2015 specific service for wpb appling fc 20141115 - to moc letter v2.pdf
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8/9/2019 2015 Specific Service for WPB Appling FC 20141115 - To MOC letter V2.pdf
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SPECIFIC STUDIES FOR Y2015‐ F&C Department
1
Confidential
November 2014
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Confidential
Part 2 – Geographic Information System Phase 2
OVERVIEW
Part 1 – Camp Projects Design & Technical Support
Part 3 – Technical Studies
F&C contains three(3) parts of special studies in Y2015
WP&B. All of the studies in the presentation arecompletely new, which are different from those inY2014.
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Confidential
Part 1 – Camp Projects Design & Technical Support
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New Camp Projects list in Y2015
1. The Guest House2. Utility System upgrade
3. Accommodation phaseⅤ(Northern Area)4. Accommodation phaseⅤ
(Southern Area )5. Warehouse Facilities
Construction and Installation
4
6. Beautification of OCC Central lawn7. Sewage & drainage system upgrade project8. Afforestation and Landscape
9. Bridge maintenance for Qala'at Saleh and 15km new Road
1 3
4
6
5
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7 2
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1.1 Project Setting Background and Justification
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• The Guest HouseIn order to meet demands of visitor reception for top government
delegation, it is necessary to build an Guest House with reinforced concrete frame structure. It include VIP room, member’s room,secretary room, body guard room, meeting room, lobby area andrelevant utility system etc. Its area is about 6,500 square meters.
• Utility System upgradeThe current utility system should be improved to match field baseimprovement.• The accommodation phaseⅤ (Northern Area )& (Southern Area ) According to the forecast of employees number in next coming 3years, it is deemed necessary to develop and construct matchedinfrastructure and apartment for the employees of PCH who will live
in field base.
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1.1 Project Setting Background and Justification
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• Warehouse Facilities Construction and InstallationLighting system at extension yard, concrete sleeper and generalmaintenance.• Beautification of OCC Central lawnBeautify the OCC central lawn, including fountain, sidewalk, flag poles,trees etc.
• Sewage & drainage system upgrade projectUpgrading the camp existing sewage and drainage systems to meet therequirements.• Afforestation and LandscapeFor environmental purposes, set landscape & plant trees in guest housearea, plant trees in accommodation phase III yard, phase IV yards,phase IV west yard and other necessary base places• Bridge maintenance for Qala'at Saleh and 15km new RoadRequirement of JMC Resoluation
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Part 1 focus on the design work, bidding, evaluation and technicalsupports including:
Conception design and basic designPreparation of ITB document which include technical and commercial
partProvision of technical support for bidding clarification and evaluationProvision of technical support during construction such as technical
consultancy
1.2 Scope of Work
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1.2 Scope of Work
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No. Item Scope of work
1 Guest House
To build the guest house( 6500 m2)with interior decoration,furniture, necessary facilities and auxiliary utility system suchas power supply system, water supply system, sewagedrainage system, communication system, HVAC and firefighting system .
2 Utility System upgradeTo construct road system, WSD system, communicationsystem, electrical system, road lamps and other unexpecteditems for base.
3 accommodation phaseⅤ(Northern Area )
To build approx. 200 set apartments for PCH staffs withinterior decoration, furniture and necessary living facilities.4 accommodation phase
Ⅴ (Southern Area )
5 Warehouse Facilities
Construction and Installation
Lighting system at extension yard, concrete sleeper and
general maintenance
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1.2 Scope of Work
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No. Item Scope of work
6 Beautification of OCC Central
lawn
Add fountain, sidewalk, flag poles, trees for OCC
central lawn. The area is about 15,000m2
7 Sewage & drainage systemupgrade project
Upgrading the camp existing sewage and drainagesystems, meet the requirements of base improvement.
8 Afforestation and Landscapeset landscape & plant trees in guest house area, planttrees in accommodation phase III yard, phase IV yards,phase IV west yard and other necessary base places
9 Bridge maintenance for Qala'atSaleh and 15 km new Road
Build 15km new road from Qalat Saleh bridge to Khalacity with 7m width asphalt pavement. The culvert andbridge will be built for new road.Maintain and strengthen the Qala’at Saleh bridge tomeet the requirement of heavy vehicle.
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Confidential
Part 2 – Geographic Information System Phase
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1 Project Setting Background and Justification
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1. The digital oilfield need the satellite images, topographical data,
underground pipeline data and geological data provided by GIS.
2. Due to the lack of integrate management platform, the future
design could not obtain the information about underground
pipelines quickly and conveniently.
3. Following the fast construction of oilfield, the underground
pipeline increase progressively and possible damages to
existed pipelines caused by the future construction continue torise.
4. Due to the lack of integrate management platform, once the
leakage accident happened, the repair will be delayed.
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1 Project Setting Background and Justification
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5. A great deal of geotechnical investigation have been executed
and the relevant data have been collected in the area of oilfield,
GIS can use the existed data to build 3D geological model for
station and to provide relevant reference for the future design.
6. The topographical survey for large-scale area of oilfield had
been finished, it is necessary to incorporate the topographical
data, geological data and detecting data of underground
pipelines into the integrate platform to management so that
improve the efficiency of design and production.
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1 Project Setting Background and Justification
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7. The oilfield construction has mushroomed over the past years and
the consequent is that the terrain and geomorphology change
constantly in duration, so the previous satellite images could not
meet the requirements of design and production management, which
still need to be updated promptly with the field variations caused by
constructions.
8. GIS will realize the integrate management of satellite images,
topographical data, geological data and underground pipeline data,
all which could be statistical analyzed by establishing the 2D visual
overlaying and classified display, to provide the service for the
design, construction and production management.
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1. Data collection and analysis.
2. Update the satellite image of oilfield.
3. Execute the topographical survey for additional 80km 2.
4. Detect the existed underground pipelines about 300km.
5. Data input (satellite images, topographical data, underground
pipeline data and geological data).
