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Culture Documents
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REVISIONS
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REVISIONS
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INTRODUCTION............................................................................................................ 12
2.1
2.2
2.2.1
2.2.2
OBJECTIVE ................................................................................................................... 19
5.1
5.2
5.3
5.4
5.4.1
Compositions ................................................................................................................................ 24
5.4.2
5.5.1
5.5.2
6.1
6.2
6.3
6.4
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6.5.1
6.5.2
Oil Transfer Booster Pumps (221-PA-002A/B/C) & Oil Transfer Pumps (221-PA-001A/B/C) ....... 35
7
7.1
7.2
7.3
7.4
7.5
7.5.1
7.5.2
Oil Transfer Booster Pumps (220-PA-002A/B/C) & Oil Transfer Pumps (220-PA-001A/B/C) ....... 38
8
8.1
8.2
8.3
8.4
Flaring System........................................................................................................... 42
8.5
Nitrogen ................................................................................................................... 44
8.6
8.7
9.1
9.2
9.3
9.4
Flaring System........................................................................................................... 48
9.5
Nitrogen ................................................................................................................... 51
9.6
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Closed Drain.............................................................................................................. 52
10
11
12
13
13.1
13.1.1
13.1.2
13.2
13.2.1
13.2.2
13.3
Available Space in FES Control Room for System Cabinet and HMI .............................. 77
13.4
13.4.1
13.4.2
13.5
13.5.1
13.5.2
13.6
13.7
14
15
16
17
APPENDICES............................................................................................................... 106
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2 out of 3
AP
Atmospheric Pressure
BMS
BOPD
BS&W
BVS
BWPD
C&E
CCED
CCC
DB
Distribution Board
DCS
DEP
DG
Diesel Generator
EPF
ESD
Emergency Shutdown
ESDV
FEED
FG
Fuel Gas
F&G
FV
Full Vacuum
GU
Guideline
HAC
HMI
HP
High Pressure
HV
High Voltage
IA
Instrument Air
ICS
ISO
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Junction Box
KOD
LP
Low Pressure
LPG
LT
Level Transmitter
LV
Low Voltage
MCC
MMSCFD
MOV
MV
Medium Voltage
MVA
NPSH
OCSP
OHL
PCV
PDO
PESD
PLC
PSV
P&ID
PT
Pressure Transmitter
RO
Restricted Orifice
RTU
RV
Relief Valve
SCADA
SDV
SP
Specification
SR
Switch Rack
TCV
TP
Tie-in Point
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TSV
TT
Temperature Transmitter
UCP
UG
Underground
UPS
WC
Water Cut
VEC
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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 preexisting 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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Description
Storage Tanks
Off-Spec Tank
Flare System
Remarks
Inadequate based upon a 48 hour
production philosophy but
adequate based on a 24 hr
retention of product.
Inadequate based on 24 hours
product retention.
LP Flare Knockout Drum Inadequate
based on momentum criteria at
inlet nozzle.
Heater Treater Relief Valves are
inadequate based on fire case
scenario.
1 more package is required
Demulsifier Package is inadequate
Diesel Storage Tank Capacity is
inadequate based on 15 days
consumption
Inadequate based on worst case
scenario i.e. No Fuel Gas Available.
Distance between 3rd Train Heater
Treater and Separator is
inadequate.
Expansion of switchgear room is not
possible.
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Description
Separators
Storage Tanks
Export Pumps
Export Booster Pumps
Flare System
Remarks
Operating outside of Operating
Envelope.
Please see section 7.4 of Report
For details, please reference the relevant sections of this Study Report alongside appendices.
