Projects

Petroleum development Oman

Bullet Points

04/05/24 Project's Information 1

Capacities – Kauther Gas Plant
• Total Gas Production 20Msm3/day
• Produced Water 2000m3/day
• Pressure of Reservoir 467.5 bar (a)
• Temperature 157 oc.
• Design Inlet Pressure 120 bar (a)
• Design Inlet Temperature 130 oc.
• Relative Humidity 98%(max) 30%(min)
• Mercury 450ng/m3
• Wind Speed 15m/s – 26m/s(1Hr.) – 39m/s(3 Sec)
• Rainfall 25mm/hr
• Operational Life 25Yrs.

04/05/24 Project's Information 2

Highlights of Project – Kauther Gas Plant
Piping
• Inch-dia – 1lac / 0.1 million
• Number of Isometrics – 1600
• Number of GA’s (Including Plot plans, Piping plans and Nozzle
orientation) – 230
• Man-hours – 24,000

Civil
• Concrete – 20,000 m3
• Steel – 3,000 MT
• Number of GA’s – 400 (Including A/G and U/G)
• Man-hours – 13,000

04/05/24 Project's Information 3

Electrical
• Number of Layouts – 160
• Power supply available – 132KV Step down to 6.6 KV
• Transformer – 8/10 MVA
• Man-hours – 3000
• Procurement:- RFQ-08, TBE-08, PR-08 (Poles, Fixtures, JB,DB,
Glands, Sockets, Earthing BOQ)

Instrumentation
• Number of Layouts – 65
• Power supply – 240V UPS redundant
• Man-hours – 5000
• Procurement:- RFQ-09, TBE-09, PR-09
(Trays,JB,DB,TG,PG,LG,TE&TW,Fittings)

04/05/24 Project's Information 4

Capacities – Harweel (Oil and Gas Plant)
• Oil Processing 10,100 Sm3/day (60,000BPD)
• Gas Injection 6 mmscmd
• Gas Export 1.5 mmscmd
• Pressure of Reservoir 545bar (a)
• Temperature 1040C
• Design Pressure 99 bar (a)
• Design Temperature 600C - 1950C
• Relative Humidity 98% (max) 30% (min)
• Mercury 16,500 ng/Sm3
• Wind Speed 12m/sec (hour) and 34m/s (3 sec Gusts)
• Rainfall 25mm/hr
• Operational Life 20 Years
• H2S – 7%

04/05/24 Project's Information 5

Highlights of Project – Harweel (Oil and Gas Plant)
Piping
• Inch-dia – 4lac / 0.4 million
• Number of Isometrics – 5500
• Number of GA’s (Including Plot plans, Piping plans and Nozzle
orientation) – 500
• Man-hours – 98,500

Civil
• Concrete – 32,000 m3
• Steel – 7,500 MT
• Number of GA’s – 400 (Including A/G and U/G)
• Man-hours – 103,000

04/05/24 Project's Information 6

Electrical
• Number of Layouts – 160
• Power supply available – 132KV Step down to 6.6 KV
• Transformer – 8/10 MVA
• Man-hours – 21,000

Instrumentation
• Number of Layouts – 65
• Power supply – 240V UPS redundant
• Man-hours – 28,300

04/05/24 Project's Information 7

Process
• Input for Process :- On the basis of Front End Engineering Design
(FEED) done by client
• Process Output starts from getting involve in preparation of Process
Design Basis with client
• Heat and Material balance or Material and Energy Balances usually
done on Hysis or Pro II.
• Process and Utility Flow Scheme (PFD & UFD)
• On basis of PFD Process Engineering Flow Scheme (PEFS/ P&I D’s.)
and On the basis of UFD Utility Engineering Flow Scheme (UEFS)
• Process description, Datasheets and Detail design calculations for
Equipment sizing and Line Sizing
• After the HAZOP of these drawings they will be issued incorporating
all the comments for Design
• Equipment List/Line List in parallel with the PEFS
• Material selection diagram
• Utility system calculations
• Utility load list and flare load
04/05/24 Project's Information 8
Material’s
• Input to Metallurgist :- Material selection report from contractor which
is on the updated process conditions and other changes resulting
from the detail design calculations
• Metallurgist to review for its suitability for the process stream
composition and operating conditions, if required suggest changes to
increase integrity of Piping and Equipment
• A specialist welding engineer will review and approve the welding
documents and procedures
• Material Selection Report
• Corrosion Report
• Specification and location of corrosion, Erosion Monitoring and
corrosion Control

04/05/24 Project's Information 9

Pipeline
Based of available Process data
• Pipeline Schedule
• Pipeline design calculations
• Hydraulic Analysis
• Route Survey report
• Dynamic simulation report
• Stress and Expansion Calculations
• CP system design report
• Detail engineering of GRE piping with Vendor

