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WAFA DESERT PLANT

PLANNED SHUTDOWN 2018


WAFA DESERT PLANT OVERVIEW
SD 2018
CONTENT
- PURPOSE OF SD 2018
- GENERAL PRESENTATION
- SCOP OF WORK
- MANPOWER – ORGANIZATIONAL CHART
- DETAILED SOW
- WORK PACKAGE CONTENTS
- SD DAILY REPORT – SAMPLE
- EQUIPMENT AND TOOLS
- REFERENCE SNAPSHOTS
- AREAS OF CONCERN

Prepared by: Ionel MOCANU DL_MEM


SD 2018
PURPOSE OF SD 2018
The main activities of SD 2018 are related to mandatory / statutory inspection TR.1 and TR.2,
replacement of Cold Box in TR.2 and insert new 9 wells.
Production Documents related to SD 2018 are in jerma Hyperlink: Production SD 2018
SD 2018 will be started on 2nd of April, following are the Production / procedures & SOW for
SD2018:
• In order to obtain stable running of GTG (of at least 2.5 MW) during the Total SD 2018, Hot
Oil & cooling water system should be kept on operation as well as the liquid train.

• All oil from wells should be treated and the treated oil should be stored at the storage tanks,
associated gas will be flared.

• List of valves to be overridden in order to keep GTG & oil train in stable operation during
the execution of the ESD cabinets works had been sent to ABB (see attached).

• In case of any failure of power generation, find out the attached draft showing the diverting
& re-diverting procedure of oil wells to the storage tank during TSD2018 (Black Out scenario).

• Isolation, Depressurizing, Purging & SD/Start up procedures prepared (see attached).


SD 2018
PURPOSE OF SD 2018
• Blinding plans were reviewed & approved by Production (See attached).

• Cold box blind plan was reviewed and approved based on BNT, SOW (See attached).

• Production gain by replace of cold box of NGL is around 400BBL/D

• Production Loss during total SD 20000bbl/d NGL, 10000 bbl/d condensate and 414
MMSCF/D

• Production Loss during partial SD 10000bbl/d NGL, 4500 bbl/d condensate5+ AND 215
MMSCF/D
SD 2018
GENERAL PRESENTATION
• The 2018 Shutdown of Wafa Plant was planned to be attended tentatively
between 2nd of April and 13th of April 2018. SD will begin with Total SD for 7
days in parallel with Partial SD for 12 days, anticipating the following
scenario(as per Master Plan):
2nd – 8th of April - Total Shutdown - Project activities, Slug
Catcher, Export Gas / Off Gas, Gas Train 1

2nd – 13th of April - Partial Shutdown - Gas Train 2 Area

Activities before and after SD2018

15th of March - 1st of April Site Preparation & Mobilization

14th of April – 20th of April Flare Activities


SD 2018
• Total Shutdown scope is targeting equipment and jobs related to the Project
activities, Slug Catcher, Export Gas / Off Gas, Gas Train 1 and main
activities are: New Inlet Gas Compression Station, New 9 Infilling Wells, Off
Gas Compressor PSV’s Testing & Calibration, Control Seal and other
various Valves replacement and / or repair, Replacement of Catalyst on Gas
Dryers.
• Partial Shutdown scope is targeting equipment located only in the Gas Train
2 Area and main activities are: Cold Box replacement, Control Seal and
other various Valves replacement and / or repair, Replacement of Catalyst on
Gas Dryers.
• The scope will be executed by an integrated team of MOG, DIETSMANN
and BONATTI personnel assisted by vendors / certified contractors
additional manpower.
• During the proposed 12 days duration (included with 1 day ramp up and 1
day ramp down) most of the SD activities will focus Static equipment but will
also include additional jobs related to other disciplines (Electric, Instrument,
IAS included tie-ins in Wells and Slug Catcher for new Projects).
SD 2018

• The molecular sieves replacement for the Gas Train 1 & 2 dryers is
conditioned by the arrival of Control Seal valves spare parts before the start
of the Total Shutdown.
• Flare activities will follow after SD 2018 completion. Start first with Flare A
repair and replaced new diverter and then flare B replacement of HP an LP
flare tips.
……………………………………………………………………………………

• The SD 2018 activities will consist of inspections, corrective work orders


(COs) – including the replacement of the molecular sieves for the gas dryers -
and preventive work orders (PMs) according to the following Scope of
Work:
SD 2018
SCOPE OF WORK

Total SD: 7 days (Total of 410 items) – Project Activities, Slug Catcher, Export Gas /
Off Gas, Gas Train 1
• 09 Vessels Inspection (including 3 Gas Dryers)
• 14 Control Seal Valves Tr. 1
• 01 PSVs in Tr. 1
• 12 PSVs in Off Gas
• 12 Valves
• 04 Electrical PMs and Cos
• 339 Instrument PMs
• 15 IAS PMs& Cos
• 04 Project Activities performed by BONATTI
SD 2018
SCOPE OF WORK

