is routed to the Fuel Gas System and any surplus gas from the Fuel Gas System is

diverted to the LP Flare KO Drum (231-VN-001) by way of a Pressure Control Valve (421-PV-

280) upstream of the Fuel Gas Filter and then routed to the LP Flare (231-FC-001) after

knockout of any entrained liquids. Any produced water from the Heater Treaters is routed to

the Evaporation Pond (591-TM-001/002). The stabilised crude from the Heater Treater Units isrouted to the Crude Oil Storage Tanks (221-TA-001A/B) and then exported using Oil Transfer

Booster Pumps (221-PA-002A/B/C) and Oil Transfer Pumps (221-PA-001A/B/C) to Saiwan

Storage via a piggable 10” Export Pipeline. Gas from the Crude Oil Storage Tanks (221-TA-

001A/B) is routed to the AP Flare KO Drum (231-VN-002) under pressure control from where it

is routed to the AP Flare (231-FC-002) after knockout of any entrained liquids.

Farha Facility also contains an Off-Spec Oil Tank (221-TA-002) which receives off-spec oil from

AP and LP Flare KO Drums (231-VN-001 & 231-VN-002), Closed Drain Drum (551-VA-001) and

Heater Treaters (201-FY-001A/B/C). The off-spec oil is routed to the inlet header of the

Production Separators (201-VS-001A/B/C) (Trains 1, 2 and 3). All skids are connected to the

Closed Drain System.

Figure 2.2.1.1 overleaf shows an overview of the Farha Crude Treatment Facility.

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Figure 2.2.1.1: Farha Facility Overview

EXISTING FACILITY

ADDITIONAL TRAINS

FC

FC

LC

LC

LC

LC

LC

LC

PV

PV

PV

PV

PV

PV

PV

LC

LC

LC

SET @ 8 BARG

SET @ 6 BARG

SET @ 6 BARG

SET @ 8 BARG

SET @ 8 BARG

SET @ 6 BARG

201-VS-001APRODUCTIONSEPARATOR

201-FY-001A

HEATER TREATER

201-VS-001BPRODUCTIONSEPARATOR

201-FY-001B

HEATER TREATER

221-TA-001A/B

Oil Storage Tank

221-PA-002A/B/C

Oil Transfer Booster Pumps

221-PA-001A/B/C

Oil Transfer Pumps

221-TA-002

Off-spec Oil Tank191-VL-001

RO

ATM FL

ATM FL

PV

AL

PV

FarhaSaiwan Pipeline

201-FY-001C

HEATER TREATER

LC

LC

LF

LF FG

PV

LF FG

PW

PWPW

LF

LF

LFLF

LF

LF

LF

LF

LF

201-VS-001CPRODUCTIONSEPARATOR

FGFG

FGFG

PW

PW

LC

LC

PWPW

LC

LC

LC

PW PW

LF = Low Pressure Flare AF = Atmospheric Flare

FG = Fuel Gas SystemPW = Produced Water

LC = Level Control ValvePV = Pressure Control Valve

FC = Flow Control Valve

INLET MANIFOLD201-XY-001A/B

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2.2.2 Saiwan Crude Treatment Facility

The Saiwan Plant is a sour facility and is currently served by a single Inlet Manifold (200-XY-

001A). However, it is envisaged that a second Inlet Manifold (200-XY-001A) will be required for

processing of SHAHD “H” and “I” produced well fluids. Each of the Inlet manifolds shall be able

to route well produced fluids to either of the two separation trains at Saiwan.

Under Phase 2B, the produced well fluids from Saiwan East wells and SHAHD “H” and “I” wells

are to be routed to the Production Separators (200-VS-001A/B) (Trains 1 & 2) where

separation takes place. The separator produced water is routed to the Evaporation Pond (590-

TM-001) and the produced crude oil is routed to the relevant Heater Treater (200-FY-001A/B)

for dehydration via heat treatment and further separation. Each separation train is served by a

dedicated Heater Treater unit. The produced gas from the Production Separators (200-VS-

001A/B) is routed to the H2S Removal Package and the produced gas from the Heater Treaters

(200-FY-001A/B) is routed to the Fuel Gas System. Currently, the H 2S Removal Package is not

in use and therefore the Separator produced gas is routed towards the Fuel Gas System. The

surplus gas from the Fuel Gas System is diverted to the LP Flare KO Drum (230-VN-001) by way

of a Pressure Control Valve (420-PV-401) upstream of the Fuel Gas Filter and then routed to

the LP Flare (230-FC-001) after knockout of any entrained liquids. Any produced water from

the Heater Treaters is routed to the Evaporation Pond (590-TM-001). The stabilised crude

from the Heater Treater units is routed to the Crude Oil Storage Tanks (220-TA-001A/B) and

then exported using Oil Transfer Booster Pumps (220-PA-002A/B/C) and Oil Transfer Pumps

(220-PA-001A/B/C) to Alam Station via a piggable 16” Export Pipeline. Gas from the Crude OilStorage Tanks (220-TA-001A/B) is routed to the AP Flare KO Drum (230-VN-002) under

pressure control from where it is routed to the AP Flare (230-FC-002) after knockout of any

entrained liquids.

Saiwan Facility also contains an Off-Spec Oil Tank (220-TA-002) which receives off-spec oil

from AP and LP Flare KO Drums (230-VN-001 & 230-VN-002), Closed Drain Drum (550-VA-001)

and Heater Treaters (200-FY-001A/B). The off-spec oil is routed to the inlet header of the

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Production Separators (200-VS-001A/B) (Trains 1 & 2). All skids are connected to the Closed Drain System. Figure 2.2.2.1 below shows an overview of the Saiwan

Crude Treatment Facility.

Figure 2.2.2.1: Saiwan Facility Overview

INLETMANIFOLD 200-XY-001A

INLETMANIFOLD 200-XY-001B

EXISTING FACILITY

ADDITIONAL TRAIN

FC

FC

LC

LC

LC

LC

LC

PV

PV

PV

PV

PV

LC

LC

SET @ 8 BARG

SET @ 6 BARG

SET @ 6 BARG

SET @ 8 BARG

200-VS-001APRODUCTIONSEPARAT OR

200-FY-001AHEATER TREATER

200-VS-001BPRODUCTIONSEPARAT OR

200-FY-001BHEATER TREATER

220-TA-001A/B

Oil Storage Tank

220-PA-002A/B/COil Transfer Booster Pumps

220-PA-001A/B/COil Transfer Pumps

220-TA-002Off-spec Oil Tank

190-VL-001

RO

ATM FL

ATM FL

PV

AL

PV

SaiwanAlamPipeline

LC

LF

LF FG

PV

LF FG

PW

PWPW

LF

LF

LFLF

LF

FGFG

PW

LC

LC

PWPW

LC

LF = Low Pressure Flare AF = Atmospheric FlareFG = Fuel Gas SystemPW = Produced Water

LC = Level Control ValvePV = Pressure Control Valve

FC = Flow Control Valve

Farha Crude

SHAHD Crude

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2.3 Station Production Capacities – Phase 2B

Required station production capacities considering Phase 2B expansion for Farha and Saiwan

Production Facilities are provided in Tables 2.3.1 and 2.3.2 below.

Table 2.3.1: Farha Facility Required Production Capacities

Farha Production Facility (Scenario 1 – Maximum Oil Flow)

Description

Required

Production

Capacity

Required Production

Capacity with 10 %

Overdesign on Flow

Required Production

Capacity with 20 %

Overdesign on Flow Units

Oil Production from 3 Separation Trains

for Export to Saiwan Storage Tanks 22000 24200 26400 BOPD

Gas to Fuel Gas System from 3 Separation

Trains 0.6 0.66 0.72 MMSCFD

Gas to Flare from Storage Tanks 1.5 1.65 1.8 MMSCFD

Produced Water from 3 Separation Trains

(Scenario 2 – Max Water from 3Separation Trains)

3980(17144)

4378(18858.4)

4776(20572.8) BWPD

Table 2.3.2: Saiwan Facility Required Production Capacities

Saiwan Production Facility (Scenario 2 - Maximum Overall Flows)

Description

Production

Capacity

Production Capacity

with 10 % Overdesign

on Flow

Production Capacity

with 20 % Overdesign

on Flow Units

Oil Production from 2 Separation

Trains (Saiwan + SHAHD) 20000 22000 24000 BOPDGas to Fuel Gas System from 3

Separation Trains 5.66 6.226 6.792 MMSCFD

Gas to Flare from Storage Tanks 0.5 0.55 0.6 MMSCFD

Produced Water from 2 Separation

Trains 28000 30800 33600 BWPD

SHAHD Crude to Storage Tanks 30000 33000 36000 BOPD

Total Crude for Export to Alam Station

after Flashing in Atm. Storage Tanks 71000 78100 85200 BOPD

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3 OBJECTIVE

The objective of this document is to establish and determine the adequacy of the existing

facilities considering the Phase 2B expansion which will see two additional Separation Trains

added to the Farha Crude Treatment Plant and a single additional Separation Train added to the

Saiwan Crude Treatment Plant.

4 SCOPE OF WORK

The scope for the adequacy checks for both Farha and Saiwan Crude Treatment Plants is as per

CCED work instruction number CCED-WI-14-629-021 Rev.02R1

and is to be conducted to

international standards and in line with existing CCED philosophies and criterion as stated within

the “Process Design Basis” document number JS1006-X-F06-0501-C2R2

.

The Saiwan H2S Removal Package is excluded from the scope of work regarding adequacy checks.Fuel Gas Systems, Fire Fighting Facilities and future Water Treatment Plants for both Farha and

Saiwan are also excluded from the scope of work for the adequacy checks under this study.

5 FARHA & SAIWAN PLANT PROCESS SIMULATIONS

5.1 Objective of Simulation

The objective of the simulation is to form a basis for developing operating envelopes for the

main process vessels and pumps in addition to carrying out calculations for adequacy checks

of main headers, utilities and a basis to carry out Pipesim hydraulic simulations for the Export

Pipelines.

5.2 Farha Simulation Description

The process was modelled as a two stage separation flash with three separation trains

operating in parallel. Each separation train consists of a Separator and a Heater Treater unit.The Heater Treater acts as the second stage of separation whereby the Separator produced oil

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is heat treated to aid the second stage of separation. The Heater Treater produces gas and

stabilised oil with very little or no produced water.

The unsaturated reservoir fluid is flashed at reservoir conditions and then mixed with water at

reservoir conditions to obtain a flowline composition to the plant. Volumes of unsaturated

reservoir fluid and water used were such as to fit the plant production profile defined by the

two scenarios as per CCED work instruction number CCED-WI-14-629-021 Rev.02

R1

anddetailed in Section 5.5 of this study report.

The plant production profile GOR was not forced within the simulation to obtain volumes as

defined by CCED work instruction number CCED-WI-14-629-021 Rev.02R1

. The reservoir fluids

were simply allowed to flash at the normal operating conditions within the Separators (8

Barg), Heater Treaters (6 Barg) and Atmospheric Storage Tanks and the volume of gas

produced was accepted as the final gas production volumes for the facility. Produced gas from

Separators and Heater Treaters was considered as the normal gas supply to the Fuel Gas

System and produced flashed gas from the Atmospheric Storage Tanks was considered as gas

to be normally flared.

Figure 5.2.1 overleaf shows the simulation PFD for Farha Crude Treatment Facility.

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5.3 Saiwan Simulation Description

The process is modelled as a two stage separation flash with two separation trains operating

in parallel. Each separation train consists of a Separator and a Heater Treater unit. The Heater

Treater acts as the second stage of separation whereby the Separator produced oil is heat

treated to aid the second stage of separation. The Heater Treater produces gas and stabilised

oil with very little or no produced water.

For Saiwan Crude Treatment Facility, two different compositions of reservoir fluids were used

namely, SHAHD and Saiwan East (one per separation train). The unsaturated reservoir fluid

was mixed with water at reservoir conditions to obtain a flowline composition to the plant.

Volumes of unsaturated reservoir fluids and water used were such as to fit the scenarios

defined by CCED and detailed in Section 5.5 of this study report.

The GOR was not forced within the simulation to obtain any defined value but rather the

reservoir fluids were simply allowed to flash at the normal operating conditions within the

Separators (8 Barg), Heater Treaters (6 Barg) and Atmospheric Storage Tanks and the volume

of gas produced was accepted as the final gas production volumes for the facility. Produced

gas from Separators and Heater Treaters was considered as the normal gas supply to the Fuel

Gas System and produced flashed gas from the Atmospheric Storage Tanks was considered as

gas to be normally flared.

Figure 5.3.1 overleaf shows the simulation PFD for Saiwan Crude Treatment Facility.

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Figure 5.3.1: Saiwan Simulation PFD

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5.4 Base Data and Assumptions

5.4.1 Compositions

Composition for Farha reservoir fluid and data to define pseudo-components was taken from

a PVT report by Schlumberger “FS-53 Final PVT Barik”R3 and shown in Table 5.4.1.1 below and

Tables 5.4.1.2 and 5.4.1.3 overleaf.