04/05/24 Project's Information 10

Mechanical
Basis of Process Data (Process Datasheets, PFD, PEFS)
• Updating and maintaining of Equipment list with all process data
• Mechanical Design Basis
• Equipment Datasheets
• Equipment Specifications
• Co-ordinate with other disciplines and vendor packages
• Equipment maintenance and lifting requirements.
• Group on the basis similar equipment components and commodity
into a minimum number of requisition/MR’s to reduce the interface
and the related documentation substantially and also help in
maximizing the potential Saving
• In conjunction with Procurement to obtain quotations from approved
Vendor’s and to check technical suitability, Delivery and Quality.
• Participate in Performance test and final inspection at vendor works.

04/05/24 Project's Information 11

Input’s required by Piping
• Process Flow Scheme (PFD)
• Process Engineering Flow Scheme (PEFS/ P&I Diag.)
• Equipment List/Line List
• Develop if required Piping Design Basis (To understand any Specific
Client Requirement)
• Available Plot Plan
• Equipment Datasheet (Process/Mechanical)
• Piping Material specification
• Vendor Information (GA of Equipments, Detail Drawings of
Equipment, Package Tie-in points) to finalize Model
• Inputs from other Disciplines thru IDC

04/05/24 Project's Information 12

Output from Piping
• Develop Plot plan from available contract plot plan
• Interconnecting Diagram (Process area – Flare area – Utilities)
• Routing Conceptual
• Model based on datasheet / Preliminary info.
• Nozzle orientations to Vendor
• To prepare Critical line list based on necessities given by Client
• Stress Checking for critical lines (Route, Size, Supporting)
• Rack Loadings to Civil
• Draft for Shelters, Equip. Supp. Platforms, Grade Platforms to Civil
• Unit plot plan to indicate the location of Equipment, Racks etc.
• MTO for piping Material (Piping and Support)
• Isometrics for fabrication
• Piping GA (Piping Plan, Piping Layout)
• Pipe road Crossings to Civil

04/05/24 Project's Information 13

Input’s required by Civil
• Site grading drawings
• Soil investigation report
• Survey report (Contour Map)
• Loadings (Equipment, Rack, Structures, Shelters)
• Draft from Piping of equipment supported Platforms, Grade
Platforms, Tech structures, Shelters, etc.
• Foundation IDC clearance from other disciplines
• Tray locations from Electrical, Shade requirement for Instruments
from Instrumentation.
• Primary pipe support location, Sleepers, Pedestals, T Post, Cleats for
Piping on equipment etc
• U/G Pipe crossings, Trench crossings (PRC’s, ERC’s, IRC’s)
• Sleeve requirement for Cables from E&I

04/05/24 Project's Information 14

Output from Civil
• Foundation Design and Modeling
o Equipment
o Rack
o Tech Structures
o Shelters
o Pipe supports, sleepers, pedestals and
o E&I accessories
• Structures Design and Modeling
o Racks
o Tech Structures
o Grade Platforms, Pedestals
o E&I Tray Supports
• Pipe sleeves for E&I
• Built up trenches for E&I also Piping
• Pits required for equipment
• Roads, Paving, Access ways

04/05/24 Project's Information 15

Input’s required by Electrical
• Available Electrical supply
• Load List (Continuous load, Intermittent load and Standby is clear)
HV, LV, Transformer and DG Set is designed from this info.
• Electrical Design Basis
• Civil information such as
Foundation layout, Rack, Platforms, Equipment supported
Structures, Shelters, Roads/Fencing. This information comes in the
form of IDC from Civil and is cleared after putting the comments.
• Piping Information such as Unit Plot plans, Piping GA’s, Model.
• Instrument trench layout which comes for IDC and also can be
checked thru Model.
• Cathodic protection requirement for Equipments

04/05/24 Project's Information 16

Output from Electrical
• Transformer size
• Key Single line diagram and consequently area wise or DB wise
• Individual D.B’s
• Cable Schedule/J.B. Schedule
• Master electrical items List (SB, Lighting poles, fixtures etc.)
• Electrical equipment specification and datasheets
• Electrical items location diagrams
• Electrical Bldgs layout,Substation (DB’s, Motor Panel, UPS,
Transformer)
• Trench and Tray layouts
• Cathodic protection
• Earthing layout
• Packaged Equipments instrumentation and electrical philosophy

04/05/24 Project's Information 17

Inputs required by Instrumentation
• To work with other disciplines especially Process to get the PEFS,
Instrument tagging, process control narrative and production of
Instrument database and index
• Civil info (as electrical)
• Piping info (as electrical)
• Cables from instrument go to JB from JB to Marshalling where they
are club and then go to Control room (DCS or IPS) i.e PLC’s and
then to console.
• Parallel signals also go to redundant where if any level indicator or
temprature indicator is not working will be indicated.