Partial SD: 12 days (Total of 195 items) – Gas Train 2 Area

• Cold Box –replacement by BONATTI


• 15 Vessels Inspection (including 3 Gas Dryers)
• 14 Control seal valves
• 07 Valves repair / replacement
• 158 Instrument PMs
SD 2018
MANPOWER – ORGANIZATIONAL CHART
Summary of Total Manpower involved in Shutdown activities is as per
below structure:

DIETSMANN DL Extra MOG BNT TOTAL


Team Manpower Staff Staff

103 66 58 60 287
• Some of the additional resources will be mobilized earlier in order to start
the preparatory activities prior to the beginning of the actual SD period; the
earlier mobilization of a certain number of personnel is also required to get
the personnel familiar with the Plant and HSE/Maintenance procedures.
SD 2018
MANPOWER – ORGANIZATIONAL CHART
Shutdown 2018 Organizational Chart rev.2 24 / hours
SD 2018
The number of Production Manpower require during 2018 shutdown as followings:
SD 2018
DETAILED SOW
000. SD-2018-SoW - FROZEN
Total SD 2018 Items List for 7 days Partial SD 2018 for 14 Days

No No Items Total SD Items Area Crane


No No Items Partial SD Items Area Crane

Off Catche
1 1 10300VA001 - Inlet Gas Slug Catcher KO Drum 65T

Filters Slug
2 2 20130VA001 - Gas Slug Catcher Liquid Holder N/A Slug Catcher
1 1 20130VA002 - Gas Slug Catcher Liquid Holder

Train 1 Gas r
3 3 10361CL001A - Off Gas Compressor Filter Gas Train 2
Vessels

4 4 10361CL001B - Off Gas Compressor Filter 2 2 12340HH001 - Cold Box Replacement 250T

dryes
5 5 11310VK001A - Gas Dryer A 65T 3 3 12310VK001A - Gas Dryer A 65T

dryes
6 6 11310VK001B - Gas Dryer B 65T

Gas
7 7 11310VK001C - Gas Dryer C 65T

Train 2
4 4 12310VK001B - Gas Dryer B 65T

ai

1
Tr

n
8 8 11310FA001 GAS HEATER 65T

Gas
5 5 12310VK001C - Gas Dryer C 65T
9 1 11310UV011 - 24"x20" RAW GAS TO VK001 A (P2) 180T
10 2 11310UV013 - 24"x20" TREATED GAS FROM VK001 A (P3) 180T 6 6 12310HA001 - Gas Gas Exchanger Gas Train 2 90T
11 3 11310UV021 - 24"x20" RAW GAS TO VK001 B (P1) 180T 7 7 12310FA001 Gas regeneration Heater Gas Train 2 NA

Control Seal valves Train 1


12 4 11310UV024 - 24"x20" RAW GAS TO VK001 C (P2) 180T
Gas Train 2

Vessels
8 8 12340HA002 - NGL Cooler FORCKLIFT
Control Seal valves

13 5 11310UV027 - 24"x20" TREATED GAS FROM VK001 B (P3) 180T


14 6 11310UV030 - 24"x20" TREATED GAS FROM VK001 C (P1) 180T 9 9 12310HC001- Regeneration Gas Cooler Gas Train 2 NA
15 7 11310UV012 - 10"x8" TREATED GAS FROM VK001 A (P2) 180T Gas Train 2
10 10 12310HC002 - Regeneration Gas Compressor Cooler NA
16 8 11310UV014 - 10"x8" TREATED GAS FROM FA001 (P1) 180T
11 11 12330HC003 - Regenerator Overhead Condenser Gas Train 2 NA
17 9 11310UV022 - 10"x8" RAW GAS FROM VK001 B (P2) 180T
18 10 11310UV025 - 10"x8" RAW GAS FROM VK001 C (P2) 180T 12 12 12340HC001 - DPCU Final Cooler Gas Train 2 NA
19 11 11310UV028 - 10"x8" TREATED GAS FROM FA001 (P1) 180T Gas Train 2
13 13 12340HC011 - TE Lube Oil Cooler 65T
20 12 11310UV034 - 10"x8" TREATED GAS FROM FA001 (P1) 180T
14 14 12330VA005 - Regenerator Reflux Drum Gas Train 2
21 13 11310UV041 - 8"x6" Treated Gas to VK001A/B/C (P1) 180T
22 14 11310UV042 - 8"x6" Treated Gas to FA001 (P1) 180T 15 15 12550VA002 - Wet Hydrocarbons Sump Drum Gas Train 2 65T
23 1 10361PSV901 - 1.5"X3" Raw Gas from CL001A 90T Gas Train 2
16 16 12330VE001 - HP Absorber NA
24 2 10361PSV902 - 1.5"X3" Raw Gas from CL001B 90T
17 17 12330VJ001 - Amine Regenerator Gas Train 2 NA
25 3 10361PSV911 - 6"X8" Raw Gas from KA001A 90T
26 4 10361PSV912 - 2"X3" Raw Gas from VA001A 90T 18 1 12310UV011 - 24"x20" RAW GAS TO VK001 A (P1) 180T