6. Upgrade the functions of GIS based on the feedback from thoseoperations.
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2 Scope of Work
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Confidential
Part 3 – Technical Studies
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Confidential
1. The key technical study for CRA clad or lined steel pipe2. Research on Key Technologies on Station Regional Cathodic
Protection in Halfaya Project IRAQ3. The key technology research on the steel spherical tank without water
spray cooling system from Iraq Halfaya project4. Feasibility Study on Dehydration of Halfaya Crude Oil
5. Technical Study of Facility Flexibility for H2S and Mercaptan Contentvariety in Associated Gas of GPP
6. Doom-Roof Tank Gas Seal Research
7. Halfaya oil field island power system SCADA study
Y2015 Technical Study Subject ListY2015 facility technical study includes 14 subjects as following,which will serve the Phase3, Post Phase3 and prospectiveproduction.
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Confidential
8. Research on vibration and its precaution of large-scale reciprocatingcompressor and its auxiliary pipelines in Halfaya
9. Compatibility study for oil-field chemicals10. Study on water injection system in Halfaya oil field11. QRA (Quantity Risk Analysis)Study Report of GPP in Halfaya oil
field12. Study on Custody transfer metering (LPG)13. Safety operation study of CPF1 and CPF2
14. Application study of EPON(Ethernet Passive Optical Network) in Oil/ Gas field
Y2015 Study List
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Confidential
1. The key technical study for CRA clad or lined steel pipe
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1. The key technical study for CRA clad or lined steel pipe
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In view of the corrosive environment is serious in HFY project, with0.5%mol H2S, 3.85%mol CO2 in gas phase, high chloride content(130,000ppm) in produced water, serious corrosion may beoccurred.
Material selection Water treatment system Water injection system
Phase ⅠCarbon steel + corrosionallowance + corrosion inhibitor /
Phase Ⅱ Above ground: DSSUnder ground: GRE GRE
1.1 Project Setting Background and Justification
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1. The key technical study for CRA clad or lined steel pipe
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Carbon steel with corrosion allowance and corrosion inhibitor
depends on the efficiency of corrosion inhibitor and operation
management, which may induce the corrosion problem out of control.
There are a few of corrosion leakage points in CPF1, such as carbon
steel piping from skimming tank to evaporation pond.
In order to control the corrosion problem, GRE(Glassfiber Reinforced
Epoxy) and DSS(Duplex Stainless Steel) were used in CPF2.
However, GRE can not cover all the system because of the limitationfor high pressure and large diameter, and DSS is very expensive.
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1. The key technical study for CRA clad or lined steel pipe
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In water injection system of CPF3 and future stage, considering highpressure & temperature, lower pH, and high flow rate, which will be
very difficult to select a suitable and economic material. More materialselection case and material performance should be studied.
Materialselection Water treatment system Water injection system
Phase Ⅲ Above ground: DSSUnder ground: GRE
Carbon steel + corrosion allowance +corrosion inhibitor GREDSS??? CRA clad or lined steel pipeFuture /
Based on the theoretical research, CRA clad or lined steel pipe will be a good choice, which hasexcellent corrosion resistance relative to carbon steel and low cost relative to pure CRA pipe inHalfaya Project.
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1. The key technical study for CRA clad or lined steel pipe
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There are many different manufacturing process for CRA clad or lined
steel pipe in standard API 5LD (Clad or Lined Pipes) that only involves
few of specified technical requirements for the product, which is hard tocontrol the product quality. And more requirements shall be added if
procurement of such product.
Current CRA clad or lined steel pipe was used was limited to carbon
steel with 316L/304ss that is not suitable for HFY project, because of
high chloride concentration, low pH value and high temperature.Carbon steel with 825 alloy steel pipe will be a good choice, so more
detailed technical study shall be done by literature & standard research
and even relevant simulated experiments.
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1. The key technical study for CRA clad or lined steel pipe
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At the same time, there are two different materials in weld joint when
clad or lined CRA steel pipe will be used, how to control welding
quality for CRA clad or lined steel pipe when keep acceptablematerial properties is a very difficult problem, more detailed technical
problems should be studied and installation guideline should be given
for field welding.
After all the studies, the technical requirement for CRA clad or lined
steel pipe and fitting should be provided to control the quality of the
product and welding of CRA clad or lined steel.
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1. The key technical study for CRA clad or lined steel pipe
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1. Survey the main forming process of CRA clad or lined steel pipe from
the standard and actual facility manufacture, and summarizeits characteristics.
2. Study the technical requirements for N08825 clad steel pipe, and
summarize the main impact factors that influence itself performance.3. Study the technical requirements for N08825 lined steel pipe, and
summarize the main impact factors that influence itself performance,
which is different from clad steel pipe.4. Study the technical requirements for N08825 clad fitting, summarize
the impact factors different from the pipe.
1.2 Scope of Work
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1. The key technical study for CRA clad or lined steel pipe
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5. Study the pipe end type for clad or lined pipe & fitting, andanalyze their advantages and disadvantages.
6. Study the corrosion resistance of welding joint by simulate experiment,which mainly include stress cracking corrosion, intergranular corrosion,pitting corrosion etc.
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Confidential
2. Research on Key Technologies on Station RegionalCathodic Protection in Halfaya Project
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2. Research on Key Technologies on Station RegionalCathodic Protection
1) In HFY phase I & II, the buried piping is carbon steel but the earthing electrode is
copper. In addition, due to low soil resistivity, it may form corrosion potential, and the
galvanic corrosion will be very easy to occur, the pipe may occur in pitting corrosion
only few months.
2.1 Project Setting Background and Justification
2) Coating protection is able to protect the pipefrom corrosion by the soil and galvanic.
However, the huge pipe coating construction
may be difficult to avoid any defects in the CPFstation. When the coating failure occurs in the
soil, the galvanic corrosion current may cause
the pipe leakage.
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2. Research on Key Technologies on Station RegionalCathodic Protection
3) According to the testing results in the geotechnical investigation of CPF2, the soil
resistivity is form 0.54 to 24Ω·m at the depth of 1.5m and ground water level is only -
0.052m to -0.316m. The site soil have strong corrosivity for buried steel pipes, and highlevel of underground water in HALFAYA Oil Field, the buried steel pipes may be faced with
high corrosion risk.
4) For the existing station lack of regional
cathodic protection system, how to adopt the
reasonable corrosion control measure to
protect the existing buried pipe with the
coating aging is very important.
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2. Research on Key Technologies on Station RegionalCathodic Protection
Based on the above analysis and cause, regional cathodic protection system should be
considered in this phase, regional cathodic protection technology will provided extra
protection for the buried pipe with coating, which will be beneficial for the buried pipe instation, but the anode location and output current value is very hard to select and decide.