Table 5.4.1.1: Farha Composition

Components

Bottomhole

Sample Components

Bottomhole

Sample

(g/mol) wt % mole % (g/mol) wt % mole %

N2 0.16 0.96 C16 2.92 2.16

CO2 0.02 0.06 C17 2.84 1.98

H2S 0 0 C18 2.85 1.87

C1 0.01 0.15 C19 2.83 1.78

C2 0.46 2.55 C20 2.4 1.44

C3 2.43 9.08 C21 2.28 1.29

i-C4 0.96 2.73 C22 2.14 1.16

n-C4 2.39 6.76 C23 2.03 1.05

i-C5 1.34 3.06 C24 1.91 0.95

n-C5 1.87 4.26 C25 1.79 0.85

C6 3.24 6.36 C26 1.68 0.77

C7 3.63 6.24 C27 1.65 0.73

C8 4.36 6.72 C28 1.58 0.67C9 3.82 5.2 C29 1.58 0.65

C10 4.1 5.05 C30 1.5 0.59

C11 3.53 3.95 C31 1.44 0.55

C12 3.1 3.17 C32 1.28 0.47

C13 3.54 3.33 C33 1.21 0.44

C14 3.27 2.84 C34 1.16 0.41

C15 3.43 2.74 C35 1.07 0.36

C36+ 16.2 4.63

Total 100 100

Molar Mass(g/mol) 164.78

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Table 5.4.1.2: Farha Compositional Properties of Bottomhole Sample

Table 5.4.1.2: Farha Zero Flash Properties of Bottomhole Sample

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Composition for Saiwan reservoir fluid and data to define pseudo-components was taken from

a PVT Analysis report prepared by Weatherford “SE2-(Saiwan East) Final PVT Report 15-07-

2009”R4

and shown in Table 5.4.1.3 below.

Table 5.4.1.3: Saiwan Composition

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Composition for SHAHD ‘H’ & ‘I’ reservoir fluids and data to define pseudo-components

was taken from a PVT Analysis report prepared by SGS “Oman CCED Well SHH-1 Prelim

Report 04-July-2015”R5

and shown in Table 5.4.1.4 below.

Table 5.4.1.4: SHAHD Composition

All molecular weights used in the simulations matched those stated by the individual PVT

reports.

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5.4.2 Key Component Conditions

The key component (equipment) operating conditions used for the simulation are as per Table

5.4.2.1 below.

Table 5.4.2.1: Key Component Operating Conditions for Simulation

Description Temperature (OC) Pressure (Barg)

Farha Reservoir 57.16 140.9

Saiwan Reservoir 61.5 179

SHAHD Reservoir 82 90

Production Separators (Farha & Saiwan) 20 5

Heater Treaters (Farha & Saiwan) 67 4

Atmospheric Storage Tanks (Farha & Saiwan)

66.7 (actual on

P&ID 58.6)

0.98 (actual on

P&ID 0.1)

5.5 Simulation Cases & Production Profile Scenarios

5.5.1 Simulation Cases

Two cases where considered for simulation for both Farha and Saiwan Plants. The first was

winter case (20OC at inlet to Production Separators) and the second was a summer case

simulation (55

O

C at inlet to Production Separators). However, for purposes of Heat & MassBalances

A1, only the normal operating conditions were considered which correspond to the

winter case simulation models.

The adequacy checks were therefore carried out with normal operating conditions (winter

case data). The data from the summer case model was not used to carry out adequacy checks

for both Farha and Saiwan Crude Treatment Facilities. The simulation case files can be found

under reference 6 of this study document.

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5.5.2 Production Profile Scenarios and Simulation Comparison

Two scenarios were considered for both Farha and Saiwan Plants. The scenarios are detailed in the following tables along with actual simulation values used and

corresponding flow deviations:

Table 5.5.2.1: Farha Production Profile Scenarios vs Simulation Values & Flow Deviations

Description

Plant

Oil

Product

ion

(BOPD)

Plant

Produced

Water

(BWPD) Reference

Simulation

Oil Value

(BOPD)

Simulation

Water

Value

(BWPD)

Simulation

Total

Produced

Gas

(MMSCFD)

Farha Scenario 1 22128 3980 CCED-WI-14-629-021 Rev.02R1 23180 4089 2.2758

Farha Scenario 2 4956 17144 CCED-WI-14-629-021 Rev.02R1

5192 17610 0.5031

Flow Deviation Scenario 1 (%) N/A N/A N/A 4.7542 2.7387 N/A

Flow Deviation Scenario 2 (%) N/A N/A N/A 4.7619 2.7182 N/A

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Table 5.5.2.2: Saiwan (Saiwan East Crude Only) Production Profile Scenarios vs Simulation Values & Flow Deviations

Description

Separator

Oil

Production

(BOPD)

Produced

Water

(BWPD) Reference

Simulation

Oil Value

(BOPD)

Simulation

Water

Value

(BWPD)

Simulation Produced

Gas (Separator +

Heater Treater)

(MMSCFD)

Saiwan Scenario 1 & 2 (Saiwan

Crude) 10000 23333

Max Separator throughput capacity of oil

based on 30 mins residence time

(Separator MRB Reference R8) - 70 %

Water Cut - CCED Instruction 10460 24020 1.1162

Flow Deviation (%) N/A N/A N/A 4.6000 2.9443 N/A

Table 5.5.2.3: Saiwan Total Produced Gas

Description Simulation Total Produced Gas (MMSCFD)Saiwan Scenario 1 2.6669

Saiwan Scenario 2 6.1581

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Table 5.5.2.4: Saiwan (SHAHD Crude Only) Production Profile Scenarios vs Simulation Values & Flow Deviations

Description

Train 2 Oil

Production

(BOPD)

Produced

Water

(BWPD) Reference

Simulation

Oil Value

(BOPD)

Simulation

Water

Value

(BWPD)

Simulation Produced

Gas (Separator + Heater

Treater) (MMSCFD)

Saiwan Scenario 1

(SHAHD 'H' & 'I' Crude) 2972 1161

SHAHD Production Profile - Max

Combined Values - Reference R7 2591 1214 1.2645

Saiwan Scenario 2

(SHAHD 'H' & 'I' Crude) 10000 3908

10,000 throughput as an absolute

maximum SHAHD production

figure. Cut same as scenario 1 -

28.1 % 9329 4368 4.5513

Flow Deviation

Scenario 1 (%) N/A N/A N/A -12.8197 4.5650 N/A

Flow Deviation

Scenario 2 (%) N/A N/A N/A -6.7100 11.7707 N/A

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In addition to the production values provided under Section 5.5.2, an additional volume of

30,000 BOPD of SHAHD stabilised crude and approximately 23,000 BOPD of Farha stabilised

crude is added to the Saiwan Storage Tanks for export to Alam Station via the Saiwan – Alam

Export Pipeline. PFDsA6&A7

for Farha and Saiwan are to be referenced alongside the Heat and

Mass Balance DocumentA1

and can be found as attachments to this Study Report.

6 FARHA PROCESS EQUIPMENT

6.1 Inlet Manifold (201-XY-001B)

The Inlet Manifold (201-XY-001B) serves the main Farha Crude Treatment Facility and provides

feed input from the wells to the Production Separators (201-VS-001A/B/C).

The Production Header of the Inlet Manifold was evaluated based upon the new worst case

flow (Scenario 1) in order to check the adequacy. Based on the calculationA8

performed, it was

found that the Production Header is adequate to handle the new increased flow. The flow

regime determined is slug and bubble flow. No details were available regarding the length of

the Production Header so a check was made simply using the nominal diameter of Pipe.

6.2 Production Separators (201-VS-001A/B/C)

All Farha Production Separators process the same well fluids and are operated in parallel to

each other and therefore see the same flow rates with regards to inputs to and outputs from

the Separator.

An operating envelope was developed based upon Scenario 1 which is the worst case with

respect to highest flow rates for both gas and liquid. It was found that the limiting factors are

the gas and liquid nozzle capacities. The upper limit for the gas nozzle capacity is 89500 Sm3/d

and that for the liquid nozzle capacity is 1576 m3/d.

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Based on scenario 1, the Production Separators would be operating within the operating

envelope at a gas capacity of 744.72 Sm3/d and a liquid capacity of 1460.136 m

3/d. BS&W data

was not available and therefore the water cut percentage was used to signify BS&W % vol/vol.

The operating envelope chartA10

is attached to this Study Report. The chart contains a black

dot, showing the operating flows of the Production Separator after the addition of 2 identical

separation trains. It is therefore concluded that the Production Separators are adequate for

operation under both scenarios 1 & 2.

The operating envelope was developed in line with API Spec 12J guidelinesR10

and references

are also made to DEPs. The Farha Production Separator MRBR9

was also referenced alongside

P&IDs in order to obtain the required information for input to the operating envelope sheet.

6.3 Dehydration (Heater Treaters 201-FY-001A/B/C)

All Farha Heater Treaters process the same crude output from their respective upstream

Production Separators which operate in parallel to each other.

An operating envelopeA11

was developed based upon Scenario 1 which is the worst case with

respect to highest crude oil flow rates. The operating envelope lies between the inlet nozzle

capacity, gas nozzle capacity and liquid nozzle capacity. The Farha Heater Treater GAR11

was

used to obtain information for input to the operating envelope sheet.

Currently, based on scenario 1, the Heater Treater is operating with a liquid flow rate of

1247.52 m3/day and a gas flow rate of 486.24 m

3/day. These values are within the established

operating envelope limits and we can therefore conclude that all three Heater Treater units

are adequate for service with respect to the increased production. The operating envelope

chartA11

is included as an attachment to this Study Report.

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6.4 Oil Storage

Farha Plant has two Crude Oil Storage (Tanks 221-TA-001A/B) which are identical in

dimensions and therefore storage capacity. Each has a capacity of 3843 m3 and based upon

the Process Design BasisR2

, each must have a capacity corresponding to 48 hrs of production.

The idea is that one tank will be in service whilst the other is acting as a standby. The gas

flashing off at the Storage Tanks is sent directly to the AP Flare under pressure control and so

we will only be considering the volume of crude oil production. Based on Scenario 1 which is

the maximum production case, the production rate is 146.6 m3/hr. This equates to 7036.8 m

3

of crude oil production over a 48 hour period.

Based upon the sizing and sparing philosophy as per the Process Design BasisR2

, the Crude Oil

Storage Tanks are inadequate. This effectively means that neither of the two tanks can act as a

standby. However, if the philosophy is changed to a 24 hour production limit per Tank, then

both tanks are adequate for 24 hrs of production and either one can be used as a standby tank

whilst the other is in operation.

It is recommended to increase the number of Storage Tanks during the detail design stage of

Phase 2B expansion project.

The Off –Spec Storage Tank is also inadequate when considering capacity to be equal to 24hrs

of normal crude production based on scenario 1. The capacity for the Off –Spec Storage Tank

is 2830 m3, whereas the required capacity based on 24 hrs crude oil production as per the

Process Design BasisR2 is 3518.4 m3.

6.5 Oil Export (Export Pumps & Pipeline)

6.5.1 10” Pipeline Farha to Saiwan

The 10” Export Pipeline from Farha to Saiwan was found to be adequate for the higher flow

scenario 1. PipesimA29

was used to simulate the Export Pipeline and the elevations used were

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as per the elevation file provided by CCEDR12

. Pressure drops and velocities were satisfactory

and acceptable. For detailed results, please make reference to the PipeSim simulation fileR14

.

6.5.2 Oil Transfer Booster Pumps (221-PA-002A/B/C) & Oil Transfer Pumps (221-PA-001A/B/C)

The volume of crude oil to be exported from Farha to Saiwan (Scenario 1) is the equivalent of

153.6 m3/hr. Each of the Oil Transfer Booster Pumps and Oil Transfer Pumps are already rated

for 73 m3/hr. The pumps will be used based upon a 2 working and 1 standby philosophy.

This means that each pump should be able to pump 76.8m3/hr of crude to Saiwan Storage

Tanks. The new pumping rate is not that much more than the existing rated flow and after

plotting on the original vendor supplied pump curves, it emerged that the pumps were

adequate with little or no difference in specifications. The marked pump curvesA12

are

attached to this Study Report.

7 SAIWAN PROCESS EQUIPMENT

7.1 Inlet Manifold

The Inlet Manifold (200-XY-001A) serves the Saiwan Crude Treatment Facility and provides

feed input from Saiwan East wells to the Production Separators (200-VS-001A/B).

The Production Header of the Inlet Manifold was evaluated based upon the new worst case

flow (10,000 BOPD throughput of Saiwan East Crude) in order to check the adequacy. Based

on the calculationA9

performed, it was found that the Production Header is adequate to handle

the new increased flow. The flow regime determined is slug flow. No details were available

regarding the length of the Production Header so a check was made simply using the nominal

diameter of Pipe.

A second Inlet Manifold (200-XY-001B) will be required to provide SHAHD ‘H’ & ‘I’ produced

well fluids to Train 2 of Saiwan Crude Treatment Plant. This would need to be sized during

detailed design of Phase 2B of the expansion project.

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7.2 Production Separators (200-VS-001A/B)

Production Separators at Saiwan, process two types of well-produced fluids. Saiwan East wells

are processed in Train 1 and SHAHD ‘H’ & ‘I’ are processed in Train 2. The higher flow rate case

for Saiwan is Scenario 2.

An operating envelopeA13

was developed based upon Scenario 2 which is the worst case with

respect to highest flow rates for both gas and liquid. It was found that the limiting factors are

the gas and liquid nozzle capacities. The upper limit for the gas nozzle capacity is 98400 Sm3/d

and that for the liquid nozzle capacity is 1576 m3/d.

Based on scenario 2, the Production Separator (200-VS-001A) with Saiwan produced well

fluids is to operate outside of the established operating envelope at a gas capacity of 22924.8

Sm3/d and a liquid capacity of 5385.36 m

3/d. BS&W data was not available and therefore the

water cut percentage of 70 % was used to signify BS&W % vol/vol.