PSVs Off Gas


27 5 10361PSV921 - 4"X6" Raw Gas from KA002A 19 2 12310UV013 - 24"x20" TREATED GAS FROM VK001 A (P3) 180T
28 6 10361PSV922 - 6"X8" Raw Gas from VA002A 90T 20 3 12310UV021 - 24"x20" RAW GAS TO VK001 B (P2) 180T
PSVs

Control Seal valves Train 2


29 7 10361PSV931 - 2"X3" Raw Gas from VA003A 21 4 12310UV024 - 24"x20" RAW GAS TO VK001 C (P2) 180T
30 8 10361PSV941 - 6"X8" Raw Gas from KA001B 90T 22 5 12310UV027 - 24"x20" TREATED GAS FROM VK001 B (P3) 180T

Control Seal valves


31 9 10361PSV942 - 2"X3" Raw Gas from VA001B 90T 23 6 12310UV030 - 24"x20" TREATED GAS FROM VK001 C (P3) 180T
32 10 10361PSV951 - 4"X6" Raw Gas from KA002B 90T 24 7 12310UV012 - 10"x8" TREATED GAS FROM VK001 A (P1) 180T
33 11 10361PSV952 - 6"X8" Raw Gas from VA002B 90T 25 8 12310UV014 - 10"x8" TREATED GAS FROM FA001 (P3) 180T
34 12 10361PSV961 - 2"X3" Raw Gas from VA003B 90T 26 9 12310UV022 - 10"x8" RAW GAS FROM VK001 B (P2) 180T
N1
TR
PS
Vs

AI

35 13 11330PSV922 - 1"X2" Raw Gas from CL001B 27 10 12310UV025 - 10"x8" RAW GAS FROM VK001 C (P2) 180T
36 1 10300SDV004A - 30" SDV Ras Gas from VA001: To replace the valve 180T 28 11 12310UV028 - 10"x8" TREATED GAS FROM FA001 (P3) 180T
Valves Slug Catcher

37 2 20130RB018B - 8" Ball Valve Downstream UV005: To replace the valve 90T 29 12 12310UV034 - 10"x8" TREATED GAS FROM FA001 (P2) 180T
Valves Replacement and repair

38 3 20130RB024B - 8" Ball Valve Downstream UV007: To replace the valve 90T 30 13 12310UV041 - 8"x6" Treated Gas to VK001A/B/C (P3) 180T
39 4 20130RB103B - 6" Ball Valve Upstream PSV914B: To replace the valve 90T
31 14 12310UV042 - 8"x6" Treated Gas to FA001 (P3) 180T
40 5 20130RB103C - 6" Ball Valve Upstream PSV914B: To replace the valve 90T
41 6 10362SDV096A - 26" SDV Sales Gas to Pipeline: To replace the valve 90T 32 1 12310HV201 (MOV001) - 20" MOV Treated Gas to CL001A - To replace the valve 90T
42 7 20130HV215 (MOV011) - 16" MOV Raw Gas to VR006: To replace the valve 65T

Valves Replacement and repair


43 8 11330RB552A - 4" Ball Valve Downstream PSV922: To replace the valve 33 2 12310HV202 (MOV002) - 20" MOV Treated Gas from CL001A - To repair the valve 90T
Valves train1

44 9 11340RB055F - 18" Ball Valve Upstream PV023A: To replace the valve 180T

Valves Train 2
34 3 12310HV203 (MOV003) - 20" MOV Treated Gas to CL001B - To repair the valve 90T
45 10 11340RB055G - 20" Ball Valve Downstream PV023A: To replace the valve 180T

46 11 11340RB077A - 20" Ball Valve Upstream SDV002A: To replace the valve FORCKLIFT 35 4 12330HV203 (MOV023) - 20" MOV Raw Gas to CL001B: To replace the valve 90T
47 12 10300SDV009 - 30" SDV Raw Gas to VA001: To replace the valve SG1 180T
36 5 12330HV204 (MOV024) - 20" MOV Raw Gas from CL001B: To replace the valve 90T

No Total SD electrical/Instrumentation/ IAS items Total Items 37 6 12340PV023A - 12" PV of ML001: To repair the valve 90T
1 Electrical PMs and Cos 4
2 Various Instrument PMs Stroke testing of various valves 339 38 7 12340RB055B - 20" Ball Valve PV023A Downstream: To repair the valve 90T
3 Various IAS PMs& Cos 16