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In order to efficiently protect the buried pipes, regional cathodic protection method can be
used together with coating.
However, there are many problems during the regional cathodic protection system in
other project , as follows:
Demanded current is not enough after the system in service, such as potential owe
protection;
Cathodic protection current is shielded in some region after the system in service ;
The arrangement of anode groundbed is unreasonable;
In order to effectively use the regional cathodic protection system, the key technologies of
regional cathodic protection shall be researched.
2. Research on Key Technologies on Station RegionalCathodic Protection
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2. Research on Key Technologies on Station RegionalCathodic Protection
2.2 Scope of Work
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The main scope of work, as follows:
Research on determining method of demanded current of regional cathodic
protection; the demanded current is most important parameter for the regional
cathodic protection system, which is also hard to accurately determine. Through
this research, to obtain an accurate and effective method to determine the
demanded current in the regional cathodic protection system.
Research on current shielding problem of regional cathodic protection; If the
current is shielded in some area of station, the buried pipes in this area will be left
unprotected. Through this research, to find the reason of shielding of current and
to avoid similar problem occurrence.
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2. Research on Key Technologies on Station RegionalCathodic Protection
Research on optimization of anode groundbed location in regional cathodic protection
system; Three groundbeds includes shallow buried high silicon cast iron anode
groundbed, shallow buried line anode groundbed and deep well groundbed can be
used in regional cathodic protection system, but the result of each type varies with
application condition. So this research will optimize the choice of anode groundbed
for different condition.
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Confidential
3. The key technology research on the steel spherical tankwithout water spray cooling system from Iraq Halfayaproject
3 T h i l S di LPG S h i l T k i h
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3.Technical Studies on LPG Spherical Tank withoutWater Spray Cooling System
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• The exposure in the sunshine will make LPG spherical tanktemperature go up, and then the saturated vapor pressure will risequickly (for example, the vapor pressure of propane is 1.61MPa at 50,however, it will reach to 2.48MPa at 70), which will bring adverseeffect to the safety of spherical tank. Therefore, the LPG spherical tank isusually needed to take cooling measure such as water spray.
• Generally, the water spray cooling system are applied to the LPGspherical tank to decrease the temperature.
Heat reflective coating for LPG spherical tank
3.1 Project Setting Background and Justification
3 T h i l S di LPG S h i l T k i h
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3.Technical Studies on LPG Spherical Tank withoutWater Spray Cooling System
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• The water spray cooling systemhas the following disadvantages:
(1) Water spray easily causes the corrosion of the surface of spherical tank.(2) After the corrosion, the surface is needed to brush paint again every one
or two years.
(3) It causes the waste of water resources and pollutes the surroundingenvironment.
• The heat reflective coatingcan effectively reduce the temperature by
reflecting sunshine, also the life of heat reflective coating is long and theuse of heat reflective coating can reduce maintenance cost and savewater.
3 T h i l St di LPG S h i l T k ith t
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3.Technical Studies on LPG Spherical Tank withoutWater Spray Cooling System
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• Because the maximum temperature and black bulb temperature arerespectively 55 and 80 in Halfaya district.
• Now, the design of LPG spherical tanks in GPP project is by using the
combined methods of water spray cooling system and heat reflectivecoating. In this way, the saturated vapor pressure of 50can beguaranteed as the basis of the design pressure.
• However as mentioned above, water spray can easily cause thecorrosion of the surface of spherical tank, and shorten the service lifeof heat reflective coating.
The design of LPG spherical tanks in GPP project
3 Technical Studies on LPG Spherical Tank without
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3.Technical Studies on LPG Spherical Tank withoutWater Spray Cooling System
• The studies are based on the concept of only using the heat reflectivecoating without spray water in order to increase coating life, reducemaintenance cost and save water.
• In this case, the saturated vapor pressure of 60may be taken as thebasis of the design pressure which will be as high as 2.01MPa for LPG.
• Due to such high design pressure, the selection of spherical shell platematerial and design method are very important in order to reduce theinvestment and welding work load during assembly.
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The studies of LPG spherical tank without water spray cooling system
3 Technical Studies on LPG Spherical Tank without
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3.Technical Studies on LPG Spherical Tank withoutWater Spray Cooling System
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• No calculation method is available about support column ofspherical tank in ASME Sec.ⅧDiv.1. The spherical tank is not onlyunder internal pressure, but also under gravity, wind load andearthquake load. The FEA(finite element analysis) design caneffectively calculate the strength and stability of support column.
• Compared to conventional design, FEA design can significantlyreduce the shell thickness of tank and reduce the weight accordingly.
• Thus, the design study on high pressure LPG spherical tank isnecessary.
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Confidential
4. Feasibility Study on Dehydration of Halfaya Crude Oil
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4.1 Project Setting Background and Justification
Increase crude oil treatment capacity of CPF2 electrostatic dehydratorsto meet the occasion of improving Halfaya crude oil production.The crude oil treatment capacity of CPF2 electrostatic dehydrators is120,000BOPD with water cut less than 10% and the water content indexfor dehydrated crude oil is less than 0.2%~0.4%.
By studying the influence factors, such as operating temperature,residence time and field strength of electrostatic dehydrator, demulsifiertype and demulsifier dosage, optimize the operating conditions ofelectrostatic dehydrators to increase the crude oil treatment capacity upto 130,000BOPD with water cut less than 10%.
4 Study on Dehydration of Halfaya Crude Oil
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4.2 Scope of Work
4.Study on Dehydration of Halfaya Crude Oil
The field operation status investigation for CPF2;
Demulsifier type screening and demulsifer dosage study;
Heat medium heaters load, the size of oil-oil heat exchangers, medium-oilheat exchangers and 2nd separators checking study;
Study and optimize operating parameters of electrostatic dehydrators andelectrostatic desalters to increase crude oil treatment capacity;
1) The influence of operating temperature on dehydration;
2) The influence of electrical field strength on dehydration;
3) The influence of inlet water cut on dehydration;
4) The influence of recycle water flow rate on dehydration.