The operating envelope chartA13

is attached to this Study Report and contains a black dot,

showing the operating flows of the Production Separator after the addition of an identical

separation train. The additional Separator is to be used to process SHAHD produced well

fluids. It is concluded that the Production Separator (200-VS-001A) is inadequate for operation

under both scenarios 1 & 2 for Saiwan East Wells.

The operating envelope was developed in line with API Spec 12J guidelines R10 and references

are also made to DEPs. The Saiwan Production Separator MRBR8

was also referenced alongside

P&IDs in order to obtain the required information for input to the operating envelope sheet.

The second Production Separator (200-VS-001B) was evaluated using SHAHD produced well

fluids and a similar operating envelopeA14

was prepared. Based on scenario 2, it was found

that the Production Separator (200-VS-001B) is inadequate to handle processing of SHAHD

produced well fluids.

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7.3 Dehydration (Heater Treaters 200-FY-001A/B)

Operating envelopes were developed for both the Saiwan Heater Treater units and it was

concluded that they are adequate to handle both Saiwan and SHAHD well produced fluids.

Under scenario 2, both are operating within the limits of the defined operating envelopeA15 &

A16. The Saiwan Heater Treater GAR14 was used alongside Unisim to obtain information for

input to the operating envelope sheet.

7.4 Oil Storage

Saiwan Plant has two Crude Oil Storage (Tanks 220-TA-001A/B) which are identical in

dimensions and therefore storage capacity. Each has a capacity of 5420 m3 and based upon


, each must have a capacity corresponding to 48 hrs of Saiwan Plant

production only (excluding Farha). The Saiwan Plant maximum production is 1667.04 m3/d

which equates to 3334.08 m3

over a period of 48 hrs. The idea is that one tank will be in

service whilst the other is acting as a standby. The gas flashing off at the Storage Tanks is sent

directly to the AP Flare under pressure control.

Based upon the sizing and sparing philosophy as per the Process Design BasisR2

, the Crude Oil

Storage Tanks are adequate.

It is noted however that we have a continuous supply of stabilised Farha and SHAHD crude

being added to the Saiwan Storage Tanks on a daily basis. At maximum flow, this amounts to

10383.84 m3/day of crude heading to Saiwan Storage Tanks. Based upon this figure, the

storage tanks would need to be operated in parallel as opposed to one being a standby tank

and we would be inclined to say that the tanks are inadequate with respect to the

standby/sparing philosophy as per the Process Design BasisR2

.

It is recommended to increase the number of Storage Tanks during the detail design stage of

Phase 2B expansion project.

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The Off –Spec Storage Tank is however adequate when considering capacity to be equal to

24hrs of normal crude production based on scenario 2. The capacity for the Off –Spec Storage

Tank is 2830 m3, whereas the required capacity based on 24 hrs crude oil production as per


is 1667.04 m3.

7.5 Oil Export (Export Pumps & Pipeline)

7.5.1 16” Pipeline Saiwan to Alam

The 16” Export Pipeline from Saiwan to Alam is found to be adequate for the highest peak

flow from Saiwan. PipesimR16

was used to simulate the Export Pipeline and the elevations used

were as per the elevation file provided by CCEDR13

. Pressure drops and velocities were

satisfactory and acceptable. For detailed results, please make reference to the PipeSim

simulation fileA30

.

7.5.2 Oil Transfer Booster Pumps (220-PA-002A/B/C) & Oil Transfer Pumps (220-PA-

001A/B/C)

The volume of crude oil to be exported from Saiwan to Alam (Scenario 2) is the equivalent of

493.4 m3/hr. Each of the Oil Transfer Booster Pumps and Oil Transfer Pumps are already rated

for 116 m3/hr.

Referencing the vendor supplied pump curves it was observed that for the Booster Pumps,

one can operate them on a 2 working and 1 standby philosophy but it means one is at the end

of the performance curves and the pumps are likely to be inefficient. Ideally one would want

to carry out this operation with 3 working pumps at a rate of 164.4m3/hr per pump. One

would require at least 1 spare for this operation.

For the Oil Transfer Pumps, the situation is worse whereby a 3 working pump (164.4m3/hr per

pump) operation leaves you at the end of the performance curves and ideally one would

require 4 working pumps to attain the required export pumping rate of 123.35 m3/hr per

pump. One would need at least 2 spares for this operation.

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The marked pump curvesA17

are attached to this Study Report.

8 FARHA UTILITIES (Excluding Electrical)

8.1 Instrument Air System

The total instrument and utility air consumption for Farha Plant is calculated to be 71.56

Nm3/hr

A2. This consumption figure takes into account all instrument air requirements for Plant

Control Valves and Shutdown Valves and also Utility Air Consumption for Heater Treater

Burners for the three trains. It also takes into account an additional 10 % for purposes of jet

cleaning during maintenance of plant equipment.

The current capacity of the Instrument Air Package is 70 Nm3/hr and is therefore inadequate.

It is recommended that another Instrument Air Package be employed in order to satisfy the

instrument air requirements and ensuring plant safety and shutdown is not compromised.

8.2 Chemical Dosing Packages

The Demulsifier Package (121-XX-001) is found to be inadequate. Considering the

incorporation of two more separation trains at Farha, the minimum delivery required for the

demulsifying agent is 18 litres per hour. The current dosing pumps are rated at a maximum

flow rate of 15 litres per hour. An additional demulsifier package will be required at Farha

Plant.

The Corrosion Inhibitor Package (121-XX-002) is found to be adequate and no additional

package is required at the Farha Plant considering the incorporation of two additional

separation trains.

For 3 Separation Trains, the total corrosion inhibitor dosing rate is 0.006m3/hr. This equates to

1.008 m3

of corrosion inhibitor requirement for 7 days. The Storage Tank is thereforeadequate based on 7 days storage as per the Process Design Basis

R2.

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The total demulsifier dosing rate is 0.018m3/hr. This equates to 3.024 m

3of demulsifier

requirement for 7 days. The Demulsifier Storage Tank is therefore inadequate based on 7 days

storage as per the Process Design BasisR2

.

8.3 Diesel Storage System

The Diesel Storage System for Farha is found to be adequate considering the incorporation of

the additional two separation trains except for the Diesel Storage Tank whose capacity is 295

m3 and the required capacity is calculated to be 299.154 m

3. The philosophy followed for the

adequacy check is as per the Process Design BasisR2

. Table 8.3.1 overleaf shows the calculated

values and corresponding checks.

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Table 8.3.1: Farha Diesel Storage System Evaluation

Diesel Storage - Farha

Description Rate Unit New Requirements Units Remarks

Diesel Unloading

Pumps (431-PA-

001A/B) 30 m3/hr N/A N/A Adequate

Diesel Transferpumps (431-PA-

002A/B) 10 m3/hr 0.8252 m

3/hr

Adequate Excludingintermediate for Fire

System

Diesel supply pumps

to HT (201-PD-

001A/B) 0.212 m3/hr 0.1652 m

3/hr Adequate

Diesel Storage Tank

Capacity (431-TA-

001) 295 m3 299.154 m

3 Inadequate

Heater Treater

Diesel Day Tank

(201-TA-001) 4 m3 3.9648 m

3

Adequate 24 Hours

Supply

DG SETS Diesel Day

Tank (431-TA-002) 18 m3 15.84 m

3

Adequate 24 Hours

Supply

Diesel Consumption

1. DG Sets 0.66 m3/hr N/A N/A

Based on 3 working +

0 Standby

2. Heater Treater

Consumption (3

trains) 0.1652 m3/hr N/A N/A N/A

3. Fire Water System 2.082 m3 N/A N/A Intermediate

Based on 15 daysconsumption size

required for Diesel

Storage Tank 299.154 m3 N/A N/A N/A

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8.4 Flaring System

Following are the assumptions used for the LP Flare study:

The LP Flare modelA28

was configured as per the overall plot planR16

and collection

network using Aspen flare system analyser version 2007.3.

The isometrics for the piping length and fittings inside the Separator and Heater

Treater skid limits were not available at the time of the adequacy check and were

assumed as 3m for tail pipe length and 10m for 4” subheader length.

Maximum allowable back pressure for relief valves fitted with bellows was limited to

30 % of the set pressure and that for conventional relief valves was limited to 10 % of

the set pressure.

Mach number was limited to 0.5 for sub-headers and header, whereas for tail pipes it

was limited to 0.7.

System back pressure (or superimposed back pressure) was maintained at 1.5 bara.

Tail pipes were sized for rated flow for each scenario.

Sizing method for vapor was selected as API 1976 and for two-phase flow, sizing

method of API 2000 was adopted for the LP Flare model.

Maximum size of the fire circle encountered for simultaneous fire relief per scenario

was considered as an area of 232 m2 equal to 17.18 m diameter as per API 521

Addendum, May 2008.

Flare Capacity and Backpressure Assessment Scenarios

The capacity and backpressure assessment for the LP Flare Header, Sub-Header and tailpipeswas carried out based on various relief contingencies using Aspen Flarenet version 2007.3.

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The maximum size of the external fire zone encountered was calculated and valves relieving

simultaneously to the LP Flare were grouped according to the identified fire zone.

Capacity and backpressure assessment for the LP Flare was based upon the following three

scenarios described below:-

Fire Zone 1 & Scenario 1

201-PSV-103A/104A (Production Separator 1)

201-PSV-201A/201B (Heater Treater 1)

421-PV-280 (normal relief from Fuel Gas Control Valve)


201-PSV-103B/104B (Production Separator 2)




201-PSV-103C/104C (Production Separator 3)



The scenarios consider relief via individual or combination of relief valves depending on the

number of equipment falling into the maximum area of the determined fire zone. Three fire

zones were identified.

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The outcome of these scenarios was checked against the existing flare capacity, the allowable

velocity limit (Mach No) & allowable backpressure limit in the event of simultaneous relief

from RVs to the LP Flare System.

The existing flare capacity of Farha is 25,500 kg/h as per the existing P&ID JS1006-F-F02-0700-

001 Rev AB.

The Flare System for Farha is found to be adequate except for the LP Flare Knockout Drum

which is inadequate based on momentum criteria at the inlet nozzle. The results can be found

in the summary tablesA24

. All vessel Relief Valves are adequate for blocked outlet, except for

the Heater Treater Relief Valves which are inadequate for the external fire case scenario.

The AP Flare capacity is 9140 Kg/hr and is adequate for the maximum relief load to AP Flare

from Crude Oil Storage Tanks for Farha Scenario 1 of 4092 Kg/hr.

8.5 Nitrogen

The Nitrogen System is hugely inadequate with respect to API2000R8

. Considering the Storage

Tank 221-TA-001A, a calculationA4

was performed based upon two working and 1 standby Oil

Transfer Booster Pumps (221-PA-002A/B/C) at maximum pumping rates. A summary of the

results is shown in the table below.

Vessel

In-breathing (Nm³/h) Total In-breathing(Nm

3 /h)

Out-breathing (Nm³/h) Totaloutbreathing

(Nm3 /h)Liquid

MovementThermal

EffectLiquid Movement Thermal

Effect

Storage Tank(221-TA-001A) 132.2 33.4 165.6 155.2 8.57 163.8

The in-breathing requirement for just one of the two storage tanks amounts to 3974.4 Nm3 of

nitrogen per day. Based upon the philosophy as depicted by the Process Design BasisR2

, the

Nitrogen System is to be sized for a back-up of 3 days. This amounts to 11923.2 Nm3 of

nitrogen required for blanketing of just one Storage Tank alone during normal operation.

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There is a second Storage Tank (221-TA-001B) which is used as a standby and also the Off-Spec

Tank (221-TA-002) which are to be considered whilst calculating the required nitrogen for

blanketing purposes but considering the current Nitrogen System capacity is 1920 Nm3, we

already know that this system is inadequate for purpose and at best can only supply

blanketing gas to one Storage Tank under normal operation for 11.5 hours.

Further to the above, it is very unlikely that the current Crude Storage Tanks fit the sizing

philosophy for Storage Tanks as per the Process Design BasisR2

i.e. one tank to be sized for 48

hrs of normal production. This would mean further Storage Tanks and therefore a much

greater requirement of nitrogen than what is foreseen above. The Nitrogen System should be

re-sized during the detailed design stage of Phase 2B of the expansion project.

8.6 Utility Water

The utility water adequacy check was carried out based upon a daily utility water consumption

value of 250 litres per day (0.25 m3/day) per user based upon the Process Design Basis

R2. This

amounts to 3.75 m3 consumption of utility water per user for a minimum period of 15 days

based upon guidelines as set by the Process Design BasisR2

.

Based upon the capacity of the Water Storage Tank 521-TA-001 (160 m3), the storage is

enough for 42 users per day for a period of 15 days. The Utility Water Pumps (521-PA-001A/B)

are more than adequate with a peak flow rate of 8 m

3

/hr. As per the Process Design Basis

R2

,this value is stated to be 5 m

3/hr as a maximum.

The Utility Water System is therefore adequate, as it fulfils all criteria as set out in the Process

Design BasisR2

.

8.7 Closed Drain System

As per the Process Design BasisR2

, the Closed Drain Drum must be sized for the liquid hold up

of one process vessel other than the Crude Oil Storage Tanks. The process vessel with the

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highest volume of liquid hold up is likely to be the Production Separator. Based upon the High-

High Level of the Production Separator (201-VS-001A), the volume of liquid held up in the

Separator equates to 13.8474 m3. The Closed Drain Drum (551-VA-001) has a capacity of 18.3

m3 and is therefore adequately sized.