Project Team Partial SD electrical/Instrumentation


No Total Items No Total Items
1 ESD Tie in IGCS project ( need 0 volt) 1 1 Electrical PMs and Cos 0
2 New cubical Tie in SS1/SS2/SS3 switchgear 3
2 Various Instrument PMs Stroke testing of various valves 158
3 9 infilling wells SG1 1
Total items 4

Recap
Recap Table
Table Partial
Total SD2018
SD2018 items
items

No Total SD Items Total No Partial SD 2018 Items Total


1 Vessels 8 1 Vessels 15
2 Control Seal Valves 14 2 Control Seal Valves 14
3 PSVs 13 3 Valves 7
4 Valves 12
4 Cold Box 1
5 Electrical 4
6 Instrumentation 339 5 Electrical 0
7 IAS 16 6 Instrumentation 158
8 Project items 4 Total Items 195
Total Items 410

Estimated Extra Manpower = 66 persons


Estimated Extra Manpower = 66 persons Estimated Extra Cranes = 2 cranes ( 180 T Crane and 65 T crane)
Estimated Extra Cranes = 2 cranes ( 180 T Crane and 65 T crane)
SD 2018
WORK PACKAGE CONTENTS
All SD 2018 WP’s with below contents are reviewed and approved by MOG.
Work package
SD 2018
SD DAILY REPORT – SAMPLE

The format of daily report will be as per below sample


SD 2018
Daily Progress “S” Curve
SD 2018
EQUIPMENT, TOOLS AND SPARE PARTS
- Equipment, tools and spare parts are prepared and started on 15th of March
to be sent to plant on loading area close to equipment that have to be serviced
as per plot plan attached to each WP. Containers with martials will be placed
on parking area as per agreement with Production and HSEQ.
- Mobilization of three extra cranes ( one provided by BNT) and vacuum unit
are planned to be on plant before or on 1st of April.
- Tools will arrive on plant 26 of March.
- Spare Parts
Vessels:
Spare parts and material for 26 vessels already transferred in SD Container No.8 to the Plant.
Valves:
15 Valves shall be replaced
- already ongoing testing in Valve workshop
- 6 Valves already transferred to the plant
4 Valves shall be repaired
- Spare parts are available
SD 2018
Control Seal valves:
Status for Train 1:
- 4 pcs 24” valves new, without actuators,
- 4 pcs 10” valves overhauled and tested (all without actuator),
- 1 pcs 8” valve complete with actuator.
- If FPO-26330 will be until 25th of March, then there will be 9 valves complete with
actuator, just to be swapped in Train 1
- Completed 24”x20” – Valve + Actuator = 4
- Completed 10”x8” – Valve + Actuator = 4
- Completed 8”x6” – Valve + Actuator = 1
Last 5 valves from total of 14, follow to be inspected / overhauled.

Status for Train 2:


- 14 valves to be inspected / overhauled
- There are in Train 2, 6pcs 10” new valves installed (in 2016 -4 and 2 – 2017) with old
actuators, so we do not expect a lot of trouble with these valve bodies.
SD 2018

REFERENCE SNAPSHOTS
• In the following slides have been displayed for further reference
snapshots subjecting the general view & activities carried-on during the
previous shutdowns in Wafa Plant for some of the main equipment listed
in 2018 SD Scope of Work or for other equipment similar to the afore
mentioned ones.
SD 2018

Preparing for a confined space Positioning of the high pressure


entry for internal inspection pump for internal cleaning
SD 2018

Tube bundle prepared for inspection


SD 2018

Reinstall the tube bundle


SD 2018

Control Seal Valves and Gas Dryers Activities


SD 2018

Regeneration Gas Heater


SD 2018
Finned Tubes in Convection zone - inside
Regeneration Gas Heater

Radiant zone - Hanger - Inside


Regeneration Gas Heater
SD 2018

Gas Dryers Gas Dryers - Loading of


new catalyst
SD 2018

AREAS OF CONCERN
- AUTOMATION ABB ARRIVAL
ESD Override – In order to prevent Total Black out, 107 valves needs to be overridden,
procedure not yet received from Engineering.
Contractor expected on Plant on 23rd of March.
- MATERIAL ARRIVAL - CS Valves-
1. 4 flange coupling and 4 protection tubes: on 14-3-18 finalizing customs clearance,
should be in Wafa in the next coming days – arrived 27th March.
2. 4 actuators 10’’x 8’’- waiting shipment to Abusita Terminal.
3. 4 actuators 24’’x20” are still in Italy, to be shipped on March 20 , 2 of the a.m. 4
actuators will not be ready on the 15th but supposedly on the 21st / 22nd March.

- COLD BOX FLANGES ALIGNMENT


Alignment of flanges in order to have nozzles stress free - possible to extend duration of
activities.
SD 2018

END OF PRESENTATION

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