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Confidential
5. Technical Study of Facility Flexibility for H2S andMercaptan Content variety in Associated Gas of GPP
5 T h i l St d f F ilit Fl ibilit f HS d M t
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5.Technical Study of Facility Flexibility for H2S and MercaptanContent variety in Associated Gas of GPP
4343
• Six sources of associated gas to GPP/MGPP: HALFAYA oilfieldCPF 1, 2 and 3, AMARAH oilfield, NOOR oilfield and MISSANoilfield;
• The H2S content of mixed gas 0.35mol% to 0.8mol%;Sour gasconcentration to sulfur recovery unit is 19%~23%(v)
• The mercaptan averaged content of mixed gas is 30ppmaccording to sample analysis.
5.1 Project Setting Background and Justification
Composition Halfaya
CPF1
Halfaya
CPF2
Halfaya
CPF3
Missan Noor Amarah
H2S (mol%) 0.25 0.34 0.41 1.8 0.5 0.4
CO2 (mol%) 2.31 2.68 3.03 3.12 5.12 2.56
Mercaptan (ppm(v)) 31 30 30 37 16 4
5 Technical Study of Facility Flexibility for HS and Mercaptan
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5.Technical Study of Facility Flexibility for H2S and MercaptanContent variety in Associated Gas of GPP
4444
5.1 Project Setting Background and Justification
• Mercaptan type is different for each oilfield.
Mercaptan type Halfaya Amarah Noor MissanCarbonoxysulphide Y Y Y Y
methyl mercaptan Y Y Y Yethyl mercaptan Y Y Y Y
dimethyl sulfide Y Y Y Ycarbon disulfide N Y Y N
special butyl mercaptan N N N Y
isobutyl mercaptan Y Y Y Yn-butyl mercaptan N N N Y
thiophene Y Y Y Y
5 Technical Study of Facility Flexibility for H2S and Mercaptan
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5.1 Project Setting Background and Justification
5.Technical Study of Facility Flexibility for H2S and MercaptanContent variety in Associated Gas of GPP
Base on the composition of raw gas, MDEA is used to remove H2S. Different H2Scontent corresponds to different amine circulation flow.
If more mercaptan in feed gas, the Special Amine Solution is used for mercaptan
removal.
Amine Unit
5.Technical Study of Facility Flexibility for H2S and Mercaptan
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5.1 Project Setting Background and Justification
5.Technical Study of Facility Flexibility for H2S and MercaptanContent variety in Associated Gas of GPP
If H2S content in sour gas is less than 15%, the sulfur recovery process can notensure the recovery rate, only if adding sour gas concentration facility.
If C/S rate in sour gas is less than 0.13, the sulfur recovery process can not ensurethe recovery rate also. SO2 emission may not meet the standard.
Sulfur Recovery and Tail treatment Unit
Normal Claus Unit Claus Tail Gas Treatment Unit
5.Technical Study of Facility Flexibility for H2S and Mercaptan
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• Following oilfield development, the feed gas content and rate from
different source may change. Some change may cause much operationand parameter difference with deign scenarios.
• The multiple sources with different H2S and mercaptan content causes
complex conditions to desulfurization and sulfur recovery unit operation.• The H2S and mercaptan content directly affects the amine circulation
flow, sulfur recovery rate, and SO2 emission;
So some operation and critical parameter regulation must be forecasted.This study is necessary for operation optimization of GPP/MGPP in thefuture.
5.1 Project Setting Background and Justification
y y y 2 pContent variety in Associated Gas of GPP
5 Technical Study of Facility Flexibility for H2S and Mercaptan
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5.Technical Study of Facility Flexibility for H2S and MercaptanContent variety in Associated Gas of GPP
4848
5.1 Project Setting Background and Justification
Design Conditions
Design Capacity 140MMSCF/dH2S in Feed Gas 0.28%(V)
CO 2 in Feed Gas 1.81 %(V)
Design Processing
H2S in Pure Gas 15 mg/m 3
H2S in Sour Gas 38 %(V)
Operating Conditions
Design Capacity 140MMSCF/dH2S in Feed Gas 0.28%(V)
CO 2 in Feed Gas 2.46 %(V)
Actual Processing Effects
H2S in Pure Gas Close to 20 mg/m 3
H2S in Sour Gas 28 %(V)
One Natural Gas Processing Plant for Example
Change
• The decreases of H2S volume fraction in sour gas will lead to performance degradation sulfurrecovery operation.
• After simulation, the changing of raw gas content of each component and temperature of leanamine solution are the main reasons that affect the plant stable operation.
• When the feed gas condition varies, a reliable simulation result is concluded through comprehensive analysis which can be used as guide to modify the operational parameters reasonably.
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5.Technical Study of Facility Flexibility for H2S and Mercaptan
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5.2 Scope of Work
Base on the Basic Design of GPP
• Build simulation model and simulate each case.• Check the flexibility of the main equipment, for example, towers, pumps,
exchangers and control valve, etc., according to the selected case.
• Confirm affected critical parameters; Evaluate the influence of different H2S,CO2 and mercaptan content.
• Analysis the influence of critical parameters; illustrate how to regulate critical
parameters, and gives recommended values of critical parameters.
2Content variety in Associated Gas of GPP
Confidential
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Confidential
6. Doom-Roof Tank Gas Seal Research
6 Doom Roof Tank Gas Seal Research
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6. Doom-Roof Tank Gas Seal Research
6.1 Project Setting Background and Justification
According to the latest production data, the production rate of non-sourgas is less than original production profile forecast, and cannot meet therequirement of blanketing gas rate of doom-roof tank.Latest non-sour gas supply is 207400sm3/d and the requirement ofblanketing gas is 257856 sm3/d.
Short of blanketing gas will endanger production safety or bring outequipment damage.
So it is necessary to solve the doom-roof tank gas seal problem.
6 Doom Roof Tank Gas Seal Research
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6. Doom-Roof Tank Gas Seal Research
6.1 Project Setting Background and Justification
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The field investigation of blanketing gas rate of doom-roof tank;
The doom-roof tank venting and breathing study;
Feasibility study of sour gas blanketing;
Feasibility study of N2 blanketing;
Flare system, oil storage tanks and blanketing gas system adaptability
checking;Optimize solution scheme for doom-roof tank gas seal.