Based upon the criteria set for the Closed Drain Pumps (551-PH-001A/B) as per the Process

Design BasisR2, the pump must be able to pump 0.942m3 of liquid from the Closed Drain Drum

within 30 minutes. With a rated flow of 10 m3/hr, the pump is more than adequate to handle

the required pump out criteria for the contained liquid. The volume of liquid held up was

calculated based upon the difference between high liquid level and low liquid level of the

Closed Drain Drum (400mm).

9 SAIWAN UTILITIES (Excluding Electrical)

9.1 Instrument Air System

The total instrument and utility air consumption for Saiwan Plant is calculated to be 59.39

Nm3/hr

A3. This consumption figure takes into account all instrument air requirements for Plant

Control Valves and Shutdown Valves and also Utility Air Consumption for Heater Treater

Burners for the two trains. It also takes into account an additional 10 % for purposes of jet

cleaning during maintenance of plant equipment.

The current capacity of the Instrument Air Package is 70 Nm3/hr and is therefore adequate.

9.2 Chemical Dosing Packages

The Demulsifier Package (120-XX-001) and the Corrosion Inhibitor Package (120-XX-002) are

found to be adequate and no additional packages are required at the Saiwan Plant considering

the incorporation of two additional separation trains.

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For 2 Separation Trains, the total corrosion inhibitor dosing rate is 0.008m3/hr. This equates to

1.344 m3 of corrosion inhibitor requirement for 7 days. The Storage Tank is therefore

adequate based on 7 days storage as per the Process Design BasisR2

.

The total demulsifier dosing rate is 0.01m3/hr. This equates to 1.68 m

3of demulsifier

requirement for 7 days. The Demulsifier Storage Tank is therefore adequate based on 7 days

storage as per the Process Design BasisR2.

9.3 Diesel Storage System

Constituent equipment for the Saiwan Diesel Storage System are found to be adequate except

for the Heater Treater Diesel Day Tank (200-TA-001), based upon the philosophy as per the

Process Design BasisR2

. Table 9.3.1 overleaf shows the calculated values and corresponding

checks.

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Table 9.3.1: Saiwan Diesel Storage System Evaluation

Diesel Storage - Saiwan

Description Rate Unit New Requirements Units Remarks

Diesel Unloading

Pumps (430-PA-

001A/B) 30 m3/hr N/A N/A Adequate

Diesel Transfer

pumps (430-PA-

002A/B) 12 m3/hr 0.7701 m

3/hr

Adequate Excluding

intermediate for Fire

System

Diesel supply pumps

to HT (200-PD-

001A/B) 0.122 m3/hr 0.1101 m

3/hr Adequate

Diesel Storage Tank

Capacity (430-TA-

001) 295 m3 278.277 m

3 Adequate

Heater Treater

Diesel Day Tank

(200-TA-001) 1.65 m3 2.6424 m

3

Not Adequate - 24

Hours Supply

DG SETS Diesel Day

Tank (430-TA-002) 20.4 m3 15.84 m

3

Adequate - 24 hours

supply

Diesel Consumption

1. DG Sets 0.66 m3/hr N/A N/A

Based on 3 working +

1 Standby

2. Heater Treater

Consumption (2

trains) 0.1101 m3/hr N/A N/A N/A

3. Fire Water System 2.082 m3 N/A N/A Intermediate

Based on 15 daysconsumption size

required for Diesel

Storage Tank 278.277 m3 N/A N/A N/A

9.4 Flaring System

Following are the assumptions used for the LP Flare study:

The LP Flare modelA28

was configured as per the overall plot planR17

and collection

network using Aspen flare system analyser version 2007.3.

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The isometrics for the piping length and fittings inside the Separator and Heater

Treater skid limits were not available at the time of the adequacy check and were

assumed as 3m for tail pipe length and 10m for 4” subheader length.

Maximum allowable back pressure for relief valves fitted with bellows was limited to

30 % of the set pressure and that for conventional relief valves was limited to 10 % of

the set pressure.

Mach number was limited to 0.5 for sub-headers and header, whereas for tail pipes it

was limited to 0.7.

System back pressure (or superimposed back pressure) was maintained at 1.5 bara.

Tail pipes were sized for rated flow for each scenario.

Sizing method for vapor was selected as API 1976 and for two-phase flow, sizing

method of API 2000 was adopted for the LP Flare model.

Maximum size of the fire circle encountered for simultaneous fire relief per scenario

was considered as an area of 232 m2 equal to 17.18 m diameter as per API 521

Addendum, May 2008.

Flare Capacity and Backpressure Assessment Scenarios

The capacity and backpressure assessment for the LP Flare Header, Sub-Header and tailpipes

was carried out based on various relief contingencies using Aspen Flarenet version 2007.3.

The maximum size of the external fire zone encountered was calculated and valves relieving

simultaneously to the LP Flare were grouped according to the identified fire zone.

Capacity and backpressure assessment for the LP Flare was based upon the following twoscenarios described overleaf:-

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200-PSV-003A/004A (Production Separator 1)




201-PSV-103B/104B (Production Separator 2)



The scenarios consider relief via individual or combination of relief valves depending on thenumber of equipment falling into the maximum area of the determined fire zone. Two fire

zones were identified.

The outcome of these scenarios was checked against the existing flare capacity, the allowable

velocity limit (Mach No) & allowable backpressure limit in the event of simultaneous relief

from RVs to the LP Flare System.

The existing flare capacity of Saiwan is 59,170 kg/h as per the existing P&ID JS1006-S-F02-

0663-001 Rev AB.

The Flare System for Saiwan is found to be adequate except for the LP Flare Knockout Drum

which is inadequate based upon the inlet nozzle momentum criteria. Also, the mach number

for the tailpipe of Production Separator Train 1 which is processing Saiwan crude is too high.

The results can be found in the summary tables A25. All vessel Relief Valves are adequate for

blocked outlet, except for the 1st

Train Production Separator (Saiwan Crude) and 2nd

Train

Heater Treater (SHAHD Crude) which are inadequate for the fire case scenario.

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The AP Flare capacity is 4200 Kg/hr and is adequate for the maximum relief load to AP Flare

from Crude Oil Storage Tanks for Saiwan Scenario 2 of 1204 Kg/hr.

9.5 Nitrogen

The Nitrogen System is hugely inadequate with respect to API2000R8

. Considering the Storage

Tank 220-TA-001A, a calculationA5

was performed based upon two working and 1 standby Oil

Transfer Booster Pumps (220-PA-002A/B/C) at maximum pumping rates. A summary of the

results is shown in the table below.

Vessel

In-breathing (Nm³/h) Total In-breathing(Nm

3 /h)

Out-breathing (Nm³/h) Total out-breathing(Nm

3 /h)Liquid

MovementThermal

Effect

LiquidMovement

ThermalEffect

Storage Tank

220-TA-001A 210.0 42.5 252.5 246.6 11.67 258.3

The in-breathing requirement for just one of the two storage tanks amounts to 6060 Nm3

of nitrogen per day. Based upon the philosophy as depicted by the Process Design BasisR2

,

the Nitrogen System is to be sized for a back-up of 3 days. This amounts to 18180 Nm3 of

nitrogen required for blanketing of just one Storage Tank alone during normal operation.

There is a second Storage Tank (220-TA-001B) which is used as a standby and also the Off-

Spec Tank (220-TA-002) which are to be considered whilst calculating the required nitrogen

for blanketing purposes but considering the current Nitrogen System capacity is 1920 Nm3,

we already know that this system is inadequate for purpose and at best can only supply

blanketing gas to one Storage Tank under normal operation for 7.5 hours.

Further to the above, it is very unlikely that the current Crude Storage Tanks fit the sizing

philosophy for Storage Tanks as per the Process Design BasisR2

i.e. one tank to be sized for

48 hrs of normal production. This would mean further Storage Tanks and therefore a much

greater requirement of nitrogen than what is foreseen above. The Nitrogen System should

be re-sized during the detailed design stage of Phase 2B of the expansion project.

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9.6 Utility Water

The utility water adequacy check was carried out based upon a daily utility water consumption

value of 250 litres per day (0.25 m3/day) per user based upon the Process Design Basis

R2. This

amounts to 3.75 m3 consumption of utility water per user for a minimum period of 15 days

based upon guidelines as set by the Process Design BasisR2.

Based upon the capacity of the Water Storage Tank 521-TA-001 (601 m3), the storage is

enough for 160 users per day for a period of 15 days. The Utility Water Pumps (521-PA-

001A/B) are more than adequate with a peak flow rate of 20 m3/hr. As per the Process Design

BasisR2

, this value is stated to be 5 m3/hr as a maximum.

The Utility Water System is therefore adequate, as it fulfils all criteria as set out in the Process

Design BasisR2

.

9.7 Closed Drain

As per the Process Design BasisR2

, the Closed Drain Drum must be sized for the liquid hold up

of one process vessel other than the Crude Oil Storage Tanks. The process vessel with the

highest volume of liquid hold up is likely to be the Production Separator. Based upon the High-

High Level of the Production Separator (200-VS-001A), the volume of liquid held up in the

Separator equates to 13.8474 m3. The Closed Drain Drum (550-VA-001) has a capacity of 18.3

m3 and is therefore adequately sized.

Based upon the criteria set for the Closed Drain Pumps (550-PH-001A/B) as per the Process

Design BasisR2

, the pump must be able to pump 0.942m3 of liquid from the Closed Drain Drum

within 30 minutes. With a rated flow of 10 m3/hr, the pump is more than adequate to handle

the required pump out criteria for the contained liquid. The volume of liquid held up was

calculated based upon the difference between high liquid level and low liquid level of the

Closed Drain Drum (400mm).

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10 FARHA MAIN HEADERS

The Crude Oil, Produced Water & Produced Gas Headers were all found to be adequate with

respect to the increased plant production.

The plant isometrics were used to evaluate lengths and equivalent lengths for fittings were

calculated and used in the final calculation for adequacy.

For the Crude Oil and Produced Gas Headers, scenario 1 flow rate values were used for the

calculation and scenario 2 flow rate values were used for Produced Water Header calculation. For

the Flare Header, please reference Section 8.4 of this Study Report.

Calculation resultsA18,A19&A20

are attached within the appendix of this Study Report.

11 SAIWAN MAIN HEADERS

The Crude Oil, Produced Water & Produced Gas Headers were all found to be adequate with

respect to the increased plant production.

The plant isometrics were used to evaluate lengths and equivalent lengths for fittings were

calculated and used in the final calculation for adequacy.

Scenario 2 flow rate values were used for all Header calculations. For the Flare Header, please

reference Section 9.4 of this Study Report.

Calculation resultsA21,A22&A23

are attached within the appendix of this Study Report.

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12 FARHA & SAIWAN OVERALL PLOT PLAN (Mechanical)

The current Farha Plant operation consists of one Heater Treater and one Separator. As per the

new expansion plan there will be two new Heater Treaters and two new Separators. The spacing

adequacy check is made to include all major equipment within this plant.

Existing Plot Plan Farha.

The cloud marked portion is new space for Farha Plant.

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Space between Major Equipment in Fahra Area.

Equipment Equipment Distance ActualDistance as per

GAP 2.5.2Remarks

OIL STORAGE TANK 221-TA-

001A

OIL STORAGE TANK 221-TA-001B 56 Meter 30 Meter

Pump 221-PA-001A/B/C OIL STORAGE TANK 221-TA-001

A/B

43.86 Meter 30 Meter


001 A/B

OFF-SPEC OIL TANK 221-TA-002 107.7 Meter 30 Meter

Fire Water Tank 731-TA-

001A/B

Tank 221-TA-001A/B 61.5 Meter 30 Meter

Fire Water Tank 731-TA-001A Compressor skid 491-VN-002 37.1 Meter 30 Meter

Heater Treater 201-XX-001A Separator 201-XY-003A 17.4 Meter 15 Meter

Separator 201-XY-003A Heater treater 201-XX-001B 20 Meter 15 Meter

Heater treater 201-XX-001B Separator 201-XY-003B 20.85 Meter 15 Meter

Separator 201-XY-003B Heater treater 201-XX-001C 19.15 Meter 15 Meter

Heater Treater 201-XX-001C Separator 201-XY-003C 15 Meter 15 Meter

DIESEL STORAGE TANK 431-

TA-001

End line of all heater treater 36 Meter 30.5 Meter

DIESEL STORAGE TANK 431-

TA-001

DG SETS DIESEL DAY TANK 431-

TA-002

55.1 Meter 30.5 Meter

DG SETS DIESEL DAY TANK 431-

TA-002

DEMULSIFIER DOSING

PACKAGE 121-XX-001

86.6 Meter 30.5 Meter

Heater Treater 201-XX-001A HEATER TREATER DIESEL DAY

TANK 201-TA-001

3.6 Meter NA

One New Demulsifier Dosing Package and One Instrument Package are planned for the future

and not included in the space adequacy checks.

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Adequate Space for Farha New Trains

For the Existing Separator 201-XY-003A to equipment 201-XX-001B, the centreline distance is 20

meters and the internal clearance is 15.75 meters which is adequate as per Shell Equipment spacing

standard. The table on the previous page indicates the distance between the equipment and the safe

distance. For equipment 201-XX-001B to equipment 201-XY-003B, there is a centreline distance of

20.85 meters and the internal clearance is 16.85 meters which is adequate as per Shell Equipment

spacing standard.