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INTRODUCTION
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-TA001A/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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2.2
Facilities Description
2.2.1
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ATM FL
LF
FG
LF
FG
SET @ 8 BARG
LF
SET @ 6 BARG
LF
221-TA-002
Off-spec Oil Tank
PV
191-VL-001
Farha Saiwan Pipeline
PV
ATM FL
PV
201-VS-001A
PRODUCTION SEPARATOR
201-FY-001A
HEATER TREATER
LC
LC
LC
LC
FC
LC
LC
PW
SET @ 8 BARG
LF
FG
LF
PW
LF
FG
221-TA-001A/B
Oil Storage Tank
PW
AL
RO
FC
LF
SET @ 6 BARG
PV
PV
201-VS-001B
PRODUCTION SEPARATOR
221-PA-001A/B/C
Oil Transfer Pumps
201-FY-001B
HEATER TREATER
LC
LC
221-PA-002A/B/C
Oil Transfer Booster Pumps
LC
LC
EXISTING FACILITY
LC
ADDITIONAL TRAINS
LF
PW
LF
PW
PW
FG
FG
LF
SET @ 6 BARG
SET @ 8 BARG
LF
PV
PV
201-VS-001C
PRODUCTION SEPARATOR
201-FY-001C
HEATER TREATER
LC
LC
LC
LC
LC
PW
PW
PW
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The Saiwan Plant is a sour facility and is currently served by a single Inlet Manifold (200-XY001A). 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 (590TM-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-VS001A/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 H2S 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 Oil
Storage 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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ATM FL
LF
FG
LF
FG
SET @ 8 BARG
LF
SET @ 6 BARG
LF
220-TA-002
Off-spec Oil Tank
PV
190-VL-001
Saiwan Alam Pipeline
PV
ATM FL
PV
200-VS-001A
PRODUCTION SEPARATOR
200-FY-001A
HEATER TREATER
LC
LC
LC
LC
FC
LC
PW
INLET MANIFOLD 200-XY-001B
SET @ 8 BARG
LC
LF
FG
LF
PW
LF
FG
PW
AL
220-TA-001A/B
Oil Storage Tank
RO
FC
LF
SET @ 6 BARG
PV
PV
200-VS-001B
PRODUCTION SEPARATOR
220-PA-001A/B/C
Oil Transfer Pumps
200-FY-001B
HEATER TREATER
LC
LC
220-PA-002A/B/C
Oil Transfer Booster Pumps
LC
LC
EXISTING FACILITY
LC
ADDITIONAL TRAIN
PW
Farha Crude
PW
PW
SHAHD Crude
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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
Description
Units
22000
24200
26400
BOPD
0.6
0.66
0.72
MMSCFD
1.5
1.65
1.8
MMSCFD
3980
(17144)
4378
(18858.4)
4776
(20572.8)
BWPD
Units
BOPD
MMSCFD
MMSCFD
28000
30000
30800
33000
33600
36000
BWPD
BOPD
71000
78100
85200
BOPD
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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.
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
5.1
5.2
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5.3
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5.4
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 BarikR3 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
(g/mol)
N2
CO2
H2S
C1
C2
C3
i-C4
n-C4
i-C5
n-C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
Bottomhole
Sample
wt %
mole %
0.16
0.96
0.02
0.06
0
0
0.01
0.15
0.46
2.55
2.43
9.08
0.96
2.73
2.39
6.76
1.34
3.06
1.87
4.26
3.24
6.36
3.63
6.24
4.36
6.72
3.82
5.2
4.1
5.05
3.53
3.95
3.1
3.17
3.54
3.33
3.27
2.84
3.43
2.74
Components
(g/mol)
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32
C33
C34
C35
C36+
Total
Molar Mass
(g/mol)
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Sample
wt %
mole %
2.92
2.16
2.84
1.98
2.85
1.87
2.83
1.78
2.4
1.44
2.28
1.29
2.14
1.16
2.03
1.05
1.91
0.95
1.79
0.85
1.68
0.77
1.65
0.73
1.58
0.67
1.58
0.65
1.5
0.59
1.44
0.55
1.28
0.47
1.21
0.44
1.16
0.41
1.07
0.36
16.2
4.63
100
100
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All molecular weights used in the simulations matched those stated by the individual PVT
reports.