6.2 Scope of Work
6. Doom-Roof Tank Gas Seal Research
Confidential
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7. Halfaya oil field island power system SCADA study
7 Halfaya oil field island power system SCADA study
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7.1 Project Setting Background and Justification
56
• CPF1: 3x5.5MW power plant PMS, substation EICS;
• CPF2: 3x10MW power plant PMS, substation EICS;• CPF3: Substation EICS;
IndividualPMS&EICScontrol system operated independently,an centralized
SCADA system is required to control and monitor each individual EICS& PMS system.
The EPC work scope only cover part of oil field with limitation,an integrated
oil field SCADA plan shall be built and be updated with the oil fieldpower system expansion, it will be the over whole design basis &guideline.
7. Halfaya oil field island power system SCADA study
7 Halfaya oil field island power system SCADA study
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CPF1 POWERPLANT3X5.5MW
10km
66kV OHTL
CPF1 (11.3MW)
CPF2 POWERPLANT3X10MW+5X30MW&66/33kV
SWITCHYARDBase Camp(5.2MW)
33kV OHTL
15kmHPS(14MW)
CPF2
(34.2MW)
FSF (14MW)
GPP
(45.3MW)CPF1 WATER
INJECTION (13.5MW)
FSF (12.4MW)CPF3
(24.3MW)
SWP1 (1.6MW)
CPF1 66/33/11 kVSWITCHYARD
FSF (2.5MW)
66/33kV SWITCHYARD
SWP2
(2.5MW)
Overall Power System in Halfaya
WATER
RESERVOIR
(5MW)
6 6 k V
C a b
l e
WATER INJECTION
STATION (4.5MW)
7. Halfaya oil field island power system SCADA study
7 Halfaya oil field island power system SCADA study
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The following key technologies of power SCADA shall be included:Configuration of Power SCADA
The power grid control system configuration shall be specified.The general guidance shall be provided for power girdcontrol system design in the future.Load Sharing and Load Shedding Philosophy
In order to realize power load management for overall power grid system, load sharing and load shedding philosophy shallbe optimized in SCADA system.Communication System Configuration
In order to get high reliability, communication system configurationfor power SCADA shall be optimized.
7. Halfaya oil field island power system SCADA study
7.2 Scope of Work
Confidential
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8. Research on vibration and its precaution of large-scalereciprocating compressor and its auxiliary pipelines in
HALFAYA
8.Research on vibration and its precaution of large-scalei ti d it ili i li
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reciprocating compressor and its auxiliary pipelines
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8.1 Project Setting Background and Justification
1.Reciprocating Compressor is the most important rotatingequipment. Compressor and their pipelines vibration is very likely tooccur and can cause serious loss and even casualties, especially forH2S contained fluid service like Halfaya.
2.Both the number and capacity of reciprocating compressors in
Phase 3 are much larger than that in phase 1 and 2, which meansprecaution of vibration is critical and necessary.
3.This study/research can be applied to double-check the
combination of compressor design(by compressor vendor ) andpipeline design (by EPC contractor) and achieve safe design andloss prevention target.
8.Research on vibration and its precaution of large-scalereciprocating compressor and its auxiliary pipelines
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reciprocating compressor and its auxiliary pipelines
HIGH PRESSURE COMPRESSOR LOW PRESSURE COMPRESSOR
CPF1DISCHARGE PRESS. 3.5MPaDESIGN PRESS. 5.5MPaCAPACITY 650,000Sm 3/DPOWER 1518kW
DISCHARGE PRESS. 1.0MPaDESIGN PRESS. 1.6MPaCAPACITY 310,000Sm 3/DPOWER 860kW
CPF2DISCHARGE PRESS. 3.5MPaDESIGN PRESS. 5.3MPaCAPACITY 1,000,000Sm 3/DPOWER 2700kW
DISCHARGE PRESS. 1.05MPaDESIGN PRESS. 1.4MPaCAPACITY 400,000Sm 3/DPOWER 1101kW
CPF3
DISCHARGE PRESS. 4.7MPa
DESIGN PRESS. 5.2MPaCAPACITY 1,600,000Sm 3/DPOWER 5100kW
DISCHARGE PRESS. 1.05MPa
DESIGN PRESS. 1.4MPaCAPACITY 800,000Sm 3/DPOWER 2100kW
8.2 Comparison of Compressors of 3 Phases
8.Research on vibration and its precaution of large-scalereciprocating compressor and its auxiliary pipelines
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reciprocating compressor and its auxiliary pipelines
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fatigue damage of pipeline , small caliber pipeline damagedparticularly.
damage of pipe insulation material .
damage of measuring instruments and the ducts on them,wrong signal of controlling system.
pipeline swing/vibration, noise , etc.
Body Vibration Axis Bending Vibrationand Torsional Vibration
Fluid Solid Coupling
Vibration of PipingSystem
8.3 Vibration Types and The Hazards
8.Research on vibration and its precaution of large-scalereciprocating compressor and its auxiliary pipelines
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Compressorsin HALFAYA:Compressorsin HALFAYA:
4reciprocatingcompressors
with highpressure,
power 5.1MW
4reciprocatingcompressors
with highpressure,
power 5.1MW
2 with lowpressure,
power 2.1MW
2 with lowpressure,
power 2.1MW
Fig 4 Plot Plan of Gas Compressor Area in HALFAYA 3
reciprocating compressor and its auxiliary pipelines
8.4 Scope of Work
8.Research on vibration and its precaution of large-scalereciprocating compressor and its auxiliary pipelines
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The following analysis will be carried out:
Static AnalysisModal AnalysisForced Response AnalysisFluid-solid coupled analysis
reciprocating compressor and its auxiliary pipelines8.4 Scope of Work
Package manufacturer and detailed engineering party cooperation:optimize reciprocating compressor and piping design .
Confidential
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9. Compatibility study for oil-field chemicals
9.Compatibility study for oil-field chemicals
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The composition of HALFAYA oilfield produced fluid is very complex, and the required qualityof treated oil, gas and water is very high.Chemicals dosage of HALFAYA oilfield is high. Mainly performances are as follows:
• Many kinds of chemicals should be injected into the system of oil-gas-water gatheringand transportation. Such as demulsifier, defoamer, reverse demulsifier, corrosioninhibitor (including oil soluble, water soluble, vapor phase ), scale inhibitor, etc. Types &dosage of chemicals used in CPF1 are shown as follows.