The equipment spacing between 201-XX-003B and 201-XX-001C is 19.15 meters and the free space

available is 15.15 meters. This is sufficient space as per Shell Equipment Spacing Standard and hence

this spacing is acceptable as per standard engineering practice.

The next equipment items to be considered are 201-XX-001C and 201-XX-003C, the centreline

distance is 15 meters but the free space in between the two equipment items is 10.75 meters which is

not sufficient.

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Existing Plot Plan Saiwan

The Saiwan Plant operation currently consists of one Heater Treater and one Separator. As per the

new expansion plan, there will be one new Heater Treater and one new Separator. This adequacy

report is made considering all major equipment items within this plant.

The cloud marked portion is new space for Saiwan.

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Space between Major Equipment in Saiwan Area.

Equipment Equipment Distance ActualDistance as per

GAP 2.5.2Remarks


001A


001B

70.6 Meter 30 Meter


001A

OFF-SPEC OIL TANK 221-TA-

002

70.6 Meter 30 Meter

Heater treater 200-XX-001A Separator 200-XY-003A 16.025 Meter 15 Meter

Separator 200-XY-003A DOSING PACKAGE 120-XX-002 17.4 Meter 15 Meter

Heater treater 200-XX-001B Separator 200-XY-003B 20 Meter 15 Meter

Heater treater 200-XX-001B Fire & utility Pump house 730-

PA-003A/B

41.5 Meter 30 Meter

430-TA-001 DIESEL STORAGE

TANK

Fire & utility Pump house 730-

PA-003A/B

42.5 Meter 30 Meter

DIESEL UNLOADING PUMP

430-PA-001

430-TA-001 DIESEL STORAGE

TANK

13.5 Meter 15 Meter Not

Adequate

DIESEL UNLOADING PUMP

430-PA-001

H2S REMOVAL UNIT 330-XX-

001

31.7 Meter 30 Meter

H2S REMOVAL UNIT 330-

XX-001 DG AREA 31.9 Meter 30 Meter

Heater treater 200-XX-

001A HEATER TREATER DIESEL

DAY TANK 200-TA-001 2.65 Meter NA

Separator 200-XY-003A DEMULSIFIER DOSING

PACKAGE 120-XX-002

20.3 Meter 15 Meter

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Adequate Space for Saiwan New Train

In Saiwan, the existing Separator (200-VS-001A) and the Heater Treater (200-FY-001A) is exactly on

the opposite side of the new Separator (200-XY-004B) and the new Heater Treater (200-XY-003C). In

between the two trains (old and new), the space is sufficient as per shell equipment spacing standard.

In the west direction 28.9 meters is available and in the north direction it is 16 meters. Also, in

between the new Separator and Heater Treater, 16.025 meters clearance is available. However, this

does not satisfy the spacing criteria as per best engineering practices.

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13 FARHA AND SAIWAN - C&A ADEQUACY CHECKS

This section provides an overview of the existing Control & Safeguarding Systems at Farha South

Station & Saiwan East Station and reviews the suitability and adequacy of these systems for the

future project and also provides adequacy of existing Control Valves “Trim” calculation and

conclusions.

13.1 Control and ESD System at Farha South Station

13.1.1 Existing DCS System at Farha South Station

The Existing Farha Control System (DCS System) for Farha South Station is SIEMENS -SIMATIC

PCS 7 Process Control System design Modular S7-400 range. Existing S7-400 System contains

ET 200M I/O communication module, includes with Process Control Function and SafetyFunction.

Farha Control System has one DCS System Cabinet (CPU/IO PANEL - FARHA-IOP-001). After

checking an existing DCS Process Control System cabinet there is sufficient spares slots

available for inclusion of new cards to interface new signals.

The existing Network Cabinet is SIEMENS and Fiber-Optic Combination Shelves is SIEMENS-

SYSTIMAX 600-G2. Network Cabinet (PANEL-FARHA- NW-001) at Farha South Station Control

Room does not have sufficient spares in Rack for inclusion of new cards but it has sufficient

space for inclusion of new Network Panels.

Existing Marshalling Cabinets at Farha South Station Control Room (MARSHALLING PANEL-

FARHA-MAR-001/002/003/004) have spare space for inclusion of a new Terminal Board.

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13.1.2 Existing ESD System at Farha South Station

The Existing Farha ESD/FGS System for Farha South Station is SIEMENS -SIMATIC PCS 7 Process

Control System design Modular S7-400 range. Existing S7-400 System contains ET 200M I/O

communication module, includes with Process Control Function and Safety Function.

Farha ESD System has three ESD System Cabinets (IO PANEL - FARHA-IOP-002/003/004) and one

FGS system cabinet (CPU/IO PANEL-731-FG-001). After checking an existing ESD/FGS system

cabinet (CPU/IO PANEL-731-FG-001) there is sufficient spares slots available in Rack for

inclusion of new cards to interface new signals.

The table overleaf shows the Spares in DCS /ESD/FGS system cabinets at Farha South Station.

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S/N SYSTEM CABINET NO. SPARE “RACKS” SPARE “SLOTS”

1 CPU/IO

PANEL-731-FG-001

RACK-2 RACK-B

SLOT 7, SLOT 8, SLOT 9, SLOT

10

2 CPU/ IO

PANEL-FARHA-IOP-001

(DCS SECTION)

NO SPARE RACKS AVAILABLE RACK-C

SLOT 9, SLOT 10

RACK-H

SLOT 8, SLOT 9, SLOT 10

3 CPU/ IO

PANEL-FARHA-IOP-002

(ESD SECTION)

NO SPARE RACKS AVAILABLE RACK-F

SLOT 9, SLOT 10

RACK-G

SLOT 9, SLOT 10

4 CPU/ IO

PANEL-FARHA-IOP-003

(ESD SECTION)

NO SPARE RACKS AVAILABLE RACK-D

SLOT 7, SLOT 8, SLOT 9, SLOT

10

RACK-E

SLOT 7,SLOT 8, SLOT 9, SLOT

10

5 CPU/ IO

PANEL-FARHA-IOP-004

(ESD 1 SECTION)

RACK- 2 RACK-I


RACK-J

SLOT 8, SLOT 9, SLOT10

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13.2 Adequacy Evaluation at Farha South Station

13.2.1 Existing DCS System at Farha South Station

DCS System Cabinet (CPU/IO PANEL - FARHA-IOP-001)

Farha DCS Section Part List

Backup Battery, Type AA, 1.9 Ah (Quantity 4) : PS1, PS2

Digital input module, DI 32 x DC 24 V (Quantity 3) : B101,B102,B103

Digital output module, DO 16 x DC 24 V/0.5 A (Quantity 1) : B204

Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 7): B305, B306, B307, B308,

C301, C302, C303

Analog Output module, AO 8 x4-20mA, HART(Quantity 3) : C404, C405, C406

RS-485 Bus Connector with Tilted Cable Outlet (without PG port):

1B1,1B2,1C1,1C2

RS-485 Bus Connector with 35° Cable Outlet (with PG port) : CPU1;CPU2 PROFIBUS FastConnect bus cable, 2-core, shielded (Quantity 10) : CPU2

DCS Module Disposition

Farha DCS Section has Four Racks: RACK A1, RACK A2, RACK B and RACK C. Rack A1 and Rack A2 has

nine slots, Slot 1, 2 reserved for 24 VDC Power Supply, Slot 3,4 reserved for CPU, Slot 5 for CP and Slot

6,7,8,9 are spare slots available. Rack B, Rack C has Active Bus Module for I/O Modules (DI, DO, AI, AO)

4-20 mA HART protocol. Rack B and C communicate with RS-485 Bus Connector with Profibus Link to

Rack A1 and Rack A2.

The following information shows the Spare Channels in Slots of RACK B and C in Farha DCS System

Cabinet (CPU/IO PANEL - FARHA-IOP-001).

Rack B, B101

Rack No. : RACK B

Slot No. : 1

I/O Module : Digital Input Module B101

Channel : 32CH, 24VDC

Spare : I2.2, I3.5, I3.6, I3.7Rack B, B102

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Rack No. : RACK B

Slot No. : 2


Channel : 32CH, 24 VDC

Spare : I4.0, I4.2, I4.4, I4.6, I5.0, I5.2, I5.6, I6.0, I6.2, I6.4, I6.6, I7.0, I7.2, I7.4, I7.5, I7.6,

, I7.7

Rack B, B103

Rack No. : RACK B

Slot No. : 3



Spare : I8.0, I8.1, I8.2, I8.3, I8.5, I8.6, I8.7, I9.0, I9.2, I9.3, I9.4, I9.6, I9.7, I10.1, I10.3,

, I10.4, I10.6, I10.7 I11.0, I11.1, I11.7

Rack B, B204

Rack No. : RACK B

Slot No. : 4

I/O Module : Digital Output Module B204


Spare : Q 00.3, Q00.4

Rack B, B305

Rack No. : RACK B

Slot No. : 5

I/O Module : Analog Input Module B305

Channel : 8CH

Signal : 4-20mA, HART (2 wire)

Spare : M7+ PIW526Rack B, B306

Rack No. : RACK B

Slot No. : 6


Channel : 8CH


Spare : M7+ PIW542

Rack B, B307

Rack No. : RACK B

Slot No. : 7

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Channel : 8CH


Spare : M7+ PIW558

Rack B, B308

Rack No. : RACK B

Slot No. : 8


Channel : 8CH


Spare : M5+PIW570, M7+ PIW574

Rack C, C301

Rack No. : RACK C

Slot No. : 1

I/O Module : Analog Input Module C301

Channel : 8CH


Spare : M7+ PIW590

Rack C, C302

Rack No. : RACK C

Slot No. : 2


Channel : 8CH


Spare : M7+ PIW606

Rack C, C303 Rack No. : RACK C

Slot No. : 3


Channel : 8CH


Spare : M7+ PIW622

Rack C, C404

Rack No. : RACK C

Slot No. : 4

I/O Module : Analog Output Module C404

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Channel : 8CH

Signal : 4-20mA

Spare : Q7+ PQW638

Rack C, C405

Rack No. : RACK C

Slot No. : 5


Channel : 8CH

Signal : 4-20mA

Spare : Q7+ PQW654

Rack C, C406

Rack No. : RACK C

Slot No. : 6


Channel : 8CH

Signal : 4-20mA

Spare : Q7+ PQW670

DCS 1 System Cabinet (CPU/IO PANEL - FARHA-IOP-001)

Farha DCS1 Section Part List

Digital input module, DI 16 x DC 24 V (Quantity 4) : H101,H102,H104,H105

Digital output module, DO 16 x DC 24 V/0.5 A (Quantity 1) : H206

Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 2): H303, H307,


1H1,1H2,

DCS1 Module Disposition

Farha DCS1 Section has one Rack: RACK H. Rack H, Slot 1, 2 reserved for RS-485 Bus Connector with

35° Cable Outlet, Rack H has Active Bus Module for I/O Modules (DI, DO, AI) 4-20 mA HART protocol.

Rack H communicates via RS-485 Bus Connector with Profibus Link to DCS section and ESD section.

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The following information shows the Spare Channels in Slots of RACK H in Farha DCS1 System Cabinet

(CPU/IO PANEL - FARHA-IOP-001).

Rack H, H101

Rack No. : RACK H

Slot No. : 1

I/O Module : Digital Input Module H101


Spare : I12.5, I13.5, I13.6, I13.7

Digital Input Module H102

Rack No. : RACK H

Slot No. : 2



Spare : I15.7

Rack H, H303

Rack No. : RACK H

Slot No. : 3

I/O Module : Analog Input Module H303

Channel : 8CH


Spare : M4+ PIW776, M5+ PIW778, M6+ PIW780, M7+782

Rack H, H104

Rack No. : RACK H

Slot No. : 4



Spare : I16.3, I16.4, I16.5, I16.6, I16.7, I17.2, I17.3, I17.4, I17.5, I17.6, I17.7

Rack H, H105

Rack No. : RACK H

Slot No. : 5



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Spare : All Channels are spare

Rack H, H206

Rack No. : RACK B

Slot No. : 4

I/O Module : Digital Output Module H206


Spare : Q02.4, Q02.5, Q02.6, Q02.7, Q03.0, Q03.1, Q03.2, Q03.4, Q03.5, Q03.6, Q03.7

Rack H, H307

Rack No. : RACK H

Slot No. : 7

I/O Module : Analog Input Module H307

Channel : 8CH


Spare : All Channels are spare

13.2.2 Existing ESD System at Farha South Station

ESD System Cabinet (IO PANEL - FARHA-IOP-002)

Farha ESD Section Part List

Digital input module, Fail Safe, DI 24 x DC 24 V (Quantity 2) : F101,G101

Digital output module Fail Safe, DO 10 x DC 24 V/0.5 A (Quantity 12) : F203…F208,

G203…208

RS-485 Bus Connector with Tilted Cable Outlet (without PG port) :

1H1,1H2,

Rack F, F101

Rack No. : RACK F

Slot No. : 1

I/O Module : Digital Input Module F101


Spare : I64.0, I64.1, I64.2, I64.3, I64.4, I64.5, I64.6, I66.3, I66.4, I66.5, I66.6, I66.7

Rack G, G101

Rack No. : RACK G

Slot No. : 1

I/O Module : Digital Input Module G101 Channel : 10CH, 24VDC

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Spare : I1064.0, I1064.1, I1064.2, I1064.3, I1064.4, I1064.5, I1064.6, I1066.3, I1066.4, ,