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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
Farha Reservoir
Saiwan Reservoir
SHAHD Reservoir
Production Separators (Farha & Saiwan)
Heater Treaters (Farha & Saiwan)
Atmospheric Storage Tanks (Farha & Saiwan)
Temperature (OC)
57.16
61.5
82
20
67
66.7 (actual on
P&ID 58.6)
5.5
5.5.1
Simulation Cases
Pressure (Barg)
140.9
179
90
5
4
0.98 (actual on
P&ID 0.1)
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 (55OC at inlet to Production Separators). However, for purposes of Heat & Mass
BalancesA1, 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
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
Plant
Oil
Product
ion
(BOPD)
Plant
Produced
Water
(BWPD)
Farha Scenario 1
22128
Farha Scenario 2
Flow Deviation Scenario 1 (%)
Flow Deviation Scenario 2 (%)
4956
N/A
N/A
Description
Reference
Simulation
Oil Value
(BOPD)
Simulation
Water
Value
(BWPD)
Simulation
Total
Produced
Gas
(MMSCFD)
3980
CCED-WI-14-629-021 Rev.02R1
23180
4089
2.2758
17144
N/A
N/A
CCED-WI-14-629-021 Rev.02R1
N/A
N/A
5192
4.7542
4.7619
17610
2.7387
2.7182
0.5031
N/A
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
Produced
Production
Water
(BOPD)
(BWPD)
10000
N/A
23333
N/A
Reference
Max Separator throughput capacity of oil
based on 30 mins residence time
(Separator MRB Reference R8) - 70 %
Water Cut - CCED Instruction
N/A
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Simulation
Oil Value
(BOPD)
Simulation
Water
Value
(BWPD)
Simulation Produced
Gas (Separator +
Heater Treater)
(MMSCFD)
10460
4.6000
24020
2.9443
1.1162
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Table 5.5.2.4: Saiwan (SHAHD Crude Only) Production Profile Scenarios vs Simulation Values & Flow Deviations
Description
Saiwan Scenario 1
(SHAHD 'H' & 'I' Crude)
Saiwan Scenario 2
(SHAHD 'H' & 'I' Crude)
Flow Deviation
Scenario 1 (%)
Flow Deviation
Scenario 2 (%)
Reference
Simulation
Oil Value
(BOPD)
Simulation
Water
Value
(BWPD)
Simulation Produced
Gas (Separator + Heater
Treater) (MMSCFD)
1161
2591
1214
1.2645
10000
3908
9329
4368
4.5513
N/A
N/A
N/A
-12.8197
4.5650
N/A
N/A
N/A
N/A
-6.7100
11.7707
N/A
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6
6.1
6.2
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6.3
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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 m 3 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 m3
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
6.5.1
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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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
7.1
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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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. The Saiwan Heater Treater GAR14 was used alongside Unisim to obtain information for
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 m 3 and based upon
the Process Design BasisR2, 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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7.5
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-PA001A/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 m 3/hr per
pump. One would need at least 2 spares for this operation.
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8
8.1
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
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Rate
Unit
New Requirements
Units
Remarks
30
m /hr
N/A
N/A
0.8252
m /hr
Adequate
Adequate Excluding
intermediate for Fire
System
10
m /hr
0.212
m /hr
0.1652
m /hr
295
299.154
3.9648
18
15.84
0.66
m /hr
0.1652
m /hr
Adequate
Inadequate
Adequate 24 Hours
Supply
Adequate 24 Hours
Supply
N/A
N/A
Based on 3 working +
0 Standby
Diesel Consumption
1. DG Sets
2. Heater Treater
Consumption (3
trains)
3. Fire Water System
Based on 15 days
consumption size
required for Diesel
Storage Tank
N/A
N/A
N/A
N/A
N/A
Intermediate
N/A
N/A
N/A
2.082
299.154
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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.
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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.
In-breathing (Nm/h)
Vessel
Liquid
Movement
Thermal
Effect
Total Inbreathing
3
(Nm /h)
Liquid Movement
Thermal
Effect
165.6
155.2
8.57
Out-breathing (Nm/h)
Total
outbreathing
3
(Nm /h)
Storage Tank
(221-TA-001A)
132.2
33.4
163.8
The in-breathing requirement for just one of the two storage tanks amounts to 3974.4 Nm 3 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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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 BasisR2. 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 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.
8.7
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9
9.1
9.2
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Rate
Unit
New Requirements
Units
Remarks
30
m /hr
N/A
N/A
0.7701
m /hr
Adequate
Adequate Excluding
intermediate for Fire
System
12
m /hr
0.122
m /hr
0.1101
m /hr
295
278.277
1.65
2.6424
20.4
15.84
0.66
m /hr
0.1101
m /hr
Adequate
Adequate
Not Adequate - 24
Hours Supply
Adequate - 24 hours
supply
N/A
N/A
Based on 3 working +
1 Standby
Diesel Consumption
1. DG Sets
2. Heater Treater
Consumption (2
trains)
3. Fire Water System
Based on 15 days
consumption size
required for Diesel
Storage Tank
9.4
N/A
N/A
N/A
N/A
N/A
Intermediate
N/A
N/A
N/A
2.082
278.277
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.