9.1 Project Setting Background and Justification
9.Compatibility study for oil-field chemicals
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• Compared to the normal oilfield, the dosage of the chemicals is high in HALFAYAoilfield. Taking corrosion inhibitor as an example, the dosage is nearly twice as muchas normally. At the same time, due to pH of produced water is only 4.8, NaOH is
also injected into the system for adjustment.• With the total production increasing, the types and dosage of the oilfield chemicals
will increase.So many kinds and quantity of chemicals are injected and existed in the production
systems. The possibilities may exist are shown as follows:• The synergistic effects between chemicals (good compatibility). The synergistic
effects are mainly caused by physical mechanism. It is helpful to improve chemicaleffects and final quality of crude oil, produced water and gas.
• The chemical reactions may occur between oilfield chemicals. This reaction mayresult in the chemical effects reduction, even the reaction products may result in thepollution of gas, oil and water, and safety risk of the gathering & transferring system.
9.Compatibility study for oil-field chemicals
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Typical chemical types:• Demulsifier: non-ionic type; cationic type; silicon-containing heterocycle type etc.• Reverse demulsifier: anionic type; metal-containing type, non-ionic type etc.• Corrosion inhibitor: oxidized type; non-ionic type; anionic type etc.• Scale inhibitor: anionic organic type; inorganic complex etc.
Because so many kinds of chemicals exist, reactions would occur among them in the system.For example, as mentioned above, anionic organic compounds could react with cationicorganic compounds, and also oxidized compounds would destroy the structure of organiccompounds which would affect the performance of chemicals.
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9.Compatibility study for oil-field chemicals
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DEMULSIFIER DEFOAMER
Typical physical reaction example:• For a specific system, the optimized dosage and performance of demulsifier are
related with demusifier CMC (Critical micelle concentration). The effect of ion on
CMC is in accordance with below formula:
Herein: ci--the total concentration of demulsifier and ion.• Other surfactants (such as defoamer ) effect mechanism are as follows: other
surfactants embedded in the micelle and are helpful / helpless to the micellestructure.
9.Compatibility study for oil-field chemicals
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Typical chemical reaction example:• PAL is common water clarifier and Al3+ plays a main role. When PAL encounters
with PH regulator NaOH, the following reaction will happen and renders PAL lesseffective and precipitation, which leads to the risk of pipeline block.
• Anionic organic compounds can react with cationic organic compounds, whichrender agent failure and precipitation.
In order to avoid the above reaction, the study about the chemical compatibility should be
carried out. The research results will be used to guide the chemical selection and to get thesynergistic effects between chemicals, and the whole effect of chemicals will be enhanced.
9.Compatibility study for oil-field chemicals
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9. 2 Scope of Work
Site and literature investigate, include investigating structure types andcharacteristics, injective process etc. Analysis test planning;Optimization tests-optimize chemical types, chemical injecting process and relatedparameters.
Condition tests-determine the appropriate chemical types, depending on theproduction process, parameters and produced water properties of HALFAYA oilfield;Compatibility tests -determine the compatibility theory and guide rule of thechemicals covered oil, gas and water phase;Report preparation-compile operation instructions for selection principle &compatibility of chemicals, and compile compatibility evaluation standard;
Confidential
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10. Study on water injection system in Halfaya oil field
10.Study on water injection system in Halfaya oil field
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Table 1.1-1 Production Profilefor CPF1
With the increasing water cut during the development of HALFAYA oil field, large scalewater injection shall be carried out for CPF1, CPF2 and CPF3.
10.1 Project Setting Background and Justification
Year
Water injection
Well
convert to Water
injection well
Water Cut Oily
waterWater
InjectionMake Up
water Production time and Capacity
% KB/d KB/d MB/d
2016 0 0 19.4 35.0 0.0
Water Injection: 210,000BWPD , Y2016~Y20182017 4 24 30.6 55.0 207.8 152.8
2018 1 2 46.8 99.0 209.5 110.52019 2 54.2 129.3 239.8 110.5
Water Injection: 300,000BWPD , Y2019~Y20212020 1 58.3 151.0 271.1 120.1
2021 3 62.1 175.1 296.9 121.8
2022 2 64.1 189.6 352.3 162.7
Water Injection: up to 440,000BWPD, Y2022~Y2029
2023 3 66.8 212.2 401.8 189.6
2024 3 70.4 248.5 439.6 191.12025 3 73.6 290.4 389.9 99.5
2026 2 74.9 309.5 364.5 55.0
2027 2 75.8 324.2 357.6 33.4
2028 2 76.4 334.6 355.7 21.1
2029 2 78.4 374.1 395.1 21.0
10.Study on water injection system in Halfaya oil field
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Table 1.1-2 Production Profilefor CPF2
Year
Water injection
Well
convert to Water
injection well
WaterCut
Oilywater
WaterInjection
Make Up water
Production time and Capacity
% MB/d MB/d MB/d
2017 0 0 19.8 52.0 0
Water Injection: 260,000BWPD , Y2017~Y20202018 5 26 25.0 65.0 222 157
2019 2 34.8 95.0 252 157
2020 3 48.3 127.3 256 129
2021 2 56.7 156.1 294 138Water Injection: up to 320,000BWPD, Y2021~Y2022
2022 4 60.2 175.9 312 137
2023 3 63.8 200.8 336 135
Water Injection: up to400,000BWPD, Y2023~Y20262024 2 66.9 220.4 350 130
2025 2 68.9 240.4 370 130
2026 1 71.4 270.4 400 130
2027 1 73.8 300.3 429 128
Water Injection: up to530,000BWPD, Y2027~Y2033
2028 0 75.9 330.2 457 127
2029 0 78.1 370.1 496 126
2030 1 75.4 317.0 442 125
2031 78.5 375.6 501 125
2032 79.6 399.6 525 125
2033 81.2 397.4 510 113
10.Study on water injection system in Halfaya oil field
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Table 1.1-3 Production Profilefor CPF3
Year
Water injection
Well
convert to Water
injection well
WaterCut
Oilywater
WaterInjection
Make Up water
Production time and Capacity
% MB/d MB/d MB/d2017 0 0 0.0 22 0
Water Injection: 250,000BWPD , Y2017~Y20212018 0 0 0.0 22 0
2019 2 13 0.0 22 216 194
2020 2 7 7.3 38 232 194
2021 1 2 11.1 47 241 194
2022 2 0 28.2 101 295 194
Water Injection: up to 450,000BWPD, Y2022~Y2027
2023 1 0 37.8 143 337 194
2024 3 2 45.3 188 382 194
2025 2 3 47.9 206 400 194
2026 5 3 49.5 218 412 194
2027 11 0 53.3 250 444 1942028 10 0 59.2 313 507 194
Water Injection: up to740,000BWPD, Y2027~Y2033
2029 9 0 61.1 336 530 194
2030 7 70.7 504 699 194
2031 8 70.9 509 703 194
2032 5 72.2 541 735 194
2033 8 72.5 539 730 191
10.Study on water injection system in Halfaya oil field
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Treated produced water specification:
Oil:≤10mg/L ; SS: ≤10mg/LParticle size of SS: ≤8μm; O2: ≤0.05mg/L