, I1066.5, I1066.6, I1066.7

Rack F, F203

Rack No. : RACK F

Slot No. : 3

I/O Module : Digital Output Module F203


Spare : Q81.1

Rack G, G203

Rack No. : RACK 5

Slot No. : 3



Spare : Q1081.1

Rack F, F204

Rack No. : RACK F

Slot No. : 4



Spare : Q88.7, Q89.0, Q89.1

Rack G, G204

Rack No. : RACK G

Slot No. : 4

I/O Module : Digital Output Module G204


Spare : Q1088.7, Q1089.0, Q1089.1

Rack F, F205

Rack No. : RACK F

Slot No. : 5



Spare : Q96.0, Q96.1, Q96.2, Q96.3,

Rack G, G205

Rack No. : RACK G

Slot No. : 5 I/O Module : Digital Output Module G205

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Spare : Q1096.0, Q1096.1, Q1096.2, Q1096.3

Rack F, F206

Rack No. : RACK F

Slot No. : 6



Spare : NO Spares

Rack G, G206

Rack No. : RACK G

Slot No. : 6



Spare : No Spares

Rack F, F207

Rack No. : RACK F

Slot No. : 7



Spare : Q113.0, Q113.1

Rack G, G207

Rack No. : RACK G

Slot No. : 7



Spare : Q1113.0, Q1113.1

Rack F, F208

Rack No. : RACK F

Slot No. : 8



Spare : Q121.0, Q121.1

Rack G, G208

Rack No. : RACK G Slot No. : 8

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Slot No. : 2

I/O Module : Redundant Analog Input Module E302

Channel : 6CH


Spare : M5+ PIW1698

Rack D, D303

Rack No. : RACK D

Slot No. : 3

I/O Module : Redundant Analog Input Module D303

Channel : 6CH


Spare : M5+ PIW714

Rack E, E303

Rack No. : RACK E

Slot No. : 3


Channel : 6CH


Spare : M5+ PIW1714

Rack D, D304

Rack No. : RACK D

Slot No. : 4


Channel : 6CH


Spare : M0+ PIW720, M1+PIW722, M5+PIW730

Rack E, E304

Rack No. : RACK E

Slot No. : 4


Channel : 6CH



Rack D, D305

Rack No. : RACK D Slot No. : 5

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Channel : 6CH


Spare : M4+PIW744, M5+PIW746

Rack E, E305

Rack No. : RACK E Slot No. : 5


Channel : 6CH



Rack D, D306

Rack No. : RACK D

Slot No. : 6


Channel : 6CH



Rack E, E306

Rack No. : RACK E

Slot No. : 6


Channel : 6CH



ESD1 System Cabinet (IO PANEL - FARHA-IOP-004)

Farah ESD1 Section Part List

Redundant Fail Safe Analog input module, AI 6 x4-20mA,(Quantity 14) : I301…I307,

J301…J306

RS-485 Bus Connector with 35 deg. Cable Outlet (without PG port) : 1I1,1I2, 1J1, 1J2

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Rack I, I301

Rack No. : RACK I

Slot No. : 1

I/O Module : Redundant Analog Input Module I301

Channel : 6CH


Spare : M5+PIW794

Rack J, J301

Rack No. : RACK J

Slot No. : 1

I/O Module : Redundant Analog Input Module J301

Channel : 6CH


Spare : M5+PIW1794

Rack I, I302

Rack No. : RACK I

Slot No. : 2


Channel : 6CH


Spare : M4+ PIW808, M5+PIW810

Rack J, J302

Rack No. : RACK J

Slot No. : 2


Channel : 6CH



Rack I, I303

Rack No. : RACK I

Slot No. : 3


Channel : 6CH

Signal : 4-20mA, HART (2 wire) Spare : M4+ PIW824, M5+PIW826

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Rack J, J303

Rack No. : RACK J

Slot No. : 3


Channel : 6CH



Rack I, I304

Rack No. : RACK I

Slot No. : 4


Channel : 6CH



Rack J, J304

Rack No. : RACK J

Slot No. : 4


Channel : 6CH



Rack I, I305

Rack No. : RACK I

Slot No. : 5


Channel : 6CH


Spare : M5+PIW858

Rack J, J305

Rack No. : RACK J

Slot No. : 5


Channel : 6CH


Spare : M5+PIW1858Rack I, I306

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Rack No. : RACK I

Slot No. : 6


Channel : 6CH


Spare : No Spares

Rack J, J306

Rack No. : RACK J

Slot No. : 6


Channel : 6CH


Spare : No Spares

Rack I, I307

Rack No. : RACK I

Slot No. : 7


Channel : 6CH


Spare : M5+PIW890

Rack J, J307

Rack No. : RACK J

Slot No. : 7


Channel : 6CH


Spare : M5+PIW1890

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13.3 Available Space in FES Control Room for System Cabinet and HMI

Farha South Station Control Room has sufficient space for putting new System Cabinets/

Marshalling Cabinets for DCS/ESD/FGS system.

Fig.13.3.1 Space available for new System cabinets and Marshalling Cabinets (DCS/ESD/FGS) at FSS

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Fig.13.3.2. Available Space for putting new HMI (operator work station) at Farha South Station

Control Room at FSS

13.4 Control and ESD System at Saiwan East Station

13.4.1 Existing DCS System at Saiwan East Station

The Existing Saiwan Control System server (DCS System) for Saiwan East Station is SIEMENS -

SIMATIC PCS 7 Process Control System design Modular S7-400 range. S7-400 System contains

ET 200M I/O communication module, includes with Process Control Function and Safety

Function.

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Saiwan Control System has one DCS System Cabinet (CPU/IO PANEL - SAIWAN-IOP-001).After

checking existing DCS Process Control system cabinets (CPU/ IO PANEL-SAIWAN-IOP-001),

there is sufficient spares slots available for inclusion of new cards to interface new signals.

Existing Marshalling Cabinets at Saiwan East Station Control Room (MARSHALLING PANEL-

SAIWAM-MAR-002/003/004) have spare space for putting new Terminal Board.

13.4.2 Existing ESD System at Saiwan East Station

The Existing ESD/FGS System for Saiwan East Station is SIEMENS -SIMATIC PCS 7 Process

Control System design Modular S7-400 range. S7-400 System contains ET 200M I/O

communication module, includes with Process Control Function and Safety Function.

Saiwan has three ESD System Cabinets (IO PANEL - SAIWAN-IOP-002/003/004). After checking

an existing ESD/FGS system cabinet (CPU/IO PANEL-730-FG-001), there are sufficient spare

slots available in Rack for inclusion of new cards to interface new signals.

The table overleaf shows the Spares in DCS /ESD/FGS system cabinets in Saiwan East Station.

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S/N SYSTEM CABINET NO. SPARE “RACKS” SPARE “SLOTS”

1 CPU/IO

PANEL-730-FG-001

RACK 1 NO SPARE SLOTS

AVAILABLE

2 CPU/IO PANEL - SAIWAN-IOP-

001

(DCS)

NO SPARE RACKS

AVAILABLE

RACK B

SLOT 9, SLOT 10

RACK C


RACK D

SLOT 9, SLOT 10


002 (ESD)

NO SPARE RACKS

AVAILABLE

NO SPARE SLOTS

AVAILABLE


003(ESD)

NO SPARE RACKS

AVAILABLE

RACK E

SLOT 9, SLOT 10

RACK F

SLOT 9, SLOT 10

13.5 Adequacy Evaluation at Saiwan East Station

13.5.1 Existing DCS System at Saiwan East Station

DCS System Cabinet (CPU/IO PANEL - SAIWAN-IOP-001)

Saiwan DCS Section Part List

Backup Battery, Type AA, 1.9 Ah (Quantity 4) : PS1, PS2

Digital input module, DI 32 x DC 24 V (Quantity 4) : B101,B102,B103,B104

Digital output module, DO 16 x DC 24 V/0.5 A (Quantity 1) : B205

Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 8): B306, B307, B308, C301

C301, C302, C303, C304, C305

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Analog Output module, AO 8 x4-20mA, HART(Quantity 4) : D401, D402, D403, D404

RS-485 Bus Connector with Tilted Cable Outlet (without PG port): 1B1,1B2,1C1,1C2, 1D1, 1D2

RS-485 Bus Connector with 35° Cable Outlet (with PG port) : CPU1;CPU2

PROFIBUS FastConnect bus cable, 2-core, shielded (Quantity 20) : CPU1, CPU2

DCS Module Disposition

Saiwan DCS Section has Four Racks: RACK A1, RACK A2, RACK B, RACK C AND RACK D. Rack A1 and

Rack A2 has nine slots, Slot 1, 2 reserved for 24 VDC Power Supply, Slot 3,4 reserved for CPU, Slot

5 for CP and Slot 6,7,8,9 are spare slots available. Rack B, Rack C and Rack D has Active Bus Module

for I/O Modules (DI, DO, AI, AO) 4-20 mA HART protocol. Rack B, C and D communicates with RS-

485 Bus Connector with Profibus Link to Rack A1 and Rack A2.

The following information shows the Spare Channels in Slots of RACK B and C in Saiwan DCS System

Cabinet (CPU/IO PANEL - SAIWAN-IOP-001).

Rack B, B101

Rack No. : RACK B

Slot No. : 1



Spare : I3.5, I3.6, I3.7

Rack B, B102

Rack No. : RACK B Slot No. : 2



Spare : I4.0, I4.1, I4.2, I4.3, I4.4, I4.5, I4.6, I4.6, I5.0, I5.1, I5.4, I5.5, I5.6, I5.7, I7.7

Rack B, B103

Rack No. : RACK B

Slot No. : 3



Spare : I8.3, I8.4, I9.1, I9.2, I11.1, I11.2, I11.3, I11.4

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Rack B, B104

Rack No. : RACK B

Slot No. : 4



Spare : NO Spares

Rack B, B205

Rack No. : RACK B

Slot No. : 5



Spare : Q01.4, Q01.5, Q01.6, Q01.7

Rack B, B306

Rack No. : RACK B

Slot No. : 6


Channel : 8CH


Spare : M7+ PIW526

Rack B, B307

Rack No. : RACK B

Slot No. : 7


Channel : 8CH


Spare : M7+ PIW542

Rack B, B308

Rack No. : RACK B

Slot No. : 8


Channel : 8CH


Spare : M7+ PIW558

Rack C, C301

Rack No. : RACK C

Slot No. : 1

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Channel : 8CH


Spare : M7+ PIW574

Rack C, C302

Rack No. : RACK C

Slot No. : 2


Channel : 8CH


Spare : M7+ PIW590

Rack C, C303

Rack No. : RACK C

Slot No. : 3


Channel : 8CH


Spare : M7+ PIW606

Rack C, C304

Rack No. : RACK C

Slot No. : 4


Channel : 8CH


Spare : M7+ PIW622

Rack C, C305

Rack No. : RACK C

Slot No. : 5


Channel : 8CH


Spare : M7+ PIW638

Rack D, D401

Rack No. : RACK D

Slot No. : 1 I/O Module : Analog Output Module D401

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Channel : 8CH

Signal : 4-20mA

Spare : Q7+ PQW654

Rack D, D402

Rack No. : RACK D

Slot No. : 2

I/O Module : Analog Output Module D402

Channel : 8CH

Signal : 4-20mA

Spare : Q7+ PQW670

Rack D, D403

Rack No. : RACK D

Slot No. : 3


Channel : 8CH

Signal : 4-20mA

Spare : Q5+ PQW682, Q6+PQW684, Q6+PQW686

Rack D, D404

Rack No. : RACK D

Slot No. : 4


Channel : 8CH

Signal : 4-20mA

Spare : Spare Slot

DCS 1 System Cabinet (CPU/IO PANEL - SAIWAN-IOP-001)

Saiwan DCS1 Section Part List

Digital input module, DI 32 x DC 24 V (Quantity 1) : D107

Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 2): D308,


1H1,1H2,

Rack D, D107 Rack No. : RACK D

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Slot No. : 7

I/O Module : Digital Input Module D107


Spare : I17.6, I17.7, I18.0 to I18.7, I19.0 to I19.7

Rack D, D308

Rack No. : RACK H

Slot No. : 8

I/O Module : Analog Input Module D308

Channel : 8CH


Spare : M1+ PIW642, M2+ PIW646, M4+ PIW648,M5+PIW650,M6+PIW652,M7+PIW654

ESD System Cabinet (IO PANEL - SAIWAN-IOP-002)

Saiwan ESD Section Part List

Digital input module, Fail Safe, DI 24 x DC 24 V (Quantity 2) : G101,H101 Digital output module Fail Safe, DO 10 x DC 24 V/0.5 A (Quantity 12) : G203…G208,

H203…H208

RS-485 Bus Connector with Tilted Cable Outlet (without PG port) :

1E1, 1E2, 1F1, 1F2,

1G1,1G2,1H1,1H2

Rack G, G101

Rack No. : RACK G

Slot No. : 1

I/O Module : Redundant Digital Input Module G101


Spare : I64.6, I64.7, I65.0 to I65.7, I66.0, I65.7

Rack H, H101

Rack No. : RACK H

Slot No. : 1

I/O Module : Redundant Digital Input Module H101


Spare : Spare Slot

Rack G, G203

Rack No. : RACK G

Slot No. : 3

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Spare : Q81.0, Q81.1

Rack H, H203

Rack No. : RACK H

Slot No. : 3



Spare : Q1081.1

Rack G, G204

Rack No. : RACK G

Slot No. : 4



Spare : Q89.0, Q89.1

Rack H, H204

Rack No. : RACK H

Slot No. : 4



Spare : Q1089.0, Q1089.1

Rack G, G205

Rack No. : RACK G

Slot No. : 5


Channel : 10CH, 24VDC Spare : Q96.0 to Q96.5

Rack H, H205

Rack No. : RACK H

Slot No. : 5



Spare : Q1096.0 to Q1096.5

Rack G, G206

Rack No. : RACK G

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Slot No. : 6



Spare : Q105.1

Rack H, H206

Rack No. : RACK H

Slot No. : 6



Spare : Q1105.1

Rack G, G207

Rack No. : RACK G

Slot No. : 7



Spare : Q112.0, Q112.3, Q112.6, Q112.7, Q113.0, Q113.1

Rack H, H207

Rack No. : RACK H

Slot No. : 7



Spare : Q1112.0, Q1112.3, Q1112.6, Q1112.7, Q1113.0, Q1113.1

Rack G, G208

Rack No. : RACK G

Slot No. : 8

I/O Module : Digital Output Module G208 Channel : 10CH, 24VDC

Spare : Q121.1

Rack H, H208

Rack No. : RACK H

Slot No. : 8

I/O Module : Digital Output Module GH08


Spare : Q1121.1

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13.5.2 Existing ESD System at Saiwan East Station

ESD System Cabinet (IO PANEL - SAIWAN-IOP-003)

Farah ESD Section Part List

Redundant Fail Safe Analog input module, AI 6 x4-20mA,(Quantity 12): E301…E306,

F301…F306.