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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. 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-F020663-001 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 tablesA25. 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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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.
In-breathing (Nm/h)
Liquid
Movement
Vessel
Storage Tank
220-TA-001A
210.0
Thermal
Effect
42.5
Total Inbreathing
3
(Nm /h)
252.5
Out-breathing (Nm/h)
Liquid
Movement
246.6
Thermal
Effect
11.67
Total outbreathing
3
(Nm /h)
258.3
The in-breathing requirement for just one of the two storage tanks amounts to 6060 Nm 3
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 OffSpec 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 Nm 3,
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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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 BasisR2. 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-PA001A/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 HighHigh 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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Distance as per
Equipment
Equipment
Distance Actual
56 Meter
30 Meter
43.86 Meter
30 Meter
107.7 Meter
30 Meter
Tank 221-TA-001A/B
61.5 Meter
30 Meter
37.1 Meter
30 Meter
Separator 201-XY-003A
17.4 Meter
15 Meter
Separator 201-XY-003A
20 Meter
15 Meter
Separator 201-XY-003B
20.85 Meter
15 Meter
Separator 201-XY-003B
19.15 Meter
15 Meter
Separator 201-XY-003C
15 Meter
15 Meter
36 Meter
30.5 Meter
55.1 Meter
30.5 Meter
TA-001
TA-002
GAP 2.5.2
Remarks
001A
Pump 221-PA-001A/B/C
A/B
OIL STORAGE TANK 221-TA001 A/B
Fire Water Tank 731-TA001A/B
TA-001
DEMULSIFIER DOSING
PACKAGE 121-XX-001
HEATER TREATER DIESEL DAY
86.6 Meter
30.5 Meter
3.6 Meter
NA
TANK 201-TA-001
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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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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Equipment
Equipment
Distance Actual
001A
001B
001A
002
Distance as per
GAP 2.5.2
70.6 Meter
30 Meter
70.6 Meter
30 Meter
Separator 200-XY-003A
16.025 Meter
15 Meter
Separator 200-XY-003A
17.4 Meter
15 Meter
Separator 200-XY-003B
20 Meter
15 Meter
41.5 Meter
30 Meter
42.5 Meter
30 Meter
13.5 Meter
15 Meter
Remarks
PA-003A/B
430-TA-001 DIESEL STORAGE Fire & utility Pump house 730TANK
PA-003A/B
430-PA-001
TANK
430-PA-001
001
DG AREA
31.7 Meter
30 Meter
31.9 Meter
30 Meter
XX-001
Heater
treater
200-XX-
001A
Separator 200-XY-003A
HEATER
Not
Adequate
TREATER
DIESEL
2.65 Meter
NA
20.3 Meter
15 Meter
DEMULSIFIER DOSING
PACKAGE 120-XX-002
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DATE
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TITLE
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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13.1
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 Safety
Function.
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 SIEMENSSYSTIMAX 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 PANELFARHA-MAR-001/002/003/004) have spare space for inclusion of a new Terminal Board.
JS1034-XX-F06-0001.A1
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(Oman Branch)
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TITLE
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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TITLE
SPARE RACKS
SPARE SLOTS
CPU/IO
RACK-2
RACK-B
PANEL-731-FG-001
CPU/ IO
RACK-C
PANEL-FARHA-IOP-001
SLOT 9, SLOT 10
(DCS SECTION)
RACK-H
SLOT 8, SLOT 9, SLOT 10
CPU/ IO
RACK-F
PANEL-FARHA-IOP-002
SLOT 9, SLOT 10
(ESD SECTION)
RACK-G
SLOT 9, SLOT 10
CPU/ IO
PANEL-FARHA-IOP-003
RACK-D
SLOT 7, SLOT 8, SLOT 9, SLOT
10
(ESD SECTION)
RACK-E
SLOT 7,SLOT 8, SLOT 9, SLOT
10
5
CPU/ IO
RACK- 2
RACK-I
PANEL-FARHA-IOP-004
(ESD 1 SECTION)
RACK-J
SLOT 8, SLOT 9, SLOT10
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TITLE
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(Oman Branch)
JOB NR.