Table 1.1-3 Produced Water Analysis
HF-5 HF-3 HF-3
Formation Mishrif Nahr Umr Mishrif
Cations
Sodium ,Na +(mg/l) 60369.4 67268.8 67257.3
Calcium,Ca 2+ (mg/l) 8000 11600 9200
Magnesium,Mg 2+ (mg/l) 1944 1458 2430
Potassium, K + (mg/l) 1707.3 858.0 2081.4
Strontium,Sr 2+ (mg/l) 497.9 386.1 1140.5
Iron ,Fe (mg/l) Nil 137.3 Nil
Anions
Chloride ,CI -(mg/l) 114487.5 129575 129575
Sulphate,SO 42- (mg/l) 360 360 320
Carbonate ,CO 32-(mg/l) Nil Nil Nil
Bicarbonate,HCO 3- (mg/l) 451.4 329.4 427.0
10.Study on water injection system in Halfaya oil field
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According to development data, the water injection development will be
carried out. The total water injection quantity for CPF1, CPF2 and CPF3 is1680,000BWPD. The total cost estimate for water injection system is about
956 million USD. Cause the large water injection capacity and the high cost
estimate, study and optimize the water injection system is necessary.
10.Study on water injection system in Halfaya oil field
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• Material selection issue study.
According to produced water and make-up water analysis, the water maybecorroded metal pipe. For example, the produced water temperature is
70~85, the pH is 4~5, the system pressure is 25MPa, and the Cl- contant
is 129575ppm, it is a hard work to give a suitable material choice. Material
selection for different injection water should be studied.
10.Study on water injection system in Halfaya oil field
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• The overall layout of water injection station and distribution valve groupand pipeline route shall be selected and optimized.
Lots of water injection wells scatter around or far away from the CPF1,
CPF2 and CPF3. Based on water injection wells locations, centralizedwater injection, scattered water injection or composite of both shall bestudied.
• Staged construction for water injection system shall be studied. According to development data, the water injection quantity is raised everyyear, the capacity of water injection station for different stage shall bestudied.
10.Study on water injection system in Halfaya oil field
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Study the material selection for water injection.
To study the material selection for different injection water (treated
produced water, surface water, sea water and unground water) in Halfaya
oilfield;
To study the possibility for raise the PH to 6~7 of treated water;To optimize the material of water injection pipeline;
Optimize the water injection method
Research on current water injection method in other oilfield;
To optimize the water injection method: centralized water injection,
scattered water injection or composite of both.
10.2 Scope of Work
10.Study on water injection system in Halfaya oil field
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Optimize the water injection system layout
To optimize Injection station layout;
To optimize the distribution valve group;
To optimize pipeline route;Optimize water injection station capacity for different stage
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11. QRA (Quantity Risk Analysis)Study Reportof GPP in Halfaya oil field
11.QRA Study Report of GPP in Halfaya oil field
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GPP(Gas Process Plant) will be built in HALFAYA oil field near CPF2 with complicated treated process,
various hazards, which will have important role during the development of HALFAYA oil field. In this study
quantitative risk analysis, risk evaluation and simulation results for the accident will be made to formulatecorresponding security plan and goal to prevent and control the happening of calamity in QRA report and at
the same time check the relative engineering of FEED (though FEED engineering meet the requirement of
relative codes and standards) and optimize it if necessary as well as to support the work in next phase.
In general, the necessity for the QRA study for GPP are as follows:
1. The process and inventory in GPP is highly dangerous and if accident happens there may be great loss
both for people’s life and facilities. Therefore it is necessary to identify and quantify risk related to
hydrocarbon and non-hydrocarbon hazards in GPP.
2. It is necessary to compare the risk level against agreed tolerance criteria and determine risk reduction
measures or mitigation to ensure risk is reduced to as low as reasonably practicable.
3. Check FEED engineering.
4. A certain support and basis will be provided by the QRA study for the work of GPP in the next phase.
11.1 Project Setting Background and Justification
11.QRA Study Report of GPP in Halfaya oil field
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• In Simple Terms:
Risk = Likelihood x Consequence
• Risk – The likelihood of a specific undesired event occurring within a specified period or specified
circumstance
• RISK = the sum, over all possible accident scenarios, of:(no. of fatalities) x (annual probability)
Introduction to QRA
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Targets, Criteria
Project Description
Identification of FailureCases
Frequency Analysis Consequence Analysis
Risk summation
Evaluation,Recommendations
Introduction to QRA
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Additional risk reductionmeasures must be pursued
Demonstration of ALARP shall be made.Risk can be tolerated if further riskreduction is impracticable or if the costand effort is unreasonably disproportionalto the benefit gained
ALARPRegion
Consider cost effective risk reduction measures.No need for detailed working to demonstrate ALARP
Medium(Tolerable) Risk
Low(Broadly
Acceptable)Risk
Intolerable Risk Additional risk reductionmeasures must be pursued
Demonstration of ALARP shall be made.Risk can be tolerated if further riskreduction is impracticable or if the costand effort is unreasonably disproportionalto the benefit gained
ALARPRegion
Consider cost effective risk reduction measures.No need for detailed working to demonstrate ALARP
Medium(Tolerable) Risk
Low(Broadly
Acceptable)Risk
Intolerable Risk
ALARP (As low as reasonable and practicable)Process
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• Remember
Risk =∑(Likelihood x Consequence)
• Individual Risk Per Annum – is defined as the probability of an individual being killed by the accident
scenario per unit time – Risk to a person in an identifiable position due to the job – Takes into account:
• time at work• time in different work locations
Risk Calculation
L i S ifi I di id l Ri k (LSIR)
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Contour of Individual Risk Level5E-05 is confined within plantboundaryContour of Individual Risk Level1E-06 is also confined within plantboundary
Location Specific Individual Risk (LSIR)
QRA S f T l
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Model Name Purpose Details
PHASTFRED
Cirrus
Physical EffectsModelling FRED /PHAST/ Cirrus should be used to model thephysical effects of a range of representative productsfor input into the risk model. Physical effectsconsidered include:Flash fire, Jet fire
Pool fireToxicity etc.