04/05/24 Project's Information 18

Output from Instrumentation
• Integration of complete process automation and Instrumentation
systems
• Instrument specification and datasheets
• Instrument and control room layout
• Instrument I/O list
• Instrument interconnection/termination diagram
• Cable schedule/Drum schedule
• Cable routing/Cable tray layout
• Process hook-ups
• Signal loop Diagram
• Utility Consumption detail
• J.B. Schedule
• Alarm and trip schedule
• Function logic diagram
• Safety analysis function evaluation (SAFE) charts

04/05/24 Project's Information 19

Process –i/p
• Components of crude
• Well Head –Conditions (Pr. Temp), Location, Capacities (oil, gas, water)
• Plant location
• Impurities and its disposal (h2s,rsh (mercaptan in form of gas),water,salt,wax)
• Oil prod, gas prod, water prod, sour gas
• Water and sour gas may be injected to well head to maintain the pressure or just to
dispose it.
• Product quality requirement
• Disposal method

Also a brief idea of

OIL – Separators-Tanks-export
Gas – Separators-Compressor-treatment

On the basis of above data

Process starts with
• FEED – Front end engineering design – its basically a package

04/05/24 Project's Information 20

• Process flow scheme/diagram and Heat and mass balance
This is done by using simulation tools such as Hysis, Pro II for Oil and Gas
• Piping and instrumentation Diagram PEFS Process Equipment flow scheme Line list is released in
15 days after the PEFS issue.
• Equipment datasheet Instrument Datasheet (metering ,relief valve,control
valve,xmitter,gauges,level inst.,analysers) is done in parallel with the PEFS.
• Utility – UFD, UEFS, (instru air/plant air,drain,water system, flare and blowdown, Nitrogen,fire
water)
• Flare and blowdown
-Relief valve sizing (for equipments)
-blow down (plant shut down in emergency)
-flare PCV (if wont work then relief valve will ultimately work)
All above is the basic engineering which is done by process then from this output of process other
discipline get their i/p to start with
Piping will start with the routing and all, mech and instru will start with the enquiry requisitions.
Sepeartor – is for Gas removing and
Knock out drum -is for liquid removing.

04/05/24 Project's Information 21

• Utilities
Flare:-HP flare – Hp headerand LP header
For HP header is connected to Inlet separation,Gas treating area, Production manifold.
For LP header is connected to fuel gas area, closed drain, TEG area
For AP header is connected to vent from storage tanks, off gas from TEG Regen scrubber.

Drain system
Closed drain system – hydrocarbon from equipment and pipeworks after depressurisation (only AP is
connected directly)
Open hazardous drain – dead stabilized hydrocarbon, diesel and other liquids from open dishpans
(hazardous area)
TEG drain system – all Teg drained from equipment and Pipework.

Fuel Gas
High pressure fuel gas is routed to fuel gas system

Instrument air
Oil injected screw type air compressor

Inert gas system

Inert gas is provided by means of dedicated nitrogen bottlle racks

Potale water system, Diesel Oil system

04/05/24 Project's Information 22

• Chemical Injection
corrosion inhibitor is injected continueosly into condensate pipeline
Foam inhibitor into TEG contactor
Methanol suppress hydrate formation
Sodium acetate injected, TEG regeneration system to PH control
Tri-ethylene glycol
Diesel fuel
Lube oil.
Pabs = Pgauge+Patm
1 atm =14.696 psi abs and 0 psi gauge

Jm-064 Harweel
• 0.4 Million inch-dia; 32,000 M3 of concrete; 7,500 MT of steel;
• 0.3 million man-hours; 60,000 BPD and the most important is 7% of H2S.
Jm-059 Kauther
• 0.1 Million Inch-dia; 20,000 M3 of concrete; 3,000 MT of steel;
• 50,000 man-hours; 20Msm3/D; .
Both projects had the same pressure range 100bar,60 bar,25 bar

04/05/24 Project's Information 23

 r R

r X D
Y
Z X = D/2 – r
r - knuckle radius
R=D=Crown radius
Z=R-r, Y= Z2 – X2

Height of D’end = R – Y

04/05/24 Project's Information 24

• Alloy – CRA Corrosion resistant alloy
Alloy 625, Alloy 825LT Sour, 6Mo.
B423 UNS N08825 – CRA
A333.6 – LTCS