JS1034
DOCUMENT NR.
REV.
JS1034-XX-F06-0001
DATE
A1
SHEET
64 of 107
TITLE
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PROJECT
(Oman Branch)
JOB NR.
JS1034
DOCUMENT NR.
REV.
JS1034-XX-F06-0001
DATE
A1
TITLE
JS1034-XX-F06-0001.A1
SHEET
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TITLE
Rack C, C406
Rack No. : RACK C
Slot No.
:6
I/O Module : Analog Output Module C406
Channel
: 8CH
Signal
: 4-20mA
Spare
: Q7+ PQW670
Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 2): H303, H307,
RS-485 Bus Connector with Tilted Cable Outlet (without PG port): 1H1,1H2,
: H101,H102,H104,H105
: H206
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Rack H, H101
Rack No. : RACK H
Slot No.
:1
I/O Module : Digital Input Module H101
Channel
: 16CH, 24VDC
Spare
: I12.5, I13.5, I13.6, I13.7
Digital Input Module H102
Rack No. : RACK H
Slot No.
:2
I/O Module : Digital Input Module H102
Channel
: 16CH, 24VDC
Spare
: I15.7
Rack H, H303
Rack No. : RACK H
Slot No.
:3
I/O Module : Analog Input Module H303
Channel
: 8CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW776, M5+ PIW778, M6+ PIW780, M7+782
Rack H, H104
Rack No. : RACK H
Slot No.
:4
I/O Module : Digital Input Module H104
Channel
: 16CH, 24VDC
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
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Rack F, F101
Rack No. : RACK F
Slot No.
:1
I/O Module : Digital Input Module F101
Channel
: 24CH, 24VDC
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
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TITLE
Spare
,
Rack F, F203
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(Oman Branch)
JOB NR.
DOCUMENT NR.
JS1034
REV.
JS1034-XX-F06-0001
DATE
A1
TITLE
: 10CH, 24VDC
: Q1096.0, Q1096.1, Q1096.2, Q1096.3
Rack G, G207
Rack No. : RACK G
Slot No.
:7
I/O Module : Digital Output Module G207
Channel
: 10CH, 24VDC
Spare
: Q1113.0, Q1113.1
Rack F, F208
Rack No. : RACK F
Slot No.
:8
I/O Module : Digital Output Module F208
Channel
: 10CH, 24VDC
Spare
: Q121.0, Q121.1
Rack G, G208
Rack No.
Slot No.
: RACK G
:8
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Rack D, D301
Rack No. : RACK D
Slot No.
:1
I/O Module : Redundant Analog Input Module D301
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW682
Rack E, E301
Rack D, D302
Rack No. : RACK D
Slot No.
:2
I/O Module : Redundant Analog Input Module D302
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW698
Rack E, E302
Rack No.
: RACK E
JS1034-XX-F06-0001.A1
: D301D306,
PROJECT
(Oman Branch)
JOB NR.
DOCUMENT NR.
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TITLE
Rack No.
Slot No.
: RACK D
:5
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Rack E, E305
Rack No. : RACK E
Slot No.
:5
I/O Module : Redundant Analog Input Module E305
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+PIW1744, M5+PIW1746
Rack D, D306
Rack No. : RACK D
Slot No.
:6
I/O Module : Redundant Analog Input Module D306
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M0+PIW752, M5+PIW762
Rack E, E306
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(Oman Branch)
JOB NR.
DOCUMENT NR.
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REV.
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DATE
A1
TITLE
Channel
Signal
Spare
Rack J, J301
: 6CH
: 4-20mA, HART (2 wire)
: M5+PIW794
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DOCUMENT NR.
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DATE
A1
TITLE
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SHEET
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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
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TITLE
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DOCUMENT NR.