The following information shows the Spare Channels in Slots of RACK E and F in Saiwan ESD System

Cabinet (IO PANEL - SAIWAN-IOP-003).

Rack E, E301

Rack No. : RACK E

Slot No. : 1


Channel : 6CH


Spare : M5+ PIW714

Rack F, F301

Rack No. : RACK F

Slot No. : 1 I/O Module : Redundant Analog Input Module F301

Channel : 6CH


Spare : M5+ PIW1714

Rack E, E302

Rack No. : RACK E

Slot No. : 2


Channel : 6CH


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Spare : M5+ PIW730

Rack E, E303

Rack No. : RACK E

Slot No. : 3


Channel : 6CH


Spare : M5+ PIW746

Rack F, F303

Rack No. : RACK F

Slot No. : 3

I/O Module : Redundant Analog Input Module F303

Channel : 6CH


Spare : M5+ PIW1746

Rack E, E304

Rack No. : RACK E

Slot No. : 4


Channel : 6CH


Spare : M5+ PIW1714

Rack D, D304

Rack No. : RACK D

Slot No. : 4


Channel : 6CH



Rack D, E304

Rack No. : RACK E

Slot No. : 4


Channel : 6CH Signal : 4-20mA, HART (2 wire)

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Spare : M5+PIW762

Rack F, F304

Rack No. : RACK F

Slot No. : 4


Channel : 6CH


Spare : M5+PIW1762

Rack E, E305

Rack No. : RACK E

Slot No. : 5


Channel : 6CH


Spare : M5+PIW778

Rack F, F305

Rack No. : RACK F

Slot No. : 5


Channel : 6CH


Spare : M5+PIW1778

Rack E, E306

Rack No. : RACK E

Slot No. : 6


Channel : 6CH


Spare : M5+PIW794

Rack F, F306

Rack No. : RACK F

Slot No. : 6


Channel : 6CH

Signal : 4-20mA, HART (2 wire) Spare : M5+PIW1794

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Rack E, E307

Rack No. : RACK E

Slot No. : 7


Channel : 6CH


Spare : M5+PIW810

Rack F F307

Rack No. : RACK F

Slot No. : 7


Channel : 6CH


Spare : M5+PIW1810

Rack E, E308

Rack No. : RACK E

Slot No. : 8


Channel : 6CH


Spare : M5+PIW826

Rack F, F308

Rack No. : RACK F

Slot No. : 8


Channel : 6CH


Spare : M5+PIW1826

ESD1 System Cabinet (IO PANEL - SAIWAN-IOP-004)

Farah ESD1 Section Part List

Redundant Fail Safe Analog input module, AI 6 x4-20mA,(Quantity 4) : G309, G310,

H309, H310

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RS-485 Bus Connector with 35 deg. Cable Outlet (without PG port) :

1I1,1I2, 1J1, 1J2

The following information shows the Spare Channels in Slots of RACK G and H in Saiwan ESD1 System

Cabinet (CPU/IO PANEL - SAIWAN-IOP-001).

Rack G, G309

Rack No. : RACK G

Slot No. : 19

I/O Module : Redundant Analog Input Module G309

Channel : 6CH


Spare : M5+PIW794

Rack J, J301

Rack No. : RACK J

Slot No. : 1

I/O Module : Redundant Analog Input Module G309 Channel : 6CH


Spare : M5+PIW1794

Rack I, I302

Rack No. : RACK I

Slot No. : 2


Channel : 6CH

Signal : 4-20mA, HART (2 wire) Spare : M4+ PIW808, M5+PIW810

Rack J, J302

Rack No. : RACK J

Slot No. : 2


Channel : 6CH



Rack I, I303

Rack No. : RACK I

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Slot No. : 3


Channel : 6CH



Rack J, J303

Rack No. : RACK J

Slot No. : 3


Channel : 6CH



Rack I, Module I304

Rack No. : RACK I

Slot No. : 4


Channel : 6CH



Rack J, J304

Rack No. : RACK J

Slot No. : 4

Channel : 6CH




Rack I, I305

Rack No. : RACK I

Slot No. : 5


Channel : 6CH


Spare : M5+PIW858

Rack J, J305

Rack No. : RACK I Slot No. : 5

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Channel : 6CH


Spare : M5+PIW1858

Rack I, I306

Rack No. : RACK I

Slot No. : 6


Channel : 6CH


Spare : No Spares

Rack J, J306

Rack No. : RACK J

Slot No. : 6


Channel : 6CH


Spare : No Spares

Rack I, I307

Rack No. : RACK I

Slot No. : 7


Channel : 6CH


Spare : M5+PIW890

Rack J, J307

Rack No. : RACK J

Slot No. : 7


Channel : 6CH


Spare : M5+PIW1890

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13.6 Available Space in SES Control Room for System Cabinet

Saiwan East Station Control Room has sufficient space for putting new System Cabinets/

Marshalling Cabinets for DCS/ESD/FGS system.

Fig.13.6.1 Space available for System Cabinets/ Marshalling Cabinets new DCS/ESD/FGS

System at SES

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13.7 Control Valve Adequacy Check

Farha: New Cv for Control Valves

M a s s F l o w r a t e ( k g / h r )

I n l e t P r e s s u r e ( b a r g )

O u t e l t P r e s s u r e (

b a r g )

O p e r a t i n g T e m p . (

D e g C )

M o l e c u l a r w e i g h t

V i s c o c i t y o f g a s

( c P )

V a p o u r P r e s s u r e ( b a r g )

S p e c i f i c H e a t R a t i o C p / C v = K

M a s s D e n s i t y k g

/ m 3

C o m p r e s s i b i l i t y

S p e c i f i c G a r v i t y

C r i t i c a l P r e s s u

r e

M i n .

21.32 4.7 3.987 20 32.5 0.01345 NA 1.252 7.511 0.9786 NA NA 0.354

N o r m .

42.64 4.987 3.987 20 32.5 0.01345 NA 1.254 8.19 0.9767 NA NA 0.582

M a x .

51.168 5 3.987 55 32.5 0.01345 NA 1.254 8.209 0.9841 NA NA 0.694

M i n .

223. 9953 3. 7 0.9868 36. 9 43.53 0 .00972 NA 1. 157 8.237 0. 9445 N A NA 2.3

N o r m .

447. 9905 3. 987 0.9868 67 43.53 0.01063 NA 1. 141 8.089 0. 9514 N A NA 4.435

M a x .

537.5886 4 0.9868 67 43.53 0 .01063 NA 1.141 8.11 0.9513 NA NA 5.373

M i n .

21085.31 4.987 3 .987 20 165.4 3.09 4.986 1 .185 810.7 NA 0.81 50.74 42

N o r m .

42170.63 4.987 3.987 20 165.4 3.09 4.986 1.185 810.7 NA 0.81 50.74 73.253 58

M a x .

50604.75 5 3.987 55 165.4 1.638 4.986 1.186 782.2 NA 0.81 50.74 87.507 62 2. For “normal” & “maximum” controllability, the existing “Trim”

can be re-used, if no concern on minimum control.

M i n .

20861. 32 3. 5 0. 9868 20 170. 527 3. 361299 3. 987 1. 181 813. 5 N A 0. 813 50. 74

N o r m .

41722. 64 3 .987 0. 9868 67 170. 527 1. 419 3. 987 1. 023 774. 5 N A 0. 774 50. 74

M a x .

50067.16 4 0.9868 67 170.527 1.419 3.987 1.023 774.5 NA 0.774 50.74 96.557 80

M i n .

4458.928 4.5 1 20 18.02 1.0017 5 1.135 1011 NA 1.011 NA 2.76 17

N o r m . 8917.855 5 1 20 18.02 1.0017 5 1.135 1011 NA 1.011 NA 5.165 32

M a x .

10701.43 5.5 1 55 18.02 1.0017 5 1.153 984 NA 0.9845 NA 5.88 35

M i n .

1065.5 3 1 20 18.02 1.002 NA 1.1812 1011 NA 1.011 NA 0.781 41

N o r m .

2131 3.5 1 67 18.02 0.417646 NA 1.0226 824.1 NA 0.824 NA 1.144 58

M a x .

2557.2 4 1 55 18.02 0.417646 NA 1.185 975.1 NA 0.975 NA 1.595 61

N o r m .

1471.681 3.98 0.9 63.52 42.282 0.0109 NA 1.147 7.903 0.9556 NA NA 14.811 11

M a x .

1766.017 4 0.9 63.51 42.282 0.0109 NA 1.147 0.186 0.955479 NA NA 115.947 52

6

2 0 1 - L V - 2 0 2 / 2 0 3

Water/

Liquid 4.91

1. Existing “Trim” is not suitable for given new process data for

minimum controllability.

1. Existing “Trim” is not suitable for given new process data for

minimum controllability.

2. For “normal” & “maximum” controllability, the existing “Trim”

can be re-used, if no concern on minimum control.

4

2 0 1 - L V - 2 0 4 A

Oil/

Liquid 136 Existing “Trim” can be re-used.

5

2 0 1 - L V - 1 0 7 A

Water/

Liquid 70.7 Existing “Trim” is not suitable for given process data.

2

2 0 1 - P V - 2 0 2

HC Gas/

Vapour 53.8

Existing “Trim” is not suitable for given process data for Min.

/Norm. /Max. Controllability.

3

2 0 1 - L V - 1 1 0 A

Oil/

Liquid 224

V A L V E O P E N I N G %

R E M A

R K S

1

2 0 1 - P V - 1 0 6 A

HC Gas/

Vapour 70.7

Existing “Trim” is not suitable for given process data for Min.

/Norm. /Max. Controllability.

S / N

T A G N

O .

P r o c e s s F l u

i d / S t a t e

NEW PROCESS CONDITION FARHA

N E W C

A L C U

L A T E D C V

E X I S T I N G R A T E D C V

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Saiwan: New Cv for Control Valves

M a s s F l o w

r a t e ( k g / h r )

I n l e t P r e

s s u r e ( b a r g )

O u t e l t P r e s s u r e ( b a r g )

O p e r a t i n g

T e m p . ( D e g C )

M o l e c u

l a r w e i g h t

V i s c o c i t y o f g a s ( c P )

V a p o u r P r

e s s u r e ( b a r g )

S p e c i f i c H e a

t R a t i o C p / C v = K

M a s s D e

n s i t y k g / m 3

C o m p r e s s i b i l i t y

S p e c i f

i c G a r v i t y

C r i t i c a l P r e s s u r e

M i n .

547.7983 4.5 4 20 27.119 0.01086 NA 1.23736 6.332174 0.968773 NA NA 11.898 52 1. Existing “Trim” is not suitable for given new process data

for minimum controllability.

N o r m .

1095.597 5 4 20 27.119 0.01086 NA 1.23999 6.926838 0.965915 NA NA 16.873 60

M a x .

1314.716 5.5 4 55 27.119 0.01086 NA 27.119 6.647134 0.973976 NA NA 17.649 61 2.

For “normal” & “maximum” controllability, the existing

“Trim” can be re-used, if no concern on minimum control.

M i n .

29535.63 4.5 4 20 214.2 8.53163 5 1.148 852.7 NA 0.8527 51.263

N o r m .

59071.27 5 4 20 214.2 8.48012 5 1.149 852.5 NA 0.8527 51.263

M a x .

70885.52 4.5 4 55 214.2 5.12095 5 1.018 826.5 NA 0.826 51.263 91.366 63

M

i n .

29238. 56 3. 5 1 20 224. 516 9. 34 4 855.954 855.954 N A 0. 855 46.883

N o r m .

58477.13 4 1 67 224.516 4.38 4 819.3 819.3 NA 0.819 46.883

M a x .

70172.55 4.5 1 67 224.516 4.38 4 819.3 819.3 NA 0.819 46.883 93.595 75

M i n .

297.07 3.5 3.5 20 36.719 0.00935 NA 1.184 7.184 0.946 NA NA

N o r m .

594.14 4 3.5 67 36.719 0.01071 NA 1.1449 7.189 0.946 NA NA 12.339

M a x .

712.97 4.5 3.5 67 36.719 0.0107 NA 1.152 7.942 0.946 NA NA 10.542

M i n .