Instrumentation
Types of signal are continueos and on-off (discreet)
There are two kind of loops open loop where the indication is there for eg. Temprature is indicated but
nothing is linked with that if it goes up or goes down nothing will be connected with that.
In close loop if say pressure exceed a particular value the relief valve will operate or something like
that.
Exchanger
For any exchanger the steam which is supplied to heat is saturated since we take out the latent heat
from it to heat the other fluid and then the outlet is condensate.
NPSH
The net positive suction head is the value of minimum suction head required to prevent the cavitation.
Cavitation is rapid formation and collapse of vapour pockets in aflowing liquid in regions of very
low pressure.
In a centrifugal pump, cavitaion causes decrease in pumps efficiency and is capable of causing
physical damage to the pump and impeller. Since cavitation has such adetrimenta; affect on
apump it must be avoided at all costs. Cavitation can be avoided by keeping the NPSH available
NPSHa greater than the NPSH required NPSHr .

04/05/24 Project's Information 25

Compressor
Dynamic – Impellers (conversion of velocity to pressure)
Positive displacement
Power = flowQxPressureP/efficiency = m3/sec x n/m2 = N-m/sec = Joule
API 618 – low piston speed
API 11P – High piston speed
Size is inversely proportional to speed
Max size less speed
Low speed big size
API Codes
Pumps Centrifugal – API 610
Pumps Reciprocating – API 674,675,676
Compressor Centrifugal – API 617
Compressor Reciprocating – API 618
Air cooled heat exchanger – API 661
Gas Turbine – API 616
Cylindrical Tanks – API 650
Pump Vendor to give following data: 1.Type of Pump, 2. Nozzle size and rating,
3.Nozzle loading as per std., 4. Suction critical 1st reducer flat side up.
B31 – Piping 0.3 Process piping for ISBL B31.3, OSBL 31.8.

04/05/24 Project's Information 26

• Harweel
Drgs/Doc – 7458
Req. – 195
Static – 180 (4200MT)
Rotating – 20 Comp. & 97 Pumps
Othr Packages – heaters -2 , Chiller – 1, Flares – 3 , Deareater – 2 , Water treatment – 1
Concrete – 33,100 CM
Steel – 6,600 MT
Piping – 380,000 ID or 635,500 IM (106.6 KM)
CS/Clad – 164.8 KM
GRE – 78.16 KM
Cable – Elect.
HT-64KM
LT-1400KM
Cable – Inst 1,246KM and Substation and Control room Bldg. 3268 SM.

04/05/24 Project's Information 27

Product Capacity

Export Oil to Main Oil Line (MOL) 10100 Sm3/day

Export Gas to Salalah Gas Line (SGL) 1.5 MMSCMD

Zalzala Gas Injection 6 MMSCMD

Sour Water Injection 840 m3/day

Legend

MMSCMD Million Standard Metre Cube Per Day

Sm3/day Standard Metre Cube per Day

BOPD Barrels of Oil per day

04/05/24 Project's Information 28

 Harweel ISBL Piping Data

Description Nos Remarks

No. Of Lines 4800

No. of Equipments 284

No. of Piping GA's 487

No. Of Under Ground Piping GA's 144

Plot size
Over All Plot Plan 1 700m x 600m &
500m x 255 m

Unit Plot Plan's 51

No. Of Isometric Lines 5023 7202 Sheets

No. Of Trim Line Isometric's 870 870 Sheets

Budget Man Hours 165000 Mumbai + Sharjah

Spent Manhours - Sharjah

77000

Spent Manhours - Mumbai Details awaited from Mumbai

Morn than 100000

04/05/24 Project's Information 29

Specifications Kauther Harweel ADCO Turkmen
Plant Gas Oil and Gas

Capacities

Gas 20 Msm3/day 1.5 Msm3/day Export and Inj. 6 Msm3/day 5 BCMA

Oil 10,100 Sm3/day i.e. 60,000BPD 720000BPD

Res. Pr. & 0C 467.5 bar (a) & 1570C 545 bar (a) &1040C

Des.inlet Pr. & 0C 120 bar (a) & 1300C 99 bar (a) & 600C to 1950C 93 bar &

Wind speed 15 m/s (hour) 39m/s (gust) 12 m/s (hour) 34m/s (gust)

Rainfall 25 mm/hr 25 mm/hr

Inch-Dia 1Lac/0.1million 4lac/0.4 million 9lac/0.9million

Lines 1600 5500

Concrete 20,000 m3 32000 m3 147000m3 90000m3

35000MT
Steel 3,000 MT 7500 MT 29000MT

Cable Electrical
(power+control) 70-80 Km 160-200 Km

Instrument Cable 250km 750km

04/05/24 Project's Information 30
 Engineering Division Manager EPC2 (NFXP Onshore Project) - QG

NRA

04/05/24 Project's Information 31