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TITLE
SPARE RACKS
SPARE SLOTS
CPU/IO
RACK 1
NO SPARE SLOTS
AVAILABLE
NO SPARE RACKS
AVAILABLE
RACK B
PANEL-730-FG-001
2
SLOT 9, SLOT 10
RACK C
SLOT 8, SLOT 9, SLOT 10
RACK D
SLOT 9, SLOT 10
NO SPARE RACKS
AVAILABLE
NO SPARE SLOTS
AVAILABLE
NO SPARE RACKS
AVAILABLE
RACK E
SLOT 9, SLOT 10
RACK F
SLOT 9, SLOT 10
13.5
Analog input module, AI 8 x4-20mA, 4W/2W, HART (Quantity 8): B306, B307, B308, C301
C301, C302, C303, C304, C305
JS1034-XX-F06-0001.A1
: PS1, PS2
: B101,B102,B103,B104
: B205
PROJECT
(Oman Branch)
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RS-485 Bus Connector with Tilted Cable Outlet (without PG port): 1B1,1B2,1C1,1C2, 1D1, 1D2
PROFIBUS FastConnect bus cable, 2-core, shielded (Quantity 20) : CPU1, CPU2
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(Oman Branch)
JOB NR.
DOCUMENT NR.
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DATE
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TITLE
Rack No.
Slot No.
: RACK C
:1
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SHEET
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TITLE
: 8CH
: 4-20mA
: Q7+ PQW654
Rack D, D107
Rack No.
: RACK D
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TITLE
Rack G, G101
Rack No. : RACK G
Slot No.
:1
I/O Module : Redundant Digital Input Module G101
Channel
: 24CH, 24VDC
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
Channel
: 24CH, 24VDC
Spare
: Spare Slot
Rack G, G203
Rack No. : RACK G
Slot No.
:3
JS1034-XX-F06-0001.A1
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(Oman Branch)
JOB NR.
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REV.
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DATE
A1
TITLE
: RACK G
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TITLE
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SHEET
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TITLE
Fail
Safe
Analog
input
module, AI
x4-20mA,(Quantity
12):
E301E306,
F301F306.
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
I/O Module : Redundant Analog Input Module E301
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW714
Rack F, F301
Rack No. : RACK F
Slot No.
:1
I/O Module : Redundant Analog Input Module F301
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW1714
Rack E, E302
JS1034-XX-F06-0001.A1
PROJECT
(Oman Branch)
JOB NR.
DOCUMENT NR.
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JS1034-XX-F06-0001
DATE
A1
TITLE
: M5+ PIW730
Rack F, F303
Rack No. : RACK F
Slot No.
:3
I/O Module : Redundant Analog Input Module F303
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW1746
Rack E, E304
Rack No. : RACK E
Slot No.
:4
I/O Module : Redundant Analog Input Module E304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+ PIW1714
Rack D, D304
Rack No. : RACK D
Slot No.
:4
I/O Module : Redundant Analog Input Module D304
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M0+ PIW720, M1+PIW722, M5+PIW730
Rack D, E304
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TITLE
: M5+PIW762
JS1034-XX-F06-0001.A1
SHEET
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TITLE
Rack E, E308
Rack No. : RACK E
Slot No.
:8
I/O Module : Redundant Analog Input Module E308
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW826
Rack F, F308
JS1034-XX-F06-0001.A1
: G309, G310,
PROJECT
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TITLE
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
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW794
Rack J, J301
Rack No. : RACK J
Slot No.
:1
I/O Module : Redundant Analog Input Module G309
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M5+PIW1794
Rack I, I302
Rack No. : RACK I
Slot No.
:2
I/O Module : Redundant Analog Input Module I302
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW808, M5+PIW810
Rack J, J302
Rack No. : RACK J
Slot No.
:2
I/O Module : Redundant Analog Input Module J302
Channel
: 6CH
Signal
: 4-20mA, HART (2 wire)
Spare
: M4+ PIW1808, M5+PIW1810
Rack I, I303
Rack No.
: RACK I
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Rack No.
Slot No.
: RACK I
:5
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Rack J, J307
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Fig.13.6.1 Space available for System Cabinets/ Marshalling Cabinets new DCS/ESD/FGS
System at SES
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TITLE
Max.