3630.637 3 0.01 20 25.654 0.0112 NA 1.235 4.767 0.978 NA NA 61.357 54 1. Existing “Trim” is not suitable for given new process data


N o r m .

7261.274 3.5 0.09 20 25.654 0.0112 NA 1.235 4.767 0.978 NA NA 113.537 67

M a x .

8713.529 4 0.79 55 25.654 0.0112 NA 1.235 4.767 0.978 NA NA 129.905 71

2. For “normal” & “maximum” controllability, the existing


M i n .

13978.21 4.5 1 20 18.02 1.002 5 1.131 1011 NA 1.011 220.2 8.657 44 1. Existing “Trim” is not suitable for given new process data


N o r m .

27956.41 5 1 20 18.02 1.002 5 1.131 1011 NA 1.011 220 16.214 59

M a x .

3547.693 5.5 1 20 18.02 1.002 5 1.131 1011 NA 1.011 220.2 18.352 61 2. For “normal” & “maximum” controllability, the existing


M i n .

1419 3.5 1 20 18.02 1.002 NA 1.131 1011 NA 1.011 NA 1.041 13

N o r m .

2838 4 1 67 18.02 0.41765 NA 1.131 1011 NA 0.824 NA 1.919 26

M a x .

3405.6 4.5 1 55 18.02 0.41765 N A 1.131 1011 NA 0.984 NA 2.126 29

Existing “Trim” is not suitable for given process data.

6

2 0 1 - L V - 0 0 7 A

Water/

Liquid 70.7

7

2 0 0 - L V - 4 0 2 / 4 0 3

Water/

Liquid 17.2

4

2 0 0 - P V - 4 0 2

HC Gas/

Vapour 53.84

5

4 0 2 - P V - 4 0 1

HC Gas/

Vapour 224

2

2 0 0 - L V - - 0 1 0 A

Oil/

Liquid 224

3

2 0 0 - L V - 4 0 4 A

Oil/

Liquid 136

V A L

V E O P E N I N G %

R E M A R K S

1

2 0 0 - P V - 0 0 6 A

HC Gas/

Vapour 70.7

S / N

T A G N O .

P r o c

e s s F l u i d / S t a t e

NEW PROCESS CONDITION SAIWAN

N E W C

A L C U L A T E D C V

E X I S T I N G R A T E D C V

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14 ELECTRICAL ADEQUACY CHECKS

Introduction

As part of Farha & Saiwan Plant Expansion, an adequacy study on the existing electrical system at

Farha & Saiwan was carried out. The study was mainly aimed to check the available spare

capacity and spare feeders at Farha & Saiwan to cater for the proposed additional loads. The

study consists of the following;

Adequacy of Existing Electrical Infrastructure at Farha

The electrical power system at Farha consists of mainly one switch gear room with one

switchboard (921-EM-002).

415V LV Switch Boards, 921-EM-002

The switch board (921-EM-002) at Farha is fed by 3* 1000 kVA 415V DG sets. The whole facility

loads are connected to this switch board. 18 spare feeders of various ratings and 5 vacant

compartments are available on this LV Switchboard. Extension of LV switchboard, 921-EM-002 is

possible with addition of one cubicle at one end as shown in the site visit report.

The proposal is made for the addition of 4*30kW Heater Treater Blowers (2 duty & 2 standby),

3*0.18kW Demulsifier Dosing Pump (2 duty & 1 standby) and an Instrument Air Package of 65kW

as part of Train 2 and Train 3 expansion. All these new electrical equipments shall be electrified

with the suitable spare feeders from the available 18 spare feeders as listed overleaf.

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Sl. No. Spare feeders Rating Vacant

Compartment

1 Q 101 15kW Q 807

2 Q 106 55kW Q 1706

3 Q 107 1.5kW Q 1707

4 Q 205 3kW Q 1904

5 Q 207 3.7kW Q 1905

6 Q 301 5.5kW 7 Q 405 7.5kW

8 Q 407 10A

9 Q 501 30kW

10 Q 601 30kW

11 Q 702 10kW

12 Q 1301 22kW

13 Q 1306 0.55kW

14 Q 1407 3kW

15 Q 1502 3.7kW

16 Q 1607 70A

17 Q 1705 100A

18 Q 1804 25A

Diesel Generators (DG set) 1000kVA, 415V

In Farha facility, there are three 1000KVA, 415V Generators. All three DG sets are manufactured

by FG Wilson (Engineering) Ltd, United Kingdom, in the year 2010.

Based on available electrical load schedule (Doc. no.: JS1034-F-E-08-0001)A26

, the connected plant

peak load including the recently added new loads under other projects is approximately

2105.03kVA (@ 0.8 p.f), whereas the total installed capacity of DG is 3000kVA. The spare

capacity of the plant is 894.97 kVA (@ 0.8 p.f), which is 29.8% of the installed capacity.

Once the new trains (Train-2 & Train-3) get commissioned, then the connected peak load of the

facility will increase to 2232.24kVA (@ 0.8 p.f) and the spare capacity of the plant will be 767.76

kVA (@ 0.8 p.f), which is 25.6% of the installed capacity.

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Electrical Switchgear Room at Farha

Expansion of the containerized switchgear room is not possible, as it will be an obstruction to the

existing piping and nearby located skids.

Adequacy of Existing Electrical Infrastructure at Saiwan

The electrical power system at Saiwan consists of mainly one switchgear room with two

switchboards (920-EM-002 & 920-EM-003).

415V LV Switch Boards, 920-EM-002

This switch board is feeding the whole plant loads except H2S removal unit. There is an availability

of 11 spare feeders of various rating and 3 vacant compartments in this LV Switchboard.

Available spare feeders and spare spaces are listed below.


Compartment

1 Q 602 30kW Q 704

2 Q 503 25A Q 601

3 Q 507 100A Q 1706

4 Q 302 3.7kW

5 Q 207 3kW

6 Q 101 15kW

7 Q 1501 22kW 8 Q 1507 3kW

9 Q 1704 7.5kW

10 Q 1705 10A

11 Q 1904 150A

The proposal is made for the addition of 2*30kW Heater Treater Blowers (1 duty & 1 standby)

and an instrument air package of 65kW as part of Train 2 expansion. These new 2 Heater Treater

Blowers and Instrument Air Package shall be electrified with the suitable spare feeders from the

available 11 spare feeders on switchboard 920-EM-002.

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Extension of this LV switchboard (920-EM-002) is possible towards the left side of the cubicle (Q1)

with 2 cubicles. The space between the Cubicle (Q1) and H 2S removal system panel shall be

utilized for this.

LV SWITCHBOARD – 920-EM-003

This switchboard is dedicated only for H2S removal unit and this switch board was switched off, as

the H2S removal unit is not operating. There is an availability of 3 spare feeders, 4 vacant

compartments and a VFD spare feeder. This is as listed below.

.


Compartment

1 Q 303 5.5kW Q 407

2 Q 406 18.5kW Q 503 3 Q 703 37kW Q 603

4 Q 501 11kW - VFD Q 704

Diesel Generators (DG set) 1000kVA, 415V

In Saiwan facility, there are four 1000kVA, 415V Generators. All four DG sets are manufactured by

FG Wilson (Engineering) Ltd, United Kingdom, in the year 2010.

Based on available electrical load schedule (Doc. no.: JS1034-S-E08-0001)A26

, the connected plant

peak load is approximately 1584.47kVA (@ 0.8 p.f), whereas the total installed capacity of DG sets

is 4000kVA. The spare capacity of the plant is 2415.53 kVA (@ 0.8 p.f), which is around 60.4% of

the installed capacity.

Once the new train (Train-2) gets commissioned, then the connected peak load of the facility will

increase to 1685.26kVA (@ 0.8 p.f) and the spare capacity of the plant will be 2314.74kVA (@ 0.8

p.f), which is around 57.9% of the installed capacity.

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Electrical Switchgear Room

Expansion of containerized switchgear room is possible towards only one side; whereas the other

side is totally obstructed with piping. The possible expansion of the containerized switch gear

room is shown in the relevant site visit report.

Conclusion

The following points are concluded from above study:

At Farha

Spare feeders are available on the 415V LV Switchboards at Farha.

Extension of switch board is possible at Farha

The proposed new 4 Heater Treater Blowers, 3 Demulsifier Dosing Pumps and the

Instrument Air Package shall be electrified with the suitable spare feeders from the

available 18 spare feeders.

Once the new trains (Train-2 & Train-3) get commissioned, then the connected peak

load of the facility will increase to 2232.24kVA (@ 0.8 p.f) and the spare capacity of

the plant will be 767.76 kVA (@ 0.8 p.f), which is 25.6% of the installed capacity.

Expansion of switchgear room towards both ends is not possible at Farha.

At Saiwan

Spare feeders are available on the 415V LV Switchboards at Saiwan.

The proposed new 2 Heater Treater Blowers and Instrument Air Package shall be

electrified with the suitable spare feeders from the available 11 spare feeders on

switchboard (920-EM-002).

Extension of LV switchboard (920-EM-002) is possible towards the left side of the

cubicle (Q1) with 2 cubicles.

Once the new train (train-2) gets commissioned, then the connected peak load of the

facility will increase to 1685.26kVA (@ 0.8 p.f) and the spare capacity of the plant will

be 2314.74kVA (@ 0.8 p.f), which is around 57.9% of the installed capacity.

Switchgear room expansion is possible at Saiwan.

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15 RECOMMENDATIONS & CONCLUSIONS

The majority of both Farha and Saiwan Plants are adequate to cater for the increased planned

production. However, some of the equipment will be required to be replaced or added to if the

expansion is to be successful. It is recommended that majority of the changes should be catered for

during the detailed design stage of Phase 2B expansion.

A table of the inadequate items for Farha is presented below:

Description Remarks

Storage Tanks

Inadequate based upon a 48 hour

production philosophy but

adequate based on a 24 hr

retention of product.

Off-Spec Tank Inadequate based on 24 hoursproduct retention.

Flare System



inlet nozzle.


Heater Treater Relief Valves are

inadequate based on fire case

scenario.

Instrument Air System 1 more package is required

Chemical Dosing Packages Demulsifier Package is inadequate


Diesel Storage Tank Capacity is

inadequate based on 15 days

consumption

Nitrogen



Plot Plan Spacing

Distance between 3rd

Train Heater

Treater and Separator is

inadequate.

Electrical Inadequacy

Expansion of switchgear room is not

possible.

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A table of the inadequate items for Saiwan Plant is presented below:

Description Remarks

Separators

Operating outside of Operating

Envelope.

Storage Tanks Please see section 7.4 of Report

Export PumpsExport Booster Pumps

Flare System



inlet nozzle. Also, Production

Separator Train 1 Tailpipe Mach

Number is too high.


1st Train Production Separator and

2nd Train Heater Treater Relief

Valves are inadequate for the fire

case scenario.


Heater Treater Diesel Day Tank is

not adequate based on a 24 hours

supply

Nitrogen



Plot Plan Spacing

Distance between Diesel Unloading

Pump and Diesel Storage Tank is in

adequate. Spacing between the

new 2nd

Train Separator and Heater

Treater is not adequate.

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16 REFERENCES

R1) CCED work instruction number CCED-WI-14-629-021 Rev.02.

R2) Process Design Basis document number JS1006-X-F06-0501-C2.

R3) Farha PVT Analysis

R4) Saiwan East PVT Analysis

R5) SHAHD H & I PVT Analysis

R6) SHAHD H&I Production Forecast

R7) Saiwan Production Separator MRB

R8) API2000 Nov 2009

R9) Farha Production Separator MRB

R10) API Spec 12J

R11) Farha Heater Treater GA

R12) Farha Pipeline Elevation

R13) Saiwan Pipeline Elevation

R14) Saiwan Heater Treater GA

R15) Farha & Saiwan FG PCV & PSV DataSheets

R16) Farha Overall Plot Plan

R17) Saiwan Overall Plot Plan

R18) API 526

R19) API 521

R20) API 520 Parts 1 & 2

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17 APPENDICES

A1) H&MB FARHA & Saiwan

A2) Farha Control Valves & SDV's

A3) Saiwan Control Valves & SDV's

A4) Blanket Calc 221-TA-001A

A5) Blanket Calc 220-TA-001A

A6) Farha PFD

A7) Saiwan PFD

A8) Farha Manifold Calculation

A9) Saiwan Manifold Calculation

A10) Operating Envelope Farha Separator

A11) Operating Envelope Farha Heater Treater

A12) Farha Booster and Export Pump Curves

A13) Operating Envelope Saiwan Separator Saiwan Crude

A14) Operating Envelope Saiwan Separator – SHAHD

A15) Operating Envelope for Saiwan Heater Treater

A16) Operating Envelope for Saiwan HT - SHAHD

A17) Saiwan Booster and Export Pump Curves

A18) Farha Crude Header Calculation

A19) Farha Produced Water Header Calculation

A20) Farha Produced Gas Header Calculation

A21) Saiwan Crude Header Calculation

A22) Saiwan Produced Water Header Calculation

A23) Saiwan Produced Gas Header Calculation

A24) Farha LP Flare Assesment Summary Tables incl RVs

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A25) Saiwan LP Flare Assessment Summary Tables incl RVs

A26) Electrical Load Lists

A27) UniSim Simulations

A28) FlareNet Files - Farha & Saiwan

A29) Farha Pipeline PipeSim

A30) Saiwan Pipeline PipeSim

Documents

JS1034-XX-F06-0001. A1