PHAST RISK
Shell Shepherd
Quantitative Risk Analysis
The mentioned software should be used to integratethe results of frequency and consequence modelling,together with population data to produce the risklevels in terms of Individual Risk Per Annum andPotential Loss of Life.
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QRA Software Tools
11.QRA Study Report of GPP in Halfaya oil field
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11.2 Scope of Work
1. Study the consequence modeling software and make the database ,such
as fire explosion parameter, the basis of the model of the local atmospheric
parameters and hazards types and properties.
2. According to simulated calculation of influence scope, identify possiblerisk of explosion and degree of fire and explosion accidents.
3. Finish the QRA report and according to the results make corresponding
security plan ,measure and goal to prevent and control the happening of
calamity.
Confidential
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12. Study for Custody Transfer Metering (LPG)
12. Study for Custody Transfer Metering (LPG)
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12.1 Project Setting Background and Justification
LPG (liquefied petroleum gas)will be produced in GPP/MGPP, PCH will
transfer the LPG to transporter through the Custody Metering System. Hence,Precise measurement during custody transfer operations is critical to ensurePCH&MOC demands.Selecting the right meter for the GPP with a high level of confidence isimperative to ensure accurate measurement at the lowest the costof PCH&MOC. According to the lessons learn of the Crude Oil in the Phase1 and Phase2,
Several months are spent to determine the type of custody transfer meterwith MOC.
12. Study for Custody Transfer Metering (LPG)
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12.1 Project Setting Background and Justification
As per the standard “Hydrocarbon Measurement Code-MOO”, there are
clarify mentioned 3 types oil product shall be measured by CTMS include:Crude oil, Natural Gas and Hydrocarbon Product.Meantime it mentioned, PD meter, Turbine meter, Coriolis meter andUltrasonic meter shall be used for Hydrocabon, certainly LPG is one kindof Hydrocarbon, but what kind of the meter shall be used in HFY fromthese 4 type meters , which type of the calibration methodology shall beused in the future , how can we get more Precise and whatelse meter can
we choose in GPP/MGPP according to NFPA 58 , 59,API and anotherinternational standard shall be considered.
12. Study for Custody Transfer Metering (LPG)
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12.2 Scope of Work
1) Study LPG transfer metering technology include thecalibration system
2) Research the specifications, codes and standards, etc;3) Investigate and contact with the related vendors;
4) Compare potential types of meters5) Prepare deliverables
Confidential
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13. Safety Operation Study in CPF1 and CPF2
13 1 Project Setting Background and Justification
13. Safety Operation Study of CPF1 and CPF2
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13.1 Project Setting Background and Justification
The safety operating parameters (such as alarm points and shut
down setting) of CPF1 and CPF2 need to be optimized andregulated after start-up due to actual condition; mainly focus on
heat medium pressure and temperature, pressure inlet and outlet
of heat exchanger, etc.
Example
The pressure low alarm of heat medium system in CPF1 is 2.5barg
originally, which is changed to 1.5barg during normal operating
because the pressure drop is too small in first few years of new plant.
13 1 Project Setting Background and Justification
13. Safety Operation Study of CPF1 and CPF2
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13.1 Project Setting Background and Justification
Due to different contractors construction in CPF1, there are many
interfaces among different contractors and different engineering
company philosophy. Gaps may exist in control system, operating
and coordination. Check and improve to eliminate the potential risk
from different projects.
13 1 Project Setting Background and Justification
13. Safety Operation Study of CPF1 and CPF2
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13.1 Project Setting Background and Justification
To further advise the operator timely carry out action when facing
emergency condition or regular inspection through the HAZOP check,
sample analyze.
Example:
1. For test separator in HAZOP report, flow may be more when the choke valve on the
well is full open not on demand, lead to inaccurate test and exceed erosional velocity.
It is needed by operator intervention.
2. Calculate the skimming time as per actual oil content in produced water, advise the
manual operating period.
13.1 Project Setting Background and Justification
13. Safety Operation Study of CPF1 and CPF2
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13.1 Project Setting Background and Justification
To recheck, analyze the related safety control loop to guarantee the
safety operation in CPF1 and CPF2.
To advise rectifications for CPF1 and CPF2, to improve and optimize
CPF3 design engineering.
13.2 Scope of Work
13. Safety Operation Study in CPF1 and CPF2
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13.2 Scope of Work
Site investigation;
Compare site operational condition with design document;
Study safety operation regulation in CPF1 and CPF2;
According actual condition, analyze operability defect;
Finish the report and give optimization scheme for safety operation.
Confidential
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14. Application Study of EPON (Ethernet Passive OpticalNetwork)in Oil Field
14. Application Study of EPON in Oil Field
14.1 Project Setting Background and Justification
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• 1) According to the actual situation of Phase I & II, Buried FiberCables between PAD/OGMs and CPFalways be cut, datatransmission also be interrupted.
• 2) High-voltage power line for PAD/OGMs willform a ringaroundCPF. 24 cores Optical Fiber Composite Ground Wire (OPGW) be
used in this power line. It will be used as backup route forPAD/OGMs data transmission.
• 3) Each PAD/OGM needs 12 cores fiber while using general
transmission technology, 24 cores OPGW only meets 2PAD/OGMs, but more than 10 PAD/OGMs around CPFs. EPONtechnology can solve lack of fiber.
14.1 Project Setting Background and Justification
14. Application Study of EPON in Oil Field
14.2 Scope of Work
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• Research of EPON technology and product;
• Study of EPON technology typical application in other industry;
• Design and experiment of EPON solution for HALFAYA oilfield;
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14.2 Scope of Work
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Thank You For Your Support!
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