Oil/
Liquid
Water/
Liquid
Water/
Liquid
Compressibility
Specific Garvity
Critical Pressure
20
32.5
0.01345
NA
1.252
7.511
0.9786
NA
NA
0.354
42.64
4.987
3.987
20
32.5
0.01345
NA
1.254
8.19
0.9767
NA
NA
0.582
51.168
3.987
55
32.5
0.01345
NA
1.254
8.209
0.9841
NA
NA
0.694
223.9953
3.7
0.9868
36.9
43.53
0.00972
NA
1.157
8.237
0.9445
NA
NA
2.3
447.9905 3.987
0.9868
67
43.53
0.01063
NA
1.141
8.089
0.9514
NA
NA
4.435
537.5886
0.9868
67
43.53
0.01063
NA
1.141
8.11
0.9513
NA
NA
5.373
21085.31 4.987
3.987
20
165.4
3.09
4.986
1.185
810.7
NA
0.81
50.74
42170.63 4.987
3.987
20
165.4
3.09
4.986
1.185
810.7
NA
0.81
50.74
Existing Trim is not suitable for given process data for Min.
/Norm. /Max. Controllability.
70.7
Existing Trim is not suitable for given process data for Min.
/Norm. /Max. Controllability.
53.8
42
73.253
REMARKS
Molecular weight
3.987
VALVE OPENING %
Operating Temp.(Deg C)
4.7
EXISTING RATED CV
Outelt Pressure(barg)
NEW CALCULATED CV
Oil/
Liquid
HC Gas/
Vapour
21.32
TAG NO.
201-PV-106A
201-PV-202
HC Gas/
Vapour
Max. Norm. Max. Norm. Min. Max. Norm. Min. Max. Norm. Min.
201-LV-110A
201-LV-204A
201-LV-107A
201-LV-202/203
S/N
58
1. Existing Trim is not suitable for given new process data for
minimum controllability.
224
50604.75
3.987
55
20861.32
3.5
0.9868
41722.64 3.987
50067.16
165.4
1.638
4.986
1.186
782.2
NA
0.81
50.74
20
1.181
813.5
NA
0.813
50.74
0.9868
67
170.527
1.419
3.987
1.023
774.5
NA
0.774
50.74
0.9868
67
170.527
1.419
3.987
1.023
774.5
NA
0.774
50.74
96.557
80
4458.928
4.5
20
18.02
1.0017
1.135
1011
NA
1.011
NA
2.76
17
8917.855
20
18.02
1.0017
1.135
1011
NA
1.011
NA
5.165
10701.43
5.5
55
18.02
1.0017
1.153
984
NA
0.9845
NA
5.88
35
1065.5
20
18.02
1.002 NA
1.1812
1011
NA
1.011
NA
0.781
41
2131
3.5
67
18.02 0.417646
NA
1.0226
824.1
NA
0.824
NA
1.144
58
2557.2
55
18.02 0.417646
NA
1.185
975.1
NA
0.975
NA
1.595
1471.681
3.98
0.9
63.52
42.282
0.0109
NA
1.147
7.903
0.9556
NA
NA
14.811
11
1766.017
0.9
63.51
42.282
0.0109
NA
1.147
0.186 0.955479
NA
NA
115.947
52
JS1034-XX-F06-0001.A1
87.507
62
136
70.7
4.91
32
1. Existing Trim is not suitable for given new process data for
minimum controllability.
61
2. For normal & maximum controllability, the existing Trim
can be re-used, if no concern on minimum control.
PROJECT
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TITLE
Max.
Water/
Liquid
Norm. Min.
Max.
Water/
Liquid
NA
NA
11.898
1095.597
20
27.119 0.01086
NA
NA
NA
16.873
1314.716
5.5
55
27.119 0.01086
NA
NA
NA
17.649
29535.63
4.5
20
214.2
8.53163
1.148
852.7
NA
0.8527
51.263
59071.27
20
214.2
8.48012
1.149
852.5
NA
0.8527
51.263
70885.52
4.5
55
214.2
5.12095
1.018
826.5
NA
0.826
51.263
29238.56
3.5
20
224.516
9.34
NA
0.855
46.883
58477.13
67
224.516
4.38
819.3
819.3
NA
0.819
46.883
70172.55
4.5
67
224.516
4.38
819.3
819.3
NA
0.819
46.883
297.07
3.5
3.5
20
36.719 0.00935
NA
1.184
7.184
0.946
NA
NA
594.14
3.5
67
36.719 0.01071
NA
1.1449
7.189
0.946
NA
NA
12.339
712.97
4.5
3.5
67
36.719
0.0107
NA
1.152
7.942
0.946
NA
NA
10.542
3630.637
0.01
20
25.654
0.0112
NA
1.235
4.767
0.978
NA
NA
61.357
7261.274
3.5
0.09
20
25.654
0.0112
NA
1.235
4.767
0.978
NA
NA
113.537
855.954 855.954
70.7
REMARKS
VALVE OPENING %
NA
EXISTING RATED CV
NEW CALCULATED CV
Critical Pressure
27.119 0.01086
Compressibility
20
Specific Garvity
4.5
Operating Temp.(Deg C)
547.7983
Molecular weight
Outelt Pressure(barg)
HC Gas/
Vapour
HC Gas/
Vapour
Oil/
Liquid
Norm. Min. Max. Norm. Min. Max. Norm. Min. Max. Norm. Min. Max. Norm. Min.
TAG NO.
200-PV-006A
201-LV-007A
200-LV-402/403
402-PV-401
Oil/
Liquid
200-LV--010A
HC Gas/
Vapour
200-LV-404A
200-PV-402
S/N
52
60
61
224
91.366
63
136
93.595
75
53.84
54
67
224
8713.529
0.79
55
25.654
0.0112
13978.21
4.5
20
18.02
1.002
27956.41
20
18.02
1.002
NA
1.235
4.767
0.978
NA
NA
129.905
71
5 1.131
1011
NA
1.011
220.2
8.657
44
1.131
1011
NA
1.011
220
16.214
59
70.7
3547.693
5.5
20
18.02
1.002
1.131
1011
NA
1.011
220.2
18.352
61
1419
3.5
20
18.02
1.002
NA
1.131
1011
NA
1.011
NA
1.041
13
2838
67
18.02
0.41765
NA
1.131
1011
NA
0.824
NA
1.919
3405.6
4.5
55
18.02
0.41765
NA
1.131
1011
NA
0.984
NA
2.126
JS1034-XX-F06-0001.A1
17.2
26
29
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TITLE
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;
JS1034-XX-F06-0001.A1
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TITLE
Spare feeders
Rating
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Q 101
Q 106
Q 107
Q 205
Q 207
Q 301
Q 405
Q 407
Q 501
Q 601
Q 702
Q 1301
Q 1306
Q 1407
Q 1502
Q 1607
Q 1705
Q 1804
15kW
55kW
1.5kW
3kW
3.7kW
5.5kW
7.5kW
10A
30kW
30kW
10kW
22kW
0.55kW
3kW
3.7kW
70A
100A
25A
Vacant
Compartment
Q 807
Q 1706
Q 1707
Q 1904
Q 1905
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TITLE
Sl. No.
Spare feeders
Rating
1
2
3
4
5
6
7
8
9
10
11
Q 602
Q 503
Q 507
Q 302
Q 207
Q 101
Q 1501
Q 1507
Q 1704
Q 1705
Q 1904
30kW
25A
100A
3.7kW
3kW
15kW
22kW
3kW
7.5kW
10A
150A
Vacant
Compartment
Q 704
Q 601
Q 1706
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 H2S 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.
.
Sl. No.
Spare feeders
Rating
1
2
3
4
Q 303
Q 406
Q 703
Q 501
5.5kW
18.5kW
37kW
11kW - VFD
Vacant
Compartment
Q 407
Q 503
Q 603
Q 704
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Conclusion
The following points are concluded from above study:
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.
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).
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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Description
Storage Tanks
Off-Spec Tank
Flare System
Remarks
Inadequate based upon a 48 hour
production philosophy but
adequate based on a 24 hr
retention of product.
Inadequate based on 24 hours
product retention.
LP Flare Knockout Drum Inadequate
based on momentum criteria at
inlet nozzle.
Heater Treater Relief Valves are
inadequate based on fire case
scenario.
1 more package is required
Demulsifier Package is inadequate
Diesel Storage Tank Capacity is
inadequate based on 15 days
consumption
Inadequate based on worst case
scenario i.e. No Fuel Gas Available.
Distance between 3rd Train Heater
Treater and Separator is
inadequate.
Expansion of switchgear room is not
possible.
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Description
Separators
Storage Tanks
Export Pumps
Export Booster Pumps
Flare System
Remarks
Operating outside of Operating
Envelope.
Please see section 7.4 of Report
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